Bobcat T2556 T2566 Telescopic Handler Service Manual 6986764 Revised 2010 PDF

Description

Bobcat T2556 T2566 Telescopic Handler Service Manual 6986764 Revised 2010 PDF

The Bobcat T2556 T2566 Telescopic Handler Service Manual 6986764 Revised 2010 PDF is an extensive mechanic’s service reference for the T2556 and T2566 telescopic handlers. At 844 pages, it provides the servicing and adjustment procedures needed for the machine and its component parts and systems, with detailed photographs, component illustrations, hydraulic diagrams, troubleshooting information, test procedures, removal and installation instructions, and component disassembly and assembly sequences.

Coverage applies to T2556 S/N A8FR11001 & Above and T2566 S/N A8G311001 & Above. The manual also identifies the machines as equipped with the Bobcat Interlock Control System (BICS). Throughout the manual, procedures are organized by service section so technicians can move from routine maintenance and system diagnosis into individual component repair and adjustment work.

File Details

• Manual type: Service Manual
• Brand: Bobcat
• Models: T2556, T2566 Telescopic Handler
• Document number: 6986764-EN (12-07)
• Revision: Revised (2-10)
• Copyright: Bobcat Company 2010
• Language: English
• Pages: 844
• File format: PDF
• Applicable serial numbers: T2556 S/N A8FR11001 & Above; T2566 S/N A8G311001 & Above

Workshop Procedures and Diagnostic Coverage

This Bobcat T2556 and T2566 service manual goes well beyond routine maintenance. Major hydraulic cylinders and valves are covered with removal and installation procedures, parts identification, disassembly, inspection and assembly information. The hydraulic section includes procedures for the lift cylinder, bucket positioning cylinder, extension cylinder, tilt cylinder, front and rear steering cylinders, quick tach cylinder, steering valve and hydraulic control valve. Detailed exploded component illustrations help identify seals, O-rings, wear rings, pistons, rods, head glands, springs, spools and related internal components during repair.

Hydraulic diagnosis is supported by troubleshooting charts, system schematics, testing instructions and adjustment procedures. The manual includes main relief valve testing and adjustment, port relief valve adjustment, steering mode valve work, pilot pressure lock-out valve testing and other hydraulic control procedures. The hydraulic schematic identifies the boom, telescopic and tilt circuits, steering, service and parking brakes, travel motor, pumps, hydraulic reservoir, fan motor, quick tach and optional hydraulic functions.

The hydrostatic section provides troubleshooting for drive-system complaints and explains hydrostatic circuit functions, along with service information for the hydrostatic drive motor and pump. Procedures progress from fault diagnosis into removal, component identification, disassembly and reassembly where applicable. This makes the Bobcat T2556 T2566 Telescopic Handler Service Manual 6986764 Revised 2010 PDF useful when the repair involves more than replacing an external service item.

Maintenance and Machine Service Information

The maintenance section provides a structured service schedule and procedures for frequently serviced areas of the machine. It covers engine oil and filter replacement, air cleaner elements, fuel filters, engine cooling system care, hydraulic and hydrostatic fluid and filter service, axle and differential lubricant checks, lubrication points, tyre maintenance and attachment-frame inspection. It also explains safe lifting and blocking, use of the approved boom stop, machine transport and towing procedures.

Service illustrations show the actual locations of filters, drains, fill points, cylinders, pivots, valves, electrical components and other service points. These visual references are particularly useful when dismantling assemblies or confirming hose, tubeline, connector and component locations before installation.

Chapters Covered

• Safety and Maintenance
  • Lifting and blocking the telescopic handler; operator cab and emergency exit; transporting, loading, unloading and fastening; towing procedures; service schedule; air cleaner service; engine cooling system; fuel system; engine lubrication; hydraulic/hydrostatic fluid and filter service; front and rear axle lubrication; machine lubrication; attachment frame; tyre maintenance; spark arrester muffler; approved boom stop; engine cover.
• Hydraulic System
  • Hydraulic system information and troubleshooting; lift cylinder; bucket positioning cylinder; extension cylinder and tubeline tray; tilt cylinder; front and rear steering cylinders; drive box; main relief valve; quick tach cylinder; port relief valves; steering mode valve block; brake valve; gear pump; fan motor; hydraulic reservoir; steering valve; hydraulic control valve; joystick; parking brake; pilot pressure lock out valve; accumulator; tow valve; front auxiliary hydraulic pressure release valve; flow control valve.
  Complete PDF Bookmark Tree

