ServiceManual(Supplement)

AMSJS Machines

PUBLISHED BY THETECHNICAL PUBLICATIONS DEPARTMENT

OF JCB SERVICE: ©WORLD PARTS CENTRE

UTTOXETER, STAFFORDSHIRE, ST14 7BS,ENGLAND

Tel. ROCESTER (01889) 590312PRINTED IN ENGLAND

Publication No. 9803/6450

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General Information

Care & Safety

Routine Maintenance

Attachments

Body & Framework

Electrics

1

2

3

A

B

CHydraulics E

FTransmission

GBrakes

JTrack & Running Gear

KEngineIssue 3

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Section 1 General Information

9803/3642E

Section 1

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Issue 2*

Contents Page No.

IntroductionCare and Safety 1 - 1

1 - 1

Section 1 General Information

9803/6450

Section 1

1 - 1

Issue 2*

Introduction

The JCB A.M.S system (Advanced Management System) isa whole machine electronic control system which replacesthe CAPS II system. The system controls engine speed,pump power, transmission, excavator functions, lights,wiper, auxiliary circuits, warning lamps, etc.

This manual is a supplement to the following JS XOMachine Service Manuals:

Manual No. Machine No. Serial No.9803/6410 JS 130

JS 160

9803/6310 JS 130WJS 145WJS 160WJS 175W

9803/6400 JS 200JS 220JS 240JS 260

9803/6320 JS 200W

9803/6420 JS 330JS 450JS 460

Note: Only those areas of the machines which are differentfrom the standard version are dealt with here. For all otheraspects refer to the above manuals.

Care and Safety

Before carrying out any maintenance procedures on thismachine, make sure you read the Care and Safetyinformation in Section 2 of the above Service Manuals . Therelevant information in that Section should be observed aswell as any care and safety information contained in thismanual.

A296531

A335431

Tracked Machine

Wheeled Machine

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Section C Electrics

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Section C

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Issue 1*

Schematic Diagram

6 5

79

8180

82 83

14 3 13 11 16 6 12 15

12345678 12345678 12345678 12345678

NO CONNECTION

AUXILLARY ONLY

C160 C160C160

BREAKER ONLY

HAMMER/AUXILLARYCOMBINED& MERGED PUMP

C160

HAMMER/AUXILLARYCOMBINED

13 47 28 910

14

81

1

12

2

109

80

6

13

38

79

6 15

5

3

7 4

C160

HAMMER/AUXILLARYCOMBINED& MERGED PUMP

11 16

84

12345678 12345678 12345678

NO CONNECTION

AUXILLARY ONLY

C160 C160

BREAKER ONLY

C160

HAMMER/AUXILLARYCOMBINED

82

13 47 28 6 5

2 1

C1608

8 52 43 1

80

7

83

HAMMERTAB

56 3

67

4 78

82 84

80

81

15

C1606 5 4 12

JS330HAMMER/AUXILLARYCOMBINED& MERGED PUMP

14 3 11 13 16 6 12

312345678 12345678

10

NO CONNECTION

BREAKER ONLYMONOBOOM

C160 C160

HAMMER/AUXILLIARYMONOBOOM

13 47 28 6 5 9

JS130 - JS260 Connection for optional hydraulic circuits (331/18657)

JS330 Connection for optional hydraulic circuits (331/18659)

JS 200W Connection for optional hydraulic circuits (331/18660)

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Section C Electrics

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Section C

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Issue 1

Cab Layout

8 Control Lock Lever

9 Left Console

10 Door Lock Release Lever

11 Optional Circuit Pedal (if fitted)

12 Facia Panel

13 Lightswitch Panel

1 Right Console

2 Right Excavator Joystick Control

3 Display Monitor

4 Right Hand Track Control

5 Left Hand Track Control

6 Travel Speed Range Change Switch

7 Left Excavator Joystick Control

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Location of Controls and Components - JS Tracked machine

