jcb ENGLISH Fault Finding COMPLETE.pdf

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HOW TO USE THIS DOCUMENT 1

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

2

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

3

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

4

ENSURE THAT ‘CURRENT PAGE’ IS SELECTED BEFORE YOU CLICK ON THE ‘OK’ BUTTON. (If you don’t 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.

5

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

i

i

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

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 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



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 Machine tracks ‘off line’ during straight tracking XO200 / 220 / 240 / 260 Machine tracks ‘off line’ during straight tracking XO330 / 450 Poor tractive effort XO130 / 160 / 180 Poor tractive effort XO200 / 220 / 240 / 260 Poor tractive effort XO330 / 450 Loss of high speed tracking XO130 / 160 / 180 Loss of high speed tracking XO200 / 220 / 240 / 260 Loss of high speed tracking XO330 / 450 Loss of creep speed tracking XO130 / 160 / 180 Loss of creep speed tracking XO200 / 220 / 240 / 260 Loss of creep speed tracking 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


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 )

2

Fault 900

Electrical problem and 0000 is displayed on monitor

( all models )

2

9803/6500

1

Issue 3

Section 1

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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:


Testing negative control signal Testing max flow cut signal Testing main pump pressure’s Testing horse power control Testing operation of main hydraulic spool (for arm main spool) Testing operation of arm 2 boost spool Testing operation of pressure switches Testing engine speed settings Testing machine cycle times

Additional information

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


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:


Testing negative control signal Testing max flow cut signal Testing main pump pressure’s Testing horse power control Testing operation of main hydraulic spool (for bucket main spool) Testing operation of boom 2 / bucket 2 boost spool Testing operation of pressure switches Testing engine speed settings Testing machine cycle times


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 negative control signal Testing max flow cut signal Testing main pump pressure’s Testing operation of swing brake Testing operation of main hydraulic spool (for swing main spool) Testing operation of pressure switches Testing engine speed settings Testing machine cycle times


9803/6500

Issue 1

Section 1

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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

Testing negative control signal Testing operation of pressure switches

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

Expected test time to complete all above tests 1 hrs

9803/6500

Issue 2

Section 1

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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

Testing operation of swing brake Testing operation of pressure switches

Additional Information

Does the swing perform smother if boom down is selected at the same time as swing? If it does check to make sure 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

Testing negative control signal Testing max flow cut signal Testing main pump pressures Testing horse power control Testing operation of pressure switches Testing engine speed settings Testing machine cycle times


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


Testing negative control signal Testing max flow cut signal Testing main pump pressure’s Testing horsepower control Testing operation of main hydraulic spool (for boom spool) Testing operation of boom 2 / bucket 2 boost spool Testing operation of pressure switches Testing engine speed settings Testing machine cycle times


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

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


Testing negative control signal Testing max flow cut signal Testing main pump pressure’s Testing horsepower control Testing operation of main hydraulic spool (for arm spool) Testing operation of arm 2 boost spool Testing operation of pressure switches Testing engine speed settings Testing machine cycle times


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


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


Testing negative control signal Testing max flow cut signal Testing main pump pressure’s Testing horsepower control Testing operation of main hydraulic spool (for bucket spool) Testing operation of boom 2 / bucket 2 boost spool Testing operation of pressure switches Testing engine speed settings Testing machine cycle times


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


Testing negative control signal Testing max flow cut signal Testing main pump pressure’s Testing operation of swing brake Testing operation of main hydraulic spool (for swing spool) Testing operation of pressure switches Testing engine speed settings Testing machine cycle times


9803/6500

Issue 2

Section 1

RETURN

PRINT

Fault Finding Index

Section 1

FF 529

FF 529


XO130W / 160W


Test 002 Test 100



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


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 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 531

FF 531


XO130W / 160W

If experiencing poor machine performance carry out following tests:


Testing negative control signal Testing max flow cut signal Testing main pump pressure’s Testing horsepower control Testing operation of pressure switches Testing engine speed settings Testing machine cycle times


