(S/N: 2802400 Onwards)
-
This service manual PDF download for the VMT 860 Tier 3 JCB Vibromax Tandem Compaction Roller has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
APPLICABLE MODELS :
JCB Vibromax Tandem Compaction Roller
JCB VMT 860 Tier 3 - From S/N: 2802400
TABLE OF CONTENTS :
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section C - Electrics
Section E - Hydraulics
Section H - Steering
Section K - Engine
Section L - Vibration
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9813/0150-1
Total Pages : 263
This JCB Vibromax service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.
More Info : http://www.sitelux.com
-
9813-0150
Section 1 - General Information
Section 1
Section 1
General Information
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Service Manual - VMT860 Tier 3
Service Manual - VMT860 Tier 3
<TABLE ROW
Section 1 - General Information
Section 1 - General Information
<TABLE ROW
Section 2 - Care and Safety
Section 2 - Care and Safety
<TABLE ROW
Section 3 - Maintenance
Section 3 - Maintenance
<TABLE ROW
Section C - Electrics
Section C - Electrics
<TABLE ROW
Section E - Hydraulics
Section E - Hydraulics
<TABLE ROW
Section H - Steering
Section H - Steering
<TABLE ROW
Section K - Engine
Section K - Engine
<TABLE ROW
Section L - Vibration
Section L - Vibration
<GRAPHIC
<GRAPHIC
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Notes:
<TABLE BODY
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
Introduction
Introduction
About This Manual
About This Manual
Machine Model and Serial Number
Machine Model and Serial Number
This manual provides information for the following model(s) in the JCB machine range:
- VMT 860 from SN 2802400
- VMT 860 from SN 2802400
Using the Service Manual
Using the Service Manual
This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department.
These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment.
The illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify.
General warnings in Section 2 are repeated throughout the manual, as well as specific warnings. Read all safety statements regularly, so you do not forget them.
Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course...
Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third.
The manufacturer's policy is one of continuous improvement. The right to change the specification of the machine without notice ...
Finally, please remember above all else safety must come first!
Section Numbering
Section Numbering
The manual is compiled in sections, the first three are numbered and contain information as follows:
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
1
1
General Information - includes torque settings and service tools.
<TABLE ROW
2
2
Care and Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
<TABLE ROW
3
3
Maintenance - includes service schedules and recommended lubricants for all the machine.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example:
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
A
A
Attachments
<TABLE ROW
B
B
Body and Framework, etc.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section.
Units of Measurement
Units of Measurement
In this publication, the S.I. system of units is used. For example, liquid capacities are given in litres. The Imperial units follow in parentheses ( ) eg 28 litres (6 gal).
Left Side, Right Side
Left Side, Right Side
In this manual, 'left'
A
B
<GRAPHIC
<GRAPHIC
Fig 1.
Cross References
Cross References
In this publication, page cross references are made by presenting the subject title printed in bold, italic and underlined. It i...
K Cross References ( T 1-2)
Identifying Your Machine
Identifying Your Machine
Machine Identification Plate
Machine Identification Plate
Your machine has an identification plate mounted as shown.
K Fig 2. ( T 1-3)
The machine and engine serial numbers can help identify exactly the type of equipment you have.
<GRAPHIC
<GRAPHIC
Fig 2.
Page left intentionally blank
Torque Settings
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Introduction
Some external fasteners on JCB machines are manufactured using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on earlier machines.
The two types of fasteners can be readily identified by colour and part number suffix.
K Table 1. Fastener Types ( T 1-5)
Table 1. Fastener Types
Table 1. Fastener Types
<TABLE
<TABLE HEADING
<TABLE ROW
Fastener Type
Colour
Part No. Suffix
<TABLE BODY
<TABLE ROW
Zinc and Yellow
Golden finish
'Z' (e.g. 1315/3712Z)
<TABLE ROW
Dacromet
Mottled silver finish
'D' (e.g. 1315/3712D)
As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must be relevant to the type of fastener.
A Dacromet bolt should not be used in conjunction with a Zinc or Yellow plated nut, as this could change the torque characteristics of the torque setting further. For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt.
All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
Dacromet bolts, due to their high corrosion resistance are used in areas where rust could occur. Dacromet bolts are only used for external applications. They are not used in applications such as gearbox or engine joint seams or internal applications.
Bolts and Screws
Bolts and Screws
Use the following torque setting tables only where no torque setting is specified in the text.
Dacromet fasteners are lubricated as part of the plating process, do not lubricate.
Torque settings are given for the following conditions:
Condition 1
Condition 1
- Un-lubricated fasteners
- Un-lubricated fasteners
- Zinc fasteners
- Yellow plated fasteners
Condition 2
Condition 2
- Zinc flake (Dacromet) fasteners
- Zinc flake (Dacromet) fasteners
- Lubricated zinc and yellow plated fasteners
- Where there is a natural lubrication. For example, cast iron components
Verbus Ripp Bolts
Verbus Ripp Bolts
<GRAPHIC
<GRAPHIC
Fig 1.
Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.
Table 2. Torque Settings - UNF Grade 'S' Fasteners
Table 2. Torque Settings - UNF Grade 'S' Fasteners
<TABLE
<TABLE HEADING
<TABLE ROW
Bolt Size
Hexagon (A/F)
Condition 1
Condition 2
<TABLE ROW
in.
mm
in.
