JCB Faults PDF

RETURN
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

ISSUE
Fault 500 Boom up operation is slow or low powered XO130 / 160 / 180 2
Fault 501 Arm operation is slow or low powered XO130 / 160 / 180 2
Fault 502 Bucket operation is slow or low powered XO130 / 160 / 180 2
Fault 503 Swing operation is slow or low powered XO130 / 160 / 180 1
Fault 504 Boom down operation is harsh when selected XO130 / 160 / 180 2
Fault 505 Swing operation is harsh when selected XO130 / 160 / 180 1
Fault 506 Machine performance is unsatisfactory XO130 / 160 / 180 1
Fault 525 Boom up operation is slow or low powered XO130W / 160W 2
Fault 526 Arm operation is slow or low powered XO130W / 160W 2
Fault 527 Bucket operation is slow or low powered XO130W / 160W 2
Fault 528 Swing operation is slow or low powered XO130W / 160W 2
Fault 529 Boom down operation is harsh when selected XO130W / 160W 2
Fault 530 Swing operation is harsh when selected XO130W / 160W 2
Fault 531 Machine performance is unsatisfactory XO130W / 160W 1
Fault 550 Boom up operation is slow or low powered XO200 / 220 / 240 / 260 2
Fault 551 Arm operation is slow or low powered XO200 / 220 / 240 / 260 2
Fault 552 Bucket operation is slow or low powered XO200 / 220 / 240 / 260 2
Fault 553 Swing operation is slow or low powered XO200 / 220 / 240 / 260 1
Fault 554 Boom down operation is harsh when selected XO200 / 220 / 240 / 260 2
Fault 555 Swing operation is harsh when selected XO200 / 220 / 240 / 260 1
Fault 556 Machine performance is unsatisfactory XO200 / 220 / 240 / 260 1
Fault 557 Poor Performance XO200W 3
Fault 558 Poor Swing Effort XO200W 3
Fault 600 Boom up operation is slow or low powered XO330 / 450 2
Fault 601 Arm operation is slow or low powered XO330 / 450 2
Fault 602 Bucket operation is slow or low powered XO330 / 450 2
Fault 603 Swing operation is slow or low powered XO330 / 450 1
Fault 604 Boom down operation is harsh when selected XO330 / 450 2
Fault 605 Swing operation is harsh when selected XO330 / 450 1
Fault 606 Machine performance is unsatisfactory XO330 / 450 1
Fault 650 Machine tracks ‘off line’ during straight tracking XO130 / 160 2
Fault 651 Machine tracks ‘off line’ during straight tracking XO200 / 220 / 240 / 260 2
Fault 652 Machine tracks ‘off line’ during straight tracking XO330 / 450 2
Fault 653 Poor tractive effort XO130 / 160 / 180 2
Fault 654 Poor tractive effort XO200 / 220 / 240 / 260 2
Fault 655 Poor tractive effort XO330 / 450 2
Fault 656 Loss of high speed tracking XO130 / 160 / 180 2
Fault 657 Loss of high speed tracking XO200 / 220 / 240 / 260 1
Fault 658 Loss of high speed tracking XO330 / 450 1
Fault 659 Loss of creep speed tracking XO130 / 160 / 180 2
Fault 660 Loss of creep speed tracking XO200 / 220 / 240 / 260 1
Fault 661 Loss of creep speed tracking XO330 / 450 1
Fault 662 Machine selects high gear even though monitor displays
another travel gear ( all tracked models ) 1
Fault 700 Wheeled machine poor top road speed XO130w / 160W 1
Fault 701 Loss of high speed ( wheeled machine ) XO130W / 160W / XO200W 3
Fault 702 Loss of creep speed ( wheeled machine ) XO130W / 160W / XO200W 3
Fault 703 Poor tractive effort ( wheeled machine ) XO130W/ 160W / XO200W 3
Fault 704 Loss of drive ( wheeled machine ) XO130W / 160W 1
Fault 705 Harsh counterbalance on releasing drive pedal XO130W / 160W 1
Fault 706 Poor Steering and Braking Performance XO200W 3
Fault 800 Excessive engine stall when stalling hydraulic service ( all models ) 2
Fault 900 Electrical problem and 0000 is displayed on monitor ( all models ) 2
9803/6500 Issue 3
RETURN PRINT
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 Testing negative control signal

Test 010 Testing max flow cut signal
Test 021 Testing main pump pressures
Test 026 Testing horse power control
Test 054 Testing operation of main hydraulic spool ( for boom spool )
Test 055 Testing operation of boom 2 / bucket 2 spool
Test 100 Testing operation of pressure switches
Test 200 Testing engine speed settings
Test 300 Testing machine cycle times
Expected test time to complete all above tests 2.5 hrs
9803/6500 Issue 2
RETURN PRINT
FF 501 FF 501
Arm Service Operation Is Slow Or Low Powered XO130 / 160 / 180
If experiencing slow or underpowered arm service operation carry out following checks:

Test 021 Testing main pump pressure’s
Test 054 Testing operation of main hydraulic spool (for arm main spool)
Test 056 Testing operation of arm 2 boost spool
Additional information
If the arm cylinder has hose burst check valve fitted then also carry out :
Test 041 Testing operation of arm HBCV
9803/6500 Issue 2
RETURN PRINT
FF502 FF 502
Bucket Service Operation Is Slow Or Low Powered XO130 / 160 / 180
If experiencing slow or underpowered bucket service operation carry out following checks:

Test 054 Testing operation of main hydraulic spool (for bucket main spool)
Test 055 Testing operation of boom 2 / bucket 2 boost spool
9803/6500 Issue 2
RETURN PRINT
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 053 Testing operation of swing brake
Test 054 Testing operation of main hydraulic spool (for swing main spool)
9803/6500 Issue 1
RETURN PRINT
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:

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
RETURN PRINT
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:

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
RETURN PRINT
FF 506 FF 506
Machine Performance is Unsatisfactory XO130 / 160 / 180
If experiencing poor machine performance carry out following checks:

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

Test 027 Testing horsepower control
Test 054 Testing operation of main hydraulic spool (for boom spool)
9803/6500 Issue 2
RETURN PRINT
FF 526 FF 526
Arm Service Operation Is Slow Or Low Powered XO130W / 160W

Test 054 Testing operation of main hydraulic spool (for arm spool)
Test 056 Testing operation of arm 2 boost spool
If the machine has arm cylinder hose burst check valve fitted then also carry out :
9803/6500 Issue 2
RETURN PRINT
FF 527 FF 527
Bucket Service Operation Is Slow Or Low Powered XO130W / 160W

Test 054 Testing operation of main hydraulic spool (for bucket spool)
9803/6500 Issue 2
RETURN PRINT
FF 528 FF 528
Swing Service Operation Is Slow Or Low Powered XO130W / 160W

Test 054 Testing operation of main hydraulic spool (for swing spool)
9803/6500 Issue 2
RETURN PRINT
FF 529 FF 529
Boom Down Operation Is Harsh When Selected XO130W / 160W

9803/6500 Issue 2
RETURN PRINT
FF 530 FF 530
Swing Operation Operation Is Harsh When Selected XO130W / 160W

Does the swing perform smother if boom down is selected at the same time as swing? If it does check to make sure that
9803/6500 Issue 1
RETURN PRINT
FF 531 FF 531
Machine Performance is Unsatisfactory XO130W / 160W
If experiencing poor machine performance carry out following tests:

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

9803/6500 Issue 2
RETURN PRINT
FF 551 FF 551
Arm Service Operation Is Slow Or Low Powered XO200 / 220 / 240 / 260

If arm cylinder has HBCV fitted then also carry out :

9803/6500 Issue 2
RETURN PRINT
FF 552 FF 552
Bucket Service Operation Is Slow Or Low Powered XO200 / 220 / 240 / 260

9803/6500 Issue 2
RETURN PRINT
FF553 FF 553
Swing Service Operation Is Slow Or Low Powered XO200 / 220 / 240 / 260

9803/6500 Issue 1
RETURN PRINT
FF 554 FF 554
Boom Down Operation Is Harsh When Selected XO200 / 220 / 240 / 260

9803/6500 Issue 2
RETURN PRINT
FF 555 FF 555
Swing Operation Operation Is Harsh When Selected XO200 / 220 / 240 / 260

Does the swing perform smoother if boom down is selected at the same time as swing? If it does check to make sure that
9803/6500 Issue 1
RETURN PRINT
FF 556 FF 556
Machine Performance is Unsatisfactory XO200 / 220 / 240 / 260

9803/6500 Issue 1
RETURN PRINT
FF 557 FF 557
Machine Performance is Unsatisfactory XO200W
Test 005 Testing load sense pressure

Test 014 Testing ∆ P shift
Test 015 Testing servo pressure
Test 031 Testing pump milliamps
9803/6500 Issue 3
RETURN PRINT
FF 558 FF 558
Poor Swing Effort XO200W

Test 057 Testing swing relief pressure
Test 058 Testing swing/boom - priority
9803/6500 Issue 3
RETURN PRINT
FF 600 FF 600
Boom Up Operation Is Slow Or Low Powered XO330 / 450

9803/6500 Issue 2
RETURN PRINT
FF 601 FF 601
Arm Service Operation Is Slow Or Low Powered XO330 / 450


If arm cylinder has HBCV fitted then also carry out :

