33 - Electrical System

Contents Page No.

Acronyms Glossary .................................................................................................................................... 33-3

33-00 Electrical System

33-00-00 General ............................................................................................................................. 33-3
33-00-50 Schematic Circuit ............................................................................................................. 33-6
33-00-90 Earth Point ..................................................................................................................... 33-63
33-03 Battery
33-03-00 General ........................................................................................................................... 33-65
33-03-03 Isolator Switch ................................................................................................................ 33-76
33-06 Battery Cable
33-06-00 General ........................................................................................................................... 33-79
33-09 Power Distribution
33-09-00 General ........................................................................................................................... 33-81
33-12 Harness
33-12-00 General ........................................................................................................................... 33-85
33-24 Instruments
33-24-03 Instrument Panel ............................................................................................................ 33-97
33-27 Interior Switch
33-27-12 Heating, Ventilating and Air-Conditioning (HVAC) ....................................................... 33-103
33-33 Console Switch
33-33-00 General ......................................................................................................................... 33-109
33-39 Interior Light
33-39-03 Cab Roof ...................................................................................................................... 33-111
33-40 Bulb
33-40-00 General ......................................................................................................................... 33-115
33-42 Exterior Light
33-42-33 Number Plate Light ...................................................................................................... 33-117
33-45 Control Module
33-45-00 General ......................................................................................................................... 33-121
33-45-06 Engine .......................................................................................................................... 33-124
33-45-09 Gearbox ........................................................................................................................ 33-134
33-45-10 Gear Change ................................................................................................................ 33-136
33-45-30 LiveLink ........................................................................................................................ 33-147
33-51 Beacon
33-51-00 General ......................................................................................................................... 33-149
33-54 Window Washer/Wipe
33-54-00 General ......................................................................................................................... 33-151
33-54-03 Tank .............................................................................................................................. 33-152
33-54-09 Front Motor ................................................................................................................... 33-153
33-54-15 Rear Window Wiper ..................................................................................................... 33-155
33-57 Electronic Diagnostic
33-57-00 General ......................................................................................................................... 33-159
33-57-03 Servicemaster .............................................................................................................. 33-161
33-57-90 Fault Codes .................................................................................................................. 33-193

9813/4800-4
2018-11-26
33-84 Sensor
33-84-09 Speed Sensor .............................................................................................................. 33-207

9813/4800-4
2018-11-26
Acronyms Glossary

ABS Anti-lock Braking System

CAN Controller Area Network
DLA Data Link Adaptor
DTC Diagnostic Trouble Code
DVD Digital Versatile Disc
ECM Engine Control Module
ECU Electronic Control Unit
GPS Global Positioning System
HPV High Pressure Valve
HVAC Heating Ventilation Air Conditioning
IMV Inlet Metering Valve
LCD Liquid Crystal Display
LED Light Emitting Diode
MIL Malfunction Indicator Lamp
PWM Pulse Width Modulation
RPM Revolutions Per Minute
SCR Selective Catalytic Reduction
SPP Service Parts Pro
SRS Smooth Ride System
TMAF Temperature and Mass Air Flow
TMAP Temperature Manifold Air Pressure
USB Universal Serial Bus

9813/4800-4
2018-11-26
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 33 - Electrical System
00 - Electrical System

00 - Electrical System

Contents Page No.

33-00-00 General ............................................................................................................................. 33-3

33-00-50 Schematic Circuit ............................................................................................................. 33-6
33-00-90 Earth Point ..................................................................................................................... 33-63

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 33 - Electrical System
00 - Electrical System
00 - General

00 - General Introduction
Introduction ...................................................... 33-3 It is important that the electrical system on the
Health and Safety ........................................... 33-4 machine is in a sound state of repair.
Technical Data ................................................. 33-4
Check (Condition) ............................................ 33-5 Make sure that all the health and safety warnings
in this section are followed. The machine must be
Check (Operation) ........................................... 33-5 safe with the battery isolated before you attempt to
disconnect any electrical connections or work in the
engine compartment.

33 - 3 9813/4800-4 33 - 3
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00 - General

Health and Safety Technical Data

Arc Welding
General
To prevent the possibility of damage to electronic
components, disconnect the battery and the Table 238. System
alternator before arc-welding on the machine or
attached implements. Item Specification
Electrical System 24V, negative earth
If the machine is equipped with sensitive electrical
equipment, i.e. amplifier drivers, electronic control
units (ECUs), monitor displays, etc., then disconnect Table 239. Battery
them before welding. Failure to disconnect the Item Specification
sensitive electrical equipment could result in Cold Crank Amps for 900A
irreparable damage to these components. one minute to 1.4VPCat
Parts of the machine are made from cast iron, welds -18°C (-0.4°F)
on cast iron can weaken the structure and break. Do Reserve Capacity (min- 110
not weld cast iron. Do not connect the welder cable utes) for 25A load
or apply any weld to any part of the engine.
Always connect the welder earth (ground) cable to Table 240. Alternator
the same component that is being welded to avoid Item Specification
damage to pivot pins, bearings and bushes. Attach Ampere 100A
the welder earth (ground) cable a distance from the
Voltage 28
part being welded no more than 0.6 m.
Notice: Do not disconnect the battery while the Table 241. Starter motor
engine is running, otherwise the electrical circuits
may be damaged. Item Specification
Starter motor 4kW
CAUTION! Understand the electrical circuit
before connecting or disconnecting an electrical For fuses and relays specification refer to operator
component. A wrong connection can cause injury manual, technical data.
and/or damage.

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Check (Condition) Check (Operation)

Examine the electrical circuits regularly for: Make sure that all the electrical equipment listed
below operate correctly.
• Damaged connectors.
• Loose connections. • Switches
• Chafing on the wiring harnesses. • Warning lights
• Corrosion. • Beacon
• Missing insulation. • Alarms
• Incorrect routing of the wiring harnesses. • Horn
• Wipers
Do not use the machine if one or more of these faults • Hourmeter
are found. You must make sure that the electrical • Battery
circuit is repaired immediately. • Lights

All defective equipment must be repaired before the

machine is used.

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50 - Schematic Circuit Introduction

Introduction ...................................................... 33-6 A schematic wiring diagram is a simplified pictorial
Diagram ........................................................... 33-9 representation of the machines electrical circuit. It
shows the components of the circuit as simplified
electrical symbols, and the power and signal
connections between the devices. The wiring
diagram is used to troubleshoot problems and to
make sure that all the connections have been made
and that everything is present.

Use the schematics together with the correct

electrical harness drawings to reference the
connector pin details.

This section may contain more than one set of

electrical schematics for different machine variants.

Understanding Electrical Schematics

Use the applicable schematic set to trace wires
and connections between electrical devices. In most
cases it will be necessary to trace wires across more
than one schematic sheet.

The example identifies the information contained on

the diagrams. It also shows how to follow wires from
one diagram sheet to another.

The harness inter-connector codes and device

harness connector codes are the same as used on
the applicable harness drawings.

Splices are not normally accessible. Splices are

inside the harness sheath and not visible on the
outside. Wires are welded together at a splice, there
are no individual connector components.

33 - 6 9813/4800-4 33 - 6
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Figure 733.

/7.B4 TO
0.50 mm² 1009A -S012
TO SWITCH:MAIN WIPER C116 #1996

C 7

-SW5
A 701/E0089
7219/0013 SWITCH: MAIN WIPER
FROM SPLICE:BACKLIGHTING S012 #1996
-C116 8 7
0.50 mm² 1009A 8/10 7/10
/3.D1 FROM

0.50 mm² 8100J B

-S011 1 D
F F 2/10 2

L H 3 3/10
4 4/10
-IC08_M -IC08_M
0.75 mm² 8006 21/21 21/21 0.75 mm² 8006 5/10 5
/9.B5 TO

#1783 6 6/10
TO MOTOR:WIPER-UPPER C058
D GD
K J
E

7236/0002
MOTOR:WIPER UPPER 9
-C058
6/6 6/6 RED 5/6 5/6 1.00 mm² 8006 5/20 5/20 0.75 mm² 8006 FROM
/7.B4
BLACK #1783 FROM SWITCH:MAIN WIPERS C116
2/6 2/6 GREEN
YELLOW
-B8 3/6 3/6
1/6 1/6 BROWN
WHITE 4/6 4/6

A Wire size (area) and number B Device harness connector code

C Device description D Connector pin number (wire location / total)
E Device internal schematic F Harness inter-connector codes
G Harness inter-connector symbol H Splice code and symbol
J Destination reference number K Destination (harness connector code)
L Destination (diagram sheet and grid)

To help locate a wire destination from other diagram Due to space limitations, the grid is sometimes
sheets use the grid reference. This identifies the omitted.
applicable location zone on the sheet in a similar way
to a map reference.

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Figure 734. Grid reference example (D4)

1 2 3 4 5 6 7 8

F GROUND
RC012:6 /15.C5 FROM 1.00 mm² 601SP
F
GROUND 1.00 mm² 601AV
RC011:1 /13.A4 FROM

GROUND 1.00 mm² 601AX CAN SHLD

RC007:2 /13.B4 FROM

P006:5 /3.D2 FROM 0.75 mm² 601HB

GROUND 2.00 mm² 601AR 6.00 mm² 601RC1 CAN SHLD

RC009:1 /12.F6 FROM

P006:10 /3.D2 FROM 0.75 mm² 601EK

-SRC5
CAN SHLD 0.75 mm² 601HK
P007:10 /3.C2 FROM

GROUND 1.50 mm² 600WP CAN SHLD

RC18:2 /12.C6 FROM

P007:5 /3.C2 FROM 0.75 mm² 601HL

GROUND 2.00 mm² 601AW CAN SHLD

RC004:1 /12.E6 FROM

P008:10 /3.A2 FROM 0.75 mm² 601X

GROUND 2.00 mm² 601FK CAN SHLD

RC003:2 /14.F7 FROM

P008:5 /3.B2 FROM 0.75 mm² 601JJ

GROUND 2.00 mm² 601DG CAN SHLD -SP3

RC005:2 /13.C7 P101:10 1.00 mm² 601TS 3.00 mm² 601JC
E /8.D4
FROM
FROM

GROUND 2.00 mm² 601KG 6.00 mm² 601RC2 10.00 mm² 601RC CAN SHLD
E
RC008:2 /13.C7 FROM

P014:1 /13.F1 0.75 mm² 601LH

-RC06
FROM

-SRC6 -SRC7 M10

CAN SHLD 0.75 mm² 601SH

P014:5 /13.E1 FROM

HYD ECU SENSOR GND 0.75 mm² 699CE CAN SHLD

SP43 /30.E6 FROM

P058:4 /15.E2 FROM 1.00 mm² 601RD

HYD ECU SENSOR GND 1.00 mm² 699SK CAN SHLD CAN SHLD
SP44 /25.C5 FROM

P013:5 /8.C1 FROM 1.00 mm² 601LL P072:17 /9.C5 FROM 1.00 mm² 601DE

HYD ECU SENSOR GND 1.00 mm² 699CH CAN SHLD CAN SHLD
P095:3 /26.D1 FROM

P016:5 /11.E6 FROM 0.75 mm² 601SY P112:2 /14.C4 FROM 1.00 mm² 601HT

HYD ECU SENSOR GND 1.00 mm² 699SJ CAN SHLD CAN SHLD -SP11
P095:6 /26.D1 FROM

P016:10 /11.E6 FROM 0.75 mm² 601JB P020:7 /11.D3 FROM 0.75 mm² 601AD 3.00 mm² 601JE

HYD ECU SENSOR GND 0.75 mm² 699CB CAN SHLD CAN SHLD
P091:2 /29.E5 FROM

P010:5 /4.E2 FROM 0.75 mm² 601NS P063:7 /9.F7 FROM 1.00 mm² 601HP

HYD ECU SENSOR GND 0.75 mm² 699CC -SP42 1.50 mm² 699CA HYD ECU SENSOR GND CAN SHLD CAN SHLD
P092:2 /29.E5 FROM FROM
/22.B7 SC9 / P039:F7 P011:5 /10.F6 FROM 0.75 mm² 601BL P073:A /17.D1 FROM 1.00 mm² 601C

D
HYD ECU SENSOR GND 0.75 mm² 699CD CAN SHLD
P087:2 /21.B7 P036:7 /25.D2 1.00 mm² 601DZ
D
FROM
FROM

HYD ECU SENSOR GND 1.00 mm² 699CG

SP2 /27.E4 FROM

HYD ECU SENSOR GND 0.75 mm² 699CF

P111:2 /29.B6 FROM

CAN SHLD 1.00 mm² 601FV

P067:10 /14.D4 FROM

CAN SHLD 1.00 mm² 601KP -SP29 3.00 mm² 601JH -SP62 10.00 mm² 600 -P030 M10
P015:10 /14.D5 FROM

CAN SHLD 1.00 mm² 601V

P013:10 /10.B1 FROM

CAN SHLD 1.00 mm² 601AC

P015:5 /14.D3 FROM

CAN SHLD 2.00 mm² 601TR

P070:16 /21.C6 FROM

CAN SHLD
C CAN SHLD 1.50 mm² 606TR
P052:1 /14.E7 FROM 1.00 mm² 601DD
P070:15 /21.C6 FROM

C
CAN SHLD 1.00 mm² 601AC CAN SHLD 1.00 mm² 610ACF
CAN SHLD P017:7 /14.C5 FROM
P013:5 /14.E2 FROM

P055:1 /12.B6 FROM 2.00 mm² 600P 10.00 mm² 600

-SP61 -P035 M10 CAN SHLD
P062:7 /27.E4 FROM 1.00 mm² 601KK
CAN SHLD 2.00 mm² 601BU
P130:3 /13.D7 FROM

CAN SHLD 0.50 mm² 601P

CAN SHLD P40:10 /9.A3 FROM

P130:4 /13.D7 FROM 2.00 mm² 601AL

CAN SHLD 1.00 mm² Y
CAN SHLD P066:11 /8.B7 FROM

2.00 mm² SCR

SPMC12 /17.C3 FROM

CAN SHLD 0.75 mm² 601BF

CAN SHLD P024:7 /10.C1 FROM

2.00 mm² SCR

SVMC15 /17.D5 FROM

CAN SHLD 1.00 mm² 601DC -SP6 2.00 mm² 601JD

CAN SHLD P023:7 /10.F2 FROM

1.00 mm² 600H

P034:2 /7.C2 FROM

CAN SHLD 1.00 mm² 601AC

P026:7 /13.F3 FROM

CAN SHLD 1.00 mm² 601AY CAN SHLD 1.00 mm² 601BB
P028:7 /13.B2 FROM
P017:7 /25.E3 FROM

B P029:7 /13.E3
CAN SHLD 1.00 mm² 601KA P021:7 /12.F3
CAN SHLD 1.00 mm² 601BH
B
FROM FROM

CAN SHLD 1.00 mm² 601AL CAN SHLD 1.00 mm² 601DX 2.00 mm² 601JF
P061:7 /16.F2 FROM
P022:7 /12.E3 FROM

-SP28
CAN SHLD 1.00 mm² 601BL CAN SHLD 1.00 mm² 601KC
P052:7 /14.B5 FROM
P065:2 /15.B5 FROM

CAN SHLD 1.00 mm² 601N

P027:7 /21.B4 FROM

CAN SHLD 0.75 mm² 601AK

P042-A /28.E2 FROM

CAN SHLD 1.00 mm² 601EN

P018:7 /30.F2 FROM

A
A

1 2 3 4 5 6 7 8

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 33 - Electrical System
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50 - Schematic Circuit

Diagram

Figure 735. Fuses and Relays............................................................................................... Page 33-11

Figure 736. Instrument Cluster............................................................................................... Page 33-15
Figure 737. ZF TCU............................................................................................................... Page 33-19
Figure 738. Management ECU...............................................................................................Page 33-23
Figure 739. 6 Cylinder JCB engine........................................................................................ Page 33-27
Figure 740. Front wiper, Rear wiper, HVAC........................................................................... Page 33-31
Figure 741. Front, Rear and Beacon......................................................................................Page 33-35
Figure 742. Road lighting....................................................................................................... Page 33-39
Figure 743. Radio, Cigar lighter and CCTV........................................................................... Page 33-43
Figure 744. Seat and Mirror heater........................................................................................ Page 33-47
Figure 745. Loader function and Livelink............................................................................... Page 33-51
Figure 746. Hydraulic Solenoid.............................................................................................. Page 33-55
Figure 747. Earth point........................................................................................................... Page 33-59

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Notes:

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Page 33-12 Figure 735. Fuses and Relays Page 33-13

D

A
B
C

335-C4002-4 sheet 01

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Page Page
33-12 33-13

Figure 735. (Part 1 of 2)

A
B
C

Page 33-13

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Page Page
33-12 33-13

Figure 735. (Part 2 of 2)

D

F
Page 33-12

335-C4002-4 sheet 01

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Page 33-16 Figure 736. Instrument Cluster Page 33-17

335-C4002-4 sheet 02

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Page Page
33-16 33-17

Figure 736. (Part 1 of 2)

Page 33-17

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 33 - Electrical System
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Page Page
33-16 33-17

Figure 736. (Part 2 of 2)

G
Page 33-16

335-C4002-4 sheet 02

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Page 33-20 Figure 737. ZF TCU Page 33-21

K

L
U

M V

X
Q

S Y

335-C4002-4 sheet 03

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Page Page
33-20 33-21

Figure 737. (Part 1 of 2)

Page 33-21
Q

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Page Page
33-20 33-21

Figure 737. (Part 2 of 2)

W
Page 33-20

335-C4002-4 sheet 03

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Page 33-24 Figure 738. Management ECU Page 33-25

AA

AB

AC

AD

AE
335-C4002-4 sheet 04

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 33 - Electrical System
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Page Page
33-24 33-25

Figure 738. (Part 1 of 2)

AA

Page 33-25
AB

AC

33 - 24 9813/4800-4 33 - 24
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Page Page
33-24 33-25

Figure 738. (Part 2 of 2)

Page 33-24

AD

AE
335-C4002-4 sheet 04

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Page 33-28 Figure 739. 6 Cylinder JCB engine Page 33-29

AF

AJ

AG AH

AH
335-C4002-4 sheet 05

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Page Page
33-28 33-29

Figure 739. (Part 1 of 2)

AF

Page 33-29
AG

33 - 28 9813/4800-4 33 - 28
 33 - Electrical System
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Page Page
33-28 33-29

Figure 739. (Part 2 of 2)

AJ
Page 33-28

AH

AH
335-C4002-4 sheet 05

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Page 33-32 Figure 740. Front wiper, Rear wiper, HVAC Page 33-33

AK

AL

AK

AQ
AP

AM

AN

335-C4002-4 sheet 06

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Page Page
33-32 33-33

Figure 740. (Part 1 of 2)

Page 33-33
AQ
AP

AN

33 - 32 9813/4800-4 33 - 32
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Page Page
33-32 33-33

Figure 740. (Part 2 of 2)

AK

AL

AK
Page 33-32

AM

335-C4002-4 sheet 06

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Page 33-36 Figure 741. Front, Rear and Beacon Page 33-37
AS
AR

AT

AU

AV

AW

AX

AY

AZ
335-C4002-4 sheet 07

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Page Page
33-36 33-37

Figure 741. (Part 1 of 2)

AR

Page 33-37

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50 - Schematic Circuit

Page Page
33-36 33-37

Figure 741. (Part 2 of 2)

AS
AR

AT

AU
Page 33-36

AV

AW

AX

AY

AZ
335-C4002-4 sheet 07

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Page 33-40 Figure 742. Road lighting Page 33-41

BA

BB

BB

BC

BC

BA
335-C4002-4 sheet 08

33 - 39 9813/4800-4 33 - 39
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Page Page
33-40 33-41

Figure 742. (Part 1 of 2)

Page 33-41

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Page Page
33-40 33-41

Figure 742. (Part 2 of 2)

BA

BB

BB
Page 33-40

BC

BC

BA
335-C4002-4 sheet 08

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33 - 42 9813/4800-4 33 - 42
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Page 33-44 Figure 743. Radio, Cigar lighter and CCTV Page 33-45

BD

BE

BF

BG

BH
335-C4002-4 sheet 09

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Page Page
33-44 33-45

Figure 743. (Part 1 of 2)

BF

Page 33-45

33 - 44 9813/4800-4 33 - 44
 33 - Electrical System
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Page Page
33-44 33-45

Figure 743. (Part 2 of 2)

BD

BE

BG
Page 33-44

BH
335-C4002-4 sheet 09

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Page 33-48 Figure 744. Seat and Mirror heater Page 33-49

AH

BJ

BK

335-C4002-4 sheet 10

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Page Page
33-48 33-49

Figure 744. (Part 1 of 2)

Page 33-49

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Page Page
33-48 33-49

Figure 744. (Part 2 of 2)

AH
Page 33-48

BJ

BK

335-C4002-4 sheet 10

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Page 33-52 Figure 745. Loader function and Livelink Page 33-53

BL

BM

BN

335-C4002-4 sheet 11

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Page Page
33-52 33-53

Figure 745. (Part 1 of 2)

BL

BM

Page 33-53

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Page Page
33-52 33-53

Figure 745. (Part 2 of 2)

Page 33-52

BN

335-C4002-4 sheet 11

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Page 33-56 Figure 746. Hydraulic Solenoid Page 33-57

BP

BQ

BR

335-C4002-4 sheet 12

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Page Page
33-56 33-57

Figure 746. (Part 1 of 2)

Page 33-57

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Page Page
33-56 33-57

Figure 746. (Part 2 of 2)

BP

BQ
Page 33-56

BR

335-C4002-4 sheet 12

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00 - Electrical System
50 - Schematic Circuit

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00 - Electrical System
50 - Schematic Circuit

Page 33-60 Figure 747. Earth point Page 33-61

BU

BT
BV

BW

BS
335-C4002-4 sheet 13

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00 - Electrical System
50 - Schematic Circuit

Page Page
33-60 33-61

Figure 747. (Part 1 of 2)

Page 33-61

BS

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 33 - Electrical System
00 - Electrical System
50 - Schematic Circuit

Page Page
33-60 33-61

Figure 747. (Part 2 of 2)

BU

BT
BV
Page 33-60

BW

335-C4002-4 sheet 13

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50 - Schematic Circuit

Item Description
AQ HVAC (Heating Venti-
Table 242.
lation Air Conditioning)
Item Description unit
A Battery isolator AR Work light switch
B Battery AS Front auxiliary worklight
C Ignition switch AT Front worklight
D Starter motor AU Rear worklight
E Alternator AV Rear auxiliary worklight
F Grid heater (Roof)
G Instrument cluster AW Rear auxiliary worklight
H Fuel level sender (Bonnet)
J Hydraulic oil tempera- AX Beacon switch
ture sender AY Beacon
K ZF computer AZ Interior light
L Speed sensor BA Number plate light
M Left side column switch BB Headlight
N Joystick BC Combi lamp
P Auto transmission dump BD CCTV system
switch BE Speaker
Q SRS (Smooth Ride Sys- BF Dropper
tem) switch BG Power socket 12V
R SRS solenoid (Optional) BH Power socket 24V
S Auto/Manual switch BJ Heated mirror
T Park brake status switch BK Heated seat (Optional)
U Internal gear chain BL Lift arm reset
speed sensor
BM Shovel reset
V Turbine speed sensor
BN Livelink ECU (Electronic
W Engine speed sensor Control Unit)
X Gearbox controller BP Quickhitch switch
Y Torque converter tem- BQ Servo isolator switch
perature sensor
BR Changeover switch
Z Filter bypass pressure
BS Earth point - Rear con-
switch
sole
AA Low brake pressure
BT Earth point - Engine
switch
BU Earth point - Front con-
AB Main pressure switch
sole
AC Emergency steer pres-
BV Earth point - Right side
sure sensor
front roof
AD Seat switch
BW Earth point - Rear chas-
AE Emergency steer motor sis
AF Electronic foot throttle
AG Fuel lift pump
AH CAN (Controller Area
Network) terminating re-
sistor
AJ Water in fuel sensor
AK Washer motor
AL Wiper motor
AM Climate control unit
AN Climate control panel
AP Heater motor switch

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 33 - Electrical System
00 - Electrical System
90 - Earth Point

90 - Earth Point

Introduction

The ground or earth refers to the reference point in an

electrical circuit from which voltages are measured,
a common return path for electrical current, or a
direct physical connection to earth. Electrical circuits
may be connected to ground or earth to prevent
user contact with dangerous voltage if the electrical
insulation fails.

