JCB Vibromax 253 263 Tandem Roller Service Repair Manual
Sample Page From The Manual:
JCB Vibromax 253 263 Tandem Roller Service Repair Manual
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 modular design of the reservoir makes it possible to completely remove the reservoir if necessary. Pressure testing of the hydraulic system has been simplified by the location of a test station in the left side of the engine compartment. Pressure testing of the drive, charge, brake release, vibratory and steering systems can be performed from one location. 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, just to the front of the lockable access panel for the fuse compartment. All electrical control components are located behind a removable 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 modular design allows for easy removal if necessary. Fixed position scrapers on the front and rear of each drum and a pressurized sprinkler bar on each drum, complete the system.
Table of Contents:
JCB Vibromax 253 263 Tandem Roller Service Repair Manual
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
GEARS20
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
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
STARTER CIRCUIT WIRING TEST 54
STARTER MOTOR TEST55
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
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
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
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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