Bobcat T41.140SLPRB, T40.180SLPRB Telescopic Handler 7400390 (Preview)
MAINTENANCE SAFETY
CONTENTS
FOREWORD
FOREWORD
SAFETY INSTRUCTIONS
Safe Operation Is The Operator’s Responsibility
Safe Operation Needs A Qualified Operator
Avoid Silica Dust
Dismantling And Disposal
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Welding And Grinding
Fire Extinguishers
PUBLICATIONS AND TRAINING RESOURCES
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
Description
Cab Door
Cab Door Window
Rear Cab Window
Cab Light
TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER
Loading And Unloading
Fastening
TOWING THE TELESCOPIC HANDLER
Procedure
SERVICE SCHEDULE
Maintenance Intervals
AIR CLEANER SERVICE
Replacing Filter Elements
Cleaning The Dust Extractor
COOLING SYSTEM
Cleaning
Checking Level
Removing And Replacing The Coolant
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Replacing The Fuel Tank Breather
Fuel Pre-Filter
Fuel 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
Removing And Replacing Hydraulic Fluid
Removing And Replacing Hydraulic / Hydrostatic Filter
Fill / Breather Cap
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 (Reduction Box)
Removing And Replacing Oil (Reduction Box)
LUBRICATING THE TELESCOPIC HANDLER
Lubrication Locations
Front Pads Lubrication
Rear Pads Lubrication
ATTACHMENT CARRIER
Inspection And Maintenance
TIRE MAINTENANCE
Wheel Nuts
Rotating
Wheel Replacement
Mounting
Pressure
APPROVED BOOM STOP
Installing The Approved Boom Stop
Removing The Approved Boom Stop
ENGINE COVER
Opening And Closing
CHAIN CHECKING AND ADJUSTING PROCEDURE
Checking / Adjustment Procedure
Extension / Retraction Chain Wear Check
STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER
Procedure
EMERGENCY EXIT
Rear Window
TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE
Storage
Return To Service
LIFTING THE TELESCOPIC HANDLER
Procedure
REMOTE START TOOL (SERVICE TOOL) KIT – 6987761
Remote Start Tool (Service Tool) – 7022042
Telescopic Handler Service Tool Harness – 6689747
Computer Service Tool Harness – 6689746
Remote Start Procedure
HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
Troubleshooting Chart
Tightening Procedures
Test Coupler Location
BOOM CYLINDER
Removal And Installation
Parts Identification
Disassembly
Assembly
SELF LEVELING (COMPENSATION) 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 / REAR)
Removal
Installation
Disassembly
Assembly
EMERGENCY VALVE
Removal And Installation
BRAKES BLOCK
Removing And Installing The Standard Brakes Block
Removing And Installing The Italian Brakes Block
Removing And Installing The German Brakes Block
ACCUMULATORS
Accumulators Pressure Relief
Removing And Installing The Park / Service Brake Accumulator
Removing And Installing The Boom Lift Valve Accumulator
SERVICE BRAKE VALVE
Removal And Installation
TANDEM GEAR PUMP
Removal And Installation
Parts Identification
Disassembly And Assembly
TANDEM GEAR PUMP (TESTING)
Fan Gear Pump Direct Test
Steering And Valve Gear Pump Direct Test
FAN MOTOR
Description
Removal And Installation
Parts Identification (Single Speed Version) (Standard)
Disassembly And Assembly (Single Speed Version) (Standard)
Parts Identification (Variable Speed Version) (Optional)
Disassembly And Assembly (Variable Speed Version) (Optional)
FAN MOTOR (VARIABLE SPEED FAN MOTOR TESTING)
Description
Testing
HYDRAULIC FLUID TANK
Removal And Installation
STEERING UNIT
Removal And Installation
STEERING UNIT (TESTING)
Testing The Steering Unit Main Relief Valve
MAIN VALVE
Troubleshooting Chart (Solenoid Valves)
Valve Section Troubleshooting
Troubleshooting Chart (Main Valve)
Removal And Installation
Parts Identification
Section Removal
Section Disassembly And Assembly
Inlet-Outlet Valve Section Disassembly And Assembly
End Housing Disassembly And Assembly
MAIN RELIEF VALVE
Testing
Adjusting
PORT RELIEF VALVES
Removal And Installation
DIVERTER VALVE
Removal And Installation
SELF LEVELING VALVE
Removal And Installation
AUXILIARY HYDRAULIC FLOW
Testing the Auxiliary Hydraulic Flow
