- This service manual PDF download for the 2.0D/G, 2.5D/G, 3.0D/G, 4x4 3.0D, 4x4 3.5D JCB Teletruk 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.
This manual provides information for the following model(s) in the JCB machine range:
– JCB Teletruk Tier 2 Machines:- – JCB Teletruk 2.5 G, 3.0 G, From S/N: 1175813 to 1176999 – JCB Teletruk 3.0D 4x4, From S/N: 1175813 to 1176569 – JCB Teletruk 3.5D, From S/N: 1175813 to 1176572 – JCB Teletruk 3.5D 4x4, From S/N: 1175813 to 1176591 – JCB Teletruk 3.0 D High Lift, From S/N: 1175813 to 1176593
– JCB Teletruk Tier 3 Machines:- – JCB Teletruk 2.5D, 3.0D, from S/N: 1176570 – JCB Teletruk 3.0D 4x4, from S/N: 1176573 – JCB Teletruk 3.5D, from S/N: 1176592 – JCB Teletruk 3.5D 4x4, from S/N: 1176586 – JCB Teletruk 3.0 D High Lift, from S/N: 1176594
Where D indicates Diesel and G indicates Liquid Petroleum Gas (LPG)
TABLE OF CONTENTS :
Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine
MANUAL SPECIFICATION :
File Format : PDF Language : English Printable : Yes Searchable : Yes Bookmarked : Yes Publication No. : 9803/9510-3 Total Pages : 660
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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9803-9510
Section 1 - General Information General Information Introduction About this Manual Machine Model and Serial Number Using the Service Manual Section Numbering Units of Measurement Left Side, Right Side Cab/Canopy Cross References Identifying your Machine Identification Machine Identification Plate Component Identification Plates 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 Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section H - Steering Service Consumables Sealing and Retaining Compounds Terms and Definitions Colour Coding Hydraulic Schematic Colour Codes
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
Section 3 - Maintenance Maintenance Routine Maintenance Service Requirements Introduction Owner/Operator Support Service/Maintenance Agreements Fit for Purpose Tests for Lifting Equipment Obtaining Replacement Parts Health and Safety Lubricants Battery Service Schedules Introduction 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 Coolant Mixtures Fuels Prepare the Machine for Maintenance Introduction How to Make the Machine Safe (Boom Lowered) Cleaning the Machine Introduction Preparing the Machine for Cleaning Cleaning the Machine Checking For Damage Check the Machine Body and Structure Check the Tyres Check the Seat and Seat Belt Check the Hydraulic Hoses and Fittings Checking the ROPS/FOPS Structure Greasing Introduction Preparing the Machine for Greasing Carriage Boom Rear Axle Sideshift Option Inner Boom Access Panels Operator's Enclosure/Cab Daily Inspection Cover Front Cover Daily Inspection Rear Cover Belly Plate (4WD Machines) Optional Trash Guard Brakes Park Brake Electrical System Battery Jump Starting the Engine Fuses Relays Bulbs Engine Oil and Filter (Perkins) Oil and Filter (Deutz 2011-L04W) Air Filter (Perkins) Air Filter (Deutz 2011-L04W) Fan Belt (Perkins) Alternator Drive Belt (Deutz 2011-L04W) Timing Belt Cooling System Diesel Fuel System Introduction Water Separator and Engine Fuel Filter Fuel Primer (Deutz 2011-L04W) Bleeding the System LPG Fuel System General Type of LPG Filling the LPG Tank Changing the LPG Tank Hydraulic System Introduction Releasing the Hydraulic Pressure Checking the Fluid Level Checking for Leaks Checking the Hoses and Pipework Changing the Filter Element Changing the Filter Element (Pal Filter) Tyres and Wheels General Tyre Inflation Changing a Wheel Forks Inspecting the Forks Changing the Forks Windscreen Washer Checking the Level Fire Extinguisher (if fitted) Checking the Fire Extinguisher
