JCB ENGLISH Fault Finding COMPLETE PDF

RETURN
HOW TO USE THIS DOCUMENT

1
Click on the Fault Index button. This will take you to an index of possible faults.
Click on the fault conditions you want to investigate. This will take you to a page
containing a list of Test Procedures relevant to the fault condition you have selected.
Click on the 1st Test Procedure. This will take you to the page containing the Test
Procedure you have selected. Select 'File - Print'.
ENSURE THAT CURRENT PAGE IS SELECTED BEFORE YOU CLICK ON THE

OK BUTTON. (If you dont do this you will print out the whole document.)
When the Print Window closes, click the Return button. This will take you back to the
list of Test Procedures.
Note: If you have scrolled down the page you may have to press the return a few
times before you get back to the Index.
Repeat steps 3 and 4 for all the other Test Procedures.
RETURN
Test Procedure Masters

This document contains all the Test Procedures, complete with their
Expected Readings. Clicking on the entry in the Test Procedure Index
will take you to the relevant procedure. Print it out, return to the Index
and repeat as required.
JCB HEAVY PRODUCTS LIMITED

FAULT FINDING SYSTEM
WARNING
The procedures described in this publication must be used in conjunction
with the relevant machine Service Manual and Operator Handbook.
Observe all relevant Safety Information contained in those documents.
PLEASE CLICK IN THE BOX BELOW TO SIGNIFY THAT YOU

HAVE READ AND UNDERSTAND THE ABOVE WARNING.
EXIT TO MAIN SCREEN
Section 1
Fault Finding Index
Section 1
FAULT FINDING INDEX

Fault 500
Fault 501
Fault 502
Fault 503
Fault 504
Fault 505
Fault 506
Boom up operation is slow or low powered

Arm operation is slow or low powered
Bucket operation is slow or low powered
Swing operation is slow or low powered
Boom down operation is harsh when selected
Swing operation is harsh when selected
Machine performance is unsatisfactory
XO130 / 160 / 180

XO130 / 160 / 180
XO130 / 160 / 180
XO130 / 160 / 180
XO130 / 160 / 180
XO130 / 160 / 180
XO130 / 160 / 180
ISSUE
2
2
2
1
2
1
1
Fault 525
Fault 526
Fault 527
Fault 528
Fault 529
Fault 530
Fault 531

XO130W / 160W
XO130W / 160W
XO130W / 160W
XO130W / 160W
XO130W / 160W
XO130W / 160W
XO130W / 160W
2
2
2
2
2
2
1
Fault 550
Fault 551
Fault 552
Fault 553
Fault 554
Fault 555
Fault 556
Fault 557
Fault 558

Poor Performance
Poor Swing Effort
XO200 / 220 / 240 / 260

XO200 / 220 / 240 / 260
XO200 / 220 / 240 / 260
XO200 / 220 / 240 / 260
XO200 / 220 / 240 / 260
XO200 / 220 / 240 / 260
XO200 / 220 / 240 / 260
XO200W
XO200W
2
2
2
1
2
1
1
3
3
Fault 600
Fault 601
Fault 602
Fault 603
Fault 604
Fault 605
Fault 606

XO330 / 450
XO330 / 450
XO330 / 450
XO330 / 450
XO330 / 450
XO330 / 450
XO330 / 450
2
2
2
1
2
1
1
Fault 650
Fault 651
Fault 652
Fault 653
Fault 654
Fault 655
Fault 656
Fault 657
Fault 658
Fault 659
Fault 660
Fault 661
Fault 662
Machine tracks off line during straight tracking

XO130 / 160
XO200 / 220 / 240 / 260
XO330 / 450
Poor tractive effort
XO130 / 160 / 180
XO200 / 220 / 240 / 260
XO330 / 450
Loss of high speed tracking
XO130 / 160 / 180
XO200 / 220 / 240 / 260
XO330 / 450
Loss of creep speed tracking
XO130 / 160 / 180
XO200 / 220 / 240 / 260
XO330 / 450
Machine selects high gear even though monitor displays
another travel gear
( all tracked models )
2
2
2
2
2
2
2
1
1
2
1
1
Fault 700
Fault 701
Fault 702
Fault 703
Fault 704
Fault 705
Fault 706
Wheeled machine poor top road speed

XO130w / 160W
Loss of high speed ( wheeled machine )
XO130W / 160W / XO200W
Loss of creep speed ( wheeled machine )
XO130W / 160W / XO200W
Poor tractive effort ( wheeled machine )
XO130W/ 160W / XO200W
Loss of drive ( wheeled machine )
XO130W / 160W
Harsh counterbalance on releasing drive pedal
XO130W / 160W
Poor Steering and Braking Performance
XO200W
1
3
3
3
1
1
3
Fault 800
Excessive engine stall when stalling hydraulic service
( all models )
Fault 900
Electrical problem and 0000 is displayed on monitor
( all models )
9803/6500
Issue 3
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 500
FF 500
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
Test 010
Test 021
Test 026
Test 054
Test 055
Test 100
Test 200
Test 300
Testing negative control signal

Testing max flow cut signal
Testing main pump pressures
Testing horse power control
Testing operation of main hydraulic spool ( for boom spool )
Testing operation of boom 2 / bucket 2 spool
Testing operation of pressure switches
Testing engine speed settings
Testing machine cycle times
Expected test time to complete all above tests 2.5 hrs
9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 501
FF 501
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
Test 010
Test 021
Test 026
Test 054
Test 056
Test 100
Test 200
Test 300

Testing operation of main hydraulic spool (for arm main spool)
Testing operation of arm 2 boost spool
Additional information
If the arm cylinder has hose burst check valve fitted then also carry out :
Test 041
Testing operation of arm HBCV
9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF502
FF 502
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
Test 010
Test 021
Test 026
Test 054
Test 055
Test 100
Test 200
Test 300

Testing operation of main hydraulic spool (for bucket main spool)
Testing operation of boom 2 / bucket 2 boost spool
9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 503
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
Test 010
Test 021
Test 053
Test 054
Test 100
Test 200
Test 300

Testing operation of swing brake
Testing operation of main hydraulic spool (for swing main spool)
9803/6500
Issue 1
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF504
FF 504
Boom Down Operation Is Harsh When Selected
XO130 / 160 / 180
If experiencing harsh operation when selecting boom down carry out following checks:
Test 001
Test 100

Pay particular attention to negative control pressure when selecting boom down.
Expected test time to complete all above tests 1 hrs
9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 505
FF 505
Swing Operation Operation Is Harsh When Selected
XO130 / 160 / 180
If experiencing harsh operation when selecting swing service carry out following checks:
Test 053
Test 100

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 that
connections to the pressure switches on shuttle block are fitted to correct switch.
9803/6500
Issue 1
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 506
FF 506
Machine Performance is Unsatisfactory
XO130 / 160 / 180
If experiencing poor machine performance carry out following checks:
Test 001
Test 010
Test 021
Test 026
Test 100
Test 200
Test 300

9803/6500
Issue 1
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 525
FF 525
Boom Up Operation Is Slow Or Low Powered XO130W / 160W

Test 002
Test 011
Test 022
Test 027
Test 054
Test 055
Test 100
Test 200
Test 300

Testing horsepower control
Testing operation of main hydraulic spool (for boom spool)
9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 526
FF 526
Arm Service Operation Is Slow Or Low Powered
XO130W / 160W
Test 002
Test 011
Test 022
Test 027
Test 054
Test 056
Test 100
Test 200
Test 300

Testing operation of main hydraulic spool (for arm spool)
Testing operation of arm 2 boost spool
If the machine has arm cylinder hose burst check valve fitted then also carry out :
Test 041
9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 527
FF 527
Bucket Service Operation Is Slow Or Low Powered XO130W / 160W

Test 002
Test 011
Test 022
Test 027
Test 054
Test 055
Test 100
Test 200
Test 300

Testing operation of main hydraulic spool (for bucket spool)
9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 528
FF 528
Swing Service Operation Is Slow Or Low Powered XO130W / 160W

Test 002
Test 011
Test 022
Test 053
Test 054
Test 100
Test 200
Test 300

Testing operation of main hydraulic spool (for swing spool)
9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 529
FF 529
XO130W / 160W
Test 002
Test 100

9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 530
FF 530
XO130W / 160W
Test 053
Test 100

Does the swing perform smother if boom down is selected at the same time as swing? If it does check to make sure that
9803/6500
Issue 1
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 531
FF 531
XO130W / 160W
If experiencing poor machine performance carry out following tests:
Test 002
Test 011
Test 022
Test 027
Test 100
Test 200
Test 300

9803/6500
Issue 1
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 550
FF 550
Boom Up Operation Is Slow Or Low Powered XO200 / 220 / 240 / 260

Test 003
Test 012
Test 023
Test 028
Test 054
Test 100
Test 200
Test 300

9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 551
FF 551
Arm Service Operation Is Slow Or Low Powered XO200 / 220 / 240 / 260
Test 003
Test 012
Test 023
Test 028
Test 054
Test 100
Test 200
Test 300

If arm cylinder has HBCV fitted then also carry out :

Test 041
9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 552
FF 552
Bucket Service Operation Is Slow Or Low Powered XO200 / 220 / 240 / 260
Test 003
Test 012
Test 023
Test 028
Test 054
Test 100
Test 200
Test 300

9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF553
FF 553
Swing Service Operation Is Slow Or Low Powered XO200 / 220 / 240 / 260
Test 003
Test 012
Test 023
Test 053
Test 054
Test 100
Test 200
Test 300

9803/6500
Issue 1
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 554
FF 554
XO200 / 220 / 240 / 260
Test 003
Test 100

9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 555
FF 555
XO200 / 220 / 240 / 260
Test 053
Test 100

Does the swing perform smoother if boom down is selected at the same time as swing? If it does check to make sure that
9803/6500
Issue 1
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 556
FF 556
XO200 / 220 / 240 / 260
Test 003
Test 012
Test 023
Test 028
Test 100
Test 200
Test 300

9803/6500
Issue 1
RETURN
Section 1
Fault Finding Index
FF 557
PRINT
Section 1
FF 557
XO200W
Test 005
Test 014
Test 015
Test 031
Test 025
Test 200
9803/6500
Testing load sense pressure

Testing P shift
Testing servo pressure
Testing pump milliamps
Issue 3
RETURN
Section 1
Fault Finding Index
FF 558
9803/6500
Section 1
FF 558
Poor Swing Effort

Test 053
Test 057
Test 058
Test 054
Test 100
Test 200
Test 300
PRINT
XO200W

Testing swing relief pressure
Testing swing/boom - priority
Issue 3
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 600
FF 600
Boom Up Operation Is Slow Or Low Powered XO330 / 450

Test 004
Test 013
Test 024
Test 029
Test 054
Test 100
Test 200
Test 300

9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 601
FF 601
Arm Service Operation Is Slow Or Low Powered XO330 / 450

Test 004
Test 013
Test 024
Test 029
Test 054
Test 100
Test 200
Test 300

If arm cylinder has HBCV fitted then also carry out :

Test 041
9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 602
FF 602
Bucket Service Operation Is Slow Or Low Powered XO330 / 450

Test 004
Test 013
Test 024
Test 029
Test 054
Test 100
Test 200
Test 300

9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 603
FF 603
Swing Service Operation Is Slow Or Low Powered XO330 / 450

Test 004
Test 013
Test 024
Test 053
Test 054
Test 100
Test 200
Test 300

The XO330 and 450 models have an additional feature of boom priority. This feature is used for truck loading to give the boom
up service priority over the swing service, before carrying out any fault finding on swing circuit ensure that this function has
been deactivated. This function is turned on and off by rocker switch on left hand console which has picture of boom on it.
9803/6500
Issue 1
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 604
FF 604
XO330 / 450
Test 004
Test 100

9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 605
FF 605
Swing Operation Operation Is Harsh When Selected XO330 / 450

