Bobcat CT4045 T4050 CT4058 Service Manual 7400445 (01-20) – PDF DOWNLOAD

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Bobcat CT4045 T4050 CT4058 Service Manual 7400445 (01-20) – PDF DOWNLOAD

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Bobcat CT4045 T4050 CT4058 Service Manual 7400445 (01-20) – PDF DOWNLOAD

Language : English
Pages : 711
Downloadable : Yes
File Type : PDF
Size:70.7 MB

DESCRIPTION:

Bobcat CT4045 T4050 CT4058 Service Manual 7400445 (01-20) – PDF DOWNLOAD

(CT4045 HST) S/N B4W211001 & Above
(CT4050 HST) S/N B4VS11001 & Above
(CT4058 HST) S/N B4VU11001 & Above

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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.

The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:

TABLE OF CONTENTS:

Bobcat CT4045 T4050 CT4058 Service Manual 7400445 (01-20) – 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 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 22
DRIVING SPEED 29
GEAR ARRANGEMENT 29
ARRANGEMENT OF MAIN SHIFT GEAR AND REAR AXLE GEARS 32
ROLLING CIRCUMFERENCE OF REAR WHEELS 33
MAINTENANCE 34
MAINTENANCE SCHEDULE CHART 34
LUBRICATION LIST 36
TIRE MAINTENANCE 37
PROPER INFLATION PRESSURE 37
WHEEL BOLT TORQUE 37
TIGHTENING TORQUE 38
GENERAL USE SCREWS, BOLTS AND NUTS 38
STUD BOLTS 38
AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS 39
SPRING PIN AND SNAP RING INSTALLATION 40
SPRING PIN TYPE 40
SNAP RING INSTALLATION 40
UNIT CONVERSION TABLE 41
ENGINE 43
ENGINE IDENTIFCATION 45
ENGINE EPA DECAL (A) 45
ENGINE NUMBER (B) 45
ASSIGNMENT STANDARD FOR ENGINE MODEL CODE 45
SPECIFICATIONS 46
ENGINE DIMENSION 47
COMPONENTS 48
SERVICING SPECIFICATIONS 49
ENGINE BODY 49
LUBRICATING SYSTEM 52
COOLING SYSTEM 52
TIGHTENING TORQUES FOR ENGINE 53
OPERATING PRINCIPLE 54
ECU 56
HIGH PRESSURE FUEL PUMP (FOR INJECTION) 65
FUEL RAIL (COMMON RAIL) 66
INJECTOR [C3I] 66
BODY AND POWER TRAIN SYSTEM 71
CYLINDER HEAD 71
CYLINDER BLOCK 71
CYLINDER HONING 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
LUBRICATING SYSTEM 75
ENGINE OIL FLOW 75
ENGINE OIL FLOW CHART 76
FUNCTION OF LUBRICATING SYSTEM 77
COOLING SYSTEM 79
COOLANT FLOW ROUTE 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
INTAKE & EXHAUST SYSTEM 91
OVERVIEW 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
FAN BELT 107
PISTON COMPRESSION PRESSURE MEASUREMENT 107
CLEARANCE ADJUSTMENT 108
VALVE CLEARANCE 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 109
TURBO CHARGER WASTEGATE PRESSURE CHECK 110
EXPLODED VIEW 111
CYLINDER BLOCK 111
OIL PAN 112
CYLINDER HEAD 113
GEARCASE 114
OIL FILTER 115
CRANKSHAFT 116
PISTON & CONNECTING ROD 117
CAM SHAFT 118
IDLE GEAR 119
ROCKER ARM & VALVE 120
FUEL EQUIPMENT 121
WATER FLANGE 122
WATER PUMP 123
CYLINDER HEAD COVER 124
FUEL FILTER & PIPE 125
INLET MANIFOLD 126
EGR 127
COOLING FAN 128
TURBOCHARGER 129
TURBO PIPE 130
AFTER TREATMENT 131
DISASSEMBLY, SERVICE AND ASSEMBLY 132
ENGINE COMPONENT REMOVAL 141
ENGINE DISASSEMBLY 147
HEAD COVER 147
GLOW PLUG AND INJECTOR 148