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


Testing negative control signal Testing max flow cut signal Testing main pump pressure’s Testing horsepower control Testing operation of main hydraulic spool (for boom spool) Testing operation of pressure switches Testing engine speed settings Testing machine cycle times


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


Testing negative control signal Testing max flow cut signal Testing main pump pressure’s Testing horsepower control Testing operation of main hydraulic spool (for arm spool) Testing operation of pressure switches Testing engine speed settings Testing machine cycle times


If arm cylinder has HBCV 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

FF 552

FF 552

Bucket Service Operation Is Slow Or Low Powered XO200 / 220 / 240 / 260 If experiencing slow or underpowered bucket service operation carry out following checks:


Testing negative control signal Testing max flow cut signal Testing main pump pressure’s Testing horsepower control Testing operation of main hydraulic spool (for bucket spool) Testing operation of pressure switches Testing engine speed settings Testing machine cycle times


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




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



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


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 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 556

FF 556


XO200 / 220 / 240 / 260





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 Testing main pump pressures Testing engine speed settings

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 operation of swing brake Testing swing relief pressure Testing swing/boom - priority Testing operation of main hydraulic spool (for swing spool) Testing operation of pressure switches Testing engine speed settings Testing machine cycle times

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


Testing negative control signal Testing max flow cut signal Testing main pump pressure’s Testing horsepower control Testing operation of main hydraulic spool (for boom spool) Testing operation of pressure switches Testing engine speed settings Testing machine cycle times


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


Testing negative control signal Testing max flow cut signal Testing main pump pressure’s Testing horsepower control Testing operation of main hydraulic spool (for arm spool) Testing operation of pressure switches Testing engine speed settings Testing machine cycle times


If arm cylinder has HBCV 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

FF 602

FF 602

Bucket Service Operation Is Slow Or Low Powered XO330 / 450 If experiencing slow or underpowered bucket service operation carry out following checks:


Testing negative control signal Testing max flow cut signal Testing main pump pressure’s Testing horsepower control Testing operation of main hydraulic spool (for bucket spool) Testing operation of pressure switches Testing engine speed settings Testing machine cycle times


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



Additional information 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


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


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

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 If experiencing poor machine performance carry out following checks:




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 negative control signal Testing main pump pressure’s Testing track motor relief valve settings Testing track motor drain line rates Testing track motor speeds

Additional information Measure the amount of deviation over a 20 metre distance and record ground conditions. If machine is fitted with priority valve in pump line (this valve usually feeds low flow / weedcutter circuit) try connecting the 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




Additional information Measure the amount of deviation over a 20 metre distance and record ground conditions. If machine is fitted with priority valve in pump line (this valve usually feeds low flow / weedcutter circuit) try connecting the 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 652

FF 652


XO330 / 450




Additional information Measure the amount of deviation over a 20 metre distance and record ground conditions. If machine is fitted with priority valve in pump line (this valve usually feeds low flow / weedcutter circuit) try connecting the 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 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

Testing negative control signal Testing main pump pressures Testing track motor relief valve settings Testing track motor drain line rates

Additional Information 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






9803/6500

Issue 2

Section 1

RETURN

PRINT

Fault Finding Index

Section 1

FF 655

FF 655


XO330 / 450






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 track motor speeds Testing pressure switches

Additional information When high speed tracking is selected is ‘hare’ symbol displayed on monitor? yes / no When high speed tracking has been selected what pressure is seen at pilot port to select high gear on track motor (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


Additional information When high speed tracking is selected is ‘hare’ symbol displayed on monitor? yes / no When high speed tracking has been selected what pressure is seen at pilot port to select high gear on track motor (see illustration below).


A318900



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


Additional information When high speed tracking is selected is ‘hare’ symbol displayed on monitor? yes / no When high speed tracking has been selected what pressure is seen at pilot port to select high gear on track motor (see illustration below).


