service repair manual

1. Service
Manual
(Supplement)
AMS
JS Machines
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE: ©
WORLD PARTS CENTRE
UTTOXETER, STAFFORDSHIRE, ST14 7BS,
ENGLAND
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
Publication No. 9803/6450
R
General Information
Care & Safety
Routine Maintenance
Attachments
Body & Framework
Electrics
1
2
3
A
B
C
Hydraulics E
FTransmission
GBrakes
JTrack & Running Gear
KEngine
Issue 3

2. i
Section 1 General Information
9803/3642E
Section 1
i
Issue 2*
Contents Page No.
Introduction
Care and Safety 1 - 1

3. 1 - 1
Section 1 General Information
9803/6450
Section 1
1 - 1
Issue 2*
Introduction
The JCB A.M.S system (Advanced Management System) is
a whole machine electronic control system which replaces
the 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 XO
Machine Service Manuals:
Manual No. Machine No. Serial No.
9803/6410 JS 130
JS 160
9803/6310 JS 130W
JS 145W
JS 160W
JS 175W
9803/6400 JS 200
JS 220
JS 240
JS 260
9803/6320 JS 200W
9803/6420 JS 330
JS 450
JS 460
Note: Only those areas of the machines which are different
from the standard version are dealt with here. For all other
aspects refer to the above manuals.
Care and Safety
Before carrying out any maintenance procedures on this
machine, make sure you read the Care and Safety
information in Section 2 of the above Service Manuals . The
relevant information in that Section should be observed as
well as any care and safety information contained in this
manual.
A296531
A335431
Tracked Machine
Wheeled Machine

4. 1 - 9
Section C Electrics
9803/6450
Section C
1 - 9
Issue 1*
Schematic Diagram
6 5
79
81
80
82 83
14 3 13 11 16 6 12 15
12345678 12345678 12345678 12345678
NO CONNECTION
AUXILLARY ONLY
C160 C160C160
BREAKER ONLY
HAMMER/
AUXILLARY
COMBINED
& MERGED PUMP
C160
HAMMER/
AUXILLARY
COMBINED
13 47 28 910
14
81
1
12
2
109
80
6
13
38
79
6 15
5
3
7 4
C160
HAMMER/
AUXILLARY
COMBINED
& MERGED PUMP
11 16
84
12345678 12345678 12345678
NO CONNECTION
AUXILLARY ONLY
C160 C160
BREAKER ONLY
C160
HAMMER/
AUXILLARY
COMBINED
82
13 47 28 6 5
2 1
C160
8
8 52 43 1
80
7
83
HAMMER
TAB
56 3
67
4 78
82 84
80
81
15
C160
6 5 4 12
JS330
HAMMER/
AUXILLARY
COMBINED
& MERGED PUMP
14 3 11 13 16 6 12
312345678 12345678
10
NO CONNECTION
BREAKER ONLY
MONOBOOM
C160 C160
HAMMER/AUXILLIARY
MONOBOOM
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)

5. 2 - 1
Section C Electrics
9803/6450
Section C
2 - 1
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
00
88
77
99
22
4455
66
!!
££
@@
33
11
Location of Controls and Components - JS Tracked machine

6. 2 - 2
Section C Electrics
9803/6450
Section C
2 - 2
Issue 2*
Cab Layout
*Location of Controls and Components - JS130W/145W/160W/175W
1 Left Excavator Joystick Control
Slew 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 Control
Boom 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
A335431
6
8
&
1
%
^
0
(
@
5
7
$
3
9
£
!
2
4
*

7. 2 - 3
Section C Electrics
9803/6450
Section C
2 - 3
Issue 1
Cab Layout
Location of Controls and Components - JS200W
1 Left Excavator Joystick Control
Slew 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 Control
Boom 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
6
8
&
1
%
^ 0
(
@
5
7
$3
9
£
!
2
4
*

