JCB JS290
Uploaded by
Oleg SelavinJCB JS290
Uploaded by
Oleg SelavinSection C
Electrics
Service Manual - JS290 - Tier III Auto
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section B - Body & Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section J - Track and Running Gear
Section K - Engine
Publication No.
9803/9800-3
World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section C - Electrics
Notes:
C-0 9803/9800-3 C-0
Section C - Electrics
Contents Page No.
Basic System Operation
Circuit Symbols ......................................................................................... C-1
Component Identification .......................................................................... C-3
Schematic Diagram .................................................................................. C-6
A.M.S (Advanced Management System) ................................................. C-7
Circuit Concepts ....................................................................................... C-9
Pulse Width Modulation (PWM) .............................................................. C-12
ECU1/EMS/FACIA Power Supply and Network ..................................... C-13
ECU 1 Supply to Output Drivers ............................................................. C-14
Engine Throttle Control ........................................................................... C-16
Pump Control for Each Mode ................................................................ C-20
Hardware Sensing .................................................................................. C-24
Auto Boost Pressure ............................................................................... C-25
Engine Oil Level Warning ....................................................................... C-28
Engine Pre Heat (Glow plugs) ................................................................ C-30
Engine Automatic Warm Up ................................................................... C-32
Engine Automatic Idle ............................................................................. C-34
Engine One Touch Idle ........................................................................... C-36
Engine Start/Stop .................................................................................... C-38
Limp Mode system ................................................................................. C-40
Lever Lock .............................................................................................. C-42
Servo Isolator ......................................................................................... C-44
Wiper ...................................................................................................... C-46
Lower Wiper (option) .............................................................................. C-48
Washer ................................................................................................... C-50
Horn ........................................................................................................ C-52
Travel Alarm ........................................................................................... C-54
Soft/Hard (Cushion) ................................................................................ C-56
Slew Brake (100%) ................................................................................. C-58
Slew lock (100% Slew Brake) ................................................................. C-62
Slew Brake Solenoid Valve Failure ......................................................... C-64
3-Speed Travel ....................................................................................... C-65
Work Lamps ........................................................................................... C-70
Viscous Fan ............................................................................................ C-72
Fuel Level Sensor/Warning .................................................................... C-74
Engine Temperature Sensor/Warning .................................................... C-77
Coolant Level Warning ........................................................................... C-81
Air Filter Blocked Warning ...................................................................... C-82
Hydraulic Temperature Sensor/Warning ................................................. C-85
Alternator/No Charge Warning ............................................................... C-90
Quick hitch (option) ................................................................................. C-92
Overload Caution (option) ...................................................................... C-94
Beacon ................................................................................................... C-96
Hammer Only ......................................................................................... C-98
Scrap Magnet Option ............................................................................ C-101
Cab Interior Lamp ................................................................................. C-102
Refuelling Pump ................................................................................... C-104
Air Conditioning .................................................................................... C-107
Heated Seat ......................................................................................... C-108
Radio and Cigar Lighter ........................................................................ C-110
Service Required Warning .................................................................... C-112
EMS Set Menu. .................................................................................... C-114
EMS Set + Mode Menu ........................................................................ C-115
EMS Set+Mode (20 sec) Menu. ........................................................... C-116
C-i C-i
Section C - Electrics
Contents Page No.
Fault Finding
JCB Servicemaster ............................................................................... C-119
Fault Finding Without Using the JCB Servicemaster Diagnostic Tool .. C-158
Service Procedure
Testing of ECU Inputs + Outputs .......................................................... C-163
Using a Multimeter ................................................................................ C-165
Battery .................................................................................................. C-169
Wiring Harness Repair ......................................................................... C-172
Harness Data
Harness Interconnection ....................................................................... C-175
Main Harness ....................................................................................... C-176
Fascia Link Harness - Type 1 ............................................................... C-182
Fascia Link Harness - Type 2 ............................................................... C-185
Cab Harness - Type A .......................................................................... C-188
Engine Harness - Type A ...................................................................... C-197
Cab Harness (includes Engine Harness) - Type B ............................... C-200
Cab Harness (includes Engine Harness) - Type C ............................... C-209
C-ii C-ii
Section C - Electrics
Basic System Operation
Circuit Symbols
Basic System Operation
Circuit Symbols
TC-013
The following notations are used in the description circuit,
drawings.
C005310GB-2
Fig 1.
Inputs and Outputs
The letters i/p and o/p refer to input and output.
The letters in brackets i.e. (C-21) refer to the connector
and pin number.
C001660-2
Fig 2.
C-1 9803/9800-3 C-1
Section C - Electrics
Basic System Operation
Circuit Symbols
Page left intentionally blank
C-2 9803/9800-3 C-2
Section C - Electrics
Basic System Operation
Component Identification
Component Identification
JS290
The item numbers in the following table are identified on the Wiring schematics in this section. K Fig 5. ( T C-6)
Item Part Number Description Location
1 728/80071 Electronic control unit 1 Behind the rear cab panel.
2 728/80073 Electronic monitor system Front of cab.
3 701/80369 Facia switch panel Right hand side of cab.
4 30/927073 Controller (heater) On Right hand console.
5 716/30155 Throttle dial On Right hand console.
6 701/80184 Key switch On Right hand console.
7 701/80214 Switch (redundancy) Behind the drivers seat.
8 30/927074 ATC Below the rear cab panel.
9 30/927072 Heater Below the rear cab panel.
10 30/927075 Controller (ATC) On Right hand console.
11 701/60030 Switch body Under right hand console.
12 701/58826 Switch cap (worklamp) On Right hand console.
13 717/12900 Cigar lighter (12v) On Right hand console.
14 332/J4821 Radio Rear of cab in the roof.
15 701/80215 Limit switch (lever) Below the lever lock bar.
16 701/60041 Switch (cab light) Outer side of left hand console.
18 700/43900 Work lamp Toolbox
19 700/50022 Work lamp Boom
20 332/J0670 Breaker pilot switch Under the cab on the breaker pedal.
21 25/221094 LH Lever switch Left hand joystick.
22 25/221095 RH Lever switch Right hand joystick.
23 332/J2740 Volt dropper Behind the rear cab panel on top of the heater box.
25 6900/0624 Wiper Front windscreen.
26 6900/0587 Room lamp Rear of cab in the roof.
27 716/30205 Battery relay In the left hand side compartment.
28 708/04100 Battery In the left hand side compartment.
29 KHR1589 Fuse link (25A) In the left hand side compartment.
30 KHR1592 Fuse link (60A) In the left hand side compartment.
31
32 25/222203 8 spool solenoid valve In the right hand side pump bay.
33 25/220996 Slew brake valve Under cab.
34 01/145194 Engine (JZ230 T3) Rear of machine.
C-3 9803/9800-3 C-3
Section C - Electrics
Basic System Operation
Component Identification
Item Part Number Description Location
35 332/J0670 Pilot switch, upper Bottom switch on Right hand side of Main Control Valve.
36 332/J0671 Pilot switch, travel Top switch on Right hand side of Main Control Valve.
37 332/J0669 Pilot switch On manifold under cab.
38
39
40 717/07700 Travel alarm Below the counterweight.
41 20/925502 Pump (JZ230 T3) In the right hand side pump bay.
42 20/925546 Refuel pump Toolbox
43 215/11950 Lower wiper Under the cab.
44 700/26700 Beacon Centre section.
45 714/40226 Air con compressor Front of engine.
46 30/925618 Air con binary switch On air-conditioning condenser in the radiator bay.
47 717/20152 Horn Between the boom rams.
48 JHN0160 Washer bottle Toolbox.
49 716/30260 Pre-heat relay In the left hand compartment under the battery relay.
50 716/30129 Temperature sensor In the hydraulic pump suction tube.
51 701/80328 Overheat switch In the hydraulic pump suction tube.
52 704/50186 Fuel level sensor In Left hand side of fuel tank.
53 331/13929 Coolant level switch In the expansion bottle in the radiator bay.
54 JNH0070 Air filter clog switch In the air induction tube.
55 701/80192 Overload pressure switch Back of the manifold between the boom ram feet.
56 332/J0671 Pilot switch, auto mode On manifold under cab.
57 332/J2971 Pilot switch, auto boost Lower front of main valve block.
58 701/60000 Switch (radio mute) On Right hand console.
59 701/60031 Switch (heated seat) On Right hand console.
60 40/910552 Heated seat switch Cab.
61 JRJ0343 Direction control valve In right hand compartment.
62 25/220536 Valve, solenoid In right hand compartment.
63 25/222887 Priority valve (w/cutter) In right hand compartment.
Priority valve (grab rotate) In right hand compartment.
64 721/10455 Hammer only Connector
65 721/11632 Hammer/Aux switch
66 701/80223 Hammer/Aux/Merge switch
67 701/60032 Switch body
68 721/10458 Hammer/Aux/Merge link harness
71 25/222397 Proportional solenoid
72 332/J4952 Main harness
73 721/12522 Cab harness
C-4 9803/9800-3 C-4
Section C - Electrics
Basic System Operation
Component Identification
Item Part Number Description Location
74 721/12509 Facia harness (ATC)
74 721/12510 Facia harness (heater)
75 721/12060 Cab engine harness
76 332/J3297 Alternator link harness
77 JHR0174 Relay
78 701/80310 Switch refueling pump
79 721/11451 Low flow harness
80 716/30259 Barometric sensor
81 706/26100 Starter safety relay
82 716/30262 Air intake temperature sensor
83 728/80070 Engine ECU
84 17/926100 Fuel lift pump
Note: Items 64 to 68 are part numbers for the bridging
harnesses and switches for the option switch in the Right E
hand console
G
F
64
H I
C160 C160
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
66
65 A408581
Fig 4.
E Multiple cables
8 7 6 5 4 3 2 1 10 9 14 3 13 11 16 6 12 15 F Single cables
G Cables joined
67 68 H Cable not joined
I Earth cables
C160 C160 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
A408580
Fig 3.
C-5 9803/9800-3 C-5
Schematic Diagram
C-6
14 25 25A
1 ECU-STD O/P 1-6 9 RADIO (MEMORY), CAB INT LAMP SW
26 2 ECU-STD O/P 7-12 10 KEY SWITCH C92 29
2 1
3 ECU-STD O/P 13-16 11 ECU-STD, EMS BATT SUPPLY (4.0)300A (4.0) 200
4 ECU-STD O/P 17-22 12 DIAGNOSTIC CAB MAIN FRAME 30
12V RADIO
19 5 ECU-STD O/P 23-28 13 AUXILIARY
MAIN WIPER EARTH EARTH 25A
HEADER 2 HEADER 4 6 HEATER/ AIR CON, AUTO FAN 14 ECU-STD,EMS,FASCIA IGN SUPPLY
CAB ROOM CAB LH CAB RH C260 29
7 HEATED SEAT, WIPER 15 REFUELING PUMP 2 1
L A M P LAMP 1 (0.5)601G (0.5)614 (4.0)301 (4.0) 201 (4.0)201 60A
LAMP 1
8 WORK LAMPS, OPT HYDS, RADIO (IGN), LIGHTER 16 FUEL LIFT PUMP 27
2 (0.5)601H 2 (0.5)614C C91
1 2
M (0.5)601L (0.5)614B
(8.0)101D
3 3
C212
(0.5)601C (0.5)614D 33 C105
4 4 C5
BATT SUPPLY
(0.5)848A
IGN SUPPLY
812B
(8)001
1
21 22 C104
GROUND
5 (0.5)601D 5 (0.5)614H 300A 300A (4)300A +24V BATT SUPPLY C259 (8)101A
SWING
1
OFF
SHUT
6 (0.5)601M 6 (0.5)614A (3.0)600 EARTH 604H 2
15 C213
7 (0.5)601F 7 (0.5)614F
612
2
(0.5)848
(0.5)601 (0.5)614K 101D C6 C107
1 2 1 2 8 8 (8)101D +24V IGNITION SUPPLY
LOCK LEVER SW (0.5)601J (0.5)614H 1 812C 1
- + - +
300D
101G
101H
300C
300B
101K
LH LEVER SWITCHES RH LEVER SWITCHES
300E
101F
9 9
101J
547
SWING
C250 C108
OFF
SHUT
10 (0.5)601K 10 (0.5)614J 301 (4)301 +24V BATT SUPPLY ECM 604K 2
EARTH C109
(0.5)545A
(0.5)408B
HORN DOZER DOZER HAM/BOOM TRAVEL ONE TOUCH GRAB GRAB 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1
HEADER 1
(0.5)607
C198 S W ON SW OFF SW PRIORITY SW CHANGE SW IDLE SW CW SW CCW SW 12V 12V
10A
15A
10A
15A
10A
6 5 4 3 2 1 C255
15A
15A
15A
10A
10A
20A
20A
20A
10A
10A
10A
(1.0)547 (1.0)547
20 BREAKER (1.0)847
1
(1.0)847 72
COM
1U 2U 3U 4U 5U 6U 7U 8U 9U 10U 11U 12U 13U 14U 15U 16U
NO
C25 2
NC
PILOT SW
847
28
(0.5)613L
(0.5)843
(0.5)845
C185
1 2 3 4 5 6 7 8 9 10
40 34
613K
(0.5)825C 1
73 C94
SWING
C1
LOCK
AUTO (0.5)752 2 (0.5)815 2
C115 FAN
AUX 1 AUX 2 60 CONNECTOR A
TRAVEL
ALARM
C214 C186 (0.5)600H 1
(0.5)612D
(1.0)612G
(0.5)612H
(0.5)612A
(0.5)612C
(0.5)612B
(0.5)612E
(0.5)612F
(3.0)612L
C224
(0.5)612J
12 11 10 9 8 7 6 5 4 3 2 1 3 2 1 1 2 3 1 2 3 4 1 2 3 1 2 3 4 1 2 3 4 1 1 2 1 2 1 2 (0.5)807B (0.5)807B BOOM PRIORITY SOL V
1
24V/12V DROPPER C34 C33 C32 C31 C30 C27 C26 C226 C216 HEATED (0.5)819 (0.5)819 2 STAGE RELIEF SOL V
(0.5)803 1
ISUZU ENGINE
SWING
2
BRAKE
HEATED SEAT SW SEAT (0.5)800
3
(0.5)800 MAX FLOW CONT SOL V (0.5)602A 2 81 (8.0)620
(0.5)806 (0.5)806 TRAVEL CHANGE SOL V B
(0.5)428
(0.5)412
(0.5)420
(0.5)429
(0.5)432
(0.5)411
(0.5)848A
(0.5)419A
(0.5)106A
(0.5)601A
(0.5)109A
(0.5)841A
(0.5)601B
(0.5)109B
C187
(0.5)613
4
(0.5)614B
(0.5)601J
(0.5)840
(0.5)613A
(0.5)613B
(0.5)613K
(0.5)601K
(0.5)601
(0.5)413
(0.5)404
SAFETY RELAY
(0.5)613J
(0.5)812 (0.5)812 SWING SHUT OFF SOL V C171
59 C172
+12V SWITCHED
5 (0.5)806 1 S C (4.5)002 (4.5)002
+24V IGNITION
+12V MEMORY
(0.5)613C
(0.5)107A
(0.5)108A
+24V BATTERY
(0.5)850 BOOM SPEED REG. C C174
(0.5)490
(0.5)843
(0.5)845
TRAVEL
(0.5)813
(0.5)808
(0.5)804
(0.5)805
6 (0.5)422D
SPEED
S
HIGH
(0.5)815 (0.5)815 TRAVEL ALARM (0.5)604E 2
7 (0.5) 408A R
(0.5)848 B
(0.5)848 LEVER LOCK SOL V (RET) R
GND
GND
(0.5)825B
8
(0.5)825D LEVER LOCK SOL V (OUT)
C189 E C173
E
614D
9 (0.5)819 1
(1.0)504A
23
(1.5)106
(1.0)302
(1.5)107
(1.5)108
(1.0)303
(1.0)304
(1.0)306
(1.0)301
(1.0)102
(1.0)103
(1.0)104
(1.0)105
(1.0)150
(1.0)109
(1.0)305
(0.5)803 (0.5)803 SWING BRAKE SOL V
2 STAGE
10
6 5 4 3 2 1
RELIEF
(0.5)752 (0.5)752 SWING LOCK SOL V (0.5)604F 2
(0.5)600G
(4.5)101C
8 7 3 2 1 2 11
(0.5)417B (0.5)417B SENSOR 0V REF
408B
C110 (0.5)817
12
(0.5)817 CUSHION SOL V
C190 (1.0)605
C202 13 (0.5)825D 1 E C97
C203 (0.5)406 (0.5)406 AIR FILTER SW (8)101E
(0.5)614K
(0.5)302A
(0.5)108B
14 C98
(0.5)107C
B
(0.5)107B
(0.5)613G
(0.5)846A
(0.5)614A
(0.5)828
(0.5)828
LEVER
LOCK
(0.5)843
(0.5)614G
(0.5)401 (0.5)401 RESERVE TANK SW (0.5)848 2 408A (0.5)109C
15 L
(0.5)430 (0.5)430 REFUELING PUMP SW (0.5)546C (0.5)547
(0.5)407
16
(0.5)407 ENG OIL LEVEL
C194 R C99
17 (0.5)807B 1
(0.5)502 (0.5)502 HEAT RELAY 49 C176
BOOM
18 ALTERNATOR
PRIORITY
(0.5)801 (0.5)801 PUMP PROP SOL V (OUT) (0.5)604B 2
19
(0.5)546
20
(0.5)546C KEY SW - BATT RELAY
C192
HEAT 76
RELAY
C102
C103
(0.5)802 (0.5)802 FAN RELIEF PWM
(4.0) 101B
EARTH 21 (0.5)817 1 C269
(0.5)422D (0.5)422D STARTER RELAY
HEADER 3 32
CUSHION
22
846B (0.5)409 (0.5)409 SENSOR +5V REF (0.5)604J 2 4 1 (4.0)003
23
(0.5)405 (0.5)405 UPPER PILOT SW 003 C100
(0.5)407
24
(0.5)407 FUEL SENSOR
C193 (0.5)502 2
AIR CONDITIONER (0.5)414
25
(0.5)414 TRAVEL PILOT SW
(0.5)800 1
(0.5)545B 1
26
FLOW
CONT
MAX
(0.5)826 (0.5)826 WINDOW WASHER (0.5)604G 2
WATER 6 KEY SWITCH (0.5)408
27
(0.5)408 ALTERNATOR SIGNAL
1 2 3 4 5 6 7 8 9 10 FACIA SW PANEL THERMO RECIRC VALVE BATTERY CLUTCH
THROTTLE CAB INT LAMP SW BOOM PRIORITY SW LOWER WIPER SW 28 C101 GLOW PLUG
STAT ACTUATOR ACTUATOR RELAY RELAY REFUELING PUMP (0.5)827
29
(0.5)827 BOOM WORKLAMP
VOL DIAL OFF (0.5)751 (0.5)751 TOOLBOX WORKLAMP
5 (0.5)810
30
(0.5)810 HORN
31
AUTO IDLE IGN 16 74 (0.5)830 (0.5)830 A/C BINARY P SW
(0.5)613G
(0.5)613G
(0.5)613H
(0.5)613A
(0.5)613K
(0.5)613B
(0.5)613B
(0.5)613F
(0.5)613J
(0.5)613J
32
(0.5)433A
33
(0.5)433A A/C COMPRESSOR C66
HEAT (0.5)831 (0.5)831 A/C BINARY P SW (0.5)604C 1
41
WIPER
(0.5)416
34
(0.5)416 OIL TEMP SENSOR
PUMP C28 18
35 CONTROL
CRANK (0.5)750 (0.5)750 CWT LAMP (0.5)801 2
SOL V
(0.5)750 1
WASHER 3 2 8 7 3 2 8 7 3 2 (0.5)108C
36
(0.5) 108C LAMP SUPPLY (0.5)108F 2
C'WEIGHT C270 OIL LEVEL SWITCH
108C
30 17 15/54 50a 19 C222 LAMP
87A
37
30
86
85
87
433A
C215 (0.5)814
38
(0.5)814 BEACON (0.5) 407 1
1 (0.5)830 1 2 30 1 2 3 4 5 6 7 8 9 (0.5)838C C179
BEACON 39
C185 C43 C200 46 C80
2 (0.5)831 C184 C230 (0.5)421 (0.5)421 BOOST PS (0.5)830 1 47
(0.5)108D
(0.5)614C
A/C
(0.5)419B
(0.5)108E
(0.5)614J
(0.5)302B
(0.5)613E
(0.5)613F
C22 40
(0.5)811B
(0.5)426
(0.5)612A
(1.0)366A
3 (0.5)433B (0.5)306B (0.5)306B REFUEL SW (0.5)831 2 BINARY (0.5)606B 1
(0.5)809
(0.5)829
58 3 QUICK HITCH 4 (1.5)832 (0.5)820
41
QUICK HITCH P SW HORN
C223 2 42
(0.5)820 (0.5)810 2
5 (1.5)833 (0.5)423 (0.5)423 OVERLOAD C76
MONITOR (EMS) 53
(0.5)427
(0.5)425
43
(0.5)417A
6 (1.5)834 (0.5)829 (0.5)829 FUEL PUMP (0.5)401 1
RADIO MUTE SW ISOLATOR 44 RESERVE
C81 TOOLBOX
433
7 (0.5)835 (0.5)434 (0.5)434 OVER HEAT (0.5)602C 2 TANK LSW
45 LAMP 0.75 W
8 (1.5)106B (0.5)751 1 1
CUSHION 46
9 (0.5)836
C77 (0.5)108D 2 18 0.75 KW
10 (0.5)600C
47
(0.5)406 1 54 2
(0.5)606D
48
(0.5)814
O/LOAD 11 846B (0.5)602B 2 AIR FILTER CRANK ANGLE SENSOR
C166 C82 18 0.75 SCR
12 504H
(1.0)303A
BEACON
(1.0)150
(0.5)108E 1
(0.5)422C
C165
(0.5)546
2 1 BOOM 0.75 Y 1
SLEW BRAKE (0.5)827 2
8 7 3 2
(0.5)416A 1 50 LAMP
(0.5)409A 2 0.75 KW 2
C110
EMERG STOP 44 606E
C79 WASHER 48
HYD OIL TEMP SENSOR 0.75 SCR CAM ANGLE SENSOR
826 (0.5)826A 1
GND (FACIA SW PANEL)
M
M
(0.5)846D
(0.5)846C
(0.5)606C 2
(0.5)612L
(0.5)845
SPI SHIELD (SPARE)
C163
CHASSIS (SPARE)
IGNIION SUPPLY
IGNITION SUPPLY
REDUNDANCY
BATT SUPPLY
BLOWER (0.5)416B 1
EMERG STOP
EMERG STOP
HYD OIL
MRST-E (SPI)
MTSR-E (SPI)
CAN SHIELD
MTSR-E (SPI)
MRST-E (SPI)
SCLK-E (SPI)
0.75 RB 1
BATT GND
FUEL SENSOR
SCLK-E (SPI)
MOTOR CONTROLLER (0.5)409B 2 OVERHEAT SW C75
52
9803/9800-3
SPARE
CAN H
422D
SPARE
SHLD
CAN L
(0.5)407 1
SHLD
GND
0.75 BY 2
51 (0.5)417B 2
C159 0.75 R
846B
3
(0.5)846A 7 LOWER WIPER
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
8 WATER TEMP SENSOR
C40 (0.5)846E M
12V CIGAR
C14 C15
REDUNDANCY SW (0.5)807B 2
43
108G
(0.5)612K
LIGHTER OPT HYDS 1 BOOM PRIORITY
(0.5)423
604B
(0.5)435A
(0.5)504E
(0.5)818A
(0.5)837
(0.5)504J
(0.5)545D
(0.5)544D
(0.5)610
(0.5)611
35
(0.5)552
(0.5)550
(0.5)553
(0.5)661
(0.5)610
(0.5)305C
SWITCH (SEE 2/2) C207
(0.5)612S
(0.5)550
(0.5)551
(0.5)552
(0.5)553
C41 HAM/AUX MERGE FLOW MERGE VALVE AUTO MODE SWING PILOT BOOM UP 1 0.75 WB 1
DIAGNOSTIC
CONNECTOR SOL V C SOL V B SOL V A P SW P SW P SW 2
C93 55 (0.5)405 1 UPPER
13 8 7 6 5 4 3 2 1 C160 3 (0.5)603 2 PILOT 0.75 UY 2
C18 62 62 62 56 37 37 (0.5)606A 4 OVERLOAD P SW
0.75 BY 3
PRESSURE
C208
BATTERY (+24V)
1 (0.5)612M
1 2 1 2 1 2 1 2 3 4 SW 36 OIL PRESSURE SENSOR
C169
C168
C167
C221
C206
C204
CAN SHIELD
2 (0.5)836 2 1 2 1 2 1
A/C
(0.5)108F
(0.5)614H
4 6 5 1 3 2 C161 (0.5)414 1 TRAVEL C72
(0.5)838
(0.5)839
(0.5)840
(0.5)841
CONTROL 3 (0.5)504D C201 C116
CAN H
PILOT
CAN L
PANEL (0.5)606G 2
GND
4 (0.5)835
P SW
(0.5)839B
(0.5)601L
0.75 U
C157 1
(0.5)403
(0.5)431
(0.5)418
(0.5)811
(0.5)613D
(0.5)601H
(0.5)614F
(0.5)601G
(0.5)838A
(0.5)431
(0.5)838B
(0.5)107D
(0.5)601F
(0.5)601K
5 (0.5)820 1
C164
600D
600D
42
600C
600E
(1.0)435B
6 C210 QUICK 0.75 N
602
603
604
605
606
607
2
(1.0)842
A B C D E F G H J (0.5)604A 2 C220
(1.0)504B
(0.5)614E (0.5)600F HITCH
7 (0.5)834 1
C13 838A A
8 (0.5)833 2
C229
REFUEL PUMP (0.5)108G
57 0.75 UW 3
839A 1 2 3 4 5 6 7 8 9 10 (0.5)600A B
9 (0.5)832 (0.5)829 1
C4 M (0.5)421 C BOOST COM RAIL PRES SENSOR
10 71
(1.0)305
10
(0.5)612H
(0.5)545A
(0.5)544A
(0.5)606F 2 P SW
838C (0.5)821 DOZER (NOT USED)
11 C228 1 0.75 SCR
C180 839B (0.5)822 (0.5)822 GRAB CW SOL V
(0.5)422B
12 2
(0.5)823 (0.5)823 GRAB CCW SOL V EARTH HEADER 0.75 BR
417A
3 1
(0.5)504C (0.5)504C
1 (0.5)824 (0.5)824 PRIORITY V
(0.5)304B (0.5)304B 4
(0.5)435A
2
(0.5)435A 417B
(0.5)816
5
BREAKER (NOT USED)
79 0.75 RU 2
(0.5)433A
WORKLAMP SW (0.5)612J
3
(0.5)612J (0.5)305
(0.5)414A
6
TRAVEL P SW
BOOST TEMP SENSOR
(0.5)430
(NOT USED)
(0.5) 306B
4
C90
(0.5)545D (0.5)545D
11 12
(0.5)802
5 C258
(0.5)600B
(0.5)544D
6
(0.5)544D 504C (1.0)504A 1
0.75 RW
C232
(0.75)507 BAROMETRIC SENSOR GND 1
(0.5)600K
C233
7 1 1 2 3 4
(0.5)822
C155 45
417
2 1
(0.5)600L
(0.5)600M
807
(0.5)837 (0.75)510 BAROMETRIC SENSOR 5V OUTPUT 61
(0.5)823
(0.5)837
(0.5)824
8 (0.5)818A 842A 2 0.75 U 2
(0.5)818A (0.5)818A (0.75)509 OIL PRESSURE SENSOR SIGNAL
842B
435A
9 3
(0.5)422
504
(0.75)508 BAROMETRIC SENSOR SIGNAL
CC-KW2000
2 1 2 1 2 1 0.75 RU 3
818
10 4
TECH 2
(0.5)807A
(0.5)600C
C156 (0.75)511 INTAKE AIR TEMP SIGNAL
IS-DIAG
SHIELD
C194
818B 5 A/C COMP
SHLD
C137
C138
C139
8 7 3 6 5 2 435B (0.75)512 BOOST TEMP.SENSOR SIGNAL
C253 BOOST PRESSURE SENSOR
C24 C225 (0.75)513
6
OIL PRESS SENSOR GND
75
825B
7
2 1
(0.5)836
1
(0.5)836 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 (0.75)514
8
OIL PRESS SENSOR 5V
LOW FLOW REFUELING 72
(0.5)424
(0.5)415
(0.5)835 (0.5)835
(0.5)612N
(0.5)612P
(0.5)504F
(0.5)504F
2 9 PRIORITY PUMP SW FAN DRIVE 0.75 G 1
(0.5)834 (0.5)834 (0.75)521 FUEL LEAK TEMP SENSOR SIGNAL LOW FLOW DIRECTION V
3 544D 544B 544 10 RELIEF
63
(0.5)422A
(0.5)833 (0.5)833 (0.75)522 WATER TEMP.SENSOR SIGNAL 0.75 SCR
4 545D 545B 545 11 C265 PROP SOL V
(0.5)832 (0.5)832 0.75 SCR
(0.75)543
(0.75)506
5 12 OVER HEAT WARNING SW
(0.75)611H
(0.75)611N
(0.5)846 (0.5)846 523B 523A (0.75)523A SUCTION CONTROL VALVE LO (0.75)530 CRANK ANGLE SENSOR PULSE (+)
6 13 20
(0.5)845 (0.5)845 (0.75)516 BOOST PRESS SENSOR SIGNAL (0.75)531 CRANK ANGLE SENSOR PULSE GND
7 14 19 1.5 W 1
(0.5)424 (0.75)517 EGR POSITION SENSOR W (0.75)616 CRANK ANGLE SENSOR SHIELD-GND
USED ON 8
(0.5)424
MAIN RELAY FUEL LIFT PUMP EMERGENCY STOP 15 18
(0.5)415 (0.5)415 (0.75)518 EGR POSITION SENSOR V (0.75)526 CAM ANGLE SENSOR PULSE 5V
WHEELED M/C ONLY 9
(0.75)519
16
EGR POSITION SENSOR U (0.75)525
17
CAM ANGLE SENSOR PULSE GND
0.75 U 2 CYLINDER 1
10 17 16
(0.75)520 BOOST PRESS SENSOR 5V 0.75 SCR (0.75)618 CAM /COM.RAIL SHIELD
8 7 3 6 5 2 18 15
C49 (0.75)525
19
CAM ANGLE SENSOR PULSE GND (0.75)522
14
WATER TEMP.SENSOR SIGNAL
0.75 UW 3
(0.5)853 (0.75)526 CAM ANGLE SENSOR PULSE 5V (0.75)520 BOOST PRESS SENSOR 5V CYLINDER 3
1 20 13
(0.5)852 0.75 SCR (0.75)514 OIL PRESS SENSOR 5V
2 21 12
(0.5)305D
(0.5)612R
(0.5)305E
515A
(0.5)853
(0.5)852
(0.5)504H
(0.75)515A COMMON RAIL PRESSURE SENSOR SIGNAL (0.75)509 OIL PRESSURE SENSOR SIGNAL
22 11 0.75 GR 4
(0.75)527 COM.RAIL PRES.,EGR POSN SENS.GND (0.75)513 OIL PRESS SENSOR GND CYLINDER 2
C181 23 10
87A
87A
87A
(0.75)524 COMMON RAIL PRESS SENSOR 5V (0.75)524 COMMON RAIL PRESS SENSOR 5V
30
86
85
87
30
86
85
87
30
86
85
87
24 9
0.75 SCR (0.75)619 CAM/COM.RAIL SHIELD (0.75)515A COMMON RAIL PRESSURE SENSOR SIGNAL
25 8
(0.75)528 EGR MOTOR V (0.75)527 COM RAIL PRESS/EGR POS SENSOR GND
C251 C254 C271 26 7 1.5 R 1
(0.75)529 SUCTION CONTROL VALVE HI 0.75 SCR (0.75)512 BOOST TEMP.SENSOR SIGNAL
(0.75)837
(0.75)505
(0.75)501C
(0.75)503B
(0.75)611E
(0.75)611M
6
(1.0)847
27
(4.0)301A
(2.0)501B
(0.75)611G
(0.75)301C
(1.0)301B
(0.75)530 CRANK ANGLE SENSOR PULSE (+) (0.75)516 BOOST PRESS SENSOR SIGNAL
28 5 0.75 UY 2 CYLINDER 5
(0.75)531 CRANK ANGLE SENSOR PULSE GND (0.75)532 BOOST PRESS SENSOR GND
29 4
0.75 SCR (0.75)617 CRANK ANGLE SENSOR SHIELD-GND 0.75 SCR
(0.5)419
30 3
(4.0)301
(0.75)532 BOOST PRESS SENSOR GND 0.75 SCR
31 2 0.75 UR 3
CYLINDER 6
(0.75)533 EGR MOTOR W
(0.75)422A
32 1
(0.75)544
(0.75)545
(0.75)837
(0.75)504
(0.75)502
(0.75)534 EGR MOTOR U
33
0.75
34 0.75 UB 4
CYLINDER 4
(0.75)535 INJECTOR #2 CYL SIGNAL
(0.5)432A 8 7 6 5 4 3 2 1 35
TEIR 3 (0.75)536
36
INJECTOR #4 CYL SIGNAL
C266
Basic System Operation
(1.5)537 INJECTOR POWER (INJECTOR#4,#5,#6) 0.75 YG 1
C252 37
(0.75)538 INJECTOR #3 CYL SIGNAL
Section C - Electrics
1.5 W INJECTOR POWER (INJECTOR#1,#2,#3)
38 1
(0.75)539 INJECTOR #6 CYL SIGNAL 1.5 R INJECTOR POWER (INJECTOR#4,#5,#6) 0.75 BY 2
84
(0.75)422A
(0.75)611K
39
(0.75)544
(0.75)545
(0.75)837
(0.75)504
(0.75)502
2
(0.75)540 INJECTOR #1 CYL SIGNAL
40 3
(0.75)541 INJECTOR #5 CYL SIGNAL
41 C262 FUEL LEAKAGE TEMP SENSOR
C261 4
(1.5)542 INJECTOR POWER (INJECTOR#1,#2,#3) LIFT PUMP 0.75 U INJECTOR #1 CYL SIGNAL
42 5
(1.0)547 FUEL LIFT PUMP (1.0)547 1 0.75 LR INJECTOR #6 CYL SIGNAL
43 M 6
501C (1.0)604D 2 0.75 UY INJECTOR #5 CYL SIGNAL
501B 44 0.75 RW 1
7
0.75 UW INJECTOR #3 CYL SIGNAL
45 8
0.75 GR INJECTOR #2 CYL SIGNAL 0.75 RB
46 9 2
0.75 GB INJECTOR #4 CYL SIGNAL
47 10
SUCTION CONTROL VALVE
(0.5)825A
75 48 11
303
102
301
12
0.75 WR 1 U
C267
0.75 WB 2 V M
(0.75)521 FUEL LEAK TEMP SENSOR SIGNAL
1
(0.75)611D
(0.75)611H
(0.75)611G
(0.75)611C
(0.75)611E
(0.75)611F
(0.75)611J
(0.75)529 SUCTION CONTROL VALVE HI
(1.5)611A
(1.5)611B
0.75 WU W
(1.5)611
2 3
(0.75)523A SUCTION CONTROL VALVE LO
3
(0.5)434 G OVERHEAT WARNING SW
4 MOTOR EGR BRUSH LESS DC
(0.75)611D
(0.75)503A
(0.75)422A
(0.75)529A
(0.75)611C
(0.75)532B
(0.75)515B
(0.75)529B
(0.75)611E
1
(0.5)612D
(1.0)612G
(1.0)303A
(1.0)102A
(1.0)301A
(0.5)811A
(0.5)304A
(1.0)304C
(0.5)544C
(0.5)612C
(0.5)414B
(1.0)303B
(1.0)102B
(1.0)301B
(0.5)612B
(0.5)545E
(1.0)612E
(0.5)612F
(1.5)611A
(1.5)501A
(1.5)611B
(0.75)502
(0.75)545
(0.75)503
(0.75)504
(0.75)544
(0.75)543
(0.75)505
(0.75)506
(0.75)507
(0.75)508
(0.75)509
(0.75)510
(0.75)511
(0.75)512
(0.75)513
(0.75)534
(0.75)514
(0.75)515
(0.75)521
(0.75)522
(0.75)524
(0.75)516
(0.75)517
(0.75)518
(0.75)519
(0.75)520
(0.75)523
(0.75)525
(0.75)526
(0.75)616
(0.75)527
(0.75)528
(0.75)530
(0.75)531
(0.75)615
(0.75)532
(0.75)533
(0.75)535
(0.75)536
(0.75)537
(0.75)538
(0.75)539
(0.75)540
(0.75)541
(0.75)542
(0.5)400
(0.5)401
(0.5)404
(0.5)405
(0.5)415
(0.5)417
(0.5)419
(0.5)421
(0.5)423
(0.5)810
(0.5)402
(0.5)403
(0.5)406
(0.5)407
(0.5)408
(0.5)409
(0.5)410
(0.5)411
(0.5)412
(0.5)413
(0.5)416
(0.5)418
(0.5)420
(0.5)422
(0.5)424
(0.5)425
(0.5)426
(0.5)427
(0.5)428
(0.5)429
(0.5)430
(0.5)431
(0.5)432
(0.5)433
(0.5)434
(1.0)104
(1.0)105
(1.0)435
(0.5)800
(0.5)801
(0.5)802
(0.5)803
(0.5)804
(0.5)805
(0.5)806
(0.5)807
(0.5)808
(0.5)809
(0.5)812
(0.5)813
(0.5)750
(0.5)751
(0.5)814
(0.5)815
(0.5)816
(0.5)817
(0.5)818
(0.5)819
(0.5)820
(0.5)821
(0.5)822
(0.5)823
(0.5)824
(0.5)825
(0.5)826
(0.5)752
(0.5)827
0.5)850
5
(1.5)611
(1.5)501
C263 FOR OEM METER R WATER TEMP SENSOR
6
(0.75)508 1 a
80 0.75 1
1 2 3 4 5 6 7 8 9 10
(0.75)507A 0.75 WR 2
2 b
C268 U
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 0.75 WB
Schematic Diagram
(0.75)510 3
3 c V
CONNECTOR A CONNECTOR B CONNECTOR C ECM VEHICLE SIDE ECM ENGINE SIDE 1
(0.75)517 EGR POSITION SENSOR W 0.75 WU 4
2 W
C8 C9 C10 C256 C257 (0.75)518 EGR POSITION SENSOR V
3 0.75 5
BAROMETRIC SENSOR (0.75)519 EGR POSITION SENSOR U
EARTH 4
HEADER 5
C264 5
EGR POSITION SENSOR
O/P36 HARDWARE SENSING
(0.75)533 EGR MOTOR W
O/P15 HIGH SPEED TRAVEL
O/P10 SWING SHUT OFF 3
82
I/P28 KEY SW (CRANK)
6
O/P22 ENG SHUTDOWN
(0.75)511
O/P1 BOOM SPEED REG.
