T2556

S/N 3630 11001

& above

SERVICE
T2566 MANUAL
S/N 3631 11001
& above

4852210 (07-06) © Bobcat Europe, 2006

Printed in Europe
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903

CORRECT

Safety Alert Symbol: This symbol with a warning statement,

means: “Warning, be alert! Your safety
is involved!” Carefully read the
message that follows.

B-10731a
Never service the Bobcat Telescopic
Handler without instructions.

CORRECT WRONG WRONG

B-16082 B-16080 B-16079

Cleaning and maintenance are Disconnecting or loosening any Never work on Telescopic
required daily. hydraulic tubeline, hose, fitting, Handler with boom up unless
component or a part failure can boom is held by an approved
cause boom to drop. Do not go boom stop. Replace if damaged.
under boom when raised unless Never modify equipment or add
supported by an approved boom attachments not approved by
stop. Replace if damaged. Bobcat Company.

WRONG WRONG WRONG

B-16081 B-16078 B-6589

B-16102 B-16102
Have good ventilation when Keep body, jewelry and clothing Lead-acid batteries produce
welding or grinding painted away from moving parts, flammable and explosive gases.
parts. electrical contact, hot parts and Keep arcs, sparks, flames and
Wear dust mask when grinding exhaust. lighted tobacco away from
painted parts. Toxic dust and gas Wear eye protection to guard batteries.
can be produced. from battery acid, compressed Batteries contain acid which
Avoid exhaust fume leaks which springs, fluids under pressure burns eyes or skin on contact.
can kill without warning. Exhaust and flying debris when engines Wear protective clothing. If acid
system must be tightly sealed. are running or tools are used. contacts body, flush well with
Use eye protection approved for water. For eye contact flush well
type of welding. and get immediate medical
attention.

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation &
Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use
genuine Bobcat replacement parts.
MSW12-0805
ALPHABETICAL INDEX

ACCUMULATOR.............................................. 20-210-01
AIR CLEANER ................................................... 70-40-01
AIR CLEANER SERVICE .................................. 10-60-01 FAN MOTOR ...................................................... 20-140-1
AIR CONDITIONING SERVICE ........................... 80-90-1 FENDER ............................................................ 50-110-1
AIR CONDITIONING SYSTEM FLOW ................ 80-10-1 FLOW CONTROL VALVE .................................. 20-240-1
AIR INTAKE COWLING ....................................... 50-71-1 FLYWHEEL AND HOUSING................................ 70-90-1
ALTERNATOR...................................................... 60-30-1 FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE..
OPTIONAL APPROVED BOOM STOP ............. 10-150-1 20-230-1
AXLE AND DIFFERENTIAL (FRONT) (For S/N 363011001 - FRONT AXLE (For S/N 363011001 - 363012000 and S/N
363012000 and S/N 363111001 - 363112000)............... 40-20-1 363111001 - 363112000)...................................... 40-30-1
AXLE AND DIFFERENTIAL (REAR) (For S/N 363011001 - FRONT AXLE (For S/N 363012001 and Above, S/N
363012000 and S/N 363111001 - 363112000)............... 40-21-1 363112001 and Above) ........................................ 40-31-1
AXLE AND DIFFERENTIAL (FRONT) (For S/N 363012001 and FRONT WIPER MOTOR.................................... 60-110-1
Above, S/N 363112001 and Above) ............................. 40-22-11 FUEL SYSTEM .................................................... 10-80-1
AXLE AND DIFFERENTIAL (REAR) (For S/N 363012001 and FUEL TANK.......................................................... 50-80-1
Above, S/N 363112001 and Above) ............................... 40-23-1
AXLE PIVOT FRAME.............................................. 40-01
AXLE TOE-IN (For S/N 363011001 - 363012000 and S/N GEAR PUMP...................................................... 20-130-1
363111001 - 363112000)...................................... 40-40-1
GENERAL AIR CONDITIONING SERVICE GUIDELINES .. 80-60-1
AXLE TOE-IN (For S/N 363012001 and Above, S/N
363112001 and Above) ........................................ 40-41-1
AXLES (FRONT AND REAR) (For S/N 363011001 -
363012000 and S/N 363111001 - 363112000)... 10-110-1 HEATER ASSEMBLY......................................... 80-170-1
AXLES (FRONT AND REAR) (For S/N 363012001 and HYDRAULIC CONNECTION SPECIFICATIONS ..... SPEC-50-1
Above, S/N 363112001 and Above) ....................10-111-1
HYDRAULIC CONTROL VALVE........................ 20-170-1
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS . SPEC-60-1
HYDRAULIC/HYDROSTATIC SYSTEM ............ 10-100-1
BASIC TROUBLESHOOTING ............................. 80-50-1
HYDRAULIC RESERVOIR ................................ 20-150-1
BATTERY ............................................................. 60-20-1
HYDRAULIC SYSTEM INFORMATION............... 20-10-1
BOOM ASSEMBLY .............................................. 50-30-1
HYDROSTATIC DRIVE MOTOR.......................... 30-30-1
BRAKE LIGHT SWITCH .................................... 60-100-1 HYDROSTATIC PUMP......................................... 30-40-1
BRAKE VALVE ................................................... 20-120-1 HYDROSTATIC SYSTEM INFORMATION .......... 30-10-1
BUCKET POSITIONING CYLINDER................... 20-30-1
COMPONENTS ................................................... 80-20-1
COMPRESSOR ................................................. 80-110-1
INCHING SWITCH ............................................. 60-150-1
CONDENSER .................................................... 80-120-1
INNER BOOM ...................................................... 50-40-1
CONVERSIONS............................................. SPEC-70-1 INSTRUMENT PANEL ......................................... 60-80-1

DASH COVER/STEERING COLUMN COVER.. 50-130-1

JOYSTICK.......................................................... 20-180-1
DRIVE BOX (For S/N 363011001 - 363012000 and S/N
363111001 - 363112000)...........................................20-70-1 JOYSTICK PANEL ............................................. 50-120-1
DRIVE BOX (For S/N 363012001 and above, S/N
363112001 and above)..............................................20-71-1
DRIVESHAFT ...................................................... 40-70-1 LIFT CYLINDER................................................... 20-20-1
LIFTING AND BLOCKING THE Telescopic Handler ......10-10-1
LIGHTS ................................................................ 60-60-1
ELECTRICAL SYSTEM INFORMATION ............. 60-10-1 LUBRICATION (For S/N 363011001 - 363012000 and S/N
ENGINE AND ENGINE MOUNTS ....................... 70-60-1 363111001 - 363112000).................................... 10-120-1
ENGINE COMPONENTS AND TESTING ........... 70-70-1 LUBRICATION (For S/N 363012001 & Above and S/N
363112001 & Above).......................................... 10-121-1
ENGINE COOLING SYSTEM .............................. 10-70-1
ENGINE COVER................................................ 10-160-1
ENGINE COVER.................................................. 50-70-1
ENGINE/HYDROSTAT ASSEMBLY..................... 70-80-1
ENGINE LUBRICATION SYSTEM.......................... 10-01
ENGINE SPECIFICATIONS...............................SPEC-01
ENGINE SPEED CONTROL................................ 70-20-1
EVAPORATOR/BLOWER UNIT......................... 80-150-1
EXPANSION VALVE .......................................... 80-160-1
EXTENSION CYLINDER ..................................... 20-40-1

4852210 (07-06) ALPHA-1 Bobcat T2556 & T2566

SERVICE MANUAL
ALPHABETICAL INDEX (CONT’D)

MACHINE TORQUE SPECIFICATIONS ........SPEC-30-1 STEERING VALVE ............................................. 20-160-1

MAIN RELIEF VALVE ...........................................20-80-1 SWITCH PANEL................................................... 60-90-1
MUFFLER.............................................................70-30-1 SYSTEM CHARGING AND RECLAMATION ..... 80-100-1
SYSTEM TROUBLESHOOTING CHART ............ 80-70-1

OIL COOLER........................................................30-20-1
OPERATOR CAB..................................................10-20-1 TEMPERATURE/PRESSURE.............................. 80-80-1
OPERATOR CAB..................................................50-10-1 TIRE MAINTENANCE ........................................ 10-130-1
OPERATOR SEAT................................................50-20-1 TILT CYLINDER ................................................... 20-50-1
TOP WIPER MOTOR ......................................... 60-120-1
PARKING BRAKE...............................................20-190-1 TORQUE SPECIFICATIONS FOR BOLTS .... SPEC-40-1
PARKING BRAKE (For S/N 363012001 and Above, S/N OPTIONAL TOW VALVE .................................... 20-220-1
363112001 and Above).........................................40-51-1 TOWING THE Telescopic Handler (For S/N 363011001 -
PARKING BRAKE (For S/N 363011001 - 363012000 and 363012000 and S/N 363111001 - 363112000)..... 10-40-1
S/N 363111001 - 363112000) ...............................40-50-1 TOWING THE Telescopic Handler (S/N 363012001 &
PEDAL ASSEMBLY ............................................60-140-1 Above, S/N 363112001 & Above)......................... 10-41-1
PORT RELIEF VALVES......................................20-100-1 TRANSPORTING THE Telescopic Handler ......... 10-30-1
PILOT PRESSURE LOCK OUT VALVE .............20-200-1 TRAVEL/SIGNAL LEVER..................................... 60-70-1
PRESSURE SWITCH.........................................80-140-1 TROUBLESHOOTING ..............................40-10-1, 70-01

QUICK TACH ........................................................50-90-1 Telescopic Handler SPECIFICATIONS .......... SPEC-10-1

QUICK TACH CYLINDER.....................................20-90-1

WEAR PADS (FRONT) ........................................ 50-50-1

OIL COOLER/RADIATOR.....................................70-50-1 WEAR PADS (REAR)........................................... 50-60-1
REAR AXLE (For S/N 363011001 - 363012000 and S/N
363111001 - 363112000) ......................................40-90-1
REAR AXLE (For S/N 363012001 and Above, S/N
363112001 and Above).........................................40-91-1
REAR REAR WEIGHTS .....................................50-100-1
REAR WIPER MOTOR.......................................60-130-1
RECEIVER/DRIER .............................................80-130-1
RECONDITIONING THE ENGINE .....................70-100-1
REGULAR MAINTENANCE .................................80-40-1

SAFETY................................................................80-30-1
SERVICE BRAKE (For S/N 363011001 - 363012000 and S/N
363111001 - 363112000) ................................................40-80-1
SERVICE BRAKE (For S/N 363012001 and Above, S/N
363112001 and Above)...................................................40-81-1
SERVICE SCHEDULE .........................................10-50-1
STARTER .............................................................60-40-1
STEERING ANGLE ADJUSTMENT (For S/N 363011001 -
363012000 and S/N 363111001 - 363112000) ...............40-60-1
STEERING ANGLE ADJUSTMENT (For S/N 363012001 and
Above, S/N 363112001 and Above) ...............................40-61-1
STEERING CYLINDER (FRONT)
STEERING CYLINDER (FRONT) (For S/N 363011001 -
363012000 and S/N 363111001 - 363012000)...............20-60-1
STEERING CYLINDER (FRONT) (For S/N 363012001 and
above, S/N 363112001 and above) ................................20-61-1
STEERING CYLINDER (FRONT) (For S/N 363012001 and
above, S/N 363112001 and above) ................................20-61-1
STEERING CYLINDER (REAR) (For S/N 363012001 and
above, S/N 363112001 and above) ................................20-63-1
STEERING MODE VALVE BLOCK ....................20-110-1

4852210 (07-06) ALPHA-2 Bobcat T2556 & T2566

SERVICE MANUAL
SAFETY &
CONTENTS MAINTENANCE

FORWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III
HYDRAULIC
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V SYSTEM
SERIAL NUMBER LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
HYDROSTATIC
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII
SYSTEM
BOBCAT TELESCOPIC HANDLER IDENTIFICATION . . . . . . . . . . . VIII

SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 DRIVE

SYSTEM
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

MAIN FRAME
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ELECTRICAL

SYSTEM &
ELECTRICAL SYSTEM AND ANALYSIS. . . . . . . . . . . . . . . . . . . . 60-01 ANALYSIS

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

ENGINE
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . . . . . 80- SERVICE

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
HVAC

SPECIFICATION
SPECIFICATION

SPECIFICATION

4852210 (07-06) I Bobcat T2556 & T2566

SERVICE MANUAL
FORWORD
This manual is for the Bobcat telescopic handler mechanic. It provides necessary servicing and
adjustment procedures for the Bobcat telescopic handler and its component parts and systems. Refer
to the Operation & Maintenance Manual for operating instructions, Starting procedure, daily checks,
etc.

A general inspection of the following items must be made after the telescopic handler has had service
or repair:
1. Check that ROPS/FOPS 9. Enclosure door latches must
(including right side window) open and close freely.
is in good condition and is not
modified.

2. Check that ROPS mounting 10. Attachment locking pins must

hardware is tightened and is function correctly and be in
Bobcat approved. good condition.

3. The seat belt must be 11. Safety treads must be in good

correctly installed, functional condition.
and in good condition.

4. Check boom support device, 12. Check for correct function of

replace if damaged. indicator lamps and gauges.

5. Machine signs must be 13. Check hydraulic fluid level,

legible and in the correct engine oil level and fuel
location. supply.

6. Check tires for wear and 14. Inspect for fuel, oil or
pressure. Use only approved hydraulic fluid leaks.
tires.

7. Check for correct function of 15. Lubricate the telescopic handler.

the work lights.

8. The parking brake must 16. Check the condition of the

function correctly. battery and cables.

4852210 (07-06) II Bobcat T2556 & T2566

SERVICE MANUAL
17. Inspect the air cleaner for 20. Operate the telescopic
damage or leaks. Check the handler and check all
condition of the element. functions.

18. Check the electrical charging 21. Check for any field
system. modification not completed.

19. Inspect for loosen or broken 22. Recommend to the owner

parts or connections. that all necessary corrections
be made before the machine
is returned to service.

4852210 (07-06) III Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) IV Bobcat T2556 & T2566
SERVICE MANUAL
SAFETY INSTRUCTIONS • The telescopic handler has a plastic Operator’s
Handbook fastened to the operator cab. Its brief
instructions are convenient to the operator. The
Handbook is available from your dealer in an English
WARNING edition or one of many other languages. See your
Bobcat dealer for more information on translated
versions.
Instructions are necessary before operating or
servicing machine. Read and understand the • The EMI Safety Manual (available in Spanish)
Operation & Maintenance Manual, Handbook and delivered with the telescopic handler gives general
signs (decals) on machine. Follow warnings and safety information.
instructions in the manuals when making repairs,
adjustments or servicing. Check for correct function • The Service Manual and Parts Manual are available
after adjustments, repairs or service. Untrained from your dealer for use by mechanics to do shop-type
operators and failure to follow instructions can cause service and repair work
injury or death.
W-2003-0199 • The telescopic handler Operator Training Course is
available through your local dealer. This course is
intended to provide rules and practices for correct
operation of the Bobcat telescopic handler. The

WARNING course is available in English and Spanish version.

• The Service Safety Training Course is available from

Warnings on the machine and in the manuals are for your Bobcat dealer. This course provides information
your safety. Failure to obey warnings can cause injury for safe and correct service procedures for Bobcat
or death. telescopic handler.
W-2044-1285
• The Bobcat telescopic handler Safety Video is
available from your Bobcat dealer.

IMPORTANT Safety Alert Symbol: This symbol

This notice identifies procedures which must be with a warning statement, means:
followed to avoid damage to the machine. “Warning, be alert! Your safety is
I-2019-0284 involved!" Carefully read the
message that follows.
The following publications provide information on the safe
use and maintenance of the telescopic handler and
attachments:

• The Delivery Report is used to assure that complete

instructions have been given to the new owner and
that the machine is in safe operating condition.

• The Operation & Maintenance Manual delivered with

the telescopic handler gives operating information as
well as routine maintenance and service procedures.
It is a part of the telescopic handler and must stay with
the machine when it is sold. Replacement Operation &
Maintenance Manuals can be ordered from your
Bobcat telescopic handler dealer.

• The telescopic handler has machine signs (decals)

which instruct on the safe operation and care. The
signs and their locations are shown in the Operation &
Maintenance Manual. Replacement signs are SI15-0803
available from your Bobcat telescopic handler dealer.

4852210 (07-06) V Bobcat T2556 & T2566

SERVICE MANUAL
SAFETY INSTRUCTIONS (CONT’D) Figure 1

FIRE PREVENTION

The machines has components that are at high

temperatures under normal operating conditions. The
primary source of high temperatures is the engine and
exhaust system. The electrical system, if damaged or
incorrectly maintained, can be a source of arcs or sparks.

Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard.
N-21901
• Do not use the machine where exhaust, arcs, sparks
or hot components can contact flammable material,
explosive dust or gases. • Know where fire extinguishers and first aid kits are
located and how to use them. Fire extinguishers are
• The operator cab, engine compartment and engine available from your Bobcat dealer. The fire
cooling system must be inspected every day and extinguisher can be installed in the location shown in
cleaned if necessary to prevent fire hazards and [Figure 1].
overheating.

• Check all electrical wiring and connections for

damage. Keep the battery terminals clean and tight.
Repair or replace any damaged part.

• Check fuel and hydraulic tubes, hoses and fittings for

damage and leakage. Never use open flame or bare
skin to check for leaks. Tighten or replace any parts
that show leakage. Always clean fluid spills. Do not
use gasoline or diesel fuel for cleaning parts. Use
commercial nonflammable solvents.

• Do not use ether or starting fluids on any engine which

has glow plugs or thermal starting systems. These
starting aids can cause explosion and injure you or
bystanders.

• Always clean the machine, disconnect the battery, and

disconnect the wiring from the electronic controllers
before welding. Cover rubber hoses, battery and all
other flammable parts. Keep a fire extinguisher near
the machine when welding. Have good ventilation
when grinding or welding painted parts. Wear dust
mask when grinding painted parts. Toxic dust or gas
can be produced.

• Stop the engine and let it cool before adding fuel. No

smoking!

• Use the procedure in the Operation & Maintenance

Manual for connecting the battery and for jump
starting.
SI16-0803

4852210 (07-06) VI Bobcat T2556 & T2566

SERVICE MANUAL
SERIAL NUMBER LOCATIONS Engine Serial Number

Always use the serial number of the telescopic handler Earlier Models
when requesting service information or when ordering
parts. Early or later models (identification made by serial Figure 3
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.

telescopic handler Serial Number

Figure 2

S2721

The engine serial number is stamped on a plate near the

injection pump or at the rear of the cylinder block [Figure
3]. Always use the full number when ordering
replacement parts.
P-24121

Later Models

The front, on the right side of the chassis [Figure 2]. Figure 4

S2720

The engine serial number can be found on the cylinder

block [Figure 4] in front of you when opening the engine
cover. Always use the full number when ordering
replacement parts.

Other Serial Numbers

Some components may also have serial numbers. Always

use these serial numbers when requesting parts.

4852210 (07-06) VII Bobcat T2556 & T2566

SERVICE MANUAL
Delivery Report Figure 5

The Delivery Report must be filled out by the dealer and

signed by the owner or operator when the telescopic
handler is delivered. An explanation of the form must be
given to the owner. Make sure it is filled out completely
[Figure 5].

B-16315

BOBCAT TELESCOPIC HANDLER IDENTIFICATION

MIRROR OPERATOR HANDBOOK &
LOAD CAPACITY CHARTS

BOOM
TELESCOPING
BOOM OPERATORS
CAB (ROPS/FOPS)

SEAT
BELT

SAFETY TREAD TIRES

(under boom, (use only approved tires LIGHTS
on top of frame) at correct pressure)
BUCKET MIRROR
ATTACHMENT
LIGHT

ENGINE
COVER

S2750
S2751

4852210 (07-06) VIII Bobcat T2556 & T2566

SERVICE MANUAL
SAFETY AND MAINTENANCE

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1 SAFETY &
MAINTENANCE
AXLES (FRONT AND REAR) (For S/N 363011001 - 363012000 and S/N
363111001 - 363112000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111-1
Checking Oil Level (Front Differential) . . . . . . . . . . . . . . . . . 10-111-2
Checking Oil Level (Planetary Carrier) . . . . . . . . . . . . . . . . . 10-111-1
Checking Oil Level (Rear Differential) . . . . . . . . . . . . . . . . . . 10-111-2
Draining Oil (Front Differential) . . . . . . . . . . . . . . . . . . . . . . . 10-111-3
Draining Oil (Planetary Carrier) . . . . . . . . . . . . . . . . . . . . . . . 10-111-1
Draining Oil (Rear Differential) . . . . . . . . . . . . . . . . . . . . . . . 10-111-2

AXLES (FRONT AND REAR) (For S/N 363012001 and Above, S/N
363112001 and Above). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111-1
Checking Oil Level (Front Differential). . . . . . . . . . . . . . . . . . 10-111-2
Checking Oil Level (Planetary Carrier) . . . . . . . . . . . . . . . . . 10-111-1
Checking Oil Level (Rear Differential) . . . . . . . . . . . . . . . . . . 10-111-2
Checking Oil Level (Drive Box) . . . . . . . . . . . . . . . . . . . . . . . 10-111-3
Draining Oil (Front Differential) . . . . . . . . . . . . . . . . . . . . . . . 10-111-3
Draining Oil (Planetary Carrier) . . . . . . . . . . . . . . . . . . . . . . . 10-111-1
Draining Oil (Rear Differential) . . . . . . . . . . . . . . . . . . . . . . . 10-111-2
Draining Oil (Drive Box). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111-3

OPTIONAL APPROVED BOOM STOP . . . . . . . . . . . . . . . . . . . 10-150-1

Installing The Approved Boom Stop . . . . . . . . . . . . . . . . . . . 10-150-1
Removing The Approved Boom Stop . . . . . . . . . . . . . . . . . . 10-150-1

ENGINE COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Cleaning The Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-2

ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Opening And Closing The Engine Cover . . . . . . . . . . . . . . . 10-160-1

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Replacing Oil And Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2

FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Continued On Next Page

4852210 (07-06) 10-01-1 Bobcat T2556 & T2566

SERVICE MANUAL
SAFETY AND MAINTENANCE (CONT’D)

HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . 10-100-1

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Replacing Hydraulic/Hydrostatic Filter. . . . . . . . . . . . . . . . . . 10-100-2

LATERAL OPERATOR RESTRAINT SYSTEM (LORS™) . . . . . 10-170-1

System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-2

LIFTING AND BLOCKING THE TELESCOPIC HANDLER . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

LUBRICATION (For S/N 363011001 - 363012000 and S/N 363111001 -

363112000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1

LUBRICATION (FOR S/N 363012001 & ABOVE AND S/N 363112001 &
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-121-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-121-1

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Cab Door Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

TIRE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Tire Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Wheel Nuts (For S/N 363011001 - 363012000 and S/N 363111001 -
363112000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

TOWING THE Telescopic Handler (For S/N 363011001 - 363012000 and

S/N 363111001 - 363112000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

TOWING THE Telescopic Handler (S/N 363012001 & Above, S/N

363112001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41-1

TRANSPORTING THE TELESCOPIC HANDLER . . . . . . . . . . . . 10-30-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

4852210 (07-06) 10-01-2 Bobcat T2556 & T2566

SERVICE MANUAL
LIFTING AND BLOCKING THE TELESCOPIC Figure 10-10-2
HANDLER

Procedure

WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to fall
or move and cause injury or death.
W-2017-0286

Figure 10-10-1
Put the floor jack under the center of the rear axle. Lift the
Versa HANDLER and install jackstands [Figure 10-10-2].

Always park the machine on a level surface.

STOP the engine. Put the floor jack under the center of
the front axle. Lift the Versa HANDLER and install
jackstands [Figure 10-10-1].

4852210 (07-06) 10-10-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 10-10-2 Bobcat T2556 & T2566
SERVICE MANUAL
OPERATOR CAB Emergency Exit

Figure 10-20-1 Figure 10-20-2

P-52745 P-34374 P-34373

The Telescopic Handler has an operator cab (ROPS and Turn the handle (Inset) [Figure 10-20-2] and push the
FOPS) (Item 1) [Figure 10-20-1] to protect the operator rear window open. (Models with enclosed cab only.) Exit
from rollover and falling objects. Check with your dealer if through the rear window opening [Figure 10-20-2].
the operator cab has been damaged. Never operate
without right window. The seat belt must be worn for roll
over protection.

ROPS/FOPS - Roll Over Protective Structure per SAE

J1040 and ISO 3471, and Falling Object Protective
Structure per SAE J1043 and ISO 3449 (FOPS Level II).

WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat. Do not operate without
right window. Changes to the cab can cause loss of
operator protection from rollover and falling objects,
and result in serious injury or death.
W-2396-1202

4852210 (07-06) 10-20-1 Bobcat T2556 & T2566

SERVICE MANUAL
OPERATOR CAB (CONT’D) Cab Door Window

Cab Door Figure 10-20-5

Figure 10-20-3

1
1

P-47202

P-47350
Turn the handle (Item 1) [Figure 10-20-5] (as shown).
Push open the window fully until it latches against the cab.
Figure 10-20-4
Figure 10-20-6

1
1

P-47201

P-47203

The cab door can be opened from the outside of the cab
using the latch (Item 1) and open from the inside of the Pull the lever (Item 1) [Figure 10-20-6] inside the cab to
cab when you squeeze the latch (Item 1) [Figure 10-20-4] disengage the latch and close the window.
(as shown).

The cab door can be locked (Item 2) [Figure 10-20-3]

with the start key.

4852210 (07-06) 10-20-2 Bobcat T2556 & T2566

SERVICE MANUAL
TRANSPORTING THE TELESCOPIC HANDLER

Procedure

Always drive the Telescopic Handler backwards (heavy

end up) onto the transport vehicle.

Figure 10-30-1

1
4 3

B-21967

The rear of the trailer must be blocked or supported

[Figure 10-30-1] when loading or unloading the
Telescopic Handler to prevent the front end of the trailer
from raising up.

Be sure the transport and towing vehicles are of adequate

size and capacity. (See “Performance Specifications” on
page SPEC-10-2 for weight of the Telescopic Handler).

Fasten the Telescopic Handler to the transport vehicle to

prevent it from moving during sudden stops or when going
up or down slopes.

• Block the wheels (Item 1) [Figure 10-30-1].

• Fasten the machine frame to the transport vehicle

(Items 2 & 3) [Figure 10-30-1].

• Attach the forks or bucket attachment to the transport

vehicle (Item 4) [Figure 10-30-1].

WARNING
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0494

4852210 (07-06) 10-30-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 10-30-2 Bobcat T2556 & T2566
SERVICE MANUAL
TOWING THE TELESCOPIC HANDLER (For S/N Figure 10-40-1
363011001 - 363012000 and S/N 363111001 -
363112000)

Procedure

The Telescopic Handler can be towed a short distance

such as removing it from mud or loading onto a transport
vehicle.

Releasing Brake Disks: To release the brake disks, turn

each of the six (6) screws (item 1) [Figure 10-40-1] in
only one half turn at a time; then repeat until all six screws
are all the way in. (It will take 4 & 1/2 to 5 turns to fully
release the brakes.) Record the number of turns so that
you can return them to the same position after towing.

NOTE: This procedure is required on the front axle

only.

NOTE: If one screw is turned all the way in before you

start turning the others, the brake can be
damaged.

There are three screws on each side (right and left)

located 120° apart [Figure 10-40-1].

Block the wheels to prevent the machine from rolling.

4852210 (07-06) 10-40-1 Bobcat T2556 & T2566

SERVICE MANUAL
TOWING THE TELESCOPIC HANDLER (For S/N For machines with optional tow valve:
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT’D) Figure 10-40-3
Procedure (Cont’d)

Disengaging the hydrostatic transmission 1

Operating
Position
It is impossible for oil to circulate in a hydrostatic transmis-
sion in a closed circuit when the machine is not running,
this operation involves making oil circulation possible:
For machines without optional tow valve:

Figure 10-40-2 Towing

Position

(Optional tow valve) P-52284

Raise the engine cover.

Turn the tow valve counterclockwise 90° (Item 1) [Figure

10-40-3] to TOWING POSITION.

S0441 Tow the Telescopic Handler at a slow speed.

• There are two identical multi-function valves [Figure 10-

40-2] on the hydrostatic transmission pump.
Engaging Brake Disks: After towing is completed, turn the
• Each valve has three 6-sided nuts of different sizes. tow valve (item 1) [Figure 10-40-3] clockwise 90° to the
• On each valve unscrew the nut from the middle 2.5 OPERATING POSITION.
turns.
On the front axle, turn all six screws out, 1/2 turn at a time,
to their original position.

4852210 (07-06) 10-40-2 Bobcat T2556 & T2566

SERVICE MANUAL
TOWING THE Telescopic Handler (S/N 363012001 & Releasing Brake Disks:
Above, S/N 363112001 & Above)
Figure 10-41-1
Procedure

The Telescopic Handler can be towed a short distance

such as removing it from mud or loading onto a transport 2
vehicle.
1

2
1

S/N 363012001 - 363012500, S/N 363112001 - 363012500 S2710

2
Block the wheels to prevent the machine from rolling.
S/N 363012501 & Above , S/N 363112501 & Above S2711

Loosen the four (two)* bolts (Item 1) until the slotted

spacer (Item 2) [Figure 10-41-1] can be removed from
under the bolt head (the bolts and washers are located on
both the front and rear side of front axle).

Remove the washer (Item 2) [Figure 10-41-1] and save

for reuse.

* Machines with S/N 363012001 - 363012500 and S/

N 363112001 - 363112500 only have brakes on the right
hand side of the front axle.

4852210 (07-06) 10-41-1 Bobcat T2556 & T2566

SERVICE MANUAL
TOWING THE Telescopic Handler (S/N 363012001 & For machines with optional tow valve:
Above, S/N 363112001 & Above) (CONT’D)
Figure 10-41-3
Procedure (Cont’d)

Figure 10-41-2
1
Operating
ACTIVE POSITION RELEASED POSITION Position

1
2

Towing
Position

(Optional tow valve) P-52284

P-68946 Raise the engine cover.

Turn the tow valve counterclockwise 90° (Item 1) [Figure

After removing the washer, tighten the bolt (Item 1)
10-41-3] to TOWING POSITION.
[Figure 10-41-1] and [Figure 10-41-2] to hold the park
brake piston (Item 2) [Figure 10-41-2] in the released
position.
Tow the Telescopic Handler at a slow speed.
Disengaging the hydrostatic transmission

It is impossible for oil to circulate in a hydrostatic transmis-

sion in a closed circuit when the machine is not running,
this operation involves making oil circulation possible:
For machines without optional tow valve:
• There are two identical multi-function valves on the hy-
drostatic transmission pump.
Figure 1

S0441

• Each valve has three 6-sided nuts of different sizes.

• On each valve unscrew the nut from the middle 2.5
turns.

4852210 (07-06) 10-41-2 Bobcat T2556 & T2566

SERVICE MANUAL
TOWING THE Telescopic Handler (S/N 363012001 & Figure 10-41-5
Above, S/N 363112001 & Above) (CONT’D)
ACTIVE POSITION RELEASED POSITION
Procedure (Cont’d)
1
Engaging Brake Disks:
3
Block the wheels to prevent the machine from rolling.

Figure 10-41-4

2
1
P-68946

2
1
Tighten the bolt (Item 1) to hold the washer (Item 2)
[Figure 10-41-5] and [Figure 10-41-5].

Tighten the bolt to 70 - 85 ft. - lb. (95 - 115 N•m) torque.

This will allow the park brake piston (Item 3) [Figure 10-
S/N 363012001 - 363012500, S/N 363112001 - 363012500 S2710 41-5] to be active again.

S/N 363012501 & Above , S/N 363112501 & Above S2711

Loosen the four (two)* bolts (Item 1) until the spacer (Item
2) [Figure 10-41-4] can be installed under the bolt head
(the bolts and washers are located on both the front and
rear side of front axle).

* Machines with S/N 363012001 - 363012500 and S/

N 363112001 - 363112500 only have brakes on the right
hand side of the front axle.

4852210 (07-06) 10-41-3 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 10-41-4 Bobcat T2556 & T2566
SERVICE MANUAL
SERVICE SCHEDULE

Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat Telescopic Handler.
Instructions are necessary before operating or servicing machine. Read
and understand the Operation & Maintenance Manual, Handbook and signs
(decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained operators and failure to
follow instructions can cause injury or death.
W-2003-0199

SERVICE SCHEDULE HOURS

■
ITEM SERVICE REQUIRED 10 50 100 250 500 1000
Engine Oil Check the oil level and add oil as needed.
Hydraulic Fluid Check fluid level and add as needed.
Articulation Pins Lubricate with multi-purpose lithium based grease.
Safety Signs, Safety Tread and Check for damaged signs (decals), safety tread and mirrors. Replace if
Mirrors damaged or worn.
Fuel Filter Clean the sediment bowl/water trap.
Nuts & Bolts Check for loose nuts and bolts. Tighten as needed.
Seat Belt Check the condition of the seat belt. Clean dirt and debris from moving parts.
Brakes Check for function. Service as necessary.
Back-up Alarm Check for function. Replace as necessary.
Tires Check for wear or damage. Inflate to correct pressure. Be sure all tires are
inflated to the same pressure. Use only approved tires.
Engine Air Filter And Air System Check condition indicator, replace element when required and empty dust
cup as needed. Check air system for leaks. See air cleaner section for more
information.
Engine Cooling System Clean debris from oil cooler, radiator and air conditioner condenser. check
coolant level cold in reservoir. Add premixed coolant as needed (See
“ENGINE COOLING SYSTEM” on page 10-70-1). Check cooling system for
leaks.
King Pins, U-Joints, Axle Oscill- Lubricate with multi-purpose lithium based grease.
ation (Front/Rear), Attach. Frame
Pivot(s), Tilt/Lift Cyl., Boom Pivot,
Leveling Cyl. (if equipped)
Telescopic Boom Slide Lubricate with multi-purpose lithium based grease. Check wear blocks for
adjustment or replacement.
Hydraulic Hoses, Tubelines & Check condition of hoses, tubelines and connectors. Repair or replace as
Connections needed.
Battery Check electrolyte level. Add distilled water as needed.
Wheel Nuts Check wheel nut torque. Tighten as needed [221 ft.-lbs. (300 Nm)]. †
Alt. & Air Cond. Belt (if equipped) Check belt tension and adjust as needed. ●
Engine Oil and Filter Replace the engine oil and filter. See “Capacities” on page SPEC-10-3 for ●
correct capacity. Use a genuine Bobcat filter.
Fuel Filter Replace the fuel filter element. Use a genuine Bobcat filter. ●
Hydraulic Fluid Filter Replace the hydraulic filter element. Use a genuine Bobcat filter. ●
Hydrostatic Fluid Filter Replace the hydraulic filter element. Use a genuine Bobcat filter. ●
Hydraulic Fluid and Filter Replace the hydraulic fluid and filter element. See SPECIFICATIONS.
Front & Rear Axle Fluid Replace the axle fluid. See SPECIFICATIONS. ♦ ◊
Engine Coolant Check freeze protection of antifreeze -34 F (-30 C). Flush cooling system and
replace with premixed coolant (See “ENGINE COOLING SYSTEM” on
page 10-70-1).
Telescopic Boom Wear Blocks Check for wear and adjust as needed. Replace as necessary.
Pivot Pins and Bushings Check for wear on the pivot pins and bushings.

† Check wheel nut torque every 8 hours for the first 24 hours. ◊ Replace fluid first time, then as indicated in chart.
● Perform service first time, then as indicated in chart. ❏ Or every 6 months
♦ Check level. ■ Or every 12 months

4852210 (07-06) 10-50-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 10-50-2 Bobcat T2556 & T2566
SERVICE MANUAL
AIR CLEANER SERVICE Figure 10-60-3

Replacing Filter Element

Figure 10-60-1

P-50805

Pull the element straight out [Figure 10-60-3].

P-52166
NOTE: Make sure all sealing surfaces are free of dirt
and debris.
Replace the large (outer) filter element only when the red
ring shows in the window of the condition indicator (Item Install a new outer element.
1) [Figure 10-60-1].
Install the dust cover and fasten[Figure 10-60-3].
NOTE: Before replacing the filter element, push the
button on the condition indicator (Item 2) Connect the filter housing clamps.
[Figure 10-60-1]. Start the engine. If the red
ring does not show, do not replace the filter
element.

Replace the inner filter every third time the outer filter is
replaced or when the red ring still shows in the indicator
window after the outer filter has been replaced.

Figure 10-60-2

1
2
P-50804

Loosen the filter housing clamps (Item 1) [Figure 10-60-

2].

Release the fastener and remove the cover (Item 2)

[Figure 10-60-2].

4852210 (07-06) 10-60-1 Bobcat T2556 & T2566

SERVICE MANUAL
AIR CLEANER SERVICE (CONT’D)

Replacing Filter Element (Cont’d)

Inner Filter

Remove the outer element.

NOTE: Make sure all sealing surfaces are free of dirt

and debris.

Figure 10-60-4

P-50806

Remove the inner filter (Item 1) [Figure 10-60-4] and

install a new element.

Install the outer element.

Install the dust cover and fasten [Figure 10-60-4].

Connect the filter housing clamp (Item 1) [Figure 10-60-

4].

4852210 (07-06) 10-60-2 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE COOLING SYSTEM Open the engine cover.

Check the cooling system every day to prevent over- Check the coolant level in the coolant reservoir.
heating, loss of performance or engine damage.
Figure 10-70-3

WARNING
Wear safety glasses to prevent eye injury when any of
the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
1
• Engine is running.
• Tools are being used.
W-2019-1285

Cleaning The Cooling System

P-52167
Figure 10-70-1

The coolant level must be between the MIN and MAX

marks (Item 1) [Figure 10-70-3] on the coolant reservoir
when the engine is cold.
1
Close the engine cover.

IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
P-52745
To much antifreeze reduces cooling system efficiency
and may cause serious premature engine damage.
Open the engine cover (Item 1) [Figure 10-70-1].
Too little antifreeze reduces the additives which
Figure 10-70-2 protect the internal engine components; reduces the
boiling point and freeze protection of the system.

Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
engine damage.
I-2124-0497

P-50816

Use low air pressure or water pressure to clean the

radiator and oil cooler [Figure 10-70-2].

Checking The Coolant Level

4852210 (07-06) 10-70-1 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE COOLING SYSTEM (CONT’D) Figure 10-70-6

Replacing The Coolant

WARNING
AVOID BURNS
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1203
1

Open the engine cover.

P-53365
Figure 10-70-4

Route the hose (Item 1) [Figure 10-70-6] out the access

panel at the rear of the engine compartment and drain the
coolant into a container.

Dispose of used coolant in an environmentally safe

1
manner.

Figure 10-70-7

P-53364

Remove the access panel (Item 1) [Figure 10-70-4] from

the rear of the engine compartment.
1
Figure 10-70-5

P-52256

Remove the engine block drain plug (Item 1) [Figure 10-

70-7].

Install the engine block drain plug.

1 Mix the coolant in a separate container.

NOTE: The Telescopic Handler is factory filled with

ethylene glycol coolant.
P-53299
Add premixed coolant, 50% water and 50% ethylene
glycol to the reservoir if the coolant level is low.
Remove the hose (Item 1) [Figure 10-70-5] from the
coolant reservoir.

Remove any tie straps.

4852210 (07-06) 10-70-2 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE COOLING SYSTEM (CONT’D)

Replacing The Coolant (Cont'd)

IMPORTANT
One gallon (3,8 L) of ethylene glycol mixed with one
gallon (3,8 L) of water is the correct mixture of coolant to AVOID ENGINE DAMAGE
provide a -34° F (-37° C) freeze protection. Always use the correct ratio of water to anti freeze.
Too much antifreeze reduces cooling system
Use a refractometer to check the condition of ethylene efficiency and may cause serious premature engine
glycol in your cooling system. damage.
Too little antifreeze reduces the additives which
Fill the radiator with the premixed coolant. Install the protect the internal engine compo nents; reduces the
radiator cap. boiling point and freeze protection of the system.
Always add a premixed solution. Adding full strength
Figure 10-70-8 concentrated coolant can cause serious premature
engine damage.
I-2124-0497

P-52167

Add coolant to the reservoir. The coolant level must be

between the MIN and MAX marks (Item 1) [Figure 10-70-
8] on the coolant reservoir.

Run the engine until it is at operating temperature.

Stop the engine.

Check the coolant level (cold) in the reservoir when cool.

Add coolant as needed.

4852210 (07-06) 10-70-3 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 10-70-4 Bobcat T2556 & T2566
SERVICE MANUAL
FUEL SYSTEM Fuel Filter

Fuel Specifications See “SERVICE SCHEDULE” on page 10-50-1 for the

service interval when to clean the sediment bowl.
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1. Figure 10-80-2

The following is one suggested blending guideline which

should prevent fuel gelling problems in cold temperatures:

TEMP. F° (C°) NO. 2 NO. 1

+15° (9°) 100% 0%
Down to -20° (-29°) 50% 50%
Below -20° (-29°) 0% 100%
1
See your fuel supplier for local recommendations.

Filling The Fuel Tank

P-52165

WARNING See “SERVICE SCHEDULE” on page 10-50-1 for the

service interval when to replace the fuel filter.
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an Remove the filter element (Item 1) [Figure 10-80-2].
explosion or fire.
W-2063-0887 Clean the area around the filter housing.

Put oil on the seal of the new filter element.

Figure 10-80-1
Install the fuel filter, and hand tighten.

WARNING
1
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285

P-52743

Remove the fuel fill cap (Item 1) [Figure 10-80-1].

Use a clean, approved safety container to add fuel of the

correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING!

Install and tighten the fuel fill cap [Figure 10-80-1].

4852210 (07-06) 10-80-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 10-80-2 Bobcat T2556 & T2566
SERVICE MANUAL
ENGINE LUBRICATION SYSTEM Oil Chart

Checking Engine Oil Figure 10-90-2

Check the engine oil level every day before starting the RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
engine for the work shift.

Figure 10-90-1

P-52253

Open the engine cover and remove the dipstick (Item 1)

[Figure 10-90-1].

Keep the oil level between the marks on the dipstick

(Inset) [Figure 10-90-1].

Use a good quality motor oil that meets API Service

Classification of CD or better. (See Oil Chart , [Figure 10-
90-2].)

4852210 (07-06) 10-90-1 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-90-4

Replacing Oil And Filter

See “SERVICE SCHEDULE” on page 10-50-1 for the

service interval for replacing the engine oil and filter.

Run the engine until it is at operating temperature. Stop

the engine.
1
Figure 10-90-3

P-50807

Open the engine cover.

Remove the oil filter (Item 1) [Figure 10-90-4].

Clean the filter housing surface.

Put clean oil on the new oil filter gasket. Install the filter
P-52254 and hand tighten.

Figure 10-90-5
Remove the access panel at the rear of the engine
compartment. Route the hose (Item 1) [Figure 10-90-3] 1
out through the access hole. Remove the cap.

Drain the oil into a container and recycle or dispose of 2

used oil in an environmentally safe manner.

Install cap and put the drain hose into the engine
compartment, install the access cover.

WARNING
P-52255
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause Remove the filler cap (Item 1) [Figure 10-90-5].
explosion or fire which can result in injury or death.
W-2103-1285
Put oil in the engine. (See “Capacities” on page SPEC-10-
3). (See Oil Chart on Page 10-90-1.)

Install fill cap, start the engine and let it run for several
minutes.

Stop the engine, and check for leaks at the oil filter.

Remove the dipstick (Item 2) [Figure 10-90-5] and check

the oil level. Add oil as needed if it is not at the top mark
[Figure 10-90-5] on the dipstick.

4852210 (07-06) 10-90-2 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC/HYDROSTATIC SYSTEM Figure 10-100-3

Checking And Adding Fluid

Use only recommended fluid in the hydraulic system.

(See “HYDRAULIC/HYDROSTATIC FLUID 1
SPECIFICATIONS” on page SPEC-60-1)

Stop the machine on a level surface. Lower the boom all

the way.

Stop the engine.

Early Models

Figure 10-100-1 S3537

2 Check the fluid level at the sight gauge (Item 1) [Figure

10-100-1].

Remove the fill / breather cap (Item 1) [Figure 10-100-3]

and add hydraulic fluid.

P-52178

Check the fluid level at the sight gauge (Item 1) [Figure

10-100-1].

Remove the fill cap (Item 2) [Figure 10-100-1].

Figure 10-100-2

P-52455

When adding oil, slowly pour the oil through the filter as
needed, until visible in the sight gauge (Item 1) [Figure
10-100-2].

Later Models

4852210 (07-06) 10-100-1 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)

Replacing Hydraulic/Hydrostatic Filter

See “SERVICE SCHEDULE” on page 10-50-1 for the

correct service intervals.
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
Open the engine cover and remove the fill cap (Item 2) sparks or lighted tobacco away from fuel and oil.
[Figure 10-100-1]. Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
Figure 10-100-4 W-2103-1285

Replacing Hydraulic Fluid

Early Models

Figure 10-100-5

P-52181

Remove the filter element (Item 1) [Figure 10-100-4].

IMPORTANT 2

P-52178
DO NOT recuperate the oil that is situated in the oil
filter.
Remove the fill cap (Item 1) [Figure 10-100-5].
Clean the surface of the filter housing where the seal
contacts the housing. Later Models
Put clean oil on the seal of the new filter element.
Figure 10-100-6
Install and hand tighten the filter element.

WARNING 1

Diesel fuel or hydraulic fluid under pressure can

penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496

S3537

Remove the fill / breather cap (Item 1) [Figure 10-100-6].

4852210 (07-06) 10-100-2 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)

Replacing Hydraulic/Hydrostatic Filter (Cont’d)

All Models

Figure 10-100-7

P-52179

Remove the reservoir drain plug (Item 1) [Figure 10-100-

7] behind the right front wheel and drain the fluid into a
container. Recycle or dispose of the fluid in an
environmentally safe manner. Reinstall the drain plug and
tighten.

Add fluid until it is at the center of the sight gauge (Item 2)

[Figure 10-100-5].

Install the fill cap.

4852210 (07-06) 10-100-3 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 10-100-4 Bobcat T2556 & T2566
SERVICE MANUAL
AXLES (FRONT AND REAR) (For S/N 363011001 - Draining Oil (Planetary Carrier)
363012000 and S/N 363111001 - 363112000)
See “SERVICE SCHEDULE” on page 10-50-1 for the
Checking Oil Level (Planetary Carrier) correct service interval.

Figure 10-110-1 Figure 10-110-2

Put the machine on a level surface with the plug Put the machine on a level surface with the plug
positioned as shown (Item 1) [Figure 10-110-1]. positioned as shown (Item 1) [Figure 10-110-2].

Remove the plug (Item 1) [Figure 10-110-1]. The oil level Remove the plug (Item 1) [Figure 10-110-2] and drain
should be at the bottom edge of the plug hole. into a container. Recycle or dispose of the used lubricant
in an environmentally safe manner.
Add gear lube through the hole if the oil level is below the
hole. (See “Capacities” on page SPEC-10-3 for capacity Reposition the plug hole and add gear lube until the lube
and type.) level is at the bottom edge of the plug hole (Item 1)
[Figure 10-110-1]. (See “Capacities” on page SPEC-10-
Install and tighten the plug. 3 for capacity and type.)

Repeat the procedure for the other side. Install and tighten the plug.

Repeat the procedure for the other side.

4852210 (07-06) 10-110-1 Bobcat T2556 & T2566

SERVICE MANUAL
AXLES (FRONT AND REAR) (For S/N 363011001 - Draining Oil (Rear Differential)
363012000 and S/N 363111001 - 363112000) (CONT'D)
See “SERVICE SCHEDULE” on page 10-50-1 for the
Checking Oil Level (Rear Differential) correct service interval.

Figure 10-110-3 Figure 10-110-4

With the machine on a level surface, remove the plug With the machine on a level surface remove the plug
(Item 1) [Figure 10-110-3]. The oil level should be at the (Item 1) [Figure 10-110-4] and drain the oil into a
bottom edge of the plug hole. container. Recycle or dispose of the used lubricant in an
environmentally safe manner. Install and tighten the plug.
Add oil through the hole if the oil level is below the hole.
(See “Capacities” on page SPEC-10-3 for capacity and Checking Oil Level (Front Differential)
type.)
Figure 10-110-5
Install and tighten the plug.

Put the machine on a level surface with the plugs

positioned as shown (Item 1) [Figure 10-110-5].

Remove the plugs (Item 1) [Figure 10-110-5]. The oil

level should be at the bottom edge of the plug hole.

Add oil through the hole if the oil level is below the hole.
(See “Capacities” on page SPEC-10-3 for capacity and
type.)

Install and tighten the plugs.

4852210 (07-06) 10-110-2 Bobcat T2556 & T2566

SERVICE MANUAL
AXLES (FRONT AND REAR) (For S/N 363011001 -
363012000 and S/N 363111001 - 363112000) (CONT’D)

Draining Oil (Front Differential)

See “SERVICE SCHEDULE” on page 10-50-1 for the

correct service interval.

Figure 10-110-6

With the machine on a level surface, remove the plug

(Item 1) [Figure 10-110-6] and drain into a container.
Recycle or dispose of the used lubricant in an
environmentally safe manner.

Install and tighten the plug.

4852210 (07-06) 10-110-3 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 10-110-4 Bobcat T2556 & T2566
SERVICE MANUAL
AXLES (FRONT AND REAR) (For S/N 363012001 and Draining Oil (Planetary Carrier)
Above, S/N 363112001 and Above)
See “SERVICE SCHEDULE” on page 10-50-1 for the
Checking Oil Level (Planetary Carrier) correct service interval.

Figure 10-111-1 Figure 10-111-2

S1852 1 S1852

Put the machine on a level surface with the plug Put the machine on a level surface with the plug
positioned as shown (item 1) [Figure 10-111-1]. positioned as shown (item 1) [Figure 10-111-2].
Remove the plug (item 1) [Figure 10-111-1]. The oil level Remove the plug (item 1) [Figure 10-111-2] and drain into
should be at the bottom edge of the plug hole. a container. Recycle or dispose of the used lubricant in an
environmentally safe manner.
Add gear lube through the hole if the oil level is below the
hole. (See “Capacities” on page SPEC-10-3 for capacity Reposition the plug hole and add gear lube until the lube
and type.) level is at the bottom edge of the plug hole (item 1)
[Figure 10-111-1]. (See “Capacities” on page SPEC-10-
Install and tighten the plug. 33 for capacity and type)
Repeat the procedure for the other side. Install and tighten the plug.

Repeat the procedure for the other side.

4852210 (07-06) 10-111-1 Bobcat T2556 & T2566

SERVICE MANUAL
AXLES (FRONT AND REAR) (For S/N 363012001 and Draining Oil (Rear Differential)
Above, S/N 363112001 and Above) (CONT’D)
See “SERVICE SCHEDULE” on page 10-50-1 for the
Checking Oil Level (Rear Differential) correct service interval.

Figure 10-111-3 Figure 10-111-4

S2067
S2067

With the machine on a level surface, remove the plug

With the machine on a level surface remove the plug (item
(item 1) [Figure 10-111-3]. The oil level should be at the
1) [Figure 10-111-4] and drain the oil into a container.
bottom edge of the plug hole.
Recycle or dispose of the used lubricant in an
environmentally safe manner. Install and tighten the plug.
Add oil through the hole if the oil level is below the hole.
(See “Capacities” on page SPEC-10-3 for capacity and
Checking Oil Level (Front Differential)
type.)
Figure 10-111-5
Install and tighten the plug.

DSC05881

Put the machine on a level surface with the plugs

positioned as shown (item 1) [Figure 10-111-5].

Remove the plugs (item 1) [Figure 10-111-5]. The oil

level should be at the bottom edge of the plug hole.

Add oil through the hole if the oil level is below the hole.
(See “Capacities” on page SPEC-10-3 for capacity and
type.)

Install and tighten the plugs.

4852210 (07-06) 10-111-2 Bobcat T2556 & T2566

SERVICE MANUAL
AXLES (FRONT AND REAR) (For S/N 363012001 and Draining Oil (Drive Box)
Above, S/N 363112001 and Above) (Cont'd)
See “SERVICE SCHEDULE” on page 10-50-1 for the
Draining Oil (Front Differential) correct service interval.

See “SERVICE SCHEDULE” on page 10-50-1 for the Figure 10-111-8

correct service interval.

Figure 10-111-6

S2068

S2069
With the machine on a level surface, remove the plug
(item 1) [Figure 10-111-6] and drain into a container.
Recycle or dispose of the used lubricant in an
With the machine on a level surface, remove the plug environmentally safe manner.
(item 1) [Figure 10-111-6] and drain into a container.
Recycle or dispose of the used lubricant in an Install and tighten the plug.
environmentally safe manner.

Install and tighten the plug.

Checking Oil Level (Drive Box)

Figure 10-111-7

S2086

Put the machine on a level surface with the plugs

positioned as shown (item 1) [Figure 10-111-5].

Remove the plugs (item 1) [Figure 10-111-5]. The oil

level should be at the bottom edge of the plug hole.

Add oil through the hole if the oil level is below the hole.
(See “Capacities” on page SPEC-10-3 for capacity and
type.)

Install and tighten the plugs.

4852210 (07-06) 10-111-3 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 10-111-4 Bobcat T2556 & T2566
SERVICE MANUAL
LUBRICATION (For S/N 363011001 - 363012000 and S/ Figure 10-120-3
N 363111001 - 363112000)
FRONT REAR
Procedure

Lubricate as specified (See “SERVICE SCHEDULE” on

page 10-50-1) for the best performance of the machine. 1

Record the operating hours each time you lubricate so

that it is performed at the correct interval.

Always use a good quality lithium based multi-purpose

grease. Apply lubricant until extra grease shows.

Lubricate the following locations on the Telescopic

Handler:

Figure 10-120-1
3. Axle Oscillation - Front and Rear Axle (Item 1) [Figure
10-120-3].

Figure 10-120-4

1. Axle Pivots - Top and bottom (Item 1) [Figure 10-120-

1] all four wheels.

Figure 10-120-2
4. Attachment Frame Pivot (Item 1) [Figure 10-120-4].
(Both sides)

2. Universal Joints - Front and Rear (Item 1) [Figure 10-

120-2].

4852210 (07-06) 10-120-1 Bobcat T2556 & T2566

SERVICE MANUAL
LUBRICATION (For S/N 363011001 - 363012000 and S/ Figure 10-120-7
N 363111001 - 363112000) (CONT'D)

Procedure (Cont’d)

Figure 10-120-5

7. Lift Cylinder Base End, Slave Cylinder Rod End (Item

1) [Figure 10-120-7].

Figure 10-120-8

5. Tilt Cylinder Base End (Item 1) [Figure 10-120-5].

Figure 10-120-6

8. Lift Cylinder Rod End, Slave Cylinder Base End (Item

1) [Figure 10-120-8].

6. Tilt Cylinder Rod End (Item 1) [Figure 10-120-6].

NOTE: Raise the boom and install Boom Stop (See

“Installing The Approved Boom Stop” on
page 10-150-1) before lubricating the Boom
and slave Cylinders.

4852210 (07-06) 10-120-2 Bobcat T2556 & T2566

SERVICE MANUAL
LUBRICATION (For S/N 363011001 - 363012000 and S/ Figure 10-120-11
N 363111001 - 363112000) (CONT'D)

Procedure (Cont’d) 1

Figure 10-120-9

P-52182

11. Cab door hinges (Item 1) [Figure 10-120-11] (Lower).

Figure 10-120-12

9. Boom Pivot (Item 1) [Figure 10-120-9] (Four Places).

Figure 10-120-10

1
12. Boom Slide [Figure 10-120-12] (Four Places).

P-52183

10. Cab Door Hinges (Item 1) [Figure 10-120-10] (Upper).

4852210 (07-06) 10-120-3 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 10-120-4 Bobcat T2556 & T2566
SERVICE MANUAL
LUBRICATION (For S/N 363012001 & Above and Figure 10-121-3
S/N 363112001 & Above)

Procedure

Lubricate as specified (See “SERVICE SCHEDULE” on

page 10-50-1) for the best performance of the machine.

Record the operating hours each time you lubricate so

that it is performed at the correct interval.
1
Always use a good quality lithium based multi-purpose
grease. Apply lubricant until extra grease shows.

Lubricate the following locations on the Telescopic

Handler: S2063

Figure 10-121-1
3. Universal Joints Front (item 1) [Figure 10-121-3]
(earlier models only).
1
Figure 10-121-4

1 S2054

1. Axle Pivots - Top and bottom (item 1) [Figure 10-121-

1] all four wheels.

Figure 10-121-2 4. Attachment Frame Pivot (item 1) [Figure 10-121-4].

(Both sides)

1
2

S2054

2. Universal Joints Rear (item 1) (earlier models only)

and Axle oscillation Rear (item 2) [Figure 10-121-2].

4852210 (07-06) 10-121-1 Bobcat T2556 & T2566

SERVICE MANUAL
LUBRICATION (For S/N 363011001 - 363012000 Figure 10-121-7
and S/N 363111001 - 363112000) (CONT’D)

Procedure (Cont’d)

Figure 10-121-5

10-20-1-8

7. Lift Cylinder Base End, Slave Cylinder Rod End (item

1) [Figure 10-121-7].

Figure 10-121-8

5. Tilt Cylinder Base End (item 1) [Figure 10-121-5].

Figure 10-121-6

8. Lift Cylinder Rod End, Slave Cylinder Base End (item

1) [Figure 10-121-8].

6. Tilt Cylinder Rod End (item 1) [Figure 10-121-6].

NOTE: Raise the boom and install Boom Stop (See

“Installing The Approved Boom Stop” on
page 10-150-1) before lubricating the Boom
and slave Cylinders.

4852210 (07-06) 10-121-2 Bobcat T2556 & T2566

SERVICE MANUAL
LUBRICATION (For S/N 363011001 - 363012000 Figure 10-121-11
and S/N 363111001 - 363112000) (CONT’D)

Procedure (Cont’d) 1

Figure 10-121-9

P-52182

11. Cab door hinges (item 1) [Figure 10-121-11] (Lower).

Figure 10-121-12

9. Boom Pivot (item 1) [Figure 10-121-9] (Four Places).

Figure 10-121-10

1
12. Boom Slide [Figure 10-121-12] (Four Places).

P-52183

10. Cab Door Hinges (item 1) [Figure 10-121-10] (Upper).

4852210 (07-06) 10-121-3 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 10-121-4 Bobcat T2556 & T2566
SERVICE MANUAL
TIRE MAINTENANCE Tire Rotation

Wheel Nuts (For S/N 363011001 - 363012000 and S/N Check the tires regularly for wear, damage and pressure.
363111001 - 363112000) (See “Tires” on page SPEC-10-3 for the correct tire
pressure.)
Figure 10-130-1
Rear tires usually wear faster than front tires. To keep the
wear even, move the front tires to the rear and rear tires to
the front.

It is important to keep the same size tires on each side of

the Telescopic Handler. If different sizes are used, each
tire will be turning at a different rate and cause excessive
wear. The tread bars of all the tires must face the same
direction.

Recommended tire pressure must be maintained to avoid

excessive tire wear and loss of stability and handling
capability. Check for the correct pressure before operating
the Telescopic Handler.

Tire Mounting
See “SERVICE SCHEDULE” on page 10-50-1 for the
service interval to check the wheel nuts. The correct
torque is 221 ft.-lbs. (300 Nm) torque [Figure 10-130-1].

Wheel Nuts (For S/N 3630 12001 and Above, S/N 3631 WARNING
12001 and Above)
Do not inflate tires above specified pressure. Failure
Figure 10-130-2 to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1285

Tires are to be repaired only by an authorized person

using the correct procedures and type of equipment.

Tires and rims must always be checked for correct size

before mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire
bead and rim flange must be lubricated with a rubber
lubricant before mounting the tire.

Avoid excessive pressure which can rupture the tire and

S2005 cause serious injury or death.

During inflation of the tire, check the tire pressure

See “SERVICE SCHEDULE” on page 10-50-1 for the frequently to avoid over inflation.
service interval to check the wheel nuts. The correct
torque is 221 ft.-lbs. (300 Nm) torque [Figure 10-130-2].

4852210 (07-06) 10-130-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 10-130-2 Bobcat T2556 & T2566
SERVICE MANUAL
OPTIONAL APPROVED BOOM STOP Figure 10-150-2

If the boom is raised for service or maintenance, use the

following procedure to install and remove the boom stop.

Installing The Approved Boom Stop

• Put the Telescopic Handler on a flat, solid and level

surface.

• With the operator in the seat, the seat belt fastened,

Travel Direction Control and the parking brake
engaged, start the engine and raise the boom and stop
the engine.

Figure 10-150-1

• Install the boom stop over the rod of the boom cylinder
(the larger one) [Figure 10-150-2].

• Install the pins and secure with fasteners [Figure 10-

150-2].

• Start the engine and lower the boom slowly [Figure

10-150-2] so that the boom stop is held securely.

Removing The Approved Boom Stop

• Start the engine and raise the boom. Stop the engine.

• Remove the fasteners, pins and boom stop.

• Have a second person remove the boom stop (Item 1) • Put the boom stop in the storage position and secure
[Figure 10-150-1] from the storage position. with pins and fasteners.

• Start the engine and lower the boom

4852210 (07-06) 10-150-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 10-150-2 Bobcat T2556 & T2566
SERVICE MANUAL
ENGINE COVER Newer models:

Opening And Closing The Engine Cover Figure 10-160-2

WARNING
AVOID INJURY OR DEATH
Never service or adjust the machine when the engine
1
is running unless instructed to do so in the manual.
W-2012-0497

Older models:

Figure 10-160-1
S2753

Pull up on the latch handle (Item 1) [Figure 10-160-2] and

rotate counterclockwise to release latch. Raise the engine
cover.

Close the engine cover before operating the Telescopic

Handler.

Release the latch (Item 1) [Figure 10-160-1] and raise

the engine cover.

Close the engine cover before operating the Telescopic

Handler.

4852210 (07-06) 10-160-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 10-160-2 Bobcat T2556 & T2566
SERVICE MANUAL
HYDRAULIC SYSTEM

ACCUMULATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-1

BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1 HYDRAULIC

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-2 SYSTEM
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

BUCKET POSITIONING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-7
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

DRIVE BOX (FOR S/N 363011001 - 363012000 AND S/N 363111001 -

363112000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-2
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-7
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

DRIVE BOX (FOR S/N 363012001 AND ABOVE, S/N 363112001 AND
ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-6
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-2

EXTENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17
Cylinder Group Removal And Installation . . . . . . . . . . . . . . . . . . . 20-40-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
Extension Cylinder Removal And Installation . . . . . . . . . . . . . . . . 20-40-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Tubeline Tray Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-9
Tubeline Tray Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-8
Upper Tubeline Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
Upper Tubeline Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-3

FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

Disassembly And Assembly (1 speed version) . . . . . . . . . . . . . . 20-140-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

FLOW CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-240-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-240-1

Continued On Next Page

4852210 (07-06) 20-01-1 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC SYSTEM (CONT’D)

FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE . 20-230-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230-1

GEAR PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1

Auxiliary Valve Section Disassembly And Assembly . . . . . . . . . 20-170-40
Auxiliary Valve Section Troubleshooting . . . . . . . . . . . . . . . . . . . 20-170-6
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-16
End Housing Disassembly And Assembly . . . . . . . . . . . . . . . . . 20-170-17
Inlet-Outlet Valve Section Disassembly And Assembly . . . . . . . 20-170-51
Lifting Valve Section Disassembly And Assembly . . . . . . . . . . . 20-170-18
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-15
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-11
Telescoping Valve Section Disassembly And Assembly . . . . . . 20-170-28
Telescoping Valve Section Troubleshooting. . . . . . . . . . . . . . . . . 20-170-2
Tilting Valve Section Disassembly And Assembly . . . . . . . . . . . 20-170-23
Troubleshooting Chart (Controllers). . . . . . . . . . . . . . . . . . . . . . . 20-170-1
Troubleshooting Chart (Control Valve). . . . . . . . . . . . . . . . . . . . 20-170-10

HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Tightening Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-4

JOYSTICK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-1

LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-7
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

When repairing hydrostatic and hydraulic systems, clean the work area
before disassembly and keep all parts clean. Always use caps and plugs
on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the
system.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-2
Testing And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Continued On Next Page

4852210 (07-06) 20-01-2 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC SYSTEM (CONT’D)

PARKING BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-190-1

Parking Brake Valve Disassembly And Assembly. . . . . . . . . . . . 20-190-3
Parking Brake Valve Removal And Installation . . . . . . . . . . . . . . 20-190-2

PORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

PILOT PRESSURE LOCK OUT VALVE . . . . . . . . . . . . . . . . . . . . . . 20-200-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-3
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-1

QUICK TACH CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-4
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-3
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

STEERING CYLINDER (FRONT) (FOR S/N 363011001 -363012000 AND S/

N 363111001 - 363012000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-3
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

STEERING CYLINDER (FRONT) (FOR S/N 363012001 AND ABOVE, S/N

363112001 AND ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Assembling the Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-7
Disassembling the Steering Cylinder. . . . . . . . . . . . . . . . . . . . . . . 20-61-6
Installing the Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-2
Removing the Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1

STEERING CYLINDER (REAR) (FOR S/N 363011001 - 363012000 AND S/N

363111001 - 363112000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-4
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-3
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1

STEERING CYLINDER (REAR) (FOR S/N 363012001 AND ABOVE, S/N

363112001 AND ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-1
Assembling the Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-8
Disassembling the Steering Cylinder. . . . . . . . . . . . . . . . . . . . . . . 20-63-6
Installing the Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-2
Removing the Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-1

Continued On Next Page

4852210 (07-06) 20-01-3 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC SYSTEM (CONT’D)

STEERING MODE VALVE BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-6

STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-9
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1

TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

OPTIONAL TOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-1

4852210 (07-06) 20-01-4 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC SYSTEM INFORMATION

mc-2340

4852210 (07-06) 20-10-1 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC SYSTEM INFORMATION (CONT’D)

mc-2340
2

4852210 (07-06) 20-10-2 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC SYSTEM INFORMATION (CONT’D)

mc-2340
3

4852210 (07-06) 20-10-3 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC SYSTEM INFORMATION (CONT’D)

Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285

PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 6
The hydraulic oil temperature warning light comes ON when hydraulics are operating. 1, 2
Slow hydraulic system action. 1, 2, 4, 8
Hydraulic action is not smooth. 1, 3, 4, 5
Boom goes up slowly at full engine RPM. 1, 2, 4, 5, 6, 7
The boom comes down with the lever in neutral position. 7, 8, 9

KEY TO CORRECT THE CAUSE

1. The fluid level is not correct..
2. The hydraulic pump has damage.
3. Relief valve is not at the correct pressure.
4. Suction leak on the inlet side of the hydraulic pump.
5. Fluid is cold. Wrong viscosity fluid.
(See “HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS” on page SPEC-60-1)
6. Using the machine for more than its rated capacity.
7. Internal leak in the lift cylinder.
8. External leak from the cylinder(s).
9. Damaged lift spool.

4852210 (07-06) 20-10-4 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC SYSTEM INFORMATION (CONT’D)

Tightening Procedures

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

To tighten the hydraulic fittings, tubelines etc. See

“HYDRAULIC CONNECTION SPECIFICATIONS” on
page SPEC-50-1, for the correct procedure and torque.

WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290

4852210 (07-06) 20-10-5 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 20-10-6 Bobcat T2556 & T2566
SERVICE MANUAL
LIFT CYLINDER Figure 20-20-3

Removal And Installation

Figure 20-20-1

Remove the rod end pivot pin retainer pin (Item 1) [Figure
20-20-3].

Figure 20-20-4
Raise the boom and support on adequate stands [Figure
20-20-1].

Figure 20-20-2

Support both cylinders using a cinch strap (Item 1)

[Figure 20-20-4].
P-52743

Remove the rear cover (Item 1) [Figure 20-20-2] from the

Telescopic Handler.

4852210 (07-06) 20-20-1 Bobcat T2556 & T2566

SERVICE MANUAL
LIFT CYLINDER (CONT'D) Figure 20-20-6

Removal And Installation (Cont'd)

Figure 20-20-5

1. Rotate the battery disconnect switch (Item 1) [Figure

20-20-6] to the right to disconnect the power supply
from the battery.

Remove the upper pivot pin using a pin removal tool (Item Figure 20-20-7
1) [Figure 20-20-5].

WARNING
Eye and body protection is required when welding or
grinding. Wear approved goggles, helmet and
clothing. Failure to wear eye and body protection can
result in serious injury.
W-2009-1285

NOTE: If a nut must be welded onto the pin for

removal, the following three steps must be
performed.
2. The side window (Item 1) and frame openings (Item 2)
[Figure 20-20-7] must be protected from sparks.

4852210 (07-06) 20-20-2 Bobcat T2556 & T2566

SERVICE MANUAL
LIFT CYLINDER (CONT'D) Figure 20-20-10

Removal And Installation (Cont'd)

Figure 20-20-8

Lower both cylinders onto a wood block (Item 1) [Figure

20-20-10].

Figure 20-20-11
3. The cylinder rod must be wrapped with a damp
welding blanket (Item 1) [Figure 20-20-8] to prevent
damage.

Figure 20-20-9

Remove the two hoses (Item 1) [Figure 20-20-11] from

the load lock.

NOTE: Mark the hoses for correct installation.

Lift and support the cylinders using a hoist and lifting strap
(Item 1). Remove the cinch strap (Item 2) [Figure 20-20-
9].

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

4852210 (07-06) 20-20-3 Bobcat T2556 & T2566

SERVICE MANUAL
LIFT CYLINDER (CONT'D) Figure 20-20-15

Removal And Installation (Cont'd)

Figure 20-20-12

Lift and remove both cylinders from the Telescopic

Handler [Figure 20-20-15].

NOTE: Protect the side window from possible

Remove the two hoses (Item 1) [Figure 20-20-12] from damage.
the cylinder.

Figure 20-20-13

Remove the base end pivot pin retainer bolt (Item 1)

[Figure 20-20-13].

Figure 20-20-14

Remove the base end pivot pin [Figure 20-20-14].

4852210 (07-06) 20-20-4 Bobcat T2556 & T2566

SERVICE MANUAL
LIFT CYLINDER (CONT'D)

Removal And Installation (Cont’d)

Figure 20-20-16

Remove the bolt and nut (Item 1) [Figure 20-20-16] and

separate the lift cylinder and bucket positioning cylinder.

4852210 (07-06) 20-20-5 Bobcat T2556 & T2566

SERVICE MANUAL
LIFT CYLINDER (CONT'D)

Parts Identification

1. Bushing
2. Grease Fitting
3. Housing
4. Wear Ring
5. Expander O-ring
6. Seal
7. Piston
8. O-ring
9. Backup Ring
10. Head Gland
11. Wiper Seal
12. Rod

4852210 (07-06) 20-20-6 Bobcat T2556 & T2566

SERVICE MANUAL
LIFT CYLINDER (CONT'D) Figure 20-20-19

Disassembly

Use the following tools to disassemble the cylinder:

MEL1074-O-ring Seal Hook

MEL1353-Cylinder Gland Nut Wrench

Clean the outside of the lift cylinder before disassembly.

Figure 20-20-17

Carefully peen the lock ring from the head gland [Figure
20-20-19].

Figure 20-20-20

Put the cylinder in a vise [Figure 20-20-17].

Figure 20-20-18

Loosen the head gland [Figure 20-20-20].

Remove the four bolts (Item 1) and remove the load lock
(Item 2) [Figure 20-20-18].

4852210 (07-06) 20-20-7 Bobcat T2556 & T2566

SERVICE MANUAL
LIFT CYLINDER (CONT'D) Figure 20-20-23

Disassembly (Cont'd)

Figure 20-20-21

Remove the set screw (Item 1) [Figure 20-20-23] from

the piston.

Figure 20-20-24
Remove the rod assembly (Item 1) [Figure 20-20-21]
from the housing.

Figure 20-20-22

Support the cylinder rod on a wood block and remove the

piston [Figure 20-20-24].

Put the rod end of the cylinder rod in a vise [Figure 20-20-
22].

4852210 (07-06) 20-20-8 Bobcat T2556 & T2566

SERVICE MANUAL
LIFT CYLINDER (CONT'D) Figure 20-20-28

Disassembly (Cont'd)

Figure 20-20-25

Remove the head gland (Item 1) [Figure 20-20-28] from

the rod.

Remove the two wear rings (Item 1) and seal (Item 2)

[Figure 20-20-25] from the piston.

Figure 20-20-26

Remove the expander O-ring (Item 1) [Figure 20-20-26].

Figure 20-20-27

Remove the O-ring (Item 1) [Figure 20-20-27] from the

piston.

4852210 (07-06) 20-20-9 Bobcat T2556 & T2566

SERVICE MANUAL
LIFT CYLINDER (CONT'D)

Disassembly (Cont'd)

Figure 20-20-29

Remove the two O-rings (Item 1) and backup ring (Item 2)

[Figure 20-20-29] from the head gland.

Figure 20-20-30

Remove the wear ring (Item 1) [Figure 20-20-30].

Figure 20-20-31

Remove the seal (Item 1), wear ring (Item 2) and wiper
(Item 3) [Figure 20-20-31].

4852210 (07-06) 20-20-10 Bobcat T2556 & T2566

SERVICE MANUAL
LIFT CYLINDER (CONT'D) Figure 20-20-34

Assembly

Use the following tools to assemble the cylinder:

MEL1033-Rod Seal Installation Tool

MEL1353-Cylinder Gland Nut Wrench

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

Figure 20-20-32 Install the center seal (Item 1) [Figure 20-20-34].

NOTE: The groove in the seal must point away from

the wiper seal (Item 1) [Figure 20-20-32].

Figure 20-20-35

Install the wiper (Item 1), wear ring (Item 2) and seal (Item
3) [Figure 20-20-32] into the head gland.

Figure 20-20-33

Install the two O-rings (Item 1) and backup ring (Item 2)

[Figure 20-20-35].

Install the wear ring (Item 1) [Figure 20-20-33].

4852210 (07-06) 20-20-11 Bobcat T2556 & T2566

SERVICE MANUAL
LIFT CYLINDER (CONT'D) Figure 20-20-39

Assembly (Cont'd)

Figure 20-20-36

Install the two wear rings (Item 1) and seal (Item 2)

[Figure 20-20-39] onto the piston.

Install the head gland (Item 1) [Figure 20-20-36] onto the

rod.

Figure 20-20-37

Install the O-ring (Item 1) [Figure 20-20-37] in the piston.

Figure 20-20-38

Install the expander O-ring (Item 1) [Figure 20-20-38] on

the piston.

4852210 (07-06) 20-20-12 Bobcat T2556 & T2566

SERVICE MANUAL
LIFT CYLINDER (CONT'D) Figure 20-20-42

Assembly (Cont'd)

Figure 20-20-40

Install and tighten the set screw (Item 1) [Figure 20-20-

42].

Figure 20-20-43
Clean off any old residue, and apply LOCTITE 242 or
equivalent to the threads on the rod [Figure 20-20-40].

Figure 20-20-41

Install the rod assembly (Item 1) [Figure 20-20-43] into

the housing.

Install the piston (Item 1) [Figure 20-20-41] on the rod

and tighten.

4852210 (07-06) 20-20-13 Bobcat T2556 & T2566

SERVICE MANUAL
LIFT CYLINDER (CONT'D)

Assembly (Cont'd)

Figure 20-20-44

Tighten the head gland [Figure 20-20-44].

Figure 20-20-45

Peen the lock ring into the groove in the head gland
[Figure 20-20-45].

Figure 20-20-46

Install the load lock (Item 1) onto the cylinder and tighten
the four bolts (Item 2) [Figure 20-20-46].

4852210 (07-06) 20-20-14 Bobcat T2556 & T2566

SERVICE MANUAL
BUCKET POSITIONING CYLINDER Figure 20-30-3

Removal And Installation

Figure 20-30-1

Remove the rod end pivot pin retainer pin (Item 1) [Figure
20-30-3].

Figure 20-30-4
Raise the boom and support on adequate stands [Figure
20-30-1].

Figure 20-30-2

Support both cylinders using a cinch strap (Item 1)

[Figure 20-30-4].
P-52743

Remove the rear cover (Item 1) [Figure 20-30-2] from the

machine.

4852210 (07-06) 20-30-1 Bobcat T2556 & T2566

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-6

Removal And Installation (Cont'd)

Figure 20-30-5

1. Rotate the battery disconnect switch (Item 1) [Figure

20-30-6] to the right to disconnect the power supply
from the battery.

Remove the upper pivot pin using a pin removal tool (Item Figure 20-30-7
1) [Figure 20-30-5].

WARNING
Eye and body protection is required when welding or
grinding. Wear approved goggles, helmet and
clothing. Failure to wear eye and body protection can
result in serious injury.
W-2009-1285

NOTE: If a nut must be welded onto the pin for removal

the following three steps must be performed.

2. The side window (Item 1) and frame openings (Item 2)

[Figure 20-30-7] must be protected from sparks.

4852210 (07-06) 20-30-2 Bobcat T2556 & T2566

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-10

Removal And Installation (Cont'd)

Figure 20-30-8

Lower both cylinders onto a wood block (Item 1) [Figure

20-30-10].

3. The cylinder rod must be wrapped with a damp

welding blanket (Item 1) [Figure 20-30-8] to prevent
damage. IMPORTANT
Figure 20-30-9 When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure 20-30-11

Lift and support the cylinders using a hoist and lifting strap
(Item 1). Remove the cinch strap (Item 2) [Figure 20-30-
9].

Remove the two hoses (Item 1) [Figure 20-30-11] from

the load lock.

NOTE: Mark the hoses for correct installation.

4852210 (07-06) 20-30-3 Bobcat T2556 & T2566

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-15

Removal And Installation (Cont'd)

Figure 20-30-12

Lift and remove both cylinders from the Telescopic

Handler [Figure 20-30-15].

NOTE: Protect the side window from possible damage.

Remove the two hoses (Item 1) [Figure 20-30-12] from
the cylinder.

Figure 20-30-13

Remove the base end pivot pin retainer bolt (Item 1)

[Figure 20-30-13].

Figure 20-30-14

Remove the base end pivot pin [Figure 20-30-14].

4852210 (07-06) 20-30-4 Bobcat T2556 & T2566

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D)

Removal And Installation (Cont'd)

Figure 20-30-16

Remove the bolt and nut (Item 1) [Figure 20-30-16] and

separate the lift cylinder and bucket positioning cylinder.

4852210 (07-06) 20-30-5 Bobcat T2556 & T2566

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D)

Parts Identification

4852210 (07-06) 20-30-6 Bobcat T2556 & T2566

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-19

Disassembly

Use the following tools to disassemble the cylinder:

MEL1074-O-ring Seal Hook

MEL1353-Cylinder Gland Nut Wrench

Clean the outside of the bucket positioning cylinder before

disassembly.

Figure 20-30-17

Remove the head gland [Figure 20-30-19].

Figure 20-30-20

Put the cylinder in a vise [Figure 20-30-17].

Figure 20-30-18

Remove the rod assembly (Item 1) [Figure 20-30-20]

from the housing.

Carefully peen the lock ring from the head gland [Figure
20-30-18].

4852210 (07-06) 20-30-7 Bobcat T2556 & T2566

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-23

Disassembly (Cont'd)

Figure 20-30-21

Remove the piston assembly (Item 1) [Figure 20-30-23]

from the rod.

Figure 20-30-24
Put the rod end of the cylinder in a vise [Figure 20-30-
21].

Figure 20-30-22

Remove the two wear rings (Item 1) and seal (Item 2)

[Figure 20-30-24] from the piston.

Support the cylinder rod on a wood block and remove the

set screw (Item 1) [Figure 20-30-22] from the piston.

4852210 (07-06) 20-30-8 Bobcat T2556 & T2566

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-28

Disassembly (Cont'd)

Figure 20-30-25

Remove the center seal (Item 1) and outer wear ring (Item
2) [Figure 20-30-28].

Remove the expander O-ring (Item 1) [Figure 20-30-25].

Figure 20-30-26

Remove the O-ring (Item 1) [Figure 20-30-26] from the

piston.

Figure 20-30-27

Remove the head gland (Item 1) [Figure 20-30-27] from

the rod.

4852210 (07-06) 20-30-9 Bobcat T2556 & T2566

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-31

Disassembly (Cont'd)

Figure 20-30-29

Remove any residue from the threads on the cylinder rod

[Figure 20-30-31].

Remove the outer wear ring (Item 1) and wiper (Item 2)

[Figure 20-30-29].

Figure 20-30-30

Remove the two O-rings (Item 1) and backup ring (Item 2)

[Figure 20-30-30].

4852210 (07-06) 20-30-10 Bobcat T2556 & T2566

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-34

Assembly

Use the following tools to assemble the cylinder:

MEL1033-Rod Seal Installation Tool

MEL1353-Cylinder Gland Nut Wrench

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

Figure 20-30-32 Install the wear ring (Item 1) [Figure 20-30-34].

Figure 20-30-35

P-32361

Install the two O-rings (Item 1) and backup ring (Item 2)

[Figure 20-30-32] onto the head gland.
Install the center seal (Item 1) [Figure 20-30-35].
Figure 20-30-33
NOTE: The groove in the seal must point away from
the wiper seal (Item 1) [Figure 20-30-33].

Install the wiper (Item 1) and wear ring (Item 2) [Figure

20-30-33].

4852210 (07-06) 20-30-11 Bobcat T2556 & T2566

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-39

Assembly (Cont'd)

Figure 20-30-36

Install the two wear rings (Item 1) and seal (Item 2)

[Figure 20-30-39].

Install the head gland (Item 1) [Figure 20-30-36] onto the

rod.

Figure 20-30-37

Install the O-ring (Item 1) [Figure 20-30-37] in the piston.

Figure 20-30-38

Install the expander O-ring (Item 1) [Figure 20-30-38]

onto the piston.

4852210 (07-06) 20-30-12 Bobcat T2556 & T2566

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-43

Assembly (Cont'd)

Figure 20-30-40

Install the rod assembly (Item 1) [Figure 20-30-43] into

the housing.

Install the piston (Item 1) [Figure 20-30-40] onto the rod.

Figure 20-30-41

Apply LOCTITE 242 or equivalent to the set screw (Item

1) [Figure 20-30-41].

Figure 20-30-42

Install the set screw (Item 1) [Figure 20-30-42] into the

piston and tighten.

4852210 (07-06) 20-30-13 Bobcat T2556 & T2566

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D)

Assembly (Cont'd)

Figure 20-30-44

Tighten the head gland [Figure 20-30-44].

Figure 20-30-45

Carefully peen the lock ring over and into the nut [Figure
20-30-45].

4852210 (07-06) 20-30-14 Bobcat T2556 & T2566

SERVICE MANUAL
EXTENSION CYLINDER Figure 20-40-3

Cylinder Group Removal And Installation

Figure 20-40-1

Remove the two bolts (Item 1) [Figure 20-40-3] from the

top of the inner boom.

Installation: Tighten the bolts to 18 ft.-lbs. (24 Nm)

Remove the inner boom. (See “Removal” on page 50-40- torque.
1)
Figure 20-40-4
Remove the bolt (Item 1) and washer (Item 2) [Figure 20-
40-1] from one side of the cylinder pin.

Installation: Tighten the bolt to 188-210 ft.-lbs. (255-285

Nm) torque.

Figure 20-40-2

Remove the two hoses (Item 1) [Figure 20-40-4] from the

tubelines.

Remove the pin assembly (Item 1) [Figure 20-40-2] from

the opposite side.

4852210 (07-06) 20-40-1 Bobcat T2556 & T2566

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Figure 20-40-7

Cylinder Group Removal And Installation (Cont'd)

Figure 20-40-5

Remove the electrical harness (if equipped) (Item 1) from

the connector housing (Item 2) [Figure 20-40-7].

NOTE: Mark the connector housing for correct

Remove the two hoses (Item 1) [Figure 20-40-5] from the installation.
bulkhead fittings.
Figure 20-40-8
Figure 20-40-6

Remove the tie straps (if equipped) (Item 1) [Figure 20-

Remove the electrical connector (if equipped) (Item 1) 40-8] and pull the electrical harness into the boom.
[Figure 20-40-6] from the auxiliary valve.

4852210 (07-06) 20-40-2 Bobcat T2556 & T2566

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Upper Tubeline Removal

Cylinder Group Removal And Installation (Cont'd) Figure 20-40-11

Figure 20-40-9 1
1
1
1

P-47464

With the extension cylinder group supported on a work

For ease of installation temporarily tie a rope onto the two surface, remove the tie straps (Item 1) [Figure 20-40-11]
hoses (Item 1) and electrical harness (Item 2) [Figure 20- from the electrical harness.
40-9].
Figure 20-40-12
Figure 20-40-10

P-47465

Remove the extension cylinder assembly from the boom Roll up the electrical harness (Item 1) [Figure 20-40-12]
[Figure 20-40-10]. and temporarily tie to the existing hose.

4852210 (07-06) 20-40-3 Bobcat T2556 & T2566

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Figure 20-40-15

Upper Tubeline Removal (Cont’d)

Figure 20-40-13

1
Slide the tubeline bracket assembly (Item 1) forward.
Remove the four hoses (Item 2) [Figure 20-40-15] from
P-47467 the tubelines.

NOTE: Mark the hoses for correct assembly.

Remove the two tie straps (Item 1) [Figure 20-40-13]
from the hoses (both sides).
Figure 20-40-16
Figure 20-40-14

P-47466

Remove the bolt (Item 1) [Figure 20-40-16] from the rod

Loosen the tubeline clamp mounting bolts (Item 1) end of the cylinder.
[Figure 20-40-14].
Lift and remove the tubelines from the top of the cylinder.
NOTE: Mark the location of the tubelines for correct
assembly.

4852210 (07-06) 20-40-4 Bobcat T2556 & T2566

SERVICE MANUAL
EXTENSION CYLINDER (CONT’D) Figure 20-40-19

Upper Tubeline Installation

Set the tubeline assembly onto the extension cylinder and

install the bolt (Item 1) and tighten to secure the tubeline
clamp bracket (Item 2) [Figure 20-40-16] to the rod end of
the cylinder.

Figure 20-40-17
1
1
2

P-47468

Figure 20-40-20
2

2
2

P-23994

Slide the tubeline bracket (Item 1) forward. Install the four

hoses (Item 2) [Figure 20-40-17] on the tubelines. 1
Figure 20-40-18 1

P-47466
2
1
Measure the distance from the front of the tubeline
bracket (Item 1) [Figure 20-40-19] to the back of the
tubeline clamps (Item 1) [Figure 20-40-20]. The correct
measurement must be 49 inches (1244,6 mm) for all four
tubelines.

To move and adjust the tubeline clamps (Item 1) loosen

the bolts (Item 2) [Figure 20-40-20].

P-47684 When the tubeline clamps are in the correct position

tighten the bolts.

Slide the tubeline bracket back. Measure the distance

from the tubeline nut (Item 1) to the tubeline clamp (Item
2) [Figure 20-40-18].

The correct measurement must be 2.00 inches (50,8 mm)

for all four tubelines.

Tighten the tubeline clamps.

4852210 (07-06) 20-40-5 Bobcat T2556 & T2566

SERVICE MANUAL
EXTENSION CYLINDER (CONT’D) Extension Cylinder Removal And Installation

Upper Tubeline Installation (Cont’d) Figure 20-40-23

Figure 20-40-21

1 1

1
P-47459

P-47467
Remove the six tie straps (Item 1) [Figure 20-40-23]
securing the electrical harness to the hose.
Install two tie straps (Item 1) [Figure 20-40-21] (both
sides) to secure the hoses to the tubeline bracket. Figure 20-40-24

Figure 20-40-22 1

1 1 1 3
1

2
2
2

P-47460

P-47464
Remove the three bolts (Item 1) and tubeline clamps (Item
2) from the cylinder. Remove the bracket (Item 3) [Figure
Secure the electrical harness to the inner tubeline (Item 1) 20-40-24].
using tie straps (Item 2) [Figure 20-40-22] approximately
every 6-8 inches (152-203 mm).

4852210 (07-06) 20-40-6 Bobcat T2556 & T2566

SERVICE MANUAL
EXTENSION CYLINDER (CONT’D) Figure 20-40-27

Extension Cylinder Removal And Installation (Cont’d)

Figure 20-40-25
2
1
2

P-47463
1
1
Remove the bolt (Item 1) and tubeline clamp (Item 2)
P-23997 [Figure 20-40-27] from both sides of the cylinder.

Figure 20-40-28
Remove the two tubelines (Item 1) from the load lock
(Item 2) [Figure 20-40-25].

Figure 20-40-26

P-47488

Slide the extension cylinder through the tubelines [Figure

P-47462 20-40-28] and remove the cylinder.

NOTE: It may be necessary to reposition the lifting

Install a hoist (Item 1) [Figure 20-40-26] to lift and support strap.
the extension cylinder.

4852210 (07-06) 20-40-7 Bobcat T2556 & T2566

SERVICE MANUAL
EXTENSION CYLINDER (CONT’D) Figure 20-40-31

Tubeline Tray Disassembly

Figure 20-40-29

1
1
1
1

P-47491

Remove the four hoses (Item 1) [Figure 20-40-31] from

P-47489 the tubelines.

NOTE: Mark the hoses for correct assembly.

Remove the tie straps (Item 1) [Figure 20-40-29]
securing the electrical harness to the hoses. Figure 20-40-32

Figure 20-40-30

2 1
1
2

P-47492

2
P-47490
Straighten the two tabs (Item 1) (both ends) and remove
the cover (Item 2) [Figure 20-40-32].
Remove the two bolts (Item 1) and tubeline mounting
brackets (Item 2) [Figure 20-40-30].

4852210 (07-06) 20-40-8 Bobcat T2556 & T2566

SERVICE MANUAL
EXTENSION CYLINDER (CONT’D) Tubeline Tray Assembly

Tubeline Tray Disassembly (Cont’d) Figure 20-40-35

Figure 20-40-33

1 6
5

2
2

4
P-27930

P-27932
Figure 20-40-36

Remove the tie strap (Item 1) from both ends of the 1

electrical harness (Item 2) [Figure 20-40-33]. Remove 5
the electrical harness.

