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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
i
Fault Finding Index
9803/6500
i
Issue 3
Section 1 Section 1
FF 500
Section 1 Fault Finding Index
9803/6500
Section 1
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
Section 1 Fault Finding Index
9803/6500
Section 1
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
Expected test time to complete all above tests 2.5 hrs
FF502
Section 1 Fault Finding Index
9803/6500
Section 1
FF 502
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
Expected test time to complete all above tests 2.5 hrs
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
Section 1 Fault Finding Index
9803/6500
Section 1
FF 503
Issue 1
Expected test time to complete all above tests 2.5 hrs
FF504
Section 1 Fault Finding Index
9803/6500
Section 1
FF 504
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
Additional information
Pay particular attention to negative control pressure when selecting boom down.
Expected test time to complete all above tests 1 hrs
FF 505
Section 1 Fault Finding Index
9803/6500
Section 1
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.
Expected test time to complete all above tests 2.5 hrs
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
Section 1 Fault Finding Index
9803/6500
Section 1
FF 506
Issue 1
Expected test time to complete all above tests 2.5 hrs
Boom Up Operation Is Slow Or Low Powered XO130W / 160W
If experiencing slow or underpowered boom up operation carry out following checks:
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
Section 1 Fault Finding Index
9803/6500
Section 1
FF 525
Issue 2
Expected test time to complete all above tests 2.5 hrs
FF 526
Section 1 Fault Finding Index
9803/6500
Section 1
FF 526
Issue 2
Arm Service Operation Is Slow Or Low Powered XO130W / 160W
If experiencing slow or underpowered arm service operation carry out following checks:
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
Additional information
If the machine has arm cylinder hose burst check valve fitted then also carry out :Test 041 Testing operation of arm HBCV
Expected test time to complete all above tests 2.5 hrs
FF 527
Section 1 Fault Finding Index
9803/6500
Section 1
FF 527
Issue 2
Bucket Service Operation Is Slow Or Low Powered XO130W / 160W
If experiencing slow or underpowered bucket service operation carry out following checks:
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
Expected test time to complete all above tests 2.5 hrs
FF 528
Section 1 Fault Finding Index
9803/6500
Section 1
FF 528
Issue 2
Swing Service Operation Is Slow Or Low Powered XO130W / 160W
If experiencing slow or underpowered swing service operation carry out following checks:
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
Expected test time to complete all above tests 2.5 hrs
FF 529
Section 1 Fault Finding Index
9803/6500
Section 1
FF 529
Issue 2
Boom Down Operation Is Harsh When Selected XO130W / 160W
If experiencing harsh operation when selecting boom down carry out following checks:
Test 002 Testing negative control signal Test 100 Testing operation of pressure switches
Additional Information
Pay particular attention to negative control pressure when selecting boom down.
Expected test time to complete all above tests 1 hrs
FF 530
Section 1 Fault Finding Index
9803/6500
Section 1
FF 530
Issue 1
Swing Operation Operation Is Harsh When Selected XO130W / 160W
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.
Expected test time to complete all above tests 1 hrs
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
Section 1 Fault Finding Index
9803/6500
Section 1
FF 531
Issue 1
Expected test time to complete all above tests 2.5 hrs
FF 550
Section 1 Fault Finding Index
9803/6500
Section 1
FF 550
Issue 2
Boom Up Operation Is Slow Or Low Powered XO200 / 220 / 240 / 260
If experiencing slow or underpowered boom up operation carry out following checks:
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
Expected test time to complete all above tests 2.5 hrs
FF 551
Section 1 Fault Finding Index
9803/6500
Section 1
FF 551
Issue 2
Arm Service Operation Is Slow Or Low Powered XO200 / 220 / 240 / 260
If experiencing slow or underpowered arm service operation carry out following checks:
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
Additional information
If arm cylinder has HBCV fitted then also carry out :Test 041 Testing operation of arm HBCV
Expected test time to complete all above tests 2.5 hrs
FF 552
Section 1 Fault Finding Index
9803/6500
Section 1
FF 552
Issue 2
Bucket Service Operation Is Slow Or Low Powered XO200 / 220 / 240 / 260
If experiencing slow or underpowered bucket service operation carry out following checks:
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
Expected test time to complete all above tests 2.5 hrs
FF553
Section 1 Fault Finding Index
9803/6500
Section 1
FF 553
Issue 1
Swing Service Operation Is Slow Or Low Powered XO200 / 220 / 240 / 260
If experiencing slow or underpowered swing service operation carry out following checks:
Test 003 Testing negative control signal Test 012 Testing max flow cut signalTest 023 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
Expected test time to complete all above tests 2.5 hrs
FF 554
Section 1 Fault Finding Index
9803/6500
Section 1
FF 554
Issue 2
Boom Down Operation Is Harsh When Selected XO200 / 220 / 240 / 260
If experiencing harsh operation when selecting boom down carry out following checks:
Test 003 Testing negative control signal Test 100 Testing operation of pressure switches
Additional Information
Pay particular attention to negative control pressure when selecting boom down.
