Bobcat CT4045 T4055 Service Manual 7412981 (07-20) – PDF DOWNLOAD

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Bobcat CT4045 T4055 Service Manual 7412981 (07-20) – PDF DOWNLOAD

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Bobcat CT4045 T4055 Service Manual 7412981 (07-20) – PDF DOWNLOAD

Language : English
Pages : 619
Downloadable : Yes
File Type : PDF
Size:60.8 MB

DESCRIPTION:

Bobcat CT4045 T4055 Service Manual 7412981 (07-20) – PDF DOWNLOAD

S/N B56V11001 & Above
S/N B56W11001 & 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 T4055 Service Manual 7412981 (07-20) – 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 23
DRIVING SPEED 29
GEAR ARRANGEMENT 29
ARRANGEMENT OF MAIN SHIFT GEAR AND REAR AXLE GEARS 32
ROLLING CIRCUMFERENCE OF REAR WHEELS 32
MAINTENANCE 33
MAINTENANCE SCHEDULE CHART 33
TIRE MAINTENANCE 35
PROPER INFLATION PRESSURE 35
WHEEL BOLT TORQUE 35
TIGHTENING TORQUE 36
GENERAL USE SCREWS, BOLTS AND NUTS 36
STUD BOLTS 36
AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS 37
SPRING PIN AND SNAP RING INSTALLATION 38
SPRING PIN TYPE 38
SNAP RING INSTALLATION 38
UNIT CONVERSION TABLE 39
ENGINE 41
ENGINE IDENTIFICATION 44
ENGINE EPA DECAL (A) 44
ENGINE NUMBER (B) 44
SPECIFICATIONS 45
ENGINE BODY 45
LUBRICATING SYSTEM 48
COOLING SYSTEM 48
FUEL SYSTEM 48
OPERATING PRINCIPLE 50
CYLINDER BLOCK 51
CYLINDER HONING 51
CRANKSHAFT 51
PISTON AND PISTON RING 51
CONNECTING ROD 52
CAMSHAFT 52
FUEL CAMSHAFT 52
ROCKER ARM ASSEMBLY 52
INTAKE AND EXHAUST VALVES 53
TIMING GEAR 53
FLYWHEEL 53
MLS CYLINDER HEAD GASKET 53
LUBRICATING SYSTEM 54
ENGINE OIL FLOW 54
ENGINE OIL FLOW CHART 55
FUNCTION OF LUBRICATING SYSTEM 56
COOLING SYSTEM 58
COOLANT FLOW ROUTE 58
WATER PUMP 59
THERMOSTAT 59
RADIATOR 60
RADIATOR CAP 60
FUEL SYSTEM 61
FUEL FLOW ROUTE 61
FUEL FILTER 62
BLEEDING THE FUEL SYSTEM 62
FUEL FEED PUMP 62
FUEL INJECTION PUMP 63
INJECTION NOZZLE 65
GOVERNOR AND STOP SYSTEM 66
BASIC PRINICPLE OF GOVERNOR SYSTEM 66
OPERATION OF GOVERNOR 67
PCV VALVE 68
TROUBLESHOOTING 69
MEASUREMENT AND ADJUSTMENT 71
FAN BELT 71
PISTON COMPRESSION PRESSURE MEASUREMENT 71
VALVE CLEARANCE 72
VALVE LIFT (DEFLECTION AND WORN CONDITION OF VALVE CAM, TAPPET, PUSH ROD, ROCKER ARM, ETC ) 73
INJECTION TIMING MEASUREMENT AND ADJUSTMENT 74
OIL PRESSURE MEASUREMENT 75
FUEL INJECTION PRESSURE 76
BUBBLE TEST FOR RADIATOR 76
INJECTION NOZZLE INSPECTION 76
CYLINDER BLOCK 77
EXPLODED VIEW 77
OIL PAN 78
CYLINDER HEAD 79
GEAR CASE 80
MAIN BEARING CASE 81
VALVE ROCKER ARM 82
CYLINDER HEAD COVER 83
CAMSHAFT 84
PISTON & CRANKSHAFT 85
FLYWHEEL 86
NOZZLE HOLDER 87
FUEL CAMSHAFT 88
SPEED CONTROL LEVER 89
ENGINE STOP LEVER 90
GOVERNOR 91
WATER PUMP 92
WATER HOSE 93
ENGINE DIASSEMBLY AND SERVICING 94
PCV VALVE 94
HEAD COVER INSTALLATION 94
GLOW PLUG AND FUEL OVERFLOW PIPE 95
HEAT SEAL REMOVAL 95
ROCKER ARM ASSEMBLY 96
REMOVAL AND INSTALLATION 96
ROCKER ARM ASSEMBLY CHECK 97
