Bobcat TR35160, TR45190, TR50210, TR40250 Telescopic Handler Repair Service Manual - 6989624

TR35160 (S/N: LLM1590000 & Above) - TR45190 (S/N: HVL1540000 & Above) - TR50210 (S/N: HVL1550000 & Above) - TR40250 (S/N: HVL1560000 & Above) 
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This workshop repair service manual PDF download for the TR35160, TR45190, TR50210, TR40250 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 
TR35160 - S/N: LLM1590000 & Above
TR45190 - S/N: HVL1540000 & Above
TR50210 - S/N: HVL1550000 & Above
TR40250 - S/N: HVL1560000 & Above


TABLE OF CONTENTS :

FOREWORD 
SAFETY & MAINTENANCE 
HYDRAULIC SYSTEM 
HYDROSTATIC SYSTEM 
DRIVE SYSTEM 
ELECTRICAL SYSTEM AND ANALYSIS 
ENGINE SERVICE 
SPECIFICATIONS 
ALPHABETICAL INDEX 


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6989624-EN (04-10)
Total Pages : 695


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
    FIRE PREVENTION
        Maintenance
        Operation
        Electrical
        Hydraulic System
        Fueling
        Starting
        Spark Arrester Exhaust System
        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 & MAINTENANCE
    LIFTING AND BLOCKING THE TELESCOPIC HANDLER
        Procedure
    OPERATOR CAB
        Description
        Cab Door
        Cab Door Window
        Cab Rear Window
        Cab Light
        Cab Roof
        Cab Ventilation
        Rotating Beacon
    TRANSPORTING THE TELESCOPIC HANDLER
        Procedure
    TOWING THE TELESCOPIC HANDLER
        Procedure
    SERVICE SCHEDULE
        Chart
        Contents Of The Inspection Checkbook (logbook)
    AIR CLEANER SERVICE (TR35160)
        Cleaning The Air Filter
    AIR CLEANER SERVICE (TR45190, TR50210, TR40250)
        Cleaning And Replacing Cartridges
        Cleaning The Primary Intake Duct
    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 (TR35160)
        Fuel Filters (TR45190, TR50210, TR40250)
        Removing Air From The Fuel System
        Cleaning The Fuel Tank
    ENGINE LUBRICATION SYSTEM
        Checking And Adding Engine Oil (TR35160)
        Checking And Adding Engine Oil (TR45190, TR50210, TR40250)
        Engine Oil Chart
        Removing And Replacing Oil And Filter (TR35160)
        Removing And Replacing Oil And Filter (TR45190, TR50210, TR40250)
    HYDRAULIC / HYDROSTATIC SYSTEM
        Hydraulic / Hydrostatic Fluid Chart
        Checking And Adding Hydraulic / Hydrostatic Fluid
        Replacing Hydraulic / Hydrostatic Fluid And Filters
    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
        Lubricating Telescopic Boom Wear Blocks
        Lubricating External Boom Chains
    TYRE MAINTENANCE
        Wheel Nuts
        Tyre Rotating
        Tyre Mounting
        Tyre Pressure
    ENGINE COVER
        Opening And Closing
    ANTI TIPPING DEVICE
        Description
        Main Work Data
        Complementary Work Data
        Attachment And Operating Mode
        Attachment Selection
        Unencoded Display Information
        Self-Diagnostics
        Anti Tipping Device Error Codes
        Remote Control Error Codes
        Diagnostics Displays
        
HYDRAULIC SYSTEM
    HYDRAULIC / HYDROSTATIC SCHEMATIC 

    HYDRAULIC SYSTEM INFORMATION
        Troubleshooting Chart
        Tightening Procedures
        Hydraulic Component Pressures
    LIFT CYLINDER
        Removal And Installation
        Parts Identification
        Section View
    EXTENSION CYLINDER (TR45190, TR50210, TR40250)
        Parts Identification
    TILT CYLINDER
        Parts Identification
    DRIVE BOX
        Parts Identification
        Disassembly
        Assembly
    FRAME LEVELING CYLINDER (TR45190, TR50210, TR40250)
        Parts Identification
    BRAKE AND GEAR VALVES
        Parts Identification
    STEERING MODE VALVE BLOCK
        Parts Identification
    STEERING VALVE
        Parts Identification
    HYDRAULIC CONTROL VALVE (TR45190, TR50210, TR40250)
        Parts Identification
        Valve Section Identification
        Lifting Valve Section
        Upperstructure Swing Valve Section
        Telescoping Valve Section
        Tilting Valve Section
        Auxiliary Valve Section
        Inlet-outlet Valve Section
        End Housing
    HYDRAULIC CONTROL VALVE (TR35160)
        Valve Section Identification
    SWING MOTOR (TR35160)
        Parts Identification
    SWING MOTOR (TR45190, TR50210, TR40250)
        Parts Identification
    SWIVEL JOINT
        Parts Identification
    STABILISER CYLINDER (TR45190, TR50210, TR40250)
        Parts Identification
    STABILISER EXTENSION CYLINDER (TR45190, TR50210, TR40250)
        Parts Identification
    REAR AXLE OSCILLATION LOCK CYLINDER
        Parts Identification
    STABILISER / LEVELING VALVE
        Parts Identification
        
