JCB PIVOT STEER TELEHandLERS TM300 Service and Repair Manual

Service Manual TM200 TM270 TM300 PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE: © ROCESTER, STAFFORDSHIRE, ST14 5LS, ENGLAND Tel. ROCESTER (01889) 590312 PRINTED IN ENGLAND Publication No. 9803/4225 General Information 1 Care & Safety 2 3 Optional Equipment A Body & Framework B Electrics C Controls D Hydraulics E Transmission F Brakes G Steering H Engine K Routine Maintenance

9803/4225 Issue 2* Introduction 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. 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 con- nections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST! 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 & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. 3 = Routine 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 & Framework ...etc. The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later issues of the manual. Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section. All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference. 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. 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards.

Neutral Circuit Pressure. Pressure generated by the operation of a service. Depending on application this may be anything between Neutral Circuit Pressure and M.R.V. Operation Pressure. Pressure that is above Neutral Circuit Pressure but lower than that denoted above. Exhaust. Oil subjected to a partial vacuum due to a drop in pressure (cavitation). Oil trapped within a chamber or line preventing movement of componenets (lock-up). Oil pressure used in a controlling device (servo). A276340 A390940 Full Presssure Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and M.R.V. operating pressure. Pressure Pressure that is above neutral circuit pressure but lower than that denoted by red. Servo Oil pressure used in controlling a device (servo). Neutral Neutral circuit pressure. Exhaust Cavitation Oil subjected to a partial vacuum due to a drop in pressure (cavitation). Lock Up Oil trapped within a chamber or line, preventing movement of components (lock up). Red Pink Orange Blue Green Light Green Yellow Colour Codes The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications Black & White Codes The following black and white coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications

i Section 1 General Information 9803/4225 Section 1 i Issue 3* Contents Page No. Machine Identification Plate 1 - 1 Typical Vehicle Identification Number (VIN) 1 - 1 Typical Engine Identification Number 1 - 1 Serial Plates 1 - 2 Torque Settings 1 - 3 JCB Standard Torque Settings B.S.P. Port Connection (Colour Coded) 1 - 4 Hose Ends and Flange Fittings (Colour Coded) 1 - 5 Service Tools Numerical List 3 - 1 Service Tools Body and Framework 4 - 1 Electrics 5 - 1 Hydraulics 6 - 1 Transmission 7 - 1 Steering 8 - 1 Engine 8 - 1 Sealing and Retaining Compounds 9 - 1 * * *

1 - 1 Section 1 General Information 9803/4225 Section 1 1 - 1 Issue 2* 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. TM200 TM270 & TM 300 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 sim- ply 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. U.K. and R.O.W. Typical Vehicle Identification Number (VIN) SLP 270 A T V E 0787034 A B C D E F G A World Manufacturer Identification B Machine Model C Steer Type (A = Articulated) D Build Type (T = Telescopic Handler) E Year of Manufacture: R = 1994 1 = 2001 S = 1995 2 = 2002 T = 1996 3 = 2003 V = 1997 4 = 2004 W = 1998 5 = 2005 X = 1999 6 = 2006 Y = 2000 7 = 2007 F Manufacturer Location (E = England) G Product Identification Number (PIN) Typical Engine Identification Number AB 50262 U 500405 P A B C D E A Engine Type AB = 4 cylinder turbo B Build Number C Country of Origin D Engine Sequence Number E Year of Manufacture A272440 S114730 *

1 - 2 Serial Plates TM200 Axles TM270 & TM300 Axles Syncro Shuttle Transmission Powershift Transmission Engine Transfer Gearbox F E D C B A Section 1 General Information 9803/4225 Section 1 1 - 2 Issue 2* A276910 S156570 S099870 S199590 S199570 S146790 D A B C F E *

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JCB PIVOT STEER TELEHandLERS TM300 Service and Repair Manual

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