Bobcat CT2535 CT2540 Service Manual – PDF DOWNLOAD

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Bobcat CT2535 CT2540 Service Manual – PDF DOWNLOAD

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Bobcat CT2535 CT2540 Service Manual – PDF DOWNLOAD

Language : English
Pages : 777
Downloadable : Yes
File Type : PDF
Size:70.9 MB

DESCRIPTION:

Bobcat CT2535 CT2540 Service Manual – PDF DOWNLOAD

S/N B4VP11001 & Above
S/N B4VZ11001 & Above
S/N B4VR11001 & Above
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. A general inspection of the following items must be made after the compact tractor has had service or repair:

TABLE OF CONTENTS:

Bobcat CT2535 CT2540 Service Manual – 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 DECALS 15
LOCATION OF DECALS 15
GENERAL 17
DESCRIPTION FOR SYMBOLS AND ABBREVIATIONS 18
TRACTOR EXTERIOR VIEW 19
IDENTIFICATION NUMBER 19
TRACTOR SERIAL NUMBER 19
ENGINE SERIAL NUMBER 20
TRANSMISSION SERIAL NUMBER 20
DIMENSIONS 21
SPECIFICATIONS 23
DRIVING SPEED 25
GEAR ARRANGEMENT 25
ARRANGEMENT OF MAIN SHIFT GEAR AND REAR AXLE GEARS 34
RELATIVE SPEED RATIO OF FRONT WHEELS 35
CALCULATION FOR RELATIVE SPEED RATIO OF FRONT WHEELS 35
METHOD OF MEASURING CIRCUMFERENCE 36
MAINTENANCE 37
MAINTENANCE SCHEDULE CHART 37
LUBRICATION LIST 39
TIRE MAINTENANCE 40
PROPER INFLATION PRESSURE 40
WHEEL BOLT TORQUE 40
TIGHTENING TORQUES 41
GENERAL USE SCREWS, BOLTS AND NUTS 41
STUD BOLTS 41
AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS 42
SPRING PIN AND SNAP RING INSTALLATION 43
SPRING PIN TYPE 43
SNAP RING INSTALLATION 43
UNIT CONVERSION TABLE 44
ENGINE 45
ENGINE IDENTIFICATION 49
ENGINE EPA DECAL (A) 49
ENGINE NUMBER (B) 49
ASSIGNMENT STANDARD FOR ENGINE MODEL CODE 50
SPECIFICATION 51
GENERAL SPECIFICATIONS 51
ENGINE DIMENSION 52
COMPONENTS 53
ENGINE PERFORMANCE CURVE 54
TORQUE 56
BRAKE HORSE POWER (HP) 56
ENGINE PERFORMANCE CURVE ANALYSIS 56
S F C (SPECIFIC FUEL CONSUMPTION) (FOR REFERENCE ONLY) 57
ENGINE BODY 58
SERVICING SPECIFICATIONS 58
LUBRICATING SYSTEM 61
COOLING SYSTEM 61
TIGHTENING TORQUES FOR ENGINE 62
OPERATING PRINCIPLE 63
CRDI (COMMON RAIL DIRECT INJECTION) SYSTEM 63
ECU 65
HIGH PRESSURE FUEL PUMP (FOR INJECTION) 74
FUEL RAIL(COMMON RAIL) 75
INJECTOR [C3I] 75
CYLINDER HEAD 80
CYLINDER BLOCK 80
CYLINDER HONING 80
BODY AND POWER TRAIN SYSTEM 80
CRANKSHAFT 81
PISTON AND PISTON RING 81
CONNECTING ROD 81
CAMSHAFT 81
ROCKER ARM ASSEMBLY 82
INTAKE AND EXHAUST VALVES 82
TIMING GEAR 83
FLYWHEEL 83
MLS CYLINDER HEAD GASKET 83
ENGINE OIL FLOW 84
LUBRICATING SYSTEM 84
