JCB VMD70 VMD100 Double Drum Walk Behind Roller Service Repair 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 9813/0300-3 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 VMD70/VMD100 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section K - Engine Section L - Vibration

Section 1 - General Information 1-0 1-0 9813/0300-2 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 ............................................................ 1-3 Service Tools Numerical List ............................................................................................ 1-5 Tool Detail Reference ................................................................................ 1-6 Section B - Body and Framework .......................................................... 1-6 Section C - Electrics .............................................................................. 1-8 Section E - Hydraulics ........................................................................... 1-9 Section L - Vibration ............................................................................ 1-13 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ..................................... 1-15 Introduction .......................................................................................... 1-15 Bolts and Screws ................................................................................. 1-15 Hydraulic Connections ............................................................................. 1-19 'O' Ring Face Seal System .................................................................. 1-19 'Torque Stop' Hose System ................................................................. 1-22 Service Consumables Sealing and Retaining Compounds ......................................................... 1-23

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

Section 1 - General Information 1-1 1-1 9813/0300-2 Introduction About This Manual Machine Model and Serial Number This manual provides information for the following model(s) in the JCB machine range: – VMD70/100 from SN 1601000 to 1601999 and 2703000 to 2704999. 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 stand correctly behind the machine and face forwards. 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 9813/0300-2 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 9813/0300-2 Identifying Your Machine Machine Identification Plate Your machine has an identification plate mounted as shown. K Fig 1. ( T 1-3) . The machine and engine serial numbers can help identify exactly the type of equipment you have. T052960-2 Fig 1. Typical Product Identification Number (PIN) 1 World Manufacturer Code (JCB) 2 Machine Type and Model 3 Randomly Generated Check Letter 4 Machine Serial Number (02802400) Component Identification Plates Engine Identification Plate The engine serial number is located on the engine crankcase next to the dipstick. 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) 332/N0674 Product Identification Number, PIN, ISO 10261 YEAR OF MANUFACTURE 1 2 3 4 JCB VMD C 02802400

Section 1 - General Information Introduction Identifying Your Machine 1-4 1-4 9813/0300-2 Page left intentionally blank

Section 1 - General Information 1-5 1-5 9813/0300-2 Service Tools Numerical List The tools listed in the table are special tools required for carrying out the procedures described in this manual. These tools are available from JCB Service. Some tools are available as kits or sets, the part numbers for parts within such kits or sets are not listed here. For full details of all tools, including the content of kits and sets, refer to Tool Detail Reference, Section 1. Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier. Part Number Description See Section - Bonded Washers - see Tool Detail Reference (Section 1) for content E - Female Cone Blanking Caps - see Tool Detail Reference (Section 1) for content E - Female Connectors - see Tool Detail Reference (Section 1) for content E - Hydraulic Flow Test Equipment - see Tool Detail Reference (Section 1) for content E - Male Adapters - BSP x BSP - see Tool Detail Reference (Section 1) for content E - Male Adapters - BSP x NPT (USA only) - see Tool Detail Reference (Section 1) for content E - Male Cone Blanking Caps - see Tool Detail Reference (Section 1) for content E - Pressure Test Points - Adaptors - see Tool Detail Reference (Section 1) for content E - Pressure Test Points - 'T' Adaptors - see Tool Detail Reference (Section 1) for content E - Rivet Nut Tool - see Tool Detail Reference (Section 1) for content B 4104/1310 Hand Cleaner B 892/00253 Hydraulic Circuit Pressure Test Kit - see Tool Detail Reference (Section 1) for content E 892/00254 Hose E 892/00279 Gauge E 892/00280 Gauge E 892/00284 Digital Tachometer C 892/00285 Hyd. Oil Temperature Probe C 892/00298 Fluke Meter C 892/00346 Gauge E 892/00347 Connector E 892/01246 Vibromax male to JCB female threaded adaptor E 892/01247 JCB male to Vibromax female threaded adaptor E 892/12345 Frequency and Vibration Measuring Tool E 993/68100 Slide Hammer Kit - see Tool Detail Reference (Section 1) for content B 892/00285 100 amp Shunt C

Section 1 - General Information Service Tools Tool Detail Reference 1-6 1-6 9813/0300-2 Tool Detail Reference Section B - Body and Framework Note: Not all service tools are illustrated. Fig 1. 993/68100 Slide Hammer Kit 1 993/68101 Slide Hammer 7 993/68107 Bar - M20 x M20 X 800 mm 2 993/68102 End Stops 8 993/68108 Adaptor - M20 x 7/8" UNF 3 993/68103 Adaptor - M20 x 5/8" UNF 9 993/68109 Adaptor - M20 x M12 4 993/68104 Adaptor - M20 x 1" UNF 10 993/68110 Adaptor - M20 x 5/8" UNF (Shoulder) 5 993/68105 Adaptor - M20 x M20 11 993/68111 Adaptor - M20 x 1/2" UNF 6 993/68106 Adaptor - M20 x M24 Fig 2. Rivet Nut Tool 1 826/01099 M6 x 16 mm Rivet Nut 826/01101 M6 x 19 mm Rivet Nut 826/01102 M8 x 18 mm Rivet Nut 826/01103 M8 x 21 mm Rivet Nut 826/01104 M10 x 23 mm Rivet Nut 826/01105A M10 x 26 mm Rivet Nut 2 - Installation Tool available from: Bollhoff Fastenings Ltd (www.bollhof.com)

JCB VMD70 VMD100 Double Drum Walk Behind Roller Service Repair Manual

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