Bobcat TL360(X) Telescopic Handler Repair Service Manual - 6990100

(S/N: AN6H11001 & Above - S/N: ANFU11001 & Above) 
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This workshop repair service manual PDF download for the TL360, TL360X Bobcat Telescopic Handler has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Bobcat Telescopic Handler TL360, TL360X
S/N: AN6H11001 & Above
S/N: ANFU11001 & Above


TABLE OF CONTENTS :

SAFETY & MAINTENANCE 
HYDRAULIC SYSTEM 
HYDROSTATIC SYSTEM 
DRIVE SYSTEM 
MAINFRAME 
ELECTRICAL SYSTEM & ANALYSIS 
ENGINE SERVICE
HEATING, VENTILATION, AIR CONDITIONING (HVAC) 
SPECIFICATIONS 
ALPHABETICAL INDEX 


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6990100 (05-11)
Total Pages : 770


This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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MAINTENANCE SAFETY
CONTENTS
FOREWORD
    FOREWORD
    SAFETY INSTRUCTIONS
        Safe Operation Is The Operator’s Responsibility
        Safe Operation Needs A Qualified Operator
        Avoid Silica Dust
    FIRE PREVENTION
        Maintenance
        Operation
        Electrical
        Hydraulic System
        Fueling
        Starting
        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 & 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
    AIR CLEANER SERVICE
        Replacing Filter Elements
    ENGINE COOLING SYSTEM
        Cleaning
        Removing And Replacing The Coolant
        Checking Level
    FUEL SYSTEM
        Fuel Specifications
        Biodiesel Blend Fuel
        Filling The Fuel Tank
        Primary Fuel Filter (Pre-Filter)
        Secondary 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
        Hydraulic / Hydrostatic Fluid Chart
        Removing And Replacing Hydraulic Fluid
        Removing And Replacing Hydraulic / Hydrostatic Filter
        Removing And Replacing Hydraulic Charge 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 (Gear Box)
        Removing And Replacing Oil (Gear Box)
    LUBRICATING THE TELESCOPIC HANDLER
        Lubrication Locations
    ATTACHMENT CARRIER
        Inspection And Maintenance
    TIRE MAINTENANCE
        Wheel Nuts
        Rotating
        Mounting
        Pressure
    APPROVED BOOM STOP (IF EQUIPPED)
        Installing The Approved Boom Stop
        Removing The Approved Boom Stop
    ENGINE COVER
        Opening And Closing
    STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER
        Procedure
    EMERGENCY EXIT
        Rear Window
    TRACTOR HOMOLOGATED EMERGENCY EXIT
        Right Rear Window
    TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE
        Storage
        Return To Service
    REMOTE START TOOL (SERVICE TOOL) KIT - MEL1563
        Remote Start Tool - MEL1563
        Service Tool Harness Control - MEL1565
        Service Tool Harness Communicator - MEL1566
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031
        Remote Start Tool (Service Tool) - 7003030
        Telescopic Handler Service Tool Harness - 6689747
        Computer Service Tool Harness - 6689746
        Remote Start Procedure
        
HYDRAULIC SYSTEM
    HYDRAULIC / HYDROSTATIC SCHEMATICS
    HYDRAULIC SYSTEM INFORMATION
        Troubleshooting Chart
        Tightening Procedures
    LIFT CYLINDER
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    SELF LEVELING CYLINDER
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    SELF LEVELING CYLINDER (LOCK VAlVE)
        Removal And Installation
    EXTENSION CYLINDER
        Cylinder Group Removal And Installation
        Upper Tubeline Removal And Installation
        Extension Cylinder Removal And Installation
        Tubeline Tray Disassembly
        Parts Identification
        Disassembly
        Assembly
    TILT CYLINDER
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    STEERING CYLINDER (FRONT / REAR)
        Removing The Steering Cylinder
        Installing The Steering Cylinder
        Disassembling The Steering Cylinder
        Assembling The Steering Cylinder
    GEAR CONTROL CYLINDER
        Removal
        Parts Identification
        Disassembly
        Assembly
        Installation
    MAIN RELIEF VALVE
        Testing And Adjustment
        Removal And Installation
    MANIFOLD
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
    BRAKE VALVE
        Removal And Installation
    GEAR PUMP
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
    FAN MOTOR
        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)
    HYDRAULIC RESERVOIR
        Removal And Installation
    STEERING VALVE
        Removal And Installation
    HYDRAULIC CONTROL VALVE
        Troubleshooting Chart (Controllers)
        Valve Section Troubleshooting
        Troubleshooting Chart (Control Valve)
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
        Inlet-Outlet Valve Section 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
        End Housing Disassembly And Assembly
    PORT RELIEF VALVES
        Adjustment Procedure
        Replacement Procedure
    PARKING BRAKE
        Parking Brake Valve Removal And Installation
    ACCUMULATOR (IF EQUIPPED)
        Removal And 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
        Parts Identification (Cont’d)
        Parts Identification (Cont’d)
        Parts Identification (Cont’d)
        Parts Identification (Cont’d)
        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
        