8. 2 - 4
Section C Electrics
9803/6450
Section C
2 - 4
Issue 1
Cab Layout
Right Console - Tracked machine only
1 Starter Switch
This key operated rotary switch has four positions. The
key can only be inserted or removed in the OFF
position. The positions are:
OFF - Isolates all electrics.
Turning key to this position stops the engine and, if
appropriate, silences the warning buzzer.
HEAT: For pre-heating the engine air intake during
cold 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 starter
motor for starting the engine. Release the key when
the engine starts and the switch returns to ON.
2 Throttle Dial
This rotary control provides progressive engine speed
control over the full range.
Note: If the engine speed does not change even after
turning the throttle dial it is because the idle switch (6)
is ON. Push the idle switch to OFF to re activate the
throttle dial.
If the engine is started with the throttle dial not at the
minimum position, no engine speed control will be
possible until after the dial has been turned to the
minimum position.
3 Hammer switch (if fitted)
Press the switch to change the additional hydraulic
circuit from hammer (reduced flow) circuit to auxiliary
(full flow) circuit.
A335442
HEAT
START
ON
OFF
33 44
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66
22

9. 2 - 5
Section C Electrics
9803/6450
Section C
2 - 5
Issue 1
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 to
swing. Selecting the boom priority switch during
simultaneous slew and boom operation will restrict flow
to the slew motor and therefore give more flow to the
boom up operation.
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 application
of maximum digging power for a period of 8 seconds,
during which time the ‘POWER UP’ message is
displayed on the Display Monitor.
6 One Touch Idle Switch
Pressing this switch instantly changes the engine rpm
back and forth between that selected for working and a
‘low idling’ speed. When ‘low idling’ has been selected
the message “LOW IDLE” is displayed on the Display
Monitor. This facility is overridden when the
Manual/Auto Change switch is set to ‘Auto’.
7 Auxiliary Circuit Switch
This three-position rocker switch, spring loaded to the
central OFF position, provides bi-directional flow for
relevant attachments, e.g. weedcutter, grab rotate.
Press and hold the switch to the right or left, as
appropriate, for as long as the attachment is to be
used. Release the switch to turn off the attachment.
Lightswitch Panel
Work Light Switch
Press the switch A to the first position to switch ON
the Standard work lights (on boom and the right hand
of the machine). Press the switch to the second
position to switch ON the optional lights (on the cab
and the counterweight - if fitted).
Heater Fan
Turn rotary switch B (on the lightswitch panel)
clockwise to turn on the heater fan. The volume of air
from the heater increases by rotating the switch
clockwise to the next position.
A350860
3
1
2
0
AA
BB

10. 2 - 6
Section C Electrics
9803/6450
Section C
2 - 6
Issue 1
Cab Layout
Right Console - Wheeled machine only
1 Starter Switch
This key operated rotary switch has four positions. The
key can only be inserted or removed in the OFF
position. The positions are:
OFF - Isolates all electrics except side lights and
hazard lights.
Turning key to this position stops the engine and, if
appropriate, silences the warning buzzer.
HEAT: For pre-heating of the engine air intake during
cold 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 starter
motor for starting the engine. Release the key when
the engine starts and the switch returns to ON.
2 Throttle Dial
This rotary control provides progressive engine speed
control over the full range.
Note: If the engine speed does not change even after
turning the throttle dial it is because the idle switch (8)
is ON. Push the idle switch to OFF to re activate the
throttle dial.
If the engine is started with the throttle dial not at the
minimum position, no engine speed control will be
possible until after the dial has been turned to the
minimum position.
3 Hazard Warning Switch
Press the switch to switch ON the hazard warning
lights. Hazard warning lights can be turned ON with or
without the ignition ON.
4 Fog Light Switch
Press the switch to switch ON the fog lights
(Headlights must be ON).
A335441a
HEAT
START
ON
OFF
33 44 55 66
11
99
77
88
22