  Complete Bookmarks

  The complete bookmarks in the “Bobcat T2556 T2566 Telescopic Handler Service Manual 6986764 Revised 2010 PDF” are as follows:

  MAINTENANCE SAFETYp. 3

  CONTENTSp. 5

  +FOREWORDp. 7

  FOREWORDp. 9

  SAFETY INSTRUCTIONSp. 11

  +FIRE PREVENTIONp. 12

  Maintenancep. 12

  Operationp. 12

  Electricalp. 12

  Hydraulic Systemp. 13

  Fuelingp. 13

  Startingp. 13

  Spark Arrester Exhaust Systemp. 13

  Welding And Grindingp. 13

  Fire Extinguishersp. 13

  +SERIAL NUMBER LOCATIONp. 14

  Telescopic Handler Serial Numberp. 14

  Engine Serial Numberp. 14

  Other Serial Numbersp. 14

  DELIVERY REPORTp. 15

  IDENTIFICATION OF THE TELESCOPIC HANDLERp. 16

  +SAFETY AND MAINTENANCEp. 17

  +LIFTING AND BLOCKING THE TELESCOPIC HANDLERp. 19

  Procedurep. 19

  +OPERATOR CABp. 21

  Emergency Exitp. 21

  Cab Doorp. 22

  Cab Door Windowp. 22

  +TRANSPORTING THE TELESCOPIC HANDLERp. 23

  Loading And Unloadingp. 23

  Fasteningp. 23

  +TOWING THE TELESCOPIC HANDLERp. 25

  Procedurep. 25

  SERVICE SCHEDULEp. 27

  +AIR CLEANER SERVICEp. 29

  Replacing Filter Elementp. 29

  +ENGINE COOLING SYSTEMp. 31

  Cleaning The Cooling Systemp. 31

  Checking The Coolant Levelp. 31

  Replacing The Coolantp. 32

  +FUEL SYSTEMp. 33

  Fuel Specificationsp. 33

  Filling The Fuel Tankp. 33

  Fuel Filterp. 33

  +ENGINE LUBRICATION SYSTEMp. 35

  Checking Engine Oilp. 35

  Oil Chartp. 35

  Replacing Oil And Filterp. 36

  +HYDRAULIC / HYDROSTATIC SYSTEMp. 37

  Checking And Adding Fluidp. 37

  Replacing Hydraulic / Hydrostatic Filterp. 37

  Replacing Hydraulic Fluidp. 38

  +AXLES (FRONT AND REAR)p. 39

  Checking Oil Level (Planetary Carrier)p. 39

  Draining Oil (Planetary Carrier)p. 39

  Checking Oil Level (Rear Differential)p. 40

  Draining Oil (Rear Differential)p. 40

  Checking Oil Level (Front Differential)p. 41

  Draining Oil (Front Differential)p. 41

  Checking Oil (Drive Box)p. 42

  Draining Oil (Drive Box)p. 42

  +LUBRICATIONp. 43

  Procedurep. 43

  +ATTACHMENT FRAMEp. 47

  Inspection And Maintenancep. 47

  +TYRE MAINTENANCEp. 49

  Wheel Nutsp. 49

  Tyre Mountingp. 49

  Tyre Rotationp. 49

  +SPARK ARRESTER MUFFLERp. 51

  Cleaningp. 51

  +APPROVED BOOM STOPp. 53

  Installing The Approved Boom Stopp. 53

  Removing The Approved Boom Stopp. 53

  +ENGINE COVERp. 55

  Opening And Closing The Engine Coverp. 55

  +HYDRAULIC SYSTEMp. 57

  +HYDRAULIC SYSTEM INFORMATIONp. 64

  Troubleshooting Chartp. 67

  HYDRAULIC SCHEMATICSp. 61

  Tightening Proceduresp. 68

  +LIFT CYLINDERp. 70

  Removal And Installationp. 70

  Parts Identificationp. 75

  Disassemblyp. 76

  Assemblyp. 80

  +BUCKET POSITIONING CYLINDERp. 84

  Removal And Installationp. 84

  Parts Identificationp. 89

  Disassemblyp. 90

  Assemblyp. 94

  +EXTENSION CYLINDERp. 98

  Cylinder Group Removal And Installationp. 98

  Upper Tubeline Removalp. 100

  Upper Tubeline Installationp. 102

  Extension Cylinder Removal And Installationp. 104

  Tubeline Tray Disassemblyp. 106

  Tubeline Tray Assemblyp. 107

  Parts Identificationp. 110

  Disassemblyp. 111

  Assemblyp. 115

  +TILT CYLINDERp. 118

  Removal And Installationp. 118

  +TILT CYLINDERp. 119

  Parts Identificationp. 120

  Disassemblyp. 121

  Assemblyp. 126

