service repair manual

1. Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
World Class
Customer Support
9803/9590-5
Publication No.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Service Manual
VM RANGE - TIER III
Service Manual - VM RANGE - TIER III
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section H - Steering
Section K - Engine
Section L - Vibration

2. Page No.
Contents
Section 1 - General Information
1-i 1-i
Introduction
About this Manual ...................................................................................... 1-1
Identifying Your Machine ........................................................................... 1-3
Service Consumables
Sealing and Retaining Compounds ........................................................... 1-7
Service Tools
Numerical List ............................................................................................ 1-9
Tool Detail Reference .............................................................................. 1-11
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners ..................................... 1-21
Vibromax Specific Torque Settings .......................................................... 1-25
Hydraulic Connections ............................................................................. 1-27

3. Section 1 - General Information
1-1 1-1
9803/9590-4
Introduction
About this Manual
Machine Model and Serial Number
This manual provides information for the following
model(s) in the JCB machine range:
– VM 46D/PD from SN 2900500
– VM 75D/PD from SN 2900500
– VM 115D/PD from SN 1801240
– VM 115HD/HPD from SN 1801240
– VM 132D/PD from SN 1801295
– VM 146D/PD from SN 1800000
– VM 166D/PD from SN 1800000
– VM 200D/PD from SN 1801445
Using the Service Manual
T11-004
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. It is expected that components will be
cleaned and lubricated where appropriate, and that any
opened hose or pipe connections will be blanked to
prevent excessive loss of hydraulic fluid and ingress of dirt.
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 is reserved. No responsibility will
be accepted for discrepancies which may occur between
specifications of the machine and the descriptions
contained in this publication.
Finally, please remember above all else safety must come
first!
Section Numbering
T11-005
The manual is compiled in sections, the first three are
numbered and contain information as follows:
The remaining sections are alphabetically coded and deal
with Dismantling, Overhaul etc. of specific components, for
example:
Section contents, technical data, circuit descriptions,
operation descriptions etc. are inserted at the beginning of
each alphabetically coded section.
1 General Information - includes torque settings and
service tools.
2 Care and Safety - includes warnings and cautions
pertinent to aspects of workshop procedures etc.
3 Maintenance - includes service schedules and
recommended lubricants for all the machine.
A Attachments
B Body and Framework, etc.

4. Section 1 - General Information
Introduction
About this Manual
1-2 1-2
9803/9590-4
Left Side, Right Side
In this manual, 'left' A and 'right' B mean your left and right
when you are seated correctly in the machine.
Fig 1.
Cab/Canopy
T1-003_2
This manual frequently makes references to the cab. For
instance, 'do not operate the machine without a manual in
the cab'. It should be noted that these statements also
apply to canopy build machines.
Cross References
T1-004_2
In this publication, page cross references are made by
presenting the subject title printed in bold, italic and
underlined. It is preceeded by the 'go to' symbol. The
number of the page upon which the subject begins, is
indicated within the brackets. For example: K Cross
References ( T 1-2).

5. Section 1 - General Information
Introduction
Identifying Your Machine
1-3 1-3
9803/9590-4
Identifying Your Machine
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.
Fig 2. Location of Machine Identification Plate.
Typical Product Identification Number (PIN)
1 World Manufacturer Identification (JCB)
2 Machine Type and Model (VM115 = VM115)
3 Randomly Generated Check Letter
4 Machine Serial Number (01801240)
OPERATING MASS
(kg) EN500-1
MAX FRONT
AXLE LOAD (kg)
TYPE
JCB VIBROMAX GmbH
SCHAEFERBERG 1
06466 GATERSLEBEN
ENGINE POWER kW
@ RPM,ISO 3046-1
MAX REAR
AXLE LOAD (kg)
Product Identification Number,PIN,ISO 10261 YEAR OF
MANUFACTURE
332/N0674
1 2 3 4
JCB VM115 C 01801240

