Engine Throttle Control

Section C - Electrics
Basic System Operation - JS330 Tier II

Component Identification
JS330 Tier II
The item numbers in the following table are identified on the wiring schematics in this section. K Fig 3. ( T C-5)
Item Part Number Description Location

1 728/18500 Electronic control unit 1 Behind the rear cab panel.
2 728/80069 Electronic monitor system Front of cab.
3 701/80168 Facia switch panel Right hand side of cab.
4 721/10430 Fusebox Behind the rear cab panel.
5 716/30070 Throttle dial On Right hand console.
6 KHR1868 Key switch On Right hand console.
7 701/80214 Switch (redundancy) Behind the drivers seat.
8 30/925367 Air conditioner/heater Below the rear cab panel.
9 701/20000 Switch (air con) On Right hand console.
10 701/58848 Switch cap (worklamp) On Right hand console.
11 701/60031 Switch body Under right hand console.
12 701/58848 Switch boom priority On Right hand console.
13 717/30000 Cigar lighter (12v) On Right hand console.
14 717/09200 Radio cassette Rear of cab in the roof.
15 701/80215 Limit switch (lever) Below the lever lock bar.
16 701/60041 Switch (cab light) Outer side of left hand console.
17 JHR0176 Switch travel change Outer side of left hand console.
18 700/43900 Work lamp Toolbox
19 JHR0151 Work lamp Boom
20 JRR0076 Breaker pilot switch Under the cab on the breaker pedal.
21 25/221094 LH Lever switch Left hand joystick.
22 25/221095 RH Lever switch Right hand joystick.
23 JHR017 Relay radio
25 6900/0624 Wiper Front windscreen.
26 6900/0587 Room lamp Rear of cab in the roof.
27 716/30205 Battery relay In the left hand side compartment.
28 708/10021 Battery In the left hand side compartment.
31 716/30091 Stop relay In the right hand side pump bay.
32 928/60124 Solenoid valve In the right hand side pump bay.
33 25/220651 Solenoid valve Under cab.
34 01/145161 Engine Rear of machine.
C-3 9803/6540-4 C-3

Item Part Number Description Location

35 JHR0185 Pilot switch, upper Bottom switch on Right hand side of Main Control Valve.
36 JHR0186 Pilot switch, travel Top switch on Right hand side of Main Control Valve.
37 701/80284 Pilot switch On manifold under cab.
38 716/92300 Throttle position sensor In the right hand side pump bay.
39 928/60027 Engine control solenoid In the right hand side pump bay.
40 717/07700 Travel alarm Below the counterweight.
41 20/925334 Pump In the right hand side pump bay.
42 JNH0027 Refuel pump Toolbox
43 JRR0053 AC supression lead
44 700/26700 Beacon Centre section.
45 714/40226 Air con compressor Front of engine.
46 30/925629 Air con binary switch On air-conditioning condenser in the radiator bay.
47 704/36300 Horn Between the boom rams.
48 JHN0160 Washer bottle Toolbox.
49 AEH0021 Pre-heat relay In the left hand compartment under the battery relay.
50 716/30129 Temperature sensor In the hydraulic pump suction tube.
51 701/80328 Overheat switch In the hydraulic pump suction tube.
52 716/30061 Fuel level sensor In Left hand side of fuel tank.
53 331/13929 Coolant level switch In the expansion bottle in the radiator bay.
54 JNH0070 Air filter clog switch In the air induction tube.
55 701/80199 Overload pressure switch Back of the manifold between the boom ram feet.
59 701/60031 Switch body
64 721/10455 Hammer only connector
65 721/11632 Hammer/Aux switch
66 701/80223 Hammer/Aux/Merge switch
67 701/60032 Switch body
68 721/10458 Hammer/Aux/Merge link harness
86 701/80240 Heater switch
88 JSJ0083 Direction control valve
89 25/221009‘ Valve solenoid
Note: Items 64 to 68 are part numbers for the bridging

harnesses and switches for the option switch in the Right
hand console
C-4 9803/6540-4 C-4

Schematic Diagram
Schematic Diagram
Fig 3. 331/30315 issue 4

C-5 9803/6540-4 C-5
Schematic Diagram
64
C160 C160
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
66
65
8 7 6 5 4 3 2 1 10 9 14 3 13 11 16 6 12 15
67 68
C160 C160 8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
A408580
Fig 4.
G
F
H I
A408581
Fig 5.
E Multiple cables
F Single cables
G Cables joined
H Cable not joined
I Earth cables
C-6 9803/6540-4 C-6

