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Bobcat TR38160 VersaHANDLER® TTC, Telescopic Handler Service Manual (SN TLM1590000-TLM1999999)

Format: PDF (Printable Document)

File Language: English

File Pages: 547

File Size: 17.08 MB (Speed Download Link)

Brand: Bobcat

Model: TR38160 VersaHANDLER® TTC, Telescopic Handler

Book No: 7266169

Serial No: SN TLM1590000-TLM1999999

Type of Document: Service Manual

Categories: ,

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Bobcat TR38160 VersaHANDLER® TTC, Telescopic Handler Service Manual (SN TLM1590000-TLM1999999)

A TR38160 VersaHANDLER is a telescopic handler you see on farms, construction sites, and rental yards, doing pallet work, lifting trusses, loading trucks, and running forks or buckets. The service manual is what I grab when I'm in a tight yard with a dead machine and I need real specs and step-by-step teardown info, not safety tips. People use it to chase down hydraulic issues, electrical gremlins, and to rebuild major components without guessing and causing a second breakdown.

What this manual helps you do

  • Trace and diagnose hydraulic problems in the boom, stabilizers, and steering circuits with proper test points and spec checks
  • Check and set hydrostatic and auxiliary pressures before you start throwing expensive parts at a drive or lift issue
  • Follow teardown and reassembly steps for cylinders, valves, driveline, and major structural components so you don't miss shims or seals
  • Diagnose electrical and control faults using wiring diagrams, connector callouts, and signal descriptions instead of random parts swapping
  • Replace and adjust mechanical linkages, brakes, boom components, and attachment systems with the correct sequences and settings

Who this is for

This is for a shop mechanic, mobile tech, rental fleet, or owner-operator who's actually wrenching on a TR38160 in the TLM1590000-TLM1999999 serial range. If you just want basic controls, daily checks, or safety info, you want the operator's handbook instead, not this manual.

FAQ

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

A: These manuals are normally searchable PDFs, and wiring diagrams are usually clear enough to zoom in on pin numbers and wire colors on a laptop or tablet.

Q: Will this cover my exact machine?

A: If your serial number falls between TLM1590000 and TLM1999999, this is the right manual family for your TR38160.

Q: Is this the right document if I'm planning major repairs?

A: Yes, this is the workshop-level service manual, meant for full diagnostics, teardown, and reassembly, not light maintenance.

Bottom line: If you're repairing or diagnosing a TR38160 in that serial range, this is the manual you want. If you're only operating it, skip this and get the operator's book.

📘 Show Index

Table of Contents:

  • FOREWORD
    • FOREWORD
    • SAFETY INSTRUCTIONS
      • Before Operation
      • Telescopic Handler Approved Applications
      • 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
      • Fuelling
      • Starting
      • Welding And Grinding
      • Fire Extinguishers
    • SERIAL NUMBER LOCATIONS
      • Telescopic Handler Serial Numbers
      • Engine Serial Number
      • Other Serial Numbers
      • Diesel Particulate (DPF) Filter
    • DELIVERY REPORT
    • BOBCAT 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 Roof Window
      • Cab Light
      • Cab Ventilation, Heating And Air Conditioning
      • Auxiliary Power Outlet
      • Recirculation / Fresh Air Control
      • Rotating Beacon
      • Hazard Lights
      • Emergency Stop Switch
      • Road Light Switch
    • TRANSPORTING THE TELESCOPIC HANDLER
      • Procedure
    • TOWING THE TELESCOPIC HANDLER
      • Procedure
      • Deactivating The External Parking Brake Manually
    • SERVICE SCHEDULE
      • Maintenance Intervals
      • Contents Of The Inspection Checkbook (logbook)
    • AIR CLEANER SERVICE
      • Replacing 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
      • Cleaning The Fuel Tank
    • ENGINE LUBRICATION SYSTEM
      • Checking And Adding Engine Oil
      • Engine Oil Chart
      • Removing And Replacing Oil And Filter
      • Removing And Replacing Crankcase Ventilation Filter
    • HYDRAULIC / HYDROSTATIC SYSTEM
      • Hydraulic / Hydrostatic Fluid Chart
      • Checking And Adding Hydraulic / Hydrostatic Fluid
      • Replacing Hydraulic / Hydrostatic Fluid And Filters
      • Cylinder Lock Valve
    • 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
      • Telescopic Boom Wear Blocks
    • TIRE MAINTENANCE
      • Wheel Nuts
      • Tire Rotating
      • Tire Mounting
      • Tire Pressure
    • ENGINE COVER
      • Opening And Closing
    • APPROVED BOOM STOP
      • Installing The Approved Boom Stop
    • ANTI TIPPING DEVICE
      • Description
      • Display Panel Data
      • By-Pass Key Switch
      • Operation
      • Attachment Selector
      • Operation
      • Anti Tipping Device Inspection
      • Anti Tipping Calibration
      • Diagnostic Screen
  • HYDRAULIC SYSTEM
    • HYDRAULIC / HYDROSTATIC SCHEMATICS
    • HYDRAULIC SYSTEM INFORMATION
      • Glossary Of Hydraulic / Hydrostatic Symbols
      • Troubleshooting Chart
      • Tightening Procedures
      • Hydraulic Component Pressures
    • LIFT AND COMPENSATION CYLINDER
      • Parts Identification
      • Section View
      • Description
      • Removal And Installation
      • Disassembly
      • Replacing Gaskets
      • Assembly
    • INTERNAL TELESCOPE CYLINDER
      • Parts Identification
      • Removal And Installation
      • Hoses Replacement
    • EXTERNAL TELESCOPE CYLINDER
      • Parts Identification
      • Internal And External Telescope Cylinder Simultaneous Extension
    • LIFT, COMPENSATION AND TILT CYLINDER
      • Tilt Cylinder Parts Identification
      • Lift, Compensation And Tilt Cylinder Hydraulic Circuit
      • Description
      • Lift, Compensation And Cylinder Operation
    • DRIVE BOX
      • Component Identification Location
      • Parts Identification
      • Disassembly
      • Assembly
    • BRAKE AND GEAR VALVES
      • Component Identification Location
      • Parts Identification
    • STEERING MODE VALVE BLOCK
      • Component Identification Location
      • Parts Identification
    • STEERING VALVE
      • Parts Identification
    • HYDRAULIC CONTROL VALVE
      • Component Identification Location
      • Priority And Safety Valve Identification Location
      • Main Valve Section Identification
      • Removal And Installation
      • Inlet Valve Section
      • Lifting Valve Section
      • Upperstructure Swing Valve Section
      • Telescoping Valve Section
      • Outlet Valve Section
      • Tilting Valve Section
      • Auxiliary Valve Section
      • Troubleshooting
    • SWING MOTOR
      • Parts Identification
      • Checking, Adding or Replacing Oil
      • Removal And Installation
    • REAR AXLE OSCILLATION LOCK CYLINDER
      • Component Identification Location
      • Parts Identification
      • Removal And Installation
    • Stabilizers Cylinder
      • Component Identification Location
      • Parts Identification
    • AIR CONDITIONING
      • Component Identification Location
  • HYDROSTATIC SYSTEM
    • HYDROSTATIC DRIVE MOTOR
      • Parts Identification
      • Removal And Installation
      • Seal Nut Replacement
      • Cover Plate Sealing
      • Control Parts Sealing
      • Hydraulic Control Sealing
      • Port Plate Disassembly
      • Positioning Piston Removal
      • Rotary Group Removal
      • Rotary Group Exchange
      • Inspection
      • Rotary Group Assembly
      • Rotary Group Adjustment
      • Port Plate Assembly
      • Torques For Bolts
      • Torques For Plugs
      • Torques For Oval Head Screw
      • Torques For Seal-Lock Sealing Nuts
      • Torques For A6V Positioning Piston