9803/6500 Issue 2
RETURN PRINT
FF 602 FF 602
Bucket Service Operation Is Slow Or Low Powered XO330 / 450

9803/6500 Issue 2
RETURN PRINT
FF 603 FF 603
Swing Service Operation Is Slow Or Low Powered XO330 / 450

The XO330 and 450 models have an additional feature of boom priority. This feature is used for truck loading to give the 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
RETURN PRINT
FF 604 FF 604
Boom Down Operation Is Harsh When Selected XO330 / 450

9803/6500 Issue 2
RETURN PRINT
FF 605 FF 605
Swing Operation Operation Is Harsh When Selected XO330 / 450

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

9803/6500 Issue 1
RETURN PRINT
FF 650 FF 650
Machine Tracks Off Line During Straight Travel XO130 / 160

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

Test 050 Testing track motor relief valve settings
Test 051 Testing track motor drain line rates
Test 052 Testing track motor speeds
Measure the amount of deviation over a 20 metre distance and record ground conditions.
If machine is fitted with priority valve in pump line (this valve usually feeds low flow / weedcutter circuit) try connecting the 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
RETURN PRINT
FF 651 FF 651
Machine Tracks Off Line During Straight Travel XO200 / 220 / 240 / 260

Swap the two main hoses on the hydraulic pump, does the problem change direction?
9803/6500 Issue 2
RETURN PRINT
FF 652 FF 652
Machine Tracks Off Line During Straight Travel XO330 / 450


Swap the two main hoses on the hydraulic pump , does the problem change direction?
9803/6500 Issue 2
RETURN PRINT
FF 653 FF 653
Poor Tractive Effort XO130 / 160 / 180

If experiencing poor tractive effort, carry out following checks:

What travel gear is the machine operating in when the problem occurs?
See also Fault 662.
9803/6500 Issue 2
RETURN PRINT
FF 654 FF 654
Poor Tractive Effort XO200 / 220 / 240 / 260


See also Fault 662.
9803/6500 Issue 2
RETURN PRINT
FF 655 FF 655
Poor Tractive Effort XO330 / 450


See also Fault 662.
9803/6500 Issue 2
RETURN PRINT
FF 656 FF 656
Loss of High Speed Tracking XO130 / 160 / 180
If experiencing loss of high speed tracking, carry out following checks:

Test 100 Testing pressure switches
When high speed tracking is selected is ‘hare’ symbol displayed on monitor? yes / no
When high speed tracking has been selected what pressure is seen at pilot port to select high gear on track motor (see
illustration below)
Pilot port to select high gear
A318900
High speed tracking Front view of 8

solenoid spool valve
A326403
When high speed tracking has been selected is electrical voltage seen at high speed tracking solenoid? yes / no ?
9803/6500 Issue 2
RETURN PRINT
FF 657 FF 657
Loss of High Speed Tracking XO200 / 220 / 240 / 260

illustration below).
A318900

A326403
9803/6500 Issue 1
RETURN PRINT
FF 658 FF 658
Loss of High Speed Tracking XO330 / 450

illustration below).
A318900

A326403
9803/6500 Issue 1
RETURN PRINT
FF 659 FF 659
Loss of Creep Speed Tracking XO130 / 160 / 180
If experiencing loss of creep speed tracking, carry out following checks:

When creep speed tracking is selected is ‘tortoise’ symbol displayed on monitor? yes / no
9803/6500 Issue 2
RETURN PRINT
FF 660 FF 660
Loss of Creep Speed Tracking XO200 / 220 / 240 / 260

9803/6500 Issue 1
RETURN PRINT
FF 661 FF 661
Loss of Creep Speed Tracking XO330 / 450

9803/6500 Issue 1
RETURN PRINT
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 middle tracking gear is selected?

2 middle tracking gear is selected and tracking service is stalled , forwards and backwards on both left and right hand
tracks?
3 high tracking gear is selected?
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
RETURN PRINT
FF 700 FF 700
Poor Top Road Speed XO130W / 160W

If experiencing poor top road speed, carry out following checks:
Test 011 Testing max flow cut / drive control signal

Test 060 Testing threshold pressure
Test 061 Testing drive motor minimum displacement setting
Test 062 Testing machine propshaft speeds
Test 200 Testing engine speeds
9803/6500 Issue 1
RETURN PRINT
FF 701 FF 701
Loss of High Speed Travel XO130W/ 160W / XO200W

If experiencing loss of high speed travel (i.e. when changing from middle to high gear no increase of speed is achieved), carry
out following checks:
Test 062 Testing propshaft speeds

Test 063 Testing clutch pack pressure / park brake pressure
The controller will not energise any solenoids if it ‘thinks’ that the engine is not running , check to make sure that the controller
is receiving a signal from the engine speed sensor.
(Check for reading on monitor rpm counter 0003 means that no signal is being received by the controller.)
Does the display on the monitor change from ‘arrow’ to ‘hare’ when selecting footswitch for gear change?
9803/6500 Issue 1
RETURN PRINT
FF 702 FF 702
Loss of Creep Speed Travel XO130W / 160W / XO200W
If experiencing loss of creep speed travel (i.e. when changing from middle to creep gear no decrease of speed is achieved),
carry out following checks:
Test 062 Testing propshaft speeds

The controller will not energise any solenoids if it ‘thinks’ that the engine is not running , check to make sure that the controller
is receiving a signal from the engine speed sensor.
(Check for reading on monitor rpm counter 0003 means that no signal is being received by the controller.)
Does the display on the monitor change from arrow to tortoise when selecting button on right hand side sub monitor?
Remember the machine will only change from middle gear to creep speed and is activated by button on right hand side sub
monitor and not by footswitch.
9803/6500 Issue 3
RETURN PRINT
FF 703 FF 703
Poor Tractive Effort XO130W / 160W / XO200W

Test 011 Testing max flow cut / drive control signal

Test 060 Testing threshold pressure
Test 061 Testing drive motor minimum displacement setting
Test 062 Testing machine propshaft speeds
Test 066 Checking theshold pressure - XO200W only,
9803/6500 Issue 3
RETURN PRINT
FF 704 FF 704
Loss of Drive XO130W / 160W
If experiencing loss of drive carry out following checks:
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
RETURN PRINT
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 PRINT
FF 706 FF 706
Poor Steering and Braking Performance XO200W

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

Test 033 Checking latch brake pressure
9803/6500 Issue 3
RETURN PRINT
FF 800 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
Expected test time to complete all above tests 1 hr
9803/6500 Issue 2
RETURN PRINT
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 Test Procedures Section 2

i TEST PROCEDURE INDEX i
ISSUE
Test 001 Testing negative control signal, XO130 / XO160 / XO180 2
Test 002 Testing negative control signal, XO130/ XO160W 2
Test 003 Testing negative control signal, XO200 / XO220 / XO240 / XO260 2
Test 004 Testing negative control signal, XO330 / XO450 2
Test 005 Testing load sense pressures, XO200W 3
Test 010 Testing max flow cut signal, XO130 / XO160 / XO180 2
Test 011 Testing max flow cut signal / drive control signal, XO130W / XO160W 2
Test 012 Testing max flow cut signal, XO200 / XO220 / XO240 / XO260 2
Test 013 Testing max flow cut signal, XO330 / XO450 2
Test 014 Testing ∆ P shift, XO200W 3
Test 015 Testing servo pressure, XO200W 3
Test 020 Testing main pump pressures , XO70 1

Test 021 Testing main pump pressures, XO130 / XO160 / XO180 1
Test 022 Testing main pump pressures, XO130W / XO160W 1
Test 023 Testing main pump pressures, XO200 / XO220 / XO240 / XO260 1
Test 024 Testing main pump pressures, XO330 / XO450 1
Test 025 Testing main pump pressures, XO200W 3
Test 026 Testing horsepower control, XO130 / XO160 / XO180 1
Test 027 Testing horsepower control, XO130W / XO160W 1
Test 028 Testing horsepower control, XO200 / XO220 / XO240 / XO260 1
Test 029 Testing horsepower control, XO330 / XO450 1
Test 030 Flow testing pump, all models 2

Test 031 Testing pump milliamps 3
Test 032 Testing steering pressure 3
Test 033 Testing latch brake pressure 3
Test 034 Flow testing pump, XO200W 3
Test 039 Testing for trapped air in HBCV pilot line, all models 1
Test 040 Testing H.B.C.V’s , XO130 boom ram, XO130W boom ram 1
Test 041 Testing H.B.C.V’s , XO130 arm ram, XO160 arm ram, XO200 arm ram, XO240 arm ram,
XO240 arm ram, XO330 arm ram 1
Test 042 Testing H.B.C.V’s, XO160 boom ram, XO160W boom ram, XO180 boom ram 1
Test 043 Testing H.B.C.V’s , XO200 boom ram, XO200W boom ram, XO240 boom ram, XO330 boom ram 3
Test 044 Testing H.B.C.V’s , XO220 T.A.B ram, XO200W T.A.B ram 3
Test 045 Testing H.B.C.V’s , XO130W T.A.B ram, XO160W T.A.B ram 1
Test 050 Testing track motor relief valve settings, all models 1
Test 051 Testing track motor drain line flow , all models 1
Test 052 Testing track motor speeds, all models 1
Test 053 Testing operation of swing brake , all models 1
Test 054 Checking operation of main hydraulic spool, all models 1
Test 055 Checking operation of boom 2 / bucket 2 boost spool, XO130, XO130W , XO160, XO160W 1
Test 056 Checking operation of arm2 / boost spool, XO130, XO130W , XO160, XO160W 2
Test 057 Testing Swing Relief Pressure, XO200W 3
Test 058 Testing Swing/Boom - Priority, XO200W 3
Test 060 Testing drive motor threshold pressure, XO130W , XO160W 2

