A Service Manual (sometimes referred to as a Repair, Technical, Workshop
or Shop Manual) is often
large and broken down in to sections for different parts of your equipment.
Service
manuals cover absolutely every aspect of your machine unless mentioned
otherwise. Sometimes, the
engine is covered in a separate service manual that is written specifically for
the
engine. Most of the time though, it’s included in the main service manual. A
service manual will
arm you with the same exact information that your local service center has and
includes
electrical and hydraulic diagrams and which are usually color and or large
foldout pages.
Most OEM service manuals will also include troubleshooting flow charts, error
codes and
exploded views of components which are a great help for disassembly and
re-assembly.

An Operator’s Manual typically describes basic equipment operation and
maintenance. This
is the manual distributed with your equipment at the time of purchase from the
dealer.

• MAINTENANCE SAFETY
• CONTENTS
• FOREWORD
• FOREWORD
• SAFETY INSTRUCTIONS
• FIRE PREVENTION
• Maintenance
• Operation
• Electrical
• Hydraulic System
• Fueling
• Starting
• Spark Arrestor Exhaust System
• 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 AND MAINTENANCE
• LIFTING AND BLOCKING THE TELESCOPIC HANDLER
• Procedure
• OPERATOR CAB
• Emergency Exit
• Cab Door
• Cab Door Window
• TRANSPORTING THE TELESCOPIC HANDLER
• Loading And Unloading
• Fastening
• TOWING THE TELESCOPIC HANDLER
• Releasing The Brake Discs
• Towing
• Engaging The Brake Discs
• SERVICE SCHEDULE
• Chart
• AIR CLEANER SERVICE
• Replacing The Filter Element
• ENGINE COOLING SYSTEM
• Cleaning The Cooling System
• Checking The Coolant Level
• Replacing The Coolant
• FUEL SYSTEM
• Fuel Specifications
• Filling The Fuel Tank
• Fuel Filter
• ENGINE LUBRICATION SYSTEM
• Checking Engine Oil
• Oil Chart
• Replacing Oil And Filter
• HYDRAULIC / HYDROSTATIC SYSTEM
• Checking And Adding Fluid
• Replacing The Hydraulic / Hydrostatic Filters
• Replacing Hydraulic Fluid
• AXLES (FRONT AND REAR)
• Checking Oil Level (Planetary Carrier)
• Draining Oil (Planetary Carrier)
• Checking Oil Level (Rear Differential)
• Draining Oil (Rear Differential)
• Checking Oil Level (Front Differential)
• Draining Oil (Front Differential)
• LUBRICATION
• Procedure
• TIRE MAINTENANCE
• Wheel Nuts
• Tire Mounting
• Tire Rotation
• Tire Pressure
• APPROVED BOOM STOP
• Installing The Approved Boom Stop
• Removing The Approved Boom Stop
• ENGINE COVER
• Opening And Closing The Engine Cover
• REMOTE START
• Connecting to the Telescopic Handler
• Remote Start Procedure (For Tools MEL1563 and MEL1565)
• Remote Start Procedure (For Tool Kit P/N 6689779)
• ALTERNATOR BELT
• Belt Adjustment
• Belt Replacement
• HYDRAULIC SYSTEM
• HYDRAULIC SYSTEM INFORMATION
• Troubleshooting Chart
• Tightening Procedures
• LIFT CYLINDER
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• BUCKET POSITIONING CYLINDER
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• EXTENSION CYLINDER
• Cylinder Group Removal And Installation
• Upper Tubeline Removal
• Upper Tubeline Installation
• Extension Cylinder Removal And Installation
• Tubeline Tray Disassembly
• Tubeline Tray Assembly
• Parts Identification
• Disassembly
• Assembly
• TILT CYLINDER
• Removal And Installation
• Parts Identification
• Disassembly
• Assembly
• STEERING CYLINDER (FRONT)
• Removing the Steering Cylinder
• Installing the Steering Cylinder
• Parts Identification
• Disassembling the Steering Cylinder
• Assembling the Steering Cylinder
• STEERING CYLINDER (REAR)
• Removing The Steering Cylinder
• Parts Identification
• Disassembling the Steering Cylinder
• Assembling the Steering Cylinder
• DRIVE BOX
• Parts Identification
• Disassembly
• Assembly
• Special Tools
• MAIN RELIEF VALVE
