Open front screen

General Information 1
Care & Safety 2
Routine Maintenance 3
Attachments A
Service Body & Framework B
Manual
Electrics C
Controls D
Teletruk Hydraulics E
From M/c No. 788001
Transmission F
Brakes G
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB AFTERMARKET TRAINING; ©
WOODSEAT, ROCESTER, STAFFORDSHIRE,
Steering H
ST14 5BW, ENGLAND
Tel. ROCESTER (01889) 594700
PRINTED IN ENGLAND
Engine K
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

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

9803/3400 Issue 1
Section 1 General Information Section 1
i i

Contents Page No.

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

9803/3400 Issue 4*
Section 1 General Information Section 1
1-1 Identification 1-1

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:

401571
SLP TLT25 V E 0788001

SLP Manufacturer (JCB)

TLT25 Machine Model (Teletruk) J.C.BAMFORD EXCAVATORS LTD.
V Year (1997) R ROCESTER, STAFFS, ENGLAND.
E Country (England) CONSTRUCTOR MADE IN UK
0788001 (PIN)
Vehicle Identification No. Product Identification No.

ENGINE SERIAL No. WEIGHT

Unit Identification
PUMP SERIAL No. YEAR OF MANUFACTURE
To confirm the identity of your machine, check the VIN plate MODEL 80/1269/EEC MODEL 80/1269/EEC
details against the serial numbers of each component. POWER KW R.P.M. POWER KW R.P.M.

Typical Engine Identification Number

This applies to the diesel engines only. 817/16599

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

9803/3400 Issue 3*
 Section 1 General Information Section 1
2-1 Torque Settings 2-1

* 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) 11/8 407 41.5 300
7/8 (22.2) 15/16 650 66.3 480
1 (25.4) 11/2 970 99.0 715
11/4 (31.7) 17/8 1940 198.0 1430
11/2 (38.1) 21/4 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.

9803/3400 Issue 2*
Section 1 General Information Section 1
2-2 Hydraulic Fittings & Torque Settings 2-2

‘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 45o 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 45o seat machined in the face of the
adaptor port.
Dimension will vary depending
on torque applied.

C
B

A
A438690

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

9803/3400 Issue 1
Section 1 General Information Section 1
2-3 Hydraulic Fittings & Torque Settings 2-3

Torque Stop Hose System

'Torque Stop' Hoses B screwed onto adaptors A etc. seal onto an 'O' ring C which is compressed into a 45o 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.
Minimum dimension fixed
by shoulder D.

B
D
A
A438700

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

9803/3400 Issue 1
 Section 1 General Information Section 1
3-1 Service Tools 3-1

Numerical List Page No.

Page No. 892/00260 Pressure Test Adapter 3-6
1406/0011 Bonded Washer 3-7 892/00261 Pressure Test Adapter 3-6
1406/0018 Bonded Washer 3-7 892/00262 Pressure Test 'T' Adapter 3 - 6/3 - 7
1406/0021 Bonded Washer 3 - 6/3 - 7 892/00263 Pressure Test 'T' Adapter 3-6
1406/0029 Bonded Washer 3-7 892/00264 Pressure Test 'T' Adapter 3-6
1604/0003 Adapter 3-7 892/00265 Pressure Test 'T' Adapter 3-6
1604/0004 Adapter 3-7 892/00268 Flow Monitoring Unit 3-6
1604/0006 Adapter 3 - 6/3 - 7 892/00269 Sensor Head 3-6
1606/0003 Adapter 3-7 892/00270 Load Valve 3-6
1606/0004 Adapter 3-7 892/00271 Adapter 3-6
1606/0007 Adapter 3-7 892/00272 Adapter 3-6
1606/0008 Adapter 3-7 892/00274 Adapter 3-7
1606/0009 Adapter 3-7 892/00275 Adapter 3-6
1612/0006 Adapter 3-6 892/00276 Adapter 3-6
4101/0251 JCB Threadlocker and sealer 4-1 892/00277 Adapter 3-6
4101/0451 JCB Threadlocker 4-1 892/00278 Gauge 3-7
4101/0552 JCB Threadlocker and Sealer (HS) 4-1 892/00279 Gauge 3-7
4101/0651 JCB Retainer (High Strength) 4-1 892/00281 AVO Meter 3-5
4102/0551 JCB High Strength Threadlocker 4-1 892/00282 Shunt 3-5
4102/1201 JCB Multi-Gasket 4-1 892/00283 Tool Kit Case 3-5
4104/0251 JCB Activator (Aerosol) 4-1 892/00284 Tachometer 3-5
4104/0253 JCB Activator (Bottle) 4-1 892/00285 Hydraulic Oil Temperature Probe 3-5
4104/1310 Hand Cleaner 3-2 892/00286 Surface Temperature Probe 3-5
892/00706 Test Probe 3-7
* 331/27987 Flank Drive Socket 3-5
892/00842 Glass Lifter 3-3
* 721/11069 Speed Sensor Test Lead 3-5
816/00189 Blanking Cap 3-8 892/00843 Folding Stand for Holding Glass 3-2
816/00190 Blanking Cap 3-8 892/00844 Long Knife 3-4
816/00193 Blanking Cap 3-8 892//00845 Cartridge Gun 3-2
816/00196 Blanking Cap 3-8 892/00846 Glass Extractor (Handles) 3-3
816/00197 Blanking Cap 3-8 892/00847 Nylon Spatula 3-4
816/00294 Blanking Cap 3-8 892/00848 Wire Starter 3-3
816/15118 Pressure Test Adapter 3-6 892/00849 Braided Cutting Wire 3-4
816/20008 Adapter 3-6 892/00923 A.R.V Test Block - Commercial Hyd. 3 - 7
816/50043 'T' Adapter 3-8 * 892/00924 Psion Walkabout 3-5
816/55038 Pressure Test 'T' Adapter 3-6 926/15500 Rubber Spacer Blocks 3-4
816/55040 Pressure Test 'T' Adapter 3-6 992/09300 Spanner 3-7
816/60096 'T' Adapter 3-8 992/09400 Spanner 3-7
826/01099 M6 x 16mm Rivet Nut 3-2 992/09500 Spanner 3-7
826/01101 M6 x 19mm Rivet Nut 3-2 992/09600 Spanner 3-7
826/01102 M8 x 21mm Rivet Nut 3-2 992/12300 12V Mobile Oven 3-2
826/01103 M8 x 18mm Rivet Nut 3-2 992/12400 240V Static Oven -2 Cartridge 3-3
826/01104 M10 x 23mm Rivet Nut 3-2 992/12600 240V Static Oven -6 Cartridge 3-3
826/01105 M10 x 26mm Rivet Nut 3-2 992/12800 Cut-Out Knife 3-3
892/00047 'T' Adapter 3-8 992/12801 ‘L’ Blades 3-3
892/00048 'T' Adapter 3-8 993/68100 Slide Hammer Kit 3-4
892/00055 Blanking Plug 3-8 993/85700 Battery tester 3-5
892/00056 Blanking Plug 3-8
892/00057 Blanking Plug 3-8 The following parts are replacement items for kits and would
892/00059 Blanking Plug 3-8 normally be included in the kit numbers quoted above.
892/00060 Blanking Plug 3-8
892/00074 Female Connector 3-8 Replacement items for kit no. 892/00253
892/00075 Female Connector 3-8 892/00201 Replacement Gauge 3 - 6
892/00077 Female Connector 3-8 892/00202 Replacement Gauge 3 - 6
892/00137 Hose 3-7 892/00203 Replacement Gauge 3 - 6
892/00223 Hand Pump 3-7 892/00254 Replacement Hose 3 - 6
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

9803/3400 Issue 2
Section 1 General Information Section 1
3-2 Service Tools 3-2

Section B - Body & Framework

826/01099 M6 x 16mm Rivet Nut

826/01101 M6 x 19mm Rivet Nut
826/01103 M8 x 18mm Rivet Nut
826/01102 M8 x 21mm Rivet Nut
826/01104 M10 x 23mm Rivet Nut
826/01105 M10 x 26mm Rivet Nut

Installation Tool Available from:

Bollhoff Fastenings Ltd.
Midacre
The Willenhall Estate
Rose Hill
Willenhall
West Midlands, WV13 2JW
S1261210

Cartridge Gun - hand operated - essential for the

application of sealants, polyurethane
materials etc.

