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 !!!!

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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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