Complete repair service manual for Bobcat TL360(X), TL470(X), TR35160, TR38160, TR45190, TR50210, TR40250 Telescopic Handlers, with all the shop information to maintain, diagnose, and repair like professional mechanics.

Bobcat TL360(X), TL470(X), TR35160, TR38160, TR45190, TR50210, TR40250 Telescopic Handlers workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

6989623 (12-10) - TR35160, TR45190, TR50210, TR40250 Telescopic Handler Operation & Maintenance Manual.pdf
6989624 (4-10) - TR35160, TR45190, TR50210, TR40250 Telescopic Handler Service Manual.pdf
6989624 (11-13) - TR35160, TR45190, TR50210, TR40250 Telescopic Handler Service Manual.pdf
6990099 (2-11) - TL360(X) Telescopic Handler Operation & Maintenance Manual.pdf
6990100 (5-11) - TL360(X) Telescopic Handler Service Manual.pdf
6990100 (06-12) - TL360(X) Telescopic Handler Service Manual.pdf
6990102 (2-11) - TL470(X) Telescopic Handler Operation & Maintenance Manual.pdf
6990103 (5-11) - TL470(X) Telescopic Handler Service Manual.pdf
6990103 (06-12) - TL470(X) Telescopic Handler Service Manual.pdf
6990103 (07-12) - TL470(X)HF Telescopic Handler Service Manual.pdf
6990609 (02-13) - TR38160 Telescopic Handler Service Manual .pdf
6990790 (05-13) - TL360(X), TL470(X), TL470(X)HF Telescopic Handler Service Manual.pdf

PRODUCT DETAILS:
Total Pages: 3,032 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
6989623 (12-10) - TR35160, TR45190, TR50210, TR40250 Telescopic Handler Operation & Maintenance Manual...1
  CONTENTS...5
  FOREWORD...7
    DECLARATION OF CONFORMITY...9
    REGULAR MAINTENANCE ITEMS (TR45190, TR50210, TR40250)...11
    LUBRICANTS AND FLUIDS...12
    SERIAL NUMBER LOCATIONS...13
      Telescopic Handler Serial Numbers...13
      Engine Serial Number...13
      Other Serial Numbers...13
    DELIVERY REPORT...13
    BOBCAT TELESCOPIC HANDLER IDENTIFICATION...14
    FEATURES, ACCESSORIES AND ATTACHMENTS...17
      Standard Items...17
      Options And Accessories...17
      Available Tyres...17
      Attachments...17
  SAFETY AND TRAINING RESOURCES...19
    SAFETY INSTRUCTIONS...21
      Before Operation...21
      Safe Operation Is The Operator’s Responsibility...22
      Safe Operation Needs A Qualified Operator...22
      Avoid Silica Dust...23
    FIRE PREVENTION...23
      Maintenance...23
      Operation...23
      Electrical...23
      Hydraulic System...24
      Fueling...24
      Starting...24
      Spark Arrester Exhaust System...24
      Welding And Grinding...24
      Fire Extinguishers...24
    MACHINE SIGNS (DECALS)...25
      No-Text Safety Signs...28
      1. Operator Cab Safety Decal (AXA1425)...29
      2. Rotating Parts (AXA1439)...30
      3. Rotating Parts (AXA1435)...30
      4. Steam And Hot Water (AXA1440)...30
      5. Hot Parts (AXA1441)...30
      6. Crush Hazard (AXA1444)...31
    PUBLICATIONS AND TRAINING RESOURCES...32
  LOAD CAPACITY CHARTS...33
    LOAD CAPACITY CHARTS...35
      TR35160...35
      TR45190...37
      TR50210...39
      TR40250...41
  OPERATING INSTRUCTIONS...43
    OPERATOR CONTROLS IDENTIFICATION...47
      Operator Components...47
      Travel Direction...48
      Steering Wheel...48
      Direction Signal...49
      Front Window Wiper...49
      Horn...49
      Headlights...49
      Steering Wheel Tilt Adjustment...50
      Left Instrument Panel...51
      Centre Indicator And Instrument Panel...52
      Right Instrument Panel...54
      Remote Control Transmitter...56
      Accelerator Lever (If Equipped)...57
      Accelerator Pedal...57
      Brake Pedal...57
      Inching Control Pedal...57
    OPERATOR CAB...58
      Description...58
      Cab Door...58
      Cab Door Window...59
      Cab Rear Window...59
      Cab Light...60
      Cab Roof...60
      Cab Ventilation...60
      Rotating Beacon...62
    STEERING MODE SELECTION...63
      Steering Controls...63
    PARKING BRAKE...64
      Operation...64
    TWO SPEED CONTROL...64
      Operation...64
    EMERGENCY PROCEDURES...65
      Emergency Button...65
      Leaving The Cab Through The Emergency Exit...65
      Manually Retracting The Boom...66
    BACK-UP ALARM SYSTEM...67
      Description...67
      Operation...67
    STABILISERS...68
      Description...68
    DRIVING AND STEERING THE TELESCOPIC HANDLER...69
      4-Wheel Steer Mode...69
      Stopping The Telescopic Handler (4-Wheel Steer Mode)...70
      2-Wheel Steer Mode...71
      Stopping The Telescopic Handler (2-Wheel Steer Mode)...72
      Crab Steer Mode...73
      Stopping The Telescopic Handler (Crab Steer Mode)...74
    HYDRAULIC CONTROLS...75
      Hydraulic Control Lever (Joystick)...75
      Double Joystick...76
    AUXILIARY HYDRAULICS...77
      Description...77
    UPPERSTRUCTURE SLEW LOCK...78
      Description...78
    ATTACHMENT SELECTOR...79
      Description...79
    DAILY INSPECTION...80
      Daily Inspection And Maintenance...80
    PRE-STARTING PROCEDURE...82
      Entering The Telescopic Handler...82
      Operation & Maintenance Manual Location...82
      Seat Adjustment...83
      Seat Belt Adjustment...84
      Panel Switch Position...84
    STARTING THE ENGINE...85
      Cold Temperature Starting...86
      Warming The Hydraulic / Hydrostatic System...86
    MONITORING THE DISPLAY PANELS...86
      Centre Indicator And Instrument Panel...86
    STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER...87
      Procedure...87
    ATTACHMENTS...88
      Pallet Forks...88
      Installation...89
      Removal...90
    OPERATING PROCEDURE...91
      Inspect The Work Area...91
      Operation...91
      Operating With A Full Bucket...92
      Operating With An Empty Bucket...92
      Raising A Load And Extending The Boom...93
      Using Front Axle Levelling (TR45190, TR50210, TR40250)...94
      Using Rear Axle Oscillation Lock...95
      Using Stabilisers...96
      Anti Tipping Device...98
      Overriding Safety Devices...99
      Remote Control...100
    TOWING THE TELESCOPIC HANDLER...102
      Procedure...102
    LIFTING THE TELESCOPIC HANDLER...104
      Procedure...104
    TRANSPORTING THE TELESCOPIC HANDLER...105
      Procedure...105
  PREVENTIVE MAINTENANCE...107
    SERVICE SCHEDULE...111
      Chart...111
      Contents Of The Inspection Checkbook (logbook)...112
    SEAT BELT...113
      Inspection And Maintenance...113
    APPROVED BOOM STOP...114
      Installing The Approved Boom Stop...114
    BACK-UP ALARM SYSTEM...115
      Description...115
      Inspecting...115
    ENGINE COVER...116
      Opening And Closing...116
    HEATING, VENTILATION AND AIR CONDITIONING (HVAC)...117
      Description...117
    AIR CLEANER SERVICE (TR35160)...118
      Cleaning The Air Filter...118
    AIR CLEANER SERVICE (TR45190, TR50210, TR40250)...119
      Cleaning And Replacing Cartridges...119
      Cleaning The Primary Intake Duct...120
    FUEL SYSTEM...121
      Fuel Specifications...121
      Biodiesel Blend Fuel...121
      Filling The Fuel Tank...122
      Fuel Filters (TR35160)...122
      Fuel Filters (TR45190, TR50210, TR40250)...123
      Removing Air From The Fuel System...124
      Cleaning The Fuel Tank...125
    ENGINE LUBRICATION SYSTEM...126
      Checking And Adding Engine Oil (TR35160)...126
      Checking And Adding Engine Oil (TR45190, TR50210, TR40250)...126
      Engine Oil Chart...127
      Removing And Replacing Oil And Filter (TR35160)...127
      Removing And Replacing Oil And Filter (TR45190, TR50210, TR40250)...129
    ENGINE COOLING SYSTEM...131
      Cleaning The Cooling System...131
      Checking The Coolant Level...132
      Removing And Replacing The Coolant...133
    ELECTRICAL SYSTEM...135
      Fuse And Relay Location / Identification...135
      Battery Maintenance...138
      Using A Booster Battery (Jump Starting)...139
      Removing And Installing Battery...140
      Battery Disconnect Switch...141
    HYDRAULIC / HYDROSTATIC SYSTEM...142
      Hydraulic / Hydrostatic Fluid Chart...142
      Checking And Adding Hydraulic / Hydrostatic Fluid...143
      Replacing Hydraulic / Hydrostatic Fluid And Filters...144
    BRAKE PEDAL...146
      Inspection And Maintenance...146
    TYRE MAINTENANCE...147
      Wheel Nuts...147
      Tyre Rotating...147
      Tyre Mounting...147
      Tyre Pressure...147
    AXLES (FRONT AND REAR)...148
      Checking And Adding Oil (Planetary Carrier)...148
      Removing And Replacing Oil (Planetary Carrier)...148
      Checking And Adding Oil (Front And Rear Differential)...149
      Removing And Replacing Oil (Front And Rear Differential)...149
      Checking And Adding Oil (Drive Box)...149
      Removing And Replacing Oil (Drive Box)...149
    SWING MOTOR...150
      Checking And Adding Oil...150
      Removing And Replacing Oil...151
    ALTERNATOR BELT...152
      Belt Adjustment (TR45190, TR50210, TR40250)...152
      Belt Replacement (TR45190, TR50210, TR40250)...152
    LUBRICATING THE TELESCOPIC HANDLER...153
      Lubrication Locations...153
      Lubricating Telescopic Boom Wear Blocks...161
      Lubricating External Boom Chains (TR45190, TR50210, TR40250)...162
    CHAIN CHECKING AND ADJUSTING PROCEDURE...163
      Chain Description (TR45190, TR50210, TR40250)...163
      Checking And Adjusting Procedure (TR45190, TR50210, TR40250)...164
      Extend And Retract Chain Wear Check (TR45190, TR50210, TR40250)...165
    TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE...166
      Storage...166
      Return To Service...166
  SYSTEM SETUP AND ANALYSIS...167
    CENTRE INDICATOR AND INSTRUMENT PANEL...169
    LIQUID CRYSTAL DISPLAY (LCD)...170
    PUSH BUTTONS...170
      Changing Information On The LCD...170
      Clock Adjustment...171
    INITIAL CHECK UP OF THE INSTRUMENTS...171
    GENERAL ALARM PILOT LIGHT...172
      Engine Error Codes (TR45190, TR50210, TR40250)...172
      Centre Indicator And Instrument Panel Pilot Lights...172
      Engine Over-Revs (TR45190, TR50210, TR40250)...172
      Engine Errors (TR45190, TR50210, TR40250)...173
      Error Menu (TR45190, TR50210, TR40250)...173
    SERVICE...174
      Engine Error Codes List (TR45190, TR50210, TR40250)...175
    ANTI TIPPING DEVICE...177
      Description...177
      Main Work Data...178
      Complementary Work Data...179
      Attachment And Operating Mode...180
      Attachment Selection...181
      Unencoded Display Information...182
      Self-Diagnostics And Alarm Messages...183
      Diagnostics Displays...186
      Language Selection...187
  SPECIFICATIONS...189
    (TR35160, TR45190, TR50210, TR40250) TELESCOPIC HANDLER SPECIFICATIONS...191
      Machine Dimensions...191
      Performance...194
      Engine...194
      Transmission...194
      Hydraulic System...195
      Differential Axles...195
      Capacities...195
      Tyres...195
      Environmental...196
  WARRANTY...197
    WARRANTY...199
  ALPHABETICAL INDEX...201
6989624 (11-13) - TR35160, TR45190, TR50210, TR40250 Telescopic Handler Service Manual...203
  FOREWORD...209
    FOREWORD...211
    SAFETY INSTRUCTIONS...213
      Safe Operation Is The Operator’s Responsibility...213
      Safe Operation Needs A Qualified Operator...213
      Avoid Silica Dust...214
      Dismantling And Disposal...214
    FIRE PREVENTION...215
      Maintenance...215
      Operation...215
      Electrical...215
      Hydraulic System...215
      Fueling...215
      Starting...215
      Welding And Grinding...216
      Fire Extinguishers...216
    SERIAL NUMBER LOCATIONS...217
      Telescopic Handler Serial Numbers...217
      Engine Serial Number...217
      Other Serial Numbers...217
    DELIVERY REPORT...217
    BOBCAT TELESCOPIC HANDLER IDENTIFICATION...218
      TR35160...218
      TR45190, TR50210 And TR40250...219
  SAFETY & MAINTENANCE...221
    LIFTING AND BLOCKING THE TELESCOPIC HANDLER...223
      Procedure...223
    OPERATOR CAB...225
      Description...225
      Cab Door...226
      Cab Door Window...226
      Cab Rear Window...227
      Cab Light...227
      Cab Roof...227
      Cab Ventilation...228
      Rotating Beacon...229
    TRANSPORTING THE TELESCOPIC HANDLER...231
      Procedure...231
    TOWING THE TELESCOPIC HANDLER...233
      Procedure...233
    SERVICE SCHEDULE...235
      Chart...235
      Contents Of The Inspection Checkbook (logbook)...236
    AIR CLEANER SERVICE (TR35160)...237
      Cleaning The Air Filter...237
    AIR CLEANER SERVICE (TR45190, TR50210, TR40250)...239
      Cleaning And Replacing Cartridges...239
      Cleaning The Primary Intake Duct...240
    ENGINE COOLING SYSTEM...241
      Cleaning The Cooling System...241
      Checking The Coolant Level...242
      Removing And Replacing The Coolant...243
    FUEL SYSTEM...245
      Fuel Specifications...245
      Biodiesel Blend Fuel...245
      Filling The Fuel Tank...246
      Fuel Filters (TR35160)...246
      Fuel Filters (TR45190, TR50210, TR40250)...247
      Removing Air From The Fuel System...248
      Cleaning The Fuel Tank...249
    ENGINE LUBRICATION SYSTEM...251
      Checking And Adding Engine Oil (TR35160)...251
      Checking And Adding Engine Oil (TR45190, TR50210, TR40250)...251
      Engine Oil Chart...252
      Removing And Replacing Oil And Filter (TR35160)...252
      Removing And Replacing Oil And Filter (TR45190, TR50210, TR40250)...254
    HYDRAULIC / HYDROSTATIC SYSTEM...257
      Hydraulic / Hydrostatic Fluid Chart...257
      Checking And Adding Hydraulic / Hydrostatic Fluid...258
      Replacing Hydraulic / Hydrostatic Fluid And Filters...259
    AXLES (FRONT AND REAR)...263
      Checking And Adding Oil (Planetary Carrier)...263
      Removing And Replacing Oil (Planetary Carrier)...263
      Checking And Adding Oil (Front And Rear Differential)...264
      Removing And Replacing Oil (Front And Rear Differential)...264
      Checking And Adding Oil (Drive Box)...264
      Removing And Replacing Oil (Drive Box)...264
    LUBRICATING THE TELESCOPIC HANDLER...265
      Lubrication Locations...265
      Lubricating Telescopic Boom Wear Blocks...273
      Lubricating External Boom Chains...274
    TYRE MAINTENANCE...275
      Wheel Nuts...275
      Tyre Rotating...275
      Tyre Mounting...275
      Tyre Pressure...275
    ENGINE COVER...277
      Opening And Closing...277
    APPROVED BOOM STOP...279
      Installing The Approved Boom Stop...279
    ANTI TIPPING DEVICE...281
      Description...281
      Main Work Data...282
      Complementary Work Data...283
      Attachment And Operating Mode...284
      Attachment Selection...285
      Unencoded Display Information...286
      Self-Diagnostics...287
      Anti Tipping Device Error Codes...288
      Remote Control Error Codes...292
      Diagnostics Displays...295
      Language Selection...296
  HYDRAULIC SYSTEM...297
    HYDRAULIC SYSTEM INFORMATION...299
      Troubleshooting Chart...324
      Tightening Procedures...325
      Hydraulic Component Pressures...325
    LIFT CYLINDER...327
      Removal And Installation...327
      Parts Identification...329
      Section View...330
    EXTENSION CYLINDER (TR45190, TR50210, TR40250)...331
      Parts Identification...331
    TILT CYLINDER...333
      Parts Identification...333
    DRIVE BOX...335
      Parts Identification...335
      Disassembly...336
      Assembly...347
    FRAME LEVELLING CYLINDER (TR45190, TR50210, TR40250)...359
      Parts Identification...359
    BRAKE AND GEAR VALVES...361
      Parts Identification...361
    STEERING MODE VALVE BLOCK...363
      Parts Identification...363
    STEERING VALVE...365
      Parts Identification...365
    HYDRAULIC CONTROL VALVE (TR45190 (EARLIER MODELS), TR50210 (EARLIER MODELS) AND TR40250 (EARLIER MODELS))...367
      Parts Identification...367
      Valve Section Identification...369
      Lifting Valve Section...370
      Upperstructure Swing Valve Section...371
      Telescoping Valve Section...372
      Tilting Valve Section...373
      Auxiliary Valve Section...374
      Inlet-outlet Valve Section...375
      End Housing...376
    HYDRAULIC CONTROL VALVE (TR35160, TR45190 (LATER MODELS), TR50210 (LATER MODELS) AND TR40250 (LATER MODELS))...377
      Parts Identification...377
      Valve Section Identification...378
      Module Valve Section...379
      Lifting Valve Section...380
      Upperstructure Swing Valve Section...381
      Telescoping Valve Section...382
      Interface Valve Section...383
      Tilting Valve Section...384
      Auxiliary Valve Section...385
    SWING MOTOR (TR35160)...387
      Parts Identification...387
    SWING MOTOR (TR45190, TR50210, TR40250)...392
      Parts Identification...392
    SWIVEL JOINT...399
      Parts Identification...399
    STABILISER CYLINDER (TR45190, TR50210, TR40250)...401
      Parts Identification...401
    STABILISER EXTENSION CYLINDER (TR45190, TR50210, TR40250)...403
      Parts Identification...403
    REAR AXLE OSCILLATION LOCK CYLINDER...405
      Parts Identification...405
    STABILISER / LEVELLING VALVE...407
      Parts Identification...407
  HYDROSTATIC SYSTEM...409
    HYDROSTATIC DRIVE MOTOR...411
      Parts Identification...411
    HYDROSTATIC PUMP...413
      Parts Identification...413
    HYDROSTATIC TRANSMISSION ADJUSTMENT...415
      Description...415
      Starting Adjustment...415
      Feeding Pressure...416
      Hydrostatic Pump Pressure...416
      Hydrostatic Motor Pressure...417
  DRIVE SYSTEM...419
    TROUBLESHOOTING...421
      Chart...421
    AXLE AND DIFFERENTIAL (FRONT)...423
      General Information...423
      Planetary Carrier Parts Identification...423
      Planetary Carrier Disassembly...424
      Steering Cylinder Parts Identification...429
      Steering Cylinder Removal...430
      Steering Cylinder Disassembly...432
      Steering Case Parts Identification...434
      Steering Case Disassembly...435
      Drive Axle Parts Identification...437
      Drive Axle Disassembly...438
      Brake System Parts Identification...440
      Brake System Disassembly...441
      Hydraulic Differential Lock Parts Identification...444
      Hydraulic Differential Lock Disassembly...445
      Differential Unit (Limited Slip) Parts Identification...449
      Differential Unit (Limited Slip) Disassembly...450
      Bevel Pinion Parts Identification...454
      Bevel Pinion Removal...455
      Bevel Pinion Installation And Adjustment...458
      Differential Unit (Limited Slip) Assembly...466
      Hydraulic Differential Lock Assembly...470
      Brake System Assembly...473
      Drive Axle Assembly...476
      Steering Case Assembly...478
      Steering Cylinder Assembly...480
      Steering Cylinder Installation...483
      Planetary Carrier Assembly...488
      Special Tools...494
    AXLE AND DIFFERENTIAL (REAR)...495
      General Information...495
      Planetary Carrier Parts Identification...495
      Planetary Carrier Disassembly...496
      Steering Cylinder Parts Identification...501
      Steering Cylinder Removal...502
      Steering Cylinder Disassembly...504
      Steering Case Parts Identification...506
      Steering Case Disassembly...507
      Drive Axle Parts Identification...509
      Drive Axle Disassembly...510
      Negative Brake Parts Identification...512
      Negative Brake Disassembly...513
      Hydraulic Differential Lock Parts Identification...517
      Hydraulic Differential Lock Disassembly...518
      Differential Unit (Limited Slip) Parts Identification...522
      Differential Unit (Limited Slip) Disassembly...523
      Bevel Pinion Parts Identification...527
      Bevel Pinion Removal...528
      Bevel Pinion Installation And Adjustment...531
      Differential Unit (Limited Slip) Assembly...539
      Hydraulic Differential Lock Assembly...543
      Negative Brake Assembly...546
      Drive Axle Assembly...554
      Steering Case Assembly...556
      Steering Cylinder Assembly...558
      Steering Cylinder Installation...561
      Planetary Carrier Assembly...566
      Special Tools...572
  ELECTRICAL SYSTEM AND ANALYSIS...573
    ELECTRICAL SYSTEM INFORMATION...654
      Troubleshooting Chart...654
      Fuse And Relay Location / Identification...655
    BATTERY...660
      Removal And Installation...660
      Battery Disconnect Switch...661
      Servicing...661
      Using A Booster Battery (Jump Starting)...662
      Battery Test...663
    ALTERNATOR (TR45190, TR50210, TR40250)...664
      Alternator Removal (Engines Without An Automatic Belt Tensioner)...664
      Alternator Installation (Engines Without An Automatic Belt Tensioner)...664
      Alternator Removal (Engines With An Automatic Belt Tensioner)...665
      Alternator Installation (Engines With An Automatic Belt Tensioner)...665
      Alternator Test...666
      Charging System Test...667
    STARTER (TR45190, TR50210, TR40250)...668
      Electric Starting Motor Removal...668
      Electric Starting Motor Installation...668
      Electric Starting System Test...669
    SENSORS AND SWITCHES...670
      Stabilisers extended and lowered (TR45190, TR50210, TR40250)...670
      Stabilisers lowered (TR35160)...670
      Upperstructure aligned with undercarriage...670
      Upperstructure rotated 174 (TR35160)...670
      Upperstructure slew lock inserted...671
      Axle oscillation lock range (12)...671
      Boom raised / lowered and extended / retracted completely (TR45190, TR50210, TR40250)...671
      Boom raised / lowered completely (TR35160)...672
    MAN PLATFORM LOAD LIMITER CALIBRATION...674
      Description...674
      Procedure...674
  ENGINE SERVICE...676
    GENERAL ALARM PILOT LIGHT (TR45190, TR50210, TR40250)...682
      Engine Errors...682
      Centre Indicator And Instrument Panel Pilot Lights...682
      Engine Over-Revs...682
      Engine Error Codes...683
      Error Menu...683
    SERVICE (TR45190, TR50210, TR40250)...684
      Engine Error Codes List...685
    SENSORS AND ELECTRICAL COMPONENTS (TR45190, TR50210, TR40250)...688
      Sensor Locations...688
      Failure Of Sensors...689
      Programmable Monitoring System (PMS)...689
      Coolant Temperature Sensor...689
      Boost Pressure Sensor...690
      Inlet Air Temperature Sensor...690
      Fuel Pressure Sensor...691
      Crankshaft Position Sensor...691
      Position Sensor For The Fuel Injection Pump...692
      Engine Oil Pressure Sensor...692
    ENGINE COMPONENTS AND TESTING (TR45190, TR50210, TR40250)...694
      Fuel Priming Pump Removal (Electric Fuel Priming Pump)...694
      Fuel Priming Pump Installation (Electric Fuel Priming Pump)...694
      Fuel Priming Pump Removal (Manual Fuel Priming Pump)...695
      Fuel Priming Pump Installation (Manual Fuel Priming Pump)...696
      Fuel Filter Base Removal (Secondary Fuel Filter)...697
      Fuel Filter Base Installation (Secondary Fuel Filter)...698
      Fuel Transfer Pump Removal...699
      Fuel Transfer Pump Installation...701
      Fuel Injection Lines Removal...703
      Fuel Injection Lines Installation...705
      Fuel Manifold (Rail) Removal...707
      Fuel Manifold (Rail) Installation...708
      Fuel Injection Pump Removal...709
      Fuel Injection Pump Installation...712
      Fuel Injection Pump Gear Removal...716
      Fuel Injection Pump Gear Installation...718
      Position Sensor (Fuel Injection Pump) Removal...720
      Position Sensor (Fuel Injection Pump) Installation...720
      Fuel Pressure Sensor Removal...721
      Fuel Pressure Sensor Installation...721
      Boost Pressure Sensor Removal...722
      Boost Pressure Sensor Installation...722
      Electronic Unit Injector Removal...723
      Electronic Unit Injector Installation...725
      Electronic Unit Injector Installation (Alternative Installation Procedure)...727
      Lifter Group Removal...729
      Lifter Group Installation...730
      Fuel System Inspection...731
      Air In Fuel Test...731
      Finding Top Centre Position For No. 1 Piston...733
      Fuel Injection Timing Check...734
      Fuel Quality Test...735
      Fuel System Prime...735
      Compression Test...736
      Glow Plugs Removal...736
      Glow Plugs Installation...737
      Glow Plugs Test...737
    FLYWHEEL AND HOUSING (TR45190, TR50210, TR40250)...738
      Flywheel Removal...738
      Flywheel Installation...739
      Flywheel Inspection...740
      Flywheel Housing Removal...741
      Flywheel Housing Installation...742
      Flywheel Housing Inspection...743
    RECONDITIONING THE ENGINE (TR45190, TR50210, TR40250)...744
      Turbo Charger Removal...744
      Turbo Charger Installation...745
      Turbo Charger Inspection...746
      Wastegate Solenoid Removal...747
      Wastegate Solenoid Installation...748
      Exhaust Manifold Removal...749
      Exhaust Manifold Installation...750
      Exhaust Elbow Removal...751
      Exhaust Elbow Installation...751
      Valve Mechanism Cover Removal...752
      Valve Mechanism Cover Installation...752
      Valve Mechanism Cover Base Removal...753
      Valve Mechanism Cover Base Installation...755
      Cylinder Head Removal...756
      Cylinder Head Installation...760
      Cylinder Head Inspection...764
      Cylinder Block Inspection...765
      Rocker Shaft And Pushrod Removal...765
      Rocker Shaft And Pushrod Installation...766
      Rocker Shaft Disassembly...768
      Rocker Shaft Assembly...769
      Inlet And Exhaust Valves Removal...770
      Inlet And Exhaust Valves Installation...772
      Air Inlet And Exhaust System Inspection...774
      Engine Valve Lash Inspection / Adjustment...776
      Valve Depth Inspection...777
      Valve Guide Inspection...778
      Inlet And Exhaust Valve Springs Removal...779
      Inlet And Exhaust Valve Springs Installation...781