Test 053
Test 100

Does the swing perform smother if boom down or boom up is selected at the same time as swing? If it does check to make
sure that connections to the pressure switches on shuttle block are fitted to correct switch.
9803/6500
Issue 1
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 606
FF 606
Machine Performance is Unsatisfactory XO330 / 450

Test 004
Test 013
Test 024
Test 029
Test 100
Test 200
Test 300

9803/6500
Issue 1
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 650
FF 650
Machine Tracks Off Line During Straight Travel
XO130 / 160
If experiencing machine tracking off line, carry out following checks:
Test 001
Test 021
Test 050
Test 051
Test 052

Testing track motor relief valve settings
Testing track motor drain line rates
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 two
main 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?
9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 651
FF 651
XO200 / 220 / 240 / 260
Test 003
Test 023
Test 050
Test 051
Test 052

Swap the two main hoses on the hydraulic pump, does the problem change direction?
9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 652
FF 652
XO330 / 450
Test 004
Test 024
Test 050
Test 051
Test 052

Swap the two main hoses on the hydraulic pump , does the problem change direction?
9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 653
FF 653
Poor Tractive Effort
XO130 / 160 / 180
If experiencing poor tractive effort, carry out following checks:
Test 001
Test 021
Test 050
Test 051

What travel gear is the machine operating in when the problem occurs?
See also Fault 662.
9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 654
FF 654
XO200 / 220 / 240 / 260
Test 003
Test 023
Test 050
Test 051

See also Fault 662.
9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 655
FF 655
XO330 / 450
Test 004
Test 024
Test 050
Test 051

See also Fault 662.
9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 656
FF 656
Loss of High Speed Tracking
XO130 / 160 / 180
If experiencing loss of high speed tracking, carry out following checks:
Test 052
Test 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 (see
illustration below)
Pilot port to select high gear
A318900
Front view of 8
spool valve
High speed tracking

solenoid
A326403
When high speed tracking has been selected is electrical voltage seen at high speed tracking solenoid?
yes / no ?
9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 657
FF 657
XO200 / 220 / 240 / 260
Test 052
Test 100

illustration below).
A318900
Front view of 8
spool valve
High speed tracking

solenoid
A326403
yes / no ?
9803/6500
Issue 1
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 658
FF 658
XO330 / 450
Test 052
Test 100

illustration below).
A318900
Front view of 8
spool valve
High speed tracking

solenoid
A326403
yes / no ?
9803/6500
Issue 1
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 659
FF 659
Loss of Creep Speed Tracking
XO130 / 160 / 180
If experiencing loss of creep speed tracking, carry out following checks:
Test 010
Test 052
Test 100

When creep speed tracking is selected is tortoise symbol displayed on monitor?
yes / no
9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 660
FF 660
XO200 / 220 / 240 / 260
Test 012
Test 052
Test 100

yes / no
9803/6500
Issue 1
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 661
FF 661
XO330 / 450
Test 013
Test 052
Test 100

yes / no
9803/6500
Issue 1
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 662
FF 662
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 display
has not changed carry out following checks :
What pressure is seen at pilot port X ( see below ) when :

1
2
3
middle tracking gear is selected?

middle tracking gear is selected and tracking service is stalled , forwards and backwards on both left and right hand
tracks?
high tracking gear is selected?
Pilot port X
A318900
Front view of 8
spool valve
High speed tracking

solenoid
A326403
What electrical voltage is seen at high speed tracking solenoid when :

1
middle tracking gear is selected?
2
high tracking gear is selected?
9803/6500
Issue 1
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 700
FF 700
Poor Top Road Speed
XO130W / 160W
If experiencing poor top road speed, carry out following checks:
Test 011
Test 022
Test 060
Test 061
Test 062
Test 100
Test 200
Testing max flow cut / drive control signal

Testing threshold pressure
Testing drive motor minimum displacement setting
Testing machine propshaft speeds
Testing engine speeds
9803/6500
Issue 1
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 701
FF 701
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), carry
out following checks:
Test 062
Test 063
Test 100
Testing propshaft speeds

Testing clutch pack pressure / park brake pressure
The controller will not energise any solenoids if it thinks that the engine is not running , check to make sure that the controller
is 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?
9803/6500
Issue 1
RETURN
Section 1
Fault Finding Index
PRINT
Section 1
FF 702
FF 702
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
Test 063
Test 100
Testing propshaft speeds

The controller will not energise any solenoids if it thinks that the engine is not running , check to make sure that the controller
is 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 sub
monitor and not by footswitch.
9803/6500
Issue 3
RETURN
Section 1
Fault Finding Index
FF 703
PRINT
Section 1
FF 703
XO130W / 160W / XO200W
Test 011
Test 022
Test 060
Test 061
Test 062
Test 066
Test 100
Test 200
Testing max flow cut / drive control signal

Testing threshold pressure
Testing drive motor minimum displacement setting
Testing machine propshaft speeds
Checking theshold pressure - XO200W only,
9803/6500
Issue 3
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 704
FF 704
Loss of Drive
XO130W / 160W
If experiencing loss of drive carry out following checks:

Test 063
When the electrical connector is removed from drive safety switch (on transmission control valve, see below) and a piece of
wire used to bridge the contacts is drive restored?
View of transmission control valve
Link wire
Harness connector
When parkbrake solenoid is overridden is drive restored? To do this push and then twist the override button this will release
the park brake solenoid (as below).
Park brake overide button
9803/6500
Issue 1
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 705
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
9803/6500
Issue 1
RETURN
Section 1
Fault Finding Index
FF 706
PRINT
Section 1
FF 706
Poor Steering and Braking Performance XO200W

If experiencing Poor Steering and Braking Performance carry out following tests:
Test 032
Test 033
9803/6500
Checking steering pressure

Checking latch brake pressure
Issue 3
RETURN
Section 1
Fault Finding Index
FF 800
PRINT
Section 1
FF 800
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 of
hydraulic pump either due to pump regulator sticking or incorrectly adjusted.
This can be confirmed by following test:
Test 030
Flow testing of hydraulic pump
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
Expected test time to complete all above tests 1 hr
9803/6500
Issue 2
Section 1
RETURN
PRINT
Fault Finding Index
Section 1
FF 900
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 chaffed
through.
9803/6500
Issue 2
JCB HEAVY PRODUCTS LIMITED

FAULT FINDING SYSTEM
WARNING
The procedures described in this publication must be used in conjunction
with the relevant machine Service Manual and Operator Handbook.
Observe all relevant Safety Information contained in those documents.
PLEASE CLICK IN THE BOX BELOW TO SIGNIFY THAT YOU

HAVE READ AND UNDERSTAND THE ABOVE WARNING.
EXIT TO MAIN SCREEN
Section 2
i
Test Procedures
Section 2
i
TEST PROCEDURE INDEX
ISSUE
2
2
2
2
3
Test 001
Test 002
Test 003
Test 004
Test 005
Testing negative control signal, XO130 / XO160 / XO180

Testing negative control signal, XO130/ XO160W
Testing negative control signal, XO200 / XO220 / XO240 / XO260
Testing negative control signal, XO330 / XO450
Testing load sense pressures, XO200W
Test 010
Test 011
Test 012
Test 013
Test 014
Test 015
Testing max flow cut signal, XO130 / XO160 / XO180

Testing max flow cut signal / drive control signal, XO130W / XO160W
Testing max flow cut signal, XO200 / XO220 / XO240 / XO260
Testing max flow cut signal, XO330 / XO450
Testing P shift, XO200W
Testing servo pressure, XO200W
2
2
2
2
3
3
Test 020
Test 021
Test 022
Test 023
Test 024
Test 025
Test 026
Test 027
Test 028
Test 029
Testing main pump pressures , XO70

Testing main pump pressures, XO130 / XO160 / XO180
Testing main pump pressures, XO130W / XO160W
Testing main pump pressures, XO200 / XO220 / XO240 / XO260
Testing main pump pressures, XO330 / XO450
Testing main pump pressures, XO200W
Testing horsepower control, XO130 / XO160 / XO180
Testing horsepower control, XO130W / XO160W
Testing horsepower control, XO200 / XO220 / XO240 / XO260
Testing horsepower control, XO330 / XO450
1
1
1
1
1
3
1
1
1
1
Test 030
Test 031
Test 032
Test 033
Test 034
Test 039
Flow testing pump, all models

Testing pump milliamps
Testing steering pressure
Testing latch brake pressure
Flow testing pump, XO200W
Testing for trapped air in HBCV pilot line, all models
2
3
3
3
3
1
Test 040
Test 041
Test 042
Test 043
Test 044
Test 045
Testing H.B.C.Vs , XO130 boom ram, XO130W boom ram

Testing H.B.C.Vs , XO130 arm ram, XO160 arm ram, XO200 arm ram, XO240 arm ram,
XO240 arm ram, XO330 arm ram
Testing H.B.C.Vs, XO160 boom ram, XO160W boom ram, XO180 boom ram
Testing H.B.C.Vs , XO200 boom ram, XO200W boom ram, XO240 boom ram, XO330 boom ram
Testing H.B.C.Vs , XO220 T.A.B ram, XO200W T.A.B ram
Testing H.B.C.Vs , XO130W T.A.B ram, XO160W T.A.B ram
1
1
3
3
1
Test 050
Test 051
Test 052
Test 053
Test 054
Test 055
Test 056
Test 057
Test 058
Testing track motor relief valve settings, all models

Testing track motor drain line flow , all models
Testing track motor speeds, all models
Testing operation of swing brake , all models
Checking operation of main hydraulic spool, all models
Checking operation of boom 2 / bucket 2 boost spool, XO130, XO130W , XO160, XO160W
Checking operation of arm2 / boost spool, XO130, XO130W , XO160, XO160W
Testing Swing Relief Pressure, XO200W
Testing Swing/Boom - Priority, XO200W
1
1
1
1
1
1
2
3
3
Test 060
Test 061
Test 062
Test 063
Test 064
Test 065
Test 066
Test 067
Testing drive motor threshold pressure, XO130W , XO160W

Testing drive motor minimum displacement setting , XO130W , XO160W
Testing wheeled machine propshaft speeds XO 130W , XO160W , XO200W
Testing clutch pack pressure / park brake pressure, XO130W , XO160W , XO200W
Testing condition of off road clutch, XO130W , XO160W / XO200W
Testing condition of on road clutch, XO130W, XO160W / XO200W
Testing Threshold Pressure, XO200W
Testing Drive Circuit, XO200W
2
1
3
3
1
1
3
3
9803/6500
Issue 3
Section 2
ii
Section 2
Test Procedures
ii
TEST PROCEDURE INDEX
ISSUE
3
2
1
1
1
1
3
Test 099
Test 100
Test 101
Test 102
Test 103
Test 104
Test 105
Testing pressure switchs- all AMS models

Testing pressure switchs
Testing throttle motor unit
Testing throttle motor driver unit
Testing monitor unit
Testing installation of engine speed sensor
AMS Throttle Fault Finding- All AMS machines
Test 200
Test 201
Testing engine speed settings, all models except XO70

Testing engine speed settings, all AMS models except XO70
3
3
Test 300
Test 301
Test 350
Test 351
Testing machine cycle times, all models

Testing machine cycle times, all AMS models
Checking slew bearing backlash, all models
Checking slew bearing vertical lift, all models
2
2
1
1
(Test 001 -099 hydraulic) (Test100 - 199 electrical)

(Test 350 -400 mechanical)
9803/6500
(Test 200 - 299 engine)
(Test 300 - 349 general)
Issue 3
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 001
TP 001
Testing Negative Control Signal - XO 130/XO 160/XO 180
REAR VEIW OF HYDRAULIC

PUMP
P11
P21
G1
G2
A302850
Fit test gauges ( 0 - 60 bar ) into hose connections to ports P11 + P21 with tee piece adapter
Warm up machine hydraulic temperature to 50 C
Port P11
Port P21
(Expected Pressures)
With max engine rpms and no services selected record negative control pressure
(25 - 35 bar *)
(25 - 35 bar*)
(0 - 3 bar)
(0 - 3 bar)
(40 bar when first

selected for 0.5 sec
then 0 bar)
(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)
Select and stall boom up service record pressure

