JS160 Operação

Section C
Electrics
Service Manual - JS160 - JS190
Section 1 - General Information
Section 2 - Care & Safety
Section 3 - Maintenance
Section B - Body & Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section J - Track & Running Gear
Section K - Engine
Publication No.
9803/6570-2
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
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C-0 9803/6570-2 C-0

Contents Page No.

Basic System Operation
Controls and Components ....................................................................... C - 1
Driver Controls and Switches .................................................................. C - 3
Operating Levers/Pedals ....................................................................... C - 18
Circuit Symbols ...................................................................................... C - 20
Component Identification ....................................................................... C - 21
Schematic Diagram ............................................................................... C - 24
Component Identification ....................................................................... C - 25
Schematic Diagram ............................................................................... C - 28
A.M.S (Advanced Management System) .............................................. C - 29
Circuit Concepts .................................................................................... C - 31
Pulse Width Modulation (PWM) ............................................................. C - 34
ECU1/EMS/FACIA Power Supply and Network .................................... C - 35
ECU 1 Supply to Output Drivers ............................................................ C - 36
Hardware Sensing ................................................................................. C - 37
Engine Throttle Control .......................................................................... C - 38
Auto Boost Pressure .............................................................................. C - 43
Engine Oil Level Warning ...................................................................... C - 46
Engine Pre Heat (Glow plugs) ............................................................... C - 48
Engine Automatic Warm Up .................................................................. C - 50
Engine Automatic Idle ............................................................................ C - 52
Engine One Touch Idle .......................................................................... C - 53
Engine Start/Stop ................................................................................... C - 55
Limp Mode system ................................................................................ C - 57
Pump Control for Each Mode ................................................................ C - 59
Lever Lock ............................................................................................. C - 65
Servo Isolator ........................................................................................ C - 66
Wiper ..................................................................................................... C - 68
Lower Wiper (option) ............................................................................. C - 70
Washer .................................................................................................. C - 72
Horn ....................................................................................................... C - 74
Travel Alarm .......................................................................................... C - 76
Soft/Hard (Cushion) ............................................................................... C - 78
Slew Brake (100%) ................................................................................ C - 80
Slew lock (100% Slew Brake) ................................................................ C - 83
Slew Brake Solenoid Valve Failure. ....................................................... C - 85
3-Speed Travel ...................................................................................... C - 86
Work Lamps .......................................................................................... C - 90
Fuel Level Sensor/Warning ................................................................... C - 92
Engine Temperature Sensor/Warning ................................................... C - 95
Coolant Level Warning .......................................................................... C - 99
Air Filter Blocked Warning ................................................................... C - 100
Warning Indicator Lamps ..................................................................... C - 101
Hydraulic Temperature Sensor/Warning .............................................. C - 102
Alternator/ No Charge Warning ........................................................... C - 106
Quick hitch (option) .............................................................................. C - 108
Overload Caution (option) ................................................................... C - 110
Beacon ................................................................................................ C - 112
Hammer Only ...................................................................................... C - 114
Scrap Magnet Option ........................................................................... C - 117
Cab Interior Lamp ................................................................................ C - 118
Refuelling Pump .................................................................................. C - 120
Air Conditioning ................................................................................... C - 121
Heated Seat ........................................................................................ C - 122
24 to 12 Volt Converter, Radio and Cigar Lighter ................................ C - 123
C-i C-i
Contents Page No.

Service Required Warning ................................................................... C - 125
EMS Set Menu. ................................................................................... C - 127
EMS Set + Mode (5 Sec) Menu ........................................................... C - 128
EMS Set+Mode (20 sec) Menu. .......................................................... C - 129
Fault Finding
JCB Service Master ............................................................................. C - 131
Using Service Master .......................................................................... C - 132
Selecting Service Tool Applications ..................................................... C - 133
Service Master 2 Machine Pages ........................................................ C - 134
System Menus ..................................................................................... C - 136
HPSetup Overview .............................................................................. C - 137
Using ECM Setup ................................................................................ C - 138
Using HPSetup .................................................................................... C - 142
DLA Port Configuration ........................................................................ C - 149
Data Link Adaptor ................................................................................ C - 151
HPDataLogs ........................................................................................ C - 152
FLASH Programming Application ........................................................ C - 164
Introduction to the Diagnostics Tool ..................................................... C - 166
Connecting to the Vehicle .................................................................... C - 167
Starting Diagnostic Mode ..................................................................... C - 168
Circuit Diagrams .................................................................................. C - 169
Indicator Lights (LEDs) ........................................................................ C - 170
Stopping Diagnostic Mode ................................................................... C - 171
Language Setting ................................................................................ C - 172
List of text messages displayed on the EMS. ...................................... C - 173
Fault Finding Without using the JCB Service Master Diagnostic Tool . C - 178
Service Procedure
Testing of ECU Inputs + Outputs ......................................................... C - 183
Wiring Harness Repair ........................................................................ C - 185
Battery ................................................................................................. C - 188
Harness Data
Main Harness ...................................................................................... C - 191
Facia Link Harness .............................................................................. C - 200
Cab Harness ........................................................................................ C - 203
Engine Harness ................................................................................... C - 214
C - ii C - ii

Controls and Components
Fig 1.
1 Right Console K Right Console ( T C-3) 5 Left Hand Track Control K Operation
Levers ( T C-19)
2 Right Excavator Joystick Control K Right
Console ( T C-3) 6 Left Excavator Joystick Control K Left
Console ( T C-6)
3 Display Monitor (adjustable view) K Monitor
Panel ( T C-7) 7 Control Lock Lever K Left Console ( T C-6)
4 Right Hand Track Control K Operation 8 Left Console K Left Console ( T C-6)
Levers ( T C-19)
9 Door Lock Release Lever.
C-1 9803/6570-2 C-1

Controls and Components
Fig 2.
10 Optional Circuit Pedal (if fitted) K Optional Circuit 17 Mobile Phone holder
Pedal (if fitted) ( T C-19)
18 Ashtray
11 Facia Panel K Fascia Panel ( T C-12)
19 Cigarette lighter/ mobile phone charger
12 Air Cond./Heater Controls K Heater/Air
Conditioning Controls ( T C-14)
13 Interior light switch (Timed) K Cab Interior

Lights ( T C-17)
14 Seat/Console Slide lever.
15 Dozer Operating lever K Right Console ( T C-3)
16 Cup holder
C-2 9803/6570-2 C-2

Driver Controls and Switches
Right Console
Fig 3.
1 Starter Switch. and the excavator and dozer are lowered before
stopping the engine.
This is operated by the starter key. It has four
positions. The key can only be removed when in the I - On. Turning the key in this position connects the
'O' position. battery to the electrical circuits The key will spring
back to this position when released from lIl.
`O' Off/Stop Engine. Turn the key to this position to
stop the engine. Make sure the controls are in neutral II - This position is not used in this application.
lll - Start. Operates the starter motor to turn the

engine. The starter switch has an inhibitor to stop the
switch being turned ON when the engine is running
Note: Do not operate the starter for more than 20 seconds

at one time.
C-3 9803/6570-2 C-3

2 Throttle Dial. rockbreaker circuit 1, auxiliary circuit 2 or merged
flow circuit 3.
This rotary control provides progressive engine
speed control over the full range.
If the engine is started with the throttle dial not at the

minimum position, no engine speed control will be
possible until the dial is first turned to the minimum
position.
Note: If the engine speed does not change even after

turning the throttle dial it is because the auto idle or the one
touch switch is ON. Push the idle switch to OFF to
reactivate the throttle dial.
R
3 SAE/ISO Indicator Light (if fitted).
The light indicates the mode the servo controls are

set in. The indicator light will always be illuminated in 1
the selected mode when the engine is running. 2 3 B
4 Hammer/Auxiliary Switch (if fitted).
Press the switch to change the additional hydraulic
a Machines with combined rockbreaker and two circuit from auxiliary (full flow) circuit to hammer
way auxiliary circuit. (reduced flow) circuit.
The switch A has two positions, press the switch 5 Heated Seat Switch (if fitted).
to change the additional hydraulic circuit from
rockbreaker circuit 1 to auxiliary circuit 2. The switch turns the heated seat ON or OFF.
Note: The seat element will only be heated when the seat
thermostat falls below 20°C.
6 Lower Wiper Switch (if fitted).
The switch turns the lower wiper ON or OFF.
7 Boom Priority Switch (if fitted)
Press the switch to change priority of boom raise to

swing. Selecting the boom priority switch during
simultaneous slew and boom operation will restrict
flow to the slew motor and therefore give more flow to
the boom up operation.
1 When the switch is pressed the monitor will display

2 A "BOOM PRIOR" acknowledgement message.
b Machines with rockbreaker, two way auxiliary 8 Radio Mute Switch.

circuit and merged circuit.
This switch is used to temporarily switch the sound
The switch B has three positions, press the switch from the radio OFF. When the mute switch is selected
to change the additional hydraulic circuit from the indicator light will illuminate. When the switch is
C-4 9803/6570-2 C-4

reselected the radio sound will resume and the
indicator will extinguish.
9 Work light Switch.
Press the switch to the first position to switch ON the

Standard work lights (on boom and the right hand of
the machine). Press the switch to the second position
to switch ON the optional lights (on the cab and the
counterweight - if fitted).
10 Auxiliary Circuit Switch (Low Flow).
This three-position rocker switch, spring loaded to the

central OFF position, provides bi-directional flow for
relevant attachments, e.g. weedcutter, grab rotate.
Press and hold the switch to the right or left, as
appropriate, for as long as the attachment is to be
used. Release the switch to turn off the attachment.
11 One Touch Idle Switch.
Pressing this switch instantly changes the engine rpm

back and forth between that selected for working and
a `low idling' speed. When `low idling' has been
selected the message "LOW IDLE" is displayed on
the Display Monitor. This facility is overridden when
the Manual/Auto Change switch is set to `Auto'.
12 Cigar Lighter/12V Power point.
To operate the lighter, press it fully into its socket.