Nm
kgf m
lbf ft
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
1/4
6.3
7/16
11.2
1.1
8.3
10.0
1.0
7.4
<TABLE ROW
5/16
7.9
1/2
22.3
2.3
16.4
20.0
2.0
14.7
<TABLE ROW
3/8
9.5
9/16
40.0
4.1
29.5
36.0
3.7
26.5
<TABLE ROW
7/16
11.1
5/8
64.0
6.5
47.2
57.0
5.8
42.0
<TABLE ROW
1/2
12.7
3/4
98.00
10.0
72.3
88.0
9.0
64.9
<TABLE ROW
9/16
14.3
13/16
140.0
14.3
103.2
126.0
12.8
92.9
<TABLE ROW
5/8
15.9
15/16
196.0
20.0
144.6
177.0
18.0
130.5
<TABLE ROW
3/4
19.0
1 1/8
343.0
35.0
253.0
309.0
31.5
227.9
<TABLE ROW
7/8
22.2
1 15/16
547.0
55.8
403.4
492.0
50.2
362.9
<TABLE ROW
1
25.4
1 1/2
814.0
83.0
600.4
732.0
74.6
539.9
<TABLE ROW
1 1/8
31.7
1 7/8
1181.0
120.4
871.1
1063.0
108.4
784.0
<TABLE ROW
1 1/4
38.1
2 1/4
1646.0
167.8
1214.0
1481.0
151.0
1092.3
Table 3. Torque Settings - Metric Grade 8.8 Fasteners
Table 3. Torque Settings - Metric Grade 8.8 Fasteners
<TABLE
<TABLE HEADING
<TABLE ROW
Bolt Size
Hexagon (A/F)
Condition 1
Condition 2
<TABLE ROW
ISO Metric Thread
mm
mm
Nm
kgf m
lbf ft
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
M5
5
8
5.8
0.6
4.3
5.2
0.5
3.8
<TABLE ROW
M6
6
10
9.9
1.0
7.3
9.0
0.9
6.6
<TABLE ROW
M8
8
13
24.0
2.4
17.7
22.0
2.2
16.2
<TABLE ROW
M10
10
17
47.0
4.8
34.7
43.0
4.4
31.7
<TABLE ROW
M12
12
19
83.0
8.5
61.2
74.0
7.5
54.6
<TABLE ROW
M16
16
24
205.0
20.9
151.2
184.0
18.8
135.7
<TABLE ROW
M20
20
30
400.0
40.8
295.0
360.0
36.7
265.5
<TABLE ROW
M24
24
36
690.0
70.4
508.9
621.0
63.3
458.0
<TABLE ROW
M30
30
46
1372.0
139.9
1011.9
1235.0
125.9
910.9
<TABLE ROW
M36
36
55
2399.0
244.6
1769.4
2159.0
220.0
1592.4
Table 4. Metric Grade 10.9 Fasteners
Table 4. Metric Grade 10.9 Fasteners
<TABLE
<TABLE HEADING
<TABLE ROW
Bolt Size
Hexagon (A/F)
Condition 1
Condition 2
<TABLE ROW
ISO Metric Thread
mm
mm
Nm
kgf m
lbf ft
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
M5
5
8
8.1
0.8
6.0
7.3
0.7
5.4
<TABLE ROW
M6
6
10
13.9
1.4
10.2
12.5
1.3
9.2
<TABLE ROW
M8
8
13
34.0
3.5
25.0
30.0
3.0
22.1
<TABLE ROW
M10
10
17
67.0
6.8
49.4
60.0
6.1
44.2
<TABLE ROW
M12
12
19
116.0
11.8
85.5
104.0
10.6
76.7
<TABLE ROW
M16
16
24
288.0
29.4
212.4
259.0
26.4
191.0
<TABLE ROW
M20
20
30
562.0
57.3
414.5
506.0
51.6
373.2
<TABLE ROW
M24
24
36
971.0
99.0
716.9
874.0
89.1
644.6
<TABLE ROW
M30
30
46
1930.0
196.8
1423.5
1737.0
177.1
1281.1
<TABLE ROW
M36
36
55
3374.0
344.0
2488.5
3036.0
309.6
2239.2
Table 5. Metric Grade 12.9 Fasteners
Table 5. Metric Grade 12.9 Fasteners
<TABLE
<TABLE HEADING
<TABLE ROW
Bolt Size
Hexagon (A/F)
Condition 1
Condition 2
<TABLE ROW
ISO Metric Thread
mm
mm
Nm
kgf m
lbf ft
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
M5
5
8
9.8
1.0
7.2
8.8
0.9
6.5
<TABLE ROW
M6
6
10
16.6
1.7
12.2
15.0
1.5
11.1
<TABLE ROW
M8
8
13
40.0
4.1
29.5
36.0
3.7
26.5
<TABLE ROW
M10
10
17
80.0
8.1
59.0
72.0
7.3
53.1
<TABLE ROW
M12
12
19
139.0
14.2
102.5
125.0
12.7
92.2
<TABLE ROW
M16
16
24
345.0
35.2
254.4
311.0
31.7
229.4
<TABLE ROW
M20
20
30
674.0
68.7
497.1
607.0
61.9
447.7
<TABLE ROW
M24
24
36
1165.0
118.8
859.2
1048.0
106.9
773.0
<TABLE ROW
M30
30
46
2316.0
236.2
1708.2
2084.0
212.5
1537.1
<TABLE ROW
M36
36
55
4049.0
412.9
2986.4
3644.0
371.6
2687.7
Table 6. Torque Settings - Rivet Nut Bolts/Screws
Table 6. Torque Settings - Rivet Nut Bolts/Screws
<TABLE
<TABLE HEADING
<TABLE ROW
Bolt Size
Nm
kgf m
lbf ft
<TABLE ROW
ISO Metric Thread
mm
<TABLE BODY
<TABLE ROW
M3
3
1.2
0.1
0.9
<TABLE ROW
M4
4
3.0
0.3
2.0
<TABLE ROW
M5
5
6.0
0.6
4.5
<TABLE ROW
M6
6
10.0
1.0
7.5
<TABLE ROW
M8
8
24.0
2.5
18.0
<TABLE ROW
M10
10
48.0
4.9
35.5
<TABLE ROW
M12
12
82.0
8.4
60.5
Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc)
Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc)
<TABLE
<TABLE HEADING
<TABLE ROW
Bolt Size
Nm
kgf m
lbf ft
<TABLE ROW
ISO Metric Thread
<TABLE BODY
<TABLE ROW
M3
2.0
0.2
1.5
<TABLE ROW
M4
6.0
0.6
4.5
<TABLE ROW
M5
11.0
1.1
8.0
<TABLE ROW
M6
19.0
1.9
14.0
<TABLE ROW
M8
46.0
4.7
34.0
<TABLE ROW
M10
91.0
9.3
67.0
<TABLE ROW
M12
159.0
16.2
117.0
<TABLE ROW
M16
395.0
40.0
292.0
<TABLE ROW
M18
550.0
56.0
406.0
<TABLE ROW
M20
770.0
79.0
568.0
<TABLE ROW
M24
1332.0
136.0
983.0
Hydraulic Connections
Hydraulic Connections
'O' Ring Face Seal System
'O' Ring Face Seal System
Adaptors Screwed into Valve Blocks
Adaptors Screwed into Valve Blocks
Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45˚ seat machined into the face of the tapped port.