CYLINDER HEAD 98
CYLINDER HEAD REMOVAL 98
CYLINDER HEAD INSTALLATION 99
CYLINDER HEAD SURFACE FLATNESS CHECK 99
INTAKE AND EXHAUST VALVES 100
VALVE REMOVAL 100
VALVE INSTALLATION 100
VALVE RECESS CHECK 100
VALVE SEAT CHECK 101
VALVE SPRING CHECK 101
INJECTION PUMP 102
VALVE SPRING SQUARENESS (TILT) 102
INJECTION PUMP REMOVAL 102
INJECTION PUMP INSTALLATION 103
INJECTION PUMP DISASSEMBLY 104
NOZZLE HOLDER DISASSEMBLY 104
GOVERNOR SPRING AND STOP SOLENOID 105
GEAR CASE 106
IDLE GEAR AND CRANK GEAR 107
VALVE CAMSHAFT 108
FUEL CAMSHAFT 108
TIMING GEAR BACKLASH 109
IDLE GEAR SIDE CLEARANCE 109
CRANK GEARS AND SHAFTS CHECK 109
VALVE CAMSHAFT GEAR SIDE CLEARANCE 110
FUEL CAMSHAFT GEAR SIDE CLEARANCE 110
IDLE GEAR OIL CLEARANCE EASUREMENT 110
IDLE GEAR BUSHING REPLACEMENT 110
VALVE CAMSHAFT OIL CLEARANCE MEASUREMENT 111
VALVE CAMSHAFT DEFLECTION CHECK 111
VALVE CAM HEIGHT MEASUREMENT 111
PISTON AND CONNECTING ROD 112
PISTON PIN BORE 113
PISTON AND CONNECTING ROD CHECK 113
PISTON PIN AND BUSHING CLEARANCE 114
PISTON RING MEASUREMENT 114
PISTON PIN BUSHING REPLACEMENT 114
PISTON RING END GAP 114
CRANKSHAFT AND FLYWHEEL 115
PISTON RING CLEARANCE 115
METAL JOURNAL BEARINGS 119
FLYWHEEL AND CRANKSHAFT CHECK 120
FLYWHEEL DEFLECTION AND CRANKSHAFT END PLAY 120
CRANKSHAFT DEFLECTION 120
CRANKSHAFT JOURNAL AND BEARING 1 OIL CLEARANCE 120
CRANKSHAFT METAL BEARING 1 REPLACEMENT 121
CRANKSHAFT JOURNAL AND BEARING 2 OIL CLEARANCE 121
CYLINDER BORE CHECK 122
CRANK PIN AND CONNECTING ROD BEARING 2 OIL CLEARANCE 122
RELIEF VALVE OF ENGINE OIL 123
OIL PUMP CHECK 123
OIL PUMP, OIL FILTER, RELIEF VALVE AND OIL STRAINER 123
THERMOSTAT 124
WATER PUMP 125
TURBO CHARGER 125
TRANSMISSION 129
SPECIFICATIONS 130
GENERAL SPECIFICATIONS 130
TIGHTENING TORQUE FOR MAJOR COMPONENTS 130
SEALANT AND ADHESIVE SPECIFICATIONS 131
STRUCTURE AND OPERATING PRINCIPLE 132
MAIN GEAR SHIFT SECTION 132
RANGE SHIFT SECTION 133
PTO 134
PTO CLUTCH PACK 135
CALCULATION FOR REAR PTO 135
FRONT WHEEL DRIVE & QT 136
EXPLODED VIEW 137
PTO INPUT SHAFT 137
PTO SHAFT 138
PTO CLUTCH 139
RANGE SHIFT SHAFT 140
RANGE SHIFT FORK 141
SPIRAL BEVEL PINION SHAFT 142
DRIVE SHAFT 143
FRONT WHEEL DRIVE SHAFT 144
COUNTER SHAFT 145
MAIN SPEED FORK 146
SHUTTLE SHAFT 147
SHUTTLE FORK 148
RANGE SHAFT 149
SPIRAL BEVEL GEAR 150
RANGE FORK 152
FRONT DRIVE SYSTEM 153
PTO COUNTER SHAFT 155
PTO CLUTCH 156
PTO SHAFT 157
PTO SHIFT FORK 158
PROPELLER SHAFT 159
DISASSEMBLY, SERVICE AND ASSEMBLY 160
CLUTCH HOUSING DISASSEMBLY AND ASSEMBLY 160
MIDDLE CASE DISASSEMBLY AND ASSEMBLY 173
TRANSMISSION CASE SECTION (RANGE SHIFT / FRONT WHEEL DRIVE SECTION) DISASSEMBLY AND ASSEMBLY 182
HST 199
SPECIFICATIONS 200
GENERAL 200
HST 200
MAJOR TIGHTENING TORQUE 201
HST STRUCTURE & COMPONENTS 202
EXTERIOR 202
OPERATING PRINCIPLE 204
STRUCTURE AND FUNCTION OF HST 204
BASIC PRINCIPLE OF HST 206
FUNCTION OF HST CHARGE PUMP 207
CHARGE RELIEF VALVE 208
NEUTRAL VALVE 209