A
I/P25 AUTO MODE P SW
I/P16 REFUEL PUMP SW
I/P5 ENGINE OVERHEAT
O/P5 REFUELING PUMP
(0.75)528
O/P16 BOOM PRIORITY
O/P30 TOOLBOX LAMP
EGR MOTOR V
I/P14 ONE TOUCH IDLE
PULSE(+) SP-CAM HAL
PULSE(+) SP-CAM HAL
I/P34 TRAVEL CHANGE
O/P8 FAN RELIEF PWM
O/P26 TRAVEL ALARM
O/P35 STARTER RELAY
O/P3 MAX FLOW CUT
O/P24 2 STAGE RELIEF
O/P20 LOW FLOW PRI
I/P18 BOOM PRI/HAM
I/P6 THROTTLE LEVER
I/P19 BOOM UP PILOT
O/P34 SWING LOCK 1
O/P9 SWING BRAKE 2
I/P20 HAMMER PILOT
7
O/P11 LOWER WIPER
PULSE(-) IF-CAM HAL
+5V REF (THROTTLE)
O/P14 CAB RH LIGHT
I/P13 O/LOAD PRESS
O/P13 CAB LH LIGHT
O/P25 QUICK HITCH
O/P29 BOOM LIGHT
I/P35 ENG OIL LEVEL
O/P2 CAB INT LAMP
PULSE(+) IF-CRANK-
I/P21 LOWER WIPER
I/P8 THROTTLE VOL
O/P28 SOFT/HARD
O/P21 LEVER LOCK
(0.75)534 EGR MOTOR U
I/P27 TRAVEL PILOT
I/P7 CAB INT LAMP
I/P29 SWING PILOT
I/P37 RES TANK SW
I/P1 HYD OIL TEMP
I/P15 BOOST P SW
O/P32 OVER HEAT
I/P26 UPPER PILOT
O/P19 CCW GRAB
I/P10 A/C CLUTCH
O/P33 CWT LIGHT
I/P32 LEVER LOCK
O/P7 PUMP PROP
SUPPLY O/P17-22
SUPPLY O/P23-28
SUPPLY O/P13-16
SUPPLY O/P13-16
I/P3 ALTERNATOR
I/P22 DOZER OFF
I/P2 WATER TEMP
I/P12 OPT LAMPS
I/P17 ENG SPEED
8
O/P18 CW GRAB
GND I/P7,8,15,16
I/P31 GRAB CCW
O/P IS-MDMAP0
I/P23 DOZER ON
O/P CC-KW2000
SUPPLY O/P7-12
SUPPLY O/P7-12
(0.75)507B
I/P9 STD LAMPS
O/P OS-BOOSTL
O/P27 BREAKER
B
O/P23 WASHER
I/P4 FUEL LEVEL
O/P PG-POWER
O/P PG-POWER
I/P11 AIR FILTER
I/P33 AIR PRESS
CAN CC-CAN-H
GND SG-5VRT2
I/P IA-OILPRESS
GND SG-5VRT3
GND SG-5VRT5
I/P OS-STARTER
I/P30 GRAB CW
CAN CC-CAN-L
SUPPLY O/P1-6
SUPPLY O/P1-6
O/P OS-MAINR
O/P OF-TACHO
- IS-EBMPOS 3
- IS-EBMPOS 2
- IS-EBMPOS 1
O/P IS-MEMCL
- IS-MDMAP 1
- IS-MDMAP 2
- IS-MDMAP 3
I/P IS-MDMEM
O/P OM-EBM2
O/P OM-EBM3
O/P OM-EBM3
O/P OM-EBM1
I/P36 PREHEAT
O/P OP-COM1
I/P OS-GLOWR
I/P IS-IDLDWN
O/P 0S-MAINR
O/P17 DOZER
O/P OP-SOM2
I/P OS-GLOWL
O/P SG-5VRT1
O/P4 BEACON
GND PG CASE
I/P IA-ACCEL 1
I/P IA-ACCEL 2
GND PG-SIGN
I/P IA-SCVVLO
I/P IS-ENGSTP
O/P IA-THBST
O/P1A SPARE
I/P IA-BPRESS
O/P7A SPARE
O/P31 SPARE
O/P IA-THOIL
SHL SG-SLD5
SHL SG-SLD4
O/P12 WIPER
SHL SG-SLD1
O/P PG-SIGN
I/P IS-IDMNL
I/P IA-SCVLO
GND I/P9-14
RS/SPI SHLD
I/P OS-OILPL
I/P IA-PFUEL
I/P IA-PFUEL
O/P IS-DIAG
- OP-SCVHI
- OP-SCVHI
O/P6 HORN
I/P OS-DIAG
I/P24 HORN
I/P IS-IDLUP
I/P IS-START
I/P IA-BARO
I/P IA-QADJ
O/P SP-5V1
O/P SP-5V2
O/P SP-5V5
O/P SP-5V4
I/P IS-IGKEY
I/P IA-THW
RESERVED
RESERVED
RESERVED
RESERVED
RESERVED
RESERVED
AIR INTAKE SENSOR
RESERVED
- OS-INJ 4
- OS-INJ 1
- OS-INJ 3
- OS-INJ 2
I/P SP-5V3
O/P IA-IAT
I/P IA-THL
RS232 RX
RS232 TX
I/P IF-SPD
CAN SLD
CHASSIS
83
I/P PS+B
I/P PS+B
I/P PS+B
+5V REF
CAN Lo
CAN Hi
0V REF
SPARE
SPARE
SPARE
PROG
BATT
GND
GND
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
IGN
N/C
N/C
N/C
N/C
N/C
OV
INPUTS SYSTEM OUTPUTS
ECU -STANDARD ECM - ENGINE
C069400
Fig 5. Electrical Schematic 332/J4979 Issue 1
C-6
Section C - Electrics
Basic System Operation
A.M.S (Advanced Management System)
A.M.S (Advanced Management System)
TC-011
Operation
B
The JCB A.M.S system is a whole machine electronic
control system. The system controls engine speed, pump
power, transmission, excavator functions, lights, wiper,
auxiliary circuits, warning lamps, etc. The system is a 'CAN
BUS' system which links Electronic Control Units (ECUs)
on the vehicle. This stands for 'Controlled Area Network'
and uses a special cable in the vehicle harness which
consists of two signal wires twisted together covered by a
C
metal foil to prevent any electrical interference. These
signal wires form the CAN -BUS. The CAN - BUS is used
to send text and fault codes between the ECUs. The
electronic units receive inputs from switches and sensors
and drive outputs such as solenoids, lamp bulbs and
motors. The outputs of the ECUs are rated to the current
requirement of the actuator.
The system comprises of the following main electronic
components.
401741-C3
401741-C4
A Electronic Control Unit -1 (ECU-1) Fig 7.
B Electronic Monitoring System (EMS)
C Fascia switch panel (FSP).
D Engine Control Module (ECM)
C030670-C3
Fig 6.
C-7 9803/9800-3 C-7
The AMS System
C-8
A
CAN BUS G
ENGINE
F
EMS ECM
D
9803/9800-3
M
B SPI BUS
ECU 1
A.M.S (Advanced Management System)
C
Basic System Operation
Section C - Electrics
T006140
Fig 8.
key
A Diagnostic port E Pump solenoid
B Facia switch panel F Inputs from switches and solenoids
C Switches and sensors G Outputs to injectors and motors
D Solenoid, lamps and motors
C-8
Section C - Electrics
Basic System Operation
Circuit Concepts
Circuit Concepts
Inputs
There are two main types of input, Digital and Analogue.
Digital type inputs are on/off type inputs (i.e. switches) and
can be Low side inputs or High side inputs. Low side inputs
are inputs that provide a ground to the ECU. High side
inputs are inputs that provide a positive feed to the ECU.
Analogue Inputs are sensor type inputs that provide a
varying type input to the ECU, this input could be a
resistance or frequency type input.
Digital inputs (on/off switch type inputs) C007180GB-2
Fig 10.
1 Low side input. The low side input is the most
frequently used input on the A.M.S system. The low
side input can be in the form of rocker switches or
pressure switches.
C007170GB-2
Fig 9.
2 High side input. The high side input is used on circuits
that require a positive feed when the ignition is
switched off, i.e. sidelights or hazard lights. The high
side input is also used on the engine preheat circuit.
C-9 9803/9800-3 C-9
Section C - Electrics
Basic System Operation
Circuit Concepts
Analogue input (i.e. sensor type inputs)
C045960GB-2
Fig 11.
C-10 9803/9800-3 C-10
Section C - Electrics
Basic System Operation
Circuit Concepts
Outputs
There are three main types of outputs Low side output,
High side output and Modulated output.
In the Low side output circuit the actuator (solenoid, relay
etc.) which is being driven already has a positive feed
available, the ECU then provides the ground side of the
circuit.
In the High side output circuit the actuator which is being
driven already has a ground available, the ECU provides
the positive side of the circuit. C007230GB-2
Fig 13.
In the Modulated Output circuit the ECU provides a PWM
(Pulse Width Modulation) signal to a proportional valve. As 3 Modulated outputs. Circuits using the modulated
the ECU varies the duty cycle of the signal the proportional output are throttle control, pump control and boom
valve will select more or less depending on the change in priority.
duty cycle.
1 Low side output. Circuits using low side output are pre
heat relay, stop solenoid relay and work lights.
C007240GB-2
Fig 14.
C007220GB-2
Fig 12.
2 High side output. The high side output is used to
operate solenoids, bulbs and horn.
C-11 9803/9800-3 C-11
Section C - Electrics
Basic System Operation
Pulse Width Modulation (PWM)
Pulse Width Modulation (PWM)
Ohms law states that, the amount of current flow in a circuit The graph A although unstable would give a current rating
is determined by the voltage, and the resistance. A 24v of three amps. To stabilize the current in the circuit, the
circuit with a resistance of 6 ohms, would draw a current of frequency would need to be increased. If the time scale on
4 amps. This would be the case for a standard solenoid, the graph A was one second, the frequency would be 4Hz
which is either on or off. (Hertz (cycles per second)). The graph B shows the same
duty cycle, but at a higher frequency of 32 Hz. The
Once the voltage is applied to the circuit, it is present 100% proportional solenoids fitted to JS machines operate at a
of the time. This would be known as a 100% duty cycle. frequency of 75 Hz.
Therefore the circuit will draw 4 amps constantly.
C007260GB-2
Fig 15. C007270GB-2
Fig 16.
A proportional solenoid requires differing amounts of
current, depending on its condition. As the coil has a fixed
resistance, changing the current rating can be done in
either of two ways,
1 Having lots of different resistors switched in and out
of the circuit at different times to change the current
flowing.
2 To change the duty cycle of the solenoid.
It is easier, more economical, and more reliable to change
the duty cycle of the circuit, especially using today's
computer/ controller technology.
The duty cycle is the amount of time a component is
switched on compared to the time it is switched off. If a
solenoid is on for three seconds, then off for one second,
on for three, off for one etc. this would be a 75% duty cycle.
C-12 9803/9800-3 C-12
ECU1/EMS/FACIA Power Supply and Network
C-13
14 5A
IGNITION EY
K SWI
TCH
ECU1 1 11 5A
BATTERY SUPP
LY
12 C5
ECU1-B
C9 10A 4
4 C210
435 STD-WHEELEDCAN LINK C250
IGNITION5
304 545 WR
BATTERY 6 3 BATTERY
544
10 2 C11
612D DIAGNOSTIC
OV 11 1
545 CONN
CAN HI 15 MAIN REL
AY
612
16 A
612E 305
GND I/P9~1417 B
545A
CAN SHIELD18 C
544 544A
CAN LO 21 D
612F
CHASSIS22 E
612G
GND I/P7,8,15,1623 F
87A
30
86
85
87
24 H
503B
501B
301A
611E
J
9803/9800-3
REDUN
DANCY SWI
TCH C13
1 435B
2 504B
600
3
600
7
600
ECU1/EMS/FACIA Power Supply and Network
600
1 2 3 4 5 6 7
C180 600 C253
600 TECH 2
8
7
6
5
4
3
2
1
C252
EARTH 7
543
HEADER 1
506 1
Basic System Operation
Section C - Electrics
EARTH H.S
305C
611C
545D
504E
435A
503B
544D
504F
610
543
506
611
611
611
550
551
552
553
552
550
553
551
610
611
501
611
611
511
545
504
544
C256
C14 C15 3
3
4
GND (FSP) 14
PG-SIGN 43
PG-SIGN 62
3
IGNITION 16
IGNITION 1
MTSR-E 3
9
8
5
SPARE 12
SPARE 11
SPARE 10
SHLD 5
PG-CASE 81
OS-MAIN R 21
6
OS-MAIN R 40
7
GROUND 2
2
1
CC-KW2000 38
EC-CAN-HI 18
MRST-E 6
SCLK-E 4
DACY 15
BATTERY 13
IG KEY 24
IS-DIAG 52
CC-CAN-LO 37
PG-POWER
PG-POWER
PG-POWER
CAN SHIELD
2 ECM 83
MTSR-E
BATTERY GND
SPARE
SHLD
PG+B
PG+B
CAN L
CAN H
MRST-E
SCLK-E
REDUN
FASCIA SWI
TCHPANEL
C048940
Fig 17.
C-13
ECU 1 Supply to Output Drivers
C-14
ECU1
1
ECU1-B
C9
104 4
SUPPLY TO O/P17 ~ 22 1
105
O/P23 ~ 28 2 301 1 15A
103B 103 102 2 15A
O/P13 ~ 16 7
103A
O/P13 ~ 16 8 103 3 15A
9803/9800-3
102B 102 104 4 10A
O/P7 ~ 12 13
102A
O/P7 ~ 12 14 105 5 10A
301B 301
O/P1 ~ 6 19 R W
301A C6 1 C5
O/P1 ~ 6 20
+24V +12V
IGN IGN
ECU 1 Supply to Output Drivers
Basic System Operation
Section C - Electrics
SUPPLY BATTERY
SUPPLY
C049120
Fig 18.
C-14
Section C - Electrics
Basic System Operation
ECU 1 Supply to Output Drivers
Page left intentionally blank
C-15 9803/9800-3 C-15
Section C - Electrics
Basic System Operation
Engine Throttle Control
Engine Throttle Control
Operation
Fig 19.
The maximum rev/min value for each mode is specified in
software. The maximum rev/min value is used as A mode
maximum. E mode maximum is 100 rev/min less than A
mode maximum. P & L mode maximum is 200 rev/min less
than A mode maximum K Fig 20. ( T C-17).
During calibration the ECU noted the maximum and mini -
mum positions of the throttle position sensor. The
maximum point became A mode maximum When the
working mode is selected the ECU will scale the full
deflection of the throttle dial (0~5v) to adjust the engine
speed between the idle position and the maximum speed
for the particular mode selected.
C-16 9803/9800-3 C-16
Section C - Electrics
Basic System Operation
Engine Throttle Control
Fig 20.
C-17 9803/9800-3 C-17
Section C - Electrics
Basic System Operation
Engine Throttle Control
Engine Throttle Control for Each Mode When the auto mode pressure switch is closed, the engine
speed will rise to the full available engine speed. When the
Operation auto mode pressure switch re-opens the engine speed will
drop to the full speed less 100 rpm for three seconds and
The machine can operate in one of four different modes, then down to 70% of the difference between auto and idle
depending upon the application required. The modes are speed (plus idle speed) for the set auto idle time, after
selected by the "MODE" button on the EMS. The EMS which it will drop to idle.
displays the selected mode alongside the power mode
legend. Selecting the different modes has the effect of When the travel pressure switch is closed, the engine
setting the maximum possible engine speed for each speed will rise to the full available engine speed. When the
working mode. Successive presses of the mode switch will travel pressure switch re-opens the engine speed will
cycle through the different modes in the order as shown remain at full for three seconds, then will drop to the full
below. speed less 100 rpm for the pre-set auto idle time, after
which it will drop to idle
Note: The last operating mode when the machine was
stopped will be restored when the machine is restarted. "E" Economy mode.
In standard mode the EMS displays "ECONOMY" and the
letter "E" next to the power mode icon. The engine is
allowed to operate over its selected rev range as defined
by its programmed rev limit in direct proportion to the
throttle input. However the maximum rev limit of 100 rpm
Fig 21.
less than the maximum permissible is imposed. Thus for a
E Economy full throttle potentiometer setting the engine revolutions is
A Auto 100 lower than it would be in the auto mode.
P Precision "P" Precision
L Lifting
In Precision mode the EMS displays "PRECISION" and
"A" Auto Mode the letter "P" next to the power mode icon. The engine is
allowed to operate over its selected rev range as defined
In Auto mode the EMS displays "AUTO" and the letter "A" by its programmed rev limit in direct proportion to the
next to the power mode icon. The engine is allowed to throttle input. However the maximum rev limit of 200 rev/
operate over its selected rev range as defined by its min less than the maximum permissible is imposed. Thus
programmed rev limit. The maximum rev limit is the same for a full throttle potentiometer setting the engine
as the maximum permissible engine revolutions. revolutions is 200 lower than it would be in the auto mode,
the same as it is for lifting mode.
When in auto mode the auto idle feature is permanently
active, if the throttle dial position is changed, the engine "L" Lifting mode
speed will not change until either the travel pressure switch
(i/p 27), the upper pressure switch (i/p 26) or the auto In Lifting mode the EMS displays "LIFTING" and the letter
mode pressure switch (i/p 25) are closed. "L" next to the power mode icon. The engine is allowed to
operate over its selected rev range as defined by its
When the upper pressure switch is closed the engine programmed rev limit in direct proportion to the throttle
speed will rise to full speed less 100 rpm (or in proportion input. However the maximum rev limit of 200 rev/min. less
to the throttle target input if less than 100%). When the than the maximum permissible is imposed. Thus for a full
upper pressure switch re-opens the engine speed will throttle potentiometer setting the engine revolutions is 200
remain at this position for 3 seconds and then drop to 70% lower than it would be in the auto mode, the same as it is
of the difference between auto and idle speed (plus idle for precision mode.
speed) for the set auto idle time, after which it will drop to
idle. The engine speed will vary according to the following
characteristic: K Fig 22. ( T C-19)
C-18 9803/9800-3 C-18
Section C - Electrics
Basic System Operation
Engine Throttle Control
Machine Auto Economy Intermediate Auto Idle Idle
JS290 1850 rpm 1750 rpm 1495 rpm 1100 rpm 900 rpm
D
E
G
Fig 22.
Item Auto Mode Pressure Switch
A Auto Pressure Switch
B Upper Pressure Switch
C Travel Pressure Switch
D Full Auto
E Economy
F Intermediate
G Idle (or auto idle if enabled or in Auto mode)
C-19 9803/9800-3 C-19
Section C - Electrics
Basic System Operation
Pump Control for Each Mode
Pump Control for Each Mode
Operation
Fig 23.
The machine can operate in four different modes,
depending upon the type of work required K Engine
Throttle Control ( T C-16). The pump output horsepower
is varied by means of a PWM signal to the pump control
solenoid valve which varies for each mode.
Tier III machines are required to reduce the "range band"
"X to Y" (pump milliamps) K Fig 25. ( T C-22), to improve
engine stability dependant on specific factors which
include:
– Barometric Pressure
– Fuel Temperature
– Air Intake Temperature
– Air Conditioning
– Engine and Hydraulic Temperature
These conditions are monitored by ECU1. Engine power
and pump power are then varied to suit the operating
conditions.
Each of the above factors has a value calculated by ECU1
of between 0 and 1. All values are then calculated to give
a dynamic control factor (DCF) of 0 to 1 which will
determine the pump output power and will vary the pump
mA to suit.
C-20 9803/9800-3 C-20
Section C - Electrics
Basic System Operation
Pump Control for Each Mode
Fig 24.
C-21 9803/9800-3 C-21
Section C - Electrics
Basic System Operation
Pump Control for Each Mode
"A" Auto Mode
The pump control signal varies with engine speed
according to the figure below:
X
Pump signal (milli amps)
Rising
Falling
1200
1400
1800
1840
Engine speed (rpm)
Fig 25. Pump Control for DCF of 1 (normal conditions) in "A" mode
X 570
Y 420
"E" Economy mode
The pump control signal varies with engine speed
according to the figure below:
Pump signal (milli amps)
Rising
Falling
0
1200
1400
Engine speed (rpm)
Fig 26. "E" mode
Z 390
"L" Lifting mode & "P" Precision mode
The pump control signal is set to zero PWM percent,
regardless of engine speed.
C-22 9803/9800-3 C-22
Section C - Electrics
Basic System Operation
Pump Control for Each Mode
RPM Setting Selection
Hammer Pr Sw
or Button ON?
NO
YES Travel Pr Sw NO Upper Pr Sw NO
A-mode?
ON? or Grab ON?
YES YES
NO
YES
YES Auto Pr Sw
NO ON?
E-mode?
YES
Overheat?
YES NO
NO
Use E-mode settings Use P or L -mode Use A-mode settings Use E-mode settings Use idle settings
settings
Fig 27.
mA Setting Selection
YES
Hammer Pr Sw
or Button ON?
NO
YES
P or L-mode?
Upper Pr Sw NO
NO
Grab ON?
YES
E-mode?
Travel Pr Sw YES
YES NO
ON?
YES
Overheat?
NO
NO
Target mA Set to Zero Determine Target mA from Determine Target mA from
E-mode Graph (Based on A-mode Graph (Based on
Current Engine Speed) Current Engine Speed)
Fig 28.
C-23 9803/9800-3 C-23
Section C - Electrics
Basic System Operation
Hardware Sensing
Hardware Sensing
TC-012_2
Operation
C049900-2
Fig 29.
Due to changes in operation of some machine systems
and harness from January 06 the ECU1 needs to know
what system is fitted to operate the correct outputs. To
sense this, machines built from January 06 have
permanent live feed to the ECU1 o/p 36 (C-29). This can
be viewed on the 5 second menu on "HARNESS TYPE,
NEW". Machines previous to January 06 will not have this
input.
All machines described in this manual will have this input
fitted.
C-24 9803/9800-3 C-24
Section C - Electrics
Basic System Operation
Auto Boost Pressure
Auto Boost Pressure
Operation
C049920-1
Fig 30.
The auto pressure boost function is only available when
the excavator is in auto mode. By default it is not available
in precision and economy mode and is permanently on
(although not indicated on the EMS) in lifting mode.
In auto mode, when the boost pressure switch is closed the
2 stage relief valve, ECU1 o/p 24 (C-27) is energised
(according to the logic diagram, K Fig 31. ( T C-26)). This
allows a pressure increase in the excavating hydraulic
circuit thus generating extra digging force.
If the boost pressure switch is seen for less than 1.5
seconds then the 2 stage relief valve is energised until the
boost pressure switch is de-energised, then the logic
sequence is reset and will allow the sequence to be started
over again.
If the boost pressure switch is seen for more than 1.5
seconds then the 2 stage relief valve should stay open for
a further 1.5 seconds. The valve cannot be re-energised
for 9 seconds after the end of the last activation
However during travel operation (denoted by the travel
pilot switch input) the 2 stage relief valve is energised. If
the boost pressure switch is closed when the travel
pressure switch is valid, the solenoid will remain energised
C-25 9803/9800-3 C-25
Section C - Electrics
Basic System Operation
Auto Boost Pressure
ON Travel P/SW
(I/p 27)
OFF
L Work E,P
mode
Boost P/SW OFF
(I/p 15)
ON
> 1.5 secs NO
YES
2 stagerelief solvalve S 2 stagerelief sol
2 stagerelief solvalve
Set ONfor 3 sec valve Set OFF
Set ONcontinuously
(including the 1.5 sec)
and set OFF for 9 seconds
C005400GB
Fig 31.
C-26 9803/9800-3 C-26
C-27
57
BOOST PRESSURE SWITCH
ECU1 1
C220
40
C8
604F
421
ECU1-A
16 414
I/P27 TRAVEL PILOT S.W.
25 421
I/P15 POWER UP SWITCH
9803/9800-3
C59
C10 2 STAGE RELIEF S.V.
ECU1-C 32
C1
604F 2
CONN A
27 819 819 2 819 819 1
O/P 24 2 STAGE RELIEF
414 26 414
C70
TRAVEL PILOT SWITCH
36
414 1
Basic System Operation
Section C - Electrics
604F 2
Auto Boost Pressure
604F
C049130
Fig 32.
C-27
Section C - Electrics
Basic System Operation
Engine Oil Level Warning
Engine Oil Level Warning
Operation
C049930-1
Fig 33.
The oil level float switch is positioned in the side of the
engine.
When the engine oil level is at an acceptable level, the float
switch is closed, applying an earth to the ECU1 i/p 35 (A-3)
When the engine oil level drops below the acceptable
level, the float switch is opened, removing the earth from
the i/p.
The i/p is only checked on machine ignition on.
The oil level check should occur before other machine or
engine faults are raised.
When the EMS receives a CAN message from the ECU1
indicating that the oil level is OK, the EMS displays the
message "ENG OIL OK" for 5 seconds.
When the EMS receives a CAN message from the ECU1
indicating that the oil level is low, the EMS displays the
message "CHK ENG OIL" for 5 seconds and the buzzer
sounds for 1.5 seconds.
C-28 9803/9800-3 C-28
Section C - Electrics
Basic System Operation
Engine Oil Level Warning
C049140-2
Fig 34.
C-29 9803/9800-3 C-29
Section C - Electrics
Basic System Operation
Engine Pre Heat (Glow plugs)
Engine Pre Heat (Glow plugs)
Operation
C049890-2
Fig 35.
This feature allows the engine cylinders to be pre-heated,
before engine cranking to assist cold start performance.
When the key switch is turned to the `Ignition' position the
ECM detects the temperature to determine whether and
for how long preheat is required. The ignition provides a
positive feed to the Preheat relay and an input to the ECM
at i/p V24.
When preheat is required, the ECM gives a ground to the
heat relay coil from o/p V10. The relay energises, which
then allows battery voltage to cross the heat relay to the
glow plugs.
The ECM sends a `glow signal' message via the CAN bus
to the EMS which displays the message "PREHEAT".
When the key switch is turned to the `crank' position the
ECU1 sends a message via the CAN bus to the ECM to
start the engine.
C-30 9803/9800-3 C-30
C-31
6
EMS
30 17 15/54 50a 19
OFF
IGN
PREHEAT HEAT
CRANK
4 1 8
C184 C185
545C
303
422
4
C25
10A 60A
30
1 303 10
+24V BATTERY
504 14
ECU1 +24V IGNITION
C91
5A 2 1
C8
ECU1- A
001 1010 +24V IGNITION
9803/9800-3
26 422
I/P 16 CRANK 49
HEAT RELAY
C269
C102 C103
C1 001 101B 1
CONN A 34
545C 20 545B
C100
1 2
C101
502
545B
ECM
C2
CONN B GLOW PLUGS
Basic System Operation
I/P OS-GLOWR V10
502 1 502 502 18 502
Section C - Electrics
502
Engine Pre Heat (Glow plugs)
V24 504 504 2 504
I/P IS-IGKEY
C049150
Fig 36.
C-31
Section C - Electrics
Basic System Operation
Engine Automatic Warm Up
Engine Automatic Warm Up
Operation
C031610GB-2
Fig 37.
This feature allows the engine to quickly warm up to 4 If the throttle volume input changes during auto warm
normal operating temperature if the vehicle is not being up then the auto warm up function is cancelled.
used.
When auto warm is activated the EMS will display the
Automatic warm up will only be performed 15 seconds message "AUTO WARM".
after the engine is started and provided the following
conditions are satisfied: The ECU1 will send a RPM target message to the ECM so
that the engine will run at the throttle dial setting for 5
1 Water temperature is less than 50 ºC (engine coolant minutes, the engine revs are then increased in 300 rev/
temperature is sent from the ECM via the CAN bus). min. steps in 3 minute intervals up to the maximum of 1800
rev/min.
2 Upper pilot pressure switch is off (excavator services
not selected) i/p28 (A-6). After 3 minutes of running at 1800 rev/min. the engine revs
will return to the throttle dial setting. If during the automatic
3 Travel pilot pressure switch is off (travel service not warm up sequence any of the required conditions change
selected) i/p27 (A-16). i.e. engine water temperature reaches 50 ºC or the
C-32 9803/9800-3 C-32
Section C - Electrics
Basic System Operation
Engine Automatic Warm Up
operator moves the throttle dial or selects an excavator
service auto warm will stop.
C005450GB-2
Fig 38. Example of auto warm up cycle if machine is
started at idle
C-33 9803/9800-3 C-33
Section C - Electrics
Basic System Operation
Engine Automatic Idle
Engine Automatic Idle
Operation
C027250GB-3
Fig 39.
When auto idle function has been selected via the switch
on the Facia Switch Panel (FSP) the engine will return
automatically to the auto idle setting if no services have
been selected for 5 seconds (default). This time can be
varied between 5 and 30 seconds via the SET menu on the
EMS.
A second press of this switch will disable the function. If the
upper, travel and boom lower pilot switches have been
inactive for the pre-set time period, the auto idle function
will operate and the engine revs will drop to the auto idle
value. The EMS will display the message "LOW IDLE".
The engine revs can be increased by pressing the auto idle
switch on the facia panel, or by the change of state of the
pilot switches (i.e. if excavator/travel service is selected).
When released from auto idle the engine revs return to the
setting of the throttle dial. By default auto idle is off.
The auto idle function is permanently active in auto mode.
The auto idle switch FS10 is disabled when in auto mode.
Note: One-touch idle overides auto idle
C-34 9803/9800-3 C-34
Section C - Electrics
Basic System Operation
Engine Automatic Idle
Page left intentionally blank
C-35 9803/9800-3 C-35
Section C - Electrics
Basic System Operation
Engine One Touch Idle
Engine One Touch Idle
Operation
C027250GB-2
Fig 40.
When one-touch idle is selected via the button on the right
hand controller the engine will return to the low idle setting,
regardless of any other input, the EMS will display the
"LOW IDLE" message to confirm selection.
A second press of this switch will disable the function and
the engine revs will return to the setting of the throttle dial.
The status of the one touch idle is retained when switching
the ignition off (e.g. If one touch idle is selected and the
ignition turned off, when the vehicle is started again one
touch idle is automatically activated).
C-36 9803/9800-3 C-36
Engine Auto Idle and One Touch Idle
C-37
C69 UPPER PILOT SWITCH
1 22 35
405 1
3 4 C31
ECU1 RH LEVER SWITCH 603 2
432
613
EARTH
HEADER 3
613 C70 TRAVEL PILOT SWITCH
C8 414 1 36
ECU1-A
6 405 C1 606 2
I/P 26 UPPER PILOT SWITCH CONN A
16 414
I/P 27 TRAVEL PILOT SWITCH 405 24 405
26 418
I/P 19BOOM UP SWITCH 414 26 414
37 432
I/P 14 ONE TOUCH IDLE C72 BOOM PILOT SWITCH
9803/9800-3
418 1 37
614F 2
2 3
LOW IDLE FS10
CANBUS SPI
Basic System Operation
Section C - Electrics
FASCIA
EMS
Engine One Touch Idle
EMS
C-37
C049300
Fig 41.
Section C - Electrics
Basic System Operation
Engine Start/Stop
Engine Start/Stop
Operation
C031471GB-2
Fig 42.
Starting/Stopping the engine Pressing the Emergency Stop Button
When the ignition key is turned to the crank position, 24v If the emergency stop button on the FSP is pressed whilst
is fed to: the engine is running, the 24v from ECU o/p 22, (C-26) to
the Emergency Stop Relay is stopped. The relay is de-
– the ECU on i/p 28, (A-26) - Crank, energized, feeding 24v from the battery to the ECM i/p V47
– the ECM on i/p V46 - START, - ENGSTP, and the engine is stopped.
– the Safety Relay.
At the same time the EMS will display the message 'EMER
STOP'. If the ignition is switched off and then back on, the
The ECU provides 24v from o/p 22 (C-26), through the
system retains the emergency stop function until the
closed contacts of the Emergency Stop button on the FSP
emergency stop button on the FSP is pressed again.
to the coil of the emergency stop selay. The relay is
energized, removing 24v from the ECM i/p V47 - ENGSTP.
Engine start is disabled unless the lever lock arm is raised.
if the ignition is switched on and the lever lock arm is
The safety relay provides an output to the starter motor,
raised, the emergency stop remains off and the engine will
and the ECM starts the engine.
not start. If cranking is attempted while the lever lock arm
is down, the LIFT_LEVER message is displayed on the
When the engine is running, if the ignition key is switched
EMS and the servo isolator LED will flash on the EMS for
off, the 24v from ECU o/p 22 (C-26) to the emergency stop
the duration of the cranking.
relay is removed. The relay is de-energized, feeding 24v
from the battery to the ECM i/p V47 - ENGSTP, and the
engine is stopped.
C-38 9803/9800-3 C-38
Section C - Electrics
Basic System Operation
Engine Start/Stop
C049310-2
Fig 43.
C-39 9803/9800-3 C-39
Section C - Electrics
Basic System Operation
Limp Mode system
Limp Mode system
Operation
EMS
Limp Mode
16 Ignition
15 Redundancy
ECU1
Key
Switch Limp mode
Switch 1
2A Sys B-5
2
+V ign
FSP
O/p 22 (C-26)
Emer. Stop
O/p 21 (C-36)
Lever Lock Sol.Valve
I/p 32 (A-33)
Lever Lock O/p 34 (C-38)
Switch
Swing Lock Sol. Valve
C030750GB-2
Fig 44.
In the event of a ECU1 failure, the redundancy switch The emergency stop switch in the facia switch panel is fed
allows the function of: from the ECU1 o/p 22 (C-26). The lever lock and swing
lock functions are fed from the ECU1 o/p 21 (C-36).
1 Lever lock
The lever lock and swing lock functions are fed from the
2 Swing lock redundancy switch via a diode.
3 Emergency shutdown The EMS will permanently display a "LIMP HOME"
message and all bar graph bars will illuminate together and
In the normal position, the redundancy switch feeds the flash on/off at half second intervals. The buzzer will sound,
ignition voltage to the ECU1 and the redundancy i/p of the this can be cancelled by pressing the ACK button.
EMS.
The engine will run at the default engine speed (approx.
In the "redundancy" position, the ignition voltage is fed to 1600 rpm).
the "emergency stop" switch in the facia switch panel, via
a diode.