A318900



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

Testing max flow cut signal Testing track motor speeds Testing pressure switches

Additional information 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





yes / no


9803/6500

Issue 1

Section 1

RETURN

PRINT

Fault Finding Index

Section 1

FF 661

FF 661


XO330 / 450





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



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:


Testing max flow cut / drive control signal Testing main pump pressures Testing threshold pressure Testing drive motor minimum displacement setting Testing machine propshaft speeds Testing pressure switches 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:


Testing propshaft speeds Testing clutch pack pressure / park brake pressure Testing pressure switches

Additional information The controller will not energise any solenoids if it ‘thinks’ that the engine is not running , check to make sure that the 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:


Testing propshaft speeds Testing clutch pack pressure / park brake pressure Testing pressure switches

Additional information The controller will not energise any solenoids if it ‘thinks’ that the engine is not running , check to make sure that the 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



Testing max flow cut / drive control signal Testing main pump pressures Testing threshold pressure Testing drive motor minimum displacement setting Testing machine propshaft speeds Checking theshold pressure - XO200W only, Testing pressure switches Testing engine speeds


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

Testing clutch pack pressure / park brake pressure

Additional information When the electrical connector is removed from drive safety switch (on transmission control valve, see below) and a piece 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 machine’s 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


2

Torque available from engine is lower than specification, this can be caused by: - fuel system fault - faulty injectors - faulty fuel injection pump This can be confirmed by having component tested at recognised fuel equipment specialist

Test 200

Testing engine speeds

Expected test time to complete all above tests 1 hr

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


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


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


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

1


Testing H.B.C.V’s , XO130 boom ram, XO130W boom ram Testing H.B.C.V’s , XO130 arm ram, XO160 arm ram, XO200 arm ram, XO240 arm ram, XO240 arm ram, XO330 arm ram Testing H.B.C.V’s, XO160 boom ram, XO160W boom ram, XO180 boom ram Testing H.B.C.V’s , XO200 boom ram, XO200W boom ram, XO240 boom ram, XO330 boom ram Testing H.B.C.V’s , XO220 T.A.B ram, XO200W T.A.B ram Testing H.B.C.V’s , XO130W T.A.B ram, XO160W T.A.B ram

1 1 3 3 1


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


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


Testing pressure switchs- all AMS models Testing pressure switch’s 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


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 rpm’s 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 Warm up machine hydraulic temperature to 50 °C

Port P11

Port P21

(Expected Pressures) With max engine rpm’s and no services selected record negative control pressure Select and stall boom up service record 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)


(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)

Fully select boom down record pressure when service first selected


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 Warm up machine hydraulic temperature to 50 °C

Port pt1 Port pt2 (Expected Pressures) With max engine rpm’s and no services selected record negative control pressure Select and stall boom up service record pressure

(30 - 35 bar*)

(30 - 35 bar*)

(0 - 3 bar)

(0 - 3 bar) (40 bar when first selected for 0.5 sec 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)

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

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 Warm up machine hydraulic temperature to 50 °C

Port PZ1/Pi1 Port PZ2/Pi2 (Expected Pressures) With max engine rpm’s and no services selected record negative control pressure Select and stall boom up service record pressure

(25 - 35 bar*)

(25 - 35 bar*)

(0 - 3 bar)

(0 - 3 bar) (40 bar when first selected for 0.5 sec 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)


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 50°C 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 ¼ 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

B

C

D

E

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 ¼ 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 Warm up machine hydraulic temperature to 50 °C

Port P12 Port P22 (Expected Pressures)

With max engine rpm’s 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 (Expected Pressures)

With max engine rpm’s and no services selected record max flow cut control pressure

(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


G

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

G

Warm up machine hydraulic temperature to 50 °C

Port P12/Pm1 Port P22/Pm2 (Expected Pressures) With max engine rpm’s and no services selected record max flow cut control pressure Select F mode and record pressure

G

(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

(Expected Pressures) 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 Warm up machine hydraulic temperature to 50 °C

Port Pm1

Port Pm2

(Expected Pressures) With max engine rpm’s and no services selected record max flow cut control pressure