Earth points can be useful when tracing electrical

faults typically when several electrical devices are
malfunctioning.

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 33 - Electrical System
03 - Battery

03 - Battery

Contents Page No.

33-03-00 General ........................................................................................................................... 33-65

33-03-03 Isolator Switch ................................................................................................................ 33-76

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03 - Battery
00 - General

00 - General Introduction
Introduction .................................................... 33-65 Batteries used in normal temperate climate
Health and Safety .......................................... 33-66 applications should not need topping up. However,
Fault-Finding .................................................. 33-67 in certain conditions (such as prolonged operation
Disconnect and Connect ............................... 33-68 in high ambient temperatures or if the alternator
overcharges) the electrolyte level should be checked
Check (Condition) .......................................... 33-71 frequently and topped up as necessary.
Charge ........................................................... 33-72
Remove and Install ....................................... 33-73 The electrolyte level should be checked in
accordance with the routine maintenance schedule.
Shorter maintenance intervals are required if the
machine is operating at high ambient temperatures
or continuously for long periods.

Later Machines may have the new type batteries

installed which include a sight glass to check the
condition of the battery. New batteries should be
used as replacements if replacing the battery on
earlier machines.

Figure 748.

A Maintenance free battery

Maintenance
To make sure that the battery provides optimum
performance the following steps should be observed:

• Make sure that the electrical connections are

clean and tight. Smear petroleum jelly on
connectors to prevent corrosion.
• When applicable - never allow the electrolyte
level to fall below the recommended level of
6mm above the plates. Use only distilled water
for topping up.
• Keep the battery at least three quarters
charged, otherwise the plates may become
sulphated (hardened) - this condition makes
recharging the battery very difficult.

Extra precautions must be taken when bench

charging maintenance free batteries, they are more
prone to damage by overcharging than the standard
type of battery:

• Never boost charge a maintenance free battery

(if installed).

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03 - Battery
00 - General

• Never charge a battery at a voltage in excess Health and Safety

of 15.8V.
• Never continue to charge a battery after it DANGER Batteries give off an explosive gas.
begins to gas. Do not smoke when handling or working on the
battery. Keep the battery away from sparks and
Quiescent Current Drain flames.
Battery electrolyte contains sulphuric acid. It can
If the machine has no permanently live circuits there burn you if it touches your skin or eyes. Wear
should be zero quiescent current drain, when the goggles. Handle the battery carefully to prevent
key-switch is off and all the lights are switched off. spillage. Keep metallic items (watches, rings, zips
etc) away from the battery terminals. Such items
It should be noted that some permanently live circuits could short the terminals and burn you.
will place a quiescent drain on the battery. Typically
the quiescent drain will be in the range of 10–20 Set all switches to off before disconnecting and
mA. If the quiescent drain measures 40 mA or more, connecting the battery. When disconnecting the
there is a problem with the wiring insulation or the battery, take off the earth (-) lead first.
accessories, if the fault is not rectified it will continue Re-charge the battery away from the machine,
to drain the battery. in a well ventilated area. Switch the charging
circuit off before connecting or disconnecting the
battery. When you have installed the battery in the
machine, wait 5 min before connecting it up.
When reconnecting, attach the positive (+) lead
first.
WARNING Keep metal watch straps and any
metal fasteners on your clothes, clear of the
positive (+) battery terminal. Such items can short
between the terminal and nearby metal work. If it
happens you can get burned.
WARNING Battery electrolyte is toxic and
corrosive. Do not breathe the gases given off
by the battery. Keep the electrolyte away from
your clothes, skin, mouth and eyes. Wear safety
glasses.
WARNING Do not top the battery up with acid.
The electrolyte could boil out and burn you.
CAUTION Understand the electrical circuit
before connecting or disconnecting an electrical
component. A wrong connection can cause injury
and/or damage.
Notice: Do not disconnect the battery while the
engine is running, otherwise the electrical circuits
may be damaged.
CAUTION The machine is negatively earthed.
Always connect the negative pole of the battery
to earth.
When connecting the battery, connect the earth
(-) lead last.
When disconnecting the battery, disconnect the
earth (-) lead first.
DANGER If you try to charge a frozen battery, or
jump start and run the engine, the battery could
explode. Do not use a battery if its electrolyte
is frozen. To prevent the battery electrolyte from
freezing, keep the battery at full charge.
CAUTION Damaged or spent batteries and any
residue from fires or spillage must be put in a

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03 - Battery
00 - General

suitable closed receptacle and must be disposed

of in accordance with local environmental waste
regulations.
Notice: Before carrying out arc welding on the
machine, disconnect the battery and alternator to
protect the circuits and components. The battery
must still be disconnected even if a battery
isolator is installed.

Fault-Finding
The most obvious sign of a battery problem is a
machine not being able to start. However, because
the battery is part of a larger electrical system
connected to other parts of the machine, a flat battery
may indicate another problem.
If something else is going wrong in the electrical
system, for example, a weak alternator, corrosion or
loose connections, cold weather starting, electrical
equipment being left on without the engine running,
interrogate the cause of the problem.
The best way to test the condition of the battery is
with an electronic battery tester. Refer to Battery-
Check Condition.
When the machine is not in use, make sure that the
electrical system is not causing a drain on the battery.
On machines with electronically controlled engines
check the operation of the power hold relay. Refer to
PIL 33-09-06.

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03 - Battery
00 - General

Disconnect and Connect

Notice: Before you install a pair of batteries to Figure 749. Parallel and
a machine, make sure you know the machines Series Connection (Example)
voltage. Some machines require two batteries but
have a 12 V electrical system. This means the
batteries need to be connected in parallel.
For 24 V machines, the batteries must be
_ _
connected in series. Incorrect voltage may result
in serious damage to the electrical system. + +
A
C
C
The illustrations show typical battery connections.
The actual battery connections installed on your
machine may look different. _ + _ +
Make sure you connect the batteries correctly for
your machine.

Disconnect 12 V 24 V
1. Make the machine safe. D B D B

Refer to: PIL 01-03-27. Figure 750. Twin Battery 12V Ma-
chines- Parallel Connection (Example)
2. Get access to the battery or batteries (depending
on the specification of your machine). The actual B
installation on your machine may vary from those
shown below.
3. If the machine has a battery isolator, move the
switch to the OFF position, then remove the key. C
4. Disconnect the battery negative lead first.
5. Disconnect the battery positive lead and store
away from the batteries.
A
A D
6. Disconnect and remove the battery link lead or
leads.

A Battery
B Positive lead
C Battery link lead
D Negative lead

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03 - Battery
00 - General

Figure 751. 24 Volt Machines- Series Connection (Example)

C

_ _ + +

A Battery B Positive lead

C Battery link lead D Negative lead

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03 - Battery
00 - General

Connect
1. Check the battery as follows:
1.1. If any terminals are dirty, clean them.
1.2. If the terminal is corroded and has white
powder, wash the terminal with hot water.
Make sure the water does not enter the
battery cells.
1.3. If considerable corrosion is found, then
clean with a wire brush or abrasive
paper. Make sure you use eye and hand
protection. Refer to Figure 752.
Figure 752.

1.4. After cleaning, apply a thin coat of

petroleum jelly to the terminals.
2. Connect the leads.
2.1. For single battery machines, connect the
positive lead then the negative lead.
2.2. For twin battery machines, first connect the
link lead or leads, then the positive terminal,
and finally the negative terminal.
3. If the machine has a battery isolator, move the
switch to the ON position.
4. Close and lock the access panels.

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03 - Battery
00 - General

Check (Condition) Table 243. Fault Diagnosis

Battery Tester Read- Remedy
ings
Battery Test CHECK: 0 -12.6 Volts: Renew battery
LOAD: less than 6 Volts
This test is to determine the electrical condition of
the battery and to give an indication of the remaining CHECK: 6 -12.4 Volts: Recharge and re-test. If
useful life. LOAD: less than 9 Volts tests are still unsatisfac-
and falls steadily but re- tory renew battery
Before you test the battery, make sure that the mains in yellow zone
battery is at least 75% charged (Specific Gravity of CHECK: less than 10 Indicates battery has
1.23 to 1.25 for ambient temperature up to 27°C). Volts: LOAD: less than 3 been over-discharged
Volts and unlikely to recover.
Make sure that the battery is completely Renew battery
disconnected from the vehicle. CHECK: more than 11 Charge battery which
Volts: LOAD: 6 - 10 Volts will probably recover
Figure 753. steady

Specific Gravity Test

The specific gravity of the electrolyte gives an idea
of the state of charge of the battery. Readings
should be taken using a hydrometer, when the
electrolyte temperature is 15°C (60°F). If the battery
has recently been on charge, wait approximately one
hour (or slightly discharge the battery) to dissipate
the surface charge before testing.

Readings should be as tabulated and should not vary

between cells by more than 0.04. A greater variation
indicates an internal fault on that particular cell.

If the electrolyte temperature is other than 15°C

(60°F) a 'correction factor' must be applied to the
reading obtained. Add 0.07 per 10°C (18°F) if the
A Battery voltage switch temperature is higher than 15°C (60°F) and subtract
B Check load switch the same if the temperature is lower.
Connect up the battery tester as follows: Table 244. Specific Gravity at 15°C (60°F))
1. Set the Check Load switch to OFF. Ambient Fully Half Dis- Fully Dis-
Temper- Charged charged charged
2. Set the battery voltage switch to 12V. ature de-
grees C
3. Connect the red flying lead to the battery positive (degrees
(+) terminal and the black flying lead to the F)
battery negative (-) terminal.
Below 27 1.270-1.290 1.190-1.210 1.110-1.130
4. Set the Check/Load switch to CHECK to read the (80)
battery no-load voltage which should be at least Above 27 1.240-1.260 1.170-1.190 1.090-1.110
12.4 volts. (80)

5. Set the Check/Load switch to LOAD and hold

down for 5-10 seconds until the meter reading
stabilises. The reading should be at least 9 volts.
6. If the tests are unsatisfactory, refer to the fault
diagnosis table.

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03 - Battery
00 - General

Charge

Precautions Before Charging

Follow all the precautions described below, to
prevent damage to the alternator and battery.

1. Make the machine safe.

Refer to: PIL 01-03.
2. Make sure that the battery negative terminal is
connected to the earth cable.
3. Do not connect or disconnect the battery
or alternator connections, or any part of the
charging circuit while the engine is in operation.
If you disregard this instruction, the regulator or
rectifying diodes will be damaged.
4. Main output cables are always in an active state
of current flow even when the engine is not in
operation. If the alternator connector is removed,
do not earth the moulded plug.
5. When you do arc welding on the machine,
remove the moulded plug (or if the separate
output cables are installed, remove the cables)
to protect the alternator.
6. If it is necessary to jump start the battery, do the
following steps.
6.1. Connect a secondary battery in parallel
without disconnecting the vehicle battery
from the charging circuit.
6.2. Connect the batteries using suitable jump
leads. Connect the positive lead to the
positive terminals of both batteries. Connect
the negative lead to the negative terminals
of both batteries.
6.3. After the jump start, safely disconnect the
jump leads and remove the secondary
battery.

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03 - Battery
00 - General

Remove and Install

CAUTION This component is heavy. It must only 4. Remove the rear grille latch which secures the
be removed or handled using a suitable lifting grille to the chassis.
method and device.
5. Open the rear grille.

Remove 6. Disconnect the negative terminal (Black) first.

1. Make the machine safe. Refer to (PIL 01-03). 7. Remove the battery link lead.

2. Install the articulation lock. Refer to (PIL 06-27). 8. Disconnect the positive terminal (Red).

3. Turn the battery isolator switch off and remove it, 9. Remove the nut, wing nut and the washer then
to isolate the battery from the electrical circuit. remove the battery clamp.

Figure 754. 10. Use the battery handle to lift the battery from the
machine.
B

B Battery identification label

C Battery isolator key
D Battery isolator switch

Figure 755.

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 33 - Electrical System
03 - Battery
00 - General

A Battery

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03 - Battery
00 - General

Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps:
1.1. Clean the battery terminals if there is any
sign of corrosion.
1.2. Apply petroleum jelly to the battery
terminals.
1.3. Connect the positive lead (Red) first and
then the negative lead (Black).

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03 - Battery
03 - Isolator Switch

03 - Isolator Switch Introduction

Introduction .................................................... 33-76 The battery isolator switch is used to disconnect the
Disconnect and Connect ............................... 33-77 battery from the machine electrics. The switch must
be turned to the OFF position if any maintenance
work is to be performed on the machine.

Some machine systems perform shut down cycles

after the engine stops. Wait until shut down cycles
are complete before setting the battery isolator
switch to the OFF position. For more information
refer to Disconnect and Connect.

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 33 - Electrical System
03 - Battery
03 - Isolator Switch

Disconnect and Connect

Disconnect
If the machine has an electronically controlled
engine, you must wait a period of time before you
isolate the battery. This is to allow the ECM (Engine
Control Module) to shutdown correctly. The time
period starts when you turn the ignition off. Check the
isolator switch label and the operators manual for the
correct time period.

In the event of an emergency, if required, remove the

isolator key without waiting.

If a radio is installed, you may lose any settings.

1. Make the machine safe.

Refer to: PIL 01-03.
2. Turn the ignition key to the off position.
3. Wait for the ECM to shutdown correctly (if
applicable).
4. Get access to the isolator key.
Refer to: PIL 33-03-03.
5. Turn the battery isolator key in the indicated
direction and remove.

Connect
1. Make sure the ignition is set to off.
2. Insert the battery isolator key and turn in the
indicated direction.

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 33 - Electrical System
06 - Battery Cable

06 - Battery Cable

Contents Page No.

33-06-00 General ........................................................................................................................... 33-79

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 33 - Electrical System
06 - Battery Cable
00 - General

00 - General

Introduction

The cables connect the battery positive and negative

terminals to the machine electrical system.

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 33 - Electrical System
09 - Power Distribution

09 - Power Distribution

Contents Page No.

33-09-00 General ........................................................................................................................... 33-81

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 33 - Electrical System
09 - Power Distribution
00 - General

00 - General Introduction
Introduction .................................................... 33-81 The electrical circuits are protected by fuses. If a
Health and Safety .......................................... 33-82 fuse blows, find out why and rectify the fault before
installing a new one.

A full up to date list of fuses and relays and their

locations can be found in the relevant operator
manual, maintenance section.

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 33 - Electrical System
09 - Power Distribution
00 - General

Health and Safety

Notice: Always replace fuses with ones of correct
ampere rating to avoid electrical system damage.
Notice: When installing auxiliary electrical
components always ensure that the additional
load rating is suitable for that particular circuit. It
is unacceptable to simply increase the fuse rating
as this can cause overloading and consequential
failure of wiring, along with failure of integral
circuit components, which the fuse is protecting.

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 33 - Electrical System
12 - Harness

12 - Harness

Contents Page No.

33-12-00 General ........................................................................................................................... 33-85

33 - 83 9813/4800-4 33 - 83
Notes:

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 33 - Electrical System
12 - Harness
00 - General

00 - General Introduction
Introduction .................................................... 33-85
Health and Safety .......................................... 33-86
Harness Drawings
Component Identification ............................... 33-87 Drawings are reproduced from production electrical
Diagram ......................................................... 33-89 harness drawings. Each harness drawing includes
Repair ............................................................ 33-89 tables showing wire connections and destinations
for all the connectors on the harness. To identify
Check (Condition) .......................................... 33-92
the correct harness drawing for a particular machine
refer to the relevant Harness Interconnection page
for the machine serial number range.

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 33 - Electrical System
12 - Harness
00 - General

Health and Safety

Notice: When installing auxiliary electrical
components always ensure that the additional
load rating is suitable for that particular circuit. It
is unacceptable to simply increase the fuse rating
as this can cause overloading and consequential
failure of wiring, along with failure of integral
circuit components, which the fuse is protecting.

Harness Repair (Butane Heater)

WARNING In addition to the warnings
incorporated into this procedure, extreme care
should be taken when handling the gas heating
tool to ensure that the flame does not damage or
set fire to any items in the vicinity of the repair,
i.e. other wires, floor panels, floor mats, sound
proofing, paintwork, etc. This tool should not be
used in any restricted location prohibiting the use
of "Naked Flames" or where risk of explosive gas
or similar safety parameters apply. No other heat
source should be used to attempt a sealed joint.
CAUTION When the heater is in use, the reflector
and the air coming out are extremely hot. Keep
away to avoid accidental burns. Do not touch the
reflector until it has had time to cool down after
switching off. If flame reappears at the reflector
when the heater is in use, the catalytic element is
damaged or used up. Stop work immediately and
replace the heater.

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 33 - Electrical System
12 - Harness
00 - General

Component Identification

Wire and Harness Number Identification

This section details the allocation of wire numbers
and the identification of wires in the wiring harness.

Figure 756.

The illustration shows a typical connector and wires. Identifica- Description

Each wire has an individual identification number tion Num-
permanently marked on it, at regular intervals along ber
it's length. The number stamped on the wire identifies 819 The wire's unique identification num-
the following: ber. The wire functions and num-
bers allocated to them are consis-
Table 245. Wire and Harness tent through out the JCB range of
Number Identification products. Refer to Wire Numbers and
Identifica- Description Functions.
tion Num- 9/371 If applicable - The part number of
ber the harness that the wire originates
# The # indicates the start of the identi- from. If the harness part number is
fication number. It is always printed to 719/37100, the number printed on the
the left of the identification number. harness wires will be 9/371 (71 and
B If applicable - The colour of the fly- 00 are common numbers and there-
ing lead that the harness wire should fore deleted).
mate with. For instance, if wire 819
from harness 719/37100 mated with Wire Numbers and Functions
a flying lead coloured black (colour
code B) then the number printed on
the wire would be B-819 9/371. Table 246. Wires 000-199, 1000-1999 (These
numbers are reserved for ignition feeds,
heater start circuits and start circuits)
Wire Number Description
Wires 000 - 099 Unfused ignition feeds
Wires 100 - 199 Fused ignition feeds (feeds via
and 1000 -1999 ignition relays are also classed
as ignition feeds). Power sup-
plies output by a control module.

33 - 87 9813/4800-4 33 - 87
 33 - Electrical System
12 - Harness
00 - General

Table 247. Wires 200-399, 2000-3999 (These Table 251. Wires In Splices
numbers are reserved for battery feeds)
Wire Number Description
Wire Number Description Various The main input wire is allocated
Wires 200-299 Unfused battery feeds. Pow- with a wire number and a suit-
and 2000-2999 er supplies output by a control able description, i.e. Wire 640
module. earth splice to earth. The addi-
Wires 300-399 Fused battery feeds. Power sup- tional wires in the splice are al-
and 3000-3999 plies output by a control module. located the same wire number
and a postfix, i.e. 640A, 640B,
etc.
Table 248. Wires 400-599, 4000-5999
Figure 758.
Wire Number Description
Wires 400-599 These numbers are reserved for
and 1000-5999 instruments, sensors and vari-
able input/output signal wires
used in electronic systems. CAN
wires also use numbers in this
series.

Table 249. Wires 600-799, 6000-7999

Wire Number Description
Wires 600-799 These numbers are used for
and 6000-7999 earth wires. When the number
is printed on to a wire it is pre-
fixed by the Earth symbol. This
symbol is printed onto the wire,
it may however be omitted from General Points
harness drawings. Where a load 1. Wires continue to have the same number even
is switched negative, the wire after passing through a connector block to
number from the load to the another harness.
switch shall be different to that
of the wire from the switch to the 2. The descriptions are applicable to JCB
earth. specification wiring harnesses. The machine
may be installed with some wiring that does
not conform to the JCB specifications, typically
Figure 757. when it is part of equipment supplied by other
manufacturers.

600
Table 250. Wires 800-999, 8000-9999
Wire Number Description
Wires 800-999 These numbers are reserved
and 8000-9999 for switched supplies to electri-
cal loads, i.e. to lights, etc. Pow-
er supplies output by a control
module.

33 - 88 9813/4800-4 33 - 88
 33 - Electrical System
12 - Harness
00 - General

Diagram Repair
Special Tools
A full set of harness drawings are available. Description Part No. Qty.
servicepro.jcb.com Wiring Crimp Tool 892/00349 1
Butane Heater 892/00350 1

Consumables
Description Part No. Size
Wiring Splice 892/00351 -
(0.5-1.5mm Red,
contains 50 off)
Wiring Splice 892/00352 -
(1.5-2.5mm Blue,
contains 50 off)
Wiring Splice (3-6mm 892/00353 -
Yellow, contains 50 off)

Instances occur where it is necessary to incorporate

auxiliary electrical components into existing electrical
circuits and although unlikely with present wiring
harnesses, repair or replace specific individual wires
within a harness. This will also apply to other
machines in addition to those of manufacture.