HYDROSTATIC SYSTEM
    HYDROSTATIC DRIVE MOTOR
        Parts Identification
    HYDROSTATIC PUMP
        Parts Identification
    HYDROSTATIC TRANSMISSION ADJUSTMENT
        Description
        Starting Adjustment
        Feeding Pressure
        Hydrostatic Pump Pressure
        Hydrostatic Motor Pressure
        
DRIVE SYSTEM
    TROUBLESHOOTING
        Chart
    AXLE AND DIFFERENTIAL (FRONT)
        General Information
        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
        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
        
ELECTRICAL SYSTEM AND ANALYSIS
    ELECTRICAL SCHEMATICS

    ELECTRICAL SYSTEM INFORMATION
        Troubleshooting Chart
        Fuse And Relay Location / Identification
    BATTERY
        Removal And Installation
        Battery Disconnect Switch
        Servicing
        Using A Booster Battery (Jump Starting)
        Battery Test
    ALTERNATOR (TR45190, TR50210, TR40250)
        Alternator Removal (Engines Without An Automatic Belt Tensioner)
        Alternator Installation (Engines Without An Automatic Belt Tensioner)
        Alternator Removal (Engines With An Automatic Belt Tensioner)
        Alternator Installation (Engines With An Automatic Belt Tensioner)
        Alternator Test
        Charging System Test
    STARTER (TR45190, TR50210, TR40250)
        Electric Starting Motor Removal
        Electric Starting Motor Installation
        Electric Starting System Test
    SENSORS AND SWITCHES
        Stabilisers extended and lowered (TR45190, TR50210, TR40250)
        Stabilisers lowered (TR35160)
        Upperstructure aligned with undercarriage
        Upperstructure rotated 174˚ (TR35160)
        Upperstructure slew lock inserted
        Axle oscillation lock range (12˚)
        Boom raised / lowered and extended / retracted completely (TR45190, TR50210, TR40250)
        Boom raised / lowered completely (TR35160)
    MAN PLATFORM LOAD LIMITER CALIBRATION
        Description
        Procedure
        
