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Bobcat (CT1025 HST) Compact Tractor Service Manual 7398893 (12-19) – PDF DDOWNLOAD
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Bobcat (CT1025 HST) Compact Tractor Service Manual 7398893 (12-19) – PDF DDOWNLOAD
S/N B4Z911001 & Above
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Description
Bobcat (CT1025 HST) Compact Tractor Service Manual 7398893 (12-19) – PDF DDOWNLOAD
FILE DETAILS:
Bobcat (CT1025 HST) Compact Tractor Service Manual 7398893 (12-19) – PDF DDOWNLOAD
Language : English
Pages : 415
Downloadable : Yes
File Type : PDF
Size: 26.6 MB
DESCRIPTION:
Bobcat (CT1025 HST) Compact Tractor Service Manual 7398893 (12-19) – PDF DDOWNLOAD
S/N B4Z911001 & Above
FOREWORD:
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, Starting procedure, daily checks, etc.
The following publications provide information on the safe use and maintenance of the Bobcat machine 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 machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
• Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
• An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
• The AEM Safety Manual delivered with the machine gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.
TABLE OF CONTENTS:
Bobcat (CT1025 HST) Compact Tractor Service Manual 7398893 (12-19) – PDF DDOWNLOAD
TABLE OF CONTENTS 5
SAFETY FIRST 7
FOR SAFTETY 8
Alert Symbols 8
SAFETY TIPS 9
SAFETY GEAR 9
WORK PLACE 9
SAFETY INSTRUCTIONS WHEN
PREPARING TRACTOR 10
AVOID FIRES 10
CAUTIONS WHEN HANDLING THE
BATTERY 11
CAUTIONS FOR HIGH PRESSURE HOSES 11
USE OF APPROPRIATE TOOLS AND EQUIPMENT 12
HANDLING OF HAZARDOUS MATERIAL 12
HANDLING OF ROTATING BLADE, SHAFT AND DRIVING BELT 13
PREVENTION OF SCALD 13
DISPOSAL OF ENVIRONMENTAL WASTE 14
CAUTIONS WHEN HANDLING TIRES 14
SAFETY DECALS 15
GENERAL 17
IDENTIFICATION NUMBER 18
TRACTOR SERIAL NUMBER LOCATION 18
ENGINE SERIAL NUMBER LOCATION 19
TRANSMISSION NUMBER 19
DIMENSIONS 20
SPECIFICATIONS 21
POWER FLOW 23
DRIVING SPEED 24
GEAR ARRANGEMENT 24
SPEED RATIO (ENGINE VS REAR AXLE) 27
REAR TIRE ROLLING CIRCUMFERENCE 27
RELATIVE SPEED RATIO OF FRONT WHEELS 28
CALCULATION FOR RELATIVE SPEED RATIO OF FRONT WHEELS 28
HOW TO MEASURE THE ACTUAL ROLLING CIRCUMFERENCE 31
MAINTENANCE SCHEDULE CHART 32
MAINTENANCE INTERVALS 32
TIRES 34
SPECIFIED INFLATION PRESSURE 34
TIGHTENING TORQUE FOR TIRE BOLTS 34
TIGHTENING TORQUE 35
GENERAL USE SCREWS, BOLTS AND NUTS 35
STUD BOLTS 35
AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS 36
UNIT CONVERSION TABLE 37
ENGINE 38
ENGINE IDENTIFICATION 40
ENGINE DECAL (A) 40
ENGINE NUMBER (B) 40
SPECIFICATIONS 41
GENERAL SPECIFICATIONS 42
SERVICING SPECIFICATIONS 43
TROUBLESHOOTING 48
EXPLODED VIEW OF ENGINE 50
CYLINDER BLOCK 50
CRANKSHAFT, PISTON 51
