JCB Vibromax VM Range – Tier III Single Drum Roller Service Manual – 9803/9590-5

This workshop repair service manual PDF download for the VM 46/75/115/132/146/166/200 D/PD JCB Vibromax Single Drum Roller has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

JCB Vibromax VM Range – Tier III

JCB VM 115 Tier llI From S/N: 1801240
JCB VM 132 Tier llI From S/N: 1801295
JCB VM 146 Tier llI From S/N: 1800000
JCB VM 166 Tier llI From S/N: 1800000
JCB VM 200 Tier llI From S/N: 1801145

This manual provides information for the following model(s) in the JCB machine range:

JCB VM 46D/PD from S/N: 2900500
JCB VM 75D/PD from S/N: 2900500
JCB VM 115D/PD from S/N: 1801240
JCB VM 115HD/HPD from S/N: 1801240
JCB VM 132D/PD from S/N: 1801295
JCB VM 146D/PD from S/N: 1800000
JCB VM 166D/PD from S/N: 1800000
JCB VM 200D/PD from S/N: 1801445

TABLE OF CONTENTS :

Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Maintenance
Section B – Body and Framework
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section H – Steering
Section K – Engine
Section L – Vibration

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9803/9590-5
Total Pages : 471

This JCB Vibromax service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

More Info : http://www.sitelux.com

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9803-9590

Section 1 – General Information
Introduction
About this Manual
Machine Model and Serial Number
Using the Service Manual
Section Numbering
Left Side, Right Side
Cab/Canopy
Cross References
Identifying Your Machine
Machine Identification Plate
Typical Product Identification Number (PIN)
Component Identification Plates
JCB Dieselmax Engine Identification
Typical Engine Identification Number
Cummins QSB Engine Identification
Typical Engine Identification Number
Service Consumables
Sealing and Retaining Compounds
Service Tools
Numerical List
Tool Detail Reference
Section B – Body and Framework
Section C – Electrics
Section E – Hydraulics
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Condition 1
Condition 2
Verbus Ripp Bolts
Vibromax Specific Torque Settings
Hydraulic Connections
‘O’ Ring Face Seal System
Adaptors Screwed into Valve Blocks
Hoses Screwed into Adaptors
Adaptors into Component Connections with Bonded Washers
‘Torque Stop’ Hose System

Section 2 – Care and Safety
Safety Notices
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety – Yours and Others
General Safety
Operating Safety
Maintenance Safety