ROCKER ARM ASSEMBLY 149
CYLINDER HEAD 151
INTAKE AND EXHAUST VALVES 153
HIGH PRESSURE FUEL PUMP 155
GEARCASE 157
GEARS IN GEARCASE 158
PISTON AND CONNECTING ROD 167
FLYWHEEL AND CRANKSHAFT 171
OIL FILTER 181
OIL PUMP 182
THERMOSTAT 184
WATER PUMP 185
FUEL FILTER 187
TURBO CHARGER 187
CLUTCH 189
SPECIFICATIONS 191
GENERAL SPECIFICATIONS 191
TIGHTENING TORQUES 191
SEALANT 191
OPERATIONAL PRINCIPLE 192
TROUBLESHOOTING 193
CLUTCH PEDAL PLAY ADJUSTMENT 194
CLUTCH STOPPER BOLT ADJUSTMENT 194
MEASUREMENT AND ADJUSTMENT 194
SAFETY START SWITCH ADJUSTMENT 195
CLUTCH DISC SPLINE BOSS AND GEAR SHAFT END PLAY 195
CLUTCH DISC WEAR INSPECTION 196
PRESSURE PLATE INSPECTION 196
THRUST BALL BEARING INSPECTION 197
FLYWHEEL SURFACE AND DEFLECTION OF ENGINE CRANKSHAFT 197
CLUTCH 198
EXPLODED VIEW 198
CLUTCH LEVER 199
CLUTCH PEDAL 200
DISASSEMBLY, SERVICE AND ASSEMBLY 201
CLUTCH DISASSEMBLY (CLUTCH DISC REPLACEMENT) 201
CLUTCH COVER INSTALLATION 202
TRANSMISSION 205
SPECIFICATIONS 206
GENERAL SPECIFICATIONS 206
TIGHTENING TORQUE FOR MAJOR COMPONENTS 207
SEALANT AND ADHESIVE SPECIFICATIONS 208
STRUCTURE AND OPERATING PRINCIPLE 209
MAIN GEAR SHIFT SECTION 209
OPERATING PRINCIPLE OF SYNCHRONIZER (SST MODELS) 211
SHUTTLE (SST MODELS) 212
RANGE SHIFT SECTION 213
PTO 215
PTO CLUTCH PACK 217
CALCULATION FOR REAR PTO 218
FRONT WHEEL DRIVE & QT 219
MID PTO (OPTIONAL) 221
INSPECTION AND ADJUSTMENT 222
SYNCHRONIZER GEAR INSPECTION 222
TROUBLESHOOTING 223
EXPLODED VIEW 224
MID PTO SHAFT 224
PTO INPUT SHAFT 225
PTO SHAFT 226
PTO CLUTCH 227
RANGE SHIFT SHAFT 228
RANGE SHIFT FORK 229
SPIRAL BEVEL PINION SHAFT 230
DRIVE SHAFT 231
FRONT WHEEL DRIVE SHAFT 232
MAIN SHAFT 233
COUNTER SHAFT 234
MAIN SPEED FORK 235
SHUTTLE SHAFT 236
SHUTTLE FORK 237
RANGE SHAFT 238
SPIRAL BEVEL GEAR 239
RANGE FORK 241
FRONT DRIVE SYSTEM 242
PTO COUNTER SHAFT 244
PTO CLUTCH 245
PTO SHAFT 246
PTO SHIFT FORK 247
PROPELLER SHAFT 248
DISASSEMBLY, SERVICE AND ASSEMBLY 249
CLUTCH HOUSING DISASSEMBLY AND ASSEMBLY 249
MIDDLE CASE DISASSEMBLY AND ASSEMBLY 262
TRANSMISSION CASE SECTION (RANGE SHIFT / FRONT WHEEL DRIVE SECTION) DISASSEMBLY AND ASSEMBLY 272
HST 288
SPECIFICATIONS 289
GENERAL 289
HST 289
MAJOR TIGHTENING TORQUE 290
HST STRUCTURE & COMPONENTS 291
EXTERIOR 291
OPERATING PRINCIPLE 293
STRUCTURE AND FUNCTION OF HST 293
BASIC PRINCIPLE OF HST 295
FUNCTION OF HST CHARGE PUMP 296
CHARGE RELIEF VALVE 297
NEUTRAL VALVE 298
HIGH PRESSURE RELIEF VALVE 300
SERVO CONTROL 301
INLET CHECK VALVE 302
OPERATION OF HST 304
NEUTRAL STATUS 304
FORWARD DRIVING 306
REVERSE DRIVING 308
HST PEDAL-ENGINE SPEED COUPLED SYSTEM 310
TROUBLESHOOTING 311
MEASUREMENT AND ADJUSTMENT 312
RELIEF PRESSURE 312
CHARGE RELIEF PRESSURE 312
RELIEF PRESSURE 313
HST PEDAL LINK ADJUSTMENT 315
HST PEDAL ADJUSTMENT 315
HST NEUTRAL POSITION ADJUSTMENT 315
CRUISE MAGNETIC CLEARANCE
ADJUSTMENT 316
BLEEDING AIR FROM HST COMPONENT 316
EXPLODED VIEW 317
HST HYDRAULIC LINE 317
HST ASSY 318
HST CONTROL 319
HST PEDAL 320
RPM LINKED 321
CRUISE 322
SERVICING 323