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Section C Electrics

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Section C

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Issue 2*

Cab Layout

*Location of Controls and Components - JS130W/145W/160W/175W

1 Left Excavator Joystick ControlSlew and dipper.

2 Horn Button

3 Alternative Horn Button (Not Germany)

4 Steering Wheel

5 Steering Column Lock Latch

6 Multipurpose Steering Column Switch

7 Foot Brake Pedal

8 Gearbox Ratio Change Switch

9 Right Excavator Joystick ControlBoom and bucket.

10 One Touch Idle Switch

11 Display Monitor

12 Left Console

13 Right Console

14 Travel Pedal

15 TAB Position Ram Pedal (if fitted)

16 Rockbreaker ON/OFF Switch (if fitted)

17 Auxiliary Circuit Switch

18 Dozer Blade Switch

19 Right Switch Panel

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Section C Electrics

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Section C

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Issue 1

Cab Layout

Location of Controls and Components - JS200W

1 Left Excavator Joystick ControlSlew and dipper.

2 Horn Button

3 Alternative Horn Button (Not Germany)

4 Steering Wheel

5 Steering Column Lock Latch

6 Multipurpose Steering Column Switch

7 Foot Brake Pedal

8 Gearbox Ratio Change Switch

9 Right Excavator Joystick ControlBoom and bucket.

10 One Touch Idle Switch

11 Display Monitor

12 Left Console

13 Right Console

14 Travel Pedal

15 TAB Position Ram Pedal (if fitted)

15 Rockbreaker ON/OFF Switch (if fitted)

16 Boom Priority Switch

17 Auxiliary Circuit Switch

18 Dozer Blade Switch

19 Right Switch Panel

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Section C Electrics

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Section C

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Issue 1

Cab Layout

Right Console - Tracked machine only

1 Starter Switch

This key operated rotary switch has four positions. Thekey can only be inserted or removed in the OFFposition. The positions are:

OFF - Isolates all electrics.

Turning key to this position stops the engine and, ifappropriate, silences the warning buzzer.

HEAT: For pre-heating the engine air intake duringcold weather, key must be held in this position.Returns to OFF when key is released.

ON - Switch position for normal running.

START: Key held in this position cranks the startermotor for starting the engine. Release the key whenthe engine starts and the switch returns to ON.

2 Throttle Dial

This rotary control provides progressive engine speedcontrol over the full range.Note: If the engine speed does not change even afterturning the throttle dial it is because the idle switch (6)is ON. Push the idle switch to OFF to re activate thethrottle dial.

If the engine is started with the throttle dial not at theminimum position, no engine speed control will bepossible until after the dial has been turned to theminimum position.

3 Hammer switch (if fitted)

Press the switch to change the additional hydrauliccircuit from hammer (reduced flow) circuit to auxiliary(full flow) circuit.

A335442

HEAT

START

ON

OFF

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Section C Electrics

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Section C

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Cab Layout

Right Console - Tracked machine only(cont'd)

4 Boom Priority Switch-if fitted (Standard on JS330)

Press the switch to change priority of boom raise toswing. Selecting the boom priority switch duringsimultaneous slew and boom operation will restrict flowto the slew motor and therefore give more flow to theboom up operation.

When the switch is pressed the monitor will display“BOOM PRIOR” acknowledgement message.

5 Power-up Button

With the Work Mode Selection switch in ‘H’ or ‘S’mode, depression of the button initiates the applicationof maximum digging power for a period of 8 seconds,during which time the ‘POWER UP’ message isdisplayed on the Display Monitor.

6 One Touch Idle Switch

Pressing this switch instantly changes the engine rpmback and forth between that selected for working and a‘low idling’ speed. When ‘low idling’ has been selectedthe message “LOW IDLE” is displayed on the DisplayMonitor. This facil i ty is overridden when theManual/Auto Change switch is set to ‘Auto’.

7 Auxiliary Circuit Switch

This three-position rocker switch, spring loaded to thecentral OFF position, provides bi-directional flow forrelevant attachments, e.g. weedcutter, grab rotate.Press and hold the switch to the right or left, asappropriate, for as long as the attachment is to beused. Release the switch to turn off the attachment.