To make sure that either the inclusion of an auxiliary

electrical component or a repair within a harness is
completed to an acceptable standard it is strongly
recommended that the following tools, equipment
and procedures are always used. Note that JCB
harnesses have an Ingress Protection rating of 67
(I.P.67).

The sheath covering of the recommended splice is

heat shrunk onto the original wire insulation. This
results in a seal and corresponding joint to IP 67
specifications.

Procedure
1. Cut the wire and remove the protective insulation
for a suitable distance dependent upon the size
of wire and splice to be used.
Special Tool: Wiring Crimp Tool (Qty.: 1)
Figure 759.
A

A Distance for splice (check size)

33 - 89 9813/4800-4 33 - 89
 33 - Electrical System
12 - Harness
00 - General

2. Using the correct sized splice, attach the new cartridge up into the reflector assembly as
section of wire required or auxiliary flying far as possible until the two elements are
lead to the existing harness and secure using clasped firmly together. An audible click will
the crimp tool. Note that each of the splices be heard.
detailed is colour-coded to make size and range
readily visible. They are secured using the Figure 762.
corresponding size and matching colour-coded
jaws of the crimp tool to ensure joint security.
This tool also incorporates a ratchet closing
mechanism which will not release until the splice
is fully closed to the correct compression size.
Consumable: Wiring Splice (0.5-1.5mm Red,
contains 50 off)
Consumable: Wiring Splice (1.5-2.5mm Blue,
contains 50 off)
Consumable: Wiring Splice (3-6mm Yellow,
contains 50 off)
3. With the Butane heater assembly, seal the
connection.
Special Tool: Butane Heater (Qty.: 1)
3.1. Remove the cap from the end of the
disposable gas cartridge.
3.4. Turn the small ring so that the air holes are
Figure 760. completely closed.
Figure 763.
A

A Cap
B Gas cartridge
3.2. Before assembling the gas cartridge to the
reflector element, turn the red ring to the left,
(in the direction of the minus sign marked
on the ring).
Figure 761.

E Small ring
F Air holes
3.5. Turn the red ring to the right (in the direction
of the plus sign) in order to turn on the
gas. Important: Before turning the heater
on, make sure that the cartridge is not hotter
than the reflector element. This may occur
if the cartridge is held in the hand for a long
time. The temperature difference between
the cartridge and the reflector element may
C Reflector element cause long yellow flames to appear on
D Red ring ignition.

3.3. Position the tube hanging down from inside

the reflector assembly into the hole at the
top of the gas cartridge. Then press the gas

33 - 90 9813/4800-4 33 - 90
 33 - Electrical System
12 - Harness
00 - General

Figure 764. Figure 766.

G Side wings
D Red ring
3.9. Side wings up, reflector head opening
3.6. Hold the heater vertically and, using a reduced. In this mode the heating is done
match or cigarette lighter, light the gas as only by the hot gas (use for dark coloured
shown. Hold the heater vertically for 1 to 2 plastic splices).
minutes until the catalytic reaction occurs.
This is indicated when the blue flame fades Figure 767.
and the ceramic element glows red. Then
turn the small ring until the air holes at
are completely open. The tool is ready
for use. Note: The fact that the sound of
liquid cannot be heard when the cartridge is
shaken does not mean it is empty. No sound
will be heard even when the cartridge is full.
Figure 765.

D Red ring
G Side wings

E Small ring
F Air holes
3.7. The heater can be used in two modes:
3.8. Side wings down, reflector head completely
open. In this mode the infra-red heat waves
are dominant (recommended for the light
coloured plastic splices).

33 - 91 9813/4800-4 33 - 91
 33 - Electrical System
12 - Harness
00 - General

Check (Condition) Figure 768. Fluke 85 Multimeter

This section describes how to use electrical

measuring devices that are used in electrical fault
finding.

Use of Multimeters
In order to obtain the maximum benefit from the
fault finding information contained in the Electrical
Section, it is important that the technician fully
understands the approach to fault finding and the
use of the recommended test equipment, in this case
a FLUKE 85 or AVO 2003 digital multimeter, or a
moving pointer analogue multimeter. The approach
is based on a fault finding check list. In tracing
the fault from the symptoms displayed you will be
directed to make measurements using a multimeter.
These instructions are intended to cover the use of
the recommended meters.

1. Make sure that the test leads are plugged into

the correct sockets. The black test lead should
be plugged into the black socket (sometimes, this
socket is also marked by a -, or E or marked as
COMMON or COM). The red test lead should be
plugged into the red socket marked with +, V or
Ω.
2. When you make a measurement, make sure that 1.2. On the AV0 meter, move the right slider
the test probes have a good clean contact with switch to position A, and the left hand slider
bare metal, free from grease, dirt, and corrosion switch to the appropriate range.
as these can cause a false reading.
3. When you measure a voltage, make sure that
the correct range is selected, that it is set to the
selector value equal to or greater than that you
are about to measure. e.g. If asked to measure
12 Volts, set the selector to the 12V range. If
there is no 12V range, set the selector to the next
range higher, 20V for instance. If the meter is set
to a range that is too low, it may be damaged.
e.g. setting to the 2V range to measure 12V.

Measuring DC Voltage
1. Select the correct range on the multimeter.
1.1. On the digital multimeter, turn the switch to
position B.

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 33 - Electrical System
12 - Harness
00 - General

Figure 769. AVO 2003 Multimeter Measuring Resistance

1. Make sure that there is no power to the part of
the circuit you are about to measure.
2. Connect one probe at one end of the component
or wire to be checked and the other probe at the
other end. It does not matter which way round the
two probes are placed.
3. Select the correct range on the multimeter.
3.1. On the digital multimeter. Turn the switch to
position C and check that the W sign at the
right hand side of the display window is on.
If the F sign is on instead, press the blue
button G to change the reading to Ω. Touch
the meter lead probes together and press
the REL3 key on the meter to eliminate the
lead resistance from the meter reading.
3.2. On the AV0 meter, move the right hand
slider switch to position B, and the left hand
slider switch to the appropriate Ohms (Ω)
range.
3.3. On an analogue meter, move the dial to the
appropriate Ohms (Ω) range.

Measuring Continuity
1. Make sure that there is no power to the part of
the circuit you are checking for continuity.
1.3. On an analogue meter, turn the dial to the
appropriate DC Volts range. 2. Connect one probe to one end of the component
or wire to be checked and the other probe to the
Figure 770. Typical Analogue Multimeter other end. It does not matter which way round the
two probes are placed.
3. Select the correct range on the multimeter.
3.1. On the digital multimeter, turn the switch
to position C and check that the beeper
symbol appears at the left hand side of
the display window. If the F sign is on
instead, press the button labelled F. If there
is continuity in the circuit, the beeper will
sound. If there is no continuity (open circuit),
the beeper will not sound.
3.2. On the AV0 meter, move the right hand
slider switch to position B, and the left
hand slider switch to position C. If there is
continuity (i.e. very low resistance) between
two points the buzzer will sound.
2. Connect the black probe to the nearest available 3.3. On an analogue meter, turn the dial to
suitable earth point, usually this will be the starter the lowest Ohms (Ω) range. If there is
motor earth, the battery negative, or the chassis. continuity (i.e. very low resistance) between
Connect the red probe to the wire or contact from two points the needle will move across fully
which you are measuring the voltage. (or almost fully) to the right hand side of the
scale.

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 33 - Electrical System
12 - Harness
00 - General

Measuring Frequency diode or diode wire. If the Avo meter does

not buzz the diode is faulty.
The AVO meter and the analogue meter are not
2.3. Connect the red probe to the end of the
capable of measuring frequency, therefore a digital
diode marked with a band, or to the male
multimeter must be used.
connector of the diode wire, the black probe
1. Insert the black plug into the COM socket on should be connected to the other end of the
the meter and attach the probe to the nearest diode or diode wire. If the Avo meter does
suitable earth point on the chassis, for example, not read 1 the diode is faulty.
the battery negative terminal. 3. On an analogue meter:
2. Insert the red probe into socket J. 3.1. Select the Ohms 1000s (1k) range, connect
3. Turn the selector switch to position A and the black probe to the end of the diode
depress G repeatedly until F is highlighted on the marked with a band, or to the male
top row of the display. connector of the diode wire, the red probe
should be connected to the other end of the
4. Press button H once. diode or diode wire. The meter should read
20-400 kΩ, if it reads more than this the
5. Touch or connect the red probe to the frequency diode is faulty.
source to be measured. Press and hold the
button if an average reading is required. 3.2. Select the Ohms 100s range, connect the
red probe to the end of the diode marked
with a band, or to the male connector of
Testing a Diode or a Diode Wire the diode wire, the black probe should
A diode wire is a diode with male connector installed be connected to the other end of the
on one end and a female connector installed on the diode or diode wire. The meter should read
other end. The diode is sealed in heatshrink sleeving. 300-400Ω, if it reads less than this the diode
To test a Diode or a Diode Wire. is faulty.

1. On the digital multimeter:

1.1. Turn the switch to position D.
1.2. Press the HOLD button and check that the
H sign appears at the top right hand side of
the display window.
1.3. Connect the black probe to the end of the
diode with a band or to the male connector
of the diode wire. Connect the red probe
to the other end of the diode or diode wire.
If the beeper does not sound the diode or
diode wire is faulty.
1.4. Connect the red probe to the end of the
diode marked with a band, or to the male
connector of the diode wire, the black probe
should be connected to the other end of the
diode or diode wire. If the beeper sounds or
the meter does not read O.L., the diode or
diode wire is faulty.
1.5. Press the HOLD button and check that the
H sign disappears from the right hand side
of the display window.
2. On the AV0 meter:
2.1. Move the right hand slider to position A, and
the left hand slider switch to position C.
2.2. Connect the black probe to the end of the
diode marked with a band, or to the male
connector of the diode wire, the red probe
should be connected to the other end of the

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 33 - Electrical System
24 - Instruments

24 - Instruments

Contents Page No.

33-24-03 Instrument Panel ............................................................................................................ 33-97

33 - 95 9813/4800-4 33 - 95
Notes:

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 33 - Electrical System
24 - Instruments
03 - Instrument Panel

03 - Instrument Panel Introduction

Introduction .................................................... 33-97 The instrument panel communicates information to
Component Identification ............................... 33-98 the operator about the systems on the machine and
Operation ....................................................... 33-99 warns of any abnormal conditions that may occur.
Remove and Install ..................................... 33-101 The instrument panel houses all the gauges and
warning lights on the machine i.e. fuel gauge, coolant
warning, engine oil pressure warning light. For more
detailed information refer to the operator manual.

33 - 97 9813/4800-4 33 - 97
 33 - Electrical System
24 - Instruments
03 - Instrument Panel

Component Identification

Figure 771.

A
E

D C

A LCD (Liquid Crystal Display) B Warning and indicator lamps

C Fuel level gauge D Coolant temperature gauge
E Engine speed

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 33 - Electrical System
24 - Instruments
03 - Instrument Panel

Operation

The gauges, warning lamps and indicator lamps are Fuel gauge: The needle position shows the current
grouped together on the instrument panel. When a level of fuel in the tank. Do not let the tank run dry, or
warning lamp comes on, an alarm will sound. air can enter the fuel system.

The LCD (Liquid Crystal Display) shows the live Coolant temperature gauge: The needle position
machine information to the operator. shows the current temperature of the engine coolant.
Do not let the needle rise into the red danger zone
Tachometer: The needle position indicates the of the gauge.
engine speed in RPM (Revolutions Per Minute).
Each division is 100 RPM.

Warning and Indicator Lamps

Figure 772.

A B C D E F G H

J K L M N P Q

Lamp test (daily): Turn the ignition key to the on the machine if any of the warning lamps do not come
position to do a start-up cycle. Only the lamps shown on, contact your JCB dealer.
should come on during the start-up cycle. Do not use

Table 252.
A Direction indica- Audible/Visual. Illuminate with the direction indicators. Use the direction in-
tors dicators to signal before you turn the machine.
B Master warning Audible/Visual. Illuminate to indicates the most severe active fault. Stop the
machine immediately and contact your JCB dealer.
C Hazard warning Visual. Comes on with the hazard warning lights (even with the ignition key
in the off position). Switch on the hazard warning lights if your machine is a
possible hazard.
D Park brake Audible/Visual. The light will illuminate when the park brake is engaged.
E Road lights Visual Only. Comes on when the roadlights are switched on.
F Main-beam lights Visual Only. Comes on when the main-beams are switched on.
G Rear fog lights Visual Only. Comes on when the rear fog lights are switched on.
H Engine pre-heat Visual. Illuminate if the engine pre-heater is active.
J Battery charging Audible/Visual. The lamp illuminates and buzzer will sound, if battery is not
condition charging while engine is running. If battery is charging, the lamp and buzzer
should go off a few seconds after the engine is started.
K High coolant tem- Audible/Visual. The light will illuminate when the engine coolant tempera-
perature ture is too high. Stop the machine immediately and remedy the fault.
L Low fuel level Visual. Illuminates when the fuel level is low.
M Engine oil pres- Audible/Visual. Illuminates if the engine oil pressure drops too low. Engine
sure will run at reduced power, an error code will be displayed. Stop the machine
immediately and remedy the fault.

33 - 99 9813/4800-4 33 - 99
 33 - Electrical System
24 - Instruments
03 - Instrument Panel

N Transmission oil Visual only. Illuminates if the transmission oil pressure is below normal. The
pressure light should go off when the engine is started.
P Brake system Audible/Visual. When the brake system charge pressure is low the lamp will
pressure come on. The buzzer will sound if the brake system charge pressure is low
when the engine is running.
Q Differential lock Audible/Visual. Illuminates when the differential lock is switched on.
R ABS (Anti-lock Audible/Visual. Illuminates when the ABS is switched on.
Braking System)
S Low steering Audible/Visual. Illuminates when the pressure is low.
pressure
T ABS 1

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 33 - Electrical System
24 - Instruments
03 - Instrument Panel

Remove and Install 7. Remove the instrument panel from the screen
moulding. Make sure that you apply the specified
extraction force.
Remove Force: 100–110N
1. Make the machine safe with the lift arm lowered. Figure 774.
Refer to (PIL 01-03). F
2. Install the articulation strut. Refer to (PIL 06-27).
3. Disconnect the battery. Refer to (PIL 33-03).
4. Remove the screw (x5) from the screen
moulding.
H H
5. Remove the screen moulding and instrument
panel from the vanity plate.
6. Disconnect the electrical connection.
Figure 773.
E G
D E Mounting plate
B F Mounting tab
G Alignment Feature
H Electrical connection pins

Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
C steps.
2. Use the alignment feature to align the display
A inside the screen moulding.
3. Tighten the screws to the correct torque values.

Table 253. Torque Values

Item Description Nm
C Screw 5

A Instrument panel
B Screen moulding
C Screw
D Vanity plates

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 33 - Electrical System
27 - Interior Switch

27 - Interior Switch

Contents Page No.

33-27-12 Heating, Ventilating and Air-Conditioning (HVAC) ....................................................... 33-103

33 - 102 9813/4800-4 33 - 102

 33 - Electrical System
27 - Interior Switch
12 - Heating, Ventilating and Air-Conditioning (HVAC)

12 - Heating, Ventilating and Air- Introduction

Conditioning (HVAC)
The manual control for the HVAC (Heating Ventilation
Introduction .................................................. 33-103 Air Conditioning) unit is located above the operator
Component Identification ............................. 33-104 near to the radio. The HVAC manual control switch
Operation ..................................................... 33-105 has the following four controls:
Remove and Install ..................................... 33-105 • Fan speed regulator - To control the fan speed.
• Air circulation control - To select fresh air or
recirculation air.
• Aircon ON/OFF switch - To switch on or switch
off air conditioning.
• Temperature regulator - To select heating or
cooling.

33 - 103 9813/4800-4 33 - 103

 33 - Electrical System
27 - Interior Switch
12 - Heating, Ventilating and Air-Conditioning (HVAC)

Component Identification

Figure 775. HVAC Control Panel

A
PO WER
OU TL ET
12V

A Fan switch
B Temperature switch
C Re-circulation switch
D Air conditioning switch

Figure 776. ATC Control Panel

E F G

H J K L M N

E Economy mode F Backlit display panel

G Automatic mode H Fan speed adjustment
J Power (On/Off) K Mode
L Defrost M Fresh/Recirculated air
N Temperature adjust

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 33 - Electrical System
27 - Interior Switch
12 - Heating, Ventilating and Air-Conditioning (HVAC)

Operation Remove and Install

The HVAC (Heating Ventilation Air Conditioning) Remove

manual control switch has the following controls:
1. Make the machine safe. Refer to (PIL 01-03).
1. Air conditioning ON/OFF switch: When switched
off, the air flow through the HVAC system is 2. Install the articulation strut. Refer to (PIL 06-27).
stopped.
3. Pull the heater / air conditioning control knobs
2. Fan speed regulator: The fan speed regulator is and remove them.
attached to a four position switch. This switch
controls the air velocity through the duct system 4. Loosen the securing nuts.
and the heater core.
Figure 777.
3. Air circulation control: When flow control is
D E
selected to fresh air position, fresh air is brought
in from outside the cab. Fresh air increases air
pressure in the cab, thus any openings leak
outward. This eliminates cold spots and provides
a more uniform cab temperature.
4. Temperature regulator: This controls the water
valve. A water valve is the primary control for a D Control knob
basic heater system. When the valve is open, E Securing nut
hot engine coolant flows through the heater core
and back to the engine. The operator can adjust 5. Remove the heater control panel securing
the control to modulate coolant flow through the screws.
heater core.
Figure 778.
5. Distribution switch (if installed): This switch
controls the air distribution inside the operator
station. When the switch is in down position, air
flows through the corner and centre vents. When
the switch is in up position, air also flows through
the floor level vents.

H
PO WER
OU TL ET
12V

F Securing screws
G Control 1
H Control 2
6. Lift the heater control panel and access the
connectors below it.
7. Disconnect the electrical connectors from the
controls (lower).

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 33 - Electrical System
27 - Interior Switch
12 - Heating, Ventilating and Air-Conditioning (HVAC)

Figure 779.
E
J
K

E Securing nut
J Electrical connector
K Controls (lower)
8. Loosen the securing nuts and remove the
controls from the heater control panel.

Install
1. The installation procedure is the opposite of the
removal procedure.

33 - 106 9813/4800-4 33 - 106

 33 - Electrical System
33 - Console Switch

33 - Console Switch

Contents Page No.

33-33-00 General ......................................................................................................................... 33-109

33 - 107 9813/4800-4 33 - 107

Notes:

33 - 108 9813/4800-4 33 - 108

 33 - Electrical System
33 - Console Switch
00 - General

00 - General

Component Identification

Figure 780.

A B

C D

E F

G H
N P

J K
Q R

L M
S T

U V

W X

Y Z

A Position light switch B Dipped beam switch

C Beacon switch D Rear fog light switch
E Front worklight switch F Rear worklight switch
G Rear wash/wipe switch H Heated rear screen switch
J Secondary steering switch K Engine mode switch
L Auto transmission switch M Transmission mode switch
N Torque converter lock switch P Differential lock switch
Q Transmission disconnect switch R Constant flow switch
S Float switch T SRS (Smooth Ride System) switch
U Return to dig switch V Boom height limit switch
W Return to carry switch X Hydraulic mode switch
Y Quickhitch disconnect switch Z Hydraulic lock switch

33 - 109 9813/4800-4 33 - 109

 33 - Electrical System
39 - Interior Light

39 - Interior Light

Contents Page No.

33-39-03 Cab Roof ...................................................................................................................... 33-111

33 - 110 9813/4800-4 33 - 110

 33 - Electrical System
39 - Interior Light
03 - Cab Roof

03 - Cab Roof

Remove and Install

The cab roof light is an LED (Light Emitting Diode) 3. Remove the screw (x2).
type bulb. You must replace the complete assembly
if it is faulty. 4. Carefully remove the light assembly out of the
aperture.
Remove 5. Disconnect the electrical connector.
1. Make the machine safe. Refer to (PIL 01-03). 6. Remove the light assembly from the machine.
2. Disconnect the battery. Refer to (PIL 33-03).

Figure 781.

A
B

A Light assembly B Screw (x2)

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 33 - Electrical System
39 - Interior Light
03 - Cab Roof

Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
step.
2. Tighten the screw to the correct torque value.

Table 254. Torque Values

Item Description Nm
B Screw (Maximum torque) 1.5

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 33 - Electrical System
40 - Bulb

40 - Bulb

Contents Page No.

33-40-00 General ......................................................................................................................... 33-115

33 - 113 9813/4800-4 33 - 113

Notes:

33 - 114 9813/4800-4 33 - 114

 33 - Electrical System
40 - Bulb
00 - General

00 - General

Introduction

Make sure the bulbs are replaced with the same type
and rating as the damaged bulb.

33 - 115 9813/4800-4 33 - 115

 33 - Electrical System
42 - Exterior Light

42 - Exterior Light

Contents Page No.

33-42-33 Number Plate Light ...................................................................................................... 33-117

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 33 - Electrical System
42 - Exterior Light
33 - Number Plate Light

33 - Number Plate Light

Remove and Install

Remove 4. Remove the fasteners.

1. Make the machine safe. Refer to (PIL 01-03). 5. Remove the grommet.

2. Isolate the battery. Refer to (PIL 33-03). 6. Remove the number plate light from the machine.

3. Disconnect the electrical connector.

Figure 782.

A Number plate light B Grommet

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 33 - Electrical System
42 - Exterior Light
33 - Number Plate Light

Install
1. The installation procedure is the opposite of the
installation procedure.

33 - 118 9813/4800-4 33 - 118

 33 - Electrical System
45 - Control Module

45 - Control Module

Contents Page No.

33-45-00 General ......................................................................................................................... 33-121

33-45-06 Engine .......................................................................................................................... 33-124
33-45-09 Gearbox ........................................................................................................................ 33-134
33-45-10 Gear Change ................................................................................................................ 33-136
33-45-30 LiveLink ........................................................................................................................ 33-147

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Notes:

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 33 - Electrical System
45 - Control Module
00 - General

00 - General Introduction
Introduction .................................................. 33-121 Modern machines use ECU (Electronic Control Unit)
Health and Safety ........................................ 33-122 to control machine systems such as hydraulics,
Operation ..................................................... 33-122 transmission and engine. In much the same way as
office computers can be ‘networked’ to communicate
with each other the machine ECU’s can be
‘networked’. Some advantages of networking are:

• Improved more intelligent control systems

• More comprehensive and reliable in-cab
instrumentation
• Service software tools can be used for fault
finding and machine control set up

The ECM (Engine Control Module) can communicate

with other machine ECU using a CANbus network
system.

