Complete repair service manual with Electrical Wiring Diagrams for Bobcat Telescopic Handlers T2250, T2556, T2566, with technical information to maintain, diagnose, and repair like professional mechanics.

Bobcat Telescopic Handlers T2250, T2556, T2566 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.

4852210 (01-08) - T2556, T2566 Service Manual.pdf
6986740 (07-08) - T2250 Service Manual.pdf
6986740 (7-08) - T2250 Telescopic Handler Service Manual.pdf
6986764 (2-10) - T2556, T2566 Telescopic Handler Service Manual.pdf
6986764 (08-12) - T2556, T2566 Telescopic Handler Service Manual.pdf
6987147 (2-10) - T2250 Telescopic Handler Service Manual.pdf
6987147 (8-12) - T2250 Telescopic Handler Service Manual.pdf
6989550 (2-10) - T2250 Telescopic Handler Operation & Maintenance Manual.pdf
6989552 (2-10) - T2556-T2566 Telescopic Handler Operation & Maintenance Manual.pdf

Total Pages: 6,413 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
4852210 (01-08) - T2556, T2566 Service Manual...1
  MAINTENANCE SAFETY...3
  ALPHABETICAL INDEX...5
  SAFETY INSTRUCTIONS...11
    FIRE PREVENTION...12
  Serial Number LocationS...13
    telescopic handler Serial Number...13
    Engine Serial Number...13
    Earlier Models...13
    Later Models...13
    Other Serial Numbers...13
    Delivery Report...14
    BOBCAT telescopic handler IDENTIFICATION...14
  LIFTING AND BLOCKING THE TELESCOPIC HANDLER...17
    Procedure...17
  OPERATOR CAB...19
    Emergency Exit...19
    Cab Door...20
    Cab Door Window...20
  TRANSPORTING THE TELESCOPIC HANDLER...21
    Procedure...21
  TOWING THE TELESCOPIC HANDLER (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)...23
    Procedure...23
  TOWING THE Telescopic Handler (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000) (CONT’D)...24
    Procedure (Cont’d)...24
  TOWING THE TELESCOPIC HANDLER (S/N 363012001 & Above, S/N 363112001 & Above)...25
    Procedure...25
  SERVICE SCHEDULE...29
  AIR CLEANER SERVICE...31
    Replacing Filter Element...31
  ENGINE COOLING SYSTEM...33
    Cleaning The Cooling System...33
    Checking The Coolant Level...33
    Replacing The Coolant...34
  FUEL SYSTEM...37
    Fuel Specifications...37
    Filling The Fuel Tank...37
    Fuel Filter...37
  ENGINE LUBRICATION SYSTEM...39
    Checking Engine Oil...39
    Oil Chart...39
    Replacing Oil And Filter...40
  HYDRAULIC/HYDROSTATIC SYSTEM...41
    Checking And Adding Fluid...41
  HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)...42
    Replacing Hydraulic/Hydrostatic Filter...42
    Replacing Hydraulic Fluid...42
  HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)...43
  AXLES (FRONT AND REAR) (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)...45
    Checking Oil Level (Planetary Carrier)...45
    Draining Oil (Planetary Carrier)...45
    Checking Oil Level (Rear Differential)...46
    Draining Oil (Rear Differential)...46
    Checking Oil Level (Front Differential)...46
    Draining Oil (Front Differential)...47
  AXLES (FRONT AND REAR) (For S/N 363012001 and Above, S/N 363112001 and Above)...49
    Checking Oil Level (Planetary Carrier)...49
    Draining Oil (Planetary Carrier)...49
    Checking Oil Level (Rear Differential)...50
    Draining Oil (Rear Differential)...50
    Checking Oil Level (Front Differential)...50
    Draining Oil (Front Differential)...51
    Checking Oil Level (Drive Box)...51
    Draining Oil (Drive Box)...51
  LUBRICATION (For S/N 363011001 - 363012000 and S/ N 363111001 - 363112000)...53
    Procedure...53
  LUBRICATION (For S/N 363012001 & Above and S/N 363112001 & Above)...57
    Procedure...57
  TIRE MAINTENANCE...61
  Wheel Nuts (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)...61
    Tire Rotation...61
    Tire Mounting...61
  OPTIONAL APPROVED BOOM STOP...63
    Installing The Approved Boom Stop...63
    Removing The Approved Boom Stop...63
  ENGINE COVER...65
    Opening And Closing The Engine Cover...65
  HYDRAULIC SYSTEM INFORMATION...71
    Troubleshooting Chart...74
    Tightening Procedures...75
  LIFT CYLINDER...77
    Removal And Installation...77
    Parts Identification...82
    Disassembly...83
    Assembly...87
  BUCKET POSITIONING CYLINDER...91
    Removal And Installation...91
    Parts Identification...96
    Disassembly...97
    Assembly...101
  EXTENSION CYLINDER...105
    Cylinder Group Removal And Installation...105
    Upper Tubeline Removal...107
    Upper Tubeline Installation...109
    Extension Cylinder Removal And Installation...110
    Tubeline Tray Disassembly...112
    Tubeline Tray Assembly...113
    Parts Identification...116
    Disassembly...117
    Assembly...121
  TILT CYLINDER...125
    Removal And Installation...125
    Parts Identification...127
    Disassembly...128
    Assembly...133
  STEERING CYLINDER (FRONT) (For S/N 363011001 - 363012000 and S/N 363111001 - 363012000)...139
    Removal And Installation...139
    Parts Identification...141
    Disassembly...142
    Assembly...145
  STEERING CYLINDER (FRONT) (For S/N 363012001 and above, S/N 363112001 and above)...151
    Removing the Steering Cylinder...151
    Installing the Steering Cylinder...152
    Disassembling the Steering Cylinder...156
    Assembling the Steering Cylinder...157
  STEERING CYLINDER (REAR) (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)...161
    Removal And Installation...161
    Parts Identification...163
    Disassembly...164
    Assembly...167
  STEERING CYLINDER (REAR) (For S/N 363012001 and above, S/N 363112001 and above)...173
    Removing the Steering Cylinder...173
    Installing the Steering Cylinder...174
    Disassembling the Steering Cylinder...178
    Assembling the Steering Cylinder...180
  DRIVE BOX (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)...183
    Parts Identification...183
    Disassembly...184
    Inspection...189
    Assembly...190
  DRIVE BOX (For S/N 363012001 and above, S/N 363112001 and above)...197
    Parts Identification...197
    Disassembly...198
    Assembly...202
  special tools...205
  MAIN RELIEF VALVE...207
    Testing And Adjustment...207
  QUICK TACH CYLINDER...209
    Removal And Installation...209
    Parts Identification...211
    Disassembly...212
    Assembly...215
  PORT RELIEF VALVES...217
    Adjustment Procedure...217
  STEERING MODE VALVE BLOCK...219
    Removal And Installation...219
    Parts Identification...221
    Disassembly...222
    Solenoid Testing...224
    Assembly...224
  BRAKE VALVE...227
    Removal And Installation...227
    Disassembly And Assembly...228
  GEAR PUMP...231
    Removal And Installation...231
  GEAR PUMP (CONT’D)...233
    Parts Identification...233
    Disassembly And Assembly...234
  FAN MOTOR...241
    Removal And Installation...241
    Parts Identification...245
    Disassembly And Assembly (1 speed version)...246
    Disassembly And Assembly (2 speed version)...249
  HYDRAULIC RESERVOIR...253
    Removal And Installation...253
  STEERING VALVE...255
    Removal And Installation...255
    Parts Identification...256
    Disassembly...257
    Inspection...263
    Assembly...263
  HYDRAULIC CONTROL VALVE...271
    Troubleshooting Chart (Controllers)...271
    Telescoping Valve Section Troubleshooting...272
    Auxiliary Valve Section Troubleshooting...276
    Troubleshooting Chart (Control Valve)...280
    Removal And Installation...281
  HYDRAULIC CONTROL VALVE (CONT’D)...285
    Parts Identification...285
    Disassembly And Assembly...286
    End Housing Disassembly And Assembly...287
    Lifting Valve Section Disassembly And Assembly...288
    Tilting Valve Section Disassembly And Assembly...293
    Telescoping Valve Section Disassembly And Assembly...298
    Auxiliary Valve Section Disassembly And Assembly...310
    Inlet-Outlet Valve Section Disassembly And Assembly...321
  JOYSTICK...325
    Removal And Installation...325
    Parts Identification...327
  PARKING BRAKE...329
    Parking Brake Valve Removal And Installation...329
    Parking Brake Valve Disassembly And Assembly...330
  PILOT PRESSURE LOCK OUT VALVE...333
    Testing...333
    Removal And Installation...334
    Disassembly And Assembly...335
  ACCUMULATOR...337
    Removal And Installation...337
  OPTIONAL TOW VALVE...339
    Removal And Installation...339
    Disassembly And Assembly...340
  FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE...345
    Removal And Installation...345
    Disassembly And Assembly...346
  FLOW CONTROL VALVE...351
    Removal And Installation...351
  HYDROSTATIC SYSTEM INFORMATION...355
    Troubleshooting Chart...355
    Replenishing Valve Function...356
  OIL COOLER...357
    Description...357
  HYDROSTATIC DRIVE MOTOR...359
    Removal And Installation...359
    Parts Identification...360
    Disassembly...363
    Inspection...374
    Assembly...376
  HYDROSTATIC PUMP...389
    Removal And Installation...389
    Parts Identification...390
    Parts Identification...392
    Disassembly...395
    Inspection...407
    Assembly...411
    Charge pressure checking procedure...426
    Charge pressure adjusting procedure...426
  TROUBLESHOOTING...431
    Chart...431
  AXLE AND DIFFERENTIAL (FRONT) (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)...433
    General Information...433
    Planetary Carrier Parts Identification...433
    Planetary Carrier Disassembly...434
    Planetary Carrier Inspection...436
    Wheel Hub Parts Identification...437
    Wheel Hub Disassembly...438
    Wheel Hub Inspection...441
    Steering Knuckle Parts Identification...442
    Steering Knuckle Disassembly...443
    Axle Housing/Drive Axle Parts Identification...445
    Axle Housing/Drive Axle Disassembly...446
    Brake Group Parts Identification...451
    Brake Group Disassembly...451
    Brake Group Inspection...457
    Differential Parts Identification...458
    Differential Disassembly...458
    Differential Inspection...461
    Pinion Group Parts Identification...462
    Pinion Group Disassembly...463
    Pinion Group Inspection...465
    Pinion Group Assembly...466
    Differential Assembly...472
    Brake Group Assembly...475
    Axle Housing/Drive Axle Assembly...485
    Steering Knuckle Assembly...490
    Wheel Hub Assembly...493
    Planetary Carrier Assembly...495
  AXLE AND DIFFERENTIAL (REAR) (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)...497
    General Information...497
    Planetary Carrier Parts Identification...497
    Planetary Carrier Disassembly...498
    Planetary Carrier Inspection...500
    Wheel Hub Parts Identification...501
    Wheel Hub Disassembly...502
    Wheel Hub Inspection...505
    Steering Knuckle Parts Identification...505
    Steering Knuckle Disassembly...506
    Axle Housing/Drive Axle Parts Identification...508
    Axle Housing/Drive Axle Disassembly...509
    Differential Parts Identification...512
    Differential Disassembly...512
    Differential Inspection...519
    Pinion Group Parts Identification...520
    Pinion Group Disassembly...521
    Pinion Group Inspection...524
    Pinion Group Assembly...525
    Differential Assembly...531
    Axle Housing/Drive Axle Assembly...542
    Steering Knuckle Assembly...545
    Wheel Hub Assembly...548
    Planetary Carrier Assembly...550
  AXLE AND DIFFERENTIAL (FRONT) (For S/N 363012001 and Above, S/N 363112001 and Above)...553
    General Information...553
    Planetary Carrier Parts Identification...553
    Planetary Carrier Disassembly...554
    Steering Knuckle Parts Identification...558
    Steering Knuckle Disassembly...559
    Brake System Identification...564
    Brake System disassembly...566
    Differential Parts Identification...575
    Differential Disassembly...576
    AXLE AND DIFFERENTIAL (FRONT) (For S/N 363012001 and Above, S/N 363112001 and Above) (Cont'd)...582
    Bevel Pinion Parts Identification...582
    Bevel Pinion Disassembly...583
    Bevel Pinion Assembly...586
    Differential Assembly...593
    Brake Assembly...598
    Steering Knuckle Assembly...611
    Planetary Carrier Assembly...617
  special tools...621
  AXLE AND DIFFERENTIAL (FRONT) (For S/N 363012501 and Above, S/N 363112501 and Above)...623
    General Information...623
    Planetary Carrier And Steering Knuckle Parts Identification...623
    Planetary Carrier Disassembly and Assembly...624
    Wheel Hub Disassembly And Assembly...626
    Steering Knuckle Disassembly And Assembly...628
    Axle Housing / Drive Axle Disassembly...630
    Brake Group Parts Identification...634
    Brake Group Disassembly...635
    Differential Parts Identification...638
    Differential Disassembly And Assembly...639
    Pinion Group Parts Identification...642
    Pinion Group Disassembly...643
    Pinion Group Assembly...644
    Brake Group Assembly...649
    Axle Housing / Drive Axle Assemby...652
    Special Tools...655
  AXLE AND DIFFERENTIAL (REAR) (For S/N 363012001 and Above, S/N 363112001 and Above)...657
    General Information...657
    Planetary Carrier Parts Identification...657
    Planetary Carrier Disassembly (Cont’d)...658
    Steering Knuckle Parts Identification...662
    Steering Knuckle Disassembly...663
    Differential Parts Identification...667
    Bevel pinion Parts Identification...673
    Differential Assembly...685
    Steering Knuckle Assembly...689
    Planetary Carrier Assembly...695
  FRONT AXLE (For S/N 363011001 - 363012000 and S/ N 363111001 - 363112000)...701
    Removal...701
    Installation...707
  FRONT AXLE (For S/N 363012001 and Above, S/N 363112001 and Above)...713
    Removal...713
    Installation...719
  AXLE TOE-IN (For S/N 363011001 - 363012000 and S/ N 363111001 - 363112000)...725
    Adjustment...725
  AXLE TOE-IN (For S/N 363012001 and Above, S/N 363112001 and Above)...727
    Adjustment...727
  PARKING BRAKE (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)...729
    Releasing The Brake For Towing...729
    Re-Activating The Brake...730
  PARKING BRAKE (For S/N 363012001 and Above, S/N 363112001 and Above)...731
    Releasing The Brake For Towing...731
    Re-Activating The Brake...732
  STEERING ANGLE ADJUSTMENT (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)...733
    Adjustment...733
  STEERING ANGLE ADJUSTMENT (For S/N 363012001 and Above, S/N 363112001 and Above)...735
    Adjustment...735
  DRIVESHAFT...737
    For S/N 363011001 - 363012000 and S/N 363111001 - 363112000...737
    Removal And Installation...737
    For S/N 363012001 and Above, S/N 363112001 and Above)...737
  SERVICE BRAKE (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)...739
    Description...739
    Bleeding The Brake Circuit...739
  SERVICE BRAKE (For S/N 363012001 and Above, S/N 363112001 and Above)...741
    Description...741
    Bleeding The Brake Circuit...741
  REAR AXLE (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)...743
    Removal...743
    Installation...746
  REAR AXLE (For S/N 363012001 and Above, S/N 363112001 and Above)...751
    Removal...751
    Installation...754
  OPERATOR CAB...761
    Removal And Installation...761
  OPERATOR SEAT...769
    Not available at time of printing...769
  BOOM ASSEMBLY...771
    Removal And Installation...771
  INNER BOOM...775
    Removal...775
    Installation...777
  WEAR PADS (FRONT)...779
    Removal And Installation...779
  WEAR PADS (REAR)...781
    Removal...781
    Installation...781
  ENGINE COVER...783
    Gas Cylinder Removal And Installation...783
    Removal And Installation...783
  AIR INTAKE COWLING...785
    Removal And Installation...785
  FUEL TANK...787
    Removal And Installation...787
  QUICK TACH...791
    Removal And Installation...791
  REAR WEIGHTS...793
    Removal And Installation...793
  FENDER...795
    Removal And Installation (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)...795
  JOYSTICK PANEL...797
    Removal And Installation...797
  DASH COVER/STEERING COLUMN COVER...799
    Removal And Installation...799
  ELECTRICAL SYSTEM INFORMATION...805
    Troubleshooting Chart...805
    Description...805
    Fuses, Diodes & Relays...805
  ELECTRICAL SYSTEM (CONT’D)...806
    Fuses, Diodes & Relays (Cont’d)...806
  BATTERY...809
    Removal And Installation...809
    Servicing...810
    Using A Booster Battery (Jump Starting)...811
  ALTERNATOR...813
    Removal And Installation...813
    Adjusting The Alternator Belt...814
  STARTER...815
    Removal And Installation...815
  STARTER (CONT’D)...816
    Parts Identification...816
    Disassembly/Assembly...817
  LIGHTS...819
    Rear Light Removal And Installation...819
    Front Light Removal And Installation...820
  TRAVEL/SIGNAL LEVER...821
    Removal And Installation...821
  INSTRUMENT PANEL...823
    Removal And Installation...823
  SWITCH PANEL...825
    Parts description...825
  BRAKE LIGHT SWITCH...827
    Removal And Installation...827
    Adjustment...827
  FRONT WIPER MOTOR...829
    Removal And Installation...829
  TOP WIPER MOTOR...833
    Removal And Installation...833
  REAR WIPER MOTOR...835
    Removal And Installation...835
  PEDAL ASSEMBLY...837
    Removal And Installation...837
    Disassembly And Assembly...838
  INCHING SWITCH...843
    Removal And Installation...843
    Adjustment...843
  SERVICE SOFTWARE (ONLY For S/N 363011001 and Above, S/N 363111001 and Above)...845
    Connecting The Laptop Computer...845
    Entering The Service Software...846
    Monitor Screen...847
    Warnings Screen...848
    Calibrate Inch Pedal...849
  Longitudinal Stability Indicator Calibration...851
    Fitting the sensor...851
    Calibration procedure...851
  TROUBLESHOOTING...857
    Chart...857
  ENGINE SPEED CONTROL...859
    Removal And Installation...859
  MUFFLER...861
    Removal And Installation...861
  AIR CLEANER...863
    Housing Removal And Installation...863
  OIL COOLER/RADIATOR...865
    Removal And Installation...865
    Disassembly And Assembly...867
  ENGINE AND ENGINE MOUNTS...869
    Removal And Installation...869
  ENGINE COMPONENTS AND TESTING...873
    Fuel Injection Pump Removal...873
    Fuel Injection Pump Installation...876
    Fuel Injectors Removal And Installation...879
    Checking The Fuel Lift Pump...881
    Fuel Lift Pump Removal And Installation...882
    Compression Checking...883
    Glow Plugs Checking...884
    Glow Plugs Removal And Installation...884
  ENGINE TIMING...887
    Procedure...887
  ENGINE/HYDROSTAT ASSEMBLY...889
    Removal And Installation...889
  FLYWHEEL AND HOUSING...903
    Removal And Installation...903
    Ring Gear Removal...906
    Ring Gear Installation...906
  RECONDITIONING THE ENGINE...907
    Turbo Charger Troubleshooting...907
    Turbo Charger Description...908
    Turbo Charger Removal And Installation...908
    Exhaust Manifold Removal And Installation...910
    Fuel Injector Cover Removal And Installation...910
    Rocker Cover Removal And Installation...911
    Cylinder Head Removal...912
    Cylinder Head Inspection...914
    Cylinder Head Installation...914
    Rocker Shaft Disassembly And Assembly...917
    Valve Removal...917
    Valve Springs Checking...918
    Valve Depth Checking...918
    Valve Guides Checking...919
    Valve Guide Removal...920
    Valve Guide Installation...920
    Valves Checking...921
    Cutting A Valve Seat...921
    Valve Seat Assembly...922
    Changing Valve Springs (With Cylinder Head Installed)...923
    Valve Clearance Adjustment...924
    Timing Case And Drive Assembly Description...925
    Timing Cover Removal...925
    Timing Cover Installation...925
    Crankshaft Pulley Removal And Installation...925
    Front Oil Seal Removal And Installation...925
    Timing Case And Gear Removal...926
    Timing Case And Gear Installation...927
    Camshaft And Tappets Removal...929
    Camshaft And Tappets Installation...930
    Pistons And Connecting Rods Description...932
    Pistons And Connecting Rods Removal...932
    Pistons And Connecting Rods Disassembly...934
    Piston Ring End Gap...934
    Piston Ring Installation...934
    Piston Ring Groove Clearance...935
    Connecting Rod Inspection...936
    Connecting Rod Bushing Replacement...936
    Piston And Connecting Rod Assembly...936
    Piston And Connecting Rod Installation...936
    Checking Piston Height...938
    Crankshaft And Bearings Description...939
    Crankshaft And Bearings Removal...939
    Inspection Of Crankshaft And Bearings...941
    Crankshaft And Bearings Installation...941
    Rear Oil Seal Removal...943
    Rear Oil Seal Housing Positioning...943
    Rear Oil Seal Installation...943
    Checking Crankshaft End Play...944
    Cooling System Description...945
    Thermostat Removal and Installation...946
    Thermostat Testing...946
    Lubricating Oil Cooler Removal And Installation...946
    Water Pump Removal...947
    Water Pump Installation...947
    Engine Lubrication System Description...948
    Oil Filter Adapter Removal And Installation...949