HIGH PRESSURE RELIEF VALVE 211
SERVO CONTROL 212
INLET CHECK VALVE 213
OPERATION OF HST 215
NEUTRAL STATUS 215
FORWARD DRIVING 217
REVERSE DRIVING 219
HST PEDAL-ENGINE SPEED COUPLED SYSTEM 221
TROUBLESHOOTING 222
MEASUREMENT AND ADJUSTMENT 223
RELIEF PRESSURE 223
CHARGE RELIEF PRESSURE 223
RELIEF PRESSURE 224
HST PEDAL LINK ADJUSTMENT 226
HST PEDAL ADJUSTMENT 226
HST NEUTRAL POSITION ADJUSTMENT 226
CRUISE MAGNETIC CLEARANCE
ADJUSTMENT 227
BLEEDING AIR FROM HST COMPONENT 227
EXPLODED VIEW 228
HST HYDRAULIC LINE 228
HST ASSY 229
HST CONTROL 230
HST PEDAL 231
RPM LINKED 232
CRUISE 233
SERVICING 234
REMOVAL AND INSTALLATION OF HST 234
DISASSEMBLY AND ASSEMBLY OF HST COMPONENTS 236
REAR AXLE 241
SPECIFICATIONS 242
TRANSMISSION FLUID 242
TIGHTENING TORQUES 242
OPERATING PRINCIPLE 243
POWER TRAIN OF REAR AXLE 243
PRINCIPLE OF DIFFERENTIAL SYSTEM 244
DIFFERENTIAL LOCK SYSTEM 245
TROUBLESHOOTING 246
INSPECTION AND ADJUSTMENT 247
BACKLASH FOR DIFFERENTIAL PINION AND SIDE GEAR 247
PRELOAD OF TAPER ROLLER
BEARING IN DIFF 247
BACKLASH FOR SPIRAL BEVEL PINION AND RING GEAR 248
TOOTH CONTACT OF SPIRAL BEVEL 249
EXPLODED VIEW 251
SPIRAL BEVEL PINION SHAFT 251
REAR DIFFERENTIAL SYSTEM 252
DIFF LOCK FORK 253
REAR AXLE 254
DISASSEMBLY, SERVICING AND ASSEMBLY 255
REAR AXLE COMPONENTS 255
REAR DIFFERENTIAL DISASSEMBLY 257
REAR DIFFERENTIAL SYSTEM
COMPONENTS DISASSEMBLY 260
REAR DIFFERENTIAL SYSTEM ASSEMBLY 260
REAR DIFFERENTIAL INSTALLATION 263
BRAKE 265
SPECIFICATIONS 266
GENERAL SPECIFICATION 266
STRUCTURE AND OPERATION PRINCIPLE 267
TROUBLESHOOTING 270
INSPECTION AND ADJUSTMENT 271
BRAKE PEDAL FREE PLAY 271
BRAKE DISC 272
BRAKE PLATE 272
CLEARANCE OF BRAKE LAMP SWITCH 272
BRAKE COMPONENTS INSPECTION 272
CAM PLATE 273
CAM PLATE AND STEEL BALL 273
EXPLODED VIEW 274
BRAKE 274
BRAKE PEDAL 275
BRAKE ROD 276
DISASSEMBLY, SERVICING AND ASSEMBLY 277
BRAKE SECTION DISASSEMBLY AND ASSEMBLY 277
FRONT AXLE 279
SPECIFICATIONS 280
GENERAL SPECIFICATIONS 280
SEALANT AND ADHESIVE 280
TIGHTENING TORQUE FOR MAJOR COMPONENTS 281
STRUCTURE AND OPERATING PRINCIPLE 282
POWER TRANSFER SYSTEM FOR FRONT AXLE 282
LOAD TRANSFER 284
FLOATING SEAL 285
TROUBLESHOOTING 286
INSPECTION AND ADJUSTMENT 287
TOE-IN 287
STEERING ANGLE 287
SWAY RESISTANCE 288
PRELOAD OF TAPER ROLLER BEARING ON SPIRAL BEVEL PINION SHAFT 288
BACKLASH FOR DIFFERENTIAL PINION AND DIFFERENTIAL SIDE GEAR 289
BACKLASH FOR SPIRAL BEVEL PINION AND 23 SPIRAL BEVEL GEAR 289
TOOTH CONTACT OF SPIRAL BEVEL GEAR 290
TOOTH CONTACT FOR UPPER BEVEL GEARS AND FINAL DRIVE BEVEL GEARS 292
EXPLODED VIEW 293
PROPELLER SHAFT 293
FRONT AXLE BRACKET 294
BEVEL PINION SHAFT 295
FRONT DIFFERENTIAL 296
BEVEL GEAR CASE 297
BEVEL GEAR SHAFT 298
FRONT AXLE CASE 300
FRONT AXLE 301
STEERING CYLINDER 302
DISASSEMBLY, SERVICE AND ASSEMBLY 303
FRONT AXLE OIL SEAL REPLACEMENT 303
BEVEL GEAR CASE OIL SEAL REPLACEMENT 307
FRONT AXLE CASE DISASSEMBLY AND ASSEMBLY 310
