Bobcat CT5545 CT5550 CT5555 CT5558 Compact Tractor Service Manual 7372814 (07-20) – PDF DOWNLOAD

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Bobcat CT5545 CT5550 CT5555 CT5558 Compact Tractor Service Manual 7372814 (07-20) – PDF DOWNLOAD

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Bobcat CT5545 CT5550 CT5555 CT5558 Compact Tractor Service Manual 7372814 (07-20) – PDF DOWNLOAD

Language : English
Pages : 796
Downloadable : Yes
File Type : PDF
Size: 72.1 MB

DESCRIPTION:

Bobcat CT5545 CT5550 CT5555 CT5558 Compact Tractor Service Manual 7372814 (07-20) – PDF DOWNLOAD

(CT5545 HST) S/N B4W411001 & Above
(CT5550 HST) S/N B4W511001 & Above
(CT5555 HST) S/N B4W611001 & Above
(CT5558 HST) S/N B4W711001 & 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.

TABLE OF CONTENTS:

Bobcat CT5545 CT5550 CT5555 CT5558 Compact Tractor Service Manual 7372814 (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 27
GEAR ARRANGEMENT 27
MAINTENANCE 29
MAINTENANCE SCHEDULE 29
LUBRICATION LIST 31
TIRE MAINTENANCE 32
PROPER INFLATION PRESSURE 32
WHEEL BOLT TORQUE 32
TIGHTENING TORQUE 33
GENERAL USE SCREWS, BOLTS AND NUTS 33
STUD BOLTS 33
AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS 34
SPRING PIN AND SNAP RING INSTALLATION 35
SPRING PIN TYPE 35
SNAP RING INSTALLATION 35
UNIT CONVERSION TABLE 36
ENGINE 37
ENGINE IDENTIFICATION 39
ENGINE EPA DECAL (A) 39
ENGINE NUMBER (B) 39
SPECIFICATIONS 40
ENGINE DIMENSION 41
COMPONENTS 42
SERVICING SPECIFICATIONS 43
ENGINE BODY 43
LUBRICATING SYSTEM 46
COOLING SYSTEM 46
OPERATING PRINCIPLE 47
CRDI (COMMON RAIL DIRECT INJECTION) SYSTEM 47
ECU 49
HIGH PRESSURE FUEL PUMP (FOR INJECTION) 58
FUEL RAIL(COMMON RAIL) 59
INJECTOR [C3I] 59
CYLINDER HEAD 64
CYLINDER BLOCK 64
CYLINDER HONING 64
BODY AND POWER TRAIN SYSTEM 64
CRANKSHAFT 65
PISTON AND PISTON RING 65
CONNECTING ROD 65
CAMSHAFT 65
ROCKER ARM ASSEMBLY 66
INTAKE AND EXHAUST VALVES 66
TIMING GEAR 67
FLYWHEEL 67
MLS CYLINDER HEAD GASKET 67
ENGINE OIL FLOW 68
LUBRICATING SYSTEM 68
ENGINE OIL FLOW CHART 69
FUNCTION OF LUBRICATING SYSTEM 70
COOLANT FLOW ROUTE 72
COOLING SYSTEM 72
WATER PUMP 73
THERMOSTAT 73
RADIATOR 74
RADIATOR CAP 74
FUEL SYSTEM 75
OVERVIEW FOR FUEL SUPPLY 75
FUEL FLOW ROUTE 75
FUEL FILTER 77
BLEEDING THE FUEL SYSTEM 78
HIGH PRESSURE FUEL PUMP 79
COMMON RAIL (FUEL RAIL) 81
INJECTOR [C3I (CALIBRATION IMPROVED INDIVIDUAL INJECTOR)] 82
FUEL HEATER AND FUEL COOLER 83
ACCELERATION SYSTEM 84
OVERVIEW 86
INTAKE & EXHAUST SYSTEM 86
EGR COOLER 88
EGR VALVE 88
AIR CONTROL VAVLE 89
CCRT (CATALYZED CONTINUOUSLY
REGENERATING TRAP) 89
TURBO CHARGER 94
SENSOR 95
SENSORS AS INPUT/OUTPUT FOR ECU 98
TROUBLESHOOTING 99
MEASUREMENT AND ADJUSTMENT 102
VALVE CLEARANCE 103
CLEARANCE ADJUSTMENT 103
VALVE LIFT (DEFLECTION AND WORN CONDITION OF VALVE CAM, TAPPET, PUSH ROD, ROCKER ARM, ETC ) 104
OIL PRESSURE MEASUREMENT 104
BUBBLE TEST FOR RADIATOR 105
TURBO CHARGER WASTEGATE PRESSURE CHECK 105
EXPLODED VIEW 107
CYLINDER BLOCK 107
OILPAN 109
CYLINDER HEAD 110
GEAR CASE 111
OIL FILTER 112
CRANK SHAFT 113
PISTON & CONNECTING ROD 114
CAM SHAFT 115
IDLE GEAR 116
ROCKER ARM & VALVE 117
FUEL EQUIPMENT 118
WATER FLANGE 119
WATER PUMP 120
CYLINDER HEAD COVER 121
FUEL FILTER & PIPE 122
INLET MANIFOLD (TIER4) 123
EGR 124
COOLING FAN 125
TURBO CHARGER 126
TURBO PIPE 127
AFTER TREATMENT (TIER4) 128
DISASSEMBLY, SERVICE AND ASSEMBLY 129
ENGINE REMOVAL 129
ENGINE COMPONENT REMOVAL 142
HEAD COVER 148
ENGINE DISASSEMBLY 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 168