Engine Throttle Control
Engine speed is controlled by the electro hydraulic throttle cylinder (throttle actuator), a throttle position sensor, an
control system. The system consists of a proportional engine speed sensor and throttle dial (potentiometer).
pressure reducing valve (throttle control valve), a hydraulic
ECU1
Throttle Dial
Throttle Dial
Input I/p A29
Engine Speed Idle Full Speed

Sensor Input Position Position
I/p A32
Engine Speed Sensor
Throttle
Position
Sensor Input
I/p A39
Throttle Position Sensor
Throttle Actuator
Throttle Control Valve
Throttle
Control Valve
Output
I/p C21
Fig 19.
C-15 9803/6540-4 C-15

Throttle Control System

E
Throttle control is achieved by an electro-hydraulic
proportional solenoid. The ECU supplies a modulated
output (which is determined by the working mode selected
A
and throttle dial position) the throttle control valve works as
a pressure reducing valve and supplies hydraulic pressure
to the throttle actuator which in turn moves the throttle
cable to increase/decrease engine speed. A sensor on the
throttle lever gives feedback to the ECU on the throttle
lever position. B
Throttle Control Circuit C
Further developments to improve the operation of the
throttle and also to protect the engine against poor F
operator driving procedures have been made.
D
If the engine is started with the throttle dial above the ¼ full
speed position, the engine will start at idle. No engine Fig 20.
speed control will then be possible until the operator turns
the throttle dial to a position which is lower than the ¼ full Note: Throttle position sensor (behind the throttle lever).
speed position. The throttle control will then function as
normal. – Throttle control valve A
– Throttle linkage B
If the operator stops the engine from full speed then the – Throttle actuator C
throttle actuator will ramp down over a two second time
period, reducing the engine rpm before stopping. – Stop solenoid D
– Throttle cable E
If the operator has selected the one touch idle function – Stop cable F
before stopping the engine, then when the engine is
restarted the throttle control will still be in one touch idle
function (i.e. the ECU remembers that one touch idle was
selected).
C-16 9803/6540-4 C-16

Throttle PWM ECU1 EMS

CAN Data
Sol. Valve O/p1 (C-21)
RPM
Flywheel I/p 17 (A-32)
Throttle volume pot (5K Ohm)

I/p 8 (A-29)
Throttle lever (5K Ohm)

I/p 6(A-39)
Ignition Switch
sys 22(B-5)
Fig 21.
Operation When the throttle system is calibrated, the throttle dial has
to be moved between minimum and maximum positions;
Engine speed is controlled by the pressure from the this gives the ECU the operating parameters of the dial.
throttle control valve moving the throttle actuator, which in The ECU will then send a 90% duty cycle to the
turn moves the throttle linkage. The output pressure from proportional solenoid (much more than required), and the
the throttle control valve is determined by the PWM signal throttle linkage will move to the maximum stop position on
supplied to the valve from the ECU. the injection pump and also compress the spring damper.
The engine speed sensor will tell the ECU the speed of the
The PWM signal supplied to the throttle control valve by engine at all times, by sending a frequency to the ECU.
the ECU is determined by:
The ECU will start to reduce the duty cycle down from 90%
– Throttle dial position in 1% increments. This will take out the compression in the
– Mode selected damper, but not change the engine RPM until the duty
cycle gets down to approx. 60%.
– Auto idle / one touch idle selected or not.
When the engine speed does change, the ECU
As pressure is supplied to the throttle actuator it moves the remembers the position of the lever potentiometer. This
throttle linkage. The movement of the throttle linkages becomes maximum revs for 'A' mode, the engine revs
adjusts the position of the throttle lever potentiometer; this reduce by 100 rpm and the ECU remembers the position
then gives a voltage signal to the ECU, indicating the of the lever potentiometer, this becomes 'E' mode’s
position of the throttle linkage. When the ECU detects that maximum engine speed. The procedure is then repeated
the throttle linkage is in the correct position the ECU keeps for 'L' & 'P' modes (which are the same engine rpm). The
the duty cycle in such a condition as to hold a constant ECU ramps down the duty cycle, which in turn reduces the
position of the lever potentiometer, and thus holding a engine speed.
constant engine speed.
When the engine speed will not reduce any more, (due to
The system also has a self checking facility, when starting the set up of the cable) i.e. the frequency of the transducer
the machine the ECU will detect the closed (Idle) not changing. The ECU remembers the position of the
resistance setting of the throttle position sensor. The lever potentiometer; this will be approx. 20% duty cycle.
resistance value should be within 5% of previously
recorded idle resistance value. If not within tolerance or if From the calibration process the ECU now has the
the operator changes the position of the throttle dial operating range of the throttle dial and the corresponding
potentiometer, and after 20 seconds the targeted value of positions for the lever.
throttle position sensor has been detected by the EMS (i.e.
throttle linkage has not moved to correct position), then Note: not the same voltage signals back to the ECU
display will show the error message 'No Throttle'.
C-17 9803/6540-4 C-17