      Front Cover Removal...783
      Front Cover Installation...783
      Crankshaft Pulley Removal (Engines With An Automatic Belt Tensioner)...784
      Crankshaft Pulley Installation (Engines With An Automatic Belt Tensioner)...784
      Crankshaft Pulley Removal (Engines Without An Automatic Belt Tensioner)...785
      Crankshaft Pulley Installation (Engines Without An Automatic Belt Tensioner)...786
      Crankshaft Pulley Check...786
      Gear Group (Front) Removal...788
      Gear Group (Front) Installation...790
      Gear Group (Front) Timing...792
      Gear Group Inspection...792
      Idler Gear Removal (Standard Idler Gear)...793
      Idler Gear Installation (Standard Idler Gear)...795
      Idler Gear Removal (Heavy-Duty Idler Gear)...797
      Idler Gear Installation (Heavy-Duty Idler Gear)...798
      Housing (Front) Removal...800
      Housing (Front) Installation...801
      Accessory Drive Removal...803
      Accessory Drive Installation...804
      Crankcase Breather Removal (Filtered Breather)...805
      Crankcase Breather Installation (Filtered Breather)...805
      Crankcase Breather Removal (Unfiltered Breather)...806
      Crankcase Breather Installation (Unfiltered Breather)...806
      Camshaft Removal...807
      Camshaft Installation...808
      Camshaft Gear Removal...809
      Camshaft Gear Installation...810
      Camshaft Bearings Removal...812
      Camshaft Bearings Installation...812
      Pistons And Connecting Rods Removal...813
      Pistons And Connecting Rods Installation...814
      Pistons And Connecting Rods Disassembly...815
      Pistons And Connecting Rods Assembly...817
      Piston Ring Groove Inspection...819
      Connecting Rod Inspection...820
      Connecting Rod Bearings Removal (Connecting Rods In Position)...820
      Connecting Rod Bearings Installation (Connecting Rods In Position)...822
      Piston Height Inspection...824
      Crankshaft Main Bearings Removal (Crankshaft In Position)...825
      Crankshaft Main Bearings Installation (Crankshaft In Position)...827
      Crankshaft Removal...830
      Crankshaft Installation...832
      Crankshaft Timing Ring Removal...836
      Crankshaft Timing Ring Installation...836
      Crankshaft Gear Removal...837
      Crankshaft Gear Installation...838
      Bearing Clearance Check...839
      Crankshaft Position Sensor Removal...840
      Crankshaft Position Sensor Installation...840
      Crankshaft Rear Seal Removal...841
      Crankshaft Rear Seal Installation...841
      Crankshaft Wear Sleeve (Rear) Removal...843
      Crankshaft Wear Sleeve (Rear) Installation...843
      Crankshaft Front Seal Removal...844
      Crankshaft Front Seal Installation...845
      Crankshaft Wear Sleeve (Front) Removal...845
      Crankshaft Wear Sleeve (Front) Installation...846
      Water Temperature Regulator Removal...847
      Water Temperature Regulator Installation...848
      Water Temperature Regulator Test...849
      Coolant Temperature Sensor Removal...850
      Coolant Temperature Sensor Installation...851
      Cooling System Check...851
      Cooling System Inspection...852
      Water Pump Removal...853
      Water Pump Installation...853
      Water Pump Inspection...854
      Engine Oil Filter Base Removal...855
      Engine Oil Filter Base Installation...855
      Engine Oil Cooler Removal...856
      Engine Oil Cooler Installation...857
      Engine Oil Cooler Inspection...858
      Engine Oil Relief Valve Removal (Engines With A Balancer Unit)...859
      Engine Oil Relief Valve Installation (Engines With A Balancer Unit)...860
      Engine Oil Relief Valve Removal (Engines Without A Balancer Unit)...861
      Engine Oil Relief Valve Installation (Engines Without A Balancer Unit)...862
      Engine Oil Pump Removal (Engines Without A Balancer Unit)...863
      Engine Oil Pump Installation (Engines Without A Balancer Unit)...864
      Engine Oil Pump Inspection...865
      Engine Oil Pan Removal (Aluminium And Pressed Steel Oil Pans)...866
      Engine Oil Pan Installation (Aluminium And Pressed Steel Oil Pans)...867
      Engine Oil Pan Removal (Cast Iron Oil Pan)...869
      Engine Oil Pan Installation (Cast Iron Oil Pan)...870
      Engine Oil Pressure Sensor Removal...872
      Engine Oil Pressure Sensor Installation...872
      Engine Oil Pressure Test...873
      Excessive Engine Oil Consumption Inspection...873
      Increased Engine Oil Temperature Inspection...874
      Excessive Bearing Wear Inspection...874
      Balancer Removal...874
      Balancer Installation...876
      Balancer Disassembly...878
      Balancer Assembly...879
      Piston Cooling Jets Removal...880
      Piston Cooling Jets Installation...880
      Inlet Air Temperature Sensor Removal...881
      Inlet Air Temperature Sensor Installation...881
      V-belts Removal (Engines Without An Automatic Belt Tensioner)...882
      V-belts Installation (Engines Without An Automatic Belt Tensioner)...882
      V-belt Test...883
      Alternator Belt Removal (Engines With An Automatic Belt Tensioner)...884
      Alternator Belt Installation (Engines With An Automatic Belt Tensioner)...885
      Fan Removal...886
      Fan Installation...886
      Fan Drive Removal...887
      Fan Drive Installation...887
      Electronic Control Module Removal...888
      Electronic Control Module Installation...889
      ECM Mounting Bracket Removal...891
      ECM Mounting Bracket Installation...892
      Air Compressor Removal...892
      Air Compressor Installation...895
      Vacuum Pump Removal...898
      Vacuum Pump Installation...898
  SPECIFICATIONS...900
    (TR35160, TR45190, TR50210, TR40250) TELESCOPIC HANDLER SPECIFICATIONS...902
      Machine Dimensions...902
      Performance...905
      Engine...905
      Transmission...905
      Hydraulic System...906
      Differential Axles...906
      Capacities...906
      Tyres...906
      Environmental...907
    ENGINE SPECIFICATIONS (TR45190, TR50210, TR40250)...908
      General...908
      Fuel Transfer Pump...908
      Electric Fuel Priming Pump...908
      Lifter Group...908
      Rocker Shaft...908
      Cylinder Head Valves...909
      Cylinder Head...909
      Turbo Charger...909
      Camshaft...910
      Camshaft Bearings...910
      Engine Oil Pump - Engines With Balancer Group...910
      Engine Oil Pressure...910
      Engine Oil Bypass Valve - Installed In The Oil Pump...910
      Engine Oil Bypass Valve - Installed In The Balancer...910
      Water Temperature Regulator And Housing...910
      Cylinder Block...911
      Crankshaft...911
      Crankshaft Journals...911
      Connecting Rod Bearing Journal...912
      Main Bearing Journal...912
      Shell For The Main Bearings...913
      Connecting Rod...913
      Piston And Rings - Rings...913
      Piston And Rings - Piston...914
      Piston And Rings - Oversize Piston...914
      Piston Cooling Jet Alignment...914
      Front Housing And Covers...914
      Gear Group (Front)...915
      Flywheel...915
      Belt Tension Chart...915
      Alternator...916
      Engine Torque Values...916
    TORQUE SPECIFICATIONS FOR BOLTS...918
      Torque for General SAE Bolts...918
      Torque For General Metric Bolts...919
    HYDRAULIC CONNECTION SPECIFICATIONS...920
      O-ring Face Seal Connection...920
      Straight Thread O-ring Fitting...920
      Tubelines And Hoses...920
      Flare Fitting...921
      O-ring Flare Fitting...922
      Port Seal Fitting...924
    CONVERSIONS...926
      Decimal And Millimeter Equivalents...926
      U.S. To Metric Conversion Chart...926
  ALPHABETICAL INDEX...928
    SERVICE MANUAL REVISION...930
    Revision No: 6989624 - 1...930
    SERVICE MANUAL REVISION...932
    Revision No: 6989624 - 2...932
  6989624-hyd-11-13-SM-TR35160-TR45190-TR50210-TR40250.pdf...0
    6989624_Hydr_1...302
    6989624_Hydr_2...303
    6989624_Hydr_3...304
    6989624_Hydr_4...305
    6989624_Hydr_5...306
    6989624_Hydr_6...307
    6989624_Hydr_7...308
    6989624_Hydr_8...309
6989624 (4-10) - TR35160, TR45190, TR50210, TR40250 Telescopic Handler Service Manual...934
  MAINTENANCE SAFETY...936
  CONTENTS...938
  FOREWORD...940
    FOREWORD...942
    SAFETY INSTRUCTIONS...944
    FIRE PREVENTION...945
      Maintenance...945
      Operation...945
      Electrical...945
      Hydraulic System...946
      Fueling...946
      Starting...946
      Spark Arrester Exhaust System...946
      Welding And Grinding...946
      Fire Extinguishers...946
    SERIAL NUMBER LOCATIONS...947
      Telescopic Handler Serial Numbers...947
      Engine Serial Number...947
      Other Serial Numbers...947
    DELIVERY REPORT...947
    BOBCAT TELESCOPIC HANDLER IDENTIFICATION...948
  SAFETY & MAINTENANCE...952
    LIFTING AND BLOCKING THE TELESCOPIC HANDLER...954
      Procedure...954
    OPERATOR CAB...956
      Description...956
      Cab Door...957
      Cab Door Window...957
      Cab Rear Window...958
      Cab Light...958
      Cab Roof...958
      Cab Ventilation...959
      Rotating Beacon...960
    TRANSPORTING THE TELESCOPIC HANDLER...962
      Procedure...962
    TOWING THE TELESCOPIC HANDLER...964
      Procedure...964
    SERVICE SCHEDULE...966
      Chart...966
      Contents Of The Inspection Checkbook (logbook)...967
    AIR CLEANER SERVICE (TR35160)...968
      Cleaning The Air Filter...968
    AIR CLEANER SERVICE (TR45190, TR50210, TR40250)...969
      Cleaning And Replacing Cartridges...969
      Cleaning The Primary Intake Duct...970
    ENGINE COOLING SYSTEM...972
      Cleaning The Cooling System...972
      Checking The Coolant Level...973
      Removing And Replacing The Coolant...974
    FUEL SYSTEM...976
      Fuel Specifications...976
      Biodiesel Blend Fuel...976
      Filling The Fuel Tank...977
      Fuel Filters (TR35160)...977
      Fuel Filters (TR45190, TR50210, TR40250)...978
      Removing Air From The Fuel System...979
      Cleaning The Fuel Tank...980
    ENGINE LUBRICATION SYSTEM...982
      Checking And Adding Engine Oil (TR35160)...982
      Checking And Adding Engine Oil (TR45190, TR50210, TR40250)...982
      Engine Oil Chart...983
      Removing And Replacing Oil And Filter (TR35160)...983
      Removing And Replacing Oil And Filter (TR45190, TR50210, TR40250)...985
    HYDRAULIC / HYDROSTATIC SYSTEM...988
      Hydraulic / Hydrostatic Fluid Chart...988
      Checking And Adding Hydraulic / Hydrostatic Fluid...989
      Replacing Hydraulic / Hydrostatic Fluid And Filters...990
    AXLES (FRONT AND REAR)...994
      Checking And Adding Oil (Planetary Carrier)...994
      Removing And Replacing Oil (Planetary Carrier)...994
      Checking And Adding Oil (Front And Rear Differential)...995
      Removing And Replacing Oil (Front And Rear Differential)...995
      Checking And Adding Oil (Drive Box)...995
      Removing And Replacing Oil (Drive Box)...995
    LUBRICATING THE TELESCOPIC HANDLER...996
      Lubrication Locations...996
      Lubricating Telescopic Boom Wear Blocks...1004
      Lubricating External Boom Chains...1005
    TYRE MAINTENANCE...1006
      Wheel Nuts...1006
      Tyre Rotating...1006
      Tyre Mounting...1006
      Tyre Pressure...1006
    ENGINE COVER...1008
      Opening And Closing...1008
    ANTI TIPPING DEVICE...1010
      Description...1010
      Main Work Data...1011
      Complementary Work Data...1012
      Attachment And Operating Mode...1013
      Attachment Selection...1014
      Unencoded Display Information...1015
      Self-Diagnostics...1016
      Anti Tipping Device Error Codes...1017
      Remote Control Error Codes...1021
      Diagnostics Displays...1024
  HYDRAULIC SYSTEM...1026
    HYDRAULIC / HYDROSTATIC SCHEMATIC ...1028
    HYDRAULIC SYSTEM INFORMATION...1045
      Troubleshooting Chart...1048
      Tightening Procedures...1049
      Hydraulic Component Pressures...1049
    LIFT CYLINDER...1051
      Removal And Installation...1051
      Parts Identification...1053
      Section View...1055
    EXTENSION CYLINDER (TR45190, TR50210, TR40250)...1057
      Parts Identification...1057
    TILT CYLINDER...1059
      Parts Identification...1059
    DRIVE BOX...1061
      Parts Identification...1061
      Disassembly...1064
      Assembly...1075
    FRAME LEVELING CYLINDER (TR45190, TR50210, TR40250)...1087
      Parts Identification...1087
    BRAKE AND GEAR VALVES...1089
      Parts Identification...1089
    STEERING MODE VALVE BLOCK...1091
      Parts Identification...1091
    STEERING VALVE...1093
      Parts Identification...1093
    HYDRAULIC CONTROL VALVE (TR45190, TR50210, TR40250)...1095
      Parts Identification...1095
      Valve Section Identification...1099
      Lifting Valve Section...1100
      Upperstructure Swing Valve Section...1101
      Telescoping Valve Section...1102
      Tilting Valve Section...1103
      Auxiliary Valve Section...1104
      Inlet-outlet Valve Section...1105
      End Housing...1106
    HYDRAULIC CONTROL VALVE (TR35160)...1107
      Valve Section Identification...1107
    SWING MOTOR (TR35160)...1109
      Parts Identification...1109
    SWING MOTOR (TR45190, TR50210, TR40250)...1114
      Parts Identification...1114
    SWIVEL JOINT...1121
      Parts Identification...1121
    STABILISER CYLINDER (TR45190, TR50210, TR40250)...1123
      Parts Identification...1123
    STABILISER EXTENSION CYLINDER (TR45190, TR50210, TR40250)...1125
      Parts Identification...1125
    REAR AXLE OSCILLATION LOCK CYLINDER...1127
      Parts Identification...1127
    STABILISER / LEVELING VALVE...1129
      Parts Identification...1129
  HYDROSTATIC SYSTEM...1131
    HYDROSTATIC DRIVE MOTOR...1133
      Parts Identification...1133
    HYDROSTATIC PUMP...1135
      Parts Identification...1135
    HYDROSTATIC TRANSMISSION ADJUSTMENT...1137
      Description...1137
      Starting Adjustment...1137
      Feeding Pressure...1138
      Hydrostatic Pump Pressure...1138
      Hydrostatic Motor Pressure...1139
  DRIVE SYSTEM...1141
    TROUBLESHOOTING...1143
      Chart...1143
    AXLE AND DIFFERENTIAL (FRONT)...1145
      General Information...1145
      Planetary Carrier Parts Identification...1145
      Planetary Carrier Disassembly...1146
      Steering Cylinder Parts Identification...1151
      Steering Cylinder Removal...1152
      Steering Cylinder Disassembly...1154
      Steering Case Parts Identification...1156
      Steering Case Disassembly...1157
      Drive Axle Parts Identification...1159
      Drive Axle Disassembly...1160
      Brake System Parts Identification...1162
      Brake System Disassembly...1163
      Hydraulic Differential Lock Parts Identification...1166
      Hydraulic Differential Lock Disassembly...1167
      Differential Unit (Limited Slip) Parts Identification...1171
      Differential Unit (Limited Slip) Disassembly...1172
      Bevel Pinion Parts Identification...1176
      Bevel Pinion Removal...1177
      Bevel Pinion Installation And Adjustment...1181
      Differential Unit (Limited Slip) Assembly...1189
      Hydraulic Differential Lock Assembly...1193
      Brake System Assembly...1196
      Drive Axle Assembly...1199
      Steering Case Assembly...1201
      Steering Cylinder Assembly...1203
      Steering Cylinder Installation...1206
      Planetary Carrier Assembly...1211
      Special Tools...1217
    AXLE AND DIFFERENTIAL (REAR)...1219
      General Information...1219
      Planetary Carrier Parts Identification...1219
      Planetary Carrier Disassembly...1220
      Steering Cylinder Parts Identification...1225
      Steering Cylinder Removal...1226
      Steering Cylinder Disassembly...1228
      Steering Case Parts Identification...1230
      Steering Case Disassembly...1231
      Drive Axle Parts Identification...1233
      Drive Axle Disassembly...1234
      Negative Brake Parts Identification...1236
      Negative Brake Disassembly...1237
      Hydraulic Differential Lock Parts Identification...1241
      Hydraulic Differential Lock Disassembly...1242
      Differential Unit (Limited Slip) Parts Identification...1246
      Differential Unit (Limited Slip) Disassembly...1247
      Bevel Pinion Parts Identification...1251
      Bevel Pinion Removal...1252
      Bevel Pinion Installation And Adjustment...1256
      Differential Unit (Limited Slip) Assembly...1264
      Hydraulic Differential Lock Assembly...1268
      Negative Brake Assembly...1271
      Drive Axle Assembly...1279
      Steering Case Assembly...1281
      Steering Cylinder Assembly...1283
      Steering Cylinder Installation...1286
      Planetary Carrier Assembly...1291
      Special Tools...1297
  ELECTRICAL SYSTEM AND ANALYSIS...1299
    ELECTRICAL SCHEMATICS...1301
    ELECTRICAL SYSTEM INFORMATION...1355
      Troubleshooting Chart...1355
      Fuse And Relay Location / Identification...1356
    BATTERY...1361
      Removal And Installation...1361
      Battery Disconnect Switch...1362
      Servicing...1362
      Using A Booster Battery (Jump Starting)...1363
      Battery Test...1364
    ALTERNATOR (TR45190, TR50210, TR40250)...1365
      Alternator Removal (Engines Without An Automatic Belt Tensioner)...1365
      Alternator Installation (Engines Without An Automatic Belt Tensioner)...1365
      Alternator Removal (Engines With An Automatic Belt Tensioner)...1366
      Alternator Installation (Engines With An Automatic Belt Tensioner)...1366
      Alternator Test...1367
      Charging System Test...1368
    STARTER (TR45190, TR50210, TR40250)...1369
      Electric Starting Motor Removal...1369
      Electric Starting Motor Installation...1369
      Electric Starting System Test...1370
    SENSORS AND SWITCHES...1371
      Stabilisers extended and lowered (TR45190, TR50210, TR40250)...1371
      Stabilisers lowered (TR35160)...1371
      Upperstructure aligned with undercarriage...1371
      Upperstructure rotated 174 (TR35160)...1371
      Upperstructure slew lock inserted...1372
      Axle oscillation lock range (12)...1372
      Boom raised / lowered and extended / retracted completely (TR45190, TR50210, TR40250)...1372
      Boom raised / lowered completely (TR35160)...1373
    MAN PLATFORM LOAD LIMITER CALIBRATION...1375
      Description...1375
      Procedure...1375
  ENGINE SERVICE...1377
    GENERAL ALARM PILOT LIGHT (TR45190, TR50210, TR40250)...1383
      Engine Errors...1383
      Centre Indicator And Instrument Panel Pilot Lights...1383
      Engine Over-Revs...1383
      Engine Error Codes...1384
      Error Menu...1384
    SERVICE (TR45190, TR50210, TR40250)...1385
      Engine Error Codes List...1386
    SENSORS AND ELECTRICAL COMPONENTS (TR45190, TR50210, TR40250)...1389
      Sensor Locations...1389
      Failure Of Sensors...1390
      Programmable Monitoring System (PMS)...1390
      Coolant Temperature Sensor...1390
      Boost Pressure Sensor...1391
      Inlet Air Temperature Sensor...1391
      Fuel Pressure Sensor...1392
      Crankshaft Position Sensor...1392
      Position Sensor For The Fuel Injection Pump...1393
      Engine Oil Pressure Sensor...1393
    ENGINE COMPONENTS AND TESTING (TR45190, TR50210, TR40250)...1395
      Fuel Priming Pump Removal (Electric Fuel Priming Pump)...1395
      Fuel Priming Pump Installation (Electric Fuel Priming Pump)...1395
      Fuel Priming Pump Removal (Manual Fuel Priming Pump)...1396
      Fuel Priming Pump Installation (Manual Fuel Priming Pump)...1397
      Fuel Filter Base Removal (Secondary Fuel Filter)...1398
      Fuel Filter Base Installation (Secondary Fuel Filter)...1399
      Fuel Transfer Pump Removal...1400
      Fuel Transfer Pump Installation...1402
      Fuel Injection Lines Removal...1404
      Fuel Injection Lines Installation...1406
      Fuel Manifold (Rail) Removal...1408
      Fuel Manifold (Rail) Installation...1409
      Fuel Injection Pump Removal...1410
      Fuel Injection Pump Installation...1413
      Fuel Injection Pump Gear Removal...1417
      Fuel Injection Pump Gear Installation...1419
      Position Sensor (Fuel Injection Pump) Removal...1421
      Position Sensor (Fuel Injection Pump) Installation...1421
      Fuel Pressure Sensor Removal...1422
      Fuel Pressure Sensor Installation...1422
      Boost Pressure Sensor Removal...1423
      Boost Pressure Sensor Installation...1423
      Electronic Unit Injector Removal...1424
      Electronic Unit Injector Installation...1426
      Electronic Unit Injector Installation (Alternative Installation Procedure)...1428
      Lifter Group Removal...1430
      Lifter Group Installation...1431
      Fuel System Inspection...1432
      Air In Fuel Test...1432
      Finding Top Centre Position For No. 1 Piston...1434
      Fuel Injection Timing Check...1435
      Fuel Quality Test...1436
      Fuel System Prime...1436
      Compression Test...1437
      Glow Plugs Removal...1437
      Glow Plugs Installation...1438
      Glow Plugs Test...1438
    FLYWHEEL AND HOUSING (TR45190, TR50210, TR40250)...1439
      Flywheel Removal...1439
      Flywheel Installation...1440
      Flywheel Inspection...1441
      Flywheel Housing Removal...1442
      Flywheel Housing Installation...1443
      Flywheel Housing Inspection...1444
    RECONDITIONING THE ENGINE (TR45190, TR50210, TR40250)...1445
      Turbo Charger Removal...1445
      Turbo Charger Installation...1446
      Turbo Charger Inspection...1447
      Wastegate Solenoid Removal...1448
      Wastegate Solenoid Installation...1449
      Exhaust Manifold Removal...1450
      Exhaust Manifold Installation...1451
      Exhaust Elbow Removal...1452
      Exhaust Elbow Installation...1452
      Valve Mechanism Cover Removal...1453
      Valve Mechanism Cover Installation...1453
      Valve Mechanism Cover Base Removal...1454
      Valve Mechanism Cover Base Installation...1456
      Cylinder Head Removal...1457
      Cylinder Head Installation...1461
      Cylinder Head Inspection...1465
      Cylinder Block Inspection...1466
      Rocker Shaft And Pushrod Removal...1466
      Rocker Shaft And Pushrod Installation...1467
      Rocker Shaft Disassembly...1469
      Rocker Shaft Assembly...1470
      Inlet And Exhaust Valves Removal...1471
      Inlet And Exhaust Valves Installation...1473
      Air Inlet And Exhaust System Inspection...1475
      Engine Valve Lash Inspection / Adjustment...1477
      Valve Depth Inspection...1478
      Valve Guide Inspection...1479
      Inlet And Exhaust Valve Springs Removal...1480
      Inlet And Exhaust Valve Springs Installation...1482
      Front Cover Removal...1484
      Front Cover Installation...1484
      Crankshaft Pulley Removal (Engines With An Automatic Belt Tensioner)...1485
      Crankshaft Pulley Installation (Engines With An Automatic Belt Tensioner)...1485
      Crankshaft Pulley Removal (Engines Without An Automatic Belt Tensioner)...1486
      Crankshaft Pulley Installation (Engines Without An Automatic Belt Tensioner)...1487
      Crankshaft Pulley Check...1487
      Gear Group (Front) Removal...1489
      Gear Group (Front) Installation...1491
      Gear Group (Front) Timing...1493
      Gear Group Inspection...1493
      Idler Gear Removal (Standard Idler Gear)...1494
      Idler Gear Installation (Standard Idler Gear)...1496
      Idler Gear Removal (Heavy-Duty Idler Gear)...1498
      Idler Gear Installation (Heavy-Duty Idler Gear)...1499
      Housing (Front) Removal...1501
      Housing (Front) Installation...1502
      Accessory Drive Removal...1504
      Accessory Drive Installation...1505
      Crankcase Breather Removal (Filtered Breather)...1506
      Crankcase Breather Installation (Filtered Breather)...1506
      Crankcase Breather Removal (Unfiltered Breather)...1507
      Crankcase Breather Installation (Unfiltered Breather)...1507
      Camshaft Removal...1508
      Camshaft Installation...1509
      Camshaft Gear Removal...1510
      Camshaft Gear Installation...1511
      Camshaft Bearings Removal...1513
      Camshaft Bearings Installation...1513
      Pistons And Connecting Rods Removal...1514
      Pistons And Connecting Rods Installation...1515
      Pistons And Connecting Rods Disassembly...1516
      Pistons And Connecting Rods Assembly...1518
      Piston Ring Groove Inspection...1520
      Connecting Rod Inspection...1521
      Connecting Rod Bearings Removal (Connecting Rods In Position)...1521
      Connecting Rod Bearings Installation (Connecting Rods In Position)...1523
      Piston Height Inspection...1525
      Crankshaft Main Bearings Removal (Crankshaft In Position)...1526
      Crankshaft Main Bearings Installation (Crankshaft In Position)...1528
      Crankshaft Removal...1531
      Crankshaft Installation...1533
      Crankshaft Timing Ring Removal...1537
      Crankshaft Timing Ring Installation...1537
      Crankshaft Gear Removal...1538
      Crankshaft Gear Installation...1539
      Bearing Clearance Check...1540
      Crankshaft Position Sensor Removal...1541
      Crankshaft Position Sensor Installation...1541
      Crankshaft Rear Seal Removal...1542
      Crankshaft Rear Seal Installation...1542
      Crankshaft Wear Sleeve (Rear) Removal...1544
      Crankshaft Wear Sleeve (Rear) Installation...1544
      Crankshaft Front Seal Removal...1545
      Crankshaft Front Seal Installation...1546
      Crankshaft Wear Sleeve (Front) Removal...1546
      Crankshaft Wear Sleeve (Front) Installation...1547
      Water Temperature Regulator Removal...1548
      Water Temperature Regulator Installation...1549
      Water Temperature Regulator Test...1550
      Coolant Temperature Sensor Removal...1550
      Coolant Temperature Sensor Installation...1551
