JCB Vibromax 1105, 1106, 1405, 1805 Single Drum Roller Service Manual

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JCB Vibromax 1105, 1106, 1405, 1805 Single Drum Roller Service Manual

$28.00 $27.00

Model: Vibromax 1105, 1106, 1405, 1805
Language: English
Format PDF
Type: Service Manual SM95005

JCB Vibromax 1105, 1106, 1405, 1805 Single Drum Roller Service Manual – 240 Pages

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Description

JCB Vibromax 1105, 1106, 1405, 1805 Single Drum Roller Service Manual

Model: Vibromax 1105, 1106, 1405, 1805
Language: English
Format PDF
Type: Service Manual SM95005

JCB Vibromax 1105, 1106, 1405, 1805 Single Drum Roller Service Manual – 240 Pages

In the fall of 1998 Vibromax introduced a new series of heavy single drum vibratory rollers. Included in the new series are the models Vibromax 1105, 1106, 1405, and 1805.

The new rollers all use the Cummins 5.9 liter 6 cylinder engine. Some engines are turbocharge and after cooled depending on the machine model. All of the new engines are tuned to meet the latest EPA emissions standards.

A Sauer Sundstrand Series 90 variable displacement, axial piston hydrostatic pump, used for machine propulsion, mounts 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 motor is mounted on the left side of the drum and drives through a planetary gearbox and is isolate from the drum by rubber buffers. The axle drive motor attach directly to the intermediate gearbox on the rear axle.

See the JCB Vibromax 1105, 1106, 1405, 1805 Single Drum Roller Service Manual table of content for more details.

The vibration system uses a Sauer Sundstrand Series 90 hydrostatic pump similar to the propulsion pump and mounted directly behind the propulsion pump. The vibratory pump supplies oil to a Series 90 hydrostatic motor mounted at the right side of the drum. The new models operate 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 vibration pump, provides the oil needed for steering. The steering pump is also a second charge pump in the propulsion/vibration circuit. 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.

The Vibromax 1105, 1106, 1405, 1805 Single Drum Roller charge pump draws oil from the reservoir, joins the steering oil at the filter, passes it through the filter and into the charge circuit. These machines come standard with parking brakes at both the front drum and therear axle. A spring applied-hydraulically release multi disc brake is part of the drum drive motor gearbox. The axle uses a spring applied hydraulically released multiple disc brake at the intermediate gearbox.

Pressure testing has been made easier by placing all the test ports at a centrally located test station under the engine hood on the right side of the machine.

The electrical system of the Vibromax 1105, 1106, 1405, 1805 Single Drum Roller consists of a 12 volt battery, starter, alternator system, optional lighting and standard instrumentation. The most notable changes from the earlier models are the mounting of the engine in a forward position and the tilting lift hood.

These changes result in a substantial ambient noise level reduction.

