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Bobcat CT2025 CT2035 CT2040 CT2535 CT2540 2000 Series Compact Tractor Service Manual 7371865(11-19) – PDF DOWNLOAD
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Bobcat CT2025 CT2035 CT2040 CT2535 CT2540 2000 Series Compact Tractor Service Manual 7371865(11-19) – PDF DOWNLOAD
Compact Tractor 2000 Series
(CT2025 HST) S/N B4VH11001 & Above
(CT2025 MAN) S/N B4VJ11001 & Above
(CT2035 HST) S/N B4VK11001 & Above
(CT2035 MAN) S/N B4VL11001 & Above
(CT2040 HST) S/N B4VM11001 & Above
(CT2040 MAN) S/N B4VN11001 & Above
(CT2535 HST) S/N B4VP11001 & Above
(CT2535 MAN) S/N B4VZ11001 & Above
(CT2540 HST) S/N B4VR11001 & Above
(CT2540 MAN) S/N B4W111001 & Above
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Description
Bobcat CT2025 CT2035 CT2040 CT2535 CT2540 2000 Series Compact Tractor Service Manual 7371865(11-19) – PDF DOWNLOAD
FILE DETAILS:
Bobcat CT2025 CT2035 CT2040 CT2535 CT2540 2000 Series Compact Tractor Service Manual 7371865(11-19) – PDF DOWNLOAD
Language : English
Pages : 717
Downloadable : Yes
File Type : PDF
Size: 54.7MB
DESCRIPTION:
Bobcat CT2025 CT2035 CT2040 CT2535 CT2540 2000 Series Compact Tractor Service Manual 7371865(11-19) – PDF DOWNLOAD
Compact Tractor 2000 Series
(CT2025 HST) S/N B4VH11001 & Above
(CT2025 MAN) S/N B4VJ11001 & Above
(CT2035 HST) S/N B4VK11001 & Above
(CT2035 MAN) S/N B4VL11001 & Above
(CT2040 HST) S/N B4VM11001 & Above
(CT2040 MAN) S/N B4VN11001 & Above
(CT2535 HST) S/N B4VP11001 & Above
(CT2535 MAN) S/N B4VZ11001 & Above
(CT2540 HST) S/N B4VR11001 & Above
(CT2540 MAN) S/N B4W111001 & Above
FORWARD
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.
TABLE OF CONTENTS:
Bobcat CT2025 CT2035 CT2040 CT2535 CT2540 2000 Series Compact Tractor Service Manual 7371865(11-19) – PDF DOWNLOAD
FORWARD 3
TABLE OF CONTENTS 5
SAFETY FIRST 7
FOR SAFETY 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 MATERIALS 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 FIRST 15
GENERAL 17
DESCRIPTION FOR SYMBOLS AND ABBREVIATIONS 19
TRACTOR SERIAL NUMBER 20
TRACTOR EXTERIOR VIEW 20
IDENTIFICATION NUMBER 20
ENGINE SERIAL NUMBER 21
TRANSMISSION SERIAL NUMBER 21
DIMENSIONS 22
SPECIFICATIONS 26
DRIVING SPEED 33
GEAR ARRANGEMENT 33
ARRANGEMENT OF MAIN SHIFT GEAR AND REAR AXLE GEARS 38
MAINTENANCE SCHEDULE 40
MAINTENANCE 40
LUBRICATION LIST 42
TIGHTENING TORQUES 43
