JCB TM310, TM310S, TM310WM TELESCOPIC WHEELED LOADER Service Repair Manual Instant Download

Service Manual TM310

Service Manual - Service Manual

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

Publication

Notes:

Introduction

About this Manual

Machine Model and Serial Number

This manual provides information for the following model(s) in the JCB machine range:

–TM310, TM310S and TM310WM from machine serial number 1314700.

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:

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.

The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example:

A Attachments

B Body and Framework, etc.

Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section.

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.

Cross References

C087420

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)

Fig 1.

Identifying your Machine

Machine Identification Plate

Your machine has an identification plate mounted as shown. The serial numbers of the machine and its major units are stamped on the plate.

Note: The machine model and build specification is indicated by the VIN (earlier machines) or PIN (later machines). Refer to Typical Vehicle Identification Number (VIN) or Typical Product Identification Number (PIN)

The serial number of each major unit is also stamped on the unit itself. If a major unit is replaced by a new one, the serial number on the identification plate will be wrong. Either stamp the new number of the unit on the identification plate, or simply stamp out the old number. This will prevent the wrong unit number being quoted when replacement parts are ordered.

The machine and engine serial numbers can help identify exactly the type of equipment you have.

Identifying your Machine

Typical Product Identification Number (PIN)

T033160-1.

Fig 3.

1 World Manufacturer Identification (3 Digits)

2 Model Number (3 Digits)

3 Loader End Type (1 Digit)

O = HT Loader End

Z = ZX Loader End

4 Designation (1 Digit)

S = Farmmaster

O = None Farmmaster

I = India

5 Check Letter (1 Digit)

The Check Letter is used to verify the authenticity of the machine's PIN.

6 Year of Manufacture (1 Digit)

7 = 2007A = 2010

8 = 2008B = 2011

9 = 2009C = 2012

7 Machine Serial Number (7 Digits)

Each machine has a unique serial number.

C051170-C1

Fig 2.

Typical Vehicle Identification Number

12345

SLPTM3103E1314700

1 World Manufacturer Identification (SLP = JCB)

2 Machine Type (TM310, TM-W)

3 Year of Manufacture (1 = 2001, 2 = 2002, 3 = 2003, 4 = 2004, 5 = 2005, 6 = 2006, 7 = 2007)

4 Manufacturers Location (E = England)

5 Machine Serial Number (1314700)

Component Identification Plates

Typical Engine Identification Number

Section 1 - General Information Introduction

Identifying your Machine

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 1-4) The data label contains important engine information and includes the engine identification number E

A typical engine identification number is explained as follows:

SA320/40001U0000104

12345

1 Engine Type

S = 4.4 litre series.

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

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

U0000104

9803/9520-07

Fig 4. Engine

Identifying your Machine

Transmission Identification Numbers

The transmission serial number is stamped on label A which is mounted on the front face.

The drop box serial number is stamped on plate B mounted on the drop box.

The axle serial number is stamped on plate C mounted on the axle.

Fig 5.

Fig 6.

Fig 7.

FOPS Data Plate !MWARNING

Do not use the machine if the falling objects protection level provided by the structure is not sufficient for the application. Falling objects can cause serious injury. 8-2-8-17

If the machine is used in any application where there is a risk of falling objects then a falling-objects protective structure (FOPS) must be installed. For further information contact your JCB Dealer

The falling objects protection structure (FOPS) is fitted with a dataplate. The dataplate indicates what level protection the structure provides.

There are two levels of FOPS:

– Level I Impact Protection - impact strength for protection from small falling objects (e.g. bricks, small concrete blocks, hand tools) encountered in operations such as highway maintenance, landscaping and other construction site services.

Level II Impact Protection - impact strength for protection from heavy falling objects (e.g. trees, rocks) for machines involved in site clearing, overhead demolition or forestry.

Identifying your Machine

ROPS Data Plate !MWARNING

You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS/FOPS. If the Roll Over Protection Structure (ROPS)/Falling Objects Protection Structure (FOPS) has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification.

INT-2-1-9_6

!MWARNING

Seat Belts

The ROPS/FOPS is designed to give you protection in an accident. If you do not wear your seat belt, you could be thrown out of the machine and crushed. You must wear a seat belt when using the machine. Fasten the seat belt before starting the engine. 0153

Machines built to FOPS/ROPS standards have a data plate attached to the inside of the cab.

C051290

Fig 8.

Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners

Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners

T11-002

Introduction

Some external fasteners on JCB machines are manufactured using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on earlier machines.

The two types of fasteners can be readily identified by colour and part number suffix. K Table 1. Fastener Types ( T 1-7)

Fastener Type ColourPart No. Suffix

Zinc and Yellow Golden finish'Z' (e.g. 1315/3712Z)

DacrometMottled silver finish'D' (e.g. 1315/3712D)

Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must be relevant to the type of fastener.