When it has heated up sufficiently it will spring
forward a little way out of its socket. It can then be
removed for use. REMEMBER IT WILL BE HOT.
Return the lighter to its socket after use.
This machine is equipped with a 12V system and can

be used for mobile phone chargers or other 12v
powered devices (maximum draw 5A).
13 Travel Speed Change Switch.
This switch is used to alter the speed of the machine

between high, medium or low K Travel Speed
Change Button ( T C-18)
C-5 9803/6570-2 C-5

Left Console
Fig 4.
1 Horn Switch.
When the horn switch is pressed the horn will sound.
Note: always press the switch and sound the horn to give
signals, when the machine is started or you engage travel
or slew.
2 Control Lock Lever.
Raising the lever provides a method of isolating the

hydraulic controls and is an integral part of the
procedure for vacating the cab. Lower the lever to
activate the hydraulic controls.
3 Boom Priority Switch.

Fig 5.
Press and hold the switch to change priority of slew to
boom raise. Release the switch to deselect boom
priority.
4 Courtesy light.
A courtesy light is provided if cabin lighting is required

during entering or preparing to leave the cab. The
timed light switch is located on the side of the left
control console, facing the door at 4. The light will self
extinguish after 5 minutes or after a second press of
the switch.
C-6 9803/6570-2 C-6

Monitor Panel 5 Scroll Up Switch.
1 Display Panel Monitor. 6 Scroll Down Switch.
The monitor panel is located at the front of the cab in 7 Warning Lamps.
the line of sight from the operator's seat. It provides
the interface with the machines system. The display Eighteen tell tale warning light indicators are included
has 20 segment bar graph gauges for fuel, hydraulic on the monitor.
and water temperatures, a clock, gear, power, mode
and hours run meter. The panel also has an eleven
character message area.
2 Mode Switch.
Press to select working mode. The machine will be in POWER
the same mode as when last switched off. Each press MODE
cycles through the modes as follows:
E-A-P-L-E
(The applied mode is indicated next to the POWER

MODE message.)
Select the appropriate work mode suitable for the

work to be carried out:
A - AUTO MODE for heavy digging or increased work

output and general digging. Not recommended for
grading due to the variation in engine rev/min and
pump control.
E - ECONOMY MODE for digging and loading with

low fuel consumption.
P - PRECISION MODE for precise or light duty work.

Fig 6.
L - LIFTING MODE for operations requiring maximum
accuracy, including lifting, with extra hydraulic
pressure available if required.
Indicates that machine hours are
3 Set Switch. displayed top left of the display. This
symbol flashes when the machine is
Press the SET switch to access the monitor menu. operating, this signifies that the hour meter
The menu can be scrolled through using the Scroll Up is increasing the service time.
and Scroll Down switches.
4 ACK Switch.
Press to acknowledge warnings shown on the Indicates the time at the top right of the
display. This will clear the message but will not put out display.
warning lamps. The ACK Switch can cancel the
warning buzzer when sounding.
C-7 9803/6570-2 C-7

Fault Indicator
See message on display panel.
Indicates that transmission information is
displayed top centre of the display.
!MCAUTION Servo Isolator ON

All the warning lights should go out within 10 seconds Illuminates when the machines servo
of the engine being started. Rectify any faults isolator is engaged. Lower the lock lever
immediately. or press the isolator switch to disengage
0009 the isolator.
Warning Lights
Low Coolant Level
Illuminates if the engine coolant level
Slew Lock ON
drops too low. Inspect and refill coolant.
Illuminates when the machine slew lock is
engaged. Press the slew lock switch to
disengage the slew lock.
High Engine coolant Temperature
Illuminates if the engine coolant
Engine Diagnostics temperature rises to high. Put the engine
into low idle and wait until the temperature
Illuminates when an error occurs with
is normal (inspect and clean radiator).
engine. Engine error code shown on
display panel. Refer to Engine Service
Manual. Low Engine Oil Pressure
Illuminates if the engine oil pressure drops
Charging System Fault too far. The light should go out when the
Illuminates when the battery voltage is engine is started. If illuminated, stop
low. If Illuminated check electrical circuit. engine, check oil level and inspect for
leaks.
Engine Air Filter Blocked

Service Required Illuminates if the engine air filter is
This warning is illuminated when a service blocked. Replace the element.
is required. The warning flashes when a
minor service is required (250 hours) and
can be cancelled by pressing the ACK
switch on the monitor. The warning will
High Hydraulic Oil Temperature
illuminate continuously when a major
service is required (500 hours) If lit Illuminates if the hydraulic fluid
continuously, contact your JCB dealer. temperature rises too high. Put the engine
into low idle and wait until the temperature
is normal (inspect and clean radiator).
C-8 9803/6570-2 C-8

Cruise Control (Wheeled Machine Only) Monitor Settings

Illuminates when cruise control is
activated on the left console switch panel. Set Switch
Press SET switch to access the monitor menu. Use the
SET menu to change the settings of some of the
machines functions. The menu can be scrolled through
using the scroll up and scroll down switches. When the
Direction Indicator (Wheeled Machine Only) required item is displayed or after adjusting settings,
press the ACK switch to confirm.
Flashes with the direction indicators. (Also
flashes when Hazard Warning Lights are
on). Use the indicators to signal before Intermittent wiper speed - Used to adjust the time
turning. delay for the intermittent wiper.
INT WIPER S
Hazard Warning Lamps Indicator (Wheeled Machine ACK
Only)
WIPER SPD -1 Use scroll keys to change speed
Flashes with the hazard warning lights
ACK
(even with the starter switch OFF). Switch
the flashers on whenever your machine is
a possible hazard. Language - Used to change the language of the
display messages.
Main Beam Indicator (Wheeled Machine Only)
Illuminates when the headlight main
beams are switched on. Date - Used to adjust to date
DATE
ACK
Travel Mode (Wheeled Machine Only) 02-10-1999 Use scroll keys to change date
Illuminates when road travel is activated ACK
on the left console switch panel.
Set Clock - Use to adjust the displayed time.
CLOCK
ACK
Low Brake Pressure (Wheeled Machine Only)
12/24? Use scroll keys to change 12h or 24h
Illuminates when the brake circuit clock
pressure falls below the pre-determined
minimum permissible. ACK
12:10 Use scroll keys to change time
ACK
Emergency Steer Mode (Wheeled Machine Only)
Illuminates to indicate that the power
steering pressure has failed. Steering is
still possible although much greater effort
is required.
C-9 9803/6570-2 C-9

Hammer hours - Used to view the total cumulative

hours the hammer has been used, also used to reset
the hour count since the last hammer service.
HAMMER HRS
ACK
12345 (Total amount of 1234 (Hours since last hammer
hours hammer used) service)
ACK
RESET HRS? Resets the hour count since the
last hammer service
ACK
Engine speed for hammer - Used to set the maximum

engine speed, when using a Rockbreaker. When using
a Rockbreaker it may be necessary to limit the engine
speed - consult your JCB Dealer.
HAMMER RPM
ACK
RPM 1200 Use scroll keys to change rpm
ACK
Auto idle time - Used to adjust the time delay for the
automatic idle system.
AUTO IDLE T
ACK
5 Use scroll keys to change time
ACK
Refuel pump - Used to adjust the fill level.

REFUEL_LVL
ACK
50 Use scroll keys to change fill level from 50
to 100% in 5% increments.
ACK
When adjustments are complete or at any time press the

SET switch again to exit the SET menu and return to the
normal display.
C - 10 9803/6570-2 C - 10
List of Monitor Messages
Message Display Meaning

