Complete repair service manual for Bobcat TL360, TL360X Telescopic Handlers, with all the shop information to maintain, diagnose, and repair like professional mechanics.

Bobcat TL360, TL360X Telescopic Handlers workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

6990100 (5-11) - TL360(X) Telescopic Handler Service Manual.pdf
6990100 (06-12) - TL360(X) Telescopic Handler Service Manual.pdf
6990790 (05-13) - TL360(X), TL470(X), TL470(X)HF Telescopic Handler Service Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,032 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

6990099 (2-11) - TL360(X) Telescopic Handler Operation & Maintenance Manual...2
  CONTENTS...6
  FOREWORD...8
    DECLARATION OF CONFORMITY...10
      Model TL360...10
      Model TL360X...11
    Certificate OF CONFORMITY...12
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...13
    REGULAR MAINTENANCE ITEMS...13
      Parts...13
      Lubricants, Fuel And Fluids...14
    SERIAL NUMBER LOCATION...15
      Telescopic Handler Serial Number...15
      Telescopic Handler Statutory Plate (If Equipped)...15
      Engine Serial Number...16
      Other Serial Numbers...16
    DELIVERY REPORT...16
    BOBCAT TELESCOPIC HANDLER IDENTIFICATION...17
    FEATURES, ACCESSORIES AND ATTACHMENTS...18
      Standard Items...18
      Options And Accessories...18
      Tractor Homologated Telescopic Handler...18
      Available Tyres...19
      Front Window Guard...19
      Front Window Guard Inspection And Maintenance...19
      Attachments...20
      Digging Buckets...20
      Light Material Buckets...20
      Bale Handler With Spikes...21
      Bale Handlers With Tubes...21
      Bale Handlers With Tines...21
      Pallet Forks...21
      Bucket Grapples...22
      Fork Grapples...22
  SAFETY & TRAINING RESOURCES...24
    SAFETY INSTRUCTIONS...26
      Before Operation...26
      Safe Operation Is The Operator’s Responsibility...27
      Safe Operation Needs A Qualified Operator...27
      Avoid Silica Dust...28
    FIRE PREVENTION...28
      Maintenance...28
      Operation...28
      Electrical...28
      Hydraulic System...29
      Fueling...29
      Starting...29
      Spark Arrester Exhaust System...29
      Welding And Grinding...29
      Fire Extinguishers...29
    PUBLICATIONS AND TRAINING RESOURCES...30
    MACHINE SIGNS (DECALS)...31
      No-Text Safety Signs...33
  LOAD CHARTS...36
    CHARTS FOR TL360(X) MACHINE...38
  OPERATING INSTRUCTIONS...44
    OPERATOR CONTROLS IDENTIFICATION...48
      Operator Components...48
      Travel Direction...49
      Steering Wheel...49
      Multi-function Lever...50
      Steering Wheel Tilt Position (If Equipped)...50
      Left Instrument Panel...51
      Centre Instrument And Indicator Panel...51
      Right Instrument And Indicator Panel...52
      Longitudinal Load Moment Indicator (LLMI)...53
      Display Panel...54
      Display Screen...56
      Temperature Control Panel...58
      Auxiliary Power Outlet...59
      Roof Console (If Equipped)...59
      Accelerator Pedal...59
      Brake Pedal And Inching Control...59
    OPERATOR CAB...60
      Description...60
      Cab Door...60
      Cab Door Window...61
      Rear Cab Window...62
      Cab Light...62
    STEERING MODE SELECTION...63
      Aligning Modes...63
      Steering Mode Management...64
      Semi-Automatic Aligning Mode Procedure...65
      Manual Aligning Mode Procedure...67
    PARKING BRAKE...68
      Operation...68
    EMERGENCY EXIT...68
    TRACTOR HOMOLOGATED EMERGENCY EXIT...69
    BACK-UP ALARM SYSTEM...70
      Description...70
      Operation...70
    DRIVING AND STEERING THE TELESCOPIC HANDLER...71
      4-Wheel Steering Mode...71
      Stopping The Telescopic Handler (4-Wheel Steering Mode)...72
      2-Wheel Steering Mode...73
      Stopping The Telescopic Handler (2-Wheel Steering Mode)...74
      Crab Steering Mode...75
      Stopping The Telescopic Handler (Crab Steering Mode)...76
    SPEED MANAGEMENT...77
      Operation...77
      Changing The Factory Default Setting...79
    HYDRAULIC CONTROLS...80
      Hydraulic Control Lever (Joystick)...80
      Changing The Maximum Auxiliary Flow...80
      Quick Couplers...81
      Auxiliary Hydraulic Release...81
    ATTACHMENT CONTROL DEVICE (ACD)...82
      Description...82
    DAILY INSPECTION...83
      Daily Inspection And Maintenance...83
      Cleaning The Operator Cab...84
    PRE-STARTING PROCEDURE...85
      Entering The Telescopic Handler...85
      Operation & Maintenance Manual And Operator’s Handbook Locations...85
      Seat Adjustment...86
      Seat Belt Adjustment...87
      Mirrors Adjustment And Cleaning...87
    STARTING THE ENGINE...88
      Cold Temperature Starting...89
      Warming The Hydraulic / Hydrostatic System...89
    MONITORING THE DISPLAY PANEL...90
      Warning And Shutdown...90
    STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER...91
      Procedure...91
    ATTACHMENTS...92
      Serial Plate...92
      Buckets...92
      Pallet Forks...96
      Bale Spikes...98
      Installing And Removing The Attachment (Manual Lock)...99
      Installing And Removing The Attachment (Hydraulic Lock) (If Equipped)...102
    OPERATING PROCEDURE...105
      Longitudinal Load Moment Controller (LLMC)...105
      Longitudinal Load Moment Controller (LLMC) Override Switch...105
      Inspect The Work Area...106
      Basic Operating Instructions...106
      Operating With A Full Bucket...107
      Operating With An Empty Bucket...107
      Filling And Emptying The Bucket...108
      Digging And Filling A Hole...109
      Raising A Load And Extending The Boom...110
      Load Capacity Charts...111
      Handling Loads With Pallet Forks...112
    TOWING THE TELESCOPIC HANDLER...116
      Procedure...116
    LIFTING THE TELESCOPIC HANDLER...118
      Procedure...118
    TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER...119
      Loading And Unloading...119
      Fastening...119
    TOWING A TRAILER WITH THE TELESCOPIC HANDLER...120
      Connecting The Electrics (If Equipped)...120
      Rear Trailer Brake Valve (If Equipped)...120
  SYSTEM SETUP & ANALYSIS...122
    DIAGNOSTIC SERVICE CODES...124
      Viewing Service Codes...124
      Service Codes List...125
    MAINTENANCE CLOCK...135
      Description...135
      Setup...135
      Reset...135
  PREVENTIVE MAINTENANCE...136
    SERVICE SCHEDULE...140
    SEAT BELT...141
      Inspection And Maintenance...141
    LLMC CALIBRATION TEST...142
      Procedure...142
    APPROVED BOOM STOP (IF EQUIPPED)...143
      Installing The Approved Boom Stop...143
      Removing The Approved Boom Stop...143
    BACK-UP ALARM SYSTEM (IF EQUIPPED)...144
      Description...144
      Inspecting...144
    ENGINE COVER...144
      Opening And Closing...144
    HEATING, VENTILATION AND AIR CONDITIONING SYSTEM (HVAC) (IF EQUIPPED)...145
      Cleaning And Maintenance...145
      Filters...145
      Condenser...146
      Air Conditioning Lubrication...146
      Troubleshooting...146
    AIR CLEANER SERVICE...146
      Replacing Filter Elements...146
    FUEL SYSTEM...148
      Fuel Specifications...148
      Biodiesel Blend Fuel...148
      Filling The Fuel Tank...149
      Primary Fuel Filter (Pre-Filter)...149
      Secondary Fuel Filter...151
      Removing Air From The Fuel System...151
    ENGINE LUBRICATION SYSTEM...152
      Checking And Adding Engine Oil...152
      Engine Oil Chart...152
      Removing And Replacing Oil And Filter...153
    ENGINE COOLING SYSTEM...154
      Cleaning...154
      Removing And Replacing The Coolant...154
      Checking Level...155
    ELECTRICAL SYSTEM...156
      Description...156
      Fuses And Relay Location / Identification...157
      Battery Maintenance...159
      Using A Booster Battery (Jump Starting)...160
      Removing And Installing Battery...161
    HYDRAULIC/HYDROSTATIC SYSTEM...163
      Checking And Adding Fluid...163
      Hydraulic / Hydrostatic Fluid Chart...164
      Removing And Replacing Hydraulic Fluid...164
      Removing And Replacing Hydraulic / Hydrostatic Filter...165
      Removing And Replacing Hydraulic Charge Filter...166
      Fill / Breather Cap...167
    AXLES (FRONT AND REAR)...168
      Checking And Adding Oil (Planetary Carrier)...168
      Removing And Replacing Oil (Planetary Carrier)...168
      Checking And Adding Oil (Rear Differential)...169
      Removing And Replacing Oil (Rear Differential)...169
      Checking And Adding Oil (Front Differential)...170
      Removing And Replacing Oil (Front Differential)...170
      Checking And Adding Oil (Gear Box)...171
