Bobcat Versa TTC Telescopic Handler T2556 T2566 Service Manual 4852210 EN US

MAINTENANCE SAFETY
ALPHABETICAL INDEX
SAFETY INSTRUCTIONS
– FIRE PREVENTION
Serial Number LocationS
– telescopic handler Serial Number
– Engine Serial Number
– Earlier Models
– Later Models
– Other Serial Numbers
– Delivery Report
– BOBCAT telescopic handler IDENTIFICATION
LIFTING AND BLOCKING THE TELESCOPIC HANDLER
– Procedure
OPERATOR CAB
– Emergency Exit
– Cab Door
– Cab Door Window
TRANSPORTING THE TELESCOPIC HANDLER
– Procedure
TOWING THE TELESCOPIC HANDLER For SN 363011001 363012000 and SN 363111001 363112000
– Procedure
TOWING THE Telescopic Handler For SN 363011001 363012000 and SN 363111001 363112000 CONTD
– Procedure Contd
TOWING THE TELESCOPIC HANDLER SN 363012001 Above, SN 363112001 Above
– Procedure
SERVICE SCHEDULE
AIR CLEANER SERVICE
– Replacing Filter Element
ENGINE COOLING SYSTEM
– Cleaning The Cooling System
– Checking The Coolant Level
– Replacing The Coolant
FUEL SYSTEM
– Fuel Specifications
– Filling The Fuel Tank
– Fuel Filter
ENGINE LUBRICATION SYSTEM
– Checking Engine Oil
– Oil Chart
– Replacing Oil And Filter
HYDRAULICHYDROSTATIC SYSTEM
– Checking And Adding Fluid
HYDRAULICHYDROSTATIC SYSTEM CONTD
– Replacing HydraulicHydrostatic Filter
– Replacing Hydraulic Fluid
HYDRAULICHYDROSTATIC SYSTEM CONTD
AXLES FRONT AND REAR For SN 363011001 363012000 and SN 363111001 363112000
– Checking Oil Level Planetary Carrier
– Draining Oil Planetary Carrier
– Checking Oil Level Rear Differential
– Draining Oil Rear Differential
– Checking Oil Level Front Differential
– Draining Oil Front Differential
AXLES FRONT AND REAR For SN 363012001 and Above, SN 363112001 and Above
– Checking Oil Level Planetary Carrier
– Draining Oil Planetary Carrier
– Checking Oil Level Rear Differential
– Draining Oil Rear Differential
– Checking Oil Level Front Differential
– Draining Oil Front Differential
– Checking Oil Level Drive Box
– Draining Oil Drive Box
LUBRICATION For SN 363011001 363012000 and S N 363111001 363112000
– Procedure
LUBRICATION For SN 363012001 Above and SN 363112001 Above
– Procedure
TIRE MAINTENANCE
Wheel Nuts For SN 363011001 363012000 and SN 363111001 363112000
– Tire Rotation
– Tire Mounting
OPTIONAL APPROVED BOOM STOP
– Installing The Approved Boom Stop
– Removing The Approved Boom Stop
ENGINE COVER
– Opening And Closing The Engine Cover
HYDRAULIC SYSTEM INFORMATION
– Troubleshooting Chart
– Tightening Procedures
LIFT CYLINDER
– Removal And Installation
– Parts Identification
– Disassembly
– Assembly
BUCKET POSITIONING CYLINDER
– Removal And Installation
– Parts Identification
– Disassembly
– Assembly
EXTENSION CYLINDER
– Cylinder Group Removal And Installation
– Upper Tubeline Removal
– Upper Tubeline Installation
– Extension Cylinder Removal And Installation
– Tubeline Tray Disassembly
– Tubeline Tray Assembly
– Parts Identification
– Disassembly
– Assembly
TILT CYLINDER
– Removal And Installation
– Parts Identification
– Disassembly
– Assembly
STEERING CYLINDER FRONT For SN 363011001 363012000 and SN 363111001 363012000
– Removal And Installation
– Parts Identification
– Disassembly
– Assembly
STEERING CYLINDER FRONT For SN 363012001 and above, SN 363112001 and above
– Removing the Steering Cylinder
– Installing the Steering Cylinder
– Disassembling the Steering Cylinder
– Assembling the Steering Cylinder
STEERING CYLINDER REAR For SN 363011001 363012000 and SN 363111001 363112000
– Removal And Installation
– Parts Identification
– Disassembly
– Assembly
STEERING CYLINDER REAR For SN 363012001 and above, SN 363112001 and above
– Removing the Steering Cylinder
– Installing the Steering Cylinder
