Bobcat TR38160 EVO XLM1590000 & Up 7285034 (04-17) (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
SERIAL NUMBER LOCATIONS
Telescopic Handler Serial Numbers
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
Cab Rear Window
Cab Roof Window
Cab Light
Cab Ventilation, Heating And Air Conditioning
Auxiliary Power Outlet
Recirculation / Fresh Air Control
Rotating Beacon
Hazard Lights
Emergency Stop Switch
Road Light Switch
TRANSPORTING THE TELESCOPIC HANDLER
Procedure
TOWING THE TELESCOPIC HANDLER
Procedure
Deactivating The External Parking Brake Manually
SERVICE SCHEDULE
Maintenance Intervals
AIR CLEANER SERVICE
Replacing The Air Filter
ENGINE COOLING SYSTEM
Cleaning The Cooling System
Checking The Coolant Level
Removing And Replacing The Coolant
FUEL SYSTEM
Fuel Specifications
Biodiesel Blend Fuel
Filling The Fuel Tank
Fuel Filters
Cleaning The Fuel Tank
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Engine Oil Chart
Removing And Replacing Oil And Filter
HYDRAULIC / HYDROSTATIC SYSTEM
Hydraulic / Hydrostatic Fluid Chart
Checking And Adding Hydraulic / Hydrostatic Fluid
Replacing Hydraulic / Hydrostatic Fluid And Filters
Cylinder Lock Valve
AXLES (FRONT AND REAR)
Checking And Adding Oil (Planetary Carrier)
Removing And Replacing Oil (Planetary Carrier)
Checking And Adding Oil (Front And Rear Differential)
Removing And Replacing Oil (Front And Rear Differential)
Checking And Adding Oil (Drive Box)
Removing And Replacing Oil (Drive Box)
LUBRICATING THE TELESCOPIC HANDLER
Lubrication Locations
Telescopic Boom Wear Blocks
TIRE MAINTENANCE
Wheel Nuts
Tire Rotating
Tire Mounting
Tire Pressure
ENGINE COVER
Opening And Closing
APPROVED BOOM STOP
Installing The Approved Boom Stop
ANTI TIPPING DEVICE
Description
Display Panel Data
By-Pass Key Switch
Operation
Attachment Selector
Operation
Anti Tipping Device Inspection
Anti Tipping Calibration
Diagnostic Screen
HYDRAULIC SYSTEM
HYDRAULIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
Troubleshooting Chart
Tightening Procedures
Hydraulic Component Pressures
LIFT AND COMPENSATION CYLINDER
Parts Identification
Section View
Description
Removal And Installation
Disassembly
Replacing Gaskets
Assembly
INTERNAL TELESCOPE CYLINDER
Parts Identification
Removal And Installation
Hose Replacement
EXTERNAL TELESCOPE CYLINDER
Parts Identification
Internal And External Telescope Cylinder Simultaneous Extension
LIFT, COMPENSATION AND TILT CYLINDER
Tilt Cylinder Parts Identification
Lift, Compensation And Tilt Cylinder Hydraulic Circuit
Description
Lift, Compensation And Cylinder Operation
DRIVE BOX
Component Identification Location
Parts Identification
Disassembly
Assembly
BRAKE AND GEAR VALVES
Component Identification Location
Parts Identification
STEERING MODE VALVE BLOCK
Component Identification Location
Parts Identification
STEERING VALVE
Parts Identification
HYDRAULIC CONTROL VALVE
Component Identification Location
Priority And Safety Valve Identification Location
Main Valve Section Identification
Removal And Installation
Inlet Valve Section
Lifting Valve Section
Upperstructure Swing Valve Section
Telescoping Valve Section
Outlet Valve Section
Tilting Valve Section
Auxiliary Valve Section
Troubleshooting
SWING MOTOR
Parts Identification
Removal And Installation
Checking, Adding Or Replacing Oil
REAR AXLE OSCILLATION LOCK CYLINDER
Component Identification Location
Parts Identification
Removal And Installation
STABILIZERS CYLINDER
Component Identification Location
Parts Identification
AIR CONDITIONING
Component Identification Location
HYDROSTATIC SYSTEM
HYDROSTATIC DRIVE MOTOR
Parts Identification
Removal And Installation
Seal Nut Replacement
Cover Plate Sealing
Control Parts Sealing
Hydraulic Control Sealing
Port Plate Disassembly
Positioning Piston Removal
Rotary Group Removal
Rotary Group Exchange
Inspection
Rotary Group Assembly
Rotary Group Adjustment
Port Plate Assembly
Torques For Bolts
Torques For Plugs
Torques For Oval Head Screw
Torques For Seal-Lock Sealing Nuts
Torques For A6V Positioning Piston
HYDROSTATIC PUMP
Component Identification Location
Parts Identification
Removal And Installation
Drive Shaft Sealing
Boost Pump Sealing
Control Piston Cover Sealing
Valves Sealing
Pressure Cut-Off Valve Sealing
Control Valve Sealing
Control Module Removal
Pump Disassembly
Rotary Group Removal
Positioning Piston Disassembly
Inspection
Rotary Group Parts Inspection
Positioning Piston And Rotary Group Assembly
Rotary Group Installation
Rotary Group DA Installation
Pump DA Assembly
Pump Assembly
Torques For Bolts
Torques For Plugs
