General Information
1
Care & Safety
2
Routine Maintenance
3
Attachments
A
Body & Framework
B
Electrics
C
Controls
D
Hydraulics
E
Transmission
F
Brakes
G
Steering
H
Engine
K
Service
Manual
Teletruk
From M/c No. 788001
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB AFTERMARKET TRAINING; ©
WOODSEAT, ROCESTER, STAFFORDSHIRE,
ST14 5BW, ENGLAND
Tel. ROCESTER (01889) 594700
PRINTED IN ENGLAND
Publication No. 9803/3400 Issue 16
Copyright © 2006 JCB AFTERMARKET TRAINING
All rights reserved. No part of this publication may be reproduced, stored in a
retrieval system, or transmitted in any form or by any other means, electronic,
mechanical, photocopying or otherwise, without prior permission from JCB
SERVICE.
This page intentionally left blank
Introduction
9803/3400 Issue 1
General
This Service Manual is designed for the benefit of JCB Distributor Service Engineers who are receiving or have received, train-
ing by JCB Technical Training Department.
These personnel have a sound knowledge of safe workshop practices, safety procedures, and general techniques associated
with the maintenance and repair of hydraulic earthmoving equipment.
The replacement of oil seals, gaskets and any other components showing obvious signs of wear or damage is expected as a
matter of course. Components should be cleaned and lubricated where appropriate, and any open hose or pipe connection must
be blanked off to prevent the loss of hydraulic fluid or allow an ingress of dirt. Finally, please remember SAFETY COMES FIRST!
Service Manual Layout
This Service manual is compiled in sections, the first three are numbered and contain information as follows:
1 General Information
2 Care and Safety
3 Routine maintenance
The remaining sections are alphabetically coded and deal with the overhaul and inspection of specific components, for exam-
ple:
A Attachments
B Body and Framework ....etc.
The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new information in
later issues of this Service Manual.
Section contents, technical data, circuit descriptions, operation descriptions etc are inserted, where necessary, at the beginning
of each alphabetically coded section.
Read the section contents to locate machine types, machine type identification is not listed on individual pages.
All sections are listed on the front cover; tabbed divider cards align directly with each individual section for quick reference.
Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry
threads. Torque figures for lubricated threads can be reduced by one third.
“Left Hand” and “Right Hand” are as viewed from the rear of the machine facing forwards.
This Service Manual covers the following machine type:
Teletruk
Product Identification Number (PIN) 0788001
General Information Section 1 Section 1
i i
9803/3400 Issue 4*
Identification
- Vehicle Identification Number 1 - 1
- Unit Identification 1 - 1
- Typical Engine Identification Number 1 - 1
Torque Settings
- Introduction - Zinc Plated Fasteners and Dacromet
Fasteners 2 - 1
- Metric Grade 8.8 Bolts 2 - 1
- UNF Grade “S” Bolts 2 - 1
- Hydraulic Fittings & Torque Settings 2 - 2
- ‘O’ Ring Face Seal System 2 - 2
- Torque Stop Hose System 2 - 3
Service Tools
- Numerical List 3 - 1
- Body and Framework 3 - 2
- Electrics 3 - 5
- Hydaulics 3 - 6
Sealing and Retaining Compounds 4 - 1
Contents Page No.
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General Information Section 1 Section 1
1 - 1 1 - 1
9803/3400 Issue 3*
Vehicle Identification Number (VIN)
The Product Identification Number (PIN), transmission pump
serial number and engine serial number positively identify the
type of Teletruk that you have. These numbers are stamped
on the machine VIN plate as shown in the following Figure.
A typical VIN is a 17 digit number as follows:
SLP TLT25 V E 0788001
SLP Manufacturer (JCB)
TLT25 Machine Model (Teletruk)
V Year (1997)
E Country (England)
0788001 (PIN)
Unit Identification
To confirm the identity of your machine, check the VIN plate
details against the serial numbers of each component.
Typical Engine Identification Number
This applies to the diesel engines only.
HR 51245 U
A B C
A Engine Type
KR = 4 cylinder naturally aspirated - up to machine serial
number 892816.
HP = 4 cylinder naturally aspirated - low emission stage 2 -
from machine serial number 892817.
HR = 4 cylinder turbo - low emission stage 2 - 3.5
machines only.
Where the service procedure differ between the engine types,
the text and or the illustration will specify.
B Build Number
C Country of Origin
Identification
CONSTRUCTOR MADE IN UK
J.C.BAMFORD EXCAVATORS LTD.