11. 2 - 7
Section C Electrics
9803/6450
Section C
2 - 7
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 from
rockbreaker (reduced flow) circuit, position 1 to
auxiliary 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 the
function of the foot pedal from rockbreaker, position 1
to boom position control, position 2.
B When combined rockbreaker and auxiliary circuits are
fitted, the switch has three positions. Press the switch
to change the function of the foot pedal from
rockbreaker (reduced flow) circuit, position 1 to
auxiliary (full flow) circuit position 2. Press further to
change to boom position control circuit position 3.
6 Boom Priority Switch (JS 200W only)
Press the switch to change priority of boom raise to
swing. Selecting the boom priority switch during
simultaneous slew and boom operation will restrict
flow to the slew motor and therefore give more flow to
the boom up operation.
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 initiates the
application of maximum digging power for a period of
8 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 rpm
back and forth between that selected for working and
a ‘low idling’ speed. When ‘low idling’ has been
selected the message ‘LOW IDLE’ is displayed on the
Display Monitor. This facility is overridden when the
Manual/Auto Change switch is set to ‘Auto’.
9 Auxiliary Circuit Switch
This three-position rocker switch, spring loaded to the
central OFF position, provides bi-directional flow for
relevant attachments, e.g. weedcutter, grab rotate.
Press and hold the switch to the right or left, as
appropriate, for as long as the attachment is to be
used. Release the switch to turn off the attachment.
R
1
2
1 2 3
R
A350950
A
B

12. 2 - 8
Section 2 Electrics
9803/6450
Section 2
2 - 8
Issue 1
Cab Layout
Lightswitch Panel
Drive Light Switch
Press switch C to the first position to switch ON
the side lights. The side lights can be turned ON
with or without the ignition being switched ON.
Press the switch to the second position to switch
ON the headlights (the ignition must be ON).
Work light Switch
Press switch B to the first position to switch ON
the Standard work lights (on boom and the right
hand of the machine). Press the switch to the
second position to switch ON the optional lights
(on the cab and the counterweight - if fitted).
The side lights must be ON in order to turn ON the
work lights.
Heater Fan
Turn rotary switch A clockwise to turn on the
heater fan. The volume of air from the heater
increases by rotating the switch clockwise to the
next position.
A350870
3
1
2
0
AA
BB CC

13. 2 - 9
Section C Electrics
9803/6450
Section C
2 - 9
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 give
signals, when the machine is started or you engage
travel or slew.
2 Control Lock Lever
Raising the lever provides a method of isolating the
hydraulic controls in addition to raising the Left
Console or operating the Servo Isolator Switch and
is an integral part of the procedure for vacating the
cab. Lower the lever to activate the hydraulic controls.
3 Boom Priority Switch (Option)
Press and hold the switch to change priority of slew to
boom raise. Release the switch to deselect boom
priority.
A335460
11
22
33
A296830
22

14. 2 - 10
Section C Electrics
9803/6450
Section C
2 - 10
Issue 1
Cab Layout
Left Console - Wheeled machines only
1 Console Tilt Handle
Turn the tilt handle anti-clockwise to unlock the
console which can then be hinged up and down.
Raising the console provides a method of isolating the
hydraulic controls (in addition to operating the Servo
Isolator Switch (on the facia panel) or raising the
Control Lock Lever (step 5)) and is an integral part of
the procedure for vacating the cab. Release the
handle and lower the console to the operating position
where it locks.
Note: For JS200W and German and Italian JS130W/160W
machines - When the console is in the raised position,
all controls except travel are isolated. When travelling
on roads,raise the left console to prevent the
accidental movement of the excavator end.
2 Left Console Switch Panel
3 Dozer Switch
This switch transfers Left Excavator Joystick controls
from the slew and dipper to the dozer blade and vice-
versa. Press the left side of the switch to select dozer
and illuminate the Dozer Selected lamp (see Warning
Light Panel, Monitor Panel); press the right side to
revert to slew and dipper. When ‘dozer’ is selected,
push the joystick forward to lower the dozer and pull it
back to raise the dozer. Release the joystick to stop
dozer movement.
4 Horn Switch
When the horn switch is pressed the horn will sound.
Note: always press the switch and sound the horn to give
signals, when the machine is started or you engage travel
or slew.
5 Control Lock Lever
Raising the lever provides a method of isolating the
hydraulic controls (in addition to raising the Left
Console (step 1) or operating the Servo Isolator
Switch (step 2)) and is an integral part of the
procedure for vacating the cab. Lower the lever to
activate the hydraulic controls.
A335460
33
11
22
44
55
A296830
55