C-40 9803/9800-3 C-40
C-41
C115 C13
LOCK 15 LIMP MODE 7 504A 14
5A
+24V IGNITION
LEVER SWITCH
3 2 1 4 6 5 1 3 2 C155 C156 4
DIODE DIODE
1
435B
504B
428
842
614
848
ECU1 C185
1 2 1 2
SWING
LOCK SV
842
818
842
825B
428 1
C8 EARTH
ECU1-A 752 2
HEADER 4
33 428 C190
I/P32 LEVERLOCK LEVER
C1 LOCK SV
C9 CONN A 848 1
ECU1-B
848 2 848 825 2
5 435 825C 1 428
IGNITION
32
9803/9800-3
752 11 752
C10
ECU1-C
26 818
O/P 22 ENGINE SHUTDOWN
O/P 21 LEVERLOCK 36 825
818A
C180
504B
435
38 752
O/P 34 SWING
LOCK
2 3 1 9
EMS
LIMP MODE FS1
Basic System Operation
Section C - Electrics
818A
3
15 435
REDUN
DANCY 8
16 504D EMERG
IGNITION STOP
Limp Mode system
CANBUS SPI FASCIA
C15
C14
C049360
Fig 45.
C-41
Section C - Electrics
Basic System Operation
Lever Lock
Lever Lock
Operation
C05530GB-2
Fig 46.
The machine is equipped with a control lock lever, which
has to be raised to exit the cab and lowered before any
hydraulic operation of the machine is possible.
Engine start is disabled unless the lever lock arm is raised.
if the ignition is switched on and the lever lock arm is
raised, the emergency stop remains off and the engine will
not start. If cranking is attempted while the lever lock arm
is down, the LIFT_LEVER message is displayed on the
EMS and the servo isolator LED will flash on the EMS for
the duration of the cranking.
When the control lever lock is in the lowered position there
is no ground available to ECU i/p 32 (A-33). This causes
the o/p 21 (C-36) to the isolator valve to be energised and
when a ground is available through the lever lock switch,
operation of the excavator controls is possible.
When the lever lock is raised to the upright position the
ground circuit for the solenoid is no longer complete. There
is a ground input to ECU1 i/p 32 (A-33) and the lever lock
warning light is illuminated.
In limp mode the lever lock solenoid valve is supplied
directly from the limp mode switch.
With park brake "ON" the excavator end will be isolated to
prevent digging against a locked transmission.
C-42 9803/9800-3 C-42
Section C - Electrics
Basic System Operation
Lever Lock
Page left intentionally blank
C-43 9803/9800-3 C-43
Section C - Electrics
Basic System Operation
Servo Isolator
Servo Isolator
Operation
C005540GB-2
Fig 47.
The operator has the ability to isolate the excavator
controls by pressing the isolator switch on the facia switch
panel.
When the Isolator switch is pressed both the warning lamp
and the switch status indicator are illuminated. ECU1 now
de-energises the output to the isolator solenoid valve o/p
21 (C-36).
A second press of the isolator switch extinguishes both the
warning lamp and the switch status indicator. ECU1 now
energises the isolator output o/p 21 (C-36) and provided
the lever lock is in the correct position, operation of the
excavator controls is possible
C-44 9803/9800-3 C-44
C-45
LOCK LEVER
EARTH SWITCH
HEADER 4
15
ECU1 1
614
C115
3 2 1
C8
ECU1-A
848
614
428
33 428
I/P 32 LOCK LEVER
C113 C114
C1
848
848
CONN A
LOCK
C10 C61 LEVER S.V.
ECU1-C
9803/9800-3
848 8 848 2
36 825 825 9 825 1
O/P 21LOCK LEVER
32
2 3
Basic System Operation
Section C - Electrics
FS5
CANBUS SPI
FASCIA
EMS
C049550
Servo Isolator
Fig 48. Lever Lock and Servo Isolator
C-45
Section C - Electrics
Basic System Operation
Wiper
Wiper
Operation
C027300GB-2
Fig 49.
The wiper has three modes of operation, intermittent,
permanently on and off. Timing for the intermittent function
is performed by ECU1, and can be varied via the set menu
on the EMS.
When the wiper switch on the Facia Switch Panel (FSP) is
pressed once o/p 12 (C-17) on ECU1 is pulsed for 0.5
seconds to start the wiper stroke. A hold on contact within
the motor assembly retains power for the return stroke of
the blade. A time delay of variable seconds is activated
before the output is energised again, thus giving
intermittent operation.
A second press of the switch enables the wiper to operate
continuously and the output is permanently energised.
A third press of the switch disables wiper operation.
C-46 9803/9800-3 C-46
C-47
ECU1 1
C37 CAB CONN
M
490 11
613 7
107 6
813 5
C10
ECU1-C
9803/9800-3
EARTH
17 HEADER 3
813
O/P 12 WIPER 613
4
C25
107 7 20A +24V IGNITION
2
3
Basic System Operation
Section C - Electrics
FS9
CANBUS SPI
FASCIA
EMS
C049560
Fig 50.
Wiper
C-47
Section C - Electrics
Basic System Operation
Lower Wiper (option)
Lower Wiper (option)
Operation
C027310GB-2
Fig 51.
The lower wiper is a customer selected option and is fitted
to the lower glass panel at the front of the operator's cab.
The wiper has three modes of operation intermittent,
continuous and off. Timing for the intermittent function is
performed by ECU1. The same timer as utilised for the
standard wiper is used to synchronise both wipers
together.
When the lower wiper button is operated the ECU1 output
number o/p 11 (C-15) is energised to start the wiper stroke.
A hold on contact within the motor assembly retains power
for the return stroke of the blade. A time delay equal to
that set for the main wiper is activated before the output is
energised again, giving intermittent operation.
A second press of the switch enables the wiper to operate
continuously and the output is permanently energised.
A third press of the switch disables wiper operation.
Note: If the upper (main) wiper is energised then the lower
wiper output is energised at the same time, synchronising
both wipers.
C-48 9803/9800-3 C-48
C-49
LOWER WIPER SWITCH
20A C6
FUSE No 8 +24v
108
IGN
20A
107 FUSE No 7
8 7 3 2 C200
400
613E +R 43
LOWER WIPER
108D
1 M
RGC8
9803/9800-3
ECU1-A
400 4 1 2 3
I/P 21 LOWER WIPER 1 C201
431
107
811
600
C10
Basic System Operation
Section C - Electrics
ECU1-C
15 811
O/P 11 LOWER WIPER
Lower Wiper (option)
C049570
C-49
Fig 52.
Section C - Electrics
Basic System Operation
Washer
Washer
Operation
C027320GB-2
Fig 53.
When the washer switch on the facia switch panel is
pressed the ECU1 operates the output o/p 23 (C-37) to the
washer pump. The ECU output is only energised whilst the
facia switch is pressed.
Whenever the washer output is energised the wiper output
ECU1 o/p 12 (C-17) is also energised. When the washer
switch is released the wiper will do three additional strokes
and then turn itself off.
If the lower wiper has been selected as an option, when the
washer button is pressed, both the upper and lower wipers
are energised.
C-50 9803/9800-3 C-50
C-51
ECU1 1
C110
DIODE C79
WASHER 48
826A 1
C10
ECU1-C
600 2
C1
CONN A
37
9803/9800-3
826 826 27 826A
O/P 23 WASHER
B
2 3
FS8
CANBUS SPI
Basic System Operation
Section C - Electrics
FASCIA
EMS
C049580
Fig 54.
Washer
C-51
Section C - Electrics
Basic System Operation
Horn
Horn
Operation
C028390GB-2
Fig 55.
When the left joystick rear button is pressed, input ECU1 i/
p 24 (A-14) is selected the horn output ECU1 o/p 6 (C-14)
is energised whilst the button is pressed.
C-52 9803/9800-3 C-52
C-53
HORN 21
SWITCH
ECU1 1
1 2 3 C34
LH LEVER EARTH
HEADER 3
412
613
C8
ECU1-A
613
I/P24 HORN 14 412
606B
C80
HORN 47
C1
606B 1
CONN A
C10 810 31 810 810 2
9803/9800-3
ECU1-C
14 810
O/P6 HORN
Basic System Operation
Section C - Electrics
C049590
Fig 56.
C-53
Horn
Section C - Electrics
Basic System Operation
Travel Alarm
Travel Alarm
Operation
C005590GB-2
Fig 57.
The travel alarm is available as an option on the tracked
machines. Whenever travel movement is requested travel
pressure switch ECU1 i/p 27 (A-16) is selected. When this
input is grounded the travel alarm output ECU1 o/p 25 (C-
23) is energised.
C-54 9803/9800-3 C-54
C-55
C94
ECU1 1 TRAVEL ALARM 40
600H 1
C8 815 2
ECU1-A
I/P27 TRAVEL PILOT SW 16 414
C1
CONN A
815 7 815 C70
TRAVEL PILOT SW
36
414 26 414 414 1
606G 2
606G
C10
ECU1-C
9803/9800-3
23 815
O/P26 TRAVEL ALARM
Basic System Operation
Section C - Electrics
C049600
Fig 58.
Travel Alarm
C-55
Section C - Electrics
Basic System Operation
Soft/Hard (Cushion)
Soft/Hard (Cushion)
Operation
C005600GB-2
Fig 59.
The soft/hard mode allows the operator to select the
response of the hydraulic circuits, soft being controlled and
hard being fierce when de-selecting boom and dipper
functions. Soft mode is the default setting when starting the
machine.
To change to hard mode the operator must select the
option by pressing cushion switch on the facia switch
panel. Cushion solenoid output ECU o/p 28 (C-25) is
energised.
The hard mode is cancelled either by turning the ignition
off, or by pressing the cushion switch for a second time.
C-56 9803/9800-3 C-56
C-57
ECU1
1
CUSHION S.V.
C10 C63
C1
32
9803/9800-3
ECU1-C 604J 2
CONN A
25 13
817 817 817 1
O/P 28 CUSHION
2 3
FS4
CANBUS SPI
Basic System Operation
Section C - Electrics
FASCIA
Soft/Hard (Cushion)
EMS
C049610
Fig 60.
C-57
Section C - Electrics
Basic System Operation
Slew Brake (100%)
Slew Brake (100%)
Operation
C028410GB-2
Fig 61.
The slew parking brake holds the current slew position of If however the upper pilot pressure switch remains de-
the machine and prevents slew drift. activated for 5 seconds or longer, the slew brake solenoid
will de-energise (brake on). The slew brake solenoid will
This is the default operation with the engine running. remain de-energised until the slew pilot pressure switch is
activated.
The operator signals for slew movement by moving the left
hand joystick. This results in the slew pilot pressure switch When L mode (lifting) is selected, the upper pilot pressure
being activated. This signals the ECU1 to energise the switch is ignored and 100% brake applied. When the slew
slew parking brake solenoid valve, thus enabling slew. pilot switch is energised the slew parking brake is lifted.
The slew pilot pressure switch is de-activated, by returning By Default Slew parking brake is automatically applied at
the joysticks to neutral, and the upper structure comes to a start up.
stop using a hydrostatic brake (cross lines relief valve). If
this condition exists for 5 seconds then the slew parking
brake solenoid is de-energised. Thus applying the slew
brake.
To prevent any damage to the slew brake occurring when
excavating the slew brake solenoid will remain energised
and the slew brake remain off, if the upper pilot pressure
switch is activated or re-activated within 5 seconds of the
slew pressure switch closing.
C-58 9803/9800-3 C-58
Section C - Electrics
Basic System Operation
Slew Brake (100%)
Slew Pilot SW i/p29(A-36) Upper Pilot SW i/p26(A-6) Slew Parking Brake Sol Machine Working Mode
Valve o/p9(C-4)
8 8 8 (=100% brake) A, E, and P
9 8 9 (=0% brake) A, E, and P
8 Less than 5 Sec 8 9 (=0% brake) A, E, and P
8 Greater or equal to 5 sec 8 8 (=100% brake) A, E, and P
8 9 9 (=0% brake) A, E, and P
9 9 9 (=0% brake) A, E, and P
8 9 8 (=100% brake) L
9 9 9 (=0% brake) L
9 8 9 (=0% brake) L
C-59 9803/9800-3 C-59
C-60
B
ECU1 1
C8 C1
ECU1-A CONN A
803 10 803 C73 SWING PILOT S.W.
37
36 431 431 1
I/P 29 SWING PILOT
405 405 25 405 601 2
6
I/P 26 UPPER PILOT
C55 SWING BRAKE S.V.
B 2 32
C10
9803/9800-3
ECU1-C 803 1
4 803
O/P 9 SWING BRAKE
C69 UPPER PILOT S.W.
35
405 1
603 2
C049630
Basic System Operation
Section C - Electrics
Fig 62.
Slew Brake (100%)
C-60
Section C - Electrics
Basic System Operation
Slew Brake (100%)
Page left intentionally blank
C-61 9803/9800-3 C-61
Section C - Electrics
Basic System Operation
Slew lock (100% Slew Brake)
Slew lock (100% Slew Brake)
Operation
C028430GB-2
Fig 63.
The slew lock prevents any slew operation of the machine, 5 seconds after the Slew Lock button is pressed the slew
even if the LH joystick is moved. It acts as 100% slew lock solenoid is energised, opening the slew brake cylinder
parking brake and disables the slew pilot circuit, by to tank and applying 100% braking force.
applying equal pressure on either side of the slew spool in
the main valve block (slew shut off). The slew lock is de-activated by a second press of the
fascia switch. This causes the switch status indicator and
The lock is operated by pressing the slew lock switch on the EMS warning lamp to be extinguished. The ECU1 de-
the fascia switch panel. When pressed the status indicator energises the slew lock and slew shut off solenoid valves.
illuminates. The EMS displays the message "SWING The slew parking brake will not be re-energised until an
LOCK", and the warning light illuminates. The EMS input from the slew pilot pressure switch is seen.
transmits the slew lock request to the ECU1 via the CAN
communications link. The slew shut off solenoid is By Default upon start slew lock is automatically
energised (effectively isolating the joysticks) and slew disengaged.
parking brake solenoids is left de-energised by the ECU1.
Swing Lock Swing Pilot Psw Swing Lock Sol Valve Swing Parking Brake Swing shut off Sol
Sol Valve Valve
FS2 i/p29(A-36) o/p8 (C-3) o/p9 (C-4) o/p10 (C-16)
8 9 8 9 8
9 8 8 (=100% brake) 9
9 + 5 Sec 9 8 (=100% brake) 9
C-62 9803/9800-3 C-62
C-63
600
1 C62 SWING SHUT OFF S.V.
ECU1
604 2
32
812 1
C8
ECU1-A
C1
CONN A C55 SWING BRAKE S.V
36 431
I/P 29 SWING PILOT
812 5 812 602 2
803 10 803 803 1
752 11 752
C10 825 9 825
ECU1-C C56 SWING LOCK S.V.
9803/9800-3
752 2
38 752
O/P34 SWING LOCK 825 1
4 803
O/P9 SWING BRAKE
16 812 C73 SWING PILOT S.W.
O/P10 SWING SHUT OFF
37
431 1
O/P21 LEVER LOCK 36 825
601 2
2 3
Basic System Operation
Section C - Electrics
Slew lock (100% Slew Brake)
FS2
CANBUS SPI
FASCIA
EMS
C-63
C049650
Fig 64.
Section C - Electrics
Basic System Operation
Slew Brake Solenoid Valve Failure
Slew Brake Solenoid Valve Failure
Operation
In the event of slew brake solenoid or the slew pressure
switch failing, the slew brake will still operate. The pilot
signal from the hand controller passes through the shuttle
block and enters the slew brake valve via port A. When the
pressure overcomes the slew brake shuttle, the signal
passes through the slew brake valve via port B and is
directed to the slew brake. When sufficient pressure is
raised the slew brake is lifted.
The slew operation will tend to be notchy, as the brake on
and off timing will depend upon the position of the slew
joystick.
Note: This operation is only to be used to make the
machine safe i.e. to slew the machine into a safe position,
for transportation to a place where an appropriate repair
can be carried out.
C-64 9803/9800-3 C-64
Section C - Electrics
Basic System Operation
3-Speed Travel
3-Speed Travel
Operation
C005630GB-2
Fig 65.
Using a combination of two solenoids (high speed travel
solenoid and max flow cut solenoid), pump flow and swash
plate position of the travel motor are used to give three
travel speeds. The selected travel speed is indicated on
the EMS as either a Hare (High), double arrow (Middle), or
Tortoise (Low) and is changed by successive presses of
the travel change switch. The current operating mode of
the machine alters the logic in which the solenoids
operate.
C075600
Fig 66.
C-65 9803/9800-3 C-65
Section C - Electrics
Basic System Operation
3-Speed Travel
Low
Middle
High
Note: The last selected travel speed when machine is
stopped is re-instated when the machine is restarted.
"E" Economy, "P" Precision & "A" Auto
Modes
At the mid travel speed the motor swash plate is in the
maximum swash position (low speed) and the pump is at
the standard setting. The max flow cut and high speed
travel solenoids are de-energised and the statuses of the
travel and upper pressure switches are ignored. The EMS
displays the "Arrow" gear icon.
When the travel change switch ECU1 i/p 34 (A-13) is
pressed the EMS displays the "Hare" gear icon. The high
speed travel solenoid is energised, ECU1 o/p 15 (C-7),
thus moving the swash plate to the minimum swash
position (high speed). The pressure switch inputs are
ignored. The machine is now in the high speed travel
mode.
When the travel change switch is pressed again the EMS
displays the "Tortoise" gear icon. The machine is now in
low speed mode. The high speed travel solenoid, ECU1 o/
p (C-7) is de energised. If the travel pressure switch is
activated i.e. travel selected, ECU1 i/p 27 (A-16) then the
Max flow cut solenoid is energised, ECU1 o/p 3 (C-1) and
the pump is put in "Q cut "mode. The max flow cut solenoid
is only energised whilst the travel pressure switch is
activated. The input from the upper pressure switch is
ignored. The next successive press of the travel change
switch, ECU1 i/p 34 (A-13) selects the mid travel speed
and the EMS displays the "Arrow" gear icon.
C-66 9803/9800-3 C-66
Section C - Electrics
Basic System Operation
3-Speed Travel
Relationship between Travel Modes A / E + P, travel motor swash plate position and
Pump "Q max cut output"
Travel Speed High Speed Travel Solenoid Output Q Max Cut Solenoid Output ECU 1 o/p 3 (C-1)
ECU 1 o/p 15 (C- 7)
Creep (Tortoise) OFF On (24v) only when travel pressure switch has
been selected i.e. travel selected
Middle (Arrow) OFF OFF
High (Hare) ON (24v) OFF
"L" Lifting Mode The next successive press of the travel change switch,
ECU1 i/p 34 (A-13) selects the mid travel speed and the
In the mid travel speed the motor swash plate is in the EMS displays the "Arrow" gear icon.
maximum swash position (low speed), the high speed
travel solenoid, ECU1 o/p 15 (C-7) is de-energised. When L mode and travel combination
only the travel pressure switch ECU1 i/p 27 (A-16) is
selected, the max flow cut solenoid, ECU1 o/p 3 (C-1) is
de-energised. When the upper pressure switch, ECU1 i/p Middle speed travel only - pump standard.
26 (A-6) only is selected, the max flow cut solenoid valve Excavating only - Q max cut
is energised, thus setting the pump to the "Q -cut" setting.
If both the travel pressure switch, ECU1 i/p 27 (A-16) and Travel & excavating - Q max cut
the upper pressure switch, ECU1 i/p 26 (A-6) are selected,
the max flow cut solenoid, ECU1 o/p 3 (C-1) remains High speed travel only - pump standard.
energised, thus leaving the pump in "Q cut" mode. The
EMS displays the "Arrow" gear icon. Excavating only - Q max cut
Travel & excavating - Q max cut
When the travel change switch, ECU1 i/p 15 (C-7) is
pressed, the EMS displays the "Hare" gear icon. The high
speed travel solenoid, ECU1 o/p 15 (C-7) is energised, Creep speed travel only - Q max cut
moving the travel motor swash plate to minimum swash Excavating only - Q max cut
position (high speed). When only the travel pressure
Travel & excavating - Q max cut
switch, ECU1 i/p 27 (A-16) is selected, the max flow cut
solenoid, ECU1 o/p 3 (C-1) is de-energised. When the
upper pressure switch, ECU1 i/p 26 (A-6) is selected, the
max flow cut solenoid valve is energised, thus setting the
pump to the "Q -cut" setting. If both the travel pressure
switch, ECU1 i/p 27 (A-16) and the upper pressure switch,
ECU1 i/p 26 (A-6) are selected, the max flow cut solenoid,
ECU1 o/p 3 (C-1) remains energised, thus leaving the
pump in "Q cut" mode.
When the travel change switch is pressed again the EMS
displays the "Tortoise" gear icon. The high speed travel
solenoid, ECU1 o/p 15 (C-7) is de energised, thus the
swash plate is set to the high swash position (low speed).
The Max flow cut solenoid, ECU1 o/p 15 (C-1) is
energised, thus putting the pump in "Q cut" mode. The
machine is now in low speed mode. The operation of the
travel pressure switch, ECU1 i/p 27 (A-16) and the upper
pressure switch ECU1 i/p 26 (A- 6) are ignored.
C-67 9803/9800-3 C-67
C-68
1 17
ECU1
C29 1 2 EARTH
C8 TRAVEL HEADER 2
ECU1-A CHANGE SWITCH
601K
601K
411
I/P26 UPPER PILOT 6 405
32
13 411 C64
I/P34 TRAVEL CHANGE
MAX FLOW CUT S.V.
16 414
I/P27 TRAVEL PILOT C1 604 2
CONN A
800 3 800 800 1
C10
ECU1-C 806 4 806
C58
800 405 24 405 HIGH SPEED TRAVEL S.V.
O/P3 MAX FLOW OUT 1
9803/9800-3
604 2
7 806 414 26 414
O/P 15 HIGH SPEED
TRAVEL SOLENOID 806 1
C69
UPPER PILOT SW
35
405 1
603 2
Basic System Operation
Section C - Electrics
C70
TRAVEL PILOT SW
36
414 1
606 2
600
3-Speed Travel
C049660
Fig 67.
C-68
Section C - Electrics
Basic System Operation
3-Speed Travel
Page left intentionally blank
C-69 9803/9800-3 C-69
Section C - Electrics
Basic System Operation
Work Lamps
Work Lamps
Operation
C028460GB-2
Fig 68.
Work lamps are located on the boom and front body (tool The switch is returned by pressing in the reverse direction
box) of the machine. An optional set of three additional boom and tool box work lamps and the optional work
work lamps can be fitted to the cab and counter weight. lamps are extinguished.
When the work light switch is moved to the first position,
the input i/p 9 (A-28) to the ECU1 is selected. This in turn
enables outputs to be turned on to the Boom, ECU1 o/p 29
(C-39) and lower front body (Tool Box), ECU1 o/p 30 (C-
20).
A second press of the same switch selects ECU1 i/p 12 (A-
17) and i/p (A-28) which in turn energises the second
optional set of cab work lamps, ECU1 o/p 13 (C-5) and o/
p 14 (C-6) and counter weight, ECU1 o/p 33 (C-18), if they
are fitted and provided that these options have been
selected in the machine setup tool.
C-70 9803/9800-3 C-70
C-71
WORK LAMP SWITCH
+24V
IGNITION
4 11
ECU1 1 5A
EARTH 14 C24 8 7 3 6 5 2
C8 HEADER 1
C180
504A
C25
415
ECU1-A
504F
504F
612P
504F
424
612P
28 424
504A 1 504F 4
I/P 9 STD. LAMPS
612P 4 612P
I/P 12 OPT. LAMPS 17 415
424 2 424 20A
108 8 IGN
415 6 415
C10
ECU1-C C37
C37 C35 CAB R/H LAMP
5 804 804 1 804 613 1
O/P 13 CAB LAMP
19
OPT 6 805 805 2 805 805 2
O/P 14 CAB LAMP
9803/9800-3
18 750
O/P 33 COUNTERWEIGHT LAMP C36 CAB L/H LAMP
20 751 613 1
O/P 30 TOOLBOX LAMP
19
STD
39 827 804 2
O/P 29 BOOM LAMP
C82
BOOM LAMP
18
108 1
827 2
Basic System Operation
Section C - Electrics
C81
C1 TOOLBOX LAMP 18
CONN A 751 1
827 29 827 108 2
751 30 751
C28
750 36 750 COUNTERWEIGHT LAMP
18
Work Lamps
750 1
108 37 108 108 2
C-71
C049670
Fig 69.
Section C - Electrics
Basic System Operation
Viscous Fan
Viscous Fan
A
ECU 1 EMS
FAN DUTY
O/p 8 (C-3)
CAN
Data
B I/p 10 (A-38)
C
I/p 1 (A-19)
D
I/p 2 (A-18)
865670
Fig 70.
A Viscous fan solenoid
C
B A/C switch 0 10 20 30 40 50 60 70 80 90 100
C Hydraulic oil temperature
100
D Engine coolant temperature
% Pulley Speed
Operation 75
X
The cooling pack temperature is controlled by an Y
electromagnetically controlled viscous coupling fan. The Z
electromagnetic clutch which drives the fan speed is
50
controlled by a PWM signal from the ECU1.
Engine water and hydraulic oil temperature are monitored
by the ECU1. As their temperatures change, the ECU1 will
vary the PWM signal to the electromagnetic clutch. This 25
100 90 80 70 60 50 40 30 20 10 0
changes the speed of the fan. As the temperature
increases the PWM signal will decrease to drive the fan % PWM Signal
faster. If the PWM signal is lost to the electromagnetic 823271
clutch the fan will run at full speed. Fig 71.
The output PWM signal will drive the fan RPM to that set X = Fan Speed +/-50rpm.
by the highest temperature as determined by the graph.
K Fig 71. ( T C-72). Y = Oil Temperature.
Z = Water Temperature.
C-72 9803/9800-3 C-72
Section C - Electrics
Basic System Operation
Viscous Fan
Page left intentionally blank
C-73 9803/9800-3 C-73
Section C - Electrics
Basic System Operation
Fuel Level Sensor/Warning
Fuel Level Sensor/Warning
Operation
C005650GB-2
Fig 72.
A float sensor is fitted to the fuel tank to measure the level
of fuel in the tank. A magnetic float rises up a tube
containing a series of 5 ohm resistors with switches in
parallel. The fuel level is displayed to the operator by
means of a bar graph gauge. The actual values can be
displayed via the EMS SET+MODE menu. Both the actual
value and bar graph values should be an average of
consecutive readings to provide a degree of dampening to
prevent false readings
Text warnings are provide for both reserve fuel and low fuel
conditions. Low fuel is also backed up by a flashing bar
graph.
The low fuel condition must be present for one consecutive
minute before the "LOW FUEL" warning is displayed.
The reserve fuel condition must be present for one
consecutive minute before the "RES FUEL" warning is
displayed.
C-74 9803/9800-3 C-74
Section C - Electrics
Basic System Operation
Fuel Level Sensor/Warning
Bar No Symbol Float Height Ohms EMS Action
From Full
0 Empty Greater Than 646 Greater than 107.5 Flashing Bar graph + "LOW FUEL"
1 646 Greater than 102.5 "RES FUEL"
2 612 Greater than 97.5
3 578 Greater than 92.5
4 544 Greater than 87.5
5 510 Greater than 82.5
6 476 Greater than 77.5
7 442 Greater than 72.5
8 408 Greater than 67.5
9 374 Greater than 62.5
10 Half 340 Greater than 57.5
11 306 Greater than 52.5
12 272 Greater than 47.5
13 238 Greater than 52.5
14 204 Greater than 37.5
15 170 Greater than 32.5
16 136 Greater than 27.5
17 102 Greater than 22.5
18 68 Greater than 17.5
19 34 Greater than 12.5
20 Full 0 Less than 12.5
C-75 9803/9800-3 C-75
C-76
ECU1 C75
C2 FUEL
CONN A SENSOR
C8 417 12 417B
407 1
ECU1-A
8 407 407 25 407 417B 2
I/P 4 FUEL LEVEL
20 417
OV REF
9803/9800-3
Basic System Operation
CANBUS
Section C - Electrics
Fuel Level Sensor/Warning
EMS
C049680
Fig 73.
C-76
Section C - Electrics
Basic System Operation
Engine Temperature Sensor/Warning
Engine Temperature Sensor/Warning
Operation
C028490GB-2
Fig 74.
The engine is fitted with a thermistor sensor and thermal The over heat switch is included as a safety measure in
switch to measure the water temperature. The engine case of the thermistor failure. If this input is grounded then
temperature (in ºC) is sent from the ECM to the ECU1 via the EMS will illuminate the water temp LED, the bar graph
the CAN bus. The temperature is displayed to the operator will flash on-off, the audible alarm will sound, "WATER
by means of a bar graph gauge. The actual values can be TEMP" will be displayed on the EMS and the mode
displayed via the EMS's SET+MODE menu. changes to "E" if in "A". The audible warning can be
cancelled by pressing the "ACK" button on the EMS.
– When the temperature rises to 101 ºC the water temp
LED is illuminated on the EMS. The engine water temperature bar graph gauge operates
– At above 130 ºC the operating mode changes to "E" as follows, K Table 1. ( T C-78).
if in "A".
– At above 105 ºC the bar graph will flash on-off, the
audible alarm will sound, and the "WATER TEMP" will
be displayed on the EMS. The audible warning can be
cancelled by pressing ACK button on the EMS.
– At above 108 C the caution LED will illuminate and
"LOW POWER" will be displayed on the EMS. This
indicates that the ECM has limited engine output to
50% of maximum.
C-77 9803/9800-3 C-77
Section C - Electrics
Basic System Operation
Engine Temperature Sensor/Warning
Table 1.
Auto Tier 3
!
Bar No Colour Temp Temp Water Caution Reduces Flashing Buzzer WATER LOW
On Off Temp LED to E Bar TEMP POWER
LED Mode graph
1 Green 50 48
2 Green 60 58
3 Green 70 68
4 Green 75 73
5 Green 80 78
6 Green 82 80
7 Green 84 82
8 Green 86 84
9 Green 88 86
10 Green 89 87
11 Green 90 88
12 Green 92 90
13 Green 93 91
14 Green 95 93
15 Green 97 95
16 Green 99 97
17 Red 101 99
18 Red 103 101
19 Red 105 103
20 Red 108 106
Overheat switch 105 91+/-4
Engine Control Module - 108 Derated performance (50%)
Overheat control
C-78 9803/9800-3 C-78
Section C - Electrics
Basic System Operation
Engine Temperature Sensor/Warning
C005670GB-2
Fig 75.
C-79 9803/9800-3 C-79
Section C - Electrics
Basic System Operation
Engine Temperature Sensor/Warning
C049690
Fig 76.
C-80 9803/9800-3 C-80
Section C - Electrics
Basic System Operation
Coolant Level Warning
Coolant Level Warning
Operation
C005680GB-2
Fig 77.
A float switch is fitted to the engine coolant reservoir. When
the reservoir is empty the float switch ECU1 i/p 37 (A-2) is
connected to ground. This causes the EMS to alarm. The
buzzer sounds for 1.5 seconds, a "COOLANT LOW"
message is displayed on the EMS and flashing low coolant
level LED illuminates for 5 seconds. This is followed by a
repetitive message and constant LED on.
C-81 9803/9800-3 C-81
Section C - Electrics
Basic System Operation
Air Filter Blocked Warning
Air Filter Blocked Warning
Operation
C005690GB-2
Fig 78.
A pressure switch is fitted to the engine air filter. When the
filter is blocked the pressure increases, thus triggering the
switch and the ECU1 i/p 11 (A-7) is connected to ground.
This causes the EMS to alarm. The buzzer sounds for 1.5
seconds, a "AIR FILTER" message is displayed on the
EMS and a flashing engine air filter blocked LED
illuminates for 5 seconds. This is followed by a repetitive
message and constant LED on.
C-82 9803/9800-3 C-82
C-83
C77
AIR FILTER CLOG SWITCH
600
C1 406 1 54
CONN A
602 2
1 406 14 406
401 15 401
ECU1 C8
ECU1- A
16 C76
2 401 COOLANT LEVEL SWITCH
I/P 37 COOLANT LEVEL
402 17 402
3 402 401 1 53
I/P 35 ENGINE OIL LEVEL
600 2
408 28 408
7 406
I/P 11 AIR FILTER CLOG
9 408
I/P 3 ALTERNATOR C270
ENGINE OIL LEVEL SWITCH
50
402
9803/9800-3
C99 ALTERNATOR
WARNING LED's 34
3
CANBUS
408
2
EMS 1
Basic System Operation
Section C - Electrics
C049700
Air Filter Blocked Warning
Fig 79. Warning Indicator Lamps
C-83
Section C - Electrics
Basic System Operation
Air Filter Blocked Warning
Page left intentionally blank
C-84 9803/9800-3 C-84
Section C - Electrics
Basic System Operation
Hydraulic Temperature Sensor/Warning
Hydraulic Temperature Sensor/Warning
Operation
C005700GB-2
Fig 80.
The hydraulic system is fitted with a thermistor and a
thermal switch to measure temperatures. The temperature
is displayed to the operator by means of a bar graph
gauge. The actual values can be displayed via the EMS's
SET and MODE menu.
When the hydraulic oil temperature reaches 97ºC the EMS
will illuminate the warning lamp. If the temperature
continues to rise the bar graph will flash on-off and an
audible warning and "HYD.TEMP" message will be given.
The audible warning can be cancelled by pressing the
"ACK" button on the EMS.
The overheat switch is included as a safety measure in
case of the thermistor failure. If this input is grounded then
the EMS will illuminate the warning lamp, sound the
audible alarm and display the overheat message. The
audible warning can be cancelled by pressing the "ACK"
button on the EMS.
Note: When the temperature reaches 98°C the pump
should be lowered to E mode.
C-85 9803/9800-3 C-85
Section C - Electrics
Basic System Operation
Hydraulic Temperature Sensor/Warning
Auto Tier 3
!
Bar No Colour Temp Temp HYD Caution Pump Flashing Buzzer HYD OVERHEAT
On Off OIL LED reduces Bar TEMP message
LED to E graph message
Mode
1 Green 0 -2
2 Green 10 8
3 Green 20 18
4 Green 30 28
5 Green 40 38
6 Green 50 48
7 Green 60 58
8 Green 70 68
9 Green 75 73
10 Green 80 78
11 Green 85 83
12 Green 90 88
13 Green 92 91
14 Green 94 93
15 Green 95 94
16 Green 96 95
17 Red 97 96
18 Red 98 97
19 Red 99 98
20 Red 100 99
Overheat switch 101 99
C-86 9803/9800-3 C-86
Section C - Electrics
Basic System Operation
Hydraulic Temperature Sensor/Warning
40000
35000
30000
Sensor 25000
resistance 20000
15000
10000
5000
0
-10 10 30 50 70 90 110
Temperature deg. C
C-87 9803/9800-3 C-87
C-88
ECU1 1
C74 HYD. OIL TEMP. SENSOR
C8 C1
CONN A 416 1 50
ECU1-A
+V REF 10 408 408 23 408 408 2
I/P 1 HYDRAULIC TEMP. 19 416 416 35 416 C163 HYD. OIL OVERHEAT SW.
416 1
51
408B 2
9803/9800-3
Hydraulic Temperature Sensor/Warning
Basic System Operation
Section C - Electrics
CANBUS
EMS
C049710
Fig 81.
C-88
Section C - Electrics
Basic System Operation
Hydraulic Temperature Sensor/Warning
Page left intentionally blank
C-89 9803/9800-3 C-89
Section C - Electrics
Basic System Operation
Alternator/No Charge Warning
Alternator/No Charge Warning
Operation
C030360GB-2
Fig 82.
The output of the alternator is monitored by the ECU1 and
a warning alarm sounded if the output voltage falls below
a set value.
When the value of the alternator input, ECU1 i/p 3 (A-9)
falls below 23 volts or above 32 volts, the ECU1 sends a
CAN message to the EMS which in turn illuminates the
warning lamp.
If the engine is running, as detected by the RPM message
from the ECM, then the internal buzzer on the EMS is
sounded and the message "ALTERNATOR" is displayed in
addition to the warning light.
C-90 9803/9800-3 C-90
C-91
25A 60A
29 30
C92 C91
2 1 FUSE LINK 2 1 FUSE LINK
C5
601
BATTERY
300A 300A 200 101
SUPPLY
TO FUSES
27 601
C6 BATTERY RELAY
IGNITION
SUPPLY 101
28 C105 620
TO FUSES C104
- +
408B C107
BATTERY 545
C108
C109 34
B
ALTERNATOR
101
B C98
CONN A 109 3 L
6
9803/9800-3
Br B 545 20 545 545 2 R
C99
OFF 1
IGN
STARTER MOTOR
620
B
C23 5 1 002
R C96
KEY SWITCH
545
303
4 34
10A
10 +24V BATTERY
303
SAFETY RELAY
Basic System Operation
Section C - Electrics
Alternator/No Charge Warning
ECU1 C171
BW
Alternator i/p 3 (A-9) 408 408 3
Crank i/p 28 (A-26) 422 422 2
620 1 101
C173
C049720
Fig 83. Alternator Charging and Battery Relay
C-91
Section C - Electrics
Basic System Operation
Quick hitch (option)
Quick hitch (option)
Operation
C005730GB-2
Fig 84.
!MWARNING SET + MODE (20 secs) Scroll to Q/H option
When using Quick Hitch Type 2, the attachment can QH ENABLE? ACK
become unexpectedly disengaged from the Quick QH ON Scroll up/down to toggle
Hitch, when any of the following occurs: between ON and OFF, ACK
QH TYPE? ACK
Power failure to the Electronic Control Unit (ECU).