6. Section 1 - General Information
Introduction
Identifying Your Machine
1-4 1-4
9803/9590-4
Component Identification Plates
844210-2
Fig 3.
1 Engine serial number
2 Drum drive motor serial number
3 Steering unit serial number
4 Rear axle serial number
5 Vibration motor serial number
6 Hydraulic pump serial number
7 Axle hydraulic drive motor serial number
5
3
2
7
4
1
6

7. Section 1 - General Information
Introduction
Identifying Your Machine
1-5 1-5
9803/9590-4
JCB Dieselmax Engine Identification
Typical Engine Identification Number
T1-005_3
Engine data labels A are located on the cylinder block at
position C and rocker cover D (if fitted). K Fig 4. ( T 1-5).
The data label contains important engine information and
includes the engine identification number E.
A typical engine identification number is explained as
follows:
1 Engine Type
S = 4.4 litre series.
2 Engine part number
3 Country of manufacture
U = United Kingdom
4 Engine Serial Number
5 Year of Manufacture
The last three parts of the engine identification number are
stamped on the cylinder block at position B.
C007820-C2
Fig 4. Engine
Cummins QSB Engine Identification
Typical Engine Identification Number
1 Engine Type, YB = 6 cylinder turbo
2 Build Number
3 Country of Origin
4 Engine Sequence Number
5 Year of Manufacture
SA 320/40001 U 00001 04
1 2 3 4 5
JCB Dieselmax (Tier 2)
A = Naturally aspirated
B = Turbocharged
C = Turbocharged and intercooled
JCB Dieselmax (Tier 3)
D = Turbocharged
E = Electronic common rail fuel injection
F = Turbocharged and after-cooled
U 00001 04
1 2 3 4 5
YB 50457 U 576887 6
B
C
D
B
E

8. Section 1 - General Information
Introduction
Identifying Your Machine
1-6 1-6
9803/9590-4
Page left intentionally blank

9. Section 1 - General Information
Service Consumables
Sealing and Retaining Compounds
1-7 1-7
9803/9590-4
Service Consumables
Sealing and Retaining Compounds
T11-001_3
Table 1.
Type Description Part No. Quantity
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
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
JCB Retainer (High Strength) For all retaining parts which are unlikely to be
dismantled.
4101/0651 50 ml
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
4101/0251 50 ml
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
4101/0552 200 ml
JCB Threadseal A medium strength thread sealing compound. 4102/1951 50 ml
JCB Activator A cleaning primer which speeds the curing rate of
anaerobic products.
4104/0251 200 ml (Aerosol)
4104/0253 1 ltr (Bottle)
JCB Cleaner/Degreaser For degreasing components prior to use of
anaerobic adhesives and sealants.
4104/1557 400 ml (Aerosol)
Direct Glazing Kit For one pane of glass; comprises of:
– 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
Ultra Fast Adhesive For direct glazing. 4103/2109 310 ml
Active Wipe 205 For direct glazing. 4104/1203 250 ml
Black Primer 206J For direct glazing. 4201/4906 30 ml
Clear Silicone Sealant To seal butt jointed glass. 4102/0901
Plastic to Metal Bonder To seal plastic to metal joints. 4103/0956 50 g
Black Polyurethane Sealant To finish exposed edges of laminated glass. 4102/2309 310 ml

10. Section 1 - General Information
Service Consumables
Sealing and Retaining Compounds
1-8 1-8
9803/9590-4
Page left intentionally blank