Figure 20-40-34 2 4

P-27931

Place the tubelines (Item 1) and (Item 2) next to each

other on the left side of the tray (Item 6) [Figure 20-40-35]
& [Figure 20-40-36].
1
P-27930
NOTE: The notch (Item 3) [Figure 20-40-35] represents
the front of the tray.
Remove the tubelines (Item 1) [Figure 20-40-34].
Place the tubelines (Item 4) and (Item 5) next to each
other on the right side of the tray (Item 6) [Figure 20-40-
35] & [Figure 20-40-36].

4852210 (07-06) 20-40-9 Bobcat T2556 & T2566

SERVICE MANUAL
EXTENSION CYLINDER (CONT’D) Figure 20-40-39

Tubeline Tray Assembly (Cont’d)

Figure 20-40-37 1
4
6

2
5
2
1
3
P-27934

Install the hose/harness assembly (Item 1) [Figure 20-40-

P-27932 39] on the tubelines on the right side of the tray.

NOTE: The hose (Item 2) must be connected to the

Place the electrical harness (Item 1) in the center of the outside tubeline (Item 3) [Figure 20-40-39].
two tubelines on the right side and secure using a tie strap
(Item 2) [Figure 20-40-37] on each end of the tubelines. Apply LOCTITE #271 onto the bolt (Item 4) and install the
hose bracket (Item 5) [Figure 20-40-39].
Figure 20-40-38
NOTE: Do not overtighten the bolt or damage will be
done to the tubelines below.
1
Install a tie strap (Item 6) [Figure 20-40-39] on the
electrical harness.

P-27933

With the tubelines held in position, install the tray cover

(Item 1) on the tray. Bend the two tabs (Item 2) [Figure
20-40-38] on each end of the tray cover.

4852210 (07-06) 20-40-10 Bobcat T2556 & T2566

SERVICE MANUAL
EXTENSION CYLINDER (CONT’D) Figure 20-40-41

Tubeline Tray Assembly (Cont’d)

Figure 20-40-40 1 1
4 1
2

5
1

P-47489

Install new tie straps (Item 1) [Figure 20-40-41]

P-27935 approximately every 6-8 inches (152-203 mm) to secure
the electrical harness to the hose.

Install the hose assembly (Item 1) [Figure 20-40-40] on

the two tubelines on the left side of the tray.

NOTE: The hose (Item 2) must be connected to the

inside tubeline (Item 3) [Figure 20-40-40].

Apply LOCTITE #271 on the bolt (Item 4) and install the

hose bracket (Item 5) [Figure 20-40-40].

NOTE: Do not overtighten the bolt or damage will be

done to the tubelines below.

4852210 (07-06) 20-40-11 Bobcat T2556 & T2566

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D)

Parts Identification

4852210 (07-06) 20-40-12 Bobcat T2556 & T2566

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Figure 20-40-44

Disassembly

Use the following tool to disassemble the cylinder:

MEL1074-O-ring Seal Hook

Clean the outside of the extension cylinder before

disassembly.

Mark the outside of the extension cylinder for ease of

assembly.

Figure 20-40-42

Carefully peen the lock ring from the head gland [Figure
20-40-44].

Figure 20-40-45

Put the cylinder in a vise [Figure 20-40-42].

Figure 20-40-43

Loosen the head gland [Figure 20-40-45].

Remove the two fittings (Item 1) and relief valves (Item 2)

[Figure 20-40-43].

4852210 (07-06) 20-40-13 Bobcat T2556 & T2566

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Figure 20-40-48

Disassembly (Cont'd)

Figure 20-40-46

Support the cylinder rod on a wood block [Figure 20-40-

48].

Figure 20-40-49
Remove the rod assembly (Item 1) [Figure 20-40-46]
from the housing.

Figure 20-40-47

Loosen the set screw (Item 1) [Figure 20-40-49].

Put the rod end of the cylinder in a vise [Figure 20-40-

47].

4852210 (07-06) 20-40-14 Bobcat T2556 & T2566

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Figure 20-40-53

Disassembly (Cont'd)

Figure 20-40-50

Remove the O-ring (Item 1) [Figure 20-40-53] from the

piston.

Remove the piston assembly (Item 1) [Figure 20-40-50]

from the rod.

Figure 20-40-51

Remove the two wear rings (Item 1) and the seal (Item 2)
[Figure 20-40-51] from the piston.

Figure 20-40-52

Remove the expander O-ring (Item 1) [Figure 20-40-52].

4852210 (07-06) 20-40-15 Bobcat T2556 & T2566

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Figure 20-40-56

Disassembly (Cont'd)

Figure 20-40-54

Remove the two O-rings (Item 1) and backup ring (Item 2)

[Figure 20-40-56].

Remove the head gland (Item 1) [Figure 20-40-54] from

the rod.

Figure 20-40-55

Remove the wiper (Item 1) and seal (Item 2) [Figure 20-

40-55] from the head gland.

4852210 (07-06) 20-40-16 Bobcat T2556 & T2566

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Figure 20-40-59

Assembly

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

Figure 20-40-57

Install the head gland (Item 1) [Figure 20-40-59] onto the

cylinder rod.

Figure 20-40-60

Install the two O-rings (Item 1) and backup ring (Item 2)

[Figure 20-40-57] on the head gland.

Figure 20-40-58

Install the O-ring (Item 1) [Figure 20-40-60] in the piston.

Install the wiper (Item 1) and seal (Item 2) [Figure 20-40-

58].

4852210 (07-06) 20-40-17 Bobcat T2556 & T2566

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Figure 20-40-64

Assembly (Cont'd)

Figure 20-40-61

Tighten the set screw (Item 1) [Figure 20-40-64].

Install the expander O-ring (Item 1) [Figure 20-40-61].

Figure 20-40-62

Install the two wear rings (Item 1) and seal (Item 2)

[Figure 20-40-62] onto the piston.

Figure 20-40-63

Install the piston (Item 1) [Figure 20-40-63] onto the rod

and hand tighten.

4852210 (07-06) 20-40-18 Bobcat T2556 & T2566

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Figure 20-40-68

Assembly (Cont'd)

Figure 20-40-65

Install the two fittings (Item 1) and two relief valves (Item
2) [Figure 20-40-68].

Install the rod assembly (Item 1) [Figure 20-40-65] in to

the housing.

Figure 20-40-66

Tighten the head gland [Figure 20-40-66].

Figure 20-40-67

Using a punch seat the lock ring to keep the head gland
from turning [Figure 20-40-67].

4852210 (07-06) 20-40-19 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 20-40-20 Bobcat T2556 & T2566
SERVICE MANUAL
TILT CYLINDER Figure 20-50-3

Removal And Installation

Figure 20-50-1

Install a lifting ring (Item 1) [Figure 20-50-3] and hoist to

the top of the cylinder.

Figure 20-50-4
Remove the quick tach assembly (See “QUICK TACH” on
page 50-90-1).

Raise the boom approximately 1-1/2 ft. and install a wood

block under the boom [Figure 20-50-1].

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

If equipped with secondary auxiliary hydraulics remove

Figure 20-50-2
the tubeline (Item 1) [Figure 20-50-4].

Remove the two hoses (Item 1) [Figure 20-50-2] from the

tubelines.

NOTE: Mark the hoses for correct installation.

4852210 (07-06) 20-50-1 Bobcat T2556 & T2566

SERVICE MANUAL
TILT CYLINDER (CONT'D)

Removal And Installation (Cont'd)

Figure 20-50-5

Remove the pivot pin retainer bolt (Item 1) [Figure 20-50-

5].

Figure 20-50-6

Remove the pivot pin [Figure 20-50-6].

Figure 20-50-7

Lower the cylinder from the boom and remove [Figure

20-50-7].

4852210 (07-06) 20-50-2 Bobcat T2556 & T2566

SERVICE MANUAL
TILT CYLINDER (CONT'D)

Parts Identification

1. Bushing
2. Grease Fitting
3. Housing
4. Relief Cartridge
5. Wear Ring
6. Expander O-ring
7. Seal
8. Lock Ring
9. Piston
10. Snap Ring
11. Cushion Sleeve
12. O-ring
13. Rod
14. Head Gland
15. Wiper
16. Set Screw

4852210 (07-06) 20-50-3 Bobcat T2556 & T2566

SERVICE MANUAL
TILT CYLINDER (CONT'D) Figure 20-50-10

Disassembly

Use the following tools to disassemble the cylinder:

MEL1074-O-ring Seal Hook

MEL1075-Adjustable Gland Nut Wrench

Clean the outside of the tilt cylinder before disassembly.

Figure 20-50-8

Remove the relief cartridge (Item 1) [Figure 20-50-10].

Figure 20-50-11

Put the cylinder in a vise [Figure 20-50-8].

Figure 20-50-9

Remove the set screw (Item 1) [Figure 20-50-11].

Remove the two hoses (Item 1) [Figure 20-50-9] from the

cylinder.

NOTE: Mark the location of the hoses for correct

assembly.

4852210 (07-06) 20-50-4 Bobcat T2556 & T2566

SERVICE MANUAL
TILT CYLINDER (CONT'D) Figure 20-50-14

Disassembly (Cont'd)

Figure 20-50-12

Put the rod end of the cylinder in a vise [Figure 20-50-

14].

Figure 20-50-15
Loosen the head gland [Figure 20-50-12].

Figure 20-50-13

Support the cylinder rod on a wood block [Figure 20-50-

15].

Remove the rod assembly (Item 1) [Figure 20-50-13].

4852210 (07-06) 20-50-5 Bobcat T2556 & T2566

SERVICE MANUAL
TILT CYLINDER (CONT'D) Figure 20-50-19

Disassembly (Cont'd)

Figure 20-50-16

Remove the expander O-ring (Item 1) [Figure 20-50-19].

Remove the lock ring (Item 1) [Figure 20-50-16].

Figure 20-50-17

Remove the piston (Item 1) [Figure 20-50-17] from the

rod.

Figure 20-50-18

Remove the two wear rings (Item 1) and seal (Item 2)

[Figure 20-50-18] from the piston.

4852210 (07-06) 20-50-6 Bobcat T2556 & T2566

SERVICE MANUAL
TILT CYLINDER (CONT'D) Figure 20-50-22

Disassembly (Cont'd)

Figure 20-50-20

Remove the two O-rings (Item 1) [Figure 20-50-22] from

the head gland.

Figure 20-50-23
Remove the O-ring (Item 1) [Figure 20-50-20] from the
inside of the piston.

Figure 20-50-21

Remove the seal (Item 1) [Figure 20-50-23] from the

head gland.

Remove the head gland (Item 1) [Figure 20-50-21] from

the rod.

4852210 (07-06) 20-50-7 Bobcat T2556 & T2566

SERVICE MANUAL
TILT CYLINDER (CONT'D) Figure 20-50-27

Disassembly (Cont'd)

Figure 20-50-24

Remove the cushion sleeve (Item 1) [Figure 20-50-27]

from the head gland.

Remove the expander O-ring (Item 1) [Figure 20-50-24].

Figure 20-50-25

Remove the wiper (Item 1) and seal (Item 2) [Figure 20-

50-25] from the head gland.

Figure 20-50-26

Remove the snap ring (Item 1) [Figure 20-50-26].

4852210 (07-06) 20-50-8 Bobcat T2556 & T2566

SERVICE MANUAL
TILT CYLINDER (CONT'D) Figure 20-50-30

Assembly

Use the following tool to assemble the cylinder:

MEL1075-Adjustable Gland Nut Wrench

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

Figure 20-50-28
Install the wiper (Item 1) and seal (Item 2) [Figure 20-50-
30] into the head gland.

Figure 20-50-31

Install the cushion sleeve (Item 1) [Figure 20-50-28] into

the head gland.

Figure 20-50-29
Install the expander O-ring (Item 1) [Figure 20-50-31].

Install the snap ring (Item 1) [Figure 20-50-29].

4852210 (07-06) 20-50-9 Bobcat T2556 & T2566

SERVICE MANUAL
TILT CYLINDER (CONT'D) Figure 20-50-34

Assembly (Cont'd)

Figure 20-50-32

Install the head gland (Item 1) [Figure 20-50-34] onto the

rod.

Figure 20-50-35
Install the seal (Item 1) [Figure 20-50-32] into the head
gland.

Figure 20-50-33

Install the O-ring (Item 1) [Figure 20-50-35] inside the

piston.

Install the two O-rings (Item 1) [Figure 20-50-33] onto the

head gland.

4852210 (07-06) 20-50-10 Bobcat T2556 & T2566

SERVICE MANUAL
TILT CYLINDER (CONT'D) Figure 20-50-38

Assembly (Cont'd)

Figure 20-50-36

Clean off any old residue, and apply LOCTITE 242 or

equivalent to the threads on the rod [Figure 20-50-38].

Figure 20-50-39
Install the expander O-ring (Item 1) [Figure 20-50-36]
onto the piston.

Figure 20-50-37

Install the piston (Item 1) [Figure 20-50-39] onto the rod.

Install the two wear rings (Item 1) and seal (Item 2)

[Figure 20-50-37].

4852210 (07-06) 20-50-11 Bobcat T2556 & T2566

SERVICE MANUAL
TILT CYLINDER (CONT'D) Figure 20-50-43

Assembly (Cont'd)

Figure 20-50-40

Apply LOCTITE 242 or equivalent to the set screw (Item

1) [Figure 20-50-43].

Install the lock ring (Item 1) [Figure 20-50-40].

Figure 20-50-41

Install the piston/rod assembly (Item 1) [Figure 20-50-41]

into the housing.

Figure 20-50-42

Tighten the head gland [Figure 20-50-42].

4852210 (07-06) 20-50-12 Bobcat T2556 & T2566

SERVICE MANUAL
TILT CYLINDER (CONT'D)

Assembly (Cont'd)

Figure 20-50-44

Install the set screw (Item 1) [Figure 20-50-44] and

tighten.

Figure 20-50-45

Install the relief cartridge (Item 1) [Figure 20-50-45].

Figure 20-50-46

Install the two hoses (Item 1) [Figure 20-50-46].

4852210 (07-06) 20-50-13 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 20-50-14 Bobcat T2556 & T2566
SERVICE MANUAL
STEERING CYLINDER (FRONT) (For S/N 363011001 - Figure 20-60-3
363012000 and S/N 363111001 - 363012000)

Removal And Installation

Figure 20-60-1

Remove the tie rod end from the axle [Figure 20-60-3].

Figure 20-60-4

Remove the front axle. (See “Removal” on page 40-30-1)

Loosen the tie rod jam nut (Item 1) [Figure 20-60-1], mark
the location of the nut for ease of assembly.

Installation: Tighten the jam nut to 185 ft.-lbs. (250 Nm)

torque.

Figure 20-60-2

Remove the tie rod ends (Item 1) [Figure 20-60-4] from

the steering cylinder.

Loosen and remove the tie rod nut (Item 1) [Figure 20-60-
2].

Installation: Tighten the nut to 160 ft.-lbs. (220 Nm)

torque.

4852210 (07-06) 20-60-1 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (FRONT) (For S/N 363011001 - Figure 20-60-7
363012000 and S/N 363111001 - 363012000) (CONT'D)

Removal And Installation (Cont'd)

Figure 20-60-5

Remove the three bolts (Item 1) [Figure 20-60-7] from the

cylinder retainer plate.

Assembly: Apply Loctite 270 to the three bolts and

tighten to 88 ft.-lbs. (120 Nm) torque.
Remove both clamps (Item 1) and remove the centering
sensor (Item 2) [Figure 20-60-5] from the cylinder. Figure 20-60-8

Figure 20-60-6

Remove the cylinder from the axle [Figure 20-60-8].

Remove the fitting (Item 1) [Figure 20-60-6] from the

cylinder.

4852210 (07-06) 20-60-2 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (FRONT) (For S/N 363011001 -363012000 and S/N 363111001 - 363012000) (CONT'D)

Parts Identification

4852210 (07-06) 20-60-3 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (FRONT) (For S/N 363011001 - Figure 20-60-11
363012000 and S/N 363111001 - 363012000) (CONT'D)

Disassembly

Use the following tool to disassemble the cylinder:

MEL1074-O-ring Seal Hook

Clean the outside of the steering cylinder before

disassembly.

Figure 20-60-9

Drive the head gland (Item 1) inwards. Remove the

internal snap ring (Item 2) [Figure 20-60-11].

Figure 20-60-12

Put the cylinder in a vise and remove the tie rod swivel
ends (Item 1) [Figure 20-60-9] from the rod.

Figure 20-60-10

Remove the rod assembly from the housing [Figure 20-

60-12].

Place a drain pan under the cylinder, remove the fitting

(Item 1) and snap ring (Item 2) [Figure 20-60-10] from the
cylinder.

NOTE: Rotate the cylinder in the vise so the fitting

port (Item 3) [Figure 20-60-10] is positioned
down to allow the oil to drain into the pan.

4852210 (07-06) 20-60-4 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (FRONT) (For S/N 363011001 - Figure 20-60-15
363012000 and S/N 363111001 - 363012000) (CONT'D)

Disassembly (Cont'd)

Figure 20-60-13

Remove the wiper seal (Item 1) [Figure 20-60-15].

Figure 20-60-16

Remove the head assembly (Item 1) and spacer (Item 2)

[Figure 20-60-13] from the rod.

Figure 20-60-14

Remove the backup ring (Item 1) and rod seal (Item 2)

[Figure 20-60-16] from the head gland.

Remove the outer seal (Item 1) [Figure 20-60-14] from

the head.

4852210 (07-06) 20-60-5 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (FRONT) (For S/N 363011001 - Figure 20-60-20
363012000 and S/N 363111001 - 363012000) (CONT'D)

Disassembly (Cont'd)

Figure 20-60-17

Remove the wiper seal (Item 1) [Figure 20-60-20] from

the housing.

Remove the wear ring (Item 1) and magnetic sensor ring

(Item 2) [Figure 20-60-17] from the piston.

Figure 20-60-18

Remove the seal (Item 1) [Figure 20-60-18].

Figure 20-60-19

Remove the expander O-ring (Item 1) [Figure 20-60-19].

4852210 (07-06) 20-60-6 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (FRONT) (For S/N 363011001 - Figure 20-60-23
363012000 and S/N 363111001 - 363012000) (CONT'D)

Disassembly (Cont'd)

Figure 20-60-21

Inspect the cylinder parts for wear or damage. Replace

any worn or damaged parts [Figure 20-60-22] & [Figure
20-60-23].

Always install new seals and O-rings. Lubricate all seals

Remove the backup ring (Item 1) and rod seal (Item 2) and O-rings with clean hydraulic fluid before installation.
[Figure 20-60-21] from the housing.
Figure 20-60-24
Assembly

Use the following tools to assembly the cylinder:

MEL1033-Rod Seal Installation Tool

MEL1396-1-Universal Seal Expander

Clean all parts in solvent and dry with compressed air.

Figure 20-60-22

Install the rod seal on the rod seal installation tool [Figure
20-60-24].

NOTE: During installation the O-ring side of the seal

must be toward the inside of the cylinder.

Rotate the handles to collapse the rod seal [Figure 20-60-

24].

4852210 (07-06) 20-60-7 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (FRONT) (For S/N 363011001 - Figure 20-60-27
363012000 and S/N 363111001 - 363012000) (CONT'D)

Assembly (Cont'd)

Figure 20-60-25

Install the expander O-ring (Item 1) [Figure 20-60-27]

onto the piston.

NOTE: The expander O-ring (Item 1) [Figure 20-60-27]

is installed in the piston groove closest to the
Install the rod seal in the housing [Figure 20-60-25]. machined end of the cylinder rod.

Figure 20-60-26 Figure 20-60-28

Install the backup ring (Item 1) and wiper seal (Item 2) Install a new seal on the tool and slowly stretch it until it
[Figure 20-60-26] into the housing. fits the piston [Figure 20-60-28].

Allow the seal to stretch for 30 seconds before installing it

on the piston.

4852210 (07-06) 20-60-8 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (FRONT) (For S/N 363011001 - Figure 20-60-31
363012000 and S/N 363111001 - 363012000) (CONT'D)

Assembly (Cont'd)

Figure 20-60-29

Install a new seal into the head gland [Figure 20-60-31].

Figure 20-60-32

Install the seal (Item 1) [Figure 20-60-29] onto the piston,

over the expander O-ring.

Figure 20-60-30

Install a new backup ring (Item 1) and wiper seal (Item 2)

[Figure 20-60-32] into the head gland.

Install the magnetic sensor ring (Item 1) and wear ring

(Item 2) [Figure 20-60-30].

4852210 (07-06) 20-60-9 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (FRONT) (For S/N 363011001 - Figure 20-60-35
363012000 and S/N 363111001 - 363012000) (CONT'D)

Assembly (Cont'd)

Figure 20-60-33

Lubricate the piston and seal and install into the housing
[Figure 20-60-35].

Figure 20-60-36

Install a new outer seal (Item 1) [Figure 20-60-33] onto

the head gland.

Figure 20-60-34

Lubricate and install the head gland into the housing and
install the internal snap ring (Item 1) [Figure 20-60-36].

Install the spacer (Item 1) and head (Item 2) onto the

machined end (Item 3) [Figure 20-60-34] of the cylinder
rod.

4852210 (07-06) 20-60-10 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (FRONT) (For S/N 363011001 -
363012000 and S/N 363111001 - 363012000) (CONT'D)

Assembly (Cont'd)

Figure 20-60-37

Pull the cylinder rod out until you are able to install the
snap ring (Item 1) [Figure 20-60-37] onto the groove in
the head gland.

Install the fitting (Item 2) [Figure 20-60-37].

Figure 20-60-38

Install the tie rod swivel ends (Item 1) [Figure 20-60-38]

onto the cylinder rod. Tighten to 300 ft.-lbs. (406 Nm)
torque.

4852210 (07-06) 20-60-11 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 20-60-12 Bobcat T2556 & T2566
SERVICE MANUAL
STEERING CYLINDER (FRONT) (FOR S/N 363012001 Figure 20-61-3
and Above, S/N 363112001 and Above)

Removing the Steering Cylinder

2
Figure 20-61-1

2 1

3
S2211

1 Disconnect the tapered pins of the articulation

(Item 1) from the steering case (Item 2) [Figure 20-61-3]
S2442
by means of a puller.

Remove the three bolts (Item 1) and remove the centering

sensor (Item 2) from the front steering cylinder Figure 20-61-4
(Item 3) [Figure 20-61-1].

Figure 20-61-2

2 2

S2443

Disconnect the left and right tie rods (Item 1) from the
1
piston (Item 2) [Figure 20-61-4].
S2210

Loosen and remove the tie rod nut (Item 1) from the tie
rod end (Item 2) [Figure 20-61-2].

4852210 (07-06) 20-61-1 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (FRONT) (FOR S/N 363012001 Installing the Steering Cylinder
and Above, S/N 363112001 and Above) (CONT’D)
Figure 20-61-7
Removing the Steering Cylinder (cont’d)

Figure 20-61-5

1
2

S2445B

S2444
Lubricate the seats of the seals and fit the steering
cylinder (Item 1) [Figure 20-61-7] into its seat.
Remove the securing screws (Item 1) from the steering
Figure 20-61-8
cylinder (Item 2) [Figure 20-61-5].

Figure 20-61-6
1

1
1

S1479

S2445
Tighten the screws (Item 1) [Figure 20-61-8] 90-100 Nm
torque.
Extract the cylinder (Item 1) [Figure 20-61-6] using a
plastic hammer.

4852210 (07-06) 20-61-2 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (FRONT) (FOR S/N 363012001 Figure 20-61-11
and Above, S/N 363112001 and Above) (CONT’D)

Installing the Steering Cylinder (cont’d)

Figure 20-61-9 1

S1483
1

2 Install the centering sensor (Item 1) for checking piston

centering and tighten the screws (Item 2) [Figure 20-61-
S2443
11].

Torque wrench setting: 5 - 6 Nm.

Connect the left and right tie rods (Item 1) by screwing
them onto the piston (Item 2) [Figure 20-61-9]. Figure 20-61-12
Torque wrench setting: 240 - 270 Nm.

Figure 20-61-10

1
2
3

1 2

S2455

3 S2454
Apply a bar (Item 1) to both of the hubs (Item 2) and lock
them . Using a level (Item 3) [Figure 20-61-12], check
that the two bars are perfectly flat and parallel to each
Insert the tapered pins of the articulation (Item 1) in the other.
steering case (Item 2) and tighten the tie rod nut (Item 3)
[Figure 20-61-10] to 270 - 300 Nm torque.

4852210 (07-06) 20-61-3 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (FRONT) (FOR S/N 363012001 Figure 20-61-15
and Above, S/N 363112001 and Above) (CONT’D)

Installing the Steering Cylinder (cont’d)

Figure 20-61-13

I max=0,80 A
1
NERO
BLACK

CONNETTORE
CONNECTOR

2 BLU
1 3
BLUE
--
4
S2456
BATTERIA
BATTERY

MARRONE Without moving the piston, check front and rear size at the
BROWN
+ edge of the bars. Max difference: 0.6 - 0.7 MM.
2A
S1486

NOTE: In order to check the rear size, rotate the bevel

pinion and check that the bars are flat.
Sensor connection card: Connect the centering sensor to
the battery and branche a multimeter (Item 1) [Figure 20- Figure 20-61-16
61-13]. Place the sensor in the centre of the piston by
slowly moving the piston, this will be determined by
measuring voltage on the multimeter.

Figure 20-61-14

S2457

If necessary, adjust the length of the steering bars

(Item 1) [Figure 20-61-16], without moving the centering
S2449
of the piston.

NOTE: With a half turn of the screw, the front size is

After the cylinder has been centered, measure the reduced by about 3 MM., whereas the rear one
distance “C” [Figure 20-61-14] and write it down for use is increased by about 3 MM.
later in the axle installation procedure.

4852210 (07-06) 20-61-4 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (FRONT) (FOR S/N 363012001 Figure 20-61-19
and Above, S/N 363112001 and Above) (CONT’D)

Installing the Steering Cylinder (cont’d)

Figure 20-61-17

1
2

S1510

S2458

CONVERGENCE ADJUSTMENT

Unloose the nuts (Item 1) and screw them onto the ball-
and-socket joints (Item 2) [Figure 20-61-17].

Figure 20-61-18

S2459

Hold the articulations still and rotate the ball-and-socket

joints (Item 1). Once the convergence has been adjusted,
lock the nuts (Item 2) [Figure 20-61-18],

Torque wrench setting for nuts: 240 - 270 Nm.

4852210 (07-06) 20-61-5 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (FRONT) (FOR S/N 363012001 Figure 20-61-22
and Above, S/N 363112001 and Above) (CONT’D)

Disassembling the Steering Cylinder

2
Figure 20-61-20

1
1

S1518
2

With the help of a drift, apply pressure to the stop ring

(Item 1) that is placed inside the cylinder
S1516
(Item 2) [Figure 20-61-22] and extract the ring using a
screwdriver.

Figure 20-61-23

IMPORTANT
Before disassembling the unit, drain the oil in the cylinder
chambers completely.

Remove the snap ring (Item 1) from the cylinder head

(Item 2) [Figure 20-61-20],

Figure 20-61-21
1
3
2
S1519
2

Hammer the piston (Item 1) on the rear of the head

(Item 2) [Figure 20-61-23] using a plastic hammer.
1
Continue hammering until the head (Item 2) is ejected
from the cylinder (Item 3) [Figure 20-61-23].

S1517

With the help of a plastic hammer, push the head

(Item 1) inside the cylinder (Item 2) [Figure 20-61-21],

NOTE: The head should line up with the edge of the

cylinder.

4852210 (07-06) 20-61-6 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (FRONT) (FOR S/N 363012001 Assembling the Steering Cylinder
and Above, S/N 363112001 and Above) (CONT’D)
Figure 20-61-26
Disassembling the Steering Cylinder (Cont’d)

Figure 20-61-24

1 2 3

S1521
A
S1520
After applying grease, install the sealing ring (Item 1) on
the shaft, the anti-extrusion ring (Item 2) and the scraper
ring (Item 3) inside the cylinder (Item 3) [Figure 20-61-
Disassemble the cylinder unit (Item 1) by extracting first
23].
the head (Item 2) then the piston (Item 3) [Figure 20-61-
24].
NOTE: Thoroughly check that positioning of the anti-
extrusion ring (Item 2) [Figure 20-61-20] is
NOTE: Note down the assembly side of the piston
correct.
(Item 3). The bevelled part “A” of the piston is
oriented towards the head (Item 2) [Figure 20-
61-24].
Figure 20-61-27
Figure 20-61-25

3 2 1

S1522

S2499

After applying grease, install the sealing ring (Item 1) on

the shaft, the anti-extrusion ring (Item 2) and the scraper
Remove all seals, anti-extrusion rings and scraper rings
ring (Item 3) in the head (Item 2) [Figure 20-61-24].
from head, cylinder and piston.

NOTE: 1) All seals must be replaced every time the

unit is disassembled.
2) Particular attention must be paid not to
damage the seats of both seals and piston
slide.

4852210 (07-06) 20-61-7 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (FRONT) (FOR S/N 363012001 Figure 20-61-30
and Above, S/N 363112001 and Above) (CONT’D)

Assembling the Steering Cylinder (Cont’d)

NOTE: Thoroughly check that positioning of the anti- 2

extrusion ring (Item 2) [Figure 20-61-27] is
correct.

Figure 20-61-28 1

S1525

centre the shaft on the cylinder (Item 1) so that it fits into

the piston (Item 2) [Figure 20-61-30].

NOTE: Apply a little grease to seals and cylinder.

Figure 20-61-31
S1523

Fit the seal (Item 1) onto the outside of the head

(Item 2) [Figure 20-61-24].
1
NOTE: In order to facilitate assembly, apply grease to
the outer surface of the piston.
Do not roll the seal (Item 1) [Figure 20-61-28].

Figure 20-61-29 2

S1526
5 3 2

1 Push the piston (Item 1) into the cylinder (Item 2)

[Figure 20-61-31] for 100 mm. using a plastic hammer.
4

S1524

Prepare the piston (Item 1) by fitting it with the guide ring

(Item 2), the magnetic ring (Item 3), the O-ring (Item 4) ad
the seal (Item 5) [Figure 20-61-29].

NOTE: In order to facilitate assembly, apply grease. If

a centering sensor is not fitted, then the magneti ring
(Item 3) should be replaced by another guide ring (Item 2)
[Figure 20-61-34].

4852210 (07-06) 20-61-8 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (FRONT) (FOR S/N 363012001 Figure 20-61-34
and Above, S/N 363112001 and Above) (CONT’D)

Assembling the Steering Cylinder (Cont’d)

Figure 20-61-32

2
1

S1530

Apply pressure to the head using two screwdrivers or

levers until the head is fastened onto the stop ring (Item 1)
S1527
[Figure 20-61-34].

Figure 20-61-35
Apply grease to head seals (Item 1), fit the head onto the
piston and push in into the cylinder (Item 2) [Figure 20- 2
61-32] using a plastic hammer.

Figure 20-61-33

S1531

Fit the snap ring (Item 1) on the head (Item 2) [Figure 20-
2 61-35].
S1529

NOTE: Make sure that the snap ring

(Item 1) [Figure 20-61-35] is securely fastened in its
Insert the stop ring (Item 1) ensuring that it fits into the seat. If necessary, force it into its seat using a drift
seat of the cylinder (Item 2) [Figure 20-61-33]. and a hammer.

4852210 (07-06) 20-61-9 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 20-61-10 Bobcat T2556 & T2566
SERVICE MANUAL
STEERING CYLINDER (REAR) (For S/N 363011001 - Figure 20-62-3
363012000 and S/N 363111001 - 363112000)

Removal And Installation

Remove the rear axle. (See “Removal And Installation” on

page 50-90-1)

Place the axle on suitable stands.

Figure 20-62-1

P-46096

Remove the tie rod end from the axle [Figure 20-62-3].
(Both sides)

Figure 20-62-4
1

P-46094

Loosen the tie rod jam nut (Item 1) [Figure 20-62-1], mark
the location of the nut for ease of installation. (Both sides)

Installation: Tighten the jam nut to 185 ft.-lbs. (250 Nm)

torque.
1
Figure 20-62-2

P-46097

Remove the tie rod ends (Item 1) [Figure 20-62-4] from

the steering cylinder. (Both sides)

P-46095

Loosen and remove the tie rod nut (Item 1) [Figure 20-62-
2]. (Both sides)

Installation: Tighten the nut to 160 ft.-lbs. (220 Nm)

torque.

4852210 (07-06) 20-62-1 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (REAR) (For S/N 363011001 - Figure 20-62-7
363012000 and S/N 363111001 - 363112000) (CONT’D)

Removal And Installation (Cont'd)

Figure 20-62-5 1

1
2

P-46100

1
Remove the three bolts (Item 1) [Figure 20-62-7] from the
cylinder retainer plate.
P-46098
Assembly: Apply Loctite 270 to the three bolts and
tighten to 88 ft.-lbs. (120 Nm) torque.
Remove both clamps (Item 1) and remove the centering
sensor (Item 2) [Figure 20-62-5] from the cylinder. Figure 20-62-8

Figure 20-62-6

P-46101

P-46099
Remove the cylinder from the axle [Figure 20-62-8].

Remove the fitting (Item 1) [Figure 20-62-6] from the

cylinder.

4852210 (07-06) 20-62-2 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (REAR) (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000) (CONT'D)

Parts Identification

4852210 (07-06) 20-62-3 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (REAR) (For S/N 363011001 - Figure 20-62-11
363012000 and S/N 363111001 - 363112000) (CONT'D)

Disassembly

Clean the outside of the steering cylinder before

disassembly.

Figure 20-62-9

Drive the head gland (Item 1) inwards. Remove the

internal snap ring (Item 2) [Figure 20-62-11].

Figure 20-62-12

Put the cylinder in a vise and remove the tie rod swivel
ends (Item 1) [Figure 20-62-9] from the rod.

Figure 20-62-10

Remove the rod assembly from the housing [Figure 20-

62-12].

Place a drain pan under the cylinder, remove the fitting

(Item 1) and snap ring (Item 2) [Figure 20-62-10] from the
cylinder.

NOTE: Rotate the cylinder in the vise so the fitting port

(Item 3) [Figure 20-62-10] is positioned down to
allow the oil to drain into the pan.

4852210 (07-06) 20-62-4 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (REAR) (For S/N 363011001 - Figure 20-62-15
363012000 and S/N 363111001 - 363112000) (CONT'D)

Disassembly (Cont'd)

Figure 20-62-13

Remove the wiper seal (Item 1) [Figure 20-62-15].

Figure 20-62-16

Remove the head gland (Item 1) and spacer (Item 2)

[Figure 20-62-13] from the rod.

Figure 20-62-14

Remove the backup ring (Item 1) and rod seal (Item 2)

[Figure 20-62-16] from the head gland.

Remove the outer seal (Item 1) [Figure 20-62-14] from

the head gland.

4852210 (07-06) 20-62-5 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (REAR) (For S/N 363011001 - Figure 20-62-20
363012000 and S/N 363111001 - 363112000) (CONT'D)

Disassembly (Cont'd)

Figure 20-62-17

Remove the wiper seal (Item 1) [Figure 20-62-20] from

the housing.

Remove the wear ring (Item 1) and magnetic sensor ring

(Item 2) [Figure 20-62-17] from the piston.

Figure 20-62-18

Remove the seal (Item 1) [Figure 20-62-18].

Figure 20-62-19

Remove the expander O-ring (Item 1) [Figure 20-62-19].

4852210 (07-06) 20-62-6 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (REAR) (For S/N 363011001 - Figure 20-62-23
363012000 and S/N 363111001 - 363112000) (CONT'D)

Disassembly (Cont'd)

Figure 20-62-21

Inspect all parts for wear or damage. Replace any worn or

damaged parts [Figure 20-62-22] & [Figure 20-62-23].

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.
Remove the backup ring (Item 1) and rod seal (Item 2)
[Figure 20-62-21] from the housing. Always use new O-rings and seals.

Assembly Figure 20-62-24

Use the following tools to assembly the cylinder:

MEL1033-Rod Seal Installation Tool

MEL1396-1-Universal Seal Expander

Clean all parts in solvent and dry with compressed air.

Figure 20-62-22

Install the rod seal on the rod seal installation tool [Figure
20-62-24].

NOTE: During installation the O-ring side of the seal

must be toward the inside of the cylinder.

Rotate the handles to collapse the rod seal [Figure 20-62-

24].

4852210 (07-06) 20-62-7 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (REAR) (For S/N 363011001 - Figure 20-62-27
363012000 and S/N 363111001 - 363112000) (CONT'D)

Assembly (Cont’d)

Figure 20-62-25

Install the expander O-ring (Item 1) [Figure 20-62-27]

onto the piston.

NOTE: The expander O-ring (Item 1) [Figure 20-62-27]

is installed in the piston groove closest to the
Install the rod seal in the housing [Figure 20-62-25]. machined end of the cylinder rod.

Figure 20-62-26 Figure 20-62-28

Install the backup ring (Item 1) and wiper seal (Item 2) Install a new seal on the tool and slowly stretch it until it
[Figure 20-62-26] into the housing. fits the piston [Figure 20-62-28].

Allow the seal to stretch for 30 seconds before installing it

on the piston.

4852210 (07-06) 20-62-8 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (REAR) (For S/N 363011001 - Figure 20-62-31
363012000 and S/N 363111001 - 363112000) (CONT'D)

Assembly (Cont'd)

Figure 20-62-29

Install a new seal into the head gland [Figure 20-62-31].

Figure 20-62-32

Install the seal (Item 1) [Figure 20-62-29] onto the piston,

over the expander O-ring.

Figure 20-62-30

Install a new backup ring (Item 1) and wiper seal (Item 2)

[Figure 20-62-32] into the head gland.

Install the magnetic sensor ring (Item 1) and wear ring

(Item 2) [Figure 20-62-30].

4852210 (07-06) 20-62-9 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (REAR) (For S/N 363011001 - Figure 20-62-35
363012000 and S/N 363111001 - 363112000) (CONT'D)

Assembly (Cont'd)

Figure 20-62-33

Lubricate the piston and seal and install into the housing
[Figure 20-62-35].

Figure 20-62-36

Install a new outer seal (Item 1) [Figure 20-62-33] onto

the head gland.

Figure 20-62-34

Lubricate and install the head gland into the housing and
install the internal snap ring (Item 1) [Figure 20-62-36].

Install the spacer (Item 1) and head (Item 2) onto the

machined end (Item 3) [Figure 20-62-34] of the cylinder
rod.

4852210 (07-06) 20-62-10 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (REAR) (For S/N 363011001 -
363012000 and S/N 363111001 - 363112000) (CONT'D)

Assembly (Cont'd)

Figure 20-62-37

Pull the cylinder rod out until you are able to install the
snap ring (Item 1) [Figure 20-62-37] onto the groove in
the head gland.

Install the fitting (Item 2) [Figure 20-62-37].

Figure 20-62-38

Install the tie rod swivel ends (Item 1) [Figure 20-62-38]

onto the cylinder rod. Tighten to 300 ft.-lbs. (406 Nm)
torque.

4852210 (07-06) 20-62-11 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 20-62-12 Bobcat T2556 & T2566
SERVICE MANUAL
STEERING CYLINDER (REAR) (FOR S/N 363012001 Figure 20-63-3
and Above, S/N 363112001 and Above)

Removing the Steering Cylinder 2

Figure 20-63-1
1

1 S2211

Disconnect the tapered pins of the articulation

(Item 1) from the steering case (Item 2) [Figure 20-63-3]
S2471
by means of a puller.

Figure 20-63-4
Remove the centering sensor (Item 1) [Figure 20-63-1] of
the steering piston.

Figure 20-63-2

2 1

S2472
1

Disconnect the left and right steering bars (Item 1) from

S2210
the piston (Item 2) [Figure 20-63-4].

Remove the nuts (Item 1) that lock the articulation pins

(Item 2) [Figure 20-63-2].

4852210 (07-06) 20-63-1 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (REAR) (FOR S/N 363012001 Installing the Steering Cylinder
and Above, S/N 363112001 and Above) (CONT’D)
Figure 20-63-7
Removing the Steering Cylinder (Cont’d)

Figure 20-63-5
1

S2475

S2473 Check that the O-rings (Item 17 & 15) [Figure 20-63-1] of
the axle unit are in good condition; lubricate the seats of
the seals and fit the steering cylinder (Item 1) [Figure 20-
Remove the securing screws (Item 1) from the steering
63-7] into its seat.
cylinder (Item 2) [Figure 20-63-5].
Figure 20-63-8
Figure 20-63-6

1
1

S2476
S2474

Lock the cylinder by cross-tightening the screws

Extract the cylinder (Item 1) [Figure 20-63-6] using a
(Item 1) [Figure 20-63-8], apply a torque of 90 - 100 Nm.
plastic hammer.

NOTE: For cylinder disassembly, refer to “HOW TO

DISASSEMBLE THE STEERING CYLINDER”.

4852210 (07-06) 20-63-2 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (REAR) (FOR S/N 367 12001 Figure 20-63-11
and Above, S/N 363112001 and Above) (CONT’D)

installing the Steering Cylinder (Cont’d)

Figure 20-63-9

S2471

Install the proximity sensor (Item 1) for checking piston

centering and tighten the screws (Item 2) [Figure 20-63-
S2477
11].

Torque wrench setting: 5 - 6 Nm

Apply Loctite 242 to the thread and connect the steering
bars by screwing the terminals onto the piston stem. Figure 20-63-12
Torque wrench setting: 240 - 270 Nm.

NOTE: It is required that the rim of the articulation is = =

riveted onto the surfaces of the piston stem.

Figure 20-63-10

1
2

S1484

Connect the sensor (item 1) [Figure 20-63-12] to the

inspection device according to either diagram.

S2478

Insert the pins (Item 1) in the steering case

(Item 2) [Figure 20-63-10] and lock into position using a
torque wrench setting of 270 - 300 Nm.

IMPORTANT
Check that the rubber guards (Item A) [Figure 20-63-
10] are intact.

4852210 (07-06) 20-63-3 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (REAR) (FOR S/N 363012001 Figure 20-63-15
and Above, S/N 363112001 and Above) (CONT’D)

installing the Steering Cylinder (Cont’d) C

Figure 20-63-13

S2449

Inspect distance “C” on one side of the piston and note

down the size for checking later adjustments.
S2479

NOTE: If cylinders come without a sensor, the

centring of the piston must be carried out on
the basis of the maximum stroke.

IMPORTANT Figure 20-63-16

Eliminate the action of the negative break.

Apply tools T16 to the hubs and lock them. Using a level
”B”, check that tools are perfectly flat and parallel to each
other.

Figure 20-63-14
I max=0,80 A

NERO
BLACK
S2480
CONNETTORE
CONNECTOR

2 BLU Without moving the piston, check front and rear size at the
1 3
BLUE
-- edge of the bars. Max. difference: 0.6 - 0.7 mm.
4

BATTERIA
BATTERY NOTE: In order to check the rear size, rotate the bevel
pinion and check that the bars are flat.
MARRONE
BROWN
+
2A
S1486

Sensor connection card: Connect the centering sensor to

the battery and branche a multimeter (Item 1) [Figure 20-
63-14]. Place the sensor in the centre of the piston by
slowly moving the piston, this will be determined by
measuring voltage on the multimeter.

4852210 (07-06) 20-63-4 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (REAR) (FOR S/N 363012001 Figure 20-63-19
and Above, S/N 363112001 and Above) (CONT’D)

installing the Steering Cylinder (Cont’d)

Figure 20-63-17

S2459

Hold the articulations still and rotate the ball-and-socket

joints. Once the convergency has been adjusted, lock the
S2481 nuts.

Torque wrench setting for nuts: 240 - 270 Nm.

If necessary, adjust convergency without moving the
centring of the piston and adjust the length of the steering Figure 20-63-20
bars (Item 1) [Figure 20-63-17],

NOTE: With a half turn of the screw, the front size is

reduced by about 3 mm., whereas the rear one
is increased by about 3 mm.

Figure 20-63-18

S1510

S2482

CONVERGENCY ADJUSTMENT

Unloose the nuts and screw them onto the ball-and-

socket joints (Item 2) [Figure 20-63-18].

4852210 (07-06) 20-63-5 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (REAR) (FOR S/N 363012001 Figure 20-63-23
and Above, S/N 363112001 and Above) (CONT’D)

Disassembling the Steering Cylinder

2
Figure 20-63-21

1
1

S1518
2

With the help of a drift, apply pressure to the stop ring

(Item 1) that is placed inside the cylinder
S1516
(Item 2) [Figure 20-63-23] and extract the ring using a
screwdriver.

Figure 20-63-24

IMPORTANT
Before disassembling the unit, drain the oil in the cylinder
chambers completely.

Remove the snap ring (Item 1) from the cylinder head

(Item 2) [Figure 20-63-21],

Figure 20-63-22
1
3
2
S1519
2

Hammer the piston (Item 1) on the rear of the head

(Item 2) [Figure 20-63-24] using a plastic hammer.
1
Continue hammering until the head (Item 2) is ejected
from the cylinder (Item 3) [Figure 20-63-24].

S1517

With the help of a plastic hammer, push the head (Item 1)

inside the cylinder (Item 2) [Figure 20-63-22],

NOTE: The head should line up with the edge of the

cylinder.

4852210 (07-06) 20-63-6 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (REAR) (FOR S/N 363012001
and Above, S/N 363112001 and Above) (CONT’D)
NOTE: 1) All seals must be replaced every time the
Disassembling the Steering Cylinder (Cont’d) unit is disassembled.
2) Particular attention must be paid not to
Figure 20-63-25
damage the seats of both seals and piston
slide.

A
S1520

Disassemble the cylinder unit (Item 1) by extracting first

the head (Item 2) then the piston (Item 3) [Figure 20-63-
25].

NOTE: Note down the assembly side of the piston

(Item 3) [Figure 20-63-25]. The bevelled part
“A” of the piston is oriented towards the head
(Item 2) [Figure 20-63-25].

Figure 20-63-26

S2499

Remove all seals, anti-extrusion rings and scraper rings

from head (Item 1), cylinder (Item 2) and piston (Item 3)
[Figure 20-63-26].

4852210 (07-06) 20-63-7 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (REAR) (FOR S/N 363012001
and Above, S/N 363112001 and Above) (CONT’D)

Assembling the Steering Cylinder IMPORTANT

Figure 20-63-27 Thoroughly check that positioning of the anti-
extrusion ring (Item 2) [Figure 20-63-28] is correct.

1 2 3 Figure 20-63-29

S1521

After applying grease, install the sealing ring (Item 1) on

the shaft, the anti-extrusion ring (Item 2) and the scraper
S1523
ring (Item 3) inside the cylinder (Item 3) [Figure 20-63-
27].
Fit the seal (Item 1) onto the outside of the head
(Item 2) [Figure 20-63-29].

IMPORTANT
Thoroughly check that positioning of the anti-
extrusion ring (Item 2) [Figure 20-63-21] is correct.
IMPORTANT
1) In order to facilitate assembly, apply grease to the
outer surface of the piston.
Figure 20-63-28 2) Do not roll the seal (Item 1) [Figure 20-63-29]

3 2 1

S1522

After applying grease, install the sealing ring

(Item 1) [Figure 20-63-28] on the shaft, the anti-extrusion
ring (Item 2) [Figure 20-63-28] and the scraper ring
(Item 3) [Figure 20-63-21] in the head
(Item 2) [Figure 20-63-25].

4852210 (07-06) 20-63-8 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (REAR) (FOR S/N 363012001 Figure 20-63-32
and Above, S/N 363112001 and Above) (CONT’D)

Assembling the Steering Cylinder (Cont’d)

Figure 20-63-30
1
5 3 2

2
4

S1526

Push the piston (Item 1) into the cylinder (Item 2)

[Figure 20-63-32] for 100 mm. using a plastic hammer.
S1524

Figure 20-63-33
Prepare the piston (Item 1) by fitting it with the guide ring
(Item 2), the magnetic ring (Item 3), the O-ring
(Item 4) and the seal (Item 5) [Figure 20-63-30]. 2
1

IMPORTANT
1) In order to facilitate assembly, apply grease.
2) If a centring sensor is not fitted, then the magnetic
ring (Item 3) [Figure 20-63-30] should be replaced by
another guide ring (Item 2) [Figure 20-63-30].
S1527

Figure 20-63-31 Apply grease to head seals (Item 1), fit the head onto the
piston and push in into the cylinder (Item 2) [Figure 20-
63-33] using a plastic hammer.

S1525

centre the shaft on the cylinder (Item 1) so that it fits into

the piston (Item 2) [Figure 20-63-31].

NOTE: Apply a little grease to seals and cylinder.

4852210 (07-06) 20-63-9 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING CYLINDER (REAR) (FOR S/N 363012001 Figure 20-63-36
and Above, S/N 363112001 and Above) (CONT’D)
2
Assembling the Steering Cylinder (Cont’d)

Figure 20-63-34

S1531

Fit the snap ring (Item 1) on the head (Item 2) [Figure 20-
2 63-36].
S1529

Insert the stop ring (Item 1) ensuring that it fits into the
seat of the cylinder (Item 3) [Figure 20-63-34]. IMPORTANT
Figure 20-63-35 Make sure that the snap ring (Item 1) [Figure 20-63-
36] is securely fastened in its seat.
If necessary, force it into its seat using a drift and a
hammer.

S1530

Apply pressure to the head using two screwdrivers or

levers until the head is fastened onto the stop ring (Item 1)
[Figure 20-63-35].

4852210 (07-06) 20-63-10 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000)

Parts Identification

4852210 (07-06) 20-70-1 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (For S/N 363011001 - 363012000 and S/N Figure 20-70-3
363111001 - 363112000) (CONT'D)

Disassembly

Remove the front axle. (See “Removal” on page 40-30-1.)

Remove the drive motor. (See “Removal And Installation”

on page 30-30-1.)

Clean the outside of the drive box before disassembly.

Mark the outside of the drive box for ease of assembly.

Figure 20-70-1

Remove the eight cover mounting bolts (Item 1) [Figure

20-70-3].

Figure 20-70-4

Mark the mounting flange and housing for correct

assembly. Remove the eight mounting bolts (Item 1)
[Figure 20-70-1]. Remove the mounting flange.

Figure 20-70-2

Install two guide bolts (Item 1) [Figure 20-70-4] to support

the housing cover when removing it from the dowels.

Place a drain pan under the drive box, remove the hose
(Item 1) [Figure 20-70-2] and drain the oil from the drive
box.

4852210 (07-06) 20-70-2 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (For S/N 363011001 - 363012000 and S/N Figure 20-70-6
363111001 - 363112000) (CONT'D)

Disassembly (Cont'd)

Figure 20-70-5

With the cover supported on a work surface, remove the

snap ring (Item 1) [Figure 20-70-6].

Figure 20-70-7

Remove the cover from the rear housing [Figure 20-70-

Remove the bearing from the shaft [Figure 20-70-7].
5].

Remove the two guide bolts (Item 1) [Figure 20-70-5].

4852210 (07-06) 20-70-3 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (For S/N 363011001 - 363012000 and S/N Figure 20-70-10
363111001 - 363112000) (CONT'D)

Disassembly (Cont'd)

Figure 20-70-8

Remove the plug (Item 1) [Figure 20-70-10] from the

shaft.

Figure 20-70-11

Remove the gear (Item 1) [Figure 20-70-8] from the shaft.

Figure 20-70-9

Remove the shaft seal (Item 1) [Figure 20-70-11] from

the housing.

Remove the shaft from the bearing and housing [Figure

20-70-9].

4852210 (07-06) 20-70-4 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (For S/N 363011001 - 363012000 and S/N Figure 20-70-14
363111001 - 363112000) (CONT'D)

Disassembly (Cont'd)

Figure 20-70-12

Install two guide bolts (Item 1) [Figure 20-70-14] and

remove the six remaining mounting bolts.

Remove the bearing from the housing [Figure 20-70-12].

Figure 20-70-13

Remove two of the rear housing mounting bolt (Item 1)

[Figure 20-70-13].

4852210 (07-06) 20-70-5 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (For S/N 363011001 - 363012000 and S/N Figure 20-70-16
363111001 - 363112000) (CONT'D)

Disassembly (Cont'd)

Figure 20-70-15

With the cover supported on a work surface, remove the

gear/bearing assembly (Item 1) [Figure 20-70-16].

Figure 20-70-17

Remove the rear cover from the axle housing [Figure 20-
Remove the snap ring (Item 1) [Figure 20-70-17] from the
70-15].
bearing.
Remove the two guide bolts (Item 1) [Figure 20-70-15].

4852210 (07-06) 20-70-6 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (For S/N 363011001 - 363012000 and S/N Inspection
363111001 - 363112000) (CONT'D)
Figure 20-70-20
Disassembly (Cont'd)

Figure 20-70-18

Inspect the gears for cracked or damaged teeth. Replace

any damaged parts [Figure 20-70-20].

Using a press, remove both bearings from the gear Figure 20-70-21
[Figure 20-70-18].

Figure 20-70-19

Inspect the splines on the shaft for wear or damaged.

Replace if worn or damaged [Figure 20-70-21].

Remove the plug (Item 1) [Figure 20-70-19] from the rear

housing.

4852210 (07-06) 20-70-7 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (For S/N 363011001 - 363012000 and S/N Figure 20-70-23
363111001 - 363112000) (CONT'D)

Assembly

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

IMPORTANT Prior to assembly

When repairing hydrostatic and hydraulic systems, Clean all sealant residue from the mating surfaces (Item 1)
clean the work area before disassembly and keep all [Figure 20-70-22] & [Figure 20-70-23] on both housings.
parts clean. Always use caps and plugs on hoses, Clean all LOCTITE residue from mounting plate bolt holes
tubelines and ports to keep dirt out. Dirt can quickly (Item 2) [Figure 20-70-23].
damage the system.
I-2003-0888 Figure 20-70-24

Figure 20-70-22

Figure 20-70-25

Clean all sealant residue from the mounting surfaces

(Item 1) [Figure 20-70-24] & [Figure 20-70-25].

Clean all LOCTITE residue from the mounting flange bolt

holes (Item 2) [Figure 20-70-25].

Clean all LOCTITE from the mounting bolts.

4852210 (07-06) 20-70-8 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (For S/N 363011001 - 363012000 and S/N Figure 20-70-28
363111001 - 363112000) (CONT'D)

Assembly (Cont'd)

Figure 20-70-26

Install the snap ring (Item 1) [Figure 20-70-28] in the

groove in the bearing.

Figure 20-70-29

Install the plug into the rear housing [Figure 20-70-26].

Figure 20-70-27

Apply a small amount of LOCTITE 609 or equivalent into

the bearing seat in the rear housing [Figure 20-70-29].

Install both bearings (Item 1) [Figure 20-70-27] onto the

gear.

4852210 (07-06) 20-70-9 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (For S/N 363011001 - 363012000 and S/N Figure 20-70-32
363111001 - 363112000) (CONT'D)

Assembly (Cont'd)

Figure 20-70-30

Install the gear/bearing assembly (Item 1) [Figure 20-70-

30] into the rear housing.

Figure 20-70-31

Install the two guide bolts (Item 1) [Figure 20-70-32] into

the axle mounting flange.

Install the rear cover onto the axle mounting flange

[Figure 20-70-32].

Apply a 3 mm bead of LOCTITE 510 gasket eliminator (or

equivalent) to the axle mounting flange (Item 1) [Figure
20-70-31] in the pattern shown.

4852210 (07-06) 20-70-10 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (For S/N 363011001 - 363012000 and S/N Figure 20-70-35
363111001 - 363112000) (CONT'D)

Assembly (Cont'd)

Figure 20-70-33

Install the seal (Item 1) [Figure 20-70-35] into the

housing.

Figure 20-70-36

Apply LOCTITE 270 (or equivalent) to the six mounting

bolts (Item 1) [Figure 20-70-33] and install. Tighten to 88
ft.-lbs. (120 Nm) torque.

Remove the two guide bolts (Item 2) [Figure 20-70-33].

Figure 20-70-34

Install the shaft (Item 1) through the seal (Item 2) [Figure

20-70-36] and support the housing with blocks.

Apply LOCTITE 270 (or equivalent) to the two remaining

mounting bolts (Item 1) [Figure 20-70-34]. Install and
tighten the bolts to 88 ft.-lbs. (120 Nm) torque.

4852210 (07-06) 20-70-11 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (For S/N 363011001 - 363012000 and S/N Figure 20-70-39
363111001 - 363112000) (CONT'D)

Assembly (Cont'd)

Figure 20-70-37

Install the gear (Item 1) [Figure 20-70-39] onto the shaft.

Figure 20-70-40

Apply a small amount of LOCTITE 609 (or equivalent) on

the bearing seat [Figure 20-70-37].

Figure 20-70-38

Install the bearing (Item 1) [Figure 20-70-40] onto the

shaft.

Install the bearing onto the shaft until it is fully seated in

the housing [Figure 20-70-38].

4852210 (07-06) 20-70-12 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (For S/N 363011001 - 363012000 and S/N Figure 20-70-43
363111001 - 363112000) (CONT'D)

Assembly (Cont'd)

Figure 20-70-41

Install the snap ring (Item 1) [Figure 20-70-41] onto the

shaft.

Figure 20-70-42

Install two guide bolts (Item 1) [Figure 20-70-43].

Install the cover [Figure 20-70-43].

NOTE: The splines and gears must be aligned to fully

install the cover onto the dowels.

Apply a 3 mm bead of LOCTITE 510 Gasket Eliminator

(or equivalent) to the rear housing surface (Item 1)
[Figure 20-70-42] in the pattern shown.

4852210 (07-06) 20-70-13 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (For S/N 363011001 - 363012000 and S/N Figure 20-70-46
363111001 - 363112000) (CONT'D)

Assembly (Cont'd)

Figure 20-70-44

Reconnect the hose (Item 1) [Figure 20-70-46] and

tighten.

Figure 20-70-47

Install six cover bolts (Item 1) and remove the guide bolts
(Item 2) [Figure 20-70-44].

Figure 20-70-45

Install the mounting flange (Item 1) and tighten the eight

mounting bolts (Item 2) [Figure 20-70-47] to 44 ft.-lbs. (60
Nm) torque.

Install the two remaining cover bolts (Item 1) [Figure 20-

70-45]. Tighten all bolts to 44 ft.-lbs. (60 Nm) torque.

4852210 (07-06) 20-70-14 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (FOR S/N 363012001 and Above, S/N 363112001 and Above)

Parts Identification

Figure 20-71-1

5
1. Gear
4
2. Circlip 3
3. Ball bearing 2
1
4. Circlip
5. Vent
6. Ring nut 27
26
7. Bearing
9
8. Ring 8
9. Plug 7
6
10. Seal
11. Ball bearing
12. Gear

24 25
10
23
11

12
13
14 13. Circlip
15 14. Ball bearing
22
15. Seal
16. Plug
17. Spring washer
18. Hexagon bolt
20 17 16
21 19. Magnet plug
19 18
20. Dowel
21. Plug
22. Flange
23. O-ring
24. Screw
25. Cover
26. Shim
27. Bearing

S2500

4852210 (07-06) 20-71-1 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (FOR S/N 363012001 and Above, S/N Figure 20-71-4
363112001 and Above) (CONT’D)

Disassembly

Remove the front axle. (See “Removal” on page 40-31-1)

1
Remove the drive motor. (See “Removal And Installation”
on page 30-30-1)

Figure 20-71-2

S2463

1 Take off the drive side flange cover (Item 1) [Figure 20-
71-4] by alternatively forcing a screwdriver into the
appropriate slots.

NOTE: Look out not to damage the surfaces.

Figure 20-71-5
S2461

Loosen the securing bolts (Item 1) [Figure 20-71-2] only 1

so that later when you pry the drive side flange cover
loose, it does not fall.

Figure 20-71-3

S2464

1
Remove the securing bolts and lift off the cover (Item 1)
[Figure 20-71-2].

S2462

Loosen the drive side flange cover using a plastic

hammer.

4852210 (07-06) 20-71-2 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (FOR S/N 363012001 and Above, S/N Figure 20-71-8
363112001 and Above) (CONT’D)

Disassembly (Cont’d)
1
Figure 20-71-6

S2488

Using two levers, remove the flange sealing ring (Item 1)

[Figure 20-71-8].
S2486

To remove the drive side shaft (Item 1), hook off the snap
Figure 20-71-9
ring (Item 2) [Figure 20-71-6].
1

Figure 20-71-7

S2432

Remove the snap ring (Item 1) [Figure 20-71-9].

S2487

Using two levers, remove the drive side shaft (Item 1)

[Figure 20-71-7].

4852210 (07-06) 20-71-3 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (FOR S/N 363012001 and Above, S/N Figure 20-71-12
363112001 and Above) (CONT’D)

Disassembly (Cont’d)

Figure 20-71-10

1
S2489

With a puller, remove the bearing (Item 1) from the flange

1 shaft (Item 2) [Figure 20-71-12].
S2433

With a puller, remove the bearing (Item 1) from the input Figure 20-71-13
shaft (Item 2) [Figure 20-71-10].

Figure 20-71-11 1

S2490

Remove the secondary gear wheel (Item 1) [Figure 20-

S2434
71-13] using two levers.

4852210 (07-06) 20-71-4 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (FOR S/N 363012001 and Above, S/N Figure 20-71-17
363112001 and Above) (CONT’D)

Disassembly (Cont’d)

Figure 20-71-14

S2493

1 Pull out the cup of the sealing ring (Item 1) by using drift
(Item 2) [Figure 20-71-10].
S2435

Remove the snap ring (Item 1) [Figure 20-71-14].

Figure 20-71-15

S2491

Remove the flange (Item 1) [Figure 20-71-15] by means

of a plastic hammer.

Figure 20-71-16

S2492

Remove the internal bearing (Item 1) [Figure 20-71-16].

4852210 (07-06) 20-71-5 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (FOR S/N 363012001 and Above, S/N Figure 20-71-20
363112001 and Above) (CONT’D)

Assembly

Figure 20-71-18

S2494

T12 Fit the flange (Item 1) [Figure 20-71-20] and fasten it.

For keying the flange (Item 1) [Figure 20-71-20], use a

S2483
plastic hammer if necessary.

Insert the sealing ring using tool T12. Figure 20-71-21

NOTE: Bring the sealing ring just to the end stop,

apply grease to the sealing lips.

Figure 20-71-19

S2495
1

Insert the bearing (Item 1) [Figure 20-71-21].

S2436

Insert the sealing ring (Item 1) [Figure 20-71-10] with a

normal tool.

NOTE: Bring the sealing ring just to the end stop,

apply grease to the sealing lips.

4852210 (07-06) 20-71-6 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (FOR S/N 363012001 and Above, S/N Figure 20-71-24
363112001 and Above) (CONT’D)

Assembly (Cont’d)

Figure 20-71-22

S2437 / S2438

1 Using a normal tool insert the bearing (Item 1) [Figure 20-

2 71-21].
S2496
Figure 20-71-25

Using a normal tool insert the bearing (Item 1) and snap

ring (Item 2) [Figure 20-71-22].

Figure 20-71-23

1 2

S2439 / S2440

Insert the snap ring (Item 1) and using a normal tool insert
the bearing (Item 2) [Figure 20-71-25].
S2497

Install the secondary gear wheel (Item 1) [Figure 20-71-

23] with a plastic hammer.

4852210 (07-06) 20-71-7 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE BOX (FOR S/N 363012001 and Above, S/N Figure 20-71-28
363112001 and Above) (CONT’D)

Assembly (Cont’d)

Figure 20-71-26
1

S2484

Install drive side flange cover, apply LOCTITE 510 to the

alignment bolts.
S2441
Figure 20-71-29

Fix the bearing with the snap ring (Item 1) [Figure 20-71-
26].

Figure 20-71-27

S2485

Tighten the alignment bolts with a torque wrench setting

of 80-90 Nm.
S2498

Hold the drive side saft (Item 1) [Figure 20-71-27] using a

plier and install the drive side shaft with a plastic hammer.

4852210 (07-06) 20-71-8 Bobcat T2556 & T2566

SERVICE MANUAL
SPECIAL TOOLS

TOOL IMAGE DESCRIPTION BOBCAT PN

T12 603 dropbox seal ex 4215 6912179

4852210 (07-06) 20-71-9 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 20-71-10 Bobcat T2556 & T2566
SERVICE MANUAL
MAIN RELIEF VALVE Figure 20-80-3

Testing And Adjustment

Figure 20-80-1

P-52913

Warm the fluid of the hydraulic system to 140° F (60° C)

P-44523 by raising and lowering the boom several times.

Start the engine, lower the restraint bar (if equipped) and
Remove the rear cover (Item 1) [Figure 20-80-1] from the run the engine speed to 2450 RPM. Raise the boom until
machine. the lift cylinder is at the end of it’s stroke. Record the
pressure at the gauge.
Figure 20-80-2
The main relief valve should open at 3844 PSI (265 Bar)
maximum.

If adjustment is needed, see next page.

P-50943

Fit a pressure gauge on the minimess connector situated

on the right side of the control valve (inlet section), (Item
1) [Figure 20-80-2].

4852210 (07-06) 20-80-1 Bobcat T2556 & T2566

SERVICE MANUAL
MAIN RELIEF VALVE (CONT’D)

Testing And Adjustment (Cont’d)

IMPORTANT
Remove the rear cover.
When repairing hydrostatic and hydraulic systems,
Figure 20-80-4 clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
1 damage the system.
I-2003-0888

Remove the rear cover.

Figure 20-80-6

P-50980

Locate the main relief valve on the front right side of the
control valve [Figure 20-80-4].

Figure 20-80-5

P-50980

1 Locate the main relief valve on the front right side of the
control valve.

Clean the area around the control valve.

2 Remove the main relief valve (Item 1) [Figure 20-80-6].

Installation: Tighten the main relief valve to 33 ft.-lbs. (45

Nm) torque.

P-44331

Loosen the lock nut (Item 1) and turn the adjustment

screw (Item 2) [Figure 20-80-5] clockwise to increase the
pressure or counterclockwise to decrease the pressure.

NOTE: A 1/4 of a turn = 632 psi (25 Bar).

Retest the main relief valve after adjustment.

4852210 (07-06) 20-80-2 Bobcat T2556 & T2566

SERVICE MANUAL
QUICK TACH CYLINDER Figure 20-90-3

Removal And Installation

Figure 20-90-1

Remove the bolt (Item 1) [Figure 20-90-3] from each side

of the cylinder.

Figure 20-90-4
Rotate the quick tach forward and place on wood blocks
[Figure 20-90-1].

Figure 20-90-2

Remove the end bushing (Item 1) [Figure 20-90-4].

Remove the two hoses (Item 1) [Figure 20-90-2] from the

cylinder.

NOTE: Mark the hoses for correct assembly.

4852210 (07-06) 20-90-1 Bobcat T2556 & T2566

SERVICE MANUAL
QUICK TACH CYLINDER (CONT'D) Figure 20-90-7

Removal And Installation (Cont'd)

Figure 20-90-5

1
2

P-32165

Remove the roll pin (Item 1) and remove the extension

rod (Item 2) [Figure 20-90-7] from the cylinder rod.

Remove the roll pin (Item 1) [Figure 20-90-5]. Figure 20-90-8

Figure 20-90-6

Remove the cylinder (Item 1) [Figure 20-90-8].

Remove the washer (Item 1) and spring (Item 2) [Figure

20-90-6] from the cylinder rod extension.

4852210 (07-06) 20-90-2 Bobcat T2556 & T2566

SERVICE MANUAL
QUICK TACH CYLINDER (CONT'D)

Parts Identification

1. Housing
2. Extension
3. Wiper
4. Seal
5. O-ring
6. Head Gland
7. Rod
8. Piston
9. Wear Ring

4852210 (07-06) 20-90-3 Bobcat T2556 & T2566

SERVICE MANUAL
QUICK TACH CYLINDER (CONT'D) Figure 20-90-11

Disassembly

Use the following tools to disassemble the cylinder:

MEL1074-O-ring Seal Hook

MEL1076-Cylinder Wrench

Clean the outside of the quick tach cylinder before

disassembly.

Figure 20-90-9

Loosen the head gland [Figure 20-90-11].

Figure 20-90-12

Place the cylinder in a vise [Figure 20-90-9].

Figure 20-90-10

Remove the rod assembly (Item 1) [Figure 20-90-12]

from the housing.

Remove the two fittings (Item 1) [Figure 20-90-10].

4852210 (07-06) 20-90-4 Bobcat T2556 & T2566

SERVICE MANUAL
QUICK TACH CYLINDER (CONT'D) Figure 20-90-15

Disassembly (Cont'd)

Figure 20-90-13

Remove the head (Item 1) [Figure 20-90-15] from each

rod.

Figure 20-90-16
Loosen the second head gland (Item 1) [Figure 20-90-13]
on the opposite side.

Figure 20-90-14

Remove the O-rings (Item 1) [Figure 20-90-16] from each

head gland.

Remove the rod assembly (Item 1) [Figure 20-90-14]

from the housing.

4852210 (07-06) 20-90-5 Bobcat T2556 & T2566

SERVICE MANUAL
QUICK TACH CYLINDER (CONT'D) Figure 20-90-19

Disassembly (Cont'd)

Figure 20-90-17

Remove the expander O-ring (Item 1) [Figure 20-90-19]

from each piston.

Remove the seal (Item 1) and wiper (Item 2) [Figure 20-

90-17] from each head gland.

Figure 20-90-18

Remove the wear ring (Item 1) and seal (Item 2) [Figure

20-90-18] from each piston.

4852210 (07-06) 20-90-6 Bobcat T2556 & T2566

SERVICE MANUAL
QUICK TACH CYLINDER (CONT'D) Figure 20-90-22

Assembly

Use the following tool to assemble the cylinder:

MEL1076-Cylinder Wrench

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

Figure 20-90-20
Install the wiper (Item 1) and seal (Item 2) [Figure 20-90-
22] in each head gland.

NOTE: The groove in the seal must point away from

the wiper seal (Item 1) [Figure 20-90-22].

Figure 20-90-23

Install a new expander O-ring (Item 1) [Figure 20-90-20]

on each piston.

Figure 20-90-21

Install the two O-rings (Item 1) [Figure 20-90-24] on each

head gland.

Install a new seal (Item 1) and wear ring (Item 2) [Figure

20-90-21] on each piston.

4852210 (07-06) 20-90-7 Bobcat T2556 & T2566

SERVICE MANUAL
QUICK TACH CYLINDER (CONT'D)

Assembly (Cont'd)

Figure 20-90-24

Install each head gland (Item 1) [Figure 20-90-24] onto

the rod.

Figure 20-90-25

Install each rod assembly (Item 1) [Figure 20-90-25] into

the housing.

Figure 20-90-26

Tighten both head glands [Figure 20-90-26].

4852210 (07-06) 20-90-8 Bobcat T2556 & T2566

SERVICE MANUAL
PORT RELIEF VALVES Figure 20-100-2

Adjustment Procedure

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. 1
I-2003-0888

P-47827
A portable hydraulic hand pump will be used to test the
work port relief valves. The hand pump must have clean
hydraulic fluid that is compatible with the Bobcat hydraulic Remove the protective end cap (Item 1) [Figure 20-100-
fluid. 2].

NOTE: The valve is shown removed from the machine Figure 20-100-3
for photo clarity.

Figure 20-100-1

P-47828

Loosen the lock nut (Item 1) [Figure 20-100-3]

P-47826

Turn the adjusting screw (Item 2) [Figure 20-100-3]

Install the hand pump, hose and a pressure gauge clockwise to increase the pressure and counterclockwise
minimum of 5000 PSI (345 Bar) into the valve section to reduce the pressure.
work port in which the port relief valve is located [Figure
20-100-1]. Pressurize this section with the hand pump NOTE: One-quarter turn is approximately 400 PSI (27.5
until the port relief valve opens and record the pressure Bar). When the correct pressure setting is
reading. obtained, tighten the locknut while holding the
adjustment screw from turning.
If the port relief pressure setting needs to be adjusted,
release the hand pump pressure valve. Adjust the port relief valve until the correct setting is
obtained.

Install the end cap.

4852210 (07-06) 20-100-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 20-100-2 Bobcat T2556 & T2566
SERVICE MANUAL
STEERING MODE VALVE BLOCK Figure 20-110-2

Removal And Installation

1

WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by 1
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
P-49002

Figure 20-110-1
Relieve hydraulic pressure.

Remove the retainer screw from the two wire connectors

1 (Item 1) [Figure 20-110-2].

Remove the wire connectors from the two solenoids.

1
1 NOTE: Mark the location of the wire connectors for
correct installation.

Figure 20-110-3

P-47999

Remove the tie straps (Item 1) [Figure 20-110-1]. 2

1

P-49003

Remove the four mounting bolts (Item 1) [Figure 20-110-

3].

NOTE: Mark the location of the valve on the block.

Remove the valve (Item 2) [Figure 20-110-3] from the

block.

4852210 (07-06) 20-110-1 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING MODE VALVE BLOCK (CONT’D) Figure 20-110-5

Removal And Installation (Cont’d)

1

IMPORTANT 1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-49005
Figure 20-110-4

Remove the four mounting bolts (Item 1) [Figure 20-110-

5] and remove the block.
1

P-49004

Remove the four hoses (Item 1) [Figure 20-110-4].

NOTE: Mark the location of the hoses.

4852210 (07-06) 20-110-2 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING MODE VALVE BLOCK (CONT'D)

Parts Identification

4852210 (07-06) 20-110-3 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING MODE VALVE BLOCK (CONT'D)

Disassembly
IMPORTANT
Clean the outside of the valve block before disassembly.
When repairing hydrostatic and hydraulic systems,
Mark the outside of the valve block for ease of assembly. clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
Figure 20-110-6 tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

1
Figure 20-110-8

1
1

P-42291

Remove the four O-rings (Item 1) [Figure 20-110-6] from

the housing.
P-42294

Figure 20-110-7
Remove the solenoids (Item 1) [Figure 20-110-8] from
the solenoid shafts.

Figure 20-110-9

1 1

P-42292

Remove the nut (Item 1) [Figure 20-110-7] from each

solenoid.
P-42295

NOTE: Mark the location of the solenoids.

Remove the O-ring (Item 1) [Figure 20-110-9] from both
shafts.

4852210 (07-06) 20-110-4 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING MODE VALVE BLOCK (CONT'D) Figure 20-110-12

Disassembly (Cont'd)

Figure 20-110-10

1 1

P-42299

Remove the O-ring (Item 1) [Figure 20-110-12] from each

P-42296 shaft.

Figure 20-110-13
Loosen the shafts (Item 1) [Figure 20-110-10].

Figure 20-110-11

5
1
4
2
1

3
P-42300

P-42297 Carefully remove the spool (Item 1) [Figure 20-110-13]

from the housing.

Remove the shaft (Item 1), pin (Item 2), spring (Item 3)
and spring retainer (Item 4) from the housing (Item 5)
[Figure 20-110-11]. (Both Sides)

4852210 (07-06) 20-110-5 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING MODE VALVE BLOCK (CONT'D) Figure 20-110-16

Solenoid Testing

Figure 20-110-14

P-42299

Install a new O-ring (Item 1) [Figure 20-110-16] on each

P-42301 shaft.

Figure 20-110-17
Use a circuit tester, touch one probe to the prong and the
other probe to the other prong [Figure 20-110-14], there
must be continuity. If there is no continuity, replace the
solenoid. 5
2
Assembly

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts. 1
3
Always install new seals and O-rings. Lubricate all seals 4
and O-rings with clean hydraulic fluid before installation.
P-42297
Figure 20-110-15

Install the spring retainer (Item 1), spring (Item 2), pin
(Item 3) and shaft (Item 4) in the housing (Item 5) [Figure
20-110-17]. (Both Sides)

P-42300

Carefully install the spool (Item 1) [Figure 20-110-15].

4852210 (07-06) 20-110-6 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING MODE VALVE BLOCK (CONT'D) Figure 20-110-20

Assembly (Cont'd)

Figure 20-110-18

1 1

P-42293

Install the O-ring (Item 1) [Figure 20-110-20] on the two

P-42296 solenoids.

Figure 20-110-21
Tighten each shaft (Item 1) [Figure 20-110-18].

Figure 20-110-19 1

2
1 1

P-42294

P-42295 Install the solenoids (Item 1) on the shafts (Item 2)

[Figure 20-110-21].

Install an O-ring (Item 1) [Figure 20-110-19] on each

shaft.

4852210 (07-06) 20-110-7 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING MODE VALVE BLOCK (CONT'D)

Assembly (Cont'd)

Figure 20-110-22

1 1

P-42292

Install the nuts (Item 1) [Figure 20-110-22] on each shaft

and hand tighten.

NOTE: Do not overtighten the nuts.

Figure 20-110-23

P-42291

Install the four O-rings (Item 1) [Figure 20-110-23] on the

housing

4852210 (07-06) 20-110-8 Bobcat T2556 & T2566

SERVICE MANUAL
BRAKE VALVE Figure 20-120-3

Removal And Installation

Figure 20-120-1

Remove the accelerator cable (Item 1) from the pedal and

mounting bracket (Item 2) [Figure 20-120-3].
P-52341
Figure 20-120-4
Remove the dash cover/column cover. (See Content
Page 50-01.)

Disconnect the two harness connectors (Item 1) [Figure

20-120-1] from the brake light switch.

Figure 20-120-2

Remove the three hoses (Item 1) [Figure 20-120-4] from

the brake valve.

NOTE: Mark hoses for correct installation.

P-42865

Disconnect the harness connector (Item 1) [Figure 20-

IMPORTANT
120-2] from the inching switch.
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

4852210 (07-06) 20-120-1 Bobcat T2556 & T2566

SERVICE MANUAL
BRAKE VALVE (CONT’D) Figure 20-120-7

Removal and Installation (Cont’d)

Figure 20-120-5

P-42870

Remove the roll pin (Item 1) and pedal (Item 2) [Figure

20-120-7].

Remove the mounting bolts (Item 1) [Figure 20-120-5]. Figure 20-120-8

Remove the pedal assembly.

Disassembly And Assembly

2
Figure 20-120-6

2 1
1

P-42871

Assembly: Align the hole (Item 1) in the pedal with the

hole (Item 2) [Figure 20-120-8] in the shaft.

P-42869

Remove the bolt (Item 1) and spring (Item 2) [Figure 20-

120-6].

4852210 (07-06) 20-120-2 Bobcat T2556 & T2566

SERVICE MANUAL
BRAKE VALVE (CONT’D) Figure 20-120-11

Disassembly And Assembly (Cont’d)

Figure 20-120-9

P-42875

Remove the shaft and bearing assembly [Figure 20-120-

P-42872 11].

Figure 20-120-12
Loosen the two set screws (Item 1) [Figure 20-120-9] on
the two bearings. 1

Figure 20-120-10
1 2

2
1 P-42876

1
Remove the flanges (Item 1) and bearings (Item 2)
P-42874 [Figure 20-120-12].

Remove the three bolts (Item 1) [Figure 20-120-10] from

both bearing flanges.

4852210 (07-06) 20-120-3 Bobcat T2556 & T2566

SERVICE MANUAL
BRAKE VALVE (CONT’D) Figure 20-120-15

Disassembly And Assembly (Cont’d)

Figure 20-120-13

P-42879

Remove the brake valve (Item 1) [Figure 20-120-15]

P-42878

Remove the three fittings (Item 1) [Figure 20-120-13]

from the brake valve.

Figure 20-120-14

2
P-42877

Remove the four bolts (Item 1) spacers (Item 2) [Figure

20-120-14] and nuts from the brake valve.

4852210 (07-06) 20-120-4 Bobcat T2556 & T2566

SERVICE MANUAL
GEAR PUMP Figure 20-130-2

Removal And Installation

1

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. 1
I-2003-0888

P-53566
Figure 20-130-1

Remove the two bolts (Item 1) [Figure 20-130-2] and

1 separate the main harness.
1
Figure 20-130-3

P-53565

Drain the hydraulic reservoir.

Unplug the electrical connectors (Item 1) [Figure 20-130- P-53581

1] in the battery box.

NOTE: Mark all electrical connectors, hoses and Remove the hose (Item 1) [Figure 20-130-3] from the
tubelines for correct assembly. pump.

4852210 (07-06) 20-130-1 Bobcat T2556 & T2566

SERVICE MANUAL
GEAR PUMP (CONT’D) Figure 20-130-6

Removal And Installation (Cont’d)

Figure 20-130-4

P-53578

Remove the two hoses (Item 1) [Figure 20-130-6] from

P-53582 the gear pump.

Figure 20-130-7
Remove the hose (Item 1) [Figure 20-130-4] from the
gear pump.

Figure 20-130-5

P-53589

Remove the two gear pump mounting bolts (Item 1)

P-53602 [Figure 20-130-7]. Remove the gear pump.

Installation: Tighten the mounting bolts to 52 - 59 ft.-lbs.

Remove the hose (Item 1) [Figure 20-130-5] from the (70,8 - 80 Nm) torque.
brake valve.

4852210 (07-06) 20-130-2 Bobcat T2556 & T2566

SERVICE MANUAL
GEAR PUMP (CONT’D)

Parts Identification

1. Fitting
2. O-ring
3. Spring
4. Spring Seat
5. Spool 1
6. Screen 2
7. Orifice Spool 3
8. Bolt
9. Housing 4
10. Plug 5
11. Seal Ring
12. Main Housing 6
13. Backup Ring
7
14. Seal Ring
15
15. Holder
16. Gear 16 13
17. Drive Shaft 14
18. Mount Plate 15
19. Thrust Plate
20. Mount Plate
21. Seal
22. Snap Ring 14
13
9
12
12
11
8 10
16
2
8

19
14
17 13

18
22 2
21
8

14 20
13
19

MS1176

4852210 (07-06) 20-130-3 Bobcat T2556 & T2566

SERVICE MANUAL
GEAR PUMP (CONT'D) Figure 20-130-10

Disassembly And Assembly

Clean the outside of the gear pump before disassembly.

Mark the outside of the gear pump for ease of assembly.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
P-55040
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 Remove the flow divider from the housing [Figure 20-
130-10].
Figure 20-130-8
Figure 20-130-11

6
1
2
1 5 4 3

1
P-55038
P-55041

Remove the fittings (Item 1) [Figure 20-130-8].

Remove the plug (Item 1), O-ring (Item 2), spring (Item 3),
Figure 20-130-9 spring seat (Item 4) and spool (Item 5) from the housing
(Item 6) [Figure 20-130-11].
1
NOTE: Always use new O-rings.

P-55039

Remove the four bolts (Item 1) [Figure 20-130-9].

Assembly: Tighten the bolts to 25 ft.-lbs. (33 Nm) torque.

4852210 (07-06) 20-130-4 Bobcat T2556 & T2566

SERVICE MANUAL
GEAR PUMP (CONT'D) Figure 20-130-14

Disassembly And Assembly (Cont'd)

Figure 20-130-12

To remove the orifice assembly (Item 1) [Figure 20-130-

14] from the spool, a holding fixture will have to be made
from a 0.750 inch thick x 1.500 inches wide x 2.0 inches
long (19 mm) thick x 38 mm wide x 50 mm long) piece of
Remove the plug (Item 1) and O-ring (Item 2) [Figure 20- hardwood. Drill a 0.550 inch (14 mm) hole in the center of
130-12] from the housing. the hardwood block. Cut the block lengthwise [Figure 20-
130-13].
Figure 20-130-13
Place both halves of the hardwood block around the
spool. Clamp the blocks in a vise [Figure 20-130-14].

NOTE: Do not use anything other than hardwood

blocks to grip the spool, or the spool will be
damaged.

Remove the orifice assembly.

Figure 20-130-15

Remove the screen (Item 1) from the orifice (Item 2)

[Figure 20-130-15] and clean.

4852210 (07-06) 20-130-5 Bobcat T2556 & T2566

SERVICE MANUAL
GEAR PUMP (CONT'D) Remove the housing/gear assembly (Item 1) [Figure 20-
130-18] from the main housing.
Disassembly And Assembly (Cont'd)
Figure 20-130-19
Figure 20-130-16

1 3
1

P-55047
P-55043

Remove the housing (Item 1) from the gear assembly

Remove the four mount bolts (Item 1) [Figure 20-130-16]. (Item 2) [Figure 20-130-19].

Figure 20-130-17 Assembly: The position of the small opening (Item 3) on

the gear holders will point towards the large port (Item 4)
[Figure 20-130-19] on the housing.

P-55044

Remove the cover (Item 1) [Figure 20-130-17].

Figure 20-130-18

P-55045

4852210 (07-06) 20-130-6 Bobcat T2556 & T2566

SERVICE MANUAL
GEAR PUMP (CONT'D) Figure 20-130-22

Disassembly And Assembly (Cont'd)

1
Figure 20-130-20 1

P-55050

Remove and discard the two O-rings (Item 1) [Figure 20-

P-55048 130-22] from the flange.

Figure 20-130-23
Remove both O-rings (Item 1) [Figure 20-130-20] from
the housing.
1 1
Figure 20-130-21

2
2

1
1
1 P-55051

Remove the four bolts (Item 1) and drive shaft (Item 2)

P-55049 [Figure 20-130-23].

Assembly: Tighten the bolts to 25 ft.-lbs. (33 Nm) torque.

Remove the backup ring (Item 1) and seal ring (Item 2)
[Figure 20-130-21] from the gear holder.

Assembly: The seal ring (Item 2) [Figure 20-130-21] is

installed onto the gear holder first followed by the backup
ring.

4852210 (07-06) 20-130-7 Bobcat T2556 & T2566

SERVICE MANUAL
GEAR PUMP (CONT'D) Figure 20-130-26

Disassembly And Assembly (Cont'd)

Figure 20-130-24

P-55055

Remove the shaft seal (Item 1) [Figure 20-130-26].

P-55053
Figure 20-130-27

Turn the housing over and remove the mount plate 2

[Figure 20-130-24].

Figure 20-130-25 1

1 3

P-55056

Remove the O-ring (Item 1) and gear assembly (Item 2)

[Figure 20-130-27] from the housing.
P-55054
Assembly: The position of the V portion (Item 3) on the
thrust plate must point towards the larger port (Item 4)
Remove the snap ring (Item 1) [Figure 20-130-25]. [Figure 20-130-27] on the housing.

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

4852210 (07-06) 20-130-8 Bobcat T2556 & T2566

SERVICE MANUAL
GEAR PUMP (CONT'D)

Disassembly And Assembly (Cont'd)

Figure 20-130-28

Remove the two thrust plates (Item 1), seal ring (Item 2)
and backup ring (Item 3) [Figure 20-130-28] from the
gears.

Assembly: The seal ring (Item 2) will be installed on the

thrust plate (Item 1) first followed by the backup ring (Item
3) [Figure 20-130-28].

4852210 (07-06) 20-130-9 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 20-130-10 Bobcat T2556 & T2566
SERVICE MANUAL
FAN MOTOR Figure 20-140-3

Removal And Installation

1

IMPORTANT
When repairing hydrostatic and hydraulic systems, 2
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-53261
Drain the radiator. (See “Replacing The Coolant” on
page 10-70-2.)
Mark the location of the hood latch (Item 1). Remove the
two mounting bolts (Item 2) [Figure 20-140-3]. Remove
Figure 20-140-1
the hood latch.

Figure 20-140-4

2
1
1

P-53265

Loosen the two hose clamps (Item 1) and remove the P-53262
radiator hose (Item 2) [Figure 20-140-1].
Remove the top hose (Item 1) [Figure 20-140-4] from the
Figure 20-140-2
fan motor.

P-53266

Remove the two mounting bolts (Item 1) and remove the

radiator support (Item 2) [Figure 20-140-2].

4852210 (07-06) 20-140-1 Bobcat T2556 & T2566

SERVICE MANUAL
FAN MOTOR (CONT’D) Figure 20-140-7

Removal And Installation (Cont’d)

Figure 20-140-5 1

1
P-53267

Remove the two bolts (Item 1) [Figure 20-140-7] (both

P-53263 sides) from the fan guard.

Figure 20-140-8
Remove the three hoses (Item 1) [Figure 20-140-5] from
the bottom of the fan motor.

Figure 20-140-6

2
1

P-53268

Tilt the cooler forward and carefully remove the fan

P-53264 assembly [Figure 20-140-8].

Loosen the screw (Item 1) and unplug the connector (Item

2) [Figure 20-140-6] (only for 2 speed fan motor).

4852210 (07-06) 20-140-2 Bobcat T2556 & T2566

SERVICE MANUAL
FAN MOTOR (CONT’D) Figure 20-140-11

Removal And Installation (Cont’d)

Figure 20-140-9 2

1 2

1
1

1
1 P-53270

Remove the four fan guard mount bolts (Item 1) and

P-53269 remove the fan guard (Item 2) [Figure 20-140-11].

Figure 20-140-12
Remove the four bolts (Item 1) and remove the blade
assembly (Item 2) [Figure 20-140-9] from the fan motor.

NOTE: Mark the direction of the fan for correct

assembly.
1
Figure 20-140-10

P-53272

Remove the nut and lock washer (Item 1) [Figure 20-140-

12].

P-53271

Mark the location of the fan motor to the fan guard for
correct assembly [Figure 20-140-10].

4852210 (07-06) 20-140-3 Bobcat T2556 & T2566

SERVICE MANUAL
FAN MOTOR (CONT’D)

Removal And Installation (Cont’d)

Figure 20-140-13

P-53273

Remove the fan blade mounting flange (Item 1) [Figure

20-140-13] from the fan motor.

4852210 (07-06) 20-140-4 Bobcat T2556 & T2566

SERVICE MANUAL
FAN MOTOR (CONT’D)

Parts Identification

1 SPEED VERSION:
1
1

2 3

2 SPEED VERSION: 1

1
1

1 Seals
2 Valve
3 Valve (2 speed version only)
* Older models 4 Coil (2 speed version only)

S2754

4852210 (07-06) 20-140-5 Bobcat T2556 & T2566

SERVICE MANUAL
FAN MOTOR (CONT’D) Figure 20-140-16

Disassembly And Assembly (1 speed version)

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-53277
Mark the housing for correct assembly.

Figure 20-140-14 Remove the O-ring (Item 1) [Figure 20-140-16] from the
plug. Replace as needed.

P-53275

Remove the three fittings (Item 1) [Figure 20-140-14].

Figure 20-140-15

4
3
2
1
P-53276

Remove the plug (Item 1), spring (Item 2) and check valve
(Item 3) from the housing (Item 4) [Figure 20-140-15].