LOW IDLE Engine at low idle (when in auto idle mode or one touch idle on)
SWING LOCK Swing lock on
OVERLOAD Warning when machine is lifting greater than capacity
OVERLOAD ON Overload warning system switched on -warning will be given if lifting load exceeds safe
capacity
AUTO WARM Automatic engine warm up system on (auto warm up is cancelled if the one touch idle
switch is pressed, the throttle dial moved or the excavator joysticks operated)
PREHEAT Engine preheat on. When the temperature is low the engine ECM automatically switches
on the preheat.
CHECK Q/H Visually check quickhitch is connected, alarm will sound. (Press ACK to confirm, alarm
will stop)
Q/H DISCON? Bucket quick hitch disconnect? (Press ACK to confirm)
Q/H DISCON Bucket quick hitch disconnected
LOW FUEL Low fuel level in fuel tank
RES FUEL Reserve level in fuel tank
EMER STOP Emergency stop (engine is shutdown and switch must be pressed again to allow engine
to be restarted)
NO THROTTLE Fault with engine control system - consult JCB Dealer
LIMP MODE Machine is in emergency back up mode (K Emergency back-up switch ( T C-13))
AUTO For heavy digging or increased work output and general digging.
ECONOMY Digging and loading with low fuel consumption.
PRECISION For precise or light duty work
LIFT For operations requiring maximum accuracy, including lifting, with extra hydraulic
pressure if required.
NO RESTART DO NOT SWITCH OFF. Engine unable to restart due to engine fault. Move machine to a
safe location before switching off.
LOW POWER Engine power reduced due to engine fault.
MOVE HAMMER Hammer used continuously for 10 seconds (therefore at risk of overheating and increased
wear).
OIL CHANGE Indicates that an oil change is required.
SERVICE RQD Indicates that a service is required.
C - 11 9803/6570-2 C - 11
Fascia Panel
Fig 7.
1 Emergency stop. 5 Isolator.
Press to stop the engine. The monitor will display Press to isolate the servo system. The monitor will
"EMER STOP" acknowledgement message. Press display "ISOLATOR" acknowledgement message.
again to allow the engine to be re-started. When pressed the controls are isolated and no
machine movement is possible.
2 Slew lock.
6 Quick hitch (Option) - Position bucket on floor.
Press the switch to apply the slew lock The monitor
will display "SWING LOCK" acknowledgement When a quickhitch system is fitted, press to release
message. Press again to release the slew lock. This the hitch. The monitor will display "Q/H DISCON?"
reverts to OFF when the engine is restarted. and the alarm will sound, press ACK switch on the
monitor within 5 seconds. The monitor will display "Q/
3 Overload caution (Option). H DISCON" acknowledgement message.
In A, E & P mode the overload caution system is set Press again to re-apply the quickhitch. The monitor
OFF. Press the switch to activate the system. In L will display "CHECK Q/H" and the alarm will sound.
mode the overload caution system is set ON. Press to Visually check quickhitch and press ACK switch on
switch the system OFF. When the system is ON, if a the monitor to confirm, the alarm will stop.
load exceeding the lift capacity of the machine is lifted
the monitor will display "OVERLOAD" warning 7 Beacon (Option).
message and a buzzer will sound.
When a beacon is fitted, press the switch to activate
4 Cushion. the beacon. The monitor will display "BEACON ON"
acknowledgement message. The switch gives power
This switch selects or deselects the cushioned mode to the jack socket into which the rotating beacon or
of operation of the boom raise/lower rams and the the service inspection lamp is plugged.
dipper in/out rams.
8 Washer.
The soft mode is automatically ON when starting the
machine. Press to change to hard mode. The monitor Press to use windscreen washer, washer will stop
will display "HARD MODE" acknowledgement when released. The wiper will operate when the
message. Press again to select the cushioned mode. washer is used.
C - 12 9803/6570-2 C - 12
9 Wiper. Emergency back-up switch
Press once to operate the wiper in intermittent mode. Under normal conditions the switch A is OFF. Under
The monitor will display "WIPER INT" emergency conditions it becomes necessary to press the
acknowledgement message. The frequency of wipe switch ON. The switch has a lock in the cap which must be
can be adjusted by the monitor menu. Press a second slid towards the centre of the switch when pressing.
time to operate the wiper continuously. The monitor
will display "WIPER ON" acknowledgement By switching the emergency back-up switch the engine
message. can be started and the hydraulic functions operated. The
engine will run at idle speed, in emergency back up mode
10 Auto idle. the monitor will display "LIMP MODE". The machine
should only be operated in this mode to allow the machine
Press the switch to activate the automatic engine idle to be moved to a safe position.
system. The monitor will display "AUTO IDLE"
acknowledgement message. The engine speed will
drop to idle when the machine has been idle for 5
seconds, the monitor will display "LOW IDLE". The
time delay can be adjusted by the monitor menu.
K Monitor Panel ( T C-7) Set switch.)
Note: In auto mode, this function is permanently engaged.
Fig 8.
Fig 9.
C - 13 9803/6570-2 C - 13
Heater/Air Conditioning Controls Using the Air Conditioning
Located on the right console, the heater/air conditioning 1 In hot weather to produce comfortable working
controls are used in conjunction with the heater fan conditions.
controls.
a Close the door and windows.
Heater Controls
b Set control D fully anti-clockwise so as to avoid
drawing hot air in from outside the cab.
c Set control A fully clockwise to direct air into the

body of the cab.
d Set control B fully anti-clockwise to avoid re-

heating the de-humidified conditioned air. If the in-
cab temperature drops too low adjust clockwise
the setting of the heat control to remedy the
situation.
2 In cold/damp weather, to minimise misting.
b Set control D fully anti-clockwise so as to avoid

drawing damp air in from outside the cab.
Fig 10.
c Set control A fully clockwise to direct air onto the
Heater Fan.
windscreen.
Turn rotary switch A clockwise to turn on the heater fan.
d Set control B fully clockwise to heat the de-
The volume of air from the heater increases by rotating the
humidified conditioned air, de-mist the screen and
switch further clockwise.
generally de-humidify the cab air.
Temperature.
Important: Operate the air conditioning for at least 10
minutes per month.
Turn rotary switch B fully anti-clockwise for minimum
temperature, turn it fully clockwise for maximum
temperature. (Intermediate positions give intermediate
temperatures.)
Air Conditioning Controls (if fitted).
Turn rotary switch C clockwise to select air conditioning.

turn the rotary switch C fully clockwise for maximum
cooling. (Intermediate positions give intermediate cooling.)
Fresh Air/Recirculated Air.
Turn rotary switch D fully clockwise for fresh air, turn it fully
anti-clockwise for recirculated air. (Intermediate positions
give a mixture of fresh and recirculated air.)
C - 14 9803/6570-2 C - 14
Heater Only Controls

Located on the right console, the heater system is
controlled by the following switches :
1 Re-circulation switch.
2 Three speed fan switch.
3 Temperature control switch.
A B
2 3 1
Fig 11.
Heater Controls
Hot air can be directed to the front windscreen (for

demisting) and/or the cab floor by adjusting the air vents.
The temperature can be adjusted by operating control 3. A
heater control switch 2 controls a three speed heater fan.
Air Control
Rotate control 1 to position A to allow fresh air to enter the

cab. Position B gives re-circulated air and should be used
when operating in a dusty working environment. Position B
can also be used to increase the heater performance
during cab warm up, and whilst operating the machine on
light duties.
Heat control
Rotate control 3 clockwise to increase the temperature.

Rotate anti-clockwise to decrease the temperature.
Heater Fan (Three Speeds)
Rotate control 2 to switch on the cab three speed heater

fan. Functions only with the starter switch at IGN.
C - 15 9803/6570-2 C - 15
Heater/Air Conditioning Controls (ATC) 1 Auto mode is activated by switch 2, the LED will
illuminate and an ‘A’ will appear on the display 7.
The heater/air conditioning can be set for automatic
temperature control (ATC). 2 Rotate control 5 to set the desired temperature.
Located on the right console, the heater system is 3 The set temperature will be displayed on panel 7.
controlled by the following switches :
4 The fan speed will be automatically set to reach and
then maintain the set temperature.
7 Note: If control 6 is moved, Auto mode will have to be

reset. Press switch 2 to reactivate.
5 In hot weather or dusty environments, recirculation

mode should be used. Select switch 3.
Defrost/Demist Mode
To activate press switch 4, the LED will illuminate and

switch symbol will be displayed on 7.
1 2 3 4 5 6
1 In hot weather to produce comfortable working
Fig 12. conditions.
1 On/Off switch. a Close the door and windows.
2 Auto mode switch. b Select recirculation switch 3.
3 Recirculation switch. c Rotate control 6 clockwise and direct air into the
body of the cab.
4 Defrost/Demist switch.
d Rotate control 5 fully anti-clockwise for maximum
5 Temperature control switch. defrost. If the in cab temperature drops to low turn
control clockwise.
6 Fan speed switch.
2 In cold/damp weather, to minimise misting.
7 Display.
Heater Controls
b Select recirculation switch 3.
Hot air can be directed to the front windscreen (for
demisting) and/or the cab floor by adjusting the air vents. c Set control 6 fully clockwise and direct air onto the
windscreen.
To activate controls press switch 1, the switch LED and
panel 7 will illuminate. d Set control 5 fully clockwise to heat the de-
humidified conditioned air, de-mist the screen and
Auto Mode generally de-humidify the cab air.
The heater can be set to a selected temperature. The fan

speed and temperature control will then be automatically
controlled to maintain the set temperature.
C - 16 9803/6570-2 C - 16
Cab Interior Lights

The interior light A is located on the left of the cab back
wall.
To turn it on, press either side of the light. To extinguish

press the side of the light to return it to the centre position.
The lamp can also be switched on using the switch on the
left hand console for a five minute period.
Fig 13.
C - 17 9803/6570-2 C - 17
Operating Levers/Pedals
Travel Levers Travel Speed Change Button

Travel is controlled by the two levers/foot pedals A and B The travel speed of the machine can be changed to high,
at the front of the cab. Each lever controls the track on the medium and low. (The travel speed is recorded at engine
same side, i.e. the left lever controls the left track, when the shutdown and the travel speed is re-applied at the next
cab is facing forwards, that is towards the recoil units. engine start up). Each time the button C is pressed, the
Before operating the travel lever, confirm whether the speed is changed to the next higher speed. (When it is at
undercarriage is facing forwards or backwards. high speed, it then selects low).
Fig 14. Fig 15.
Note: When not travelling, do not place your feet on the Travel Mode Choice Selected
travel pedals. High Speed. Use when the ground is
level. When climbing a slope and the
!MWARNING load increases, it automatically changes
to medium and when the load reduces, it
When the cab is swung around so that it is facing the returns automatically to high.
track motor end of the undercarriage, the action of the Medium Speed
tracking controls is reversed. Take extra care!
8-2-8-1
Low Speed. Use when climbing or
descending a slope or when the ground
is rough. It does not change
automatically.
C - 18 9803/6570-2 C - 18
Operation Levers Optional Circuit Pedal (if fitted)

The boom, arm, bucket and slew operations can be By operating the pedal A, a full flow auxiliary circuit can be
controlled individually or simultaneously. The operation operated (if fitted).
speed varies according to the operation lever stroke.
When the hand is released from the operation lever, the
lever returns automatically to neutral.
401870 Fig 17.