CANbus Communications System

CAN (Controller Area Network) is an electronic
communications system that connects all the
machine ECU to one pair of data wires, this is called
the CANbus. Coded data is sent to and from the
ECU on the CANbus. By connecting Servicemaster
diagnostic software to the CANbus, data is seen and
decoded for use by a service engineer.

CANbus System Schematic

A typical CANbus system architecture is shown for
illustration purposes only below: Refer to Figure 783.

Figure 783. Typical CANbus architecture

ECU ECU ECU ECU ECU

F B C E G

Hi

Lo

Hi H
ECU Lo

A D

The CAN architecture may differ on your machine.

Refer to: PIL 33-00-50.

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 33 - Electrical System
45 - Control Module
00 - General

Health and Safety Operation

Arc Welding The machines use an ECU (Electronic Control
To prevent the possibility of damage to electronic Unit) to control machine operations. The ECU uses
components, disconnect the battery and the analogue and digital signals from machine sensors,
alternator before arc-welding on the machine or switches etc. and uses this data to supply a feed or
attached implements. a ground connection for other machine devices. The
If the machine is equipped with sensitive electrical machines can have one or more ECU’s depending
equipment, i.e. amplifier drivers, electronic control on the model variant. For information on each ECU,
units (ECUs), monitor displays, etc., then disconnect refer to the correct topic in the subsequent pages.
them before welding. Failure to disconnect the
The machine ECU's can be connected to JCB
sensitive electrical equipment could result in
servicemaster diagnostic software to check ECU
irreparable damage to these components.
version and operation. Refer to electrical system-
Parts of the machine are made from cast iron, welds electronic diagnostic. Refer to: PIL 33-57.
on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable ECU Inputs
or apply any weld to any part of the engine.
Always connect the welder earth (ground) cable to There are two main types of input, digital and
the same component that is being welded to avoid analogue.
damage to pivot pins, bearings and bushes. Attach
the welder earth (ground) cable a distance from the Digital inputs (On-Off switch type inputs)
part being welded no more than 0.6 m.
Digital type inputs are on-off type inputs (i.e.
Notice: Do not disconnect the battery while the switches). The digital inputs can be low side inputs or
engine is running, otherwise the electrical circuits high side inputs. The low side inputs are inputs that
may be damaged. provide a ground to the ECU. The high side inputs
are the inputs that provide a positive feed to the ECU.

Low side input

The low side input is the most frequently used input

on an electrical system. The low side input can be in
the form of rocker switches or pressure switches.

Figure 784.

C
12 v
B

A ECU
B Input
C Switch (rocker, pressure etc.)

High side input

The high side input is used on circuits that require a

positive feed when the ignition is switched off, e.g.
sidelights or hazard lights.

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 33 - Electrical System
45 - Control Module
00 - General

Figure 785. Figure 787.

A A
C

C
12 v 12 v
B B

A ECU A ECU
B Input B Output
C Switch (lights etc.) C Solenoid or relay coil

Analogue inputs (Sensor type switch inputs) High side output

Analogue inputs are sensor type inputs that provide In the high side output circuit, the solenoid or relay
a varying type input to the ECU. This input could be which is being driven already has a ground available.
a voltage, resistance or frequency type input. The ECU provides the positive side of the circuit.

Figure 786. Figure 788.

A A C
E
B
5v 12 v
C B

D A ECU
B Output
C Solenoid or relay coil
A ECU
B Sensor ref voltage Modulated outputs
C Sensor ref 0 voltage
D Thumbwheel input (potentiometer type input) In the modulated output circuit, the ECU provides
E Thumbwheel position switch a PWM (Pulse Width Modulation) signal to a
proportional valve. As the ECU varies the duty cycle
ECU Outputs of the signal, the proportional valve will be selected
depending on the change in duty cycle.
There are three main types of outputs. Low side
output, High side output and Modulated output. Figure 789.

Low side output A C

In the low side output circuit, the solenoid or relay

which is being driven already has a positive feed B
available. The ECU then provides ground to the
circuit.

A ECU
B Output
C Proportional solenoid

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 33 - Electrical System
45 - Control Module
06 - Engine

06 - Engine Introduction
Introduction .................................................. 33-124 Central to the engine control system is the ECM
Component Identification ............................. 33-125 (Engine Control Module). The prime function of the
Operation ..................................................... 33-132 ECM is to initiate fuel injection. The engine cannot
Remove and Install ..................................... 33-133 run without the ECM.

Signals from electrical sensors are continually

monitored and processed by the ECM to determine
when, how much and to which cylinder fuel must be
injected.

The ECM controls fuel injection by energising

electrical actuators in the fuel injectors, high pressure
fuel pump and the common fuel rail.

Note: Other devices are connected to the ECM to

control other engine related systems, refer to (PIL
15-84).

Figure 790.
TDC 2 3

5
4

C1 C2

D1 D2 6

1 ECM 2 Camshaft position sensor

3 Camshaft target disc 4 Crankshaft position sensor
5 Crankshaft mounted target disc 6 Fuel injector

33 - 124 9813/4800-4 33 - 124

 33 - Electrical System
45 - Control Module
06 - Engine

Component Identification

The schematic and component list is for a typical

engine. The machine may not contain all of the
components listed.

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 33 - Electrical System
45 - Control Module
06 - Engine

Engine Interface Connector

Figure 791.
U02

U10.1
U15.1

U10.2
U15.2
U10.3

U10.4

U14

U36
U20

U09

U08

U33

U19
U07

U12

U11
U32
U02

U31
U13

1 4
5 8
9 12
13 16
17 20
21 24
25 28
29 32
33 36
37 40
41 44
45 48
49 52
53 56
57 59
60 62
61

U02

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 33 - Electrical System
45 - Control Module
06 - Engine

U02 ECM (Engine Control Module) connector U07 TMAP (Temperature Manifold Air
(black) Pressure) sensor
U08 High pressure rail sensor U09 HPV (High Pressure Valve)
U10-1 Fuel injector - cylinder 1 U10-2 Fuel injector - cylinder 2
U10-3 Fuel injector - cylinder 3 U10-4 Fuel injector - cylinder 4
U11 Fuel temperature sensor U12 Engine coolant temperature sensor
U13 Crank position sensor U14 Camshaft position sensor (engine
phase)
U15-1 Knock sensor 1 U15-2 Knock sensor 2
U19 Oil pressure switch U20 IMV (Inlet Metering Valve)
U31 Oil temperature sensor U32 Exhaust temperature sensor
U33 Exhaust manifold pressure sensor U36 Intercooler outlet temperature sensor

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 33 - Electrical System
45 - Control Module
06 - Engine

Engine Electrical Interface

Figure 792.

U03
X
U02
U01

S F

R G

E
A

H
Q
J
K P
N

1 4
5 8
9 12
13 16
17 20
21 24
25 28
29 32
33 36
U01

37 40
41 44
45 48
49 52
53 56
57 59
60 62
61

U01

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 33 - Electrical System
45 - Control Module
06 - Engine

01 ECM connector (Grey) 02 CAN (Controller Area Network) termination 1

03 Machine to engine interconnect A Machine CAN termination 2
C Engine oil level switch D Foot throttle position sensor
E Hand throttle position sensor F TMAF (Temperature and Mass Air Flow)
sensor (if installed)
G Fuel pressure sensor H Cruise control (if installed)
J Engine speed control K Brake light switch
N Low fuel switch P Clutch switch (if installed)
Q Key switch (engine start/shut off) R Lambda sensor
S Water in fuel switch T Fuel pump
Y HVAC (Heating Ventilation Air Conditioning)
Compressor (if installed)

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 33 - Electrical System
45 - Control Module
06 - Engine

Engine ECU Power Supply

Figure 793. Harness connector MF13

B
A
62 4

60 1

A Connector pins B Machine harness connector

C Engine harness connector

Table 255. Engine ECU power supply

Harness con-
nector MF13
Connectors Pins Details
MF13 57 60 49 43 Harness connec-
tor - engine ECU
(grey).
MF06 K M N H Harness connec-
tor - engine fuse/
relay box.

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 33 - Electrical System
45 - Control Module
06 - Engine

Table 256. Engine ECU earths

Harness con-
nector MF13
Connectors Pins Details
MF13 58 69 61 62 Harness connec-
tor - engine ECU
(grey).
-ve battery via isolator switch. Note: Ma-
chines with SCR
(Selective Cat-
alytic Reduction)
systems have
an isolator relay.
This ensures the
correct engine
and SCR system
power down se-
quence even if
the operator sets
the battery isola-
tor switch to off.

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 33 - Electrical System
45 - Control Module
06 - Engine

Operation Other operating parameters may initiate automatic

engine shut down by the ECM. For example low
engine oil pressure or sensor faults.
The ECM (Engine Control Module) achieves
effective fuel injection by controlling two main Engine Fault Diagnostics
systems:
Since the ECM continually scans for expected inputs
Pressure Control from all connected devices it is capable of detecting
related electrical faults. These faults are datalogged
Fuel pressure in the common rail is varied according in the ECM memory. By connecting diagnostics
to engine operating parameters. software any faults recorded can be displayed in
code form. This assists service personnel when
For example when the engine speed and load is tracing faults with the fuel injection system.
high, fuel can be injected at very high pressure to
achieve optimum combustion. When engine speed In addition to fault datalogging, the ECM will respond
and load is low, fuel pressure must be reduced. In to some faults by shutting the engine down, thus
these conditions injecting fuel at too high a pressure preventing serious engine damage.
would result in poor combustion.
The ECM also has the facility to drive cab mounted
Engine cold starts require special conditions. The warning devices such as coolant temperature and oil
ECM increases fuel pressure to facilitate cold starting pressure displays.
and cold running.

The ECM actuates the inlet metering valve and high

pressure rail fuel valve to control fuel pressure.

Injection Control
Injection control requires the ECM calculation of the
following:

• Engine phase - to determine which cylinder is

firing.
• Injection timing - to determine when injection
takes place in relation to crankshaft position.
• Fuel flow - to determine how much fuel and
therefore, the duration of injection. The ECM
uses data from the various engine sensors
to calculate the injection timing and fuel flow
requirements using a `data map' stored in its
memory. Refer to the Fuel Injection Cycle

Idle Speed Control

The ECM incorporates an engine idle speed control
module. When the operator closes the throttle the
ECM initiates the idle control. The minimum fuel is
calculated to maintain the programmed idle speed.

Engine Shut Down

The ECM initiates engine shut down in response to
inputs from an operator controlled stop ignition key
switch.

Engine shut down is achieved by ceasing fuel

injection. When an engine stop input is received by
the ECM no current is sent to the injector solenoid
coils.

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 33 - Electrical System
45 - Control Module
06 - Engine

Remove and Install is a non serviceable item. If the ECM is defective

it must be replaced.

Before Removal Important: Do not install an ECM from another

engine. Although identical in appearance the internal
1. Ensure that the engine is safe to work on. If the configuration is unique to every ECM. If the ECM
engine has been running let it cool before you has been renewed it must be flashed with the correct
start the service work. set-up data files and programmed with the correct
injector codes.
2. Get access to the engine.
Carefully inspect the ECM housing. If it is defective
Figure 794. replace it.

Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
D steps.
2. Make sure that the earth strap is correctly
installed adjacent to the engine bedplate.
3. Tighten the bolts to the correct torque value.

E,F Table 257. Torque Values

Item Nm
C
C 24

D
G

A Electrical connector (Grey) -ECM (Engine

Control Module)
B Electrical connector (Black) - ECM
C Fixing bolts
D ECM
E Washer
F Bush
G Earth strap

Remove
1. Disconnect the battery.
2. Disconnect the electrical connectors at theECM.
Do not touch the electrical connector pins on the
ECM.
3. Undo the fixing bolts and carefully lift off the ECM
together with the washers and mounting bushes.
Note the position of earth strap. Note: The ECM

33 - 133 9813/4800-4 33 - 133

 33 - Electrical System
45 - Control Module
09 - Gearbox

09 - Gearbox Introduction
Introduction .................................................. 33-134 The gearbox control module is installed in the cab
Remove and Install ..................................... 33-135 behind the rear cab panel.

Figure 795.

H Gearbox control module

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 33 - Electrical System
45 - Control Module
09 - Gearbox

Remove and Install Figure 797.

H

Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Install the articulation strut. Refer to (PIL 06-27).
3. Remove the thumb screws that secure the
fusebox cover.
G
4. Remove the fusebox cover.
G Bolts 3
5. Remove the fixing bolts 1 (x3) that secure the H Gearbox ECU
rear cab panel.
6. Remove the bolts 2 inside the document holder. Install
Figure 796. 1. The installation procedure is the opposite of the
removal procedure.
D B
C

B Screws
C Fusebox cover
D Bolts 1
E Bolts 2
F Rear cab panel
7. Lift the door side first and remove the rear cab
panel.
8. Push the connector tab down and separate the
connector.
9. Remove the bolts 3 (x4) that attach the gearbox
ECU (Electronic Control Unit) to the rear of the
cab frame.
10. Remove the gearbox ECU from the machine.

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 33 - Electrical System
45 - Control Module
10 - Gear Change

10 - Gear Change Introduction

Introduction .................................................. 33-136 The electro-hydraulic gear change control unit is
Component Identification ............................. 33-137 installed on the transmission rear case. The control
Remove and Install ..................................... 33-139 unit consist of six proportional valves, a main
Disassemble and Assemble ........................ 33-141 pressure valve, and a pressure reducing valve. The
clutches of the transmission are selected through the
proportional valves.

The proportional valve consists of a pressure

regulator, follow-on slide and vibration damper. The
pressure reducing valve creates a control pressure
of 9bar (130.4psi) for the actuation of the follow-
on slides. The pressurised oil (16–18bar (231.9–
260.9psi)) is directed through the follow-on slide to
the respective clutch.

33 - 136 9813/4800-4 33 - 136

 33 - Electrical System
45 - Control Module
10 - Gear Change

Component Identification

Figure 798.
C D M

A A
L L

K
E
L L

J B F
B
L L

H
G

N N
Q P
A-A

R S
B-B

C System pressure valve D Pressure reducing valve

E Proportional valve- clutch 4th speed F Proportional valve- clutch reverse
G Proportional valve- clutch 1st speed H Proportional valve- clutch 3rd speed
J Proportional valve- clutch forward K Proportional valve- clutch 2nd speed
L Pressure regulators M Electrical connection to control unit
N Valve block P Housing
Q Cover R Dust plate
S Gasket

33 - 137 9813/4800-4 33 - 137

 33 - Electrical System
45 - Control Module
10 - Gear Change

In view B-B the proportional valve- clutch forward

is shown, other proportional valves are functionally
identical.

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 33 - Electrical System
45 - Control Module
10 - Gear Change

Remove and Install

Remove 4. Remove gasket 1, gasket 2 and intermediate

plate.
1. Remove the socket head screws (x2).
5. Remove the screws, nuts and washers.
2. Install the threaded alignment dowels in place of
the socket head screws. This is to prevent hidden 6. Separate the duct plate from the gearbox
components from falling out. housing.

3. Remove the remaining socket head screws and 7. Remove the gasket 3.
separate the control unit from the duct plate.

Figure 799.

H
J
G
A

B
D
E
F

C
K

A Socket screw B Control unit

C Duct plate D Gasket 1
E Intermediate plate F Gasket 2
G Screw H Nut
J Washer K Gasket 3

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 33 - Electrical System
45 - Control Module
10 - Gear Change

Install
1. Install gasket 3 and the duct plate onto the
gearbox housing.
2. Secure the duct plate with the screws, washer,
and nuts.
3. Install the gasket 2, intermediate plate, and the
gasket1 onto the duct plate.
3.1. Make sure that the gasket 1, gasket, and
the intermediate plate are installed in their
correct orientation.
3.2. The intermediate plate is positioned
between gasket 2 and gasket 1.
4. Remove the two threaded alignment dowels
installed during removal.
5. Install the screw plug with a new O-ring.
Figure 800.

L Screw plug
6. Tighten the plug to the correct torque value.
7. Put the hydraulic control unit in position.
8. Attach the control unit with socket head screws.
9. Tighten the socket head screws to the correct
torque value.

Table 258. Torque Values

Item Nm
G 9.5
L 30

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 33 - Electrical System
45 - Control Module
10 - Gear Change

Disassemble and Assemble

Disassemble 10.1. Remove the remaining screws 4.

Refer to Figure 801. 11. Remove the housing cover 1 and gasket 5 from
the valve housing by loosening the adjusting
1. Match-mark relative the positions of the valve screws uniformly to release the spring loading.
housing, housing cover 1, housing cover 2, end
12. Remove the spring 1 and fixing 1.
cover 1 and end cover 2 to each other.
13. Remove the fixing 2 and spring 2.
2. Remove the socket head screws.
14. Remove the fixing 3 and spring 3.
3. Remove the duct plate, gasket 3, intermediate
plate and gasket 4 from the valve housing. 15. Remove the screws 4 (x3), fixing plate 2 and
pressure regulators 2.
4. Remove the retaining clamp.
16. Remove the outermost screws 6 (x2) and replace
5. Remove the screws 1 and screws 2.
provisionally with adjusting screws.
6. Remove the end cover 1 and gasket 1 from the
16.1. Remove the remaining screws 6.
housing cover 1 and cable harness.
17. Remove the housing cover 2 and gasket 6 from
7. Remove the end cover 2 and gasket 2 from the
the valve housing by loosening the adjusting
housing cover 2.
screws uniformly to release the spring loading.
8. Disconnect the cable harness from the pressure
18. Remove the fixing 4 and spring 4.
regulators 1 (x3) and the pressure regulators 2
(x3) and remove. 19. Remove the fixing 5 and spring 5.
9. Remove the three screws 3, fixing plate 1 and 20. Remove the fixing 6 and spring 6.
pressure regulators 1.
21. Remove the diaphragms.
10. Remove the two outermost screws 4 and replace
provisionally with adjusting screws.

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 33 - Electrical System
45 - Control Module
10 - Gear Change

Figure 801.
M
B
Y
F Z

C AA
V AB AK
AJ
W
P

A AM
N AL

U
T
S
X

AE
Q AF E
D
R
AC
AD

AQ AG
L
G K
J AP AH
H AN

A Valve Housing B End cover 1

C Gasket1 D End cover 2
E Gasket 2 F Cable harness
G Socket head screws/Torx screws H Duct plate
J Gasket 3 K Intermediate plate
L Gasket 4 M Retaining clamp
N Screw 1 P Housing cover 1
Q Gasket 5 R Screw 2
S Housing cover 2 T Gasket 6
U Pressure regulator 1 (x3) V Screw 3 (x3)
W Fixing plate 1 X Screw 4
Y Spring 1 Z Fixing 1
AA Fixing 2 AB Spring 2
AC Fixing 3 AD Spring 3
AE Screw 5 (x3) AF Fixing plate 2
AG Pressure regulator 2 AH Screw 6
AJ Fixing 4 AK Spring 4
AL Fixing 5 AM Spring 5
AN Fixing 6 AP Spring 6
AQ Diaphragms

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 33 - Electrical System
45 - Control Module
10 - Gear Change

Assemble 7. Assemble gasket 5 and housing cover 1.

Refer to Figure 801. wherever not specified. 7.1. Uniformly put the housing cover 1 in
position and secure with the adjusting
1. Check all components for damage and replace if screws unit contact is achieved.
necessary. 7.2. Remove the cylindrical pins installed at step
6.
1.1. Before installation, check the free travel of
all moving parts in the housing. 7.3. Pay attention to the different housing
covers. Install the recess of 15mm diameter
1.2. Spools can be changed individually.
facing the spring 1 of the pressure reducing
1.3. Lubricate the components before assembly. valve. Refer to Figure 801.
2. Position the diaphragms. Figure 804.
2.1. Make sure that the concave side points
upwards until contact is achieved. Refer to
Figure 802.
Figure 802.
Y AR

Y Spring 1
AR15mm Recess
3. Install spring 1 and fixing 1.
7.4. Attach the housing cover 1 with the screws
4. Install fixing 2 and spring 2. 4 at the remaining positions.
5. Install fixing 3 and spring 3. 7.5. Remove the two adjusting screws and
install the remaining screws 3.
5.1. Pre-load the compression springs of the
follow-on slides (fixing 3 and spring 3). 7.6. Tighten the screws 4 to the correct torque
value.
6. Put the spool provisionally by means of 5mm
cylindrical pins at positions shown. Refer to 8. Install the pressure regulators 1 with the fixing
Figure 803. plate1 and the screws 3.

Figure 803. 8.1. Makes sure that the claws of the fixing
plates 1 point downwards. Pay attention
to the radial installation position of the
pressure regulators. Refer to Figure 805.

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 33 - Electrical System
45 - Control Module
10 - Gear Change

Figure 805. 13.4. Attach the housing cover 1 with the screws
6 at the remaining positions.
13.5. Remove the adjusting screws (x2) and
W install the remaining screws 5.
13.6. Tighten the screws 6 to the correct torque
value.
14. Install the pressure regulators 2 with the fixing
plate 2 and the screws 5.
14.1. Makes sure that the claws of the fixing
plates 2 point downward. Pay attention
to the radial installation position of the
pressure regulators.
W Fixing plate 1
14.2. Tighten the screw 5 to the correct torque
8.2. Tighten the screw 3 to the correct torque value. Refer to Figure 807.
value.
Figure 807.
9. Install fixing 4 and spring 4.
10. Install fixing 5 and spring 5.
11. Install fixing 6 and spring 6.
11.1. Pre-load the compression springs of the
follow-on slides (fixing 6 and spring 6).
12. Position the spool provisionally by means of
5mm cylindrical pins at positions shown. Refer to
Figure 806.
Figure 806.

