Bobcat CT4045 T4050 CT4055 Service Manual 7372753 (12-19) – PDF DOWNLOAD

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Bobcat CT4045 T4050 CT4055 Service Manual 7372753 (12-19) – PDF DOWNLOAD

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Bobcat CT4045 T4050 CT4055 Service Manual 7372753 (12-19) – PDF DOWNLOAD

Language : English
Pages : 664
Downloadable : Yes
File Type : PDF
Size: 64.2 MB

DESCRIPTION:

Bobcat CT4045 T4050 CT4055 Service Manual 7372753 (12-19) – PDF DOWNLOAD

(CT4045 SST) S/N B4VT11001 & Above
(CT4050 SST) S/N B4VV11001 & Above
(CT4055 SST) S/N B4V311001 & 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 CT4045 T4050 CT4055 Service Manual 7372753 (12-19) – 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 DECALS 15
GENERAL 16
DESCRIPTION FOR SYMBOLS AND ABBREVIATIONS 17
TRACTOR EXTERIOR VIEW 18
IDENTIFICATION NUMBER 18
TRACTOR SERIAL NUMBER 18
ENGINE SERIAL NUMBER 19
TRANSMISSION SERIAL NUMBER 19
DIMENSIONS 20
SPECIFICATIONS 22
DRIVING SPEED 27
GEAR ARRANGEMENT 27
ARRANGEMENT OF MAIN SHIFT GEAR AND REAR AXLE GEARS 29
ROLLING CIRCUMFERENCE OF REAR WHEELS 29
ROTATING SPEED RATIO (ENGINE VS REAR AXLE) 30
MAINTENANCE 31
MAINTENANCE SCHEDULE CHART 31
LUBRICATION LIST 33
TIRE MAINTENANCE 34
PROPER INFLATION PRESSURE 34
WHEEL BOLT TORQUE 34
TIGHTENING TORQUES 35
GENERAL USE SCREWS, BOLTS AND NUTS 35
STUD BOLTS 35
AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS 36
SPRING PIN AND SNAP RING INSTALLATION 37
SPRING PIN TYPE 37
SNAP RING INSTALLATION 37
UNIT CONVERSION TABLE 38
ENGINE 40
ENGINE IDENTIFICATION 42
ENGINE EPA DECAL (A) 42
ENGINE NUMBER (B) 42
ASSIGNMENT STANDARD FOR ENGINE MODEL CODE 43
SPECIFICATIONS 44
GENERAL SPECIFICATIONS 44
ENGINE DIMENSION 45
COMPONENTS 46
TORQUE 47
BRAKE HORSE POWER (HP) 47
ENGINE PERFORMANCE CURVE ANALYSIS 47
S F C (SPECIFIC FUEL CONSUMPTION) (FOR REFERENCE ONLY) 48
ENGINE BODY 49
SERVICING SPECIFICATIONS 49
LUBRICATING SYSTEM 52
COOLING SYSTEM 52
TIGHTENING TORQUES FOR ENGINE 53
OPERATING PRINCIPLE 54
CRDI (COMMON RAIL DIRECT INJECTION) SYSTEM 54
ECU 56
HIGH PRESSURE FUEL PUMP (FOR INJECTION) 65
FUEL RAIL(COMMON RAIL) 66
INJECTOR [C3I] 66
CYLINDER HEAD 71
CYLINDER BLOCK 71
CYLINDER HONING 71
BODY AND POWER TRAIN SYSTEM 71
CRANKSHAFT 72
PISTON AND PISTON RING 72
CONNECTING ROD 72