REMOVAL AND INSTALLATION OF HST 323
DISASSEMBLY AND ASSEMBLY OF HST COMPONENTS 325
REAR AXLE 330
SPECIFICATIONS 331
TRANSMISSION FLUID 331
TIGHTENING TORQUES 331
OPERATING PRINCIPLE 332
POWER TRAIN OF REAR AXLE 332
PRINCIPLE OF DIFFERENTIAL SYSTEM 333
DIFFERENTIAL LOCK SYSTEM 334
TROUBLESHOOTING 335
INSPECTION AND ADJUSTMENT 336
BACKLASH FOR DIFFERENTIAL PINION AND SIDE GEAR 336
PRELOAD OF TAPER ROLLER
BEARING IN DIFF 336
BACKLASH FOR SPIRAL BEVEL PINION AND RING GEAR 337
TOOTH CONTACT OF SPIRAL BEVEL 338
EXPLODED VIEW 340
SPIRAL BEVEL PINION SHAFT 340
REAR DIFFERENTIAL SYSTEM 342
DIFF LOCK FORK 343
REAR AXLE 344
DISASSEMBLY, SERVICING AND ASSEMBLY 345
REAR AXLE COMPONENTS 345
REAR DIFFERENTIAL DISASSEMBLY 347
REAR DIFFERENTIAL SYSTEM
COMPONENTS DISASSEMBLY 350
REAR DIFFERENTIAL SYSTEM ASSEMBLY 350
REAR DIFFERENTIAL INSTALLATION 353
BRAKE 354
SPECIFICATIONS 355
GENERAL SPECIFICATION 355
STRUCTURE AND OPERATION PRINCIPLE 356
TROUBLESHOOTING 359
INSPECTION AND ADJUSTMENT 360
BRAKE PEDAL FREE PLAY 360
BRAKE DISC 361
BRAKE PLATE 361
CLEARANCE OF BRAKE LAMP SWITCH 361
BRAKE COMPONENTS INSPECTION 361
CAM PLATE 362
CAM PLATE AND STEEL BALL 362
EXPLODED VIEW 363
BRAKE 363
BRAKE PEDAL 364
BRAKE ROD 365
DISASSEMBLY, SERVICING AND ASSEMBLY 366
Brake section disassembly and assembly 366
FRONT AXLE 368
SPECIFICATIONS 369
GENERAL SPECIFICATIONS 369
SEALANT AND ADHESIVE 369
TIGHTENING TORQUE FOR MAJOR COMPONENTS 370
STRUCTURE AND OPERATING PRINCIPLE 371
POWER TRANSFER SYSTEM FOR FRONT AXLE 371
DIFFERENTIAL SYSTEM 374
LOAD TRANSFER 375
FLOATING SEAL 376
TROUBLESHOOTING 377
INSPECTION AND ADJUSTMENT 378
TOE-IN 378
STEERING ANGLE 378
SWAY RESISTANCE 379
PRELOAD OF TAPER ROLLER BEARING ON SPIRAL BEVEL PINION SHAFT 379
BACKLASH FOR DIFFERENTIAL PINION AND DIFFERENTIAL SIDE GEAR 380
BACKLASH FOR SPIRAL BEVEL PINION AND 23 SPIRAL BEVEL GEAR 380
TOOTH CONTACT OF SPIRAL BEVEL GEAR 381
TOOTH CONTACT FOR UPPER BEVEL GEARS AND FINAL DRIVE BEVEL GEARS 383
EXPLODED VIEW 384
PROPELLER SHAFT 384
FRONT AXLE BRACKET 385
BEVEL PINION SHAFT 386
FRONT DIFFERENTIAL 387
BEVEL GEAR CASE 388
BEVEL GEAR SHAFT 389
FRONT AXLE CASE 391
FRONT AXLE 392
STEERING CYLINDER 393
DISASSEMBLY, SERVICE AND ASSEMBLY 394
FRONT AXLE OIL SEAL REPLACEMENT 394
BEVEL GEAR CASE OIL SEAL REPLACEMENT 398
FRONT AXLE CASE DISASSEMBLY AND ASSEMBLY 401
FRONT DIFFERENTIAL SYSTEM REMOVAL AND INSTALLATION 403
FRONT DIFFERENTIAL SYSTEM DISASSEMBLY AND ASSEMBLY COMPONENTS 408
STEERING SYSTEM 410
SPECIFICATIONS AND TIGHTENING TORQUE 411
SPECIFICATIONS FOR STEERING SYSTEM 411
TIGHTENING TORQUE FOR MAJOR COMPONENTS 411
HYDRAULIC PUMP 411
POWER STEERING UNIT 411
STEERING CYLINDER 411
STRUCTURE AND OPERATING PRINCIPLE 412
OPERATING DIAGRAM 412
STEERING UNIT 414
OPERATING PRINCIPLE 414
STRUCTURE AND SPECIFICATIONS 415
OPERATING PRINCIPLE OF STEERING SYSTEM 416
STRUCTURE AND OPERATING PRINCIPLE 420
TROUBLESHOOTING 421
INSPECTION AND ADJUSTMENT 422
STEERING UNIT RELIEF VALVE PRESSURE CHECK 422
FRONT AXLE TOE-IN ADJUSTMENT 422
