JCB Vibromax 405, 605, 606 Single Drum Rollers Service Repair Manual
Description:
JCB Vibromax 405, 605, 606 Single Drum Rollers Service Repair Manual
A steering pump, mounted to the rear of the vibratory pump, provides the oil needed for steering. The steering pump also acts as the 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. These machines come standard with parking brakes at both the front drum and the rear axle. A spring applied-hydraulically released 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 input shaft. Pressure testing has been made easier by placing all the test ports at a centrally located test station under the engine hood. The electrical system consists of a 12 volt battery, starter, alternator system, optional lighting and standard instrumentation. The most notable changes from the earlier model is the mounting of the engine in a forward position and the tilting hood. These changes result in a substantial ambient noise level reduction.
Table of Contents:
JCB Vibromax 405, 605, 606 Single Drum Rollers Service Repair Manual
SECTION ONE
GENERAL INFORMATION 1 – 1
MACHINE DESCRIPTION 1 – 3
SERIAL NUMBERS 1 – 5
IDENTIFYING MACHINE COMPONENTS 1 – 6
FLUID SPECIFICATIONS – 405 1 – 8
FLUID SPECIFICATIONS – 605 1 – 9
MACHINE SPECIFICATIONS 1 – 10
Model 405 1 – 11
Model 605 1 – 13
Model 606 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 – 26
SECTION TWO
ENGINE 2 – 1
ENGINE DATA 2 – 2
CUMMINS ENGINE WARRANTY 2 – 3
ENGINE REMOVAL 2 – 4
SECTION THREE
ELECTRICAL 3 – 1
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 3 – 13
UNDERSTANDING BATTERIES 3 – 13
BATTERY DIAGNOSTICS 3 – 14
UNDERSTANDING ALTERNATORS 3 – 15
CHARGING SYSTEM DIAGNOSTICS 3 – 16
VOLTAGE CHECKS AT ALTERNATOR 3 – 17
SYSTEM LEAKAGE 3 – 17
CIRCUIT WIRING TEST 3 – 17
MEASURING ALTERNATOR OUTPUT 3 – 18
UNDERSTANDING STARTERS 3 – 18
STARTER SOLENOID 3 – 19
STARTER SYSTEM DIAGNOSTICS 3 – 19
SOLENOID CIRCUIT TEST 3 – 19
STARTER CIRCUIT WIRING TEST 3 – 20
STARTER MOTOR TEST 3 – 21
INSTRUMENTATION PANEL 3 – 23
EMERGENCY STOP SWITCH/ BRAKE SWITCH 3 – 25
HIGH SPEED CIRCUIT 3 – 27
VIBRATION CIRCUIT 3 – 29
LIGHTING CIRCUIT 3 – 31
WORK LIGHTS, ACCESSORY PLUG, HEATER AND WIPERS 3 – 33
CAB WIRING 3 – 42
WIRE HARNESS 7241/80315 (0) 3 – 43
WIRE CHART 7241/80315 (0) 3 – 48
405 REAR HARNESS 7210/80510 3 – 52
WIRE CHART 7210/80510 3 – 53
605 REAR HARNESS 7221/80510 3 – 56
WIRE CHART 7221/80510 3 – 57
SECTION FOUR
HYDRAULIC 4 – 1
405 HYD COOLER LINES 4 – 2
605 HYD COOLER LINES 4 – 4
405 HYD DRAIN LINES 4 – 6
605 HYD DRAIN LINES 4 – 8
405 HYD CHARGE SYSTEM 4 – 10
605 HYD CHARGE SYSTEM 4 – 12
405 HYD TEST STATION 4 – 14
605 HYD TEST STATION 4 – 15
HYDRAULIC TEST FITTINGS 4 – 17
405 PROPULSION SYSTEM 4 – 18
605 PROPULSION SYSTEM 4 – 20
PROPULSION SCHEMATIC 4 – 22
PROPULSION SYSTEM DIAGNOSTICS 4 – 24
INTERNAL LEAKAGE 4 – 24
405 VIBRATION SYSTEM 4 – 26
605 VIBRATION SYSTEM 4 – 28
VIBRATION FREQUENCY 4 – 32
VIBRATION AMPLITUDE 4 – 34
VIBRATORY SYSTEM DIAGNOSTICS 4 – 35
405 STEERING SYSTEM 4 – 36