Note: A Dacromet bolt should not be used in conjunction with a Zinc or Yellow plated nut, as this could change the torque characteristics of the torque setting further. For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt.

Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.

Note: Dacromet bolts, due to their high corrosion resistance are used in areas where rust could occur. Dacromet bolts are only used for external applications. They are not used in applications such as gearbox or engine joint seams or internal applications.

Bolts and Screws

Use the following torque setting tables only where no torque setting is specified in the text.

Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate.

Torque settings are given for the following conditions:

Condition 1

–Un-lubricated fasteners

–Zinc fasteners

–Yellow plated fasteners

Condition 2

–Zinc flake (Dacromet) fasteners

–Lubricated zinc and yellow plated fasteners

–Where there is a natural lubrication. For example, cast iron components

Verbus Ripp Bolts

Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.

Table 1. Fastener Types

Fig 9.

Section 1 - General Information

Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners

Bolt SizeHexagon (A/F)Condition 1Condition 2

Table 2. Torque Settings - UNF Grade 'S' Fasteners

Table 3. Torque Settings - Metric Grade 8.8 Fasteners

Section 1 - General Information

Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners

Table 4. Metric Grade 10.9 Fasteners

Table 5. Metric Grade 12.9 Fasteners

Section 1 - General Information

Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners

Table 6. Torque Settings - Rivet Nut Bolts/Screws

Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc)

Hydraulic Connections

Torque Settings

Hydraulic Connections

'O' Ring Face Seal System

Adaptors Screwed into Valve Blocks

Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port.

Table 8. Torque Settings - BSP Adaptors

Table 9. Torque Settings - SAE Connections

Hoses Screwed into Adaptors

Torque Settings

Hydraulic Connections

Hoses 10-B screwed into adaptors 10-A seal onto an `O' ring 10-C which is compressed into a 45° seat machined into the face of the adaptor port.

Note: Dimension 10-D will vary depending upon the torque applied.

Fig 10.

Table 10. BSP Hose - Torque Settings

Adaptors into Component Connections with Bonded Washers

Table 11. BSP Adaptors with Bonded Washers - Torque Settings

'Torque Stop' Hose System

`Torque Stop' Hoses 11-B screwed into adaptors 11-A seal onto an 'O' ring 11-C which is compressed into a 45° seat machined in the face of the adaptor port. To prevent the 'O' ring being damages as a result of over tightening, 'Torque

Stop' Hoses have an additional shoulder 11-D, which acts as a physical stop.

Note: Minimum dimension 11-E fixed by shoulder 11-D

Fig 11.

Table 12. BSP `Torque Stop' Hose - Torque Settings

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.

Tool Detail Reference

Section B - Body and Framework

1 826/01099M6 x 16 mm Rivet Nut

826/01101M6 x 19 mm Rivet Nut

826/01102M8 x 18 mm Rivet Nut

826/01103M8 x 21 mm Rivet Nut

826/01104M10 x 23 mm Rivet Nut

826/01105AM10 x 26 mm Rivet Nut

2 -Installation Tool available from: Bollhoff Fastenings Ltd (www.bollhof.com)

Fig 13. Rivet Nut Tool

Tool Detail Reference

Minimum 2 off - Essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage.

Used with braided cutting wire to cut out broken glass.

Essential for preparing new glass prior to installation.

General tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will chip the glass edge.

Used to access braided cutting wire through original polyurethane seal.

Hand operated. Essential for the application of sealants,

materials etc.

Fig 14. 892/00842 Glass Lifter

Fig 15. 892/00843 Folding Stand

Fig 16. 892/00845 Cartridge Gun

polyurethane

Fig 17. 892/00846 Glass Extractor (Handles)

K Fig 20. ( T 1-18)

Fig 18. 892/00847 Nylon Spatula

Fig 19. 892/00848 Wire Starter

K Fig 20. ( T 1-18)

Tool Detail Reference

Required to pre-heat adhesive prior to use. No plug supplied.

Note: 110V models available upon request - contact JCB Technical Service.

remove broken glass.

25

(1 in.)

Fig 20. 892/00849 Braided Cutting Wire Consumable heavy duty cut-out wire used with the glass extraction tool. K Fig 17. ( T 1-17). Approx 25 m length.

Fig 21. 926/15500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame. Unit quantity = 500 off.

Fig 22. 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 23. 992/12400 Static Oven 240V

Fig 24. 992/12800 Cut-Out Knife Used to

Fig 25. 992/12801 'L' Blades

mm

cut. Replacement blades for cut-out knife. K Fig 24. ( T 1-18). Unit quantity = 5 off.