      Removing And Replacing Oil (Gear Box)...171
    ALTERNATOR BELT...172
      Belt Adjustment...172
      Belt Replacement...172
    AIR CONDITIONING BELT...173
      Belt Adjustment...173
      Belt Replacement...173
    TYRE MAINTENANCE...175
      Wheel Nuts...175
      Rotating...175
      Mounting...175
      Pressure...175
    LUBRICATING THE TELESCOPIC HANDLER...176
      Lubrication Locations...176
    ATTACHMENT CARRIER...178
      Inspection And Maintenance...178
    TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE...179
      Storage...179
      Return To Service...179
  SPECIFICATIONS...180
    (TL360) TELESCOPIC HANDLER SPECIFICATIONS...182
      Machine Dimensions...182
      Performance...183
      Weights...183
      Engine...183
      Controls...184
      Drive System...184
      Traction...184
      Steering...184
      Brakes...184
      Fluid Capacities...185
      Hydraulic System...185
      Electrical System...185
      Instrument Panel...186
      Environmental...186
  WARRANTY...188
    WARRANTY...190
  ALPHABETICAL INDEX...192
6990100 (06-12) - TL360(X) Telescopic Handler Service Manual...194
  MAINTENANCE SAFETY...196
  CONTENTS...198
  FOREWORD...200
    FOREWORD...202
    SAFETY INSTRUCTIONS...204
      Safe Operation Is The Operator’s Responsibility...204
      Safe Operation Needs A Qualified Operator...204
      Avoid Silica Dust...205
    FIRE PREVENTION...205
      Maintenance...205
      Operation...205
      Electrical...205
      Hydraulic System...206
      Fueling...206
      Starting...206
      Welding And Grinding...206
      Fire Extinguishers...206
    SERIAL NUMBER LOCATION...207
      Telescopic Handler Serial Number...207
      Engine Serial Number...208
      Other Serial Numbers...208
    DELIVERY REPORT...208
    BOBCAT TELESCOPIC HANDLER IDENTIFICATION...209
  SAFETY AND MAINTENANCE...210
    LIFTING AND BLOCKING THE TELESCOPIC HANDLER...212
      Procedure...212
    OPERATOR CAB...214
      Description...214
      Cab Door...214
      Cab Door Window...215
      Rear Cab Window...216
      Cab Light...216
    TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER...218
      Loading And Unloading...218
      Fastening...218
    TOWING THE TELESCOPIC HANDLER...220
      Procedure...220
    SERVICE SCHEDULE...222
    AIR CLEANER SERVICE...224
      Replacing Filter Elements...224
    ENGINE COOLING SYSTEM...226
      Cleaning...226
      Checking Level...227
      Removing And Replacing The Coolant...228
    FUEL SYSTEM...230
      Fuel Specifications...230
      Biodiesel Blend Fuel...230
      Filling The Fuel Tank...231
      Primary Fuel Filter (Pre-Filter)...231
      Secondary Fuel Filter...233
      Removing Air From The Fuel System...234
    ENGINE LUBRICATION SYSTEM...236
      Checking And Adding Engine Oil...236
      Engine Oil Chart...236
      Removing And Replacing Oil And Filter...237
    HYDRAULIC / HYDROSTATIC SYSTEM...240
      Checking And Adding Fluid...240
      Hydraulic / Hydrostatic Fluid Chart...241
      Removing And Replacing Hydraulic Fluid...241
      Removing And Replacing Hydraulic / Hydrostatic Filter...242
      Removing And Replacing Hydraulic Charge Filter...243
      Fill / Breather Cap...244
    AXLES (FRONT AND REAR)...246
      Checking And Adding Oil (Planetary Carrier)...246
      Removing And Replacing Oil (Planetary Carrier)...246
      Checking And Adding Oil (Rear Differential)...247
      Removing And Replacing Oil (Rear Differential)...247
      Checking And Adding Oil (Front Differential)...248
      Removing And Replacing Oil (Front Differential)...248
      Checking And Adding Oil (Gear Box)...249
      Removing And Replacing Oil (Gear Box)...249
    LUBRICATING THE TELESCOPIC HANDLER...250
      Lubrication Locations...250
    ATTACHMENT CARRIER...252
      Inspection And Maintenance...252
    TYRE MAINTENANCE...254
      Wheel Nuts...254
      Rotating...254
      Mounting...254
      Pressure...254
    APPROVED BOOM STOP...256
      Installing The Approved Boom Stop...256
      Removing The Approved Boom Stop...256
    ENGINE COVER...258
      Opening And Closing...258
    STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER...260
      Procedure...260
    EMERGENCY EXIT...262
      Right Rear Window...262
    TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE...264
      Storage...264
      Return To Service...264
    LIFTING THE TELESCOPIC HANDLER...266
      Procedure...266
    REMOTE START TOOL (SERVICE TOOL) KIT - MEL1563...268
      Remote Start Tool - MEL1563...268
      Service Tool Harness Control - MEL1565...269
      Service Tool Harness Communicator - MEL1566...270
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031...272
      Remote Start Tool (Service Tool) - 7003030...272
      Telescopic Handler Service Tool Harness - 6689747...273
      Computer Service Tool Harness - 6689746...275
      Remote Start Procedure...275
  HYDRAULIC SYSTEM...278
    HYDRAULIC / HYDROSTATIC SCHEMATICS...282
    HYDRAULIC SYSTEM INFORMATION...294
      Glossary Of Hydraulic / Hydrostatic Symbols...294
      Troubleshooting Chart...297
      Tightening Procedures...298
    LIFT CYLINDER...300
      Removal And Installation...300
      Parts Identification...303
      Disassembly...304
      Assembly...309
    SELF LEVELING CYLINDER...314
      Removal And Installation...314
      Parts Identification...316
      Disassembly...317
      Assembly...320
    SELF LEVELING CYLINDER (LOCK VALVE)...324
      Removal And Installation...324
    EXTENSION CYLINDER...326
      Cylinder Group Removal And Installation...326
      Upper Tubeline Removal And Installation...328
      Extension Cylinder Removal And Installation...330
      Tubeline Tray Disassembly...331
      Parts Identification...333
      Disassembly...334
      Assembly...338
    TILT CYLINDER...342
      Removal And Installation...342
      Parts Identification...345
      Disassembly...346
      Assembly...351
    STEERING CYLINDER (FRONT / REAR)...356
      Removal...356
      Installation...358
      Disassembly...360
      Assembly...362
    GEAR CONTROL CYLINDER...366
      Removal...366
      Parts Identification...368
      Disassembly...369
      Assembly...370
      Installation...371
    MAIN RELIEF VALVE...372
      Testing And Adjustment...372
      Removal And Installation...373
    MANIFOLD...374
      Removal And Installation...374
      Parts Identification...375
      Disassembly And Assembly...376
    BRAKE VALVE...378
      Removal And Installation...378
    GEAR PUMP...380
      Removal And Installation...380
      Parts Identification...382
      Disassembly And Assembly...383
    FAN MOTOR...388
      Removal And Installation...388
      Parts Identification (Single Speed Version) (Standard)...390
      Disassembly And Assembly (Single Speed Version) (Standard)...391
      Parts Identification (Variable Speed Version) (Optional)...394
      Disassembly And Assembly (Variable Speed Version) (Optional)...395
    HYDRAULIC RESERVOIR...402
      Removal And Installation...402
    STEERING VALVE...404
      Removal And Installation...404
    HYDRAULIC CONTROL VALVE...406
      Troubleshooting Chart (Controllers)...406
      Valve Section Troubleshooting...407
      Troubleshooting Chart (Control Valve)...411
      Removal And Installation...412
      Parts Identification...414
      Disassembly And Assembly...415
      Inlet-Outlet Valve Section Disassembly And Assembly...416
      Lifting Valve Section Disassembly And Assembly...417
      Tilting Valve Section Disassembly And Assembly...421
      Telescoping Valve Section Disassembly And Assembly...425
      Auxiliary Valve Section Disassembly And Assembly...429
      End Housing Disassembly And Assembly...433
    PORT RELIEF VALVES...436
      Testing...436
      Replacement Procedure...437
    PARKING BRAKE...438
      Valve Removal And Installation...438
    ACCUMULATOR...440
      Removal And Installation...440
  HYDROSTATIC SYSTEM...442
    HYDROSTATIC SYSTEM INFORMATION...444
      Troubleshooting Chart...444
      Replenishing Valve Function...445
    OIL COOLER...446
      Removal And Installation...446
    HYDROSTATIC DRIVE MOTOR...448
      Removal And Installation...448
      Parts Identification...449
      Disassembly...452
      Inspection...463
      Assembly...465
    HYDROSTATIC PUMP...478
      Removal And Installation...478
      Parts Identification...480
      Shaft Disassembly...485
      Relief Valves Disassembly And Assembly...487
      Charge Pump Disassembly...488