Table 8. Torque Settings - BSP Adaptors
Table 8. Torque Settings - BSP Adaptors
<TABLE
<TABLE HEADING
<TABLE ROW
BSP Adaptor Size
Hexagon (A/F)
Nm
kgf m
lbf ft
<TABLE ROW
in.
mm
<TABLE BODY
<TABLE ROW
1/4
19.0
18.0
1.8
13.0
<TABLE ROW
3/8
22.0
31.0
3.2
23.0
<TABLE ROW
1/2
27.0
49.0
5.0
36.0
<TABLE ROW
5/8
30.0
60.0
6.1
44.0
<TABLE ROW
3/4
32.0
81.0
8.2
60.0
<TABLE ROW
1
38.0
129.0
13.1
95.0
<TABLE ROW
1 1/4
50.0
206.0
21.0
152.0
Table 9. Torque Settings - SAE Connections
Table 9. Torque Settings - SAE Connections
<TABLE
<TABLE HEADING
<TABLE ROW
SAE Tube Size
SAE Port Thread Size
Hexagon (A/F)
Nm
kgf m
lbf ft
<TABLE ROW
mm
<TABLE BODY
<TABLE ROW
4
7/16 - 20
15.9
20.0 - 28.0
2.0 - 2.8
16.5 - 18.5
<TABLE ROW
6
9/16 - 18
19.1
46.0 - 54.0
4.7 - 5.5
34.0 - 40.0
<TABLE ROW
8
3/4 - 16
22.2
95.0 - 105.0
9.7 - 10.7
69.0 - 77.0
<TABLE ROW
10
7/8 - 14
27.0
130.0 - 140.0
13.2 - 14.3
96.0 - 104.0
<TABLE ROW
12
1 1/16 - 12
31.8
190.0 - 210.0
19.4 - 21.4
141.0 - 155.0
<TABLE ROW
16
1 5/16 - 12
38.1
290.0 - 310.0
29.6 - 31.6
216.0 - 230.0
<TABLE ROW
20
1 5/8
47.6
280.0 - 380.0
28.5 - 38.7
210.0 - 280.0
Hoses Screwed into Adaptors
Hoses Screwed into Adaptors
<GRAPHIC
<GRAPHIC
Fig 2.
Hoses
2-B
2
2-A
2
2-C
2
Dimension
2-D
2
Table 10. BSP Hose - Torque Settings
Table 10. BSP Hose - Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
BSP Hose Size
Hexagon (A/F)
Nm
kgf m
lbf ft
<TABLE ROW
in.
mm
<TABLE BODY
<TABLE ROW
1/8
14.0
14.0 - 16.00
1.4 - 1.6
10.3 - 11.8
<TABLE ROW
1/4
19.0
24.0 - 27.0
2.4 - 2.7
17.7 - 19.9
<TABLE ROW
3/8
22.0
33.0 - 40.0
3.4 - 4.1
24.3 - 29.5
<TABLE ROW
1/2
27.0
44.0 - 50.0
4.5 - 5.1
32.4 - 36.9
<TABLE ROW
5/8
30.0
58.0 - 65.0
5.9 - 6.6
42.8 - 47.9
<TABLE ROW
3/4
32.0
84.0 - 92.0
8.6 - 9.4
61.9 - 67.8
<TABLE ROW
1
38.0
115.0 - 126.0
11.7 - 12.8
84.8 - 92.9
<TABLE ROW
1 1/4
50.0
189.0 - 200.0
19.3 - 20.4
139.4 - 147.5
<TABLE ROW
1 1/2
55.0
244.0 - 260.0
24.9 - 26.5
180.0 - 191.8
Adaptors into Component Connections with Bonded Washers
Adaptors into Component Connections with Bonded Washers
Table 11. BSP Adaptors with Bonded Washers - Torque Settings
Table 11. BSP Adaptors with Bonded Washers - Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
BSP Size
Nm
kgf m
lbf ft
<TABLE ROW
in.
<TABLE BODY
<TABLE ROW
1/8
20.0
2.1
15.0
<TABLE ROW
1/4
34.0
3.4
25.0
<TABLE ROW
3/8
75.0
7.6
55.0
<TABLE ROW
1/2
102.0
10.3
75.0
<TABLE ROW
5/8
122.0
12.4
90.0
<TABLE ROW
3/4
183.0
18.7
135.0
<TABLE ROW
1
203.0
20.7
150.0
<TABLE ROW
1 1/4
305.0
31.0
225.0
<TABLE ROW
1 1/2
305.0
31.0
225.0
'Torque Stop' Hose System
'Torque Stop' Hose System
<GRAPHIC
<GRAPHIC
Fig 3.