Fig 16.
Note: When not using the service pedal, do not rest your
Note: When the slew lever is returned to neutral, the feet on the pedal.
machine will still not stop rotating immediately due to
inertia.Take this into consideration when performing swing ISO Operating Method
operations.The operation of the bucket attachment is
reversed when it is fitted in the reverse position; care must This machine's operation conforms to the ISO operating
be observed. method unless fitted with an ISO to SAE conversion
switch.
C - 19 9803/6570-2 C - 19
Circuit Symbols
Circuit Symbols
The following notations are used in the description circuit, drawings.
Normally Closed
PWM Pressure Switch
Solenoid Valve
Normally Open
Pressure Switch
Solenoid Valve
Frequency Input
Analogue Input
(Potentiometer)
ºt
Float Switch
Analogue Input
(Thermistor)
Switched Input D.C. Supply

(Latching) (Alternator)
Switched Input
(Push to make)
Switched Input
(Push to Break)
Fig 18.
Inputs and Outputs

ECU1
The letters I/p and O/p refer to input and output. O/p (G-21)
The letters in brackets i.e. (C-21) refer to the connector I/p (A-32)
and pin number.
I/p (A-29)
I/p (A-39)
sys (B-5)
Fig 19.
C - 20 9803/6570-2 C - 20
Component Identification
JS160/180
The item numbers in the following table are identified on
the Wiring schematics in this section. K Fig 22. ( T C-24).
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.
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 30/926484 Air conditioner Below the rear cab panel.
9 30/926483 Heater Below the rear cab panel.
10 30/925588 Controller (air con) 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.
14 717/20346 Radio cassette 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
20 701/80374 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.
23 717/20154 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.
32 25/222203 Valve, solenoid In the right hand side pump bay.
34 01/145194 Engine Rear of machine.
35 701/80374 Pilot switch, upper Bottom switch on Right hand side of Main Control Valve.
36 701/80375 Pilot switch, travel Top switch on Right hand side of Main Control Valve.
37 701/80373 Pilot switch x 2 Swing and Boom On manifold under cab.
40 717/07700 Travel alarm Below the counterweight.
41 20/925502 Pump 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.
C - 21 9803/6570-2 C - 21

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.
56 701/80372 Pilot switch, auto mode On manifold under cab.
57 701/80462 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 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 Harness
65 701/11632 Harness
66 701/80223 Switch Body
68 721/10458 Harness HAM/AUX Merged
71 25/222397 Proportional Solenoid
72 721/12305 Harness - main
73 721/12059 Harness - cab
74 721/11637 Harness - facia
75 721/12060 Harness - engine
77 JHR0174 Relay
78 701/80310 Switch refueling pump
79 721/11451 Harness - Low flow
80 716/30259 Sensor barometric
81 716/26100 Starter safety relay
82 716/30262 Air intake temp 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
hand console
C - 22 9803/6570-2 C - 22
G
F
H I
A408581
Fig 21.
E Multiple cables
F Single cables
G Cables joined
H Cable not joined
I Earth cables
Fig 20.
C - 23 9803/6570-2 C - 23
Schematic Diagram
C - 24
JS160/180
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
LAMP LAMP (0.5)601G 1 (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
(8.0)101D
M 3 (0.5)601L 3 (0.5)614B
C212 C191A C105
33
BATT SUPPLY
(0.5)601C (0.5)614D
4 4 C5
IGN SUPPLY
(0.5)848A
(8)001
0.5 UW 1
GROUND
21 22 5 (0.5)601D 5 (0.5)614H 300A 300A (4)300A +24V BATT SUPPLY C259 C104 (8)101A
SWING
1
SHUT
(0.5)601M (0.5)614A
OFF
6 6 (3.0)600 EARTH 0.5 B 2
15 C213
7 (0.5)601F 7 (0.5)614F
612
2
(0.5)848 C191B
(0.5)601 (0.5)614K 101D C6 C107
1 2 1 2 8 8 (8)101D +24V IGNITION SUPPLY
LOCK LEVER SW 1 0.5 UW 1
300D
101H
101G
(0.5)601J (0.5)614H
300C
101K
- + - +
300B
101F
300E
101J
LH LEVER SWITCHES RH LEVER SWITCHES 9 9
547
SWING
C250
SHUT
10 (0.5)601K 10 (0.5)614J C108
0.5 B 2
OFF
(0.5)545A
301 (4)301 +24V BATT SUPPLY ECM
(0.5)408B
EARTH 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
C109
HORN DOZER DOZER HAM/BOOM TRAVEL ONE TOUCH GRAB GRAB 1
HEADER 1
(0.5)607B
C198 SW ON SW OFF SW PRIORITY SW CHANGE SW IDLE SW CW SW CCW SW 12V 12V
15A
15A
15A
10A
10A
20A
20A
20A
10A
10A
10A
10A
15A
15A
10A
6 5 4 3 2 1 C255
5A
(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
AUX 1 AUX 2 60 CONNECTOR A
TRAVEL
C115
ALARM
FAN
C186
(0.5)612D
(1.0)612G
(0.5)612H
(0.5)612A
(0.5)612C
(0.5)612B
(0.5)600H 1
(0.5)612E
(0.5)612F
(3.0)612L
C214
(0.5)612J
C224 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
BRAKE
2
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)106A
(0.5)848A
(0.5)419A
(0.5)601A
(0.5)109A
(0.5)841A
(0.5)601B
(0.5)109B
(0.5)613
M
(0.5)614B
(0.5)601J
C187
(0.5)840
4
(0.5)613A
(0.5)613B
(0.5)613K
(0.5)601K
(0.5)613J
(0.5)601
(0.5)413
(0.5)404
(0.5)812 (0.5)812 SWING SHUT OFF SOL V SAFETY RELAY C171
59 C172
+12V SWITCHED
(0.5)613C
(0.5)107A
(0.5)108A
(0.5)806 1 S C (4.5)002 (4.5)002
+24V IGNITION
+12V MEMORY
(0.5)490
(0.5)843
(0.5)845
(0.5)813
(0.5)808
(0.5)804
(0.5)805
+24V BATTERY
(0.5)850 BOOM SPEED REG. C C174
TRAVEL
SPEED
6 (0.5)422D 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
614D
E
(1.0)504A
9 (0.5)819 1
(1.0)301
(1.0)102
(1.0)103
(1.0)104
(1.0)105
(1.5)106
(1.0)302
(1.5)107
(1.5)108
(1.0)303
(1.0)304
(1.0)150
(1.0)109
(1.0)306
(1.0)305
23 (0.5)803 (0.5)803 SWING BRAKE SOL V
2 STAGE
10
RELIEF
6 5 4 3 2 1
(0.5)600G
(0.5)752 (0.5)752 SWING LOCK SOL V (0.5)604F 2
(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)302A
(0.5)108B
(0.5)107C
(0.5)107B
(0.5)613G
(0.5)614A
(0.5)614K
(0.5)828
(0.5)828
C98
LEVER
14 B
(0.5)846
(0.5)843
(0.5)614G
LOCK
(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)812 1
(0.5)502 (0.5)502 HEAT RELAY 49 C176
SWING
SHUT OFF
18 ALTERNATOR
(0.5)801 (0.5)801 PUMP PROP SOL V (OUT) (0.5)604H 2
19
(0.5)546 (0.5)546C KEY SW - BATT RELAY HEAT
20 C192
C102
C103
(0.5)802 (0.5)802 FAN RELIEF PWM RELAY
(4.0) 101B
EARTH 21 (0.5)817 1 C269
(0.5)422D (0.5)422D STARTER RELAY
32
CUSHION
HEADER 3 22
(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
FLOW
26
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
(0.5)613G
(0.5)613G
(0.5)613H
74
(0.5)613A
(0.5)830
(0.5)613K
(0.5)613B
(0.5)613B
(0.5)830 A/C BINARY P SW

(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
(0.5)108D
47
(0.5)614C
(0.5)419B
C184 C230
(0.5)108E
(0.5)614J
2 (0.5)831 (0.5)421 (0.5)421 BOOST PS (0.5)830 1
(0.5)302B
(0.5)613E
(0.5)613F
A/C
(0.5)811B
(0.5)426
C22 40
(0.5)612A
(1.0)366A
(0.5)809
(0.5)829
3 (0.5)433B (0.5)306B (0.5)306B REFUEL SW (0.5)831 2 BINARY (0.5)606B 1
58 3 QUICK HITCH 4 (0.5)832 (0.5)820
41
QUICK HITCH P SW HORN
C223 2 42
(0.5)820 (0.5)810 2
5 (0.5)833 (0.5)423 (0.5)423 OVERLOAD C76
53
(0.5)427
(0.5)425
(0.5)417A
RADIO MUTE SW
MONITOR (EMS) ISOLATOR 6 (0.5)834 (0.5)829
43
(0.5)829 FUEL PUMP (0.5)401 1
RESERVE
44 TOOLBOX
C81
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
(0.5)814A
48
O/LOAD 11 (0.5)602B 2 AIR FILTER CRANK ANGLE SENSOR
C166 C82 18
9803/6570-2
0.75 SCR
(1.0)303A
12
(1.0)150
BEACON
(0.5)422C
(0.5)108E 1
(0.5)546
SLEW BRAKE 2 1 C165 (0.5)827 2
BOOM 0.75 Y 1
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)612L
(0.5)606C 2
(0.5)845
SPI SHIELD (SPARE)
IGNITION SUPPLY
C163
CHASSIS (SPARE)
IGNIION SUPPLY
REDUNDANCY
EMERG STOP
EMERG STOP
BATT SUPPLY
MRST-E (SPI)
MTSR-E (SPI)
(0.5)416B 1
MTSR-E (SPI)
MRST-E (SPI)
SCLK-E (SPI)
BLOWER
CAN SHIELD
HYD OIL
SCLK-E (SPI)
0.75 RB 1
BATT GND
MOTOR CONTROLLER (0.5)409B 2 OVERHEAT SW C75 FUEL SENSOR