QH TYPE 1 Scroll up/down to toggle
When the redundancy switch is engaged. between type 1 and 2 ACK
If an electrical component in the Quick Hitch system When the quick hitch switch is activated the EMS will
should fail. display the "Q/H DISCON?" message to verify the switch
0178 operation and the switch status indicator will illuminate.
The Quick hitch option allows the operator to quickly If the "ACK" switch on the EMS is not pressed within 5
change the attachment from within the cab. seconds then the display reverts to normal and the switch
status indicator is extinguished.
There are two types that can be fitted and they operate in
different ways. The solenoid valve will only be energised/de-energised
once the "ACK" button on the EMS is activated. This is
included as a safety feature to prevent accidental
Quick hitch type 1 Q/H off = output is switched on
operation of the quick hitch system.
Q/H on = output is switched off
Once the "ACK" button is pressed the EMS displays the
message "Q/H DISCON" and the ECU1 o/p 23 (C-28) is
Quick hitch type 2 Q/H off = output is switched off
de-energised (type 1) or energised (type 2). The buzzer is
Q/H on = output is switched on sounded while the quick hitch is disconnected.
The system can be enabled and switched between types To reconnect quick hitch press "ACK". The EMS will
via the SET + MODE (20 seconds) menu: display "Check Q/H" instructing the operator to visually
check the quick hitch attachment is securely connected.
Press "ACK" again to switch off buzzer.
C-92 9803/9800-3 C-92
C-93
ECU1 1
C10
ECU1-C
C1 C157
CONN A QUICKHITCH
28 820 1
820 820 42 820
9803/9800-3
O/P 23 QUICKHITCH
600 2
600
2 3
FS6
CANBUS SPI
Basic System Operation
Section C - Electrics
ACK FASCIA
EMS
Quick hitch (option)
C049760
Fig 85.
C-93
Section C - Electrics
Basic System Operation
Overload Caution (option)
Overload Caution (option)
Operation
C049770GB-2
Fig 86.
Overload caution is used as a warning to the operator that
the machine is lifting a mass which is exceeding the safe
load capacity of the machine. An overload is indicated after
the overload pressure switch, ECU1 i/p 13 (A-27) has been
activated.
By default the overload override option is not enabled in A
(Auto), E (Economy) & P (Precision) modes until the
overload switch is selected. When selecting the overload
switch on the facia switch panel the EMS displays the
acknowledge message "OVERLOAD ON" and the staus
LED illuminates. A second press of the switch disables the
overload override function and the status LED is
extinguished.
When entering L (Lifting) Mode, the overload override
warning system is automatically activated. The status
indicator for FS6 illuminates. The operation of overload
switch will cancel the overload warning system.
If a overload condition is reached whilst the overload
function is selected, the EMS will display "OVERLOAD"
and the buzzer will sound.
C-94 9803/9800-3 C-94
C-95
ECU1 1
C8 CONN A
ECU1-A C93
C1 OVERLOAD CAUTION
CONN A PRESSURE SWITCH 55
27
423 423 43 423 23
I/P 13 OVERLOAD
606
9803/9800-3
2 3
FS3
Basic System Operation
Section C - Electrics
Overload Caution (option)
FASCIA
EMS
C049780
Fig 87.
C-95
Section C - Electrics
Basic System Operation
Beacon
Beacon
Operation
C005750GB-2
Fig 88.
Beacon is activated by pressing the beacon switch on the
facia switch panel and ECU1 o/p 4 (C-22) is switched on.
Beacon operation is cancelled by a second press of the
facia switch thus disabling the ECU1 output and
extinguishing the status LED.
C-96 9803/9800-3 C-96
C-97
ECU1 1
606D
C10 C166
ECU1-C BEACON
44
C1 606D 1 606D
CONN A
9803/9800-3
22
814 814 38 815 815 2 816
O/P 4 BEACON
2 3
FS7
CANBUS SPI
Basic System Operation
Section C - Electrics
FASCIA
EMS
C049790
Fig 89.
Beacon
C-97
Section C - Electrics
Basic System Operation
Hammer Only
Hammer Only
Operation
C030430GB-1
Fig 90.
The hammer is operated by pressing the foot pedal
forward which supplies a pilot pressure signal to close the
pressure switch and operate the option spool in the main
control valve (MCV). When the pressure switch is closed,
ECU 1 i/p 20 (A-11) senses the grounding of the pressure
switch, which reduces the engine rpm to a level preset in
the SET menu.
The throttle potentiometer normally increases/decreases
the engine rpm from idle to max engine speed but will not
exceed the preset hammer value, regardless of its
position. The maximum "hammer revs" (engine rpm) can
be set by the operator via the SET menu on the EMS. The
up and down buttons will increase/decrease the rev/min
value, by 25 rpm for each press. Whatever value is set by
the operator is stored and becomes the new default value.
The original default value for "Hammer RPM" is 1200 rev/
min.
C-98 9803/9800-3 C-98
C-99
EMS
2 3 4 C160
OPT HYDRAULIC SWITCH
841
614
840
ECU1 1
C8
ECU1- A C112 HAMMER PILOT SWITCH
841 1
I/P 20 HAMMER
11 841
20
840 2
9803/9800-3
EARTH HEADER 4
614
ECM
Basic System Operation
Section C - Electrics
C050180
Fig 91. Hammer Only
Hammer Only
C-99
C-100
SWITCH LOGIC
3 6 11 12 13 14 15 16
0=MERGED CIRCUIT
1=AUXILIARY CIRCUIT HAM 2
2=HAMMER CIRCUIT AUX 1
MERG 0
106 4
EMS C25
10 9 3 14 11 13 16 6 12 15 20A
8 +24V IGNITION
108
C169 HAMMER/AUXILIARY
AUX C S.V. CHANGE OVER SOL V
C160 OPT 2 3 4 5 6 7
HYDRAULICS EARTH 601 601 2
SWITCH HEADER 2
841
614
840
839
838
108
ECU1 839 1
1
C8
C112
C167
9803/9800-3
ECU1- A HAMMER PILOT SWITCH
AUX A S.V. MERGED 1 SOL V
11 841 841 1 28
I/P 20 HAMMER 601 2
840 2
838 1
C1
C161
CONN A
DIODE
2 839 839 18 839
C168
838 838 39 838 AUX B S.V. MERGED 2 SOL V
1
ECM
Basic System Operation
601 2
Section C - Electrics
614
838 1
EARTH
HEADER 4
Hammer Only
C050190
Fig 92. Combined Hammer/Auxiliary/Merged
C-100
Section C - Electrics
Basic System Operation
Scrap Magnet Option
Scrap Magnet Option
Operation
C030460GB-2
Fig 93.
When a scrap handling magnet attachment is fitted to the rpm. value in 50 rpm. increments (allowable range to be
machine, the high voltage required for its operation is the low idle setting to S mode full engine speed setting for
supplied by an engine driven generator. If the minimum the particular model). The default setting for the minimum
engine rpm is too low, the supply voltage to the magnet engine speed is 1000 rpm.
may decrease to the point where any material on the
magnet may drop off. To prevent this the machine has the The rpm setting of this feature is stored and is used each
capability to set the minimum engine speed so that it time the machine is used whilst the scrap magnet function
doesn't fall below a predetermined level whilst the scrap is enabled. The scrap magnet option is switched off
magnet is being used. through the EMS SET menu.
The feature can be switched on or off and the minimum If a target value less than the machines idle rpm is
rpm set via the SET menu of the EMS by the "SCRAP selected, then the machine will default to the original Idle
MAG" option. When this feature is enabled the throttle setting.
volume potentiometer is re-scaled so that in the minimum
position the engine rpm is that pre-set through the
following procedure.
Set the Minimum Engine RPM for Scrap Magnet
Use
Press the SET and MODE buttons on the EMS for 5
seconds then use the scroll buttons until "SCRAP MAG" is
displayed.
Press the ACK button (this will alternate the function on/
off). Set the display to "ON", the display will change
between "MAG ON" and "MAG OFF").
Press the 'ACK' button, the display will change to "RPM
1000". Pressing the scroll buttons will then change the
C-101 9803/9800-3 C-101
Section C - Electrics
Basic System Operation
Cab Interior Lamp
Cab Interior Lamp
Operation
C005790GB-2
Fig 94.
A switch near the cab door can be pressed to switch on the
cab interior light for access to the machine in the dark. The
input i/p 7 (A-30) activates the ECU1 when the ignition is
switched off. When the light switch is pressed the cab light
will be switched on for 5 minutes or until a second press of
the light switch within the 5 minute period.
The cab interior light has an integral override switch to
switch on the lamp independently of the ECU1.
C-102 9803/9800-3 C-102
C-103
CAB INTERIOR
LAMP SWITCH
4
C5
10A
302B 10 + 24V
1 BATTERY
3 2 C222
ECU1 C6
302B
426
108 9 20A +24V
IGN
ECU1-A
I/P 7 CAB A30 426
INTERIOR LAMP
CAB INTERIOR
26 LAMP
C214
9803/9800-3
808 3
108 4
613 7
ECU1-C
O/P 2 CAB C11 808
INTERIOR LAMP
Basic System Operation
Section C - Electrics
C049800
Fig 95.
Cab Interior Lamp
C-103
Section C - Electrics
Basic System Operation
Refuelling Pump
Refuelling Pump
Operation
+24V Refuel Pump
Relay ECU1 EMS
O/P5 (C-13)
M
CAN bus
Refuel Pump
Motor
Ov Ref (A-20)
Fuel Level
Sensor
I/P4 (A-8)
I/P16 (A-35)
Refuel Pump
Switch
C030500GB-3
Fig 96.
ECU1 Requirements If a second falling edge is detected on the fuel pump input,
then the feature is de-activated and the fuel pump output
A refuelling pump can also be installed on the machine. is turned off.
This pump can be used in two different modes: automatic
or manual. Note: If any errors are present on the fuel level sensor,
then the refuel pump's automatic mode is not allowed.
Note: The refuel pump feature is only present when the
machine is fitted with a new harness. If the machine is not
fitted with a new harness the input and output pins used for
this feature are assigned to other functions
Automatic Mode
A short press of the fuel pump momentary switch is used
to turn on and off the fuel pump's automatic mode. When
the refuelling pump switch is pressed, a high (+Vbatt) is
measured at the input to the ECU1. When the button is
released, the input is open circuit and a `low' will be
measured by the ECU1. If the button is held for less than 2
seconds, then this falling edge will trigger the refuelling
pump feature into automatic mode. While in automatic
mode, the output to the refuelling pump relay is energized.
The fuel level input is monitored during this functionality.
When the fuel level reaches the Max Refuel Level, the fuel
pump output is turned off. The filtering that is normally
used to smooth out fuel level readings is not used in this
case so that there is no delay in the fuel level reading.
C-104 9803/9800-3 C-104
Section C - Electrics
Basic System Operation
Refuelling Pump
Default Max Refuel Level Parameter The value is initially set during `Vehicle Setup' using the
`Default max refuel level' parameter. Subsequent changes
The position of the Fuel Sensor varies on different to the value using the SET menu are retained on ignition
machines. Therefore, the accuracy of the sensed level restart but are overwritten again by the `Vehicle Setup'
when the machine is on a slope, varies by machine. There tool. The menu option allows changes in 5% steps within a
is an ability to vary the default maximum refuel level (in range of 50 to 100%.
Automatic refuel mode) dependant on machine type. The
addition of this parameter enables this level to be specified To prevent running the refuel pump dry, the following
during `Vehicle Setup'. This parameter should only be limitation is also appllied:
adjusted during `Vehicle Setup'.
If the refuel pump output has been on for a specified time
Max Auto Refuel Level - Menu Option without any change to the fuel level in the tank, then the
refuel pump output turns off. The auto refuel run-dry time-
Where refuelling a machine on a slope is unavoidable out can be varied as large machines (with large fuel tanks)
(despite JCB recommendations), the machine operator have slow changing fuel level indications. A software
can adjust the maximum auto refuel level using an option parameter specifies this time in seconds. This time is
in the SET menu. The menu option functions as shown. specified during `Vehicle Setup' dependant on model.
Up Button Pressed
Auto Idle Time 85_PERC
Up Button Pressed ACK Down Button Pressed
Button
Pressed
REFUEL_LVL 90_PERC
ACK
Button
Up Button Pressed Pressed
Up Button Pressed
Travel Mode
95_PERC
Up Button Pressed
T036740
Fig 97.
Manual Mode refuelling switch has been released. At this point the output
will turn off and the refuelling feature will be off.
If, at any time, the refuelling pump input is pressed and
held for more than 2 seconds, then the refuelling pump will Note: If manual mode is entered from automatic mode,
be in manual mode. This mode allows the user to manually then automatic mode is NOT resumed when the switch is
add fuel to the tank. Once in manual mode, the refuelling released.
pump output is turned on. The output remains on until the
C-105 9803/9800-3 C-105
Section C - Electrics
Basic System Operation
Refuelling Pump
Wake-up
The refuelling pump switch is connected to one of the
wake-up inputs on the ECU1. If the ECU1 is in a `WAKE-
UP' state this feature will operate normally.
Limitations
The fuel pump feature will be off if the system is in a
`CRANKING' or a `RUNNING' state. If the output is on
when either of these states is entered, then the output and
feature will be turned off.
Also, the refuelling pump input is ignored while in either of
these states. If the refuelling pump input is pressed when
the system enters a `KEY-ON' state from a `RUNNING' or
`CRANKING' state, then the following falling edge should
be ignored. If the vehicle's redundancy switch has been
turned on, the fuel pump feature can still be activated as a
wake-up input. In this case, the EMS will notify the ECU1
that the system is in redundancy mode and this feature will
be disabled.
C-106 9803/9800-3 C-106
Section C - Electrics
Basic System Operation
Air Conditioning
C049830-2
Air Conditioning
Fig 98.
C-107 9803/9800-3 C-107
Section C - Electrics
Basic System Operation
Heated Seat
Heated Seat
Operation
C030500GB-2
Fig 99.
When the heated seat switch is selected, an electrical
current passes over the seat thermostat to the heating
element. The element will then warm the seat.
The thermostat is set to 20°C - ON and 30°C - OFF.
On initial starting when the heated seat switch is selected,
the heated seat element will turn on only if the thermostat
is below 30°C. Once the thermostat reaches 30°C the
heater will turn off. The element will only be re-heated if the
thermostat temperature falls below 20°C.
C-108 9803/9800-3 C-108
Section C - Electrics
Basic System Operation
Heated Seat
Page left intentionally blank
C-109 9803/9800-3 C-109
Section C - Electrics
Basic System Operation
Radio and Cigar Lighter
Radio and Cigar Lighter
Operation
Radio
The radio has a permanent 12-volt supply from pin 4 of the
voltage converter to pin 5 of the radio. The permanent
supply is to retain the memory in the radio.
The 12-volt switched supply to power the radio is fed from
pin 5 of the voltage converter to pin 2 of the radio via a
rocker switch (Mute button) in the right hand console of the
cab. Operating the mute button simply turns off the power
supply to the radio.
Cigar lighter
The cigar lighter/phone charger, is fed from the switched
feed only.
C-110 9803/9800-3 C-110
Section C - Electrics
Basic System Operation
Radio and Cigar Lighter
4
14 C25
RADIO FUSE 20A C6
109B 8 +24
BATTERY
IGNITION
IGN
GND
FUSE 10A C5
302 9 +24
C39 6 5 4 3 2 1 Battery
EH 4
613
843
Voltage
CAB HARNESS C224 Converter
C214 9 8 7 302 1 + 24V Battery
845
843
109B 2 + 24V Ignition
EH 3 614A 3 GND
C159
846A 843
13 4 + 12V Memory
C225 846
C40 5 +12V Switched
840A 6
614
12V CIGAR 6 GND
LIGHTER 845 7
612K
C41
C180
612K 4 B EH 4
RADIO MUTE SWITCH 58
EH 1
8
846D
612L
846C
845
C049840
Fig 100.
C-111 9803/9800-3 C-111
Section C - Electrics
Basic System Operation
Service Required Warning
Service Required Warning
Operation
C005800GB-2
Fig 101.
The service warning LED in the EMS will illuminate (no "ACK" button, the EMS will set the time for the next minor
buzzer) when the next service or oil change is due, service event to 500 hours from the time when the "ACK"
according to the service schedule. The EMS also displays button was pressed. When the oil change interval is set for
"SERVICE RQD" and/or "OIL CHANGE". The total 125 or 250 hours, and additional repetitive "OIL CHANGE"
elapsed time will be decided by the recorded hours on the message is displayed and cancelled as above.
hour meter.
Major service intervals occur every 500 hours with the first
Oil change intervals can be set to 250 or 500 hour intervals occurring at 500 hours. At the major service intervals the
in "vehicle setup": service warning LED will flash and a "SERVICE RQD"
message will be displayed on the EMS from 20 hours
Oil change intervals can be set to 125, 250 or 500 hour before the preset 500 hour time has been reached. The
intervals in the EMS SET+MODE (20 sec) Menu. warning can be cleared by the operator by pressing the
"ACK" button but will re-occur every time the ignition is
switched ON until reset by JCB service engineer. 20 hours
125 hours the oil change message is displayed at
after the 500 hour pre-set time has been reached an error
125 hours and at every subsequent 125
is written to the error log indicating that the service has
hour intervals including minor and major
been missed. An additional repetitive "OIL CHANGE"
service points.
message is displayed and cancelled as below.
250 hours the oil change message is displayed at
minor and major service points. The major service warning can be cancelled in one of two
500 hours the oil change message is only displayed ways:
at major service points.
1 Through the JCB approved service tool.
Minor service intervals occur every 250 hours with the first
occurring at 250 hours. At the minor service intervals the 2 Through the EMS Set + Mode (20 sec) menu
service warning LED will flash and a "SERVICE RQD"
message will be displayed on the EMS until the ACK
button is pressed. Once the operator has pressed the
C-112 9803/9800-3 C-112
Section C - Electrics
Basic System Operation
Service Required Warning
Cancellation of the Service indicator digit will flash until the ACK button is pressed, after which
the next digit will flash until all of the digits have been
JCB Service personnel will be able to cancel the main entered. Once the code is entered and the set button
service indicator by entering the dealer code from the pressed the service warning is cancelled and the code
SET+MODE menu structure. saved in memory. The saved data will be updated at the
next service interval by the newly entered dealer code.
When the Service sub menu is reached and entered the
dealer will be prompted to enter a four digit code by the use Note: The dealer entered code can be accessed only by
of the "Up/Down" keys and the "ACK" button. The required Factory service engineers with the service tool software.
Step Action Remark
1 SET + MODE (20 seconds)
2 SERVICE OFF
3 ACK
4 0000
5 Press "Up/Down" to select digit "ACK" to accept selection & move to Repeat step 5 until all five digits entered
next digit
6 Eg. 1 2 3 4
7 Press "SET" to enter and save code Reset service warning &
extinguish warning lamp.
8 Return to SET + MODE menu.
9 SERVICE OFF
C-113 9803/9800-3 C-113
Section C - Electrics
Basic System Operation
EMS Set Menu.
EMS Set Menu.
When the SET button on the EMS is pressed a sub menu scroll through the menu and the item is selected by
structure appears, enabling the operator to customise the pressing the "ACK" button. Pressing "SET" at any time will
machine operations and confirm the local time/date. The return the operator to the normal display.
following functions are available: The up/down arrows
INT WIPER S X Intermittent wiper speed. Scroll keys to increase/decrease the delay between strokes
time. "ACK" to accept new value.
LANGUAGE Language can be changed between one and up to four languages, the languages are
installed at machine set up.
DATE XX-XX-XXXX The current date. Use the scroll keys to increase the value. "ACK" to move to the
month section. Repeat until the year is entered "ACK" to return to menu.
CLOCK 12/24? 24 Clock format the arrow keys select 12/24 hour format. "ACK" to accept format then the
current time is displayed.
XX:XX Use the scroll keys to set the current time. "ACK" to accept value.
HAMMER XXXXX - - The total hours that the hammer pressure switch has been activated is displayed on
HOUR XXXX the left of the display (Up to 99,999 Max.) and the digits on the right which flash
represent the hours accumulated since the last hammer service (up to 9,999 max.)
The four flashing digits can be reset by pressing the "ACK" button.This Item will only
be displayed if previously selected in set up tool Reset Hrs? A further press of the
"ACK" button will set the hours since service to zero.
HAMMER RPM XXXX The maximum hammer revs allowed. Use the scroll keys to set the desired rpm.
RPM Increments/decrements in 50 rev/min. "ACK" to accept the new value.
REFUEL LVL XX Allow the fuel tank to be filled with fuel to a preset percentage, 50-100%
AUTO IDLE T XX Auto idle delay time. Scroll keys increase/decrease the delay time. "ACK" to accept
new delay time.
C-114 9803/9800-3 C-114
Section C - Electrics
Basic System Operation
EMS Set + Mode Menu
EMS Set + Mode Menu
When the SET and MODE buttons on the EMS are to set option configurations. The following functions are
pressed together a sub menu appears, enabling the available:
technician to view more detailed data on the machine and
MODEL NAME Displays the model type.
HRDWARE VER Displays the hardware version
SFTWARE VER Displays the software version.
SCRAP MAG The current status of the scrap magnet function is displayed. The up arrows changes the status
to "ON" and the down arrows change it to "OFF". If the "ACK" is pressed the display shows the
scrap magnet rev/min.
SENSOR VOLT Displays the sensor circuit voltage in volts.
BATT VOLTS Displays the battery voltage in volts.
ALT VOLTS Displays the alternator output voltage in volts.
THRTTLE POT Displays the throttle volume dial value in Ohms
FUEL LEVEL Displays the fuel level sensor value in%
FAN DUTY Displays the current duty cycle of the fan control solenoid in %." On machines with a Viscous
Clutch Fan, this menu item shows the duty cycle (in %) of the PWM output from the ECU1 to the
fan, 100% = idling and 0% = fully on.
BAROMETER Displays the current barometric pressure in kPa
WATER TEMP Displays the current engine coolant temperature in °C
HYD TEMP Displays the current hydraulic oil temperature in °C
PILOT SWTCH Displays the status of the pressure switches. Use the scroll keys to go through the following
switches, the current status will be displayed:
TRAVEL Travel Pressure switch status
AUTO Auto mode Pressure switch status
BOOST Boost Pressure switch status
BOOM Boom Pressure switch status
UPPER Upper Pressure switch status
SLEW Slew Pressure switch status
HAMMER (1) Hammer Pressure switch status
PUMP AMPS Displays the current duty cycle of the pump control solenoid in mA
RPM VALUE Displays the current value of the engine speed in RPM.
SERIAL NO Displays the serial number.
(1) If enabled
C-115 9803/9800-3 C-115
Section C - Electrics
Basic System Operation
EMS Set+Mode (20 sec) Menu.
EMS Set+Mode (20 sec) Menu.
When the SET and MODE buttons on the EMS are solenoids for testing purposes. The up/down arrows scrolls
pressed together for 20 seconds a sub menu structure through the menu and the item is selected by pressing the
appears, enabling JCB trained personnel to cancel the "ACK" button. Pressing "SET" at any time will return the
intermediate service warning, calibrate the throttle and operator to the normal display.
override the engine speed sensor input to energise
SERVICE OFF The intermediate service warning can be cancelled by entering this menu
OIL CHG INT The oil change interval can be set to "0", "1" or "2". 0 = 500 hour oil change (less than 0.2%
sulphur), 1 = 250 hour oil change (0.2% - 0.4% sulphur), 2 = 125 hour oil change (more than 0.4%
sulphur).
FAN TEST? When selected this menu option will cause the fan to run at a fixed (predetermined) speed
regardless of machine temperatures.
OVERRIDE? When selected this function enables outputs to solenoids even when the engine is off, for testing
purposes.
KEROSEN ENG Press ACK. Use the scroll buttons to turn either "ON" or "OFF". Press ACK.
QH ENABLE? Up or down arrows enable/disable function. "ACK" enters a configuration menu.
QH TYPE? Up or down arrows change between type 1 or type 2. "ACK" to accept selection and return.
HRSEPWR MON When selected this function will log information on engine speed, pump milliamps and mode over
a selectable period up to 15 mins and display the data as a graph.
CALIBRATION Throttle calibration. The throttle calibration should be performed on every new machine, when the
throttle linkage parts are replaced or when the "NO THROTTLE" warning appears on the EMS.
HAM WARNING(1) The hammer warning can be set "ON" or "OFF"
(1) Only When enabled
C-116 9803/9800-3 C-116
Section C - Electrics
Basic System Operation
EMS Set+Mode (20 sec) Menu.
Service Off Solenoid Override
The service warning can be cancelled by entering this Machine Controlled functions.
menu. To enter this menu the following procedure must be
followed: When the ignition is energised and the engine is not
running, (which the ECU can detect by either of the
– Press and hold the "SET" and "MODE" buttons on the following inputs: engine oil pressure and/or engine speed
EMS together for 20 seconds, until the "SERVICE sensor input) then the following functions are allowed:
OFF" is displayed.
– Press the "ACK" button. You are now in the a Wiper
"SERVICE OFF" routine and four zeros will appear in
b Washer
the display and you will be prompted to enter the JCB
dealer code. c Horn
– "0"000 Will be displayed and the left hand digit will d Indicators
be flashing. The up and down arrows are used to e Headlight flash
select the digit value and "ACK" to enter/accept the
value and move to the next digit. When all digits are f Work lamps Buzzer will sound but can be
entered the final press of "ACK' followed by a press of cancelled by "ACK")
the "SET" button will extinguish the service indicator g Side lights Buzzer will sound but can be
and record the service event. (hours, time and dealer cancelled by "ACK")
code to the service history file).
h Headlights Buzzer will sound but can be
cancelled by "ACK")
The intermediate service warning can be cancelled
by pressing the "ACK" button on the EMS. i Beacon Buzzer will sound but can be
cancelled by "ACK")
Note: Information stored in the service history is available
via the JCB Diagnostic tool. With the ignition on but the engine not started all solenoids
with the exception of the ESOS solenoids are de energised
to reduce battery drain and to reduce engine load whilst
cranking.
For maintenance purposes an override facility is
incorporated to safely operate the solenoid outputs whilst
the engine is not operating. This feature, once enabled, is
automatically cancelled by switching the ignition off and
then back on. To enter the override facility the following
procedure must be followed:
– Press and hold the "SET" and "MODE" buttons on the
EMS simultaneously for 20 seconds, until the
"SERVICE OFF" message is displayed.
– Use the scroll arrows until the "OVER-RIDE?"
message is displayed.
– Press the "ACK" button. You are now in the solenoid
over-ride function. This is confirmed by the message
"OVER-RIDE?" and internal buzzer will sound. The
solenoids can now be operated as though the engine
was running.
C-117 9803/9800-3 C-117
Section C - Electrics
Basic System Operation
EMS Set+Mode (20 sec) Menu.
Horse Power Control Data Logging Throttle Calibration
Facility
Throttle calibration is obtained via the Set + Mode (20 sec)
When selected this function will log information on engine menu on the EMS. The throttle calibration should be
speed, pump milliamps and mode over a selectable period performed on every new machine, when the throttle
up to 15 mins and display the data as a graph. linkage parts are replaced or when the "NO THROTTLE"
warning appears on the EMS.
– Press and hold the "SET" and "MODE" buttons on the
EMS simultaneously for 20 seconds, until the To enter throttle calibration the following procedure must
"SERVICE OFF" message is displayed. be followed:
– Use the scroll arrows until the "HRSEPWR MON"
– The engine must be started, and warmed up to
message is displayed.
normal operating temperatures.
– Press the "ACK" button. You are now in the datalog
– Press and hold the "SET" and "MODE" buttons on the
function. This is confirmed by the message
EMS simultaneously for 20 seconds, until the
"MINUTES 1".
"SERVICE OFF" message is displayed.
– The time period for logging can now be adjusted from
– Use the scroll arrows until the "CALIBRATE"
1 to 15 minutes using the arrow keys.
message is displayed.
– Press 'ACK' to start recording, the EMS will display
– Press the "ACK" button. You are now in the throttle
"RUNNING" When complete the display will return to
calibration routine and the message "T VOL MIN" will
normal.
appear in the display.
– The results of this test are then viewed through the
– Rotate the throttle volume dial to the minimum
Servicemaster, Data logging application using a
position.
laptop.
– Press "ACK". The "T VOL MAX" message will then be
displayed.
– Rotate the throttle volume dial to the maximum
position.
– Press "ACK".
– When complete throttle control will be restored to the
throttle volume dial. "CAL DONE" is displayed. The
EMS will revert to the normal display
Note: If the engine is stopped during the calibration, the
"RECALIBRATE" message is displayed and the procedure
has to be restarted. If the throttle volume dial minimum and
maximum values are the same, or the wrong way round,
then "RECALIBRATE" is also displayed.
C-118 9803/9800-3 C-118
Section C - Electrics
Fault Finding
JCB Servicemaster
Fault Finding
JCB Servicemaster
TC-010
Introduction The interface also provides several key features that will
accompany all JCB projects, a multi language editing tool
Servicemaster is a gateway application allowing a large that provides a means of individual text string translation
number of vehicle support applications to be linked using for all JCB applications and the means to select a localised
one familiar interface. The interface acts as a graphical tool language translation for each JCB application.
for selecting the target vehicle from a database of vehicle
families and triggering the particular service tool The contents of this document aim to explain to you, the
application desired. This removes the need for a user to user, how to operate this application and to make most of
'remember' every individual service tool available and its functionality.
select which one is intended for a particular machine.
C065910
Fig 102.
C-119 9803/9800-3 C-119
Section C - Electrics
Fault Finding
JCB Servicemaster
Using Servicemaster
The Servicemaster application consists of a database of
records relating vehicle product ranges and service tool
applications. At most, any one product range has one
application for each of the service tool modules. In the
image the selected vehicle range is the 'Heavy Products'
range of excavators. K Fig 102. ( T C-119). The
application buttons (or icons) visible below the vehicle
images are gateways to the individual service tool
applications. The user need only to decide which type of
tool is required for the task at hand, click the respective
icon and the service tool will be opened.
Product Range Selectors Use the two arrow icons to
toggle through the database
list of product ranges
supported by Servicemaster.
Application Buttons These buttons access the
underlying service tool
applications available for the
selected product range
System Menus Functions are accessed by
clicking the right mouse
button anywhere on the main
form.
Selecting Service Tool Applications
Service tool applications are selected by firstly locating
and selecting from the list of product ranges the range
which contains the vehicle that is to be worked on. The
service tool applications which are available to the product
range selected are made accessible by clicking on one of
the icons that will be displayed on the lower portion of the
main screen.
Only those applications which are supported by the CFE
will have a visible icon. As and when new applications are
made available by software vendors they can be included
into the product range by updating the product range
database.
C-120 9803/9800-3 C-120
Section C - Electrics
Fault Finding
JCB Servicemaster
Table 2.
Operating parameter settings, Option/Attachment control,
Vehicle Setup
Alternative language support, Model/Serial number identification.
C001750
Running data collection, Operating data, Statistics, Device error log
Data Logging
recording. K HPDataLogs ( T C-137).
C001760
Service/Engine hour records, Service dealership codes. K Using
Service History
HP Service ( T C-144).
C001770
Flash Loader ECU Reprogramming and software update/revision capability.
C031160
Diagnostics ECU I/O (input and output) testing and diagnostics.
C001790
Short cut to technical data spread sheet for machine performance
Technical Data
and setting. CD3 needs to be installed
C031170
Short cut to JS fault finding guide. Fault finding guide on CD3 will
JS Fault Finding Guide
need to be installed.
C031170
ECM Setup Specific to Tier 3 engine machines.
C001750
Short cut to injector checker tool. This tool enables the user to turn
Injector Checker
each injector on or off as required, for diagnosing injector faults.
C001790
Electrical Error Codes Short cut to electrical error codes. CD3 needs to be installed
C031170
C-121 9803/9800-3 C-121
Section C - Electrics
Fault Finding
JCB Servicemaster
JS Machine Pages Service History Icon
Selecting this icon will open the service history tool. This
tool displays a service log of completed and missed
services. It is also possible to add an additional service
comment such as "pressures reset" to the service log. The
service log can also be printed out or exported to a floppy
disk.
Data Logger Icon
Selecting this icon will open the data-logging tool. This tool
stores and displays information on electrical faults and
error codes. This tool also logs and displays information on
machine operation i.e. the numbers of hours the machine
has spent in each of the working modes, the number of
hours the machine has been tracking, swinging and
excavating. Error logs can also be reset.
Flashloader Icon
C065920 Selecting this icon will open the programming tool which is
Fig 103. used to input new software to machines with ECU software
version 8 and onwards.
Vehicle Setup Icon
Selecting this icon will open the vehicle setup tool which is
used to enable circuits or functions such as additional
working lights, hammer circuit, stabilizers and boom
priority which are additional to the basic machine.
Note: It should be noted that if a circuit or function is not
enabled in the setup tool then it will not operate.
Diagnostics Icon
Selecting this icon will open the diagnostic tool which
allows the engineer to test a significant amount of
functions on the machine including solenoid operation,
engine speed and pump control signal. The diagnostic
functions are grouped into Engine and Drive systems,
Hydraulic system, Electrical system and Vehicle and CAN
Information sections.
A list of the available circuits in each category will be
shown when selecting a functional section. Each item in C065930
the list can be selected for viewing while the diagnostic tool Fig 104.
is operating. To view a circuit diagram, click in the check
box area to the left of the item in the list. When checked, HP Flashloader Icon
the circuit diagram will be shown in the right hand side of
the window. When an item is unchecked, the circuit Selecting this icon will open the programming tool which is
diagram will be closed. used to input new software to machines with ECU software
prior to version 8.
C-122 9803/9800-3 C-122
Section C - Electrics
Fault Finding
JCB Servicemaster
ECM Setup Tool System Menus
Selecting this icon will open the engine control setup tool System menu functions are accessed by pressing the right
used for programming ECMs Data can be copied from an mouse button anywhere on the main Servicemaster form.
old, damaged ECM and then loaded onto a replacement
ECM for example.
Manage Applications Opens the configure
applications form which
Injector Checker
allows the user to add,
delete, update information
Selecting this icon will open the injector checker tool. This
relating to the applications
tool enables the user to turn each injector on or off as
supported by product ranges.
required, for diagnosing injector faults.
Multi Lingual Support Opens a text editing tool
Fault Finding Guide Icon used to control application
text strings which can be
Selecting this icon will open the JS Fault Finding guide translated into almost any
which is located on the JCB Service Information Pack WINDOWS supported
DVD, if not installed during Servicemaster 2 set up. This language
guide gives useful information on test procedures and fault DLA Programmer Opens an application for the
finding on JS hydraulic and electrical systems. reprogramming of the DLA
module.
Technical Data
Properties Used to define various
options and settings used by
Selecting this icon will open a pdf document containing
the Servicemaster
various JS machine technical data.
application.
Tier 3 Troubleshooting About Box Shows software version,
date, developers information
Selecting this icon will open a pdf document describing the etc.
structure and the troubleshooting of electronic control fuel
injection systems (common rail type) in 4HK1, 4JJ1 and
6HK1industrial engines (Isuzu T3).
Electrical Error Codes
This shows all electrical error codes sent from the ECU's
357800
Fig 105.
C-123 9803/9800-3 C-123
Section C - Electrics
Fault Finding
JCB Servicemaster
Using ECM Setup
The ECM Setup tool is included in Servicemaster 2 for use
with Tier 3 engines.
The ECM Setup tool is used to:
1 Write the `QR code' of a replacement fuel injector to
an ECM. K Write QR code. ( T C-124).
860901
2 Read unique engine details from a damaged ECM. Fig 107.
K Read Engine Details ( T C-125).
4 Select from the drop-down menu the `Engine Model
3 Write unique engine details to a replacement ECM. Code'. K Fig 107. ( T C-124).
K Write Engine Details ( T C-126).
Write QR code.
To write the QR code of a replacement injector to the ECM
use the following procedure.
Note: Example shows replacement injector 3.
1 Connect the PC to the vehicle through a DLA and
switch on the ignition.
812351
Fig 108.
5 From the new injector, note the QR code.
K Fig 108. ( T C-124)
Note: Do Not use the struck out numbers.
860900
Fig 106.
2 Open the ECM Setup tool from within Servicemaster.
3 The ECM Setup tool will attempt to connect to the
CAN bus, after which, the `Connect' button will be
greyed out.
C-124 9803/9800-3 C-124
Section C - Electrics
Fault Finding
JCB Servicemaster
860902
Fig 109.
6 Enter the new QR code, as shown, into the boxes for
the replacement injector. K Fig 109. ( T C-125).
860903
Fig 111.
7 Select button A. The QR code is now written to the
ECM.
3 The ECM Setup tool will attempt to connect to the
CAN bus, after which, the `Connect' button will be
Read Engine Details greyed out.