    Oil Pan Removal And Installation...949
    Oil Screen And Pick-up Tube...950
    Oil Pump Removal...950
    Oil Pump Installation...951
    Oil Pump Disassembly And Assembly...952
    Oil Pressure Relief Valve Disassembly And Assembly...952
    Engine Block Description...953
    Engine Block Disassembly And Assembly...953
    Piston Cooling Jet Removal...954
    Piston Cooling Jet Installation...954
    Piston Cooling Jet Alignment...954
    Inspection...954
    Cylinder Liner Inspection...955
    Cylinder Liner Removal...956
    Cylinder Liner Installation...957
  AIR CONDITIONING SYSTEM FLOW...961
    Principals...961
    Chart...962
  COMPONENTS...963
    Identification...963
  SAFETY...965
    Safety Equipment...965
  REGULAR MAINTENANCE...967
    Filter Element Removal And Installation...967
    Compressor Drive Belt Inspection...968
    Cleaning The Condenser...968
  BASIC TROUBLESHOOTING...969
    Poor A/C Performance...969
    Compressor Drive Belt Inspection...969
    Checking The Electrical System...970
  GENERAL AIR CONDITIONING SERVICE GUIDELINES...975
    Compressor Oil...975
    Compressor Oil Check...975
    Component Replacement And Refrigeration Leaks...977
  SYSTEM TROUBLESHOOTING CHART...979
    Chart...979
    Gauge Pressure Related Troubleshooting...980
  TEMPERATURE/PRESSURE...983
    Chart...983
  AIR CONDITIONING SERVICE...985
    Chart...985
  SYSTEM CHARGING AND RECLAMATION...987
    Reclamation Procedure...987
    Charging Procedure With A Manifold Gauge Set...990
    Charging Procedure...991
  COMPRESSOR...993
    Removal And Installation...993
    Compressor Clutch Disassembly And Assembly...994
  CONDENSER...999
    Removal And Installation...999
  RECEIVER/DRIER...1001
    Removal And Installation...1001
  PRESSURE SWITCH...1003
    Removal And Installation...1003
  EVAPORATOR/BLOWER UNIT...1005
    Removal And Installation...1005
  EXPANSION VALVE...1007
    Removal And Installation...1007
  HEATER ASSEMBLY...1009
    Removal And Installation...1009
    Fan Removal And Installation...1010
    Core Removal And Installation...1010
  TELESCOPIC HANDLER SPECIFICATIONS...1015
    Dimensional Specifications...1015
    Performance Specifications...1016
    Engine...1016
    Controls...1016
    Drive System...1016
    Tires...1017
    Capacities...1017
    Hydraulic System...1017
    Electrical System...1017
    Instrument Panel...1017
  ENGINE SPECIFICATIONS...1019
    General...1019
    Cylinder Head...1019
    Valve Guides...1019
    Exhaust Valves...1020
    Intake Valves...1020
    Valve Springs...1020
    Rocker Shaft, Rockers And Bushings...1021
    Pistons And Piston Rings...1021
    Connecting Rods And Bearings...1022
    Crankshaft...1022
    Crankshaft Re-Grind Data...1023
    Main Bearings...1024
    Thrust Washers...1024
    Camshaft And Thrust Washer...1024
    Cylinder Block...1024
    Cylinder Liners...1025
    Fuel Injection Pump...1025
    Fuel Injectors...1025
    Fuel Lift Pump...1025
    Timing Case And Timing Gears...1026
    Oil Pump, Gear And Relief Valve...1027
    Turbocharger...1027
    Flywheel...1027
    Water Pump And Thermostat...1028
    Engine Torque Component...1029
  MACHINE TORQUE SPECIFICATIONS...1031
    Specifications...1031
  TORQUE SPECIFICATIONS FOR BOLTS...1033
    Torque for General SAE Bolts...1033
    Torque For General Metric Bolts...1034
  HYDRAULIC CONNECTION SPECIFICATIONS...1035
    O-ring Face Seal Connection...1035
    Straight Thread O-ring Fitting...1035
    Tubelines And Hoses...1035
    Flare Fitting...1036
    O-ring Flare Fitting...1037
    Port Seal Fitting...1039
  HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...1041
    Specifications...1041
  CONVERSIONS...1043
    Decimal And Millimeter Equivalents...1043
    U.S. To Metric Conversion...1044
6986740 (07-08) - T2250 Service Manual...1045
  MAINTENANCE SAFETY...1047
  ALPHABETICAL INDEX...1049
  CONTENTS...1051
    FOREWORD...1053
    SAFETY INSTRUCTIONS...1055
    FIRE PREVENTION...1056
      Maintenance...1056
      Operation...1056
      Electrical...1056
      Hydraulic System...1056
      Fueling...1056
      Starting...1056
      Welding And Grinding...1057
      Fire Extinguishers...1057
    SERIAL NUMBER LOCATION...1058
      Engine Serial Number...1058
    DELIVERY REPORT...1059
    BOBCAT TELESCOPIC HANDLER IDENTIFICATION...1060
  SAFETY AND MAINTENANCE...1061
    LIFTING AND BLOCKING THE TELESCOPIC HANDLER...1063
      Procedure...1063
    OPERATOR CAB...1065
      Emergency Exit...1065
      Cab Door...1066
      Cab Door Window...1066
    TRANSPORTING THE TELESCOPIC HANDLER...1067
      Procedure...1067
    TOWING THE TELESCOPIC HANDLER...1069
      Releasing The Brake Discs...1069
      Towing...1070
      Engaging The Brake Discs...1070
    SERVICE SCHEDULE...1071
      Chart...1071
    AIR CLEANER SERVICE...1073
      Replacing The Filter Element...1073
    ENGINE COOLING SYSTEM...1075
      Cleaning The Cooling System...1075
      Checking The Coolant Level...1075
      Replacing The Coolant...1076
    FUEL SYSTEM...1077
      Fuel Specifications...1077
      Filling The Fuel Tank...1077
      Fuel Filter...1078
    ENGINE LUBRICATION SYSTEM...1079
      Checking Engine Oil...1079
      Oil Chart...1079
      Replacing Oil And Filter...1079
    HYDRAULIC / HYDROSTATIC SYSTEM...1081
      Checking And Adding Fluid...1081
      Replacing The Hydraulic / Hydrostatic Filters...1081
      Replacing Hydraulic Fluid...1082
    AXLES (FRONT AND REAR)...1083
      Checking Oil Level (Planetary Carrier)...1083
      Draining Oil (Planetary Carrier)...1083
      Checking Oil Level (Rear Differential)...1084
      Draining Oil (Rear Differential)...1084
      Checking Oil Level (Front Differential)...1085
      Draining Oil (Front Differential)...1085
    LUBRICATION...1087
      Procedure...1087
    TIRE MAINTENANCE...1091
      Wheel Nuts...1091
      Tire Mounting...1091
      Tire Rotation...1091
      Tire Pressure...1091
    APPROVED BOOM STOP...1093
      Installing The Approved Boom Stop...1093
      Removing The Approved Boom Stop...1093
    ENGINE COVER...1095
      Opening And Closing The Engine Cover...1095
    REMOTE START...1097
      Connecting to the Telescopic Handler...1097
  HYDRAULIC SYSTEM...1101
    HYDRAULIC / HYDROSTATIC SCHEMATICS...1105
    HYDRAULIC SYSTEM INFORMATION...1108
      Troubleshooting Chart...1111
      Tightening Procedures...1112
    LIFT CYLINDER...1114
      Removal And Installation...1114
      Parts Identification...1118
      Disassembly...1119
      Assembly...1123
    BUCKET POSITIONING CYLINDER...1128
      Removal And Installation...1128
      Parts Identification...1132
      Disassembly...1133
      Assembly...1136
    EXTENSION CYLINDER...1140
      Cylinder Group Removal And Installation...1140
      Upper Tubeline Removal...1142
      Upper Tubeline Installation...1143
      Extension Cylinder Removal And Installation...1144
      Tubeline Tray Disassembly...1145
      Tubeline Tray Assembly...1147
      Parts Identification...1149
      Disassembly...1150
      Assembly...1154
    TILT CYLINDER...1158
      Removal And Installation...1158
      Parts Identification...1160
      Disassembly...1161
      Assembly...1164
    STEERING CYLINDER (FRONT)...1168
      Removing the Steering Cylinder...1168
      Installing the Steering Cylinder...1169
      Disassembling the Steering Cylinder...1171
      Assembling the Steering Cylinder...1172
    STEERING CYLINDER (REAR)...1176
      Removing The Steering Cylinder...1176
      Disassembling The Steering Cylinder...1179
      Assembling The Steering Cylinder...1181
    DRIVE BOX...1184
      Parts Identification...1184
      Disassembly...1185
      Assembly...1189
      Special Tools...1192
    MAIN RELIEF VALVE...1194
      Testing And Adjustment...1194
      Removal And Installation...1195
    BOB-TACH CYLINDER...1196
      Not available at time of printing...1196
    PORT RELIEF VALVES...1198
      Parts Identification...1198
      Adjustment Procedure...1199
    STEERING MODE VALVE BLOCK...1200
      Removal And Installation...1200
      Parts Identification...1201
      Disassembly...1202
      Solenoid Testing...1204
      Assembly...1204
    BRAKE VALVE...1208
      Removal And Installation...1208
      Disassembly And Assembly...1209
    GEAR PUMP...1212
      Removal And Installation...1212
      Parts Identification...1214
      Disassembly And Assembly...1215
    HYDRAULIC RESERVOIR...1218
      Removal And Installation...1218
    STEERING VALVE...1220
      Removal And Installation...1220
      Parts Identification...1221
      Disassembly...1222
      Inspection...1225
      Assembly...1225
    HYDRAULIC CONTROL VALVE...1230
      Troubleshooting Chart (Controllers)...1230
      Telescoping Valve Section Troubleshooting...1231
      Auxiliary Valve Section Troubleshooting...1235
      Troubleshooting Chart (Control Valve)...1239
      Removal And Installation...1240
      Parts Identification...1244
      Disassembly And Assembly...1245
      End Housing Disassembly And Assembly...1245
      Telescoping and Auxiliary Valve Section Disassembly And Assembly...1246
      Lifting and Tilting Valve Section Disassembly And Assembly...1248
      Inlet-Outlet Valve Section Disassembly And Assembly...1249
    JOYSTICK...1250
      Removal And Installation...1250
    PARKING BRAKE...1252
      Parking Brake Valve Removal And Installation...1252
      Parking Brake Valve Disassembly And Assembly...1253
    WORKGROUP LOCKOUT VALVE...1256
      Testing...1256
      Removal And Installation...1257
      Disassembly And Assembly...1258
    TOW VALVE...1260
      Removal And Installation...1260
      Disassembly And Assembly...1261
    FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE...1266
      Removal And Installation...1266
      Disassembly And Assembly...1267
    MANIFOLD...1272
      Removal And Installation...1272
      Disassembly...1274
  HYDROSTATIC SYSTEM...1276
    HYDROSTATIC SYSTEM INFORMATION...1278
      Troubleshooting Chart...1278
      Replenishing Valve Function...1279
    OIL COOLER...1280
      Removal And Installation...1280
    HYDROSTATIC DRIVE MOTOR...1282
      Removal And Installation...1282
      Parts Identification...1283
      Disassembly...1286
      Inspection...1297
      Assembly...1299
    HYDROSTATIC PUMP...1312
      Removal And Installation...1312
      Parts Identification...1314
      Disassembly...1319
      Inspection...1331
      Assembly...1335
    DRIVE BELT...1350
      Description...1350
      Shield Removal And Installation...1350
      Adjusting...1351
      Belt Removal And Installation...1352
      Tensioner Pulley Removal And Installation...1353
      Tensioner Pulley Parts Identification...1355
      Tensioner Pulley Disassembly And Assembly...1356
  DRIVE SYSTEM...1360
    TROUBLESHOOTING...1362
      Chart...1362
    AXLE AND DIFFERENTIAL (FRONT)...1364
      Description...1364
      Planetary Carrier And Wheel Hub Parts Identification...1364
      Planetary Carrier Disassembly...1365
      Wheel Hub Disassembly...1367
      Steering Knuckle And Drive Shaft Parts Identification...1370
      Steering Knuckle Disassembly...1371
      Axle Housing / Drive Shaft Disassembly...1375
      Brake Group Parts Identification...1378
      Brake Group Disassembly...1379
      Differential Parts Identification...1383
      Differential Disassembly...1384
      Pinion Group Parts Identification...1387
      Pinion Group Disassembly...1388
      Pinion Group Assembly...1390
      Differential Assembly...1396
      Brake Group Assembly...1399
      Axle Housing / Drive Shaft Assembly...1403
      Steering Knuckle Assembly...1406
      Wheel Hub Assembly...1412
      Planetary Carrier Assembly...1413
      Special Tools...1416
    AXLE AND DIFFERENTIAL (REAR)...1418
      Description...1418
      Planetary Carrier And Wheel Hub Parts Identification...1418
      Planetary Carrier Disassembly...1419
      Wheel Hub Disassembly...1421
      Steering Knuckle and Drive Shaft Parts Identification...1424
      Steering Knuckle Disassembly...1425
      Axle Housing / Drive Shaft Disassembly...1429
      Differential Parts Identification...1432
      Pinion Group Parts Identification...1437
      Pinion Group Disassembly...1438
      Pinion Group Assembly...1442
      Differential Assembly...1450
      Steering Knuckle Assembly...1454
      Planetary Carrier Assembly...1460
      Special Tools...1465
    FRONT AXLE...1466
      Removal...1466
      Installation...1470
    AXLE TOE-IN...1474
      Adjustment...1474
    PARKING BRAKE...1476
      Releasing The Brake Discs...1476
      Engaging The Brake Discs...1477
    STEERING ANGLE ADJUSTMENT...1478
      Adjustment...1478
    DRIVESHAFT...1480
      Removal And Installation...1480
    SERVICE BRAKE...1482
      Description...1482
      Bleeding The Brake Circuit...1482
    REAR AXLE...1484
      Removal...1484
      Installation...1487
  MAIN FRAME...1490
    OPERATOR CAB...1492
      Removal And Installation...1492
    OPERATOR SEAT...1500
      Removal And Installation...1500
      Assembly And Disassembly...1500
    BOOM ASSEMBLY...1504
      Removal And Installation...1504
    INNER BOOM...1508
      Removal...1508
      Installation...1510
    WEAR PADS (FRONT)...1512
      Removal And Installation...1512
    WEAR PADS (REAR)...1514
      Removal...1514
      Installation...1514
    ENGINE COVER...1516
      Locking Mechanism Removal And Installation...1516
      Removal And Installation...1516
      Lock...1517
    FUEL TANK...1518
      Removal And Installation...1518
    BOB-TACH...1520
      Removal And Installation...1520
    REAR WEIGHTS...1522
      Removal And Installation...1522
    FENDER...1524
      Removal And Installation...1524
    JOYSTICK PANEL...1528
      Joystick Panel Cover Removal and Installation...1528
    DASH COVER/STEERING COLUMN COVER...1530
      Steering Column Cover Removal And Installation...1530
      Dash Cover Removal And Installation...1531
  ELECTRICAL SYSTEM AND ANALYSIS...1532
    ELECTRICAL SCHEMATICS...1534
    ELECTRICAL SYSTEM INFORMATION...1552
      Troubleshooting Chart...1552
      Description...1553
      Fuses, Diodes And Relays...1553
      Fuses, Diodes & Relays (Cont’d)...1554
    BATTERY...1556
      Removal And Installation...1556
      Servicing...1557
      Using A Booster Battery (Jump Starting)...1558
    ALTERNATOR...1560
      Removal And Installation...1560
      Adjusting The Alternator Belt...1561
    STARTER...1562
      Testing...1562
      Removal And Installation...1563
      Parts Identification...1565
    LIGHTS...1566
      Rear Light Removal And Installation...1566
      Front Light Removal And Installation...1567
    TRAVEL LEVER...1568
      Removal And Installation...1568
    INSTRUMENT PANEL...1570
      Removal And Installation...1570
    INSTRUMENT PANEL...1571
    FRONT WIPER MOTOR...1572
      Removal And Installation...1572
    TOP WIPER MOTOR...1574
      Removal And Installation...1574
    REAR WIPER MOTOR...1578
      Removal And Installation...1578
    PEDAL ASSEMBLY...1582
      Removal And Installation...1582
      Disassembly And Assembly...1583
    INCHING SWITCH...1588
      Removal And Installation...1588
      Adjustment...1588
      Inching Control Calibration (Display Controller)...1589
    SERVICE SOFTWARE...1592
      Connecting Remote Start Tool to Laptop Computer...1592
      Connecting Remote Start Tool to Telescopic Handler...1593
      Entering The Service Software...1594
      Calibrate Inch Pedal...1595
    MAIN CONTROLLER...1598
      Removal And Installation...1598
      Connector Identification...1599
    DIAGNOSTIC SERVICE CODES...1600
      Viewing Service Codes...1600
      Service Codes List...1600
  ENGINE SERVICE...1606
    ENGINE INFORMATION...1608
      Description...1608
      Specifications...1609
      Torque Values...1613
      Troubleshooting...1614
      Compression - Checking...1616
    ENGINE AND ENGINE MOUNTS...1618
      Removal And Installation...1618
    ENGINE AND HYDROSTAT ASSEMBLY...1622
      Removal And Installation...1622
    ENGINE SPEED CONTROL...1632
      Removal And Installation...1632
    MUFFLER...1634
      Removal And Installation...1634
    AIR CLEANER...1636
      Removal And Installation...1636
      Air Intake Cowling Removal And Installation...1636
    ENGINE COOLING SYSTEM...1638
      Radiator Removal And Installation...1638
      Fan Removal And Installation...1640
      Water Pump Removal And Installation...1640
      Water Pump Disassembly And Assembly...1641
      Thermostat Housing Removal And Installation...1641
    LUBRICATION SYSTEM...1644
      Oil Pan Removal And Installation...1644
      Oil Pump Removal And Installation...1645
      Oil Pump Inspection...1645
      Oil Filter Cooler Removal And Installation...1647
      Engine Oil Pressure - Testing...1648
    FUEL SYSTEM...1650
      Fuel Camshaft Removal And Installation...1650
      Injection Pump Governor Housing Removal And Installation...1652
      Injection Pump Governor Housing Disassembly And Assembly...1654
      Fuel Shutoff Solenoid - Checking...1656
      Fuel Shutoff Solenoid - Removal And Installation...1656
      Fuel Injection Pump Removal And Installation...1657
      Fuel Injection Pump Housing Removal...1665
      Fuel Injection Pump Housing Installation...1669
      Injection Pump Timing...1672
      Fuel Injector Removal and Installation...1675
      Fuel Injector Nozzle Pressure - Checking...1677
      Nozzle Spraying Condition...1677
      Valve Seat Tightness...1678
    CYLINDER HEAD...1680
      Intake Air Heater - Testing...1680
      Intake Air Heater Removal And Installation...1680
      Valve Clearance Adjustment...1681
      Valve Timing - Checking...1682
      Cylinder Head Removal And Installation...1683
      Cylinder Head Disassembly And Assembly...1686
      Cylinder Head - Servicing...1687
      Cylinder Head Top Clearance...1687
      Valve Guide - Checking...1688
      Reconditioning The Valve And Valve Seat...1690
      Valve Spring...1692
      Valve Tappets...1693
      Rocker Arm And Shaft - Checking...1694
    CRANKSHAFT AND PISTONS...1696
      Piston And Connecting Rod Removal And Installation...1696
      Piston And Connecting Rod - Servicing...1698
      Cylinder Bore Checking...1703
      Connecting Rod Alignment...1704
      Crankshaft Gear Removal And Installation...1704
      Crankshaft And Bearings Removal and Installation...1705
      Crankshaft And Bearings - Servicing...1709
    CAMSHAFT AND TIMING GEARS...1716
      Timing Gearcase Cover Removal And Installation...1716
      Timing Gears Backlash - Checking...1717
      Camshaft - Servicing...1718
      Idle Gear And Shaft Removal And Installation...1720
      Idler Gear And Shaft - Servicing...1721
    TURBOCHARGER...1724
      Description...1724
      Testing...1724
      Removal And Installation...1725
    FLYWHEEL AND HOUSING...1726
      Flywheel Removal And Installation...1726
      Ring Gear Removal And Installation...1726
      Housing Removal And Installation...1727
  HEATING, VENTILATION, AIR CONDITIONING...1728
    AIR CONDITIONING SYSTEM FLOW...1730
      Description...1730
      Chart...1731
    COMPONENTS...1732
      Identification...1732
    SAFETY...1734
      Safety Equipment...1734
    REGULAR MAINTENANCE...1736
      Filter Element Removal And Installation...1736
      Compressor And Alternator Drive Belt Inspection...1737
      Cleaning The Condenser...1737
    BASIC TROUBLESHOOTING...1738
      Poor A/C Performance...1738
      Compressor And Alternator Drive Belt Inspection...1738
      Checking The Electrical System...1739
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...1744
      Compressor Oil...1744
      Compressor Oil Check...1744
      Component Replacement And Refrigeration Leaks...1746
    SYSTEM TROUBLESHOOTING CHART...1748
      Chart...1748
      Gauge Pressure Related Troubleshooting...1749
    TEMPERATURE AND PRESSURE...1752
      Chart...1752
    AIR CONDITIONING SERVICE...1754
      Chart...1754
    SYSTEM CHARGING AND RECLAMATION...1756
      Reclamation Procedure...1756
      Charging Procedure With A Manifold Gauge Set...1759
    COMPRESSOR...1762
      Removal And Installation...1762
      Compressor Clutch Disassembly And Assembly...1763
    CONDENSER...1768
      Removal And Installation...1768
    RECEIVER / DRIER...1770
      Removal And Installation...1770
    PRESSURE SWITCH...1772
      Removal And Installation...1772
    EVAPORATOR/BLOWER UNIT...1774
      Removal And Installation...1774
    EXPANSION VALVE...1778
      Removal And Installation...1778
    HEATER ASSEMBLY...1780
      Removal And Installation...1780
      Fan Removal And Installation...1781