ENGINE OIL FLOW CHART 85
FUNCTION OF LUBRICATING SYSTEM 86
COOLANT FLOW ROUTE 88
COOLING SYSTEM 88
WATER PUMP 89
THERMOSTAT 89
RADIATOR 90
FUEL SYSTEM 91
OVERVIEW FOR FUEL SUPPLY 91
FUEL FLOW ROUTE 91
FUEL FILTER 93
BLEEDING THE FUEL SYSTEM 93
HIGH PRESSURE FUEL PUMP 94
COMMON RAIL (FUEL RAIL) 96
INJECTOR [C3I (CALIBRATION IMPROVED INDIVIDUAL INJECTOR)] 97
FUEL COOLER 98
ACCELERATION SYSTEM 99
OVERVIEW 100
INTAKE & EXHAUST SYSTEM 100
EGR COOLER 102
EGR VALVE 102
AIR CONTROL VAVLE 103
CCRT (CATALYZED CONTINUOUSLY REGENERATING TRAP) 103
SENSOR 108
SENSORS AS INPUT/OUTPUT FOR ECU 111
TROUBLESHOOTING 112
MEASUREMENT AND ADJUSTMENT 114
VALVE CLEARANCE 115
CLEARANCE ADJUSTMENT 115
VALVE LIFT (DEFLECTION AND WORN CONDITION OF VALVE CAM, TAPPET, PUSH ROD, ROCKER ARM, ETC ) 116
OIL PRESSURE MEASUREMENT 116
BUBBLE TEST FOR RADIATOR 117
EXPLODED VIEW 118
IDLE GEAR 119
ROCKER ARM VALVE 120
EGR 121
EGR COOLER 122
ECU 123
CYLINDER BLOCK 124
GEAR CASE 125
CRANK SHAFT 126
PISTON CONNECTING ROD 127
FUEL EQUIPMENT 128
CYLINDER HEAD COVER 129
AFTER TREATMENT 130
ELECTRICAL PARTS 131
ENGINE DISASSEMBLY AND SERVICING 132
ENGINE COMPONENT REMOVAL 138
ENGINE DISASSEMBLY 143
HEAD COVER 143
GLOW PLUG AND INJECTOR 144
ROCKER ARM ASSEMBLY 145
CYLINDER HEAD 147
INTAKE AND EXHAUST VALVES 148
HIGH PRESSURE FUEL PUMP 150
GEAR CASE 151
GEARS IN GEAR CASE 152
PISTON AND CONNECTING ROD 161
FLYWHEEL AND CRANKSHAFT 166
OIL FILTER 175
OIL PUMP 175
THERMOSTAT 177
WATER PUMP 178
FUEL FILTER 180
ENGINE IDENTIFICATION 181
ENGINE EPA DECAL (A) 181
ENGINE NUMBER (B) 181
ASSIGNMENT STANDARD FOR ENGINE MODEL CODE 182
SPECIFICATIONS 183
GENERAL SPECIFICATIONS 183
ENGINE PERFORMANCE CURVE 184
ENGINE PERFORMANCE CURVE ANALYSIS 186
SERVICING SPECIFICATIONS 188
OPERATING PRINCIPLE 193
BODY AND POWER TRAIN SYSTEM 193
LUBRICATING SYSTEM 197
COOLING SYSTEM 201
FUEL FLOW ROUTE 204
FUEL SYSTEM 204
FUEL FILTER 205
BLEEDING THE FUEL SYSTEM 205
FUEL FEED PUMP 205
FUEL INJECTION PUMP 206
INJECTION NOZZLE 208
GOVERNOR AND STOP SYSTEM 209
BASIC PRINCIPLE OF GOVERNOR SYSTEM 209
OPERATION OF GOVERNOR 210
PCV VALVE 211
TROUBLESHOOTING 212
MEASUREMENT AND ADJUSTMENT 214
VALVE CLEARANCE 215
VALVE LIFT (DEFLECTION AND WORN CONDITION OF VALVE CAM, TAPPET, PUSH ROD, ROCKER ARM, ETC ) 215
INJECTION TIMING MEASUREMENT AND ADJUSTMENT 216
OIL PRESSURE MEASUREMENT 217
BUBBLE TEST FOR RADIATOR 218
INJECTION NOZZLE INSPECTION 218
EXPLODED VIEW 219
CYLINDER BLOCK 219
GEAR CASE 220
MAIN BEARING CASE 221
VALVE ROCKER ARM 222
CAMSHAFT 223
PISTON & CRANKSHAFT 224
NOZZLE HOLDER 225
