JCB TM310 Farm Master Loader Service Repair Manual

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 9803/9520-06 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 3 Routine Maintenance Service Manual - TM310 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

Section 3 - Routine Maintenance 3-0 3-0 9803/9520-06 Notes:

Page No. Contents Section 3 - Routine Maintenance 3 - i 3 - i Maintenance Service Requirements .............................................................................. 3 - 1 Introduction .......................................................................................... 3 - 1 Owner/Operator Support ..................................................................... 3 - 1 Service/Maintenance Agreements ...................................................... 3 - 1 Initial Service and Inspection (100 Hours) ........................................... 3 - 1 Lifting Regulations - Inspections and Tests ......................................... 3 - 2 Obtaining Replacement Parts .............................................................. 3 - 2 Service Schedules .................................................................................... 3 - 3 Introduction .......................................................................................... 3 - 3 How to Use the Service Schedules ..................................................... 3 - 3 Pre-start Cold Checks, Service Points and Fluid Levels ..................... 3 - 4 Health and Safety ..................................................................................... 3 - 7 Lubricants ............................................................................................ 3 - 7 Battery ................................................................................................. 3 - 9 First Aid - Electrolyte ........................................................................... 3 - 9 Fluids, Lubricants and Capacities ........................................................... 3 - 11 Cleaning the Machine ............................................................................. 3 - 12 Checking for Damage ............................................................................. 3 - 13 Seat Belt ................................................................................................. 3 - 14 Checking the Seat Belt Condition and Security ................................. 3 - 14 Checking the ROPS/FOPS Structure ..................................................... 3 - 15 Fire Extinguisher (if fitted) ....................................................................... 3 - 16 Checking the Fire Extinguisher ......................................................... 3 - 16 Greasing ................................................................................................. 3 - 17 Boom Pivot Pins ................................................................................ 3 - 18 Centre Pivot and Steering Ram ......................................................... 3 - 19 Propshaft Joints ................................................................................. 3 - 20 Inner and Outer Booms ..................................................................... 3 - 20 Engine Canopy ....................................................................................... 3 - 21 Opening the Canopy ......................................................................... 3 - 21 Closing the Canopy ........................................................................... 3 - 21 Heating and Ventilation .......................................................................... 3 - 22 Cleaning the Cab Heater Filter .......................................................... 3 - 22 Electrical System .................................................................................... 3 - 23 Battery ............................................................................................... 3 - 23 Jump Starting the Engine .................................................................. 3 - 25 Fuses ................................................................................................. 3 - 26 Relay Identification ............................................................................ 3 - 26 Engine .................................................................................................... 3 - 27 Checking the Oil Level ...................................................................... 3 - 27 Changing the Oil and Filter ................................................................ 3 - 28 Coolant Mixtures ............................................................................... 3 - 29 Checking the Coolant Level .............................................................. 3 - 29 Changing the Coolant ........................................................................ 3 - 30 Front End Accessory Drive (FEAD) Belt ........................................... 3 - 31 Engine Crankcase Ventilation ........................................................... 3 - 32 Engine Air Filter ................................................................................. 3 - 33 Fuel System ............................................................................................ 3 - 34 Filling the Tank .................................................................................. 3 - 34 Draining the Water Separator and Fuel Filter .................................... 3 - 35 Changing the Filter Element .............................................................. 3 - 36 Changing the Water Separator Pre- Filter ......................................... 3 - 37 Bleeding the Fuel System ................................................................. 3 - 38

Section 3 - Routine Maintenance Contents 3 - ii 3 - ii Page No. Contents Hydraulic System .................................................................................... 3 - 39 Checking the Fluid Level ................................................................... 3 - 39 Changing the Filter Element .............................................................. 3 - 40 Transmission .......................................................................................... 3 - 41 Checking the Transmission Oil Level ................................................ 3 - 41 Changing the Transmission Oil and Filter ......................................... 3 - 42 Transfer Gearbox ................................................................................... 3 - 44 Checking the Oil Level ...................................................................... 3 - 44 Changing the Oil ................................................................................ 3 - 44 Axles ....................................................................................................... 3 - 45 Checking the Oil Level ...................................................................... 3 - 45 Changing the Oil ................................................................................ 3 - 45 Tyres and Wheels ................................................................................... 3 - 46 Tyre Inflation ...................................................................................... 3 - 46 Checking the Wheel Nut Torques ...................................................... 3 - 46 Windscreen Washer ............................................................................... 3 - 47

Section 3 - Routine Maintenance 3-1 3-1 9803/9520-06 Maintenance Service Requirements Introduction T3-002 Your machine has been designed and built to give maximum performance, economy and ease of use under a wide variety of operating conditions. Prior to delivery, your machine was inspected both at the Factory and by your Distributor to ensure that it reaches you in optimum condition. To maintain this condition and ensure trouble free operation it is important that the routine services, as specified in this Manual, are carried out by an approved JCB Distributor at the recommended intervals. This section of the Manual gives full details of the service requirements necessary to maintain your JCB machine at peak efficiency. It can be seen from the Service Schedules on the following pages that many essential service checks should only be carried out by a JCB trained specialist. Only JCB Distributor Service Engineers have been trained by JCB to carry out such specialist tasks, and only JCB Distributor Service Engineers are equipped with the necessary special tools and test equipment to perform such tasks, thoroughly, safely, accurately and efficiently. JCB regularly updates its Distributors advising them of any product developments, changes in specifications and procedures. Therefore only a JCB Distributor is fully able to maintain and service your machine. A Service Record Sheet or Book is provided which will enable you to plan your service requirements and keep a service history record. It should be dated, signed and stamped by your Distributor each time your machine is serviced. Remember, if your machine has been correctly maintained, not only will it give you improved reliability but its resale value will be greatly enhanced. Owner/Operator Support JCB together with your Distributor wants you to be completely satisfied with your new JCB machine. If you do encounter a problem however, you should contact your Distributor's Service Department who are there to help you! You will have been given the names of the relevant service contacts at your Distributor when the machine was installed. To get the most from your Distributor please help them to satisfy you by: 1 Giving your name, address and telephone number. 2 Quoting your machine model and serial number. 3 Date of purchase and hours of work. 4 Nature of the problem. Remember, only your JCB Distributor has access to the vast resources available at JCB to help support you. In addition, your Distributor is able to offer a variety of programmes covering Warranty, Fixed Price Servicing, Safety Inspections, including weight tests, covering both legal and insurance requirements. Service/Maintenance Agreements To help plan and spread the costs of maintaining your machine, we strongly recommend you take advantage of the many Service and Maintenance Agreements your Distributor can offer. These can be tailor made to meet your operating conditions, work schedule etc. Please consult your JCB Distributor for details. Initial Service and Inspection (100 Hours) T3-005 To further protect your machine's performance it is essential your JCB Distributor carries out an initial service and inspection when the machine is one month old or when it has completed 100 hours of operation (whichever occurs first). You should notify your Distributor in advance to allow the necessary arrangements to be made.

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JCB TM310 Farm Master Loader Service Repair Manual

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