      Core Removal And Installation...1781
  SPECIFICATIONS...1784
    TELESCOPIC HANDLER TELESCOPIC TOOL CARRIER (TTC) SPECIFICATIONS...1786
      Machine Dimensions...1786
      Performance...1787
      Engine...1787
      Controls...1787
      Drive System...1787
      Tires...1788
      Capacities...1788
      Hydraulic System...1788
      Electrical System...1788
      Instrument Panel...1788
    ENGINE SPECIFICATIONS...1790
      General...1790
      Cylinder Head...1790
      Valve Guides...1790
      Exhaust Valves...1791
      Intake Valves...1791
      Valve Springs...1791
      Rocker Shaft, Rockers And Bushings...1792
      Pistons And Piston Rings...1792
      Connecting Rods And Bearings...1793
      Crankshaft...1793
      Crankshaft Re-Grind Data...1794
      Main Bearings...1795
      Thrust Washers...1795
      Camshaft And Thrust Washer...1795
      Cylinder Block...1795
      Cylinder Liners...1796
      Fuel Injection Pump...1796
      Fuel Injectors...1796
      Fuel Lift Pump...1796
      Timing Case And Timing Gears...1797
      Oil Pump, Gear And Relief Valve...1798
      Turbocharger...1798
      Flywheel...1798
      Water Pump And Thermostat...1799
      Engine Torque Component...1800
    MACHINE TORQUE SPECIFICATIONS...1802
      Specifications...1802
    TORQUE SPECIFICATIONS FOR BOLTS...1804
      Torque for General SAE Bolts...1804
      Torque For General Metric Bolts...1805
    HYDRAULIC CONNECTION SPECIFICATIONS...1806
      O-ring Face Seal Connection...1806
      Straight Thread O-ring Fitting...1806
      Tubelines And Hoses...1806
      Flare Fitting...1807
      O-ring Flare Fitting...1808
      Port Seal Fitting...1810
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...1812
      Specifications...1812
    CONVERSIONS...1814
      Decimal And Millimeter Equivalents...1814
      U.S. To Metric Conversion...1815
6986740 (7-08) - T2250 Telescopic Handler Service Manual...1816
  MAINTENANCE SAFETY...1818
  ALPHABETICAL INDEX...1820
  CONTENTS...1822
    FOREWORD...1824
    SAFETY INSTRUCTIONS...1826
    FIRE PREVENTION...1827
      Maintenance...1827
      Operation...1827
      Electrical...1827
      Hydraulic System...1827
      Fueling...1827
      Starting...1827
      Welding And Grinding...1828
      Fire Extinguishers...1828
    SERIAL NUMBER LOCATION...1829
      Engine Serial Number...1829
    DELIVERY REPORT...1830
    BOBCAT TELESCOPIC HANDLER IDENTIFICATION...1831
  SAFETY AND MAINTENANCE...1832
    LIFTING AND BLOCKING THE TELESCOPIC HANDLER...1834
      Procedure...1834
    OPERATOR CAB...1836
      Emergency Exit...1836
      Cab Door...1837
      Cab Door Window...1837
    TRANSPORTING THE TELESCOPIC HANDLER...1838
      Procedure...1838
    TOWING THE TELESCOPIC HANDLER...1840
      Releasing The Brake Discs...1840
      Towing...1841
      Engaging The Brake Discs...1841
    SERVICE SCHEDULE...1842
      Chart...1842
    AIR CLEANER SERVICE...1844
      Replacing The Filter Element...1844
    ENGINE COOLING SYSTEM...1846
      Cleaning The Cooling System...1846
      Checking The Coolant Level...1846
      Replacing The Coolant...1847
    FUEL SYSTEM...1848
      Fuel Specifications...1848
      Filling The Fuel Tank...1848
      Fuel Filter...1849
    ENGINE LUBRICATION SYSTEM...1850
      Checking Engine Oil...1850
      Oil Chart...1850
      Replacing Oil And Filter...1850
    HYDRAULIC / HYDROSTATIC SYSTEM...1852
      Checking And Adding Fluid...1852
      Replacing The Hydraulic / Hydrostatic Filters...1852
      Replacing Hydraulic Fluid...1853
    AXLES (FRONT AND REAR)...1854
      Checking Oil Level (Planetary Carrier)...1854
      Draining Oil (Planetary Carrier)...1854
      Checking Oil Level (Rear Differential)...1855
      Draining Oil (Rear Differential)...1855
      Checking Oil Level (Front Differential)...1856
      Draining Oil (Front Differential)...1856
    LUBRICATION...1858
      Procedure...1858
    TIRE MAINTENANCE...1862
      Wheel Nuts...1862
      Tire Mounting...1862
      Tire Rotation...1862
      Tire Pressure...1862
    APPROVED BOOM STOP...1864
      Installing The Approved Boom Stop...1864
      Removing The Approved Boom Stop...1864
    ENGINE COVER...1866
      Opening And Closing The Engine Cover...1866
    REMOTE START...1868
      Connecting to the Telescopic Handler...1868
  HYDRAULIC SYSTEM...1872
    HYDRAULIC / HYDROSTATIC SCHEMATICS...1876
    HYDRAULIC SYSTEM INFORMATION...1879
      Troubleshooting Chart...1882
      Tightening Procedures...1883
    LIFT CYLINDER...1885
      Removal And Installation...1885
      Parts Identification...1889
      Disassembly...1890
      Assembly...1894
    BUCKET POSITIONING CYLINDER...1899
      Removal And Installation...1899
      Parts Identification...1903
      Disassembly...1904
      Assembly...1907
    EXTENSION CYLINDER...1911
      Cylinder Group Removal And Installation...1911
      Upper Tubeline Removal...1913
      Upper Tubeline Installation...1914
      Extension Cylinder Removal And Installation...1915
      Tubeline Tray Disassembly...1916
      Tubeline Tray Assembly...1918
      Parts Identification...1920
      Disassembly...1921
      Assembly...1925
    TILT CYLINDER...1929
      Removal And Installation...1929
      Parts Identification...1931
      Disassembly...1932
      Assembly...1935
    STEERING CYLINDER (FRONT)...1939
      Removing the Steering Cylinder...1939
      Installing the Steering Cylinder...1940
      Disassembling the Steering Cylinder...1942
      Assembling the Steering Cylinder...1943
    STEERING CYLINDER (REAR)...1947
      Removing The Steering Cylinder...1947
      Disassembling The Steering Cylinder...1950
      Assembling The Steering Cylinder...1952
    DRIVE BOX...1955
      Parts Identification...1955
      Disassembly...1956
      Assembly...1960
      Special Tools...1963
    MAIN RELIEF VALVE...1965
      Testing And Adjustment...1965
      Removal And Installation...1966
    BOB-TACH CYLINDER...1967
      Not available at time of printing...1967
    PORT RELIEF VALVES...1969
      Parts Identification...1969
      Adjustment Procedure...1970
    STEERING MODE VALVE BLOCK...1971
      Removal And Installation...1971
      Parts Identification...1972
      Disassembly...1973
      Solenoid Testing...1975
      Assembly...1975
    BRAKE VALVE...1979
      Removal And Installation...1979
      Disassembly And Assembly...1980
    GEAR PUMP...1983
      Removal And Installation...1983
      Parts Identification...1985
      Disassembly And Assembly...1986
    HYDRAULIC RESERVOIR...1989
      Removal And Installation...1989
    STEERING VALVE...1991
      Removal And Installation...1991
      Parts Identification...1992
      Disassembly...1993
      Inspection...1996
      Assembly...1996
    HYDRAULIC CONTROL VALVE...2001
      Troubleshooting Chart (Controllers)...2001
      Telescoping Valve Section Troubleshooting...2002
      Auxiliary Valve Section Troubleshooting...2006
      Troubleshooting Chart (Control Valve)...2010
      Removal And Installation...2011
      Parts Identification...2015
      Disassembly And Assembly...2016
      End Housing Disassembly And Assembly...2016
      Telescoping and Auxiliary Valve Section Disassembly And Assembly...2017
      Lifting and Tilting Valve Section Disassembly And Assembly...2019
      Inlet-Outlet Valve Section Disassembly And Assembly...2020
    JOYSTICK...2021
      Removal And Installation...2021
    PARKING BRAKE...2023
      Parking Brake Valve Removal And Installation...2023
      Parking Brake Valve Disassembly And Assembly...2024
    WORKGROUP LOCKOUT VALVE...2027
      Testing...2027
      Removal And Installation...2028
      Disassembly And Assembly...2029
    TOW VALVE...2031
      Removal And Installation...2031
      Disassembly And Assembly...2032
    FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE...2037
      Removal And Installation...2037
      Disassembly And Assembly...2038
    MANIFOLD...2043
      Removal And Installation...2043
      Disassembly...2045
  HYDROSTATIC SYSTEM...2047
    HYDROSTATIC SYSTEM INFORMATION...2049
      Troubleshooting Chart...2049
      Replenishing Valve Function...2050
    OIL COOLER...2051
      Removal And Installation...2051
    HYDROSTATIC DRIVE MOTOR...2053
      Removal And Installation...2053
      Parts Identification...2054
      Disassembly...2057
      Inspection...2068
      Assembly...2070
    HYDROSTATIC PUMP...2083
      Removal And Installation...2083
      Parts Identification...2085
      Disassembly...2090
      Inspection...2102
      Assembly...2106
    DRIVE BELT...2121
      Description...2121
      Shield Removal And Installation...2121
      Adjusting...2122
      Belt Removal And Installation...2123
      Tensioner Pulley Removal And Installation...2124
      Tensioner Pulley Parts Identification...2126
      Tensioner Pulley Disassembly And Assembly...2127
  DRIVE SYSTEM...2131
    TROUBLESHOOTING...2133
      Chart...2133
    AXLE AND DIFFERENTIAL (FRONT)...2135
      Description...2135
      Planetary Carrier And Wheel Hub Parts Identification...2135
      Planetary Carrier Disassembly...2136
      Wheel Hub Disassembly...2138
      Steering Knuckle And Drive Shaft Parts Identification...2141
      Steering Knuckle Disassembly...2142
      Axle Housing / Drive Shaft Disassembly...2146
      Brake Group Parts Identification...2149
      Brake Group Disassembly...2150
      Differential Parts Identification...2154
      Differential Disassembly...2155
      Pinion Group Parts Identification...2158
      Pinion Group Disassembly...2159
      Pinion Group Assembly...2161
      Differential Assembly...2167
      Brake Group Assembly...2170
      Axle Housing / Drive Shaft Assembly...2174
      Steering Knuckle Assembly...2177
      Wheel Hub Assembly...2183
      Planetary Carrier Assembly...2184
      Special Tools...2187
    AXLE AND DIFFERENTIAL (REAR)...2189
      Description...2189
      Planetary Carrier And Wheel Hub Parts Identification...2189
      Planetary Carrier Disassembly...2190
      Wheel Hub Disassembly...2192
      Steering Knuckle and Drive Shaft Parts Identification...2195
      Steering Knuckle Disassembly...2196
      Axle Housing / Drive Shaft Disassembly...2200
      Differential Parts Identification...2203
      Pinion Group Parts Identification...2208
      Pinion Group Disassembly...2209
      Pinion Group Assembly...2213
      Differential Assembly...2221
      Steering Knuckle Assembly...2225
      Planetary Carrier Assembly...2231
      Special Tools...2236
    FRONT AXLE...2237
      Removal...2237
      Installation...2241
    AXLE TOE-IN...2245
      Adjustment...2245
    PARKING BRAKE...2247
      Releasing The Brake Discs...2247
      Engaging The Brake Discs...2248
    STEERING ANGLE ADJUSTMENT...2249
      Adjustment...2249
    DRIVESHAFT...2251
      Removal And Installation...2251
    SERVICE BRAKE...2253
      Description...2253
      Bleeding The Brake Circuit...2253
    REAR AXLE...2255
      Removal...2255
      Installation...2258
  MAIN FRAME...2261
    OPERATOR CAB...2263
      Removal And Installation...2263
    OPERATOR SEAT...2271
      Removal And Installation...2271
      Assembly And Disassembly...2271
    BOOM ASSEMBLY...2275
      Removal And Installation...2275
    INNER BOOM...2279
      Removal...2279
      Installation...2281
    WEAR PADS (FRONT)...2283
      Removal And Installation...2283
    WEAR PADS (REAR)...2285
      Removal...2285
      Installation...2285
    ENGINE COVER...2287
      Locking Mechanism Removal And Installation...2287
      Removal And Installation...2287
      Lock...2288
    FUEL TANK...2289
      Removal And Installation...2289
    BOB-TACH...2291
      Removal And Installation...2291
    REAR WEIGHTS...2293
      Removal And Installation...2293
    FENDER...2295
      Removal And Installation...2295
    JOYSTICK PANEL...2299
      Joystick Panel Cover Removal and Installation...2299
    DASH COVER/STEERING COLUMN COVER...2301
      Steering Column Cover Removal And Installation...2301
      Dash Cover Removal And Installation...2302
  ELECTRICAL SYSTEM AND ANALYSIS...2303
    ELECTRICAL SCHEMATICS...2305
    ELECTRICAL SYSTEM INFORMATION...2323
      Troubleshooting Chart...2323
      Description...2324
      Fuses, Diodes And Relays...2324
      Fuses, Diodes & Relays (Cont’d)...2325
    BATTERY...2327
      Removal And Installation...2327
      Servicing...2328
      Using A Booster Battery (Jump Starting)...2329
    ALTERNATOR...2331
      Removal And Installation...2331
      Adjusting The Alternator Belt...2332
    STARTER...2333
      Testing...2333
      Removal And Installation...2334
      Parts Identification...2336
    LIGHTS...2337
      Rear Light Removal And Installation...2337
      Front Light Removal And Installation...2338
    TRAVEL LEVER...2339
      Removal And Installation...2339
    INSTRUMENT PANEL...2341
      Removal And Installation...2341
    INSTRUMENT PANEL...2342
    FRONT WIPER MOTOR...2343
      Removal And Installation...2343
    TOP WIPER MOTOR...2345
      Removal And Installation...2345
    REAR WIPER MOTOR...2349
      Removal And Installation...2349
    PEDAL ASSEMBLY...2353
      Removal And Installation...2353
      Disassembly And Assembly...2354
    INCHING SWITCH...2359
      Removal And Installation...2359
      Adjustment...2359
      Inching Control Calibration (Display Controller)...2360
    SERVICE SOFTWARE...2363
      Connecting Remote Start Tool to Laptop Computer...2363
      Connecting Remote Start Tool to Telescopic Handler...2364
      Entering The Service Software...2365
      Calibrate Inch Pedal...2366
    MAIN CONTROLLER...2369
      Removal And Installation...2369
      Connector Identification...2370
    DIAGNOSTIC SERVICE CODES...2371
      Viewing Service Codes...2371
      Service Codes List...2371
  ENGINE SERVICE...2377
    ENGINE INFORMATION...2379
      Description...2379
      Specifications...2380
      Torque Values...2384
      Troubleshooting...2385
      Compression - Checking...2387
    ENGINE AND ENGINE MOUNTS...2389
      Removal And Installation...2389
    ENGINE AND HYDROSTAT ASSEMBLY...2393
      Removal And Installation...2393
    ENGINE SPEED CONTROL...2403
      Removal And Installation...2403
    MUFFLER...2405
      Removal And Installation...2405
    AIR CLEANER...2407
      Removal And Installation...2407
      Air Intake Cowling Removal And Installation...2407
    ENGINE COOLING SYSTEM...2409
      Radiator Removal And Installation...2409
      Fan Removal And Installation...2411
      Water Pump Removal And Installation...2411
      Water Pump Disassembly And Assembly...2412
      Thermostat Housing Removal And Installation...2412
    LUBRICATION SYSTEM...2415
      Oil Pan Removal And Installation...2415
      Oil Pump Removal And Installation...2416
      Oil Pump Inspection...2416
      Oil Filter Cooler Removal And Installation...2418
      Engine Oil Pressure - Testing...2419
    FUEL SYSTEM...2421
      Fuel Camshaft Removal And Installation...2421
      Injection Pump Governor Housing Removal And Installation...2423
      Injection Pump Governor Housing Disassembly And Assembly...2425
      Fuel Shutoff Solenoid - Checking...2427
      Fuel Shutoff Solenoid - Removal And Installation...2427
      Fuel Injection Pump Removal And Installation...2428
      Fuel Injection Pump Housing Removal...2436
      Fuel Injection Pump Housing Installation...2440
      Injection Pump Timing...2443
      Fuel Injector Removal and Installation...2446
      Fuel Injector Nozzle Pressure - Checking...2448
      Nozzle Spraying Condition...2448
      Valve Seat Tightness...2449
    CYLINDER HEAD...2451
      Intake Air Heater - Testing...2451
      Intake Air Heater Removal And Installation...2451
      Valve Clearance Adjustment...2452
      Valve Timing - Checking...2453
      Cylinder Head Removal And Installation...2454
      Cylinder Head Disassembly And Assembly...2457
      Cylinder Head - Servicing...2458
      Cylinder Head Top Clearance...2458
      Valve Guide - Checking...2459
      Reconditioning The Valve And Valve Seat...2461
      Valve Spring...2463
      Valve Tappets...2464
      Rocker Arm And Shaft - Checking...2465
    CRANKSHAFT AND PISTONS...2467
      Piston And Connecting Rod Removal And Installation...2467
      Piston And Connecting Rod - Servicing...2469
      Cylinder Bore Checking...2474
      Connecting Rod Alignment...2475
      Crankshaft Gear Removal And Installation...2475
      Crankshaft And Bearings Removal and Installation...2476
      Crankshaft And Bearings - Servicing...2480
    CAMSHAFT AND TIMING GEARS...2487
      Timing Gearcase Cover Removal And Installation...2487
      Timing Gears Backlash - Checking...2488
      Camshaft - Servicing...2489
      Idle Gear And Shaft Removal And Installation...2491
      Idler Gear And Shaft - Servicing...2492
    TURBOCHARGER...2495
      Description...2495
      Testing...2495
      Removal And Installation...2496
    FLYWHEEL AND HOUSING...2497
      Flywheel Removal And Installation...2497
      Ring Gear Removal And Installation...2497
      Housing Removal And Installation...2498
  HEATING, VENTILATION, AIR CONDITIONING...2499
    AIR CONDITIONING SYSTEM FLOW...2501
      Description...2501
      Chart...2502
    COMPONENTS...2503
      Identification...2503
    SAFETY...2505
      Safety Equipment...2505
    REGULAR MAINTENANCE...2507
      Filter Element Removal And Installation...2507
      Compressor And Alternator Drive Belt Inspection...2508
      Cleaning The Condenser...2508
    BASIC TROUBLESHOOTING...2509
      Poor A/C Performance...2509
      Compressor And Alternator Drive Belt Inspection...2509
      Checking The Electrical System...2510
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...2515
      Compressor Oil...2515
      Compressor Oil Check...2515
      Component Replacement And Refrigeration Leaks...2517
    SYSTEM TROUBLESHOOTING CHART...2519
      Chart...2519
      Gauge Pressure Related Troubleshooting...2520
    TEMPERATURE AND PRESSURE...2523
      Chart...2523
    AIR CONDITIONING SERVICE...2525
      Chart...2525
    SYSTEM CHARGING AND RECLAMATION...2527
      Reclamation Procedure...2527
      Charging Procedure With A Manifold Gauge Set...2530
    COMPRESSOR...2533
      Removal And Installation...2533
      Compressor Clutch Disassembly And Assembly...2534
    CONDENSER...2539
      Removal And Installation...2539
    RECEIVER / DRIER...2541
      Removal And Installation...2541
    PRESSURE SWITCH...2543
      Removal And Installation...2543
    EVAPORATOR/BLOWER UNIT...2545
      Removal And Installation...2545
    EXPANSION VALVE...2549
      Removal And Installation...2549
    HEATER ASSEMBLY...2551
      Removal And Installation...2551
      Fan Removal And Installation...2552
      Core Removal And Installation...2552
  SPECIFICATIONS...2555
    TELESCOPIC HANDLER TELESCOPIC TOOL CARRIER (TTC) SPECIFICATIONS...2557
      Machine Dimensions...2557
      Performance...2558
      Engine...2558
      Controls...2558
      Drive System...2558
      Tires...2559
      Capacities...2559
      Hydraulic System...2559
      Electrical System...2559
      Instrument Panel...2559
    ENGINE SPECIFICATIONS...2561
      General...2561
      Cylinder Head...2561
      Valve Guides...2561
      Exhaust Valves...2562
      Intake Valves...2562
      Valve Springs...2562
      Rocker Shaft, Rockers And Bushings...2563
      Pistons And Piston Rings...2563
      Connecting Rods And Bearings...2564
      Crankshaft...2564
      Crankshaft Re-Grind Data...2565
      Main Bearings...2566
      Thrust Washers...2566
      Camshaft And Thrust Washer...2566
      Cylinder Block...2566
      Cylinder Liners...2567
      Fuel Injection Pump...2567
      Fuel Injectors...2567
      Fuel Lift Pump...2567
      Timing Case And Timing Gears...2568
      Oil Pump, Gear And Relief Valve...2569
      Turbocharger...2569
      Flywheel...2569
      Water Pump And Thermostat...2570
      Engine Torque Component...2571
    MACHINE TORQUE SPECIFICATIONS...2573
      Specifications...2573
    TORQUE SPECIFICATIONS FOR BOLTS...2575
      Torque for General SAE Bolts...2575
      Torque For General Metric Bolts...2576
    HYDRAULIC CONNECTION SPECIFICATIONS...2577
      O-ring Face Seal Connection...2577
      Straight Thread O-ring Fitting...2577
      Tubelines And Hoses...2577
      Flare Fitting...2578
      O-ring Flare Fitting...2579
      Port Seal Fitting...2581
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...2583
      Specifications...2583
    CONVERSIONS...2585
      Decimal And Millimeter Equivalents...2585
      U.S. To Metric Conversion...2586
6986764 (08-12) - T2556, T2566 Telescopic Handler Service Manual...2587