FLYWHEEL AND CRANKSHAFT 173
OIL FILTER 182
OIL PUMP 183
THERMOSTAT 185
WATER PUMP 186
FUEL FILTER 188
TURBO CHARGER 188
TRANSMISSION 190
SPECIFICATIONS 192
GENERAL SPECIFICATIONS 192
TIGHTENING TORQUE FOR MAJOR COMPONENTS 193
SEALANT AND ADHESIVE SPECIFICATIONS 194
STRUCTURE AND OPERATING PRINCIPLE 195
OPERATING PRINCIPLE OF SYNCHRONIZER 196
RANGE SHIFT SECTION 197
CREEP SHIFT SPEED SECTION 198
SHIFT LINK SYSTEM 199
SHIFT LINK FOR MAIN GEAR SHIFT SECTION 199
SHIFT LINK FOR SHUTTLE SECTION 200
PTO 201
PTO CLUTCH PACK 202
MID PTO 202
CALCULATION FOR REAR PTO AND MID PTO 203
REAR PTO 203
MID PTO 203
FRONT WHEEL DRIVE 204
INSPECTION AND ADJUSTMENT 205
TROUBLESHOOTING 206
EXPLODED VIEW 207
COUNTER SHAFT 209
SHUTTLE SHAFT 210
RANGE SHAFT 212
CREEP SHAFT 213
SHAFT, SPIRAL BEVEL 215
FRONT DRIVE SYSTEM 217
PTO COUNTER SHAFT 219
PTO CLUTCH 221
PTO SHAFT 223
MAIN SPEED FORK 225
PTO SHIFT FORK 226
SHUTTLE FORK 227
RANGE FORK 228
CREEP FORK 229
PTO LEVER 230
MAIN SHIFT LEVER 231
RANGE SHIFT LEVER 232
SHUTTLE 233
DISASSEMBLY, SERVICE AND ASSEMBLY 234
MAIN SHIFT SECTION DISASSEMBLY 234
CLUTCH HOUSING AND MIDDLE CASE
REMOVAL 234
SHUTTLE SHIFT SECTION, CREEP SPEED SECTION AND PTO CLUTCH DISASSEMBLY 236
PTO CLUTCH DISASSEMBLY 242
SHUTTLE SHAFT BEARING COVER INSTALLATION 243
RANGE SHIFT SECTION, 4WD SECTION AND PTO DRIVE SECTION DISASSEMBLY 244
RANGE SHIFT SECTION DISASSEMBLY 244
WD SECTION REMOVAL & INSTALLATION 249
PTO DRIVE SECTION(PTO SHAFT REMOVAL & INSTALLATION, OIL SEAL REPLACE) 251
HST 254
GENERAL INFORMATION 255
SPECIFICATIONS 255
GENERAL 255
HST 255
MAJOR TIGHTENING TORQUE 255
HST COMPONENTS & CIRCUIT DIAGRAM 256
COMPONENTS 256
CIRCUIT DIAGRAM 257
OPERATING PRINCIPLE 258
STRUCTURE AND FUNCTION 258
POWER TRAIN 258
THE INSTALLATION LOCATION OF HST 259
BASIC PRINCIPLE 260
HYDRAULIC PUMP 260
FUNCTION HST CHARGE PUMP 261
HYDRAULIC MOTOR 261
CHARGE PUMP LOCATION 262
CHARGE RELIEF VALVE 263
NEUTRAL VALVE 264
OPERATION OF NEUTRAL VALVE (WHEN IN TRAL) 264
OPERATION OF NEUTRAL VALVE (FOR FORWARD • REVERSE DRIVING) 265
HIGH PRESSURE RELIEF VALVE 266
EXAMPLE FOR OPERATION OF HIGH PRESSURE RELIEF VALVE 266
SERVO CONTROL 267
INLET CHECK VALVE 268
OPERATION OF INLET CHECK VALVE 268
OPERATION OF HST 270
NEUTRAL STATUS 270
FORWARD DRIVING 272
REVERSE DRIVING 274
EXPLODED VIEW 276
PEDAL 276
SERVICING 278
REMOVAL AND INSTALLATION OF HST 278
REMOVAL AND INSTALLATION OF HST COMPONENTS 281
REAR AXLE 288
SPECIFICATIONS 289
TRANSMISSION FLUID 289
TIGHTENING TORQUES 289
OPERATING PRINCIPLE 290
POWER TRAIN OF REAR AXLE 290
PRINCIPLE OF DIFFERENTIAL SYSTEM 291
DIFFERENTIAL LOCK SYSTEM 292
TROUBLESHOOTING 293
INSPECTION AND ADJUSTMENT 294
BACKLASH FOR DIFFERENTIAL PINION AND SIDE GEAR 294
PRELOAD OF TAPER ROLLER
BEARING IN DIFF 294
BACKLASH FOR SPIRAL BEVEL PINION AND RING GEAR 295
TOOTH CONTACT OF SPIRAL BEVEL 296
EXPLODED VIEW 298
SPIRAL BEVEL PINION SHAFT 298
REAR DIFFERENTIAL SYSTEM 300
DIFF LOCK FORK 301
REAR AXLE 302
REAR WHEEL 303
DISASSEMBLY, SERVICING AND ASSEMBLY 304
REAR AXLE COMPONENTS 304
REAR WHEEL NUT 306
REAR DIFFERENTIAL SYSTEM 306
BRAKE 310
SPECIFICATIONS 311
GENERAL SPECIFICATION 311
TIGHTENING TORQUE 311
STRUCTURE AND OPERATION PRINCIPLE 312
TROUBLESHOOTING 316
INSPECTION AND ADJUSTMENT 317
BRAKE PEDAL FREE PLAY 317
CLEARANCE OF BRAKE LAMP SWITCH 317
BRAKE UNIT 318
CAM LEVER FREE PLAY 318
CAM PLATE 318
CAM PLATE AND STEEL BALL 318
EXPLODED VIEW 319
BRAKE CASE 319
BRAKE PEDAL 321
DISASSEMBLY, SERVICING AND ASSEMBLY 323
REMOVAL OF BRAKE CASE 323
