Section C: Service Manual - JS200, JS140 & JS205
Section C: Service Manual - JS200, JS140 & JS205
Electrics
Service Manual - JS200, JS140 & JS205
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body & Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section J - Track and Running Gear
Section K - Engine
Publication No.
9813/0400-2
World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section C - Electrics
Notes:
Service Procedure
Using a Multimeter .................................................................................. C-23
Measuring DC Voltage ....................................................................... C-24
Measuring Resistance ........................................................................ C-24
Measuring Continuity .......................................................................... C-25
Measuring Frequency ......................................................................... C-25
Testing a Diode or a Diode Wire ......................................................... C-26
Battery .................................................................................................... C-27
Maintenance ....................................................................................... C-27
Testing ................................................................................................ C-27
Specific Gravity Testing ...................................................................... C-29
Wiring Harness Repair ........................................................................... C-30
Introduction ......................................................................................... C-30
Repair Procedure ............................................................................... C-30
Harness Data
JS200 ..................................................................................................... C-33
Main Harness ..................................................................................... C-33
Facia Harness .................................................................................... C-37
Cab Harness ...................................................................................... C-38
AC Harness ........................................................................................ C-44
JS140 ..................................................................................................... C-45
Main Harness ..................................................................................... C-45
Cab Harness ...................................................................................... C-46
JS205 ..................................................................................................... C-47
Main Harness ..................................................................................... C-47
Cab Roof Harness .............................................................................. C-50
Instrument Harness ............................................................................ C-51
Cab Base Harness ............................................................................. C-53
Boom Lamp Harness .......................................................................... C-55
Battery Charge Lead Harness ............................................................ C-56
C-i C-i
Section C - Electrics
Contents
C-ii C-ii
Section C - Electrics
Item Description
48 Battery
49 Battery
50 Fuse
51 E Mode
52 P Mode
53 Servo Isolator
54 Slew Lock
55 Master Warning
56 Alternator
57 Air Filter
58 Coolant Pressure
59 Engine Oil Pressure
60 Hyd Oil Temp
61 Water Temp
62 Master Warning
38 37 36 35 35
50
34
49
48 33
39 41
40
32
31
30
1 29
28
2
47 27
3 26
4 25
9813/0400-2
24
5 44 23
43 45 46
42
6 22
7 21
8 20 19
51 18
52 17
53
54 16
55 15
Schematic Diagram
62 12
10
T056750
Fig 1. 229/01100 issue 5
C-3
C-4
9813/0400-2
Service Procedure
Using a Multimeter
TC-002
Fig 1. FLUKE 85
c On an analogue meter.
If there is continuity in the circuit, the beeper will 5 Touch or connect the red probe to the frequency
sound. If there is no continuity (open circuit), the source to be measured. Press and hold button if an
beeper will not sound. average reading is required.
c On an analogue meter.
A diode wire is a diode with male connector fitted on one i Select the Ohms 1000s (1k) range.
end and a female connector fitted on the other end. The
diode is sealed in heatshrink sleeving. Connect the black probe to the end of the
diode marked with a band, or to the male
1 To test a Diode or a Diode Wire connector of the diode wire, the red probe
should be connected to the other end of the
a On the FLUKE 85. diode or diode wire. The meter should read
20-400 kΩ, if it reads more than this the diode
i Turn the switch to position 1-D. is faulty.
ii Press the HOLD button and check that the H ii Select the Ohms 100s range.
sign appears at the top right hand side of the
display window. Connect the red probe to the end of the diode
marked with a band, or to the male connector
iii Connect the black probe to the end of the of the diode wire, the black probe should be
diode with a band or to the male connector of connected to the other end of the diode or
the diode wire. Connect the red probe to the diode wire. The meter should read 300-400Ω,
other end of the diode or diode wire. If the if it reads less than this the diode is faulty.
beeper does not sound the diode or diode wire
is faulty.
Battery
TC-001_4
Maintenance !MWARNING
To ensure that the battery provides optimum performance Batteries give off an explosive gas. Do not smoke
the following steps should be observed: when handling or working on the battery. Keep the
battery away from sparks and flames.
1 Make sure that the electrical connections are clean
and tight. Smear petroleum jelly on connectors to Battery electrolyte contains sulphuric acid. It can burn
prevent corrosion. you if it touches your skin or eyes. Wear goggles.
Handle the battery carefully to prevent spillage. Keep
2 When applicable - never allow the electrolyte level to metallic items (watches, rings, zips etc) away from the
fall below the recommended level - 6 mm (1/4 in) battery terminals. Such items could short the
above the plates. Use only distilled water for topping terminals and burn you.
up.
Set all switches to OFF before disconnecting and
3 Keep the battery at least three quarters charged, connecting the battery. When disconnecting the
otherwise the plates may become sulphated battery, take off the earth (-) lead first.
(hardened) - this condition makes recharging the
battery very difficult. Re-charge the battery away from the machine, in a well
ventilated area. Switch the charging circuit off before
Extra precautions must be taken when bench charging connecting or disconnecting the battery. When you
maintenance free batteries, they are more prone to have installed the battery in the machine, wait five
damage by overcharging than the standard type of battery: minutes before connecting it up.
– Never boost-charge a maintenance free battery. When reconnecting, fit the positive (+) lead first.
5-3-4-12
– Never charge a maintenance free battery at a voltage
in excess of 15.8 Volts.
Testing
– Never continue to charge a maintenance free battery
after it begins to gas.
This test is to determine the electrical condition of the
battery and to give an indication of the remaining useful
'life'.
Note: Do not hold the switch in the LOAD position for more
than 10 seconds.