  MAINTENANCE SAFETY...2589
  CONTENTS...2591
  FOREWORD...2593
    FOREWORD...2595
    SAFETY INSTRUCTIONS...2597
    FIRE PREVENTION...2598
      Maintenance...2598
      Operation...2598
      Electrical...2598
      Hydraulic System...2599
      Fueling...2599
      Starting...2599
      Spark Arrester Exhaust System...2599
      Welding And Grinding...2599
      Fire Extinguishers...2599
    SERIAL NUMBER LOCATION...2600
      Telescopic Handler Serial Number...2600
      Engine Serial Number...2600
      Other Serial Numbers...2600
    DELIVERY REPORT...2601
    TELESCOPIC HANDLER IDENTIFICATION...2602
  SAFETY & MAINTENANCE...2603
    LIFTING AND BLOCKING THE TELESCOPIC HANDLER...2605
      Procedure...2605
    OPERATOR CAB (ROPS / FOPS)...2607
      Cab Door...2608
      Cab Door Window...2608
    TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER...2609
      Loading And Unloading...2609
      Fastening...2609
    TOWING THE TELESCOPIC HANDLER...2611
      Procedure...2611
    SERVICE SCHEDULE...2613
      Chart...2613
    AIR CLEANER SERVICE...2615
      Replacing Filter Element...2615
    ENGINE COOLING SYSTEM...2617
      Cleaning...2617
      Removing And Replacing The Coolant...2617
      Checking Level...2619
    FUEL SYSTEM...2621
      Fuel Specifications...2621
      Biodiesel Blend Fuel...2621
      Filling The Fuel Tank...2622
      Secondary Fuel Filter...2622
      Primary Fuel Filter (Pre-Filter)...2623
      Removing Air From The Fuel System...2624
    ENGINE LUBRICATION SYSTEM...2625
      Checking And Adding Engine Oil...2625
      Engine Oil Chart...2625
      Removing And Replacing Oil And Filter...2626
    HYDRAULIC / HYDROSTATIC SYSTEM...2627
      Checking And Adding Fluid...2627
      Hydraulic / Hydrostatic Fluid Chart...2627
      Removing And Replacing Hydraulic Fluid...2628
      Removing And Replacing Hydraulic / Hydrostatic Filter...2629
      Hydraulic Tank Breather...2629
    ATTACHMENT CARRIER...2631
      Inspection And Maintenance...2631
    AXLES (FRONT AND REAR)...2633
      Checking Oil Level (Planetary Carrier)...2633
      Removing And Replacing Oil (Planetary Carrier)...2633
      Checking And Adding Oil (Front Differential)...2634
      Removing And Replacing Oil (Front Differential)...2634
      Checking And Adding Oil (Rear Differential)...2635
      Removing And Replacing Oil (Rear Differential)...2635
      Checking And Adding Oil (Front Drop Box)...2636
      Removing And Replacing Oil (Front Drop Box)...2636
    LUBRICATING THE TELESCOPIC HANDLER...2637
      Lubrication Locations...2637
    TIRE MAINTENANCE...2641
      Wheel Nuts...2641
      Rotating...2641
      Mounting...2641
    APPROVED BOOM STOP...2643
      Installing The Approved Boom Stop...2643
      Removing The Approved Boom Stop...2643
    ENGINE COVER...2645
      Opening And Closing...2645
    TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE...2647
      Storage...2647
      Return To Service...2647
    STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER...2649
      Procedure...2649
    EMERGENCY EXIT...2651
      Rear Window...2651
  HYDRAULIC SYSTEM...2653
    HYDRAULIC SCHEMATIC...2657
    HYDRAULIC SYSTEM INFORMATION...2663
      Glossary Of Hydraulic / Hydrostatic Symbols...2663
      Troubleshooting Chart...2666
      Tightening Procedures...2667
    LIFT CYLINDER...2669
      Removal And Installation...2669
      Parts Identification...2674
      Disassembly...2675
      Assembly...2679
    BUCKET POSITIONING CYLINDER...2683
      Removal And Installation...2683
      Parts Identification...2688
      Disassembly...2689
      Assembly...2693
    EXTENSION CYLINDER...2697
      Cylinder Group Removal And Installation...2697
      Upper Tubeline Removal...2699
      Upper Tubeline Installation...2701
      Extension Cylinder Removal And Installation...2703
      Tubeline Tray Disassembly...2705
      Tubeline Tray Assembly...2706
      Parts Identification...2709
      Disassembly...2710
      Assembly...2714
    TILT CYLINDER...2717
      Removal And Installation...2717
    TILT CYLINDER...2718
      Parts Identification...2719
      Disassembly...2720
      Assembly...2725
    STEERING CYLINDER (FRONT)...2731
      Removal...2731
      Installation...2732
      Disassembly...2734
      Assembly...2735
    STEERING CYLINDER (REAR)...2739
      Removal...2739
      Installation...2740
      Disassembly...2742
      Assembly...2744
    DRIVE BOX...2747
      Parts Identification...2747
      Disassembly...2748
      Assembly...2752
      Special Tools...2755
    MAIN RELIEF VALVE...2757
      Testing And Adjustment...2757
      Removal And Installation...2758
    QUICK-TACH CYLINDER...2759
      Removal And Installation...2759
      Parts Identification...2761
      Disassembly...2762
      Assembly...2765
    PORT RELIEF VALVES...2767
      Adjustment Procedure...2767
    STEERING MODE VALVE BLOCK...2769
      Removal And Installation...2769
      Parts Identification...2771
      Disassembly...2772
      Solenoid Testing...2774
      Assembly...2774
    BRAKE VALVE...2777
      Removal And Installation...2777
      Disassembly And Assembly...2778
    GEAR PUMP...2781
      Removal And Installation...2781
      Parts Identification...2783
      Disassembly And Assembly...2784
    FAN MOTOR...2791
      Removal And Installation...2791
      Parts Identification...2795
      Disassembly And Assembly...2796
    HYDRAULIC FLUID RESERVOIR...2799
      Removal And Installation...2799
    STEERING VALVE...2801
      Removal And Installation...2801
      Parts Identification...2802
      Disassembly...2803
      Inspection...2809
      Assembly...2810
    HYDRAULIC CONTROL VALVE...2817
      Troubleshooting Chart (Controllers)...2817
      Telescoping Valve Section Troubleshooting...2818
      Auxiliary Valve Section Troubleshooting...2822
      Troubleshooting Chart (Control Valve)...2826
      Removal And Installation...2827
      Parts Identification...2831
      Disassembly And Assembly...2832
      End Housing Disassembly And Assembly...2833
      Telescoping Valve Section Disassembly And Assembly...2834
      Auxiliary Valve Section Disassembly And Assembly...2846
      Lifting Valve Section Disassembly And Assembly...2857
      Tilting Valve Section Disassembly And Assembly...2862
      Inlet-Outlet Valve Section Disassembly And Assembly...2868
    JOYSTICK...2873
      Removal And Installation...2873
    PARKING BRAKE...2875
      Valve Removal And Installation...2875
      Valve Disassembly And Assembly...2876
    PILOT PRESSURE LOCKOUT VALVE...2879
      Testing...2879
      Removal And Installation...2880
      Disassembly And Assembly...2881
    ACCUMULATOR...2883
      Removal And Installation...2883
    TOW VALVE...2885
      Removal And Installation...2885
      Disassembly And Assembly...2886
    FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE...2891
      Removal And Installation...2891
      Disassembly And Assembly...2892
    FLOW CONTROL VALVE...2897
      Removal And Installation...2897
  HYDROSTATIC SYSTEM...2899
    HYDROSTATIC SYSTEM INFORMATION...2901
      Troubleshooting Chart...2901
      Replenishing Valve Function...2902
    OIL COOLER...2903
      Description...2903
    HYDROSTATIC DRIVE MOTOR...2905
      Removal And Installation...2905
      Parts Identification...2906
      Disassembly...2909
      Inspection...2920
      Assembly...2922
    HYDROSTATIC PUMP...2935
      Removal And Installation...2935
      Parts Identification...2936
      Disassembly...2941
      Inspection...2953
      Assembly...2957
      Charge Pressure Checking Procedure...2972
      Charge Pressure Adjusting Procedure...2972
  DRIVE SYSTEM...2973
    TROUBLESHOOTING...2975
      Chart...2975
    AXLE AND DIFFERENTIAL (FRONT)...2977
      Description...2977
      Planetary Carrier And Wheel Hub Parts Identification...2977
      Planetary Carrier Disassembly And Assembly...2978
      Wheel Hub Disassembly And Assembly...2980
      Steering Knuckle Disassembly And Assembly...2982
      Axle Housing / Drive Axle Disassembly...2984
      Brake Group Parts Identification...2988
      Brake Group Disassembly...2989
      Differential Parts Identification...2992
      Differential Disassembly And Assembly...2993
      Pinion Group Parts Identification...2996
      Pinion Group Disassembly...2997
      Pinion Group Assembly...2998
      Brake Group Assembly...3003
      Axle Housing / Drive Axle Assemby...3006
      Special Tools...3009
    AXLE AND DIFFERENTIAL (REAR)...3011
      Description...3011
      Planetary Carrier And Wheel Hub Parts Identification...3011
      Planetary Carrier Disassembly...3012
      Steering Knuckle Parts Identification...3016
      Steering Knuckle Disassembly...3017
      Differential Parts Identification...3021
      Differential Disassembly...3022
      Bevel Pinion Parts Identification...3027
      Bevel Pinion Disassembly...3028
      Bevel Pinion Assembly...3032
      Differential Assembly...3041
      Steering Knuckle Assembly...3045
      Planetary Carrier Assembly...3051
      Special Tools...3056
    FRONT AXLE...3059
      Removal...3059
      Installation...3064
    AXLE TOE-IN...3069
      Adjustment...3069
    PARKING BRAKE...3071
      Releasing The Brake For Towing...3071
      Re-Activating The Brake...3072
    STEERING ANGLE ADJUSTMENT...3073
      Adjustment...3073
    DRIVE SHAFT...3075
      Removal And Installation...3075
    SERVICE BRAKE...3077
      Description...3077
      Bleeding The Brake Circuit...3077
    REAR AXLE...3079
      Removal...3079
      Installation...3082
  MAINFRAME...3087
    OPERATOR CAB (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)...3089
      Removal And Installation...3089
    OPERATOR CAB (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)...3097
      Removal And Installation...3097
    OPERATOR SEAT...3105
      Removal And Installation...3105
    BOOM ASSEMBLY...3107
      Removal And Installation...3107
    INNER BOOM...3111
      Removal...3111
      Installation...3113
    WEAR PADS (FRONT)...3115
      Removal And Installation...3115
    WEAR PADS (REAR)...3117
      Removal...3117
      Installation...3117
    ENGINE COVER...3119
      Removal And Installation...3119
      Gas Cylinder Removal And Installation...3119
    AIR INTAKE COWLING...3121
      Removal And Installation...3121
    FUEL TANK...3123
      Removal And Installation...3123
    QUICK-TACH...3127
      Removal And Installation...3127
    REAR WEIGHTS...3129
      Removal And Installation...3129
    FENDER...3131
      Removal And Installation...3131
    JOYSTICK PANEL (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)...3133
      Removal And Installation...3133
    JOYSTICK PANEL (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)...3135
      Removal And Installation...3135
    DASH COVER / STEERING COLUMN COVER (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)...3137
      Removal And Installation...3137
    DASH COVER / STEERING COLUMN COVER (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)...3141
      Removal And Installation...3141
  ELECTRICAL SYSTEM & ANALYSIS...3145
    ELECTRICAL SCHEMATIC...3147
    ELECTRICAL SYSTEM INFORMATION (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)...3183
      Troubleshooting Chart...3183
      Description...3185
      Fuses, Diode And Relay Location / Identification...3185
    ELECTRICAL SYSTEM INFORMATION (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)...3189
      Troubleshooting Chart...3189
      Description...3190
      Fuses, Diodes And Relays...3190
    BATTERY...3193
      Removal And Installation...3193
      Servicing...3194
      Using A Booster Battery (Jump Starting)...3195
    ALTERNATOR...3197
      Removal And Installation...3197
      Belt Adjustment...3198
      Belt Replacement...3198
    STARTER...3199
      Removal And Installation...3199
      Parts Identification...3200
      Disassembly...3201
      Inspection And Repair...3206
      Assembly...3210
    LIGHTS...3215
      Rear Light Removal And Installation...3215
      Front Light Removal And Installation...3216
    TRAVEL / SIGNAL LEVER (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)...3219
      Removal And Installation...3219
    TRAVEL / SIGNAL LEVER (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)...3221
      Removal And Installation...3221
    TRAVEL / SIGNAL LEVER (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE) (CONT’D)...3222
      Removal And Installation (Cont’d)...3222
    INSTRUMENT PANEL...3223
      Removal And Installation...3223
    SWITCH PANEL (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)...3225
      Removal And Installation...3225
      Parts Description...3226
    SWITCH PANEL (S/N A8FR13000 - 14999, S/N A8G313000 - 14999)...3229
      Removal And Installation...3229
    SWITCH PANEL (S/N A8FR15000 & ABOVE, S/N A8G315000 & ABOVE)...3231
      Removal And Installation...3231
    BRAKE LIGHT SWITCH...3233
      Removal And Installation...3233
      Adjustment...3233
    WIPER MOTOR (FRONT)...3235
      Removal And Installation...3235
    WIPER MOTOR (TOP)...3239
      Removal And Installation...3239
    WIPER MOTOR (REAR)...3241
      Removal And Installation...3241
    PEDAL ASSEMBLY...3243
      Removal And Installation...3243
      Disassembly And Assembly...3244
    INCHING SWITCH...3249
      Removal And Installation...3249
      Adjustment...3249
    SERVICE SOFTWARE...3251
      Connecting The Laptop Computer...3251
      Entering The Service Software...3252
      Monitor Screen...3253
      Warnings Screen...3255
      Calibrate Inch Pedal...3256
      Calibrate Creep Potentiometer...3257
      Program / Update Susmic Controller...3259
    LONGITUDINAL STABILITY INDICATOR CALIBRATION (S/N A8FR11001 - 14999, S/N A8G311001 - 14999)...3261
      Installing The Sensor...3261
      Calibration Procedure...3261
    LLMI / LLMC SYSTEM (S/N A8FR15000 & ABOVE, S/N A8G315000 & ABOVE)...3263
      System Calibration...3263
      Calibration Test...3265
      System Failure Reports...3266
      System Components Identification...3270
      LLMS Removal...3272
      LLMS Installation...3273
      LLMC Controller Removal...3275
      LLMC Controller Installation...3278
  ENGINE SERVICE...3281
    ENGINE INFORMATION...3285
      Specifications...3285
      Troubleshooting...3296
    ENGINE SPEED CONTROL...3299
      Removal And Installation...3299
    MUFFLER...3301
      Removal And Installation...3301
    AIR CLEANER...3303
      Housing Removal And Installation...3303
    OIL COOLER / RADIATOR...3305
      Removal And Installation...3305
      Disassembly And Assembly...3308
    ENGINE AND ENGINE MOUNTS...3311
      Removal And Installation...3311
    ENGINE COMPONENTS AND TESTING...3315
      Fuel Injection Pump Removal...3315
      Fuel Injection Pump Installation...3318
      Fuel Injector Removal And Installation...3321
      Checking The Fuel Lift Pump...3323
      Fuel Lift Pump Removal And Installation...3324
      Compression Checking...3324
      Glow Plugs Checking...3325
      Glow Plugs Removal And Installation...3326
    ENGINE TIMING...3327
      Procedure...3327
    ENGINE / HYDROSTAT ASSEMBLY...3329
      Removal And Installation...3329
    FLYWHEEL AND HOUSING...3343
      Removal And Installation...3343
      Ring Gear Removal...3346
      Ring Gear Installation...3346
    RECONDITIONING THE ENGINE...3347
      Turbocharger Troubleshooting...3347
      Turbocharger Description...3348
      Turbocharger Removal And Installation...3348
      Exhaust Manifold Removal And Installation...3350
      Fuel Injector Cover Removal And Installation...3350
      Rocker Cover Removal And Installation...3351
      Cylinder Head Removal...3352
      Cylinder Head Inspection...3354
      Cylinder Head Installation...3355
      Rocker Shaft Disassembly And Assembly...3358
      Valve Removal...3358
      Valve Springs Checking...3359
      Valve Depth Checking...3359
      Valve Guides Checking...3360
      Valve Guide Removal...3361
      Valve Guide Installation...3361
      Valves Checking...3362
      Cutting A Valve Seat...3362
      Valve Seat Assembly...3363
      Changing Valve Springs (With Cylinder Head Installed)...3364
      Valve Clearance Adjustment...3365
      Timing Case And Drive Assembly Description...3366
      Timing Cover Removal...3366
      Timing Cover Installation...3366
      Crankshaft Pulley Removal And Installation...3366
      Front Oil Seal Removal And Installation...3366
      Timing Case And Gear Removal...3367
      Timing Case And Gear Installation...3368
      Camshaft And Tappets Removal...3370
      Camshaft And Tappets Installation...3371
      Pistons And Connecting Rods Description...3372
      Pistons And Connecting Rods Removal...3372
      Pistons And Connecting Rods Disassembly...3374
      Piston Ring End Gap...3374
      Piston Ring Installation...3374
      Piston Ring Groove Clearance...3375
      Connecting Rod Inspection...3376
      Connecting Rod Bushing Replacement...3376
      Piston And Connecting Rod Assembly...3376
      Piston And Connecting Rod Installation...3376
      Checking Piston Height...3378
      Crankshaft And Bearings Description...3378
      Crankshaft And Bearings Removal...3378
      Inspection Of Crankshaft And Bearings...3380
      Crankshaft And Bearings Installation...3381
      Rear Oil Seal Removal...3382
      Rear Oil Seal Housing Positioning...3382
      Rear Oil Seal Installation...3383
      Checking Crankshaft End Play...3384
      Cooling System Description...3384
      Cooling System Description (Cont’d)...3385
      Thermostat Removal and Installation...3385
      Thermostat Testing...3386
      Lubricating Oil Cooler Removal And Installation...3386
      Water Pump Removal...3386
      Water Pump Installation...3386
      Engine Lubrication System Description...3387
      Oil Filter Adapter Removal And Installation...3388
      Oil Pan Removal And Installation...3388
      Oil Screen And Pick-up Tube...3389
      Oil Pump Removal...3389
      Oil Pump Removal (Cont'd)...3390
      Oil Pump Installation...3390
      Oil Pump Installation (Cont'd)...3391
      Oil Pump Disassembly And Assembly...3391
      Oil Pump Disassembly And Assembly (Cont'd)...3392
      Oil Pressure Relief Valve Disassembly And Assembly...3392
      Engine Block Description...3393
      Engine Block Disassembly And Assembly...3393
      Piston Cooling Jet Removal...3394
      Piston Cooling Jet Installation...3394
      Piston Cooling Jet Alignment...3394
      Inspection...3394
      Cylinder Liner Inspection...3395
      Cylinder Liner Removal...3396
      Cylinder Liner Installation...3397
  HEATING, VENTILATION, AIR CONDITIONING...3399
    AIR CONDITIONING SYSTEM FLOW...3401
      Description...3401
      Chart...3402
      Components...3403
      Safety Equipment...3406
    REGULAR MAINTENANCE...3407
      Filters...3407
      Compressor And Alternator Drive Belt Inspection...3407
      Cleaning The Condenser...3408
      Air Conditioning Lubrication...3408
      Air Conditioning Service Chart...3409
    TROUBLESHOOTING...3411
      Blower Motor Does Not Operate...3411
      Blower Motor Operates Normally, But Air Flow Is Insufficient...3411
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...3411
      The Compressor Does Not Operate At All, Or Operates Improperly...3411
      Gauge Pressure Related Troubleshooting...3412
      Troubleshooting Tree...3414
      Temperature / Pressure Chart...3418
      Poor A/C Performance...3419
      HVAC Repair And Leaks...3420
      Electrical System...3421
    SYSTEM CHARGING AND RECLAMATION...3427
      Reclamation Procedure...3427
      Charging Procedure With A Manifold Gauge Set...3430
      Charging Procedure...3431
    COMPRESSOR...3433
      Removal And Installation...3433
      Oil...3434
      Oil Check...3434
      Clutch Disassembly And Assembly...3436
    CONDENSER (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)...3441
      Removal And Installation...3441
    CONDENSER (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)...3443
      Removal And Installation...3443
    RECEIVER / DRIER...3445
      Removal And Installation...3445
    PRESSURE SWITCH...3447
      Removal And Installation...3447
    EVAPORATOR / BLOWER UNIT (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)...3449
      Removal And Installation...3449
    EVAPORATOR / BLOWER UNIT (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)...3451
      Removal And Installation...3451
    EXPANSION VALVE (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)...3453
      Removal And Installation...3453