Test 061 Testing drive motor minimum displacement setting , XO130W , XO160W 1
Test 062 Testing wheeled machine propshaft speeds XO 130W , XO160W , XO200W 3
Test 063 Testing clutch pack pressure / park brake pressure, XO130W , XO160W , XO200W 3
Test 064 Testing condition of off road clutch, XO130W , XO160W / XO200W 1
Test 065 Testing condition of on road clutch, XO130W, XO160W / XO200W 1
Test 066 Testing Threshold Pressure, XO200W 3
Test 067 Testing Drive Circuit, XO200W 3
9803/6500 Issue 3
Section 2 Test Procedures Section 2
ii TEST PROCEDURE INDEX ii
ISSUE
Test 099 Testing pressure switchs- all AMS models 3
Test 100 Testing pressure switch’s 2
Test 101 Testing throttle motor unit 1
Test 102 Testing throttle motor driver unit 1
Test 103 Testing monitor unit 1
Test 104 Testing installation of engine speed sensor 1
Test 105 AMS Throttle Fault Finding- All AMS machines 3
Test 200 Testing engine speed settings, all models except XO70 3
Test 201 Testing engine speed settings, all AMS models except XO70 3
Test 300 Testing machine cycle times, all models 2

Test 301 Testing machine cycle times, all AMS models 2
Test 350 Checking slew bearing backlash, all models 1
Test 351 Checking slew bearing vertical lift, all models 1
(Test 001 -099 hydraulic) (Test100 - 199 electrical) (Test 200 - 299 engine) (Test 300 - 349 general)
(Test 350 -400 mechanical)
9803/6500 Issue 3
RETURN PRINT
Section 2 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*)
Select and stall boom up service record pressure (0 - 3 bar) (0 - 3 bar)

(40 bar when first
Fully select boom down record pressure when service first selected selected for 0.5 sec (25 - 35 bar)
then 0 bar)
Select and stall bucket open service record pressure (0 bar) (12 - 16 bar)
Select and stall bucket close service record pressure (0 bar) (12 - 16 bar)
Select and stall dipper open service record pressure (0 - 3 bar) (0 - 3 bar)
Select and stall arm close service record pressure (0 - 3 bar) (0 - 3 bar)
Select and stall swing left service record pressure (25 - 35 bar) (0 - 3 bar)
Select and stall swing right service record pressure (25 - 35 bar) (0 - 3 bar)
Select and stall left hand track forward record pressure (0 - 3 bar) (25 - 35 bar)
Select and stall left hand track backwards record pressure (0 - 3 bar) (25 - 35 bar)
Select and stall right hand track forwards record pressure (25 - 35 bar) (0 - 3 bar)
Select and stall right hand track backwards record pressure (25 - 35 bar) (0 - 3 bar)
* This pressure will vary with oil temperature and engine speed.
9803/6500 Issue 2
RETURN PRINT
TP 002 TP 002
Testing Negative Control Signal - XO 130W/XO 160W
REAR VEIW OF HYDRAULIC

PUMP
P11
P21
G1
G2
A302850
Fit test gauges ( 0 - 60 bar ) into hose connections to ports P11 + P21 with tee piece adapter
Port P11 Port P21

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

(40 bar when first
Fully select boom down record pressure when service first selected selected for 0.5 sec (25 - 35 bar)
then 0 bar)
Select and stall bucket open service record pressure (0 - 3 bar) (12 - 16 bar)
Select and stall bucket close service record pressure (0 - 3 bar) (12 - 16 bar)
Select and stall drive service forward record pressure (0 - 3 bar) (0 - 3 bar)
Select and stall drive service backwards record pressure (0 - 3 bar) (0 - 3 bar)
9803/6500 Issue 2
RETURN PRINT
TP 003 TP 003
Testing Negative Control Signal - XO 200/XO 220/XO 240/XO 260
VIEW FROM REAR OF

HYDRAULIC PUMP
Port Pt2
A318950
Port Pt1
Fit test gauges ( 0 - 60 bar ) into hose connections to ports Pt1 + Pt2 with tee piece adapter
Port pt1 Port pt2

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

(40 bar when first
Fully select boom down record pressure when service first selected (30 - 35 bar) selected for 0.5 sec
then 0 bar)
Select and stall bucket open service record pressure (24 - 26 bar) (0 bar)
Select and stall bucket close service record pressure (24 - 26 bar) (0 bar)
Select and stall left hand track forward record pressure (30 - 35 bar) (0 - 3 bar)
Select and stall left hand track backwards record pressure (30 - 35 bar) (0 - 3 bar)
Select and stall right hand track forwards record pressure (0 - 3 bar) (30 - 35 bar)
Select and stall right hand track backwards record pressure (0 - 3 bar) (30 - 35 bar)
9803/6500 Issue 2
RETURN PRINT
Section2 Test Procedure Section 2
TP 004 TP 004
Testing Negative Control Signal - XO 330/XO 450
Pi1 Pi2
PZ2
PZ1
A436100
Tier 2 Machines A436080
Fit test gauges ( 0 - 60 bar ) into hose connections to ports PZ1 + PZ1 with tee piece adapter
Port PZ1/Pi1 Port PZ2/Pi2

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

(40 bar when first
Fully select boom down record pressure when service first selected (25 - 35 bar*) selected for 0.5 sec
then 0 - 3 bar)
Select and stall bucket open service record pressure (16 - 20 bar) (0 - 3 bar)
Select and stall bucket close service record pressure (16 - 20 bar) (0 - 3 bar)
Select and stall swing left service record pressure (0 bar) (25 - 35 bar)
Select and stall swing right service record pressure (0 bar) (25 - 35 bar)
Select and stall left hand track forward record pressure (0 bar) (25 - 35 bar)
Select and stall left hand track backwards record pressure (0 bar) (25 - 35 bar)
Select and stall right hand track forwards record pressure (25 - 35 bar) (0 bar)
Select and stall right hand track backwards record pressure (25 - 35 bar) (0 bar)
9803/6500 Issue 3
RETURN PRINT
TP 005 TP 005
Testing Load Sense Cut Off Pressure XO200W
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
Max pressure NO power boost 290 bar
Max pressure Power boost selected 320 bar
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 PRINT
TP 010 TP 010
Test Max Flow Signal - XO 130/XO 160/XO 180

P12
Pm2
P22
Pm1
A31895
JS11200 JS 130 from 890083
JS160 from 703390
JS180 from 27.05.01
Fit test gauges ( 0 - 60 bar ) into hose connections to ports P12 + P22 or Ports Pm1 to Pm2 with tee piece adapter
Port P12 Port P22

With max engine 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


9803/6500 Issue 3
RETURN PRINT
TP 011 TP 011
Test Max Flow Cut Signal/Drive Control Signal - XO 130W/XO 160W
P12
Pm2
P22
Pm1
A31895
JS11200
JS 130 from 890083
JS160 from 703390
JS180 from 27.05.01
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

G Remove connector from drive pressure switch ( under cab floor ) connect terminals of harness connector together with a
short length of wire
Port P12/Pm1 Port P22/Pm2

Select high speed gear ( hare on monitor ) record pressure (40 bar) (28 bar)
Select high speed gear and also select dozer mode

( by switch on left hand controller ) but do not operate dozer, record presure (0 - 1.5 bar) (0 - 1.5 bar)
Select medium speed gear ( arrow on monitor ) record pressure (40 bar) (28 bar)
Select medium speed gear and also select dozer mode

( by switch on left hand controller ) but do not operate dozer, record pressure (0 - 1.5 bar) (0 - 1.5 bar)
Select creep speed gear ( tortoise on monitor ) record pressure (0 - 1.5 bar) (40 bar)
Select creep speed and also select dozer mode record pressure (0 - 1.5 bar) (40 bar)
9803/6500 Issue 3
RETURN PRINT
TP 012 TP 012
Test Max Flow Signal - XO 200/XO 220/XO 240/XO 260
VIEW FROM REAR OF

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

9803/6500 Issue 2
RETURN PRINT
TP 013 TP 013
Test Max Flow Signal - XO 330/XO 450
Port Pm1 Port Pm2
Port SC A436110
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
Port SC/ Pm1 /Pm2

With max engine rpm’s and no services selected record pressure (0 - 1.5 bar)
Select F mode and record pressure (40 bar)

then select track service record pressure (40 bar)
9803/6500 Issue 3
RETURN PRINT
TP014 TP014
Testing ∆ P Shift XO200W
A437080
Fit test gauge ( 0 - 60 bar ) to A with tee piece adapter
9803/6500 Issue 3
RETURN PRINT
TP015 TP015
Testing Servo Pressure XO200W
3
1
A436040
Fit test gauges ( 0 - 600 bar ) into test point 1 Expected Pressures
Warm up machine hydraulic temperature to 50 °C 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
RETURN PRINT
TP 020 TP 020
Testing Main Pump Pressure XO 70
G1
A297090
G1 Main, Dipper, Swing