(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

G

Warm up machine hydraulic temperature to 50 °C

A436080

Port SC/ Pm1 /Pm2 (Expected Pressures) With max engine rpm’s 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

A

A437080

Fit test gauge ( 0 - 60 bar ) to A with tee piece adapter Warm up machine hydraulic temperature to 50 °C

9803/6500

Issue 3

RETURN

Section2

PRINT

Section 2

Test Procedure

TP015

TP015

3

2

1

Testing Servo Pressure XO200W

A436040

Fit test gauges ( 0 - 600 bar ) into test point 1 Warm up machine hydraulic temperature to 50 °C

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 Warm up machine hydraulic temperature to 50 °C

Port G1 Port G2 (Expected Pressures) With max engine rpm’s 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)

Select and stall boom up service record pressure

* 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


Fit test gauges ( 0 - 600 bar ) into hose connections to ports G1 + G2 Warm up machine hydraulic temperature to 50 °C Port G1

Port G2

(Expected Pressures) With max engine rpm’s and no services selected record pump pressure

(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 (Expected Pressures) With max engine rpm’s and no services selected record pump pressure

(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)

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

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

(Expected Pressures) With max engine rpm’s and no services selected record pump pressure

(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)


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

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 Warm up machine hydraulic temperature to 50 °C

Port MA1/a1 Port MA2/a2 (Expected Pressures) With max engine rpm’s and no services selected record pump pressure

(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

3

2

1

Testing Main Pump Pressure XO200W

A436040

Fit test gauges ( 0 - 600 bar ) into test point 3 Warm up machine hydraulic temperature to 50 °C (Expected Pressures) Test Point 3 With max engine rpm’s and no services selected record pump pressure

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


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

With maximum engine rpms and no services operated. Select S mode measure and record milliamps and 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

With maximum engine rpms and no services operated. Select L mode measure and record milliamps and 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


Tier 2 Machines


A326230 A407830

●


●

Separate proportional solenoid electrical connector. Using service connector from electrical test kit WDB0055 connect fluke meter in series as shown right.

Brown/Black (BrB)

Brown/Black (BrB)

+ -

OR ●

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

●


Pump side harness

+ -

Link wire

XO 130w

XO 160w


Milliamps


Milliamps


11.5 bar +/- 10%

355 ma

12 bar +/- 10%

370 ma


11.5 bar +/- 10%

355 ma

12 bar +/- 10%

370 ma

With maximum engine rpms and no services operated. Select S mode measure and record milliamps and secondary pressure.

7.5 bar +/- 10%

250 ma

8 bar +/- 10%

265 ma

0 bar

0 ma

0 bar

0 ma

With maximum engine rpms and no services operated. Select L mode measure and record milliamps and secondary pressure. 9803/6500

Issue 1

RETURN

Section2

PRINT

Section 2

Test Procedure

TP 028

TP 028


XO200 / XO220 / XO240 /XO 260 Proportional solenoid secondary pressure measurement port


Later Machines

A407830

A326240


Brown/Black (BrB)


Brown/Black (BrB)

+ -

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

Pump side harness

+ -


Link wire

XO 200 / XO 220

XO 240 / XO 260


Milliamps


Milliamps


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*

With maximum engine rpms and no services operated. Select S mode measure and record milliamps and secondary pressure.`

28 bar +/- 1 bar

305 ma

26 bar +/- 1 bar

330 ma

40 bar

0 ma

40 bar

0 ma

With maximum engine rpms and no services operated. Select L mode measure and record milliamps and 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

Fit gauge ( 0 - 60 bar ) into proportional solenoid secondary pressure measurement port using suitable ad apter (port thread is 1/4 BSP ‘O’ ring fitting).

Brown/Black (BrB)


Brown/Black (BrB)

+ -

OR Pump side harness

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

+ -

Warm up machine hydraulic temperature to 50 °C. Link wire

XO 330

With maximum engine rpms and no services operated. Select H mode measure and record milliamps and secondary pressure. With maximum engine rpms and dipper service selected and stalled. Select H mode measure and record milliamps and secondary pressure. With maximum engine rpms and no services operated. Select S mode measure and record milliamps and secondary pressure. With maximum engine rpms and no services operated. Select L mode measure and record milliamps and secondary pressure. 9803/6500

XO 450


Milliamps


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.

