JCB TM320 Telehandler Service Manual

Name: JCB TM320 Telehandler Service Manual
Brand: MidWestTech
SKU: 9813-4700-1
Price: 79.83 USD
Availability: InStock

723 pages · Publication 9813-4700-1

$79.83

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Models: TM320
Manual type: Service Manual
Pages: 723
Publication: 9813-4700-1
Condition: Brand new

JCB TM320 Telehandler Service Manual, publication 9813-4700-1

What's inside

From the manual's own table of contents: 7 sections, 505 entries. See sample pages (PDF, 390 KB)

Search the contents

General83 topics

About this Manual
Machine Model and Serial Number
General
Name and Address of the Manufacturer
Using this Manual
Left Side, Right Side
Cross References
Product Compliance
Identifying Your Machine
Machine Identification Plate
Typical Product Identification Number
Component Identification
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Hydraulic Connections
O' Ring Face Seal System
Torque Stop' Hose System
Numerical List
Tool Detail Reference
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section H - Steering
Section K - Engine
Sealing and Retaining Compounds
Colour Coding
Hydraulic Schematic Colour Codes
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety - Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Labels
Safety Label Identification
Part Numbers and Descriptions
Service Requirements
Owner/Operator Support
Service/Maintenance Agreements
Initial Service and Inspection
Fit for Purpose Tests for Lifting Equipment
Obtaining Replacement Parts
Health and Safety
Lubricants
Hygiene
Storage
Waste Disposal
Handling
First Aid - Oil
Spillage
Fires
First Aid - DEF
Battery
Warning Symbols
First Aid - Electrolyte
Service Schedules
How to Use the Service Schedules
Calendar Equivalents
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Fluids, Lubricants and Capacities
Specifications
Fuels
Acceptable and Unacceptable Fuels
Usage and Effects of Fuels
Acceptable Fuels
Unacceptable Fuels
Sulphur Content
Effects of Fuel Contaminates
Coolant Mixtures
Diesel Exhaust Fluid (DEF)
Spillages
Preventing Contamination of the DEF tank
Preventing Cross Contamination of Diesel Fuel and DEF
Tools
Tool Locations
Carrying Tools onto the Machine
Prepare the Machine for Maintenance
How to Make the Machine Safe (Boom Lowered)
How to Make the Machine Safe (Boom Lifted)

Section 3 - Routine Maintenance119 topics

Cleaning the Machine
Detergents
Pressure Washing and Steam Cleaning
Checking for Damage
Check the Machine Body and Structure
Check the Seat and Seat Belt
Check the Hydraulic Hoses and Fittings
Check the Electrical Circuits
Check the Tyres
Checking the ROPS/FOPS Structure
Greasing
Preparing the Machine for Greasing
Boom Pivot Pins
Centre Pivot and Steering Ram
Inner and Outer Booms
Driveshaft Joints
Quickhitch Locking-Pins
Industrial Carriage
Seat
Access Panels
Engine Cover
Opening the Cover
Closing the Cover
Heating and Air Conditioning
Cleaning the Cab Heater Filter
Brakes
Park Brake
Testing the Park Brake
Park Brake Adjustment
Electrical System
Battery Disconnection/Connection
Battery Isolator
Jump Starting the Engine
Fuses and Relays
Primary Fuses
Secondary Fuses
Relays
Bulb Specification
Engine
Engine Oil and Filter
Checking the Oil Level
Changing the Oil and Filter
Cooling System
Checking the Coolant Level
Changing the Coolant
Front End Accessory Drive Belt
Checking the Front End Accessory Belt
Changing the Front End Accessory Belt
Air Cleaner
Changing the Filter Elements
Engine Crankcase Ventilation
Changing the Filter Element
Fuel System
Water Separator and Engine Fuel Filter
Draining the Water Separator and the Engine Fuel Filter
Changing the Water Separator Pre-Filter
Changing the Fuel Filter Element
Bleeding the Fuel System
Hydraulic System
Release the Hydraulic Pressure
Checking the Hydraulic Fluid Level
Changing the Hydraulic Filter Element
Transmission
Checking the Transmission Oil Level
Changing the Transmission Oil and Filter
Transmission (Filter and Strainer)
Transfer Gearbox
Checking the Gearbox Oil Level
Changing the Gearbox Oil
Axles
Checking the Axle Oil Level
Changing the Axle Oil
Tyres and Wheels
Tyre Inflation
Procedure
Checking the Wheel Nut Torques
Windscreen Washer
Fire Extinguisher (if fitted)
Checking the Fire Extinguisher
Air Conditioning (Option)
Load Moment Indicator (LMI)
Cooling Pack
Air Conditioning
Fault Codes
General Fault Finding
Diagnostic Tests
LMI Test Box
12V Supply and Fuse Test (V1)
Transducer 12V Supply Test (V2)
Display Box Functional Test
Transducer Output Test (V3) - with Transducer Fitted
Harness Wiring Continuity and Short Circuit Test
Transducer Output Test (V4) - with Transducer Removed
Test Results
Rivet Nuts
Fitting Procedure
Slide Hammer Kit
Service Checks
Off-Season Operation
Leak Testing
Tightening Leaking Hoses
Refrigerant Charging and Discharging
Refrigerant Recovery
Evacuating (Vacuuming)
Relubricating
Charging
Binary Pressure Switch Testing
Compressor Drive Belt - Adjustment
Condenser Matrix Cleaning
ROPS, FOPS Structure - Checks
Direct Glazing
Removing the Broken Glass and Old Sealant
Preparing the Cab Frame Aperture
Preparing the New Glass
Installing the New Glass
Fork Carriage Removal and Replacement
Removal
Replacement
Boom Removal and Replacement