• Testing And Adjustment
• Removal And Installation
• PORT RELIEF VALVES
• Parts Identification
• Adjustment Procedure
• STEERING MODE VALVE BLOCK
• Removal And Installation
• Parts Identification
• Disassembly
• Solenoid Testing
• Assembly
• BRAKE VALVE
• Removal And Installation
• Disassembly And Assembly
• GEAR PUMP
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• HYDRAULIC RESERVOIR
• Removal And Installation
• STEERING VALVE
• Removal And Installation
• Parts Identification
• Disassembly
• Inspection
• Assembly
• HYDRAULIC CONTROL VALVE
• Troubleshooting Chart (Controllers)
• Telescoping Valve Section Troubleshooting
• Auxiliary Valve Section Troubleshooting
• Troubleshooting Chart (Control Valve)
• Removal And Installation
• Parts Identification
• Disassembly And Assembly
• End Housing Disassembly And Assembly
• Telescoping and Auxiliary Valve Section Disassembly And Assembly
• Lifting and Tilting Valve Section Disassembly And Assembly
• Inlet-Outlet Valve Section Disassembly And Assembly
• JOYSTICK
• Removal And Installation
• PARKING BRAKE
• Parking Brake Valve Removal And Installation
• Parking Brake Valve Disassembly And Assembly
• WORKGROUP LOCKOUT VALVE
• Testing
• Removal And Installation
• Disassembly And Assembly
• TOW VALVE
• Removal And Installation
• Disassembly And Assembly
• FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE
• Removal And Installation
• Disassembly And Assembly
• MANIFOLD
• Removal And Installation
• Disassembly
• HYDROSTATIC SYSTEM
• HYDROSTATIC SYSTEM INFORMATION
• Troubleshooting Chart
• Replenishing Valve Function
• OIL COOLER
• Removal And Installation
• HYDROSTATIC DRIVE MOTOR
• Removal And Installation
• Parts Identification
• Disassembly
• Inspection
• Assembly
• HYDROSTATIC PUMP (For S/N AC1911001 – 11999)
• Removal And Installation
• Parts Identification
• Disassembly
• Inspection
• Assembly
• HYDROSTATIC PUMP (FOR S/N AC1912000 & ABOVE)
• Removal And Installation
• Parts Identification
• 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 BELT
• Description
• Shield Removal And Installation
• Adjusting
• Belt Removal And Installation
• Tensioner Pulley Removal And Installation
• Tensioner Pulley Parts Identification
• Tensioner Pulley Disassembly And Assembly
• DRIVE SYSTEM
• TROUBLESHOOTING
• Chart
• AXLE AND DIFFERENTIAL (FRONT)
• Description
• Planetary Carrier And Wheel Hub Parts Identification
• Planetary Carrier Disassembly
• Wheel Hub Disassembly
• Steering Knuckle And Drive Shaft Parts Identification
• Steering Knuckle Disassembly
• Axle Housing / Drive Shaft Disassembly
• Brake Group Parts Identification
• Brake Group Disassembly
• Differential Parts Identification
• Differential Disassembly
• Pinion Group Parts Identification
• Pinion Group Disassembly
• Pinion Group Assembly
• Differential Assembly
• Brake Group Assembly
• Axle Housing / Drive Shaft Assembly
• Steering Knuckle Assembly
• Wheel Hub Assembly
• Planetary Carrier Assembly
• Special Tools
• AXLE AND DIFFERENTIAL (REAR)
• Description
• Planetary Carrier And Wheel Hub Parts Identification
• Planetary Carrier Disassembly
• Wheel Hub Disassembly
• Steering Knuckle and Drive Shaft Parts Identification
• Steering Knuckle Disassembly
• Axle Housing / Drive Shaft Disassembly
• Differential Parts Identification
• Pinion Group Parts Identification
• Pinion Group Disassembly
• Pinion Group Assembly
• Differential Assembly
• Steering Knuckle Assembly
• Planetary Carrier Assembly
• Special Tools
• FRONT AXLE
• Removal
• Installation
• AXLE TOE-IN
• Adjustment
• PARKING BRAKE
• Releasing The Brake Discs
• Engaging The Brake Discs
• STEERING ANGLE ADJUSTMENT
• Adjustment
• DRIVESHAFT
• Removal And Installation
• SERVICE BRAKE
• Description
• Bleeding The Brake Circuit
• REAR AXLE
• Removal
• Installation
• MAIN FRAME