4852210 (07-06) 20-140-6 Bobcat T2556 & T2566

SERVICE MANUAL
FAN MOTOR (CONT’D) Figure 20-140-19

Disassembly And Assembly (1 speed version) (Cont’d)

Figure 20-140-17

1
1

1 1 P-53281

Remove the quad ring (Item 1) [Figure 20-140-19] from

P-53278 the housing.

Figure 20-140-20
Remove the four bolts (Item 1) [Figure 20-140-17] from
the end. 2
Assembly: Tighten bolts to 32-35 ft.-lbs. (43-47 Nm) 1
torque.

Figure 20-140-18

P-53282

Remove the gear assembly (Item 1) from the housing

(Item 2) [Figure 20-140-20].

P-53279

Remove the end cover (Item 1) from the main housing

(Item 2) [Figure 20-140-18].

4852210 (07-06) 20-140-7 Bobcat T2556 & T2566

SERVICE MANUAL
FAN MOTOR (CONT’D) Figure 20-140-23

Disassembly And Assembly (1 speed version) (Cont’d)

Figure 20-140-21

P-53285

1
Inspect the gears (Item 1) [Figure 20-140-23] for damage
P-53283 or wear

Remove the backup ring/seal (Item 1) [Figure 20-140-21]

from the gear holder.

Figure 20-140-22

P-53256

Remove the snap ring (Item 1) (Older Models Only) and

remove the seal (Item 2) [Figure 20-140-22].

Assembly: The open part of the seal goes into the

housing first.

4852210 (07-06) 20-140-8 Bobcat T2556 & T2566

SERVICE MANUAL
FAN MOTOR (CONT’D) Figure 20-140-26

Disassembly And Assembly (2 speed version)

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 4
3
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. 2
I-2003-0888
1
P-53276
Figure 20-140-24

Remove the plug (Item 1), spring (Item 2) and check valve
2 1 (Item 3) from the housing (Item 4) [Figure 20-140-15].

Figure 20-140-27

P-53274
1

Remove the nut (Item 1) and solenoid (Item 2) [Figure

20-140-24].
P-53277
Mark the housing for correct assembly.

Figure 20-140-25 Remove the O-ring (Item 1) [Figure 20-140-16] from the
plug. Replace as needed.

2
1

P-53275

Remove the solenoid (Item 1) and three fittings (Item 2)

[Figure 20-140-14].

4852210 (07-06) 20-140-9 Bobcat T2556 & T2566

SERVICE MANUAL
FAN MOTOR (CONT’D) Figure 20-140-30

Disassembly And Assembly (2 speed version) (Cont’d)

Figure 20-140-28

1
1

1 1 P-53281

Remove the quad ring (Item 1) [Figure 20-140-19] from

P-53278 the housing.

Figure 20-140-31
Remove the four bolts (Item 1) [Figure 20-140-17] from
the end. 2
Assembly: Tighten bolts to 32-35 ft.-lbs. (43-47 Nm) 1
torque.

Figure 20-140-29

P-53282

Remove the gear assembly (Item 1) from the housing

(Item 2) [Figure 20-140-20].

P-53279

Remove the end cover (Item 1) from the main housing

(Item 2) [Figure 20-140-18].

4852210 (07-06) 20-140-10 Bobcat T2556 & T2566

SERVICE MANUAL
FAN MOTOR (CONT’D) Figure 20-140-34

Disassembly And Assembly (2 speed version) (Cont’d)

Figure 20-140-32

P-53285

1
Inspect the gears (Item 1) [Figure 20-140-23] for damage
P-53283 or wear

Remove the backup ring/seal (Item 1) [Figure 20-140-21]

from the gear holder.

Figure 20-140-33

P-53256

Remove the snap ring (Item 1) (Older Models Only) and

remove the seal (Item 2) [Figure 20-140-22].

Assembly: The open part of the seal goes into the

housing first.

4852210 (07-06) 20-140-11 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 20-140-12 Bobcat T2556 & T2566
SERVICE MANUAL
HYDRAULIC RESERVOIR Figure 20-150-3

Removal And Installation

2
Remove the engine/hydrostat assembly. (See “Removal
And Installation” on page 70-80-1)

Figure 20-150-1

1 P-55215

Remove the hose (Item 1) [Figure 20-150-3] from the

tubeline.

Remove the mounting bolt (Item 2) [Figure 20-150-3].

P-55213
Figure 20-150-4

Remove the two bolts (Item 1) [Figure 20-150-1].

Figure 20-150-2

1 1

2
P-55216

Loosen the nut (Item 1) [Figure 20-150-4] on the tubeline.

P-55214
Remove the tubeline.

Remove the bolt (Item 1) and shield (Item 2) [Figure 20-

150-2].

4852210 (07-06) 20-150-1 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC RESERVOIR (CONT’D) Figure 20-150-7

Removal And Installation (Cont’d)

Figure 20-150-5

P-55220

Figure 20-150-8
P-55217

Remove the hose (Item 1) [Figure 20-150-5] from the

tank.

Figure 20-150-6

P-55219

1
Remove the two tank mounting bolts (Item 1) [Figure 20-
150-7] and [Figure 20-150-8].

Remove the hydraulic reservoir.

P-55218

Remove the two hoses (Item 1) [Figure 20-150-6] from

the filter.

4852210 (07-06) 20-150-2 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING VALVE

Removal And Installation

Remove the dash cover/column cover (See “Removal

And Installation” on page 50-130-1).
IMPORTANT
Figure 20-160-1 When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
1 damage the system.
I-2003-0888

Figure 20-160-2

P-42863

Remove the five hoses (Item 1) [Figure 20-160-1] from

the steering valve.

NOTE: Mark hoses for correct installation.

Remove the four bolts (Item 1) [Figure 20-160-2] and

remove the steering valve.

4852210 (07-06) 20-160-1 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING VALVE (CONT’D)

Parts Identification

1. Bolt
2. End Cap
3. Spacer Gear
4. O-ring
5. Geroler Assembly
6. Drive Shaft
7. Valve Plate 1
8. Spool
9. Sleeve
10. Springs
11. Drive Pin 3 2
12. Pin
13. Check Ball 4
14. Housing
15. Thrust Washer 5
16. Thrust Bearing 6
17. Quad Ring
18. Seal Housing
4
19. Seal
20. Retainer Ring 7
21. Ball Seat
22. Poppet 4
23. Spring
24. Plug 8
10

22
23
24
13 9
21
23
24 11

14
15
16 12
15 13
17
13
4
21
18
23
20 24
19
MS1226

4852210 (07-06) 20-160-2 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING VALVE (CONT'D) Figure 20-160-5

Disassembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure 20-160-3
Remove the end cap (Item 1) [Figure 20-160-5].

Figure 20-160-6

Remove the fittings (Item 1) from the steering valve

[Figure 20-160-3].

Figure 20-160-4 Remove and discard the O-ring (Item 1) [Figure 20-160-
6].

Figure 20-160-7

Remove the seven end cap bolts (Item 1) [Figure 20-160-

4].

Remove the spacer gear (Item 1) [Figure 20-160-7].

4852210 (07-06) 20-160-3 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING VALVE (CONT'D) Figure 20-160-11

Disassembly (Cont'd)

Figure 20-160-8

Remove the valve plate (Item 1) [Figure 20-160-11].

Remove the geroler assembly (Item 1) [Figure 20-160-8].

Figure 20-160-9

Remove the O-ring (Item 1) [Figure 20-160-9] from the

valve plate.

Figure 20-160-10

Remove the drive shaft (Item 1) [Figure 20-160-10].

4852210 (07-06) 20-160-4 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING VALVE (CONT'D) Figure 20-160-14

Disassembly (Cont'd)

Figure 20-160-12

Remove the three pins (Item 1) [Figure 20-160-14] from

each port.

NOTE: Record the location of each pin for correct

Remove the O-ring (Item 1) [Figure 20-160-12] from the assembly.
housing.
Figure 20-160-15
Figure 20-160-13

Remove the three check balls (Item 1) [Figure 20-160-15]

Mark the location of the three ports (Item 1) [Figure 20- from each port.
160-13] for correct assembly.
NOTE: Record the location of each check ball for
correct assembly.

4852210 (07-06) 20-160-5 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING VALVE (CONT'D) Figure 20-160-18

Disassembly (Cont'd)

Figure 20-160-16

Remove and discard the seal (Item 1) [Figure 20-160-

18].

Figure 20-160-19
Remove the seal retainer ring (Item 1) [Figure 20-160-
16].

Figure 20-160-17

Remove and discard the quad ring seal (Item 1) [Figure

20-160-19].

Remove the seal housing (Item 1) [Figure 20-160-17] by

prying upward.

4852210 (07-06) 20-160-6 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING VALVE (CONT'D) Figure 20-160-22

Disassembly (Cont'd)

Figure 20-160-20

Remove the control spool/sleeve assembly (Item 1) from

the metering end of the housing (Item 2) [Figure 20-160-
22].

Remove and discard the O-ring (Item 1) [Figure 20-160- NOTE: When removing the spool, keep the drive pin
20] from the housing. (Item 3) [Figure 20-160-22] horizontal. If the pin
becomes vertical, it may drop from the spool
Figure 20-160-21 and get caught in an oil passage inside the
housing.

Figure 20-160-23

Remove the two thrust washers (Item 1) and thrust

bearing (Item 2) [Figure 20-160-21] from the spool.

Remove the drive pin (Item 1) [Figure 20-160-23].

4852210 (07-06) 20-160-7 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING VALVE (CONT'D) Figure 20-160-26

Disassembly (Cont'd)

Figure 20-160-24

Remove the two check valve plugs (Item 1), springs (Item
2), ball seat (Item 3) and check ball (Item 4) [Figure 20-
160-26] from the housing.

Remove the spool (Item 1) from the sleeve (Item 2) NOTE: Record the location of each check ball
[Figure 20-160-24]. assembly for correct assembly.

NOTE: If the spool and sleeve will not slide or rotate Figure 20-160-27
within each other freely or in the housing, they
must be replaced.

Figure 20-160-25

Remove the check valve plug (Item 1), spring (Item 2) and
poppet (Item 3) [Figure 20-160-27] from the housing.

NOTE: Record the location of the port for correct

Remove the springs (Item 1) [Figure 20-160-25] from the assembly.
spool.

NOTE: There are six springs positioned three per side

and back to back.

4852210 (07-06) 20-160-8 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING VALVE (CONT'D) Assembly

Inspection

Figure 20-160-28
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Prior to assembly, clean and lightly oil all parts.

Figure 20-160-30

Inspect the spool (Item 1) and sleeve (Item 2) [Figure 20-

160-28] for any damage or wear. Replace as needed.

Figure 20-160-29

Install a new O-ring (Item 1) [Figure 20-160-30] on the

three check valve plugs.

Figure 20-160-31

Inspect the drive shaft (Item 1) [Figure 20-160-29] for

damage or wear.

Install the poppet (Item 1), spring (Item 2) and plug (Item
3) [Figure 20-160-31] into the correct port marked earlier.

4852210 (07-06) 20-160-9 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING VALVE (CONT'D) Figure 20-160-34

Assembly (Cont’d)

Figure 20-160-32

Install the spool (Item 1) into the sleeve (Item 2) [Figure

20-160-34].

NOTE: The spool should turn freely inside the sleeve.

Install the check ball (Item 1), ball seat (Item 2), spring
(Item 3) and plug (Item 4) [Figure 20-160-32] into the Figure 20-160-35
correct port marked earlier.

Turn each of the port plugs (Item 3) [Figure 20-160-31]

and (Item 4) [Figure 20-160-32] in the housing until they
are tight, then back each of them out 1-1/2 turns.

Figure 20-160-33

Install the drive pin (Item 1) [Figure 20-160-35].

Install the springs (Item 1) [Figure 20-160-33] into the

spool.

NOTE: There are six springs and should be positioned

three per side and back to back.

4852210 (07-06) 20-160-10 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING VALVE (CONT'D) Figure 20-160-38

Assembly (Cont'd)

Figure 20-160-36

Install a new O-ring (Item 1) [Figure 20-160-38] into the

housing.

Figure 20-160-39
Install the control spool/sleeve assembly (Item 1) into the
metering end of the housing (Item 2) [Figure 20-160-36].

NOTE: When installing the spool assembly keep the

drive pin (Item 3) [Figure 20-160-36] horizontal.
If the pin becomes vertical it may drop from the
spool and get caught in an oil passage inside
the housing.

Figure 20-160-37

Install a new quad ring seal (Item 1) [Figure 20-160-39].

Figure 20-160-40

Install the two thrust washers (Item 1) and thrust bearing

(Item 2) [Figure 20-160-37] on the spool.

Install a new seal (Item 1) [Figure 20-160-40].

4852210 (07-06) 20-160-11 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING VALVE (CONT'D) Figure 20-160-43

Assembly (Cont'd)

Figure 20-160-41

Install the three check balls (Item 1) [Figure 20-160-43] in

their proper port (marked earlier).

Figure 20-160-44
Install the seal housing (Item 1) [Figure 20-160-41].

Figure 20-160-42

Install the three pins (Item 1) [Figure 20-160-44] in their

proper port (marked earlier).

Install the seal retainer ring (Item 1) [Figure 20-160-42].

4852210 (07-06) 20-160-12 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING VALVE (CONT'D) Figure 20-160-47

Assembly (Cont'd)
3
Figure 20-160-45

2
P-44862

Align the groove (Item 1) in the drive shaft with the drive
pin (Item 2) [Figure 20-160-47] and install the drive shaft.
Be sure the drive shaft is engaged with the pin.
Install a new O-ring (Item 1) [Figure 20-160-45] into the
housing groove. NOTE: The pin (Item 2) must be parallel with the port
face of the housing (Item 3) [Figure 20-160-47].
Figure 20-160-46
Figure 20-160-48

P-44864
Align and install the 14 hole valve plate (Item 1) [Figure
20-160-46] on the housing.
To assure proper geroler alignment, mark the top of the
drive shaft (Item 1) (as shown) parallel to the port face
(Item 2) [Figure 20-160-48].

Install a new O-ring (Item 3) [Figure 20-160-48] into the

valve plate groove.

4852210 (07-06) 20-160-13 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING VALVE (CONT'D) Figure 20-160-51

Assembly (Cont'd)

Figure 20-160-49 1 2

2
2

P-27161

3 Install the spacer gear (Item 1) and a new O-ring (Item 2)

P-44863 [Figure 20-160-51] into the geroler plate groove.

Figure 20-160-52
Install the geroler star (Item 1) [Figure 20-160-49] onto
the valve plate and drive shaft.

NOTE: Align the two valleys (Item 2) of the star with the
mark on the drive gear (Item 3) [Figure 20-160-
49].

Figure 20-160-50

1
2

Install the end cap using the seven bolts (Item 1) [Figure
20-160-52]. Tighten to 8-13 ft.-lbs. (11-18 Nm) torque in a
criss cross pattern.

P-44865

Install the outer gear (Item 1) onto the star (Item 2)

[Figure 20-160-50] and align the bolt holes without
disengaging the drive shaft.

4852210 (07-06) 20-160-14 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING VALVE (CONT'D)

Assembly (Cont'd)

Figure 20-160-53

Install the fittings (Item 1) [Figure 20-160-53] as shown.

4852210 (07-06) 20-160-15 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 20-160-16 Bobcat T2556 & T2566
SERVICE MANUAL
HYDRAULIC CONTROL VALVE

Troubleshooting Chart (Controllers)

The following troubleshooting chart is provided for

assistance in locating and correcting problems which are
WARNING
most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285

PROBLEM CAUSE CORRECTION

None of the controllers work Insufficient power supply Check battery voltage
Insufficient pilot pressure Check pilot pressure
Plugged controller filter Clean filter
Only one controller works No actuation signal Check signal voltage
Unsuitable actuation signal Check signal voltage
Insufficient actuation power supply Check signal voltage
All controllers not working or jerky Plugged controller filter Clean filter
One controller not working or jerky Faulty actuation signal Check signal
Friction or jamming of the plunger Replace controller
One controller not working or jerky Contamination of the proportional Replace controller
in one direction valve in the controller
Controller creeps Neutral position incorrect Adjust neutral adjustment
Oil leakage between control valve Faulty seals Replace seal
and controller
Oil leakage between controllers Faulty controller couplers Replace controller couplers

4852210 (07-06) 20-170-1 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-2

Telescoping Valve Section Troubleshooting

Record the serial number of the machine, control valve

and control module.

The following procedure must be done with the control

valve in the machine. The control valve is removed for
photo clarity.

With the engine OFF, the key switch in the run position, 1
move the joystick handle to relieve any hydraulic
pressure.

Remove the rear cover from machine. P-52900

Figure 10-10-1
1. Locate the telescoping valve section (Item 1) [Figure
20-170-2] on the control valve.

P-50797

The hydraulic control function switch (Item 1) [Figure 10-

10-1] must be ON (light is on) for all testing procedures.

4852210 (07-06) 20-170-2 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-4

Telescoping Valve Section Troubleshooting (Cont’d)

Figure 20-170-3
m
1 Maximu
l
Neutra
1
m
Minimu

P-47793
P-52155

2. With the engine OFF, the key in the run position, check
that the battery voltage on the controller connector 4. With the telescopic function switch (Item 1) [Figure
(Item 1) [Figure 20-170-3] (pin 1, blue wire) is at least 20-170-4] in the minimum (back) position check that
12 volts or higher. the voltage on the controller connector (Item 1)
[Figure 20-170-3] (pin 3, brown wire) is 0.9 volts. If the
3. With the engine OFF, the key in the run position, check voltage drops below 0.9 volts the controller will
the regulated voltage on the controller connector (Item interpret this as a failure.
1) [Figure 20-170-3] (pin 4, black wire) is 5 volts. If 5
volts is not seen, replace the controller. 5. With the telescopic function switch (Item 1) [Figure
20-170-4] in the neutral (middle) position check that
the voltage on the controller connector (Item 1)
[Figure 20-170-3] (pin 3, brown wire) is 2.5 volts.

6. With the telescopic function switch (Item 1) [Figure

20-170-4] in the maximum (forward) position check
that the voltage on the controller connector (Item 1)
[Figure 20-170-3] (pin 3, brown wire) is 4.1 volts.

If one of the three voltage readings in Steps 4, 5 and 6 is

not correct, replace the joystick handle. (See “JOYSTICK”
on page 20-180-1)

If all voltage readings in Steps 4, 5 and 6 are correct go to

step 7.

4852210 (07-06) 20-170-3 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Checking Drain Pressure

Telescoping Valve Section Troubleshooting (Cont’d) Figure 20-170-7

Checking Pilot Pressure

1
Figure 20-170-5

P-52915

11. Remove the cap (Item 1) [Figure 20-170-7] from the

P-52912 tee fitting.

Figure 20-170-8
7. Locate the test fitting (Item 1) [Figure 20-170-5] below
the control valve and remove the cap.

Figure 20-170-6

P-52913

12. Install a 500 PSI (35 bar) gauge on the tee fitting
P-52913 [Figure 20-170-8].

13. Start the engine, lower the restraint bar (if equipped)
8. Install a 1000 PSI (70 bar) gauge on the test fitting and run the engine at 2200 RPM. Record the pressure.
[Figure 20-170-6]. The pressure at the gauge should be 22 PSI (1,5 bar)
maximum.
9. Start the engine, lower the restraint bar (if equipped)
and run the engine at 2200 RPM. Record the pressure. 14. Remove the gauge.
The pressure at the gauge should be 508 PSI (35 bar)
maximum.

10. Remove the gauge.

4852210 (07-06) 20-170-4 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-11

Telescoping Valve Section Troubleshooting (Cont’d)

Figure 20-170-9

1 2
P-52901

17. If the telescopic function does not work, remove the

P-52155 two screws (Item 1) and remove the cover (Item 2)
[Figure 20-170-11].

15. With adequate room in front of the machine, start the 18. Start the engine, lower the restraint bar (if equipped)
engine, lower the restraint bar (if equipped) and run and run the engine at 2200 RPM.
the engine at 2200 RPM. Move the telescopic control
switch (Item 1) [Figure 20-170-9] forward and back to Figure 20-170-12
see if this function works. Stop the engine.

Figure 20-170-10

P-61126

P-47793 19. Manually push and pull the spool (Item 1) [Figure 20-
170-12] to test the movement of the telescopic
function in both directions.
16. If the telescopic function does not work, with the
engine running unplug the controller connector (Item NOTE: If by manually operating the spool, and the
1) [Figure 20-170-10] and plug it back in. telescopic function is working the controller
must be replaced.

4852210 (07-06) 20-170-5 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-14

Auxiliary Valve Section Troubleshooting

Record the serial number of the machine, control valve

and control module.

The following procedure must be done with the control

valve in the machine. The control valve is removed for
photo clarity.

With the engine OFF, the key switch in the run position, 1
move the joystick handle to relieve any hydraulic
pressure.

Figure 20-170-13 P-52900

1. Locate the auxiliary valve section (Item 1) [Figure 20-

1 170-14] on the control valve.

P-50797

The hydraulic control function switch (Item 1) must be ON

(light is on) and the front auxiliary hydraulics ON/OFF
switch (Item 2) [Figure 20-170-13] must be ON (top
position).

4852210 (07-06) 20-170-6 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-16

Auxiliary Valve Section Troubleshooting (Cont’d)

Figure 20-170-15
m
Maximu
1
l
Neutra
m
Minimu
1

P-47793
P-52155

2. With the engine OFF, the key in the run position, check
that the battery voltage on the controller connector 4. With the auxiliary function switch (Item 1) [Figure 20-
(Item 1) [Figure 20-170-15] (pin 1, blue wire) is at 170-16] in the minimum (back) position check that the
least 12 volts or higher. voltage on the controller connector (Item 1) [Figure
20-170-15] (pin 3, brown wire) is 0.9 volts. If the
3. With the engine OFF, they key switch in the run voltage drops below 0.9 volts the controller will
position, check the regulated voltage on the controller interpret this as a failure.
connector (Item 1) [Figure 20-170-15] (pin 4, black
wire) is 5 volts. If 5 volts is not seen, replace the 5. With the auxiliary function switch (Item 1) [Figure 20-
controller. 170-16] in the neutral (middle) position check that the
voltage on the controller connector (Item 1) [Figure
20-170-15] (pin 3, brown wire) is 2.5 volts.

6. With the auxiliary function switch (Item 1) [Figure 20-

170-16] in the maximum (forward) position check that
the voltage on the controller connector (Item 1)
[Figure 20-170-15] (pin 3, brown wire) is 4.1 volts.

If one of the three voltage readings in Steps 4, 5 and 6 is

not correct, replace the joystick handle. (See “JOYSTICK”
on page 20-180-1)

If all voltage readings in Steps 4, 5 and 6 are correct go to

step 7.

4852210 (07-06) 20-170-7 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Checking Drain Pressure

Auxiliary Valve Section Troubleshooting (Cont’d) Figure 20-170-19

Checking Pilot Pressure

1
Figure 20-170-17

P-52915

11. Remove the cap (Item 1) [Figure 20-170-19] from the

P-52912 tee fitting.

Figure 20-170-20
7. Locate the test fitting (Item 1) [Figure 20-170-17]
below the control valve and remove the cap.

Figure 20-170-18

P-52913

12. Install a 500 PSI (35 bar) gauge on the tee fitting
P-52913 [Figure 20-170-20].

13. Start the engine, lower the restraint bar (if equipped)
8. Install a 1000 PSI (70 bar) gauge on the test fitting and run the engine at 2200 RPM. Record the pressure.
[Figure 20-170-18]. The pressure at the gauge should be 22 PSI (1,5 bar)
maximum.
9. Start the engine, lower the restraint bar (if equipped)
and run the engine at 2200 RPM. Record the pressure. 14. Remove the gauge.
The pressure at the gauge should be 508 PSI (35 bar)
maximum.

10. Remove the gauge.

4852210 (07-06) 20-170-8 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-23

Auxiliary Valve Section Troubleshooting (Cont’d)

Figure 20-170-21

1 2

P-52901

17. If the auxiliary function does not work, remove the two
P-52155 screws (Item 1) and remove the cover (Item 2) [Figure
20-170-23].

15. With adequate room in front of the machine, start the 18. Start the engine, lower the restraint bar (if equipped)
engine, lower the restraint bar (if equipped) and run and run the engine at 2200 RPM.
the engine at 2200 RPM. Move the auxiliary control
switch (Item 1) [Figure 20-170-21] forward and back Figure 20-170-24
to see if this function works. Stop the engine.

Figure 20-170-22

P-61228

P-47793 19. Manually push and pull the spool (Item 1) [Figure 20-
170-24] to test the movement of the auxiliary function
in both directions.
16. If the telescopic function does not work, with the
engine running unplug the controller connector (Item NOTE: If by manually operating the spool, and the
1) [Figure 20-170-22] and plug it back in. auxiliary function is working the controller
must be replaced.

4852210 (07-06) 20-170-9 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D)

Troubleshooting Chart (Control Valve)

WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
W-2004-1285

PROBLEM CAUSE CORRECTION

Lack of strength at all actuators Load sense relief cartridge defective Replace relief cartridge
Load sense relief cartridge out of Make necessary adjustments
adjustment
Lack of force on one actuator only Secondary relief valve out of adjust- Reset to original pressure
ment
Secondary relief valve blocked open Replace relief valve
Lack of load hold Load check valve failure Replace load check valve
Excessive clearance between hous- Replace housing and spool
ing and spool
Simultaneous movement of con- Blockage of individual compensator Remove and clean orifice
trols orifice
Individual pressure compensator Replace housing and compensator
blocked
Load sense line leakage Replace load sense regulator
Engine remains under load after Flow regulator blocked Replace flow regulator
spools are returned to neutral Flow regulator filter clogged Replace filter
Detent malfunction Controller defective Replace controller
Spool return difficult Tie rod bolts too tight Re-torque tie rod bolts
Spool leaking oil Defective spool seal Replace spool seal
Oil leakage between valve section Defective seals Replace seals

4852210 (07-06) 20-170-10 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-26

Removal And Installation

Relieve hydraulic pressure. Drain the hydraulic reservoir.

(See “Replacing Hydraulic Fluid” on page 10-100-2)

WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
P-52901
physician familiar with this injury is not received
immediately.
W-2145-0290 Remove the tubeline (Item 1) [Figure 20-170-26].

Figure 20-170-27

IMPORTANT
When making repairs on hydraulic system, clean the
work area before disassemble and keep all parts
clean. Always use caps and plugs on hoses, tubelines
and ports to keep dirt out. Dirt can quickly damage
the system.
I-2056-0793

Remove the fuel tank (See “Removal And Installation” on

page 50-80-1). 1
P-52902
Figure 20-170-25

Remove the two hoses (Item 1) [Figure 20-170-27].

P-52900

Remove the tubeline (Item 1) [Figure 20-170-25].

NOTE: Mark all hoses and tubelines for correct

installation.

4852210 (07-06) 20-170-11 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-30

Removal And Installation (Cont’d)

Figure 20-170-28 1

P-52905

1
Remove the two tubelines (Item 1) and two hoses (Item 2)
1
P-52903 [Figure 20-170-30].

Figure 20-170-31
Remove the five hoses (Item 1) [Figure 20-170-28] from
the control valve.

Figure 20-170-29

1
2

1 1 P-52906

Remove any tie straps (Item 1) from the electrical

P-52904 harness. Remove the tubeline (Item 2) [Figure 20-170-
31].

Remove the five hoses (Item 1) [Figure 20-170-29] from

the control valve.

4852210 (07-06) 20-170-12 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-34

Removal And Installation (Cont’d)

1
Figure 20-170-32

P-52911

Remove the mounting bolt (Item 1) [Figure 20-170-34]

P-52907 from the lower front right hand side of the control valve.

Figure 20-170-35
Disconnect the two wire connectors (Item 1) [Figure 20-
170-32] from the main wire harness.

NOTE: Mark the location of the connectors for correct

installation.
1 1

Figure 20-170-33

P-52910
1

Remove the two mounting bolts (Item 1) [Figure 20-170-

35] from the control valve.

Installation: Tighten the mounting bolts to 18-19 ft.-lbs..

(24-26 Nm) torque.

P-52908

Remove the tubeline (Item 1) [Figure 20-170-33] from the

front right hand side of the control valve.

4852210 (07-06) 20-170-13 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D)

Removal And Installation (Cont’d)

Figure 20-170-36

P-52909

Install a hoist and lift strap (Item 1) [Figure 20-170-36] on

the control valve.

Use care not to damage the tubelines or fittings.

Raise the hoist and remove the control valve.

4852210 (07-06) 20-170-14 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D)

Parts Identification

1. End Housing
2. Lifting Valve Section
3. Tilting Valve Section
4. Telescoping Valve Section
5. Auxiliary Valve Section
6. Inlet-Outlet Valve Section

4 5
6
2 3

P-47794

4852210 (07-06) 20-170-15 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-38

Disassembly And Assembly

Clean the outside of the control valve before disassembly.

Mark the outside of the control valve for ease of assembly.

IMPORTANT
When making repairs on hydraulic system, clean the
work area before disassemble and keep all parts
clean. Always use caps and plugs on hoses, tubelines
P-47794
and ports to keep dirt out. Dirt can quickly damage
the system.
I-2056-0793 Remove all hydraulic fittings [Figure 20-170-38].

Figure 20-170-37 Figure 20-170-39

P-47793 P-47795

Remove the tubeline (Item 1) [Figure 20-170-37]. Remove the three nuts (Item 1) [Figure 20-170-39] from
the tie rod bolts.

Assembly: Tighten the nuts to 26 ft.-lbs. (35 Nm) torque.

4852210 (07-06) 20-170-16 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Remove the O-ring (Item 1) [Figure 20-170-42] from the
plug.
End Housing Disassembly And Assembly

Figure 20-170-40

P-47796

Remove the end housing (Item 1) [Figure 20-170-40].

Figure 20-170-41

1
2

P-42984

Remove the dust cap (Item 1) and plug (Item 2) [Figure

20-170-41] from the end housing.

Figure 20-170-42

P-42985

4852210 (07-06) 20-170-17 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-45

Lifting Valve Section Disassembly And Assembly

Figure 20-170-43

1
1

P-42989

Remove the plug (Item 1) [Figure 20-170-45] from the

P-47797 valve section.

Figure 20-170-46
Remove the lifting valve section (Item 1) [Figure 20-170-
43].

Figure 20-170-44
1
2
1

P-42990

1 Remove the two O-rings (Item 1) and backup ring (Item 2)

P-42987 [Figure 20-170-46] from the plug.

Remove the four O-rings (Item 1) [Figure 20-170-44]

from the valve section.

4852210 (07-06) 20-170-18 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-49

Lifting Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-47

P-42993

Remove the O-ring (Item 1) [Figure 20-170-49] from the

1 cover.
P-42991
Figure 20-170-50

Loosen the four screws (Item 1) [Figure 20-170-47].

Assembly: Tighten the screws to 7 ft,-lbs. (10 Nm)

torque.

Figure 20-170-48

2 2

1 1
P-42995

Remove the spring (Item 1) and spring retainer (Item 2)

[Figure 20-170-50] from the spool.

P-42992

Remove the four screws (Item 1) and cover (Item 2)

[Figure 20-170-48].

4852210 (07-06) 20-170-19 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-53

Lifting Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-51

1
1

P-42997

Loosen the four screws (Item 1) [Figure 20-170-53].

P-42996 Assembly: Tighten the screws to 7 ft.-lbs. (10 Nm)

torque.

Remove the relief valve (Item 1) [Figure 20-170-51] from Figure 20-170-54
the valve section.

Assembly: Tighten the relief valve to 33 ft.-lbs. (45 Nm)

torque.

Figure 20-170-52 2

1
2

1
P-42998

Remove the four screws (Item 1) and cover (Item 2)

[Figure 20-170-54] from the valve section.

P-42988

Remove the two O-rings (Item 1) and backup ring (Item 2)

[Figure 20-170-52] from the relief valve.

4852210 (07-06) 20-170-20 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-57

Lifting Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-55

P-44000

Remove the spool (Item 1) [Figure 20-170-57] from the

valve section.
P-42993
Figure 20-170-58

Remove the O-ring (item 1) [Figure 20-170-55] from the

cover.

Figure 20-170-56

1
2
1

P-44275

Remove the two plugs (Item 1) [Figure 20-170-58] from

the valve section.
P-42999
Assembly: Tighten the plugs to 20-24 ft.-lbs. (27-33 Nm)
torque.
Remove the spring (Item 1) and spring retainer (Item 2)
[Figure 20-170-56] from the spool.

4852210 (07-06) 20-170-21 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-61

Lifting Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-59
1

2
1

P-44278

Loosen the plug (Item 1) [Figure 20-170-61].

P-44276 Assembly: Tighten the plug to 40-49 ft.-lbs. (54-66 Nm)

torque.

Remove the spring (Item 1) and poppet (Item 2) [Figure Figure 20-170-62
20-170-59] from the plugs.

Figure 20-170-60

1
3

P-44279

P-44277 Remove the individual pressure compensator plug (Item

1) poppet (Item 2) and guide (Item 3) [Figure 20-170-62]
from the valve section.
Remove the O-ring (Item 1) [Figure 20-170-60] from the
plugs.

4852210 (07-06) 20-170-22 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-65

Lifting Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-63

1
1

P-44002

Remove the four O-rings (Item 1) [Figure 20-170-65]

from the valve section.
P-44280
Figure 20-170-66

Remove the O-ring (Item 1) [Figure 20-170-63] from the

plug.

Tilting Valve Section Disassembly And Assembly

Figure 20-170-64 1

P-44003

Remove the relief valve (Item 1) [Figure 20-170-66] from

the valve section,

Assembly: Tighten the relief valve to 33 ft,-lbs. (45 Nm)

P-44001 torque.

Remove the tilting valve section (Item 1) [Figure 20-170-

64]

4852210 (07-06) 20-170-23 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-69

Tilting Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-67

1
1

P-44005

Remove the four screws (Item 1) and cover (Item 2)

[Figure 20-170-69] from the valve section.
P-42988
Figure 20-170-70

Remove the two O-rings (Item 1) and backup ring (Item 2)

[Figure 20-170-67] from the relief valve.

Figure 20-170-68

P-42993
1
Remove the O-ring (Item 1) [Figure 20-170-70] from the
cover.
P-44004

Loosen the four screws (Item 1) [Figure 20-170-68] on

the cover.

Assembly: Tighten the screws to 7 ft.-lbs. (10 Nm)

torque.

4852210 (07-06) 20-170-24 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-73

Tilting Valve Section Disassembly And Assembly

(Cont’d)
1
Figure 20-170-71
2

2
1

P-42988

Remove the two O-rings (Item 1) and backup ring (Item 2)

[Figure 20-170-73] from the relief valve.
P-44006
Figure 20-170-74

Remove the spring (Item 1) and spring retainer (Item 2)

[Figure 20-170-71] from the spool.

Figure 20-170-72

1
1

P-44008

Loosen the four screws (Item 1) [Figure 20-170-74] on

the cover.
P-44007
Assembly: Tighten the screws to 7 ft.-lbs. (10 Nm)
torque.
Remove the relief valve (Item 1) [Figure 20-170-72] from
the valve section.

Assembly: Tighten the relief valve to 33 ft.-lbs. (45 Nm)

torque.

4852210 (07-06) 20-170-25 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-77

Tilting Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-75

2
1

2
1

P-44010

Remove the spring (Item 1) and spring retainer (Item 2)

[Figure 20-170-77] from the spool.
P-44009
Figure 20-170-78

Remove the four screws (Item 1) and cover (Item 2)

[Figure 20-170-75] from the valve section.

Figure 20-170-76

P-44011

Remove the spool (Item 1) [Figure 20-170-78] from the

valve section.
P-42993

Remove the O-ring (Item 1) [Figure 20-170-76] from the

cover.

4852210 (07-06) 20-170-26 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-81

Tilting Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-79 1

P-44277
1

Remove the O-ring (Item 1) [Figure 20-170-81] from the

plugs.
P-44275
Figure 20-170-82

Remove the two plugs (Item 1) [Figure 20-170-79] from

the valve section.

Assembly: Tighten the plugs to 20-24 ft.-lbs. (27-33 Nm)

torque. 1

Figure 20-170-80

2
1

P-44278

Loosen the plug (Item 1) [Figure 20-170-82].

Assembly: Tighten the plug to 40-49 ft.-lbs. (54-66 Nm)

torque.

P-44276

Remove the spring (Item 1) and poppet (Item 2) [Figure

20-170-80] from the plugs.

4852210 (07-06) 20-170-27 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Telescoping Valve Section Disassembly And
Assembly
Tilting Valve Section Disassembly And Assembly
(Cont’d) Figure 20-170-85

Figure 20-170-83
1

1 P-47799

P-44279
Remove the telescoping valve section (Item 1) [Figure
20-170-85].
Remove the individual pressure compensator plug (Item
1) poppet (Item 2) and guide (Item 3) [Figure 20-170-83] Figure 20-170-86
from the valve section.

Figure 20-170-84

1 1

P-44013

P-44280 Remove the four O-rings (Item 1) [Figure 20-170-86]

from the valve section.

Remove the O-ring (Item 1) [Figure 20-170-84] from the

plug.

4852210 (07-06) 20-170-28 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-89

Telescoping Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-170-87

P-44016

1
Remove the O-ring (Item 1) [Figure 20-170-89] from the
controller assembly.
P-44014
Figure 20-170-90

Remove the two screws (Item 1) [Figure 20-170-87] from

the controller assembly.

Assembly: Tighten the screws to 10-12 ft.-lbs. (14-16

Nm) torque.

Figure 20-170-88
1

P-44017

Remove the two couplers (Item 1) [Figure 20-170-90]

from the controller assembly.

1
P-44015

Remove the controller assembly (Item 1) [Figure 20-170-

88] from the valve section.

4852210 (07-06) 20-170-29 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-93

Telescoping Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-170-91

2
1

P-44020

Remove the four screws (Item 1) and cover (Item 2)

[Figure 20-170-93] from the controller assembly.
P-44018
Figure 20-170-94

Remove the two O-rings (Item 1) [Figure 20-170-91] from

the couplers.

Figure 20-170-92

1 P-44021

Remove the seal (Item 1) [Figure 20-170-94] from the

1 cover.
P-44019

Loosen the four screws (Item 1) [Figure 20-170-92] on

the controller assembly.

Assembly: Tighten the screws to 2-3 ft.-lbs. (3-3,5 Nm)

torque.

4852210 (07-06) 20-170-30 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-97

Telescoping Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-170-95

1
2
P-44024
1

Remove the port block (Item 1) from the controller (Item 2)

[Figure 20-170-97].
P-44022

Remove the plug (Item 1) [Figure 20-170-95] from the

cover.

Figure 20-170-96

P-44023

Remove the O-ring (Item 1) [Figure 20-170-96] from the

plug.

4852210 (07-06) 20-170-31 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-100

Telescoping Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-170-98 1
2

1
2 P-44027

Remove the spool (Item 1) and spring (Item 2) [Figure

4 20-170-100] from the port valve.
P-47808
Figure 20-170-101

Remove the two valve cartridges (Item 1) and plunger

(Item 2) [Figure 20-170-98] from the controller.

NOTE: The upper valve cartridge (Item 3) is for 1

extending the boom and the lower valve
cartridge (Item 4) [Figure 20-170-98] is for
retracting the boom.

Figure 20-170-99

P-44028

Remove the three O-rings (Item 1) [Figure 20-170-101]

from the spool.
1
2

5
4
3
P-47810

Remove the cover (Item 1), poppet (Item 2), spool (Item
3) and spacer (Item 4) from the valve (Item 5) [Figure 20-
170-99].

4852210 (07-06) 20-170-32 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-104

Telescoping Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-170-102 1
2
1

P-42988

1 Remove the two O-rings (Item 1) and backup ring (Item 2)

[Figure 20-170-104] from the relief valve.
P-47811
Figure 20-170-105

Remove the four O-rings (Item 1) [Figure 20-170-102]

from the valve.

Figure 20-170-103

1 1

P-44037

Loosen the screw (Item 1) [Figure 20-170-105] on the

piston.
P-44036
Assembly: Tighten the screw to 7 ft.-lbs. (10 Nm) torque.

Remove the relief valve (Item 1) [Figure 20-170-103]

from the valve section.

Assembly: Tighten the valve to 33 ft.-lbs. (45 Nm) torque.

4852210 (07-06) 20-170-33 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-108

Telescoping Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-170-106

P-44040

2
Remove the plug (Item 1) [Figure 20-170-108] from the
1
valve section.
P-44038
Figure 20-170-109

Remove the screw (Item 1) and piston (Item 2) [Figure

20-170-106] from the adapter.
1
Figure 20-170-107

P-42990

1 Remove the two O-rings (Item 1) and backup ring (Item 2)

[Figure 20-170-109] from the plug.
P-44039

Remove the two O-rings (Item 1) [Figure 20-170-107]

from the piston.

4852210 (07-06) 20-170-34 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-112

Telescoping Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-170-110

1
P-44044

1 Install a hex wrench in the screw (Item 1) [Figure 20-170-

112] on the end of the spool.
P-44041
Figure 20-170-113

Loosen the two screws (item 1) [Figure 20-170-110] on

the cover.

Assembly: Tighten the screws to 7 ft.-lbs. (10 Nm)

torque.
1
Figure 20-170-111

2
P-44045

1
Loosen the adapter (Item 1) [Figure 20-170-113].

Assembly: Tighten the adapter to 7-8 ft.-lbs. (9-11 Nm)

torque.

P-44042

Remove the two screws (Item 1) and cover (Item 2)

[Figure 20-170-111] from the valve section.

4852210 (07-06) 20-170-35 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-116

Telescoping Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-170-114

P-44048

Remove the washer (Item 1) [Figure 20-170-116] from

the valve section.
P-44046
Figure 20-170-117

Remove the adapter (Item 1) [Figure 20-170-114] from

the spool.

Figure 20-170-115

P-44049

Assembly: Install the countersunk side of the washer

(Item 1) [Figure 20-170-117] into the valve section.
P-44047

Remove the O-ring (Item 1)[Figure 20-170-115] from the

adapter.

4852210 (07-06) 20-170-36 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-120

Telescoping Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-170-118 1

P-44053

Assembly: The lip on the seal (Item 1) [Figure 20-170-

120] fits inside the retainer (Item 3) [Figure 20-170-119].
P-44050
Figure 20-170-121

Remove the spool (Item 1) [Figure 20-170-118] from the

valve section. Cut

NOTE: When the spool is removed, use care not to

scratch the spool surface and do not
interchange spools and valve blocks.
0.710” 2.0”
Figure 20-170-119

3
1.500”
2 0.750”
1 B-14674

To remove the spring assembly from the spool a holding

fixture will have to be made from a .750 inch thick x 1.500
inch wide x 2.0 inch long (19 mm thick x 38 mm wide x 51
mm long) piece of hardwood. Drill a 0.710 inch (18 mm)
hole in the center of the hardwood block. Cut the block
lengthwise [Figure 20-170-121].
P-44051

Remove the O-ring (Item 1) seal (Item 2) and retainer

(Item 3) [Figure 20-170-119] from the spool.

4852210 (07-06) 20-170-37 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-124

Telescoping Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-170-122

2
P-44275
1

Remove the two plugs (Item 1) [Figure 20-170-124] from

the valve section;
P-33886
Assembly: Tighten the plugs to 20-24 ft.-lbs. (27-33 Nm)
torque.
Using the wood blocks clamp the spool (Item 1) [Figure
20-170-122] in a vise. Figure 20-170-125

NOTE: Do not use anything other than hardwood

blocks to grip the spool, or the spool will be
damaged. 2
1
Loosen the screw (Item 2) [Figure 20-170-122].

Assembly: Tighten the screw to 7 ft.-lbs. (10 Nm) torque.

Figure 20-170-123

P-44276

Remove the spring (Item 1) and poppet (Item 2) [Figure

20-170-125] from the plugs.
1
4

3
2
P-44052

Remove the screw (Item 1), spring retainer (Item 2),

spring (Item 3) and spring retainer (Item 4) [Figure 20-
170-123] from the spool.

4852210 (07-06) 20-170-38 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-128

Telescoping Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-170-126

3
1

1
P-44279

Remove the individual pressure compensator plug (Item

1) poppet (Item 2) and guide (Item 3) [Figure 20-170-128]
P-44277 from the valve section.

Figure 20-170-129
Remove the O-ring (Item 1) [Figure 20-170-126] from the
plugs.

Figure 20-170-127

P-44280

Remove the O-ring (Item 1) [Figure 20-170-129] from the

P-44278 plug.

Loosen the plug (Item 1) [Figure 20-170-127].

Assembly: Tighten the plug to 40-49 ft.-lbs. (54-66 Nm)

torque.

4852210 (07-06) 20-170-39 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-132

Auxiliary Valve Section Disassembly And Assembly

Figure 20-170-130

P-47802

Remove the two screws (Item 1) [Figure 20-170-132]

P-47800 from the controller assembly.

Assembly: Tighten the screws to 10-12 ft.-lbs. (14-16

Remove the auxiliary valve section (Item 1) [Figure 20- Nm) torque.
170-130].
Figure 20-170-133
Figure 20-170-131

1
1

P-47803
P-47801

Remove the controller assembly (Item 1) [Figure 20-170-

Remove the four O-rings (Item 1) [Figure 20-170-131] 133] from the valve section.
from the valve section.

4852210 (07-06) 20-170-40 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-136

Auxiliary Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-134

1
P-47806

Remove the two couplers (Item 1) [Figure 20-170-136]

from the connecting flange.
P-47804
Figure 20-170-137

Remove the O-ring (Item 1) [Figure 20-170-134] from the

controller assembly.

Figure 20-170-135
1

2
1 P-44018

3 Remove the two O-rings (Item 1) [Figure 20-170-137]

from the couplers.
P-47805

Remove the two screws (Item 1) from the connecting

flange (Item 2) [Figure 20-170-135]. Remove the
connecting flange.

Controller Filter Removal And Installation:

Remove the filter (Item 3) [Figure 20-170-135] from the

port.

NOTE: The valve assembly does not have to be

removed for this procedure.

4852210 (07-06) 20-170-41 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-140

Auxiliary Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-138

P-44021

1 Remove the seal (Item 1) [Figure 20-170-140] from the

cover.
P-44060
Figure 20-170-141

Loosen the four screws (Item 1) [Figure 20-170-138].

Assembly: Tighten the screws to 2-3 ft.-lbs. (3-3,5 Nm)

torque.

Figure 20-170-139

2
1 P-44022

Remove the plug (Item 1) [Figure 20-170-141] from the

cover.

P-44061

Remove the four screws (Item 1) and cover (Item 2)

[Figure 20-170-139] from the controller assembly.

4852210 (07-06) 20-170-42 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-144

Auxiliary Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-142

1 2

P-47808

Remove the two valve cartridges (Item 1) and plunger

(Item 2) [Figure 20-170-144] from the controller.
P-44023
Figure 20-170-145

Remove the O-ring (Item 1) [Figure 20-170-142] from the

plug. 1

Figure 20-170-143 2
5

3
4

P-47810

2 Remove the cover (Item 1), poppet (Item 2), spool (Item
1 3) and spacer (Item 4) from the valves (Item 5) [Figure
P-44062 20-170-145].

Remove the controller (Item 1) from the port block (Item 2)

[Figure 20-170-143].

4852210 (07-06) 20-170-43 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-148

Auxiliary Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-146

1
2
1

P-47811

Remove the four O-rings (Item 1) [Figure 20-170-148]

from the valves.
P-44027
Figure 20-170-149

Remove the spool (Item 1) and spring (Item 2) [Figure

20-170-100] from the port valve.

Figure 20-170-147

P-47812

Remove the plug (Item 1) [Figure 20-170-149]. (Both

sides)
P-44065

Remove the three O-rings (Item 1) [Figure 20-170-147]

from the spools.

4852210 (07-06) 20-170-44 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-152

Auxiliary Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-150

2
1
2

1
P-47815

1
Remove the screw (Item 1) and piston (Item 2) [Figure
20-170-152] from the adapter.
P-47813
Figure 20-170-153

Remove the two O-rings (Item 1) and backup ring (Item 2)

[Figure 20-170-150] from the plugs.

Figure 20-170-151

1
1

P-47816

Remove the two O-rings (Item 1) [Figure 20-170-153]

from the piston.
P-47814

Loosen the screw (Item 1) [Figure 20-170-151] on the

piston.

Assembly: Tighten the screw to 7 ft.-lbs. (10 Nm) torque.

4852210 (07-06) 20-170-45 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-156

Auxiliary Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-154

P-47825

1
Remove the O-ring (Item 1) [Figure 20-170-156] from the
cover.
P-47817
Figure 20-170-157

Loosen the two screws (Item 1) [Figure 20-170-154] on

the cover.

Assembly: Tighten the screws to 7 ft.-lbs. (10 Nm)

torque.

Figure 20-170-155

P-47819

Install a hex wrench in the screw (Item 1) [Figure 20-170-

157].

1
2

P-47818

Remove the two screws (Item 1) and cover (Item 2)

[Figure 20-170-155] from the valve section.

4852210 (07-06) 20-170-46 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-160

Auxiliary Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-158

P-44049

Assembly: Install the countersunk side of the washer

(Item 1) [Figure 20-170-160] into the valve section.
P-47820
Figure 20-170-161

Loosen the adapter (Item 1) [Figure 20-170-158].

Assembly: Tighten the adapter to 7-8 ft.-lbs. (9-11 Nm)

torque.
1
Figure 20-170-159

2 P-44047

1
Remove the O-ring (Item 1) [Figure 20-170-161] from the
adapter.

P-47821

Remove the adapter (Item 1) and washer (Item 2) [Figure

20-170-159] from the valve section.

4852210 (07-06) 20-170-47 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-164

Auxiliary Valve Section Disassembly And Assembly

(Cont’d)
1
Figure 20-170-162

P-44053

Assembly: The lip on the seal (Item 1) [Figure 20-170-

164] fits inside the retainer.
P-47822
Figure 20-170-165

Remove the spool (Item 1) [Figure 20-170-162] from the

valve section. Cut

NOTE: When the spool is removed, use care not to

scratch the spool surface and do not
interchange spools and valve blocks.
0.710” 2.0”
Figure 20-170-163

3
2 1.500”
0.750”
1
B-14674

To remove the spring assembly from the spool a holding

fixture will have to be made from a .750 inch thick x 1.500
inch wide x 2.0 inch long (19 mm thick x 38 mm wide x 51
mm long) piece of hardwood. Drill a 0.710 inch (18 mm)
hole in the center of the hardwood block. Cut the block
lengthwise [Figure 20-170-165].
P-44051

Remove the O-ring (Item 1), seal (Item 2) and retainer

(Item 3) [Figure 20-170-163] from the spool.

4852210 (07-06) 20-170-48 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-168

Auxiliary Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-166

2
1 P-47823

Remove the two load check valve plugs (Item 1) [Figure

20-170-168] from the valve section.
P-33886
Assembly: Tighten the plugs to 20-24 ft.-lbs. (27-33 Nm)
torque.
Using the wood blocks clamp the spool (Item 1) [Figure
20-170-166] in a vise. Figure 20-170-169

NOTE: Do not use anything other than hardwood

blocks to grip the spool, or the spool will be
damaged. 2
1
Loosen the screw (Item 2) [Figure 20-170-166].

Assembly: Tighten the screw to 7 ft.-lbs. (10 Nm) torque.

Figure 20-170-167

P-44276

Remove the spring (Item 1) and poppet (Item 2) [Figure

20-170-169] from the plugs.
1 4

3
2
P-44052

Remove the screw (Item 1), spring retainer (Item 2),

spring (Item 3) and spring retainer (Item 4) [Figure 20-
170-167] from the spool.

4852210 (07-06) 20-170-49 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-172

Auxiliary Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-170

3
2
1 1

P-47824

Remove the individual pressure compensator plug (Item

1), poppet (Item 2) and guide (Item 3) [Figure 20-170-
P-44277 172] from the valve section.

Figure 20-170-173
Remove the O-ring (Item 1) [Figure 20-170-170] from the
plugs.

Figure 20-170-171

1
1

P-44280

Remove the O-ring (Item 1) [Figure 20-170-173] from the

P-44282 plug.

Loosen the plug (Item 1) [Figure 20-170-171].

Assembly: Tighten the plug to 40-49 ft.lbs. (54-66 Nm)

torque.

4852210 (07-06) 20-170-50 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-176

Inlet-Outlet Valve Section Disassembly And Assembly

Figure 20-170-174
1

P-44106

Remove the O-ring (Item 1) [Figure 20-170-176] from the

P-44104 plug.

Figure 20-170-177
Remove the four O-rings (Item 1) [Figure 20-170-174]
from the valve section.

Figure 20-170-175
1

P-44107

Remove the spring, shims and piston (Item 1) [Figure 20-

P-44105 170-177] from the valve section.

Remove the flushing valve plug (Item 1) [Figure 20-170-

175] from the valve section.

Assembly: Tighten the plug to 74 ft.-lbs. (100 Nm)

torque.

4852210 (07-06) 20-170-51 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-180

Inlet-Outlet Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-178
1

P-44110

Remove the load sense relief cartridge (Item 1) [Figure

20-170-180] from the valve section.
P-44108
Assembly: Tighten the relief valve to 33 ft.-lbs. (45 Nm)
torque.
Remove the plug (Item 1) [Figure 20-170-178] from the
valve section. Figure 20-170-181

Assembly: Tighten the plug to 15 ft.-lbs. (20 Nm) torque.

Figure 20-170-179

2
1

P-44111

Remove the two O-rings (Item 1) and backup ring (Item 2)

P-44109 [Figure 20-170-181] from the relief cartridge.

Remove the O-ring (Item 1) [Figure 20-170-179] from the

plug.

4852210 (07-06) 20-170-52 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-184

Inlet-Outlet Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-182
1

1
P-44268

Remove the O-ring (Item 1) [Figure 20-170-184] from the

plug.
P-44112
Figure 20-170-185

Remove the flow regulator valve (Item 1) [Figure 20-170-

182] from the valve section.

Assembly: Tighten the flow regulator valve to 15 ft.-lbs.

(20 Nm) torque.

Figure 20-170-183 1

4
3
P-44269
2 1

Remove the screen (Item 1) [Figure 20-170-185] from the

valve.

P-44265

Remove the plug (Item 1), shim (Item 2), spring (Item 3)
and spool (Item 4) [Figure 20-170-183] from the valve.

4852210 (07-06) 20-170-53 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-188

Inlet-Outlet Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-170-186
1

P-44115

1 2
Remove the O-ring (Item 1) [Figure 20-170-188] from the
test fitting.
P-44267
Figure 20-170-189

Remove the two O-rings (Item 1) and backup ring (Item 2)

[Figure 20-170-186] from the flow regulator valve.

Figure 20-170-187
1

P-44116

Remove the cap (Item 1) [Figure 20-170-189] from the

test fitting.
P-44114
Clean all parts in solvent and dry with compressed air.

Remove the test fitting (Item 1) [Figure 20-170-187] from Inspect all parts for wear or damage. Replace any worn or
the valve section. damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

4852210 (07-06) 20-170-54 Bobcat T2556 & T2566

SERVICE MANUAL
JOYSTICK Figure 20-180-3

Removal And Installation

Remove the dash cover/steering column cover (See

“Removal And Installation” on page 50-130-1) 2

Remove the joystick panel (See “Removal And 1

Installation” on page 50-120-1). 1

Figure 20-180-1

P-61640

Remove the four mounting bolts (Item 1) and spacers

(Item 2) [Figure 20-180-3].

Installation: The joystick harness (Item 2) [Figure 20-

1 180-3] must be positioned around the swivel joint as
shown.

P-61622

Disconnect the electrical connector (Item 1) [Figure 20-

WARNING
180-1].
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
NOTE: The joystick is not serviceable and must be
penetrating the skin. This can cause serious injury
replaced as a complete unit.
and possible death if proper medical treatment by a
physician familiar with this injury is not received
Figure 20-180-2
immediately.
W-2145-0290

P-61623

Raise the dust boot (Item 1) [Figure 20-180-2].

4852210 (07-06) 20-180-1 Bobcat T2556 & T2566

SERVICE MANUAL
JOYSTICK (CONT’D)

Removal And Installation (Cont’d)

IMPORTANT
When making repairs on hydraulic system, clean the
work area before disassemble and keep all parts
clean. Always use caps and plugs on hoses, tubelines
and ports to keep dirt out. Dirt can quickly damage
the system.
I-2056-0793

Figure 20-180-4

P-61624

Remove the six hoses (Item 1) [Figure 20-180-4] from

the joystick.

Mark the hoses for correct assembly.

Figure 20-180-5

P-61623

Remove the joystick assembly (Item 1) [Figure 20-180-

5].

4852210 (07-06) 20-180-2 Bobcat T2556 & T2566

SERVICE MANUAL
Parts Identification

1 Joystick
2 Lever Assy
3 Bellow
4 Plate
5 Set of push rods

S2755

4852210 (07-06) 20-180-3 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 20-180-4 Bobcat T2556 & T2566
SERVICE MANUAL
PARKING BRAKE Figure 20-190-4

Parking Brake Valve Removal And Installation

Figure 20-190-1

1
1

P-44430

Support the brake valve (Item 1) [Figure 20-190-8] and

P-44428 remove the two screws (Item 1) [Figure 20-190-9].

Remove the parking brake valve.

Remove the pin retainer (Item 1) [Figure 20-190-6].

Figure 20-190-2

P-44429

Remove the pin (Item 1) [Figure 20-190-7] from the lever.

Figure 20-190-3

P-47964

4852210 (07-06) 20-190-1 Bobcat T2556 & T2566

SERVICE MANUAL
PARKING BRAKE (CONT’D) Figure 20-190-7

Parking Brake Valve Disassembly And Assembly

Clean the outside of the brake valve before disassembly.

3
Mark the outside of the brake valve for ease of assembly.
2
Figure 20-190-5
1

1 P-44440

1
Remove the collar (Item 1), spring (Item 2) and shaft (Item
3) [Figure 20-190-12] from the housing.

Figure 20-190-8

S2756

Remove the fittings (Item 1) [Figure 20-190-10].

Figure 20-190-6
1

1
P-44441

Remove the washer (Item 1) [Figure 20-190-13] from the

housing

P-44439

Loosen the collar (Item 1) [Figure 20-190-11].

NOTE: Use care removing the collar. The collar is

under spring pressure.

4852210 (07-06) 20-190-2 Bobcat T2556 & T2566

SERVICE MANUAL
PARKING BRAKE (CONT’D)

Parking Brake Valve Disassembly And Assembly

(Cont’d)

Figure 20-190-9

P-44442

Remove the electrical connector (Item 1) [Figure 20-190-

14] from the housing.

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

4852210 (07-06) 20-190-3 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 20-190-4 Bobcat T2556 & T2566
SERVICE MANUAL
PILOT PRESSURE LOCK OUT VALVE Figure 20-200-3

Testing

Raise the boom and install the boom stop. (See “Installing
The Approved Boom Stop” on page 10-150-1)

Figure 20-200-1

1
P-52913

Install a 1000 psi (70 Bar) gauge on the test fitting [Figure
20-200-3].

Start the engine and run engine at 2200 rpm.

P-52743
Record the pressure. The pressure at the gauge should
be 392 Psi (27 Bar) at min. rpm to 493 Psi (34 Bar) at
Remove the rear cover (Item 1) [Figure 20-200-1]. max. rpm.

Figure 20-200-2 The pilot pressure lock out valve is not adjustable. If the
pressure is incorrect, replace the pilot pressure lock out
valve. (See “Removal And Installation” on page 20-200-2)
1

P-52912

Locate the test fitting (Item 1) [Figure 20-200-2] below

the control valve and remove the cap.

4852210 (07-06) 20-200-1 Bobcat T2556 & T2566

SERVICE MANUAL
PILOT PRESSURE LOCK OUT VALVE (CONT’D)

Removal And Installation

WARNING
Relieve hydraulic pressure. Drain the hydraulic reservoir
(See “Replacing Hydraulic Fluid” on page 10-100-2). Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
Figure 20-200-4 penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290

1
IMPORTANT
When making repairs on hydraulic system, clean the
work area before disassemble and keep all parts
clean. Always use caps and plugs on hoses, tubelines
and ports to keep dirt out. Dirt can quickly damage
P-52743 the system.
I-2056-0793

Remove the rear cover (Item 1) [Figure 20-200-4]. Figure 20-200-6

Mark the hoses and electrical connectors for correct
installation. 1

Figure 20-200-5

1
1 P-52915

Remove the two tubelines (Item 1) [Figure 20-200-6].

P-52914

Remove the screw (Item 1) and unplug the electrical

connector (Item 2) [Figure 20-200-5].

NOTE: The fuel tank is removed for photo purposes.

4852210 (07-06) 20-200-2 Bobcat T2556 & T2566

SERVICE MANUAL
PILOT PRESSURE LOCK OUT VALVE (CONT’D) Disassembly And Assembly

Removal And Installation (Cont’d) Figure 20-200-9

Figure 20-200-7

1
P-44338

P-52916
Remove the nut (Item 1) and coil (Item 2) [Figure 20-200-
9] from the spool.
Remove the tubeline (Item 1) [Figure 20-200-7].
Figure 20-200-10
Figure 20-200-8

1
1

P-44337
P-52917

Remove the spool (Item 1) [Figure 20-200-10].

Remove the two mounting bolts (Item 1) and remove the
pilot pressure lock out valve (Item 2) [Figure 20-200-8].

4852210 (07-06) 20-200-3 Bobcat T2556 & T2566

SERVICE MANUAL
PILOT PRESSURE LOCK OUT VALVE (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 20-200-11

2 1

1 2
1
2
P-44340

Remove the three O-rings (Item 1) and four backup rings

(Item 2) [Figure 20-200-11] from the spool.

Figure 20-200-12

1
P-44341

Remove the fittings (Item 1) [Figure 20-200-12].

Wash the valve in clean solvent and dry with compressed

air. Check the components for wear or damage. Replace
any worn or damaged components. Always use new O-
rings and backup rings.

Apply clean hydraulic fluid to the components during

assembly.

4852210 (07-06) 20-200-4 Bobcat T2556 & T2566

SERVICE MANUAL
ACCUMULATOR

Removal And Installation

Raise the boom and install the boom stop. (See “Installing
The Approved Boom Stop” on page 10-150-1)

The accumulator is located below the hydraulic control

valve.

Relieve hydraulic pressure.

WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290

IMPORTANT
When making repairs on hydraulic system, clean the
work area before disassemble and keep all parts
clean. Always use caps and plugs on hoses, tubelines
and ports to keep dirt out. Dirt can quickly damage
the system.
I-2056-0793

Figure 20-210-1

P-52918

Remove the accumulator (Item 1) [Figure 20-210-1] from

the manifold.

4852210 (07-06) 20-210-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 20-210-2 Bobcat T2556 & T2566
SERVICE MANUAL
OPTIONAL TOW VALVE Figure 20-220-2

Removal And Installation

Open the engine cover.

Figure 20-220-1 1

P-53126

Mark the hoses for correct installation. Remove the two

hoses (Item 1) [Figure 20-220-2].

P-53124 Figure 20-220-3

Position the tow valve to towing position to relieve

hydraulic pressure [Figure 20-220-1].

WARNING 3

1
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
P-53125
immediately.
W-2145-0290

Remove the two bolts, nuts (Item 1) and strap (Item 2).
Remove the tow valve (Item 3) [Figure 20-220-3].

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

4852210 (07-06) 20-220-1 Bobcat T2556 & T2566

SERVICE MANUAL
TOW VALVE (CONT’D) Figure 20-220-6

Disassembly And Assembly

Clean the outside of the tow valve before disassembly.

Mark the outside of the tow valve for ease of assembly.

Figure 20-220-4
1

P-46750

Remove the retainer (Item 1) and stop plate (Item 2)

2 [Figure 20-220-6].

NOTE: Record the position of the stop plate for proper

1 assembly.
P-46747
Figure 20-220-7

Remove the screw (Item 1) and washer (Item 2) [Figure

20-220-4].

Figure 20-220-5

1
1 1

P-46752

Remove the two fittings (Item 1) [Figure 20-220-7].

P-46749

Remove the handle (Item 1) [Figure 20-220-5].

4852210 (07-06) 20-220-2 Bobcat T2556 & T2566

SERVICE MANUAL
TOW VALVE (CONT’D) Figure 20-220-10

Disassembly And Assembly (Cont’d)

Figure 20-220-8 1

P-46755
1

Remove the O-ring (Item 1) [Figure 20-220-10] from the

P-46753 adapters.

Remove the O-ring (Item 1) [Figure 20-220-8] from the

fittings.

Figure 20-220-9

1 1

P-46754

Remove the two adapters (Item 1) [Figure 20-220-9].

4852210 (07-06) 20-220-3 Bobcat T2556 & T2566

SERVICE MANUAL
TOW VALVE (CONT’D) Figure 20-220-13

Disassembly And Assembly (Cont’d)

Figure 20-220-11
1

P-46759

Figure 20-220-14
P-46756

Figure 20-220-12
1

1
P-46760

Assembly: Align the slot (Item 1) [Figure 20-220-13]

P-46758 with the notch (Item 1) [Figure 20-220-14] in the shaft.

Remove the seal (Item 1) [Figure 20-220-11] from the

valve. (Both sides)

Assembly: The concave side of the seal (Item 1) [Figure

20-220-11] fits over the ball (Item 2) [Figure 20-220-12].

Turn the shaft (Item 1) until the shaft and ball (Item 2)
[Figure 20-220-12] are in the position shown. Remove
the ball.

Assembly: Record the position of the shaft and ball for

proper assembly.

4852210 (07-06) 20-220-4 Bobcat T2556 & T2566

SERVICE MANUAL
TOW VALVE (CONT’D) Figure 20-220-17

Disassembly And Assembly (Cont’d)

Figure 20-220-15

1
1

P-46762

Remove the seal (Item 1) [Figure 20-220-17] from the

P-46763 housing.

Clean all parts in solvent and dry with compressed air.

Remove the shaft (Item 1) [Figure 20-220-15] by
pressing the shaft into the housing. Inspect all parts for wear or damage. Replace any worn or
damaged parts.
Figure 20-220-16
Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation.

P-46761

Remove the O-ring (Item 1) [Figure 20-220-16] from the

shaft.

4852210 (07-06) 20-220-5 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 20-220-6 Bobcat T2556 & T2566
SERVICE MANUAL
FRONT AUXILIARY HYDRAULIC PRESSURE Figure 20-230-2
RELEASE VALVE

Removal And Installation

1
Figure 20-230-1

P-49012

Turn the handle (Item 1) [Figure 20-230-2] to relieve

hydraulic pressure.
P-24098
Figure 20-230-3
Raise the boom and install the boom stop [Figure 20-230-
1].

Stop the engine.

Engage the parking brake.

2
Exit the machine. 1

WARNING
Hydraulic fluid escaping under pressure can have P-49013

sufficient force to enter a person’s body by

penetrating the skin. This can cause serious injury
Remove the two bolts (Item 2) [Figure 20-230-2], nuts
and possible death if proper medical treatment by a
(Item 1) and strap (Item 2) [Figure 20-230-3].
physician familiar with this injury is not received
immediately.
W-2145-0290

4852210 (07-06) 20-230-1 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AUXILIARY HYDRAULIC PRESSURE Disassembly And Assembly
RELEASE VALVE (CONT’D)
Clean the outside of the pressure release valve before
Removal And Installation (Cont’d) disassembly.

Figure 20-230-4 Mark the outside of the pressure release valve for ease of
assembly.

Figure 20-230-5

2
2
P-49014

Relocate the valve (Item 1) and remove the two hoses 1

P-46747
(Item 2) [Figure 20-230-4].

Mark the hoses for correct installation. Remove the screw (Item 1) and washer (Item 2) [Figure
20-230-5].
Remove the valve.
Figure 20-230-6

IMPORTANT
When making repairs on hydraulic system, clean the
work area before disassemble and keep all parts 1
clean. Always use caps and plugs on hoses, tubelines
and ports to keep dirt out. Dirt can quickly damage
the system.
I-2056-0793

P-46749

Remove the handle (Item 1) [Figure 20-230-6].

4852210 (07-06) 20-230-2 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AUXILIARY HYDRAULIC PRESSURE Figure 20-230-9
RELEASE VALVE (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 20-230-7

1
1

P-46753
2

Remove the O-ring (Item 1) [Figure 20-230-9] from the

fittings.
P-46750
Figure 20-230-10

Remove the retainer (Item 1) and stop plate (Item 2)

[Figure 20-230-7].

NOTE: Record the position of the stop plate for proper

assembly.

Figure 20-230-8

1 1

P-46754

Remove the two adapters (Item 1) [Figure 20-230-10].

1 1

P-46752

Remove the two fittings (Item 1) [Figure 20-230-8].

4852210 (07-06) 20-230-3 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AUXILIARY HYDRAULIC PRESSURE Figure 20-230-12
RELEASE VALVE (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 20-230-11

1
1

P-46756

Figure 20-230-13

P-46755

Remove the O-ring (Item 1) [Figure 20-230-11] from the

adapters. 2

P-46758

Remove the seal (Item 1) [Figure 20-230-12] from the

valve. (Both sides)

Assembly: The concave side of the seal (Item 1) [Figure

20-230-12] fits over the ball (Item 2) [Figure 20-230-13].

Turn the shaft (Item 1) until the shaft and ball (Item 2)
[Figure 20-230-13] are in the position shown.

Assembly: Record the position of the shaft and ball for

proper assembly.

4852210 (07-06) 20-230-4 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AUXILIARY HYDRAULIC PRESSURE Figure 20-230-16
RELEASE VALVE (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 20-230-14

P-46763

Remove the shaft (Item 1) [Figure 20-230-16] by

pressing the shaft into the housing.
P-46759
Figure 20-230-17
Figure 20-230-15

P-46761

P-46760
Remove the O-ring (Item 1) [Figure 20-230-17] from the
shaft.
Assembly: Align the slot (Item 1) [Figure 20-230-14]
with the notch (Item 1) [Figure 20-230-15] in the shaft.

4852210 (07-06) 20-230-5 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AUXILIARY HYDRAULIC PRESSURE
RELEASE VALVE (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 20-230-18

P-46762

Remove the seal (Item 1) [Figure 20-230-18] from the

housing.

Wash the components in clean solvent and dry with

compressed air.

Check the components for wear or damage. Replace any

worn or damaged components. Always use new O-rings
and seals.

Apply clean hydraulic fluid to the O-rings and seals during

assembly.

4852210 (07-06) 20-230-6 Bobcat T2556 & T2566

SERVICE MANUAL
FLOW CONTROL VALVE Figure 20-240-3

Removal And Installation

Figure 20-240-1

1 1

P-49008

Remove the flow control valve (Item 1) [Figure 20-240-3]

P-52743 from the front of the hydraulic control valve.

Installation: Tighten the flow control valve to 15 ft.-lbs.

Remove the rear cover (Item 1) [Figure 20-240-1]. (20 Nm) torque..

Figure 20-240-2 Figure 20-240-4

P-52744 P-44263

The flow control valve is located on the front right side of Remove and clean the filter (Item 1) [Figure 20-240-4].
the hydraulic control valve.
NOTE: Check the filter for any damage. Replace the
filter if required.

4852210 (07-06) 20-240-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 20-240-2 Bobcat T2556 & T2566
SERVICE MANUAL
HYDROSTATIC SYSTEM

HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-18
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-16
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-2
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
HYDROSTATIC
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1 SYSTEM
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-23
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-19
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

HYDROSTATIC SYSTEM INFORMATION. . . . . . . . . . . . . . . . . . 30-10-1

Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

4852210 (07-06) 30-01-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 30-01-2 Bobcat T2556 & T2566
SERVICE MANUAL
HYDROSTATIC SYSTEM INFORMATION

Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285

PROBLEM CAUSE
The Telescopic Handler does not move 1, 2
The Telescopic Handler does not move in a straight line. 3, 4
The hydrostatic system is overheating. 5, 6, 7, 8
Warning light comes ON. 5, 8, 9, 10, 11

KEY TO CORRECT THE CAUSE

1. The hydrostatic pump has damage.
2. The hydrostatic motor has damage.
3. The tires do not have the correct tire pressure.
4. The tires are not the same size.
5. The hydrostatic fluid is not at the correct level.
6. The oil cooler has a restriction.
7. The temperature sending switch is not operating correctly.
8. The Telescopic Handler is not being operated at the correct RPM.
9. The sender is defective.
10. Pump is defective or worn hydrostatics
11. Hydraulic filter is plugged.

4852210 (07-06) 30-10-1 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC SYSTEM INFORMATION (CONT’D)

Replenishing Valve Function

IMPORTANT
Figure 30-10-1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

The functions of the replenishing valves are:

1. To give replacement fluid to the low pressure side of

the hydrostatic circuit. Replacement fluid is needed
Valve Moves For because of normal internal leakage and the controlled
Function 1 Charge Oil flow to the oil cooler for cooling; Function 1 [Figure
30-10-1].
Replacement
2. To keep high pressure fluid out of the low pressure
side of the hydrostatic circuitry; Function 2 [Figure 30-
10-1].

Valve Stays on Seat

to Hold High
Pressure for
Drive
Function 2 B-2804

4852210 (07-06) 30-10-2 Bobcat T2556 & T2566

SERVICE MANUAL
OIL COOLER

Description

The oil cooler is a combined radiator/oil cooler. See

“Removal And Installation” on page 70-50-1 for Radiator/
Oil Cooler Removal And Installation.

4852210 (07-06) 30-20-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 30-20-2 Bobcat T2556 & T2566
SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR

Removal And Installation

Remove the front axle (For S/N 363011001 - 363012000

and S/N 363111001 - 363112000: See “Removal” on
page 40-30-1).

Remove the front axle (For S/N 363012001 and Above, S/

N 363112001 and Above: See “Removal” on page 40-31-
1)

Figure 30-30-1

P-22325

Install a chain hoist and lifting strap to lift and support the
drive motor [Figure 30-30-2].

Remove the four mounting bolts (Item 1) [Figure 30-30-2]

from the drive motor.

Assembly: Tighten the mounting bolts to 140-155 ft.-lbs.

(190-210 Nm) torque.

Remove the hydrostatic drive motor from the axle

housing.

4852210 (07-06) 30-30-1 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D)

Parts Identification

1. Plug
2. O-ring
3. Spring
4. Poppet
5. Housing
6. Bolt
7. Spring Seat
8. Spool
9. Gasket
10. Spacer
11. Backup Ring
12. Shaft
13. Housing

13

4852210 (07-06) 30-30-2 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D)

Parts Identification (Cont’d)

4852210 (07-06) 30-30-3 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D)

Parts Identification (Cont’d)

4852210 (07-06) 30-30-4 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-4

Disassembly

Clean the outside of the drive motor before disassembly.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Remove the solenoid nut (Item 1) [Figure 30-30-5].

Figure 30-30-2
Figure 30-30-5

Place the hydrostatic drive motor on a work surface, mark

the sections for correct assembly [Figure 30-30-3]. Remove the solenoid (Item 1) [Figure 30-30-6] from the
shaft.
Figure 30-30-3

Remove the four bolts (Item 1) [Figure 30-30-4] and

remove the solenoid housing.

4852210 (07-06) 30-30-5 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-8

Disassembly (Cont'd)

Figure 30-30-6

Remove the O-ring (Item 1) and pin (Item 2) from the

solenoid shaft (Item 3) [Figure 30-30-9].

Figure 30-30-9
Remove and discard the O-ring (Item 1) [Figure 30-30-7]
from the solenoid.

Figure 30-30-7

Loosen the large nut (Item 1) [Figure 30-30-10] on the

compensator valve.

Do not loosen the small nut (Item 2) [Figure 30-30-10].

Remove the solenoid shaft (Item 1) and O-ring (Item 2)
[Figure 30-30-8] from the housing.

4852210 (07-06) 30-30-6 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-12

Disassembly (Cont'd)

Figure 30-30-10

Remove the plug (Item 1) [Figure 30-30-13] from the

housing.

Figure 30-30-13
Remove the adjusting screw (Item 1), valve spring (Item
2) and spool assembly (Item 3) [Figure 30-30-11] from
the housing.

Figure 30-30-11

Remove and discard the O-ring (Item 1) [Figure 30-30-

14] from the plug.

Remove and discard the O-ring (Item 1) [Figure 30-30-

12] from the adjustment screw.

4852210 (07-06) 30-30-7 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D)

Disassembly (Cont'd)

Figure 30-30-14

Remove the two fittings (Item 1) [Figure 30-30-15] from

the housing.

Figure 30-30-15

Remove both spool limiters (Item 1) [Figure 30-30-16].

Figure 30-30-16

Remove the spool (Item 1) [Figure 30-30-17].

4852210 (07-06) 30-30-8 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-19

Disassembly (Cont'd)

Figure 30-30-17

Lift and remove the end cap (Item 1) [Figure 30-30-20]

from the housing.

Figure 30-30-20
Remove and discard the six O-rings (Item 1) [Figure 30-
30-18] from the housing.

Figure 30-30-18

Remove the gasket (Item 1) [Figure 30-30-21] from the

end cap.

Remove the eight bolts (Item 1) [Figure 30-30-19] from

the end cap.

4852210 (07-06) 30-30-9 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-24

Disassembly (Cont'd)

Figure 30-30-21

Remove the plug (Item 1), spring (Item 2), spring seat
(Item 3) and spool (Item 4) [Figure 30-30-25] from the
housing.

Remove the piston (Item 1) [Figure 30-30-22] from the

end cap.

Figure 30-30-22

Remove the seal (Item 1) [Figure 30-30-23] from the

piston.

Figure 30-30-23

Loosen the plug (Item 1) [Figure 30-30-24].

4852210 (07-06) 30-30-10 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-28

Disassembly (Cont'd)

Figure 30-30-25

Remove and discard the O-ring (Item 1) [Figure 30-30-

29] from the plug.

Remove and discard the O-ring (Item 1) [Figure 30-30-

26] from the plug.

Figure 30-30-26

Loosen the plug (Item 1) [Figure 30-30-27].

Figure 30-30-27

Remove the plug (Item 1), spring (Item 2) and spring seat
(Item 3) [Figure 30-30-28] from the housing.

4852210 (07-06) 30-30-11 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-31

Disassembly (Cont'd)

Figure 30-30-29

Remove the valve segment (Item 1) [Figure 30-30-32]

from the cylinder.

Figure 30-30-32
Loosen and remove the relief valve (Item 1) [Figure 30-
30-30] from the housing.

Figure 30-30-30

Remove and discard the O-ring (Item 1). Remove eight

mounting bolts (Item 2) [Figure 30-30-33] from the
mounting plate.

Remove the plug (Item 1), O-rings (Item 2), spring (Item
3) and poppet (Item 4) from the relief valve housing (Item
5) [Figure 30-30-31].

4852210 (07-06) 30-30-12 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-35

Disassembly (Cont'd)

Figure 30-30-33

Remove the cylinder block (Item 1) and synchronizing

shaft assembly (Item 2) [Figure 30-30-36] from the
housing.

Remove the mounting plate (Item 1) [Figure 30-30-34] NOTE: It is not important that the pistons are installed
using a suitable puller. in their original position.

Figure 30-30-34 Figure 30-30-36

Remove and discard the seal (Item 1) [Figure 30-30-35] Remove the bearing plate (Item 1) [Figure 30-30-37] from
from the mounting plate. the cylinder block.

4852210 (07-06) 30-30-13 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-39

Disassembly (Cont'd)

Figure 30-30-37

Press the piston/shaft assembly from the housing [Figure

30-30-40].

DO NOT damage the pistons.

Remove the bearing from the cylinder block [Figure 30-
30-38]. Figure 30-30-40

DO NOT damage the bearing plate surface of the cylinder

block.

Figure 30-30-38

Pry up the peened notch (Item 1) [Figure 30-30-41] in the

ring nut.

Remove the O-ring (Item 1) [Figure 30-30-39] from the

housing.

4852210 (07-06) 30-30-14 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-43

Disassembly (Cont'd)

Figure 30-30-41

Using a clamp, compress the spring seat and spring, and

drive the pin (Item 1) [Figure 30-30-44] inwards. Release
the clamp.

Remove the ring nut (Item 1) [Figure 30-30-42] from the Figure 30-30-44
shaft.

Figure 30-30-42

Remove the pin (Item 1), spring (Item 2) and spring seat
(Item 3) [Figure 30-30-45] from the shaft assembly.

Remove the large bearing and race (Item 1), small

bearing and race (Item 2) and spacer (Item 3) [Figure 30-
30-43] from the shaft.

4852210 (07-06) 30-30-15 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-47

Disassembly (Cont'd)

Figure 30-30-45

Inspect the cylinder block assembly for wear or damage.

The piston bores (Item 1) must be smooth. The races for
the synchronizing shaft rollers (Item 2) [Figure 30-30-48]
must not be worn.
Remove the piston rings (Item 1) [Figure 30-30-46] from
the pistons. If there is any defect in the cylinder block or pistons, the
complete rotating group must be replaced.
NOTE: If any portion of the shaft assembly, bearings
or races must be replaced, the complete shaft/
bearing assembly must be replaced. The only
serviceable part is the piston rings (Item 1)
[Figure 30-30-46].

Inspection

Clean all parts in solvent and use air pressure to dry them.
DO NOT use cloth or paper as small pieces of material
can get into the system and cause damage.

Figure 30-30-46

Inspect the running (bronze) surface of the bearing plate

(Item 1) and locating pin holes (Item 2) [Figure 30-30-47]
for wear. Replace if damaged or worn.

4852210 (07-06) 30-30-16 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-50

Inspection (Cont'd)

Figure 30-30-48

Inspect the valve segment for damage or wear on the

sealing surface (Item 1) [Figure 30-30-51].

Check that the spindle is located correctly in the valve

Inspect the piston (Item 1) [Figure 30-30-49] for wear or segment by measuring distance "A" [Figure 30-30-51]. If
damage. this dimension is not within 1.36 to 1.37 inch (34.5 to 34.7
mm) the assembly must be replaced.
Figure 30-30-49

Inspect the swash plate running surface (Item 1) [Figure

30-30-50] in the end cap for wear or damage.

4852210 (07-06) 30-30-17 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-52

Assembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or Using a clamp, compress the spring and spring seat
damaged parts. [Figure 30-30-53].

Always install new seals and O-rings. Lubricate all seals Figure 30-30-53
and O-rings with clean hydraulic fluid before installation.

Figure 30-30-51

Install the pin (Item 1) [Figure 30-30-54] as shown.

NOTE: Clamp is removed for photo clarity.

Install the spring (Item 1) and spring seat (Item 2) into the
shaft assembly (Item 3) [Figure 30-30-52].

4852210 (07-06) 30-30-18 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-56

Assembly (Cont'd)

Figure 30-30-54

Using a punch seat the ring nut into the groove in the
shaft. [Figure 30-30-57].

Figure 30-30-57
Support the shaft assembly in a press without causing
damage to the pistons, install the large bearing and race
(Item 1), spacer (Item 2) and small bearing and race (Item
3) [Figure 30-30-55] into the shaft assembly.

NOTE: Be sure not to over press the bearings, they

should be able to roll freely.

Figure 30-30-55

Press the piston/shaft assembly into the housing [Figure

30-30-58].

DO NOT DAMAGE THE PISTONS.

Install the ring nut (Item 1) [Figure 30-30-56] onto the

shaft.

NOTE: Do not over tighten the ring nut and that there
is no noticeable looseness in the bearing.

4852210 (07-06) 30-30-19 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-60

Assembly (Cont'd)

Figure 30-30-58

Install the mounting plate onto the housing, install the

eight mounting bolts (Item 1) [Figure 30-30-61] and
tighten to 46 ft.-lbs. (63 Nm) torque.

Install a new seal (Item 1) [Figure 30-30-59] into the Figure 30-30-61
mounting plate until it is fully seated.

Figure 30-30-59

Install a new O-ring (Item 1) [Figure 30-30-62] onto the

mounting plate.

Install a new O-ring (Item 1) [Figure 30-30-60] onto the

housing.

4852210 (07-06) 30-30-20 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-63

Assembly (Cont'd)

Figure 30-30-62

Figure 30-30-64

Press a new bearing into the cylinder block until it is

located 0.53 to 0.55 inch (13.5 to 14.0 mm) below the
bearing plate surface [Figure 30-30-63].

Install new piston rings (Item 1) [Figure 30-30-64] onto

the pistons, make sure the spherical surface (Item 1)
[Figure 30-30-65] conforms to the shape of the piston.

An identification mark (Item 2) [Figure 30-30-64] &

[Figure 30-30-65] is on the "outer" side of the piston ring.

The ends of the piston rings must NOT overlap each

other.

4852210 (07-06) 30-30-21 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-67

Assembly (Cont'd)

Figure 30-30-65

Install the synchronizing shaft support pin (Item 1) [Figure

30-30-68] into the cylinder block and retain with grease.

Figure 30-30-68
Install the bearing plate (Item 1) [Figure 30-30-66] with
the bronze surface facing up onto the cylinder block.

Figure 30-30-66

Install the six synchronizing shaft rollers (Item 1) [Figure

30-30-69] onto the synchronizing shaft and retain with
grease.

Position the housing on end, tip the three pistons (Item 1)

[Figure 30-30-67] closest to the minimum angle stop out
toward the housing.

4852210 (07-06) 30-30-22 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-71

Assembly (Cont'd)

Figure 30-30-69

Install the synchronizing shaft and rollers (Item 1) [Figure

30-30-72] into the motor shaft races. When properly
installed the synchronizing shaft should move freely in all
directions.
NOTE: The recess (Item 1) [Figure 30-30-70] on each
roller MUST face the synchronizing shaft. NOTE: The motor shaft end of the synchronizing shaft
is smaller than the cylinder end.
Figure 30-30-70
Figure 30-30-72

Install the synchronizing shaft support pin (Item 1) [Figure

30-30-71] into the motor shaft assembly and retain with When installing the cylinder block, the races (Item 1)
grease. [Figure 30-30-73] in the cylinder block must be positioned
so the synchronizing shaft rollers (Item 2) [Figure 30-30-
73] and pistons (Item 3) [Figure 30-30-72] and their
bores (Item 2) [Figure 30-30-73] are aligned.

Install the six pistons (Item 3) [Figure 30-30-72] into the

cylinder bores, tilt the block so the synchronizing shaft
rollers enter their races in the block and the support pin
(Item 3) [Figure 30-30-73] enter the recess.

Lift the cylinder block slightly and guide the three

remaining pistons in position.

4852210 (07-06) 30-30-23 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-75

Assembly (Cont'd)

Figure 30-30-73

Install a new seal (Item 1) [Figure 30-30-76] onto the

piston.

Figure 30-30-76
If the cylinder block (Item 1) [Figure 30-30-74] is properly
installed, there should be very little rotational free-play
between the block and the motor shaft.

NOTE: A brass rod may be used to guide the pistons

into their bores.

Lubricate the pistons and cylinder block bores with

hydraulic oil.

Figure 30-30-74

Lubricate and install the piston (Item 1) [Figure 30-30-77]

into the end cap.

Install a new gasket (Item 1) [Figure 30-30-75] onto the

housing.

Install the valve segment (Item 2) [Figure 30-30-75] onto

the cylinder block and retain with heavy grease.

NOTE: The hole (Item 3) in the valve segment should

be opposite the minimum displacement
adjustment screw (Item 4) [Figure 30-30-75].

4852210 (07-06) 30-30-24 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-79

Assembly (Cont'd)

Figure 30-30-77

Install the relief valve (Item 1) [Figure 30-30-80] into the

housing and tighten to 38 ft.-lbs. (52 Nm) torque.

Figure 30-30-80
NOTE: Note the position of the hole (Item 1) [Figure
30-30-78] in the end cap.

Figure 30-30-78

3
5 1 4
4 2

Install a new O-ring (Item 1) [Figure 30-30-81] onto the

plug.
P-22501

Assemble the poppet (Item 1) and spring (Item 2) into the

relief valve housing (Item 3) install O-rings (Item 4) and
plug (Item 5) [Figure 30-30-79].

4852210 (07-06) 30-30-25 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-83

Assembly (Cont'd)

Figure 30-30-81

Install the spring seat (Item 1), spring (Item 2) and plug
(Item 3) [Figure 30-30-84] into the housing and tighten to
30 ft.-lbs. (41 Nm) torque.

Install the spool (Item 1), spring seat (Item 2), spring (Item Figure 30-30-84
3) and plug (Item 4) [Figure 30-30-82] into the housing
and tighten to 30 ft.-lbs. (41 Nm) torque.

Figure 30-30-82

Align the hole in the piston (Item 1) and the valve segment
(Item 2) [Figure 30-30-85].

Install a new O-ring (Item 1) [Figure 30-30-83] onto the

plug.

4852210 (07-06) 30-30-26 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-87

Assembly (Cont'd)

Figure 30-30-85

Install a new O-ring (Item 1) [Figure 30-30-88] onto the

plug.

Figure 30-30-88
Install the end cap housing and tighten the eight bolts
(Item 1) [Figure 30-30-86] to 85 ft.-lbs. (115 Nm) torque.

Figure 30-30-86

Install the plug (Item 1) [Figure 30-30-89] into the

housing.

Install six new O-rings (Item 1) [Figure 30-30-87] onto the

housing.

4852210 (07-06) 30-30-27 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-91

Assembly (Cont'd)

Figure 30-30-89

Install a new O-ring (Item 1) [Figure 30-30-92] onto the

solenoid shaft.

Lightly lubricate the pin (Item 2) [Figure 30-30-92] and

Install a new O-ring (Item 1) [Figure 30-30-90] onto the install into the solenoid shaft.
adjustment screw.
Figure 30-30-92
Figure 30-30-90

Install a new O-ring (Item 1) and solenoid shaft assembly

Install the spool (Item 1), spring (Item 2) and adjusting (Item 2) [Figure 30-30-93] into the housing.
screw (Item 3) [Figure 30-30-91] into the housing and
tighten to 7 ft.-lbs. (9 Nm) torque.

4852210 (07-06) 30-30-28 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-95

Assembly (Cont'd)

Figure 30-30-93

Install the solenoid housing assembly (Item 1) with four

bolts (Item 2) [Figure 30-30-96]. Tighten the bolts to 58
ft.-lbs. (78 Nm) torque.

Install the solenoid housing (Item 1) onto the shaft and

install a new O-ring (Item 2) [Figure 30-30-94].