– Disassembling the Steering Cylinder
– Assembling the Steering Cylinder
DRIVE BOX For SN 363011001 363012000 and SN 363111001 363112000
– Parts Identification
– Disassembly
– Inspection
– Assembly
DRIVE BOX For SN 363012001 and above, SN 363112001 and above
– Parts Identification
– Disassembly
– Assembly
special tools
MAIN RELIEF VALVE
– Testing And Adjustment
QUICK TACH CYLINDER
– Removal And Installation
– Parts Identification
– Disassembly
– Assembly
PORT RELIEF VALVES
– Adjustment Procedure
STEERING MODE VALVE BLOCK
– Removal And Installation
– Parts Identification
– Disassembly
– Solenoid Testing
– Assembly
BRAKE VALVE
– Removal And Installation
– Disassembly And Assembly
GEAR PUMP
– Removal And Installation
GEAR PUMP CONTD
– Parts Identification
– Disassembly And Assembly
FAN MOTOR
– Removal And Installation
– Parts Identification
– Disassembly And Assembly 1 speed version
– Disassembly And Assembly 2 speed version
HYDRAULIC RESERVOIR
– Removal And Installation
STEERING VALVE
– Removal And Installation
– Parts Identification
– Disassembly
– Inspection
– Assembly
HYDRAULIC CONTROL VALVE
– Troubleshooting Chart Controllers
– Telescoping Valve Section Troubleshooting
– Auxiliary Valve Section Troubleshooting
– Troubleshooting Chart Control Valve
– Removal And Installation
HYDRAULIC CONTROL VALVE CONTD
– Parts Identification
– Disassembly And Assembly
– End Housing Disassembly And Assembly
– Lifting Valve Section Disassembly And Assembly
– Tilting Valve Section Disassembly And Assembly
– Telescoping Valve Section Disassembly And Assembly
– Auxiliary Valve Section Disassembly And Assembly
– InletOutlet Valve Section Disassembly And Assembly
JOYSTICK
– Removal And Installation
– Parts Identification
PARKING BRAKE
– Parking Brake Valve Removal And Installation
– Parking Brake Valve Disassembly And Assembly
PILOT PRESSURE LOCK OUT VALVE
– Testing
– Removal And Installation
– Disassembly And Assembly
ACCUMULATOR
– Removal And Installation
OPTIONAL TOW VALVE
– Removal And Installation
– Disassembly And Assembly
FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE
– Removal And Installation
– Disassembly And Assembly
FLOW CONTROL VALVE
– Removal And Installation
HYDROSTATIC SYSTEM INFORMATION
– Troubleshooting Chart
– Replenishing Valve Function
OIL COOLER
– Description
HYDROSTATIC DRIVE MOTOR
– Removal And Installation
– Parts Identification
– Disassembly
– Inspection
– Assembly
HYDROSTATIC PUMP
– Removal And Installation
– Parts Identification
– Parts Identification
– Disassembly
– Inspection
– Assembly
– Charge pressure checking procedure
– Charge pressure adjusting procedure
TROUBLESHOOTING
– Chart
AXLE AND DIFFERENTIAL FRONT For SN 363011001 363012000 and SN 363111001 363112000
– General Information
– Planetary Carrier Parts Identification
– Planetary Carrier Disassembly
– Planetary Carrier Inspection
– Wheel Hub Parts Identification
– Wheel Hub Disassembly
– Wheel Hub Inspection
– Steering Knuckle Parts Identification
– Steering Knuckle Disassembly
– Axle HousingDrive Axle Parts Identification
– Axle HousingDrive Axle Disassembly
– Brake Group Parts Identification
– Brake Group Disassembly
– Brake Group Inspection
– Differential Parts Identification
– Differential Disassembly
– Differential Inspection
– Pinion Group Parts Identification
– Pinion Group Disassembly
– Pinion Group Inspection
– Pinion Group Assembly
– Differential Assembly
– Brake Group Assembly
– Axle HousingDrive Axle Assembly
– Steering Knuckle Assembly
– Wheel Hub Assembly
– Planetary Carrier Assembly
AXLE AND DIFFERENTIAL REAR For SN 363011001 363012000 and SN 363111001 363112000
– General Information
