JCB Teletruk 2.0D/G through 3.5D Forklift 1997 Service Manual (P/N 9803/3400)

JCB Teletruk Service Manual P/N 9803/3400, Issue 16 covers diesel and LPG forklifts from machine number 788001, including 2WD, 4x4, and 3.0D HL configurations.

• Engine and LPG service: Engine and radiator removal and replacement, LPG fault finding, vaporizer checks, carburetor adjustment, and fuel-filter service.

• Hydraulic repairs: Main/steering pump inspection and resealing, control-valve service, relief-valve testing, unloader adjustment, ram repair, and carriage tilt/compensation bleeding.

• Hydrostatic drive: Transmission-pump replacement, bleeding and minor repairs, drive-motor and parking-brake service, rear-axle repairs, and steer-sensor testing.

• Susmic controls: IT throttle-pedal, brake-pedal, lift-valve and engine-actuator calibration, parameter checks, and TCR/anti-slip diagnostic error charts.

• Electrical diagnosis and LMI: Serial-specific wiring diagrams, connector pin views, charging and starting tests, and Load Moment Indicator calibration with test weights.

• Boom and attachments: Inner-boom and wear-pad replacement, boom alignment, carriage service, fork and bucket procedures, and Changezee Quickhitch attachment operations.

• Cab and steering: Direct-glazing windshield replacement, hydraulic steering-unit disassembly and assembly, and power track rod service.

JCB wrote this manual for distributor service engineers receiving or having completed its technical training, with existing knowledge of safe workshop practices and hydraulic equipment repair.

Hydrostatic Drive and Hydraulic Service

The transmission chapter details pump/engine coupling work, shaft-seal replacement, charge-pump service, multi-function valve cartridges, and drive-motor brake-pack inspection and testing. JCB limits transmission-pump and drive-motor work to the minor repairs described, recommending reconditioned or replacement units when more extensive work is required.

The transmission-pump bleeding section addresses the risk of internal pump damage when air remains in the circuit at initial startup. Separate startup checks apply after pump or motor removal.

Hydraulic test-port references distinguish transmission, loader, steering, and brake circuits. The Transmission & Valve Hydraulic Circuit schematics separate IT and TCR arrangements, while the 3.5D 4x4 Priority, Steering and Fan Circuit shows its additional hydraulic equipment.

Main/steering pump procedures concentrate on inspection and resealing. The triple-pump steering flow/relief valve is a sealed assembly requiring replacement if faulty. Reference tables distinguish zinc-plated and Dacromet fasteners and cover hydraulic fittings and O-ring face seals.

Susmic, Wiring and Load Moment Diagnosis

IT diagnosis follows the Psion interface, including the Flow Chart for Sensor Set-up, sensor checks, actuator calibration, and error listings. The service-tool list identifies the Psion Walkabout 892/00924 and service software lead 892/00931. These are Psion diagnostic instructions; laptop diagnostics are referred to JCB technical service.

TCR coverage separates its mechanical throttle controls and LED fault codes from the IT calibration procedures. Wiring diagrams distinguish diesel and LPG engines, single- and twin-pedal controls, and serial-number changes.

The 3.0D Four Wheel Drive Speed Sensor Wiring and 3.5D 4x4 Differential Lock diagrams accompany mainframe and cab harness drawings, connector views, and fuse and relay tables. On the 3.0D 4x4, insufficient rear steer-sensor cable slack can damage electrical components during operation.

LMI procedures distinguish the earlier indicator through serial number 0893470 from the digital unit beginning at 0893471. Display-box, axle-transducer, and harness tests help isolate the source of an indication fault before selecting a replacement component.

Engine and LPG Repair Scope

Engine coverage includes specifications, removal and replacement, and radiator service. Further engine work is referred to separate engine service manuals, which are not included in this PDF.

LPG fault charts address starting problems, power loss, and stalling. Fuel-valve, vaporizer, and carburetor disassembly depends on the appropriate service repair kits and their fitting instructions; the illustrations alone are reference views.

Boom, Cab and Steering Work

Direct-glazing procedures cover glass removal, cab-frame preparation, bonding, and curing requirements. Boom illustrations show wear-pad locations, alignment shims, and removal points; exploded component views support drive-motor and steering assembly identification.

Rear-axle coverage includes wheel hubs, steering swivels, and spring-plunger shimming. The steering section adds hydraulic steering-unit and power track rod disassembly and assembly.

Servicing industrial lifting equipment involves significant physical hazards. Always use appropriate personal protective equipment and ensure the machine is properly stabilized before maintenance or inspections.

A Preview of Engine Adjustment Data

These examples are a small selection of the engine adjustment data included in the manual.

KR and HP naturally aspirated diesels, and the HR turbo diesel fitted to 3.5-ton machines, specify cold inlet and exhaust valve clearance of 0.2 mm (0.0078 in).

The LPG engine specification lists spark plug clearance of 0.9 mm (0.035 in), alongside separate ignition, lubrication, and fuel-system data.

Text Search, Numbered Bookmarks and PDF Contents

Search and diagram viewing: Text search is limited: much of the body text and several schematic pages cannot be found with ordinary word searches. Numbered block bookmarks are present, with some inactive entries. Small labels on wiring and harness drawings require zooming, and several schematics are sideways.

Supplied as one printable 609-page PDF. The total includes the cover, introduction, and 72 blank or intentionally blank pages.