JCB VIBROMAX 1103 SINGLE DRUM ROLLER Service Manual

SERVICE MANUAL SM90001 1103 SINGLE DRUM ROLLER July 1998

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

TABLE OF CONTENTS July 1998 3 SECTION ONE GENERAL INFORMATION MACHINE DESCRIPTION ......................................................................... 1 - 3 SERIAL NUMBERS .........................................................................1 - 5 IDENTIFYING MACHINE COMPONENTS ...................................... 1 - 6 SAFETY, GENERAL .................................................................................. 1 - 7 SPARK ARRESTER ........................................................................1 - 7 SAFETY, PERSONAL ................................................................................ 1 - 7 SAFETY, MACHINE OPERATION............................................................. 1 - 8 SAFETY, MAINTENANCE .........................................................................1 - 9 GENERAL INFORMATION ......................................................................1 - 12 CLEANING .................................................................................... 1 - 12 INSPECTION ................................................................................. 1 - 12 BEARINGS .................................................................................... 1 - 12 NEEDLE BEARINGS ..................................................................... 1 - 12 GEARS ..........................................................................................1 - 12 OIL SEALS, O-RINGS, & GASKETS ............................................ 1 - 12 SHAFTS ........................................................................................ 1 - 12 SERVICE PARTS .......................................................................... 1 - 12 LUBRICATION .............................................................................. 1 - 12 STANDARD TORQUE DATA ................................................................... 1 - 13 MACHINE SPECIFICATIONS .................................................................. 1 - 15 FLUID SPECIFICATIONS ........................................................................ 1 - 17 DIESEL FUEL SPECIFICATION ............................................................... 1 - 18 ENGINE OIL SPECIFICATION ................................................................ 1 - 19 TIRE BALLAST ........................................................................................ 1 - 20 SECTION TWO ENGINE CUMMINS ENGINE WARRANTY .............................................................. 2 - 3 ENGINE REMOVAL ................................................................................... 2 - 4 SECTION THREE ELECTRICAL GENERAL INFORMATION ........................................................................3 - 2 INSTRUMENT PANEL ............................................................................... 3 - 4 UNDERSTANDING ELECTRICAL SCHEMATICS ....................................3 - 7 UNDERSTANDING RELAYS ..................................................................... 3 - 9 VIBROMAX RELAYS .................................................................... 3 - 11 STARTER/CHARGING CIRCUIT (before JKC8302000) ......................... 3 - 13 STARTER/CHARGING CIRCUIT (AFTER JKC8302000) ........................3 - 15 UNDERSTANDING BATTERIES .............................................................3 - 15 BATTERY DIAGNOSTICS ............................................................ 3 - 16

TABLE OF CONTENTS 4 July 1998 UNDERSTANDING ALTERNATORS ...................................................... 3 - 17 CHARGING SYSTEM DIAGNOSTICS ......................................... 3 - 18 VOLTAGE CHECKS AT ALTERNATOR ..................................... 3 - 19 SYSTEM LEAKAGE ..................................................................... 3 - 19 CIRCUIT WIRING TEST ............................................................... 3 - 19 MEASURING ALTERNATOR OUTPUT ....................................... 3 - 20 UNDERSTANDING STARTERS ................................................... 3 - 20 STARTER SOLENOID .................................................................. 3 - 21 STARTER SYSTEM DIAGNOSTICS ...................................................... 3 - 21 SOLENOID CIRCUIT TEST .......................................................... 3 - 21 STARTER CIRCUIT WIRING TEST ............................................. 3 - 22 STARTER MOTOR TEST ............................................................. 3 - 23 INSTRUMENTATION PANEL ................................................................. 3 - 25 EMERGENCY STOP SWITCH/ BRAKE SWITCH .................................. 3 - 27 VIBRATION CIRCUIT .............................................................................. 3 - 29 VIBRATION AFTER JKC8300700 .......................................................... 3 - 31 LIGHTING CIRCUIT ................................................................................ 3 - 33 WORK LIGHTS, ACCESSORY PLUG, HEATER AND WIPERS ........... 3 - 35 CAB WIRING ........................................................................................... 3 - 46 WIRE HARNESS 7250/16315 ................................................................. 3 - 47 WIRE CHART 7250/16315 ...................................................................... 3 - 52 WIRE HARNESS 7250/16110 ................................................................. 3 - 56 WIRE CHART 7250/16110 ...................................................................... 3 - 59 SECTION FOUR HYDRAULIC PUMP SUCTION LINES ............................................................................ 4 - 2 HYDRAULIC COOLING SYSTEM............................................................. 4 - 4 HYDRAULIC DRAIN LINES ...................................................................... 4 - 6 HYDRAULIC TEST SYSTEM .................................................................... 4 - 8 HYDRAULIC TEST STATION ................................................................... 4 - 9 CHARGE SYSTEM .................................................................................. 4 - 11 PROPULSION SYSTEM ......................................................................... 4 - 13 MULTIFUNCTION VALVES .................................................................... 4 - 17 PROPULSION SYSTEM DIAGNOSTICS................................................ 4 - 18 INTERNAL LEAKAGE .................................................................. 4 - 18 PUMP SERVO CONTROL ...................................................................... 4 - 19 VIBRATION SYSTEM .............................................................................. 4 - 21 VIBRATION FREQUENCY ...................................................................... 4 - 23 VIBRATION AMPLITUDE ........................................................................ 4 - 25 VIBRATORY SYSTEM DIAGNOSTICS .................................................. 4 - 26 STEERING SYSTEM............................................................................... 4 - 27 PARKING BRAKE SYSTEM .................................................................... 4 - 30 TOWING YOUR MACHINE .......................................................... 4 - 31 PARKING BRAKE DIAGNOSTICS .......................................................... 4 - 31

