Bobcat T40140 T40170 Telescopic Handler Service Manual 6986768 (2010)

Description

Bobcat T40140 T40170 Telescopic Handler Service Manual 6986768 (2010)

This Bobcat T40140 T40170 Telescopic Handler Service Manual 6986768 (2010) is written for the mechanic who services the T40140 and T40170 telescopic handlers. It gives servicing and adjustment procedures for the machine and its component parts and systems, and it is intended to be used together with the Operation and Maintenance Manual for starting, daily checks, and operator routines. Machines in this publication carry the Bobcat Interlock Control System (BICS) and are identified by serial numbers S/N A8GA11001 and above and S/N A8GB11001 and above. Publication 6986768-EN was issued 08-08 and revised 02-10, printed in Belgium, and copyrighted by Bobcat Company in 2010.

File Details

• Manual type: Service Manual
• Brand / models: Bobcat T40140 and T40170 telescopic handlers
• Serial ranges: S/N A8GA11001 and above; S/N A8GB11001 and above
• Language: English
• Page count: 862
• File format: PDF
• Document number: 6986768-EN (08-08) Revised (02-10)
• Copyright: Bobcat Company 2010

Machines And Systems Covered

Both models share the same Perkins 1104D-44TA turbo-charged four-cylinder diesel and the same hydrostatic four-wheel-drive layout. Rated capacity is 4000 kg on each machine. Lift height on tyres is 13430 mm on the T40140 and 17430 mm on the T40170; on stabilisers those figures become 13610 mm and 17180 mm. Maximum reach on tyres is 9800 mm versus 13730 mm. Unladen weight with no attachment is 10000 kg on the T40140 and 10790 kg on the T40170. The hydraulic pump is engine driven at 25 GPM (95 L/min) with system pressure of 3843 PSI (265 Bar). Travel is infinitely variable through a hydrostatic piston pump and one fully reversing hydrostatic motor, with low range 0-8 km/h and high range 0-30 km/h. Steering uses a wheel with three mode selections: front-wheel, all-wheel, and crab. Boom, tilt, and auxiliary functions are commanded from an electric joystick with switches. Standard tyres are four Dunlop 400/80 x 24 156B units, inflated to 4,25 bar on the T40140 and 4,75 bar on the T40170 when used with the rigid pallet frame and forks shown in the dimensional drawings.

Fluid capacities in the specification section are identical across both models: 140 L fuel tank (diesel Grade No. 2 or Grade No. 1), 145 L hydraulic/hydrostatic complete circuit and 77 L tank only (EQUIVIS ZS 46), 17 L engine cooling system with a 50/50 ethylene glycol mixture for -34°F (-37°C) freeze protection, 8,5 L engine lubrication circuit, 6,7 L front axle central casing, 6,6 L rear axle central casing, and 0,8 L each in the front reduction gearbox, front axle transfer box, and rear planetary carrier using Bobcat axle fluid P/N 100032-06A. The electrical system uses a 14,2 Volt 70 A alternator with internal regulator, a 12 V 105 Ah 720 A battery, and a 12 V 2,8 kW starter, with centralized fuse, relay and diode protection plus separate electronic boxes for hydrostatic transmission control and for stabiliser, CDDL and AMA functions.

Chapters Covered

• Safety and Maintenance — lifting and blocking; operator cab emergency exit, door and window; transporting and fastening; towing and park-brake bypass; service schedule; air cleaner; engine cooling; fuel system; engine lubrication; hydraulic/hydrostatic fluid and filters; front and rear axle oils; lubrication; attachment frame; tyre maintenance; spark arrester muffler; approved boom stop; engine cover; telescoping chain tension and wear
• Hydraulic System — system information and troubleshooting; lift, bucket positioning, extension, tilt, front and rear steering, quick tach, frame leveling and stabiliser cylinders; drive box; main relief, port relief, flow control, brake, steering, steering-mode, parking-brake, pressure-reducing, accumulator and tow valves; gear pump; fan motor; hydraulic reservoir; hydraulic control valve and joystick; stabiliser control valve
• Hydrostatic System — troubleshooting and replenishing valve function; combined radiator/oil cooler; hydrostatic drive motor removal, inspection and assembly; hydrostatic pump removal, inspection and assembly
• Drive System — troubleshooting; front and rear axle and differential teardown (planetary carriers, steering knuckles, drive axles, brake system, differential, bevel pinion); front and rear axle R&I; axle toe-in; parking brake release for towing; steering angle; driveshaft; service brake bleeding
• Main Frame — operator cab (split at S/N A8GA12999 / A8GB12999 and A8GA13000 / A8GB13000); seat; boom assembly, end boom, intermediate boom (second intermediate boom on T40170), boom tray and pivot link; front and rear wear pads; engine cover and air intake cowling; fuel tank; Quick Tach; front and rear weights; fender; dash and joystick panel variants; stabiliser frame
• Electrical System and Analysis — electrical information and troubleshooting by serial group; fuses, diodes and relays; battery and jump starting; alternator and belt; starter; wiring diagrams including radio and man-platform circuits; monitor functions and fault codes; frame-leveling related sensors
• Engine Service — troubleshooting chart; speed control cable; muffler; air cleaner housing; oil cooler/radiator; engine and mounts; fuel injection pump, injectors, lift pump, compression and glow plugs; engine timing; engine/hydrostat assembly; flywheel and housing; full engine reconditioning (turbocharger, cylinder head, valves, timing case, camshaft, pistons, crankshaft, oil pump, liners)
• Heating, Ventilation, Air Conditioning — R134a system flow; compressor, condenser, receiver/drier, expansion valve and evaporator; regular maintenance; charging and reclamation; receiver/drier and pressure switch
• Specifications — dimensional and performance data for T40140 and T40170; engine, fan pump, controls, drive, tyres, capacities, hydraulic and electrical data; Perkins engine rebuild limits; machine and general bolt torques; hydraulic connection specs; fluid specifications; conversions
• Alphabetical Index

