JCB TM310 Agricultural Loader Repair Service Manual
JCB TM310 Agricultural Loader Repair Service Manual
(S/N: 1314700 Onwards) - This service manual PDF download for the TM310 JCB Farm Master Loader 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.
Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Network Systems
MANUAL SPECIFICATION :
File Format : PDF Language : English Printable : Yes Searchable : Yes Bookmarked : Yes Publication No. : 9803/9520-06 Total Pages : 649
This 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 !!!!
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9803-9520
Section 1 - General Information Introduction About this Publication Schematic Codes Colour Codes Machine Identification Machine Identification Plate Data Plate Typical Vehicle Identification Number (VIN) Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Introduction Bolts and Screws Hydraulic Connections 'O' Ring Face Seal System 'Torque Stop' Hose System Service Tools Numerical List Tool Detail Reference Service Aids Sealing and Retaining Compounds
Section 2 - Care and Safety Care and Safety Safety Notices Important Information The Operator Manual Safety Warnings Safety Check List Safety - Yours and Others General Safety Operating Safety Maintenance Safety Safety Decals Introduction Safety Decal Recognition General Procedures Introduction Parking the Machine and Making it Safe Articulation Locks Installing the Articulation Locks Removing the Articulation Locks Venting Hydraulic Pressure Venting Braking Pressure Connecting/Disconnecting Hydraulic Hoses Introduction Connecting the Hoses Disconnecting the Hoses Quick Release Couplings Connecting and Disconnecting Hydraulic Contamination Hydraulic Fluid Quality Effects of Contamination Cleaning Operation Contaminant Standards Filters Battery Disconnection/Connection Disconnection Connection Removing and Replacing Components Battery Charging System Precautions Hydraulic Rams Installation Caution During Use Maintenance, Inspection Points
Section 3 - Routine Maintenance Routine Maintenance Maintenance Service Requirements Introduction Owner/Operator Support Service/Maintenance Agreements Initial Service and Inspection (100 Hours) Lifting Regulations - Inspections and Tests Obtaining Replacement Parts Service Schedules Introduction How to Use the Service Schedules Pre-start Cold Checks, Service Points and Fluid Levels Health and Safety Lubricants Battery First Aid - Electrolyte Fluids, Lubricants and Capacities Cleaning the Machine Checking for Damage Seat Belt Checking the Seat Belt Condition and Security Checking the ROPS/FOPS Structure Fire Extinguisher (if fitted) Checking the Fire Extinguisher Greasing Boom Pivot Pins Centre Pivot and Steering Ram Propshaft Joints Inner and Outer Booms Engine Canopy Opening the Canopy Closing the Canopy Heating and Ventilation Cleaning the Cab Heater Filter Electrical System Battery Jump Starting the Engine Fuses Relay Identification Engine Checking the Oil Level Changing the Oil and Filter Coolant Mixtures Checking the Coolant Level Changing the Coolant Front End Accessory Drive (FEAD) Belt Engine Crankcase Ventilation Engine Air Filter Fuel System Filling the Tank Draining the Water Separator and Fuel Filter Changing the Filter Element Changing the Water Separator Pre- Filter Bleeding the Fuel System Hydraulic System Checking the Fluid Level Changing the Filter Element Transmission Checking the Transmission Oil Level Changing the Transmission Oil and Filter Transfer Gearbox Checking the Oil Level Changing the Oil Axles Checking the Oil Level Changing the Oil Tyres and Wheels Tyre Inflation Checking the Wheel Nut Torques Windscreen Washer
Section B - Body and Framework Body and Framework Technical Data Air Conditioning (Option) Basic Operation Load Moment Indicator (LMI) Cooling Pack Fault Finding Air Conditioning Load Moment Indicator (LMI) Fault Codes General Fault Finding Diagnostic Tests Service Procedures Rivet Nuts Fitting Procedure Slide Hammer Kit Fitting Procedure Air Conditioning (Option) Service Checks Leak Testing Tightening Leaking Hoses Refrigerant Charging and Discharging Binary Pressure Switch Testing Compressor Drive Belt - Adjustment Condenser Matrix Cleaning Cab ROPS, FOPS Structure - Checks Direct Glazing Boom Fork Carriage Removal and Replacement Removal Replacement Boom Removal and Replacement Removal Replacement Dismantling and Assembly Dismantling Assembly Boom Shim Adjustment Articulated Joint Removal and Replacement Load Moment