Fully select boom down record pressure when service first selected
* This pressure will vary with oil temperature and engine speed.
9803/6500
Issue 2
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 002
TP 002
Testing Negative Control Signal - XO 130W/XO 160W
REAR VEIW OF HYDRAULIC

PUMP
P11
P21
G1
G2
A302850
Fit test gauges ( 0 - 60 bar ) into hose connections to ports P11 + P21 with tee piece adapter
Port P11
Port P21
(25 - 35 bar*)
(25 - 35 bar *)
(0 - 3 bar)
(0 - 3 bar)
(40 bar when first

then 0 bar)
(25 - 35 bar)
(0 - 3 bar)
(12 - 16 bar)
(0 - 3 bar)
(12 - 16 bar)
(0 - 3 bar)
(0 - 3 bar)
(0 - 3 bar)
(0 - 3 bar)
(25 - 35 bar)
(0 - 3 bar)
(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)
9803/6500
Issue 2
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 003
TP 003
Testing Negative Control Signal - XO 200/XO 220/XO 240/XO 260
VIEW FROM REAR OF

HYDRAULIC PUMP
Port Pt2
A318950
Port Pt1
Fit test gauges ( 0 - 60 bar ) into hose connections to ports Pt1 + Pt2 with tee piece adapter
Port pt1
Port pt2
(30 - 35 bar*)
(30 - 35 bar*)
(0 - 3 bar)
(0 - 3 bar)
(40 bar when first
then 0 bar)
(30 - 35 bar)
(24 - 26 bar)
(0 bar)
(24 - 26 bar)
(0 bar)
(0 - 3 bar)
(0 - 3 bar)
(0 - 3 bar)
(0 - 3 bar)
(0 - 3 bar)
(30 - 35 bar)
(0 - 3 bar)
(30 - 35 bar)
(30 - 35 bar)
(0 - 3 bar)
(30 - 35 bar)
(0 - 3 bar)
(0 - 3 bar)
(30 - 35 bar)
(0 - 3 bar)
(30 - 35 bar)
9803/6500
Issue 2
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 004
TP 004
Testing Negative Control Signal - XO 330/XO 450
PZ2
Pi1
Pi2
PZ1
A436100
Tier 2 Machines
A436080
Fit test gauges ( 0 - 60 bar ) into hose connections to ports PZ1 + PZ1 with tee piece adapter
Port PZ1/Pi1
Port PZ2/Pi2
(25 - 35 bar*)
(25 - 35 bar*)
(0 - 3 bar)
(0 - 3 bar)
(40 bar when first
then 0 - 3 bar)
(25 - 35 bar*)
(16 - 20 bar)
(0 - 3 bar)
(16 - 20 bar)
(0 - 3 bar)
(0 - 3 bar)
(0 - 3 bar)
(0 - 3 bar)
(0 - 3 bar)
(0 bar)
(25 - 35 bar)
(0 bar)
(25 - 35 bar)
(0 bar)
(25 - 35 bar)
(0 bar)
(25 - 35 bar)
(25 - 35 bar)
(0 bar)
(25 - 35 bar)
(0 bar)
9803/6500
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 005
TP 005
Testing Load Sense Cut Off Pressure XO200W

B
A
A437080
To check the Load Sense cut off pressure carry out the following:
Warm up hydraulic system to 50C
Connect a pressure gauge (0~400 bar) at the Load Sense port of the pump A or at B if test point is fitted.
Generate MAX standard Load Sense pressure by stalling out the bucket service and recording the pressure
on the gauge.
Select Power boost and again stall out the bucket service, and record the pressure reading.
If the pressures are incorrect then adjust as required.
Expected
Pressures
290 bar
320 bar
Max pressure NO power boost

Max pressure Power boost selected
Adjusting the Load Sense Cut Off Valve
Remove the pilot hose and cap off hose but leave
the valve open to atmosphere.
Hold C and slacken off lock nut B.
Screw in A clockwise as far as it will go, then lock off B.
A
Hold E and slacken off lock nut D

Operate and stall the dipper (max RPM) and by
screwing C adjust the pressure (recorded on the LS
pressure gauge) to 320bar. Now lock nut D
Hold C and slacken lock nut B.
Again stall the dipper service and set the pressure to
290bar by screwing out A.
Re-tighten lock nut B.
Re-fit the pilot hose.
9803/6500
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 010
TP 010
Test Max Flow Signal - XO 130/XO 160/XO 180

P12
Pm2
P22
Pm1
A31895
JS11200
JS 130 from 890083

JS160 from 703390
JS180 from 27.05.01
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)
Port Pm1
Port Pm2
(0 - 1.5 bar)
(0 - 1.5 bar)
(40 bar)
(40 bar)

(40 bar)
(40 bar)
9803/6500
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 011
TP 011
Test Max Flow Cut Signal/Drive Control Signal - XO 130W/XO 160W

P12
Pm2
P22
Pm1
A31895
JS11200
JS 130 from 890083

JS160 from 703390
JS180 from 27.05.01
Fit test gauges ( 0 - 60 bar ) into hose connections to ports P12 + P22 or Ports Pm1 to Pm2 with tee piece adapter
Port P12/Pm1
Port P22/Pm2
(0 - 1.5 bar)
(0 - 1.5 bar)
(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)
(0 - 1.5 bar)
(0 - 1.5 bar)
(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
(0 - 1.5 bar)
(40 bar)
Select high speed gear and also select dozer mode

( by switch on left hand controller ) but do not operate dozer, record presure
Select medium speed gear ( arrow on monitor ) record pressure
9803/6500
record pressure
Issue 3
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 012
TP 012
Test Max Flow Signal - XO 200/XO 220/XO 240/XO 260

VIEW FROM REAR OF
HYDRAULIC PUMP
Port Pm2
Port Pm1
A318950
Fit test gauges ( 0 - 60 bar ) into hose connections to ports Pm1 + Pm2 with tee piece adapter
Port Pm1
Port Pm2
(0 - 1.5 bar)
(0 - 1.5 bar)
(40 bar)
(40 bar)

(40 bar)
(40 bar)
9803/6500
Issue 2
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 013
TP 013
Test Max Flow Signal - XO 330/XO 450

Port Pm1
Port SC
Port Pm2
A436110
Tier 2 Machines
G
Fit test gauge ( 0 - 60 bar ) to port SC or port Pm1/Pm2 with tee piece adapter
A436080
Port SC/ Pm1 /Pm2

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

(40 bar)
9803/6500
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP014
TP014
Testing P Shift XO200W
A437080
Fit test gauge ( 0 - 60 bar ) to A with tee piece adapter

9803/6500
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP015
TP015
Testing Servo Pressure XO200W
A436040
Fit test gauges ( 0 - 600 bar ) into test point 1

Expected Pressures
No Services
35 bar
Any service selected
35 bar
Pressures to be tested at maximum engine speed
To adjust servo pressure:

Remove blank plug A.
Use an Allen key into B and adjust as required: Screw in
to increase pressure / out to de-crease pressure.
Re-fit cap A
A
B
A436200
9803/6500
Issue 3
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 020
TP 020
Testing Main Pump Pressure XO 70
G1
A297090
G1
G2
Main, Dipper, Swing

Main, Boom, Bucket
G2
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*)
(284 bar)
(284 bar)
(12 - 20 bar*)
(284 bar)
(12 - 20 bar*)
(284 bar)
(284 bar)
(284 bar)
Select and stall dipper close service record pressure
(284 bar)
(284 bar)
(206 bar)
(12 - 20 bar*)
(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.

9803/6500
Issue 1
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 021
TP 021
Testing Main Pump Pressure XO 130/XO 160/XO 180

REAR VIEW OF
HYDRAULIC PUMP
G1
G2
G1
403610
G2
A302850
JS 130 from 890083

JS160 from 703390
JS180 from 27.05.01

Port G1
Port G2
(25 - 35 bar*)
(25 - 35 bar*)
(314 bar)
(314 bar)
(314 bar)
(180 - 314 bar)
(314 bar)
(180 - 314 bar)
(314 bar)
(314 bar)
(314 bar)
(314 bar)
(25 - 35 bar)
(310 bar)
(25 - 35 bar)
(310 bar)
(345 bar)
(25 - 35 bar)
(345 bar)
(25 - 35 bar)
(25 - 35 bar)
(345 bar)
(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.

9803/6500
Issue 3
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 022
TP 022
Testing Main Pump Pressure XO 130W/XO 160W

VIEW OF
HYDRAULIC PUMP
G1
G2
A302840

Port G1
Port G2
(25 - 35 bar*)
(25 - 35 bar*)
(314 bar)
(314 bar)
(314 bar)
(180 - 314 bar)
(314 bar)
(180 - 314 bar)
(314 bar)
(314 bar)
(314 bar)
(314 bar)
(25 - 35 bar)
(310 bar)
(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)
9803/6500
Issue 1
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 023
TP 023
Testing Main Pump Pressure XO 200/XO 220/XO 240/XO 260
FRONT VIEW OF
HYDRAULIC PUMP
Port G1
(nearest engine)
Port G2

Port G1
Port G2
(25 - 35 bar*)
(25 - 35 bar*)
(318 bar)
(318 bar)
(210 - 318 bar)
(318 bar)
(210 - 318 bar)
(318 bar)
(318 bar)
(318 bar)
(318 bar)
(318 bar)
(279 bar)
(25 - 35 bar)
(279 bar)
(25 - 35 bar)
(25 - 35 bar)
(343 bar)
(25 - 35 bar)
(343 bar)
(343 bar)
(25 - 35 bar)
(343 bar)
(25 - 35 bar)
(343 bar)
(343 bar)
9803/6500
Issue 1
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 024
TP 024
Testing Main Pressure Excavator Services XO 330/XO 450
a1
a2
MA1
MA2
A436110
Tier 2 Machines
A436080
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
(25 - 35 bar*)
(25 - 35 bar*)
(318 bar)
(318 bar)
(200 - 318 bar)
(318 bar)
(200 - 318 bar)
(318 bar)
(318 bar)
(318 bar)
(318 bar)
(318 bar)
(279 bar)
(25 - 35 bar)
(279 bar)
(25 - 35 bar)
(318 bar)
(25 - 35 bar)
(318 bar)
(25 - 35 bar)
(25 - 34 bar)
(318 bar)
(25 - 35 bar)
(318 bar)
(348 bar)
(348 bar)
9803/6500
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP025
TP025
Testing Main Pump Pressure XO200W
A436040
Fit test gauges ( 0 - 600 bar ) into test point 3

Test Point 3
(40bar*)
(314 bar)
(314 bar)
(314 bar)
(314 bar)
(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)
Note: Operating power boost, (two stage relief) will increase the Main releif valve pressure to 343 bar.
9803/6500
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 026
Testing Horsepower Control
VIEW FROM
UNDERSIDE OF
HYDRAULIC PUMP
TP 026
XO130 / XO160 / XO180

Tier 2
Machines
Proportional solenoid
secondary pressure
measurement port
A407830
A326230
Fit gauge ( 0 - 60 bar ) into proportional solenoid

secondary pressure measurement port using suitable
adapter (port thread is 1/4 BSP O ring fitting).
Brown/Black (BrB)
Separate proportional solenoid electrical connector.

