Bobcat T40140, T40170 Telescopic Handler Factory Service & Shop Manual
Catalog:
Model:
Complete workshop repair & service manual with electrical wiring diagrams for Bobcat T40140, T40170 Telescopic Handler. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.
This Bobcat T40140, T40170 Telescopic Handler service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.
4852040 (8-03) - T40140, T40170 V2 Boom Service Manual.pdf
6986768 (2-10) - T40140, T40170 Telescopic Handler Service Manual.pdf
6989561 (2-10) - T40140 Telescopic Handler Operation & Maintenance Manual.pdf
6989562 (2-10) - T40170 Telescopic Handler Operation & Maintenance Manual.pdf
EXCERPT:
CONTENTS
SAFETY AND MAINTENANCE . . . . . 10-01
HYDRAULIC SYSTEM . . . . 20-01
HYDROSTATIC SYSTEM . . 30-01
DRIVE SYSTEM . . . . . 40-01
MAIN FRAME . . . . . . . 50-01
ELECTRICAL SYSTEM AND ANALYSIS . . 60-01
ENGINE SERVICE . . . 70-01
HEATING, VENTILATION, AIR CONDITIONING . . . . 80-01
SPECIFICATIONS . . . . SPEC-01
ALPHABETICAL INDEX . . . .INDEX-01
…
PARKING BRAKE
Releasing The Brake For Towing
Block all four wheels to prevent the machine from moving once the parking brake is released.
Locate the six brake release bolts (three per side) on the front axle.
4852040 (10-12) - T40140, T40170 V2 Boom Service Manual............1
CONTENTS............2
NEW BOOM............3
Introduction............4
Stronger boom............4
Material............4
Counter jib............4
New boom design............5
Different components of the boom............5
Front part of element 1............5
Front part of element 2............5
Rear part of element 2............6
Front part of element 3............6
Rear part of element 3............7
Rear part of element 4............7
Telescoping cylinder............8
Cassette.............8
Pads............9
New concept............9
Lubricator built into the pads............9
Glide angle iron for the pads............9
Compensation cylinder............10
Mechanical kinematics of the boom............10
Tensioner for lower chains............10
Hooking up the chains............11
Hydraulic kinematics of the boom............11
Electric enclosure............12
Feature of the T40170............12
Attachments............12
SPECIFIC PROCEDURES - V2 BOOM............13
Safety............14
Removal and installation of the chains/hoses cassette............14
Removal............14
Installation............15
Removal and installation of boom elements............15
Remove elements 2 and 3 (T40140) or 2, 3 and 4 (T40170)............15
Checking the tension of the telescoping chains............17
Checking the wear of the telescoping chains............17
Adjusting the extension and retraction chains............18
Tools needed............18
First............18
Retraction chains............18
Extension chains............18
Replacing the boom retraction or extension chains............19
General views............19
Work on rear of boom............20
Work on front of boom............20
Replacing boom pads............20
Parts............20
Front pads of the elements............21
Removing............21
Installation............21
Rear pads of the elements............22
Removing............22
Installation............22
Important reminder............23
Removal and installation of the compensation cylinder............23
Removal............23
Installation............24
Removal and installation of the tilt cylinder............25
Removal............25
Installation............25
Removal and installation of the lift cylinder............26
Removal............26
Installation............27
Removal and installation of the telescoping cylinder............27
Removal............27
Installation............28
T40140 SPECIFICATIONS............29
Introduction............30
Detailed specifications............30
General............30
Hydrostatic Transmission............30
Cycle time............31
Load Charts............31
T40140 on stabilisers............31
T40140 on tyres............32
Platform load charts............32
Load Chart 1............32
Load Chart 2............33
Load Chart 3............33
Load Chart 4............34
Self leveling and side shift of the load............34
Dimensions............35
T40170 SPECIFICATIONS............37
Introduction............38
Detailed specifications............38
General............38
Hydrostatic Transmission............38
Cycle time............39
Load Charts............39
T40170 on stabilisers............39
T40170 on tyres............40
Platform load charts............40
Load Chart 1............40
Load Chart 2............41
Load Chart 3............41
Load Chart 4............42
Self leveling and side shift of the load............42
Dimensions............43
SERVICE MANUAL REVISION............45
Revision No: T40140, T40170 - 1............45
4852040 (8-03) - T40140, T40170 V2 Boom Service Manual............47
CONTENTS............48
NEW BOOM............49
Introduction............50
Stronger boom............50
Material............50
Counter jib............50
New boom design............51
Different components of the boom............51
Front part of element 1............51
Front part of element 2............51
Rear part of element 2............52
Front part of element 3............52
Rear part of element 3............53
Rear part of element 4............53
Telescoping cylinder............54
Cassette.............54
Pads............55
New concept............55
Lubricator built into the pads............55
Glide angle iron for the pads............55
Compensation cylinder............56
Mechanical kinematics of the boom............56
Tensioner for lower chains............56
Hooking up the chains............57
Hydraulic kinematics of the boom............57
Electric enclosure............58
Feature of the T40170............58
Attachments............58
SPECIFIC PROCEDURES - V2 BOOM............59
Safety............60
Removal and installation of the chains/hoses cassette............60
Removal............60
Installation............61
Removal and installation of boom elements............61
Remove elements 2 and 3 (T40140) or 2, 3 and 4 (T40170)............61
Checking the tension of the telescoping chains............63
Checking the wear of the telescoping chains............63
Adjusting the extension and retraction chains............64
Tools needed............64
First............64
Retraction chains............64
Extension chains............64
Replacing the boom retraction or extension chains............65
General views............65
Work on rear of boom............66
Work on front of boom............66
Replacing boom pads............66
Parts............66
Front pads of the elements............67
Removing............67
Installation............67
Rear pads of the elements............68
Removing............68
Installation............68
Important reminder............69
Removal and installation of the compensation cylinder............69
Removal............69
Installation............70
Removal and installation of the tilt cylinder............71
Removal............71
Installation............71
Removal and installation of the lift cylinder............72
Removal............72
Installation............73
Removal and installation of the telescoping cylinder............73
Removal............73
Installation............74
T40140 SPECIFICATIONS............75
Introduction............76
Detailed specifications............76
General............76
Hydrostatic Transmission............76
Cycle time............77
Load Charts............77
T40140 on stabilisers............77
T40140 on tyres............78
Platform load charts............78
Load Chart 1............78
Load Chart 2............79
Load Chart 3............79
Load Chart 4............80
Self leveling and side shift of the load............80
Dimensions............81
T40170 SPECIFICATIONS............83
Introduction............84
Detailed specifications............84
General............84
Hydrostatic Transmission............84
Cycle time............85
Load Charts............85
T40170 on stabilisers............85
T40170 on tyres............86
Platform load charts............86
Load Chart 1............86
Load Chart 2............87
Load Chart 3............87
Load Chart 4............88
Self leveling and side shift of the load............88
Dimensions............89
4950145 (08-08) - T40140-T40170 Service Manual............91
MAINTENANCE SAFETY............93
ALPHABETICAL INDEX............95
CONTENTS............97
FOREWORD............98
SAFETY INSTRUCTIONS............101
FIRE PREVENTION............102
Maintenance............102
Operation............102
Electrical............102
Hydraulic System............102
Fueling............102
Starting............102
Welding And Grinding............103
Fire Extinguishers............103
SERIAL NUMBER LOCATIONS............104
Telescopic Handler Serial Number............104
Engine Serial Number............104
Other Serial Numbers............104
Delivery Report............105
SAFETY AND MAINTENANCE............107
LIFTING AND BLOCKING THE TELESCOPIC HANDLER............109
Procedure............109
OPERATOR CAB............111
Emergency Exit............111
Cab Door............112
Cab Door Window............112
TRANSPORTING THE TELESCOPIC HANDLER............113
Procedure............113
TOWING THE TELESCOPIC HANDLER............115
Procedure............115
SERVICE SCHEDULE............117
AIR CLEANER SERVICE............119
Replacing Filter Element............119
ENGINE COOLING SYSTEM............121
Cleaning The Cooling System............121
Checking The Coolant Level............121
Replacing The Coolant............122
FUEL SYSTEM............123
Fuel Specifications............123
Filling The Fuel Tank............123
Fuel Filter............123
ENGINE LUBRICATION SYSTEM............125
Checking Engine Oil............125
Oil Chart............125
Replacing Oil And Filter............126
HYDRAULIC / HYDROSTATIC SYSTEM............127
Checking And Adding Fluid............127
Replacing Hydraulic / Hydrostatic Filter............127
Replacing Hydraulic Fluid............128
AXLES (FRONT AND REAR)............129
Checking Oil Level (Planetary Carrier)............129
Draining Oil (Planetary Carrier)............129
Checking Oil Level (Rear Differential)............130
Draining Oil (Rear Differential)............130
Checking Oil Level (Front Differential)............130
Draining Oil (Front Differential)............131
LUBRICATION............133
Procedure............133
TIRE MAINTENANCE............137
Wheel nuts............137
Tire Rotation............137
Tire Mounting............137
APPROVED BOOM STOP............139
Installing The Approved Boom Stop............139
Removing The Approved Boom Stop............139
ENGINE COVER............141
Opening And Closing The Engine Cover............141
HYDRAULIC SYSTEM............143
HYDRAULIC SYSTEM INFORMATION............147
Glossary Of Hydraulic / Hydrostatic Symbols............147
Troubleshooting Chart............150
Tightening Procedures............151
LIFT CYLINDER............153
Removal And Installation............153
Parts Identification............156
Disassembly............157
Assembly............158
BUCKET POSITIONING CYLINDER............159
Removal And Installation............159
BUCKET POSITIONING CYLINDER (CONT’D)............160
Parts Identification............160
Disassembly............161
Assembly............161
EXTENSION CYLINDER............163
Cylinder Group Removal And Installation............163
Parts Identification............166
Disassembly............167
Assembly............167
TILT CYLINDER............169
Removal And Installation............169
Parts Identification............171
Disassembly............172
Assembly............172
STEERING CYLINDER (FRONT)............173
Removing the Steering Cylinder............173
Disassembling the Steering Cylinder............175
Assembling the Steering Cylinder............176
STEERING CYLINDER (REAR)............181
Removing the Steering Cylinder............181
Installing the Steering Cylinder............183
Disassembling the Steering Cylinder............184
Assembling the Steering Cylinder............186
DRIVE BOX............189
Parts Identification............189
Disassembly............190
Assembly............194
Special Tools............197
MAIN RELIEF VALVE............199
Testing And Adjustment............199
Removal and Installation............200
QUICK TACH CYLINDER............203
Removal And Installation............203
Parts Identification............205
Disassembly............206
Assembly............206
FRAME LEVELING CYLINDER............207
Removal And Installation............207
Parts Identification............209
Disassembly............210
Assembly............210
STEERING MODE VALVE BLOCK............211
Removal And Installation............211
Parts Identification............213
Disassembly............214
Solenoid Testing............216
Assembly............216
BRAKE VALVE............219
Removal And Installation............219
Disassembly And Assembly............220
GEAR PUMP............223
Removal And Installation............223
Parts Identification............226
Disassembly And Assembly............227
FAN MOTOR............233
Removal And Installation............233
Parts Identification............237
Disassembly And Assembly............238
HYDRAULIC RESERVOIR............241
Removal And Installation............241
STEERING VALVE............243
Removal And Installation............243
Parts Identification............244
Disassembly............245
Inspection............248
Assembly............248
HYDRAULIC CONTROL VALVE............253
Checking Drain Pressure............253
Valve Section Troubleshooting (Auxiliary Section Example)............253
Removal And Installation............256
Parts Identification............258
Section Removal............265
Section Disassembly And Assembly............265
Inlet Section Disassembly And Assembly............269
PORT RELIEF VALVES............273
Removal And Installation............273
FLOW CONTROL VALVE............275
Removal And Installation............275
PARKING BRAKE............277
Parking Brake Valve Removal And Installation............277
Parking Brake Valve Disassembly And Assembly............278
PRESSURE REDUCING VALVE............281
Testing............281
Removal And Installation............282
ACCUMULATOR............283
Removal And Installation............283
TOW VALVE............285
Removal And Installation............285
Disassembly And Assembly............286
STABILIZER CYLINDER............291
Removal And Installation............291
Parts Identification............293
Disassembly............294
Assembly............295
STABILIZER CONTROL VALVE............297
Parts Identification............297
Removal............298
HYDROSTATIC SYSTEM............301
HYDROSTATIC SYSTEM INFORMATION............303
Troubleshooting Chart............303
Replenishing Valve Function............304
OIL COOLER............305
Description............305
HYDROSTATIC DRIVE MOTOR............307
Removal And Installation............307
Parts Identification............308
Disassembly............311
Inspection............326
Assembly............328
HYDROSTATIC PUMP............345
Removal And Installation............345
Parts Identification............347
Disassembly............351
Inspection............361
Assembly............365
DRIVE SYSTEM............379
TROUBLESHOOTING............381
Chart............381
AXLE AND DIFFERENTIAL (FRONT)............383
General Information............383
Planetary Carrier Parts Identification............383
Planetary Carrier Disassembly............384
Steering Knuckle and Drive Axle Parts Identification............389
Steering Knuckle Disassembly............390
Drive Axle Disassembly............392
Brake system Identification............394
Brake System Disassembly............395
Differential Parts Identification............399
Differential Disassembly............400
Bevel pinion Parts Identification............405
Bevel Pinion Disassembly............406
Bevel Pinion Assembly............409
Differential assembly............418
Brake System Assembly............423
Drive Axle Assembly............430
Steering Knuckle Assembly............432
Planetary carrier Assembly............435
Special Tools............440
AXLE AND DIFFERENTIAL (REAR)............441
General Information............441
Planetary Carrier Parts Identification............441
Steering Knuckle and Drive Axle Parts Identification............447
Steering Knuckle Disassembly............448
Differential and Bevel Pinion Parts Identification............450
Differential Disassembly............451
Bevel pinion Disassembly............455
Bevel pinion Assembly............458
Differential Assembly............466
Steering Knuckle Assembly............471
Planetary Carrier Assembly............474
Special tools............478
FRONT AXLE............479
Removal............479
AXLE TOE-IN............485
Adjustment............485
PARKING BRAKE............487
Releasing The Brake For Towing............487
Re-Activating The Brake............488
STEERING ANGLE ADJUSTMENT............489
Adjustment............489
DRIVESHAFT............491
Removal And Installation............491
SERVICE BRAKE............493
Description............493
Bleeding The Brake Circuit............493
REAR AXLE............495
Removal............495
MAIN FRAME............499
OPERATOR CAB............501