    EXPANSION VALVE (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)...3455
      Removal And Installation...3455
    HEATER ASSEMBLY...3457
      Removal And Installation...3457
      Fan Removal And Installation...3458
      Core Removal And Installation...3459
  SPECIFICATIONS...3461
    (T2556) TELESCOPIC HANDLER SPECIFICATIONS...3463
      Dimensional Specifications...3463
      Performance Specifications...3464
      Weights...3464
      Engine...3464
      Controls...3465
      Drive System...3465
      Traction...3465
      Steering...3465
      Brakes...3465
      Fluid Capacities...3466
      Hydraulic System...3466
      Electrical...3466
      Instruments...3467
      Environmental...3467
      Temperature Range...3467
    (T2566) TELESCOPIC HANDLER SPECIFICATIONS...3469
      Dimensional Specifications...3469
      Performance Specifications...3470
      Weights...3470
      Engine...3470
      Controls...3471
      Drive System...3471
      Traction...3471
      Steering...3471
      Brakes...3471
      Fluid Capacities...3472
      Hydraulic System...3472
      Electrical...3472
      Instruments...3473
      Environmental...3473
      Temperature Range...3473
    MACHINE TORQUE SPECIFICATIONS...3475
      Axle...3475
      Boom...3475
      Drive Box...3475
      Drive Motor...3475
      Engine...3476
      Hydraulic Pump...3476
    TORQUE SPECIFICATIONS FOR BOLTS...3477
      Torque for General SAE Bolts...3477
      Torque For General Metric Bolts...3478
    HYDRAULIC CONNECTION SPECIFICATIONS...3479
      O-ring Face Seal Connection...3479
      Straight Thread O-ring Fitting...3479
      Tubelines And Hoses...3479
      Port Seal Fitting...3480
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...3481
      Specifications...3481
    CONVERSIONS...3483
      Decimal And Millimeter Equivalents...3483
      U.S. To Metric Conversion...3483
  ALPHABETICAL INDEX...3485
  SERVICE MANUAL REVISION...3489
    Revision No: T2556, T2566 - 1...3489
    Revision No: T2556, T2566 - 2...3491
    Revision No: T2556, T2566 - 3...3493
6986764 (2-10) - T2556, T2566 Telescopic Handler Service Manual...3497
  MAINTENANCE SAFETY...3499
  CONTENTS...3501
  FOREWORD...3503
    FOREWORD...3505
    SAFETY INSTRUCTIONS...3507
    FIRE PREVENTION...3508
      Maintenance...3508
      Operation...3508
      Electrical...3508
      Hydraulic System...3509
      Fueling...3509
      Starting...3509
      Spark Arrester Exhaust System...3509
      Welding And Grinding...3509
      Fire Extinguishers...3509
    SERIAL NUMBER LOCATION...3510
      Telescopic Handler Serial Number...3510
      Engine Serial Number...3510
      Other Serial Numbers...3510
    DELIVERY REPORT...3511
    IDENTIFICATION OF THE TELESCOPIC HANDLER...3512
  SAFETY AND MAINTENANCE...3513
    LIFTING AND BLOCKING THE TELESCOPIC HANDLER...3515
      Procedure...3515
    OPERATOR CAB...3517
      Emergency Exit...3517
      Cab Door...3518
      Cab Door Window...3518
    TRANSPORTING THE TELESCOPIC HANDLER...3519
      Loading And Unloading...3519
      Fastening...3519
    TOWING THE TELESCOPIC HANDLER...3521
      Procedure...3521
    SERVICE SCHEDULE...3523
    AIR CLEANER SERVICE...3525
      Replacing Filter Element...3525
    ENGINE COOLING SYSTEM...3527
      Cleaning The Cooling System...3527
      Checking The Coolant Level...3527
      Replacing The Coolant...3528
    FUEL SYSTEM...3529
      Fuel Specifications...3529
      Filling The Fuel Tank...3529
      Fuel Filter...3529
    ENGINE LUBRICATION SYSTEM...3531
      Checking Engine Oil...3531
      Oil Chart...3531
      Replacing Oil And Filter...3532
    HYDRAULIC / HYDROSTATIC SYSTEM...3533
      Checking And Adding Fluid...3533
      Replacing Hydraulic / Hydrostatic Filter...3533
      Replacing Hydraulic Fluid...3534
    AXLES (FRONT AND REAR)...3535
      Checking Oil Level (Planetary Carrier)...3535
      Draining Oil (Planetary Carrier)...3535
      Checking Oil Level (Rear Differential)...3536
      Draining Oil (Rear Differential)...3536
      Checking Oil Level (Front Differential)...3537
      Draining Oil (Front Differential)...3537
      Checking Oil (Drive Box)...3538
      Draining Oil (Drive Box)...3538
    LUBRICATION...3539
      Procedure...3539
    ATTACHMENT FRAME...3543
      Inspection And Maintenance...3543
    TYRE MAINTENANCE...3545
      Wheel Nuts...3545
      Tyre Mounting...3545
      Tyre Rotation...3545
    SPARK ARRESTER MUFFLER...3547
      Cleaning...3547
    APPROVED BOOM STOP...3549
      Installing The Approved Boom Stop...3549
      Removing The Approved Boom Stop...3549
    ENGINE COVER...3551
      Opening And Closing The Engine Cover...3551
  HYDRAULIC SYSTEM...3553
    HYDRAULIC SYSTEM INFORMATION...3560
      Troubleshooting Chart...3563
      HYDRAULIC SCHEMATICS...3557
      Tightening Procedures...3564
    LIFT CYLINDER...3566
      Removal And Installation...3566
      Parts Identification...3571
      Disassembly...3572
      Assembly...3576
    BUCKET POSITIONING CYLINDER...3580
      Removal And Installation...3580
      Parts Identification...3585
      Disassembly...3586
      Assembly...3590
    EXTENSION CYLINDER...3594
      Cylinder Group Removal And Installation...3594
      Upper Tubeline Removal...3596
      Upper Tubeline Installation...3598
      Extension Cylinder Removal And Installation...3600
      Tubeline Tray Disassembly...3602
      Tubeline Tray Assembly...3603
      Parts Identification...3606
      Disassembly...3607
      Assembly...3611
    TILT CYLINDER...3614
      Removal And Installation...3614
    TILT CYLINDER...3615
      Parts Identification...3616
      Disassembly...3617
      Assembly...3622
    STEERING CYLINDER (FRONT)...3628
      Removing The Steering Cylinder...3628
      Installing The Steering Cylinder...3629
      Disassembling The Steering Cylinder...3631
      Assembling The Steering Cylinder...3632
    STEERING CYLINDER (REAR)...3636
      Removing The Steering Cylinder...3636
      Installing The Steering Cylinder...3637
      Disassembling The Steering Cylinder...3639
      Assembling The Steering Cylinder...3641
    DRIVE BOX...3644
      Parts Identification...3644
      Disassembly...3645
      Assembly...3649
      Special Tools...3652
    MAIN RELIEF VALVE...3654
      Testing And Adjustment...3654
      Removal And Installation...3655
    QUICK TACH CYLINDER...3656
      Removal And Installation...3656
      Parts Identification...3658
      Disassembly...3659
      Assembly...3662
    PORT RELIEF VALVES...3664
      Adjustment Procedure...3664
    STEERING MODE VALVE BLOCK...3666
      Removal And Installation...3666
      Parts Identification...3668
      Disassembly...3669
      Solenoid Testing...3671
      Assembly...3671
    BRAKE VALVE...3674
      Removal And Installation...3674
      Disassembly And Assembly...3675
    GEAR PUMP...3678
      Removal And Installation...3678
      Parts Identification...3680
      Disassembly And Assembly...3681
    FAN MOTOR...3688
      Removal And Installation...3688
      Parts Identification...3692
      Disassembly And Assembly...3693
    HYDRAULIC RESERVOIR...3696
      Removal And Installation...3696
    STEERING VALVE...3698
      Removal And Installation...3698
      Parts Identification...3699
      Disassembly...3700
      Inspection...3706
      Assembly...3707
    HYDRAULIC CONTROL VALVE...3714
      Troubleshooting Chart (Controllers)...3714
      Telescoping Valve Section Troubleshooting...3715
      Auxiliary Valve Section Troubleshooting...3719
      Troubleshooting Chart (Control Valve)...3723
      Removal And Installation...3724
      Parts Identification...3728
      Disassembly And Assembly...3729
      End Housing Disassembly And Assembly...3730
      Lifting Valve Section Disassembly And Assembly...3731
      Tilting Valve Section Disassembly And Assembly...3736
      Telescoping Valve Section Disassembly And Assembly...3742
      Auxiliary Valve Section Disassembly And Assembly...3754
      Inlet-Outlet Valve Section Disassembly And Assembly...3765
    JOYSTICK...3770
      Removal And Installation...3770
    PARKING BRAKE...3772
      Parking Brake Valve Removal And Installation...3772
      Parking Brake Valve Disassembly And Assembly...3773
    PILOT PRESSURE LOCK OUT VALVE...3776
      Testing...3776
      Removal And Installation...3777
      Disassembly And Assembly...3778
    ACCUMULATOR...3780
      Removal And Installation...3780
    TOW VALVE...3782
      Removal And Installation...3782
      Disassembly And Assembly...3783
    FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE...3788
      Removal And Installation...3788
      Disassembly And Assembly...3789
    FLOW CONTROL VALVE...3794
      Removal And Installation...3794
  HYDROSTATIC SYSTEM...3796
    HYDROSTATIC SYSTEM INFORMATION...3798
      Troubleshooting Chart...3798
      Replenishing Valve Function...3799
    OIL COOLER...3800
      Description...3800
    HYDROSTATIC DRIVE MOTOR...3802
      Removal And Installation...3802
      Parts Identification...3803
      Disassembly...3806
      Inspection...3817
      Assembly...3819
    HYDROSTATIC PUMP...3832
      Removal And Installation...3832
      Parts Identification...3833
      Disassembly...3838
      Inspection...3850
      Assembly...3854
      Charge pressure checking procedure...3869
      Charge pressure adjusting procedure...3869
  DRIVE SYSTEM...3870
    TROUBLESHOOTING...3872
      Chart...3872
    AXLE AND DIFFERENTIAL (FRONT)...3874
      General Information...3874
      Planetary Carrier And Wheel Hub Parts Identification...3874
      Planetary Carrier Disassembly And Assembly...3875
      Wheel Hub Disassembly And Assembly...3877
      Steering Knuckle Disassembly And Assembly...3879
      Axle Housing / Drive Axle Disassembly...3881
      Brake Group Parts Identification...3885
      Brake Group Disassembly...3886
      Differential Parts Identification...3889
      Differential Disassembly And Assembly...3890
      Pinion Group Parts Identification...3893
      Pinion Group Disassembly...3894
      Pinion Group Assembly...3895
      Brake Group Assembly...3900
      Axle Housing / Drive Axle Assemby...3903
      Special Tools...3906
    AXLE AND DIFFERENTIAL (REAR)...3908
      General Information...3908
      Planetary Carrier And Wheel Hub Parts Identification...3908
      Planetary Carrier Disassembly...3909
      Steering Knuckle Parts Identification...3913
      Steering Knuckle Disassembly...3914
      Differential Parts Identification...3918
      Differential Disassembly...3919
      Bevel Pinion Parts Identification...3924
      Bevel Pinion Disassembly...3925
      Bevel Pinion Assembly...3929
      Differential Assembly...3938
      Steering Knuckle Assembly...3942
      Planetary Carrier Assembly...3948
      Special Tools...3953
    FRONT AXLE...3956
      Removal...3956
      Installation...3961
    AXLE TOE-IN...3966
      Adjustment...3966
    PARKING BRAKE...3968
      Releasing The Brake For Towing...3968
      Re-Activating The Brake...3969
    STEERING ANGLE ADJUSTMENT...3970
      Adjustment...3970
    DRIVESHAFT...3972
      Removal And Installation...3972
    SERVICE BRAKE...3974
      Description...3974
      Bleeding The Brake Circuit...3974
    REAR AXLE...3976
      Removal...3976
      Installation...3979
  MAIN FRAME...3984
    OPERATOR CAB (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)...3986
      Removal And Installation...3986
    OPERATOR CAB (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)...3994
      Removal And Installation...3994
    OPERATOR SEAT...4002
      Removal And Installation...4002
    BOOM ASSEMBLY...4004
      Removal And Installation...4004
    INNER BOOM...4008
      Removal...4008
      Installation...4010
    WEAR PADS (FRONT)...4012
      Removal And Installation...4012
    WEAR PADS (REAR)...4014
      Removal...4014
      Installation...4014
    ENGINE COVER...4016
      Gas Cylinder Removal And Installation...4016
      Removal And Installation...4016
    AIR INTAKE COWLING...4018
      Removal And Installation...4018
    FUEL TANK...4020
      Removal And Installation...4020
    QUICK TACH...4024
      Removal And Installation...4024
    REAR WEIGHTS...4026
      Removal And Installation...4026
    FENDER...4028
      Removal And Installation...4028
    JOYSTICK PANEL (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)...4030
      Removal And Installation...4030
    JOYSTICK PANEL (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)...4032
      Removal And Installation...4032
    DASH COVER / STEERING COLUMN COVER (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)...4034
      Removal And Installation...4034
    DASH COVER / STEERING COLUMN COVER (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)...4038
      Removal And Installation...4038
  ELECTRICAL SYSTEM AND ANALYSIS...4042
    ELECTRICAL SYSTEM INFORMATION (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)...4063
      Troubleshooting Chart...4063
      Description...4064
      Fuses, Diodes And Relays...4064
    ELECTRICAL SCHEMATICS (S/N 13000 & ABOVE)...4044
    ELECTRICAL SCHEMATICS (S/N 12001 - 12999)...4053
    ELECTRICAL SYSTEM INFORMATION (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)...4067
      Troubleshooting Chart...4067
      Description...4068
      Fuses, Diodes And Relays...4068
    BATTERY...4071
      Removal And Installation...4071
      Servicing...4072
      Using A Booster Battery (Jump Starting)...4073
    ALTERNATOR...4075
      Removal And Installation...4075
      Adjusting The Alternator Belt...4076
    STARTER...4077
      Removal And Installation...4077
      Parts Identification...4078
      Disassembly...4079
      Inspection And Repair...4084
      Assembly...4088
    LIGHTS...4093
      Rear Light Removal And Installation...4093
      Front Light Removal And Installation...4094
    TRAVEL / SIGNAL LEVER (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)...4097
      Removal And Installation...4097
    TRAVEL / SIGNAL LEVER (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)...4099
      Removal And Installation...4099
    INSTRUMENT PANEL...4101
      Removal And Installation...4101
    SWITCH PANEL (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)...4103
      Removal And Installation...4103
      Parts description...4104
    SWITCH PANEL (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)...4107
      Removal And Installation...4107
      Parts description...4108
    BRAKE LIGHT SWITCH...4111
      Removal And Installation...4111
      Adjustment...4111
    FRONT WIPER MOTOR...4113
      Removal And Installation...4113
    TOP WIPER MOTOR...4117
      Removal And Installation...4117
    REAR WIPER MOTOR...4119
      Removal And Installation...4119
    PEDAL ASSEMBLY...4121
      Removal And Installation...4121
      Disassembly And Assembly...4122
    INCHING SWITCH...4127
      Removal And Installation...4127
      Adjustment...4127
    SERVICE SOFTWARE...4129
      Connecting The Laptop Computer...4129
      Entering The Service Software...4130
      Monitor Screen...4131
      Warnings Screen...4133
      Calibrate Inch Pedal...4134
      Calibrate Creep Potentiometer...4135
      Program / Update Susmic Controller...4137
  ENGINE SERVICE...4139
    TROUBLESHOOTING...4143
      Chart...4143
    ENGINE SPEED CONTROL...4145
      Removal And Installation...4145
    MUFFLER...4147
      Removal And Installation...4147
    AIR CLEANER...4149
      Housing Removal And Installation...4149
    OIL COOLER / RADIATOR...4151
      Removal And Installation...4151
      Disassembly And Assembly...4154
    ENGINE AND ENGINE MOUNTS...4157
      Removal And Installation...4157
    ENGINE COMPONENTS AND TESTING...4161
      Fuel Injection Pump Removal...4161
      Fuel Injection Pump Installation...4164
      Fuel Injectors Removal And Installation...4167
      Checking The Fuel Lift Pump...4169
      Fuel Lift Pump Removal And Installation...4170
      Compression Checking...4170
      Glow Plugs Checking...4171
      Glow Plugs Removal And Installation...4172
    ENGINE TIMING...4173
      Procedure...4173
    ENGINE / HYDROSTAT ASSEMBLY...4175
      Removal And Installation...4175
    FLYWHEEL AND HOUSING...4189
      Removal And Installation...4189
      Ring Gear Removal...4192
      Ring Gear Installation...4192
    RECONDITIONING THE ENGINE...4193
      Turbo Charger Troubleshooting...4193
      Turbo Charger Description...4194
      Turbo Charger Removal And Installation...4194
      Exhaust Manifold Removal And Installation...4196
      Fuel Injector Cover Removal And Installation...4196
      Rocker Cover Removal And Installation...4197
      Cylinder Head Removal...4198
      Cylinder Head Inspection...4200
      Cylinder Head Installation...4201
      Rocker Shaft Disassembly And Assembly...4204
      Valve Removal...4204
      Valve Springs Checking...4205
      Valve Depth Checking...4205
      Valve Guides Checking...4206
      Valve Guide Removal...4207
      Valve Guide Installation...4207
      Valves Checking...4208
      Cutting A Valve Seat...4208
      Valve Seat Assembly...4209
      Changing Valve Springs (With Cylinder Head Installed)...4210
      Valve Clearance Adjustment...4211
      Timing Case And Drive Assembly Description...4212
      Timing Cover Removal...4212
      Timing Cover Installation...4212
      Crankshaft Pulley Removal And Installation...4212
      Front Oil Seal Removal And Installation...4212
      Timing Case And Gear Removal...4213
      Timing Case And Gear Installation...4214
      Camshaft And Tappets Removal...4216
      Camshaft And Tappets Installation...4217
      Pistons And Connecting Rods Description...4218
      Pistons And Connecting Rods Removal...4218
      Pistons And Connecting Rods Disassembly...4220
      Piston Ring End Gap...4220
      Piston Ring Installation...4220
      Piston Ring Groove Clearance...4221
      Connecting Rod Inspection...4222
      Connecting Rod Bushing Replacement...4222
      Piston And Connecting Rod Assembly...4222
      Piston And Connecting Rod Installation...4222
      Checking Piston Height...4224
      Crankshaft And Bearings Description...4224
      Crankshaft And Bearings Removal...4224
      Inspection Of Crankshaft And Bearings...4226
      Crankshaft And Bearings Installation...4227
      Rear Oil Seal Removal...4228
      Rear Oil Seal Housing Positioning...4228
      Rear Oil Seal Installation...4229
      Checking Crankshaft End Play...4229
      Cooling System Description...4230
      Thermostat Removal and Installation...4231
      Thermostat Testing...4232
      Lubricating Oil Cooler Removal And Installation...4232
      Water Pump Removal...4232
      Water Pump Installation...4232
      Engine Lubrication System Description...4233
      Oil Filter Adapter Removal And Installation...4234
      Oil Pan Removal And Installation...4234
      Oil Screen And Pick-up Tube...4235
      Oil Pump Removal...4235
      Oil Pump Installation...4236
      Oil Pump Disassembly And Assembly...4237
      Oil Pressure Relief Valve Disassembly And Assembly...4237
      Engine Block Description...4238
      Engine Block Disassembly And Assembly...4238
      Piston Cooling Jet Removal...4239
      Piston Cooling Jet Installation...4239
      Piston Cooling Jet Alignment...4239
      Inspection...4239
      Cylinder Liner Inspection...4240
      Cylinder Liner Removal...4241
      Cylinder Liner Installation...4242
  HEATING, VENTILATION, AIR CONDITIONING...4243
    AIR CONDITIONING SYSTEM FLOW...4245
      Principles...4245
      Chart...4246
    COMPONENTS...4247
      Identification...4247
    SAFETY...4251
      Safety Equipment...4251
    REGULAR MAINTENANCE...4253
      Filter Element Removal And Installation...4253
      Compressor Drive Belt Inspection...4253
      Cleaning The Condenser...4254
    BASIC TROUBLESHOOTING...4255
      Poor A/C Performance...4255
      Compressor Drive Belt Inspection...4256
      Checking The Electrical System...4257
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...4265
      Compressor Oil...4265
      Compressor Oil Check...4265
      Component Replacement And Refrigeration Leaks...4267
    SYSTEM TROUBLESHOOTING CHART...4269
    TEMPERATURE / PRESSURE...4273
      Chart...4273
    AIR CONDITIONING SERVICE...4275
      Chart...4275
    SYSTEM CHARGING AND RECLAMATION...4277
      Reclamation Procedure...4277
      Charging Procedure With A Manifold Gauge Set...4280
      Charging Procedure...4281
    COMPRESSOR...4283
      Removal And Installation...4283
      Compressor Clutch Disassembly And Assembly...4284
    CONDENSER (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)...4289
      Removal And Installation...4289