      Piston Pump Disassembly...490
      Solenoid Block Disassembly...493
      Inspection...495
      Piston Pump Assembly...497
      Charge Pump Assembly...501
      Solenoid Block Assembly...503
      Shaft Assembly...505
  DRIVE SYSTEM...508
    TROUBLESHOOTING...510
      Chart...510
    AXLE AND DIFFERENTIAL (FRONT)...512
      General Information...512
      Planetary Carrier Parts Identification...512
      Planetary Carrier Disassembly...513
      Steering Knuckle And Drive Axle Parts Identification...518
      Steering Knuckle Disassembly...519
      Drive Axle Disassembly...521
      Brake System Parts Identification...523
      Brake System Disassembly...524
      Differential Parts Identification...527
      Differential Disassembly...528
      Bevel Pinion Parts Identification...533
      Bevel Pinion Disassembly...534
      Bevel Pinion Assembly...537
      Differential Assembly...545
      Brake System Assembly...551
      Drive Axle Assembly...554
      Steering Knuckle Assembly...556
      Planetary Carrier Assembly...559
      Special Tools...564
    AXLE AND DIFFERENTIAL (REAR)...566
      General Information...566
      Planetary Carrier Parts Identification...566
      Planetary Carrier Disassembly...567
      Steering Knuckle And Drive Axle Parts Identification...572
      Steering Knuckle Disassembly...573
      Differential Parts Identification...575
      Differential Disassembly...576
      Bevel Pinion Parts Identification...581
      Bevel Pinion Disassembly...582
      Bevel Pinion Assembly...585
      Differential Assembly...593
      Steering Knuckle Assembly...599
      Planetary Carrier Assembly...602
      Special Tools...607
    FRONT AXLE...608
      Removal And Installation...608
    AXLE TOE-IN...612
      Adjustment...612
    PARKING BRAKE...614
      Releasing The Brake For Towing...614
      Adjustment...614
      Brake Cylinder Removal...615
      Brake Cylinder Disassembly And Assembly...615
      Brake Disc Removal And Installation...618
      Brake Cylinder Installation...618
    STEERING ANGLE ADJUSTMENT...620
      Adjustment...620
    DRIVESHAFT...622
      Rear Driveshaft Removal And Installation...622
      Front Driveshaft Removal And Installation...622
    SERVICE BRAKE...624
      Description...624
      Bleeding The Brake Circuit...624
    REAR AXLE...626
      Removal And Installation...626
    GEAR BOX...630
      Removal And Installation...630
      Parts Identification...632
      Disassembly...635
      Assembly...644
  MAINFRAME...652
    OPERATOR CAB...654
      Removal And Installation...654
    OPERATOR SEAT...658
      Removal And Installation...658
    FIXED BOOM...660
      Removal...660
      Installation...661
    INNER BOOM...664
      Removal And Installation...664
    WEAR PADS (FRONT)...668
      Removal And Installation...668
    WEAR PADS (REAR)...670
      Removal And Installation...670
    ENGINE COVER...672
      Gas Cylinder Removal And Installation...672
      Removal And Installation...672
    FUEL TANK...674
      Removal And Installation...674
    ATTACHMENT CARRIER (QUICK-TACH)...678
      Removal And Installation...678
    COUNTERWEIGHT...680
      Removal And Installation...680
    FENDER...682
      Removal And Installation...682
    STEERING COLUMN COVER...684
      Removal And Installation...684
    DASH COVER...686
      Removal And Installation...686
    JOYSTICK PANEL...690
      Removal And Installation...690
  ELECTRICAL SYSTEM AND ANALYSIS...692
    ELECTRICAL SCHEMATICS...694
    ELECTRICAL SYSTEM INFORMATION...712
      Troubleshooting Chart...712
      Description...713
      Fuses And Relay Location / Identification...714
    BATTERY...718
      Removal And Installation...718
      Using A Booster Battery (Jump Starting)...719
    ALTERNATOR...722
      Removal And Installation...722
      Belt Adjustment...723
      Belt Replacement...723
    STARTER...724
      Testing...724
      Removal And Installation...724
    LIGHTS...726
      Rear Light Removal And Installation...726
      Rear Light Bulb Replacement...727
      Front Light Removal And Installation...728
      Front Light Bulb Replacement...729
    SIGNAL LEVER...730
      Removal And Installation...730
    DISPLAY...732
      Removal And Installation...732
    INSTRUMENT PANELS...734
      Right Instrument And Indicator Panel Removal And Installation...734
      Left Instrument Panel Removal And Installation...734
    BOOM ANGLE SENSOR...736
      Removal And Installation...736
      Calibration...737
    FRONT WIPER MOTOR...740
      Removal And Installation...740
    TOP WIPER MOTOR...742
      Removal And Installation...742
    REAR WIPER MOTOR...744
      Removal And Installation...744
    PEDAL ASSEMBLY...748
      Removal And Installation...748
    INCHING SENSOR...750
      Removal And Installation...750
      Calibration...751
    SERVICE PC (LAPTOP COMPUTER)...754
      Connecting Remote Start Tool (Service Tool) - MEL1563...754
      Connecting Remote Start Tool (Service Tool) - 6689778...754
    FUEL LEVEL SENDER...756
      Removal And Installation...756
    JOYSTICK...760
      Removal And Installation...760
    LLMI / LLMC SYSTEM...762
      System Calibration...762
      Calibration Test...764
      System Failure Reports...765
      System Components Identification...770
      LLMS Removal...772
      LLMS Installation...773
      LLMC Removal And Installation...774
  ENGINE SERVICE...776
    ENGINE INFORMATION...780
      Specifications...780
      Troubleshooting...791
      Engine Removal And Installation...793
      Compression Checking...798
    ENGINE AND HYDROSTAT ASSEMBLY...800
      Removal And Installation...800
    ENGINE SPEED CONTROL...806
      Removal And Installation...806
    MUFFLER...808
      Removal And Installation...808
    AIR CLEANER...810
      Housing Removal And Installation...810
    ENGINE COOLING SYSTEM...812
      Oil Cooler / Intercooler / Radiator Removal And Installation...812
      Cooling System Description...815
      Thermostat Removal and Installation...816
      Thermostat Testing...816
      Lubricating Oil Cooler Removal And Installation...816
      Water Pump Removal...817
      Water Pump Installation...817
      Expansion Tank Removal And Installation...817
    LUBRICATION SYSTEM...818
      Engine Lubrication System Description...818
      Oil Filter Adapter Removal And Installation...819
      Oil Pan Removal And Installation...819
      Oil Screen And Pick-up Tube...820
      Oil Pump Removal...820
      Oil Pump Installation...821
      Oil Pump Disassembly And Assembly...822
      Oil Pressure Relief Valve Disassembly And Assembly...823
    FUEL SYSTEM...824
      Fuel Injection Pump Removal...824
      Fuel Injection Pump Installation...827
      Fuel Injectors Removal And Installation...831
      Checking The Fuel Lift Pump...833
      Fuel Lift Pump Removal And Installation...834
      Exhaust Manifold Removal And Installation...834
      Fuel Injector Cover Removal And Installation...835
      Rocker Cover Removal And Installation...835
    CYLINDER HEAD...838
      Glow Plugs Checking...838
      Glow Plugs Removal And Installation...839
      Removal...840
      Inspection...842
      Installation...843
      Rocker Shaft Disassembly And Assembly...846
      Valve Removal...846
      Valve Springs Checking...847
      Valve Depth Checking...847
      Valve Guide Checking...848
      Valve Guide Removal...849
      Valve Guide Installation...849
      Valve Checking...850
      Cutting A Valve Seat...850
      Valve Seat Assembly...851
      Changing Valve Springs (With Cylinder Head Installed)...852
      Valve Clearance Adjustment...853
      Engine Block Description...854
      Engine Block Disassembly And Assembly...854
      Engine Block Inspection...855
      Cylinder Liner Inspection...855
      Cylinder Liner Removal...856
      Cylinder Liner Installation...857
    CRANKSHAFT AND PISTONS...858
      Pistons And Connecting Rods Description...858
      Pistons And Connecting Rods Removal...858
      Pistons And Connecting Rods Disassembly...859
      Piston Ring End Gap...860
      Piston Ring Installation...861
      Piston Ring Groove Clearance...862
      Piston Cooling Jet Removal...862
      Piston Cooling Jet Installation...862
      Piston Cooling Jet Alignment...863
      Connecting Rod Inspection...863
      Connecting Rod Bushing Replacement...863
      Piston And Connecting Rod Assembly...864
      Piston And Connecting Rod Installation...864
      Checking Piston Height...866
