JCB Vibromax 355, 365, 455, 465 Roller Service Repair Manual
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JCB Vibromax 355, 365, 455, 465 Roller Service Repair Manual
- The operator’s platform was designed using modern techniques to assure good visibility and operator comfort. The operator’s seat box can be tilted forward to gain easy access to the machine’s hydraulic pumps and valves. Both tandem roller models operate at a vibration frequency of 3300 vibrations per minute (55 Hz). Vibratory operation is available for either the front drum or both drums. A two frequency/two amplitude option is available for both the 3.5 and 4.5 metric ton machines.
- The second vibration frequency is 3000 vpm. (50 Hz). On the “K” model only the front drum will vibrate. The hydrostatic drive system allows for infinitely variable ground speed. All machines are equipped with a two speed arrangement which provides greater control in the 0 to 4 mph range. The hydrostatic drive system consists of a piston pump and front and rear drum drive motors. Hydraulic release, spring applied parking brakes are incorporated into the design of the drum motors.
- On the “K” model two smaller hydraulic motors are used to drive the right and left side pneumatic tires. Brakes are also incorporated into “K” model drive motors. As a factory option, these machines offer an articulation offset of five inches (127 mm) to the left or right of center position. This feature is most useful when compacting asphalt on tight turns. These machines are equipped with an intermittent sprinkler system for use in asphalt applications. The water tanks are made of a rust proof synthetic material.
- The system is a pressure spray type with sprinkler tubes fitted with nozzles. The system controls are designed to allow variable off times in the automatic mode to minimize water usage. The pneumatic “K” model offers separate sprinkler systems for the front and rear of the machine to allow the use of special soap solutions on the rear tires.
- Both systems have variable controls. Each drum is equipped with front and rear scrapers. The scrapers are spring loaded against the drum and can easily be moved away from the drum for soil and gravel compaction jobs. Scrapers are also available on the “K” model. A cocoa mat option is also available. As sold in the United States the machines are fitted with a Roll Over Protective Structure (ROPS). A seat belt is provided as part of the ROPS system.
- As sold in the United States the machines are also fitted with a standard Back-up alarm system and an emergency stop system. All models include a centralized testing station for quick and easy diagnostics for the various hydraulic systems. Road lights, work lights, FOPS, and a sun roof are four standard options. Other additional equipment such as beacon lights, slow moving machine signs, etc., are available as special order items. If you have special needs please contact your dealer.
Table Of Contents:
JCB Vibromax 355, 365, 455, 465 Roller Service Repair Manual
SECTION ONE
GENERAL INFORMATION
MACHINE DESCRIPTION 1 – 3
SERIAL NUMBERS 1 – 4
GENERAL SAFETY 1 – 6
SPARK ARRESTER 1 – 6
PERSONAL SAFETY 1 – 7
OPERATING SAFETY 1 – 8
MAINTENANCE SAFETY 1 – 11
GENERAL INFORMATION 1 – 14
CLEANING 1 – 14
INSPECTION 1 – 14
BEARINGS 1 – 14
NEEDLE BEARINGS 1 – 14
GEARS 1 – 14
OIL SEALS, O-RINGS, & GASKETS 1 – 14
SHAFTS 1 – 15
SERVICE PARTS 1 – 15
LUBRICATION 1 – 15
STANDARD TORQUE DATA 1 – 15
METRIC/USA CONVERSIONS 1 – 17
MACHINE SPECIFICATIONS 1 – 18
355/365 SPECIFICATIONS 1 – 18
ENGINE DATA 1 – 19
OPERATING DATA 1 – 19
455/465 SPECIFICATIONS 1 – 20
ENGINE DATA 1 – 21
OPERATING DATA 1 – 21
FLUID CAPACITY 1 – 22
PNEUMATIC TIRE PRESSURE 1 – 22
DIESEL FUEL SPECIFICATION 1 – 23
ENGINE OIL SPECIFICATION 1 – 24
SECTION TWO
ENGINE R&I
ENGINE COOLING SYSTEM 2 – 2
ENGINE EXHAUST SYSTEM 2 – 3
ENGINE INTAKE SYSTEM 2 – 4
ENGINE FUEL SYSTEM 2 – 5