G2 Main, Boom, Bucket
G2
Fit test gauges ( 0 - 60 bar ) into hose connections to ports G1 + G2
Port G1 Port G2
With max engine rpm’s and no services selected record pump pressure (12 - 20 bar*) (12 - 20 bar*)
Select and stall boom up service record pressure (284 bar) (284 bar)
Select and stall bucket open service record pressure (12 - 20 bar*) (284 bar)
Select and stall bucket close service record pressure (12 - 20 bar*) (284 bar)
Select and stall dipper open service record pressure (284 bar) (284 bar)
Select and stall dipper close service record pressure (284 bar) (284 bar)
Select and stall swing left service record pressure (206 bar) (12 - 20 bar*)
Select and stall swing right service record pressure (206 bar) (12 - 20 bar*)
Select and stall left hand track service forwards record pressure (284 bar) (12 - 20 bar*)
Select and stall left hand track service backwards record pressure (284 bar) (12 - 20 bar*)
Select and stall right hand track service forwards record pressure (12 - 20 bar*) (284 bar)
Select and stall right hand track service backwards record pressure (12 - 20 bar*) (284 bar)
* This pressure will depend on engine speed and oil temperature.
9803/6500 Issue 1
RETURN PRINT
TP 021 TP 021
Testing Main Pump Pressure XO 130/XO 160/XO 180

REAR VIEW OF
HYDRAULIC PUMP
G1
G2
G1
403610
G2
JS 130 from 890083
JS160 from 703390
A302850 JS180 from 27.05.01
Port G1 Port G2
Select and stall swing left service record pressure (25 - 35 bar) (310 bar)
Select and stall swing right service record pressure (25 - 35 bar) (310 bar)
Select and stall left hand track service forwards record pressure (345 bar) (25 - 35 bar)
Select and stall left hand track service backwards record pressure (345 bar) (25 - 35 bar)
Select and stall right hand track service forwards record pressure (25 - 35 bar) (345 bar)
Select and stall right hand track service backwards record pressure (25 - 35 bar) (345 bar)
Select F mode and then select stall boom up service record pressure (345 bar) (345 bar)
* This pressure will depend on oil temperature and engine speed.

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

VIEW OF
HYDRAULIC PUMP
G1
G2
A302840
Port G1 Port G2
Select and stall swing left service record pressure (25 - 35 bar) (310 bar)
Select and stall swing right service record pressure (25 - 35 bar) (310 bar)
Select and stall drive service forwards record pressure (345 bar) (345 bar)
Select and stall drive service backwards record pressure (345 bar) (345 bar)
Select F mode and then select and stall boom up service record pressure (345 bar) (345 bar)
9803/6500 Issue 1
RETURN PRINT
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
Select and stall left hand track service forwards record pressure (25 - 35 bar) (343 bar)
Select and stall left hand track service backwards record pressure (25 - 35 bar) (343 bar)
Select and stall right hand track service forwards record pressure (343 bar) (25 - 35 bar)
Select and stall right hand track service backwards record pressure (343 bar) (25 - 35 bar)
9803/6500 Issue 1
RETURN PRINT
TP 024 TP 024
Testing Main Pressure Excavator Services XO 330/XO 450
a1
a2
MA1
MA2
A436110
Fit test gauges ( 0 - 600 bar ) into hose connections to ports MA1 + MA2 or ports a1 + a2 for Tier 2 machines
Port MA1/a1 Port MA2/a2

Select and stall left hand track service forwards record pressure (318 bar) (25 - 35 bar)
Select and stall left hand track service backwards record pressure (318 bar) (25 - 35 bar)
Select and stall right hand track service forwards record pressure (25 - 34 bar) (318 bar)
Select and stall right hand track service backwards record pressure (25 - 35 bar) (318 bar)
9803/6500 Issue 3
RETURN PRINT
TP025 TP025
Testing Main Pump Pressure XO200W
3
1
A436040
Fit test gauges ( 0 - 600 bar ) into test point 3
Test Point 3
With max engine rpm’s and no services selected record pump pressure (40bar*)
Select and stall boom up service record pressure (314 bar)
Select and stall bucket open service record pressure (314 bar)
Select and stall bucket close service record pressure (314 bar)
Select and stall dipper open service record pressure (314 bar)
Select and stall dipper close service record pressure (314 bar)
Select and stall swing left service record pressure (use swing lock bar) (240 bar)
Select and stall swing right service record pressure (use swing lock bar) (279 bar)
Apply brakes and select drive forwards record pressure (343 bar)
Apply brakes and select drive backwards record pressure (343 bar)
Select and stall dozer uo record pressure (250 bar)
Select and stall dozer down record pressure (250 bar)
Select and stall stabilisers up record pressure (250 bar)
Select and stall stabilisers down record pressure (250 bar)
Select and stall TAB out record pressure (314 bar)
Select and stall TAB in record pressure (280 bar)
Note: Operating power boost, (two stage relief) will increase the Main releif valve pressure to 343 bar.
9803/6500 Issue 3
RETURN PRINT
TP 026 TP 026
Testing Horsepower Control XO130 / XO160 / XO180
Tier 2
VIEW FROM Machines
Proportional solenoid
UNDERSIDE OF secondary pressure
HYDRAULIC PUMP measurement port
A407830
A326230
Brown/Black (BrB) Brown/Black (BrB)

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

Using service connector from electrical test kit WDB0055
connect fluke meter in series as shown right.
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 130 XO 160 X0 180
Horsepower Milliamps Horsepower Milliamps Horsepower Milliamps

Control control control
secondary secondary secondary
pressure pressure pressure
With maximum engine rpms and no

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

dipper service selected and stalled. 11.5 bar 355 ma 12 bar 370 ma 12 bar 370 ma
Select H mode measure and record +/- 10% +/- 10% +/- 10%
milliamps and secondary pressure.
With maximum engine rpms and no 7.5 bar 250 ma* 8 bar 265 ma 8 bar 265 ma
services operated. Select S mode +/- 10%* +/- 10%* +/- 10%*
measure and record milliamps and 625 bar 220 ma*
secondary pressure. +/- 10%*

services operated. Select L mode 0 bar 0 ma 0 bar 0 ma 0 bar 0 ma
measure and record milliamps and
secondary pressure.
* Early XO 130 machines use 250 ma in S mode, later XO 130 machines use 220 ma
9803/6500 Issue 3
RETURN PRINT
TP 027 TP 027
Testing Horsepower Control XO 130w/XO 160w
VIEW FROM Tier 2

UNDERSIDE OF Proportional solenoid secondary
pressure measurement port Machines
HYDRAULIC PUMP
A326230
A407830
● Fit gauge ( 0 - 60 bar ) into proportional solenoid

● Separate proportional solenoid electrical connector.

+ -
OR
Pump side
● Using link wire, connect fluke meter in series as shown.
harness
+ -
● Warm up machine hydraulic temperature to 50 °C.
Link wire
XO 130w XO 160w
Horsepower Milliamps Horsepower Milliamps

Control control
secondary secondary
pressure pressure

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

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

services operated. Select S mode 7.5 bar 250 ma 8 bar 265 ma
measure and record milliamps and +/- 10% +/- 10%
secondary pressure.

services operated. Select L mode 0 bar 0 ma 0 bar 0 ma
secondary pressure.
9803/6500 Issue 1
RETURN PRINT
TP 028 TP 028
Testing Horsepower Control XO200 / XO220 / XO240 /XO 260
VIEW FROM UNDERSIDE OF Proportional solenoid secondary

pressure measurement port Later Machines
HYDRAULIC PUMP
A407830
A326240
Fit gauge ( 0 - 60 bar ) into proportional solenoid

secondary pressure measurement port using suitable Brown/Black (BrB) Brown/Black (BrB)
Separate proportional solenoid electrical connector.

connect fluke meter in series as shown right. + -
OR
Using link wire, connect fluke meter in series as shown. Pump side
harness
+ -
Link wire
XO 200 / XO 220 XO 240 / XO 260

Control control
secondary secondary
pressure pressure

services operated. Select H mode 7 ~12 bar 570 ma 7 ~14 bar 520 ma
measure and record milliamps and 10 ~16 bar* 495 ma 7 ~14 bar* 520 ma*
secondary pressure.

dipper service selected and stalled. 7 ~12 bar 570 ma 7 ~14 bar 520 ma
Select H mode measure and record 10 ~16 bar* 495 ma 7 ~14 bar* 520 ma*

services operated. Select S mode 28 bar 305 ma 26 bar 330 ma
measure and record milliamps and +/- 1 bar +/- 1 bar
secondary pressure.`

services operated. Select L mode 40 bar 0 ma 40 bar 0 ma
secondary pressure.
* Pre low emission machines
9803/6500 Issue 3
RETURN PRINT
TP 029 TP 029
Testing Horsepower Control XO 330 / XO 450

Tier 2 Machines
VIEW OF Proportional solenoid secondary
HYDRAULIC PUMP pressure measurement port
A326250
A436290
Fit gauge ( 0 - 60 bar ) into proportional solenoid Brown/Black (BrB) Brown/Black (BrB)
ad apter (port thread is 1/4 BSP ‘O’ ring fitting).