      Crankshaft And Bearings Description...866
      Crankshaft And Bearings Removal...866
      Inspection Of Crankshaft And Bearings...868
      Crankshaft And Bearings Installation...869
      Rear Oil Seal Removal...870
      Rear Oil Seal Housing Positioning...871
      Rear Oil Seal Installation...871
      Checking Crankshaft End Play...872
    CAMSHAFT AND TIMING GEARS...874
      Engine Timing Procedure...874
      Timing Case And Drive Assembly Description...875
      Timing Cover Removal...875
      Timing Cover Installation...875
      Crankshaft Pulley Removal And Installation...875
      Front Oil Seal Removal And Installation...875
      Timing Case And Gear Removal...876
      Timing Case And Gear Installation...877
      Camshaft And Tappets Removal...879
      Camshaft And Tappets Installation...880
    TURBOCHARGER...882
      Troubleshooting...882
      Description...883
      Removal And Installation...883
    FLYWHEEL AND HOUSING...886
      Removal And Installation...886
      Flywheel Inspection...888
      Ring Gear Removal...888
      Ring Gear Installation...888
  HEATING, VENTILATION, AIR CONDITIONING (HVAC)...890
    AIR CONDITIONING SYSTEM FLOW...892
      Description...892
      Chart...893
      Components...894
      Safety Equipment...896
    REGULAR MAINTENANCE...898
      Filters...898
      Air Conditioning Belt Adjustment...898
      Belt Replacement...898
      Cleaning The Condenser...900
      Air Conditioning Lubrication...900
      Air Conditioning Service Chart...901
      Evaporator / Heater Coil...902
    TROUBLESHOOTING...906
      Blower Motor Does Not Operate...906
      Blower Motor Operates Normally But Air Flow Is Insufficient...906
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...906
      The Compressor Does Not Operate At All Or Operates Improperly...906
      Gauge Pressure Related Troubleshooting...907
      Temperature / Pressure Chart...909
      Poor A/C Performance...910
      HVAC Repair And Leaks...910
      Electrical System...911
    SYSTEM CHARGING AND RECLAMATION...916
      Reclamation And Charging With Recovery / Charging Unit...916
    COMPRESSOR...920
      Removal And Installation...920
      Oil...922
      Oil Check...922
      Clutch Disassembly And Assembly...924
    CONDENSER...928
      Removal And Installation...928
    RECEIVER / DRIER...930
      Removal And Installation...930
    PRESSURE SWITCH...932
      Removal And Installation...932
    EVAPORATOR / HEATER UNIT...934
      Removal And Installation...934
    THERMOSTAT...938
      Description...938
      Removal And Installation...939
    EXPANSION VALVE...942
      Removal And Installation...942
  SPECIFICATIONS...944
    (TL360) TELESCOPIC HANDLER SPECIFICATIONS...946
      Machine Dimensions...946
      Performance...947
      Weights...947
      Engine...948
      Controls...948
      Drive System...948
      Traction...949
      Steering...949
      Brakes...949
      Fluid Capacities...949
      Hydraulic System...949
      Electrical System...950
      Instrument Panel...950
      Environmental...950
    MACHINE TORQUE SPECIFICATIONS...952
      Axle...952
      Boom...952
      Drive Box...952
      Drive Motor...952
      Engine...953
      Hydraulic Pump...953
    TORQUE SPECIFICATIONS FOR BOLTS...954
      Torque for General SAE Bolts...954
      Torque For General Metric Bolts...955
    HYDRAULIC CONNECTION SPECIFICATIONS...956
      O-ring Face Seal Connection...956
      Straight Thread O-ring Fitting...956
      Tubelines And Hoses...956
      Flare Fitting...957
      O-ring Flare Fitting...958
      Port Seal Fitting...960
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...962
      Specifications...962
    CONVERSIONS...964
      Decimal And Millimeter Equivalent Chart...964
      U.S. To Metric Conversion Chart...964
  ALPHABETICAL INDEX...966
6990100 (5-11) - TL360(X) Telescopic Handler Service Manual...968
  FOREWORD...0
    FOREWORD...976
    SAFETY INSTRUCTIONS...978
      Safe Operation Is The Operator’s Responsibility...978
      Safe Operation Needs A Qualified Operator...978
      Avoid Silica Dust...979
    FIRE PREVENTION...979
      Maintenance...979
      Operation...979
      Electrical...979
      Hydraulic System...980
      Fueling...980
      Starting...980
      Welding And Grinding...980
      Fire Extinguishers...980
    SERIAL NUMBER LOCATION...981
      Telescopic Handler Serial Number...981
      Engine Serial Number...982
      Other Serial Numbers...982
    DELIVERY REPORT...982
    BOBCAT TELESCOPIC HANDLER IDENTIFICATION...983
  SAFETY & MAINTENANCE...984
    LIFTING AND BLOCKING THE TELESCOPIC HANDLER...986
      Procedure...986
    OPERATOR CAB...988
      Description...988
      Cab Door...988
      Cab Door Window...989
      Rear Cab Window...990
      Cab Light...990
    TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER...992
      Loading And Unloading...992
      Fastening...992
    TOWING THE TELESCOPIC HANDLER...994
      Procedure...994
    SERVICE SCHEDULE...996
    AIR CLEANER SERVICE...998
      Replacing Filter Elements...998
    ENGINE COOLING SYSTEM...1000
      Cleaning...1000
      Removing And Replacing The Coolant...1001
      Checking Level...1002
    FUEL SYSTEM...1004
      Fuel Specifications...1004
      Biodiesel Blend Fuel...1004
      Filling The Fuel Tank...1005
      Primary Fuel Filter (Pre-Filter)...1005
      Secondary Fuel Filter...1007
      Removing Air From The Fuel System...1007
    ENGINE LUBRICATION SYSTEM...1008
      Checking And Adding Engine Oil...1008
      Engine Oil Chart...1008
      Removing And Replacing Oil And Filter...1009
    HYDRAULIC/HYDROSTATIC SYSTEM...1012
      Checking And Adding Fluid...1012
      Hydraulic / Hydrostatic Fluid Chart...1013
      Removing And Replacing Hydraulic Fluid...1013
      Removing And Replacing Hydraulic / Hydrostatic Filter...1014
      Removing And Replacing Hydraulic Charge Filter...1016
      Fill / Breather Cap...1017
    AXLES (FRONT AND REAR)...1018
      Checking And Adding Oil (Planetary Carrier)...1018
      Removing And Replacing Oil (Planetary Carrier)...1018
      Checking And Adding Oil (Rear Differential)...1019
      Removing And Replacing Oil (Rear Differential)...1019
      Checking And Adding Oil (Front Differential)...1020
      Removing And Replacing Oil (Front Differential)...1020
      Checking And Adding Oil (Gear Box)...1021
      Removing And Replacing Oil (Gear Box)...1021
    LUBRICATING THE TELESCOPIC HANDLER...1022
      Lubrication Locations...1022
    ATTACHMENT CARRIER...1024
      Inspection And Maintenance...1024
    TIRE MAINTENANCE...1026
      Wheel Nuts...1026
      Rotating...1026
      Mounting...1026
      Pressure...1026
    APPROVED BOOM STOP (IF EQUIPPED)...1028
      Installing The Approved Boom Stop...1028
      Removing The Approved Boom Stop...1028
    ENGINE COVER...1030
      Opening And Closing...1030
    STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER...1032
      Procedure...1032
    EMERGENCY EXIT...1034
      Rear Window...1034
    TRACTOR HOMOLOGATED EMERGENCY EXIT...1036
      Right Rear Window...1036
    TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE...1038
      Storage...1038
      Return To Service...1038
    REMOTE START TOOL (SERVICE TOOL) KIT - MEL1563...1040
      Remote Start Tool - MEL1563...1040
      Service Tool Harness Control - MEL1565...1041
      Service Tool Harness Communicator - MEL1566...1042
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031...1044
      Remote Start Tool (Service Tool) - 7003030...1044
      Telescopic Handler Service Tool Harness - 6689747...1045
      Computer Service Tool Harness - 6689746...1047
      Remote Start Procedure...1047
  HYDRAULIC SYSTEM...1050
    HYDRAULIC SYSTEM INFORMATION...1058
      Troubleshooting Chart...1061
      Tightening Procedures...1062
    LIFT CYLINDER...1064
      Removal And Installation...1064
      Parts Identification...1067
      Disassembly...1068
      Assembly...1073
    SELF LEVELING CYLINDER...1078
      Removal And Installation...1078
      Parts Identification...1080
      Disassembly...1081
      Assembly...1084
    SELF LEVELING CYLINDER (LOCK VAlVE)...1088
      Removal And Installation...1088
    EXTENSION CYLINDER...1090
      Cylinder Group Removal And Installation...1090
      Upper Tubeline Removal And Installation...1092
      Extension Cylinder Removal And Installation...1094
      Tubeline Tray Disassembly...1095
      Parts Identification...1097
      Disassembly...1098
      Assembly...1102