Using service connector from electrical test kit WDB0055
connect fluke meter in series as shown right.
OR
Using link wire, connect fluke meter in series as shown.
Brown/Black (BrB)
+ -
Pump side
harness
+ -
Warm up machine hydraulic temperature to 50 C.
Link wire
XO 130
XO 160
X0 180
Horsepower
Control
secondary
pressure
Milliamps
Horsepower
control
secondary
pressure
Milliamps
Horsepower
control
secondary
pressure
Milliamps
With maximum engine rpms and no

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

dipper service selected and stalled.
Select H mode measure and record
milliamps and secondary pressure.
11.5 bar
+/- 10%
355 ma
12 bar
+/- 10%
370 ma
12 bar
+/- 10%
370 ma

services operated. Select S mode
secondary pressure.
7.5 bar
+/- 10%*
625 bar
+/- 10%*
250 ma*
8 bar
+/- 10%*
265 ma
8 bar
+/- 10%*
265 ma
0 bar
0 ma
0 bar
0 ma
0 bar
0 ma

services operated. Select L mode
secondary pressure.
220 ma*
* Early XO 130 machines use 250 ma in S mode, later XO 130 machines use 220 ma
9803/6500
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 027
TP 027
XO 130w/XO 160w
VIEW FROM
UNDERSIDE OF
HYDRAULIC PUMP
Tier 2
Machines
Proportional solenoid secondary

pressure measurement port
A326230
A407830


Brown/Black (BrB)
Brown/Black (BrB)
+ -
OR
Pump side
harness
+ -
Link wire
XO 130w
XO 160w
Horsepower
Control
secondary
pressure
Milliamps
Horsepower
control
secondary
pressure
Milliamps

secondary pressure.
11.5 bar
+/- 10%
355 ma
12 bar
+/- 10%
370 ma

11.5 bar
+/- 10%
355 ma
12 bar
+/- 10%
370 ma

secondary pressure.
7.5 bar
+/- 10%
250 ma
8 bar
+/- 10%
265 ma
0 bar
0 ma
0 bar
0 ma

secondary pressure.
9803/6500
Issue 1
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 028
TP 028
XO200 / XO220 / XO240 /XO 260

VIEW FROM UNDERSIDE OF

HYDRAULIC PUMP
Later Machines
A407830
A326240

Brown/Black (BrB)

Brown/Black (BrB)
+ -
OR
Pump side
harness
+ -
Link wire
XO 200 / XO 220
XO 240 / XO 260
Horsepower
Control
secondary
pressure
Milliamps
Horsepower
control
secondary
pressure
Milliamps

secondary pressure.
7 ~12 bar
10 ~16 bar*
570 ma
495 ma
7 ~14 bar
7 ~14 bar*
520 ma
520 ma*

7 ~12 bar
10 ~16 bar*
570 ma
495 ma
7 ~14 bar
7 ~14 bar*
520 ma
520 ma*

secondary pressure.`
28 bar
+/- 1 bar
305 ma
26 bar
+/- 1 bar
330 ma
40 bar
0 ma
40 bar
0 ma

secondary pressure.
* Pre low emission machines
9803/6500
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 029
TP 029
XO 330 / XO 450
VIEW OF
HYDRAULIC PUMP
Tier 2 Machines

A326250
A436290

ad apter (port thread is 1/4 BSP O ring fitting).
Brown/Black (BrB)

Brown/Black (BrB)
+ -
OR
Pump side
harness
+ -

Link wire
XO 330

secondary pressure.
secondary pressure.
secondary pressure.
9803/6500
XO 450
Horsepower
Control
secondary
pressure
Milliamps
Horsepower
control
secondary
pressure
Milliamps
11.8 ~13.7 bar
520 ma
TBA
TBA
11.8 ~13.7 bar
520 ma
TBA
TBA
7.8 ~9.8 bar
410 ma
TBA
TBA
0 bar
0 ma
TBA
TBA
Issue 3
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 030
TP 030
Flow Testing Pumps - all XO Models except XO 70

G
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

G
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 sheet
attached).
Repeat this test for S mode, F mode and L mode.
To Confirm Maximum Flow Setting

G
Disconnect negative control pilot hose from pump which is being tested, plug the hoses and leave ports on pump open
to atmosphere.
Set machine to max engine rpms in H mode have the load valve on flow meter fully open and do not operate any
services.
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

G
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 on
sheet 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 on
sheet attached).
Increase the pressure in steps of 25 bar each time recording the pressure on both pumps, flow on the meter, engine
rpms 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, maximum
flow and horsepower control.
9803/6500
Issue 2
Section 2
RETURN
PRINT
Test Procedure
Section 2
Flow testing Pumps - all XO Models except XO 70 (Continued)

Minimum Flow Pump 1
Mode Pressure in P1 Pressure in P2
Flow
Rpm
Minimum Flow Pump 2

Maximum Flow Pump 1

Flow
Rpm
Maximum Flow Pump 2

Flow
Rpm
Flow
Rpm
Horsepower Control Pump 1 H Mode

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

Rpm Pump Ma
Horsepower Control Pump 1 S Mode

Rpm Pump Ma
Horsepower Control Pump 2 S Mode

Rpm Pump Ma
Horsepower Control Pump 1 L Mode

Rpm Pump Ma
Horsepower Control Pump 2 L Mode

Rpm Pump Ma
9803/6500
Issue 2
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 031
TP 031
Testing Milliamps XO200W
Brown/Black (BrB)
Brown/Black (BrB)

OR
+ -

Pump side
harness
+ -
Link wire
330470
Milliamps
measure and record milliamps.
495 ma

dipper service stalled.Select H mode,
measure and record milliamps.
495 ma
9803/6500
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 032
TP 032
Testing Steering Pressure XO200W
A436040
Fit a high pressure gauge into test point 2

Warm the hydraulic oil to 50C.
Record pressure with engine at Max speed.
Pressure should be recorded when the steering is held at full lock either way.
Expected Pressures
Steering held at full lock
175 bar
To Adjust Steering Pressure:

Slacken locknut A.
Use an Allen key to adjust pressure B.
Note: Screw B in to increase or out to de-crease pressure.
Tighten locknut A.
A
B
A436250
9803/6500
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 033
Testing Brake Latch Pressure
TP 033
XO200W
Test Point A
A436190
Fit a low pressure gauge into test point A on the rear axle of the machine (40 bar)
Run machine and latch the foot brake down, Record pressure.
Expected Brake Latch Pressure
65 bar
A436120
If this pressure is incorrect then adjust pressure by increasing or decreasing length of rod B.
9803/6500
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 034
TP 034
Flow Testing Pump - XO200W

Flowmeter
LS - pressure manometer
Adjustable Throttle
pc
Test Spool for max pump flow Part No. SSP0099
Pump Pressure
Fit pressure test gauges (0 - 600 bar) to main pump test points.
Install the special test spool SSP0099 in the bucket section of the main control valve.
Intall a flow meter and the metering orifice with the pressure gauge between the working ports A and B of the Bucket
section.
Install flow meter and load valve as close as possible to pump outlet in one of the pump lines.
Open the metering orifice completely.
Start the engine and warm up the hydraulic oil to at least 50 C.
Operated the bucket and record the maximum pump flow from the flow meter
9803/6500
Issue 3
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 039
TP 039
Testing for Trapped Air in HBCV Pilot Line

All HBCV installations except XO130 boom, XO130Wboom, XO 130W/XO 160W TAB
cylinders.
Boom HBCV Installation
1
Warm up hydraulic system to 50 C and operate boom up and down several times.
Set dipper to fully extend position and lower boom until bucket rests on the ground.
Set the engine speed to idle.
Whilst operator slowly selects boom down, open the bleed screw on one of the HBCVs (this is located next to the P port
on the valve).
Allow oil to flow through bled screw until a clear column of oil has been seen for at least three seconds.
Close bleed screw whilst operator is still selecting boom down.
Repeat procedure for other side.
Arm HBCV Installation

1
Warm up hydraulic system to 50 C and operate dipper in and out several times.
Set dipper to fully extended position and lower boom until bucket rests on the ground.
Set the engine speed to idle.
Whilst operator slowly selects dipper in, open the bleed screw on one of the HBCV (this is located next to the P port
on the valve).
Allow oil to flow through bled screw until a clear column of oil has been seen for at least three seconds.
Close bleed screw whilst operator is still selecting dipper in.
9803/6500
Issue 1
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 040
TP 040
Testing Boom Hose Burst Check Valve XO 130/XO 130W Boom Ram
Port E
Port P
Warm up the hydraulic system to 50 C.

Set the Main Relief Valve (MRV) pressure above the Auxiliary Relief Valve (ARV) pressure.
Set dipper to vertical position with bucket 300 mm (12) above ground and operate the emergency stop button to stop
the engine.
Select boom down until the bucket rests on the ground, then fully select the lever for boom down, this will ensure that the
pressure in the boom circuit has been vented.
It is only possible to test the relief valve setting of one side at a time.
Decide which side check valve you wish to test first.
On the relevant side valve to be tested.
Remove pilot hose from port P, plug hose and leave port open to atmosphere.
Remove pilot hose from port E, plug hose an fit test gauge (0 - 600 bar) to port on valve.
Start engine and raise boom.
Carefully select boom down and slowly build pressure until boom starts to move slowly and steadily.
Record pressure at this point, this is relief setting of HBCV.
To adjust this setting, remove cap from small cartridge on end of HBCV and adjust as necessary.
Refit pilot hoses and repeat this procedure for other side.
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
XO130W
9803/6500
350 bar
350 bar
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 041
TP 041
Testing Hose Burst Check Valve - Arm Ram

XO 130/XO 160/ XO 200/XO 220/ XO 240/XO 260/XO 330
Port E
Port P
A
A409671

Set dipper to fully extend position with bucket 300 mm (12) above ground and operate the emergency stop button, to
stop the engine.
Select arm in until the bucket rests on the ground, then fully select the lever for arm in, this will ensure that the pressure
in the arm circuit has been vented.
Fit test gauge (0 - 600 bar) to port E using appropriate adapter.
Start engine, lift boom to give clearance to move arm.
Carefully select arm in and slowly build pressure until arm starts to move slowly and steadily.
To adjust this setting, remove cap from small cartridge A and adjust as necessary.
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
XO130W
XO160
XO200/220
XO240/260
XO330
9803/6500
758500 ~
716500 ~
701000 ~ 702503
702504 ~
705000 ~ 705824
705824 ~
708500 ~ 708748
708748 ~
702500 ~ 712562
350 bar
350 bar
350 bar
370 - 390 bar
350 bar
370 - 390 bar
350 bar
370 - 390 bar
350 bar
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 042
TP 042
Testing Boom Hose Burst Check Valve XO160 / XO 160W / XO 180
VIEW FROM UNDERSIDE OF

LEFT HAND BOOM RAM
Port P
Port E

the engine.
Remove pilot hose from port E, plug hose and fit test gauge (0 - 600 bar) to port on valve.
XO160
XO160W
9803/6500
702000 ~
718500 ~
350 bar
350 bar
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 043
TP 043
Testing Boom Hose Burst Check Valve XO 200 /XO 220 /XO 220LR /XO 240 /XO 260 /XO 330/
XO 200W
VIEW OF LEFT HAND BOOM
CYLINDER
Port E
Port P
Set dipper to vertical position with bucket 300 mm (12) above ground and operate the emergency stop button to stop the
engine.
Remove pilot hose from port E, plug hose and fit test gauge (0 - 600 bar) to port on valve.
XO220/220
XO240/260
XO330
9803/6500
705000 ~
708500 ~
712500 ~ 712562
712562 ~
350 bar
350 bar
350 bar
370 - 390 bar
Issue 3
RETURN
Section2
Test Procedure
TP 044
PRINT
Section 2
TP 044
Testing TAB Ram Hose Burst Check Valve XO 220/ XO200W

Port E
Port P

the engine.
Select TAB down until the bucket rests on the ground, then fully select the pedal for TAB down, this will ensure that the
pressure in the TAB circuit has been vented.
Carefully select TAB down and slowly build pressure until TAB starts to move slowly and steadily.
To adjust this setting, remove cap from small cartridge and adjust as necessary.
NB - If TAB is selected too quickly a higher pressure will be seen at pressure gauge giving false reading of relief setting.