EXPLODED VIEW 423
STEERING CYLINDER 423
STEERING COLUMN 424
POWER STEERING UNIT 425
DISASSEMBLY, SERVICE AND ASSEMBLY 427
STEERING UNIT REMOVAL 427
STEERING UNIT (ORBITROL UNIT) COMPONENTS DISASSEMBLY 430
STEERING UNIT COMPONENTS ASSEMBLY 432
RELIEF VALVE DISASSEMBLY AND
ASSEMBLY 435
STEERING CYLINDER REMOVAL 436
HYDRAULIC SYSTEM 439
SPECIFICATIONS 441
GENERAL SPECIFICATIONS 441
TIGHTENING TORQUE 442
STRUCTURE AND OPERATING PRINCIPLE 443
COMPONENT ARRANGEMENT 443
OPERATING DIAGRAM 444
OPERATING PRINCIPLE 444
IMPLEMENT SECTION 445
MAIN SECTION 446
COMPONENTS 447
HYDRAULIC FILTER 447
GEAR PUMP 448
MODULATOR VALVE (PTO, 4WD) 449
AUX HYDRAULIC VALVE 452
LIFT CONTROL VALVE (PCV VALVE) 454
HYDRAULIC BLOCK [ROPS MODEL] 456
OIL COOLER [HST MODEL] 464
HYDRAULIC LIFT CYLINDER 465
TROUBLESHOOTING 468
INSPECTION AND ADJUSTMENT 470
STEERING UNIT RELIEF PRESSURE INSPECTION 471
INSPECTION USING EXTERNAL HYDRAULIC VALVE COUPLER 471
LEVER SETTING OF HYDRAULIC LIFT CYLINDER 472
ADJUSTING THE POSITION CONTROL LEVER 472
EXPLODED VIEW 473
HYDRAULIC CYLINDER 473
EXTERNAL HYDRAULIC 474
MODULATE VALVE 475
SUCTION LINE 477
GEAR PUMP 478
HYDRAULIC BLOCK [ROPS MODEL] 479
OIL COOLER 480
LIFT CONTROL VALVE 481
POSITION CONTROL 482
TOP LINK 483
DOWN SPEED CONTROL 484
DISASSEMBLY, SERVICE AND ASSEMBLY 485
GEAR PUMP & HYDRAULIC FILTER 485
DISASSEMBLY OF GEAR PUMP 486
GEAR PUMP ASSEMBLY
COMPONENTS ASSEMBLY 488
MODULATOR VALVE DISASSEMBLY 490
MODULATOR VALVE 490
MODULATOR VALVE ASSEMBLY 491
REMOTE HYDRAULIC VALVE (DOUBLE ACTING VALVE) 492
AUX HYDRAULIC (DOUBLE ACTING) VALVE ASSEMBLY COMPONENTS DISASSEMBLY 493
AUX HYDRAULIC VALVE ASSEMBLY COMPONENTS ASSEMBLY 494
HYDRAULIC CYLINDER 495
HYDRAULIC CYLINDER ASSEMBLY DISASSEMBLY 496
HYDRAULIC CYLINDER ASSEMBLY REASSEMBLY 498
LIFT CONTROL VALVE 500
FLOW CONTROL VALVE 502
RELIEF VALVE 502
HYDRAULIC BLOCK [ROPS MODEL] 503
HYDRAULIC BLOCK ASSEMBLY COMPONENTS DISASSEMBLY 503
HYDRAULIC / HYDROSTATIC SCHEMATICS 505
ELECTRIC SYSTEM AND DIAGNOSIS 507
SPECIFICATIONS 509
WIRING IDENTIFICATION 510
CROSS SECTIONAL AREA OF WIRING 511
SYMBOLS FOR ELECTRIC COMPONENTS 511
FUSE 512
INSPECTION 512
CAUSE FOR BLOWN FUSE 512
ELECTRIC DEVICE DIAGNOSIS 513
OPERATING PRINCIPLE 514
WHEN IGNITION SWITCH IS TURNED TO “ACC” POSITION 516
WHEN IGNITION SWITCH IS TURNED TO “ON” POSITION 517
OPERATING PRINCIPLE OF PREHEAT 518
WHEN IGNITION SWITCH IS TURNED TO “ST” POSITION 519
ECU OPERATION 521
ELECTRIC COMPONENTS 522
SLOW-BLOW FUSE 523
IGNITION SWITCH 524
IGNITION SWITCH OPERATION 524
Key switch test 524
START MOTOR 525
ALTERNATOR 525
COMBINATION SWITCH 527
FLASHER UNIT 529
GLOW RELAY 531
FUSE & RELAY BOX 531
5P RELAY 531
MICRO 4P RELAY 532
GLOW PLUG 533
MICRO 5P RELAY 533
COOLANT TEMPERATURE SENSOR 534
ENGINE STOP SOLENOID 535
FUEL SENDER 536
HAZARD WARNING LAMP SWITCH 537
ECU 538
SENSORS AND RELAYS 538
CRANKSHAFT WHEEL SENSOR 539
FUEL RAIL PRESSURE SENSOR 540
ACCELERATION (KNOCK) SENSORS 541
HIGH-PRESSURE FUEL PUMP
TEMPERATURE SENSOR 542
WATER-IN-FUEL SENSOR 543