  +STEERING CYLINDER (FRONT)p. 132

  Removing The Steering Cylinderp. 132

  Installing The Steering Cylinderp. 133

  Disassembling The Steering Cylinderp. 135

  Assembling The Steering Cylinderp. 136

  +STEERING CYLINDER (REAR)p. 140

  Removing The Steering Cylinderp. 140

  Installing The Steering Cylinderp. 141

  Disassembling The Steering Cylinderp. 143

  Assembling The Steering Cylinderp. 145

  +DRIVE BOXp. 148

  Parts Identificationp. 148

  Disassemblyp. 149

  Assemblyp. 153

  Special Toolsp. 156

  +MAIN RELIEF VALVEp. 158

  Testing And Adjustmentp. 158

  Removal And Installationp. 159

  +QUICK TACH CYLINDERp. 160

  Removal And Installationp. 160

  Parts Identificationp. 162

  Disassemblyp. 163

  Assemblyp. 166

  +PORT RELIEF VALVESp. 168

  Adjustment Procedurep. 168

  +STEERING MODE VALVE BLOCKp. 170

  Removal And Installationp. 170

  Parts Identificationp. 172

  Disassemblyp. 173

  Solenoid Testingp. 175

  Assemblyp. 175

  +BRAKE VALVEp. 178

  Removal And Installationp. 178

  Disassembly And Assemblyp. 179

  +GEAR PUMPp. 182

  Removal And Installationp. 182

  Parts Identificationp. 184

  Disassembly And Assemblyp. 185

  +FAN MOTORp. 192

  Removal And Installationp. 192

  Parts Identificationp. 196

  Disassembly And Assemblyp. 197

  +HYDRAULIC RESERVOIRp. 200

  Removal And Installationp. 200

  +STEERING VALVEp. 202

  Removal And Installationp. 202

  Parts Identificationp. 203

  Disassemblyp. 204

  Inspectionp. 210

  Assemblyp. 211

  +HYDRAULIC CONTROL VALVEp. 218

  Troubleshooting Chart (Controllers)p. 218

  Telescoping Valve Section Troubleshootingp. 219

  Auxiliary Valve Section Troubleshootingp. 223

  Troubleshooting Chart (Control Valve)p. 227

  Removal And Installationp. 228

  Parts Identificationp. 232

  Disassembly And Assemblyp. 233

  End Housing Disassembly And Assemblyp. 234

  Lifting Valve Section Disassembly And Assemblyp. 235

  Tilting Valve Section Disassembly And Assemblyp. 240

  Telescoping Valve Section Disassembly And Assemblyp. 246

  Auxiliary Valve Section Disassembly And Assemblyp. 258

  Inlet-Outlet Valve Section Disassembly And Assemblyp. 269

  +JOYSTICKp. 274

  Removal And Installationp. 274

  +PARKING BRAKEp. 276

  Parking Brake Valve Removal And Installationp. 276

  Parking Brake Valve Disassembly And Assemblyp. 277

  +PILOT PRESSURE LOCK OUT VALVEp. 280

  Testingp. 280

  Removal And Installationp. 281

  Disassembly And Assemblyp. 282

  +ACCUMULATORp. 284

  Removal And Installationp. 284

  +TOW VALVEp. 286

  Removal And Installationp. 286

  Disassembly And Assemblyp. 287

  +FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVEp. 292

  Removal And Installationp. 292

  Disassembly And Assemblyp. 293

  +FLOW CONTROL VALVEp. 298

  Removal And Installationp. 298

  +HYDROSTATIC SYSTEMp. 300

  +HYDROSTATIC SYSTEM INFORMATIONp. 302

  Troubleshooting Chartp. 302

  Replenishing Valve Functionp. 303

  +OIL COOLERp. 304

  Descriptionp. 304

  +HYDROSTATIC DRIVE MOTORp. 306

  Removal And Installationp. 306

  Parts Identificationp. 307

  Disassemblyp. 310

  Inspectionp. 321

  Assemblyp. 323

  +HYDROSTATIC PUMPp. 336

  Removal And Installationp. 336

  Parts Identificationp. 337

  Disassemblyp. 342

  Inspectionp. 354