STABILIZER / FRAME LEVELING VALVE
Removal
Installation
Disassembly
Solenoid Testing
Assembly
STABILIZER CYLINDER
Removal
Parts Identification
Disassembly
Assembly
Installation
FRAME LEVELING CYLINDER
Removal And Installation
Parts Identification
Disassembly
Assembly
HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
Test Coupler Location
OIL COOLER
Description
HYDROSTATIC DRIVE MOTOR
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
HYDROSTATIC PUMP
Removal And Installation
Parts Identification
Shaft Disassembly
Relief Valves Disassembly And Assembly
Charge Pump Disassembly
Piston Pump Disassembly
Solenoid Block Disassembly
Inspection
Piston Pump Assembly
Charge Pump Assembly
Solenoid Block Assembly
Shaft Assembly
CHARGE PRESSURE
Description
Testing And Adjusting
MULTI-FUNCTION VALVES
Description
Testing
PRESSURE COMPENSATION OVERRIDE VALVE (PCOR)
Description
Testing And Adjusting
DRIVE SYSTEM
DRIVE SYSTEM TROUBLESHOOTING
Chart
AXLE AND DIFFERENTIAL (FRONT)
Description
Planetary Carrier And Drive Axle Parts Identification
Planetary Carrier Disassembly
Steering Knuckle Parts Identification
Steering Knuckle Disassembly
Drive Axle Disassembly
Brake Group Parts Identification
Brake Group Disassembly
Differential And Pinion Group Parts Identification
Differential Disassembly
Pinion Group Disassembly
Pinion Group Assembly
Differential Assembly
Brake Group Assembly
Drive Axle Assembly
Steering Knuckle Assembly
Planetary Carrier Assembly
AXLE AND DIFFERENTIAL (REAR)
Description
Planetary Carrier And Drive Axle Parts Identification
Planetary Carrier Disassembly
Steering Knuckle Parts Identification
Steering Knuckle Disassembly
Differential And Pinion Group Parts Identification
Differential Disassembly
Pinion Group Disassembly
Pinion Group Assembly
Differential Assembly
Steering Knuckle Assembly
Planetary Carrier Assembly
FRONT AXLE
Removal
Installation
Mounting Bolts Tightening Torque Check
AXLE TOE-IN
Adjustment
STEERING ANGLE ADJUSTMENT
Adjustment
PARK BRAKE
Park Brake Removal, Disassembly And Assembly
REDUCTION BOX
Removal And Installation
Parts Identification
Disassembly
Assembly
DRIVE SHAFT
Removal And Installation
SERVICE BRAKE
Description
Bleeding The Brake Circuit
REAR AXLE
Removal And Installation
MAINFRAME
OPERATOR CAB
Removal And Installation
OPERATOR SEAT
Removal And Installation
BOOM ASSEMBLY
Removal And Installation
BOOM TRAY
Removal And Installation
END BOOM
Removal
Installation
INTERMEDIATE BOOM
Removal Of The First Intermediate Boom (T40.180SLPRB)
Installation Of The First Intermediate Boom (T40.180SLPRB)
Removal Of The Second Intermediate Boom (T40.180SLPRB) / Intermediate Boom (T41.140SLPRB)
Installation Of The Second Intermediate Boom (T40.180SLPRB) / Intermediate Boom (T41.140SLPRB)
WEAR PADS (FRONT)
Boom Wear Pad Checking
Removal
Installation
WEAR PADS (REAR)
Boom Wear Pad Checking
Removal
Installation
ENGINE COVER
Gas Cylinder Removal And Installation
Removal And Installation
FUEL TANK
Removal And Installation
ATTACHMENT CARRIER (QUICK-TACH)
Removal And Installation
COUNTERWEIGHT
Removal And Installation
FENDER
Removal And Installation
STEERING COLUMN COVER
Removal And Installation
DASH COVER
Removal And Installation
JOYSTICK PANEL
Removal And Installation
STABILIZER FRAME
Removal
ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Cab Harness Connectors
Mainframe Harness Connectors
Engine Bay Harness Connectors
Engine Harness Connectors
Troubleshooting Chart
Description
Fuses And Relay Location / Identification
BATTERY
Removing And Installing The Battery
Using A Booster Battery (Jump Starting)
ALTERNATOR
Belt Adjustment
Belt Checking
Belt Replacement
Removal And Installation
STARTER
Testing
Removal And Installation
LIGHTS
Rear Light Removal And Installation
Front Light Removal And Installation
Rear Work Light Removal And Installation
SIGNAL LEVER
Removal And Installation
DISPLAY
Removal And Installation
INSTRUMENT PANEL
Removal And Installation
BOOM ANGLE SENSOR
Removal And Installation
FRONT WIPER MOTOR
