Service Manual (Supplement) AMS JS Machines PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JOB SERVICE: © WORLD PARTS CENTRE UTTOXETER, STAFFORDSHIRE, ST14 7BS, ENGLAND Tel. ROGESTER (01889) 590312 PRINTED IN ENGLAND Publication No, 8802/6450 General Information Care & Safety Routine Maintenance Attachments Body & Framework Electrics Hydraulics Transmission Brakes Track & Running Gear Engine AIC IOIMIMIO!|(WIiPlalni=aSection 1 General Information Section 1 Contents Page No. Introduction Care and Safety et ‘900336426 iesue 2°Section 1 Genet | Information Section 1 1- Introducti ‘The JCB AMS system (Advanced Management System) is 1a whole machine electronic control system which replaces the CAPS II system. The system cantrols engin speed, Pump powe wiper, auniliary circuits, warning lamps, etc. ‘transmission, excavator functions, lights, This manual is a supplement to the following JS. XO Machina Service Manuals: Manual Na. Machine No. Serial No. gg0ge4t0 © JS 130 38 180 98036310 JS 130W us 445W Js 160W 38 1750 98036400 JS -200 38 220 38 240 438 260 geoqe220 © 4S 200W 98036420 © JS-330 38 450 38 460 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 Sectan 2 of the above Service Manuals . The relevant information in that Section should be observed as wall as any care and safety information contained in this manual ‘Tracked Machine Wheoled Machine 4 aX ‘eansieaso| tesueSection C Electrics Section C 1-9 Schematic Diagram 1-9 48130 - JS260 Connection for optional hydraulic circuits (331/18657) ela > CoH & @) a ( = 58330 Connection for optional hydraulic circuits (331/18659) ieee = eel P eH t @ 48 200W Connection for optional hydraulic circuits (231/18660) ely . 6] | pa] pa Le if @ sr comecris i} ‘e06a50 Issue 7" 4 dXSection C Electrics Section C 2-4 Cab Layout 24 Location of Controls and Components - JS Tracked machine 1 2 3 4 6 7 \ K AK wK W Right Console Contr! Leck Lever Right Excavator Joystick Control 9 Lett Console Display Monitor 10 Door Lock Release Lever Right Hand Track Gontrot ‘11 Optional Circuit Pedal (if ited) Left Hand Track Gontral 12. Facia Panel Travel Speed Range Change Switch 13. Lightswitch Pane! Left Excavator Joystick Control a0sie450 taaue 4Section © Electrics Section C 2-2 Cab Layout 2-2 “Location of Controls and Components - JS130W/145W/160W/175W Ta, Left Excavator Joystick Control Slew and dipper. Horn Button Alternative Hom Button (Not Germany) Steering Wheel 5 Stesring Column Lock Latch 6 Multipurpose Steoring Column Switch 7 Foot Brake Pedal 8 Gearbox Ratio Ghange Switch 9 Right Excavator Joystick Controt Boom and bucket. 10 One Touch Idle Switch Display Monitor Left Console Right Console Travel Pedal TAB Position Ram Pedal (i fitod) Rockbreaker ON/OFF Switch (if fit) ‘Auxiliary Circuit Switch Dozer Blade Switch Right Switch Panel senaeas0 Teas 2°Section C Electrics Section C 2-3 Cab Layout Location of Controls and Components - JS200W 2-3 1. Left Excavator Joystick Control Slew and dipper. 2 Hom Button 3. Alternative Horn Button (Not Germany) 4 Steering Whe: 5 Steering Column Lock Latch 6 Multipurpose Steering Column Switch 7 Foot Brake Pedal 8 Gearbox Ratio Change Switch 9. Right Excavator Joystick Gontro! Boor and bucket. 10 One Touch Idle Switch 18 15 16 7 9 Display Monitor Left Console Right Console Travel Pedal ‘TAB Position Ram Padsal (ted) Rockbreaker ON/OFF Switch (i fted) Boom Priority Switch Aunitiary Gircult Switch Dozer Blade Switch Right Switch Panel se0avea60 fasue 4Section C Electrics. Section C 2-4 Gab Layout 2-4 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. Raturns to OFF when key is releaced, ON - Switch position for normal running. START: Key held in this position cranks the starter ‘motor for starting the engine. Release the key whan the engine etarte and the with returns to ON, Throttle Dial This rotary control provides progressive engine spead ‘control ever the full range. Note: If the angina speed doos not change even after tuming the throtle dal itis because the idle switch (6) Js ON. Push the idle switch to OFF to re activate the throttle dial Ie the angine is started with the throttle cial not at the ‘minimum position, no sngine speed control will be possible until after the dial has been tured to the ‘minimum position. Hammer switch (i fitted) Prast the switch to change the additional hydraulic circuit frem hammer (tedueed flow) circuit to auszliary {full flow) circuit. 