If the machine is switched off before completing
calibration, when the machine is restarted then EMS will
display the message 'Calibrate' and throttle calibration will
have to be done again.
C-18 9803/6540-4 C-18

C-19
39
C68 ENGINE CONTROL S.V.
5 R 1
1 2 3 C22 B 2
THROTTLE VOLUME DIAL
1
SG
SR
B
ECU1 C8 C2
CONN A CONN B
31 SU R A
+5V REF
34
C87
20 S SU D
0V REF ENGINE SPEED SENSOR
WY 1
29 SR S E S 2
I/P 8 THROTTLE VOL.
32 WY WG G
I/P 17 ENGINE SPEED
39 WG WY M
I/P 6 THROTTLE LEVER
9803/6540-4
C67
C8 C1 38
ECU1-A ECU1-A SU 2
I/P 25 AUTO MODE P SW GW WG 3

S 1
C9
CONN B
AUTO MODE P SW
5 P
IGNITION
C10
CONN C
4
21

R
O/P 1 THROTTLE CONT.
14 5A
P
+24V IGNITION
A406970
Fig 22.
C-19
Engine Throttle Control for each mode
ECU1
Throttle PWM EMS
Sol. Valve O/p 1 (C-21)
CAN Data A, E, P, L
I/p 17 (A-32)
Flywheel Mode
I/p 6 (A-29)
I/p A-29
Throttle volume pot (5K Ohm)
Throttle lever (5K Ohm) I/p 6 (A-39)
Upper pilot switch

I/p 26 (A-6)
Travel pilot switch I/p 27 (A-16)
Auto mode pilot I/p 25 (A-4)

switch
Fig 23.
Operation
E Economy
The JS machine can operate in one of four different A Auto
modes, depending upon the application required. The P Precision
modes are selected by the “Mode” button on the EMS. The
EMS displays the selected mode alongside the power L Lifting
mode legend. Selecting the different modes has the effect
of setting the maximum possible engine speed for each “A” Auto Mode
working mode. Successive presses of the Mode switch will
cycle through the different modes in the order as shown In Auto mode the EMS displays “AUTO” and the letter “A”
below. next to the power mode icon. The engine is allowed to
operate over its selected rev range as defined by its
Note: The last operating mode when the machine was programmed rev limit and the throttle sense input, (ECU1
stopped will be restored when the machine is restarted. I/p6) in direct proportion to the throttle input. The maximum
rev limit is the same as the maximum permissible engine
revolutions.
E A P L
When in auto mode the auto idle feature is permanently
active, if the throttle dial position is changed, the engine
Fig 24. speed will not change until either the travel p SW (I/p 27),
the upper p SW (I/p 26) or the auto mode p SW (I/p 25) are
closed.
C-20 9803/6540-4 C-20

When the upper pressure switch is closed the engine then down to 70% of this position for the pre-set auto idle
speed will rise to full speed less 100 rpm (or in proportion time, after which it will drop to idle.
to the throttle target input if less than 100%). When the
upper pressure switch re-opens the engine speed will When the travel pressure switch is closed, the engine
remain at this position for 3 seconds and then drop to 70% speed will rise to the full available engine speed. When the
of this position for the pre-set auto idle time, after which it travel pressure switch re-opens the engine speed will
will drop to idle. remain at full for three seconds, then will drop to the full
speed less 100 rpm for the pre-set auto idle time, after
When the auto mode pressure switch is closed, the engine which it will drop to idle
speed will rise to the full available engine speed. When the
auto mode pressure switch re-opens the engine speed will The engine speed will vary according to the following
drop to the full speed less 100 rpm for three seconds and characteristic: K Fig 25. ( T C-21)
A. Auto Mode Pressure

Switch
A
B. Upper Pressure Switch
B
C. Travel Pressure Switch C
D. Full Auto 2150 rpm D

