JCB TM200, TM270, TM300 Agricultural Loader Repair Service Manual

TM200 (S/N: 0633777 Onwards) - TM270 (S/N: 0787000 Onwards) - TM300 (S/N: 1017000 Onwards)
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This service manual PDF download for the TM200, TM270, TM300 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.


APPLICABLE MODELS :

JCB Farm Master Loader

JCB Agricultural Loader TM200 - (S/N: 0633777 Onwards)
JCB Agricultural Loader TM270 - (S/N: 0787000 Onwards)
JCB Agricultural Loader TM300 - (S/N: 1017000 Onwards)


TABLE OF CONTENTS :

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


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/4225 Issue 4
Total Pages : 504


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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Contents
Introduction
Hydraulic Codes

Section 1: General Information
Machine Identification Plate
Serial Plates
Torque Settings
Service Tools Numerical List
Service Tools
Body and Framework
Electrics
Hydraulics
Transmission
Steering
Engine
Sealing and Retaining Compounds

Section 2: Care and Safety
Safety Notices
General Safety
Operating Safety
Maintenance Safety

Section 3: Routine Maintenance
Lubricants and Capacities
1000 Series Engine
New 1000 Series Engine
New 1000 Series Engine (North America)
Lubricants - Health and Safety
Service Schedules
Articulation Lock
TM 200
TM 270/300
Greasing
Boom Pivot Points TM200/270
Centre Pivot and Steering Ram
Propshafts
Inner and Outer Booms
Boom Pivot Points TM300
General
Checking for Damage
Cleaning the Machine
Cab
Checking the ROPS/FOPS Structure
Cleaning the Cab Heater Filter
Checking the Seat Belt Security and Condition
Checking the Fire Extinguisher (if fitted)
Electrics
Battery
First Aid - Electrolyte
Windscreen Washer
Hydraulic System
Checking the Fluid Level
Changing the Filter Canister
Synchro Shuttle Transmission
Checking the Oil Level
Changing the Oil and Filter
Powershift and Transmission
Checking the Oil Level
Changing the Oil and Filter
Transfer Gearbox
Checking the Oil Level
Changing the Oil
Front and Rear Axles
Checking the Oil Level
Changing the Oil
Tyres and Wheels
Inflating the Tyres
Checking the Wheelnut Torques
Engine
Opening the Canopy
Closing the Canopy
Opening the Engine Cover TM300
closing the Engine Cover TM300
Fuel System
Types of Fuel
Fuel Standards
Low Temperature Fuels
Filling the Tank
Draining the Fuel Filter
Changing the Fuel Filter Element
Draining the Sedimenter Bowl
Cleaning the Sedimenter Bowl
Bleeding the Fuel System
Draining the Fuel Filter TM300
Changing the Fuel Filter TM300
Draining the Fuel Sedimenter TM300
Bleeding the Fuel System TM300
Fuel Pipes TM300
Engine Air Filter
Changing the Air Filter Elements (TM200/270)
Changing the Air Filter Elements (TM 270 from Ser. No. 787118)
Cleaning the Pre-Cleaner (if fitted)
Changing the Air Filter Elements (TM300)
Engine Oil and Filter
Checking the Oil Level (TM200/270)
Changing the Oil and Filter (TM200/270)
Checking the Oil Level (TM300)
Changing the Oil and Filter (TM300)
Engine Cooling System
Checking the Coolant System
Coolant Mixtures
Changing the Coolant (TM200/270)
Checking the Coolant TM300
Changing the Coolant TM300
Adjusting the Drive Belt

Section B: Body and Framework
Direct Glazing
Cooling Pack TM300
Central Pivot - Dismantling and Assembly TM 200
Articulated Joint TM270/300
Boom Shim Adjustment
Rivet Nut Fitting Procedure

Section C: Electrics
Technical Data
TM 200
TM 270
Test Methods
Use of Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
How to Test a Diode or Diode Wire
Batteries
Safety
Specific Gravity Test
Battery Testing
Wiring Harness Repair
Harness Repair Introduction
Tools Required
Procedure
Starter Motor
Starting Circuit Test
Removal and Replacement
Dismantling and Assembly
Alternator
General Description
Service Precautions
Charging Test
Removal and Replacement
Dismantling and Assembly
Safe Load Indicator
Adjustment
Transducer Removal and Replacement
Testing
Electronic Speedometer (TM 270)
Calibration
Setting
Circuit Schematics
TM 200
TM 270 (to Serial No. M787040)
TM 270 (from Serial No. M787041)
Wiring Harness Diagrams
TM 200
TM 270
Wiring Harness Locations
TM 270