Figure 30-30-94

Install the solenoid nut (Item 1) [Figure 30-30-95] and

hand tighten.

4852210 (07-06) 30-30-29 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 30-30-30 Bobcat T2556 & T2566
SERVICE MANUAL
HYDROSTATIC PUMP Figure 30-40-3

Removal And Installation

1
Figure 30-40-1

P-53792

Remove the four mounting bolts (Item 1) [Figure 30-40-3]

1 from the hydrostatic pump.
P-53788

Assembly: Tighten the mounting bolts to 69-78 ft.-lbs.

Remove the engine/hydrostat assembly (See “Removal (94-106 Nm) torque.
And Installation” on page 70-80-1).
Remove the hydrostatic pump.
Remove the gear pumps (See “Removal And Installation”
on page 20-130-1).

Remove the return hose (Item 1) [Figure 30-40-1] from

the hydrostatic pump.

Figure 30-40-2

P-53790

Install a chain hoist and lifting strap to lift and support the
hydrostatic pump [Figure 30-40-2].

4852210 (07-06) 30-40-1 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D)

Parts Identification

4852210 (07-06) 30-40-2 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D)

Parts Identification (Cont'd)

4852210 (07-06) 30-40-3 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT’D)

Parts Identification

1. Key
2. Charge Pump Shaft
3. Pin
4. Wear Plate
5. Gears
6. Coupling
7. Seal
8. Charge Pump Cover
9. Retaining Plate
10. Bolt
1
11. O-ring
12. Flange Adaptor 2
3
13. Washer
14. Bolt 4
15. O-ring
5

7
12
13

14

11
9

15 10

B-23152

4852210 (07-06) 30-40-4 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D)

Parts Identification (Cont'd)

1. Valve Plate
2. Retaining Ring
3. Spring Retainer
4. Spring
5. Spring Seat
6. Cylinder
7. Bolt
8. Slipper Guide Bearing
9. Spacer
10. Slipper Guide
11. Piston
12. Bolt
13. Bolt
14. Block
15. Spring
16. Servo Arm
17. Pin
18. Washer
19. Swash Plate Guide
20. Pin
21. Locator Link
22. Swash Plate
23. Bearing Assembly
24. Pin
25. Housing

4852210 (07-06) 30-40-5 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D)

Parts Identification (Cont'd)

4852210 (07-06) 30-40-6 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-5

Disassembly

Clean the outside of the pump before disassembly.

Mark the outside of the pump for ease of assembly.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Remove the three bolts (Item 1) [Figure 30-40-5].
I-2003-0888

Remove the retainer plate (Item 2) [Figure 30-40-5] from

Figure 30-40-4 the pump housing.

Figure 30-40-6

Remove the retainer bolt (Item 1). Remove the coupler

gear (Item 2) [Figure 30-40-4] from the shaft.
Remove the shaft and bearing assembly from the housing
[Figure 30-40-6].

NOTE: If the shaft or bearing assembly become stuck

in the housing, lightly tap on the shaft.

4852210 (07-06) 30-40-7 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-9

Disassembly (Cont'd)

Figure 30-40-7

Remove the bearing (Item 1) [Figure 30-40-9] from the

shaft.

Place the pump on the work surface with the charge pump
Remove the shaft seal (Item 1) [Figure 30-40-7] from the up.
shaft.
Mark the pump housings for correct assembly.
Figure 30-40-8
Before removing the relief valve mark the plug, lock nut
and housing for approximate assembly adjustment.

Figure 30-40-10

Remove the snap ring (Item 1) and spacer washer (Item

2) [Figure 30-40-8] from the shaft.

Remove the relief valve lock nut (Item 1) and the plug
(Item 2) [Figure 30-40-10].

4852210 (07-06) 30-40-8 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-13

Disassembly (Cont'd)

Figure 30-40-11

Remove the four mounting bolts (Item 1) [Figure 30-40-

13] from the flange adapter.

Remove the flange adapter (Item 2) [Figure 30-40-13].

Remove the spring and relief poppet from the charge
pump housing [Figure 30-40-11]. Figure 30-40-14

Figure 30-40-12

Lift and remove the charge pump (Item 1) [Figure 30-40-

14] from the pump housing.
Remove the two mounting bolts (Item 1) [Figure 30-40-
12].

NOTE: Remove the lifting bracket (Item 2) [Figure 30-

40-12] from the pump.

4852210 (07-06) 30-40-9 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-17

Disassembly (Cont'd)

Figure 30-40-15

Only if wear marks are present, remove the bushing (Item

1) from the charge pump cover (Item 2) [Figure 30-40-
17].

Remove the six bolts (Item 1) and remove the retaining Figure 30-40-18
plate (Item 2) [Figure 30-40-15] from the charge pump.

Figure 30-40-16

Remove the coupler (Item 1) [Figure 30-40-18].

Remove the charge pump cover (Item 1) [Figure 30-40-

16].

4852210 (07-06) 30-40-10 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-21

Disassembly (Cont'd)

Figure 30-40-19

Remove the eccentric ring (Item 1) and alignment pin

(Item 2) [Figure 30-40-21] from the pump.

Note the position of the alignment pin.

Remove the charge pump shaft (Item 1) and key (Item 2)
[Figure 30-40-19] from the pump. Figure 30-40-22

Figure 30-40-20

Remove the charge pump wear plate (Item 1) [Figure 30-

40-22].
Remove the charge pump gears (Item 1) [Figure 30-40-
20]. Remove the O-ring (Item 2) [Figure 30-40-22].

4852210 (07-06) 30-40-11 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-25

Disassembly (Cont'd)

Figure 30-40-23

Remove the multi-function valve assemblies (Item 1)

[Figure 30-40-25] from the housing.

Figure 30-40-26
Remove the swash plate leveler spring shims (Item 1)
[Figure 30-40-23] from the spring pockets.

Inspect the journal bearing (Item 2) [Figure 30-40-23].

Replace as needed.

Figure 30-40-24

Remove the gasket (Item 1) and the valve plate (Item 2)

from the housing. Note the direction of the arrows (Item 3)
[Figure 30-40-26] on the valve plate for proper assembly.

For proper operation, if the plugs are removed from the

housing they must be returned to their original position
[Figure 30-40-24].

Installation: Tighten the servo relief valve plug (Item 1) to

9 ft.-lbs. (12 Nm) torque. Tighten the rotation pipe plugs
(Item 2) [Figure 30-40-24] to 4 ft.-lbs. (5.4 Nm) torque.

4852210 (07-06) 30-40-12 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-29

Disassembly (Cont'd)

Figure 30-40-27

Remove the swash plate hold down spring (Item 1)

[Figure 30-40-29].

Figure 30-40-30
Remove the two leveler springs (Item 1) [Figure 30-40-
27].

Figure 30-40-28

Mark the position of the side cover.

Remove the six bolts (Item 1) [Figure 30-40-30] from the

side cover.
Remove both spring seats (Item 1) [Figure 30-40-28]
from the swash plate leveler.

4852210 (07-06) 30-40-13 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-33

Disassembly (Cont'd)

Figure 30-40-31

Remove the leveler (Item 1) and slide inserts (Item 2)

[Figure 30-40-33] from the side cover.

Inspect the slide inserts for wear or damage.

Remove the side cover/swash plate leveler assembly
from the housing [Figure 30-40-31]. Replace if needed.

Figure 30-40-32 Figure 30-40-34

Remove and discard the O-ring (Item 1). Loosen and Remove the six solenoid manifold mounting bolts (Item 1).
remove both guide posts (Item 2) [Figure 30-40-32]. Remove the manifold (Item 2) [Figure 30-40-34].

4852210 (07-06) 30-40-14 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-37

Disassembly (Cont'd)

Figure 30-40-35

Remove the solenoids (Item 1) [Figure 30-40-37] from

the manifold.

Figure 30-40-38
Remove the gasket (Item 1) [Figure 30-40-35] from the
manifold.

Figure 30-40-36

Remove and discard the three O-rings (Item 1) [Figure

30-40-38] from the solenoid.

Remove the four solenoid mounting bolts (Item 1) [Figure

30-40-36].

4852210 (07-06) 30-40-15 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-41

Disassembly (Cont'd)

Figure 30-40-39

Remove the cylinder block (Item 1) [Figure 30-40-41]

through the housing end opening. The swash plate and
piston assembly will remain in the housing.

Remove the anchor pin (Item 1) [Figure 30-40-39]. Figure 30-40-42

Figure 30-40-40

Remove the swash plate/piston assembly (Item 1)

[Figure 30-40-42] from the pump housing.
Remove the cage locator link (Item 1) [Figure 30-40-40]
from the swash plate.

4852210 (07-06) 30-40-16 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-45

Disassembly (Cont'd)

Figure 30-40-43

Remove the swash plate bearing races (Item 1) [Figure

30-40-45] from the housing.

Figure 30-40-46
Remove the four slipper guide bearing retainer bolts (Item
1) [Figure 30-40-43].

Figure 30-40-44

Remove the bronze slider block (Item 1) [Figure 30-40-

46] from the servo piston.

Mark the position of the servo end covers.

Remove the swash plate bearings (Item 1) [Figure 30-40-
44] from the housing.

4852210 (07-06) 30-40-17 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-49

Disassembly (Cont'd)

Figure 30-40-47

Measure and record the adjustment setting for

approximate installation adjustment [Figure 30-40-49].

Figure 30-40-50
Remove the three bolts and remove the servo end cover.
Remove and discard both O-rings (Item 1) [Figure 30-40-
47].

Figure 30-40-48

Remove the servo piston (Item 1) from the housing (Item

2) [Figure 30-40-50].

Remove and discard the O-ring (Item 3) [Figure 30-40-

50].
Remove the three bolts (Item 1) [Figure 30-40-48] and
remove the servo adjustment cover.

4852210 (07-06) 30-40-18 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-53

Inspection

Figure 30-40-51

Inspect the servo piston and seal rings (Item 1) [Figure

30-40-53] for wear. If worn, remove the seal rings and
expander O-rings from the piston.

Clean all parts in solvent and use air pressure to dry them. Install new expander O-rings into the grooves in the servo
DO NOT use cloth or paper as small pieces of material piston. Carefully install the piston seal rings over the
can get into the system and cause damage. expander rings. Do not overstretch the piston seal rings.

Check the wear plate (Item 1) and charge pump gears Figure 30-40-54
(Item 2) [Figure 30-40-51] for damage or wear.

Figure 30-40-52

Lubricate the seal rings and carefully slide the servo

piston (Item 1) into the cylinder (Item 2) [Figure 30-40-
54]. Allow the assembly to set for 5 minutes to allow the
Check the valve plate [Figure 30-40-52], the surface seal rings to return to their original size.
must be smooth and free of scratches. If scratches can be
felt with a finger nail, replace the part.

4852210 (07-06) 30-40-19 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-57

Inspection (Cont'd)

Figure 30-40-55

Servo arm (Item 1) [Figure 30-40-57] alignment is critical

for proper pump operation. For this reason, removal of the
servo arm from the swash plate is not recommended.

Check the swash plate assembly surface, it must be If the servo arm must be removed from the swash plate.
smooth and free of scratches [Figure 30-40-55]. Remove the swash plate guide bolt (Item 2) and the servo
arm mounting bolt (Item 3) [Figure 30-40-57].
Figure 30-40-56
Installation: The servo arm (Item 1) [Figure 30-40-57]
must be carefully aligned with the slot and threaded holes
in the swash plate while installing, and must be pressed
completely into the swash plate slot.

Tighten the swash plate guide bolt and servo arm bolt to
24 ft.-lbs. (32 Nm) torque.

Figure 30-40-58

Inspect the swash plate guide (Item 1) [Figure 30-40-56]

for wear. Replace as needed. 1

The threaded holes (Item 1) [Figure 30-40-58] in the

swash plate must be cleaned prior to assembly.

4852210 (07-06) 30-40-20 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-62

Inspection (Cont'd)

Figure 30-40-59

Check each piston (Item 1) and piston shoe (Item 2)

[Figure 30-40-62] for wear or scratches.

Figure 30-40-60

If the headed roll pin and flat washer (Item 1) [Figure 30-
40-59] must be installed in the swash plate, the distance
between the washer and the side of the swash plate must
be .21 inch (5,33 mm) [Figure 30-40-60].

Figure 30-40-61

Check the swash plate bearings (Item 1) [Figure 30-40-

61] for wear and damage. Replace as needed.

4852210 (07-06) 30-40-21 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-65

Inspection (Cont'd)

Figure 30-40-63

Inspect the shaft seal (Item 1) [Figure 30-40-65]. Replace

if needed.

Remove and discard the O-ring (Item 2) [Figure 30-40-

Check the cylinder block bores for wear or scratches 65].
[Figure 30-40-63].
Inspect the multi-function valve cartridge for damage to
If there is any defect in the cylinder block or pistons, the parts or O-rings.
complete rotating group must be replaced.
Figure 30-40-66
Figure 30-40-64

Replace O-rings as needed [Figure 30-40-66].

Check the shaft for wear or damage in the spline and
bearing areas [Figure 30-40-64].

Check the bearing for correct operation. Remove the race

(Item 1) [Figure 30-40-64] from the shaft only if it is
necessary to replace the bearing.

4852210 (07-06) 30-40-22 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-68

Assembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Clean all parts in solvent and dry with compressed air.

Lubricate the slipper running surface on the swash plate,
Inspect all parts for wear or damage. Replace any worn or center the piston and guide on the swash plate [Figure
damaged parts. 30-40-68].

Always install new seals and O-rings. Lubricate all seals Figure 30-40-69
and O-rings with clean hydraulic fluid before installation.

Figure 30-40-67

Apply LOCTITE #242 to four NEW retainer bolts (Item 1).

Install the slipper guide bearings (Item 2) and spacers
(Item 3) [Figure 30-40-69].
Put the piston assemblies into the slipper guide [Figure
30-40-67]. Tighten the four bolts to 10 ft.-lbs. (13,5 Nm) torque.

NOTE: Always use NEW retainer bolts with proper

locking compound.

NOTE: The slipper guides and piston slippers must

slide freely on the swash plate.

4852210 (07-06) 30-40-23 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-72

Assembly (Cont'd)

Figure 30-40-70

Assemble and lubricate the bearing cage (Item 1) [Figure

30-40-72], and install it on the bearing races.

Figure 30-40-73
Lubricate the pistons and cylinder block bores. Install the
assembled swash plate and pistons into the cylinder block
[Figure 30-40-70].

NOTE: The pistons and bores are not selectively

fitted.

Figure 30-40-71

Install the bronze slider block (Item 1) [Figure 30-40-73]

on the swash plate servo arm.

Install the swash plate bearing races (Item 1) [Figure 30-

40-71] into the housing. Note the locating pins are offset
in the housing to assure proper assembly.

4852210 (07-06) 30-40-24 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-76

Assembly (Cont'd)

Figure 30-40-74

Lower the cylinder block and swash plate assembly until

the swash plate is properly located on the bearings
[Figure 30-40-76].

Carefully lower the cylinder block and swash plate Figure 30-40-77
assembly into the housing [Figure 30-40-74].

Figure 30-40-75

Install new O-rings (Item 1) [Figure 30-40-77] on the

servo end cap.

Holding the cylinder block and swash plate assembly Lightly lubricate the O-rings and the inner surface of the
approximately 1/2" (12 mm) above the bearings. Position end cap.
the servo piston (Item 1) on the bronze slider block (Item
2) [Figure 30-40-75]. Take care not to wedge the block,
the parts should slide freely.

4852210 (07-06) 30-40-25 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-80

Assembly (Cont'd)

Figure 30-40-78

Install the servo adjustment cover over the servo piston

until the piston adjustment screw touches the cover. Using
a hex wrench, turn the adjustment screw
counterclockwise while holding the cover until it is in
Hold the servo piston in position and install the servo end position [Figure 30-40-80].
cap [Figure 30-40-78].
NOTE: Do not install the bolts at this time.
Figure 30-40-79
Figure 30-40-81

Install the three end cap mounting bolts (Item 1) [Figure

30-40-79]. Tighten to 10 ft.-lbs. (13,5 Nm) torque. Align the slot in the swash plate bearing cage (Item 1)
with the pin (Item 2) in the swash plate and the pin hole
Lightly lubricate the O-rings and inner surface of the (Item 3) [Figure 30-40-81] in the housing.
adjustment cover.

4852210 (07-06) 30-40-26 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-84

Assembly (Cont'd)

Figure 30-40-82

Position the two side cover inserts (Item 1) and

swashplate leveler (Item 2) on the side cover. Note the
orientation of the leveler and the notch (Item 3) [Figure
30-40-84] in the cover.
Hook the cage locator link (Item 1) over the pin (Item 2)
[Figure 30-40-82] between the swash plate and washer. Figure 30-40-85
Rotate the link into the slot in the bearing cage.

Install the anchor pin (Item 3) [Figure 30-40-82] through

the locator link and into the housing.

Figure 30-40-83

Install the two guide post bolts (Item 1) [Figure 30-40-85]

through the leveler and inserts. Install the sealing nuts
and tighten to 17 ft.-lbs. (23 Nm) torque.

Install a new O-ring (Item 2) [Figure 30-40-85] on the

cover.
Push the swashplate assembly toward the servo piston
until the swash plate guide contacts the bearing races.
Check for clearance between the servo arm and the slider
block [Figure 30-40-83]. If no clearance is present,
recheck the assembly of the bearing cage and races.

4852210 (07-06) 30-40-27 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-88

Assembly (Cont'd)

Figure 30-40-86

Use a depth micrometer to measure the distance from the

end cap to the swash plate surface (Item 1). Take a
second measurement at a point 90° (Item 2) [Figure 30-
40-88] from the first point of measurement. These
Lift the swash plate leveler and install the side cover measurements must not vary more than .001 inches (.025
[Figure 30-40-86]. mm).

Figure 30-40-87 Figure 30-40-89

Install the two side cover bolts (Item 1) [Figure 30-40-87] Rotate the side cover [Figure 30-40-89] (which will also
finger tight. rotate the leveler and swash plate) until the zero angle
position is established, as determined by a second depth
Apply a force of 5 - 10 ft.-lbs. (22 - 44 Nm) to the swash measurement.
plate leveler to make sure both leveler arms contact the
swash plate.

Make sure the swash plate assembly is seated correctly

on the bearings.

4852210 (07-06) 30-40-28 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-92

Assembly (Cont'd)

Figure 30-40-90

Install the three servo adjustment cover mounting bolts

(Item 1) [Figure 30-40-92]. Tighten to 10 ft.-lbs. (13,5
Nm) torque.

After the zero angle position has been established, tighten Figure 30-40-93
the two side cover bolts (Item 1) [Figure 30-40-90].

Figure 30-40-91

Turn the adjustment screw on the servo, which will rotate

the swash plate assembly until a zero angle position is
established [Figure 30-40-93].
Install the four remaining side cover bolts, apply LOCTITE
#242 to the threads of the "thru" bolts (Item 1) [Figure 30-
40-91].

First tighten the four side cover bolts (Item 2) to 24 ft.-lbs.

(32,5 Nm) torque. Tighten the two remaining side cover
bolts (Item 1) [Figure 30-40-91] to 18.5 ft.-lbs. (25 Nm)
torque.

4852210 (07-06) 30-40-29 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-96

Assembly (Cont'd)

Figure 30-40-94

Install new O-rings (Item 1) [Figure 30-40-96] on the

solenoid spool.

Figure 30-40-97
Use a depth micrometer to measure the distance from the
end cap to the swash plate surface [Figure 30-40-94].
Take a second measurement at a point 180° from the first
point of measurement. These measurements must not
vary more than .001 inch (.025 mm).

Figure 30-40-95

Lightly lubricate both solenoid spools and install into the

manifold housing and retain with the four screws (Item 1)
[Figure 30-40-97].

Without turning the servo adjustment screw, install the

sealed nut (Item 1) [Figure 30-40-95] and tighten.

4852210 (07-06) 30-40-30 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-100

Assembly (Cont'd)

Figure 30-40-98

Install the spring (Item 1) [Figure 30-40-100] on the servo

arm link.

Figure 30-40-101
Apply assembly lube on the gasket (Item 1) [Figure 30-
40-98] and install on the manifold housing.

Figure 30-40-99

2
2 Install the spring seats (Item 1) [Figure 30-40-101] on the
leveler arms.
P18601

Install the manifold assembly (Item 1) on the pump with

the six screws (Item 2) [Figure 30-40-99].

4852210 (07-06) 30-40-31 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-104

Assembly (Cont'd)

Figure 30-40-102

Install a new gasket (Item 1) [Figure 30-40-104] on the

housing.

Figure 30-40-105
Install both springs (Item 1) [Figure 30-40-102] on the
leveler spring seats.

Lubricate the running surface of the cylinder (Item 2)

[Figure 30-40-102].

Figure 30-40-103

Lubricate the end cap journal bearing (Item 1). Install the
hardened shims (Item 2) [Figure 30-40-105] in the charge
pump pockets for the swash plate leveler springs. Retain
the shims with assembly lube.

Turn the charge pump housing over.

Install the valve plate (Item 1) [Figure 30-40-103] on the

alignment pins.

NOTE: The direction of the arrow cut outs (Item 2)

[Figure 30-40-103] in the valve plate.

4852210 (07-06) 30-40-32 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-108

Assembly (Cont'd)

Figure 30-40-106

Install the eccentric ring (Item 1) in the charge pump and

align with the alignment pin (Item 2) [Figure 30-40-108].

Figure 30-40-109
Lightly lubricate the alignment pin (Item 1) [Figure 30-40-
106] and install into the charge pump housing, in the
position marked at time of disassembly. This will properly
align the wear plate and eccentric ring.

Install a new O-ring (Item 2) [Figure 30-40-106].

Figure 30-40-107

Apply assembly lube and install the charge pump gears

(Item 1), charge pump shaft (Item 2) and key (Item 3)
[Figure 30-40-109] into the pump.

Lubricate both sides of the wear plate (Item 1) and install

in the charge pump. Align the wear plate with the
alignment pin (Item 2) [Figure 30-40-107].

4852210 (07-06) 30-40-33 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-112

Assembly (Cont'd)

Figure 30-40-110

Install the retaining plate cover (Item 1) and six bolts (Item
2) [Figure 30-40-112]. Tighten the bolts to 10 ft.-lbs. (13,5
Nm) torque.

Install the coupler (Item 1) [Figure 30-40-110]. Figure 30-40-113

Figure 30-40-111

Lower the charge pump onto the pump housing while

positioning the three springs in their pockets [Figure 30-
Install the charge pump cover (Item 1) [Figure 30-40- 40-113].
111].
When properly installed, the charge pump will engage the
Rotate until the pin hole in the cover aligns with the pin. alignment pins, but the springs will hold the charge pump
housing 1/8 to 1/4 (3 to 8 mm) away from the pump
housing.

4852210 (07-06) 30-40-34 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-116

Assembly (Cont'd)

Figure 30-40-114

Install the spring and relief poppet into the charge pump
[Figure 30-40-116].

Figure 30-40-117
Install the flange adapter (Item 1) and four bolts (Item 2)
[Figure 30-40-114]. Tighten the bolts to 90 ft.-lbs. (122
Nm) torque.

Figure 30-40-115

Install the plug with lock nut (Item 1) [Figure 30-40-117],

align the marks made at disassembly. Tighten the lock nut
to 38 ft.-lbs. (52 Nm) torque.

Install the two mounting bolts (Item 1) [Figure 30-40-115]

and tighten to 28 ft.-lbs. (38 Nm) torque.

NOTE: Install the lifting bracket (Item 2) [Figure 30-40-

115].

4852210 (07-06) 30-40-35 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-120

Assembly (Cont'd)

Figure 30-40-118

Install the shaft and bearing assembly, aligning the shaft

spline with the cylinder block spline. Continue to lower the
shaft and align with the charge pump journal bearing and
charge pump coupler [Figure 30-40-120].
Lightly lubricate and install both multi-function valve
assemblies (Item 1) [Figure 30-40-118] in the charge Figure 30-40-121
pump. Tighten to 66 ft.-lbs. (89 Nm) torque.

Figure 30-40-119

Install a new O-ring (Item 1) [Figure 30-40-121].

Lubricate the seal with assembly lube and install the seal
Install the bearing (Item 1), the spacer washer (Item 2) assembly on the drive shaft and in the housing [Figure
and the snap ring (Item 3) [Figure 30-40-119] on the drive 30-40-120].
shaft.

Position the pump on the charge pump end.

4852210 (07-06) 30-40-36 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D)

Assembly (Cont'd) NOTE: When installing the coupler, maintain a .0625

inch (1,59 mm) gap from the pump mount
Figure 30-40-122 flange to the coupler [Figure 30-40-123] &
[Figure 30-40-124].

Remove the case plug (Item 3) [Figure 30-40-123] and fill

with clean hydraulic fluid prior to start up.

Rotate the pump shaft with a torque wrench to assure

correct assembly. The torque required to turn the shaft
(after "break away") should be within:

MINIMUM MAXIMUM
4 ft.-lbs. (5,4 Nm) 9 ft.-lbs. (12,2 Nm)

Install the retainer plate (Item 1) and three bolts (Item 2)

[Figure 30-40-122]. Tighten the bolts in a sequenced
pattern to 12 ft.-lbs. (16 Nm) torque.

Figure 30-40-123

Install the coupler gear (Item 1) on the shaft and install the
bolt (Item 2) [Figure 30-40-123].

Figure 30-40-124

0.0625”
(1,59 mm)

4852210 (07-06) 30-40-37 Bobcat T2556 & T2566

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Charge pressure adjusting procedure

Charge pressure checking procedure Figure 30-40-126

Heat the hydraulic oil to 60°C by driving the machine and/

or performing boom lifting and telescoping operations.
Measure temperature in the oil tank or at the hydraulic
pump entry.

Check the maximum engine speed: the value should be

2450 rpm + 50.

If necessary, adjust the stop screw of the engine speed

control cable, which is situated on the injection pump.
Also check the speed control pedal stop.
1
Figure 30-40-125
B-15045

The charge pressure can be adjusted with the charge

pressure relieve valve (Item 1) [Figure 30-40-126] ,
situated on the right side of the hydrostatic pump.

NOTE: Difference in charge pressure between min.

engine speed and max. engine speed should
not be under 101 Psi (7 Bar) without exceeding
145 Psi (10 Bar).
1 Charge pressure at min. engine speed should
at least be 261 Psi (18 Bar).

S3089 Loosen the counterbolt on the charge pressure relieve

valve (Item 1) [Figure 30-40-126].

Use a 9/16 key to adjust the valve. Then perform the

above procedure “Charge pressure checking procedure”
on page 38.
Re-adjust if needed, until the right value has been
reached.

NOTE: A low charge pressure value may result from a

leak, so adjusment of the charge pressure
1 relieve valve will then have no effect.

S3088

Remove the test fitting (Item 1) [Figure 30-40-125]

situated on the hydraulic oil filter body and connect a
pressure gauge (0-60 Bar).
If needed, use an adapter 9/16 to connect the gauge.

With the travel direction lever in neutral position, start the

engine and go to maximum engine speed.

Pressure should stabilize on 435 Psi + 30 (30 Bar + 2).

If adjustment is needed, follow the procedure as

described below.

4852210 (07-06) 30-40-38 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE SYSTEM

AXLE AND DIFFERENTIAL (FRONT) (For S/N 363011001 - 363012000

and S/N 363111001 - 363112000) . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Axle Housing/Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . 40-20-53
Axle Housing/Drive Axle Disassembly . . . . . . . . . . . . . . . . . 40-20-14
Axle Housing/Drive Axle Parts Identification . . . . . . . . . . . . . 40-20-13
Brake Group Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-19
Brake Group Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-25
Brake Group Parts Identification . . . . . . . . . . . . . . . . . . . . . . 40-20-19
Differential Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-40
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-26
Differential Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-29
Differential Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . 40-20-26
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Pinion Group Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-34
DRIVE
Pinion Group Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-31
SYSTEM
Pinion Group Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-33
Pinion Group Parts Identification. . . . . . . . . . . . . . . . . . . . . . 40-20-30
Planetary Carrier Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-63
Planetary Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
Planetary Carrier Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-4
Planetary Carrier Parts Identification. . . . . . . . . . . . . . . . . . . . 40-20-1
Steering Knuckle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-58
Steering Knuckle Disassembly . . . . . . . . . . . . . . . . . . . . . . . 40-20-11
Steering Knuckle Parts Identification. . . . . . . . . . . . . . . . . . . 40-20-10
Wheel Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-61
Wheel Hub Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-6
Wheel Hub Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-9
Wheel Hub Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . 40-20-5

AXLE AND DIFFERENTIAL (REAR) (For S/N 363011001 - 363012000

and S/N 363111001 - 363112000) . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
Axle Housing/Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . 40-21-46
Axle Housing/Drive Axle Disassembly . . . . . . . . . . . . . . . . . 40-21-13
Axle Housing/Drive Axle Parts Identification . . . . . . . . . . . . . 40-21-12
Differential Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-35
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-16
Differential Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-23
Differential Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . 40-21-16
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
Pinion Group Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-29
Pinion Group Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-25
Pinion Group Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-28
Pinion Group Parts Identification. . . . . . . . . . . . . . . . . . . . . . 40-21-24
Planetary Carrier Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-54
Planetary Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 40-21-2
Planetary Carrier Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-4

Continued On Next Page

4852210 (07-06) 40-01-1 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE SYSTEM (CONT’D)

AXLE AND DIFFERENTIAL (REAR) (For S/N 363011001 - 363012000 and S/N 363111001 -
363112000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
Planetary Carrier Parts Identification . . . . . . . . . . . . . . . . . 40-21-1
Steering Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-49
Steering Knuckle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-10
Steering Knuckle Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-9
Wheel Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-52
Wheel Hub Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-6
Wheel Hub Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-9
Wheel Hub Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-5

AXLE AND DIFFERENTIAL (FRONT) (For S/N 363012001 and Above, S/N 363112001 and
Above). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-1
Bevel Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-34
Bevel Pinion Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-31
Bevel Pinion Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-30
Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-46
Brake System disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-14
Brake System Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-12
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-41
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-24
Differential Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-23
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-1
Planetary Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-65
Planetary Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-2
Planetary Carrier Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-1
Steering Knuckle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-7
Steering Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-59
Steering Knuckle Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22-6

AXLE AND DIFFERENTIAL (REAR) (For S/N 363012001 and Above, S/N 363112001 and
Above). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-1
Bevel pinion Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-17
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-29
Differential Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-11
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-1
Steering Knuckle Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-6
Steering Knuckle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-7
Steering Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-33
Planetary Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-39
Planetary Carrier Disassembly (Cont’d) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-2
Planetary Carrier Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-23-1

AXLE TOE-IN (For S/N 363012001 and Above, S/N 363112001 and Above) . . . . . . . . . . 40-41-1
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-41-1

AXLE TOE-IN (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000). . . . . 40-40-1
Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

Continued On Next Page

4852210 (07-06) 40-01-2 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVE SYSTEM (CONT’D)

DRIVESHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1

FRONT AXLE (For S/N 363012001 and Above, S/N 363112001 and Above) . . . . . . . . . . 40-31-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-31-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-31-1

FRONT AXLE (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000) . . . . 40-30-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

PARKING BRAKE (For S/N 363012001 and Above, S/N 363112001 and Above). . . . . . . 40-51-1
Re-Activating The Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-51-2
Releasing The Brake For Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-51-1

PARKING BRAKE (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000) . 40-50-1
Re-Activating The Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-2
Releasing The Brake For Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

REAR AXLE (For S/N 363012001 and Above, S/N 363112001 and Above) . . . . . . . . . . . 40-91-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-91-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-91-1

REAR AXLE (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000) . . . . . 40-90-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-91-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-91-1

SERVICE BRAKE (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000) . 40-80-1
Bleeding The Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

SERVICE BRAKE (FOR S/N 363012001 AND ABOVE, S/N 363112001 AND ABOVE) . . 40-81-1
Bleeding The Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-81-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-81-1

STEERING ANGLE ADJUSTMENT (For S/N 363011001 - 363012000 and S/N 363111001 -
363112000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

STEERING ANGLE ADJUSTMENT (FOR S/N 363012001 AND ABOVE, S/N 363112001 AND
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61-1

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1

4852210 (07-06) 40-01-3 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 40-01-4 Bobcat T2556 & T2566
SERVICE MANUAL
TROUBLESHOOTING

Chart

The following Troubleshooting Chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.

PROBLEM CAUSE
Pinion or Ring gear tooth broken 1, 2, 3, 4, 5, 6
Pinion teeth pitted 5, 11
Axle housing bent 12, 13
Worn or pitted bearings 3, 5, 6, 11, 14
Oil leakage 6, 9, 14
Excessive wear on input shaft splines 3, 16, 17, 19
Pinion teeth fatigue 7, 12, 17, 19
Side gear spline worn 17, 19
Thrust washer surface worn 5, 6, 7
Inner diameter of tapered roller bearing worn 5, 6, 18, 19
Bent or broken half shaft 19
Half shaft broken at wheel side 20, 21

KEY TO CORRECT THE CAUSE

1. Excessive gear load
2. Incorrect gear adjustment (excessive play)
3. Pinion nut loose
4. Incorrect gear adjustment (insufficient play)
5. Insufficient lubrication
6. Contaminated oil
7. Incorrect lubrication
8. Worn bearings
9. Operation at high temperature
10. Low oil level
11. Excessive use
12. Overloaded
13. Accident
14. Normal Wear
15. Lip seal damaged
16. Pinion axle play
17. Continuous overload
18. Excessive pinion axle play
19. Vehicle intensively operated or overloaded
20. Wheel loose
21. Beam housing bent

4852210 (07-06) 40-10-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 40-10-2 Bobcat T2556 & T2566
SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N
363011001 - 363012000 and S/N 363111001 -
363112000)

General Information
• Drive motor removal. (See “HYDROSTATIC DRIVE
MOTOR” on page 30-30-1)
For photo clarity, the following axle procedures are done
with the complete axle assembly removed from the
• Drive box removal. (See “DRIVE BOX (For S/N
machine, although the planetary carrier, wheel hub,
363011001 - 363012000 and S/N 363111001 -
steering knuckle and drive axle procedures may be done
363112000)” on page 20-70-1)
with the axle assembly installed in the machine. For
complete axle repair, the following must be done:
• Steering cylinder removal (See “STEERING
CYLINDER (FRONT) (For S/N 363011001 -
• Axle removal (See “FRONT AXLE (For S/N
363012000 and S/N 363111001 - 363012000)” on
363011001 - 363012000 and S/N 363111001 -
page 20-60-1).
363112000)” on page 40-30-1).

Planetary Carrier Parts Identification

4852210 (07-06) 40-20-1 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-2
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Planetary Carrier Disassembly

Clean the outside of the planetary carrier before

disassembly.

Mark the outside of the planetary carrier for ease of

assembly.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all Remove the two screws (Item 1) [Figure 40-20-2] from
parts clean. Always use caps and plugs on hoses, the planetary carrier.
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Figure 40-20-3
I-2003-0888

Figure 40-20-1

Remove the planetary carrier (Item 1) [Figure 40-20-3]

from the axle.

With the drain plug (Item 1) [Figure 40-20-1] in the

position shown, place a drain pan under the hub and
remove the plug.

4852210 (07-06) 40-20-2 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-6
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Planetary Carrier Disassembly (Cont'd)

Figure 40-20-4

Remove the thrust plate (Item 1) [Figure 40-20-6].

Figure 40-20-7

Remove and discard the O-ring (Item 1) [Figure 40-20-4]

from the planetary carrier.

Figure 40-20-5

Remove the three gears (Item 1) [Figure 40-20-7] with

needle bearings from each gear shaft.

NOTE: Mark the gear location for correct assembly.

Remove the three snap rings (Item 1) [Figure 40-20-5].

4852210 (07-06) 40-20-3 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Planetary Carrier Inspection
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D) Figure 40-20-9
Planetary Carrier Disassembly (Cont'd)

Figure 40-20-8

Inspect the planetary gears (Item 1) [Figure 40-20-9] for

worn or cracked teeth.

If any of the planetary gears are damaged, replace all the

Remove the thrust washers (Item 1) [Figure 40-20-8]
planetary gears and drive axle end of the drive axle
from each shaft.
assembly. One damaged gear can cause a microscopic
fatigue crack in mating teeth and cause premature failure
after servicing.

Figure 40-20-10

If any of the bearing shafts (Item 1) [Figure 40-20-10] are

damaged, replace all bearing shafts.

If the thrust pin (Item 2) [Figure 40-20-10] is worn,

replace the entire planetary carrier.

4852210 (07-06) 40-20-4 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000) (CONT'D)

Wheel Hub Parts Identification

4852210 (07-06) 40-20-5 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-13
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Wheel Hub Disassembly

Figure 40-20-11

Remove the six ring gear mounting bolts (Item 1) [Figure

40-20-13].

Figure 40-20-14

Remove the snap ring (Item 1) [Figure 40-20-11].

Figure 40-20-12

Install two bolts (Item 1) into the ring gear as shown, and
tighten equally pushing the ring gear assembly (Item 2)
[Figure 40-20-14] from the shaft.

Remove the thrust washer (Item 1) and spacer (Item 2)

[Figure 40-20-12].

4852210 (07-06) 40-20-6 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-17
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Wheel Hub Disassembly (Cont'd)

Figure 40-20-15

Remove the inner bearing (Item 1) [Figure 40-20-17]

from the swivel housing.

Figure 40-20-18

Remove the ring gear assembly [Figure 40-20-15].

Figure 40-20-16

Remove the retainer ring (Item 1) [Figure 40-20-18] from

the ring gear assembly.

Remove the outer bearing and hub assembly from the

axle [Figure 40-20-16].

NOTE: Use care while removing, as assembly may

remove easy.

4852210 (07-06) 40-20-7 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-21
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Wheel Hub Disassembly (Cont'd)

Figure 40-20-19

Remove the seal (Item 1) [Figure 40-20-21] from the hub.

Figure 40-20-22

Remove the gear (Item 1) from the ring gear (Item 2)

[Figure 40-20-19].

Figure 40-20-20

Using a brass drift remove both bearing races (Item 1)

[Figure 40-20-22] from the hub.

Remove the six bushings (Item 1) [Figure 40-20-20] from

the gear if damaged or worn.

4852210 (07-06) 40-20-8 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Wheel Hub Inspection

Figure 40-20-23

Inspect the ring gear (Item 1) and inner gear (Item 2)

[Figure 40-20-23] for broken or damaged teeth.

If the ring gear or inner gear are damaged, replace both

parts.

4852210 (07-06) 40-20-9 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Steering Knuckle Parts Identification

4852210 (07-06) 40-20-10 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-26
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Steering Knuckle Disassembly

Clean the outside of the steering knuckle before

disassembly.

Mark the outside of the steering knuckle for ease of

assembly.

Figure 40-20-24

Lift and remove the knuckle assembly from the axle

[Figure 40-20-26].

Figure 40-20-27

Remove the three bolts (Item 1) and king pin (Item 2)

[Figure 40-20-24] from the bottom of the knuckle.

Figure 40-20-25

1
Remove the Belleville washers (Item 1) [Figure 40-20-27]
from the top and bottom of the axle.

NOTE: The bottom Belleville washer is smaller than

the top Belleville washer.

P-42821

Remove the bolt (Item 1) and king pin (Item 2) [Figure 40-
20-25] from the top of the knuckle.

4852210 (07-06) 40-20-11 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-30
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Steering Knuckle Disassembly (Cont'd)

Figure 40-20-28

Using a puller, remove the top and bottom bushings from

the axle [Figure 40-20-29] & [Figure 40-20-30].

Figure 40-20-31

Remove the spacer washer (Item 1) [Figure 40-20-28]

from the top of the axle.

Figure 40-20-29

Remove the seal (Item 1) [Figure 40-20-31] from the

knuckle assembly.

4852210 (07-06) 40-20-12 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-33
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Steering Knuckle Disassembly (Cont'd)

Figure 40-20-32

Remove the ball type bearing (Item 1) [Figure 40-20-33]

from the lower king pin.

NOTE: Removal procedure will destroy the ball

bearing.
Remove the bushing (Item 1) [Figure 40-20-32] from the
knuckle assembly.

Axle Housing/Drive Axle Parts Identification

4852210 (07-06) 40-20-13 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-36
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Axle Housing/Drive Axle Disassembly

Clean the outside of the axle housing before disassembly.

Mark the outside of the axle housing for ease of assembly.

Figure 40-20-34

Remove the two snap rings (Item 1) [Figure 40-20-36]

across from each other.

Figure 40-20-37

Remove the drive axle from the axle housing [Figure 40-
20-34].

Figure 40-20-35

Drive the upper bearing cup down to push the opposite

bearing cup partially through the yoke [Figure 40-20-37].

NOTE: The bottom bearing cup will not be completely

removed.

Remove the seal (Item 1) and bushing (Item 2) [Figure

40-20-35] from the axle end housing.

4852210 (07-06) 40-20-14 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-40
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Axle Housing/Drive Axle Disassembly (Cont'd)

Figure 40-20-38

Turn the shaft over and remove the bearing cup (Item 1).
Remove the drive shaft (Item 2) [Figure 40-20-40] from
the yoke.

Figure 40-20-41
Turn the shaft over and remove the bearing cup (Item 1)
[Figure 40-20-38].

Figure 40-20-39

Remove the two snap rings (Item 1) [Figure 40-20-41]

from the yoke.

Drive the cross (Item 1) [Figure 40-20-39] down to push

the opposite bearing cup through the yoke.

NOTE: Drive shaft end (Item 2) [Figure 40-20-39] may

fall out of the yoke.

4852210 (07-06) 40-20-15 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-44
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Axle Housing/Drive Axle Disassembly (Cont'd)

Figure 40-20-42

Press the second bearing cup through the yoke [Figure

40-20-44].

Figure 40-20-45

Using two different size sockets and a vice, press one

bearing cup into the yoke while pushing the opposite
bearing cup through the yoke [Figure 40-20-42].

Figure 40-20-43

Remove the bearing cup (Item 1) and cross (Item 2)

[Figure 40-20-45] from the yoke.

Remove the bearing cup (Item 1) [Figure 40-20-43].

4852210 (07-06) 40-20-16 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-48
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Axle Housing/Drive Axle Disassembly (Cont'd)

Figure 40-20-46

Remove the nut (Item 1) [Figure 40-20-48] from the

bottom of the housing.

Figure 40-20-49

With the axle supported on a secure work surface or floor

mark the axle housing to the center housing for correct
assembly [Figure 40-20-46].

Figure 40-20-47

Remove the remaining mounting bolts (Item 1) [Figure

1 40-20-49].
1

P-23039

Remove the two axle housing mounting bolts and install

two alignment bolts (Item 1) [Figure 40-20-47].

4852210 (07-06) 40-20-17 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-51
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Axle Housing/Drive Axle Disassembly (Cont'd)

Figure 40-20-50

Remove the O-ring (Item 1) [Figure 40-20-51] from the

axle housing.

Separate the axle housing from the brake housing

[Figure 40-20-50].

Remove the axle housing.

4852210 (07-06) 40-20-18 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000) (CONT'D)

Brake Group Parts Identification

Brake Group Disassembly NOTE: For friction plate replacement do not remove
the brake housing.
Clean the outside of the brake group before disassembly.
Figure 40-20-53
Mark the outside of the brake group for ease of assembly.

Figure 40-20-52

Remove the tube lines (Item 1) [Figure 40-20-53].

NOTE: Mark the tube lines for correct installation.

Remove the brake separator plates, friction plates and
coupler from the brake housing [Figure 40-20-52].

4852210 (07-06) 40-20-19 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-56
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Brake Group Disassembly (Cont'd)

Figure 40-20-54

Separate and remove the brake housing from the center

housing [Figure 40-20-56].

Figure 40-20-57

Remove the stud bolt (Item 1) [Figure 40-20-54] from the

housing.

Figure 40-20-55

Remove and discard the O-ring (Item 1) [Figure 40-20-

57] from the center housing.

Remove the upper mounting bolt (Item 1) [Figure 40-20-

55] from the housing.

4852210 (07-06) 40-20-20 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-60
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Brake Group Disassembly (Cont'd)

Figure 40-20-58

Remove and discard the two O-rings (Item 1) [Figure 40-

20-60] from the piston.

Figure 40-20-61

Remove the three bolts (Item 1) [Figure 40-20-58] from

the brake housing.

NOTE: There are six bevel washers nested in

opposing direction on each bolt.

Figure 40-20-59

Turn the three brake adjusting screws (Item 1) [Figure

40-20-61] out (counterclockwise) equally.

Remove and discard the O-ring (Item 2) [Figure 40-20-

61].

Remove the piston (Item 1) [Figure 40-20-59] from the

brake housing.

4852210 (07-06) 40-20-21 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-64
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Brake Group Disassembly (Cont'd)

Figure 40-20-62

Remove the split ring retainer (Item 1) [Figure 40-20-64].

Figure 40-20-65

Using a 6-1/2 inch O.D. tube and suitable press, apply

enough downward pressure on the Belleville springs
allowing the split ring retainer ring to drop down [Figure
40-20-62].

Figure 40-20-63

Remove the two Belleville springs (Item 1) [Figure 40-20-

65].

With the split ring retainer ring (Item 1) in the down

position, remove the split ring (Item 2) [Figure 40-20-63].

Carefully release the pressure and remove the brake

housing from the press.

4852210 (07-06) 40-20-22 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-68
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Brake Group Disassembly (Cont'd)

Figure 40-20-66

Remove and discard the two O-rings (Item 1) [Figure 40-

20-68] from the pins.

Figure 40-20-69

Remove the three snap rings (Item 1) [Figure 40-20-66]

from the pins.

Figure 40-20-67

Remove the brake plate (Item 1) [Figure 40-20-69] from

the brake housing.

Push the three pins (Item 1) [Figure 40-20-67] from the

brake plate.

4852210 (07-06) 40-20-23 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-72
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Brake Group Disassembly (Cont'd)

Figure 40-20-70

Remove and discard the O-ring (Item 1) [Figure 40-20-

72] from the adjusting screw.

Figure 40-20-73

Remove the two O-rings (Item 1) [Figure 40-20-70] from

the brake plate.

Figure 40-20-71

Turn the brake housing over and remove the lock nut
retainer (Item 1) and bolt (Item 2) [Figure 40-20-73].

Remove the jam nut (Item 1) adjusting screw (Item 2) and

wedge (Item 3) [Figure 40-20-71] from the brake housing.

4852210 (07-06) 40-20-24 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Brake Group Inspection
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D) Figure 40-20-76
Brake Group Disassembly (Cont'd)

Figure 40-20-74

Inspect the friction plates (Item 1) [Figure 40-20-76] for

wear. Replace all friction plates at the same time.

Figure 40-20-77
Remove the internal nut (Item 1) [Figure 40-20-74] from
the brake housing by rotating counterclockwise using
special tool CA119030.

Figure 40-20-75

Inspect the internal and external splines on the coupler for

damage or wear [Figure 40-20-77].

Remove the race by gently taping out of the brake

housing [Figure 40-20-75].

4852210 (07-06) 40-20-25 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000) (CONT'D)

Differential Parts Identification

Differential Disassembly Figure 40-20-79

Clean the outside of the differential before disassembly.

Mark the outside of the differential for ease of assembly.

Figure 40-20-78

Mark the housing for correct assembly [Figure 40-20-79].

Remove the differential assembly (Item 1) [Figure 40-20-

78] from the axle housing.

4852210 (07-06) 40-20-26 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-82
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Disassembly (Cont'd)

Figure 40-20-80

Remove the discs and spacers (Item 1) [Figure 40-20-82]

from the pinion gear.

Figure 40-20-83

Support the differential assembly in a vise. Remove the

twelve bolts (Item 1) and ring gear (Item 2) [Figure 40-20-
80].

Figure 40-20-81

Remove the pinion gear (Item 1) [Figure 40-20-83].

Separate the housings [Figure 40-20-81].

4852210 (07-06) 40-20-27 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-86
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Disassembly (Cont'd)

Figure 40-20-84

Remove the gear (Item 1) and cup washer (Item 2) from

the spindle (Item 3) [Figure 40-20-86].

Remove the spindle/gear assemblies (Item 1) [Figure 40-

20-84].

Figure 40-20-85

Remove the bearing from the housing [Figure 40-20-85].

4852210 (07-06) 40-20-28 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-89
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Inspection

Figure 40-20-87

Inspect the cup washers (Item 1) [Figure 40-20-89] for

damage or wear. Replace as needed.

Figure 40-20-88

Inspect the pinion gears [Figure 40-20-87] & [Figure 40-

20-88] for broken or damaged teeth.

If either gear is damaged, replace both gears.

4852210 (07-06) 40-20-29 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000) (CONT'D)

Pinion Group Parts Identification

4852210 (07-06) 40-20-30 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-92
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Pinion Group Disassembly

Clean the outside of the pinion group before disassembly.

Figure 40-20-90

Remove the nut (Item 1) and washer (Item 2) [Figure 40-

20-92].

Figure 40-20-93

Pry up the peened notch (Item 1) [Figure 40-20-90] in the

nut.

Figure 40-20-91

Free the pinion from the housing using a soft faced

hammer [Figure 40-20-93].

Loosen the nut using special tools CA119099 and

CA715022 [Figure 40-20-91].

4852210 (07-06) 40-20-31 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-96
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Pinion Group Disassembly (Cont'd)

Figure 40-20-94

Remove the two washers (Item 1) and spacer (Item 2)

[Figure 40-20-96] from the pinion shaft.

Figure 40-20-97

Remove the pinion shaft from the housing [Figure 40-20-

94].

Figure 40-20-95

Remove the bearing from the pinion shaft [Figure 40-20-

97].

P-25691

Remove the outer bearing (Item 1) [Figure 40-20-95].

4852210 (07-06) 40-20-32 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Pinion Group Inspection
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D) Figure 40-20-100
Pinion Group Disassembly (Cont'd)

Figure 40-20-98

Inspect the pinion gear (Item 1) and shaft splines (Item 2)

[Figure 40-20-100] for broken or damaged teeth.

Remove the outer race from the housing [Figure 40-20-

98].

Figure 40-20-99

Remove the inner race from the housing [Figure 40-20-

99].

4852210 (07-06) 40-20-33 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-102
363011001 - 363012000 and S/N 363111001 -
363112000)) (CONT'D)

Pinion Group Assembly

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

IMPORTANT
Install the inner race [Figure 40-20-102].
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all Figure 40-20-103
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure 40-20-101

Install the bearing (Item 1) [Figure 40-20-103] onto the

dummy pinion tool CA715040.

Install the outer race [Figure 40-20-101].

4852210 (07-06) 40-20-34 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-105
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Pinion Group Assembly (Cont’d)

Figure 40-20-104

Figure 40-20-106

Install the dummy pinion and bearing into the center

housing and install the outer bearing and lock nut [Figure
40-20-104].

Tighten the lock nut to eliminate any bearing end play. DO

NOT overtighten the nut.

Install both brake housings (Item 1) [Figure 40-20-105]

onto the center housing. Install and tighten the bolt (Item
1) [Figure 40-20-106].

Figure 40-20-107

Insert the dummy differential tool CA715041 into the

brake housings [Figure 40-20-107].

4852210 (07-06) 40-20-35 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-110
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Pinion Group Assembly (Cont'd)

Figure 40-20-108

To determine the thickness of the shim to be installed

between the pinion and bearing, subtract the value
stamped on the end of the pinion (Item 1) [Figure 40-20-
110] from the value X (above).

Figure 40-20-111
Figure 40-20-109

Select the shim [Figure 40-20-111] from the chart below:

Using a depth gauge (Item 1) [Figure 40-20-108] &
[Figure 40-20-109] measure thru the reference hole in
the dummy pinion. SHIM THICKNESS RANGE
Thick 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
X = (distance to be measured)
A = (measured value) Qty. - - - - - - - - - -
B = (given value) = 100 ± 0,01 mm
C = (given value) = 45 mm
(A + C) - B = X

4852210 (07-06) 40-20-36 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-114
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Pinion Group Assembly (Cont'd)

Figure 40-20-112
1

P-25700

Remove the dummy pinion tool (Item 1) [Figure 40-20-

114] from the center housing.

Figure 40-20-115

Remove the dummy differential tool [Figure 40-20-112].

Figure 40-20-113

Remove the bearing (Item 1) [Figure 40-20-115] from the

dummy pinion.

Remove both brake housings (Item 1) [Figure 40-20-113]

from the center housing.

4852210 (07-06) 40-20-37 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-118
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Pinion Group Assembly (Cont'd)

Figure 40-20-116

Install the two washers (Item 1) and collapsible spacer

(Item 2) [Figure 40-20-118] onto the shaft.

Figure 40-20-119

Install the shims selected (Item 1) [Figure 40-20-116]

onto the pinion shaft.

NOTE: The beveled edge must go towards the gear.

Figure 40-20-117

Install the pinion gear assembly into the center housing

and install the outer bearing [Figure 40-20-119].

NOTE: Drive the outer bearing onto the shaft, have an

assistant place a second hammer on the
pinion head to absorb the impact.

Install the bearing (Item 1) [Figure 40-20-117] onto the

pinion shaft until it is fully seated.

4852210 (07-06) 40-20-38 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-122
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Pinion Group Assembly (Cont'd)

Figure 40-20-120

Install the special tool CA715116 (Item 1) [Figure 40-20-

122] onto the pinion shaft.

Figure 40-20-123

Install the backing washer (Item 1) and nut (Item 2)

[Figure 40-20-120].

Figure 40-20-121

Attach one end of a light rope to the special tool [Figure

40-20-123]. Make 2 or 3 complete wraps around the tool.
Attach the spring scale perpendicular to the housing to
measure the rolling torque on the bearings. Tighten (or
loosen) the nut (Item 1) [Figure 40-20-121] until 2-3 lb (.9
- 1.4 Kg) of smooth and continuous rolling torque is
Tighten the nut using the special tools CA119099 and
measured on the spring scale.
CA715022.

NOTE: The tightening torque is determined by

measuring the force required to rotate the
pinion (preload of bearings). (See [Figure 40-
20-123].)

Tighten the nut in incremental steps. If overtightened

(preload to high) the collapsed spacer must be replaced
and the procedure repeated [Figure 40-20-121].

4852210 (07-06) 40-20-39 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-126
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Assembly

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

Figure 40-20-124

Install the remaining discs (Item 1) [Figure 40-20-126]

onto the shaft, alternating between steel and friction.

Figure 40-20-127

Install the bearing (Item 1) [Figure 40-20-124] onto each

housing.

Figure 40-20-125

Install the gear/disc assembly into the housing [Figure

40-20-127].

NOTE: Make sure the disc remains in correct position.

Install the disc (Item 1) [Figure 40-20-125] that is one half

friction and the other half metal onto the gear splines.

NOTE: The metal side must be next to the gear.

4852210 (07-06) 40-20-40 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-130
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Assembly (Cont'd)

Figure 40-20-128

Set the gear/discs assembly (Item 1) [Figure 40-20-130]

onto the spindle gears.

Figure 40-20-131

Install the gear (Item 1) and cup washer (Item 2) onto the
spindle (Item 3) [Figure 40-20-128].

Figure 40-20-129

Install the housing (Item 1) onto the housing/gear

assembly (Item 2) [Figure 40-20-131]. Make sure to align
the reference marks made earlier.

Install the spindle/gear assemblies (Item 1) [Figure 40-

20-129] into the housing.

4852210 (07-06) 40-20-41 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-133
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Assembly (Cont'd)

Figure 40-20-132

Apply LOCTITE #270 to the end of the mounting bolts

[Figure 40-20-133].

Install the ring gear (Item 1) and twelve bolts (Item 2)

[Figure 40-20-132]. Tighten the bolts to 58 ft.-lbs. (78
Nm) torque.

4852210 (07-06) 40-20-42 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-136
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Brake Group Assembly

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

Figure 40-20-134

Lightly lubricate and install two new O-rings (Item 1)

[Figure 40-20-136] onto the brake plate.

Figure 40-20-137

Install the bearing race into the housing until it is flush with
center surface (Item 1) [Figure 40-20-134].

Figure 40-20-135

Lightly lubricate and install new O-rings (Item 1) [Figure

40-20-137] onto the pins.

Install the internal adjusting nut (Item 1) [Figure 40-20-

135] into the brake housing by rotating clockwise until it is
tight against the bearing race.

4852210 (07-06) 40-20-43 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-140
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Brake Group Assembly (Cont'd)

Figure 40-20-138 1

1
1

Install the three wedges (Item 1) [Figure 40-20-140] into

the brake housing as shown.

Figure 40-20-141

Install the three pins into the brake plate and retain with
the snap rings (Item 1) [Figure 40-20-138].

Figure 40-20-139

Lubricate and install a new O-ring (Item 1) [Figure 40-20-

141] onto the adjusting screw.

Install the adjusting screw (Item 2) and jam nut (Item 3)

[Figure 40-20-141] into the housing.
Align the holes in the brake housing with the pins (Item 1)
[Figure 40-20-139] and install the brake plate into the
brake housing until it is fully seated.

Turn the brake housing over.

4852210 (07-06) 40-20-44 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-144
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Brake Group Assembly (Cont'd)

Figure 40-20-142

Using a 6-1/2 inch O.D. tube and suitable press, apply

enough downward pressure on the Belleville springs
allowing the split ring retainer to drop down [Figure 40-
20-144].

NOTE: Make sure the Belleville springs are centered in

Install the Belleville springs (Item 1) [Figure 40-20-142]
the housing.
into the brake housing.
Figure 40-20-145
NOTE: The inner edges of the Belleville springs must
touch for correct installation.

Figure 40-20-143

With the split ring retainer (Item 1) in the down position,

install the split ring (Item 2) [Figure 40-20-145] into the
groove in the brake housing.
Temporarily place the spring retainer ring (Item 1) [Figure
Carefully release press pressure making sure that the
40-20-143] on the Belleville springs.
split ring is fully seating the housing groove and the
retainer ring secures the split ring.

Remove the housing from the press.

4852210 (07-06) 40-20-45 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-148
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Brake Group Assembly (Cont'd)

Figure 40-20-146

Align the holes in the piston and the threaded holes in the
housing and install the piston (Item 1) [Figure 40-20-148]
into the housing.

Figure 40-20-149
Install a new O-ring (Item 1) [Figure 40-20-146] on the
housing.

Turn the three brake adjusting screws (Item 2) [Figure

40-20-146] in (clockwise) equally.

Figure 40-20-147

Be sure that the bolt assembly is in the arrangement

shown [Figure 40-20-149].

Lightly lubricate and install two new O-rings (Item 1)

[Figure 40-20-147] onto the piston.

4852210 (07-06) 40-20-46 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-152
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Brake Group Assembly (Cont'd)

Figure 40-20-150

Set the pinion assembly (Item 1) in the center housing as

shown. Install the two guide bolts (Item 2) [Figure 40-20-
152].

Figure 40-20-153
Install the bolt assembly (Item 1) [Figure 40-20-150] into
the brake housing and tighten washer to 7 ft.-lbs. (10 Nm)
torque.

Figure 40-20-151

Install the brake housing and two bolts (Item 1) [Figure

40-20-153].

NOTE: Be sure the bearing (Item 2) [Figure 40-20-153]

on the pinion gear is aligned with the brake
housing race.
Install a new O-ring (Item 1) [Figure 40-20-151] onto the
center housing.

4852210 (07-06) 40-20-47 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-156
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Brake Group Assembly (Cont'd)

Figure 40-20-154

Install the tool CA715055 (Item 1) on the pinion shaft

[Figure 40-20-156].

Figure 40-20-157

Install the two guide bolts (Item 1) [Figure 40-20-154].

Figure 40-20-155

Using a dial gauge, move the pinion shaft back and forth
and make a note of the backlash between the pinion and
ring gear [Figure 40-20-157].

Check that the backlash is within the allowed margins of

Install the brake housing and two bolts (Item 1) [Figure
0.007 - 0.009 inches (0.18 - 0.23 mm).
40-20-155].

NOTE: Be sure the bearing on the pinion gear is

aligned with the brake housing race.

Tighten the upper bolt to 59 ft.-lbs. (80 Nm) and the

bottom bolt to 88 ft.-lbs. (120 Nm) torque.

4852210 (07-06) 40-20-48 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-160
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Brake Group Assembly (Cont'd)

Figure 40-20-158

Attach one end of a light rope to the special tool and make
2 or 3 wraps around the tool. Attach the spring scale to
the opposite end of the rope. Pull the scale perpendicular
to the housing to measure the rolling torque on the
bearings. The value is 2 - 3 lbs. (0.9 to 1.4 Kg) [Figure
40-20-160].
Adjusting the lock nuts [Figure 40-20-158]:
- If the backlash measured is under the permissible range,
- If the total preload is under the permissible range, tighten
tighten the lock nut on the side opposite the crown wheel
the two lock nuts by same amount, retaining the value of
and unscrew the lock nut on the other side by the same
the pinion ring gear backlash.
amount.
-If the total preload is above the permissible range, slacken
- If the backlash is above the permissible range, tighten the
the two lock nuts by the same amount, retaining the value
lock nut on the side of the crown wheel and loosen the lock
of the pinion ring gear backlash.
nut on the other side by the same amount.
Figure 40-20-161
Once the pinion and ring gear adjustment has been
carried out, check that there is at least a minimal preload
on the differential cage bearings. If necessary, repeat the
steps if backlash is still outside the permissible ranges.

Once the pinion/ring gear backlash has been determined,

the total preload of the pinion ring gear wheel bearings
must be measured, to verify that if falls within the
permissible limits.

Figure 40-20-159

Stake the lock nut (Item 1) [Figure 40-20-161] on the

pinion.

Install the special tool CA715116 (Item 1) [Figure 40-20-

159] onto the pinion shaft.

4852210 (07-06) 40-20-49 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-164
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Brake Group Assembly (Cont'd)

Figure 40-20-162

Temporarily install the brake housing and bolts (Item 1)

[Figure 40-20-164].

Figure 40-20-165

Temporarily remove the brake housing bolts (Item 1)

[Figure 40-20-162] opposite from the ring gear. Remove
the brake housing.

Figure 40-20-163

Turn the pinion using the special tool CA715022 several

turns [Figure 40-20-165].

Remove the brake housing [Figure 40-20-162].

Use colored lead and brush to paint 3 or 4 teeth of the ring

gear in three opposite places [Figure 40-20-163].

4852210 (07-06) 40-20-50 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-168
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Brake Group Assembly (Cont'd)

Check the wear pattern of the pinion/ring gear teeth.

Figure 40-20-166

Excessive contact on flank of tooth - adjust the backlash

[Figure 40-20-168].

Figure 40-20-169

Correct Pattern - If pinion/ring gear has been properly

adjusted, wear pattern (contact) should be shown [Figure
40-20-166].

Figure 40-20-167

Once the wear pattern is correct, install the lock nut

retainer (Item 1) and bolt (Item 2) [Figure 40-20-169]
tighten the bolt to 10 ft.-lbs. (13 Nm) torque.

Excessive contact on tooth edge - adjust the backlash

[Figure 40-20-167].

4852210 (07-06) 40-20-51 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-172
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Brake Group Assembly (Cont'd)

Figure 40-20-170

Install the coupler (Item 1) [Figure 40-20-172] in the

friction plate.

Figure 40-20-173

Install the two tubelines (Item 1) [Figure 40-20-170].

Figure 40-20-171

Note the position of the groove (Item 2) [Figure 40-20-

173] in the coupler.

Install the second friction plate (Item 1) onto the coupler

(Item 2) [Figure 40-20-173].
Install the thick spacer plate into the grooves in the brake
housing followed by a friction plate and a thin spacer plate
[Figure 40-20-71].

4852210 (07-06) 40-20-52 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-176
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Brake Group Assembly (Cont'd)

Figure 40-20-174

Install the axle housing onto the brake housing by sliding

on the alignment pins [Figure 40-20-176].

Figure 40-20-177

Install the second thick spacer plate followed by the thin

spacer plate [Figure 40-20-174].

Axle Housing/Drive Axle Assembly

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

Figure 40-20-175
Install and tighten the mounting bolts (Item 1) [Figure 40-
20-177].

Install a new O-ring (Item 1) [Figure 40-20-175] on the

axle housing.

4852210 (07-06) 40-20-53 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-179
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Axle Housing/Drive Axle Assembly (Cont'd)

Figure 40-20-178

Remove the two alignment bolts (Item 1) [Figure 40-20-

179], install the two remaining bolts, tighten all bolts to
236 ft.-lbs. (320 Nm) torque.

Install the nut (Item 1) [Figure 40-20-178] to the stud on

the bottom of the housing. Tighten to 140 ft.-lbs. (190 Nm)
torque.

4852210 (07-06) 40-20-54 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-182
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Axle Housing/Drive Axle Assembly (Cont'd)

Figure 40-20-180

Press the bearing cup into the yoke [Figure 40-20-182].

Figure 40-20-183

Partially install a new bearing cup (Item 1) [Figure 40-20-

180] into the yoke.

Figure 40-20-181

Install the second bearing cup into the yoke and press
onto the cross [Figure 40-20-183].

NOTE: Use care not to lose or drop any needle

bearings out of position.

Install the cross (Item 1) [Figure 40-20-181] into the

bearing cup.

4852210 (07-06) 40-20-55 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-186
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Axle Housing/Drive Axle Assembly (Cont'd)

Figure 40-20-184

Partially install a new bearing cup (Item 1) [Figure 40-20-

186] into the yoke.

Figure 40-20-187

Fully press the two bearing cups into the drive shaft yoke
[Figure 40-20-184].

Figure 40-20-185

Install the cross/shaft assembly into the bearing cup

[Figure 40-20-187].

Install the two snap rings (Item 1) [Figure 40-20-185].

4852210 (07-06) 40-20-56 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-190
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Axle Housing/Drive Axle Assembly (Cont'd)

Figure 40-20-188

Install a new bushing (Item 1) and seal (Item 2) [Figure

40-20-190] into the axle housing.

Lightly lubricate the new seal and bushing.

Figure 40-20-191
Install the second bearing cup into the yoke and press
onto the cross [Figure 40-20-188].

NOTE: Use care not to lose or drop any needle

bearings out of position.

Figure 40-20-189

Install the drive axle into the axle housing aligning the
shaft with the splines.

NOTE: Use care not to damage the seal.

Make sure the bearing cups are fully seated and install
both snap rings [Figure 40-20-189].

4852210 (07-06) 40-20-57 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-194
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Steering Knuckle Assembly

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

Figure 40-20-192

Figure 40-20-195

Install the bushing (Item 1) [Figure 40-20-192] into the

knuckle housing.

Figure 40-20-193
Install the bushings into the top and bottom of the axle
[Figure 40-20-194] & [Figure 40-20-195].

NOTE: The cupped bushing goes on the bottom.

Install a new seal (Item 1) [Figure 40-20-193] into the

knuckle housing.

4852210 (07-06) 40-20-58 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-198
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Steering Knuckle Assembly (Cont'd)

Figure 40-20-196

Install the knuckle assembly onto the axle [Figure 40-20-

198].

Figure 40-20-199

Install the spacer washer (Item 1) [Figure 40-20-196] on

the top bushing.
2
Figure 40-20-197

P-42821

Install the upper king pin (Item 1) and bolt (Item 2) [Figure
40-20-199]. Tighten to 140 ft.-lbs. (190 Nm) torque.

Install the Belleville washers (Item 1) [Figure 40-20-197]

on the top and bottom bushing.

NOTE: The larger Belleville washer is on top.

4852210 (07-06) 40-20-59 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-201
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Steering Knuckle Assembly (Cont'd)

Figure 40-20-200

Install the lower king pin (Item 1) and three bolts (Item 2)
[Figure 40-20-201]. Tighten to 140 ft.-lbs. (190 Nm)
torque.

Lubricate the upper and lower king pins.

Place the lower king pin in a vise or press and install the
ball bearing (Item 1) [Figure 40-20-200] onto the king pin
shaft until it is fully seated.

4852210 (07-06) 40-20-60 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-204
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Wheel Hub Assembly

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

Figure 40-20-202

Install the six bushings (Item 1) [Figure 40-20-204] into

the gear.

Figure 40-20-205

Install both bearing races (Item 1) [Figure 40-20-202] into

the hub.

Figure 40-20-203

Install the gear (Item 1) into the ring gear (Item 2) [Figure
40-20-205].

Install the retainer ring (Item 3) [Figure 40-20-205] into

the groove in the ring gear.

Lightly lubricate the seal (Item 1) [Figure 40-20-203] and

install into the hub.

4852210 (07-06) 40-20-61 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-208
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Wheel Hub Assembly (Cont'd)

Figure 40-20-206

Install the ring gear assembly (Item 1) onto the steering

knuckle. Install the six mounting bolts (Item 2) [Figure 40-
20-208] and tighten to 88 ft.-lbs. (120 Nm) torque.

Figure 40-20-209
Install the inner bearing (Item 1) [Figure 40-20-206] onto
the steering knuckle.

Figure 40-20-207

Install the spacer (Item 1) and thrust washer (Item 2)

[Figure 40-20-209] on the axle shaft.

Install the hub assembly (Item 1) and outer bearing (Item

2) [Figure 40-20-207] onto the steering knuckle.

4852210 (07-06) 40-20-62 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-212
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Wheel Hub Assembly (Cont'd)

Figure 40-20-210

Using grease to hold the needle bearings in position,

install the gears onto the shaft [Figure 40-20-212].

Figure 40-20-213

Install the snap ring (Item 1) [Figure 40-20-210] onto the

axle shaft.

Planetary Carrier Assembly

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

Figure 40-20-211
Install the thrust plate (Item 1) [Figure 40-20-213] and
snap rings (Item 2) [Figure 40-20-213].

Install the thrust washers (Item 1) [Figure 40-20-11] onto

the shafts.

4852210 (07-06) 40-20-63 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (For S/N Figure 40-20-216
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Planetary Carrier Assembly (Cont'd)

Figure 40-20-214

Install the two screws (Item 1) [Figure 40-20-216] and

tighten to 18 ft.-lbs. (25 Nm) torque.

Figure 40-20-217

Install a new O-ring (Item 1) [Figure 40-20-214] onto the

planetary carrier.

Figure 40-20-215

Install a new O-ring (Item 1) [Figure 40-20-217] onto the

drain plug.

See “AXLES (FRONT AND REAR) (For S/N 363011001 -

363012000 and S/N 363111001 - 363112000)” on
page 10-110-1 or See “AXLES (FRONT AND REAR) (For
Install the planetary carrier (Item 1) [Figure 40-20-215].
S/N 363012001 and Above, S/N 363112001 and Above)”
on page 10-111-1 for filling the axle assembly with fluid.

4852210 (07-06) 40-20-64 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N
363011001 - 363012000 and S/N 363111001 -
363112000)

General Information
• Rear Axle removal. (See “REAR AXLE (For S/N
363011001 - 363012000 and S/N 363111001 -
For photo clarity, the following axle procedures are done
363112000)” on page 40-90-1)
with the complete axle assembly removed from the
machine, although the planetary carrier, wheel hub,
• Rear steering cylinder removal. (See “STEERING
steering knuckle and drive axle procedures may be done
CYLINDER (REAR) (For S/N 363011001 - 363012000
with the axle assembly installed in the machine. For
and S/N 363111001 - 363112000)” on page 20-62-1)
complete axle repair, the following must be done:

Planetary Carrier Parts Identification

1. Plug
2. Bolt
3. Planetary Carrier
4. Thrust Pin
5. Shaft 9
6. Needle Bearings 8
7. Gear 6
7
8. Thrust Washer
9. Snap Ring
6

4
1

2 3

b-19863

4852210 (07-06) 40-21-1 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-2
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Planetary Carrier Disassembly

Clean the outside of the planetary carrier before

disassembly.

Mark the outside of the planetary carrier for ease of

assembly.
1

IMPORTANT
P-46103

When repairing hydrostatic and hydraulic systems,

clean the work area before disassembly and keep all
Remove the two screws (Item 1) [Figure 40-21-2] from
parts clean. Always use caps and plugs on hoses,
the planetary carrier. (Both sides)
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 40-21-3

Figure 40-21-1

P-46104

1
P-46102 Remove the planetary carrier (Item 1) [Figure 40-21-3]
from the axle. (Both sides)

With the drain plug (Item 1) [Figure 40-21-1] in the

position shown, place a drain pan under the hub, remove
the plug and drain the oil from the planetary carrier.
Dispose of the oil in an environmentally safe manner.
(Both sides)

4852210 (07-06) 40-21-2 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-6
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Planetary Carrier Disassembly (Cont'd)

1
Figure 40-21-4

P-46107
1

Remove the thrust washers (Item 1) [Figure 40-21-6].

Figure 40-21-7
P-46105

Remove and discard the O-ring (Item 1) [Figure 40-21-4]

1
from the planetary carriers.

Figure 40-21-5

1 P-46108

1
1 Remove the three gears (Item 1) [Figure 40-21-7] with
needle bearings from each gear shaft.

NOTE: Mark the gear location for correct assembly.

P-46106

Remove the three snap rings (Item 1) [Figure 40-21-5].

4852210 (07-06) 40-21-3 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-9
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Planetary Carrier Inspection 1

1
Figure 40-21-8

1
2

P-46109

1 If any of the bearing shafts (Item 1) [Figure 40-21-9] are

damaged, replace all bearing shafts.

P-46110 If the thrust pin (Item 2) [Figure 40-21-9] is worn, replace

the entire planetary carrier.
Inspect the planetary gears (Item 1) [Figure 40-21-8] for
worn or cracked teeth.

If any of the planetary gears are damaged, replace all the

planetary gears and drive axle end of the drive axle
assembly. One damaged gear can cause a microscopic
fatigue crack in mating teeth and cause premature failure
after servicing.

4852210 (07-06) 40-21-4 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000) (CONT'D)

Wheel Hub Parts Identification

4852210 (07-06) 40-21-5 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-12
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Wheel Hub Disassembly 1

Figure 40-21-10

P-46114

Remove the six ring gear mounting bolts (Item 1) [Figure

40-21-12]. (Both sides)

P-46111 Figure 40-21-13

Remove the snap ring (Item 1) [Figure 40-21-10]. (Both

sides)

Figure 40-21-11

1 1

2 P-46115

Install two bolts (Item 1) into the ring gear as shown, and
tighten equally pushing the ring gear assembly (Item 2)
[Figure 40-21-13] from the shaft. (Both sides)
P-46113

Remove the thrust washer (Item 1) and spacer (Item 2)

[Figure 40-21-11]. (Both sides)

4852210 (07-06) 40-21-6 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-16
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)
1
Wheel Hub Disassembly (Cont'd)

Figure 40-21-14

P-46120

Remove the inner bearing (Item 1) [Figure 40-21-16]

from the swivel housing. (Both sides)

P-46116 Figure 40-21-17

Remove the ring gear assembly [Figure 40-21-14]. (Both

sides)

Figure 40-21-15

Remove the retainer ring (Item 1) [Figure 40-21-17] from

the ring gear assembly.

P-46117

Remove the outer bearing and hub assembly from the

axle [Figure 40-21-15]. (Both sides)

NOTE: Use care while removing, as assembly may

remove easy.

4852210 (07-06) 40-21-7 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-20
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)
1
Wheel Hub Disassembly (Cont'd)

Figure 40-21-18

P-46121

Remove the seal (Item 1) [Figure 40-21-20] from the hub.

Figure 40-21-21

Remove the gear (Item 1) from the ring gear (Item 2)

[Figure 40-21-18].

Figure 40-21-19

P-46122

Using a brass drift remove both bearing races (Item 1)

[Figure 40-21-21] from the hub.

Remove the six bushings (Item 1) [Figure 40-21-19] from

the gear if damaged or worn.

4852210 (07-06) 40-21-8 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Wheel Hub Inspection

Figure 40-21-22
Inspect the ring gear (Item 1) and inner gear (Item 2)
[Figure 40-21-22] for broken or damaged teeth.

If the ring gear or innergear are damaged, replace both

parts.

Steering Knuckle Parts Identification

4852210 (07-06) 40-21-9 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-25
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Steering Knuckle Disassembly 1

Clean the outside of the steering knuckle before

disassembly.

Mark the outside of the steering knuckle for ease of

assembly.

Figure 40-21-23
2

P-42821

Remove the bolt (Item 1) and king pin (Item 2) [Figure 40-
21-25] from the top of the knuckle. (Both sides)

Figure 40-21-26

P-46124

Remove the drain plug (Item 1) [Figure 40-21-23]. Drain

the fluid into a pan.

Figure 40-21-24

Lift and remove the knuckle assembly from the axle

[Figure 40-21-26]. (Both sides)

Remove the three bolts (Item 1) and king pin (Item 2)

[Figure 40-21-24] from the bottom of the knuckle. (Both
sides)

4852210 (07-06) 40-21-10 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-29
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Steering Knuckle Disassembly (Cont'd)

Figure 40-21-27

Figure 40-21-30

Remove the Belleville washers (Item 1) [Figure 40-21-27]

from the top and bottom of the axle. (Both sides)

NOTE: The bottom Belleville washer is smaller than

the top Belleville washer.

Figure 40-21-28

Using a puller, remove the top and bottom bushings from

the axle [Figure 40-21-29] & [Figure 40-21-30]. (Both
sides)

Figure 40-21-31

Remove the spacer washer (Item 1) [Figure 40-21-28]

from the top of the axle. (Both sides)

Remove the seal (Item 1) [Figure 40-21-31] from the

knuckle assembly. (Both sides)

4852210 (07-06) 40-21-11 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-33
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Steering Knuckle Disassembly (Cont'd)

Figure 40-21-32

Remove the ball type bearing (Item 1) [Figure 40-21-33]

from the lower king pins.

NOTE: Removal procedure will destroy the ball

bearing.
Remove the bushing (Item 1) [Figure 40-21-32] from the
knuckle assembly. (Both sides)

Axle Housing/Drive Axle Parts Identification

4852210 (07-06) 40-21-12 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-36
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Axle Housing/Drive Axle Disassembly

Clean the outside of the axle housing before disassembly.

Mark the outside of the axle housing for ease of assembly.

Figure 40-21-34

Remove the two snap rings (Item 1) [Figure 40-21-36]

across from each other.

Figure 40-21-37

Remove the drive axle from the axle housing [Figure 40-
21-34]. (Both sides)

Figure 40-21-35

Drive the upper bearing cup down to push the opposite

bearing cup partially through the yoke [Figure 40-21-37].

NOTE: The bottom bearing cup will not be completely

removed.

Remove the seal (Item 1) and bushing (Item 2) [Figure

40-21-35] from the axle end housing. (Both sides)

4852210 (07-06) 40-21-13 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-40
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Axle Housing/Drive Axle Disassembly (Cont'd)

Figure 40-21-38

Turn the shaft over and remove the bearing cup (Item 1).
Remove the drive shaft (Item 2) [Figure 40-21-40] from
the yoke.

Figure 40-21-41
Turn the shaft over and remove the bearing cup (Item 1)
[Figure 40-21-38].

Figure 40-21-39

Remove the two snap rings (Item 1) [Figure 40-21-41]

from the yoke.

Drive the cross (Item 1) [Figure 40-21-39] down to push

the opposite bearing cup through the yoke.

NOTE: Drive shaft end (Item 2) [Figure 40-21-39] may

fall out of the yoke.

4852210 (07-06) 40-21-14 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-44
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Axle Housing/Drive Axle Disassembly (Cont'd)

Figure 40-21-42

Press the second bearing cup through the yoke [Figure

40-21-44].

Figure 40-21-45

Using two different size sockets and a vice, press one

bearing cup into the yoke while pushing the opposite
bearing cup through the yoke [Figure 40-21-42].

Figure 40-21-43

Remove the bearing cup (Item 1) and cross (Item 2)

[Figure 40-21-45] from the yoke.

Remove the bearing cup (Item 1) [Figure 40-21-43].

4852210 (07-06) 40-21-15 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000) (CONT'D)

Differential Parts Identification

Differential Disassembly Figure 40-21-47

Clean the outside of the differential before disassembly.

Mark the outside of the differential for ease of assembly.

Figure 40-21-46

P-46128

1
Remove the O-ring (Item 1) [Figure 40-21-47] from the
front mount bracket.

P-46125

Remove the front (Item 1) and rear (Item 2) [Figure 40-

21-46] mount brackets.

4852210 (07-06) 40-21-16 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-50
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Disassembly (Cont'd)

Figure 40-21-48

P-46129

1 Loosen the retainer (Item 1) [Figure 40-21-50] on the rear

mount bracket.

P-46127 Figure 40-21-51

Loosen the retainer (Item 1) [Figure 40-21-48] on the

front mount bracket.
1
Figure 40-21-49

P-46130

1 Remove the bushing (Item 1) [Figure 40-21-51] from the

rear mount bracket.

P-46126

Remove the bushing (Item 1) [Figure 40-21-49] from the

front mount bracket.

4852210 (07-06) 40-21-17 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-54
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Disassembly (Cont'd)

Figure 40-21-52

2
2
2
1
1 1

P-46133

2
2 Remove the differential assembly (Item 1) [Figure 40-21-
2
54].
2 2
P-46131 Figure 40-21-55

Remove the bolts (Item 1) & (Item 2) [Figure 40-21-52].

Figure 40-21-53

P-46134

Remove the snap ring (Item 1) [Figure 40-21-55] from the

drive coupler.
P-46132

Install studs (Item 1) [Figure 40-21-53] in the bolt holes

(Item 1) [Figure 40-21-52].

4852210 (07-06) 40-21-18 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-58
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Disassembly (Cont'd)

1
Figure 40-21-56

P-46212

Remove the internal nut (Item 1) [Figure 40-21-58] from

the housing by rotating counterclockwise using special
tool CA119030. (Both sides)
P-46135

Figure 40-21-59
Remove the drive coupler (Item 1) [Figure 40-21-56].

Figure 40-21-57

2 1
1

P-46214
2

Remove the four bolts (Item 1) and remove the yokes

P-46211 (Item 2) [Figure 40-21-59].

Remove the bolt (Item 1) and retainer (Item 2) [Figure 40-

21-57]. (Both sides)

4852210 (07-06) 40-21-19 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-62
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Disassembly (Cont'd)

Figure 40-21-60

P-23932

Mark the housing for correct assembly [Figure 40-21-62].

P-46215

Remove the ring gear assembly [Figure 40-21-60].

Figure 40-21-61

1 1

P-46216

Remove the bearing races (Item 1) [Figure 40-21-61].

4852210 (07-06) 40-21-20 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-65
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Disassembly (Cont'd)

Figure 40-21-63

Remove the discs and spacers (Item 1) [Figure 40-21-65]

from the pinion gear.

Figure 40-21-66

Support the differential assembly in a vise. Remove the

twelve bolts (Item 1) and ring gear (Item 2) [Figure 40-21-
63].

Figure 40-21-64

Remove the pinion gear (Item 1) [Figure 40-21-66].

Separate the housings [Figure 40-21-64].

4852210 (07-06) 40-21-21 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-69
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Disassembly (Cont'd)

Figure 40-21-67

Remove the gear (Item 1) and cup washer (Item 2) from

the spindle (Item 3) [Figure 40-21-69].

Remove the spindle/gear assemblies (Item 1) [Figure 40-

21-67].

Figure 40-21-68

Remove the bearing from the housing [Figure 40-21-68].

4852210 (07-06) 40-21-22 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-72
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Inspection

Figure 40-21-70

Inspect the cup washers (Item 1) [Figure 40-21-72] for

damage or wear. Replace as needed.

Figure 40-21-71

Inspect the pinion gear [Figure 40-21-70] & [Figure 40-

21-71] for broken or damaged teeth.

If either gear is damaged, replace both gears.

4852210 (07-06) 40-21-23 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N 363011001 - 363012000 and S/N 363111001 - 363112000) (CONT’D)

Pinion Group Parts Identification

1. Housing
2. Pinion Shaft 1
3. Shim
4. Inner Bearing/Race
5. Washer
6. Spacer
7. Outer Bearing/Race
8. Lock Washer
9. Nut

5
6

5
7

MS1838

4852210 (07-06) 40-21-24 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-75
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)
1
Pinion Group Disassembly

Clean the outside of the pinion group before disassembly.

Figure 40-21-73

P-46220

Remove the washer (Item 1) [Figure 40-21-75].

1
P-46217

Remove the seal (Item 1) [Figure 40-21-73].

Figure 40-21-74

P-46219

Remove the O-ring (Item 1) [Figure 40-21-74].

4852210 (07-06) 40-21-25 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-78
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Pinion Group Disassembly (Cont’d)

Figure 40-21-76

1 1

P-46223

Remove the washer (Item 1) [Figure 40-21-78].

Figure 40-21-79
P-46221

Straighten the peened notch (Item 1) [Figure 40-21-76] in

the nut.

Figure 40-21-77

P-46224

Free the pinion from the housing using a soft faced

hammer [Figure 40-21-79].

P-46222

Loosen the nut using special tools CA119099 and

CA715022 [Figure 40-21-77] and remove the nut.

4852210 (07-06) 40-21-26 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-82
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Pinion Group Disassembly (Cont'd)

Figure 40-21-80

Remove the two washers (Item 1) and spacer (Item 2)

[Figure 40-21-82] from the pinion shaft.

Figure 40-21-83
P-46229

Remove the pinion shaft from the housing [Figure 40-21-

80].

Figure 40-21-81

Remove the bearing from the pinion shaft [Figure 40-21-

83].

P-46230

Remove the outer bearing (Item 1) [Figure 40-21-81].

4852210 (07-06) 40-21-27 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Pinion Group Inspection
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D) Figure 40-21-86
Pinion Group Disassembly (Cont'd)

Figure 40-21-84

Inspect the pinion gear (Item 1) and shaft splines (Item 2)

[Figure 40-21-86] for broken or damaged teeth.
P-46228

Remove the outer race from the housing [Figure 40-21-

84].

Figure 40-21-85

P-46227

Remove the inner race from the housing [Figure 40-21-

84].

4852210 (07-06) 40-21-28 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-88
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Pinion Group Assembly

Clean all parts in solvent and dry with compressed air. 1

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

IMPORTANT P-46228

Install the outer race [Figure 40-21-88].

When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Figure 40-21-89
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

1
Prior to assembly, clean and lightly oil all parts.

Figure 40-21-87

Install the bearing (Item 1) [Figure 40-21-89] onto the

dummy pinion tool CA715040.

P-46227

Install the inner race [Figure 40-21-87].

4852210 (07-06) 40-21-29 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-92
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Pinion Group Assembly (Cont'd)

Figure 40-21-90

2 2
1

1
P-46233

Install the yokes (Item 1) and bolts (Item 2) [Figure 40-21-

92]. Tighten the bolts.

P-46231 Figure 40-21-93

Install the dummy pinion and bearing into the center

housing and install the outer bearing and lock nut (Item 1)
[Figure 40-21-90].

Tighten the lock nut to eliminate any bearing end play. DO 1

NOT overtighten the nut.

Figure 40-21-91

P-46234

P-46232

Insert the dummy differential tool CA715041 into the

housing [Figure 40-21-91].

4852210 (07-06) 40-21-30 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-96
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Pinion Group Assembly (Cont'd)

Figure 40-21-94

Select the correct shim [Figure 40-21-96] from the chart

below:

SHIM THICKNESS RANGE

Thick 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
Using a depth gauge (Item 1) [Figure 40-21-93] &
[Figure 40-21-94] measure thru the reference hole in the Qty. - - - - - - - - - -
dummy pinion.
Figure 40-21-97
X = (distance to be measured)
A = (measured value)
B = (given value) = 100 ± 0,01 mm
C = (given value) = 45 mm
(A + C) - B = X

Figure 40-21-95
1
1

P-46233

Remove the bolts (Item 1) and yokes (Item 2) [Figure 40-

21-97].

To determine the thickness of the shim to be installed

between the pinion and bearing, subtract the value
stamped on the end of the pinion (Item 1) [Figure 40-21-
95] from the value X.

4852210 (07-06) 40-21-31 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-100
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Pinion Group Assembly (Cont'd)

Figure 40-21-98

Remove the bearing (Item 1) [Figure 40-21-100] from the

dummy pinion.
1
Figure 40-21-101
P-46232

Remove the dummy differential tool (Item 1) [Figure 40-

21-98] from the housing.

Figure 40-21-99

Install the shims selected (Item 1) [Figure 40-21-101]

onto the pinion shaft.

NOTE: The beveled edge must go towards the gear.

P-46231

Remove the dummy pinion tool (Item 1) [Figure 40-21-

99] from the center housing.

4852210 (07-06) 40-21-32 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-104
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Pinion Group Assembly (Cont'd)

Figure 40-21-102
1

P-46226

Install the outer bearing (Item 1) [Figure 40-21-104].

Figure 40-21-105

Install the bearing (Item 1) [Figure 40-21-102] onto the

pinion shaft until it is fully seated.

Figure 40-21-103

1
P-46229

Install the pinion assembly (Item 1) [Figure 40-21-105].

Install the two washers (Item 1) and collapsible spacer

(Item 2) [Figure 40-21-103] onto the shaft.

4852210 (07-06) 40-21-33 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-108
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Pinion Group Assembly (Cont'd)

Figure 40-21-106

2
1
P-46210

Install the special tool CA715116 (Item 1) [Figure 40-21-

108] onto the pinion shaft.

P-46221 Figure 40-21-109

Install the backing washer (Item 1) and nut (Item 2)

[Figure 40-21-106].

Figure 40-21-107

P-46208

Attach one end of a light rope to the special tool [Figure

40-21-109]. Make 2 or 3 complete wraps around the tool.
Attach the spring scale perpendicular to the housing to
P-46222 measure the rolling torque on the bearings. Tighten (or
loosen) the nut (Item 1) [Figure 40-21-106] until 2-3 lb (.9
- 1.4 Kg) of smooth and continuous rolling torque is
Gradually tighten the nut (See Figure 108 & 109 for the
measured on the spring scale.
proper procedure) using the special tools CA119099 and
CA715022 (Item 1) [Figure 40-21-107].

NOTE: The tightening torque is determined by

measuring the force required to rotate the
pinion (preload of bearings).

SEE Figure 108 & 109. Tighten the nut in incremental

steps. If overtightened (preload too high) the collapsible
spacer (Item 2) [Figure 40-21-103] must be replaced and
the procedure repeated [Figure 40-21-107].

4852210 (07-06) 40-21-34 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-112
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Assembly

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

Figure 40-21-110

Install the remaining discs (Item 1) [Figure 40-21-112]

onto the shaft, alternating between steel and friction.