FRONT DIFFERENTIAL SYSTEM REMOVAL AND INSTALLATION 312
FRONT DIFFERENTIAL SYSTEM DISASSEMBLY AND ASSEMBLY COMPONENTS 317
STEERING SYSTEM 319
SPECIFICATIONS AND TIGHTENING TORQUE 320
SPECIFICATIONS FOR STEERING SYSTEM 320
TIGHTENING TORQUE FOR MAJOR COMPONENTS 320
HYDRAULIC PUMP 320
POWER STEERING UNIT 320
STEERING CYLINDER 320
STRUCTURE AND OPERATING PRINCIPLE 321
OPERATING DIAGRAM 321
STEERING UNIT 323
OPERATING PRINCIPLE 323
STRUCTURE AND SPECIFICATIONS 324
OPERATING PRINCIPLE OF STEERING SYSTEM 325
STRUCTURE AND OPERATING PRINCIPLE 329
TROUBLESHOOTING 330
INSPECTION AND ADJUSTMENT 331
STEERING UNIT RELIEF VALVE PRESSURE CHECK 331
FRONT AXLE TOE-IN ADJUSTMENT 331
EXPLODED VIEW 332
STEERING CYLINDER 332
STEERING COLUMN 333
POWER STEERING UNIT 334
DISASSEMBLY, SERVICE AND ASSEMBLY 335
STEERING UNIT REMOVAL 335
STEERING UNIT (ORBITROL UNIT) COMPONENTS DISASSEMBLY 338
STEERING UNIT COMPONENTS ASSEMBLY 340
RELIEF VALVE DISASSEMBLY AND
ASSEMBLY 343
STEERING CYLINDER REMOVAL 344
HYDRAULIC SYSTEM 347
SPECIFICATIONS 349
GENERAL SPECIFICATIONS 349
TIGHTENING TORQUE 350
STRUCTURE AND OPERATING PRINCIPLE 351
COMPONENT ARRANGEMENT 351
OPERATING DIAGRAM 352
OPERATING PRINCIPLE 352
IMPLEMENT SECTION 353
MAIN SECTION 354
COMPONENTS 355
HYDRAULIC FILTER 355
GEAR PUMP 356
MODULATOR VALVE (PTO, 4WD) 357
AUX HYDRAULIC VALVE 360
LIFT CONTROL VALVE (PCV VALVE) 362
HYDRAULIC BLOCK [ROPS MODEL] 364
OIL COOLER [HST MODEL] 372
HYDRAULIC LIFT CYLINDER 373
TROUBLESHOOTING 376
INSPECTION AND ADJUSTMENT 378
STEERING UNIT RELIEF PRESSURE INSPECTION 379
INSPECTION USING EXTERNAL HYDRAULIC VALVE COUPLER 379
LEVER SETTING OF HYDRAULIC LIFT CYLINDER 380
ADJUSTING THE POSITION CONTROL LEVER 380
EXPLODED VIEW 381
HYDRAULIC CYLINDER 381
EXTERNAL HYDRAULIC 382
MODULATE VALVE 383
SUCTION LINE 384
GEAR PUMP 385
HYDRAULIC BLOCK [ROPS MODEL] 386
OIL COOLER 387
LIFT CONTROL VALVE 388
POSITION CONTROL 389
TOP LINK 390
DOWN SPEED CONTROL 391
DISASSEMBLY, SERVICE AND ASSEMBLY 392
GEAR PUMP & HYDRAULIC FILTER 392
DISASSEMBLY OF GEAR PUMP 393
GEAR PUMP ASSEMBLY
COMPONENTS ASSEMBLY 395
MODULATOR VALVE DISASSEMBLY 397
MODULATOR VALVE 397
MODULATOR VALVE ASSEMBLY 398
REMOTE HYDRAULIC VALVE (DOUBLE ACTING VALVE) 399
AUX HYDRAULIC (DOUBLE ACTING) VALVE ASSEMBLY COMPONENTS DISASSEMBLY 400
AUX HYDRAULIC VALVE ASSEMBLY COMPONENTS ASSEMBLY 401
HYDRAULIC CYLINDER 402
HYDRAULIC CYLINDER ASSEMBLY DISASSEMBLY 403
HYDRAULIC CYLINDER ASSEMBLY REASSEMBLY 405
LIFT CONTROL VALVE 407
FLOW CONTROL VALVE 409
RELIEF VALVE 409
HYDRAULIC BLOCK [ROPS MODEL] 410
HYDRAULIC BLOCK ASSEMBLY COMPONENTS DISASSEMBLY 410
HYDRAULIC / HYDROSTATIC SCHEMATICS 413
ELECTRIC SYSTEM AND DIAGNOSIS 415
SPECIFICATIONS 417
WIRING IDENTIFICATION 418
CROSS SECTIONAL AREA OF WIRING 419
SYMBOLS FOR ELECTRIC COMPONENTS 419
FUSE 420
INSPECTION 420
CAUSE FOR BLOWN FUSE 420
ELECTRIC DEVICE DIAGNOSIS 421
OPERATING PRINCIPLE 422