• OPERATOR CAB (S/N AC1912999 & bELOW)
• Removal And Installation
• OPERATOR CAB (S/N AC1913000 & ABOVE)
• Removal And Installation
• OPERATOR SEAT
• Removal And Installation
• Assembly And Disassembly
• BOOM ASSEMBLY
• Removal And Installation
• INNER BOOM
• Removal
• Installation
• WEAR PADS (FRONT)
• Removal And Installation
• WEAR PADS (REAR)
• Removal
• Installation
• ENGINE COVER
• Locking Mechanism Removal And Installation
• Removal And Installation
• Lock
• FUEL TANK
• Removal And Installation
• BOB-TACH
• Removal And Installation
• REAR WEIGHTS
• Removal And Installation
• FENDER
• Removal And Installation
• JOYSTICK PANEL (S/N AC1912999 & bELOW)
• Joystick Panel Cover Removal and Installation
• JOYSTICK PANEL
• Joystick Panel Cover Removal and Installation
• DASH COVER/STEERING COLUMN COVER (S/N AC1912999 & bELOW)
• Steering Column Cover Removal And Installation
• Dash Cover Removal And Installation
• DASH COVER/STEERING COLUMN COVER (S/N AC1913000 & ABOVE)
• Removal And Installation
• ELECTRICAL SYSTEM AND ANALYSIS
• ELECTRICAL SYSTEM INFORMATION (S/N AC1912999 & bELOW)
• Troubleshooting Chart
• Description
• Fuses, Diodes And Relays
• ELECTRICAL SYSTEM INFORMATION (S/N AC1913000 & ABOVE)
• Troubleshooting Chart
• Description
• Fuses, Diodes And Relays
• BATTERY
• Removal And Installation
• Servicing
• Using A Booster Battery (Jump Starting)
• ALTERNATOR
• Removal And Installation
• Adjusting The Alternator Belt
• STARTER
• Testing
• Removal And Installation
• Parts Identification
• LIGHTS
• Rear Light Removal And Installation
• Rear Light Removal And Installation
• Front Light Removal And Installation
• TRAVEL LEVER (S/N AC1912999 & bELOW)
• Removal And Installation
• TRAVEL LEVER (S/N AC1913000 & above)
• Removal And Installation
• INSTRUMENT PANEL (S/N AC1912999 & BELOW)
• Removal And Installation
• INSTRUMENT PANEL (S/N AC1913000 & ABOVE)
• Removal And Installation
• SWITCH PANEL (S/N AC1913000 & ABOVE)
• Removal And Installation
• FRONT WIPER MOTOR
• Removal And Installation
• TOP WIPER MOTOR
• Removal And Installation
• REAR WIPER MOTOR
• Removal And Installation
• PEDAL ASSEMBLY
• Removal And Installation
• Disassembly And Assembly
• INCHING SWITCH
• Removal And Installation
• Adjustment
• Inching Control Calibration (Display Controller)
• SERVICE SOFTWARE
• Connecting Remote Start Tool to Laptop Computer
• Connecting Remote Start Tool (Service Tool)
• Connecting Remote Start Tool to Telescopic Handler
• Entering The Service Software
• Calibrate Inch Pedal
• MAIN CONTROLLER
• Removal And Installation
• Connector Identification
• DIAGNOSTIC SERVICE CODES
• Viewing Service Codes
• Service Codes List
• ENGINE SERVICE
• ENGINE INFORMATION
• Description
• Troubleshooting
• Compression – Checking
• ENGINE AND ENGINE MOUNTS
• Removal And Installation
• ENGINE AND HYDROSTAT ASSEMBLY
• Removal And Installation
• ENGINE SPEED CONTROL
• Removal And Installation
• MUFFLER
• Removal And Installation
• AIR CLEANER
• Removal And Installation
• Air Intake Cowling Removal And Installation
• ENGINE COOLING SYSTEM
• Radiator Removal And Installation
• Fan Removal And Installation
• Water Pump Removal And Installation
• Water Pump Disassembly And Assembly
• Thermostat Housing Removal And Installation
• LUBRICATION SYSTEM
• Oil Pan Removal And Installation
• Oil Pump Removal And Installation
• Oil Pump Inspection
• Oil Filter Cooler Removal And Installation
• Engine Oil Pressure – Testing
• FUEL SYSTEM
• Fuel Camshaft Removal And Installation
• Injection Pump Governor Housing Removal And Installation
• Injection Pump Governor Housing Disassembly And Assembly
• Fuel Shutoff Solenoid – Checking
• Fuel Shutoff Solenoid – Removal And Installation
• Fuel Injection Pump Removal And Installation
• Fuel Injection Pump Housing Removal
• Fuel Injection Pump Housing Installation