Torques For Seal-Lock Sealing Nuts
Torques For A4V Orifices
Special Tools
HYDROSTATIC TRANSMISSION ADJUSTMENT
Description
Start Of Control Setting Adjustment
Low Pressure Valve (Boost Pressure) Adjustment
Mechanical Zero Position Adjustment
Hydraulic Zero Position Adjustment
High Pressure Valves And Pressure Cut-Off Adjustment
Bypass Valve Adjustment
DA Control Adjustment
Starting Adjustment
DRIVE SYSTEM
TROUBLESHOOTING
Chart
AXLE AND DIFFERENTIAL (FRONT)
General Information
Parts Identification
Planetary Carrier Parts Identification
Planetary Carrier Disassembly
Steering Cylinder Parts Identification
Steering Cylinder Removal
Steering Cylinder Disassembly
Steering Case Parts Identification
Steering Case Disassembly
Drive Axle Parts Identification
Drive Axle Disassembly
Brake System Parts Identification
Brake System Disassembly
Hydraulic Differential Lock Parts Identification
Hydraulic Differential Lock Disassembly
Differential Unit (Limited Slip) Parts Identification
Differential Unit (Limited Slip) Disassembly
Bevel Pinion Parts Identification
Bevel Pinion Removal
Bevel Pinion Installation And Adjustment
Differential Unit (Limited Slip) Assembly
Hydraulic Differential Lock Assembly
Brake System Assembly
Drive Axle Assembly
Steering Case Assembly
Steering Cylinder Assembly
Steering Cylinder Installation
Planetary Carrier Assembly
Special Tools
AXLE AND DIFFERENTIAL (REAR)
General Information
Parts Identification
Planetary Carrier Parts Identification
Planetary Carrier Disassembly
Steering Cylinder Parts Identification
Steering Cylinder Removal
Steering Cylinder Disassembly
Steering Case Parts Identification
Steering Case Disassembly
Drive Axle Parts Identification
Drive Axle Disassembly
Negative Brake Parts Identification
Negative Brake Disassembly
Hydraulic Differential Lock Parts Identification
Hydraulic Differential Lock Disassembly
Differential Unit (Limited Slip) Parts Identification
Differential Unit (Limited Slip) Disassembly
Bevel Pinion Parts Identification
Bevel Pinion Removal
Bevel Pinion Installation And Adjustment
Differential Unit (Limited Slip) Assembly
Hydraulic Differential Lock Assembly
Negative Brake Assembly
Drive Axle Assembly
Steering Case Assembly
Steering Cylinder Assembly
Steering Cylinder Installation
Planetary Carrier Assembly
Special Tools
MAINFRAME
BOOM ASSEMBLY
Boom Cable Reel Replacement
Procedure
OPERATOR SEAT
Removal And Installation
ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Troubleshooting Chart
Fuse And Relay Location / Identification
BATTERY
Removing And Installing Battery
Battery Disconnect Switch
Servicing
Using A Booster Battery (Jump Starting)
SENSORS AND SWITCHES
Stabilizers Angle
Upperstructure Slew Lock Inserted
Upperstructure Rotation
Boom / Chassis Angle
Boom Length Cable
Accelerator Pedal
Inching Switch
Stop Switch
Rabbit Mode Switch
Parking Brake Pressure Switch
Hydraulic Oil Filter Clogged
Fuel Level
Pressure Transducers
Gear Box Speed Sensor
Gear Position Sensor
Service Brake Accumulator Pressure Switch
Service Brake Pressure Switch (Turtle / Rabbit Authorization)
Air Filter Clogged
Flatness Sensor
Directionals
Seat Switch
MAN PLATFORM LOAD LIMITER CALIBRATION
Description
Procedure
BOOM ELECTRICAL CABLE
Black Hose For Electrical Cable Replacement
Electrical Cable Replacement
GROUNDS
Location Identification
CONTROL UNITS
MC2M-T Control Unit
MC2M-C Control Unit
MIDAC Plus Control Unit
AL-GA TFT Control Unit
Machine Error Diagnostics
LIGHTS
Rear Light Removal And Installation
Rear Light Bulb Replacement
INSTRUMENT PANELS
Right Instrument And Indicator Panel Removal And Installation
BOOM ANGLE-LENGTH TRANSDUCER (ACQ) CALIBRATION
Procedure
STABILIZERS CALIBRATION
Procedure
UPPERSTRUCTURE ANGLE CALIBRATION
Procedure
ENGINE SERVICE
ENGINE INFORMATION
Description
Warranty
AIR CLEANER SERVICE
Replacing The Air Filter
ENGINE COOLING SYSTEM
Water Pump Removal And Installation
Water Pump Disassembly And Assembly
Thermostat Housing Removal And Installation
Thermostat – Checking
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Housing Removal And Installation
SPECIFICATIONS
TR38160 EVO TELESCOPIC HANDLER SPECIFICATIONS
Machine Dimensions
Performance
Engine
Transmission
Hydraulic System
Differential Axles
Capacities
Tires
Environmental
Temperature Range
Oil And Fluid Types
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
Flare Fitting
O-ring Flare Fitting
Port Seal Fitting
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion Chart
ALPHABETICAL INDEX
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