Using service connector from electrical test kit WDB0055 + -
OR
Pump side
Using link wire, connect fluke meter in series as shown. harness
+ -
Link wire
XO 330 XO 450

Control control
secondary secondary
pressure pressure

services operated. Select H mode 11.8 ~13.7 bar 520 ma TBA TBA
secondary pressure.

dipper service selected and stalled. 11.8 ~13.7 bar 520 ma TBA TBA
Select H mode measure and record

services operated. Select S mode 7.8 ~9.8 bar 410 ma TBA TBA
secondary pressure.

services operated. Select L mode 0 bar 0 ma TBA TBA
secondary pressure.
9803/6500 Issue 3
RETURN PRINT
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
RETURN PRINT
Flow testing Pumps - all XO Models except XO 70 (Continued)

Minimum Flow Pump 1 Minimum Flow Pump 2
Mode Pressure in P1 Pressure in P2 Flow Rpm Mode Pressure in P1 Pressure in P2 Flow Rpm
H H
S S
F F
L L
Maximum Flow Pump 1 Maximum Flow Pump 2

Mode Pressure in P1 Pressure in P2 Flow Rpm Mode Pressure in P1 Pressure in P2 Flow Rpm
H H
S S
F F
L L
Horsepower Control Pump 1 H Mode Horsepower Control Pump 2 H Mode

Pressure in P1 Pressure in P2 Flow Rpm Pump Ma Pressure in P1 Pressure in P2 Flow Rpm Pump Ma
Horsepower Control Pump 1 S Mode Horsepower Control Pump 2 S Mode

Horsepower Control Pump 1 L Mode Horsepower Control Pump 2 L Mode

9803/6500 Issue 2
RETURN PRINT
TP 031 TP 031
Testing Milliamps XO200W

OR
+ -
Using link wire, connect fluke meter in series as shown.
Pump side
harness
+ -
Link wire
330470
Milliamps

services operated. Select H mode 495 ma
measure and record milliamps.

dipper service stalled.Select H mode, 495 ma
measure and record milliamps.
9803/6500 Issue 3
RETURN PRINT
TP 032 TP 032
Testing Steering Pressure XO200W
3
1
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
A436250
9803/6500 Issue 3
RETURN PRINT
TP 033 TP 033
Testing Brake Latch Pressure XO200W
Test Point A
A436190
Fit a low pressure gauge into test point A on the rear axle of the machine (40 bar)
Run machine and latch the foot brake down, Record pressure.
Expected Brake Latch Pressure 65 bar
A436120
If this pressure is incorrect then adjust pressure by increasing or decreasing length of rod B.
9803/6500 Issue 3
RETURN PRINT
TP 034 TP 034
Flow Testing Pump - XO200W

Flowmeter
LS - pressure manometer
Adjustable Throttle
pc T
T P
Test Spool for max pump flow Part No. SSP0099
Pump Pressure
Fit pressure test gauges (0 - 600 bar) to main pump test points.
Install the special test spool SSP0099 in the bucket section of the main control valve.
Intall a flow meter and the metering orifice with the pressure gauge between the working ports A and B of the Bucket
section.
Install flow meter and load valve as close as possible to pump outlet in one of the pump lines.
Open the metering orifice completely.
Start the engine and warm up the hydraulic oil to at least 50 °C.
Operated the bucket and record the maximum pump flow from the flow meter
9803/6500 Issue 3
RETURN PRINT
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 PRINT
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 350 bar
XO130W 350 bar
9803/6500 Issue 3
RETURN PRINT
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
A409671
Set dipper to fully extend position with bucket 300 mm (12”) above ground and operate the emergency stop button, to
stop the engine.
Select arm in until the bucket rests on the ground, then fully select the lever for arm in, this will ensure that the pressure
in the arm circuit has been vented.
Fit test gauge (0 - 600 bar) to port E using appropriate adapter.
Start engine, lift boom to give clearance to move arm.
Carefully select arm in and slowly build pressure until arm starts to move slowly and steadily.
To adjust this setting, remove cap from small cartridge A and adjust as necessary.
Re-set the Main Relief Valve to the orignal setting.
NB - If arm is selected too quickly a higher pressure will be seen at pressure gauge giving false reading of relief setting
Relief Valve Settings
XO130 758500 ~ 350 bar

XO130W 716500 ~ 350 bar
XO160 701000 ~ 702503 350 bar
702504 ~ 370 - 390 bar
XO200/220 705000 ~ 705824 350 bar
705824 ~ 370 - 390 bar
XO240/260 708500 ~ 708748 350 bar
708748 ~ 370 - 390 bar
XO330 702500 ~ 712562 350 bar
9803/6500 Issue 3
RETURN PRINT
TP 042 TP 042
Testing Boom Hose Burst Check Valve XO160 / XO 160W / XO 180
VIEW FROM UNDERSIDE OF

LEFT HAND BOOM RAM
Port P
Port E
the engine.
Remove pilot hose from port E, plug hose and fit test gauge (0 - 600 bar) to port on valve.
XO160 702000 ~ 350 bar

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

Port E
Port P
the engine.
Select TAB down until the bucket rests on the ground, then fully select the pedal for TAB down, this will ensure that the
pressure in the TAB circuit has been vented.
Carefully select TAB down and slowly build pressure until TAB starts to move slowly and steadily.
To adjust this setting, remove cap from small cartridge and adjust as necessary.
NB - If TAB is selected too quickly a higher pressure will be seen at pressure gauge giving false reading of relief setting.
XO220 TAB 705000 ~ 350 bar
9803/6500 Issue 3
RETURN PRINT
TP 045 TP 045
Testing TAB Ram Hose Burst Check Valve XO130W / XO160W
Port P
the engine.
Select TAB down until the bucket rests on the ground, then fully select the pedal for TAB down, this will ensure that the
pressure in the TAB circuit has been vented.
Carefully select TAB down and slowly build pressure until TAB starts to move slowly and steadily.
To adjust this setting, remove cap from small cartridge and adjust as necessary.
NB - If TAB is selected too quickly a higher pressure will be seen at pressure gauge giving false reading of relief setting.
XO130W 716500 ~ 350 bar

XO160W 718500 ~ 350 bar
9803/6500 Issue 3
RETURN PRINT
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 350 bar

XO200/XO220/XO240/XO260 353 bar
XO330/XO450 324 bar
9803/6500 Issue 1
RETURN PRINT
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 (consult Technical Service Department)
for 1 min
Select and stall left hand track motor reverse (consult Technical Service Department)
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 (consult Technical Service Department)
for 1 min
Select and stall right hand track motor reverse (consult Technical Service Department)
for 1 min
Refit hose to track motor
Expected Drain Line Rates - consult Technical Service Department
9803/6500 Issue 1
RETURN PRINT
TP 052 TP 052
Testing Track Motor Speeds - All XO Machines

Raise one track off floor by slewing machine through 90° and lifting machine using boom and dipper.
Make a mark on outside face of track motor.
Operate track service forward and reverse for approx 5 mins to distribute warm oil around track motor circuit
FOR ALL FOLLOWING TESTS USE STANDARD MODE, FULL ENGINE 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
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
9803/6500 Issue 1
RETURN PRINT
TP 053 TP 053
Testing Swing Brake Pressure - All XO Machines except XO 70
Swing Motor
A405810
Fit pressure test gauge ( 0 - 60 bar ) into hose connection on hose A on the swing motor.
Pressure at port B
(Expected Pressure)
With engine at max 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
RETURN PRINT
TP 054 TP 054
Checking the Operation of the Main Hydraulic Spool - All XO Machines
Cylinder port B Cylinder port A
Sectional view of valve block

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

is being selected opposite end of spool
(Expected Pressure) (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 28 bar XO130W 716500 ~ 716593 28 bar

758373 ~ 758421 32 bar 716594 ~ 716618 32 bar
758422 ~ 40 bar 716619 ~ 40 bar
XO160 702000 ~ 702250 28 bar XO160W 718500 ~ 718560 28 bar

702251 ~ 702290 32 bar 718561 ~ 718586 32 bar
702291 ~ 40 bar 718587 ~ 40 bar
XO200/220 705001 ~ 705632 28 bar XO240/260 708501 ~ 708683 28 bar

705633 ~ 705687 32 bar 708684 ~ 708703 32 bar
705688 ~ 40 bar 708704 ~ 40 bar
XO330 712501 ~ 712514 32 bar XO450 714501 ~ 40 bar

712514 ~ 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
RETURN PRINT
TP 055 TP 055
Testing the Operation of Boom 2/Bucket 2/Boost Spool XO 130/XO 130W/ XO 160/
XO160W
VIEW LOOKING DOWN
ON TOP OF MAIN
CONTROL VALVE ➩ front of machine
Port d
Port dr2
Port b
A318940

Fit pressure gauges ( 0 - 60 bar ) into ports b ( pilot port to select bucket boost )
d ( pilot port to select boom boost )
dr2 ( spool chamber drain port )
Port b Port d Port dr2

(Expected Pressures) (Expected Pressures) (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 28 bar XO130W 716500 ~ 716593 28 bar

758373 ~ 758421 32 bar 716594 ~ 716618 32 bar
758422 ~ 40 bar 716619 ~ 40 bar
* XO160 702000 ~ 702250 28 bar XO160W 718500 ~ 718560 28 bar

702251 ~ 702290 32 bar 718561 ~ 718586 32 bar
702291 ~ 40 bar 718587 ~ 40 bar
9803/6500 Issue 1
RETURN PRINT
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
➩ front of machine
CONTROL VALVE
Port a1
Port dr1
A318940
Fit pressure gauges ( 0 - 60 bar ) into ports al ( pilot port to select boost spool )
and port dr1 ( spool chamber drain port )
Port al Port dr1

(Expected Pressures) (Expected Pressures)
With max engine rpm’s and no services selected (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)
* XO130 758000 ~ 758372 28 bar XO130W 716500 ~ 716593 28 bar

758373 ~ 758421 32 bar 716594 ~ 716618 32 bar
758422 ~ 40 bar 716619 ~ 40 bar
* XO160 702000 ~ 702250 28 bar XO160W 718500 ~ 718560 28 bar

702251 ~ 702290 32 bar 718561 ~ 718586 32 bar
702291 ~ 40 bar 718587 ~ 40 bar
9803/6500 Issue 2
RETURN PRINT
TP 057 TP 057
Testing Swing Relief Pressure - XO200W
Note: The manual swing lock bar should be installed for the followingh test.
Fit a high pressure gauge into the LS port 1 on the pump.

