Bobcat CT122 Compact Tractor Service Manual SNABF511001 & Above – PDF DOWNLOAD

Description

Bobcat CT122 Compact Tractor Service Manual SNABF511001 & Above – PDF DOWNLOAD

FILE DETAILS:

Bobcat CT122 Compact Tractor Service Manual SNABF511001 & Above – PDF DOWNLOAD

Language : English
Pages : 675
Downloadable : Yes
File Type : PDF
Size:17.9 MB

DESCRIPTION:

Bobcat CT122 Compact Tractor Service Manual SNABF511001 & Above – PDF DOWNLOAD

FOREWORD

This manual is for the Bobcat compact tractor mechanic. It provides necessary servicing and adjustment procedures for the Bobcat compact tractor and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

SAFETY INSTRUCTIONS:
Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual,
Handbook and 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. Failure
to follow instructions can cause injury or death.
The following publications provide information on the safe use and maintenance of the loader 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 loader gives operating information as well as routin e
maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement
Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.
• The loader 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 available from your Bobcat loader dealer.
• The loader 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 edition or one of many other languages. See your
Bobcat dealer for more information on translated versions.
• The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and
repair work.
• The Skid–Steer Loader Operator Training Course is available through your local dealer. This course is intended to provide
rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish version.
• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.

TABLE OF CONTENTS:

Bobcat CT122 Compact Tractor Service Manual SNABF511001 & Above – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
Use Safety Rules 12
Safety Rules For Power Take-Off (PTO) Driven Implements 13
Compact Tractor Requirements and Capabilities 13
FIRE PREVENTION 14
Maintenance 14
Operation 14
Electrical 14
Hydraulic System 14
Fueling 14
Starting 14
Spark Arrestor Exhaust System 14
Welding And Grinding 15
Fire Extinguishers 15
SERIAL NUMBER LOCATIONS 16
Compact Tractor Serial Number 16
Engine Serial Number 16
Loader Serial Number (Optional) 17
DELIVERY REPORT 18
COMPACT TRACTOR IDENTIFICATION 19
COMPACT TRACTOR IDENTIFICATION (WITH OPTIONAL LOADER AND REAR BALLAST) 20
COMPACT TRACTOR IDENTIFICATION (WITH OPTIONAL THREE-POINT IMPLEMENT AND FRONT BALLAST) 21
SAFETY & MAINTENANCE 23
SUPPORTING THE COMPACT TRACTOR ON JACKSTANDS 27
Procedure 27
ENGINE COVER 29
Opening And Closing 29
SEAT BELT 31
Inspection And Maintenance 31
TRANSPORTING THE COMPACT TRACTOR ON A TRAILER 33
Loading And Unloading 33
Fastening 34
TOWING THE COMPACT TRACTOR 35
Procedure 35
AXLE TOE IN 37
Inspection And Maintenance 37
SERVICE SCHEDULE 39
Chart 39
AIR CLEANER SERVICE 41
Replacing Filter Element 41
ENGINE COOLING SYSTEM 43
Checking Level 43
Cleaning 44
Hoses And Clamps 45
Removing And Replacing Coolant 45
FUEL SYSTEM 47
Fuel Specifications 47
Biodiesel Blend Fuel 47
Filling The Fuel Tank 48
Fuel Filter 49
Removing Air From The Fuel System 50
Filling A Portable Fuel Container 50
ENGINE LUBRICATION SYSTEM 51
Checking And Adding Engine Oil 51
Engine Oil Chart 51
Removing And Replacing Oil And Filter 52
HYDRAULIC / HYDROSTATIC / TRANSMISSION SYSTEM 55
Checking And Adding Fluid 55
Transmission / Differential Fluid Chart 55
Removing And Replacing Hydraulic / Hydrostatic / Transmission Filters 56
Removing And Replacing Hydraulic / Transmission Fluid 57
Hoses And Clamps 57
FRONT AXLE 59
Checking And Adding Lubricant 59
Removing And Replacing Lubricant 59
Axle Pivot 60
SPARK ARRESTOR MUFFLER 61
Cleaning Procedure 61
COMPACT TRACTOR STORAGE AND RETURN TO SERVICE 63
Storage 63
Return To Service 64
ALTERNATOR BELT 65
Belt Adjustment 65
Belt Replacement 65
LUBRICATING THE COMPACT TRACTOR 67
Lubrication Locations 67
TIRE MAINTENANCE 71
Front Wheel Nuts / Bolts 71
Rear Wheel Nuts 71
Mounting 71
Wheel Spacing (AG Tires Only) 72
PIVOT PINS 73
Inspection And Maintenance 73
SAFETY INTERLOCK SYSTEM – NEUTRAL START 75
Inspection And Maintenance 75
SAFETY INTERLOCK SYSTEM – OPERATING 77
Inspection And Maintenance 77
PARKING BRAKE SYSTEM 79
Inspection And Maintenance 79
BRAKE SYSTEM 81
Inspection And Maintenance 81
Adjusting 82
TRAVEL CONTROL PEDAL 83
Inspection And Maintenance 83
Adjustment Procedure 83
CLUTCH SYSTEM 85
Inspection And Maintenance 85
Adjusting 86
Draining Water From Clutch Housing 86
BOB-TACH (HAND LEVER) 87
Inspection And Maintenance 87
HYDRAULIC SYSTEM 89
HYDRAULIC / HYDROSTATIC SCHEMATIC 93
HYDRAULIC SYSTEM INFORMATION 95
Glossary Of Hydraulic / Hydrostatic Symbols For Compact Tractors 95
Troubleshooting The Hydraulic Circuit 99
Troubleshooting The Joystick Valve Circuit 99
Troubleshooting The Power Lift Circuit 100
Troubleshooting The Steering Circuit 101
MAIN RELIEF VALVE 103
Testing Information 103
Testing And Adjusting The Main Relief Valve 103
HYDRAULIC PUMP 109
Removal And Installation 109
Parts Identification 110
Disassembly 111
Assembly 113
STEERING VALVE 115
Removal And Installation 115
Parts Identification 117
Disassembly 118
Inspection 123
Assembly 123
STEERING CYLINDER 131
Removal And Installation 131
Parts Identification 132
Disassembly And Assembly 133
RIGHT JOYSTICK (IF EQUIPPED) 135
Removal And Installation 135
Parts Identification 139
