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

Copyright © 2004 JCB SERVICE. 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. World Class Customer Support 9803/9510-04 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Section 3 Maintenance Service Manual - Teletruk 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

Section 3 - Maintenance 3-0 3-0 9803/9510-04 Notes:

Page No. Contents Section 3 - Maintenance 3-i 3-i Routine Maintenance Service Requirements ............................................................................... 3-1 Introduction ............................................................................................ 3-1 Owner/Operator Support ....................................................................... 3-1 Service/Maintenance Agreements ........................................................ 3-1 Fit for Purpose Tests for Lifting Equipment ............................................ 3-1 Obtaining Replacement Parts ................................................................ 3-1 Health and Safety ...................................................................................... 3-3 Lubricants .............................................................................................. 3-3 Battery ................................................................................................... 3-5 Service Schedules ..................................................................................... 3-7 Introduction ............................................................................................ 3-7 How to Use the Service Schedules ....................................................... 3-7 Calendar Equivalents ............................................................................ 3-8 Pre-start Cold Checks, Service Points and Fluid Levels ....................... 3-9 Functional Test and Final Inspection ................................................... 3-11 Fluids, Lubricants and Capacities ............................................................ 3-12 Coolant Mixtures ................................................................................. 3-13 Fuels .................................................................................................... 3-14 Prepare the Machine for Maintenance .................................................... 3-17 Introduction .......................................................................................... 3-17 How to Make the Machine Safe (Boom Lowered) ............................... 3-18 Cleaning the Machine .............................................................................. 3-19 Introduction .......................................................................................... 3-19 Preparing the Machine for Cleaning .................................................... 3-19 Cleaning the Machine .......................................................................... 3-20 Checking For Damage ............................................................................. 3-21 Check the Machine Body and Structure .............................................. 3-21 Check the Tyres .................................................................................. 3-21 Check the Seat and Seat Belt ............................................................. 3-22 Check the Hydraulic Hoses and Fittings ............................................. 3-22 Checking the ROPS/FOPS Structure .................................................. 3-22 Greasing .................................................................................................. 3-23 Introduction .......................................................................................... 3-23 Preparing the Machine for Greasing ................................................... 3-23 Carriage ............................................................................................... 3-24 Boom ................................................................................................... 3-24 Rear Axle ............................................................................................. 3-25 Sideshift Option ................................................................................... 3-25 Inner Boom .......................................................................................... 3-26 Access Panels ......................................................................................... 3-27 Operator's Enclosure/Cab ................................................................... 3-27 Daily Inspection Cover ........................................................................ 3-29 Front Cover ......................................................................................... 3-30 Daily Inspection Rear Cover ................................................................ 3-31 Belly Plate (4WD Machines) ................................................................ 3-32 Optional Trash Guard .......................................................................... 3-32 Brakes ..................................................................................................... 3-33 Park Brake ........................................................................................... 3-33 Electrical System ..................................................................................... 3-34 Battery ................................................................................................. 3-34 Jump Starting the Engine .................................................................... 3-35 Fuses ................................................................................................... 3-37 Relays ................................................................................................. 3-41 Bulbs ................................................................................................... 3-42