    TILT CYLINDER...1106
      Removal And Installation...1106
      Parts Identification...1109
      Disassembly...1110
      Assembly...1115
    STEERING CYLINDER (FRONT / REAR)...1120
      Removing The Steering Cylinder...1120
      Installing The Steering Cylinder...1122
      Disassembling The Steering Cylinder...1124
      Assembling The Steering Cylinder...1126
    GEAR CONTROL CYLINDER...1130
      Removal...1130
      Parts Identification...1132
      Disassembly...1133
      Assembly...1134
      Installation...1135
    MAIN RELIEF VALVE...1136
      Testing And Adjustment...1136
      Removal And Installation...1137
    MANIFOLD...1138
      Removal And Installation...1138
      Parts Identification...1139
      Disassembly And Assembly...1140
    BRAKE VALVE...1142
      Removal And Installation...1142
    GEAR PUMP...1144
      Removal And Installation...1144
      Parts Identification...1146
      Disassembly And Assembly...1147
    FAN MOTOR...1152
      Removal And Installation...1152
      Parts Identification (Single Speed Version) (Standard)...1154
      Disassembly And Assembly (Single Speed Version) (Standard)...1155
      Parts Identification (Variable Speed Version) (Optional)...1158
      Disassembly And Assembly (Variable Speed Version) (Optional)...1159
    HYDRAULIC RESERVOIR...1166
      Removal And Installation...1166
    STEERING VALVE...1168
      Removal And Installation...1168
    HYDRAULIC CONTROL VALVE...1170
      Troubleshooting Chart (Controllers)...1170
      Valve Section Troubleshooting...1171
      Troubleshooting Chart (Control Valve)...1175
      Removal And Installation...1176
      Parts Identification...1178
      Disassembly And Assembly...1179
      Inlet-Outlet Valve Section Disassembly And Assembly...1180
      Lifting Valve Section Disassembly And Assembly...1181
      Tilting Valve Section Disassembly And Assembly...1185
      Telescoping Valve Section Disassembly And Assembly...1189
      Auxiliary Valve Section Disassembly And Assembly...1193
      End Housing Disassembly And Assembly...1197
    PORT RELIEF VALVES...1200
      Adjustment Procedure...1200
      Replacement Procedure...1200
    PARKING BRAKE...1202
      Parking Brake Valve Removal And Installation...1202
    ACCUMULATOR (IF EQUIPPED)...1204
      Removal And Installation...1204
  HYDROSTATIC SYSTEM...1206
    HYDROSTATIC SYSTEM INFORMATION...1208
      Troubleshooting Chart...1208
      Replenishing Valve Function...1209
    OIL COOLER...1210
      Description...1210
    HYDROSTATIC DRIVE MOTOR...1212
      Removal And Installation...1212
      Parts Identification...1213
      Disassembly...1216
      Inspection...1227
      Assembly...1229
    HYDROSTATIC PUMP...1242
      Removal And Installation...1242
      Parts Identification...1244
      Parts Identification (Cont’d)...1245
      Parts Identification (Cont’d)...1246
      Parts Identification (Cont’d)...1247
      Parts Identification (Cont’d)...1248
      Shaft Disassembly...1249
      Relief Valves Disassembly And Assembly...1251
      Charge Pump Disassembly...1252
      Piston Pump Disassembly...1254
      Solenoid Block Disassembly...1257
      Inspection...1259
      Piston Pump Assembly...1261
      Charge Pump Assembly...1265
      Solenoid Block Assembly...1267
      Shaft Assembly...1269
  DRIVE SYSTEM...1272
    TROUBLESHOOTING...1274
      Chart...1274
    AXLE AND DIFFERENTIAL (FRONT)...1276
      General Information...1276
      Planetary Carrier Parts Identification...1276
      Planetary Carrier Disassembly...1277
      Steering Knuckle And Drive Axle Parts Identification...1282
      Steering Knuckle Disassembly...1283
      Drive Axle Disassembly...1285
      Brake System Parts Identification...1287
      Brake System Disassembly...1288
      Differential Parts Identification...1291
      Differential Disassembly...1292
      Bevel Pinion Parts Identification...1297
      Bevel Pinion Disassembly...1298
      Bevel Pinion Assembly...1301
      Differential Assembly...1309
      Brake System Assembly...1315
      Drive Axle Assembly...1318
      Steering Knuckle Assembly...1320
      Planetary Carrier Assembly...1323
      Special Tools...1328
    AXLE AND DIFFERENTIAL (REAR)...1330
      General Information...1330
      Planetary Carrier Parts Identification...1330
      Steering Knuckle And Drive Axle Parts Identification...1336
      Steering Knuckle Disassembly...1337
      Differential Parts Identification...1339
      Differential Disassembly...1340
      Bevel Pinion Parts Identification...1345
      Bevel Pinion Disassembly...1346
      Bevel Pinion Assembly...1349
      Differential Assembly...1357
      Steering Knuckle Assembly...1363
      Planetary Carrier Assembly...1366
      Planetary Carrier Assembly...1367
      Special Tools...1371
    FRONT AXLE...1372
      Removal And Installation...1372
    AXLE TOE-IN...1376
      Adjustment...1376
    PARKING BRAKE...1378
      Releasing The Brake For Towing...1378
      Parking Brake Adjustment...1378
      Brake Cylinder Removal...1379
      Brake Disc Removal And Installation...1382
      Brake Cylinder Installation...1382
    STEERING ANGLE ADJUSTMENT...1384
      Adjustment...1384
    DRIVESHAFT...1386
      Rear Driveshaft Removal And Installation...1386
      Front Driveshaft Removal And Installation...1386
    SERVICE BRAKE...1388
      Description...1388
      Bleeding The Brake Circuit...1388
    REAR AXLE...1390
      Removal And Installation...1390
    GEAR BOX...1394
      Removal And Installation...1394
      Parts Identification...1396
      Disassembly...1399
      Assembly...1408
  MAINFRAME...1416
    OPERATOR CAB...1418
      Removal And Installation...1418
    OPERATOR SEAT...1422
      Removal And Installation...1422
    FIXED BOOM...1424
      Removal...1424
      Installation...1425
    INNER BOOM...1428
      Removal And Installation...1428
    WEAR PADS (FRONT)...1432
      Removal And Installation...1432
    WEAR PADS (REAR)...1434
      Removal And Installation...1434
    ENGINE COVER...1436
      Gas Cylinder Removal And Installation...1436
      Removal And Installation...1436
    FUEL TANK...1438
      Removal And Installation...1438
    ATTACHMENT CARRIER (QUICK-TACH)...1442
      Removal And Installation...1442
    COUNTERWEIGHT...1444
      Removal And Installation...1444
    FENDER...1446
      Removal And Installation...1446
    STEERING COLUMN COVER...1448
      Removal And Installation...1448
    DASH COVER...1450
      Removal And Installation...1450
    JOYSTICK PANEL...1454
      Removal And Installation...1454
  ELECTRICAL SYSTEM & ANALYSIS...1456
    ELECTRICAL SYSTEM INFORMATION...1476
      Troubleshooting Chart...1476
      Description...1477
      Fuses And Relay Location / Identification...1478
    BATTERY...1482
      Removing And Installing Battery...1482
      Using A Booster Battery (Jump Starting)...1483
    ALTERNATOR...1486
      Removal And Installation...1486
      Belt Adjustment...1487
      Belt Replacement...1487
    STARTER...1488
      Testing...1488
      Removal And Installation...1488
    LIGHTS...1490
      Rear Light Removal And Installation...1490
      Rear Light Bulb Replacement...1491
      Front Light Removal And Installation...1492
      Front Light Bulb Replacement...1493
    SIGNAL LEVER...1494
      Removal And Installation...1494
    DISPLAY...1496
      Removal And Installation...1496
    INSTRUMENT PANELS...1498
      Right Instrument And Indicator Panel Removal And Installation...1498
      Left Instrument Panel Removal And Installation...1498
    BOOM ANGLE SENSOR...1500
      Removal And Installation...1500
      Calibration...1501
    FRONT WIPER MOTOR...1504
      Removal And Installation...1504
    TOP WIPER MOTOR...1506
      Removal And Installation...1506
    REAR WIPER MOTOR...1508
      Removal And Installation...1508
    PEDAL ASSEMBLY...1512
      Removal And Installation...1512
    INCHING SENSOR...1514
      Removal And Installation...1514
      Calibration...1515
    SERVICE PC (LAPTOP COMPUTER)...1518
      Connecting Remote Start Tool (Service Tool) - MEL1563...1518
      Connecting Remote Start Tool (Service Tool) - 6689778...1518
    FUEL LEVEL SENDER...1520
      Removal And Installation...1520
    JOYSTICK...1524
      Removal And Installation...1524
    LLMI / LLMC SYSTEM...1526
      System Calibration...1526
      Calibration Test...1528
      System Failure Reports...1529
      System Components Identification...1533
      LLMS Removal...1535
      LLMS Installation...1536
      LLMC Removal And Installation...1537