JCB part number -

892/00845

Hand Cleaner - special blend for the removal of

polyurethane adhesives.

JCB part number - 4104/1310

(454g; 1 lb tub) S186240 S186270

Folding Stand for

Holding Glass - essential
for preparing new glass
prior to installation.

JCB part number -

12V Mobile Oven - 1 cartridge capacity - required to 892/00843
pre-heat adhesive prior to use. It is fitted with a male
plug (703/23201) which fits into a female socket
(715/04300).

JCB part number - 992/12300

S186280
S186250

9803/3400 Issue 1
Section 1 General Information Section 1
3-3 Service Tools 3-3

Section B - Body & Framework (cont’d)

240V Static Oven - available with 2 or 6 cartridge Glass Lifter - minimum 2 off - essential for glass
capacity - required to pre-heat adhesive prior to use. installation, 2 required to handle large panes of glass.
No plug supplied. Note: 110V models available upon Ensure suction cups are protected from damage
request - contact JCB Technical Service. during storage.

JCB part number: JCB part number - 892/00842

992/12400 - 2 Cartridge x 240V
992/12600 - 6 Cartridge x 240V

S186260 S186300

Wire Starter - used to

access braided cutting wire
(below) through original
polyurethane seal.

Cut-Out Knife - used to

remove broken glass.

JCB part number - 992/12800

JCB part number - 892/00848

S186310 S186340

'L' Blades - 25 mm (1 in) cut - replacement blades for

cut-out knife (above).

JCB part number - 992/12801 (unit quantity = 5 off)

Glass Extractor (Handles) - used with braided cutting

wire (below) to cut out broken glass.

JCB part number - 892/00846

S186320 S186350

9803/3400 Issue 1
Section 1 General Information Section 1
3-4 Service Tools 3-4

Section B - Body & Framework (cont’d)

Long Knife - used to give extended reach for normally

Braided Cutting Wire - consumable heavy duty cut-out inaccessible areas.
wire used with the glass extraction tool (above).
JCB part number - 892/00844
JCB part number - 892/00849
(approx 25 m length)

S186330 S186360

Rubber Spacer Blocks - used to provide the correct

set clearance between glass edge
and cab frame.

JCB part number - 926/15500

(unit quantity = 500 off)
Nylon Spatula - general
tool used for smoothing
sealants - also used to re-install
glass in rubber glazing because metal
tools will chip the glass edge.

JCB part number - 892/00847

* S186470-V1 S186550

Slide Hammer Kit - 993/68100

1 :993/68101 Slide Hammer 6 :993/68106 Adaptor - M20 x M24
2 :993/68102 End Stops 7 :993/68107 Bar - M20 x M20 X 800MM
3 :993/68103 Adaptor - M20 x 5/8" UNF 8 :993/68108 Adaptor - M20 x 7/8" UNF
4 :993/68104 Adaptor - M20 x 1" UNF 9 :993/68109 Adaptor - M20 x M12
5 :993/68105 Adaptor - M20 x M20 * 10 :993/68110 Adaptor - M20 x M16
11 :993/68111 Adaptor - M20 x 1/2" UNF

2 2
11 5

1 3
6
2 4
9
10
8

S196910

9803/3400 Issue 3*
Section 1 General Information Section 1
3-5 Service Tools 3-5

Section C - Electrics

239510

993/85700 Battery Tester

* S188231

AVO Test Kit

1 892/00283 Tool Kit Case

2 892/00281 AVO Meter
3 892/00286 Surface Temperature Probe
4 892/00284 Venture Microtach Digital Tachometer A437530

5 892/00282 100 Amp Shunt - Open Type

331/27987 Flank Drive Socket
6 892/00285 Hydraulic Temperature Probe

1 4
3
1
2
1
2
4
3

A437560

1 892/00924 Psion Walkabout 721/11069 Speed Sensor Test Lead

2 892/00931 Psion Service Software Lead

9803/3400 Issue 4*
Section 1 General Information Section 1
3-6 Service Tools 3-6

Section E - Hydraulics

Hydraulic Circuit Pressure Test Kit

892/00253 Pressure Test Kit

892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in2)

892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in2)

892/00203 Replacement Gauge 0-400 bar (0-400 lbf/in2)

892/00254 Replacement Hose

188120

188130 200140

Pressure Test Adapters

Pressure Test 'T' Adapters
892/00255 1/4 in BSP x Test Point
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 892/00256 3/8 in BSP x Test Point
816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point 892/00257 1/2 in BSP x Test Point
816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point 892/00258 5/8 in BSP x Test Point
892/00263 5/8 in M BSP x 5/8 in F BSP x Test Point 816/15118 3/4 in BSP x Test Point
892/00264 3/4 in M BSP x 3/4 in F BSP x Test Point 892/00259 1 in BSP x Test Point
892/00265 1 in M BSP x 1 in F BSPP x Test Point 892/00260 1.1/4 in BSP x Test Point
892/00261 5/8 in UNF x Test Point

Flow Test Equipment

892/00268 Flow Monitoring Unit

892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)
892/00270 Load Valve
1406/0021 Bonded Washer
1604/0006 Adapter 3/4 in M x 3/4 in M BSP
1612/0006 Adapter 3/4 in F x 3/4 in M BSP
892/00271 Adapter 3/4 in F x 5/8 in M BSP
892/00272 Adapter 5/8 in F x 3/4 in M BSP
816/20008 Adapter 3/4 in F x 1/2 in M BSP
892/00275 Adapter 1/2 in F x 3/4 in M BSP
892/00276 Adapter 3/4 in F x 3/8 in M BSP
188150 892/00277 Adapter 3/8 in F x 3/4 in M BSP

9803/3400 Issue 1
Section 1 General Information Section 1
3-7 Service Tools 3-7

Section E - Hydraulics

220840

S270650

892/00252 Test Block for A. R. V. - Husco valves

892/00923 Test Block for A. R. V.
- Commercial Hydraulic valves

193850
188140
Hand Pump Equipment

892/00223 Hand Pump Bonded Washers

892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper 1406/0011 1/4 in BSP
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 1406/0018 1/2 in BSP
892/00706 Test Probe 1406/0021 3/4 in BSP
892/00278 Gauge 0 - 40 bar (0 - 600 lbf/in2) 1406/0029 1.1/4 in BSP
892/00279 Gauge 0 - 400 bar (0 - 6000 lbf/in2)

193860
193930
Male Adapters - BSP x BSP

1606/0003 3/8 in x 1/4 in

1604/0003 3/8 in x 3/8 in Hexagon Spanners for Ram Pistons and End Caps
1606/0004 1/2 in x 1/4 in
1606/0007 1/2 in x 3/8 in 992/09300 55 mm A/F
1604/0004 1/2 in x 1/2 in 992/09400 65 mm A/F
1606/0008 3/4 in x 3/8 in 992/09500 75 mm A/F
1606/0009 3/4 in x 1/2 in 992/09600 85 mm A/F
1604/0006 3/4 in x 3/4 in

9803/3400 Issue 1
Section 1 General Information Section 1
3-8 Service Tools 3-8

Section E - Hydraulics

193880
193870

Male Cone Blanking Plug

Female Cone Blanking Plug
816/00294 1/4 in BSP
892/00055 1/4 in BSP 816/00189 3/8 in BSP
892/00056 3/8 in BSP 816/00190 1/2 in BSP
892/00057 1/2 in BSP 816/00197 5/8 in BSP
892/00059 3/4 in BSP 816/00196 3/4 in BSP
892/00060 1 in BSP'T' 816/00193 1 in BSP

193890 193900

'T' Adapters Female Connectors

892/00047 3/8 in BSP (A) x 1/4 in BSP (B) 892/00074 3/8 in BSP x 3/8 in BSP
892/00048 1/2 in BSP (A) x 1/4 in BSP (B) 892/00075 1/2 in BSP x 1/2 in BSP
816/50043 3/4 in BSP (A) x 1/4 in BSP (B) 892/00077 3/4 in BSP x 3/4 in BSP
816/60096 3/4 in BSP (A) x 3/4 in BSP (B)

9803/3400 Issue 1
Section 1 General Information Section 1
4-1 Sealing and Retaining Compounds 4-1

Sealing and Retaining Compounds

JCB Multi-Gasket A medium strength sealant suitable for all
sizes of gasket flanges, and for hydraulic fittings
of 25-65mm diameter. 4102/1212 50ml

JCB High Strength Threadlocker A high strength locking fluid for use with threaded
components. Gasketing for all sizes of flange where
the strength of the joint is important. 4102/0551 50ml

JCB Retainer (High Strength) For all retaining parts which are unlikely to be
dismantled. 4101/0651 50ml

JCB Threadlocker and Sealer A high strength locking fluid for sealing 4101/0250 10ml
and retaining nuts, bolts, and screws up to 4101/0251 50ml
50mm diameter, and for hydraulic fittings up
to 25mm diameter.