Expected test time to complete all above tests 1 hrs
FF 555
Section 1 Fault Finding Index
9803/6500
Section 1
FF 555
Issue 1
Swing Operation Operation Is Harsh When Selected XO200 / 220 / 240 / 260
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 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.
Expected test time to complete all above tests 1 hrs
FF 556
Machine Performance is Unsatisfactory XO200 / 220 / 240 / 260
If experiencing poor machine performance carry out following checks:
Test 003 Testing negative control signal Test 012 Testing max flow cut signalTest 023 Testing main pump pressuresTest 028 Testing horsepower controlTest 100 Testing operation of pressure switchesTest 200 Testing engine speed settingsTest 300 Testing machine cycle times
Section 1 Fault Finding Index
9803/6500
Section 1
FF 556
Issue 1
Expected test time to complete all above tests 2.5 hrs
FF 557
Machine Performance is Unsatisfactory XO200W
If experiencing poor machine performance carry out following checks:
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
Section 1 Fault Finding Index
9803/6500
Section 1FF 557
Issue 3
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
Section 1 Fault Finding Index
9803/6500
Section 1FF 558
Issue 3
FF 600
Section 1 Fault Finding Index
9803/6500
Section 1
FF 600
Issue 2
Boom Up Operation Is Slow Or Low Powered XO330 / 450
If experiencing slow or underpowered boom up operation carry out following checks:
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
Expected test time to complete all above tests 2.5 hrs
FF 601
Section 1 Fault Finding Index
9803/6500
Section 1
FF 601
Issue 2
Arm Service Operation Is Slow Or Low Powered XO330 / 450
If experiencing slow or underpowered arm service operation carry out following checks:
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
Additional information
If arm cylinder has HBCV fitted then also carry out :Test 041 Testing operation of arm HBCV
Expected test time to complete all above tests 2.5 hrs
FF 602
Section 1 Fault Finding Index
9803/6500
Section 1
FF 602
Issue 2
Bucket Service Operation Is Slow Or Low Powered XO330 / 450
If experiencing slow or underpowered bucket service operation carry out following checks:
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
Expected test time to complete all above tests 2.5 hrs
FF 603
Section 1 Fault Finding Index
9803/6500
Section 1
FF 603
Issue 1
Swing Service Operation Is Slow Or Low Powered XO330 / 450
If experiencing slow or underpowered swing service operation carry out following checks:
Test 004 Testing negative control signal Test 013 Testing max flow cut signalTest 024 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
Additional information
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.
Expected test time to complete all above tests 2.5 hrs
FF 604
Section 1 Fault Finding Index
9803/6500
Section 1
FF 604
Issue 2
Boom Down Operation Is Harsh When Selected XO330 / 450
If experiencing harsh operation when selecting boom down carry out following checks:
Test 004 Testing negative control signal Test 100 Testing operation of pressure switches
Additional information
Pay particular attention to negative control pressure when selecting boom down.
Expected test time to complete all above tests 1 hrs
FF 605
Section 1 Fault Finding Index
9803/6500
Section 1
FF 605
Issue 1
Swing Operation Operation Is Harsh When Selected XO330 / 450
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 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.
Expected test time to complete all above tests 1 hrs
FF 606
Machine Performance is Unsatisfactory XO330 / 450
If experiencing poor machine performance carry out following checks:
Test 004 Testing negative control signal Test 013 Testing max flow cut signalTest 024 Testing main pump pressuresTest 029 Testing horsepower controlTest 100 Testing operation of pressure switchesTest 200 Testing engine speed settingsTest 300 Testing machine cycle times
Section 1 Fault Finding Index
9803/6500
Section 1
FF 606
Issue 1
Expected test time to complete all above tests 2.5 hrs
FF 650
Section 1 Fault Finding Index
9803/6500
Section 1
FF 650
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
Additional information
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?
Expected test time to complete all above tests 4 hrs
FF 651
Section 1 Fault Finding Index
9803/6500
Section 1
FF 651
Issue 2
Machine Tracks Off Line During Straight Travel XO200 / 220 / 240 / 260
If experiencing machine tracking off line, carry out following checks:
Test 003 Testing negative control signalTest 023 Testing main pump pressuresTest 050 Testing track motor relief valve settingsTest 051 Testing track motor drain line ratesTest 052 Testing track motor speeds
Additional information
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?