`Torque Stop' Hoses
3-B
3
3-A
3
3-C
3
3-D
3
Minimum dimension
3-E
3
3-D
3
Table 12. BSP `Torque Stop' Hose - Torque Settings
Table 12. BSP `Torque Stop' Hose - Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
BSP Hose Size
Hexagon (A/F)
Nm
kgf m
lbf ft
<TABLE ROW
in.
mm
<TABLE BODY
<TABLE ROW
1/8
14.0
14.0
1.4
10.0
<TABLE ROW
1/4
19.0
27.0
2.7
20.0
<TABLE ROW
3/8
22.0
40.0
4.1
30.0
<TABLE ROW
1/2
27.0
55.0
5.6
40.0
<TABLE ROW
5/8
30.0
65.0
6.6
48.0
<TABLE ROW
3/4
32.0
95.0
9.7
70.0
<TABLE ROW
1
38.0
120.0
12.2
89.0
<TABLE ROW
1 1/4
50.0
189.0
19.3
140.0
<TABLE ROW
1 1/2
55.0
244.0
24.9
180.0
Service Tools
Service Tools
Numerical List
Numerical List
The tools listed in the table are special tools required for carrying out the procedures described in this manual. These tools are available from JCB Service.
Some tools are available as kits or sets, the part numbers for parts within such kits or sets are not listed here. For full details of all tools, including the content of kits and sets, refer to
Tool Detail Reference, Section 1
Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Part Number
Description
See Section
<TABLE BODY
<TABLE ROW
-
Bonded Washers - see Tool Detail Reference (Section 1) for content
Tool Detail Reference (Section 1)
E
E
<TABLE ROW
-
Female Cone Blanking Caps - see Tool Detail Reference (Section 1) for content
Tool Detail Reference (Section 1)
E
E
<TABLE ROW
-
Female Connectors - see Tool Detail Reference (Section 1) for content
Tool Detail Reference (Section 1)
E
E
<TABLE ROW
-
Hydraulic Flow Test Equipment - see Tool Detail Reference (Section 1) for content
Tool Detail Reference (Section 1)
E
E
<TABLE ROW
-
Male Adapters - BSP x BSP - see Tool Detail Reference (Section 1) for content
Tool Detail Reference (Section 1)
E
E
<TABLE ROW
-
Male Adapters - BSP x NPT (USA only) - see Tool Detail Reference (Section 1) for content
Tool Detail Reference (Section 1)
E
E
<TABLE ROW
-
Male Cone Blanking Caps - see Tool Detail Reference (Section 1) for content
Tool Detail Reference (Section 1)
E
E
<TABLE ROW
-
Pressure Test Points - Adaptors - see Tool Detail Reference (Section 1) for content
Tool Detail Reference (Section 1)
E
E
<TABLE ROW
-
Pressure Test Points - 'T' Adaptors - see Tool Detail Reference (Section 1) for content
Tool Detail Reference (Section 1)
E
E
<TABLE ROW
892/00253
Hydraulic Circuit Pressure Test Kit - see Tool Detail Reference (Section 1) for content
Tool Detail Reference (Section 1)
E
E
<TABLE ROW
892/00254
Hose
E
E
<TABLE ROW
892/00279
Gauge
E
E
<TABLE ROW
892/00280
Gauge
E
E
<TABLE ROW
892/00284
Digital Tachometer
C
C
<TABLE ROW
892/00285
Hyd. Oil Temperature Probe
C
C
<TABLE ROW
892/00298
Fluke Meter
C
C
<TABLE ROW
892/00346
Gauge
E
E
<TABLE ROW
892/00347
Connector
E
E
<TABLE ROW
892/01246
Vibromax male to JCB female threaded adaptor
E
<TABLE ROW
892/01247
JCB male to Vibromax female threaded adaptor
E
<TABLE ROW
892/12345
Frequency and Vibration Measuring Tool
E
E
<TABLE ROW
892/00285
100 amp Shunt
C
C
Tool Detail Reference
Tool Detail Reference
Section C - Electrics
Section C - Electrics
Not all service tools are illustrated.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 1. 892/00298 Fluke Meter
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 2. 892/00285 Hydraulic Temperature Probe
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 3. 892/00284 Venture Microtach Digital Tachometer
Section E - Hydraulics
Section E - Hydraulics
Not all service tools are illustrated.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 4. Male Adaptors
Male Adapters - BSP x BSP
<TABLE ROW
1606/2052
3/8 in. x 1/4 in.
<TABLE ROW
1604/0003A
3/8 in. x 3/8 in.
<TABLE ROW
892/00071
3/8 in. x 3/8 in. taper
<TABLE ROW
1606/0004
1/2 in. x 1/4 in.
<TABLE ROW
1606/0007A
1/2 in. x 3/8 in.
<TABLE ROW
1604/0004A
1/2 in. x 1/2 in.
<TABLE ROW
1606/0017
5/8 in. x 1/2 in.
<TABLE ROW
1606/0008
3/4 in. x 3/8 in.
<TABLE ROW
Male Adapters - BSP x NPT (USA only)
1606/0009
3/4 in. x 1/2 in.
<TABLE ROW
816/00439
3/8 in. x 1/4 in.
1604/2055
3/4 in. x 3/4 in.
<TABLE ROW
816/00440
1/2 in. x 1/4 in.
1606/0012
3/4 in. x 1 in.
<TABLE ROW
816/15007A
3/8 in. x 3/8 in.
1606/0014
3/4 in. x 1.1/4 in.
<TABLE ROW
816/15008
1/2 in. x 3/8 in.