Threadseal A medium strength thread sealing compound. 4102/1951 50ml

Threadlocker A locking fluid for use on threads larger than

50mm dia. 4101/0451 50ml

Activator A cleaning primer which speeds the curing rate 4104/0251 (1ltr)
of anaerobic products. 4104/0253 Bottle
(200ml)

Cleaner / Degreaser For degreasing components prior to use of

anaerobic adhesives and sealants. 4104/1557 400ml

Direct Glazing Kit For one pane of glass, comprises items

marked † below plus applicator nozzle etc. 993/55700

† Ultra Fast Adhesive For direct glazing 4103/2109 310 ml

† Active Wipe 205 For direct glazing 4104/1206 30 ml

4104/1203 250 g

† Black Primer 206J For direct glazing 4201/4906 30 ml

Clear Silicone Sealant To seal butt jointed glass 4102/0933

Black Polyurethane Sealant To finish exposed edges of laminated glass 4102/2309 310 ml

JCB Cleaner & Degreaser For degreasing components prior to use of anaerobic
adhesives and sealants. 4104/1538 Aerosol

9803/3400 Issue 2
Section 2 Care & Safety Section 2
i i

Contents Page No.

Safety Notices 1-1

General 2-1

General Safety 3-1

Operating Safety 4-1

Maintenance Safety 5-1

9803/3400 Issue 1
Section 2 Care & Safety Section 2
1-1 Safety Notices 1-1

In this manual and on the machine there are safety notices. Each notice starts with a signal
word The meanings of the signal words are given below.

! DANGER
Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable
that the operator (or others) could be killed or seriously injured.
INT-1-2-1

! WARNING
Denotes a hazard exists. If proper precautions are not taken, the operator (or others could
be killed or seriously injured.
INT-1-2-2

! CAUTION
Denotes a reminder of safety practices. Failure to follow these safety practices could result
in injury to the operator (or others) and possible damage to the machine.
INT-1-2-3

! WARNING
Study this Service Manual before carrying out any maintenance work on the machine. You
must always understand and observe the relevant laws and regulations If you are unsure
about anything, ask your JCB Distributor.

9803/3400 Issue 1
Section 2 Care & Safety Section 2
2-1 General 2-1

Introduction
This section of the Manual is intended to REMIND the
operator of basic safety requirements when operating
industrial machinery. It is not a complete list of hazards that
may exist when operating or maintaining the Teletruk.

SPECIFIC HAZARDS RELATING TO MAINTENANCE

INSTRUCTIONS ARE DETAILED IN THE RELEVANT
SECTIONS OF THIS MANUAL.

Safety First - Yours And Other People’s

All industrial equipment can be hazardous. When a machine
is properly maintained, it is a safe machine to work with. But
when it is poorly maintained it can become a danger to you
(the operator) and others.

In this Manual and on the machine you will find warning

messages. Read and understand them. They tell you of
potential hazards and how to avoid them. If you do not fully
understand the warning messages, ask your supervisor or
JCB Distributor to explain them.

But safety is not just a matter of responding to the warnings.

All the time you are working on or with the machine you must
be thinking what hazards there might be and how to avoid
them.

Do not work with the machine until you are sure you can
control it. Do not start any job until you are sure that you and
those around you will be safe. If you are unsure of anything,
about the machine or the job, ask someone who knows. Do
not assume anything.

Remember
BE CAREFUL
BE ALERT
BE SAFE
INT-1-3-1/1

9803/3400 Issue 1
Section 2 Care & Safety Section 2
3-1 General Safety 3-1

! WARNING
Manual. You and others can be injured if you maintain the
machine without first studying this Manual. Read the safety
instructions before maintaining the machine. If you do not
understand anything, ask your supervisor or JCB Distributor to
explain it. Keep this Manual clean and in good condition.
GEN 10-1

! WARNING
Clothing. You can be injured if you do not wear the proper
clothing. Loose clothing can get caught in the machinery.
Wear protective clothing to suit the job. Examples of protective
clothing are: a hard hat, safety shoes, safety glasses, a well
fitting overall, ear protectors and industrial gloves. Keep cuffs
fastened. Do not wear a necktie or scarf. Keep long hair
restrained.
INT-1-3-6

! WARNING
Care and Alertness. All the time you are working with or on
the machine, take care and stay alert. Always be careful.
Always be alert for hazards.
INT-1-3-5

! WARNING
Fires. If your machine is equipped with a fire extinguisher,
make sure it is checked regularly. Keep it in the correct
machine location until you need to use it.

Do not use water to put out a machine fire, you could spread
an oil fire or get a shock from an electrical fire. Use carbon
dioxide, dry chemical or foam extinguishers. Contact your
nearest fire department as quickly as possible. Firefighters
should use self-contained breathing apparatus.
INT-3-2-7/1

! WARNING
Alcohol and Drugs. It is extremely dangerous to operate
machinery when under the influence of alcohol or drugs. Do
not consume alcoholic drinks or take drugs before or whilst
operating the machine or attachments. Be aware of medicines
which can cause drowsiness.
INT-1-3-9

! CAUTION
Regulations. Obey all laws, work site and local regulations
which affect you and your machine.
INT-1-3-3

9803/3400 Issue 1
Section 2 Care & Safety Section 2
4-1 Operating Safety 4-1

! WARNING
Decals. You can be injured if you do not obey the decal safety
instructions. Keep decals clean. Replace unreadable or
missing decals with new ones before operating the machine.
Make sure replacement parts include warning decals where
necessary.
INT-1-3-4
! WARNING
Machine Condition. A defective machine can injure you or
others. Do not operate a machine which is defective or has
missing parts. Make sure the maintenance procedures in this
Manual are completed before using the machine.
INT-2-1-2
! WARNING
Practice. You or others can be killed or seriously injured if you
do unfamiliar operations without first practising them. Practice
away from the work site on a clear area. Keep other people
away. Do not perform new operations until you are sure you
can do them safely.
INT-2-1-1
! DANGER
The Teletruk is installed with a Roll Over Protection Structure
(ROPS) to ISO 3471 1994, and an Over Head Guard (OHG)
to ISO 6055 1979. You could be killed or seriously injured if
you operate this machine with a damaged or missing
ROPS/OHG. If the ROPS/OHG has been in an accident, do
not use the machine until the structure has been renewed.
Modifications and repairs that are not approved by the
manufacturer may be dangerous and will invalidate the
ROPS/OHG certification.
12-5-1-2
! WARNING
Training. Operators and Service Staff should be trained in the
Safety Guidelines for the normal use of Telescopic Lift Trucks.
12-1-1-5

! WARNING
Seat Belts. The operator’s enclosure is designed to give you
protection in an accident. If you do not wear your seat belt,
you could be thrown out of the machine and crushed. You
must wear a seat belt when using the machine. Fasten the
seat belt before starting the engine.
12-1-1-4

