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