20316450 Tsue |Section C Electrics Section C 2-5 Gab Layout 2-5 Right Console - Tracked machine only (cont'd) 4) Boom Priority Switch-if fitted (Standard on JS220} Press the switch to change priority of boom raise to swing. Selecting the boom priority switch during simultaneous slaw and boom aperation will restrict flow to the slew motor and therafore give mora 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! ‘mada, depression of tha button initates the application ‘of maximum digging power for a period of 8 ssconds, during which lime the ‘POWER UP” message is splayed on the Display Monitor. ‘One Touch lle Switch Pressing this ewitch instantly changes the engine 1pm back and forth between that selected for working and a “low idling’ speed. When ‘low iding’ has been selected the message “LOW IDLE" is displayed on the Display Monitor. This facility is overridden when the ManualiAuto Change switch is sat to ‘Auto! Auxiliary Circuit Switch ‘Thig three position rocker switeh, 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. Relaace the switeh to turn off the attachment. Lightswitch Panel Work Light Switch Press the switch A to the fist position to saiteh ON the Standard wark lights (on boom and the right hand of the machina). Press the switch to the second pposition to switch ON the optional lights (on the cab and the counterweight - if fitted). Heater Fan Turn rotary switch B (on the lightswitch panel) ‘lockwise to turn on the heater fan. The volume of air from the heater increases by rotating the switch clockwise to the next position, 038450 lave #Section C Electrics Section C 2-6 Cab Layout 2-6 ht Console - Wheeled mact e only 1 Starter Switch This key operated rotary switch has four positions. The key can only be inserted ar removed in the OFF position. The positions are: OFF - leolates all electrics except side lights and hazard lights. Turning key to this position staps the engine and, if appropriate, silences the warning buzzer. HEAT: For pre-haating of ths angina air intake during cold weather, kay must be held in this pesition. Returns to OFF whan key isreleased, (ON - Swatch position for normal running. START: Key held in this position eranks the starter moter for starting the engine. Relases the key when the engine starts and the switch returns to ON, Throttle Dial This rotary contral provides progressive engine speed control over the full range. Note: If the engine speed does not change even after turning the throttle cial it is because the idle switch (8) ig ON. Push tha idle switch to OFF to ra activate the throttle dal I 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 tumed to the ‘minimum position. Hazard Warning Switch Press the switch to switch ON the hazard warning lights. Hazard warning fights can be turned ON with of without the ignition ON. Fog Light Switch Prass the switch to switch ON the fog lights (Headlights must be ON). ‘eansie480Section C Electrics Section C 2-7 Cab Layout Right Console (cont'd) 5 Plockbreaker switch (i ited JS200W only) For monoboom equippad machines: A The switch has tw positions, press the switch to change the additional hydraulic circuit fram rockbreaker (reduced flow) circuit, position 1 to auxiliary full low position 2, For triple articulating boom equipped machines: A When a rockbreaker circutt only is fitted, the switch has two positions, Press the switeh to change the function af the foot pedal from rockbreaker, position 1 to boom position cantral, position 2. BB When combined rackbreaker and auxiliary circuits are fittad, the switch has three positions. Press the switch to change the function of the foot pedal fram reckbreaker (reduced flow) circuit, pesition 1 to auxiliary {full flaw) circuit position 2. Press further to change to boom positien control circuit pasition 3 6 Boom Priority Switch (JS 200W only) Press the switch to change prionty of boom raise to ‘swing. Selecting the boom pricrity switch during simultanegus slew and boom operation will restrict flow to the slew motor and therefore give mare flow to the boom up operation. When the switch is pressed the monitor will display *BOOM PRIOR” acknewledgement massage. 