15. 2 - 11
Section C Electrics
9803/6450
Section C
2 - 11
Issue 1
Cab Layout
Left Console Switch Panel
Wheeled machines only
1 Left hand stabilizer down
When pressed the left hand stabilizer will lower, the
indicator light next to the switch will illuminate only
when the switch is pressed.
2 Right hand stabilizer down
When pressed the right hand stabilizer will lower, the
indicator light next to the switch will illuminate only
when the switch is pressed.
3 Left hand stabilizer up
When pressed the left hand stabilizer will raise, the
indicator light next to the switch will illuminate only
when the switch is pressed.
4 Right hand stabilizer up
When pressed the right hand stabilizer will raise, the
indicator light next to the switch will illuminate only
when the switch is pressed.
5 Cushion
The soft mode is automatically ON when starting the
machine. Press to change to hard mode. The monitor
will display “ HARD MODE” acknowledgement
message.
This switch selects or deselects the cushioned mode
of operation of the boom raise/lower rams and the
dipper in/out rams. In the cushioned mode the
hydraulic system is protected from the potentially
harmful effects of suddenly stopping any of the rams
with a heavily loaded bucket or other attachment. For
lighter work it may be desirable to operate in the non-
cushioned mode.
At engine start-up, the cushioned mode is
automatically selected, with the switch lamp off. Press
the button to select the non-cushioned mode and light
the switch lamp. Press again to select the cushioned
mode.
6 Isolator
Press to isolate the servo system. The monitor will
display “ISOLATOR” acknowledgement message.
When pressed the controls are isolated and no
machine operation is possible.
A335150
2211
33
55
44
66

16. 2 - 12
Section C Electrics
9803/6450
Section C
2 - 12
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 the
turn. 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 the
turn. 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 operate
the windscreen wipers. Fully anti-clockwise is OFF, the
middle position is INTERMITTENT wipe, and the fully
clockwise position is CONTINUOUS wipe.
The wipers will self-park when switched off. Functions
only with the starter switch at ON.
4 Windscreen Washer
Push the sleeve towards the steering wheel to operate
the windscreen washer. Functions only with the starter
switch at ON.
5 Main Beam
Lift the lever to switch on the main beam. Lift the lever
once more to reselect dipped beam. Functions only
with sidelights and headlights selected to ON.
Note: Lifting the lever with main beam switched off will
flash the main beam.
6 Horn
Press to sound the horn. Functions only with the
starter switch at ON.
JS04020
1
255
44
6
3

17. 2 - 13
Section C Electrics
9803/6450
Section C
2 - 13
Issue 1
Cab Layout
1 Display Panel
The EMS instrument panel is located at the front right
hand side of the cab. It provides information from the
machine. The LCD has 20 segment bar graph gauges
for fuel, hydraulic and water temperatures, a clock,
gear, power, mode and hours run meter. The panel
also has an eleven character message area.
2 Mode Switch
Press to select working mode. The machine will be in
the same mode as when last switched off. Each press
cycles through the modes as follows:
S H L F S
(The applied mode is indicated next to the POWER
MODE message.)
Select the appropriate work mode suitable for the work
to be carried out:
H - HEAVY MODE
for heavy digging or increased work output.
S - STANDARD MODE
for general digging and loading work.
L - LIGHT MODE
for precise or light duty work
F - FINE MODE
for operations requiring maximum accuracy, including
lifting, with extra hydraulic pressure available when
required.
3 Set Switch
Press the SET switch to access the monitor menu. The
menu can be scrolled through using the Scroll Up and
Scroll Down switches.
4 Scroll Up Switch
5 Scroll Down Switch
6 ACK Switch
Press to acknowledge warnings shown on the display.
This will clear the message but will not put out warning
lamps. The ACK Switch can cancel the warning buzzer
when sounding.
7 Warning lamps
Eighteen tell tale warning light indicators are included
on the monitor.
! CAUTION
All the warning lights should go out within 10 seconds
of the engine being started. Rectify any faults
immediately.
0009
A335120
POWER
MODE
Monitor Panel
Indicates that machine hours are displayed top
left of the display. This symbol flashes when
the machine is operating, this signifies that the
hour meter is increasing the service time.
Indicates the time at the top right of the
display.
Indicates that transmission information is
displayed top centre of the display.
11
55
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22