Disconnect and blank off the 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 B C D E
9803/6500 Issue 3
RETURN PRINT
TP 058 TP 058
Testing Swing/Boom Priority - XO200W
A436380
To test the swing/boom priority:

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

When checking with boom priority boom up must be selected at the same time as swing.
Boom priority is selectable between 0 and 10.
The pressure difference between each digit is approx 1.5 bar.
Expected pressure
Machine in Boom Priority 15 bar
Machine in Swing Priority 40 bar
This pressure is dependant upon the temperature of the oil.
9803/6500 Issue 3
RETURN PRINT
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
RETURN PRINT
TP 061 TP 061
Testing Drive Motor Minimum Displacement Setting XO130W / XO145W/ XO160W/ XO175W
The minimum displacement setting determines the maximum road speed of the machine, to check the setting carry out the
following
Remove the four capscrews which hold the lower plate in place
Check dimension ‘A’ against the table below
If dimension ‘A’ is incorrect adjust to correct setting
View of drive motor
A301900
Locking and sealing nut
Dimension A
130W 15 mm
130W ( German build only ) 27 mm
160W 15 mm
160W ( German build only ) 31 mm
9803/6500 Issue 1
RETURN PRINT
TP 062 TP 062
Testing Propshaft RPM XO 130W / XO145 / XO 160W XO175W / XO200W
Fit reflective tape

onto propshaft
A301900
Raise the machine off the ground using dozer blade, stabilizer legs or excavator end
Select high gear and then select drive forwards for 2 - 3 mins to allow the system to distribute warm oil around the circuit
Attach reflective tape to propshaft and using tachometer record propshaft rpm’s as follows
FOR ALL TESTS USE MAX ENGINE RPM’S AND FULLY SELECT DRIVE PEDAL
XO130W XO145W XO160W XO175W XO 200W

Expected Expected Expected Expected
rpm’s rpm’s rpm’s rpm’s rpm’s
(German build ) (German build ) (German build) (German build) (German build)
High gear 2500 rpm 2700 rpm 2700 3000 2700 - 2850
(1760 rpm) (1760 rpm) (1760 rpm) (1760 rpm) (2150 - 2250)
High gear with

dozer mode selected 1750 rpm 1000 rpm 1940 rpm 1000 1000
but dozer not operated (1250 rpm) (1250 rpm) (1250 rpm) (1250 rpm) (1250 rpm)
Medium gear 680 rpm 850 rpm 764 rpm 850 800 - 848
(500 rpm) (500 rpm) (500 rpm) (500 rpm) (800 - 848)
Medium gear with 460 rpm 350 rpm 520 rpm 350 270
dozer mode selected (330 rpm) (330 rpm) (330 rpm) (330 rpm) (270)
but dozer not operated
Creep gear 290 rpm 350 rpm 340 rpm 350 300 - 325
(200 rpm) (200 rpm) (200 rpm) (200 rpm) (300 - 325)
Creep gear with 290 rpm 350 rpm (340 rpm) 350 (300)
dozer mode selected (200 rpm) (200 rpm) (200 rpm) (200 rpm) (300)
but dozer not operated
Tolerance +/- 50 rpm’s unless otherwise stated
9803/6500 Issue 3
RETURN PRINT
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 Port B1
(Expected Pressure) (Expected Pressure)
With max engine rpm’s and high travel gear selected (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)
With max engine rpm’s and high travel gear selected,

select park brake on ( in cab ) (0 - 3 bar) (14 bar)
9803/6500 Issue 3
RETURN PRINT
TP 064 TP 064
Testing Condition of Off Road Clutch 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
RETURN PRINT
TP 065 TP 065
Testing Condition of On Road Clutch XO130W / XO160W / X0220W
On road clutch test

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

Pilot pressure to the drive pedal.
Before travel can take place the following procedures can be tested:
Pilot pressure from the pilot pump to the pilot filter.
Pilot pressure from pilot filter to the IN port of the transmission control valve.
Pilot pressure from the OUT port of the transmission control valve to the C1 port of the 9 station solenoid block.
Note:The Servo isolator (C1 and the drive isolator C3) must be energised before servo pressure will be available to the drive
pedal.
Pilot pressure from the pedal
Middle Speed
Pilot pressure from the pedal (forward) at port 1.
Pressure will now close the travel pressure switch on the shuttle valve (port S4)
Pressure from port B8 will enter the valve block on port b2.
The spool will now move allowing oil system oil to go to the travel motor.
Transmission control valve

Pilot pressure enters the valve and is reduced to 31 bar +/- 2 bar by the pressure reduction valve.
Oil is now available to the park brake spool.
Park brake on = no oil = no drive
Park brake off and oil is available through the gear change spool and out of port A1.
Any pressure that was in B1 can now be vented back to tank to stop both clutch packs operating.
31bar now lifts the clutch pack off and drive can be used in middle speed.
High speed.
Hydraulically the only difference is in the transmission control valve.
When high speed is selected the high-speed travel spool is energised and oil is now available through the B1 port.
Any oil that was in the A1 port again will be vented to tank.
Creep speed
Creep speed can only be selected when the machine is in Middle speed.
As per Middle speed and!
A hydraulic signal from the shuttle block (C9) to the 9 station solenoid block.
Electrically the creep speed solenoid is now energised and the servo pressure is now reduced to 15bar via the pressure
reduction valve. This now limits the amount of spool movement within the valve block.
At the same time the creep speed solenoid is energised the DPshift solenoid is energised.
Now servo pressure from the transmission control valve port C2 is available DPshift solenoid port Pst. This pressure will
act against the pump reducing its flow.
A437080
∆Pshift solenoid 1
Note: Drive cannot be activated until the clutch pack has been pressurised.
9803/6500 Issue 3
RETURN PRINT
TP 067 TP 067
Testing the drive circuit - XO200W - cont’d
3 Speed Travel
Creep relay
Travel pressure switch

Controller
Travel IN
CN5 (6)
pedal
24v
Travel change switch
OUT IN
CN7 (7)
Creep CN4 (4)
OUT
solenoid CN6 (1)
valve
Gear change
solenoid valve
Travel
Max Flow (Q) Cut
Pump
flow cut
relays
Amplifier 3 Travel pressure switch

4
5
GND 6
Pump flow
GND 9 control
24v 10
10v 11 Pilot pump
24v Main pump

OUT
OUT
CN6 (15)
CN6 (5)
Controller
9803/6500 Issue 3
RETURN PRINT
TP 067 TP 067
Testing the drive circuit - XO200W - cont’d
Operation Gear change Creep speed Pump flow cut

solenoid valve solenoid valve solenoid valve
Travel only ON OFF OFF
Travel & Dozer ON ON OFF
High Travel & Other ON OFF OFF
Travel only OFF OFF OFF
Travel & Dozer OFF ON OFF
Mid. Travel & Other OFF OFF OFF
Travel only OFF ON ON
Travel & Dozer OFF ON ON
Low Travel & Other OFF ON ON
Work S, H, L
mode
OFF
Travel Pressure
Switch
Travel High, Mid

Mode
ON Blade OFF
Low
Flow cut Creep Solenoid No signal to

solenoid valve Valve ON solenoid valves
ON
9803/6500 Issue 3
RETURN PRINT
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
Function Boom Boom up Hammer Slew Travel Upper Boost
Boom up OFF ON OFF OFF OFF ON Only if main pump

pressure is above
335 bar
Boom down ON OFF OFF OFF OFF ON OFF
Dipper in OFF OFF OFF OFF OFF ON Only if main pump

pressure is above
335 bar
Dipper out OFF OFF OFF OFF OFF ON Only if main pump
pressure is above
335 bar
Bucket in and OFF OFF OFF OFF OFF ON Only if main pump
out pressure is above
335bar
Slew left and OFF OFF OFF ON OFF ON OFF

right
Travel OFF OFF OFF OFF ON OFF OFF
Hammer OFF OFF ON OFF OFF ON OFF
9803/6500 Issue 3
RETURN PRINT
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 (expected (expected (expected

display) display) display) 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
RETURN PRINT
TP 101 TP 101
Testing Throttle Motor Unit - All XO Machines except XO 70
1 Black Common to coils

2 Dark Green Motor Case Earth
3 Blue C.W Limit Switch
Throttle 4 Brown Coil A
Motor 1 2 3 5 Red Coil B
Connector 6 Light Green C/CW Limit Switch
4 5 6 7 Orange Coil A1
8 Yellow Coil B1
7 8 9
9 White 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 BLUE BROWN RED LIGHT ORANGE YELLOW WHITE