INSTALLATION OF PARTS IN BRAKE CASE 323
FRONT AXLE 326
SPECIFICATIONS 327
GENERAL SPECIFICATIONS 327
SEALANT AND ADHESIVE 327
TIGHTENING TORQUE FOR MAJOR COMPONENTS 328
STRUCTURE AND OPERATING PRINCIPLE 329
POWER TRANSFER SYSTEM FOR FRONT AXLE 329
DIFFERENTIAL SYSTEM 331
LOAD TRANSFER 332
FLOATING SEAL 333
TROUBLESHOOTING 334
INSPECTION AND ADJUSTMENT 335
TOE-IN 335
STEERING ANGLE 335
SWAY RESISTANCE 336
PRELOAD OF TAPER ROLLER BEARING ON SPIRAL BEVEL PINION SHAFT 336
BACKLASH FOR DIFFERENTIAL PINION AND DIFFERENTIAL SIDE GEAR 337
BACKLASH FOR SPIRAL BEVEL PINION AND 23 SPIRAL BEVEL GEAR 337
TOOTH CONTACT OF SPIRAL BEVEL GEAR 338
TOOTH CONTACT FOR UPPER BEVEL GEARS AND FINAL DRIVE BEVEL GEARS 340
EXPLODED VIEW 341
PROPELLER SHAFT 341
FRONT AXLE BRACKET 342
BEVEL PINION SHAFT 343
FRONT DIFFERENTIAL 345
BEVEL GEAR CASE 347
BEVEL GEAR SHAFT 349
FRONT AXLE CASE (LH) 351
FRONT AXLE 353
STEERING CYLINDER 355
DISASSEMBLY, SERVICE AND ASSEMBLY 356
FRONT AXLE OIL SEAL REPLACEMENT 356
BEVEL GEAR CASE OIL SEAL REPLACEMENT 360
FRONT AXLE CASE DISASSEMBLY AND ASSEMBLY 362
FRONT DIFFERENTIAL SYSTEM REMOVAL AND INSTALLATION 364
FRONT DIFFERENTIAL SYSTEM DISASSEMBLY AND ASSEMBLY COMPONENTS 369
STEERING SYSTEM 372
SPECIFICATIONS AND TIGHTENING TORQUE 373
SPECIFICATIONS FOR STEERING SYSTEM 373
TIGHTENING TORQUE FOR MAJOR COMPONENTS 373
STRUCTURE AND OPERATING PRINCIPLE 374
OPERATING DIAGRAM 374
OPERATING PRINCIPLE OF STEERING UNIT 376
OPERATING PRINCIPLE OF STEERING SYSTEM 377
STRUCTURE AND OPERATING PRINCIPLE 380
TROUBLESHOOTING 381
INSPECTION AND ADJUSTMENT 382
STEERING UNIT RELIEF VALVE PRESSURE CHECK 382
FRONT AXLE TOE-IN ADJUSTMENT 382
EXPLODED VIEW 383
STEERING CYLINDER 383
STEERING 384
POWER STEERING UNIT 386
DISASSEMBLY, SERVICE AND ASSEMBLY 387
STEERING CYLINDER REMOVAL 387
STEERING COLUMN REMOVAL 388
STEERING UNIT DISASSEMBLY AND ASSEMBLY 390
STEERING HYDRAULIC HOSE DISCONNECTION 394
HYDRAULIC SYSTEM 396
SPECIFICATIONS 398
GENERAL SPECIFICATIONS 398
TIGHTENING TORQUE 399
STRUCTURE AND OPERATING PRINCIPLE 400
COMPONENT ARRANGEMENT 400
OPERATING PRINCIPLE 402
OPERATING DIAGRAM 402
IMPLEMENT SECTION 403
MAIN SECTION 405
COMPONENTS 406
HYDRAULIC FILTER 406
GEAR PUMP 407
MODULATOR VALVE (PTO, 4WD, Q/T[JP]) 408
JOYSTICK VALVE 410
REMOTE HYDRAULIC VALVE 415
MLS (MITA LOAD SENSING) VALVE 417
LIFT CONTROL VALVE (PROPORTIONAL CONTROL VALVE) (ELECTRONIC TYPE) 421
LINK MECHANISM IN THE LIFTING CYLINDER [US, EU, AU, GE] 422
DRAFT CONTROL SYSTEM 427
LIFT CYLINDER 429
OIL COOLER 430
TROUBLESHOOTING 431
INSPECTION AND ADJUSTMENT 432
INPUT PRESSURE INSPECTION OF MODULATOR VALVE 432
STEERING UNIT RELIEF PRESSURE INSPECTION 432
INSPECTION USING EXTERNAL HYDRAULIC VALVE COUPLER 433
SETTING OF POSITION LEVER RANGE 434
ADJUSTING THE POSITION CONTROL LEVER 434
SETTING THE DRAFT 435
ADJUSTING THE SENSITIVITY OF HYDRAULIC LIFTING ARM [US, EU, AU, GE] 436
EXPLODED VIEW 437
GEAR PUMP 438
POWER STEERING UNIT 439
JOYSTICK VALVE 440
LIFT CONTROL VALVE 443
MODULATE VALVE 444
OUTSIDE DRAW VALVE 445
HYD CYLINDER 446
LIFT CYLINDER 447
HYDRAULIC SYSTEM 448
SUCTION LINE 450
COOLING SYSTEM 451
DISASSEMBLY, SERVICE AND ASSEMBLY 452
GEAR PUMP REMOVAL AND REASSEMBLY 452
DISASSEMBLY OF GEAR PUMP 453
INSPECTION 454
ASSEMBLY 455
REMOVAL 457
MODULATOR VALVE REMOVAL AND INSTALLATION 457
DISASSEMBLY AND ASSEMBLY 458
JOYSTICK VALVE REMOVAL AND INSTALLATION 460
REMOVAL 460
DISASSEMBLY 460
ASSEMBLY 462
REMOVAL 463
REMOTE HYDRAULIC (DOUBLE ACTING) VALVE REMOVAL AND INSTALLATION 463