ENGINE STOP LEVER 226
WATER PUMP 227
WATER HOSE 228
FUEL CAMSHAFT 229
SPEED CONTROL PLATE 230
ENGINE DISASSEMBLY AND SERVICING 231
ENGINE REMOVAL 231
PCV VALVE 240
HEAD COVER INSTALLATION 240
ENGINE COMPONENTS DISASSAMBLY AND ASSEMBLY 240
GLOW PLUG AND FUEL OVERFLOW PIPE 241
HEAT SEAL REMOVAL 241
ROCKER ARM ASSEMBLY 242
CYLINDER HEAD 244
INTAKE AND EXHAUST VALVES 246
INJECTION PUMP 248
GOVERNOR SPRING AND STOP SOLENOID 250
GEAR CASE 251
IDLE GEAR AND CRANK GEAR 252
VALVE CAMSHAFT 253
FUEL CAMSHAFT 253
CRANK GEARS AND SHAFTS CHECK 254
PISTON AND CONNECTING ROD 256
PISTON AND CONNECTING ROD CHECK 258
PISTON RING MEASUREMENT 259
CRANKSHAFT AND FLYWHEEL 260
METAL JOURNAL BEARINGS 264
FLYWHEEL AND CRANKSHAFT CHECK 265
CYLINDER BORE CHECK 267
OIL PUMP, OIL FILTER, RELIEF VALVE AND OIL STRAINER 268
THERMOSTAT 269
WATER PUMP 270
CLUTCH 271
SPECIFICATION 272
GENERAL SPECIFICATIONS 272
TIGHTENING TORQUES 272
SEALANT 272
OPERATIONAL PRINCIPLE 273
TROUBLESHOOTING 274
MEASUREMENT AND ADJUSTMENT 275
CLUTCH PEDAL PLAY ADJUSTMENT 275
CLUTCH STOPPER BOLT ADJUSTMENT 275
SAFETY START SWITCH ADJUSTMENT 276
CLUTCH DISC SPLINE BOSS AND GEAR SHAFT END PLAY 276
CLUTCH DISC WEAR INSPECTION 277
PRESSURE PLATE INSPECTION 277
THRUST BALL BEARING INSPECTION 278
FLYWHEEL SURFACE AND DEFLECTION OF ENGINE CRANKSHAFT 278
EXPLODED VIEW 279
CLUTCH 279
CLUTCH RELEASE 280
CLUTCH PEDAL 281
DISASSEMBLY, SERVICE AND ASSEMBLY 282
CLUTCH DISASSEMBLY (CLUTCH DISC REPLACEMENT) 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
RANGE SHIFT SECTION 290
PTO GEAR SHIFT SECTION 291
FRONT WHEEL DRIVE SECTION 292
TROUBLESHOOTING 294
EXPLODED VIEW 295
PTO CLUTCH 295
DRIVE SHAFT 296
RANGE SHIFT SHAFT 297
RANGE SHIFT FORK 298
PTO SHAFT 299
PTO SHIFT FORK 300
MID PTO LEVER (IND PTO) 301
FRONT WHEEL DRIVE SHAFT 302
PTO INPUT SHAFT 303
PTO CLUTCH 304
PROPELLER SHAFT 305
CLUTCH HOUSING REMOVAL 306
DISASSEMBLY, SERVICE AND ASSEMBLY 306
CLUTCH HOUSING ASSEMBLY DISASSEMBLY 308
MIDDLE CASE DISASSEMBLY 308
TRANSMISSION CASE RANGE SHIFT SECTION DISASSEMBLY 310
FRONT WHEEL DRIVE SECTION DISASSEMBLY 314
PTO SHAFT DISASSEMBLY 315
HST 317
SPECIFICATIONS 318
GENERAL 318
HST 318
MAJOR TIGHTENING TORQUE 318
HST STRUCTURE & COMPONENTS 319
EXTERIOR 319
COMPONENTS 320
OPERATING PRINCIPLE 322
STRUCTURE AND FUNCTION OF HST 322
BASIC PRINCIPLE OF HST 324
FUNCTION HST CHARGE PUMP 325
CHARGE RELIEF VALVE 326
HIGH PRESSURE RELIEF VALVE 327
OPERATION OF HST 328
NEUTRAL STATUS 328
FORWARD DRIVING 329
REVERSE DRIVING 330
TROUBLESHOOTING 331
MEASUREMENT AND ADJUSTMENT 332
