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

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


TABLE OF CONTENTS :

Section 1 - General Information
Section 2 - Care & Safety
Section 3 - Routine Maintenance
Section A - Attachments
Section B - Body & 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. : 9803/3400 Issue 16
Total Pages : 609


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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Cover

Section 1
Identification
Vechile Identification Number
Torque Settings
Service Tools
Numerical List
Body & Framework
Electrics
Hydraulics
Sealing & Retaining Compounds

Section 2
Safety Notices
General
General Safety
Operating Safety
Maintenance Safety

Section 3
Capacities & Lubricants
Health & Safety
Service Schedule
Checking the Operator Enclosure
Cleaning the Machine
Greasing
Electrics
Safety
Checking the Electrolyte Level
Checking the Battery Terminals
Battery Isolator
Hydraulics
Checking the Oil Level
Filter R & R
Air Filter
Cooling System
Coolant Mixtures
Checking the coolant level
Engine Oil
Fuel System Diesel
Types of Fuel
Draining the Sedimenter
Bleeding
Fuel System LPG
General
Filling the Tank
Changing the Tank
Fan Belt
Steer Sensor

Section A
Quick Release Couplings
Hydraulic Hoses
Inspect the Forks
Bucket
Quickhitch

Section B
Operator Enclosure
Raising the Teletruk
Access for Maintenance
Cab
Seat
Direct Glazing
Emergency Exit
Counterweight
Diesel Tank
Hydraulic Tank
Carriage
Boom
Remove the Boom
Replace the Boom
Boom Alignment

Section C
Tecnical Data
Test Methods
Use of a Multimeter
Schematics
Diesel Engine, Single Pedal
Diesel Engine, Twin Pedal
LPG Engine, Single Pedal
LPG Engine, Twin Pedal
Diesel Engine TCR and 3.0D HL
LPG Engine TCR
2 Speed, Intelligent
2 Speed, Traction Control
3.0D 4 Wheel Drive Option
3.5D 4x4
3.5D 4x4 Differential Lock
Speed Sensor
Battery
Alternator
Starter Motor
Load Moment Indicator
Wire Harness Repair
Fault Finding
Harness Data

Section D
Technical Data
Torque Convertor Response
Introduction
Susmic Controller
Error Codes
Sensors and Actuators
Brake Pedal
Parking Brake Switch
3.0 4x4 Speed Sensor
Intellegent Transmission
Introduction
Loading Psion with JCB Software
Activating the Psion
Sensor Set Up
Calibration
Parameters Menu
Time Adjustments Menu
Sensor Check Procedure
Susmic Controller R & R
Sensors & Actuators R & R
Elecrical Displacement Control
Pulse Pickup Speed Sensor R & R
Brake Pedal R & R
Throttle Pedal R & R
Parking Brake Switch R & R
Sensor & Actuators Setting Up

Section E
Technical Data
Hydraulic Contamination
Schematics
To 788390
IT From 788391
Transmission TCR Option
Valve Block TCR Option
3.0D 4x4 Drive
2 Wheel Drive TCR
3.5 Valve Block
3.5D Steer & Fan
3.5D Hydraulic Services
3.5D Transmission
Pressure Test Points
Descriptions
Air Blast Cooler
Liquid Cooler
Pumps
R & R
Steering Flow Relief Valve
Valves
Control Valve
Main Relief Valve
Auxiliary Relief Valve
Unloader Valve
Anti Slip Valve
Flow Divider
Rams
Lift Ram R & R
Compensating Ram R & R
Extension Ram R & R
Tilt/Crowd Ram R & R
Typical Ram D & A
Bleeding Procedure

Section F
Description
Moving a Disabled Machine
Wheels and Tyres
Drive Motors
Drive Motor R & R
4 Wheel Drive R & R
Park Brake D & A
2 Speed Spool D & A
Flushing Valve
Park brake Test
Transmission Pump
R & R
Bleeding
Pump/Engine Coupling
Shaft Seal
Multi Function Valve
Charge Pump
Servo Piston Seals (TCR)
Rear Axle
Rear Axle R & R
Wheel Hub D & A
Steer Swivel D & A
Steer Swivel 3.0D D & A
Steer Sensor Testing 3.0D
Spring Plunger Shimming

Section G

Section H
Description
Steer Valve
Power Track Rod

Section K
Technical Data
Radiator R & R
Engine R & R
LPG Fuel System
Description
Safety Procedure
Fault Finding
Checks & Adjustments
Tank R & R
Fuel Valve & Filter
Carburettor

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