DISASSEMBLY AND ASSEMBLY 464
REMOVAL 465
HYDRAULIC CYLINDER DISASSEMBLY AND ASSEMBLY [US, EU, AU, GE] 465
DISASSEMBLY 466
ASSEMBLY 470
MLS VALVE REMOVAL AND REASSEMBLY [US, EU, AU, GE] 474
REMOVAL 474
DISASSEMBLY AND REASSEMBLY OF MLS COMPONENTS 474
DISASSEMBLY 475
REASSEMBLY 476
LIFT CYLINDER DISASSEMBLY AND ASSEMBLY 478
HYDRAULIC / HYDROSTATIC SCHEMATICS 480
ELECTRIC SYSTEM AND CALIBRATION 482
SPECIFICATIONS 484
WIRING IDENTIFICATION 485
CROSS SECTIONAL AREA OF WIRING 486
SYMBOLS FOR ELECTRIC COMPONENTS 486
FUSE 487
INSPECTION 487
CAUSE FOR BLOWN FUSE 487
ELECTRIC DEVICE DIAGNOSIS 488
OPERATING PRINCIPLE 489
WHEN IGNITION SWITCH IS TURNED TO “ACC” POSITION 491
WHEN IGNITION SWITCH IS TURNED TO “ON” POSITION 492
OPERATING PRINCIPLE OF PREHEAT 493
WHEN IGNITION SWITCH IS TURNED TO “ST” POSITION 494
CHARGE WARNING LAMP OPERATION 495
HST CONTROL SYSTEM 496
ECU OPERATION 498
ELECTRIC COMPONENTS 499
SLOW-BLOW FUSE 500
IGNITION SWITCH 501
IGNITION SWITCH OPERATION 501
KEY SWITCH TEST 501
START MOTOR 502
ALTERNATOR 502
COMBINATION SWITCH ASSEMBLY 503
FLASHER UNIT 506
TERMINAL IDENTIFICATION AND CIRCUIT 506
FLASHER UNIT TEST 506
ENGINE STOP, ECU / START RELAY (5P) 507
GLOW / CABIN RELAY 508
RELAY (5P) 508
COOLANT TEMPERATURE SENSOR 510
ENGINE OIL PRESSURE SWITCH 510
FUEL SENDER 510
HAZARD WARNING LAMP SWITCH 511
ECU 512
SENSORS AND RELAYS 512
CRANKSHAFT WHEEL SENSOR 513
FUEL RAIL PRESSURE SENSOR 514
ACCELERATION (KNOCK) SENSORS 515
HIGH-PRESSURE FUEL PUMP TEMPERATURE SENSOR 516
WATER-IN-FUEL SENSOR 517
EXHAUST GAS TEMP SENSOR 518
CAMSHAFT WHEEL SENSOR 519
EGR VALVE SENSOR 520
MAF SENSOR 521
INTAKE AIR PRESSURE SENSOR / TEMPERATURE SENSOR 522
DPF DIFFERENTIAL PRESSURE SENSOR 524
HAND THROTTLE LEVER SENSOR 525
AIR CONTROL VALVE SENSOR 525
THROTTLE SENSOR 526
ESCORT UNIT 529
DISPLAY UNIT 530
BRAKE SWITCH 531
PARKING BRAKE MICRO SWITCH 531
SAFETY START SWITCH 532
ONE SIDE BRAKE SWITCH 532
4WD / PTO SOLENOID 533
PTO AUTO / MANUAL SWITCH 533
PTO SWITCH 534
SWITCHES 535
CRUISE PTO SWITCH 535
CRUISE CONTROL RES / SET SWITCH 536
SPEED CRUSE CONTROL SWITCH 537
HST RESPONSE CONTROL 537
LINKED PEDAL SWITCH 537
NO STALL SWITCH / SPEED LIMIT SWITCH 537
CALIBRATION SWITCH 538
DPF REGENERATION SWITCH 538
MODE / ECO SWITCH 539
HITCH CONTROL SWITCH BOX 540
SAFETY CONTROLLER 541
ONE-TOUCH LIFTING / LOWERING
SWITCH 541
HST CONTROLLER 546
POSITION SENSOR 550
INSTRUMENT PANEL 551
COMPONENTS AND LOCATIONS 551
CONNECTOR 552
CIRCUIT DIAGRAM 553
GAUGES AND INDICATORS 554
TROUBLESHOOTING 560
WHEN THE ENGINE CANNOT BE STARTED 560
WHEN THE SYSTEM IS NOT CHARGED 562
PreHeat 564
WHEN THE PTO DOES NOT OPERATE 568
WHEN THE 4WD CONTROL SYSTEM DOES NOT OPERATE 571
WHEN HIGH AND LOW BEAMS CANNOT BE OPERATED 573
FUEL GAUGE OPERATION 575
TEMPERATURE GAUGE OPERATION 576
TACHOMETER OPERATION WITH THE ENGINE RUNNING 577
HOURMETER OPERATION 578
WHEN THE MANUAL HORIZONTAL SYSTEM DOES NOT OPERATE [JP] 579
WHEN THE HORIZONTAL AUTO SYSTEM DOES NOT OPERATE [JP] 581
WHEN THE QT CONTROL SYSTEM DOES NOT OPERATE [JP] 583
WHEN THE LIFT ARM DOES NOT OPERATE [JP] 584
WHEN THE HORIZONTAL CYLINDER DOES NOT OPERATE [JP] 585
EXPLODED VIEW 587
LIGHT 588
FRAME ELECTRICAL SYSTEM 1 589
CABIN ELECTRICAL SYSTEM 1 590
CALIBRATION, DIAGNOSIS AND UPGRADE 594
CALIBRATION 594
HST FORWARD / REVERSE PEDAL 594
DIAGNOSIS 596
HST CONTROLLER 596
UPGRADE 601
DIAGNOSTIC PROGRAM 605
COMPOSITION 631
DTC (DIAGNOSTIC TROUBLE CODE) 631
ERORR CODE & ACTION 632
FAULT DIAGNOSIS CODE DESCRIPTION 647
ELECTRICAL SCHEMATICS 690