GREEN GREEN
BLACK 3 - 3.6Ω 3 - 3.6Ω 3 - 3.6Ω 3 - 3.6Ω
DARK
GREEN
BLUE ↔
BROWN 3 - 3.6Ω 6 - 7.2Ω 6 - 7.2Ω 6 - 7.2Ω
RED 3 - 3.6Ω 6 - 7.2Ω 6 - 7.2Ω 6 - 7.2Ω
LIGHT ↔
GREEN
ORANGE 3 - 3.6Ω 6 - 7.2Ω 6 - 7.2Ω 6 - 7.2Ω
YELLOW 3 - 3.6Ω 6 - 7.2Ω 6 - 7.2Ω 6 - 7.2Ω
WHITE ↔ ↔
Indicates no contact
↔ Indicates no contact until limit switch closes then 0.5Ω
9803/6500 Issue 1
RETURN PRINT
TP 102 TP 102
Testing Throttle Motor Driver Unit - All XO Machines except XO 70

No Function
1 Coil A1 throttle motor

2 Coil B1 throttle motor
3 Earth shielding
4 Earth main
5 Motor pulse
1 2 3 4 5 6 7 8 6 Acc ignition
7 CW control
9 10 11 12 13 14 15 16 17 8 CCW control
9 Coil A throttle motor
10 Coil B throttle motor
11 Coil common feed
Front View of Throttle Motor Drive Unit showing 12 Common limit switches
Terminal Numbers 13 24V feed
14 Spare
15 Limit switch (signal to
controller)
16 Limit switch CW
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 9 10 11 12 13 14 15 16 17
1
2
3 0 2.69 8k 5.6 5.6 0 0 0 5.6 5.6 5.6
k k k k k k
4 0 2.69 8k 5.6 5.6 0 0 0 5.6 5.6 5.6
k k k k k k
5 2.69 2.69 10.1 7.2 7.2 2.69 2.69 7.2 7.2 7.2
k k k k k k k k k k
6 8k 8k 10.1 13.6 13.6 8k 8k 13.6 13.6 13.6
k k k k k k
7 5.6 5.6 7.2 13.6 10.1 5.6 5.6 10.1 10.1 10.1
k k k k k k k k k k
8 5.6 5.6 7.2 13.6 10.1 5.6 5.6 10.1 10.1 10.1
k k k k k k k k k k
9
10
11
12 0 0 2.69 8k 5.6 5.6 0 5.6 5.6 5.6
k k k k k k
13 130 110 0 0 0
k k
14 0 0 2.69 8k 5.6 5.6 0 5.6 5.6 5.6
k k k k k k
15 5.6 5.6 7.2 13.6 10.1 10.1 5.6 5.6 0 10.1
k k k k k k k k k
16 5.6 5.6 7.2 13.6 10.1 10.1 5.6 5.6 0 10.1
k k k k k k k k k
17 5.6 5.6 7.2 13.6 10.1 10.1 5.6 5.6 10.1 10.1
k k k k k k k k k k
indicates no connection
9803/6500 Issue 1
RETURN PRINT
TP 103 TP 103
Testing Monitor Unit - All XO Machines except XO 70
WORK MODE
Message
MODE
CLOCK WATER TEMP HYD. OIL TEMP FUEL
1 black ground
2 green/white adjust hours indication
3 blue/green adjust minute indication 1 2 3 4
4 space
5 red/yellow 24V supply
6 red/green 10V supply 5 6 7 8 9
7 yellow/white data
8 yellow/gold data
9 yellow/green data
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 2 3 4 5 6 7 8 9
1 6 kΩ 6 kΩ x 6 kΩ 6 kΩ 6 kΩ
2 6 kΩ 1 kΩ x 1 kΩ 1 kΩ 1 kΩ
3 6 kΩ 1 kΩ x 1 kΩ 1 kΩ 1 kΩ
4 x x x x x 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 1 kΩ
9 6 kΩ 1 kΩ 1 kΩ x 1 kΩ 1 kΩ
Indicates no connection
9803/6500 Issue 1
RETURN PRINT
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:

damage.


housing.
Clearance between sensor tip and ring gear 3.0 mm + 0.25 mm/
-0.25 mm (0.188 + 0.001 / -0.01 in).
Continued on next page....
9803/6500 Issue 1
RETURN PRINT
Testing Installation of Engine Speed Sensor (cont’d) -

Installation procedure XO 200 / XO 210 / XO 220 / XO 260 / XO 200W Isuzu engine:

damage.
3 Carefully screw in the sensor.
4 Torque tighten to 44~54 Nm (32.5~39.7 lbf ft).
-0 mm (0.122 + 0.016 / -0 in).
Installation procedure XO 200W JCB Diesel engine:

damage.


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

damage.


housing.
Torque tighten to 29.4 Nm (21.69 lbf ft).
-0.2 mm (0.137 + 0.008 / -0.008 in).
9803/6500 Issue 1
RETURN PRINT
TP 105 TP 105
AMS Throttle Fault Finding - All AMS Machines

E
H
A
K
AMS Throttle Assembly J
Note: Throttle position sensor
(behind the throttle lever)
A Throttle control valve
B Throttle linkage
B
C Throttle actuator
D Stop solenoid C
E Throttle cable
F Stop cable
G Throttle Lever F
H Feedback Potentiometer
D
G
A436300
This document describes the procedure for trouble shooting 4 Check the feed back potentiometer (Sensor). Start the
AMS throttle problems. Specifically when the engine can be engine and display "SENSE POT" on the monitor.
started, but the throttle dial cannot control the engine Manually move the lever (See figure 2 item G). Does the
speed. value change smoothly? If YES go to 5, if NO check the
potentiometer is securely fixed. Check the wiring (Figure
Perform the following checks: 1), if both are correct replace the potentiometer (Figure 2
a Confirm "one touch" or "auto idle" is not item H).
selected.Confirm that the hammer pressure switch is not
closed and check that the machine is not in 5 Check the throttle cable and linkages are free. With the
redundancymode. engine stopped, disconnect the throttle linkage (Figure 2
b Check the fuse A2 (15 Amp) - Replace if blown. at J) and then push/pull the cable. Does the lever on the
c Recalibrate the throttle system on the 20-second menu. injection pump move smoothly? If NO, cable is broken or
d Check the software version in each module sticking - Replace the cable and recheck. Does the lever
(ECU1,ECUW and EMS). If required, re-programme with G move smoothly? If NO, replace the nylon bush. If YES,
the latest software. go to 6.
e Check the set up configuration and correct if wrong
6 Reconnect the throttle linkage to the lever. Start the
Note: The "NO THROTTLE" message may appear during engine and manually push the lever (Figure 2 item G).
AUTOWARM UP with ECU1 version 1.25 and EMS Does the engine speed increase? If YES, go to 7 if NO,
version1.18 or lower. possible injection pump failure.
If the problems persist after the above checks: 7 Checking the throttle solenoid (Figure 2 item A).
1 When calibrating the throttle does the engine speed a Check the hosing to the solenoid is correct. Is the
initially increase then start to slowly reduce supply hose going to the "P" port? Is the tank hose
(normalprocedure)?. If YES go to 2, if NO go to 5. connected to the "T" port? Is the actuator hose
connected to the "A" port? If YES go to 7b. If NO
2 Check the engine speed sensor - Start the engine and connect the hoses correctly.
display engine RPM on the monitor. Is the correct engine b Check the pressure at port "P". Is the pressure greater
speed displayed. If YES go to 3, if NO, check engine than 30 bar? If YES go to 7c if NO check the servo
speed sensor gap and check the harness using figure 1. pressure system.
If both are correct replace the sensor 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
3 Check the throttle dial potentiometer. Start the engine blockage.
and display "THROTTLE POT" on the monitor. Turn the d Disconnect the connector at the solenoid and start the
dial to minimum, then to maximum. Does the value engine. Arrange temporary wiring to supply 24 volts
change form 0 to 5000 smoothly? If YES, go to 4, if NO, directly to Pin 1 of the solenoid valve (see Figure 1) and a
check the potentiometer is securely fixed, check the ground/earth to pin 2. Does the engine go to maximum
wiring using figure 2. If both are correct replacen the rev/min? If YES, go to 7e, if NO, Install a 40 bar test
potentiometer. point in port "A" of the proportional solenoid valve at
position "K" (see figure 2).
9803/6500 Issue 3
RETURN PRINT
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
FromService
ServiceManual Supplement
Manual Supplement 51
9803/6450
9803/6450Page 5-12
Page 5-12 C68 ENGINE CONTROL S.V.
5 R 1
1 2 3 C22 2
THROTTLE VOLUME DIAL
1
SG
SR
ECU1 C8 C2
CONN A CONN B
10 SG R A
+V REF
80
C87
20 S SG D
0V REF ENGINE SPEED SENSOR
WY 1
29 SR S E S 2
I/P 8 THROTTLE VOL.
32 WY WG G
I/P 17 ENGINE SPEED
39 WG WY M
I/P 6 THROTTLE LEVER
70 THROTTLE POSITION
SG 1 SENSOR
C9
CONN B WG 2
S 3
5 P
IGNITION
2A
CONN B 19 15A
20
C10
CONN C
15A FUSE AT CONN B 19 AND 20
FEEDS OUTPUTS 1 - 6
O/P 1 THROTTLE CONT.