GENERAL USE SCREWS, BOLTS, AND NUTS 43
STUD BOLTS 43
AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS 44
SPRING PIN AND SNAP RING INSTALLATION 45
SPRING PIN TYPE 45
SNAP RING INSTALLATION 45
UNIT CONVERSION TABLE 46
ENGINE 47
ENGINE IDENTIFICATION 51
ENGINE EPA DECAL (A) 51
ENGINE NUMBER (B) 51
SPECIFICATIONS 52
GENERAL SPECIFICATIONS 52
ENGINE DIMENSION 53
COMPONENTS 54
ENGINE PERFORMANCE CURVE 55
TORQUE 57
BRAKE HORSE POWER (HP) 57
ENGINE PERFORMANCE CURVE ANALYSIS 57
S F C (SPECIFIC FUEL CONSUMPTION) 58
ENGINE BODY 59
SERVICING SPECIFICATIONS 59
LUBRICATING SYSTEM 62
COOLING SYSTEM 62
TIGHTENING TORQUES FOR ENGINE 63
OPERATING PRINCIPLE 64
CRDI (COMMON RAIL DIRECT INJECTION) SYSTEM 64
ECU 66
HIGH PRESSURE FUEL PUMP (FOR INJECTION) 75
FUEL RAIL(COMMON RAIL) 76
INJECTOR [C3I] 76
CYLINDER HEAD 81
CYLINDER BLOCK 81
CYLINDER HONING 81
BODY AND POWER TRAIN SYSTEM 81
CRANKSHAFT 82
PISTON AND PISTON RING 82
CONNECTING ROD 82
CAMSHAFT 82
ROCKER ARM ASSEMBLY 83
INTAKE AND EXHAUST VALVES 83
TIMING GEAR 84
FLYWHEEL 84
MLS CYLINDER HEAD GASKET 84
ENGINE OIL FLOW 85
LUBRICATING SYSTEM 85
ENGINE OIL FLOW CHART 86
FUNCTION OF LUBRICATING SYSTEM 87
COOLANT FLOW ROUTE 89
COOLING SYSTEM 89
WATER PUMP 90
THERMOSTAT 90
RADIATOR 91
RADIATOR CAP 91
FUEL SYSTEM 92
OVERVIEW FOR FUEL SUPPLY 92
FUEL FLOW ROUTE 92
FUEL FILTER 94
BLEEDING THE FUEL SYSTEM 94
HIGH PRESSURE FUEL PUMP 95
COMMON RAIL (FUEL RAIL) 97
INJECTOR [C3I (CALIBRATION IMPROVED INDIVIDUAL INJECTOR)] 98
FUEL COOLER 99
ACCELERATION SYSTEM 100
OVERVIEW 101
INTAKE & EXHAUST SYSTEM 101
EGR COOLER 103
EGR VALVE 103
AIR CONTROL VAVLE 104
CCRT (CATALYZED CONTINUOUSLY
REGENERATING TRAP) 104
SENSOR 109
SENSORS AS INPUT/OUTPUT FOR ECU 112
TROUBLESHOOTING 113
MEASUREMENT AND ADJUSTMENT 115
VALVE CLEARANCE 116
CLEARANCE ADJUSTMENT 116
VALVE LIFT (DEFLECTION AND WORN CONDITION OF VALVE CAM, TAPPET, PUSH ROD, ROCKER ARM, ETC ) 117
OIL PRESSURE MEASUREMENT 117
BUBBLE TEST FOR RADIATOR 118
EXPLODED VIEW 119
GEAR CASE 120
CYLINDER HEAD COVER 121
CRANK SHAFT 122
PISTON & CONNECTING ROD 123
CAMSHAFT 124
IDLE GEAR 125
ROCKER ARM & VALVE 126
EH3-G131002 INTAKE MANIFOLD 127
EH3-G141001 OIL PUMP 128
EH3-G142001 OIL PAN 129
EH3-G144001 OIL FILTER 130
FUEL EQUIPMENT 131
WATER FLANGE 132
EH3-G163001 WATER PUMP 133
EGR 134
EH3-G172001 EGR COOLER 135
EGR COOLER 136
TC2-G115001 AFTERTREATMENT 137
TC2-G117005 FUEL FILTER 138
TC2-G119001 ECU 139