605 STEERING SYSTEM 4 – 38
STEERING SYSTEM SCHEMATIC 4 – 40
405 PARKING BRAKE SYSTEM 4 – 41
605 PARKING BRAKE SYSTEM 4 – 43
PARKING BRAKE SCHEMATIC 4 – 45
TOWING YOUR MACHINE 4 – 46
TOWING PROCEDURE 4 – 47
405 DIFFERENTIAL LOCK SYSTEM 4 – 48
605 DIFFERENTIAL LOCK SYSTEM 4 – 50
DIFFERENTIAL LOCK SCHEMATIC 4 – 52
405 HYDRAULIC COMPONENTS 4 – 53
405 HYDRAULIC SCHEMATIC 4 – 54
605 HYDRAULIC COMPONENTS 4 – 55
605 HYDRAULIC SCHEMATIC 4 – 56
SECTION FIVE
POWER TRAIN 5 – 1
GENERAL INFORMATION 5 – 2
OPERATION 5 – 3
405 SPETH AXLE 5 – 4
405 DIFFERENTIAL GEARS 5 – 5
405 INTERMEDIATE GEARS 5 – 5
405 AXLE PLANETARY 5 – 6
605 SPETH AXLE 5 – 7
605/606 AXLE REPAIRS 5 – 7
REAR AXLE REMOVAL 5 – 8
REAR AXLE INSTALLATION 5 – 9
AXLE TUBE DISASSEMBLY 5 – 10
PLANETARY & TUBE DISSASSEMBLY 5 – 12
PLANETARY & TUBE ASSEMBLY 5 – 14
605 INTERMEDIATE GEARS 5 – 16
INTERMEDIATE GEAR DISASSEMBLY 5 – 18
INTERMEDIATE GEAR ASSEMBLY 5 – 20
605 DIFFERENTIAL GEARS 5 – 28
405 DRUM ASSEMBLY 5 – 29
605 DRUM ASSEMBLY 5 – 35
DRUM REMOVAL 5 – 40
DRUM INSTALLATION 5 – 40
RIGHT SIDE BEARING COVER 5 – 41
DRUM DRIVE BEARING REMOVAL 5 – 41
DRUM DRIVE BEARING ASSEMBLY 5 – 43
DRUM DRIVE MOTOR REPAIRS 5 – 44
DRUM DRIVE GEARBOX 5 – 45
GFT 17 T2/312 2 GEARBOX 5 – 47
SECTION SIX
PARKING BRAKE SYSTEM 6 – 1
405 PARKING BRAKE SYSTEM 6 – 2
605 PARKING BRAKE SYSTEM 6 – 4
PARKING BRAKE SCHEMATIC 6 – 6
TOWING YOUR MACHINE 6 – 7
TOWING PROCEDURE 6 – 8
405 AXLE BRAKE 6 – 9
405 AXLE BRAKE PARTS LIST 6 – 11
605 AXLE BRAKE 6 – 12
605 AXLE BRAKE PARTS LIST 6 – 14
SECTION SEVEN
VIBRATION SYSTEM 7 – 1
LIFTING DEVICE 7 – 2
DRUM EXCITER SHAFT 7 – 3
405 VIBRATION SYSTEM 7 – 4
605 VIBRATION SYSTEM 7 – 6
VIBRATION FREQUENCY 7 – 10
VIBRATION AMPLITUDE 7 – 11
VIBRATORY SYSTEM DIAGNOSTICS 7 – 12
405 DRUM DRAWING 7 – 13
405 DRUM – LEFT SIDE 7 – 14
405 DRUM – RIGHT SIDE 7 – 17
605/606 DRUM DRAWING 7 – 21
605 DRUM – LEFT SIDE 7 – 22
605 DRUM – RIGHT SIDE 7 – 25
DRUM REMOVAL 7 – 28
DRUM INSTALLATION 7 – 28
RIGHT SIDE BEARING COVER 7 – 29
EXCITER BEARING REMOVAL 7 – 30
EXCITER BEARING ASSEMBLY 7 – 32
SECTION EIGHT
STEERING SYSTEM 8 – 1
405 STEERING SYSTEM 8 – 2
605 STEERING SYSTEM 8 – 4
STEERING SYSTEM SCHEMATIC 8 – 6
SPECIAL TOOLS 8 – 7
ARTICULATION JOINTS 8 – 8
JOINT DISASSEMBLY 8 – 10
JOINT ASSEMBLY 8 – 14
STEERING CYLINDER 8 – 17
SECTION NINE
CHASSIS 9 – 1
DRUM FRAME 9 – 2
405 REAR FRAME 9 – 3
605 REAR FRAME 9 – 4
405 – 605 SUB-FRAME 9 – 5
HOOD 9 – 6
605 OPERATOR PLATFORM 9 – 7
ROLLOVER PROTECTION STRUCTURE 9 – 8
SECTION TEN
ATTACHMENTS 10 – 1
405 LEVELING BLADE 10 – 2
605 LEVELING BLADE 10 – 3
LEVELING BLADE SYSTEM SCHEMATIC 10 – 4
405 BLADE SYSTEM LINES 10 – 5
605 BLADE SYSTEM LINES 10 – 6
BLADE SYSTEM PUMP 10 – 7
BLADE SYSTEM VALVE 10 – 8
405 BLADE VALVE LINKAGE 10 – 9
605 BLADE VALVE LINKAGE 10 – 10
605DA DUAL WATER TANK 10 – 11
605DA DRUM SPRINKLER 10 – 12
605DA TIRE SPRINKLER 10 – 13
605DA TIRE SCRAPER 10 – 14
605DA DRUM SCRAPER 10 – 14
605DA SPRINKLER CONTROL 10 – 15
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