21 R 4
C25
1 2A
P
+24V IGNITION
A346060
9803/6500 Issue 3
RETURN PRINT
TP 105 TP 105
AMS Throttle Fault Finding - All AMS Machines - cont’d
Thottle
Calibtration
Data
Throttle control
Data
Throttle calibration data
Typical values
Lower Upper Remarks
1 Dial lower band 0 70
2 Dial upper band 950 1000
3 Sense lower band (idle) 185 485
4 Sense upper band (max) 445 760 Usually 170~350 greater than sense lower band value.
5 Sense upper band (S mode) 410 720 Usually 25~45 lower than sense upper band (H mode).
6 Sense upper band (H mode) 445 760 Usually same as sense upper band (max) or within 10
- Except JS145W & JS175W.
7 Sense upper band (F mode) 390 700 Usually 45~65 lower than sense upper band (H mode).
8 Sense upper band (L mode) 390 700 Usually 45~65 lower than sense upper band (H mode).
9 Sense upper band (drive) 445 760 Usually same as sense upper band (max) or within 10
Note: These are typical values, actual values will vary Integral term is the response time which is not needed for
according to the machine. Values outside these ranges this publication.
may still be acceptable.
Duty cycle is the frequency of the signal sent to the
All the figures in the control data are a binary code and can proportional solenoid.
not be measured any other way.
The dial bands are read from the throttle dial. The sensor
value is read from the feedback potentiometer.
The value in the boxes will represent the values seen when
the machine was calibrated.
Throttle percentage is the percent the throttle dial is turned.
Expected value is the value it expects to see from the

feedback potentiometer which is recorded when the throttle
is calibrated.
Actual value is what the feedback potentiometer is really

sending.
Error term is the difference between the expected and

actual.
9803/6500 Issue 3
RETURN PRINT
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 (see table below)
( H mode minimum rpm’s )
Expected Milliamps
Select H mode, max engine rpm’s and stall arm close service (see table below)
record milliamps
Model XO130 XO130W XO160/ XO160W XO200 XO200W XO240 XO330 XO450
180 220 260
High Idle 2385 2385 - 2505 - 2505 - 2205 - 2205 2450 - 2250 - 2200
(flight speed) 2260 2260 2480 2480 2170 2365 2365
rpm’s
Arm stall H mode 2220 2220 2340 2340 1930 2160 2180 2050 2050
minimum rpm’s
Stall H mode 355 385 370 370 570 495 520 520 410
minimum milliamps
9803/6500 Issue 3
RETURN PRINT
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 Expected RPM Dipper In Expected RPM Bucket
(No service selected) stalled Close stalled
"A" mode with the 2145 +/- 50 RPM 2040 +/- 50 1970 +/- 50
auto pressure switch
shorted out
"A" mode with the 1945 +/- 50 RPM (Only for 3 2040 +/- 50 1950 +/- 50
auto pressure switch seconds after any service is
connected de-selected, then 1360 RPM
+/- 50RPM for X seconds
"E" mode. 2045 +/- 50RPM 1950 +/- 50 1950 +/- 50
"L" & "P" mode 1945 +/- 50RPM 1850 +/- 50 1870 +/- 50
9803/6500 Issue 3
RETURN PRINT
TP 300 TP 300
Testing Machine Cycle Times - All XO Machines
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 XO130 XO130W XO160/ X0160W XO200 XO200W XO240 XO330 XO450
180 /220 /260
Boom up 2.25 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
Arm out 2.4 ~ 3.0 2.4 ~ 3.0 2.8 ~ 3.6 2.8 ~ 3.6 2.4 ~ 3.4 2.5 ~3.5 2.9 ~ 3.9 2.4 ~ 3.0 2.5 ~3.5
Arm in 2.3 2.9 ~ 3.8 2.9 ~ 3.8 3.2 ~ 4.1 3.2 ~ 4.1 3.5 ~ 4.5 4.0 ~5.0 3.8 ~ 4.8 2.9 ~ 3.8 3.7 ~4.8
Bucket open 2.6 1.6 ~ 2.5 1.6 ~ 2.5 1.8 ~ 3.0 1.8 ~ 3.0 1.7 ~ 2.7 2.1 ~3.1 1.9 ~ 2.9 1.6 ~ 2.5 4.0 ~5.0
Bucket close 2.1 ~ 3.2 2.1 ~ 3.2 2.9 ~ 3.9 2.9 ~ 3.9 2.3 ~ 3.3 2.3 ~3.3 2.6 ~ 3.6 2.1 ~ 3.2 2.5 ~3.5
Swing left 4.5 4.3 ~ 5.0 4.3 ~ 5.0 5.2 ~ 5.7 5.2 ~ 5.7 4.7 ~ 5.7 5.5 ~6.7 5.3 ~ 6.3 4.3 ~ 5.0 5.5 ~6.5
Swing right 4.5 4.3 ~ 5.0 4.3 ~ 5.0 5.2 ~ 5.7 5.2 ~ 5.7 4.7 ~ 5.7 5.5 ~6.7 5.3 ~ 6.3 4.3 ~ 5.0 5.5 ~6.5
9803/6500 Issue 2
RETURN PRINT
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 Expected Gearbox RPM

Creep (Tortoise) 24 +/- 4
Middle 28 +/- 5
High (Rabbit) 46 +/- 6
9803/6500 Issue 3
RETURN PRINT
TP 350 TP 350
Checking Slew Bearing Backlash - All XO Machines
Set bucket 1mtr above ground with dipper fully extended
Attach dial test indicator to lower half of slew bearing and set needle to bolt head on top half of slew bearing
Stop the machine . By hand push bucket fully to one side and hold whilst dial test indicator is set to zero
By hand push bucket fully to other side and record measurement on dial test indicator
Alternatively
Set bucket 1mtr above ground with dipper fully extended, stop machine
By hand push bucket fully to one side and hold whilst a mark is made across the two halves of slew bearing
By hand push bucket fully to other side and hold, make a further mark on bottom half of bearing (which is in line with
original mark on top half of bearing )
Record measurement between two marks and conuslt Technical Service Department
9803/6500 Issue 1
RETURN PRINT
TP 351 TP 351
Checking slew Bearing Vertical Lift - All XO Machines
1 First set the Dipper in a perpendicular position and 2 Install a dial gauge and set the needle to the Zero Point.
position the bucket 200 mm above the ground, stop the
engine.
3 Start the engine and lift the main body with the bucket, 4 Then rotate the main body 180° and repeat the
when the bottom of the shoe is 100 mm above the procedure, this time the needle will rotate clockwise.
ground, note the reading on the dial gauge. The needle This value becomes L3.
will turn in the counter clockwise direction. This value
becomes L1, lower the body to the ground and confirm
the needle reads zero.
5 Next, place the dial gauge on the rear of the vehicle and 6 The average lateral movement is shown as the result of
repeat the two above procedures to obtain L2 and L4. the equation L1 + L2 + L3 + L4
2
Note: Always stop the engine when installing or removing

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

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HOW TO USE THIS DOCUMENT

4 ENSURE THAT ‘CURRENT PAGE’ IS SELECTED BEFORE YOU CLICK ON THE

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

Test Procedure Masters

FAULT FINDING SYSTEM

Observe all relevant Safety Information contained in those documents.

PLEASE CLICK IN THE BOX BELOW TO SIGNIFY THAT YOU

Section 1 Fault Finding Index Section 1

FAULT FINDING INDEX

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

Test 001 Testing negative control signal

Expected test time to complete all above tests 2.5 hrs

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

Test 001 Testing negative control signal

Expected test time to complete all above tests 2.5 hrs

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

Test 001 Testing negative control signal

Expected test time to complete all above tests 2.5 hrs

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

Test 001 Testing negative control signal

Expected test time to complete all above tests 2.5 hrs

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

Test 001 Testing negative control signal

Expected test time to complete all above tests 1 hrs

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

Test 053 Testing operation of swing brake

Expected test time to complete all above tests 2.5 hrs

Machine Performance is Unsatisfactory XO130 / 160 / 180

If experiencing poor machine performance carry out following checks:

Test 001 Testing negative control signal

Expected test time to complete all above tests 2.5 hrs

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

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

Test 002 Testing negative control signal

Expected test time to complete all above tests 2.5 hrs

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

Test 002 Testing negative control signal

Expected test time to complete all above tests 2.5 hrs

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

Test 002 Testing negative control signal

Expected test time to complete all above tests 2.5 hrs

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

Test 002 Testing negative control signal

Expected test time to complete all above tests 2.5 hrs

Boom Down Operation Is Harsh When Selected XO130W / 160W

Test 002 Testing negative control signal

Expected test time to complete all above tests 1 hrs

Swing Operation Operation Is Harsh When Selected XO130W / 160W

Test 053 Testing operation of swing brake

Expected test time to complete all above tests 1 hrs

Machine Performance is Unsatisfactory XO130W / 160W

If experiencing poor machine performance carry out following tests:

Test 002 Testing negative control signal

Expected test time to complete all above tests 2.5 hrs

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

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

Test 003 Testing negative control signal

Expected test time to complete all above tests 2.5 hrs

Test 003 Testing negative control signal

If arm cylinder has HBCV fitted then also carry out :

Expected test time to complete all above tests 2.5 hrs

Test 003 Testing negative control signal