ROCESTER, STAFFS, ENGLAND.
Vehicle Identification No. Product Identification No.
ENGINE SERIAL No. WEIGHT
PUMP SERIAL No. YEAR OF MANUFACTURE
MODEL 80/1269/EEC MODEL 80/1269/EEC
POWER KW R.P.M. POWER KW R.P.M.
817/16599
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401571
General Information Section 1 Section 1
2 - 1 2 - 1
9803/3400 Issue 2*
Torque Settings
Introduction - Zinc Plated Fasteners and Dacromet Fasteners
JCB Teletruks are assembled using an improved type of corrosion resistant finish. This type of finish is called Dacromet and
replaces the original Zinc and Yellow plating used on earlier machines.
The two types of fasteners can be readily identified by colour and part number suffix as follows:
Fastener Type Colour Part Number
Zinc and Yellow Golden finish ‘Z’ (e.g. 1315/3712Z)
Dacromet Mottled silver finish ‘D’ (e.g. 1315/3712D)
Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must
be relevant to the type of fasteners.
Note: A Dacromet bolt should not be used in conjunction with a Zinc and Yellow plated nut, as this could change the torque
characteristics of the torque settings further. For the same reason, a Dacromet nut should not be used in conjunction with a
Zinc and Yellow plated bolt.
Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the
figures stated. For lubricated threads the values should be REDUCED by one third.
Metric Grade 8.8 Bolts
Bolt size Zinc Plated Fasteners Dacromet Fasteners
Diameter Hexagon (A/F) Torque Settings Torque Settings
mm mm Nm kgf m lbf ft Nm kgf m lbf ft
M6 x 1.0 10 12 1.2 9 9 0.9 7
M8 x 1.25 13 28 3.0 21 22.5 2.3 17
M10 x 1.5 17 56 5.7 42 47.5 4.8 35
M12 x 1.75 19 98 10 72 80 8.2 59
M14 x 2 22 133 13.6 98
M16 x 2 24 244 25 180 200 20.4 148
M18 x 2.5 27 350 36 258 278 28.4 205
M20 x 2.5 30 476 48 352 392 40 289
M24 x 3 36 822 84 607 675 69 498
M30 x 3.5 46 1633 166 1205 1348 138 994
UNF Grade 'S' Bolts
Bolt Size Hexagon (A/F) Torque Settings
in (mm) in Nm kgf m lbf ft
1
/4 (6.3)
7
/16 14 1.4 10
5
/16 (7.9)
1
/2 28 2.8 20
3
/8 (9.5)
9
/16 49 5.0 36
7
/16 (11.1)
5
/8 78 8.0 58
1
/2 (12.7)
3
/4 117 12.0 87
9
/16 (14.3)
13
/16 170 17.3 125
5
/8 (15.9)
15
/16 238 24.3 175
3
/4 (19.0) 1
1
/8 407 41.5 300
7
/8 (22.2) 1
5
/16 650 66.3 480
1 (25.4) 1
1
/2 970 99.0 715
1
1
/4 (31.7) 1
7
/8 1940 198.0 1430
1
1
/2 (38.1) 2
1
/4 3390 345.0 2500
Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
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General Information Section 1 Section 1
2 - 2 2 - 2
9803/3400 Issue 1
Hydraulic Fittings & Torque Settings
‘O’ Ring Face Seal System
Adaptors screwed into valve blocks
Adaptors screwed into valve blocks, etc. seal onto an 'O' ring which is compressed into a 45
o
seat machined in the face of the
tapped port.
Common Spanner Size (A/F) Tightening Torque
Adaptor Size mm in. Nm lbf ft
1/4” BSP 19 0.75 18 13
3/8” BSP 22 0.875 31 23
1/2” BSP 27 1 49 36
5/8” BSP 30 60 44
3/4” BSP 32 1.25 81 60
1” BSP 38 1.5 129 95
1 1/4” BSP 206 152
SAE SAE Port Common Spanner Size (A/F) Tightening Torque
Tube Size Thread Size mm in. Nm lbf ft
4 7/16 - 20 15.9 0.625 20 - 28 16.5 - 18.5
6 9/16 - 18 19.1 0.750 46 - 54 34 - 40
8 3/4 - 16 22.2 0.875 95 - 105 69 - 77
10 7/8 - 14 27.0 1.063 130 - 140 96 - 104
12 1.1/16 - 12 31.8 1.250 190 - 210 141 - 155
16 1.5/16 - 12 38.1 1.500 290 - 310 216 - 230
20 1.5/8 - 12 47.6 1.875 280 - 380 210 - 280
Hoses Screwed onto Adaptors
Hoses B screwed onto adaptors A etc. seal onto an 'O' ring C which is compressed into a 45
o
seat machined in the face of the
adaptor port.