Removal And Installation
TOP WIPER MOTOR
Removal And Installation
REAR WIPER MOTOR
Removal And Installation
SERVICE BRAKE PEDAL ASSEMBLY
Removal And Installation
INCHING SENSOR
Removal And Installation
SERVICE PC (LAPTOP COMPUTER)
Connecting Remote Start Tool (Service Tool) – 6987761
FUEL LEVEL SENDER
Removal And Installation
JOYSTICK
Removal And Installation
LLMI / LLMC SYSTEM
System Components Identification
LLMS Removal
LLMS Installation
LLMC Removal And Installation
TRAVEL DIRECTION LEVER
Removal And Installation
CONTROLLERS
Description
Gateway Controller
Drive Controller
Work Group Controller
Display Controller
LLMI Controller
LLMC Controller
Engine Controller
MAINTENANCE CLOCK
Description
Setup
Reset
CALIBRATION
Calibrating The Hydrostatic Pump
Calibrating The Boom Angle Sensor
Calibrating The Lift Coils
Calibrating The Inching Sensor
Calibrating The Frame Leveling Sensor
Calibrating The LLMI / LLMC System
LLMC Calibration Test
LLMI / LLMC System Failure Reports
ENGINE SERVICE
ENGINE INFORMATION
Description
Tightening Torques For Main Parts
Sensor Location
Engine Specifications
Engine Serial Numbers
Torque Values
Troubleshooting
Removal And Installation
Disassembling The Engine
Assembling The Engine
ENGINE BAY ASSEMBLY
Removal And Installation
ENGINE SPEED CONTROL
Removal And Installation
EXHAUST PIPE
Removal And Installation
AIR CLEANER
Housing Removal And Installation
COOLING SYSTEM
General Information
Hydraulic Oil Cooler / Intercooler / Radiator Removal And Installation
Expansion Tank Removal And Installation
Removing The Coolant Pump
Installing The Coolant Pump
Removing The Thermostat
Installing The Thermostat
Checking The Thermostat
Cooling System Check
Cooling System Inspection
LUBRICATION SYSTEM
General Information
Troubleshooting
Removing The Oil Pump
Installing The Oil Pump
Checking The Oil Pump
Removing The Oil Suction Pipe
Installing The Oil Suction Pipe
Removing The Oil Filter Assembly
Installing The Oil Filter Assembly
Checking the Oil Filter Assembly
Removing The Oil Pan
Installing The Oil Pan
DIESEL PARTICULATE FILTER (DPF)
Removal And Installation
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
General Information
EXHAUST GAS RECIRCULATION (EGR) SYSTEM (CONT’D)
Removing The EGR
Installing The EGR
TURBOCHARGER
General Information
Troubleshooting
Removing The Turbocharger
Installing The Turbocharger
Checking The Turbocharger
INTAKE / EXHAUST SYSTEM
Removing The Intake Manifold
Installing The Intake Manifold
Removing The Exhaust Manifold
Installing The Exhaust Manifold
Removing The Throttle (Inlet Pipe) And The Intake Stake
Installing The Throttle (Inlet Pipe) And The Intake Stake
FUEL SYSTEM
General Information
Removing The Fuel Return Hose
Installing The Fuel Return Hose
Removing The Injector
Installing The Injector
Checking The Injector
Removing The Common Rail
Installing The Common Rail
Checking the Common Rail
Removing The Fuel Injection Pump
Installing The Fuel Injection Pump
Removing The Fuel Injection Pump Drive Gear
Installing The Fuel Injection Pump Drive Gear
CYLINDER BLOCK / HEAD
Disassembling The Cylinder Block
Assembling The Cylinder Block
General Inspection Of Cylinder Block
Measurement Of Inside Diameter Of Main Bearing Bore
Measurement Of Inside Diameter Of Piston Bore
Measurement of Inside Diameter of Camshaft Bearing
Removing The Cylinder Head
Installing The Cylinder Head
Checking The Cylinder Head
Removing Valves
Installing Valves
Measurement of Inside Diameter of Valve Guide
Measurement Of Valve Stem End
Measurement Of Valve Step Height
Measurement Of Gap Between Piston And Valve
Checking The Valve Spring
Removing The Rocker Arms
Installing The Rocker Arms
Checking The Rocker Arms
Checking The Rocker Arm Shaft
Removing The Valve Tappets
Installing The Valve Tappets
Checking The Valve Tappets
Removing The Push Rods
Installing The Push Rods
Checking The Deflection Of The Push Rod
Removing The Camshaft
Removing The Camshaft Gear
Installing The Camshaft Gear
Installing The Camshaft
Measuring The Camshaft Journal O.D.
