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Bobcat T35120 VersaHANDLER® TTC, Telescopic Handler Service Manual (SN A8GS11001-A8GS99999)

Format: PDF (Printable Document)

File Language: English

File Pages: 942

File Size: 47.67 MB (Speed Download Link)

Brand: Bobcat

Model: T35120 VersaHANDLER® TTC, Telescopic Handler

Book No: 6986767

Serial No: SN A8GS11001-A8GS99999

Type of Document: Service Manual

Categories: ,

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Bobcat T35120 VersaHANDLER® TTC, Telescopic Handler Service Manual (SN A8GS11001-A8GS99999)

On a job, the T35120 VersaHANDLER is your reach machine: lifting pallets of block, setting trusses, feeding materials over forms where a skid or CTL can't reach. The service manual is what the mechanic or owner-operator grabs when the boom won't extend, a hydraulic function is weak, or an electrical fault keeps it from starting or moving. They're looking for step-by-step teardown, test specs, and wiring info, not how to run the controls.

What this manual helps you do

  • Diagnose hydraulic issues in the boom and stabilizers, then check pressures and isolate bad valves or cylinders
  • Trace and troubleshoot electrical faults using wiring diagrams for lights, safety circuits, sensors, and controllers
  • Follow teardown and reassembly procedures on the telescopic boom, axles, steering, and driveline components
  • Adjust, verify, and pressure-test the hydrostatic and load-handling systems after repairs so the machine lifts and drives correctly
  • Replace and set up wear parts like pins, bushings, brakes, and steering components with the right sequences and checks

Who this is for

This is for anyone working on a Bobcat T35120 VersaHANDLER TTC with serial number A8GS11001 through A8GS99999: small contractors, rental fleets, field techs, and shop mechanics who already know which end of a wrench to hold. If you only want basic operating tips or daily maintenance, you want the operator's handbook instead, not this service manual.

FAQ

Q: Is this a searchable PDF and are the wiring diagrams readable?

A: Yes, it's typically a searchable PDF, and the wiring diagrams are laid out so you can zoom in and read circuits clearly on-screen or printed.

Q: Will this cover my exact T35120 machine?

A: If your serial number falls between A8GS11001 and A8GS99999, this is the right service manual for your unit.

Q: Is this the right document if I'm doing real repairs, not just changing fluids?

A: Yes, this is the workshop service manual, meant for diagnostics, teardown, and repair, not just routine maintenance.

Bottom line: If your T35120's serial tag is in that A8GS11001-A8GS99999 range and you're doing actual repair work, this is the manual you want. If you're just learning to run it, skip this one.

📘 Show Index

Table of Contents:

  • 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 (ROPS / FOPS)
      • Cab Door
      • Cab Door Window
    • TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER
      • Loading And Unloading
      • Fastening
    • TOWING THE TELESCOPIC HANDLER
      • Procedure
    • SERVICE SCHEDULE
      • Chart
    • AIR CLEANER SERVICE
      • Replacing Filter Element(s)
    • ENGINE COOLING SYSTEM
      • Cleaning
      • Removing And Replacing The Coolant
      • Checking Level
    • FUEL SYSTEM
      • Fuel Specifications
      • Biodiesel Blend Fuel
      • Filling The Fuel Tank
      • Secondary Fuel Filter
      • Primary Fuel Filter (Pre-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
      • Hydraulic Tank Breather
    • 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 (Front Drop Box)
      • Removing And Replacing Oil (Front Drop Box)
    • LUBRICATING THE TELESCOPIC HANDLER
      • Lubrication Locations
    • ATTACHMENT CARRIER
      • Inspection And Maintenance
    • TIRE MAINTENANCE
      • Wheel Nuts
      • Rotating
      • Mounting
    • APPROVED BOOM STOP
      • Installing The Approved Boom Stop
      • Removing The Approved Boom Stop
    • ENGINE COVER
      • Opening And Closing
    • CHAIN
      • Checking And Adjustment Procedure
      • Extend / Retract Chain Wear Check
    • TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE
      • Storage
      • Return To Service
    • STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER
      • Procedure
    • EMERGENCY EXIT
      • Rear Window
  • HYDRAULIC SYSTEM
    • HYDRAULIC / HYDROSTATIC SCHEMATICS
    • HYDRAULIC SYSTEM INFORMATION
      • Glossary Of Hydraulic / Hydrostatic Symbols
      • 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
      • Parts Identification
      • Disassembly
      • Assembly
    • TILT CYLINDER
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • STEERING CYLINDER (FRONT)
      • Removing The Steering Cylinder
      • Installing The Steering Cylinder
      • Disassembling The Steering Cylinder
      • Assembling The Steering Cylinder
    • STEERING CYLINDER (REAR)
      • Removing The Steering Cylinder
      • Installing The Steering Cylinder
      • 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
    • QUICK-TACH CYLINDER
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • FRAME LEVELING CYLINDER
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Assembly
    • 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
    • FAN MOTOR
      • Removal And Installation
      • Parts Identification
      • Disassembly And Assembly
    • HYDRAULIC FLUID RESERVOIR
      • Removal And Installation
    • STEERING VALVE
      • Removal And Installation
      • Parts Identification
      • Disassembly
      • Inspection
      • Assembly
    • HYDRAULIC CONTROL VALVE
      • Checking Drain Pressure
      • Valve Section Troubleshooting (Auxiliary Section Example)
      • Removal And Installation
      • Parts Identification
      • Section Removal
      • Section Disassembly And Assembly
      • Inlet Section Disassembly And Assembly
      • Inlet Section Disassembly And Assembly (Cont’d)
    • PORT RELIEF VALVES
      • Removal And Installation
    • FLOW CONTROL VALVE
      • Removal And Installation
      • PARKING BRAKE
      • Parking Brake Valve Removal And Installation
      • Parking Brake Valve Disassembly And Assembly
      • Parking Brake Valve Disassembly And Assembly (Cont’d)
    • ACCUMULATOR
      • Removal And Installation
    • TOW VALVE
      • Removal And Installation
      • Disassembly And Assembly
    • STABILIZER CYLINDER (IF EQUIPPED)
      • Removal
      • Parts Identification
      • Disassembly
      • Assembly
      • Installation
    • STABILIZER CONTROL VALVE (IF EQUIPPED)
      • Parts Identification
      • Removal
      • Installation
  • HYDROSTATIC SYSTEM
    • 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
      • Disassembly
      • Inspection
      • Assembly
  • 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
      • Steering Knuckle And Drive Axle Parts Identification
      • Steering Knuckle Disassembly
      • Differential And Bevel Pinion Parts Identification
      • Differential Disassembly
      • Bevel Pinion Disassembly
      • Bevel Pinion Assembly
      • Differential Assembly
      • Steering Knuckle Assembly
      • Planetary Carrier Assembly
      • Special Tools
    • FRONT AXLE
      • Removal
      • Installation
    • AXLE TOE-IN
      • Adjustment
    • PARKING BRAKE
      • Releasing The Brake For Towing
      • Re-Activating The Brake
    • STEERING ANGLE ADJUSTMENT
      • Adjustment
    • DRIVE SHAFT
      • Removal And Installation
    • SERVICE BRAKE
      • Description
      • Bleeding The Brake Circuit
    • REAR AXLE
      • Removal
      • Installation
  • MAINFRAME
    • OPERATOR CAB (S/N A8GS12999 & BELOW)
      • Removal And Installation
    • OPERATOR CAB (S/N A8GS13000 & ABOVE)
      • Removal And Installation
    • OPERATOR SEAT
      • Removal And Installation
    • FIXED BOOM
      • Removal
      • Installation
    • END BOOM
      • Removal
      • Installation
    • WEAR PADS (FRONT)
      • Removal
      • 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
    • JOYSTICK PANEL (S/N A8GS12999 & BELOW)
      • Removal And Installation
    • JOYSTICK PANEL (S/N A8GS13000 & ABOVE)
      • Removal And Installation