Lightswitch Panel

Work Light Switch

Press the switch A to the first position to switch ONthe Standard work lights (on boom and the right handof the machine). Press the switch to the secondposition to switch ON the optional lights (on the caband the counterweight - if fitted).

Heater Fan

Turn rotary switch B (on the lightswitch panel)clockwise to turn on the heater fan. The volume of airfrom the heater increases by rotating the switchclockwise to the next position.

A350860

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Section C Electrics

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Section C

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Issue 1

Cab Layout

Right Console - Wheeled machine only

1 Starter Switch

This key operated rotary switch has four positions. Thekey can only be inserted or removed in the OFFposition. The positions are:

OFF - Isolates all electrics except side lights andhazard lights.

Turning key to this position stops the engine and, ifappropriate, silences the warning buzzer.

HEAT: For pre-heating of the engine air intake duringcold weather, key must be held in this position.Returns to OFF when key is released.

ON - Switch position for normal running.

START: Key held in this position cranks the startermotor for starting the engine. Release the key whenthe engine starts and the switch returns to ON.

2 Throttle Dial

This rotary control provides progressive engine speedcontrol over the full range.Note: If the engine speed does not change even afterturning the throttle dial it is because the idle switch (8)is ON. Push the idle switch to OFF to re activate thethrottle dial.

If the engine is started with the throttle dial not at theminimum position, no engine speed control will bepossible until after the dial has been turned to theminimum position.

3 Hazard Warning Switch

Press the switch to switch ON the hazard warninglights. Hazard warning lights can be turned ON with orwithout the ignition ON.

4 Fog Light Switch

Press the switch to switch ON the fog l ights(Headlights must be ON).

A335441a

HEAT

START

ON

OFF

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Section C Electrics

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Section C

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Issue 1

Cab Layout

Right Console (cont'd)

5 Rockbreaker switch (if fitted JS200W only)

For monoboom equipped machines:A The switch has two positions, press the switch to

change the additional hydraulic circuit fromrockbreaker (reduced flow) circuit, position 1 toauxiliary full flow position 2.

For triple articulating boom equipped machines:A When a rockbreaker circuit only is fitted, the switch

has two positions. Press the switch to change thefunction of the foot pedal from rockbreaker, position 1to boom position control, position 2.

B When combined rockbreaker and auxiliary circuits arefitted, the switch has three positions. Press the switchto change the function of the foot pedal fromrockbreaker (reduced flow) circuit, position 1 toauxiliary (full flow) circuit position 2. Press further tochange to boom position control circuit position 3.

6 Boom Priority Switch (JS 200W only)

Press the switch to change priority of boom raise toswing. Selecting the boom priority switch duringsimultaneous slew and boom operation will restrictflow to the slew motor and therefore give more flow tothe boom up operation.

When the switch is pressed the monitor will display“BOOM PRIOR” acknowledgement message.

7 Power-up Button

With the Work Mode Selection switch in ‘H’ or ‘S’mode, depression of the button init iates theapplication of maximum digging power for a period of8 seconds, during which time the ‘POWER UP’message is displayed on the Display Monitor.

8 One Touch Idle Switch

Pressing this switch instantly changes the engine rpmback and forth between that selected for working anda ‘low idling’ speed. When ‘low idling’ has beenselected the message ‘LOW IDLE’ is displayed on theDisplay Monitor. This facility is overridden when theManual/Auto Change switch is set to ‘Auto’.

9 Auxiliary Circuit Switch

This three-position rocker switch, spring loaded to thecentral OFF position, provides bi-directional flow forrelevant attachments, e.g. weedcutter, grab rotate.Press and hold the switch to the right or left, asappropriate, for as long as the attachment is to beused. Release the switch to turn off the attachment.

