JCB Vibromax 253, 263 Tandum Roller Service Manual

JCB Vibromax 253, 263 Tandum Roller Service Manual

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Model: Vibromax 253, 263
Language: English
Format PDF
Type: Service Manual

JCB Vibromax 253, 263 Tandum Roller Service Manual – 174 Pages

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Description

JCB Vibromax 253, 263 Tandum Roller Service Manual

Model: Vibromax 253, 263
Language: English
Format PDF
Type: Service Manual

JCB Vibromax 253, 263 Tandum Roller Service Manual – 174 Pages

The Vibromax 253 Series vibratory roller is a new from the ground up machine, replacing the 252. The 253 is a 2.5 metric ton, tandem drum machine with articulated steering, hydrostatic drive and a hydraulically driven vibration system and has a 1000 mm (39 inch) drum width while the Vibromax 263 is the 1200 mm (47 inch) drum width version.

A Kubota D1403B, water cooled, three cylinder in-line diesel engine, mounted in the rear chassis, provides the power for the machine. The engine has a 29.0 Net Horse Power rating at 2600 RPM.

A Sauer Sunstrand variable displacement hydrostatic pump, used for machine propulsion, is mount to the flywheel end of the engine. It provides oil for the front and rear Poclain, fixed displacement, drum drive motors in a parallel path. The motors are located on the right hand side of the drums and are connect directly to the drum, without gear reduction.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, lefthand 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.

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TABLE OF CONTENTS

SECTION ONE
GENERAL INFORMATION…………………………………………. 9
MACHINE DESCRIPTION …………………………………………………………….11
SERIAL NUMBERS…………………………………………………………………………… 13
IDENTIFYING MACHINE COMPONENTS …………………………………………… 14
SAFETY, GENERAL ……………………………………………………………………15
SPARK ARRESTER………………………………………………………………………….. 15
SAFETY, PERSONAL…………………………………………………………………. 15
SAFETY, MACHINE OPERATION …………………………………………………16
SAFETY, MAINTENANCE ……………………………………………………………..7
GENERAL INFORMATION………………………………………………………….. 20
CLEANING………………………………………………………………………………………. 20
INSPECTION ……………………………………………………………………………………20
BEARINGS ……………………………………………………………………………………….20
NEEDLE BEARINGS ………………………………………………………………………… 20
GEARS……………………………………………………………………………………………..20
OIL SEALS, O-RINGS, & GASKETS ……………………………………………………20
SHAFTS ………………………………………………………………………………………….. 20
SERVICE PARTS ………………………………………………………………………………20
LUBRICATION ………………………………………………………………………………….20
STANDARD TORQUE DATA ………………………………………………………. 21
METRIC/USA CONVERSIONS …………………………………………………….. 22
MACHINE SPECIFICATIONS………………………………………………………. 23
FLUID SPECIFICATIONS …………………………………………………………….25
DIESEL FUEL SPECIFICATION…………………………………………………… 26
ENGINE OIL SPECIFICATION ……………………………………………………..27

TABLE OF CONTENTS

SECTION TWO
ENGINE R&I ……………………………………………………………. 29
ENGINE REMOVAL & INSTALLATION ………………………………………… 31
ENGINE REMOVAL …………………………………………………………………………. 32
ENGINE OVERHAUL ……………………………………………………………………….. 32
INSTALLATION ……………………………………………………………………………….. 33
SECTION THREE
ELECTRICAL SYSTEMS………………………………………….. 35
ELECTRICAL INFORMATION……………………………………………………… 36
RELAY LOCATION CHART ………………………………………………………… 37
FUSE LOCATION CHART…………………………………………………………… 37
UNDERSTANDING ELECTRICAL SCHEMATICS………………………….. 39
UNDERSTANDING RELAYS ……………………………………………………….. 41
VIBROMAX RELAYS………………………………………………………………………… 43
EMERGENCY STOP CIRCUIT …………………………………………………….. 45
STARTER/ CHARGING CIRCUIT…………………………………………………. 47
UNDERSTANDING BATTERIES ………………………………………………….. 47
BATTERY DIAGNOSTICS ………………………………………………………………… 48
UNDERSTANDING ALTERNATORS ……………………………………………. 49
CHARGING SYSTEM DIAGNOSTICS ………………………………………………… 50
VOLTAGE CHECKS AT ALTERNATOR …………………………………………….. 51
SYSTEM LEAKAGE …………………………………………………………………………. 51
CIRCUIT WIRING TEST…………………………………………………………………….. 51
MEASURING ALTERNATOR OUTPUT……………………………………………….. 52
UNDERSTANDING STARTERS ………………………………………………………… 52
STARTER SOLENOID ……………………………………………………………………… 53
STARTER SYSTEM DIAGNOSTICS …………………………………………….. 53
SOLENOID CIRCUIT TEST ………………………………………………………………. 53