11. Section 1 - General Information
1-9 1-9
9803/9590-4
Service Tools
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.
Note: 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.
Part
Number
Description See Section
- Bonded Washers - see Tool Detail Reference (Section 1) for content E
- Female Cone Blanking Caps - see Tool Detail Reference (Section 1) for content E
- Female Connectors - see Tool Detail Reference (Section 1) for content E
- Hydraulic Flow Test Equipment - see Tool Detail Reference (Section 1) for content E
- Male Adapters - BSP x BSP - see Tool Detail Reference (Section 1) for content E
- Male Adapters - BSP x NPT (USA only) - see Tool Detail Reference (Section 1) for
content
E
- Male Cone Blanking Caps - see Tool Detail Reference (Section 1) for content E
- Pressure Test Points - Adaptors - see Tool Detail Reference (Section 1) for content E
- Pressure Test Points - 'T' Adaptors - see Tool Detail Reference (Section 1) for content E
- Rivet Nut Tool - see Tool Detail Reference (Section 1) for content B
4104/1310 Hand Cleaner B
892/00253 Hydraulic Circuit Pressure Test Kit - see Tool Detail Reference (Section 1) for content E
892/00254 Hose E
892/00279 Gauge E
892/00280 Gauge E
892/00284 Digital Tachometer C
892/00285 Hyd. Oil Temperature Probe C
892/00298 Fluke Meter C
892/00346 Gauge E
892/00347 Connector E
892/00842 Glass Lifter B
892/00843 Folding Stand for Holding Glass B
892/00845 Cartridge Gun B
892/00846 Glass Extractor (Handles) B
892/00847 Nylon Spatula B

12. Section 1 - General Information
Service Tools
Numerical List
1-10 1-10
9803/9590-4
892/00848 Wire Starter B
892/00849 Braided Cutting Wire B
892/01246 Vibromax male to JCB female threaded adaptor E
892/01247 JCB male to Vibromax female threaded adaptor E
892/12345 Frequency and Vibration Measuring Tool E
926/15500 Rubber Spacer Blocks B
992/12300 12V Mobile Oven B
992/12400 24V Static Oven (2 Cartridge) B
992/12800 Cut-Out Knife B
992/12801 'L' Blades B
993/68100 Slide Hammer Kit - see Tool Detail Reference (Section 1) for content B
Part
Number
Description See Section

13. Section 1 - General Information
Service Tools
Tool Detail Reference
1-11 1-11
9803/9590-4
Tool Detail Reference
Section B - Body and Framework
Note: Not all service tools are illustrated.
Fig 5. 993/68100 Slide Hammer Kit
1 993/68101 Slide Hammer 7 993/68107 Bar - M20 x M20 X 800 mm
2 993/68102 End Stops 8 993/68108 Adaptor - M20 x 7/8" UNF
3 993/68103 Adaptor - M20 x 5/8" UNF 9 993/68109 Adaptor - M20 x M12
4 993/68104 Adaptor - M20 x 1" UNF 10 993/68110 Adaptor - M20 x 5/8" UNF (Shoulder)
5 993/68105 Adaptor - M20 x M20 11 993/68111 Adaptor - M20 x 1/2" UNF
6 993/68106 Adaptor - M20 x M24
Fig 6. Rivet Nut Tool
1 826/01099 M6 x 16 mm Rivet Nut
826/01101 M6 x 19 mm Rivet Nut
826/01102 M8 x 18 mm Rivet Nut
826/01103 M8 x 21 mm Rivet Nut
826/01104 M10 x 23 mm Rivet Nut
826/01105A M10 x 26 mm Rivet Nut
2 - Installation Tool available from: Bollhoff
Fastenings Ltd (www.bollhof.com)
Fig 7. 892/00842 Glass Lifter
Minimum 2 off - Essential for glass installation, 2 required
to handle large panes of glass. Ensure suction cups are
protected from damage during storage.

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15. Section 1 - General Information
Service Tools
Tool Detail Reference
1-12 1-12
9803/9590-4
Fig 8. 892/00843 Folding Stand
Essential for preparing new glass prior to installation.
Fig 9. 892/00845 Cartridge Gun
Hand operated. Essential for the application of sealants,
polyurethane materials etc.
Fig 10. 892/00846 Glass Extractor (Handles)
Used with braided cutting wire to cut out broken glass.
K Fig 13. ( T 1-13).
Fig 11. 892/00847 Nylon Spatula
General tool used for smoothing sealants - also used to
re-install glass in rubber glazing because metal tools will
chip the glass edge.
Fig 12. 892/00848 Wire Starter
Used to access braided cutting wire through original
polyurethane seal. K Fig 13. ( T 1-13).