    CONDENSER (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)...4291
      Removal And Installation...4291
    RECEIVER / DRIER...4293
      Removal And Installation...4293
    PRESSURE SWITCH...4295
      Removal And Installation...4295
    EVAPORATOR / BLOWER UNIT (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)...4297
      Removal And Installation...4297
    EVAPORATOR / BLOWER / HEATER UNIT (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)...4299
      Removal And Installation...4299
    EXPANSION VALVE (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)...4301
      Removal And Installation...4301
    EXPANSION VALVE (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)...4303
      Removal And Installation...4303
    HEATER ASSEMBLY...4305
      Removal And Installation...4305
      Fan Removal And Installation...4306
      Core Removal And Installation...4307
  SPECIFICATIONS...4309
    TELESCOPIC HANDLER SPECIFICATIONS...4311
      Dimensional Specifications...4311
      Performance Specifications...4312
      Engine...4312
      Fan Pump...4312
      Controls...4312
      Drive System...4313
      Tyres...4313
      Capacities...4313
      Hydraulic System...4314
      Electrical System...4314
      Instrument Panel...4314
    ENGINE SPECIFICATIONS...4315
      General...4315
      Cylinder Head...4315
      Valve Guides...4315
      Exhaust Valves...4316
      Intake Valves...4316
      Valve Springs...4316
      Rocker Shaft, Rockers And Bushings...4317
      Pistons And Piston Rings...4317
      Connecting Rods And Bearings...4318
      Crankshaft...4318
      Crankshaft Re-Grind Data...4319
      Main Bearings...4320
      Thrust Washers...4320
      Camshaft And Thrust Washer...4320
      Cylinder Block...4320
      Cylinder Liners...4321
      Fuel Injection Pump...4321
      Fuel Injectors...4321
      Fuel Lift Pump...4321
      Timing Case And Timing Gears...4322
      Oil Pump, Gear And Relief Valve...4323
      Turbocharger...4323
      Flywheel...4323
      Water Pump And Thermostat...4324
      Engine Torque Component...4325
    MACHINE TORQUE SPECIFICATIONS...4327
      Axle...4327
      Boom...4327
      Drive Box...4327
      Drive Motor...4327
      Engine...4328
      Hydraulic Pump...4328
    TORQUE SPECIFICATIONS FOR BOLTS...4329
      Torque for General SAE Bolts...4329
      Torque For General Metric Bolts...4330
    HYDRAULIC CONNECTION SPECIFICATIONS...4331
      O-ring Face Seal Connection...4331
      Straight Thread O-ring Fitting...4331
      Tubelines And Hoses...4331
      Port Seal Fitting...4332
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...4333
      Specifications...4333
    CONVERSIONS...4335
      Decimal And Millimeter Equivalents...4335
      U.S. To Metric Conversion...4335
  ALPHABETICAL INDEX...4337
  SERVICE MANUAL REVISION...4339
    Revision No: T2556, T2566 - 1...4339
6987147 (2-10) - T2250 Telescopic Handler Service Manual...4341
  MAINTENANCE SAFETY...4343
  CONTENTS...4345
  FOREWORD...4347
    FOREWORD...4349
    SAFETY INSTRUCTIONS...4351
    FIRE PREVENTION...4352
      Maintenance...4352
      Operation...4352
      Electrical...4352
      Hydraulic System...4353
      Fueling...4353
      Starting...4353
      Spark Arrestor Exhaust System...4353
      Welding And Grinding...4353
      Fire Extinguishers...4353
    SERIAL NUMBER LOCATION...4354
      Telescopic Handler Serial Number...4354
      Engine Serial Number...4354
      Other Serial Numbers...4354
    DELIVERY REPORT...4354
    BOBCAT telescopic handler IDENTIFICATION...4355
  SAFETY AND MAINTENANCE...4357
    LIFTING AND BLOCKING THE TELESCOPIC HANDLER...4359
      Procedure...4359
    OPERATOR CAB...4361
      Emergency Exit...4361
      Cab Door...4362
      Cab Door Window...4362
    TRANSPORTING THE TELESCOPIC HANDLER...4363
      Loading And Unloading...4363
      Fastening...4363
    TOWING THE TELESCOPIC HANDLER...4365
      Releasing The Brake Discs...4365
      Towing...4366
      Engaging The Brake Discs...4366
    SERVICE SCHEDULE...4367
      Chart...4367
    AIR CLEANER SERVICE...4369
      Replacing The Filter Element...4369
    ENGINE COOLING SYSTEM...4371
      Cleaning The Cooling System...4371
      Checking The Coolant Level...4371
      Replacing The Coolant...4372
    FUEL SYSTEM...4373
      Fuel Specifications...4373
      Filling The Fuel Tank...4373
      Fuel Filter...4374
    ENGINE LUBRICATION SYSTEM...4375
      Checking Engine Oil...4375
      Oil Chart...4375
      Replacing Oil And Filter...4375
    HYDRAULIC / HYDROSTATIC SYSTEM...4377
      Checking And Adding Fluid...4377
      Replacing The Hydraulic / Hydrostatic Filters...4377
      Replacing Hydraulic Fluid...4378
    AXLES (FRONT AND REAR)...4379
      Checking Oil Level (Planetary Carrier)...4379
      Draining Oil (Planetary Carrier)...4379
      Checking Oil Level (Rear Differential)...4380
      Draining Oil (Rear Differential)...4380
      Checking Oil Level (Front Differential)...4381
      Draining Oil (Front Differential)...4381
    LUBRICATION...4383
      Procedure...4383
    TIRE MAINTENANCE...4387
      Wheel Nuts...4387
      Tire Mounting...4387
      Tire Rotation...4387
      Tire Pressure...4387
    APPROVED BOOM STOP...4389
      Installing The Approved Boom Stop...4389
      Removing The Approved Boom Stop...4389
    ENGINE COVER...4391
      Opening And Closing The Engine Cover...4391
    REMOTE START...4393
      Connecting to the Telescopic Handler...4393
      Remote Start Procedure (For Tools MEL1563 and MEL1565)...4395
      Remote Start Procedure (For Tool Kit P/N 6689779)...4396
    ALTERNATOR BELT...4397
      Belt Adjustment...4397
      Belt Replacement...4397
  HYDRAULIC SYSTEM...4399
    HYDRAULIC SYSTEM INFORMATION...4407
      Troubleshooting Chart...4410
      Tightening Procedures...4411
    LIFT CYLINDER...4413
      Removal And Installation...4413
      Parts Identification...4417
      Disassembly...4418
      Assembly...4422
    BUCKET POSITIONING CYLINDER...4427
      Removal And Installation...4427
      Parts Identification...4431
      Disassembly...4432
      Assembly...4435
    EXTENSION CYLINDER...4439
      Cylinder Group Removal And Installation...4439
      Upper Tubeline Removal...4441
      Upper Tubeline Installation...4442
      Extension Cylinder Removal And Installation...4443
      Tubeline Tray Disassembly...4444
      Tubeline Tray Assembly...4446
      Parts Identification...4448
      Disassembly...4449
      Assembly...4453
    TILT CYLINDER...4457
      Removal And Installation...4457
      Parts Identification...4459
      Disassembly...4460
      Assembly...4463
    STEERING CYLINDER (FRONT)...4467
      Removing the Steering Cylinder...4467
      Installing the Steering Cylinder...4468
      Parts Identification...4470
      Disassembling the Steering Cylinder...4471
      Assembling the Steering Cylinder...4472
    STEERING CYLINDER (REAR)...4475
      Removing The Steering Cylinder...4475
      Parts Identification...4478
      Disassembling the Steering Cylinder...4479
      Assembling the Steering Cylinder...4480
    DRIVE BOX...4483
      Parts Identification...4483
      Disassembly...4484
      Assembly...4488
      Special Tools...4491
    MAIN RELIEF VALVE...4493
      Testing And Adjustment...4493
      Removal And Installation...4494
    PORT RELIEF VALVES...4495
      Parts Identification...4495
      Adjustment Procedure...4496
    STEERING MODE VALVE BLOCK...4497
      Removal And Installation...4497
      Parts Identification...4498
      Disassembly...4499
      Solenoid Testing...4501
      Assembly...4501
    BRAKE VALVE...4505
      Removal And Installation...4505
      Disassembly And Assembly...4506
    GEAR PUMP...4509
      Removal And Installation...4509
      Parts Identification...4511
      Disassembly And Assembly...4512
    HYDRAULIC RESERVOIR...4515
      Removal And Installation...4515
    STEERING VALVE...4517
      Removal And Installation...4517
      Parts Identification...4518
      Disassembly...4519
      Inspection...4522
      Assembly...4522
    HYDRAULIC CONTROL VALVE...4527
      Troubleshooting Chart (Controllers)...4527
      Telescoping Valve Section Troubleshooting...4528
      Auxiliary Valve Section Troubleshooting...4532
      Troubleshooting Chart (Control Valve)...4536
      Removal And Installation...4537
      Parts Identification...4541
      Disassembly And Assembly...4542
      End Housing Disassembly And Assembly...4542
      Telescoping and Auxiliary Valve Section Disassembly And Assembly...4543
      Lifting and Tilting Valve Section Disassembly And Assembly...4545
      Inlet-Outlet Valve Section Disassembly And Assembly...4546
    JOYSTICK...4547
      Removal And Installation...4547
    PARKING BRAKE...4549
      Parking Brake Valve Removal And Installation...4549
      Parking Brake Valve Disassembly And Assembly...4550
    WORKGROUP LOCKOUT VALVE...4553
      Testing...4553
      Removal And Installation...4554
      Disassembly And Assembly...4555
    TOW VALVE...4557
      Removal And Installation...4557
      Disassembly And Assembly...4558
    FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE...4563
      Removal And Installation...4563
      Disassembly And Assembly...4564
    MANIFOLD...4569
      Removal And Installation...4569
      Disassembly...4571
  HYDROSTATIC SYSTEM...4573
    HYDROSTATIC SYSTEM INFORMATION...4575
      Troubleshooting Chart...4575
      Replenishing Valve Function...4576
    OIL COOLER...4577
      Removal And Installation...4577
    HYDROSTATIC DRIVE MOTOR...4579
      Removal And Installation...4579
      Parts Identification...4580
      Disassembly...4583
      Inspection...4594
      Assembly...4596
    HYDROSTATIC PUMP (For S/N AC1911001 - 11999)...4609
      Removal And Installation...4609
      Parts Identification...4611
      Disassembly...4616
      Inspection...4628
      Assembly...4632
    HYDROSTATIC PUMP (FOR S/N AC1912000 & ABOVE)...4647
      Removal And Installation...4647
      Parts Identification...4649
      Shaft Disassembly...4654
      Relief Valves Disassembly And Assembly...4656
      Charge Pump Disassembly...4657
      Piston Pump Disassembly...4659
      Solenoid Block Disassembly...4663
      Inspection...4665
      Piston Pump Assembly...4668
      Charge Pump Assembly...4672
      Solenoid Block Assembly...4674
      Shaft Assembly...4676
    DRIVE BELT...4679
      Description...4679
      Shield Removal And Installation...4679
      Adjusting...4680
      Belt Removal And Installation...4681
      Tensioner Pulley Removal And Installation...4682
      Tensioner Pulley Parts Identification...4684
      Tensioner Pulley Disassembly And Assembly...4685
  DRIVE SYSTEM...4689
    TROUBLESHOOTING...4691
      Chart...4691
    AXLE AND DIFFERENTIAL (FRONT)...4693
      Description...4693
      Planetary Carrier And Wheel Hub Parts Identification...4693
      Planetary Carrier Disassembly...4694
      Wheel Hub Disassembly...4696
      Steering Knuckle And Drive Shaft Parts Identification...4699
      Steering Knuckle Disassembly...4700
      Axle Housing / Drive Shaft Disassembly...4704
      Brake Group Parts Identification...4707
      Brake Group Disassembly...4708
      Differential Parts Identification...4712
      Differential Disassembly...4713
      Pinion Group Parts Identification...4716
      Pinion Group Disassembly...4717
      Pinion Group Assembly...4719
      Differential Assembly...4725
      Brake Group Assembly...4728
      Axle Housing / Drive Shaft Assembly...4732
      Steering Knuckle Assembly...4735
      Wheel Hub Assembly...4741
      Planetary Carrier Assembly...4742
      Special Tools...4745
    AXLE AND DIFFERENTIAL (REAR)...4747
      Description...4747
      Planetary Carrier And Wheel Hub Parts Identification...4747
      Planetary Carrier Disassembly...4748
      Wheel Hub Disassembly...4750
      Steering Knuckle and Drive Shaft Parts Identification...4753
      Steering Knuckle Disassembly...4754
      Axle Housing / Drive Shaft Disassembly...4758
      Differential Parts Identification...4761
      Pinion Group Parts Identification...4766
      Pinion Group Disassembly...4767
      Pinion Group Assembly...4771
      Differential Assembly...4779
      Steering Knuckle Assembly...4783
      Planetary Carrier Assembly...4789
      Special Tools...4794
    FRONT AXLE...4795
      Removal...4795
      Installation...4799
    AXLE TOE-IN...4803
      Adjustment...4803
    PARKING BRAKE...4805
      Releasing The Brake Discs...4805
      Engaging The Brake Discs...4806
    STEERING ANGLE ADJUSTMENT...4807
      Adjustment...4807
    DRIVESHAFT...4809
      Removal And Installation...4809
    SERVICE BRAKE...4811
      Description...4811
      Bleeding The Brake Circuit...4811
    REAR AXLE...4813
      Removal...4813
      Installation...4816
  MAIN FRAME...4819
    OPERATOR CAB (S/N AC1912999 & bELOW)...4823
      Removal And Installation...4823
    OPERATOR CAB (S/N AC1913000 & ABOVE)...4831
      Removal And Installation...4831
    OPERATOR SEAT...4839
      Removal And Installation...4839
      Assembly And Disassembly...4839
    BOOM ASSEMBLY...4843
      Removal And Installation...4843
    INNER BOOM...4847
      Removal...4847
      Installation...4849
    WEAR PADS (FRONT)...4851
      Removal And Installation...4851
    WEAR PADS (REAR)...4853
      Removal...4853
      Installation...4853
    ENGINE COVER...4855
      Locking Mechanism Removal And Installation...4855
      Removal And Installation...4855
      Lock...4856
    FUEL TANK...4857
      Removal And Installation...4857
    BOB-TACH...4859
      Removal And Installation...4859
    REAR WEIGHTS...4861
      Removal And Installation...4861
    FENDER...4863
      Removal And Installation...4863
    JOYSTICK PANEL (S/N AC1912999 & bELOW)...4865
      Joystick Panel Cover Removal and Installation...4865
    JOYSTICK PANEL...4867
      Joystick Panel Cover Removal and Installation...4867
    DASH COVER/STEERING COLUMN COVER (S/N AC1912999 & bELOW)...4869
      Steering Column Cover Removal And Installation...4869
      Dash Cover Removal And Installation...4870
    DASH COVER/STEERING COLUMN COVER (S/N AC1913000 & ABOVE)...4871
      Removal And Installation...4871
  ELECTRICAL SYSTEM AND ANALYSIS...4875
    ELECTRICAL SYSTEM INFORMATION (S/N AC1912999 & bELOW)...4892
      Troubleshooting Chart...4892
      Description...4893
      Fuses, Diodes And Relays...4893
    ELECTRICAL SYSTEM INFORMATION (S/N AC1913000 & ABOVE)...4896
      Troubleshooting Chart...4896
      Description...4897
      Fuses, Diodes And Relays...4897
    BATTERY...4900
      Removal And Installation...4900
      Servicing...4901
      Using A Booster Battery (Jump Starting)...4902
    ALTERNATOR...4904
      Removal And Installation...4904
      Adjusting The Alternator Belt...4905
    STARTER...4906
      Testing...4906
      Removal And Installation...4907
      Parts Identification...4909
    LIGHTS...4910
      Rear Light Removal And Installation...4910
      Rear Light Removal And Installation...4911
      Front Light Removal And Installation...4912
    TRAVEL LEVER (S/N AC1912999 & bELOW)...4914
      Removal And Installation...4914
    TRAVEL LEVER (S/N AC1913000 & above)...4916
      Removal And Installation...4916
    INSTRUMENT PANEL (S/N AC1912999 & BELOW)...4918
      Removal And Installation...4918
    INSTRUMENT PANEL (S/N AC1913000 & ABOVE)...4920
      Removal And Installation...4920
    SWITCH PANEL (S/N AC1913000 & ABOVE)...4922
      Removal And Installation...4922
    FRONT WIPER MOTOR...4924
      Removal And Installation...4924
    TOP WIPER MOTOR...4926
      Removal And Installation...4926
    REAR WIPER MOTOR...4930
      Removal And Installation...4930
    PEDAL ASSEMBLY...4934
      Removal And Installation...4934
      Disassembly And Assembly...4935
    INCHING SWITCH...4940
      Removal And Installation...4940
      Adjustment...4940
      Inching Control Calibration (Display Controller)...4941
    SERVICE SOFTWARE...4944
      Connecting Remote Start Tool to Laptop Computer...4944
      Connecting Remote Start Tool (Service Tool)...4944
      Connecting Remote Start Tool to Telescopic Handler...4945
      Entering The Service Software...4946
      Calibrate Inch Pedal...4947
    MAIN CONTROLLER...4950
      Removal And Installation...4950
      Connector Identification...4951
    DIAGNOSTIC SERVICE CODES...4952
      Viewing Service Codes...4952
      Service Codes List...4953
  ENGINE SERVICE...4958
    ENGINE INFORMATION...4962
      Description...4962
      Troubleshooting...4963
      Compression - Checking...4965
    ENGINE AND ENGINE MOUNTS...4966
      Removal And Installation...4966
    ENGINE AND HYDROSTAT ASSEMBLY...4970
      Removal And Installation...4970
    ENGINE SPEED CONTROL...4980
      Removal And Installation...4980
    MUFFLER...4982
      Removal And Installation...4982
    AIR CLEANER...4984
      Removal And Installation...4984
      Air Intake Cowling Removal And Installation...4984
    ENGINE COOLING SYSTEM...4986
      Radiator Removal And Installation...4986
      Fan Removal And Installation...4988
      Water Pump Removal And Installation...4988
      Water Pump Disassembly And Assembly...4989
      Thermostat Housing Removal And Installation...4989
    LUBRICATION SYSTEM...4992
      Oil Pan Removal And Installation...4992
      Oil Pump Removal And Installation...4993
      Oil Pump Inspection...4993
      Oil Filter Cooler Removal And Installation...4995
      Engine Oil Pressure - Testing...4996
    FUEL SYSTEM...4998
      Fuel Camshaft Removal And Installation...4998
      Injection Pump Governor Housing Removal And Installation...5000
      Injection Pump Governor Housing Disassembly And Assembly...5002
      Fuel Shutoff Solenoid - Checking...5004
      Fuel Shutoff Solenoid - Removal And Installation...5004
      Fuel Injection Pump Removal And Installation...5005
      Fuel Injection Pump Housing Removal...5013
      Fuel Injection Pump Housing Installation...5017
      Injection Pump Timing...5020
      Fuel Injector Removal and Installation...5023
      Fuel Injector Nozzle Pressure - Checking...5025
      Nozzle Spraying Condition...5025
      Valve Seat Tightness...5026
    CYLINDER HEAD...5028
      Intake Air Heater - Testing...5028
      Intake Air Heater Removal And Installation...5028
      Valve Clearance Adjustment...5029
      Valve Timing - Checking...5030
      Cylinder Head Removal And Installation...5031
      Cylinder Head Disassembly And Assembly...5034
      Cylinder Head - Servicing...5034
      Cylinder Head Top Clearance...5035
      Valve Guide - Checking...5036
      Reconditioning The Valve And Valve Seat...5038
      Valve Spring...5040
      Valve Tappets...5041
      Rocker Arm And Shaft - Checking...5042
    CRANKSHAFT AND PISTONS...5044
      Piston And Connecting Rod Removal And Installation...5044
      Piston And Connecting Rod - Servicing...5046
      Cylinder Bore Checking...5051
      Connecting Rod Alignment...5052
      Crankshaft Gear Removal And Installation...5052
      Crankshaft And Bearings Removal and Installation...5053
      Crankshaft And Bearings - Servicing...5057
    CAMSHAFT AND TIMING GEARS...5064
      Timing Gearcase Cover Removal And Installation...5064
      Timing Gears Backlash - Checking...5065
      Camshaft - Servicing...5066
      Idle Gear And Shaft Removal And Installation...5068
      Idler Gear And Shaft - Servicing...5069
      Balancer Shaft Servicing...5072
    TURBOCHARGER...5074
      Description...5074
      Testing...5074
      Removal And Installation...5075
    FLYWHEEL AND HOUSING...5076
      Flywheel Removal And Installation...5076
      Ring Gear Removal And Installation...5076
      Housing Removal And Installation...5077
    EXHAUST GAS RECIRCULATION (EGR) SYSTEM...5078
      Checking The Function Of EGR System...5078
      Disassembly And Assembly...5081
  HEATING, VENTILATION, AIR CONDITIONING...5084
    AIR CONDITIONING SYSTEM FLOW...5086
      Description...5086
      Chart...5087
    COMPONENTS (S/N AC1912999 & bELOW)...5088
      Identification...5088
    COMPONENTS (S/N AC1913000 & ABOVE)...5090
      Identification...5090
    SAFETY...5092
      Safety Equipment...5092
    REGULAR MAINTENANCE...5094
      Filter Element Removal And Installation...5094
      Compressor And Alternator Drive Belt Inspection...5094
      Cleaning The Condenser...5095
    BASIC TROUBLESHOOTING...5096
      Poor A/C Performance...5096
      Compressor And Alternator Drive Belt Inspection...5097
      Checking The Electrical System...5097
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...5104
      Compressor Oil...5104