! WARNING
Controls. You or others can be killed or seriously injured if
you operate the control levers from outside the cab. Operate
the control levers only when you are correctly seated inside
the cab.
INT-2-1-3

! WARNING
Visibility. Accidents can be caused by working in poor
visibility. Keep windows clean and use your lights to improve
visibility. Do not operate the machine if you cannot see
properly.
INT-2-1-11

! WARNING
Passengers. Passengers in or on the machine can cause
accidents. The Teletruk is a one man machine. Do not carry
passengers.
INT-2-2-2

9803/3400 Issue 1
Section 2 Care & Safety Section 2
5-1 Maintenance Safety 5-1

! WARNING Kinked or crushed hoses

Raised Attachments. Raised attachments can fall and injure
you. Do not walk or work under raised attachments unless
they are safely blocked.
INT-1-3-8
! WARNING
Raised Machine. NEVER position yourself or any part of you
body under a raised machine which is not properly supported.
If the machine moves unexpectedly you could become
trapped and suffer serious injury or be killed.
INT-3-3-7/1
! WARNING
Soft Ground. A machine can sink into soft ground. Never
work under a machine on soft ground.
INT-3-2-4
! WARNING
Lifting Equipment. You can be injured if you use faulty lifting
equipment. Make sure that lifting equipment is in good
condition. Make sure that lifting tackle complies with all local
regulations and is suitable for the job. Make sure that lifting
equipment is strong enough for the job.
INT-1-3-7
! WARNING
Repairs. Do not try to do repairs or any other type of
maintenance work you do not understand. JCB Distributor
Engineers have been trained in all aspects of the Teletruk.
12-1-1-1
Embedded armouring in outer covers
Displaced end fittings.
INT-3-3-2
! WARNING
Metal Splinters. You can be injured by flying metal splinters
when driving pins in or out. Use a soft faced hammer or drift
to remove and fit metal pins. Always wear safety glasses.
INT-3-1-3
! WARNING
Electrical Circuits. Understand the electrical circuit before
connecting or disconnecting an electrical component. A wrong
connection can cause injury and/or damage.
INT-3-1-4
Do not disconnect the battery while the engine is running
otherwise the electrical circuits may be damaged.
INT-3-1-14
! WARNING
Communications. Bad communications can cause
accidents. If two or more people are working on the machine,
make sure each is aware of what the others are doing. Before
starting the engine make sure the others are clear of the
danger areas; examples of danger areas are: the rotating
blades and belt on the engine, the attachments and linkages,
and anywhere beneath or behind the machine. People can be
killed or injured if these precautions are not taken.
INT-3-1-5

! WARNING ! CAUTION
‘O’ rings, Seals and Gaskets. Badly fitted, damaged or
Modifications and Welding. Non-approved modifications
rotted ‘O’ rings, seals and gaskets can cause leakages and
can cause injury and damage. Parts of the machine are made
possible accidents. Renew whenever disturbed, unless
from cast iron; welds on cast iron can weaken the structure
otherwise instructed. Do not use Trichloroethane or paint
and break. Do not weld cast iron. Contact you JCB Distributor
thinners near ‘O’ rings and seals.
for advice before modifying the machine. INT-3-2-12
INT-3-1-2/1

! WARNING ! CAUTION
Cleaning. Cleaning metal parts with incorrect solvents can
Hydraulic Fluid. Fine jets of hydraulic fluid at high pressure
cause corrosion. Use only recommended cleaning agents and
can penetrate the skin. Do not use your fingers to check for
solvents.
hydraulic fluid leaks. Do not put you face close to suspected INT-3-2-11
leaks. Hold a piece of cardboard close to suspected leaks and
then inspect the cardboard for signs of hydraulic fluid. If
hydraulic fluid penetrates your skin, get medical help
! CAUTION
immediately. Machine Modifications. This machine is manufactured in
INT-3-1-10/1 compliance with legislative and other requirements. It should
not be altered in any way which could affect or invalidate any
! WARNING of the requirements. For advice consult your JCB Distributor.
I2-1-1-3
Hydraulic Pressure. Hydraulic fluid at pressure can injure
you. Make the machine safe before connecting or
disconnecting couplings; lower the payload to the ground,
stop the engine then operate the hydraulic controls a few
times to vent residual hydraulic pressure from the system.
12-1-1-2

! WARNING
Hydraulic Hoses. Damaged hoses can cause fatal accidents.
Inspect the hoses regularly for:
Damaged end fittings
Chafed outer covers
Ballooned outer covers

9803/3400 Issue 1
Section 2 Care & Safety Section 2
5-2 5-2

! CAUTION
Arc Welding. Before carrying out arc welding on the machine,
disconnect the battery and alternator to protect the circuits
and components.

The battery must still be disconnected even if a battery isolator

is fitted.

Make sure that the welding earth return path is kept as short
as possible. This prevents high currents being induced in the
machine chassis or wiring harnesses.

If the machine is equipped with electronic control units

(E.C.U.s), then disconnect them before welding. Failure to
disconnect the E.C.U.s could result in irreparable damage to
the electronic components.
INT-3-1-15

9803/3400 Issue 1
This page intentionally left blank
Section 3 Routine Maintenance Section 3
i i

Contents Page No.

Fluids, Capacities and Lubricants 1-1

Lubricants
Health and Safety 1-2

Service Schedules 2-1

Operator’s Enclosure and Seat Belt 3-1

* Cleaning the Machine 3-2

Greasing 4-1

Electrics
Battery Safety 5-1
Checking the Electrolyte Level 5-2
Checking the Battery Terminals 5-2
Warning Symbols 5-2

Hydraulic System
Checking the Fluid Level 6-1
Checking for Leaks 6-1
Checking the Hoses and Pipework 6-1
Filter - Removal and Replacement 6-2

Air Filter
Changing the Elements 7-1

Cooling System
Coolant Mixture 8-1
* Checking the Coolant Level - Diesel Engine 8-2

Engine Oil
Checking the Oil Level (Diesel) 9-1
Changing the Oil and Filter (Diesel) 9-2

Fuel System - Diesel

Types of Fuel 10 - 1
Filling the Tank 10 - 1
Draining the Sedimenter 10 - 2
Bleeding the Diesel Fuel System (if required) 10 - 3

Fuel System - LPG

General 11 - 1
Type of LPG 11 - 1
Filling the LPG Tank 11 - 2

Fan Belt (Diesel and LPG Engine

Checking the Fan Belt Tension 12 - 1

Transmission
Steer Spindle (4x4 Option Only) 13 - 1

9803/3400 Issue 6*
 Section 3 Routine Maintenance Section 3
1-1 1-1

Fluids, Capacities and Lubricants

ITEM CAPACITY FLUID/LUBRICANT SPECIFICATION

Engine Oil
NAT ASP
Up to SN892816 8.2 litres JCB 10W/30 Multigrade SAE10W/30
*
API CF4/SG

From SN892817 10 litres JCB Extreme Performance CH4/SJ (ACES E5-B3-A3)

Engine Oil 15W/40

Turbo 10 litres JCB Extreme Performance CH4/SJ (ACES E5-B3-A3)

Engine Oil 15W/40

LPG 8.2 litres JCB 10W/30 Multigrade SAE10W/30

API CF4/SG

Hydraulic System 55 litres JCB 15W/40 Multigrade API CF4/SG 15W/40

JCB 10W/30 Multigrade API CF4/SG 10W/30

Cooling System 5.5 litres Antifreeze JCB Universal Antifreeze/water ASTM D3306-74
11 litres total coolant (see Coolant Mixtures)
mixture

Fuel System 90 litres Diesel oil (see Types of Fuel) ASTM D975-66T Nos. 1D, 2D
Liquid Petroleum Gas (LPG)
(see LPG Fuel System)