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19. 2 - 14
Section C Electrics
9803/6450
Section C
2 - 14
Issue 2*
Cab Layout
Monitor Panel (cont’d)
High Engine Coolant Temperature
Illuminates if the engine coolant temperature
rises to high. Stop the engine and rectify the
problem before further use.
Low Engine Oil Pressure
Illuminates if the engine oil pressure drops too
far. The light should go out when the engine is
started. If illuminated, stop engine, check oil
leve, top up as necessary and inspect for leaks.
Charging System Fault
Illuminates when the battery voltage is low. If
Illuminated check electrical charging circuit.
Service Required
This 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 the
ACK switch on the monitor. The warning will illuminate
continuously when a major service is required (500
hours). If lit continuously, contact your JCB dealer.
Low Air Pressure
Only used on JS 330 and JS 460 machines.
Illuminates if the air pressure is low. Check the
air pressure.
High Hydraulic Oil Temperature
Illuminates if the hydraulic fluid temperature
rises too high. Stop the engine and rectify the
problem before further use
Low Coolant Level
Illuminates if the engine coolant level drops too
low. Inspect and refill coolant.
Engine Oil Filter Blocked
Illuminates if the engine oil filter is blocked.
Replace the engine filter (change engine oil
when replacing the filter).
Slew Lock ON
Illuminates when the machine slew lock is
engaged. Press the slew lock switch to
disengage the slew lock.
Servo Isolator ON
Illuminates when the machines servo isolator
is engaged. Lower the lock lever or press the
isolator switch to disengage the isolator.
Engine Air Filter Blocked
Illuminates if the engine air filter is blocked.
Replace the element.
Low Hydraulic Oil Level (Option)
Indicates low oil in the hydraulic tank. Check
oil level.
Direction Indicator
(Wheeled machine only)
Flashes with the direction indicators. (Auto
flashes 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 (even
with the starter switch OFF).
Main Beam Indicator
(Wheeled machine only)
Illuminates when the headlight main beams
are switched on.
Dozer Mode Indicator
(Wheeled machine only)
Illuminates when the machine has the dozer
selected.
Low Brake Pressure
(Wheeled machine only)
Illuminates when the brake circuit pressure
falls below the pre-determined minimum
permissible.
Emergency Steer Mode
(Wheeled machine only)
Illuminates to indicate that the power steering
pressure has failed. Steering is still possible
although much greater effort is required.
Warning Lights
*

20. 2 - 15
Section C Electrics
9803/6450
Section C
2 - 15
Issue 1
Cab Layout
Monitor Panel (cont’d)
Set Switch
Press set switch to access the monitor menu. This allows the operator to change the settings of some of the machine’s
functions. The menu can be scrolled through using the scroll up and scroll down switches.
Set clock - Use to adjust the displayed time.
CLOCK
ACK
12/24? Use scroll keys to change 12h or 24h clock
ACK
12:10 Use scroll keys to change time
ACK
Auto idle time - Used to adjust the time delay for the automatic idle system.
AUTO IDLE T
ACK
5 Use scroll keys to change time 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 S
ACK
WIPER SPD -1 Use scroll keys to change speed
ACK
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 RPM
ACK
RPM 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 since
the last hammer service.
HAMMER HRS
ACK
12345 1234
(Total amount of hours hammer used) (Hours since last hammer service)
ACK
RESET HRS? Resets the hour count since the last hammer service
ACK
Date - Used to adjust to date
DATE
ACK
02-10-1999 Use scroll keys to change date
ACK
SET 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 magnet
attachment it may be necessary to increase the engine idle speed to ensure sufficient electric power to the
attachment - consult your JCB Dealer.
SCRAP MAG
ACK
SCRP MG OFF Use the scroll keys to change between ON & OFF
ACK
RPM 1000 Use the scroll keys to change RPM
ACK