Disassembly And Assembly 140
Adjustment 142
RIGHT JOYSTICK VALVE (IF EQUIPPED) 143
Removal And Installation 143
Parts Identification 146
Disassembly 147
Inspection 151
Assembly 151
HYDRAULIC FILTER 155
Description 155
Filter Bracket Removal And Installation 155
OIL COOLER 157
Removal And Installation 157
THREE POINT HITCH HOUSING 159
Removal And Installation 159
AUXILIARY CONTROL VALVE 161
Valve End Cap Removal And Installation 161
Valve Section Parts Identification 163
Valve Section Disassembly And Assembly 164
ROCK SHAFT 171
Removal And Installation 171
Inspection 173
MLS VALVE 175
Removal And Installation 175
Parts Identification 176
Disassembly And Assembly 177
Adjustment 186
THREE POINT CYLINDER 189
Removal And Installation 189
Disassembly And Assembly 190
Inspection 191
THREE POINT CYLINDER CONTROL 193
Removal And Installation 193
FRONT WHEEL DRIVE CASE 199
Removal And Installation 199
Parts Identification 200
Disassembly 201
Assembly 205
ROCK SHAFT LIFT ARMS 209
Removal And Installation 209
FLOW CONTROL VALVE 211
Removal And Installation 211
Parts Identification 213
Disassembly And Assembly 214
CYLINDER (Lift) (EARLY MODELS) 219
Testing 219
Removal And Installation 219
Parts Identification 222
Disassembly 223
Assembly 225
CYLINDER (LIFT) (LATE MODELS) 229
Testing 229
Removal And Installation 229
Parts Identification 232
Disassembly 233
Assembly 235
CYLINDER (TILT) (EARLY MODELS) 239
Testing 239
Removal And Installation 239
Parts Identification 241
Disassembly 242
Assembly 244
CYLINDER (TILT) (LATE MODELS) 249
Testing 249
Removal And Installation 249
Parts Identification 251
Disassembly 252
Assembly 254
HYDROSTATIC SYSTEM 257
HYDROSTATIC SYSTEM INFORMATION 259
Troubleshooting Chart 259
HYDROSTATIC PUMP 261
Removal And Installation 261
Parts Identification 262
Disassembly 263
Inspection 275
Assembly 277
Hydrostatic Pump Start-Up 289
HYDROSTATIC PUMP TESTING 291
Charge Pressure Testing 291
Forward Drive Relief Testing 292
Reverse Drive Relief Testing 293
DRIVE SYSTEM 295
SERVICE BRAKE 299
Troubleshooting Chart 299
Description 300
Brake Pedal Clearance Adjustment 301
BRAKE PEDAL ASSEMBLY 303
Removal And Installation 303
DRIVESHAFT 305
Removal And Installation 305
AXLE CASE 307
Removal And Installation 307
Parts Identification 310
Disassembly And Assembly 311
BRAKE CASE 317
Removal And Installation 317
Parts Identification 318
Disassembly And Assembly 319
Inspection 323
TRANSMISSION 325
Troubleshooting Chart 325
Middle Case / Output Shaft Group Parts Identification 326
Middle Case / Output Shaft Group Disassembly 327
Middle Case / Output Shaft Group Inspection 332
PTO Driving Shaft Group Parts Identification 333
PTO Driving Shaft Group Disassembly 334
PTO Driving Shaft Group Inspection 335
Differential Parts Identification 336
Differential Disassembly 337
Differential Inspection 341
Pinion Shaft Parts Identification 342
Pinion Shaft Disassembly 343
Pinion Shaft Inspection 347
Range Shifter Shaft Group Parts Identification 348
Range Shifter Shaft Group Disassembly 349
Range Shifter Shaft Group Inspection 351
Mid PTO Shaft Group Parts Identification 352
Mid PTO Shaft Group Disassembly 353
Mid PTO Shaft Group Inspection 356
Rear PTO Group Parts Identification 357
Rear PTO Group Disassembly 358
Rear PTO Group Inspection 362
Rear PTO Group Assembly 364
Mid PTO Shaft Group Assembly 369
Range Shifter Shaft Group Assembly 373
Pinion Shaft Assembly 376
Differential Assembly 380
PTO Driving Shaft Group Assembly 386
Middle Case / Output Shaft Group Assembly 387
FRONT AXLE 393
Removal And Installation 393
AXLE AND DIFFERENTIAL 395
Troubleshooting Chart 395
Gear Case Cover Parts Identification 396
Gear Case Cover Disassembly 397