  Assemblyp. 358

  Charge pressure checking procedurep. 373

  Charge pressure adjusting procedurep. 373

  +DRIVE SYSTEMp. 374

  +TROUBLESHOOTINGp. 376

  Chartp. 376

  +AXLE AND DIFFERENTIAL (FRONT)p. 378

  General Informationp. 378

  Planetary Carrier And Wheel Hub Parts Identificationp. 378

  Planetary Carrier Disassembly And Assemblyp. 379

  Wheel Hub Disassembly And Assemblyp. 381

  Steering Knuckle Disassembly And Assemblyp. 383

  Axle Housing / Drive Axle Disassemblyp. 385

  Brake Group Parts Identificationp. 389

  Brake Group Disassemblyp. 390

  Differential Parts Identificationp. 393

  Differential Disassembly And Assemblyp. 394

  Pinion Group Parts Identificationp. 397

  Pinion Group Disassemblyp. 398

  Pinion Group Assemblyp. 399

  Brake Group Assemblyp. 404

  Axle Housing / Drive Axle Assembyp. 407

  Special Toolsp. 410

  +AXLE AND DIFFERENTIAL (REAR)p. 412

  General Informationp. 412

  Planetary Carrier And Wheel Hub Parts Identificationp. 412

  Planetary Carrier Disassemblyp. 413

  Steering Knuckle Parts Identificationp. 417

  Steering Knuckle Disassemblyp. 418

  Differential Parts Identificationp. 422

  Differential Disassemblyp. 423

  Bevel Pinion Parts Identificationp. 428

  Bevel Pinion Disassemblyp. 429

  Bevel Pinion Assemblyp. 433

  Differential Assemblyp. 442

  Steering Knuckle Assemblyp. 446

  Planetary Carrier Assemblyp. 452

  Special Toolsp. 457

  +FRONT AXLEp. 460

  Removalp. 460

  Installationp. 465

  +AXLE TOE-INp. 470

  Adjustmentp. 470

  +PARKING BRAKEp. 472

  Releasing The Brake For Towingp. 472

  Re-Activating The Brakep. 473

  +STEERING ANGLE ADJUSTMENTp. 474

  Adjustmentp. 474

  +DRIVESHAFTp. 476

  Removal And Installationp. 476

  +SERVICE BRAKEp. 478

  Descriptionp. 478

  Bleeding The Brake Circuitp. 478

  +REAR AXLEp. 480

  Removalp. 480

  Installationp. 483

  +MAIN FRAMEp. 488

  +OPERATOR CAB (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)p. 490

  Removal And Installationp. 490

  +OPERATOR CAB (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)p. 498

  Removal And Installationp. 498

  +OPERATOR SEATp. 506

  Removal And Installationp. 506

  +BOOM ASSEMBLYp. 508

  Removal And Installationp. 508

  +INNER BOOMp. 512

  Removalp. 512

  Installationp. 514

  +WEAR PADS (FRONT)p. 516

  Removal And Installationp. 516

  +WEAR PADS (REAR)p. 518

  Removalp. 518

  Installationp. 518

  +ENGINE COVERp. 520

  Gas Cylinder Removal And Installationp. 520

  Removal And Installationp. 520

  +AIR INTAKE COWLINGp. 522

  Removal And Installationp. 522

  +FUEL TANKp. 524

  Removal And Installationp. 524

  +QUICK TACHp. 528

  Removal And Installationp. 528

  +REAR WEIGHTSp. 530

  Removal And Installationp. 530

  +FENDERp. 532

  Removal And Installationp. 532

  +JOYSTICK PANEL (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)p. 534

  Removal And Installationp. 534

  +JOYSTICK PANEL (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)p. 536

  Removal And Installationp. 536

  +DASH COVER / STEERING COLUMN COVER (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)p. 538

  Removal And Installationp. 538

  +DASH COVER / STEERING COLUMN COVER (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)p. 542

