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Bobcat T2256, T2266 telescopic handler pdf service manual

Name: Bobcat T2256, T2266 telescopic handler pdf service manual
Brand: Bobcat
SKU: BOBCAT-T2556_T2566-4852210-sm
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Reference BOBCAT-T2556_T2566-4852210-sm

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Format: PDF

Pages: 1044

File size: 41.75 MB

Language: English

Models: T2256, T2266 S/N 3630 11001 & above, S/N 3631 11001 & above

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Table of Contents for BOBCAT-T2556_T2566-4852210-sm manual

MAINTENANCE SAFETY
ALPHABETICAL INDEX
SAFETY INSTRUCTIONS
- FIRE PREVENTION
Serial Number LocationS
- telescopic handler Serial Number
- Engine Serial Number
- Earlier Models
- Later Models
- Other Serial Numbers
- Delivery Report
- BOBCAT telescopic handler IDENTIFICATION
LIFTING AND BLOCKING THE TELESCOPIC HANDLER
- Procedure
OPERATOR CAB
- Emergency Exit
- Cab Door
- Cab Door Window
TRANSPORTING THE TELESCOPIC HANDLER
- Procedure
TOWING THE TELESCOPIC HANDLER (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)
- Procedure
TOWING THE Telescopic Handler (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000) (CONT'D)
- Procedure (Cont'd)
TOWING THE TELESCOPIC HANDLER (S/N 363012001 & Above, S/N 363112001 & Above)
- Procedure
SERVICE SCHEDULE
AIR CLEANER SERVICE
- Replacing 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
HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D)
- Replacing Hydraulic/Hydrostatic Filter
- Replacing Hydraulic Fluid
HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D)
AXLES (FRONT AND REAR) (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)
- 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)
AXLES (FRONT AND REAR) (For S/N 363012001 and Above, S/N 363112001 and Above)
- 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)
- Checking Oil Level (Drive Box)
- Draining Oil (Drive Box)
LUBRICATION (For S/N 363011001 - 363012000 and S/ N 363111001 - 363112000)
- Procedure
LUBRICATION (For S/N 363012001 & Above and S/N 363112001 & Above)
- Procedure
TIRE MAINTENANCE
Wheel Nuts (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)
- Tire Rotation
- Tire Mounting
OPTIONAL APPROVED BOOM STOP
- Installing The Approved Boom Stop
- Removing The Approved Boom Stop
ENGINE COVER
- Opening And Closing The Engine Cover
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) (For S/N 363011001 - 363012000 and S/N 363111001 - 363012000)
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
STEERING CYLINDER (FRONT) (For S/N 363012001 and above, S/N 363112001 and above)
- Removing the Steering Cylinder
- Installing the Steering Cylinder
- Disassembling the Steering Cylinder
- Assembling the Steering Cylinder
STEERING CYLINDER (REAR) (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
STEERING CYLINDER (REAR) (For S/N 363012001 and above, S/N 363112001 and above)
- Removing the Steering Cylinder
- Installing the Steering Cylinder
- Disassembling the Steering Cylinder
- Assembling the Steering Cylinder
DRIVE BOX (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)
- Parts Identification
- Disassembly
- Inspection
- Assembly
DRIVE BOX (For S/N 363012001 and above, S/N 363112001 and above)
- Parts Identification
- Disassembly
- Assembly
special tools
MAIN RELIEF VALVE
- Testing And Adjustment
QUICK TACH CYLINDER
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
PORT RELIEF VALVES
- 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
GEAR PUMP (CONT'D)
- Parts Identification
- Disassembly And Assembly
FAN MOTOR
- Removal And Installation
- Parts Identification
- Disassembly And Assembly (1 speed version)
- Disassembly And Assembly (2 speed version)
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
HYDRAULIC CONTROL VALVE (CONT'D)
- Parts Identification
- Disassembly And Assembly
- End Housing 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
- Inlet-Outlet Valve Section Disassembly And Assembly
JOYSTICK
- Removal And Installation
- Parts Identification
PARKING BRAKE
- Parking Brake Valve Removal And Installation
- Parking Brake Valve Disassembly And Assembly
PILOT PRESSURE LOCK OUT VALVE
- Testing
- Removal And Installation
- Disassembly And Assembly
ACCUMULATOR
- Removal And Installation
OPTIONAL TOW VALVE
- Removal And Installation
- Disassembly And Assembly
FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE
- Removal And Installation
- Disassembly And Assembly
FLOW CONTROL VALVE
- Removal And Installation
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
- Disassembly
- Inspection
- Assembly
- Charge pressure checking procedure
- Charge pressure adjusting procedure