Grease Points - JCB Special HP or MPL Grease Lithium based, No. 2 consistency

Boom Runways - Waxoyl -

9803/3400 Issue 8*
Section 3 Routine Maintenance
1-2
It is most important that you read and understand this information and the publications referred to. Make sure that all
of your colleagues who are concerned with lubricants read it too.
Lubricants - Health and Safety
Hygiene
JCB lubricants are not a health risk when used properly for
their intended purposes.
However, excessive or prolonged skin contact can remove
the natural fats from your skin, causing dryness and
irritation.
Low viscosity oils are more likely to do this, therefore
particular care is necessary in handling used oils which can
be diluted with fuel contamination.
Whenever you are handling oil products you should maintain
good standards of care and personal and plant hygiene. For
details of these precautions we advise you to read the
relevant publications issued by your local health authority,
and note the following:
Storage
Always keep lubricants out of the reach of children.
Never store lubricants in open or unlabelled containers.
Waste Disposal
All waste products should be disposed of in accordance with
all the relevant regulations.
The collection and disposal of used engine oil should be in
accordance with any local regulations. Never pour used
engine oil into sewers, drains or on the ground.
Handling
New Oil
There are no special precautions needed for the handling or
use of new oil, beside normal care and hygiene practices.
Used Oil
Used engine crankcase lubricants contain harmful
contaminants. In laboratory tests it was shown that used
engine oils can cause skin cancer.
Here are precautions to protect your health when handling
used engine oil:
1 Avoid prolonged, excessive or repeated skin contact
with used engine oils.
2 Apply a barrier cream to the skin before handling used
engine oil.
9803/3400
Section 3
1-2
3 Note the following when removing engine oil from skin:
a Wash your skin thoroughly with soap and water.
b Using a nail brush will help.
c Use special hand cleansers to help clean dirty
hands.
d Never use petrol, diesel fuel or paraffin for washing.
e Avoid skin contact with oil soaked clothing.
f Don't keep oily rags in pockets.
g Wash dirty clothing before re-use.
h Throw away oil-soaked shoes.
First Aid - Oil
Swallowing.
If oil is swallowed you should not induce vomiting. Get
medical advice.
Skin
In the case of excessive skin contact you should wash with
soap and water.
Eyes
In the case of eye contact, flush with water for 15 minutes. If
irritation persists, get medical attention.
Spillage
Absorb on sand or a locally approved brand of absorbent
granules. Scrape up and remove to a chemical disposal
area.
Fires
Extinguish with carbon dioxide, dry chemical or foam.
Firefighters should use self contained breathing apparatus.
! WARNING
Do not use water to put out an oil fire. This will only
spread it because oil floats on water.
Extinguish oil and lubricant fires with carbon dioxide, dry
chemical or foam. Fire fighters should use self contained
breathing apparatus.
7-3-1-3/1
Issue 2
 Section 3 Routine Maintenance Section 3
2-1 Service Schedules 2-1

A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular
maintenance and lubrication jobs listed in the schedules are done to keep the machine in a safe and efficient working
condition.

The schedules are based on machine running hours. Keep a regular check on the hourmeter readings. Do not use a machine
which is due for a service. Make sure any defects found during the regular maintenance checks are rectified immediately.

z = Initial 250 Hour Check Only „ = Regular Maintenance Check

Pre-start Cold Checks Operation 250 500 1000 2000
Service Points and Fluid Levels Hr Hr Hr Hr

ENGINE (LPG and Diesel)

Oil and Filter (see note) - Change z „ „ „
Air Cleaner Dust Valve - Clean „ „ „
Air Cleaner Outer Element - Change „ „ „
Air Cleaner Inner Element - Change „
Fuel Filter (Diesel only) - Change z „ „ „
Coolant Level - Check z „ „ „
Antifreeze Strength - Check z „ „ „
Air Cleaner Hose - Security z „ „ „
Fuel Sedimenter (Diesel only) - Drain z „ „ „
Fan Belt Tension/Condition - Check z „ „ „
Valve Clearances (Diesel only) - Check and Adjust „ „
Engine Mount Security - Check z „
Radiator Matrix - Clean z „ „ „
Radiator Hose - Condition z „ „ „
Spark Plugs (LPG only) - Clean/Replace „ „ „
Clean turbo charger impeller casing and turbo charger
compressor casing „ „ „
Fit new engine breather (HR build only) „ „

Note: If operating under arduous conditions change the engine oil filter every 250 hours

TRANSMISSION AND AXLES

Wheel Nuts Security - Check z „ „ „
Tyre Pressures and Condition - Check z „ „ „
Rear Wheel Hub Bearings and Pins - Check „ „
Steer Linkage for Wear - Check „ „ „
Steer Spindle (4 Wheel Drive Option Only) - Check „ „

HYDRAULICS
Suction Strainer Oil Sample/Change - Clean „
Oil Level - Check z „ „ „
Oil Filter - Change z „ „ „
Ram Piston Rods for Damage or Leakage - Check z „ „ „
Hoses & Pipework - Damage or Leaks - Check z „ „ „
Motor Mounting Bolts Security - Check z „ „
Hydraulic Oil - Change „

ELECTRICS
Wiring for Chafing - Check z „ „ „
Battery Terminals for Condition and Tightness - Check z „ „ „

BODY AND FRAMEWORK

All Pivot Pins - Check and Grease z „ „ „
All Hinges - Grease z „ „ „
* Wear Pad Runways - Waxoyl z „ „ „
Seat/Seat Belt Security and Condition - Check z „ „ „
Bodywork for Damage - Check z „ „ „
* Windscreen Washer Fluid Level - Fill z „ „ „
Check boom rear wear pad mounting bolts for tightness (56Nm, 41lbf ft) z „ „ „

9803/3400 Issue 5*
 Section 3 Routine Maintenance Section 3
2-2 Service Schedules 2-2

Pre-start Cold Checks Operation 250 500 1000 2000

Service Points and Fluid Levels Hr Hr Hr Hr

PAINTWORK
Condition - Check „ „ „

Functional Test Operation 250 500 1000 2000

and Final Inspection Hr Hr Hr Hr

ENGINE
Idle Speed - Check and Adjust z „ „ „
Maximum No Load Speed - Check and Adjust z „ „ „
Exhaust Smoke - Check z „ „ „
Engine for Vibration/Noise - Check z „ „ „
Fuel System For Leaks (LPG only) - Check „ „ „ „
Fuel System - Fuel Lock, Vapourisor Carburettor (LPG only) - Check „ „

TRANSMISSION AND AXLES

Transmission for Vibration/Noise - Check z „ „ „
Transmission Pressures - Check „ „ „

HYDRAULICS
Operation of All Services - Check z „ „ „
Operation of Carriage Tilt/Crowd and Self Level - Check „ „ „
MRV Pressure - Check and Adjust „ „ „
* Steer Circuit Pressure - Check and Adjust „ „ „
Steer Circuit Operation - Check z „ „ „
Hoses for Damage and Leaks - Check z „ „ „
Pipework for Damage and Leaks - Check z „ „ „

BRAKES
Parking Brake Operation - Check z „ „ „
Foot Brake Operation - Check z „ „ „

ELECTRICS
* All Electrical Equipment Operation - Check z „ „ „
Load Moment Indicator - Check/Calibrate z „ „ „

ATTACHMENTS
Attachment Operation - Check „ „ „
Forks Condition/Security - Check z „ „ „
Correct Load Chart For Attachment Fitted - Check z „ „ „

GENERAL
Fluid Leaks (e.g. coolant, engine, oil, fuel, hydraulic oil, etc.) - Check z „ „ „

9803/3400 Issue 6*
Section 3 Routine Maintenance Section 3
3-1 Operator’s Enclosure and Seat Belt 3-1

Checking the Operator’s Enclosure

Carry out a thorough inspection of the operators enclosure.
If any damage is discovered, contact your JCB distributor.

! DANGER
The Teletruk is installed with a Roll Over Protection
Structure (ROPS) to ISO 3471 1994, and an Over Head
Guard (OHG) to ISO 6055 1979. You could be killed or
seriously injured if you operate this machine with a
damaged or missing ROPS/OHG. If the ROPS/OHG has
been in an accident, do not use the machine until the
structure has been renewed. Modifications and repairs
that are not approved by the manufacturer may be
dangerous and will invalidate the ROPS/OHG
certification.
12-5-1-2

Checking Seat Belt Condition and Security

When checking the seat belt, look for signs of fraying and
stretching. Make sure the stitching is not loose or damaged.
Make sure the buckle assembly is working correctly and not
damaged. Install a new belt every three years.