Section B - Body and Framework49 topics

Dismantling and Assembly
Dismantling
Assembly
Shim Adjustment
Removal and Replacement
Transducer
EMS Unit and Front Console
Side Switch Panel
Hose Connections
Fuel Level Sender
Internal Components
Front Floor Mat
Variflow Pump Access Panel
Front Blind
Roof Blind
Roof Liner
Pressure Switch
Condenser
Front Mudguard
Rear Mudguard
General Information
General Electrical Data
TM320 Tier 4F Machines
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Alternator
General Description
Service Precautions
Charging Circuit Test
Check 1
Check 2
Alternator Charging Test
Starter Motor
Starting Circuit Test
Wire and Harness Number Identification
Wire Numbers and Functions
Wires In Splices
General Points
Wiring Harness Repair
Repair Procedure
Maintenance
Test Procedures
High Rate Discharge Test
Specific Gravity Testing
Disconnection and Connection

Section C - Electrics32 topics

Removal, Inspection and Replacement
Dismantle and Assemble
Renewing the Voltage Regulator and Brushes
Renewing the Drive Pulley
Renewing the Brush Gear
Renewing the Starter Solenoid
Drawings and Interconnection
Harnesses
Main Hydraulic Pump
Variable Flow
Auxiliary Pump
Control Valve Block
Maximum RPM Cycle Times
Smooth Ride System (SRS)
Accumulator
Flowshare
Component Location and Identification
Oil Pump
Load Sensing
Pressure Compensation (Flowshare)
Hydraulic Circuit Operation
Variable Displacement Pump Operation
Hydraulic Variable Control System (HVCS)
Pulse Width Modulation (PWM)
Flow and Pressure Tests
Checking Pump Flow
System Pressure Check
Checking the Servo Pilot Pressure
`Positional Type' Hydraulic Adaptors
Bleeding the Hydraulic System
Hand Control Valve
Dismantling, Inspection and Assembly

Section E - Hydraulics69 topics

Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Lift Ram
Displacement Rams
Extension Ram
Tilt Ram
Typical Ram
Displacement Ram
Technical Data
System Description
Hydraulic Schematic
Valves and Transducers
Fault Finding
Accumulators
Charging and Discharging
Longitudinal Load Moment
System Overview
Setting the Volume and Brightness
Warm Up Procedure
Daily Functional Check
Longitudinal Load Moment Control
Principal of Operation
Groundworks Mode and Pick and Place Mode
System Flow Diagram
LMI Transducers
Angle Sensors
LMI Output Signal (PWM)
Groundworks Mode Enable
End-Damping
Diagnostic Fault Codes
Blink Error Codes
Test Weight
LLMI, LLMC Calibration Check
Machine Stability Check
System Checks
Calibration
Hot Test Settings
TM320 Machines
TM320S Machines
Tyre Pressures and Sizes
Front Axles
Unit Identification
Designation
Rear Axles
Powershift Gearboxes
Transmission Assembly
PS760 Transmission
Forward, Neutral and Reverse (F/N/R)
Operation Characteristics
PS763 and PS766 Powershift Gearboxes
Principle of Operation
Hydraulic and Electrical Operation
Component Key
Operation Characteristics - PS760 Gearbox
Start Up
`Manual' Gear Select
`Automatic' Gear Selection
Park Brake ON
Transmission Disconnect
Joystick Direction Switch
Limp Modes
Lock Up Torque Converter Operation
Drivepaths - 3 Speed
Forward
Reverse
Drivepaths - 6 Speed
Torque Converter