CAMSHAFT 72
ROCKER ARM ASSEMBLY 73
INTAKE AND EXHAUST VALVES 73
TIMING GEAR 74
FLYWHEEL 74
MLS CYLINDER HEAD GASKET 74
ENGINE OIL FLOW 75
LUBRICATING SYSTEM 75
ENGINE OIL FLOW CHART 76
FUNCTION OF LUBRICATING SYSTEM 77
COOLANT FLOW ROUTE 79
COOLING SYSTEM 79
WATER PUMP 80
THERMOSTAT 80
RADIATOR 81
RADIATOR CAP 81
FUEL SYSTEM 82
OVERVIEW FOR FUEL SUPPLY 82
FUEL FLOW ROUTE 82
FUEL FILTER 84
BLEEDING THE FUEL SYSTEM 84
HIGH PRESSURE FUEL PUMP 85
COMMON RAIL (FUEL RAIL) 87
INJECTOR [C3I (CALIBRATION IMPROVED INDIVIDUAL INJECTOR)] 88
FUEL COOLER 89
ACCELERATION SYSTEM 90
OVERVIEW 91
INTAKE & EXHAUST SYSTEM 91
EGR COOLER 93
EGR VALVE 93
AIR CONTROL VAVLE 94
CCRT (CATALYZED CONTINUOUSLY REGENERATING TRAP) 94
TURBO CHARGER 99
SENSOR 100
SENSORS AS Input / Output FOR ECU 103
TROUBLESHOOTING 104
MEASUREMENT AND ADJUSTMENT 107
VALVE CLEARANCE 108
CLEARANCE ADJUSTMENT 108
VALVE LIFT (DEFLECTION AND WORN CONDITION OF VALVE CAM, TAPPET, PUSH ROD, ROCKER ARM, ETC ) 109
OIL PRESSURE MEASUREMENT 109
BUBBLE TEST FOR RADIATOR 110
TURBO CHARGER WASTEGATE PRESSURE CHECK 110
EXPLODED VIEW 112
CYLINDER BLOCK 112
OILPAN 114
CYLINDER HEAD 115
GEARCASE 116
OIL FILTER 117
CRANK SHAFT 118
PISTON & CONNECTING ROD 119
CAM SHAFT 120
IDLE GEAR 121
ROCKER ARM & VALVE 122
FUEL EQUIPMENT 123
WATER FLANGE 124
WATER PUMP 125
CYLINDER HEAD COVER 126
FUEL FILTER & PIPE 127
INLET MANIFOLD 128
EGR 129
COOLING FAN 130
TURBOCHARGER 131
TURBO PIPE 132
AFTER TREATMENT 133
DISASSEMBLY, SERVICE AND ASSEMBLY 134
ENGINE REMOVAL 134
ENGINE COMPONENT REMOVAL 142
ENGINE DISASSEMBLY 148
HEAD COVER 148
GLOW PLUG AND INJECTOR 149
ROCKER ARM ASSEMBLY 150
CYLINDER HEAD 152
INTAKE AND EXHAUST VALVES 154
HIGH PRESSURE FUEL PUMP 156
GEAR CASE 158
GEARS IN GEAR CASE 159
PISTON AND CONNECTING ROD 169
FLYWHEEL AND CRANKSHAFT 173
OIL FILTER 183
OIL PUMP 184
THERMOSTAT 186
WATER PUMP 187
FUEL FILTER 189
TURBO CHARGER 189
CLUTCH 192
SPECIFICATIONS 194
GENERAL SPECIFICATIONS 194
TIGHTENING TORQUES 194
SEALANT 194
OPERATING PRINCIPLE 195
TROUBLESHOOTING 196
MEASUREMENT AND ADJUSTMENT 197
SAFETY START SWITCH ADJUSTMENT 198
CLUTCH DISC SPLINE BOSS AND GEAR SHAFT END PLAY 198
CLUTCH DISC WEAR INSPECTION 199
PRESSURE PLATE INSPECTION 199
THRUST BALL BEARING INSPECTION 200
FLYWHEEL SURFACE AND DEFLECTION OF ENGINE CRANKSHAFT 200