Make sure the belt mounting bolts are undamaged, correctly

installed and fully tightened.

! WARNING
Replace the seat belt with a new one if it is damaged, if
the fabric is worn, or if the machine has been in an
accident. Install a new seat belt every three years
regardless of condition.
2-3-1-8

9803/3400 Issue 2 *
Section 3 Routine Maintenance Section 3
3-2 Cleaning the Machine 3-2

Park the machine on firm level ground, engage the parking

brake, lower the boom to the ground, switch OFF the engine
and remove the starter key. Allow the engine and exhaust
system to cool.

Clean the machine using water and/or steam. Avoid using

neat detergent - always dilute detergents as per the
manufacturer’s recommendations, otherwise damage to the
paint finish may occur. Always grease the machine after
pressure washing or steam cleaning.

Always adhere to local regulations regarding the disposal of

debris created from machine cleaning.

Make sure there are no unprotected electrical wires before

proceeding.
3.5D 2 wheel drive and 3.0D HL machines
Note: Excessive power washing can damage seals and
bearings. Do not direct high power water jets directly at oil
seals or universal joints.

Do not steam clean or power wash inside the cab. Take care
when cleaning electrical components and connectors.

Pay particular attention to the following:

1 Remove debris and loose articles from inside the cab.

2 If the radiator tubes/fins get clogged the radiator will be

less efficient.

Brush off all debris from the cooler tubes and fins using
a soft bristle brush. Make sure the loosened material is
brushed out of the cooler enclosure.

3.5D and 3.0D HL machines, open the engine cover

and undo the bolts A and remove the panel B to clean
engine side od radiator. To clean rear side of radiator
gain access through the counter weight opening.

3 Debris can collect under the boom. Remove especially

all combustible material.

4 Do not allow debris to accumulate around the engine,

pay particular attention to the exhaust area, remove all
combustible material.

5 Throughly dry piston rams and protect with clean

transmission or hydraulic oil if necessary.

9803/3400 Issue 2*
This page intentionally left blank
Section 3 Routine Maintenance Section 3
4-1 Greasing 4-1

General
The Teletruk must be greased regularly to keep it working
efficiently. Regular greasing will also increase the machine’s
working life.
Grease of the correct specification should be applied with a
grease gun (except for the boom pads runway, which should
have Waxoyl applied along its length). Stop greasing when
fresh grease appears at the joint. Use JCB High Pressure
(HP) grease for improved machine reliability.
*
Location of Greasing Points
For the purposes of greasing, the Teletruk is split into five
separate sections:
Carriage
The six grease points on the carriage are as follows:
A Right Carriage Pivot.
B Right Carriage Ram Upper Pivot.
C Right Carriage Ram Lower Pivot.
D Left Carriage Pivot.
E Left Carriage Ram Lower Pivot.
F Left Carriage Ram Upper Pivot.
F B

A Carriage.
B Boom.
C Rear steer axle.
D Sideshift.
E Boom pads runway.

Note: Refer to the following figures for the location of

each individual grease point.

Greasing Procedure C
D E
C054860
1 Park the Teletruk on firm level ground.

! WARNING Boom
After raising or extending the boom, ensure that chocks
or suitable supports are used to prevent it from falling. Remove the rear boom cover. The six grease nipples and
12-5-1-3 Waxoyl points on the boom are as follows:
2 Raise and extend the boom. A Right Boom Pivot.
B Left Boom Pivot.
3 Apply the park brake. C Boom Pads Runway (Waxoyl).
D Raise/Lower Ram Lower Pivot.
4 Stop the engine and remove the ignition key. E Raise/Lower Ram Upper Pivot.
F Compensation Ram Upper Pivot.
5 Remove the dust caps.

6 Apply grease to the grease points and apply Waxoyl as

detailed in the relevant Servicing Schedule.

7 Count off each greasing point in turn until all greasing

points have been lubricated.

8 Replace the dust caps as required.

G Compensation Ram Lower Pivot.

9803/3400 Issue 4*
Section 3 Routine Maintenance Section 3
4-2 Greasing 4-2

Rear Axle Sideshift (Optional)

2 Wheel Drive Machines The two grease points on the sideshift mechanism (if fitted)
are as follows:
The six grease points on the rear axle are as follows:
E Top Rail Right Side.
A Left Stub Shaft (Every 500 Hrs only). F Top Rail Left Side.
B Left Steering Link Outer Pivot.
C Left Steering Link Inner Pivot. Apply a smear of grease to the Bottom Rail G.
D Right Steering Link Inner Pivot.
E Right Steering Link Outer Pivot.
F Right Stub Shaft (Every 500 Hrs only).

A401730-V3

4x4 Machines

The eight grease points on the rear axle are as follows:

A Stub Shaft (left and right).

B Steering Link Outer Pivot (left and right).
C Steering Link Inner Pivot (left and right).
D Swivel trunnion bearings (left and right).

B
C

D
* 804080
*

3.0D 4x4 3.5D 4x4

9803/3400 Issue 3*
Section 3 Routine Maintenance Section 3
5-1 Electrics 5-1

Safety
! WARNING
Batteries give off an explosive gas. Do not smoke when
handling or working on the battery. Keep the battery
away from sparks or flame.
Battery electrolyte contains sulphuric acid. It can burn
you if it touches your skin or eyes. Wear safety glasses
and suitable clothing. Handle the battery carefully to
prevent spillage. Keep metallic items (watches, rings,
zips etc) away from the battery terminals. Such items
could short the terminals and burn you.
Set all switches in the cab to OFF before disconnecting
and connecting the battery. When disconnecting the
battery, take off the earth (-) lead first. When
reconnecting, install the positive (+) lead first.
Re-charge the battery away from the machine, in a well
ventilated area. Switch the charging circuit off before
connecting or disconnecting the battery. When you have
installed the battery in the machine, wait five minutes
before connecting it up.

! WARNING
Battery. A battery with a frozen electrolyte can explode if
it is used or charged. Do not use a machine with a frozen
battery. To help prevent the battery from freezing, keep
the battery fully charged.
INT-3-1-7

! WARNING
Electrolyte. Battery electrolyte is toxic and corrosive. Do
not breathe the gasses given off by the battery. Keep the
electrolyte away from clothes, skin, mouth and eyes.
Wear safety glasses.
INT-3-2-1/2

! CAUTION
Damaged or spent batteries and any residue from fires or
spillages should be put in a closed acid proof receptacle
and must be disposed of in accordance with local
environmental waste regulations.
INT-3-1-12

First Aid - Electrolyte

Do the following if electrolyte:

Gets in your eyes: Immediately flush with tepid water for 15

minutes, always get medical attention.

Is swallowed: Do not induce vomiting. Drink large quantities

of water or milk. Then drink milk of magnesia, beaten egg or
vegetable oil. Get medical advise.

Gets onto your skin: Flush with water, remove affected

clothing. Cover burns with a sterile dressing then get medical
help.

9803/3400 Issue 1
Section 3 Routine Maintenance Section 3
5-2 Electrics 5-2

Checking the Electrolyte Level

Maintenance free batteries used in normal temperate climate
applications should not need topping up. However, in certain
conditions (such as prolonged operation at tropical
temperatures or if the alternator overcharges) the electrolyte
level should be checked as described below.

1 Park the machine on firm level ground and lower the

boom.
2 Apply the park brake. 6 mm
3 Stop the engine and remove the ignition key.
4 Switch the battery isolator to off and remove the key.
5 Remove the battery cell cover(s) A.
6 Make sure the level in each cell is 6 mm (0.25 in.) above
the plates.
7 If necessary, top up with distilled water.
8 Refit the battery cell cover(s).
9 Insert the key and switch the battery isolator to on.