EXHAUST GAS TEMP SENSOR 544
CAMSHAFT WHEEL SENSOR 545
EGR VALVE SENSOR 546
MAF SENSOR 547
INTAKE AIR PRESSURE SENSOR / TEMPERATURE SENSOR 548
DPF DIFFERENTIAL PRESSURE SENSOR 550
THROTTLE POSITION SENSOR (TPS) 551
AIR CONTROL VALVE SENSOR 551
BRAKE SWITCH 552
PARKING BRAKE MICRO SWITCH 553
4WD / QT SWITCH [DK6010C-EU] 553
QUICK TURN ANGLE SWITCH [DK6010C-EU] 554
SAFETY START SWITCH [DK6010C-EU] 555
ONE SIDE BRAKE SWITCH 556
SAFETY SWITCH 557
PTO SAFETY SWITCH 557
RANGE SHIFT SAFETY SWITCH 557
PTO AUTO / MANUAL SWITCH 559
PTO SWITCH 560
SWITCHES 561
CRUISE PTO SWITCH 561
CRUISE CONTROL RES / SET SWITCH 562
PREHEAT CONTROLLER [AU] 563
DPF REGENERATION SWITCH 563
SAFETY CONTROL UNIT [EU] 565
INSTRUMENT PANEL 567
SYMBOLS AND ARRANGEMENT 567
CONNECTOR 568
CIRCUIT DIAGRAM 569
GAUGES AND INDICATORS 570
LAMPS 575
HEADLAMP 575
TURN SIGNAL LAMP 576
REAR COMBINATION LAMP 577
WHEN THE ENGINE CANNOT BE STARTED 578
TROUBLESHOOTING 578
WHEN THE SYSTEM IS NOT CHARGED 580
WHEN THE SYSTEM IS NOT PREHEATED MANUALLY 582
WHEN THE SYSTEM IS NOT PREHEATED AUTOMATICALLY 584
WHEN THE PTO DOES NOT OPERATE 587
WHEN THE HEAD LAMP CANNOT BE OPERATED 589
FUEL GAUGE OPERATION 591
TEMPERATURE GAUGE OPERATION 593
TACHOMETER OPERATION WITH THE ENGINE RUNNING 595
HOURMETER OPERATION 597
START CONTROL 598
EXPLODED VIEW 598
LIGHT CONTROL 599
WIRE HARNESS 600
DISPLAY CONTROL 601
ENGINE ELECTRICAL (1) 602
ENGINE ELECTRICAL (2) 603
ENGINE ELECTRICAL (3) 604
ENGINE ELECTRICAL (4) 605
GLOW CONTROL 606
PTO CONTROL 607
SAFETY STARTER 608
SPEED SENSOR 609
DIAGNOSTIC PROGRAM 610
DIAGNOSIS 610
DTC (DIAGNOSTIC TROUBLE CODE) 636
COMPOSITION 636
ERORR CODE & ACTION 637
FAULT DIAGNOSIS CODE DESCRIPTION 659
ELECTRICAL SCHEMATICS 701
INDEX 703
4WD / QT SWITCH [DK6010C-EU] 553
ACCELERATION SYSTEM 90
AFTER TREATMENT 131
ALERT SYMBOLS 8
ALTERNATOR 525
AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS 39
AVOID FIRES 10
BACKLASH FOR DIFFERENTIAL PINION AND DIFFERENTIAL SIDE GEAR 380
BACKLASH FOR DIFFERENTIAL PINION AND SIDE GEAR 336
BACKLASH FOR SPIRAL BEVEL PINION AND 23 SPIRAL BEVEL GEAR 380
BACKLASH FOR SPIRAL BEVEL PINION AND RING GEAR 337
BEVEL GEAR CASE 388
BEVEL GEAR CASE OIL SEAL REPLACEMENT 398
BEVEL GEAR SHAFT 389
BEVEL PINION SHAFT 386
BLEEDING AIR FROM HST COMPONENT 316
BODY AND POWER TRAIN SYSTEM 71
BRAKE 363
BRAKE COMPONENTS INSPECTION 361
BRAKE PEDAL 364
BRAKE PEDAL FREE PLAY 360
BRAKE ROD 365
BRAKE SECTION DISASSEMBLY AND ASSEMBLY 366
BRAKE SWITCH 552
BUBBLE TEST FOR RADIATOR 109
CALCULATION FOR REAR PTO 218
CAM SHAFT 118
CAUTIONS FOR HIGH PRESSURE HOSES 11
CAUTIONS WHEN HANDLING THE BATTERY 11
CAUTIONS WHEN HANDLING TIRES 14
CHARGE RELIEF PRESSURE 312
CLEARANCE OF BRAKE LAMP SWITCH 361
CLUTCH 198
CLUTCH COVER INSTALLATION 202
CLUTCH DISASSEMBLY (CLUTCH DISC REPLACEMENT) 201
CLUTCH DISC SPLINE BOSS AND GEAR SHAFT END PLAY 195
CLUTCH DISC WEAR INSPECTION 196
CLUTCH HOUSING DISASSEMBLY AND ASSEMBLY 249
CLUTCH LEVER 199
CLUTCH PEDAL 200
CLUTCH PEDAL PLAY ADJUSTMENT 194
CLUTCH STOPPER BOLT ADJUSTMENT 194