OIL PUMP & CAMSHAFT 52
TIMING GEAR CASE, GOVERNOR 53
CYLINDER HEAD, EXHAUST MANIFOLD 54
OIL PAN, REAR PLATE, STARTING MOTOR 55
INJECTION PUMP, INJECTOR 56
ROCKER ARM ASSY 57
HEAD COVER 58
WATER PUMP 59
NTE COMPONENTS 60
SERVICING AND OPERATING 61
ENGINE DISASSEMBLY ORDER 67
DISASEMBLY AND INSPECTION OF
MAIN ENGINE PARTS 71
ROCKER ARM ASSY 71
CYLINDER HEAD ASSY 72
CYLINDER BLOCK 75
PISTON AND PISTON RING 76
CONNECTING ROD 78
CONNECTING ROD METAL 78
BEARING HOLDER 79
CRANKSHAFT BEARING 80
CRANKSHAFT 81
FLYWHEEL AND RING GEAR 82
CAMSHAFT ASSY 83
TIMING GEAR 83
OIL FLOW 84
OIL PUMP 85
OIL FILTER 86
WATER PUMP ASSEMBLY 86
THERMOSTAT 86
RADIATOR 87
FUEL FILTER 88
GOVERNOR 89
INJECTION PUMP 89
NOZZLE AND HOLDER 90
AIR CLEANER 91
REASSEMBLY 92
RELIEF VALVE ASSEMBLY WITH O-RING 92
CRANKSHAFT AND BEARING HOLDER ASSEMBLY 92
REAR PLATE 93
FLYWHEEL 93
PISTON AND CONNECTING ROD ASSEMBLY 93
SUCTION PIPE AND SUCTION FILTER 94
OIL PAN 94
OIL LEVEL GAUGE AND GAUGE GUIDE 94
FRONT PLATE 94
CAMSHAFT ASSY · TACHOMETER SHAFT · PLATE 95
IDLE GEAR · OIL PUMP ASSY 95
TIMING GEAR CASE 96
CRANKSHAFT PULLEY 97
INJECTION PUMP ASSEMBLY 97
INJECTION TIMING ADJUSTMENT 98
OIL FILTER 99
ENGINE STOP SOLENOID 99
TAPPET 99
CYLINDER HEAD 99
OIL PIPE 100
PUSH ROD AND ROCKER ARM ASSY 101
VALVE CLEARANCE ADJUSTMENT 101
HEAD COVER 102
WATER PUMP ASSY, RADIATOR HOSE 102
GLOW PLUG · CONNECTOR 103
OIL PRESSURE SWITCH 103
NOZZLE AND HOLDER ASSY 103
RETURN PIPE COMPL · INJECTION PIPE 104
ALTERNATOR ASSY 104
DRIVE GEAR ASSEMBLY AND HYDRAULIC OIL 104
V BELT · FAN PULLEY · COOLING FAN 105
EXHAUST MANIFOLD AND MUFFLER ASSEMBLY 105
ECU (ENGINE CONTROL UNIT) & SENSORS 106
TRANSMISSION 108
SPECIFICATIONS 109
GENERAL SPECIFICATIONS 109
TIGHTENING TORQUE FOR MAJOR COMPONENTS 109
Sealant and Adhesive Specifications 110
STRUCTURE AND OPERATING PRINCIPLE 111
Structure 111
Main Gear Shift & Shuttle System 112
Range Shift Section 113
PTO 114
PTO Clutch Pack 117
Calculation for Rear PTO and Mid PTO 117
Front Wheel Drive 118
TROUBLESHOOTING 120
EXPLODED VIEW OF TRANSMISSION 121
HI-LOW Gear 121
Bevel Pinoin Gear 122
PTO Gear 123
4WD Drive 124
4WD Joint 125
Auto 4WD (Optional) 126
SERVICING 127
Transmission Removal 127
FWD Case Removal 139
Transmission Case Disassembly 149
PTO Drive Section Disassembly 155
PTO Clutch Assembly – Disassembly 161
HST 164
SPECIFICATIONS 165
General 165
HST 165
Major Tightening Torque 165
OPERATING PRINCIPLE 166
STRUCTURE AND FUNCTION 168
Power Train 168
HST Components 169
Major HST Component Structure and Function 170
Circuit Diagram 170
Pump, Motor and Swash Plate 171
Charge Relief Valve 172
High Pressure Relief Valve 173
Inlet Check Valve (Anti-Cavitation Valve) 174
Operation of HST 176
Neutral Status 176
Forward Driving 178
Reverse Driving 180
INSPECTION AND ADJUSTMENT 182
HST Neural Position Setting 182