  ENGINE SERVICE...1538
    ENGINE INFORMATION...1542
      Specifications...1542
      Troubleshooting...1554
    ENGINE SPEED CONTROL...1556
      Removal And Installation...1556
    MUFFLER...1558
      Removal And Installation...1558
    AIR CLEANER...1560
      Housing Removal And Installation...1560
    EXPANSION TANK...1562
      Removal And Installation...1562
    OIL COOLER / INTERCOOLER / RADIATOR...1564
      Removal And Installation...1564
    ENGINE AND ENGINE MOUNTS...1568
      Removal And Installation...1568
    .ENGINE COMPONENTS AND TESTING...1574
      Fuel Injection Pump Removal...1574
      Fuel Injection Pump Installation...1577
      Fuel Injectors Removal And Installation...1581
      Checking The Fuel Lift Pump...1583
      Fuel Lift Pump Removal And Installation...1584
      Compression Checking...1584
      Glow Plugs Checking...1585
      Glow Plugs Removal And Installation...1587
    ENGINE TIMING...1588
      Procedure...1588
    ENGINE / HYDROSTAT ASSEMBLY...1590
      Removal And Installation...1590
    FLYWHEEL AND HOUSING...1596
      Removal And Installation...1596
      Flywheel Inspection...1598
      Ring Gear Removal...1598
      Ring Gear Installation...1598
    TURBOCHARGER...1600
      Turbo Charger Troubleshooting...1600
      Turbo Charger Description...1601
      Turbo Charger Removal And Installation...1601
    FUEL SYSTEM...1604
      Exhaust Manifold Removal And Installation...1604
      Fuel Injector Cover Removal And Installation...1604
      Rocker Cover Removal And Installation...1605
    CYLINDER HEAD...1608
      Cylinder Head Removal...1608
      Cylinder Head Inspection...1610
      Cylinder Head Installation...1610
      Rocker Shaft Disassembly And Assembly...1613
      Valve Removal...1613
      Valve Springs Checking...1614
      Valve Depth Checking...1614
      Valve Guides Checking...1615
      Valve Guide Removal...1616
      Valve Guide Installation...1616
      Valves Checking...1617
      Cutting A Valve Seat...1618
      Valve Seat Assembly...1619
      Changing Valve Springs (With Cylinder Head Installed)...1620
      Valve Clearance Adjustment...1621
    CAMSHAFT AND TIMING GEARS...1622
      Timing Case And Drive Assembly Description...1622
      Timing Cover Removal...1622
      Timing Cover Installation...1622
      Crankshaft Pulley Removal And Installation...1622
      Front Oil Seal Removal And Installation...1622
      Timing Case And Gear Removal...1623
      Timing Case And Gear Installation...1624
      Camshaft And Tappets Removal...1626
      Camshaft And Tappets Installation...1627
    CRANKSHAFT AND PISTONS...1630
      Pistons And Connecting Rods Description...1630
      Pistons And Connecting Rods Removal...1630
      Pistons And Connecting Rods Disassembly...1631
      Piston Ring End Gap...1632
      Piston Ring Installation...1633
      Piston Ring Groove Clearance...1634
      Connecting Rod Inspection...1634
      Connecting Rod Bushing Replacement...1634
      Piston And Connecting Rod Assembly...1635
      Piston And Connecting Rod Installation...1635
      Checking Piston Height...1637
      Crankshaft And Bearings Description...1637
      Crankshaft And Bearings Removal...1637
      Inspection Of Crankshaft And Bearings...1639
      Crankshaft And Bearings Installation...1640
      Rear Oil Seal Removal...1641
      Rear Oil Seal Housing Positioning...1642
      Rear Oil Seal Installation...1642
      Checking Crankshaft End Play...1643
    ENGINE COOLING SYSTEM...1644
      Cooling System Description...1644
      Thermostat Removal and Installation...1645
      Thermostat Testing...1645
      Lubricating Oil Cooler Removal And Installation...1645
      Water Pump Removal...1646
      Water Pump Installation...1646
    LUBRICATION SYSTEM...1648
      Engine Lubrication System Description...1648
      Oil Filter Adapter Removal And Installation...1649
      Oil Pan Removal And Installation...1649
      Oil Screen And Pick-up Tube...1650
      Oil Pump Removal...1650
      Oil Pump Installation...1651
      Oil Pump Disassembly And Assembly...1652
      Oil Pressure Relief Valve Disassembly And Assembly...1653
    ENGINE BLOCK...1654
      Engine Block Description...1654
      Engine Block Disassembly And Assembly...1654
      Piston Cooling Jet Removal...1655
      Piston Cooling Jet Installation...1655
      Piston Cooling Jet Alignment...1655
      Inspection...1655
      Cylinder Liner Inspection...1656
      Cylinder Liner Removal...1657
      Cylinder Liner Installation...1658
  HEATING, VENTILATION, AIR CONDITIONING (HVAC)...1660
    AIR CONDITIONING SYSTEM FLOW...1662
      Principles...1662
      Chart...1663
    COMPONENTS...1664
      Identification...1664
    SAFETY...1666
      Safety Equipment...1666
    REGULAR MAINTENANCE...1668
      Filter Element Removal And Installation...1668
      Air Conditioning Belt Adjustment...1668
      Belt Replacement...1668
      Cleaning The Condenser...1670
      Evaporator / Heater Coil...1670
    BASIC TROUBLESHOOTING...1674
      Poor A/C Performance...1674
      Checking The Electrical System...1675
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...1680
      Compressor Oil...1680
      Compressor Oil Check...1680
      Component Replacement And Refrigeration Leaks...1682
    SYSTEM TROUBLESHOOTING CHART...1684
    TEMPERATURE / PRESSURE...1688
      Chart...1688
    AIR CONDITIONING SERVICE...1690
      Chart...1690
    SYSTEM CHARGING AND RECLAMATION...1692
      Reclamation And Charging With Recovery / Charging Unit...1692
    COMPRESSOR...1696
      Removal And Installation...1696
      Compressor Clutch Disassembly And Assembly...1698
    CONDENSER...1702
      Removal And Installation...1702
    RECEIVER / DRIER...1704
      Removal And Installation...1704
    PRESSURE SWITCH...1706
      Removal And Installation...1706
    EVAPORATOR / HEATER UNIT...1708
      Removal And Installation...1708
    EXPANSION VALVE...1712
      Removal And Installation...1712
    THERMOSTAT...1714
      Description...1714
      Removal And Installation...1715
  SPECIFICATIONS...1718
    (TL360) TELESCOPIC HANDLER SPECIFICATIONS...1720
      Machine Dimensions...1720
      Performance...1721
      Weights...1721
      Engine...1722
      Controls...1722
      Drive System...1722
      Traction...1723
      Steering...1723
      Brakes...1723
      Fluid Capacities...1723
      Hydraulic System...1723
      Electrical System...1724
      Instrument Panel...1724
      Environmental...1724
    MACHINE TORQUE SPECIFICATIONS...1726
      Axle...1726
      Boom...1726
      Drive Box...1726
      Drive Motor...1726
      Engine...1727
      Hydraulic Pump...1727
    TORQUE SPECIFICATIONS FOR BOLTS...1728
      Torque for General SAE Bolts...1728
      Torque For General Metric Bolts...1729
    HYDRAULIC CONNECTION SPECIFICATIONS...1730
      O-ring Face Seal Connection...1730
      Straight Thread O-ring Fitting...1730
      Tubelines And Hoses...1730
      Port Seal Fitting...1731
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...1732
      Specifications...1732
    CONVERSIONS...1734
      Decimal And Millimeter Equivalent Chart...1734
      U.S. To Metric Conversion Chart...1734
  ALPHABETICAL INDEX...1736
6990790 (05-13) - TL360(X), TL470(X), TL470(X)HF Telescopic Handler Service Manual...1738
  MAINTENANCE SAFETY...1740
  CONTENTS...1742
  FOREWORD...1744
    FOREWORD...1746
    SAFETY INSTRUCTIONS...1748
      Safe Operation Is The Operator’s Responsibility...1748
      Safe Operation Needs A Qualified Operator...1748
      Avoid Silica Dust...1749
      Dismantling And Disposal...1749
    FIRE PREVENTION...1750
      Maintenance...1750
      Operation...1750
      Electrical...1750
      Hydraulic System...1750
      Fueling...1750
      Starting...1750
      Welding And Grinding...1751
      Fire Extinguishers...1751
    SERIAL NUMBER LOCATION...1752
      Telescopic Handler Serial Number...1752
      Telescopic Handler Statutory Plate...1752
      Engine Serial Number...1753
      Diesel Oxidation Catalytic Converter Serial Number...1753
      Other Serial Numbers...1753
    DELIVERY REPORT...1754
    BOBCAT TELESCOPIC HANDLER IDENTIFICATION...1755
  SAFETY AND MAINTENANCE...1756
    LIFTING AND BLOCKING THE TELESCOPIC HANDLER...1760
      Procedure...1760
    OPERATOR CAB...1762
      Description...1762
      Cab Door...1762
      Cab Door Window...1763
      Rear Cab Window...1764
      Cab Light...1764
    TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER...1766
