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
9813/0650
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 115- TIER II
Service Manual - VM 115- TIER II
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section H - Steering
Section K - Engine
Section L - Vibration

2. 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
9813/0650
Publication No.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section 1
General Information
Service Manual - VM 115- TIER II
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section H - Steering
Section K - Engine
Section L - Vibration

3. Page No.Contents
Section 1 - General Information
1 - i 1 - i
Introduction
About This Manual ....................................................................................1 - 1
Machine Model and Serial Number .....................................................1 - 1
Using this Manual ................................................................................1 - 1
Cab/Canopy ........................................................................................1 - 1
Left Side, Right Side ............................................................................1 - 1
Cross References ................................................................................1 - 1
Machine Description .................................................................................1 - 2
The JCB Vibromax Vibratory Single Drum Roller ................................1 - 2
............................................................................................................1 - 2
Component Locations .........................................................................1 - 3
Safety Labels ............................................................................................1 - 5
Introduction ..........................................................................................1 - 5
Safety Label Identification ...................................................................1 - 6
Identifying Your Machine ..........................................................................1 - 8
Machine Identification Plate ................................................................1 - 8
Component Identification Plates ..........................................................1 - 9
Machine Security ....................................................................................1 - 10
Construction Equipment Security And Registration Scheme (CESAR) .1-
10
Service Consumables
Sealing and Retaining Compounds ........................................................1 - 11
Service Tools
Numerical List .........................................................................................1 - 13
Tool Detail Reference .............................................................................1 - 15
Section B - Body and Framework ......................................................1 - 15
Section C - Electrics ..........................................................................1 - 18
Section E - Hydraulics .......................................................................1 - 19
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners ....................................1 - 24
Introduction ........................................................................................1 - 24
Bolts and Screws ...............................................................................1 - 24
Vibromax Specific Torque Settings .........................................................1 - 28
Hydraulic Connections ............................................................................1 - 30
'O' Ring Face Seal System ................................................................1 - 30
'Torque Stop' Hose System ...............................................................1 - 33

4. Section 1 - General Information
1 - 1 1 - 19813/0650
Introduction
About This Manual
Machine Model and Serial Number
This manual provides information for the following
model(s) in the JCB machine range:
– VM 115 from SN 2034000 onwards
Using this Manual
T1-044
This manual is arranged to give you a good understanding
of the machine and its safe operation. It also contains
maintenance information and specification data. Read this
manual from front to back before using the machine for the
first time. Particular attention must be given to all the safety
aspects of operating and maintaining the machine.
If there is anything you are not sure about, ask your JCB
distributor or employer. Do not guess, you or others could
be killed or seriously injured.
General warnings in this chapter are repeated throughout
the book, as well as specific warnings. Read all the safety
statements regularly, so you do not forget them.
Remember that the best operators are the safest
operators.
The illustrations in this manual are for guidance only.
Where the machines differ, the text and or the illustration
will specify.
This manual contains original instructions, verified by the
manufacturer (or their authorised representative).
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.
All optional equipment included in this manual may not be
available in all territories.
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.
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.
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 1-1).

5. Section 1 - General Information
Introduction
Machine Description
1 - 2 1 - 29813/0650
Machine Description
The JCB Vibromax Vibratory Single
Drum Roller
The self-propelled vibratory single drum roller is designed
with a compaction device consisting of a metallic
cylindrical drum which compacts material such as crushed
rock, earth, asphalt or gravel, through a rolling and/or
vibrating action or the compaction device. (The machine
complies with ISO Standard 6165:2002).
Machines are characterised by smooth drum (`D' Models)
or pad foot (`PD' Models) drum configurations
All models are fitted with a hydrostatic drive system which
allows for infinitely variable travel speeds. The engine
speed is always set to maximum and the drive lever is
used to control the road speed.There are two speed
ranges for both the drum and rear axle. The rear axles are
a `no spin' design for improved traction.
A hydrostatic system is also used to turn the machine's
vibratory shaft. The machines are designed with an
overturning weight system on the vibratory shaft, the VM
46D/PD only has one Frequency/Amplitude, all others
have low/high rates.
The machine has articulated steering for a shorter turning
radius and oscillation joints to allow operating on rough
terrain.
Note: The illustration(s) show a typical machine model;
your machine may look different from the model shown.
The machine is intended only for compacting beds of
earthy building materials when running over the subgrade
in the forward or reverse direction with or without vibration.
These building materials include soil types ranging from
stones to silty sand and having water contents ranging
from 40% to 110% of the optimum water content. These
figures are in accordance to the standard Proctor test DIN
18127.
Fine-grained soils or soils having higher water contents
require a qualified trial compaction.
The machine is intended to be used only on a subgrade
gradient up to the permissible gradient.

