JCB VMT160 VMT260 Tier2 and Tier4 Roller Service Repair Manual INSTANT

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 9803/9530-6 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 VMT160 VMT260 Tier 2 and Tier 4 Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section C - Electrics Section E - Hydraulics Section H - Steering Section K - Engine Section L - Vibration

Section 1 - General Information 1-0 1-0 9803/9530-6 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 .............................................................................. 1-2 Identifying Your Machine ........................................................................... 1-3 Machine Identification Plate .................................................................. 1-3 Component Identification Plates ............................................................ 1-4 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-7 Introduction ............................................................................................ 1-7 Bolts and Screws ................................................................................... 1-7 Vibromax Specific Torque Settings .......................................................... 1-11 Hydraulic Connections ............................................................................. 1-13 'O' Ring Face Seal System .................................................................. 1-13 'Torque Stop' Hose System ................................................................. 1-16 Service Tools Numerical List .......................................................................................... 1-17 Tool Detail Reference .............................................................................. 1-18 Body and Framework .......................................................................... 1-18 Electrics ............................................................................................... 1-20 Hydraulics ............................................................................................ 1-21 Service Aids Sealing and Retaining Compounds ......................................................... 1-25 Terms and Definitions Colour Coding .......................................................................................... 1-27 Hydraulic Schematic Colour Codes ..................................................... 1-27

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

Section 1 - General Information 1-1 1-1 9803/9530-6 Introduction About this Manual Machine Model and Serial Number This manual provides information for the following model(s) in the JCB machine range: – VMT 160-90 from serial no. 1700515 to 1701469 and 2802000 to 2804999 – VMT 260-100 from serial no. 1700515 to 1701469 and 2802000 to 2804999 – VMT 260-120 from serial no. 1700515 to 1701469 and 2802000 to 2804999 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. 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 9803/9530-6 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. Fig 1.

Section 1 - General Information Introduction Identifying Your Machine 1-3 1-3 9803/9530-6 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. Typical Product Identification Number (PIN) Fig 2. Gatersleben Germany VMT 260 JCB 1700690 2700 2007 23.5 kg kW 2 Werk-Nr Serial no. No. de serie Gewicht Weight Poits Betrieb/Max. Operating/max. Operatinnel/max Motorleistung Engine performance Puissance de moteur

Section 1 - General Information Introduction Identifying Your Machine 1-4 1-4 9803/9530-6 Component Identification Plates V014700-1 Fig 3. Table 1. 1 Front drive motor serial number 2 Rear drive motor serial number 3 Steering unit serial number 4 Front vibration motor serial number 5 Rear vibration motor serial number 6 Hydraulic pump serial number 7 Engine serial number 1 2 6 7 5 3 4

Section 1 - General Information Introduction Identifying Your Machine 1-5 1-5 9803/9530-6 Engine Identification Number The full engine serial number is on the engine label which is located on the rocker cover. K Fig 4. ( T 1-5) T019440 Fig 4. Roll Over Protection Structure (ROPS) Your machine is built to the ROPS standard and has an identification label fitted on the ROPS frame. A typical identification label is shown below. K Fig 5. ( T 1-5) V015080-1 Fig 5. Model: D722 Serial No 6G5700 Code No 1G368-13000

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JCB VMT160 VMT260 Tier2 and Tier4 Roller Service Repair Manual INSTANT

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