Figure 40-21-113

Install the bearing (Item 1) [Figure 40-21-110] onto each

housing.

Figure 40-21-111

Install the gear/disc assembly into the housing [Figure

40-21-113].

NOTE: Make sure the disc remains in correct position.

Install the disc (Item 1) [Figure 40-21-111] that is one half

friction and the other half metal onto the gear splines.

NOTE: The metal side must be next to the gear.

4852210 (07-06) 40-21-35 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-116
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Assembly (Cont'd)

Figure 40-21-114

Set the gear/discs assembly (Item 1) [Figure 40-21-116]

onto the spindle gears.

Figure 40-21-117

Install the gear (Item 1) cup washer (Item 2) onto the

spindle (Item 3) [Figure 40-21-114].

Figure 40-21-115

Install the housing (Item 1) onto the housing/gear

assembly (Item 2) [Figure 40-21-117]. Make sure to align
the reference marks made earlier.

Install the spindle/gear assemblies (Item 1) [Figure 40-

21-115] into the housing.

4852210 (07-06) 40-21-36 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-120
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Assembly (Cont'd)

Figure 40-21-118 1 1

P-46216

Install the bearing races (Item 1) [Figure 40-21-120] on

the bearings.

Figure 40-21-121

Install the ring gear (Item 1) and twelve bolts (Item 2)

[Figure 40-21-118]. Tighten the bolts to 58 ft.-lbs. (78
Nm) torque.
1
Figure 40-21-119

P-46215

Install the differential assembly (Item 1) [Figure 40-21-

121] in the housing.

Apply LOCTITE #270 to the end of the mounting bolts

[Figure 40-21-119].

4852210 (07-06) 40-21-37 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-124
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT’D)

Differential Assembly (Cont’d)

Figure 40-21-122

2
2 P-46212

Tighten the internal nut (Item 1) [Figure 40-21-123] using

1 special tool CA119030 (Item 1) [Figure 40-21-124]. (Both
sides)
P-46214

Figure 40-21-125
Install the yokes (Item 1) with the four bolts (Item 2)
[Figure 40-21-122].

Figure 40-21-123

P-46207

Using a dial gauge, move the ring gear back and forth and
make a note of the backlash between the pinion and ring
P-46213 gear [Figure 40-21-125].

Check that the backlash is within the permissible range of

Install the internal nut (Item 1) [Figure 40-21-123]. (Both
0.007 - 0.009 inches (0.18 - 0.23 mm).
sides)

4852210 (07-06) 40-21-38 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-128
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Assembly (Cont'd)

Figure 40-21-126

P-46235

Attach one end of a light rope to the special tool and make
2 or 3 wraps around the tool. Attach the spring scale to
the opposite end of the rope. Pull the scale perpendicular
P-46212 to the housing to measure the rolling torque on the
bearings. The value is 2 - 3 lbs. (0.9 to 1.4 Kg) [Figure
40-21-128].
Adjusting the lock nuts [Figure 40-21-126]:
- If the backlash measured is under the permissible range,
- If the total preload is under the permissible range,
tighten the lock nut on the side opposite the crown wheel
tighten the two lock nuts by same amount, retaining the
and unscrew the lock nut on the other side by the same
value of the pinion ring gear backlash. -If the total preload
amount.
is above the permissible range, slacken the two lock nuts
- If the backlash is above the permissible range, tighten the
by the same amount, retaining the value of the pinion ring
lock nut on the side of the crown wheel and loosen the lock
gear backlash.
nut on the other side by the same amount.
Once the pinion and ring gear adjustment has been
Figure 40-21-129
carried out, check that there is at least a minimal preload
on the differential cage bearings. If necessary, repeat the
steps if backlash is still outside the permissible range.
1
Once the pinion/ring gear backlash has been determined,
the total preload of the pinion ring gear wheel bearings
must be measured, to verify that it falls within the
permissible range.

Figure 40-21-127

P-46221

Stake the lock nut (Item 1) [Figure 40-21-129] on the

pinion.

P-46236

Install the special tool CA715116 (Item 1) [Figure 40-21-

127] onto the pinion shaft.

4852210 (07-06) 40-21-39 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-132
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Assembly (Cont'd)

Figure 40-21-130

Correct Pattern - If pinion/ring gear has been properly

adjusted, wear pattern (contact) should be as shown
[Figure 40-21-132].
P-46211
Figure 40-21-133

Use colored lead and brush to paint 3 or 4 teeth of the ring

gear in three opposite places (Item 1) [Figure 40-21-130].

Figure 40-21-131

Excessive contact on tooth edge - adjust the backlash

[Figure 40-21-133].

P-46237

Turn the pinion using the special tool CA715022 several

turns [Figure 40-21-131].

Check the wear pattern of the pinion/ring gear teeth.

4852210 (07-06) 40-21-40 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-136
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Assembly (Cont'd) 1

Figure 40-21-134

P-46220

Install the washer (Item 1) [Figure 40-21-136] in the

housing.

Figure 40-21-137

Excessive contact on flank of tooth - adjust the backlash

[Figure 40-21-134].

Figure 40-21-135
1

2
P-46219

1
Install the O-ring (Item 1) [Figure 40-21-137].

P-46211
B-46211

Once the wear pattern is correct install the lock nut

retainer (Item 1) and bolt (Item 2) [Figure 40-21-135].

Tighten the bolt to 10 ft.-lbs. (13 Nm) torque. (Both sides)

4852210 (07-06) 40-21-41 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-140
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Assembly (Cont'd)

Figure 40-21-138

P-46134

Install the snap ring (Item 1) [Figure 40-21-140].

1
Figure 40-21-141
P-46217

1
Install the seal (Item 1) [Figure 40-21-138].

Figure 40-21-139

P-46297

Apply a 3 mm bead of LOCTITE 510 Gasket Eliminator

(or equivalent) to the axle housing (Item 1) [Figure 40-21-
141] in the pattern shown.
P-46135

Install the drive coupler (Item 1) [Figure 40-21-139].

4852210 (07-06) 40-21-42 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-144
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Assembly (Cont'd)

1
Figure 40-21-142

P-46131

Install the ten bolts (Item 1) [Figure 40-21-144] .

Figure 40-21-145
P-46133

Install the differential assembly [Figure 40-21-142].

1
Figure 40-21-143

1
P-46130

Install the bushing (Item 1) [Figure 40-21-145] in the rear

mount bracket.

P-46132

Remove the alignment studs (Item 1) [Figure 40-21-143].

4852210 (07-06) 40-21-43 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-148
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Assembly (Cont'd)

Figure 40-21-146

1 P-46127

Tighten the retainer (Item 1) [Figure 40-21-148].

Figure 40-21-149
P-46129

Tighten the retainer (Item 1) [Figure 40-21-146] on the

rear mount bracket.

Figure 40-21-147

1
1

P-46128

Install the O-ring (Item 1) [Figure 40-21-149] in the front

mount bracket.

P-46126

Install the bushing (Item 1) [Figure 40-21-147] in the front

mount bracket.

4852210 (07-06) 40-21-44 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Differential Assembly (Cont'd)

Figure 40-21-150

P-46125

Install the front (Item 1) and rear (Item 2) [Figure 40-21-

150] mount brackets on the axle housing.

Figure 40-21-151

P-46124

Install the plug (Item 1 [Figure 40-21-151] in the axle

housing.

4852210 (07-06) 40-21-45 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-154
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Axle Housing/Drive Axle Assembly

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

Figure 40-21-152

Press the bearing cup into the yoke [Figure 40-21-154].

Figure 40-21-155

Partially install a new bearing cup (Item 1) [Figure 40-21-

152] into the yoke.

Figure 40-21-153

Install the second bearing cup into the yoke and press
onto the cross [Figure 40-21-155].

NOTE: Use care not to lose or drop any needle

bearings out of position.

Install the cross (Item 1) [Figure 40-21-153] into the

bearing cup.

4852210 (07-06) 40-21-46 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-158
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Axle Housing/Drive Axle Assembly (Cont'd)

Figure 40-21-156

Partially install a new bearing cup (Item 1) [Figure 40-21-

158] into the yoke.

Figure 40-21-159

Fully press the two bearing cups into the drive shaft yoke
[Figure 40-21-156].

Figure 40-21-157

Install the cross/shaft assembly into the bearing cup

[Figure 40-21-159].

Install the two snap rings (Item 1) [Figure 40-21-157].

4852210 (07-06) 40-21-47 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-162
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Axle Housing/Drive Axle Assembly (Cont'd)

Figure 40-21-160

Install a new bushing (Item 1) and seal (Item 2) [Figure

40-21-162] into the axle housing.

Lightly lubricate the new seal and bushing.

Figure 40-21-163
Install the second bearing cup into the yoke and press
onto the cross [Figure 40-21-160].

NOTE: Use care not to lose or drop any needle

bearings out of position.

Figure 40-21-161

Install the drive axle into the axle housing aligning the
shaft with the splines [Figure 40-21-163].

NOTE: Use care not to damage the seal.

Make sure the bearing cups are fully seated and install
both snap rings (Item 1) [Figure 40-21-161].

4852210 (07-06) 40-21-48 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-166
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Steering Knuckle Assembly

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

Figure 40-21-164

Figure 40-21-167

Install the bushing (Item 1) [Figure 40-21-164] into the

knuckle housing.

Figure 40-21-165
Install the bushings into the top and bottom of the axle
[Figure 40-21-166] & [Figure 40-21-167].

NOTE: The cupped bushing goes on the bottom.

Install a new seal (Item 1) [Figure 40-21-165] into the

knuckle housing.

4852210 (07-06) 40-21-49 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-170
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Steering Knuckle Assembly (Cont'd)

Figure 40-21-168

Install the knuckle assembly onto the axle [Figure 40-21-

170]. (Both sides)

Figure 40-21-171

Install the spacer washer (Item 1) [Figure 40-21-168] on

the top bushing.

Figure 40-21-169

P-42821

Install the upper king pin (Item 1) and bolt (Item 2) [Figure
40-21-171]. Tighten to 140 ft.-lbs. (190 Nm) torque. (Both
sides)

Install the Belleville washers (Item 1) [Figure 40-21-169]

on the top and bottom bushing.

NOTE: The larger Belleville washer is on top.

4852210 (07-06) 40-21-50 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-173
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Steering Knuckle Assembly (Cont'd)

Figure 40-21-172

Install the lower king pin (Item 1) and three bolts (Item 2)
[Figure 40-21-173]. Tighten to 140 ft.-lbs. (190 Nm)
torque. (Both sides)

Lubricate the upper and lower king pins.

Place the lower king pin in a vise or press and install the
ball bearing (Item 1) [Figure 40-21-172] onto the king pin
shaft until it is fully seated.

4852210 (07-06) 40-21-51 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-176
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Wheel Hub Assembly

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

Figure 40-21-174

Install the six bushings (Item 1) [Figure 40-21-176] into

the gear.

Figure 40-21-177

P-46122

Install both bearing races (Item 1) [Figure 40-21-174] into

the hub.

Figure 40-21-175

Install the gear (Item 1) into the ring gear (Item 2) [Figure
40-21-177].

Install the retainer ring (Item 3) [Figure 40-21-177] into

the groove in the ring gear.

P-46121

Lightly lubricate the seal (Item 1) [Figure 40-21-175] and

install into the hub.

4852210 (07-06) 40-21-52 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-180
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Wheel Hub Assembly (Cont'd)

1
Figure 40-21-178

1
1

P-46114

Install the ring gear assembly (Item 1) onto the steering

knuckle. Install the six mounting bolts (Item 2) [Figure 40-
21-180] and tighten to 88 ft.-lbs. (120 Nm) torque. (Both
P-46120 sides)

Figure 40-21-181
Install the inner bearing (Item 1) [Figure 40-21-178] onto
the steering knuckle. (Both sides)

Figure 40-21-179

1
1

P-46113

Install the spacer (Item 1) and thrust washer (Item 2)

P-46117 [Figure 40-21-181] on the axle shaft. (Both sides)

Install the hub assembly (Item 1) and outer bearing (Item

2) [Figure 40-21-179] onto the steering knuckle. (Both
sides)

4852210 (07-06) 40-21-53 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-184
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Wheel Hub Assembly (Cont'd) 2

Figure 40-21-182

1 1 1 2

1
P-46106

Install the thrust washers (Item 1) and snap rings (Item 2)

[Figure 40-21-184].

P-46112 Figure 40-21-185

Install the snap ring (Item 1) [Figure 40-21-182] onto the

axle shaft.

Planetary Carrier Assembly

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation. 1
P-46105
Figure 40-21-183

Install a new O-ring (Item 1) [Figure 40-21-185] onto the

planetary carrier.
1

P-46108

Using grease to hold the needle bearings in position,

install the gears onto the shaft [Figure 40-21-183].

4852210 (07-06) 40-21-54 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N Figure 40-21-188
363011001 - 363012000 and S/N 363111001 -
363112000) (CONT'D)

Planetary Carrier Assembly (Cont'd)

Figure 40-21-186

Install a new O-ring (Item 1) [Figure 40-21-188] onto the

drain plug.

See Page 10-110-01 for filling the axle assembly and

P-46104
planetary carriers with fluid.

Install the planetary carrier (Item 1) [Figure 40-21-186].

(Both sides)

Figure 40-21-187

P-46103

Install the two screws (Item 1) [Figure 40-21-187] and

tighten to 18 ft.-lbs. (25 Nm) torque. (Both sides)

4852210 (07-06) 40-21-55 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 40-21-56 Bobcat T2556 & T2566
SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N 363012001 and Above, S/N 363112001 and Above)

General Information

For photo clarity, the following axle procedures are done • Drive box removal. (See “DRIVE BOX (For S/N
with the complete axle assembly removed from the 363012001 and above, S/N 363112001 and above)”
machine, although the planetary carrier, wheel hub, on page 20-71-1)
steering knuckle and drive axle procedures may be done
with the axle assembly installed in the machine. For • Steering cylinder removal (See “STEERING
complete axle repair, the following must be done. CYLINDER (FRONT) (For S/N 363012001 and above,
S/N 363112001 and above)” on page 20-61-1)
• Axle removal (See “FRONT AXLE (For S/N
363012001 and Above, S/N 363112001 and Above)”
on page 40-31-1)

Planetary Carrier Parts Identification

1. Seal
2. Bearing

1
3. Wheel stud
3 4. Wheel hub
2 4
5 5. Nut
6. O-ring
22 7. Bearing
6
7 8. Snap Ring
8 9. Ring gear
10. Ring gear support
9
10
15 16 17
11. Locking plate 11

12. Ring 12
13
13. Snap Ring
14. Washer 14
15. Snap Ring 18
19 20
16. Planet gear
17. Bearing 23
18. Planet gear carrier 24

19. O-ring
20. Plug
21. Countersunk bolt
22. Planet gear carrier
23. Stud 21
24. Nut
25. Ring Gear Support
S2190

4852210 (07-06) 40-22-1 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-3
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Planetary Carrier Disassembly

1
Figure 40-22-1

1
S2192

Remove the securing bolts and the complete planet gear

carrier (Item 1) [Figure 40-22-3].

S2190
Figure 40-22-4

Loosen the securing bolts (Item 1) [Figure 40-22-1] only

so that later when you pry the hub loose, it does not fall of
the planet gear carrier.
1
Figure 40-22-2
1
1
2

S2193

Remove the snap rings (Item 1) [Figure 40-22-4].

S2191

Remove the planet gear carrier (Item 1) from the wheel

hub (Item 2) [Figure 40-22-2] by alternatively forcing a
screwdriver into the appropriate slots.

4852210 (07-06) 40-22-2 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-7
363012001 and Above, S/N 363112001 and Above)
(CONT'D)
1
Planetary Carrier Disassembly (Cont’d)

Figure 40-22-5

S2197
1
1
Remove the Snap ring (Item 1) [Figure 40-22-7].

Figure 40-22-8
S2194

With the help of a puller, remove the planet wheel gears

(Item 1) [Figure 40-22-5].
2
NOTE: Note the assembly side of the planet wheel 1
gears.

Figure 40-22-6

S2198

Unloose and remove the tightening nuts (Item 1) from the

ring gear (Item 2) [Figure 40-22-8].

S2195 / S2196

NOTE: Note down the direction of assembly of planet

wheel gears [Figure 40-22-6].

4852210 (07-06) 40-22-3 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-11
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Planetary Carrier Disassembly (Cont’d)

1
Figure 40-22-9

S2201

Using a puller; remove the complete ring gear (Item 1)

[Figure 40-22-11] by acting on the stud bolts.
S2199
Figure 40-22-12

Remove the shim washer (Item 1) [Figure 40-22-9].

Figure 40-22-10

S2202

Partially extract the wheel hub (Item 1) [Figure 40-22-12]

S2200
using a plastic hammer.

NOTE: Alternately hammer on several equidistant

Remove the locking plate (Item 1) [Figure 40-22-10]. points.

4852210 (07-06) 40-22-4 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-15
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Planetary Carrier Disassembly (Cont’d)

Figure 40-22-13

S2205 / S2206

Remove the external thrust blocks of bearings, using the

provider.

S2203X NOTE: Hammer in an alternate sequence to prevent

crawling and deformation of the thrust blocks.
Remove the external bearing (Item 1) [Figure 40-22-13].
Figure 40-22-16
Figure 40-22-14

1 1

S2207

S2204X

Remove the sealing ring from the steering case (Item 1)

Remove the complete wheel hub (Item 1) [Figure 40-22- [Figure 40-22-16]. Pay due attention not to damage the
14] by hand. seat of bearing.

4852210 (07-06) 40-22-5 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Steering Knuckle Parts Identification

19. Nut
1 20. Bolt
2
3 21. Steering adjust bolt
22. Articulated tie rod
23. Ring
24. Cylinder

2
25. Cylinder bolt
1 26. Bolt
27. Electronic sensor
25
28. O-ring
29. Pivot
22
26
23 4
27
1. Thrust bushing 7 5
28
2. Seal 29 6
24
3. Joint
8
4. Nut
23 9
5. Washer
10
6. Stud 22
11
7. Cap
12
8. Grease fitting RIGHT: 13
9. Cap
LEFT: 14
10. Shim
11. Seal
20
12. Bushing 21
19 15
13. Steering case
11
14. Steering case 18
15. Articulation 8

16. Bolt 9
17. 16
18. Pivot pin 17

S1389

4852210 (07-06) 40-22-6 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Remove the nuts (Item 1) that lock the articulation pins
363012001 and Above, S/N 363112001 and Above) (Item 2) [Figure 40-22-19].
(CONT'D)
Figure 40-22-20
Steering Knuckle Disassembly

Figure 40-22-17 2

S2211

S2208
Disconnect the tapered pins of the articulation
(Item 1) from the steering case (Item 2) [Figure 40-22-
20] by means of a puller.
Note the measure of the screw.

Figure 40-22-18

S2209

Loose the lockscrew to allow the passage of the tool.

Figure 40-22-19

S2210

4852210 (07-06) 40-22-7 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-22
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Steering Knuckle Disassembly (cont’d)

Figure 40-22-21
2

1 2

1
2
S2427A

S2425X

Unloose and remove the fitting screws (Item 1)

[Figure 40-22-21] from the articulation pin.

NOTE: Screws can not be re-used.

1
S2427B

Using two levers, remove the bottom articulation pin

(Item 1) complete with front sealing ring (Item 2)
[Figure 40-22-22].

4852210 (07-06) 40-22-8 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-25
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Steering Knuckle Disassembly (cont’d) 1

1

Figure 40-22-23

S1394
S2431

Remove the complete steering case (Item 1) [Figure 40-

22-25].
1
S2428A Figure 40-22-26

Using two levers, remove the top articulation pin (Item 1)

complete with front seal (Item 2) and shims (Item 3)
[Figure 40-22-23].

Figure 40-22-24

1 1
2 3
S2212

Remove the bushing from the steering case (Item 1)

[Figure 40-22-26].
S1393
NOTE: Note down the orientation of bushing.
Configuration of the upper (Item 1) articulation pin with
shims (Item 2) and the lower articulation pin (Item 3)
[Figure 40-22-24].

4852210 (07-06) 40-22-9 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-29
363012001 and Above, S/N 363112001 and Above)
(CONT'D)
2
Steering Knuckle Disassembly (cont’d)

Figure 40-22-27

S2216

1
Remove the articulation pins (Item 1) and the front sealing
rings (Item 2) [Figure 40-22-29].

S2213 NOTE: Note down the side for assembly

Figure 40-22-30
Remove the U-joint (Item 1) [Figure 40-22-27].

NOTE: To remove the u-joint use, if necessary, a

plastic hammer or a lever.

Figure 40-22-28

S2217

2 If the ball cover need replacing, remove it from the bottom

articulation pin.
1

S2214 / S2215

Using a puller for inner parts, remove the top bush

(Item 1) and the bottom ball-bush (Item 2) [Figure 40-22-
28].

4852210 (07-06) 40-22-10 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Steering Knuckle Disassembly (cont’d)

Figure 40-22-31

S2218

Remove seal ring and the bushing from the arm.

NOTE:Note down the side for assembly.

4852210 (07-06) 40-22-11 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N 363012001 and Above, S/N 363112001 and Above) (CONT'D)

Brake System Identification

Figure 40-22-32

FOR S/N 363012001 - 363012500, S/N 363112001 - 363112500

1 1. Brake disc
2. Intermediate brake disc
3. Bushing
4. Detend ball
2
5. Spring
4 6. Spacer
7. Circlip
3
5 8. Shim
9
6 9. Intermediate brake disc
10 7 10. Roll pin
8
7 11
11. Roll pin
12 12. O-ring
13 13. Piston
14. O-ring
14
15 16 15. Back-up ring
17 16. Back-up ring
17. O-ring
16
18. Bolt
19. Piston
17
20. O-ring
21. Pin
18 22. O-ring
23. O-ring
19
24. Piston
22
25. Spring
26. Ring nut
23
24

25

20
21
26

S2162

4852210 (07-06) 40-22-12 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N 363012001 and Above, S/N 363112001 and Above) (CONT'D)

Brake System Identification (Cont’d)

Figure 40-22-33

FOR S/N 363012501 and Above, S/N 363112501 and Above

2 1. Brake disc
1 2. Intermediate brake disc
3 3. Bushing
11 12
4 13 4. Piston
14
5. Adjusting bolt
7
8 6. Spring
9
7. Backup ring
5
10 8. O-ring
6
9. Backup ring
10. O-ring
11. Spring
12. Adjusting bolt
13. O-ring
15
14. Plug
15. Back-up ring

17
16. O-ring

18
17. Pilot bolt
18. Bolt
16 19. O-ring
20. Pin
21 21. Piston
16
22. O-ring
19 23. O-ring
20 24. Piston
22
25. O-ring
23
26. Ring nut
24

25

26
S3091

4852210 (07-06) 40-22-13 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-36
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake System disassembly

Figure 40-22-34

S2163
P1

P1 = SAHR brake port. Release pressure 15-30 bar.

P2 = service brake port.
P3 = Hydraulic diff. lock port.
Working pressure 15-25 bar.
S2380
B1 = SAHR brake bleeding screw.
B2 = Service brake bleeding screw.
Connect an external pump to the union piece “P1” of the
negative brake and introduce a pressure of 15 30 bar of Figure 40-22-37
the Belleville washers (Item 1) [Figure 40-22-34].

Figure 40-22-35

S2220 / S1429
S2222
2
1

S2220 / S2163 Insert block screws to end stroke and release pression.

Loosen the unlocking screws (Item 1) and remove both

stop washers (Item 2) [Figure 40-22-35]. IMPORTANT
If the screws are tot be replaced, note down the differ-
ent colours for the different brake gap.

4852210 (07-06) 40-22-14 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-40
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake system disassembly

Figure 40-22-38

S2226

1
Sling the arm to be removed and connect it to a hoist,
remove screws.
S2223 / S2224
Figure 40-22-41

Remove the screws of the planetary gearbox cover on

the brake side. Remove the planetary gearbox cover
(Item 1) [Figure 40-22-38].

Figure 40-22-39

S2227

Take off the arm and lay it down vertically.

S2225

Remove the axle half shaft.

4852210 (07-06) 40-22-15 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-44
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake system disassembly

Figure 40-22-42

S2231

Loosen the before installed provisional screws in the

same sequence and same measure.
S2228 / S2229
Figure 40-22-45

In order to keep the disc springs of the negative brake

preloaded, screw down the screws with washers to the
end stop.

Figure 40-22-43

S2232

Insert the screws of the puller (M12) into the tapholes of

the negative brake and remove the pistons of the brake.

S2230

Remove the negative brake locking screws (30).

Always exchange the O-ring (31).

4852210 (07-06) 40-22-16 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-48
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake system disassembly

Figure 40-22-46
1

S2235

Remove intermediate disc (Item 1) [Figure 40-22-48].

NOTE: Sign the assembly position.

S2233

Pull out brake piston assembly module.

Figure 40-22-49

Figure 40-22-47

S2236

Applying pressure to the fi rst hole, remove the service

S2234 / S2165
brake piston (Item 1) [Figure 40-22-49].

IMPORTANT
Check locking screw (Item 1) [Figure 40-22-47] of the
brake piston module.

4852210 (07-06) 40-22-17 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-52
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake system disassembly

Figure 40-22-50

S2239

Turn upside down the brake module and with a pin driver
remove the locking pin of the slotted nut.
S2237

Figure 40-22-53
Applying pressure to the second hole, remove the
hydraulic block piston (Item 1) [Figure 40-22-50].

Figure 40-22-51

S2240

Sign the position of the slotted nut.

S2238

Applying pressure to the third hole, remove the three

bolts (Item 1) [Figure 40-22-51].

4852210 (07-06) 40-22-18 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Applying pressure, remove the piston (Item 1) [Figure 40-
363012001 and Above, S/N 363112001 and Above) 22-56] of the negative brake.
(CONT'D)
Figure 40-22-57
Brake system disassembly

Figure 40-22-54

S2244 / S2245

S2241
Check the position of the anti-extrusion and O-rings.

Unscrew the slotted nut (Item 1) [Figure 40-22-54].

Figure 40-22-55

S2242

Remove the disc springs (Item 1) [Figure 40-22-55].

Figure 40-22-56

S2243

4852210 (07-06) 40-22-19 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-60
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake system disassembly 1

Figure 40-22-58

1
2

S2248

2
Remove the snap ring (Item 1) from the intermediate disc
(2) [Figure 40-22-60].
S2246
Figure 40-22-61

Check the position of the O-rings (Item 1 and 2)

[Figure 40-22-58].

Figure 40-22-59

1
S2249

1 2
Remove coupling (Item 1) and washers (Item 2)
[Figure 40-22-61].

NOTE: Build a stack of washers and check the

measure.
S2247

Check the position of the anti-extrusion rings (Item 1) and

O-rings (Item 2) [Figure 40-22-59].

4852210 (07-06) 40-22-20 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-64
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake system disassembly

Figure 40-22-62

S2252

1
Remove the fixing ball (Item 1) [Figure 40-22-64].

Figure 40-22-65
S2250

Using a puller, preload the spring (Item 1) [Figure 40-22- 2

62].

Figure 40-22-63

S2253

Remove the spring (Item 1) and washer (Item 2)

[Figure 40-22-65].
1

S2251

Remove the snap ring (Item 1) [Figure 40-22-63].

WARNING
Spring is preloaded.

4852210 (07-06) 40-22-21 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake system disassembly

Figure 40-22-66

S2254

Remove the snap ring (Item 1) [Figure 40-22-66] of the

brake stack

Figure 40-22-67

S2255

Remove the brake discs one after the other.

NOTE: If they are not to be substituted, do not mix up

the sequence.

4852210 (07-06) 40-22-22 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N 363012001 and Above, S/N 363112001 and Above) (CONT'D)

Differential Parts Identification

1. Shim
2. Bearing
3 3. Bevel gear set
2
4. Shim
1
5. Taper roller bearing
6. Differential carrier
7. Bolt
8. Flange
9. Differential pinion

4 5 6 10. Spindle
11. Friction washer
12. Differential side
3
8 gear
10 9 13. Bolt
11 12 13 14. Shaft retainer
7 14 15. Pin
13 16. Differential side
15 gear
16
17 17. Detend ball
18 10 18. Bushing
19 13
9 19. Circlip
20
8 20. Intermediate clutch
22 disc
22 21. clutch disc
24 23. Bearing
25
21 24. Circlip
26
27 25. Circlip
23 28
29

S2501

4852210 (07-06) 40-22-23 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-70
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Differential Disassembly

To proceed, first remove the left arm.

Figure 40-22-68
1

S2261

Remove the snap ring (Item 1) [Figure 40-22-70] that

secures the thrust bearing.

Figure 40-22-71
S2258 / S2259

IMPORTANT
Position the differential gear sideways into the recess
in order to be able to pull it out. 1

Figure 40-22-69
S2262

Remove the snap ring (Item 1) and thrust bearing (Item 2)

[Figure 40-22-71].

S2260

Pull out the differental.

4852210 (07-06) 40-22-24 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-74
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Differential Disassembly

Figure 40-22-72

1
2

S2265

Remove the brake side planetary gear.

Figure 40-22-75
S2263

Remove the hydraulic block discs (Item 1 and 2)

[Figure 40-22-72] one after the other.

Figure 40-22-73

1 S2172

S2264

Remove the snap ring (Item 1) [Figure 40-22-73] that

secures the planetary gear.

4852210 (07-06) 40-22-25 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-78
363012001 and Above, S/N 363112001 and Above)
(CONT'D)
2
Differential Disassembly
1
Figure 40-22-76

S2267

1
Using a puller, extract the bearing (35) and the washer
(34).
S2266
Figure 40-22-79

Remove the snap ring (Item 1) [Figure 40-22-76] out of

it’s seat by moving it sideways.

Figure 40-22-77 1

S2269
2 1

Remove fixing screws (Item 1) of the crown wheel

3
(Item 2) [Figure 40-22-79]; exchange each time when
removed.
S2268

Remove completely bearing (Item 1), washer (Item 2) and

snap ring (Item 3) [Figure 40-22-77].

4852210 (07-06) 40-22-26 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-82
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Differential Disassembly 1 2 3

Figure 40-22-80

S2272 / S2273

1
Remove the three spider blocking pins (Item 1, 2 and 3)
[Figure 40-22-82] by using a pin driver .
S2270
Figure 40-22-83

Extract the crown wheel (Item 1) [Figure 40-22-80].

Figure 40-22-81

S2274

Move the two opposite mounted short bolts (Item 1)

[Figure 40-22-83] to the outside of the box using the
S2271
same pin driver.

Remove the tapered roller bearing (Item 1) [Figure 40-

22-81] of the crown wheel side, using two levers.

4852210 (07-06) 40-22-27 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-86
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Differential Disassembly

Figure 40-22-84
2
3

2
1

S2276 / S2277

1 Remove the long bolt (Item 1), spherical washers (Item 2)

and satellite wheels (Item 3) [Figure 40-22-86].

S2275 Figure 40-22-87

Drive out the long bolt (Item 1) and pull out the spider
(Item 2) [Figure 40-22-84] from the centre.
1

Figure 40-22-85

1 S2278
2
3
Remove the planetary gear (Item 1) [Figure 40-22-87].

S2276 / S2277

Remove the two half bolts (Item 1) [Figure 40-22-85],

spherical washers (Item 2) [Figure 40-22-85] and satellite
wheels (Item 3) [Figure 40-22-85].

4852210 (07-06) 40-22-28 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Differential Disassembly

Figure 40-22-88

S2279

Arrangement of the differential.

4852210 (07-06) 40-22-29 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N 363012001 and Above, S/N 363112001 and Above) (CONT'D)

Bevel Pinion Parts Identification

1. Bevel pinion
2. Bearing
3. shim
4. spacer
5. spacer
6. Bearing
1
7. Bolt

3
4
5
6
7

S2174

4852210 (07-06) 40-22-30 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-91
363012001 and Above, S/N 363112001 and Above)
(CONT'D) 1

Bevel Pinion Disassembly

Figure 40-22-89

1 1

S2463

Place two levers into the appropriate slots.

NOTE: Look out not to damage the surfaces.

S2461

Figure 40-22-92
Remove screws (Item 1) of the drive side flange cover
(Item 2) [Figure 40-22-89].
1
Figure 40-22-90

S2464

Lift off the cover (Item 1) [Figure 40-22-92].

2462

Take off the drive side flange cover.

4852210 (07-06) 40-22-31 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-94
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Bevel pinion Disassembly (Cont’d)

Figure 40-22-93

S2286X

Remove the pinion (Item 1) [Figure 40-22-94].

S2285X
S2466
Figure 40-22-95

T06

S2287
S2285X
S2467

Figure 40-22-96
Remove the nut (Item 1) [Figure 40-22-93] using tool
T06.

S2288

Using a puller and a press, remove the inner bearing

(Item 1) from the pinion (Item 2) [Figure 40-22-96].

4852210 (07-06) 40-22-32 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-99
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Bevel pinion Disassembly (Cont’d)

Figure 40-22-97

1
1

S2292

Remove the thrust block of the internal bearing (Item 1)

1 as well as the shim washers (Item 2) [Figure 40-22-99].
S2289
Figure 40-22-100

Remove the thrust block of the external bearing (Item 1)

[Figure 40-22-97].

Figure 40-22-98

1
S2465

Remove the snap ring (Item 1) [Figure 40-22-100].

S2291
Figure 40-22-101

Insert a drift in the appropriate holes.

S2469

Remove the cap (Item 1) [Figure 40-22-101].

4852210 (07-06) 40-22-33 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-104
363012001 and Above, S/N 363112001 and Above)
(CONT'D) I = 98 mm Y = -0.1 mm

Bevel Pinion Assembly

Figure 40-22-102

S2297 / S2298

Check nominal dimension “I” as marked on the pinion.

30 mm Add up to or subtract from “I” the variation indicated as “Y
” to obtain the actual centre distance “I”.
S2295

EXAMPLE:I =INT ± Y ==98-0,1=97,9mm

CALCULATING PINION CENTRE DISTANCE
NOTE: C61 = Match part number
Using a faceplate, reset a centesimal comparator “DG” on
a calibrated block (whose known thickness is 30 mm).

Preload the comparator by about 3 mm.

Figure 40-22-103

D 1

S2296

Bring inner bearing (Item 1) [Figure 40-22-103], complete

with thrust block, under comparator “DG”.

ATTENTION! Press the thrust block centrally and carry

out several measurements by rotating the thrust block.

EXAMPLE: 30 - 0,55 = 29,45 = “D”.

4852210 (07-06) 40-22-34 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-107
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Bevel pinion Assembly (Cont’d)

Figure 40-22-105

T8
1
S2301

Using special tool T8. Partially insert the thrust block of

the bearings and the selected shims (Item 1 and 2)
[Figure 40-22-107].
S2299

Figure 40-22-108
C61 = bevel gear set matching number

(-0,1) = Y variation from the theorical I =98

Figure 40-22-106

S2302

S2300

Calculate shims “S” for insertion under the thrust block of

the inner bearing using the following formula:

S = X - (I + D) where: X = fixed dimension

I = actual pinion centre distance

D = Total bearing thickness;

EXAMPLE: S = 128 - (97,9+29,45) = 0,65 mm

4852210 (07-06) 40-22-35 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-111
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Bevel pinion Assembly (Cont’d)

Figure 40-22-109 T9

S2176

Figure 40-22-112

S2303

Connect the tension rod to the press and move the thrust
block of the bearings into the seats.

Disconnect the press and remove the tension rod.

T9
NOTE: Before starting the next stage, make sure that
the thrust block has been completely inserted
into its seat.

S2305

Figure 40-22-110
Introduce the tracer of a depth comparator “DDG” into
either side hole of tool T9.

Reset the comparator with a preload of about 3 mm.

T9
1 2
S2304

CALCULATING PINION BEARINGS ROLLING TORQUE

Introduce tool T9 complete with bearings (Item 1 and 2)

[Figure 40-22-110] into the main body; tighten by hand
until a rolling torque is definitely obtained.

4852210 (07-06) 40-22-36 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-115
363012001 and Above, S/N 363112001 and Above)
(CONT'D) 1 T9
Bevel pinion Assembly (Cont’d)

Figure 40-22-113 2

S2307

Assemble on top of the tool T9 and between the two

bearings the shim (Item 1) and the largest calibrated shim
T9 (Item 2) [Figure 40-22-115].
S2177

Figure 40-22-116
Figure 40-22-114 T9

T9

T9
2
1 S2308

S2509
Measure the difference H using a dial gauge DDG

Remove the comparator and take out tool and bearing kits E.g. H = A -B = 2.93 mm
from the main body.

Reinstall every part, also introducing a distance piece

between bearings (Item 1 and 2) [Figure 40-22-114].
Tighten the entire pack by hand.

4852210 (07-06) 40-22-37 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-119
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Bevel pinion Assembly (Cont’d) 1

Figure 40-22-117

S2507

Fit the pinion (Item 1) [Figure 40-22-119], shim “S1” and

distance piece in the main body.
S2309
NOTE: The finer shims must be placed in- between
the thicker ones.
Calculate the shim S2 to be inserted.
Figure 40-22-120
E.g. S2 = H + X = 3.01 mm
where X = fixed value to obtain = 0.07...0.08 mm
100°C 1
Figure 40-22-118

100°C

1
S2508

Heat the external bearing to a temperature of about

100 C° and fit it on to the pinion (Item 1) [Figure 40-22-
S2310
120] so as to complete the pack as shown in the figure.

NOTE: Lightly lubricate bearing with SAE85W90 oil.

Insert shim S2 (Item 1) [Figure 40-22-118]. Measure the
difference H using a dial gauge DDG

E.g. H = A -B = 2.93 mm

4852210 (07-06) 40-22-38 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-123
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Bevel pinion Assembly (Cont’d)

Figure 40-22-121

T5
S2504

With the help of a torque meter, check the torque of the

pinion. Torque: 80 - 120 Ncm.
S2466

Install the nut (Item 1) [Figure 40-22-121]

LOCTITE 270.
without IMPORTANT
If torque exceeds the maximum value, then the size of
Figure 40-22-122 shim “S1” between the bearing and the distance
piece needs to be increased.
If torque does not reach the set value, increase the
torque setting of the ring nut in different stages to
obtain a maximum value of 500 Nm.

T5

IMPORTANT
If torque does not reach the set value, increase the
torque setting of the ring nut in different stages to
S2507
obtain a maximum value of 570 Nm.

Lock the wrench (Item T5) [Figure 40-22-122], rotate the

pinion using a dynamometric wrench,up to a minimum
required torque setting of 260-300 Nm.
IMPORTANT
If torque does not reach the minimum value, then the
size of shim “S1” needs to be reduced.

4852210 (07-06) 40-22-39 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-125
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Bevel pinion Assembly (Cont’d)

1

IMPORTANT
When calculating the increase or decrease in size of
shim “S1”, bear in mind that a variation of shim of
0.01 mm corresponds to a variation of 60 Ncm in the
torque of the pinion.
S2464

Figure 40-22-124 Install the drive side flange cover (Item 1) [Figure 40-22-
125].

Figure 40-22-126

T11
1

S2483

Apply Arexons rubber cement to the outer surface of the

new seal ring and fit ring in the main body using driver
T11. S2461

Tighten the screws (Item 1) [Figure 40-22-126] of the

drive side flange cover.

4852210 (07-06) 40-22-40 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-129
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Differential Assembly

Figure 40-22-127

S2323

Insert the two half bolts, spherical washers and satellite

wheels.
S2321
Figure 40-22-130

3 2
Differential module assembled

Figure 40-22-128

S2324

Partially insert the long bolt (Item 1) , satellite wheels

(Item 2) and spherical washers (Item 3) [Figure 40-22-
S2322
130].

Lubricate and insert washer and plantary wheel.

4852210 (07-06) 40-22-41 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-133
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Differential Assembly (Cont’d)

Figure 40-22-131

S2326

Insert completely the half bolts (Item 1) [Figure 40-22-

133].
S2180
Figure 40-22-134

Figure 40-22-132 1 2 3

S2327

Centre the pin holes and insert the 3 pins (Item 1, 2 and 3)
[Figure 40-22-134].
S2325

NOTE: Check the free rotation of the satellite wheels

on the bolts.
Insert spider (Item 1) [Figure 40-22-132] and completely
insert the long bolt .

4852210 (07-06) 40-22-42 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-137
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Differential Assembly (Cont’d)

Figure 40-22-135

S2330

Insert and substitute, if necessary, the discs of the

differential lock.ATTENTION: First and last disc have to
be of steel.
S2328

Figure 40-22-138
Insert the planetary wheel together with the centering
2
sleeve (Item 1) [Figure 40-22-135]. NOTE: The centering
sleeve must have the fixing ball assembled.

Figure 40-22-136

1
S2331

Insert thrust bearing (Item 1) and snap ring (Item 2)

[Figure 40-22-138].
S2329

Insert snap ring (Item 1) [Figure 40-22-136] of the

planetary wheel.

4852210 (07-06) 40-22-43 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-141
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Differential Assembly (Cont’d) 100°C

Figure 40-22-139
1

S2334

1
Assemble the bearing (Item 1) [Figure 40-22-141].

NOTE: Heat the bearing to 100°C before assembling.

S2332

Insert crown wheel (Item 1) [Figure 40-22-139].

Figure 40-22-142
Figure 40-22-140

1
1

S2335

S2333

Assemble the snap ring (Item 1) [Figure 40-22-142] in it´s

seat.
Insert the screws (Item 1) [Figure 40-22-140]. Tighten
screws with a torque wrench setting of 78-86 Nm.

NOTE: Always use new screws to fi x the crown

wheel. In case the screws are not thread
locking pretreated, use Loctite 270.

4852210 (07-06) 40-22-44 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Differential Assembly (Cont’d)

Figure 40-22-143

S2336

Assemble shim (Item 1) and bearing (Item 2) [Figure 40-

22-143].

NOTE: Heat the bearing as well as the shim to 100 °C

before assembling.

4852210 (07-06) 40-22-45 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-146
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake Assembly

Figure 40-22-144

1
S2339

Figure 40-22-147

S2337

Insert spring (Item 1) and washer (Item 2) [Figure 40-22-

144] onto the hydraulic block coupling.

Figure 40-22-145

1
4

2
S2339

S2338

Preload the spring (Item 1) by using a puller acting on the

washer (Item 2) [Figure 40-22-145].

Insert the snap ring (Item 3) and the fixing ball (Item 4)
[Figure 40-22-145].

4852210 (07-06) 40-22-46 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-150
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake Assembly (Cont’d) 1

Figure 40-22-148

1 2

S2341

Insert the bolts (Item 1) [Figure 40-22-150].

S2339

Figure 40-22-151
Shift the cut of the snap ring (Item 1) according to the ball
(Item 2) [Figure 40-22-138].

Figure 40-22-149

S2342

Insert the hydraulic block piston (Item 1) [Figure 40-22-

S2340
151].

Complete the O-rings and anti-extrusion rings on all

pistons.

IMPORTANT
The O-rings always have to be assembled from the
pressure facing side.

4852210 (07-06) 40-22-47 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-154
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake Assembly (Cont’d)

1
Figure 40-22-152

1
S2345

Turn upside down and insert the negative brake piston

(Item 1) [Figure 40-22-154].
S2343
Figure 40-22-155

Insert the service brake piston (Item 1) [Figure 40-22-

152] hammering alternately with a plastic hammer. 1

Figure 40-22-153

S2346

Screw up the slotted nut (Item 1) [Figure 40-22-155] for

about 5 turns.
S2344

Insert the intermediate disc (Item 1) [Figure 40-22-153]

observing the previously signed position.

4852210 (07-06) 40-22-48 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-158
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake Assembly (Cont’d)

Figure 40-22-156

D = 44.7 mm

S2348

Determine the level “A” between external plane and the

brake plate by the adjustment of the slotted nut.
S2347
NOTE: To define the level A adjust the slotted nut
always to the smaller value by driving to the
closer notch.
Find out the level of the brake discs “D”.
A = 141 - (D+G) = 141 - 46,1 = 94,9 mm
E.g. D=44.7 mm
X = constant value 141 mm
Add to D the value G = brake clearance (e.g. 1.4 mm).

D + G = 44,7 + 1,4 = 46,1

Figure 40-22-159
Figure 40-22-157
D = 44,7mm

S2349

S2339

4852210 (07-06) 40-22-49 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-162
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake Assembly (Cont’d)

Figure 40-22-160

S2352

Turn upside down and fit on the intermediate disc.

S2350

Figure 40-22-163

IMPORTANT
To determine the level A the slotted nut has to be
operated without spring mounted.

Figure 40-22-161

S2353

Select a pack of washers of 1.5 mm

S4=1.5 mm const.

S2351

Before removing the slotted nut in order to insert the

springs, note down the distance Z from the plane to the
tooth near the pin.

NOTE: Sign.

4852210 (07-06) 40-22-50 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-166
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake Assembly (Cont’d)

Figure 40-22-164
1

1
S2356X

3
Insert the brake discs (Item 1) [Figure 40-22-166] in the
right sequence.
S2354
NOTE: The first brake disc to be inserted must be of
friction material.
Insert and bring into position washers (Item 1) and
coupling (Item 2) into the brake module (Item 3)
[Figure 40-22-164].
Figure 40-22-167
Figure 40-22-165

S2357X

S2355

Insert the brake discs (Item 1) [Figure 40-22-167] in the

right sequence.
With the positioned pack determine the distance L
between coupling and brake disc surface.
NOTE: The last brake disc to be inserted must be of
metal material.
E.g. L=37.5 mm

4852210 (07-06) 40-22-51 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-170
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake Assembly (Cont’d)

Figure 40-22-168

S2360

Correction of the shims S4 depending on the calculation

of the value “R”.
S2358
NOTE: The value of “R” has always to result in 0.1
mm. in case it is not so, the shims S4 (Item 1)
[Figure 40-22-170] under the coupling have to
Zero the depth gage from the plane of the splined
be modified.
coupling to the surface of the brake discs.

NOTE: Press the brake disc pack before zeroing,

execute the mesurement in some points and
take an average.

Figure 40-22-169

S2359

CHECK OF THE CLEARANCE “R” BETWEEN

COUPLING AND THRUST BEARING.

Find out the distance “M” between the brake discs surface
and thrust bearing.

E.g. M=36.4mm Brake discs clearance G = 1,4

R =(M+G)-L=(34,6+1,4)-37,5=0,3mm

4852210 (07-06) 40-22-52 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-173
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake Assembly (Cont’d)

1
Figure 40-22-171

S2363

Turn upside down and unscrew the slotted nut (Item 1)

[Figure 40-22-173].
S2361
Figure 40-22-174

Depending on the calculation assemble the exact shims 1

to arrive at R=0.1 mm. Assemble all with safety ring.
where 1.5 const.

Shims S4 z.B.: S4= 1,5+(0,3-0,1)= 1,5+0,2= 1,7mm

0.3mm = R calculated clearance
0.1mm = R wanted clearance

Figure 40-22-172

S2364
1

Insert the disc springs in the right position (Item 1)

[Figure 40-22-174].

S2362

Insert the complete intermediate disc (Item 1) [Figure 40-

22-172].

4852210 (07-06) 40-22-53 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-177
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake Assembly (Cont’d)

Figure 40-22-175

S2367

Check the earlier measured distance Z from the plane to

the tooth next to the pin.
S2365
Figure 40-22-178

Insert at the bottom the piston of the negative brake and

screw up the slotted nut (Item 1) [Figure 40-22-175].

Figure 40-22-176

S2368

Put the pin in (Item 1) [Figure 40-22-178] locking

position.
S2366

Screw down the slotted nut to the earlier determined

position.

4852210 (07-06) 40-22-54 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-181
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake Assembly (Cont’d)

Figure 40-22-179

S2371

S2369 IMPORTANT
Check locking screw of the brake piston module.
Insert two screws of M12 to fix the break arm.

Figure 40-22-180 Figure 40-22-182

S2372
S2370

Insert the brake module facing the input holes to the top.

IMPORTANT
Position the groove of the brake module in line with
the lock screw in the arm.

4852210 (07-06) 40-22-55 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-185
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake Assembly (Cont’d)

Figure 40-22-183

S2375

Alternately tighten with a torque wrench setting of max. 45

Nm.
S2373
Figure 40-22-186

Insert the piston to the end stop by alternating light

strokes and remove the screws.

Figure 40-22-184

S2376X

Insert the negative brake unlocking screw (Item 1)

[Figure 40-22-186] up to the end stop.
S2374

Temporary insert screws M12x45.

4852210 (07-06) 40-22-56 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Insert the screws and tighten them alternately.
363012001 and Above, S/N 363112001 and Above)
(CONT'D) Figure 40-22-190
Brake Assembly (Cont’d)

Figure 40-22-187

S2380

Introduce a pressure of max. 25 bar and loosen the

S2377
unlocking screws.

Remove the two auxiliary screws.

Figure 40-22-188

S2378

Exchange and lubricate the O-ring and insert the arm to

the box.

Figure 40-22-189

S2379

4852210 (07-06) 40-22-57 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-193
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Brake Assembly (Cont’d)

Figure 40-22-191

S2186

S2164

Figure 40-22-192

S2381

Insert the two “U”-shaped shims and tighten the screws

with a torque wrench setting of 95-115 Nm.

NOTE:The position of the negative brake is unlocked.

4852210 (07-06) 40-22-58 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-196
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Steering Knuckle Assembly

Figure 40-22-194

S2383

Lubricate the outer surface of the sealing ring (Item 1)

1
[Figure 40-22-196]; fit them into their seat using tool
T14 [Figure 40-22-196].
S2382

Figure 40-22-197
Lubricate the bushing (Item 1) [Figure 40-22-194] and
the seat of the steering case. Install the bushing, using
tool T13.

Figure 40-22-195

S1499

S1497

4852210 (07-06) 40-22-59 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-200
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Steering Knuckle Assembly (Cont’d)

Figure 40-22-198

S2387

Fit the front sealing rings onto the articulation pins.

1
S2384 / S2385
NOTE: Carefully check that the rings are properly
oriented.

Using special tool T15 apply a repositionable jointing Figure 40-22-201

compound for seals to the outer surface of the sealing
ring. Position the sealing ring in the steering case (Item 1)
[Figure 40-22-198].

NOTE: Check that the ring is correctly oriented.

Figure 40-22-199

S2388X / S2389X

Lubricate the top bush or the bottom ball bush and fit
them into the fulcrum holes of the arm.

S2386

If the bottom articulation pin has been extracted, position

the pin under a press and fi t the ball cover (20).

4852210 (07-06) 40-22-60 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-204
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Steering Knuckle Assembly (Cont’d)

Figure 40-22-202

S2393

Insert the u-joint (Item 1) [Figure 40-22-204].

Figure 40-22-205
S2390 / S2391

Lubricate the bushing (2) and the seat of the steering

case (1). Install the bushing (2), using tool T13.

Figure 40-22-203

S2431

Lubricate the terminal of the u-joint and install the steering

case.

Pay due attention not to damage the dust cover rings and
S2392
the sealing rings.

Lubricate and fit the sealing ring onto tool T14; install the
rings into the arm.

IMPORTANT
Pay particular attention to the direction of assembly
of the rings.

4852210 (07-06) 40-22-61 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-208
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Steering Knuckle Assembly (Cont’d)

Figure 40-22-206

2
S2397

1 Lubricate the steering case.

S2395

Figure 40-22-209
Prepare a series of shims (Item 1) [Figure 40-22-206] of
0,4 up to 0,7 mm.

To be assembled under the upper pin (Item 2) [Figure 40-

22-206].
2
Figure 40-22-207

1
S2398X

Fit the unit (Item 1) in the steering case (Item 2)

[Figure 40-22-206]. Position the screws and tightly
tighten.

S2396X

Lubricate and install the unit in the steering case.

4852210 (07-06) 40-22-62 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-212
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Steering Knuckle Assembly (Cont’d)

Figure 40-22-210

S2401
1

Check by means of a lever that there is no vertical gap.

In case there is any gap, determine the width and reduce

S2399
it by removing shims.

Tighten the new fittin screws (Item 1) [Figure 40-22-206]

of top articulation pins in sequence using the cross
Figure 40-22-213
tightening method.

Torque wrench setting: 90 - 100 Nm.

Figure 40-22-211

S2402

1
Check the torque of the pins, which has to be 40 - 80 Nm.
If the preliminary measured value is too high, the shims
S2400
have to be increased.

Tighten the new fittin screws (Item 1) [Figure 40-22-206]

of bottom articulation pins in sequence using the cross
tightening method.

Torque wrench setting: 90 - 100 Nm.

4852210 (07-06) 40-22-63 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Steering Knuckle Assembly (Cont’d)

Figure 40-22-214

S2403

Look for the position of the notch regarding the safety

cotter pin hole when the nut is fi naly locked max 300 Nm.

Figure 40-22-215

S2404

Bring the lockscrew to the quote at the measure

previously survey.

4852210 (07-06) 40-22-64 Bobcat T2556 & T2566

SERVICE MANUAL
.AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-218
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Planetary Carrier Assembly

Figure 40-22-216

S2409

Install the external bearing (Item 1) [Figure 40-22-218].

NOTE: Move the bearing to the limit stop by

S2405 / S2406
hammering lightly all around the edge.

Position the lower part of tool T1 and the thrust block of

the external bearing .
Figure 40-22-219
Figure 40-22-217

1 S2410

S2408 / S2408

Install the wheel hub (Item 1) [Figure 40-22-219].

Lubricate the seats of the bearings and position the hub
on a proper tool; position the thrust block of the internal
bearing (Item 1) [Figure 40-22-217].

NOTE: Check that the thrust block is correctly

oriented.

4852210 (07-06) 40-22-65 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-222
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Planetary Carrier Assembly (Cont’d)

Figure 40-22-220

1
S2413

Install the safety flange (Item 1) [Figure 40-22-220].

Using Tecno Lube /101, grease the surface of the safety
1 flange that touches the crown wheel.
S2411

Figure 40-22-223
Install the crown wheel (Item 1) [Figure 40-22-220].

Figure 40-22-221

S2414

Coat the nuts (Item 1) [Figure 40-22-220] with Loctite 242

and screw them.
S2412

Fit the complete crown flange (Item 1) [Figure 40-22-

220].

NOTE: In order to fasten the flange (36), use a plastic

hammer and alternately hammer on several
equidistant points.

4852210 (07-06) 40-22-66 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-226
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Planetary Carrier Assembly (Cont’d)

Figure 40-22-224

1
S2417

Install the snap ring (Item 1) [Figure 40-22-226].

Figure 40-22-227
S2415

Tighten nuts (Item 1) [Figure 40-22-224] in two stages,

using the criss-cross method.

Initial torque wrench setting: 90 Nm.

Final torque wrench setting: 100 Nm.

Figure 40-22-225

S2418

Check the continuous rolling torque on the hub.

1 Torque 7 - 20 Nm.

S2416

Install the distance piece (Item 1) [Figure 40-22-225].

4852210 (07-06) 40-22-67 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (FOR S/N Figure 40-22-230
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Planetary Carrier Assembly (Cont’d) 1 2

IMPORTANT
Check the condition and position of the O-ring.

Figure 40-22-228
S2423

Fit the planetary gear cover (Item 1) onto the wheel hub
(Item 2) [Figure 40-22-230].

Figure 40-22-231.

S2420 / S2421

Fit the planetary gear (Item 1) [Figure 40-22-230] onto

the planetary gear cover.

IMPORTANT S2424X

The jointed portion of the internal ring of the bearings

Torque wrench 40-50 Nm. MZ-G755
must face the bottom of the pin.

Figure 40-22-229

S2422

Lock into position the planetary gears (16) with the snap
rings (15).

4852210 (07-06) 40-22-68 Bobcat T2556 & T2566

SERVICE MANUAL
SPECIAL TOOLS

TOOL
T2556-
BOBCAT PN IMAGE DESCRIPTION T2566

6912173 PINION RING NUT T06

6912176 DUMMY PINION T09

6912178 INPUT FLANGE SEAL T11

6912179 603 DROPBOX SEAL T12

U-JOINT ARM &

6912180 T13
STEERING CASE BUSHING

6912181 U-JOINT SEAL, ARM SIDE T14

6912182 WHEEL HUB SEAL T15

4852210 (07-06) 40-22-69 Bobcat T2556 & T2566

SERVICE MANUAL
TOOL
T2556-
BOBCAT PN IMAGE DESCRIPTION T2566

6912185 603 COVER SEAL X

U-JOINT SEAL,
6912186 X
STEERING CASE SIDE

4852210 (07-06) 40-22-70 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (For S/N 363012001 and Above, S/N 363112001 and Above)

General Information

For photo clarity, the following axle procedures are done Rear Axle removal. (See “REAR AXLE (For S/N
with the complete axle assembly removed from the 363012001 and Above, S/N 363112001 and Above)” on
machine, although the planetary carrier, wheel hub, page 40-91-1)
steering knuckle and drive axle procedures may be done
with the axle assembly installed in the machine. For Rear steering cylinder removal. (See “STEERING
complete axle repair, the following must be done. CYLINDER (REAR) (For S/N 363012001 and above, S/N
363112001 and above)” on page 20-63-1)

Planetary Carrier Parts Identification

1. Seal
2. Bearing
3. Wheel stud
1 4. Wheel hub
3
2 4 5. Nut
5 6. O-ring
7. Bearing
22
6 8. Circlip
7 9. Ring gear
8 10. Ring gear support

9
10
11. Locking plate 15 16 17
12. Ring 11
12
13. Circlip
13
14. Washer
15. Circlip 14
16. Planet gear 18
19 20
17. Bearing
18. Planet gear carrier 23
24
19. O-ring
20. Plug
21. Countersunk bolt
22. Planet gear carrier
23. Stud
24. Nut 21
25. Ring Gear Support S2190

4852210 (07-06) 40-23-1 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-3
363012001 and Above, S/N 363112001 and Above)
(CONT'D)
1
Planetary Carrier Disassembly (Cont’d)

Figure 40-23-1

S2192
1

Remove the complete planetary carrier cover (Item 1)

[Figure 40-23-3].

S2190
Figure 40-23-4

Remove the securing screws (Item 1) [Figure 40-23-1]

from the planetary carrier cover.
1
Figure 40-23-2
1
1
2
1

S2193

Remove the snap rings (Item 1) [Figure 40-23-4].

S2191

Remove the planetary carrier cover (Item 1) from the

steering case (Item 2) [Figure 40-23-2] by alternatively
forcing a screwdriver into the appropriate slots.

4852210 (07-06) 40-23-2 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-7
363012001 and Above, S/N 363112001 and Above)
(CONT'D)
1
Planetary Carrier Disassembly (Cont’d)

Figure 40-23-5

1
S2197

Remove the Snap ring (Item 1) [Figure 40-23-7].

Figure 40-23-8
S2194

With the help of a puller, remove the planet wheel gears

1
(Item 1) [Figure 40-23-5].

NOTE: Note the assembly side of the planet wheels. 2

Figure 40-23-6

S2198X

Unloose and remove the tightening nuts (Item 1) from the

crown flange (Item 2) [Figure 40-23-8].

S2195 / S2196

NOTE: Note down the direction of assembly of

planetary gears.

4852210 (07-06) 40-23-3 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-11
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Planetary Carrier Disassembly (Cont’d)

1
Figure 40-23-9

S2201X

Using a puller; remove the complete crown flange (Item 1)

[Figure 40-23-11] by acting on the stud bolts.
S2199
Figure 40-23-12

Remove the shim washer (Item 1) [Figure 40-23-9].

1
Figure 40-23-10

S2202X

Partially extract the hub (Item 1) [Figure 40-23-12] using

a plastic hammer.

S2200X
NOTE: Alternately hammer on several equidistant
points.

Remove the safety flange (Item 1) [Figure 40-23-10].

4852210 (07-06) 40-23-4 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-15
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Planetary Carrier Disassembly (Cont’d)

2
Figure 40-23-13

1
1

S2205 / S2206

Remove the external thrust blocks of bearings (Item 1),

using the provider (Item 2) [Figure 40-23-15].
S2203X
NOTE: Hammer in an alternate sequence to prevent
crawling and deformation of the thrust blocks.
Remove the external bearing (Item 1) [Figure 40-23-13].
Figure 40-23-16
Figure 40-23-14

1
1

S2207

S2204X

Remove the sealing ring from the steering case (Item 1)

Remove the complete hub (Item 1) [Figure 40-23-14] by [Figure 40-23-16]. Pay due attention not to damage the
hand. seat of bearing.

4852210 (07-06) 40-23-5 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N 363012001 and Above, S/N 363112001 and Above) (CONT'D)

Steering Knuckle Parts Identification

19. Nut
1
2 20. Bolt
3 21. Steering adjust bolt
22. Articulated tie rod
23. Ring
24. Cylinder
2 25. Cylinder bolt
1
26. Bolt
27. Electronic sensor
25
28. O-ring
29. Pivot
22
26
23 4
27
7 5
1. Thrust bushing 28
29 6
2. Seal 24
3. Joint 8
4. Nut 23 9
5. Washer 10
22
6. Stud 11
7. Cap 12
8. Grease fitting RIGHT: 13

9. Cap LEFT: 14
10. Shim
11. Seal 20
21
12. Bushing 19 15
13. Steering case 11
14. Steering case 18
8
15. Articulation
9
16. Bolt
16
17.
17
18. Pivot pin

S1389

4852210 (07-06) 40-23-6 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-19
363012001 and Above, S/N 363112001 and Above)
(CONT'D) 1

Steering Knuckle Disassembly

Figure 40-23-17

S2210

Remove the nuts (Item 1) that lock the articulation pins

(Item 2) [Figure 40-23-19].
S2208
Figure 40-23-20

Note the measure of the screw.

2
Figure 40-23-18
1

S2211

Disconnect the tapered pins of the articulation

(Item 1) from the steering case (Item 2) [Figure 40-23-
S2209
20] by means of a puller.

Loose the lockscrew and inser it to allow the passage of

tool.

4852210 (07-06) 40-23-7 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Using two levers, remove the bottom articulation pin
363012001 and Above, S/N 363112001 and Above) (Item 1) [Figure 40-23-22] complete with front sealing
(CONT'D) ring (Item 2) [Figure 40-23-22].
Steering Knuckle Disassembly (Cont’d)
Figure 40-23-23
Figure 40-23-21

1 2

1 2

1 3
S2428A

S2425X
Using two levers, remove the top articulation pin (Item 1)
complete with front seal (Item 2) and shims (Item 3)
Unloose and remove the fitting screws (Item 1) [Figure 40-23-23].
[Figure 40-23-21] from the articulation pin.
Figure 40-23-24
NOTE: Screws can not be re-used.

Figure 40-23-22
2

1
3
2

S1393

Configuration of the upper (Item 1) articulation pin with

1 shims (Item 2) and the lower articulation pin (Item 3)
S2427A [Figure 40-23-24].

S2427B

4852210 (07-06) 40-23-8 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-27
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Steering Knuckle Disassembly (Cont’d)

Figure 40-23-25

1
S2213

Remove the U-joint (Item 1) [Figure 40-23-27].

S2431
NOTE: To remove the u-joint use, if necessary, a
plastic hammer or a lever.

Remove the complete steering case (Item 1) [Figure 40- Figure 40-23-28
23-25].

Figure 40-23-26

2
1

S2214 / S2215

Using a puller for inner parts, remove the top bush

S2212
(Item 1) and the bottom ball-bush (Item 2) [Figure 40-23-
28].
Remove the bushing from the steering case (Item 1)
[Figure 40-23-26].

NOTE: Note down the orientation of bushing.

4852210 (07-06) 40-23-9 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-31
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Steering Knuckle Disassembly (Cont’d)

Figure 40-23-29 1

S2218

Remove seal ring (Item 1) [Figure 40-23-31] and the

1 bushing from the arm.

S2216 NOTE:Note down the side for assembly

Check the position of the anti-extrusion and O-rings.

Remove the articulation pins (Item 1) and the front sealing
rings (Item 2) [Figure 40-23-29].

NOTE: Note down the side for assembly

Figure 40-23-30

S2217

If the ball cover (Item 1) [Figure 40-23-30] need

replacing, remove it from the bottom articulation pin.

4852210 (07-06) 40-23-10 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N 363012001 and Above, S/N 363112001 and Above) (CONT'D)

Differential Parts Identification

1. Nut
2. O-ring
3. Flange
4. Coverplate
5. Seal
6. Spacer
7. Bearing
12 8. Ring
13 9. Plug
14
15
10. Shim
16 11. Taper roller bearing
17 18
19
12. Shim
20 13. Taper roller bearing
21 14. Bolt
7 11 21 15. Differential carrier
10
9 22 16. Friction washer
8 17
7 16 17. Diferrential side
6 23
5 13 gear
4 12
3 21 18. Friction washer
20
2
1 19 19. Differential pinion
18 20. Spindle
21. Bolt
24
22. Pin
23. Cover
24. Hexagon Bolt

SPC002060

S1426

4852210 (07-06) 40-23-11 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Pull out the differental (Item 1) [Figure 40-23-34].
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Differential Disassembly (Cont’d)

Figure 40-23-32

S2256

Remove the brake side arm (Item 1) [Figure 40-23-32].

Sling the arm to be removed and connect it to a hoist,
remove screws of the crown wheel side arm.

Figure 40-23-33

S2257

Figure 40-23-34

S2260

4852210 (07-06) 40-23-12 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-37
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Differential Disassembly (Cont’d)

Figure 40-23-35
1

2
S2268

1
Separate the crown wheel (Item 1) from the differential
2 box (Item 2) [Figure 40-23-37].
S2266
Figure 40-23-38

Extract the bearing (Item 1) from the differential carrier

(Item 2) [Figure 40-23-35]. 1

Figure 40-23-36

1
2

2
S2269 / S2270

Extract the bearing (Item 1) partially and using a puller,

remove the bearing (Item 2) [Figure 40-23-38] of the
crown wheel side.
S2267

Remove fixing screws (Item 1) of the crown wheel

(Item 2) [Figure 40-23-36]; exchange each time when
removed.

4852210 (07-06) 40-23-13 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-41
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Differential Disassembly (Cont’d)

1
Figure 40-23-39

S2274

Remove the fixing pins (Item 1) [Figure 40-23-41] of the

differential cross bolts.
S2271 / S2272
Figure 40-23-42

Remove the cover (Item 1) [Figure 40-23-39] from the 1

blocking side of the differential unit.

Figure 40-23-40 2

1 2

S2275

With a pin-driver (Item 1) push the two bolts (Item 2)

[Figure 40-23-42] to the outside.
S2273

Remove the shim washer (Item 1) and the planetary gear

(Item 2) [Figure 40-23-40].

4852210 (07-06) 40-23-14 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Remove the cross bolts (Item 1) [Figure 40-23-45].
363012001 and Above, S/N 363112001 and Above)
(CONT'D) Figure 40-23-46
Differential Disassembly (Cont’d)
1
Figure 40-23-43

S2279

Remove the planetary gear (Item 1) [Figure 40-23-46].

S2276

Remove the bolts with the help of a drift (Item 1)

[Figure 40-23-43].

Figure 40-23-44

S2277

Remove the two halfes of the cross bolts (Item 1)

[Figure 40-23-44] with the help of a drift.

Figure 40-23-45

S2278

4852210 (07-06) 40-23-15 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Differential Disassembly (Cont’d)

Figure 40-23-47

S2279B

Remove the shim washer (Item 1) and the planetary gear

(Item 2) [Figure 40-23-47].

Figure 40-23-48

S2279C

Arrangement of the differential.

4852210 (07-06) 40-23-16 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N 363012001 and Above, S/N 363112001 and Above) (CONT'D)

Bevel pinion Parts Identification

1. Nut
2. O-ring
3. Flange
4. Coverplate
5. Seal
6. Spacer
7. Bearing
8. Ring
9. Plug 7 11
10
10. Shim 9
11. Taper roller Bearing 8
7
6
5
4
3
2
1

S1568

4852210 (07-06) 40-23-17 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-51
363012001 and Above, S/N 363112001 and Above)
(CONT'D)
2
Bevel pinion Disassembly

Figure 40-23-49

1
1
2
S2282 / S2283

Remove the flange (Item 1) complete with guard (Item 2)

[Figure 40-23-51] by means of a puller.
S2280
Figure 40-23-52

Make positional marks across nut (Item 1) and pinion

(Item 2) tang; If disassembly is awkward, heat the check
nut (Item 1) [Figure 40-23-49] of the flange at 80C°.

NOTE: Heating is meant to unloose the setting of

Loctite on the nut (Item 1) [Figure 40-23-49].

Figure 40-23-50

S2287

T5

S2281X

Position tool T5, so as to avoid pinion rotation. Unloose

and remove the nut (1); also remove the O-ring (6).

4852210 (07-06) 40-23-18 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-55
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Bevel pinion Disassembly (Cont’d)

Figure 40-23-53

S2286X

Remove the pinion (Item 1) [Figure 40-23-55], shims and

distance piece. Refer and keep to the positions marked
during disassembly.
S2284X

Figure 40-23-56
Remove the sealing ring (Item 1) [Figure 40-23-51].

Figure 40-23-54
2

S2288

1
Using a puller and a press, remove the inner bearing
S2285X
(Item 1) from the pinion (Item 2) [Figure 40-23-56].

Remove the sealing ring (Item 1) and spacer (Item 2)

[Figure 40-23-54].

NOTE: sealing rings (3) must be replaced each time

the unit is disassembled.

4852210 (07-06) 40-23-19 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-59
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Bevel pinion Disassembly (Cont’d)

Figure 40-23-57

1
1

S2292

Remove the thrust block of the internal bearing (Item 1)

1 as well as the shim washers (Item 2) [Figure 40-23-59].
S2289
Figure 40-23-60

Remove the thrust block of the external bearing (Item 1)

[Figure 40-23-57].

Figure 40-23-58 1

S2293

Remove the snap ring (Item 1) [Figure 40-23-60].

Figure 40-23-61
S2290 / S2291

Insert a drift in the appropriate holes.

S2294

Remove the cap (Item 1) [Figure 40-23-61].

4852210 (07-06) 40-23-20 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-64
363012001 and Above, S/N 363112001 and Above)
(CONT'D) I = 98 mm Y = -0.1 mm

Bevel pinion Assembly (Cont’d)

Figure 40-23-62

S2297 / S2298

Check nominal dimension “I” as marked on the pinion.

30 mm Add up to or subtract from “I” the variation indicated as “Y
” to obtain the actual centre distance “I”.
S2295

EXAMPLE:I =INT ± Y ==98-0,1=97,9mm

CALCULATING PINION CENTRE DISTANCE
NOTE: C61 =Match part number
Using a faceplate, reset a centesimal comparator “DG” on
a calibrated block (whose known thickness is 30 mm).

Preload the comparator by about 3 mm.

Figure 40-23-63

D 1

S2296

Bring inner bearing (Item 1) [Figure 40-23-63], complete

with thrust block, under comparator “DG”.

ATTENTION! Press the thrust block centrally and carry

out several measurements by rotating the thrust block.

EXAMPLE: 30 - 0,55 = 29,45 = “D”.

4852210 (07-06) 40-23-21 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-67
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Bevel pinion Assembly (Cont’d)

Figure 40-23-65

1
S2301

Using a proper tool, Partially insert the thrust block of the

bearings (Item 1) [Figure 40-23-67].
S2299
Figure 40-23-68

C61 = bevel gear set matching number

(-0,1) = Y variation from the theorical I =98

Figure 40-23-66

S2302

S2300

Calculate shims “S” for insertion under the thrust block of

the inner bearing using the following formula:

S = X - (I + D) where: X = fixed dimension

I = actual pinion centre distance

D = Total bearing thickness;

EXAMPLE: S = 128 - (97,9+29,45) = 0,65 mm

4852210 (07-06) 40-23-22 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-71
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Bevel pinion Assembly (Cont’d)

Figure 40-23-69 T9

S2176

Figure 40-23-72

S2303

Connect the tension rod to the press and move the thrust
block of bearings into the seats.
T9
Disconnect the press and remove the tension rod.

NOTE: Before starting the next stage, make sure that

the thrust block has been completely inserted
into its seat. S2305

Introduce the tracer of a depth comparator “DDG” into

Figure 40-23-70 either side hole of tool T9.

Reset the comparator with a preload of about 3 mm.

T9
1 2

S2304

CALCULATING PINION BEARINGS ROLLING TORQUE

Introduce tool T9 complete with bearings (Item 1 and 2)

[Figure 40-23-70] into the main body; tighten by hand
until a rolling torque is definitely obtained.

4852210 (07-06) 40-23-23 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-75
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Bevel pinion Assembly (Cont’d)

T9
Figure 40-23-73

S2307

Assemble on top of the tool T9 [Figure 40-23-75] and

between the two bearings the shim and the largest
T9 calibrated shim.
S2177

Figure 40-23-76
Figure 40-23-74 T9

T9

1 2
T9
S2308

S2306

Measure the difference H using a dial gauge DDG

Remove the comparator and take out tool and bearing kits
E.g. H = A -B = 2.93 mm.
from the main body.

Reinstall every part, also introducing a distance piece

between bearings (Item 1) and (Item 2) [Figure 40-23-
74]. Tighten the entire pack by hand.

4852210 (07-06) 40-23-24 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-79
363012001 and Above, S/N 363112001 and Above)
(CONT'D) 1 3 4 2 5
Bevel pinion Assembly (Cont’d)

Figure 40-23-77

S2311

Fit the pinion (Item 1), shim “S1” (Item 2) and distance
piece (Item 3 and 4) in the main body (Item 3) [Figure 40-
23-79].
S2309

NOTE: The finer shims must be placed in- between

the thicker ones.
Calculate the shim S2 to be inserted.
Figure 40-23-80
E.g. S2 = H + X = 3.01 mm
where X = fixed value to obtain = 0.07...0.08 mm

Figure 40-23-78
100°C

100°C

S2312

Heat the external bearing (Item 1) [Figure 40-23-80] to a

S2310
temperature of about 100 C° and fit it on to the pinion (11)
so as to complete the pack as shown in the figure.
Measure the difference H using a dial gauge DDG
NOTE: Lightly lubricate bearing with SAE85W90 oil.
E.g. H = A -B = 2.93 mm

4852210 (07-06) 40-23-25 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-83
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Bevel pinion Disassembly (Cont’d) TX1

Figure 40-23-81

S2316

Lock the wrench TX1 [Figure 40-23-83], rotate the pinion

using a dynamometric wrench, up to a minimum required
torque setting of 260 - 300 Nm.
S2313

Insert the spacer (Item 1) [Figure 40-23-81].

NOTE: Check the using friction of the washer.

Figure 40-23-82

S2315

Install the flange (Item 1) onto the pinion withou sealing

ring and install the nut (Item 2) [Figure 40-23-82] without
LOCTITE 270.

4852210 (07-06) 40-23-26 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Bevel pinion Disassembly (Cont’d)

IMPORTANT
When calculating the increase or decrease in size of
Figure 40-23-84 shim “S1”, bear in mind that a variation of shim of
0.01 mm corresponds to a variation of 60 Ncm in the
torque of the pinion.

Figure 40-23-85

1
2
S2317X

Rolling Torque 80 -120 Nm. 1

IMPORTANT S2280

If torque exceeds the maximum value, then the size of

shim “S1” between the bearing and the distance Make positional marks across nut (Item 1) and pinion
piece needs to be increased. (Item 2) tang; then remove nut and flange (Item 3)
If torque does not reach the set value, increase the [Figure 40-23-85]
torque setting of the ring nut in different stages to
obtain a maximum value of 500 Nm. Figure 40-23-86

1 T11

IMPORTANT
If torque does not reach the set value, increase the
torque setting of the ring nut in different stages to
obtain a maximum value of 570 Nm.

S2314

IMPORTANT Apply Arexons rubber cement to the outer surface of the

If torque does not reach the minimum value, then the new seal ring (Item 1) [Figure 40-23-86] and fit ring in the
size of shim “S1” needs to be reduced. main body using driver T11.

4852210 (07-06) 40-23-27 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Bevel pinion Disassembly (Cont’d)

Figure 40-23-87

S2283

Oil seal ring lips and install flange (Item 1) . Mount O-ring
(Item 2) and apply Loctite 270 to pinion tang; tighten nut
(Item 3) [Figure 40-23-87].

Figure 40-23-88

TX1

T5

S2320X

Lock the wrench TX1 [Figure 40-23-87], rotate the pinion

using adynamometric wrench, up to a minimum required
torque setting of 260-300 Nm.

4852210 (07-06) 40-23-28 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-91
363012001 and Above, S/N 363112001 and Above)
(CONT'D) 3

Differential Assembly

Figure 40-23-89
1
2 2

S2323

Insert the gear wheel (Item 1) with the spherical washer

(Item 2) and the bolt (Item 3) [Figure 40-23-91] to keep
them in position.
S2321

Figure 40-23-92
Insert the washer (Item 1) and the gear wheel (Item 2) 1
[Figure 40-23-89] on the crown wheel side.
2
Figure 40-23-90 2
3
3

1 2

S2324

Insert the gear wheels (Item 1) with the spherical washers

(Item 2) and the bolt (Item 3) [Figure 40-23-92].
S2322

Insert the gear wheel (Item 1) with the spherical washer

(Item 2) and the bolt (Item 3) [Figure 40-23-90] to keep
them in position.

4852210 (07-06) 40-23-29 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-95
363012001 and Above, S/N 363112001 and Above)
(CONT'D)
1
Differential Assembly (Cont’d)

Figure 40-23-93

S2326

Bring the pin holes in line with the help of a pin-driver

(Item 1) [Figure 40-23-95].

S2323 Figure 40-23-96

Insert the crossbolt (Item 1) [Figure 40-23-93] in the

correct position.

Figure 40-23-94
1

S2327

Insert pins (Item 1) [Figure 40-23-96] to end of stroke.

S2325

Insert the bolts in their position.

4852210 (07-06) 40-23-30 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-99
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Differential Disassembly (Cont’d)

Figure 40-23-97

S2330

Torque wrench setting: 58 Nm.

Figure 40-23-100
S2328

Insert planetary gear wheel (Item 1) together with washer

(Item 2) [Figure 40-23-97].

Figure 40-23-98
2

1
1
S2331

Install the crown wheel (Item 1). Fix the screws (Item 2)
[Figure 40-23-100] of the crown wheel.

NOTE: Use LOCTITE 270 on screws not treated with

S2329
DRILOC.

Coat the nuts (Item 1) [Figure 40-23-98] with Loctite 270

and screw them.

4852210 (07-06) 40-23-31 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Differential Disassembly (Cont’d)

Figure 40-23-101

S2332

Tighten the screws of the crown wheel using the criss

cross method. Torque wrench setting: 128-142 Nm.

Figure 40-23-102

110°C
1

S2333

Heat up the roll bearings (Item 1) [Figure 40-23-102] to

110°C and insert it onto the differential.

4852210 (07-06) 40-23-32 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-105
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Steering Knuckle Assembly

T14
Figure 40-23-103

1
S2383

1 Lubricate the outer surface of the sealing ring (Item 1); fit
them into their seat using tool T14 [Figure 40-23-105].
S2382
Figure 40-23-106

Lubricate the bushing (Item 1) [Figure 40-23-103] and

the seat of the steering case. Install the bushing, using
tool T13.

Figure 40-23-104

S1499

S1497

4852210 (07-06) 40-23-33 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-109
363012001 and Above, S/N 363112001 and Above)
(CONT'D)
1
Steering Knuckle Assembly (Cont’d) 3

Figure 40-23-107

S2387

1 Fit the front sealing rings (Item 1) onto the articulation pins
(Item 2) [Figure 40-23-109].
S2384 / S2385
NOTE: Carefully check that the rings are properly
oriented (Item 3) [Figure 40-23-109].
Using special tool T15 apply a repositionable jointing
Figure 40-23-110
compound for seals to the outer surface of the sealing ring
(Item 1). Position the sealing ring (Item 2) in the steering
case (Item 3) [Figure 40-23-107].

NOTE: Check that the ring (Item 1) [Figure 40-23-105]

is correctly oriented.

Figure 40-23-108

S2388 / S2389

Lubricate the top bush or the bottom ball bush and fit
them into the fulcrum holes of the arm.
1

S2386

If the bottom articulation pin (Item 1) [Figure 40-23-108]

has been extracted, position the pin under a press and fit
the ball cover.

4852210 (07-06) 40-23-34 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-113
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Steering Knuckle Assembly (Cont’d)

Figure 40-23-111

S2393X

Insert the u-joint (Item 1) [Figure 40-23-113].

Figure 40-23-114
S2390 / S2391

Lubricate the bushing and the seat of the steering case.

Install the bushing, using tool T13.

Figure 40-23-112

S2394

Lubricate the terminal of the u-joint and install the steering

case.

Pay due attention not to damage the dust cover rings and
S2392
the sealing rings.

Lubricate and fit the sealing ring onto tool T14; install the
rings into the arm.

IMPORTANT
Pay particular attention to the direction of assembly
of the rings.

4852210 (07-06) 40-23-35 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-117
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Steering Knuckle Assembly (Cont’d)

Figure 40-23-115

1 S2397

Lubricate the steering case.

Figure 40-23-118
S2395

Prepare a series of shims (Item 1) [Figure 40-23-115] of

0,4 up to 0,7 mm.

To be assembled under the upper pin (Item 1) [Figure 40- 2

23-113].

Figure 40-23-116 1

S2398

Fit the unit (Item 1) in the steering case (Item 2)

[Figure 40-23-118]. Position the screws and tightly
tighten.

S2396

Lubricate and install the unit in the steering case.

4852210 (07-06) 40-23-36 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-121
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Steering Knuckle Assembly (Cont’d)

Figure 40-23-119

S2401

Check by means of a lever that there is no vertical gap.

In case there is any gap, determine the width and reduce

S2399
it by removing shims.

Figure 40-23-122
Tighten the new fittin screws (Item 1) [Figure 40-23-119]
of top articulation pins in sequence using the cross
tightening method.

Torque wrench setting: 90 - 100 Nm.

Figure 40-23-120

S2402X

Check the torque of the pins, which has to be between 40

1 and 80 Nm. If the preliminary measured value is too high,
the shims have to be increased.
S2400

Tighten the new fittin screws (Item 1) [Figure 40-23-120]

of bottom articulation pins in sequence using the cross
tightening method.

Torque wrench setting: 90 - 100 Nm.

4852210 (07-06) 40-23-37 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Steering Knuckle Assembly (Cont’d)

Figure 40-23-123

S2403X

Look for the position of the notch regarding the safety

cotter pin hole when the nut is fi naly locked max 300 Nm.

Figure 40-23-124

S2404

Bring the lockscrew to the quote at the measure

previously survey.

4852210 (07-06) 40-23-38 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-127
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Planetary Carrier Assembly 1

Figure 40-23-125

S2409

Install the external bearing (Item 1) [Figure 40-23-127].

NOTE: Move the bearing to the limit stop by

S2405 / S2406
hammering lightly all around the edge.

Position a proper tool and the thrust block of the external

bearing (Item 1) [Figure 40-23-125].
Figure 40-23-128
Figure 40-23-126
1

1
S2410

S2407 / S2408

Install the wheel hub (Item 1) [Figure 40-23-128].

Lubricate the seats of the bearings and position the hub
(Item 1) on the proper tool; position the thrust block of the
internal bearing (Item 2) [Figure 40-23-126].

NOTE: Check that the thrust block is correctly

oriented.

4852210 (07-06) 40-23-39 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-131
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Planetary carrier Assembly (Cont’d)

Figure 40-23-129 1

S2413

Install the security flange (Item 1) [Figure 40-23-131].

Using Tecno Lube /101, grease the surface of the safety
flange that touches the crown wheel.
S2411

Figure 40-23-132
Install the crown wheel (Item 1) [Figure 40-23-129].

Figure 40-23-130
1

S2414

Coat the nuts (Item 1) [Figure 40-23-132] with Loctite 242

S2412
and screw them.

Fit the complete crown flange (Item 1) [Figure 40-23-

130].

NOTE: In order to fasten the flange, use a plastic

hammer and alternately hammer on several
equidistant points.

4852210 (07-06) 40-23-40 Bobcat T2556 & T2566

SERVICE MANUAL
.AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-135
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Planetary carrier Assembly (Cont’d) 1

Figure 40-23-133

S2417

Install the snap ring (Item 1) [Figure 40-23-135].

Figure 40-23-136
S2415

Tighten nuts (Item 1) [Figure 40-23-133] in two stages, 1

using the criss-cross method.

Initial torque wrench setting: 90 Nm.

Final torque wrench setting: 100 Nm.

Figure 40-23-134

S2418

1
Check the continuous rolling torque on the hub (Item 1)
[Figure 40-23-136].

Torque 7 - 20 Nm.

S2416

Install the distance piece (Item 1) [Figure 40-23-134].

4852210 (07-06) 40-23-41 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (FOR S/N Figure 40-23-139
363012001 and Above, S/N 363112001 and Above)
(CONT'D)

Planetary carrier Assembly (Cont’d)

Figure 40-23-137 2

S2422

Lock into position the planetary gears (Item 1) with the

snap rings (Item 2) [Figure 40-23-139].
S2419
Figure 40-23-140

1 2

IMPORTANT
Check the condition and position of the O-ring (Item
1) [Figure 40-23-137].

Figure 40-23-138

S2423

Fit the planetary gear cover (Item 1) onto the wheel hub
(Item 2) [Figure 40-23-140].
1
2 Figure 40-23-141

S2420 / S2421

Fit the planetary gear (Item 1) onto the planetary gear

cover (Item 2) [Figure 40-23-138].

IMPORTANT S2190

The jointed portion of the internal ring of the bearings Torque wrench 40-50 Nm.
must face the bottom of the pin.

4852210 (07-06) 40-23-42 Bobcat T2556 & T2566

SERVICE MANUAL
SPECIAL TOOLS

TOOL
T2556-
BOBCAT PN IMAGE DESCRIPTION T2566

6912173 PINION RING NUT T06

6912176 DUMMY PINION T09

6912178 INPUT FLANGE SEAL T11

6912179 603 DROPBOX SEAL T12

U-JOINT ARM &

6912180 T13
STEERING CASE BUSHING

6912181 U-JOINT SEAL, ARM SIDE T14

6912182 WHEEL HUB SEAL T15

6912185 603 COVER SEAL X

4852210 (07-06) 40-23-43 Bobcat T2556 & T2566

SERVICE MANUAL
TOOL
T2556-
BOBCAT PN IMAGE DESCRIPTION T2566

U-JOINT SEAL,
6912186 X
STEERING CASE SIDE

4852210 (07-06) 40-23-44 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363011001 - 363012000 and S/ Figure 40-30-3
N 363111001 - 363112000)

Removal

Figure 40-30-1

Remove the hose (Item 1) [Figure 40-30-3] from the right

side of the drive motor.

NOTE: Mark all hoses for correct installation.

Fully retract the telescoping boom and raise enough to

allow the front axle to be removed from under the frame.

Rotate the battery disconnect switch (Item 1) [Figure 40- IMPORTANT

30-1] to the right, to disconnect the power supply from the
battery. When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Drain the hydraulic reservoir. (See “Replacing Hydraulic parts clean. Always use caps and plugs on hoses,
Fluid” on page 10-100-2) tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Figure 40-30-2 I-2003-0888

Figure 40-30-4

Remove the four driveshaft mounting bolts (Item 1)

[Figure 40-30-2]. Lower the driveshaft.
Remove the hose (Item 1) [Figure 40-30-4] from the left
side of the drive motor.

4852210 (07-06) 40-30-1 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363011001 - 363012000 and S/ Figure 40-30-7
N 363111001 - 363112000) (CONT'D)

Removal (Cont'd)

Figure 40-30-5

Remove the brake tube line (Item 1) [Figure 40-30-7]

from the left side of the axle.

Figure 40-30-8

Remove the lower four bolt flange hose (Item 1) [Figure

40-30-5].

Figure 40-30-6

Remove the brake hose (Item 1) [Figure 40-30-8] from

the right side of the axle.

Remove the hose (Item 1) [Figure 40-30-6] from the drive

motor.

4852210 (07-06) 40-30-2 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363011001 - 363012000 and S/ Figure 40-30-11
N 363111001 - 363112000) (CONT'D)

Removal (Cont'd)

Figure 40-30-9

Remove the two hoses (Item 1) [Figure 40-30-11] from

the steering cylinder.

Figure 40-30-12

Unplug the two head light electrical connectors (Item 1)

[Figure 40-30-9] from the main harness.

NOTE: Mark all connectors for correct assembly.

Figure 40-30-10

Remove the tie straps (Item 1) [Figure 40-30-12] from the

brake hose and tube line.

Reposition all hoses and wires to the left side.

Unplug the electrical connector (Item 1) and remove the

tie straps (Item 2) [Figure 40-30-10].

4852210 (07-06) 40-30-3 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363011001 - 363012000 and S/ Figure 40-30-15
N 363111001 - 363112000) (CONT'D)

Removal (Cont'd)

Figure 40-30-13

Remove the electrical plug retainer bolt (Item 1). Remove

the electrical plug (Item 2) [Figure 40-30-15].

Figure 40-30-16

Remove the upper four bolt flange hose (Item 1) [Figure

40-30-13].

Figure 40-30-14

Remove the two mounting plate bolts (Item 1) [Figure 40-

30-16] from both sides.

Remove the hose (Item 1) [Figure 40-30-14] from the

drive motor.

4852210 (07-06) 40-30-4 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363011001 - 363012000 and S/ Figure 40-30-19
N 363111001 - 363112000) (CONT'D)

Removal (Cont'd)

Figure 40-30-17

P-44143

Remove the two bolts (Item 1) [Figure 40-30-19] and

remove the front fenders.

Figure 40-30-20
Lift the front of the machine and place jack stands under
the frame as shown [Figure 40-30-17].

Place a block in front and behind the rear wheel.

Figure 40-30-18

Re-route the head light harness (Item 1) out from under

the frame. Remove the two light bar mounting bolts (Item
2) [Figure 40-30-20] and remove the light bar.

Remove the eight lug nuts and washers (Item 1) [Figure

40-30-18] from each front tire.

Remove both front tires.

4852210 (07-06) 40-30-5 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363011001 - 363012000 and S/ Figure 40-30-23
N 363111001 - 363112000) (CONT'D)

Removal (Cont'd)

Figure 40-30-21

Have an assistant balance the axle on the floor jack and

lower the floor jack slowly. Roll the axle out from under the
frame [Figure 40-30-23].