Indicator (LMI) Removal and Replacement Transducer Instrument Panels EMS Unit and Front Console Removal Replacement Side Switch Panel Removal Replacement Roof Mounted Panel Removal Replacement Hydraulic Tank Removal and Replacement Removal Replacement Hose Connections Fuel Tank Removal and Replacement Removal Replacement Fuel Level Sender Cab Removal and Replacement Removal Replacement Hose Connections Internal Components Front Floor Mat Variflow Pump Access Panel Front Blind Roof Blind Roof Liner External Components Door Handle Removal and Replacement Door Removal and Replacement Air Conditioning (Option) Removal and Replacement Pressure Switch Condenser Mudguards Removal and Replacement Front Mudguard Rear Mudguard
Section C - Electrics Electrics Technical Data General Electrical Data Fuses and Relays Secondary Fuses Relays Primary Fuses Schematic Circuits Schematic A - Primary Fuses, Secondary Fuses, Ignition Switch and Relays Schematic B - Engine Schematic C - Gearbox Schematic D - Instrumentation Schematic E -SRS and Accessories Schematic F - Front Wipe, Rear Wipe and Heater/Air Conditioning Schematic G - Front and Rear Worklights, Boom Light and Beacon Schematic H - Roadlighting Schematic J - Auxiliary and Boom Hydraulics Schematic K - Earthing Schematic L - CAN Overview Service Procedures Using a Multimeter Measuring DC Voltage Measuring Resistance Measuring Continuity Measuring Frequency Testing a Diode or a Diode Wire Battery Maintenance First Aid - Electrolyte Testing Specific Gravity Testing Alternator General Description Service Precautions Charging Circuit Test Alternator Charging Test Starter Motor Starting Circuit Test Wire and Harness Number Identification Introduction Wire Numbers and Functions Wiring Harness Repair Introduction Repair Procedure Battery Removal and Replacement Removal Alternator Removal, Inspection and Replacement Dismantle and Assemble Renewing the Voltage Regulator and Brushes Renewing the Drive Pulley Starter Motor Removal, Inspection and Replacement Dismantle and Assemble Renewing the Brush Gear Renewing the Starter Solenoid Harness Data Drawings and Interconnection Harnesses Drawings
Section E - Hydraulics Hydraulics Technical Data Hydraulic Pump Variable Flow Auxiliary Pump Control Valve Block Maximum rpm Cycle Times Smooth Ride System (SRS) Accumulator Basic Operation Flowshare Component Location and Identification Oil Pump Load Sensing Pressure Compensation (Flowshare) Hydraulic Circuit Operation Circuit Descriptions Variflow Pump Operation Hydraulic Variable Control System (HVCS) Pulse Width Modulation (PWM) Schematic Circuits TM310 Hand Control Valve (Servo) Hand Control Valve Removal and Replacement Dismantling, Inspection and Assembly Main Pump Removal and Replacement Removal Replacement Dismantle and Assemble Control Valve Block Handling Removal Replacement Hose Connections Service Procedures Flow and Pressure Tests Checking Pump Flow System Pressures Checking the Servo Pilot Pressure `Positional Type' Hydraulic Adaptors Fitting Procedure Bleeding the Hydraulic System Boom Internal Pipes and Hoses Removal and Replacement Removal Assembly Hydraulic Rams Precautions During Use Installation Caution During Use Maintenance, Inspection Points Lift Ram Removal Replacement Displacement Rams Removal Replacement Extension Ram Removal Replacement Tilt Ram Removal Replacement Dismantle and Assemble Typical Ram Tilt Ram Lift Ram Extension Ram Displacement Ram Smooth Ride System (SRS) Technical Data Description Hydraulic Schematic Fault Finding Accumulators Charging and Discharging Removal and Replacement Dismantling and Assembly Anti-Cavitation Valve Removal and Replacement Removal Replacement Hose Connections
Section F - Transmission Transmission Technical Data Tyre Pressures and Sizes TM310 and TM310S TM-W Front Axles Unit Identification Rear Axles Unit Identification Powershift Gearboxes PS763 3-Speed PS766 6-Speed Basic Operation General Description Transmission Assembly PS760 Transmission Front Axles Limited Slip Differential (LSD) Front Axle Standard Maxtrack Front Axle Rear Axles Limited Slip Differential (LSD) Rear Axle Standard Maxtrack Rear Axle Dual Control Forward, Neutral and Reverse (F/N/R) Operation Characteristics PS763 and PS766 Powershift Gearboxes Component Identification Principle of Operation Hydraulic and Electrical Operation Operation Characteristics - PS760 Gearbox Drivepaths - 3 Speed Drivepaths - 6 Speed Torque Converter Component Identification Principle of Operation Lock-Up