E. Economy 2050 rpm E
F. Intermediate 1735 rpm F
G. Auto Idle 1200 rpm

H. Idle 1000 rpm G
H
Fig 25.
Note: Xs denotes the auto idle time as determined in the

EMS (5-30 seconds).
C-21 9803/6540-4 C-21

“E” Economy mode.
In standard mode the EMS displays “ECONOMY” and the

letter “E” next to the power mode icon. The engine is
allowed to operate over its selected rev range as defined
by its programmed rev limit and the throttle sense input,
(ECU1 I/p A 39) in direct proportion to the throttle input.
However the maximum rev limit of 100 rpm less than the
maximum permissible is imposed. Thus for a full throttle
potentiometer setting the engine revolutions is 100 lower
than it would be in the Auto mode.
“P” Precision
In Precision mode the EMS displays “PRECISION” and the

letter “P” next to the power mode icon. The engine is
allowed to operate over its selected rev range as defined
by its programmed rev limit and the throttle sense input,
(ECU1 I/p A 39) in direct proportion to the throttle input.
However the maximum rev limit of 200 rev/min less than
the maximum permissible is imposed. Thus for a full
throttle potentiometer setting the engine revolutions is 200
lower than it would be in the Auto mode, the same as it is
for Lifting mode.
“L” Lifting mode
In Lifting mode the EMS displays “LIFTING” and the letter

“L” next to the power mode icon. The engine is allowed to
operate over its selected rev range as defined by its
programmed rev limit and the throttle sense input, (ECU1
I/p A 39) in direct proportion to the throttle input. However
the maximum rev limit of 200 rev/min. less than the
maximum permissible is imposed. Thus for a full throttle
potentiometer setting the engine revolutions is 200 lower
than it would be in the Auto mode, the same as it is for
Precision mode.
C-22 9803/6540-4 C-22

Relationship between mode and engine revolutions rev/min. less than the maximum speed possible, E mode
per minute maximum and 200 rev/min. less than maximum P+ L mode
maximum.
During calibration the ECU detected the maximum
possible engine speed, and noted the position of the When the working mode is selected the ECU will scale the
throttle position sensor. This point became A mode full deflection of the throttle dial (O~ 5v) to adjust the
maximum. Next the controller found the position of the engine speed between the idle position and the maximum
throttle position sensor when the engine speed was 100 speed for the particular mode selected.
Maximum Possible
Maximum Permissible
“A” mode Max.
REV/MIN
“E” mode Max.
-100 RPM
-100 RPM
“P & L” mode max.
Idle
5K Ohm Throttle Potentiometer

Fig 26.
C-23 9803/6540-4 C-23

Stop Solenoid Setting Procedure 6 Ensure the cable outer is positioned centrally and in-
line, avoiding any kinks in the cable.
1 Park the machine on firm and level ground. Stop the
engine and remove the starter key. 7 Tighten the nuts G to retain the setting and remove
the fixture/spacer B fitted in step 3.
2 Gain access to the AMS Stop Cable.
8 Manually push and release the solenoid A to ensure
3 Push and hold the solenoid A FULLY-IN. A suitable free movement of the cable
size fixture or spacer B may be used to hold this
position. K Table 1. Fixture/Spacer Length The system should then be tested to ensure fuel
( T C-24) This section should take up all the available delivery ceases when the solenoid is de-energized. if
solenoid travel. fuel is still being fed in this state and the engine over-
runs, please do the following
Table 1. Fixture/Spacer Length
Model Length X a Loosen the M10 Thin Nut H securing the solenoid
adjustment M10 capscrew J
JS330 20mm (0.8 in.)
b Wind-out the M10 capscrew J slowly until the
4 K Fig 27. ( T C-24) Fit the nipple end of the cable C engine stops.
into the fuel cut-off lever D and place the threaded
outer into the mounting bracket E on the engine. c Tighten the M10 Thin Nut H and retest for engine
Ensure that the washer F and securing nut G is over-run with the solenoid de-energized.
positioned either side of the bracket.
Note: This process can also be used to take up any cable
5 Adjust the cable using the nuts F and washers G to stretch encountered.
remove any slack Y from the cable. Check at this
stage that the fuel cut-off lever is in the ‘FULL RUN
POSITION’ FR and is full on the stop.
Fig 27.
C-24 9803/6540-4 C-24

Engine Throttle Control

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Section C - Electrics

Basic System Operation - JS330 Tier II

Item Part Number Description Location

C-3 9803/6540-4 C-3

Item Part Number Description Location

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

C-4 9803/6540-4 C-4

Fig 3. 331/30315 issue 4

C-6 9803/6540-4 C-6