CHARGE RELIEF VALVE PRESSURE CHECK 332
HP RELIEF VALVE PRESSURE CHECK 333
HST NEUTRAL POSITION ADJUSTMENT 335
HST PEDAL LINK ADJUSTMENT 335
HST PEDAL ADJUSTMENT 335
CRUISE MAGNETIC CLEARANCE
ADJUSTMENT (OPTIONAL) 336
BLEEDING AIR FROM HST COMPONENT 336
EXPLODED VIEW 337
HST PEDAL 337
HST CONTROL (IND PTO) 338
RPM LINKED 339
HST ASSY 340
SERVICING 341
HST DISASSEMBLY AND ASSEMBLY 341
HST COMPONENTS DISASSEMBLY AND ASSEMBLY 341
REAR AXLE 345
SPECIFICATIONS 346
TRANSMISSION FLUID 346
TIGHTENING TORQUES 346
OPERATING PRINCIPLE 347
POWER TRAIN OF REAR AXLE 347
PRINCIPLE OF DIFFERENTIAL SYSTEM 348
DIFFERENTIAL LOCK SYSTEM 349
TROUBLESHOOTING 350
INSPECTION AND ADJUSTMENT 351
BACKLASH FOR DIFFERENTIAL PINION AND SIDE GEAR 351
PRELOAD OF TAPER ROLLER BEARING IN DIFF 351
BACKLASH FOR SPIRAL BEVEL PINION AND RING GEAR 352
TOOTH CONTACT OF SPIRAL BEVEL 353
EXPLODED VIEW 355
REAR AXLE 355
REAR DIFFERENTIAL 356
REAR DIFF LOCK 357
SPIRAL BEVEL GEAR 358
DISASSEMBLY, SERVICING AND ASSEMBLY 359
REAR AXLE COMPONENTS 359
REAR DIFFERENTIAL DISASSEMBLY 361
REAR DIFFERENTIAL SYSTEM COMPONENTS DISASSEMBLY 364
REAR DIFFERENTIAL SYSTEM ASSEMBLY 364
REAR DIFFERENTIAL INSTALLATION 367
BRAKE 369
SPECIFICATIONS 370
GENERAL SPECIFICATION 370
STRUCTURE AND OPERATING PRINCIPLE 371
TROUBLESHOOTING 375
INSPECTION AND ADJUSTMENT 376
BRAKE PEDAL FREE PLAY 376
CLEARANCE OF BRAKE LAMP SWITCH 377
BRAKE PEDAL STOPPER 377
BRAKE COMPONENTS INSPECTION 377
BRAKE DISC 377
BRAKE PLATE 377
CAM PLATE 378
CAM PLATE AND STEEL BALL 378
EXPLODED VIEW 379
BRAKE 379
BRAKE PEDAL (NONE CLUTCH) 380
BRAKE ROD 381
DISASSEMBLY, SERVICING AND ASSEMBLY 382
BRAKE SECTION DISASSEMBLY AND ASSEMBLY 382
FRONT AXLE 385
SPECIFICATIONS 386
GENERAL SPECIFICATIONS 386
SEALANT AND ADHESIVE 386
TIGHTENING TORQUE FOR MAJOR COMPONENTS 387
STRUCTURE AND OPERATING PRINCIPLE 388
POWER TRANSFER SYSTEM FOR FRONT AXLE 388
DIFFERENTIAL SYSTEM 391
LOAD TRANSFER 392
TROUBLESHOOTING 393
INSPECTION AND ADJUSTMENT 394
TOE-IN 394
STEERING ANGLE 394
SWAY RESISTANCE 395
PRELOAD OF TAPER ROLLER BEARING ON SPIRAL BEVEL PINION SHAFT 395
BACKLASH FOR DIFFERENTIAL PINION AND DIFFERENTIAL SIDE GEAR 396
BACKLASH FOR SPIRAL BEVEL PINION AND 21 SPIRAL BEVEL GEAR 396
TOOTH CONTACT OF SPIRAL BEVEL GEAR 397
TOOTH CONTACT FOR UPPER BEVEL GEARS AND FINAL DRIVE BEVEL GEARS 399
EXPLODED VIEW 400
FRONT DIFF SYSTEM 400
BEVEL PINION SHAFT 401
BEVEL GEAR CASE 402
FRONT AXLE CASE 403
FRONT AXLE 404
STEERING CYLINDER 405
PROPELLER SHAFT 406
FRONT AXLE BRACKET 407
DISASSEMBLY, SERVICING AND ASSEMBLY 408
FRONT AXLE OIL SEAL REPLACEMENT 408