Using a floor jack, apply upward pressure to lift and

support the front axle [Figure 40-30-21].

Figure 40-30-22

Remove the two axle mounting bolts (Item 1) and

mounting plates (Item 2) [Figure 40-30-22] from each
side of the axle.

4852210 (07-06) 40-30-6 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363011001 - 363012000 and S/ Figure 40-30-26
N 363111001 - 363112000) (CONT'D)

Installation

Figure 40-30-24

Install the bottom plate (Item 1) and mounting bolts and

nuts (Item 2) [Figure 40-30-26]. Tighten to 275-300 ft.-
lbs. (370-410 Nm) torque.

Figure 40-30-27
Have an assistant balance the axle on the floor jack and
roll the axle under the frame [Figure 40-30-24].

Figure 40-30-25

Route the head light harness (Item 1) through the bracket

and under the frame. Install the two mounting bolts and
nuts (Item 2) [Figure 40-30-27] and tighten to 275-300 ft.-
lbs. (370-410 Nm) torque.
Raise the floor jack, lifting the axle upward and into
position [Figure 40-30-25].

4852210 (07-06) 40-30-7 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363011001 - 363012000 and S/ Figure 40-30-30
N 363111001 - 363112000) (CONT'D)

Installation (Cont'd)

Figure 40-30-28
1

P-22279

Raise the machine and remove the two jack stands (Item
1) [Figure 40-30-30].
P-44143
Lower the jack.

Install the front fenders using two bolts (Item 1) [Figure Figure 40-30-31
40-30-28]. Tighten to 90-100 ft.-lbs. (125-140 Nm) torque.

Figure 40-30-29

Install the two bottom plate mounting bolts (Item 1)

[Figure 40-30-31]. Tighten to 275-300 ft.-lbs. (370-410
Nm) torque.
Install both front tires, tighten the nuts (Item 1) [Figure 40-
30-29] to 221 ft.-lbs. (300 Nm) torque.

4852210 (07-06) 40-30-8 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363011001 - 363012000 and S/ Figure 40-30-34
N 363111001 - 363112000) (CONT'D)

Installation (Cont'd)

Figure 40-30-32

Install the upper four bolt flange hose (Item 1) [Figure 40-
30-34] to the drive motor.

Figure 40-30-35

Plug the electrical plug (Item 1) into the axle and install
the retainer bolt (Item 2) [Figure 40-30-32].

Figure 40-30-33

Route the brake hose (Item 1) next to the tube line and
install tie straps (Item 2) [Figure 40-30-35].

Install the hose (Item 1) [Figure 40-30-33].

4852210 (07-06) 40-30-9 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363011001 - 363012000 and S/ Figure 40-30-38
N 363111001 - 363112000) (CONT'D)

Installation (Cont'd)

Figure 40-30-36

1
1

Plug in the two head light electrical connectors (Item 1)

[Figure 40-30-38].

P-22293 Figure 40-30-39

Install the two steering hoses (Item 1) [Figure 40-30-36]

on the steering cylinder.

Figure 40-30-37

Install the brake hose (Item 1) [Figure 40-30-39] to the

right side of the axle.

Plug the electrical connector (Item 1) into the axle

solenoid. Secure the electrical harness (Item 2) to the
steering hoses with tie straps (Item 3) [Figure 40-30-37].

4852210 (07-06) 40-30-10 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363011001 - 363012000 and S/ Figure 40-30-42
N 363111001 - 363112000) (CONT'D)

Installation (Cont'd)

Figure 40-30-40

Install the lower four bolt flange hose (Item 1) [Figure 40-
30-42].

Figure 40-30-43

Install the brake tube line (Item 1) [Figure 40-30-40] to

the left side of the axle.

Figure 40-30-41

Install the hose (Item 1) [Figure 40-30-43] to the left side

of the drive motor.

Install the hose (Item 1) [Figure 40-30-41] to the drive

motor.

4852210 (07-06) 40-30-11 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363011001 - 363012000 and S/ Figure 40-30-45
N 363111001 - 363112000) (CONT'D)

Installation (Cont'd)

Figure 40-30-44

Install the drive shaft using the four mounting bolts (Item
1) [Figure 40-30-45].

Fill the hydraulic reservoir. (See “Replacing Hydraulic

Fluid” on page 10-100-2)
Install the hose (Item 1) [Figure 40-30-44] to the right
side of the drive motor.

4852210 (07-06) 40-30-12 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363012001 and Above, S/N Figure 40-31-3
363112001 and Above)

Removal 1

Figure 40-31-1

S1909

Remove the hose (item 1) [Figure 40-31-3] from the right

side of the drive motor.
S1856

NOTE: Mark all hoses for correct installation.

Fully retract the telescoping boom and raise enough to
allow the front axle to be removed from under the frame.

Rotate the battery disconnect switch (item 1) [Figure 40-

31-1] to the right, to disconnect the power supply from the
IMPORTANT
battery. When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Drain the hydraulic reservoir. (See “Replacing Hydraulic parts clean. Always use caps and plugs on hoses,
Fluid” on page 10-100-2) tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Figure 40-31-2 I-2003-0888

Figure 40-31-4
1

S1914

Remove the four driveshaft mounting bolts (item 1)

[Figure 40-31-2]. Lower the driveshaft. S1911

Remove the hose (item 1) [Figure 40-31-4] from the left

side of the drive motor.

4852210 (07-06) 40-31-1 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363012001 and Above, S/N Figure 40-31-7
363112001 and Above) (CONT'D)

Removal (Cont'd)

Figure 40-31-5

1
S1909

Remove the hose (item 1) [Figure 40-31-7] from the drive

motor.
S1901
Figure 40-31-8

Remove the lower four bolt flange hose (item 1) [Figure

40-31-5].

Figure 40-31-6

1 2

1 S1856

Remove the brake tube line (item 1) [Figure 40-31-8] and

(item 2) [Figure 40-31-8] from the left side of the axle.
S1897

Remove the hose (item 2) [Figure 40-31-6] next to the

upper four bolt flange hose.

4852210 (07-06) 40-31-2 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363012001 and Above, S/N Figure 40-31-11
363112001 and Above) (CONT'D)

Removal (Cont'd)

Figure 40-31-9
1

S1856

Remove the hose (item 1) [Figure 40-31-11] on the right

side of the steering cylinder.
S1908
Figure 40-31-12

Unplug the head light electrical connector (item 1) [Figure

40-31-9] from the main harness.

NOTE: Mark all connectors for correct assembly.

1
Figure 40-31-10

S1889

Remove the hose (item 1) [Figure 40-31-12] on the left

2 side of the steering cylinder.

Remove the tie straps from the brake hose and tube line.
S1906
Reposition all hoses and wires to the left side.

Unplug the two head light electrical connector (item 2)

[Figure 40-31-10]. Unplug the electrical connector (item
1) and remove the tie straps (item 3) [Figure 40-31-10].

4852210 (07-06) 40-31-3 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363012001 and Above, S/N
363112001 and Above) (CONT'D)

Removal (Cont'd)

Figure 40-31-13

2
S1899

Remove the upper four bolt flange hose (item 1) [Figure

40-31-13]. Remove the hose (item 2) [Figure 40-31-13]
next to the upper four bolt flange hose.

Figure 40-31-14

S1915

Remove the four mounting plate bolts (item 1) [Figure 40-

31-14] from both sides.

4852210 (07-06) 40-31-4 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363012001 and Above, S/N Figure 40-31-17
363112001 and Above) (CONT'D)

Removal (Cont'd)

Figure 40-31-15
1

S1951

Remove the four bolts (item 1) [Figure 40-31-17] and

remove the front fenders.
S1916

Lift the front of the machine and place jack stands under
the frame as shown [Figure 40-31-15].

Place a block in front and behind the rear wheel.

Figure 40-31-16

S1852

Remove the eight lug nuts and washers (item 1) [Figure

40-31-16] from each front tire.

Remove both front tires.

4852210 (07-06) 40-31-5 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363012001 and Above, S/N Figure 40-31-20
363112001 and Above) (CONT'D)

Removal (Cont'd)

Figure 40-31-18

S1925

Have an assistant balance the axle on the floor jack and

lower the floor jack slowly. Roll the axle out from under the
S1916 frame [Figure 40-31-20].

Using a floor jack, apply upward pressure to lift and

support the front axle [Figure 40-31-18].

Figure 40-31-19

S1919

Remove the two axle mounting bolts (item 1) and

mounting plates (item 2) [Figure 40-31-19] from each
side of the axle.

4852210 (07-06) 40-31-6 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363012001 and Above, S/N Figure 40-31-23
363112001 and Above) (CONT'D)

Installation

Figure 40-31-21
2

S1919

Install the bottom plate (item 1) and mounting bolts and

nuts (item 2) [Figure 40-31-23]. Tighten to 275-300 ft.-lbs.
S1925 (370-410 Nm) torque.

Figure 40-31-24
Have an assistant balance the axle on the floor jack and
roll the axle under the frame [Figure 40-31-21].

Figure 40-31-22
1

S1856

Install the front fenders using four bolts (item 1) [Figure

S1916 40-31-24]. Tighten to 90-100 ft.-lbs. (125-140 Nm) torque.

Raise the floor jack, lifting the axle upward and into
position [Figure 40-31-22].

4852210 (07-06) 40-31-7 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363012001 and Above, S/N Figure 40-31-27
363112001 and Above) (CONT'D)

Installation (Cont'd)

Figure 40-31-25
1

S1915

Install the four bottom plate mounting bolts (item 1)

[Figure 40-31-27]. Tighten to 275-300 ft.-lbs. (370-410
S1852
Nm) torque.

Install both front tires, tighten the nuts (item 1) [Figure 40-
31-25] to 221 ft.-lbs. (300 Nm) torque.

Figure 40-31-26

S1916

Raise the machine and remove the two jack stands

(item 1) [Figure 40-31-26].

Lower the jack.

4852210 (07-06) 40-31-8 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363012001 and Above, S/N Figure 40-31-30
363112001 and Above) (CONT'D)

Installation (Cont'd)

Figure 40-31-28 1

1
S1887

install the hose (item 1) [Figure 40-31-30] on the right

2 side of the steering cylinder.
S1899
Figure 40-31-31
Install the upper four bolt flange hose (item 1) [Figure 40-
31-28]. Install the hose (item 2) [Figure 40-31-28] next to
1
the upper four bolt flange hose.

Figure 40-31-29 3

1
2

S1906

Connect the two head light electrical connector (item 2)

[Figure 40-31-31]. Unplug the electrical connector (item
1) and remove the tie straps (item 3) [Figure 40-31-31].
S1889

Install the hose (item 1) [Figure 40-31-29] on the left side

of the steering cylinder.

Install the tie straps from the brake hose and tube line.

4852210 (07-06) 40-31-9 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363012001 and Above, S/N
363112001 and Above) (CONT'D)

Installation (Cont'd)

Figure 40-31-32

S1911

Connect the head light electrical connector (item 1)

[Figure 40-31-32] from the main harness.

NOTE:Mark all connectors for correct assembly.

Figure 40-31-33

1 2

S1885

Install the brake tube line (item 1) [Figure 40-31-33] and

(item 2) [Figure 40-31-33] from the left side of the axle.

4852210 (07-06) 40-31-10 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363012001 and Above, S/N Figure 40-31-36
363112001 and Above) (CONT'D)

Installation (Cont'd) 1

Figure 40-31-34

1
S1909

Install the hose (item 1) [Figure 40-31-36] from the right

side of the drive motor.
S1901
NOTE: Mark all hoses for correct installation.

Install the brake tube line (item 1) [Figure 40-31-34] to

the left side of the axle.

Figure 40-31-35 IMPORTANT

When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
1 damage the system.
I-2003-088

Figure 40-31-37

S1911

Install the hose (item 1) [Figure 40-31-35] from the left

side of the drive motor.

S1914

Install the four driveshaft mounting bolts (item 1) [Figure

40-31-37]. Lower the driveshaft.

4852210 (07-06) 40-31-11 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT AXLE (For S/N 363012001 and Above, S/N
363112001 and Above) (CONT'D)

Installation (Cont'd)

Figure 40-31-38

S1856

Rotate the battery disconnect switch (item 1) [Figure 40-

31-38] to the right, to disconnect the power supply from
the battery.

Fill the hydraulic reservoir. (See “Replacing Hydraulic

Fluid” on page 10-100-2)

4852210 (07-06) 40-31-12 Bobcat T2556 & T2566

SERVICE MANUAL
AXLE TOE-IN (For S/N 363011001 - 363012000 and S/ Figure 40-40-3
N 363111001 - 363112000)

Adjustment

The axle is removed from the machine for photo clarity,

but this procedure may be completed with the axle
installed in the machine.

Turn the steering wheel until the steering cylinder rod is

positioned in the center. Measure the exposed part of the
cylinder rod on each side of the cylinder housing making
sure they are the same length.

Figure 40-40-1

If measurement is not the same, adjust both tie rod ends

(Item 1) by loosening or tightening the track rods (Item 2)
[Figure 40-40-3] of both tie rods until the measurement is
the same.

Tighten the nut (Item 3) [Figure 40-40-3] to 221 ft.-lbs.

(300 Nm) torque.

Install two identical, straight bars (Item 1) [Figure 40-40-

1] onto the wheel hub and secure them using lug nuts.

NOTE: The two bars must be perpendicular to the

ground.

Figure 40-40-2

Measure the distance between the ends of the two bars

[Figure 40-40-2]. The measurement must be equal.

4852210 (07-06) 40-40-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 40-40-2 Bobcat T2556 & T2566
SERVICE MANUAL
AXLE TOE-IN (For S/N 363012001 and Above, S/N Figure 40-41-3
363112001 and Above)

Adjustment

The axle is removed from the machine for photo clarity, 1 2

but this procedure may be completed with the axle
installed in the machine.
3
Turn the steering wheel until the steering cylinder rod is
positioned in the center. Measure the exposed part of the
cylinder rod on each side of the cylinder housing making
sure they are the same length.

Figure 40-41-1
S2056

e ter If measurement is not the same, adjust both tie rod ends
1m (item 1) by loosening or tightening the track rods (item 2)
[Figure 40-41-3] of both tie rods until the measurement is
the same.

Tighten the nut (item 3) [Figure 40-41-3] to 221 ft.-lbs.

1
(300 Nm) torque.

S2056

Install two identical, straight bars (item 1) [Figure 40-41-

1] onto the wheel hub and secure them using lug nuts.

NOTE: The two bars must be perpendicular to the

ground.

Figure 40-41-2

S2056

Measure the distance between the ends of the two bars

[Figure 40-41-2]. The measurement must be equal.

4852210 (07-06) 40-41-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 40-41-2 Bobcat T2556 & T2566
SERVICE MANUAL
PARKING BRAKE (For S/N 363011001 - 363012000 and Figure 40-50-2
S/N 363111001 - 363112000)

Releasing The Brake For Towing

1
Figure 40-50-1

Towing
Position

P-52284

Locate the tow valve (Item 1) [Figure 40-50-2], turn

counterclockwise 90° to the towing position.

The machine is now ready to be towed.

Block all four wheels to prevent the machine from moving

once the parking brake is disabled.

Locate the six brake release bolts (three per side) on the
front axle.
Alternately turn the brake release bolts (Item 1, 2 & 3)
[Figure 40-50-1] "IN" (clockwise) 1/2 turn each until you
feel resistance. Continue to turn each release bolt in
equally 1/2 turn for a total of approximately 5 complete
turns.

4852210 (07-06) 40-50-1 Bobcat T2556 & T2566

SERVICE MANUAL
PARKING BRAKE (For S/N 363011001 - 363012000 and Figure 40-50-4
S/N 363111001 - 363112000) (CONT'D)
Operating
Re-Activating The Brake
Position
Figure 40-50-3 1

Locate the tow valve (Item 1) [Figure 40-50-4] under the

hood, turn clockwise 90° to the run position.

The parking brake is now re-activated.

Block all four wheels to prevent the machine from moving.

Locate the six brake release bolts (three per side) on the
front axle.
Alternately turn the brake release bolts (Item 1, 2 & 3)
[Figure 40-50-3] "OUT" (counterclockwise) 1/2 turn until
the torque drops off sharply. Continue to turn each release
bolt out equally 1/2 turn until the brake release bolt
presses against the bolt housing. After the brake release
bolt is touching the bolt housing turn each brake release
bolt "IN" (clockwise) a1/4 turn.

4852210 (07-06) 40-50-2 Bobcat T2556 & T2566

SERVICE MANUAL
PARKING BRAKE (For S/N 363012001 and Above, S/N Figure 40-51-3
363112001 and Above)

Releasing The Brake For Towing

1
Figure 40-51-1

Towing
Position

P-52284

Locate the tow valve (item 1) [Figure 40-51-3], turn

counterclockwise 90° to the towing position.
S1199
The machine is now ready to be towed.

Figure 40-51-2

S2064

Releasing Brake Disks: There are two screws (item 1)

[Figure 40-51-2], one at the front and one at the rear side
of the front axle. Loosen both screws just enough to so
that the U-shaped spacer can be removed. Put both
spacers in a safe space so that they will not get lost.

NOTE: This procedure is required on the front axle

only.

NOTE: Do not completely remove the screws to

prevent oil leakage.

4852210 (07-06) 40-51-1 Bobcat T2556 & T2566

SERVICE MANUAL
PARKING BRAKE (For S/N 363012001 and Above, S/N Figure 40-51-6
363112001 and Above) (CONT'D)
Operating
Re-Activating The Brake
Position
Figure 40-51-4 1

Locate the tow valve (item 1) [Figure 40-51-6] under the

hood, turn clockwise 90° to the run position.
S1199

The parking brake is now re-activated.

Figure 40-51-5

S2064

Re-tighten the screws with the U-shaped spacer removed.

Do this gradually by alternately fastening each screw 1/4
turn at a time until they bite.

NOTE: This procedure is required on the front axle

only.

NOTE: Do not completely remove the screws to

prevent oil leakage.

4852210 (07-06) 40-51-2 Bobcat T2556 & T2566

SERVICE MANUAL
STEERING ANGLE ADJUSTMENT (For S/N 363011001 Figure 40-60-3
- 363012000 and S/N 363111001 - 363112000)

Adjustment

The axle is removed from the machine for photo clarity,

but this procedure may be completed with the axle
installed in the machine.

Figure 40-60-1

Adjust the stop (Item 1) [Figure 40-60-3] as needed.

Tighten the lock nut to 110 ft.-lbs. (150 Nm) torque.

Figure 40-60-4

Install a straight bar (Item 1) onto the wheel hub and

secure using lug nuts. Turn the steering wheel completely
to one side. Place a straight bar (Item 2) [Figure 40-60-1]
on the pinion shaft.

Figure 40-60-2

Turn the steering wheel completely to the other side

[Figure 40-60-4] and repeat above procedure.

Use an angle gauge, to obtain a reading of 32-35 degrees

[Figure 40-60-2].

4852210 (07-06) 40-60-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 40-60-2 Bobcat T2556 & T2566
SERVICE MANUAL
STEERING ANGLE ADJUSTMENT (For S/N 363012001 Figure 40-61-3
and Above, S/N 363112001 and Above)

Adjustment
1
The axle is removed from the machine for photo clarity,
but this procedure may be completed with the axle
installed in the machine.

Figure 40-61-1

S2061

Adjust the stop (item 1) [Figure 40-61-3] as needed.

Tighten the lock nut to 110 ft.-lbs. (150 Nm) torque.

Figure 40-61-4
2

S2059
1

Install a straight bar (item 1) onto the wheel hub and

secure using lug nuts. Turn the steering wheel completely
to one side. Place a straight bar (item 2) [Figure 40-61-1]
on the pinion shaft.

Figure 40-61-2

S2062

Turn the steering wheel completely to the other side

[Figure 40-61-4] and repeat above procedure.

32-35
Degrees

S2060

Use an angle gauge, to obtain a reading of 32-35 degrees

[Figure 40-61-2].

4852210 (07-06) 40-61-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 40-61-2 Bobcat T2556 & T2566
SERVICE MANUAL
DRIVESHAFT For S/N 363012001 and Above, S/N 363112001 and
Above)
For S/N 363011001 - 363012000 and S/N 363111001 -
363112000 Figure 40-70-3

Removal And Installation

Figure 40-70-1
1

S1859

Remove the four drive shaft mounting bolts (item 1)

[Figure 40-70-3] from rear end of the drive shaft.

Figure 40-70-4
Remove the four drive shaft mounting bolts (item 1)
[Figure 40-70-3] from each end of the drive shaft.

Figure 40-70-2
1

S1914

Remove the four drive shaft mounting bolts (item 1)

[Figure 40-70-4] from front end of the drive shaft.

Remove the drive shaft out the rear of the machine

[Figure 40-70-2]

4852210 (07-06) 40-70-1 Bobcat T2556 & T2566

SERVICE MANUAL
DRIVESHAFT (For S/N 363012001 and Above, S/N
363112001 and Above) (CONT’D)

Figure 40-70-5

S1873

Remove the drive shaft out the rear of the machine

[Figure 40-70-5]

4852210 (07-06) 40-70-2 Bobcat T2556 & T2566

SERVICE MANUAL
SERVICE BRAKE (For S/N 363011001 - 363012000 and Figure 40-80-2
S/N 363111001 - 363112000)

Description

There are two bleed screws located on each side of the

front axle differential housing.

Air trapped in the brake lines may cause a spongy feel 1

2
and/or delayed activation of the service brake.

Use the following procedure to remove air from the brake

circuit.

Bleeding The Brake Circuit

P-44789
Lift and block the machine. (See “Procedure” on page 10-
10-1)
Figure 40-80-3
NOTE: Position the jackstands to allow starting the
machine and driving the wheels.

Figure 40-80-1

2 1
1

P-44790

Remove the caps and loosen the four bleed screws (Item
P-44788 1) and (Item 2) [Figure 40-80-2] [Figure 40-80-3].

WARNING: Hydraulic fluid will be forced from the

The bleed screws are accessible through the holes (Item bleed screws during the following procedure:
1) [Figure 40-80-1] in the main frame.
With the aid of an assistant, start the engine, lower the
restraint bar and apply the service brake until a
continuous stream of clean hydraulic fluid, with no air,
flows from the inside bleed screws (Item 1) [Figure 40-
80-2] and [Figure 40-80-3]. Stop the engine and tighten
the two inside bleed screws.

Start the machine, engage the hydrostat and turn the

wheels until a continuous stream of clean hydraulic fluid,
with no air, flows from the outside bleed screws (Item 2)
[2] and [3]. Stop the engine and tighten the two outside
bleed screws.

Lower the machine and test for proper brake operation.

4852210 (07-06) 40-80-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 40-80-2 Bobcat T2556 & T2566
SERVICE MANUAL
SERVICE BRAKE (For S/N 363012001 and Above, S/N
363112001 and Above)

Description

There are two bleed screws located on each side of the

front axle differential housing.

Air trapped in the brake lines may cause a spongy feel

and/or delayed activation of the service brake.

Use the following procedure to remove air from the brake

circuit.

Bleeding The Brake Circuit

Lift and block the machine. (See “Procedure” on page 10-

10-1)

NOTE: Position the jack stands to allow starting the

machine and driving the wheels.

Figure 40-81-1

1
2

S1885

Remove the caps and loosen the four bleed screws (item
1) and (item 2) [Figure 40-81-1].

WARNING: Hydraulic fluid will be forced from the

bleed screws during the following procedure:

With the aid of an assistant, start the engine and apply the
service brake until a continuous stream of clean hydraulic
fluid, with no air, flows from the inside bleed screws (item
1) [Figure 40-81-1]. Stop the engine and tighten the two
inside bleed screws.

Start the machine, engage the hydrostat and turn the

wheels until a continuous stream of clean hydraulic fluid,
with no air, flows from the outside bleed screws (item 2)
[2] and [3]. Stop the engine and tighten the two outside
bleed screws.

Lower the machine and test for proper brake operation.

4852210 (07-06) 40-81-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 40-81-2 Bobcat T2556 & T2566
SERVICE MANUAL
REAR AXLE (For S/N 363011001 - 363012000 and S/N Figure 40-90-2
363111001 - 363112000)

Removal

Position the machine on the work surface.

Relieve hydraulic pressure.

WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury P-47987

and possible death if proper medical treatment by a

physician familiar with this injury is not received
Lift the rear of the machine and place jackstands under
immediately.
W-2145-0290
the frame as shown.

Place a block in front and behind the front wheel [Figure

Figure 40-90-1 40-90-2].

Figure 40-90-3

1
1

P18440

P-22280
Rotate the battery disconnect switch (Item 1) [Figure 40-
90-1] to the right, to disconnect the power supply from the
battery. Remove the eight lug nuts and washers (Item 1) [Figure
40-90-3] from each rear tire.
Drain the hydraulic reservoir. (See “Replacing Hydraulic
Fluid” on page 10-100-2) Remove both rear tires.

4852210 (07-06) 40-90-1 Bobcat T2556 & T2566

SERVICE MANUAL
REAR AXLE (For S/N 363011001 - 363012000 and S/N
363111001 - 363112000) (CONT’D)

Removal (Cont’d) IMPORTANT

Figure 40-90-4 When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure 40-90-6

1
1

P-44941

Remove the two bolts (Item 1) [Figure 40-90-4] and

remove the rear fenders.

Figure 40-90-5

P-44943

Remove the hose (Item 1) [Figure 40-90-6] from the

steering cylinder.

1 NOTE: Mark all hoses for correct installation.

Figure 40-90-7

1
P-44942

Remove the four bolts (Item 1) [Figure 40-90-5] and nuts

from the driveshaft.

P-44944

Remove the hose (Item 1) [Figure 40-90-7] from the

steering cylinder.

4852210 (07-06) 40-90-2 Bobcat T2556 & T2566

SERVICE MANUAL
REAR AXLE (For S/N 363011001 - 363012000 and S/N Figure 40-90-10
363111001 - 363112000) (CONT’D)

Removal (Cont’d)

Figure 40-90-8

P-44945

Remove the two bolts (Item 1) [Figure 40-90-10] from the

front mount bracket.
P-44951
Figure 40-90-11

Disconnect the electrical connector (Item 1) [Figure 40-

90-8].

Figure 40-90-9

1
1

P-44946

Remove the two bolts (Item 1) [Figure 40-90-11] from the

1 1 rear mount bracket.
P-47989

Install two jackstands (Item 1) [Figure 40-90-9] under the

axle.

4852210 (07-06) 40-90-3 Bobcat T2556 & T2566

SERVICE MANUAL
REAR AXLE (For S/N 363011001 - 363012000 and S/N Figure 40-90-14
363111001 - 363112000) (CONT’D)

Removal (Cont’d)

Figure 40-90-12

P-47988

Raise the floor jack, lifting the axle upward and into
position [Figure 40-90-14].
P-47988
Figure 40-90-15

Remove the jackstands from the axle.

Have an assistant balance the axle on the floor jack and

lower the floor jack slowly. Roll the axle out from under the
frame [Figure 40-90-12].

Installation

Figure 40-90-13

1
1
P-47989

Install jackstands (Item 1) [Figure 40-90-15] under the

axle.

P-47990

Have an assistant balance the axle on the floor jack and

roll the axle under the frame [Figure 40-90-13].

4852210 (07-06) 40-90-4 Bobcat T2556 & T2566

SERVICE MANUAL
REAR AXLE (For S/N 363011001 - 363012000 and S/N Figure 40-90-18
363111001 - 363112000) (CONT’D)

Installation (Cont’d)
1
Figure 40-90-16

P-44951
1 1

Plug the wire connector (Item 1) [Figure 40-90-18] into

the wire harness.
P-44946
Figure 40-90-19

Install the two bolts (Item 1) [Figure 40-90-16] in the rear

mount bracket.

Figure 40-90-17

P-44944
1

Install the hose (Item 1) [Figure 40-90-19] on the steering

cylinder.
P-44945

Install the two bolts (Item 1) [Figure 40-90-17] in the front

mounting bracket.

4852210 (07-06) 40-90-5 Bobcat T2556 & T2566

SERVICE MANUAL
REAR AXLE (For S/N 363011001 - 363012000 and S/N Figure 40-90-22
363111001 - 363112000) (CONT’D)

Installation (Cont’d)

Figure 40-90-20
1

1 P-44941

Install the rear fenders (Item 1) with two bolts (Item 2)

[Figure 40-90-22].
P-44943
Figure 40-90-23

Install the hose (Item 1) [Figure 40-90-20] on the steering

cylinder

Figure 40-90-21 1

P-22280

1
Install the rear tires with eight nuts (Item 1) [Figure 40-90-
23] and washers.
P-44942
Tighten the nuts to 221 ft.-lbs. (300 Nm) torque.

Install the driveshaft (Item 1) with four bolts (Item 2)

[Figure 40-90-21]. Tighten the bolts to 87 ft.-lbs. (118 Nm)
torque.

4852210 (07-06) 40-90-6 Bobcat T2556 & T2566

SERVICE MANUAL
REAR AXLE (For S/N 363011001 - 363012000 and S/N Figure 40-90-25
363111001 - 363112000) (CONT’D)

Installation (Cont’d)

Figure 40-90-24

P18440

Rotate the battery disconnect switch (Item 1) [Figure 40-

90-25] to the left, to restore the power supply from the
P-47987 battery.

Fill the hydraulic reservoir. (See Page 10-100-01.)

Raise the machine and remove the jackstands. Lower the
machine and remove the blocks from the front tire [Figure
40-90-24].

4852210 (07-06) 40-90-7 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 40-90-8 Bobcat T2556 & T2566
SERVICE MANUAL
REAR AXLE (For S/N 363012001 and Above, S/N Figure 40-91-2
363112001 and Above)

Removal

Position the machine on the work surface.

Relieve hydraulic pressure.

WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury S1857

and possible death if proper medical treatment by a

physician familiar with this injury is not received
Lift the rear of the machine and place jack stands under
immediately.
W-2145-0290
the frame as shown.

Place a block in front and behind the front wheel [Figure

Figure 40-91-1 40-91-2].

Figure 40-91-3

1
1

S1856

S1852
Rotate the battery disconnect switch (item 1) [Figure 40-
91-1] to the right, to disconnect the power supply from the
battery. Remove the eight lug nuts and washers (item 1) [Figure
40-91-3] from each rear tire.
Drain the hydraulic reservoir. (See “Replacing Hydraulic
Fluid” on page 10-100-2) Remove both rear tires.

4852210 (07-06) 40-91-1 Bobcat T2556 & T2566

SERVICE MANUAL
REAR AXLE (For S/N 363012001 and Above, S/N
363112001 and Above) (CONT’D)

Removal (Cont’d) IMPORTANT

Figure 40-91-4 When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1

Figure 40-91-6

S1951

Remove the two bolts (item 1) [Figure 40-91-4] and

remove the rear fenders.

Figure 40-91-5

S1862

Remove the hose (item 1) [Figure 40-91-6] from the

steering cylinder.

NOTE: Mark all hoses for correct installation.

1 Figure 40-91-7

S1859

Remove the four bolts (item 1) [Figure 40-91-5] and nuts

from the driveshaft.

S1864

Remove the hose (item 1) [Figure 40-91-7] from the

steering cylinder.

4852210 (07-06) 40-91-2 Bobcat T2556 & T2566

SERVICE MANUAL
REAR AXLE (For S/N 363012001 and Above, S/N Figure 40-91-10
363112001 and Above) (CONT’D)

Removal (Cont’d)

Figure 40-91-8

S1872
1
Remove the two bolts (item 1) [Figure 40-91-10] from the
front mount bracket.
S1870
Figure 40-91-11

Disconnect the electrical connector (item 1) [Figure 40-

91-8].

Figure 40-91-9

1
1

S1871

1 Remove the two bolts (item 1) [Figure 40-91-11] from the

rear mount bracket.
1 S1874

Install two jack stands (item 1) [Figure 40-91-9] under the

axle.

4852210 (07-06) 40-91-3 Bobcat T2556 & T2566

SERVICE MANUAL
REAR AXLE (For S/N 363012001 and Above, S/N Figure 40-91-14
363112001 and Above) (CONT’D)

Removal (Cont’d)

Figure 40-91-12

1
1
S1874

Install jack stands (item 1) [Figure 40-91-14] under the

axle.
S1876

Remove the jack stands from the axle.

Have an assistant balance the axle on the floor jack and

lower the floor jack slowly. Roll the axle out from under the
frame [Figure 40-91-12].

Installation

Figure 40-91-13

S1876

Have an assistant balance the axle on the floor jack and

roll the axle under the frame [Figure 40-91-13].

Raise the floor jack, lifting the axle upward and into
position.

4852210 (07-06) 40-91-4 Bobcat T2556 & T2566

SERVICE MANUAL
REAR AXLE (For S/N 363012001 and Above, S/N Figure 40-91-17
363112001 and Above) (CONT’D)

Installation (Cont’d)
1
Figure 40-91-15

S1870
1
1
Plug the wire connector (item 1) [Figure 40-91-17] into
the wire harness.
S1871
Figure 40-91-18

Install the two bolts (item 1) [Figure 40-91-15] in the rear

mount bracket.

Figure 40-91-16

1 S1864

Install the hose (item 1) [Figure 40-91-18] on the steering

cylinder.
S1872

Install the two bolts (item 1) [Figure 40-91-16] in the front

mounting bracket.

4852210 (07-06) 40-91-5 Bobcat T2556 & T2566

SERVICE MANUAL
REAR AXLE (For S/N 363012001 and Above, S/N Figure 40-91-21
363112001 and Above) (CONT’D)

Installation (Cont’d)

Figure 40-91-19
2

1 S1951

Install the rear fenders (item 1) with four bolts (item 2)

[Figure 40-91-21].
S1862
Figure 40-91-22

Install the hose (item 1) [Figure 40-91-19] on the steering

cylinder

Figure 40-91-20 1

1 S1852

Install the rear tires with eight nuts (item 1) [Figure 40-91-
2 22] and washers.
S1859
Tighten the nuts to 221 ft.-lbs. (300 Nm) torque.

Install the driveshaft (item 2) with four bolts (item 1)

[Figure 40-91-20]. Tighten the bolts to 87 ft.-lbs. (118 Nm)
torque.

4852210 (07-06) 40-91-6 Bobcat T2556 & T2566

SERVICE MANUAL
REAR AXLE (For S/N 363012001 and Above, S/N
363112001 and Above) (CONT’D)

Installation (Cont’d)

Figure 40-91-23

S1857

Raise the machine to remove the jack stands. Lower the

machine and remove the blocks from the front tire [Figure
40-91-23].

Figure 40-91-24

S1853

Rotate the battery disconnect switch (item 1) [Figure 40-

91-24] to the left, to restore the power supply from the
battery.

Fill the hydraulic reservoir. (See “Replacing Hydraulic

Fluid” on page 10-100-2)

4852210 (07-06) 40-91-7 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 40-91-8 Bobcat T2556 & T2566
SERVICE MANUAL
MAIN FRAME

AIR INTAKE COWLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-71-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-71-1

BOOM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

CANOPY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11-1

DASH COVER/STEERING COLUMN COVER . . . . . . . . . . . . . 50-130-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1

ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Gas Cylinder Removal And Installation. . . . . . . . . . . . . . . . . . 50-70-1

FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Removal And Installation (For S/N 363011001 - 363012000 and S/N
363111001 - 363112000). . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

INNER BOOM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

JOYSTICK PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Not available at time of printing . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

QUICK TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

REAR WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

WEAR PADS (FRONT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

WEAR PADS (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

4852210 (07-06) 50-01-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 50-01-2 Bobcat T2556 & T2566
SERVICE MANUAL
OPERATOR CAB Figure 50-10-3

Removal And Installation

Figure 50-10-1

1
1
2

1
P18438

Remove the three screws (Item 1) from the access cover

P-24098 (Item 2) [Figure 50-10-3] located on the back of the cab.

Remove the access cover.

Raise the boom and install the boom stop (Item 1) [Figure
50-10-1]. Remove the battery. (See “Removal And Installation” on
page 60-20-1)
Relieve the hydraulic pressure.
Figure 50-10-4
Figure 50-10-2

1
1

P-53565
P18440

Unplug the electrical connectors (Item 1) [Figure 50-10-4]

Rotate the battery disconnect switch (Item 1) [Figure 50- in the battery box.
10-2] to the right, to disconnect the power supply from the
battery. NOTE: Mark all electrical connectors, hoses and
tubelines for correct assembly.

4852210 (07-06) 50-10-1 Bobcat T2556 & T2566

SERVICE MANUAL
OPERATOR CAB (CONT’D) Figure 50-10-7

Removal And Installation (Cont’d)

Figure 50-10-5

1
1

P-53571

1
Remove the side cover (Item 1) [Figure 50-10-7].
P-53566
If machine is equipped with air conditioning, remove the
refrigerant from the A/C system. (See “Reclamation
Remove the two bolts (Item 1) [Figure 50-10-5] and
Procedure” on page 80-100-1)
separate the main harness connector.
Figure 50-10-8
Figure 50-10-6

P-53572
P-53570

Remove the cover (Item 1) [Figure 50-10-8].

Remove the fuse box cover (Item 1) [Figure 50-10-6].

4852210 (07-06) 50-10-2 Bobcat T2556 & T2566

SERVICE MANUAL
OPERATOR CAB (CONT’D) Figure 50-10-11

Removal And Installation (Cont’d)

Figure 50-10-9

P-53585

Unplug the connector (Item 1) [Figure 50-10-11] located

P-53573 under the fuse box.

Figure 50-10-12
Temporarily remove the protective covering (Item 1)
[Figure 50-10-9] from the A/C hoses and expansion
valve.

Figure 50-10-10

1
1
P-53575

Loosen the mounting bracket bolt (Item 1) [Figure 50-10-

12].
P-53574

Remove the bolt (Item 1) and plate (Item 2) [Figure 50-

10-10]. Remove the A/C hoses.

NOTE: Plug the A/C hoses to prevent contamination.

4852210 (07-06) 50-10-3 Bobcat T2556 & T2566

SERVICE MANUAL
OPERATOR CAB (CONT’D)

Removal And Installation (Cont’d)

IMPORTANT
Figure 50-10-13
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure 50-10-15

1
P-53576
1

Remove the two A/C hoses (Item 1) and harness (Item 2)

[Figure 50-10-13] completely from the rear corner of the 1
cab.

Figure 50-10-14 1

P-53581

1 Remove the five hoses (Item 1) [Figure 50-10-15].

Figure 50-10-16

1
1

P-53577

Remove the nut and washer (Item 1) and remove the

ground wires (Item 2) [Figure 50-10-14].
1
P-53602

WARNING Remove the three hoses (Item 1) [Figure 50-10-16] from

Hydraulic fluid escaping under pressure can have the brake valve. Remove any necessary tie straps.
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290

4852210 (07-06) 50-10-4 Bobcat T2556 & T2566

SERVICE MANUAL
OPERATOR CAB (CONT’D) Figure 50-10-19

Removal And Installation (Cont’d)

Figure 50-10-17

P-53604

Remove the engine speed control cable (Item 1) [Figure

P-47976 50-10-19] from the bracket.

Figure 50-10-20
Remove the seven hoses [Figure 50-10-17].

Open the engine cover.

Figure 50-10-18

P-47977

Install a hoist to lift and support the operator cab [Figure

50-10-20].
P-53603

Remove the engine speed control cable (Item 1) [Figure

50-10-18].

4852210 (07-06) 50-10-5 Bobcat T2556 & T2566

SERVICE MANUAL
OPERATOR CAB (CONT’D) Figure 50-10-23

Removal And Installation (Cont’d)

Figure 50-10-21

2
1 1

P-47981

Remove the nut (Item 1) and bolt. Remove the grounding

P-47978 strap (Item 2) [Figure 50-10-23].

Figure 50-10-24
Remove the operator cab mount bolt (Item 1) and washer
(Item 2) [Figure 50-10-21] from the front of the cab.

Figure 50-10-22

P-47979

Loosen the rear mounting bolt (Item 1) [Figure 50-10-24],

P-52743 remove the nut.

NOTE: The bolt cannot be removed from the mount.

Remove the rear cover (Item 1) [Figure 50-10-22] from
the machine.

4852210 (07-06) 50-10-6 Bobcat T2556 & T2566

SERVICE MANUAL
OPERATOR CAB (CONT’D)

Removal And Installation (Cont’d)

Figure 50-10-25

1
P-47980

Figure 50-10-26

2 2

P-49050

Remove the bolts (Item 10 [Figure 50-10-25] nuts (Item

1) and rubber cushions (Item 2) [Figure 50-10-26].

Figure 50-10-27

P-47982

Lift and remove the operator cab [Figure 50-10-27].

4852210 (07-06) 50-10-7 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 50-10-8 Bobcat T2556 & T2566
SERVICE MANUAL
OPERATOR SEAT

Not available at time of printing

4852210 (07-06) 50-20-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 50-20-2 Bobcat T2556 & T2566
SERVICE MANUAL
BOOM ASSEMBLY Figure 50-30-3

Removal And Installation

Figure 50-30-1

Place a wood block (Item 1) [Figure 50-30-3] under the

lift cylinder/bucket positioning cylinder.

Figure 50-30-4
Lower the boom onto adequate stands or blocks as
shown [Figure 50-30-1].

Figure 50-30-2

Remove the pivot pin retainer pin (Item 1) [Figure 50-30-

4] from the lift cylinder/bucket positioning cylinder.
P-52746

Remove the rear cover (Item 1) [Figure 50-30-2] from the

machine.

4852210 (07-06) 50-30-1 Bobcat T2556 & T2566

SERVICE MANUAL
BOOM ASSEMBLY (CONT'D) Figure 50-30-7

Removal And Installation (Cont'd)

Figure 50-30-5

Lift and support the cylinders using a hoist and lifting strap
(Item 1). Remove the cinch strap (Item 2) [Figure 50-30-
7].

Support both cylinders using a cinch strap (Item 1) Figure 50-30-8

[Figure 50-30-5].

Figure 50-30-6

Lower both cylinders onto a wood block (Item 1) [Figure

50-30-8].

Remove the lift cylinder pivot pin using a pin removal tool
(Item 1) [Figure 50-30-6].

NOTE: See “Removal And Installation” on page 20-20-

1 for more information on removing and
installing the lift cylinder.

4852210 (07-06) 50-30-2 Bobcat T2556 & T2566

SERVICE MANUAL
BOOM ASSEMBLY (CONT'D) Figure 50-30-11

Removal And Installation (Cont'd)

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure 50-30-9
Disconnect the six hydraulic hoses (Item 1) [Figure 50-
30-11] from the tubelines.

NOTE: Mark the hoses for correct installation.

Figure 50-30-12

Disconnect the secondary auxiliary harness connector

(Item 1) [Figure 50-30-9].

Figure 50-30-10

Install a lifting chain (Item 1) [Figure 50-30-12] on the

front of the boom.

Disconnect the light harness connector (Item 1) [Figure

50-30-10].

4852210 (07-06) 50-30-3 Bobcat T2556 & T2566

SERVICE MANUAL
BOOM ASSEMBLY (CONT'D) Figure 50-30-16

Removal And Installation (Cont'd)

Figure 50-30-13

Lift and remove the boom assembly [Figure 50-30-16].

Install a lifting chain (Item 1) [Figure 50-30-13] at the rear

of the boom.

Figure 50-30-14

Remove the bolt (Item 1) and washer (Item 2) [Figure 50-

30-14] from the boom pin.

Figure 50-30-15

Remove the boom pin [Figure 50-30-15].

4852210 (07-06) 50-30-4 Bobcat T2556 & T2566

SERVICE MANUAL
INNER BOOM Figure 50-40-3

Removal

Figure 50-40-1

Disconnect the light harness connector (Item 1) [Figure

50-40-3].
P-52746

Remove the rear cover (Item 1) [Figure 50-40-1].

IMPORTANT
Remove the front wear pads. (See “Removal And
Installation” on page 50-50-1) When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Figure 50-40-2 parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure 50-40-4

Disconnect the secondary auxiliary harness connector

(Item 1) [Figure 50-40-2] (if equipped).

Remove the six hydraulic hoses (Item 1) [Figure 50-40-4]

from the tubelines.

NOTE: Mark the hoses for correct installation.

4852210 (07-06) 50-40-1 Bobcat T2556 & T2566

SERVICE MANUAL
INNER BOOM (CONT'D) Figure 50-40-6

Removal (Cont'd)

Figure 50-40-5

Begin sliding the inner boom from the main boom. Before
the inner boom is completely removed, position a hoist
and lifting strap on the inner boom. Carefully continue to
remove the inner boom completely [Figure 50-40-6].
Place a wood block (Item 1) under the cylinder for
support. Remove the bolt (Item 2) [Figure 50-40-5] from
the cylinder.

Loosen the rear wear pad adjusting bolts (Item 3) [Figure

50-40-5].

4852210 (07-06) 50-40-2 Bobcat T2556 & T2566

SERVICE MANUAL
INNER BOOM (CONT'D) Figure 50-40-9

Installation

Figure 50-40-7

Install the bolt (Item 1) [Figure 50-40-9] through the

support pin and into the cylinder. Tighten the bolt to 221
ft.-lbs. (300 Nm) torque.

Apply grease to the inside top and bottom corners of the Remove the wood block (Item 2) [Figure 50-40-9].
main boom [Figure 50-40-7].
Figure 50-40-10
Figure 50-40-8

Install the six hoses (Item 1) [Figure 50-40-10] on the

Install the end of the inner boom (Item 1) into the main tubelines.
boom (Item 2) [Figure 50-40-8] approximately 2 ft. (610
mm).

Install the front wear pads. (See “Removal And

Installation” on page 50-50-1)

Remove the lifting strap and slide the inner boom fully into
the main boom.

4852210 (07-06) 50-40-3 Bobcat T2556 & T2566

SERVICE MANUAL
INNER BOOM (CONT'D) Figure 50-40-13

Installation (Cont'd)

Figure 50-40-11 1

P-52746

Install the rear cover (Item 1) [Figure 50-40-13].

Reconnect the light harness connector (Item 1) [Figure

50-40-11].

Figure 50-40-12

Reconnect the front auxiliary harness connector (Item 1)

[Figure 50-40-12].

Adjust the wear pads. (See “Removal And Installation” on

page 50-50-1)

4852210 (07-06) 50-40-4 Bobcat T2556 & T2566

SERVICE MANUAL
WEAR PADS (FRONT) Figure 50-50-3

Removal And Installation

Figure 50-50-1

Remove the wear pad (Item 1) and inner support (Item 2)

[Figure 50-50-3].

With both upper wear pads removed, use a hoist and

Extend the inner boom approximately 2 ft. (610 mm) and lifting strap at the end of the boom, apply upwards
mark the location of the inner supports and wear pads pressure, lifting the inner boom off the bottom wear pads.
(Item 1) [Figure 50-50-1].
Figure 50-50-4
Figure 50-50-2

Remove the bottom wear pads (Item 1) [Figure 50-50-4].

Remove the four bolts (Item 1) and two blocks (Item 2)
[Figure 50-50-2] from the boom.

Installation: Tighten the bolts to 43 ft.-lbs. (58 Nm).

4852210 (07-06) 50-50-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 50-50-2 Bobcat T2556 & T2566
SERVICE MANUAL
WEAR PADS (REAR) Figure 50-60-3

Removal

Remove the inner boom. (See “Removal” on page 50-40-

1)

Figure 50-60-1

Install the new wear pad (Item 1) [Figure 50-60-3].

Figure 50-60-4

With the inner boom supported, remove the wear pad

(Item 1) [Figure 50-60-1].

NOTE: Grease was removed for photo clarity.

Installation

Figure 50-60-2

Apply grease to the wear pads [Figure 50-60-4].

Install the inner boom. (See “Installation” on page 50-40-

3) DO NOT hook up hoses at this time.

Loosen the adjustment screw (Item 1) until the adjusting

plate (Item 2) is flush with the wear pad retainer (Item 3)
[Figure 50-60-2].

4852210 (07-06) 50-60-1 Bobcat T2556 & T2566

SERVICE MANUAL
WEAR PADS (REAR) (CONT'D) Figure 50-60-7

Installation (Cont'd)

Figure 50-60-5

Connect the secondary auxiliary harness (Item 1) [Figure

50-60-7].

Figure 50-60-8
Turn the adjusting bolts (Item 1) [Figure 50-60-5] equally,
centering the inner boom inside the main boom. Tighten
the adjusting bolts to 29 ft.-lbs. (39 Nm) torque.

Figure 50-60-6

Connect the light harness connector (Item 1) [Figure 50-

60-8].

Install the rear cover.

Install the hoses (Item 1) [Figure 50-60-6] on the

tubelines.

4852210 (07-06) 50-60-2 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE COVER Removal And Installation

Gas Cylinder Removal And Installation Remove the gas cylinder.

Figure 50-70-1 Figure 50-70-2

P-53123

Figure 50-70-3

P-53121

Lift the engine cover [Figure 50-70-1]. Add a support to

prevent the cover from closing when the gas cylinder is
removed. P-53122

Remove the retainer clips (Item 1) [Figure 50-70-1] at

Remove the four hinge mounting bolts (Item 1) [Figure
both of the ball joints ends. Remove the ball joints from
50-70-2] and [Figure 50-70-3].
the ends.
Remove the engine cover.
Remove the gas cylinder.

WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death.
W-2113-0288

4852210 (07-06) 50-70-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 50-70-2 Bobcat T2556 & T2566
SERVICE MANUAL
AIR INTAKE COWLING Figure 50-71-3

Removal And Installation

Figure 50-71-1

P-53295

While supporting the air intake cowling remove the two

P-53297 bolts (Item 1) [Figure 50-71-3].

Remove the air intake cowling.

Figure 50-71-2

P-53296

Remove the bolt (Item 1) [Figure 50-71-1] & [Figure 50-

71-2].

4852210 (07-06) 50-71-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 50-71-2 Bobcat T2556 & T2566
SERVICE MANUAL
FUEL TANK Figure 50-70-3

Removal And Installation

Figure 50-70-1 1

P-52894

Remove the two fittings (Item 1) [Figure 50-70-3].

P-52743
Installation: Use teflon tape on the fitting threads.

Remove the rear cover (Item 1) [Figure 50-70-1]. Figure 50-70-4

Figure 50-70-2

2
1

1 2

P-52898

P-52893
Loosen the bolt (Item 1) [Figure 50-70-4] (both sides) and
slide the bracket forward.
Remove the plug (Item 1) [Figure 50-70-2] and drain the
fuel into an approved container.

After tank is drained reinstall the drain plug.

Remove the two fuel lines (Item 2) [Figure 50-70-2] mark

the hoses for correct assembly.

4852210 (07-06) 50-80-1 Bobcat T2556 & T2566

SERVICE MANUAL
FUEL TANK (CONT’D) Figure 50-70-7

Removal And Installation (Cont'd)

Figure 50-70-5 1

2
1

P-52895

Remove the bolt (Item 1) and rear plate (Item 2) [Figure

P-52919 50-70-7].

Figure 50-70-8
Unplug both tail light harnesses (Item 1) [Figure 50-70-5].

Figure 50-70-6 2

P-52896

P-52920 Remove the bolt (Item 1) (both sides) and remove the
cross bracket (Item 2) [Figure 50-70-8].

Remove the tail light harness (Item 1) [Figure 50-70-6]

from the frame. (both sides)

4852210 (07-06) 50-80-2 Bobcat T2556 & T2566

SERVICE MANUAL
FUEL TANK (CONT’D)

Removal And Installation (Cont'd)

Figure 50-70-9

P-52897

Unplug the harness (Item 1) [Figure 50-70-9] from the

fuel tank.

Figure 50-70-10

P-52899

Remove the fuel tank [Figure 50-70-10].

4852210 (07-06) 50-80-3 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 50-80-4 Bobcat T2556 & T2566
SERVICE MANUAL
QUICK TACH Figure 50-90-3

Removal And Installation

Figure 50-90-1

Remove the pivot pin [Figure 50-90-3].

Figure 50-90-4

Lower the boom onto a wood block and put a chain (Item
1) [Figure 50-90-1] around the quick tach and boom to
keep the quick tach from rotating forward.

Figure 50-90-2

Remove the pivot pin retainer bolt (Item 1) [Figure 50-90-

2].
Start the engine and retract the tilt cylinder by moving the
joystick to the right.

Stop the engine.

4852210 (07-06) 50-90-1 Bobcat T2556 & T2566

SERVICE MANUAL
QUICK TACH (CONT'D) Figure 50-90-7

Removal And Installation (Cont'd)

Figure 50-90-5

Remove the quick tach pivot pin retainer bolt (Item 1)

[Figure 50-90-7].

Figure 50-90-8
Using a hoist, lower the quick tach onto the wood blocks
[Figure 50-90-5].

Figure 50-90-6

Remove the quick tach pivot pin (Item 1) [Figure 50-90-

8].

Start the engine, raise the boom and remove the quick
Disconnect the secondary auxiliary couplers (Item 1) tach.
[Figure 50-90-6].

4852210 (07-06) 50-90-2 Bobcat T2556 & T2566

SERVICE MANUAL
REAR WEIGHTS Figure 50-100-3

Removal And Installation

Figure 50-100-1 1

P-52920

Remove the tail light harness (Item 1) [Figure 50-100-3]

P-52743 from the frame and unplug.

Figure 50-100-4
Remove the rear cover (Item 1) [Figure 50-100-1].

Figure 50-100-2

P-52921

P-52919 Position a hoist as shown to lift and support the rear

weight [Figure 50-100-4].

Disconnect the tail light harness connector (Item 1)

[Figure 50-100-2] from the main harness.

4852210 (07-06) 50-100-1 Bobcat T2556 & T2566

SERVICE MANUAL
REAR WEIGHTS (CONT'D) Figure 50-100-7

Removal And Installation (Cont'd)

Figure 50-100-5

P-52924

Slide the weight forward to release it from the mounting

P-52922 pin [Figure 50-100-7].

Figure 50-100-8
Figure 50-100-6

P-52925
P-52923

Lift and remove the weight [Figure 50-100-8].

Remove the two mounting bolts (Item 1) [Figure 50-100-
5] & [Figure 50-100-6].

4852210 (07-06) 50-100-2 Bobcat T2556 & T2566

SERVICE MANUAL
FENDER

Removal And Installation (For S/N 363011001 - Removal And Installation (For S/N 363012001 and
363012000 and S/N 363111001 - 363112000) Above, S/N 363112001 and Above)

Figure 50-110-1 Figure 50-110-2

P-42458 S1954

Remove the two fender mount bolts (item 1) [Figure 50- Remove the eight lug nuts and washers (item 1) [Figure
110-1]. Remove the fender. 50-110-2] from the tire. Remove the tire.

Installation: Tighten the bolts to 90-100 ft.-lbs. (125-140 Figure 50-110-3

Nm) torque.

S1951

Remove the four bolts (item 1) from the fender mount

brackets (item 2) [Figure 50-110-3].

Remove the fender.

Installation: Tighten the bolts to 90-100 ft.-lbs. (125-140

Nm) torque.

4852210 (07-06) 50-110-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 50-110-2 Bobcat T2556 & T2566
SERVICE MANUAL
JOYSTICK PANEL Figure 50-120-2

Removal And Installation

Remove the instrument panel. (See “Removal And

Installation” on page 60-80-1)

Remove the switch panel. (See “SWITCH PANEL” on

page 60-90-1)

Remove the dash cover/steering column cover. (See

“Removal And Installation” on page 50-130-1)

Figure 50-120-1

P-49017

Remove the joystick panel.

P-49019

Remove the fuse box cover (Item 1) and side cover (Item
2) [Figure 50-120-1].

4852210 (07-06) 50-120-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 50-120-2 Bobcat T2556 & T2566
SERVICE MANUAL
DASH COVER/STEERING COLUMN COVER Figure 50-130-3

Removal And Installation

Remove the instrument panel (See “Removal And

Installation” on page 60-80-1).
1
Remove the switch panel (See “SWITCH PANEL” on
page 60-90-1).

Figure 50-130-1

P-52330

Remove the screw (Item 1) [Figure 50-130-3] from the

right side of the dash.
1 1
Figure 50-130-4

P-52328 1

Remove the two screws (Item 1) [Figure 50-130-1] from 1

the center of the dash cover.

Figure 50-130-2

1 1
1 P-52331

1 Remove the four screws (Item 1) [Figure 50-130-4] from

the right side of the dash cover.

P-42835

Remove the two dash cover mounting screws (Item 1)

[Figure 50-130-2].

4852210 (07-06) 50-130-1 Bobcat T2556 & T2566

SERVICE MANUAL
DASH COVER/STEERING COLUMN COVER (CONT'D) Figure 50-130-7

Removal And Installation (Cont'd)

Figure 50-130-5

1
1 P-42845

Remove the two screws (Item 1) [Figure 50-130-7] from

P-52332 the right side of the column cover.

Figure 50-130-8
Remove the five screws (Item 1) [Figure 50-130-5] from
the left side of the dash cover.

Figure 50-130-6

P-42846

Remove the screw (Item 1) [Figure 50-130-8] from the

P-52335 left side of the column cover.

Lift and remove the dash cover [Figure 50-130-6].

4852210 (07-06) 50-130-2 Bobcat T2556 & T2566

SERVICE MANUAL
DASH COVER/STEERING COLUMN COVER (CONT'D)

Removal And Installation (Cont'd)

Figure 50-130-9

P-42848

Remove the steering column cover [Figure 50-130-9].

4852210 (07-06) 50-130-3 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 50-130-4 Bobcat T2556 & T2566
SERVICE MANUAL
ELECTRICAL SYSTEM AND ANALYSIS

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Adjusting The Alternator Belt. . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting). . . . . . . . . . . . . . . . . 60-20-3

BRAKE LIGHT SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . 60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Fuses, Diodes & Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

FRONT WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

INCHING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1 ELECTRICAL

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1 SYSTEM &
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1 ANALYSIS

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Light Removal And Installation . . . . . . . . . . . . . . . . . . . 60-60-2
Rear Light Removal And Installation . . . . . . . . . . . . . . . . . . . . 60-60-1

PEDAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-2
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

REAR WIPER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

SERVICE SOFTWARE (ONLY FOR S/N 363011001 AND ABOVE, S/N

363111001 AND ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-160-1
Calibrate Inch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-160-5
Connecting The Laptop Computer . . . . . . . . . . . . . . . . . . . . . . .60-160-1
Entering The Service Software . . . . . . . . . . . . . . . . . . . . . . . . . .60-160-2
Monitor Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-160-3
Warnings Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-160-4

Continued On Next Page

4852210 (07-06) 60-01-1 Bobcat T2556 & T2566

SERVICE MANUAL
ELECTRICAL SYSTEM AND ANALYSIS (CONT’D)

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3

SWITCH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Parts description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

TOP WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

TRAVEL/SIGNAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

4852210 (07-06) 60-01-2 Bobcat T2556 & T2566

SERVICE MANUAL
ELECTRICAL SYSTEM INFORMATION

Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Instructions are necessary before operating or
most common. Many of the recommended procedures servicing machine. Read and understand the
must be done by authorized Bobcat Service Personnel Operation & Maintenance Manual, Handbook and
only. signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs,
adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained
operators and failure to follow instructions can cause
injury or death.
W-2003-0199

PROBLEM CAUSE
Battery will not take charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9
Warning light comes ON. 5, 8, 9, 10, 11

KEY TO CORRECT THE CAUSE

1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.

Description Fuses, Diodes & Relays

Figure 60-10-1 Figure 60-10-2

1 1

P-24156 P-52172

The Telescopic Handler has a 12 volt, negative ground The electrical system is protexted by fuses, diodes and
alternator charging system. The electrical system is relays.
protected by fuses located in the cab in the right console
Remove the console cover (Item 1) [Figure 60-10-1].
(Item 1) [Figure 60-10-1].
Remove the cover(s) from the rows of fuses/relays/diodes
The fuses will protect the electrical system when there is (Item 1) [Figure 60-10-2] to check or replace fuses,
an electrical overload. The reason of the overload must diodes or relays.
be found before starting the engine again.
Two relays and two fuses are located in the rear of the
engine compartment. See page 60-10-4.

4852210 (07-06) 60-10-1 Bobcat T2556 & T2566

SERVICE MANUAL
ELECTRICAL SYSTEM (CONT’D)

Fuses, Diodes & Relays (Cont’d)

Figure 60-10-3

F3
F2
F1

E2
E1

S2704

4852210 (07-06) 60-10-2 Bobcat T2556 & T2566

SERVICE MANUAL
Fuses and Diodes Relays

[Figure 60-10-3] [Figure 60-10-3]

Reference Gauge Function protected Reference Function performed

1 15 A Rear work lights 1 Rear work lights

2 15 A Front work lights 2 Front work lights

3 10 A Headlights 3 Horn

4 15 A Low beam headlights 4 Not used

5 7.5 A Horn and cab light 5 Hydraulic function on boom

6 15 A High beam headlights 6 Low beam headlights

7 10 A 12 accessory plug (cigarette lighter) 7 High beam headlights

8 7.5 A Left park lights 8 Advance safety if parking brake tight

9 7.5 A Right park lights 9 Neutral start

10 7.5 A Hazard warning lights 10 Not used

11 DIODE 1 A Parking brake 11 Low travel speed

12 DIODE 1 A Advance safety if parking brake tight 12 Second hydraulic function on boom

13 10 A Second hydraulic function on boom (option) 13 Rear travel light / backup alarm

14 15 A Fuel pump 14 Fuel pump

15 7.5 A Stability indicator 15 Not used

16 3A Hydraulic function on boom 16 Not used

17 7.5 A Rotating beacon (option) 17 Not used

Brake lights, rear hydraulic options, stop 18 Not used

18 10 A
lights
19 Radio control (option)
19 7.5 A Low travel speed
20 Not used
20 15 A Front wiper
21 Cooling fan reverse (option)
21 7.5 A Transmission control box supply

22 7.5 A Engine cut-off E01 Starting motor relay

23 7.5 A Joystick E02 Preheat relay

Direction signal and boom angle
24 7.5 A
measurement E16 Air conditioning compressor (option)
25 10 A Steering mode control
E17 Air conditioning fan (option)
26 20 A Heating fan Center for the directional signals (located beneath the fuse
E18
box)
27 7.5 A Travel direction

28 7.5 A Instrument panel supply

Rear travel light and roof windscreen wiper

29 10 A
(option)
Rear windscreen wiper: Rear windscreen and
30 7.5 A
roof washer

31 10 A Boom angle measurement

Cooling fan reverse (option) and side offset

32 7.5 A
correction

01 20 A Air conditioning compressor (option)

02 7.5 A Air conditioning fan (option)

F1 50 A Switched power fuse (+)

F2 40 A Unswitched power fuse (+)

F3 50 A Preheat (glow plugs)

4852210 (07-06) 60-10-3 Bobcat T2556 & T2566

SERVICE MANUAL
ELECTRICAL SYSTEM INFORMATION (CONT’D)

Fuses, Diodes & Relays (Cont’d)

Figure 60-10-4

P-52177

2 4

1
3

P-52176

Remove the access panel at the rear of the engine

compartment. The relay/fuse receptacles are located
under the air conditioning compressor [Figure 60-10-4].

FUSES

Ref. Description Amps

1 Unswitched Power Fuse 40
2 Switched Power Fuse 50

RELAYS

Ref. Description
3 Starting Motor Relay
4 Preheat Relay

4852210 (07-06) 60-10-4 Bobcat T2556 & T2566

SERVICE MANUAL
BATTERY Figure 60-20-2

Removal And Installation

WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and rubber
gloves to keep acid off body.In case of acid contact,
wash immediately with water.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
S3092
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. Remove the tie strap (Item 1) and bolt (Item 2) [Figure
W-2065-1296
60-20-2].

Figure 60-20-1 Figure 60-20-3

S3093

Remove the three bolts (Item 1) from the battery access

door (Item 2) [Figure 60-20-1]. Always disconnect the negative cable (Item 1) [Figure 60-
20-3] first to prevent sparks.

Remove the positive battery cable (Item 2) [Figure 60-20-

3].

Remove the battery.

4852210 (07-06) 60-20-1 Bobcat T2556 & T2566

SERVICE MANUAL
BATTERY (CONT'D) Figure 60-20-5

Servicing

WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and rubber
gloves to keep acid off body.In case of acid contact,
wash immediately with water.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. Always clean the terminals and cable ends when installing
W-2065-1296 a new battery [Figure 60-20-4] and [Figure 60-20-5].

When installing the battery in the loader, do not touch any

Figure 60-20-4 metal parts with the battery terminal posts.

Connect and tighten the battery cables. Connect the

negative (-) cable last to prevent sparks.

Figure 60-20-6

The battery cables must be clean and the connections

tight. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate (baking soda) and
water solution [Figure 60-20-6].

Check the electrolyte level in the battery. Add distilled

water as needed.

Put Battery Saver (P/N 6664458) or grease on the battery

terminals and cable ends to prevent corrosion.

4852210 (07-06) 60-20-2 Bobcat T2556 & T2566

SERVICE MANUAL
BATTERY (CONT'D) Figure 60-20-7

Using A Booster Battery (Jump Starting)

WARNING
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at engine frame.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F. (16°C.) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury.
W-2066-1296 Connect the end of the first cable to the positive (+)
terminal of the booster battery. Connect the other end of
the same cable to the positive terminal (Item 1) [Figure
60-20-7] on the Telescopic Handler battery.

IMPORTANT Connect the end of the second cable to the negative (-)
terminal of the booster battery. Connect the other end of
the same cable to the Telescopic Handler where the
Damage to the alternator can occur if:
negative cable connects to the frame (Item 2) [Figure 60-
• Engine is operated with battery cables
20-7].
disconnected.
• Battery cables are connected when using a fast
Keep cables away from moving parts. Start the engine.
charger or when welding on the loader. (Remove
both cables from the battery.)
After the engine has started, remove the ground (-) cable
• Extra battery cables (booster cables) are
(Item 2) [Figure 60-20-7] first.
connected wrong.
I-2023-1285
Remove the cable from the positive terminal (Item 1)
[Figure 60-20-7].
If it is necessary to use a booster battery to start the
engine, BE CAREFUL! There must be one person in the
operator's seat and one person to connect and disconnect
the battery cables.

The key switch must be OFF. The booster battery must be

12 volt.

NOTE: The battery compartment is located in front of

the left rear tire, on the back side of the cab.

4852210 (07-06) 60-20-3 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 60-20-4 Bobcat T2556 & T2566
SERVICE MANUAL
ALTERNATOR Figure 60-30-3

Removal And Installation

Figure 60-30-1

1 P-52603

Loosen and remove the alternator adjusting bolt (Item 1)

P-52621 [Figure 60-30-3].

Figure 60-30-4
Open the engine cover.

Remove the four bolts (Item 1) and belt shield (Item 2)

[Figure 60-30-1]. 1
Figure 60-30-2

P-52604

1
Loosen and remove both mounting bolts (Item 1) [Figure
60-30-4].

P-52602 Remove the alternator.

Remove the three connectors (Item 1) [Figure 60-30-2]

from the back of the alternator.

4852210 (07-06) 60-30-1 Bobcat T2556 & T2566

SERVICE MANUAL
ALTERNATOR (CONT’D) Figure 60-30-7

Adjusting The Alternator Belt

Stop the engine.

1
Open the engine cover.

Figure 60-30-5

2
P-52606

Move the alternator until the belt has 5/16 inch (8,0 mm)
1 movement at the middle of the belt span (Item 1) [Figure
60-30-7] with 15 lbs. (20 Nm) of force.

Tighten the adjustment and mounting bolts.

P-52621
Install the belt shield.

Remove the two bolts (Item 1) and the belt shield (Item 2) Close the engine cover
[Figure 60-30-5].

Figure 60-30-6

P-52605

Loosen the two alternator mounting bolts (Item 1) [Figure

60-30-6].

Loosen the adjustment bolt (Item 2) [Figure 60-30-6].

4852210 (07-06) 60-30-2 Bobcat T2556 & T2566

SERVICE MANUAL
STARTER Figure 60-40-3

Removal And Installation

Figure 60-40-1
1

P-55920

Remove the three wires (Item 1) [Figure 60-40-3] from

P18440 the starter.

Figure 60-40-4
Rotate the battery disconnect switch (Item 1) [Figure 60-
40-1] to the right, to disconnect the power supply from the
battery.
1
Figure 60-40-2

2 1

P-55921

Remove the three nuts and bolts (Item 1) [Figure 60-40-

4] and remove the starter.
P-53364
Installation: Tighten to 40-45 ft.-lbs. (54-61 Nm) torque.

Remove the access cover mounting bolt (Item 1) and

remove the access cover (Item 2) [Figure 60-40-2].

4852210 (07-06) 60-40-1 Bobcat T2556 & T2566

SERVICE MANUAL
STARTER (CONT’D)

Parts Identification

Starter Parts Are Not serviceable.

4852210 (07-06) 60-40-2 Bobcat T2556 & T2566

SERVICE MANUAL
STARTER (CONT’D)

Disassembly/Assembly

The starter is not serviceable. If the starter is defective

please contact your dealer to order a complete starter.

4852210 (07-06) 60-40-3 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 60-40-4 Bobcat T2556 & T2566
SERVICE MANUAL
LIGHTS Figure 60-60-3

Rear Light Removal And Installation

Figure 60-60-1

1 1

1
Remove the two lens retainer screws (Item 1) [Figure 60-
60-3].
P-52743
Figure 60-60-4
Remove the four rear cover mounting bolts (Item 1)
[Figure 60-60-1]. Remove the cover.

Figure 60-60-2

Remove the two light mounting bolts (Item 1) [Figure 60-

60-4].

Remove the light assembly.

Disconnect the light harness connector (Item 1) [Figure
60-60-2] from the main harness.

4852210 (07-06) 60-60-1 Bobcat T2556 & T2566

SERVICE MANUAL
LIGHTS (CONT'D) Figure 60-60-6

Front Light Removal And Installation

Figure 60-60-5

Remove the two bolts (Item 1) [Figure 60-60-6] and

remove the light.

Disconnect the light harness connector (Item 1) [Figure

60-60-5] from the light.

4852210 (07-06) 60-60-2 Bobcat T2556 & T2566

SERVICE MANUAL
TRAVEL/SIGNAL LEVER Figure 60-70-3

Removal And Installation

1
Remove the instrument panel. See “Removal And
Installation” on page 60-80-1)

Figure 60-60-1

1
P-52344

Disconnect the two signal control wire connectors (Item 1)

[Figure 60-70-3].

Figure 60-70-4
P-52340

Rotate the battery disconnect switch (Item 1) [Figure 60-

60-1] to the right, to disconnect the power supply from the
battery.

Figure 60-70-2 1

1
1
P-52345

Remove the two screws (Item 1) [Figure 60-70-4] from

the travel/signal levers.

P-52343

Disconnect the travel control wire harness connector

(Item 1) [Figure 60-70-2].

4852210 (07-06) 60-70-1 Bobcat T2556 & T2566

SERVICE MANUAL
TRAVEL/SIGNAL LEVER (CONT’D) Figure 60-70-7

Removal And Installation (Cont’d)

Figure 60-70-5

1
P-52349

Installation: Align the pin (Item 1) in the travel lever with

P-52347 the top hole (Item 2) [Figure 60-70-7] in the steering
column.

Remove the signal lever (Item 1) [Figure 60-70-5].

Figure 60-70-6

P-52348

Remove the travel lever (Item 1) [Figure 60-70-6].

4852210 (07-06) 60-70-2 Bobcat T2556 & T2566

SERVICE MANUAL
INSTRUMENT PANEL Figure 60-80-3

Removal And Installation

1
Figure 60-80-1

P-52323

Remove the five instrument panel mounting bolts (Item 1)

[Figure 60-80-3].

Remove the temperature control knob (Item 1) [Figure Figure 60-80-4

60-80-1]. (If Equipped)

Figure 60-80-2

Tilt the instrument panel forward and unplug all

connectors [Figure 60-80-4]. Remove the instrument
panel.
Remove the nut (Item 1) [Figure 60-80-2] letting the
temperature controller fall inward. NOTE: Mark the connectors for correct installation.

4852210 (07-06) 60-80-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 60-80-2 Bobcat T2556 & T2566
SERVICE MANUAL
SWITCH PANEL

Parts description

WITHOUT AMA

39
34 14
13
35 12
15
41 32 18
33
5
19
2 17 21

16 19
4
1
30 24
20

7
19
31
22
28
8
23

3
9
29

10
10

11

WITHOUT FRAME LEVELING

36 37 38 37 40
S3087

4852210 (07-06) 60-90-1 Bobcat T2556 & T2566

SERVICE MANUAL
SWITCH PANEL (CONT’D)

Parts description (Cont’d)

1 L.H. control panel plate

2 R.H. control panel plate
3 Screw
4 Instrument panel
5 Bezel
6 Switch, beacon light
7 Warning Switch
8 Heating Control Valve
9 Fan Speed Switch
10 Bezel For outer left and right positions
11 Bezel For middle positions
12 Trailer turn indicator
13 Steering mode indicator
14 Steering mode switch
15 Lever Switch
16 Switch, head lamp
17 Working light switch
18 Fog light switch
19 Blank Plug
20 Switch, rear wiper/washer
21 Switch, roof wiper (Option)
22 Switch, transmission mode
23 Locking switch
24 Switch, aux. hydr.
28 Ignition Switch
29 Set of keys (ignition)
30 Knob
31 Set of keys
32 Screw
33 Stability indicator and wire harness
34 Washer
35 Nut
36 Support for frame leveling knob
37 Screw
38 Switch (proportional)
39 Spacer
40 Plate
41 Plug

4852210 (07-06) 60-90-2 Bobcat T2556 & T2566

SERVICE MANUAL
BRAKE LIGHT SWITCH Adjustment

Removal And Installation Figure 60-100-3

Figure 60-100-1

P-52341 Remove the dash cover/column cover. (See “Removal

And Installation” on page 50-130-1)
Remove the dash cover/column cover (See “Removal
Loosen the nut (Item 1) [Figure 60-100-2].
And Installation” on page 50-130-1)
With the brake pedal at rest, turn the adjustment bolt (Item
Unplug the switch connector (Item 1) [Figure 60-100-1]
2) [Figure 60-100-3] until it touches the brake light switch
from the wiring harness.
plug.
Figure 60-100-2
Tighten the nut (Item 1) [Figure 60-100-2].

Loosen the nut (Item 1) [Figure 60-100-2]. Remove the

switch.

4852210 (07-06) 60-100-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 60-100-2 Bobcat T2556 & T2566
SERVICE MANUAL
FRONT WIPER MOTOR Figure 60-110-3

Removal And Installation

Figure 60-110-1

Remove the two mounting bracket bolts (Item 1) [Figure

60-110-3].

Remove the dash cover/steering column cover. (See

“Removal And Installation” on page 50-130-1) Figure 60-110-4

Remove the four lower mounting bracket bolts (Item 1)

[Figure 60-110-1].

Figure 60-110-2

Reposition the steering column assembly (as shown).

Disconnect the front wiper connector (Item 1) [Figure 60-

110-2] from the main harness.

Reposition the main wire harness to the right side of the

cab.

4852210 (07-06) 60-110-1 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT WIPER MOTOR (CONT'D) Figure 60-110-8

Removal and Installation (Cont'd)

Figure 60-110-5

Remove both outer nuts (Item 1) [Figure 60-110-8].

Remove the spray tube (Item 1) [Figure 60-110-5].

Figure 60-110-6

Flip open the wiper covers and remove the two nuts (Item
1) [Figure 60-110-6].

Figure 60-110-7

Remove the wiper arms from the wiper motor shafts

[Figure 60-110-7].

4852210 (07-06) 60-110-2 Bobcat T2556 & T2566

SERVICE MANUAL
FRONT WIPER MOTOR (CONT'D) Figure 60-110-10

Removal And Installation (Cont'd)

Figure 60-110-9

Remove the wiper motor from inside the cab [Figure 60-
110-10].

Remove both inner nuts and washers (Item 1) [Figure 60-

110-9].

4852210 (07-06) 60-110-3 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 60-110-4 Bobcat T2556 & T2566
SERVICE MANUAL
TOP WIPER MOTOR Figure 60-120-3

Removal And Installation

Figure 10-120-1

Disconnect the wiper motor connector (Item 1) [Figure

60-120-3] from the harness.

Figure 60-120-4
Remove the two screws (Item 1) [Figure 10-120-1] from
the upper panel.

Figure 60-120-2

Remove the washer tube (Item 1) [Figure 60-120-4].

Slide the upper panel forward on the support rails [Figure

60-120-2].

Lower the panel.

4852210 (07-06) 60-120-1 Bobcat T2556 & T2566

SERVICE MANUAL
TOP WIPER MOTOR (CONT'D) Remove the plastic nut (Item 1) and extension post (Item
2) [Figure 60-120-7].
Removal And Installation (Cont'd)
Figure 60-120-8
Figure 60-120-5

While supporting the wiper motor inside the cab, have an

Flip open the wiper covers and remove the nut (Item 1) assistant remove the two nuts (Item 1) [Figure 60-120-8].
and clip (Item 2) [Figure 60-120-5].
Remove the wiper motor.
Figure 60-120-6

Remove the wiper arms from the wiper shafts [Figure 60-
120-6].

Figure 60-120-7

4852210 (07-06) 60-120-2 Bobcat T2556 & T2566

SERVICE MANUAL
REAR WIPER MOTOR Figure 60-130-3

Removal And Installation

Figure 60-130-1

Flip open the wiper cover and remove the nut (Item 1)
[Figure 60-130-3].

Figure 60-130-4
Remove the two screws (Item 1) [Figure 60-130-1] from
the upper panel and slide the upper panel forward.

Figure 60-130-2

Remove the wiper arm [Figure 60-130-4].

Disconnect the rear wiper motor connector (Item 1)

[Figure 60-130-2] from the harness.

4852210 (07-06) 60-130-1 Bobcat T2556 & T2566

SERVICE MANUAL
REAR WIPER MOTOR (CONT'D) Figure 60-130-6

Removal And Installation (Cont'd)

Figure 60-130-5

Remove the plastic cover (Item 1) and two nuts (Item 2)

[Figure 60-130-6].

Remove the wiper motor.

Have an assistant support the wiper motor [Figure 60-
130-5].

4852210 (07-06) 60-130-2 Bobcat T2556 & T2566

SERVICE MANUAL
PEDAL ASSEMBLY Figure 60-140-3

Removal And Installation

Figure 60-140-1

Remove the accelerator cable (Item 1) from the pedal and

mounting bracket (Item 2) [Figure 60-140-3].
P-42864
Figure 60-140-4
Remove the dash cover/column cover. (See “Removal
And Installation” on page 50-130-1)

Disconnect the two connectors (Item 1) [Figure 60-140-1]

from the brake light switch.

Figure 60-140-2

Remove the three hoses (Item 1) [Figure 60-140-4] from

the brake valve.

NOTE: Mark hoses for correct installation.

P-42865

Disconnect the connector (Item 1) [Figure 60-140-2] from

IMPORTANT
the inching switch.
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

4852210 (07-06) 60-140-1 Bobcat T2556 & T2566

SERVICE MANUAL
PEDAL ASSEMBLY (CONT’D) Figure 60-140-7

Removal and Installation (Cont’d)

Figure 60-140-5

P-42870

Remove the roll pin (Item 1) and pedal (Item 2) [Figure

60-140-7].

Remove the mounting bolts (Item 1) [Figure 60-140-5]. Figure 60-140-8

Remove the pedal assembly.

Disassembly And Assembly

2
Figure 60-140-6

2 1
1

P-42871

Installation: Align the hole (Item 1) in the pedal with the

hole (Item 2) [Figure 60-140-8] in the shaft.

P-42869

Remove the bolt (Item 1) and spring (Item 2) [Figure 60-

140-6].

4852210 (07-06) 60-140-2 Bobcat T2556 & T2566

SERVICE MANUAL
PEDAL ASSEMBLY (CONT’D) Figure 60-140-11

Disassembly And Assembly (Cont’d)

Figure 60-140-9

P-42875

Remove the shaft and bearing assembly [Figure 60-140-

P-42872 11].

Figure 60-140-12
Loosen the two set screws (Item 1) [Figure 60-140-9] on
the two bearings. 1

Figure 60-140-10
1 2

2
1 P-42876

1
Remove the flanges (Item 1) and bearings (Item 2)
P-42874 [Figure 60-140-12].

Remove the three bolts (Item 1) [Figure 60-140-10] from

both bearing flanges.

4852210 (07-06) 60-140-3 Bobcat T2556 & T2566

SERVICE MANUAL
PEDAL ASSEMBLY (CONT’D) Figure 60-140-15

Disassembly And Assembly (Cont’d)

Figure 60-140-13

P-42879

Remove the brake valve (Item 1) [Figure 60-140-15].

P-42878
Figure 60-140-16

Remove the three fittings (Item 1) [Figure 60-140-13]

from the brake valve.

Figure 60-140-14
1

2
1

1
P-42880

Remove the retainer pin (Item 1) and washer (Item 2)

2 [Figure 60-140-16].
P-42877

Remove the four bolts (Item 1) spacers (Item 2) [Figure

60-140-14] and nuts from the brake valve.

4852210 (07-06) 60-140-4 Bobcat T2556 & T2566

SERVICE MANUAL
PEDAL ASSEMBLY (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 60-140-17

P-42881

Remove the pedal (Item 1) [Figure 60-140-17].

4852210 (07-06) 60-140-5 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 60-140-6 Bobcat T2556 & T2566
SERVICE MANUAL
INCHING SWITCH Adjustment

Removal And Installation Figure 60-150-3

Figure 60-150-1

Remove the dash cover/column cover. (See “Removal

And Installation” on page 50-130-1)

Remove the tie strap (Item 1) and unplug the switch

connector (Item 2) [Figure 60-150-1] from the harness.

Figure 60-150-2

Remove the dash cover/column cover. (See “Removal

And Installation” on page 50-130-1)

With the brake pedal in the rest position, turn the

adjustment bolt (Item 1) so that it is 0.31 in. (8 mm) away
from the switch body (Item 2) [Figure 60-150-3].

Check that the potentiometer rod (Item 3) [Figure 60-150-

3] is in contact with the center of the adjusting bolt.

Remove the two mounting bolts and nuts (Item 1) [Figure When adjustment is complete, tighten the nut (Item 4)
60-150-2]. [Figure 60-150-3] without turning the adjusting bolt.

Installation:
- Before installation, make sure that the 2 resistors (see
electric diagram) are on the switch’s wiring.
- Be sure the switch is on the front side of the mounting
bracket.

Remove the switch.

4852210 (07-06) 60-150-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 60-150-2 Bobcat T2556 & T2566
SERVICE MANUAL
SERVICE SOFTWARE (ONLY FOR S/N 363011001 and Figure 60-160-3
Above, S/N 363111001 and Above)

Connecting The Laptop Computer

Figure 60-160-1
2
1

P-47342

Plug the connector (Item 1) from the laptop computer into

the nine pin connector (Item 2) [Figure 60-160-3].
P-47349
Figure 60-160-4

Remove the console cover (Item 1) [Figure 60-160-1].

Figure 60-160-2

P-47344

Open the laptop and begin [Figure 60-160-4].

P-47340

Locate the nine pin connector (Item 1) [Figure 60-160-2].

4852210 (07-06) 60-160-1 Bobcat T2556 & T2566

SERVICE MANUAL
SERVICE SOFTWARE (CONT’D) Figure 60-160-7

Entering The Service Software

Figure 60-160-5

P-45348

This is the Main Screen of the Telescopic Handler

P-45352 analyzer program [Figure 60-160-7].

Figure 60-160-8
Click the Telescopic Handler icon (Item 1) [Figure 60-
160-5] to enter the program.

Figure 60-160-6

P-45349

The options icon will take you to the options screen

P-45350 [Figure 60-160-8]. The com port can be changed, if com
port 1 is already being used.

The option screen will appear when entering the

Telescopic Handler service analyzer [Figure 60-160-6].
The com port can be changed, if com port 1 is already
being used.

4852210 (07-06) 60-160-2 Bobcat T2556 & T2566

SERVICE MANUAL
SERVICE SOFTWARE (CONT’D) Figure 60-160-11

Monitor Screen

Figure 60-160-9

1
P-45330

The Inch/Brake pedal graph (Item 1) [Figure 60-160-11]

P-45348 should move as the pedal is pressed down.

Figure 60-160-12
Select the Monitor icon (Item 1) [Figure 60-160-9].

Figure 60-160-10 1

P-45331

P-45329 The travel control position lever (Item 1) [Figure 60-160-

12] should move as the lever in the Telescopic Handler is
moved (when handbrake is off).
The Monitor screen displays the engine RPM, travel
control position, battery voltage, propel curve, sensor
voltage, brake release switch, inch/brake pedal,
transmission mode, drive switch and creep switch [Figure
60-160-10].

If one of the icons does not change when the function is

operated, the circuit is not operating properly or the
susmic controller has a malfunction.

4852210 (07-06) 60-160-3 Bobcat T2556 & T2566

SERVICE MANUAL
SERVICE SOFTWARE (CONT’D) Warnings Screen

Monitor Screen (Cont’d) Figure 60-160-14

Figure 60-160-13

1
1

2
P-45348

P-45332
Select on the warning icon (Item 1) [Figure 60-160-14].

The Work Switch is turned on, the icon (Item 1) will turn Figure 60-160-15
on and the Transmission mode will change to work (Item
2) [Figure 60-160-13].

P-45334

The warning screen will show codes and problem with the
controller [Figure 60-160-15] (only when the codes are
present).

4852210 (07-06) 60-160-4 Bobcat T2556 & T2566

SERVICE MANUAL
SERVICE SOFTWARE (CONT’D) Calibrate Inch Pedal

Warnings Screen (Cont’d) Figure 60-160-16

Error # Description
01 Sensor supply voltage-sensor volt-
age out of range
17 Software did not load properly- 1
Restart program and reload soft-
ware
18 Inch pedal calibration failed-recali-
brate the inch pedal
19 Inch/brake potentiometer-no pedal
setup done, value too low, value too
high P-45348
20 Engine speed pickup-engine speed
missed when starting engine Select the calibrate inch pedal icon (Item 1) [Figure 60-
21 Propel current-short cut, open cir- 160-16].
cuit
22 F-N-R switch-short cut between for- Figure 60-160-17
ward and reverse
23 Engine speed pickup-engine speed
interrupted
24 Hydro motor propel current-short
cut, open circuit
25 Creep drive calibration failed-recali-
brate the creep drive potentiometer
26 Creep drive potentiometer-value 1
too low, value too high
27 Motor speed pickup-motor speed
interrupted
P-45346

Click on the Start Calibration (Item 1) [Figure 60-160-17].

4852210 (07-06) 60-160-5 Bobcat T2556 & T2566

SERVICE MANUAL
SERVICE SOFTWARE (CONT’D) Figure 60-160-20

Calibrate Inch Pedal (Cont’d)

Figure 60-160-18

P-45346

1
Click the exit (Item 1) [Figure 60-160-20] to get out of the
P-45345 calibrate inch pedal.

Press the brake pedal down approximately 1/2 the stroke

and click on the set max position icon (Item 1) [Figure 60-
160-18].

Figure 60-160-19

P-45351

Release the brake pedal and click on the set min position
icon (Item 1) [Figure 60-160-19].

4852210 (07-06) 60-160-6 Bobcat T2556 & T2566

SERVICE MANUAL
LONGITUDINAL STABILITY INDICATOR Figure 60-170-2
CALIBRATION

Fitting the sensor

Figure 60-170-1

22 11
1

1. Turn off the ignition. Push buzzer button

(Item 1) [Figure 60-170-2] and hold it.
2. While holding the buzzer button (Item 1) [Figure 60-
2 170-2] pressed, start the machine. Hold the button for
2
S3084
another 5 seconds and release it when the green
LED's light up.
Remove the paint around the 2 M10-threaded holes on 3. With the machine unloaded and the boom retracted,
the rear axle and verify flatness of the surface. The raise the boom until the maximum angle.
surface must be perfectly flat.
4. Wait until the machine stabilizes.
Degrease the surface. 5. Push the buzze button (Item 1) [Figure 60-170-2] for
5 seconds and wait until the “STOP” light turns red.
Apply Loctite to the threads of both screws.
6. Lower the boom.
Fit the sensor (p/n 6910655) (Item 1) [Figure 60-170-1] 7. Take a load that can make the machine tip (do not
by alternately fastening both screws until a torque value of exceed the maximum authorized load) over and lift it
60 Nm is reached. 30 centimeters above the ground.
8. Extend the boom till the rear wheels do no longer
touch the ground. Use, if needed, the shunt key
Calibration procedure (located above the contact key).

IMPORTANT WARNING
Chain up the rear of the machine to the floor, to
The following adjustments must be done on a flat prevent tipping over too far.
surface, without braking and conform to the
telescopic handler safety prescriptions.
9. Push the buzzer button (Item 1) [Figure 60-170-2] for
5 seconds and wait until all lights of the indicator turn
on.
10. If the shunt key has been activated, turn it off now.
11. Retract the boom and then extend again to check if
the LED's (Item 2) [Figure 60-170-2] light up in the
right order and the buzzer works and if the system
works ok.
The order is: green, orange, buzzer, red and “STOP”.
Aggravating movements (such as extending the
boom) will be stopped when the “STOP” light turns
on.
12. Remove the load.