Expected test time to complete all above tests 4 hrs
FF 652
Section 1 Fault Finding Index
9803/6500
Section 1
FF 652
Issue 2
Machine Tracks Off Line During Straight Travel XO330 / 450
If experiencing machine tracking off line, carry out following checks:
Test 004 Testing negative control signalTest 024 Testing main pump pressuresTest 050 Testing track motor relief valve settingsTest 051 Testing track motor drain line ratesTest 052 Testing track motor speeds
Additional information
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?
Expected test time to complete all above tests 4 hrs
FF 653
Section 1 Fault Finding Index
9803/6500
Section 1
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
Additional Information
What travel gear is the machine operating in when the problem occurs?
See also Fault 662.
Expected test time to complete all above tests 2 hrs
FF 654
Section 1 Fault Finding Index
9803/6500
Section 1
FF 654
Issue 2
Poor Tractive Effort XO200 / 220 / 240 / 260
If experiencing poor tractive effort, carry out following checks:
Test 003 Testing negative control signalTest 023 Testing main pump pressuresTest 050 Testing track motor relief valve settingsTest 051 Testing track motor drain line rates
Additional Information
What travel gear is the machine operating in when the problem occurs?
See also Fault 662.
Expected test time to complete all above tests 2 hrs
FF 655
Section 1 Fault Finding Index
9803/6500
Section 1
FF 655
Issue 2
Poor Tractive Effort XO330 / 450
If experiencing poor tractive effort, carry out following checks:
Test 004 Testing negative control signalTest 024 Testing main pump pressuresTest 050 Testing track motor relief valve settingsTest 051 Testing track motor drain line rates
Additional Information
What travel gear is the machine operating in when the problem occurs?
See also Fault 662.
Expected test time to complete all above tests 2 hrs
FF 656
Section 1 Fault Finding Index
9803/6500
Section 1
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
Additional information
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 ?
Expected test time to complete all above tests 1.5 hrs
A318900
Pilot port to select high gear
A326403
High speed trackingsolenoid
Front view of 8spool valve
FF 657
Section 1 Fault Finding Index
9803/6500
Section 1
FF 657
Issue 1
Loss of High Speed Tracking XO200 / 220 / 240 / 260
If experiencing loss of high speed tracking, carry out following checks:
Test 052 Testing track motor speedsTest 100 Testing pressure switches
Additional information
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 ?
Expected test time to complete all above tests 1.5 hrs
A318900
Pilot port to select high gear
A326403
High speed trackingsolenoid
Front view of 8spool valve
Loss of High Speed Tracking XO330 / 450
If experiencing loss of high speed tracking, carry out following checks:
Test 052 Testing track motor speedsTest 100 Testing pressure switches
Additional information
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 ?
FF 658
Section 1 Fault Finding Index
9803/6500
Section 1
FF 658
Issue 1
Expected test time to complete all above tests 1.5 hrs
A318900
Pilot port to select high gear
A326403
High speed trackingsolenoid
Front view of 8spool valve
FF 659
Section 1 Fault Finding Index
9803/6500
Section 1
FF 659
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
Additional information
When creep speed tracking is selected is tortoise symbol displayed on monitor? yes / no
Expected test time to complete all above tests 2 hrs
FF 660
Section 1 Fault Finding Index
9803/6500
Section 1
FF 660
Issue 1
Loss of Creep Speed Tracking XO200 / 220 / 240 / 260
If experiencing loss of creep speed tracking, carry out following checks:
Test 012 Testing max flow cut signalTest 052 Testing track motor speedsTest 100 Testing pressure switches
Additional information
When creep speed tracking is selected is tortoise symbol displayed on monitor? yes / no
Expected test time to complete all above tests 2 hrs
FF 661
Section 1 Fault Finding Index
9803/6500
Section 1
FF 661
Issue 1
Loss of Creep Speed Tracking XO330 / 450
If experiencing loss of creep speed tracking, carry out following checks:
Test 013 Testing max flow cut signalTest 052 Testing track motor speedsTest 100 Testing pressure switches
Additional information
When creep speed tracking is selected is tortoise symbol displayed on monitor? yes / no
Expected test time to complete all above tests 2 hrs
FF 662
Section 1 Fault Finding Index
9803/6500
Section 1
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?