G

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

G

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

To Confirm Minimum Flow Setting G

Set machine to H mode.

G

Stall boom up service and record pressure in each pump, flow on flow meter and engine rpm’s ( record this on sheet attached).

G

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.

G

Set machine to max engine rpm’s in H mode have the load valve on flow meter fully open and do not operate any services.

G

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

G

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.

G

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

G

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

G

Record the pressure on both pumps, flow on flow meter, engine rpm’s and proportional solenoid current (record this on sheet attached).

G

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

G

Record the pressure on both pumps, flow on flow meter, engine rpm’s and proportional solenoid current (record this on sheet attached).

G

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

G

DO NOT increase pressure above 350 bar.

G

Reset the load valve to fully open.

G

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 Mode Pressure in P1 Pressure in P2

H

H

S

S

F

F

L

L

Maximum Flow Pump 1 Mode Pressure in P1 Pressure in P2

Flow

Rpm

Maximum Flow Pump 2 Mode Pressure in P1 Pressure in P2

Flow

Rpm

Flow

Rpm

H

H

S

S

F

F

L

L

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

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

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

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

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

Horsepower Control Pump 2 L Mode Pressure in P1 Pressure in P2 Flow 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)

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. Warm up machine hydraulic temperature to 50 °C.

Pump side harness

+ -

Link wire

330470

Milliamps With maximum engine rpms and no services operated. Select H mode measure and record milliamps.

495 ma

With maximum engine rpms and 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

3

2

1

Testing Steering Pressure XO200W

A436040

Fit a high pressure gauge into test point 2 Warm the hydraulic oil to 50°C. 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

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

B

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

T

pc

T

P

p

Test Spool for max pump flow Part No. SSP0099

Pump Pressure

P

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.

2

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

3

Set the engine speed to idle.

4

Whilst operator slowly selects boom down, open the bleed screw on one of the HBCV’s (this is located next to the ‘P’ port on the valve).

5

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

6

Close bleed screw whilst operator is still selecting boom down.

7

Repeat procedure for other side.

Arm HBCV Installation 1

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

2

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

3

Set the engine speed to idle.

4

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

5

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

6

Close bleed screw whilst operator is still selecting dipper in.

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

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 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. Remove pilot hose from port P, plug hose and leave port open to atmosphere. 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. Record pressure at this point, this is relief setting of HBCV. 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

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 and 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 the Main Relief Valve to the orignal setting. NB - If boom is selected too quickly a higher pressure will be seen at pressure gauge giving false reading of relief setting. Relief Valve Settings XO160 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 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 and 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 the Main Relief Valve to the orignal setting. NB - If boom is selected too quickly a higher pressure will be seen at pressure gauge giving false reading of relief setting. Relief Valve Settings 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

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 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. Remove pilot hose from port P, plug hose and leave port open to atmosphere. Fit test gauge (0 - 600 bar) to port E using appropriate adapter. Start engine and raise boom. Carefully select TAB down and slowly build pressure until TAB 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 and adjust as necessary. Re-set the Main Relief Valve to the orignal setting. NB - If TAB is selected too quickly a higher pressure will be seen at pressure gauge giving false reading of relief setting.

Relief Valve Settings 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

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 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. Remove pilot hose from port P, plug hose and leave port open to atmosphere. Fit test gauge (0 - 600 bar) to port E using appropriate adapter. Start engine and raise boom. Carefully select TAB down and slowly build pressure until TAB 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 and adjust as necessary. Re-set the Main Relief Valve to the orignal setting. NB - If TAB is selected too quickly a higher pressure will be seen at pressure gauge giving false reading of relief setting.