    • DASH COVER / STEERING COLUMN COVER (S/N A8GS12999 & BELOW)
      • Removal And Installation
    • DASH COVER / STEERING COLUMN COVER (S/N A8GS13000 & ABOVE)
      • Removal And Installation
    • INTERMEDIATE BOOM
      • Removal
      • Installation
    • BOOM TRAY
      • Removal And Installation
    • STABILIZER FRAME (IF EQUIPPED)
      • Removal
      • Installation
  • ELECTRICAL SYSTEM & ANALYSIS
    • ELECTRICAL SCHEMATICS
    • ELECTRICAL SYSTEM INFORMATION (S/N A8GS12999 & BELOW)
      • Troubleshooting Chart
      • Description
      • Fuses, Diode And Relay Location / Identification
    • ELECTRICAL SYSTEM INFORMATION (S/N A8GS13000 & ABOVE)
      • Troubleshooting Chart
      • Description
      • Fuses, Diode And Relay Location / Identification
    • BATTERY
      • Removal And Installation
      • Servicing
      • 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
      • Front Light Removal And Installation
    • TRAVEL / SIGNAL LEVER (S/N A8GS12999 & BELOW)
      • Removal And Installation
    • TRAVEL / SIGNAL LEVER (S/N A8GS13000 & ABOVE)
      • Removal And Installation
    • INSTRUMENT PANEL
      • Removal And Installation
    • SWITCH PANEL (S/N A8GS12999 & BELOW)
      • Removal And Installation
      • Parts Description
    • SWITCH PANEL (S/N A8GS13000 – 14999)
      • Removal And Installation
    • SWITCH PANEL (S/N A8GS15000 & ABOVE)
      • Removal And Installation
    • BRAKE LIGHT SWITCH
      • Removal And Installation
      • Adjustment
    • WIPER MOTOR (Front)
      • Removal And Installation
    • WIPER MOTOR (TOP)
      • Removal And Installation
    • WIPER MOTOR (REAR)
      • Removal And Installation
    • PEDAL ASSEMBLY
      • Removal And Installation
    • INCHING SWITCH
      • Removal And Installation
      • Adjustment
    • SERVICE SOFTWARE
      • Connecting The Laptop Computer
      • Entering The Service Software
      • Monitor Screen
      • Warnings Screen
      • Calibrate Inch Pedal
      • Calibrate Creep Potentiometer
      • Program / Update Susmic Controller
    • FRAME LEVEL SPEED SWITCH
      • Description
      • Removal
      • Installation
    • LONGITUDINAL STABILITY INDICATOR CALIBRATION (S/N A8GS11001-14999)
      • Fitting The Sensor
      • Calibration Procedure
    • LLMI / LLMC SYSTEM (S/N A8GS15000 & ABOVE)
      • System Calibration
      • Calibration Test
      • System Failure Reports
      • System Components Identification
      • LLMS Removal
      • LLMS Installation
      • LLMC Controller Removal
      • LLMC Controller Installation
    • JOYSTICK
      • Removal And Installation
  • ENGINE SERVICE
    • ENGINE INFORMATION
      • Specifications
      • Troubleshooting
    • 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
      • Turbocharger Troubleshooting
      • Turbocharger Description
      • Turbocharger 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
  • HEATING, VENTILATION, AIR CONDITIONING
    • AIR CONDITIONING SYSTEM FLOW
      • Description
      • Chart
      • Components
      • Safety Equipment
    • REGULAR MAINTENANCE
      • Filters
      • Compressor And Alternator Drive Belt Inspection
      • Cleaning The Condenser
      • Air Conditioning Lubrication
      • Air Conditioning Service Chart
    • 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
      • Troubleshooting Tree
      • Temperature / Pressure Chart
      • Poor A/C Performance
      • HVAC Repairs And Leaks
      • Electrical System
    • SYSTEM CHARGING AND RECLAMATION
      • Reclamation Procedure
      • Charging Procedure With A Manifold Gauge Set
      • Charging Procedure
    • COMPRESSOR
      • Removal And Installation
      • Oil
      • Oil Check
      • Clutch Disassembly And Assembly
    • CONDENSER (S/N A8GS12999 & BELOW)
      • Removal And Installation
    • CONDENSER (S/N A8GS13000 & ABOVE)
      • Removal And Installation
    • RECEIVER / DRIER
      • Removal And Installation
    • PRESSURE SWITCH
      • Removal And Installation
    • EVAPORATOR / BLOWER UNIT (S/N A8GS12999 & BELOW)
      • Removal And Installation
    • EVAPORATOR / BLOWER UNIT (S/N A8GS13000 & ABOVE)
      • Removal And Installation
    • EXPANSION VALVE (S/N A8GS12999 & BELOW)
      • Removal And Installation
    • EXPANSION VALVE (S/N A8GS13000 & ABOVE)
      • Removal And Installation
    • HEATER ASSEMBLY
      • Removal And Installation
      • Fan Removal And Installation
      • Core Removal And Installation
  • SPECIFICATIONS
    • (T35120SL) TELESCOPIC HANDLER SPECIFICATIONS
      • Dimensional Specifications
      • Performance Specifications
      • Weights
      • Engine
      • Controls
      • Drive System
      • Traction
      • Steering
      • Brakes
      • Fluid Capacities
      • Hydraulic System
      • Electrical
      • Instruments
      • Environmental
      • Temperature Range
    • MACHINE TORQUE SPECIFICATIONS
      • Axle
      • Boom
      • Drive Box
      • Drive Motor
      • Engine
      • Hydraulic Pump
    • 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
      • Port Seal Fitting
    • HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
      • Specifications
    • CONVERSIONS
      • Decimal And Millimeter Equivalents
      • U.S. To Metric Conversion
  • ALPHABETICAL INDEX
  • SERVICE MANUAL REVISION
    • Revision No: T35120SL MP – 1

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