BEVEL GEAR CASE AND FRONT AXLE CASE DISASSEMBLY AND ASSEMBLY 411
FRONT DIFFERENTIAL SYSTEM REMOVAL AND INSTALLATION 414
FRONT DIFFERENTIAL SYSTEM DISASSEMBLY AND ASSEMBLY COMPONENTS 419
STEERING SYSTEM 421
SPECIFICATIONS AND TIGHTENING TORQUE 422
SPECIFICATIONS FOR STEERING SYSTEM 422
TIGHTENING TORQUE FOR MAJOR COMPONENTS 422
HYDRAULIC PUMP 422
POWER STEERING UNIT 422
STEERING CYLINDER 422
STRUCTURE AND OPERATING PRINCIPLE 423
OPERATING DIAGRAM 423
STEERING UNIT 425
OPERATING PRINCIPLE 425
STRUCTURE AND SPECIFICATIONS 426
OPERATING PRINCIPLE OF STEERING SYSTEM 427
STRUCTURE AND OPERATING PRINCIPLE 431
TROUBLESHOOTING 432
INSPECTION AND ADJUSTMENT 433
STEERING UNIT RELIEF VALVE PRESSURE CHECK 433
FRONT AXLE TOE-IN ADJUSTMENT 433
EXPLODED VIEW 434
POWER STEERING UNIT 434
STEERING COLUMN 435
DISASSEMBLY, SERVICING AND ASSEMBLY 436
STEERING UNIT REMOVAL 436
STEERING UNIT (ORBITROL UNIT) COMPONENTS DISASSEMBLY 441
STEERING UNIT COMPONENTS ASSEMBLY 443
STEERING CYLINDER REMOVAL 446
RELIEF VALVE DISASSEMBLY AND ASSEMBLY 446
HYDRAULIC SYSTEM 449
HYDRAULIC / HYDROSTATIC SCHEMATICS 451
SPECIFICATIONS 453
GENERAL SPECIFICATIONS 453
TIGHTENING TORQUE 454
STRUCTURE AND OPERATING PRINCIPLE 455
OPERATING PRINCIPLE 455
OPERATING DIAGRAM 455
IMPLEMENT SECTION 456
MAIN SECTION 457
COMPONENTS 458
GEAR PUMP 459
REAR AUX VALVE (REMOTE HYDRAULIC VALVE) 460
LIFT CONTROL VALVE (PCV VALVE) 462
HYDRAULIC BLOCK 465
LOADER JOYSTICK VALVE 468
MODULATOR VALVE 469
OIL COOLER 471
HYDRAULIC LIFT CYLINDER 472
TROUBLESHOOTING 474
INSPECTION AND ADJUSTMENT 475
STEERING UNIT RELIEF PRESSURE INSPECTION 475
INSPECTION USING EXTERNAL HYDRAULIC VALVE COUPLER 475
MODULATOR VALVE (PTO CLUTCH) OPERATING PRESSURE INSPECTION 476
LEVER SETTING OF HYDRAULIC LIFT CYLINDER 477
PRE-INSPECTION 477
ADJUSTING THE POSITION CONTROL LEVER 478
SETTING THE JOYSTICK LEVER 479
EXPLODED VIEW 480
MODULATE VALVE 481
HYDRAULIC CYLINDER 482
LIFT CYLINDER 483
JOYSTICK VALVE 484
EXTERNAL HYDRAULIC VALVE (DS) 485
HYDRAULIC SYSTEM (1) 486
HYDRAULIC SYSTEM 487
GEAR PUMP 488
DOUBLE ACTING VALVE LEVER 489
JOYSTICK LEVER 490
DISASSEMBLY, SERVICE AND ASSEMBLY 491
HYDRAULIC PUMP & HYDRAULIC FILTER REMOVAL AND REASSEMBLY 491
DISASSEMBLY OF GEAR PUMP 492
GEAR PUMP ASSEMBLY COMPONENTS ASSEMBLY 494
AUX HYDRAULIC VALVE (DOUBLE ACTING VALVE) 496
AUX HYDRAULIC (DOUBLE ACTING) VALVE ASSEMBLY COMPONENTS – DISASSEMBLY AND ASSEMBLY 497
HYDRAULIC CYLINDER 499
HYDRAULIC CYLINDER ASSEMBLY DISASSEMBLY 500
HYDRAULIC CYLINDER ASSEMBLY REASSEMBLY 503
LIFT CONTROL VALVE 504
FLOW CONTROL VALVE 506