15. Connect the cable harness to the pressure

AS regulator 1 and the pressure regulator 2.
15.1. Pay attention to the installation position of
the cable harness.
16. Install the gasket 3 on the housing cover 1.
17. Install the harness connector into the end cover 1
against the shoulder. Make sure that the groove
faces the guide nose of the cover 1.
AS 19mm Recess 18. Attach the end cover with the screws 1.
13. Assemble gasket 6 and housing cover 2. 19. Tighten the screws 1 to the correct torque value.
13.1. Uniformly put the housing cover 2 in 20. Secure the harness connectors by means of the
position and secure with the adjusting retaining clamp.
screws until contact is achieved.
21. Install the end cover 2 and gasket 4 with the
13.2. Remove the cylindrical pins installed at screws 2.
step 12.
13.3. Pay attention to the different housing 22. Tighten the screws 2 to the correct torque value.
covers. Install the recess of 19mm 23. Install the intermediate plate with gaskets as
diameter facing the main pressure valve follows:
(fixing 4 and spring 4). Refer to Figure 806.
23.1. Install the alignment dowels (x2) and
install gasket 4. Refer to Figure 808.

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 33 - Electrical System
45 - Control Module
10 - Gear Change

Figure 808. 23.7. Remove the alignment dowels installed at

step 23.1.
AT L
23.8. Tighten the socket head screws to the
correct torque value.
23.9. Install the screw plugs with new O-rings at
the positions shown. Refer to Figure 810.
Figure 810.

AV

AT Alignment dowel (x2)

L Gasket4
23.2. Pay attention to the difference between
gasket 3 and gasket 4.
23.3. Put the screens flush mounted into the
bore of the intermediate plate. Refer to
Figure 809.
AV Screw plugs
Figure 809.
23.10. Tighten the screw plugs to the correct
torque value.
K 23.11. For the procedure to install the coated
intermediate sheet (no gaskets) refer to
step 24.
24. Install the intermediate plate coated sheet
AU (without gaskets) as follows:
24.1. Install the alignment dowels (x2). Refer to
Figure 811.
Figure 811.
AT

K Intermediate plate
AUScreens
23.4. Install the screens visible on the side
facing duct plate. AT Alignment dowel (x2)
23.5. Install the intermediate plate, screens 24.2. Put the screens flush mounted into the
uppermost, followed by the gasket. bore of the intermediate plate. Refer to
Figure 812.
23.6. Install the duct plate and secure it
uniformly with socket head screws.

33 - 145 9813/4800-4 33 - 145

 33 - Electrical System
45 - Control Module
10 - Gear Change

Figure 812. 24.6. Remove the alignment dowels installed at

step 24.1.

K 24.7. Tighten the socket head screws to the

correct torque value.
24.8. Install the screw plugs with new O-rings at
the positions shown. Refer to Figure 813.

AU Figure 813.

AV

AV Screw plugs
K Intermediate plate
AUScreens 24.9. Tighten the screw plugs to the correct
torque value.
24.3. Install the screens visible on the side 24.10. If the later type Coated Intermediate
facing duct plate. Sheet is being installed as a replacement
24.4. Install the intermediate plate screens for the earlier Gasket Type, it is most
uppermost. Take care not to damage the important that it is installed with the
coating. correct shorter torx screws. Refer to the
bolt installation chart.
24.5. Install the duct plate and secure it
uniformly with the socket head screws.

Table 259. Bolt Installation Chart

Type Length Application Torque Setting
Torx Screw M6 X 80 Paper gaskets 12N·m
Torx Screw M6 X 76 Coated sheets 9.5N·m
Torx Screw M6 X 25 Paper gaskets 12N·m
Torx Screw M6 X 23 Coated sheets 9.5N·m

Table 260. Torque Values

Item Nm
G 9.5
N 5.5
R 5.5
V 5.5
X 5.5
AE 5.5
AH 5.5
AV 6

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 33 - Electrical System
45 - Control Module
30 - LiveLink

30 - LiveLink Livelink ECU (Elec-

tronic Control Unit)
Protocol NMEA 01
Technical Data
GSM Specifications
Table 261. Frequency bands Quad band: GSM 850,
900, 1800, 1900 MHz
Livelink ECU (Elec- GPRS GPRS multi class 10
tronic Control Unit)
Current consumption Peak current at 1.35A
Operating voltage 12/24 VDC system for 577
Sleep current <0.003A (24V system) Antenna On board SMD antenna
Environmental specifica- IP 69
tion
Operating temperature -40–85°C (-39.9–
184.9°F)
Weight Approximately 0.37kg
Battery specification Li-ion, 2200mah, 3.7V
All Analog Input
Voltage Max. 32VDC both (12V
and 24V systems)
Max. 0VDC both (12V
and 24V systems)
All Digital Inputs
Voltage Max. 32VDC both (12V
and 24V systems)
Max. 0VDC both (12V
and 24V systems)
Minimum volt logic low 2VDC both (12V and
24V systems)
Minimum volt logic high 3VDC both (12V and
24V systems)
All Frequency Inputs
Frequency (max.) 2,000Hz
Voltage (p-p) (max) 32VDC both (12V and
24V systems)
Minimum volt logic low 2VDC both (12V and
24V systems)
Minimum volt logic high 3VDC both (12V and
24V systems)
GPS (Global Positioning
System) Receiver Speci-
fications
Receiver type 48 channels, GPS L1
frequency
Time to first fix Cold start: <33 s (aver-
age)- under open sky
Warm start: <33 s (aver-
age)- under open sky
Hot start: <1 s (aver-
age)- under open sky
Accuracy: Autonomous,
2.5m CEP (Circular Er-
ror Probable)
Update rate 1Hz
Antenna Integrated ceramic patch
antenna

33 - 147 9813/4800-4 33 - 147

 33 - Electrical System
51 - Beacon

51 - Beacon

Contents Page No.

33-51-00 General ......................................................................................................................... 33-149

33 - 148 9813/4800-4 33 - 148

 33 - Electrical System
51 - Beacon
00 - General

00 - General

Introduction

Beacons are rotating or flashing lights affixed to

the top of a machine to attract the attention of
surrounding vehicles and pedestrians.

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 33 - Electrical System
54 - Window Washer/Wipe

54 - Window Washer/Wipe

Contents Page No.

33-54-00 General ......................................................................................................................... 33-151

33-54-03 Tank .............................................................................................................................. 33-152
33-54-09 Front Motor ................................................................................................................... 33-153
33-54-15 Rear Window Wiper ..................................................................................................... 33-155

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 33 - Electrical System
54 - Window Washer/Wipe
00 - General

00 - General

Introduction

The wash/wipe system is used to remove rain and

debris from the front or rear window. The main
components of the system are:

• Wiper Arm.
• Wiper Blade.
• Nozzle (jet).
• Wiper Motor Mechanism.
• Tank (reservoir).
• Washer Pump.
• Wash/Wipe Switch.
• Multifunction Switch (intermittent speed
settings).

The wiper assembly consists of an arm, pivoting at

one end with a long rubber blade attached to the
other. The blade is swung back and forth over the
glass, pushing water from its surface. The speed is
normally adjustable, with several continuous speeds
and often one or more intermittent settings. Some
machines may use two wiper arms.

The wipers operate together with the washer system.

The washer pump supplies a mixture of water,
alcohol, and detergent (washer fluid) from a tank to
the windows through a hose. The fluid is dispensed
through small nozzles mounted below the screen. It
is essential the correct washer fluid is used as an
incorrect fluid could freeze in colder climates and
damage the pump. Although antifreeze is chemically
similar to windscreen wiper fluid, it should not be
used because it can damage the paintwork.

33 - 151 9813/4800-4 33 - 151

 33 - Electrical System
54 - Window Washer/Wipe
03 - Tank

03 - Tank

Drain and Fill

1. Make the machine safe with the lift arm lowered. 3. Open the washer bottle cap. The washer bottle
is inside the compartment.
Refer to: PIL 01-03.
2. Open the HVAC (Heating Ventilation Air
Conditioning) cover assembly.

Figure 814.

A Washer bottle

4. Fill the windscreen washer bottle with a suitable

liquid.
5. Make sure that the liquid contains de-icing fluid to
prevent from freezing. Do not put engine coolant
anti-freeze in the washer bottle.
6. Close and lock the HVAC cover assembly.

33 - 152 9813/4800-4 33 - 152

 33 - Electrical System
54 - Window Washer/Wipe
09 - Front Motor

09 - Front Motor

Remove and Install

Remove 5. Disconnect the electrical connector.

1. Make the machine safe with the lift arm lowered. 6. Remove the wiper arm. Refer to (PIL 33-54-15).
Refer to: PIL 01-03-27. 7. Remove the spindle cover and retaining nut from
the spindle.
2. Install the articulation strut. Refer to (PIL 06-27).
8. Remove the anti-rotation fixing.
3. Open the rear chassis cover.
9. Remove the seals.
4. Remove the screws 1 then remove the rear
panel. 10. From inside the cab remove the wiper motor.

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54 - Window Washer/Wipe
09 - Front Motor

Figure 815.

K
J

H G

B Screw 1 C Rear panel

D Wiper trim E Screw 2
F Spindle cover G Retaining nut
H Seal J Anti-rotation fixing
K Rear wiper motor L Wiper arm

Install
1. Installation is the opposite of the removal
procedure.

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15 - Rear Window Wiper

15 - Rear Window Wiper

Remove and Install

Remove 4. Remove the screws 1 then remove the fuse cover

moulding.
1. Make the machine safe with the lift arm lowered.
5. Disconnect the electrical connector.
Refer to: PIL 01-03-27.
6. From outside the cab, lift the wiper trim up and
2. Install the articulation strut. remove the screw 2.
Refer to: PIL 06-27-15.
7. Remove the wiper arm.
3. Open the rear chassis cover.

Figure 816.

K
J

G C

F
D

A Screw 1 B Fuse cover moulding

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15 - Rear Window Wiper

C Wiper trim D Screw 2

E Spindle cover F Retaining nut
G Seal H Anti-rotation fixing
J Rear wiper motor K Wiper arm

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15 - Rear Window Wiper

Install
1. The installation procedure is the opposite of the
removal procedure.

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57 - Electronic Diagnostic

Contents Page No.

33-57-00 General ......................................................................................................................... 33-159

33-57-03 Servicemaster .............................................................................................................. 33-161
33-57-90 Fault Codes .................................................................................................................. 33-193

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 33 - Electrical System
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00 - General

00 - General Introduction
Introduction .................................................. 33-159 JCB machines use the latest developments in
Health and Safety ........................................ 33-160 electronic management of machine systems. This
means that machine systems such as service
hydraulics, engine, transmission and steering are
controlled using ECU (Electronic Control Unit)'s.
The ECU's process inputs from electrical sensors
and then send signals to electrical actuators on the
applicable devices. The ECU's are also connected
to the machine CAN (Controller Area Network) bus
electronic communication system.

Fault Finding
Faults with ECU controlled systems can be difficult
or impossible to trace using traditional methods. In
addition to the primary function of machine control
the ECU's are also able to detect possible faults
with sensors and actuators. The faults are logged
using a code system. Use Servicemaster to see and
understand these codes. In addition Servicemaster
has direct links to relevant on screen help information
about relevant devices. This information is designed
to help you identify, test, and if applicable, remove
and replace devices.

Poor Maintenance
System faults that are present, or have happened in
the past can be seen. This is not only useful when
fault finding but can also identify poor standards of
maintenance - for example a log showing a history
of water in fuel detected. Use Servicemaster to see
and understand these logs.

Machine Set-up Data

Machine parameters such as tyre sizes, gear shift
points and engine injector calibration codes are all
stored and used by the relevant control ECU's.
During the life of the machine it will be necessary
to change some of these parameters. Without the
correct data the machine will not operate correctly.

Re-Programming ECU's
The ECU's use pre-loaded data to compute
responses to inputs from sensors. If an ECU is
replaced the correct data files must be programmed
(`flashed') into the ECU memory. New data files may
also be issued by JCB Service to improve machine
operation. This will also require the ECU to be re-
programmed.

Summary
With the latest Servicemaster software loaded on
your laptop and you can:

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• Fault find. Health and Safety

• Check maintenance standards, to see if the
machine has been abused. WARNING Make sure you read and follow any
• View and change machine set-up data. on screen instructions. Failure to follow the
• Flash ECU's with the correct data files instructions could result in death or injury.

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03 - Servicemaster Introduction
Introduction .................................................. 33-161 JCB Servicemaster is an application to allow
Technical Data ............................................. 33-176 engineers to diagnose and setup the various
Operation ..................................................... 33-176 electronic control units within the JCB product range.
Preparation .................................................. 33-178 The tools comprise of a front end generic user
interface that allows the user to select the machine
Disconnect and Connect ............................. 33-192 which they wish to work on as well as a number of
various tools which allow:

• Programming electronic control units

• Diagnosing electronic issues
• Setup of various options
• Checking the service history of the machine.

JCB Servicemaster is updated on a monthly basis by

incorporating Web Update. This is a program which
works alongside Servicemaster to let the user know
and allow them to download an update as and when
it becomes available.

JCB Servicemaster software is for use with Microsoft

Windows and a laptop personal computer. The
laptop computer is connected to the machine
diagnostic socket using special cables and an
adaptor.

Use Servicemaster software to:

• Display data from a machine ECU (Electronic

Control Unit)
• Change data stored in a ECU

Servicemaster software communicates with the

machine ECM (Engine Control Module) using the
CAN (Controller Area Network)bus. Refer to: PIL
33-45.

Structure
Servicemaster software is supplied via DVD and
updated via internet. A selector window is used
to choose the correct software tool set for each
machine range. Each tool is specific to the chosen
machine range. The tool icons are shortcuts to the
tool software files. Detailed information about how
to use the tools is given in the applicable machine
documentation.

Servicemaster Front Screen

The start-up page of Servicemaster is known as the
front screen. This interface allows the user to easily
and quickly navigate to the machine they are working
on to ensure that they have the applicable tools for
that machine.

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Figure 817. Typical Front Screen

Once the user has clicked on the applicable machine View engine and machine operating parameters in
type they will be able to select the tool they require real time. Perform system tests. View, save or clear
from a list of the tools available for that machine ECU fault code log.
range. Below are screen-shots showing the different
machine tool sets. Figure 820. Flash Programmer tool

Servicemaster Tools
Servicemaster Tool sets are different for each
machine range. When you have navigated to the
correct machine type via the front end, you will be
greeted with the relevant tools for that particular
machine. These tools are accessed by a single click
on the icon of the tool you require. There are 6 main View ECU software file version. Upload and
tools within Servicemaster, these are: Reprogramme software updates to the ECU
memory. Upload revisions to software.
Figure 818. Machine/Engine Set-up tool
Figure 821. Data Logger tool

View and change engine and machine specification

data stored in the engine ECU. Settings include: Running Data Collection, Operating Data, Statistics,
Device Error Log Recording.
• Parameter settings
• Option/Attachment control Figure 822. Help
• Alternative Language Support
• Model/Serial Number Identification
Figure 819. Diagnostics tool

Comprehensive information about ECU connected

devices.

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Additional Service Tool Starting the Diagnostics

As well as the tools stated above there are also third 1. Turn ON the machine ignition and additionally
party tools for some of the machine ranges which will start the engine if required (taking normal
need to be installed. These tools are denoted by the precautions).
following symbol:
2. Start JCB Servicemaster on the laptop computer.
Figure 823.
Figure 825.

To install these applications you need to take the

following steps:

1. On the front end, click the other tab.

2. Click on general.
3. Click onto "extra applications".
4. Choose the relevant tool which you require to be
installed and run the installer.

Once the installer has been run, the icon should have 3. Make sure that the correct DLA (Data Link
changed within the machine tool page. e.g. the above Adaptor) is selected in the chooser. Click on
icon has now become: Utilities, DLA Setup. The DLA Chooser window
opens. Check the button to match to the Current
Figure 824. Device. Click Apply.
Figure 826.

Diagnostics Tool - User Guide

Introduction
The diagnostics software tool is part of the
JCB Servicemaster software suite. The diagnostics
software is designed to be an easy to use fault finding
tool.
Diagnostics Overview
Connecting the Diagnostics
There are several key elements to the diagnostics
To use Diagnostics your laptop computer must be tool. These can be seen labelled below. Each
connected to the machine CAN bus. element is explained in detail in later sections.

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Figure 827.
1 2 3 4 5 6 7 8 9 10

11

12 13 14

1 Menu bar 2 Start and stop buttons

3 Main window 4 ECU setup page
5 Dashboard page 6 ECU status page
7 Lock up torque converter page 8 Solenoid Test Mode Page
9 Solenoid Identification Page 10 ECU block diagram page
11 Page list 12 LED (Light Emitting Diode) status key
13 Page display area 14 Status bar

The page list differs depending on the type of ECU • Pressing the ALT key will cause the File option
connected. on the Menu Bar to be highlighted. You can then
use the arrow keys to navigate the menus.
Some gearboxes are not fitted with a lock up torque • Notice that all the menu items on the Menu
converter. The diagnostics software always displays Bar have a letter that is underlined (e.g. the
the page even if it is not applicable. 'F' in File). Holding down the ALT key and
pressing the required letter key will activate that
Navigating within Diagnostics option (i.e. either open the menu or execute
a function). For example, if you wish to open
Navigation is designed to be via a mouse. On Laptop the Preferences Dialogue this can be done by
PCs this may take the form of a small joystick pressing ALT + O (to open the Options menu)
or touch sensitive pad and some buttons, usually then ALT + P (to execute the Preferences
located near to the keyboard. option).
As with most Windows based programs, it is possible Menu Bar-File Menu
to navigate the diagnostics software using the
keyboard by pressing certain combinations of keys. The File Menu contains an Exit option to close down
the program.
Note: This can be particularly useful for certain
Laptop computers where the mouse/joystick can be
oversensitive. Try out the following, it may come in
useful one day.

There are two main methods of navigation described

below:

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Figure 828. • English (United Kingdom)

• French (France)
• German (Germany)
• Spanish (International Sort)

Note: The language option only effects text within the

Main Window (e.g. Page List, LED Status Key, etc).
Language support is not available for the text within
the page displays.

Once your preferences have been selected either:

Click on the OK button to apply them or click on the

Cancel button to leave them unchanged.

Road Speed Settings.

• Open the road speed setting window.

• Press the Load button to upload the data from
On exiting the program communications with both
the ECU.
ECU and DLA are shut down.
• If the rolling radius of the wheel has been
Menu Bar-Options Menu changed (due to a tyre installation change
for example) input the rolling radius and the
Figure 829. associated axle ratio.
• To change the speed units displayed by the
diagnostics software check the required button
on the Display Units panel.
• Press the OK button to save the settings and
close the window.
Figure 831.

• Start Diagnostics to commence

communications with the ECU.
• Stop Diagnostics to cease communications.
• Controller Status Click on the buttons to toggle
ON or OFF the diagnostics connection with the
machine CAN system.
Figure 830.

Menu Bar - Window Menu

Like most other Windows based programs where

there are multiple sub-windows or Pages used, there
• Preferences option opens up the Preference are usually options to organise how they are laid-out.
Dialogue. Shiftmaster Diagnostics software is no different and
• From the Preferences Dialogue there is support offers the following options:
for multiple languages. Use the drop-down
menu and scroll bar to chose the required • Cascade
language. Languages available are:

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• Tile Horizontally Page List

• Tile Vertically
In the top left corner of the main window is displayed
Figure 832. a list of pages which can be displayed.

Figure 835.

Clicking in the box next to the required page will

make that page appear in the main window display
area. (A tick will also appear in the box to show it
is being displayed.) At any time the user may swap
between displayed pages simply by clicking in the
check box of the required page in the page list. The
function keys, F2, F3 etc. can also be used to select
pages as required.
Menu Bar-Help Menu
Status bar
Figure 833.
There are 2 items of interest displayed on the
Status Bar, which is located along the bottom of the
Diagnostics main window.

Figure 836.

• About: Opens a window showing the part Connected ECU: The type of ECU connected to the
number and the version number of the installed Diagnostics tool is indicated on the far left side of the
copy of the Diagnostics software Status bar.
• Help: Opens a help file about the software.
• Engine Help: Opens a help file containing CAN communications: Two small LEDs indicate data
information about the engine sensor and being transmitted (red) and received (green) over the
actuator devices for engine control. CAN communications link.

Start and Stop Buttons These LEDs can be seen to be flashing rapidly
as data is transported. This can be another useful
These offer the same function as the Start aid to determining the state of any established
Diagnostics and Stop Diagnostics options within communications.
the Options Menu. To start the Diagnostics tool
communicating with the gearbox ECU simply click Connection Status: Indicates if the diagnostics
on the Start Button (large green LED) at the top of software is connected, connecting or not connected
the Main Window. Similarly, click on the Stop Button to the ECM.
(large red LED) to cease communications.
Information Window: Displays information about data
Figure 834. on the diagnostics pages when the mouse is rolled
over the fields.

ECU Setup Page

This page displays crucial information about the ECU

configuration.

It is always useful to confirm that this is the correct

configuration for the machine before commencing
any fault finding.

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The ECU setup page displays the following are communications errors present then this will
information; contain either:

ECU Setup Description: • ‘'NO DLA COMMS' if there are problems in

communication with the DLA, or ‘'NO ECU
As well as its operating software, the gearbox ECU COMMS' if the DLA is working but the
also stores a group of setup data (or settings). This Shiftmaster ECU is not responding.
setup data is used to tailor how a certain ECU part
number functions. The setup data is loaded during Hardware Version: The hardware version is a
the manufacturing process and has been approved reference to the build level of the electronics. Future
for use in the intended application. developments may mean that hardware upgrades
are required. This may effect which software can be
The engineer can use this data to verify that the used.
correct setup data is being used. The shiftmaster
setup software tool is designed to view and update Software Version: The software version refers to the
current setup data. issue level of the ECU operating software. Again,
future developments may require software revisions.
Application Code Part Number: During normal
operation the application code is displayed. If there

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Figure 837.

ETS Function the file on the computer which is to be

connected to the gearbox ECU. The shiftmaster
The ETS function provides a means of loading and diagnostic program needs to open this file and
uploading gearbox ECU software setup files between obtain the software version and other applicable
the ECU and the computer. On earlier versions of information to make sure it is compatible with
servicemaster a separate program was required to the ECU connected to the computer.
perform this function. This is now incorporated within • Send ETS Data: This allows the computer to
shiftmaster diagnostics 2.3. The setup files have a send a software setup file to the gearbox ECU.
file name extension of ets. • Receive ETS Data: This reads the existing
setup file from the gearbox ECU.
• Load ETS File: A revision to the gearbox • Save ETS File: This saves the data received
ECU software file may be supplied by JCB for from the ECU onto the computer.
installation on particular ECU models. Store

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Dashboard Page

Figure 838.

- Requested Gear: This is the demand from the Figure 839.

operator.

- Selected Gear: This is the actual gear being

selected by the ECU.

Note: The operator Requested Gear is not always

the same as the Selected Gear, e.g. when the ECU
blocks shifts when offering protection.