TABLE OF CONTENTS July 1998 5 DIFFERENTIAL LOCK SYSTEM .............................................................4 - 35 HYDRAULIC SCHEMATIC ......................................................................4 - 38 SECTION FIVE FINAL DRIVES GENERAL INFORMATION ........................................................................5 - 2 OPERATION .............................................................................................. 5 - 3 KESSLER AXLE.......................................................................................... 5 - 4 SPETH STANDARD AXLE ........................................................................ 5 - 5 REAR AXLE REMOVAL ............................................................................. 5 - 6 AXLE INSTALLATION ................................................................................ 5 - 7 AXLE TUBE DISASSEMBLY ..................................................................... 5 - 8 PLANETARY DISSASSEMBLY ............................................................... 5 - 10 DIFFERENTIAL LOCK REMOVAL .......................................................... 5 - 12 DIFFERENTIAL LOCK ASSEMBLY ......................................................... 5 - 13 AXLE TUBE AND PLANETARY ASSEMBLY ..........................................5 - 14 INTERMEDIATE GEARBOX DISASSEMBLY ......................................... 5 - 18 INTERMEDIATE GEARBOX ASSEMBLY ............................................... 5 - 20 DIFFERENTIAL DISASSEMBLY .............................................................5 - 22 DIFFERENTIAL ASSEMBLY ................................................................... 5 - 24 DRUM REMOVAL .................................................................................... 5 - 29 DRUM INSTALLATION ............................................................................ 5 - 29 DRUM DRIVE ........................................................................................... 5 - 30 DRUM DRIVE BEARING REMOVAL ....................................................... 5 - 34 DRUM DRIVE BEARING INSTALLATION ............................................... 5 - 36 DRUM DRIVE MOTOR REPAIRS ........................................................... 5 - 36 SECTION SIX PARKING BRAKE SYSTEM DESCRIPTION ...........................................................................................6 - 2 RELEASE AND TOWING .......................................................................... 6 - 4 DRUM MOTOR BRAKE ............................................................................. 6 - 5 DISASSEMBLY OF MOTOR BRAKE.............................................. 6 - 6 ASSEMBLY OF MOTOR BRAKE .................................................... 6 - 6 STANDARD AXLE BRAKE ........................................................................ 6 - 8 BAND BRAKE ADJUSTMENT ................................................................... 6 - 9 BAND BRAKE CYLINDER ....................................................................... 6 - 10 HEAVY DUTY AXLE BRAKE ................................................................... 6 - 11