      Cooling System Check...1551
      Cooling System Inspection...1552
      Water Pump Removal...1553
      Water Pump Installation...1553
      Water Pump Inspection...1554
      Engine Oil Filter Base Removal...1555
      Engine Oil Filter Base Installation...1555
      Engine Oil Cooler Removal...1556
      Engine Oil Cooler Installation...1557
      Engine Oil Cooler Inspection...1558
      Engine Oil Relief Valve Removal (Engines With A Balancer Unit)...1559
      Engine Oil Relief Valve Installation (Engines With A Balancer Unit)...1560
      Engine Oil Relief Valve Removal (Engines Without A Balancer Unit)...1561
      Engine Oil Relief Valve Installation (Engines Without A Balancer Unit)...1562
      Engine Oil Pump Removal (Engines Without A Balancer Unit)...1563
      Engine Oil Pump Installation (Engines Without A Balancer Unit)...1564
      Engine Oil Pump Inspection...1565
      Engine Oil Pan Removal (Aluminium And Pressed Steel Oil Pans)...1566
      Engine Oil Pan Installation (Aluminium And Pressed Steel Oil Pans)...1567
      Engine Oil Pan Removal (Cast Iron Oil Pan)...1569
      Engine Oil Pan Installation (Cast Iron Oil Pan)...1570
      Engine Oil Pressure Sensor Removal...1572
      Engine Oil Pressure Sensor Installation...1572
      Engine Oil Pressure Test...1573
      Excessive Engine Oil Consumption Inspection...1573
      Increased Engine Oil Temperature Inspection...1574
      Excessive Bearing Wear Inspection...1574
      Balancer Removal...1574
      Balancer Installation...1576
      Balancer Disassembly...1578
      Balancer Assembly...1579
      Piston Cooling Jets Removal...1580
      Piston Cooling Jets Installation...1580
      Inlet Air Temperature Sensor Removal...1581
      Inlet Air Temperature Sensor Installation...1581
      V-belts Removal (Engines Without An Automatic Belt Tensioner)...1582
      V-belts Installation (Engines Without An Automatic Belt Tensioner)...1582
      V-belt Test...1583
      Alternator Belt Removal (Engines With An Automatic Belt Tensioner)...1584
      Alternator Belt Installation (Engines With An Automatic Belt Tensioner)...1585
      Fan Removal...1586
      Fan Installation...1586
      Fan Drive Removal...1587
      Fan Drive Installation...1587
      Electronic Control Module Removal...1588
      Electronic Control Module Installation...1589
      ECM Mounting Bracket Removal...1591
      ECM Mounting Bracket Installation...1592
      Air Compressor Removal...1592
      Air Compressor Installation...1595
      Vacuum Pump Removal...1598
      Vacuum Pump Installation...1598
  SPECIFICATIONS...1599
    (TR35160, TR45190, TR50210, TR40250) TELESCOPIC HANDLER SPECIFICATIONS...1601
      Machine Dimensions...1601
      Performance...1604
      Engine...1604
      Transmission...1604
      Hydraulic System...1605
      Differential Axles...1605
      Capacities...1605
      Tyres...1605
      Environmental...1606
    ENGINE SPECIFICATIONS (TR45190, TR50210, TR40250)...1607
      General...1607
      Fuel Transfer Pump...1607
      Electric Fuel Priming Pump...1607
      Lifter Group...1607
      Rocker Shaft...1607
      Cylinder Head Valves...1608
      Cylinder Head...1608
      Turbo Charger...1608
      Camshaft...1609
      Camshaft Bearings...1609
      Engine Oil Pump - Engines With Balancer Group...1609
      Engine Oil Pressure...1609
      Engine Oil Bypass Valve - Installed In The Oil Pump...1609
      Engine Oil Bypass Valve - Installed In The Balancer...1609
      Water Temperature Regulator And Housing...1609
      Cylinder Block...1610
      Crankshaft...1610
      Crankshaft Journals...1610
      Connecting Rod Bearing Journal...1611
      Main Bearing Journal...1611
      Shell For The Main Bearings...1612
      Connecting Rod...1612
      Piston And Rings - Rings...1612
      Piston And Rings - Piston...1613
      Piston And Rings - Oversize Piston...1613
      Piston Cooling Jet Alignment...1613
      Front Housing And Covers...1613
      Gear Group (Front)...1614
      Flywheel...1614
      Belt Tension Chart...1614
      Alternator...1615
      Engine Torque Values...1615
    TORQUE SPECIFICATIONS FOR BOLTS...1617
      Torque for General SAE Bolts...1617
      Torque For General Metric Bolts...1618
    HYDRAULIC CONNECTION SPECIFICATIONS...1619
      O-ring Face Seal Connection...1619
      Straight Thread O-ring Fitting...1619
      Tubelines And Hoses...1619
      Flare Fitting...1620
      O-ring Flare Fitting...1621
      Port Seal Fitting...1623
    CONVERSIONS...1625
      Decimal And Millimeter Equivalents...1625
      U.S. To Metric Conversion Chart...1625
  ALPHABETICAL INDEX...1627
6990099 (2-11) - TL360(X) Telescopic Handler Operation & Maintenance Manual...1629
  CONTENTS...1633
  FOREWORD...1635
    DECLARATION OF CONFORMITY...1637
      Model TL360...1637
      Model TL360X...1638
    Certificate OF CONFORMITY...1639
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...1640
    REGULAR MAINTENANCE ITEMS...1640
      Parts...1640
      Lubricants, Fuel And Fluids...1641
    SERIAL NUMBER LOCATION...1642
      Telescopic Handler Serial Number...1642
      Telescopic Handler Statutory Plate (If Equipped)...1642
      Engine Serial Number...1643
      Other Serial Numbers...1643
    DELIVERY REPORT...1643
    BOBCAT TELESCOPIC HANDLER IDENTIFICATION...1644
    FEATURES, ACCESSORIES AND ATTACHMENTS...1645
      Standard Items...1645
      Options And Accessories...1645
      Tractor Homologated Telescopic Handler...1645
      Available Tyres...1646
      Front Window Guard...1646
      Front Window Guard Inspection And Maintenance...1646
      Attachments...1647
      Digging Buckets...1647
      Light Material Buckets...1647
      Bale Handler With Spikes...1648
      Bale Handlers With Tubes...1648
      Bale Handlers With Tines...1648
      Pallet Forks...1648
      Bucket Grapples...1649
      Fork Grapples...1649
  SAFETY & TRAINING RESOURCES...1651
    SAFETY INSTRUCTIONS...1653
      Before Operation...1653
      Safe Operation Is The Operator’s Responsibility...1654
      Safe Operation Needs A Qualified Operator...1654
      Avoid Silica Dust...1655
    FIRE PREVENTION...1655
      Maintenance...1655
      Operation...1655
      Electrical...1655
      Hydraulic System...1656
      Fueling...1656
      Starting...1656
      Spark Arrester Exhaust System...1656
      Welding And Grinding...1656
      Fire Extinguishers...1656
    PUBLICATIONS AND TRAINING RESOURCES...1657
    MACHINE SIGNS (DECALS)...1658
      No-Text Safety Signs...1660
  LOAD CHARTS...1663
    CHARTS FOR TL360(X) MACHINE...1665
  OPERATING INSTRUCTIONS...1671
    OPERATOR CONTROLS IDENTIFICATION...1675
      Operator Components...1675
      Travel Direction...1676
      Steering Wheel...1676
      Multi-function Lever...1677
      Steering Wheel Tilt Position (If Equipped)...1677
      Left Instrument Panel...1678
      Centre Instrument And Indicator Panel...1678
      Right Instrument And Indicator Panel...1679
      Longitudinal Load Moment Indicator (LLMI)...1680
      Display Panel...1681
      Display Screen...1683
      Temperature Control Panel...1685
      Auxiliary Power Outlet...1686
      Roof Console (If Equipped)...1686
      Accelerator Pedal...1686
      Brake Pedal And Inching Control...1686
    OPERATOR CAB...1687
      Description...1687
      Cab Door...1687
      Cab Door Window...1688
      Rear Cab Window...1689
      Cab Light...1689
    STEERING MODE SELECTION...1690
      Aligning Modes...1690
      Steering Mode Management...1691
      Semi-Automatic Aligning Mode Procedure...1692
      Manual Aligning Mode Procedure...1694
    PARKING BRAKE...1695
      Operation...1695
    EMERGENCY EXIT...1695
    TRACTOR HOMOLOGATED EMERGENCY EXIT...1696
    BACK-UP ALARM SYSTEM...1697
      Description...1697
      Operation...1697
    DRIVING AND STEERING THE TELESCOPIC HANDLER...1698
      4-Wheel Steering Mode...1698
      Stopping The Telescopic Handler (4-Wheel Steering Mode)...1699
      2-Wheel Steering Mode...1700
      Stopping The Telescopic Handler (2-Wheel Steering Mode)...1701
      Crab Steering Mode...1702
      Stopping The Telescopic Handler (Crab Steering Mode)...1703
    SPEED MANAGEMENT...1704
      Operation...1704
      Changing The Factory Default Setting...1706
    HYDRAULIC CONTROLS...1707
      Hydraulic Control Lever (Joystick)...1707
      Changing The Maximum Auxiliary Flow...1707
      Quick Couplers...1708
      Auxiliary Hydraulic Release...1708
    ATTACHMENT CONTROL DEVICE (ACD)...1709
      Description...1709
    DAILY INSPECTION...1710
      Daily Inspection And Maintenance...1710
      Cleaning The Operator Cab...1711
    PRE-STARTING PROCEDURE...1712
      Entering The Telescopic Handler...1712
      Operation & Maintenance Manual And Operator’s Handbook Locations...1712
      Seat Adjustment...1713
      Seat Belt Adjustment...1714
      Mirrors Adjustment And Cleaning...1714
    STARTING THE ENGINE...1715
      Cold Temperature Starting...1716
      Warming The Hydraulic / Hydrostatic System...1716
    MONITORING THE DISPLAY PANEL...1717
      Warning And Shutdown...1717
    STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER...1718
      Procedure...1718
    ATTACHMENTS...1719
      Serial Plate...1719
      Buckets...1719
      Pallet Forks...1723
      Bale Spikes...1725
      Installing And Removing The Attachment (Manual Lock)...1726
      Installing And Removing The Attachment (Hydraulic Lock) (If Equipped)...1729
    OPERATING PROCEDURE...1732
      Longitudinal Load Moment Controller (LLMC)...1732
      Longitudinal Load Moment Controller (LLMC) Override Switch...1732
      Inspect The Work Area...1733
      Basic Operating Instructions...1733
      Operating With A Full Bucket...1734
      Operating With An Empty Bucket...1734
      Filling And Emptying The Bucket...1735
      Digging And Filling A Hole...1736
      Raising A Load And Extending The Boom...1737
      Load Capacity Charts...1738
      Handling Loads With Pallet Forks...1739
    TOWING THE TELESCOPIC HANDLER...1743
      Procedure...1743
    LIFTING THE TELESCOPIC HANDLER...1745
      Procedure...1745
    TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER...1746
      Loading And Unloading...1746
      Fastening...1746
    TOWING A TRAILER WITH THE TELESCOPIC HANDLER...1747
      Connecting The Electrics (If Equipped)...1747
      Rear Trailer Brake Valve (If Equipped)...1747
  SYSTEM SETUP & ANALYSIS...1749
    DIAGNOSTIC SERVICE CODES...1751
      Viewing Service Codes...1751
      Service Codes List...1752
    MAINTENANCE CLOCK...1762
      Description...1762
      Setup...1762
      Reset...1762
  PREVENTIVE MAINTENANCE...1763
    SERVICE SCHEDULE...1767
    SEAT BELT...1768
      Inspection And Maintenance...1768
    LLMC CALIBRATION TEST...1769
      Procedure...1769
    APPROVED BOOM STOP (IF EQUIPPED)...1770
      Installing The Approved Boom Stop...1770
      Removing The Approved Boom Stop...1770
    BACK-UP ALARM SYSTEM (IF EQUIPPED)...1771
      Description...1771
      Inspecting...1771
    ENGINE COVER...1771
      Opening And Closing...1771
    HEATING, VENTILATION AND AIR CONDITIONING SYSTEM (HVAC) (IF EQUIPPED)...1772
      Cleaning And Maintenance...1772
      Filters...1772
      Condenser...1773
      Air Conditioning Lubrication...1773
      Troubleshooting...1773
    AIR CLEANER SERVICE...1773
      Replacing Filter Elements...1773
    FUEL SYSTEM...1775
      Fuel Specifications...1775
      Biodiesel Blend Fuel...1775
      Filling The Fuel Tank...1776
      Primary Fuel Filter (Pre-Filter)...1776
      Secondary Fuel Filter...1778
      Removing Air From The Fuel System...1778
    ENGINE LUBRICATION SYSTEM...1779
      Checking And Adding Engine Oil...1779
      Engine Oil Chart...1779
      Removing And Replacing Oil And Filter...1780
    ENGINE COOLING SYSTEM...1781
      Cleaning...1781
      Removing And Replacing The Coolant...1781
      Checking Level...1782
    ELECTRICAL SYSTEM...1783
      Description...1783
      Fuses And Relay Location / Identification...1784
      Battery Maintenance...1786
      Using A Booster Battery (Jump Starting)...1787
      Removing And Installing Battery...1788
    HYDRAULIC/HYDROSTATIC SYSTEM...1790
      Checking And Adding Fluid...1790
      Hydraulic / Hydrostatic Fluid Chart...1791
      Removing And Replacing Hydraulic Fluid...1791
      Removing And Replacing Hydraulic / Hydrostatic Filter...1792
      Removing And Replacing Hydraulic Charge Filter...1793
      Fill / Breather Cap...1794
    AXLES (FRONT AND REAR)...1795
      Checking And Adding Oil (Planetary Carrier)...1795
      Removing And Replacing Oil (Planetary Carrier)...1795
      Checking And Adding Oil (Rear Differential)...1796
      Removing And Replacing Oil (Rear Differential)...1796
      Checking And Adding Oil (Front Differential)...1797
      Removing And Replacing Oil (Front Differential)...1797
      Checking And Adding Oil (Gear Box)...1798
      Removing And Replacing Oil (Gear Box)...1798
    ALTERNATOR BELT...1799
      Belt Adjustment...1799
      Belt Replacement...1799
    AIR CONDITIONING BELT...1800
      Belt Adjustment...1800
      Belt Replacement...1800
    TYRE MAINTENANCE...1802
      Wheel Nuts...1802
      Rotating...1802
      Mounting...1802
      Pressure...1802
    LUBRICATING THE TELESCOPIC HANDLER...1803
      Lubrication Locations...1803
    ATTACHMENT CARRIER...1805
      Inspection And Maintenance...1805
    TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE...1806
      Storage...1806
      Return To Service...1806
  SPECIFICATIONS...1807
    (TL360) TELESCOPIC HANDLER SPECIFICATIONS...1809
      Machine Dimensions...1809
      Performance...1810
      Weights...1810
      Engine...1810
      Controls...1811
      Drive System...1811
      Traction...1811
      Steering...1811
      Brakes...1811
      Fluid Capacities...1812
      Hydraulic System...1812
      Electrical System...1812
      Instrument Panel...1813
      Environmental...1813
  WARRANTY...1815
    WARRANTY...1817
  ALPHABETICAL INDEX...1819
6990100 (06-12) - TL360(X) Telescopic Handler Service Manual...1821
  MAINTENANCE SAFETY...1823
  CONTENTS...1825
  FOREWORD...1827
    FOREWORD...1829
    SAFETY INSTRUCTIONS...1831
      Safe Operation Is The Operator’s Responsibility...1831
      Safe Operation Needs A Qualified Operator...1831
      Avoid Silica Dust...1832
    FIRE PREVENTION...1832
      Maintenance...1832
      Operation...1832
      Electrical...1832
      Hydraulic System...1833
      Fueling...1833
      Starting...1833
      Welding And Grinding...1833
      Fire Extinguishers...1833
    SERIAL NUMBER LOCATION...1834
      Telescopic Handler Serial Number...1834
      Engine Serial Number...1835
      Other Serial Numbers...1835
    DELIVERY REPORT...1835
    BOBCAT TELESCOPIC HANDLER IDENTIFICATION...1836
  SAFETY AND MAINTENANCE...1837
    LIFTING AND BLOCKING THE TELESCOPIC HANDLER...1839
      Procedure...1839
    OPERATOR CAB...1841
      Description...1841
      Cab Door...1841
      Cab Door Window...1842
      Rear Cab Window...1843
      Cab Light...1843
    TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER...1845
      Loading And Unloading...1845
      Fastening...1845
    TOWING THE TELESCOPIC HANDLER...1847
      Procedure...1847
    SERVICE SCHEDULE...1849
    AIR CLEANER SERVICE...1851
      Replacing Filter Elements...1851
    ENGINE COOLING SYSTEM...1853
      Cleaning...1853
      Checking Level...1854
      Removing And Replacing The Coolant...1855
    FUEL SYSTEM...1857
      Fuel Specifications...1857
      Biodiesel Blend Fuel...1857
      Filling The Fuel Tank...1858
      Primary Fuel Filter (Pre-Filter)...1858
      Secondary Fuel Filter...1860
      Removing Air From The Fuel System...1861
    ENGINE LUBRICATION SYSTEM...1863
      Checking And Adding Engine Oil...1863
      Engine Oil Chart...1863
      Removing And Replacing Oil And Filter...1864
    HYDRAULIC / HYDROSTATIC SYSTEM...1867
      Checking And Adding Fluid...1867
      Hydraulic / Hydrostatic Fluid Chart...1868
      Removing And Replacing Hydraulic Fluid...1868
      Removing And Replacing Hydraulic / Hydrostatic Filter...1869
      Removing And Replacing Hydraulic Charge Filter...1870
      Fill / Breather Cap...1871
    AXLES (FRONT AND REAR)...1873
      Checking And Adding Oil (Planetary Carrier)...1873
      Removing And Replacing Oil (Planetary Carrier)...1873
      Checking And Adding Oil (Rear Differential)...1874
      Removing And Replacing Oil (Rear Differential)...1874
      Checking And Adding Oil (Front Differential)...1875
      Removing And Replacing Oil (Front Differential)...1875
      Checking And Adding Oil (Gear Box)...1876
      Removing And Replacing Oil (Gear Box)...1876
    LUBRICATING THE TELESCOPIC HANDLER...1877
      Lubrication Locations...1877
    ATTACHMENT CARRIER...1879
      Inspection And Maintenance...1879
    TYRE MAINTENANCE...1881
      Wheel Nuts...1881
      Rotating...1881
      Mounting...1881
      Pressure...1881
    APPROVED BOOM STOP...1883
      Installing The Approved Boom Stop...1883
      Removing The Approved Boom Stop...1883
    ENGINE COVER...1885
      Opening And Closing...1885
    STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER...1887
      Procedure...1887
    EMERGENCY EXIT...1889
      Right Rear Window...1889
    TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE...1891
      Storage...1891
      Return To Service...1891
    LIFTING THE TELESCOPIC HANDLER...1893
      Procedure...1893
    REMOTE START TOOL (SERVICE TOOL) KIT - MEL1563...1895
      Remote Start Tool - MEL1563...1895
      Service Tool Harness Control - MEL1565...1896
      Service Tool Harness Communicator - MEL1566...1897
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031...1899
      Remote Start Tool (Service Tool) - 7003030...1899
      Telescopic Handler Service Tool Harness - 6689747...1900
      Computer Service Tool Harness - 6689746...1902
      Remote Start Procedure...1902
  HYDRAULIC SYSTEM...1905
    HYDRAULIC / HYDROSTATIC SCHEMATICS...1909
    HYDRAULIC SYSTEM INFORMATION...1921
      Glossary Of Hydraulic / Hydrostatic Symbols...1921
      Troubleshooting Chart...1924
      Tightening Procedures...1925
    LIFT CYLINDER...1927
      Removal And Installation...1927
      Parts Identification...1930
      Disassembly...1931
      Assembly...1936
    SELF LEVELING CYLINDER...1941
      Removal And Installation...1941
      Parts Identification...1943
      Disassembly...1944
      Assembly...1947
    SELF LEVELING CYLINDER (LOCK VALVE)...1951
      Removal And Installation...1951
    EXTENSION CYLINDER...1953
      Cylinder Group Removal And Installation...1953
      Upper Tubeline Removal And Installation...1955
      Extension Cylinder Removal And Installation...1957
      Tubeline Tray Disassembly...1958
      Parts Identification...1960
      Disassembly...1961
      Assembly...1965
    TILT CYLINDER...1969
      Removal And Installation...1969
      Parts Identification...1972
      Disassembly...1973
      Assembly...1978
    STEERING CYLINDER (FRONT / REAR)...1983
      Removal...1983
      Installation...1985
      Disassembly...1987
      Assembly...1989
    GEAR CONTROL CYLINDER...1993
      Removal...1993
      Parts Identification...1995
      Disassembly...1996
      Assembly...1997
      Installation...1998
    MAIN RELIEF VALVE...1999
      Testing And Adjustment...1999
      Removal And Installation...2000
    MANIFOLD...2001
      Removal And Installation...2001
      Parts Identification...2002
      Disassembly And Assembly...2003
    BRAKE VALVE...2005
      Removal And Installation...2005
    GEAR PUMP...2007
      Removal And Installation...2007
      Parts Identification...2009
      Disassembly And Assembly...2010
    FAN MOTOR...2015
      Removal And Installation...2015
      Parts Identification (Single Speed Version) (Standard)...2017
      Disassembly And Assembly (Single Speed Version) (Standard)...2018
      Parts Identification (Variable Speed Version) (Optional)...2021
      Disassembly And Assembly (Variable Speed Version) (Optional)...2022
    HYDRAULIC RESERVOIR...2029
      Removal And Installation...2029
    STEERING VALVE...2031
      Removal And Installation...2031
    HYDRAULIC CONTROL VALVE...2033
      Troubleshooting Chart (Controllers)...2033
      Valve Section Troubleshooting...2034
      Troubleshooting Chart (Control Valve)...2038
      Removal And Installation...2039
      Parts Identification...2041
      Disassembly And Assembly...2042
      Inlet-Outlet Valve Section Disassembly And Assembly...2043
      Lifting Valve Section Disassembly And Assembly...2044
      Tilting Valve Section Disassembly And Assembly...2048
      Telescoping Valve Section Disassembly And Assembly...2052
      Auxiliary Valve Section Disassembly And Assembly...2056
      End Housing Disassembly And Assembly...2060
    PORT RELIEF VALVES...2063
      Testing...2063
      Replacement Procedure...2064
    PARKING BRAKE...2065
      Valve Removal And Installation...2065
    ACCUMULATOR...2067
      Removal And Installation...2067
  HYDROSTATIC SYSTEM...2069
    HYDROSTATIC SYSTEM INFORMATION...2071
      Troubleshooting Chart...2071
      Replenishing Valve Function...2072
    OIL COOLER...2073
      Removal And Installation...2073
    HYDROSTATIC DRIVE MOTOR...2075
      Removal And Installation...2075
      Parts Identification...2076
      Disassembly...2079
      Inspection...2090
      Assembly...2092
    HYDROSTATIC PUMP...2105
      Removal And Installation...2105
      Parts Identification...2107
      Shaft Disassembly...2112
      Relief Valves Disassembly And Assembly...2114
      Charge Pump Disassembly...2115
      Piston Pump Disassembly...2117
      Solenoid Block Disassembly...2120
      Inspection...2122
      Piston Pump Assembly...2124
      Charge Pump Assembly...2128
      Solenoid Block Assembly...2130
      Shaft Assembly...2132
  DRIVE SYSTEM...2135
    TROUBLESHOOTING...2137
      Chart...2137
    AXLE AND DIFFERENTIAL (FRONT)...2139
      General Information...2139
      Planetary Carrier Parts Identification...2139
      Planetary Carrier Disassembly...2140
      Steering Knuckle And Drive Axle Parts Identification...2145
      Steering Knuckle Disassembly...2146
      Drive Axle Disassembly...2148
      Brake System Parts Identification...2150
      Brake System Disassembly...2151
      Differential Parts Identification...2154
      Differential Disassembly...2155
      Bevel Pinion Parts Identification...2160
      Bevel Pinion Disassembly...2161
      Bevel Pinion Assembly...2164
      Differential Assembly...2172
      Brake System Assembly...2178
      Drive Axle Assembly...2181
      Steering Knuckle Assembly...2183
      Planetary Carrier Assembly...2186
      Special Tools...2191
    AXLE AND DIFFERENTIAL (REAR)...2193
      General Information...2193
      Planetary Carrier Parts Identification...2193
      Planetary Carrier Disassembly...2194
      Steering Knuckle And Drive Axle Parts Identification...2199
      Steering Knuckle Disassembly...2200
      Differential Parts Identification...2202
      Differential Disassembly...2203
      Bevel Pinion Parts Identification...2208
      Bevel Pinion Disassembly...2209
      Bevel Pinion Assembly...2212
      Differential Assembly...2220
      Steering Knuckle Assembly...2226
      Planetary Carrier Assembly...2229
      Special Tools...2234
    FRONT AXLE...2235
      Removal And Installation...2235
    AXLE TOE-IN...2239
      Adjustment...2239
    PARKING BRAKE...2241
      Releasing The Brake For Towing...2241
      Adjustment...2241
      Brake Cylinder Removal...2242
      Brake Cylinder Disassembly And Assembly...2242
      Brake Disc Removal And Installation...2245
      Brake Cylinder Installation...2245
    STEERING ANGLE ADJUSTMENT...2247
      Adjustment...2247
    DRIVESHAFT...2249
      Rear Driveshaft Removal And Installation...2249
      Front Driveshaft Removal And Installation...2249
    SERVICE BRAKE...2251
      Description...2251
      Bleeding The Brake Circuit...2251
    REAR AXLE...2253
      Removal And Installation...2253
    GEAR BOX...2257
      Removal And Installation...2257
      Parts Identification...2259
      Disassembly...2262
      Assembly...2271
  MAINFRAME...2279
    OPERATOR CAB...2281
      Removal And Installation...2281
    OPERATOR SEAT...2285
      Removal And Installation...2285
    FIXED BOOM...2287
      Removal...2287
      Installation...2288
    INNER BOOM...2291
      Removal And Installation...2291
    WEAR PADS (FRONT)...2295
      Removal And Installation...2295
    WEAR PADS (REAR)...2297
      Removal And Installation...2297
    ENGINE COVER...2299
      Gas Cylinder Removal And Installation...2299
      Removal And Installation...2299
    FUEL TANK...2301
      Removal And Installation...2301
    ATTACHMENT CARRIER (QUICK-TACH)...2305
      Removal And Installation...2305
    COUNTERWEIGHT...2307
      Removal And Installation...2307
    FENDER...2309
      Removal And Installation...2309
    STEERING COLUMN COVER...2311
      Removal And Installation...2311
    DASH COVER...2313
      Removal And Installation...2313
    JOYSTICK PANEL...2317
      Removal And Installation...2317
  ELECTRICAL SYSTEM AND ANALYSIS...2319
    ELECTRICAL SCHEMATICS...2321
    ELECTRICAL SYSTEM INFORMATION...2339
      Troubleshooting Chart...2339