4852210 (07-06) 60-170-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 60-170-2 Bobcat T2556 & T2566
SERVICE MANUAL
ENGINE SERVICE

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . 70-40-1

ENGINE AND ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

ENGINE COMPONENTS AND TESTING . . . . . . . . . . . . . . . . . . 70-70-1

Checking The Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-9
Compression Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-11
Glow Plugs Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12
Glow Plugs Removal And Installation . . . . . . . . . . . . . . . . . . 70-70-12
Fuel Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . 70-70-4
Fuel Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Injectors Removal And Installation . . . . . . . . . . . . . . . . . 70-70-7
Fuel Lift Pump Removal And Installation . . . . . . . . . . . . . . . 70-70-10

ENGINE/HYDROSTAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

ENGINE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-71-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-71-1

FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Ring Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-4
Ring Gear Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-4

MUFFLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1

OIL COOLER/RADIATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-3
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Continued On Next Page

4852210 (07-06) 70-01-1 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE SERVICE (CONT’D)

RECONDITIONING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-1

Camshaft And Tappets Installation . . . . . . . . . . . . . . . . . . . . . .70-100-24
Camshaft And Tappets Removal . . . . . . . . . . . . . . . . . . . . . . . .70-100-23
Changing Valve Springs (With Cylinder Head Installed) . . . . . .70-100-17
Checking Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . .70-100-38
Checking Piston Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-32
Connecting Rod Bushing Replacement. . . . . . . . . . . . . . . . . . .70-100-30
Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-30
Cooling System Description . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-39
Crankshaft And Bearings Description . . . . . . . . . . . . . . . . . . . .70-100-33
Crankshaft And Bearings Installation. . . . . . . . . . . . . . . . . . . . .70-100-35
Crankshaft And Bearings Removal . . . . . . . . . . . . . . . . . . . . . .70-100-33
Crankshaft Pulley Removal And Installation . . . . . . . . . . . . . . .70-100-19
Cutting A Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-15
Cylinder Head Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-8
Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-8
Cylinder Head Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-6
Cylinder Liner Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-49
Cylinder Liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-51
Cylinder Liner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-50
Engine Block Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-47
Engine Block Disassembly And Assembly . . . . . . . . . . . . . . . .70-100-47
Engine Lubrication System Description. . . . . . . . . . . . . . . . . . .70-100-42
Exhaust Manifold Removal And Installation . . . . . . . . . . . . . . . .70-100-4
Fuel Injector Cover Removal And Installation . . . . . . . . . . . . . . .70-100-4
Front Oil Seal Removal And Installation . . . . . . . . . . . . . . . . . .70-100-19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-48
Inspection Of Crankshaft And Bearings . . . . . . . . . . . . . . . . . .70-100-35
Lubricating Oil Cooler Removal And Installation . . . . . . . . . . . .70-100-40
Oil Filter Adapter Removal And Installation . . . . . . . . . . . . . . . .70-100-43
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . .70-100-43
Oil Pressure Relief Valve Disassembly And Assembly . . . . . . .70-100-46
Oil Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . .70-100-46
Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-45
Oil Pump Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-44
Oil Screen And Pick-up Tube70-100-44

Continued On Next Page

4852210 (07-06) 70-01-2 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE SERVICE (CONT’D)

RECONDITIONING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . .70-100-1

Piston And Connecting Rod Assembly . . . . . . . . . . . . . . . . .70-100-30
Piston And Connecting Rod Installation . . . . . . . . . . . . . . . .70-100-30
Piston Cooling Jet Alignment . . . . . . . . . . . . . . . . . . . . . . . .70-100-48
Piston Cooling Jet Installation . . . . . . . . . . . . . . . . . . . . . . . .70-100-48
Piston Cooling Jet Removal . . . . . . . . . . . . . . . . . . . . . . . . .70-100-48
Piston Ring End Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-28
Piston Ring Groove Clearance . . . . . . . . . . . . . . . . . . . . . . .70-100-29
Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-28
Pistons And Connecting Rods Description . . . . . . . . . . . . . .70-100-26
Pistons And Connecting Rods Disassembly . . . . . . . . . . . . .70-100-28
Pistons And Connecting Rods Removal . . . . . . . . . . . . . . . .70-100-26
Rear Oil Seal Housing Positioning . . . . . . . . . . . . . . . . . . . .70-100-37
Rear Oil Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-37
Rear Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-37
Rocker Cover Removal And Installation . . . . . . . . . . . . . . . . .70-100-5
Rocker Shaft Disassembly And Assembly . . . . . . . . . . . . . . 70-100-11
Thermostat Removal and Installation . . . . . . . . . . . . . . . . . .70-100-40
Thermostat Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-40
Timing Case And Drive Assembly Description . . . . . . . . . . .70-100-19
Timing Case And Gear Installation . . . . . . . . . . . . . . . . . . . .70-100-21
Timing Case And Gear Removal. . . . . . . . . . . . . . . . . . . . . .70-100-20
Timing Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-19
Timing Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-19
Turbo Charger Description . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-2
Turbo Charger Removal And Installation . . . . . . . . . . . . . . . .70-100-2
Turbo Charger Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .70-100-1
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .70-100-18
Valve Depth Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-12
Valve Guides Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-13
Valve Guide Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-14
Valve Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-14
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-11
Valve Seat Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-16
Valve Springs Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-12
Valves Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-15
Water Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-41
Water Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-100-41

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-10-1

4852210 (07-06) 70-01-3 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 70-01-4 Bobcat T2556 & T2566
SERVICE MANUAL
TROUBLESHOOTING

Chart

The following troubleshooting chart is provided for assistance in location and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.

PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start (cold). 2, 5, 6, 7
Engine will not start. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10
Difficult to start. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19 20, 21
No power for engine. 9, 11, 15, 16, 17, 18, 19, 21, 22, 25, 26, 27
Engine is mis-firing. 11, 15, 16, 17, 18, 19, 20 ,21, 22, 23, 24
Too much fuel consumption. 7, 16, 17, 18, 20 ,21, 22, 28, 29, 30
Black exhaust. 16, 17, 18, 19 20, 22, 25, 27
Blue/white exhaust. 4, 7, 16, 18, 19, 22, 31, 32
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 48, 51
Engine knocking. 4, 5, 17, 18, 19 ,20, 23, 34, 35, 36, 37, 38
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 14, 20, 21, 22, 25, 26, 27, 28, 29, 40, 52
Vibration 16, 30, 50, 51, 52
High oil pressure warning. 4, 33, 36
Overheating. 18, 19, 20, 22, 25, 31, 33, 46, 47, 48, 49
Too much crankcase pressure. 25, 35, 36, 42
Poor compression. 17, 18, 22, 23, 30, 32, 34, 35, 36, 44
Start and stop. 9, 11, 13, 15, 17, 22, 23, 30
Excessive oil consumption 4, 22, 32, 36, 40, 41, 42, 43, 44, 45

4852210 (07-06) 70-10-1 Bobcat T2556 & T2566

SERVICE MANUAL
TROUBLESHOOTING (CONT'D)

Chart (Cont'd)

KEY TO CORRECT THE CAUSE

1. Battery capacity low. 27. Poor boost pressure.
2. Bad electrical connections 28. Fuel leak.
3. Faulty starter motor. 29. Lubrication oil diluted by fuel.
4. Incorrect grade of oil. 30. Sticking valves.
5. Incorrect grade of fuel. 31. Leaking head gasket.
6. Incorrect use of cold starting equipment. 32. Worn valve guides/stems.
7. Faulty cold starting equipment. 33. Faulty thermostat.
8. Insufficient fuel in tank. 34. Incorrect piston height.
9. Faulty stop control. 35. Broken/worn piston rings.
10. Broken fuel injection pump drive. 36. Worn cylinder liners.
11. Air in the fuel system 37. Worn wrist pins.
12. Restricted fuel feed. 38. Excessive camshaft end play.
13. Fuel tank vent blocked. 39. Excessive timing gear backlash.
14. Plugged fuel filters. 40. Oil leaks.
15. Faulty fuel pump. 41. New or rebuilt engine not broken in.
16. Low compression. 42. Plugged breather pipe.
17. Incorrect valve clearance. 43. Glazed cylinder liners.
18. Incorrect valve timing. 44. Worn pistons.
19. Incorrect fuel pump timing. 45. Worn valve stem seals.
20. Faulty injectors. 46. Coolant level low.
21. Faulty fuel injection pump. 47. Faulty water pump.
22. Plugged air filter. 48. Loose or broken blower fan belt.
23. Broken or weak valve springs. 49. Radiator cooling fins plugged.
24. Overheating. 50. Damaged blower fan.
25. Restricted exhaust system. 51. Loose flywheel.
26. Water in fuel. 52. Broken engine mounts.

4852210 (07-06) 70-10-2 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE SPEED CONTROL

Removal And Installation Figure 70-20-3

Figure 70-20-1

P-53128

Open the engine cover.

Remove the floor mat and insulation from the cab floor.
Remove the engine speed control cable (Item 1) [Figure
Remove the speed control cable (Item 1) from the pedal 70-20-3] from the linkage.
and mounting bracket (Item 2) [Figure 70-20-1].
Figure 70-20-4
Remove the battery box cover.

Figure 70-20-2

P-53127

Remove the engine speed control cable from the

mounting bracket (Item 2) [Figure 70-20-4].
Carefully pull the speed control cable (Item 1) [Figure 70-
Remove any necessary cable ties, carefully remove the
20-2] through the cab and into the battery box.
speed control cable.

4852210 (07-06) 70-20-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 70-20-2 Bobcat T2556 & T2566
SERVICE MANUAL
MUFFLER

Removal And Installation For S/N 363012001 and Above, S/N 363112001 and
Above:
Figure 70-30-1
Figure 70-30-3

1
1
1

P-53129
P-56708

Open the engine cover.

Remove the muffler mounting bolts (Item 1) [Figure 70-
Remove the three exhaust mounting bolts (Item 1) 30-3].
[Figure 70-30-1].
Remove the muffler.
For S/N 363011001 - 363012000, S/N 363111001 -
363112000:

Figure 70-30-2

1
P-56708

Remove the four muffler mounting bolts (Item 1) [Figure

70-30-2].

Remove the muffler.

4852210 (07-06) 70-30-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 70-30-2 Bobcat T2556 & T2566
SERVICE MANUAL
AIR CLEANER

Housing Removal And Installation Figure 70-40-2

Figure 70-40-1

P-53132

P-53131
Remove both mounting bolts (Item 1) [Figure 70-40-2].

Open the engine cover. Remove the air cleaner housing assembly.

Loosen the clamps (Item 1) [Figure 70-40-1] and remove

the hoses from the air cleaner.

4852210 (07-06) 70-40-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 70-40-2 Bobcat T2556 & T2566
SERVICE MANUAL
OIL COOLER/RADIATOR Figure 70-50-3

Removal And Installation

Remove the engine cover. (See “Removal And

Installation” on page 50-70-1)
1
Drain the hydraulic reservoir. (See “Removal And
Installation” on page 50-100-1)

Remove the fan motor. (See “Removal And Installation”

on page 20-140-1)

Figure 70-50-1

P-53302

Remove the upper hydraulic hose (Item 1) [Figure 70-50-

1
3].

Figure 70-50-4

P-53300

Remove the two lower radiator hoses (Item 1) [Figure 70-

50-1]. 1

Figure 70-50-2

P-53303

Remove the two nuts (Item 1) [Figure 70-50-4] from the

condenser (if equipped with airconditioning option).
1

P-53301

Remove the lower hydraulic hose (Item 1) [Figure 70-50-

2].

4852210 (07-06) 70-50-1 Bobcat T2556 & T2566

SERVICE MANUAL
OIL COOLER/RADIATOR (CONT’D) Figure 70-50-7

Removal And Installation (Cont'd)

Figure 70-50-5

1
1

P-22025

Remove both oil cooler/radiator mounting bolts (Item 1)

P-53304 [Figure 70-50-7] from the bottom of the engine pan.

Figure 70-50-8
Position the condenser (Item 1) [Figure 70-50-5] (as
shown).

Figure 70-50-6

P-53305

Install a hoist and chain to the oil cooler/radiator [Figure

70-50-6].

P-53307

Lift and remove the oil cooler/radiator assembly [Figure

70-50-8].

4852210 (07-06) 70-50-2 Bobcat T2556 & T2566

SERVICE MANUAL
OIL COOLER/RADIATOR (CONT’D) Figure 70-50-11

Disassembly And Assembly

Figure 70-50-9

1
2

2 1
P-53311

2
Remove the bolts (Item 1) and remove the upper bracket
P-53309 (Item 2) [Figure 70-50-11].

Figure 70-50-12
Remove the two bolts (Item 1) and remove the two
brackets (Item 2) [Figure 70-50-9].

Figure 70-50-10

1
P-53312

1 Support the oil cooler/radiator assembly as shown

P-53310 [Figure 70-50-12].

Remove both rubber mounts (Item 1) [Figure 70-50-10]

by turning counterclockwise.

4852210 (07-06) 70-50-3 Bobcat T2556 & T2566

SERVICE MANUAL
OIL COOLER/RADIATOR (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 70-50-13

1
2 1 1

P-53313

Remove the three bracket mounting bolts (Item 1) (both

sides) and remove the condenser mounting bracket (Item
2) and shroud (Item 3) [Figure 70-50-13].

4852210 (07-06) 70-50-4 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE AND ENGINE MOUNTS Figure 70-60-2

Removal And Installation

Remove the engine/hydrostat assembly. (See Page 70- 1

80-01.)

NOTE: Set the engine/hydrostat assembly on blocks,

to allow access to remove the motor mount
bolts.

Remove the hydrostatic pump. (See Page 30-40-01.)

Remove the flywheel and housing. (See Page 70-90-1.)

If equipped with air conditioning, remove the hoses from P-53806

the compressor. (See Contents page 80-110-01.)

Figure 70-60-1 Remove the hose (Item 1) [Figure 70-60-2] and

reposition.

Figure 70-60-3
1

P-53805

Remove the hose (Item 1) [Figure 70-60-1] from the P-53807

thermostat housing.

Remove the lower radiator hose (Item 1) [Figure 70-60-3]

from the water pump.

4852210 (07-06) 70-60-1 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE AND ENGINE MOUNTS (CONT’D) Figure 70-60-6

Removal And Installation (Cont’d)

Figure 70-60-4 1
2

P-53810

1
Remove the bolt and nut (Item 1) at the rear of the engine
P-53808 compartment and remove the access panel (Item 2)
[Figure 70-60-6].

Remove the intake hose (Item 1) [Figure 70-60-4] from Figure 70-60-7
the turbo.

Figure 70-60-5

2 1

1
2
1

P-53811

P-53809 Remove the two bolts (Item 1) and remove the two fuse
assemblies (Item 2) [Figure 70-60-7].

Remove the three bolts (Item 1) and exhaust tube (Item 2)

[Figure 70-60-5].

4852210 (07-06) 70-60-2 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE AND ENGINE MOUNTS (CONT’D) Figure 70-60-10

Removal And Installation (Cont’d)

Figure 70-60-8

P-53814

Install a hoist and chain to the lifting brackets [Figure 70-

P-53812 60-10] (as shown).

Figure 70-60-11
Reposition the electrical harness [Figure 70-60-8] (as
shown).

Figure 70-60-9

1 1

P18931

Remove both front engine mount bolts (Item 1) [Figure

P-53813 70-60-11].

Installation: Tighten the engine mount bolts to 185-200

Install a lifting bracket (Item 1) [Figure 70-60-9] in the ft.-lbs. (250-271 Nm) torque.
position shown.

4852210 (07-06) 70-60-3 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE AND ENGINE MOUNTS (CONT’D)

Removal And Installation (Cont’d)

Figure 70-60-12

P-53815

Lift and remove the engine [Figure 70-60-12]

4852210 (07-06) 70-60-4 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE COMPONENTS AND TESTING Figure 70-70-2

Fuel Injection Pump Removal

NOTE: Read and fully understand the following

procedure before removing the fuel injection
pump. Failure to remove the pump correctly
will result in incorrect pump timing and the 2
pump will have to be sent to an authorized
Delpi dealer to be retimed. The internal
adjustment for pump timing is tamper proof.
High and low idle adjustments of the fuel
injection pump are factory set and
adjustments cannot be made to the fuel pump. 1

Set the engine to TDC number one cylinder compression P-55774

stroke. (See Engine Timing Page 70-71-01.)

Figure 70-70-1 Loosen the lock bolt (Item 1) and move the washer (Item
2) [Figure 70-70-2] (to the position shown). Retighten the
locking screw to 12 ft.-lbs. (17 Nm) torque.

Remove the nut and washer (Item 1) [Figure 70-70-1].

1 Figure 70-70-3

P-55531

NOTE: If the fuel pump nut (Item 1) [Figure 70-70-1] is

loosened before the fuel pump timing is set
and the pump locked, the fuel pump timing will
be lost and the fuel pump will have to be sent P-55529
into the dealer to be reset.

Apply pressure counterclockwise by hand to the fuel Using a gear puller, remove the fuel pump gear [Figure
pump gear to remove backlash from the gears. 70-70-3].

4852210 (07-06) 70-70-1 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE COMPONENTS AND TESTING (CONT'D) Figure 70-70-6

Fuel Injection Pump Removal (Cont'd)

Figure 70-70-4

P-55524

Remove the fuel line (Item 1) [Figure 70-70-6] from the

P-55522 front of the pump.

Figure 70-70-7
Remove the harness (Item 1) [Figure 70-70-4].

NOTE: Mark the connectors for correct installation.

Figure 70-70-5
1

P-55525

Remove the fuel line (Item 1) [Figure 70-70-7] from the

rear of the pump.
P-55523

Remove the connector (Item 1) [Figure 70-70-5] from the

top of the pump.

4852210 (07-06) 70-70-2 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE COMPONENTS AND TESTING (CONT'D) Figure 70-70-10

Fuel Injection Pump Removal (Cont'd)

Figure 70-70-8
1

1
P-55533

Disconnect the return spring (Item 1) [Figure 70-70-10]

P-55526 from the pump linkage.

Figure 70-70-11
Remove the four fuel tubelines (Item 1) [Figure 70-70-8].

IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them. 1
I-2029-0289

Figure 70-70-9

P-55528

Remove the mount bolt (Item 1) [Figure 70-70-11] from

the bracket.

P-55527

Remove the tubeline (Item 1) [Figure 70-70-9] from the

top of the pump.

4852210 (07-06) 70-70-3 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injection Pump Installation

Fuel Injection Pump Removal (Cont'd) The engine must be set to TDC number one cylinder,
compression stroke before the pump is fitted. (See Engine
Figure 70-70-12 Timing Page 70-01.)

NOTE: The new fuel pump will be supplied with the

1 pump shaft in the locked position. Do not
1 unlock the shaft of the fuel pump until the fuel
pump gear is fitted.

Install a new O-ring onto the pump flange.

Figure 70-70-13

1
1
1
P-55532

Remove the three mount bolts (Item 1) [Figure 70-70-12]

and remove the pump.

P-55532

Install the fuel pump and tighten the three bolts (Item 1)
[Figure 70-70-13] to 18 ft.-lbs. (25 Nm) torque.

Figure 70-70-14

P-55528

Install the mount bolt (Item 1) [Figure 70-70-14]. Do not

tighten at this time.

4852210 (07-06) 70-70-4 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE COMPONENTS AND TESTING (CONT'D) Figure 70-70-17

Fuel Injection Pump Installation (Cont'd)

Figure 70-70-15
2

1
2

P-55775

Loosen the locking bolt (Item 1) and move the washer

P-55531 (Item 2) [Figure 70-70-17] to the position shown and
tighten the bolt to 9 ft.-lbs. (12 Nm) torque.

Fit the gear (Item 1) onto the tapered shaft. Make sure the Retighten the nut (Item 1) [Figure 70-70-16] to 65 ft.-lbs.
fuel pump gear is correctly in mesh with the idler gear and (88 Nm) torque.
install the washer and nut (Item 2) [Figure 70-70-15]. Do
not tighten at this time. Figure 70-70-18

NOTE: The backlash must be removed before the fuel

injection pump is released. Failure to do so will
make the fuel pump timing incorrect.
1
Figure 70-70-16

P-55776

Remove the two timing pins (Item 1) [Figure 70-70-18].

Lightly lubricate each gear with clean engine oil.

P-55530
Install the timing case cover. (See Page 70-100-19.)

Apply pressure counterclockwise by hand to the fuel Install the glow plugs. (See Page 70-70-01.)
pump gear to remove the backlash from all the gears.
Tighten the nut (Item 1) [Figure 70-70-16] to 18 ft.-lbs. Install the rocker cover. (See Page 70-100-5.)
(24 Nm) torque.

4852210 (07-06) 70-70-5 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE COMPONENTS AND TESTING (CONT'D) Figure 70-70-21

Fuel Injection Pump Installation (Cont'd)

Figure 70-70-19
1

1 1

P-55525

Install the tubelines (Item 1) [Figure 70-70-21] to the

P-55528 pump and tighten to 21 ft.-lbs. (27 Nm) torque.

Do not overtighten.
Tighten the mount bolt (Item 1) [Figure 70-70-19] to 32
ft.-lbs. (44 Nm) torque. Figure 70-70-22

Figure 70-70-20

1
1

P-55524

P-55533

Connect the return spring (Item 1) [Figure 70-70-20] to

the pump linkage.

4852210 (07-06) 70-70-6 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injectors Removal And Installation

Fuel Injection Pump Installation (Cont'd)

Figure 70-70-23
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
1 not use your bare hand. Wear safety goggles. If fluid
2
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496

Figure 70-70-25

P-55523
1

Install the two fuel lines (Item 1) [Figure 70-70-22] and 1 2

[Figure 70-70-23].

Install the electrical connector (Item 2) [Figure 70-70-23].

Figure 70-70-24
1

P-55513

Remove the three bolts (Item 1) and remove the fuel

injector cover (Item 2) [Figure 70-70-25].

1 Figure 70-70-26

1
P-55522

Install the harness (Item 1) [Figure 70-70-24].

Remove air from the system.

P-55517

Remove the breather hose (Item 1) [Figure 70-70-26].

4852210 (07-06) 70-70-7 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE COMPONENTS AND TESTING (CONT'D)

Fuel Injector Removal And Installation (Cont'd)

IMPORTANT
Figure 70-70-27
Do not bend the high pressure fuel injection tubes
3 4 when removing or installing them.
3 I-2029-0289

Figure 70-70-29
1
1 1
1

2 1

P-55518

Remove the two bolts (Item 1) and remove the breather

fitting (Item 2) [Figure 70-70-27].
P-55613
Remove the two bolts (Item 3) and remove the fuel filter
assembly (Item 4) [Figure 70-70-27].
Disconnect the injector tubelines (Item 1) [Figure 70-70-
Figure 70-70-28 29] from the injectors.

Installation: Tighten the tubelines to 20 ft.-lbs. (27 Nm)

1 torque.

Remove the tubelines.

Figure 70-70-30

1 1
1
P-55777
2

Disconnect the four injector tubelines (Item 1) [Figure 70-

70-28] from the injector pump.

Installation: Tighten the tubelines to 20 ft.-lbs. (27 Nm) 3

torque.
P-55614

Remove the fuel return hoses (Item 1) and remove the

bolt (Item 2) and clamp (Item 3) [Figure 70-70-30].

Installation: Tighten bolt to 20 ft.-lbs. (27 Nm) torque.

4852210 (07-06) 70-70-8 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE COMPONENTS AND TESTING (CONT'D) Figure 70-70-33

Fuel Injector Removal And Installation (Cont'd)

Figure 70-70-31

P-55616

Installation: Always replace the copper washer (Item 1)

P-55615 [Figure 70-70-33] at the nozzle. If the washer remains in
the cylinder head, it must be removed.

Remove the injector from the cylinder head [Figure 70- Checking The Fuel Lift Pump
70-31]].
Figure 70-70-34
Figure 70-70-32

P-55525
P-55617

Remove the fuel lift pipe (Item 1) [Figure 70-70-34] from

Installation: The roll pin must be in the position shown the injector pump, fit a suitable pipe with a pressure test
[Figure 70-70-32]. point and connect a pressure gauge.

Operate the engine at idler for two minutes to allow any

trapped air to be removed.

Standard pressure should be 4 PSI (.3 Bar).

4852210 (07-06) 70-70-9 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE COMPONENTS AND TESTING (CONT'D)

Fuel Lift Pump Removal And Installation

Figure 70-70-35

1
2

1
P-53563

Remove the two fuel lines (Item 1) and electrical harness

(Item 2) [Figure 70-70-35] from the fuel lift pump/filter
assembly.

Figure 70-70-36

1
2

P-55518

Remove the two fuel lines (Item 1) and three bolts (Item 2)
[Figure 70-70-36] and remove the fuel lift pump/filter
assembly.

4852210 (07-06) 70-70-10 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE COMPONENTS AND TESTING (CONT'D) If the measurement is below the allowable limit, check the
cylinder, piston ring, top clearance, valve and cylinder
Compression Checking head.

The tools listed will be needed to do the following Compression Pressure should be 290-570 PSI (20-35
procedure: Bar).

MEL10630 - Engine Compression Kit Compression tests should only be used to compare
MEL1352 - Compression Adapter between the cylinders of an engine. (If one or more
cylinders vary by more than 50 PSI (3.5 Bar) then those
The engine must be at operating temperature. cylinders may be faulty.

Remove the glow plugs. (See Page 70-70-14.) Figure 70-70-39

Figure 70-70-37

1
P-55633

P-55631
Push the button on the compression gauge to release
pressure [Figure 70-70-39].
Install the correct compression adapter (Item 1) [Figure
70-70-37] into the cylinder head. Connect the fuel stop solenoid.

Figure 70-70-38

P-55632

Connect the compression gauge to the adapter [Figure

70-70-38].

Make sure the engine speed control is fully backward

(engine idle).

Disconnect the fuel stop solenoid.

Crank the engine with the starter at 200-300 RPM.

4852210 (07-06) 70-70-11 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE COMPONENTS AND TESTING (CONT'D) Glow Plugs Removal And Installation

Glow Plugs Checking Disconnect the negative (-) cable from the battery.

Disconnect the glow plug cables and leads. Figure 70-70-42

Figure 70-70-40

2
P-55517

P-55629
Remove the hose clamp (Item 1), the two bolts (Item 2)
and remove the breather (Item 3) [Figure 70-70-42].
Use an ohmmeter to check the glow plugs [Figure 70-70-
40]. Figure 70-70-43

Figure 70-70-41

1
2 1
1

P-55626

P-55630
Remove the nut (Item 1) [Figure 70-70-43]] from the top
of each glow plug.
Touch one probe to the end of the glow plug and the other
probe to the body of glow plug [Figure 70-70-41]. Installation: Tighten to 1.5 ft.-lbs. (2 Nm) torque.

The reading must be between 1 and 2 ohms [Figure 70- Disconnect the engine harness wire (Item 2) [Figure 70-
70-41]. If the resistance is infinite, the coil of the glow plug 70-43] from the glow plug.
is broken.
Remove the glow plug connecting strap (Item 3) [Figure
Repeat the procedure for each glow plug. 70-70-43].

4852210 (07-06) 70-70-12 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE COMPONENTS AND TESTING (CONT'D)

Glow Plugs Removal And Installation (Cont’d)

Figure 70-70-44

1
1

P-55627

Loosen and remove the glow plugs (Item 1) [Figure 70-

70-44].

Installation: Tighten the glow plug to 13 ft.-lbs. (18 Nm)

torque.

4852210 (07-06) 70-70-13 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 70-70-14 Bobcat T2556 & T2566
SERVICE MANUAL
ENGINE TIMING Figure 70-71-2

Procedure

The tool listed will be needed to do the following

procedure:

MEL -1638 Camshaft Timing Pin 1

MEL -1639 Crankshaft Timing Pin

Remove the rocker cover. (See Page 70-01.)

Remove the glow plugs. (See Page 70-01.)

Remove the timing case cover. (See Page 70-01.) P-55601

NOTE: The marks on the timing gears are not to be

used as timing marks. The marks indicate the Carefully rotate the crankshaft in the normal direction of
front of the gear only. rotation. Align the hole in the crankshaft with the hole in
the cylinder block and timing case and install the
crankshaft timing pin (MEL-1639) (Item 1) [Figure 70-71-
Figure 70-71-1 2]. Push the pin fully into the hole.

Figure 70-71-3

1 2

P-55600

P-55602
To set the number one piston to TDC on the correct
stroke, rotate the crankshaft in the normal direction of
rotation until the intake valve (Item 1) of the number four Insert the camshaft timing pin (MEL-1638) (Item 1)
cylinder has just opened and the exhaust valve (Item 2) [Figure 70-71-3] through the hole in the camshaft gear
[Figure 70-71-1] of the same cylinder has not closed and into the body of the timing case. With the two pins
fitted the engine is set at TDC number one on the
completely. compression stroke.
NOTE: The camshaft timing pin is a push fit into the
timing case. The camshaft gear can rotate a
small amount when the pin is fitted. This
allows the assembly of the gears and removal
of the backlash from the gears, with the timing
pins fitted.
Remove the timing pin from each gear.
Install the timing case cover. (See Page 70-01.)
Install the glow plugs. (See Page 70-01.)
Install the rocker cover. (See Page 70-01.)

4852210 (07-06) 1 -1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 1-2 Bobcat T2556 & T2566
SERVICE MANUAL
ENGINE/HYDROSTAT ASSEMBLY Figure 70-80-2

Removal And Installation 1

Raise the boom and install the boom stop. (See Page 10-
150-01.)

Remove the engine cover. (See “Removal And

Installation” on page 50-70-1)

Remove the air intake cowling. (See “Removal And

Installation” on page 50-71-1)

Drain the hydraulic reservoir. (See “Replacing Hydraulic 1

Fluid” on page 10-100-2)
P-53566
Drain the radiator. (See “Replacing The Coolant” on
page 10-70-2)
Remove the two bolts (Item 1) [Figure 70-80-2] and
Remove the battery. (See “Removal And Installation” on separate the main harness connector.
page 60-20-1)
Figure 70-80-3
Remove the muffler. (See “Removal And Installation” on
page 70-30-1)

Remove the drive shaft. (See “Removal And Installation” 1

on page 40-70-1)

If equipped with air conditioning, remove the refrigerant

from the A/C system. (See “Reclamation Procedure” on
page 80-100-1)

Figure 70-80-1

1 P-53570
1

Remove the fuse box cover (Item 1) [Figure 70-80-3].

P-53565

Unplug the electrical connectors (Item 1) [Figure 70-80-1]

in the battery box.

NOTE: Mark all electrical connectors, hoses and

tubelines for correct assembly.

4852210 (07-06) 70-80-1 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE/HYDROSTAT ASSEMBLY (CONT'D) Figure 70-80-6

Removal And Installation (Cont'd)

Figure 70-80-4

P-53573

Temporarily remove the protective covering (Item 1)

P-53571 [Figure 70-80-6] from the A/C hoses and expansion
valve.

Remove the side cover (Item 1) [Figure 70-80-4]. Figure 70-80-7

Figure 70-80-5

1
1

P-53574

P-53572
Remove the bolt (Item 1) and plate (Item 2) [Figure 70-
80-7]. Remove the A/C hoses.
Remove the cover (Item 1) [Figure 70-80-5].
NOTE: Plug the A/C hoses to prevent contamination.

4852210 (07-06) 70-80-2 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE/HYDROSTAT ASSEMBLY (CONT'D) Figure 70-80-10

Removal And Installation (Cont'd)

Figure 70-80-8

1
2

1
P-53576

Remove the two A/C hoses (Item 1) and harness (Item 2)

P-53585 [Figure 70-80-10] completely from the rear corner of the
cab.

Unplug the connector (Item 1) [Figure 70-80-8] located Figure 70-80-11

under the fuse box.

Figure 70-80-9

P-53577
1

P-53575 Remove the nut and washer (Item 1) and remove the
ground wires (Item 2) [Figure 70-80-11].

Loosen the mounting bracket bolt (Item 1) [Figure 70-80-

9].

4852210 (07-06) 70-80-3 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE/HYDROSTAT ASSEMBLY (CONT'D) Figure 70-80-14

Removal And Installation (Cont'd)

Figure 70-80-12 1

1
2

P-53568
1

Remove both heater hoses (Item 1) [Figure 70-80-14]

P-53564 through the center hole in the frame and out the battery
box.

Remove the tie straps (Item 1) and remove the hose (Item Figure 70-80-15
2) [Figure 70-80-12] from the tubeline.

Figure 70-80-13

1
1

P-53560

P-53559 Remove the two hoses (Item 1) [Figure 70-80-15] from

the tow valve.

Remove the two heater hoses (Item 1) [Figure 70-80-13]

from the engine.

4852210 (07-06) 70-80-4 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE/HYDROSTAT ASSEMBLY (CONT'D) Figure 70-80-18

Removal And Installation (Cont'd)

Figure 70-80-16
1
2

P-53563

1 Cut the tie strap (Item 1) and remove the two fuel lines
P-53263 (Item 2) [Figure 70-80-18].

Figure 70-80-19
Remove the hose (Item 1) [Figure 70-80-16] from the fan
motor.

Figure 70-80-17

P-53593

Route the two fuel lines (Item 1) [Figure 70-80-19]

P-53569 through the center frame (as shown).

Route the two heater hoses and bottom hose from the fan
motor through the frame (as shown) [Figure 70-80-17].
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

4852210 (07-06) 70-80-5 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE/HYDROSTAT ASSEMBLY (CONT'D) Figure 70-80-22

Removal And Installation (Cont'd)

Figure 70-80-20

P-53579

Remove the hose (Item 1) [Figure 70-80-22] from the

P-53567 gear pump.

Figure 70-80-23
Remove the hose (Item 1) [Figure 70-80-20] from the
rear of the hydrostatic pump.

Figure 70-80-21

1
1

P-53588

Remove the two electrical connectors (Item 1) [Figure 70-

P-53578 80-23] from the hydrostatic solenoids.

Remove the hose (Item 1) [Figure 70-80-21] from the

gear pump.

4852210 (07-06) 70-80-6 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE/HYDROSTAT ASSEMBLY (CONT'D) Figure 70-80-26

Removal And Installation (Cont'd)

Figure 70-80-24

P-53589

Remove the four bolt flange hydraulic hose (Item 1)

P-53581 [Figure 70-80-26] from the hydrostat.

Figure 70-80-27
Remove the hose (Item 1) [Figure 70-80-24] from the
gear pump.

Figure 70-80-25

1
P-53590

Remove the tubeline (Item 1) [Figure 70-80-27] from the

P-53582 hydrostat.

Remove the hose (Item 1) [Figure 70-80-25] from the

gear pump.

4852210 (07-06) 70-80-7 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE/HYDROSTAT ASSEMBLY (CONT'D) Figure 70-80-30

Removal And Installation (Cont'd)

Figure 70-80-28 1

P-53595

Remove the hose (Item 1) [Figure 70-80-30] from the tee

P-53592 fitting on the hydraulic oil reservoir.

Figure 70-80-31
Remove the hose (Item 1) [Figure 70-80-28] from the
hydrostat.

Figure 70-80-29
1

1 P-53598

Remove the hose (Item 1) [Figure 70-80-31] from the

P-53594 large tubeline.

Remove the hose (Item 1) [Figure 70-80-29] from the

front of the hydrostat.

4852210 (07-06) 70-80-8 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE/HYDROSTAT ASSEMBLY (CONT'D) Figure 70-80-34

Removal And Installation (Cont'd)

Figure 70-80-32

1
1

1
P-53602

Remove the three hoses (Item 1) [Figure 70-80-34] from

P-53599 the brake valve.

Figure 70-80-35
Remove the four bolt flange hydraulic hose (Item 1)
[Figure 70-80-32] from the front of the hydrostat.

Figure 70-80-33

P-53584

Remove the small harness (Item 1) [Figure 70-80-35]

P-53601 from the battery cables inside the frame.

Remove the hose (Item 1) [Figure 70-80-33] from the

large tubeline.

4852210 (07-06) 70-80-9 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE/HYDROSTAT ASSEMBLY (CONT'D) Figure 70-80-38

Removal And Installation (Cont'd)

Figure 70-80-36

P-53603

Remove the engine speed control cable (Item 1) [Figure

P-53625 70-80-38].

Figure 70-80-39
Disconnect the engine speed sensor connector (Item 1)
[Figure 70-80-36].

Figure 70-80-37

P-53604

Remove the engine speed control cable (Item 1) [Figure

P-53586 70-80-39] from the bracket.

Remove the wire harness through the frame (as shown)

[Figure 70-80-37].

4852210 (07-06) 70-80-10 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE/HYDROSTAT ASSEMBLY (CONT'D) Figure 70-80-42

Removal And Installation (Cont'd)

Figure 70-80-40

P-53587

Remove the A/C hoses and harness and position as

P-53605 shown [Figure 70-80-42].

Figure 70-80-43
Route the engine speed control cable (Item 1) [Figure 70-
80-40] through the center frame.

Figure 70-80-41

P-53624

Remove the ground strap mounting bolt (Item 1) [Figure

P-55919 70-80-43].

Remove nut (Item 1) and cable clamp (Item 2) [Figure 70-

80-41].

4852210 (07-06) 70-80-11 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE/HYDROSTAT ASSEMBLY (CONT'D) Figure 70-80-46

Removal And Installation (Cont'd)

Figure 70-80-44

P-53618

Figure 70-80-47
P-53620

Install a chain hoist to lift and secure the engine assembly

[Figure 70-80-44]. 1

Figure 70-80-45

P-53617

Figure 70-80-48

P-53619

Remove the engine assembly mounting bolt (Item 1)

[Figure 70-80-45] from the lower front. 1

P-53616

Remove the three engine assembly mounting bolts (Item

1) [Figure 70-80-46], [Figure 70-80-47] and [Figure 70-
80-48].

4852210 (07-06) 70-80-12 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE/HYDROSTAT ASSEMBLY (CONT'D) Figure 70-80-51

Removal And Installation (Cont'd)

Figure 70-80-49

P-53627

Remove the hose (Item 1) [Figure 70-80-51] from the

P-55918 hydrostat.

Figure 70-80-52
Lift the engine assembly up approximately one inch (25
mm) and pull the engine assembly away from the
machine about ten inches (250 mm) [Figure 70-80-49].

Figure 70-80-50

1
P-53629

Remove the engine assembly from the machine [Figure

70-80-52].
P-53626

Remove the hose (Item 1) [Figure 70-80-50] from the

reservoir.

4852210 (07-06) 70-80-13 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 70-80-14 Bobcat T2556 & T2566
SERVICE MANUAL
FLYWHEEL AND HOUSING Figure 70-90-3

Removal And Installation

Remove the engine/hydrostat assembly. (See “Removal

And Installation” on page 70-80-1)
1
NOTE: Set the engine/hydrostat assembly on blocks,
to allow access to remove the motor mount
bolts.

Remove the hydrostatic pump. (See “Removal And

Installation” on page 30-40-1)

Remove the starter. (See “Removal And Installation” on

page 60-40-1) P-53796

Figure 70-90-1
Remove both rear engine mounting bolts (Item 1) [Figure
70-90-2] & [Figure 70-90-3].

Installation: Tighten engine mounting bolts to 185-200

ft.-lbs. (250-271 Nm) torque.

Figure 70-90-4

P-53793

Install lifting brackets and hoist on the housing to lift and

support [Figure 70-90-1].

Figure 70-90-2
P-53797

Lifting from the housing assembly, raise the engine

slightly and place support blocks under the oil pan [Figure
1 70-90-4].

Lower the engine assembly on the support blocks.

P-53794

4852210 (07-06) 70-90-1 Bobcat T2556 & T2566

SERVICE MANUAL
FLYWHEEL AND HOUSING (CONT'D) Figure 70-90-7

Removal And Installation (Cont'd)

Figure 70-90-5 1

1
1

P-53800

Remove the six coupler mounting bolts (Item 1) [Figure

P-53798 70-90-7]. Remove the coupler.

Installation: Tighten the bolts to 40-45 ft.-lbs. (54-61 Nm)

Loosen and remove the ten flywheel housing mount bolts torque.
(Item 1) [Figure 70-90-5].
Figure 70-90-8
Installation: Tighten to 40-45 ft.-lbs. (54-61 Nm) torque.

Figure 70-90-6

P-53801

P-53799 Remove two of the flywheel mount bolts and install two
guide studs (Item 1) [Figure 70-90-8] in the flywheel to
prevent the fly wheel from falling.
Remove the flywheel housing from the engine [Figure 70-
90-6].

4852210 (07-06) 70-90-2 Bobcat T2556 & T2566

SERVICE MANUAL
FLYWHEEL AND HOUSING (CONT'D) Figure 70-90-10

Removal And Installation (Cont'd)

2 2
Figure 70-90-9

1
1

2
2
2

P-53804

2 If removing the backing plate (Item 1) is required, loosen

P-53803 and remove the eight mounting bolts (Item 2) [Figure 70-
90-10].

Install a chain hoist (Item 1) [Figure 70-90-9]. Installation: Tighten the bolts to 52 ft.-lbs. (70 Nm)
torque.
Remove the remainder of the bolts (Item 2) [Figure 70-
90-9]. Remove the flywheel by sliding outward over the Check the flywheel and ring gear for wear or damage.
guide studs. Replace as needed.

Installation: Tighten the flywheel bolts to 77 ft.-lbs. (105

Nm) torque.

4852210 (07-06) 70-90-3 Bobcat T2556 & T2566

SERVICE MANUAL
FLYWHEEL AND HOUSING (CONT'D) Figure 70-90-12

Removal And Installation (Cont'd)

Figure 70-90-11

Check the alignment of the flywheel face [Figure 70-90-

12].

The misalignment must not be more than 0.001 inch (0,03

Install a dial indicator to check the flywheel run out mm) total indicator reading for every 1.0 inch (25 mm) of
[Figure 70-90-11]. the flywheel radius from the crankshaft axis to the dial
gauge plunger.
Flywheel run out must be less than 0.012 inch (0,30 mm).
Example: The misalignment must not be greater than
0.008 inch (0,203 mm) at 8 inches. (203 mm) from the
centerline of the crankshaft towards the outside of the
flywheel.

During this check keep the crankshaft pressed toward the

front so crankshaft end play will not affect the reading.

Ring Gear Removal

Before the ring gear is removed note the position of the

chamfer on the teeth.

Heat the ring gear enough to expand it and hit it with a

hammer evenly to remove it.

Be careful not to damage the flywheel during this

operation.

Ring Gear Installation

The ring gear is a heat expansion fit on the flywheel.

Do not heat the ring gear to a temperature greater than

480° F (250° C) make sure the ring gear chamfer is in the
correct position.

4852210 (07-06) 70-90-4 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE

Turbo Charger Troubleshooting

The chart below is given to assist in the correct diagnosis of turbocharger faults.

If the inside of the intake manifold is wet, check that there is not a fuel leak from the starting aid.

PROBLEM CAUSE
Not enough power 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28
Black Smoke 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28
Blue Smoke 1, 2, 4, 6, 8, 9, 17, 19, 20, 21, 22, 30, 31, 32
High Lubricating Oil Consumption 2, 8, 15, 17, 19, 20, 28, 29, 31, 32
Two Much Lubricating Oil At Turbine End 2, 7, 8, 17, 19, 20, 22, 28, 30, 31, 32
Two Much Lubricating Oil At Compressor End 1, 2, 4, 5, 6, 8, 19, 20, 21, 28, 31, 32
Not Enough Lubrication 8, 12, 14, 15, 16, 23, 24, 29, 32, 33, 34, 35
Lubricating Oil In The Exhaust Manifold 2, 7, 17, 18, 19, 20, 22, 28, 31, 32
Inside The Induction Manifold Wet 1, 2, 3, 4, 5, 6, 8, 10, 11, 17, 18, 19, 20, 21, 28, 32, 36, 37
Damaged Compressor Impeller 3, 4, 6, 8, 12, 15, 16, 20, 21, 23, 24, 29, 32, 33, 35, 36
Damaged Turbine Rotor 7, 8, 12, 13, 14, 15, 16, 18, 20, 22, 23, 24, 25, 27, 29, 29, 32, 33, 34,
35
Rotating Assembly Does Not Turn Freely 3, 6, 7, 8, 12, 13, 14, 15, 16, 18, 20, 21, 22, 23, 24, 29, 32, 33, 34, 35
Worn Bearings, Bearing Bores, Journals 6, 7, 8, 12, 13, 14, 15, 16, 23, 24, 29, 33, 34, 35
Noise From Turbocharger 1, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 20, 21, 22, 23,
24, 29, 32, 33, 34, 35
Sludge or Carbon Deposit In Bearing Housing 2, 11, 13, 14, 15, 17, 18, 24, 29, 33, 34, 35

KEY TO CORRECT THE CAUSE

1. Air filter element dirty. 17. Restricted lubricating oil drain pipe.
2. Restricted crankcase breather. 18. Turbine housing damage or restricted.
3. Air filter element missing, leaking or not sealing 19. Leakage from turbocharger seals.
correctly. Loose connection to turbocharger.
4. Internal distortion or restriction in pipe from air filter to 20. Worn turbocharger bearings.
turbocharger.
5. Damaged/restricted crossover pipe, turbocharger to 21. Excessive dirt in turbocharger housing.
induction manifold.
6. Restriction between air filter and turbocharger. 22. Excessive carbon behind turbine rotor.
7. Restriction in exhaust system. 23. Engine speed raised too rapidly at initial start.
8. Turbocharger loose or clamps/setscrews loose. 24. Insufficient engine idle period.
9. Induction manifold cracked or loose, flanges distorted. 25. Faulty fuel injection pump.
10. Exhaust manifold cracked or loose. 26. Worn or damaged fuel injectors.
11. Restricted exhaust system. 27. Valves burned.
12. Delay of lubricating oil to turbocharger at engine start. 28. Worn piston rings. flanges distorted.
13. Insufficient lubrication. 29. Lubricating oil leakage from supply pipe.
14. Dirty lubricating oil. 30. Excessive starting fluid (on initial engine start).
15. Incorrect lubricating oil. 31. Excessive engine idle period.
16. Restricted lubricating oil supply pipe. 32. Restriction in turbocharger bearing housing.
33. Restriction in lubricating oil filter.
34. Engine stopped too soon from high load.
35. Insufficient lubricating oil.
36. Fuel leakage from fuelled starting aid.
37. Crack in back plate of compressor.

4852210 (07-06) 70-100-1 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Turbo Charger Removal And Installation

Turbo Charger Description Figure 70-100-2

WARNING
Turbochargers, operate at high speed and high 1
temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact
with hot surfaces.
W-2257-1196

2
Figure 70-100-1

P-55619

Remove the two bolts (Item 1) and remove the extension

tube (Item 2) [Figure 70-100-2].

Figure 70-100-3

1
P-55618

The turbocharger (Item 1) [Figure 70-100-1] is placed

between the exhaust and intake manifolds. It is driven by
hot exhaust gases and supplies air at more than 1
atmospheric pressure to the intake. It is lubricated by oil
from the main gallery.
P-55515
The oil flows from the filter adapter through the bearing
housing and returns to the engine block.
Loosen the intake tube clamp (Item 1) [Figure 70-100-3].
The turbocharger should only be serviced by an
authorized dealer or repair shop.

4852210 (07-06) 70-100-2 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-6

Turbo Charger Removal And Installation (Cont'd)

Figure 70-100-4

1 1

P-55621

Remove the oil return line (Item 1) [Figure 70-100-6].

P-55516
Figure 70-100-7

Remove the four bolts (Item 1) and remove the intake

tube (Item 2) [Figure 70-100-4].

Figure 70-100-5
1 1

1 P-55624

Remove the four nuts (Item 1) [Figure 70-100-7] for the

turbocharger to exhaust manifold flange.
P-55623
Installation: Apply anti-seize compound to the mounting
studs. Tighten the nuts to 33 ft.-lbs. (44 Nm) torque.
Disconnect the oil supply tubeline (Item 1) [Figure 70-
100-5]. Remove the turbocharger and gasket from the exhaust
manifold.
Installation: Fill the bearing housing with clean oil
through the oil supply port. Tighten banjo fitting to 16 ft.- The turbocharger must only be serviced by an authorized
lbs. (22 Nm) torque. repair shop.

Before starting the engine, disconnect the electrical stop

control. Crank the engine until oil pressure is obtained.
Stop cranking and reconnect the stop control.

4852210 (07-06) 70-100-3 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Fuel Injector Cover Removal And Installation

Exhaust Manifold Removal And Installation Figure 70-100-10

Remove the turbocharger. (See Page 70-100-2)

1
Figure 70-100-8
1

1 1

P-55513

Remove the three bolts (Item 1) [Figure 70-100-10].

P-55625
Installation: Tighten the bolts to 7 ft.-lbs. (9 Nm) torque.

Remove the eight mount bolts (Item 1) [Figure 70-100-8]. Figure 70-100-11

Remove the exhaust manifold and gasket.

Figure 70-100-9

5 2 8
1

4 3 7
6 P-55514

Remove the cover [Figure 70-100-11].

P-55625

Installation: Tighten the bolts in the sequence shown

[Figure 70-100-9] to 24 ft.-lbs. (33 Nm) torque.

4852210 (07-06) 70-100-4 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-14

Rocker Cover Removal And Installation

Remove the fuel injector cover. (See Page 70-100-4.) 1

Figure 70-100-12

P-55517

1 Remove the breather hose (Item 1) [Figure 70-100-14].

Figure 70-100-15
P-55515

Loosen the intake tube clamp (Item 1) [Figure 70-100-

12].

Figure 70-100-13
1

1
2 1

P-55518
1

Remove the two bolts (Item 1) and remove the breather

fitting (Item 2) [Figure 70-100-15].

P-55516

Remove the four bolts (Item 1) and remove the intake

tube (Item 2) [Figure 70-100-13].

4852210 (07-06) 70-100-5 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Cylinder Head Removal

Rocker Cover Removal And Installation (Cont'd) Remove the turbo charger. (See page 70-100-2.)

Figure 70-100-16 Remove the exhaust manifold. (See Page 70-100-4.)

Remove the alternator. (See page 60-30-1.)

1 1
Remove the fuel lift pump. (See Page 70-70-10.)

Remove the fuel injectors. (See Page 70-70-7.)

Remove the glow plugs. (See Page 70-70-12.)

Figure 70-100-18
1

1
1
P-55519

Remove the ten mount bolts (Item 1) [Figure 70-100-16].

Figure 70-100-17

1
1 10 3 5
8
P-55681

Unplug the engine cooling temperature sensor (Item 1)

[Figure 70-100-18].

NOTE: Mark wires for correct installation.

Figure 70-100-19
7
6 4 9 2
P-55519

Installation: Tighten the bolts in the sequence shown

[Figure 70-100-17] to 7 ft.-lbs. (9 Nm) torque.

P-55682

Unplug the intake manifold pressure sensor (Item 1)

[Figure 70-100-19].

Reposition the harness.

4852210 (07-06) 70-100-6 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-22

Cylinder Head Removal (Cont'd)

Figure 70-100-20

P-8718A

Remove the push rods [Figure 70-100-22].

P-55683
Figure 70-100-23

Remove the tubeline (Item 1) [Figure 70-100-20].

8
9 5 1 4
Figure 70-100-21

2
1

10 7
6 2 3

B-23183

1 Release the cylinder head bolts evenly and gradually in

P-55684 the sequence shown [Figure 70-100-23].

Check the head bolts for distortion and damage. Replace

Remove the two bolts (Item 1) and remove the coolant by- as needed.
pass tube (Item 2) [Figure 70-100-21].
Lift off the cylinder head and clean the bottom face.
Remove the rocker cover. (See Page 70-100-5.)

Remove the rocker assembly. (See Page 70-100-11.)

4852210 (07-06) 70-100-7 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Cylinder Head Installation

Cylinder Head Inspection Make sure the mating surfaces of the head and block are
clean.
Figure 70-100-24
Clean the engine block bolt bores with the correct size tap
to ensure correct torque for the cylinder head bolts.

1 1 1 1 1 3 Clean any debris out of the cylinder bores.

2 Figure 70-100-25

2 2
1

3 FRONT TOP

B-5564

Put a straight edge on the cylinder head as shown in

[Figure 70-100-24].

Using a feeler gauge between the straight edge and head,

B-5562
check for warping.

Maximum allowed (Item 1) is 0.0012 inches (0,03 mm), NOTE: The locating pins (Item 1) are pressed in the
(Item 2) is 0.0019 inches (0,05 mm) and (Item 3) [Figure engine block so the head gasket (Item 2)
70-100-24] is 0.0019 inches (0,05 mm). [Figure 70-100-25] can be positioned correctly.

The head may be machined removing only a minimum The head gasket is installed with no sealer.
amount. Head thickness must not be less than 4.614
inches (117,20 mm). Place the head gasket in position with the Front Top (Item
2) [Figure 70-100-25] marks in the correct position.
Completely clean the rest of the head.
Lower the cylinder head in position.
Check for cracks or other damage.

4852210 (07-06) 70-100-8 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-28

Cylinder Head Installation (Cont'd)

225° 270°
Figure 70-100-26

3
2 6 10 7

B-5563A
1 4
5 9 8
If no angle gauge is available make a suitable mark on the
B-23183 head bolt corner. Make another mark on the cylinder head
the correct number of flats away [Figure 70-100-28]. Turn
the head bolt until the lines match.
Tighten the head bolts to 37 ft.-lbs. (50 Nm) in the
sequence shown [Figure 70-100-26]. Figure 70-100-29

Tighten the head bolts to 74 ft.-lbs. (100 Nm) in the

sequence shown [Figure 70-100-26].

Figure 70-100-27

P-8718A

Install the push rods [Figure 70-100-29].

P-8839 Make sure the push rods seat in the tappet sockets.

Install the rocker assembly. (See Page 70-100-11.)

Additional tightening of the head bolts requires the use of
a torque angle gauge (Item 1) [Figure 70-100-27]. Install the rocker cover. (See Page 70-100-5.)
Tighten the short bolts to 225° and long bolts to 270° in
the same sequence as shown in [Figure 70-100-26].

4852210 (07-06) 70-100-9 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-32

Cylinder Head Installation (Cont'd)

Figure 70-100-30

1
P-55682

2 Connect the intake manifold pressure sensor (Item 1)

P-55684 [Figure 70-100-32].

Figure 70-100-33
Install the coolant by-pass pipe (Item 1) and two screws
(Item 2) [Figure 70-100-30].

Figure 70-100-31

1
1

P-55681

Connect the engine cooling temperature sensor (Item 1)

P-55683 [Figure 70-100-33].

Install the glow plugs. (See Page 70-70-12.)

Install the tubeline (Item 1) [Figure 70-100-31].
Install the fuel injectors. (See Page 70-70-7.)

Install the fuel lift pump. (See page 70-70-10.)

Install the alternator. (See Page 60-30-1.)

Install the exhaust manifold. (See Page 70-100-4.)

Install the turbo charger. (See Page 70-100-2.)

4852210 (07-06) 70-100-10 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Valve Removal

Rocker Shaft Disassembly And Assembly NOTE: Mark all components so they can be returned to
the same position.
Figure 70-100-34
Figure 70-100-35

1
4 5

3
2 3
2
P-8719A

P-8720A

Remove the clips (Item 1) [Figure 70-100-34] from both

ends of the shaft. Using a valve spring compressor compress the springs
and remove the retainers (Item 1) [Figure 70-100-35].
Remove the rocker arm (Item 2) and spring (Item 3)
[Figure 70-100-34]. Release the compressor and remove the valve spring cap
(Item 2), spring (Item 3), valve seal/spring seat washer
Continue to disassemble the rocker shaft. (Item 4) and valve (Item 5) [Figure 70-100-35].

Clean and inspect all components for damage and wear. Clean and inspect all components.

Check the clearance between the rocker arms and shaft.

Using a press and adapter, remove the old bushing and

press in the new one making sure the oil holes line up.

Shaft O.D. 0.9828-0.9837 inch

(24,96-24,99 mm)
Rocker Arm Bore Dia. 0.9848-09.863 inch
(25,02-25,05 mm)
Clearance Between Rocker Arm 0.0010-0.0035 inch
& Shaft (0,026-0,089 mm)

If the clearance is more than 0.005 inch (0,13 mm)

replace the bushing(s).

4852210 (07-06) 70-100-11 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Valve Depth Checking

Valve Springs Checking Figure 70-100-37

Figure 70-100-36

1.358 inch
(34,5 mm)

N-00533

B-5552
Check the valve depth as shown in [Figure 70-100-37].

Use the following chart [Figure 70-100-36]. The maximum depth is 0.081 inch (2,06 mm) for both
intake and exhaust valves.
Valve Springs
If the valve is below the limits, install a new valve and
Compressed Height 1.358 inch (34,5 mm)
recheck the valve depth. If it is still below limits a new
Installed Pressure 51 ft.-lbs. (229 N) valve seat insert must be installed.

When the depth is less than 0.060-0.071 inch (1,53-1,81

mm) the seat may be ground to lower the valve depth.

4852210 (07-06) 70-100-12 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D)

Valve Guides Checking Interference fit of valve guide to cylinder head: 0.0003-
0.0019 inch (0,007-0,047 mm)
Figure 70-100-38
Overall Diameter (Item 3) [Figure 70-100-38]
1
Intake & Exhaust 2.008-2.028 inch
4 (51,00-51,50 mm)

3 Protrusion from bottom recess for valve spring;

(Item 4) [Figure 70-100-38] 0.486-0.498 inch
(12,35-12,65 mm)

2 To check the valve guides for wear using a valve.

Set up dial indicator gauge (Item 1) [Figure 70-100-38] as

B-5551
shown.

Figure 70-100-39 Lift the valve (Item 2) 0.60 inches (15,0 mm) and move
the valve in and away from the gauge (Item 1) [Figure 70-
100-38]. Record this reading.

If the clearance exceeds 0.009 inches (0,22 mm) for

3 intake or 0.010 inches ),25 mm) for exhaust (Item 3)
1
[Figure 70-100-39] the valve guide needs to be replaced.

B-5566A

The valve guides can be checked for wear with either of

the operations listed in [Figure 70-100-38] or [Figure 70-
100-39].

Use the following chart to check valve guides.

Inside Diameter
(Item 1) [Figure 70-100-38] 0.3543-0.3552 inch
(9,00-9,02 mm)

Outside Diameter (Item 2) [Figure 70-100-38]

Intake & Exhaust 0.5131-0.5137 inch
(13,04-13,05 mm)

4852210 (07-06) 70-100-13 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Valve Guide Installation

Valve Guide Removal Figure 70-100-41

Clean the guide bore in the head.

Figure 70-100-40

B-5548

Clean the guide bore in the head.

Lubricate the outer surface of the new guide (Item 1)

B-5549 [Figure 70-100-41] with the engine oil.

Put the guide in position on the valve guide removal/

Install a valve guide removal/installation tool (Item 1) on installation tool (Item 2) [Figure 70-100-41].
the valve guide (Item 2) [Figure 70-100-40].
Pull the guide into the cylinder head.
Pull the guide (Item 2) [Figure 70-100-40] out of the
cylinder head. When correctly positioned the top of the guide should
extend 0.486-0.498 inch (12,35-12,65 mm) above the
valve spring seat as shown on Page 70-100-13 [Figure
70-100-38].

4852210 (07-06) 70-100-14 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D)

Valves Checking Cutting A Valve Seat

NOTE: If the valves do not meet specifications they Before any work is done the valve guides must meet
need to be replaced. They cannot be ground. specifications or have been replaced.

Figure 70-100-42 Install the pilot in the valve guide.

Select the correct size cutter.

Valve Seat Angle 30°

4
Figure 70-100-43

1
B-5567

Use the following chart [Figure 70-100-41] to check the

valve dimensions.

Ref. Valve Specifications N-00532

1. Intake 5.076-5.093 inch (128,92-
129,37 mm)
Exhaust 5.075-5.093 inch (128,92- Carefully turn the cutter in a clockwise direction using
129,37 mm) even downward pressure. Keep the valve seat as narrow
as possible [Figure 70-100-42].
2. Intake 0.3525-0.3533 inch (8,95-
8,98 mm)
Remove any cutting debris.
Exhaust 0.3519-0.3528 inch (8,93-
8,96 mm) Install the valve and lightly tap.
3. Intake 1.819-1.829 inch (46,20-
46,45 mm) Check the valve depth to make sure that it is within limits.
Exhaust 1.634-1.644 inch (41,51- (See Page 70-100-13.)
41,75 mm)
4. Intake 0.062-0.072 inch (1,58- NOTE: If the valve seat is worn or damaged, a new
(Production) valve seat insert can be installed.
1,84 mm)
Intake (Ser- 0.082 inch (2,09 mm)
vice Max.)
Exhaust 0.060-0.071 inch (5,53-
(Production) 1,81 mm)
Exhaust (Ser- 0.081 inch (2,06 mm)
vice Max.)
Intake/ 30°
Exhaust Valve
Face Angle

4852210 (07-06) 70-100-15 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D)

Valve Seat Assembly

WARNING
Wear safety glasses to prevent eye injury when any of
the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285

Lubricate the valve stems (Item 1) [Figure 70-100-42]

with clean engine oil and install them in the respective
guides.

Figure 70-100-44

4 5

2 3

P-8720A

Install new valve seals/spring seat washer (Item 2)

[Figure 70-100-43].

Install the spring (Item 3) [Figure 70-100-43] on the

washer (make sure the larger diameter is against the
cylinder head).

Place the valve cap (Item 4) [Figure 70-100-43] on the

spring.

Using a valve spring compressor compress the springs

and install the retainers (Item 5) [Figure 70-100-43].

4852210 (07-06) 70-100-16 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Release the compressor and remove the valve spring(s).

Changing Valve Springs (With Cylinder Head Place the new valve springs in position.
Installed)
Compress the valve springs and install the retainers.
Remove the rocker cover.

Figure 70-100-45

B-5565

Rotate the crankshaft clockwise until the intake valve has

opened and the exhaust valve has not fully closed. In this
position the piston (Item 1) [Figure 70-100-45] will be at
approximately T.D.C.

Remove the rocker shaft assembly.

Figure 70-100-46

N-00531

Install the valve spring compressor and adapter [Figure

70-100-46].

Compress the valve springs squarely and remove the

retainers.

NOTE: Do not rotate the crankshaft while the valve

springs are removed.

4852210 (07-06) 70-100-17 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-48

Valve Clearance Adjustment

Adjust the valve clearance as follows:

Figure 70-100-47

1 2 3 4 5 6 7 8

2 1

B-5569

Figure 70-100-49

3 Cylinder
B-5568 No. 1 2 3 4
Valve No. 1 2 3 4 5 6 7 8
Valve
Loosen the lock nut (Item 1) [Figure 70-100-47]. 1=Intake I E I E I E I E
E=Exhaust
Turn the adjustment screw (Item 2) [Figure 70-100-47]
until the correct clearance is obtained. Use the following sequence to set the valves [Figure 70-
100-48] & [Figure 70-100-49].
NOTE: The clearance is measured between the rocker
arm and valve stem tip (Item 3) [Figure 70-100-
47]. a. With the rocker arm rocking (valves 7 & 8) on No. 4
cylinder set clearance at No. 1 cylinder (valves 1 &
2).
Adjust the valve clearance as follows:
b. With the rocker arm rocking (valves 3 & 4) on No. 2
0.008 inch (0,20 mm) Intake cylinder set clearance at No. 3 cylinder (valves 5 &
6).
0.018 inch (0,45 mm) Exhaust
c. With the rocker arm rocking (valves 1 & 2) on No. 1
cylinder set clearance at No. 4 cylinder (valves 7 &
8).
d. With the rocker arm rocking (valves 5 & 6) on No. 3
cylinder set clearance at No. 2 cylinder (valves 3 &
4).

4852210 (07-06) 70-100-18 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Crankshaft Pulley Removal And Installation

Timing Case And Drive Assembly Description Figure 70-100-51

The timing case is made of aluminum and the cover is

made of tin and in most applications, the timing gears are
made of steel. The drive from the crankshaft passes to the
idler gear, to the camshaft gear, to the gear on the fuel 1
injection pump and to the water pump.

The camshaft and fuel injection pump run at half the

speed of the crankshaft. 1

Timing Cover Removal 2

Remove the water pump. (See Page 70-100-41.)

Figure 70-100-50 P-55685

Remove the three bolts (Item 1) and thrust block (Item 2)

[Figure 70-100-51].

1 Installation: Tighten the bolts to 85 ft.-lbs. (115 Nm)

2
1 torque.

Remove the pulley.

1 Front Oil Seal Removal And Installation

1
Remove the crankshaft pulley. (See Page 70-100-19.)
1
P-55521 Remove the oil seal using a seal removal tool.

Do not damage the edge of the seal housing.

Remove the timing cover bolts (Item 1) and remove the
timing cover (Item 2) [Figure 70-100-50]. Figure 70-100-52

Timing Cover Installation

Clean the gasket mating surfaces.

Place the gasket and timing cover on the engine.

Remove the timing pins if fitted.

Hold the timing cover in position and install two bolts that
are on opposite sides of the cover. Do not tighten the
bolts.

Install the water pump. (See Page 70-100-41.) 1

P-55686
Do not tighten bolts at this time.

Tighten the cover bolts and water pump bolts to 16 ft.-lbs. Install the oil seal (Item 1) [Figure 70-100-52] into the
(22 Nm) torque. housing using the special tool.

Install crankshaft pulley. (See Page 70-100-19.)

4852210 (07-06) 70-100-19 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-55

Timing Case And Gear Removal

Remove the timing cover. (See Page 70-100-19.)

1
Remove the crankshaft pulley. (See Page 70-100-19.)

Remove the fuel injection pump. (See Page 70-70-1.)

Figure 70-100-53

1
P-55689

Remove the idler gear (Item 1) [Figure 70-100-55] by

moving the gear assembly forward and lifted over the front
2
oil seal housing.

NOTE: Do not turn the crankshaft with the idler gear

1 removed.

P-55684 Figure 70-100-56

Remove the two bolts (Item 1) and remove the coolant by-
pass tube (Item 2) [Figure 70-100-53].
2 1
Figure 70-100-54

3 1

P-55690
2

Remove the bolt (Item 1) and washer (Item 2) [Figure 70-

1 100-56].

P-55688

Remove the three bolts (Item 1) and plate (Item 2) from

the idler gear (Item 3) [Figure 70-100-54].

4852210 (07-06) 70-100-20 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Timing Case And Gear Installation

Timing Case And Gear Removal (Cont'd) Clean the mating surfaces, if the oil pan was not removed
trim the oil gasket flush with the block.
Figure 70-100-57
Figure 70-100-59
1
1 2
2

2
2

P-55691
2 2 P-55692

Remove the camshaft gear (Item 1) [Figure 70-100-57].

Fit the timing case (Item 1) onto the cylinder block and
NOTE: Use care not to lose the key from the key way. hand tighten the bolts (Item 2) [Figure 70-100-59].

Figure 70-100-58 After the cover is correctly aligned, tighten the mount bolts
(Item 2) [Figure 70-100-59]to 16 ft.-lbs (22 Nm) torque.

1 Figure 70-100-60
1

1
1
2

2 2 P-55692

Remove all the timing case mount bolts (Item 1) and the
P-55691
four bolts (Item 2) [Figure 70-100-58] from the front of the
oil pan.
Install the camshaft gear (Item 1) onto the shaft using
Remove the timing case from the engine. alignment pin (Item 2) [Figure 70-100-60] for correct
alignment.

4852210 (07-06) 70-100-21 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-63

Timing Case And Gear Installation (Cont'd)

Figure 70-100-61
1

2
2

1 P-55688

Install the plate (Item 1) and three bolts (Item 2) [Figure

P-55690 70-100-63].

Tighten the bolts to 33 ft.- lbs. (44 Nm) torque.

Install the washer (Item 1) and bolt (Item 2) [Figure 70-
100-61] and tighten to 70 ft.-lbs. (95 Nm) torque. Figure 70-100-64

Figure 70-100-62

1
2

P-55684

P-55689
Install the coolant by-pass tube (Item 1) using the two
bolts (Item 2) [Figure 70-100-64].
Install the idler gear (Item 1) make sure the hole (Item 2)
[Figure 70-100-62] is towards the cylinder head. Install the fuel injection pump. (See Page 70-70-1.)

Install the crankshaft pulley. (See Page 70-100-19.)

Install the timing cover. (See Page 70-100-19.)

4852210 (07-06) 70-100-22 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-66

Camshaft And Tappets Removal

Remove the timing case cover. (See Page 70-100-19.)

Remove the fuel injection pump. (See Page 70-70-1.) 1

Remove the timing case. (See Page 70-100-20.)

Remove the rocker cover, rocker assembly and push

rods. (See Page 70-100-5.)

Remove the fuel pump and gasket.

Figure 70-100-65 P-8741

Remove the camshaft thrust washer (Item 1) [Figure 70-

100-66].

Figure 70-100-67

P-8740

Turn the engine over and remove the oil pan mounting
bolts [Figure 70-100-65].

Remove the oil pan and gasket. P-8742

Installation: Tighten the oil pan mounting bolts to 16 ft.-

lbs. (22 Nm) torque. Carefully remove the camshaft (Item 1) [Figure 70-100-
67].

4852210 (07-06) 70-100-23 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Camshaft And Tappets Installation

Camshaft And Tappets Removal (Cont’d) Clean and inspect the camshaft and tappets for excessive
wear and damage.
Figure 70-100-68
Inspect the camshaft bushing for excessive wear and
damage.

NOTE: Only the front camshaft journal bore has a

bushing.

1 Clearance between the camshaft journals, the bushing

1 and camshaft bore is 0.0025 - 0.0055 inch (0,06 - 0,14
mm).

Make sure all components are clean and lubricated with

clean engine oil.

Figure 70-100-69
P-8743

Remove the tappets (Item 1) [Figure 70-100-68] from the

block.

1
1

P-08743

Install the tappets (Item 1) [Figure 70-100-69].

Figure 70-100-70

P-8742

Carefully install the camshaft (Item 1) [Figure 70-100-70].

4852210 (07-06) 70-100-24 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D)

Camshaft And Tappets Installation (Cont’d)

Figure 70-100-71

1
2

P-8741

Install the camshaft thrust washer (Item 1). Make sure that
the dowel pin (Item 2) [Figure 70-100-71] lines up with
the hole in the thrust washer.

Install the timing case. (See Page 70-100-21.)

Check camshaft end play. The end play for a new engine
is 0.004 - 0.022 inch (0,10 - 0,55 mm), service limits 0.023
inch (0,60 mm).

Install the timing gears. (See Page 70-100-21.)

Install the fuel injection pump. (See Page 70-70-4.)

Install the push rods and rocker assembly. (See Page 70-
100-11.)

Install the timing cover. (See Page 70-100-19.)

Install the oil pan. (See Page 70-100-43.)

4852210 (07-06) 70-100-25 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-73

Pistons And Connecting Rods Description

The pistons have a Quadram combustion chamber. They

have two compression rings and one oil control ring. The
top ring groove has a hard metal insert to reduce wear.
Full floating piston pins are used and are retained by snap
rings.

Controlled expansion pistons have a steel insert ring in

the piston skirt. The connecting rods are molybdenum
steel. The connecting rods on the turbocharged engines
have wedge shaped small ends. The location of the
bearing caps to the connecting rods is made by serrations
and the cap is retained by two bolts.

The pistons used in the 1000 series engines have two Mark and remove the connecting rod caps (Item 1)
compression rings and one oil control ring. All the rings [Figure 70-100-73].
are above the piston pin. Each of the three piston rings
have different design features. Always use the engine NOTE: Do not allow the connecting rods to hit the
identification number to order new parts. cooling jets.

Pistons And Connecting Rods Removal Figure 70-100-74

Figure 70-100-72

Turn the connecting rods 90° to prevent contact with the

piston cooling jets (Item 1) [Figure 70-100-74]. Push the
Remove the cylinder head. (See Page 70-100-6.) piston and rod assemblies out the top of the cylinder.

Remove all the carbon from the top of the cylinder liners.

Remove the oil pan. (See Page 70-100-43.)

Remove the oil pick up screen and tube (Item 1) [Figure

70-100-72].

4852210 (07-06) 70-100-26 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D)

Pistons And Connecting Rods Removal (Cont’d)

Figure 70-100-75

Inspect the crankshaft journals (Item 1) [Figure 70-100-

75] for wear or damage.

NOTE: Keep all parts together so they can be replaced

in their original position.

NOTE: Before installing the pistons check cylinder

bore for wear or damage. (See Page 70-100-
49.)

4852210 (07-06) 70-100-27 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Piston Ring End Gap

Pistons And Connecting Rods Disassembly Figure 70-100-78

Figure 70-100-76

Place the piston rings in the upper part of the cylinder to

check the end gap [Figure 70-100-78].
Mark the piston to indicate the cylinder number (Item 1)
[Figure 70-100-76] as shown on the connecting rod. Top Ring End Gap 0.0118-0.0216 inch (0,30-
0,55 mm)
Figure 70-100-77
Second Ring End Gap 0.0275-0.0374 inch (0,70-
0,95 mm)
Third Ring End Gap 0.0118-0.0216 inch (0,30-
0,55 mm)

Piston Ring Installation

Figure 70-100-79

Remove the piston rings (Item 1) [Figure 70-100-77] with

a ring expander.

Remove the snap rings (Item 2) [Figure 70-100-77] which

retain the piston pin.

Push the piston pin (Item 3) [Figure 70-100-77] out by

hand. If the pin doesn't push out easily, heat the piston to
100°-120° F (40°-50° C) for easier removal. Install the spring of the oil control ring in the bottom
groove with the latch pin inside both ends of the spring
Remove the connecting rod (Item 4) [Figure 70-100-77]. [Figure 70-100-79].

4852210 (07-06) 70-100-28 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Piston Ring Groove Clearance

Piston Ring Installation (Cont'd) Figure 70-100-81

Use a ring expander to install the piston rings.

Install the oil spring on the bottom groove of the piston

with the latch pin inside both ends of the spring.

Figure 70-100-80

With the piston rings installed, check the groove

clearance [Figure 70-100-81].

Top Ring Wedge

Second Ring Side 0.002 - 0.003 inch (0,05 -
Clearance 0,09 mm)
Install the oil control ring over the spring (Item 1) [Figure Third Ring Side Clearance 0.0011 - 0.0029 inch (0,03 -
70-100-80]. 0,07 mm)

Make sure the ring gap is 180° from the latch pin.

Install the cast iron ring with the tapered face (Item 2)
[Figure 70-100-80] in the second groove with the word
TOP or symbol facing the top of the piston.

New second rings have a green identification mark, which

must be on the left of the ring gap after the ring is installed
and the piston is upright.

The second ring has an external step at the bottom of the

tapered face.

Place the chromium ring (Item 3) [Figure 70-100-80] with

the symbol or word TOP up when installed on the piston.

The top ring (Item 3) [Figure 70-100-80] has an internal

step.

New top rings have a red or blue identification mark,

which must be on the left of the ring gap after the ring is
installed and the piston is uptight.

Make sure the ring gaps are 120° apart.

4852210 (07-06) 70-100-29 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Piston And Connecting Rod Assembly

Connecting Rod Inspection Figure 70-100-83

Figure 70-100-82

Install the connecting rod (Item 1), piston pin (Item 2) and
two snap rings (Item 3) [Figure 70-100-83] in the piston.
Checking the connecting rod for distortion [Figure 70-
100-82]. Piston And Connecting Rod Installation

NOTE: The large and small end bores must be square Apply a light coat of oil to the piston and piston rings.
and parallel within the limits of ± 0.010 inch
(0,25 mm). NOTE: Make sure the piston ring end gaps are 120°
apart.
Measure this 5.0 inch (127 mm) on each side of the
connecting rod axis on a test fixture. Figure 70-100-84

With the piston pin bushing installed the limit is reduced to

± 0.0025 inch (0,06 mm).

Check the pin bushing for wear or damage. Replace as

needed.

Connecting Rod Bushing Replacement

Press out the old bushing. Clean the bore and remove
any burrs.

Press in the new bushing making sure the oil feed holes
line up.

Ream the bushing to get the proper clearance of 0.0009 -

0.0017 inch (0,023 - 0,044 mm) between the small end Install the ring compressor over the piston rings [Figure
bushing and piston pin. 70-100-84].

Carefully place the connecting rod in the cylinder and

using a hammer handle, push the piston in the bore.

4852210 (07-06) 70-100-30 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-87

Piston And Connecting Rod Installation (Cont'd)

Figure 70-100-85

Install the upper and lower bearing shells in position

making sure the locating tang (Item 1) [Figure 70-100-87]
is in the correct position.

When the piston has cleared the cooling jet, rotate the NOTE: New connecting rod nuts must be installed
piston assembly so that the arrow or FRONT mark is each time the rod caps are removed.
toward the front of the engine [Figure 70-100-85].
Figure 70-100-88
Figure 70-100-86

Install the caps (Item 1) [Figure 70-100-88] and nuts.

Clean the bearing surfaces and crank pin. Lubricate the Gradually tighten the nuts to 13 ft.-lbs. (18 Nm) torque.
crank pin (Item 1) [Figure 70-100-86] with clean engine Tighten to a final torque of 52 ft.-lbs. (70 Nm). The
oil. fasteners must be tightened a further 120°.

Rotate the crankshaft. The crankshaft must rotate

smoothly.

4852210 (07-06) 70-100-31 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D)

Piston And Connecting Rod Installation (Cont'd)

Figure 70-100-89

Install the oil pick up tube and screen (Item 1) [Figure 70-
100-89].

Install the oil pan. (See Page 70-100-43.)

Checking Piston Height

Rotate the crankshaft until the piston is approximately at

top dead center (T.D.C.).

Using a dial indication gauge, pre-load the plunger on the

top surface of the block and zero the gauge.

Carefully move the dial gauge so that the plunger is on

top of the piston above the axis of the piston pin.

Rotate the crankshaft to bring the piston to it's highest

point. Record this gauge reading.

When installed, the top surface of the piston is slightly

above the surface of the cylinder block.

The height above the surface of the block should be 0.008

to 0.014 inch (0,21 to 0,35 mm).

Install the cylinder head. (See Page 70-100-8.)

4852210 (07-06) 70-100-32 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-91

Crankshaft And Bearings Description

The crankshaft is a chrome-moly forging which has five

main journals. End play is controlled by two half thrust
washers on both sides of the center main bearing.

The main bearings have steel backs with a aluminium/ tin

bearing material. The main bearing caps are made of cast
iron.

The front and rear oil seals are viton lip seals with a dust
lip to the outside of the main lip.

Crankshaft And Bearings Removal

Figure 70-100-90 Remove the two bolts (Item 1) [Figure 70-100-91]

retaining the bridge piece.

Remove the bridge piece.

Figure 70-100-92

Remove the water pump. (See Page 70-100-41.)

Remove timing case cover. (See Page 70-100-19.)

Remove the fuel injection pump. (See Page 70-70-04.)

Mark the main bearing caps (Item 1) [Figure 70-100-92]
Remove the timing gears and timing case. (See Page 70- for correct installation.
100-20.)
Remove the main bearing cap bolts.
Remove the flywheel. (See Page 70-90-1.)

Remove the pistons and connecting rods (See Page 70-

100-28), keeping them in order.

Remove the rear oil seal housing (Item 1) [Figure 70-100-

90].

4852210 (07-06) 70-100-33 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-96

Crankshaft And Bearings Removal (Cont'd)

Figure 70-100-93

Remove the crankshaft bearings from the engine block

[Figure 70-100-96].

Keep the bearings with their respective caps for

Remove the main bearing caps (Item 1) [Figure 70-100- installation.
93].

Figure 70-100-94

Remove the thrust washers from the sides of the center

main bearing bore [Figure 70-100-94].

Figure 70-100-95

Remove the crankshaft [Figure 70-100-95].

4852210 (07-06) 70-100-34 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Crankshaft And Bearings Installation

Inspection Of Crankshaft And Bearings Figure 70-100-98

Figure 70-100-97

Clean the main bearing bores and install the upper

bearing shells in position. Lubricate the bearings with
Check the crankshaft for wear [Figure 70-100-97]. The clean engine oil [Figure 70-100-98].
maximum wear and out of round of the crank journals is
0.0016 inch (0,04 mm). NOTE: Only the upper half of the bearings has oil
lubrication holes and must be installed in the
The main journals and the crank pins of standard size can cylinder block.
be machined 0.010 inch (0,25 mm) 0.020 inch (0,50 mm)
or 0.030 inch (0,75 mm). Figure 70-100-99

NOTE: See “ENGINE SPECIFICATIONS” on

page SPEC-20-1 for more crankshaft
specifications.

Check the oil clearance of the bearings.

All Main Bearings 0.0022 - 0.0046 inch (0,057

- 0,117 mm)

Thrust Washer Thickness

Standard 0.089 - 0.091 inch (2,26 -
2,31 mm)
Oversize 0.096 - 0.098 inch (2,45 -
2,50 mm)
Make sure the main journals are clean and install the
crankshaft in the block [Figure 70-100-99].

Make sure the locating pins for the main caps are in
position.

4852210 (07-06) 70-100-35 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-101

Crankshaft And Bearings Installation (Cont'd)

Figure 70-100-100

Install the bridge piece, and using a straight edge, align

the bridge with the cylinder block [Figure 70-100-101].
Tighten the bridge retaining bolts to 12 ft.-lbs. (16 Nm)
torque.
Clean and install the upper and lower thrust bearings on
each side of the center main bearing [Figure 70-100- Figure 70-100-102
100].

Clean the main caps and install the bearings.

Lubricate the bearings with clean engine oil.

Install the main cap bolts and torque in steps working from
the center outward.

Step 1 65 ft.-lbs. (88 Nm)

Step 2 125 ft.-lbs. (170 Nm)
Step 3 185 ft.-lbs. (250 Nm)

Clean the bridge piece and apply a bead of LOCTITE

#518 in the corners and around the thread holes on the
block. Inject LOCTITE #518 into the groove (Item 1) at each end
of the bridge piece. Continue to inject sealant until it
leaves the lower groove (Item 2) [Figure 70-100-102] at
the front and rear of the piece.

4852210 (07-06) 70-100-36 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-104

Rear Oil Seal Removal

Remove the bolts that retain the seal housing. Remove

the housing.

Inspect the seal for wear or damage. Replace even if

there is only a small nick or scratch.

Inspect the crankshaft flange for damage.

Clean the block, seal housing, and crankshaft.

Rear Oil Seal Housing Positioning

The tool listed will be needed to do the following

procedure; Install the seal in the seal housing using the seal
installation tool. Seat the seal to the correct depth [Figure
MEL1532 - Rear Crankshaft Seal Installation Tool 70-100-104].

Figure 70-100-103 Rear Oil Seal Installation

Install the new seal in the housing.

Figure 70-100-105

The seal can be installed from flush with the housing face
(Item 1) [Figure 70-100-103] to 0.27 inch (6,86 mm) (Item
2) [Figure 70-100-103] back from the housing face. Install
seal so that the seal lip does not line up with any worn
areas on the crankshaft. Make sure the dowels (Item 1) [Figure 70-100-105] are in
the block correctly.

Install the new gasket (Item 2) on the housing (Item 3)

[Figure 70-100-105].

Install the seal replacer tool (PD145-3) (Item 4) [Figure

70-100-105] on the crankshaft.

Lubricate the seal, tool, and crankshaft with clean engine

oil.

Carefully push the seal and housing (Item 3) [Figure 70-

100-105] over the tool and crankshaft and into position on
the dowels. Remove the tool.

4852210 (07-06) 70-100-37 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-108

Rear Oil Seal Installation (Cont'd)

Figure 70-100-106

Remove the pry bar and record the dial indicator reading
[Figure 70-100-108].

The end play specification is 0.002 - 0.015 inch (0,05 -

Tighten the bolts (Item 1) [Figure 70-100-106] to 16 ft.- 0,38 mm) maximum.
lbs. (22 Nm) torque.
If end play is excessive there is over size thrust washers
Checking Crankshaft End Play available to reduce movement.

The axial movement of the crankshaft is controlled by two Figure 70-100-109

half thrust washers placed on both sides of the center
main bearing.

Figure 70-100-107

The end play can also be checked using a feeler gauge

[Figure 70-100-109].

Pry the crankshaft to the rear of the cylinder block and

Install a dial indicator on the end of the crankshaft [Figure measure the distance between the thrust washer and
70-100-107]. crankshaft.

Pry the crankshaft to the rear of the cylinder block and set
the dial indicator to zero.

4852210 (07-06) 70-100-38 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-112

Cooling System Description

Figure 70-100-110 1

P-55778

The coolant then passes around the cylinders and in the

P-55520 cylinder head. The coolant leaves the cylinder head at the
front and passes into the thermostat housing (Item 1)
[Figure 70-100-112].
Coolant from the radiator passes through the centrifugal
water pump (Item 1) [Figure 70-100-110], to assist the If the thermostat is closed, the coolant goes directly
flow of the coolant through the system. through a by-pass to the inlet side of the water pump. If
the thermostat is open, the thermostat closes the by-pass
The water pump is gear driven from the gear off the fuel and the coolant passes to the radiator.
injection pump.

From the water pump, the coolant passes through a

passage in the timing case.

The coolant passes through a passage in the left side of

the cylinder block to the rear of the cylinder block.

Figure 70-100-111

P-55781

The oil cooler (Item 1) [Figure 70-100-111] is installed on

the left side of the engine. Coolant from the by-pass
connection at the rear of the coolant pump passes
through a pipe to the oil cooler.

4852210 (07-06) 70-100-39 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Thermostat Testing

Thermostat Removal and Installation Hang the thermostats in a suitable container filled with
coolant.
Drain the engine coolant until it is below the thermostat
level. Heat the coolant gradually. Use a thermometer to check
the temperature when it starts to open and when it's fully
Figure 70-100-113 open.

If the thermostats do not operate correctly they must be

1 replaced.

1 NOTE: Identify thermostat temperature by the

stamping on the by-pass valve.

Lubricating Oil Cooler Removal And Installation

Figure 70-100-115

1 1

P-55778

Remove the bolts (Item 1) [Figure 70-100-113] and 2

thermostat housing.

Installation: Make sure all gasket surfaces are clean.

Replace the gasket before installing the thermostat
housing.

Figure 70-100-114 1 1
P-55782

Remove the eight mounting bolts (Item 1) and remove the

cooler (Item 2) [Figure 70-100-115].

Installation: Check oil level using the dipstick add oil as

needed.

P-55780

Remove the housing and thermostat [Figure 70-100-

114].

4852210 (07-06) 70-100-40 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D)

Water Pump Removal

Remove the coolant from the cooling system.

Figure 70-100-116

1
1

P-55520

Remove the mounting bolts (Item 1) [Figure 70-100-116]

from the water pump.

Remove the water pump.

Water Pump Installation

Clean the gasket surfaces and replace the gasket.

Install the water pump in the timing cover. The pump is a

tighten fit in the cover and is pulled into position by
tightening the bolts evenly.

Install the water pump bolts (Item 1) [Figure 70-100-116]

and tighten to 16 ft.-lbs. (72 Nm) torque.

4852210 (07-06) 70-100-41 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-119

Engine Lubrication System Description

Figure 70-100-117

P-55773

The engine oil passes from the filter (Item 1) [Figure 70-
100-119] to the cylinder block.

Pressure lubrication is supplied by a rotor type pump The oil passes to the main bearings of the crankshaft and
(Item 1) [Figure 70-100-117] which is driven through an through passages in the crankshaft to the big end
bearings. The pistons and the cylinder bores are
idler gear from the crankshaft gear. lubricated by splash and oil mist.

Engine oil from the oil pan sump passes through a Engine oil passes from the main bearings through
strainer (Item 2) [Figure 70-100-117] and pipe to the passages in the cylinder block to the journals of the
camshaft. Engine oil passes from the center journal of the
suction side of the pump. camshaft through a passage in the cylinder block and
cylinder head to a restriction in the pedestal of the rocker
The engine oil passes from the outlet side of the pump shaft, at a reduced pressure, to feed the rocker bushing.
The oil passes through a passage in the rocker shaft to
through a pipe to a relief valve (Item 3) [Figure 70-100- the bearings of the rocker levers. The valve stems, valve
117], which is installed in the bottom left side of the springs and the tappets are lubricated by splash and oil
cylinder block. The relief valves opens if the oil pressure is mist.
too high; this allows some of the engine oil to return to the
The hub of the idler gear is lubricated by oil from the
sump. cylinder block and the timing gears are splash lubricated.

Figure 70-100-118 The turbocharger is lubricated by oil after the filter. Oil is
supplied from a connection on the right side of the
cylinder block through an external pipe to the
turbocharger. The oil passes through the turbocharger
and returns through a pipe to the oil pan sump.

P-55779

From the relief valve, engine oil passes to a plate type oil
cooler (Item 1) [Figure 70-100-118].

4852210 (07-06) 70-100-42 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-122

Engine Lubrication System Description (Cont'd)

Figure 70-100-120

Remove the oil pan retaining bolts [Figure 70-100-122].

Remove the pan and gasket.

Turbocharged engines have piston cooling jets (Item 1)
[Figure 70-100-120]. These jets are connected to the oil Clean the pan in solvent and dry with compressed air.
pressure rail and spray lubricating oil inside the pistons to
keep them cool. Clean the block surface.

Oil Filter Adapter Removal And Installation Installation: Place a new gasket on the oil pan. Place two
bolts on each side to position the oil pan correctly. Install
Figure 70-100-121 the remaining bolts. Tighten the bolts to 16 ft.-lbs. (22 Nm)
torque [Figure 70-100-122].

1
1

P-55773

Remove the oil filter.

Remove the four bolts (Item 1) and the filter adapter (Item
2) [Figure 70-100-121].

Clean the filter adapter and the block mounting surfaces.

Using a new gasket, install the adapter (Item 2) [Figure

70-100-121] on the block.

Install the oil filter.

Oil Pan Removal And Installation

4852210 (07-06) 70-100-43 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-124

Oil Screen And Pick-up Tube

Figure 70-100-123

Remove the oil pressure relief valve (Item 1) [Figure 70-

100-124].

Remove the oil screen and pick-up tube.

Remove the bolt (Item 1) that holds the bracket (Item 2)
[Figure 70-100-123] to the main bearing cap. The oil pump is installed on the number 1 main bearing
cap.
Remove the bolts (Item 3) [Figure 70-100-123] from the
pick-up tube flange. NOTE: The pump can be removed with the main
bearing cap if a spanner wrench is available
Remove the pick-up tube (Item 4) [Figure 70-100-123] that will allow the torque to be applied directly
and gasket. to the main cap bolts.

Wash the assembly in solvent and dry with compressed If there is no spanner wrench, the front timing case cover
air. must be removed. (See Page 70-100-19.)
Check the tube and strainer for cracks or other damage.
Replace as necessary. Figure 70-100-125

Loosely assemble the bracket (Item 2) [Figure 70-100-

123] with the pick-up tube to the main bearing cap.

Install the pick up tube gasket and mounting bolts (Item 3)

[Figure 70-100-123].

Tighten the mounting bolts to 16 ft.-lbs. (22 Nm) torque.

Tighten the bolt (Item 1) [Figure 70-100-123] for the pick-

up tube bracket.

Tighten the bolt to 16 ft.-lbs. (22 Nm) torque.

Oil Pump Removal

NOTE: The oil pump has a channel in the body of the Remove the snap ring (Item 1), idler gear (Item 2) [Figure
pump. Oil from the front main bearing passes 70-100-125], and washer.
down the channel of the pump to an oil hole in
the idler shaft for lubrication of the idler shaft Remove the bolts and oil pump.
bushing.