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table of contents
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
Model 1105 ………………………………………………………………………………………. 1 – 9
Model 1106 ……………………………………………………………………………………… 1 – 11
Model 1405 ……………………………………………………………………………………… 1 – 13
Model 1805 ……………………………………………………………………………………… 1 – 15
STANDARD TORQUE DATA ………………………………………………………………….. 1 – 16
DIESEL FUEL SPECIFICATION ……………………………………………………………… 1 – 18
ENGINE OIL SPECIFICATION ……………………………………………………………….. 1 – 19
SAFETY, GENERAL ……………………………………………………………………………… 1 – 20
SPARK ARRESTER ………………………………………………………………………………. 1 – 20
SAFETY, PERSONAL ……………………………………………………………………………. 1 – 21
SAFETY, MACHINE OPERATION …………………………………………………………… 1 – 22
SAFETY, MAINTENANCE ……………………………………………………………………… 1 – 25
SAFETY, DECALS ………………………………………………………………………………… 1 – 27
HYDRAULIC HOOD OPERATION……………………………………………………………. 1 – 30
HOOD INSTRUCTIONS …………………………………………………………………………. 1 – 32
SECTION TWO
ENGINE
ENGINE DATA ………………………………………………………………………………………… 2 – 2
CUMMINS ENGINE WARRANTY……………………………………………………………… 2 – 3
ENGINE REMOVAL ………………………………………………………………………………… 2 – 4
table of contents
2
SECTION THREE
ELECTRICAL
GENERAL INFORMATION ………………………………………………………………………. 3 – 2
FUSE LOCATION ……………………………………………………………………………………. 3 – 3
RELAY LOCATION …………………………………………………………………………………. 3 – 3
INSTRUMENT PANEL …………………………………………………………………………….. 3 – 4
UNDERSTANDING ELECTRICAL SCHEMATICS ………………………………………. 3 – 7
UNDERSTANDING RELAYS ……………………………………………………………………. 3 – 9
VIBROMAX RELAYS ………………………………………………………………………… 3 – 11
STARTER/CHARGING CIRCUIT (Cummins 6B5.9C) ………………………………… 3 – 13
STARTER/CHARGING CIRCUIT (Cummins 6BT5.9C) ………………………………. 3 – 15
UNDERSTANDING BATTERIES …………………………………………………………….. 3 – 15
BATTERY DIAGNOSTICS …………………………………………………………………. 3 – 16
UNDERSTANDING ALTERNATORS ……………………………………………………….. 3 – 17
CHARGING SYSTEM DIAGNOSTICS ………………………………………………… 3 – 18
VOLTAGE CHECKS AT ALTERNATOR …………………………………………….. 3 – 19
SYSTEM LEAKAGE ………………………………………………………………………….. 3 – 19
CIRCUIT WIRING TEST ……………………………………………………………………. 3 – 19
MEASURING ALTERNATOR OUTPUT ………………………………………………. 3 – 20
UNDERSTANDING STARTERS ……………………………………………………………… 3 – 20
STARTER SOLENOID ………………………………………………………………………. 3 – 21
STARTER SYSTEM DIAGNOSTICS …………………………………………………… 3 – 21
SOLENOID CIRCUIT TEST ……………………………………………………………….. 3 – 21
STARTER CIRCUIT WIRING TEST ……………………………………………………. 3 – 22
STARTER MOTOR TEST ………………………………………………………………….. 3 – 23
INSTRUMENTATION PANEL …………………………………………………………………. 3 – 25
EMERGENCY STOP SWITCH/ BRAKE SWITCH ……………………………………… 3 – 27
HIGH SPEED CIRCUIT ………………………………………………………………………….. 3 – 29
VIBRATION CIRCUIT …………………………………………………………………………….. 3 – 31
LIGHTING CIRCUIT………………………………………………………………………………. 3 – 33
WORK LIGHTS, ACCESSORY PLUG, HEATER AND WIPERS …………………. 3 – 35
CAB WIRING ………………………………………………………………………………………… 3 – 44
WIRE HARNESS 7241/80315 (0) ……………………………………………………………. 3 – 45
WIRE CHART 7241/80315 (0) ………………………………………………………………… 3 – 50
WIRE HARNESS 7241/80110(0)A …………………………………………………………… 3 – 54
WIRE CHART 7241/80110(0)A ……………………………………………………………….. 3 – 55
WIRE HARNESS 7241/80510(0)B …………………………………………………………… 3 – 56
WIRE CHART 7241/80510(0)B ……………………………………………………………….. 3 – 57
table of contents
3
SECTION FOUR
HYDRAULIC
PUMP SUCTION LINES …………………………………………………………………………… 4 – 2
HYDRAULIC COOLING SYSTEM …………………………………………………………….. 4 – 4
HYDRAULIC DRAIN LINES ……………………………………………………………………… 4 – 6
HYDRAULIC TEST SYSTEM ……………………………………………………………………. 4 – 8
HYDRAULIC TEST STATION…………………………………………………………………… 4 – 9
CHARGE SYSTEM ……………………………………………………………………………….. 4 – 11
PROPULSION SYSTEM ………………………………………………………………………… 4 – 13
MULTIFUNCTION VALVES ……………………………………………………………………. 4 – 17
PROPULSION SYSTEM DIAGNOSTICS …………………………………………………. 4 – 18
INTERNAL LEAKAGE ……………………………………………………………………….. 4 – 18