! WARNING * A089660-1

Do not top up the battery with acid. The electrolyte could

boil over and burn you.
2-3-4-6

Checking the Battery Terminals Warning Symbols

1 Park the Teletruk on firm level ground and lower the
boom. The following warning symbols may be found on the battery.

2 Apply the park brake and select neutral. Symbol Meaning

3 Stop the engine and remove the ignition key.

Keep away from children.
4 Switch the battery isolator to off and remove the key.

5 Open the daily inspection cover (Refer to Refer to Section

B). Shield eyes.

6 Disconnect each battery terminal in turn and thoroughly

clean the terminal and clamp.
No smoking, no naked flames,
7 Refit the battery terminals and fully tighten. no sparks.

8 Protect the terminals and clamps with petroleum jelly to

prevent corrosion.
Explosive Gas.
9 Close the daily inspection cover.

10 Insert the key and switch the battery isolator to on.

Battery acid.

Note operating instructions.

9803/3400 Issue 4*
 Section 3 Routine Maintenance Section 3
5-3 Electrics 5-3

Battery Isolator
To disconnect the battery from the machine electrics a
battery isolator has been fitted.

* Note: On some machines the isolator is fitted in the

counterweight.

! CAUTION
Except in an emergency, do not use the battery isolator to
switch OFF the engine. Failure to comply may result in
damage to the electrical circuits.
INT-3-2-13
B C
At the end of a working cycle or if the machine is being left
unattended, provided the lights are not required, the battery
must be isolated. Before attempting to start the engine or use
the machine electrics the battery isolator key must be fitted A
and switched on.

1 To isolate the battery turn the battery isolator key A in an

counter-clockwise direction B and remove. Keep the
key in a safe place and available for when the machine
is next required. 324690

2 To connect the battery insert the key A and turn in a

clockwise direction C.

! CAUTION
Arc Welding. Before carrying out arc welding on the *
machine, disconnect the battery and alternator to protect
the circuits and components.

The battery must still be disconnected even if a battery

isolator is fitted.

Make sure that the welding earth return path is kept as

short as possible. This prevents high currents being
induced in the machine chassis or wiring harnesses.

If the machine is equipped with electronic control units

(E.C.U.s), then disconnect them before welding. Failure to C053610
disconnect the E.C.U.s could result in irreparable damage
to the electronic components.
INT-3-1-15

9803/3400 Issue 4*
This page intentionally left blank
Section 3 Routine Maintenance Section 3
6-1 Hydraulic System 6-1

Checking the Oil Level

1 Park the Teletruk on firm level ground and lower the *
boom.
2 Apply the park brake and select neutral.
3 Stop the engine and remove the ignition key.
4 Check the level at the sight gauge A. If necessary, top up
with the correct hydraulic oil through filler B (Refer to
Fluids, Capacities and Lubricants). B
! CAUTION
If the fluid is cloudy, then water or air has contaminated
the system. This could damage the hydraulic pump.
Contact your Distributor immediately.
U/12-5-1-4
A

Checking for Leaks C053630

! WARNING
Fine jets of hydraulic oil at high pressure can penetrate
the skin. Do not use your fingers to check for oil leaks. Do
not put your face close to suspected leaks. Hold a piece
of cardboard close to suspected leaks and then inspect
the cardboard for signs of hydraulic oil. If hydraulic oil
penetrates your skin, get medical help immediately.
INT-3-1-10/1

If pools of oil appear below or on the machine, find the cause

of the leak as follows:

1 Thoroughly clean and dry the area.

2 Start the engine and operate the relevant system a few
times to locate the leak. Inspect the area to find the cause
of the leak. If necessary, hold cardboard next to the
suspected component to help identify the location.
3 Stop the engine and dissipate the hydraulic pressure from
the system by operating the controls a few times.
4 Rectify the leak as required.

Notice: If necessary, report the fault to your JCB Distributor

for assistance in carrying out the repair.

Checking the Hoses and Pipework

! WARNING
After raising or extending the boom, ensure that blocks
or suitable supports are used to prevent it from falling.
12-5-1-3

1 Tilt the cab forward or position the boom or steering as

required to gain access to each hose or pipe.

2 Inspect each hose in turn. Make sure they are free from
cuts, signs of leakage, bulging, fraying or any other
damage.

3 Inspect each pipe in turn. Make sure they are free from
cracks, signs of leakage, corrosion or any other damage.

4 Position the boom in its retracted and lowered position.

5 Apply the park brake and stop the engine. Remove the
ignition key.

9803/3400 Issue 2*
 Section 3 Routine Maintenance Section 3
6-2 Hydraulic System 6-2

Filter - Removal and Replacement

Removal
! WARNING
Make the machine safe before getting beneath it. Park
the machine on level ground. Make sure the engine is
stopped, the parking brake engaged and the
transmission is in neutral. Disconnect the battery. Chock
both sides of all four wheels.
5-3-2-1/1
Replacement
1 Ensure the filter head B is clean.
2 Using clean hydraulic oil, fill the new filter canister
(allowing time for the oil to pass through the filter
element) and lubricate seal C. (Seal C is not shown but is
located between the canister A and the head B.)

1 Extend and lower boom to its lowest position.
2 Make the machine safe by stopping the engine, removing
the key, and chocking the wheels.
3 Open front cover (Refer to Access Procedures for
Maintenance, Section B)
! WARNING
Hydraulic Pressure
It is not possible to vent all residual pressure. Loosen the
connection one full turn and allow the pressure to
dissipate. Keep face and hands well clear of pressurized
hydraulic oil and wear protective glasses.
3 Install the new filter canister hand tight only, and ensure
it is clean and dry.
4 Start the machine and operate the boom controls to
pressurize the system. Ensure the boom is left fully
extended with the carriage on the ground.
5 Stop the engine and remove the ignition key.
6 Inspect the filter canister for leaks.
7 Check the hydraulic oil level and top up if necessary.
8 Refit the front cover (Refer to Section B).

4 Ensure that all hydraulic pressure is released from the

system (By operating the lift lever).

5 Remove the old canister A, using a chain wrench if

necessary.

C
A

9803/3400 Issue 2*
 Section 3 Routine Maintenance Section 3
7-1 Air Filter 7-1

Changing the Elements

! CAUTION
The outer element must be replaced with a new one
immediately if the warning light on the instrument panel
illuminates.
U-2-3-3-1
Notice: Do not attempt to wash or clean the elements - they
must only be renewed.
Do not run the engine with the dust valve J removed.
A new inner element must be fitted at least every third time
the outer element is changed. As a reminder, mark the inner
element with a felt tipped pen each time the outer element is
changed.
1 Stop the engine.
2 Open the daily inspection cover (Refer to Section B).
3 Depress clips B and lift off cover C. Remove outer
element D. Take care not to tap or knock the element. If
the inner element is to be changed, lift up pulls E and
remove inner element F.
4 Clean inside the canister H, cover C and dust valve J.
5 Insert the new elements into the canister, pushing them
firmly in so that seals G and K are fully seated. Fit cover
C with dust valve J at the bottom. Push the cover firmly
into position and make sure it is secured by clips B.
6 Make sure that the wire is connected to the Air Filter
Blocked switch.

9803/3400 Issue 3*
Section 3 Routine Maintenance Section 3
8-1 Cooling System 8-1

Coolant Mixtures
*To prevent the coolant freezing in cold conditions, antifreeze
must be added. The protection provided by JCB Universal
Antifreeze is shown below.

Solution Maintains circulation Protects against

down to damage down to
deg C deg F deg C deg F
50% -33 -27 -45 -49

Never use less than 45% antifreeze solution otherwise there

will not be enough corrosion protection.

Never use more than 50% antifreeze solution otherwise the

cooling system may be damaged.

Leave the antifreeze in all the year round as it gives protection

against corrosion.

Check the strength of antifreeze solution at least once a year,

preferably at the start of the cold period. Always renew the
antifreeze every two years.

A 50% antifreeze solution should be used even if frost

protection is not needed. This gives protection against
corrosion and raises the coolant's boiling point.