  Removal And Installationp. 542

  +ELECTRICAL SYSTEM AND ANALYSISp. 546

  +ELECTRICAL SYSTEM INFORMATION (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)p. 567

  Troubleshooting Chartp. 567

  Descriptionp. 568

  Fuses, Diodes And Relaysp. 568

  ELECTRICAL SCHEMATICS (S/N 13000 & ABOVE)p. 548

  ELECTRICAL SCHEMATICS (S/N 12001 – 12999)p. 557

  +ELECTRICAL SYSTEM INFORMATION (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)p. 571

  Troubleshooting Chartp. 571

  Descriptionp. 572

  Fuses, Diodes And Relaysp. 572

  +BATTERYp. 575

  Removal And Installationp. 575

  Servicingp. 576

  Using A Booster Battery (Jump Starting)p. 577

  +ALTERNATORp. 579

  Removal And Installationp. 579

  Adjusting The Alternator Beltp. 580

  +STARTERp. 581

  Removal And Installationp. 581

  Parts Identificationp. 582

  Disassemblyp. 583

  Inspection And Repairp. 588

  Assemblyp. 592

  +LIGHTSp. 597

  Rear Light Removal And Installationp. 597

  Front Light Removal And Installationp. 598

  +TRAVEL / SIGNAL LEVER (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)p. 601

  Removal And Installationp. 601

  +TRAVEL / SIGNAL LEVER (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)p. 603