Section F - Transmission42 topics

Lock-Up Torque Converter
State 1: Torque Converter Unlocked
State 2: Torque Converter Locked
Forward and Reverser Clutch Operation
Mainshaft, Layshaft and 6-Speed Clutch Operation
Powershift Gearbox (PS 760 3 Speed)
Quick Reference
Electrical Connections
Wires and Connectors
Transmission Dump Operation
Powershift Gearbox (PS766 ECU 2.3 6 Speed)
Transmission ECU
ECU Location
ECU Electrical Connections
ECU Feeds and Earths
Lock Up Torque Converter
Electrical Diagram
Powershift Gearbox
Fault Finding Tables
When Removing
When Replacing
Operation Overview
System Components
Gearbox Integral
Dismantle, Inspection and Assemble
Dismantle the Multi-Plate Brake Pack
Dismantle the Brake Actuator
Inspection
Assemble the Brake Actuator
Assemble the Multi-Plate Brake Pack
Service Brakes
Bleeding the Braking System
Bleeding the System
Hydraulic Pressure Tests
Standby and Steering Pressure
Engine Mountings
Special Tools
Lifting Equipment
Before Removal
Remove
Component Location
Electrical Operation and Schematics

Section K - Engine49 topics

Description
Operation
DEF Coolant Circuit Connections
SCR Fuse/Relay Box
Location
SCR ECU
SCR Catalyst
DEF Line Heaters and Relays
Coolant Solenoid
DEF Dosing Module
Removal and Replacement Guide
DEF Supply Module
NOx and Exhaust Temperature Sensors
NOx Sensors
Temperature Sensor
DEF Tank and Components
Diesel Exhaust Fluid Filter
Replace
What is the Network System?
CANbus Communications System
Earth Points
EMS Display
EMS Set-up
Using JCB Servicemaster 2
Using EMS Display Panel
Connected Devices
Fault Code Displays
CAN Enabled Display
CANbus Connected Computer
Electronic Monitoring System ECU Fault Codes
Operator Warnings
Fault Code Log
Reading the Fault Code Log with JCB Servicemaster
Fault Code List
Why Use Servicemaster?
Identify Poor Maintenance
Access Machine Set Up Data
Re-Programming ECUs
Summary
What is Servicemaster?
Servicemaster Structure
Tool Sets
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

Section M - Network Systems55 topics

JCB 4.4L Tier 4 SJ Diagnostics Tool - User Guide
Care and Safety
Connecting 4.4L Tier 4 Diagnostics
Starting 4.4L Tier 4 Diagnostics
4.4L Tier 4 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
Status bar
LED Status Key
Engine Connector Page
Machine Connector Page
Actuator Tests Page
Fault Codes Page
ShiftMaster Diagnostics 2.3 - User Guide
Installing ShiftMaster Diagnostics
Connecting Shiftmaster Diagnostics
Starting ShiftMaster Diagnostics
ShiftMaster Diagnostics Overview
Navigating within ShiftMaster Diagnostics
ECU Setup Page
ETS Function
Dashboard Page
ECU Status Page
Transmission Speed
Gears
Misc Inputs
Misc Outputs
Torque Converter Lock Up (TCLU) Page
Solenoid Test Mode Page
Solenoid Identification Page
ECU Block Diagram Page
Connection Problems
TM310 / TM320 Setup - User Guide
Installing
Connection
Starting TM310 / TM320 Setup
Navigating within TM310 /TM320 Setup
Menu Bar - Utilities Menu
Vehicle Setup
Configure Electronic Instrument Cluster Vehicle Setup
Options
Configure Electronic Instrument Cluster Options
Language
Write
Read
Engine Setup - User Guide
Starting Engine Setup
Navigating within Engine Setup
Configure Engine Setup
Injector Calibration
Configure Injector Setup

Inside this manual

Real pages from this service manual (723 pages). Open the sample pages (PDF, 389 KB)

Sample pages from the JCB TM320 Telehandler Service Manual: Diagram, Specifications, Troubleshooting, Color page, Color page

Diagram, page 251: Section C - Electrics
Specifications, page 306: Section E - Hydraulics
Troubleshooting, page 636: Section M - Network Systems
Color page, page 604: Section K - Engine
Color page, page 434: Section F - Transmission

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 723 pages

Quantity one is the manual described above.

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Ships in 1 business day.

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Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).