Gear Case Cover Inspection 400
Axle Case Group Parts Identification 401
Axle Case Group Disassembly 402
Axle Case Group Inspection 408
Axle Support Removal 409
Pinion Shaft Removal 411
Pinion Shaft Parts Identification 412
Pinion Shaft Disassembly 413
Pinion Shaft Inspection 413
Differential Removal 414
Differential Parts Identification 415
Differential Disassembly 416
Differential Inspection 419
Differential Assembly 420
Differential Installation 424
Pinion Shaft Assembly 425
Pinion Shaft Installation 426
Axle Support Installation 428
Axle Case Group Assembly 430
STEERING AXLE ADJUSTMENT 441
Toe-In Checking 441
Toe-In Adjustment 441
Rocking Force 441
Steering Angle Adjustment 442
SEPARATING THE TRACTOR 443
Procedure 443
MAINFRAME 451
OPERATOR SEAT 453
Removal And Installation 453
CONSOLE COVER 455
Left Side Removal And Installation 455
Right Side Removal And Installation 456
HYDROSTATIC TRANSMISSION CASE 457
Removal And Installation 457
REAR PTO CONTROL 461
Linkage Removal And Installation 461
Disassembly And Assembly 461
MID PTO CONTROL 463
Linkage Removal And Installation 463
Linkage Disassembly And Assembly 463
UPPER COVER 465
Removal And Installation 465
FLOOR MAT 467
Removal And Installation (Right Side) 467
Removal And Installation (Left Side) 467
FLOOR PLATE 469
Removal And Installation (Left Side) 469
Removal And Installation (Right Side) 470
ENGINE COVER 471
Removal And Installation 471
ENGINE SIDE COVER 473
Removal And Installation 473
FENDER 475
Removal And Installation (Right Side) 475
Removal And Installation (Left Side) 476
FIREWALL 479
Removal And Installation 479
ROPS 485
Removal And Installation 485
Bracket Removal And Installation 486
PTO SAFETY SHIELD 487
Removal And Installation 487
DRAW BAR 489
Removal And Installation 489
DRAW BAR ASSEMBLY 491
Removal And Installation 491
THREE POINT HITCH LOWER LINKS 493
Left Side Removal And Installation 493
Right Side Removal And Installation 493
Top Link Assembly Removal And Installation 494
FUEL TANK 495
Removal And Installation 495
BOB-TACH (HAND LEVER) 497
Description 497
Removal And Installation 497
Parts Identification 498
Lever And Wedge Disassembly And Assembly 499
ELECTRICAL SYSTEM & ANALYSIS 501
ELECTRICAL SCHEMATIC 503
ELECTRICAL SYSTEM INFORMATION 504
Glossary Of Electrical Symbols 504
Electrical Component Location 507
Troubleshooting 508
Description 509
Fuse And Relay Location – Engine Compartment 509
Fuse And Relay Location – Instrument Panel 510
BATTERY 512
Removing And Installing Battery 512
Battery Maintenance 513
Using A Booster Battery (Jump Starting) 514
ALTERNATOR 516
Belt Adjustment 516
Belt Replacement 516
Charging System Inspection 517
Alternator Voltage Testing 518
Low Voltage Testing 518
High Voltage Testing 519
Removal And Installation 520
Parts Identification 521
STARTER 522
Testing 522
Removal And Installation 523
Parts Identification 524
HOOD LIGHTS 526
Removal And Installation 526
Bulb Removal And Installation 526
REAR LIGHTS 528
Removal And Installation 528
Bulb Removal And Installation 529
TURN INDICATORS 530
Removal And Installation 530
Bulb Removal And Installation 531
SEAT SENSOR 532
Removal And Installation 532
FUEL LEVEL SENDER 534
Removal And Installation 534
INSTRUMENT PANEL 536
Removal And Installation 536
CENTER CONSOLE COVER 540
Removal And Installation 540
TRANSMISSION COVER 542
Removal And Installation 542
PTO SWITCHES 544
Removal And Installation 544
Adjustment 545
HORN 546
Removal And Installation 546
CRUISE CONTROL 548
Inspection And Maintenance 548
Adjusting The Cruise Control Tension 548
ENGINE SERVICE 550
ENGINE INFORMATION 554
Description 554
Specifications (Engine Model 3C100LWB) 555
Cylinder Head 555
Valves 555