CLUTCH LEVER GROUP 201
EXPLODED VIEW 201
CLUTCH LEVER GROUP 202
CLUTCH PEDAL GROUP 203
DISASSEMBLY, SERVICE AND ASSEMBLY 204
CLUTCH DISASSEMBLY (CLUTCH DISC REPLACEMENT) 204
CLUTCH COVER INSTALLATION 205
TRANSMISSION 206
SPECIFICATIONS 208
GENERAL SPECIFICATIONS 208
TIGHTENING TORQUE FOR MAJOR COMPONENTS 209
SEALANT AND ADHESIVE SPECIFICATIONS 210
STRUCTURE AND OPERATING PRINCIPLE 211
OPERATING PRINCIPLE OF SYNCHRONIZER 212
SHUTTLE 213
PTO CLUTCH PACK 216
CALCULATION FOR REAR PTO 216
FRONT WHEEL DRIVE & QT 217
INSPECTION AND ADJUSTMENT 218
TROUBLESHOOTING 219
EXPLODED VIEW 220
COUNTER SHAFT 222
MAIN SPEED FORK 224
SHUTTLE SHAFT 225
SHUTTLE FORK 229
FRONT DRIVE SYSTEM 235
PTO COUNTER SHAFT 239
PTO CLUTCH 240
PROPELLER SHAFT 243
HYD CLUTCH 244
DISASSEMBLY, SERVICE AND ASSEMBLY 246
CLUTCH HOUSING REMOVAL 246
MIDDLE CASE REMOVAL 259
SHUTTLE SHAFT ASSEMBLY 263
HYDRAULIC CLUTCH COMPONENTS DISASSEMBLY AND ASSEMBLY 263
SYNCHRONIZER ASSEMBLY 264
MIDDLE CASE SECTION (SHUTTLE SHIFT SECTION) ASSEMBLY 265
TRANSMISSION CASE SECTION (RANGE SHIFT / 4WD SECTION) DISASSEMBLY AND ASSEMBLY 267
SPIRAL BEVEL PINION SHAFT DISASSEMBLY 270
SPIRAL BEVEL PINION SHAFT ASSEMBLY 272
18 GEAR SHAFT DISASSEMBLY 273
PTO SHAFT DISASSEMBLY 274
REAR AXLE 277
SPECIFICATIONS 278
TRANSMISSION FLUID 278
TIGHTENING TORQUES 278
OPERATING PRINCIPLE 279
POWER TRAIN OF REAR AXLE 279
PRINCIPLE OF DIFFERENTIAL SYSTEM 280
DIFFERENTIAL LOCK SYSTEM 281
TROUBLESHOOTING 282
INSPECTION AND ADJUSTMENT 283
BACKLASH FOR DIFFERENTIAL PINION AND SIDE GEAR 283
PRELOAD OF TAPER ROLLER
BEARING IN DIFF 283
BACKLASH FOR SPIRAL BEVEL PINION AND RING GEAR 284
TOOTH CONTACT OF SPIRAL BEVEL 285
EXPLODED VIEW 287
SPIRAL BEVEL GEAR 287
REAR DIFFERENTIAL SYSTEM 288
DIFF LOCK FORK 289
REAR AXLE 290
DISASSEMBLY, SERVICING AND ASSEMBLY 291
REAR AXLE COMPONENTS 291
REAR DIFFERENTIAL DISASSEMBLY 293
REAR DIFFERENTIAL SYSTEM
COMPONENTS DISASSEMBLY 296
REAR DIFFERENTIAL SYSTEM ASSEMBLY 296
REAR DIFFERENTIAL INSTALLATION 299
BRAKE 301
SPECIFICATIONS 302
GENERAL SPECIFICATION 302
STRUCTURE AND OPERATING PRINCIPLE 303
TROUBLESHOOTING 306
INSPECTION AND ADJUSTMENT 307
BRAKE PEDAL FREE PLAY 307
BRAKE DISC 308
BRAKE PLATE 308
CLEARANCE OF BRAKE LAMP SWITCH 308
BRAKE COMPONENTS INSPECTION 308
CAM PLATE 309