Expected test time to complete all above tests 1.5 hrs
A318900
Pilot port X
A326403
High speed trackingsolenoid
Front view of 8spool valve
FF 700
Section 1 Fault Finding Index
9803/6500
Section 1
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
Expected test time to complete all above tests 3 hrs
FF 701
Section 1 Fault Finding Index
9803/6500
Section 1
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
Additional information
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?
Expected test time to complete all above tests 1.5 hrs
FF 702
Section 1 Fault Finding Index
9803/6500
Section 1FF 702
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
Additional information
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.
Expected test time to complete all above tests 1.5 hrs
FF 703
Section 1 Fault Finding Index
9803/6500
Section 1FF 703
Issue 3
Poor Tractive Effort XO130W / 160W / XO200W
If experiencing poor tractive effort, 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 066 Checking theshold pressure - XO200W only,Test 100 Testing pressure switchesTest 200 Testing engine speeds
Expected test time to complete all above tests 3 hrs
Loss of Drive XO130W / 160W
If experiencing loss of drive carry out following checks:
Test 063 Testing clutch pack pressure / park brake pressure
Additional information
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
Section 1 Fault Finding Index
9803/6500
Section 1
FF 704
Issue 1
Expected test time to complete all above tests 1.5 hrs
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
Section 1 Fault Finding Index
9803/6500
Section 1
FF 705
Issue 1
Expected test time to complete all above tests 1 hrs
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
Section 1 Fault Finding Index
9803/6500
Section 1FF 706
Issue 3
FF 800
Section 1 Fault Finding Index
9803/6500
Section 1FF 800
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 4 hrs
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
Additional information
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.
Section 1 Fault Finding Index
9803/6500
Section 1
FF 900
Issue 2
Expected test time to complete all above tests 2 hrs
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
i
9803/6500
i
Issue 3
Section 2 Section 2Test Procedures
TEST PROCEDURE INDEX
ii
Test Procedures
9803/6500
ii
Issue 3
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
9803/6500
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 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 - 3 bar) (12 - 16 bar)
Select and stall bucket close service record pressure (0 - 3 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 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)
(40 bar when firstselected for 0.5 sec
then 0 bar)
* This pressure will vary with oil temperature and engine speed.
(Expected Pressures)
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 boom up service record pressure (0 - 3 bar) (0 - 3 bar)
Fully select boom down record pressure when service first selected (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 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 (0 - 3 bar) (30 - 35 bar)
Select and stall swing right service record pressure (0 - 3 bar) (30 - 35 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)
* This pressure will vary with oil temperature and engine speed.
(40 bar when firstselected for 0.5 sec
then 0 bar)
(Expected Pressures)
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
O Warm up machine hydraulic temperature to 50 C
Port PZ1/Pi1 Port PZ2/Pi2
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 (16 - 20 bar) (0 - 3 bar)
Select and stall bucket close service record pressure (16 - 20 bar) (0 - 3 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 (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)
* This pressure will vary with oil temperature and engine speed.
(40 bar when firstselected for 0.5 sec
then 0 - 3 bar)
(Expected Pressures)
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
O Warm up machine hydraulic temperature to 50 C
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)
(Expected Pressures)
P12
P22
A31895JS 130 from 890083JS160 from 703390JS180 from 27.05.01
Port Pm1 Port Pm2
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)
(Expected Pressures)
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
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)
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)
(Expected Pressures)
(Expected Pressures)
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
O Warm up machine hydraulic temperature to 50 C
Port Pm1 Port Pm2
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)
(Expected Pressures)
Port Pm2
Port Pm1
VIEW FROM REAR OFHYDRAULIC PUMP
TP 013
9803/6500
TP 013
Issue 3
Test ProcedureSection2 Section 2
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)
(Expected Pressures)
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
O Warm up machine hydraulic temperature to 50 C
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 Warm up machine hydraulic temperature to 50 C
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
O Warm up machine hydraulic temperature to 50 C
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.
(Expected Pressures)
G1 Main, Dipper, SwingG2 Main, Boom, Bucket
G1
G2
TP 021
9803/6500
TP 021
Issue 3
Test ProcedureSection2 Section 2
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
With max engine rpms and no services selected record pump pressure (25 - 35 bar*) (25 - 35 bar*)
Select and stall boom up service record pressure (314 bar) (314 bar)
Select and stall bucket open service record pressure (314 bar) (180 - 314 bar)
Select and stall bucket close service record pressure (314 bar) (180 - 314 bar)
Select and stall dipper open service record pressure (314 bar) (314 bar)
Select and stall dipper close service record pressure (314 bar) (314 bar)
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.