Valve Timing 555
Cylinder 556
Valve Springs 556
Rocker Arms 556
Tappet 556
Camshaft 557
Timing Gear 557
Piston Rings 558
Connecting Rods 558
Crankshaft 559
Oil Pump 560
Thermostat 560
Radiator 560
Fuel Injection Pump 561
Fuel Injection Nozzles 561
Engine Bolt Torque 562
Troubleshooting 563
Engine Removal And Installation 566
Compression – Checking 568
ENGINE SPEED CONTROL 570
Cable Removal And Installation 570
Lever Removal And Installation 572
SPARK ARRESTOR MUFFLER 574
Removal And Installation 574
AIR CLEANER 576
Removal And Installation 576
Bracket Removal And Installation 576
ENGINE COOLING SYSTEM 578
Description 578
Radiator Removal And Installation 579
Water Pump Removal And Installation 583
Water Pump Disassembly And Assembly 583
Thermostat Housing Removal And Installation 584
Testing The Thermostat 584
LUBRICATION SYSTEM 586
Description 586
Oil Pan Removal And Installation 587
Oil Pump Removal And Installation 587
Oil Pump Inspection 588
Engine Oil Pressure – Testing 589
Oil Filter 589
FUEL SYSTEM 590
Description 590
Fuel Camshaft Removal And Installation 591
Fuel Shutoff Solenoid Checking 591
Fuel Shutoff Removal And Installation 592
Fuel Injection Pump Removal And Installation 593
Fuel Injection Pump Timing 597
Fuel Injector Removal And Installation 600
Fuel Injector Nozzle Pressure – Checking 601
Nozzle Spray Condition 602
Valve Seat Tightness 602
Bleeding The Fuel System 603
CYLINDER HEAD 604
Glow Plug – Testing 604
Glow Plug Removal And Installation 605
Valve Clearance Adjustment 606
Valve Timing – Checking 606
Cylinder Head Removal And Installation 607
Cylinder Head Disassembly And Assembly 610
Cylinder Head Servicing 610
Cylinder Head Top Clearance 611
Valve Guide – Checking 611
Reconditioning The Valve And Valve Seat 613
Valve Spring 614
Valve Tappets 615
Rocker Arm And Shaft – Checking 615
CRANKSHAFT AND PISTONS 616
Piston And Connecting Rod Removal And Installation 616
Piston And Connecting Rod – Servicing 618
Cylinder Bore – Checking 620
Connecting Rod – Alignment 620
Crankshaft And Bearings Removal And Installation 621
Crankshaft And Bearings – Servicing 623
CAMSHAFT AND TIMING GEARS 626
Timing Gearcase Cover Removal And Installation 626
Timing Gears Backlash – Checking 628
Idler Gear And Shaft Removal And Installation 628
Camshaft – Servicing 630
Idler Gear And Shaft – Servicing 631
FLYWHEEL AND HOUSING 632
Flywheel Removal And Installation 632
FAN 634
Removal And Installation 634
CLUTCH ASSEMBLY 636
Removal And Installation 636
Clutch Disc Inspection 636
Pressure Plate Inspection 637
Clutch Pedal Play Adjustment 637
Clutch Pedal Stop Bolt Adjustment 637
CLUTCH HOUSING 638
Removal And Installation 638
Parts Identification 642
Disassembly 643
Inspection 647
Assembly 649
SPECIFICATIONS 654
CT122 COMPACT TRACTOR SPECIFICATIONS 656
Dimensions (Standard Machine) 656
Dimensions (With Optional Loader) 657
Performance 658
Controls 658
Engine 659
Hydraulic System 659
Electrical 659
Power Take-Off (PTO) System (Rear-PTO) 660
Power Take-Off (PTO) System (Mid-PTO Optional) 660
Drive System 660
Steering 660
Capacities 661
Tires 661
Loader (If Equipped) 661
TORQUE SPECIFICATIONS FOR BOLTS 662
Torque For General SAE Bolts 662
Torque For General Metric Bolts 663
TRANSMISSION / DIFFERENTIAL FLUID SPECIFICATIONS 664
Specifications 664
CONVERSIONS 666
Decimal And Millimeter Equivalent Chart 666
U S To Metric Conversion Chart 666
ALPHABETICAL INDEX 668
SERVICE MANUAL REVISION 670
Revision No: CT122 – 1 670
Revision No: CT122 – 2 672
Revision No: CT122 – 3 674

IMAGES PREVIEW OF THE MANUAL:

Customer Support: [email protected]

https://vimeo.com/840834868?share=copy

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.M