Section 3 – Maintenance
Routine Maintenance
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Initial Service and Inspection
Obtaining Replacement Parts
Health and Safety
Lubricants
Introduction
Hygiene
Storage
Waste Disposal
Handling
First Aid – Oil
Spillage
Fires
Battery
Warning Symbols
First Aid – Electrolyte
Service Schedules
Introduction
How to Use the Service Schedules
Calander Equivalents
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Fluids, Lubricants and Capacities
Coolant Mixtures
Fuel
Acceptable and Unacceptable Fuels
Sulphur Content
Effects of Fuel Contaminates
Tools
Toolbox (if fitted)
Carrying Tools onto the Machine
Prepare the Machine for Maintenance
Introduction
Make the Machine Safe
Cleaning the Machine
Introduction
Detergents
Pressure Washing and Steam Cleaning
Prepare the Machine
Cleaning the Machine
Check the Machine for Damage
Check the Machine Body and Structure
Check the Tyres
Check the Hydraulic Hoses and Fittings
Check the Seat and Seat Belt
Check the Drums
Check the Coolant System
Checking the ROPS Structure
Access Panels
Battery Access Panel
Opening and Closing
Engine Cover
Opening and Closing
Brakes
Electrical System
Battery
Battery Disconnection/Connection
Checking the Electrolyte Level
Jump Starting the Engine
Fuses
Main Fuses
Cab Fuses
Relays
Engine
Oil and Filter
Checking the Oil Level
Changing the Oil and Filter
Coolant
Checking the Coolant Level
Changing the Coolant
Drive Belt
Adjust the Drive Belt
Front End Accessory Drive (FEAD) Belt – VM75/VM115/VM132/VM146
Introduction
Inspecting the Drive Belt
Changing the Drive Belt
Cleaning the Engine Breather Gauze – VM75
Error Codes
Cummins Engine – VM166/200
JCB Engine – VM115/132/146
Engine Air Filter
Cleaning the Air Filter Dust Valve
Changing the Elements
Fuel System – All Machines
Introduction
Low Fuel Levels
Filling the Fuel Tank
Draining the Fuel Tank
Fuel System – VM75/VM115/VM132/VM146
Water Separator and Engine Fuel Filter
Introduction
Draining the Water Separator and Engine Fuel Filter
Changing the Water Separator Pre-Filter
Cleaning Water Separator Pump (if fitted)
Changing the Engine Fuel Filter Element
Bleeding the System
Mechanical Fuel Injection System
Electronic Fuel Injection System
Fuel System – VM46/VM166/VM200
Changing the Engine Fuel Filter Element
VM46
VM166/VM200
Bleeding the System
VM46
VM166/VM200
Hydraulic System
Introduction
Releasing the Hydraulic Pressure
Oil and Filter
Checking the Hydraulic Fluid Level
Changing the Hydraulic Fluid and Filter Element
Hydraulic Test Station
Transmission
Rear Axle
Torque Settings
Checking the Axle Oil Level
Changing the Axle Oil
Checking the Hub Oil Level
Changing the Hub Oil
Tyres and Wheels
Tyre Inflation
Introduction
Procedure
Checking the Wheel Nut Torques
Drum
Smooth Drum Scraper
Pad Foot Scraper
Rubber Buffers
Drum Drive Gearbox
General Information
Checking the oil level
Changing the Oil
Vibration System
Oil
Checking the Oil Level
Changing the Oil
Windscreen Washer
Checking the Level

Section B – Body and Framework
Service Procedures
Cab Structure
Direct Glazing
Removing the Broken Glass and Old Sealant
Preparing the Cab Frame Aperture
Preparing the New Glass
Installing the New Glass
Windscreen Wiper Motor
Removal and Replacement
Wiper Motor
Removal
Replacement

Section C – Electrics
Basic Operation
Electrical System (VM115-VM200)
Starter/Charging Circuit
Emergency Stop
Instrument Panel
Brake Switch
Front and Rear High Speed
Vibration
Road Lighting
Work Lights/Accessory Plug
Cab
Schematic Circuits
Electrical Circuit Diagrams
Understanding Circuit Diagrams
Vibromax Relays
VM46
VM75
VM115-VM200
Harness Data
Drawings and Interconnections
VM115 JCB Engine Harness
VM132, 146 JCB Engine Harness
VM166, 200 Cummins Engine Harness
VM115, 132, 146, 166, 200 Dashboard Harness
VM46, 75 Dashboard Harness – Type 1
VM46, 75 Dashboard Harness – Type 2
Seat Base Harness (All Machines)
VM46, 75 Relay Plate Harness – Type 1
VM46, 75 Relay Plate Harness – Type 2
VM46 Frame Harness
VM75 Frame Harness – Type 1
VM75 Frame Harness – Type 2
VM75 Front Road Lights
VM75 Rear Road Lights Harness – Type 1
VM75 Rear Road Lights Harness – Type 2
VM75 Front Worklight Harness
VM75 Rear Worklight Harness
Service Procedures
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
Testing
Specific Gravity Testing
Alternator
General Description
Service Precautions
Charging Circuit Test
Check 1
Check 2
Alternator Charging Test
Starter Motor
Starting Circuit Test
Wiring Harness Repair
Introduction
Repair Procedure
Starter Motor – JCB Engine
Removal and Replacement
Alternator – JCB Engine
Removal and Replacement