Removal and Installation............501
OPERATOR SEAT............509
Removal And Installation............509
BOOM ASSEMBLY............511
Removal And Installation............511
END BOOM............515
Removal............515
Installation............517
WEAR PADS (FRONT)............519
Removal............519
Installation............520
WEAR PADS (REAR)............523
Removal............523
Installation............523
ENGINE COVER............525
Gas Cylinder Removal And Installation............525
Removal And Installation............525
AIR INTAKE COWLING............527
Removal And Installation............527
FUEL TANK............529
Removal And Installation............529
QUICK TACH............533
Removal And Installation............533
REAR WEIGHTS............535
Removal And Installation............535
FENDER............537
Removal And Installation............537
FRONT WEIGHT............539
Removal And Installation............539
DASH COVER / STEERING COLUMN COVER............541
Removal And Installation............541
JOYSTICK PANEL............545
Removal And Installation............545
INTERMEDIATE BOOM............547
Removal of the First Intermediate Boom (T40170 & T40140)............547
Installation of the First Intermediate Boom (T40170 & T40140)............548
Removal of the Second Intermediate Boom (T40170)............549
Installation of the Second Intermediate Boom (T40170)............550
BOOM TRAY............553
Removal And Installation............553
CHAIN CHECKING AND ADJUSTING PROCEDURE............557
Checking The Tension Of The Telescoping Chains Of The T40140 / T40170............557
STABILIZER FRAME............561
Removal............561
ELECTRICAL SYSTEM AND ANALYSIS............563
ELECTRICAL SYSTEM INFORMATION............565
Description............565
Checking The Battery Fluid Level............565
Checking The State of Fuses, Diodes And Relays............565
Checking The Working Order of Controls, Lighting And Signalling............566
Checking The State of Electric Connections............566
Fuses, Diodes & Relays............567
Fuses And Diodes............568
Relays............568
BATTERY............569
Removal And Installation............569
Servicing............570
Using A Booster Battery (Jump Starting)............571
ALTERNATOR............573
Removal And Installation............573
Adjusting The Alternator Belt............574
STARTER............575
Removal And Installation............575
Assembly / disassembly............576
LIGHTS............577
Rear Light Removal And Installation............577
Front Light Removal And Installation............578
TRAVEL / SIGNAL LEVER............579
Removal And Installation............579
INSTRUMENT PANEL............581
Removal And Installation............581
SWITCH PANEL............583
Removal And Installation............583
BRAKE LIGHT SWITCH............585
Removal And Installation............585
Adjustment............585
FRONT WIPER MOTOR............587
Removal And Installation............587
TOP WIPER MOTOR............591
Removal And Installation............591
REAR WIPER MOTOR............593
Removal And Installation............593
PEDAL ASSEMBLY............595
Removal And Installation............595
Disassembly And Assembly............596
INCHING SWITCH............601
Removal And Installation............601
Adjustment............601
SERVICE SOFTWARE............603
Connecting The Laptop Computer............603
Entering The Service Software............604
Monitor Screen............605
Warnings Screen............606
Calibrate Inch Pedal............607
Calibrate Creep Potentiometer............609
Program / Update Susmic Controller............610
FRAME LEVEL SPEED SWITCH............613
Description............613
Removal............613
Installation............614
Disassembly And Assembly............615
JOYSTICK............617
Removal And Installation............617
ENGINE SERVICE............619
TROUBLESHOOTING............623
Chart............623
ENGINE SPEED CONTROL............625
Removal And Installation............625
MUFFLER............627
Removal And Installation............627
AIR CLEANER............629
Housing Removal And Installation............629
OIL COOLER / RADIATOR............631
Removal And Installation............631
Disassembly And Assembly............633
ENGINE AND ENGINE MOUNTS............635
Removal And Installation............635
ENGINE COMPONENTS AND TESTING............639
Fuel Injection Pump Removal............639
Fuel Injection Pump Installation............642
Fuel Injectors Removal And Installation............645
Checking The Fuel Lift Pump............647
Fuel Lift Pump Removal And Installation............648
Compression Checking............648
Glow Plugs Checking............649
Glow Plugs Removal And Installation............650
ENGINE TIMING............651
Procedure............651
ENGINE / HYDROSTAT ASSEMBLY............653
Removal And Installation............653
FLYWHEEL AND HOUSING............665
Removal And Installation............665
Ring Gear Removal............668
Ring Gear Installation............668
RECONDITIONING THE ENGINE............669
Turbo Charger Troubleshooting............669
Turbo Charger Description............670
Turbo Charger Removal And Installation............670
Exhaust Manifold Removal And Installation............672
Fuel Injector Cover Removal And Installation............672
Rocker Cover Removal And Installation............673
Cylinder Head Removal............674
Cylinder Head Inspection............676
Cylinder Head Installation............676
Rocker Shaft Disassembly And Assembly............679
Valve Removal............679
Valve Springs Checking............680
Valve Depth Checking............680
Valve Guides Checking............681
Valve Guide Removal............682
Valve Guide Installation............682
Valves Checking............683
Cutting A Valve Seat............683
Valve Seat Assembly............684
Changing Valve Springs (With Cylinder Head Installed)............685
Valve Clearance Adjustment............686
Timing Case And Drive Assembly Description............687
Timing Cover Removal............687
Timing Cover Installation............687
Crankshaft Pulley Removal And Installation............687
Front Oil Seal Removal And Installation............687
Timing Case And Gear Removal............688
Timing Case And Gear Installation............689
Camshaft And Tappets Removal............691
Camshaft And Tappets Installation............692
Pistons And Connecting Rods Description............693
Pistons And Connecting Rods Removal............693
Pistons And Connecting Rods Disassembly............695
Piston Ring End Gap............695
Piston Ring Installation............695
Piston Ring Groove Clearance............696
Connecting Rod Inspection............697
Connecting Rod Bushing Replacement............697
Piston And Connecting Rod Assembly............697
Piston And Connecting Rod Installation............697
Checking Piston Height............699
Crankshaft And Bearings Description............699
Crankshaft And Bearings Removal............699
Inspection Of Crankshaft And Bearings............701
Crankshaft And Bearings Installation............702
Rear Oil Seal Removal............703
Rear Oil Seal Housing Positioning............703
Rear Oil Seal Installation............704
Checking Crankshaft End Play............704
Cooling System Description............705
Thermostat Removal and Installation............706
Thermostat Testing............707
Lubricating Oil Cooler Removal And Installation............707
Water Pump Removal............707
Water Pump Installation............707
Engine Lubrication System Description............708
Oil Filter Adapter Removal And Installation............709
Oil Pan Removal And Installation............709
Oil Screen And Pick-up Tube............710
Oil Pump Removal............710
Oil Pump Installation............711
Oil Pump Disassembly And Assembly............712
Oil Pressure Relief Valve Disassembly And Assembly............712
Engine Block Description............713
Engine Block Disassembly And Assembly............713
Piston Cooling Jet Removal............714
Piston Cooling Jet Installation............714
Piston Cooling Jet Alignment............714
Inspection............714
Cylinder Liner Inspection............715
Cylinder Liner Removal............716
Cylinder Liner Installation............717
HEATING, VENTILATION, AIR CONDITIONING............719
AIR CONDITIONING SYSTEM FLOW............721
Principals............721
Chart............722
COMPONENTS............723
Identification............723
SAFETY............725
Safety Equipment............725
REGULAR MAINTENANCE............727
Filter Element Removal And Installation............727
Compressor Drive Belt Inspection............728
Cleaning The Condenser............728
BASIC TROUBLESHOOTING............729
Poor A/C Performance............729
Compressor Drive Belt Inspection............729
Checking The Electrical System............730
GENERAL AIR CONDITIONING SERVICE GUIDELINES............735
Compressor Oil............735
Compressor Oil Check............735
Component Replacement And Refrigeration Leaks............736
SYSTEM TROUBLESHOOTING CHART............737
TEMPERATURE / PRESSURE............741
Chart............741
AIR CONDITIONING SERVICE............743
Chart............743
SYSTEM CHARGING AND RECLAMATION............745
Reclamation Procedure............745
Charging Procedure With A Manifold Gauge Set............748
Charging Procedure............749
COMPRESSOR............751
Removal And Installation............751
Compressor Clutch Disassembly And Assembly............752
CONDENSER............757
Removal And Installation............757
RECEIVER / DRIER............759
Removal And Installation............759
PRESSURE SWITCH............761
Removal And Installation............761
EVAPORATOR / BLOWER UNIT............763
Removal And Installation............763
EXPANSION VALVE............765
Removal And Installation............765
HEATER ASSEMBLY............767
Removal And Installation............767
Fan Removal And Installation............768
Core Removal And Installation............768
SPECIFICATIONS............771
TELESCOPIC HANDLER SPECIFICATIONS............773
Dimensional Specifications T40140............773
Dimensional Specifications T40170............773
Performance Specifications............774
Engine............774
Controls............774
Drive System............775
Tires............775
Capacities............775
Hydraulic System............775
Electrical System............776
Instrument Panel............776
ENGINE SPECIFICATIONS............777
General............777
Cylinder Head............777
Valve Guides............777
Exhaust Valves............778
Intake Valves............778
Valve Springs............778
Rocker Shaft, Rockers And Bushings............779
Pistons And Piston Rings............779
Connecting Rods And Bearings............780
Crankshaft............780
Crankshaft Re-Grind Data............781
Main Bearings............782
Thrust Washers............782
Camshaft And Thrust Washer............782
Cylinder Block............782
Cylinder Liners............783
Fuel Injection Pump............783
Fuel Injectors............783
Fuel Lift Pump............783
Timing Case And Timing Gears............784
Oil Pump, Gear And Relief Valve............785
Turbocharger............785
Flywheel............785
Water Pump And Thermostat............786
Engine Torque Component............787
MACHINE TORQUE SPECIFICATIONS............789
Axle............789
Boom............789
Drive Box............789
Drive Motor............789
Engine............790
Hydraulic Pump............790
TORQUE SPECIFICATIONS FOR BOLTS............791
Torque for General SAE Bolts............791
Torque For General Metric Bolts............792
HYDRAULIC CONNECTION SPECIFICATIONS............793
O-ring Face Seal Connection............793
Straight Thread O-ring Fitting............793
Tubelines And Hoses............793
Flare Fitting............794
O-ring Flare Fitting............795
Port Seal Fitting............797
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS............799
Specifications............799
CONVERSIONS............801
Decimal And Millimeter Equivalents............801
U.S. To Metric Conversion............802
6986768 (08-08) Revised (08-12) - T40140, T40170 Telescopic Handler Service Manual............803
MAINTENANCE SAFETY............805
CONTENTS............807
FOREWORD............809
FOREWORD............811
SAFETY INSTRUCTIONS............813
FIRE PREVENTION............814
Maintenance............814
Operation............814
Electrical............814
Hydraulic System............815
Fueling............815
Starting............815
Spark Arrester Exhaust System............815
Welding And Grinding............815
Fire Extinguishers............815
SERIAL NUMBER LOCATION............816
Telescopic Handler Serial Number............816
Engine Serial Number............816
Other Serial Numbers............816
DELIVERY REPORT............817
BOBCAT TELESCOPIC HANDLER IDENTIFICATION............818
SAFETY AND MAINTENANCE............819
LIFTING AND BLOCKING THE TELESCOPIC HANDLER............821
Procedure............821
OPERATOR CAB (ROPS / FOPS)............823
Emergency Exit............823
Cab Door............824
Cab Door Window............824
TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER............825
Loading And Unloading............825
Fastening............825
TOWING THE TELESCOPIC HANDLER............827
Procedure............827
SERVICE SCHEDULE............829
AIR CLEANER SERVICE............831
Replacing Filter Element............831
ENGINE COOLING SYSTEM............833
Cleaning............833
Removing And Replacing The Coolant............833
Checking Level............835
FUEL SYSTEM............837
Fuel Specifications............837
Biodiesel Blend Fuel............837
Filling The Fuel Tank............838
Secondary Fuel Filter............838
Primary Fuel Filter (Pre-Filter)............839
Removing Air From The Fuel System............840
ENGINE LUBRICATION SYSTEM............841
Checking And Adding Engine Oil............841
Engine Oil Chart............841
Removing And Replacing Oil And Filter............842
HYDRAULIC / HYDROSTATIC SYSTEM............843
Checking And Adding Fluid............843
Hydraulic / Hydrostatic Fluid Chart............843
Removing And Replacing Hydraulic Fluid............844
Removing And Replacing Hydraulic / Hydrostatic Filter............845
Hydraulic Tank Breather............845
ATTACHMENT CARRIER............847
Inspection And Maintenance............847
AXLES (FRONT AND REAR)............849
Checking Oil Level (Planetary Carrier)............849
Draining Oil (Planetary Carrier)............849
Checking Oil Level (Rear Differential)............850
Draining Oil (Rear Differential)............850
Checking Oil Level (Front Differential)............850
Draining Oil (Front Differential)............851
LUBRICATING THE TELESCOPIC HANDLER............853
Lubrication Locations............853
TYRE MAINTENANCE............857
Wheel Nuts............857
Rotation............857
Mounting............857
APPROVED BOOM STOP............859
Installing The Approved Boom Stop............859
Removing The Approved Boom Stop............859
ENGINE COVER............861
Opening And Closing............861
CHAIN............863
Checking And Adjustment Procedure............863
Extend / Retract Chain Wear Check............864
TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE............865
Storage............865
Return To Service............865
STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER............867
Procedure............867
EMERGENCY EXIT............869
Rear Window............869
HYDRAULIC SYSTEM............871
HYDRAULIC / HYDROSTATIC SCHEMATICS............875
HYDRAULIC SYSTEM INFORMATION............877
Glossary Of Hydraulic / Hydrostatic Symbols............877
Troubleshooting Chart............880
Tightening Procedures............881
LIFT CYLINDER............883
Removal And Installation............883
Parts Identification............886
Disassembly............887
Assembly............888
BUCKET POSITIONING CYLINDER............889
Removal And Installation............889
Parts Identification............890
Disassembly............891
Assembly............891
EXTENSION CYLINDER............893
Cylinder Group Removal And Installation............893
Parts Identification............896
Disassembly............897
Assembly............897
TILT CYLINDER............899
Removal And Installation............899
Parts Identification............901
Disassembly............902
Assembly............902
STEERING CYLINDER (FRONT)............903
Removal And Installation............903
Disassembly............905
Assembly............906
STEERING CYLINDER (REAR)............911
Removal............911
Installation............913
Disassembly............914
Assembly............916
DRIVE BOX............919
Parts Identification............919
Disassembly............920
Assembly............924
Special Tools............927
MAIN RELIEF VALVE............929
Testing............929
Adjustment............930
Removal and Installation............930
QUICK-TACH CYLINDER............933
Removal And Installation............933
Parts Identification............935
Disassembly............936
Assembly............936
FRAME LEVELING CYLINDER............937
