JCB Vibromax 255 265 Tandem Roller Service Repair Workshop Manual

SERVICE MANUAL SM61005 255 / 265 TANDEM ROLLER December 2000

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 i SECTION ONE GENERAL INFORMATION MACHINE DESCRIPTION ............................................................................... 1 - 3 SAFETY, GENERAL ........................................................................................ 1 - 7 SAFETY, PERSONAL...................................................................................... 1 - 7 SAFETY, MACHINE OPERATION .................................................................. 1 - 8 SAFETY, MAINTENANCE ............................................................................. 1 - 10 GENERAL INFORMATION ............................................................................ 1 - 12 STANDARD TORQUE DATA ........................................................................ 1 - 13 METRIC/USA CONVERSIONS ..................................................................... 1 - 14 MACHINE SPECIFICATIONS........................................................................ 1 - 15 FLUID SPECIFICATIONS .............................................................................. 1 - 17 DIESEL FUEL SPECIFICATION.................................................................... 1 - 18 ENGINE OIL SPECIFICATION ...................................................................... 1 - 19 SECTION TWO ENGINE R&I ENGINE REMOVAL & INSTALLATION ........................................................... 2 - 3 SECTION THREE ELECTRICAL CIRCUITS INSTRUMENT PANEL ..................................................................................... 3 - 2 Instrument panel, left side.......................................................................... 3 - 3 Combination indicator ................................................................................. 3 - 4 Instrument panel, right side ........................................................................ 3 - 5 OPERATOR’S CONSOLE ............................................................................... 3 - 6 ELECTRICAL INFORMATION......................................................................... 3 - 8 RELAY LOCATION CHART............................................................................. 3 - 9 FUSE LOCATION CHART ............................................................................... 3 - 9 UNDERSTANDING ELECTRICAL SCHEMATICS ....................................... 3 - 11 UNDERSTANDING RELAYS......................................................................... 3 - 14 EMERGENCY STOP CIRCUIT...................................................................... 3 - 17 STARTER/ CHARGING CIRCUIT ................................................................. 3 - 19 UNDERSTANDING BATTERIES ................................................................... 3 - 19 UNDERSTANDING ALTERNATORS ....................................................... 3 - 21 STARTER SYSTEM DIAGNOSTICS ............................................................. 3 - 25

table of contents ii NEUTRAL SWITCH CIRCUIT........................................................................ 3 - 29 INSTRUMENTATION PANEL ........................................................................ 3 - 31 COMBINATION INDICATOR.................................................................... 3 - 32 OPERATOR’S CONSOLE ............................................................................. 3 - 33 PARKING BRAKE CIRCUIT .......................................................................... 3 - 35 VIBRATION CONTROL CIRCUIT.................................................................. 3 - 35 SPRINKLER CIRCUIT ................................................................................... 3 - 37 ACCESSORY SOCKETS .............................................................................. 3 - 37 SPRINKLER CIRCUIT ("K" option) ................................................................ 3 - 39 LIGHTING CIRCUIT....................................................................................... 3 - 41 HAZARD/ DIRECTIONAL CIRCUIT............................................................... 3 - 41 BACK-UP ALARM .......................................................................................... 3 - 42 WIRE HARNESS LAYOUT ............................................................................ 3 - 43 WIRE HARNESS 7131/80115 ....................................................................... 3 - 46 WIRE CHART 7131/80115 ............................................................................ 3 - 49 WIRE HARNESS 7131/80255 ....................................................................... 3 - 51 WIRE CHART 7131/80255 ............................................................................ 3 - 55 ELECTRICAL SCHEMATICS ........................................................................ 3 - 59 SECTION FOUR HYDRAULIC SYSTEMS PROPULSION DRAWINGS ............................................................................. 4 - 2 PROPULSION SYSTEM .................................................................................. 4 - 5 PROPULSION SYSTEM DIAGNOSTICS................................................... 4 - 5 VIBRATION DRAWINGS ................................................................................. 4 - 7 VIBRATION SYSTEM .................................................................................... 4 - 10 VIBRATION SYSTEM DIAGNOSTICS ..................................................... 4 - 11 STEERING DRAWINGS ................................................................................ 4 - 12 STEERING SYSTEM ..................................................................................... 4 - 15 STEERING SYSTEM DIAGNOSTICS...................................................... 4 - 15 HYDRAULIC RESERVOIR ............................................................................ 4 - 16 HYDRAULIC OIL FILTER .............................................................................. 4 - 17 HYDRAULIC OIL RESERVOIR ..................................................................... 4 - 17 BRAKE SYSTEM DRAWINGS ...................................................................... 4 - 18 PARKING BRAKES ....................................................................................... 4 - 21 PARKING BRAKE DIAGNOSTICS........................................................... 4 - 21 HYDRAULIC TEST PORTS ........................................................................... 4 - 22 HYDRAULIC COMPONENT LOCATIONS .................................................... 4 - 30