– Planetary Carrier Parts Identification
– Planetary Carrier Disassembly
– Planetary Carrier Inspection
– Wheel Hub Parts Identification
– Wheel Hub Disassembly
– Wheel Hub Inspection
– Steering Knuckle Parts Identification
– Steering Knuckle Disassembly
– Axle HousingDrive Axle Parts Identification
– Axle HousingDrive Axle Disassembly
– Differential Parts Identification
– Differential Disassembly
– Differential Inspection
– Pinion Group Parts Identification
– Pinion Group Disassembly
– Pinion Group Inspection
– Pinion Group Assembly
– Differential Assembly
– Axle HousingDrive Axle Assembly
– Steering Knuckle Assembly
– Wheel Hub Assembly
– Planetary Carrier Assembly
AXLE AND DIFFERENTIAL FRONT For SN 363012001 and Above, SN 363112001 and Above
– General Information
– Planetary Carrier Parts Identification
– Planetary Carrier Disassembly
– Steering Knuckle Parts Identification
– Steering Knuckle Disassembly
– Brake System Identification
– Brake System disassembly
– Differential Parts Identification
– Differential Disassembly
– AXLE AND DIFFERENTIAL FRONT For SN 363012001 and Above, SN 363112001 and Above Contd
– Bevel Pinion Parts Identification
– Bevel Pinion Disassembly
– Bevel Pinion Assembly
– Differential Assembly
– Brake Assembly
– Steering Knuckle Assembly
– Planetary Carrier Assembly
special tools
AXLE AND DIFFERENTIAL FRONT For SN 363012501 and Above, SN 363112501 and Above
– General Information
– Planetary Carrier And Steering Knuckle Parts Identification
– Planetary Carrier Disassembly and Assembly
– Wheel Hub Disassembly And Assembly
– Steering Knuckle Disassembly And Assembly
– Axle Housing Drive Axle Disassembly
– Brake Group Parts Identification
– Brake Group Disassembly
– Differential Parts Identification
– Differential Disassembly And Assembly
– Pinion Group Parts Identification
– Pinion Group Disassembly
– Pinion Group Assembly
– Brake Group Assembly
– Axle Housing Drive Axle Assemby
– Special Tools
AXLE AND DIFFERENTIAL REAR For SN 363012001 and Above, SN 363112001 and Above
– General Information
– Planetary Carrier Parts Identification
– Planetary Carrier Disassembly Contd
– Steering Knuckle Parts Identification
– Steering Knuckle Disassembly
– Differential Parts Identification
– Bevel pinion Parts Identification
– Differential Assembly
– Steering Knuckle Assembly
– Planetary Carrier Assembly
FRONT AXLE For SN 363011001 363012000 and S N 363111001 363112000
– Removal
– Installation
FRONT AXLE For SN 363012001 and Above, SN 363112001 and Above
– Removal
– Installation
AXLE TOEIN For SN 363011001 363012000 and S N 363111001 363112000
– Adjustment
AXLE TOEIN For SN 363012001 and Above, SN 363112001 and Above
– Adjustment
PARKING BRAKE For SN 363011001 363012000 and SN 363111001 363112000
– Releasing The Brake For Towing
– ReActivating The Brake
PARKING BRAKE For SN 363012001 and Above, SN 363112001 and Above
– Releasing The Brake For Towing
– ReActivating The Brake
STEERING ANGLE ADJUSTMENT For SN 363011001 363012000 and SN 363111001 363112000
– Adjustment
STEERING ANGLE ADJUSTMENT For SN 363012001 and Above, SN 363112001 and Above
– Adjustment
DRIVESHAFT
– For SN 363011001 363012000 and SN 363111001 363112000
– Removal And Installation
– For SN 363012001 and Above, SN 363112001 and Above
SERVICE BRAKE For SN 363011001 363012000 and SN 363111001 363112000
– Description
– Bleeding The Brake Circuit
SERVICE BRAKE For SN 363012001 and Above, SN 363112001 and Above
– Description
– Bleeding The Brake Circuit
REAR AXLE For SN 363011001 363012000 and SN 363111001 363112000
– Removal
– Installation
REAR AXLE For SN 363012001 and Above, SN 363112001 and Above
– Removal
– Installation