1 Connect the PC to the vehicle through a DLA and
switch on the ignition.
860900-2
860900 Fig 112.
Fig 110.
4 Select button A. The ECM Setup tool will read and
2 Open the ECM Setup tool from within Servicemaster. display the following:
a Injector QR codes. K Fig 113. ( T C-126).
C-125 9803/9800-3 C-125
Section C - Electrics
Fault Finding
JCB Servicemaster
5 Select `Disconnect' from the `File' menu pull down or
select button B.
6 To copy the details on to a new ECM follow the next
procedure. K Write Engine Details ( T C-126).
Important: DO NOT switch the laptop off, close the ECM
setup tool or disconnect the DLA when reading or writing
to a new ECM.
Note: If the details can not be read from the ECM contact
JCB Service.
860903-1
Write Engine Details
Fig 113.
Copy details from existing ECM. K Read Engine
b Engine Serial Number. K Fig 114. ( T C-126).
Details ( T C-125).
Important: DO NOT switch the laptop off, close the ECM
setup tool or disconnect the DLA when reading or writing
to a new ECM.
1 Turn ignition off.
2 Remove ECM unit and replace with new unit.
860904
Fig 114.
c Q Tone. K Fig 115. ( T C-126).
860900-1
Fig 116.
3 Select the connect button A.
T011600
Fig 115.
C-126 9803/9800-3 C-126
Section C - Electrics
Fault Finding
JCB Servicemaster
4 The ECM Setup tool will attempt to connect to the
CAN bus, after which, the `Connect' button will be
greyed out.
860907
Fig 117.
5 The QR code will be displayed for each injector. T011620
Select buttons B to write each code to the ECM. Fig 119.
T011610
Fig 118.
6 On the `Rewrite Engine Serial Number' tab page,
select button C to write the serial number to the ECM.
7 On the `Rewrite Q Tone' tab page, select button D to
write Q-trim values to the ECM.
C-127 9803/9800-3 C-127
Section C - Electrics
Fault Finding
JCB Servicemaster
HPSetup Overview 1 Connecting the Data Link Adaptor (DLA)
HPSetup is part of a suite of software modules designed The DLA supplied to JCB and related dealerships is the
for the Advanced Management System (AMS) The task of only tool required to connect to the vehicles onboard CAN
HPSetup is to ensure that the vehicle can be configured data network.
out in the field or as it leaves the production line as per
customer requirements. It includes the ability to set various You will require a PC and all JCB applications installed and
vehicle attachment options for differing vehicle functions/ a free Parallel port, serial port or USB.
design and the programming of alternative languages into
the EMS so the operator can view information in his/her – Connect the DLA to the your computer.
native tongue. – Attach the second cable in between the DLA and the
on vehicle service connector, located in this diagram.
Features – Power up the vehicle (optional, the power may be
permanent).
Vehicle profile read and write functionality, offering the
– Ensure that the power on LED is illuminated.
ability to modify the vehicles fitted options.
Data Link Adaptor (DLA) utilising the J1939 CAN Bus
standard interface.
Application multi language support, options provided to B
J
C
A
D
E
F
H G
allow the PC application to operate in many different
languages. Note this is not the same as alternative
languages used in the EMS module. In this instance we
refer to the PC applications switching from a standard
English test to another language of choice.
Using HPSetup
In order to operate this software correctly it must have
been installed using the JCB Servicemaster Installation
disk to ensure the correct files, databases and resources
have been initialise.
1 Connecting to the vehicle.
2 Starting HPSetup.
3 Setting up a Vehicle Profile.
A406130
4 Writing Vehicle Profile. Fig 120.
5 Reading current Vehicle Profile.
6 Closing.
7 Options.
C-128 9803/9800-3 C-128
Section C - Electrics
Fault Finding
JCB Servicemaster
2 Starting HPSetup The Options installed on the vehicle may then be selected
using the check boxes (being checked defines the option
To open the HPSetup Application: as 'Installed'). The "Custom Options" checkbox allows the
user to configure the options outside of the normal
1 Boot PC into WINDOWS guidelines for what devices are implemented on particular
machines. In general Wheeled and Tracked machines
2 Start the JCB Servicemaster CFE have several distinct options available that are not always
available on the other. The "Custom Options" checkbox
3 Select the Heavy Products Range of Excavators allows these to be over-written on demand, use of this
option should only be made under instruction from JCB
4 Click the icon to open the HPSetup application Heavy Products Engineering.
The HPSetup tool when opened takes several seconds to Build date is once programmable only, on leaving the
open because it must search the vehicle network and production line (actual build) further writes will be ignored.
detect the presence of each ECU attached and identify
them. As soon as network analysis is complete then the After setting up the VP, the user must now select the
main form will come into view. alternative languages files which are to be sent to the EMS
module for storage. The EMS is able to select an
There are also many error checks made with respect to the alternative operating language apart from English (the
operation of the DLA, should any issues with DLA errors be default language in all JCB machines).
encountered you will need to read DLA Trouble Shooting.
Click the left mouse button or select the "Next" button, on
HPSetup should now be ready for use. the languages tab sheet. Use the country drop down list
box to display the list of alternative languages supported
3 Setting Up A Vehicle Profile by HPSetup. The text boxes below the country list box
display up to three alternative languages that will be stored
The Vehicle Profile (VP) information sent to the machine into the EMS. K Table 4. Language Cross Reference
requires the user to select the following data fields, ( T C-134).
An option has been provided to program the languages
Model Number Drop down list of currently
independently of programming the complete vehicle VP,
supported machines from
this way it is somewhat simpler to update language text
which the user is to select one
when moving the vehicle from one location to another.
particular value. This selection
in turn controls the number
The VP is now ready to be written.
and type of options available
(and some default settings
Click on the "Write" button (or F12) to have the current VP
which cannot be changed) for
written to the machine. The diagnostics messages
that particular model.
received during read and write operations are displayed in
Serial Number Must be completed before the the canvas area provided. Verifying the write can be done
VP can be written to the by clicking the "Read" button (F11). This reads the data
vehicle. back from the ECU1 (it does not however read the
Build Date Date the machine was first contents of the alternative language tables). Check the
programmed. values read back against your original settings.
Alternative Languages Pre-defined display text used
on EMS.
Models Options List of fitted options on vehicle,
as required to complete
customer requirements. (see
guidelines)
C-129 9803/9800-3 C-129
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JCB Servicemaster
4 Writing Vehicle Profile <F12>
The user can program the vehicle connected using the
"Write" button at any time (or pressing F12 key). Several
programming checks are made to ensure all required
values are made (Model Type, Languages etc.) to ensure
the data written will not make any invalid conditions in the
vehicle system.
The "Write" button is disabled if the network connection is
not available, try the Connect button first if this is the case.
5 Reading Vehicle Profile <F11>
On occasion it may be necessary for the VP to be read
back from ECU1 to check settings or pre-load current
settings ready for updating because of new options being
fitted to the vehicle.
Connect vehicle to the PC via the DLA, power up the
vehicle and then run HPSetup.
Click the "Read" button.
When the data has been read from ECU1 it is stored
back into the data entry boxes on the Vehicle Setup
C031190-1
Fig 121. and Languages tab sheets.
Note: It is not possible to extract the contents of the EMS
Language tables from the EMS.
6 Closing HPSetup
Closing HPSetup is performed using normal WINDOWS
based methods of menu selection and/or the clicking of the
"close" icon in the upper right corner of the window title bar.
7 Options - Multi Language Support
From the utilities menu, choose "Select Language" to
select the Language of the country the visual text for the
PC Application (HPSetup) needs to be translated. This
function allows HPSetup to be operated by users from
many countries, thus reducing the need to make many
customised setup service tool applications.
Any language files supplied as part of the HPSetup tool will
be automatically detected by the software and displayed in
C031200 the selection box. Representations are made by National
Fig 122. Flag and some text identifying (region or dialect)
belonging to the country selected. Typically this allows
several regional dialects of any single country to be
selected.
C-130 9803/9800-3 C-130
Section C - Electrics
Fault Finding
JCB Servicemaster
As soon as a new flag is selected all WINDOWS based text
is translated using the translation text files.
C031210
Fig 123.
C-131 9803/9800-3 C-131
Section C - Electrics
Fault Finding
JCB Servicemaster
Guidelines for Setting Up a Vehicle Using the Set Up Tool
Select the options according to the following guidelines
Travel Alarm: For all USA tracked machines or machines fitted with the option travel alarm.
Overload Caution: For all machines with Hose Burst Check Valves (HBCV) option.
Quick Hitch: Machines equipped with quick hitch option.
Lower Wiper: For all machines equipped with lower wiper option
Grab Rotate: For wheeled machines with low flow pipework without priority valve.
Weed Cutter A/Bucket: For wheeled machines with low flow pipework with priority valve.
Low Flow: For tracked machines with low flow pipework (any spec).
Stabilisers (non Auto For all wheeled machines equipped with stabilisers.
Wh):
Add. Work Lamps: Machines equipped with additional cab and counterweight lamps (including JS130HD).
Full Flow Lines: For all machines equipped with full flow pipework (breaker, auxiliary, combined or merged
pump circuits).
Boom priority: For machine equipped with boom priority option (future option).
Custom Options: This allows all above options to be specified for any machine.
This to be used for sales specials only.
Dozer (non Auto Wh.): For XO wheeled and all tracked machines equipped with dozer blade option.
Dig End Isolate: For wheeled machines equipped with the dig end isolation option fitted. (This is standard
on Auto wheeled machines)
Refuelling Pump: For all machines equipped with the refuelling pump option.
Hydraulic Fan: For all machines equipped with the hydraulic fan option.
Cruise Control: For all machines equipped with the cruise control option. (Travel Option is a pre-requisite)
Viscous Clutch Fan: For all machines equipped with the viscous clutch fan option.
Auto Wh. Frt. Stabs: For Auto wheeled machines equipped with the front stabiliser option.
Auto Wh. Rear Stabs: For Auto wheeled machines equipped with the rear stabiliser option.
Auto Wh. Frt. Dozer: For Auto wheeled machines equipped with the front dozer option (and rear dozer or
stabilisers).
Auto Wh. Rear Dozer: For Auto wheeled machines equipped with the rear dozer option (and front dozer or
stabilisers).
Auto Wh. Travel: For Auto wheeled machines equipped with the travel option. (This is a standard option)
Auto Wh. L/H Drive: For Auto wheeled left hand drive machines.
250 hr Oil Change: For machines in areas with poor fuel quality.
C-132 9803/9800-3 C-132
Section C - Electrics
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JCB Servicemaster
Alternative Language Cross Reference
Language tables programmed into the EMS module are
selected using the following table. Pre-defined languages
are automatically loaded when the user selects the
destination territory (country). Up to three languages (in
addition to English) may be stored in the EMS modules,
each of which is operator selectable using EMS menu
functions.
Table 3. Abbreviation Guide
Country Abr Country Abr
Africa AF Italy IT
Austria AT Latin America LA
Belgium BE Luxembourg LU
Bosnia/Croatia BA / Netherlands NL
HR
Canada CA Norway NO
Czech Rep. CZ Poland PL
Denmark DK Portugal PT
East Europe EE Russia RU
Finland FI Spain ES
France FR Sweden SE
Germany DE Switzerland CH
Greece GR Turkey TR
Iceland IS UK UK
Ireland IE USA US
Israel IL Hungarian HU
K Table 4. Language Cross Reference ( T C-134).
C-133 9803/9800-3 C-133
Table 4. Language Cross Reference
C-134
Country Abbreviation
Language AF AT BE BA CA CZ DK EE FI FR DE GR IS IS IE IL IT LA LU NL NO PL PT RU ES SE CH TR UK US HU
HR
English z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z
Czech
Danish
Dutch
Finnish
Flemish
French
German
Greek
Icelandic
9803/9800-3
Italian
Norwegian
Polish
Portuguese
Spanish
Swedish
Turkish
Section C - Electrics
Hungarian
Croatian
z Default Language Alternative Language
JCB Servicemaster
Fault Finding
For explanation of country abbreviations. K Table 3. Abbreviation Guide ( T C-133).
C-134
Section C - Electrics
Fault Finding
JCB Servicemaster
DLA Port Configuration 2 A dialogue box is displayed. Choose the type of
device required and then click "Apply".
Servicemaster 2 can be configured to communicate
through specified ports on the laptop.
1 From any Servicemaster 2 screen click the "Utilities"
tab, scroll down and click "DLA setup"
K Fig 124. ( T C-135).
868640
Fig 126.
3 If the "Parallel/Serial" option is selected a second
dialogue box will appear. The communication ports
that Servicemaster 2 will communicate through and
the order in which it will try and communicate will be
displayed in the window K Fig 127. ( T C-136).
C065920
Fig 124.
Or select "DLA" from the drop down menu and then
double click the "COM port Chooser" icon
K Fig 125. ( T C-135).
868630
Fig 125.
C-135 9803/9800-3 C-135
Section C - Electrics
Fault Finding
JCB Servicemaster
Data Link Adaptor
The DLA is a universal device for connecting several data
communications mediums to the PC via a single piece of
hardware. HPSetup uses the J1939 CAN specification for
on vehicle network and communications. Being one of the
cheapest methods to connect the PC to the vehicle bus the
DLA has proven its ability in applications such as
diagnostics, data logging and vehicle setup procedure
tools like HPSetup. Power for the DLA is taken from the
vehicle power supply via the 15 way connector so it
requires no internal source of power and is self regulating
up to +40V, giving great protection and versatility because
it can be connected to most forms of automotive
machinery operating between 5 and 40V DC. Once
connected to the PC the DLA is auto detected and
initialised by software eliminating any need for the user to
determine port settings, data transfer rates.
DLA Trouble Shooting
Failure of the software to initialise the DLA will prevent any
C043730 read/write operations. This section will help debug the
Fig 127. error and get the DLA working. Follow this list of checks to
perform to help diagnose the problem.
4 To add a new communication port to the list click
"Add". Enter the new port number as required. 1 Cables, ensure that the correct cables are used
K Fig 128. ( T C-136) between the PC/DLA/On-Vehicle connector.
2 Inspect cables for possible damage, replace if
necessary.
3 Check that good firm connections have been made
between all devices.
4 Power up the vehicle and make sure the power LED
on the DLA is ON, if the LED is not illuminated there
may be a problem with the power supplied to the unit
or the DLA regulator system is not working. To check
the power to the DLA unplug the DLA from the
vehicle, use a digital multi-meter to check the voltage
between pins 6 and 8. There should be a minimum of
C043740
Fig 128. 12 V DC (or IGNITION Voltage, see vehicle
specifications) between these two pins. Suspect the
Note: It is recommended that no more than four ports are vehicle power supply if there is not, else the DLA
identified in the list, as this may cause Servicemaster to should be replaced because of a problem with it's
hang when connecting to a vehicle. internal circuitry.
5 With the Vehicle power ON, start HPSetup application
and visually observe the CAN activity LED and note
the error message displayed by the PC. If the LED
does not flash off/ON several times after it has been
initialised by the PC then there is probably a hardware
C-136 9803/9800-3 C-136
Section C - Electrics
Fault Finding
JCB Servicemaster
problem with the DLA. Replace the DLA. Error HPDataLogs
messages displayed by the DLA driver software often
indicates the origin of the problem. It may help to HPDataLogs is an application designed to extract, compile
power down the vehicle, wait a few seconds and then and present operating data taken from a JS Excavators
retry establishing connection. operating the Advanced Management System (AMS) . The
application software connects a PC to the On-Vehicle
network via the DLA (Data Link Adapter) and provides a
simple means of requesting data from the network nodes
(ECU1, EMS and/or ECW1).
Data collected includes operating hours for particular
vehicle functions, hydraulic and coolant statistics. A
secondary function on the application is to download
additional information taken from 'run time' logging, here
D
the Operator places AMS into a mode to collect running
C
B E
A
J F
H G
information for 15 minutes at a time. The application allows
this data to be downloaded, displayed and printed.
Starting HPDatalogs
1 Connect DLA to vehicle On-Board Service connector
and to the Personal Computer that will run the
HPDataLogs application.
2 Open JCB Servicemaster
3 Select the Heavy Products Range of Excavators
4 Click the Data logging icon. K Selecting Service
Tool Applications ( T C-120).
5 The main HP data logging screen will open.
A406132
Fig 129.
6_14
Fig 130.
C-137 9803/9800-3 C-137
Section C - Electrics
Fault Finding
JCB Servicemaster
User Functions
C001870
Fig 134.
C001840
Fig 131. Allows the operator to close the application.
Allows the operator to print the current selected data logs
C001880
Fig 135.
Change the language used for written text in the
application and return to the Servicemaster CFE.
C001850
Fig 132.
Allows the operator to read the current data logs from the
vehicle. After downloading AMS automatically clears old
records ready for next vehicle use. F11 is the shortcut key
to this function. C001890
Fig 136.
View on-vehicle network node status.
C001860
C001900
Fig 133.
Fig 137.
Running data recorded during the operation of the vehicle
View help file.
can be view, downloaded, printed using this feature.
C-138 9803/9800-3 C-138
Section C - Electrics
Fault Finding
JCB Servicemaster
Tab Box Options
The TAB fields to select the Data Log information which
you wish to view.
C001910
Fig 138.
6_16
View about box and application information. Fig 141.
Working Hours Shows accumulated operating hours
Database Selection Criteria for vehicle functions.
Engine Coolant Shows accumulated operating hours
Record sets belonging to vehicle data logs, past and
in several temperature ranges and
present can be selected using the following controls.
data logs of critical events.
Hydraulic Oils Shows accumulated operating hours
in several temperature ranges and
data logs of critical events.
Error Logs View list of Error Logs reported
during the selected period.
Working Hours
VAN12
Fig 139.
Details actual vehicle working hours accumulated for
various operating conditions.
Allows the operator to select from the database the list of
records belonging to a specific vehicle using it's serial
number as the index field. Set this field first.
VAN13
Fig 140.
Data logs belonging to the selected Vehicle serial number
are further filtered by selecting the date on which the logs
were downloaded.
^_17A
Fig 142.
C-139 9803/9800-3 C-139
Section C - Electrics
Fault Finding
JCB Servicemaster
Engine Coolant
Details engine coolant operating conditions and
accumulated operating hours within defined temperature
ranges.
Date Date of the event.
Duration Time in minutes of the event.
Machine Hours Actual engine hours at which the event
took place.
6_17C
Fig 144.
Error Logs
Various error events are recorded and saved as logs for
future analysis by service and engineering personnel. Any
error logs detected and uploaded from the vehicle can be
displayed in the error log tab sheet.
Error Types Details the type of error event logged.
Engine Hours Engine hours at the time the error
6_17B event occurred.
Fig 143.
Duration (min) Time in minutes of the error event. May
Hydraulic Oil be blank or zero depending on the type
of error, some events do not require a
Details hydraulic oil operating conditions since last service duration parameter.
and accumulated operating hours within defined Output Number Identifies the hardware output using
temperature ranges. the system/schematic circuit ID.
Date Date of the event.
Duration Time in minutes of the event.
Machine Hours Actual engine hours at which the event
took place.
C-140 9803/9800-3 C-140
Section C - Electrics
Fault Finding
JCB Servicemaster
6_17D
Fig 145.
C-141 9803/9800-3 C-141
Section C - Electrics
Fault Finding
JCB Servicemaster
HP Control Monitoring being stopped by the vehicle operator. The graph displays
the pump PWM and RPM against time.
Horse power control monitoring is used to record operating
conditions during the 15 minutes prior to the recording The running data logs are retained until the next time the
user requests running data to be recorded.
6_18
Fig 146.
C-142 9803/9800-3 C-142
Section C - Electrics
Fault Finding
JCB Servicemaster
Downloading the Running Data User Input
1 Select and open the running data form from the Zoom: The operator can use the left mouse button to drag
HPDLog applications main menu bar. on an area of the graph, this are will be zoomed in when
the left button is released. To do this the user places the
2 Using the menu options on the running data form now mouse pointer to the upper left part of the area of the
open, select the Read function, alternatively use the graphic which is to be zoomed in, press and hold down the
F11 key. left mouse button and drag the cursor over the area to be
highlighted. Keep dragging the mouse until you reach the
bottom right of the target area and release the left mouse
button. The selected are will then be zoomed into.
Service History
The Service history tool is an application designed to
retrieve and display Service history records stored by
AMS. Simple functionality makes the tool ideal for quick
6_18A
Fig 147. referencing of stored data, additionally import, export and
printing facilities make information exchange between
Exporting Data service and JCB service departments very easy.
The running data form may be exported to a string Several forms of service history events are recorded by the
delimited text file for importing into another Windows EMS module,
based application.
Scheduled Where at pre-defined intervals the
Service Service LED on the EMS display is
Events triggered and the service indicator is
acknowledged by the operator. These
events are generally for must do service
operations as specified in the service
manual.
Unscheduled Are those events that may develop due to
6_18B Service changes to the specification of the
Fig 148. Events machine or the repair of some system
function, system or component. These
Printing Reports unscheduled events are 'added' to the
EMS list of service history events by the
The running data form can be printed out as a document service engineer responsible for the
suitable for distribution or fax purposes. service.
This application is responsible for reading, writing, printing,
import, export and control of the service history records
taken from any HP vehicle.
6_16C
Fig 149.
C-143 9803/9800-3 C-143
Section C - Electrics
Fault Finding
JCB Servicemaster
Using HP Service Allows the user to select
from the database the
HP service can be used as a stand-alone application or service history for any
through the JCB Servicemaster CFE. vehicle that has been
connected to it and 6JUL3
1 Connect Vehicle/DLA/PC using the supplied cables. downloaded.
2 Power up the vehicle. Load service history list
from vehicle attached to
3 Run HPSetup. PC. K Load Service
History ( T C-145).
6JUL4
Open using the Servicemaster CFE.
Import service history
Open Servicemaster CFE. exported from another
Click on the "Service History icon". K Selecting service history user.
Service Tool Applications ( T C-120). K Import Service
6JUL5
Opening using Windows. History ( T C-145).
Click WINDOWS "Start" button on toolbar. Select Export service history,
"RUN... menu item". Use the browse button to locate exports the current service
"HPService.exe". Click OK after selecting the file. history record set to file for
another user to import.
6JUL6
K Export Service
History ( T C-145).
Delete service history,
deletes the current list of
entries from the Database.
K Delete Service
^JUL7
History ( T C-146).
Print Service Record the
current service history.
K Printing Service
History ( T C-146).
6JUL8
Add Service Record,
allows the user to insert a
6JUL1
record into the current
Fig 150.
Vehicle service history. A
6JUL9
special option for Services
The HP service application will open and look like that
which are not pre-planned.
shown.
K To Add A Service
History
Record ( T C-146).
C-144 9803/9800-3 C-144
Section C - Electrics
Fault Finding
JCB Servicemaster
Load Service History
Service history records can be taken from the vehicle by
clicking on the "Load service History" button. K Using HP
Service ( T C-144).
The list of service history records are then stored in the
local database in a chronological order, as shown below.
VAN38
Fig 152.
All Import/Export files have the .shi extension.
6JUL10
Fig 151. After importing the file it is displayed in the usual SH grid.
In the example above four SH records have been saved Export Service History
from the vehicle detailing the service interval, current
engine hours at the time of service and the dealer code of The currently displayed list of service history records can
the service centre who performed the service. be exported to a file for distribution to other users who are
interested with any of the information stored in the records.
Should the module recording the SH ever be replaced the
service history manager safely keeps this data and will To export service history records, select from the vehicle
append the new records from the replaced module. But serial number list the serial number belonging to the
this will only be true as long as the serial number of the vehicle that is to be exported. Click the export service
vehicle is not changed and engine hours are 'set' to history button to open the 'Save as...' dialogue box, (shown
approximately the old number of engine hours prior to below). Enter or select a file name (for over-writing) that is
exchange. to receive the exported data. K Using HP
Service ( T C-144).
Import Service History
The service history manager provides tools for Importing
and exporting individual SH records from one personal
computer to another, this makes the task of sharing
information very easy over a largely distributed computer
system.
To import a file the user simply clicks on the "Import
Service History" button and then use the dialogue box to
locate the file that is to be imported. K Using HP
Service ( T C-144).
VAN37
Fig 153.
The click the 'Save' button to have the table contents
exported.
C-145 9803/9800-3 C-145
Section C - Electrics
Fault Finding
JCB Servicemaster
Printing Service History To Add A Service History Record
The service history of any vehicle can be printed using the Connect the vehicle, power up and make sure the PC has
default printer settings of the PC running the application. logged onto the vehicle network.
How to Print Service History: Click the "Add Service History Record" button. K Using
HP Service ( T C-144).
Use the vehicle serial number selection box to select a set
of History Records. In the form below enter the dealership code and a
comment (up to 30 characters maximum) relating to the
nature of the unscheduled service.
6JUL3
Fig 154.
Click the "Print" button. K Using HP Service ( T C-144).
Delete Service History
The currently selected vehicle service history may be
deleted at any time. 6JUL11
Fig 156.
How to Delete a Service History:
Click the "OK" button to send the record to the vehicles
Use the vehicle serial number selection box to select a set internal service history table. The "OK" button is only
of History Records. enabled when valid data is entered into the dealer code
and comment fields.
Closing HPService
To close HPService use the exit menu item on the
6JUL3
Fig 155. HPService main window menu bar.
Click the "Delete" button. K Using HP
Service ( T C-144).
Add Service History Record
At some point in time a vehicle may undergo some form of
service operation that is outside of the normal preset
service intervals. This option allows the service engineer to
include into the vehicles current service history list an entry
for a non-scheduled service event. The special
significance of this event is two fold, firstly because the
scheduled hours are 'unscheduled' then we must set the
service interval to zero and because we have the ability to
enter text into the comments field the service engineer can
associate text with the unscheduled service event.
C-146 9803/9800-3 C-146
Section C - Electrics
Fault Finding
JCB Servicemaster
FLASH Programming Application
"FLASHLOADER" Training Guide
This application is primarily based on a generic FLASH
programming design which requires little information back
from the module that is to be programmed other than it's
source address (SA) utilises the DLA to link to the on-
vehicle CAN network to obtain network node information
and to pass the FLASH program application code.
To limit use to the JCB Heavy Products application
operator selections have been limited to programming the
ECU1, EMS and the ECUW. Other operator input is
restricted to supplying the file names for applications that
are to be written to the individual network nodes.
Using FLASHECU
Preparation
C065930
Fig 158.
1 Connect DLA to PC and to the on-vehicle connector
using the DLA cables provided. Select ECU module icon to be programmed.
2 Power up vehicle with engine off and check vehicle is
operational.
Opening FLASHECU application
C065950
1 Open the JCB Servicemaster desktop. Fig 159.
2 Select the Heavy Products JS Excavator product Use the browse buttons or type into the text input box the
range name of the file to be programmed into the ECU module.
3 Click on the flash icon shown below. Programming FLASH
Only those ECU modules detected on the network can be
programmed. After selecting the application to program
into FLASH click the "Start" button. Confirm if appropriate.
FLASH programming will begin immediately.
C065580
The progress bar indicates FLASH programming progress.
Fig 157.
Stop Programming
4 The application should open as shown
The "Stop" button terminates programming at any time, the
side effect of this will be that any embedded code already
existing prior to reprogramming will be corrupted. The
"Stop" button is only to be used if the 'progress' of the
FLASH function stalls, then the FLASH program will be
interrupted to bring the target ECU into program mode
once again.
C-147 9803/9800-3 C-147
Section C - Electrics
Fault Finding
JCB Servicemaster
The following message indicates an error occurred during Introduction to the Diagnostics Tool
programming. "redo" the flash loading procedure
The diagnostics window provides a framework for
analysing each functional section of the vehicle. It does
this by requesting and collecting data from the vehicle
network using the DLA (Data Link Adapter). The data after
filtering and interpretation is then used to display the
current real time state of I/O, running data values etc. of
the particular function control circuit under observation.
Because the diagnostics tool adds little overhead to the
C065980 CAN Bus or loading on the ECU nodes it operates
Fig 160. unnoticed, thus retaining a high degree of real time
efficiency.
The following message indicates that programming has
been completed successfully. For information on using this diagnostic tool see the
following sections:
1 Connecting to the Vehicle
2 Starting Diagnostic Mode
3 Analysing Circuits
4 Stopping Diagnostic Mode
C065990
Fig 161.
5 Language Preferences
The status bar located at the bottom of the diagnostic tool
window shows some CAN network information. The CAN
address of each of the modules (if present) are shown in
the ECU, ECUW and EMS sections. The red and green
indicator lights turn on when there are messages received
or sent by the diagnostic software.
C-148 9803/9800-3 C-148
Section C - Electrics
Fault Finding
JCB Servicemaster
C066000
Fig 162.
C-149 9803/9800-3 C-149
Section C - Electrics
Fault Finding
JCB Servicemaster
Connecting to the Vehicle
The DLA supplied to JCB and related dealerships is the
only tool required to connect to the vehicle's onboard CAN
network.
You will require a PC with Windows and a parallel printer
port, serial port or USB. A cable is supplied with the DLA
D
and is specifically designed for this application.
C
B E
A
J F
H G
Connect the DLA to your computer's port using the
cable supplied with the DLA.
Attach the second cable between the DLA and the on
vehicle service connector 163-A.
Power up the vehicle.
Ensure that the power LED on the DLA is illuminated.
A406132
416401-C1 Fig 164.
A
406410-C1
Fig 163.
C-150 9803/9800-3 C-150
Section C - Electrics
Fault Finding
JCB Servicemaster
Starting Diagnostic Mode
To start the diagnostic mode, press the green "Start"
button, or select "Start Diagnostics" from the "Options"
menu.
C066010
Fig 165.
When the diagnostic mode is started:
the diagnostic software checks the vehicle model
number and installed options and displays only the
diagnostic functions that are available on the vehicle.
C066030
starts the real time monitoring of the vehicle's Fig 166.
systems.
all of the circuit diagram windows are continuously The fuel level diagram shows the current fuel level in %.
refreshed with the current values.
Note: If the DLA is not connected to the computer or it is
not powered, you will see an error message when starting
the diagnostics mode. You will be asked to retry or cancel.
If you click "Cancel", the diagnostic mode will start but will
not be able to show any real time information from the
vehicle. If you press "Retry", after connecting and turning
on the DLA, the diagnostic mode will start and the real time
information will be shown.
Circuit Diagrams C066040
Fig 167.
The circuit diagrams provide you with real time information
while the diagnostic software is running. The state or level
of all inputs and outputs of each functional circuit are
shown and continually updated as the conditions on the
vehicle change. This information allows for quick
troubleshooting of the vehicle. There are two example
circuit diagrams below showing the style of the diagnostic
information.
The horn diagram shows the state (on/off) of the horn
switches and the state of the output that drives the horn.
C-151 9803/9800-3 C-151
Section C - Electrics
Fault Finding
JCB Servicemaster
Indicator Lights (LEDs) key is also visible in the lower left hand corner of the main
HP Diagnostics window.
The indicator lights in the diagnostic circuit diagrams will
appear in one of the states (colours) below. This colour
Off (Dark Green) - the input or output is off or inactive.
On / Active (Light Green) - the input or output is on or activated.
Not Present (White) - this option is not available on this machine
Open Circuit (Aqua) - the output is in an open circuit condition indicating that there is nothing connected to
the output (PWM and High Side outputs only).
Short Circuit (Red) - the output is in a short circuit condition indicating that the output is connected directly
to the battery or earth ground (PWM and High Side outputs only).
Overheated (Fusia) - the output has registering an overheat condition
No Voltage (Yellow) - the output circuit does not have battery power indicating that a fuse may be open
(PWM and High Side outputs only).
Active PWM (Purple) - the output is on.
No Data (Grey) - no data is being received by the ECU.
C-152 9803/9800-3 C-152
Section C - Electrics
Fault Finding
JCB Servicemaster
Stopping Diagnostic Mode Language Setting
To stop the diagnostic mode, press the red "Stop" button or Select "Preferences" from the "Options" menu to view the
select "Stop Diagnostics" from the "Options" menu. preferences dialogue. To change the language used by the
diagnostic tool software, select the desired language from
the list of supported languages.
All language files supplied as part of the diagnostic tool will
be automatically detected by the software and displayed in
C066020 the selection box. Representations are made by national
Fig 168. flag and some text identifying (region or dialect) belonging
to the country. This allows several regional dialects of any
Stopping diagnostic mode will stop the real time monitoring single country to be made available.
of the vehicle and disengage the DLA from the CAN
network. The circuit diagram windows are not refreshed As soon as a new language is selected and the "OK"
with new values. button is pressed, all of the program's text is translated
(changed) using the selected language file.
C-153 9803/9800-3 C-153
Section C - Electrics
Fault Finding
JCB Servicemaster
Electrical Fault Text Messages Note: 1 Open circuits can only be detected when the
output has been turned off. Open circuit s are indicated by
Displayed on the EMS.
100 series codes.
Electrical fault error code. Note: 2 Short circuit conditions can only be detected when
the output is turned on. Short circuits are indicated by a
Electrical errors are displayed immediately on the EMS 200 series code.
with an alarm buzzer. Pressing "ACK" stops the buzzer
and cause the messages to become repetitive. Note: 3 Open circuits, short circuits and no voltage
detections cannot be done on the low side drivers.
Note: 4 See Harness Data
Error Codes Error String Description
101 CRANK A crank signal was not detected by the ECU1.
102 FUEL The fuel sensor is open-circuit
103 EN TMP The engine temperature sensor is open-circuit.
104 HYD TMP The hydraulic temperature sensor is open-circuit.
105 SET PT The throttle set potentiometer is open-circuit.
106 SENS PT The throttle sense potentiometer is open-circuit.
107 OIL SW The oil pressure switch is reporting oil pressure is present when the engine is not
running.
108 FLYWHEEL The flywheel sensor is reporting an engine speed even though the engine is not
running.
109 ALT The alternator is reporting a voltage even when the engine is not running.
110 THR SOL The throttle solenoid is open-circuit. This can only be detected when the engine is not
running.
111 BOOM SP The boom lower speed regulation output is open-circuit.
113 MAX FLW "The max flow solenoid is open-circuit. For JS200W machines, this error can only be
detected when the engine is not running due to the fact that this is a proportional valve
on these machines.
115 BOOM The boom priority solenoid is open-circuit.
116 FL PMP The refuel pump output is open-circuit.
117 HORN The horn output is open-circuit.
118 HYD PMP "The hydraulic pump is open-circuit. Because this is a proportional valve, this error can
only be detected when the engine is not running. "
119 SLW LCK The slew lock solenoid is open-circuit.
120 HYD FAN The hydraulic fan output is open-circuit. This can only be detected when the engine is
not running.
121 SLW BRK The slew brake solenoid is open-circuit.
122 SLW ST The slew shut off solenoid is open-circuit.
127 TL CHNG The travel change solenoid is open-circuit.
128 WASHER The washer motor is open-circuit.
129 DOZER The dozer solenoid is open-circuit.
C-154 9803/9800-3 C-154
Section C - Electrics
Fault Finding
JCB Servicemaster
Error Codes Error String Description
130 GRB CW The grab/rotate clockwise solenoid is open-circuit.
131 GRB CCW The grab/rotate counter-clockwise solenoid is open-circuit.
132 LW FLOW The low flow solenoid is open-circuit.
133 ISOL The hydraulic isolator solenoid is open-circuit.
135 2 STAGE The 2nd stage relief solenoid is open-circuit.
136 QK HTCH The quick hitch solenoid is open-circuit.
138 HAMMER The hammer solenoid is open-circuit.
139 CUSHION The hard/soft cushion solenoid is open-circuit.
142 ENG SD The engine shutdown output is open-circuit.
143 GLW PLG The glow plugs output is open-circuit.
156 TL FLW3 The travel flow 3 solenoid is open-circuit.
157 TL FLW2 The travel flow 2 solenoid is open-circuit.
158 GR CHNG The M2 or gear change solenoid is open-circuit.
159 BRKE LT The brake light output is open-circuit.
160 AXLE LK The axle lock solenoid is open-circuit.
161 STAB UP The stabilizer up solenoid is open-circuit.
162 STAB DN The stabilizer down solenoid is open-circuit.
163 STAB LH The stabilizer left solenoid is open-circuit.
164 STAB RH The stabilizer right solenoid is open-circuit.
165 CRUISE The cruise control solenoid is open-circuit.
166 DIG ISL The dig end isolation solenoid is open-circuit.
167 PRK BK The M1 or park brake solenoid is open-circuit.
168 DRV ISL The drive isolate solenoid is open-circuit.
202 FUEL The fuel level sensor is short-circuit.
203 EN TMP The engine temperature sensor is short-circuit.
204 HYD TMP The hydraulic temperature sensor is short-circuit.
205 SET PT The throttle set potentiometer is short-circuit.
206 SENS PT The throttle sense potentiometer is short-circuit.
210 THR SOL The throttle solenoid is short-circuit. This can only be detected when the engine is not
running.