(Expected Pressures)
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
O Fit test gauges ( 0 - 600 bar ) into hose connections to ports G1 + G2
O Warm up machine hydraulic temperature to 50 C
Port G1 Port G2
With max engine rpms and no services selected record pump pressure (25 - 35 bar*) (25 - 35 bar*)
Select and stall boom up service record pressure (314 bar) (314 bar)
Select and stall bucket open service record pressure (314 bar) (180 - 314 bar)
Select and stall bucket close service record pressure (314 bar) (180 - 314 bar)
Select and stall dipper open service record pressure (314 bar) (314 bar)
Select and stall dipper close service record pressure (314 bar) (314 bar)
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)
(Expected Pressures)
* This pressure will depend on oil temperature and engine speed.
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
O Fit test gauges ( 0 - 600 bar ) into hose connections to ports G1 + G2
O Warm up machine hydraulic temperature to 50 C
Port G1 Port G2
With max engine rpms and no services selected record pump pressure (25 - 35 bar*) (25 - 35 bar*)
Select and stall boom up service record pressure (318 bar) (318 bar)
Select and stall bucket open service record pressure (210 - 318 bar) (318 bar)
Select and stall bucket close service record pressure (210 - 318 bar) (318 bar)
Select and stall dipper open service record pressure (318 bar) (318 bar)
Select and stall dipper close service record pressure (318 bar) (318 bar)
Select and stall swing left service record pressure (279 bar) (25 - 35 bar)
Select and stall swing right service record pressure (279 bar) (25 - 35 bar)
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)
Select F mode and then select stall boom up service record pressure (343 bar) (343 bar)
(Expected Pressures)
* This pressure will depend on oil temperature and engine speed.
FRONT VIEW OFHYDRAULIC PUMP
Port G1(nearest engine)
Port G2
TP 024
9803/6500
TP 024
Issue 3
Test ProcedureSection2 Section 2
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
O Warm up machine hydraulic temperature to 50 C
Port MA1/a1 Port MA2/a2
With max engine rpms and no services selected record pump pressure (25 - 35 bar*) (25 - 35 bar*)
Select and stall boom up service record pressure (318 bar) (318 bar)
Select and stall bucket open service record pressure (200 - 318 bar) (318 bar)
Select and stall bucket close service record pressure (200 - 318 bar) (318 bar)
Select and stall dipper open service record pressure (318 bar) (318 bar)
Select and stall dipper close service record pressure (318 bar) (318 bar)
Select and stall swing left service record pressure (279 bar) (25 - 35 bar)
Select and stall swing right service record pressure (279 bar) (25 - 35 bar)
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)
Select F mode and then select stall boom up service record pressure (348 bar) (348 bar)
(Expected Pressures)
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)
* This pressure will depend on oil temperature and engine speed.
O Fit test gauges ( 0 - 600 bar ) into test point 3
O Warm up machine hydraulic temperature to 50 C
1 2 3A436040
(Expected Pressures)
TP 026
9803/6500
TP 026
Issue 3
Test ProcedureSection2 Section 2
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
Test ProcedureSection2 Section 2
Testing Horsepower Control XO 130w/XO 160w
Fit gauge ( 0 - 60 bar ) into proportional solenoidsecondary pressure measurement port using suitable
adapter (port thread is 1/4 BSP O ring fitting).
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
Brown/Black (BrB) Brown/Black (BrB)
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
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 FROM UNDERSIDE OFHYDRAULIC PUMP
Proportional solenoid secondarypressure measurement port
XO 200 / XO 220 XO 240 / XO 260
Horsepower Milliamps Horsepower MilliampsControl controlsecondary secondarypressure pressure
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
Brown/Black (BrB) Brown/Black (BrB)
A407830
Later Machines
TP 029
9803/6500
TP 029
Issue 3
Test ProcedureSection2 Section 2
A326250
VIEW OFHYDRAULIC PUMP
Proportional solenoid secondarypressure measurement port
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).
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.
XO 330 XO 450
Horsepower Milliamps Horsepower MilliampsControl controlsecondary secondarypressure pressure
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
Brown/Black (BrB) Brown/Black (BrB)
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
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.
+ -
+ -
330470
Pump sideharness
Link wire
Brown/Black (BrB) Brown/Black (BrB)
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
Test ProcedureSection2 Section 2
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
Test ProcedureSection2 Section 2
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 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 Remove pilot hose from port P, plug hose and leave port open to atmosphere.
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 Record pressure at this point, this is relief setting of HBCV.
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
Test ProcedureSection2 Section 2
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 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 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 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
Test ProcedureSection2 Section 2
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 stop theengine.
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 t
Recommended