      Description...2340
      Fuses And Relay Location / Identification...2341
    BATTERY...2345
      Removal And Installation...2345
      Using A Booster Battery (Jump Starting)...2346
    ALTERNATOR...2349
      Removal And Installation...2349
      Belt Adjustment...2350
      Belt Replacement...2350
    STARTER...2351
      Testing...2351
      Removal And Installation...2351
    LIGHTS...2353
      Rear Light Removal And Installation...2353
      Rear Light Bulb Replacement...2354
      Front Light Removal And Installation...2355
      Front Light Bulb Replacement...2356
    SIGNAL LEVER...2357
      Removal And Installation...2357
    DISPLAY...2359
      Removal And Installation...2359
    INSTRUMENT PANELS...2361
      Right Instrument And Indicator Panel Removal And Installation...2361
      Left Instrument Panel Removal And Installation...2361
    BOOM ANGLE SENSOR...2363
      Removal And Installation...2363
      Calibration...2364
    FRONT WIPER MOTOR...2367
      Removal And Installation...2367
    TOP WIPER MOTOR...2369
      Removal And Installation...2369
    REAR WIPER MOTOR...2371
      Removal And Installation...2371
    PEDAL ASSEMBLY...2375
      Removal And Installation...2375
    INCHING SENSOR...2377
      Removal And Installation...2377
      Calibration...2378
    SERVICE PC (LAPTOP COMPUTER)...2381
      Connecting Remote Start Tool (Service Tool) - MEL1563...2381
      Connecting Remote Start Tool (Service Tool) - 6689778...2381
    FUEL LEVEL SENDER...2383
      Removal And Installation...2383
    JOYSTICK...2387
      Removal And Installation...2387
    LLMI / LLMC SYSTEM...2389
      System Calibration...2389
      Calibration Test...2391
      System Failure Reports...2392
      System Components Identification...2397
      LLMS Removal...2399
      LLMS Installation...2400
      LLMC Removal And Installation...2401
  ENGINE SERVICE...2403
    ENGINE INFORMATION...2407
      Specifications...2407
      Troubleshooting...2418
      Engine Removal And Installation...2420
      Compression Checking...2425
    ENGINE AND HYDROSTAT ASSEMBLY...2427
      Removal And Installation...2427
    ENGINE SPEED CONTROL...2433
      Removal And Installation...2433
    MUFFLER...2435
      Removal And Installation...2435
    AIR CLEANER...2437
      Housing Removal And Installation...2437
    ENGINE COOLING SYSTEM...2439
      Oil Cooler / Intercooler / Radiator Removal And Installation...2439
      Cooling System Description...2442
      Thermostat Removal and Installation...2443
      Thermostat Testing...2443
      Lubricating Oil Cooler Removal And Installation...2443
      Water Pump Removal...2444
      Water Pump Installation...2444
      Expansion Tank Removal And Installation...2444
    LUBRICATION SYSTEM...2445
      Engine Lubrication System Description...2445
      Oil Filter Adapter Removal And Installation...2446
      Oil Pan Removal And Installation...2446
      Oil Screen And Pick-up Tube...2447
      Oil Pump Removal...2447
      Oil Pump Installation...2448
      Oil Pump Disassembly And Assembly...2449
      Oil Pressure Relief Valve Disassembly And Assembly...2450
    FUEL SYSTEM...2451
      Fuel Injection Pump Removal...2451
      Fuel Injection Pump Installation...2454
      Fuel Injectors Removal And Installation...2458
      Checking The Fuel Lift Pump...2460
      Fuel Lift Pump Removal And Installation...2461
      Exhaust Manifold Removal And Installation...2461
      Fuel Injector Cover Removal And Installation...2462
      Rocker Cover Removal And Installation...2462
    CYLINDER HEAD...2465
      Glow Plugs Checking...2465
      Glow Plugs Removal And Installation...2466
      Removal...2467
      Inspection...2469
      Installation...2470
      Rocker Shaft Disassembly And Assembly...2473
      Valve Removal...2473
      Valve Springs Checking...2474
      Valve Depth Checking...2474
      Valve Guide Checking...2475
      Valve Guide Removal...2476
      Valve Guide Installation...2476
      Valve Checking...2477
      Cutting A Valve Seat...2477
      Valve Seat Assembly...2478
      Changing Valve Springs (With Cylinder Head Installed)...2479
      Valve Clearance Adjustment...2480
      Engine Block Description...2481
      Engine Block Disassembly And Assembly...2481
      Engine Block Inspection...2482
      Cylinder Liner Inspection...2482
      Cylinder Liner Removal...2483
      Cylinder Liner Installation...2484
    CRANKSHAFT AND PISTONS...2485
      Pistons And Connecting Rods Description...2485
      Pistons And Connecting Rods Removal...2485
      Pistons And Connecting Rods Disassembly...2486
      Piston Ring End Gap...2487
      Piston Ring Installation...2488
      Piston Ring Groove Clearance...2489
      Piston Cooling Jet Removal...2489
      Piston Cooling Jet Installation...2489
      Piston Cooling Jet Alignment...2490
      Connecting Rod Inspection...2490
      Connecting Rod Bushing Replacement...2490
      Piston And Connecting Rod Assembly...2491
      Piston And Connecting Rod Installation...2491
      Checking Piston Height...2493
      Crankshaft And Bearings Description...2493
      Crankshaft And Bearings Removal...2493
      Inspection Of Crankshaft And Bearings...2495
      Crankshaft And Bearings Installation...2496
      Rear Oil Seal Removal...2497
      Rear Oil Seal Housing Positioning...2498
      Rear Oil Seal Installation...2498
      Checking Crankshaft End Play...2499
    CAMSHAFT AND TIMING GEARS...2501
      Engine Timing Procedure...2501
      Timing Case And Drive Assembly Description...2502
      Timing Cover Removal...2502
      Timing Cover Installation...2502
      Crankshaft Pulley Removal And Installation...2502
      Front Oil Seal Removal And Installation...2502
      Timing Case And Gear Removal...2503
      Timing Case And Gear Installation...2504
      Camshaft And Tappets Removal...2506
      Camshaft And Tappets Installation...2507
    TURBOCHARGER...2509
      Troubleshooting...2509
      Description...2510
      Removal And Installation...2510
    FLYWHEEL AND HOUSING...2513
      Removal And Installation...2513
      Flywheel Inspection...2515
      Ring Gear Removal...2515
      Ring Gear Installation...2515
  HEATING, VENTILATION, AIR CONDITIONING (HVAC)...2517
    AIR CONDITIONING SYSTEM FLOW...2519
      Description...2519
      Chart...2520
      Components...2521
      Safety Equipment...2523
    REGULAR MAINTENANCE...2525
      Filters...2525
      Air Conditioning Belt Adjustment...2525
      Belt Replacement...2525
      Cleaning The Condenser...2527
      Air Conditioning Lubrication...2527
      Air Conditioning Service Chart...2528
      Evaporator / Heater Coil...2529
    TROUBLESHOOTING...2533
      Blower Motor Does Not Operate...2533
      Blower Motor Operates Normally But Air Flow Is Insufficient...2533
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...2533
      The Compressor Does Not Operate At All Or Operates Improperly...2533
      Gauge Pressure Related Troubleshooting...2534
      Temperature / Pressure Chart...2536
      Poor A/C Performance...2537
      HVAC Repair And Leaks...2537
      Electrical System...2538
    SYSTEM CHARGING AND RECLAMATION...2543
      Reclamation And Charging With Recovery / Charging Unit...2543
    COMPRESSOR...2547
      Removal And Installation...2547
      Oil...2549
      Oil Check...2549
      Clutch Disassembly And Assembly...2551
    CONDENSER...2555
      Removal And Installation...2555
    RECEIVER / DRIER...2557
      Removal And Installation...2557
    PRESSURE SWITCH...2559
      Removal And Installation...2559
    EVAPORATOR / HEATER UNIT...2561
      Removal And Installation...2561
    THERMOSTAT...2565
      Description...2565
      Removal And Installation...2566
    EXPANSION VALVE...2569
      Removal And Installation...2569
  SPECIFICATIONS...2571
    (TL360) TELESCOPIC HANDLER SPECIFICATIONS...2573
      Machine Dimensions...2573
      Performance...2574
      Weights...2574
      Engine...2575
      Controls...2575
      Drive System...2575
      Traction...2576
      Steering...2576
      Brakes...2576
      Fluid Capacities...2576
      Hydraulic System...2576
      Electrical System...2577
      Instrument Panel...2577
      Environmental...2577
    MACHINE TORQUE SPECIFICATIONS...2579
      Axle...2579
      Boom...2579
      Drive Box...2579
      Drive Motor...2579
      Engine...2580
      Hydraulic Pump...2580
    TORQUE SPECIFICATIONS FOR BOLTS...2581
      Torque for General SAE Bolts...2581
      Torque For General Metric Bolts...2582
    HYDRAULIC CONNECTION SPECIFICATIONS...2583
      O-ring Face Seal Connection...2583
      Straight Thread O-ring Fitting...2583
      Tubelines And Hoses...2583
      Flare Fitting...2584
      O-ring Flare Fitting...2585
      Port Seal Fitting...2587
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...2589
      Specifications...2589
    CONVERSIONS...2591
      Decimal And Millimeter Equivalent Chart...2591
      U.S. To Metric Conversion Chart...2591
  ALPHABETICAL INDEX...2593
6990100 (5-11) - TL360(X) Telescopic Handler Service Manual...2595
  FOREWORD...0
    FOREWORD...2603
    SAFETY INSTRUCTIONS...2605
      Safe Operation Is The Operator’s Responsibility...2605
      Safe Operation Needs A Qualified Operator...2605
      Avoid Silica Dust...2606
    FIRE PREVENTION...2606
      Maintenance...2606
      Operation...2606
      Electrical...2606
      Hydraulic System...2607
      Fueling...2607
      Starting...2607
      Welding And Grinding...2607
      Fire Extinguishers...2607
    SERIAL NUMBER LOCATION...2608
      Telescopic Handler Serial Number...2608
      Engine Serial Number...2609
      Other Serial Numbers...2609
    DELIVERY REPORT...2609
    BOBCAT TELESCOPIC HANDLER IDENTIFICATION...2610
  SAFETY & MAINTENANCE...2611
    LIFTING AND BLOCKING THE TELESCOPIC HANDLER...2613
      Procedure...2613
    OPERATOR CAB...2615
      Description...2615
      Cab Door...2615
      Cab Door Window...2616
      Rear Cab Window...2617
      Cab Light...2617
    TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER...2619
      Loading And Unloading...2619
      Fastening...2619
    TOWING THE TELESCOPIC HANDLER...2621
      Procedure...2621
    SERVICE SCHEDULE...2623
    AIR CLEANER SERVICE...2625
      Replacing Filter Elements...2625
    ENGINE COOLING SYSTEM...2627
      Cleaning...2627
      Removing And Replacing The Coolant...2628
      Checking Level...2629
    FUEL SYSTEM...2631
      Fuel Specifications...2631
      Biodiesel Blend Fuel...2631
      Filling The Fuel Tank...2632
      Primary Fuel Filter (Pre-Filter)...2632
      Secondary Fuel Filter...2634
      Removing Air From The Fuel System...2634
    ENGINE LUBRICATION SYSTEM...2635
      Checking And Adding Engine Oil...2635
      Engine Oil Chart...2635
      Removing And Replacing Oil And Filter...2636
    HYDRAULIC/HYDROSTATIC SYSTEM...2639
      Checking And Adding Fluid...2639
      Hydraulic / Hydrostatic Fluid Chart...2640
      Removing And Replacing Hydraulic Fluid...2640
      Removing And Replacing Hydraulic / Hydrostatic Filter...2641
      Removing And Replacing Hydraulic Charge Filter...2643
      Fill / Breather Cap...2644
    AXLES (FRONT AND REAR)...2645
      Checking And Adding Oil (Planetary Carrier)...2645
      Removing And Replacing Oil (Planetary Carrier)...2645
      Checking And Adding Oil (Rear Differential)...2646
      Removing And Replacing Oil (Rear Differential)...2646
      Checking And Adding Oil (Front Differential)...2647
      Removing And Replacing Oil (Front Differential)...2647
      Checking And Adding Oil (Gear Box)...2648
      Removing And Replacing Oil (Gear Box)...2648
    LUBRICATING THE TELESCOPIC HANDLER...2649
      Lubrication Locations...2649
    ATTACHMENT CARRIER...2651
      Inspection And Maintenance...2651
    TIRE MAINTENANCE...2653
      Wheel Nuts...2653
      Rotating...2653
      Mounting...2653
      Pressure...2653
    APPROVED BOOM STOP (IF EQUIPPED)...2655
      Installing The Approved Boom Stop...2655
      Removing The Approved Boom Stop...2655
    ENGINE COVER...2657
      Opening And Closing...2657
    STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER...2659
      Procedure...2659
    EMERGENCY EXIT...2661
      Rear Window...2661
    TRACTOR HOMOLOGATED EMERGENCY EXIT...2663
      Right Rear Window...2663
    TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE...2665
      Storage...2665
      Return To Service...2665
    REMOTE START TOOL (SERVICE TOOL) KIT - MEL1563...2667
      Remote Start Tool - MEL1563...2667
      Service Tool Harness Control - MEL1565...2668
      Service Tool Harness Communicator - MEL1566...2669
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031...2671
      Remote Start Tool (Service Tool) - 7003030...2671
      Telescopic Handler Service Tool Harness - 6689747...2672
      Computer Service Tool Harness - 6689746...2674
      Remote Start Procedure...2674
  HYDRAULIC SYSTEM...2677
    HYDRAULIC SYSTEM INFORMATION...2685
      Troubleshooting Chart...2688
      Tightening Procedures...2689
    LIFT CYLINDER...2691
      Removal And Installation...2691
      Parts Identification...2694
      Disassembly...2695
      Assembly...2700
    SELF LEVELING CYLINDER...2705
      Removal And Installation...2705
      Parts Identification...2707
      Disassembly...2708
      Assembly...2711
    SELF LEVELING CYLINDER (LOCK VAlVE)...2715
      Removal And Installation...2715
    EXTENSION CYLINDER...2717
      Cylinder Group Removal And Installation...2717
      Upper Tubeline Removal And Installation...2719
      Extension Cylinder Removal And Installation...2721
      Tubeline Tray Disassembly...2722
      Parts Identification...2724
      Disassembly...2725
      Assembly...2729
    TILT CYLINDER...2733
      Removal And Installation...2733
      Parts Identification...2736
      Disassembly...2737
      Assembly...2742
    STEERING CYLINDER (FRONT / REAR)...2747
      Removing The Steering Cylinder...2747
      Installing The Steering Cylinder...2749
      Disassembling The Steering Cylinder...2751
      Assembling The Steering Cylinder...2753
    GEAR CONTROL CYLINDER...2757
      Removal...2757
      Parts Identification...2759
      Disassembly...2760
      Assembly...2761
      Installation...2762
    MAIN RELIEF VALVE...2763
      Testing And Adjustment...2763
      Removal And Installation...2764
    MANIFOLD...2765
      Removal And Installation...2765
      Parts Identification...2766
      Disassembly And Assembly...2767
    BRAKE VALVE...2769
      Removal And Installation...2769
    GEAR PUMP...2771
      Removal And Installation...2771
      Parts Identification...2773
      Disassembly And Assembly...2774
    FAN MOTOR...2779
      Removal And Installation...2779
      Parts Identification (Single Speed Version) (Standard)...2781
      Disassembly And Assembly (Single Speed Version) (Standard)...2782
      Parts Identification (Variable Speed Version) (Optional)...2785
      Disassembly And Assembly (Variable Speed Version) (Optional)...2786
    HYDRAULIC RESERVOIR...2793
      Removal And Installation...2793
    STEERING VALVE...2795
      Removal And Installation...2795
    HYDRAULIC CONTROL VALVE...2797
      Troubleshooting Chart (Controllers)...2797
      Valve Section Troubleshooting...2798
      Troubleshooting Chart (Control Valve)...2802
      Removal And Installation...2803
      Parts Identification...2805
      Disassembly And Assembly...2806
      Inlet-Outlet Valve Section Disassembly And Assembly...2807
      Lifting Valve Section Disassembly And Assembly...2808
      Tilting Valve Section Disassembly And Assembly...2812
      Telescoping Valve Section Disassembly And Assembly...2816
      Auxiliary Valve Section Disassembly And Assembly...2820
      End Housing Disassembly And Assembly...2824
    PORT RELIEF VALVES...2827
      Adjustment Procedure...2827
      Replacement Procedure...2827
    PARKING BRAKE...2829
      Parking Brake Valve Removal And Installation...2829
    ACCUMULATOR (IF EQUIPPED)...2831
      Removal And Installation...2831
  HYDROSTATIC SYSTEM...2833
    HYDROSTATIC SYSTEM INFORMATION...2835
      Troubleshooting Chart...2835
      Replenishing Valve Function...2836
    OIL COOLER...2837
      Description...2837
    HYDROSTATIC DRIVE MOTOR...2839
      Removal And Installation...2839
      Parts Identification...2840
      Disassembly...2843
      Inspection...2854
      Assembly...2856
    HYDROSTATIC PUMP...2869
      Removal And Installation...2869
      Parts Identification...2871
      Parts Identification (Cont’d)...2872
      Parts Identification (Cont’d)...2873
      Parts Identification (Cont’d)...2874
      Parts Identification (Cont’d)...2875
      Shaft Disassembly...2876
      Relief Valves Disassembly And Assembly...2878
      Charge Pump Disassembly...2879
      Piston Pump Disassembly...2881
      Solenoid Block Disassembly...2884
      Inspection...2886
      Piston Pump Assembly...2888
      Charge Pump Assembly...2892
      Solenoid Block Assembly...2894
      Shaft Assembly...2896
  DRIVE SYSTEM...2899
    TROUBLESHOOTING...2901
      Chart...2901
    AXLE AND DIFFERENTIAL (FRONT)...2903
      General Information...2903
      Planetary Carrier Parts Identification...2903
      Planetary Carrier Disassembly...2904
      Steering Knuckle And Drive Axle Parts Identification...2909
      Steering Knuckle Disassembly...2910
      Drive Axle Disassembly...2912
      Brake System Parts Identification...2914
      Brake System Disassembly...2915
      Differential Parts Identification...2918
      Differential Disassembly...2919
      Bevel Pinion Parts Identification...2924
      Bevel Pinion Disassembly...2925
      Bevel Pinion Assembly...2928
      Differential Assembly...2936
      Brake System Assembly...2942
      Drive Axle Assembly...2945
      Steering Knuckle Assembly...2947
      Planetary Carrier Assembly...2950
      Special Tools...2955
    AXLE AND DIFFERENTIAL (REAR)...2957
      General Information...2957
      Planetary Carrier Parts Identification...2957
      Steering Knuckle And Drive Axle Parts Identification...2963
      Steering Knuckle Disassembly...2964
      Differential Parts Identification...2966
      Differential Disassembly...2967
      Bevel Pinion Parts Identification...2972
      Bevel Pinion Disassembly...2973
      Bevel Pinion Assembly...2976
      Differential Assembly...2984
      Steering Knuckle Assembly...2990
      Planetary Carrier Assembly...2993
      Planetary Carrier Assembly...2994
      Special Tools...2998
    FRONT AXLE...2999
      Removal And Installation...2999
    AXLE TOE-IN...3003
      Adjustment...3003
    PARKING BRAKE...3005
      Releasing The Brake For Towing...3005
      Parking Brake Adjustment...3005
      Brake Cylinder Removal...3006
      Brake Disc Removal And Installation...3009
      Brake Cylinder Installation...3009
    STEERING ANGLE ADJUSTMENT...3011
      Adjustment...3011
    DRIVESHAFT...3013
      Rear Driveshaft Removal And Installation...3013
      Front Driveshaft Removal And Installation...3013
    SERVICE BRAKE...3015
      Description...3015
      Bleeding The Brake Circuit...3015
    REAR AXLE...3017
      Removal And Installation...3017
    GEAR BOX...3021
      Removal And Installation...3021
      Parts Identification...3023
      Disassembly...3026
      Assembly...3035
  MAINFRAME...3043
    OPERATOR CAB...3045
      Removal And Installation...3045
    OPERATOR SEAT...3049
      Removal And Installation...3049
    FIXED BOOM...3051
      Removal...3051
      Installation...3052
    INNER BOOM...3055
      Removal And Installation...3055
    WEAR PADS (FRONT)...3059
      Removal And Installation...3059
    WEAR PADS (REAR)...3061
      Removal And Installation...3061
    ENGINE COVER...3063
      Gas Cylinder Removal And Installation...3063
      Removal And Installation...3063
    FUEL TANK...3065
      Removal And Installation...3065
    ATTACHMENT CARRIER (QUICK-TACH)...3069
      Removal And Installation...3069
    COUNTERWEIGHT...3071
      Removal And Installation...3071
    FENDER...3073
      Removal And Installation...3073
    STEERING COLUMN COVER...3075
      Removal And Installation...3075
    DASH COVER...3077
      Removal And Installation...3077
    JOYSTICK PANEL...3081
      Removal And Installation...3081
  ELECTRICAL SYSTEM & ANALYSIS...3083
    ELECTRICAL SYSTEM INFORMATION...3103
      Troubleshooting Chart...3103
      Description...3104
      Fuses And Relay Location / Identification...3105
    BATTERY...3109
      Removing And Installing Battery...3109
      Using A Booster Battery (Jump Starting)...3110
    ALTERNATOR...3113
      Removal And Installation...3113
      Belt Adjustment...3114
      Belt Replacement...3114
    STARTER...3115
      Testing...3115
      Removal And Installation...3115
    LIGHTS...3117
      Rear Light Removal And Installation...3117
      Rear Light Bulb Replacement...3118
      Front Light Removal And Installation...3119
      Front Light Bulb Replacement...3120
    SIGNAL LEVER...3121
      Removal And Installation...3121
    DISPLAY...3123
      Removal And Installation...3123
    INSTRUMENT PANELS...3125
      Right Instrument And Indicator Panel Removal And Installation...3125
      Left Instrument Panel Removal And Installation...3125
    BOOM ANGLE SENSOR...3127
      Removal And Installation...3127
      Calibration...3128
    FRONT WIPER MOTOR...3131
      Removal And Installation...3131
    TOP WIPER MOTOR...3133
      Removal And Installation...3133
    REAR WIPER MOTOR...3135
      Removal And Installation...3135
    PEDAL ASSEMBLY...3139
      Removal And Installation...3139
    INCHING SENSOR...3141
      Removal And Installation...3141
      Calibration...3142
    SERVICE PC (LAPTOP COMPUTER)...3145
      Connecting Remote Start Tool (Service Tool) - MEL1563...3145
      Connecting Remote Start Tool (Service Tool) - 6689778...3145
    FUEL LEVEL SENDER...3147
      Removal And Installation...3147
    JOYSTICK...3151
      Removal And Installation...3151
    LLMI / LLMC SYSTEM...3153
      System Calibration...3153
      Calibration Test...3155
      System Failure Reports...3156
      System Components Identification...3160
      LLMS Removal...3162
      LLMS Installation...3163
      LLMC Removal And Installation...3164
  ENGINE SERVICE...3165
    ENGINE INFORMATION...3169
      Specifications...3169
      Troubleshooting...3181
    ENGINE SPEED CONTROL...3183
      Removal And Installation...3183
    MUFFLER...3185
      Removal And Installation...3185
    AIR CLEANER...3187
      Housing Removal And Installation...3187
    EXPANSION TANK...3189
      Removal And Installation...3189
    OIL COOLER / INTERCOOLER / RADIATOR...3191
      Removal And Installation...3191
    ENGINE AND ENGINE MOUNTS...3195
      Removal And Installation...3195
    .ENGINE COMPONENTS AND TESTING...3201
      Fuel Injection Pump Removal...3201
      Fuel Injection Pump Installation...3204
      Fuel Injectors Removal And Installation...3208
      Checking The Fuel Lift Pump...3210
      Fuel Lift Pump Removal And Installation...3211
      Compression Checking...3211
      Glow Plugs Checking...3212
      Glow Plugs Removal And Installation...3214
    ENGINE TIMING...3215
      Procedure...3215
    ENGINE / HYDROSTAT ASSEMBLY...3217
      Removal And Installation...3217
    FLYWHEEL AND HOUSING...3223
      Removal And Installation...3223
      Flywheel Inspection...3225
      Ring Gear Removal...3225
      Ring Gear Installation...3225
    TURBOCHARGER...3227
      Turbo Charger Troubleshooting...3227
      Turbo Charger Description...3228
      Turbo Charger Removal And Installation...3228
    FUEL SYSTEM...3231
      Exhaust Manifold Removal And Installation...3231
      Fuel Injector Cover Removal And Installation...3231
      Rocker Cover Removal And Installation...3232
    CYLINDER HEAD...3235
      Cylinder Head Removal...3235
      Cylinder Head Inspection...3237
      Cylinder Head Installation...3237
      Rocker Shaft Disassembly And Assembly...3240
      Valve Removal...3240
      Valve Springs Checking...3241
      Valve Depth Checking...3241
      Valve Guides Checking...3242
      Valve Guide Removal...3243
      Valve Guide Installation...3243
      Valves Checking...3244
      Cutting A Valve Seat...3245
      Valve Seat Assembly...3246
      Changing Valve Springs (With Cylinder Head Installed)...3247
      Valve Clearance Adjustment...3248
    CAMSHAFT AND TIMING GEARS...3249
      Timing Case And Drive Assembly Description...3249
      Timing Cover Removal...3249
      Timing Cover Installation...3249
      Crankshaft Pulley Removal And Installation...3249
      Front Oil Seal Removal And Installation...3249
      Timing Case And Gear Removal...3250
      Timing Case And Gear Installation...3251
      Camshaft And Tappets Removal...3253
      Camshaft And Tappets Installation...3254
    CRANKSHAFT AND PISTONS...3257
      Pistons And Connecting Rods Description...3257
      Pistons And Connecting Rods Removal...3257
      Pistons And Connecting Rods Disassembly...3258
      Piston Ring End Gap...3259
      Piston Ring Installation...3260
      Piston Ring Groove Clearance...3261
      Connecting Rod Inspection...3261
      Connecting Rod Bushing Replacement...3261
      Piston And Connecting Rod Assembly...3262
      Piston And Connecting Rod Installation...3262
      Checking Piston Height...3264