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 Parts Identification
        Differential Disassembly
        Bevel Pinion Parts Identification
        Bevel Pinion Disassembly
        Bevel Pinion Assembly
        Differential Assembly
        Steering Knuckle Assembly
        Planetary Carrier Assembly
        Planetary Carrier Assembly
        Special Tools
    FRONT AXLE
        Removal And Installation
    AXLE TOE-IN
        Adjustment
    PARKING BRAKE
        Releasing The Brake For Towing
        Parking Brake Adjustment
        Brake Cylinder Removal
        Brake Disc Removal And Installation
        Brake Cylinder Installation
    STEERING ANGLE ADJUSTMENT
        Adjustment
    DRIVESHAFT
        Rear Driveshaft Removal And Installation
        Front Driveshaft Removal And Installation
    SERVICE BRAKE
        Description
        Bleeding The Brake Circuit
    REAR AXLE
        Removal And Installation
    GEAR BOX
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
        
MAINFRAME
    OPERATOR CAB
        Removal And Installation
    OPERATOR SEAT
        Removal And Installation
    FIXED BOOM
        Removal
        Installation
    INNER BOOM
        Removal And Installation
    WEAR PADS (FRONT)
        Removal And Installation
    WEAR PADS (REAR)
        Removal And 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
        
ELECTRICAL SYSTEM & ANALYSIS
    ELECTRICAL SCHEMATICS
    ELECTRICAL SYSTEM INFORMATION
        Troubleshooting Chart
        Description
        Fuses And Relay Location / Identification
    BATTERY
        Removing And Installing Battery
        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
        Rear Light Bulb Replacement
        Front Light Removal And Installation
        Front Light Bulb Replacement
    SIGNAL LEVER
        Removal And Installation
    DISPLAY
        Removal And Installation
    INSTRUMENT PANELS
        Right Instrument And Indicator Panel Removal And Installation
        Left Instrument Panel Removal And Installation
    BOOM ANGLE SENSOR
        Removal And Installation
        Calibration
    FRONT WIPER MOTOR
        Removal And Installation
    TOP WIPER MOTOR
        Removal And Installation
    REAR WIPER MOTOR
        Removal And Installation
    PEDAL ASSEMBLY
        Removal And Installation
    INCHING SENSOR
        Removal And Installation
        Calibration
    SERVICE PC (LAPTOP COMPUTER)
        Connecting Remote Start Tool (Service Tool) - MEL1563
        Connecting Remote Start Tool (Service Tool) - 6689778
    FUEL LEVEL SENDER
        Removal And Installation
    JOYSTICK
        Removal And Installation
    LLMI / LLMC SYSTEM
        System Calibration
        Calibration Test
        System Failure Reports
        System Components Identification
        LLMS Removal
        LLMS Installation
        LLMC 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
    EXPANSION TANK
        Removal And Installation
    OIL COOLER / INTERCOOLER / RADIATOR
        Removal And Installation
    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
        Flywheel Inspection
        Ring Gear Removal
        Ring Gear Installation
    TURBOCHARGER
        Turbo Charger Troubleshooting
        Turbo Charger Description
        Turbo Charger Removal And Installation
    FUEL SYSTEM
        Exhaust Manifold Removal And Installation
        Fuel Injector Cover Removal And Installation
        Rocker Cover Removal And Installation
    CYLINDER HEAD
        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
    CAMSHAFT AND TIMING GEARS
        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
    CRANKSHAFT AND PISTONS
        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
    ENGINE COOLING SYSTEM
        Cooling System Description
        Thermostat Removal and Installation
        Thermostat Testing
        Lubricating Oil Cooler Removal And Installation
        Water Pump Removal
        Water Pump Installation
    LUBRICATION SYSTEM
        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
        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 (HVAC)
    AIR CONDITIONING SYSTEM FLOW
        Principles
        Chart
    COMPONENTS
        Identification
    SAFETY
        Safety Equipment
    REGULAR MAINTENANCE
        Filter Element Removal And Installation
        Air Conditioning Belt Adjustment
        Belt Replacement
        Cleaning The Condenser
        Evaporator / Heater Coil
    BASIC TROUBLESHOOTING
        Poor A/C Performance
        Checking The Electrical System
    GENERAL AIR CONDITIONING SERVICE GUIDELINES
        Compressor Oil
        Compressor Oil Check
        Component Replacement And Refrigeration Leaks
    SYSTEM TROUBLESHOOTING CHART
    TEMPERATURE / PRESSURE
        Chart
    AIR CONDITIONING SERVICE
        Chart
    SYSTEM CHARGING AND RECLAMATION
        Reclamation And Charging With Recovery / Charging Unit
    COMPRESSOR
        Removal And Installation
        Compressor Clutch Disassembly And Assembly
    CONDENSER
        Removal And Installation
    RECEIVER / DRIER
        Removal And Installation
    PRESSURE SWITCH
        Removal And Installation
    EVAPORATOR / HEATER UNIT
        Removal And Installation
    EXPANSION VALVE
        Removal And Installation
    THERMOSTAT
        Description
        Removal And Installation
        
SPECIFICATIONS
    (TL360) TELESCOPIC HANDLER SPECIFICATIONS
        Machine Dimensions
        Performance
        Weights
        Engine
        Controls
        Drive System
        Traction
        Steering
        Brakes
        Fluid Capacities
        Hydraulic System
        Electrical System
        Instrument Panel
        Environmental
    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 Equivalent Chart
        U.S. To Metric Conversion Chart
        
ALPHABETICAL INDEX

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