OPERATOR CAB
– Removal And Installation
OPERATOR SEAT
– Not available at time of printing
BOOM ASSEMBLY
– Removal And Installation
INNER BOOM
– Removal
– Installation
WEAR PADS FRONT
– Removal And Installation
WEAR PADS REAR
– Removal
– Installation
ENGINE COVER
– Gas Cylinder Removal And Installation
– Removal And Installation
AIR INTAKE COWLING
– Removal And Installation
FUEL TANK
– Removal And Installation
QUICK TACH
– Removal And Installation
REAR WEIGHTS
– Removal And Installation
FENDER
– Removal And Installation For SN 363011001 363012000 and SN 363111001 363112000
JOYSTICK PANEL
– Removal And Installation
DASH COVERSTEERING COLUMN COVER
– Removal And Installation
ELECTRICAL SYSTEM INFORMATION
– Troubleshooting Chart
– Description
– Fuses, Diodes Relays
ELECTRICAL SYSTEM CONTD
– Fuses, Diodes Relays Contd
BATTERY
– Removal And Installation
– Servicing
– Using A Booster Battery Jump Starting
ALTERNATOR
– Removal And Installation
– Adjusting The Alternator Belt
STARTER
– Removal And Installation
STARTER CONTD
– Parts Identification
– DisassemblyAssembly
LIGHTS
– Rear Light Removal And Installation
– Front Light Removal And Installation
TRAVELSIGNAL LEVER
– Removal And Installation
INSTRUMENT PANEL
– Removal And Installation
SWITCH PANEL
– Parts description
BRAKE LIGHT SWITCH
– Removal And Installation
– Adjustment
FRONT WIPER MOTOR
– Removal And Installation
TOP WIPER MOTOR
– Removal And Installation
REAR WIPER MOTOR
– Removal And Installation
PEDAL ASSEMBLY
– Removal And Installation
– Disassembly And Assembly
INCHING SWITCH
– Removal And Installation
– Adjustment
SERVICE SOFTWARE ONLY For SN 363011001 and Above, SN 363111001 and Above
– Connecting The Laptop Computer
– Entering The Service Software
– Monitor Screen
– Warnings Screen
– Calibrate Inch Pedal
Longitudinal Stability Indicator Calibration
– Fitting the sensor
– Calibration procedure
TROUBLESHOOTING
– Chart
ENGINE SPEED CONTROL
– Removal And Installation
MUFFLER
– Removal And Installation
AIR CLEANER
– Housing Removal And Installation
OIL COOLERRADIATOR
– Removal And Installation
– Disassembly And Assembly
ENGINE AND ENGINE MOUNTS
– Removal And Installation
ENGINE COMPONENTS AND TESTING
– Fuel Injection Pump Removal
– Fuel Injection Pump Installation
– Fuel Injectors Removal And Installation
– Checking The Fuel Lift Pump
– Fuel Lift Pump Removal And Installation
– Compression Checking
– Glow Plugs Checking
– Glow Plugs Removal And Installation
ENGINE TIMING
– Procedure
ENGINEHYDROSTAT ASSEMBLY
– Removal And Installation
FLYWHEEL AND HOUSING
– Removal And Installation
– Ring Gear Removal
– Ring Gear Installation
RECONDITIONING THE ENGINE
– Turbo Charger Troubleshooting
– Turbo Charger Description
– Turbo Charger Removal And Installation
– Exhaust Manifold Removal And Installation
– Fuel Injector Cover Removal And Installation
– Rocker Cover Removal And Installation
– Cylinder Head Removal
– Cylinder Head Inspection
– Cylinder Head Installation
– Rocker Shaft Disassembly And Assembly
– Valve Removal
– Valve Springs Checking
– Valve Depth Checking
– Valve Guides Checking
– Valve Guide Removal
– Valve Guide Installation
– Valves Checking
– Cutting A Valve Seat
– Valve Seat Assembly
– Changing Valve Springs With Cylinder Head Installed
– Valve Clearance Adjustment
– Timing Case And Drive Assembly Description
– Timing Cover Removal
– Timing Cover Installation
– Crankshaft Pulley Removal And Installation
– Front Oil Seal Removal And Installation
– Timing Case And Gear Removal
– Timing Case And Gear Installation
– Camshaft And Tappets Removal
– Camshaft And Tappets Installation
– Pistons And Connecting Rods Description