WHEN IGNITION SWITCH IS TURNED TO “ACC” POSITION 424
WHEN IGNITION SWITCH IS TURNED TO “ON” POSITION 425
OPERATING PRINCIPLE OF PREHEAT 426
WHEN IGNITION SWITCH IS TURNED TO “ST” POSITION 427
ECU OPERATION 429
ELECTRIC COMPONENTS 430
SLOW-BLOW FUSE 431
IGNITION SWITCH 432
IGNITION SWITCH OPERATION 432
KEY SWITCH TEST 432
START MOTOR 433
ALTERNATOR 433
COMBINATION SWITCH 435
FLASHER UNIT 437
GLOW RELAY 439
FUSE & RELAY BOX 439
5P RELAY 439
MICRO 4P RELAY 440
GLOW PLUG 441
MICRO 5P RELAY 441
COOLANT TEMPERATURE SENSOR 442
FUEL SENDER 443
HAZARD WARNING LAMP SWITCH 444
ECU 445
SENSORS AND RELAYS 445
CRANKSHAFT WHEEL SENSOR 446
FUEL RAIL PRESSURE SENSOR 447
ACCELERATION (KNOCK) SENSORS 448
HIGH-PRESSURE FUEL PUMP
TEMPERATURE SENSOR 449
WATER-IN-FUEL SENSOR 450
EXHAUST GAS TEMP SENSOR 451
CAMSHAFT WHEEL SENSOR 452
EGR VALVE SENSOR 453
MAF SENSOR 454
INTAKE AIR PRESSURE SENSOR / TEMPERATURE SENSOR 455
DPF DIFFERENTIAL PRESSURE SENSOR 457
THROTTLE POSITION SENSOR (TPS) 458
AIR CONTROL VALVE SENSOR 458
BRAKE SWITCH 459
PARKING BRAKE MICRO SWITCH 460
4WD / QT SWITCH [DK6010C-EU] 460
QUICK TURN ANGLE SWITCH [DK6010C-EU] 461
SAFETY START SWITCH [DK6010C-EU] 462
ONE SIDE BRAKE SWITCH 463
SAFETY SWITCH 464
PTO SAFETY SWITCH 464
RANGE SHIFT SAFETY SWITCH 464
PTO AUTO / MANUAL SWITCH 466
PTO SWITCH 467
SWITCHES 468
CRUISE PTO SWITCH 468
CRUISE CONTROL RES / SET SWITCH 469
PREHEAT CONTROLLER [AU] 470
DPF REGENERATION SWITCH 470
SAFETY CONTROL UNIT [EU] 472
INSTRUMENT PANEL 474
SYMBOLS AND ARRANGEMENT 474
CONNECTOR 475
CIRCUIT DIAGRAM 476
GAUGES AND INDICATORS 477
LAMPS 482
HEADLAMP 482
TURN SIGNAL LAMP 483
REAR COMBINATION LAMP 484
TROUBLESHOOTING 485
WHEN THE ENGINE CANNOT BE STARTED 485
WHEN THE SYSTEM IS NOT CHARGED 487
WHEN THE SYSTEM IS NOT PREHEATED MANUALLY 489
WHEN THE SYSTEM IS NOT PREHEATED AUTOMATICALLY 491
WHEN THE PTO DOES NOT OPERATE 494
WHEN THE HEAD LAMP CANNOT BE OPERATED 496
FUEL GAUGE OPERATION 498
TEMPERATURE GAUGE OPERATION 500
TACHOMETER OPERATION WITH THE ENGINE RUNNING 502
HOURMETER OPERATION 504
EXPLODED VIEW 505
START CONTROL 505
LIGHT CONTROL 506
WIRE HARNESS 507
DISPLAY CONTROL 508
ENGINE ELECTRICAL (1) 509
ENGINE ELECTRICAL (2) 510
ENGINE ELECTRICAL (3) 511
ENGINE ELECTRICAL (4) 512
GLOW CONTROL 513
PTO CONTROL 514
SAFETY STARTER 515
SPEED SENSOR 516
DIAGNOSIS 517
DIAGNOSTIC PROGRAM 517
DTC (DIAGNOSTIC TROUBLE CODE) 543
COMPOSITION 543
ERORR CODE & ACTION 544
FAULT DIAGNOSIS CODE DESCRIPTION 566
ELECTRICAL SCHEMATICS 609
INDEX 611
4WD / QT SWITCH 460
ALERT SYMBOLS 8
ALTERNATOR 433
AVOID FIRES 10
BACKLASH FOR DIFFERENTIAL PINION AND DIFFERENTIAL SIDE GEAR 289
BACKLASH FOR DIFFERENTIAL PINION AND SIDE GEAR 247
BACKLASH FOR SPIRAL BEVEL PINION AND 23 SPIRAL BEVEL GEAR 289
BACKLASH FOR SPIRAL BEVEL PINION AND RING GEAR 248
BEVEL GEAR CASE 297
BEVEL GEAR CASE OIL SEAL REPLACEMENT 307
BEVEL GEAR SHAFT 298
BEVEL PINION SHAFT 295
BLEEDING AIR FROM HST COMPONENT 227