RELIEF VALVE 506
HYDRAULIC BLOCK ASSEMBLY COMPONENTS DISASSEMBLY 507
REMOVAL 508
LOADER JOYSTICK VALVE 508
DISASSEMBLY 509
MODULATOR VALVE DISASSEMBLY 510
ELECTRIC SYSTEM AND DIAGNOSIS 513
ELECTRICAL SCHEMATICS 515
SPECIFICATIONS 518
CIRCUIT AND COMPONENT LOCATION 519
WIRING IDENTIFICATION 520
WIRING COLOR IDENTIFICATION 520
CROSS SECTIONAL AREA OF WIRING 521
SYMBOLS FOR ELECTRIC COMPONENTS 521
FUSE 522
INSPECTION 522
CAUSE FOR BLOWN FUSE 522
ELECTRIC DEVICE DIAGNOSIS 523
ELECTRIC COMPONENTS 524
FUSE 524
FUSE BOX 524
SLOW-BLOW FUSE 525
IGNITION SWITCH 526
IGNITION SWITCH OPERATION 526
KEY SWITCH TEST 526
START MOTOR 527
ALTERNATOR 527
COMBINATION SWITCH 528
FLASHER UNIT 530
GLOW RELAY 532
FUSE & RELAY BOX 532
5P RELAY 532
GLOW PLUG 534
MICRO 5P RELAY 534
MICRO 4P RELAY 534
COOLANT TEMPERATURE SENSOR 535
ENGINE OIL PRESSURE SWITCH 536
FUEL SENDER 537
HAZARD WARNING LAMP SWITCH 538
ECU 539
SENSORS AND RELAYS 539

S/N B4VP11001 & Above
S/N B4VZ11001 & Above
S/N B4VR11001 & Above
S/N B4W111001 & Above
CRANKSHAFT WHEEL SENSOR 540
FUEL RAIL PRESSURE SENSOR 541
ACCELERATION (KNOCK) SENSORS 542
HIGH-PRESSURE FUEL PUMP TEMPERATURE SENSOR 543
WATER-IN-FUEL SENSOR 544
EXHAUST GAS TEMP SENSOR 545
CAMSHAFT WHEEL SENSOR 546
EGR VALVE SENSOR 547
MAF SENSOR 548
INTAKE AIR PRESSURE SENSOR/TEMPERATURE SENSOR 549
DPF DIFFERENTIAL PRESSURE SENSOR 551
THROTTLE POSITION SENSOR (TPS) 552
AIR CONTROL VALVE SENSOR 552
BRAKE SWITCH 553
PARKING BRAKE MICRO SWITCH 554
SAFETY START SWITCH 554
CRUISE SWITCH [HST MODEL :OPTIONAL] 555
PARKING BRAKE SWITCH [EU] 555
SWITCHS 555
LINKED PEDAL SWITCH 556
DPF REGENERATION SWITCH 557
PREHEAT CONTROLLER [AU] 557
SAFETY CONTROL UNIT [EU] 559
INSTRUMENT PANEL 562
SYMBOLS AND COMPONENTS 562
CONNECTOR 563
GAUGES AND INDICATORS 564
HOUR METER 568
HEADLAMP 569
LAMPS 569
WORK LAMP 571
REAR COMBINATION LAMP 572
LICENSE LAMP (IF FITTED) 573
TROUBLESHOOTING 574
WHEN THE ENGINE CANNOT BE STARTED 574
WHEN THE SYSTEM IS NOT CHARGED 577
WHEN THE SYSTEM IS NOT PREHEATED AUTOMATICALLY 579
WHEN THE HEAD LAMP CANNOT BE OPERATED 581
FUEL GAUGE OPERATION 583
TEMPERATURE GAUGE OPERATION 584
TACHOMETER OPERATION WITH THE ENGINE RUNNING 586
HOUR METER OPERATION 587
EXPLODED VIEW 588
LIGHT CONTROL 588
WIRE HARNESS 589
ENGINE ELECTRICAL (1) 590
ENGINE ELECTRICAL (2) 591
ENGINE ELECTRICAL (3) 592
ALTERNATOR 593
FRONT WORKING LAMP 594
CABIN WIRE HARNESS 595
FUEL SENDER 596
TIER4 CONTROL 597
SPEAKER ANTENNA 598
REAR GLASS DEFOGGER 599
START CONTROL 600
PTO CONTROL 601
GLOW CONTROL 602
DISPLAY CONTROL 603