Remove the oil pan. (See Page 70-100-43.)

4852210 (07-06) 70-100-44 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-127

Oil Pump Installation

Figure 70-100-126

Check that there is a minimum of 0.003 inch (0,076 mm)

backlash between the idler gear and oil pump gear
[Figure 70-100-127].

Fill the pump with engine oil. End play for the idler gear should be 0.0019/0.0108 inch
(0,050/0,275 mm).
If the number one main cap was removed, reinstall and
tighten to 185 ft.-lbs. (250 Nm) torque. Install the oil screen and pick-up tube. (See Page 70-100-
44.)
Install the pump on the main cap and tighten to 16 ft.-lbs.
(22 Nm) torque.
Install the pressure relief valve.
Check the idler gear and bushing for wear.
Install the oil pan. (See Page 70-100-43.)
Lubricate with clean engine oil and install the washer, idler
gear (Item 1) and snap ring (Item 2) [Figure 70-100-126].

Check the backlash between oil pump and idler gears.

There must be a minimum of 0.003 inch (0,076 mm).

4852210 (07-06) 70-100-45 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-130

Oil Pump Disassembly And Assembly

Figure 70-100-128

Check the rotor end play [Figure 70-100-130].

Rotor end play must be 0.001-0.004 inch (0,03-0,10 mm).

NOTE: If any part is worn enough to effect Install the cover and tighten the bolts to 16 ft.-lbs. (22 Nm)
performance replace the complete oil pump. torque.

Remove the cover of the oil pump. Oil Pressure Relief Valve Disassembly And Assembly

Remove the outer rotor and thoroughly clean. Check for Figure 70-100-131
cracks or other damage.

Install the outer rotor and check the outer rotor to body
clearance [Figure 70-100-128].

Clearance between the outer rotor and body must be

0.006-0.013 inch (0,15-0,34 mm).

Figure 70-100-129

Press the end plate (Item 1) in the valve body (Item 2) and
remove the snap ring (Item 3) [Figure 70-100-131].

Remove the end plate (Item 1), spring (Item 4), and
plunger (Item 5) from the body (Item 2) [Figure 70-100-
131].

Clean the parts in solvent and dry with compressed air.

Check the inner rotor to outer rotor clearance [Figure 70- Lubricate the bore of the valve body (Item 2), plunger
100-129]. (Item 5) and the end plate (Item 1) [Figure 70-100-131]
with clean engine oil before assembly.
Clearance between the inner rotor and outer rotor must
be 0.0015 - 0.005 inch (0,04-0,13 mm).

4852210 (07-06) 70-100-46 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-133

Engine Block Description

Figure 70-100-132

A bushing (Item 1) [Figure 70-100-133] is installed in the

cylinder block for the front camshaft journal while the
other camshaft journals run directly in the block.

The cylinder block is made of cast iron and provides full Engine Block Disassembly And Assembly
length support for the dry liners.
Remove the water pump. (See Page 70-100-41.)
The liners (Item 1) [Figure 70-100-132] are made of cast
iron. Production liners are a press fit and service liners are Remove the fuel injection pump. (See Page 70-70-1.)
a transion fit. Both types of liners are honed with silicon
carbide tools to a specially controlled finish to ensure long Remove the oil cooler. (See Content Page 30-01.)
engine life and low oil consumption.
Remove the oil filter and oil pan. (See Page 70-100-43.)

Remove the turbocharger. (See Page 70-100-2.)

Remove the lift fuel pump. (See Page 70-70-109.)

Remove the starter. (See Content Page 60-40-1.)

Remove the cylinder head. (See Page 70-100-6.)

Remove the timing case and gears. (See Page 70-100-

20.)

Remove the piston and connecting rod assemblies. (See

Page 70-100-26.)

Remove the camshaft and tappets. (See Page 70-100-

23.)

Remove the engine mounting bracket and flywheel. (See

Page 70-90-1.)

Remove the rear oil seal and the crankshaft. (See Page
70-100-37.)

4852210 (07-06) 70-100-47 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Piston Cooling Jet Alignment

Piston Cooling Jet Removal Figure 70-100-136

Figure 70-100-134

2.2”
(55,25 mm)

0.55”
(14 mm)
N-00535

Insert a 0.067 inch (1,70 mm) diameter rod of suitable

Remove the piston cooling jet assembly (Item 1) [Figure length, in the jet.
70-100-134] from the engine block.
The tip of the rod must extend out the top of the cylinder in
Figure 70-100-135 an area 2.2 inch (55,25 mm) in height and .55 inch (14
mm) of width to provide proper cooling jet alignment to
cool the pistons [Figure 70-100-136].

Inspection

Clean all passages of coolant and oil.

Check the block for cracks or other damage.

NOTE: The top face of the block must not be

machined. This will affect liner flange depth
and piston height above the top face of the
cylinder block.

Check the camshaft bushing for wear. If the bushing

needs to be replaced, press out old one. Press a new one
Inspect the jet tube (Item 1), mount bolt (Item 2) and in, insuring that the oil holes line up.
alignment pin (Item 3) [Figure 70-100-135] for damage.
Replace as needed.

Piston Cooling Jet Installation

Clean all parts in solvent and dry with compressed air.

Install the cooling jet (Item 1) being sure it is seated

correctly on the dowel (Item 3) [Figure 70-100-135] in the
block.

Install the mounting bolt (Item 2) [Figure 70-100-135] and

tighten to 7 ft.-lbs. 9 Nm) torque.

4852210 (07-06) 70-100-48 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Figure 70-100-138

Cylinder Liner Inspection

Figure 70-100-137

Check the cylinder liner bore for out of round or wear

beyond service limits [Figure 70-100-138]. The inside
diameter of the service liner should be 3.937-3.939 inch
(100,00-100,06 mm).
The condition of a cylinder liner is decided by:
A flex type hone may be used to clean up small scoring or
• The amount and location of polished areas. pitting.

• Wear. Damaged or worn liners must be replaced.

• Damage to the liner wall.

NOTE: It is not necessary to replace the liners if: The

honed finish can be clearly seen. Engine
performance and oil consumption is
acceptable.

Examine the liner surface (Item 1) [Figure 70-100-137]

for cracks, deep scratches and polished areas where the
honed finish is worn away.

4852210 (07-06) 70-100-49 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D)

Cylinder Liner Removal

Figure 70-100-139

NOTE: Where several liners are to be removed or a

very tight production liner is found, a press
should be used.

When one liner is replaced, a hand tool is available and

the following procedure can be done with the crank shaft
installed.

Rotate the crankshaft (if installed) to provide access to the

liner and protect the crank pin from damage.

Place the tool (Item 1) over the center of the liner (Item 2).
Make sure the flat bearing race (Item 3) [Figure 70-100-
139] is against the bottom of the recess.

Install the rod (Item 4) through the handle (Item 5) [Figure

70-100-139].

Place the adapter (Item 6) [Figure 70-100-139] under the

cylinder liner. Tighten the nut and washer. Turn the handle
and pull out the old liner.

4852210 (07-06) 70-100-50 Bobcat T2556 & T2566

SERVICE MANUAL
RECONDITIONING THE ENGINE (CONT'D) Adjust the rod until it is below the bottom of the block
surface.
Cylinder Liner Installation
Install the adapter (Item 6) [Figure 70-100-140] on the
rod. Center the adapter against the bottom of the block.

IMPORTANT Tighten the nut and washer.

Turn the handle and press the liner in the bore, stopping
For the first five hours after the new liners have been when approximately 2 inch (50 mm) remain. Apply
installed: LOCTITE #603 to the outer surface below the flange and
• Do not operate at full load. to the flange recess.
• Do not operate at high speed.
• Do not allow engine to idle for extended periods. Continue to press the liner into position. Remove the tool.
I-2117-1196

NOTE: Do Not hit the cylinder liners with a hammer.

Figure 70-100-140 They will be damaged.

Figure 70-100-141

Check liner protrusion with a dial gauge [Figure 70-100-

141].

The liner may have 0.004 inch (0,10 mm) protrusion or

recession from the block face.

Allow 15 minutes before measuring the bore. The liner will

take six hours to reach full strength.

The inside diameter of the service liner should be 3.937-

3.939 in. (100,00- 100,06 mm).

New piston rings must be used when the cylinder liners

Clean the cylinder bore and the outside of the liner. have been replaced.

Lubricate the cylinder bore with engine oil. The measurement must be from the flange (Item 1) of the
cylinder liner, not the top of the flame ring (Item 2) [Figure
Start the liner (Item 1) [Figure 70-100-140] in the bore. 70-100-141].
Make sure it is started straight.

With the adapter (Item 2) on the top of the liner, place the
bearing (Item 3) [Figure 70-100-140] in the recess at the
top.

Place the threaded rod (Item 4) through the handle (Item

5) and liner (Item 1) [Figure 70-100-140].

4852210 (07-06) 70-100-51 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 70-100-52 Bobcat T2556 & T2566
SERVICE MANUAL
HEATING, VENTILATION, AIR CONDITIONING

AIR CONDITIONING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1

AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . 80-10-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
Principals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1

Checking The Electrical System . . . . . . . . . . . . . . . . . . . . . . . 80-50-2
Compressor Drive Belt Inspection. . . . . . . . . . . . . . . . . . . . . . 80-50-1
Poor A/C Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1

COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1
Compressor Clutch Disassembly And Assembly . . . . . . . . . 80-110-2
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1

CONDENSER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1

EVAPORATOR/BLOWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1

EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-160-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-160-1 HVAC

GENERAL AIR CONDITIONING SERVICE GUIDELINES . . . . . 80-60-1

Component Replacement And Refrigeration Leaks . . . . . . . . 80-60-3
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
Compressor Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1

HEATER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1

Core Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 80-170-2
Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 80-170-2
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1

PRESSURE SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1

RECEIVER/DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1
Removal And Installation80-130-1

Contined On Next Page

4852210 (07-06) 80--1 Bobcat T2556 & T2566

SERVICE MANUAL
HEATING, VENTILATION, AIR CONDITIONING (CONT’D)

REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Cleaning The Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-2
Compressor Drive Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . 80-40-2
Filter Element Removal And Installation . . . . . . . . . . . . . . . . . . . 80-40-1

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1

SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . 80-100-1

Charging Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-5
Charging Procedure With A Manifold Gauge Set . . . . . . . . . . . 80-100-4
Reclamation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1

SYSTEM TROUBLESHOOTING CHART. . . . . . . . . . . . . . . . . . . . . 80-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1
Gauge Pressure Related Troubleshooting . . . . . . . . . . . . . . . . . 80-70-2

TEMPERATURE/PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1

4852210 (07-06) 80--2 Bobcat T2556 & T2566

SERVICE MANUAL
AIR CONDITIONING SYSTEM FLOW

Principals

In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed
circuit. At these five points in the system the refrigerant goes through pressure and temperature changes.

The compressor (Item 1) ”Chart” on page 80-10-2 takes in heated, low pressure refrigerant gas through the suction valve
(low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge
valve (high pressure side) on the condenser (Item 2) ”Chart” on page 80-10-2.

Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.

The liquid refrigerant moves on to the receiver/drier (Item 3) ”Chart” on page 80-10-2 where impurities such as moisture
and dirt are filtered out. The receiver/drier also serves as the storage tank for the liquid refrigerant. The liquid refrigerant
(still under high pressure) flows to the expansion valve (Item 4) ”Chart” on page 80-10-2.

The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) ”Chart” on page 80-10-2. As the
refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-
pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the evaporator fan
(blower) (Item 6) ”Chart” on page 80-10-2. Since the refrigerant is colder than the air, it absorbs the heat from the air and
produces cooled air, which is pushed into the cab by the fan. The moisture in the air condenses on the evaporator coil
and drips into the drain pan, which directs the water out of the cab.

The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.

4852210 (07-06) 80-10-1 Bobcat T2556 & T2566

SERVICE MANUAL
AIR CONDITIONING SYSTEM FLOW (CONT'D)

Chart

4852210 (07-06) 80-10-2 Bobcat T2556 & T2566

SERVICE MANUAL
COMPONENTS Figure 80-20-3

Identification

Figure 80-20-1

2
1

1 P-52592

Receiver/Drier: The receiver/drier (Item 1) [Figure 80-20-

P-52591 3] is the unit that receives the liquid refrigerant from the
condenser and removes moisture and foreign matter from
the system. It also serves as a storage tank for the extra
Compressor: The compressor (Item 1) [Figure 80-20-1] is liquid refrigerant until it is needed by the evaporator.
the pump that circulates the refrigerant throughout the
system. It raises the pressure of the refrigerant for heat Figure 80-20-4
transfer through the condenser and evaporator.

NOTE: The A/C System (compressor) is

recommended to be turned on for at least 5
minutes weekly throughout the year to
lubricate the internal components.

Figure 80-20-2

1
Pressure Switch: The pressure switch (Item 1) [Figure
80-20-2] is located on the receiver/drier assembly (Item 2)
[Figure 80-20-3]. It will disengage the compressor clutch
if the pressure readings are too low or too high, which
indicates loss of refrigerant.

P-52613

Condenser: The condenser (Item 1) [Figure 80-20-2] is

the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.

4852210 (07-06) 80-20-1 Bobcat T2556 & T2566

SERVICE MANUAL
COMPONENTS (CONT'D) Figure 80-20-7

Identification (Cont'd)

Figure 80-20-5

Blower Fan Switch: This is a three position switch (Item 1)

[Figure 80-20-7]. When the blower fan switch is in the
OFF position the A/C will not engage.

Evaporator Unit: The evaporator unit (Item 1) [Figure 80-

20-5] is located behind the operator seat inside the cab.
The unit delivers the cold air for the A/C into the cab. The
unit also contains the blower fan, evaporator coil and
thermostat which are not serviceable.

Figure 80-20-6

Expansion Valve: The expansion valve (Item 1) [Figure

80-20-6] controls the amount of refrigerant entering the
evaporator coil.

4852210 (07-06) 80-20-2 Bobcat T2556 & T2566

SERVICE MANUAL
SAFETY

Safety Equipment Figure 80-30-1

WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500

WARNING
In servicing A/C and heater systems you will be exposed
HFC 134A refrigerant can be dangerous if not
to high pressures, temperatures and several chemical
properly handled. Liquid 134A may cause blindness if
hazards. Moving belts and pulleys are normal shop
it contacts the eyes and may cause serious frostbite if
hazards.
it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
In addition to exercising caution in your work, DO WEAR
when it contacts open flame or very hot
SAFETY GLASSES OR A FACE SHIELD [Figure 80-30-
substances.
1] when you are using R-134a or a leak detector,
• NEVER SMOKE when there is the possibility of
adjusting service valves or the manifold gage set
even small amounts of 134A in the air.
connectors. Safety glasses or a transparent face shield
Any servicing work that involves release or addition
are practical safety items and one or the other is
of 134A to the system must be done by a competent
absolutely required.
refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration
Figure 80-30-2
equipment.
W-2373-0500

R-134a inside a canister or in an A/C system is a liquid

under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO 21.6 F DEGREES
"INSTANTLY". If it spills on your skin or in your eyes you
should flood the area with cool water and SEEK
MEDICAL ATTENTION FAST! It is a good idea to wear
gloves [Figure 80-30-2] to prevent frost bite if you should
get refrigerant on your hands.

4852210 (07-06) 80-30-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 80-30-2 Bobcat T2556 & T2566
SERVICE MANUAL
REGULAR MAINTENANCE

Filter Element Removal And Installation

Figure 80-40-1

Remove the four mount bolts (Item 1) [Figure 80-40-1]

from the fresh air filter cover at the front of the cab.

Remove the two filter mount bolts (Item 2) [Figure 80-40-

1].

Inside the filter housing, remove the filter and backup

screen.

The fresh air filter is made of open cell foam and should
be cleaned with water. A mild detergent may also be
used.

4852210 (07-06) 80-40-1 Bobcat T2556 & T2566

SERVICE MANUAL
REGULAR MAINTENANCE (CONT'D) Cleaning The Condenser

Compressor Drive Belt Inspection Open the engine cover.

It is a good rule to regularly inspect (weekly) the Temporarily remove the air cleaner. (See Page 70-40-1.)
compressor drive belt for tension and wear.
Figure 80-40-3
Open the engine cover.

Remove the drive belt cover.

Figure 80-40-2

1
1

P-52613

Clean the condenser (Item 1) [Figure 80-40-3] using

water or air pressure.
P-52591
NOTE: Clean between the oil cooler and condenser.

Check the tension on the compressor belt (Item 1)

[Figure 80-40-2].

4852210 (07-06) 80-40-2 Bobcat T2556 & T2566

SERVICE MANUAL
BASIC TROUBLESHOOTING

Poor A/C Performance Inspect the sight glass located on the receiver/drier for air
bubbles. (See “REGULAR MAINTENANCE” on page 80-
Start the Telescopic Handler, engage the parking brake. 40-1)
Engage the A/C system with the blower fan on high. Run
the Telescopic Handler at full RPM for approximately 15 Compressor Drive Belt Inspection
minutes, with the cab door closed.
Regularly inspect (weekly) the compressor drive belt for
Figure 80-50-1 wear.

Open the engine cover.

Remove the belt cover.

Figure 80-50-3

Figure 80-50-2

P-52591

Check the tension on the compressor belt (Item 1)

[Figure 80-50-3].

Check the temperature at the louvers (Item 1) [Figure 80-

50-1] with a thermometer [Figure 80-50-2].

The louver temperature should be between 36-53°.F (2.2-

11,6° C) depending on the amount of humidity in the air.

If the louver temperature is too high. (See “SYSTEM

TROUBLESHOOTING CHART” on page 80-70-1)

Check the blower fan for proper operation or noise, and

replace if necessary. (See “EVAPORATOR/BLOWER
UNIT” on page 80-150-1.)

Check the belt tension on the A/C compressor. (See

“Compressor Drive Belt Inspection” on page 80-40-2)

Check the A/C condenser for dirt or mud, and clean if

necessary. (See “Cleaning The Condenser” on page 80-
40-2)

4852210 (07-06) 80-50-1 Bobcat T2556 & T2566

SERVICE MANUAL
BASIC TROUBLESHOOTING (CONT'D) Figure 80-50-6

Checking The Electrical System

Figure 80-50-4

P-52598
1

If the compressor clutch does not engage, check the fuse

P-52591 (Item 1) [Figure 80-50-6]. Replace the fuse if needed.

Figure 80-50-7
Check to see if the compressor clutch (Item 1) [Figure 80-
50-4] is engaging.

Turn the ignition key switch to the RUN position without

starting the machine. 1

Figure 80-50-5

P-52593

Unplug the connector (Item 1) [Figure 80-50-7] from the

compressor.

Turn the blower fan switch (Item 1) [Figure 80-50-5] to

the first on position, the compressor clutch should make a
click sound, which indicates the clutch is engaging.

4852210 (07-06) 80-50-2 Bobcat T2556 & T2566

SERVICE MANUAL
BASIC TROUBLESHOOTING (CONT'D) Figure 80-50-10

Checking The Electrical System (Cont'd)

Figure 80-50-8

1
1

P-52592

Disconnect the machine harness (Item 1) [Figure 80-50-

P-52597 10] from the pressure switch.

Figure 80-50-11
With a multimeter check the resistance to the compressor
clutch connector (Item 1) [Figure 80-50-8].

If there is no resistance value replace the compressor

clutch. (See “COMPRESSOR” on page 80-110-1)

Figure 80-50-9

P-52618

With the key switch to the run position (engine off) and the
blower fan switch on the first position. Use a multimeter to
check the main harness (Item 1) [Figure 80-50-11] for
voltage.

There should be 12 volts. If there is no voltage, check the

With a multimeter, check the voltage to the compressor harness for broken wires.
clutch at the main harness (Item 1) [Figure 80-50-9].

If there is no power at the clutch, check the wiring harness

for broken wires.

If there is no power at the clutch, reconnect the wiring

harness to the compressor clutch.

4852210 (07-06) 80-50-3 Bobcat T2556 & T2566

SERVICE MANUAL
BASIC TROUBLESHOOTING (CONT'D) Figure 80-50-14

Checking The Electrical System (Cont'd)

Figure 80-50-12

Check the main harness (Item 1) [Figure 80-50-14] for

voltage. The voltage should be 12 volts. If there is no
P-52619 voltage, check the harness for broken wires.

Figure 80-50-15
If there is voltage at the harness, check the resistance at
the pressure switch (Item 1) [Figure 80-50-12].

If there is no resistance value, check for a low refrigerant

level. (See Contents Page 80-01.)

If good resistance value is observed, the pressure switch

is good.

Reconnect the main harness to the pressure switch.

Figure 80-50-13

If there is voltage at the wiring harness, check the

thermostat wire (green) for resistance. The resistance
value should be 10 ohms at 68° F (20 ° C) [Figure 80-50-
15].

If there is no resistance, replace the entire blower fan unit.

Disconnect the thermostat wiring connector (Item 1)

[Figure 80-50-13] from the main harness.

4852210 (07-06) 80-50-4 Bobcat T2556 & T2566

SERVICE MANUAL
BASIC TROUBLESHOOTING (CONT'D) Figure 80-50-18

Checking The Electrical System (Cont'd)

Figure 80-50-16

Check the main harness (Item 1) [Figure 80-50-18] for

voltage. The voltage should be 12 volts if there is no
voltage check the harness for broken wires.

Remove the fuse box cover (Item 1) [Figure 80-50-16]. Figure 80-50-19

Figure 80-50-17

If there is voltage at the main harness check the blower

fan switch [Figure 80-50-19] for resistance.
Disconnect the main wire harness connectors (Item 1)
[Figure 80-50-17] from the switch. With the switch in the OFF position, there should be zero
resistance between all terminals.
NOTE: Mark the wires for correct assembly. With the switch in the 1 position, there should be
resistance between C terminal and the B terminal. And
also between the C terminal and the L terminal frame
[Figure 80-50-19].

With the switch in the 2 position, there should be

resistance between C terminal and the B terminal. And
also between the C terminal and the M terminal frame
[Figure 80-50-19].

With the switch in the 3 position, there should be

resistance between C terminal and the B terminal. And
also between the C terminal and the H terminal frame
[Figure 80-50-19].

If any of the above resistance tests fail, replace the blower

fan switch.

4852210 (07-06) 80-50-5 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 80-50-6 Bobcat T2556 & T2566
SERVICE MANUAL
GENERAL AIR CONDITIONING SERVICE GUIDELINES Compressor Oil Check

Compressor Oil The compressor oil should be checked as follows when oil
is being added to an in service machine.
Figure 80-60-1
There is a close affinity between oil and refrigerant.
During normal operation, part of the oil circulates with the
refrigerant in the system. therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run-in advance to
insure return of oil to the compressor.

If the amount of refrigerant in the system has decreased,

charge the system. (See “SYSTEM CHARGING AND
RECLAMATION” on page 80-100-1)

Open the cab door and windows.

Run the blower fan at maximum speed.

Run the compressor for at least 20 minutes at 800-1200

RPM.
The compressor (Item 1) [Figure 80-60-1] is factory filled
with 150-170 cc's of PAG oil (Poly Alkelene Glycol). Remove the compressor from the machine. (See
“COMPRESSOR” on page 80-110-1)
Unlike engine oil, it is not necessary to frequently check or
change the compressor oil.

It is necessary to check, replenish or replace the

compressor oil in the following cases:

1. When the evaporator, condenser or receiver-drier is

replaced.

2. When refrigerant has leaked from the system.

3. When refrigerant is suddenly released from the

cooling cycle.

4. When any related problems occur in the cooling cycle.

When one of the components (the evaporator, condenser

or receiver-drier) is replaced, one ounce (30 cc) of PAG
oil should be added for each component replaced.

If the A/C compressor is changed, no oil should be added

to the system, because the compressor comes factory
filled with oil.

NOTE: Only PAG oil should be used. Never mix R-12

and R-134a Oils.

4852210 (07-06) 80-60-1 Bobcat T2556 & T2566

SERVICE MANUAL
GENERAL AIR CONDITIONING SERVICE GUIDELINES NOTE: After draining the oil through the drain hole and
(CONT'D) the connectors, extract the remaining oil
through the discharge-side connector by
Compressor Oil Check (Cont'd) rotating the drive pulley (Item 1) [Figure 80-60-
4] several times by hand.
Figure 80-60-2
Measure the drained oil in a measuring cylinder.

Check the oil for contamination, dirt, metal shavings, or

varnish color, discard the oil if contaminated.

NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.

Figure 80-60-5

Figure 80-60-3

Add new compressor oil through the suction side

connector (Item 1) [Figure 80-60-5].

Installation: Add 150-170 cc's of PAG oil.

NOTE: The suction port on the compressor is marked

with an S and is the large port on the
Remove the oil drain plug (Item 1) [Figure 80-60-2] and compressor.
drain the oil through the connectors and the oil drain hole
(Item 1) [Figure 80-60-3].

Installation: Tighten the oil drain plug to 9.4-10.8 ft.-lbs.

(13-15 Nm) torque.

Figure 80-60-4

4852210 (07-06) 80-60-2 Bobcat T2556 & T2566

SERVICE MANUAL
GENERAL AIR CONDITIONING SERVICE GUIDELINES
(CONT'D)

Component Replacement And Refrigeration Leaks

Figure 80-60-6

P-52592

Whenever the A/C system is opened to the atmosphere or

there has been a leak in the system, the receiver/drier
(Item 1) [Figure 80-60-6] must be changed.

Never leave hose fittings, compressor fittings or

components uncapped while working on the A/C system.

4852210 (07-06) 80-60-3 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 80-60-4 Bobcat T2556 & T2566
SERVICE MANUAL
SYSTEM TROUBLESHOOTING CHART

Chart

Blower motor does not operate

POSSIBLE CAUSE INSPECTION SOLUTION

1. Blown Fuse. Inspect the fuse/wiring. Replace fuse/repair wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or connector.
connection.
3. Fan motor malfunc- Check the lead wires from the motor with a circuit tester. Replace Evaporator/Blower
tion. Unit.
4. Fan motor switch Check power into and out of the fan switch. Replace Fan Switch.
malfunction.

Blower motor operates normally, but air flow is insufficient

Possible Cause Inspection Solution

1. Evaporator inlet Check evaporator for plugging. Remove obstruction and clean
obstruction evaporator fins with air or
water.
2. Defective thermo. Check thermostat using a circuit tester. Replace Evaporator/Blower
switch (frozen unit.
evaporator).

Insufficient cooling although air flow and compressor operation are normal

POSSIBLE CAUSE INSPECTION SOLUTION

1. System low on The high side pressure will be low and bubbles may be Repair any leaks and recharge
refrigerant. present in sight glass on receive drier. the refrigerant to the correct
level.
2. Excessive The high pressure side pressure will be high. Use refrigerant recovery
refrigerant. equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.

The compressor does not operate at all, or operates improperly

POSSIBLE CAUSE INSPECTION SOLUTION

1. Loose drive belt. The belt is vibrating or oscillating. Adjust tension.
2. Internal compressor The compressor is locked up and the belt slips. Replace compressor.
malfunction.
Magnetic clutch related
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic clutch.
5. Oil on the clutch Clutch slips. Replace or clean the clutch
surface. surface.
6. Open coil. Clutch does not engage and there is not reading when a circuit Replace clutch.
tester is connected between the coil and terminals.
7. Broken wiring or Clutch will not engage. Inspect the ground and connections. Repair.
poor ground.
8. Wiring harness Test the conductance of the pressure switch, thermostat, Check operation.
components. Relay, etc.

4852210 (07-06) 80-70-1 Bobcat T2556 & T2566

SERVICE MANUAL
SYSTEM TROUBLESHOOTING CHART (CONT'D)

Gauge Pressure Related Troubleshooting

Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86-96 degrees F
(30-38 degrees C) and compressor speed of approximately 2000 RPM are:

High pressure side pressure: 210-265 PSI

Low pressure side pressure: 15-33 PSI
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure.

POSSIBLE CAUSE INSPECTION SOLUTION

Low pressure side The low pressure side pressure normally becomes too high
Too high. when the high pressure side pressure is too high. As this is
explained below, the following inspection is only used when
the low pressure side is too high.
1. Expansion valve Frost is present on the suction hose. Replace expansion valve
opens too far.
2. Defective The high and low pressure side gauge pressures equalize Replace compressor.
compressor when the magnetic clutch is disengaged.
Low pressure side
Too low.
1. Low refrigerant The high side pressure will be low and bubbles may be Repair any leaks and recharge
charge present in sight glass on receiver drier. the refrigerant to the correct
level.
2. Clogged or closed The expansion valve's inlet side is frosted. Moisture or other Clean or replace the expansion
expansion valve. Contaminants can be the cause. Valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion Negative low pressure reading may be shown.
valve.
4. Thermostat The evaporator is frozen. Replace Evaporator/Blower unit.
malfunction.
High pressure side
Too high.
1. Poor condenser Dirty or clogged condenser fins. Condenser fans not Clean fins, and/or repair the fan.
performance. Operating.
2. Excessive The high pressure side pressure will be high. Use refrigerant recovery
refrigerant. equipment to capture excess
refrigerant. Charge to the correct
refrigerant level.
3. Excessive oil The high pressure side will be high. Evacuate system. Remove oil
charge from condenser and compressor.
Measure oil from compressor
and add correct oil charge back
into compressor. Flush system
with nitrogen. Replace drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
Refrigerant.
5. Restriction in High pressure side will be high, and low pressure side will be Evacuate and flush system
drier,condenser or low. replacing defective parts.
high pressure line.

4852210 (07-06) 80-70-2 Bobcat T2556 & T2566

SERVICE MANUAL
SYSTEM TROUBLESHOOTING CHART (CONT'D)

Gauge Pressure Related Troubleshooting (Cont'd)

POSSIBLE CAUSE INSPECTION SOLUTION

High pressure side
too low
1. Low refrigerant The high side pressure will be low and bubbles may be Repair any leaks and recharge
charge present in sight glass on receiver drier. the refrigerant to the correct
level.
System pressures
Equal
1. Clutch not operating See magnetic clutch related topics above.
2. Compressor not Equal high and low pressures. Replace compressor.
pumping.

4852210 (07-06) 80-70-3 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 80-70-4 Bobcat T2556 & T2566
SERVICE MANUAL
TEMPERATURE/PRESSURE
NORMAL CONDENSER RANGE
Chart TEMP F. PSIG
93 110.20
NORMAL EVAPORATOR RANGE
94 112.10
TEMP F. PSIG
95 114.10
16 15.69 100 124.30
18 17.04 102 128.50
20 18.43 104 132.90
22 19.87 106 137.30
24 21.35 108 141.90
26 22.88 110 146.50
28 24.47 112 151.30
30 26.10 114 156.10
32 27.79 116 161.10
34 29.52 118 166.10
36 31.32 120 171.30
38 33.17 122 176.60
40 35.07 124 182.00
42 37.03 126 187.50
44 39.05 128 193.10
45 40.09 130 198.90
50 45.48 135 213.70
55 51.27 140 229.40
60 57.47 145 245.80
65 64.10 150 263.00
70 71.19 155 281.10
75 78.75 160 300.10
80 86.80 165 320.10
85 95.40 170 340.80
90 104.40
91 106.30
92 108.20

Evaporator

Pressures represent gas temperatures inside the coil. not the coil surface. For an estimate of the temperature of the air
coming off the coil add 8-10 degrees F. to the temperature on the chart.

Condenser

Temperatures are not ambient temperatures but condensing temperatures. Add 40 degrees F. to the ambient
temperature to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for
ambient temperature.

Conditions and pressures will vary from system to system.

4852210 (07-06) 80-80-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 80-80-2 Bobcat T2556 & T2566
SERVICE MANUAL
AIR CONDITIONING SERVICE

Chart

Service Company/Phone Number:

Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:

Explain services required:

Post Service Conditions 15 Minutes 30 Minutes Notes

Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:

4852210 (07-06) 80-90-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 80-90-2 Bobcat T2556 & T2566
SERVICE MANUAL
SYSTEM CHARGING AND RECLAMATION

Reclamation Procedure Figure 80-100-3

Figure 80-100-1

P-52599 NOTE: Before reclaiming a refrigeration system, it is

recommended to identify the type of
refrigerant that is in the A/C system and if it is
Open the engine cover. pure enough to use. The tool MEL 1592,
Refrigerant Identifier (Item 1) [Figure 80-100-3]
Remove the access cover mounting bolt (Item 1). will determine, the kind of refrigerant and any
Remove the access cover (Item 2) [Figure 80-100-1]. possible harmful or dangerous substances
that may be present in the system. Thus
Figure 80-100-2 preventing mixing of dangerous material with
your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems
that are reclaimed and charged from your MEL
1581 Recovery/Recycling/Recharging
Machine.

Remove the protective cap and connect the refrigerant

identifier to the low pressure hose (Item 1) [Figure 80-
100-2].

Connect the refrigerant identifier to its power source.

Locate the low pressure port (Item 1) and high pressure

port (Item 2) [Figure 80-100-2] on the back side of the
compressor.

WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500

NOTE: This test is run with the engine OFF, and the A/
C switch in the OFF position.

4852210 (07-06) 80-100-1 Bobcat T2556 & T2566

SERVICE MANUAL
SYSTEM CHARGING AND RECLAMATION (CONT'D)

Reclamation Procedure (Cont'd)

Figure 80-100-4 WARNING

HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness if
it contacts the eyes and may cause serious frostbite if
it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air.
Any servicing work that involves release or addition
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration
P-52630
equipment.
W-2373-0500
Follow the steps displayed on the refrigerant identifier
screen [Figure 80-100-4]. Figure 80-100-5

Allow two minutes for the refrigerant identifier to display

the type of refrigerant and air content. An alarm will sound
if potentially flammable hydrocarbons are present and will
also indicate on the visual display.

Disconnect the refrigerant identifier from the A/C.

If the refrigerant is dangerous or flammable, it must be

evacuated from the A/C system into a separate container
and properly and safety disposed of.

If R134a is found, evacuate the system.

IMPORTANT: Only A/C trained technicians should

perform the reclaiming and recharging
procedure. Use an approved recovery/charging unit [Figure 80-100-
5] to evacuate the system.

Connect the reclaimer to the A/C charge ports.

4852210 (07-06) 80-100-2 Bobcat T2556 & T2566

SERVICE MANUAL
SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-100-8

Reclamation Procedure (Cont'd)

Figure 80-100-6

NOTE: The reclaimer unit, has a complete step by step

set of instructions [Figure 80-100-8] to follow
for reclamation and recharging of the A/C
system. a trained technician should follow
Connect the Red hose (Item 1) [Figure 80-100-6] to the these instructions as they may very slightly
high pressure port and open the valve. depending on the model and brand of
reclaimer used.
Connect the Blue hose (Item 2) [Figure 80-100-6] to the
low pressure port and open the valve.

Figure 80-100-7

Turn the reclaimer unit [Figure 80-100-7] to the ON

position and follow the on screen instructions.

4852210 (07-06) 80-100-3 Bobcat T2556 & T2566

SERVICE MANUAL
SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-100-10

Charging Procedure With A Manifold Gauge Set

Open the hood.

WARNING
2
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives 1
a toxic gas.
W-2371-0500
P-52662

Figure 80-100-9
Connect the Red hose (Item 1) [Figure 80-100-10] to the
high pressure port and open the valve.

Connect the Blue hose (Item 2) [Figure 80-100-10] to the

low pressure port and open the valve.
1
1 Figure 80-100-11

P-52622
1

Check to see that the hand valves (Item 1) [Figure 80-

100-9] are closed on the manifold gauge set.

If there is any refrigerant in the A/C system, it must be

recovered by an approved A/C reclamation procedure. P-52624
(See page 80-01.)

Connect the gauges to the A/C charge ports. Connect the Yellow hose (Item 1) [Figure 80-100-11] to
the vacuum pump.

4852210 (07-06) 80-100-4 Bobcat T2556 & T2566

SERVICE MANUAL
SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-100-14

Charging Procedure With A Manifold Gauge Set

(Cont’d)

Figure 80-100-12

1
A thermistor vacuum gauge (Item 1) [Figure 80-100-14]
can be used to determine the critical vacuum level during
evacuation. It is a solid state instrument that constantly
P-52626 monitors and visually indicates the vacuum level.

The thermistor vacuum gauge is used with the vacuum

Start the vacuum pump and open ISO-valve (Item 1)
pump [Figure 80-100-14].
[Figure 80-100-12] on the vacuum pump.
Start the vacuum pump and open ISO-valve on the
Run the vacuum pump for at least 5-10 minutes to insure
vacuum pump.
that a vacuum has been pulled on the system.

Close the ISO-valve (Item 1) [Figure 80-100-12] (which Be sure that both hand valves, and both charge port
isolates the vacuum pump from the A/C system) and turn valves are open.
OFF the vacuum pump.
Run the vacuum pump for at least 45 minutes to insure
Charging Procedure that all the moisture is boiled out of the system.

Figure 80-100-13 Stop the vacuum pump and close the ISO-valve on the
vacuum pump.

Close both hand valves on the manifold gauge set and

remove the yellow hose from the vacuum pump that goes
to the manifold gauge set.
1
Remove the vacuum pump and thermistor vacuum
gauge.

P-52623

Note vacuum pressure indicated on the low pressure

(Blue) gauge (Item 1) [Figure 80-100-13]. Let stand for 5-
10 minutes and recheck the pressure for changes.

If the pressure drops, this may be an indication of a leak in

the A/C system.

Determine the problem with the A/C system and repair it.

4852210 (07-06) 80-100-5 Bobcat T2556 & T2566

SERVICE MANUAL
SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-100-17

Charging Procedure (Cont’d)

Figure 80-100-15

1
2 Turn the A/C fan switch (Item 1) [Figure 80-100-17] to
HIGH position.
P-52631
Start the machine, and run at medium speed.
Place a refrigerant container with R134a (Item 1) on a
Watch the scale and run system until the predetermined
charging scale (Item 2) [Figure 80-100-15] and zero out
amount of refrigerant is added to the A/C system.
the scale.
The A/C system holds 1.76 lbs (0,800 Kg) of refrigerant.
Connect the yellow hose (Item 3) [Figure 80-100-15] from
the manifold gauge set to the valve on the refrigerant
Turn off the valve on the refrigerant container, and hand
tank.
valves on the manifold gauge set.
Figure 80-100-16
Turn off the engine and remove the A/C charging
equipment from the machine.
2 Install access cover.

Close the engine cover.

P-52632

Open the valve on the refrigerant container (Item 1) and

open the low pressure hand valve (Blue) (Item 2) [Figure
80-100-16] on the manifold gauge set. Allow the vacuum
to pull in the refrigerant until the pressure stabilizes.

4852210 (07-06) 80-100-6 Bobcat T2556 & T2566

SERVICE MANUAL
COMPRESSOR

Removal And Installation

WARNING
Evacuate the A/C system. (See “SYSTEM CHARGING
AND RECLAMATION” on page 80-100-1) In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
Remove the alternator. (See “Removal And Installation” eyes. In contact with a flame, R134a refrigerant gives
on page 60-30-1) a toxic gas.
W-2371-0500
Remove the compressor belt.
Figure 80-110-3
Figure 80-110-1

1 1
1

P-52609
P-52607

Remove the compressor hoses (Item 1) [Figure 80-110-

Remove the two tensioner pulley mount belts (Item 1) 3].
[Figure 80-110-1]. Remove the pulley assembly.
Installation: Tighten the hoses to 22 ft.-lbs. (29,8 Nm)
Figure 80-110-2 torque.

Cap and plug the hoses and fittings with the proper A/C
caps and plugs.
1
Figure 80-110-4

1
P-52608

Unplug the connector (Item 1) [Figure 80-110-2] from the

compressor.
P-52610
Mark the compressor hoses for correct installation.

Remove the mount bolts (Item 1) [Figure 80-110-4].

Remove the compressor.

4852210 (07-06) 80-110-1 Bobcat T2556 & T2566

SERVICE MANUAL
COMPRESSOR (CONT'D) Figure 80-110-7

Compressor Clutch Disassembly And Assembly

Figure 80-110-5

The armature plate puller (Item 1) [Figure 80-110-7] can

be constructed by drilling three 0.315 inch (8 mm) holes in
a flat circular plate, located 1.25 inches (31,75 mm) apart.

Remove the center armature nut (Item 1) [Figure 80-110- Figure 80-110-8
5].

Assembly: Tighten the armature nut to 8 ft.-lbs. (12 Nm).

Figure 80-110-6

Attach the armature puller plate (Item 1) to the armature

plate using the three bolts (Item 2) [Figure 80-110-8].

To remove the armature plate (Item 1) [Figure 80-110-6]

from the clutch face you must make an armature plate
puller.

4852210 (07-06) 80-110-2 Bobcat T2556 & T2566

SERVICE MANUAL
COMPRESSOR (CONT'D)

Compressor Clutch Disassembly And Assembly The specified clearance for the clutch is 0.01-0.02 in. (0.3-
(Cont'd) 0.6 mm) adjusting shims are available in the following
thicknesses.
Figure 80-110-9
0.0039 in. (0.1 mm)
0.0118 in. (0.3 mm)
0.0197 in. (0.5 mm)
Figure 80-110-11

Attach a slide hammer puller to the armature puller tool

[Figure 80-110-9].

Figure 80-110-10
Remove the snap ring (Item 1) [Figure 80-110-11] from
the pulley assembly.

Figure 80-110-12

Remove the armature plate (Item 1) [Figure 80-110-10]

from the compressor clutch.

Remove the shims (Item 2) [Figure 80-110-10] from the

armature shaft or armature plate. Remove the pulley from the compressor [Figure 80-110-
12].
Assembly: Insure that the clutch has the correct
clearance by adding the shims (Item 2) [Figure 80-110-
10].

4852210 (07-06) 80-110-3 Bobcat T2556 & T2566

SERVICE MANUAL
COMPRESSOR (CONT'D) Figure 80-110-15

Compressor Clutch Disassembly And Assembly

(Cont'd)

Figure 80-110-13

Remove the harness retainer screw assembly (Item 1)

[Figure 80-110-15].

Figure 80-110-16

The pulley assembly and bearing [Figure 80-110-13]

must be replaced as a complete unit.

Figure 80-110-14

Remove the snap ring (Item 1) [Figure 80-110-16] from

the coil.

Remove the lock (Item 1) and connector (Item 2) [Figure

80-110-14] from the compressor harness.

4852210 (07-06) 80-110-4 Bobcat T2556 & T2566

SERVICE MANUAL
COMPRESSOR (CONT'D)

Compressor Clutch Disassembly And Assembly

(Cont'd)

Figure 80-110-17

Remove the coil from the compressor [Figure 80-110-17].

Figure 80-110-18

The compressor [Figure 80-110-18] must be replaced as

a complete unit.

4852210 (07-06) 80-110-5 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 80-110-6 Bobcat T2556 & T2566
SERVICE MANUAL
CONDENSER Figure 80-120-2

Removal And Installation

Remove the refrigerant from the A/C system. (See

“SYSTEM CHARGING AND RECLAMATION” on
page 80-100-1) 1

WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
P-52611
a toxic gas.
W-2371-0500

Remove the A/C hose (Item 1) [Figure 80-120-2] from the

Figure 80-120-1 condenser.

Figure 80-120-3

P-52612

P-52614
Remove the hose (Item 1) [Figure 80-120-1] from the
condenser.
Remove the two nuts (Item 1) [Figure 80-120-3] from
NOTE: Install caps and plugs on all fittings. each side of the condenser.

Tilt the condenser forward and remove.

4852210 (07-06) 80-120-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 80-120-2 Bobcat T2556 & T2566
SERVICE MANUAL
RECEIVER/DRIER Figure 80-130-2

Removal And Installation 1 1

Open the engine cover.

Remove the refrigerant from the A/C system. (See

“SYSTEM CHARGING AND RECLAMATION” on
page 80-100-1)

Remove the air cleaner. (See “AIR CLEANER” on

page 70-40-1)

WARNING P-52616

In the event of a leakage, wear safety goggles. Remove the two hoses (Item 1) [Figure 80-130-2] from
Escaping refrigerant can cause severe injuries to the Receiver/Drier.
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas. NOTE: Mark the hoses for correct installation.
W-2371-0500

NOTE: Install caps and plugs on all fittings.

Figure 80-130-1
Loosen the bolt (Item 2) [Figure 80-130-2] on the
mounting bracket.

P-52592

Unplug the connector (Item 1) [Figure 80-130-1] from the

pressure switch.

4852210 (07-06) 80-130-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 80-130-2 Bobcat T2556 & T2566
SERVICE MANUAL
PRESSURE SWITCH Figure 80-140-2

Removal And Installation

Open the engine cover.

Remove the refrigerant from the A/C system. (See

“SYSTEM CHARGING AND RECLAMATION” on 1
page 80-100-1)

WARNING
In the event of a leakage, wear safety goggles.
P-52616
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas. Remove the pressure switch (Item 1) [Figure 80-140-2]
W-2371-0500
from the Receiver/Drier assembly.

Figure 80-140-1

2
1

P-52592

Unplug the connector (Item 1) from the pressure switch

(Item 2) [Figure 80-140-1].

4852210 (07-06) 80-140-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) 80-140-2 Bobcat T2556 & T2566
SERVICE MANUAL
EVAPORATOR/BLOWER UNIT Figure 80-150-3

Removal And Installation

WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500

Figure 10-151-1

Temporarily remove the covering (Item 1) [Figure 80-150-

3] from the A/C hoses and expansion valve.

Figure 80-150-4

Remove the refrigerant from the A/C system. (See

“SYSTEM CHARGING AND RECLAMATION” on
page 80-100-1)

Remove the fuse box cover (Item 1) [Figure 10-151-1].

Remove the bolt (Item 1) and plate (Item 2) [Figure 80-
Figure 80-150-2 150-4]. Remove both A/C hoses.

NOTE: Plug the A/C hoses to avoid contamination.

Remove the rear panel (Item 1) [Figure 80-150-2].

4852210 (07-06) 80-150-1 Bobcat T2556 & T2566

SERVICE MANUAL
EVAPORATOR/BLOWER UNIT (CONT'D) Figure 80-150-7

Removal And Installation (Cont'd)

Figure 80-150-5

Remove the front mounting bolt (Item 1) [Figure 80-150-

7].

Lay the evaporator/blower unit on the seat.

Disconnect the thermostat wiring connector (Item 1)
[Figure 80-150-5]. Figure 80-150-8

Figure 80-150-6

Remove the drain hose (Item 1) [Figure 80-150-8].

Remove the three mount bolts (Item 1) and ground wire Remove the evaporator/blower unit from the machine.
(Item 2) [Figure 80-150-6] from the back of the
evaporator unit.

4852210 (07-06) 80-150-2 Bobcat T2556 & T2566

SERVICE MANUAL
EXPANSION VALVE Figure 80-160-3

Removal And Installation

WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500

Figure 80-160-1

Temporarily remove the covering (Item 1) [Figure 80-160-

3] from the A/C hoses and expansion valve.

Figure 80-160-4

Remove the refrigerant from the A/C system. (See

“SYSTEM CHARGING AND RECLAMATION” on
page 80-100-1)

Remove the fuse box cover (Item 1) [Figure 80-160-1].

Remove the bolt (Item 1) and plate (Item 2) [Figure 80-
Figure 80-160-2 160-4]. Remove both A/C hoses.

NOTE: Plug the A/C hoses to avoid contamination.

Remove the rear panel (Item 1) [Figure 80-160-2].

4852210 (07-06) 80-160-1 Bobcat T2556 & T2566

SERVICE MANUAL
EXPANSION VALVE (CONT'D) Figure 80-160-6

Removal And Installation (Cont'd)

Figure 80-160-5

The expansion valve (Item 1) [Figure 80-160-6] is

replaced as a complete unit.

Remove the two mount bolts (Item 1) [Figure 80-160-5].

Remove the expansion valve.

4852210 (07-06) 80-160-2 Bobcat T2556 & T2566

SERVICE MANUAL
HEATER ASSEMBLY Figure 80-170-3

Removal And Installation

Remove the travel/signal levers. (See “TRAVEL/SIGNAL

LEVER” on page 60-70-1)

Remove the instrument panel. (See “INSTRUMENT

PANEL” on page 60-80-1)

Remove the switch panel. (See “SWITCH PANEL” on

page 60-90-1)

Remove the dash cover/steering column cover. (See

“DASH COVER/STEERING COLUMN COVER” on
page 50-130-1)

Figure 80-170-1 Clamp the heater hoses [Figure 80-170-3].

Figure 80-170-4

Disconnect the harness connector (Item 1) [Figure 80-

170-1].
Remove the heater hoses (Item 1) [Figure 80-170-4] from
Figure 80-170-2 the heater assembly.

NOTE: Mark the hoses for correct installation.

Remove the vent hoses (Item 1) [Figure 80-170-2] from

the top of the assembly.

4852210 (07-06) 80-170-1 Bobcat T2556 & T2566

SERVICE MANUAL
HEATER ASSEMBLY (CONT'D) Figure 80-170-7

Removal And Installation (Cont'd)

Figure 80-170-5

Remove the blower fan mounting bolts (Item 1) [Figure

80-170-7] and remove the blower fan.

Core Removal And Installation

Remove the mounting bolts (Item 1) [Figure 80-170-5]
and remove the heater assembly. Figure 80-170-8

Fan Removal And Installation

Figure 80-170-6

Remove the two flange mounting nuts (Item 1) [Figure

80-170-8].

Carefully remove the clip (Item 1) and cable (Item 2)

[Figure 80-170-6].

4852210 (07-06) 80-170-2 Bobcat T2556 & T2566

SERVICE MANUAL
HEATER ASSEMBLY (CONT'D) Figure 80-170-11

Core Removal And Installation (Cont'd)

Figure 80-170-9

Remove the four screws (Item 1) [Figure 80-170-11] from

the vent bracket.

Figure 80-170-12
Remove the flange/linkage assembly (Item 1) [Figure 80-
170-9] from assembly.

Figure 80-170-10

Remove the end bracket (Item 1) and spacer (Item 2)

[Figure 80-170-12] from the assembly.

Remove the two bolts (Item 1) [Figure 80-170-10] and

save for later use.

4852210 (07-06) 80-170-3 Bobcat T2556 & T2566

SERVICE MANUAL
HEATER ASSEMBLY (CONT'D) Figure 80-170-14

Core Removal And Installation (Cont'd)

Figure 80-170-13

Slide the core from the housing [Figure 80-170-14].

Be sure to separate the bracket (Item 1) and tab (Item 2)

[Figure 80-170-13].

4852210 (07-06) 80-170-4 Bobcat T2556 & T2566

SERVICE MANUAL
SPECIFICATIONS

CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-70-1
Decimal And Millimeter Equivalents . . . . . . . . . . . . . . . . . SPEC-70-1
U.S. To Metric Conversion. . . . . . . . . . . . . . . . . . . . . . . . . SPEC-70-2

ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1

Camshaft And Thrust Washer . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6
Connecting Rods And Bearings . . . . . . . . . . . . . . . . . . . . SPEC-20-4
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4
Crankshaft Re-Grind Data . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-5
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-7
Engine Torque Component . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-11
Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-9
Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-7
Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-7
Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Intake Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6
Oil Pump, Gear And Relief Valve . . . . . . . . . . . . . . . . . . . SPEC-20-9
Pistons And Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Rocker Shaft, Rockers And Bushings . . . . . . . . . . . . . . . . SPEC-20-3
Thrust Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6
Timing Case And Timing Gears . . . . . . . . . . . . . . . . . . . . SPEC-20-8
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-9
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Valve Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Water Pump And Thermostat . . . . . . . . . . . . . . . . . . . . . SPEC-20-10

HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . SPEC-50-1

Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-2
O-ring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
O-ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-3
Port Seal Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-5 SPECIFICATIONS
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1

HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS. . . . SPEC-60-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1

MACHINE TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . SPEC-30-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1

Continued On Next Page

4852210 (07-06) SPEC-01-1 Bobcat T2556 & T2566

SERVICE MANUAL
SPECIFICATIONS (CONT’D)

TORQUE SPECIFICATIONS FOR BOLTS. . . . . . . . . . . . . . . . . .SPEC-40-1

Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
Torque for General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1

TELESCOPIC HANDLER SPECIFICATIONS. . . . . . . . . . . . . . . .SPEC-10-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Dimensional Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3

4852210 (07-06) SPEC-01-2 Bobcat T2556 & T2566

SERVICE MANUAL
TELESCOPIC HANDLER SPECIFICATIONS

Dimensions are given for machine equipped with standard tires and may vary with other tire types.

• All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

• Where applicable, specifications conform to SAE, ASME or ISO standards and are subject to change without notice.

Dimensional Specifications

T2556 T2566
A 82.6 inches (2097 mm) 82.6 inches (2097 mm)
B 62.2 inches (1580 mm) 62.2 inches (1580 mm)
C 78.1 inches (1984 mm) 78.1 inches (1984 mm)
D 98.4 inches (2499 mm) 98.4 inches (2499 mm)
E 153.9 inches (3909 mm) 179.0 inches (4548 mm)
F 178.5 inches (4554 mm) 193.1 inches (4905 mm)
G 15.2 inches (385 mm) 15.2 inches (385 mm)
H 184.8 inches (4694 mm) 198.4 inches (5039 mm)
J 58.0 inches (1473 mm) 58.0 inches (1473 mm)
K 147.4 inches (3744 mm) 147.4 inches (3744 mm)
L 217.7 inches (5530 mm) 252.0 inches (6400 mm)
M 42.0 inches (1067 mm) 58.7 inches (1490 mm)

4852210 (07-06) SPEC-10-1 Bobcat T2556 & T2566

SERVICE MANUAL
TELESCOPIC HANDLER SPECIFICATIONS (CONT’D)

Performance Specifications

T2556 T2566
Operating Weight 11023 lbs. (5100 kg) 12412 lbs. (5630 kg)
Maximum Rated Capacity *5511 lbs. (2500 kg) *5511 lbs. (2500 kg)
*Rated Load Capacity can change depending on which approved attachment is used

• Where applicable, specifications conform to SAE, ASME or ISO standards and are subject to change without notice.

Engine

Make/Model PERKINS 1104C-44T (Turbo-charged)

Fuel/Cooling Diesel/Liquid
Horsepower (SAE Net) 100 HP (74,5 kW)
Number of Cylinders Four
Lubrication Pressure System W/Filter
Air Cleaner Dry replaceable cartridge w/safety element

Controls

Steering Steering Wheel w/ 3 Mode Selections (Front-Wheel, All-Wheel, Crab)

Hydraulics Joystick w/ switches
Auxiliary Hydraulics Electric Switches on Joystick
Parking Brake Hand Operated Lever

Drive System

Main Drive Hydrostatic 4 wheel drive

Transmission Infinitely variable hydrostatic piston pump, driving 1 fully reversing hydrostatic motor
Final Drive Front Differential with reduction gear box, Rear Differential, Planetary Axles with Oil
Lubrication.

Travel Speed
Low Range 0-4.4 mph (7.1 km/hr)
High Range 0-18.7 mph (30,1 km/hr)

4852210 (07-06) SPEC-10-2 Bobcat T2556 & T2566

SERVICE MANUAL
TELESCOPIC HANDLER SPECIFICATIONS (CONT’D)

Tires

Standard Tires Titan Lift Rigger II 400/70-20-58 PSI (4 Bar)

Optional Tires Dunlop T37 400/70x20-44 PSI (3 Bar)
Dunlop 405/70 - 20 SPT9 (4 Bar)
Continental Traction Farmer 15.0/55-17-51 PSI (3.5 Bar)
BFGoodrich 400/70x20 (4.10 Bar)

Capacities

Type
Fuel Tank 31.7 gals. (120 L) Diesel #2 or #1
Hyd./Hydros. System 22 gals. (83 L) EQUIVIS ZS 46
Eng. Cooling System 18 qts. (17 L) Antifreeze mixture (Ethylene Glycol)

Engine Oil Change w/Filter 9 qts (8,5 L) See oil chart

Front Axle 6.87 qts. (6.5 L) (for S/N 3631 12500 & 100032-06A
below)

9.51 qts. (9 L) (for S/N 3631 12501 &

above)
Rear Axle 11qts. (10 L) 100032-06A
Front Reduction Gearbox 0.85 qts. (0,8 L) 100032-06A

Hydraulic System

Hydraulic Pump Engine driven, 22 GPM (83 L/min)

Hydraulic Pressure 3843 PSI (265 BAR)
Auxiliary Flow

Electrical System

Alternator 14.2 Volt, 70 amp with internal regulator

Battery 12 V — 105 Ah — 700A

Instrument Panel

Full compliment of instrumentation for engine, hydraulic and machine functions.

4852210 (07-06) SPEC-10-3 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) SPEC-10-4 Bobcat T2556 & T2566
SERVICE MANUAL
ENGINE SPECIFICATIONS

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.

General

Number Of Cylinders 4
Cylinder Arrangement In-line
Cycle 4 Stroke
Direction Of Rotation Clockwise From The Front
Intake System Turbocharged
Combustion System Direct Injection
Nominal Bore 3.937 (100)
Stroke 4.134 (105)
Compression Ratio 17.25:1
Displacement 243 C.I. (4 liters)
Firing Order 1-3-4-2

Cylinder Head

Head Thickness 4.643 - 4.647 (117,95 - 118,05)

Head Thickness After Machining (Minimum) 4.614 (117,20)
Valve Seat Angle 30°
Leak Test Pressure 29 PSI (2 Bar)

Valve Guides

Inside Diameter 0.3248-0.3287 (8,250-8,350)

Outside Diameter 0.5131-0.5137 (13,034-13,047)
Valve Guide Bore 0.5118-0.5129 (13,000-13,027)
Valve Guide Clearance In The Cylinder Head (Interference) 0.0003-0.00019 (0,007-0,047)
Overall Length:
Intake 5.076-5.093 (128,92-129,37)
Exhaust 5.075-5.093 (128,92-129,37)
Protrusion From Bottom 0.486-0.498 (12,35-12,65)

4852210 (07-06) SPEC-20-1 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.

Exhaust Valves

Valve Stem Diameter 0.3515-0.3 528(8,93-8,96)

Valve Guide Clearance 0.0016-0.0033 (0,040-0,84)
Maximum 0.006 (0,15)
Valve Head Diameter 1.634-1.644 (41,51-41,75)
Valve Face Angle 30°
Overall Length 5.075-5.093 (128,92-129,37)
Seal Type Stem seal with integral seating washer
Valve Seat Angle 30°
Valve Clearance 0.018 (0,45)
Exhaust Depth (Production) 0.060-0.071 (1,53-1,81)
Exhaust Depth (Service) 0.081 (2,06)

Intake Valves

Valve Stem Diameter 0.3525-0.3535 (8,95-8,98)

Valve Guide Clearance 0.0010-0.0027 (0,025-0,069)
Maximum 0.005 (0,13)
Valve Head Diameter 1.819-1.829 (46,20-46,45)
Valve Face Angle 30°
Overall Length 5.076-5.093 (128,92-129,37)
Seal Type Stem seal with integral seating washer
Valve Seat Angle 30°
Valve Clearance 0.008 (0,20)
Intake Depth (Production) 0.062-0.072 (1,58-1,84)
Intake Depth (Service) 0.082 (2,09)

Valve Springs

Installed Height 1.358 (34,5)

Installed Height Pressure 51 lbs. (229 N)
Number Of Active Coils 3.8

4852210 (07-06) SPEC-20-2 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.

Rocker Shaft, Rockers And Bushings

Shaft Outside Diameter 0.9828-0.9837(24,962-24,987 )

Clearance Between Rocker Arm Bushing and Shaft 0.0010-0.0035 (0,26-0,89)
Maximum 0.007 (0,17)

Pistons And Piston Rings

Type Fastram combustion bowl inserted top ring groove,

graphite skirt
Piston Pin Bore Diameter 1.5631-1.5633 (39,703-39,709 )
Piston Projection Above the Block Deck 0.008-0.0137 (0,21-0,35)
Top Ring Groove Width Tapered
Second Ring Groove Width 0.0999-0.1007 (2,54-2,56)
Third Ring Groove Width 0.1385-0.1393 (3,52-3,54)
Top Ring Barrel Face, Molybdenum insert, Keystone
Second Ring Taper Face, Cast Iron, Internal Bottom Step
Oil Control Ring Two Piece Coil Spring Loaded, Chromium Face
Top Ring Width Tapered
Second Ring Width 0.097-0.098 (2,48-2,49)
Third Ring Width 0.1366-0.1374 (3,47-3,49)
Top Ring Side Clearance Wedge
Second Ring Side Clearance 0.002-0.003 (0,05-0,09)
Third Ring Side Clearance 0.0011-0.0027 (0,03-0,07)
Top Ring End Gap 0.011-0.021 (0,30-0,55)
Second Ring End Gap 0.027-0.037 (0,70-0,95)
Third Ring End Gap 0.0118-0.0216 (0,30-0,55)
Piston Pin Type Full Floating
Piston Pin Outside Diameter 1.5628-1.5630 (39,694-39,700)
Piston Boss Clearance 0.0001-0.0006 (0,003-0,015)
Bushing Type Steel Back, Lead Bronze Tin Bearing Material
Bushing Outside Diameter 1.7190-1.7259 (43,66-43,84)
Bushing Inside Diameter (Reamed) 1.5638-1.5645 (39,723-39,738)
Piston Pin Bushing Clearance 0.0009-0.0017 (0,023-0,044)

4852210 (07-06) SPEC-20-3 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.

Connecting Rods And Bearings

Connecting Rod Type H Section, Wedge Shape Small End

Connecting Rod Cap Location Flat joint face with dowels
Crank Pin End Diameter 2.6460-2.6465 (67,21-67,22 )
Piston Pin End 1.693-1.694 (43,01-43,03)
Length Between Centers 8.624-8.626 (219,05-219,10)
Bearing Type Steel Back, Lead Bronze Bearing Material with Lead
Finish
Bearing Width 1.240-1.255 (31,55-31,88)
Bearing Thickness At The Center 0.0723-0.0725 (1,835-1,842)
Bearing Clearance 0.0012-0.0032 (0,03-0,081)
Bearing Undersize Available -0.010 (-0,25), -0.020 (-0,50), -0.030 (-0,75)

Crankshaft

Main Journals 2.998-2.999 (76,16-76,18)

Maximum Wear And Out Of Round Of The Journals And 0.0016 (0,04)
Crank Pins
Width Of Center Journal 1.738-1.741 (44,15-44,22)
Width Of Other Journals 1.545-1.549 (39,24-39,34)
Crank Pin Diameters 2.499-2.500 (63,47-63,49)
Width Of Crank Pins 1.589-1.591 (40,35-40,42)
Crankshaft End Play 0.0002-0.015 (0,05-0,38)
Thrust Washer Thickness: Std. 0.089-0.091 (2,26-2,31)
Oversize 0.096-0.098 (2,45-2,50)
Main Bearing Oil Clearance 0.0022-0.0046 (0,057-0,117)

4852210 (07-06) SPEC-20-4 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.

Crankshaft (Cont'd)

Undersize Journals And Crank Pins 0.010 (0,25), 0.020 (0,50), 0.030 (0,75)

With the crankshaft on V-blocks check the maximum run-out of the journals. They must not exceed these specifications
below and the difference in run-out between journals must not exceed 0.004 (0,10)

Journal #1 Mounting
Journal #2 0.003 (0,08)
Journal #3 0.006 (0,15)
Journal #4 0.003 (0,08)
Journal #5 Mounting

Crankshaft Re-Grind Data

The finished sizes for crankshaft journals which have been ground undersize are given in the table below:

ITEM 0.010 (0,25) 0.020 (0,51) 0.030 (0,76)

1 2.9884-2.9892 2.9784-2.96792 2.9684-2.9692
(75.909-75.930) (75,649-75,670) (75,399-75,420)
2 2.488-2.4896 2.4788-2.4796 2.4688-2.4696
(63,220-63,240) (62,962-62,982) (62,708-62,728)
3 1.554 (39,47) maximum - -
4 1.474 (37,44) maximum - -
5 1.759 (44,68) maximum - -
6 1.596 (40,55) maximum - -
7 Do not machine this diameter - -
8 Do not machine this diameter - -
9 0.1448-0.1452 (3,68-3,69) - -

Crankshaft Heat Treatment: 60 Hour Nitride

NOTE: Crankshafts that have been nitrided for 60 hours can be machined 0.010 (0,25) without the need to
harden again. Check the crankshaft for cracks before and after machining. Demagnetize the crankshaft
after it has been checked for cracks. Remove any sharp corners from the oil holes. Surface finish and
fillet radii must be maintained.

4852210 (07-06) SPEC-20-5 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.

Main Bearings

Type Steel Back, 20% Tin Aluminium

All Others 1.244-1.255 (31,62-31,88)
Bearing Thickness (center) 0.0820-0.0823 (2,083-2,089)
Bearing Clearance 0.0022-0.0046 (0,057-0,117)
Bearing Undersize Available -0.010 (-0,25) -0.020 (-0,50) -0.030 (-0,75)

Thrust Washers

Type Steel back, bearing material

Position Each Side Of Center Main Bearing
Standard 0.089-0.091 (2,26-2,31 )
Oversize 0.096-0.098 (2,45-2,50 )

Camshaft And Thrust Washer

Journal #1 Diameter 1.997-1.998 (50,71-50,74)

Journal #2 Diameter 1.987-1.988 (50,46-50,48)
Journal #3 Diameter 1.967-1.968 (49,95-49,98)
Cam Lift (Intake) 0.2768-0.2807 (7,03-7,13)
Cam Lift (Exhaust) 0.3135-0.3174 (7,963-8,063)
Maximum Wear And Out Of Round 0.021 (0,05)
Camshaft End Play (Production) 0.004-0.022 (0,10-0,55)
Service Limits 0.023 (0,60)
Thrust Washer Type 360°
Thrust Washer Thickness 0.216-0.218 (5,49-5,54)
Thrust Washer Recess Depth 0.218-0.222 (5,54-5,64)

Cylinder Block

Cylinder Bore Diameter 4.1338-4.1348 (105,000-105,025 )

Main Bearing Bore Diameter 3.166-3.167 (80,416-80,442)

4852210 (07-06) SPEC-20-6 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.

Cylinder Liners

Production Dry, Interference Fit, Flanged, With Flame Ring

Service Dry, Interference Fit, Flanged, With Flame Ring
Production Liner Outside Diameter 4.105-4.106 (104,25-104,28)
Production Liner Clearance 0.001-0.003 (0,03-0,08)
Production Liner Inside Diameter 3.937-3.938 (100,00-100,03)
Service Liner Clearance ±0.001 ( ±0,03)
Inside Diameter Of Service Liner With Flame Ring 3.937-3.961 (100,0-100,63)
(Installed)
Maximum 0.010 (0,25)
Flange Thickness 0.150-0.152 (3,81-3,86)
Liner Projection From Deck Surface 0.004 (0,10) Above or 0.004 (0,10) Below
Hose Angle 30/35°
Piston Cooling Jets 7 ft.lbs. (9 Nm)

Fuel Injection Pump

Type DELPHI DP 210 with locking screw

Rotation From Drive End Clockwise
Fuel System Self Vent

Fuel Injectors

Working Pressure 4263 PSI (294 Bar)

Fuel Lift Pump

Type Electrically operated

Method of Drive Electric Motor 12V/24V
Standard Pressure 6-10 PSI (0,41-0,69 Bar)
Minimum Pressure 3.75 PSI (0,26 Bar)

4852210 (07-06) SPEC-20-7 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.

Timing Case And Timing Gears

Camshaft Gear Number Of Teeth 68

Camshaft Gear Bore Diameter 1.375-1.376 (34,93-34,95)
Camshaft Hub Outside Diameter 1.374-1.375 (34,90-34,92)
Fuel Pump Gear Number Of Teeth (Electronic) 68
Fuel Pump Gear Bore (Electronic) 1.417-1.419 (29,99-30,02)
Crankshaft Gear Number Of Teeth 34
Crankshaft Gear Bore Diameter 1.875-1.8760 (47,625-47,650)
Crankshaft Gear Hub Diameter 1.875-1.8758 (47,625-47,645)
Crankshaft Gear Clearance -0.0008 - +0.0008 (-0,020 - +0,020)
Idler Gear Number Of Teeth 73
Idler Gear Bore Diameter 2.250-2.251 (57,14-57,18)
(With Needle Bearings) 2.848-2.849 (72,35-72,36)
Width Of Idler Gear And Bushing Assembly (Fitted) 1.186-1.187 (30,14-30,16)
Flanged Bushing Inside Assembly (Fitted) 1.999-2.000 (50,78-50,80)
Idler Gear Hub Outside Diameter 1.9990-1.9999 (50,70-50,74)
(With Needle Bearings) 1.967-1.968 (49,975-49,988)
Idler Gear Hub Bushing Clearance 0.0016-0.0039 (0,04-0,10)
Gear End Play (Production Limits) 0.004-0.008 (0,10-0,20)
(With Needle Bearings) 0.0039-0.0295 (0,10-0,75)
Service Limit 0.015 (0,38)
Backlash For All Gears 0.003 (0,08) Minimum

4852210 (07-06) SPEC-20-8 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.

Oil Pump, Gear And Relief Valve

Type of Oil Pump Gear Driven, Differential Rotor

Number Of Lobes Inner 5, Outer 6
Clearance Of Outer Rotor To Body 0.006-0.013 (0,15-0,34)
End Play
Inner Rotor 0.001-0.004 (0,04-0,09)
Outer Rotor 0.0010-0.0029 (0,025-0,076)
Oil Pump Idler Gear Bushing I.D. 0.6303-0.6314 (16,012-16,038)
Idler Shaft O.D. 0.6285-0.5292 (15,966-15,984)
Idler Gear Shaft Bushing Clearance 0.0011-0.0028 (0,028-0,072)
Oil Pump Idler Gear End Play 0.0019-0.0108 (0,050-0,275)
Relief Valve Plunger Bore Diameter 0.7578-0.7598 (19,250-19,300)
Relief Valve Plunger Outside Diameter 0.7553-0.7563 (19,186-19,211)
Clearance 0.0015-0.0044 (0,039-0,114)
Length Of The Spring (Installed) 2.35 (59,8)
Load On The Spring (Installed) 3.6-5.2 PSI (0,25 -0,36 Bar)
Pressure To Open Pressure Relief Valve 60-68 PSI (4,14-4,69 Bar)
Oil Filter Type Full Flow Screw-on Type Canister
Pressure To Open By-pass Valve In Oil Filter 8-12 PSI (0,55-0,83 Bar)

Turbocharger

Type Garrett GT25

Flywheel

Run-Out Less than 0.012 (0,30)

Misalignment 0.001 (0,03) @ 1.0 (25)

4852210 (07-06) SPEC-20-9 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.

Water Pump And Thermostat

Type Centrifugal, Gear Drive

Shaft Outside Diameter 0.8435-0.8440 (21,425-21,438)
Drive Gear Bore Diameter 0.8415-0.8425 (21,375-21,400)
Drive Gear Shaft Clearance 0.0009-0.0024 (0,025-0,063)
Impeller Bore Diameter 0.4701-0.4712 (11,943-11,971)
Impeller Shaft Outside Diameter 0.4723-0.4727 (11,997-12,008)
Impeller Clearance On Shaft 0.0010-0.0025 (0,026-0,065)
Bearing Bore Diameter 1.5743-1.5753 (39,989-40,014)
Bearing Diameter 1.5743-1.5747 (39,989-40,000)
Bearing Clearance In Pump Body +0.0009/-0.0005 (+0,025/-0,011)
Thermostat Type Wax Pellet, By-pass Blanking

NOMINAL TEMPERATURE
STAMPED ON START TO OPEN FULLY OPEN MINIMUM VALVE LIFT,
THERMOSTAT BY-PASS TEMPERATURE TEMPERATURE FULLY OPEN
VALVE
180° F (82° C) 170°/185° F (77°/85° C) 198°/208° F (92°/98° C) 0.35 (9,0)

4852210 (07-06) SPEC-20-10 Bobcat T2556 & T2566

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

Engine Torque Component

COMPONENT FT.-LBS. NM
Bridge Piece To Block 12 16
Camshaft Gear Bolt 70 95
Connecting Rod Nuts
Step 1 13 18
Final 52 70
Crank Pulley Bolts 85 115
Cylinder Head Bolt
Step One 37 50
Step Two 74 100
Step Three 225°
Step Three - Long Bolts 270°
Engine Mounting Bridge To Frame 200 271
Exhaust Manifold Bolts 24 33
Flywheel Cover To Housing 45 61
Flywheel Housing To Cylinder Block 52 70
Flywheel To Crankshaft Bolts 77 105
Fuel Injector Nut 22 30
Fuel Injection Pump Gear Nut 18 24
Fuel Injection Pump Flange Nuts 18 24
Fuel Lift Pump Bolts 16 22
High Pressure Fuel Lines Fittings 22 30
Idler Gear Hub Bolts 33 44
Main Bearing Bolts
Step 1 65 88
Step 2 125 170
Step 3 185 250
Oil Pan Bolts 16 22
Oil Pan Plug 25 34
Oil Pump Cover 16 22
Oil Pump To Front Main Cap 16 22
Oil Transfer Plate Bolts 22 30
Piston Cooling Jets 7 9
Rear Oil Seal Housing Bolts 16 22
Rocker Cover Nuts (With Shim Washer) 7 9
Rocker Shaft Bracket Nuts 20 27
Timing Case To Block 16 22
Timing Case Cover To Timing Case Bolts 16 22
Turbocharger To Manifold Nuts 33 44
Water Pump To Timing Case Bolts & Nuts 16 22

4852210 (07-06) SPEC-20-11 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) SPEC-20-12 Bobcat T2556 & T2566
SERVICE MANUAL
MACHINE TORQUE SPECIFICATIONS

Specifications

AXLE

FT.-LBS. NM
Axle To Frame Mounting Bolts 275-300 370-410
Brake Housing Hex Bolt 59 80
Brake Housing Spring Bolts 7 10
Brake Housing Stud 88 120
Differential Lock Retainer Bolt 10 13
Fender Mount Bolt 90-100 125-140
Housing Bolt 236 320
Housing Nut 140 190
King Pin Mount Bolts 140 190
Pinion Ring Gear Bolts 10 13
Planetary Cover Bolts 18 25
Planetary Gear Mount Bolts 88 120
Steering Cylinder Bolts 88 120
Tie Rod Jam Nut 185 250
Tie Rod Nut 160 220
Tie Rod Swivel End 300 406
Turn Stop Adjust Jam Nut 110 150
Wheel Nuts 221 300

BOOM

FT.-LBS. NM
Extension Cylinder Base End 133 180
Extension Cylinder Rod End 188-210 255-285
Wear Pads Front 43 58
Wear Pads Rear 29 39

DRIVE BOX

FT.-LBS. NM
Cover Bolts 44 60
Inner Housing Bolts 88 120
Mounting Flange Bolts 44 60

DRIVE MOTOR

FT.-LBS. NM
End Cap Bolts 85 115
Mounting Bolts 155 210
Mounting Plate Bolts 46 63

4852210 (07-06) SPEC-30-1 Bobcat T2556 & T2566

SERVICE MANUAL
MACHINE TORQUE SPECIFICATIONS (CONT’D)

Specifications (Cont’d)

ENGINE

FT.-LBS. NM
A/C Compressor Mount Bolts 88 120
Alternator Mount Bolts 45 54
Starter Mount Bolts 45 54

HYDRAULIC PUMP

FT.-LBS. NM
Filter Head 90 122
Flange Adapter 90 122
Guide Post Bolts 17 23
Mounting Bolts 78 106
Retaining Plate 10 13
Servo End Cap 10 13
Side Cover Bolts 24 32

4852210 (07-06) SPEC-30-2 Bobcat T2556 & T2566

SERVICE MANUAL
TORQUE SPECIFICATIONS FOR BOLTS

Torque for General SAE Bolts

The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Melroe that have zinc phosphate coating are specified by the letter H following the part number.

THREAD SIZE SAE GRADE 5 SAE GRADE 8

INCH. LBS.(Nm) .250 80-90 (9,0-10,2) 110-120 (12,4-13,6)
.3125 180-200 (20,3-22,6) 215-240 (24,2-27,1)
FOOT LBS.(Nm) .375 25-28 (34-38) 35-40 (47-54)
.4375 40-45 (54-61) 60-65 (81-88)
.500 65-70 (88-95) 90-100 (122-136)
.5625 90-100 (122-136) 125-140 (170-190)
.625 125-140 (170-190) 175-190 (240-260)
.750 220-245 (300-330) 300-330 (410-450)
.875 330-360 (450-490) 475-525 (645-710)
1.000 475-525 (645-710) 725-800 (985-1085)
1.125 650-720 (880-975) 1050-1175 (1425-1600)
1.250 900-1000 (1200-1360) 1475-1625 (2000-2200)
1.375 1200-1350 (1630-1830) 2000-2200 (2720-2980)
1.500 1500-1650 (2040-2240) 2600-2850 (3530-3870)
1.625 2000-2800 (2720-2980) 3450-3800 (4680-5150)
1.750 2500-2750 (3390-3730) 4300-4800 (5830-6500)
1.875 3150-3500 (4270-4750) 5500-6100 (5830-6500)
2.000 3800-4200 (5150-5700) 6500-7200 (8800-9800)

4852210 (07-06) SPEC-40-1 Bobcat T2556 & T2566

SERVICE MANUAL
TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)

Torque For General Metric Bolts

THREAD SIZE MATERIAL

(DIA. X PITCH) HEAD MARK 4 HEAD MARK 7 HEAD MARK 10
M 5 x 0.8 3-4 ft.-lbs. (4-5 Nm)
M 6 x 1.0 6-7 ft.-lbs. (8-9 Nm) 6-9 ft.-lbs. (8-12
Nm)
M 8 x 1.25 6-9 ft.-lbs. (8-12 11-16 ft.-lbs. (15-22 18-25 ft.-lbs. (24-34
Nm) Nm) Nm)
M 10 x 1.25 13-18 ft.-lbs. (18-24 22-30 ft.-lbs. (30-41 36-50 ft.-lbs. (49-68
Nm) Nm) Nm)
M 12 x 1.25 22-30 ft.-lbs. (30-41 40-54 ft.-lbs. (54-73 69-87 ft.-lbs. (94-
Nm) Nm) 118 Nm)
M 14 x 1.5 36-50 ft.-lbs. (49-68 58-80 ft.-lbs. (79- 116-137 ft.-lbs.
Nm) 108 Nm) (157-186 Nm)

4852210 (07-06) SPEC-40-2 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONNECTION SPECIFICATIONS Straight Thread O-ring Fitting

O-ring Face Seal Connection Figure Spec-50-2

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure Spec-50-1

Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until
the washer is tight against the surface [Figure Spec-50-
2].

Tubelines And Hoses

Replace any tubelines that are bent or flattened. They will

restrict flow, which will slow hydraulic action and cause
heat.

Replace hoses which show signs of wear, damage or

weather cracked rubber.

When the fitting is tightened, you can feel when the fitting Always use two wrenches when loosening and tightening
is tight to eliminate leakage caused by under or over hose or tubeline fittings.
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
Spec-50-1].

4852210 (07-06) SPEC-50-1 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONNECTION SPECIFICATIONS Use the following procedure to tighten the flare fitting:
(CONT'D)
Tighten the nut until it makes contact with the seat. Make
Flare Fitting a mark across the flats of both the male and female parts
of the connection (Item 1) [Figure Spec-50-3].
Figure Spec-50-3
Use the chart below to find the correct tightness needed
(Item 2) [Figure Spec-50-3]. If the fitting leaks after
tightening, disconnect it and inspect the seat area for
damage.

FLARE FITTING TIGHTENING TORQUE

TUBELINE NEW ROTATE RE-ASSEMBLY

TORQUE FT.-
WRENCH SIZE OUTSIDE THREAD SIZE NO. OF HEX ROTATE NO. OF
LBS. (NM)
DIAMETER FLATS HEX FLATS
5/8" 5/16" 1/2" - 20 17 (23) 2-1/2 1
11/16" 3/8" 9/16" - 18 22 (30) 2 1
7/8" 1/2" 3/4" - 16 40 (54) 2 1
1" 5/8" 7/8" - 14 60 (81) 1-1/2 1
1-1/4" 3/4" 1-1/16" - 12 84 (114) 1 3/4
1-3/8" 1" 1-5/16" - 12 118 (160) 3/4 3/4

4852210 (07-06) SPEC-50-2 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONNECTION SPECIFICATIONS Use the following procedure to tighten the O-ring flare
(CONT'D) fitting.

O-ring Flare Fitting Figure Spec-50-5

Figure Spec-50-4

Tighten the nut until it contacts with the seat. Make a mark
across the flats of both the male and female parts of the
The flare is the primary seal, the O-ring is the secondary connection (Item 1) [Figure Spec-50-5].
seal and helps absorb vibration and pressure pulses at
the connection [Figure Spec-50-4]. Use the chart below to find the correct tightness needed
(Item 2) [Figure Spec-50-5]. If the fitting leaks after
If necessary, the O-ring-flare fitting can be used without tightening, disconnect it and inspect the seat area for
an O-ring. damage.

FLARE FITTING TIGHTENING TORQUE

** ***
TUBELINE *
NEW ROTATE RE-ASSEMBLY
WRENCH SIZE OUTSIDE THREAD SIZE TORQUE FT.-
NO. OF HEX ROTATE NO. OF
DIAMETER LBS. (NM)
FLATS HEX FLATS
5/8" 5/16" 1/2" - 20 17 (23) 2-1/2 1
11/16" 3/8" 9/16" - 18 22 (30) 2 1
7/8" 1/2" 3/4" - 16 40 (54) 2 1
1" 5/8" 7/8" - 14 60 (81) 1-1/2 1
1-1/4" 3/4" 1-1/16" - 12 84 (114) 1 3/4
1-3/8" 1" 1-5/16" - 12 118 (160) 3/4 3/4

* If a torque wrench is used to tighten a new fitting to a used hose/tubeline.

* If a torque wrench is used to tighten a used fitting to a new hose/tubeline.
* If a torque wrench is used to tighten a new fitting to a new hose/tubeline.
** If using the hex flat tightening method to tighten a new fitting to a new hose/tubeline.
** If using the hex flat tightening method to tighten a new fitting to a used hose/tubeline.
*** If using the hex flat tightening method to tighten a used fitting to a new hose/tubeline.

4852210 (07-06) SPEC-50-3 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONNECTION SPECIFICATIONS Figure Spec-50-7
(CONT'D)

O-ring Flare Fitting (Cont'd)

Figure Spec-50-6

Always remove the O-ring (Item 1) [Figure Spec-50-7]

from the flare face as shown.

An O-ring (Item 2) [Figure Spec-50-7] is added to the flat

boss of the fitting to seal the connection in this application.
NOTE: O-ring flare fittings are not recommended in all
applications. Use the standard flare fittings in
these applications.

Do not use a O-ring flare fitting when a copper bonnet

orifice is used. When tightened the connection at the
bonnet may distort the flare face and prevent it from
sealing.

Use a standard flare fitting (Item 1) [Figure Spec-50-6] as

shown.

When a O-ring flare fitting is used as a straight thread port

adapter the O-ring flare face is not used to seal. The O-
ring may come off the fitting and enter the system.

4852210 (07-06) SPEC-50-4 Bobcat T2556 & T2566

SERVICE MANUAL
HYDRAULIC CONNECTION SPECIFICATIONS NOTE: Port seal fittings are not recommended in all
(CONT'D) applications. Use O-ring boss fittings in these
applications.
Port Seal Fitting
Figure Spec-50-9
Figure Spec-50-8

Do not use port seal fittings when a thread in orifice (Item

1) [Figure Spec-50-9] is used in the port. The orifice may
interfere with the fitting and prevent it from sealing.

Use an O-ring boss fitting (Item 1) [Figure Spec-50-9] as

shown.

PORT SEAL AND O-RING BOSS TIGHTENING

TORQUE

FITTING NUT TORQUE

THREAD SIZE
WRENCH SIZE FT.LBS. (NM)
11/16" 9/16" - 18 22 (30)
15/16" 3/4" - 16 40 (54)
1 - 1/8" 7/8" - 14 60 (81)
The nut is the primary seal, the O-ring is the secondary
seal and helps absorb vibration and pressure pulses at 1 - 1/4" 1 - 1/16" - 12 84 (114)
the connection [Figure Spec-50-8]. 1 - 1/2" 1 - 5/16" - 12 118 (160)

The hex portion of the nut does not contact the surface of
the component when the nut is tight.

Use the following procedure to tighten the port seal fitting:

Port seal and nut, washer and O-ring (O-ring Boss) fittings
use the same tightening torque valve chart.

If a torque wrench cannot be used, use the following

method.

Tighten the nut until it just makes metal to metal contact,

you can feel the resistance.

Tighten the nut with a wrench no more than one hex flat
maximum.

Do not over tighten the port seal fitting.

NOTE: If a torque wrench cannot be used, use the hex

flat tightening method as an approximate
guideline.

4852210 (07-06) SPEC-50-5 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) SPEC-50-6 Bobcat T2556 & T2566
SERVICE MANUAL
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS

Specifications

Use Bobcat axle fluid (P/N 100032-06A), for the drive box, When temperatures below zero degree F (-18°C) are
planetarys and axle housing. common, the machine must be kept in a warm building.
Extra warm-up time must be used each time the machine
Use Bobcat hydraulic/hydrostatic transmission fluid (P/N is started during cold temperature conditions. Cold fluid
6563328). If this fluid is not available, use 10W-30 or will not flow easily and it makes action on the hydraulic
10W-40 SAE Motor Oil (5W-30 for 0°F [-18°C] and function slower. Loss of fluid flow to the hydrostatic pump
Below). can cause hydraulic/hydrostatic system damage in less
than 60 seconds.
DO NOT use automatic transmission fluids in the
Telescopic Handler or permanent damage to the
transmission will result.
WARNING
WARNING During cold weather (32°F [0°C] and below), do not
operate machine until the engine has run for at least
five minutes at less than half throttle. This warm-up
Diesel fuel or hydraulic fluid under pressure can period is necessary for foot pedal operation and safe
penetrate skin or eyes, causing serious injury or stopping. Do not operate controls during warm-up
death. Fluid leaks under pressure may not be visible. period.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid When temperatures are below -20°F (-30°C), the
enters skin or eyes, get immediate medical attention hydrostatic oil must be heated or kept warm. The
from a physician familiar with this injury. hydrostatic system will not get enough oil at low
W-2072-0496 temperatures. Park the machine in an area where the
temperature will be above 0°F (-18°C) if possible.
W-2027-1285

4852210 (07-06) SPEC-60-1 Bobcat T2556 & T2566

SERVICE MANUAL
4852210 (07-06) SPEC-60-2 Bobcat T2556 & T2566
SERVICE MANUAL
CONVERSIONS

Decimal And Millimeter Equivalents

FRACTIONS DECIMALS MM FRACTIONS DECIMALS MM

1/64 0.015625 0.397 33/64 0.515625 13.097
1/32 0.03125 0.794 17/32 0.53125 13.494
3/64 0.046875 1.191 35/64 0.546875 13.891
1/16 0.0625 1.588 9/16 0.5625 14.288
5/64 0.078125 1.984 37/64 0.578125 14.684
3/32 0.09375 2.381 19/32 0.59375 15.081
7/64 0.109375 2.778 39/64 0.609375 15.478
1/8 0.1250 3.175 5/8 0.6250 15.875
9/64 0.140625 3.572 41/64 0.640625 16.272
5/32 0.15625 3.969 21/32 0.65625 16.669
11/64 0.171875 4.366 43/64 0.671875 17.066
3/16 0.1876 4.762 11/16 0.6875 17.462
13/64 0.203125 5.159 45/64 0.703125 17.859
7/32 0.21875 5.556 23/32 0.71875 18.256
15/64 0.234375 5.953 47/64 0.734375 18.653
1/4 0.2500 6.350 3/4 0.7500 19.050
17/64 0.265625 6.747 49/64 0.765625 19.447
9/32 0.28125 7.144 25/32 0.78125 19.844
19/64 0.296875 7.541 51/64 0.796875 20.241
5/16 0.3125 7.938 13/16 0.8125 20.638
21/64 0.328125 8.334 53/64 0.828125 21.034
11/32 0.34375 8.731 27/32 0.84375 21.431
23/64 0.359375 9.128 55/64 0.859375 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.390625 9.922 57/64 0.890625 22.622
13/32 0.40625 10.319 29/32 0.90625 23.019
27/64 0.421875 10.716 59/64 0.921875 23.416
7/16 0.4375 11.112 15/16 0.9375 23.812
29/64 0.453125 11.509 61/64 0.953125 24.209
15/32 0.46875 11.906 31/32 0.96875 24.606
31/64 0.484375 12.303 63/64 0.984375 25.003
1/2 0.5000 12.700 1 1.000 25.400
1 mm = 0.001" =
0.03937" 0.0254 mm

4852210 (07-06) SPEC-70-1 Bobcat T2556 & T2566

SERVICE MANUAL
CONVERSION (CONT’D)

U.S. To Metric Conversion

TO CONVERT INTO MULTIPLY BY

LINEAR MEASUREMENT Miles Kilometers 1.609
Yards Meters 0.9144
Feet Meters 0.3048
Feet Centimeters 30.48
Inches Meters 0.0254
Inches Centimeters 2.54
Inches Millimeters 25.4
AREA Square Miles Square Kilometers 2.59
Square Feet Square Meters 0.0929
Square Inches Square Centimeters 6.452
Acre Hectare 0.4047
VOLUME Cubic Yards Cubic Meters 0.7646
Cubic Feet Cubic Meters 0.02832
Cubic Inches Cubic Centimeters 16.39
WEIGHT Tons (Short) Metric Tons 0.9078
Pounds Kilograms 0.4536
Ounces (Avdp.) Grams 28.3495
PRESSURE Bar Pounds/Square Inch 14,5
WORK Foot-Pounds Newton-Metre 1.356
LIQUID VOLUME Quarts Liters 0.9463
Gallons Liters 3.785
LIQUID FLOW Gallons/Minute Liters/Minute 3.785
TEMPERATURE Fahrenheit Celsius 1.Subtract 32°
2. Multiply by 5/9

4852210 (07-06) SPEC-70-2 Bobcat T2556 & T2566

SERVICE MANUAL