DISASSEMBLY, SERVICE AND ASSEMBLY 140
ENGINE REMOVAL 140
ENGINE COMPONENT REMOVAL 146
HEAD COVER 151
ENGINE DISASSEMBLY 151
GLOW PLUG AND INJECTOR 152
ROCKER ARM ASSEMBLY 153
CYLINDER HEAD 155
INTAKE AND EXHAUST VALVES 156
HIGH PRESSURE FUEL PUMP 158
GEAR CASE 159
GEARS IN GEAR CASE 160
PISTON AND CONNECTING ROD 169
FLYWHEEL AND CRANKSHAFT 174
OIL FILTER 183
OIL PUMP 183
THERMOSTAT 185
WATER PUMP 186
FUEL FILTER 188
ENGINE IDENTIFICATION 189
ENGINE EPA DECAL (A) 189
SPECIFICATIONS 190
GENERAL SPECIFICATIONS 190
CYLINDER HEAD 191
VALVES 191
VALVE TIMING 191
ENGINE BODY 191
CYLINDER BORE 192
VALVE SPRING 192
ROCKER ARM 192
TAPPET 192
CAMSHAFT 193
TIMING GEAR 193
PISTON RING 194
CONNECTING ROD 194
CRANKSHAFT 195
OIL PUMP 195
LUBRICATING SYSTEM 195
COOLING SYSTEM 196
FUEL SYSTEM 196
THERMOSTAT 196
RADIATOR 196
INJECT PUMP 196
INJECTION NOZZLE 196
TIGHTENING TORQUES 197
SEPERATING PRINCIPLE 198
LUBRICATING SYSTEM 198
COOLING SYSTEM 199
FUEL SYSTEM 200
FUEL FLOW ROUTE 200
FUEL FILTER 201
BLEEDING THE FUEL SYSTEM 201
FUEL FEED PUMP 202
FUEL INJECTION PUMP 202
BASIC PRINCIPLE OF GOVERNOR SYSTEM 207
GOVERNOR SYSTEM 207
OPERATION OF GOVERNOR 208
PCV
(POSITIVE CRANKCASES VENTILATION) 209
AIR HEATER 209
PCV VALVE 209
INTAKE & EXHAUST SYSTEM 209
TROUBLESHOOTING 210
MEASUREMENT AND ADJUSTMENT 213
FAN BELT 213
ENGINE BODY 213
CHECKING AND ADJUSTING 213
VALVE CLEARANCE 214
INJECTION TIMING MEASUREMENT AND ADJUSTMENT 215
ENGINE OIL PRESSURE 217
EXPLODED VIEW 218
CYLINDER BLOCK GROUP 218
OIL PAN GROUP 219
GEAR CASE GROUP 220
MAIN BEARING CASE GROUP 221
VALVE ROCKER ARM GROUP 222
CYLINDER HEAD COVER GROUP 223
CAMSHAFT GROUP 224
PISTON & CAMSHAFT GROUP 225
NOZZLE HOLDER GROUP 226
FUEL CAMSHAFT GROUP 227
SPEED CONTROL LEVER GROUP 228
GOVERNOR GROUP 229
WATER PUMP GROUP 230
WATER HOSE GROUP 231
ENGINE DISASSEMBLY AND SERVICING 232
REMOVAL AND REASSEMBLY 232
DISASSEMBLING OTHER ENGINE PARTS 232
CYLINDER HEAD COVER, GLOW PLUGS AND FUEL OVERFLOW PIPES 232
HEAT SEAL REMOVAL PROCEDURE 233
ROCKER ARM ASSEMBLY 233
CYLINDER HEAD 234
VALVE 235
INJECTION PUMP 235
CRANKCASE 239
IDLE GEAR AND CRANK GEAR 240
VALVE CAMSHAFT 240
FUEL CAMSHAFT 241
CONNECTING ROD AND PISTON 241
CRANKSHAFT 243
INSPECTION FOR OVERHAUL 246
CYLINDER HEAD AND VALVE 246
VALVE SPRING 248
CHECKING OIL CLEARANCE
BETWEEN ROCKER ARM SHAFT AND
BUSHING 249
TIMING GEARS AND CAMSHAFTS 250
CONNECTING ROD AND PISTON 254
CRANKSHAFT 257