XO220 TAB
9803/6500
705000 ~
350 bar
Issue 3
RETURN
Section2
Test Procedure
TP 045
PRINT
Section 2
TP 045
Testing TAB Ram Hose Burst Check Valve XO130W / XO160W
Port P

the engine.
Select TAB down until the bucket rests on the ground, then fully select the pedal for TAB down, this will ensure that the
pressure in the TAB circuit has been vented.
Carefully select TAB down and slowly build pressure until TAB starts to move slowly and steadily.
To adjust this setting, remove cap from small cartridge and adjust as necessary.
NB - If TAB is selected too quickly a higher pressure will be seen at pressure gauge giving false reading of relief setting.

XO130W
XO160W
9803/6500
716500 ~
718500 ~
350 bar
350 bar
Issue 3
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 050
TP 050
Testing Track Motor Relief Valve Settings - All XO Machines
ARV
Alternative pressure
measuring ports
ARV
A318900
Fit pressure gauges ( 0 - 600 bar ) to main pump test ports ( see relevant test procedure for testing main pump
pressures).
Warm up hydraulic system to 50 C.
Testing Track Motor ARV Settings

Raise the setting of the main relief valve to enable the setting of the track motor ARVs to be reached.
Expected relief valve setting

Select and stall left hand track motor forward
(see table below)
Select and stall left hand track motor reverse
(see table below)
Select and stall right hand track motor forward
(see table below)
Select and stall right hand track motor reverse
(see table below)
Reset MRV to correct pressure
Travel Motor Relief Valve Settings

XO130W/XO160/XO180
XO200/XO220/XO240/XO260
XO330/XO450
9803/6500
350 bar
353 bar
324 bar
Issue 1
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 051
TP 051
Testing Track Motor Drain Line Flow Rate - All XO Machines
VIEW OF TRACK MOTOR

(COVER REMOVED)
Drain port D
A318900
Warm up hydraulic system to 50 C

Remove tank hose from drain port D on left hand track motor
Plug hose
Fit hose between drain port D and measuring container
Set machine to max engine rpms in middle gear (arrow on monitor)
Expected drain line rate ltrs / min
Select and stall left hand track motor forward
for 1 min
(consult Technical Service Department)
Select and stall left hand track motor reverse

for 1 min
Refit hose to track motor

Repeat above proceedure for right hand track motor
Expected drain line rate ltrs / min
Select and stall right hand track motor forward

for 1 min
Select and stall right hand track motor reverse

for 1 min

Expected Drain Line Rates - consult Technical Service Department
9803/6500
Issue 1
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 052
TP 052
Testing Track Motor Speeds - All XO Machines

Raise one track off floor by slewing machine through 90 and lifting machine using boom and dipper.
Make a mark on outside face of track motor.
Operate track service forward and reverse for approx 5 mins to distribute warm oil around track motor circuit
FOR ALL FOLLOWING TESTS USE STANDARD MODE, FULL ENGINE RPMS AND FULLY SELECT TRACK PEDAL
Expected RPMS
In high travel gear, select left hand track forward
(see table below)
In high travel gear, select left hand track backward
(see table below)
In medium travel gear, select left hand track forward
(see table below)
In medium travel gear, select left hand track backward
(see table below)
In creep travel gear, select left hand track forward
(see table below)
In creep travel gear, select left hand track backward
(see table below)
Expected RPMS
In high travel gear, select right hand track forward
(see table below)
In high travel gear, select right hand track backward
(see table below)
In medium travel gear, select right hand track forward
(see table below)
In medium travel gear, select right hand track backward
(see table below)
In creep travel gear, select right hand track forward
(see table below)
In creep travel gear, select right hand track backward
(see table below)
Expected Track Motor Speeds
9803/6500
Track motor rpms in high gear
Track motor rpms in low gear
XO130
48.5
31.25
XO160
47.25
26.75
XO180
TBA
TBA
XO200/220
47.5
27.5
XO240/260
46.26
27.75
XO330
TBA
TBA
X0450
TBA
TBA
Issue 1
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 053
TP 053
Testing Swing Brake Pressure - All XO Machines except XO 70
Swing Motor
A405810
Fit pressure test gauge ( 0 - 60 bar ) into hose connection on hose A on the swing motor.
Pressure at port B
(Expected Pressure)
With engine at max rpms no services selected
record pressure
(14 bar)
Select swing service

record pressure
(40 bar)
Deselect swing service

record pressure
(40 bar for 5 secs then 14 bar)
Select 100% swing lock

record pressure
(after 5 secs 0 - 1.5 bar)
9803/6500
Issue 3
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 054
TP 054
Checking the Operation of the Main Hydraulic Spool - All XO Machines
Cylinder port B
Cylinder port A
Sectional view of valve block

showing spool and pilot ports
Pilot port b
Pilot port
Valve block
Main spool
A325404
Identify which is main directional spool for service being tested, and which side of that spool is supplied pilot pressure
when service is operated in desired direction
Fit pressure gauges ( 0 - 60 bar ) to this port and also to port on opposite end of spool
Pressure at spool port which

is being selected
(Expected Pressure)
Pressure at spool port at

opposite end of spool
(Expected Pressure)
With max engine rpms and

no service selected
(0 - 3 bar)
(0 - 3 bar)
With service fully selected
(28 - 40 bar*)
(0 - 3 bar)
XO130
758000 ~ 758372
758373 ~ 758421
758422 ~
28 bar
32 bar
40 bar
XO130W
716500 ~ 716593
716594 ~ 716618
716619 ~
28 bar
32 bar
40 bar
XO160
702000 ~ 702250
702251 ~ 702290
702291 ~
28 bar
32 bar
40 bar
XO160W
718500 ~ 718560
718561 ~ 718586
718587 ~
28 bar
32 bar
40 bar
XO200/220
705001 ~ 705632
705633 ~ 705687
705688 ~
28 bar
32 bar
40 bar
XO240/260
708501 ~ 708683
708684 ~ 708703
708704 ~
28 bar
32 bar
40 bar
XO330
712501 ~ 712514
712514 ~
32 bar
40 bar
XO450
714501 ~
40 bar
Vent system pressure

Remove spool cap from main valve block and withdraw spool check for scratches / imperfections or any signs of
sticking. Refit spool into valve block and check forsmoothness of operation by slowly pushing spool in and out of valve
block.
9803/6500
Issue 1
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 055
TP 055
Testing the Operation of Boom 2/Bucket 2/Boost Spool XO 130/XO 130W/ XO 160/
XO160W
VIEW LOOKING DOWN
ON TOP OF MAIN
CONTROL VALVE
front of machine
Port d
Port dr2
Port b
A318940

Fit pressure gauges ( 0 - 60 bar ) into ports
b ( pilot port to select bucket boost )

d ( pilot port to select boom boost )
dr2 ( spool chamber drain port )
Port b
Port d
Port dr2
With max engine rpms and no services

selected
(0 - 3 bar)
(0 - 3 bar)
(0 - 3 bar)
Select and stall boom up service
(0 - 3 bar)
(28 - 40 bar)
(0 - 3 bar)
Select and stall bucket open service
(28 - 40 bar*)
(0 - 3 bar)
(0 - 3 bar)
Select and stall bucket close service
(28 - 40 bar*)
(0 - 3 bar)
(0 - 3 bar)
XO130
758000 ~ 758372
758373 ~ 758421
758422 ~
28 bar
32 bar
40 bar
XO130W
716500 ~ 716593
716594 ~ 716618
716619 ~
28 bar
32 bar
40 bar
XO160
702000 ~ 702250
702251 ~ 702290
702291 ~
28 bar
32 bar
40 bar
XO160W
718500 ~ 718560
718561 ~ 718586
718587 ~
28 bar
32 bar
40 bar
9803/6500
Issue 1
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 056
TP 056
Testing the Operation of the Arm 2 Boost Spool - XO 130/XO 130W/XO 160/XO 160W
VIEW LOOKING DOWN
ON TOP OF MAIN
CONTROL VALVE
front of machine
Port a1
Port dr1
A318940

Fit pressure gauges ( 0 - 60 bar ) into ports al ( pilot port to select boost spool )
and port dr1 ( spool chamber drain port )
Port al
Port dr1
(0 - 3 bar)
(0 - 3 bar)
Select and stall arm out service
(28 - 40 bar*)
(0 - 3 bar)
Select and stall arm in service
(28 - 40 bar*)
(0 - 3 bar)
With max engine rpms and no services selected
XO130
758000 ~ 758372
758373 ~ 758421
758422 ~
28 bar
32 bar
40 bar
XO130W
716500 ~ 716593
716594 ~ 716618
716619 ~
28 bar
32 bar
40 bar
XO160
702000 ~ 702250
702251 ~ 702290
702291 ~
28 bar
32 bar
40 bar
XO160W
718500 ~ 718560
718561 ~ 718586
718587 ~
28 bar
32 bar
40 bar
9803/6500
Issue 2
RETURN
Section2
Test Procedure
PRINT
Section 2
TP 057
TP 057
Testing Swing Relief Pressure - XO200W

Note: The manual swing lock bar should be installed for the followingh test.
Fit a high pressure gauge into the LS port 1 on the pump.

Disconnect and blank off the pilot hose 2 on the swing motor.
Start the engine and run the machine at 1250rpm.
With the swing service Fully selected, recorded pressure.
If the swing main relief pressure is low, adjustment should be made at the torque control valve. This is situated on the main
valve block on the bottom side of the swing section.
To adjust swing relief pressure:
Remove the pilot hose from the torque control valve.
Using the correct tools hold C and loosen lock nut B
Wind in A as far as it will go, then lock off B
Hold E and slacken lock nut D
Re-fit the pilot hose to the torque control valve
Start and run the machine at a minimum of 1250 rpm
With the swing service FULLY selected adjust C until the pressure on the LS port reaches 230bar.
Once this pressure has been set, tighten locknut D.
9803/6500
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 058
TP 058
Testing Swing/Boom Priority - XO200W
A436380
To test the swing/boom priority:

Locate the swing/boom priority valve and install a 60 bar pressure gauge at A.
Install the manual swing lock bar.
Record the pressure with the machine in Boom priority (AMS machines mode 1) and in Swing priority
Note: AMS machines only

When checking with boom priority boom up must be selected at the same time as swing.
Boom priority is selectable between 0 and 10.
The pressure difference between each digit is approx 1.5 bar.
Machine in Boom Priority

Machine in Swing Priority
Expected pressure
15 bar
40 bar
This pressure is dependant upon the temperature of the oil.
9803/6500
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 060
TP 060
Testing Drive Motor Threshold Pressure XO 130W/ XO 145/ XO 160W/ XO 175

Port X4
View of drive motor
Port X1
Threshold pressure
adjuster
A301900
Warm up the hydraulic system to 50.