Section A - Attachments Attachments Attachments Introduction Connecting/Disconnecting Hydraulic Hoses Introduction Connecting the Hydraulic Hoses Disconnecting the Hydraulic Hoses Quick Release Couplings Changezee Quickhitch Installing and Removing Changezee Quickhitch Attachments Installing Removing Quickhitch Engaging and Disengaging the Shovel/Attachments Disengaging the Shovel/Attachments Engaging the Shovel/Attachments Bucket Removal and Replacement Removing the Bucket Replacing the Bucket Forks Inspect the Forks Changing The Forks
Section B - Body and Framework Body and Framework Service Tools Numerical List Access Procedures for Maintenance Cab and Access Covers Operator's Enclosure/Cab Raising the Teletruk Lowering the Teletruk Daily Inspection Cover Front Cover Daily Inspection Rear Cover Boom Removal and Replacement of the Inner Boom Removing the Inner Boom and Wear Pads Replacing the Inner Boom and Fitting New Wear Pads Removal and Replacement of the Boom Removing the Boom Replacing the Boom Boom Shimming Procedure Hydraulic Tank Drain and Flush the Hydraulic Tank Diesel Fuel Tank Drain and Flush the Fuel Tank Counterweight Removal and Replacement Removing the Counterweight Replacing the Counterweight Carriage Removal and Replacement Removing the Carriage Replacing the Carriage Service Procedures Rivet Nuts Fitting Procedure Cab Removal and Replacement Removing the Cab Replacing the Cab Glazing Direct Glazing Emergency Exit (If Fitted) Fixed Rear Screen Opening Rear Screen Opening Rear Screen With Breaker Operator's Seat Removal and Replacement Removing the Operator's Seat Replacing the Operator's Seat
Section C - Electrics Electrics Service Tools Numerical List Technical Data Introduction General Bulbs Fuses Primary Fuses Machines From Serial No. 788644 Excluding 3.5D 4x4 Machines Main Fuses Main Relays 3.5D 4x4 Machines Main Fuses Main Relays Harness Data (Early Machines) Drawings Introduction Mainframe Harness Location Mainframe Harness - CAD 721/10524 Issue 2 Mainframe Harness - CAD 721/10805 Issue 1 Mainframe Harness - CAD 721/10845 Issue 3 Mainframe Harness - CAD 721/11533 Issue 2 Mainframe Harness - CAD 721/10708 Issue 2 Mainframe Harness - CAD 721/10809 Issue 1 Mainframe Harness - CAD 721/11215 Issue 2 Mainframe Harness - CAD 721/10832 Issue 1 Mainframe Harness - CAD 721/11029 Issue 2 Mainframe Harness - CAD 721/11890 Issue 1 Mainframe Harness - CAD 721/12011 Issue 2 Mainframe Harness - CAD 721/12013 Issue 2 Auxiliary Switch Harness - CAD 721/ 00542 Issue 4 Parkbrake Solenoid Harness - CAD 721/ 10847 Issue 1 Parkbrake Solenoid Harness - CAD 721/ 11030 Issue 1 Parkbrake Solenoid Harness - CAD 721/11247 Issue 2 Parkbrake Solenoid Harness - CAD 721/10765 Issue 1 Main Cab Harness - CAD 721/10525 Issue 4 Main Cab Harness - CAD 721/10844 Issue 2 Main Cab Harness - CAD 721/11239 Issue 5 Additional Cab Harness - CAD 721/10843 Issue 3 Additional Cab Harness - CAD 721/ 11996 Issue 2 Worklight Left Hand - CAD 721/00479 Issue 3 Worklight Right Hand - CAD 721/ 00480 Issue 3 Worklight Rear / Beacon - CAD 721/ 00481 Issue 8 Roadlights Harness - CAD 721/00862 Issue 2 Roadlights Harness - CAD 721/10530 Issue 4 Roadlights Harness - CAD 721/10531 Issue 4 Roadlights Harness - CAD 721/10532 Issue 3 Roadlights Harness - CAD 721/10543 Issue 3 Roadlights Harness - CAD 721/10535 Issue 2 Flow Divider Harness - CAD 721/ 11194 Issue 3 Flow Divider Harness - CAD 721/ 10668 Issue 1 Reverse Alarm Harness - CAD 721/10517 Issue 1 Wash Wipe Harness - CAD 721/10519 Issue 1 Wash Wipe Harness - CAD 721/10518 Issue 2 Air Filter (Ex) Harness - CAD 721/10301 Issue 3 Radio and Interior Light Harness - CAD 721/00708 Issue 3 Radio and Interior Light Harness - CAD 721/00688 Issue 3 