Removal And Installation............937
Parts Identification............939
Disassembly............940
Assembly............940
STEERING MODE VALVE BLOCK............941
Removal And Installation............941
Parts Identification............943
Disassembly............944
Solenoid Testing............946
Assembly............946
BRAKE VALVE............949
Removal And Installation............949
Disassembly And Assembly............950
GEAR PUMP............953
Removal And Installation............953
Parts Identification............956
Disassembly And Assembly............957
FAN MOTOR............963
Removal And Installation............963
Parts Identification............967
Disassembly And Assembly............968
HYDRAULIC FLUID RESERVOIR............971
Removal And Installation............971
STEERING VALVE............973
Removal And Installation............973
Parts Identification............974
Disassembly............975
Inspection............978
Assembly............978
HYDRAULIC CONTROL VALVE............983
Checking Drain Pressure............983
Valve Section Troubleshooting (Auxiliary Section Example)............983
Removal And Installation............986
Parts Identification............988
Section Removal............995
Section Disassembly And Assembly............995
Inlet Section Disassembly And Assembly............1000
Inlet Section Disassembly And Assembly (Cont’d)............1001
PORT RELIEF VALVES............1003
Removal And Installation............1003
FLOW CONTROL VALVE............1005
Removal And Installation............1005
PARKING BRAKE............1007
Parking Brake Valve Removal And Installation............1007
Parking Brake Valve Disassembly And Assembly............1008
PRESSURE REDUCING VALVE............1011
Testing............1011
Removal And Installation............1012
ACCUMULATOR............1013
Removal And Installation............1013
TOW VALVE............1015
Removal And Installation............1015
Disassembly And Assembly............1016
STABILISER CYLINDER............1021
Removal And Installation............1021
Parts Identification............1023
Disassembly............1024
Assembly............1025
STABILISER CONTROL VALVE............1027
Parts Identification............1027
Removal............1028
Installation............1030
HYDROSTATIC SYSTEM............1033
HYDROSTATIC SYSTEM INFORMATION............1035
Troubleshooting Chart............1035
Replenishing Valve Function............1036
OIL COOLER............1037
Description............1037
HYDROSTATIC DRIVE MOTOR............1039
Removal And Installation............1039
Parts Identification............1040
Disassembly............1043
Inspection............1058
Assembly............1060
HYDROSTATIC PUMP............1077
Removal And Installation............1077
Parts Identification............1079
Disassembly............1083
Inspection............1093
Assembly............1097
DRIVE SYSTEM............1111
TROUBLESHOOTING............1113
Chart............1113
AXLE AND DIFFERENTIAL (FRONT)............1115
General Information............1115
Planetary Carrier Parts Identification............1115
Planetary Carrier Disassembly............1116
Steering Knuckle And Drive Axle Parts Identification............1121
Steering Knuckle Disassembly............1122
Drive Axle Disassembly............1124
Brake System Parts Identification............1126
Brake System Disassembly............1127
Differential Parts Identification............1131
Differential Disassembly............1132
Bevel Pinion Parts Identification............1137
Bevel Pinion Disassembly............1138
Bevel Pinion Assembly............1141
Differential Assembly............1150
Brake System Assembly............1155
Drive Axle Assembly............1161
Steering Knuckle Assembly............1163
Planetary Carrier Assembly............1166
Special Tools............1170
AXLE AND DIFFERENTIAL (REAR)............1171
General Information............1171
Planetary Carrier Parts Identification............1171
Steering Knuckle And Drive Axle Parts Identification............1177
Steering Knuckle Disassembly............1178
Differential And Bevel Pinion Parts Identification............1180
Differential Disassembly............1181
Bevel Pinion Disassembly............1185
Bevel Pinion Assembly............1188
Differential Assembly............1196
Steering Knuckle Assembly............1201
Planetary Carrier Assembly............1204
Special Tools............1208
FRONT AXLE............1209
Removal............1209
AXLE TOE-IN............1215
Adjustment............1215
PARKING BRAKE............1217
Releasing The Brake For Towing............1217
Re-Activating The Brake............1218
STEERING ANGLE ADJUSTMENT............1219
Adjustment............1219
DRIVE SHAFT............1221
Removal And Installation............1221
SERVICE BRAKE............1223
Description............1223
Bleeding The Brake Circuit............1223
REAR AXLE............1225
Removal And Installation............1225
MAINFRAME............1229
OPERATOR CAB (S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW)............1231
Removal and Installation............1231
OPERATOR CAB (S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE)............1239
Removal And Installation............1239
OPERATOR SEAT............1247
Removal And Installation............1247
BOOM ASSEMBLY............1249
Removal And Installation............1249
END BOOM............1253
Removal............1253
Installation............1255
WEAR PADS (FRONT)............1257
Removal............1257
Installation............1258
WEAR PADS (REAR)............1261
Removal............1261
Installation............1261
ENGINE COVER............1263
Gas Cylinder Removal And Installation............1263
Removal And Installation............1263
AIR INTAKE COWLING............1265
Removal And Installation............1265
FUEL TANK............1267
Removal And Installation............1267
QUICK-TACH............1271
Removal And Installation............1271
REAR WEIGHTS............1273
Removal And Installation............1273
FENDER............1275
Removal And Installation............1275
PIVOT LINK............1277
Removal And Installation............1277
JOYSTICK PANEL (S/N A8GA12999 & BELOW, A8GB12999 & BELOW)............1281
Removal And Installation............1281
JOYSTICK PANEL (S/N A8GA13000 & ABOVE, A8GB13000 & ABOVE)............1283
Removal And Installation............1283
DASH COVER / STEERING COLUMN COVER (S/N A8GA12999 & BELOW, A8GB12999 & BELOW)............1285
Removal And Installation............1285
DASH COVER / STEERING COLUMN COVER (S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE)............1289
Removal And Installation............1289
INTERMEDIATE BOOM............1293
Removal of the First Intermediate Boom............1293
Installation of the First Intermediate Boom............1294
Removal of the Second Intermediate Boom (T40170)............1295
Installation of the Second Intermediate Boom (T40170)............1296
BOOM TRAY............1299
Removal And Installation............1299
STABILISER FRAME............1303
Removal............1303
Installation............1304
FRONT WEIGHT............1307
Removal And Installation............1307
ELECTRICAL SYSTEM & ANALYSIS............1309
ELECTRIAL SCHEMATICS............1311
ELECTRICAL SYSTEM INFORMATION (S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW)............1388
Troubleshooting Chart............1388
Description............1390
Fuses, Diode And Relay Location / Identification............1390
ELECTRICAL SYSTEM INFORMATION (S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE)............1394
Troubleshooting Chart............1394
Description............1395
Fuses, Diodes And Relays............1395
BATTERY............1398
Removal And Installation............1398
Servicing............1399
Using A Booster Battery (Jump Starting)............1400
ALTERNATOR............1402
Removal And Installation............1402
Adjusting The Alternator Belt............1403
STARTER............1404
Testing............1404
Removal And Installation............1404
Parts Identification............1406
LIGHTS............1408
Rear Light Removal And Installation............1408
Front Light Removal And Installation............1409
TRAVEL / SIGNAL LEVER (S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW)............1412
Removal And Installation............1412
TRAVEL / SIGNAL LEVER (S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE)............1414
Removal And Installation............1414
INSTRUMENT PANEL............1416
Removal And Installation............1416
SWITCH PANEL (S/N A8GA12999 & BELOW, A8GB12999 & BELOW)............1418
Removal And Installation............1418
Parts description............1419
SWITCH PANEL (S/N A8GA13000 - 14999, A8GB13000 - 14999)............1422
Removal And Installation............1422
SWITCH PANEL (S/N A8GA15000 & ABOVE, S/N A8GB15000 & ABOVE)............1424
Removal And Installation............1424
BRAKE LIGHT SWITCH............1426
Removal And Installation............1426
Adjustment............1426
WIPER MOTOR (FRONT)............1428
Removal And Installation............1428
WIPER MOTOR (TOP)............1432
Removal And Installation............1432
WIPER MOTOR (REAR)............1434
Removal And Installation............1434
PEDAL ASSEMBLY............1436
Removal And Installation............1436
Disassembly And Assembly............1437
INCHING SWITCH............1442
Removal And Installation............1442
Adjustment............1442
SERVICE SOFTWARE............1444
Connecting The Laptop Computer............1444
Entering The Service Software............1445
Monitor Screen............1446
Warnings Screen............1448
Calibrate Inch Pedal............1449
Calibrate Creep Potentiometer............1450
Program / Update Susmic Controller............1452
FRAME LEVEL SPEED SWITCH............1454
Description............1454
Removal............1454
Installation............1455
LONGITUDINAL STABILITY INDICATOR CALIBRATION (S/N A8GA11001-14999, S/N A8GB11001-14999)............1456
Fitting The Sensor............1456
Calibration Procedure............1456
LLMI / LLMC SYSTEM (S/N A8GA15000 & ABOVE, S/ N A8GB15000 & ABOVE)............1458
System Calibration............1458
Calibration Test............1460
System Failure Reports............1461
System Components Identification............1466
LLMS Removal............1467
LLMS Installation............1469
LLMC Controller Removal............1471
LLMC Controller Installation............1473
BCC MAIN CONTROLLER (S/N A8GA12001 & ABOVE, S/N A8GB12001 & ABOVE)............1476
Removal And Installation............1476
JOYSTICK............1478
Removal And Installation............1478
ENGINE SERVICE............1480
ENGINE INFORMATION............1484
Specifications............1484
Troubleshooting............1495
ENGINE SPEED CONTROL............1498
Removal And Installation............1498
MUFFLER............1500
Removal And Installation............1500
AIR CLEANER............1502
Housing Removal And Installation............1502
OIL COOLER / RADIATOR............1504
Removal And Installation............1504
Disassembly And Assembly............1507
ENGINE AND ENGINE MOUNTS............1510
Removal And Installation............1510
ENGINE COMPONENTS AND TESTING............1514
Fuel Injection Pump Removal............1514
Fuel Injection Pump Installation............1517
Fuel Injectors Removal And Installation............1520
Checking The Fuel Lift Pump............1523
Fuel Lift Pump Removal And Installation............1524
Compression Checking............1524
Glow Plugs Checking............1525
Glow Plugs Removal And Installation............1526
ENGINE TIMING............1528
Procedure............1528
ENGINE / HYDROSTAT ASSEMBLY............1530
Removal And Installation............1530
FLYWHEEL AND HOUSING............1544
Removal And Installation............1544
Ring Gear Removal............1547
Ring Gear Installation............1547
RECONDITIONING THE ENGINE............1548
Turbo Charger Troubleshooting............1548
Turbo Charger Description............1549
Turbo Charger Removal And Installation............1549
Exhaust Manifold Removal And Installation............1551
Fuel Injector Cover Removal And Installation............1551
Rocker Cover Removal And Installation............1552
Cylinder Head Removal............1553
Cylinder Head Inspection............1555
Cylinder Head Installation............1556
Rocker Shaft Disassembly And Assembly............1559
Valve Removal............1559
Valve Springs Checking............1560
Valve Depth Checking............1560
Valve Guides Checking............1561
Valve Guide Removal............1562
Valve Guide Installation............1562
Valves Checking............1563
Cutting A Valve Seat............1563
Valve Seat Assembly............1564
Changing Valve Springs (With Cylinder Head Installed)............1565
Valve Clearance Adjustment............1566
Timing Case And Drive Assembly Description............1567
Timing Cover Removal............1567
Timing Cover Installation............1567
Crankshaft Pulley Removal And Installation............1567
Front Oil Seal Removal And Installation............1567
Timing Case And Gear Removal............1568
Timing Case And Gear Installation............1569
Camshaft And Tappets Removal............1571
Camshaft And Tappets Installation............1572
Pistons And Connecting Rods Description............1573
Pistons And Connecting Rods Removal............1573
Pistons And Connecting Rods Disassembly............1575
Piston Ring End Gap............1575
Piston Ring Installation............1575
Piston Ring Groove Clearance............1576
Connecting Rod Inspection............1577
Connecting Rod Bushing Replacement............1577
Piston And Connecting Rod Assembly............1577
Piston And Connecting Rod Installation............1577
Checking Piston Height............1579
Crankshaft And Bearings Description............1579
Crankshaft And Bearings Removal............1579
Inspection Of Crankshaft And Bearings............1581
Crankshaft And Bearings Installation............1582
Rear Oil Seal Removal............1583
Rear Oil Seal Housing Positioning............1583
Rear Oil Seal Installation............1584
Checking Crankshaft End Play............1584
Cooling System Description............1585
Thermostat Removal and Installation............1586
Thermostat Testing............1587
Lubricating Oil Cooler Removal And Installation............1587
Water Pump Removal............1587
Water Pump Installation............1587
Engine Lubrication System Description............1588
Oil Filter Adapter Removal And Installation............1589
Oil Pan Removal And Installation............1589
Oil Screen And Pick-up Tube............1590
Oil Pump Removal............1590
Oil Pump Installation............1591
Oil Pump Disassembly And Assembly............1592
Oil Pressure Relief Valve Disassembly And Assembly............1592
Engine Block Description............1593
Engine Block Disassembly And Assembly............1593
Piston Cooling Jet Removal............1594
Piston Cooling Jet Installation............1594
Piston Cooling Jet alignment............1594
Inspection............1594
Cylinder Liner Inspection............1595
Cylinder Liner Removal............1596
Cylinder Liner Installation............1597
HEATING, VENTILATION, AIR CONDITIONING............1598
AIR CONDITIONING SYSTEM FLOW............1600
Principles............1600
Chart............1601
Components............1602
Safety Equipment............1605
REGULAR MAINTENANCE............1606
Filters............1606
Compressor And Alternator Drive Belt Inspection............1606
Cleaning The Condenser............1607
Air Conditioning Lubrication............1607
Air Conditioning Service Chart............1608
TROUBLESHOOTING............1610
Blower Motor Does Not Operate............1610
Blower Motor Operates Normally, But Air Flow Is Insufficient............1610
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal............1610
The Compressor Does Not Operate At All, Or Operates Improperly............1610
Gauge Pressure Related Troubleshooting............1611
Troubleshooting Tree............1613
Temperature / Pressure Chart............1617
Poor A/C Performance............1618
HVAC Repair And Leaks............1619
Electrical System............1620
SYSTEM CHARGING AND RECLAMATION............1628
Reclamation Procedure............1628
Charging Procedure With A Manifold Gauge Set............1631
Charging Procedure............1632
COMPRESSOR............1634
Removal And Installation............1634
Oil............1635
Oil Check............1635
Clutch Disassembly And Assembly............1637
CONDENSER (S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW)............1642
Removal And Installation............1642
CONDENSER (S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE)............1644
Removal And Installation............1644
RECEIVER / DRIER............1646
Removal And Installation............1646
PRESSURE SWITCH............1648
Removal And Installation............1648
EVAPORATOR / BLOWER UNIT (S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW)............1650
Removal And Installation............1650
EVAPORATOR / BLOWER UNIT (S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE)............1652