CAM PLATE AND STEEL BALL 309
EXPLODED VIEW 310
REAR SHAFT CASE 310
BRAKE PEDAL 312
BRAKE ROD 313
DISASSEMBLY, SERVICING AND ASSEMBLY 314
BRAKE SECTION DISASSEMBLY AND ASSEMBLY 314
FRONT AXLE 317
SPECIFICATIONS 318
GENERAL SPECIFICATIONS 318
SEALANT AND ADHESIVE 318
TIGHTENING TORQUE FOR MAJOR COMPONENTS 319
STRUCTURE AND OPERATING PRINCIPLE 320
POWER TRANSFER SYSTEM FOR FRONT AXLE 320
DIFFERENTIAL SYSTEM 323
LOAD TRANSFER 324
FLOATING SEAL 325
TROUBLESHOOTING 326
INSPECTION AND ADJUSTMENT 327
TOE-IN 327
STEERING ANGLE 327
SWAY RESISTANCE 328
PRELOAD OF TAPER ROLLER BEARING ON SPIRAL BEVEL PINION SHAFT 328
BACKLASH FOR DIFFERENTIAL PINION AND DIFFERENTIAL SIDE GEAR 329
BACKLASH FOR SPIRAL BEVEL PINION AND 23 SPIRAL BEVEL GEAR 329
TOOTH CONTACT OF SPIRAL BEVEL GEAR 330
TOOTH CONTACT FOR UPPER BEVEL GEARS AND FINAL DRIVE BEVEL GEARS 332
EXPLODED VIEW 333
PROPELLER SHAFT 333
FRONT AXLE BRACKET 334
BEVEL PINION SHAFT 335
FRONT DIFFERENTIAL 337
BEVEL GEAR CASE 339
BEVEL GEAR SHAFT 341
FRONT AXLE CASE 343
FRONT AXLE 345
STEERING CYLINDER 347
DISASSEMBLY, SERVICING AND ASSEMBLY 348
FRONT AXLE OIL SEAL REPLACEMENT 348
BEVEL GEAR CASE OIL SEAL REPLACEMENT 352
FRONT AXLE CASE DISASSEMBLY AND ASSEMBLY 355
FRONT DIFFERENTIAL SYSTEM REMOVAL AND INSTALLATION 357
FRONT DIFFERENTIAL SYSTEM DISASSEMBLY AND ASSEMBLY COMPONENTS 362
STEERING SYSTEM 365
SPECIFICATIONS AND TIGHTENING TORQUE 366
SPECIFICATIONS FOR STEERING SYSTEM 366
TIGHTENING TORQUE FOR MAJOR COMPONENTS 366
HYDRAULIC PUMP 366
POWER STEERING UNIT 366
STEERING CYLINDER 366
STRUCTURE AND OPERATING PRINCIPLE 367
OPERATING DIAGRAM 367
STEERING UNIT 369
OPERATING PRINCIPLE 369
STRUCTURE AND SPECIFICATIONS 370
OPERATING PRINCIPLE OF STEERING SYSTEM 371
STRUCTURE AND OPERATING PRINCIPLE 375
TROUBLESHOOTING 376
INSPECTION AND ADJUSTMENT 377
STEERING UNIT RELIEF VALVE PRESSURE CHECK 377
FRONT AXLE TOE-IN ADJUSTMENT 377
EXPLODED VIEW 378
STEERING CYLINDER 378
STEERING COLUMN 380
STEERING HOSE 381
POWER STEERING UNIT 382
DISASSEMBLY, SERVICING AND ASSEMBLY 383
STEERING UNIT REMOVAL 383
STEERING UNIT (ORBITROL UNIT) COMPONENTS DISASSEMBLY 386
STEERING UNIT COMPONENTS ASSEMBLY 389
RELIEF VALVE DISASSEMBLY AND ASSEMBLY 393
STEERING CYLINDER REMOVAL 394
HYDRAULIC SYSTEM 397
SPECIFICATIONS 399
GENERAL SPECIFICATIONS 399
TIGHTENING TORQUE 400