! WARNING
Antifreeze can be harmful. Obey the manufacturer's
instructions when handling neat or diluted antifreeze.
7-3-4-4
! WARNING
The cooling system is pressurized when the coolant is
hot. Hot coolant will burn you. Make sure the engine is
cool before checking the coolant level or draining the
system.
2-3-3-3

9803/3400 Issue 3*
 Section 3 Routine Maintenance Section 3
8-2 Cooling System 8-2

Checking the Coolant Level

! WARNING
A
The cooling system is pressurized when the coolant is hot.
Hot coolant will burn. Make sure the engine is switched off
and sufficiently cooled before checking the coolant level
or draining the system.
INT-2-3-3-3
! CAUTION
Antifreeze can be harmful. Obey the manufacturer’s
instructions when handling neat or diluted antifreeze.
7-3-4-4

1 Park the Teletruk on firm level ground and lower the boom.

2 Apply the park brake and select neutral.

B
3 Stop the engine and remove the ignition key. Let the
engine cool down before proceeding.

4 a All 2.0/2.5/3.0 Machines and 3.5D 4x4 281340

Open the daily inspection cover (Refer to Access
Procedures for Maintenance). All 2.0/2.5/3.0 Machines
* b All 3.5 Machines (Except 3.5D 4x4) and 3.0D HL
Open the rear daily inspection cover (Refer to Access
Procedures for Maintenance).

5 Check that the coolant level is within the High and Low
marks on the expansion tank B.

6 If necessary, top up the system with a suitable mixture as

follows:

a Top up the expansion tank through filler cap A.

b Refit the filler cap A and make sure it is tight.
c Close the daily inspection cover.
d Run the engine for a few minutes to raise the coolant to
working temperature and pressure. Stop the engine
and top up the system again if required.
e Check for leaks.

All 3.5 Machines (Except 3.5D 4x4) and 3.0D HL 760220-V1

3.5D 4x4 Machines

9803/3400 Issue 4*
Section 3 Routine Maintenance Section 3
9-2 Engine Oil 9-2

Changing the Oil and Filter

! WARNING
Hot oil and engine components can burn. Make sure the
engine is turned off and sufficiently cooled before
attempting this job. B
INT-2-3-3-2

1 Park the Teletruk on firm level ground and lower the A

boom.

*2 Machines with LPG engines, turn the fuel valve OFF and
run the engine until it stalls.

3 Apply the park brake and select neutral.

4 Stop the engine and remove the ignition key.

5 Open the daily inspection cover (Refer to Section B).

6 Place a suitable container under the machine to catch the

oil.

7 Remove the drain plug and allow oil to drain into

E
container.
G
8 After emptying the sump replace the drain plug.
327530
9 Unscrew the filter canister E, using a chain wrench if
necessary. Remember that it will contain some oil.

10 Clean filter head on the engine.

11 Add clean engine oil to the new filter canister. Allow time
for the oil to pass through the filter element.

12 Smear the seal G on the new filter canister with clean

engine oil.

13 Screw in the new filter canister - hand tight only.

14 Fill the engine with the recommended oil, to the MAX

mark on the dipstick A, through the filler point B. Wipe off
any spilt oil, refit the filler cap and make sure it is secure.

15 Make sure the engine will not start by removing the

engine shut-off solenoid (ESOS) fuse, diesel engine
machines only. Turn the engine using the starter key until
the oil pressure warning light is extinguished.

16 Refit the engine shut-off solenoid fuse, diesel engine

machines only. LPG engines, slowly open the fuel valve.
Start the engine and check for leaks. When the engine
has cooled, check the oil level and, if necessary, top up
with clean engine oil.

17 Close and secure the engine compartment rear door and

hinged top cover.

9803/3400 Issue 2*
Section 3 Routine Maintenance Section 3
10 - 1 Fuel System - Diesel 10 - 1

*Types of Fuel Low Temperature Fuels

Use good quality diesel fuel to get the correct power and Special winter fuels may be available for engine operation at
performance from your engine. The recommended fuel temperatures below 0 °C (32 °F). These fuels have a lower
specification for JCB engines is given below. viscosity. They also limit wax formation in the fuel at low
temperatures. (Wax forming in the fuel can stop the fuel
Cetane Number: 45 (minimum) flowing through the filter).
Viscosity: 2.5/4.5 Centistokes at 40 °C (104 °F)
Density: 0.835/0.855 kg/litre Flow improvers may also be available. These can be added
(0.872/0.904 lb/pint) to the fuel to reduce wax formation.
Sulphur: 0.5% of mass (maximum)
Distillation: 85% at 350 °C (662 °F)
Petrol
Cetane Number ! WARNING
Do not use petrol in this engine. Do not mix petrol with
Indicates ignition performance. Fuel with a low cetane the diesel fuel. In storage tanks the petrol could rise to
number can cause cold start problems and affect the top and form flammable vapors.
combustion. INT-3-1-6

Viscosity
Is the resistance to flow. If this is outside limits, the engine
performance can be affected.
Density
Lower density will reduce engine power. Higher density will
increase both engine power and exhaust smoke.
Filling the Tank
! WARNING
Diesel fuel is flammable; keep naked flames away from
the machine. Do not smoke while refueling the machine
or working on the engine. Do not refuel with the engine
running. There could be a fire and injury if you do not
follow these precautions.
INT-3-2-2

Sulphur At the end of every working day, fill the tank through the filler
A with the correct type of fuel.
High sulphur content can cause engine wear. (High sulphur
fuel is not normally found in North America, Europe or This will prevent condensation from developing in the fuel
Australia.) If you have to use high sulfur fuel you must also tank overnight.
use a highly alkaline engine lubricating oil; or change the
normal oil more frequently.

Distillation

This indicates the mixture of different hydrocarbons in the

fuel. A high ratio of lightweight hydrocarbons can affect the
combustion characteristics.

274850

9803/3400 Issue 2*
Section 3 Routine Maintenance Section 3
10 - 2 Fuel System - Diesel 10 - 2

Draining the Sedimenter *

1 Park the Teletruk on firm level ground and lower the
boom.

2 Apply the park brake and select neutral.

3 Stop the engine and remove the ignition key.

4 Open the daily inspection cover (Refer to Section B).

5 Drain off any water in the sediment bowl B by opening the

tap A. Drain into a suitable container and dispose of in
accordance with environmental regulations.

6 Re-tighten tap A.

7 Check for leaks.

8 Close the daily inspection cover.

B

A
C053420

9803/3400 Issue 3*
Section 3 Routine Maintenance Section 3
10 - 3 Fuel System - Diesel 10 - 3

Bleeding the Diesel Fuel System (if required)

1 Park the Teletruk on firm level ground and lower the boom.
*
2 Apply the park brake and select neutral.

3 Stop the engine and remove the ignition key.

4 Open the daily inspection cover (Refer to Access

Procedures for Maintenance, Section B).

5 Make sure there is sufficient fuel in the tank.

6 Open the fuel injection pump vent valve A. A

7 Operate the priming pump C or priming pump lever B
slowly until fuel with no air flows freely from the valve, then
close the valve.

Notice: If no fuel is moved when the priming lever B is

operated then the pump diaphragm may have rested in a *
maximum lift position. To move the diaphragm, use the
starter key to turn the engine slightly, then try the priming
lever again.

8 Slacken the bleed plug on the sedimentor bowl and again

operate the lift pump priming lever until fuel with no air
flows freely from the plug, then tighten the plug. B
9 Remove the E.S.O.S. fuse to prevent the engine from 281350 S255860
starting.
*
! WARNING
To bleed the injectors you must turn the engine. When the
engine is turning, there are parts rotating in the engine
compartment.

Before starting this job make sure that you have no loose
clothing (cuffs, ties etc) which could get caught in rotating
parts.
C
When the engine is turning, keep clear of rotating parts.
2-3-3-8

10 Slacken each injector feed pipe in turn, at the injector, and

operate the starter to turn the engine until air free fuel
emits from the joint then re-tighten the pipe union.

11 Replace the E.S.O.S. fuse and start the engine. Check for
smooth running. If the engine continues to run roughly,
repeat the bleeding procedure.

12 Close the daily inspection cover.

9803/3400 Issue 4*
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