JCB 2.0D/G, 2.5D/G, 3.0D/G, 4x4 3.0D, 4x4 3.5D Teletruk Repair Service Manual

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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.


APPLICABLE MODELS :

JCB Teletruk
JCB Teletruk 2.0D/G, 2.5D/G, 3.0D/G - S/N: 788001 Onwards
JCB Teletruk 4x4 3.0D, 4x4 3.5D - S/N: 788001 Onwards

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

– 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. : 9803/9510-4
Total Pages : 666


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
Daily Inspection Cover
Front Cover
Daily Inspection Rear Cover
Raising the Teletruk
Lowering the Teletruk
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
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 / LLMI with LLMC
Digital LMI (If fitted)
Introduction
Calibration Procedure
Diagnostic Fault Codes
Diagnostic Tests
Sensor Removal
Sensor Replacement
LLMI with LLMC (if fitted)
Longitudinal Load Moment Indicator (LLMI) (If fitted)
Longitudinal Load Moment Indicator With Longitudinal Load Motion Control (If fitted)
Load Charts and Boom Indicators
Load Charts and Boom Indicators (If fitted)
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 G - Brakes
Brakes
Cross References
Brakes
Brake Pedal
Pressure Reducing Valve

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

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