Face Fan Harness - CAD 721/00687 Issue 3 Keypad Ignition Harness - CAD 721/ 00648 Issue 2 Harness Data (Later Machines) Drawings Introduction Mainframe Harness Location Mainframe Harness - CAD 721/11767 Issue 1 Mainframe Harness - CAD 721/11766 Issue 1 Mainframe Harness - CAD 332/S1043 Issue 1 Mainframe Harness - CAD 721/12427 Issue 1 Additional Mainframe Harness - CAD 332/S4514 Issue 1 Additional Mainframe Harness - CAD 332/S3256 Issue 1 Main Cab Harness - CAD 721/11770 Issue 1 Additional Cab Harness - CAD 332/ S4513 Issue 1 Additional Cab Harness - CAD 332/ S3257 Issue 1 Full Roadlights Harness - CAD 721/ 11773 Issue 1 Partial Roadlights Harness - CAD 721/ 11774 Issue 1 Radio Harness - CAD 721/11775 Issue 1 Schematic Circuits (Early Machines) Main Components Machines Up to Serial Number 892343 (Diesel Engine - TCR and 3.0D HL) Machines From Serial Number 892344 (Diesel Engine - TCR and 3.0D HL) 3.5D 4x4 Machines Machines with LPG Engine 3.0D 4x4 System 3.5D 4x4 System (Differential Lock) Schematic Circuits (Later Machines) Main Components Machines From Serial Number XXXXX - Diesel Engine - TCR 2.5 / 3.0D (332/S2643-2) 2.5/3.0D Machines (332-S2643 - Issue 3) 4x4 System - 4 Wheel Drive (853- 30070 Issue 3) 3.0D 4x4 Machines (332-V2773 - Issue 1) 3.5D 4x4 Machines (331/47180-2) 3.5D Machines (331-47180 - Issue 3) 3.5D 4x4 Machines (332-V1654) Machines with TCR LPG Engine (331/ 47182-2) Machines with LPG Engine USA (332/ S3031) 3.5D 4x4 System - Differential Lock (853-30081) Alternator Alternator Alternator (Perkins Engine) - Removal and Replacement Dismantle and Assemble Alternator Alternator Alternator (Deutz Engine) - Removal and Replacement Starter Motor Removal and Replacement Load Moment Indicator Digital LMI Introduction Calibration Procedure Diagnostic Fault Codes Diagnostic Tests Sensor Removal Sensor Replacement 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
Section D - Controls Controls Technical Data Torque Convertor Response Susmic Controller Introduction Safe Maintenance Practices Safe Parking Introduction Torque Convertor Response 3.0D 4 x 4 Anti-Slip Control System Susmic Controller Removal and Repacement Removal Replacement Diagnostic LED's Sensors and Actuators 2.5DG, 3.0DG, 3.5D 2WD and 3.5D 4 x 4 3.0D 4 Wheel Drive Error Codes NFPE Controller Error Codes 3.0D 4 x 4 STATUS Error (ASC Controller) Throttle Cable Control Diesel Engine Removal Replacement LPG Engine Removal Replacement Brake Pedal Sensor Removal and Replacement Removal Replacement Adjusting the Potentiometer Control Valve Early Type Removal Replacement Later Type Removal Replacement Parkbrake Switch Removal and Replacement Removal Replacement Pulse Pick-up (Speed Sensor) Removal and Replacement Removal Replacement 3.0D 4 x 4 Option Testing Removal of Front Speed Sensor Replacement of Front Speed Sensor Removal of Rear Speed Sensor Replacement of Rear Speed Sensor
Section E - Hydraulics Hydraulics Service Tools Numerical List Technical Data Specifications 4 x 4 Additional Components Basic Operation Description Hydraulic System Transmission System Steering System Braking System Introduction to Hydraulic Schematic Symbols General (Basic and Functional Symbols) Control Valves Example of Schematic Circuit 4 Wheel Drive (3.0D 4 x 4 Machines) 2 Speed Operation 4 Wheel Drive Operation (3.5D 4 x 4 Machines) Service Procedures Hydraulic Contamination Hydraulic Fluid Quality Effects of Contamination Cleaning Operation Contaminant Standards Filters `Positional Type' Hydraulic Adaptors Fitting Procedure Connecting/Disconnecting Hydraulic Hoses Flow and Pressure Tests Pressure Tapping Points Schematic Circuits Machines up to Serial No. M788390 Component Key Transmission and Valve Hydraulic