TROUBLESHOOTING
- Chart
AXLE AND DIFFERENTIAL (FRONT) (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)
- General Information
- Planetary Carrier Parts Identification
- Planetary Carrier Disassembly
- Planetary Carrier Inspection
- Wheel Hub Parts Identification
- Wheel Hub Disassembly
- Wheel Hub Inspection
- Steering Knuckle Parts Identification
- Steering Knuckle Disassembly
- Axle Housing/Drive Axle Parts Identification
- Axle Housing/Drive Axle Disassembly
- Brake Group Parts Identification
- Brake Group Disassembly
- Brake Group Inspection
- Differential Parts Identification
- Differential Disassembly
- Differential Inspection
- Pinion Group Parts Identification
- Pinion Group Disassembly
- Pinion Group Inspection
- Pinion Group Assembly
- Differential Assembly
- Brake Group Assembly
- Axle Housing/Drive Axle Assembly
- Steering Knuckle Assembly
- Wheel Hub Assembly
- Planetary Carrier Assembly
AXLE AND DIFFERENTIAL (REAR) (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)
- General Information
- Planetary Carrier Parts Identification
- Planetary Carrier Disassembly
- Planetary Carrier Inspection
- Wheel Hub Parts Identification
- Wheel Hub Disassembly
- Wheel Hub Inspection
- Steering Knuckle Parts Identification
- Steering Knuckle Disassembly
- Axle Housing/Drive Axle Parts Identification
- Axle Housing/Drive Axle Disassembly
- Differential Parts Identification
- Differential Disassembly
- Differential Inspection
- Pinion Group Parts Identification
- Pinion Group Disassembly
- Pinion Group Inspection
- Pinion Group Assembly
- Differential Assembly
- Axle Housing/Drive Axle Assembly
- Steering Knuckle Assembly
- Wheel Hub Assembly
- Planetary Carrier Assembly
AXLE AND DIFFERENTIAL (FRONT) (For S/N 363012001 and Above, S/N 363112001 and Above)
- General Information
- Planetary Carrier Parts Identification
- Planetary Carrier Disassembly
- Steering Knuckle Parts Identification
- Steering Knuckle Disassembly
- Brake System Identification
- Brake System disassembly
- Differential Parts Identification
- Differential Disassembly
- AXLE AND DIFFERENTIAL (FRONT) (For S/N 363012001 and Above, S/N 363112001 and Above) (Cont'd)
- Bevel Pinion Parts Identification
- Bevel Pinion Disassembly
- Bevel Pinion Assembly
- Differential Assembly
- Brake Assembly
- Steering Knuckle Assembly
- Planetary Carrier Assembly
special tools
AXLE AND DIFFERENTIAL (FRONT) (For S/N 363012501 and Above, S/N 363112501 and Above)
- General Information
- Planetary Carrier And Steering Knuckle Parts Identification
- Planetary Carrier Disassembly and Assembly
- Wheel Hub Disassembly And Assembly
- Steering Knuckle Disassembly And Assembly
- Axle Housing / Drive Axle Disassembly
- Brake Group Parts Identification
- Brake Group Disassembly
- Differential Parts Identification
- Differential Disassembly And Assembly
- Pinion Group Parts Identification
- Pinion Group Disassembly
- Pinion Group Assembly
- Brake Group Assembly
- Axle Housing / Drive Axle Assemby
- Special Tools
AXLE AND DIFFERENTIAL (REAR) (For S/N 363012001 and Above, S/N 363112001 and Above)
- General Information
- Planetary Carrier Parts Identification
- Planetary Carrier Disassembly (Cont'd)
- Steering Knuckle Parts Identification
- Steering Knuckle Disassembly
- Differential Parts Identification
- Bevel pinion Parts Identification
- Differential Assembly
- Steering Knuckle Assembly
- Planetary Carrier Assembly
FRONT AXLE (For S/N 363011001 - 363012000 and S/ N 363111001 - 363112000)
- Removal
- Installation
FRONT AXLE (For S/N 363012001 and Above, S/N 363112001 and Above)
- Removal
- Installation
AXLE TOE-IN (For S/N 363011001 - 363012000 and S/ N 363111001 - 363112000)
- Adjustment
AXLE TOE-IN (For S/N 363012001 and Above, S/N 363112001 and Above)
- Adjustment
PARKING BRAKE (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)
- Releasing The Brake For Towing
- Re-Activating The Brake
PARKING BRAKE (For S/N 363012001 and Above, S/N 363112001 and Above)
- Releasing The Brake For Towing
- Re-Activating The Brake
STEERING ANGLE ADJUSTMENT (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)
- Adjustment
STEERING ANGLE ADJUSTMENT (For S/N 363012001 and Above, S/N 363112001 and Above)
- Adjustment
DRIVESHAFT
- For S/N 363011001 - 363012000 and S/N 363111001 - 363112000
- Removal And Installation
- For S/N 363012001 and Above, S/N 363112001 and Above)
SERVICE BRAKE (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)
- Description
- Bleeding The Brake Circuit
SERVICE BRAKE (For S/N 363012001 and Above, S/N 363112001 and Above)
- Description
- Bleeding The Brake Circuit
REAR AXLE (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)
- Removal
- Installation
