Section C

Electrics
Service Manual - JS Auto Range - Tracked Excavators - JCB Engine
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 & Running Gear
Section K - Engine

Publication No.
9813/1000-3

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 9813/1000-3 C-0

 Section C - Electrics

Contents Page No.

Basic System Operation
Circuit Symbols ........................................................................................ C - 1
Schematic Diagram ................................................................................. C - 3
A.M.S (Advanced Management System) .............................................. C - 11
Circuit Concepts .................................................................................... C - 13
Pulse Width Modulation (PWM) ............................................................. C - 16
ECU 1 Supply to Output Drivers ............................................................ C - 17
Engine Throttle Control .......................................................................... C - 19
Pump Control for Each Mode ............................................................... C - 25
Hardware Sensing ................................................................................. C - 29
Auto Boost Pressure .............................................................................. C - 30
Engine Oil Level Warning ...................................................................... C - 33
Engine Automatic Warm Up .................................................................. C - 35
Engine Automatic Idle ............................................................................ C - 37
Engine One Touch Idle .......................................................................... C - 39
Engine Start/Stop - JS160-220 .............................................................. C - 43
Engine Cranking .................................................................................... C - 45
Alternator/ No Charge Warning - JS115-145 ......................................... C - 47
Alternator/No Charge Warning - JS160-220 .......................................... C - 48
Limp Mode system ................................................................................ C - 50
Lever Lock ............................................................................................. C - 52
Servo Isolator ........................................................................................ C - 54
Wiper ..................................................................................................... C - 56
Lower Wiper (option) ............................................................................. C - 58
Washer .................................................................................................. C - 60
Horn ....................................................................................................... C - 62
Travel Alarm .......................................................................................... C - 64
Soft/Hard (Cushion) ............................................................................... C - 66
Slew Brake (100%) ................................................................................ C - 68
Slew lock (100% Slew Brake) ................................................................ C - 72
Slew Brake Solenoid Valve Failure ........................................................ C - 74
3-Speed Travel ...................................................................................... C - 75
Work Lamps .......................................................................................... C - 80
Viscous Fan ........................................................................................... C - 82
Fuel Level Sensor/Warning ................................................................... C - 83
Engine Temperature Sensor/Warning ................................................... C - 86
Coolant Level Warning .......................................................................... C - 91
Air Filter Blocked Warning ..................................................................... C - 92
Hydraulic Temperature Sensor/Warning ................................................ C - 94
Quick hitch (option) ................................................................................ C - 98
Overload Caution (option) ................................................................... C - 100
Beacon ................................................................................................ C - 102
Hammer Only ...................................................................................... C - 104
Scrap Magnet Option ........................................................................... C - 108
Cab Interior Lamp ................................................................................ C - 110
Refuelling Pump .................................................................................. C - 112
Heated Seat ........................................................................................ C - 114
24 to 12 Volt Converter, Radio and Power Socket .............................. C - 115
Service Required Warning ................................................................... C - 118
EMS Set Menu .................................................................................... C - 120
EMS Set + Mode Menu ....................................................................... C - 121
EMS Set+Mode (20 sec) Menu. .......................................................... C - 122

Fault Finding
JCB Servicemaster .............................................................................. C - 125

C-i C-i
 Section C - Electrics

Contents Page No.

Fault Finding Without Using the JCB Servicemaster Diagnostic Tool . C - 160

Service Procedure
Testing of ECU Inputs + Outputs ......................................................... C - 165
Using a Multimeter ............................................................................... C - 167
Battery ................................................................................................. C - 171
Wiring Harness Repair ........................................................................ C - 174

Harness Data
Harness Interconnection ...................................................................... C - 177
Main Harness JS115-145 .................................................................... C - 178
Main Harness JS160-JS180 ................................................................ C - 183
Main Harness JS200-JS220 ................................................................ C - 189
Fascia Link Harness ............................................................................ C - 195
Cab Harness JS115-145 ..................................................................... C - 205
Engine Harness JS115-145 ................................................................. C - 213
Cab Harness JS160-JS220 (Includes Engine Harness) ...................... C - 215

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.