211 BOOM SP The boom lower speed regulation output is short-circuit.
212 INT LT The interior light is short-circuit.
213 MAX FLW "The max flow solenoid is short-circuit. For JS200W machines, this error can only be
detected when the engine is not running due to the fact that this is a proportional valve
on these machines.
214 BEACON The beacon output is short-circuit.
215 BOOM PR The boom priority solenoid is short-circuit.
216 FL PMP The refuel pump solenoid is short-circuit.
C-155 9803/9800-3 C-155
Section C - Electrics
Fault Finding
JCB Servicemaster
Error Codes Error String Description
217 HORN The horn output is short-circuit.
218 HYD PMP "The hydraulic pump is short-circuit. Because this is a proportional valve, this error can
only be detected when the engine is not running."
219 SLW LCK The slew lock solenoid is short-circuit.
220 HYD FAN The hydraulic fan solenoid is short-circuit. The fault can only be detected when the
engine is not running.
221 SLW BRK The slew brake solenoid is short-circuit.
222 SLW ST The slew shut off solenoid is short-circuit.
223 LW WIPR The lower wiper motor is short-circuit.
224 WIPER The wiper motor is short-circuit.
225 LH CAB LT The boom work light is short-circuit.
226 RH CAB LT The toolbox work light is short-circuit.
227 TL CHNG The travel change solenoid is short-circuit.
228 WASHER The washer motor is short-circuit.
229 DOZER The dozer solenoid is short-circuit.
230 GRB CW The grab/rotate clockwise solenoid is short-circuit.
231 GRB CCW The grab/rotate counter-clockwise solenoid is short-circuit.
232 LW FLOW The low flow solenoid is short-circuit.
233 ISOL The isolator solenoid is short-circuit.
234 EMG STP The emergency stop solenoid is short-circuit.
235 2 STAGE The 2nd stage relief solenoid is short-circuit.
236 QK HTCH The quick hitch solenoid is short-circuit.
237 TL ALRM The travel alarm output is short-circuit.
238 HAMMER The hammer solenoid is short-circuit.
239 CUSHION The hard/soft cushion solenoid is short-circuit.
240 BOOM LT The boom work light is short-circuit.
241 TLBX LT The toolbox work light is short-circuit.
242 ENG SD The engine shutdown solenoid is short-circuit.
243 GLW PLG The glow plugs are short-circuit.
244 CNT LT The counter-weight work light is short-circuit.
245 LH IND The LH turn indicator is short-circuit.
246 LH SIDE The LH sidelight is short-circuit.
247 LH FOG The LH fog light is short-circuit.
248 LH MAIN The LH main beam is short-circuit.
249 LH DIP The LH dip beam is short-circuit.
250 RH IND The RH turn indicator is short-circuit.
251 RH SIDE The RH sidelight is short-circuit.
252 RH FOG The RH fog light is short-circuit
C-156 9803/9800-3 C-156
Section C - Electrics
Fault Finding
JCB Servicemaster
Error Codes Error String Description
253 RH MAIN The RH main beam is short-circuit.
254 RH DIP The RH dip beam is short-circuit.
255 HZD LED The hazard LED is short-circuit.
256 TL FLW3 The travel flow 3 solenoid is short-circuit.
257 TL FLW2 The travel flow 2 solenoid is short-circuit.
258 GR CHNG The M2 or gear change solenoid is short-circuit.
259 BRKE LT The brake light output is short-circuit.
260 AXLE LK The axle lock solenoid is short-circuit.
261 STAB UP The stabilizer up solenoid is short-circuit.
262 STAB DN The stabilizer down solenoid is short-circuit.
263 STAB LH The stabilizer left solenoid is short-circuit.
264 STAB RH The stabilizer right solenoid is short-circuit.
265 CRUISE The cruise control solenoid is short-circuit.
266 DIG ISL The dig end isolate solenoid is short-circuit.
267 PRK BK The M1 or park brake solenoid is short-circuit.
268 DRV ISL The drive isolate solenoid is short-circuit.
300 EC1 CAN The ECU1 module is no longer communicating on the CAN bus.
301 ECW CAN The ECUW module is no longer communicating on the CAN bus.
302 THRT CAL The difference between the minimum and maximum calibration points for the throttle
dial pot is less than 100 A/D points.
304 THRT CAL The throttle dial pot is greater than 10% but the engine is still running at the idle position.
This condition must exist for at least 15 seconds before it is reported. This error does
not exist on machines fitted with an EEC.
C-157 9803/9800-3 C-157
Section C - Electrics
Fault Finding
Fault Finding Without Using the JCB Servicemaster Diagnostic Tool
Fault Finding Without Using the JCB Servicemaster Diagnostic Tool
TC-015
Introduction 6 To remove the ECU-1, remove the three Allen screws
which fasten the computers to a frame. To remove the
The AMS system is designed so that all of the components machine harnesses from the computers, undo the
that are connected to the system are able to communicate Allen screw integral to each connector. Re-assembly
with each other. This means not only are the machine is a reversal of this procedure.
hours displayed on the Electronic Monitor (EMS) but also
they are recorded in the Electronic Control Unit 1 (ECU-1). Note: On the ECU-1 the identification letters for the
individual harness connectors and the fixed harness
connections on the computer itself, are the cast letters
Changing Machine Components
(A,B,C) on the body of the computer.This is vital when
identifying connectors and pins during fault diagnosis.
Under such circumstances where fault diagnosis is not
possible by using the JCB Servicemaster diagnostic tool
7 The Facia Switch Panel (FSP) is not affected by any
then the following actions must be taken in circumstances
changes of other components.
where a change of the Electronic Control Unit 1 (ECU-1)
and/or the Electronic Monitor System (EMS) is
The system comprises of the following main electronic
unavoidable.
components:
1 If either a new ECU-1 or new EMS. is fitted to either a
new or old machine, the machines working hours will 170-A Electronic Control Unit -1 (ECU-1)
pass automatically to the new units and upgrade them 169-B Electronic Monitoring System (EMS)
when the machines ignition is switched on.
169-C Fascia switch panel (FSP).
Note: This includes stock machines with over 1 hour
recorded by the AMS system.
B
2 Only under extreme circumstances should either the
ECU-1 or the EMS be transferred to a machine with
lower working hours than the donor machine. The
effect of this would be to automatically transfer the
higher hours information to the recipient machine.
Note: This process is not reversible.
3 When either an ECU-1. or EMS is changed on a
machine, the machine system must be set up again
using the Set Up Service Tool. Without this action
some options previously active would not function
and the throttle system would not be calibrated.
C
4 To remove the EMS unit, carefully pull the unit away
from the facia panel. The unit is held in place by a
retaining seal only and is a tight fit, do not attempt to
lever the unit out as this could cause damage to the
the E.MS and the facia panel. Re-assembly is a
reversal of this procedure.
401740-C1
5 To access the ECU-1,remove the seven panel screws 401741-C1
Fig 169.
from the panel behind the seat and remove panel.
C-158 9803/9800-3 C-158
Section C - Electrics
Fault Finding
Fault Finding Without Using the JCB Servicemaster Diagnostic Tool
C030670-C1
Fig 170.
C-159 9803/9800-3 C-159
Section C - Electrics
Fault Finding
Fault Finding Without Using the JCB Servicemaster Diagnostic Tool
Fault Diagnosis (General) Diagnostic Connector where the Data Link Adaptor
Service Tool connects to the machine 172-B. The value
Note: The method of testing the EMS, and ECU-1 input should be 60 ohms, + / - 5 ohms.
and output voltages is shown in Section C Service
procedures.
Note: K Connector Identification ( T C-176).
Permanent Battery Supply (Ignition Off)
ECU-1 permanent battery supply can be measured at
harness Connector B, Pin 6 ( 24 v+).
EMS permanent battery supply can be measured at
the harness Connector, Pin 13 (24 v +).
Ignition On
E.CU-1 ignition supply can be measured at harness
Connector B, Pin 5 (24 v +).
E.CU-1 output voltages can be measured at harness
Connector B, Pins 1, 2, 7, 8, 13, 14, 19, 20.
EMS ignition supply can be measured at the harness
Connector, Pin 16 (24 v +).
Ground Tests.
E.CU-1 grounds can be tested at harness Connector
B, Pins 11,17, 23, and harness Connector C, Pins 9, C030670
10. Fig 171.
E.MS grounds can be tested at the harness
Connector, Pins 14, 17, 18. Unit Tests.
Can - Bus Network Tests. Check the resistance between Pin 6 and Pin 7 on the EMS.
unit, the reading should be 120 ohms + / - 10 ohms.
If all 3 travel mode symbols flash together, this would
Check the resistance between Pin 15 and Pin 21 on the
indicate a Can - Bus Network problem, use the Harness
ECU-1 unit connector 172-B, the reading should be 120
Tests and the Unit Tests to identify the faulty component.
ohms + /- 0 ohms.
Harness Tests.
Check for continuity between:
EMS harness Connector Pin 6 and ECU1. harness
Connector B, Pin 21.
Check for continuity between EMS harness Connector Pin
7 and ECU1 harness Connector B, Pin 15.
Check the resistance between Pin 7 and Pin 8 at the -
C-160 9803/9800-3 C-160
Section C - Electrics
Fault Finding
Fault Finding Without Using the JCB Servicemaster Diagnostic Tool
the input and output voltages is shown in, Section C
Service Procedures.
ECU-1. stores the following data log Information:
Hydraulic Overheating.
Engine Overheating.
No Throttle.
Throttle Re-calibration.
Air Filter Blocked.
Low Air Pressure.
Low Engine Oil Pressure.
If the ECU-1 is changed the data log Information stored in
it will not be transferred to the new unit, therefore if
B 416401-C2
possible the data log Information must be downloaded
A before the changes take place.
416401-C2
Fig 172. EMS Failure.
Fault Diagnosis ECU-1 When the machine is started all 18 warning indicator lamps
should "flash" for approximately 1 second and the
If the engine turns over but will not start, change to "Limp elements within the monitors Liquid Crystal Display (LCD)
Mode" and if the machine starts the ECU-1 may have should come on for the same time period.
failed. This check assumes all other "Engine Failure To
Start" checks have been completed. If there is a failure of the EMS unit, the machine can be
moved by using the "LIMP MODE" switch 172-A located
If there is a failure of the ECU-1 unit, the machine can be behind the seat.
moved by using the "LIMP MODE" Switch 172-A located
behind the seat. Note: The machine will only run at engine idle r.p.m. and
should only be operated in this mode to allow the machine
Note: The machine will only run at engine idle r.p.m. and to be moved to a safe position for repairs. The machine
should only be operated in this mode to allow the machine does not function in the same manner as earlier models
to be moved to a safe position for repairs. The machine fitted with a Redundancy Switch.
does not function in the same manner as earlier models
fitted with a Redundancy Switch. The EMS stores the following data log Information:
To test the ECU-1, several individual circuits can be used Limp Mode Use.
to identify ECU-1 failure. These are basic circuits which do Alternator Low Charge Warning.
not require the use of solenoids but are actuated by the
use of a single switch. Circuit Driver Errors (Open Circuits, Short Circuits, No
Voltage.)
Horn circuit
If the EMS is changed the data log Information stored in it
Wiper circuit will not be transferred to the new unit, therefore if possible
Washer circuit the data log Information must be downloaded before the
Travel alarm circuit (American Machines Only) changes take place.
Work lights circuit
The individual circuit can then be checked by testing the
ECU-1 input and output voltages. The method of testing
C-161 9803/9800-3 C-161
Section C - Electrics
Fault Finding
Fault Finding Without Using the JCB Servicemaster Diagnostic Tool
Fault Diagnosis - Facia Switch Panel
(FSP)
When the ignition is switched ON check all of the switch
buttons LED's function for 1 second.
If not, conduct tests using the JCB Servicemaster
Diagnostic Tool. (Section C)
Confirm +24v ignition supply is on pin 1 of the FSP
connector. Confirm earth on pin 2 of the FSP connector
K Connector Identification ( T C-176).
Carefully remove the facia switch panel 173-C using a thin
bladed screw driver to lever out the unit from the cab panel.
C002050
Fig 173.
Fig 174.
C-162 9803/9800-3 C-162
Section C - Electrics
Service Procedure
Testing of ECU Inputs + Outputs
TC-014_2
Remove panel behind drivers seat, for access to the ECU Testing Low Side Input
A.
With the switch open the meter will read 0v.
With the switch closed the meter will read 24-28v.
ECU
Switch (rocker, momentary,
pressure, level, etc.)
Input
Red lead
V
Black lead
C005840GB
Fig 176.
Testing High Side Input
A
With the switch open the meter will read 0v.
With the switch closed the meter will read 24-28v.
ECU Switch (lights, engine preheat,
C030670-C1
Fig 175. etc.)
Care should be taken when testing the inputs + outputs of Input
the ECU to ensure that correct test method is used to Red lead
determine if the ECU is functioning normally.
V
Note: Inputs/outputs should be checked with engine
Black lead
running or in solenoid override mode, refer to Section C,
EMS Set+Mode (20 sec) Menu. C005850GB
Fig 177.
C-163 9803/9800-3 C-163
Section C - Electrics
Service Procedure
Testing of ECU Inputs + Outputs
Testing Low Side Output Solenoid connected output off = 0.1 V approx.
Solenoid connected output on = battery voltages
With the output off the meter will read 0v. nominal.
Solenoid disconnected output off = reduced voltage
With the output on the meter will read 24-28v. (15 V - 22 V).
Solenoid disconnected output on = battery voltage
Actuator; relay coils nominal.
ECU
Shorted to ground = 0 V.
Shorted high (to positive) = battery voltage.
Output
Red lead ECU
Black lead
µ
+24
C005860GB
Fig 178. Output IN ST
supply +24v
Vbb OUT A
A
Testing High Side Output
With the output off the meter will read 0v. Driver
With the output on the meter will read 24-28v.
Pull up
Resistor 10k
*
Actuator (solenoid, motor,
bulb, horn relay)
ECU C005880GB
Fig 180.
Output
Red lead
Black lead
C005870GB
Fig 179.
The ECU is internally configured to give short circuit
protection and detection of short circuit / open circuit, this
is done by internal resistors. This internal configuration can
give some confusing results when testing the outputs on
the ECU.
Voltage at point A:
C-164 9803/9800-3 C-164
Section C - Electrics
Service Procedure
Using a Multimeter
Using a Multimeter
TC-002
In order to obtain maximum benefit from the fault finding
information contained in Section C it is important that the
technician fully understands the approach to fault finding
and the use of the recommended test equipment, in this
case a FLUKE 85 or AVO 2003 digital multimeter, or a
moving pointer (analogue) multimeter. The approach is
based on a fault finding check list. In tracing the fault from
the symptoms displayed you will be directed to make
measurements using a multimeter.
These instructions are intended to cover the use of the
recommended multimeters.
Fig 182. AVO 2003
Fig 181. FLUKE 85
Fig 183. A Typical Analogue Meter
1 Make sure that the test leads are plugged into the
correct sockets. The black test lead should be
C-165 9803/9800-3 C-165
Section C - Electrics
Service Procedure
Using a Multimeter
plugged into the black socket (sometimes, this socket Measuring Resistance
is also marked by a "-", or "E" or marked as
"COMMON" or "COM"). The red test lead should be 1 Make sure there is no power to the part of the circuit
plugged into the red socket marked with "+", "V" or you are about to measure.
"Ω".
2 Connect one probe at one end of the component or
2 When making measurements ensure that the test wire to be checked and the other probe at the other
probes have a good clean contact with bare metal, end. It does not matter which way round the two
free from grease, dirt, and corrosion as these can probes are placed.
cause a false reading.
3 Select the correct range on the multimeter.
3 When measuring voltage: Make sure that the correct
range is selected, that is set the selector to a value a On the FLUKE 85.
equal to or greater than that you are about to
measure. e.g. If asked to measure 12 Volts, set the i Turn the switch to position 181-C and check
selector to the 12V range. If there is no 12V range, set that the W sign at the right hand side of the
the selector to the next range higher, 20V for display window is on. If the F sign is on
instance. If the meter is set to a range that is too low, instead, press the blue button 181-G to
it may be damaged. e.g. setting to the 2V range to change the reading to Ω. Touch the meter
measure 12V. lead probes together and press the REL3 key
on the meter to eliminate the lead resistance
Measuring DC Voltage from the meter reading.
1 Select the correct range on the multimeter. b On the AV0 2003.
a On the FLUKE 85. i Move the right hand slider switch to position
182-B, and the left hand slider switch to the
Turn the switch to position 181-B. appropriate Ohms (Ω) range.
b On the AV0 2003. c On an analogue meter.
Move the dial to the appropriate Ohms (Ω)
Move the right slider switch to position 182-A, and
i
the left hand slider switch to the appropriate
range.
range.
c On an analogue meter.
Turn the dial to the appropriate DC Volts range.
2 Connect the black probe to the nearest available
suitable earth point, usually this will be the starter
motor earth, the battery negative, or the chassis.
Connect the red probe to the wire or contact from
which you are measuring the voltage.
C-166 9803/9800-3 C-166
Section C - Electrics
Service Procedure
Using a Multimeter
Measuring Continuity Measuring Frequency
1 Make sure there is no power to the part of the circuit The AVO 2003 and the analogue meter are not capable of
you are checking for continuity. measuring frequency, therefore a Fluke 85 digital
multimeter must be used.
2 Connect one probe to one end of the component or
wire to be checked and the other probe to the other 1 Insert the black plug into the COM socket on the
end. It does not matter which way round the two meter and attach the probe to the nearest suitable
probes are placed. earth point on the chassis, for example, the battery
negative terminal.
3 Select the correct range on the multimeter.
2 Insert the red probe into socket 181-J.
a On the FLUKE 85.
3 Turn the selector switch to position 181-A and
Turn the switch to position 181-C and check that depress 181-G repeatedly until 181-F is highlighted
the beeper symbol appears at the left hand side of on the top row of the display.
the display window. If the F sign is on instead,
press the button labelled 181-F in the meter 4 Press button 181-H once.
drawing.
5 Touch or connect the red probe to the frequency
If there is continuity in the circuit, the beeper will source to be measured. Press and hold button if an
sound. If there is no continuity (open circuit), the average reading is required.
beeper will not sound.
b On the AV0 2003.
Move the right hand slider switch to position 182-
B, and the left hand slider switch to position 182-
C.
If there is continuity (i.e. very low resistance)
between two points the buzzer will sound.
c On an analogue meter.
Turn the dial to the lowest Ohms (Ω) range.
If there is continuity (i.e. very low resistance)
between two points the needle will move across
fully (or almost fully) to the right hand side of the
scale.
C-167 9803/9800-3 C-167
Section C - Electrics
Service Procedure
Using a Multimeter
Testing a Diode or a Diode Wire diode wire. If the Avometer does not read "1"
the diode is faulty.
A diode wire is a diode with male connector fitted on one
end and a female connector fitted on the other end. The c On an analogue meter.
diode is sealed in heatshrink sleeving.
i Select the Ohms 1000s (1k) range.
1 To test a Diode or a Diode Wire
Connect the black probe to the end of the
a On the FLUKE 85. diode marked with a band, or to the male
connector of the diode wire, the red probe
i Turn the switch to position 181-D. should be connected to the other end of the
diode or diode wire. The meter should read
ii Press the HOLD button and check that the H 20-400 kΩ, if it reads more than this the diode
sign appears at the top right hand side of the is faulty.
display window.
ii Select the Ohms 100s range.
iii Connect the black probe to the end of the
diode with a band or to the male connector of Connect the red probe to the end of the diode
the diode wire. Connect the red probe to the marked with a band, or to the male connector
other end of the diode or diode wire. If the of the diode wire, the black probe should be
beeper does not sound the diode or diode wire connected to the other end of the diode or
is faulty. diode wire. The meter should read 300-400Ω,
if it reads less than this the diode is faulty.
iv Connect the red probe to the end of the diode
marked with a band, or to the male connector
of the diode wire, the black probe should be
connected to the other end of the diode or
diode wire. If the beeper sounds or the meter
does not read O.L., the diode or diode wire is
faulty.
v Press the HOLD button and check that the H
sign disappears from the right hand side of the
display window.
b On the AV0 2003.
i Move the right hand slider to position 182-A,
and the left hand slider switch to position 182-
C.
ii Connect the black probe to the end of the
diode marked with a band, or to the male
connector of the diode wire, the red probe
should be connected to the other end of the
diode or diode wire. If the Avometer does not
buzz the diode is faulty.
iii Connect the red probe to the end of the diode
marked with a band, or to the male connector
of the diode wire, the black probe should be
connected to the other end of the diode or
C-168 9803/9800-3 C-168
Section C - Electrics
Service Procedure
Battery
Battery
TC-001_4
Maintenance !MWARNING
To ensure that the battery provides optimum performance Batteries give off an explosive gas. Do not smoke
the following steps should be observed: when handling or working on the battery. Keep the
battery away from sparks and flames.
1 Make sure that the electrical connections are clean
and tight. Smear petroleum jelly on connectors to Battery electrolyte contains sulphuric acid. It can burn
prevent corrosion. you if it touches your skin or eyes. Wear goggles.
Handle the battery carefully to prevent spillage. Keep
2 When applicable - never allow the electrolyte level to metallic items (watches, rings, zips etc) away from the
fall below the recommended level - 6 mm (1/4 in) battery terminals. Such items could short the
above the plates. Use only distilled water for topping terminals and burn you.
up.
Set all switches to OFF before disconnecting and
3 Keep the battery at least three quarters charged, connecting the battery. When disconnecting the
otherwise the plates may become sulphated battery, take off the earth (-) lead first.
(hardened) - this condition makes recharging the
battery very difficult. Re-charge the battery away from the machine, in a well
ventilated area. Switch the charging circuit off before
Extra precautions must be taken when bench charging connecting or disconnecting the battery. When you
maintenance free batteries, they are more prone to have installed the battery in the machine, wait five
damage by overcharging than the standard type of battery: minutes before connecting it up.
– Never boost-charge a maintenance free battery. When reconnecting, fit the positive (+) lead first.
5-3-4-12
– Never charge a maintenance free battery at a voltage
in excess of 15.8 Volts.
Testing
– Never continue to charge a maintenance free battery
after it begins to gas.
This test is to determine the electrical condition of the
battery and to give an indication of the remaining useful
'life'.
Before testing ensure that the battery is at least 75%
charged (SG of 1.23 to 1.25 for ambient temperature up to
27°C).
Ensure that the battery is completely disconnected from
the vehicle.
Connect up the battery tester as follows:
1 Set the CHECK/LOAD switch 184-A to OFF.
2 Set rocker switch 184-B to the battery voltage (12V).
3 Connect the red flying lead to the battery positive (+)
terminal and the black flying lead to the battery
negative (-) terminal.
C-169 9803/9800-3 C-169
Section C - Electrics
Service Procedure
Battery
4 Set the CHECK/LOAD switch 184-A to CHECK to
read the battery no-load voltage which should be at
least 12.4 volts.
5 Set the CHECK/LOAD switch 184-A to LOAD and
hold down for 5-10 seconds until the meter reading
stabilises. The reading should be at least 9 volts.
Note: Do not hold the switch in the LOAD position for more
than 10 seconds.
6 K Table 5. Fault Diagnosis ( T C-170), if the
foregoing tests are unsatisfactory. Fig 184. Battery Tester
Table 5. Fault Diagnosis
Battery Tester Readings Remedy
1 CHECK: 0 - 12.6 Volts Renew battery
LOAD: less than 6 Volts
2 CHECK: 6 - 12.4 Volts Recharge and re-test. If tests still unsatisfactory renew
battery.
LOAD: less than 9 Volts and falls steadily but remains
in yellow zone.
3 CHECK: less than 10 Volts Indicates battery has been over-discharged and unlikely to
recover. Renew battery.
LOAD: less than 3 Volts
4 CHECK: more than 11 Volts Charge battery which will probably recover.
LOAD: 6 - 10 Volts steady
C-170 9803/9800-3 C-170
Section C - Electrics
Service Procedure
Battery
Specific Gravity Testing Readings should be as tabulated and should not vary
between cells by more than 0.04. A greater variation
The specific gravity of the electrolyte gives an idea of the indicates an internal fault on that particular cell.
state of charge of the battery. Readings should be taken
using a hydrometer, when the electrolyte temperature is If the electrolyte temperature is other than 15°C (60°F) a
15°C (60°F). If the battery has recently been on charge, 'correction factor' must be applied to the reading obtained.
wait approximately one hour (or slightly discharge the Add 0.07 per 10°C (18°F) if the temperature is higher than
battery) to dissipate the surface charge before testing. 15°C (60°F) and subtract the same if the temperature is
lower.
Table 6. Specific Gravity at 15°C (60°F)
Fully Charged Half Discharged Fully Discharged
Ambient temperature up to 27°C (80°F) 1.270 - 1.290 1.190 - 1.210 1.110 - 1.130
Ambient temperature above 27°C (80°F) 1.240 - 1.260 1.170 - 1.190 1.090 - 1.110
C-171 9803/9800-3 C-171
Section C - Electrics
Service Procedure
Wiring Harness Repair
Wiring Harness Repair
TC-004
Introduction !MCAUTION
Instances do occur where it is necessary to incorporate When the heater is in use, the reflector and the air
auxiliary electrical components into existing electrical coming out are extremely hot. Keep away to avoid
circuits and, although unlikely with present wiring accidental burns. Do not touch the reflector until it has
harnesses, repair or replace specific individual wires within had time to cool down after switching off. If flame
a harness. This will also apply to other machines in reappears at the reflector when the heater is in use, the
addition to those of manufacture. catalytic element is damaged or used up. Stop work
immediately and replace the heater.
To ensure that either the inclusion of an auxiliary electrical ELEC-2-3
component or a repair within a harness is completed to an
acceptable standard it is strongly recommended that the Repair Procedure
following tools, equipment and procedures are always
used. Note that JCB harnesses have an International Table 7. Tools Required
Protection rating of 67 (I.P.67). Part No. Description Qty
892/00350 Butane Heater assembly 1
The sheath covering of the recommended splice is heat
shrunk onto the original wire insulation. This results in a 892/00349 Crimp tool 1
seal and corresponding joint to IP 67 specifications. 892/00351 Splice 0.5-1.5 mm (Red) 50
892/00352 Splice 1.5-2.5 mm (Blue) 50
!MCAUTION 892/00353 Splice 3.0-6.0 mm (Yellow) 50
When installing Auxiliary Electrical Components
always ensure that the additional load rating is 1 Cut the wire and remove the protective insulation for
suitable for that particular circuit. It is unacceptable to a suitable distance dependent upon the size of wire
simply increase the fuse rating as this can cause and splice to be used. For the splices detailed in
overloading and consequential failure of wiring, along K Table 7. ( T C-172), the dimension is 7mm.
with failure of integral circuit components, which the
fuse is protecting.
ELEC-2-1
!MWARNING
In addition to the warnings incorporated into this
procedure, extreme care should be taken when
handling the gas heating tool to ensure that the flame
does not damage or set fire to any items in the vicinity
of the repair, i.e. other wires, floor panels, floor mats,
sound proofing, paintwork, etc. This tool should not
be used in any restricted location prohibiting the use
of "Naked Flames" or where risk of explosive gas or
similar safety parameters apply. No other heat source
should be used to attempt a sealed joint. Fig 185.
ELEC-2-2
2 Using the correct sized splice, attach the new section
of wire required or auxiliary flying lead to the existing
harness and secure using the crimp tool.
K Fig 185. ( T C-172). Note that each of the splices
detailed is colour-coded to make size and range
C-172 9803/9800-3 C-172
Section C - Electrics
Service Procedure
Wiring Harness Repair
readily visible. They are secured using the
corresponding size and matching colour-coded jaws
of the crimp tool to ensure joint security. This tool also
incorporates a ratchet closing mechanism which will
not release until the splice is fully closed to the correct
compression size.
3 With the Butane heater assembly, seal the
connection. K Fig 186. ( T C-173).
a Remove the cap 187-A from the end of the
disposable gas cartridge 187-B.
Fig 188.
d Turn the small ring 189-E so that the air holes at
189-F are completely closed.
Fig 186.
b Before assembling the gas cartridge to the
reflector element 188-C, turn the red ring 188-D to
the left, (in the direction of the minus sign marked
on the ring).
Fig 189.
e Turn the red ring 190-D to the right (in the
direction of the plus sign) in order to turn on the
Fig 187.
gas.
c Position the tube hanging down from inside the
Important: Before turning the heater on, make sure that
reflector assembly into the hole at the top of the
the cartridge is not hotter than the reflector element. This
gas cartridge. Then press the gas cartridge up
may occur if the cartridge is held in the hand for a long
into the reflector assembly as far as possible until
time. The temperature difference between the cartridge
the two elements are clasped firmly together.
and the reflector element may cause long yellow flames to
K Fig 188. ( T C-173). A click will be heard.
appear on ignition.
C-173 9803/9800-3 C-173
Section C - Electrics
Service Procedure
Wiring Harness Repair
g The heater can be used in two modes:
i Side wings 192-G down, reflector head
completely open. In this mode the infra-red
heat waves are dominant (recommended for
the light coloured plastic splices).
Fig 190.
f Hold the heater vertically and, using a match or
cigarette lighter, light the gas as shown.
Hold the heater vertically for 1 to 2 minutes until
the catalytic reaction occurs. This is indicated Fig 192.
when the blue flame fades and the ceramic
element glows red. Then turn the small ring 191- ii Side wings 193-G up, reflector head opening
E until the air holes at 191-F are completely open. reduced. In this mode the heating is done only
The tool is ready for use. by the hot gas (use for dark coloured plastic
splices).
Note: The fact that the sound of liquid cannot be heard
when the cartridge is shaken does not mean it is empty. No
sound will be heard even when the cartridge is full.
Fig 193.
h To switch off the heater, turn the red ring 193-D to
Fig 191.
the left (in the direction of the minus sign).
Table 8.
C-174 9803/9800-3 C-174
Harness Data
C-175
Harness Interconnection
Cab Sub Harness -
Main components connected
to this harness:
Roof
Facia Link Harness -
Main components
connected to this
harness:
Electronic Monitoring
System (EMS)
Power Socket
Radio Mute Switch
Facia Switch Panel
HVAC Controller
9803/9800-3
Main Harness -
Main components
connected to this
harness:
Slew Brake Valve
Main Control Valve
8 Spool Solenoid -
Shuttle Valve
Fuse link - Ignition
Battery
Glow Plugs
Alternator
Starter Motor
Engine
Temperature - Sensors
Work Lights
Section C - Electrics
Cab Harness -
Main components
connected to this
Harness Interconnection
harness:
Electronic Control
ECU1
ECM
Fuses
Harness Data
Voltage Converter
Diagnostic Connector
Wiper motors
Control Lever Switches
Ignition Switch
Throttle Dial
C-175
Interior Light Switch
Fig 194. Harness Location and Interconnection (Type 2 Fascia Harness and Type C Cab Harness Shown)
Section C - Electrics
Harness Data
Main Harness
Main Harness
C5
FULLY TAPED
1 064 Y [300] 37/0.33 (3.00)
2 051 Y [600] 37/0.33 (3.00)
UNTAPED
CONVO
LUTE TUBE
SPACETAPE
C6
24V SUPPLY
1 066. Y [101D] 84/0.36 (8.00) C5
50
60
C110
C176
100
DIODE WASHER
ALT DIODE
C6 1 101 Y [606E] 19/0.19 (0.50) 1 039 Y [545E] 19/0.19 (0.50)
50
2 100 Y [826B] 19/0.19 (0.50) 2 301 Y [545D] 19/0.19 (0.50)
30
ID LABEL
50
S02
20
L 022. Y [826A] 19/0.19 (0.50) R 022 Y [826] 19/0.19 (0.50)
0
C110
L 100 Y [826B] 19/0.19 (0.50) R
100
C176
50
50
50 390 100 200 50
1 C250 1840 10
S01 S02 120
S01
B
15
0
L 032 Y [816] 19/0.19 (0.50) R 033 Y [816A] 19/0.19 (0.50)
50
L 034 Y [816B] 19/0.19 (0.50) R
C250 [C250]
24V ECM IGN SUPPLY Main Wires:
1 247 Y [301] 37/0.37 (4.00)
0
0
S51
C164
1800
100
S50
50
C164
EARTH CONN
C258 1 299 Y [600F] 19/0.19 (0.50)
2 034 Y [816B] 19/0.19 (0.50)
P S
#
!
$ C2
"
%
&
&
! '
'
"
#
#
$ !
$ S51
% !! #
% ! & L 268 - [SCR1] SCREEN R 802 Y [619] 19/0.19 (0.50)
!" !' !
" ' $
!# " "
% Main Wires:
!
!$ &
"
! &
!% !
" '
"# '
!&
"! "
"$ #
"" #
"% $ !
"&
$
% !!
% ! &
!" !'
"
S50
'
!# "
! L 263 - [SCR2] SCREEN R 800 Y [617] 19/0.19 (0.50)
!$ "
!
!% Main Wires:
"
"#
!&
"!
"$
""
"%
"& CUT_BACK_SCR2 [1800]
1 998 - [SCR] SCREEN
C258
C2
CONNECTOR C
CONNECTOR A
1 290. Y [507] 19/0.23 (0.75) 17 276 Y [519] 19/0.23 (0.75) 33 260 Y [534] 19/0.23 (0.75) 1 153 Y [807B] 19/0.19 (0.50) 17 246 Y [402] 19/0.19 (0.50) 33 028 Y [433A] 19/0.19 (0.50)
2 289 Y [510] 19/0.23 (0.75) 18 275 Y [520] 19/0.23 (0.75) 34 (-) 2 002 Y [819] 19/0.19 (0.50) 18 038 Y [546] 19/0.19 (0.50) 34 029 Y [831] 19/0.19 (0.50)
3 288 Y [509] 19/0.23 (0.75) 19 274 R [525] 19/0.19 (0.50) 35 304 Y [535] 19/0.19 (0.50) 3 003 Y [800] 19/0.19 (0.50) 19 017 Y [801] 19/0.19 (0.50) 35 045 Y [416] 19/0.19 (0.50)
4 287 Y [508] 19/0.23 (0.75) 20 273 B [526] 19/0.19 (0.50) 36 305 Y [536] 19/0.19 (0.50) 4 004 Y [806] 19/0.19 (0.50) 20 039. Y [545C] 19/0.19 (0.50) 36 030 Y [750] 19/0.19 (0.50)
5 286 Y [511] 19/0.23 (0.75) 21 (-) 37 259 Y [537] 19/0.32 (1.50) 5 005 Y [812] 19/0.19 (0.50) 21 110 Y [802] 19/0.19 (0.50) 37 031 Y [108C] 19/0.19 (0.50)
6 285 Y [512] 19/0.23 (0.75) 22 271 G [515A] 19/0.19 (0.50) 38 258 Y [538] 19/0.23 (0.75) 6 (-) 22 040 Y [422D] 19/0.19 (0.50) 38 032 Y [816] 19/0.19 (0.50)
7 284 Y [513] 19/0.19 (0.50) 23 270 K [527] 19/0.19 (0.50) 39 257 Y [541] 19/0.23 (0.75) 7 006 Y [815] 19/0.19 (0.50) 23 078 Y [409] 19/0.19 (0.50) 39 (-)
8 283 Y [514] 19/0.23 (0.75) 24 269 S [524] 19/0.19 (0.50) 40 256 Y [540] 19/0.23 (0.75) 8 007 Y [848] 19/0.19 (0.50) 24 019 Y [405] 19/0.19 (0.50) 40 201 Y [421] 19/0.19 (0.50)
9 (-) 25 802 Y [619] 19/0.19 (0.50) 41 255 Y [539] 19/0.23 (0.75) 9 008 Y [825] 19/0.19 (0.50) 25 044 Y [407] 19/0.19 (0.50) 41 062 Y [306B] 19/0.19 (0.50)
10 282 Y [521] 19/0.23 (0.75) 26 267 Y [528] 19/0.23 (0.75) 42 254 Y [542] 19/0.32 (1.50) 10 009 Y [803] 19/0.19 (0.50) 26 021 Y [414] 19/0.19 (0.50) 42 046 Y [820] 19/0.19 (0.50)
11 281 Y [522] 19/0.23 (0.75) 27 266 Y [529] 19/0.23 (0.75) 43 253 Y [529A] 19/0.23 (0.75) 11 010 Y [752] 19/0.19 (0.50) 27 022 Y [826] 19/0.19 (0.50) 43 047 Y [423] 19/0.19 (0.50)
12 (-) 28 265 B [530] 19/0.19 (0.50) 44 (-) 12 036 Y [417B] 19/0.19 (0.50) 28 023 Y [408] 19/0.19 (0.50) 44 048 Y [829] 19/0.19 (0.50)
13 280 Y [523A] 19/0.23 (0.75) 29 264 R [531] 19/0.19 (0.50) 45 (-) 13 012 Y [817] 19/0.19 (0.50) 29 024 Y [827] 19/0.19 (0.50) 45 (-)
14 279 Y [516] 19/0.23 (0.75) 30 800 Y [617] 19/0.19 (0.50) 46 (-) 14 013 Y [406] 19/0.19 (0.50) 30 025 Y [751] 19/0.19 (0.50) 46 (-)
15 278 Y [517] 19/0.23 (0.75) 31 262 Y [532] 19/0.23 (0.75) 47 (-) 15 014 Y [401] 19/0.19 (0.50) 31 026 Y [810] 19/0.19 (0.50) 47 (-)
16 277 Y [518] 19/0.23 (0.75) 32 261 Y [533] 19/0.23 (0.75) 48 (-) 16 015 Y [430] 19/0.19 (0.50) 32 027 Y [830] 19/0.19 (0.50) 48 (-)
Fig 195. Main Harness `A' 332/J4952 issue 2
C-176 9803/9800-3 C-176
Section C - Electrics
Harness Data
Main Harness
FULLY TAPED %&$# #' !