      Crankshaft And Bearings Description...3264
      Crankshaft And Bearings Removal...3264
      Inspection Of Crankshaft And Bearings...3266
      Crankshaft And Bearings Installation...3267
      Rear Oil Seal Removal...3268
      Rear Oil Seal Housing Positioning...3269
      Rear Oil Seal Installation...3269
      Checking Crankshaft End Play...3270
    ENGINE COOLING SYSTEM...3271
      Cooling System Description...3271
      Thermostat Removal and Installation...3272
      Thermostat Testing...3272
      Lubricating Oil Cooler Removal And Installation...3272
      Water Pump Removal...3273
      Water Pump Installation...3273
    LUBRICATION SYSTEM...3275
      Engine Lubrication System Description...3275
      Oil Filter Adapter Removal And Installation...3276
      Oil Pan Removal And Installation...3276
      Oil Screen And Pick-up Tube...3277
      Oil Pump Removal...3277
      Oil Pump Installation...3278
      Oil Pump Disassembly And Assembly...3279
      Oil Pressure Relief Valve Disassembly And Assembly...3280
    ENGINE BLOCK...3281
      Engine Block Description...3281
      Engine Block Disassembly And Assembly...3281
      Piston Cooling Jet Removal...3282
      Piston Cooling Jet Installation...3282
      Piston Cooling Jet Alignment...3282
      Inspection...3282
      Cylinder Liner Inspection...3283
      Cylinder Liner Removal...3284
      Cylinder Liner Installation...3285
  HEATING, VENTILATION, AIR CONDITIONING (HVAC)...3287
    AIR CONDITIONING SYSTEM FLOW...3289
      Principles...3289
      Chart...3290
    COMPONENTS...3291
      Identification...3291
    SAFETY...3293
      Safety Equipment...3293
    REGULAR MAINTENANCE...3295
      Filter Element Removal And Installation...3295
      Air Conditioning Belt Adjustment...3295
      Belt Replacement...3295
      Cleaning The Condenser...3297
      Evaporator / Heater Coil...3297
    BASIC TROUBLESHOOTING...3301
      Poor A/C Performance...3301
      Checking The Electrical System...3302
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...3307
      Compressor Oil...3307
      Compressor Oil Check...3307
      Component Replacement And Refrigeration Leaks...3309
    SYSTEM TROUBLESHOOTING CHART...3311
    TEMPERATURE / PRESSURE...3315
      Chart...3315
    AIR CONDITIONING SERVICE...3317
      Chart...3317
    SYSTEM CHARGING AND RECLAMATION...3319
      Reclamation And Charging With Recovery / Charging Unit...3319
    COMPRESSOR...3323
      Removal And Installation...3323
      Compressor Clutch Disassembly And Assembly...3325
    CONDENSER...3329
      Removal And Installation...3329
    RECEIVER / DRIER...3331
      Removal And Installation...3331
    PRESSURE SWITCH...3333
      Removal And Installation...3333
    EVAPORATOR / HEATER UNIT...3335
      Removal And Installation...3335
    EXPANSION VALVE...3339
      Removal And Installation...3339
    THERMOSTAT...3341
      Description...3341
      Removal And Installation...3342
  SPECIFICATIONS...3345
    (TL360) TELESCOPIC HANDLER SPECIFICATIONS...3347
      Machine Dimensions...3347
      Performance...3348
      Weights...3348
      Engine...3349
      Controls...3349
      Drive System...3349
      Traction...3350
      Steering...3350
      Brakes...3350
      Fluid Capacities...3350
      Hydraulic System...3350
      Electrical System...3351
      Instrument Panel...3351
      Environmental...3351
    MACHINE TORQUE SPECIFICATIONS...3353
      Axle...3353
      Boom...3353
      Drive Box...3353
      Drive Motor...3353
      Engine...3354
      Hydraulic Pump...3354
    TORQUE SPECIFICATIONS FOR BOLTS...3355
      Torque for General SAE Bolts...3355
      Torque For General Metric Bolts...3356
    HYDRAULIC CONNECTION SPECIFICATIONS...3357
      O-ring Face Seal Connection...3357
      Straight Thread O-ring Fitting...3357
      Tubelines And Hoses...3357
      Port Seal Fitting...3358
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...3359
      Specifications...3359
    CONVERSIONS...3361
      Decimal And Millimeter Equivalent Chart...3361
      U.S. To Metric Conversion Chart...3361
  ALPHABETICAL INDEX...3363
6990102 (2-11) - TL470(X) Telescopic Handler Operation & Maintenance Manual...3365
  CONTENTS...3369
  FOREWORD...3371
    DECLARATION OF CONFORMITY...3373
      Model TL470...3373
      Model TL470X...3374
    Certificate OF CONFORMITY...3375
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...3376
    REGULAR MAINTENANCE ITEMS...3376
      Parts...3376
      Lubricants, Fuel And Fluids...3377
    SERIAL NUMBER LOCATION...3378
      Telescopic Handler Serial Number...3378
      Telescopic Handler Statutory Plate (If Equipped)...3378
      Engine Serial Number...3379
      Other Serial Numbers...3379
    DELIVERY REPORT...3379
    BOBCAT TELESCOPIC HANDLER IDENTIFICATION...3380
    FEATURES, ACCESSORIES AND ATTACHMENTS...3381
      Standard Items...3381
      Options And Accessories...3381
      Tractor Homologated Telescopic Handler...3381
      Available Tyres...3382
      Front Window Guard...3382
      Front Window Guard Inspection And Maintenance...3382
      Attachments...3383
      Digging Buckets...3383
      Light Material Buckets...3383
      Bale Handler With Spikes...3384
      Bale Handlers With Tubes...3384
      Bale Handlers With Tines...3384
      Pallet Forks...3384
      Bucket Grapples...3385
      Fork Grapples...3385
  SAFETY & TRAINING RESOURCES...3387
    SAFETY INSTRUCTIONS...3389
      Before Operation...3389
      Safe Operation Is The Operator’s Responsibility...3390
      Safe Operation Needs A Qualified Operator...3390
      Avoid Silica Dust...3391
    FIRE PREVENTION...3391
      Maintenance...3391
      Operation...3391
      Electrical...3391
      Hydraulic System...3392
      Fueling...3392
      Starting...3392
      Spark Arrester Exhaust System...3392
      Welding And Grinding...3392
      Fire Extinguishers...3392
    PUBLICATIONS AND TRAINING RESOURCES...3393
    MACHINE SIGNS (DECALS)...3394
      No-Text Safety Signs...3396
  LOAD CHARTS...3399
    CHARTS FOR TL470(X) MACHINE...3401
  OPERATING INSTRUCTIONS...3407
    OPERATOR CONTROLS IDENTIFICATION...3411
      Operator Components...3411
      Travel Direction...3412
      Steering Wheel...3412
      Multi-function Lever...3413
      Steering Wheel Tilt Position (If Equipped)...3413
      Left Instrument Panel...3414
      Centre Instrument And Indicator Panel...3414
      Right Instrument And Indicator Panel...3415
      Longitudinal Load Moment Indicator (LLMI)...3416
      Display Panel...3417
      Display Screen...3419
      Temperature Control Panel...3421
      Auxiliary Power Outlet...3422
      Roof Console (If Equipped)...3422
      Accelerator Pedal...3422
      Brake Pedal And Inching Control...3422
    OPERATOR CAB...3423
      Description...3423
      Cab Door...3423
      Cab Door Window...3424
      Rear Cab Window...3425
      Cab Light...3425
    STEERING MODE SELECTION...3426
      Aligning Modes...3426
      Steering Mode Management...3427
      Semi-Automatic Aligning Mode Procedure...3428
      Manual Aligning Mode Procedure...3430
    PARKING BRAKE...3431
      Operation...3431
    EMERGENCY EXIT...3431
    TRACTOR HOMOLOGATED EMERGENCY EXIT...3432
    BACK-UP ALARM SYSTEM...3433
      Description...3433
      Operation...3433
    DRIVING AND STEERING THE TELESCOPIC HANDLER...3434
      4-Wheel Steering Mode...3434
      Stopping The Telescopic Handler (4-Wheel Steering Mode)...3435
      2-Wheel Steering Mode...3436
      Stopping The Telescopic Handler (2-Wheel Steering Mode)...3437
      Crab Steering Mode...3438
      Stopping The Telescopic Handler (Crab Steering Mode)...3439
    SPEED MANAGEMENT...3440
      Operation...3440
      Changing The Factory Default Setting...3442
    HYDRAULIC CONTROLS...3443
      Hydraulic Control Lever (Joystick)...3443
      Changing The Maximum Auxiliary Flow...3443
      Quick Couplers...3444
      Auxiliary Hydraulic Release...3444
    ATTACHMENT CONTROL DEVICE (ACD)...3445
      Description...3445
    DAILY INSPECTION...3446
      Daily Inspection And Maintenance...3446
      Cleaning The Operator Cab...3447
    PRE-STARTING PROCEDURE...3448
      Entering The Telescopic Handler...3448
      Operation & Maintenance Manual And Operator’s Handbook Locations...3448
      Seat Adjustment...3449
      Seat Belt Adjustment...3450
      Mirrors Adjustment And Cleaning...3450
    STARTING THE ENGINE...3451
      Cold Temperature Starting...3452
      Warming The Hydraulic / Hydrostatic System...3452
    MONITORING THE DISPLAY PANEL...3453
      Warning And Shutdown...3453
    STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER...3454
      Procedure...3454
    ATTACHMENTS...3455
      Serial Plate...3455
      Buckets...3455
      Pallet Forks...3459
      Bale Spikes...3461
      Installing And Removing The Attachment (Manual Lock)...3462
      Installing And Removing The Attachment (Hydraulic Lock) (If Equipped)...3465
    OPERATING PROCEDURE...3468
      Longitudinal Load Moment Controller (LLMC)...3468
      Longitudinal Load Moment Controller (LLMC) Override Switch...3468
      Inspect The Work Area...3469
      Basic Operating Instructions...3469
      Operating With A Full Bucket...3470
      Operating With An Empty Bucket...3470
      Filling And Emptying The Bucket...3471
      Digging And Filling A Hole...3472
      Raising A Load And Extending The Boom...3473
      Load Capacity Charts...3473
      Handling Loads With Pallet Forks...3474
    TOWING THE TELESCOPIC HANDLER...3478
      Procedure...3478
    LIFTING THE TELESCOPIC HANDLER...3480
      Procedure...3480
    TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER...3481
      Loading And Unloading...3481
      Fastening...3481
    TOWING A TRAILER WITH THE TELESCOPIC HANDLER...3482
      Connecting The Electrics (If Equipped)...3482
      Rear Trailer Brake Valve (If Equipped)...3482
  SYSTEM SETUP & ANALYSIS...3483
    DIAGNOSTIC SERVICE CODES...3485
      Viewing Service Codes...3485
      Service Codes List...3486
    MAINTENANCE CLOCK...3496
      Description...3496
      Setup...3496
      Reset...3496
  PREVENTIVE MAINTENANCE...3497
    SERVICE SCHEDULE...3501
    SEAT BELT...3502
      Inspection And Maintenance...3502
    LLMC CALIBRATION TEST...3503
      Procedure...3503
    APPROVED BOOM STOP (IF EQUIPPED)...3504
      Installing The Approved Boom Stop...3504
      Removing The Approved Boom Stop...3504
    BACK-UP ALARM SYSTEM (IF EQUIPPED)...3505
      Description...3505
      Inspecting...3505
    ENGINE COVER...3505
      Opening And Closing...3505
    HEATING, VENTILATION AND AIR CONDITIONING SYSTEM (HVAC) (IF EQUIPPED)...3506
      Cleaning And Maintenance...3506
      Filters...3506
      Condenser...3507
      Air Conditioning Lubrication...3507
      Troubleshooting...3507
    AIR CLEANER SERVICE...3508
      Replacing Filter Elements...3508
    FUEL SYSTEM...3510
      Fuel Specifications...3510
      Biodiesel Blend Fuel...3510
      Filling The Fuel Tank...3511
      Primary Fuel Filter (Pre-Filter)...3511
      Secondary Fuel Filter...3513
      Removing Air From The Fuel System...3513
    ENGINE LUBRICATION SYSTEM...3514
      Checking And Adding Engine Oil...3514
      Engine Oil Chart...3514
      Removing And Replacing Oil And Filter...3515
    ENGINE COOLING SYSTEM...3516
      Cleaning...3516
      Removing And Replacing The Coolant...3516
      Checking Level...3517
    ELECTRICAL SYSTEM...3518
      Description...3518
      Fuses And Relay Location / Identification...3519
      Battery Maintenance...3521
      Using A Booster Battery (Jump Starting)...3522
      Removing And Installing Battery...3523
    HYDRAULIC/HYDROSTATIC SYSTEM...3525
      Checking And Adding Fluid...3525
      Hydraulic / Hydrostatic Fluid Chart...3526
      Removing And Replacing Hydraulic Fluid...3526
      Removing And Replacing Hydraulic / Hydrostatic Filter...3527
      Removing And Replacing Hydraulic Charge Filter...3528
      Fill / Breather Cap...3529
    AXLES (FRONT AND REAR)...3530
      Checking And Adding Oil (Planetary Carrier)...3530
      Removing And Replacing Oil (Planetary Carrier)...3530
      Checking And Adding Oil (Rear Differential)...3531
      Removing And Replacing Oil (Rear Differential)...3531
      Checking And Adding Oil (Front Differential)...3532
      Removing And Replacing Oil (Front Differential)...3532
      Checking And Adding Oil (Gear Box)...3533
      Removing And Replacing Oil (Gear Box)...3533
    ALTERNATOR BELT...3534
      Belt Adjustment...3534
      Belt Replacement...3534
    AIR CONDITIONING BELT...3535
      Belt Adjustment...3535
      Belt Replacement...3535
    TYRE MAINTENANCE...3537
      Wheel Nuts...3537
      Rotating...3537
      Mounting...3537
      Pressure...3537
    LUBRICATING THE TELESCOPIC HANDLER...3538
      Lubrication Locations...3538
    ATTACHMENT CARRIER...3540
      Inspection And Maintenance...3540
    TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE...3541
      Storage...3541
      Return To Service...3541
  SPECIFICATIONS...3543
    (TL470) TELESCOPIC HANDLER SPECIFICATIONS...3545
      Machine Dimensions...3545
      Performance...3546
      Weights...3546
      Engine...3546
      Controls...3547
      Drive System...3547
      Traction...3547
      Steering...3547
      Brakes...3547
      Fluid Capacities...3548
      Hydraulic System...3548
      Electrical System...3548
      Instrument Panel...3549
      Environmental...3549
  WARRANTY...3551
    WARRANTY...3553
  ALPHABETICAL INDEX...3555
6990103 (06-12) - TL470(X) Telescopic Handler Service Manual...3557
  MAINTENANCE SAFETY...3559
  CONTENTS...3561
  FOREWORD...3563
    FOREWORD...3565
    SAFETY INSTRUCTIONS...3567
      Safe Operation Is The Operator’s Responsibility...3567
      Safe Operation Needs A Qualified Operator...3567
      Avoid Silica Dust...3568
    FIRE PREVENTION...3568
      Maintenance...3568
      Operation...3568
      Electrical...3568
      Hydraulic System...3569
      Fueling...3569
      Starting...3569
      Welding And Grinding...3569
      Fire Extinguishers...3569
    SERIAL NUMBER LOCATION...3570
      Telescopic Handler Serial Number...3570
      Engine Serial Number...3571
      Other Serial Numbers...3571
    DELIVERY REPORT...3571
    BOBCAT TELESCOPIC HANDLER IDENTIFICATION...3572
  SAFETY AND MAINTENANCE...3573
    LIFTING AND BLOCKING THE TELESCOPIC HANDLER...3575
      Procedure...3575
    OPERATOR CAB...3577
      Description...3577
      Cab Door...3577
      Cab Door Window...3578
      Rear Cab Window...3579
      Cab Light...3579
    TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER...3581
      Loading And Unloading...3581
      Fastening...3581
    TOWING THE TELESCOPIC HANDLER...3583
      Procedure...3583
    SERVICE SCHEDULE...3585
    AIR CLEANER SERVICE...3587
      Replacing Filter Elements...3587
    ENGINE COOLING SYSTEM...3589
      Cleaning...3589
      Checking Level...3590
      Removing And Replacing The Coolant...3591
    FUEL SYSTEM...3593
      Fuel Specifications...3593
      Biodiesel Blend Fuel...3593
      Filling The Fuel Tank...3594
      Primary Fuel Filter (Pre-Filter)...3594
      Secondary Fuel Filter...3596
      Removing Air From The Fuel System...3597
    ENGINE LUBRICATION SYSTEM...3599
      Checking And Adding Engine Oil...3599
      Engine Oil Chart...3599
      Removing And Replacing Oil And Filter...3600
    HYDRAULIC / HYDROSTATIC SYSTEM...3603
      Checking And Adding Fluid...3603
      Hydraulic / Hydrostatic Fluid Chart...3604
      Removing And Replacing Hydraulic Fluid...3604
      Removing And Replacing Hydraulic / Hydrostatic Filter...3605
      Removing And Replacing Hydraulic Charge Filter...3606
      Fill / Breather Cap...3607
    AXLES (FRONT AND REAR)...3609
      Checking And Adding Oil (Planetary Carrier)...3609
      Removing And Replacing Oil (Planetary Carrier)...3609
      Checking And Adding Oil (Rear Differential)...3610
      Removing And Replacing Oil (Rear Differential)...3610
      Checking And Adding Oil (Front Differential)...3611
      Removing And Replacing Oil (Front Differential)...3611
      Checking And Adding Oil (Gear Box)...3612
      Removing And Replacing Oil (Gear Box)...3612
    LUBRICATING THE TELESCOPIC HANDLER...3613
      Lubrication Locations...3613
    ATTACHMENT CARRIER...3615
      Inspection And Maintenance...3615
    TYRE MAINTENANCE...3617
      Wheel Nuts...3617
      Rotating...3617
      Mounting...3617
      Pressure...3617
    APPROVED BOOM STOP...3619
      Installing The Approved Boom Stop...3619
      Removing The Approved Boom Stop...3619
    ENGINE COVER...3621
      Opening And Closing...3621
    STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER...3623
      Procedure...3623
    EMERGENCY EXIT...3625
      Right Rear Window...3625
    TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE...3627
      Storage...3627
      Return To Service...3627
    LIFTING THE TELESCOPIC HANDLER...3629
      Procedure...3629
    REMOTE START TOOL (SERVICE TOOL) KIT - MEL1563...3631
      Remote Start Tool - MEL1563...3631
      Service Tool Harness Control - MEL1565...3632
      Service Tool Harness Communicator - MEL1566...3633
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031...3635
      Remote Start Tool (Service Tool) - 7003030...3635
      Telescopic Handler Service Tool Harness - 6689747...3636
      Computer Service Tool Harness - 6689746...3638
      Remote Start Procedure...3638
  HYDRAULIC SYSTEM...3641
    HYDRAULIC / HYDROSTATIC SCHEMATICS...3645
    HYDRAULIC SYSTEM INFORMATION...3657
      Glossary Of Hydraulic / Hydrostatic Symbols...3657
      Troubleshooting Chart...3660
      Tightening Procedures...3661
    LIFT CYLINDER...3663
      Removal And Installation...3663
      Parts Identification...3666
      Disassembly...3667
      Assembly...3672
    SELF LEVELING CYLINDER...3677
      Removal And Installation...3677
      Parts Identification...3679
      Disassembly...3680
      Assembly...3683
    SELF LEVELING CYLINDER (LOCK VALVE)...3687
      Removal And Installation...3687
    EXTENSION CYLINDER...3689
      Cylinder Group Removal And Installation...3689
      Upper Tubeline Removal And Installation...3691
      Extension Cylinder Removal And Installation...3693
      Tubeline Tray Disassembly...3694
      Parts Identification...3696
      Disassembly...3697
      Assembly...3701
    TILT CYLINDER...3705
      Removal And Installation...3705
      Parts Identification...3708
      Disassembly...3709
      Assembly...3714
    STEERING CYLINDER (FRONT / REAR)...3719
      Removal...3719
      Installation...3721
      Disassembly...3723
      Assembly...3725
    GEAR CONTROL CYLINDER...3729
      Removal...3729
      Parts Identification...3731
      Disassembly...3732
      Assembly...3733
      Installation...3734
    MAIN RELIEF VALVE...3735
      Testing And Adjustment...3735
      Removal And Installation...3736
    MANIFOLD...3737
      Removal And Installation...3737
      Parts Identification...3738
      Disassembly And Assembly...3739
    BRAKE VALVE...3741
      Removal And Installation...3741
    GEAR PUMP...3743
      Removal And Installation...3743
      Parts Identification...3745
      Disassembly And Assembly...3746
    FAN MOTOR...3751
      Removal And Installation...3751
      Parts Identification (Single Speed Version) (Standard)...3753
      Disassembly And Assembly (Single Speed Version) (Standard)...3754
      Parts Identification (Variable Speed Version) (Optional)...3757
      Disassembly And Assembly (Variable Speed Version) (Optional)...3758
    HYDRAULIC RESERVOIR...3765
      Removal And Installation...3765
    STEERING VALVE...3767
      Removal And Installation...3767
    HYDRAULIC CONTROL VALVE...3769
      Troubleshooting Chart (Controllers)...3769
      Valve Section Troubleshooting...3770
      Troubleshooting Chart (Control Valve)...3774
      Removal And Installation...3775
      Parts Identification...3777
      Disassembly And Assembly...3778
      Inlet-Outlet Valve Section Disassembly And Assembly...3779
      Lifting Valve Section Disassembly And Assembly...3780
      Tilting Valve Section Disassembly And Assembly...3784
      Telescoping Valve Section Disassembly And Assembly...3788
      Auxiliary Valve Section Disassembly And Assembly...3792
      End Housing Disassembly And Assembly...3796
    PORT RELIEF VALVES...3799
      Testing...3799
      Replacement Procedure...3800
    PARKING BRAKE...3801
      Valve Removal And Installation...3801
    ACCUMULATOR (IF EQUIPPED)...3803
      Removal And Installation...3803
  HYDROSTATIC SYSTEM...3805
    HYDROSTATIC SYSTEM INFORMATION...3807
      Troubleshooting Chart...3807
      Replenishing Valve Function...3808
    OIL COOLER...3809
      Removal And Installation...3809
    HYDROSTATIC DRIVE MOTOR...3811
      Removal And Installation...3811
      Parts Identification...3812
      Disassembly...3815
      Inspection...3826
      Assembly...3828
    HYDROSTATIC PUMP...3841
      Removal And Installation...3841
      Parts Identification...3843
      Shaft Disassembly...3848
      Relief Valves Disassembly And Assembly...3850
      Charge Pump Disassembly...3851
      Piston Pump Disassembly...3853
      Solenoid Block Disassembly...3856
      Inspection...3858
      Piston Pump Assembly...3860
      Charge Pump Assembly...3864
      Solenoid Block Assembly...3866
      Shaft Assembly...3868
  DRIVE SYSTEM...3871
    TROUBLESHOOTING...3873
      Chart...3873
    AXLE AND DIFFERENTIAL (FRONT)...3875
      General Information...3875
      Planetary Carrier Parts Identification...3875
      Planetary Carrier Disassembly...3876
      Steering Knuckle And Drive Axle Parts Identification...3881
      Steering Knuckle Disassembly...3882
      Drive Axle Disassembly...3884
      Brake System Parts Identification...3886
      Brake System Disassembly...3887
      Differential Parts Identification...3890
      Differential Disassembly...3891
      Bevel Pinion Parts Identification...3896
      Bevel Pinion Disassembly...3897
      Bevel Pinion Assembly...3900
      Differential Assembly...3908
      Brake System Assembly...3914
      Drive Axle Assembly...3917
      Steering Knuckle Assembly...3919
      Planetary Carrier Assembly...3922
      Special Tools...3927
    AXLE AND DIFFERENTIAL (REAR)...3929
      General Information...3929
      Planetary Carrier Parts Identification...3929
      Planetary Carrier Disassembly...3930
      Steering Knuckle And Drive Axle Parts Identification...3935
      Steering Knuckle Disassembly...3936
      Differential Parts Identification...3938
      Differential Disassembly...3939
      Bevel Pinion Parts Identification...3944
      Bevel Pinion Disassembly...3945
      Bevel Pinion Assembly...3948
      Differential Assembly...3956
      Steering Knuckle Assembly...3962
      Planetary Carrier Assembly...3965
      Special Tools...3970
    FRONT AXLE...3971
      Removal And Installation...3971
    AXLE TOE-IN...3975
      Adjustment...3975
    PARKING BRAKE...3977
      Releasing The Brake For Towing...3977
      Adjustment...3977
      Brake Cylinder Removal...3978
      Brake Cylinder Disassembly And Assembly...3978
      Brake Disc Removal And Installation...3981
      Brake Cylinder Installation...3981
    STEERING ANGLE ADJUSTMENT...3983
      Adjustment...3983
    DRIVESHAFT...3985
      Rear Driveshaft Removal And Installation...3985
      Front Driveshaft Removal And Installation...3985
    SERVICE BRAKE...3987
      Description...3987
      Bleeding The Brake Circuit...3987
    REAR AXLE...3989
      Removal And Installation...3989
    GEAR BOX...3993
      Removal And Installation...3993
      Parts Identification...3995
      Disassembly...3998
      Assembly...4007
  MAINFRAME...4015
    OPERATOR CAB...4017
      Removal And Installation...4017
    OPERATOR SEAT...4021
      Removal And Installation...4021
    FIXED BOOM...4023
      Removal...4023
      Installation...4024
    INNER BOOM...4027
      Removal And Installation...4027
    WEAR PADS (FRONT)...4031
      Removal And Installation...4031
    WEAR PADS (REAR)...4033
      Removal And Installation...4033
    ENGINE COVER...4035
      Gas Cylinder Removal And Installation...4035
      Removal And Installation...4035
    FUEL TANK...4037
      Removal And Installation...4037
    ATTACHMENT CARRIER (QUICK-TACH)...4041
      Removal And Installation...4041
    COUNTERWEIGHT...4043
      Removal And Installation...4043
    FENDER...4045
      Removal And Installation...4045
    STEERING COLUMN COVER...4047
      Removal And Installation...4047
    DASH COVER...4049
      Removal And Installation...4049
    JOYSTICK PANEL...4053
      Removal And Installation...4053
  ELECTRICAL SYSTEM AND ANALYSIS...4055
    ELECTRICAL SCHEMATICS...4057
    ELECTRICAL SYSTEM INFORMATION...4075
      Troubleshooting Chart...4075
      Description...4076
      Fuses And Relay Location / Identification...4077
    BATTERY...4081
      Removal And Installation...4081
      Using A Booster Battery (Jump Starting)...4082
    ALTERNATOR...4085
      Removal And Installation...4085
      Belt Adjustment...4086
      Belt Replacement...4086
    STARTER...4087
      Testing...4087
      Removal And Installation...4087
    LIGHTS...4089
      Rear Light Removal And Installation...4089
      Rear Light Bulb Replacement...4090