Relief Valve Settings 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 pressure’s). 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 ARV’s 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 rpm’s 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 Refit hose to 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


Refit hose to track motor 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 Warm up hydraulic system to 50 °C. 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 RPM’S AND FULLY SELECT TRACK PEDAL

Expected RPM’S 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 RPM’S 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 rpm’s in high gear

Track motor rpm’s 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

A

Swing Motor A405810

Fit pressure test gauge ( 0 - 60 bar ) into hose connection on hose A on the swing motor. Warm up hydraulic system to 50 °C.

Pressure at port B (Expected Pressure) With engine at max rpm’s 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 Warm up hydraulic system to 50 °C

*

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

Pressure at spool port at opposite end of spool (Expected Pressure)

With max engine rpm’s 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 ~


XO160

702000 ~ 702250 702251 ~ 702290 702291 ~


XO160W

718500 ~ 718560 718561 ~ 718586 718587 ~


XO200/220

705001 ~ 705632 705633 ~ 705687 705688 ~


XO240/260

708501 ~ 708683 708684 ~ 708703 708704 ~


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

Warm up hydraulic system to 50 °C 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 (Expected Pressures)

Port d (Expected Pressures)

Port dr2 (Expected Pressures)

With max engine rpm’s 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 ~


XO130W

716500 ~ 716593 716594 ~ 716618 716619 ~


*

XO160

702000 ~ 702250 702251 ~ 702290 702291 ~


XO160W

718500 ~ 718560 718561 ~ 718586 718587 ~


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

Warm up hydraulic system to 50 °C Fit pressure gauges ( 0 - 60 bar ) into ports al ( pilot port to select boost spool ) and port dr1 ( spool chamber drain port )

Port al (Expected Pressures)

Port dr1 (Expected Pressures)

(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 rpm’s and no services selected

*

XO130

758000 ~ 758372 758373 ~ 758421 758422 ~


XO130W

716500 ~ 716593 716594 ~ 716618 716619 ~


*

XO160

702000 ~ 702250 702251 ~ 702290 702291 ~


XO160W

718500 ~ 718560 718561 ~ 718586 718587 ~


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.

1

2

Fit a high pressure gauge into the LS port 1 on the pump. Disconnect and blank off the ¼ 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 ¼ 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 ¼ 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.

A

9803/6500

B

C

D

E

Issue 3

RETURN

Section2

PRINT

Section 2

Test Procedure

TP 058

TP 058

Testing Swing/Boom Priority - XO200W

A

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

A

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

Warm up hydraulic system to 50 °C 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 rpm’s as follows

FOR ALL TESTS USE MAX ENGINE RPM’S AND FULLY SELECT DRIVE PEDAL XO130W

XO145W

Expected Expected rpm’s rpm’s (German build ) (German build )

High gear

XO160W

XO175W

XO 200W

Expected rpm’s (German build)

Expected rpm’s (German build)

rpm’s (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 but dozer not operated

290 rpm (200 rpm)

350 rpm (200 rpm)

(340 rpm) (200 rpm)

350 (200 rpm)

(300) (300)

High gear with dozer mode selected but dozer not operated

Tolerance +/- 50 rpm’s 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 rpm’s and medium travel gear selected

(32 bar)

(0 - 3 bar)

With max engine rpm’s and creep travel gear selected

(32 bar)

(0 - 3 bar)

(0 - 3 bar)

(14 bar)

With max engine rpm’s and high travel gear selected

With max engine rpm’s 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

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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

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Section2

PRINT

Section 2

Test Procedure

TP 066

TP 066

Testing Threshold Pressure XO200W

G

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

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Section2

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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.

1

A437080

∆Pshift solenoid 1 Note: Drive cannot be activated until the clutch pack has been pressurised.

9803/6500

Issue 3

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Section2

PRINT

Section 2

Test Procedure

TP 067

TP 067

Testing the drive circuit - XO200W - cont’d 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

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Section2

PRINT

Section 2

Test Procedure

TP 067

TP 067

Testing the drive circuit - XO200W - cont’d

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

F

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

1

Start the engine.

