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 |