COMBINATION SWITCH 527
COMPONENT ARRANGEMENT 443
COMPONENTS 48
COMPONENTS 447
COOLANT TEMPERATURE SENSOR 534
COOLING FAN 128
COOLING SYSTEM 79
COUNTER SHAFT 234
CRANKSHAFT 116
CRDI (COMMON RAIL DIRECT INJECTION) SYSTEM 54
CROSS SECTIONAL AREA OF WIRING 511
CRUISE 322
CRUISE MAGNETIC CLEARANCE
ADJUSTMENT 316
CYLINDER BLOCK 111
CYLINDER HEAD 113
CYLINDER HEAD COVER 124
DESCRIPTIONS FOR SYMBOLS AND ABBREVIATIONS 18
DIAGNOSIS 610
DIAGNOSTIC PROGRAM 610
DIFFERENTIAL LOCK SYSTEM 334
DIFFERENTIAL SYSTEM 374
DIFF LOCK FORK 343
DIMENSIONS 21
DISASSEMBLY AND ASSEMBLY OF HST COMPONENTS 325
DISASSEMBLY, SERVICE AND ASSEMBLY 132
DISASSEMBLY, SERVICE AND ASSEMBLY 201
DISASSEMBLY, SERVICE AND ASSEMBLY 249
DISASSEMBLY, SERVICE AND ASSEMBLY 394
DISASSEMBLY, SERVICE AND ASSEMBLY 485
DISASSEMBLY, SERVICE AND ASSEMBLY 427
DISASSEMBLY, SERVICING AND ASSEMBLY 345
DISASSEMBLY, SERVICING AND ASSEMBLY 366
DISPLAY CONTROL 601
DISPOSAL OF ENVIRONMENTAL WASTE 14
DOWN SPEED CONTROL 484
DRIVE SHAFT 231
DRIVING SPEED 29
DTC (DIAGNOSTIC TROUBLE CODE) 636
ECU 538
ECU OPERATION 521
EGR 127
ELECTRIC COMPONENTS 522
ELECTRIC DEVICE DIAGNOSIS 513
ENGINE COMPONENT REMOVAL 141
ENGINE DIMENSION 47
ENGINE DISASSEMBLY 147
ENGINE ELECTRICAL (1) 602
ENGINE ELECTRICAL (2) 603
ENGINE ELECTRICAL (3) 604
ENGINE ELECTRICAL (4) 605
ENGINE EPA DECAL (A) 45
ENGINE IDENTIFICATION 45
ENGINE NUMBER (B) 45
ENGINE REMOVAL 132
ENGINE SERIAL NUMBER 20
ENGINE STOP SOLENOID 535
EXPLODED VIEW 111
EXPLODED VIEW 198
EXPLODED VIEW 224
EXPLODED VIEW 317
EXPLODED VIEW 363
EXPLODED VIEW 384
EXPLODED VIEW 473
EXPLODED VIEW 598
EXPLODED VIEW 340
EXPLODED VIEW 423
EXTERNAL HYDRAULIC 474
FAN BELT 107
FLASHER UNIT 529
FLOATING SEAL 376
FLOW CONTROL VALVE 502
FLYWHEEL SURFACE AND DEFLECTION OF ENGINE CRANKSHAFT 197
FOR SAFETY 8
FRONT AXLE 392
FRONT AXLE BRACKET 385
FRONT AXLE CASE 391
FRONT AXLE CASE DISASSEMBLY AND ASSEMBLY 401
FRONT AXLE OIL SEAL REPLACEMENT 394
FRONT AXLE TOE-IN ADJUSTMENT 422
FRONT DIFFERENTIAL 387
FRONT DIFFERENTIAL SYSTEM DISASSEMBLY AND ASSEMBLY COMPONENTS 408
FRONT DIFFERENTIAL SYSTEM REMOVAL AND INSTALLATION 403
FRONT DRIVE SYSTEM 242
FRONT WHEEL DRIVE & QT 219
FRONT WHEEL DRIVE SHAFT 232
FUEL EQUIPMENT 121
FUEL FILTER & PIPE 125
FUEL GAUGE OPERATION 591
FUEL SENDER 536
FUEL SYSTEM 82
FUSE 512
FUSE 522
FUSE & RELAY BOX 531
GEAR ARRANGEMENT 29
GEARCASE 114
GEAR PUMP 478
GEAR PUMP & HYDRAULIC FILTER 485
GENERAL 289
GENERAL SPECIFICATION 355
GENERAL SPECIFICATIONS 46
GENERAL SPECIFICATIONS 191
GENERAL SPECIFICATIONS 206
GENERAL SPECIFICATIONS 369
GENERAL SPECIFICATIONS 441
GENERAL USE SCREWS, BOLTS AND NUTS 38
GLOW CONTROL 606
GLOW PLUG 533
GLOW RELAY 531
HANDLING OF HAZARDOUS MATERIALS 12
HANDLING OF ROTATING BLADE, SHAFT AND DRIVING BELT 13
HAZARD WARNING LAMP SWITCH 537
HOURMETER OPERATION 597
HST 289
HST ASSY 318
HST CONTROL 319
HST HYDRAULIC LINE 317
HST NEUTRAL POSITION ADJUSTMENT 315
HST PEDAL 320
HST PEDAL-ENGINE SPEED COUPLED SYSTEM 310
HST STRUCTURE & COMPONENTS 291
HYDRAULIC BLOCK [ROPS MODEL] 479
