JCB VIBROMAX VM66 Single Drum Roller Service Repair Manual

SERVICE MANUAL SM86066 SINGLE DRUM ROLLER June 2004 Model VM 66

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 SECTION ONE GENERAL INFORMATION MACHINE DESCRIPTION ............................................................................... 1 - 3 SERIAL NUMBERS............................................................................... 1 - 5 IDENTIFYING MACHINE COMPONENTS ........................................... 1 - 6 FLUID SPECIFICATIONS ................................................................................ 1 - 7 MACHINE SPECIFICATIONS.......................................................................... 1 - 8 STANDARD TORQUE DATA.............................................................. 1 - 10 DIESEL FUEL SPECIFICATION ......................................................... 1 - 12 ENGINE OIL SPECIFICATION ...................................................................... 1 - 13 SAFETY, GENERAL ...................................................................................... 1 - 14 SPARK ARRESTER ...................................................................................... 1 - 14 PERSONAL.................................................................................................... 1 - 15 MACHINE OPERATION ................................................................................ 1 - 16 MAINTENANCE ............................................................................................. 1 - 19 MAINTENANCE SCHEDULE ........................................................................ 1 - 23 SECTION TWO ENGINE CUMMINS ENGINE WARRANTY.................................................................... 2 - 2 SECTION THREE ELECTRICAL GENERAL INFORMATION .............................................................................. 3 - 3 FUSES ............................................................................................................. 3 - 4 RELAYS ........................................................................................................... 3 - 5 INSTRUMENT PANEL ..................................................................................... 3 - 6 UNDERSTANDING ELECTRICAL SCHEMATICS ........................................ 3 - 11 UNDERSTANDING RELAYS......................................................................... 3 - 14 STARTER/CHARGING CIRCUIT .................................................................. 3 - 17 EMERGENCY STOP ..................................................................................... 3 - 17 UNDERSTANDING BATTERIES ................................................................... 3 - 17 UNDERSTANDING ALTERNATORS ............................................................ 3 - 19 UNDERSTANDING STARTERS.................................................................... 3 - 22 INSTRUMENTATION PANEL ........................................................................ 3 - 27 BRAKE SWITCH ............................................................................................ 3 - 29 HIGH SPEED CIRCUIT ................................................................................. 3 - 31 VIBRATION CIRCUIT .................................................................................... 3 - 33 ROAD LIGHTING CIRCUIT ........................................................................... 3 - 35

2 WORK LIGHTS & ACCESSORY PLUG ........................................................ 3 - 37 CAB CIRCUITS .............................................................................................. 3 - 39 ELECTRICAL SCHEMATICS ........................................................................ 3 - 40 PLUG CONNECTORS ................................................................................... 3 - 48 INSTRUMENT HARNESS 7242/80435 ......................................................... 3 - 49 WIRE CHART 7242/80435 ............................................................................ 3 - 51 RELAY/FUSE HARNESS 7242/80415 .......................................................... 3 - 54 WIRE CHART 7242/80415 ............................................................................ 3 - 56 REAR HARNESS 7222/80510 ....................................................................... 3 - 60 WIRE CHART 7222/80510 ............................................................................ 3 - 62 SECTION FOUR HYDRAULIC HYD. COOLER LINES ..................................................................................... 4 - 2 HYD. DRAIN LINES ......................................................................................... 4 - 5 HYD. CHARGE SYSTEM ................................................................................ 4 - 7 HYD. TEST STATION ...................................................................................... 4 - 9 HYDRAULIC TEST FITTINGS ....................................................................... 4 - 10 PROPULSION SYSTEM ................................................................................ 4 - 11 PROPULSION SCHEMATIC ......................................................................... 4 - 13 PROPULSION SYSTEM DIAGNOSTICS ...................................................... 4 - 15 VIBRATION SYSTEM .................................................................................... 4 - 17 VIBRATION FREQUENCY ............................................................................ 4 - 21 VIBRATION AMPLITUDE .............................................................................. 4 - 23 VIBRATORY SYSTEM DIAGNOSTICS ......................................................... 4 - 24 STEERING SYSTEM ..................................................................................... 4 - 25 STEERING SYSTEM SCHEMATIC............................................................... 4 - 27 PARKING BRAKE SYSTEM .......................................................................... 4 - 29 PARKING BRAKE SCHEMATIC.................................................................... 4 - 31 TOWING YOUR MACHINE ........................................................................... 4 - 33 TOWING PROCEDURE...................................................................... 4 - 34 PUMP CONTROL VALVE.............................................................................. 4 - 35 HYDRAULIC COMPONENTS........................................................................ 4 - 37 HYDRAULIC SCHEMATIC ............................................................................ 4 - 38 SECTION FIVE POWER TRAIN DRUM ASSEMBLY .......................................................................................... 5 - 2 DRUM REMOVAL ............................................................................................ 5 - 7 DRUM INSTALLATION.................................................................................... 5 - 7 RIGHT SIDE BEARING COVER...................................................................... 5 - 8