RaIse the machine off the ground using dozer blade, stabiliser legs or excavator end.
Fit adapters (14 mm O ring to fit into motor casing/appropriate fitting for test gauges) into ports X1 and X4 and fit test
gauges (0 - 600 bar) onto adapters.
Select high gear and then select drive forwards 2 - 3 mins to allow the system to distribute warm oil around the circuit.
Fully select and lock brake pedal.
Slowly select drive service pedal and carefully build pressure in drive circuit
Pressure should build in port X4.
Note the pressure in port X4 when pressure starts to raise in port X1.
If pressure in port X4 does not reach 210 bar or raised higher than 230 bar then the setting screw will need to be
adjusted.
To adjust pressure remove cap from adjuster. Screwing the adjuster in will increase the pressure, screwing the adjuster
out will decrease the pressure (only make small adjustments).
If threshold pressure is too high then machine will have poor hillclimbing ability and if threshold pressure is too low then poor
top speed will be achieved.
Threshold Pressure Settings

XO130W
210 ~ 230 bar
XO160W
210 ~ 230 bar
XO145W and XO175W 190 bar
9803/6500
Issue 3
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 061
TP 061
Testing Drive Motor Minimum Displacement Setting XO130W / XO145W/ XO160W/ XO175W
The minimum displacement setting determines the maximum road speed of the machine, to check the setting carry out the
following
Remove the four capscrews which hold the lower plate in place
Check dimension A against the table below
If dimension A is incorrect adjust to correct setting
View of drive motor
A301900
Locking and sealing nut
Dimension A
130W
15 mm
130W ( German build only )
27 mm
160W
15 mm
160W ( German build only )
31 mm
9803/6500
Issue 1
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 062
TP 062
Testing Propshaft RPM XO 130W / XO145 / XO 160W XO175W / XO200W
Fit reflective tape

onto propshaft
A301900

Raise the machine off the ground using dozer blade, stabilizer legs or excavator end
Select high gear and then select drive forwards for 2 - 3 mins to allow the system to distribute warm oil around the circuit
Attach reflective tape to propshaft and using tachometer record propshaft rpms as follows
FOR ALL TESTS USE MAX ENGINE RPMS AND FULLY SELECT DRIVE PEDAL
XO130W
XO145W
Expected
Expected
rpms
rpms
(German build ) (German build )
High gear
XO160W
XO175W
XO 200W
Expected
rpms
(German build)
Expected
rpms
(German build)
rpms
(German build)
2500 rpm
(1760 rpm)
2700 rpm
(1760 rpm)
2700
(1760 rpm)
3000
(1760 rpm)
2700 - 2850
(2150 - 2250)
1750 rpm
(1250 rpm)
1000 rpm
(1250 rpm)
1940 rpm
(1250 rpm)
1000
(1250 rpm)
1000
(1250 rpm)
Medium gear
680 rpm
(500 rpm)
850 rpm
(500 rpm)
764 rpm
(500 rpm)
850
(500 rpm)
800 - 848
(800 - 848)
Medium gear with

dozer mode selected
but dozer not operated
460 rpm
(330 rpm)
350 rpm
(330 rpm)
520 rpm
(330 rpm)
350
(330 rpm)
270
(270)
Creep gear
290 rpm
(200 rpm)
350 rpm
(200 rpm)
340 rpm
(200 rpm)
350
(200 rpm)
300 - 325
(300 - 325)
Creep gear with

dozer mode selected
290 rpm
(200 rpm)
350 rpm
(200 rpm)
(340 rpm)
(200 rpm)
350
(200 rpm)
(300)
(300)
High gear with

dozer mode selected
Tolerance +/- 50 rpms unless otherwise stated
9803/6500
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 063
TP 063
Testing Clutch Pack Pressure/Park Brake Pressure XO130W/XO160W / XO200W

VIEW OF HYDRAULIC
PUMP BAY
Port A1
Port B1
A306500
Warm up hydraulic system to at 50 C.

Fit test gauges ( 0 - 60 bar ) into ports A1+ B1
Port A1
(Expected Pressure)
Port B1
(Expected Pressure)
(0 - 3 bar)
(32 bar)
With max engine rpms and medium travel gear selected
(32 bar)
(0 - 3 bar)
With max engine rpms and creep travel gear selected
(32 bar)
(0 - 3 bar)
(0 - 3 bar)
(14 bar)
With max engine rpms and high travel gear selected
With max engine rpms and high travel gear selected,

select park brake on ( in cab )
9803/6500
Issue 3
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 064
Testing Condition of Off Road Clutch
TP 064
XO130W / XO160W / X0220W

Off road clutch test
point
A326270
To test the condition of the seals in the off road clutch pack, carry out the following procedure:
Park the machine on firm level ground, apply park brake and release pressure from hydraulic tank.
Disconnect and plug the hoses from the drive motor. Remove drive motor from transmission housing.
Remove plug from the off road clutch test point and fit adapter part number SST0018, test gauge (0 - 60 bar) and hand
pump, as detailed in Technical Information Bulletin (11/057).
Note: It is only possible to test the off road clutch using special adapter SST0018 as this clutch pack has a leak off
facility which lubricates the main bearing in gearbox. The special adapter blanks off this function to allow pressure
testing.
Using hand pump, build up pressure in clutch pack to 35 bar then lock off hand pump to hold pressure in clutch.
Monitor pressure in clutch for any signs of loss of pressure.
No loss of pressure should be seen over 3 minutes.
If any loss of pressure is seen the clutch unit will have to be removed for investigation/re-sealing.
9803/6500
Issue 1
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 065
Testing Condition of On Road Clutch
TP 065
XO130W / XO160W / X0220W
On road clutch test

point
A326280
To test the condition of the seals in the on road clutch pack, carry out the following procedure:
Park the machine on firm level ground, apply park brake and release pressure from hydraulic tank.
Disconnect and plug the hose shown.
Remove adapter from on road clutch test point and fit adapter part number 816/15160, test gauge (0-60 bar) and hand
pump, as detailed in Technical Information Bulletin (11/057).
Using hand pump, build up pressure in clutch pack to 35 bar then lock off hand pump to hold pressure in clutch.
Monitor pressure in clutch for any signs of loss of pressure.
No loss of pressure should be seen over 3 minutes.
If any loss of pressure is seen the clutch unit will have to be removed for investigation/resealing.
9803/6500
Issue 1
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 066
TP 066
Testing Threshold Pressure XO200W
M
A437090
Fit a pressure gauge (0 - 600 bar) in to the drive motor ports M1 and G.
With the machine at working temperature drive the machine against its brakes in middle speed at max rpm.
OR
Raise the machine off the floor, drive the machine at Max rpm in middle speed. Slowly apply the brakes and monitor the
two gauges.
Drive should be taken up slowly and the pressure gauge on G should be 190~200 bar before the pressure gauge on M1
will rise from 0 bar to equal the pressure on port G.
Threshold pressure equals 190~200 bar.
Note: The adjustment is made by the setting screw shown below. Turning the adjustment screw in (clockwise) will decrease
the pressure setting.
Adjustment Screw
9803/6500
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 067
TP 067
Testing the drive circuit - XO200W

Pilot pressure to the drive pedal.
Before travel can take place the following procedures can be tested:
Pilot pressure from the pilot pump to the pilot filter.
Pilot pressure from pilot filter to the IN port of the transmission control valve.
Pilot pressure from the OUT port of the transmission control valve to the C1 port of the 9 station solenoid block.
Note:The Servo isolator (C1 and the drive isolator C3) must be energised before servo pressure will be available to the drive
pedal.
Pilot pressure from the pedal
Middle Speed
Pilot pressure from the pedal (forward) at port 1.
Pressure will now close the travel pressure switch on the shuttle valve (port S4)
Pressure from port B8 will enter the valve block on port b2.
The spool will now move allowing oil system oil to go to the travel motor.
Transmission control valve
Pilot pressure enters the valve and is reduced to 31 bar +/- 2 bar by the pressure reduction valve.
Oil is now available to the park brake spool.
Park brake on = no oil = no drive
Park brake off and oil is available through the gear change spool and out of port A1.
Any pressure that was in B1 can now be vented back to tank to stop both clutch packs operating.
31bar now lifts the clutch pack off and drive can be used in middle speed.
High speed.
Hydraulically the only difference is in the transmission control valve.
When high speed is selected the high-speed travel spool is energised and oil is now available through the B1 port.
Any oil that was in the A1 port again will be vented to tank.
Creep speed
Creep speed can only be selected when the machine is in Middle speed.
As per Middle speed and!
A hydraulic signal from the shuttle block (C9) to the 9 station solenoid block.
Electrically the creep speed solenoid is now energised and the servo pressure is now reduced to 15bar via the pressure
reduction valve. This now limits the amount of spool movement within the valve block.
At the same time the creep speed solenoid is energised the DPshift solenoid is energised.
Now servo pressure from the transmission control valve port C2 is available DPshift solenoid port Pst. This pressure will
act against the pump reducing its flow.
A437080
Pshift solenoid 1
Note: Drive cannot be activated until the clutch pack has been pressurised.
9803/6500
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 067
TP 067
Testing the drive circuit - XO200W - contd

3 Speed Travel
Creep relay
Travel pressure switch
Controller
IN
Travel
pedal
CN5 (6)
24v
Travel change switch
OUT
Creep
solenoid
valve
CN7 (7)
OUT
IN
CN4 (4)
CN6 (1)
Gear change
solenoid valve
Travel
Max Flow (Q) Cut
Pump
flow cut
relays
Amplifier
Travel pressure switch
3
4
5
GND 6
Pump flow
control
GND 9
24v 10
Pilot pump
10v 11
24v
OUT
CN6 (15)
CN6 (5)
OUT
Main pump
Controller
9803/6500
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 067
TP 067
Testing the drive circuit - XO200W - contd
High
Mid.
Low
Work
mode
Operation
Gear change
solenoid valve
Creep speed
solenoid valve
Pump flow cut

solenoid valve
Travel only
ON
OFF
OFF
Travel & Dozer
ON
ON
OFF
Travel & Other
ON
OFF
OFF
Travel only
OFF
OFF
OFF
Travel & Dozer
OFF
ON
OFF
Travel & Other
OFF
OFF
OFF
Travel only
OFF
ON
ON
Travel & Dozer
OFF
ON
ON
Travel & Other
OFF
ON
ON
S, H, L
Travel Pressure
Switch
Travel
Mode
OFF
High, Mid
ON
Blade
OFF
Low
Flow cut
solenoid valve
ON
9803/6500
Creep Solenoid
Valve ON
No signal to
solenoid valves
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 099
TP 099
Testing Pressure Switches - All AMS Machines except XO 70
POWER
MODE
A335120
Start the engine.
Press the set and mode buttons together for 5 seconds to access the Sub menu.
Use the Up and Down arrow buttons, until the Pilot SW appears on the screen.
Press ACK button.
Use the up & down buttons to scroll through the individual switches and check against the chart below.
Note:
22 bar = 319 lb in2

335 bar = 4857.5 lb in2
9803/6500
Function
Boom
Boom up Hammer
Slew
Travel
Boom up
OFF
ON
OFF
OFF
OFF
ON
Boom down
ON
OFF
OFF
OFF
OFF
ON
Dipper in
OFF
OFF
OFF
OFF
OFF
ON
Dipper out
OFF
OFF
OFF
OFF
OFF
ON
Bucket in and
out
OFF
OFF
OFF
OFF
OFF
ON
Slew left and

right
OFF
OFF
OFF
ON
Travel
OFF
OFF
OFF
OFF
Hammer
OFF
OFF
ON
OFF
OFF
ON
OFF
Upper
Boost
Only if main pump
pressure is above
335 bar
OFF
Only if main pump

pressure is above
335 bar
Only if main pump
pressure is above
335 bar
Only if main pump
pressure is above
335bar
ON
OFF
OFF
OFF
ON
OFF
Issue 3
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 100
TP 100
Testing Pressure Switches - All XO Machines except XO 70
WORK MODE
Message
MODE
CLOCK
WATER TEMP HYD. OIL TEMP
FUEL
Clock Screen
Remove the cover over redundancy buttons

Start engine
Press change button once
Press select button until CH : PS is displayed
The pressure switch information will be displayed on clock screen
Pressure Switch Screen Display