Section E – Hydraulics
Basic Operation
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Example Circuit Key
Component Location
Hydraulic Schematics and Circuit Descriptions
Hydraulic Schematics
VM46
VM75
VM115
VM132
VM146/VM166
VM200
Circuit Descriptions
Charge Circuit
Steering Circuit
Park Brake Circuit
Drive Circuit (Working Speed)
Drive Circuit (High Speed)
Anti Slip System Circuit
Vibration Circuit
Hydraulic Hoses and Pipework
VM46
Drive Circuit
Steering Circuit
Vibration Circuit
Oil Cooler Circuit
Oil Leakage Circuit
Pressure Filter Circuit
Control Circuit
Park Brake Circuit
VM75
Drive Circuit
Steering Circuit
Vibration Circuit
Oil Cooler Circuit
Oil Leakage Circuit
Pressure Filter Circuit
Control Circuit
Park Brake Circuit
VM115
Drive Circuit
Steering Circuit
Vibration Circuit
Oil Cooler Circuit
Oil Leakage Circuit
Pressure Filter Circuit
Park Brake Circuit
VM132
Drive Circuit
Steering Circuit
Vibration Circuit
Oil Cooler Circuit
Oil Leakage Circuit
Pressure Filter Circuit
VM146
Drive Circuit
Steering Circuit
Vibration Circuit
Oil Cooler Circuit
Oil Leakage Circuit
Pressure Filter Circuit
VM166
Drive Circuit
Steering Circuit
Vibration Circuit
Oil Cooler Circuit
Oil Leakage Circuit
Pressure Filter Circuit
VM200
Drive Circuit
Steering Circuit
Vibration Circuit
Oil Cooler Circuit
Oil Leakage Circuit
Pressure Filter Circuit
Fault Finding
Hydraulic System
Internal Leakage

Section F – Transmission
Axle
JCB Axle
Drum Drive Gearbox – GFT17
Dismantling and Assembly
Dismantling
Brake
Gearbox
Assembly
Gearbox
Brake
Installation
Setting of Angular Contact Ball Bearings
Securing of Shaft Nut
Alternative Securing of Shaft Nut
Planet Gears
Axial Clearance (one piece sun gear shaft)
Axial Clearance (two piece input shaft/ sun gear)
Multiple-Disk Brake
Testing
Test set up
Lubrication
Speed, Running Time
Thermal Parameters
Running Noise
Tightness Testing
Hydraulic Brakes
Oil Contamination Test
Drum Drive Gearbox GFT36
Dismantling and Assembly
Dismantling
Brake
Gearbox
Assembly
Gearbox
Assembly Cont.
Brake
Installation
Setting of Angular Contact Ball Bearings
Planet Gears
Axial Clearance
Multiple-Disk Brake
Testing
Test set up
Lubrication
Speed, Running Time
Thermal Parameters
Running Noise
Leakage Testing
Hydraulic Brakes
Oil Contamination Test

Section H – Steering
Articulation Joint
Disassembly and Assembly
Disassembly
Assembly

Section K – Engine
Technical Data
JCB Dieselmax Engine
Unit Identification
Specifications
Cummins QSB Engine
Unit Identification
Specifications
Electrical Connections
Cold Start Heater – JCB Engine
Introduction
Component Key:
`Blink’ Codes
Engine Fault Codes
JCB Engine – VM115/132/146
Cummins Engine – VM166/200

Section L – Vibration
Technical Data
Vibration System
VM 46
VM 75
VM 115
VM 132
VM 146
VM 166
VM 200
Vibration System
Description
Basic Operation
Vibration Frequency
Vibration Amplitude
Fault Finding
Vibration System
Diagnostics
Measurement of Vibration System Performance
Vibration System Hydraulic Fault Diagnosis Tables
Vibration Coupling
Removal and Replacement
Removal
Installation
Drum
Removal and Replacement
Removal
Replacement
Exciter Bearing
Removal
Replacement

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