– Pistons And Connecting Rods Removal
– Pistons And Connecting Rods Disassembly
– Piston Ring End Gap
– Piston Ring Installation
– Piston Ring Groove Clearance
– Connecting Rod Inspection
– Connecting Rod Bushing Replacement
– Piston And Connecting Rod Assembly
– Piston And Connecting Rod Installation
– Checking Piston Height
– Crankshaft And Bearings Description
– Crankshaft And Bearings Removal
– Inspection Of Crankshaft And Bearings
– Crankshaft And Bearings Installation
– Rear Oil Seal Removal
– Rear Oil Seal Housing Positioning
– Rear Oil Seal Installation
– Checking Crankshaft End Play
– Cooling System Description
– Thermostat Removal and Installation
– Thermostat Testing
– Lubricating Oil Cooler Removal And Installation
– Water Pump Removal
– Water Pump Installation
– Engine Lubrication System Description
– Oil Filter Adapter Removal And Installation
– Oil Pan Removal And Installation
– Oil Screen And Pickup Tube
– Oil Pump Removal
– Oil Pump Installation
– Oil Pump Disassembly And Assembly
– Oil Pressure Relief Valve Disassembly And Assembly
– Engine Block Description
– Engine Block Disassembly And Assembly
– Piston Cooling Jet Removal
– Piston Cooling Jet Installation
– Piston Cooling Jet Alignment
– Inspection
– Cylinder Liner Inspection
– Cylinder Liner Removal
– Cylinder Liner Installation
AIR CONDITIONING SYSTEM FLOW
– Principals
– Chart
COMPONENTS
– Identification
SAFETY
– Safety Equipment
REGULAR MAINTENANCE
– Filter Element Removal And Installation
– Compressor Drive Belt Inspection
– Cleaning The Condenser
BASIC TROUBLESHOOTING
– Poor AC Performance
– Compressor Drive Belt Inspection
– Checking The Electrical System
GENERAL AIR CONDITIONING SERVICE GUIDELINES
– Compressor Oil
– Compressor Oil Check
– Component Replacement And Refrigeration Leaks
SYSTEM TROUBLESHOOTING CHART
– Chart
– Gauge Pressure Related Troubleshooting
TEMPERATUREPRESSURE
– Chart
AIR CONDITIONING SERVICE
– Chart
SYSTEM CHARGING AND RECLAMATION
– Reclamation Procedure
– Charging Procedure With A Manifold Gauge Set
– Charging Procedure
COMPRESSOR
– Removal And Installation
– Compressor Clutch Disassembly And Assembly
CONDENSER
– Removal And Installation
RECEIVERDRIER
– Removal And Installation
PRESSURE SWITCH
– Removal And Installation
EVAPORATORBLOWER UNIT
– Removal And Installation
EXPANSION VALVE
– Removal And Installation
HEATER ASSEMBLY
– Removal And Installation
– Fan Removal And Installation
– Core Removal And Installation
TELESCOPIC HANDLER SPECIFICATIONS
– Dimensional Specifications
– Performance Specifications
– Engine
– Controls
– Drive System
– Tires
– Capacities
– Hydraulic System
– Electrical System
– Instrument Panel
ENGINE SPECIFICATIONS
– General
– Cylinder Head
– Valve Guides
– Exhaust Valves
– Intake Valves
– Valve Springs
– Rocker Shaft, Rockers And Bushings
– Pistons And Piston Rings
– Connecting Rods And Bearings
– Crankshaft
– Crankshaft ReGrind Data
– Main Bearings
– Thrust Washers
– Camshaft And Thrust Washer
– Cylinder Block
– Cylinder Liners
– Fuel Injection Pump
– Fuel Injectors
– Fuel Lift Pump
– Timing Case And Timing Gears
– Oil Pump, Gear And Relief Valve
– Turbocharger
– Flywheel
– Water Pump And Thermostat
– Engine Torque Component
MACHINE TORQUE SPECIFICATIONS
– Specifications
TORQUE SPECIFICATIONS FOR BOLTS
– Torque for General SAE Bolts
– Torque For General Metric Bolts
HYDRAULIC CONNECTION SPECIFICATIONS
– Oring Face Seal Connection
– Straight Thread Oring Fitting
– Tubelines And Hoses
– Flare Fitting
– Oring Flare Fitting
– Port Seal Fitting
HYDRAULICHYDROSTATIC FLUID SPECIFICATIONS
– Specifications
CONVERSIONS
– Decimal And Millimeter Equivalents
– U.S. To Metric Conversion