(expected
display)
(expected
display)
(expected
display)
(expected
display)
With no services selected
Select boom up service
Select travel service
Select swing service
Select boom down
Select boom up (XO330/450 only)
Select hammer service (if fitted)
9803/6500
Issue 1
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 101
TP 101
Testing Throttle Motor Unit - All XO Machines except XO 70
Throttle
Motor
Connector
1
2
3
4
5
6
7
8
9
Black
Dark Green
Blue
Brown
Red
Light Green
Orange
Yellow
White
Common to coils
Motor Case Earth
C.W Limit Switch
Coil A
Coil B
C/CW Limit Switch
Coil A1
Coil B1
Common to Limit Switches
089571
If suspecting a failed throttle motor unit, a bench test of the unit can be made using the chart below by check
resistances between terminals (the colors in the chart correspond to wire colors on motor connector).
Pay particular attention to resistance between pins 4 (brown wire), 5 (red wire), 7 (orange wire) and 8 (yellow wire) to pin
1 (black wire) as these are connections for internal coils of motor (indicated by shaded areas).
BLACK
DARK
GREEN
BLUE
BLACK
BROWN
RED
3 - 3.6
3 - 3.6
LIGHT
GREEN
ORANGE
YELLOW
3 - 3.6
3 - 3.6
WHITE
DARK
GREEN
BLUE
BROWN
3 - 3.6
RED
3 - 3.6
6 - 7.2
6 - 7.2
6 - 7.2
6 - 7.2
6 - 7.2
6 - 7.2
LIGHT
GREEN
ORANGE
3 - 3.6
6 - 7.2
6 - 7.2
YELLOW
3 - 3.6
6 - 7.2
6 - 7.2
WHITE
6 - 7.2
6 - 7.2
Indicates no contact
Indicates no contact until limit switch closes then 0.5
9803/6500
Issue 1
Section 2
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PRINT
Test Procedure
Section 2
TP 102
TP 102
Testing Throttle Motor Driver Unit - All XO Machines except XO 70

No
1
Coil A1 throttle motor
2
Coil B1 throttle motor
3
Earth shielding
4
Earth main
5
Motor pulse
6
Acc ignition
7
CW control
8
CCW control
9
Coil A throttle motor
10
Coil B throttle motor
11
Coil common feed
12
Common limit switches
13
24V feed
14
Spare
15
Limit switch (signal to
controller)
16
Limit switch CW
5 6 7 8
1 2 3 4
Function
9 10 11 12 13 14 15 16 17
Front View of Throttle Motor Drive Unit showing

Terminal Numbers
If suspecting a failed throttle motor driver unit then a bench test can be carried out by checking the resistances between
terminals as in the chart below
Pay particular attention to resistance between pins 1, 2, 9, 10 and other pins as these are connections to motor coils
(the shaded area of the table)
1
2.69
k
8k
5.6
k
2.69
k
8k
10.1
k
10
11
12
13
14
15
16
17
5.6
k
5.6
k
5.6
k
5.6
k
5.6
k
5.6
k
5.6
k
5.6
k
5.6
k
7.2
k
7.2
k
2.69
k
2.69
k
7.2
k
7.2
k
7.2
k
13.6
k
13.6
k
8k
8k
13.6
k
13.6
k
13.6
k
10.1
k
5.6
k
5.6
k
10.1
k
10.1
k
10.1
k
5.6
k
5.6
k
10.1
k
10.1
k
10.1
k
5.6
k
5.6
k
5.6
k
5.6
k
5.6
k
5.6
k
10.1
k
1
2
3
4
2.69
k
2.69
k
8k
8k
10.1
k
5.6
k
5.6
k
7.2
k
13.6
k
5.6
k
5.6
k
7.2
k
13.6
k
10.1
k
2.69
k
8k
5.6
k
5.6
k
130
k
110
k
9
10
11
12
13
14
2.69
k
8k
5.6
k
5.6
k
15
5.6
k
5.6
k
7.2
k
13.6
k
10.1
k
10.1
k
5.6
k
5.6
k
16
5.6
k
5.6
k
7.2
k
13.6
k
10.1
k
10.1
k
5.6
k
5.6
k
17
5.6
k
5.6
k
7.2
k
13.6
k
10.1
k
10.1
k
5.6
k
5.6
k
10.1
k
10.1
k
10.1
k
indicates no connection
9803/6500
Issue 1
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 103
TP 103
Testing Monitor Unit - All XO Machines except XO 70
WORK MODE
Message
MODE
CLOCK
1
2
3
4
5
6
7
8
9
black
green/white
blue/green
space
red/yellow
red/green
yellow/white
yellow/gold
yellow/green
WATER TEMP HYD. OIL TEMP
FUEL
ground
adjust hours indication
adjust minute indication
24V supply
10V supply
data
data
data
If suspecting a failed monitor unit a bench test can be carried out by checking the resistances between terminals as in
table below
1
1
6 k
6 k
1 k
6 k
6 k
6 k
1 k
1 k
1 k
1 k
1 k
1 k
6 k
6 k
1 k
3.8M
3.8M
3.8M
3.8M
3.8M
3.8M
2M
2M
2M
2M
2M
2M
6 k
1 k
1 k
1 k
1 k
6 k
6 k
1 k
1 k
6 k
1 k
1 k
1 k
1 k
1 k
Indicates no connection
9803/6500
Issue 1
Section 2
RETURN
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Test Procedure
Section 2
TP 104
TP 104
Testing Installation of Engine Speed Sensor If the engine speed sensor is incorrectly set it can lead to loss of machine performance and CAPS related functions, e.g. loss
of high speed travel or loss of power boost functions.
If the engine speed sensor fails completely or the electrical connection is lost, the number 0003 will be displayed on the self
check monitor when checking engine revolutions. This will be displayed even when the engine is running.
To check the installation of the engine rpm sensor carry out the following procedure.
Installation procedure XO 130 / XO 130w / XO 160 / XO 160w Isuzu engine:
1
Remove sensor, clean sensor with dry lint free cloth and
inspect the tip of the sensor for damage.
Ensure that threads of sensor are clean and free from

damage.
Carefully screw in the sensor until it touches the ring gear.

(Do not use excessive force).
Make a mark across from the sensor onto the flywheel

housing.
Using the mark as a guide, back out the sensor two full
rotations and fasten with the lock nut.
Torque tighten to 44~54 Nm (32.5~39.7 lbf ft).

Clearance between sensor tip and ring gear 3.0 mm + 0.1 mm/-0
mm (0.118 + 0.004 / -0 in).
Installation procedure XO 130w / XO 160w JCB Diesel engine:

1

damage.


housing.

Clearance between sensor tip and ring gear 3.0 mm + 0.25 mm/
-0.25 mm (0.188 + 0.001 / -0.01 in).
Continued on next page....
9803/6500
Issue 1
Section 2
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Test Procedure
Section 2
Testing Installation of Engine Speed Sensor (contd) Installation procedure XO 200 / XO 210 / XO 220 / XO 260 / XO 200W Isuzu engine:
1

damage.
Carefully screw in the sensor.
-0 mm (0.122 + 0.016 / -0 in).
Installation procedure XO 200W JCB Diesel engine:

1

damage.


housing.

-0.25 mm (0.118 + 0.01 / -0.01 in).
Installation procedure XO 330 / XO 450 Isuzu engine:
1

damage.


housing.
Torque tighten to 29.4 Nm (21.69 lbf ft).

-0.2 mm (0.137 + 0.008 / -0.008 in).
9803/6500
Issue 1
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Section2
PRINT
Section 2
Test Procedure
TP 105
TP 105
AMS Throttle Fault Finding - All AMS Machines

E
A
K
AMS Throttle Assembly
Note: Throttle position sensor
(behind the throttle lever)
A Throttle control valve
B Throttle linkage
C Throttle actuator
D Stop solenoid
E Throttle cable
F Stop cable
G Throttle Lever
H Feedback Potentiometer
J
B
C
F
D
G
A436300
This document describes the procedure for trouble shooting

AMS throttle problems. Specifically when the engine can be
started, but the throttle dial cannot control the engine
speed.
Perform the following checks:
a Confirm "one touch" or "auto idle" is not
selected.Confirm that the hammer pressure switch is not
closed and check that the machine is not in
redundancymode.
b Check the fuse A2 (15 Amp) - Replace if blown.
c Recalibrate the throttle system on the 20-second menu.
d Check the software version in each module
(ECU1,ECUW and EMS). If required, re-programme with
the latest software.
e Check the set up configuration and correct if wrong
Note: The "NO THROTTLE" message may appear during
AUTOWARM UP with ECU1 version 1.25 and EMS
version1.18 or lower.
If the problems persist after the above checks:
1 When calibrating the throttle does the engine speed
initially increase then start to slowly reduce
(normalprocedure)?. If YES go to 2, if NO go to 5.
2
Check the engine speed sensor - Start the engine and

display engine RPM on the monitor. Is the correct engine
speed displayed. If YES go to 3, if NO, check engine
speed sensor gap and check the harness using figure 1.
If both are correct replace the sensor
Check the throttle dial potentiometer. Start the engine

and display "THROTTLE POT" on the monitor. Turn the
dial to minimum, then to maximum. Does the value
change form 0 to 5000 smoothly? If YES, go to 4, if NO,
check the potentiometer is securely fixed, check the
wiring using figure 2. If both are correct replacen the
potentiometer.
9803/6500
Check the feed back potentiometer (Sensor). Start the

engine and display "SENSE POT" on the monitor.
Manually move the lever (See figure 2 item G). Does the
value change smoothly? If YES go to 5, if NO check the
potentiometer is securely fixed. Check the wiring (Figure
1), if both are correct replace the potentiometer (Figure 2
item H).
5 Check the throttle cable and linkages are free. With the
engine stopped, disconnect the throttle linkage (Figure 2
at J) and then push/pull the cable. Does the lever on the
injection pump move smoothly? If NO, cable is broken or
sticking - Replace the cable and recheck. Does the lever
G move smoothly? If NO, replace the nylon bush. If YES,
go to 6.
6 Reconnect the throttle linkage to the lever. Start the
engine and manually push the lever (Figure 2 item G).
Does the engine speed increase? If YES, go to 7 if NO,
possible injection pump failure.
7
Checking the throttle solenoid (Figure 2 item A).

a Check the hosing to the solenoid is correct. Is the
supply hose going to the "P" port? Is the tank hose
connected to the "T" port? Is the actuator hose
connected to the "A" port? If YES go to 7b. If NO
connect the hoses correctly.
b Check the pressure at port "P". Is the pressure greater
than 30 bar? If YES go to 7c if NO check the servo
pressure system.
c Check the pressure at port "T". Is the pressure less
than 1 bar? If YES go to 7d if NO check tank line for
blockage.
d Disconnect the connector at the solenoid and start the
engine. Arrange temporary wiring to supply 24 volts
directly to Pin 1 of the solenoid valve (see Figure 1) and a
ground/earth to pin 2. Does the engine go to maximum
rev/min? If YES, go to 7e, if NO, Install a 40 bar test
point in port "A" of the proportional solenoid valve at
position "K" (see figure 2).
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 105
TP 105
AMS Throttle Fault Finding - All AMS Machines - contd

d contd
With the engine running does the pressure change as the
throttle dial is moved? typical values are 4 bar idle and
20 bars at full rev/min. if YES, check the linkage is free, if
the linkage is free, change the actuator "C". If NO
replace the solenoid "A".
Note: on earlier AMS machines the steel pipe connecting
the solenoid "A" to the actuator "C" can be replaced with
hose 627/10016.
e
Check the wiring to the solenoid for breaks or shorts. Is

the wiring OK? If YES, go to 8, if NO, repair the harness.
Checking the ECU1 function:

Check other ECU1 functions e.g. horn, wipers,lights etc.
All throttle functions are carried out by the ECU1. Do all
other tested functions work correctly? If YES, go to 9 if
NO, replace the ECU1.
Have any additional circuits been fitted to the machine.

e.g. Isolator, CB radio etc. Disconnect any additional
equipment installed and re-check.
10 Report the fault to technical service with the following

information:
Machine serial number
Any error codes displayed on the monitor or data
logger.
Throttle control data recorded during problem (See
following page).
Throttle calibration data. (See following page).
AMS Throttle Circuit Fig 1
From
Manual
Supplement
FromService
Service
Manual
Supplement
9803/6450
Page
5-12
9803/6450
Page
5-12
51
C68
SR
1
SG
+V REF
C22
THROTTLE VOLUME DIAL
C2
CONN B
C8
CONN A
ECU1
ENGINE CONTROL S.V.
10
SG
20
29
SG
SR
32
WY
WG
39
WG
WY
80
C87
0V REF
I/P 8 THROTTLE VOL.
I/P 17 ENGINE SPEED
I/P 6 THROTTLE LEVER
70 THROTTLE POSITION
SENSOR
WG 2
S 3
2A
CONN B 19
20
15A
C10
CONN C
O/P 1 THROTTLE CONT.
SG 1
C9
CONN B
IGNITION
WY
ENGINE SPEED SENSOR
21
15A FUSE AT CONN B 19 AND 20

FEEDS OUTPUTS 1 - 6
R
C25
P
4
2A
+24V IGNITION
A346060
9803/6500
Issue 3
RETURN
Section2
Test Procedure
PRINT
Section 2
TP 105
TP 105
AMS Throttle Fault Finding - All AMS Machines - contd
Thottle
Calibtration
Data
Throttle control
Data
Throttle calibration data
1
2
3
4
5
6
Typical values
Lower
Dial lower band
0
Dial upper band
950
Sense lower band (idle)
185
Sense upper band (max)
445
Sense upper band (S mode) 410
Sense upper band (H mode) 445
Upper
70
1000
485
760
720
760
7
8
9
Sense upper band (F mode) 390

Sense upper band (L mode) 390
Sense upper band (drive)
445
700
700
760
Note: These are typical values, actual values will vary

according to the machine. Values outside these ranges
may still be acceptable.
All the figures in the control data are a binary code and can
not be measured any other way.
Remarks
Usually 170~350 greater than sense lower band value.