Section E: Hydraulics
Technical Data
TM 200
TM 270
TM 300
Basic System Operation
Loader Control Valve TM200
Neutral Circuit
Boom Lift Operation
Boom Lower Operation
Boom Extend Operation
Hose Burst Operation
Relief Valve and Spool Location
Removal and Replacement TM200/270
Dismantling and Assembly
Relief Valve and Intersection Sealing
Solenoid Operated Spool
Pilot Pressure Operated Spool
Pressure Testing
Main and Auxiliary Pressure Relief Valves
Servo
Loader Control Valve TM300
Overview
Control ValveSections
Pressure Relief Valve Locations
Neutral Circuit
Extent Retract Circuit
Tilt Circuit
Hand Control Valve (Servo) TM300
Removal and Replacement
Dismantling, Inspection and Assembly
Pumps
TM 200
Removal and Replacement
Dismantling and Assembly
TM 270/300
Removal and Replacement
Dismantling and Assembly
Pressure Testing
Oil Cooler TM300
Introduction, Removal and Replacement
Removal
Replacement
Unloader Valve
TM 270
Removal and Replacement
Dismantling and Assembly
Pressure Testing
Internal Pipes and Hoses
Typical Ram
Smooth Ride System
Technical Data
Description
Fault Finding
Accumulators
Charging and Discharging
Removal and Replacement
Dismantling, Inspection and Assembly
Schematic Circuit
TM 200
TM 270
TM 270 From Ser. No. 787118
TM 300
TM 300 From Ser. No. 1017046

Section F: Transmission
Technical Data
TM 200
Front and Rear Axles
TM 270/300
Front Axle
Rear Axle
Tyre Pressures
Synchro Shuttle Transmission
Powershift Transmission
Transfer Gearbox
Propshafts
Removing and Replacing
Front and Rear Axles - TM 200
Cut-a-way of Axle
Removing and Replacing
Hub, Driveshaft and Brakes
Dismantling
Assembly
Central Drivehead
Dismantling
Assembly
Renewing the Pinion Oil Seal
Differential
Dismantling
Assembly
Limited Slip Differential
Dismantling
Assembly
Front and Rear Axles - TM 270/300
Cut-a-way of Axle
Removing and Replacing
Front Axle
Brakes, Dismantling and Assembly
Hub and Driveshaft
Dismantling
Assembly
Central Drivehead
Renewing the Pinion Oil Seal
Dismantling
Assembly
Limited Slip Differential
Dismantling
Assembly
Transfer Gear Box
Removal and Replacement
Dismantling and Assembly
Transmission Mounting - TM 270/300
Synchro Shuttle Transmission
SS640 Section Views and Torque Figures
Description
Synchromesh
Clutch Operation
Fault Finding
Gear Box
Dismantling
Assembly
Solenoid Valve
Dismantling
Assembly
Reverser Unit
Dismantling
Assembly
Torque Converter
Replacing
Stall Test
Pressure and Flow Test
Powershift Transmission
Summary of Changes
PS700 Section Views and Torque Figures
General Description
Hydraulic Operation
Powershift Drivepaths
TM 200/TM 270 To Ser. No. 787118
TM 200/TM 270 From Ser. No. 787119
Clutch Operation
Fault Finding
PS 700 Gearbox
Dismantling (see summary of changes)
Assemvly (see summary of changes)
Solenoid Valve
Dismantling
Assembly
PS700 Input Clutch and Reverser Clutch
Dismantling
Dismantling (Later Type Reverser)
Assembly
Assembly (Later Type Reverser)
PS700 Mainshaft
Dismantling
Assembly
PS700 Layshaft
Dismantling
Assembly
Torque Converter
Removal and Replacement
Stall Test
Testing for Clutch Leakage
Pressure and Flow Testing
Powershift (with reverser Shaft Sealing Plug & PS750)
PS750 Section Views and Torque Figures
Dismantling (see summary of changes)
Assembling (see summary of changes)
PS750 Input Clutch and Reverser Clutch
Dismantling
Assembly
PS750 Mainshaft
Dismantling
Assembly
PS 750 Layshaft
Dismantling
Assembly
Polytetraflourethylene (PTFE) Piston Ring Seals
Fitting Procedure
Collapsible Spacer - Assembly
Extra Low Ratio Gear

Section G: Brakes
Technical Data
TM200
TM270
Parking Brake
TM200 & TM270 to Ser. No. 787075
Adjusting the Parking Brake
Adjusting the Brake Pads
Adjusting the Cable Slack
Renewing the Pads
Dismantling and Assembly
TM 270 from Ser. No. 787076 & TM300
Adjusting the Parking Brake
Adjusting the Caliper
Adjusting the Cable Slack
Caliper - Removal and Replacement
Caliper - Dismantling and Assembly
Checking the Brake Pad Wear
Renewing the Brake Pads
Testing the Parking Brake
Ratchet Type
Over-Centre Type
Fault Finding
Service Brakes
Dismantling and Assembly (See Transmission, Front and Rear Axle)
Bleeding Procedure
Foot Brake Valve
TM 200
TM 270 & TM300
Accumulator Charge Valve
Removal and Replacement
TM 200
TM 270 & TM300
Dismantling and Assembly
TM 200
TM 270 & TM300
Brake System Pressure Testing

Section H: Steering
Technical Data
TM 200
TM 270 & TM300
Priority Valve
TM 200
Operation 1 - Neutral
Operation 2 - Turning
Steering
TM 200
Operation 1 - Neutral
Operation 2 - Right Turn
Operation 3 - Left Turn
Operation 4 - Left Turn, Unassisted
Operation 5 - Shock Valve
Steering Unit
Dismantling and Assembly
TM 200
TM 270 & TM300
Steering Ram
Removal and Replacement
TM 200
TM 270 & TM300
Dismantling and Assembly
Pressure Testing
TM 200
TM 270 & TM300

Section K: Engine
Technical Data
1000 Series
New 1000 Series
1100 Series
Turbocharger Installation TM300

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