Removal And Installation............1652
EXPANSION VALVE (S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW)............1654
Removal And Installation............1654
EXPANSION VALVE (S/N A8GA13000 & ABOVE, A8GB13000 & ABOVE)............1656
Removal And Installation............1656
HEATER ASSEMBLY............1658
Removal And Installation............1658
Fan Removal And Installation............1659
Core Removal And Installation............1660
SPECIFICATIONS............1662
(T40140) TELESCOPIC HANDLER SPECIFICATIONS............1664
Dimensional Specifications............1664
Performance Specifications............1665
Weights............1665
Engine............1665
Controls............1666
Drive System............1666
Traction............1666
Steering............1666
Brakes............1666
Fluid Capacities............1667
Hydraulic System............1667
Electrical............1667
Instruments............1668
Environmental............1668
Temperature Range............1668
(T40170) TELESCOPIC HANDLER SPECIFICATIONS............1670
Dimensional Specifications............1670
Performance Specifications............1671
Weights............1671
Engine............1671
Controls............1672
Drive System............1672
Traction............1672
Steering............1672
Brakes............1672
Fluid Capacities............1673
Hydraulic System............1673
Electrical............1673
Instruments............1674
Environmental............1674
Temperature Range............1674
MACHINE TORQUE SPECIFICATIONS............1676
Axle............1676
Boom............1676
Drive Box............1676
Drive Motor............1676
Engine............1677
Hydraulic Pump............1677
TORQUE SPECIFICATIONS FOR BOLTS............1678
Torque for General SAE Bolts............1678
Torque For General Metric Bolts............1679
HYDRAULIC CONNECTION SPECIFICATIONS............1680
O-ring Face Seal Connection............1680
Straight Thread O-ring Fitting............1680
Tubelines And Hoses............1680
Port Seal Fitting............1681
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS............1682
Specifications............1682
CONVERSIONS............1684
Decimal And Millimeter Equivalents............1684
U.S. To Metric Conversion............1684
ALPHABETICAL INDEX............1686
SERVICE MANUAL REVISION............1690
Revision No: T40140, T40170 - 1............1690
Revision No: T40140, T40170 - 2............1692
Revision No: T40140, T40170 - 3............1694
6986768 (2-10) - T40140, T40170 Telescopic Handler Service Manual............1698
MAINTENANCE SAFETY............1700
CONTENTS............1702
FOREWORD............1704
FOREWORD............1706
SAFETY INSTRUCTIONS............1708
FIRE PREVENTION............1709
Maintenance............1709
Operation............1709
Electrical............1709
Hydraulic System............1710
Fueling............1710
Starting............1710
Spark Arrester Exhaust System............1710
Welding And Grinding............1710
Fire Extinguishers............1710
SERIAL NUMBER LOCATION............1711
Telescopic Handler Serial Number............1711
Engine Serial Number............1711
Other Serial Numbers............1711
DELIVERY REPORT............1712
BOBCAT TELESCOPIC HANDLER IDENTIFICATION............1713
SAFETY AND MAINTENANCE............1714
LIFTING AND BLOCKING THE TELESCOPIC HANDLER............1716
Procedure............1716
OPERATOR CAB............1718
Emergency Exit............1718
Cab Door............1719
Cab Door Window............1719
TRANSPORTING THE TELESCOPIC HANDLER............1720
Loading And Unloading............1720
Fastening............1720
TOWING THE TELESCOPIC HANDLER............1722
Procedure............1722
SERVICE SCHEDULE............1724
AIR CLEANER SERVICE............1726
Replacing Filter Element............1726
ENGINE COOLING SYSTEM............1728
Cleaning The Cooling System............1728
Checking The Coolant Level............1729
Replacing The Coolant............1729
FUEL SYSTEM............1732
Fuel Specifications............1732
Filling The Fuel Tank............1732
Fuel Filter............1732
ENGINE LUBRICATION SYSTEM............1734
Checking Engine Oil............1734
Oil Chart............1734
Replacing Oil And Filter............1735
HYDRAULIC / HYDROSTATIC SYSTEM............1736
Checking And Adding Fluid............1736
Replacing Hydraulic / Hydrostatic Filter............1736
Replacing Hydraulic Fluid............1737
AXLES (FRONT AND REAR)............1738
Checking Oil Level (Planetary Carrier)............1738
Draining Oil (Planetary Carrier)............1738
Checking Oil Level (Rear Differential)............1739
Draining Oil (Rear Differential)............1739
Checking Oil Level (Front Differential)............1739
Draining Oil (Front Differential)............1740
LUBRICATION............1742
Procedure............1742
ATTACHMENT FRAME............1746
Inspection And Maintenance............1746
TYRE MAINTENANCE............1748
Wheel Nuts............1748
Tyre Mounting............1748
Tyre Rotation............1748
SPARK ARRESTER MUFFLER............1750
Cleaning............1750
APPROVED BOOM STOP............1752
Installing The Approved Boom Stop............1752
Removing The Approved Boom Stop............1752
ENGINE COVER............1754
Opening And Closing The Engine Cover............1754
CHAIN CHECKING AND ADJUSTING PROCEDURE............1756
Checking The Tension Of The Telescoping Chains............1756
HYDRAULIC SYSTEM............1760
HYDRAULIC SCHEMATICS............1764
HYDRAULIC SYSTEM INFORMATION............1766
Troubleshooting Chart............1769
Tightening Procedures............1770
LIFT CYLINDER............1772
Removal And Installation............1772
Parts Identification............1775
Disassembly............1776
Assembly............1777
BUCKET POSITIONING CYLINDER............1778
Removal And Installation............1778
Parts Identification............1779
Disassembly............1780
Assembly............1780
EXTENSION CYLINDER............1782
Cylinder Group Removal And Installation............1782
Parts Identification............1785
Disassembly............1786
Assembly............1786
TILT CYLINDER............1788
Removal And Installation............1788
Parts Identification............1790
Disassembly............1791
Assembly............1791
STEERING CYLINDER (FRONT)............1792
Removal And Installation............1792
Disassembly............1794
Assembly............1795
STEERING CYLINDER (REAR)............1800
Removal............1800
Installation............1802
Disassembly............1803
Assembly............1805
DRIVE BOX............1808
Parts Identification............1808
Disassembly............1809
Assembly............1813
Special Tools............1816
MAIN RELIEF VALVE............1818
Testing............1818
Adjustment............1819
Removal and Installation............1819
QUICK TACH CYLINDER............1822
Removal And Installation............1822
Parts Identification............1824
Disassembly............1825
Assembly............1825
FRAME LEVELING CYLINDER............1826
Removal And Installation............1826
Parts Identification............1828
Disassembly............1829
Assembly............1829
STEERING MODE VALVE BLOCK............1830
Removal And Installation............1830
Parts Identification............1832
Disassembly............1833
Solenoid Testing............1835
Assembly............1835
BRAKE VALVE............1838
Removal And Installation............1838
Disassembly And Assembly............1839
GEAR PUMP............1842
Removal And Installation............1842
Parts Identification............1845
Disassembly And Assembly............1846
FAN MOTOR............1852
Removal And Installation............1852
Parts Identification............1856
Disassembly And Assembly............1857
HYDRAULIC RESERVOIR............1860
Removal And Installation............1860
STEERING VALVE............1862
Removal And Installation............1862
Parts Identification............1863
Disassembly............1864
Inspection............1867
Assembly............1867
HYDRAULIC CONTROL VALVE............1872
Checking Drain Pressure............1872
Valve Section Troubleshooting (Auxiliary Section Example)............1872
Removal And Installation............1875
Parts Identification............1877
Section Removal............1884
Section Disassembly And Assembly............1884
Inlet Section Disassembly And Assembly............1888
PORT RELIEF VALVES............1892
Removal And Installation............1892
FLOW CONTROL VALVE............1894
Removal And Installation............1894
JOYSTICK............1896
Removal And Installation............1896
PARKING BRAKE............1898
Parking Brake Valve Removal And Installation............1898
Parking Brake Valve Disassembly And Assembly............1899
PRESSURE REDUCING VALVE............1902
Testing............1902
Removal And Installation............1903
ACCUMULATOR............1904
Removal And Installation............1904
TOW VALVE............1906
Removal And Installation............1906
Disassembly And Assembly............1907
STABILISER CYLINDER............1912
Removal And Installation............1912
Parts Identification............1914
Disassembly............1915
Assembly............1916
STABILISER CONTROL VALVE............1918
Parts Identification............1918
Removal............1919
HYDROSTATIC SYSTEM............1922
HYDROSTATIC SYSTEM INFORMATION............1924
Troubleshooting Chart............1924
Replenishing Valve Function............1925
OIL COOLER............1926
Description............1926
HYDROSTATIC DRIVE MOTOR............1928
Removal And Installation............1928
Parts Identification............1929
Disassembly............1932
Inspection............1947
Assembly............1949
HYDROSTATIC PUMP............1966
Removal And Installation............1966
Parts Identification............1968
Disassembly............1972
Inspection............1982
Assembly............1986
DRIVE SYSTEM............2000
TROUBLESHOOTING............2002
Chart............2002
AXLE AND DIFFERENTIAL (FRONT)............2004
General Information............2004
Planetary Carrier Parts Identification............2004
Planetary Carrier Disassembly............2005
Steering Knuckle And Drive Axle Parts Identification............2010
Steering Knuckle Disassembly............2011
Drive Axle Disassembly............2013
Brake System Parts Identification............2015
Brake System Disassembly............2016
Differential Parts Identification............2020
Differential Disassembly............2021
Bevel Pinion Parts Identification............2026
Bevel Pinion Disassembly............2027
Bevel Pinion Assembly............2030
Differential Assembly............2039
Brake System Assembly............2044
Drive Axle Assembly............2050
Steering Knuckle Assembly............2052
Planetary Carrier Assembly............2055
Special Tools............2059
AXLE AND DIFFERENTIAL (REAR)............2060
General Information............2060
Planetary Carrier Parts Identification............2060
Steering Knuckle And Drive Axle Parts Identification............2066
Steering Knuckle Disassembly............2067
Differential And Bevel Pinion Parts Identification............2069
Differential Disassembly............2070
Bevel Pinion Disassembly............2074
Bevel Pinion Assembly............2077
Differential Assembly............2085
Steering Knuckle Assembly............2090
Planetary Carrier Assembly............2093
Special Tools............2097
FRONT AXLE............2098
Removal............2098
AXLE TOE-IN............2104
Adjustment............2104
PARKING BRAKE............2106
Releasing The Brake For Towing............2106
Re-Activating The Brake............2107
STEERING ANGLE ADJUSTMENT............2108
Adjustment............2108
DRIVESHAFT............2110
Removal And Installation............2110
SERVICE BRAKE............2112
Description............2112
Bleeding The Brake Circuit............2112
REAR AXLE............2114
Removal And Installation............2114
MAIN FRAME............2118
OPERATOR CAB (S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW)............2120
Removal and Installation............2120
OPERATOR CAB (S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE)............2128
Removal And Installation............2128
OPERATOR SEAT............2136
Removal And Installation............2136
BOOM ASSEMBLY............2138
Removal And Installation............2138
END BOOM............2142
Removal............2142
Installation............2144
WEAR PADS (FRONT)............2146
Removal............2146
Installation............2147
WEAR PADS (REAR)............2150
Removal............2150
Installation............2150
ENGINE COVER............2152
Gas Cylinder Removal And Installation............2152
Removal And Installation............2152
AIR INTAKE COWLING............2154
Removal And Installation............2154
FUEL TANK............2156
Removal And Installation............2156
QUICK TACH............2160
Removal And Installation............2160
REAR WEIGHTS............2162
Removal And Installation............2162
FENDER............2164
Removal And Installation............2164
FRONT WEIGHT............2166
Removal And Installation............2166
DASH COVER / STEERING COLUMN COVER (S/N A8GA12999 & BELOW, A8GB12999 & BELOW)............2168
Removal And Installation............2168
DASH COVER / STEERING COLUMN COVER (S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE)............2172
Removal And Installation............2172
JOYSTICK PANEL (S/N A8GA12999 & BELOW, A8GB12999 & BELOW)............2176
Removal And Installation............2176
JOYSTICK PANEL (S/N A8GA13000 & ABOVE, A8GB13000 & ABOVE)............2178
Removal And Installation............2178
INTERMEDIATE BOOM............2180
Removal of the First Intermediate Boom............2180
Installation of the First Intermediate Boom............2181
Removal of the Second Intermediate Boom (T40170)............2182
Installation of the Second Intermediate Boom (T40170)............2183
BOOM TRAY............2186
Removal And Installation............2186
PIVOT LINK............2190
Removal And Installation............2190
STABILISER FRAME............2194
Removal............2194
Installation............2195
ELECTRICAL SYSTEM AND ANALYSIS............2198
ELECTRICAL SYSTEM INFORMATION (S/N A8HM12999 & BELOW, S/N A8HN12999 & BELOW)............2276
Troubleshooting Chart............2276
Description............2277
Fuses, Diodes And Relays............2277
Fuses And Diodes............2279
Relays............2279
ELECTRICAL SCHEMATICS (S/N 13000 & ABOVE)............2200
ELECTRICAL SCHEMATICS (S/N 12001 - 12999)............2219
ELECTRICAL SCHEMATICS (S/N 11001 - 11999)............2238
ELECTRICAL SYSTEM INFORMATION (S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE)............2282
Troubleshooting Chart............2282
Description............2283
Fuses, Diodes And Relays............2283
BATTERY............2286
Removal And Installation............2286
Servicing............2287
Using A Booster Battery (Jump Starting)............2288
ALTERNATOR............2290
Removal And Installation............2290
Adjusting The Alternator Belt............2291
STARTER............2292
Removal And Installation............2292
Parts Identification............2293
Disassembly............2294
Inspection And Repair............2299
Assembly............2303
LIGHTS............2308
Rear Light Removal And Installation............2308
Front Light Removal And Installation............2309
TRAVEL / SIGNAL LEVER (S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW)............2312
Removal And Installation............2312
TRAVEL / SIGNAL LEVER (S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE)............2314
Removal And Installation............2314
INSTRUMENT PANEL............2316
Removal And Installation............2316
SWITCH PANEL (S/N A8GA12999 & BELOW, A8GB12999 & BELOW)............2318
Removal And Installation............2318
Parts description............2319
SWITCH PANEL (S/N A8GA13000 & ABOVE, A8GB13000 & ABOVE)............2322
Removal And Installation............2322
Parts description............2323
BRAKE LIGHT SWITCH............2326
Removal And Installation............2326
Adjustment............2326
FRONT WIPER MOTOR............2328
Removal And Installation............2328
TOP WIPER MOTOR............2332
Removal And Installation............2332
REAR WIPER MOTOR............2334
Removal And Installation............2334
PEDAL ASSEMBLY............2336
Removal And Installation............2336
Disassembly And Assembly............2337
INCHING SWITCH............2342
Removal And Installation............2342
Adjustment............2342
SERVICE SOFTWARE............2344
Connecting The Laptop Computer............2344
Entering The Service Software............2345
Monitor Screen............2346
Warnings Screen............2348
Calibrate Inch Pedal............2349
Calibrate Creep Potentiometer............2350
Program / Update Susmic Controller............2352
FRAME LEVEL SPEED SWITCH............2354
Description............2354
Removal............2354
Installation............2355
ENGINE SERVICE............2356
TROUBLESHOOTING............2360
Chart............2360
ENGINE SPEED CONTROL............2362
Removal And Installation............2362
MUFFLER............2364