TABLE OF CONTENTS

STARTER CIRCUIT WIRING TEST ……………………………………………………. 54
STARTER MOTOR TEST……………………………………………………………………55
NEUTRAL SWITCH CIRCUIT ………………………………………………………. 57
INSTRUMENTATION PANEL ………………………………………………………. 59
PARKING BRAKE CIRCUIT ………………………………………………………… 61
VIBRATION CONTROL CIRCUIT…………………………………………………. 61
SPRINKLER CIRCUIT…………………………………………………………………. 63
ACCESSORY SOCKETS…………………………………………………………….. 63
LIGHTING CIRCUIT ……………………………………………………………………. 65
HAZARD/ DIRECTIONAL CIRCUIT………………………………………………. 65
BACK-UP ALARM ……………………………………………………………………… 66
WIRE HARNESS 7130/02015 ………………………………………………………. 68
WIRE HARNESS 7130/02055 ………………………………………………………. 71
ELECTRICAL SCHEMATICS ………………………………………………………. 75
SECTION FOUR
HYDRAULIC SYSTEMS……………………………………………. 81
PROPULSION SYSTEM ……………………………………………………………… 83
PROPULSION SYSTEM DIAGNOSTICS ………………………………………. 83
INTERNAL LEAKAGE ………………………………………………………………………..83
PUMP SERVO CONTROL…………………………………………………………………. 84
VIBRATION SYSTEM …………………………………………………………………. 87
VIBRATION SYSTEM DIAGNOSTICS …………………………………………..88
VIBRATION FREQUENCY ………………………………………………………………… 88
STEERING SYSTEM…………………………………………………………………… 91
STEERING SYSTEM DIAGNOSTICS……………………………………………. 91
HYDRAULIC RESERVOIR ……………………………………………………………92

TABLE OF CONTENTS

HYDRAULIC OIL FILTER ……………………………………………………………. 93
HYDRAULIC OIL RESERVOIR ……………………………………………………. 93
PARKING BRAKES……………………………………………………………………. 95
PARKING BRAKE DIAGNOSTICS ………………………………………………. 95
HYDRAULIC TEST PORTS…………………………………………………………. 96
HYDRAULIC SCHEMATIC ………………………………………………………….. 97
HYDRAULIC COMPONENTS ………………………………………………………. 99
POCLAIN MC05 PROPULSION MOTOR …………………………………….. 100
SAUER/SUNDSTRAND SERIES 42 PROPULSION PUMP ……………. 103
SECTION FIVE
DRUM DRIVE ………………………………………………………… 107
DRUM ASSEMBLY DRAWING ………………………………………………….. 111
DRUM REMOVAL…………………………………………………………………….. 115
DRIVE MOTOR REMOVAL ………………………………………………………… 115
DRIVE MOTOR REPAIR……………………………………………………………. 117
DRIVE MOTOR INSTALLATION………………………………………………… 117
DRUM DRIVE BEARING REMOVAL ………………………………………….. 117
DRUM BEARING INSTALLATION ……………………………………………… 119
DRUM INSTALLATION ……………………………………………………………… 119
SECTION SIX
PARKING BRAKE SYSTEM ……………………………………. 121
PARK BRAKE TESTING …………………………………………………………… 123
BRAKE RELEASE FOR TOWING………………………………………………. 123

TABLE OF CONTENTS

BRAKE REPAIRS …………………………………………………………………….. 125
BRAKE DISASSEMBLY ……………………………………………………………………125
BRAKE ASSEMBLY …………………………………………………………………………125
SECTION SEVEN
VIBRATORY SYSTEM ……………………………………………. 127
VIBRATORY SHAFT REMOVAL………………………………………………… 133
VIBRATORY SHAFT INSTALLATION …………………………………………135
SECTION EIGHT
STEERING SYSTEM ………………………………………………. 137
ARTICULATION JOINTS …………………………………………………………… 139
ARTICULATION PARTS……………………………………………………………. 140
HORIZONTAL PIVOT DISASSEMBLY………………………………………………. 143
STEERING PIVOT DISASSEMBLY…………………………………………………… 143
STEERING PIVOT ASSEMBLY …………………………………………………………145
HORIZONTAL PIVOT INSTALLATION ……………………………………………….145
STEERING CYLINDER ……………………………………………………………… 146
SECTION NINE
CHASSIS ………………………………………………………………. 147
FRAME …………………………………………………………………………………….149
PANELS …………………………………………………………………………………..150
OPERATOR PLATFORM…………………………………………………………… 151
WATER TANK …………………………………………………………………………..152
WATER TANK COATING …………………………………………………………..153
INERTOL POXITAR …………………………………………………………………………153

TABLE OF CONTENTS

ROLL OVER PROTECTIVE STRUCTURE (ROPS) ………………………. 154
ROPS MAINTENANCE …………………………………………………………………… 155
ROPS DAMAGE…………………………………………………………………………….. 155
ROPS BOLT TORQUE ……………………………………………………………………. 155
SUN ROOF ………………………………………………………………………………. 156
SECTION TEN
ATTACHMENTS ……………………………………………………. 157
WATER SPRINKLER SYSTEM ………………………………………………….. 158
SPRINKLER FUNCTION…………………………………………………………………. 159
STORAGE PREPARATION …………………………………………………………….. 159
DRUM SCRAPERS…………………………………………………………………… 160
SCRAPER ADJUSTMENT ………………………………………………………………. 161
LIGHT KIT 87130/20120 ……………………………………………………………. 162
LIGHT KIT INSTALLATION ……………………………………………………………… 163
SPOTLIGHT KIT 87130/20100 …………………………………………………… 164
SPOTLIGHT INSTALLATION …………………………………………………………… 165
BACK UP ALARM KIT 87130/20200 …………………………………………… 166
ALARM INSTALLATION ………………………………………………………………….. 167

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