JCB 2.5 G, 3.0 G, 3.0D 4x4, 3.5D, 3.5D 4x4, 3.0 D High Lift, 2.5D, 3.0D Teletruk Service Manual

Name: JCB 2.5 G, 3.0 G, 3.0D 4x4, 3.5D, 3.5D 4x4, 3.0 D High Lift, 2.5D, 3.0D Teletruk Service Manual
Brand: MidWestTech
SKU: 9803-9510-08
Price: 69.61 USD
Availability: InStock

545 pages · Publication 9803-9510-08

$69.61

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Models: 2.5 G, 3.0 G, 3.0D 4x4, 3.5D, 3.5D 4x4, 3.0 D High Lift, 2.5D, 3.0D
Serial coverage: Tier 2 Machines: 2.5 G, 3.0 G, from 1175813 to 1176999, 3.0D 4x4, from 1175813 to 1176569, 3.5D, from 1175813 to 1176572, 3.5D 4x4, from 1175813 to 1176591, 3.0 D High Lift, from 1175813 to 1176593, Tier 3 Machines: 2.5D, 3.0D, from SN 1176570, 3.0D 4x4, from SN 1176573, 3.5D, from SN 1176592, 3.5D 4x4, from SN 1176586, 3.0 D High Lift, from SN 1176594
Manual type: Service Manual
Pages: 545
Publication: 9803-9510-08
Condition: Brand new

JCB 2.5 G, 3.0 G, 3.0D 4x4, 3.5D, 3.5D 4x4, 3.0 D High Lift, 2.5D, 3.0D Teletruk Service Manual, publication 9803-9510-08

What's inside

From the manual's own table of contents: 5 sections, 356 entries. See sample pages (PDF, 403 KB)

Search the contents

General79 topics

About this Manual
Machine Model and Serial Number
Using the Service Manual
Section Numbering
Left Side, Right Side
Cab/Canopy
Cross References
Identification
Machine Identification Plate
Component Identification Plates
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
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
Service Requirements
Owner/Operator Support
Service/Maintenance Agreements
Fit for Purpose Tests for Lifting Equipment
Obtaining Replacement Parts
Health and Safety
Lubricants
Battery
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
Coolant Mixtures
Fuels
Prepare the Machine for Maintenance
How to Make the Machine Safe (Boom Lowered)
Cleaning the Machine
Preparing the Machine for Cleaning
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
Preparing the Machine for Greasing
Carriage
Boom
Rear Axle
Sideshift Option
Inner Boom
Access Panels
Operator's Enclosure/Cab
Daily Inspection Cover
Daily Inspection Rear Cover
Belly Plate (4WD Machines)
Optional Trash Guard
Brakes
Park Brake
Electrical System
Jump Starting the Engine
Fuses
Relays
Bulbs

Section 3 - Maintenance76 topics

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
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
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
Tyre Inflation
Changing a Wheel
Changing A Solid Tyre
Forks
Inspecting the Forks
Changing the Forks
Windscreen Washer
Checking the Level
Fire Extinguisher (if fitted)
Checking the Fire Extinguisher
Connecting/Disconnecting Hydraulic Hoses
Connecting the Hydraulic Hoses
Disconnecting the Hydraulic Hoses
Quick Release Couplings
Installing and Removing Changezee Quickhitch Attachments
Installing
Removing
Engaging and Disengaging the Shovel/Attachments
Disengaging the Shovel/Attachments
Engaging the Shovel/Attachments
Removal and Replacement
Removing the Bucket
Replacing the Bucket
Inspect the Forks
Cab and Access Covers
Raising the Teletruk
Lowering the Teletruk
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
Drain and Flush the Hydraulic Tank
Drain and Flush the Fuel Tank
Removing the Counterweight
Replacing the Counterweight
Removing the Carriage
Replacing the Carriage
Rivet Nuts
Fitting Procedure
Removing the Cab
Replacing the Cab
Glazing
Direct Glazing
Emergency Exit (If Fitted)
Fixed Rear Screen
Opening Rear Screen
Opening Rear Screen With Breaker