Common Spanner Size (A/F) Tightening Torque
Hose Size mm in. Nm lbf ft
1/8” BSP 14 14 10
1/4” BSP 19 0.75 24 18
3/8” BSP 22 0.875 33 24
1/2” BSP 27 1 44 33
5/8” BSP 30 58 43
3/4” BSP 32 1.25 84 62
1” BSP 38 1.5 115 85
1 1/4” BSP 189 140
1 1/2” BSP 244 180
B
A
C
A438690
Dimension will vary depending
on torque applied.
General Information Section 1 Section 1
2 - 3 2 - 3
9803/3400 Issue 1
Hydraulic Fittings & Torque Settings
Torque Stop Hose System
'Torque Stop' Hoses B screwed onto adaptors A etc. seal onto an 'O' ring C which is compressed into a 45
o
seat machined in
the face of the adaptor port. To prevent the ‘O’ ring being damaged as a result of over tightening, 'Torque Stop' Hoses have
an additional shoulder, which acts as a physical stop.
Common Spanner Size (A/F) Tightening Torque
Hose Size mm in. Nm lbf ft
1/8” BSP 14 14 10
1/4” BSP 19 0.75 27 20
3/8” BSP 22 0.875 40 30
1/2” BSP 27 1 55 40
5/8” BSP 30 65 48
3/4” BSP 32 1.25 95 70
1” BSP 38 1.5 120 89
1 1/4” BSP 189 140
1 1/2” BSP 244 180
A438700
D
B
A
C
Minimum dimension fixed
by shoulder D.
General Information Section 1 Section 1
3 - 1 3 - 1
9803/3400 Issue 2
Service Tools
Numerical List
Page No.
1406/0011 Bonded Washer 3 - 7
1406/0018 Bonded Washer 3 - 7
1406/0021 Bonded Washer 3 - 6/3 - 7
1406/0029 Bonded Washer 3 - 7
1604/0003 Adapter 3 - 7
1604/0004 Adapter 3 - 7
1604/0006 Adapter 3 - 6/3 - 7
1606/0003 Adapter 3 - 7
1606/0004 Adapter 3 - 7
1606/0007 Adapter 3 - 7
1606/0008 Adapter 3 - 7
1606/0009 Adapter 3 - 7
1612/0006 Adapter 3 - 6
4101/0251 JCB Threadlocker and sealer 4 - 1
4101/0451 JCB Threadlocker 4 - 1
4101/0552 JCB Threadlocker and Sealer (HS) 4 - 1
4101/0651 JCB Retainer (High Strength) 4 - 1
4102/0551 JCB High Strength Threadlocker 4 - 1
4102/1201 JCB Multi-Gasket 4 - 1
4104/0251 JCB Activator (Aerosol) 4 - 1
4104/0253 JCB Activator (Bottle) 4 - 1
4104/1310 Hand Cleaner 3 - 2
331/27987 Flank Drive Socket 3 - 5
721/11069 Speed Sensor Test Lead 3 - 5
816/00189 Blanking Cap 3 - 8
816/00190 Blanking Cap 3 - 8
816/00193 Blanking Cap 3 - 8
816/00196 Blanking Cap 3 - 8
816/00197 Blanking Cap 3 - 8
816/00294 Blanking Cap 3 - 8
816/15118 Pressure Test Adapter 3 - 6
816/20008 Adapter 3 - 6
816/50043 'T' Adapter 3 - 8
816/55038 Pressure Test 'T' Adapter 3 - 6
816/55040 Pressure Test 'T' Adapter 3 - 6
816/60096 'T' Adapter 3 - 8
826/01099 M6 x 16mm Rivet Nut 3 - 2
826/01101 M6 x 19mm Rivet Nut 3 - 2
826/01102 M8 x 21mm Rivet Nut 3 - 2
826/01103 M8 x 18mm Rivet Nut 3 - 2
826/01104 M10 x 23mm Rivet Nut 3 - 2
826/01105 M10 x 26mm Rivet Nut 3 - 2
892/00047 'T' Adapter 3 - 8
892/00048 'T' Adapter 3 - 8
892/00055 Blanking Plug 3 - 8
892/00056 Blanking Plug 3 - 8
892/00057 Blanking Plug 3 - 8
892/00059 Blanking Plug 3 - 8
892/00060 Blanking Plug 3 - 8
892/00074 Female Connector 3 - 8
892/00075 Female Connector 3 - 8
892/00077 Female Connector 3 - 8
892/00137 Hose 3 - 7
892/00223 Hand Pump 3 - 7
892/00252 A.R.V Test Block - Husco 3 - 7
892/00253 Pressure Test Kit 3 - 6
892/00255 Pressure Test Adapter 3 - 6
892/00256 Pressure Test Adapter 3 - 6
892/00257 Pressure Test Adapter 3 - 6
892/00258 Pressure Test Adapter 3 - 6
892/00259 Pressure Test Adapter 3 - 6
Page No.