UNTAPED 2 1
CONVO
LUTE TUBE
SPACE TAPE ( '
4 1
3 2
1 2
$# %
%&$# #'
$
1 2
% "%
%
%
%
%
%
$ %
1 2 '*+, !+-./0
%
%
'*+, !+-./0
CONNECT
1 2
1 2
)% !
C
A
!"% ' %
%
%
'*+, !+-./0 1
2
$ % 1 2
%
%
%
! "# $$
'*+, !+-./0
"
1 2
1 2 ! "# $$
Fig 196. Main Harness `B' 332/J4952 issue 2
C-177 9803/9800-3 C-177
Section C - Electrics
Harness Data
Main Harness
1
!# $
4.3mm
!# $
1
2 8.0mm
4.3mm
" !# $
1
1
1
2
2
1
1
!
3 2
"
3 1
B "'() %(*+,-
1
1
2
!
!
D
!
"'() %(*+,-
"'() %(*+,- "'() %(*+,-
"'() %(*+,-
10 8
7 4
A B
3 1
1 2 $
" "&
! % FULLY TAPED
UNTAPED
2 1
CONVO
LUTE TUBE
SPACE TAPE
Fig 197. Main Harness `C' 332/J4952 issue 2
C-178 9803/9800-3 C-178
Section C - Electrics
Harness Data
Main Harness
"&
! !
(
! !
2 1 ! !
C
! !
! !
! ! ! ! !
)*+ *,-./
8.0mm
CONNECT
2 1 1 2
2 1
! !
! ' ! !
! !
# ! ! ! 1 2
! !
! !
5.80mm ! !
! !
$ %& '
! !
! !
1 2
1 2 1 2
"
# ! !
! !
B A
# ! !
! !
! !
FULLY TAPED
C
UNTAPED
CONVO
LUTE TUBE
SPACE TAPE
Fig 198. Main Harness `D' 332/J4952 issue 2
C-179 9803/9800-3 C-179
Section C - Electrics
Harness Data
Main Harness
) #
) #
" "
) # " "
,-. -/012
,-. -/012
FULLYTAPED
# #$ # # #+ # UNTAPED
" " " " " "
" "
" "
" "
" "
" "
CONVO
LUTE TUBE
" "
" " " "
" "
" " " " SPACE TAPE
" "
" " " "
* " "
! " "
$ " " " "
" " " "
" " ! " "
1 2 3 4
5 6 7 8
9 10 11 12
1 4 '% % # #
" "
5 8 " "
" "
9 12 1 2 3
13 16
4 5 6
20
17
$ #
" "
" "
" "
1 2 3 4
5 6 7 8
" "
" "
" "
$ %$
# " "
- +
'% ' %
5.30mm
( " "
) " "
# " "
F
D
!
'
" "
" "
" "
" "
" "
" "
$ " " " "
+ " " * " "
" " "
,-. -/012
" " " " "
% ! " "
" "
" "
2 1
1 2 CONNECT
2 1 1 2
1 2 1 2 & '
" " " "
" " $ " "
# ! " "
" " " ! " "
" "
Fig 199. Main Harness `E' 332/J4952 issue 2
C-180 9803/9800-3 C-180
Section C - Electrics
Harness Data
Main Harness
FULLYTAPED
UNTAPED
!$ #$$&
"") #"# CONVO
LUTE TUBE
" &
(
SPACE TAPE
1 2 1 2
1 2
1 2 #%$ !$
$
' #
#
)+,- ,./01
50
E 1 2
CONNECT
1 2
! " ! #$
1 2 1 2
1 2 1 2
)* &" # $%$# "
'
!
Fig 200. Main Harness `F' 332/J4952 issue 2
C-181 9803/9800-3 C-181
Section C - Electrics
Harness Data
Fascia Link Harness - Type 1
Fascia Link Harness - Type 1
TC-016
Connector Location
2 4, 6
9
11, 12, 13, 14,15
1 5
3
10
8 7
A407772
Fig 201.
Connector Identification
Table 9.
Item Connector Function Location
1 C14 Monitor EMS K Fig 202. ( T C-183) & K Fig 203. ( T C-184)
2 C15 Facia Switch Panel K Fig 202. ( T C-183) & K Fig 203. ( T C-184)
3 C24 Worklamp Switch K Fig 202. ( T C-183) & K Fig 203. ( T C-184)
4 C309 Cigar Lighter K Fig 202. ( T C-183) & K Fig 203. ( T C-184)
5 C49 Road Light Switch (Red Marker -Tape) K Fig 202. ( T C-183) & K Fig 203. ( T C-184)
6 C159 Cigar Lighter Illumination K Fig 202. ( T C-183) & K Fig 203. ( T C-184)
7 C180 Cab 1 (Cab Harness connection) K Fig 202. ( T C-183) & K Fig 203. ( T C-184)
8 C181 Wheeled Harness K Fig 202. ( T C-183) & K Fig 203. ( T C-184)
9 C223 Radio Mute switch K Fig 202. ( T C-183) & K Fig 203. ( T C-184)
10 C225 Cab 3 (Cab harness connection) K Fig 202. ( T C-183) & K Fig 203. ( T C-184)
11 430 Panel Illumination K Fig 203. ( T C-184) (heater only)
12 410 Fresh/Recirc. 2 K Fig 203. ( T C-184) (heater only)
13 420 Fresh/Recirc. 1 K Fig 203. ( T C-184) (heater only)
14 380 Water Valve K Fig 203. ( T C-184) (heater only)
15 370 Blower Speed Switch K Fig 203. ( T C-184) (heater only)
C-182 9803/9800-3 C-182
Section C - Electrics
Harness Data
Fascia Link Harness - Type 1
721/12510
Fig 202. Machines with Heater 721/12510 issue 1
C-183 9803/9800-3 C-183
Section C - Electrics
Harness Data
Fascia Link Harness - Type 1
721/12509
Fig 203. Machines with ATC 721/12509 issue 1
C-184 9803/9800-3 C-184
Section C - Electrics
Harness Data
Fascia Link Harness - Type 2
Fascia Link Harness - Type 2
Connector Location
2 4
9
11, 12, 13, 14,15
1 5
3
7
8
A407772
Fig 204.
Connector Identification
Table 10.
Item Connector Function Location
1 C14 Monitor EMS K Fig 205. ( T C-186) & K Fig 206. ( T C-187)
2 C15 Facia Switch Panel K Fig 205. ( T C-186) & K Fig 206. ( T C-187)
3 C24 Worklamp Switch K Fig 205. ( T C-186) & K Fig 206. ( T C-187)
4 C309 Power Socket K Fig 205. ( T C-186) & K Fig 206. ( T C-187)
5 C49 Road Light Switch (Red Marker -Tape) K Fig 205. ( T C-186) & K Fig 206. ( T C-187)
7 C180 Cab 1 (Cab Harness connection) K Fig 205. ( T C-186) & K Fig 206. ( T C-187)
8 C181 Wheeled Harness K Fig 205. ( T C-186) & K Fig 206. ( T C-187)
9 C223 Radio Mute switch K Fig 205. ( T C-186) & K Fig 206. ( T C-187)
11 430 Panel Illumination K Fig 206. ( T C-187) (heater only)
12 410 Fresh/Recirc. 2 K Fig 206. ( T C-187) (heater only)
13 420 Fresh/Recirc. 1 K Fig 206. ( T C-187) (heater only)
14 380 Water Valve K Fig 206. ( T C-187) (heater only)
15 370 Blower Speed Switch K Fig 206. ( T C-187) (heater only)
C-185 9803/9800-3 C-185
C-186
14 13
2 1
12
15 11
9803/9800-3
Section C - Electrics
UNTAPED
Fascia Link Harness - Type 2
CONVOLUTE TUBE
SPACE TAPE
T044150
Fig 205. Machines with Heater 332/J3258 issue 2
Harness Data
C-186
C-187
7
9803/9800-3
UNTAPED
CONVOLUTE TUBE
SPACE TAPE
T044160
Fig 206. Machines with ATC 332/J3257 issue 2
Section C - Electrics
Fascia Link Harness - Type 2
Harness Data
C-187
Section C - Electrics
Harness Data
Cab Harness - Type A
Cab Harness - Type A
TC-017
Connector Location
For connector identification K Table 11. ( T C-189)
25 26 27 22 34
28 13
10, 11, 12
32,33
1, 2, 3, 4
29
31
16, 17, 18, 14 15
20, 21, 22
35, 36 47
39 40
41
43
5, 7, 9, 38 8, 50, 51
49
52, 53
48
6 55
37
56
54
Fig 207.
C-188 9803/9800-3 C-188
Section C - Electrics
Harness Data
Cab Harness - Type A
Connector Identification Item Connector Function
29 C1 Connector A
Table 11.
Item Connector Function 30 - 37 K Cab Harness `E' 721/12522 - Issue
1 ( T C-194)
1 - 10 K Cab Harness `A' 721/12522 - Issue
1 ( T C-190) 30 C4 Wheeled Cab (Not used)
1 C0173 Earth Header 31 C164 Earth Connection
2 C0174 Earth Header 32 C6 24V Supply (Ignition)
3 C0175 Earth Header 33 C5 24V Supply (Battery)
4 C0176 Earth Header 34 C37 Cab Sub Harness
5 C115 Lever Limit Switch 35 C180 Facia Link 1
6 C222 Interior Lamp Switch 36 C225 Facia Link 3
7 C33 (Dozer On Switch (wheeled only)) 37 C21 HVAC Unit Control (Air Con)
8 C32 Lever Hammer Switch 38 - 46 K Cab Harness `F' 721/12522 - Issue
1 ( T C-195)
9 C34 Horn Switch (Red Marker Tape)
38 C65 Boom Priority Switch
10 C0009 Auto Fan
39 C201 Lower Wiper
11 - 21 K Cab Harness `B' 721/12522 - Issue
1 ( T C-191) 40 C112 Breaker Pilot Switch
11 C0007 Auxiliary 1 41 C167 Merge Solenoid Valve B
12 C0202 Auxiliary 2 42 C163 Merge Solenoid Valve C
13 C224 Voltage Converter 43 C169 Hammer/Auxiliary Solenoid Valve C
14 C210 Diagnostic Connector 44 C71 Boom up P Switch
15 C13 Redundancy Switch 45 C73 Swing Pilot P Switch
16 C228 Lower Wiper (Diode) 46 C221 Auto Mode P Switch
17 C227 Wiper 2 (Diode) 47 - 56 K Cab Harness `G' 721/12522 - Issue
1 ( T C-196)
18 C110 Diode 1 Washer
47 C203 Heated Seat
19 C161 Diode 5
48 C160 Optional Hydraulic Switch
20 C155 Diode 3 Redundancy 1
49 C22 Throttle Dial
21 C156 Diode 4 Redundancy 2
50 C31 Right hand Lever Switch
22 - 27 K Cab Harness `C' 721/12522 - Issue
1 ( T C-192) 51 C30 Grab (Red Marker Tape)
22 C236 Fuse Box 52 C23A Key Switch
23 C255 Lift Pump Fuse 53 C23B Key Switch
24 C230 Refuel Pump Relay 54 C43 Boom Priority Switch
25 C8 Electronic Control Unit (ECU) A 55 C202 Heated Seat Switch (Green Marker -
Tape)
26 C9 Electronic Control Unit (ECU) B
56 C200 Lower Wiper Switch (Green Marker -
27 C10 Electronic Control Unit (ECU) C Tape)
28 - 29 K Cab Harness `D' 721/12522 - Issue
1 ( T C-193)
28 C252 Tier 3 Link
C-189 9803/9800-3 C-189
Section C - Electrics
Harness Data
Cab Harness - Type A
Fig 208. Cab Harness `A' 721/12522 - Issue 1
C-190 9803/9800-3 C-190
Section C - Electrics
Harness Data
Cab Harness - Type A
PVC TUBE C0210 [C11]
FULLY TAPED
14 C
D DIAGNOSTIC CONN
A 111 Y [111B] 19/0.19 (0.50)
UNTAPED E
B A B 270 Y [270UY] 19/0.26 (1.00)
FIT WIRE 225 INTO CAVITIE C 223 R [223R] 19/0.19 (0.50)
CONVOLUTE TUBE D 224 U [224U] 19/0.19 (0.50)
E OF CONNECTOR C0210
F E
C0210_1 [C11_1] F
J G
DIAGNOSTIC CONN H G H
1 225 - [225SCR] SCREEN J
C11_1
C11
C0207 [C224] C0211 [C13]
REDUNDANCY SWITCH 15
50
VOLT DROPPER 50
1
2
3
284 Y [284G] 19/0.19 (0.50)
281 Y [281RDG] 19/0.19 (0.50)
299 Y [299BO] 19/0.19 (0.50)
13 9 10 1 087 Y [087PU] 19/0.26 (1.00)
2 127. Y [127P.] 19/0.19 (0.50)
50 6 3 3 118. Y [118BDG.] 19/0.19 (0.50)
4 291 Y [291R] 19/0.19 (0.50)
4
5 290 Y [290Y] 19/0.19 (0.50)
360 C13 5
6 297 Y [297BO] 19/0.19 (0.50) 5 2 6
7
8
4 1 9
10
7 8
130
6 1
50 240
5 2 330
C224 340
4 3
50
C0214 [C228]
LOWER WIPER
S04 [S04]
S04 1 132 Y [132N] 19/0.19 (0.50)
2 133 Y [133DGU] 19/0.19 (0.50)
16
L 118 Y [118BDG] 19/0.19 (0.50) R 118. Y [118BDG.] 19/0.19 (0.50)
L 205 Y [205PDG] 19/0.19 (0.50) R
2 1
C228
C0213 [C227]
C0204 [C0204] 12 C0202 [C0202]
AUX 2 WIPER 2 17
100
AUX 2 BLANK 1 245 Y [245BU] 19/0.19 (0.50)
1 130 Y [130DGW] 19/0.19 (0.50)
2 131 Y [131DGR] 19/0.19 (0.50)
1 (497063200) 2 288 Y [288UR] 19/0.19 (0.50) 2 1
2 (497063200) C227
80
C0167 [C110]
DIODE 1 WASHER
1 2 CO
1 2 1 201 Y [201BO] 19/0.19 (0.50)
2 202 Y [202DGR] 19/0.19 (0.50)
18
C110 2 1
0
110
C0204 C0202
C0166 [C161]
DIODE 5
1 211 Y [211DGU] 19/0.19 (0.50)
2 210 Y [210DGB] 19/0.19 (0.50)
19
2 1
C161
80
105
C0203 [C0203] 11 C0007 [C0007]
AUX BLANK AUX C0165 [C155]
80
1 (497063200)
2 (497063200)
1 165 Y [165BU] 19/0.19 (0.50)
2 287 Y [287UR] 19/0.19 (0.50)
2 1
DIODE 3 REDUN 1
1 205 Y [205PDG] 19/0.19 (0.50)
20
C155 2 206 Y [206UK] 19/0.19 (0.50)
85
1 2 CONNECT
DIODES TO BE TAPED TOGETHER
1 2
ONTO MAIN HARNESS 497000300 C0164 [C156] 21
2 1 DIODE 4 REDUN 2
0 C156 1 118 Y [118BDG] 19/0.19 (0.50)
2 208 Y [208ODG] 19/0.19 (0.50)
C0203 C0007 80 60
C
20 80 50 50
10 C0009 260 10
S05 [S05] S05
S06 [S06] S06
C0009 [C0009] L 087. Y [087PU.] 19/0.26 (1.00) R 087 Y [087PU] 19/0.26 (1.00) L 271 Y [271UR] 19/0.26 (1.00) R 287 Y [287UR] 19/0.19 (0.50)
AUTO FAN L 128 Y [128PU] 19/0.19 (0.50) R L R 288 Y [288UR] 19/0.19 (0.50)
1 167 Y [167UDG] 19/0.19 (0.50)
A
T003760
Fig 209. Cab Harness `B' 721/12522 - Issue 1
C-191 9803/9800-3 C-191
C-192
C0024 [C8]
ECU CONN A
1
2
250 Y [250R] 19/0.19 (0.50)
014 Y [014YU] 19/0.19 (0.50)
21
22
022 Y [022UO] 19/0.19 (0.50)
075. Y [075NU.] 19/0.19 (0.50)
25
3 016 Y [016YDG] 19/0.19 (0.50) 23 (492218303)
4 034 Y [034DGW] 19/0.19 (0.50) 24 076 Y [076PDG] 19/0.19 (0.50)
5 066 Y [066UR] 19/0.19 (0.50) 25 077 Y [077DGY] 19/0.19 (0.50)
6 023 Y [023OB] 19/0.19 (0.50) 26 041 Y [041BW] 19/0.19 (0.50)
S14 [S14] 7 013 Y [013YU] 19/0.19 (0.50) 27 054 Y [054DGU] 19/0.19 (0.50) 1 2 3 4 5 6 7 8 9 10 C0022 [C9]
L 107 Y [107DGR] 19/0.19 (0.50) R 107. Y [107DGR.] 19/0.19 (0.50) 8 051 Y [051YR] 19/0.19 (0.50) 28 078 Y [078UY] 19/0.19 (0.50)
L 202 Y [202DGR] 19/0.19 (0.50) R 9 027 Y [027WR] 19/0.19 (0.50) 29 079 Y [079SR] 19/0.19 (0.50) ECU CONN B
10 050 Y [050SDG] 19/0.19 (0.50) 30 251 Y [251RW] 19/0.19 (0.50) 1 084 Y [084O] 19/0.26 (1.00) 13 093 Y [093W] 19/0.26 (1.00)
11 068 Y [068GR] 19/0.19 (0.50) 31 120 Y [120SU] 19/0.19 (0.50) 11 20 2 085 Y [085S] 19/0.26 (1.00) 14 158 Y [158N] 19/0.26 (1.00)
30 12 (492218303) 32 (492218303) 3 (492218303) 15 226 R [226R] 19/0.19 (0.50)
B 420
D 13
14
070 Y [070GY] 19/0.19 (0.50)
071 Y [071DGR] 19/0.19 (0.50)
33
34
080 Y [080U] 19/0.19 (0.50)
081 Y [081PU] 19/0.19 (0.50)
21 30 4
5
(492218303)
087. Y [087PU.] 19/0.26 (1.00)
16
17
(492218303)
097 Y [097B] 19/0.19 (0.50)
15 072 Y [072UW] 19/0.19 (0.50) 35 015 Y [015UB] 19/0.19 (0.50) 6 088 Y [088SR] 19/0.26 (1.00) 18 (492218303)
16 073 Y [073G] 19/0.19 (0.50) 36 024 Y [024NY] 19/0.19 (0.50) 7 089 Y [089RB] 19/0.26 (1.00) 19 098 Y [098DGB] 19/0.26 (1.00)
17 083 Y [083Y] 19/0.19 (0.50) 37 082 Y [082BY] 19/0.19 (0.50) 8 090 Y [090RB] 19/0.26 (1.00) 20 099 Y [099DGB] 19/0.26 (1.00)
31 32 33 34 35 36 37 38 39 40
40 18 (492218303) 38 057 Y [057W] 19/0.19 (0.50) 9 (492218303) 21 227 U [227U] 19/0.19 (0.50)
20
19 052 Y [052NW] 19/0.19 (0.50) 39 (492218303) 10 (492218303) 22 101 Y [101B] 19/0.19 (0.50)
20 074 Y [074S] 19/0.19 (0.50) 40 240 Y [240BY] 19/0.19 (0.50) 11 092 Y [092S] 19/0.19 (0.50) 23 102 Y [102B] 19/0.26 (1.00)
S07 [S07] C8 12 (492218303) 24 (492218303)
L 275 Y [275R] 50/0.45 (8.00) R 255 Y [255R] 37/0.33 (3.00) S11 [S11]
L R 256 Y [256R] 19/0.41 (2.50)
L 262 Y [262DGB] 19/0.26 (1.00) R 098 Y [098DGB] 19/0.26 (1.00)
L R 257 Y [257R] 37/0.33 (3.00)
L R 099 Y [099DGB] 19/0.26 (1.00) 1 2 3 4 5 6
L R 258 N [258R] 65/0.30 (4.50) S07
L R 261 Y [261R] 19/0.26 (1.00) S11 30
S12 [S12]
26
7 12
20
L 263 Y [263R] 19/0.26 (1.00) R 093 Y [093W] 19/0.26 (1.00)
L R 158 Y [158N] 19/0.26 (1.00)
S08 [S08] 13 18
L 113 Y [113R] 19/0.26 (1.00) R 259. Y [259W.] 37/0.37 (4.00) C9
S12 30
L 254 Y [254R] 19/0.26 (1.00) R S13 [S13]
S08 L 259 Y [259W] 37/0.37 (4.00) R
L 260 Y [260W] 19/0.37 (2.00) R L 264 Y [264RB] 19/0.26 (1.00) R 089 Y [089RB] 19/0.26 (1.00)
L R 090 Y [090RB] 19/0.26 (1.00) 19 20 21 22 23 24
S13
50
S09 [S09] 30
10
10
L 064 Y [064SR] 19/0.19 (0.50) R 269 Y [269SR] 19/0.26 (1.00)
L 088 Y [088SR] 19/0.26 (1.00) R
S09
9803/9800-3
L 125 Y [125SR] 19/0.19 (0.50) R
90 30 40 100
22
50
620
200 75 75 50 24 630 650 670 690
C236 520 S10 570 C230
C0227 [C230]
10
50
13
1U 1 S10 [S10]
L 067 Y [067U] 19/0.26 (1.00) R 067. Y [067U.] 19/0.26 (1.00)
REFUELING PUMP RELAY C0226 [C9_1] 27
30 067. Y [067U.] 19/0.26 (1.00) ECU CONN B
100
L 114 Y [114U] 19/0.19 (0.50) R
87A C10
13U 87 091 Y [091DG] 19/0.19 (0.50) 1 228 - [228SCR] SCREEN C9_1
86 056 Y [056SDG] 19/0.19 (0.50) 1 2 3 4 5 6 7 8 9 10
85 094 Y [094B] 19/0.19 (0.50) FIT WIRE 228 INTO CAVITIE
18 OF CONNECTOR C0022
540
14 23 11 20
50
C255 [C255] 21 30
14U LIFT PUMP FUSE C0018 [C10]
C255 1 2 1 151 Y [151DG] 19/0.26 (1.00) ECU CONN C
2 152 Y [152RDG] 19/0.26 (1.00) 1 003 Y [003OW] 19/0.19 (0.50) 21 161 Y [161SDG] 19/0.19 (0.50)
31 32 33 34 35 36 37 38 39 40
2 018 Y [018NB] 19/0.19 (0.50) 22 037 Y [037NW] 19/0.19 (0.50)
3 020 Y [020UDG] 19/0.19 (0.50) 23 006 Y [006RDG] 19/0.19 (0.50)
C0212 [C236] 4 009 Y [009UR] 19/0.19 (0.50) 24 063 Y [063PS] 19/0.19 (0.50)
Section C - Electrics
15 FUSEBOX 5 103 Y [103RB] 19/0.19 (0.50) 25 012 Y [012SR] 19/0.19 (0.50)
6 104 Y [104RY] 19/0.19 (0.50) 26 108. Y [108UK.] 19/0.19 (0.50)
1 254 Y [254R] 19/0.26 (1.00) 1U 262 Y [262DGB] 19/0.26 (1.00) 7 004 Y [004 GW] 19/0.19 (0.50) 27 002 Y [002UY] 19/0.19 (0.50)
2 255 Y [255R] 37/0.33 (3.00) 2U 263 Y [263R] 19/0.26 (1.00) 8 001 Y [001SB] 19/0.19 (0.50) 28 053 Y [053K] 19/0.19 (0.50)
15U 3 3U 264 Y [264RB] 19/0.26 (1.00) 9 105 Y [105B] 19/0.19 (0.50) 29 064 Y [064SR] 19/0.19 (0.50)
4 256 Y [256R] 19/0.41 (2.50) 4U 084 Y [084O] 19/0.26 (1.00) 10 106 Y [106B] 19/0.19 (0.50) 30 (492218303)
5 5U 085 Y [085S] 19/0.26 (1.00) 11 011 Y [011DG] 19/0.19 (0.50) 31 (492218303)
6 257 Y [257R] 37/0.33 (3.00) 6U 143 Y [143UDG] 19/0.32 (1.50) 12 (492218303) 32 059 Y [059YB] 19/0.19 (0.50)
Cab Harness - Type A
16 7 7U 055 Y [055DG] 19/0.19 (0.50) 13 056 Y [056SDG] 19/0.19 (0.50) 33 060 Y [060YU] 19/0.19 (0.50)
8 258 N [258R] 65/0.30 (4.50) 8U 267 Y [267RDG] 19/0.32 (1.50) 14 030 Y [030DGW] 19/0.19 (0.50) 34 061 Y [061Y] 19/0.19 (0.50)
9 9U 268 Y [268G] 19/0.26 (1.00)
PVC TUBE 15 252 Y [252DGU] 19/0.19 (0.50) 35 062 Y [062YDG] 19/0.19 (0.50)
16U 10 259 Y [259W] 37/0.37 (4.00) 10U 150 Y [150RY] 19/0.26 (1.00) 16 005 Y [005UW] 19/0.19 (0.50) 36 008 Y [008ODG] 19/0.19 (0.50)
11 11U 269 Y [269SR] 19/0.26 (1.00)
FULLY TAPED 17 107 Y [107DGR] 19/0.19 (0.50) 37 026 Y [026YR] 19/0.19 (0.50)
Harness Data
12U 12 12 260 Y [260W] 19/0.37 (2.00) 12U 270 Y [270UY] 19/0.26 (1.00) 18 035 Y [035RU] 19/0.19 (0.50) 38 010 Y [010UB] 19/0.19 (0.50)
13 261 Y [261R] 19/0.26 (1.00) 13U 271 Y [271UR] 19/0.26 (1.00)
14 217 Y [217R] 19/0.26 (1.00) 14U 272 Y [272P] 19/0.26 (1.00)
UNTAPED 19 (492218303) 39 028 Y [028RS] 19/0.19 (0.50)
20 029 Y [029RW] 19/0.19 (0.50) 40 (492218303)
15 113 Y [113R] 19/0.26 (1.00) 15U 067 Y [067U] 19/0.26 (1.00)
16 151 Y [151DG] 19/0.26 (1.00) 16U 152 Y [152RDG] 19/0.26 (1.00)
CONVOLUTE TUBE
T003770
Fig 210. Cab Harness `C' 721/12522 - Issue 1
C-192
Section C - Electrics
Harness Data
Cab Harness - Type A
29 C0042 [C1]
CONNECTOR A
1 001. Y [001SB.] 19/0.19 (0.50) 17 016 Y [016YDG] 19/0.19 (0.50) 33 032 Y [032N] 19/0.19 (0.50)
2 002 Y [002UY] 19/0.19 (0.50) 18 045 Y [045BR] 19/0.19 (0.50) 34 033 Y [033O] 19/0.19 (0.50)
3 003 Y [003OW] 19/0.19 (0.50) 19 018 Y [018NB] 19/0.19 (0.50) 35 052 Y [052NW] 19/0.19 (0.50)
4 004 Y [004 GW] 19/0.19 (0.50) 20 046 Y [046BU] 19/0.26 (1.00) 36 035 Y [035RU] 19/0.19 (0.50)
5 005 Y [005UW] 19/0.19 (0.50) 21 020 Y [020UDG] 19/0.19 (0.50) 37 036 Y [036RDG] 19/0.19 (0.50)
6 161 Y [161SDG] 19/0.19 (0.50) 22 047 Y [047BW] 19/0.19 (0.50) 38 037 Y [037NW] 19/0.19 (0.50)
7 006 Y [006RDG] 19/0.19 (0.50) 23 050 Y [050SDG] 19/0.19 (0.50) 39 156 Y [156DGU] 19/0.19 (0.50)
8 007 Y [007BDG] 19/0.19 (0.50) 24 023 Y [023OB] 19/0.19 (0.50) 40 077 Y [077DGY] 19/0.19 (0.50)
9 008. Y [008ODG.] 19/0.19 (0.50) 25 051 Y [051YR] 19/0.19 (0.50) 41 114 Y [114U] 19/0.19 (0.50)
10 009 Y [009UR] 19/0.19 (0.50) 26 025 Y [025G] 19/0.19 (0.50) 42 053 Y [053K] 19/0.19 (0.50)
11 010 Y [010UB] 19/0.19 (0.50) 27 026 Y [026YR] 19/0.19 (0.50) 43 054 Y [054DGU] 19/0.19 (0.50)
12 042 Y [042S] 19/0.19 (0.50) 28 027 Y [027WR] 19/0.19 (0.50) 44 091 Y [091DG] 19/0.19 (0.50)
13 012 Y [012SR] 19/0.19 (0.50) 29 028 Y [028RS] 19/0.19 (0.50) 45 240 Y [240BY] 19/0.19 (0.50)
14 013 Y [013YU] 19/0.19 (0.50) 30 029 Y [029RW] 19/0.19 (0.50) 46
15 014 Y [014YU] 19/0.19 (0.50) 31 030 Y [030DGW] 19/0.19 (0.50) 47
16 015 Y [015UB] 19/0.19 (0.50) 32 031 Y [031DG] 19/0.19 (0.50) 48
1
5 2
11 6 3
7 4
18 12
19 13 8
9
25 20 14 10
32 21 15
26
22 16
33 27
28 23 17
39 34
29
40 35
30 24
41 36
42 37 31
45
46 43 38
47 44
48
FIT WIRE 222 INTO CAVITIE
8 OF CONNECTOR C252
C252 [C252] 8 1
TEIR 3 LINK
1 045 Y [045BR] 19/0.19 (0.50)
2 153 Y [153P] 19/0.26 (1.00) 7 2
3 154 Y [154BW] 19/0.19 (0.50)
4 155 Y [155U] 19/0.19 (0.50)
5 (499161900)
C1
6 220 R [220R] 19/0.19 (0.50) 6 3
7 221 U [221U] 19/0.19 (0.50)
100
8 (499161900)
5 4
100
C252 810
28 100
50
C252_1 [C252_1]
1 222 - [222SCR] SCREEN
C252_1 S22 [S22]
L 001 Y [001SB] 19/0.19 (0.50) R 001. Y [001SB.] 19/0.19 (0.50)
S22 L 157 Y [157SB] 19/0.19 (0.50) R
50
S21 [S21]
L 032. Y [032N.] 19/0.19 (0.50) R 032 Y [032N] 19/0.19 (0.50)
L 057 Y [057W] 19/0.19 (0.50) R S21
40
FIT HSS OVER S20 [S20] FIT HSS OVER
S15, S16 AND S17 L 025. Y [025G.] 19/0.19 (0.50) R 025 Y [025G] 19/0.19 (0.50)
L 073 Y [073G] 19/0.19 (0.50) R S20
S23, S24 AND S25
S15 [S15] S17 [S17] S25 [S25]
L 222 - [222SCR] SCREEN R 228 - [228SCR] SCREEN L 220 R [220R] 19/0.19 (0.50) R 226 R [226R] 19/0.19 (0.50)
S23 [S23]
L 237 - [237SCR] SCREEN R L 235 R [235R] 19/0.19 (0.50) R L 225 - [225SCR] SCREEN R 231 - [231SCR] SCREEN L 223 R [223R] 19/0.19 (0.50) R 229 R [229R] 19/0.19 (0.50)
L 237 - [237SCR] SCREEN R L 235 R [235R] 19/0.19 (0.50) R
50
S16 [S16] S24 [S24]
B L 221 U [221U] 19/0.19 (0.50)
L 236 U [236U] 19/0.19 (0.50)
R 227 U [227U] 19/0.19 (0.50)
R L 224 U [224U] 19/0.19 (0.50)
L 236 U [236U] 19/0.19 (0.50)
R 230 U [230U] 19/0.19 (0.50)
R
E
30 15 0 0 0 15 30 30 20 55 0 0 0 15
420 S14 S15 S17 1660 S18 S19 770 S36 S23 S24 S25 1670
S16
S14 [S14] S18 [S18] S36 [S36]
L 107 Y [107DGR] 19/0.19 (0.50) R 107. Y [107DGR.] 19/0.19 (0.50) L 008 Y [008ODG] 19/0.19 (0.50) R 008. Y [008ODG.] 19/0.19 (0.50) L 143 Y [143UDG] 19/0.32 (1.50) R 143. Y [143UDG.] 19/0.32 (1.50)
L 202 Y [202DGR] 19/0.19 (0.50) R L 208 Y [208ODG] 19/0.19 (0.50) R L 167 Y [167UDG] 19/0.19 (0.50) R
S19 [S19]
L 107. Y [107DGR.] 19/0.19 (0.50) R 107.. Y [107DGR..] 19/0.19 (0.50)
L 131 Y [131DGR] 19/0.19 (0.50) R
C
PVC TUBE
FULLY TAPED
UNTAPED
CONVOLUTE TUBE
T003780
Fig 211. Cab Harness `D' 721/12522 - Issue 1
C-193 9803/9800-3 C-193
Section C - Electrics
Harness Data
Cab Harness - Type A
34 C0217 [C37]
CAB SUB HARNESS
1 104 Y [104RY] 19/0.19 (0.50) 7 180 Y [180BW] 19/0.19 (0.50)
2 103 Y [103RB] 19/0.19 (0.50) 8 289 Y [289RY] 19/0.19 (0.50)
3 011 Y [011DG] 19/0.19 (0.50) 9 291 Y [291R] 19/0.19 (0.50)
4 280 Y [280RDG] 19/0.19 (0.50) 10 (499161900)
5 107.. Y [107DGR..] 19/0.19 (0.50) 11 130 Y [130DGW] 19/0.19 (0.50)
6 295 Y [295DG] 19/0.19 (0.50) 12 (499161900)
1 6
12 7
33 C37
FIT WIRE 231 INTO CAVITIE
7 OF CONNECTOR C0225
C0216 [C5] C0225_1 [C180_1]
24V SUPPLY (BATT) FASCIA LINK 1
1 259. Y [259W.] 37/0.37 (4.00) 1 231 - [231SCR] SCREEN
2 058 Y [058B] 37/0.33 (3.00) 1 2
C180_1
35 C0225
FASCIA LINK 1
[C180]
C5
1 127 Y [127P] 19/0.19 (0.50)
2 125 Y [125SR] 19/0.19 (0.50)
10 8
32 3 128 Y [128PU] 19/0.19 (0.50)
100
4 126 Y [126B] 19/0.19 (0.50)
C0215 [C6] 50 7 4 5 229 R [229R] 19/0.19 (0.50)
24V SUPPLY 6 230 U [230U] 19/0.19 (0.50)
50
3 1 7 (491114200)
1 275 Y [275R] 50/0.45 (8.00)
1 8 155 Y [155U] 19/0.19 (0.50)
9 108 Y [108UK] 19/0.19 (0.50)
50 C180 10 (491114200)
C6 50
920
100
50
36 C0224 [C225]
31 C164 [C164]
50
10 1
FASCIA LINK 3
137 Y [137UO] 19/0.19 (0.50)
8
EARTH CONN C225 2 135 Y [135OW] 19/0.19 (0.50)
1 300 Y [300BO] 19/0.19 (0.50)
C164 3 286 Y [286YR] 19/0.19 (0.50)
2 (497063200) 4 7 4 146 Y [146U] 19/0.19 (0.50)
100
5 285 Y [285DGW] 19/0.19 (0.50)
6 290 Y [290Y] 19/0.19 (0.50)
1 2 1 3 7 289 Y [289RY] 19/0.19 (0.50)
8 078 Y [078UY] 19/0.19 (0.50)
9 083 Y [083Y] 19/0.19 (0.50)
10 (491114200)
0
C4_1 C4 C21
1 6
3 1
CONNECT
1 2 3
50
6 4
4 5 6 12 7
30
C0218
HVAC UNIT CONN
[C21]
37
C0201 [C4_1] C0046 [C4] 1 031 Y [031DG] 19/0.19 (0.50) 7 135 Y [135OW] 19/0.19 (0.50)
PLUG WHEELED OPTION CAB 2 033 Y [033O] 19/0.19 (0.50) 8 143. Y [143UDG.] 19/0.32 (1.50)
1 059 Y [059YB] 19/0.19 (0.50) 3 032. Y [032N.] 19/0.19 (0.50) 9 137 Y [137UO] 19/0.19 (0.50)
1 (497063200)
2 060 Y [060YU] 19/0.19 (0.50) 4 285 Y [285DGW] 19/0.19 (0.50) 10 145 Y [145BU] 19/0.19 (0.50)
2 (497063200)
3 061 Y [061Y] 19/0.19 (0.50) 5 146 Y [146U] 19/0.19 (0.50) 11 (499161900)
3 (497063200)
4 062 Y [062YDG] 19/0.19 (0.50) 6 286 Y [286YR] 19/0.19 (0.50) 12 (499161900)
4 (497063200)
5 (497063200) 5 063 Y [063PS] 19/0.19 (0.50)
6 (497063200) 6 025. Y [025G.] 19/0.19 (0.50)
S29 S29 [S29]
L 127 Y [127P] 19/0.19 (0.50) R 127. Y [127P.] 19/0.19 (0.50)
L R 153 Y [153P] 19/0.26 (1.00)
L R 272 Y [272P] 19/0.26 (1.00)
50
S28 [S28]
S26 [S26] L 058. Y [058B.] 37/0.33 (3.00) R 058 Y [058B] 37/0.33 (3.00)
S31 [S31]
L 159 Y [159B] 19/0.19 (0.50) R
L 042 Y [042S] 19/0.19 (0.50) R 042. Y [042S.] 19/0.19 (0.50) S28 L 055. Y [055DG.] 19/0.19 (0.50) R 055 Y [055DG] 19/0.19 (0.50)