Circuit Component Key 3.0D 4 x 4 Drive Circuit Component Key Transmission and Valve Block Circuit- 2 Wheel Drive Machines Component Key 3.5D 4 x 4 Machines Priority, Steering, Drive and Fan Circuit Component Key Hydraulic Pump Steering/Main Hydraulic Pumps Removal Replacement Dismantling Inspection Assembly Steering Flow/Relief Valve (Double Pump) Dismantling Assembly Steering Flow/Relief Valve (Triple Pump) Dismantling Assembly Hydraulic Valves Control Valve Removal Replacement Dismantling Assembling Control Valve Spool Dismantling Assembly Main Relief Valve (MRV) Testing Auxiliary Relief Valve (ARV) Testing - Removed Testing - Fitted Unloader Valve Description Adjustment Removal Replacement Anti-Slip Valves - 4WD (3.0D 4 x 4 Machines) Removal Replacement Flow Divider Valve 2.5D/G, 3.0D/G and 3.5D 2 Wheel Drive Machines Description Removal Replacement Flow Divider Pressure Switch 2.5D, 3.0D and 3.5D Machines Description Removal Replacement Flow Divider Valve 3.5D 4 x 4 (Hydraulic Integrated Circuit) (HIC) Removal Replacement Hydraulic Oil Cooler Air Blast Type Removal Replacement Liquid to Liquid Cooler Description Removal Replacement Hydraulic Rams Lift Ram Removal Replacement Compensating Ram Removal Replacement Extension Ram Removal Replacement Tilt/Crowd Ram Removal Replacement Assemble and Dismantle Typical Ram
Section F - Transmission Transmission Technical Data Hydraulic Wheel Motors Service Tools Numerical List Tool Detail Reference Transmission System Transmission Pump and Motor Description Purge Valve Operation (4 x 4 Machines) Component Key Moving A Disabled Machine Recovery Fault Finding Drive Motors Drive Motors Removal and Replacement Removal Replacement 4 Wheel Drive Option Removal of Rear Wheel Motors Replacement Dismantling And Assembly Rexroth Drive Motors Poclain Drive Motors Transmission Pump Removal and Replacement Removal Replacement Torque Settings Bleeding Procedure Start-Up Procedure Pump/Engine Coupling Shaft Seal Multi-Function Valve Cartridge Charge Pressure Relief Valve Charge Pump (with transmission pump removed) Servo Piston Cover Seals Purge Valve Removal and Replacement Removal Replacement Wheels and Tyres General Inflating the Tyres Tyre Inflation Changing A Wheel Changing A Solid Tyre Rear Axle Removal and Replacement Removal Replacement Torque Settings Wheel Hubs Dismantling Assembly Torque Settings Steering Swivel Dismantling Assembly Steering Swivel - 3.0D 4 x 4 Option Dismantling Inspection Assembly Torque Settings Steer Sensor Testing Spring Plunger Shimming Procedure Shimming Procedure Load Moment Indicator Calibration
Section H - Steering Steering Steering Description Hydraulic Steering Unit Removal and Replacement Removal Replacement Torque Settings Dismantling and Assembly Dismantling Assembly Pressure Relief Valve Cartridge Shock Valves Power Track Rod Removal and Replacement Removal Replacement Torque Settings Dismantling and Assembly DIsmantling Assembly
Section K - Engine Engine Service Tools Numerical List Technical Data 100 Series Diesel Engine Machines - Up to Serial No. 892816 400 Series Diesel Engine Machines - From Serial No. 892817 LPG Engine 400 Series Turbo Diesel Engine Fitted to 3.5 Tonne Machines Fault Finding LPG Fuel System Checks and Adjustments Adjust the Carburettor Engine Removal and Replacement Diesel and LPG Engine Removal Replacement LPG Fuel System Description Safety Procedures LPG Tank Removal and Replacement Removal Replacement Fuel System Components (LPG) Vapouriser, Fuel Valve and Filter Removal and Replacement Fuel Valve and Filter Replacement of Fuel Filter Element Dismantling and Assembly Vapouriser Dismantling and Assembly Carburettor Removal Replacement Dismantling and Assembly