• Injection Pump Timing
• Fuel Injector Removal and Installation
• Fuel Injector Nozzle Pressure – Checking
• Nozzle Spraying Condition
• Valve Seat Tightness
• CYLINDER HEAD
• Intake Air Heater – Testing
• Intake Air Heater Removal And Installation
• Valve Clearance Adjustment
• Valve Timing – Checking
• Cylinder Head Removal And Installation
• Cylinder Head Disassembly And Assembly
• Cylinder Head – Servicing
• Cylinder Head Top Clearance
• Valve Guide – Checking
• Reconditioning The Valve And Valve Seat
• Valve Spring
• Valve Tappets
• Rocker Arm And Shaft – Checking
• CRANKSHAFT AND PISTONS
• Piston And Connecting Rod Removal And Installation
• Piston And Connecting Rod – Servicing
• Cylinder Bore Checking
• Connecting Rod Alignment
• Crankshaft Gear Removal And Installation
• Crankshaft And Bearings Removal and Installation
• Crankshaft And Bearings – Servicing
• CAMSHAFT AND TIMING GEARS
• Timing Gearcase Cover Removal And Installation
• Timing Gears Backlash – Checking
• Camshaft – Servicing
• Idle Gear And Shaft Removal And Installation
• Idler Gear And Shaft – Servicing
• Balancer Shaft Servicing
• TURBOCHARGER
• Description
• Testing
• Removal And Installation
• FLYWHEEL AND HOUSING
• Flywheel Removal And Installation
• Ring Gear Removal And Installation
• Housing Removal And Installation
• EXHAUST GAS RECIRCULATION (EGR) SYSTEM
• Checking The Function Of EGR System
• Disassembly And Assembly
• HEATING, VENTILATION, AIR CONDITIONING
• AIR CONDITIONING SYSTEM FLOW
• Description
• Chart
• COMPONENTS (S/N AC1912999 & bELOW)
• Identification
• COMPONENTS (S/N AC1913000 & ABOVE)
• Identification
• SAFETY
• Safety Equipment
• REGULAR MAINTENANCE
• Filter Element Removal And Installation
• Compressor And Alternator Drive Belt Inspection
• Cleaning The Condenser
• BASIC TROUBLESHOOTING
• Poor A/C Performance
• Compressor And Alternator Drive Belt Inspection
• Checking The Electrical System
• GENERAL AIR CONDITIONING SERVICE GUIDELINES
• Compressor Oil
• Compressor Oil Check
• Component Replacement And Refrigeration Leaks
• SYSTEM TROUBLESHOOTING CHART
• Chart
• Gauge Pressure Related Troubleshooting
• TEMPERATURE AND PRESSURE
• Chart
• AIR CONDITIONING SERVICE
• Chart
• SYSTEM CHARGING AND RECLAMATION
• Reclamation Procedure
• Charging Procedure With A Manifold Gauge Set
• COMPRESSOR
• Removal And Installation
• Compressor Clutch Disassembly And Assembly
• CONDENSER (S/N AC1912999 & bELOW)
• Removal And Installation
• CONDENSER (S/N AC1912999 & bELOW)
• Removal And Installation
• RECEIVER / DRIER
• Removal And Installation
• PRESSURE SWITCH
• Removal And Installation
• EVAPORATOR/BLOWER UNIT (S/N AC1912999 & bELOW)
• Removal And Installation
• EVAPORATOR/BLOWER UNIT (S/N AC1913000 & ABOVE)
• Removal And Installation
• EXPANSION VALVE (S/N AC1912999 & bELOW)
• Removal And Installation
• EXPANSION VALVE (S/N A8G813000 & ABOVE)
• Removal And Installation
• HEATER ASSEMBLY
• Removal And Installation
• Fan Removal And Installation
• Core Removal And Installation
• SPECIFICATIONS
• (T2250) TELESCOPIC HANDLER SPECIFICATIONS
• Dimensional Specifications
• Performance Specifications
• Weights
• Engine
• Controls
• Drive System
• Traction
• Steering
• Brakes
• Fluid Capacities
• Hydraulic System
• Electrical
• Instruments
• Environmental
• Temperature Range
• ENGINE SPECIFICATIONS
• General
• Fuel System
• Cylinder Head
• Valve Guides
• Valve Tappets
• Exhaust Valves
• Intake Valves
• Valve Springs
• Valve Timing
• Rocker Arm
• Camshaft
• Timing Gear
• Piston And Piston Ring
• Connecting Rod
• Cylinder Bore
• Crankshaft
• Oil Pump
• Cooling System
• Intake Air Heater
• Torque Values
• Engine Torque Component
• MACHINE TORQUE SPECIFICATIONS
• Specifications
• 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
• ALPHABETICAL INDEX