52
CAN H
SPARE
SPARE
CAN L
SHLD
422D (0.5)407 1
SHLD
GND
0.75 BY 2
51 (0.5)417B 2
C159
846B
0.75 R 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)612K
OPT HYDS 43
(0.5)423
LIGHTER
(0.5)818A
(0.5)504J
(0.5)837
(0.5)545D
(0.5)544D
(0.5)435A
(0.5)504E
(0.5)552
(0.5)550
(0.5)553
(0.5)661
(0.5)610
(0.5)610
(0.5)611
(0.5)550
(0.5)551
(0.5)552
(0.5)553
35
(0.5)305C
SWITCH (SEE 2/2) C207

(0.5)612S
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 1
(0.5)108F
2 (0.5)836
(0.5)614H
A/C 2 1 2 1
(0.5)838
(0.5)839
(0.5)840
(0.5)841
CONTROL 3 (0.5)504D
4 6 5 1 3 2 C161 C201 C116
(0.5)414 1 TRAVEL C72
CAN H
PILOT
CAN L
PANEL (0.5)606G 2
GND
4 (0.5)835
(0.5)839B
(0.5)601L
P SW
(0.5)403
(0.5)431
(0.5)418
0.75 U
(0.5)811
(0.5)613D
(0.5)601H
C157 1
(0.5)614F
(0.5)601G
(0.5)838A
(0.5)838B
(0.5)107D
(0.5)431
(0.5)601F
(0.5)601K
5 (0.5)820 1
C164
(1.0)435B
600D
600D
600C
600E
42
(1.0)842
QUICK
602
603
604
605
606
607
6 C210 0.75 N
(1.0)504B
2 2
A B C D E F G H J (0.5)614E (0.5)600F (0.5)604A C220
7 (0.5)834
C13 838A
1
(0.5)814B
HITCH 57
(0.5)421 1 0.75 UW 3
8 (0.5)833 2 REFUEL PUMP
839A C229 1 2 3 4 5 6 7 8 9 10 (0.5)600A 2 BOOST
9 (0.5)832 (0.5)829 1
C4 M P SW COM RAIL PRES SENSOR
10
(1.0)305
(0.5)612H
(0.5)545A
(0.5)544A
10
71 838C (0.5)821 DOZER (NOT USED)
(0.5)606F 2
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
417A
EARTH HEADER 0.75 BR 1
(0.5)504C (0.5)504C 3
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 3 (0.5)414A TRAVEL P SW
(0.5) 306B
(0.5)430
(0.5)612J (0.5)612J (0.5)305 6 (NOT USED) BOOST TEMP SENSOR
4
C90
(0.5)545D (0.5)545D
(0.5)802
11
(0.5)600B
12 (0.5)544D
5
(0.5)544D 504C (1.0)504A C258 1
6
C232
(0.75)507 BAROMETRIC SENSOR GND 0.75 RW 1
(0.5)600K
(0.5)822
C233
7 1
(0.5)600L
1 2 3 4
(0.5)600M
417
C155 1
45
(0.5)823
807 2
61
(0.5)824
(0.5)837 (0.5)837 842A (0.75)510 BAROMETRIC SENSOR 5V OUTPUT
8 (0.5)818A 2 0.75 U 2
(0.5)818A (0.5)818A (0.75)509 OIL PRESSURE SENSOR SIGNAL
842B
435A
(0.5)422
9 3
CC-KW2000
504
(0.75)508 BAROMETRIC SENSOR SIGNAL 2 1 2 1 2 1 0.75 RU 3
(0.5)807A
(0.5)600C
818
10 4
TECH 2
IS-DIAG
C156
SHIELD
(0.75)511 INTAKE AIR TEMP SIGNAL
C194
A/C COMP
SHLD
818B 5
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
825B
2 1
7 75
(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)612N
(0.5)612P
(0.5)504F
(0.5)504F
(0.5)835 (0.5)835
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 10 RELIEF
(0.5)422A
544D
(0.5)833
4
(0.5)833
545D
544B
545B
544
545
(0.75)522
11
WATER TEMP. SENSOR SIGNAL 63 C265 PROP SOL V
0.75 SCR
(0.75)543
(0.75)506
(0.5)832 (0.5)832 0.75 SCR
(0.75)611H
(0.75)611N
5 12 OVER HEAT WARNING SW
(0.5)846 (0.5)846 523B 523A (0.75)523A SUCTION CONTROL VALVE LO (0.75)532A CRANK ANGLE SENSOR PULSE GND
6 13 20
(0.5)845 (0.5)845 (0.75)516 BOOST PRESS SENSOR SIGNAL (0.75)531 CRANK ANGLE SENSOR SIGNAL
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)520A 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 INJECTOR 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)520B BOOST PRESS SENSOR 5V(+) INJECTOR 4
1 20 13
(0.5)852 0.75 SCR (0.75)514 OIL PRESS SENSOR 5V(+)
(0.5)305D
(0.5)612R
(0.5)305E
(0.5)852
(0.5)853
12
(0.5)504H
2 515A 21
(0.75)515A COMMON RAIL PRESSURE SENSOR SIGNAL (0.75)509 OIL PRESSURE SENSOR SIGNAL
22 11
C181 (0.75)527 COM.RAIL PRES.,EGR POSN SENS. GND (0.75)513 OIL PRESS SENSOR GND
23 10 1.5 R 1
87A
87A
87A
(0.75)524 COMMON RAIL PRESS SENSOR 5V (0.75)524C 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 UY 2
(0.75)528 EGR MOTOR V (0.75)527C COM RAIL PRESS SENSOR GND INJECTOR 3
C251 C254 C271 26 7
0.75 SCR
(0.75)837
(0.75)529 SUCTION CONTROL VALVE HI (0.75)512
(0.75)505
BOOST TEMP. SENSOR SIGNAL
(0.75)501C
(0.75)503B
(0.75)611E
(0.75)611M
(1.0)847
(4.0)301A
(2.0)501B
(0.75)611G
(0.75)301C
27 6
(1.0)301B
(0.75)530 CRANK ANGLE SENSOR PULSE (+) (0.75)516 BOOST PRESS SENSOR SIGNAL
28 5 0.75 UR 3
(0.75)531 CRANK ANGLE SENSOR PULSE GND (0.75)532 BOOST PRESS SENSOR GND INJECTOR 2

29 4
(0.5)419
0.75 SCR (0.75)617 CRANK ANGLE SENSOR SHIELD-GND 0.75 SCR (0.75)527B CAM ANGLE SENSOR PULSE GND 0.75 SCR
30 3
(4.0)301
(0.75)532 BOOST PRESS SENSOR GND (0.75)524B CAM ANGLE SENSOR PULSE 5V(+) 0.75 SCR
31 2
(0.75)533 EGR MOTOR W
(0.75)422A
(0.75)544
(0.75)545
(0.75)837
(0.75)504
(0.75)502
32 1
(0.75)534 EGR MOTOR U 0.75 YG 1
33
0.75
34
(0.75)535 0.75 BY 2
(0.5)432A 8 7 6 5 4 3 2 1 35
TEIR 3 (0.75)536
36 C266
(1.5)537 INJECTOR POWER (INJECTOR#2,#3)
37 FUEL LEAKAGE TEMP SENSOR
C252 (0.75)538 INJECTOR #4 CYL SIGNAL (1.5)542 INJECTOR POWER (INJECTOR#1,#4)
38 1
(0.75)539 INJECTOR #2 CYL SIGNAL
(0.75)422A
(0.75)611K