- Transmission Speed: This is the current

transmission output speed which is directly related
to the road speed (through axle ratio and tyre size).
The transmission speed sensor is located next to the
output gear and detects the passing of the gear teeth.
The sensor has a fixed installation, no adjustment
is necessary. This signal is used by the ECU to
determine gear-shifting and protection strategies.

- ECU 2.2/2.3 only. The speed may be displayed

as a frequency value or, alternatively, road speed in
MPH or KPH. Use the Options Menu, Road Speed
Settings to select the required units.

ECU Status Page

This page gives a detailed picture of how the ECU

is operating.

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Figure 840. output LED will be coloured yellow when ON, or

blue when OFF.

Note: During certain gear-shifts the gearbox ECU will

perform electrical Modulation to improve gear-shift
quality. The ECU does this by adding delays to off-
going and/or on-coming clutches and so overlapping
energised outputs. These delays are in the order of
a few hundred milliseconds but it is sometimes long
enough to be observed on the status LED’s. Thus,
during certain shifts it is quite normal to observe more
than 2 outputs ON at any one time.

4WD
• Direct 4WD: An ECU input which is usually
derived from the machine footbrake switch
(which also controls the brake lights).
Whenever this signal is present the 4WD
Solenoid output is energised.
• Indirect 4WD: An ECU input which is usually
Information in this display is constantly updated in derived from a command from a console
real time. The status of the ECU electrical inputs and mounted '4WD selector' switch. (However,
outputs is displayed using simulated LED. The LED this switch arrangement may change between
change colour depending on the status of the inputs machines.)
and outputs. A key in the bottom left corner of the • 4WD Solenoid (Bank 2): An ECU output to the
main window explains the colours. transmission 4WD solenoid. The output status
is indicated by a coloured LED, grey - output
The following is a brief explanation of each feature. OFF, red - output ON (solenoid energised).
The ECU and Diagnostics software proactively
Transmission Speed: scans the solenoids for electrical open and
short circuits. In the event of a circuit problem
This is the current transmission output speed which the corresponding solenoid output LED will be
is directly related to the road speed (through axle coloured yellow when ON, or blue when OFF.
ratio and tyre size). The transmission speed sensor • 4WD Configuration: Depending on the type of
is located next to the output gear and detects the 4WD clutch installed, 4wheel drive OR 2 wheel
passing of the gear teeth. The sensor has a fixed drive may be selected when the ‘4WD’ solenoid
installation, no adjustment is necessary. This signal is energised. The clutch may be a ‘Spring
is used by the ECU to determine gear-shifting and Applied’ or ‘Pressure Applied’ type.
protection strategies. • 4WD Status: Indicates if 4WD is ‘Engaged’ or
‘Disengaged’.
Gears
Misc Inputs
• Inputs: The items on the left show the signal
lines connected to the gear selection lever These inputs are derived from the remaining
and where installed the selection switch on operator controls. The input status is indicated by a
the hydraulic control lever (Joystick). The gear coloured LED, grey - input OFF, green - input ON.
selection lever is the left hand half of the
control lever assembly mounted on the steering • Handbrake Switch: Signal derived from the
column. The hydraulic control lever (Joystick Park brake switch. Used to hold the
ECU 2.3 machines) has a selection switch for transmission in Neutral if the park brake is
forward, neutral and reverse gears. The input applied. Two types of switch may be installed
status is indicated by a coloured LED, grey - NO (Normally Open) or NC (Normally Closed).
input OFF, green - input ON. • Footbrake Switch: If Installed. Two types of
• Outputs: The items on the right are the power switch may be fitted NO (Normally Open) or NC
outputs to the transmission solenoid valves. (Normally Closed).
The output status is indicated by a coloured • Dump Switch: (or Transmission Disconnect)
LED, grey - output OFF, red - output ON Signal usually derived from a momentary
(solenoid energised). The ECU and Diagnostics switch. Temporarily selects Neutral when
software proactively scans the solenoids for pressed (usually to divert engine power to
electrical open and short circuits. In the event hydraulics).
of a circuit problem the corresponding solenoid

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• Throttle Switch: Signal derived from a switch Misc Outputs

installed to the machine throttle pedal. Used
to interact with the Automatic Mode of gear- These are the additional ECU outputs, generally
shifting. used to control cab instrumentation such as a Driver
• Pressure Switch: Signal derived from the Indicator (lamp and buzzer where fitted), low Oil
transmission mounted Low Oil Pressure Pressure Lamp and Kickdown Indicator. The output
Switch. status is indicated by a coloured LED, grey - output
• Kickdown Switch: Signal derived from a OFF, red - output ON.
momentary button used to temporarily select
the next lowest gear. Torque Converter Lock Up (TCLU) Page
• Oil Temp Switch: Signal derived from the
transmission oil temperature switch. The TCLU control page displays information relating
to the torque converter lock up operation.

Figure 841.

7 8

11

10

9
5
1
2
1

12 14

13 4

1 Engine speed sensor 2 Engine speed RPM (Revolutions Per Minute)

(real time)

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3 Engine speed sensor input status LED 4 Transmission output speed sensor
5 Transmission speed RPM (real time) 6 Transmission speed sensor input status LED
7 Lock up clutch solenoid status LED 8 Lock up clutch solenoid valve symbol
9 Engine speed - lock up clutch OFF value 10 Engine speed - lock up clutch ON value
11 Lock up clutch system active or inactive 12 Reference value - engine, transmission speed
differential
13 Engine, transmission speed differential (real 14 Current gear selected
time)

For operation of the lock up clutch two speed Figure 842.

references are required by the ECU. D
Engine speed (n/min) is read from the input side
of the transmission. The engine speed input is
connected to the ECU (pin 31A) and a green input C
LED indicates the signal status.
B
Transmission output speed is taken from the same
signal source as described in dashboard page.
The transmission output speed is connected to the
ECU(pin 03B) and a green input LED(6) indicates the
signal status.

Two padlock symbols can be seen above the engine

speed display. The locked padlock indicates the
speed at which the lock up clutch (LUC) is switched
ON and the unlocked padlock indicates when the A
LUC is switched OFF.

Real time engine and transmission output speed are

also displayed on the graphic.

A maximum differential speed reference value (12) A Stator

is indicated next to a padlock symbol. If all the other B Turbine
interlocks are observed and the differential speed C Impeller
(13) is below that of the reference value (12), then D Lock up clutch
the LUC is enabled.
Solenoid Test Mode Page
The circular graphic represents the torque converter
and its elements. The Solenoid Test Mode page allows testing of
each transmission solenoid individually. Since gear
selection always requires two solenoid valves to
be energised the tests can be carried out with the
transmission in neutral. For electrical tests the engine
does not have to be running. For hydraulic clutch
pressure testing the engine must be running, before
using the Test Mode facility disconnect the drive
shafts at the gearbox.

Important: Disconnect the drive shafts at the gearbox

before you use the test mode facility.

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Figure 843.

• Initial Conditions: To enable the test mode the the mouse. While the button is held down the
handbrake must be ON, the FNR lever set ECU is forced to output power to the indicator
to NEUTRAL and the road speed must be and or warning devices. The output status is
ZERO. The conditions are displayed in the indicated by a coloured LED, grey - output OFF,
Initial Conditions panel. red - output ON. If the devices are working they
• Start/Stop Button: Press the button to toggle the will illuminate and/or sound as applicable.
test mode either on or off as required. ‘TEST • To test the Neutral Start and Low Oil Pressure
MODE READY’ or ‘TEST MODE ACTIVE’ is switches: Click the appropriate button using the
displayed as applicable. If the initial conditions mouse. While the button is held down the ECU
are not compatible with the test mode the Start/ is forced to output power to the switch. The
Stop button is disabled and NOT ALLOWED is output status is indicated by a coloured LED,
displayed. grey - output OFF, red - output ON.
• To Test a Solenoid: If tests are being carried
out with the engine running, make sure that Note: If the test mode is not enabled make sure that
the drive shafts are disconnected at the the START button is pressed (large green ‘LED’ at
gearbox. Click the appropriate button using the the top left corner of the screen).
mouse. The ECU is forced to output power
to the selected solenoid. The output status is Flashloader Tool-User Guide
indicated by a coloured LED, grey - output
OFF, red - output ON (solenoid energised). The Flashloader software tool is part of the JCB
The ECU and Diagnostics software proactively Servicemaster software suite. If the ECU is replaced
scans the solenoids for electrical open and and the data file in its flash memory is not applicable
short circuits. In the event of a circuit problem it will be necessary to flash the ECU memory with the
the corresponding solenoid output LED will be correct data file. The Flashloader software tool can
coloured yellow when ON, or blue when OFF. be used to access the data file name currently loaded
• To test the Driver, Kickdown and reverse in the ECU memory and is necessary upload a new
Indicators: Click the appropriate button using data file to the ECU.

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Connecting Flash Loader Figure 845.

To use Flashloader your laptop computer must be

connected to the machine CANbus.

Starting Flashloader
1. Turn ON the machine ignition but DO NOT start
the engine.
2. Start JCB Servicemaster on the laptop computer.
Figure 844.

5. The Flashloader tool will then open.

Figure 846.

Using Flashloader

Important: Do not turn off the ignition or isolate the

system by accidentally engaging the operators seat
isolation switch when using the flashloader. This
3. Make sure that the correct DLA is selected in will interrupt the flash signal to the ECU and will
the chooser. Click on Utilities, DLA Setup. The irreparably damage the ECU.
DLA Chooser window opens. Check the button
to match to the Current Device. Click Apply. 1. Make sure that the machine ignition switch is set
to ON but do not start the engine.
4. Select the required machine range.
2. Click on the ECU icon.
3. Click on the Browse button and select the correct
data file. Click Open.

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Figure 847.

4. Click on the Start button. A confirmation window 5. When the programming is complete switch the
will appear. Click on the Yes to start the machine ignition to the OFF position.
reprogramming of the ECU. The progress bar is
displayed.

Figure 848.

6. Before starting the machine make sure that

the machine setup data is correct. You must
check that all other relevant machine settings are
correctly configured. Use the setup software tool.

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Technical Data Operation

Refer to Electrical System, Electronic Diagnostic, Start Servicemaster

Fault Codes. Refer to: PIL 33-57-90.
1. Set up Servicemaster, refer to Servicemaster.
Refer to: PIL 33-57-03.
2. Double click on the Servicemaster icon. (The
icon is found on the desktop or in the Start menu,
Programs, JCB).
Figure 849.

3. The Servicemaster window will open.

Figure 850.

4. Double click the desired machine group.

5. Access the relevant servicemaster tool to
perform the operation. For full details of the
Servicemaster tools, refer to Introduction.
Refer to: PIL 33-57-03.

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Figure 851.

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Preparation

Set-up Servicemaster Servicemaster Setup - First Time

The procedures below describe how to set up 1. Install Servicemaster on your laptop/PC through
Servicemaster for USB (Universal Serial Bus) the DVD.
compatible equipment. There are other procedures
and options. These are described in detail in the 2. Run the "Servicemaster Web Update".
Servicemaster help files contained on the JCB 3. Open Servicemaster on your laptop/PC.
Service Information DVD (Digital Versatile Disc).
4. Install the "DLA laptop driver software" on your
Before you start Servicemaster set up procedure laptop/PC.
make sure that you have following:
5. Configure the DLA type and communications
1 A Microsoft Windows compatible laptop port.
computer with a DVD drive and/or a USB port.
Refer to Figure 852. 6. Make sure that the DLA flash memory contains
the latest firmware file.
a Make a note that Servicemaster is
compatible with Windows 98, 2000, ME, 7. Connect Servicemaster to the machine
XP, Vista, and 7 operating systems (32 bit through the CAN (Controller Area Network)bus
and 64bit). connections.
2 The latest Servicemaster software (DVD and
internet connection for web updates). Refer to JCB Servicemaster - New Installation
Figure 852.
3 A JCB compatible DLA (Data Link Adaptor). This topic covers the new installation of JCB
Refer to Figure 852. Servicemaster on a new laptop/PC (Personal
4 The correct connection cables. Refer to Figure Computer).
852.
a Do not connect any cables to the laptop, 1. Insert the CD (Compact Disk) into your computer/
DLA or machine at this time. laptop.

Figure 852. 2. Open the "My Computer" option to select the

"SM2_V10-0-3 (D:)" CD drive.
3. Select and open the "SM2_V10-0-3 (D:)" CD
drive to explore its contents. Refer to Figure 853.

A Laptop computer
B Servicemaster software
C DLA
D Connection cables

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Figure 853. Figure 855.

7. A warning message window will appear on the

screen. Refer to Figure 856.
7.1. Click the "OK" option.
Figure 856.

8. A new window "JCB Servicemaster Installation

Wizard" will appear on the screen. Refer to
Figure 857.
4. Select and open the "Setup.exe" application. 8.1. Click the "Next" option to proceed.
5. A new window "JCB Servicemaster Setup" will Figure 857.
appear on the screen.
5.1. Click the "Install V10.0.3" option to start the
setup application. Refer to Figure 854.
Figure 854.

9. Put "User Name" and "Organization" details into

6. A new window "Select Setup Language" will the "Customer Registration" screen. Refer to
appear on the screen. Refer to Figure 855. Figure 858.
6.1. Use the drop down option to select the 9.1. Click the "Next" option when you inserted
suitable language. details.
6.2. Click the "OK" option to confirm selected
language.

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Figure 858. Figure 860.

10. Select all the "Setup Type" screen options for the 12. The language "Error" windows will appear on the
complete installation. Refer to Figure 859. screen during the installation process. Refer to
Figure 861.
Figure 859.
12.1. Click the "Ignore" option to skip the error
windows.
12.2. These language "Error" windows will be
installed after through the web update of
Servicemaster.
Figure 861.

11. The "Ready to Install this Program" screen will

show you its setup location in your computer.
Refer to Figure 860.
11.1. Click the "Next" option to start installation.

13. A new message window will appear on the

screen, after the installation. Refer to Figure 862.
13.1. Click the "OK" button.

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Figure 862. Update" program. Do the below steps to download

and install the JCB web update.

1. Use the web address www.business.jcb.com to

install JCB web update.
2. A web page will open on the screen. Refer to
Figure 865.
Figure 865.

14. A new "Completed" message will appear on

the "JCB Servicemaster_2V10.0.3 Installation
Wizard" screen. Refer to Figure 863.
14.1. Click the "Finish" option.
14.2. The JCB portal will open for Servicemaster
web update, after the installation.
Figure 863.

3. If you do not already have a User ID and

Password, click the "Get Support" option.
3.1. Apply for an account to get access to
JDS (JCB Distribution System) and SPP
(Service Parts Pro).
4. Once you logged in, you will find a link "JDS" on
the left side tool bar. Refer to Figure 866.
4.1. Click the "JDS" link.

15. The two program shortcuts will be created on the

computer desktop. Refer to Figure 864.
Figure 864.

JCB Servicemaster Web Update - New

Installation
Once you installed JCB Servicemaster on your
laptop/PC you will need to keep it updated. JCB
Servicemaster is updated through the "JCB Web

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Figure 866. Figure 868.

6.1. Click the "click here" link which is the orange

colour text sentence to download JCB web
update.
7. A new "File Download - Security Warning"
window will appear on the screen. Refer to Figure
869.
Figure 869.

5. A new screen "JCB DISTRIBUTION SYSTEM"

will open. Refer to Figure 867.
Figure 867.

7.1. Click the "Run" option to start download.

8. Because of the computer system firewall, you
may get warning window "Internet Explorer -
Security Warning". Refer to Figure 870.
8.1. Click the "Run" option to proceed.
5.1. Click the "SM Web Update" link option of the Figure 870.
left side tool bar.
6. A new "Servicemaster Web Update" screen will
open. Refer to Figure 868.

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9. A new "JCB Web Update (V2.02) Installation 2. After the installation you will need to authorise the
Wizard" window will open. Refer to Figure 871. download to ensure that you get future updates.
9.1. Once the download is finished, it will 3. Get access to the "Servicemaster Web Update"
automatically run. screen. Refer to Figure 873.
Figure 871. 4. The "Servicemaster Web Update" screen will
have one of the red or orange dialogue box.
Refer to Figure 873.
4.1. The dialogue box depends on the download
privileges attached to your name (red for
pre-release and orange for full release
only).
Figure 873.

10. The"JCB Web Update" program shortcut will be

created on the computer desktop. Refer to Figure
872.
Figure 872.
5. Click the dialogue box to start the authorisation
process. Refer to Figure 874.
5.1. A new window "Servicemaster Pre-Release
Initiating New Authorisation" will open.
Figure 874.

11. Refer to the below section "JCB Web Update 6. After the system download authorisation
Downloads - Authorisation" to authorise your process, "Download" option will reflect on the
downloads. window. Refer to Figure 875.

JCB Web Update Downloads - 6.1. Click the "Download" option to download
the JCB web update.
Authorisation
Figure 875.
The below authorisation procedure is needed to
access the downloads through the "JCB Web
Update" on a laptop/PC.

1. It is necessary to authorise the download after

the installation, to make sure that you get future
updates.

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7. The authorisation process of "JCB Web Update" 1. Once you complete the DLA driver software
is now complete. installation procedure, it will not require to do
again on your laptop/PC.
Servicemaster Updates - "JCB Web 2. Do not connect the DLA or cables to the machine
Update" Program or laptop/PC before to install the DLA driver
software.
The updates for Servicemaster is downloaded
through the "JCB Web Update" program on a laptop/ 3. Open Servicemaster on your laptop computer.
PC. Refer to the below steps.
4. Click the "Other" tab to get access to the
1. Run the "JCB WebUpdate" program either by "General Support" icon.
using desktop shortcut or "Help" menu within
Servicemaster, to do a Servicemaster update. 5. Click the "General Support" icon to get access to
the "DLA" icon.
2. The "JCB WebUpdate" program will check for
updates and inform you if there is any to 6. Click the "DLA" icon. Refer to Figure 878.
download. Refer to Figure 876.
Figure 878.
Figure 876.

2.1. You may click the "Details" option to check

which files have been changed, added or
removed.
2.2. Click the "Download" option to download
the updates.
3. Once the updates downloaded, the "JCB Web
Update" will give option to install them. Refer to
7. Select and open the USB driver icon. Refer to
Figure 877.
Figure 879.
3.1. You may select options to install the
7.1. Make a note that the other drivers icon
updates immediately or at a later date.
are also available for the computers with
Figure 877. serial ports (no USB ) and other versions of
Microsoft Windows.
7.2. If your laptop does not have a USB port,
select and open the correct driver icon.
Figure 879.

DLA Driver Software - Installation

When you use Servicemaster first time on
your laptop/PC (which is newly installed with
Servicemaster software), the DLA driver software is
necessary to install first. Do the below steps to install
the DLA driver software.

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8. A new window "Driver Installer" will open. Refer 7.2. Make a note that the older DLA and laptop
to Figure 880. computers may not be compatible with the
USB ports. Select the "Parallel/Serial DLA"
8.1. Obey the window instructions to the device in the DLA chooser.
complete the DLA driver software
installation. Figure 882.
Figure 880.

DLA Type and Communications Port -

Configuration
When you use Servicemaster first time on
your laptop/PC (which is newly installed with
Servicemaster software) make sure that the correct
DLA and laptop/PC port is selected to communicate DLA Firmware File - Check
with the DLA. Do the below steps to configuration the
DLA with the laptop/PC. The DLA has software embedded in its own flash
memory. This file must be replaced with a new one
1. Once you complete the DLA configuration, it will when new firmware is released. You will only have to
not require to do again on your laptop/PC. Check the DLA firmware file version if you receive a
new Servicemaster version or use a different DLA.
2. Open Servicemaster on your laptop computer.
1. Make sure that the DLA is connected to the
3. Click the "Other" tab to get access to the laptop computer.
"General Support" icon.
2. Open Servicemaster on your laptop computer.
4. Click the "General Support" icon to get access to
the "DLA" icon. 3. Click the "Other" tab to get access to the
"General Support" icon.
5. Click the "DLA" icon.
4. Click the "General Support" icon to get access to
6. Select and open the "COM Port Chooser" icon. the "DLA" icon.
Refer to Figure 881.
5. Click the "DLA" icon.
Figure 881.
6. Select and open the USB DLA Flashloader" icon.
Refer to Figure 883.
6.1. Make a note that the older DLA and
laptop computers may not be compatible
with the USB ports. Select and open the
"Flashloader for Serial/Parallel DLA" icon.
Figure 883.

7. A new "DLA Chooser" window will open. Refer to

Figure 882.
7.1. Select the USB /Serial DLA" device and
click the "Apply" option to confirm.

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7. A window USB Device Flash Update Tool" will and application version (for example - 2.01).
open. Refer to Figure 884. Refer to Figure 886.
7.1. The firmware details in the DLA are Figure 886.
displayed with the application version (for
example - 1.04). Refer to Figure 884.
Figure 884.

A
A Start option
9. Load a new firmware file.

A Browse option 9.1. If the firmware in the DLA is not up to date,

load the new file.
8. Check for a new firmware file.
10. Click the "Start" option and obey the on-screen
8.1. Click the "Browse" option and find the instructions.
file stored within the JCB Servicemaster
directory on your laptop hard drive. Refer to Servicemaster Engine Diagnostic Page
Figure 885. Function (T4 Final Engine)
8.2. Select the file and click the "Open" option.
The T4 final Ecomax engine platform is available on
Figure 885. Servicemaster updates.

If you load the T4 final platform, you will need a

different process to enter the old T3 common rail
diagnostic page for live data and fault codes.

The engine setup page and the flash loader pages

will still work normally, but to identify the fault codes
and sensor readings, you will need to follow the
following instructions:

1. Make the machine safe.

Refer to: PIL 01-03.
2. Turn the ignition switch to the OFF position.
3. Launch Servicemaster in the normal way and
8.3. The selected file appears in the firmware click on the original JCB Dieselmax icon. Refer
file name' field together with its release date to Figure 887.

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Figure 887.

4. The standard diagnostic page will appear on the 5. Click the green activation option at the top left
screen. corner of the screen. Refer to Figure 888.

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Figure 888.

6. Click the accept button. Refer to Figure 889. 7. The engine selection screen will appear. Refer to
Figure 890.
Figure 889.

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Figure 890.

7.1. Select the "TierII/TierIII" option. 8. The detected engine page will confirm your
selection. Refer to Figure 891.

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Figure 891.

8.1. Click the "OK" option. 9. The diagnostic page will appear as before, but
there will be no data displayed yet. Refer to
Figure 892.