PUMP SERVO CONTROL ……………………………………………………………………… 4 – 19
VIBRATION SYSTEM ……………………………………………………………………………. 4 – 21
VIBRATION FREQUENCY ……………………………………………………………………… 4 – 23
VIBRATION AMPLITUDE………………………………………………………………………… 4 – 25
VIBRATORY SYSTEM DIAGNOSTICS ……………………………………………………. 4 – 26
STEERING SYSTEM …………………………………………………………………………….. 4 – 27
PARKING BRAKE SYSTEM …………………………………………………………………… 4 – 30
TOWING YOUR MACHINE …………………………………………………………………….. 4 – 31
TOWING PROCEDURE …………………………………………………………………………. 4 – 32
PARKING BRAKE DIAGNOSTICS ………………………………………………………….. 4 – 32
DIFFERENTIAL LOCK SYSTEM …………………………………………………………….. 4 – 35
HOOD LIFT SYSTEM……………………………………………………………………………… 4 – 38
HYDRAULIC COMPONENTS………………………………………………………………….. 4 – 40
HYDRAULIC SCHEMATIC ……………………………………………………………………… 4 – 41
SECTION FIVE
POWER TRAIN
GENERAL INFORMATION ………………………………………………………………………. 5 – 2
OPERATION ………………………………………………………………………………………….. 5 – 3
SPETH AXLE …………………………………………………………………………………………. 5 – 4
REAR AXLE REMOVAL…………………………………………………………………………… 5 – 5
REAR AXLE INSTALLATION……………………………………………………………………. 5 – 6
AXLE TUBE DISASSEMBLY …………………………………………………………………… 5 – 8
PLANETARY DISSASSEMBLY ………………………………………………………………. 5 – 10
DIFFERENTIAL LOCK REMOVAL …………………………………………………………… 5 – 12
DIFFERENTIAL LOCK ASSEMBLY…………………………………………………………. 5 – 13
table of contents
4
AXLE TUBE AND PLANETARY ASSEMBLY ……………………………………………. 5 – 14
INTERMEDIATE GEARBOX DISASSEMBLY ……………………………………………. 5 – 18
INTERMEDIATE GEARBOX ASSEMBLY…………………………………………………. 5 – 20
DIFFERENTIAL DISASSEMBLY ……………………………………………………………… 5 – 22
DIFFERENTIAL ASSEMBLY …………………………………………………………………… 5 – 24
DRUM REMOVAL …………………………………………………………………………………. 5 – 29
DRUM INSTALLATION ………………………………………………………………………….. 5 – 29
DRUM DRIVE ……………………………………………………………………………………….. 5 – 30
DRUM DRIVE BEARING REMOVAL ……………………………………………………….. 5 – 32
DRUM DRIVE BEARING INSTALLATION ………………………………………………… 5 – 34
DRUM DRIVE MOTOR REPAIRS ……………………………………………………………. 5 – 36
DRUM DRIVE GEARBOX ………………………………………………………………………. 5 – 36
GFT 17 T2/312 2 GEARBOX ………………………………………………………………….. 5 – 38
GFT 36 T3 1042 GEARBOX …………………………………………………………………… 5 – 40
SECTION SIX
PARKING BRAKE SYSTEM
DESCRIPTION ……………………………………………………………………………………….. 6 – 2
BRAKE RELEASE AND TOWING …………………………………………………………….. 6 – 4
TOWING PROCEDURE …………………………………………………………………………… 6 – 5
AXLE BRAKE …………………………………………………………………………………………. 6 – 6
AXLE BRAKE PARTS LIST …………………………………………………………………. 6 – 8
SECTION SEVEN
VIBRATION SYSTEM
VIBRATION SYSTEM ……………………………………………………………………………… 7 – 2
VIBRATION FREQUENCY ……………………………………………………………………….. 7 – 3
VIBRATION AMPLITUDE …………………………………………………………………………. 7 – 5
VIBRATORY SYSTEM DIAGNOSTICS ……………………………………………………… 7 – 6
LIFTING DEVICE ……………………………………………………………………………………. 7 – 7
DRUM REMOVAL …………………………………………………………………………………… 7 – 8
DRUM INSTALLATION ……………………………………………………………………………. 7 – 8
EXCITER BEARING REMOVAL ……………………………………………………………….. 7 – 9
EXCITER BEARING ASSEMBLY ……………………………………………………………. 7 – 13
DRUM EXCITER SHAFT ……………………………………………………………………….. 7 – 14
table of contents
5
SECTION EIGHT
STEERING SYSTEM
SPECIAL TOOLS ……………………………………………………………………………………. 8 – 2
ARTICULATION JOINTS …………………………………………………………………………. 8 – 3
JOINT DISASSEMBLY…………………………………………………………………………….. 8 – 5
JOINT ASSEMBLY ………………………………………………………………………………….. 8 – 9
STEERING CYLINDER ………………………………………………………………………….. 8 – 12
SECTION NINE
CHASSIS
DRUM FRAME ……………………………………………………………………………………….. 9 – 2
REAR FRAME ………………………………………………………………………………………… 9 – 3
HOOD ……………………………………………………………………………………………………. 9 – 4
OPERATOR PLATFORM …………………………………………………………………………. 9 – 5
ROLLOVER PROTECTION STRUCTURE …………………………………………………. 9 – 6
SECTION TEN
ATTACHMENTS
LEVELING BLADE ………………………………………………………………………………… 10 – 2
BLADE CONTROL ………………………………………………………………………………… 10 – 3
BLADE HYDRAULIC LINES ……………………………………………………………………. 10 – 4

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