CABIN 696
COMPONENTS 698
INTERIOR DEVICES 698
A/C CONTROLLER 700
INTERIOR LAMP 700
AIR INTAKE GRILLE 700
SUN VISOR 701
SWITCH PANEL 701
CD PLAYER / BT PLAYER 701
CABIN FUSE BOX 702
INTERIOR REAR VIEW MIRROR 702
WIPER MOTOR (FRONT) 702
WIPER MOTOR (REAR) 703
DOOR LATCH ASSEMBLY 703
SIDE WINDOW HANDLE 703
REAR DOOR HANDLE 703
POWER SOCKET 704
AIR CYLINDER 704
SPEAKER 704
EXTERNAL DEVICES 705
EXTERIOR FILTER ASSEMBLY 706
FRONT / REAR WORK LAMP 706
TAIL LAMP 706
FRONT / REAR WIPERS 706
WASHER FLUID TANK 707
7-PIN SOCKET 707
REAR VIEW MIRROR 707
ANTENNA 707
FRONT COMBINATION LAMP 708
FRAME 709
EXPLODED VIEW 709
COVER 711
ROOF 712
GLASS 714
DOOR 715
GLASS 717
GLASS 718
SEAL 719
CABIN DISASSEMBLY AND ASSEMBLY 720
CABIN REMOVAL 720
COMPONENT REMOVAL 724
SEAT REMOVAL 724
INTERIOR FENDER (RH) REMOVAL 725
RIGHT PILLAR COVER REMOVAL 726
LEFT INTERIOR FENDER REMOVAL 726
LEFT PILLAR COVER REMOVAL 727
DOOR REMOVAL 728
DOOR GLASS REMOVAL 728
SIDE DOOR HANDLE REMOVAL 729
REAR GLASS HANDLE REMOVAL 729
CABIN CEILING PLATE REMOVAL 730
OPENING CABIN ROOF 731
ELECTRIC COMPONENT REMOVAL
AND INSTALLATION 732
WASHER FLUID TANK REMOVAL 732
FRONT UPPER WORK LAMP 732
INTERIOR LAMP 734
FRONT TURN SIGNAL LAMP, TAIL LAMP AND BACK-UP LAMP 734
SWITCH PANEL (WORK LAMP & WIPER SWITCH) 735
FRONT WIPER / MOTOR 736
REAR WIPER / MOTOR 737
ANTENNA 738
CABIN PANEL WIRING 738
CONTROL WIRING 740
A/C AND HEATER 742
SPECIFICATION 743
AIR-CON / HEATER MAIN SPEC 743
PRINCIPLE OF COOLING SYSTEM 744
SYSTEM FLOW 744
COOLING CYCLE 745
REFRIGERANT AND COMPRESSOR OIL 746
COMPRESSOR 747
RECEIVER-DRIER 748
INSPECTION 748
INSPECTION 749
CONDENSER 749
EXPANSION VALVE 750
EVAPORATOR 750
INSPECTION 750
INSPECTION 750
INSPECTION 751
HEATER CORE 751
AIR CONDITIONER/HEATER SYSTEM 752
AIR INLET AND VENT 752
AIR FLOW 753
ACTUATOR 754
COOLING SYSTEM 756
A/C ASSEMBLY 756
A/C ELECTRICAL CONNECTOR 757
A/C CONTROLLER 758
RESISTOR 761
THERMOCON 762
CHECK AND ADJUSTMENT 763
TROUBLESHOOTING BY GAUGE 763
NORMAL CONDITION 763
INSUFFICIENT REFRIGERANT 764
EXCESSIVE REFRIGERANT, POOR
CONDENSER COOLING 764
AIR INTRUSION INTO CYCLE 765
DEFECTIVE EXPANSION VALVE 765
POOR COMPRESSION 766
MOISTURE INTRUSION INTO COOLING CYCLE 766
POOR RECIRCULATION OF REFRIGERANT 767
INSPECTION AND ADJUSTMENT FOR CABIN SYSTEM 767
TROUBLESHOOTING 771
VISUAL INSPECTION 771
DIAGNOSIS BY SYMPTOM 772
TROUBLESHOOTING FOR POOR COOLING / HEATING PERFORMANCE 773
POOR COOLING 773
POOR HEATING 775
EXPLODED VIEW 776
AIRCON, HEATER 776
HEATER 778
A/C RELATED COMPONENT DISASSEMBLY AND ASSEMBLY 780
A/C FILTER REMOVAL 780
A/C ASSEMBLY REMOVAL 780
A/C ASSEMBLY DISASSEMBLY 780
A/C ASSEMBLY COMPONENTS DISASSEMBLY 782
A/C CONTROLLER REMOVAL 784
COMPRESSOR REMOVAL 785
COMPRESSOR INSTALLATION 786
CONDERSER REMOVAL 787
INDEX 788
4WD / PTO SOLENOID 533
A/C ASSEMBLY REMOVAL 780
ACCELERATION SYSTEM 84
A/C CONTROLLER REMOVAL 784
A/C FILTER REMOVAL 780
A/C RELATED COMPONENT DISASSEMBLY AND ASSEMBLY 780
ADJUSTING THE SENSITIVITY OF HYDRAULIC LIFTING ARM 436
AFTER TREATMENT 128
AIR CONDITIONER / HEATER SYSTEM 752
AIRCON, HEATER 776
AIR-CON / HEATER MAIN SPEC 743
AIR INTRUSION INTO CYCLE 765
ALERT SYMBOLS 8
ALTERNATOR 502
AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS 34
AVOID FIRES 10
BACKLASH FOR DIFFERENTIAL PINION AND DIFFERENTIAL SIDE GEAR 337
BACKLASH FOR DIFFERENTIAL PINION AND SIDE GEAR 294
BACKLASH FOR SPIRAL BEVEL PINION AND 23 SPIRAL BEVEL GEAR 337
BACKLASH FOR SPIRAL BEVEL PINION AND RING GEAR 295
BASIC PRINCIPLE 260
BEVEL GEAR CASE 347
