Bobcat T35120SL MP Telescopic Handler 6986767 (Preview)
MAINTENANCE SAFETY
CONTENTS
FOREWORD
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrestor Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATION
Telescopic Handler Serial Number
Engine Serial Number
Other Serial Numbers
DELIVERY REPORT
BOBCAT TELESCOPIC HANDLER IDENTIFICATION
SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE TELESCOPIC HANDLER
Procedure
OPERATOR CAB (ROPS / FOPS)
Cab Door
Cab Door Window
TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER
Loading And Unloading
Fastening
TOWING THE TELESCOPIC HANDLER
Procedure
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Replacing Filter Element(s)
ENGINE COOLING SYSTEM
Cleaning
Removing And Replacing The Coolant
Checking Level
FUEL SYSTEM
Fuel Specifications
Biodiesel Blend Fuel
Filling The Fuel Tank
Secondary Fuel Filter
Primary Fuel Filter (Pre-Filter)
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Engine Oil Chart
Removing And Replacing Oil And Filter
HYDRAULIC / HYDROSTATIC SYSTEM
Checking And Adding Fluid
Hydraulic / Hydrostatic Fluid Chart
Removing And Replacing Hydraulic Fluid
Removing And Replacing Hydraulic / Hydrostatic Filter
Hydraulic Tank Breather
AXLES (FRONT AND REAR)
Checking And Adding Oil (Planetary Carrier)
Removing And Replacing Oil (Planetary Carrier)
Checking And Adding Oil (Rear Differential)
Removing And Replacing Oil (Rear Differential)
Checking And Adding Oil (Front Differential)
Removing And Replacing Oil (Front Differential)
Checking And Adding Oil (Front Drop Box)
Removing And Replacing Oil (Front Drop Box)
LUBRICATING THE TELESCOPIC HANDLER
Lubrication Locations
ATTACHMENT CARRIER
Inspection And Maintenance
TIRE MAINTENANCE
Wheel Nuts
Rotating
Mounting
APPROVED BOOM STOP
Installing The Approved Boom Stop
Removing The Approved Boom Stop
ENGINE COVER
Opening And Closing
CHAIN
Checking And Adjustment Procedure
Extend / Retract Chain Wear Check
TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE
Storage
Return To Service
STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER
Procedure
EMERGENCY EXIT
Rear Window
HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
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
Parts Identification
Disassembly
Assembly
TILT CYLINDER
Removal And Installation
Parts Identification
Disassembly
Assembly
STEERING CYLINDER (FRONT)
Removing The Steering Cylinder
Installing The Steering Cylinder
Disassembling The Steering Cylinder
Assembling The Steering Cylinder
STEERING CYLINDER (REAR)
Removing The Steering Cylinder
Installing The Steering Cylinder
Disassembling The Steering Cylinder
Assembling The Steering Cylinder
DRIVE BOX
Parts Identification
Disassembly
Assembly
Special Tools
MAIN RELIEF VALVE
Testing And Adjustment
Removal And Installation
QUICK-TACH CYLINDER
Removal And Installation
Parts Identification
Disassembly
Assembly
FRAME LEVELING CYLINDER
Removal And Installation
Parts Identification
Disassembly
Assembly
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
Parts Identification
Disassembly And Assembly
FAN MOTOR
Removal And Installation
Parts Identification
Disassembly And Assembly
HYDRAULIC FLUID RESERVOIR
Removal And Installation
STEERING VALVE
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
HYDRAULIC CONTROL VALVE
Checking Drain Pressure
Valve Section Troubleshooting (Auxiliary Section Example)
Removal And Installation
Parts Identification
Section Removal
Section Disassembly And Assembly
Inlet Section Disassembly And Assembly
Inlet Section Disassembly And Assembly (Cont’d)
PORT RELIEF VALVES
Removal And Installation