16. Section 1 - General Information
Service Tools
Tool Detail Reference
1-13 1-13
9803/9590-4
Fig 13. 892/00849 Braided Cutting Wire
Consumable heavy duty cut-out wire used with the glass
extraction tool. K Fig 10. ( T 1-12). Approx 25 m length.
Fig 14. 926/15500 Rubber Spacer Blocks
Used to provide the correct set clearance between glass
edge and cab frame. Unit quantity = 500 off.
Fig 15. 992/12300 Mobile Oven 12V
1 cartridge capacity. Required to pre-heat adhesive prior
to use. It is fitted with a male plug (703/23201) which fits
into a female socket (715/04300).
Fig 16. 992/12400 Static Oven 240V
Required to pre-heat adhesive prior to use. No plug
supplied.
Note: 110V models available upon request - contact JCB
Technical Service.
Fig 17. 992/12800 Cut-Out Knife
Used to remove broken glass.
Fig 18. 992/12801 'L' Blades
25 mm (1 in.) cut. Replacement blades for cut-out knife.
K Fig 17. ( T 1-13). Unit quantity = 5 off.

17. Section 1 - General Information
Service Tools
Tool Detail Reference
1-14 1-14
9803/9590-4
Fig 19. 4104/1310 Hand Cleaner
Special blend for the removal of polyurethane adhesives
(454g; 1 lb tub).

18. Section 1 - General Information
Service Tools
Tool Detail Reference
1-15 1-15
9803/9590-4
Section C - Electrics
Note: Not all service tools are illustrated.
Fig 20. 892/00298 Fluke Meter
Fig 21. 892/00285 Hydraulic Temperature Probe
Fig 22. 892/00284 Venture Microtach Digital
Tachometer

19. Section 1 - General Information
Service Tools
Tool Detail Reference
1-16 1-16
9803/9590-4
Section E - Hydraulics
Note: Not all service tools are illustrated.
Fig 23. Male Adaptors
Male Adapters - BSP x BSP
1606/2052 3/8 in. x 1/4 in.
1604/0003A 3/8 in. x 3/8 in.
892/00071 3/8 in. x 3/8 in. taper
1606/0004 1/2 in. x 1/4 in.
1606/0007A 1/2 in. x 3/8 in.
1604/0004A 1/2 in. x 1/2 in.
1606/0017 5/8 in. x 1/2 in.
1606/0008 3/4 in. x 3/8 in.
Male Adapters - BSP x NPT (USA only) 1606/0009 3/4 in. x 1/2 in.
816/00439 3/8 in. x 1/4 in. 1604/2055 3/4 in. x 3/4 in.
816/00440 1/2 in. x 1/4 in. 1606/0012 3/4 in. x 1 in.
816/15007A 3/8 in. x 3/8 in. 1606/0014 3/4 in. x 1.1/4 in.
816/15008 1/2 in. x 3/8 in. 1606/0015 1 in. x 1.1/4 in.
Fig 24. Pressure Test Adapters
892/00255 1/4 in. BSP x Test Point
892/00256 3/8 in. BSP x Test Point
892/00257 1/2 in. BSP x Test Point
892/00258 5/8 in. BSP x Test Point
816/15118 3/4 in. BSP x Test Point
892/00259 1 in BSP x Test Point
892/00260 1.1/4 in. BSP x Test Point
892/00261 5/8 in. UNF x Test Point
Fig 25. Pressure Test 'T' Adapters
816/55045 1/4 in. M BSP x 1/4 in. F BSP x Test Point
816/55038 3/8 in. M BSP x 3/8 in. F BSP x Test Point
816/55040 1/2 in. M BSP x 1/2 in. F BSP x Test Point
892/00263 5/8 in. M BSP x 5/8 in. F BSP x Test Point
892/00264 3/4 in. M BSP x 3/4 in. F BSP x Test Point
892/00265 1 in. M BSP x 1 in. F BSP x Test Point
892/00266 1.1/4 in. M BSP x 1.1/4 in. F BSP x Test Point
892/00267 1.1/4 in. M BSP x 1.1/2 in. F BSP x Test Point