JCB VM46D VM46PD VM75D VM75PD VM115D VM115PD VM115HD VM115HPD VM132D VM132PD VM146D VM146PD VM166D VM166PD VM200D VM200PD Smooth Drum Roller Service & Repair Workshop Manual

Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. World Class Customer Support 9803/9500-4 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Service Manual VM RANGE - TIER II Service Manual - VM RANGE - TIER II Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section H - Steering Section K - Engine Section L - Vibration

Section 1 - General Information 1-0 1-0 9803/9500-4 Notes:

Page No. Contents Section 1 - General Information 1-i 1-i Introduction About this Manual ...................................................................................... 1-1 Machine Model and Serial Number ....................................................... 1-1 Using the Service Manual ..................................................................... 1-1 Section Numbering ................................................................................ 1-1 Left Side, Right Side .............................................................................. 1-1 Cross References .................................................................................. 1-2 Identifying Your Machine ........................................................................... 1-3 Machine Identification Plate .................................................................. 1-3 Component Identification Plates ............................................................ 1-4 Service Consumables Sealing and Retaining Compounds ........................................................... 1-5 Service Tools Numerical List ............................................................................................ 1-7 Tool Detail Reference ................................................................................ 1-9 Section B - Body and Framework .......................................................... 1-9 Section C - Electrics ............................................................................ 1-13 Section E - Hydraulics ......................................................................... 1-14 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ..................................... 1-19 Introduction .......................................................................................... 1-19 Bolts and Screws ................................................................................. 1-19 Vibromax Specific Torque Settings .......................................................... 1-23 Hydraulic Connections ............................................................................. 1-25 'O' Ring Face Seal System .................................................................. 1-25 'Torque Stop' Hose System ................................................................. 1-28

Page No. Contents Section 1 - General Information 1-ii 1-ii

Section 1 - General Information 1-1 1-1 9803/9500-4 Introduction About this Manual Machine Model and Serial Number This manual provides information for the following model(s) in the JCB machine range: – VM46D/PD from SN 1800000 – VM75D/PD from SN 1800000 – VM 115D/PD from SN 1800000 – VM 115H from SN 1800000 – VM 132D/PD from SN 1800000 – VM 146D/PD from SN 1800000 – VM 166D/PD from SN 1800000 – VM 200D/PD from SN 1800000 Using the Service Manual T11-004 This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. The illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify. General warnings in Section 2 are repeated throughout the manual, as well as specific warnings. Read all safety statements regularly, so you do not forget them. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. The manufacturer's policy is one of continuous improvement. The right to change the specification of the machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publication. Finally, please remember above all else safety must come first! Section Numbering T11-005 The manual is compiled in sections, the first three are numbered and contain information as follows: The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section. Left Side, Right Side In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine. 1 General Information - includes torque settings and service tools. 2 Care and Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. 3 Maintenance - includes service schedules and recommended lubricants for all the machine. A Attachments B Body and Framework, etc.

Section 1 - General Information Introduction About this Manual 1-2 1-2 9803/9500-4 Fig 1. Cross References T1-004_2 In this publication, page cross references are made by presenting the subject title printed in bold, italic and underlined. It is preceeded by the 'go to' symbol. The number of the page upon which the subject begins, is indicated within the brackets. For example: K Cross References ( T 1-2) .

Section 1 - General Information Introduction Identifying Your Machine 1-3 1-3 9803/9500-4 Identifying Your Machine Machine Identification Plate Your machine has an identification plate mounted as shown. K Fig 2. ( T 1-3) . The machine and engine serial numbers can help identify exactly the type of equipment you have. T040760-16 Fig 2. Typical Product Identification Number (PIN) 1 World Manufacturer Identification (JCB) 2 Machine Type and Model (VM115 = VM115) 3 Randomly Generated Check Letter 4 Machine Serial Number (01801240) OPERATING MASS (kg) EN500-1 MAX FRONT AXLE LOAD (kg) TYPE JCB VIBROMAX GmbH SCHAEFERBERG 1 06466 GATERSLEBEN ENGINE POWER kW @ RPM, ISO 3046-1 MAX REAR AXLE LOAD (kg) Product Identification Number, PIN, ISO 10261 YEAR OF MANUFACTURE 332/N0674 1 2 3 4 JCB VM115 C 01801240

Section 1 - General Information Introduction Identifying Your Machine 1-4 1-4 9803/9500-4 Component Identification Plates 844210-2 Fig 3. 1 Engine serial number 2 Drum drive motor serial number 3 Steering unit serial number 4 Rear axle serial number 5 Vibration motor serial number 6 Hydraulic pump serial number 7 Axle hydraulic drive motor serial number 5 3 2 7 4 1 6

Section 1 - General Information Service Consumables Sealing and Retaining Compounds 1-5 1-5 9803/9500-4 Service Consumables Sealing and Retaining Compounds T11-001_4 Table 1. Type Description Part No. Quantity JCB Multi-Gasket A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65 mm diameter. 4102/1212 50 ml JCB High Strength Threadlocker A high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where the strength of the joint is important. 4102/0551 50 ml JCB Retainer (High Strength) For all retaining parts which are unlikely to be dismantled. 4101/0601 10 ml 4101/0651 50 ml JCB Threadlocker and Sealer A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter. 4101/0250 10 ml 4101/0251 50 ml JCB Threadlocker and Sealer (High Strength) A high strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter. 4101/0550 10 ml 4101/0552 200 ml JCB Threadseal A medium strength thread sealing compound. 4102/1951 50 ml JCB Activator A cleaning primer which speeds the curing rate of anaerobic products. 4104/0251 200 ml (Aerosol) 4104/0253 1 ltr (Bottle) JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic adhesives and sealants. 4104/1557 400 ml (Aerosol) Direct Glazing Kit For one pane of glass; comprises of: – 1 x Ultra Fast Adhesive (310 ml) – 1 x Active Wipe 205 (30 ml) – 1 x Black Primer 206J (30 ml) – plus applicator nozzle etc. 993/55700 Ultra Fast Adhesive For direct glazing. 4103/2109 310 ml Active Wipe 205 For direct glazing. 4104/1203 250 ml Black Primer 206J For direct glazing. 4201/4906 30 ml Clear Silicone Sealant To seal butt jointed glass. 4102/0901 Plastic to Metal Bonder To seal plastic to metal joints. 4103/0956 50 g Black Polyurethane Sealant To finish exposed edges of laminated glass. 4102/2309 310 ml

Section 1 - General Information Service Consumables Sealing and Retaining Compounds 1-6 1-6 9803/9500-4 Page left intentionally blank

JCB VM46D VM46PD VM75D VM75PD VM115D VM115PD VM115HD VM115HPD VM132D VM132PD VM146D VM146PD VM166D VM166PD VM200D VM200PD Smooth Drum Roller Service & Repair Workshop Manual

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