3 DRUM DRIVE BEARING REMOVAL ............................................................... 5 - 8 DRUM DRIVE BEARING ASSEMBLY ........................................................... 5 - 10 DRUM DRIVE MOTOR REPAIRS ................................................................. 5 - 11 DRUM DRIVE GEARBOX.............................................................................. 5 - 12 GFT 17 T2/312 2 GEARBOX ......................................................................... 5 - 14 SECTION SIX PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM ............................................................................ 6 - 2 PARKING BRAKE SCHEMATIC...................................................................... 6 - 4 TOWING YOUR MACHINE ............................................................................. 6 - 6 TOWING PROCEDURE........................................................................ 6 - 7 SECTION SEVEN VIBRATION SYSTEM LIFTING DEVICE ............................................................................................. 7 - 2 DRUM EXCITER SHAFT ................................................................................. 7 - 3 VIBRATION SYSTEM ...................................................................................... 7 - 4 VIBRATION FREQUENCY .............................................................................. 7 - 8 VIBRATION AMPLITUDE ................................................................................ 7 - 9 VIBRATORY SYSTEM DIAGNOSTICS ......................................................... 7 - 10 DRUM DRAWING .......................................................................................... 7 - 11 DRUM - LEFT SIDE ....................................................................................... 7 - 12 DRUM - RIGHT SIDE..................................................................................... 7 - 15 DRUM REMOVAL .......................................................................................... 7 - 18 DRUM INSTALLATION.................................................................................. 7 - 18 RIGHT SIDE BEARING COVER.................................................................... 7 - 19 EXCITER BEARING REMOVAL .................................................................... 7 - 20 EXCITER BEARING ASSEMBLY .................................................................. 7 - 22 SECTION EIGHT STEERING SYSTEM STEERING SYSTEM ....................................................................................... 8 - 2 STEERING SYSTEM SCHEMATIC................................................................. 8 - 4 SPECIAL TOOLS............................................................................................. 8 - 6 ARTICULATION JOINTS ................................................................................. 8 - 7 JOINT DISASSEMBLY .................................................................................... 8 - 9 JOINT ASSEMBLY ........................................................................................ 8 - 13

4 SECTION NINE CHASSIS SECTION TEN ATTACHMENTS ROLL OVER PROTECTION STRUCTURE (ROPS) ..................................... 10 - 2 ROPS TIGHTENING TORQUES) ....................................................... 10 - 2

June 2004 1 - 1 SECTION ONE GENERAL INFORMATION

1 - 2 June 2004

SM86066 - SECTION ONE GENERAL INFORMATION June 2004 1 - 3 MACHINE DESCRIPTION This book introduces the new Vibromax 6 series single drum rollers. Included within the pag- es of the book are materials covering the Model VM66. The new roller uses the Cum- mins 3.3 liter 4 cylinder engine. The engine is turbocharged and tuned to meet the latest EPA emissions standards. A Mannesman Rexroth vari- able displacement, axial piston hydrostatic pump, used for machine propulsion, is mounted to the flywheel end of the engine. It provides oil to a Rexroth 2 speed drum drive motor and a 2 speed axle drive motor in a parallel path. The Rexroth drum motor is mounted on the left side of the drum, drives through a L&S planetary gearbox and is isolated from the drum by rubber buffers. This ar- rangement is used in the heavy roller models with a great deal of success. The axle drive motor is attached directly to the in- termediate gearbox incorporated into the rear axle.

SM86066 - SECTION ONE GENERAL INFORMATION 1 - 4 June 2004 The vibration system on the VM66 uses a Rexroth hydrostatic pump mounted directly behind the propulsion pump. It is similar in design to the propulsion pump. The vibratory pump supplies oil to a Rexroth hydrostatic motor mounted at the right side of the drum. This operates at frequencies of 1740 or 2160 vibrations per minute on both the smooth drum and pad foot versions. A steering pump, mounted to the rear of the vibratory pump, provides the oil needed for steering. The steering pump also acts as the charge pump in the propulsion and vibration systems. 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. This machine comes standard with parking brakes at both the front drum and the rear axle. A spring applied-hydraulically released multi disc brake is part of the drum drive motor gearbox. The axle uses a spring applied hydraulically released multiple disc brake at each axle shaft. Pressure testing has been made easier by placing all the test ports at a centrally locat- ed test station under the engine hood. The electrical system consists of a 12 volt battery, starter, alternator system, optional lighting and standard instrumentation.

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JCB VIBROMAX VM66 Single Drum Roller Service Repair Manual

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