HYDRAULIC BLOCK [ROPS MODEL] 503
HYDRAULIC CYLINDER 473
HYDRAULIC CYLINDER 495
IDENTIFICATION NUMBER 19
IDLE GEAR 119
IGNITION SWITCH 524
INLET MANIFOLD 126
INPUT PRESSURE INSPECTION OF MODULATOR VALVE 470
INSPECTION AND ADJUSTMENT 360
INSPECTION AND ADJUSTMENT 222
INSPECTION AND ADJUSTMENT 378
INSPECTION AND ADJUSTMENT 470
INSPECTION AND ADJUSTMENT 336
INSPECTION AND ADJUSTMENT 422
INSPECTION USING EXTERNAL HYDRAULIC VALVE COUPLER 471
INSTRUMENT PANEL 567
INTAKE & EXHAUST SYSTEM 91
LAMPS 575
LEVER SETTING OF HYDRAULIC LIFT CYLINDER 472
LIFT CONTROL VALVE 481
LIFT CONTROL VALVE 500
LIGHT CONTROL 599
LOAD TRANSFER 375
LUBRICATING SYSTEM 75
LUBRICATION LIST 36
MAIN GEAR SHIFT SECTION 209
MAIN SHAFT 233
MAIN SPEED FORK 235
MAINTENANCE 34
MAINTENANCE SCHEDULE CHART 34
MAJOR TIGHTENING TORQUE 290
MEASUREMENT AND ADJUSTMENT 107
MEASUREMENT AND ADJUSTMENT 194
MEASUREMENT AND ADJUSTMENT 312
MIDDLE CASE DISASSEMBLY AND ASSEMBLY 262
MID PTO (OPTIONAL) 221
MID PTO SHAFT 224
MODULATE VALVE 475
MODULATOR VALVE 490
OIL COOLER 480
OIL FILTER 115
OIL PAN 112
OIL PRESSURE MEASUREMENT 109
ONE SIDE BRAKE SWITCH 556
OPERATING DIAGRAM 412
OPERATING PRINCIPLE 54
OPERATING PRINCIPLE 293
OPERATING PRINCIPLE 514
OPERATING PRINCIPLE 332
OPERATING PRINCIPLE 444
OPERATING PRINCIPLE OF PREHEAT 518
OPERATING PRINCIPLE OF STEERING SYSTEM 416
OPERATING PRINCIPLE OF SYNCHRONIZER (SST MODELS) 211
OPERATIONAL PRINCIPLE 192
OPERATION OF HST 304
PARKING BRAKE MICRO SWITCH 553
PISTON COMPRESSION PRESSURE MEASUREMENT 107
PISTON & CONNECTING ROD 117
POSITION CONTROL 482
POWER STEERING UNIT 425
POWER TRAIN OF REAR AXLE 332
POWER TRANSFER SYSTEM FOR FRONT AXLE 371
PREHEAT CONTROLLER [AU] 563
PRELOAD OF TAPER ROLLER
BEARING IN DIFF 336
PRELOAD OF TAPER ROLLER BEARING ON SPIRAL BEVEL PINION SHAFT 379
PRESSURE PLATE INSPECTION 196
PREVENTION OF SCALD 13
PRINCIPLE OF DIFFERENTIAL SYSTEM 333
PROPELLER SHAFT 248
PROPELLER SHAFT 384
PROPER INFLATION PRESSURE 37
PTO 215
PTO AUTO / MANUAL SWITCH 559
PTO CLUTCH 227
PTO CLUTCH 245
PTO CLUTCH PACK 217
PTO CONTROL 607
PTO COUNTER SHAFT 244
PTO INPUT SHAFT 225
PTO SHAFT 226
PTO SHAFT 246
PTO SHIFT FORK 247
PTO SWITCH 560
QUICK TURN ANGLE SWITCH [DK6010C-EU] 554
RANGE FORK 241
RANGE SHAFT 238
RANGE SHIFT FORK 229
RANGE SHIFT SECTION 213
RANGE SHIFT SHAFT 228
REAR AXLE 344
REAR AXLE COMPONENTS 345
REAR DIFFERENTIAL DISASSEMBLY 347
REAR DIFFERENTIAL SYSTEM 342
RELIEF PRESSURE 312
RELIEF PRESSURE 313
RELIEF VALVE 502
REMOTE HYDRAULIC VALVE (DOUBLE ACTING VALVE) 492
REMOVAL AND INSTALLATION OF HST 323
ROCKER ARM & VALVE 120
RPM LINKED 321
SAFETY CONTROL UNIT [EU] 565
SAFETY DECALS 15
SAFETY GEAR 9
SAFETY INSTRUCTIONS WHEN
PREPARING TRACTOR 10
SAFETY STARTER 608
SAFETY START SWITCH ADJUSTMENT 195
SAFETY START SWITCH [DK6010C-EU] 555
SAFETY SWITCH 557
SAFETY TIPS 9
SEALANT 191
SEALANT AND ADHESIVE 369
SEALANT AND ADHESIVE SPECIFICATIONS 208
SENSOR 100
SENSORS AND RELAYS 538
SERVICING 323
SERVICING SPECIFICATIONS 49
SHUTTLE FORK 237
SHUTTLE SHAFT 236