Figure 892.

10. Turn the ignition switch to the ON position. Refer

to Figure 893.

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Figure 893.

10.1. The data will appear on the diagnostic 11. The active fault codes will see on the diagnostic
page. page. Refer to Figure 894.

Figure 894.

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Disconnect and Connect Note: Older DLA and laptop computers may not be
compatible with USB ports. Use the serial PC cable
Special Tools to connect the DLA to the laptop serial port.
Description Part No. Qty.
1. Make sure the machine ignition system is OFF.
Machine Cable 718/20237 1
Data Link Adaptor 892/01174 1 2. To use the Servicemaster diagnostic tool,
(DLA) Kit connect the laptop computer to the machine.
Special Tool: Data Link Adaptor (DLA) Kit (Qty.:
To use Servicemaster, connect your laptop computer
1)
to the machine CAN (Controller Area Network) bus.
Special Tool: Machine Cable (Qty.: 1)
Connection is made using the DLA (Data Link
Adaptor) and the applicable cables. 3. Connect the USB PC Cable to the DLA and a free
port on the laptop computer.
Figure 895.
4. Connect the Machine Cable to the DLA. The
Machine Cable has a 15-way D-type connector
on one end and a 9-way CAN connector on the
other. Plug the 15-way connector into the DLA
and tighten the thumb screws.
D Figure 896.

B
E

C
D
A USB PC Cable
B Serial PC cable
A C Centre pin location tab
B D Locking ring
5. Connect the 9-way CAN connector into the
machines Diagnostics Connector as follows:
5.1. Position the CAN connector to align the
centre pin location tab with the diagnostics
connector.
A USB PC Cable - 718/20235 5.2. Couple the connectors. Turn the locking
B Serial PC Cable - 718/20236 ring clockwise to secure the connectors.
C USB DLA - 728/26500
D Machine Cable - 718/20237
E Kit - 892/01174 (contains items A, B, C and D)

Note: Connect the USB cable directly to the laptop

computer. Do not connect the cable via a USB hub.

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90 - Fault Codes Introduction

Introduction .................................................. 33-193 Should faults occur related to an ECU (Electronic
Technical Data ............................................. 33-195 Control Unit) or devices connected to it, the
electronic system will generate the applicable fault
codes. A complete list of fault codes is stored within
the applicable Servicemaster tools set.

Fault Code Structure

The structure of fault codes, otherwise known
as DTC (Diagnostic Trouble Code)'s has been
standardised to a 7 digit code for all on and off-
highway machine and vehicle applications. The
standard (referred to as J2012) requires all fault
codes to conform to the following structure.

• 1st character - defines the system on the

vehicle (e.g. P = Powertrain, C= Chassis, U =
Network).
• 2nd and 3rd characters - defines the sub-
system (e.g. transmission, CAN (Controller
Area Network) network, brakes etc).
• 4th and 5th characters - specifies the particular
component, circuit or fault (e.g. starter relay).
• 6th and 7th characters - referred to as the
'Failure Type Byte' (FTB) which indicates the
particular failure (e.g. 11 = short circuit to
ground). See FTB Numbers below for a full list.

Some specific fault codes are defined by

international standard, while other codes may be
defined by individual vehicle manufacturers.

Fault Code Display Systems

Depending on the machine specification fault codes
recorded by the engine ECU can be accessed and
displayed in several ways:

CAN Enabled Display

The machine may be equipped with a CAN enabled
display. Such a display will be capable of displaying
all recorded codes, for example P0047. All logged
codes will be displayed. The operator may also
have a facility to erase the fault code log. See
the applicable machine documentation for further
information.

CAN BUS Connected Computer

Fault codes logged can be accessed via a
suitable laptop computer running the applicable
diagnostics software, JCB 444 Engine Diagnostics
for example. The computer must be connected to the
machine CAN BUS socket using a DLA (Data Link
Adaptor). Once connected all recorded codes can be
displayed. The engineer also has a facility to erase
the fault code log.

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Failure Type Byte (FTB) Numbers Number Failure Type Byte (FTB) De-
scription
92 Performance or incorrect opera-
Table 262. tion.
Number Failure Type Byte (FTB) De- 98 Component or system over tem-
scription perature.
0 No sub-type information.
2 General signal failure. Malfunction Indicator Light (MIL)
4 System internal failure.
Figure 897.
5 System programming failure.
7 Mechanical failure.
9 Component failure.
11 Short Circuit To Ground (SC2G).
12 Short Circuit To Battery
(SC2VBAT). Amber/Red light. The MIL (Malfunction Indicator
13 Open Circuit (OC). Lamp) light comes on to show that a system error
16 Circuit voltage below threshold. has been detected. Refer to Figure 897.
17 Circuit voltage above threshold. - Red light. The light comes ON (and a continuous
18 Circuit current below threshold. audible alarm sounds) to indicate faults that may
19 Circuit current above threshold. result in serious damage to the machine or make the
1A Circuit resistance above thresh- machine dangerous to operate. This is known as a
old. ‘STOP NOW’ fault.
1B Circuit resistance below thresh- - Amber light. The light comes ON (and an audible
old. alarm sounds for one second) to indicate faults that
1C Circuit voltage out of range. may result in reduced machine performance but are
1F Circuit intermittent. not dangerous. They are unlikely to damage the
23 Signal stuck low. machine. This is known as a ‘SERVICE’ fault.
24 Signal stuck high. When the MIL light comes ON another applicable
26 Signal rate of change below system warning may display. These lights can show
threshold. a blink code. Refer to: PIL 33-57-90.
27 Signal rate of change above
threshold. Blink Codes
29 Signal invalid.
2F Signal erratic. Some machine systems are equipped with a
dedicated indicator light. If there is a system fault the
31 No Signal (lost/missing).
light can display fault codes as a series of blinks.
36 Signal frequency too low.
37 Signal frequency too high. For example code E127 can be displayed as a series
38 Signal frequency incorrect. of blinks as follows:
45 Program memory failure. Table 263.
46 Calibration / Parameter memory
failure. 1 Blink
47 Watchdog / micro-controller / mi- 2 Second delay
croprocessor failure. 2 Blink Blink
4B Over temperature. 2 Second delay
62 Signal compare failure. 7 Blink Blink Blink Blink Blink Blink Blink
64 Signal plausibility failure.
The light will be ON for approximately 1s and OFF
71 Actuator stuck. for approximately 0.5s. There is an OFF time of
72 Actuator stuck open. approximately 2s between error code digits.
73 Actuator stuck closed.
85 Signal above allowable range. When a blink code is displayed the MIL light can
also come ON. Refer to Electronic Diagnostic,
86 CAN signal invalid. Fault Codes, Introduction, Malfunction Indicator Light
(MIL). Refer to: PIL 33-57-90.

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Fault Code log Technical Data

The fault code log can be read on the instrument
panel LCD (Liquid Crystal Display). Alternatively use Table 264. ATC ECU Faults
the JCB Servicemaster diagnostics tool.
Fault Code Description
Read the fault code log on the instrument panel LCD B1147-16 Battery voltage valid but low
via the service menu. Use JCB Servicemaster and B114A-17 Evaporator temperature voltage
a laptop computer connected to machine CANbus to above normal
see the codes. B114B-16 Evaporator temperature voltage be-
low normal
B114C-17 Cab temperature voltage above nor-
mal
B114D-16 Cab temperature voltage below nor-
mal
B114E-17 Duct temperature voltage above nor-
mal
B114F-16 Duct temperature voltage below nor-
mal

Table 265. ATC Keypad Faults

Fault Description
Codes
B1110-93 'Decrease fan speed' button failure
B1111-93 'Increase fan speed' button failure
B1112-93 'Max Air-Con' button failure
B1113-93 'De-mist' button failure
B1114-93 'Mode door close' button failure
B1115-93 'Recirculation' button failure
B1116-93 'Mode door open' button failure
B1117-93 'Full fresh air mode' button failure
B1118-93 'Air-Con' button failure
B1119-93 'Auto mode' button failure
B111A-93 'Reduce temperature' button failure
B111B-93 'Increase temperature' button failure
B111C-94 'Decrease fan speed' button stuck
B111D-94 'Increase fan speed' button stuck
B111E-94 'Max Air-Con' button stuck
B111F-94 'De-mist' button stuck
B1120-94 'Mode door close' button stuck
B1121-94 'Recirculation' button stuck
B1122-94 'Mode door open' button stuck
B1123-94 'Full fresh air mode' button stuck
B1124-94 'Air-Con' button stuck
B1125-94 'Auto mode' button stuck
B1126-94 'Reduce temperature' button stuck
B1127-94 'Increase temperature' button stuck
B1162-08 CAN Error Passive
B1166-08 CAN RX Error
B116A-08 CAN TX Error
B116E-16 VREF Voltage Low
B1172-17 VREF Voltage High
B118A-09 Shift Register Fault

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Table 266. Front Display Faults Fault Description

Fault Description Codes
Codes C15A1-13 Lift and lower solenoid return - Open
B1021-21 Screen was level low circuit
B10C4-00 Operator not present C15A2-11 Lift and lower solenoid return - Short
circuit to ground
P06B8-44 Error log full
C15A3-12 Lift and lower solenoid return - Short
P1115-1E Fuel Gauge - Out of range (OOR) circuit to battery
P2264-00 Water in fuel C15A4-13 Crowd and dump solenoid return -
P2280-22 Engine air filter blocked Open circuit
P2560-21 Coolant level low C15A5-11 Crowd and dump solenoid return -
Short circuit to ground
Table 267. Hydraulic ECU Faults
C15A6-12 Crowd and dump solenoid return -
Fault Description Short circuit to battery
Codes
B102E-15 Auxiliary changeover solenoid back
driven Table 268. IO Module 1 Faults
B102F-11 Auxiliary changeover solenoid short Fault Description
circuit Codes
B1030-13 Auxiliary changeover solenoid open B10CB-13 Front auxiliary work lamps - Open
circuit circuit
C100D-15 Tow Hitch Rotate Solenoid back dri- B10CB-19 Front auxiliary work lamps - Over
ven current
C100E-11 Tow Hitch Rotate Solenoid short cir- B10CB-2A Front auxiliary work lights - On when
cuit (1) demanded off
C100F-13 Tow Hitch Rotate Solenoid open cir- B10CB-2A Front auxiliary work lights - Off when
cuit (2) demanded on
C152E-62 Boom Lever rationality fault B10CB-4B Front auxiliary work lamps - Thermal
C152F-23 Boom Lever track 1 - Out of range shutdown
(OOR) B10CC-13 Heated mirrors and rear screen -
C1531-23 Boom Lever Track 2 - Out of range Open circuit
(OOR) B10CC-19 Heated mirrors and rear screen -
C1538-62 Bucket Lever rationality fault Over current
C1539-23 Bucket Lever Track 1 - Out of range B10CC-2A Heated mirrors and rear screen - On
(OOR) (1) when demanded off
C153B-23 Bucket Lever Track 2 - Out of range B10CC-2A Heated mirrors and rear screen - Off
(OOR) (2) when demanded on
C1595-13 Lift Solenoid - Open circuit B10CC-4B Heated mirrors and rear screen -
C1596-11 Lift Solenoid - Short circuit to ground Thermal shutdown
C1597-12 Lift Solenoid - Short circuit to battery B10CD-13 Left hand front work lamps - Open
circuit
C1598-13 Lower Solenoid - Open circuit
B10CD-19 Left hand front work lamps - Over
C1599-11 Lower Solenoid - Short circuit to
current
ground
B10CD-2A Left hand front work lamps - On
C159A-12 Lower Solenoid - Short circuit to bat-
(1) when demanded off
tery
B10CD-2A Left hand front work lamps - Off
C159B-13 Crowd Solenoid - Open circuit
(2) when demanded on
C159C-11 Crowd Solenoid - Short circuit to
B10CD-4B Left hand front work lamps - Thermal
ground
shutdown
C159D-12 Crowd Solenoid - Short circuit to bat-
B10CE-13 Right hand front work lamps - Open
tery
circuit
C159E-13 Dump Solenoid - Open circuit
B10CE-19 Right hand front work lamps - Over
C159F-11 Dump Solenoid - Short circuit to current
ground
B10CE-2A Right hand front work lamps - On
C15A0-12 Dump Solenoid - Short circuit to bat- (1) when demanded off
tery

33 - 196 9813/4800-4 33 - 196

 33 - Electrical System
57 - Electronic Diagnostic
90 - Fault Codes

Fault Description Fault Description

Codes Codes
B10CE-2A Right hand front work lamps - Off B10C6-19 Right hand side lights - Over current
(2) when demanded on B10C6-2A Right hand side lights - On when de-
B10CE-4B Right hand front work lamps - Ther- (1) manded off
mal shutdown B10C6-2A Right hand side lights - Off when de-
B10CF-13 Rear auxiliary work lamps - Open cir- (2) manded on
cuit B10C6-4B Right hand side lights - Thermal
B10CF-19 Rear auxiliary work lamps - Over cur- shutdown
rent B10C7-13 Headlamps - Open circuit
B10CF-2A Rear auxiliary work lamps - On when B10C7-19 Headlamps - Over current
(1) demanded off B10C7-2A Headlamps - On when demanded off
B10CF-2A Rear auxiliary work lamps - Off when (1)
(2) demanded on B10C7-2A Headlamps - Off when demanded on
B10CF-4B Rear auxiliary work lamps - Thermal (2)
shutdown B10C7-4B Headlamps - Thermal shutdown
B10D0-13 Beacon - Open circuit B10C8-13 Main beam lamps - Open circuit
B10D0-19 Beacon - Over current B10C8-19 Main beam lamps - Over current
B10D0-2A Beacon - On when demanded off B10C8-2A Main beam lamps - On when de-
(1) (1) manded off
B10D0-2A Beacon - Off when demanded on B10C8-2A Main beam lamps - Off when de-
(2) (2) manded on
B10D0-4B Beacon - Thermal shutdown B10C8-4B Main beam lamps - Thermal shut-
B10D1-13 Rear work lamps - Open circuit down
B10D1-19 Rear work lamps - Over current B10C9-13 Rear washer motor - Open circuit
B10D1-2A Rear work lamps - On when de- B10C9-19 Rear washer motor - Over current
(1) manded off B10C9-2A Rear washer motor - On when de-
B10D1-2A Rear work lamps - Off when de- (1) manded off
(2) manded on B10C9-2A Rear washer motor - Off when de-
B10D1-4B Rear work lamps - Thermal shut- (2) manded on
down B10C9-4B Rear washer motor - Thermal shut-
B10D2-13 Reverse alarm and lights - Open cir- down
cuit B10CA-13 Rear wiper motor - Open circuit
B10D2-19 Reverse alarm and lights - Over cur- B10CA-19 Rear wiper motor - Over current
rent
B10CA-2A Rear wiper motor - On when de-
B10D2-2A Reverse alarm and lights - On when (1) manded off
(1) demanded off
B10CA-2A Rear wiper motor - Off when de-
B10D2-2A Reverse alarm and lights - Off when (2) manded on
(2) demanded on
B10CA-4B Rear wiper motor - Thermal shut-
B10D2-4B Reverse alarm and lights - Thermal down
shutdown
C1037-13 Quick hitch unlock valve - Open cir-
cuit
Table 269. IO Module 2 Faults C1037-19 Quick hitch unlock valve - Over cur-
Fault Description rent
Codes C1037-2A Quick hitch unlock valve - On when
B10C5-13 Left hand side lights - Open circuit (1) demanded off
B10C5-19 Left hand side lights - Over current C1037-2A Quick hitch unlock valve - Off when
(2) demanded on
B10C5-2A Left hand side lights - On when de-
(1) manded off C1037-4B Quick hitch unlock valve - Thermal
shutdown
B10C5-2A Left hand side lights - Off when de-
(2) manded on C1038-13 Left direction indicators - Open circuit
B10C5-4B Left hand side lights - Thermal shut- C1038-19 Left direction indicators - Over cur-
down rent
B10C6-13 Right hand side lights - Open circuit

33 - 197 9813/4800-4 33 - 197

 33 - Electrical System
57 - Electronic Diagnostic
90 - Fault Codes

Fault Description Fault Description

Codes Codes
C1038-2A Left direction indicators - On when B10EF-94 'Rear fog lights' button stuck
(1) demanded off B10F0-94 'Front work lamps' button stuck
C1038-2A Left direction indicators - Off when B10F1-94 'Rear work lamps' button stuck
(2) demanded on B10F2-94 'Rear wash and wipe' button stuck
C1038-4B Left direction indicators - Thermal B10F3-94 'Heated rear screen' button stuck
shutdown
B10F4-94 'Secondary steering test' button stuck
C1039-13 Right direction indicators - Open cir-
cuit B10F5-94 'Engine mode' button stuck
C1039-19 Right direction indicators - Over cur- B10F6-94 'Auto transmission mode' button
rent stuck
C1039-2A Right direction indicators - On when B10F7-94 'Transmission mode' button stuck
(1) demanded off B1160-08 CAN Error Passive
C1039-2A Right direction indicators - Off when B1164-08 CAN RX Error
(2) demanded on B1168-08 CAN TX Error
C1039-4B Right direction indicators - Thermal B116C-16 VREF Voltage Low
shutdown B1170-17 VREF Voltage High
C103A-13 Rear fog lamps - Open circuit B1188-09 Shift Register Fault
C103A-19 Rear fog lamps - Over current
C103A-2A Rear fog lamps - On when demand- Table 271. Keypad 2 Faults
(1) ed off Fault Description
C103A-2A Rear fog lamps - Off when demand- Codes
(2) ed on B10F8-93 'Torque converter lock-up' button fail-
C103A-4B Rear fog lamps - Thermal shutdown ure
C103B-13 Brake lights - Open circuit B10F9-93 'Differential lock' button failure
C103B-19 Brake lights - Over current B10FA-93 'Transmission disconnect' button fail-
C103B-2A Brake lights - On when demanded off ure
(1) B10FB-93 'Constant flow' button failure
C103B-2A Brake lights - Off when demanded on B10FC-93 'Manual fan reverse' button failure
(2) B10FD-93 'SRS' button failure
C103B-4B Brake lights - Thermal shutdown B10FE-93 'Return to dig' button failure
B10FF-93 'Boom height limit' button failure
Table 270. Keypad 1 Faults B1100-93 'Return to carry' button failure
Fault Description B1101-93 'Hydraulic mode' button failure
Codes B1102-93 'Quick hitch unlock' button failure
B10E0-93 'Side lights' button failure B1103-93 'Hydraulic lock' button failure
B10E1-93 'Headlamps' button failure B1104-94 'Torque converter lock-up' button
B10E2-93 'Beacon' button failure stuck
B10E3-93 'Rear fog lights' button failure B1105-94 'Differential lock' button stuck
B10E4-93 'Front work lamps' button failure B1106-94 'Transmission disconnect' button
stuck
B10E5-93 'Rear work lamps' button failure
B1107-94 'Constant flow' button stuck
B10E6-93 'Rear wash and wipe' button failure
B1108-94 'Manual fan reverse' button stuck
B10E7-93 'Heated rear screen' button failure
B1109-94 'SRS' button stuck
B10E8-93 'Secondary steering test' button fail-
ure B110A-94 'Return to dig' button stuck
B10E9-93 'Engine mode' button failure B110B-94 'Boom height limit' button stuck
B10EA-93 'Auto transmission mode' button fail- B110C-94 'Return to carry' button stuck
ure B110D-94 'Hydraulic mode' button stuck
B10EB-93 'Transmission mode' button failure B110E-94 'Quick hitch unlock' button stuck
B10EC-94 'Side lights' button stuck B110F-94 'Hydraulic lock' button stuck
B10ED-94 'Headlamps' button stuck B1161-08 CAN Error Passive
B10EE-94 'Beacon' button stuck B1165-08 CAN RX Error

33 - 198 9813/4800-4 33 - 198

 33 - Electrical System
57 - Electronic Diagnostic
90 - Fault Codes

Fault Description Fault Description

Codes Codes
B1169-08 CAN TX Error B103C-13 1st Auxiliary - Solenoid B - Open cir-
B116D-16 VREF Voltage Low (1) cuit
B1171-17 VREF Voltage High B103C-13 2nd Auxiliary - Solenoid B - Open cir-
(2) cuit
B1189-09 Shift Register Fault
B1043-12 1st Auxiliary Return - Short circuit to
Table 272. Live Link ECU Faults (1) battery
B1043-12 2nd Auxiliary Return - Short circuit to
Fault Description (2) battery
Codes
B1044-11 1st Auxiliary Return - Short circuit to
U1900-16 Vehicle battery voltage below normal (1) ground
U1901-16 Internal voltage below normal B1044-11 2nd Auxiliary Return - Short circuit to
U1902-18 Live Link output for relay 0 current (2) ground
below normal or open circuit B1045-13 1st Auxiliary Return - Open circuit
U1903-18 Live Link output for relay 1 current (1)
below normal or open circuit B1045-13 2nd Auxiliary Return - Open circuit
U1904-85 ECU above temperature threshold (2)
U1905-84 ECU below temperature threshold B1150-45 Application Checksum Failed
U1906-96 Accelerometer internal failure B1151-44 Constant Data Checksum Failed
U1908-09 GPS (Global Positioning System) an- B1152-46 Setup Data Checksum Failed
tenna not OK B1153-85 Coolant temperature high
U1909-96 No communication with GPS (Global B1154-85 Torque converter temperature high
Positioning System) module
B1155-85 Hydraulic oil temperature high
U190A-09 SIM card failure
B1404-11 Foot brake pressure sensor STG -
U190B-96 No communication with GSM module short circuit to ground
U190D-06 Anti tamper lockout B1404-12 Foot brake pressure sensor - short
circuit to battery
Table 273. Management ECU Faults B1558-11 Reverse Fan Solenoid - Short circuit
Fault Description to ground
Codes B1558-12 Reverse Fan Solenoid - Short circuit
B1037-15 1st Auxiliary - Solenoid A - Short cir- to battery
(1) cuit to battery B1558-13 Reverse Fan Solenoid - Open circuit
B1037-15 2nd Auxiliary - Solenoid A - Short cir- B162B-11 Interposing start relay - Short circuit
(2) cuit to battery to ground
B1037-29 1st Auxiliary - Solenoid A Current B162B-12 Interposing start relay - Short circuit
(1) Mismatch to battery
B1037-29 2nd Auxiliary - Solenoid A Current B162B-13 Interposing start relay - Open circuit
(2) Mismatch B162E-11 Servo Isolator Solenoid - Short circuit
B1038-11 1st Auxiliary - Solenoid A - Short cir- to ground
(1) cuit to ground B162E-12 Servo Isolator Solenoid - Short circuit
B1038-11 2nd Auxiliary - Solenoid A - Short cir- to battery
(2) cuit to ground B162E-13 Servo Isolator Solenoid - Open circuit
B1039-13 1st Auxiliary - Solenoid A Supply - C1004-11 SRS Solenoid - Short circuit to
(1) Open circuit ground
B1039-13 2nd Auxiliary - Solenoid A - Open cir- C1004-12 SRS Solenoid - Short circuit to bat-
(2) cuit tery
B103A-15 1st Auxiliary - Solenoid B - Short cir- C1004-13 SRS Solenoid - Open circuit
(1) cuit to battery
C102C-11 Variable fan solenoid - Short circuit
B103A-15 2nd Auxiliary Solenoid b - Short cir- to ground
(2) cuit to battery
C102C-12 Variable fan solenoid - Short circuit
B103B-11 1st Auxiliary - Solenoid B - Short cir- to battery
(1) cuit to ground
C102C-13 Variable fan solenoid - Open circuit
B103B-11 2nd Auxiliary - Solenoid B - Short cir-
(2) cuit to ground

