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Bobcat TR38160 VersaHANDLER® TTC, Telescopic Handler Service Manual (SN LLM1590267-LLM1599999)

Format: PDF (Printable Document)

File Language: English

File Pages: 381

File Size: 11.91 MB (Speed Download Link)

Brand: Bobcat

Model: TR38160 VersaHANDLER® TTC, Telescopic Handler

Book No: 6990609

Serial No: SN LLM1590267-LLM1599999

Type of Document: Service Manual

Categories: ,

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Bobcat TR38160 VersaHANDLER® TTC, Telescopic Handler Service Manual (SN LLM1590267-LLM1599999)

This TR38160 VersaHANDLER TTC is the big telescopic handler you see unloading pallets, setting trusses, and handling materials where a skid-steer just can't reach. The service manual is what I grab when I'm in a muddy yard, laptop on the tire, trying to sort a hydraulic issue or an electrical fault without wasting a day on guesswork. If you're chasing a warning light, a boom function that's weak, or you're planning a teardown, this is the book you want, not the little operator's booklet from the cab pocket.

What this manual helps you do

  • Diagnose hydraulic problems in the boom, outriggers, and steering using step-by-step test and pressure-check procedures
  • Trace and troubleshoot electrical faults with wiring diagrams that show connector locations and pin IDs
  • Follow teardown and reassembly procedures for major components like axles, boom sections, cylinders, and driveline parts
  • Check and set adjustments on linkages, boom wear pads, brakes, and steering so the machine runs straight and tight
  • Verify service intervals, bleed procedures, and system reset steps after you replace pumps, valves, or sensors

Who this is for

This is aimed at shop mechanics, mobile techs, rental fleets, and owner-operators who are actually wrenching on a TR38160 in the LLM1590267-LLM1599999 serial range. If you just need basic controls, safety, and daily checks, you want the operator's handbook instead, not this service manual.

FAQ

Q: Is this a searchable PDF, and can I read the wiring diagrams on a laptop or tablet?

A: These manuals are usually supplied as searchable PDFs, and the wiring diagrams are laid out so you can zoom in and read connector labels clearly.

Q: Does this cover my exact machine?

A: It's written for TR38160 VersaHANDLER TTC units in the LLM1590267 to LLM1599999 serial number range, so your tag needs to fall in that window.

Q: Is this the right document if I'm planning repairs, not just maintenance?

A: Yes, this is the workshop-level service manual, meant for diagnostics and repair, not the operator's or parts book.

Bottom line: If your TR38160's serial number falls in that range and you're doing your own diagnostics and repairs, this is the right manual. If you only need how-to-drive info, skip it.

📘 Show Index

Table of Contents:

  • FOREWORD
    • FOREWORD
    • SAFETY INSTRUCTIONS
      • Safe Operation Is The Operator’s Responsibility
      • Safe Operation Needs A Qualified Operator
      • Avoid Silica Dust
      • Dismantling And Disposal
    • FIRE PREVENTION
      • Maintenance
      • Operation
      • Electrical
      • Hydraulic System
      • Fueling
      • Starting
      • Welding And Grinding
      • Fire Extinguishers
    • SERIAL NUMBER LOCATIONS
      • Telescopic Handler Serial Numbers
      • Engine Serial Number
      • Other Serial Numbers
    • DELIVERY REPORT
    • TELESCOPIC HANDLER IDENTIFICATION
  • SAFETY AND MAINTENANCE
    • LIFTING AND BLOCKING THE TELESCOPIC HANDLER
      • Procedure
    • OPERATOR CAB
      • Description
      • Cab Door
      • Cab Door Window
      • Cab Rear Window
      • Cab Light
      • Cab Roof
      • Cab Ventilation
      • Rotating Beacon
    • TRANSPORTING THE TELESCOPIC HANDLER
      • Procedure
    • TOWING THE TELESCOPIC HANDLER
      • Procedure
    • SERVICE SCHEDULE
      • Chart
      • Contents Of The Inspection Checkbook (logbook)
    • AIR CLEANER SERVICE
      • Cleaning The Air Filter
    • ENGINE COOLING SYSTEM
      • Cleaning The Cooling System
      • Checking The Coolant Level
      • Removing And Replacing The Coolant
    • FUEL SYSTEM
      • Fuel Specifications
      • Biodiesel Blend Fuel
      • Filling The Fuel Tank
      • Fuel Filters
      • Removing Air From The Fuel System
      • Cleaning The Fuel Tank
    • ENGINE LUBRICATION SYSTEM
      • Checking And Adding Engine Oil
      • Engine Oil Chart
      • Removing And Replacing Oil And Filter
    • HYDRAULIC / HYDROSTATIC SYSTEM
      • Hydraulic / Hydrostatic Fluid Chart
      • Checking And Adding Hydraulic / Hydrostatic Fluid
      • Replacing Hydraulic / Hydrostatic Fluid And Filters
    • AXLES (FRONT AND REAR)
      • Checking And Adding Oil (Planetary Carrier)
      • Removing And Replacing Oil (Planetary Carrier)
      • Checking And Adding Oil (Front And Rear Differential)
      • Removing And Replacing Oil (Front And Rear Differential)
      • Checking And Adding Oil (Drive Box)
      • Removing And Replacing Oil (Drive Box)
    • LUBRICATING THE TELESCOPIC HANDLER
      • Lubrication Locations
      • Lubricating Telescopic Boom Wear Blocks
    • TYRE MAINTENANCE
      • Wheel Nuts
      • Tyre Rotating
      • Tyre Mounting
      • Tyre Pressure
    • ENGINE COVER
      • Opening And Closing
    • APPROVED BOOM STOP
      • Installing The Approved Boom Stop
    • ANTI TIPPING DEVICE
      • Description
      • Main Work Data
      • Complementary Work Data
      • Attachment And Operating Mode
      • Attachment Selection
      • Unencoded Display Information
      • Self-Diagnostics
      • Anti Tipping Device Error Codes
      • Remote Control Error Codes
      • Diagnostic Displays
      • Language Selection
  • HYDRAULIC SYSTEM
    • HYDRAULIC / HYDROSTATIC SCHEMATICS
    • HYDRAULIC SYSTEM INFORMATION
      • Glossary Of Hydraulic / Hydrostratic Symbols
      • Troubleshooting Chart
      • Tightening Procedures
      • Hydraulic Component Pressures
    • LIFT CYLINDER
      • Removal And Installation
      • Parts Identification
      • Section View
    • INTERNAL TELESCOPE CYLINDER
      • Parts Identification
    • EXTERNAL TELESCOPE CYLINDER
      • Parts Identification
    • TILT CYLINDER
      • Parts Identification
    • DRIVE BOX
      • Parts Identification
      • Disassembly
      • Assembly
    • BRAKE AND GEAR VALVES
      • Parts Identification
    • STEERING MODE VALVE BLOCK
      • Parts Identification
    • STEERING VALVE
      • Parts Identification
    • HYDRAULIC CONTROL VALVE
      • Valve Section Identification
      • Inlet Valve Section
      • Lifting Valve Section
      • Upperstructure Swing Valve Section
      • Telescoping Valve Section
      • Outlet Valve Section
      • Tilting Valve Section
      • Auxiliary Valve Section
    • SWING MOTOR
      • Parts Identification
      • Checking, Adding or Replacing Oil
    • REAR AXLE OSCILLATION LOCK CYLINDER