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 Section C - Electrics
Basic System Operation
Circuit Symbols

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 Section C - Electrics
Basic System Operation
Schematic Diagram

Schematic Diagram

JS115-145 Item Part Number Description

41 333/J3309 Pump
The item numbers in the following table are identified on
the wiring schematics in this section. K Fig 12. ( T C-10). 42 20/925546 Refuel pump
43 333/J2693 Lower wiper
Item Part Number Description 44 332/S4197 Beacon
1 332/K6848 Electronic control unit 1 45 320/08563 Air con compressor
2 332/K4244 Electronic monitor system 46 30/925618 Air con binary switch
3 701/80369 Facia switch panel 47 717/20152 Horn
5 716/30155 Throttle dial 48 JHN0160 Washer bottle
6 701/80184 Key switch 50 716/30129 Temperature sensor
7 701/80214 Switch (redundancy) 51 701/80328 Overheat switch
8 332/K6274 ATC 52 333/J2937 Fuel level sensor
9 332/J3834 Heater 53 331/13929 Coolant level switch
10 332/K4895 Controller (ATC) 54 JNH0070 Air filter clog switch
10 332/K4896 Controller (Heater) 55 701/80192 Overload pressure switch
11 701/E0034 Switch body 56 332/J0671 Pilot switch, auto mode
12 701/E8826 Switch cap (worklamp) 57 332/J2971 Pilot switch, auto boost
13 332/L6105 Power Socket (12v) 58 701/E0001 Switch (radio mute)
14 717/K4986 Radio 59 701/E0034 Switch (heated seat)
15 701/80215 Limit switch (lever) 60 332/K6199 Heated seat
16 701/E0041 Switch (cab light) 61 332/K2446 Direction control valve
18 700/43900 Work lamp 64 721/10455 Harness hammer
19 700/50022 Work lamp 65 701/11632 Harness
20 332/J0670 Breaker pilot switch 66 701/E0223 Switch body
21 25/222892 LH Lever switch 67 701/E0032 Switch body
22 25/222892 RH Lever switch 68 721/10458 Harness Ham/Aux merged
23 717/C5944 Volt dropper 71 25/222397 Proportional Solenoid
25 714/40289 Wiper 72 333/J7614 Harness - main
26 6900/0587 Room lamp 73 333/J7613 Harness - cab
27 716/30205 Battery relay 74 333/J7614 Harness - facia ATC
28 332/F3103 Battery 74 333/J7616 Harness - facia Heater
32 332/J4523 Valve block solenoid 77 JHR0174 Relay
35 332/J0670 Pilot switch, upper 78 701/80310 Switch refueling pump
36 332/J0671 Pilot switch, travel 79 721/11451 Harness - low flow
37 332/J0669 Pilot switch 80 717/C5945 Volt Dropper 15A
40 717/07700 Travel alarm 81 701/47400 Battery Isolator

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 Section C - Electrics
Basic System Operation
Schematic Diagram

Item Part Number Description

E
82 265/00893 Battery Isolator Relay 24V Cover
83 333/S5959 Relay 24V Relay G
F
85 332/J9681 Cab PCB
716/C9471 Ambient Temp Sensor
333/J3630 Throttle Actuator
333/J3672 Throttle Position Sensor H I
320/09522 RPM Sensor

Note: Items 64 to 68 are part numbers for the bridging A408581

harnesses and switches for the option switch in the right Fig 4.
hand console
E Multiple cables
F Single cables
G Cables joined
H Cable not joined
I Earth cables

Fig 3.

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 Section C - Electrics
Basic System Operation
Schematic Diagram

Fig 5. 333/J6805 - Issue 1 - Sheet 2 - ATC Schematic

Fig 6. 333/J6805 - Issue 1 - Sheet 2 - Heater Schematic

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 Section C - Electrics
Basic System Operation
Schematic Diagram

Fig 7. 333/J6805 - Issue 1 - Sheet 1

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 Section C - Electrics
Basic System Operation
Schematic Diagram