  Removal And Installationp. 603

  +INSTRUMENT PANELp. 605

  Removal And Installationp. 605

  +SWITCH PANEL (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)p. 607

  Removal And Installationp. 607

  Parts descriptionp. 608

  +SWITCH PANEL (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)p. 611

  Removal And Installationp. 611

  Parts descriptionp. 612

  +BRAKE LIGHT SWITCHp. 615

  Removal And Installationp. 615

  Adjustmentp. 615

  +FRONT WIPER MOTORp. 617

  Removal And Installationp. 617

  +TOP WIPER MOTORp. 621

  Removal And Installationp. 621

  +REAR WIPER MOTORp. 623

  Removal And Installationp. 623

  +PEDAL ASSEMBLYp. 625

  Removal And Installationp. 625

  Disassembly And Assemblyp. 626

  +INCHING SWITCHp. 631

  Removal And Installationp. 631

  Adjustmentp. 631

  +SERVICE SOFTWAREp. 633

  Connecting The Laptop Computerp. 633

  Entering The Service Softwarep. 634

  Monitor Screenp. 635

  Warnings Screenp. 637

  Calibrate Inch Pedalp. 638

  Calibrate Creep Potentiometerp. 639

  Program / Update Susmic Controllerp. 641

  +ENGINE SERVICEp. 643

  +TROUBLESHOOTINGp. 647

  Chartp. 647

  +ENGINE SPEED CONTROLp. 649

  Removal And Installationp. 649

  +MUFFLERp. 651

  Removal And Installationp. 651

  +AIR CLEANERp. 653

  Housing Removal And Installationp. 653

  +OIL COOLER / RADIATORp. 655

  Removal And Installationp. 655

  Disassembly And Assemblyp. 658

  +ENGINE AND ENGINE MOUNTSp. 661

  Removal And Installationp. 661

  +ENGINE COMPONENTS AND TESTINGp. 665

  Fuel Injection Pump Removalp. 665

  Fuel Injection Pump Installationp. 668

  Fuel Injectors Removal And Installationp. 671

  Checking The Fuel Lift Pumpp. 673

  Fuel Lift Pump Removal And Installationp. 674

  Compression Checkingp. 674

  Glow Plugs Checkingp. 675

  Glow Plugs Removal And Installationp. 676

  +ENGINE TIMINGp. 677

  Procedurep. 677

  +ENGINE / HYDROSTAT ASSEMBLYp. 679

  Removal And Installationp. 679

  +FLYWHEEL AND HOUSINGp. 693

  Removal And Installationp. 693

  Ring Gear Removalp. 696

  Ring Gear Installationp. 696

  +RECONDITIONING THE ENGINEp. 697

  Turbo Charger Troubleshootingp. 697

  Turbo Charger Descriptionp. 698

  Turbo Charger Removal And Installationp. 698

  Exhaust Manifold Removal And Installationp. 700

  Fuel Injector Cover Removal And Installationp. 700

  Rocker Cover Removal And Installationp. 701

  Cylinder Head Removalp. 702

  Cylinder Head Inspectionp. 704

  Cylinder Head Installationp. 705

  Rocker Shaft Disassembly And Assemblyp. 708

  Valve Removalp. 708

  Valve Springs Checkingp. 709

  Valve Depth Checkingp. 709

  Valve Guides Checkingp. 710

  Valve Guide Removalp. 711

  Valve Guide Installationp. 711

  Valves Checkingp. 712

  Cutting A Valve Seatp. 712

  Valve Seat Assemblyp. 713

  Changing Valve Springs (With Cylinder Head Installed)p. 714

  Valve Clearance Adjustmentp. 715

  Timing Case And Drive Assembly Descriptionp. 716

  Timing Cover Removalp. 716

  Timing Cover Installationp. 716

  Crankshaft Pulley Removal And Installationp. 716

  Front Oil Seal Removal And Installationp. 716

  Timing Case And Gear Removalp. 717

  Timing Case And Gear Installationp. 718

  Camshaft And Tappets Removalp. 720

  Camshaft And Tappets Installationp. 721