BEVEL GEAR CASE OIL SEAL REPLACEMENT 360
BEVEL GEAR SHAFT 349
BEVEL PINION SHAFT 343
BODY AND POWER TRAIN SYSTEM 64
BRAKE CASE 319
BRAKE PEDAL 321
BRAKE PEDAL FREEPLAY 317
BRAKE SWITCH 531
BRAKE UNIT 318
BUBBLE TEST FOR RADIATOR 105
CABIN DISASSEMBLY AND ASSEMBLY 720
CABIN ELECTRICAL SYSTEM 1 590
CABIN REMOVAL 720
CALCULATION FOR REAR PTO AND MID PTO 203
CALIBRATION 594
CALIBRATION, DIAGNOSIS AND UPGRADE 594
CAM LEVER FREEPLAY 318
CAM SHAFT 115
CAUTIONS FOR HIGH PRESSURE HOSES 11
CAUTIONS WHEN HANDLING THE BATTERY 11
CAUTIONS WHEN HANDLING TIRES 14
CHARGE PUMP LOCATION 262
CHARGE RELIEF VALVE 263
CHARGE WARNING LAMP OPERATION 495
CHECK AND ADJUSTMENT 763
CLEARANCE OF BRAKE LAMP SWITCH 317
COMBINATION SWITCH ASSEMBLY 503
COMPONENT ARRANGEMENT 400
COMPONENT REMOVAL 724
COMPONENTS 698
COMPONENTS 42
COMPONENTS 406
COMPRESSOR 747
COMPRESSOR INSTALLATION 786
COMPRESSOR REMOVAL 785
CONDENSER 749
CONDERSER REMOVAL 787
COOLANT TEMPERATURE SENSOR 510
COOLING FAN 125
COOLING SYSTEM 72
COOLING SYSTEM 451
COOLING SYSTEM 756
COUNTER SHAFT 209
COVER 711
CRANK SHAFT 113
CRDI (COMMON RAIL DIRECT INJECTION) SYSTEM 47
CREEP FORK 229
CREEP SHAFT 213
CREEP SHIFT SPEED SECTION 198
CROSS SECTIONAL AREA OF WIRING 486
CYLINDER BLOCK 107
CYLINDER HEAD 110
CYLINDER HEAD COVER 121
DEFECTIVE EXPANSION VALVE 765
DESCRIPTION FOR SYMBOLS AND ABBREVIATIONS 18
DIAGNOSIS 596
DIAGNOSIS BY SYMPTOM 772
DIAGNOSTIC PROGRAM 605
DIFFERENTIAL LOCK SYSTEM 292
DIFFERENTIAL SYSTEM 331
DIFF LOCK FORK 301
DIMENSIONS 21
DISASSEMBLY, SERVICE AND ASSEMBLY 129
DISASSEMBLY, SERVICE AND ASSEMBLY 234
DISASSEMBLY, SERVICE AND ASSEMBLY 356
DISASSEMBLY, SERVICE AND ASSEMBLY 387
DISASSEMBLY, SERVICE AND ASSEMBLY 452
DISASSEMBLY, SERVICING AND ASSEMBLY 304
DISASSEMBLY, SERVICING AND ASSEMBLY 323
DISPLAY UNIT 530
DISPOSAL OF ENVIRONMENTAL WASTE 14
DOOR 715
DRIVING SPEED 27
DTC (DIAGNOSTIC TROUBLE CODE) 631
ECU 512
ECU OPERATION 498
EGR 124
ELECTRIC COMPONENT REMOVAL
AND INSTALLATION 732
ELECTRIC COMPONENTS 499
ELECTRIC DEVICE DIAGNOSIS 488
ELECTRIC SYSTEM 1 587
ENGINE COMPONENT REMOVAL 142
ENGINE DIMENSION 41
ENGINE DISASSEMBLY 148
ENGINE EPA DECAL (A) 39
ENGINE IDENTIFICATION 39
ENGINE NUMBER (B) 39
ENGINE OIL PRESSURE SWITCH 510
ENGINE REMOVAL 129
ENGINE SERIAL NUMBER 20
ENGINE STOP, ECU / START RELAY (5P) 507
ESCORT UNIT 529
EVAPORATOR 750
EXCESSIVE REFRIGERANT, POOR
CONDENSER COOLING 764
EXPANSION VALVE 750
EXPLODED VIEW 107
EXPLODED VIEW 207
EXPLODED VIEW 276
EXPLODED VIEW 298
EXPLODED VIEW 319
EXPLODED VIEW 341
EXPLODED VIEW 383
EXPLODED VIEW 437
EXPLODED VIEW 587
EXPLODED VIEW 709
EXPLODED VIEW 776
EXTERNAL DEVICES 705
FAN BELT 102
FLASHER UNIT 506
FLOATING SEAL 333
FOR SAFETY 8
FRAME 709
FRAME ELECTRICAL SYSTEM 1 589
FRONT AXLE 353
FRONT AXLE BRACKET 342
FRONT AXLE CASE DISASSEMBLY AND ASSEMBLY 362
FRONT AXLE CASE (LH) 351
FRONT AXLE OIL SEAL REPLACEMENT 356
FRONT AXLE TOE-IN ADJUSTMENT 382
FRONT DIFFERENTIAL 345
FRONT DIFFERENTIAL SYSTEM DISASSEMBLY AND ASSEMBLY COMPONENTS 369
FRONT DIFFERENTIAL SYSTEM REMOVAL AND INSTALLATION 364
FRONT DRIVE SYSTEM 217
FRONT WHEEL DRIVE 204
FUEL EQUIPMENT 118
FUEL FILTER & PIPE 122
FUEL GAUGE OPERATION 575
FUEL SENDER 510
FUEL SYSTEM 75
FUNCTION HST CHARGE PUMP 261
FUSE 487
FUSE 499
GEAR ARRANGEMENT 27
GEAR CASE 111
GEAR PUMP 438
GEAR PUMP REMOVAL AND REASSEMBLY 452
GENERAL SPECIFICATION 311
GENERAL SPECIFICATIONS 40
GENERAL SPECIFICATIONS 192
GENERAL SPECIFICATIONS 327
GENERAL SPECIFICATIONS 398
GENERAL USE SCREWS, BOLTS AND NUTS 33