7 Power-up Button With the Work Mode Selection switch in 'H! or 'S! mede, depression of the button initiates the application of maximum digging power for a period of 8 secands. 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 rm back and forth betwean that selected for werking and ‘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 Ghange suritch is set to ‘Auto’ © Ausiliary Circuit Switeh This thrae-position rackar switch, spring loaded to the central OFF position, pravicies bi-directional flow for relevant atfachments, 2.9. weedeutter, 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 tur off the attachment. 2-7 anos oeoseas0Section 2 Electrics Section 2 2-8 Cab Layout 2-8 Lightswitch Panel Drive Light Switch ress switch € to the first position to switch ON the sida lights, The side lights ean 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 ewiteh B to the first position to switch ON the Standard work lights (oa 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 - i fitted) “The side lights must be ON in order to turn ON the work lights. Heater Fan Turn rotary switch A clockwise to turn an the heater fan. The volume of air from the heatar increases by rotating the switeh clockwise to the next position. ‘eansieaso Iesue 1Section C Electrics 2-9 Cab Layout Left Console - Tracked machines only l 1 Horn Switch 3 When the horn switch is pressed the ham will sound, Note: always press the swilch and sound the hom to give signals, when the machine is started or you engage travel or slew. Boom Prierity Switch (Option) Press and hold the switch to change priority of slew to boom raise. Release the switch to deselect boom priority. Section C 2-9 2 Control Lock Lever Raising the lever provides @ method of isolating the hydraulic cantrols in addition to raising the Left Console or oparating the Servo Isolator Switch and |g an integral part of the procedure for vacating the cab, Lower the lever to activate the hydraulic controls. stoste450 Tasue 4Section C Electrics Section C 2-10 Cab Layout 2-10 Left Console - Wheeled machines only a @) aa a 1 Console Tilt Handle Turn the tilt handle anti-clockwise to unlock the cansole which can then be hinged up and down. Raising the console provides a method af isolating the hydraulic controls (in addition to operating the Servo Isolater Switch (on the facia panel) or raising the Control Lock Laver (stap §)) and is an integral part of the procedure far vacating the cab. Release the handle and lower the console to the operating position where it locks, Note: For JS200W and German and Italian JS120W/160W" ‘machines - When the consale is in the raised position, all controls except travel are isolated. When travelling on raads,raise the Iaft console to pravent the accidental movement of tha exeawater and 2. Laft Console Switch Panel 3 Dozer Switch ‘This switch transfers Left Exeavater Joystick controle from the slew and dipper to the dozer blade and vice- versa. Press the left side of the switch fo selact dozer ‘and illuminate the Dozer Selected lamp (see Warning Light Panel, Monitor Panel) press the right side to revert to slew and dipper. When ‘dazer’ is selected, push the joystick forward to lower the dozer and pull it back to raisa the dazer. 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 fo give signals, when the machine is started or you engage travel or slew. 5 Gontrol Lock Lever Raising the lever pravides a method of isolating the hydraulic controls (in addition to raising the Left Console (step 1) or operating the Servo Isolator Switch (stop 2)) and is an integral part of tha procedure for vaeating the cab. Lower ths lever to activate the hydraulic controls. ‘eansieaso| sue 4Section C Electrics Section C 2-11 Cab Layout 2-11 Left Console Switch Panel Wheeled machines only 1 Left hand stabilizer down When pressed the left hand stabilizar will lower, the indicator light neat to the switch will illuminate only when the switch is prassed. 