      Front Light Removal And Installation...4091
      Front Light Bulb Replacement...4092
    SIGNAL LEVER...4093
      Removal And Installation...4093
    DISPLAY...4095
      Removal And Installation...4095
    INSTRUMENT PANELS...4097
      Right Instrument And Indicator Panel Removal And Installation...4097
      Left Instrument Panel Removal And Installation...4097
    BOOM ANGLE SENSOR...4099
      Removal And Installation...4099
      Calibration...4100
    FRONT WIPER MOTOR...4103
      Removal And Installation...4103
    TOP WIPER MOTOR...4105
      Removal And Installation...4105
    REAR WIPER MOTOR...4107
      Removal And Installation...4107
    PEDAL ASSEMBLY...4111
      Removal And Installation...4111
    INCHING SENSOR...4113
      Removal And Installation...4113
      Calibration...4114
    SERVICE PC (LAPTOP COMPUTER)...4117
      Connecting Remote Start Tool (Service Tool) - MEL1563...4117
      Connecting Remote Start Tool (Service Tool) - 6689778...4117
    FUEL LEVEL SENDER...4119
      Removal And Installation...4119
    JOYSTICK...4123
      Removal And Installation...4123
    LLMI / LLMC SYSTEM...4125
      System Calibration...4125
      Calibration Test...4127
      System Failure Reports...4128
      System Components Identification...4132
      LLMS Removal...4134
      LLMS Installation...4135
      LLMC Removal And Installation...4136
  ENGINE SERVICE...4137
    ENGINE INFORMATION...4141
      Specifications...4141
      Troubleshooting...4152
      Engine Removal And Installation...4154
      Compression Checking...4159
    ENGINE AND HYDROSTAT ASSEMBLY...4163
      Removal And Installation...4163
    ENGINE SPEED CONTROL...4169
      Removal And Installation...4169
    MUFFLER...4171
      Removal And Installation...4171
    AIR CLEANER...4173
      Housing Removal And Installation...4173
    ENGINE COOLING SYSTEM...4175
      Oil Cooler / Intercooler / Radiator Removal And Installation...4175
      Cooling System Description...4178
      Thermostat Removal And Installation...4179
      Thermostat Testing...4179
      Lubricating Oil Cooler Removal And Installation...4179
      Water Pump Removal...4180
      Water Pump Installation...4180
      Expansion Tank Removal And Installation...4180
    LUBRICATION SYSTEM...4181
      Engine Lubrication System Description...4181
      Oil Filter Adapter Removal And Installation...4182
      Oil Pan Removal And Installation...4182
      Oil Screen And Pick-up Tube...4183
      Oil Pump Removal...4183
      Oil Pump Installation...4184
      Oil Pump Disassembly And Assembly...4185
      Oil Pressure Relief Valve Disassembly And Assembly...4186
    FUEL SYSTEM...4187
      Fuel Injection Pump Removal...4187
      Fuel Injection Pump Installation...4190
      Fuel Injectors Removal And Installation...4194
      Checking The Fuel Lift Pump...4196
      Fuel Lift Pump Removal And Installation...4197
      Exhaust Manifold Removal And Installation...4197
      Fuel Injector Cover Removal And Installation...4198
      Rocker Cover Removal And Installation...4198
    CYLINDER HEAD...4201
      Glow Plugs Checking...4201
      Glow Plugs Removal And Installation...4203
      Removal...4204
      Inspection...4206
      Installation...4206
      Rocker Shaft Disassembly And Assembly...4209
      Valve Removal...4209
      Valve Springs Checking...4210
      Valve Depth Checking...4210
      Valve Guide Checking...4211
      Valve Guide Removal...4212
      Valve Guide Installation...4212
      Valve Checking...4213
      Cutting A Valve Seat...4213
      Valve Seat Assembly...4214
      Changing Valve Springs (With Cylinder Head Installed)...4215
      Valve Clearance Adjustment...4216
      Engine Block Description...4217
      Engine Block Disassembly And Assembly...4217
      Engine Block Inspection...4218
      Cylinder Liner Inspection...4218
      Cylinder Liner Removal...4219
      Cylinder Liner Installation...4220
    CRANKSHAFT AND PISTONS...4221
      Pistons And Connecting Rods Description...4221
      Pistons And Connecting Rods Removal...4221
      Pistons And Connecting Rods Disassembly...4222
      Piston Ring End Gap...4223
      Piston Ring Installation...4224
      Piston Ring Groove Clearance...4225
      Piston Cooling Jet Removal...4225
      Piston Cooling Jet Installation...4225
      Piston Cooling Jet Alignment...4226
      Connecting Rod Inspection...4226
      Connecting Rod Bushing Replacement...4226
      Piston And Connecting Rod Assembly...4227
      Piston And Connecting Rod Installation...4227
      Checking Piston Height...4229
      Crankshaft And Bearings Description...4229
      Crankshaft And Bearings Removal...4229
      Inspection Of Crankshaft And Bearings...4231
      Crankshaft And Bearings Installation...4232
      Rear Oil Seal Removal...4233
      Rear Oil Seal Housing Positioning...4234
      Rear Oil Seal Installation...4234
      Checking Crankshaft End Play...4235
    CAMSHAFT AND TIMING GEARS...4237
      Engine Timing Procedure...4237
      Timing Case And Drive Assembly Description...4238
      Timing Cover Removal...4238
      Timing Cover Installation...4238
      Crankshaft Pulley Removal And Installation...4238
      Front Oil Seal Removal And Installation...4238
      Timing Case And Gear Removal...4239
      Timing Case And Gear Installation...4240
      Camshaft And Tappets Removal...4242
      Camshaft And Tappets Installation...4243
    TURBOCHARGER...4245
      Troubleshooting...4245
      Description...4246
      Removal And Installation...4246
    FLYWHEEL AND HOUSING...4249
      Removal And Installation...4249
      Flywheel Inspection...4251
      Ring Gear Removal...4251
      Ring Gear Installation...4251
  HEATING, VENTILATION, AIR CONDITIONING (HVAC)...4253
    AIR CONDITIONING SYSTEM FLOW...4255
      Description...4255
      Chart...4256
      Components...4257
      Safety Equipment...4259
    REGULAR MAINTENANCE...4261
      Filters...4261
      Air Conditioning Belt Adjustment...4261
      Belt Replacement...4261
      Cleaning The Condenser...4263
      Air Conditioning Lubrication...4263
      Air Conditioning Service Chart...4264
      Evaporator / Heater Coil...4265
    TROUBLESHOOTING...4269
      Blower Motor Does Not Operate...4269
      Blower Motor Operates Normally, But Air Flow Is Insufficient...4269
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...4269
      The Compressor Does Not Operate At All, Or Operates Improperly...4269
      Gauge Pressure Related Troubleshooting...4270
      Temperature / Pressure Chart...4272
      Poor A/C Performance...4273
      HVAC Repair And Leaks...4274
      Electrical System...4274
    SYSTEM CHARGING AND RECLAMATION...4279
      Reclamation And Charging With Recovery / Charging Unit...4279
    COMPRESSOR...4283
      Removal And Installation...4283
      Oil...4285
      Oil Check...4285
      Clutch Disassembly And Assembly...4287
    CONDENSER...4291
      Removal And Installation...4291
    RECEIVER / DRIER...4293
      Removal And Installation...4293
    PRESSURE SWITCH...4295
      Removal And Installation...4295
    EVAPORATOR / HEATER UNIT...4297
      Removal And Installation...4297
    THERMOSTAT...4301
      Description...4301
      Removal And Installation...4302
    EXPANSION VALVE...4305
      Removal And Installation...4305
  SPECIFICATIONS...4307
    (TL470) TELESCOPIC HANDLER SPECIFICATIONS...4309
      Machine Dimensions...4309
      Performance...4310
      Weights...4310
      Engine...4311
      Controls...4311
      Drive System...4311
      Traction...4312
      Steering...4312
      Brakes...4312
      Fluid Capacities...4312
      Hydraulic System...4312
      Electrical System...4313
      Instrument Panel...4313
      Environmental...4313
    MACHINE TORQUE SPECIFICATIONS...4315
      Axle...4315
      Boom...4315
      Drive Box...4315
      Drive Motor...4315
      Engine...4316
      Hydraulic Pump...4316
    TORQUE SPECIFICATIONS FOR BOLTS...4317
      Torque for General SAE Bolts...4317
      Torque For General Metric Bolts...4318
    HYDRAULIC CONNECTION SPECIFICATIONS...4319
      O-ring Face Seal Connection...4319
      Straight Thread O-ring Fitting...4319
      Tubelines And Hoses...4319
      Flare Fitting...4320
      O-ring Flare Fitting...4321
      Port Seal Fitting...4323
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...4325
      Specifications...4325
    CONVERSIONS...4327
      Decimal And Millimeter Equivalent Chart...4327
      U.S. To Metric Conversion Chart...4327
  ALPHABETICAL INDEX...4329
6990103 (07-12) - TL470(X)HF Telescopic Handler Service Manual...4331
  MAINTENANCE SAFETY...4333
  CONTENTS...4335
  FOREWORD...4337
    FOREWORD...4339
    SAFETY INSTRUCTIONS...4341
      Safe Operation Is The Operator’s Responsibility...4341
      Safe Operation Needs A Qualified Operator...4341
      Avoid Silica Dust...4342
    FIRE PREVENTION...4342
      Maintenance...4342
      Operation...4342
      Electrical...4342
      Hydraulic System...4343
      Fueling...4343
      Starting...4343
      Welding And Grinding...4343
      Fire Extinguishers...4343
    SERIAL NUMBER LOCATION...4344
      Telescopic Handler Serial Number...4344
      Engine Serial Number...4345
      Other Serial Numbers...4345
    DELIVERY REPORT...4345
    BOBCAT TELESCOPIC HANDLER IDENTIFICATION...4346
  SAFETY AND MAINTENANCE...4347
    LIFTING AND BLOCKING THE TELESCOPIC HANDLER...4349
      Procedure...4349
    OPERATOR CAB...4351
      Description...4351
      Cab Door...4351
      Cab Door Window...4352
      Rear Cab Window...4353
      Cab Light...4353
    TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER...4355
      Loading And Unloading...4355
      Fastening...4355
    TOWING THE TELESCOPIC HANDLER...4357
      Procedure...4357
    SERVICE SCHEDULE...4359
      Chart...4359
    AIR CLEANER SERVICE...4361
      Replacing Filter Elements...4361
    ENGINE COOLING SYSTEM...4363
      Cleaning...4363
      Checking Level...4363
      Removing And Replacing The Coolant...4364
    FUEL SYSTEM...4365
      Fuel Specifications...4365
      Biodiesel Blend Fuel...4365
      Filling The Fuel Tank...4366
      Primary Fuel Filter (Pre-Filter)...4366
      Secondary Fuel Filter...4368
      Removing Air From The Fuel System...4369
    ENGINE LUBRICATION SYSTEM...4371
      Checking And Adding Engine Oil...4371
      Engine Oil Chart...4371
      Removing And Replacing Oil And Filter...4372
    HYDRAULIC / HYDROSTATIC SYSTEM...4375
      Checking And Adding Fluid...4375
      Hydraulic / Hydrostatic Fluid Chart...4376
      Removing And Replacing Hydraulic Fluid...4376
      Removing And Replacing Hydraulic / Hydrostatic Filters...4377
      Removing And Replacing Hydraulic Charge Filter...4379
      Fill / Breather Cap...4380
    AXLES (FRONT AND REAR)...4381
      Checking And Adding Oil (Planetary Carrier)...4381
      Removing And Replacing Oil (Planetary Carrier)...4381
      Checking And Adding Oil (Rear Differential)...4382
      Removing And Replacing Oil (Rear Differential)...4382
      Checking And Adding Oil (Front Differential)...4383
      Removing And Replacing Oil (Front Differential)...4383
      Checking And Adding Oil (Gear Box)...4384
      Removing And Replacing Oil (Gear Box)...4384
    LUBRICATING THE TELESCOPIC HANDLER...4385
      Lubrication Locations...4385
    ATTACHMENT CARRIER...4387
      Inspection And Maintenance...4387
    TIRE MAINTENANCE...4389
      Wheel Nuts...4389
      Rotating...4389
      Mounting...4389
      Pressure...4389
    APPROVED BOOM STOP...4391
      Installing...4391
      Removing...4391
    ENGINE COVER...4393
      Opening And Closing...4393
    STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER...4395
      Procedure...4395
    EMERGENCY EXIT...4397
      Rear Window...4397
      Right Rear Window...4397
    TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE...4399
      Storage...4399
      Return To Service...4399
    LIFTING THE TELESCOPIC HANDLER...4401
      Procedure...4401
    REMOTE START TOOL (SERVICE TOOL) KIT - MEL1563...4403
      Remote Start Tool - MEL1563...4403
      Service Tool Harness Control - MEL1565...4404
      Service Tool Harness Communicator - MEL1566...4405
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031...4407
      Remote Start Tool (Service Tool) - 7003030...4407
      Telescopic Handler Service Tool Harness - 6689747...4408
      Computer Service Tool Harness - 6689746...4410
      Remote Start Procedure...4410
  HYDRAULIC SYSTEM...4413
    HYDRAULIC / HYDROSTATIC SCHEMATICS...4417
    HYDRAULIC SYSTEM INFORMATION...4419
      Glossary Of Hydraulic / Hydrostatic Symbols...4419
      Troubleshooting Chart...4422
      Tightening Procedures...4423
    LIFT CYLINDER...4425
      Removal And Installation...4425
      Parts Identification...4428
      Disassembly...4429
      Assembly...4434
    SELF LEVELING CYLINDER...4439
      Removal And Installation...4439
      Parts Identification...4441
      Disassembly...4442
      Assembly...4445
    SELF LEVELING CYLINDER (LOCK VALVE)...4449
      Removal And Installation...4449
    EXTENSION CYLINDER...4451
      Cylinder Group Removal And Installation...4451
      Upper Tubeline Removal And Installation...4453
      Extension Cylinder Removal And Installation...4455
      Tubeline Tray Disassembly...4456
      Parts Identification...4458
      Disassembly...4459
      Assembly...4463
    TILT CYLINDER...4467
      Removal And Installation...4467
      Parts Identification...4470
      Disassembly...4471
      Assembly...4476
    STEERING CYLINDER (FRONT / REAR)...4481
      Removal...4481
      Installation...4483
      Disassembly...4485
      Assembly...4487
    GEAR CONTROL CYLINDER...4491
      Removal...4491
      Parts Identification...4493
      Disassembly...4494
      Assembly...4495
      Installation...4496
    MAIN RELIEF VALVE...4497
      Testing And Adjustment...4497
      Removal And Installation...4498
    MANIFOLD...4499
      Removal And Installation...4499
      Parts Identification...4500
      Disassembly And Assembly...4501
    BRAKE VALVE...4503
      Removal And Installation...4503
    PISTON PUMP...4505
      Removal And Installation...4505
      Parts Identification...4507
      Disassembly And Assembly...4508
    FAN MOTOR...4519
      Removal And Installation...4519
      Parts Identification (Single Speed Version) (Standard)...4521
      Disassembly And Assembly (Single Speed Version) (Standard)...4522
      Parts Identification (Variable Speed Version) (Optional)...4525
      Disassembly And Assembly (Variable Speed Version) (Optional)...4526
    HYDRAULIC FLUID RESERVOIR...4533
      Removal And Installation...4533
    STEERING VALVE...4535
      Removal And Installation...4535
    HYDRAULIC CONTROL VALVE...4537
      Troubleshooting Chart (Controllers)...4537
      Valve Section Troubleshooting...4538
      Troubleshooting Chart (Control Valve)...4542
      Removal And Installation...4543
      Parts Identification...4545
      Disassembly And Assembly...4546
      End Housing Disassembly And Assembly...4547
      Auxiliary Valve Section Disassembly And Assembly...4548
      Telescoping Valve Section Disassembly And Assembly...4552
      Tilting Valve Section Disassembly And Assembly...4556
      Lifting Valve Section Disassembly And Assembly...4560
      Inlet-Outlet Valve Section Disassembly And Assembly...4564
    PORT RELIEF VALVES...4567
      Testing...4567
      Replacement Procedure...4568
    PARKING BRAKE...4569
      Valve Removal And Installation...4569
    ACCUMULATOR...4571
      Removal And Installation...4571
    FAN PUMP...4573
      Removal And Installation...4573
      Disassembly And Assembly...4574
  HYDROSTATIC SYSTEM...4579
    HYDROSTATIC SYSTEM INFORMATION...4581
      Troubleshooting Chart...4581
      Replenishing Valve Function...4582
    OIL COOLER...4583
      Description...4583
    HYDROSTATIC DRIVE MOTOR...4585
      Removal And Installation...4585
      Parts Identification...4586
      Disassembly...4589
      Inspection...4600
      Assembly...4602
    HYDROSTATIC PUMP...4615
      Removal And Installation...4615
      Parts Identification...4617
      Shaft Disassembly...4622
      Relief Valves Disassembly And Assembly...4624
      Charge Pump Disassembly...4625
      Piston Pump Disassembly...4627
      Solenoid Block Disassembly...4630
      Inspection...4632
      Piston Pump Assembly...4634
      Charge Pump Assembly...4638
      Solenoid Block Assembly...4640
      Shaft Assembly...4642
  DRIVE SYSTEM...4645
    TROUBLESHOOTING...4647
      Chart...4647
    AXLE AND DIFFERENTIAL (FRONT)...4649
      Description...4649
      Planetary Carrier Parts Identification...4649
      Planetary Carrier Disassembly...4650
      Steering Knuckle And Drive Axle Parts Identification...4655
      Steering Knuckle Disassembly...4656
      Drive Axle Disassembly...4658
      Brake Group Parts Identification...4660
      Brake Group Disassembly...4661
      Differential Parts Identification...4664
      Differential Disassembly...4665
      Pinion Group Parts Identification...4670
      Pinion Group Disassembly...4671
      Pinion Group Assembly...4674
      Differential Assembly...4682
      Brake Group Assembly...4688
      Drive Axle Assembly...4691
      Steering Knuckle Assembly...4693
      Planetary Carrier Assembly...4696
      Special Tools...4701
    AXLE AND DIFFERENTIAL (REAR)...4703
      Description...4703
      Planetary Carrier Parts Identification...4703
      Planetary Carrier Disassembly...4704
      Steering Knuckle And Drive Axle Parts Identification...4709
      Steering Knuckle Disassembly...4710
      Differential Parts Identification...4712
      Differential Disassembly...4713
      Pinion Group Parts Identification...4718
      Pinion Group Disassembly...4719
      Pinion Group Assembly...4722
      Differential Assembly...4730
      Steering Knuckle Assembly...4736
      Planetary Carrier Assembly...4739
      Planetary Carrier Assembly...4740
      Special Tools...4744
    FRONT AXLE...4745
      Removal And Installation...4745
    AXLE TOE-IN...4749
      Adjustment...4749
    PARKING BRAKE...4751
      Releasing The Brake For Towing...4751
      Adjustment...4751
      Brake Cylinder Removal...4752
      Brake Cylinder Disassembly And Assembly...4752
      Brake Disc Removal And Installation...4755
      Brake Cylinder Installation...4755
    STEERING ANGLE ADJUSTMENT...4757
      Adjustment...4757
    DRIVESHAFT...4759
      Rear Driveshaft Removal And Installation...4759
      Front Driveshaft Removal And Installation...4759
    SERVICE BRAKE...4761
      Description...4761
      Bleeding The Brake Circuit...4761
    REAR AXLE...4763
      Removal And Installation...4763
    GEAR BOX...4767
      Removal And Installation...4767
      Parts Identification...4769
      Disassembly...4770
      Assembly...4779
  MAINFRAME...4787
    OPERATOR CAB...4789
      Removal And Installation...4789
    OPERATOR SEAT...4793
      Removal And Installation...4793
    FIXED BOOM...4795
      Removal...4795
      Installation...4796
    INNER BOOM...4799
      Removal And Installation...4799
    WEAR PADS (FRONT)...4803
      Removal And Installation...4803
    WEAR PADS (REAR)...4805
      Removal And Installation...4805
    ENGINE COVER...4807
      Gas Cylinder Removal And Installation...4807
      Removal And Installation...4807
    FUEL TANK...4809
      Removal And Installation...4809
    ATTACHMENT CARRIER (QUICK-TACH)...4813
      Removal And Installation...4813
    COUNTERWEIGHT...4815
      Removal And Installation...4815
    FENDER...4817
      Removal And Installation...4817
    STEERING COLUMN COVER...4819
      Removal And Installation...4819
    DASH COVER...4821
      Removal And Installation...4821
    JOYSTICK PANEL...4825
      Removal And Installation...4825
  ELECTRICAL SYSTEM AND ANALYSIS...4827
    ELECTRICAL SCHEMATICS...4829
    ELECTRICAL SYSTEM INFORMATION...4848
      Troubleshooting Chart...4848
      Description...4849
      Fuses And Relay Location / Identification...4849
    BATTERY...4852
      Removal And Installation...4852
      Using A Booster Battery (Jump Starting)...4854
    ALTERNATOR...4856
      Removal And Installation...4856
      Belt Adjustment...4857
      Belt Replacement...4857
    STARTER...4858
      Testing...4858
      Removal And Installation...4858
    LIGHTS...4860
      Rear Light Removal And Installation...4860
      Rear Light Bulb Replacement...4861
      Front Light Removal And Installation...4862
      Front Light Bulb Replacement...4863
    SIGNAL LEVER...4864
      Removal And Installation...4864
    DISPLAY...4866
      Removal And Installation...4866
    INSTRUMENT PANELS...4868
      Right Instrument And Indicator Panel Removal And Installation...4868
      Left Instrument Panel Removal And Installation...4868
    BOOM ANGLE SENSOR...4870
      Removal And Installation...4870
      Calibration...4871
    FRONT WIPER MOTOR...4874
      Removal And Installation...4874
    TOP WIPER MOTOR...4876
      Removal And Installation...4876
    REAR WIPER MOTOR...4878
      Removal And Installation...4878
    PEDAL ASSEMBLY...4882
      Removal And Installation...4882
    INCHING SENSOR...4884
      Removal And Installation...4884
      Calibration...4885
    SERVICE PC (LAPTOP COMPUTER)...4888
      Connecting Remote Start Tool (Service Tool) - MEL1563...4888
      Connecting Remote Start Tool (Service Tool) - 7003030...4888
    FUEL LEVEL SENDER...4890
      Removal And Installation...4890
    JOYSTICK...4894
      Removal And Installation...4894
    LLMI / LLMC SYSTEM...4896
      System Calibration...4896
      Calibration Test...4898
      System Failure Reports...4899
      System Components Identification...4903
      LLMS Removal...4905
      LLMS Installation...4906
      LLMC Removal And Installation...4907
  ENGINE SERVICE...4908
    ENGINE INFORMATION...4910
      Fuel System Information...4910
      Specifications...4911
      Troubleshooting...4913
      Engine Removal And Installation...4915
    ENGINE AND HYDROSTAT ASSEMBLY...4924
      Removal And Installation...4924
    ENGINE SPEED CONTROL...4930
      Removal And Installation...4930
    MUFFLER...4932
      Removal And Installation...4932
    AIR CLEANER...4934
      Housing Removal And Installation...4934
    ENGINE COOLING SYSTEM...4936
      Oil Cooler / Intercooler / Radiator Removal And Installation...4936
      Water Temperature Regulator Removal...4939
      Water Temperature Regulator Installation...4940
      Water Temperature Regulator Test...4941
      Cooling System Check...4941
      Cooling System Inspection...4942
      Engine Oil Cooler Removal...4943
      Engine Oil Cooler Installation...4944
      Engine Oil Cooler Inspection...4945
      Water Pump Removal...4946
      Water Pump Installation...4946
      Water Pump Inspection...4947
      Water Pump Bypass Tube Removal...4948
      Water Pump Bypass Tube Installation...4948
      Expansion Tank Removal And Installation...4948
    LUBRICATION SYSTEM...4950
      Engine Oil Filter Base Removal...4950
      Engine Oil Filter Base Installation...4950
      Engine Oil Pressure Test...4951
      Excessive Engine Oil Consumption Inspection...4951
      Increased Engine Oil Temperature Inspection...4952
      Excessive Bearing Wear Inspection...4952
    FUEL SYSTEM...4954
      Fuel Priming Pump Removal...4954
      Fuel Priming Pump Installation...4954
      Fuel System Inspection...4955
      Fuel Quality Test...4955
      Fuel System Prime...4956
    CYLINDER HEAD...4958
      Valve Mechanism Cover Removal...4958
      Valve Mechanism Cover Installation...4958
      Air Inlet And Exhaust System Inspection...4960
    CRANKSHAFT SEALS AND BEARINGS...4962
      Crankshaft Rear Seal Removal...4962
      Crankshaft Rear Seal Installation...4962
      Crankshaft Wear Sleeve (Rear) Removal...4964
      Crankshaft Wear Sleeve (Rear) Installation...4964
      Crankshaft Front Seal Removal...4965
      Crankshaft Front Seal Installation...4966
      Crankshaft Wear Sleeve (Front) Removal...4966
      Crankshaft Wear Sleeve (Front) Installation...4967
    TIMING COVER...4968
      Timing Cover Removal...4968
      Timing Cover Installation...4968
    CRANKSHAFT PULLEY...4970
      Crankshaft Pulley Removal...4970
      Crankshaft Pulley Installation...4970
      Crankshaft Pulley Check...4971
    TURBOCHARGER...4972
      Troubleshooting...4972
      Description...4973
      Removal And Installation...4973
    FLYWHEEL AND HOUSING...4976
      Flywheel Removal...4976
      Flywheel Installation...4977
      Flywheel Inspection...4978
      Flywheel Housing Removal...4979
      Flywheel Housing Installation...4980
      Flywheel Housing Inspection...4981
      Crankcase Breather Removal...4982
      Crankcase Breather Installation...4982
    ELECTRONIC CONTROL MODULE...4984
      Removal...4984
      Installation...4985
      Mounting Bracket Removal...4986
      Mounting Bracket Installation...4986
  HEATING, VENTILATION, AIR CONDITIONING (HVAC)...4988
    AIR CONDITIONING SYSTEM FLOW...4990
      Description...4990
      Chart...4991
      Components...4992
      Safety Equipment...4994
    REGULAR MAINTENANCE...4996
      Filters...4996
      Air Conditioning Belt Adjustment...4997
      Belt Replacement...4997
      Cleaning The Condenser...4998
      Air Conditioning Lubrication...4998
      Air Conditioning Service Chart...4999