ENGINE SERVICE
    GENERAL ALARM PILOT LIGHT (TR45190, TR50210, TR40250)
        Engine Errors
        Centre Indicator And Instrument Panel Pilot Lights
        Engine Over-Revs
        Engine Error Codes
        Error Menu
    SERVICE (TR45190, TR50210, TR40250)
        Engine Error Codes List
    SENSORS AND ELECTRICAL COMPONENTS (TR45190, TR50210, TR40250)
        Sensor Locations
        Failure Of Sensors
        Programmable Monitoring System (PMS)
        Coolant Temperature Sensor
        Boost Pressure Sensor
        Inlet Air Temperature Sensor
        Fuel Pressure Sensor
        Crankshaft Position Sensor
        Position Sensor For The Fuel Injection Pump
        Engine Oil Pressure Sensor
    ENGINE COMPONENTS AND TESTING (TR45190, TR50210, TR40250)
        Fuel Priming Pump Removal (Electric Fuel Priming Pump)
        Fuel Priming Pump Installation (Electric Fuel Priming Pump)
        Fuel Priming Pump Removal (Manual Fuel Priming Pump)
        Fuel Priming Pump Installation (Manual Fuel Priming Pump)
        Fuel Filter Base Removal (Secondary Fuel Filter)
        Fuel Filter Base Installation (Secondary Fuel Filter)
        Fuel Transfer Pump Removal
        Fuel Transfer Pump Installation
        Fuel Injection Lines Removal
        Fuel Injection Lines Installation
        Fuel Manifold (Rail) Removal
        Fuel Manifold (Rail) Installation
        Fuel Injection Pump Removal
        Fuel Injection Pump Installation
        Fuel Injection Pump Gear Removal
        Fuel Injection Pump Gear Installation
        Position Sensor (Fuel Injection Pump) Removal
        Position Sensor (Fuel Injection Pump) Installation
        Fuel Pressure Sensor Removal
        Fuel Pressure Sensor Installation
        Boost Pressure Sensor Removal
        Boost Pressure Sensor Installation
        Electronic Unit Injector Removal
        Electronic Unit Injector Installation
        Electronic Unit Injector Installation (Alternative Installation Procedure)
        Lifter Group Removal
        Lifter Group Installation
        Fuel System Inspection
        Air In Fuel Test
        Finding Top Centre Position For No. 1 Piston
        Fuel Injection Timing Check
        Fuel Quality Test
        Fuel System Prime
        Compression Test
        Glow Plugs Removal
        Glow Plugs Installation
        Glow Plugs Test
    FLYWHEEL AND HOUSING (TR45190, TR50210, TR40250)
        Flywheel Removal
        Flywheel Installation
        Flywheel Inspection
        Flywheel Housing Removal
        Flywheel Housing Installation
        Flywheel Housing Inspection
    RECONDITIONING THE ENGINE (TR45190, TR50210, TR40250)
        Turbo Charger Removal
        Turbo Charger Installation
        Turbo Charger Inspection
        Wastegate Solenoid Removal
        Wastegate Solenoid Installation
        Exhaust Manifold Removal
        Exhaust Manifold Installation
        Exhaust Elbow Removal
        Exhaust Elbow Installation
        Valve Mechanism Cover Removal
        Valve Mechanism Cover Installation
        Valve Mechanism Cover Base Removal
        Valve Mechanism Cover Base Installation
        Cylinder Head Removal
        Cylinder Head Installation
        Cylinder Head Inspection
        Cylinder Block Inspection
        Rocker Shaft And Pushrod Removal
        Rocker Shaft And Pushrod Installation
        Rocker Shaft Disassembly
        Rocker Shaft Assembly
        Inlet And Exhaust Valves Removal
        Inlet And Exhaust Valves Installation
        Air Inlet And Exhaust System Inspection
        Engine Valve Lash Inspection / Adjustment
        Valve Depth Inspection
        Valve Guide Inspection
        Inlet And Exhaust Valve Springs Removal
        Inlet And Exhaust Valve Springs Installation
        Front Cover Removal
        Front Cover Installation
        Crankshaft Pulley Removal (Engines With An Automatic Belt Tensioner)
        Crankshaft Pulley Installation (Engines With An Automatic Belt Tensioner)
        Crankshaft Pulley Removal (Engines Without An Automatic Belt Tensioner)
        Crankshaft Pulley Installation (Engines Without An Automatic Belt Tensioner)
        Crankshaft Pulley Check
        Gear Group (Front) Removal
        Gear Group (Front) Installation
        Gear Group (Front) Timing
        Gear Group Inspection
        Idler Gear Removal (Standard Idler Gear)
        Idler Gear Installation (Standard Idler Gear)
        Idler Gear Removal (Heavy-Duty Idler Gear)
        Idler Gear Installation (Heavy-Duty Idler Gear)
        Housing (Front) Removal
        Housing (Front) Installation
        Accessory Drive Removal
        Accessory Drive Installation
        Crankcase Breather Removal (Filtered Breather)
        Crankcase Breather Installation (Filtered Breather)
        Crankcase Breather Removal (Unfiltered Breather)
        Crankcase Breather Installation (Unfiltered Breather)
        Camshaft Removal
        Camshaft Installation
        Camshaft Gear Removal
        Camshaft Gear Installation
        Camshaft Bearings Removal
        Camshaft Bearings Installation
        Pistons And Connecting Rods Removal
        Pistons And Connecting Rods Installation
        Pistons And Connecting Rods Disassembly
        Pistons And Connecting Rods Assembly
        Piston Ring Groove Inspection
        Connecting Rod Inspection
        Connecting Rod Bearings Removal (Connecting Rods In Position)
        Connecting Rod Bearings Installation (Connecting Rods In Position)
        Piston Height Inspection
        Crankshaft Main Bearings Removal (Crankshaft In Position)
        Crankshaft Main Bearings Installation (Crankshaft In Position)
        Crankshaft Removal
        Crankshaft Installation
        Crankshaft Timing Ring Removal
        Crankshaft Timing Ring Installation
        Crankshaft Gear Removal
        Crankshaft Gear Installation
        Bearing Clearance Check
        Crankshaft Position Sensor Removal
        Crankshaft Position Sensor Installation
        Crankshaft Rear Seal Removal
        Crankshaft Rear Seal Installation
        Crankshaft Wear Sleeve (Rear) Removal
        Crankshaft Wear Sleeve (Rear) Installation
        Crankshaft Front Seal Removal
        Crankshaft Front Seal Installation
        Crankshaft Wear Sleeve (Front) Removal
        Crankshaft Wear Sleeve (Front) Installation
        Water Temperature Regulator Removal
        Water Temperature Regulator Installation
        Water Temperature Regulator Test
        Coolant Temperature Sensor Removal
        Coolant Temperature Sensor Installation
        Cooling System Check
        Cooling System Inspection
        Water Pump Removal
        Water Pump Installation
        Water Pump Inspection
        Engine Oil Filter Base Removal
        Engine Oil Filter Base Installation
        Engine Oil Cooler Removal
        Engine Oil Cooler Installation
        Engine Oil Cooler Inspection
        Engine Oil Relief Valve Removal (Engines With A Balancer Unit)
        Engine Oil Relief Valve Installation (Engines With A Balancer Unit)
        Engine Oil Relief Valve Removal (Engines Without A Balancer Unit)
        Engine Oil Relief Valve Installation (Engines Without A Balancer Unit)
        Engine Oil Pump Removal (Engines Without A Balancer Unit)
        Engine Oil Pump Installation (Engines Without A Balancer Unit)
        Engine Oil Pump Inspection
        Engine Oil Pan Removal (Aluminium And Pressed Steel Oil Pans)
        Engine Oil Pan Installation (Aluminium And Pressed Steel Oil Pans)
        Engine Oil Pan Removal (Cast Iron Oil Pan)
        Engine Oil Pan Installation (Cast Iron Oil Pan)
        Engine Oil Pressure Sensor Removal
        Engine Oil Pressure Sensor Installation
        Engine Oil Pressure Test
        Excessive Engine Oil Consumption Inspection
        Increased Engine Oil Temperature Inspection
        Excessive Bearing Wear Inspection
        Balancer Removal
        Balancer Installation
        Balancer Disassembly
        Balancer Assembly
        Piston Cooling Jets Removal
        Piston Cooling Jets Installation
        Inlet Air Temperature Sensor Removal
        Inlet Air Temperature Sensor Installation
        V-belts Removal (Engines Without An Automatic Belt Tensioner)
        V-belts Installation (Engines Without An Automatic Belt Tensioner)
        V-belt Test
        Alternator Belt Removal (Engines With An Automatic Belt Tensioner)
        Alternator Belt Installation (Engines With An Automatic Belt Tensioner)
        Fan Removal
        Fan Installation
        Fan Drive Removal
        Fan Drive Installation
        Electronic Control Module Removal
        Electronic Control Module Installation
        ECM Mounting Bracket Removal
        ECM Mounting Bracket Installation
        Air Compressor Removal
        Air Compressor Installation
        Vacuum Pump Removal
        Vacuum Pump Installation
        
