JCB Vibromax Tandem Rollers 255, 265 Service Repair Manual
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JCB Vibromax Tandem Rollers 255, 265 Service Repair Manual
The 255/265 Series vibratory roller is a redesign of the 253/263. The machine remains a 2.5 metric ton, tandem drum machine with articulated steering, hydrostatic drive and a hydraulically driven vibration system. The 255 has a 1000 mm (39 inch) drum width while the 265 is a 1200 mm (47 inch) drum width version. These machines are also offered with a “K” version which is a combination roller built with pneumatic tires in place of the rear drum. A Kubota D1403B, water cooled, three cylinder in-line diesel engine, mounted in the rear chassis, provides the power for the machine. The standard engine has a 29.0 Net Horse Power rating at 2600 RPM. An optional high horsepower Kubota D1403B (37 horsepower) is also available. Both engines meet the latest exhaust emissions standards. A Sauer Sunstrand hydrostatic propulsion pump provides oil for the front and rear Poclain, fixed displacement, drum drive motors in a parallel path. On the “K” model combination roller there are three propulsion motors in parallel. Propulsion system controls are enhanced with the addition of a high and low operating range. The motors are located on the right hand side of the drums and are connected directly to the drum. 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, left hand 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. Pressure testing of the hydraulic system has been simplified by the location of a test station inside the left side access door. Pressure testing of the drive, charge, vibratory and steering systems can be performed from this one location.
Table of Contents:
JCB Vibromax Tandem Rollers 255, 265 Service Repair Manual
SECTION ONE
GENERAL INFORMATION
MACHINE DESCRIPTION 1 – 3
SAFETY, GENERAL 1 – 7
SAFETY, PERSONAL 1 – 7
SAFETY, MACHINE OPERATION 1 – 8
SAFETY, MAINTENANCE 1 – 10
GENERAL INFORMATION 1 – 12
STANDARD TORQUE DATA 1 – 13
METRIC/USA CONVERSIONS 1 – 14
MACHINE SPECIFICATIONS 1 – 15
FLUID SPECIFICATIONS 1 – 17
DIESEL FUEL SPECIFICATION 1 – 18
ENGINE OIL SPECIFICATION 1 – 19
SECTION TWO
ENGINE R&I
ENGINE REMOVAL & INSTALLATION 2 – 3
SECTION THREE
ELECTRICAL CIRCUITS
INSTRUMENT PANEL 3 – 2
Instrument panel, left side3 – 3
Combination indicator 3 – 4
Instrument panel, right side 3 – 5
OPERATOR’S CONSOLE 3 – 6
ELECTRICAL INFORMATION 3 – 8
RELAY LOCATION CHART 3 – 9
FUSE LOCATION CHART 3 – 9
UNDERSTANDING ELECTRICAL SCHEMATICS 3 – 11
UNDERSTANDING RELAYS 3 – 14
EMERGENCY STOP CIRCUIT 3 – 17
STARTER/ CHARGING CIRCUIT 3 – 19
UNDERSTANDING BATTERIES 3 – 19
UNDERSTANDING ALTERNATORS3 – 21
STARTER SYSTEM DIAGNOSTICS 3 – 25
NEUTRAL SWITCH CIRCUIT 3 – 29
INSTRUMENTATION PANEL 3 – 31
COMBINATION INDICATOR3 – 32
OPERATOR’S CONSOLE 3 – 33
PARKING BRAKE CIRCUIT 3 – 35
VIBRATION CONTROL CIRCUIT 3 – 35
SPRINKLER CIRCUIT 3 – 37
ACCESSORY SOCKETS 3 – 37
SPRINKLER CIRCUIT (“K” option) 3 – 39
LIGHTING CIRCUIT 3 – 41
HAZARD/ DIRECTIONAL CIRCUIT 3 – 41
BACK-UP ALARM 3 – 42
WIRE HARNESS LAYOUT 3 – 43
WIRE HARNESS 7131/80115 3 – 46
WIRE CHART 7131/80115 3 – 49
WIRE HARNESS 7131/80255 3 – 51
WIRE CHART 7131/80255 3 – 55
ELECTRICAL SCHEMATICS 3 – 59
SECTION FOUR
HYDRAULIC SYSTEMS
PROPULSION DRAWINGS 4 – 2
PROPULSION SYSTEM 4 – 5
PROPULSION SYSTEM DIAGNOSTICS4 – 5
VIBRATION DRAWINGS 4 – 7
VIBRATION SYSTEM 4 – 10
VIBRATION SYSTEM DIAGNOSTICS4 – 11
STEERING DRAWINGS 4 – 12
STEERING SYSTEM 4 – 15
STEERING SYSTEM DIAGNOSTICS4 – 15
HYDRAULIC RESERVOIR 4 – 16
HYDRAULIC OIL FILTER 4 – 17
HYDRAULIC OIL RESERVOIR 4 – 17
BRAKE SYSTEM DRAWINGS 4 – 18
PARKING BRAKES 4 – 21
PARKING BRAKE DIAGNOSTICS4 – 21
HYDRAULIC TEST PORTS 4 – 22
HYDRAULIC COMPONENT LOCATIONS 4 – 30
HYDRAULIC SCHEMATIC 4 – 31
HYDRAULIC SCHEMATIC (“K” model) 4 – 32
“K” MODEL SYSTEMS 4 – 33
HYDRAULIC COMPONENTS
POCLAIN MC05 PROPULSION MOTOR 4 – 38
SAUER/SUNDSTRAND SERIES 42 PROPULSION PUMP 4 – 41
SECTION FIVE
POWER TRAIN
DRUM REMOVAL 5 – 11
DRIVE MOTOR REMOVAL 5 – 11
DRIVE MOTOR REPAIR 5 – 13
DRIVE MOTOR INSTALLATION 5 – 13
DRUM DRIVE BEARING REMOVAL 5 – 13
DRUM BEARING INSTALLATION 5 – 15
DRUM INSTALLATION 5 – 15
PNEUMATIC TIRE DRIVE 5 – 16
SECTION SIX
PARKING BRAKE SYSTEM
PARK BRAKE TESTING 6 – 5
BRAKE RELEASE FOR TOWING 6 – 5
TOWING PROCEDURE6 – 6
BRAKE REPAIRS 6 – 8
SECTION SEVEN
VIBRATORY SYSTEM
VIBRATORY SHAFT REMOVAL 7 – 9
INSTALLING VIBRATORY SHAFT 7 – 11
SECTION EIGHT
STEERING SYSTEM
SECTION NINE
CHASSIS
FRAME 9 – 3
HOOD & DOOR PANELS 9 – 4
OPERATOR PLATFORM 9 – 5
WATER TANK 9 – 6
WATER TANK COATING 9 – 7
ROLL OVER PROTECTIVE STRUCTURE (ROPS) 9 – 8
SUN ROOF 9 – 10
SECTION TEN
ATTACHMENTS
WATER SPRINKLER SYSTEM 10 – 2
DRUM SCRAPERS 10 – 6
ROAD LIGHT KIT 87130/20120 10 – 8
WORK LIGHT KIT 87130/20100 10 – 10
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⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
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