1606/0015
1 in. x 1.1/4 in.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 5. Pressure Test Adapters
892/00255
1/4 in. BSP x Test Point
<TABLE ROW
892/00256
3/8 in. BSP x Test Point
<TABLE ROW
892/00257
1/2 in. BSP x Test Point
<TABLE ROW
892/00258
5/8 in. BSP x Test Point
<TABLE ROW
816/15118
3/4 in. BSP x Test Point
<TABLE ROW
892/00259
1 in BSP x Test Point
<TABLE ROW
892/00260
1.1/4 in. BSP x Test Point
<TABLE ROW
892/00261
5/8 in. UNF x Test Point
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 6. Pressure Test 'T' Adapters
816/55045
1/4 in. M BSP x 1/4 in. F BSP x Test Point
<TABLE ROW
816/55038
3/8 in. M BSP x 3/8 in. F BSP x Test Point
<TABLE ROW
816/55040
1/2 in. M BSP x 1/2 in. F BSP x Test Point
<TABLE ROW
892/00263
5/8 in. M BSP x 5/8 in. F BSP x Test Point
<TABLE ROW
892/00264
3/4 in. M BSP x 3/4 in. F BSP x Test Point
<TABLE ROW
892/00265
1 in. M BSP x 1 in. F BSP x Test Point
<TABLE ROW
892/00266
1.1/4 in. M BSP x 1.1/4 in. F BSP x Test Point
<TABLE ROW
892/00267
1.1/4 in. M BSP x 1.1/2 in. F BSP x Test Point
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 7. 'T' Adapters
892/00047
3/8 in. BSP (A) x 1/4 in. BSP (B)
A
B
<TABLE ROW
892/00048
1/2 in. BSP (A) x 1/4 in. BSP (B)
A
B
<TABLE ROW
892/00049
5/8 in. BSP (A) x 1/4 in. BSP (B)
A
B
<TABLE ROW
816/50043
3/4 in. BSP (A) x 1/4 in. BSP (B)
A
B
<TABLE ROW
892/00051
1 in. BSP (A) x 1/4 in. BSP (B)
A
B
<TABLE ROW
816/50005
1/2 in. BSP (A) x 1/2 in. BSP (B)
A
B
<TABLE ROW
816/60096
3/4 in. BSP (A) x 3/4 in. BSP (B)
A
B
<TABLE ROW
816/00017
1 in. BSP (A) x 1 in. BSP (B)
A
B
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 8. Female Blanking Caps
892/00055A
1/4 in. BSP
<TABLE ROW
892/00056A
3/8 in. BSP
<TABLE ROW
892/00057
1/2 in. BSP
<TABLE ROW
892/00058A
5/8 in. BSP
<TABLE ROW
892/00059A
3/4 in. BSP
<TABLE ROW
892/00060
1 in. BSP
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 9. Male Cone Blanking Caps
816/90045
1/4 in. BSP
<TABLE ROW
816/00189A
3/8 in. BSP
<TABLE ROW
816/00190A
1/2 in. BSP
<TABLE ROW
816/90022
5/8 in. BSP
<TABLE ROW
816/90274
3/4 in. BSP
<TABLE ROW
816/90205
1 in. BSP
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 10. Female Connectors
892/00074
3/8 in. BSP x 3/8 in. BSP
<TABLE ROW
892/00075
1/2 in. BSP x 1/2 in. BSP
<TABLE ROW
892/00076
5/8 in. BSP x 5/8 in. BSP
<TABLE ROW
892/00077
3/4 in. BSP x 3/4 in. BSP
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 11. Bonded Washers
1406/0011
1/4 in. BSP
<TABLE ROW
1406/0018
1/2 in. BSP
<TABLE ROW
1406/0014
5/8 in. BSP
<TABLE ROW
1406/0021
3/4 in. BSP
<TABLE ROW
1406/0029
1.1/4 in. BSP
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 12. Flow Test Equipment
892/00268
Flow Monitoring Unit
<TABLE ROW
892/00269
Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)
<TABLE ROW
892/00273
Sensor Head 0 - 380 l/min (0 - 85.5 UK gal/min)
<TABLE ROW
892/00293
Connector Pipe
<TABLE ROW
892/00270
Load Valve
<TABLE ROW
1406/0021
Bonded Washer
<TABLE ROW
1604/0006A
Adapter 3/4 in M x 3/4 in M BSP
<TABLE ROW
1612/2054
Adapter 3/4 in F x 3/4 in M BSP
<TABLE ROW
892/00271
Adapter 3/4 in F x 5/8 in M BSP
<TABLE ROW
892/00272
Adapter 5/8 in F x 3/4 in M BSP
<TABLE ROW
816/20008
Adapter 3/4 in F x 1/2 in M BSP
<TABLE ROW
892/00275
Adapter 1/2 in F x 3/4 in M BSP
<TABLE ROW
892/00276
Adapter 3/4 in F x 3/8 in M BSP
<TABLE ROW
892/00277
Adapter 3/8 in F x 3/4 in M BSP
<TABLE ROW
1606/0015
Adapter 1.1/4 in M BSP x 1 in M BSP
<TABLE ROW
892/00078
Connector 1 in F x 1 in F BSP
<TABLE ROW
1604/0008
Adapter 1 in M x 1 in M BSP
<TABLE ROW
1604/0008
Adapter 1 in M x 3/4 in M BSP
<TABLE ROW
816/20013
Adapter 3/4 in F x 1 in M BSP
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 13. 892/ 00253 Hydraulic Circuit Pressure Test Kit
892/00201
Replacement Gauge 0-20 bar (0-300 lbf/in2)
2
<TABLE ROW
892/00202
Replacement Gauge 0-40 bar (0-600 lbf/in2)
2
<TABLE ROW
892/00203
Replacement Gauge 0-400 bar (0-6000 lbf/in2)
2
<TABLE ROW
892/00254
Replacement Hose
<TABLE ROW
993/69800
Seal Kit for 892/00254 (can also be used with probe 892/00706)
<TABLE ROW
892/00706
Test Probe
<TABLE ROW
892/00347
Connector - Hose to gauge
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 14. Hydraulic Circuit Test Gauges and Connections
892/00280
Pressure Gauge 0-600 bar (0-9000 lbf/in2)
2
<TABLE ROW
892/00279
Pressure Gauge 0-400 bar (0-6000 lbf/in2)
2
<TABLE ROW
892/00346
Pressure Gauge 0-70 bar (0-1000 lbf/in2)
2
<TABLE ROW
892/00347
Connector
<TABLE ROW
892/00254
Hose
<GRAPHIC
<GRAPHIC
Fig 15. Adaptor (item A)
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Item
Part No
Description
Qty
<TABLE ROW
A
892/01247
JCB male to Vibromax female threaded adaptor - Connects JCB female test hose to male Vibromax test point
a/r
<TABLE ROW
B
892/01246
Vibromax male to JCB female threaded adaptor - Connects Vibromax female test hose to JCB male test point
a/r
In order to use JCB test hoses and gauges on JCB Vibromax machines (and where applicable, other manufacturers machines fitted wi...
