Complete repair service manual with electrical wiring diagrams for Bobcat Telescopic Handlers T40140, T40170, T40180, with technical information to maintain, diagnose, repair, and service like professional mechanics.

Bobcat Telescopic Handlers T40140-T40170-T40180 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.

4852040 (8-03) - T40140, T40170 V2 Boom Service Manual.pdf
4852040 (10-12) - T40140, T40170 V2 Boom Service Manual.pdf
4950145 (08-08) - T40140-T40170 Service Manual.pdf
6986768 (2-10) - T40140, T40170 Telescopic Handler Service Manual.pdf
6986768 (08-08) Revised (08-12) - T40140, T40170 Telescopic Handler Service Manual.pdf
6989561 (2-10) - T40140 Telescopic Handler Operation & Maintenance Manual.pdf
6989562 (2-10) - T40170 Telescopic Handler Operation & Maintenance Manual.pdf
6990783 (07-14) - T40140, T40180 Telescopic Handler Service Manual.pdf
6990786 (07-14) - T40140, T40180 Telescopic Handler Service Manual.pdf

Pages: 4,183
File Format: PDF
Language: English

MAIN SECTIONS
SAFETY AND MAINTENANCE . . 10-01
HYDRAULIC SYSTEM . . 20-01
HYDROSTATIC SYSTEM . . 30-01
DRIVE SYSTEM . . 40-01
MAINFRAME . . 50-01
ELECTRICAL SYSTEM & ANALYSIS . . 60-01
ENGINE SERVICE . . 70-01
HEATING, VENTILATION, AIR CONDITIONING . . 80-01
SPECIFICATIONS . . SPEC-01
ALPHABETICAL INDEX . .INDEX-01

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

Bobcat Telescopic Handlers T40140-T40170-T40180 Repair Service Manuals