6. Section 1 - General Information
Introduction
Machine Description
1 - 3 1 - 39813/0650
Component Locations
1 Articulation Joint
2a Smooth Drum
2b Tamping Foot Drum shells
3 Lifting and Towing Eyes
4a Canopy
5 Battery
6 Hydraulic Tank
7 Engine
8 Rear Axle
9 Air Filter
10 Drum Drive Motor
11 Isolation Pad
12 Scraper
13 Exhaust
14 Fuel Tank
15 Oil/Water Cooler
16 Vibration Motor
17 Steering Ram
18 Hydraulic Pumps
19 Axle Hydraulic Drive Motor
20 Hydraulic Test Station

7. Section 1 - General Information
Introduction
Machine Description
1 - 4 1 - 49813/0650
Fig 2.
5

8. Section 1 - General Information
Introduction
Safety Labels
1 - 5 1 - 59813/0650
Safety Labels
Introduction
T1-014_2
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 yourself in dangerous positions to read the safety
labels. If you do not understand the hazard shown on the
safety label, then refer to Safety Label Identification.
Note: 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 labels where necessary. Each safety label
has a part number printed on it, use this number to order a
new safety label from your JCB distributor.

9. Section 1 - General Information
Introduction
Safety Labels
1 - 6 1 - 69813/0650
Safety Label Identification
Fig 3.
ISO-01A ISO-010A ISO-015C
ISO-05C
ISO-07D
ISO-07D
ISO-09A
ISO-02C
ISO-06BISO-09A

10. Section 1 - General Information
Introduction
Safety Labels
1 - 7 1 - 79813/0650
Part Numbers and Description
ISO-01A
Part Number: 817/70014
Description: Warning. Read the
operator manual before you operate
the machine.
ISO-02C
Part Number: 332/P7181
Description: Crushing of whole body
install the articulation lock before you
start maintenance work. Refer to
Articulation Lock (Operation
Section).
ISO-05C
Part Number: 817/70012
Description: Runover. Start the engine
from the operator seat only. Do not
short across the terminals.
ISO-06B
Part Number: 332-F5860
Description: Pressure hazard. Refer
to Cooling System (Routine
Maintenance Section).
ISO-07D
Part Number: 817-70027
Description: Crush hazard. Keep a
safe distance from the moving parts.
ISO-09A
Part Number: 332-P4581
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).
ISO-010A
Part Number: 817/70029
Description: Crush hazard. Wear the
seat belt when you operate the
machine.
ISO-015C
Part Number: 817/70021
Description: Noise warning. Wear
applicable ear protection.

11. Section 1 - General Information
Introduction
Identifying Your Machine
1 - 8 1 - 89813/0650
Identifying Your Machine
Machine Identification Plate
Your machine has an identification plate mounted as
shown. K Fig 4. ( T 1-8).
The machine and engine serial numbers can help identify
exactly the type of equipment you have.
Fig 4.
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)
1 2 3 4
JCB VM115 C 01801240

12. Section 1 - General Information
Introduction
Identifying Your Machine
1 - 9 1 - 99813/0650
Component Identification Plates
Fig 5.
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

13. Section 1 - General Information
Introduction
Machine Security
1 - 10 1 - 109813/0650
Machine Security
Construction Equipment Security And
Registration Scheme (CESAR)
T1-020
JCB are pleased to announce, the availability of CESAR a
simple, effective method of machine identification and
registration that operates throughout the United Kingdom
and Ireland and across the whole spectrum of JCB
products.
CESAR is a scheme to help reduce plant theft, and was
developed by the Metropolitan Police and the Home Office
Plant Theft Action Group.
The key to the scheme is its simplicity and will mean that
every police officer in the country will know how to identify
construction machinery and verify ownership. This will
provide a major leap forward in both protecting machinery,
and recovering it.
The Construction Equipment Association is managing the
scheme, and Datatag are providing the security material
and support. JCB is fully supportive of the CESAR initiative
and will offer it as a factory fit option across the range.
The CESAR kit includes 2 Tamper proof triangular ID
plates fitted on either side of the machine, a unique
transponder, mini radio frequency identification tags
(RFIDs) concealed throughout the machine, Datatag micro
dots, and a unique DNA coded chemical painted on the
machines major components. Plus a registration certificate
logged onto the CESAR or DVLA databases, and a change
of keeper form.

14. Section 1 - General Information
Service Consumables
Sealing and Retaining Compounds
1 - 11 1 - 119813/0650
Service Consumables
Sealing and Retaining Compounds
T11-001_4
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.
4101/0601 10 ml
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

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16. Section 1 - General Information
1 - 13 1 - 139813/0650
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

17. Section 1 - General Information
Service Tools
Numerical List
1 - 14 1 - 149813/0650
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