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A350950

A

B

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Section 2 Electrics

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Section 2

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Issue 1

Cab Layout

Lightswitch Panel

Drive Light Switch

Press switch C to the first position to switch ONthe side lights. The side lights can be turned ONwith or without the ignition being switched ON.Press the switch to the second position to switchON the headlights (the ignition must be ON).

Work light Switch

Press switch B to the first position to switch ONthe Standard work lights (on boom and the righthand of the machine). Press the switch to thesecond position to switch ON the optional lights(on the cab and the counterweight - if fitted).

The side lights must be ON in order to turn ON thework lights.

Heater Fan

Turn rotary switch A clockwise to turn on theheater fan. The volume of air from the heaterincreases by rotating the switch clockwise to thenext position.

A350870

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Section C Electrics

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Section C

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Issue 1

Cab Layout

Left Console - Tracked machines only

1 Horn Switch

When the horn switch is pressed the horn will sound.

Note: always press the switch and sound the horn to givesignals, when the machine is started or you engagetravel or slew.

2 Control Lock Lever

Raising the lever provides a method of isolating thehydraulic controls in addition to raising the LeftConsole or operating the Servo Isolator Switch andis an integral part of the procedure for vacating thecab. Lower the lever to activate the hydraulic controls.

3 Boom Priority Switch (Option)

Press and hold the switch to change priority of slew toboom raise. Release the switch to deselect boompriority.

A335460

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Section C Electrics

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Section C

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Issue 1

Cab Layout

Left Console - Wheeled machines only

1 Console Tilt Handle

Turn the tilt handle anti-clockwise to unlock theconsole which can then be hinged up and down.Raising the console provides a method of isolating thehydraulic controls (in addition to operating the ServoIsolator Switch (on the facia panel) or raising theControl Lock Lever (step 5)) and is an integral part ofthe procedure for vacating the cab. Release thehandle and lower the console to the operating positionwhere it locks.

Note: For JS200W and German and Italian JS130W/160Wmachines - When the console is in the raised position,all controls except travel are isolated. When travellingon roads,raise the left console to prevent theaccidental movement of the excavator end.

2 Left Console Switch Panel

3 Dozer Switch

This switch transfers Left Excavator Joystick controlsfrom the slew and dipper to the dozer blade and vice-versa. Press the left side of the switch to select dozerand illuminate the Dozer Selected lamp (see WarningLight Panel, Monitor Panel); press the right side torevert to slew and dipper. When ‘dozer’ is selected,push the joystick forward to lower the dozer and pull itback to raise the dozer. Release the joystick to stopdozer movement.

4 Horn Switch

When the horn switch is pressed the horn will sound.

Note: always press the switch and sound the horn to givesignals, when the machine is started or you engage travelor slew.

5 Control Lock Lever

Raising the lever provides a method of isolating thehydraulic controls (in addition to raising the LeftConsole (step 1) or operating the Servo IsolatorSwitch (step 2)) and is an integral part of theprocedure for vacating the cab. Lower the lever toactivate the hydraulic controls.

A335460

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A296830

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Section C Electrics

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Section C

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Issue 1

Cab Layout

Left Console Switch PanelWheeled machines only

1 Left hand stabilizer down

When pressed the left hand stabilizer will lower, theindicator light next to the switch will illuminate onlywhen the switch is pressed.

2 Right hand stabilizer down

When pressed the right hand stabilizer will lower, theindicator light next to the switch will illuminate onlywhen the switch is pressed.

3 Left hand stabilizer up

When pressed the left hand stabilizer will raise, theindicator light next to the switch will illuminate onlywhen the switch is pressed.

4 Right hand stabilizer up

When pressed the right hand stabilizer will raise, theindicator light next to the switch will illuminate onlywhen the switch is pressed.

5 CushionThe soft mode is automatically ON when starting themachine. Press to change to hard mode. The monitorwil l display “ HARD MODE” acknowledgementmessage.

This switch selects or deselects the cushioned modeof operation of the boom raise/lower rams and thedipper in/out rams. In the cushioned mode thehydraulic system is protected from the potentiallyharmful effects of suddenly stopping any of the ramswith a heavily loaded bucket or other attachment. Forlighter work it may be desirable to operate in the non-cushioned mode.