Removal And Installation............2364
AIR CLEANER............2366
Housing Removal And Installation............2366
OIL COOLER / RADIATOR............2368
Removal And Installation............2368
Disassembly And Assembly............2371
ENGINE AND ENGINE MOUNTS............2374
Removal And Installation............2374
ENGINE COMPONENTS AND TESTING............2378
Fuel Injection Pump Removal............2378
Fuel Injection Pump Installation............2381
Fuel Injectors Removal And Installation............2384
Checking The Fuel Lift Pump............2386
Fuel Lift Pump Removal And Installation............2387
Compression Checking............2387
Glow Plugs Checking............2388
Glow Plugs Removal And Installation............2389
ENGINE TIMING............2390
Procedure............2390
ENGINE / HYDROSTAT ASSEMBLY............2392
Removal And Installation............2392
FLYWHEEL AND HOUSING............2406
Removal And Installation............2406
Ring Gear Removal............2409
Ring Gear Installation............2409
RECONDITIONING THE ENGINE............2410
Turbo Charger Troubleshooting............2410
Turbo Charger Description............2411
Turbo Charger Removal And Installation............2411
Exhaust Manifold Removal And Installation............2413
Fuel Injector Cover Removal And Installation............2413
Rocker Cover Removal And Installation............2414
Cylinder Head Removal............2415
Cylinder Head Inspection............2417
Cylinder Head Installation............2418
Rocker Shaft Disassembly And Assembly............2421
Valve Removal............2421
Valve Springs Checking............2422
Valve Depth Checking............2422
Valve Guides Checking............2423
Valve Guide Removal............2424
Valve Guide Installation............2424
Valves Checking............2425
Cutting A Valve Seat............2425
Valve Seat Assembly............2426
Changing Valve Springs (With Cylinder Head Installed)............2427
Valve Clearance Adjustment............2428
Timing Case And Drive Assembly Description............2429
Timing Cover Removal............2429
Timing Cover Installation............2429
Crankshaft Pulley Removal And Installation............2429
Front Oil Seal Removal And Installation............2429
Timing Case And Gear Removal............2431
Timing Case And Gear Installation............2432
Camshaft And Tappets Removal............2434
Camshaft And Tappets Installation............2435
Pistons And Connecting Rods Description............2436
Pistons And Connecting Rods Removal............2436
Pistons And Connecting Rods Disassembly............2438
Piston Ring End Gap............2438
Piston Ring Installation............2438
Piston Ring Groove Clearance............2439
Connecting Rod Inspection............2440
Connecting Rod Bushing Replacement............2440
Piston And Connecting Rod Assembly............2440
Piston And Connecting Rod Installation............2440
Checking Piston Height............2442
Crankshaft And Bearings Description............2442
Crankshaft And Bearings Removal............2442
Inspection Of Crankshaft And Bearings............2444
Crankshaft And Bearings Installation............2445
Rear Oil Seal Removal............2446
Rear Oil Seal Housing Positioning............2446
Rear Oil Seal Installation............2447
Checking Crankshaft End Play............2447
Cooling System Description............2448
Thermostat Removal and Installation............2449
Thermostat Testing............2450
Lubricating Oil Cooler Removal And Installation............2450
Water Pump Removal............2450
Water Pump Installation............2450
Engine Lubrication System Description............2451
Oil Filter Adapter Removal And Installation............2452
Oil Pan Removal And Installation............2452
Oil Screen And Pick-up Tube............2453
Oil Pump Removal............2453
Oil Pump Installation............2454
Oil Pump Disassembly And Assembly............2455
Oil Pressure Relief Valve Disassembly And Assembly............2455
Engine Block Description............2456
Engine Block Disassembly And Assembly............2456
Piston Cooling Jet Removal............2457
Piston Cooling Jet Installation............2457
Piston Cooling Jet alignment............2457
Inspection............2457
Cylinder Liner Inspection............2458
Cylinder Liner Removal............2459
Cylinder Liner Installation............2460
HEATING, VENTILATION, AIR CONDITIONING............2462
AIR CONDITIONING SYSTEM FLOW............2464
Principles............2464
Chart............2465
COMPONENTS............2466
Identification............2466
SAFETY............2470
Safety Equipment............2470
REGULAR MAINTENANCE............2472
Filter Element Removal And Installation............2472
Compressor Drive Belt Inspection............2472
Cleaning The Condenser............2473
BASIC TROUBLESHOOTING............2474
Poor A/C Performance............2474
Compressor Drive Belt Inspection............2475
Checking The Electrical System............2476
GENERAL AIR CONDITIONING SERVICE GUIDELINES............2482
Compressor Oil............2482
Compressor Oil Check............2482
Component Replacement And Refrigeration Leaks............2484
SYSTEM TROUBLESHOOTING CHART............2486
TEMPERATURE / PRESSURE............2490
Chart............2490
AIR CONDITIONING SERVICE............2492
Chart............2492
SYSTEM CHARGING AND RECLAMATION............2494
Reclamation Procedure............2494
Charging Procedure With A Manifold Gauge Set............2497
Charging Procedure............2498
COMPRESSOR............2500
Removal And Installation............2500
Compressor Clutch Disassembly And Assembly............2501
CONDENSER (S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW)............2506
Removal And Installation............2506
CONDENSER (S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE)............2508
Removal And Installation............2508
RECEIVER / DRIER............2510
Removal And Installation............2510
PRESSURE SWITCH............2512
Removal And Installation............2512
EVAPORATOR / BLOWER UNIT (S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW)............2514
Removal And Installation............2514
EVAPORATOR / BLOWER/HEATER UNIT (S/N A8GA13000 & ABOVE, S/N A8GB13000 & ABOVE)............2516
Removal And Installation............2516
EXPANSION VALVE (S/N A8GA12999 & BELOW, S/N A8GB12999 & BELOW)............2518
Removal And Installation............2518
EXPANSION VALVE (S/N A8GA13000 & ABOVE, A8GB13000 & ABOVE)............2520
Removal And Installation............2520
HEATER ASSEMBLY............2522
Removal And Installation............2522
Fan Removal And Installation............2523
Core Removal And Installation............2524
SPECIFICATIONS............2526
TELESCOPIC HANDLER SPECIFICATIONS............2528
Dimensional Specifications T40140............2528
Dimensional Specifications T40170............2528
Performance Specifications............2529
Engine............2529
Fan Pump............2529
Controls............2530
Drive System............2530
Tyres............2530
Capacities............2531
Hydraulic System............2531
Electrical System............2531
Instrument Panel............2531
ENGINE SPECIFICATIONS............2532
General............2532
Cylinder Head............2532
Valve Guides............2532
Exhaust Valves............2533
Intake Valves............2533
Valve Springs............2533
Rocker Shaft, Rockers And Bushings............2534
Pistons And Piston Rings............2534
Connecting Rods And Bearings............2535
Crankshaft............2535
Crankshaft Re-Grind Data............2536
Main Bearings............2537
Thrust Washers............2537
Camshaft And Thrust Washer............2537
Cylinder Block............2537
Cylinder Liners............2538
Fuel Injection Pump............2538
Fuel Injectors............2538
Fuel Lift Pump............2538
Timing Case And Timing Gears............2539
Oil Pump, Gear And Relief Valve............2540
Turbocharger............2540
Flywheel............2540
Water Pump And Thermostat............2541
Engine Torque Component............2542
MACHINE TORQUE SPECIFICATIONS............2544
Axle............2544
Boom............2544
Drive Box............2544
Drive Motor............2544
Engine............2545
Hydraulic Pump............2545
TORQUE SPECIFICATIONS FOR BOLTS............2546
Torque for General SAE Bolts............2546
Torque For General Metric Bolts............2547
HYDRAULIC CONNECTION SPECIFICATIONS............2548
O-ring Face Seal Connection............2548
Straight Thread O-ring Fitting............2548
Tubelines And Hoses............2548
Port Seal Fitting............2549
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS............2550
Specifications............2550
CONVERSIONS............2552
Decimal And Millimeter Equivalents............2552
U.S. To Metric Conversion............2552
ALPHABETICAL INDEX............2554
SERVICE MANUAL REVISION............2558
Revision No: T40140, T40170 - 1............2558
6989561 (2-10) - T40140 Telescopic Handler Operation & Maintenance Manual............2560
CONTENTS............2564
FOREWORD............2566
DECLARATION OF CONFORMITY............2568
Model T40140............2568
BOBCAT COMPANY IS IS0 9001 CERTIFIED............2569
REGULAR MAINTENANCE ITEMS............2569
Parts............2569
Lubricants, Fuel and Fluids............2570
SERIAL NUMBER LOCATION............2571
Telescopic Handler Serial Number............2571
Engine Serial Number............2571
Other Serial Numbers............2571
DELIVERY REPORT............2572
BOBCAT telescopic handler IDENTIFICATION............2573
FEATURES, ACCESSORIES AND ATTACHMENTS............2574
Standard Items............2574
Options And Accessories............2574
Available Tyres............2574
Attachments............2574
Windscreen Grill............2575
Windscreen Grill Inspection And Maintenance............2575
SAFETY & TRAINING RESOURCES............2576
SAFETY INSTRUCTIONS............2578
Before Operation............2578
Safe Operation Is The Operator’s Responsibility............2579
Safe Operation Needs A Qualified Operator............2579
Avoid Silica Dust............2580
FIRE PREVENTION............2580
Maintenance............2580
Operation............2580
Electrical............2580
Hydraulic System............2581
Fueling............2581
Starting............2581
Spark Arrester Exhaust System............2581
Welding And Grinding............2581
Fire Extinguishers............2581
PUBLICATIONS AND TRAINING RESOURCES............2582
MACHINE SIGNS (DECALS)............2583
No-Text Safety Signs............2586
LOAD CHARTS............2590
CHARTS............2592
OPERATING INSTRUCTIONS............2594
OPERATOR CONTROLS IDENTIFICATION............2596
Operator Components............2596
Travel Direction And Two-Speed Control............2596
Steering Wheel............2597
Direction Signal............2597
Front Wiper/Washer/Headlight Dimmer............2597
Horn............2597
Steering Wheel Tilt Adjustment............2598
Longitudinal Stability Indicator / AMA System............2598
Centre Instrument Panel............2599
Right Instrument And Indicator Panel............2600
Left Instrument Panel............2602
Heater / Air Conditioning Controls (If Equipped)............2602
Rear Console............2603
Accelerator Pedal............2603
Brake Pedal And Inching Control............2603
Self-Levelling/Side Shift Switch............2604
OPERATOR CAB (ROPS / FOPS)............2605
Description............2605
Cab Door............2605
Cab Door Window............2606
STEERING MODE SELECTION............2607
Steering Controls............2607
PARKING BRAKE............2608
Operation............2608
EMERGENCY EXIT............2608
Rear Window............2608
BACK-UP ALARM SYSTEM (IF EQUIPPED)............2609
Description............2609
Operation............2609
DRIVING AND STEERING THE TELESCOPIC HANDLER............2610
4-Wheel Steering Mode............2610
Stopping The Telescopic Handler (4-Wheel Steering Mode)............2611
2-Wheel Steering Mode............2612
Stopping The Telescopic Handler (2-Wheel Steering Mode)............2613
Crab Steering Mode............2614
Stopping The Telescopic Handler (Crab Steering Mode)............2615
CREEP MODE OPERATION............2616
Description............2616
Operation............2616
HYDRAULIC CONTROLS............2617
Hydraulic Control Lever (Joystick)............2617
Auxiliary Hydraulic Release............2618
DAILY INSPECTION............2619
Daily Inspection And Maintenance............2619
PRE-STARTING PROCEDURE............2621
Entering The Telescopic Handler............2621
Operation & Maintenance Manual Locations............2621
Seat Adjustment............2622
Seat Belt Adjustment............2622
Panel Switch Position............2623
STARTING THE ENGINE............2624
Cold Temperature Starting............2625
Warming The Hydraulic / Hydrostatic System............2625
MONITORING THE DISPLAY PANELS............2626
Panel............2626
STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER............2626
Procedure............2626
ATTACHMENTS............2627
Installing And Removing The Attachment (Manual Locking)............2627
Installing And Removing The Attachment (Hydraulic Locking) (Optional)............2628
OPERATING PROCEDURE............2630
Aggravating Movements Arrester System (AMA)............2630
Deactivation Switch Key for the Aggravating Movements Arrester (AMA) System............2630
Inspecting The Work Area............2631
Basic Operating Instructions............2631
Operating With A Full Bucket............2632
Operating With An Empty Bucket............2632
Filling And Emptying The Bucket............2633
Digging And Filling A Hole............2634
Raising A Load And Extending The Boom............2635
Using Self-Levelling/Side Shift............2636
Using Stabilisers............2637
Load Capacity Charts............2638
TOWING THE telescopic handler............2639
Procedure............2639
LIFTING THE telescopic handler............2641
TRANSPORTING THE telescopic handler............2642
Loading And Unloading............2642
Fastening............2642
PREVENTIVE MAINTENANCE............2644
SERVICE SCHEDULE............2648
SEAT BELT............2649
Inspection And Maintenance............2649
APPROVED BOOM STOP (IF EQUIPPED)............2650
Installing The Approved Boom Stop............2650
Removing The Approved Boom Stop............2650
BACK-UP ALARM SYSTEM (IF EQUIPPED)............2651
Description............2651
Inspecting............2651
ENGINE COVER............2651
Opening And Closing............2651
Heating, VENTILATION AND AIR CONDITIONING System (HVAC)............2652
Cleaning And Maintenance............2652
Filters............2652
Condenser............2652
Air Conditioning Lubrication............2652
Troubleshooting............2652
AIR CLEANER SERVICE............2653
Replacing Filters............2653
FUEL SYSTEM............2655
Fuel Specifications............2655
Biodiesel Blend Fuel............2655
Filling The Fuel Tank............2655
Secondary Fuel Filter............2656
Primary Fuel Filter (Pre-Filter)............2656
Removing Air From The Fuel System............2657
ENGINE LUBRICATION SYSTEM............2658
Checking And Adding Engine Oil............2658
Engine Oil Chart............2658
Removing And Replacing Oil And Filter............2659
ENGINE COOLING SYSTEM............2660
Cleaning............2660
Removing And Replacing The Coolant............2661
Checking Level............2662
ELECTRICAL SYSTEM............2662
Description............2662
Fuses, Diode And Relay Location / Identification............2663
Battery Maintenance............2665
Using A Booster Battery (Jump Starting)............2666
Removing And Installing Battery............2667
Battery Disconnect Switch............2669
HYDRAULIC/HYDROSTATIC SYSTEM............2670
Checking And Adding Fluid............2670
Hydraulic / Hydrostatic Fluid Chart............2670
Removing And Replacing Hydraulic Fluid............2671
Removing And Replacing Hydraulic/Hydrostatic Filter............2672
Hydraulic Tank Breather............2672
AXLES (FRONT AND REAR)............2673
Checking And Adding Oil (Planetary Carrier)............2673
Removing And Replacing Oil (Planetary Carrier)............2673
Checking And Adding Oil (Rear Differential)............2674
Removing And Replacing Oil (Rear Differential)............2674
Checking And Adding Oil (Front Differential)............2675
Removing And Replacing Oil (Front Differential)............2675
Checking And Adding Oil (Front Drop Box)............2676
Removing And Replacing Oil (Front Drop Box)............2676
ALTERNATOR BELT............2677
Belt Adjusting............2677
Belt Replacement............2677
TYRE MAINTENANCE............2678
Wheel Nuts............2678
Tyre Mounting............2678
Tyre Rotating............2678
Tyre Pressure............2678
LUBRICATING THE TELESCOPIC HANDLER............2679
Lubrication Locations............2679
ATTACHMENT FRAME............2683
Inspection And Maintenance............2683
CHAIN CHECKING AND ADJUSTING PROCEDURE............2684
Checking/Adjustment Procedure............2684
Extend/Retract Chain Wear Check............2685
TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE............2686
Storage............2686
Return To Service............2686