CYLINDER BORE 260
LUBRICATING SYSTEM 260
COOLING SYSTEM 262
FUEL SYSTEM 265
CLUTCH 267
SPECIFICATION 269
GENERAL SPECIFICATIONS 269
TIGHTENING TORQUES 269
SEALANT 269
OPERATIONAL PRINCIPLE 270
TROUBLESHOOTING 272
MEASUREMENT AND ADJUSTMENT 273
CLUTCH PEDAL PLAY ADJUSTMENT 273
CLUTCH STOPPER BOLT ADJUSTMENT 273
SAFETY START SWITCH ADJUSTMENT 274
CLUTCH DISC SPLINE BOSS AND GEAR SHAFT END PLAY 274
CLUTCH DISC WEAR INSPECTION 275
PRESSURE PLATE INSPECTION 275
THRUST BALL BEARING INSPECTION 276
FLYWHEEL SURFACE AND DEFLECTION OF ENGINE CRANKSHAFT 276
EXPLODED VIEW 277
CLUTCH LEVER 277
CLUTCH 279
CLUTCH PEDAL 281
CLUTCH DISASSEMBLY (CLUTCH DISC REPLACEMENT) 282
DISASSEMBLY, SERVICE AND ASSEMBLY 282
CLUTCH ASSEMBLY 283
TRANSMISSION 285
SPECIFICATIONS 287
GENERAL SPECIFICATIONS 287
TIGHTENING TORQUE FOR MAJOR COMPONENTS 287
SEALANT AND ADHESIVE SPECIFICATIONS 288
STRUCTURE AND OPERATING PRINCIPLE 289
MAIN GEAR SHIFT SECTION 289
OPERATING PRINCIPLE OF SYNCHRONIZER 292
RANGE SHIFT SECTION 293
PTO GEAR SHIFT SECTION 297
FRONT WHEEL DRIVE SECTION 301
INSPECTION AND ADJUSTMENT 303
SYNCHRONIZER GEAR INSPECTION 303
TROUBLESHOOTING 304
EXPLODED VIEW 305
MAIN SHAFT 305
SHAFT 1 306
SHAFT 2 307
REVERSE SHAFT 308
RANGE SHAFT 309
PTO DRIVE SHAFT 310
FRONT DRIVE SYSTEM 311
RANGE FORK 312
PTO SHIFT FORK 313
FRONT DRIVE FORK 314
PROPELLER SHAFT 315
PTO SHAFT 316
MAIN SPEED FORK 317
MAIN SHAFT 318
HST PROPER SHAFT 319
RANGE SHAFT 320
PTO DRIVE SHAFT 321
CLUTCH HOUSING REMOVAL 322
DISASSEMBLY, SERVICE AND ASSEMBLY 322
CLUTCH HOUSING ASSEMBLY DISASSEMBLY 325
TRANSMISSION CASE MAIN SHIFT, RANGE SHIFT SECTION DISASSEMBLY 328
FRONT WHEEL DRIVE SECTION DISASSEMBLY 333
TRANSMISSION CASE SHIFT SECTION ASSEMBLY 334
PTO SHAFT DISASSEMBLY 337
HST (HST MODEL) 339
SPECIFICATIONS 340
GENERAL 340
HST 340
MAJOR TIGHTENING TORQUE 340
HST STRUCTURE & COMPONENTS 341
EXTERIOR 341
COMPONENTS 342
OPERATING PRINCIPLE 344
STRUCTURE AND FUNCTION OF HST 344
BASIC PRINCIPLE OF HST 347
FUNCTION HST CHARGE PUMP 348
CHARGE RELIEF VALVE 349
HIGH PRESSURE RELIEF VALVE 350
Operation of HST 351
NEUTRAL STATUS 351
FORWARD DRIVING 352
REVERSE DRIVING 353
TROUBLESHOOTING 354
MEASUREMENT AND ADJUSTMENT 355
CHARGE RELIEF VALVE PRESSURE CHECK 355
HP RELIEF VALVE PRESSURE CHECK 356
HST PEDAL LINK ADJUSTMENT 358
HST PEDAL ADJUSTMENT 358
HST NEUTRAL POSITION ADJUSTMENT 358
CRUISE MAGNETICE CLEARANCE ADJUSTMENT (OPTIONAL) 359
