JCB TM310 Agricultural Loader Service Manual – 9803/9520-06

(S/N: 1314700 Onwards)
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This workshop repair 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.

APPLICABLE MODELS :

JCB Farm Master Loader

JCB Agricultural Loader TM310 – S/N: 1314700 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
Section M – Network Systems

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 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

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