      Loading And Unloading...1766
      Fastening...1766
    TOWING THE TELESCOPIC HANDLER...1768
      Procedure...1768
    SERVICE SCHEDULE...1772
      Maintenance Intervals...1772
    AIR CLEANER SERVICE...1776
      Replacing Filter Elements...1776
    ENGINE COOLING SYSTEM...1778
      Cleaning...1778
      Checking Level...1778
      Removing And Replacing The Coolant...1779
    FUEL SYSTEM...1780
      Fuel Specifications...1780
      Biodiesel Blend Fuel...1780
      Filling The Fuel Tank...1781
      Primary Fuel Filter (Pre-Filter)...1781
      Secondary Fuel Filter...1783
      Removing Air From The Fuel System...1783
    ENGINE LUBRICATION SYSTEM...1784
      Checking And Adding Engine Oil...1784
      Engine Oil Chart...1784
      Removing And Replacing Oil And Filter...1785
    HYDRAULIC / HYDROSTATIC SYSTEM...1788
      Checking And Adding Fluid...1788
      Hydraulic / Hydrostatic Fluid Chart...1789
      Removing And Replacing Hydraulic Fluid...1789
      Removing And Replacing Hydraulic / Hydrostatic Filters...1790
      Removing And Replacing Hydraulic Charge Filter...1792
      Fill / Breather Cap...1792
      Hydraulic Fluid Air Bleeding Procedure (Only For TL470(X)HF)...1793
    AXLES (FRONT AND REAR)...1798
      Checking And Adding Oil (Planetary Carrier)...1798
      Removing And Replacing Oil (Planetary Carrier)...1798
      Checking And Adding Oil (Rear Differential)...1799
      Removing And Replacing Oil (Rear Differential)...1799
      Checking And Adding Oil (Front Differential)...1800
      Removing And Replacing Oil (Front Differential)...1800
      Checking And Adding Oil (Gear Box)...1801
      Removing And Replacing Oil (Gear Box)...1801
    LUBRICATING THE TELESCOPIC HANDLER...1802
      Lubrication Locations...1802
      Front Pads Lubrication...1803
      Rear Pads Lubrication...1804
    ATTACHMENT CARRIER...1806
      Inspection And Maintenance...1806
    TIRE MAINTENANCE...1808
      Wheel Nuts...1808
      Rotating...1808
      Wheel replacement...1808
      Mounting...1809
      Pressure...1809
    APPROVED BOOM STOP...1810
      Installing...1810
      Removing...1810
    ENGINE COVER...1812
      Opening And Closing...1812
    STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER...1814
      Procedure...1814
    EMERGENCY EXIT...1816
      Rear Window...1816
      Right Rear Window...1816
    TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE...1818
      Storage...1818
      Return To Service...1818
    LIFTING THE TELESCOPIC HANDLER...1820
      Procedure...1820
    REMOTE START TOOL (SERVICE TOOL) KIT - MEL1563...1822
      Remote Start Tool - MEL1563...1822
      Service Tool Harness Control - MEL1565...1823
      Service Tool Harness Communicator - MEL1566...1824
    REMOTE START TOOL (SERVICE TOOL) KIT - 7217666...1826
      Remote Start Tool (Service Tool) - 7022042...1826
      Telescopic Handler Service Tool Harness - 6689747...1827
      Computer Service Tool Harness - 6689746...1829
      Remote Start Procedure...1829
  HYDRAULIC SYSTEM...1832
    HYDRAULIC / HYDROSTATIC SCHEMATICS...1836
    HYDRAULIC SYSTEM INFORMATION...1840
      Glossary Of Hydraulic / Hydrostatic Symbols...1840
      Troubleshooting Chart...1843
      Tightening Procedures...1844
    LIFT CYLINDER...1846
      Removal And Installation...1846
      Parts Identification...1849
      Disassembly...1850
      Assembly...1855
    SELF LEVELING CYLINDER...1860
      Removal And Installation...1860
      Parts Identification...1862
      Disassembly...1863
      Assembly...1866
    SELF LEVELING CYLINDER (LOCK VALVE)...1870
      Removal And Installation...1870
    EXTENSION CYLINDER...1872
      Cylinder Group Removal And Installation...1872
      Upper Tubeline Removal And Installation...1874
      Extension Cylinder Removal And Installation...1876
      Tubeline Tray Disassembly...1877
      Parts Identification...1879
      Disassembly...1880
      Assembly...1884
    TILT CYLINDER...1888
      Removal And Installation...1888
      Parts Identification...1891
      Disassembly...1892
      Assembly...1897
    STEERING CYLINDER (FRONT / REAR)...1902
      Removal...1902
      Installation...1904
      Disassembly...1906
      Assembly...1908
    GEAR CONTROL CYLINDER...1912
      Removal...1912
      Parts Identification...1914
      Disassembly...1915
      Assembly...1916
      Installation...1917
    MAIN RELIEF VALVE...1918
      Testing And Adjustment...1918
      Removal And Installation...1919
    MANIFOLD...1920
      Removal And Installation...1920
      Parts Identification...1921
      Disassembly And Assembly...1922
    BRAKE VALVE...1924
      Removal And Installation...1924
    PISTON PUMP (FOR TL470(X)HF)...1926
      Test Tools Installation...1926
      Troubleshooting Chart...1930
      Removal And Installation...1933
      Parts Identification...1935
      Disassembly And Assembly...1936
    GEAR PUMP (FOR TL360(X) AND TL470(X))...1946
      Removal And Installation...1946
      Parts Identification...1948
      Disassembly And Assembly...1949
    FAN MOTOR...1954
      Removal And Installation...1954
      Parts Identification (Single Speed Version) (Standard)...1956
      Disassembly And Assembly (Single Speed Version) (Standard)...1957
      Parts Identification (Variable Speed Version) (Optional)...1960
      Disassembly And Assembly (Variable Speed Version) (Optional)...1961
    HYDRAULIC FLUID RESERVOIR...1968
      Removal And Installation...1968
    STEERING VALVE...1970
      Removal And Installation...1970
    HYDRAULIC CONTROL VALVE...1972
      Troubleshooting Chart (Controllers)...1972
      Valve Section Troubleshooting...1973
      Troubleshooting Chart (Control Valve)...1977
      Removal And Installation...1978
      Parts Identification...1980
      Disassembly And Assembly...1981
      End Housing Disassembly And Assembly...1982
      Auxiliary Valve Section Disassembly And Assembly...1983
      Telescoping Valve Section Disassembly And Assembly...1987
      Tilting Valve Section Disassembly And Assembly...1991
      Lifting Valve Section Disassembly And Assembly...1995
      Inlet-Outlet Valve Section Disassembly And Assembly...1999
    PORT RELIEF VALVES...2002
      Testing...2002
      Replacement Procedure...2003
    PARKING BRAKE...2004
      Valve Removal And Installation...2004
    ACCUMULATOR...2006
      Removal And Installation...2006
    FAN PUMP (ONLY FOR TL470(X)HF)...2008
      Removal And Installation...2008
      Parts Identification...2009
      Disassembly And Assembly...2010
  HYDROSTATIC SYSTEM...2014
    HYDROSTATIC SYSTEM INFORMATION...2016
      Troubleshooting Chart...2016
      Replenishing Valve Function...2017
    OIL COOLER...2018
      Description...2018
    HYDROSTATIC DRIVE MOTOR...2020
      Removal And Installation...2020
      Parts Identification...2021
      Disassembly...2024
      Inspection...2035
      Assembly...2037
    HYDROSTATIC PUMP...2050
      Calibration...2050
      Removal And Installation...2052
      Parts Identification...2054
      Shaft Disassembly...2059
      Relief Valves Disassembly And Assembly...2061
      Charge Pump Disassembly...2062
      Piston Pump Disassembly...2064
      Solenoid Block Disassembly...2067
      Inspection...2069
      Piston Pump Assembly...2071
      Charge Pump Assembly...2075
      Solenoid Block Assembly...2077
      Shaft Assembly...2079
  DRIVE SYSTEM...2082
    DRIVE SYSTEM TROUBLESHOOTING...2084
      Chart...2084
    AXLE AND DIFFERENTIAL (FRONT)...2086
      Description...2086
      Planetary Carrier Parts Identification...2086
      Planetary Carrier Disassembly...2087
      Steering Knuckle And Drive Axle Parts Identification...2092
      Steering Knuckle Disassembly...2093
      Drive Axle Disassembly...2095
      Brake Group Parts Identification...2097
      Brake Group Disassembly...2098
      Differential Parts Identification...2101
      Differential Disassembly...2102
      Pinion Group Parts Identification...2107
      Pinion Group Disassembly...2108
      Pinion Group Assembly...2111
      Differential Assembly...2119
      Brake Group Assembly...2125
      Drive Axle Assembly...2128
      Steering Knuckle Assembly...2130
      Planetary Carrier Assembly...2133
      Special Tools...2138
    AXLE AND DIFFERENTIAL (REAR)...2140
      Description...2140
      Planetary Carrier Parts Identification...2140
      Planetary Carrier Disassembly...2141
      Steering Knuckle And Drive Axle Parts Identification...2146
      Steering Knuckle Disassembly...2147
      Differential Parts Identification...2149