REAR AXLE (For S/N 363012001 and Above, S/N 363112001 and Above)
- Removal
- Installation
OPERATOR CAB
- Removal And Installation
OPERATOR SEAT
- Not available at time of printing
BOOM ASSEMBLY
- Removal And Installation
INNER BOOM
- Removal
- Installation
WEAR PADS (FRONT)
- Removal And Installation
WEAR PADS (REAR)
- Removal
- Installation
ENGINE COVER
- Gas Cylinder Removal And Installation
- Removal And Installation
AIR INTAKE COWLING
- Removal And Installation
FUEL TANK
- Removal And Installation
QUICK TACH
- Removal And Installation
REAR WEIGHTS
- Removal And Installation
FENDER
- Removal And Installation (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)
JOYSTICK PANEL
- Removal And Installation
DASH COVER/STEERING COLUMN COVER
- Removal And Installation
ELECTRICAL SYSTEM INFORMATION
- Troubleshooting Chart
- Description
- Fuses, Diodes & Relays
ELECTRICAL SYSTEM (CONT'D)
- Fuses, Diodes & Relays (Cont'd)
BATTERY
- Removal And Installation
- Servicing
- Using A Booster Battery (Jump Starting)
ALTERNATOR
- Removal And Installation
- Adjusting The Alternator Belt
STARTER
- Removal And Installation
STARTER (CONT'D)
- Parts Identification
- Disassembly/Assembly
LIGHTS
- Rear Light Removal And Installation
- Front Light Removal And Installation
TRAVEL/SIGNAL LEVER
- Removal And Installation
INSTRUMENT PANEL
- Removal And Installation
SWITCH PANEL
- Parts description
BRAKE LIGHT SWITCH
- Removal And Installation
- Adjustment
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
SERVICE SOFTWARE (ONLY For S/N 363011001 and Above, S/N 363111001 and Above)
- Connecting The Laptop Computer
- Entering The Service Software
- Monitor Screen
- Warnings Screen
- Calibrate Inch Pedal
Longitudinal Stability Indicator Calibration
- Fitting the sensor
- Calibration procedure
TROUBLESHOOTING
- Chart
ENGINE SPEED CONTROL
- Removal And Installation
MUFFLER
- Removal And Installation
AIR CLEANER
- Housing Removal And Installation
OIL COOLER/RADIATOR
- Removal And Installation
- Disassembly And Assembly
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
- Ring Gear Removal
- Ring Gear Installation
RECONDITIONING THE ENGINE
- Turbo Charger Troubleshooting
- Turbo Charger Description
- Turbo Charger Removal And Installation
- Exhaust Manifold Removal And Installation
- Fuel Injector Cover Removal And Installation
- Rocker Cover Removal And Installation
- 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
- 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
- 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
- Cooling System Description
- Thermostat Removal and Installation
- Thermostat Testing
- Lubricating Oil Cooler Removal And Installation
- Water Pump Removal
- Water Pump Installation
- 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 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
AIR CONDITIONING SYSTEM FLOW
- Principals
- Chart
COMPONENTS
- Identification
SAFETY
- Safety Equipment
REGULAR MAINTENANCE
- Filter Element Removal And Installation
- Compressor Drive Belt Inspection
- Cleaning The Condenser
BASIC TROUBLESHOOTING
- Poor A/C Performance
- Compressor 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/PRESSURE
- Chart
AIR CONDITIONING SERVICE
- Chart
SYSTEM CHARGING AND RECLAMATION
- Reclamation Procedure
- Charging Procedure With A Manifold Gauge Set
- Charging Procedure
COMPRESSOR
- Removal And Installation
- Compressor Clutch Disassembly And Assembly
CONDENSER
- Removal And Installation
RECEIVER/DRIER
- Removal And Installation
PRESSURE SWITCH
- Removal And Installation
EVAPORATOR/BLOWER UNIT
- Removal And Installation
EXPANSION VALVE
- Removal And Installation
HEATER ASSEMBLY
- Removal And Installation
- Fan Removal And Installation
- Core Removal And Installation
TELESCOPIC HANDLER SPECIFICATIONS
- Dimensional Specifications
- Performance Specifications
- Engine
- Controls
- Drive System
- Tires
- Capacities
- Hydraulic System
- Electrical System
- Instrument Panel
ENGINE SPECIFICATIONS
- General
- Cylinder Head
- Valve Guides
- Exhaust Valves
- Intake Valves
- Valve Springs
- Rocker Shaft, Rockers And Bushings
- Pistons And Piston Rings
- Connecting Rods And Bearings
- Crankshaft
- Crankshaft Re-Grind Data
- Main Bearings
- Thrust Washers
- Camshaft And Thrust Washer
- Cylinder Block
- Cylinder Liners
- Fuel Injection Pump
- Fuel Injectors
- Fuel Lift Pump
- Timing Case And Timing Gears
- Oil Pump, Gear And Relief Valve
- Turbocharger
- Flywheel
- Water Pump And Thermostat
- 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

Document type: Service manual
Language: English
Machinery type: telescopic handler

Brand

BOBCAT-T2556_T2566-4852210-sm-pr - 2.77MB

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