Usually 25~45 lower than sense upper band (H mode).
Usually same as sense upper band (max) or within 10
- Except JS145W & JS175W.
Usually same as sense upper band (max) or within 10
Integral term is the response time which is not needed for
this publication.
Duty cycle is the frequency of the signal sent to the
proportional solenoid.
The dial bands are read from the throttle dial. The sensor
value is read from the feedback potentiometer.
The value in the boxes will represent the values seen when
the machine was calibrated.
Throttle percentage is the percent the throttle dial is turned.
Expected value is the value it expects to see from the
feedback potentiometer which is recorded when the throttle
is calibrated.
Actual value is what the feedback potentiometer is really
sending.
Error term is the difference between the expected and
actual.
9803/6500
Issue 3
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Section2
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Section 2
Test Procedure
TP 200
TP 200
Testing Engine Speed Settings - All XO Machines except XO 70

On CAP2 Machines
Warm up engine water temperature to 50 C (122F).
Remove cover over redundancy buttons
Press the change button once ( display will now show CH : MN )
Press the select button once ( display will now show CH : RPM )
Press the select button once more ( display will now show CH : PWM )
Expected RPMs
Select H mode and max engine rpms ( flight speed)
(see table below)
Select S mode and max engine rpms
(see table below)
Select L mode and max engine rpms
(see table below
Select H mode, max engine rpms and stall arm close service
( H mode minimum rpms )
(see table below)
Expected Milliamps
Select H mode, max engine rpms and stall arm close service
record milliamps
Model
XO130
XO130W
High Idle
(flight speed)
rpms
Arm stall H mode
minimum rpms
2385
2260
2385 2260
2220
2220
355
385
Stall H mode
minimum milliamps
9803/6500
XO160/
180
2505 2480
(see table below)
XO160W
XO200
220
XO200W
XO240
260
XO330
XO450
2505 2480
2205 2170
2205
2450 2365
2250 2365
2200
2340
2340
1930
2160
2180
2050
2050
370
370
570
495
520
520
410
Issue 3
RETURN
Section2
PRINT
Section 2
Test Procedure
TP 201
TP 201
Testing Engine Speed Settings - All AMS Machines

Warm Engine water temperature above 50 C (122F).
Press Set + Mode for 5 seconds (On the EMS).
Use the up and down arrows to scroll to the RPM value.
Press ACK to view engine speed.
POWER
MODE
Auto Power Boost Pressure

Switch
Note: The Harness Connector
should be labeled with a green
marker tape
Mode
Expected RPM High idle

(No service selected)
Expected RPM Dipper In

stalled
2040 +/- 50
Expected RPM Bucket

Close stalled
1970 +/- 50
"A" mode with the

auto pressure switch
shorted out
2145 +/- 50 RPM
"A" mode with the

auto pressure switch
connected
1945 +/- 50 RPM (Only for 3

seconds after any service is
de-selected, then 1360 RPM
+/- 50RPM for X seconds
2040 +/- 50
1950 +/- 50
"E" mode.
2045 +/- 50RPM
"L" & "P" mode
1945 +/- 50RPM
1950 +/- 50
1850 +/- 50
1950 +/- 50
1870 +/- 50
9803/6500
Issue 3
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 300
TP 300
Testing Machine Cycle Times - All XO Machines

Operate each service over its full travel 10 times to ensure that warm oil has been circulated
Using a stopwatch time each service from start to end of travel, whilst fully selecting handcontroller lever
Repeat this five times and take average of these readings
If machine is fitted with HBCVs and any delay is felt between selecting handcontroller and cylinder moving, try bleeding
pilot signal to check valve by opening bleed nipple on HBCV and selecting service, then repeat cycle times
Machine Cycle Times in seconds

XO70
Boom up
2.25
Arm out
XO130
XO130W
XO160/
180
X0160W
XO200
/220
XO200W
XO240
/260
XO330
XO450
3.0 ~ 3.9 3.0 ~ 3.9 3.1 ~ 3.9 3.1 ~ 3.9 3.4 ~ 4.4 3.4 ~4.4 3.6 ~ 4.6 3.0 ~ 3.9 3.3 ~4.3
2.4 ~ 3.0 2.4 ~ 3.0 2.8 ~ 3.6 2.8 ~ 3.6 2.4 ~ 3.4 2.5 ~3.5 2.9 ~ 3.9 2.4 ~ 3.0 2.5 ~3.5
Arm in
2.3
2.9 ~ 3.8 2.9 ~ 3.8 3.2 ~ 4.1 3.2 ~ 4.1 3.5 ~ 4.5 4.0 ~5.0 3.8 ~ 4.8 2.9 ~ 3.8 3.7 ~4.8
Bucket open
2.6
1.6 ~ 2.5 1.6 ~ 2.5 1.8 ~ 3.0 1.8 ~ 3.0 1.7 ~ 2.7 2.1 ~3.1 1.9 ~ 2.9 1.6 ~ 2.5 4.0 ~5.0
Bucket close
2.1 ~ 3.2 2.1 ~ 3.2 2.9 ~ 3.9 2.9 ~ 3.9 2.3 ~ 3.3 2.3 ~3.3 2.6 ~ 3.6 2.1 ~ 3.2 2.5 ~3.5
Swing left
4.5
4.3 ~ 5.0 4.3 ~ 5.0 5.2 ~ 5.7 5.2 ~ 5.7 4.7 ~ 5.7 5.5 ~6.7 5.3 ~ 6.3 4.3 ~ 5.0 5.5 ~6.5
Swing right
4.5
4.3 ~ 5.0 4.3 ~ 5.0 5.2 ~ 5.7 5.2 ~ 5.7 4.7 ~ 5.7 5.5 ~6.7 5.3 ~ 6.3 4.3 ~ 5.0 5.5 ~6.5
9803/6500
Issue 2
RETURN
Section2
Test Procedure
PRINT
Section 2
TP 301
TP 301
Testing Machine Cycle Times - All AMS Machines

Warm up hydraulic system to 50 C (122F).
Select S mode only
Operate all services 10 times to ensure warm oil as been circulated through all the services.
Use a stopwatch to measure the time is takes for the service to complete one cycle with the hand controller fully
selected.
Repeat five times and take the average time.
If the machine is fitted with HBCVs and any delay is felt when operating dipper in, then the HBCV must be bled of any air
and the test repeated.
Service operated
Time. (Seconds)
Boom Up
3.0 - 3.7
Dipper In
3.0 - 3.6
Dipper Out
2.5 - 3.0
BucketOpen
2.0 - 2.5
Bucket Close
2.3 - 2.7
Slew. (1 revolution)
4.7 - 5.2
Track motor speed in S mode.

Raise one track off the floor by slewing the machine through 90 degrees and lifting the machine using the boom and
dipper.
Make a mark on the outside edge of the Track Gearbox.
Operate the track motor in forward and reverse for 5 minutes, changing gear at regular intervals to distribute warm oil
through the system.
Speed selected
Creep (Tortoise)
Middle
High (Rabbit)
9803/6500
Expected Gearbox RPM

24 +/- 4
28 +/- 5
46 +/- 6
Issue 3
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 350
TP 350
Checking Slew Bearing Backlash - All XO Machines
Set bucket 1mtr above ground with dipper fully extended

Attach dial test indicator to lower half of slew bearing and set needle to bolt head on top half of slew bearing
Stop the machine . By hand push bucket fully to one side and hold whilst dial test indicator is set to zero
By hand push bucket fully to other side and record measurement on dial test indicator
Alternatively
Set bucket 1mtr above ground with dipper fully extended, stop machine
By hand push bucket fully to one side and hold whilst a mark is made across the two
halves of slew bearing
By hand push bucket fully to other side and hold, make a further mark on bottom half of bearing (which is in line with
original mark on top half of bearing )
Record measurement between two marks and conuslt Technical Service Department
9803/6500
Issue 1
Section 2
RETURN
PRINT
Test Procedure
Section 2
TP 351
TP 351
Checking slew Bearing Vertical Lift - All XO Machines
First set the Dipper in a perpendicular position and

position the bucket 200 mm above the ground, stop the
engine.
Install a dial gauge and set the needle to the Zero Point.
Start the engine and lift the main body with the bucket,
when the bottom of the shoe is 100 mm above the
ground, note the reading on the dial gauge. The needle
will turn in the counter clockwise direction. This value
becomes L1, lower the body to the ground and confirm
the needle reads zero.
Then rotate the main body 180 and repeat the

procedure, this time the needle will rotate clockwise.
This value becomes L3.
Next, place the dial gauge on the rear of the vehicle and
repeat the two above procedures to obtain L2 and L4.
The average lateral movement is shown as the result of

the equation L1 + L2 + L3 + L4
2
Note: Always stop the engine when installing or removing

the dial gauge or reading the dial gauge.
9803/6500
Issue 1

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

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Fault Finding Index

FAULT FINDING INDEX

Boom up operation is slow or low powered

XO130 / 160 / 180

Boom up operation is slow or low powered

Boom up operation is slow or low powered

XO200 / 220 / 240 / 260

Boom up operation is slow or low powered

Machine tracks off line during straight tracking

Wheeled machine poor top road speed

Excessive engine stall when stalling hydraulic service

Electrical problem and 0000 is displayed on monitor

Fault Finding Index

Boom Up Operation Is Slow Or Low Powered

XO130 / 160 / 180

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

Testing negative control signal

Expected test time to complete all above tests 2.5 hrs

Fault Finding Index

Arm Service Operation Is Slow Or Low Powered

XO130 / 160 / 180

Testing negative control signal

Expected test time to complete all above tests 2.5 hrs

Fault Finding Index

Bucket Service Operation Is Slow Or Low Powered

XO130 / 160 / 180

Testing negative control signal

Expected test time to complete all above tests 2.5 hrs

Fault Finding Index

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

Testing negative control signal

Expected test time to complete all above tests 2.5 hrs

Fault Finding Index

Boom Down Operation Is Harsh When Selected

XO130 / 160 / 180

Testing negative control signal

Expected test time to complete all above tests 1 hrs

Fault Finding Index

Swing Operation Operation Is Harsh When Selected

XO130 / 160 / 180

Testing operation of swing brake

Expected test time to complete all above tests 2.5 hrs

Fault Finding Index

Machine Performance is Unsatisfactory

XO130 / 160 / 180

If experiencing poor machine performance carry out following checks:

Testing negative control signal

Expected test time to complete all above tests 2.5 hrs

Fault Finding Index

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

Testing negative control signal