Part of the JCB Repair Manuals.
Within the hour you could be under a Teletruk with the lift arm propped on its maintenance strut, or plugged into the CANbus reading fault codes. This service manual covers the JCB TLT 30D High Lift, TLT 35D and TLT 35D 4x4 from serial 2252520, publication 9813/2500-4.
It includes technical data for both the Kohler KDI 2504 TCR and KDI 1903 TCR, plus the 2WD and 4WD hydraulic schematics. Relief valve pressures, wiring diagrams, fault code tables and the Servicemaster procedures are all in there.
When it's just you and the machine in a quiet yard with an amber light on, there's nobody to ring. You buy it once, and it's yours to keep for this machine.
What's Inside This JCB TLT 30D High Lift, TLT 35D, TLT 35D 4x4 Manual
| System | Pages | Key Topics |
|---|---|---|
| Machine: Safety, Model/Serial and Service Points | 1-30 | Model and Serial Number, Safety, About This Manual, Description, Cleaning |
| Attachments, Couplings and Load Handling | 31-54 | Attachments, Lift Arm Quickhitch, Shovel, Fork, Work Platform |
| Body and Framework | 55-114 | Moveable Panel and Cover, Lift Arm, Pivot Pins, Carriage, Counterweight, Identification Label, Tools, Maintenance Strut, Fire Extinguisher, Window Guard |
| Operator Station | 115-174 | Window, Operator Seat, Seat Belt, Door, Controls, Cables and Fittings, Safety Label/Chart, Steering Wheel, Mount |
| Heating, Ventilating and Air-Conditioning (HVAC) | 175-182 | Heater Unit |
| Engine - General, Technical Data and Fault-Finding | 183-213 | Kohler KDI 2504 TCR / KDI 1903 TCR Technical Data, Fault-Finding Tables, Drain and Fill |
| Engine - Crankcase, Cylinder Head, Crankshaft, Camshaft, Valves and Pistons | 214-345 | Crankcase, Cylinder Head, Bedplate, Crankshaft, Camshaft, Engine Belt, Oil Filter, Air Filter, Crankcase Ventilation Filter, Valve, Connecting Rod, Piston |
| Engine - Rocker, Lubrication, Timing Gear, Starting and Sensors | 346-480 | Rocker and Fittings, Oil Sump, Timing Gear, Flywheel, Oil Filler, Oil Pump, Oil Cooler, Alternator, Starter Motor, Sensor, Switch, Cold Start Heater |
| Fuel and Exhaust System | 481-578 | Tank, Level Sender, Filter, Water Separator, Injection, Exhaust, Fuel Pipe |
| Cooling System | 579-632 | Cooling Pack, Expansion Tank, Pump, Thermostat, Hose |
| Brake System | 633-644 | Service Brake, Park Brake |
| Steering System | 645-674 | Pump, Steer Unit/Valve, Column, Front Track Rod |
| Driveline | 675-760 | Axle, Hub, Wheel, Wheel Drive Pump, Wheel Drive Motor, Tyre |
| Hydraulic System | 761-892 | Technical Data (Relief Valve Pressures), Schematic Circuit (2WD / 4WD), Tank, Filter, Variable Displacement Pump, Cylinder / Ram, Lift Arm Control Valve Block, Directional Control Valve, Hose, Connectors |
| Electrical System - Schematics, Battery, Harness and Instruments | 893-1007 | Schematic Circuit (Wiring Diagrams), Battery, Power Distribution, Harness, Alarm, Instruments, Interior Switch, Bulb, Control Module, Window Washer/Wipe |
| Electronic Diagnostic (Servicemaster), Fault Codes and Load Motion Control | 1008-1088 | Fault Codes (DTC), Electronic Diagnostic, Load Motion Control System, Sensor, Solenoid |
| Fasteners and Fixings | 1089-1116 | Screws, Bolts, Bearings, Clips, Threaded Insert |
| Consumable Products | 1117-1164 | Oil, Grease, Fluids, Locking Fluids, Solvents and Primers, Adhesive, Sealant, Fuel |
| After Sales: Maintenance Schedules and Special Tools | 1165-1200 | Maintenance Schedules, Clothing and Personal Protective Equipment (PPE), Special Tools, Units of Measurement |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine (KDI 2504 TCR) | Kohler KDI 2504 TCR, 4 cylinders, 2.482L, 46kW, 249Nm | p. 194 |
| Engine (KDI 1903 TCR) | Kohler KDI 1903 TCR, 3 cylinders, 1.861L, 42kW at 2200 RPM | p. 194 |
| Emission compliance | US-EPA Tier 4 final, EU Stage IIIB | p. 194 |
| MRV (Main Relief Valve) at 2800 RPM | 245bar (3,550.7psi) | p. 767 |
| ARV (Auxiliary Relief Valve) | 255bar (3,695.6psi) | p. 767 |
| Steering Orbitrol Unit | 150bar (2,173.9psi) | p. 767 |
| Fuel tank (TLT 35D [T4F]) | 55L | p. 1124 |
| Engine oil (TLT 35D [T4F]) | 11.2L | p. 1124 |
| Cooling system (TLT 35D [T4F]) | 11L | p. 1124 |
| Hydraulics (TLT 35D [T4F]) | 62.5L | p. 1124 |
| Engine oil and filter | Replace every 500 h (arduous: 250 hours) | p. 1171 |
JCB TLT 30D High Lift, TLT 35D, TLT 35D 4x4 Common Problems This Manual Covers
Engine does not start
Work through Table 12 in the engine fault-finding section (page 206). Look at the battery terminals first. If they are sulphated or corroded, clean them. If battery voltage is too low, recharge or replace the battery. A clogged fuel filter is also on the list, and the fix is to replace the filter. The Fuel and Exhaust System section covers the filter and water separator.