DIAGNOSIS 604
DIAGNOSTIC PROGRAM 604
DTC (DIAGNOSTIC TROUBLE CODE) 630
COMPOSITION 630
FAULT CODE &ACTION 631
FAULT DIAGNOSIS CODE DESCRIPTION 652
CABIN 694
COMPONENTS 696
INTERIOR DEVICES 696
A/C CONTROLLER 700
INTERIOR LAMP 700
AIR INTAKE GRILL 700
SUN VISOR 701
SWITCH PANEL 701
CD PLAYER / BT PLAYER (OPTIONAL) 701
INTERIOR REAR VIEW MIRROR 702
WIPER MOTOR (FRONT) 702
WIPER MOTOR (REAR) 702
DOOR LATCH ASSEMBLY 702
REAR DOOR HANDLE 703
AIR CYLINDER 703
SPEAKER 703
EXTERNAL DEVICES 704
EXTERIOR FILTER ASSEMBLY 705
FRONT/REAR WORK LAMP 705
REAR COMBINATION LAMP 705
FRONT/REAR WIPERS 705
WASHER FLUID TANK 706
7-PIN SOCKET 706
REAR VIEW MIRROR 706
ANTENNA 706
FRONT COMBINATION LAMP 707
LICENSE LAMP 707
EXPLODED VIEW 708
CABIN FRAME 708
ROOF 709
DOOR 710
FRONT GLASS 711
REAR GLASS 712
WIPER (FRONT) 713
WIPER (REAR) 714
CABIN DISASSEMBLY AND ASSEMBLY 715
CABIN REMOVAL 715
SEAT REMOVAL 720
COMPONENT REMOVAL 720
DOOR REMOVAL 721
DOOR GLASS REMOVAL 721
REAR GLASS HANDLE REMOVAL 722
ROOM MIRROR 723
WASHER FLUID TANK REMOVAL 723
INTERIOR LAMP 724
SWITCH PANEL (WORK LAMP AND WIPER SWITCH) 724
FRONT WIPER / MOTOR 725
REAR WIPER/MOTOR 726
ANTENNA 727
A/C AND HEATER 728
SPECIFICATION 729
AIR-CON/HEATER MAIN SPEC 729
PRINCIPLE OF COLLING SYSTEM 730
COOLING CYLCE 731
REFRIGERANT AND COMPRESSOR OIL 732
COMPRESSOR 733
RECEIVER-DRIER 734
INSPECTION 734
CONDENSER 735
INSPECTION 735
EXPANSION VALVE 736
EVAPORATOR 736
INSPECTION 736
INSPECTION 736
HEATER CORE 737
INSPECTION 737
AIR CONDITIONER/HEATER SYSTEM 738
AIR INLET AND VENT 738
AIR FLOW 739
ACTUATOR 740
COOLING SYSTEM 741
A/C ASSEMBLY 741
A/C ELECTRICAL CONNECTOR 742
A/C CONTROLLER 743
RESISTOR 746
CHECK AND ADJUSTMENT 747
TROUBLESHOOTING BY GAUGE 747
NORMAL CONDITION 748
INSUFFICIENT REFRIGERANT 748
EXCESSIVE REFRIGERANT, POOR
CONDENSER COOLING 748
AIR INTRUSION INTO CYCLE 749
DEFECTIVE EXPANSION VALVE 749
POOR COMPRESSION 750
MOISTURE INTRUSION INTO COOLING CYCLE 750
POOR RECIRCULATION OF REFRIGERANT 751
INSPECTION AND ADJUSTMENT FOR CABIN SYSTEM 751
TROUBLESHOOTING 755
VISUAL INSPECTION 755
DIAGNOSIS BY SYMPTOM 756
TROUBLESHOOTING FOR POOR COOLING/HEATING PERFORMANCE 757
POOR COOLING 757
POOR HEATING 759
EXPLODED VIEW 760
AIR CONDITIONER HEATER 760
AIR CONDITIONER DRIVE 761
A/C RELATED COMPONENT DISSASSEMBLY AND ASSEMBLY 762
A/C FILTER REMOVAL 762
A/C ASSEMBLY REMOVAL 762
A/C ASSEMBLY COMPONENTS DISASSEMBLY 764
A/C CONTROLLER REMOVAL 766
COMPRESSOR REMOVAL 767
COMPRESSOR INSTALLATION 768
CONDERSER REMOVAL 769
INDEX 770

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