892/00260 Pressure Test Adapter 3 - 6
892/00261 Pressure Test Adapter 3 - 6
892/00262 Pressure Test 'T' Adapter 3 - 6/3 - 7
892/00263 Pressure Test 'T' Adapter 3 - 6
892/00264 Pressure Test 'T' Adapter 3 - 6
892/00265 Pressure Test 'T' Adapter 3 - 6
892/00268 Flow Monitoring Unit 3 - 6
892/00269 Sensor Head 3 - 6
892/00270 Load Valve 3 - 6
892/00271 Adapter 3 - 6
892/00272 Adapter 3 - 6
892/00274 Adapter 3 - 7
892/00275 Adapter 3 - 6
892/00276 Adapter 3 - 6
892/00277 Adapter 3 - 6
892/00278 Gauge 3 - 7
892/00279 Gauge 3 - 7
892/00281 AVO Meter 3 - 5
892/00282 Shunt 3 - 5
892/00283 Tool Kit Case 3 - 5
892/00284 Tachometer 3 - 5
892/00285 Hydraulic Oil Temperature Probe 3 - 5
892/00286 Surface Temperature Probe 3 - 5
892/00706 Test Probe 3 - 7
892/00842 Glass Lifter 3 - 3
892/00843 Folding Stand for Holding Glass 3 - 2
892/00844 Long Knife 3 - 4
892//00845 Cartridge Gun 3 - 2
892/00846 Glass Extractor (Handles) 3 - 3
892/00847 Nylon Spatula 3 - 4
892/00848 Wire Starter 3 - 3
892/00849 Braided Cutting Wire 3 - 4
892/00923 A.R.V Test Block - Commercial Hyd. 3 - 7
892/00924 Psion Walkabout 3 - 5
926/15500 Rubber Spacer Blocks 3 - 4
992/09300 Spanner 3 - 7
992/09400 Spanner 3 - 7
992/09500 Spanner 3 - 7
992/09600 Spanner 3 - 7
992/12300 12V Mobile Oven 3 - 2
992/12400 240V Static Oven -2 Cartridge 3 - 3
992/12600 240V Static Oven -6 Cartridge 3 - 3
992/12800 Cut-Out Knife 3 - 3
992/12801 ‘L’ Blades 3 - 3
993/68100 Slide Hammer Kit 3 - 4
993/85700 Battery tester 3 - 5
The following parts are replacement items for kits and would
normally be included in the kit numbers quoted above.
Replacement items for kit no. 892/00253
892/00201 Replacement Gauge 3 - 6
892/00202 Replacement Gauge 3 - 6
892/00203 Replacement Gauge 3 - 6
892/00254 Replacement Hose 3 - 6
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JCB Forklift TELETRUK 2.0D/G 2.5D/G 3.0D/G 35 Service Manual
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Description
The JCB Teletruk forklift 2.0 D/G 2.5 D/G 3.0 D/G, 3.0D 4*4, 3.5D 4*4 Service Manual contains comprehensive information, diagrams, actual real photo illustrations, and schemes. These provide complete step-by-step operations for repair, servicing, technical maintenance, and troubleshooting procedures for your machine. This manual offers all the information needed for repairing your machine without the need for professional service.
One of the advantages of having digital files instead of a hard-printed manual is the ability to use the Search feature in Acrobat to quickly find specific information and print out exact pages as needed. The manual covers serial numbers 788001 onwards and has a publication number of 9803-9510. It is available in English language and has 609 pages with a file size of 247Mb.
The manual includes the following sections:
- General Information
- Care and Safety
- Routine Maintenance
- Attachments
- Body and Framework
- Electronics
- Controls
- Hydraulics
- Transmission
- Brakes
- Steering
- Engine
We have a comprehensive collection of manuals for JCB machines. If you have any questions or are looking for a specific manual, feel free to reach out to us. Have a great day!