table of contents iii HYDRAULIC SCHEMATIC ............................................................................ 4 - 31 HYDRAULIC SCHEMATIC (“K” model) ......................................................... 4 - 32 “K” MODEL SYSTEMS .................................................................................. 4 - 33 HYDRAULIC COMPONENTS POCLAIN MC05 PROPULSION MOTOR ...................................................... 4 - 38 SAUER/SUNDSTRAND SERIES 42 PROPULSION PUMP.......................... 4 - 41 SECTION FIVE POWER TRAIN DRUM REMOVAL .......................................................................................... 5 - 11 DRIVE MOTOR REMOVAL ........................................................................... 5 - 11 DRIVE MOTOR REPAIR ............................................................................... 5 - 13 DRIVE MOTOR INSTALLATION ................................................................... 5 - 13 DRUM DRIVE BEARING REMOVAL ............................................................. 5 - 13 DRUM BEARING INSTALLATION................................................................. 5 - 15 DRUM INSTALLATION.................................................................................. 5 - 15 PNEUMATIC TIRE DRIVE ............................................................................. 5 - 16 SECTION SIX PARKING BRAKE SYSTEM PARK BRAKE TESTING.................................................................................. 6 - 5 BRAKE RELEASE FOR TOWING ................................................................... 6 - 5 TOWING PROCEDURE ............................................................................. 6 - 6 BRAKE REPAIRS ............................................................................................ 6 - 8 SECTION SEVEN VIBRATORY SYSTEM VIBRATORY SHAFT REMOVAL ..................................................................... 7 - 9 INSTALLING VIBRATORY SHAFT................................................................ 7 - 11 SECTION EIGHT STEERING SYSTEM

table of contents iv SECTION NINE CHASSIS FRAME............................................................................................................. 9 - 3 HOOD & DOOR PANELS ................................................................................ 9 - 4 OPERATOR PLATFORM ................................................................................ 9 - 5 WATER TANK.................................................................................................. 9 - 6 WATER TANK COATING ................................................................................ 9 - 7 ROLL OVER PROTECTIVE STRUCTURE (ROPS) ........................................ 9 - 8 SUN ROOF .................................................................................................... 9 - 10 SECTION TEN ATTACHMENTS WATER SPRINKLER SYSTEM ..................................................................... 10 - 2 DRUM SCRAPERS........................................................................................ 10 - 6 ROAD LIGHT KIT 87130/20120..................................................................... 10 - 8 WORK LIGHT KIT 87130/20100 .................................................................. 10 - 10

1 - 1 SECTION ONE GENERAL INFORMATION

SM61005 - SECTION ONE GENERAL INFORMATION 1 - 2 Built with serviceability in mind .

SM61005 - SECTION ONE GENERAL INFORMATION 1 - 3 MACHINE DESCRIPTION The 255/265 Series vibratory roller is a redesign of the 253/263. The machine remains a 2.5 metric ton, tandem drum machine with articulated steering, hydrostatic drive and a hydraulically driven vibration system. The 255 has a 1000 mm (39 inch) drum width while the 265 is a 1200 mm (47 inch) drum width version. These machines are also offered with a “K” version which is a combination roller built with pneumatic tires in place of the rear drum. A Kubota D1403B, water cooled, three cylinder in-line diesel engine, mounted in the rear chassis, provides the power for the machine. The standard engine has a 29.0 Net Horse Power rating at 2600 RPM. An optional high horsepower Kubota D1403B (37 horsepower) is also available. Both engines meet the latest exhaust emissions standards. A Sauer Sunstrand hydrostatic propulsion pump provides oil for the front and rear Poclain, fixed displacement, drum drive motors in a parallel path. On the “K” model combination roller there are three propulsion motors in parallel. Propulsion system controls are enhanced with the addition of a high and low operating range. The motors are located on the right hand side of the drums and are connected directly to the drum. The vibration system consists of a fixed displacement gear pump mounted to the back of the propulsion pump. This gear pump drives the two gear motors (one on each drum, left hand side) in a series flow path, with options of vibration to the front drum only, rear drum only, both drums or neither drum. Oil from the vibration circuit passes through an air to oil cooler at the engine radiator. The exciter shafts and the drum bearings are oil lubricated, eliminating the need for grease zerks. Pressure testing of the hydraulic system has been simplified by the location of a test station inside the left side access door. Pressure testing of the drive, charge, vibratory and steering systems can be performed from this one location.

SM61005 - SECTION ONE GENERAL INFORMATION 1 - 4 Front and rear parking brakes are provided on the 255/265. The drum brakes are inte- gral to the drive motors. The brakes are spring applied / hydraulically released and are controlled by a switch on the dash and by an emergency stop switch on the right operators console. A brake release valve and a brake hand pump are located under the hood on the left side of the machine. These items provide for brake release when towing a disabled machine. A steering pump, mounted to the back of the vibration pump, provides oil for the steering control valve and a single steering cylinder at the articulation joint. The joint is maintenance free, providing 40 degrees of articulation and 15 degrees of oscillation. An articulation joint safety lock completes the steering system. The return oil flow from the vibratory circuit and the steering circuit passes through a 10 micron oil filter mounted in the top of the hydraulic reservoir. A filter bypass and a pressure differential switch completes the filter circuit. The hydraulic reservoir is located below the operators platform on the left side of the rear chassis. The electrical system consists of the standard starter, battery and charging circuit along with optional lighting, hazard and directional lights. The instrument panel includes switches for vibration, sprinklers, lights and brakes along with the standard instrument cluster of warning lights and an hour meter. An emergency stop button is located right of the operator’s seat. All electrical fuses and relays are located behind a door panel on the right side of the operators platform. A 53 gallon water tank is located on the front chassis, providing water for the asphalt sprinkler system. The tank’s modu- lar design allows for easy removal if neces- sary. On the “K” model combination roller the water tank has two separate compart- ments and the system has two water pumps to allow for the use of a special spray on the pneumatic tires. Pressurized sprinkler bars with spray nozzles on each drum, or tires on the “K” model, complete the water system. Spring loaded scrapers are provided on the front and rear of each drum. This arrangement keeps a constant scraper pressure against the drum.

JCB Vibromax 255 265 Tandem Roller Service Repair Workshop Manual

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