SPECIFICATIONS............2688
(T40140) TELESCOPIC HANDLER SPECIFICATIONS............2690
Dimensional Specifications............2690
Performance Specifications............2691
Weights............2691
Engine............2691
Controls............2692
Drive System............2692
Traction............2692
Steering............2692
Brakes............2692
Fluid Capacities............2693
Hydraulic System............2693
Electrical............2693
Instruments............2694
Environmental............2694
Temperature Range............2694
WARRANTY............2696
WARRANTY............2698
ALPHABETICAL INDEX............2700
6989562 (2-10) - T40170 Telescopic Handler Operation & Maintenance Manual............2702
OPERATOR SAFETY WARNINGS............2704
CONTENTS............2706
FOREWORD............2708
DECLARATION OF CONFORMITY............2710
Model T40170............2710
BOBCAT COMPANY IS IS0 9001 CERTIFIED............2711
REGULAR MAINTENANCE ITEMS............2711
Parts............2711
Lubricants, Fuel and Fluids............2712
SERIAL NUMBER LOCATION............2713
Telescopic Handler Serial Number............2713
Engine Serial Number............2713
Other Serial Numbers............2713
DELIVERY REPORT............2714
BOBCAT telescopic handler IDENTIFICATION............2715
FEATURES, ACCESSORIES AND ATTACHMENTS............2716
Standard Items............2716
Options And Accessories............2716
Available Tyres............2716
Attachments............2716
Windscreen Grill............2717
Windscreen Grill Inspection And Maintenance............2717
SAFETY & TRAINING RESOURCES............2718
SAFETY INSTRUCTIONS............2720
Before Operation............2720
Safe Operation Is The Operator’s Responsibility............2721
Safe Operation Needs A Qualified Operator............2721
Avoid Silica Dust............2722
FIRE PREVENTION............2722
Maintenance............2722
Operation............2722
Electrical............2722
Hydraulic System............2723
Fueling............2723
Starting............2723
Spark Arrester Exhaust System............2723
Welding And Grinding............2723
Fire Extinguishers............2723
PUBLICATIONS AND TRAINING RESOURCES............2724
MACHINE SIGNS (DECALS)............2725
No-Text Safety Signs............2728
LOAD CHARTS............2732
CHARTS............2734
OPERATING INSTRUCTIONS............2736
OPERATOR CONTROLS IDENTIFICATION............2738
Operator Components............2738
Travel Direction And Two-Speed Control............2738
Steering Wheel............2739
Direction Signal............2739
Front Wiper/Washer/Headlight Dimmer............2739
Horn............2739
Steering Wheel Tilt Adjustment............2740
Longitudinal Stability Indicator / AMA System............2740
Centre Instrument Panel............2741
Right Instrument And Indicator Panel............2742
Left Instrument Panel............2744
Heater / Air Conditioning Controls (If Equipped)............2744
Rear Console............2745
Accelerator Pedal............2745
Brake Pedal And Inching Control............2745
Self-Levelling/Side Shift Switch............2746
OPERATOR CAB (ROPS / FOPS)............2747
Description............2747
Cab Door............2747
Cab Door Window............2748
STEERING MODE SELECTION............2749
Steering Controls............2749
PARKING BRAKE............2750
Operation............2750
EMERGENCY EXIT............2750
Rear Window............2750
BACK-UP ALARM SYSTEM (IF EQUIPPED)............2751
Description............2751
Operation............2751
DRIVING AND STEERING THE TELESCOPIC HANDLER............2752
4-Wheel Steering Mode............2752
Stopping The Telescopic Handler (4-Wheel Steering Mode)............2753
2-Wheel Steering Mode............2754
Stopping The Telescopic Handler (2-Wheel Steering Mode)............2755
Crab Steering Mode............2756
Stopping The Telescopic Handler (Crab Steering Mode)............2757
CREEP MODE OPERATION............2758
Description............2758
Operation............2758
HYDRAULIC CONTROLS............2759
Hydraulic Control Lever (Joystick)............2759
Auxiliary Hydraulic Release............2760
DAILY INSPECTION............2761
Daily Inspection And Maintenance............2761
PRE-STARTING PROCEDURE............2763
Entering The Telescopic Handler............2763
Operation & Maintenance Manual Locations............2763
Seat Adjustment............2764
Seat Belt Adjustment............2764
Panel Switch Position............2765
STARTING THE ENGINE............2766
Cold Temperature Starting............2767
Warming The Hydraulic / Hydrostatic System............2767
MONITORING THE DISPLAY PANELS............2768
Panel............2768
STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER............2768
Procedure............2768
ATTACHMENTS............2769
Installing And Removing The Attachment (Manual Locking)............2769
Installing And Removing The Attachment (Hydraulic Locking) (Optional)............2770
OPERATING PROCEDURE............2772
Aggravating Movements Arrester System (AMA)............2772
Deactivation Switch Key for the Aggravating Movements Arrester (AMA) System............2772
Inspecting The Work Area............2773
Basic Operating Instructions............2773
Operating With A Full Bucket............2774
Operating With An Empty Bucket............2774
Filling And Emptying The Bucket............2775
Digging And Filling A Hole............2776
Raising A Load And Extending The Boom............2777
Using Self-Levelling/Side Shift............2778
Using Stabilisers............2779
Load Capacity Charts............2780
TOWING THE telescopic handler............2781
Procedure............2781
LIFTING THE telescopic handler............2783
TRANSPORTING THE telescopic handler............2784
Loading And Unloading............2784
Fastening............2784
PREVENTIVE MAINTENANCE............2786
SERVICE SCHEDULE............2790
SEAT BELT............2791
Inspection And Maintenance............2791
APPROVED BOOM STOP (IF EQUIPPED)............2792
Installing The Approved Boom Stop............2792
Removing The Approved Boom Stop............2792
BACK-UP ALARM SYSTEM (IF EQUIPPED)............2793
Description............2793
Inspecting............2793
ENGINE COVER............2793
Opening And Closing............2793
Heating, VENTILATION AND AIR CONDITIONING System (HVAC)............2794
Cleaning And Maintenance............2794
Filters............2794
Condenser............2794
Air Conditioning Lubrication............2794
Troubleshooting............2794
AIR CLEANER SERVICE............2795
Replacing Filters............2795
FUEL SYSTEM............2797
Fuel Specifications............2797
Biodiesel Blend Fuel............2797
Filling The Fuel Tank............2797
Secondary Fuel Filter............2798
Primary Fuel Filter (Pre-Filter)............2798
Removing Air From The Fuel System............2799
ENGINE LUBRICATION SYSTEM............2800
Checking And Adding Engine Oil............2800
Engine Oil Chart............2800
Removing And Replacing Oil And Filter............2801
ENGINE COOLING SYSTEM............2802
Cleaning............2802
Removing And Replacing The Coolant............2803
Checking Level............2804
ELECTRICAL SYSTEM............2804
Description............2804
Fuses, Diode And Relay Location / Identification............2805
Battery Maintenance............2807
Using A Booster Battery (Jump Starting)............2808
Removing And Installing Battery............2809
Battery Disconnect Switch............2811
HYDRAULIC/HYDROSTATIC SYSTEM............2812
Checking And Adding Fluid............2812
Hydraulic / Hydrostatic Fluid Chart............2812
Removing And Replacing Hydraulic Fluid............2813
Removing And Replacing Hydraulic/Hydrostatic Filter............2814
Hydraulic Tank Breather............2814
AXLES (FRONT AND REAR)............2815
Checking And Adding Oil (Planetary Carrier)............2815
Removing And Replacing Oil (Planetary Carrier)............2815
Checking And Adding Oil (Rear Differential)............2816
Removing And Replacing Oil (Rear Differential)............2816
Checking And Adding Oil (Front Differential)............2817
Removing And Replacing Oil (Front Differential)............2817
Checking And Adding Oil (Front Drop Box)............2818
Removing And Replacing Oil (Front Drop Box)............2818
ALTERNATOR BELT............2819
Belt Adjusting............2819
Belt Replacement............2819
TYRE MAINTENANCE............2820
Wheel Nuts............2820
Tyre Mounting............2820
Tyre Rotating............2820
Tyre Pressure............2820
LUBRICATING THE TELESCOPIC HANDLER............2821
Lubrication Locations............2821
ATTACHMENT FRAME............2825
Inspection And Maintenance............2825
CHAIN CHECKING AND ADJUSTING PROCEDURE............2826
Checking/Adjustment Procedure............2826
Extend/Retract Chain Wear Check............2827
TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE............2828
Storage............2828
Return To Service............2828
SPECIFICATIONS............2830
(T40170) TELESCOPIC HANDLER SPECIFICATIONS............2832
Dimensional Specifications............2832
Performance Specifications............2833
Weights............2833
Engine............2833
Controls............2834
Drive System............2834
Traction............2834
Steering............2834
Brakes............2834
Fluid Capacities............2835
Hydraulic System............2835
Electrical............2835
Instruments............2836
Environmental............2836
Temperature Range............2836
WARRANTY............2838
WARRANTY............2840
ALPHABETICAL INDEX............2842
6990783 (07-14) - T40140, T40180 Telescopic Handler Service Manual............2844
MAINTENANCE SAFETY............2846
CONTENTS............2848
FOREWORD............2850
FOREWORD............2852
SAFETY INSTRUCTIONS............2854
Safe Operation Is The Operator’s Responsibility............2854
Safe Operation Needs A Qualified Operator............2854
Avoid Silica Dust............2855
Dismantling And Disposal............2855
FIRE PREVENTION............2856
Maintenance............2856
Operation............2856
Electrical............2856
Hydraulic System............2856
Fueling............2856
Starting............2856
Welding And Grinding............2857
Fire Extinguishers............2857
SERIAL NUMBER LOCATION............2858
Telescopic Handler Serial Number............2858
Engine Serial Number............2859
Diesel Oxidation Catalytic Converter Serial Number............2859
Other Serial Numbers............2859
DELIVERY REPORT............2860
BOBCAT TELESCOPIC HANDLER IDENTIFICATION............2861
SAFETY AND MAINTENANCE............2862
LIFTING AND BLOCKING THE TELESCOPIC HANDLER............2866
Procedure............2866
OPERATOR CAB............2868
Description............2868
Cab Door............2868
Cab Door Window............2869
Rear Cab Window............2870
Cab Light............2870
TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER............2872
Loading And Unloading............2872
Fastening............2872
TOWING THE TELESCOPIC HANDLER............2874
Procedure............2874
SERVICE SCHEDULE............2878
Maintenance Intervals............2878
AIR CLEANER SERVICE............2882
Replacing Filter Elements............2882
ENGINE COOLING SYSTEM............2884
Cleaning............2884
Checking Level............2884
Removing And Replacing The Coolant............2885
FUEL SYSTEM............2886
Fuel Specifications............2886
Biodiesel Blend Fuel............2886
Filling The Fuel Tank............2887
Primary Fuel Filter (Pre-Filter)............2887
Secondary Fuel Filter............2889
Removing Air From The Fuel System............2889
ENGINE LUBRICATION SYSTEM............2890
Checking And Adding Engine Oil............2890
Engine Oil Chart............2890
Removing And Replacing Oil And Filter............2891
HYDRAULIC / HYDROSTATIC SYSTEM............2894
Checking And Adding Fluid............2894
Hydraulic / Hydrostatic Fluid Chart............2895
Removing And Replacing Hydraulic Fluid............2895
Removing And Replacing Hydraulic / Hydrostatic Filters............2896
Fill / Breather Cap............2897
AXLES (FRONT AND REAR)............2898
Checking And Adding Oil (Planetary Carrier)............2898
Removing And Replacing Oil (Planetary Carrier)............2898
Checking And Adding Oil (Rear Differential)............2899
Removing And Replacing Oil (Rear Differential)............2899
Checking And Adding Oil (Front Differential)............2900
Removing And Replacing Oil (Front Differential)............2900
Checking And Adding Oil (Reduction Box)............2901
Removing And Replacing Oil (Reduction Box)............2901
LUBRICATING THE TELESCOPIC HANDLER............2902
Lubrication Locations............2902
Front Pads Lubrication............2905
Rear Pads Lubrication............2905
ATTACHMENT CARRIER............2906
Inspection And Maintenance............2906
TYRE MAINTENANCE............2908
Wheel Nuts............2908
Rotating............2908
Wheel replacement............2908
Mounting............2909
Pressure............2909
APPROVED BOOM STOP............2910
Installing The Approved Boom Stop............2910
Removing The Approved Boom Stop............2910
ENGINE COVER............2912
Opening And Closing............2912
CHAIN CHECKING AND ADJUSTING PROCEDURE............2914
Checking/Adjustment Procedure............2914
Extension / Retraction Chain Wear Check............2915
STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER............2916
Procedure............2916
EMERGENCY EXIT............2918
Rear Window............2918
TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE............2920
Storage............2920
Return To Service............2920
LIFTING THE TELESCOPIC HANDLER............2922
Procedure............2922
REMOTE START TOOL (SERVICE TOOL) KIT - MEL1563............2924
Remote Start Tool - MEL1563............2924
Service Tool Harness Control - MEL1565............2925
Service Tool Harness Communicator - MEL1566............2926
REMOTE START TOOL (SERVICE TOOL) KIT - 7217666............2928
Remote Start Tool (Service Tool) - 7022042............2928
Telescopic Handler Service Tool Harness - 6689747............2929
Computer Service Tool Harness - 6689746............2931
Remote Start Procedure............2931
HYDRAULIC SYSTEM............2934
HYDRAULIC SYSTEM INFORMATION............2938
Glossary Of Hydraulic / Hydrostatic Symbols............2938
Troubleshooting Chart............2941
Tightening Procedures............2942
LIFT CYLINDER............2944
Removal And Installation............2944
Parts Identification............2947
Disassembly............2948
Assembly............2949
SELF LEVELLING CYLINDER............2950
Removal And Installation............2950
Parts Identification............2951
Disassembly............2952
Assembly............2952
EXTENSION CYLINDER............2954
Cylinder Group Removal And Installation............2954
Parts Identification............2957
Disassembly............2958
Assembly............2958
TILT CYLINDER............2960
Removal And Installation............2960
Parts Identification............2962
Disassembly............2963
Assembly............2963
STEERING CYLINDER (FRONT / REAR)............2964
Removal............2964
Installation............2966
Disassembly............2968
Assembly............2970
EMERGENCY VALVE............2974
Removal And Installation............2974
PARKING BRAKE............2976
Valve Removal And Installation............2976
ACCUMULATORS............2978
Parking Brake Accumulator Removal And Installation............2978
Service Brake Accumulator Removal And Installation............2978
Boom Valve Accumulator Removal And Installation............2979
BRAKE VALVE............2980
Removal And Installation............2980
GEAR PUMP............2982
Removal And Installation............2982
Parts Identification............2984
Disassembly And Assembly............2985
FAN MOTOR............2990
Removal And Installation............2990
Parts Identification (Single Speed Version) (Standard)............2992
Disassembly And Assembly (Single Speed Version) (Standard)............2993
Parts Identification (Variable Speed Version) (Optional)............2996
Disassembly And Assembly (Variable Speed Version) (Optional)............2997
HYDRAULIC FLUID RESERVOIR............3004
Removal And Installation............3004
STEERING VALVE............3006
Removal And Installation............3006
HYDRAULIC CONTROL VALVE............3008
Troubleshooting Chart (Solenoid Valves)............3008
Valve Section Troubleshooting............3009
Troubleshooting Chart (Control Valve)............3013
Removal And Installation............3014
Parts Identification............3017
Section Removal............3024
Section Disassembly And Assembly............3024
Inlet Section Disassembly And Assembly............3029
PORT RELIEF VALVES............3032
Removal And Installation............3032
HYDROSTATIC SYSTEM............3034
HYDROSTATIC SYSTEM INFORMATION............3036
Troubleshooting Chart............3036
Replenishing Valve Function............3037
OIL COOLER............3038
Description............3038
HYDROSTATIC DRIVE MOTOR............3040
Removal And Installation............3040
Parts Identification............3041
Disassembly............3044