Measuring The Camshaft
Removing The Flywheel Housing
Installing The Flywheel Housing
Removing The Breather Hose
Installing The Breather Hose
Removing The Cylinder Head Cover
Installing The Cylinder Head Cover
Removing The Idle Gear
Installing The Idle Gear
Measuring The Outside Diameter Of The Idle Gear Shaft
Measuring The Inside Diameter Of The Idle Gear
Removing The Lifting Hooks
Installing The Lifting Hooks
Removing The Front Oil Seal Holder
Installing The Front Oil Seal Holder
ENGINE DRIVING SYSTEM
Removing The Crankshaft
Installing The Crankshaft
Measuring The Diameter Of The Crankshaft Main Journal
Measuring The Crankshaft Bearing Clearance
Measuring The Deflection Of The Crankshaft
Removing The Timing Wheel
Installing The Timing Wheel
Removing The Pistons
Disassembling The Pistons
Assembling The Pistons
Installing The Pistons
Measuring The Inside Diameter Of The Piston Pin Bore In Pistons
Measuring The Step Height Of The Piston Top Side
Measuring The Piston Ring End Gap
Measuring The Outside Diameter Of The Piston Pin
Disconnecting The Connecting Rod
Installing The Connecting Rod
Measuring The Inside Diameter Of The Connecting Rod Small End
Measuring The Inside Diameter Of The Connecting Rod Big End
Measuring The Connecting Rod Big End Clearance
Removing The Crankshaft Pulley
Installing The Crankshaft Pulley
ENGINE TIMING
General Description
Adjusting The Engine Timing
Checking The Gear Backlash
Checking The Axial Play Of Gears
HEATING, VENTILATION, AIR CONDITIONING (HVAC)
AIR CONDITIONING SYSTEM FLOW
Description
Chart
Components
Safety Equipment
REGULAR MAINTENANCE
Cab Filter
A/C System Water Condensate Rubber Valves
Belt Adjustment
Belt Replacement
Cleaning The Condenser
Air Conditioning Lubrication
Air Conditioning Service Chart
A/C SYSTEM 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
Temperature / Pressure Chart
Poor A/C Performance
HVAC Repair And Leaks
Electrical System
SYSTEM CHARGING AND RECLAMATION
Reclamation And Charging With Recovery / Charging Unit
COMPRESSOR
Removal And Installation
Oil
Oil Check
Clutch Disassembly And Assembly
CONDENSER
Removal And Installation
RECEIVER / DRIER
Removal And Installation
PRESSURE SWITCH
Removal And Installation
EVAPORATOR / HEATER UNIT
Removal And Installation
THERMOSTAT
Description
Removal And Installation
EXPANSION VALVE
Removal And Installation
SPECIFICATIONS
T41.140SLPRB TELESCOPIC HANDLER SPECIFICATIONS
Machine Dimensions
Performance
Weights
Engine
Controls
Drive System
Traction
Steering
Brakes
Fluid Capacities
Hydraulic System
Electrical System
Temperature Range
Altitude
Instrument Panel
Environmental
T40.180SLPRB TELESCOPIC HANDLER SPECIFICATIONS
Machine Dimensions
Performance
Weights
Engine
Controls
Drive System
Traction
Steering
Brakes
Fluid Capacities
Hydraulic System
Electrical System
Temperature Range
Altitude
Instrument Panel
Environmental
VISIBILITY DIAGRAMS
Model T41.140SLPRB
Model T40.180SLPRB
LIFTING AND TIE-DOWN SPECIFICATIONS
Lifting
Tie Down
MACHINE TORQUE SPECIFICATIONS
Axle
Boom
Reduction Box
Drive Motor
Engine
Hydraulic Pump
TORQUE SPECIFICATIONS FOR BOLTS
Torque for General SAE Bolts
Torque For General Metric Bolts
HYDRAULIC CONNECTION SPECIFICATIONS
Straight Thread O-ring Fitting
Tubelines And Hoses
Flare Fitting
O-ring Flare Fitting
Port Seal Fitting
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalent Chart
U.S. To Metric Conversion Chart
SERVICE TOOLS REQUIRED
Remote Start Tools
Hydraulic Tools
Drive Tools
Electrical Tools
Special Drive Tools
ALPHABETICAL INDEX
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