HYDRAULIC PUMP CONTROLS 2 – 6
ENGINE MOUNTS 2 – 7
ENGINE REMOVAL 2 – 8
ENGINE OVERHAUL 2 – 9
KUBOTA ENGINE WARRANTY 2 – 9
ENGINE INSTALLATION 2 – 12
SECTION THREE
ELECTRICAL CIRCUITS
INSTRUMENT PANEL 3 – 2
Instrument Panel, Single Amplitude 3 – 2
Instrument Panel, Two Amplitude 3 – 4
Instrument Panel, “K” Model 3 – 6
Combination Indicator 3 – 8
Instrument Panel, Right Side 3 – 9
OPERATOR’S CONSOLE 3 – 10
ELECTRICAL INFORMATION 3 – 11
Fuses 3 – 12
Relays 3 – 13
UNDERSTANDING ELECTRICAL SCHEMATICS 3 – 15
UNDERSTANDING RELAYS 3 – 18
VIBROMAX RELAYS 3 – 19
EMERGENCY STOP CIRCUIT 3 – 21
STARTER/ CHARGING CIRCUIT 3 – 23
UNDERSTANDING BATTERIES 3 – 23
BATTERY DIAGNOSTICS 3 – 24
UNDERSTANDING ALTERNATORS 3 – 25
CHARGING SYSTEM DIAGNOSTICS 3 – 26
VOLTAGE CHECKS AT ALTERNATOR 3 – 27
SYSTEM LEAKAGE 3 – 27
CIRCUIT WIRING TEST 3 – 27
MEASURING ALTERNATOR OUTPUT 3 – 28
UNDERSTANDING STARTERS 3 – 28
STARTER SOLENOID 3 – 29
STARTER SYSTEM DIAGNOSTICS 3 – 29
SOLENOID CIRCUIT TEST 3 – 29
STARTER CIRCUIT WIRING TEST 3 – 30
STARTER MOTOR TEST 3 – 31
NEUTRAL SWITCH CIRCUIT 3 – 33
NEUTRAL SWITCH CIRCUIT 3 – 35
INSTRUMENTATION PANEL 3 – 37
PARKING BRAKE CIRCUIT 3 – 39
VIBRATION CONTROL CIRCUIT (one amplitude) 3 – 39
VIBRATION CONTROL CIRCUIT (two amplitude) 3 – 41
SPRINKLER CIRCUIT 3 – 43
LIGHTING CIRCUIT 3 – 45
HAZARD/ DIRECTIONAL CIRCUIT 3 – 45
BACK-UP ALARM 3 – 46
WIRE HARNESS LAYOUT 3 – 47
WIRE HARNESS 7140/81115 3 – 48
WIRE CHART 7140/81115 3 – 50
WIRE HARNESS 7140/81255 3 – 52
WIRE CHART 7140/81255 3 – 54
WIRE HARNESS 7140/82115 3 – 57
WIRE CHART 7140/82115 3 – 60
WIRE HARNESS 7140/82255 3 – 62
WIRE CHART 7140/82255 3 – 64
ELECTRICAL SCHEMATICS 3 – 69
SECTION FOUR
HYDRAULIC SYSTEMS
PROPULSION DRAWINGS 4 – 2
PROPULSION SYSTEM 4 – 5
PROPULSION SYSTEM DIAGNOSTICS 4 – 5
INTERNAL LEAKAGE 4 – 5
PUMP SERVO CONTROL 4 – 6
VIBRATION DRAWINGS (one amplitude) 4 – 10
VIBRATION SYSTEM (one amplitude) 4 – 13
VIBRATION DRAWINGS (two amplitude) 4 – 16
VIBRATION SYSTEM (two amplitude) 4 – 19
VIBRATION SYSTEM DIAGNOSTICS 4 – 22
VIBRATION FREQUENCY 4 – 22
STEERING DRAWINGS (without offset) 4 – 23
STEERING SYSTEM (without offset) 4 – 26
STEERING SYSTEM DIAGNOSTICS 4 – 26
STEERING DRAWINGS (with offset) 4 – 27
STEERING SYSTEM (with offset) 4 – 29
BRAKE SYSTEM DRAWINGS 4 – 30
PARKING BRAKES SYSTEM 4 – 35
PARKING BRAKE DIAGNOSTICS 4 – 35
HYDRAULIC TEST PORTS 4 – 36
COOLER LINES 4 – 49
SUCTION LINES 4 – 53
HYDRAULIC FILTERS 4 – 56
HYDRAULIC COMPONENTS 4 – 57
HYDRAULIC SCHEMATICS 4 – 58
HYDRAULIC COMPONENTS
POCLAIN MC05 PROPULSION MOTOR 4 – 66
SAUER/SUNDSTRAND SERIES 42 PROPULSION PUMP 4 – 69
SECTION FIVE
POWER TRAIN
DRUM CROSS-SECTION 5 – 6
DRUM REMOVAL 5 – 13
DRIVE MOTOR REMOVAL 5 – 13
DRIVE MOTOR REPAIR 5 – 15
DRIVE MOTOR INSTALLATION 5 – 15
DRUM DRIVE BEARING REMOVAL 5 – 15
DRUM BEARING INSTALLATION 5 – 17
DRUM INSTALLATION 5 – 17
PNEUMATIC TIRE DRIVE 5 – 18
SECTION SIX
PARKING BRAKE SYSTEM
PARK BRAKE TESTING 6 – 7
BRAKE RELEASE FOR TOWING 6 – 7
TOWING PROCEDURE 6 – 8
BRAKE REPAIRS 6 – 10
BRAKE DISASSEMBLY 6 – 10
BRAKE ASSEMBLY 6 – 10
SECTION SEVEN
VIBRATORY SYSTEM
VIBRATION SHAFT (two amplitude) 7 – 5
DRUM REMOVAL 7 – 7
VIBRATION SHAFT REMOVAL 7 – 7
LEFT VIB BEARING REMOVAL 7 – 9
LEFT BEARING INSTALLATION 7 – 9
RIGHT BEARING INSTALLATION 7 – 11
DRUM INSTALLATION 7 – 11
SECTION EIGHT
STEERING SYSTEM
HORIZONTAL PIVOT DISASSEMBLY 8 – 7
STEERING PIVOT DISASSEMBLY 8 – 7
SECTION NINE
CHASSIS
ROLL-OVER PROTECTION STRUCTURE (ROPS) 9 – 3
ROPS maintenance 9 – 3
ROPS damage 9 – 3
Tightening torques 9 – 4
SECTION TEN
ATTACHMENTS
FRONT HARNESS 7140/90106 10 – 2
REAR HARNESS 7140/90111 10 – 2
8364/01150 WORKLIGHT CONNECTOR 10 – 2
INSTALLATION OF 87140/90100 WORK LIGHT KIT 10 – 2
INSTALLATION OF 87140/90150 ROAD LIGHT KIT 10 – 3
FUSE LAYOUT 10 – 7
RELAY LAYOUT 10 – 8
SPRINKLER SYSTEM 10 – 9
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⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.