Tool Detail Reference

Fig 26. 4104/1310 Hand Cleaner Special blend for the removal of polyurethane adhesives (454g; 1 lb tub).

Fig 27. 892/00913 Grease Gun Attachment

Fig 28. 892/00844 Long Knife Used to give extended reach for normally inaccessible areas.

Fig 29. 892/00848 Wire Starter Used to access braided cutting wire through original polyurethane seal.

Fig 30. 926/15500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame. Unit quantity = 500 off.

Tool Detail Reference

Section C - Electrics

AVO Test Kit:

1 892/00283 Tool Kit Case

2 892/00298 Fluke Meter 85

3 892/00286 Surface Temperature Probe

4 892/00284 Venture Microtach Digital Tachometer

5 892/00282 100 amp Shunt - open type

6 892/00285 Hydraulic Temperature Probe

For testing load moment indicator system

9803/9520-07

Fig 31. AVO Test Kit

Fig 32. 993/85700 Battery Tester

Fig 33. 721/10885 Interconnecting Cable Use with 892/01033

Fig 34. 892/00905 LMI Test Box

Tool Detail Reference

Note: Also requires 721/10885 interconnecting cable

ItemDescription

1Data Link Adaptor (DLA), enables data exchange between the machine ECUs (Electronic Control Units) and laptop PC loaded with the applicable ServiceMaster diagnostics software

2Interconnecting cable, DLA to laptop PC. Several cables are included to enable compatibility with different PC port types

3Kit carrying case

Fig 35. 892/01033 Electronic Test Kit

Fig 36. 892/01096 Speed Sensor Test Harness

Fig 37. Electrical Repair Kit

Section E - Hydraulics

Tool Detail Reference

Male Adapters - BSP x BSP

1606/20523/8 in. x 1/4 in.

1604/0003A3/8 in. x 3/8 in.

892/000713/8 in. x 3/8 in. taper

1606/00041/2 in. x 1/4 in.

1606/0007A1/2 in. x 3/8 in.

1604/0004A1/2 in. x 1/2 in.

1606/00175/8 in. x 1/2 in.

1606/00083/4 in. x 3/8 in.

Male Adapters - BSP x NPT (USA only)1606/00093/4 in. x 1/2 in.

816/004393/8 in. x 1/4 in.1604/20553/4 in. x 3/4 in.

816/004401/2 in. x 1/4 in.1606/00123/4 in. x 1 in.

816/15007A3/8 in. x 3/8 in.1606/00143/4 in. x 1.1/4 in.

816/150081/2 in. x 3/8 in.1606/00151 in. x 1.1/4 in.

892/002551/4 in. BSP x Test Point

in. BSP x Test Point

in. BSP x Test Point

in. BSP x Test Point

9803/9520-07

Fig 38. Male Adaptors

Fig 39. Pressure Test Adapters

Fig 40. Pressure Test 'T' Adapters

Tool Detail Reference

892/000473/8 in. BSP (A) x 1/4 in. BSP (B)

892/000481/2 in. BSP (A) x 1/4 in. BSP (B)

892/000495/8 in. BSP (A) x 1/4 in. BSP (B)

816/500433/4 in. BSP (A) x 1/4 in. BSP (B)

892/000511 in. BSP (A) x 1/4 in. BSP (B)

816/500051/2 in. BSP (A) x 1/2 in. BSP (B)

816/600963/4 in. BSP (A) x 3/4 in. BSP (B)

816/000171 in. BSP (A) x 1 in. BSP (B)

892/00055A1/4 in. BSP

892/00056A3/8 in. BSP

892/000571/2 in. BSP

892/00058A5/8 in. BSP

892/00059A3/4 in. BSP

892/000601 in. BSP

816/900451/4 in. BSP

816/00189A3/8 in. BSP

816/00190A1/2 in. BSP

816/900225/8 in. BSP

816/902743/4 in. BSP

816/902051 in. BSP

892/000743/8 in. BSP x 3/8 in. BSP

892/000751/2 in. BSP x 1/2 in. BSP

892/000765/8 in. BSP x 5/8 in. BSP

892/000773/4 in. BSP x 3/4 in. BSP

1406/00111/4 in. BSP

1406/00181/2 in. BSP

1406/00145/8 in. BSP

1406/00213/4 in. BSP

1406/00291.1/4 in. BSP

9803/9520-07

Fig 41. 'T' Adapters

Fig 42. Female Blanking Caps

Fig 43. Male Cone Blanking Caps

Fig 44. Female Connectors

Fig 45. Bonded Washers

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Fig 46. Ram Protection Sleeves

Fig 47. 892/00334 Ram Seal Fitting Tool

Fig 48. Hexagon Spanners for Ram Pistons and End

Fig 49. 892/01027 Piston Seal Assembly Tool