BLEEDING AIR FROM HST COMPONENT 359
EXPLODED VIEW 360
TRANSMISSION CASE 360
HST ASSY 361
HST EXTERNAL HYDRAULIC LINE 362
HST PEDAL 363
CRUISE (OPTIONAL) 364
HST CONTROL 365
SERVICING 366
HST DISASSEMBLY AND ASSEMBLY 366
HST COMPONENTS DISASSEMBLY AND ASSEMBLY 366
REAR AXLE 371
SPECIFICATIONS 373
TRANSMISSION FLUID 373
TIGHTENING TORQUES 373
OPERATING PRINCIPLE 374
PRINCIPLE OF DIFFERENTIAL SYSTEM 375
DIFFERENTIAL LOCK SYSTEM 376
TROUBLESHOOTING 377
INSPECTION AND ADJUSTMENT 378
BACKLASH FOR SPIRAL BEVEL PINION AND RING GEAR 379
TOOTH CONTACT OF SPIRAL BEVEL 380
EXPLODED VIEW 382
REAR DIFFERENTIAL SYSTEM 383
DIFFERENTIAL LOCK FORK 384
REAR AXLE 385
DISASSEMBLY, SERVICING AND ASSEMBLY 386
REAR DIFFERENTIAL DISASSEMBLY 389
REAR DIFFERENTIAL SYSTEM
COMPONENTS DISASSEMBLY 391
REAR DIFFERENTIAL SYSTEM ASSEMBLY 392
REAR DIFFERENTIAL INSTALLATION 394
BRAKE 397
SPECIFICATIONS 398
GENERAL SPECIFICATION 398
STRUCTURE AND OPERATION PRINCIPLE 399
TROUBLESHOOTING 403
INSPECTION AND ADJUSTMENT 404
BRAKE PEDAL FREE PLAY 404
CLEARANCE OF BRAKE LAMP SWITCH 405
BRAKE PEDAL STOPPER 405
BRAKE COMPONENTS INSPECTION 405
BRAKE DISC 405
BRAKE PLATE 405
CAM PLATE 406
CAM PLATE AND STEEL BALL 406
EXPLODED VIEW 407
BRAKE PEDAL 407
DISASSEMBLY, SERVICING AND ASSEMBLY 408
BRAKE SECTION DISASSEMBLY AND ASSEMBLY 408
FRONT AXLE 411
SPECIFICATIONS 412
GENERAL SPECIFICATIONS 412
SEALANT AND ADHESIVE 412
TIGHTENING TORQUE FOR MAJOR COMPONENTS 413
STRUCTURE AND OPERATING PRINCIPLE 414
POWER TRANSFER SYSTEM FOR FRONT AXLE 414
DIFFERENTIAL SYSTEM 419
LOAD TRANSFER 420
TROUBLESHOOTING 421
INSPECTION AND ADJUSTMENT 422
TOE-IN 422
STEERING ANGLE 422
SWAY RESISTANCE 423
PRELOAD OF TAPER ROLLER BEARING ON SPIRAL BEVEL PINION SHAFT 423
BACKLASH FOR DIFFERENTIAL PINION AND DIFFERENTIAL SIDE GEAR 424
BACKLASH FOR SPIRAL BEVEL PINION AND 23 SPIRAL BEVEL GEAR 424
TOOTH CONTACT OF SPIRAL BEVEL GEAR 425
TOOTH CONTACT FOR UPPER BEVEL GEARS AND FINAL DRIVE BEVEL GEARS 427
EXPLODED VIEW 428
FRONT DIFFERENTIAL 428
FRONT AXLE CASE 429
FRONT AXLE 430
FRONT AXLE BRACKET 431
BEVEL PINION SHAFT 432
DIFF GEAR SHAFT 433
DISASSEMBLY, SERVIE AND ASSEMBLY 434
FRONT AXLE OIL SEAL REPLACEMENT 434
BEVEL GEAR CASE AND FRONT AXLE CASE DISASSEMBLY AND ASSEMBLY 437
FRONT DIFFERENTIAL SYSTEM REMOVAL AND INSTALLATION 440
FRONT DIFFERENTIAL SYSTEM DISASSEMBLY AND ASSEMBLY COMPONENTS 445
STEERING SYSTEM 447