  Pistons And Connecting Rods Descriptionp. 722

  Pistons And Connecting Rods Removalp. 722

  Pistons And Connecting Rods Disassemblyp. 724

  Piston Ring End Gapp. 724

  Piston Ring Installationp. 724

  Piston Ring Groove Clearancep. 725

  Connecting Rod Inspectionp. 726

  Connecting Rod Bushing Replacementp. 726

  Piston And Connecting Rod Assemblyp. 726

  Piston And Connecting Rod Installationp. 726

  Checking Piston Heightp. 728

  Crankshaft And Bearings Descriptionp. 728

  Crankshaft And Bearings Removalp. 728

  Inspection Of Crankshaft And Bearingsp. 730

  Crankshaft And Bearings Installationp. 731

  Rear Oil Seal Removalp. 732

  Rear Oil Seal Housing Positioningp. 732

  Rear Oil Seal Installationp. 733

  Checking Crankshaft End Playp. 733

  Cooling System Descriptionp. 734

  Thermostat Removal and Installationp. 735

  Thermostat Testingp. 736

  Lubricating Oil Cooler Removal And Installationp. 736

  Water Pump Removalp. 736

  Water Pump Installationp. 736

  Engine Lubrication System Descriptionp. 737

  Oil Filter Adapter Removal And Installationp. 738

  Oil Pan Removal And Installationp. 738

  Oil Screen And Pick-up Tubep. 739

  Oil Pump Removalp. 739

  Oil Pump Installationp. 740

  Oil Pump Disassembly And Assemblyp. 741

  Oil Pressure Relief Valve Disassembly And Assemblyp. 741

  Engine Block Descriptionp. 742

  Engine Block Disassembly And Assemblyp. 742

  Piston Cooling Jet Removalp. 743

  Piston Cooling Jet Installationp. 743

  Piston Cooling Jet Alignmentp. 743

  Inspectionp. 743

  Cylinder Liner Inspectionp. 744

  Cylinder Liner Removalp. 745

  Cylinder Liner Installationp. 746

  +HEATING, VENTILATION, AIR CONDITIONINGp. 747

  +AIR CONDITIONING SYSTEM FLOWp. 749

  Principlesp. 749

  Chartp. 750

  +COMPONENTSp. 751

  Identificationp. 751

  +SAFETYp. 755

  Safety Equipmentp. 755

  +REGULAR MAINTENANCEp. 757

  Filter Element Removal And Installationp. 757

  Compressor Drive Belt Inspectionp. 757

  Cleaning The Condenserp. 758

  +BASIC TROUBLESHOOTINGp. 759

  Poor A/C Performancep. 759

  Compressor Drive Belt Inspectionp. 760

  Checking The Electrical Systemp. 761

  +GENERAL AIR CONDITIONING SERVICE GUIDELINESp. 769

  Compressor Oilp. 769

  Compressor Oil Checkp. 769

  Component Replacement And Refrigeration Leaksp. 771

  SYSTEM TROUBLESHOOTING CHARTp. 773

  +TEMPERATURE / PRESSUREp. 777

  Chartp. 777

  +AIR CONDITIONING SERVICEp. 779

  Chartp. 779

  +SYSTEM CHARGING AND RECLAMATIONp. 781

  Reclamation Procedurep. 781

  Charging Procedure With A Manifold Gauge Setp. 784

  Charging Procedurep. 785

  +COMPRESSORp. 787

  Removal And Installationp. 787

  Compressor Clutch Disassembly And Assemblyp. 788

  +CONDENSER (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)p. 793

  Removal And Installationp. 793

  +CONDENSER (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)p. 795

  Removal And Installationp. 795

  +RECEIVER / DRIERp. 797

  Removal And Installationp. 797

  +PRESSURE SWITCHp. 799

  Removal And Installationp. 799

  +EVAPORATOR / BLOWER UNIT (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)p. 801

  Removal And Installationp. 801

  +EVAPORATOR / BLOWER / HEATER UNIT (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)p. 803