      Evaporator / Heater Coil...5000
    TROUBLESHOOTING...5004
      Blower Motor Does Not Operate...5004
      Blower Motor Operates Normally, But Air Flow Is Insufficient...5004
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...5004
      The Compressor Does Not Operate At All, Or Operates Improperly...5004
      Gauge Pressure Related Troubleshooting...5005
      Temperature / Pressure Chart...5007
      Poor A/C Performance...5008
      HVAC Repair And Leaks...5008
      Electrical System...5009
    SYSTEM CHARGING AND RECLAMATION...5014
      Reclamation And Charging With Recovery / Charging Unit...5014
    COMPRESSOR...5018
      Removal And Installation...5018
      Oil...5020
      Oil Check...5020
      Clutch Disassembly And Assembly...5022
    CONDENSER...5026
      Removal And Installation...5026
    RECEIVER / DRIER...5028
      Removal And Installation...5028
    PRESSURE SWITCH...5030
      Removal And Installation...5030
    EVAPORATOR / HEATER UNIT...5032
      Removal And Installation...5032
    THERMOSTAT...5036
      Description...5036
      Removal And Installation...5037
    EXPANSION VALVE...5040
      Removal And Installation...5040
  SPECIFICATIONS...5042
    (TL470(X)HF) TELESCOPIC HANDLER SPECIFICATIONS...5044
      Machine Dimensions...5044
      Performance...5045
      Weights...5045
      Engine...5046
      Controls...5046
      Drive System...5046
      Traction...5047
      Steering...5047
      Brakes...5047
      Fluid Capacities...5047
      Hydraulic System...5047
      Cycle Times...5048
      Electrical System...5048
      Instrument Panel...5049
      Environmental...5049
    MACHINE TORQUE SPECIFICATIONS...5050
      Axle...5050
      Boom...5050
      Drive Box...5050
      Drive Motor...5050
      Engine...5051
      Hydraulic Pump...5051
    TORQUE SPECIFICATIONS FOR BOLTS...5052
      Torque for General SAE Bolts...5052
      Torque For General Metric Bolts...5053
    HYDRAULIC CONNECTION SPECIFICATIONS...5054
      O-ring Face Seal Connection...5054
      Straight Thread O-ring Fitting...5054
      Tubelines And Hoses...5054
      Flare Fitting...5055
      O-ring Flare Fitting...5056
      Port Seal Fitting...5058
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...5060
      Specifications...5060
    CONVERSIONS...5062
      Decimal And Millimeter Equivalent Chart...5062
      U.S. To Metric Conversion Chart...5062
  ALPHABETICAL INDEX...5064
6990103 (5-11) - TL470(X) Telescopic Handler Service Manual...5066
  FOREWORD...0
    FOREWORD...5074
    SAFETY INSTRUCTIONS...5076
      Safe Operation Is The Operator’s Responsibility...5076
      Safe Operation Needs A Qualified Operator...5076
      Avoid Silica Dust...5077
    FIRE PREVENTION...5077
      Maintenance...5077
      Operation...5077
      Electrical...5077
      Hydraulic System...5078
      Fueling...5078
      Starting...5078
      Welding And Grinding...5078
      Fire Extinguishers...5078
    SERIAL NUMBER LOCATION...5079
      Telescopic Handler Serial Number...5079
      Engine Serial Number...5080
      Other Serial Numbers...5080
    DELIVERY REPORT...5080
    BOBCAT TELESCOPIC HANDLER IDENTIFICATION...5081
  SAFETY & MAINTENANCE...5082
    LIFTING AND BLOCKING THE TELESCOPIC HANDLER...5084
      Procedure...5084
    OPERATOR CAB...5086
      Description...5086
      Cab Door...5086
      Cab Door Window...5087
      Rear Cab Window...5088
      Cab Light...5088
    TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER...5090
      Loading And Unloading...5090
      Fastening...5090
    TOWING THE TELESCOPIC HANDLER...5092
      Procedure...5092
    SERVICE SCHEDULE...5094
    AIR CLEANER SERVICE...5096
      Replacing Filter Elements...5096
    ENGINE COOLING SYSTEM...5098
      Cleaning...5098
      Removing And Replacing The Coolant...5099
      Checking Level...5100
    FUEL SYSTEM...5102
      Fuel Specifications...5102
      Biodiesel Blend Fuel...5102
      Filling The Fuel Tank...5103
      Primary Fuel Filter (Pre-Filter)...5103
      Secondary Fuel Filter...5105
      Removing Air From The Fuel System...5105
    ENGINE LUBRICATION SYSTEM...5106
      Checking And Adding Engine Oil...5106
      Engine Oil Chart...5106
      Removing And Replacing Oil And Filter...5107
    HYDRAULIC/HYDROSTATIC SYSTEM...5110
      Checking And Adding Fluid...5110
      Hydraulic / Hydrostatic Fluid Chart...5111
      Removing And Replacing Hydraulic Fluid...5111
      Removing And Replacing Hydraulic / Hydrostatic Filter...5112
      Removing And Replacing Hydraulic Charge Filter...5114
      Fill / Breather Cap...5115
    AXLES (FRONT AND REAR)...5116
      Checking And Adding Oil (Planetary Carrier)...5116
      Removing And Replacing Oil (Planetary Carrier)...5116
      Checking And Adding Oil (Rear Differential)...5117
      Removing And Replacing Oil (Rear Differential)...5117
      Checking And Adding Oil (Front Differential)...5118
      Removing And Replacing Oil (Front Differential)...5118
      Checking And Adding Oil (Gear Box)...5119
      Removing And Replacing Oil (Gear Box)...5119
    LUBRICATING THE TELESCOPIC HANDLER...5120
      Lubrication Locations...5120
    ATTACHMENT CARRIER...5122
      Inspection And Maintenance...5122
    TIRE MAINTENANCE...5124
      Wheel Nuts...5124
      Rotating...5124
      Mounting...5124
      Pressure...5124
    APPROVED BOOM STOP (IF EQUIPPED)...5126
      Installing The Approved Boom Stop...5126
      Removing The Approved Boom Stop...5126
    ENGINE COVER...5128
      Opening And Closing...5128
    STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER...5130
      Procedure...5130
    EMERGENCY EXIT...5132
      Rear Window...5132
    TRACTOR HOMOLOGATED EMERGENCY EXIT...5134
      Right Rear Window...5134
    TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE...5136
      Storage...5136
      Return To Service...5136
    REMOTE START TOOL (SERVICE TOOL) KIT - MEL1563...5138
      Remote Start Tool - MEL1563...5138
      Service Tool Harness Control - MEL1565...5139
      Service Tool Harness Communicator - MEL1566...5140
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031...5142
      Remote Start Tool (Service Tool) - 7003030...5142
      Telescopic Handler Service Tool Harness - 6689747...5143
      Computer Service Tool Harness - 6689746...5145
      Remote Start Procedure...5145
  HYDRAULIC SYSTEM...5148
    HYDRAULIC SYSTEM INFORMATION...5156
      Troubleshooting Chart...5159
      Tightening Procedures...5160
    LIFT CYLINDER...5162
      Removal And Installation...5162
      Parts Identification...5165
      Disassembly...5166
      Assembly...5171
    SELF LEVELING CYLINDER...5176
      Removal And Installation...5176
      Parts Identification...5178
      Disassembly...5179
      Assembly...5182
    SELF LEVELING CYLINDER (LOCK VAlVE)...5186
      Removal And Installation...5186
    EXTENSION CYLINDER...5188
      Cylinder Group Removal And Installation...5188
      Upper Tubeline Removal And Installation...5190
      Extension Cylinder Removal And Installation...5192
      Tubeline Tray Disassembly...5193
      Parts Identification...5195
      Disassembly...5196
      Assembly...5200
    TILT CYLINDER...5204
      Removal And Installation...5204
      Parts Identification...5207
      Disassembly...5208
      Assembly...5213
    STEERING CYLINDER (FRONT/REAR)...5218
      Removing The Steering Cylinder...5218
      Installing The Steering Cylinder...5220
      Disassembling The Steering Cylinder...5222
      Assembling The Steering Cylinder...5224
    GEAR CONTROL CYLINDER...5228
      Removal...5228
      Parts Identification...5230
      Disassembly...5231
      Assembly...5232
      Installation...5233
    MAIN RELIEF VALVE...5234
      Testing And Adjustment...5234
      Removal And Installation...5235
    MANIFOLD...5236
      Removal And Installation...5236
      Parts Identification...5237
      Disassembly And Assembly...5238
    BRAKE VALVE...5240
      Removal And Installation...5240
    GEAR PUMP...5242
      Removal And Installation...5242
      Parts Identification...5244
      Disassembly And Assembly...5245
    FAN MOTOR...5250
      Removal And Installation...5250
      Parts Identification (Single Speed Version) (Standard)...5252
      Disassembly And Assembly (Single Speed Version) (Standard)...5253
      Parts Identification (Variable Speed Version) (Optional)...5256
      Disassembly And Assembly (Variable Speed Version) (Optional)...5257
    HYDRAULIC RESERVOIR...5264
      Removal And Installation...5264
    STEERING VALVE...5266
      Removal And Installation...5266
    HYDRAULIC CONTROL VALVE...5268
      Troubleshooting Chart (Controllers)...5268
      Valve Section Troubleshooting...5269
      Troubleshooting Chart (Control Valve)...5273
      Removal And Installation...5274
      Parts Identification...5276
      Disassembly And Assembly...5277
      Inlet-Outlet Valve Section Disassembly And Assembly...5278
      Lifting Valve Section Disassembly And Assembly...5279
      Tilting Valve Section Disassembly And Assembly...5283
      Telescoping Valve Section Disassembly And Assembly...5287
      Auxiliary Valve Section Disassembly And Assembly...5291
      End Housing Disassembly And Assembly...5295
    PORT RELIEF VALVES...5298
      Adjustment Procedure...5298
      Replacement Procedure...5298
    PARKING BRAKE...5300
      Parking Brake Valve Removal And Installation...5300
    ACCUMULATOR (IF EQUIPPED)...5302
      Removal And Installation...5302
  HYDROSTATIC SYSTEM...5304
    HYDROSTATIC SYSTEM INFORMATION...5306
      Troubleshooting Chart...5306
      Replenishing Valve Function...5307
    OIL COOLER...5308
      Description...5308
    HYDROSTATIC DRIVE MOTOR...5310
      Removal And Installation...5310
      Parts Identification...5311
      Disassembly...5314
      Inspection...5325
      Assembly...5327
    HYDROSTATIC PUMP...5340
      Removal And Installation...5340
      Parts Identification...5342
      Parts Identification (Cont’d)...5343
      Parts Identification (Cont’d)...5344
      Parts Identification (Cont’d)...5345
      Parts Identification (Cont’d)...5346
      Shaft Disassembly...5347
      Relief Valves Disassembly And Assembly...5349
      Charge Pump Disassembly...5350
      Piston Pump Disassembly...5352
      Solenoid Block Disassembly...5355
      Inspection...5357
      Piston Pump Assembly...5359
      Charge Pump Assembly...5363
      Solenoid Block Assembly...5365
      Shaft Assembly...5367
  DRIVE SYSTEM...5370
    TROUBLESHOOTING...5372
      Chart...5372
    AXLE AND DIFFERENTIAL (FRONT)...5374
      General Information...5374
      Planetary Carrier Parts Identification...5374
      Planetary Carrier Disassembly...5375
      Steering Knuckle And Drive Axle Parts Identification...5380
      Steering Knuckle Disassembly...5381
      Drive Axle Disassembly...5383
      Brake System Parts Identification...5385
      Brake System Disassembly...5386
      Differential Parts Identification...5389
      Differential Disassembly...5390
      Bevel Pinion Parts Identification...5395
      Bevel Pinion Disassembly...5396
      Bevel Pinion Assembly...5399
      Differential Assembly...5407
      Brake System Assembly...5413
      Drive Axle Assembly...5416
      Steering Knuckle Assembly...5418
      Planetary Carrier Assembly...5421
      Special Tools...5426
    AXLE AND DIFFERENTIAL (REAR)...5428
      General Information...5428
      Planetary Carrier Parts Identification...5428
      Steering Knuckle And Drive Axle Parts Identification...5434
      Steering Knuckle Disassembly...5435
      Differential Parts Identification...5437
      Differential Disassembly...5438
      Bevel Pinion Parts Identification...5443
      Bevel Pinion Disassembly...5444
      Bevel Pinion Assembly...5447
      Differential Assembly...5455
      Steering Knuckle Assembly...5461
      Planetary Carrier Assembly...5464
      Planetary Carrier Assembly...5465
      Special Tools...5469
    FRONT AXLE...5470
      Removal And Installation...5470
    AXLE TOE-IN...5474
      Adjustment...5474
    PARKING BRAKE...5476
      Releasing The Brake For Towing...5476
      Parking Brake Adjustment...5476
      Brake Cylinder Removal...5477
      Brake Disc Removal And Installation...5480
      Brake Cylinder Installation...5480
    STEERING ANGLE ADJUSTMENT...5482
      Adjustment...5482
    DRIVESHAFT...5484
      Rear Driveshaft Removal And Installation...5484
      Front Driveshaft Removal And Installation...5484
    SERVICE BRAKE...5486
      Description...5486
      Bleeding The Brake Circuit...5486
    REAR AXLE...5488
      Removal And Installation...5488
    GEAR BOX...5492
      Removal And Installation...5492
      Parts Identification...5494
      Disassembly...5497
      Assembly...5506
  MAINFRAME...5514
    OPERATOR CAB...5516
      Removal And Installation...5516
    OPERATOR SEAT...5520
      Removal And Installation...5520
    FIXED BOOM...5522
      Removal...5522
      Installation...5523
    INNER BOOM...5526
      Removal And Installation...5526
    WEAR PADS (FRONT)...5530
      Removal And Installation...5530
    WEAR PADS (REAR)...5532
      Removal And Installation...5532
    ENGINE COVER...5534
      Gas Cylinder Removal And Installation...5534
      Removal And Installation...5534
    FUEL TANK...5536
      Removal And Installation...5536
    ATTACHMENT CARRIER (QUICK-TACH)...5540
      Removal And Installation...5540
    COUNTERWEIGHT...5542
      Removal And Installation...5542
    FENDER...5544
      Removal And Installation...5544
    STEERING COLUMN COVER...5546
      Removal And Installation...5546
    DASH COVER...5548
      Removal And Installation...5548
    JOYSTICK PANEL...5552
      Removal And Installation...5552
  ELECTRICAL SYSTEM AND ANALYSIS...5554
    ELECTRICAL SYSTEM INFORMATION...5574
      Troubleshooting Chart...5574
      Description...5575
      Fuses And Relay Location / Identification...5576
    BATTERY...5580
      Removing And Installing Battery...5580
      Using A Booster Battery (Jump Starting)...5581
    ALTERNATOR...5584
      Removal And Installation...5584
      Belt Adjustment...5585
      Belt Replacement...5585
    STARTER...5586
      Testing...5586
      Removal And Installation...5586
    LIGHTS...5588
      Rear Light Removal And Installation...5588
      Rear Light Bulb Replacement...5589
      Front Light Removal And Installation...5590
      Front Light Bulb Replacement...5591
    SIGNAL LEVER...5592
      Removal And Installation...5592
    DISPLAY...5594
      Removal And Installation...5594
    INSTRUMENT PANELS...5596
      Right Instrument And Indicator Panel Removal And Installation...5596
      Left Instrument Panel Removal And Installation...5596
    BOOM ANGLE SENSOR...5598
      Removal And Installation...5598
      Calibration...5599
    FRONT WIPER MOTOR...5602
      Removal And Installation...5602
    TOP WIPER MOTOR...5604
      Removal And Installation...5604
    REAR WIPER MOTOR...5606
      Removal And Installation...5606
    PEDAL ASSEMBLY...5610
      Removal And Installation...5610
    INCHING SENSOR...5612
      Removal And Installation...5612
      Calibration...5613
    SERVICE PC (LAPTOP COMPUTER)...5616
      Connecting Remote Start Tool (Service Tool) - MEL1563...5616
      Connecting Remote Start Tool (Service Tool) - 6689778...5616
    FUEL LEVEL SENDER...5618
      Removal And Installation...5618
    JOYSTICK...5622
      Removal And Installation...5622
    LLMI / LLMC SYSTEM...5624
      System Calibration...5624
      Calibration Test...5626
      System Failure Reports...5627
      System Components Identification...5631
      LLMS Removal...5633
      LLMS Installation...5634
      LLMC Removal And Installation...5635
  ENGINE SERVICE...5636
    ENGINE INFORMATION...5640
      Specifications...5640
      Troubleshooting...5651
    ENGINE SPEED CONTROL...5654
      Removal And Installation...5654
    MUFFLER...5656
      Removal And Installation...5656
    AIR CLEANER...5658
      Housing Removal And Installation...5658
    EXPANSION TANK...5660
      Removal And Installation...5660
    OIL COOLER / INTERCOOLER / RADIATOR...5662
      Removal And Installation...5662
    ENGINE AND ENGINE MOUNTS...5666
      Removal And Installation...5666
    ENGINE COMPONENTS AND TESTING...5672
      Fuel Injection Pump Removal...5672
      Fuel Injection Pump Installation...5675
      Fuel Injectors Removal And Installation...5679
      Checking The Fuel Lift Pump...5681
      Fuel Lift Pump Removal And Installation...5682
      Compression Checking...5682
      Glow Plugs Checking...5683
      Glow Plugs Removal And Installation...5685
    ENGINE TIMING...5686
      Procedure...5686
    ENGINE / HYDROSTAT ASSEMBLY...5688
      Removal And Installation...5688
    FLYWHEEL AND HOUSING...5694
      Removal And Installation...5694
      Flywheel Inspection...5696
      Ring Gear Removal...5696
      Ring Gear Installation...5696
    TURBOCHARGER...5698
      Turbo Charger Troubleshooting...5698
      Turbo Charger Description...5699
      Turbo Charger Removal And Installation...5699
    FUEL SYSTEM...5702
      Exhaust Manifold Removal And Installation...5702
      Fuel Injector Cover Removal And Installation...5702
      Rocker Cover Removal And Installation...5703
    CYLINDER HEAD...5706
      Cylinder Head Removal...5706
      Cylinder Head Inspection...5708
      Cylinder Head Installation...5708
      Rocker Shaft Disassembly And Assembly...5711
      Valve Removal...5711
      Valve Springs Checking...5712
      Valve Depth Checking...5712
      Valve Guides Checking...5713
      Valve Guide Removal...5714
      Valve Guide Installation...5714
      Valves Checking...5715
      Cutting A Valve Seat...5715
      Valve Seat Assembly...5716
      Changing Valve Springs (With Cylinder Head Installed)...5717
      Valve Clearance Adjustment...5718
    CAMSHAFT AND TIMING GEARS...5720
      Timing Case And Drive Assembly Description...5720
      Timing Cover Removal...5720
      Timing Cover Installation...5720
      Crankshaft Pulley Removal And Installation...5720
      Front Oil Seal Removal And Installation...5720
      Timing Case And Gear Removal...5721
      Timing Case And Gear Installation...5722
      Camshaft And Tappets Removal...5724
      Camshaft And Tappets Installation...5725
    CRANKSHAFT AND PISTONS...5728
      Pistons And Connecting Rods Description...5728
      Pistons And Connecting Rods Removal...5728
      Pistons And Connecting Rods Disassembly...5729
      Piston Ring End Gap...5730
      Piston Ring Installation...5731
      Piston Ring Groove Clearance...5732
      Connecting Rod Inspection...5732
      Connecting Rod Bushing Replacement...5732
      Piston And Connecting Rod Assembly...5733
      Piston And Connecting Rod Installation...5733
      Checking Piston Height...5735
      Crankshaft And Bearings Description...5735
      Crankshaft And Bearings Removal...5735
      Inspection Of Crankshaft And Bearings...5737
      Crankshaft And Bearings Installation...5738
      Rear Oil Seal Removal...5739
      Rear Oil Seal Housing Positioning...5740
      Rear Oil Seal Installation...5740
      Checking Crankshaft End Play...5741
    ENGINE COOLING SYSTEM...5742
      Cooling System Description...5742
      Thermostat Removal and Installation...5743
      Thermostat Testing...5743
      Lubricating Oil Cooler Removal And Installation...5743
      Water Pump Removal...5744
      Water Pump Installation...5744
    LUBRICATION SYSTEM...5746
      Engine Lubrication System Description...5746
      Oil Filter Adapter Removal And Installation...5747
      Oil Pan Removal And Installation...5747
      Oil Screen And Pick-up Tube...5748
      Oil Pump Removal...5748
      Oil Pump Installation...5749
      Oil Pump Disassembly And Assembly...5750
      Oil Pressure Relief Valve Disassembly And Assembly...5751
    ENGINE BLOCK...5752
      Engine Block Description...5752
      Engine Block Disassembly And Assembly...5752
      Piston Cooling Jet Removal...5753
      Piston Cooling Jet Installation...5753
      Piston Cooling Jet Alignment...5753
      Inspection...5753
      Cylinder Liner Inspection...5754
      Cylinder Liner Removal...5755
      Cylinder Liner Installation...5756
  HEATING, VENTILATION, AIR CONDITIONING (HVAC)...5758
    AIR CONDITIONING SYSTEM FLOW...5760
      Principles...5760
      Chart...5761
    COMPONENTS...5762
      Identification...5762
    SAFETY...5764
      Safety Equipment...5764
    REGULAR MAINTENANCE...5766
      Filter Element Removal And Installation...5766
      Air Conditioning Belt Adjustment...5766
      Belt Replacement...5766
      Cleaning The Condenser...5768
      Evaporator / Heater Coil...5768
    BASIC TROUBLESHOOTING...5772
      Poor A/C Performance...5772
      Checking The Electrical System...5773
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...5778
      Compressor Oil...5778
      Compressor Oil Check...5778
      Component Replacement And Refrigeration Leaks...5780
    SYSTEM TROUBLESHOOTING CHART...5782
    TEMPERATURE / PRESSURE...5786
      Chart...5786
    AIR CONDITIONING SERVICE...5788
      Chart...5788
    SYSTEM CHARGING AND RECLAMATION...5790
      Reclamation And Charging With Recovery / Charging Unit...5790
    COMPRESSOR...5794
      Removal And Installation...5794
      Compressor Clutch Disassembly And Assembly...5796
    CONDENSER...5800
      Removal And Installation...5800
    RECEIVER / DRIER...5802
      Removal And Installation...5802
    PRESSURE SWITCH...5804
      Removal And Installation...5804
    EVAPORATOR / HEATER UNIT...5806
      Removal And Installation...5806
    EXPANSION VALVE...5810
      Removal And Installation...5810
    THERMOSTAT...5812
      Description...5812
      Removal And Installation...5813
  SPECIFICATIONS...5816
    (TL470) TELESCOPIC HANDLER SPECIFICATIONS...5818
      Machine Dimensions...5818
      Performance...5819
      Weights...5819
      Engine...5820
      Controls...5820
      Drive System...5820
      Traction...5821
      Steering...5821
      Brakes...5821
      Fluid Capacities...5821
      Hydraulic System...5821
      Electrical System...5822
      Instrument Panel...5822
      Environmental...5822
    MACHINE TORQUE SPECIFICATIONS...5824
      Axle...5824
      Boom...5824
      Drive Box...5824
      Drive Motor...5824
      Engine...5825
      Hydraulic Pump...5825
    TORQUE SPECIFICATIONS FOR BOLTS...5826
      Torque for General SAE Bolts...5826
      Torque For General Metric Bolts...5827
    HYDRAULIC CONNECTION SPECIFICATIONS...5828
      O-ring Face Seal Connection...5828
      Straight Thread O-ring Fitting...5828
      Tubelines And Hoses...5828
      Port Seal Fitting...5829
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...5830
      Specifications...5830
    CONVERSIONS...5832
      Decimal And Millimeter Equivalent Chart...5832
      U.S. To Metric Conversion Chart...5832
  ALPHABETICAL INDEX...5834
6990609 (02-13) - TR38160 Telescopic Handler Service Manual ...5836
  FOREWORD...5842
    FOREWORD...5844
    SAFETY INSTRUCTIONS...5846
      Safe Operation Is The Operator’s Responsibility...5846
      Safe Operation Needs A Qualified Operator...5846
      Avoid Silica Dust...5847
    FIRE PREVENTION...5847
      Maintenance...5847
      Operation...5847
      Electrical...5847
      Hydraulic System...5848
      Fueling...5848
      Starting...5848
      Welding And Grinding...5848
      Fire Extinguishers...5848
    SERIAL NUMBER LOCATIONS...5849
      Telescopic Handler Serial Numbers...5849
      Engine Serial Number...5849
      Other Serial Numbers...5849
    DELIVERY REPORT...5849
    TELESCOPIC HANDLER IDENTIFICATION...5850
  SAFETY AND MAINTENANCE...5852
    LIFTING AND BLOCKING THE TELESCOPIC HANDLER...5854
      Procedure...5854
    OPERATOR CAB...5856
      Description...5856
      Cab Door...5856
      Cab Door Window...5857
      Cab Rear Window...5857
      Cab Light...5858
      Cab Roof...5858
      Cab Ventilation...5858
      Rotating Beacon...5860
    TRANSPORTING THE TELESCOPIC HANDLER...5862
      Procedure...5862
    TOWING THE TELESCOPIC HANDLER...5864
      Procedure...5864
    SERVICE SCHEDULE...5866
      Chart...5866
      Inspection Checkbook...5867
    AIR CLEANER SERVICE...5868
      Cleaning The Air Filter...5868
    ENGINE COOLING SYSTEM...5870
      Cleaning The Cooling System...5870
      Checking The Coolant Level...5871
      Removing And Replacing The Coolant...5872
    FUEL SYSTEM...5874
      Fuel Specifications...5874
      Biodiesel Blend Fuel...5874
      Filling The Fuel Tank...5875
      Fuel Filters...5875
      Removing Air From The Fuel System...5876
      Cleaning The Fuel Tank...5877
    ENGINE LUBRICATION SYSTEM...5878
      Checking And Adding Engine Oil...5878
      Engine Oil Chart...5878
      Removing And Replacing Oil And Filter...5879
    HYDRAULIC / HYDROSTATIC SYSTEM...5882
      Hydraulic / Hydrostatic Fluid Chart...5882
      Checking And Adding Hydraulic / Hydrostatic Fluid...5883
      Replacing Hydraulic / Hydrostatic Fluid And Filters...5884
    AXLES (FRONT AND REAR)...5888
      Checking And Adding Oil (Planetary Carrier)...5888
      Removing And Replacing Oil (Planetary Carrier)...5888
      Checking And Adding Oil (Front And Rear Differential)...5889
      Removing And Replacing Oil (Front And Rear Differential)...5889
      Checking And Adding Oil (Drive Box)...5889