BODY AND POWER TRAIN SYSTEM 50
BRAKE 274
BRAKE COMPONENTS INSPECTION 272
BRAKE PEDAL 275
BRAKE PEDAL FREE PLAY 271
BRAKE ROD 276
BRAKE SECTION DISASSEMBLY AND ASSEMBLY 277
BRAKE SWITCH 459
BUBBLE TEST FOR RADIATOR 76
CALCULATION FOR REAR PTO 135
CAMSHAFT 84
CAUTIONS FOR HIGH PRESSURE HOSES 11
CAUTIONS WHEN HANDLING THE BATTERY 11
CAUTIONS WHEN HANDLING TIRES 14
CHARGE RELIEF PRESSURE 223
CLEARANCE OF BRAKE LAMP SWITCH 272
CLUTCH HOUSING DISASSEMBLY AND ASSEMBLY 160
COMBINATION SWITCH 435
COMPONENT ARRANGEMENT 351
COMPONENTS 355
COOLANT TEMPERATURE SENSOR 442
COOLING SYSTEM 58
COUNTER SHAFT 145
CRANK GEARS AND SHAFTS CHECK 109
CRANKSHAFT AND FLYWHEEL 115
CROSS SECTIONAL AREA OF WIRING 419
CRUISE 233
CRUISE MAGNETIC CLEARANCE
ADJUSTMENT 227
CYLINDER BLOCK 77
CYLINDER BORE CHECK 122
CYLINDER HEAD 79
CYLINDER HEAD 98
CYLINDER HEAD COVER 83
DIAGNOSIS 517
DIAGNOSTIC PROGRAM 517
DIFFERENTIAL LOCK SYSTEM 245
DIFFERENTIAL SYSTEM 284
DIFF LOCK FORK 253
DISASSEMBLY AND ASSEMBLY OF HST COMPONENTS 236
DISASSEMBLY, SERVICE AND ASSEMBLY 160
DISASSEMBLY, SERVICE AND ASSEMBLY 303
DISASSEMBLY, SERVICE AND ASSEMBLY 392
DISASSEMBLY, SERVICE AND ASSEMBLY 335
DISASSEMBLY, SERVICING AND ASSEMBLY 255
DISASSEMBLY, SERVICING AND ASSEMBLY 277
DISPLAY CONTROL 508
DISPOSAL OF ENVIRONMENTAL WASTE 14
DOWN SPEED CONTROL 391
DRIVE SHAFT 143
DTC (DIAGNOSTIC TROUBLE CODE) 543
ECU 445
ECU OPERATION 429
ELECTRIC COMPONENTS 430
ELECTRIC DEVICE DIAGNOSIS 421
ENGINE DIASSEMBLY AND SERVICING 94
ENGINE ELECTRICAL (1) 509
ENGINE ELECTRICAL (2) 510
ENGINE ELECTRICAL (3) 511
ENGINE ELECTRICAL (4) 512
ENGINE EPA DECAL (A) 44
ENGINE IDENTIFICATION 44
ENGINE NUMBER (B) 44
ENGINE STOP LEVER 90
EXPLODED VIEW 137
EXPLODED VIEW 228
EXPLODED VIEW 274
EXPLODED VIEW 293
EXPLODED VIEW 381
EXPLODED VIEW 505
EXPLODED VIEW 77
EXPLODED VIEW 251
EXPLODED VIEW 332
EXTERNAL HYDRAULIC 382
FAN BELT 71
FLASHER UNIT 437
FLOATING SEAL 285
FLOW CONTROL VALVE 409
FLYWHEEL 86
FLYWHEEL AND CRANKSHAFT CHECK 120
FOR SAFETY 8
FRONT AXLE 301
FRONT AXLE BRACKET 294
FRONT AXLE CASE 300
FRONT AXLE CASE DISASSEMBLY AND ASSEMBLY 310
FRONT AXLE OIL SEAL REPLACEMENT 303
FRONT AXLE TOE-IN ADJUSTMENT 331
FRONT DIFFERENTIAL 296
FRONT DIFFERENTIAL SYSTEM DISASSEMBLY AND ASSEMBLY COMPONENTS 317
FRONT DIFFERENTIAL SYSTEM REMOVAL AND INSTALLATION 312
FRONT DRIVE SYSTEM 153
FRONT WHEEL DRIVE & QT 136
FRONT WHEEL DRIVE SHAFT 144
FUEL CAMSHAFT 88
FUEL CAMSHAFT 108
FUEL GAUGE OPERATION 498
FUEL SENDER 443
FUEL SYSTEM 61
FUSE 420
FUSE 430
FUSE & RELAY BOX 439
GEAR CASE 80
GEAR CASE 106
GEAR PUMP 385
GEAR PUMP & HYDRAULIC FILTER 392
GENERAL 200
GENERAL SPECIFICATION 266
GENERAL SPECIFICATIONS 130
GENERAL SPECIFICATIONS 280
GENERAL SPECIFICATIONS 349
GLOW CONTROL 513
GLOW PLUG 441
GLOW PLUG AND FUEL OVERFLOW PIPE 95
GLOW RELAY 439
GOVERNOR 91
GOVERNOR AND STOP SYSTEM 66
GOVERNOR SPRING AND STOP SOLENOID 105
HANDLING OF HAZARDOUS MATERIALS 12