FLOW CONTROL VALVE
Removal And Installation
PARKING BRAKE
Parking Brake Valve Removal And Installation
Parking Brake Valve Disassembly And Assembly
Parking Brake Valve Disassembly And Assembly (Cont’d)
ACCUMULATOR
Removal And Installation
TOW VALVE
Removal And Installation
Disassembly And Assembly
STABILIZER CYLINDER (IF EQUIPPED)
Removal
Parts Identification
Disassembly
Assembly
Installation
STABILIZER CONTROL VALVE (IF EQUIPPED)
Parts Identification
Removal
Installation
HYDROSTATIC SYSTEM
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
Disassembly
Inspection
Assembly
DRIVE SYSTEM
TROUBLESHOOTING
Chart
AXLE AND DIFFERENTIAL (FRONT)
General Information
Planetary Carrier Parts Identification
Planetary Carrier Disassembly
Steering Knuckle And Drive Axle Parts Identification
Steering Knuckle Disassembly
Drive Axle Disassembly
Brake System Parts Identification
Brake System Disassembly
Differential Parts Identification
Differential Disassembly
Bevel Pinion Parts Identification
Bevel Pinion Disassembly
Bevel Pinion Assembly
Differential Assembly
Brake System Assembly
Drive Axle Assembly
Steering Knuckle Assembly
Planetary Carrier Assembly
Special Tools
AXLE AND DIFFERENTIAL (REAR)
General Information
Planetary Carrier Parts Identification
Steering Knuckle And Drive Axle Parts Identification
Steering Knuckle Disassembly
Differential And Bevel Pinion Parts Identification
Differential Disassembly
Bevel Pinion Disassembly
Bevel Pinion Assembly
Differential Assembly
Steering Knuckle Assembly
Planetary Carrier Assembly
Special Tools
FRONT AXLE
Removal
Installation
AXLE TOE-IN
Adjustment
PARKING BRAKE
Releasing The Brake For Towing
Re-Activating The Brake
STEERING ANGLE ADJUSTMENT
Adjustment
DRIVE SHAFT
Removal And Installation
SERVICE BRAKE
Description
Bleeding The Brake Circuit
REAR AXLE
Removal
Installation
MAINFRAME
OPERATOR CAB (S/N A8GS12999 & BELOW)
Removal And Installation
OPERATOR CAB (S/N A8GS13000 & ABOVE)
Removal And Installation
OPERATOR SEAT
Removal And Installation
FIXED BOOM
Removal
Installation
END BOOM
Removal
Installation
WEAR PADS (FRONT)
Removal
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
JOYSTICK PANEL (S/N A8GS12999 & BELOW)
Removal And Installation
JOYSTICK PANEL (S/N A8GS13000 & ABOVE)
Removal And Installation
DASH COVER / STEERING COLUMN COVER (S/N A8GS12999 & BELOW)
Removal And Installation
DASH COVER / STEERING COLUMN COVER (S/N A8GS13000 & ABOVE)
Removal And Installation
INTERMEDIATE BOOM
Removal
Installation
BOOM TRAY
Removal And Installation
STABILIZER FRAME (IF EQUIPPED)
Removal
Installation
ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION (S/N A8GS12999 & BELOW)
Troubleshooting Chart
Description
Fuses, Diode And Relay Location / Identification
ELECTRICAL SYSTEM INFORMATION (S/N A8GS13000 & ABOVE)
Troubleshooting Chart
Description
Fuses, Diode And Relay Location / Identification
BATTERY
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
ALTERNATOR
Removal And Installation
Belt Adjustment
Belt Replacement
STARTER
Testing
Removal And Installation
LIGHTS
Rear Light Removal And Installation
Front Light Removal And Installation
TRAVEL / SIGNAL LEVER (S/N A8GS12999 & BELOW)
Removal And Installation
TRAVEL / SIGNAL LEVER (S/N A8GS13000 & ABOVE)
Removal And Installation
INSTRUMENT PANEL
Removal And Installation
SWITCH PANEL (S/N A8GS12999 & BELOW)
Removal And Installation
Parts Description
SWITCH PANEL (S/N A8GS13000 – 14999)
Removal And Installation
SWITCH PANEL (S/N A8GS15000 & ABOVE)
Removal And Installation
BRAKE LIGHT SWITCH
Removal And Installation
Adjustment
WIPER MOTOR (Front)