      Differential Disassembly...2150
      Pinion Group Parts Identification...2155
      Pinion Group Disassembly...2156
      Pinion Group Assembly...2159
      Differential Assembly...2167
      Steering Knuckle Assembly...2173
      Planetary Carrier Assembly...2176
      Planetary Carrier Assembly...2177
      Special Tools...2181
    FRONT AXLE...2182
      Removal And Installation...2182
    AXLE TOE-IN...2186
      Adjustment...2186
    PARKING BRAKE...2188
      Releasing The Brake For Towing...2188
      Adjustment...2188
      Brake Cylinder Removal...2189
      Brake Cylinder Disassembly And Assembly...2189
      Brake Disc Removal And Installation...2192
      Brake Cylinder Installation...2192
    STEERING ANGLE ADJUSTMENT...2194
      Adjustment...2194
    DRIVESHAFT...2196
      Rear Driveshaft Removal And Installation...2196
      Front Driveshaft Removal And Installation...2196
    SERVICE BRAKE...2198
      Description...2198
      Bleeding The Brake Circuit...2198
    REAR AXLE...2200
      Removal And Installation...2200
    GEAR BOX...2204
      Removal And Installation...2204
      Parts Identification...2206
      Disassembly...2207
      Assembly...2216
  MAINFRAME...2224
    OPERATOR CAB...2226
      Removal And Installation...2226
    OPERATOR SEAT...2230
      Removal And Installation...2230
    FIXED BOOM...2232
      Removal...2232
      Installation...2233
    INNER BOOM...2236
      Removal And Installation...2236
    WEAR PADS (FRONT)...2240
      Removal And Installation...2240
    WEAR PADS (REAR)...2242
      Removal And Installation...2242
    ENGINE COVER...2244
      Gas Cylinder Removal And Installation...2244
      Removal And Installation...2244
    FUEL TANK...2246
      Removal And Installation...2246
    ATTACHMENT CARRIER (QUICK-TACH)...2250
      Removal And Installation...2250
    COUNTERWEIGHT...2252
      Removal And Installation...2252
    FENDER...2254
      Removal And Installation...2254
    STEERING COLUMN COVER...2256
      Removal And Installation...2256
    DASH COVER...2258
      Removal And Installation...2258
    JOYSTICK PANEL...2262
      Removal And Installation...2262
  ELECTRICAL SYSTEM AND ANALYSIS...2264
    ELECTRICAL SCHEMATICS...2266
    ELECTRICAL SYSTEM INFORMATION...2304
      Troubleshooting Chart...2304
      Description...2305
      Fuses And Relay Location / Identification...2305
    BATTERY...2308
      Removal And Installation...2308
      Using A Booster Battery (Jump Starting)...2310
    ALTERNATOR...2312
      Removal And Installation...2312
      Belt Adjustment...2313
      Belt Checking...2313
      Belt Replacement...2313
    STARTER...2314
      Testing...2314
      Removal And Installation...2315
    LIGHTS...2318
      Rear Light Removal And Installation...2318
      Rear Light Bulb Replacement...2319
      Front Light Removal And Installation...2320
      Front Light Bulb Replacement...2321
    SIGNAL LEVER...2322
      Removal And Installation...2322
    DISPLAY...2324
      Removal And Installation...2324
    INSTRUMENT PANELS...2326
      Right Instrument And Indicator Panel Removal And Installation...2326
      Left Instrument Panel Removal And Installation...2326
    BOOM ANGLE SENSOR...2328
      Removal And Installation...2328
      Calibration...2329
    FRONT WIPER MOTOR...2332
      Removal And Installation...2332
    TOP WIPER MOTOR...2334
      Removal And Installation...2334
    REAR WIPER MOTOR...2336
      Removal And Installation...2336
    PEDAL ASSEMBLY...2340
      Removal And Installation...2340
    INCHING SENSOR...2342
      Removal And Installation...2342
      Calibration...2343
    SERVICE PC (LAPTOP COMPUTER)...2346
      Connecting Remote Start Tool (Service Tool) - MEL1563...2346
      Connecting Remote Start Tool (Service Tool) - 7217666...2346
    FUEL LEVEL SENDER...2348
      Removal And Installation...2348
    JOYSTICK...2352
      Removal And Installation...2352
    LLMI / LLMC SYSTEM...2354
      System Calibration...2354
      Calibration Test...2356
      System Failure Reports...2357
      System Components Identification...2361
      LLMS Removal...2363
      LLMS Installation...2364
      LLMC Removal And Installation...2365
  ENGINE SERVICE...2366
    ENGINE...2368
      Removal And Installation...2368
    ENGINE AND HYDROSTAT ASSEMBLY...2376
      Removal And Installation...2376
    ENGINE SPEED CONTROL...2382
      Removal And Installation...2382
    MUFFLER...2384
      Removal And Installation...2384
    AIR CLEANER...2386
      Housing Removal And Installation...2386
    ENGINE COOLING SYSTEM...2388
      Oil Cooler / Intercooler / Radiator Removal And Installation...2388
      Cooling System Check...2392
      Cooling System Inspection...2392
      Expansion Tank Removal And Installation...2393
  HEATING, VENTILATION, AIR CONDITIONING (HVAC)...2394
    AIR CONDITIONING SYSTEM FLOW...2396
      Description...2396
      Chart...2397
      Components...2398
      Safety Equipment...2400
    REGULAR MAINTENANCE...2402
      Filters...2402
      Air Conditioning Belt Adjustment...2403
      Belt Replacement...2403
      Cleaning The Condenser...2404
      Air Conditioning Lubrication...2404
      Air Conditioning Service Chart...2405
      Evaporator / Heater Coil...2406
    A/C SYSTEM TROUBLESHOOTING...2410
      Blower Motor Does Not Operate...2410
      Blower Motor Operates Normally, But Air Flow Is Insufficient...2410
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...2410
      The Compressor Does Not Operate At All, Or Operates Improperly...2410
      Gauge Pressure Related Troubleshooting...2411
      Temperature / Pressure Chart...2413
      Poor A/C Performance...2414
      HVAC Repair And Leaks...2414
      Electrical System...2415
    SYSTEM CHARGING AND RECLAMATION...2420
      Reclamation And Charging With Recovery / Charging Unit...2420
    COMPRESSOR...2424
      Removal And Installation...2424
      Oil...2426
      Oil Check...2426
      Clutch Disassembly And Assembly...2428
    CONDENSER...2432
      Removal And Installation...2432
    RECEIVER / DRIER...2434
      Removal And Installation...2434
    PRESSURE SWITCH...2436
      Removal And Installation...2436
    EVAPORATOR / HEATER UNIT...2438
      Removal And Installation...2438
    THERMOSTAT...2442
      Description...2442
      Removal And Installation...2443
    EXPANSION VALVE...2446
      Removal And Installation...2446
  SPECIFICATIONS...2448
    (TL360(X)) TELESCOPIC HANDLER SPECIFICATIONS...2450
      Machine Dimensions...2450
      Performance...2451
      Weights...2451
      Engine...2452
      Controls...2452
      Drive System...2453
      Traction...2453
      Steering...2453
      Brakes...2453
      Fluid Capacities...2454
      Hydraulic System...2454
      Cycle Times...2454
      Electrical System...2454
      Instrument Panel...2455
      Environmental...2456
    (TL470(X)) TELESCOPIC HANDLER SPECIFICATIONS...2457
      Machine Dimensions...2457
      Performance...2458
      Weights...2458
      Engine...2459
      Controls...2459
      Drive System...2460
      Traction...2460
      Steering...2460
      Brakes...2460
      Fluid Capacities...2461
      Hydraulic System...2461
      Cycle Times...2461
      Electrical System...2461
      Instrument Panel...2462
      Environmental...2463
    (TL470(X)HF) TELESCOPIC HANDLER SPECIFICATIONS...2464
      Machine Dimensions...2464
      Performance...2465
      Weights...2465
      Engine...2466
      Controls...2466
      Drive System...2467
      Traction...2467
      Steering...2467
      Brakes...2467
      Fluid Capacities...2468
      Hydraulic System...2468
      Cycle Times...2468
      Electrical System...2468
      Instrument Panel...2469
      Environmental...2470
    MACHINE TORQUE SPECIFICATIONS...2472
      Axle...2472
      Boom...2472
      Drive Box...2472
      Drive Motor...2472
      Engine...2473
      Hydraulic Pump...2473
    TORQUE SPECIFICATIONS FOR BOLTS...2474
      Torque for General SAE Bolts...2474
      Torque For General Metric Bolts...2475
    HYDRAULIC CONNECTION SPECIFICATIONS...2476
      O-ring Face Seal Connection...2476
      Straight Thread O-ring Fitting...2476
      Tubelines And Hoses...2476
      Flare Fitting...2477
      O-ring Flare Fitting...2478
      Port Seal Fitting...2480
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...2482
      Specifications...2482
    CONVERSIONS...2484
      Decimal And Millimeter Equivalent Chart...2484
      U.S. To Metric Conversion Chart...2484
  ALPHABETICAL INDEX...2486