84
(0.75)544
(0.75)545
(0.75)837
(0.75)504
(0.75)502
39 2
40 3 0.75 RW 1
41 C262 4
(1.5)542 INJECTOR POWER (INJECTOR#1,#4) C261 LIFT PUMP (0.75)540 INJECTOR #1 CYL SIGNAL
42 5 0.75 RB 2
(1.0)529A FUEL LIFT PUMP (1.0)547 - (0.75)539 INJECTOR #2 CYL SIGNAL
43 M 6
501C (1.0)604D + (0.75)541 INJECTOR #3 CYL SIGNAL SUCTION CONTROL VALVE
501B 44 7
45 8
46 9
47 10 0.75 WR 1 U
(0.5)825A
75 48 11
303
102
301
12 0.75 WB 2 V M
0.75 WU 3 W
C267
MOTOR EGR BRUSH LESS DC
(0.75)521 FUEL LEAK TEMP SENSOR SIGNAL
(0.75)611D
(0.75)611G
(0.75)611H
1
(0.75)611C
(0.75)611E
(0.75)611F
(0.75)611J
(1.5)611A
(1.5)611B
(0.75)529 SUCTION CONTROL VALVE HI
(1.5)611
2
(0.75)523A SUCTION CONTROL VALVE LO 0.75 1
3
Schematic Diagram
(0.5)828 G OVERHEAT WARNING SW
4
(0.75)611D
0.75 WR
(0.75)503A
(0.75)422A
(0.75)529A
(0.75)611C
(0.75)515B
(0.75)532B
(0.75)529B
(0.75)611E
2
(0.5)612D
(1.0)612G
(0.5)811A
(0.5)304A
(1.0)303A
(1.0)102A
(1.0)301A
(0.5)544C
(1.0)304C
(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)501A
(1.5)611A
U
(1.5)611B
(0.75)502
(0.75)503
(0.75)531
(0.75)536
(0.75)545
(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)514
(0.75)515
(0.75)521
(0.75)522
(0.75)524
(0.75)516
(0.75)517
(0.75)518
(0.75)520
(0.75)519
(0.75)523
(0.75)525
(0.75)526
(0.75)616
(0.75)527
(0.75)528
(0.75)530
(0.75)615
(0.75)532
(0.75)533
(0.75)534
(0.75)535
(0.75)537
(0.75)538
(0.75)539
(0.75)540
(0.75)541
(0.75)542
1
(0.5)400
(0.5)401
(0.5)402
(0.5)403
(0.5)404
(0.5)405
(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)415
(0.5)416
(0.5)417
(0.5)418
(0.5)419
(0.5)420
(0.5)421
(0.5)422
(0.5)423
(0.5)424
(0.5)425
(0.5)426
(0.5)434
(0.5)427
(0.5)428
(0.5)429
(0.5)430
(0.5)431
(0.5)432
(0.5)433
(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)810
(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
(1.5)611
(1.5)501
5
C263 FOR OEM METER R WATER TEMP SENSOR 0.75 WB 3
6 V
(0.75)508 1 a
80
0.75 WU 4
1 2 3 4 5 6 7 8 9 10 W
(0.75)507A 2 b
C268 0.75 5
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)510 3 c
CONNECTOR A CONNECTOR B CONNECTOR C ECM VEHICLE SIDE ECM ENGINE SIDE (0.75)524A
1
EGR POSITION SENSOR 5V(+)
(0.75)517 EGR POSITION SENSOR W EGR POSITION SENSOR
C8 C9 C10 C257 2
C256 (0.75)518 EGR POSITION SENSOR V
3
BAROMETRIC SENSOR (0.75)519 EGR POSITION SENSOR U
EARTH 4
O/P36 HARDWARE SENSING
HEADER 5 (0.75)527A EGR POSITION SENSOR GND

O/P15 HIGH SPEED TRAVEL
C264 5
O/P10 SWING SHUT OFF 3
O/P22 ENG SHUTDOWN

O/P1 BOOM SPEED REG.
I/P25 AUTO MODE P SW
I/P16 REFUEL PUMP SW
I/P5 ENGINE OVERHEAT
O/P5 REFUELING PUMP

O/P16 BOOM PRIORITY
I/P14 ONE TOUCH IDLE
O/P30 TOOLBOX LAMP
PULSE(+) SP-CAM HAL
PULSE(+) SP-CAM HAL

I/P28 KEY SW (CRANK)
O/P8 FAN RELIEF PWM
6
I/P34 TRAVEL CHANGE
O/P24 2 STAGE RELIEF

O/P35 STARTER RELAY
O/P26 TRAVEL ALARM

O/P3 MAX FLOW CUT
O/P20 LOW FLOW PRI

I/P19 BOOM UP PILOT
I/P6 THROTTLE LEVER

I/P18 BOOM PRI/HAM
O/P34 SWING LOCK 1
(0.75)511
O/P9 SWING BRAKE 2
A
I/P20 HAMMER PILOT
PULSE(-) IF-CAM HAL

+5V REF (THROTTLE)
O/P14 CAB RH LIGHT

I/P13 O/LOAD PRESS
O/P11 LOWER WIPER

O/P13 CAB LH LIGHT
(0.75)528 EGR MOTOR V

I/P35 ENG OIL LEVEL
O/P25 QUICK HITCH
O/P29 BOOM LIGHT
PULSE(+) IF-CRANK-
O/P2 CAB INT LAMP
I/P21 LOWER WIPER
I/P8 THROTTLE VOL

I/P27 TRAVEL PILOT
O/P21 LEVER LOCK

I/P7 CAB INT LAMP
I/P29 SWING PILOT
O/P28 SOFT/HARD
I/P37 RES TANK SW
I/P1 HYD OIL TEMP
7
I/P26 UPPER PILOT
I/P15 BOOST P SW
O/P32 OVER HEAT

I/P10 A/C CLUTCH
O/P33 CWT LIGHT

I/P32 LEVER LOCK
O/P19 CCW GRAB

SUPPLY O/P17-22
SUPPLY O/P23-28
SUPPLY O/P13-16
SUPPLY O/P13-16
O/P7 PUMP PROP

I/P3 ALTERNATOR
I/P22 DOZER OFF

I/P12 OPT LAMPS
I/P2 WATER TEMP
I/P17 ENG SPEED
GND I/P7,8,15,16
(0.75)534 EGR MOTOR U

O/P18 CW GRAB
I/P31 GRAB CCW
I/P23 DOZER ON
SUPPLY O/P7-12
O/P IS-MDMAP0
SUPPLY O/P7-12
O/P CC-KW2000
I/P9 STD LAMPS
I/P4 FUEL LEVEL
O/P OS-BOOSTL
I/P11 AIR FILTER
O/P27 BREAKER
I/P33 AIR PRESS
I/P IA-OILPRESS
O/P23 WASHER
I/P OS-STARTER
O/P PG-POWER
O/P PG-POWER
I/P30 GRAB CW
CAN CC-CAN-H
GND SG-5VRT2
GND SG-5VRT3
- IS-EBMPOS 3
- IS-EBMPOS 2
- IS-EBMPOS 1
GND SG-5VRT5
SUPPLY O/P1-6
SUPPLY O/P1-6
8
CAN CC-CAN-L
O/P OS-MAINR
O/P OF-TACHO
- IS-MDMAP 1
- IS-MDMAP 2
- IS-MDMAP 3
I/P36 PREHEAT
O/P IS-MEMCL
I/P IS-MDMEM
I/P IS-IDLDWN
O/P OM-EBM2
O/P OM-EBM3
O/P OM-EBM3
O/P OM-EBM1
(0.75)507B
I/P OS-GLOWR
I/P IA-ACCEL 1
I/P IA-ACCEL 2
O/P 0S-MAINR
O/P OP-COM1
I/P OS-GLOWL
O/P SG-5VRT1
O/P17 DOZER
I/P IA-SCVVLO
O/P OP-SOM2
B
O/P4 BEACON
GND PG CASE
GND PG-SIGN
I/P IS-ENGSTP
O/P IA-THBST
I/P IA-BPRESS
O/P1A SPARE
O/P IA-THOIL
O/P7A SPARE
O/P31 SPARE
SHL SG-SLD5
SHL SG-SLD4
O/P12 WIPER
SHL SG-SLD1
O/P PG-SIGN
I/P IS-IDMNL
I/P IA-SCVLO
I/P OS-OILPL
GND I/P9-14
RS/SPI SHLD
I/P IA-PFUEL
I/P IA-PFUEL
- OP-SCVHI
- OP-SCVHI
O/P IS-DIAG
I/P IS-IDLUP
I/P IS-START
I/P OS-DIAG
I/P IA-BARO
I/P24 HORN
I/P IA-QADJ
O/P6 HORN
I/P IS-IGKEY
O/P SP-5V1
O/P SP-5V2
O/P SP-5V5
O/P SP-5V4
I/P IA-THW
- OS-INJ 4
- OS-INJ 2
- OS-INJ 1
- OS-INJ 3
RESERVED
RESERVED
RESERVED
RESERVED
RESERVED
RESERVED
I/P SP-5V3
RESERVED
O/P IA-IAT
I/P IA-THL
I/P IF-SPD
RS232 RX
AIR INTAKE SENSOR

RS232 TX
CAN SLD
CHASSIS
I/P PS+B
I/P PS+B
I/P PS+B
+5V REF
CAN Lo
83
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
Fig 22. 331/67321 issue 1

C - 24
JS190
The item numbers in the following table are identified on
the Wiring schematics in this section. K Fig 22. ( T C-24).