B
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 16. 892/12345 Frequency and Vibration Measuring Tool
<TABLE ROW
Allows the service engineer to measure the frequency of the vibrating drum (it will also measure engine speed on any type of machinery).
Service Consumables
Service Consumables
Sealing and Retaining Compounds
Sealing and Retaining Compounds
Table 1.
Table 1.
<TABLE
<TABLE HEADING
<TABLE ROW
Type
Description
Part No.
Quantity
<TABLE BODY
<TABLE ROW
JCB Multi-Gasket
A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65 mm diameter.
4102/1212
50 ml
<TABLE ROW
JCB High Strength Threadlocker
A high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where the strength of the joint is important.
4102/0551
50 ml
<TABLE ROW
JCB Retainer (High Strength)
For all retaining parts which are unlikely to be dismantled.
4101/0651
50 ml
<TABLE ROW
JCB Threadlocker and Sealer
A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter.
4101/0250
10 ml
<TABLE ROW
4101/0251
50 ml
<TABLE ROW
JCB Threadlocker and Sealer (High Strength)
A high strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter.
4101/0550
10 ml
<TABLE ROW
4101/0552
200 ml
<TABLE ROW
JCB Threadseal
A medium strength thread sealing compound.
4102/1951
50 ml
<TABLE ROW
JCB Activator
A cleaning primer which speeds the curing rate of anaerobic products.
4104/0251
200 ml (Aerosol)
<TABLE ROW
4104/0253
1 ltr (Bottle)
<TABLE ROW
JCB Cleaner/Degreaser
For degreasing components prior to use of anaerobic adhesives and sealants.
4104/1557
400 ml (Aerosol)
<TABLE ROW
Direct Glazing Kit
For one pane of glass; comprises of:
- 1 x Ultra Fast Adhesive (310 ml)
- 1 x Ultra Fast Adhesive (310 ml)
- 1 x Active Wipe 205 (30 ml)
- 1 x Black Primer 206J (30 ml)
- plus applicator nozzle etc.
993/55700
<TABLE ROW
Ultra Fast Adhesive
For direct glazing.
4103/2109
310 ml
<TABLE ROW
Active Wipe 205
For direct glazing.
4104/1203
250 ml
<TABLE ROW
Black Primer 206J
For direct glazing.
4201/4906
30 ml
<TABLE ROW
Clear Silicone Sealant
To seal butt jointed glass.
4102/0901
<TABLE ROW
Plastic to Metal Bonder
To seal plastic to metal joints.
4103/0956
50 g
<TABLE ROW
Black Polyurethane Sealant
To finish exposed edges of laminated glass.
4102/2309
310 ml
Page left intentionally blank
Section 2 - Care and Safety
Section 2
Section 2
Care and Safety
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Service Manual - VMT860 Tier 3
Service Manual - VMT860 Tier 3
<TABLE ROW
Section 1 - General Information
Section 1 - General Information
<TABLE ROW
Section 2 - Care and Safety
Section 2 - Care and Safety
<TABLE ROW
Section 3 - Maintenance
Section 3 - Maintenance
<TABLE ROW
Section C - Electrics
Section C - Electrics
<TABLE ROW
Section E - Hydraulics
Section E - Hydraulics
<TABLE ROW
Section H - Steering
Section H - Steering
<TABLE ROW
Section K - Engine
Section K - Engine
<TABLE ROW
Section L - Vibration
Section L - Vibration
<GRAPHIC
<GRAPHIC
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Notes:
<TABLE BODY
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
Safety Notices
Safety Notices
Important Information
Important Information
The Operator Manual
The Operator Manual
Do not operate the machine without an Operator Manual, or if there is anything on the machine you do not understand.
You and others can be killed or seriously injured if you operate or maintain the machine without first studying the Operator Man...
Do not operate the machine without an Operator Manual, or if there is anything on the machine you do not understand.
Treat the Operator Manual as part of the machine. Keep it clean and in good condition. Replace the Operator Manual immediately if it is lost, damaged or becomes unreadable.
Safety Warnings
Safety Warnings
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
This safety alert system identifies important safety messages in this manual. When you see this symbol, be alert, your safety is involved, carefuly read the message that follows, and inform other operators.
In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below.
Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured.
Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured.
Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine.
Safety Check List
Safety Check List
Safety - Yours and Others
Safety - Yours and Others
All machinery can be hazardous. When a machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others.
In this manual and on the machine you will find warning messages. Read and understand them. They tell you of potential hazards a...
But safety is not just a matter of responding to the warnings. All the time you are working on or with the machine you must be thinking what hazards there might be and how to avoid them.
Do not work with the machine until you are sure that you can control it.
Do not start any job until you are sure that you and those around you will be safe.
If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything.
Remember
BE CAREFUL
BE CAREFUL
BE ALERT
BE SAFE
General Safety
General Safety
To operate the machine safely you must know the machine and have the skill to use it. You must abide by all relevant laws, healt...
Care and Alertness
All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards.
Clothing
You can be injured if you do not wear the proper clothing. Loose clothing can get caught in the machinery. Wear protective cloth...
Alcohol and Drugs
It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume alcoholic drinks or take drugs before or while operating the machine or attachments. Be aware of medicines which can cause drowsiness.
Feeling Unwell
Do not attempt to operate the machine if you are feeling unwell. By doing so you could be a danger to yourself and those you work with.
Mobile Phones
Switch off your mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such an area could cause an explosion or fire resulting in death or serious injury.
Switch off and do not use your mobile phone when refuelling the machine.
Lifting Equipment
You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that li...
Raised Equipment
Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a ...
Make sure that no-one goes near the machine while you install or remove the mechanical device.