Inspection............3052
Assembly............3054
HYDROSTATIC PUMP............3064
Calibration............3064
Removal And Installation............3066
Parts Identification............3068
Shaft Disassembly............3073
Relief Valves Disassembly And Assembly............3075
Charge Pump Disassembly............3076
Piston Pump Disassembly............3078
Solenoid Block Disassembly............3081
Inspection............3083
Piston Pump Assembly............3085
Charge Pump Assembly............3089
Solenoid Block Assembly............3091
Shaft Assembly............3093
DRIVE SYSTEM............3096
DRIVE SYSTEM TROUBLESHOOTING............3098
Chart............3098
AXLE AND DIFFERENTIAL (FRONT)............3100
Description............3100
Planetary Carrier Parts Identification............3100
Planetary Carrier Disassembly............3101
Steering Knuckle And Drive Axle Parts Identification............3106
Steering Knuckle Disassembly............3107
Drive Axle Disassembly............3109
Brake Group Parts Identification............3111
Brake Group Disassembly............3112
Differential Parts Identification............3115
Differential Disassembly............3116
Pinion Group Parts Identification............3121
Pinion Group Disassembly............3122
Pinion Group Assembly............3125
Differential Assembly............3133
Brake Group Assembly............3139
Drive Axle Assembly............3142
Steering Knuckle Assembly............3144
Planetary Carrier Assembly............3147
Special Tools............3152
AXLE AND DIFFERENTIAL (REAR)............3154
Description............3154
Planetary Carrier Parts Identification............3154
Planetary Carrier Disassembly............3155
Steering Knuckle And Drive Axle Parts Identification............3160
Steering Knuckle Disassembly............3161
Differential Parts Identification............3163
Differential Disassembly............3164
Pinion Group Parts Identification............3169
Pinion Group Disassembly............3170
Pinion Group Assembly............3173
Differential Assembly............3181
Steering Knuckle Assembly............3187
Planetary Carrier Assembly............3190
Planetary Carrier Assembly............3191
Special Tools............3195
FRONT AXLE............3196
Removal And Installation............3196
AXLE TOE-IN............3202
Adjustment............3202
PARKING BRAKE............3204
Parking Brake Removal, Disassembly And Assembly............3204
STEERING ANGLE ADJUSTMENT............3206
Adjustment............3206
DRIVESHAFT............3208
Removal And Installation............3208
SERVICE BRAKE............3210
Description............3210
Bleeding The Brake Circuit............3210
REAR AXLE............3212
Removal And Installation............3212
REDUCTION BOX............3216
Removal And Installation............3216
Parts Identification............3217
Disassembly............3218
Assembly............3222
Special Tools............3225
MAINFRAME............3226
OPERATOR CAB............3228
Removal And Installation............3228
OPERATOR SEAT............3232
Removal And Installation............3232
BOOM ASSEMBLY............3234
Removal And Installation............3234
BOOM TRAY............3238
Removal And Installation............3238
END BOOM............3242
Removal............3242
Installation............3244
INTERMEDIATE BOOM............3246
Removal Of The First Intermediate Boom (T40180)............3246
INTERMEDIATE BOOM............3247
Installation Of The First Intermediate Boom (T40180)............3248
Removal Of The Second Intermediate Boom (T40180) / Intermediate Boom (T40140)............3250
Installation Of The Second Intermediate Boom (T40180) / Intermediate Boom (T40140)............3251
WEAR PADS (FRONT)............3252
Removal............3252
Installation............3253
WEAR PADS (REAR)............3254
Removal............3254
Installation............3254
ENGINE COVER............3256
Gas Cylinder Removal And Installation............3256
Removal And Installation............3256
FUEL TANK............3258
Removal And Installation............3258
ATTACHMENT CARRIER (QUICK-TACH)............3260
Removal And Installation............3260
COUNTERWEIGHT............3262
Removal And Installation............3262
FENDER............3264
Removal And Installation............3264
STEERING COLUMN COVER............3266
Removal And Installation............3266
DASH COVER............3268
Removal And Installation............3268
JOYSTICK PANEL............3270
Removal And Installation............3270
STABILISER FRAME............3272
Removal............3272
ELECTRICAL SYSTEM AND ANALYSIS............3274
ELECTRICAL SYSTEM INFORMATION............3297
Troubleshooting Chart............3297
Description............3298
Fuses And Relay Location / Identification............3298
BATTERY............3301
Removal And Installation............3301
Using A Booster Battery (Jump Starting)............3303
ALTERNATOR............3305
Removal And Installation............3305
Belt Adjustment............3306
Belt Checking............3306
Belt Replacement............3306
STARTER............3307
Testing............3307
Removal And Installation............3308
LIGHTS............3311
Rear Light Removal And Installation............3311
Rear Light Bulb Replacem ent............3312
Front Light Removal And Installation............3313
Front Light Bulb Replacement............3314
SIGNAL LEVER............3315
Removal And Installation............3315
DISPLAY............3317
Removal And Installation............3317
INSTRUMENT PANEL............3319
Removal And Installation............3319
BOOM ANGLE SENSOR............3321
Removal And Installation............3321
Calibration............3322
FRONT WIPER MOTOR............3325
Removal And Installation............3325
TOP WIPER MOTOR............3327
Removal And Installation............3327
REAR WIPER MOTOR............3329
Removal And Installation............3329
PEDAL ASSEMBLY............3331
Removal And Installation............3331
INCHING SENSOR............3333
Removal And Installation............3333
Calibration............3334
SERVICE PC (LAPTOP COMPUTER)............3337
Connecting Remote Start Tool (Service Tool) - MEL1563............3337
Connecting Remote Start Tool (Service Tool) - 7217666............3337
FUEL LEVEL SENDER............3339
Removal And Installation............3339
JOYSTICK............3341
Removal And Installation............3341
LLMI / LLMC SYSTEM............3343
System Calibration............3343
Calibration Test............3345
System Failure Reports............3346
System Components Identification............3349
LLMS Removal............3351
LLMS Installation............3352
LLMC Removal And Installation............3353
TRAVEL DIRECTION LEVER............3355
Removal And Installation............3355
CONTROLLERS............3357
Description............3357
Engine Controller............3357
Gateway Controller............3358
Drive Controller............3359
Workgroup Controller............3360
Display Controller............3360
LLMI Controller............3361
LLMC Controller............3362
ENGINE SERVICE............3363
ENGINE............3365
Removal And Installation............3365
ENGINE AND HYDROSTAT ASSEMBLY............3373
Removal And Installation............3373
ENGINE SPEED CONTROL............3377
Removal And Installation............3377
MUFFLER............3379
Removal And Installation............3379
AIR CLEANER............3381
Housing Removal And Installation............3381
ENGINE COOLING SYSTEM............3383
Oil Cooler / Intercooler / Radiator Removal And Installation............3383
Cooling System Check............3386
Cooling System Inspection............3386
Expansion Tank Removal And Installation............3387
HEATING, VENTILATION, AIR CONDITIONING (HVAC)............3389
AIR CONDITIONING SYSTEM FLOW............3391
Description............3391
Chart............3392
Components............3393
Safety Equipment............3395
REGULAR MAINTENANCE............3397
Cab Filter............3397
Belt Adjustment............3398
Belt Replacement............3398
Cleaning The Condenser............3399
Air Conditioning Lubrication............3399
Air Conditioning Service Chart............3400
A/C SYSTEM TROUBLESHOOTING............3401
Blower Motor Does Not Operate............3401
Blower Motor Operates Normally, But Air Flow Is Insufficient............3401
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal............3401
The Compressor Does Not Operate At All, Or Operates Improperly............3401
Gauge Pressure Related Troubleshooting............3402
Temperature / Pressure Chart............3404
Poor A/C Performance............3405
HVAC Repair And Leaks............3405
Electrical System............3406
SYSTEM CHARGING AND RECLAMATION............3411
Reclamation And Charging With Recovery / Charging Unit............3411
COMPRESSOR............3415
Removal And Installation............3415
Oil............3417
Oil Check............3417
Clutch Disassembly And Assembly............3419
CONDENSER............3423
Removal And Installation............3423
RECEIVER / DRIER............3425
Removal And Installation............3425
PRESSURE SWITCH............3427
Removal And Installation............3427
EVAPORATOR / HEATER UNIT............3429
Removal And Installation............3429
THERMOSTAT............3431
Description............3431
Removal And Installation............3432
EXPANSION VALVE............3433
Removal And Installation............3433
SPECIFICATIONS............3435
(T40140) TELESCOPIC HANDLER SPECIFICATIONS............3437
Machine Dimensions............3437
Performance............3438
Weights............3438
Engine............3439
Controls............3439
Drive System............3440
Traction............3440
Steering............3440
Brakes............3440
Fluid Capacities............3441
Hydraulic System............3441
Electrical System............3441
Temperature Range............3441
Altitude............3441
Instrument Panel............3442
Environmental............3442
Visibility Diagrams............3443
(T40180) TELESCOPIC HANDLER SPECIFICATIONS............3447
Machine Dimensions............3447
Performance............3448
Weights............3448
Engine............3449
Controls............3449
Drive System............3450
Traction............3450
Steering............3450
Brakes............3450
Fluid Capacities............3451
Hydraulic System............3451
Electrical System............3451
Temperature Range............3451
Altitude............3451
Instrument Panel............3452
Environmental............3452
Visibility Diagrams............3453
MACHINE TORQUE SPECIFICATIONS............3457
Axle............3457
Boom............3457
Reduction Box............3457
Drive Motor............3457
Engine............3458
Hydraulic Pump............3458
TORQUE SPECIFICATIONS FOR BOLTS............3459
Torque for General SAE Bolts............3459
Torque For General Metric Bolts............3460
HYDRAULIC CONNECTION SPECIFICATIONS............3461
O-ring Face Seal Connection............3461
Straight Thread O-ring Fitting............3461
Tubelines And Hoses............3461
Flare Fitting............3462
O-ring Flare Fitting............3463
Port Seal Fitting............3465
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS............3467
Specifications............3467
CONVERSIONS............3469
Decimal And Millimeter Equivalent Chart............3469
U.S. To Metric Conversion Chart............3469
ALPHABETICAL INDEX............3471
6990786 (07-14) - T40140, T40180 Telescopic Handler Service Manual............3473
MAINTENANCE SAFETY............3475
CONTENTS............3477
FOREWORD............3479
FOREWORD............3481
SAFETY INSTRUCTIONS............3483
Safe Operation Is The Operator’s Responsibility............3483
Safe Operation Needs A Qualified Operator............3483
Avoid Silica Dust............3484
Dismantling And Disposal............3484
FIRE PREVENTION............3485
Maintenance............3485
Operation............3485
Electrical............3485
Hydraulic System............3485
Fueling............3485
Starting............3485
Welding And Grinding............3486
Fire Extinguishers............3486
SERIAL NUMBER LOCATION............3487
Telescopic Handler Serial Number............3487
Engine Serial Number............3487
Other Serial Numbers............3487
DELIVERY REPORT............3488
BOBCAT TELESCOPIC HANDLER IDENTIFICATION............3489
SAFETY AND MAINTENANCE............3491
LIFTING AND BLOCKING THE TELESCOPIC HANDLER............3495
Procedure............3495
OPERATOR CAB............3497
Description............3497
Cab Door............3497
Cab Door Window............3498
Rear Cab Window............3499
Cab Light............3499
TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER............3501
Loading And Unloading............3501
Fastening............3501
TOWING THE TELESCOPIC HANDLER............3503
Procedure............3503
SERVICE SCHEDULE............3507
Maintenance Intervals............3507
AIR CLEANER SERVICE............3509
Replacing Filter Elements............3509
ENGINE COOLING SYSTEM............3511
Cleaning............3511
Checking Level............3511
Removing And Replacing The Coolant............3512
FUEL SYSTEM............3513
Fuel Specifications............3513
Biodiesel Blend Fuel............3513
Filling The Fuel Tank............3514
Primary Fuel Filter (Pre-Filter)............3514
Secondary Fuel Filter............3516
Removing Air From The Fuel System............3516
ENGINE LUBRICATION SYSTEM............3517
Checking And Adding Engine Oil............3517
Engine Oil Chart............3517
Removing And Replacing Oil And Filter............3518
HYDRAULIC / HYDROSTATIC SYSTEM............3519
Checking And Adding Fluid............3519
Hydraulic / Hydrostatic Fluid Chart............3520
Removing And Replacing Hydraulic Fluid............3520
Removing And Replacing Hydraulic / Hydrostatic Filters............3521
Fill / Breather Cap............3522
AXLES (FRONT AND REAR)............3523
Checking And Adding Oil (Planetary Carrier)............3523
Removing And Replacing Oil (Planetary Carrier)............3523
Checking And Adding Oil (Rear Differential)............3524
Removing And Replacing Oil (Rear Differential)............3524
Checking And Adding Oil (Front Differential)............3525
Removing And Replacing Oil (Front Differential)............3525
Checking And Adding Oil (Reduction Box)............3526
Removing And Replacing Oil (Reduction Box)............3526
LUBRICATING THE TELESCOPIC HANDLER............3527
Lubrication Locations............3527
Front Pads Lubrication............3530
Rear Pads Lubrication............3530
ATTACHMENT CARRIER............3531
Inspection And Maintenance............3531
TYRE MAINTENANCE............3533
Wheel Nuts............3533
Rotating............3533
Wheel replacement............3533
Mounting............3534
Pressure............3534
APPROVED BOOM STOP............3535
Installing The Approved Boom Stop............3535
Removing The Approved Boom Stop............3535
ENGINE COVER............3537
Opening And Closing............3537
CHAIN CHECKING AND ADJUSTING PROCEDURE............3539
Checking/Adjustment Procedure............3539
Extension / Retraction Chain Wear Check............3540
STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER............3541
Procedure............3541
EMERGENCY EXIT............3543
Rear Window............3543
TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE............3545
Storage............3545
Return To Service............3545
LIFTING THE TELESCOPIC HANDLER............3547
Procedure............3547
REMOTE START TOOL (SERVICE TOOL) KIT - MEL1563............3549
Remote Start Tool - MEL1563............3549
Service Tool Harness Control - MEL1565............3550
Service Tool Harness Communicator - MEL1566............3551
REMOTE START TOOL (SERVICE TOOL) KIT - 7217666............3553
Remote Start Tool (Service Tool) - 7022042............3553
Telescopic Handler Service Tool Harness - 6689747............3554
Computer Service Tool Harness - 6689746............3556
Remote Start Procedure............3556
HYDRAULIC SYSTEM............3559
HYDRAULIC SYSTEM INFORMATION............3563
Glossary Of Hydraulic / Hydrostatic Symbols............3563
Troubleshooting Chart............3566
Tightening Procedures............3567
LIFT CYLINDER............3569
Removal And Installation............3569
Parts Identification............3572
Disassembly............3573
Assembly............3574
SELF LEVELLING CYLINDER............3575
Removal And Installation............3575
Parts Identification............3576
Disassembly............3577
Assembly............3577
EXTENSION CYLINDER............3579
Cylinder Group Removal And Installation............3579
Parts Identification............3582
Disassembly............3583
Assembly............3583
TILT CYLINDER............3585
Removal And Installation............3585
Parts Identification............3587
Disassembly............3588
Assembly............3588
STEERING CYLINDER (FRONT / REAR)............3589
Removal............3589
Installation............3591
Disassembly............3593
Assembly............3595
EMERGENCY VALVE............3599
Removal And Installation............3599
PARKING BRAKE............3601
Valve Removal And Installation............3601