GERNERAL INFORMATION 255
GLASS 714
GLASS 717
GLASS 718
GLOW / CABIN RELAY 508
HANDLING OF HAZARDOUS MATERIALS 12
HANDLING OF ROTATING BLADE, SHAFT AND DRIVING BELT 13
HAND THROTTLE LEVER SENSOR 525
HAZARD WARNING LAMP SWITCH 511
HEATER 778
HEATER CORE 751
HIGH PRESSURE RELIEF VALVE 266
HITCH CONTROL SWITCH BOX 540
HOURMETER OPERATION 578
HST 437
HST COMPONENTS & CIRCUIT DIAGRAM 256
HST CONTROLLER 546
HST CONTROL SYSTEM 496
HYD CYLINDER 446
HYDRAULIC CYLINDER DISASSEMBLY AND ASSEMBLY 465
HYDRAULIC SYSTEM 448
IDENTIFICATION NUMBER 19
IDLE GEAR 116
IGNITION SWITCH 501
INLET CHECK VALVE 268
INLET MANIFOLD (TIER4) 123
INPUT PRESSURE INSPECTION OF MODULATOR VALVE 432
INSPECTION AND ADJUSTMENT 294
INSPECTION AND ADJUSTMENT 317
INSPECTION AND ADJUSTMENT 205
INSPECTION AND ADJUSTMENT 335
INSPECTION AND ADJUSTMENT 382
INSPECTION AND ADJUSTMENT 432
INSPECTION AND ADJUSTMENT FOR CABIN SYSTEM 767
INSPECTION USING EXTERNAL HYDRAULIC VALVE COUPLER 433
INSTALLATION OF PARTS IN BRAKE CASE 323
INSTRUMENT PANEL 551
INSUFFICIENT REFRIGERANT 764
INTAKE & EXHAUST SYSTEM 86
INTERIOR DEVICES 698
JOYSTICK VALVE 440
JOYSTICK VALVE REMOVAL AND INSTALLATION 460
LIFT CONTROL VALVE 443
LIFT CYLINDER 447
LIFT CYLINDER DISASSEMBLY AND ASSEMBLY 478
LIGHT 588
LOAD TRANSFER 332
LUBRICATING SYSTEM 68
LUBRICATION LIST 31
MAIN GEAR SHIFT & SHUTTLE SYSTEM 195
MAIN SHAFT 207
MAIN SHIFT LEVER 231
MAIN SHIFT SECTION DISASSEMBLY 234
MAIN SPEED FORK 225
MAINTENANCE 29
MAINTENANCE SCHEDULE 29
MEASUREMENT AND ADJUSTMENT 102
MID PTO 202
MLS VALVE REMOVAL AND REASSEMBLY 474
MODULATE VALVE 444
MODULATOR VALVE REMOVAL AND INSTALLATION 457
MOISTURE INTRUSION INTO COOLING CYCLE 766
NEUTRAL VALVE 264
NORMAL CONDITION 763
OIL FILTER 112
OILPAN 109
OIL PRESSURE MEASUREMENT 104
ONE SIDE BRAKE SWITCH 532
OPERATING DIAGRAM 374
OPERATING PRINCIPLE 47
OPERATING PRINCIPLE 258
OPERATING PRINCIPLE 290
OPERATING PRINCIPLE 489
OPERATING PRINCIPLE 402
OPERATING PRINCIPLE OF PREHEAT 493
OPERATING PRINCIPLE OF STEERING SYSTEM 377
OPERATING PRINCIPLE OF STEERING UNIT 376
OPERATING PRINCIPLE OF SYNCHRONIZER 196
OPERATION OF HST 270
OUTSIDE DRAW VALVE 445
PARKING BRAKE MICRO SWITCH 531
PEDAL 276
PISTON COMPRESSION PRESSURE MEASUREMENT 102
PISTON & CONNECTING ROD 114
POOR COMPRESSION 766
POOR RECIRCULATION OF REFRIGERANT 767
POSITION SENSOR 550
POWER STEERING UNIT 386
POWER STEERING UNIT 439
POWER TRAIN OF REAR AXLE 290
POWER TRANSFER SYSTEM FOR FRONT AXLE 329
PREHEAT 564
PRELOAD OF TAPER ROLLER
BEARING IN DIFF 294
PRELOAD OF TAPER ROLLER BEARING ON SPIRAL BEVEL PINION SHAFT 336
PREVENTION OF SCALD 13
PRINCIPLE OF COOLING SYSTEM 744
PRINCIPLE OF DIFFERENTIAL SYSTEM 291
PROPELLER SHAFT 341
PROPER INFLATION PRESSURE 32
PTO 201
PTO AUTO / MANUAL SWITCH 533
PTO CLUTCH 221
PTO CLUTCH PACK 202
PTO COUNTER SHAFT 219
PTO LEVER 230
PTO SHAFT 223
PTO SHIFT FORK 226
PTO SWITCH 534
RANGE FORK 228
RANGE SHAFT 212
RANGE SHIFT LEVER 232
RANGE SHIFT SECTION 197
RANGE SHIFT SECTION, 4WD SECTION AND PTO DRIVE SECTION DISASSEMBLY 244
REAR AXLE 302
REAR AXLE COMPONENTS 304
REAR DIFFERENTIAL SYSTEM 300
REAR DIFFERENTIAL SYSTEM 306
REAR WHEEL 303
REAR WHEEL NUT 306
RECEIVER-DRIER 748
RELAY (5P) 508
REMOTE HYDRAULIC (DOUBLE ACTING) VALVE REMOVAL AND INSTALLATION 463
REMOVAL AND INSTALLATION OF HST 278
REMOVAL AND INSTALLATION OF HST COMPONENTS 281
REMOVAL OF BRAKE CASE 323
ROCKER ARM & VALVE 117
ROOF 712
SAFETY CONTROLLER 541
SAFETY DECALS 15
SAFETY GEAR 9
SAFETY INSTRUCTIONS WHEN PREPARING TRACTOR 10
SAFETY START SWITCH 532