SPECIFCATIONS AND TIGHTENING TORQUE 449
SPECIFICATIONS FOR STEERING SYSTEM 449
TIGHTENING TORQUE FOR MAJOR COMPONENTS 449
HYDRAULIC PUMP 449
POWER STEERING UNIT 449
STEERING CYLINDER 449
OPERATING DIAGRAM 450
STRUCTURE AND OPERATING PRINCIPLE 450
STEERING UNIT 452
OPERATING PRINCIPLE 452
STRUCTURE AND SPECIFICATIONS 453
OPERATING PRINCIPLE OF STEERING SYSTEM 454
STRUCTURE AND OPERATING PRINCIPLE 458
TROUBLESHOOTING 459
INSPECTION AND ADJUSTMENT 460
EXPLODED VIEW 461
STEERING CYLINDER 461
POWER STEERING CYLINDER 462
STEERING COLUMN 463
DISASSEMBLY, SERVICE AND ASSEMBLY 464
STEERING UNIT (ORBITROL UNIT) COMPONENTS DISASSEMBLY 466
STEERING UNIT COMPONENTS ASSEMBLY 468
STEERING CYLINDER REMOVAL 471
RELIEF VALVE DISASSEMBLY AND ASSEMBLY 471
HYDRAULIC SYSTEM 473
HYDRAULIC SCHEMATICS 475
SPECIFCATIONS 479
GENERAL SPECIFICATIONS 479
TIGHTENING TORQUE 480
STRUCTURE AND OPERATING PRINCIPLE 481
COMPONENT ARRANGEMENT 481
OPERATING PRINCIPLE 483
OPERATING DIAGRAM 483
IMPLEMENT SECTION 484
MAIN SECTION 485
HYDRAULIC FILTER 486
HST FILTER [HST MODEL] 486
COMPONENTS 486
GEAR PUMP 487
REAR AUX VALVE (REMOTE HYDRAULIC VALVE) 488
LIFT CONTROL VALVE (PCV VALVE) 490
HYDRAULIC BLOCK 493
LOADER JOYSTICK VALVE 495
OIL COOLER [HST MODEL] 496
HYDRAULIC LIFT CYLINDER 497
TROUBLESHOOTING 499
INSPECTION AND ADJUSTMENT 500
LEVER SETTING OF HYDRAULIC LIFT CYLINDER 501
PRE-INSPECTION 501
ADJUSTING THE POSITION CONTROL LEVER 502
SETTING THE JOYSTICK LEVER 503
HYD CYLINDER 504
EXPLODED VIEW 504
LIFT CONTROL VALVE 505
HYDRAULIC 1 506
HYDRAULIC 2 507
EXTERNAL HYDRAULIC VALVE 508
HYDRAULIC BLOCK (T3) 509
SUCTION PIPE GROUP (T4) 510
GEAR PUMP 511
DISASSEMBLY, SERVICE AND ASSEMBLY 512
DISASSEMBLY OF GEAR PUMP 513
GEAR PUMP ASSEMBLY
COMPONENTSASSEMBLY 515
AUX HYDRAULIC VALVE (DOUBLE ACTING VALVE) 517
HYDRAULIC CYLINDER 518
HYDRAULIC CYLINDER ASSEMBLY DISASSEMBLY 519
HYDRAULIC CYLINDER ASSEMBLY REASSEMBLY 522
LIFT CONTROL VALVE 523
FLOW CONTROL VALVE 525
RELIEF VALVE 525
HYDRAULIC BLOCK 526
HYDRAULIC BLOCK ASSEMBLY
COMPONENTS DISASSEMBLY 526
LOADER JOYSTICK VALVE 527
REMOVAL 527
DISASSEMBLY 528
ELECTRIC SYSTEM AND DIAGNOSIS 531
ELECTRICAL SCHEMATICS 533
SPECIFCATIONS 537
WIRING IDENTIFICATION 538
WIRING COLOR IDENTIFICATION 538
CROSS SECTIONAL AREA OF WIRING 539
SYMBOLS FOR ELECTRIC COMPONENTS 539
FUSE 540
INSPECTION 540
CAUSE FOR BLOWN FUSE 540
ELECTRIC DEVICE DIAGNOSIS 541
OPERATING PRINCIPLE 542