ACCUMULATORS............3603
Parking Brake Accumulator Removal And Installation............3603
Service Brake Accumulator Removal And Installation............3603
Boom Valve Accumulator Removal And Installation............3604
BRAKE VALVE............3605
Removal And Installation............3605
GEAR PUMP............3607
Removal And Installation............3607
Parts Identification............3609
Disassembly And Assembly............3610
FAN MOTOR............3615
Removal And Installation............3615
Parts Identification (Single Speed Version) (Standard)............3617
Disassembly And Assembly (Single Speed Version) (Standard)............3618
Parts Identification (Variable Speed Version) (Optional)............3621
Disassembly And Assembly (Variable Speed Version) (Optional)............3622
HYDRAULIC FLUID RESERVOIR............3629
Removal And Installation............3629
STEERING VALVE............3631
Removal And Installation............3631
HYDRAULIC CONTROL VALVE............3633
Troubleshooting Chart (Solenoid Valves)............3633
Valve Section Troubleshooting............3634
Troubleshooting Chart (Control Valve)............3638
Removal And Installation............3639
Parts Identification............3642
Section Removal............3649
Section Disassembly And Assembly............3649
Inlet Section Disassembly And Assembly............3654
PORT RELIEF VALVES............3657
Removal And Installation............3657
HYDROSTATIC SYSTEM............3659
HYDROSTATIC SYSTEM INFORMATION............3661
Troubleshooting Chart............3661
Replenishing Valve Function............3662
OIL COOLER............3663
Description............3663
HYDROSTATIC DRIVE MOTOR............3665
Removal And Installation............3665
Parts Identification............3666
Disassembly............3669
Inspection............3677
Assembly............3679
HYDROSTATIC PUMP............3689
Calibration............3689
Removal And Installation............3691
Parts Identification............3693
Shaft Disassembly............3698
Relief Valves Disassembly And Assembly............3700
Charge Pump Disassembly............3701
Piston Pump Disassembly............3703
Solenoid Block Disassembly............3706
Inspection............3708
Piston Pump Assembly............3710
Charge Pump Assembly............3714
Solenoid Block Assembly............3716
Shaft Assembly............3718
DRIVE SYSTEM............3721
DRIVE SYSTEM TROUBLESHOOTING............3723
Chart............3723
AXLE AND DIFFERENTIAL (FRONT)............3725
Description............3725
Planetary Carrier Parts Identification............3725
Planetary Carrier Disassembly............3726
Steering Knuckle And Drive Axle Parts Identification............3731
Steering Knuckle Disassembly............3732
Drive Axle Disassembly............3734
Brake Group Parts Identification............3736
Brake Group Disassembly............3737
Differential Parts Identification............3740
Differential Disassembly............3741
Pinion Group Parts Identification............3746
Pinion Group Disassembly............3747
Pinion Group Assembly............3750
Differential Assembly............3758
Brake Group Assembly............3764
Drive Axle Assembly............3767
Steering Knuckle Assembly............3769
Planetary Carrier Assembly............3772
Special Tools............3777
AXLE AND DIFFERENTIAL (REAR)............3779
Description............3779
Planetary Carrier Parts Identification............3779
Planetary Carrier Disassembly............3780
Steering Knuckle And Drive Axle Parts Identification............3785
Steering Knuckle Disassembly............3786
Differential Parts Identification............3788
Differential Disassembly............3789
Pinion Group Parts Identification............3794
Pinion Group Disassembly............3795
Pinion Group Assembly............3798
Differential Assembly............3806
Steering Knuckle Assembly............3812
Planetary Carrier Assembly............3815
Planetary Carrier Assembly............3816
Special Tools............3820
FRONT AXLE............3821
Removal And Installation............3821
AXLE TOE-IN............3827
Adjustment............3827
PARKING BRAKE............3829
Parking Brake Removal, Disassembly And Assembly............3829
STEERING ANGLE ADJUSTMENT............3831
Adjustment............3831
DRIVESHAFT............3833
Removal And Installation............3833
SERVICE BRAKE............3835
Description............3835
Bleeding The Brake Circuit............3835
REAR AXLE............3837
Removal And Installation............3837
REDUCTION BOX............3841
Removal And Installation............3841
Parts Identification............3842
Disassembly............3843
Assembly............3847
Special Tools............3850
MAINFRAME............3851
OPERATOR CAB............3853
Removal And Installation............3853
OPERATOR SEAT............3857
Removal And Installation............3857
BOOM ASSEMBLY............3859
Removal And Installation............3859
BOOM TRAY............3863
Removal And Installation............3863
END BOOM............3867
Removal............3867
Installation............3869
INTERMEDIATE BOOM............3871
Removal Of The First Intermediate Boom (T40180)............3871
INTERMEDIATE BOOM............3872
Installation Of The First Intermediate Boom (T40180)............3873
Removal Of The Second Intermediate Boom (T40180) / Intermediate Boom (T40140)............3875
Installation Of The Second Intermediate Boom (T40180) / Intermediate Boom (T40140)............3876
WEAR PADS (FRONT)............3877
Removal............3877
Installation............3878
WEAR PADS (REAR)............3879
Removal............3879
Installation............3879
ENGINE COVER............3881
Gas Cylinder Removal And Installation............3881
Removal And Installation............3881
FUEL TANK............3883
Removal And Installation............3883
ATTACHMENT CARRIER (QUICK-TACH)............3885
Removal And Installation............3885
COUNTERWEIGHT............3887
Removal And Installation............3887
FENDER............3889
Removal And Installation............3889
STEERING COLUMN COVER............3891
Removal And Installation............3891
DASH COVER............3893
Removal And Installation............3893
JOYSTICK PANEL............3895
Removal And Installation............3895
STABILISER FRAME............3897
Removal............3897
ELECTRICAL SYSTEM AND ANALYSIS............3899
ELECTRICAL SYSTEM INFORMATION............3920
Troubleshooting Chart............3920
Description............3921
Fuses And Relay Location / Identification............3921
BATTERY............3924
Removal And Installation............3924
Using A Booster Battery (Jump Starting)............3926
ALTERNATOR............3928
Removal And Installation............3928
Belt Adjustment............3929
Belt Checking............3929
Belt Replacement............3929
STARTER............3930
Testing............3930
Removal And Installation............3931
LIGHTS............3934
Rear Light Removal And Installation............3934
Rear Light Bulb Replacem ent............3935
Front Light Removal And Installation............3936
Front Light Bulb Replacement............3937
SIGNAL LEVER............3938
Removal And Installation............3938
DISPLAY............3940
Removal And Installation............3940
INSTRUMENT PANEL............3942
Removal And Installation............3942
BOOM ANGLE SENSOR............3944
Removal And Installation............3944
Calibration............3945
FRONT WIPER MOTOR............3948
Removal And Installation............3948
TOP WIPER MOTOR............3950
Removal And Installation............3950
REAR WIPER MOTOR............3952
Removal And Installation............3952
PEDAL ASSEMBLY............3954
Removal And Installation............3954
INCHING SENSOR............3956
Removal And Installation............3956
Calibration............3957
SERVICE PC (LAPTOP COMPUTER)............3960
Connecting Remote Start Tool (Service Tool) - MEL1563............3960
Connecting Remote Start Tool (Service Tool) - 7217666............3960
FUEL LEVEL SENDER............3962
Removal And Installation............3962
JOYSTICK............3964
Removal And Installation............3964
LLMI / LLMC SYSTEM............3966
System Calibration............3966
Calibration Test............3968
System Failure Reports............3969
System Components Identification............3972
LLMS Removal............3974
LLMS Installation............3975
LLMC Removal And Installation............3976
TRAVEL DIRECTION LEVER............3978
Removal And Installation............3978
CONTROLLERS............3980
Description............3980
Engine Controller............3980
Gateway Controller............3981
Drive Controller............3982
Workgroup Controller............3983
Display Controller............3983
LLMI Controller............3984
LLMC Controller............3985
ENGINE SERVICE............3986
ENGINE INFORMATION............3990
Specifications............3990
Troubleshooting............4001
Engine Removal And Installation............4003
Compression Checking............4008
ENGINE AND HYDROSTAT ASSEMBLY............4012
Removal And Installation............4012
ENGINE SPEED CONTROL............4016
Removal And Installation............4016
MUFFLER............4018
Removal And Installation............4018
AIR CLEANER............4020
Housing Removal And Installation............4020
ENGINE COOLING SYSTEM............4022
Oil Cooler / Intercooler / Radiator Removal And Installation............4022
Cooling System Description............4025
Thermostat Removal And Installation............4026
Thermostat Testing............4026
Lubricating Oil Cooler Removal And Installation............4026
Water Pump Removal............4027
Water Pump Installation............4027
Expansion Tank Removal And Installation............4027
LUBRICATION SYSTEM............4028
Engine Lubrication System Description............4028
Oil Filter Adapter Removal And Installation............4029
Oil Pan Removal And Installation............4029
Oil Screen And Pick-up Tube............4030
Oil Pump Removal............4030
Oil Pump Installation............4031
Oil Pump Disassembly And Assembly............4032
Oil Pressure Relief Valve Disassembly And Assembly............4033
FUEL SYSTEM............4034
Fuel Injection Pump Removal............4034
Fuel Injection Pump Installation............4037
Fuel Injectors Removal And Installation............4041
Checking The Fuel Lift Pump............4043
Fuel Lift Pump Removal And Installation............4044
Exhaust Manifold Removal And Installation............4044
Fuel Injector Cover Removal And Installation............4045
Rocker Cover Removal And Installation............4045
CYLINDER HEAD............4048
Glow Plugs Checking............4048
Glow Plugs Removal And Installation............4050
Removal............4051
Inspection............4053
Installation............4053
Rocker Shaft Disassembly And Assembly............4056
Valve Removal............4056
Valve Springs Checking............4057
Valve Depth Checking............4057
Valve Guide Checking............4058
Valve Guide Removal............4059
Valve Guide Installation............4059
Valve Checking............4060
Cutting A Valve Seat............4060
Valve Seat Assembly............4061
Changing Valve Springs (With Cylinder Head Installed)............4062
Valve Clearance Adjustment............4063
Engine Block Description............4064
Engine Block Disassembly And Assembly............4064
Engine Block Inspection............4065
Cylinder Liner Inspection............4065
Cylinder Liner Removal............4066
Cylinder Liner Installation............4067
CRANKSHAFT AND PISTONS............4068
Pistons And Connecting Rods Description............4068
Pistons And Connecting Rods Removal............4068
Pistons And Connecting Rods Disassembly............4069
Piston Ring End Gap............4070
Piston Ring Installation............4071
Piston Ring Groove Clearance............4072
Piston Cooling Jet Removal............4072
Piston Cooling Jet Installation............4072
Piston Cooling Jet Alignment............4073
Connecting Rod Inspection............4073
Connecting Rod Bushing Replacement............4073
Piston And Connecting Rod Assembly............4074
Piston And Connecting Rod Installation............4074
Checking Piston Height............4076
Crankshaft And Bearings Description............4076
Crankshaft And Bearings Removal............4076
Inspection Of Crankshaft And Bearings............4078
Crankshaft And Bearings Installation............4079
Rear Oil Seal Removal............4080
Rear Oil Seal Housing Positioning............4081
Rear Oil Seal Installation............4081
Checking Crankshaft End Play............4082
CAMSHAFT AND TIMING GEARS............4084
Engine Timing Procedure............4084
Timing Case And Drive Assembly Description............4085
Timing Cover Removal............4085
Timing Cover Installation............4085
Crankshaft Pulley Removal And Installation............4085
Front Oil Seal Removal And Installation............4085
Timing Case And Gear Removal............4086
Timing Case And Gear Installation............4087
Camshaft And Tappets Removal............4089
Camshaft And Tappets Installation............4090
TURBOCHARGER............4092
Troubleshooting............4092
Description............4093
Removal And Installation............4093
FLYWHEEL AND HOUSING............4096
Removal And Installation............4096
Flywheel Inspection............4098
Ring Gear Removal............4098
Ring Gear Installation............4098
HEATING, VENTILATION, AIR CONDITIONING (HVAC)............4100
AIR CONDITIONING SYSTEM FLOW............4102
Description............4102
Chart............4103
Components............4104
Safety Equipment............4106
REGULAR MAINTENANCE............4108
Cab Filter............4108
Belt Adjustment............4109
Belt Replacement............4109
Cleaning The Condenser............4110
Air Conditioning Lubrication............4110
Air Conditioning Service Chart............4111
A/C SYSTEM TROUBLESHOOTING............4112
Blower Motor Does Not Operate............4112
Blower Motor Operates Normally, But Air Flow Is Insufficient............4112
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal............4112
The Compressor Does Not Operate At All, Or Operates Improperly............4112
Gauge Pressure Related Troubleshooting............4113
Temperature / Pressure Chart............4115
Poor A/C Performance............4116
HVAC Repair And Leaks............4116
Electrical System............4117
SYSTEM CHARGING AND RECLAMATION............4122
Reclamation And Charging With Recovery / Charging Unit............4122
COMPRESSOR............4126
Removal And Installation............4126
Oil............4128
Oil Check............4128
Clutch Disassembly And Assembly............4130
CONDENSER............4134
Removal And Installation............4134
RECEIVER / DRIER............4136
Removal And Installation............4136
PRESSURE SWITCH............4138
Removal And Installation............4138
EVAPORATOR / HEATER UNIT............4140
Removal And Installation............4140
THERMOSTAT............4142
Description............4142
Removal And Installation............4143
EXPANSION VALVE............4144
Removal And Installation............4144
SPECIFICATIONS............4146
(T40140) TELESCOPIC HANDLER SPECIFICATIONS............4148
Machine Dimensions............4148
Performance............4149
Weights............4149
Engine............4150
Controls............4150
Drive System............4151
Traction............4151
Steering............4151
Brakes............4151
Fluid Capacities............4152
Hydraulic System............4152
Electrical System............4152
Temperature Range............4152
Altitude............4152
Instrument Panel............4153
Visibility Diagrams............4154
(T40180) TELESCOPIC HANDLER SPECIFICATIONS............4158
Machine Dimensions............4158
Performance............4159
Weights............4159
Engine............4160
Controls............4160
Drive System............4161
Traction............4161
Steering............4161
Brakes............4161
Fluid Capacities............4162
Hydraulic System............4162
Electrical System............4162
Temperature Range............4162
Altitude............4162
Instrument Panel............4163
Visibility Diagrams............4164
MACHINE TORQUE SPECIFICATIONS............4168
Axle............4168
Boom............4168
Reduction Box............4168
Drive Motor............4168
Engine............4169
Hydraulic Pump............4169
TORQUE SPECIFICATIONS FOR BOLTS............4170
Torque for General SAE Bolts............4170
Torque For General Metric Bolts............4171
HYDRAULIC CONNECTION SPECIFICATIONS............4172
O-ring Face Seal Connection............4172
Straight Thread O-ring Fitting............4172
Tubelines And Hoses............4172
Flare Fitting............4173
O-ring Flare Fitting............4174
Port Seal Fitting............4176
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS............4178
Specifications............4178
CONVERSIONS............4180
Decimal And Millimeter Equivalent Chart............4180
U.S. To Metric Conversion Chart............4180
ALPHABETICAL INDEX............4182