SAFETY TIPS 9
SEAL 719
SEALANT AND ADHESIVE 327
SEALANT AND ADHESIVE SPECIFICATIONS 194
SENSOR 95
SENSORS AND RELAYS 512
SERVICING 278
SERVICING SPECIFICATIONS 43
SERVO CONTROL 267
SETTING OF POSITION LEVER RANGE 434
SHAFT, SPIRAL BEVEL 215
SHIFT LINK SYSTEM 199
SHUTTLE 233
SHUTTLE FORK 227
SHUTTLE SHAFT 210
SHUTTLE SHIFT SECTION, CREEP SPEED SECTION AND PTO CLUTCH DISASSEMBLY 236
SNAP RING INSTALLATION 35
SPECIFICATION 743
SPECIFICATION 23
SPECIFICATION 40
SPECIFICATION 192
SPECIFICATION 289
SPECIFICATION 311
SPECIFICATION 327
SPECIFICATION 398
SPECIFICATION 484
SPECIFICATIONS 255
SPECIFICATIONS AND TIGHTENING TORQUE 373
SPECIFICATIONS FOR STEERING SYSTEM 373
SPIRAL BEVEL PINION SHAFT 298
SPRING PIN AND SNAP RING INSTALLATION 35
SPRING PIN TYPE 35
START MOTOR 502
STEERING 384
STEERING ANGLE 335
STEERING COLUMN REMOVAL 388
STEERING CYLINDER 355
STEERING CYLINDER 383
STEERING CYLINDER REMOVAL 387
STEERING HYDRAULIC HOSE DISCONNECTION 394
STEERING UNIT DISASSEMBLY AND ASSEMBLY 390
STEERING UNIT RELIEF PRESSURE INSPECTION 432
STEERING UNIT RELIEF VALVE PRESSURE CHECK 382
STRUCTURE AND FUNCTION 258
STRUCTURE AND OPERATING PRINCIPLE 329
STRUCTURE AND OPERATING PRINCIPLE 195
STRUCTURE AND OPERATING PRINCIPLE 374
STRUCTURE AND OPERATING PRINCIPLE 400
STRUCTURE AND OPERATING PRINCIPLE 380
STRUCTURE AND OPERATION PRINCIPLE 312
STUD BOLTS 33
SUCTION LINE 450
SWAY RESISTANCE 336
SWITCHES 535
SYMBOLS FOR ELECTRIC COMPONENTS 486
SYNCHRONIZER GEAR INSPECTION 205
SYSTEM FLOW 744
TACHOMETER OPERATION WITH THE ENGINE RUNNING 577
TEMPERATURE GAUGE OPERATION 576
THROTTLE SENSOR 526
TIGHTENING TORQUE 33
TIGHTENING TORQUE 311
TIGHTENING TORQUE 399
TIGHTENING TORQUE FOR MAJOR COMPONENTS 193
TIGHTENING TORQUE FOR MAJOR COMPONENTS 328
TIGHTENING TORQUE FOR MAJOR COMPONENTS 373
TIGHTENING TORQUES 289
TIRE MAINTENANCE 32
TOE-IN 335
TOOTH CONTACT FOR UPPER BEVEL GEARS AND FINAL DRIVE BEVEL GEARS 340
TOOTH CONTACT OF SPIRAL BEVEL 296
TOOTH CONTACT OF SPIRAL BEVEL GEAR 338
TRACTOR EXTERIOR VIEW 19
TRACTOR SERIAL NUMBER 19
TRANSMISSION FLUID 289
TRANSMISSION SERIAL NUMBER 20
TROUBLESHOOTING 206
TROUBLESHOOTING 293
TROUBLESHOOTING 381
TROUBLESHOOTING 431
TROUBLESHOOTING 560
TROUBLESHOOTING 771
TROUBLESHOOTING 99
TROUBLESHOOTING 316
TROUBLESHOOTING 334
TROUBLESHOOTING BY GAUGE 763
TROUBLESHOOTING FOR POOR COOLING / HEATING PERFORMANCE 773
TURBO CHARGER 126
TURBO CHARGER WASTEGATE PRESSURE CHECK 105
TURBO PIPE 127
UNIT CONVERSION TABLE 36
UPGRADE 601
USE OF APPROPRIATE TOOLS AND EQUIPMENT 12
VALVE CLEARANCE 103
VALVE LIFT (DEFLECTION AND WORN CONDITION OF VALVE CAM, TAPPET, PUSH ROD, ROCKER ARM, ETC ) 104
VISUAL INSPECTION 771
WATER FLANGE 119
WATER PUMP 120
WHEEL BOLT TORQUE 32
WHEN HIGH AND LOW BEAMS CANNOT BE OPERATED 573
WHEN IGNITION SWITCH IS IN “OFF” POSITION 489
WHEN IGNITION SWITCH IS TURNED TO “ACC” POSITION 491
WHEN IGNITION SWITCH IS TURNED TO “ON” POSITION 492
WHEN IGNITION SWITCH IS TURNED TO “ST” POSITION 494
WHEN THE 4WD CONTROL SYSTEM DOES NOT OPERATE 571
WHEN THE ENGINE CANNOT BE STARTED 560
WHEN THE HORIZONTAL AUTO SYSTEM DOES NOT OPERATE [JP] 581
WHEN THE HORIZONTAL CYLINDER DOES NOT OPERATE [JP] 585
WHEN THE LIFT ARM DOES NOT OPERATE [JP] 584
WHEN THE MANUAL HORIZONTAL SYSTEM DOES NOT OPERATE [JP] 579
WHEN THE PTO DOES NOT OPERATE 568
WHEN THE QT CONTROL SYSTEM DOES NOT OPERATE [JP] 583
WHEN THE SYSTEM IS NOT CHARGED 562
WIRING COLOR IDENTIFICATION 485
WIRING IDENTIFICATION 485
WORK PLACE 9

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