STRUCTURE AND OPERATING PRINCIPLE 401
COMPONENT ARRANGEMENT 401
OPERATING PRINCIPLE 402
OPERATING DIAGRAM 402
IMPLEMENT SECTION 403
MAIN SECTION 404
COMPONENTS 405
HYDRAULIC FILTER 405
GEAR PUMP 406
MODULATOR VALVE (PTO, 4WD) 407
REMOTE HYDRAULIC VALVE 409
LIFT CONTROL VALVE (PCV VALVE) 411
HYDRAULIC BLOCK 414
SHUTTLE VALVE (H-SHUTTLE TYPE MODEL) 416
OIL COOLER [TH] 418
HYDRAULIC LIFT CYLINDER 419
TROUBLESHOOTING 425
INSPECTION AND ADJUSTMENT 427
INPUT PRESSURE INSPECTION OF MODULATOR VALVE 427
STEERING UNIT RELIEF PRESSURE INSPECTION 427
INSPECTION USING EXTERNAL HYDRAULIC VALVE COUPLER 428
LEVER SETTING OF HYDRAULIC LIFT CYLINDER 429
ADJUSTING THE POSITION CONTROL LEVER 429
SETTING THE DRAFT 430
ONE-TOUCH LIFTING LEVER ADJUSTMENT 431
EXPLODED VIEW 432
HYD CYLINDER 432
EXTERNAL HYDRAULIC 433
MODULATE VALVE 434
SUCTION LINE 435
GEAR PUMP 436
HYDRAULIC BLOCK 437
OIL COOLER 438
LIFT CONTROL VALVE 439
POSITION CONTROL 440
DRAFT CONTROL 441
TOP LINK 442
ONE TOUCH LINK 443
DOWN SPEED CONTROL 444
DISASSEMBLY, SERVICING AND ASSEMBLY 445
GEAR PUMP REMOVAL AND REASSEMBLY 445
DISASSEMBLY OF GEAR PUMP 446
GEAR PUMP ASSEMBLY
COMPONENTS ASSEMBLY 448
MODULATOR VALVE 450
Modulator valve disassembly 450
Modulator valve assembly 451
SHUTTLE VALVE (FOR H-SHUTTLE MODEL) 452
SHUTTLE VALVE DISASSEMBLY 452
REMOTE HYDRAULIC VALVE (DOUBLE ACTING VALVE) 454
AUX HYDRAULIC (DOUBLE ACTING) VALVE ASSEMBLY COMPONENTS DISASSEMBLY 455
AUX HYDRAULIC VALVE ASSEMBLY 456
HYDRAULIC CYLINDER 457
HYDRAULIC CYLINDER ASSEMBLY DISASSEMBLY 458
HYDRAULIC CYLINDER ASSEMBLY REASSEMBLY 461
LIFT CONTROL VALVE 463
FLOW CONTROL VALVE 464
RELIEF VALVE 465
HYDRAULIC BLOCK 465
HYDRAULIC BLOCK ASSEMBLY COMPONENTS DISASSEMBLY 466
HYDRAULIC / HYDROSTATIC SCHEMATICS 467
ELECTRIC SYSTEM AND DIAGNOSIS 469
SPECIFICATIONS 471
WIRING IDENTIFICATION 472
CROSS SECTIONAL AREA OF WIRING 473
SYMBOLS FOR ELECTRIC COMPONENTS 473
FUSE 474
INSPECTION 474
CAUSE FOR BLOWN FUSE 474
ELECTRIC DEVICE DIAGNOSIS 475
OPERATING PRINCIPLE 476
WHEN IGNITION SWITCH IS TURNED TO “ACC” POSITION 478
OPERATING PRINCIPLE OF PREHEAT 480
WHEN IGNITION SWITCH IS TURNED TO “ST” POSITION 481
CHARGE WARNING LAMP OPERATION 482
ELECTRIC COMPONENTS 484
IGNITION SWITCH 485
SLOW-BLOW FUSE 485
IGNITION SWITCH OPERATION 485
START MOTOR 486