Raised Machine
NEVER position yourself or any part of your body under a raised machine which is not properly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed.
Lightning
Lightning can kill you. Do not use the machine if there is lightning in your area.
Machine Modifications
This machine is manufactured in compliance with legislative and other requirements. It should not be altered in any way which could affect or invalidate any of these requirements. For advice consult your JCB Distributor.
Operating Safety
Operating Safety
Machine Condition
A defective machine can injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this manual are completed before using the machine.
Machine Limits
Operating the machine beyond its design limits can damage the machine, it can also be dangerous. Do not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved modifications.
Engine/Steering Failure
If the engine or steering fails, stop the machine as quickly as possible. Do not operate the machine until the fault has been corrected.
Exhaust Gases
Breathing the machine exhaust gases can harm and possibly kill you. Do not operate the machine in closed spaces without making s...
Work Sites
Work sites can be hazardous. Inspect the site before working on it. Look for potholes, weak ground, hidden rocks etc. Check for ...
Communications
Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you will be working with o...
Parking
An incorrectly parked machine can move without an operator. Follow the instructions in the Operator Manual to park the machine correctly.
Banks and Trenches
Banked material and trenches can collapse. Do not work or drive too close to banks and trenches where there is danger of collapse.
Ramps and Trailers
Water, mud, ice, grease and oil on ramps or trailers can cause serious accidents. Make sure ramps and trailers are clean before driving onto them. Use extreme caution when driving onto ramps and trailers.
Safety Barriers
Unguarded machines in public places can be dangerous. In public places, or where your visibility is reduced, place barriers around the work area to keep people away.
Sparks
Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in closed areas where there is flammable material, vapour or dust.
Hazardous Atmospheres
This machine is designed for use in normal out door atmospheric conditions. It should not be used in an enclosed area without ad...
Regulations
Obey all laws, work site and local regulations which affect you and your machine.
Practice
You or others can be killed or seriously injured if you do unfamiliar operations without first practising them. Practise away fr...
Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must not be allowed to accumulate wit...
Keep the machine controls clean and dry. Your hands and feet could slide off slippery controls. If that happens you could lose control of the machine.
Visibility
Accidents can be caused by working in poor visibility. Use your lights to improve visibility. Keep the road lights, windows and mirrors clean.
Do not operate the machine if you cannot see clearly.
Electrical Power Cables
You could be electrocuted or badly burned if you get the machine or its attachments too close to electrical power cables.
You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near electric power lines.
Before you start using the machine, check with your electricity supplier if there are any buried power cables on the site.
There is a minimum clearance required for working beneath overhead power cables. You must obtain details from your local electricity supplier.
If you have an attachment which is not covered in the Operator Manual do not install it, use it or remove it until you have obtained, read and understood the pertinent information. Install attachments only on the machines for which they were designed.
Use only the JCB approved attachments that are specified for your machine. Operating with non- specified attachments can overload the machine, causing possible damage and machine instability which could result in injury to yourself or others.
The use of non-approved attachments could invalidate your warranty.
Working Platform
Using the machine as a working platform is hazardous; you can fall off and be killed or injured. Never use the machine as a working platform.
The engine has exposed rotating parts. Switch OFF the engine before working in the engine compartment. Do not use the machine with the engine cover open.
You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS/FOPS. If the Roll Over Protecti...
Reversing
Reversing at high speeds can cause accidents. Do not reverse in a high gear with full throttle. Always drive at a safe speed to suit working conditions.
Controls
You or others can be killed or seriously injured if you operate the control levers from outside the machine. Operate the control levers only when you are correctly seated.
Passengers
Passengers in or on the machine can cause accidents. Do not carry passengers.
Fires
If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the correct machine location until you need to use it.
Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire. Use carbon diox...
Should the machine start to roll over, you can be crushed if you try to leave the cab. If the machine starts to roll over, do not try and jump from the cab. Stay in the cab, with your seat belt fastened.
Entering/Leaving
Entering or leaving the cab or canopy must only be made where steps and handrails are provided. Always face the machine when ent...
Hillsides
Operating the machine on hillsides can be dangerous if proper precautions are not taken. Ground conditions can be changed by rain, snow, ice etc. Check the site carefully. Operate at a suitable slow speed on hillsides.
Slopes
When travelling on a slope, drive slowly and keep the roller up hill of the machine. This will increase stability.
Hill sides
Operating on hillsides can be dangerous, especially moving across a slope. If the slope is too steep, your machine could roll over.
Maintenance Safety
Maintenance Safety
Communications
Bad communications can cause accidents. If two or more people are working on the machine, make sure each is aware of what the ot...
Repairs
If your machine does not function correctly in any way, get it repaired straight away. Neglect of necessary repairs could result...
Metal Splinters
You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or copper pin to remove and fit metal pins. Always wear safety glasses.
Electrical Circuits
Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage.
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear prot...
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure...
Fuel
Fuel is flammable; keep naked flames away from the fuel system. Stop the engine immediately if a fuel leak is suspected. Do not ...
Oil
Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants...
It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants.
Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites.
Soft Ground
A machine can sink into soft ground. Never work under a machine on soft ground.
Always wear safety glasses when dismantling assemblies containing components under pressure from springs. This will protect against eye injury from components accidentally flying out.
Rams
The efficiency of the rams will be affected if they are not kept free of solidified dirt. Clean dirt from around the rams regularly. When leaving or parking the machine, close all rams if possible to reduce the risk of weather corrosion.
Cleaning
Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents.
When using cleaning agents, solvents or other chemicals, you must adhere to the manufacturer's instructions and safety precautions.
'O' rings, Seals and Gaskets
Badly fitted, damaged or rotted 'O' rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed unless otherwise instructed. Do not use Triochloroethane or paint thinners near 'O' rings and seals.
Hydraulic Hoses
Damaged hoses can cause fatal accidents. Inspect the hoses regularly. Do not use the machine if a hose or hose fitting is damaged.