Section 3 - Maintenance Contents 3-ii 3-ii Page No. Contents Engine ..................................................................................................... 3-43 Oil and Filter (Perkins) ......................................................................... 3-43 Oil and Filter (Deutz 2011-L04W) ........................................................ 3-45 Air Filter (Perkins) ................................................................................ 3-47 Air Filter (Deutz 2011-L04W) ............................................................... 3-48 Fan Belt (Perkins) ................................................................................ 3-49 Alternator Drive Belt (Deutz 2011-L04W) ............................................ 3-50 Timing Belt ........................................................................................... 3-51 Cooling System ................................................................................... 3-52 Diesel Fuel System .................................................................................. 3-53 Introduction .......................................................................................... 3-53 Water Separator and Engine Fuel Filter .............................................. 3-53 Fuel Primer (Deutz 2011-L04W) .......................................................... 3-56 Bleeding the System ........................................................................... 3-57 LPG Fuel System .................................................................................... 3-58 General ................................................................................................ 3-58 Type of LPG ........................................................................................ 3-59 Filling the LPG Tank ............................................................................ 3-59 Changing the LPG Tank ...................................................................... 3-59 Hydraulic System ..................................................................................... 3-60 Introduction .......................................................................................... 3-60 Releasing the Hydraulic Pressure ....................................................... 3-61 Checking the Fluid Level ..................................................................... 3-62 Checking for Leaks .............................................................................. 3-63 Checking the Hoses and Pipework ..................................................... 3-63 Changing the Filter Element ................................................................ 3-64 Changing the Filter Element (Pal Filter) .............................................. 3-64 Tyres and Wheels .................................................................................... 3-65 General ................................................................................................ 3-65 Tyre Inflation ........................................................................................ 3-66 Changing a Wheel ............................................................................... 3-67 Forks ....................................................................................................... 3-69 Inspecting the Forks ............................................................................ 3-69 Changing the Forks ............................................................................. 3-69 Windscreen Washer ................................................................................ 3-71 Checking the Level .............................................................................. 3-71 Fire Extinguisher (if fitted) ........................................................................ 3-72 Checking the Fire Extinguisher ........................................................... 3-72

Section 3 - Maintenance Routine Maintenance Service Requirements 3-1 3-1 9803/9510-04 Routine Maintenance Service Requirements Introduction T3-095 Your machine has been designed and built to give maximum performance, economy and ease of use under a wide variety of operating conditions. Prior to delivery, your machine was inspected both at the Factory and by your Distributor to ensure that it reaches you in optimum condition. To maintain this condition and ensure trouble free operation it is important that the routine services, as specified in this Manual, are carried out by an approved JCB Distributor at the recommended intervals. This section of the Manual gives full details of the service requirements necessary to maintain your JCB machine at peak efficiency. A Service Manual for your machine is available from your JCB Distributor. The Service Manual contains information on how to repair, dismantle and assemble your machine correctly. It can be seen from the Service Schedules on the following pages that many essential service checks should only be carried out by a JCB trained specialist. Only JCB Distributor Service Engineers have been trained by JCB to carry out such specialist tasks, and only JCB Distributor Service Engineers are equipped with the necessary special tools and test equipment to perform such tasks, thoroughly, safely, accurately and efficiently. JCB regularly updates its Distributors advising them of any product developments, changes in specifications and procedures. Therefore only a JCB Distributor is fully able to maintain and service your machine. A Service Record Sheet or Book is provided which will enable you to plan your service requirements and keep a service history record. It should be dated, signed and stamped by your Distributor each time your machine is serviced. Remember, if your machine has been correctly maintained, not only will it give you improved reliability but its resale value will be greatly enhanced. Owner/Operator Support JCB together with your Distributor wants you to be completely satisfied with your new JCB machine. If you do encounter a problem however, you should contact your Distributor's Service Department who are there to help you! You will have been given the names of the relevant service contacts at your Distributor when the machine was installed. To get the most from your Distributor please help them to satisfy you by: 1 Giving your name, address and telephone number. 2 Quoting your machine model and serial number. 3 Date of purchase and hours of work. 4 Nature of the problem. Remember, only your JCB Distributor has access to the vast resources available at JCB to help support you. In addition, your Distributor is able to offer a variety of programmes covering Warranty, Fixed Price Servicing, Safety Inspections, including weight tests, covering both legal and insurance requirements. Service/Maintenance Agreements To help plan and spread the costs of maintaining your machine, we strongly recommend you take advantage of the many Service and Maintenance Agreements your Distributor can offer. These can be tailor made to meet your operating conditions, work schedule etc. Please consult your JCB Distributor for details. Fit for Purpose Tests for Lifting Equipment T3-097 All lifting equipment (for example forks, lifting hooks and shackles) need regular inspection and testing by a competent person to ensure they are fit for purpose. This may be needed every six months or at least annually in some countries to meet and comply with legislation and for insurance purposes. Check with your local JCB distributor for further advice. Obtaining Replacement Parts T3-096 If you use non-genuine JCB parts or consumables, then you can compromise the health and safety of the operator and cause machine failure A Parts Book for your machine is available from your JCB Distributor. The Parts Book will help you identify parts and order them from your JCB distributor.

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

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