Specific Gravity Testing Readings should be as tabulated and should not vary
between cells by more than 0.04. A greater variation
The specific gravity of the electrolyte gives an idea of the indicates an internal fault on that particular cell.
state of charge of the battery. Readings should be taken
using a hydrometer, when the electrolyte temperature is If the electrolyte temperature is other than 15°C (60°F) a
15°C (60°F). If the battery has recently been on charge, 'correction factor' must be applied to the reading obtained.
wait approximately one hour (or slightly discharge the Add 0.07 per 10°C (18°F) if the temperature is higher than
battery) to dissipate the surface charge before testing. 15°C (60°F) and subtract the same if the temperature is
lower.
Introduction !MCAUTION
Instances do occur where it is necessary to incorporate When the heater is in use, the reflector and the air
auxiliary electrical components into existing electrical coming out are extremely hot. Keep away to avoid
circuits and, although unlikely with present wiring accidental burns. Do not touch the reflector until it has
harnesses, repair or replace specific individual wires within had time to cool down after switching off. If flame
a harness. This will also apply to other machines in reappears at the reflector when the heater is in use, the
addition to those of manufacture. catalytic element is damaged or used up. Stop work
immediately and replace the heater.
To ensure that either the inclusion of an auxiliary electrical ELEC-2-3
component or a repair within a harness is completed to an
acceptable standard it is strongly recommended that the Repair Procedure
following tools, equipment and procedures are always
used. Note that JCB harnesses have an International Table 3. Tools Required
Protection rating of 67 (I.P.67). Part No. Description Qty
892/00350 Butane Heater assembly 1
The sheath covering of the recommended splice is heat
shrunk onto the original wire insulation. This results in a 892/00349 Crimp tool 1
seal and corresponding joint to IP 67 specifications. 892/00351 Splice 0.5-1.5 mm (Red) 50
892/00352 Splice 1.5-2.5 mm (Blue) 50
!MCAUTION 892/00353 Splice 3.0-6.0 mm (Yellow) 50
When installing Auxiliary Electrical Components
always ensure that the additional load rating is 1 Cut the wire and remove the protective insulation for
suitable for that particular circuit. It is unacceptable to a suitable distance dependent upon the size of wire
simply increase the fuse rating as this can cause and splice to be used. For the splices detailed in
overloading and consequential failure of wiring, along K Table 3. ( T C-30), the dimension is 7mm.
with failure of integral circuit components, which the
fuse is protecting.
ELEC-2-1
!MWARNING
In addition to the warnings incorporated into this
procedure, extreme care should be taken when
handling the gas heating tool to ensure that the flame
does not damage or set fire to any items in the vicinity
of the repair, i.e. other wires, floor panels, floor mats,
sound proofing, paintwork, etc. This tool should not
be used in any restricted location prohibiting the use
of "Naked Flames" or where risk of explosive gas or
similar safety parameters apply. No other heat source
should be used to attempt a sealed joint. Fig 5.
ELEC-2-2
2 Using the correct sized splice, attach the new section
of wire required or auxiliary flying lead to the existing
harness and secure using the crimp tool.
K Fig 5. ( T C-30). Note that each of the splices
detailed is colour-coded to make size and range
Fig 8.
d Turn the small ring 9-E so that the air holes at 9-F
are completely closed.
Fig 6.
Fig 9.
e Turn the red ring 10-D to the right (in the direction
of the plus sign) in order to turn on the gas.
Fig 7.
Important: Before turning the heater on, make sure that
c Position the tube hanging down from inside the
the cartridge is not hotter than the reflector element. This
reflector assembly into the hole at the top of the
may occur if the cartridge is held in the hand for a long
gas cartridge. Then press the gas cartridge up
time. The temperature difference between the cartridge
into the reflector assembly as far as possible until
and the reflector element may cause long yellow flames to
the two elements are clasped firmly together.
appear on ignition.
K Fig 8. ( T C-31). A click will be heard.
Fig 10.
Fig 13.
Harness Data
JS200
Main Harness
Note: All wires are yellow colour
T056760
Fig 2. 332/P1386-3 sheet 1 From 1308803 and 1909000
T056760-2
Fig 3. 332/P1386-3 sheet 2 From 1308803 and 1909000
Connector Identification
9813/0400-2
T056780
Fig 4. 229/01222-1 sheet 1
Section C - Electrics
Harness Data
JS200
C-37
Section C - Electrics
Harness Data
JS200
Cab Harness
Note: All wires are yellow colour
Connector Identification
2
T056770
Fig 6. 333/P6340-1 sheet 1 (1309166-1772752) and (1909000-1909173)
1
3
T056770-1
Fig 7. 333/P6340-1 sheet 2 (1309166-1772752) and (1909000-1909173)
AC Harness
Note: All wires are yellow colour
Connector Identification
JS140
Main Harness
Note: All wires are yellow colour
Connector Identification
Connector Identification
9813/0400-2
Section C - Electrics
Fig 13. 229/02695-1
Harness Data
JS140
C-46
JS205
C-47
Main Harness
9813/0400-2
Section C - Electrics
Harness Data
D068710
Fig 14. JS205 (334/P1440) (Sheet 1 of 2)
JS205
C-47
Section C - Electrics
Harness Data
JS205
D068710-1
Fig 15. JS205 (334/P1440) (Sheet 2 of 2)
C-48 9813/0400-2 C-48
Section C - Electrics
Harness Data
JS205
D068710-9
Fig 16. JS205 (335/A8135)
C-49 9813/0400-2 C-49
Section C - Electrics
Harness Data
JS205
D068710-2
D068710-11
Section C - Electrics
Fig 23. JS205 (334/L5447)
Harness Data
JS205
C-56