HST Forward Pedal Travel Adjustment 183
Pressure Testing 184
High Pressure Relief Valves 184
TROUBLESHOOTING 188
EXPLODED VIEW OF HST 190
Main Shaft Joint 190
HST Pedal 191
ASSY, HST 192
SERVICING 193
HST Removal 193
HST Components Disassembly 194
REAR AXLE 198
SPECIFICATIONS 199
Transmission Fluid 199
Tightening Torques 199
OPERATING PRINCIPLE 200
Power Train of Rear Axle 200
Principle of Differential System 201
Differential Lock System 202
TROUBLESHOOTING 204
MEASUREMENT AND ADJUSTMENT 204
Backlash for Differential Pinion and Side Gear 204
Pre-load Of Taper Roller Bearing in Diff 205
Backlash for Spiral Bevel Pinion and Ring Gear 206
Tooth Contact of Spiral Bevel 206
EXPLODED VIEW OF REAR AXLE 208
G260 Rear Differential System 208
G265 Rear Axle 209
SERVICING 210
Rear Axle Removal 210
Rear Differential System Removal 213
Rear Differential System Assembly Disassembly 215
BRAKE 218
SPECIFICATIONS 219
BASIC OPERATING PRINCIPLE 219
Basic Principle 219
Braking Force Forward/Reverse Driving 221
TROUBLESHOOTING 222
INSPECTION AND ADJUSTMENT 223
Brake Pedal Free Play 223
Brake Switch Setting (Optional) 224
Parking Brake Switch Adjustment (CT1025) 225
Brake Cam Lever Free Play 226
Brake Components Inspection 226
EXPLODED VIEW OF BRAKE 227
G250 Brake 227
G418 Brake Pedal 228
SERVICING 229
Brake Parts Removal 229
FRONT AXLE 232
SPECIFICATIONS 233
General Specifications 233
Sealant and Adhesive 233
Tightening Torque for Major Components 234
OPERATING PRINCIPLE 235
Power Transfer System for Front Axle 235
Differential System 236
Load Transfer 237
TROUBLESHOOTING 238
MEASUREMENT AND ADJUSTMENT 239
Toe In 239
Backlash for Spiral Bevel Pinion and Spiral Bevel Gear 239
Tooth Contact of Spiral Bevel Gear 240
EXPLODED VIEW OF FRONT AXLE 241
Front Axle Support 241
Bevel Gear Case 242
Front Axle Case 243
Front Axle 244
SERVICING 245
Front Axle Removal 245
Front Axle Disassembly and
Assembly 247
Steering Cylinder Removal 247
Front Axle Cover Disassembly 248
Bevel Gear Case Disassembly 249
Front Differential System Disassembly 250
Bevel Pinion Shaft Removal 252
STEERING SYSTEM 254
SPECIFICATIONS 255
Steering Cylinder 255
Steering Unit 255
Tightening Torque for Main Components 255
OPERATING PRINCIPLE 256
Hydraulic Circuit for Steering Operation 256
Operating Principle 257
Operation 258
Structure 262
TROUBLESHOOTING 265
INSPECTION AND ADJUSTMENT 266
Steering Relief Opening Pressure 266
Relief Valve Pressure Adjustment 267
EXPLODED VIEW OF STEERING SYSTEM 269
G335 Steering Cylinder 269
G422 Steering & Hand Accel 270
G615 Power Steering Unit 271
SERVICING 272
Steering Cylinder 272
Steering Unit Removal 274
Disassembly of Power Steering Unit Components 275
Inspection 278
Installation 278
Steering Hydraulic Tube Location 282
HYDRAULIC SYSTEM 284
HYDRAULIC SCHEMATIC 285