Waxoyl contains turpentine substitute which is flammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period.
Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area.
Working Under the Machine
Make the machine safe before getting beneath it. Ensure that any fitments on the machine are secure; engage the park brake, remove the starter key, disconnect the battery.
Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton, Fluorel ...
New fluoroelastomeric components at ambient temperature require no special safety precautions.
Used fluoroelastomeric components whose temperatures have not exceeded 300˚C (572˚F) require no special safety precautions. If e...
Used fluoroelastomeric components subjected to temperatures greater than 300˚C (572˚F) (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn:
1 Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains.
1 Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains.
2 Thoroughly wash contaminated area with detergent and water.
3 Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations.
DO NOT BURN FLUOROELASTOMERIC MATERIALS.
Protect your eyes when grinding metal. Wear safety glasses or goggles. Remove or protect any combustible materials from the area which could be ignited by sparks.
To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a brush to clean components.
Arc Welding
To prevent the possibility of damage to electronic components, disconnect the battery and the alternator before arc-welding on the machine or attached implements.
If the machine is equipped with sensitive electrical equipment, i.e. amplifier drivers, electronic control units (E.C.U.s), moni...
Parts of the machine are made from cast iron; welds on cast iron can weaken the structure and break. Do not weld cast iron. Do not connect the welder cable or apply any weld to any part of the engine.
Always connect the welder earth (ground) cable to the same component that is being welded, i.e. boom or dipper, to avoid damage ...
Counterweights
Your machine may be fitted with counterweights. They are extremely heavy. Do not attempt to remove them.
Compressed air is dangerous. Wear suitable eye protection and gloves. Never point a compressed air jet at yourself or others.
Petrol
Do not use petrol in this machine. Do not mix petrol with the diesel fuel; in storage tanks the petrol will rise to the top and form flammable vapours.
The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before you work on the cooling system.
Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged.
If you try to charge a frozen battery, or jump start and run the engine, the battery could explode. Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery at full charge.
Battery Gases
Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure t...
Electrolyte
Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery. Keep the electrolyte away from your clothes, skin, mouth and eyes. Wear safety glasses.
Battery Terminals
The machine is negatively earthed. Always connect the negative pole of the battery to earth.
When connecting the battery, connect the earth (-) lead last.
When disconnecting the battery, disconnect the earth (-) lead first.
Safety Labels
Safety Labels
Introduction
Introduction
Safety labels are strategically placed around the machine to remind you of possible hazards.
Safety Labels
Safety labels on the machine warn you of particular hazards. You can be injured if you do not obey the safety instructions shown.
Safety labels are strategically placed around the machine to remind you of possible hazards.
If you need eye-glasses for reading, make sure you wear them when reading the safety labels. Do not over-stretch or place yourse...
Safety Label Identification
The illustration(s) show a typical machine model. Your machine may look different from the model shown.
Keep all safety labels clean and readable. Replace lost or damaged safety labels. Make sure replacement parts include safety lab...
Safety Label Identification
Safety Label Identification
<GRAPHIC
<GRAPHIC
Fig 1.
Part Numbers and Description
Part Numbers and Description
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
ISO-01A
ISO-01A
<GRAPHIC
<GRAPHIC
817-70014-3
<TABLE ROW
Part Number: 817/70014
<TABLE ROW
Description: Warning. Read the operator manual before you operate the machine.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
ISO-02C
ISO-02C
<GRAPHIC
<GRAPHIC
332-P7181-1
<TABLE ROW
Part Number: 332/P7181
<TABLE ROW
Description: Crushing of whole body. Install the articulation lock before you start maintenance work. Refer to Articulation Lock (Operation Section).
Articulation Lock (Operation Section)
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
ISO-04E
ISO-04E
<TABLE ROW
Part Number: 332/U9190
<TABLE ROW
Description: Burns to fingers and hands. Stay a safe distance away.
<TABLE ROW
<GRAPHIC
<GRAPHIC
332-U9190-1
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
ISO-07D
ISO-07D
<GRAPHIC
<GRAPHIC
817-70027-2
<TABLE ROW
Part Number: 817/70027
<TABLE ROW
Description: Crush hazard. Keep a safe distance from the moving parts.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
ISO-09A
ISO-09A
<GRAPHIC
<GRAPHIC
332-P4581-1
<TABLE ROW
Part Number: 332/P4581
<TABLE ROW
Description: Severing of hands or fingers. Keep clear of/do not reach into the moving parts. Stop the engine and remove the starter key before you start maintenance work. Refer to Making the Machine Safe (Routine Maintenance Section).
Making the Machine Safe (Routine Maintenance Section)
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
ISO-010A
ISO-010A
<GRAPHIC
<GRAPHIC
817-70029-3
<TABLE ROW
Part Number: 817/70029
<TABLE ROW
Description: Crush hazard. Wear the seat belt when you operate the machine.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
ISO-015C
ISO-015C
<GRAPHIC
<GRAPHIC
817-70021-2
<TABLE ROW
Part Number: 817/70021
<TABLE ROW
Description: Noise warning. Wear applicable ear protection.
Section 3 - Maintenance
Routine Maintenance
Service Requirements
Health and Safety
Service Schedules
Fluids, Lubricants and Capacities
Tools
Prepare the Machine for Maintenance
Cleaning the Machine
Check the Machine for Damage
Access Panels
Brakes
Electrical System
Engine
Fuel System
Hydraulic System
Sprinkler System
Drum
Vibration System
Section C - Electrics
Section E - Hydraulics
Section H - Steering
Articulation Joint
Removal and Replacement
Steering
Fault Finding
Section K - Engine
Engine
Basic Engine Data
Injectors
Removal and Replacement
Alternator
Removal and Replacement
Section L - Vibration
Vibration System
Description
Fault Finding
Vibration System
Drum
Removal and Replacement
Dismantling and Assembly
JCB Vibromax VMT 860 Tier 3 Tandem Compaction Roller Repair Service Manual.pdf
Source : Sitelux.com