33 - 199 9813/4800-4 33 - 199

 33 - Electrical System
57 - Electronic Diagnostic
90 - Fault Codes

Fault Description Fault Description

Codes Codes
C10E0-11 Secondary Steer Relay - Short circuit C10F1-13 Pump Dump Solenoid Open Circuit
to ground P0115-87 Coolant temperature missing from
C10E0-12 Secondary Steer Relay - Short circuit CAN bus
to battery P0321-87 Engine speed missing from CAN bus
C10E0-13 Secondary Steer Relay - Open circuit P0509-16 Battery Voltage - Out of range (LOW)
C10E1-11 Brake Charge Solenoid - Short circuit P0509-17 Battery Voltage - Out of range
to ground (HIGH)
C10E1-12 Brake Charge Solenoid - Short circuit P0642-16 Vref (reference voltage) - Out of
to battery range (LOW)
C10E1-13 Brake Charge Solenoid - Open circuit P0642-17 Vref (reference voltage) - Out of
C10E2-2A Variable fan solenoid - Current mis- range (HIGH)
match P0937-87 Hydraulic oil temperature missing
C10E3-1C Secondary steering pressure sensor from CAN bus
- Out of range P1725-29 Low Brake Pressure Detected
C10E3-2A Secondary Steer Pressure Check (1)
Failed P1725-29 Brake Pressure Sensor - Out of
C10E3-68 Secondary Steer Pressure is too high (2) range
at key-on P2783-87 Torque converter temperature miss-
C10E4-16 Low Hydraulic (Steering) Pressure ing from CAN bus
C10E4-2A Main hydraulic pressure sensor - Out P3417-87 Engine intake manifold temperature
of range missing from CAN bus
C10E4-68 Main Pump Pressure is too high at
key-on
Table 274. Rotary Control Switch Faults
C10E5-11 Bucket lever detent solenoid - Short
circuit to ground Fault Description
Codes
C10E5-12 Bucket lever detent solenoid - Short
circuit to battery B1128-93 Button 1 Failure
C10E5-13 Bucket lever detent solenoid - Open B1129-93 Button 2 Failure
circuit B112A-93 Button 3 Failure
C10E6-11 Boom lever detent solenoid - Short B112B-93 Button 4 Failure
circuit to ground B112C-93 Button 5 Failure
C10E6-12 Boom lever detent solenoid - Short B112D-93 Button 6 Failure
circuit to battery B112E-94 Button 1 Stuck
C10E6-13 Boom lever detent solenoid - Open B112F-94 Button 2 Stuck
circuit
B1130-94 Button 3 Stuck
C10E7-64 Boom Reset Switch Fault
B1131-94 Button 4 Stuck
C10E8-64 Bucket Reset Switch Fault
B1132-94 Button 5 Stuck
C10E9-62 Auxiliary lever 1 - Signal rationality
fault B1133-94 Button 6 Stuck
C10EA-62 Auxiliary lever 2 signal rationality B1138-42 EEPROM Sector Malfunction
fault B1139-42 EEPROM Complete Failure
C10EB-1C Auxiliary Lever 1 Signal 1 - Out of B113A-47 Watchdog Timer Error
range B113B-45 Illegal Op Code Error
C10EC-1C Auxiliary Lever 1 Signal 1 - Out of B113C-9A EMI Failure
range B113D-49 Crystal Oscillator Failure
C10ED-1C Auxiliary Lever 1 Signal 2 - Out of B113E-88 Bus Idle Error
range
B113F-88 LED Bus Idle Error
C10EE-1C Auxiliary Lever 2 Signal 2 - Out of
range B1140-93 Button 1 LED Failure
C10EF-11 Pump Dump Solenoid Short circuit to B1141-93 Button 2 LED Failure
ground B1142-93 Button 3 LED Failure
C10F0-12 Pump Dump Solenoid short circuit to B1143-93 Button 4 LED Failure
battery B1144-93 Button 5 LED Failure

33 - 200 9813/4800-4 33 - 200

 33 - Electrical System
57 - Electronic Diagnostic
90 - Fault Codes

Fault Description Fault Description

Codes Codes
B1145-93 Button 6 LED Failure P1757-31 EEC1 Timeout
B1146-05 Encoder Data Erratic P1758-31 EEC3 Timeout
P1759-02 AEB-Request And Park brake test
Signals on at same time
Table 275. Transmission ECU Faults
P175C-86 CCO Request Signal
Fault Description P175D-86 Shift Lever Signal
Codes
P1761-86 Engine Torque Signal
P0219-00 Over-speed Engine
P1762-86 Reference Engine Torque Signal
P064F-00 Application Error
P1763-86 Actual Engine Torque Signal
P064F-42 Configuration Lost
P1764-86 Nom Friction Torque Signal
P0704-12 Clutch cutoff / Inch pedal input -
Short circuit to battery P1765-31 EEC2 Timeout
P0704-14 Clutch Cutoff / Inch pedal Input - P1766-12 Clutch K1 - Short circuit to battery
Short circuit to ground OR Open cir- P1767-11 Clutch K1 - Short circuit to ground
cuit P1768-13 Clutch K1 - Open circuit
P0717-11 Turbine Speed Input - Short circuit to P1769-12 Clutch K2 - Short circuit to battery
ground P176A-11 Clutch K2 - Short circuit to ground
P0717-13 Turbine Speed Input - Short circuit to P176B-13 Clutch K2 - Open circuit
battery OR Open circuit
P176C-12 Clutch K3 - Short circuit to battery
P0717-2A Turbine Speed Input - Logical error
P176D-11 Clutch K3 - Short circuit to ground
P0720-11 Output Speed Input - Short circuit to
ground P176E-13 Clutch K3 - Open circuit
P0720-15 Output Speed Input - Short circuit to P176F-12 Clutch converter - Short circuit to bat-
battery OR Open circuit tery
P0720-29 Output Speed Zero Doesn't Fit To P1770-11 Clutch converter - Short circuit to
Other Speed Signals ground
P0720-2A Output Speed Input - Logical error P1771-13 Clutch converter - Open circuit
P0725-11 Engine Speed Input- Short circuit to P1775-12 Clutch K4 - Short circuit to battery
ground P1776-11 Clutch K4 - Short circuit to ground
P0725-15 Engine Speed Input - Short circuit to P1777-13 Clutch K4 - Open circuit
battery OR Open circuit P1778-12 Clutch KV - Short circuit to battery
P0725-2A Engine Speed Input - Logical error P1779-11 Clutch KV - Short circuit to ground
P0C2F-11 Internal Speed Input - Short circuit to P177A-13 Clutch KV - Open circuit
ground P177B-12 Clutch KR - Short circuit to battery
P0C2F-15 Internal Speed Input - Short circuit to P177C-11 Clutch KR - Short circuit to ground
battery OR Open circuit
P177D-13 Clutch KR - Open circuit
P0C2F-2A Internal Speed Input - Logical error
P177E-11 DLM transversal output - Short circuit
P173A-86 Gear range signal - Logical error to ground
P173C-86 Direction select (Signal 2) shift lever - P177F-12 DLM transversal output - Short circuit
Logical error to battery
P1749-15 Transmission sump temperature sen- P1780-13 DLM transversal output - Open circuit
sor - Short circuit to battery OR Open
P179F-07 Slippage at Clutch K1
circuit
P17A0-07 Slippage at Clutch K2
P174A-11 Transmission sump temperature sen-
sor input - Short circuit to ground P17A1-07 Slippage at Clutch K3
P174B-15 Retarder / Torque converter tempera- P17A2-07 Slippage at Clutch K4
ture sensor - Short circuit to battery P17A3-07 Slippage at Clutch KV
OR Open circuit P17A4-07 Slippage at Clutch Kr
P174C-11 Retarder / Torque converter temper- P17A5-4B Over-temp Sump
ature sensor input - Short circuit to P17A7-00 Differential Pressure Oil Filter
ground
P17A8-74 Slippage at Converter Lockup Clutch
P1754-31 DCT1 Timeout
P17A9-00 Over-speed Output
P1756-31 Engine Conf Timeout

33 - 201 9813/4800-4 33 - 201

 33 - Electrical System
57 - Electronic Diagnostic
90 - Fault Codes

Fault Description Code Description

Codes P0099 Intake Air Temperature Sensor 2 Cir-
P17AF-07 Transmission Input Torque Overload cuit Intermittent/Erratic
P17B0-4B Over-temp Converter Output P0105 Manifold Absolute Pressure/Baro-
P17B6-12 Power supply for sensors - Short cir- metric Pressure Circuit
cuit to battery P0106 Manifold Absolute Pressure/Baro-
P17B7-11 Power supply for sensors - Short cir- metric Pressure Circuit Range/Per-
cuit to ground formance
P17B8-16 Low voltage at battery P0110 Intake Air Temperature Sensor 1 Cir-
cuit
P17B9-17 High voltage at battery
P0111 Intake Air Temperature Sensor 1 Cir-
P17BA-01 Error At Valve Power Supply Vps1
cuit Low
P17BB-01 Error Valve Power Supply Vps2
P0124 Intake Air Temperature Sensor 1 Cir-
P17C0-42 General EEPROM Fault cuit High
P17C2-93 Clutch Failure P0113 Intake Air Temperature Sensor 1 Cir-
P17C3-46 Clutch Adjustment Data Lost Or Inch cuit High
pedal Calibration Data Lost P0115 Engine Coolant Temperature Sensor
P17C4-00 Transmission input torque out of al- 1 Circuit
lowed range P0116 Engine Coolant Temperature Sensor
P2793-64 Logical error At Direction Select Sig- 1 Circuit Range/Performance
nal P0117 Engine Coolant Temperature Sensor
U0121-00 AEB Request Signal 1 Circuit Low
P0118 Engine Coolant Temperature Sensor
1 Circuit High
Table 276. Engine Fault Codes
P0120 Throttle/Pedal Position Sen-
Code Description sor/Switch "A" Circuit
P0001 Fuel Volume Regulator Control Cir- P0121 Throttle/Pedal Position Sen-
cuit/Open sor/Switch "A" Circuit Range/Perfor-
P0002 Fuel Volume Regulator Control Cir- mance
cuit Range/Performance P0180 Fuel Temperature Sensor "A" Circuit
P0003 Fuel Volume Regulator Control Cir- P0181 Fuel Temperature Sensor "A" Circuit
cuit Low Range/Performance
P0004 Fuel Volume Regulator Control Cir- P0182 Fuel Temperature Sensor "A" Circuit
cuit High Low
P0016 Crankshaft Position - Camshaft Posi- P0183 Fuel Temperature Sensor "A" Circuit
tion Correlation High
P0087 Fuel Rail/System Pressure - Too Low P0190 Fuel Rail Pressure Sensor "A" Circuit
P0088 Fuel Rail/System Pressure - Too P0191 Fuel Rail Pressure Sensor "A" Circuit
High Range/Performance
P0089 Fuel Pressure Regulator 1 Perfor- P0192 Fuel Rail Pressure Sensor "A" Circuit
mance Low
P0090 Fuel Pressure Regulator 1 Control P0193 Fuel Rail Pressure Sensor "A" Circuit
Circuit/Open High
P0091 Fuel Pressure Regulator 1 Control P0194 Fuel Rail Pressure Sensor "A" Circuit
Circuit Low Intermittent/Erratic
P0092 Fuel Pressure Regulator 1 Control P0200 Injector Circuit/Open
Circuit High P0201 Injector Circuit/Open - Cylinder 1
P0095 Intake Air Temperature Sensor 2 Cir- P0202 Injector Circuit/Open - Cylinder 2
cuit
P0203 Injector Circuit/Open - Cylinder 3
P0096 Intake Air Temperature Sensor 2 Cir-
cuit Range/Performance P0204 Injector Circuit/Open - Cylinder 4
P0097 Intake Air Temperature Sensor 2 Cir- P0205 Injector Circuit/Open - Cylinder 5
cuit Low P0206 Injector Circuit/Open - Cylinder 6
P0098 Intake Air Temperature Sensor 2 Cir- P0218 Transmission Fluid Over Tempera-
cuit High ture Condition

33 - 202 9813/4800-4 33 - 202

 33 - Electrical System
57 - Electronic Diagnostic
90 - Fault Codes

Code Description Code Description

P0220 Throttle/Pedal Position Sen- P02A11 Cylinder 6 Fuel Trim at Minimum
sor/Switch "B" Circuit Limit
P0236 Turbocharger/Supercharger Boost P02EE Cylinder 1 Injector Circuit Range/
Sensor "A" Circuit Range/Perfor- P02EF Cylinder 2 Injector Circuit Range/
mance P02F0 Cylinder 3 Injector Circuit Range/
P0252 Injection Pump Fuel Metering Con- P02F1 Cylinder 4 Injector Circuit Range/
trol "A" Range/Performance (Cam/
Rotor/Injector) P02F2 Cylinder 5 Injector Circuit Range/
P0253 Injection Pump Fuel Metering Control P02F3 Cylinder 6 Injector Circuit Range/
"A" Low (Cam/Rotor/Injector) P0335 Crankshaft Position Sensor "A" Cir-
P0254 Injection Pump Fuel Metering Control cuit
"A" High (Cam/Rotor/Injector) P0340 Camshaft Position Sensor "A" Circuit
P0261 Cylinder 1 Injector Circuit Low P0341 Camshaft Position Sensor "A" Circuit
P0262 Cylinder 1 Injector Circuit High Range/Performance
P0263 Cylinder 1 Contribution/Balance P0371 Timing Reference High Resolution
Signal "A" Too Many Pulses
P0264 Cylinder 2 Injector Circuit Low
P0372 Timing Reference High Resolution
P0265 Cylinder 2 Injector Circuit High Signal "A" Too Few Pulses
P0266 Cylinder 2 Contribution/Balance P0374 Timing Reference High Resolution
P0267 Cylinder 3 Injector Circuit Low Signal "A" No Pulses
P0268 Cylinder 3 Injector Circuit High P0500 Vehicle Speed Sensor "A"
P0269 Cylinder 3 Contribution/Balance P0501 Vehicle Speed Sensor "A" Range/
P0270 Cylinder 4 Injector Circuit Low Performance
P0271 Cylinder 4 Injector Circuit High P0503 Vehicle Speed Sensor "A" Intermit-
P0272 Cylinder 4 Contribution/Balance tent/Erratic/High
P0273 Cylinder 5 Injector Circuit Low P0520 Low Oil Pressure Lamp Drive Circuit
P0274 Cylinder 5 Injector Circuit High P0521 Engine Oil Pressure Sensor/Switch
Range/Performance
P0275 Cylinder 6 Contribution/Balance
P0522 High Oil Pressure
P0276 Cylinder 6 Injector Circuit Low
P0523 Low Oil Pressure
P0277 Cylinder 6 Injector Circuit High
P0560 System Voltage
P0278 Cylinder 6 Contribution/Balance
P0562 System Voltage Low
P029A Cylinder 1 Fuel Trim at Maximum
Limit P0563 System Voltage High
P029B Cylinder 1 Fuel Trim at Minimum P0566 Cruise Control "Off" Signal
Limit P0567 Cruise Control "Resume" Signal
P029E Cylinder 2 Fuel Trim at Maximum P0569 Cruise Control "Coast" Signal
Limit P0570 Cruise Control "Accelerate" Signal
P029F Cylinder 2 Fuel Trim at Minimum P0575 Cruise Control Input Circuit
Limit P0602 Control Module Programming Error
P02A2 Cylinder 3 Fuel Trim at Maximum P0603 Internal Control Module Keep Alive
Limit Memory (KAM) Error
P02A3 Cylinder 3 Fuel Trim at Minimum P0604 Internal Control Module Random Ac-
Limit cess Memory (RAM) Error
P02A6 Cylinder 4 Fuel Trim at Maximum P0605 Internal Control Module Read Only
Limit Memory (ROM) Error
P02A7 Cylinder 4 Fuel Trim at Minimum P0606 Functional Safety Fault
Limit
P0607 Functional Safety Fault
P02A8 Cylinder 5 Fuel Trim at Maximum
Limit P060A Functional Safety Fault
P02A9 Cylinder 5 Fuel Trim at Minimum P060B Functional Safety Fault
Limit P0612 Engine Speed Relay Driver
P02A10 Cylinder 6 Fuel Trim at Maximum P0615 Starter Relay Circuit
Limit P0616 Starter Relay Circuit Low

33 - 203 9813/4800-4 33 - 203

 33 - Electrical System
57 - Electronic Diagnostic
90 - Fault Codes

Code Description Code Description

P0617 Starter Relay Circuit High P1503 Hand Throttle Fault - Limp Home
P061B Functional Safety Fault Mode
P061C Functional Safety Fault P1504 Hand Throttle Fault - Reduced
Torque Mode
P061E Functional Safety Fault
P1506 Throttle/Pedal Global Fault - Limp
P0627 Lift Pump Global Fault - Open Circuit
Home Mode
P0628 Lift Pump Global Fault - Short Circuit
P1509 CAN Communication Error on TSC
to Ground
P1602 Starter Motor Relay Global Driver
P0629 Lift Pump Global Fault - Short Circuit
to Battery P1603 Functional Safety Fault
P062B Functional Safety Fault P1604 Functional Safety Fault
P062D Fuel Injector Driver Circuit Perfor- P1605 Functional Safety Fault
mance P1606 Functional Safety Fault
P062E Fuel Injector Driver Circuit Perfor- P2120 Hand Pedal Signal Track 1 Fault
mance P2125 Hand Pedal Signal Track 2 Fault
P062F Internal Control Module EEPROM P2135 Throttle/Pedal Position Sen-
Error sor/Switch "A"/"B" Voltage Correla-
P0630 VIN Not Programmed or Incompati- tion
ble - ECM/PCM P2138 Hand Pedal Signal Correlation Fault
P0641 Sensor Reference Voltage "A" Cir- P2147 Injector Voltage Supply Fault
cuit/Open P2148 Injector Voltage Supply Fault
P0650 Malfunction Indicator Lamp (MIL) P2226 Barometric Pressure Sensor "A" Cir-
Control Circuit cuit
P0651 Sensor Reference Voltage "B" Cir- P2228 Barometric Pressure Sensor "A" Cir-
cuit/Open cuit Low
P0655 Check Engine Light (CEL) Fault P2229 Barometric Pressure Sensor "A" Cir-
P0656 Fuel Level Output Circuit cuit High
P0668 PCM/ECM/TCM Internal Tempera- P2264 Water in Fuel Sensor Circuit
ture Sensor "A" Circuit Low P2265 Water in Fuel Sensor Circuit Range/
P0669 PCM/ECM/TCM Internal Tempera- Performance
ture Sensor "A" Circuit High P2266 Water in Fuel Sensor Circuit Low
P0685 ECM/PCM Power Relay Control Cir- P2267 Water in Fuel Sensor Circuit High
cuit/Open
P2269 Water in Fuel Condition
P0697 Sensor Reference Voltage "C" Cir-
cuit/Open P250B Engine Oil Level Sensor Circuit
Range/Performance
P1101 Rail Pressure Control Error Positive
Fault P256A Engine Idle Speed Selector Sen-
sor/Switch Circuit/Open
P1102 Rail Pressure Control Error Negative
Fault P256B Engine Idle Speed Selector Sen-
sor/Switch Range/Performance
P1103 Rail Pressure Fault
P256C Engine Idle Speed Selector Sen-
P1104 Injector Update Fault sor/Switch Circuit Low
P1105 Injector Update Fault P256D Engine Idle Speed Selector Sen-
P1106 Injector Update Fault sor/Switch Circuit High
P1107 Injector Update Fault U0001 High Speed CAN Communication
P1108 Injector Update Fault Bus
P1109 Injector Update Fault U0073 Control Module Communication Bus
P110A Injector Update Fault A Off
P110B Injector Update Fault U0100 Lost Communication with ECM/PCM
"A"
P1500 Foot Throttle/Pedal Fault - Limp
Home Mode U0121 Lost Communication With Anti Lock
Brake (ABS) Control Module
P1501 Foot Throttle/Pedal Fault - Reduced
Torque Mode

33 - 204 9813/4800-4 33 - 204

 33 - Electrical System
57 - Electronic Diagnostic
90 - Fault Codes

Code Description
U0401 Invalid Data Received From ECM/
PCM "A"
U3FFF SAE DTC does not exist - will require
manufacturer's specific

33 - 205 9813/4800-4 33 - 205

 33 - Electrical System
84 - Sensor

84 - Sensor

Contents Page No.

33-84-09 Speed Sensor .............................................................................................................. 33-207

33 - 206 9813/4800-4 33 - 206

 33 - Electrical System
84 - Sensor
09 - Speed Sensor

09 - Speed Sensor

Remove and Install

Consumables
Description Part No. Size
Special HP Grease 4003/2020 0.5 kg
4003/2017 0.4 kg
4003/2006 12.5 kg
4003/2005 50 kg

Remove
1. Disconnect the electrical connection from the
speed sensor.
2. Remove the speed sensor.
3. Remove the O-rings and discard them.
Figure 898.

Install
1. Apply grease to the new O-rings and attach them
to the speed sensor.
Consumable: Special HP Grease
2. Attach the speed sensor.
3. Tighten the speed sensor to the correct torque
value.

Table 277. Torque Values

Item Nm
A 23

33 - 207 9813/4800-4 33 - 207

Notes:

33 - 208 9813/4800-4 33 - 208