SPECIFICATIONS 289
OPERATING PRINCIPLE 290
SCHEMATIC AND CIRCUIT DIAGRAM 290
HYDRAULIC SCHEMATIC AND BASIC OPERATION 290
CIRCUIT DIAGRAM 290
HYDRAULIC PUMP 291
COMPONENTS 291
OIL FILTER 292
AUXILIARY DOUBLE ACTING VALVE (OPTIONAL) 294
HPL VALVE (HYD POWER LIFT) 300
MOWER LIFT LINKAGE 307
TROUBLESHOOTING 308
INSPECTION AND ADJUSTMENT 309
AUX DOUBLE ACTING VALVE PRESSURE
(OPTIONAL) 310
FEEDBACK PLATE ADJUSTMENT 310
HYD CYLINDER 313
EXPLODED VIEW OF HYDRAULIC SYSTEM 313
FILTER AND PIPE 314
GEAR PUMP 315
CONTROL (HPL) VALVE 316
DOUBLE ACTING VALVE 317
REAR HYDRAULIC PIPE (Option) 318
FRONT HYDRAULIC PIPE (Option) 319
SHUT-OFF VALVE (Option) 320
SERVICING 321
DOUBLE ACTING VALVE (OPTIONAL)
DISASSEMBLY AND ASSEMBLY 323
Double Acting Valve Components Removal and Installation 325
GEAR PUMP DISASSEMBLY 328
CONTROL VALVE DISASSEMBLY AND ASSEMBLY 329
Control Valve Components Disassembly 331
Assembly 336
ELECTRIC SYSTEM 338
ELECTRICAL SCHEMATICS 340
SPECIFICATIONS 341
GENERAL INFORMATION 342
SYMBOLS FOR ELECTRIC COMPONENTS 343
WIRING COLOR IDENTIFICATION 344
FUSE 345
INSPECTION 345
CAUSE FOR BLOWN FUSE 345
ELECTRIC DEVICE DIAGNOSIS 346
OPERATING PRINCIPLE 347
WHEN IGNITION SWITCH IS IN “OFF” POSITION 347
WHEN IGNITION SWITCH IS IN “ACC” POSITION 348
WHEN IGNITION SWITCH IS IN TURNED TO “ON” POSITION 349
WHEN IGNITION SWITCH IS IN TURNED TO “ST” POSITION 351
OPERATING PRINCIPLE OF PREHEAT CONTROLLER 352
ECU 353
CHECKING ELECTRICAL PARTS 356
KEY SWITCH 357
COMBINATION SWITCH 358
FLASHER UNIT 360
30/20A 5P RELAY 360
HAZARD WARNING FLASHER SWITCH 361
GLOW PLUG 362
ECU 363
ACTUATOR 369
PRESSURE SENSOR 369
SPEED SENSOR (MPU: MAGNET PICK UP) 370
PARKING BRAKE MICRO SWITCH 371
BRAKE SWITCH (OPTIONAL) 371
INSTRUMENT PANEL 372
COMPONENTS AND LOCATIONS 372
CIRCUIT DIAGRAM FOR INSTRUMENT PANEL 373
GAUGES AND INDICATORS 374
CLUSTER LAMP TEST 377
OIL PRESSURE SWITCH 378
DUAL TEMPERATURE SWITCH 378
FUEL SENSOR 379
ALTERNATOR 380
PREHEAT CONTROLLER 381
NEUTRAL SAFETY SWITCH 384
PTO CLUTCH SAFETY SWITCH 384
HEAD LAMP 385
TURN SIGNAL LAMP 386
TAIL LAMP 386
TROUBLESHOOTING 387
Exploded view OF ELECTRIC SYSTEm 402
TRANSMISSION ELECTRICAL SYSTEM 403
CHASSIS ELECTRICAL SYSTEM 404
CRUISE (OPTIONAL) 405
WIRE HARNESS 406
LIGHT 407
WORKING LAMP 408
WHEN THE ENGINE CANNOT BE STARTED 387
WHEN THE SYSTEM IS NOT CHARGED 389
WHEN THE SYSTEM IS NOT PREHEATED AUTOMATICALLY 391
WHEN THE CRUISE SYSTEM CANNOT BE OPERATED (OPTIONAL) 393
WHEN THE HEAD LAMP CANNOT BE OPERATED 395
TACHOMETER OPERATION WITH THE ENGINE RUNNING 396
FUEL GAUGE OPERATION 397
TEMPERATURE GAUGE OPERATION 399
HOUR METER OPERATION 401
INDEX 409
IMAGES PREVIEW OF THE MANUAL:
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- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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