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 prassed. 3) Lefthand stabilizer up When pressed the laff hand stabilizer will raise, tha Indicator light next to the switeh will iluminate only when the switch is pressed. 4) Righthand stabilizer up When pressed the right hand stabilizer will raise, the indicator light neat to the switch will illuminate only when the switch is prassed. 5 Cushion The soft mode is automatically ON when starting the machine. Press to change to hard mada. The monitor will display “HARD MODE" acknowladgement message. This switch selects or daselacts the cushioned mada of operation of the boom raiseilower rams and the dipper in/out rams. In the cushioned mode the j hydraulic system is protected from the potentially Z harmful affacts of suddenly stopping any of the rams with a heavily loaded bucket or other allachment. For lighter work it may be desirable to operate in the non- cushioned mode. At engine start-up, the cushioned moda is ‘automatically calectad, with the switch lamp off. Pross the button to select the non-cushionad mods and light the switch lamp. Press again lo select the cushioned mode 6 Isolator Prass to isolate the servo system. The monitor will display “ISOLATOR” acknowledgemant message. When pressed the cantrols are isolated and no machine operation is possible. ‘oansie40 tava 4Section C Electrics Section © 2-12 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 luin. Functions only with the starter switch at ON. (Canceis automatically when steering wheel centres.) 2. Direction Indicators (Left) Push the lever away from you to indicale a left tum. ‘Switch the indicators off when you have completed the turn. Functions only with the starter switch at ON. (Cancets automatically when steering wheel centres.) 3 Windscreen Wiper Rotale the three position lever barrel switch to operate: the windscreen wipers. Fully anti-clockwise is OFF. the middle position is INTERMITTENT wipe, and the Tully Clockwise position is CONTINUOUS wipa, The wipers will sel-park when switched off. Functions. only with the starter switch at ON. 4 Windscreen Washer Push the sleeve tonards the steering wheel to operate: the windscreen washer. Functions only with the starter snitch at ON, 5) Main Beam Lif the lever to switch on the main beam. Lif the lever once mara to reselect dippad beam. Functions only: with sidelights and headlights selacted to ON. Note: Lifting the fever with main beam switched off wit ash the main bean 6 Horn Pross to sound the harn. Functions only with the starter switch at ON 2-12 ‘e00si6450Section C Electrics Section © 213 Cab Layout 2013 Monitor Panel 4 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 temparaturas, a clock. gear, power, made and hours run mater. The panel also has an alavan character message area. 2 Mode Switch Press to select working mode. The machine willbe in the same mode as when last switched off. Each press cycles through the madas as fallows: SSHPLOFSS (The applied mode is indicated next ta the POWER MODE message.) ‘Select the appropriate work made suitable for the work to be carried out: H-HEAVY MODE for heavy digging or increased work output 8 - STANDARD MODE for general digging and loading work. L- LIGHT MODE for precise er light duty werk F - FINE MODE for operations requiring maximum accuracy. inctudir liting, with extra hydraulic pressure available when roquirad, 2 Set Switch Press the SET switch to access the monitor menu, Tha menu can ba scrolled through using the Scroll Up and Scroll Down switches. 