Removal And Installation
WIPER MOTOR (TOP)
Removal And Installation
WIPER MOTOR (REAR)
Removal And Installation
PEDAL ASSEMBLY
Removal And Installation
INCHING SWITCH
Removal And Installation
Adjustment
SERVICE SOFTWARE
Connecting The Laptop Computer
Entering The Service Software
Monitor Screen
Warnings Screen
Calibrate Inch Pedal
Calibrate Creep Potentiometer
Program / Update Susmic Controller
FRAME LEVEL SPEED SWITCH
Description
Removal
Installation
LONGITUDINAL STABILITY INDICATOR CALIBRATION (S/N A8GS11001-14999)
Fitting The Sensor
Calibration Procedure
LLMI / LLMC SYSTEM (S/N A8GS15000 & ABOVE)
System Calibration
Calibration Test
System Failure Reports
System Components Identification
LLMS Removal
LLMS Installation
LLMC Controller Removal
LLMC Controller Installation
JOYSTICK
Removal And Installation
ENGINE SERVICE
ENGINE INFORMATION
Specifications
Troubleshooting
ENGINE SPEED CONTROL
Removal And Installation
MUFFLER
Removal And Installation
AIR CLEANER
Housing Removal And Installation
OIL COOLER / RADIATOR
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
ENGINE / HYDROSTAT ASSEMBLY
Removal And Installation
FLYWHEEL AND HOUSING
Removal And Installation
Ring Gear Removal
Ring Gear Installation
RECONDITIONING THE ENGINE
Turbocharger Troubleshooting
Turbocharger Description
Turbocharger 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 Pick-up 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
HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW
Description
Chart
Components
Safety Equipment
REGULAR MAINTENANCE
Filters
Compressor And Alternator Drive Belt Inspection
Cleaning The Condenser
Air Conditioning Lubrication
Air Conditioning Service Chart
TROUBLESHOOTING
Blower Motor Does Not Operate
Blower Motor Operates Normally, But Air Flow Is Insufficient
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
The Compressor Does Not Operate At All, Or Operates Improperly
Gauge Pressure Related Troubleshooting
Troubleshooting Tree
Temperature / Pressure Chart
Poor A/C Performance
HVAC Repairs And Leaks
Electrical System
SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
Charging Procedure With A Manifold Gauge Set
Charging Procedure
COMPRESSOR
Removal And Installation
Oil
Oil Check
Clutch Disassembly And Assembly
CONDENSER (S/N A8GS12999 & BELOW)
Removal And Installation
CONDENSER (S/N A8GS13000 & ABOVE)
Removal And Installation
RECEIVER / DRIER
Removal And Installation
PRESSURE SWITCH
Removal And Installation
EVAPORATOR / BLOWER UNIT (S/N A8GS12999 & BELOW)
Removal And Installation
EVAPORATOR / BLOWER UNIT (S/N A8GS13000 & ABOVE)
Removal And Installation
EXPANSION VALVE (S/N A8GS12999 & BELOW)
Removal And Installation
EXPANSION VALVE (S/N A8GS13000 & ABOVE)
Removal And Installation
HEATER ASSEMBLY
Removal And Installation
Fan Removal And Installation
Core Removal And Installation
SPECIFICATIONS
(T35120SL) TELESCOPIC HANDLER SPECIFICATIONS
Dimensional Specifications
Performance Specifications
Weights
Engine
Controls
Drive System
Traction
Steering
Brakes
Fluid Capacities
Hydraulic System
Electrical
Instruments
Environmental
Temperature Range
MACHINE TORQUE SPECIFICATIONS
Axle
Boom
Drive Box
Drive Motor
Engine
Hydraulic Pump
TORQUE SPECIFICATIONS FOR BOLTS
Torque for General SAE Bolts
Torque For General Metric Bolts
HYDRAULIC CONNECTION SPECIFICATIONS
O-ring Face Seal Connection
Straight Thread O-ring Fitting
Tubelines And Hoses
Port Seal Fitting
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion
ALPHABETICAL INDEX
SERVICE MANUAL REVISION
Revision No: T35120SL MP – 1
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