    • HYDROSTATIC PUMP
      • Component Identification Location
      • Parts Identification
      • Removal And Installation
      • Drive Shaft Sealing
      • Boost Pump Sealing
      • Control Piston Cover Sealing
      • Valves Sealing
      • Pressure Cut-off Valve Sealing
      • Control Valve Sealing
      • Control Module Removal
      • Pump Disassembly
      • Rotary Group Removal
      • Positioning Piston Disassembly
      • Inspection
      • Rotary Group Parts Inspection
      • Positioning Piston and Rotary Group Assembly
      • Rotary Group Installation
      • Rotary Group DA Installation
      • Pump DA Assembly
      • Pump Assembly
      • Torques For Bolts
      • Torques For Plugs
      • Torques For Seal-Lock Sealing Nuts
      • Torques For A4V Orifices
      • Special Tools
    • HYDROSTATIC TRANSMISSION ADJUSTMENT
      • Description
      • Start Of Control Setting Adjustment
      • Low Pressure Valve (Boost Pressure) Adjustment
      • Mechanical Zero Position Adjustment
      • Hydraulic Zero Position Adjustment
      • High Pressure Valves And Pressure Cut-Off Adjustment
      • Bypass Valve Adjustment
      • DA Control Adjustment
      • Starting Adjustment
  • DRIVE SYSTEM
    • TROUBLESHOOTING
      • Chart
    • AXLE AND DIFFERENTIAL (FRONT)
      • General Information
      • Parts Identification
      • 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
      • Parts Identification
      • 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
  • MAINFRAME
    • BOOM ASSEMBLY
      • Boom Cable Reel Replacement
      • Procedure
    • OPERATOR SEAT
      • Removal And Installation
  • ELECTRICAL SYSTEM AND ANALYSIS
    • ELECTRICAL SCHEMATICS
    • ELECTRICAL SYSTEM INFORMATION
      • Glossary Of Electrical Symbols
      • Troubleshooting Chart
      • Fuse And Relay Location / Identification
    • BATTERY
      • Removing And Installing Battery
      • Battery Disconnect Switch
      • Servicing
      • Using A Booster Battery (Jump Starting)
    • SENSORS AND SWITCHES
      • Stabilizers Angle
      • Upperstructure Slew Lock Inserted
      • Upperstructure Rotation
      • Boom / Chassis Angle
      • Boom Length Cable
      • Accelerator Pedal
      • Inching Switch
      • Stop Switch
      • Rabbit Mode Switch
      • Parking Brake Pressure Switch
      • Hydraulic Oil Filter Clogged
      • Fuel Level
      • Pressure Transducers
      • Gear Box Speed Sensor
      • Gear Position Sensor
      • Service Brake Accumulator Pressure Switch
      • Service Brake Pressure Switch (Turtle / Rabbit Authorization)
      • Air Filter Clogged
      • Flatness Sensor
      • Directionals
      • Seat Switch
    • MAN PLATFORM LOAD LIMITER CALIBRATION
      • Description
      • Procedure
    • BOOM ELECTRICAL CABLE
      • Black Hose for Electrical Cable Replacement
      • Electrical Cable Replacement
    • GROUNDS
      • Location Identification
    • CONTROL UNITS
      • MC2M-T Control Unit
      • MC2M-C Control Unit
      • MIDAC Plus Control Unit
      • AL-GA TFT Control Unit
      • Engine Control Unit (ECU)
      • Engine Control Unit (ECU) Removal And Installation
      • Machine Error Diagnostics
    • LIGHTS
      • Rear Light Removal And Installation
      • Rear Light Bulb Replacement
    • INSTRUMENT PANELS
      • Right Instrument And Indicator Panel Removal And Installation
    • BOOM ANGLE-LENGTH TRANSDUCER (ACQ) CALIBRATION
      • Procedure
    • STABILIZERS CALIBRATION
      • Procedure
    • UPPERSTRUCTURE ANGLE CALIBRATION
      • Procedure
  • ENGINE SERVICE
    • ENGINE INFORMATION
      • Description
      • Warranty
      • Specifications
      • Sensor Location
      • Torque Values
      • Troubleshooting
    • DIESEL PARTICULATE FILTER (DPF) SYSTEM
      • Description
      • DPF Regeneration Table
      • Regeneration Control Levels
      • Operation
      • Service Regeneration
      • DPF Cleaning
    • AIR CLEANER SERVICE
      • Replacing The Air Filter
    • ENGINE COOLING SYSTEM
      • Water Pump Removal And Installation
      • Water Pump Disassembly And Assembly
      • Thermostat Housing Removal And Installation
      • Thermostat – Checking
    • FLYWHEEL AND HOUSING
      • Flywheel Removal And Installation
      • Ring Gear Removal And Installation
      • Housing Removal And Installation
    • EXHAUST GAS RECIRCULATION (EGR) SYSTEM
      • Description
      • Removal And Installation
  • SPECIFICATIONS
    • TR38160 EVO TELESCOPIC HANDLER SPECIFICATIONS
      • Machine Dimensions
      • Performance
      • Engine
      • Transmission
      • Hydraulic System
      • Differential Axles
      • Capacities
      • Tires
      • Environmental
      • Temperature Range
      • Oil And Fluid Types
    • 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
    • HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
      • Specifications
    • 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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