WHEN IGNITION SWITCH IS IN “OFF” POSITION 542
WHEN IGNITION SWITCH IS TURNED TO “ACC” POSITION 544
OPERATING PRINCIPLE OF PREHEAT 546
WHEN IGNITION SWITCH IS TURNED TO “ST” POSITION 548
CHARGE WARNING LAMP OPERATION 550
ELECTRIC COMPONENTS 552
SLOW-BLOW FUSE 553
IGNITION SWITCH 554
IGNITION SWITCH OPERATION 554
KEY SWITCH TEST 554
START MOTOR 555
ALTERNATOR 555
COMBINATION SWITCH 556
FLASHER UNIT 558
GLOW RELAY 559
FUSE & RELAY BOX 559
5P RELAY 559
GLOW PLUG 561
MICRO 5P RELAY 561
MICRO 4P RELAY 561
COOLANT TEMPERATURE SENSOR 562
ENGINE STOP SOLENOID 563
ENGINE OIL PRESSURE SWITCH 564
PICKUP SENSOR 564
FUEL SENDER 565
HAZARD WARNING LAMP SWITCH 566
ECU 567
SENSORS AND RELAYS 567
CRANKSHAFT WHEEL SENSOR 568
FUEL RAIL PRESSURE SENSOR 569
ACCELERATION (KNOCK) SENSORS 570
HIGH-PRESSURE FUEL PUMP TEMPERATURE SENSOR 571
WATER-IN-FUEL SENSOR 572
EXHAUST GAS TEMP SENSOR 573
CAMSHAFT WHEEL SENSOR 574
EGR VALVE SENSOR 575
MAF SENSOR 576
INTAKE AIR PRESSURE SENSOR/TEMPERATURE SENSOR 577
DPF DIFFERENTIAL PRESSURE SENSOR 579
THROTTLE POSITION SENSOR (TPS) 580
AIR CONTROL VALVE SENSOR 580
BRAKE SWITCH 581
PARKING BRAKE MICRO SWITCH 582
SAFETY START SWITCH 582
ONE SIDE BRAKE SWITCH 583
PTO SAFETY SWITCH 584
SWITCHS 584
CRUISE SWITCH [HST MODEL :OPTIONAL] 584
LINKED PEDAL SWITCH 585
DPF REGENERATION SWITCH [3H-TM(H)4 MODEL] 586
SAFETY CONTROL UNIT [EU] 587
PREHEAT CONTROLLER [CK2610(H)-US] 590
INSTRUMENT PANEL 591
SYBOMLS AND COMPONENTS 591
CONNECTOR 592
GAUGES AND INDICATORS 593
LAMPS 598
HEADLAMP 598
FRONT COMBINATION LAMP 599
WORK LAMP 600
REAR COMBINATION LAMP 600
WHEN THE ENGINE CANNOT BE STARTED 602
TROUBLESHOOTING 602
WHEN THE SYSTEM IS NOT CHARGED 604
WHEN THE SYSTEM IS NOT PREHEATED MANUALLY 606
WHEN THE SYSTEM IS NOT PREHEATED AUTOMATICALLY 608
WHEN THE HEAD LAMP CANNOT BE OPERATED 611
FUEL GAUGE OPERATION 613
TEMPERATURE GAUGE OPERATION 615
TACHOMETER OPERATION WITH THE ENGINE RUNNING 617
HOUR METER OPERATION 619
ENGINE ELECTRICAL 620
EXPLODED VIEW 620
ENGINE ELETRICAL (2) 621
START CONTROL 622
LIGHT CONTROL 623
WIRE HARNESS 624
DISPLAY CONTROL 625
ENGINE ELECTRICAL (3) 626
GLOW CONTROL 627
FUEL HEATER (WIRE) 628
FUEL SENDER 629
PTO CONTROL 630
TIER 4 CONTROL 631
DIAGNOSTIC PROGRAM 632
DIAGNOSIS 632
DTC (DIAGNOSTIC TROUBLE CODE) 658
COMPOSITION 658
ERORR CODE & ACTION 659
FAULT DIAGNOSIS CODE DESCRIPTION 670
INDEX 711
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