HANDLING OF ROTATING BLADE, SHAFT AND DRIVING BELT 13
HAZARD WARNING LAMP SWITCH 444
HEAD COVER INSTALLATION 94
HEAT SEAL REMOVAL 95
HOURMETER OPERATION 504
HST 200
HST ASSY 229
HST CONTROL 230
HST HYDRAULIC LINE 228
HST NEUTRAL POSITION ADJUSTMENT 226
HST PEDAL 231
HST PEDAL-ENGINE SPEED COUPLED SYSTEM 221
HST STRUCTURE & COMPONENTS 202
HYDRAULIC BLOCK [ROPS MODEL] 386
HYDRAULIC BLOCK [ROPS MODEL] 410
HYDRAULIC CYLINDER 381
HYDRAULIC CYLINDER 402
IDLE GEAR AND CRANK GEAR 107
IGNITION SWITCH 432
INJECTION NOZZLE INSPECTION 76
INJECTION PUMP 102
INJECTION TIMING MEASUREMENT AND ADJUSTMENT 74
INPUT PRESSURE INSPECTION OF MODULATOR VALVE 378
INSPECTION AND ADJUSTMENT 271
INSPECTION AND ADJUSTMENT 287
INSPECTION AND ADJUSTMENT 378
INSPECTION AND ADJUSTMENT 247
INSPECTION AND ADJUSTMENT 331
INSPECTION USING EXTERNAL HYDRAULIC VALVE COUPLER 379
INSTRUMENT PANEL 474
INTAKE AND EXHAUST VALVES 100
LAMPS 482
LEVER SETTING OF HYDRAULIC LIFT CYLINDER 380
LIFT CONTROL VALVE 388
LIFT CONTROL VALVE 407
LIGHT CONTROL 506
LOAD TRANSFER 284
LUBRICATING SYSTEM 54
MAIN BEARING CASE 81
MAIN GEAR SHIFT SECTION 132
MAIN SPEED FORK 146
MAJOR TIGHTENING TORQUE 201
MEASUREMENT AND ADJUSTMENT 223
MEASUREMENT AND ADJUSTMENT 71
METAL JOURNAL BEARINGS 119
MIDDLE CASE DISASSEMBLY AND ASSEMBLY 173
MODULATE VALVE 383
MODULATOR VALVE 397
NOZZLE HOLDER 87
OIL COOLER 387
OIL PAN 78
OIL PRESSURE MEASUREMENT 75
OIL PUMP, OIL FILTER, RELIEF VALVE AND OIL STRAINER 123
ONE SIDE BRAKE SWITCH 463
OPERATING DIAGRAM 321
OPERATING PRINCIPLE 204
OPERATING PRINCIPLE 422
OPERATING PRINCIPLE 50
OPERATING PRINCIPLE 243
OPERATING PRINCIPLE 352
OPERATING PRINCIPLE OF PREHEAT 426
OPERATING PRINCIPLE OF STEERING SYSTEM 325
OPERATION OF HST 215
PARKING BRAKE MICRO SWITCH 460
PCV VALVE 68
PCV VALVE 94
PISTON AND CONNECTING ROD 112
PISTON AND CONNECTING ROD CHECK 113
PISTON COMPRESSION PRESSURE MEASUREMENT 71
PISTON & CRANKSHAFT 85
PISTON RING MEASUREMENT 114
POSITION CONTROL 389
POWER STEERING UNIT 334
POWER TRAIN OF REAR AXLE 243
POWER TRANSFER SYSTEM FOR FRONT AXLE 282
PREHEAT CONTROLLER 470
PRELOAD OF TAPER ROLLER
BEARING IN DIFF 247
PRELOAD OF TAPER ROLLER BEARING ON SPIRAL BEVEL PINION SHAFT 288
PREVENTION OF SCALD 13
PRINCIPLE OF DIFFERENTIAL SYSTEM 244
PROPELLER SHAFT 159
PROPELLER SHAFT 293
PTO 134
PTO AUTO / MANUAL SWITCH 466
PTO CLUTCH 139
PTO CLUTCH 156
PTO CLUTCH PACK 135
PTO CONTROL 514
PTO COUNTER SHAFT 155
PTO INPUT SHAFT 137
PTO SHAFT 138
PTO SHAFT 157
PTO SHIFT FORK 158
PTO SWITCH 467
QUICK TURN ANGLE SWITCH 461
RANGE FORK 152
RANGE SHAFT 149
RANGE SHIFT FORK 141
RANGE SHIFT SECTION 133
RANGE SHIFT SHAFT 140
REAR AXLE 254
REAR AXLE COMPONENTS 255
REAR DIFFERENTIAL DISASSEMBLY 257
REAR DIFFERENTIAL SYSTEM 252
RELIEF PRESSURE 223
RELIEF PRESSURE 224
RELIEF VALVE 409
REMOTE HYDRAULIC VALVE (DOUBLE ACTING VALVE) 399
REMOVAL AND INSTALLATION OF HST 234
ROCKER ARM ASSEMBLY 96
RPM LINKED 232
SAFETY CONTROL UNIT 472