      • Parts Identification
    • STABILISER / LEVELLING VALVE
      • Parts Identification
  • HYDROSTATIC SYSTEM
    • HYDROSTATIC DRIVE MOTOR
      • Parts Identification
    • HYDROSTATIC PUMP
      • Parts Identification
    • HYDROSTATIC TRANSMISSION ADJUSTMENT
      • Description
      • Starting Adjustment
      • Feeding Pressure
      • Hydrostatic Pump Pressure
      • Hydrostatic Motor Pressure
  • DRIVE SYSTEM
    • TROUBLESHOOTING
      • Chart
    • AXLE AND DIFFERENTIAL (FRONT)
      • General Information
      • Planetary Carrier Parts Identification
      • Planetary Carrier Disassembly
      • Steering Cylinder Parts Identification
      • Steering Cylinder Removal
      • Steering Cylinder Disassembly
      • Steering Case Parts Identification
      • Steering Case Disassembly
      • Drive Axle Parts Identification
      • Drive Axle Disassembly
      • Brake System Parts Identification
      • Brake System Disassembly
      • Hydraulic Differential Lock Parts Identification
      • Hydraulic Differential Lock Disassembly
      • Differential Unit (Limited Slip) Parts Identification
      • Differential Unit (Limited Slip) Disassembly
      • Bevel Pinion Parts Identification
      • Bevel Pinion Removal
      • Bevel Pinion Installation And Adjustment
      • Differential Unit (Limited Slip) Assembly
      • Hydraulic Differential Lock Assembly
      • Brake System Assembly
      • Drive Axle Assembly
      • Steering Case Assembly
      • Steering Cylinder Assembly
      • Steering Cylinder Installation
      • Planetary Carrier Assembly
      • Special Tools
    • AXLE AND DIFFERENTIAL (REAR)
      • General Information
      • Planetary Carrier Parts Identification
      • Planetary Carrier Disassembly
      • Steering Cylinder Parts Identification
      • Steering Cylinder Removal
      • Steering Cylinder Disassembly
      • Steering Case Parts Identification
      • Steering Case Disassembly
      • Drive Axle Parts Identification
      • Drive Axle Disassembly
      • Negative Brake Parts Identification
      • Negative Brake Disassembly
      • Hydraulic Differential Lock Parts Identification
      • Hydraulic Differential Lock Disassembly
      • Differential Unit (Limited Slip) Parts Identification
      • Differential Unit (Limited Slip) Disassembly
      • Bevel Pinion Parts Identification
      • Bevel Pinion Removal
      • Bevel Pinion Installation And Adjustment
      • Differential Unit (Limited Slip) Assembly
      • Hydraulic Differential Lock Assembly
      • Negative Brake Assembly
      • Drive Axle Assembly
      • Steering Case Assembly
      • Steering Cylinder Assembly
      • Steering Cylinder Installation
      • Planetary Carrier Assembly
      • Special Tools
  • ELECTRICAL SYSTEM AND ANALYSIS
    • ELECTRICAL SCHEMATICS
    • ELECTRICAL SYSTEM INFORMATION
      • Troubleshooting Chart
      • Fuse And Relay Location / Identification
    • BATTERY
      • Removal And Installation
      • Battery Disconnect Switch
      • Servicing
      • Using A Booster Battery (Jump Starting)
      • Battery Test
    • SENSORS AND SWITCHES
      • Stabilisers Lowered
      • Upperstructure Aligned With Undercarriage
      • Upperstructure Rotated 174°
      • Upperstructure Slew Lock Inserted
      • Axle Oscillation Lock Range (12°)
      • Boom Raised / Lowered Completely
    • MAN PLATFORM LOAD LIMITER CALIBRATION
      • Description
      • Procedure
  • SPECIFICATIONS
    • (TR38160) TELESCOPIC HANDLER SPECIFICATIONS
      • Machine Dimensions
      • Performance
      • Engine
      • Transmission
      • Hydraulic System
      • Differential Axles
      • Capacities
      • Tyres
      • Environmental
    • 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
    • CONVERSIONS
      • Decimal And Millimeter Equivalents
      • U.S. To Metric Conversion Chart
    • SERVICE TOOLS REQUIRED
      • Remote Start Tools
      • Hydraulic Tools
      • Drive Tools
      • Electrical Tools
      • Engine Tools
      • HVAC Tools
  • ALPHABETICAL INDEX

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