At engine start-up, the cushioned mode isautomatically selected, with the switch lamp off. Pressthe button to select the non-cushioned mode and lightthe switch lamp. Press again to select the cushionedmode.

6 IsolatorPress to isolate the servo system. The monitor willdisplay “ ISOLATOR” acknowledgement message.When pressed the controls are isolated and nomachine operation is possible.

A335150

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Section C

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Issue 1

Cab Layout

Multi-Purpose Steering Column Switch(Wheeled Machines only)

1 Direction Indicators (Right)

Pull the lever towards you to indicate a right turn.Switch the indicators off when you have completed theturn. Functions only with the starter switch at ON.(Cancels automatically when steering wheel centres.)

2 Direction Indicators (Left)

Push the lever away from you to indicate a left turn.Switch the indicators off when you have completed theturn. Functions only with the starter switch at ON.(Cancels automatically when steering wheel centres.)

.

3 Windscreen Wiper

Rotate the three position lever barrel switch to operatethe windscreen wipers. Fully anti-clockwise is OFF, themiddle position is INTERMITTENT wipe, and the fullyclockwise position is CONTINUOUS wipe.

The wipers will self-park when switched off. Functionsonly with the starter switch at ON.

4 Windscreen Washer

Push the sleeve towards the steering wheel to operatethe windscreen washer. Functions only with the starterswitch at ON.

5 Main Beam

Lift the lever to switch on the main beam. Lift the leveronce more to reselect dipped beam. Functions onlywith sidelights and headlights selected to ON.

Note: Lifting the lever with main beam switched off willflash the main beam.

6 Horn

Press to sound the horn. Functions only with thestarter switch at ON.

JS040201

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Section C Electrics

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Section C

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Issue 1

Cab Layout

1 Display PanelThe EMS instrument panel is located at the front righthand side of the cab. It provides information from themachine. The LCD has 20 segment bar graph gaugesfor fuel, hydraulic and water temperatures, a clock,gear, power, mode and hours run meter. The panelalso has an eleven character message area.

2 Mode SwitchPress to select working mode. The machine will be inthe same mode as when last switched off. Each presscycles through the modes as follows:S H L F S(The applied mode is indicated next to the POWERMODE message.)Select the appropriate work mode suitable for the workto be carried out:

H - HEAVY MODEfor heavy digging or increased work output.

S - STANDARD MODEfor general digging and loading work.

L - LIGHT MODEfor precise or light duty work

F - FINE MODEfor operations requiring maximum accuracy, includinglifting, with extra hydraulic pressure available whenrequired.

3 Set SwitchPress the SET switch to access the monitor menu. Themenu can be scrolled through using the Scroll Up andScroll Down switches.

4 Scroll Up Switch

5 Scroll Down Switch

6 ACK SwitchPress to acknowledge warnings shown on the display.This will clear the message but will not put out warninglamps. The ACK Switch can cancel the warning buzzerwhen sounding.

7 Warning lampsEighteen tell tale warning light indicators are includedon the monitor.

! CAUTIONAll the warning lights should go out within 10 secondsof the engine being started. Rectify any faultsimmediately.0009

A335120

POWERMODE

Monitor Panel

Indicates that machine hours are displayed topleft of the display. This symbol flashes whenthe machine is operating, this signifies that thehour meter is increasing the service time.

Indicates the time at the top right of thedisplay.

Indicates that transmission information isdisplayed top centre of the display.

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Section C Electrics

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Section C

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Issue 2*

Cab Layout

Monitor Panel (cont’d)

High Engine Coolant TemperatureIlluminates if the engine coolant temperaturerises to high. Stop the engine and rectify theproblem before further use.

Low Engine Oil PressureIlluminates if the engine oil pressure drops toofar. The light should go out when the engine isstarted. If illuminated, stop engine, check oilleve, top up as necessary and inspect for leaks.