4 Scroll Up Switch 5 ScrollDown Switch 6 ACK Switch Press to acknowledge warnings shown on the display. ‘This will clear tha meseaga but will nat put out warning lamps, The ACK Switch ean eancel the warming buzzer when sounding, 7 Warning lamps Eightoon tell tala warring light indicators are includad fon the monitor. A caution All the warning lights should go out within 10 seconds. of the engine being started. Rectify any faults immediately. ove a [9] O ENGINE TEMP Bote, 2 Indicates that machine hours are displayed top lft of the display. This eymbol 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. ‘9a0aie450Section C Electrics Section C 2-44 Cab Layout Monitor Panel (cont'd) Warning Lights 6i O- High Engine Coolant Temperature Nurninates # the engine esolant tompersturs rises to high. Stop the engine and rectify the problem before further use, Low Engine Oil Pressure luinates if the engine oil pressure drops too far. The light should go aut whan the engine is started. If illuminated, stop engine, check ol Jeve, top up as necessary and inspect for leaks. Gharging System Fault liuminates when the battery voltage is low. If Murninated check electrical charging circuit Service Required ‘This waming is urinated when a service is required. ‘The warring fashes when a minor service is required (250 hours) and can be cancelled by pressing the ‘ACK swtch onthe montar. Tha warring wl ilurinate ‘eonfnucusly whan a major series ie requred (600 hours. iccontruously, contact your JCB dealae Low Air Prossura Only used on JS 330 and JS 460 machines. Nurinates # the air pressure is low. Check the sir proseure. High Hydraulic Oil Temperature Murninates # the hydraulic Fuld temperature rises too high. Stop the engine and rectify the problem before further use Low Coolant Level luminates if the engine coolant level drops too ow. Inspect and refill coolant Engine Oil Fiter Blocked Numinates # tha engine cil fer is blacked Replace the engine filer (change engine ail when replacing the filter). 2o14 Slew Lock ON Muminates when the machine slew lock is engaged. Press the slaw lock switch ta disengage the slew lock. ‘Servo Isolator ON Muminates when the machines serve isolator is engaged, Lawar the lock lever ar press the isolator switch lo disengage the isolator. Engine Air Filter Blocked Mlurninates ifthe engine air fiter is blacked. Replace the element Low Hydraulic Gil Level (Option) Indicates low oil in the hydraulic tank. Check ail love sction Indicator (Wheeled machine only) Flashes with the direction indicators. (Auto flashes when Hazard Warming 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 ewitch OFF. Main Beam Indicator (Wheeled machine only) Mumninates when the haadight main beams fare snitehsd on Dozer Mode Indicator (Wheeled machine only) Muminates when the machine has the dozer solactad. Low Brake Pressure (Wheeled machine only) Murninates when the brake circu pressure falls below the pre-determined minimum permissibi. Emergency Steer Mode (Wheeled machine only) Mlumninates to indicate that the power steering pressure has failed. Staring is stil possible although much greater effort is required. sensieasa Issue 2°Section C Electrics Section C 2-15 Cab Layout 2-15 Monitor Panel (cont'd) Sat Switch Prass set ewitch to accass the manitor menu. This allows the operator to change the saltings of some of the machine's functions. The menu canbe scrolled through using the scroll up and serall down swilches, Set clock - Use to adjust the displayed time. ‘clock ACK 12287 Use scrall keys fo change 12h of 28h clock AGK 1210 Use scrall keys to change time AGK ‘Auto idle time - Used to adjust the time delay for the automatic dle system, ‘AUTO IDLET ACK 5 Use scrall keys to change time delay (in seconds} AGK 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 ecroll keys to change sped 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 scrall keys to change ram Hammer hours - Used to view the tolal cumulative hours the hammer has been used, also used to resal the hour count since the last hammar service HAMMER HRS ACK 12345 1234 (Total amaunt of hours hammer used) (Houre sines last hammer serviee) ACK RESET HRS? Resets the hour count since the last hammer service AGK Date - Used to adjust to date DATE ACK 02-10-1999 Use scrall keys to change date AGK SET Return to normal display ‘Scrap Magnet - Used to cot the Minimum angine epaed for scrap magnet. The minimum engine idling :paed can be adjusted using this option. When using a serap magnet ‘allachmant it may be necessary fo increase the engine idle speed fo ensure sufficient elactric power to the ‘allachment - consult your JCB Dealer SGRAP MAG ACK SCRF MG OFF — Use the scroll keys to change between ON & OFF ACK RPM 1000 Use the scroll keys fo change RPM AGK ansieaso Tau 4