Torque Converter Component Identification Principle of Operation Systems Description PS763 and PS766 Powershift Gearboxes Forward and Reverser Clutch Operation Mainshaft, Layshaft and 6-Speed Clutch Operation Electrical Connections Powershift Gearbox (PS 760 3 Speed) Introduction Quick Reference Wires and Connectors Powershift Gearbox (PS766 ECU 2.3 6 Speed) Introduction Quick Reference Wires and Connectors Transmission ECU ECU Location ECU Electrical Connections ECU Feeds and Earths Lock Up Torque Converter Introduction Quick Reference Wires and Connectors Fault Finding Powershift Gearbox Introduction Fault Finding Tables Powershift Gearbox Removal and Replacement Dismantling and Assembly Front Axle Removal and Replacement When Removing When Replacing Dismantle and Assemble Rear Axle Removal and Replacement When Removing When Replacing Dismantle and Assemble Propshafts Removal and Replacement When Removing When Replacing Transfer Gearbox Removal and Replacement Removal Replacement
Section G - Brakes Brakes Park Brake Gearbox Integral Dismantle, Inspection and Assemble Brake Pump Removal and Replacement Removal Replacement Brake Valve Removal and Replacement Removal Replacement Service Procedures Service Brakes Bleeding the Braking System
Section H - Steering Steering Service Procedures Bleeding the System Hydraulic Pressure Tests Standby and Steering Pressure Steer Rams Removal and Replacement Dismantle and Assemble Hydraulic Steer Unit Removal and Replacement Removal Replacement Hose Connections Steering Manifold Removal and Replacement Removal Replacement Hose Connections
Section K - Engine Engine Technical Data Basic Engine Data Introduction Engine Types Unit Identification Silencer Removal and Replacement Removal Replacement Cooling Pack Removal and Replacement Removal Replacement Dismantle and Assemble Coolant Expansion Tank Removal and Replacement Removal Replacement Circuit Descriptions Engine ECU - SE Engines Machine Electrical Interface Engine ECU Power-Up Cold Start Heater Fuel Lift Pump Throttle Position Sensor Electronic Fault Codes
Section M - Network Systems Network Systems Network Systems Description What is the Network System? CANbus Communications System Wires and Connectors Electronic Monitoring System Description EMS Display EMS Set-up Connected Devices Electronic Fault Codes Fault Code Displays CAN Enabled Display CANbus Connected Computer Electronic Monitoring System ECU Fault Codes Operator Warnings Fault Code Log Fault Code List Servicemaster Why Use Servicemaster? Introduction Fault Finding Identify Poor Maintenance Access Machine Set Up Data Re-Programming ECUs Summary What is Servicemaster? Introduction CANbus Communications System Servicemaster Structure How to Set Up Servicemaster Install Servicemaster Start Servicemaster Load the DLA Laptop Driver Software Configure the DLA Type and Communications Port Check the DLA Firmware File Connect Servicemaster to the Machine CANbus Servicemaster Tools Summary JCB 4.4L Tier 3 SE Diagnostics Tool - User Guide Introduction Care and Safety Connecting 4.4L Tier 3 Diagnostics Starting 4.4L Tier 3 Diagnostics 4.4L Tier 3 Diagnostics Overview Navigating within Diagnostics Menu Bar - File Menu Menu Bar - Options Menu Menu Bar - Window Menu Menu Bar - Help Menu Start and Stop Buttons Page List Status bar LED Status Key Engine Connector Page Machine Connector Page Actuator Tests Page Fault Codes Page ShiftMaster Diagnostics 2.3 - User Guide Introduction Care and Safety Installing ShiftMaster Diagnostics Connecting Shiftmaster Diagnostics Starting ShiftMaster Diagnostics ShiftMaster Diagnostics Overview Navigating within ShiftMaster Diagnostics Menu Bar - File Menu Menu Bar - Options Menu Menu Bar - Window Menu Menu Bar - Help Menu Start and Stop Buttons Page List Status bar ECU Setup Page Dashboard Page ECU Status Page Torque Converter Lock Up (TCLU) Page Solenoid Test Mode Page Solenoid Identification Page ECU Block Diagram Page Connection Problems General Information TM310 Setup - User Guide Introduction Care and Safety Installing Connection Starting TM310 Setup Navigating within TM310 Setup Menu Bar - File Menu Menu Bar - Utilities Menu Menu Bar - Help Menu Vehicle Setup Options Language Write Read Connection Problems Engine Setup - User Guide Introduction Care and Safety Installing Connection Starting Engine Setup Navigating within Engine Setup Menu Bar - File Menu Menu Bar - Utilities Menu Menu Bar - Help Menu General Injector Calibration Write Read Connection Problems