      Compressor Oil Check...5104
      Component Replacement And Refrigeration Leaks...5106
    SYSTEM TROUBLESHOOTING CHART...5108
      Chart...5108
      Gauge Pressure Related Troubleshooting...5109
    TEMPERATURE AND PRESSURE...5112
      Chart...5112
    AIR CONDITIONING SERVICE...5114
      Chart...5114
    SYSTEM CHARGING AND RECLAMATION...5116
      Reclamation Procedure...5116
      Charging Procedure With A Manifold Gauge Set...5120
    COMPRESSOR...5124
      Removal And Installation...5124
      Compressor Clutch Disassembly And Assembly...5125
    CONDENSER (S/N AC1912999 & bELOW)...5130
      Removal And Installation...5130
    CONDENSER (S/N AC1912999 & bELOW)...5132
      Removal And Installation...5132
    RECEIVER / DRIER...5134
      Removal And Installation...5134
    PRESSURE SWITCH...5136
      Removal And Installation...5136
    EVAPORATOR/BLOWER UNIT (S/N AC1912999 & bELOW)...5138
      Removal And Installation...5138
    EVAPORATOR/BLOWER UNIT (S/N AC1913000 & ABOVE)...5142
      Removal And Installation...5142
    EXPANSION VALVE (S/N AC1912999 & bELOW)...5144
      Removal And Installation...5144
    EXPANSION VALVE (S/N A8G813000 & ABOVE)...5146
      Removal And Installation...5146
    HEATER ASSEMBLY...5148
      Removal And Installation...5148
      Fan Removal And Installation...5149
      Core Removal And Installation...5149
  SPECIFICATIONS...5152
    (T2250) TELESCOPIC HANDLER SPECIFICATIONS...5154
      Dimensional Specifications...5154
      Performance Specifications...5155
      Weights...5155
      Engine...5155
      Controls...5156
      Drive System...5156
      Traction...5156
      Steering...5156
      Brakes...5156
      Fluid Capacities...5157
      Hydraulic System...5157
      Electrical...5157
      Instruments...5158
      Environmental...5158
      Temperature Range...5158
    ENGINE SPECIFICATIONS...5160
      General...5160
      Fuel System...5160
      Cylinder Head...5160
      Valve Guides...5161
      Valve Tappets...5161
      Exhaust Valves...5161
      Intake Valves...5162
      Valve Springs...5162
      Valve Timing...5162
      Rocker Arm...5162
      Camshaft...5164
      Timing Gear...5164
      Piston And Piston Ring...5166
      Connecting Rod...5166
      Cylinder Bore...5166
      Crankshaft...5166
      Oil Pump...5167
      Cooling System...5167
      Intake Air Heater...5167
      Torque Values...5168
      Engine Torque Component...5169
    MACHINE TORQUE SPECIFICATIONS...5170
      Specifications...5170
    TORQUE SPECIFICATIONS FOR BOLTS...5172
      Torque for General SAE Bolts...5172
      Torque For General Metric Bolts...5173
    HYDRAULIC CONNECTION SPECIFICATIONS...5174
      O-ring Face Seal Connection...5174
      Straight Thread O-ring Fitting...5174
      Tubelines And Hoses...5174
      Flare Fitting...5175
      O-ring Flare Fitting...5176
      Port Seal Fitting...5178
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...5180
      Specifications...5180
    CONVERSIONS...5184
      Decimal And Millimeter Equivalents...5184
      U.S. To Metric Conversion...5185
  ALPHABETICAL INDEX...5186
6987147 (8-12) - T2250 Telescopic Handler Service Manual...5188
  MAINTENANCE SAFETY...5190
  CONTENTS...5192
  FOREWORD...5194
    FOREWORD...5196
    SAFETY INSTRUCTIONS...5198
    FIRE PREVENTION...5199
      Maintenance...5199
      Operation...5199
      Electrical...5199
      Hydraulic System...5200
      Fueling...5200
      Starting...5200
      Spark Arrestor Exhaust System...5200
      Welding And Grinding...5200
      Fire Extinguishers...5200
    SERIAL NUMBER LOCATION...5201
      Telescopic Handler Serial Number...5201
      Engine Serial Number...5201
      Other Serial Numbers...5201
    DELIVERY REPORT...5201
    BOBCAT TELESCOPIC HANDLER IDENTIFICATION...5202
  SAFETY AND MAINTENANCE...5204
    LIFTING AND BLOCKING THE TELESCOPIC HANDLER...5206
      Procedure...5206
    OPERATOR CAB (ROPS / FOPS)...5208
      Emergency Exit...5208
      Cab Door...5209
      Cab Door Window...5209
    TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER...5210
      Loading And Unloading...5210
      Fastening...5210
    TOWING THE TELESCOPIC HANDLER...5212
      Releasing The Brake Discs...5212
      Towing...5213
      Engaging The Brake Discs...5213
    SERVICE SCHEDULE...5214
      Chart...5214
    AIR CLEANER SERVICE...5216
      Replacing The Filter Element...5216
    ENGINE COOLING SYSTEM...5218
      Cleaning...5218
      Removing And Replacing The Coolant...5219
      Checking Level...5220
    FUEL SYSTEM...5222
      Fuel Specifications...5222
      Filling The Fuel Tank...5222
      Fuel Filter...5223
    ENGINE LUBRICATION SYSTEM...5224
      Checking Engine Oil...5224
      Oil Chart...5224
      Replacing Oil And Filter...5224
    HYDRAULIC / HYDROSTATIC SYSTEM...5226
      Checking And Adding Fluid...5226
      Replacing The Hydraulic / Hydrostatic Filters...5226
      Replacing Hydraulic Fluid...5227
    ATTACHMENT CARRIER...5228
      Inspection And Maintenance...5228
    BOB-TACH (HAND LEVER) (IF EQUIPPED)...5230
      Inspection And Maintenance...5230
    AXLES (FRONT AND REAR)...5232
      Checking Oil Level (Planetary Carrier)...5232
      Draining Oil (Planetary Carrier)...5232
      Checking Oil Level (Rear Differential)...5233
      Draining Oil (Rear Differential)...5233
      Checking Oil Level (Front Differential)...5234
      Draining Oil (Front Differential)...5234
    LUBRICATING THE TELESCOPING HANDLER...5236
      Procedure...5236
    TIRE MAINTENANCE...5240
      Wheel Nuts...5240
      Tire Mounting...5240
      Tire Rotation...5240
      Tire Pressure...5240
    APPROVED BOOM STOP (IF EQUIPPED)...5242
      Installing The Approved Boom Stop...5242
      Removing The Approved Boom Stop...5242
    ENGINE COVER...5244
      Opening And Closing The Engine Cover...5244
    REMOTE START...5246
      Connecting to the Telescopic Handler...5246
      Remote Start Procedure (For Tools MEL1563 and MEL1565)...5248
      Remote Start Procedure (For Tool Kit P/N 6689779)...5249
    TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE...5250
      Storage...5250
      Return to Service...5250
    STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER...5252
      Procedure...5252
    EMERGENCY EXIT...5254
      Rear Window...5254
  HYDRAULIC SYSTEM...5256
    HYDRAULIC / HYDROSTATIC SCHEMATIC...5260
    HYDRAULIC SYSTEM INFORMATION...5266
      Troubleshooting Chart...5269
      Tightening Procedures...5270
    LIFT CYLINDER...5272
      Removal And Installation...5272
      Parts Identification...5276
      Disassembly...5277
      Assembly...5281
    BUCKET POSITIONING CYLINDER...5286
      Removal And Installation...5286
      Parts Identification...5290
      Disassembly...5291
      Assembly...5294
    EXTENSION CYLINDER...5298
      Cylinder Group Removal And Installation...5298
      Upper Tubeline Removal...5300
      Upper Tubeline Installation...5301
      Extension Cylinder Removal And Installation...5302
      Tubeline Tray Disassembly...5303
      Tubeline Tray Assembly...5305
      Parts Identification...5307
      Disassembly...5308
      Assembly...5312
    TILT CYLINDER...5316
      Removal And Installation...5316
      Parts Identification...5318
      Disassembly...5319
      Assembly...5322
    STEERING CYLINDER (FRONT)...5326
      Removing the Steering Cylinder...5326
      Installing the Steering Cylinder...5327
      Parts Identification...5329
      Disassembling the Steering Cylinder...5330
      Assembling the Steering Cylinder...5331
    STEERING CYLINDER (REAR)...5334
      Removing The Steering Cylinder...5334
      Parts Identification...5337
      Disassembling the Steering Cylinder...5338
      Assembling the Steering Cylinder...5339
    DRIVE BOX...5342
      Parts Identification...5342
      Disassembly...5343
      Assembly...5347
      Special Tools...5350
    MAIN RELIEF VALVE...5352
      Testing And Adjustment...5352
      Removal And Installation...5353
    PORT RELIEF VALVES...5354
      Parts Identification...5354
      Adjustment Procedure...5355
    STEERING MODE VALVE BLOCK...5356
      Removal And Installation...5356
      Parts Identification...5357
      Disassembly...5358
      Solenoid Testing...5360
      Assembly...5360
    BRAKE VALVE...5364
      Removal And Installation...5364
      Disassembly And Assembly...5365
    GEAR PUMP...5368
      Removal And Installation...5368
      Parts Identification...5370
      Disassembly And Assembly...5371
    HYDRAULIC FLUID RESERVOIR...5374
      Removal And Installation...5374
    STEERING VALVE...5376
      Removal And Installation...5376
      Parts Identification...5377
      Disassembly...5378
      Inspection...5381
      Assembly...5381
    HYDRAULIC CONTROL VALVE (FOR S/N AC1911001 - 11251)...5386
      Troubleshooting Chart (Controllers)...5386
      Telescoping Valve Section Troubleshooting...5387
      Auxiliary Valve Section Troubleshooting...5391
      Troubleshooting Chart (Control Valve)...5395
      Removal And Installation...5396
      Parts Identification...5400
      Disassembly And Assembly...5401
      End Housing Disassembly And Assembly...5401
      Telescoping and Auxiliary Valve Section Disassembly And Assembly...5402
      Lifting and Tilting Valve Section Disassembly And Assembly...5404
      Inlet-Outlet Valve Section Disassembly And Assembly...5405
    HYDRAULIC CONTROL VALVE (FOR S/N AC1911252 & ABOVE)...5406
      Troubleshooting Chart (Controllers)...5406
      Telescoping Valve Section Troubleshooting...5407
      Auxiliary Valve Section Troubleshooting...5411
      Troubleshooting Chart (Control Valve)...5415
      Removal And Installation...5416
      Parts Identification...5422
      Disassembly And Assembly...5423
      End Housing Disassembly And Assembly...5423
      Telescoping and Auxiliary Valve Section Disassembly And Assembly...5424
      Lifting and Tilting Valve Section Disassembly And Assembly...5426
      Inlet-Outlet Valve Section Disassembly And Assembly...5427
    JOYSTICK...5428
      Removal And Installation...5428
    PARKING BRAKE...5430
      Parking Brake Valve Removal And Installation...5430
      Parking Brake Valve Disassembly And Assembly...5431
    WORKGROUP LOCKOUT VALVE...5434
      Testing...5434
      Removal And Installation...5435
      Disassembly And Assembly...5436
    TOW VALVE...5438
      Removal And Installation...5438
      Disassembly And Assembly...5439
    FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE...5444
      Removal And Installation...5444
      Disassembly And Assembly...5445
    MANIFOLD (FOR S/N AC1911001 - 11251)...5450
      Removal And Installation...5450
      Disassembly...5452
    MANIFOLD (FOR S/N AC1911252 & ABOVE)...5454
      Removal And Installation...5454
      Disassembly...5455
  HYDROSTATIC SYSTEM...5460
    HYDROSTATIC SYSTEM INFORMATION...5462
      Troubleshooting Chart...5462
      Replenishing Valve Function...5463
    OIL COOLER...5464
      Removal And Installation...5464
    HYDROSTATIC DRIVE MOTOR...5466
      Removal And Installation...5466
      Parts Identification...5467
      Disassembly...5470
      Inspection...5481
      Assembly...5483
    HYDROSTATIC PUMP (FOR S/N AC1911001 - 11999)...5496
      Removal And Installation...5496
      Parts Identification...5498
      Disassembly...5503
      Inspection...5515
      Assembly...5519
    HYDROSTATIC PUMP (FOR S/N AC1912000 & ABOVE)...5534
      Removal And Installation...5534
      Parts Identification...5536
      Shaft Disassembly...5541
      Relief Valves Disassembly And Assembly...5543
      Charge Pump Disassembly...5544
      Piston Pump Disassembly...5546
      Solenoid Block Disassembly...5550
      Inspection...5552
      Piston Pump Assembly...5555
      Charge Pump Assembly...5559
      Solenoid Block Assembly...5561
      Shaft Assembly...5563
    DRIVE BELT...5566
      Description...5566
      Shield Removal And Installation...5566
      Belt Adjustment...5567
      Belt Removal And Installation...5568
      Tensioner Pulley Removal And Installation...5569
      Tensioner Pulley Parts Identification...5571
      Tensioner Pulley Disassembly And Assembly...5572
  DRIVE SYSTEM...5576
    TROUBLESHOOTING...5578
      Chart...5578
    AXLE AND DIFFERENTIAL (FRONT)...5580
      Description...5580
      Planetary Carrier And Wheel Hub Parts Identification...5580
      Planetary Carrier Disassembly...5581
      Wheel Hub Disassembly...5583
      Steering Knuckle And Drive Shaft Parts Identification...5586
      Steering Knuckle Disassembly...5587
      Axle Housing / Drive Shaft Disassembly...5591
      Brake Group Parts Identification...5594
      Brake Group Disassembly...5595
      Differential Parts Identification...5599
      Differential Disassembly...5600
      Pinion Group Parts Identification...5603
      Pinion Group Disassembly...5604
      Pinion Group Assembly...5606
      Differential Assembly...5612
      Brake Group Assembly...5615
      Axle Housing / Drive Shaft Assembly...5619
      Steering Knuckle Assembly...5622
      Wheel Hub Assembly...5628
      Planetary Carrier Assembly...5629
      Special Tools...5632
    AXLE AND DIFFERENTIAL (REAR)...5634
      Description...5634
      Planetary Carrier And Wheel Hub Parts Identification...5634
      Planetary Carrier Disassembly...5635
      Wheel Hub Disassembly...5637
      Steering Knuckle and Drive Shaft Parts Identification...5640
      Steering Knuckle Disassembly...5641
      Axle Housing / Drive Shaft Disassembly...5645
      Differential Parts Identification...5648
      Pinion Group Parts Identification...5653
      Pinion Group Disassembly...5654
      Pinion Group Assembly...5658
      Differential Assembly...5666
      Steering Knuckle Assembly...5670
      Planetary Carrier Assembly...5676
      Special Tools...5681
    FRONT AXLE...5682
      Removal...5682
      Installation...5686
    AXLE TOE-IN...5690
      Adjustment...5690
    PARKING BRAKE...5692
      Releasing The Brake Discs...5692
      Engaging The Brake Discs...5693
    STEERING ANGLE ADJUSTMENT...5694
      Adjustment...5694
    DRIVE SHAFT...5696
      Removal And Installation...5696
    SERVICE BRAKE...5698
      Description...5698
      Bleeding The Brake Circuit...5698
    REAR AXLE...5700
      Removal...5700
      Installation...5703
  MAIN FRAME...5706
    OPERATOR CAB (S/N AC1912999 & BELOW)...5708
      Removal And Installation...5708
    OPERATOR CAB (S/N AC1913000 & ABOVE)...5716
      Removal And Installation...5716
    OPERATOR SEAT...5722
      Removal And Installation...5722
      Assembly And Disassembly...5722
    BOOM ASSEMBLY...5726
      Removal And Installation...5726
    INNER BOOM...5730
      Removal...5730
      Installation...5732
    WEAR PADS (FRONT)...5734
      Removal And Installation...5734
    WEAR PADS (REAR)...5736
      Removal...5736
      Installation...5736
    ENGINE COVER...5738
      Locking Mechanism Removal And Installation...5738
      Removal And Installation...5738
      Lock...5739
    FUEL TANK...5740
      Removal And Installation...5740
    BOB-TACH...5742
      Removal And Installation...5742
    COUNTERWEIGHT...5744
      Removal And Installation...5744
    FENDER...5746
      Removal And Installation...5746
    JOYSTICK PANEL (S/N AC1912999 & bELOW)...5748
      Joystick Panel Cover Removal and Installation...5748
    JOYSTICK PANEL (S/N AC1913000 & ABOVE)...5750
      Joystick Panel Cover Removal and Installation...5750
    DASH COVER/STEERING COLUMN COVER (S/N AC1912999 & BELOW)...5752
      Steering Column Cover Removal And Installation...5752
      Dash Cover Removal And Installation...5753
    DASH COVER/STEERING COLUMN COVER (S/N AC1913000 & ABOVE)...5754
      Removal And Installation...5754
  ELECTRICAL SYSTEM AND ANALYSIS...5758
    ELECTRICAL SCHEMATIC...5760
    ELECTRICAL SYSTEM INFORMATION (S/N AC1912999 & BELOW)...5812
      Troubleshooting Chart...5812
      Description...5813
      Fuses, Diodes And Relays...5813
    ELECTRICAL SYSTEM INFORMATION (S/N AC1913000 & ABOVE)...5816
      Troubleshooting Chart...5816
      Description...5817
      Fuses, Diodes And Relays...5817
    BATTERY...5820
      Removal And Installation...5820
      Servicing...5821
      Using A Booster Battery (Jump Starting)...5822
    ALTERNATOR...5824
      Removal And Installation...5824
      Belt Adjustment...5825
      Belt Replacement...5825
    STARTER...5826
      Testing...5826
      Removal And Installation...5827
    LIGHTS...5830
      Rear Light Removal And Installation...5830
      Front Light Removal And Installation...5832
    TRAVEL LEVER (S/N AC1912999 & BELOW)...5834
      Removal And Installation...5834
    TRAVEL LEVER (S/N AC1913000 & ABOVE)...5836
      Removal And Installation...5836
    INSTRUMENT PANEL (S/N AC1912999 & BELOW)...5838
      Removal And Installation...5838
    INSTRUMENT PANEL (S/N AC1913000 & ABOVE)...5840
      Removal And Installation...5840
    SWITCH PANEL (S/N AC1913000 & ABOVE)...5842
      Removal And Installation...5842
    FRONT WIPER MOTOR...5844
      Removal And Installation...5844
    TOP WIPER MOTOR...5846
      Removal And Installation...5846
    REAR WIPER MOTOR...5850
      Removal And Installation...5850
    PEDAL ASSEMBLY...5854
      Removal And Installation...5854
      Disassembly And Assembly...5855
    INCHING SWITCH...5860
      Removal And Installation...5860
      Adjustment...5860
      Inching Control Calibration (Display Controller)...5861
    SERVICE SOFTWARE...5864
      Connecting Remote Start Tool to Laptop Computer...5864
      Connecting Remote Start Tool (Service Tool)...5864
      Connecting Remote Start Tool to Telescopic Handler...5865
      Entering The Service Software...5866
      Calibrate Inch Pedal...5867
    MAIN CONTROLLER...5870
      Removal And Installation...5870
      Connector Identification...5871
    DIAGNOSTIC SERVICE CODES...5872
      Viewing Service Codes...5872
      Service Codes List...5873
    LONGITUDINAL STABILITY INDICATOR CALIBRATION (S/N AC1911001-14999)...5878
      Fitting The Sensor...5878
      Calibration Procedure...5878
    LLMI / LLMC SYSTEM (S/N AC1915000 & ABOVE)...5880
      System Calibration...5880
      Calibration Test...5882
      System Failure Reports...5883
      System Components Identification...5887
      LLMS Removal...5889
      LLMS Installation...5891
      LLMC Controller Removal...5894
      LLMC Controller Installation...5897
  ENGINE SERVICE...5900
    ENGINE INFORMATION...5902
      Description...5902
      Specifications...5903
      Troubleshooting...5911
      Compression - Checking...5913
    ENGINE AND ENGINE MOUNTS...5914
      Removal And Installation...5914
    ENGINE AND HYDROSTAT ASSEMBLY...5918
      Removal And Installation...5918
    ENGINE SPEED CONTROL...5928
      Removal And Installation...5928
    MUFFLER...5930
      Removal And Installation...5930
    AIR CLEANER...5932
      Removal And Installation...5932
      Air Intake Cowling Removal And Installation...5932
    ENGINE COOLING SYSTEM...5934
      Radiator Removal And Installation...5934
      Fan Removal And Installation...5936
      Water Pump Removal And Installation...5936
      Water Pump Disassembly And Assembly...5937
      Thermostat Housing Removal And Installation...5937
    LUBRICATION SYSTEM...5940
      Oil Pan Removal And Installation...5940
      Oil Pump Removal And Installation...5941
      Oil Pump Inspection...5941
      Oil Filter Cooler Removal And Installation...5943
      Engine Oil Pressure - Testing...5944
    FUEL SYSTEM...5946
      Fuel Camshaft Removal And Installation...5946
      Injection Pump Governor Housing Removal And Installation...5948
      Injection Pump Governor Housing Disassembly And Assembly...5950
      Fuel Shutoff Solenoid - Checking...5952
      Fuel Shutoff Solenoid - Removal And Installation...5952
      Fuel Injection Pump Removal And Installation...5953
      Fuel Injection Pump Housing Removal...5961
      Fuel Injection Pump Housing Installation...5965
      Injection Pump Timing...5968
      Fuel Injector Removal and Installation...5971
      Fuel Injector Nozzle Pressure - Checking...5973
      Nozzle Spraying Condition...5973
      Valve Seat Tightness...5974
    CYLINDER HEAD...5976
      Intake Air Heater - Testing...5976
      Intake Air Heater Removal And Installation...5976
      Valve Clearance Adjustment...5977
      Valve Timing - Checking...5978
      Cylinder Head Removal And Installation...5979
      Cylinder Head Disassembly And Assembly...5982
      Cylinder Head - Servicing...5982
      Cylinder Head Top Clearance...5983
      Valve Guide - Checking...5984
      Reconditioning The Valve And Valve Seat...5986
      Valve Spring...5988