Taken together, the Bobcat T40140 T40170 Telescopic Handler Service Manual 6986768 (2010) is a shop-level repair book rather than an operator handbook. A technician can lift and block the machine, release the spring-applied front-axle park brake and turn the tow valve for short-distance recovery, then return those adjustments before returning the handler to work. The same book walks through boom-stop installation before major work, cab and boom removal (with serial-split cab and dash procedures), wear-pad and telescoping-chain service, complete cylinder and valve work, hydrostatic pump and motor overhaul, front and rear axle rebuilds with special tools, electrical diagnosis, Perkins 1104D-44TA in-frame and out-of-frame engine work, and R134a air-conditioning service.

Maintenance Intervals And Daily Work

The service schedule in the Bobcat T40140 T40170 service manual groups tasks at 10, 50, 100, 250, 500 and 1000 hours (or 12 months at the last interval). Daily and short-interval items include engine oil and hydraulic fluid level checks, lubrication of articulation pins, king pins, axle oscillation, attachment-frame pivots, tilt/lift cylinders, boom pivot, self-levelling/side-shift cylinder and structure, telescopic boom slides, door hinges and stabiliser cylinders, plus inspection of safety signs, treads, mirrors, seat belt, brakes, tyres, air filter indicator, cooling pack and hydraulic lines. Wheel nuts are specified at 221 ft.-lb. (300 N·m), with a first-24-hour check every 8 hours. Engine oil and filter, outer air filter, primary and secondary fuel filters, and the hydraulic filter are first-time-then-interval items. Hydraulic fluid and filter, axle fluid, boom wear blocks, pivot pins and bushings, and engine valve lash appear at the longer intervals. Coolant freeze protection is checked at -34°F (-30°C) in the schedule table, with a flush and premix replacement every two years. Air-cleaner service is condition-indicator driven: replace the outer element when the red ring shows, and replace the inner safety element every third outer change or if the indicator still flags after an outer change.

Hydraulic, Hydrostatic And Drive Work

Hydraulic chapters in this T40140 T40170 workshop manual cover more than hose replacement. Each major cylinder has removal, parts identification, disassembly and assembly steps. The drive box, gear pump and fan motor are fully torn down. Main relief testing and adjustment, control-valve drain-pressure checks, auxiliary-section troubleshooting, port relief and flow-control valves, the three-mode steering valve block with solenoid testing, brake valve, parking-brake valve, pressure-reducing valve, accumulator and tow valve are all documented. Stabiliser cylinders and the stabiliser control valve are included for machines so equipped. Hydrostatic work goes through replenishing-valve function, then complete disassembly, inspection and assembly of the drive motor (mounting bolts 140-155 ft.-lb. / 190-210 N·m) and the hydrostatic pump. Drive-system pages rebuild the front axle including the wet brake pack and bevel pinion, rebuild the rear axle and differential, set toe-in and steering angle, service the driveshaft, and bleed the service-brake circuit. Only the front axle has brakes; park-brake release for towing is a four-bolt, quarter-turn procedure with a matching reactivation sequence.

IMAGES PREVIEW

Engine, Electrical And Cab Climate

The Perkins 1104D-44TA section matches the performance sheet: turbo-charged, liquid-cooled diesel, 100 HP (74,5 kW) SAE net, four cylinders in line, 4.133 in. (105 mm) bore, 5.000 in. (127 mm) stroke, 18.2:1 compression, 269 in³ (4,4 L) displacement, firing order 1-3-4-2, clockwise rotation from the front, direct injection, maximum torque 410 N·m at 1400 rpm. Engine service in the Bobcat T40140 T40170 Telescopic Handler Service Manual 6986768 (2010) includes injection-pump R&I with TDC number-one timing pins, injector and lift-pump work, compression comparison between cylinders, glow-plug checks, combined engine/hydrostat removal, flywheel and ring-gear work, and a long reconditioning chapter covering turbocharger diagnosis, cylinder head and valve service (valves that fail spec are replaced, not ground), timing case and gears, camshaft and tappets, pistons and rings, crankshaft and bearings with re-grind data, oil pump and relief valve, piston cooling jets, and cylinder liner inspection and replacement. Electrical analysis covers charging and starting faults, fuse and relay maps, booster-battery procedure, alternator belt deflection, hydrostatic monitor screens (engine RPM, travel control position, battery voltage, propel curve, sensor voltage, brake-release switch) and related fault codes. HVAC pages explain R134a high- and low-side state changes through compressor, condenser, receiver/drier, expansion valve and evaporator, then move into belt and condenser service, electrical checks, reclamation and charging, and component replacement. Compressor oil is specified as 150-170 cc of PAG oil from the factory fill.

Use This Manual On The Job

The Bobcat T40140 T40170 Telescopic Handler Service Manual 6986768 (2010) supports scheduled maintenance, leak and overheating diagnosis, boom and attachment-frame work, cylinder and valve overhaul, hydrostatic pump and motor rebuild, axle and brake service, cab and boom structural R&I, electrical troubleshooting, Perkins 1104D-44TA testing and reconditioning, and R134a climate-system service. Following the printed pressures, torques, wear limits and serial-split procedures keeps lift capacity, travel control and interlock function inside the values Bobcat published for these handlers. After payment you receive the PDF immediately—no shipping—so you can open it on a phone, tablet or shop computer and print the pages you need at the machine.