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.
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 30/926484 Air conditioner Below the rear cab panel.
9 30/926483 Heater Below the rear cab panel.
10 30/925588 Controller (air con) 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.
14 717/20346 Radio cassette 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
20 701/80374 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.
23 717/20154 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.
34 01/145194 Engine Rear of machine.
35 701/80374 Pilot switch, upper Bottom switch on Right hand side of Main Control Valve.
36 701/80375 Pilot switch, travel Top switch on Right hand side of Main Control Valve.
37 701/80373 Pilot switch x 2 Swing and Boom On manifold under cab.
40 717/07700 Travel alarm Below the counterweight.
41 20/925502 Pump 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.
C - 25 9803/6570-2 C - 25

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.
56 701/80372 Pilot switch, auto mode On manifold under cab.
57 701/80462 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 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 Harness
65 701/11632 Harness
68 721/10458 Harness HAM/AUX Merged
71 25/222397 Proportional Solenoid
72 721/12305 Harness - main
73 721/12059 Harness - cab
74 721/11637 Harness - facia
75 721/12060 Harness - engine
77 JHR0174 Relay
78 701/80310 Switch refueling pump
79 721/11451 Harness - Low flow
80 716/30259 Sensor barometric
81 716/26100 Starter safety relay
82 716/30262 Air intake temp 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
hand console
C - 26 9803/6570-2 C - 26
G
F
H I
A408581
Fig 24.
E Multiple cables
F Single cables
G Cables joined
H Cable not joined
I Earth cables
Fig 23.
C - 27 9803/6570-2 C - 27
Schematic Diagram
C - 28
JS190
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
LAMP LAMP (0.5)601G 1 (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
(8.0)101D
M 3 (0.5)601L 3 (0.5)614B
C212 C191A C105
33
BATT SUPPLY
(0.5)601C (0.5)614D
4 4 C5
IGN SUPPLY
(0.5)848A
(8)001
0.5 UW 1
GROUND
21 22 5 (0.5)601D 5 (0.5)614H 300A 300A (4)300A +24V BATT SUPPLY C259 C104 (8)101A
SWING
1
SHUT
(0.5)601M (0.5)614A
OFF
6 6 (3.0)600 EARTH 0.5 B 2
15 C213
7 (0.5)601F 7 (0.5)614F
612
2
(0.5)848 C191B
(0.5)601 (0.5)614K 101D C6 C107
1 2 1 2 8 8 (8)101D +24V IGNITION SUPPLY
LOCK LEVER SW 1 0.5 UW 1
300D
101H
101G
(0.5)601J (0.5)614H
300C
101K
- + - +
300B
101F
300E
101J
LH LEVER SWITCHES RH LEVER SWITCHES 9 9
547
SWING
C250
SHUT
10 (0.5)601K 10 (0.5)614J C108
0.5 B 2
OFF
(0.5)545A
301 (4)301 +24V BATT SUPPLY ECM
(0.5)408B
EARTH 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
C109
HORN DOZER DOZER HAM/BOOM TRAVEL ONE TOUCH GRAB GRAB 1
HEADER 1
(0.5)607B
C198 SW ON SW OFF SW PRIORITY SW CHANGE SW IDLE SW CW SW CCW SW 12V 12V
15A
15A
15A
10A
10A
20A
20A
20A
10A
10A
10A
10A
15A
15A
10A
6 5 4 3 2 1 C255
5A
(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
AUX 1 AUX 2 60 CONNECTOR A
TRAVEL
C115
ALARM
FAN
C186
(0.5)612D
(1.0)612G
(0.5)612H
(0.5)612A
(0.5)612C
(0.5)612B
(0.5)600H 1
(0.5)612E
(0.5)612F
(3.0)612L
C214
(0.5)612J
C224 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
BRAKE
2
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)106A
(0.5)848A
(0.5)419A
(0.5)601A
(0.5)109A
(0.5)841A
(0.5)601B
(0.5)109B
(0.5)613
M
(0.5)614B
(0.5)601J
C187
(0.5)840
4
(0.5)613A
(0.5)613B
(0.5)613K
(0.5)601K
(0.5)613J
(0.5)601
(0.5)413
(0.5)404
(0.5)812 (0.5)812 SWING SHUT OFF SOL V SAFETY RELAY C171
59 C172
+12V SWITCHED
(0.5)613C
(0.5)107A
(0.5)108A
(0.5)806 1 S C (4.5)002 (4.5)002
+24V IGNITION
+12V MEMORY
(0.5)490
(0.5)843
(0.5)845
(0.5)813
(0.5)808
(0.5)804
(0.5)805
+24V BATTERY
(0.5)850 BOOM SPEED REG. C C174
TRAVEL
SPEED
6 (0.5)422D 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
614D
E
(1.0)504A
9 (0.5)819 1
(1.0)301
(1.0)102
(1.0)103
(1.0)104
(1.0)105
(1.5)106
(1.0)302
(1.5)107
(1.5)108
(1.0)303
(1.0)304
(1.0)150
(1.0)109
(1.0)306
(1.0)305
23 (0.5)803 (0.5)803 SWING BRAKE SOL V
2 STAGE
10
RELIEF
6 5 4 3 2 1
(0.5)600G
(0.5)752 (0.5)752 SWING LOCK SOL V (0.5)604F 2
(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)302A
(0.5)108B
(0.5)107C
(0.5)107B
(0.5)613G
(0.5)614A
(0.5)614K
(0.5)828
(0.5)828
C98
LEVER
14 B
(0.5)846
(0.5)843
(0.5)614G
LOCK
(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)812 1
(0.5)502 (0.5)502 HEAT RELAY 49 C176
SWING
SHUT OFF
18 ALTERNATOR
(0.5)801 (0.5)801 PUMP PROP SOL V (OUT) (0.5)604H 2
19
(0.5)546 (0.5)546C KEY SW - BATT RELAY HEAT
20 C192
C102
C103
(0.5)802 (0.5)802 FAN RELIEF PWM RELAY
(4.0) 101B
EARTH 21 (0.5)817 1 C269
(0.5)422D (0.5)422D STARTER RELAY
32
CUSHION
HEADER 3 22
(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
FLOW
26
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
(0.5)613G
(0.5)613G
(0.5)613H
74
(0.5)613A
(0.5)830
(0.5)613K
(0.5)613B
(0.5)613B
(0.5)830 A/C BINARY P SW

(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
(0.5)108D
47
(0.5)614C
(0.5)419B
C184 C230
(0.5)108E
(0.5)614J
2 (0.5)831 (0.5)421 (0.5)421 BOOST PS (0.5)830 1
(0.5)302B
(0.5)613E
(0.5)613F
A/C
(0.5)811B
(0.5)426
C22 40
(0.5)612A
(1.0)366A
(0.5)809
(0.5)829
3 (0.5)433B (0.5)306B (0.5)306B REFUEL SW (0.5)831 2 BINARY (0.5)606B 1
58 3 QUICK HITCH 4 (0.5)832 (0.5)820
41
QUICK HITCH P SW HORN
C223 2 42
(0.5)820 (0.5)810 2
5 (0.5)833 (0.5)423 (0.5)423 OVERLOAD C76
53
(0.5)427
(0.5)425
(0.5)417A
RADIO MUTE SW
MONITOR (EMS) ISOLATOR 6 (0.5)834 (0.5)829
43
(0.5)829 FUEL PUMP (0.5)401 1
RESERVE
44 TOOLBOX
C81
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
(0.5)814A
48
O/LOAD 11 (0.5)602B 2 AIR FILTER CRANK ANGLE SENSOR
C166 C82 18
9803/6570-2
0.75 SCR
(1.0)303A
12
(1.0)150
BEACON
(0.5)422C
(0.5)108E 1
(0.5)546
SLEW BRAKE 2 1 C165 (0.5)827 2
BOOM 0.75 Y 1
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)612L
(0.5)606C 2
(0.5)845
SPI SHIELD (SPARE)
IGNITION SUPPLY
C163
CHASSIS (SPARE)
IGNIION SUPPLY
REDUNDANCY
EMERG STOP
EMERG STOP
BATT SUPPLY
MRST-E (SPI)
MTSR-E (SPI)
(0.5)416B 1
MTSR-E (SPI)
MRST-E (SPI)
SCLK-E (SPI)
BLOWER
CAN SHIELD
HYD OIL
SCLK-E (SPI)
0.75 RB 1
BATT GND
MOTOR CONTROLLER (0.5)409B 2 OVERHEAT SW C75 FUEL SENSOR

52
CAN H
SPARE
SPARE
CAN L
SHLD
422D (0.5)407 1
SHLD
GND
0.75 BY 2
51 (0.5)417B 2
C159
846B
0.75 R 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)612K
OPT HYDS 43
(0.5)423
LIGHTER
(0.5)818A
(0.5)504J
(0.5)837
(0.5)545D
(0.5)544D
(0.5)435A
(0.5)504E
(0.5)552
(0.5)550
(0.5)553
(0.5)661
(0.5)610
(0.5)610
(0.5)611
(0.5)550
(0.5)551
(0.5)552
(0.5)553
35
(0.5)305C
SWITCH (SEE 2/2) C207