Section C - Electrics97 topics

Drawings
Mainframe Harness Location
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 Anti Slip Controls
3.5D 4x4 System (Differential Lock)
Machines with TCR LPG Engine (331/47182-2)
Machines with LPG Engine USA (332/S3031)
Alternator
Alternator (Perkins Engine) - Removal and Replacement
Dismantle and Assemble
Alternator (Deutz Engine) - Removal and Replacement
Digital LMI (If fitted)
Calibration Procedure
Diagnostic Fault Codes
Diagnostic Tests
Sensor Removal
Sensor Replacement
LLMI with LLMC (if fitted)
Longitudinal Load Moment Indicator (LLMI) (If fitted)
(If fitted)
LLMI with LLMC (from Serial Number 1539978 to 1541223)
Description
System Components
LLMI with LLMC (from Serial Number 1541224)
Hose Installation
Lift Charts
Load Charts and Boom Indicators (If fitted)
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Maintenance
First Aid - Electrolyte
Testing
Specific Gravity Testing
General Description
Service Precautions
Charging Circuit Test
Alternator Charging Test
Starter Motor
Starting Circuit Test
Wire and Harness Number Identification
Wire Numbers and Functions
Wiring Harness Repair
Repair Procedure
Why Use ServiceMaster?
Fault Finding
Identify Poor Maintenance
Access Machine Set-up Data
Re-Programming ECUs
Summary
What is Servicemaster?
CANbus Communications System
Servicemaster Structure
How to Set-up Servicemaster
New Installation of JCB ServiceMaster DVD
New Installation of JCB ServiceMaster WebUpdate
Authorising JCB WebUpdate Downloads
Using JCB WebUpdate to Download Updates
JCB ServiceMaster
ServiceMaster Front End
Selecting Service Tool Applications
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
Diagnostic Connectors
Teletruk Diagnostics
Getting Started
Hex File Download
TCR Brake Pedal Calibration
ASC Diagnostics (3.0D 4x4 Machines Only)
Torque Convertor Response
Susmic Controller
Safe Maintenance Practices
Safe Parking
2WD Machines
4x4 Machines
Removal and Repacement
Removal
Replacement
Diagnostic LED's
3.0D 4 Wheel Drive
NFPE Controller Error Codes
3.0D 4 x 4 STATUS Error (ASC Controller)
Diesel Engine
LPG Engine
Adjusting the Potentiometer
Early Type
Later Type

Section D - Controls34 topics

3.0D 4x4 ASC Option
Removal of Front Speed Sensor
Replacement of Front Speed Sensor
Removal of Rear Speed Sensor
Replacement of Rear Speed Sensor
Specifications
4x4 Additional Components
Steering System
Braking System
Transmission System
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Wheel Drive (3.0D 4x4 Machines)
Speed Operation
Wheel Drive Operation (3.5D 4x4 Machines)
Integrated Pump Mounted 4x4 System (3.0D/3.5D 4x4 Machines)
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
`Positional Type' Hydraulic Adaptors
Flow and Pressure Tests
Pressure Tapping Points
Machines up to Serial No. M788390
Component Key
Transmission and Valve Hydraulic Circuit
3.0D 4x4 Drive Circuit
Transmission and Valve Block Circuit- 2 Wheel Drive Machines
3.5D 4x4 Machines Priority, Steering, Drive and Fan Circuit
Machines from Serial No. 1541224

Section E - Hydraulics46 topics

Steering/Main Hydraulic Pumps
Dismantling
Inspection
Assembly
Steering Flow/Relief Valve (Double Pump)
Steering Flow/Relief Valve (Triple Pump)
Control Valve - Earlier Machines
Assembling
Control Valve Spool - Earlier Machines
Control Valve - Later Machines
Main Relief Valve (MRV)
Auxiliary Relief Valve (ARV)
Testing - Removed
Testing - Fitted
Unloader Valve
Adjustment
Anti-Slip Valves - 4WD (3.0D 4x4 Machines)
Flow Divider Pressure Switch 2.5D, 3.0D and 3.5D Machines
Flow Divider Valve 3.5D 4x4 (Hydraulic Integrated Circuit) (HIC)
Air Blast Type
Liquid to Liquid Cooler
Lift Ram
Compensating Ram
Extension Ram
Tilt/Crowd Ram
Assemble and Dismantle
Typical Ram
Hydraulic Wheel Motors
Transmission Pump and Motor
Purge Valve Operation (4 x 4 Machines)
Recovery
Drive Motors
Wheel Drive Option
Removal of Rear Wheel Motors
Dismantling And Assembly
Rexroth Drive Motors
Poclain Drive Motors
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

Section F - Transmission19 topics

Wheel Hubs
Steering Swivel
Steering Swivel - 3.0D 4 x 4 Option
Steer Sensor Testing
Spring Plunger Shimming Procedure
Shimming Procedure
Load Moment Indicator Calibration
Series Diesel Engine Machines - Up to Serial No. 892816
Series Diesel Engine Machines - From Serial No. 892817
Series Turbo Diesel Engine Fitted to 3.5 Tonne Machines
Checks and Adjustments
Adjust the Carburettor
Diesel and LPG Engine
Safety Procedures
Vapouriser, Fuel Valve and Filter
Fuel Valve and Filter
Replacement of Fuel Filter Element
Vapouriser
Carburettor

Inside this manual

Real pages from this service manual (545 pages). Open the sample pages (PDF, 402 KB)

Sample pages from the JCB 2.5 G, 3.0 G, 3.0D 4x4, 3.5D, 3.5D 4x4, 3.0 D High Lift and 2 more Teletruk Service Manual: Specifications, Diagram, Repair procedure, Color page, Color page

Specifications, page 72: Section 3 - Maintenance
Diagram, page 288: Section C - Electrics
Repair procedure, page 456: Section F - Transmission
Color page, page 354: Section E - Hydraulics
Color page, page 19: Section 1 - General Information

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, 545 pages

Quantity one is the manual described above.

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Other editions and similar models

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