Bobcat TL470(X) Telescopic Handler Service Manual (Ver. June 2012)

Bobcat TL470(X) Telescopic Handler Service Manual
S/N ANL711001 & Above
S/N ANMG11001 & Above
S/N AVM111001 & Above
S/N AVM611001 & Above

Type of machine: Telescopic Handler
Print No: 6990103, June 2012
Language and Format: English/PDF
Instant Download after payment. Please make sure your email address is correct.

The Service Manual will give you complete information on repair, servicing and preventative maintenance, for your Bobcat TL470(X) Telescopic Handler.

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Table of contents:
1. FOREWORD

2. SAFETY AND 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
Checking Level
Removing And Replacing The Coolant
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
TYRE MAINTENANCE
Wheel Nuts
Rotating
Mounting
Pressure
APPROVED BOOM STOP
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
Right Rear Window
TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE
Storage
Return To Service
LIFTING THE TELESCOPIC HANDLER
Procedure
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

3. HYDRAULIC SYSTEM
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
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)
Removal
Installation
Disassembly
Assembly
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
Testing
Replacement Procedure
PARKING BRAKE
Valve Removal And Installation
ACCUMULATOR (IF EQUIPPED)
Removal And Installation

4. 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
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

5. 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
Planetary Carrier Disassembly
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
Special Tools
FRONT AXLE
Removal And Installation
AXLE TOE-IN
Adjustment
PARKING BRAKE
Releasing The Brake For Towing
Adjustment
Brake Cylinder Removal
Brake Cylinder Disassembly And Assembly
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

6. 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

7. ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
Description
Fuses And Relay Location / Identification
BATTERY
Removal And Installation
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

8. ENGINE SERVICE
ENGINE INFORMATION
Specifications
Troubleshooting
Engine Removal And Installation
Compression Checking
ENGINE AND HYDROSTAT ASSEMBLY
Removal And Installation
ENGINE SPEED CONTROL
Removal And Installation
MUFFLER
Removal And Installation
AIR CLEANER
Housing Removal And Installation
ENGINE COOLING SYSTEM
Oil Cooler / Intercooler / Radiator Removal And Installation
Cooling System Description
Thermostat Removal And Installation
Thermostat Testing
Lubricating Oil Cooler Removal And Installation
Water Pump Removal
Water Pump Installation
Expansion Tank Removal And 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
FUEL SYSTEM
Fuel Injection Pump Removal
Fuel Injection Pump Installation
Fuel Injectors Removal And Installation
Checking The Fuel Lift Pump
Fuel Lift Pump Removal And Installation
Exhaust Manifold Removal And Installation
Fuel Injector Cover Removal And Installation
Rocker Cover Removal And Installation
CYLINDER HEAD
Glow Plugs Checking
Glow Plugs Removal And Installation
Removal
Inspection
Installation
Rocker Shaft Disassembly And Assembly
Valve Removal
Valve Springs Checking
Valve Depth Checking
Valve Guide Checking
Valve Guide Removal
Valve Guide Installation
Valve Checking
Cutting A Valve Seat
Valve Seat Assembly
Changing Valve Springs (With Cylinder Head Installed)
Valve Clearance Adjustment
Engine Block Description
Engine Block Disassembly And Assembly
Engine Block Inspection
Cylinder Liner Inspection
Cylinder Liner Removal
Cylinder Liner 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
Piston Cooling Jet Removal
Piston Cooling Jet Installation
Piston Cooling Jet Alignment
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
CAMSHAFT AND TIMING GEARS
Engine Timing Procedure
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
TURBOCHARGER
Troubleshooting
Description
Removal And Installation
FLYWHEEL AND HOUSING
Removal And Installation
Flywheel Inspection
Ring Gear Removal
Ring Gear Installation

9. HEATING, VENTILATION, AIR CONDITIONING (HVAC)
AIR CONDITIONING SYSTEM FLOW
Description
Chart
Components
Safety Equipment
REGULAR MAINTENANCE
Filters
Air Conditioning Belt Adjustment
Belt Replacement
Cleaning The Condenser
Air Conditioning Lubrication
Air Conditioning Service Chart
Evaporator / Heater Coil
TROUBLESHOOTING
Blower Motor Does Not Operate
Blower Motor Operates Normally, But Air Flow Is Insufficient
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
The Compressor Does Not Operate At All, Or Operates Improperly
Gauge Pressure Related Troubleshooting
Temperature / Pressure Chart
Poor A/C Performance
HVAC Repair And Leaks
Electrical System
SYSTEM CHARGING AND RECLAMATION
Reclamation And Charging With Recovery / Charging Unit
COMPRESSOR
Removal And Installation
Oil
Oil Check
Clutch Disassembly And Assembly
CONDENSER
Removal And Installation
RECEIVER / DRIER
Removal And Installation
PRESSURE SWITCH
Removal And Installation
EVAPORATOR / HEATER UNIT
Removal And Installation
THERMOSTAT
Description
Removal And Installation
EXPANSION VALVE
Removal And Installation

SPECIFICATIONS

ALPHABETICAL INDEX