JS160-JS220 Item Part Number Description

43 215/11950 Lower wiper
The item numbers in the following table are identified on
the wiring schematics in this section. K Fig 12. ( T C-10). 44 332/S4197 Beacon
45 123/04999 Air con compressor
Item Part Number Description 46 30/926997 Air con binary switch
1 332/K6848 Electronic control unit 1 47 717/20152 Horn
2 332/K4244 Electronic monitor system 48 JHN0160 Washer bottle
3 701/80369 Facia switch panel 50 716/30129 Temperature sensor
5 716/30155 Throttle dial 51 701/80328 Overheat switch
6 701/80184 Key switch 52 333/J2937 Fuel level sensor
7 701/80214 Switch (redundancy) 53 331/13929 Coolant level switch
8 332/K6274 ATC 54 JNH0070 Air filter clog switch
9 332/J3834 Heater 55 701/80192 Overload pressure switch
10 332/K4895 Controller (ATC) 56 332/J0671 Pilot switch, auto mode
10 332/K4896 Controller (Heater) 57 332/J2971 Pilot switch, auto boost
11 701/E0034 Switch body 58 701/E0001 Switch (radio mute)
12 701/E8826 Switch cap (worklamp) 59 701/E0034 Switch (heated seat)
13 332/L6105 Power Socket (12v) 60 332/K6199 Heated seat
14 717/K4986 Radio 61 JRJ0343 Direction control valve
15 701/80215 Limit switch (lever) 62 25/220536 Valve, solenoid
16 701/E8906 Switch (cab light) 63 25/222887 Priority valve (w/cutter)
18 700/43900 Work lamp Priority valve (grab rotate)
19 700/50022 Work lamp 64 721/10455 Harness hammer
20 332/J0670 Breaker pilot switch 65 701/11632 Harness
21 25/221094 LH Lever switch 66 701/E0223 Switch body
22 25/221095 RH Lever switch 67 701/E0032 Switch body
23 717/C5944 Volt dropper 68 721/10458 Harness Ham/Aux merged
25 6900/0624 Wiper 72 25/222397 Harness - main JS160
26 6900/0587 Room lamp 72 332/J2881 Harness - main JS200
27 716/30205 Battery relay 73 332/J2885 Harness - cab
28 332/F3103 Battery 74 332/K2452 Harness - facia ATC
32 25/222203 Valve block 8 station 74 332/K2461 Harness - facia Heater
35 332/J0670 Pilot switch, upper 77 JHR0174 Relay
36 332/J0671 Pilot switch, travel 78 701/80310 Switch refueling pump
37 332/J0669 Pilot switch 79 721/11451 Harness - low flow
40 717/07700 Travel alarm 80 717/C5945 Volt Dropper 15A
41 333/J0818 Pump JS160 81 701/47400 Battery Isolator
41 333/J4187 Pump JS200 82 265/00893 Battery Isolator Relay 24V Cover
42 20/925675 Refuel pump 83 333/S5959 Relay 24V Relay

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 Section C - Electrics
Basic System Operation
Schematic Diagram

Item Part Number Description

E
84 717/20359 Relay Box
85 332/J9681 Cab PCB G
F
86 717/20359 POD BOX

Note: Items 64 to 68 are part numbers for the bridging

harnesses and switches for the option switch in the right
hand console H I

A408581

Fig 9.
E Multiple cables
F Single cables
G Cables joined
H Cable not joined
I Earth cables

Fig 8.

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 Section C - Electrics
Basic System Operation
Schematic Diagram

Fig 10. 332/K4939 - Issue 4 - Sheet 2 - ATC Schematic

Fig 11. 332/K4939 - Issue4 - Sheet 2 - Heater Schematic

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 Section C - Electrics
Basic System Operation
Schematic Diagram

Fig 12. 332/K4939 - Issue 4 - Sheet 1

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 Section C - Electrics
Basic System Operation
A.M.S (Advanced Management System)

A.M.S (Advanced Management System)

Operation
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
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.
D
A Electronic Control Unit -1 (ECU-1) Fig 14. JS160-220
B Electronic Monitoring System (EMS)
C Fascia switch panel (FSP).
B
D Engine Control Module (ECM)
JS160-220 Models only.

401741-C3

401741-C4
Fig 15.
A

C030670-C3
Fig 13.

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 The AMS System

C-12
Electronic Engine Only

A
CAN BUS G
ENGINE
F

EMS ECM

9813/1000
M
B SPI BUS

ECU 1

C
T006140-1
Fig 16.

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
A.M.S (Advanced Management System)
Section C - Electrics

C-12
Basic System Operation
 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 18.
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 17.

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.

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 Section C - Electrics
Basic System Operation
Circuit Concepts
Analogue input (i.e. sensor type inputs)

C045960GB-2
Fig 19.

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 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 21.
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 22.

C007220GB-2
Fig 20.

2 High side output. The high side output is used to

operate solenoids, bulbs and horn.

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 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 23. C007270GB-2
Fig 24.
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.

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