Manual Section: Engine: General, Technical Data and Fault-Finding p. 206Engine overheats
Table 21 on page 207 covers an overheating engine and includes a damaged cylinder head gasket, which calls for replacing the gasket. Rule out the cheap stuff before you strip the head. The Cooling System section covers the cooling pack, expansion tank, pump, thermostat and hoses.
Manual Section: Engine: General, Technical Data and Fault-Finding / Cooling System p. 207Blue smoke from the exhaust
Table 16 on page 207 lists a high oil sump level as a cause of blue smoke, and the fix given is to replace the engine oil. Check the dipstick before you suspect rings or valves. The crankcase ventilation filter and oil sump are covered in the engine crankcase and lubrication sections.
Manual Section: Engine: General, Technical Data and Fault-Finding p. 207Hydraulic relief pressures out of specification
Check pressures against the Hydraulic System technical data on page 767, with oil at 50 °C. The MRV (Main Relief Valve) should read 245bar (3,550.7psi) at 2800 RPM and the ARV 255bar (3,695.6psi). The Steering Orbitrol Unit is 150bar (2,173.9psi) and the Brake Pressure Reducing Valve is 25bar (362.3psi). Use the 2WD or 4WD schematic to trace the circuit.
Manual Section: Hydraulic System: Technical Data and Schematic Circuit p. 767Frequently Asked Questions
How do I clear a fault code on a JCB TLT 35D?
You can read the fault code log on the instrument panel LCD through the service menu (page 1051). You can also read it with JCB Servicemaster on a laptop connected to the machine CANbus. The manual only lists clearing under Servicemaster, which can 'View, save or clear ECU fault code log' (page 1012). Fix the cause first, or all you've done is wipe the evidence. p. 1051
What do the red and amber warning lights mean on a Teletruk?
A red light with a continuous alarm is a 'STOP NOW' fault (page 1050). An amber light with the alarm sounding for one second is a 'SERVICE' fault. The manual says that means reduced performance but nothing dangerous. Read the log before you decide whether to finish the shift. p. 1050
How do I decode a code such as C0042 on a TLT 30D High Lift?
Codes are 7 digit codes to J2012. The first character tells you the system: P = Powertrain, C = Chassis, U = Network (page 1049). C0042 is Inch/Brake pedal signal voltage incorrect, and C0023 is Brake lamp fault (page 1051). The same table lists b155e as Proportional cooling fan output fault - Short to battery. p. 1051
What torque does the TLT 35D manual give for an M12 Grade 8.8 bolt?
For coarse metric Grade 8.8, M12 is 83 / 74 N·m and M10 is 47 / 43 N·m, for Condition 1 / 2 (page 1102). A Grade 10.9 M12 goes to 116 / 104 N·m. Check the bolt head markings before you reach for the wrench. p. 1102
What oil does the TLT 35D [T4F] engine take, and how often is it changed?
The capacity table for the TLT 35D [T4F] lists 11.2L of JCB Ultra performance 5W40 (page 1124). Replace the engine oil and filter at 500 h (page 1171). Under arduous conditions, do an engine oil flush every 250 hours and replace the oil and filter (page 1173). p. 1124
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