(0.5)612S
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 1
(0.5)108F
2 (0.5)836
(0.5)614H
A/C 2 1 2 1
(0.5)838
(0.5)839
(0.5)840
(0.5)841
CONTROL 3 (0.5)504D
4 6 5 1 3 2 C161 C201 C116
(0.5)414 1 TRAVEL C72
CAN H
PILOT
CAN L
PANEL (0.5)606G 2
GND
4 (0.5)835
(0.5)839B
(0.5)601L
P SW
(0.5)403
(0.5)431
(0.5)418
0.75 U
(0.5)811
(0.5)613D
(0.5)601H
C157 1
(0.5)614F
(0.5)601G
(0.5)838A
(0.5)838B
(0.5)107D
(0.5)431
(0.5)601F
(0.5)601K
5 (0.5)820 1
C164
(1.0)435B
600D
600D
600C
600E
42
(1.0)842
QUICK
602
603
604
605
606
607
6 C210 0.75 N
(1.0)504B
2 2
A B C D E F G H J (0.5)614E (0.5)600F (0.5)604A C220
7 (0.5)834
C13 838A
1
(0.5)814B
HITCH 57
(0.5)421 1 0.75 UW 3
8 (0.5)833 2 REFUEL PUMP
839A C229 1 2 3 4 5 6 7 8 9 10 (0.5)600A 2 BOOST
9 (0.5)832 (0.5)829 1
C4 M P SW COM RAIL PRES SENSOR
10
(1.0)305
(0.5)612H
(0.5)545A
(0.5)544A
10
71 838C (0.5)821 DOZER (NOT USED)
(0.5)606F 2
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
417A
EARTH HEADER 0.75 BR 1
(0.5)504C (0.5)504C 3
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 3 (0.5)414A TRAVEL P SW
(0.5) 306B
(0.5)430
(0.5)612J (0.5)612J (0.5)305 6 (NOT USED) BOOST TEMP SENSOR
4
C90
(0.5)545D (0.5)545D
(0.5)802
11
(0.5)600B
12 (0.5)544D
5
(0.5)544D 504C (1.0)504A C258 1
6
C232
(0.75)507 BAROMETRIC SENSOR GND 0.75 RW 1
(0.5)600K
(0.5)822
C233
7 1
(0.5)600L
1 2 3 4
(0.5)600M
417
C155 1
45
(0.5)823
807 2
61
(0.5)824
(0.5)837 (0.5)837 842A (0.75)510 BAROMETRIC SENSOR 5V OUTPUT
8 (0.5)818A 2 0.75 U 2
(0.5)818A (0.5)818A (0.75)509 OIL PRESSURE SENSOR SIGNAL
842B
435A
(0.5)422
9 3
CC-KW2000
504
(0.75)508 BAROMETRIC SENSOR SIGNAL 2 1 2 1 2 1 0.75 RU 3
(0.5)807A
(0.5)600C
818
10 4
TECH 2
IS-DIAG
C156
SHIELD
(0.75)511 INTAKE AIR TEMP SIGNAL
C194
A/C COMP
SHLD
818B 5
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
825B
2 1
7 75
(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)612N
(0.5)612P
(0.5)504F
(0.5)504F
(0.5)835 (0.5)835
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 10 RELIEF
(0.5)422A
544D
(0.5)833
4
(0.5)833
545D
544B
545B
544
545
(0.75)522
11
WATER TEMP. SENSOR SIGNAL 63 C265 PROP SOL V
0.75 SCR
(0.75)543
(0.75)506
(0.5)832 (0.5)832 0.75 SCR
(0.75)611H
(0.75)611N
5 12 OVER HEAT WARNING SW
(0.5)846 (0.5)846 523B 523A (0.75)523A SUCTION CONTROL VALVE LO (0.75)532A CRANK ANGLE SENSOR PULSE GND
6 13 20
(0.5)845 (0.5)845 (0.75)516 BOOST PRESS SENSOR SIGNAL (0.75)531 CRANK ANGLE SENSOR SIGNAL
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)520A 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 INJECTOR 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)520B BOOST PRESS SENSOR 5V(+) INJECTOR 4
1 20 13
(0.5)852 0.75 SCR (0.75)514 OIL PRESS SENSOR 5V(+)
(0.5)305D
(0.5)612R
(0.5)305E
(0.5)852
(0.5)853
12
(0.5)504H
2 515A 21
(0.75)515A COMMON RAIL PRESSURE SENSOR SIGNAL (0.75)509 OIL PRESSURE SENSOR SIGNAL
22 11
C181 (0.75)527 COM.RAIL PRES.,EGR POSN SENS. GND (0.75)513 OIL PRESS SENSOR GND
23 10 1.5 R 1
87A
87A
87A
(0.75)524 COMMON RAIL PRESS SENSOR 5V (0.75)524C 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 UY 2
(0.75)528 EGR MOTOR V (0.75)527C COM RAIL PRESS SENSOR GND INJECTOR 3
C251 C254 C271 26 7
0.75 SCR
(0.75)837
(0.75)529 SUCTION CONTROL VALVE HI (0.75)512
(0.75)505
BOOST TEMP. SENSOR SIGNAL
(0.75)501C
(0.75)503B
(0.75)611E
(0.75)611M
(1.0)847
(4.0)301A
(2.0)501B
(0.75)611G
(0.75)301C
27 6
(1.0)301B
(0.75)530 CRANK ANGLE SENSOR PULSE (+) (0.75)516 BOOST PRESS SENSOR SIGNAL
28 5 0.75 UR 3
(0.75)531 CRANK ANGLE SENSOR PULSE GND (0.75)532 BOOST PRESS SENSOR GND INJECTOR 2

29 4
(0.5)419
0.75 SCR (0.75)617 CRANK ANGLE SENSOR SHIELD-GND 0.75 SCR (0.75)527B CAM ANGLE SENSOR PULSE GND 0.75 SCR
30 3
(4.0)301
(0.75)532 BOOST PRESS SENSOR GND (0.75)524B CAM ANGLE SENSOR PULSE 5V(+) 0.75 SCR
31 2
(0.75)422A
(0.75)544
(0.75)545
(0.75)837
(0.75)504
(0.75)502
32 1
(0.75)534 EGR MOTOR U 0.75 YG 1
33
0.75
34
(0.75)535 0.75 BY 2
(0.5)432A 8 7 6 5 4 3 2 1 35
TEIR 3 (0.75)536
36 C266
37 FUEL LEAKAGE TEMP SENSOR
C252 (0.75)538 INJECTOR #4 CYL SIGNAL (1.5)542 INJECTOR POWER (INJECTOR#1,#4)
38 1
(0.75)422A
(0.75)611K

84
(0.75)544
(0.75)545
(0.75)837
(0.75)504
(0.75)502
39 2
40 3 0.75 RW 1
41 C262 4
(1.5)542 INJECTOR POWER (INJECTOR#1,#4) C261 LIFT PUMP (0.75)540 INJECTOR #1 CYL SIGNAL
42 5 0.75 RB 2
(1.0)529A FUEL LIFT PUMP (1.0)547 - (0.75)539 INJECTOR #2 CYL SIGNAL
43 M 6
501C (1.0)604D + (0.75)541 INJECTOR #3 CYL SIGNAL SUCTION CONTROL VALVE
501B 44 7
45 8
46 9
47 10 0.75 WR 1 U
(0.5)825A
75 48 11
303
102
301
12 0.75 WB 2 V M
0.75 WU 3 W
C267
MOTOR EGR BRUSH LESS DC
(0.75)521 FUEL LEAK TEMP SENSOR SIGNAL
(0.75)611D
(0.75)611G
(0.75)611H
1
(0.75)611C
(0.75)611E
(0.75)611F
(0.75)611J
(1.5)611A
(1.5)611B
(0.75)529 SUCTION CONTROL VALVE HI
(1.5)611
2
(0.75)523A SUCTION CONTROL VALVE LO 0.75 1
3
Schematic Diagram
(0.5)828 G OVERHEAT WARNING SW
4
(0.75)611D
0.75 WR
(0.75)503A
(0.75)422A
(0.75)529A
(0.75)611C
(0.75)515B
(0.75)532B
(0.75)529B
(0.75)611E
2
(0.5)612D
(1.0)612G
(0.5)811A
(0.5)304A
(1.0)303A
(1.0)102A
(1.0)301A
(0.5)544C
(1.0)304C
(0.5)612C
(0.5)414B
(1.0)303B
(1.0)102B
(1.0)301B

JS160 Operação

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Section C

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C-0 9803/6570-2 C-0

Contents Page No.

Contents Page No.

Basic System Operation

C-1 9803/6570-2 C-1

13 Interior light switch (Timed) K Cab Interior

14 Seat/Console Slide lever.

15 Dozer Operating lever K Right Console ( T C-3)

C-2 9803/6570-2 C-2

Driver Controls and Switches

lll - Start. Operates the starter motor to turn the

Note: Do not operate the starter for more than 20 seconds

C-3 9803/6570-2 C-3

If the engine is started with the throttle dial not at the

Note: If the engine speed does not change even after

3 SAE/ISO Indicator Light (if fitted).

The light indicates the mode the servo controls are

6 Lower Wiper Switch (if fitted).

The switch turns the lower wiper ON or OFF.

7 Boom Priority Switch (if fitted)

Press the switch to change priority of boom raise to

1 When the switch is pressed the monitor will display

b Machines with rockbreaker, two way auxiliary 8 Radio Mute Switch.

C-4 9803/6570-2 C-4

9 Work light Switch.

Press the switch to the first position to switch ON the

10 Auxiliary Circuit Switch (Low Flow).

This three-position rocker switch, spring loaded to the

11 One Touch Idle Switch.

Pressing this switch instantly changes the engine rpm

12 Cigar Lighter/12V Power point.

To operate the lighter, press it fully into its socket.

This machine is equipped with a 12V system and can

13 Travel Speed Change Switch.

This switch is used to alter the speed of the machine

C-5 9803/6570-2 C-5

When the horn switch is pressed the horn will sound.

2 Control Lock Lever.

Raising the lever provides a method of isolating the

3 Boom Priority Switch.

A courtesy light is provided if cabin lighting is required

C-6 9803/6570-2 C-6

Monitor Panel 5 Scroll Up Switch.

1 Display Panel Monitor. 6 Scroll Down Switch.

Press to select working mode. The machine will be in POWER

cycles through the modes as follows:

(The applied mode is indicated next to the POWER

Select the appropriate work mode suitable for the

A - AUTO MODE for heavy digging or increased work

E - ECONOMY MODE for digging and loading with

P - PRECISION MODE for precise or light duty work.

C-7 9803/6570-2 C-7

!MCAUTION Servo Isolator ON

Engine Air Filter Blocked

C-8 9803/6570-2 C-8

Cruise Control (Wheeled Machine Only) Monitor Settings

C-9 9803/6570-2 C-9