      Removing And Replacing Oil (Drive Box)...5889
    LUBRICATING THE TELESCOPIC HANDLER...5890
      Lubrication Locations...5890
      Lubricating Telescopic Boom Wear Blocks...5895
    TYRE MAINTENANCE...5896
      Wheel Nuts...5896
      Tyre Rotating...5896
      Tyre Mounting...5896
      Tyre Pressure...5896
    ENGINE COVER...5898
      Opening And Closing...5898
    APPROVED BOOM STOP...5900
      Installing The Approved Boom Stop...5900
    ANTI TIPPING DEVICE...5902
      Description...5902
      Main Work Data...5903
      Complementary Work Data...5904
      Attachment And Operating Mode...5905
      Attachment Selection...5906
      Unencoded Display Information...5907
      Self-Diagnostics...5908
      Anti Tipping Device Error Codes...5909
      Remote Control Error Codes...5913
      Diagnostic Displays...5916
      Language Selection...5917
  HYDRAULIC SYSTEM...5918
    HYDRAULIC SCHEMATIC...5920
    HYDRAULIC SYSTEM INFORMATION...5921
      Glossary Of Hydraulic / Hydrostratic Symbols...5921
      Troubleshooting Chart...5924
      Tightening Procedures...5925
      Hydraulic Component Pressures...5925
    LIFT CYLINDER...5927
      Removal And Installation...5927
      Parts Identification...5929
      Section View...5930
    INTERNAL TELESCOPE CYLINDER...5931
      Parts Identification...5931
    EXTERNAL TELESCOPE...5933
      Parts Identification...5933
    TILT CYLINDER...5935
      Parts Identification...5935
    DRIVE BOX...5937
      Parts Identification...5937
      Disassembly...5938
      Assembly...5949
    BRAKE AND GEAR VALVES...5961
      Parts Identification...5961
    STEERING MODE VALVE BLOCK...5963
      Parts Identification...5963
    STEERING VALVE...5965
      Parts Identification...5965
    HYDRAULIC CONTROL VALVE...5967
      Valve Section Identification...5967
      Inlet Valve Section...5968
      Lifting Valve Section...5969
      Upperstructure Swing Valve Section...5970
      Telescoping Valve Section...5971
      Outlet Valve Section...5972
      Tilting Valve Section...5973
      Auxiliary Valve Section...5974
    SWING MOTOR...5975
      Parts Identification...5975
    REAR AXLE OSCILLATION LOCK CYLINDER...5981
      Parts Identification...5981
    STABILISER / LEVELLING VALVE...5983
      Parts Identification...5983
  HYDROSTATIC SYSTEM...5985
    HYDROSTATIC DRIVE MOTOR...5987
      Parts Identification...5987
    HYDROSTATIC PUMP...5989
      Parts Identification...5989
    HYDROSTATIC TRANSMISSION ADJUSTMENT...5991
      Description...5991
      Starting Adjustment...5991
      Feeding Pressure...5992
      Hydrostatic Pump Pressure...5992
      Hydrostatic Motor Pressure...5993
  DRIVE SYSTEM...5995
    TROUBLESHOOTING...5997
      Chart...5997
    AXLE AND DIFFERENTIAL (FRONT)...5999
      General Information...5999
      Planetary Carrier Parts Identification...5999
      Planetary Carrier Disassembly...6000
      Steering Cylinder Parts Identification...6005
      Steering Cylinder Removal...6006
      Steering Cylinder Disassembly...6008
      Steering Case Parts Identification...6010
      Steering Case Disassembly...6011
      Drive Axle Parts Identification...6013
      Drive Axle Disassembly...6014
      Brake System Parts Identification...6016
      Brake System Disassembly...6017
      Hydraulic Differential Lock Parts Identification...6020
      Hydraulic Differential Lock Disassembly...6021
      Differential Unit (Limited Slip) Parts Identification...6025
      Differential Unit (Limited Slip) Disassembly...6026
      Bevel Pinion Parts Identification...6030
      Bevel Pinion Removal...6031
      Bevel Pinion Installation And Adjustment...6034
      Differential Unit (Limited Slip) Assembly...6042
      Hydraulic Differential Lock Assembly...6046
      Brake System Assembly...6049
      Drive Axle Assembly...6052
      Steering Case Assembly...6054
      Steering Cylinder Assembly...6056
      Steering Cylinder Installation...6059
      Planetary Carrier Assembly...6064
      Special Tools...6070
    AXLE AND DIFFERENTIAL (REAR)...6071
      General Information...6071
      Planetary Carrier Parts Identification...6071
      Planetary Carrier Disassembly...6072
      Steering Cylinder Parts Identification...6077
      Steering Cylinder Removal...6078
      Steering Cylinder Disassembly...6080
      Steering Case Parts Identification...6082
      Steering Case Disassembly...6083
      Drive Axle Parts Identification...6085
      Drive Axle Disassembly...6086
      Negative Brake Parts Identification...6088
      Negative Brake Disassembly...6089
      Hydraulic Differential Lock Parts Identification...6093
      Hydraulic Differential Lock Disassembly...6094
      Differential Unit (Limited Slip) Parts Identification...6098
      Differential Unit (Limited Slip) Disassembly...6099
      Bevel Pinion Parts Identification...6103
      Bevel Pinion Removal...6104
      Bevel Pinion Installation And Adjustment...6107
      Differential Unit (Limited Slip) Assembly...6115
      Hydraulic Differential Lock Assembly...6119
      Negative Brake Assembly...6122
      Drive Axle Assembly...6130
      Steering Case Assembly...6132
      Steering Cylinder Assembly...6134
      Steering Cylinder Installation...6137
      Planetary Carrier Assembly...6142
      Special Tools...6148
  ELECTRICAL SYSTEM AND ANALYSIS...6149
    ELECTRICAL SCHEMATICS...6151
    ELECTRICAL SYSTEM INFORMATION...6177
      Troubleshooting Chart...6177
      Fuse And Relay Location / Identification...6178
    BATTERY...6181
      Removal And Installation...6181
      Battery Disconnect Switch...6182
      Servicing...6182
      Using A Booster Battery (Jump Starting)...6183
      Battery Test...6184
    SENSORS AND SWITCHES...6185
      Stabilisers Lowered...6185
      Upperstructure Aligned With Undercarriage...6185
      Upperstructure Rotated 174...6185
      Upperstructure Slew Lock Inserted...6186
      Axle Oscillation Lock Range (12)...6186
      Boom Raised / Lowered Completely...6186
    MAN PLATFORM LOAD LIMITER CALIBRATION...6187
      Description...6187
      Procedure...6187
  SPECIFICATIONS...6189
    (TR38160) TELESCOPIC HANDLER SPECIFICATIONS...6191
      Machine Dimensions...6191
      Performance...6192
      Engine...6192
      Transmission...6192
      Hydraulic System...6193
      Differential Axles...6193
      Capacities...6193
      Tyres...6193
      Environmental...6193
    TORQUE SPECIFICATIONS FOR BOLTS...6195
      Torque for General SAE Bolts...6195
      Torque For General Metric Bolts...6196
    HYDRAULIC CONNECTION SPECIFICATIONS...6197
      O-ring Face Seal Connection...6197
      Straight Thread O-ring Fitting...6197
      Tubelines And Hoses...6197
      Flare Fitting...6198
      O-ring Flare Fitting...6199
      Port Seal Fitting...6201
    CONVERSIONS...6203
      Decimal And Millimeter Equivalents...6203
      U.S. To Metric Conversion Chart...6203
  ALPHABETICAL INDEX...6205
6990790 (05-13) - TL360(X), TL470(X), TL470(X)HF Telescopic Handler Service Manual...6206
  MAINTENANCE SAFETY...6208
  CONTENTS...6210
  FOREWORD...6212
    FOREWORD...6214
    SAFETY INSTRUCTIONS...6216
      Safe Operation Is The Operator’s Responsibility...6216
      Safe Operation Needs A Qualified Operator...6216
      Avoid Silica Dust...6217
      Dismantling And Disposal...6217
    FIRE PREVENTION...6218
      Maintenance...6218
      Operation...6218
      Electrical...6218
      Hydraulic System...6218
      Fueling...6218
      Starting...6218
      Welding And Grinding...6219
      Fire Extinguishers...6219
    SERIAL NUMBER LOCATION...6220
      Telescopic Handler Serial Number...6220
      Telescopic Handler Statutory Plate...6220
      Engine Serial Number...6221
      Diesel Oxidation Catalytic Converter Serial Number...6221
      Other Serial Numbers...6221
    DELIVERY REPORT...6222
    BOBCAT TELESCOPIC HANDLER IDENTIFICATION...6223
  SAFETY AND MAINTENANCE...6224
    LIFTING AND BLOCKING THE TELESCOPIC HANDLER...6228
      Procedure...6228
    OPERATOR CAB...6230
      Description...6230
      Cab Door...6230
      Cab Door Window...6231
      Rear Cab Window...6232
      Cab Light...6232
    TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER...6234
      Loading And Unloading...6234
      Fastening...6234
    TOWING THE TELESCOPIC HANDLER...6236
      Procedure...6236
    SERVICE SCHEDULE...6240
      Maintenance Intervals...6240
    AIR CLEANER SERVICE...6244
      Replacing Filter Elements...6244
    ENGINE COOLING SYSTEM...6246
      Cleaning...6246
      Checking Level...6246
      Removing And Replacing The Coolant...6247
    FUEL SYSTEM...6248
      Fuel Specifications...6248
      Biodiesel Blend Fuel...6248
      Filling The Fuel Tank...6249
      Primary Fuel Filter (Pre-Filter)...6249
      Secondary Fuel Filter...6251
      Removing Air From The Fuel System...6251
    ENGINE LUBRICATION SYSTEM...6252
      Checking And Adding Engine Oil...6252
      Engine Oil Chart...6252
      Removing And Replacing Oil And Filter...6253
    HYDRAULIC / HYDROSTATIC SYSTEM...6256
      Checking And Adding Fluid...6256
      Hydraulic / Hydrostatic Fluid Chart...6257
      Removing And Replacing Hydraulic Fluid...6257
      Removing And Replacing Hydraulic / Hydrostatic Filters...6258
      Removing And Replacing Hydraulic Charge Filter...6260
      Fill / Breather Cap...6260
      Hydraulic Fluid Air Bleeding Procedure (Only For TL470(X)HF)...6261
    AXLES (FRONT AND REAR)...6266
      Checking And Adding Oil (Planetary Carrier)...6266
      Removing And Replacing Oil (Planetary Carrier)...6266
      Checking And Adding Oil (Rear Differential)...6267
      Removing And Replacing Oil (Rear Differential)...6267
      Checking And Adding Oil (Front Differential)...6268
      Removing And Replacing Oil (Front Differential)...6268
      Checking And Adding Oil (Gear Box)...6269
      Removing And Replacing Oil (Gear Box)...6269
    LUBRICATING THE TELESCOPIC HANDLER...6270
      Lubrication Locations...6270
      Front Pads Lubrication...6271
      Rear Pads Lubrication...6272
    ATTACHMENT CARRIER...6274
      Inspection And Maintenance...6274
    TIRE MAINTENANCE...6276
      Wheel Nuts...6276
      Rotating...6276
      Wheel replacement...6276
      Mounting...6277
      Pressure...6277
    APPROVED BOOM STOP...6278
      Installing...6278
      Removing...6278
    ENGINE COVER...6280
      Opening And Closing...6280
    STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER...6282
      Procedure...6282
    EMERGENCY EXIT...6284
      Rear Window...6284
      Right Rear Window...6284
    TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE...6286
      Storage...6286
      Return To Service...6286
    LIFTING THE TELESCOPIC HANDLER...6288
      Procedure...6288
    REMOTE START TOOL (SERVICE TOOL) KIT - MEL1563...6290
      Remote Start Tool - MEL1563...6290
      Service Tool Harness Control - MEL1565...6291
      Service Tool Harness Communicator - MEL1566...6292
    REMOTE START TOOL (SERVICE TOOL) KIT - 7217666...6294
      Remote Start Tool (Service Tool) - 7022042...6294
      Telescopic Handler Service Tool Harness - 6689747...6295
      Computer Service Tool Harness - 6689746...6297
      Remote Start Procedure...6297
  HYDRAULIC SYSTEM...6300
    HYDRAULIC / HYDROSTATIC SCHEMATICS...6304
    HYDRAULIC SYSTEM INFORMATION...6308
      Glossary Of Hydraulic / Hydrostatic Symbols...6308
      Troubleshooting Chart...6311
      Tightening Procedures...6312
    LIFT CYLINDER...6314
      Removal And Installation...6314
      Parts Identification...6317
      Disassembly...6318
      Assembly...6323
    SELF LEVELING CYLINDER...6328
      Removal And Installation...6328
      Parts Identification...6330
      Disassembly...6331
      Assembly...6334
    SELF LEVELING CYLINDER (LOCK VALVE)...6338
      Removal And Installation...6338
    EXTENSION CYLINDER...6340
      Cylinder Group Removal And Installation...6340
      Upper Tubeline Removal And Installation...6342
      Extension Cylinder Removal And Installation...6344
      Tubeline Tray Disassembly...6345
      Parts Identification...6347
      Disassembly...6348
      Assembly...6352
    TILT CYLINDER...6356
      Removal And Installation...6356
      Parts Identification...6359
      Disassembly...6360
      Assembly...6365
    STEERING CYLINDER (FRONT / REAR)...6370
      Removal...6370
      Installation...6372
      Disassembly...6374
      Assembly...6376
    GEAR CONTROL CYLINDER...6380
      Removal...6380
      Parts Identification...6382
      Disassembly...6383
      Assembly...6384
      Installation...6385
    MAIN RELIEF VALVE...6386
      Testing And Adjustment...6386
      Removal And Installation...6387
    MANIFOLD...6388
      Removal And Installation...6388
      Parts Identification...6389
      Disassembly And Assembly...6390
    BRAKE VALVE...6392
      Removal And Installation...6392
    PISTON PUMP (FOR TL470(X)HF)...6394
      Test Tools Installation...6394
      Troubleshooting Chart...6398
      Removal And Installation...6401
      Parts Identification...6403
      Disassembly And Assembly...6404
    GEAR PUMP (FOR TL360(X) AND TL470(X))...6414
      Removal And Installation...6414
      Parts Identification...6416
      Disassembly And Assembly...6417
    FAN MOTOR...6422
      Removal And Installation...6422
      Parts Identification (Single Speed Version) (Standard)...6424
      Disassembly And Assembly (Single Speed Version) (Standard)...6425
      Parts Identification (Variable Speed Version) (Optional)...6428
      Disassembly And Assembly (Variable Speed Version) (Optional)...6429
    HYDRAULIC FLUID RESERVOIR...6436
      Removal And Installation...6436
    STEERING VALVE...6438
      Removal And Installation...6438
    HYDRAULIC CONTROL VALVE...6440
      Troubleshooting Chart (Controllers)...6440
      Valve Section Troubleshooting...6441
      Troubleshooting Chart (Control Valve)...6445
      Removal And Installation...6446
      Parts Identification...6448
      Disassembly And Assembly...6449
      End Housing Disassembly And Assembly...6450
      Auxiliary Valve Section Disassembly And Assembly...6451
      Telescoping Valve Section Disassembly And Assembly...6455
      Tilting Valve Section Disassembly And Assembly...6459
      Lifting Valve Section Disassembly And Assembly...6463
      Inlet-Outlet Valve Section Disassembly And Assembly...6467
    PORT RELIEF VALVES...6470
      Testing...6470
      Replacement Procedure...6471
    PARKING BRAKE...6472
      Valve Removal And Installation...6472
    ACCUMULATOR...6474
      Removal And Installation...6474
    FAN PUMP (ONLY FOR TL470(X)HF)...6476
      Removal And Installation...6476
      Parts Identification...6477
      Disassembly And Assembly...6478
  HYDROSTATIC SYSTEM...6482
    HYDROSTATIC SYSTEM INFORMATION...6484
      Troubleshooting Chart...6484
      Replenishing Valve Function...6485
    OIL COOLER...6486
      Description...6486
    HYDROSTATIC DRIVE MOTOR...6488
      Removal And Installation...6488
      Parts Identification...6489
      Disassembly...6492
      Inspection...6503
      Assembly...6505
    HYDROSTATIC PUMP...6518
      Calibration...6518
      Removal And Installation...6520
      Parts Identification...6522
      Shaft Disassembly...6527
      Relief Valves Disassembly And Assembly...6529
      Charge Pump Disassembly...6530
      Piston Pump Disassembly...6532
      Solenoid Block Disassembly...6535
      Inspection...6537
      Piston Pump Assembly...6539
      Charge Pump Assembly...6543
      Solenoid Block Assembly...6545
      Shaft Assembly...6547
  DRIVE SYSTEM...6550
    DRIVE SYSTEM TROUBLESHOOTING...6552
      Chart...6552
    AXLE AND DIFFERENTIAL (FRONT)...6554
      Description...6554
      Planetary Carrier Parts Identification...6554
      Planetary Carrier Disassembly...6555
      Steering Knuckle And Drive Axle Parts Identification...6560
      Steering Knuckle Disassembly...6561
      Drive Axle Disassembly...6563
      Brake Group Parts Identification...6565
      Brake Group Disassembly...6566
      Differential Parts Identification...6569
      Differential Disassembly...6570
      Pinion Group Parts Identification...6575
      Pinion Group Disassembly...6576
      Pinion Group Assembly...6579
      Differential Assembly...6587
      Brake Group Assembly...6593
      Drive Axle Assembly...6596
      Steering Knuckle Assembly...6598
      Planetary Carrier Assembly...6601
      Special Tools...6606
    AXLE AND DIFFERENTIAL (REAR)...6608
      Description...6608
      Planetary Carrier Parts Identification...6608
      Planetary Carrier Disassembly...6609
      Steering Knuckle And Drive Axle Parts Identification...6614
      Steering Knuckle Disassembly...6615
      Differential Parts Identification...6617
      Differential Disassembly...6618
      Pinion Group Parts Identification...6623
      Pinion Group Disassembly...6624
      Pinion Group Assembly...6627
      Differential Assembly...6635
      Steering Knuckle Assembly...6641
      Planetary Carrier Assembly...6644
      Planetary Carrier Assembly...6645
      Special Tools...6649
    FRONT AXLE...6650
      Removal And Installation...6650
    AXLE TOE-IN...6654
      Adjustment...6654
    PARKING BRAKE...6656
      Releasing The Brake For Towing...6656
      Adjustment...6656
      Brake Cylinder Removal...6657
      Brake Cylinder Disassembly And Assembly...6657
      Brake Disc Removal And Installation...6660
      Brake Cylinder Installation...6660
    STEERING ANGLE ADJUSTMENT...6662
      Adjustment...6662
    DRIVESHAFT...6664
      Rear Driveshaft Removal And Installation...6664
      Front Driveshaft Removal And Installation...6664
    SERVICE BRAKE...6666
      Description...6666
      Bleeding The Brake Circuit...6666
    REAR AXLE...6668
      Removal And Installation...6668
    GEAR BOX...6672
      Removal And Installation...6672
      Parts Identification...6674
      Disassembly...6675
      Assembly...6684
  MAINFRAME...6692
    OPERATOR CAB...6694
      Removal And Installation...6694
    OPERATOR SEAT...6698
      Removal And Installation...6698
    FIXED BOOM...6700
      Removal...6700
      Installation...6701
    INNER BOOM...6704
      Removal And Installation...6704
    WEAR PADS (FRONT)...6708
      Removal And Installation...6708
    WEAR PADS (REAR)...6710
      Removal And Installation...6710
    ENGINE COVER...6712
      Gas Cylinder Removal And Installation...6712
      Removal And Installation...6712
    FUEL TANK...6714
      Removal And Installation...6714
    ATTACHMENT CARRIER (QUICK-TACH)...6718
      Removal And Installation...6718
    COUNTERWEIGHT...6720
      Removal And Installation...6720
    FENDER...6722
      Removal And Installation...6722
    STEERING COLUMN COVER...6724
      Removal And Installation...6724
    DASH COVER...6726
      Removal And Installation...6726
    JOYSTICK PANEL...6730
      Removal And Installation...6730
  ELECTRICAL SYSTEM AND ANALYSIS...6732
    ELECTRICAL SCHEMATICS...6734
    ELECTRICAL SYSTEM INFORMATION...6772
      Troubleshooting Chart...6772
      Description...6773
      Fuses And Relay Location / Identification...6773
    BATTERY...6776
      Removal And Installation...6776
      Using A Booster Battery (Jump Starting)...6778
    ALTERNATOR...6780
      Removal And Installation...6780
      Belt Adjustment...6781
      Belt Checking...6781
      Belt Replacement...6781
    STARTER...6782
      Testing...6782
      Removal And Installation...6783
    LIGHTS...6786
      Rear Light Removal And Installation...6786
      Rear Light Bulb Replacement...6787
      Front Light Removal And Installation...6788
      Front Light Bulb Replacement...6789
    SIGNAL LEVER...6790
      Removal And Installation...6790
    DISPLAY...6792
      Removal And Installation...6792
    INSTRUMENT PANELS...6794
      Right Instrument And Indicator Panel Removal And Installation...6794
      Left Instrument Panel Removal And Installation...6794
    BOOM ANGLE SENSOR...6796
      Removal And Installation...6796
      Calibration...6797
    FRONT WIPER MOTOR...6800
      Removal And Installation...6800
    TOP WIPER MOTOR...6802
      Removal And Installation...6802
    REAR WIPER MOTOR...6804
      Removal And Installation...6804
    PEDAL ASSEMBLY...6808
      Removal And Installation...6808
    INCHING SENSOR...6810
      Removal And Installation...6810
      Calibration...6811
    SERVICE PC (LAPTOP COMPUTER)...6814
      Connecting Remote Start Tool (Service Tool) - MEL1563...6814
      Connecting Remote Start Tool (Service Tool) - 7217666...6814
    FUEL LEVEL SENDER...6816
      Removal And Installation...6816
    JOYSTICK...6820
      Removal And Installation...6820
    LLMI / LLMC SYSTEM...6822
      System Calibration...6822
      Calibration Test...6824
      System Failure Reports...6825
      System Components Identification...6829
      LLMS Removal...6831
      LLMS Installation...6832
      LLMC Removal And Installation...6833
  ENGINE SERVICE...6834
    ENGINE...6836
      Removal And Installation...6836
    ENGINE AND HYDROSTAT ASSEMBLY...6844
      Removal And Installation...6844
    ENGINE SPEED CONTROL...6850
      Removal And Installation...6850
    MUFFLER...6852
      Removal And Installation...6852
    AIR CLEANER...6854
      Housing Removal And Installation...6854
    ENGINE COOLING SYSTEM...6856
      Oil Cooler / Intercooler / Radiator Removal And Installation...6856
      Cooling System Check...6860
      Cooling System Inspection...6860
      Expansion Tank Removal And Installation...6861
  HEATING, VENTILATION, AIR CONDITIONING (HVAC)...6862
    AIR CONDITIONING SYSTEM FLOW...6864
      Description...6864
      Chart...6865
      Components...6866
      Safety Equipment...6868
    REGULAR MAINTENANCE...6870
      Filters...6870
      Air Conditioning Belt Adjustment...6871
      Belt Replacement...6871
      Cleaning The Condenser...6872
      Air Conditioning Lubrication...6872
      Air Conditioning Service Chart...6873
      Evaporator / Heater Coil...6874
    A/C SYSTEM TROUBLESHOOTING...6878
      Blower Motor Does Not Operate...6878
      Blower Motor Operates Normally, But Air Flow Is Insufficient...6878
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...6878
      The Compressor Does Not Operate At All, Or Operates Improperly...6878
      Gauge Pressure Related Troubleshooting...6879
      Temperature / Pressure Chart...6881
      Poor A/C Performance...6882
      HVAC Repair And Leaks...6882
      Electrical System...6883
    SYSTEM CHARGING AND RECLAMATION...6888
      Reclamation And Charging With Recovery / Charging Unit...6888
    COMPRESSOR...6892
      Removal And Installation...6892
      Oil...6894
      Oil Check...6894
      Clutch Disassembly And Assembly...6896
    CONDENSER...6900
      Removal And Installation...6900
    RECEIVER / DRIER...6902
      Removal And Installation...6902
    PRESSURE SWITCH...6904
      Removal And Installation...6904
    EVAPORATOR / HEATER UNIT...6906
      Removal And Installation...6906
    THERMOSTAT...6910
      Description...6910
      Removal And Installation...6911
    EXPANSION VALVE...6914
      Removal And Installation...6914
  SPECIFICATIONS...6916
    (TL360(X)) TELESCOPIC HANDLER SPECIFICATIONS...6918
      Machine Dimensions...6918
      Performance...6919
      Weights...6919
      Engine...6920
      Controls...6920
      Drive System...6921
      Traction...6921
      Steering...6921
      Brakes...6921
      Fluid Capacities...6922
      Hydraulic System...6922
      Cycle Times...6922
      Electrical System...6922
      Instrument Panel...6923
      Environmental...6924
    (TL470(X)) TELESCOPIC HANDLER SPECIFICATIONS...6925
      Machine Dimensions...6925
      Performance...6926
      Weights...6926
      Engine...6927
      Controls...6927
      Drive System...6928
      Traction...6928
      Steering...6928
      Brakes...6928
      Fluid Capacities...6929
      Hydraulic System...6929
      Cycle Times...6929
      Electrical System...6929
      Instrument Panel...6930
      Environmental...6931
    (TL470(X)HF) TELESCOPIC HANDLER SPECIFICATIONS...6932
      Machine Dimensions...6932
      Performance...6933
      Weights...6933
      Engine...6934
      Controls...6934
      Drive System...6935
      Traction...6935
      Steering...6935
      Brakes...6935
      Fluid Capacities...6936
      Hydraulic System...6936
      Cycle Times...6936
      Electrical System...6936
      Instrument Panel...6937
      Environmental...6938
    MACHINE TORQUE SPECIFICATIONS...6940
      Axle...6940
      Boom...6940
      Drive Box...6940
      Drive Motor...6940
      Engine...6941
      Hydraulic Pump...6941
    TORQUE SPECIFICATIONS FOR BOLTS...6942
      Torque for General SAE Bolts...6942
      Torque For General Metric Bolts...6943
    HYDRAULIC CONNECTION SPECIFICATIONS...6944
      O-ring Face Seal Connection...6944
      Straight Thread O-ring Fitting...6944
      Tubelines And Hoses...6944
      Flare Fitting...6945
      O-ring Flare Fitting...6946
      Port Seal Fitting...6948
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...6950
      Specifications...6950
    CONVERSIONS...6952
      Decimal And Millimeter Equivalent Chart...6952
      U.S. To Metric Conversion Chart...6952
  ALPHABETICAL INDEX...6954

Bobcat Telescopic Handlers TL360(X), TL470(X), TR35160, TR38160, TR45190, TR50210, TR40250 Repair Service Manuals