Charging System FaultIlluminates when the battery voltage is low. IfIlluminated check electrical charging circuit.

Service RequiredThis warning is illuminated when a service is required.The warning flashes when a minor service is required(250 hours) and can be cancelled by pressing theACK switch on the monitor. The warning will illuminatecontinuously when a major service is required (500hours). If lit continuously, contact your JCB dealer.

Low Air PressureOnly used on JS 330 and JS 460 machines.Illuminates if the air pressure is low. Check theair pressure.

High Hydraulic Oil TemperatureIlluminates if the hydraulic fluid temperaturerises too high. Stop the engine and rectify theproblem before further use

Low Coolant LevelIlluminates if the engine coolant level drops toolow. Inspect and refill coolant.

Engine Oil Filter BlockedIlluminates if the engine oil filter is blocked.Replace the engine filter (change engine oilwhen replacing the filter).

Slew Lock ONIlluminates when the machine slew lock isengaged. Press the slew lock switch todisengage the slew lock.

Servo Isolator ONIlluminates when the machines servo isolatoris engaged. Lower the lock lever or press theisolator switch to disengage the isolator.

Engine Air Filter BlockedIlluminates if the engine air filter is blocked.Replace the element.

Low Hydraulic Oil Level (Option)Indicates low oil in the hydraulic tank. Checkoil level.

Direction Indicator(Wheeled machine only)Flashes with the direction indicators. (Autoflashes when Hazard Warning Lights are on).Use the indicators to signal before turning.

Hazard Warning Lamps Indicator(Wheeled machine only)Flashes with the hazard warning lights (evenwith the starter switch OFF).

Main Beam Indicator(Wheeled machine only)Illuminates when the headlight main beamsare switched on.

Dozer Mode Indicator(Wheeled machine only)Illuminates when the machine has the dozerselected.

Low Brake Pressure (Wheeled machine only)Illuminates when the brake circuit pressurefalls below the pre-determined minimumpermissible.

Emergency Steer Mode(Wheeled machine only)Illuminates to indicate that the power steeringpressure has failed. Steering is still possiblealthough much greater effort is required.

Warning Lights

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Section C Electrics

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Section C

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Issue 1

Cab Layout

Monitor Panel (cont’d)

Set SwitchPress set switch to access the monitor menu. This allows the operator to change the settings of some of the machine’sfunctions. The menu can be scrolled through using the scroll up and scroll down switches.

Set clock - Use to adjust the displayed time.CLOCKACK12/24? Use scroll keys to change 12h or 24h clockACK12:10 Use scroll keys to change timeACK

Auto idle time - Used to adjust the time delay for the automatic idle system.AUTO IDLE TACK5 Use scroll keys to change time delay (in seconds)ACK

Language - Used to change the language of the display messages.

Intermittent wiper speed - Used to adjust the time delay for the intermittent wiper.INT WIPER SACKWIPER SPD -1 Use scroll keys to change speedACK

Engine speed for hammer - Used to set the maximum engine speed, when using a hammer. When using a hammer it may be necessary to limit the engine speed - consult your JCB Dealer.

HAMMER RPMACKRPM 1200 Use scroll keys to change rpm

Hammer hours - Used to view the total cumulative hours the hammer has been used, also used to reset the hour count sincethe last hammer service.

HAMMER HRSACK12345 1234(Total amount of hours hammer used) (Hours since last hammer service)ACKRESET HRS? Resets the hour count since the last hammer serviceACK

Date - Used to adjust to dateDATEACK02-10-1999 Use scroll keys to change dateACKSET Return to normal display

Scrap Magnet - Used to set the Minimum engine speed for scrap magnet.The minimum engine idling speed can be adjusted using this option. When using a scrap magnetattachment it may be necessary to increase the engine idle speed to ensure sufficient electric power to theattachment - consult your JCB Dealer.

SCRAP MAGACKSCRP MG OFF Use the scroll keys to change between ON & OFFACKRPM 1000 Use the scroll keys to change RPMACK