2

Press the set and mode buttons together for 5 seconds to access the Sub menu.

3

Use the Up and Down arrow buttons, until the Pilot SW appears on the screen.

4

Press ACK button.

5

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

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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

0

0

0

0

Select boom up service

0

0

1

0

Select travel service

0

0

0

1

Select swing service

0

0

1

1

Select boom down

0

0

1

1

Select boom up (XO330/450 only)

0

0

1

1

Select hammer service (if fitted)

0

0

1

1

9803/6500

Issue 1

Section 2

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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

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 resistance’s 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 - 3.6Ω

3 - 3.6Ω

LIGHT GREEN

ORANGE

YELLOW

3 - 3.6Ω

3 - 3.6Ω

WHITE

DARK GREEN ↔

BLUE BROWN

3 - 3.6Ω

RED

3 - 3.6Ω

6 - 7.2Ω 6 - 7.2Ω

6 - 7.2Ω

6 - 7.2Ω

6 - 7.2Ω

6 - 7.2Ω

LIGHT GREEN

↔

ORANGE

3 - 3.6Ω

6 - 7.2Ω

6 - 7.2Ω

YELLOW

3 - 3.6Ω

6 - 7.2Ω

6 - 7.2Ω

WHITE

↔

6 - 7.2Ω 6 - 7.2Ω ↔

Indicates no contact ↔

Indicates no contact until limit switch closes then 0.5Ω

9803/6500

Issue 1

Section 2

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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 resistance’s 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

3

4

5

6

7

8

0

2.69 k

8k

5.6 k

2.69 k

8k 10.1 k

9

10

11

12

13

14

15

16

17

5.6 k

0

0

0

5.6 k

5.6 k

5.6 k

5.6 k

5.6 k

0

0

0

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

0

5.6 k

5.6 k

5.6 k

0

0

0

5.6 k

5.6 k

5.6 k

0

10.1 k

1 2 3 4

0

5

2.69 k

2.69 k

6

8k

8k

10.1 k

7

5.6 k

5.6 k

7.2 k

13.6 k

8

5.6 k

5.6 k

7.2 k

13.6 k

10.1 k

0

0

2.69 k

8k

5.6 k

5.6 k

130 k

110 k

9 10 11 12 13 14

0

0

2.69 k

8k

5.6 k

5.6 k

0

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

0

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

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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

1

2

5

6

7

3

4

8

9

If suspecting a failed monitor unit a bench test can be carried out by checking the resistance’s between terminals as in table below

1 1

2

3

4

6 kΩ

6 kΩ 1 kΩ

5

6

7

8

9

x

6 kΩ

6 kΩ

6 kΩ

x

1 kΩ

1 kΩ

1 kΩ

x

1 kΩ

1 kΩ

1 kΩ

x

x

x

2

6 kΩ

3

6 kΩ

1 kΩ

4

x

x

x

5

3.8MΩ

3.8MΩ

3.8MΩ

x

3.8MΩ

3.8MΩ

3.8MΩ

6

2MΩ

2MΩ

2MΩ

x

2MΩ

2MΩ

2MΩ

7

6 kΩ

1 kΩ

1 kΩ

x

1 kΩ

1 kΩ

8

6 kΩ

6 kΩ

1 kΩ

x

1 kΩ

9

6 kΩ

1 kΩ

1 kΩ

x

1 kΩ

x

x

1 kΩ 1 kΩ

Indicates no connection

9803/6500

Issue 1

Section 2

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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.

2

Ensure that threads of sensor are clean and free from damage.

3

Carefully screw in the sensor until it touches the ring gear. (Do not use excessive force).

4

Make a mark across from the sensor onto the flywheel housing.

5

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


2


3


4


5


Torque tighten to 44~54 Nm (32.5~39.7 lbf ft). 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

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Test Procedure

Section 2

Testing Installation of Engine Speed Sensor (cont’d) Installation procedure XO 200 / XO 210 / XO 220 / XO 260 / XO 200W Isuzu engine: 1


2


3

Carefully screw in the sensor.