      Valve Tappets...5989
      Rocker Arm And Shaft - Checking...5990
    CRANKSHAFT AND PISTONS...5992
      Piston And Connecting Rod Removal And Installation...5992
      Piston And Connecting Rod - Servicing...5994
      Cylinder Bore Checking...5999
      Connecting Rod Alignment...6000
      Crankshaft Gear Removal And Installation...6000
      Crankshaft And Bearings Removal and Installation...6001
      Crankshaft And Bearings - Servicing...6005
    CAMSHAFT AND TIMING GEARS...6012
      Timing Gearcase Cover Removal And Installation...6012
      Timing Gears Backlash - Checking...6013
      Camshaft - Servicing...6014
      Idle Gear And Shaft Removal And Installation...6016
      Idler Gear And Shaft - Servicing...6017
      Balancer Shaft Servicing...6020
    TURBOCHARGER...6022
      Description...6022
      Testing...6022
      Removal And Installation...6023
    FLYWHEEL AND HOUSING...6024
      Flywheel Removal And Installation...6024
      Ring Gear Removal And Installation...6024
      Housing Removal And Installation...6025
    EXHAUST GAS RECIRCULATION (EGR) SYSTEM...6026
      Checking The Function Of EGR System...6026
      Disassembly And Assembly...6029
  HEATING, VENTILATION, AIR CONDITIONING...6032
    AIR CONDITIONING SYSTEM FLOW...6034
      Description...6034
      Chart...6035
      Components...6036
      Safety Equipment...6040
    REGULAR MAINTENANCE...6042
      Filters...6042
      Compressor And Alternator Drive Belt Inspection...6043
      Cleaning The Condenser...6044
      Air Conditioning Lubrication...6044
      Air Conditioning Service Chart...6045
    TROUBLESHOOTING...6046
      Gauge Pressure Related Troubleshooting...6047
      Troubleshooting Tree...6049
      Temperature / Pressure Chart...6053
      Poor A/C Performance...6054
      HVAC Repair And Leaks...6055
      Checking The Electrical System...6056
    SYSTEM CHARGING AND RECLAMATION...6062
      Reclamation Procedure...6062
      Charging Procedure With A Manifold Gauge Set...6066
    COMPRESSOR...6070
      Removal And Installation...6070
      Compressor Oil...6072
      Compressor Oil Check...6072
      Compressor Clutch Disassembly And Assembly...6074
    CONDENSER (S/N AC1912999 & BELOW)...6078
      Removal And Installation...6078
    CONDENSER (S/N AC1913000 & ABOVE)...6080
      Removal And Installation...6080
    RECEIVER / DRIER...6082
      Removal And Installation...6082
    PRESSURE SWITCH...6084
      Removal And Installation...6084
    EVAPORATOR/BLOWER UNIT (S/N AC1912999 & BELOW)...6086
      Removal And Installation...6086
    EVAPORATOR/BLOWER UNIT (S/N AC1913000 & ABOVE)...6090
      Removal And Installation...6090
    EXPANSION VALVE (S/N AC1912999 & BELOW)...6092
      Removal And Installation...6092
    EXPANSION VALVE (S/N AC1913000 & ABOVE)...6094
      Removal And Installation...6094
    HEATER ASSEMBLY...6096
      Removal And Installation...6096
      Fan Removal And Installation...6097
      Core Removal And Installation...6098
  SPECIFICATIONS...6100
    (T2250) TELESCOPIC HANDLER SPECIFICATIONS...6102
      Machine Dimensions...6102
      Performance...6103
      Weights...6103
      Engine...6103
      Controls...6104
      Drive System...6104
      Traction...6104
      Steering...6104
      Brakes...6104
      Fluid Capacities...6105
      Hydraulic System...6105
      Electrical System...6105
      Instrument Panel...6106
      Environmental...6106
      Temperature Range...6106
    MACHINE TORQUE SPECIFICATIONS...6108
      Specifications...6108
    TORQUE SPECIFICATIONS FOR BOLTS...6110
      Torque for General SAE Bolts...6110
      Torque For General Metric Bolts...6111
    HYDRAULIC CONNECTION SPECIFICATIONS...6112
      O-ring Face Seal Connection...6112
      Straight Thread O-ring Fitting...6112
      Tubelines And Hoses...6112
      Flare Fitting...6113
      O-ring Flare Fitting...6114
      Port Seal Fitting...6116
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...6118
      Specifications...6118
    CONVERSIONS...6120
      Decimal And Millimeter Equivalents...6120
      U.S. To Metric Conversion...6121
  ALPHABETICAL INDEX...6122
6989550 (2-10) - T2250 Telescopic Handler Operation & Maintenance Manual...6126
  CONTENTS...6130
  FOREWORD...6132
    DECLARATION OF CONFORMITY...6134
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...6135
    REGULAR MAINTENANCE ITEMS...6135
      Parts...6135
      Lubricants, Fuel and Fluids...6136
    SERIAL NUMBER LOCATION...6137
      Telescopic Handler Serial Number...6137
      Engine Serial Number...6137
      Other Serial Numbers...6137
    DELIVERY REPORT...6137
    BOBCAT telescopic handler IDENTIFICATION...6138
    FEATURES, ACCESSORIES AND ATTACHMENTS...6139
      Standard Items...6139
      Options And Accessories...6139
      Attachments...6139
      Windscreen Grill...6140
      Windscreen Grill Inspection And Maintenance...6140
  SAFETY & TRAINING RESOURCES...6142
    SAFETY INSTRUCTIONS...6144
      Before Operation...6144
      Safe Operation Is The Operator’s Responsibility...6145
      Safe Operation Needs A Qualified Operator...6145
      Avoid Silica Dust...6146
    FIRE PREVENTION...6146
      Maintenance...6146
      Operation...6146
      Electrical...6146
      Hydraulic System...6147
      Fueling...6147
      Starting...6147
      Spark Arrester Exhaust System...6147
      Welding And Grinding...6147
      Fire Extinguishers...6147
    PUBLICATIONS AND TRAINING RESOURCES...6148
    MACHINE SIGNS (DECALS)...6149
      No-Text Safety Signs...6152
  LOAD CHARTS...6156
    CHARTS FOR T2250 MACHINE...6158
  OPERATING INSTRUCTIONS...6160
    OPERATOR CONTROLS IDENTIFICATION...6162
      Operator Components...6162
      Travel Direction And Two Speed Control...6162
      Steering Wheel...6162
      Centre Instrument Panel...6163
      Indicator Lights...6164
      Longitudinal Stability Indicator / AMA System...6164
      Right Instrument And Indicator Panel...6165
      Heater / Air Conditioning Controls (If Equipped)...6166
      Accelerator Pedal...6166
      Brake Pedal And Inching Control...6166
    OPERATOR CAB (ROPS / FOPS)...6167
      Description...6167
      Cab Door...6167
      Cab Door Window...6168
    STEERING MODE SELECTION...6169
      Steering Controls...6169
    PARKING BRAKE...6170
      Operation...6170
    EMERGENCY EXIT...6170
      Rear Window...6170
    BACK-UP ALARM SYSTEM (IF EQUIPPED)...6171
      Description...6171
      Operation...6171
    DRIVING AND STEERING THE TELESCOPIC HANDLER...6172
      4-Wheel Steering Mode...6172
      Stopping The Telescopic Handler (4-Wheel Steering Mode)...6173
      2-Wheel Steering Mode...6174
      Stopping The Telescopic Handler (2-Wheel Steering Mode)...6175
      Crab Steering Mode...6176
      Stopping The Telescopic Handler (Crab Steering Mode)...6177
    CREEP MODE OPERATION - SMS (SPEED MANAGEMENT SYSTEM)...6178
      Operation...6178
      Work Mode Operation...6178
    HYDRAULIC CONTROLS...6179
      Hydraulic Control Lever (Joystick)...6179
      Auxiliary Hydraulic Pressure Release...6180
      Second Auxiliary Hydraulic Couplers (If Equipped)...6180
    ATTACHMENT CONTROL DEVICE (ACD)...6181
      Description...6181
    DAILY INSPECTION...6182
      Daily Inspection And Maintenance...6182
    PRE-STARTING PROCEDURE...6184
      Entering The Telescopic Handler...6184
      Operation & Maintenance Manual Location...6184
      Seat Adjustment...6185
      Seat Belt Adjustment...6185
      Panel Switch Position...6185
    STARTING THE ENGINE...6186
      Cold Temperature Starting...6186
      Warming The Hydraulic / Hydrostatic System...6186
    MONITORING THE DISPLAY PANELS...6187
      Panel...6187
    STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER...6187
      Procedure...6187
    ATTACHMENTS...6188
      Choosing The Correct Bucket...6188
      Installing And Removing The Attachment (Manual Quick-Tach) (Standard)...6188
      Installing And Removing The Attachment (Bob-Tach)...6190
      Quick Couplers...6193
    OPERATING PROCEDURE...6194
      Aggravating Movements Arrester System (AMA)...6194
      Deactivation Switch Key for the Aggravating Movements Arrester (AMA) System...6194
      Inspecting The Work Area...6195
      Basic Operating Instructions...6195
      Operating With A Full Bucket...6196
      Operating With An Empty Bucket...6196
      Filling And Emptying The Bucket...6197
      Digging And Filling A Hole...6198
      Raising A Load And Extending The Boom...6199
      Load Capacity Charts...6199
      Levelling The Ground Using Float (If Equipped)...6200
    TOWING THE TELESCOPIC HANDLER...6201
      Procedure...6201
    LIFTING THE TELESCOPIC HANDLER...6203
      Procedure...6203
    TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER...6204
      Loading And Unloading...6204
      Fastening...6204
  PREVENTIVE MAINTENANCE...6206
    SERVICE SCHEDULE...6210
      Chart...6210
    SEAT BELT...6211
      Inspection And Maintenance...6211
    APPROVED BOOM STOP (IF EQUIPPED)...6212
      Installing The Approved Boom Stop...6212
      Removing The Approved Boom Stop...6212
    BACK-UP ALARM SYSTEM (IF EQUIPPED)...6213
      Description...6213
      Inspecting...6213
    ENGINE COVER...6214
    HEATING, VENTILATION AND AIR CONDITIONING System (HVAC)...6215
      Cleaning And Maintenance...6215
      Filters...6215
      Condenser...6215
      Air Conditioning Lubrication...6215
      Troubleshooting...6215
    AIR CLEANER SERVICE...6216
      Replacing Filters...6216
    FUEL SYSTEM...6217
      Fuel Specifications...6217
      Biodiesel Blend Fuel...6217
      Filling The Fuel Tank...6218
      Fuel Filter...6218
      Removing Air From The Fuel System...6219
    ENGINE LUBRICATION SYSTEM...6220
      Checking And Adding Engine Oil...6220
      Engine Oil Chart...6220
      Removing And Replacing Oil And Filter...6221
    ENGINE COOLING SYSTEM...6222
      Cleaning...6222
      Removing And Replacing The Coolant...6223
      Checking Level...6224
    ELECTRICAL SYSTEM...6225
      Description...6225
      Fuse, Diode And Relay Location / Identification...6225
      Battery Maintenance...6227
      Using A Booster Battery (Jump Starting)...6227
      Removing And Installing Battery...6229
      Battery Disconnect Switch...6230
    HYDRAULIC/HYDROSTATIC SYSTEM...6231
      Checking And Adding Fluid...6231
      Hydraulic / Hydrostatic Fluid Chart...6231
      Removing And Replacing Hydraulic Fluid...6232
      Removing And Replacing Hydraulic Filter...6233
    TYRE MAINTENANCE...6234
      Wheel Nuts...6234
      Rotating...6234
      Mounting...6234
      Tyre Pressure...6234
      Checking And Adding Oil (Planetary Carrier)...6235
      Removing And Replacing Oil (Planetary Carrier)...6235
      Checking And Adding Oil (Rear Differential)...6236
      Removing And Replacing Oil (Rear Differential)...6236
      Checking And Adding Oil (Front Differential)...6237
      Removing And Replacing Oil (Front Differential)...6237
    ALTERNATOR BELT...6238
      Belt Adjustment...6238
      Belt Replacement...6238
    DRIVE BELT...6239
      Belt Adjustment...6239
      Belt Replacement...6240
    LUBRICATING THE TELESCOPIC HANDLER...6241
      Lubrication Locations...6241
    PIVOT PIN...6244
      Inspection And Maintenance...6244
    QUICK-TACH...6245
      Inspection And Maintenance...6245
    BOB-TACH (HAND LEVER) (IF EQUIPPED)...6246
      Inspection And Maintenance...6246
    TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE...6247
      Storage...6247
      Return to Service...6247
  SYSTEM SETUP & ANALYSIS...6248
    DIAGNOSTIC SERVICE CODES...6250
      Viewing Service Codes...6250
      Service Codes List...6250
  SPECIFICATIONS...6256
    (T2250) TELESCOPIC HANDLER SPECIFICATIONS...6258
      Dimensional Specifications...6258
      Performance Specifications...6259
      Weights...6259
      Engine...6259
      Controls...6260
      Drive System...6260
      Steering...6260
      Brakes...6260
      Fluid Capacities...6261
      Hydraulic System...6261
      Electrical...6261
      Instruments...6262
      Environmental...6262
      Temperature Range...6262
  WARRANTY...6264
    WARRANTY...6266
  ALPHABETICAL INDEX...6268
6989552 (2-10) - T2556-T2566 Telescopic Handler Operation & Maintenance Manual...6270
  CONTENTS...6274
  FOREWORD...6276
    DECLARATION OF CONFORMITY...6278
      Model T2556...6278
      Model T2566...6279
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...6280
    REGULAR MAINTENANCE ITEMS...6280
      Parts...6280
      Lubricants, Fuel and Fluids...6281
    SERIAL NUMBER LOCATION...6282
      Telescopic Handler Serial Number...6282
      Engine Serial Number...6282
      Other Serial Numbers...6282
    DELIVERY REPORT...6283
    BOBCAT telescopic handler IDENTIFICATION...6284
    FEATURES, ACCESSORIES AND ATTACHMENTS...6285
      Standard Items...6285
      Options And Accessories...6285
      Available Tyres...6285
      Attachments...6285
      Windscreen Grill...6286
      Windscreen Grill Inspection And Maintenance...6286
  SAFETY & TRAINING RESOURCES...6288
    SAFETY INSTRUCTIONS...6290
      Before Operation...6290
      Safe Operation Is The Operator’s Responsibility...6291
      Safe Operation Needs A Qualified Operator...6291
      Avoid Silica Dust...6292
    FIRE PREVENTION...6292
      Maintenance...6292
      Operation...6292
      Electrical...6292
      Hydraulic System...6293
      Fueling...6293
      Starting...6293
      Spark Arrester Exhaust System...6293
      Welding And Grinding...6293
      Fire Extinguishers...6293
    PUBLICATIONS AND TRAINING RESOURCES...6294
    MACHINE SIGNS (DECALS)...6295
      No-Text Safety Signs...6298
  LOAD CHARTS...6302
    CHARTS FOR T2556 MACHINE...6304
    CHARTS FOR T2566 MACHINE...6306
  OPERATING INSTRUCTIONS...6308
    OPERATOR CONTROLS IDENTIFICATION...6310
      Operator Components...6310
      Travel Direction And Two-Speed Control...6310
      Steering Wheel...6311
      Direction Signal...6311
      Front Wiper/Washer/Headlight Dimmer...6311
      Horn...6311
      Steering Wheel Tilt Adjustment...6312
      Longitudinal Stability Indicator / AMA System...6312
      Centre Instrument Panel...6313
      Right Instrument And Indicator Panel...6314
      Left Instrument Panel...6316
      Heater / Air Conditioning Controls (If Equipped)...6316
      Rear Console...6317
      Accelerator Pedal...6317
      Brake Pedal And Inching Control...6317
    OPERATOR CAB (ROPS / FOPS)...6318
      Description...6318
      Cab Door...6318
      Cab Door Window...6319
    STEERING MODE SELECTION...6320
      Steering Controls...6320
    PARKING BRAKE...6321
      Operation...6321
    EMERGENCY EXIT...6321
      Rear Window...6321
    BACK-UP ALARM SYSTEM (IF EQUIPPED)...6322
      Description...6322
      Operation...6322
    DRIVING AND STEERING THE TELESCOPIC HANDLER...6323
      4-Wheel Steering Mode...6323
      Stopping The Telescopic Handler (4-Wheel Steering Mode)...6324
      2-Wheel Steering Mode...6325
      Stopping The Telescopic Handler (2-Wheel Steering Mode)...6326
      Crab Steering Mode...6327
      Stopping The Telescopic Handler (Crab Steering Mode)...6328
    CREEP MODE OPERATION...6329
      Description...6329
      Operation...6329
    HYDRAULIC CONTROLS...6330
      Hydraulic Control Lever (Joystick)...6330
      Auxiliary Hydraulic Release...6331
    DAILY INSPECTION...6332
      Daily Inspection And Maintenance...6332
    PRE-STARTING PROCEDURE...6334
      Entering The Telescopic Handler...6334
      Operation & Maintenance Manual Location...6334
      Seat Adjustment...6335
      Seat Belt Adjustment...6335
      Panel Switch Position...6336
    STARTING THE ENGINE...6337
      Cold Temperature Starting...6338
      Warming The Hydraulic / Hydrostatic System...6338
    MONITORING THE DISPLAY PANELS...6339
      Panel...6339
    STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER...6339
      Procedure...6339
    ATTACHMENTS...6340
      Installing And Removing The Attachment (Manual Locking)...6340
      Installing And Removing The Attachment (Hydraulic Locking) (Optional)...6341
    OPERATING PROCEDURE...6343
      Aggravating Movements Arrester System (AMA)...6343
      Deactivation Switch Key for the Aggravating Movements Arrester (AMA) System...6343
      Inspecting The Work Area...6344
      Basic Operating Instructions...6344
      Operating With A Full Bucket...6345
      Operating With An Empty Bucket...6345
      Filling And Emptying The Bucket...6346
      Digging And Filling A Hole...6347
      Raising A Load And Extending The Boom...6348
      Load Capacity Charts...6348
    TOWING THE telescopic handler...6349
      Procedure...6349
    LIFTING THE telescopic handler...6351
    TRANSPORTING THE telescopic handler...6352
      Loading And Unloading...6352
      Fastening...6352
  PREVENTIVE MAINTENANCE...6354
    SERVICE SCHEDULE...6358
    SEAT BELT...6359
      Inspection And Maintenance...6359
    APPROVED BOOM STOP (IF EQUIPPED)...6360
      Installing The Approved Boom Stop...6360
      Removing The Approved Boom Stop...6360
    BACK-UP ALARM SYSTEM (IF EQUIPPED)...6361
      Description...6361
      Inspecting...6361
    ENGINE COVER...6361
      Opening And Closing...6361
    Heating, VENTILATION AND AIR CONDITIONING System (HVAC)...6362
      Cleaning And Maintenance...6362
      Filters...6362
      Condenser...6362
      Air Conditioning Lubrication...6362
      Troubleshooting...6362
    AIR CLEANER SERVICE...6363
      Replacing Filters...6363
    FUEL SYSTEM...6365
      Fuel Specifications...6365
      Biodiesel Blend Fuel...6365
      Filling The Fuel Tank...6365
      Secondary Fuel Filter...6366
      Primary Fuel Filter (Pre-Filter)...6366
      Removing Air From The Fuel System...6367
    ENGINE LUBRICATION SYSTEM...6368
      Checking And Adding Engine Oil...6368
      Engine Oil Chart...6368
      Removing And Replacing Oil And Filter...6369
    ENGINE COOLING SYSTEM...6370
      Cleaning...6370
      Removing And Replacing The Coolant...6371
      Checking Level...6372
    ELECTRICAL SYSTEM...6372
      Description...6372
      Fuses, Diode And Relay Location / Identification...6373
      Battery Maintenance...6375
      Using A Booster Battery (Jump Starting)...6376
      Removing And Installing Battery...6377
      Battery Disconnect Switch...6379
    HYDRAULIC/HYDROSTATIC SYSTEM...6380
      Checking And Adding Fluid...6380
      Hydraulic / Hydrostatic Fluid Chart...6380
      Removing And Replacing Hydraulic Fluid...6381
      Removing And Replacing Hydraulic/Hydrostatic Filter...6382
      Hydraulic Tank Breather...6382
    AXLES (FRONT AND REAR)...6383
      Checking And Adding Oil (Planetary Carrier)...6383
      Removing And Replacing Oil (Planetary Carrier)...6383
      Checking And Adding Oil (Front Differential)...6384
      Removing And Replacing Oil (Front Differential)...6384
      Checking And Adding Oil (Rear Differential)...6385
      Removing And Replacing Oil (Rear Differential)...6385
      Checking And Adding Oil (Front Drop Box)...6386
      Removing And Replacing Oil (Front Drop Box)...6386
    ALTERNATOR BELT...6387
      Belt Adjusting...6387
      Belt Replacement...6387
    TYRE MAINTENANCE...6388
      Wheel Nuts...6388
      Tyre Mounting...6388
      Tyre Rotating...6388
      Tyre Pressure...6388
    LUBRICATING THE TELESCOPIC HANDLER...6389
      Lubrication Locations...6389
    PIVOT PIN...6392
      Inspection And Maintenance...6392
    ATTACHMENT FRAME...6393
      Inspection And Maintenance...6393
    TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE...6394
      Storage...6394
      Return To Service...6394
  SPECIFICATIONS...6396
    (T2556) TELESCOPIC HANDLER SPECIFICATIONS...6398
      Dimensional Specifications...6398
      Performance Specifications...6399
      Weights...6399
      Engine...6399
      Controls...6400
      Drive System...6400
      Traction...6400
      Steering...6400
      Brakes...6400
      Fluid Capacities...6401
      Hydraulic System...6401
      Electrical...6401
      Instruments...6402
      Environmental...6402
      Temperature Range...6402
    (T2566) TELESCOPIC HANDLER SPECIFICATIONS...6404
      Dimensional Specifications...6404
      Performance Specifications...6405
      Weights...6405
      Engine...6405
      Controls...6406
      Drive System...6406
      Traction...6406
      Steering...6406
      Brakes...6406
      Fluid Capacities...6407
      Hydraulic System...6407
      Electrical...6407
      Instruments...6408
      Environmental...6408
      Temperature Range...6408
  WARRANTY...6410
    WARRANTY...6412
  ALPHABETICAL INDEX...6414

Bobcat Telescopic Handlers T2250, T2556, T2566 Repair Service Manuals