  Removal And Installationp. 803

  +EXPANSION VALVE (S/N A8FR12999 & BELOW, S/N A8G312999 & BELOW)p. 805

  Removal And Installationp. 805

  +EXPANSION VALVE (S/N A8FR13000 & ABOVE, S/N A8G313000 & ABOVE)p. 807

  Removal And Installationp. 807

  +HEATER ASSEMBLYp. 809

  Removal And Installationp. 809

  Fan Removal And Installationp. 810

  Core Removal And Installationp. 811

  +SPECIFICATIONSp. 813

  +TELESCOPIC HANDLER SPECIFICATIONSp. 815

  Dimensional Specificationsp. 815

  Performance Specificationsp. 816

  Enginep. 816

  Fan Pumpp. 816

  Controlsp. 816

  Drive Systemp. 817

  Tyresp. 817

  Capacitiesp. 817

  Hydraulic Systemp. 818

  Electrical Systemp. 818

  Instrument Panelp. 818

  +ENGINE SPECIFICATIONSp. 819

  Generalp. 819

  Cylinder Headp. 819

  Valve Guidesp. 819

  Exhaust Valvesp. 820

  Intake Valvesp. 820

  Valve Springsp. 820

  Rocker Shaft, Rockers And Bushingsp. 821

  Pistons And Piston Ringsp. 821

  Connecting Rods And Bearingsp. 822

  Crankshaftp. 822

  Crankshaft Re-Grind Datap. 823

  Main Bearingsp. 824

  Thrust Washersp. 824

  Camshaft And Thrust Washerp. 824

  Cylinder Blockp. 824

  Cylinder Linersp. 825

  Fuel Injection Pumpp. 825

  Fuel Injectorsp. 825

  Fuel Lift Pumpp. 825

  Timing Case And Timing Gearsp. 826

  Oil Pump, Gear And Relief Valvep. 827

  Turbochargerp. 827

  Flywheelp. 827

  Water Pump And Thermostatp. 828

  Engine Torque Componentp. 829

  +MACHINE TORQUE SPECIFICATIONSp. 831

  Axlep. 831

  Boomp. 831

  Drive Boxp. 831

  Drive Motorp. 831

  Enginep. 832

  Hydraulic Pumpp. 832

  +TORQUE SPECIFICATIONS FOR BOLTSp. 833

  Torque for General SAE Boltsp. 833

  Torque For General Metric Boltsp. 834

  +HYDRAULIC CONNECTION SPECIFICATIONSp. 835

  O-ring Face Seal Connectionp. 835

  Straight Thread O-ring Fittingp. 835

  Tubelines And Hosesp. 835

  Port Seal Fittingp. 836

  +HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONSp. 837

  Specificationsp. 837

  +CONVERSIONSp. 839

  Decimal And Millimeter Equivalentsp. 839

  U.S. To Metric Conversionp. 839

  ALPHABETICAL INDEXp. 841

  +SERVICE MANUAL REVISIONp. 843

  Revision No: T2556, T2566 – 1p. 843

• Hydrostatic System
  • Hydrostatic system information and troubleshooting; replenishing valve function; oil cooler; hydrostatic drive motor; hydrostatic pump and related service procedures.
• Drive System
  • Drive-system troubleshooting; axle and differential service, including front axle information; drive-system components and associated removal, installation and repair procedures.
• Main Frame
  • Operator cab service with procedures divided by applicable serial-number groups, together with major frame-mounted machine components and assemblies.
• Electrical System and Analysis
  • Electrical system information and troubleshooting; serial-number-specific electrical coverage; fuses, diodes and relays; charging, starting and wiring-related diagnosis; electrical component and circuit analysis.
• Engine Service
  • Engine troubleshooting; engine speed control; engine-related service components; cooling and exhaust-related assemblies; engine/hydrostat assembly removal and installation; engine service procedures and torque data.
• Heating, Ventilation, Air Conditioning
  • Air conditioning system flow and principles; HVAC component identification; safety; basic troubleshooting; electrical checks; general air-conditioning service; system charging and reclamation; compressor and heater-related service.
• Specifications
  • Telescopic handler dimensional and performance specifications; engine information; machine torque specifications; hydraulic connection specifications; hydraulic/hydrostatic fluid information and other service specifications.
• Alphabetical Index
  • Reference index for locating systems, components and procedures throughout the manual.

Together, these chapters provide a broad repair path from scheduled maintenance and initial fault finding through system testing, adjustment, component removal and internal repair. The manual repeatedly combines written procedures with photographs, illustrations, exploded views, schematics and specified measurements or torque values so work can be followed in the context of the actual T2556 and T2566 assemblies.

Hydraulic, Electrical and Engine Reference

The hydraulic information is particularly detailed. A full hydraulic schematic identifies the major pumps, valves, cylinders, motor and control circuits. The manual records a hydraulic reservoir system capacity of 31.7 Gal. (120 L), along with pump-flow and pressure information used during system diagnosis and adjustment. The main relief valve procedure includes use of a hydraulic tester, fluid warming and pressure testing rather than relying only on symptom descriptions.

Engine information identifies the PERKINS 1104D-44TA. The hydraulic schematic data records 74.5 kW @2200 rpm and 410 Nm @1400 rpm, with an engine speed range shown from 850 rpm minimum to 2400 rpm maximum. Engine service is integrated with the rest of the machine procedures, including the engine/hydrostat assembly, cooling, lubrication, fuel and related service work.

The electrical section provides separate information where the machine configuration changes by serial number. It covers the 12 volt negative-earth charging system, fuse, diode and relay locations, troubleshooting and circuit diagnosis. This is complemented by the HVAC section, where electrical checks, component identification and air-conditioning troubleshooting are included alongside mechanical service procedures.

Detailed Component Repair

A major strength of the Bobcat T2556 T2566 telescopic handler service manual is the amount of component-level work illustrated step by step. Cylinder sections show how assemblies are removed from the machine, how hoses and pivot pins are handled, how individual cylinders are dismantled, and where seals, wear rings, O-rings and internal components fit during assembly. Similar depth appears in drive box, valve and steering work.

IMAGES PREVIEW

The extension-cylinder section, for example, includes cylinder-group removal, upper tubeline removal and installation, tubeline tray disassembly and assembly, individual cylinder removal, parts identification, disassembly and reassembly. Correct tubeline positioning measurements and fastening instructions are included where required. Steering-cylinder procedures cover removal from the axle, tie-rod or steering-bar connections, internal sealing components and reassembly. The drive-box section provides an exploded parts identification drawing followed by disassembly, assembly and special-tool information.

Safety information is incorporated throughout the service procedures. Instructions address supporting the boom, depressurizing hydraulic components, protecting against fluid injection, handling batteries and fuel, welding precautions, machine blocking and checking correct function after repair. The manual’s foreword specifically directs operating instructions, starting procedures and daily checks to the separate Operation & Maintenance Manual; this service manual is focused on mechanic-level servicing, adjustment and repair of the machine and its systems.

Repair Your T2556 or T2566 with the Correct Service Information

The Bobcat T2556 T2566 Telescopic Handler Service Manual 6986764 Revised 2010 PDF gives you the procedures needed to diagnose system faults, perform scheduled service, remove and install assemblies, rebuild many hydraulic components, test and adjust hydraulic functions, trace electrical problems, service the drive and engine systems, and work with the heating and air-conditioning system. Having the correct procedures, diagrams, measurements, pressure settings and torque specifications available while the machine is being repaired helps reduce guesswork and provides a consistent reference from diagnosis through final assembly.

Your manual is supplied as an instant PDF download after purchase. There is no physical book and no shipping delay. Open the PDF on a computer, tablet or phone, keep it available in the workshop, and print the pages or procedures you need for the job.