L 074 Y [074S] 19/0.19 (0.50) R L 292 Y [292DG] 19/0.19 (0.50) R 295 Y [295DG] 19/0.19 (0.50)
50
L 296 Y [296DG] 19/0.19 (0.50) R
15 20 20 100
1670 S26 S27 890 S31
S27 [S27]
D L 108. Y [108UK.] 19/0.19 (0.50)
L 206 Y [206UK] 19/0.19 (0.50)
R 108 Y [108UK] 19/0.19 (0.50)
R
F
PVC TUBE
FULLY TAPED
UNTAPED
CONVOLUTE TUBE
T003790
Fig 212. Cab Harness `E' 721/12522 - Issue 1
C-194 9803/9800-3 C-194
Section C - Electrics
Harness Data
Cab Harness - Type A
C0002 [C112]
BREAKER PILOT SW
1 068. Y [068GR.] 19/0.19 (0.50)
2 197 Y [197NU] 19/0.19 (0.50)
40
C0172 [C112_1]
C0228 [C201_1]
39 C0205 [C201] 1 2
CONNECT
2 1 BLANKING CONN
1 (499161900)
2 (499161900)
PLUG LOWER WIPER
1 (499161900) 1 132 Y [132N] 19/0.19 (0.50)
2 (499161900) 2 292 Y [292DG] 19/0.19 (0.50) 0
3 (499161900) 3 252. Y [252DGU.] 19/0.19 (0.50)
4 (499161900) 4 171 Y [171BU] 19/0.19 (0.50) C112 C112_1
C0232 [C167]
10
C0238 [C167_1]
MERGE FLOW SOL V B
1 4 4 1 1 038 Y [038DGU] 19/0.19 (0.50) 41 PLUG
1 (499161900)
CONNECT
1330 2 096 Y [096BU] 19/0.19 (0.50)
2 (499161900)
2 3 3 2
240
CONNECT
2 1
1 2
0 10 440 10
C201_1 C201 1360 1320 1280 C167 0 C167_1
C0237 [C163_1]
42
100
PLUG
C0231 [C163] 1 (499161900)
ID LABEL
2 (499161900)
MERGE FLOW SOL V C
140
1310
1 086 Y [086DGU] 19/0.19 (0.50) CONNECT
2 095 Y [095BU] 19/0.19 (0.50)
1 2 2 1
325
90 10
1240 1250 C163 0 C163_1
C0240 [C169_1]
C0234 [C169]
43 PLUG
1 (499161900)
2 (499161900)
HAM/AUX/SOL V C
200
1 017 Y [017DGB] 19/0.19 (0.50)
2 100 Y [100BU] 19/0.19 (0.50) 1 2
CONNECT
2 1
940
1200 1210 10 C169 0 C169_1
C0235 [C71_1]
C0230 [C71] CONNECT PLUG
BOOM UP P.SW 2 1
1 2 1 (499161900)
1 022 Y [022UO] 19/0.19 (0.50) 2 (499161900)
C65 [C65] 2 110 Y [110BO] 19/0.19 (0.50)
BOOM PRIORITY
1 157 Y [157SB] 19/0.19 (0.50) 44
450
2 159 Y [159B] 19/0.19 (0.50)
0
1130 10 C71 C71_1
1 2
140
50 450 1000 70 1110 10
38 C65 1700 1090 1100 C73
140 MARKER TAPE RED
Insulation Node: 1110 [C73] C0233
2 Spot Tape 497003103 SWING PILOT P SW
1 024 Y [024NY] 19/0.19 (0.50)
225
2 109 Y [109BU] 19/0.19 (0.50)
1160 10
S34 [S34] MARKER TAPE C221
L 133 Y [133DGU] 19/0.19 (0.50) R 252. Y [252DGU.] 19/0.19 (0.50)
Insulation Node: 1160
45
L 252 Y [252DGU] 19/0.19 (0.50) R
S34
2 Spot Tape 497003106
46 1 2
1 2
[C221] C0229
50
AUTO MODE P SW
S33 [S33] 1 034 Y [034DGW] 19/0.19 (0.50)
L 068 Y [068GR] 19/0.19 (0.50) R 068. Y [068GR.] 19/0.19 (0.50) 2 112 Y [112BW] 19/0.19 (0.50)
L 212 Y [212GR] 19/0.19 (0.50) R S33
E G
50
50 100 200
S32 1060 S35 S30
S32 [S32] S35 [S35] S30 [S30]
L 036 Y [036RDG] 19/0.19 (0.50) R 195 Y [195RDG] 19/0.19 (0.50) L 017 Y [017DGB] 19/0.19 (0.50) R 017. Y [017DGB.] 19/0.19 (0.50) L 038. Y [038DGU.] 19/0.19 (0.50) R 038 Y [038DGU] 19/0.19 (0.50)
L 267 Y [267RDG] 19/0.32 (1.50) R 216 Y [216RDG] 19/0.19 (0.50) L 210 Y [210DGB] 19/0.19 (0.50) R L R 086 Y [086DGU] 19/0.19 (0.50)
L 280 Y [280RDG] 19/0.19 (0.50) R 281. Y [281RDG.] 19/0.19 (0.50) L R 156 Y [156DGU] 19/0.19 (0.50)
L 281 Y [281RDG] 19/0.19 (0.50) R L R 211 Y [211DGU] 19/0.19 (0.50)
PVC TUBE
FULLY TAPED
UNTAPED
CONVOLUTE TUBE
T003800
Fig 213. Cab Harness `F' 721/12522 - Issue 1
C-195 9803/9800-3 C-195
Section C - Electrics
Harness Data
Cab Harness - Type A
PVC TUBE
C0180 [C160_1]
FULLY TAPED
OPTS HYD SW PLUG
C0168 [C160] 1 (497063217) UNTAPED
1
OPTS HYD SW
(497063217)
2
3
4
(497063217)
(497063217)
(497063217)
48 CONVOLUTE TUBE
2 212 Y [212GR] 19/0.19 (0.50) 5 (497063217)
3 213 Y [213BO] 19/0.19 (0.50) 6 (497063217)
4 197 Y [197NU] 19/0.19 (0.50) 7 (497063217)
5 017. Y [017DGB.] 19/0.19 (0.50) 8 (497063217)
6 038. Y [038DGU.] 19/0.19 (0.50)
7 216 Y [216RDG] 19/0.19 (0.50) C0026 [C22]
8 (497063217)
THROTTLE DIAL
6 8
1 120 Y [120SU] 19/0.19 (0.50)
2 079 Y [079SR] 19/0.19 (0.50)
3 042. Y [042S.] 19/0.19 (0.50)
49
1 3
CONNECT
2
4 5 4 5
7
8 1 3 3 1
6
50
0
C0027 [C31]
47 C160 C160_1 C22
RH LEVER SWITCH
C0208 [C203] 1 070 Y [070GY] 19/0.19 (0.50)
2 168 Y [168BU] 19/0.19 (0.50)
HEATED SWITCH 3 082 Y [082BY] 19/0.19 (0.50)
1 294 Y [294Y] 19/0.19 (0.50) 4 172 Y [172BW] 19/0.19 (0.50)
2 298 Y [298BO] 19/0.19 (0.50)
50
50
1550
51
2 1 1450
C0028 [C30]
C203 GRAB CCW/CW
1 066 Y [066UR] 19/0.19 (0.50)
C31 2 169 Y [169BU] 19/0.19 (0.50)
3 072 Y [072UW] 19/0.19 (0.50)
50
4 170 Y [170BU] 19/0.19 (0.50)
250
250
1410
25
Clip_002
750
[1390] Clip_001 [1430]
160 40 1440 210 210 25 25
1390 1400 1430 0 1540 1620 1640 C30
MARKER TAPE RED
F 150 Insulation Node: 1640
75
1 Spot Tape 497003103
150
150
S38 [S38]
S38 L 041 Y [041BW] 19/0.19 (0.50) R 140 Y [140BW] 37/0.37 (4.00)
L 047 Y [047BW] 19/0.19 (0.50) R
L 154 Y [154BW] 19/0.19 (0.50) R
1480
MARKER TAPE GREEN
75
1500 Insulation Node: 1500
MARKER TAPE GREEN 1510
Insulation Node: 1480
2 Spot Tape 497003106
2 Spot Tape 497003103
50
S39 [S39]
50
50
C202 L 115 Y [115RY] 37/0.37 (4.00) R 150 Y [150RY] 19/0.26 (1.00)
S39
55
100
9 10
1590
C200 C43
54
56 6 3
50
5 2 9 10
50
9 10
6 3 3
4 1
6 3
7 8 5 2
5 2 C23B C23A
4
C0221 [C202]
4 1
HEATED SEAT SWITCH
4 1 5 6
7
2 1 52
7 8
7 8 1
2 055. Y [055DG.] 19/0.19 (0.50) 9 C0219 [C23A]
[C200] 3 294 Y [294Y] 19/0.19 (0.50) C0047 [C43] KEY SWITCH A
C0220 4
BOOM PRI SW 1 115 Y [115RY] 37/0.37 (4.00)
5
LOWER WIPER SWITCH 6 1 2
10 8 3
1 7 189 Y [189BW] 19/0.19 (0.50) 2 192 Y [192NU] 19/0.19 (0.50)
2 250 Y [250R] 19/0.19 (0.50) 8 296 Y [296DG] 19/0.19 (0.50) 3 193 Y [193BO] 19/0.19 (0.50) 4 140 Y [140BW] 37/0.37 (4.00)
3 184 Y [184BW] 19/0.19 (0.50) 9 4
4 10 5
C0222 [C23B]
5
6
7 186 Y [186BW] 19/0.19 (0.50)
6
7
8
194 Y [194BO] 19/0.19 (0.50)
195 Y [195RDG] 19/0.19 (0.50)
53 KEY SWITCH B
5 046 Y [046BU] 19/0.26 (1.00)
8 281. Y [281RDG.] 19/0.19 (0.50) 9
6 217 Y [217R] 19/0.26 (1.00)
9 10
7
10
8
9
10
T003810
Fig 214. Cab Harness `G' 721/12522 - Issue 1
C-196 9803/9800-3 C-196
Section C - Electrics
Harness Data
Engine Harness - Type A
Engine Harness - Type A
Connector Identification
Table 12.
Item Connector Function
1 - 8 K Engine Harness `A' ( T C-198)
1 C258 Cab Connector C
2 C271
3 C254
4 C251 ECM Main Relay
5 C253 Tech 2
6 C255 Lift Pump Fuse
7 C252 T3 Engine Cab Link
8 C250
9 - 11 K Engine Harness `B' ( T C-199)
9 C257 ECM Engine
10 C256 ECM Engine
11 EH Earth Header
C-197 9803/9800-3 C-197
Section C - Electrics
Harness Data
Engine Harness - Type A
C271 [C271] C254 [C254] ECM MAIN RELAY C251 [C251]
30 073 Y [73 R] 19/0.23 (0.75) 30 002 Y [2 WR] 19/0.26 (1.00) 30 803 Y [803 WR] 19/0.41 (2.50)
87A 020 Y [20 BU] 19/0.23 (0.75) 87A 87A
87 87 010 Y [10 DGR] 19/0.26 (1.00) 87 003 Y [3 R] 19/0.37 (2.00)
074 Y [74 U] 19/0.23
86 (0.75) 86 006 Y [6 R] 19/0.23 (0.75) 86 007. Y [7 KB.] 19/0.23 (0.75)
072 Y [72 B] 19/0.23
85 (0.75) 85 012 Y [12 B] 19/0.23 (0.75) 85 009 Y [9 B] 19/0.23 (0.75)
2 3 4
1
C258 [C258]
CAB CONN C C271
1 030 Y [30 S] 19/0.23 (0.75) 17 048 Y [48 DGB] 19/0.23 (0.75) 33 063 Y [63 WR] 19/0.23 (0.75) C254
2 031 Y [31 SDG] 19/0.23 (0.75) 18 049 Y [49 RW] 19/0.23 (0.75) 34 C251
100
3 032 Y [32 UY] 19/0.23 (0.75) 19 050 B [50 B] 19/0.19 (0.50) 35 064 Y [64 DGR] 19/0.23 (0.75)
4 033 Y [33 KDG] 19/0.23 (0.75) 20 051 R [51 R] 19/0.19 (0.50) 36 065 Y [65 DGB] 19/0.23 (0.75)
5 034 Y [34 KU] 19/0.23 (0.75) 21 052 Y [52 BW] 19/0.23 (0.75) 37 066 Y [66 R] 19/0.23 (0.75)
100
6 035 Y [35 BR] 19/0.23 (0.75) 22 038 K [38 K] 19/0.19 (0.50) 38 067 Y [67 UW] 19/0.23 (0.75)
100
7 036 Y [36 BY] 19/0.23 (0.75) 23 054 G [54 G] 19/0.19 (0.50) 39 068 Y [68 UR] 19/0.23 (0.75)
8 037 Y [37 WB] 19/0.23 (0.75) 24 042 S [42 S] 19/0.19 (0.50) 40 069 Y [69 U] 19/0.23 (0.75)
9 25 053 Y [53 BW] 19/0.23 (0.75) 41 070 Y [70 UY] 19/0.23 (0.75)
10 040 Y [40 YDG] 19/0.23 (0.75) 26 055 Y [55 WB] 19/0.23 (0.75) 42 071 Y [71 W] 19/0.23 (0.75)
11 041 Y [41 RB] 19/0.23 (0.75) 27 056. Y [56 RW.] 19/0.23 (0.75) 43 011 Y [11 DGR] 19/0.26 (1.00)
100
12 28 058 R [58 R] 19/0.19 (0.50) 44
13 043. Y [43 RB.] 19/0.23 (0.75) 29 059 B [59 B] 19/0.19 (0.50) 45
14 045 Y [45 U] 19/0.23 (0.75) 30 060 Y [60 B] 19/0.23 (0.75) 46
15
16
046 Y [46 DGY] 19/0.23 (0.75)
047 Y [47 DGW] 19/0.23 (0.75)
31
32
061 Y [61 RU] 19/0.23 (0.75)
062 Y [62 WU] 19/0.23 (0.75)
47
48
C253 [C253] 5
TECH 2
1 016 Y [16 KG] 19/0.23 (0.75) 9
50
2 10
3 11
S16 [S16] 4
5
015 Y [15 B] 19/0.23 (0.75)
014 Y [14 B] 19/0.23 (0.75)
12
13
L 803 Y [803 WR] 19/0.41 (2.50) R 001. Y [1 WR.] 37/0.37 (4.00) 6 14
S16 7 013 Y [13 KO] 19/0.23 (0.75) 15
8 16
1
5 2 [C255]
11 6 3 6 C255
18 12 7 4 LIFT PUMP FUSE
8 1 011 Y [11 DGR] 19/0.26 (1.00) 16 8
19 13
2 010 Y [10 DGR] 19/0.26 (1.00)
9
20 14 10
25 15 7
21 15
50
32 26
22 16 14 6
33 27
28 23 17
39 34 2 1 100 300 13 5
29
40 35
30 70 C253
41 36 24 C255 12 4
37 31
45 42
11 3
100
46 43 38
47 44 10 2
48
S08 [S08] 9 1
L 001. Y [1 WR.] 37/0.37 (4.00) R 001 Y [1 WR] 37/0.37 (4.00) S08
L 002 Y [2 WR] 19/0.26 (1.00) R
L 073 Y [73 R] 19/0.23 (0.75) R
30
C258
S07 [S07]
L 012 Y [12 B] 19/0.23 (0.75) R 014. Y [14 B.] 19/0.23 (0.75)
L 014 Y [14 B] 19/0.23 (0.75) R S07
S11 [S11]
L 053 Y [53 BW] 19/0.23 (0.75) R 997 - [SCR3] SCREEN
70
25 ID LABEL
25 50 100 100 100 55
290 280 S10 0 S11 10 40 60
MARKER TAPE RED S10 [S10]
Insulation Node: 290 L 060 Y [60 B] 19/0.23 (0.75)
L
R 998 - [SCR2] SCREEN
R 999 - [SCR1] SCREEN B
50
10 Spot Tape 497003103
300
320
CUT_BACK_SCR4 [320]
1 996 - [SCR4] SCREEN
8
100
C250 [C250]
1 001 Y [1 WR] 37/0.37 (4.00)
C252
C250
7
C252 [C252] 5 4
T3 ENGINE CAB LINK
1 017 Y [17 BR] 19/0.23 (0.75) 6 3
2 018 Y [18 P] 19/0.23 (0.75)
3 019 Y [19 BW] 19/0.23 (0.75)
4 074 Y [74 U] 19/0.23 (0.75)
PVC TUBE 5 (499161900) 7 2
FULLY TAPED 6 021 R [21 R] 19/0.19 (0.50)
7 022 U [22 U] 19/0.19 (0.50)
UNTAPED 8 (499161900) 8 1
CONVOLUTE TUBE
T003850-1
Fig 215. Engine Harness `A'
C-198 9803/9800-3 C-198
Section C - Electrics
Harness Data
Engine Harness - Type A
C256 [C256]
C257 ECM ENGINE
ECM ENGINE
[C257] 9 1 024 Y [24 B] 19/0.32 (1.50) 28 (418745601) 55 (418745601)
2 004 Y [4 R] 19/0.32 (1.50) 29 (418745601) 56 (418745601)
82 801 Y [801 N] 19/0.19 (0.50)
83 040 Y [40 YDG] 19/0.23 (0.75)
102
103
(418745601)
055 Y [55 WB] 19/0.23 (0.75)
10 3
4
025 Y [25 B] 19/0.32 (1.50)
026 Y [26 B] 19/0.32 (1.50)
30
31
(418745601)
(418745601)
57
58
(418745601)
(418745601)
84 041 Y [41 RB] 19/0.23 (0.75) 104 (418745601) 5 005 Y [5 R] 19/0.32 (1.50) 32 (418745601) 59 (418745601)
85 (418745601) 105 056 Y [56 RW] 19/0.23 (0.75) 6 (418745601) 33 (418745601) 60 030 Y [30 S] 19/0.23 (0.75)
86 (418745601) 106 058 R [58 R] 19/0.19 (0.50) 7 (418745601) 34 (418745601) 61 031 Y [31 SDG] 19/0.23 (0.75)
87 042 S [42 S] 19/0.19 (0.50) 107 059 B [59 B] 19/0.19 (0.50) 8 (418745601) 35 (418745601) 62 028 Y [28 B] 19/0.23 (0.75)
88 (418745601) 108 800 Y [800 BW] 19/0.19 (0.50) 9 (418745601) 36 (418745601) 63 (418745601)
89 043 Y [43 RB] 19/0.23 (0.75) 109 061 Y [61 RU] 19/0.23 (0.75) 10 017 Y [17 BR] 19/0.23 (0.75) 37 022 U [22 U] 19/0.19 (0.50) 64 (418745601)
90 039 Y [39 U] 19/0.19 (0.50) 110 062 Y [62 WU] 19/0.23 (0.75) 11 (418745601) 38 013 Y [13 KO] 19/0.23 (0.75) 65 (418745601)
91 045 Y [45 U] 19/0.23 (0.75) 111 063 Y [63 WR] 19/0.23 (0.75) 12 (418745601) 39 (418745601) 66 (418745601)
92 046 Y [46 DGY] 19/0.23 (0.75) 112 (418745601) 13 (418745601) 40 008 Y [8 KB] 19/0.23 (0.75) 67 032 Y [32 UY] 19/0.23 (0.75)
93 047 Y [47 DGW] 19/0.23 (0.75) 113 057 Y [57 RW] 19/0.23 (0.75) 14 (418745601) 41 (418745601) 68 (418745601)
94 048 Y [48 DGB] 19/0.23 (0.75) 114 064 Y [64 DGR] 19/0.23 (0.75) 15 (418745601) 42 (418745601) 69 (418745601)
95 049 Y [49 RW] 19/0.23 (0.75) 115 065 Y [65 DGB] 19/0.23 (0.75) 16 (418745601) 43 027 Y [27 B] 19/0.23 (0.75) 70 (418745601)
96 (418745601) 116 066 Y [66 R] 19/0.23 (0.75) 17 (418745601) 44 (418745601) 71 033 Y [33 KDG] 19/0.23 (0.75)
44
63
25
97 044 Y [44 RB] 19/0.23 (0.75) 117 067 Y [67 UW] 19/0.23 (0.75) 18 021 R [21 R] 19/0.19 (0.50) 45 (418745601) 72 034 Y [34 KU] 19/0.23 (0.75)
6
98 050 B [50 B] 19/0.19 (0.50) 118 068 Y [68 UR] 19/0.23 (0.75) 19 (418745601) 46 019 Y [19 BW] 19/0.23 (0.75) 73 (418745601)
99 051 R [51 R] 19/0.19 (0.50) 119 069 Y [69 U] 19/0.23 (0.75) 20 (418745601) 47 020 Y [20 BU] 19/0.23 (0.75) 74 035 Y [35 BR] 19/0.23 (0.75)
100 052 Y [52 BW] 19/0.23 (0.75) 120 070 Y [70 UY] 19/0.23 (0.75) 21 007 Y [7 KB] 19/0.23 (0.75) 48 (418745601) 75 (418745601)
101 054 G [54 G] 19/0.19 (0.50) 121 071 Y [71 W] 19/0.23 (0.75) 22 (418745601) 49 (418745601) 76 (418745601)
23 (418745601) 50 (418745601) 77 (418745601)
24 018 Y [18 P] 19/0.23 (0.75) 51 (418745601) 78 (418745601)
25 (418745601) 52 016 Y [16 KG] 19/0.23 (0.75) 79 036 Y [36 BY] 19/0.23 (0.75)
106
26 (418745601) 53 (418745601) 80 037 Y [37 WB] 19/0.23 (0.75)
82
90
98
27 (418745601) 54 (418745601) 81 029 Y [29 B] 19/0.23 (0.75)
89
105
113
97
114
24
81
62
119
43
2
5
121
116
C256&R1
C257&R121
100
S15 [S15]
100
L 023 Y [23 B] 19/0.19 (0.50) R
S13 [S13] S15 L 996 - [SCR4] SCREEN R
L 999 - [SCR1] SCREEN R 800 Y [800 BW] 19/0.19 (0.50)
100
S13
S14 [S14] S05 [S05]
0 0
S14
L 039 Y [39 U] 19/0.19 (0.50) R 038 K [38 K] 19/0.19 (0.50) L 007 Y [7 KB] 19/0.23 (0.75) R 007. Y [7 KB.] 19/0.23 (0.75)
360 L 008 Y [8 KB] 19/0.23 (0.75) R
S05
CUT_BACK_SCR2_3 [360] L 801 Y [801 N] 19/0.19 (0.50) R
100
1 998 - [SCR2] SCREEN
100
2 997 - [SCR3] SCREEN S02 [S02]
S02 L 043 Y [43 RB] 19/0.23 (0.75) R 043. Y [43 RB.] 19/0.23 (0.75) S04 [S04]
L 044 Y [44 RB] 19/0.23 (0.75) R
L 003 Y [3 R] 19/0.37 (2.00) R 004 Y [4 R] 19/0.32 (1.50)
S04 L 006 Y [6 R] 19/0.23 (0.75) R 005 Y [5 R] 19/0.32 (1.50)
200
A
100
20 175 100 700
S09 130 150 S06 EH
S09 [S09] S06 [S06]
L 056. Y [56 RW.] 19/0.23 (0.75) R 056 Y [56 RW] 19/0.23 (0.75) L 024 Y [24 B] 19/0.32 (1.50) R 024. Y [24 B.] 19/0.32 (1.50)
L R 057 Y [57 RW] 19/0.23 (0.75) L 072 Y [72 B] 19/0.23 (0.75) R
PVC TUBE
FULLY TAPED 11 EH [EH]
EARTH HEADER
UNTAPED
1 024. Y [24 B.] 19/0.32 (1.50)
CONVOLUTE TUBE 2 025 Y [25 B] 19/0.32 (1.50)
3 026 Y [26 B] 19/0.32 (1.50)
4 029 Y [29 B] 19/0.23 (0.75)
5 028 Y [28 B] 19/0.23 (0.75)
6 027 Y [27 B] 19/0.23 (0.75)
7 023 Y [23 B] 19/0.19 (0.50)
8 015 Y [15 B] 19/0.23 (0.75)
9 014. Y [14 B.] 19/0.23 (0.75)
10 009 Y [9 B] 19/0.23 (0.75)
T003860-1
Fig 216. Engine Harness `B'
C-199 9803/9800-3 C-199
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type B
Cab Harness (includes Engine Harness) - Type B
Connector Identification Item Connector Function
34 - 39 K Cab Harness `D' 332/J3663 - Issue
Table 13. 1 ( T C-205)
Item Connector Function
34 C258 Cab Connector C
1 - 10 K Cab Harness `A' 332/J3663 - Issue
1 ( T C-202) 35 C1 Connector A
1 C0173 Earth Header 36 C0218 HVAC Unit Connector
2 C0174 Earth Header 37 C8 ECU Connector A
3 C0175 Earth Header 38 C164 Earth Connector
4 C0176 Earth Header 39 C4 Wheeled Option Cab
5 C115 Lever Limit Switch 40 - 47 K Cab Harness `E' 332/J3663 - Issue
1 ( T C-206)
6 C222 Interior Lamp Switch
40 C180 Fascia Link 1
7 C33 (Dozer On Switch (wheeled only))
41 C811 Fascia Link 3
8 C32 Lever Hammer Switch
42 C10 ECU Connector C
9 C34 Horn Switch
43 C9 ECU Connector B
10 EH Earth Header
44 C6 24V Supply
11 - 25 K Cab Harness `B' 332/J3663 - Issue
1 ( T C-203) 45 C5 24V Supply (battery)
11 C219 Auxiliary 1 46 C0250
12 C226 Auxiliary 2 47 C0214 Cab Roof Harness
13 C224 Voltage Converter 48 - 62 K Cab Harness `F' 332/J3663 - Issue
1 ( T C-207)
14 C11 Diagnostic Connector
48 C112 Breaker Pilot Switch
15 C13 Redundancy Switch
49 C172 Blanking Connection
16 C228 Lower Wiper
50 C0232 Merge Flow Solenoid B
17 C227 Wiper 2
51 C167_1 Plug
18 C110 Diode 1 Washer
52 C163 Merge Solenoid Valve C
19 C161 Diode 5
53 C163_1 Plug
20 C155 Diode 3 Redundancy 1
54 C169 Ham/Aux/Sol V C
21 C156 Diode 4 Redundancy 2
55 C169_1 Plug
22 C320 Int Lamp Diode
56 C204 Boom Up Pressure Switch
23 C0256 ECM Engine
57 C71_1 Plug
24 C0009 Auto Fan
58 C73 Swing Pilot Switch
25 C318 Qualcom Tracking
59 C221 Auto Mode Pressure Switch
26 - 33 K Cab Harness `C' 332/J3663 - Issue
1 ( T C-204) 60 C57 Boom Priority
26 C296 Fuse Box 61 C201 Lower Wiper
27 C254 Lift Pump 62 C201_1 Plug
28 C230 Refuel Pump Relay 63 - 72 K Cab Harness `G' 332/J3663 - Issue
1 ( T C-208)
29 C271 Emergency Stop
63 C22 Throttle Dial
30 C0251 Main Relay
64 C0027 Lever Switch
31 C0257 ECM Engine
65 C30 Grab CCW/CW
32 C263 Barometric
66 C184 Key Switch A
33 C252 Teir III Link
67 C43 Boom Priority Switch
68 C202 Heated Seat Switch
C-200 9803/9800-3 C-200
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type B
Item Connector Function
69 C185 Key Switch B
70 C0220 Lower Wiper Switch
71 C203 Heated Switch
72 C160 Options Hydraulic Switch
C-201 9803/9800-3 C-201
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type B
7 8
6
9
B
2
3
10
4
FULLY TAPED
UNTAPED
CONVOLUTE TUBE
SPACETAPE
T027190-1
Fig 217. Cab Harness `A' 332/J3663 - Issue 1
C-202 9803/9800-3 C-202
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type B
14
13
15
12
16
11
17
18
19
25
A 20
24 21
22
C
23
FULLY TAPED
UNTAPED
CONVOLUTE TUBE
SPACETAPE
T027200-1
Fig 218. Cab Harness `B' 332/J3663 - Issue 1
C-203 9803/9800-3 C-203
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type B
33
B D
32
28 29 27 30
26
31
FULLY TAPED
UNTAPED
CONVOLUTE TUBE
SPACETAPE
T027210-1
Fig 219. Cab Harness `C' 332/J3663 - Issue 1
C-204 9803/9800-3 C-204
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type B
34
FULLY TAPED
UNTAPED
CONVOLUTE TUBE
SPACETAPE
35
39
38
36
C
37
T027220-1
Fig 220. Cab Harness `D' 332/J3663 - Issue 1
C-205 9803/9800-3 C-205
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type B
FULLY TAPED
47 UNTAPED
CONVOLUTE TUBE
SPACETAPE
46
40
45
44
41
D F
43
42
T027230-1
Fig 221. Cab Harness `E' 332/J3663 - Issue 1
C-206 9803/9800-3 C-206
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type B
FULLY TAPED
UNTAPED
CONVOLUTE TUBE
48 49 SPACETAPE
PVC TUBE
50
51
62
61
52
53
54
55
56
57
60
58
59
E G
T027240-1
Fig 222. Cab Harness `F' 332/J3663 - Issue 1
C-207 9803/9800-3 C-207
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type B
1
63
3
2
4 5
7
6 8
72
71
64
70
69
65
68
66
67
FULLY TAPED
UNTAPED
CONVOLUTE TUBE
SPACETAPE
T027250-1
Fig 223. Cab Harness `G' 332/J3663 - Issue 1
C-208 9803/9800-3 C-208
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type C
Cab Harness (includes Engine Harness) - Type C
Connector Identification Item Connector Function
33 C349 Beacon Relay
Table 14.
Item Connector Function 34 C251 Main Relay
1 - 10 K Cab Harness `A' 332/J3254 - Issue 35 - 39 K Cab Harness `E' 332/J3254 - Issue
3 ( T C-211) 3 ( T C-215)
1 C0173 Earth Header 35 C1 Connector A
2 C0174 Earth Header 36 C0218 HVAC Unit Connector
3 C0175 Earth Header 37 C8 ECU Connector A
4 C0176 Earth Header 38 C164 Earth Connector
5 C115 Lever Limit Switch 39 C4 Wheeled Option Cab
6 C222 Interior Lamp Switch 40 - 46 K Cab Harness `F' 332/J3254 - Issue
3 ( T C-216)
7 C33 (Dozer On Switch (wheeled only))
40 C180 Fascia Link 1
8 C32 Lever Hammer Switch
41 C0214 Cab Roof Harness
9 C34 Horn Switch
42 C10 ECU Connector C
10 EH Earth Header
43 C9 ECU Connector B
11 - 25 K Cab Harness `B' 332/J3254 - Issue
3 ( T C-212) 44 C6 24V Supply
11 C219 Auxiliary 1 45 C5 24V Supply (battery)
12 C226 Auxiliary 2 46 C0250
13 C0253 Tech 2 47 - 62 K Cab Harness `G' 332/J3254 - Issue
3 ( T C-217)
14 C11 Diagnostic Connector
47 C0214 Cab Roof Harness
15 C13 Redundancy Switch
48 C112 Breaker Pilot Switch
16 C214 Lower Wiper
49 C172 Blanking Connection
17 C228 Wiper 2
50 C0232 Merge Flow Solenoid B
18 C110 Diode 1 Washer
51 C167_1 Plug
19 C161 Diode 5
52 C163 Merge Solenoid Valve C
20 C155 Diode 3 Redundancy 1
53 C163_1 Plug
21 C156 Diode 4 Redundancy 2
54 C169 Ham/Aux/Sol V C
22 C320 Int Lamp Diode
55 C169_1 Plug
23 C0256 ECM Engine
56 C204 Boom Up Pressure Switch
24 C224 Volt Dropper
57 C71_1 Plug
25 C318 Qualcom Tracking
58 C73 Swing Pilot Switch
26 - 30 K Cab Harness `C' 332/J3254 - Issue
3 ( T C-213) 59 C221 Auto Mode Pressure Switch
26 C254 Lift Pump 60 C57 Boom Priority
27 C230 Refuel Pump Relay 61 C201 Lower Wiper
28 C271 Emergency Stop 62 C201_1 Plug
29 C0257 ECM Engine 63 - 72 K Cab Harness `H' 332/J3254 - Issue
3 ( T C-218)
30 C0263 Barometric
63 C22 Throttle Dial
31 - 34 K Cab Harness `D' 332/J3254 - Issue
3 ( T C-214) 64 C0027 Lever Switch
31 C252 Tier 3 Link 65 C30 Grab CCW/CW
32 C296 Fusebox 66 C184 Key Switch A
67 C43 Boom Priority Switch
C-209 9803/9800-3 C-209
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type C
Item Connector Function
68 C202 Heated Seat Switch
69 C185 Key Switch B
70 C0220 Lower Wiper Switch
71 C203 Heated Switch
72 C160 Options Hydraulic Switch
C-210 9803/9800-3 C-210
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type C
6
9
5 FULLY TAPED
UNTAPED
CONVOLUTE TUBE
SPACE TAPE
PVC TUBE
3
B
4 10
T044210
Fig 224. Cab Harness `A' 332/J3254 - Issue 3
C-211 9803/9800-3 C-211
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type C
14
13
15
24
FULLY TAPED
UNTAPED
12 CONVOLUTE TUBE
SPACE TAPE
PVC TUBE
11
17 18
16 19 20
25
21
A 22
23
T044220
Fig 225. Cab Harness `B' 332/J3254 - Issue 3
C-212 9803/9800-3 C-212
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type C
30
B
29
27
28
26
FULLY TAPED
UNTAPED
CONVOLUTE TUBE
SPACE TAPE
PVC TUBE
T044230
Fig 226. Cab Harness `C' 332/J3254 - Issue 3
C-213 9803/9800-3 C-213
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type C
31
C
E
32
34
33
FULLY TAPED
UNTAPED
CONVOLUTE TUBE
SPACE TAPE
PVC TUBE
T044240
Fig 227. Cab Harness `D' 332/J3254 - Issue 3
C-214 9803/9800-3 C-214
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type C
FULLY TAPED
UNTAPED
CONVOLUTE TUBE
SPACE TAPE
PVC TUBE
35
39
38 36
D F
37
T044250
Fig 228. Cab Harness `E' 332/J3254 - Issue 3
C-215 9803/9800-3 C-215
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type C
FULLY TAPED
UNTAPED
CONVOLUTE TUBE
SPACE TAPE
PVC TUBE
41
46
45
40
44
E G
42
43
T044260
Fig 229. Cab Harness `F' 332/J3254 - Issue 3
C-216 9803/9800-3 C-216
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type C
49
48
FULLY TAPED
62 UNTAPED
CONVOLUTE TUBE
SPACE TAPE
PVC TUBE
50
61
51
52
53
54 55
56 57
58
60
F H
59
T044270
Fig 230. Cab Harness `G' 332/J3254 - Issue 3
C-217 9803/9800-3 C-217
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type C
63
1 3
4
2
5 64
71 6
7
8
72 65
G 67
66
70
69
68
FULLY TAPED
UNTAPED
CONVOLUTE TUBE
SPACE TAPE
PVC TUBE
T044280
Fig 231. Cab Harness `H' 332/J3254 - Issue 3
C-218 9803/9800-3 C-218
Section C - Electrics
Harness Data
Cab Harness (includes Engine Harness) - Type C
Page left intentionally blank
C-219 9803/9800-3 C-219
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