SHUTTLE (SST MODELS) 212
SNAP RING INSTALLATION 40
SPECIFICATIONS 22
SPECIFICATIONS 46
SPECIFICATIONS 191
SPECIFICATIONS 206
SPECIFICATIONS 289
SPECIFICATIONS 355
SPECIFICATIONS 369
SPECIFICATIONS 441
SPECIFICATIONS 509
SPECIFICATIONS 331
SPECIFICATIONS AND TIGHTENING TORQUE 411
SPECIFICATIONS FOR STEERING SYSTEM 411
SPEED SENSOR 609
SPIRAL BEVEL GEAR 239
SPIRAL BEVEL PINION SHAFT 230
SPIRAL BEVEL PINION SHAFT 340
SPRING PIN AND SNAP RING INSTALLATION 40
SPRING PIN TYPE 40
START CONTROL 598
START MOTOR 525
STEERING ANGLE 378
STEERING COLUMN 424
STEERING CYLINDER 393
STEERING CYLINDER 423
STEERING CYLINDER REMOVAL 436
STEERING UNIT 414
STEERING UNIT RELIEF PRESSURE INSPECTION 471
STEERING UNIT RELIEF VALVE PRESSURE CHECK 422
STEERING UNIT REMOVAL 427
STRUCTURE AND FUNCTION OF HST 293
STRUCTURE AND OPERATING PRINCIPLE 209
STRUCTURE AND OPERATING PRINCIPLE 443
STRUCTURE AND OPERATING PRINCIPLE 371
STRUCTURE AND OPERATING PRINCIPLE 412
STRUCTURE AND OPERATING PRINCIPLE 420
STRUCTURE AND OPERATION PRINCIPLE 356
STUD BOLTS 38
SUCTION LINE 477
SWAY RESISTANCE 379
SWITCHES 561
SYMBOLS FOR ELECTRIC COMPONENTS 511
SYNCHRONIZER GEAR INSPECTION 222
TACHOMETER OPERATION WITH THE ENGINE RUNNING 595
TEMPERATURE GAUGE OPERATION 593
THROTTLE POSITION SENSOR (TPS) 551
THRUST BALL BEARING INSPECTION 197
TIGHTENING TORQUE 38
TIGHTENING TORQUE 442
TIGHTENING TORQUE FOR MAJOR COMPONENTS 207
TIGHTENING TORQUE FOR MAJOR COMPONENTS 370
TIGHTENING TORQUE FOR MAJOR COMPONENTS 411
TIGHTENING TORQUES 191
TIGHTENING TORQUES 331
TIRE MAINTENANCE 37
TOE-IN 378
TOOTH CONTACT FOR UPPER BEVEL GEARS AND FINAL DRIVE BEVEL GEARS 383
TOOTH CONTACT OF SPIRAL BEVEL 338
TOOTH CONTACT OF SPIRAL BEVEL GEAR 381
TOP LINK 483
TRACTOR EXTERIOR VIEW 19
TRACTOR SERIAL NUMBER 19
TRANSMISSION CASE SECTION (RANGE SHIFT / FRONT WHEEL DRIVE SECTION) DISASSEMBLY AND ASSEMBLY 272
TRANSMISSION FLUID 331
TRANSMISSION SERIAL NUMBER 20
TROUBLESHOOTING 223
TROUBLESHOOTING 311
TROUBLESHOOTING 468
TROUBLESHOOTING 578
TROUBLESHOOTING 104
TROUBLESHOOTING 193
TROUBLESHOOTING 335
TROUBLESHOOTING 359
TROUBLESHOOTING 377
TROUBLESHOOTING 421
TURBOCHARGER 129
TURBO CHARGER WASTEGATE PRESSURE CHECK 110
TURBO PIPE 130
UNIT CONVERSION TABLE 41
USE OF APPROPRIATE TOOLS AND EQUIPMENT 12
VALVE CLEARANCE 108
VALVE LIFT (DEFLECTION AND WORN CONDITION OF VALVE CAM, TAPPET, PUSH ROD, ROCKER ARM, ETC ) 109
WATER FLANGE 122
WATER PUMP 123
WHEEL BOLT TORQUE 37
WHEN IGNITION SWITCH IS IN “OFF” POSITION 514
WHEN IGNITION SWITCH IS TURNED TO “ACC” POSITION 516
WHEN IGNITION SWITCH IS TURNED TO “ON” POSITION 517
WHEN IGNITION SWITCH IS TURNED TO “ST” POSITION 519
WHEN THE ENGINE CANNOT BE STARTED 578
WHEN THE HEAD LAMP CANNOT BE OPERATED 589
WHEN THE PTO DOES NOT OPERATE 587
WHEN THE SYSTEM IS NOT CHARGED 580
WHEN THE SYSTEM IS NOT PREHEATED AUTOMATICALLY 584
WHEN THE SYSTEM IS NOT PREHEATED MANUALLY 582
WIRE HARNESS 600
WIRING COLOR IDENTIFICATION 510
WIRING IDENTIFICATION 510
WORK PLACE 9

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