SAFETY DECALS 15
SAFETY GEAR 9
SAFETY INSTRUCTIONS WHEN
PREPARING TRACTOR 10
SAFETY STARTER 515
SAFETY START SWITCH 462
SAFETY SWITCH 464
SAFETY TIPS 9
SEALANT AND ADHESIVE 280
SEALANT AND ADHESIVE SPECIFICATIONS 131
SENSORS AND RELAYS 445
SERVICING 234
SERVICING SPECIFICATIONS 45
SHUTTLE FORK 148
SHUTTLE SHAFT 147
SPECIFICATIONS 130
SPECIFICATIONS 200
SPECIFICATIONS 266
SPECIFICATIONS 280
SPECIFICATIONS 349
SPECIFICATIONS 417
SPECIFICATIONS 45
SPECIFICATIONS 242
SPECIFICATIONS AND TIGHTENING TORQUE 320
SPECIFICATIONS FOR STEERING SYSTEM 320
SPEED CONTROL LEVER 89
SPEED SENSOR 516
SPIRAL BEVEL GEAR 150
SPIRAL BEVEL PINION SHAFT 142
SPIRAL BEVEL PINION SHAFT 251
START CONTROL 505
START MOTOR 433
STEERING ANGLE 287
STEERING COLUMN 333
STEERING CYLINDER 302
STEERING CYLINDER 332
STEERING CYLINDER REMOVAL 344
STEERING UNIT 323
STEERING UNIT RELIEF PRESSURE INSPECTION 378
STEERING UNIT RELIEF VALVE PRESSURE CHECK 331
STEERING UNIT REMOVAL 335
STRUCTURE AND FUNCTION OF HST 204
STRUCTURE AND OPERATING PRINCIPLE 132
STRUCTURE AND OPERATING PRINCIPLE 351
STRUCTURE AND OPERATING PRINCIPLE 282
STRUCTURE AND OPERATING PRINCIPLE 321
STRUCTURE AND OPERATING PRINCIPLE 329
STRUCTURE AND OPERATING PRINCIPLE 267
SUCTION LINE 384
SWAY RESISTANCE 288
SWITCHES 468
SYMBOLS FOR ELECTRIC COMPONENTS 419
TACHOMETER OPERATION WITH THE ENGINE RUNNING 502
TEMPERATURE GAUGE OPERATION 500
THERMOSTAT 124
THROTTLE POSITION SENSOR (TPS) 458
TIGHTENING TORQUE 350
TIGHTENING TORQUE FOR MAJOR COMPONENTS 130
TIGHTENING TORQUE FOR MAJOR COMPONENTS 281
TIGHTENING TORQUE FOR MAJOR COMPONENTS 320
TIGHTENING TORQUES 242
TOE-IN 287
TOOTH CONTACT FOR UPPER BEVEL GEARS AND FINAL DRIVE BEVEL GEARS 292
TOOTH CONTACT OF SPIRAL BEVEL 249
TOOTH CONTACT OF SPIRAL BEVEL GEAR 290
TOP LINK 390
TRANSMISSION CASE SECTION (RANGE SHIFT / FRONT WHEEL DRIVE SECTION) DISASSEMBLY AND ASSEMBLY 182
TRANSMISSION FLUID 242
TROUBLESHOOTING 222
TROUBLESHOOTING 376
TROUBLESHOOTING 485
TROUBLESHOOTING 69
TROUBLESHOOTING 246
TROUBLESHOOTING 270
TROUBLESHOOTING 286
TROUBLESHOOTING 330
TURBO CHARGER 125
USE OF APPROPRIATE TOOLS AND EQUIPMENT 12
VALVE CAMSHAFT 108
VALVE CLEARANCE 72
VALVE LIFT (DEFLECTION AND WORN CONDITION OF VALVE CAM, TAPPET, PUSH ROD, ROCKER ARM, ETC ) 73
VALVE ROCKER ARM 82
WATER HOSE 93
WATER PUMP 92
WATER PUMP 125
WHEN IGNITION SWITCH IS IN “OFF” POSITION 422
WHEN IGNITION SWITCH IS TURNED TO “ACC” POSITION 424
WHEN IGNITION SWITCH IS TURNED TO “ON” POSITION 425
WHEN IGNITION SWITCH IS TURNED TO “ST” POSITION 427
WHEN THE ENGINE CANNOT BE STARTED 485
WHEN THE HEAD LAMP CANNOT BE OPERATED 496
WHEN THE PTO DOES NOT OPERATE 494
WHEN THE SYSTEM IS NOT CHARGED 487
WHEN THE SYSTEM IS NOT PREHEATED AUTOMATICALLY 491
WHEN THE SYSTEM IS NOT PREHEATED MANUALLY 489
WIRE HARNESS 507
WIRING COLOR IDENTIFICATION 418
WIRING IDENTIFICATION 418
WORK PLACE 9

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