KEY SWITCH TEST 486
ALTERNATOR 487
COMBINATION SWITCH 488
FLASHER UNIT 490
TERMINAL IDENTIFICATION AND CIRCUIT 490
FLASHER UNIT TEST 490
GLOW RELAY 491
FUSE & RELAY BOX 491
5P RELAY 491
GLOW PLUG 493
MICRO 5P RELAY 493
MICRO 4P RELAY 493
COOLANT TEMPERATURE SENSOR 494
ENGINE OIL PRESSURE SWITCH 494
FUEL SENDER 495
HAZARD WARNING LAMP SWITCH 496
ECU 497
SENSORS AND RELAYS 497
CRANKSHAFT POSITION SENSOR 498
FUEL RAIL PRESSURE SENSOR 499
ACCELERATION (KNOCK) SENSORS 500
HIGH-PRESSURE FUEL PUMP
TEMPERATURE SENSOR 501
WATER-IN-FUEL SENSOR 502
EXHAUST GAS TEMP SENSOR 503
CAMSHAFT WHEEL SENSOR 504
EGR VALVE SENSOR 505
MAF SENSOR 506
INTAKE AIR PRESSURE SENSOR/TEMPERATURE SENSOR 507
DPF DIFFERENTIAL PRESSURE SENSOR 509
THROTTLE POSITION SENSOR (TPS) 510
AIR CONTROL VALVE SENSOR 510
BRAKE SWITCH 511
PARKING BRAKE MICRO SWITCH 512
4WD / QT SWITCH [EU] 512
QUICK TURN ANGLE SWITCH [EU] 513
SAFETY START SWITCH 514
ONE SIDE BRAKE SWITCH 515
SAFETY SWITCH 516
NEUTRAL SWITCH 516
PTO SAFETY SWITCH 516
RANGE SHIFT SAFETY SWITCH 517
PTO AUTO/MANUAL SWITCH 518
PTO SWITCH 519
SWITCHS 520
CRUISE PTO SWITCH 520
CRUISE CONTROL RES/SET SWITCH 521
PREHEAT CONTROLLER [AU] 522
DPF REGENERATION SWITCH 522
SAFETY CONTROL UNIT [EU] 524
INSTRUMENT PANEL 526
SYMBOLS AND COMPONENTS 526
CONNECTOR 527
GAUGES AND INDICATORS 528
LAMPS 534
TURN SIGNAL LAMP 534
REAR COMBINATION LAMP 535
TROUBLESHOOTING 536
WHEN THE SYSTEM IS NOT CHARGED 539
WHEN THE SYSTEM IS NOT PREHEATED MANUALLY 541
WHEN THE SYSTEM IS NOT PREHEATED AUTOMATICALLY 543
WHEN THE PTO DOES NOT OPERATE 545
WHEN THE 4WD CONTROL SYSTEM DOES NOT OPERATE 547
WHEN THE QUICK TURN CONTROL SYSTEM DOES NOT OPERATE [EU] 549
WHEN THE HEAD LAMP CANNOT BE OPERATED 551
FUEL GAUGE OPERATION 553
TEMPERATURE GAUGE OPERATION 555
TACHOMETER OPERATION WITH THE ENGINE RUNNING 557
HOUR METER OPERATION 559
EXPLODED VIEW 560
GLOW CONTROL 561
ENGINE ELECTRIC 3 562
FRONT WORKING LAMP 563
LIGHT CONTROL 564
WIRE MAIN HARNESS 565
DISPLAY CONTROL 566
PTO CONTROL 567
THROTTLE CONTROL, PTO CRUISE SWITCH AND DPF SWITCH 568
DIAGNOSIS 569
DIAGNOSTIC PROGRAM 569
DTC (DIAGNOSTIC TROUBLE CODE) 595
COMPOSITION 595
ERORR CODE & ACTION 596
FAULT DIAGNOSIS CODE DESCRIPTION 610
ELECTRICAL SCHEMATICS 653
INDEX 655

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