SPECIFICATIONS
    (TR35160, TR45190, TR50210, TR40250) TELESCOPIC HANDLER SPECIFICATIONS
        Machine Dimensions
        Performance
        Engine
        Transmission
        Hydraulic System
        Differential Axles
        Capacities
        Tyres
        Environmental
    ENGINE SPECIFICATIONS (TR45190, TR50210, TR40250)
        General
        Fuel Transfer Pump
        Electric Fuel Priming Pump
        Lifter Group
        Rocker Shaft
        Cylinder Head Valves
        Cylinder Head
        Turbo Charger
        Camshaft
        Camshaft Bearings
        Engine Oil Pump - Engines With Balancer Group
        Engine Oil Pressure
        Engine Oil Bypass Valve - Installed In The Oil Pump
        Engine Oil Bypass Valve - Installed In The Balancer
        Water Temperature Regulator And Housing
        Cylinder Block
        Crankshaft
        Crankshaft Journals
        Connecting Rod Bearing Journal
        Main Bearing Journal
        Shell For The Main Bearings
        Connecting Rod
        Piston And Rings - Rings
        Piston And Rings - Piston
        Piston And Rings - Oversize Piston
        Piston Cooling Jet Alignment
        Front Housing And Covers
        Gear Group (Front)
        Flywheel
        Belt Tension Chart
        Alternator
        Engine Torque Values
    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
    CONVERSIONS
        Decimal And Millimeter Equivalents
        U.S. To Metric Conversion Chart
        
ALPHABETICAL INDEX

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