TABLE OF CONTENTS 6 July 1998 SECTION SEVEN VIBRATION SYSTEM VIBRATION SYSTEM ................................................................................ 7 - 2 VIBRATION FREQUENCY ........................................................................ 7 - 3 VIBRATION AMPLITUDE .......................................................................... 7 - 5 VIBRATORY SYSTEM DIAGNOSTICS .................................................... 7 - 6 LIFTING DEVICE ....................................................................................... 7 - 7 DRUM REMOVAL ..................................................................................... 7 - 8 DRUM INSTALLATION ............................................................................. 7 - 8 EXCITER BEARING REMOVAL ............................................................... 7 - 9 EXCITER BEARING ASSEMBLY............................................................ 7 - 14 SMOOTH DRUM SHAFT ........................................................................ 7 - 15 PADFOOT DRUM SHAFT ....................................................................... 7 - 16 SECTION EIGHT STEERING SYSTEM SPECIAL TOOLS ...................................................................................... 8 - 2 ARTICULATION JOINTS ........................................................................... 8 - 3 JOINT DISASSEMBLY .............................................................................. 8 - 5 JOINT ASSEMBLY .................................................................................... 8 - 9 STEERING CYLINDER ........................................................................... 8 - 12 SECTION NINE CHASSIS DRUM FRAME .......................................................................................... 9 - 2 REAR FRAME ........................................................................................... 9 - 3 SIDE FRAME ............................................................................................. 9 - 4 ENGINE COMPARTMENT PANELS......................................................... 9 - 5 OPERATOR PLATFORM .......................................................................... 9 - 6 ROLLOVER PROTECTION STRUCTURE ............................................... 9 - 7 SECTION TEN ATTACHMENTS LEVELING BLADE .................................................................................. 10 - 2 BLADE CONTROL .................................................................................. 10 - 3 BLADE HYDRAULIC LINES .................................................................... 10 - 4

July 1998 1 - 1 SECTION ONE GENERAL INFORMATION CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. 1

1 - 2 July 1998

SECTION ONE GENERAL INFORMATION July 1998 1 - 3 MACHINE DESCRIPTION The 1103 Vibratory Roller is the replacement for the 1102. Like the 1102, the 1103 is available in smooth drum or pad foot drum con- figuration. The 1103 how- ever, is also offered with a standard Speth axle or a heavy duty Speth axle for high gradeability applica- tions. The 1103 uses the Cum- mins 5.9 liter 6 cylinder tur- bocharged engine at 130 gross horsepower. Chang- es in the drive pump and the addition of a heavy duty axle drive motor result in improved machine performance. The vibratory drum diameter remains the same and drum width is two inches narrower. The drum’s centrifugal force has been increased 22%. A Sauer Sundstrand Series 90 variable displacement, axial piston hydrostatic pump, used for machine propulsion, is mounted to the flywheel end of the engine. It provides oil to a Poclain MS25 drum drive motor and a Sauer Sundstrand 2 speed axle drive motor in a parallel path. The Poclain motor is mounted on the left side of the drum and is isolated from the drum by rubber buffers. The axle drive motor on the standard axle has a displacement of 80 cc while the motor on the heavy duty axle displaces 110cc. The vibration system uses a Sauer Sundstrand Series 90 hydrostatic pump similar to the propulsion pump and mounted directly behind the propulsion pump. The vibratory pump supplies oil to a Sauer Sundstrand hydrostatic motor mounted at the right side of the drum. Like the 1102, the 1103 smooth drum operates at frequencies of 1680 or 2160 vibrations per minute,

SECTION ONE GENERAL INFORMATION 1 - 4 July 1998 while the pad foot version operates only at the lower frequency. A steering pump, mounted to the rear of the vibration pump, provides the oil needed for steering. The steering pump is also a sec- ond charge pump in the propulsion/vibration circuit. The steering pump draws oil from the reservoir, passes it through the steering control valve, through the inline hydraulic filter, and into the charge circuit. The charge pump draws oil from reservoir, joins the steering oil at the filter, passes it through the filter and into the charge circuit. The 1103 has brakes at both the front drum and the rear axle. A spring applied-hydrau- lically released multi disc brake is part of the drum drive motor. The standard axle machine uses a spring applied-hydraulical- ly released band brake at the intermediate gearbox while the heavy duty axle incorpo- rates multiple disc brakes at the intermediate gearbox. Pressure testing of the 1103 has been made easier by placing all the test ports at a centrally located test station under the op- erators platform on the right side of the machine. The electrical system of the 1103 consists of a 12 volt battery, starter, alternator system, optional lighting and standard instrumentation.

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JCB VIBROMAX 1103 SINGLE DRUM ROLLER Service Manual

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