4

Torque tighten to 44~54 Nm (32.5~39.7 lbf ft).

Clearance between sensor tip and ring gear 3.1 mm + 0.4 mm/ -0 mm (0.122 + 0.016 / -0 in).

Installation procedure XO 200W JCB Diesel engine: 1


2


3


4


5


Torque tighten to 44~54 Nm (32.5~39.7 lbf ft). Clearance between sensor tip and ring gear 3.0 mm + 0.25 mm/ -0.25 mm (0.118 + 0.01 / -0.01 in). Installation procedure XO 330 / XO 450 Isuzu engine: 1


2


3


4


5


Torque tighten to 29.4 Nm (21.69 lbf ft). Clearance between sensor tip and ring gear 3.5 mm + 0.2 mm/ -0.2 mm (0.137 + 0.008 / -0.008 in). 9803/6500

Issue 1

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Section2

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Section 2

Test Procedure

TP 105

TP 105

AMS Throttle Fault Finding - All AMS Machines E

H

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

3

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

4

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

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Section 2

Test Procedure

TP 105

TP 105

AMS Throttle Fault Finding - All AMS Machines - cont’d d cont’d 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.

8

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.

9

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

2

3

SR

S

1

1 SG

5

+V REF

2

C22 THROTTLE VOLUME DIAL

C2 CONN B

C8 CONN A

ECU1

ENGINE CONTROL S.V.

1

R

10

SG

20

S

29

R

A

SG

D

SR

S

E

32

WY

WG

G

39

WG

WY

M

80

C87 0V REF I/P 8 THROTTLE VOL. I/P 17 ENGINE SPEED I/P 6 THROTTLE LEVER

5

2

70 THROTTLE POSITION SENSOR

WG 2 S 3

P

2A

CONN B 19 20

15A

C10 CONN C

O/P 1 THROTTLE CONT.

1

S

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

1

4 2A +24V IGNITION

A346060

9803/6500

Issue 3

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Section2

Test Procedure

PRINT

Section 2

TP 105

TP 105

AMS Throttle Fault Finding - All AMS Machines - cont’d

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 45~65 lower than sense upper band (H mode). Usually 45~65 lower than sense upper band (H mode). 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

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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 CAP’2 Machines Warm up engine water temperature to 50 °C (122°F). 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 RPM’s Select H mode and max engine rpm’s ( flight speed)

(see table below)

Select S mode and max engine rpm’s

(see table below)

Select L mode and max engine rpm’s

(see table below

Select H mode, max engine rpm’s and stall arm close service ( H mode minimum rpm’s )

(see table below)

Expected Milliamps Select H mode, max engine rpm’s and stall arm close service record milliamps

Model

XO130

XO130W

High Idle (flight speed) rpm’s Arm stall H mode minimum rpm’s

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

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Section2

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Section 2

Test Procedure

TP 201

TP 201

Testing Engine Speed Settings - All AMS Machines Warm Engine water temperature above 50 °C (122°F). 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

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Section 2

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Test Procedure

Section 2

TP 300

TP 300

Testing Machine Cycle Times - All XO Machines Warm up hydraulic system to 50 °C Operate each service over it’s 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 HBCV’s 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

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Section2

Test Procedure

PRINT

Section 2

TP 301

TP 301

Testing Machine Cycle Times - All AMS Machines Warm up hydraulic system to 50 °C (122°F). 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

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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

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Test Procedure

Section 2

TP 351

TP 351

Checking slew Bearing Vertical Lift - All XO Machines

1

First set the Dipper in a perpendicular position and position the bucket 200 mm above the ground, stop the engine.

2

Install a dial gauge and set the needle to the Zero Point.

3

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.

4

Then rotate the main body 180° and repeat the procedure, this time the needle will rotate clockwise. This value becomes L3.

5

Next, place the dial gauge on the rear of the vehicle and repeat the two above procedures to obtain L2 and L4.

6

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.

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Issue 1

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