Bobcat CT1025 HST B4Z911001 & Up 7398893 (12-19) (Preview)
TABLE OF CONTENTS
SAFETY FIRST
FOR SAFTETY
Alert Symbols
SAFETY TIPS
SAFETY GEAR
WORK PLACE
SAFETY INSTRUCTIONS WHEN PREPARING TRACTOR
AVOID FIRES
CAUTIONS WHEN HANDLING THE BATTERY
CAUTIONS FOR HIGH PRESSURE HOSES
USE OF APPROPRIATE TOOLS AND EQUIPMENT
HANDLING OF HAZARDOUS MATERIAL
HANDLING OF ROTATING BLADE, SHAFT AND DRIVING BELT
PREVENTION OF SCALD
DISPOSAL OF ENVIRONMENTAL WASTE
CAUTIONS WHEN HANDLING TIRES
SAFETY DECALS
GENERAL
IDENTIFICATION NUMBER
TRACTOR SERIAL NUMBER LOCATION
ENGINE SERIAL NUMBER LOCATION
TRANSMISSION NUMBER
DIMENSIONS
SPECIFICATIONS
POWER FLOW
DRIVING SPEED
GEAR ARRANGEMENT
SPEED RATIO (ENGINE VS. REAR AXLE)
REAR TIRE ROLLING CIRCUMFERENCE
RELATIVE SPEED RATIO OF FRONT WHEELS
CALCULATION FOR RELATIVE SPEED RATIO OF FRONT WHEELS
HOW TO MEASURE THE ACTUAL ROLLING CIRCUMFERENCE
MAINTENANCE SCHEDULE CHART
MAINTENANCE INTERVALS
TIRES
SPECIFIED INFLATION PRESSURE
TIGHTENING TORQUE FOR TIRE BOLTS
TIGHTENING TORQUE
GENERAL USE SCREWS, BOLTS AND NUTS
STUD BOLTS
AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS
UNIT CONVERSION TABLE
ENGINE
ENGINE IDENTIFICATION
ENGINE DECAL (A)
ENGINE NUMBER (B)
SPECIFICATIONS
GENERAL SPECIFICATIONS
SERVICING SPECIFICATIONS
TROUBLESHOOTING
EXPLODED VIEW OF ENGINE
CYLINDER BLOCK
CRANKSHAFT, PISTON
OIL PUMP & CAMSHAFT
TIMING GEAR CASE, GOVERNOR
CYLINDER HEAD, EXHAUST MANIFOLD
OIL PAN, REAR PLATE, STARTING MOTOR
INJECTION PUMP, INJECTOR
ROCKER ARM ASSY
HEAD COVER
WATER PUMP
NTE COMPONENTS
SERVICING AND OPERATING
ENGINE DISASSEMBLY ORDER
DISASEMBLY AND INSPECTION OF MAIN ENGINE PARTS
ROCKER ARM ASSY
CYLINDER HEAD ASSY
CYLINDER BLOCK
PISTON AND PISTON RING
CONNECTING ROD
CONNECTING ROD METAL
BEARING HOLDER
CRANKSHAFT BEARING
CRANKSHAFT
FLYWHEEL AND RING GEAR
CAMSHAFT ASSY
TIMING GEAR
OIL FLOW
OIL PUMP
OIL FILTER
WATER PUMP ASSEMBLY
THERMOSTAT
RADIATOR
FUEL FILTER
GOVERNOR
INJECTION PUMP
NOZZLE AND HOLDER
AIR CLEANER
REASSEMBLY
RELIEF VALVE ASSEMBLY WITH O-RING
CRANKSHAFT AND BEARING HOLDER ASSEMBLY
REAR PLATE
FLYWHEEL
PISTON AND CONNECTING ROD ASSEMBLY
SUCTION PIPE AND SUCTION FILTER
OIL PAN
OIL LEVEL GAUGE AND GAUGE GUIDE
FRONT PLATE
CAMSHAFT ASSY · TACHOMETER SHAFT · PLATE
IDLE GEAR · OIL PUMP ASSY
TIMING GEAR CASE
CRANKSHAFT PULLEY
INJECTION PUMP ASSEMBLY
INJECTION TIMING ADJUSTMENT
OIL FILTER
ENGINE STOP SOLENOID
TAPPET
CYLINDER HEAD
OIL PIPE
PUSH ROD AND ROCKER ARM ASSY
VALVE CLEARANCE ADJUSTMENT
HEAD COVER
WATER PUMP ASSY, RADIATOR HOSE
GLOW PLUG · CONNECTOR
OIL PRESSURE SWITCH
NOZZLE AND HOLDER ASSY
RETURN PIPE COMPL · INJECTION PIPE
ALTERNATOR ASSY
DRIVE GEAR ASSEMBLY AND HYDRAULIC OIL
V BELT · FAN PULLEY · COOLING FAN
EXHAUST MANIFOLD AND MUFFLER ASSEMBLY
ECU (ENGINE CONTROL UNIT) & SENSORS
TRANSMISSION
SPECIFICATIONS
GENERAL SPECIFICATIONS
TIGHTENING TORQUE FOR MAJOR COMPONENTS
Sealant and Adhesive Specifications
STRUCTURE AND OPERATING PRINCIPLE
Structure
Main Gear Shift & Shuttle System
Range Shift Section
PTO
PTO Clutch Pack
Calculation for Rear PTO and Mid PTO
Front Wheel Drive
TROUBLESHOOTING
EXPLODED VIEW OF TRANSMISSION
HI-LOW Gear
Bevel Pinoin Gear
PTO Gear
4WD Drive
4WD Joint
Auto 4WD (Optional)
SERVICING
Transmission Removal
FWD Case Removal
Transmission Case Disassembly
PTO Drive Section Disassembly
PTO Clutch Assembly – Disassembly
HST
SPECIFICATIONS
General
HST
Major Tightening Torque
OPERATING PRINCIPLE
STRUCTURE AND FUNCTION
Power Train
HST Components
Major HST Component Structure and Function
Circuit Diagram
Pump, Motor and Swash Plate
Charge Relief Valve
High Pressure Relief Valve
Inlet Check Valve (Anti-Cavitation Valve)
Operation of HST
Neutral Status
Forward Driving
Reverse Driving
INSPECTION AND ADJUSTMENT
HST Neural Position Setting
HST Forward Pedal Travel Adjustment
Pressure Testing
High Pressure Relief Valves
TROUBLESHOOTING
EXPLODED VIEW OF HST
Main Shaft Joint
HST Pedal
ASSY, HST
SERVICING
HST Removal
HST Components Disassembly
REAR AXLE
SPECIFICATIONS
Transmission Fluid
Tightening Torques
OPERATING PRINCIPLE
Power Train of Rear Axle
Principle of Differential System
Differential Lock System
TROUBLESHOOTING
MEASUREMENT AND ADJUSTMENT
Backlash for Differential Pinion and Side Gear
Pre-load Of Taper Roller Bearing in Diff
Backlash for Spiral Bevel Pinion and Ring Gear
Tooth Contact of Spiral Bevel
EXPLODED VIEW OF REAR AXLE
G260 Rear Differential System
G265 Rear Axle
SERVICING
Rear Axle Removal
Rear Differential System Removal
Rear Differential System Assembly Disassembly
BRAKE
SPECIFICATIONS
BASIC OPERATING PRINCIPLE
Basic Principle
Braking Force Forward/Reverse Driving
TROUBLESHOOTING
INSPECTION AND ADJUSTMENT
Brake Pedal Free Play
Brake Switch Setting (Optional)
Parking Brake Switch Adjustment (CT1025)
Brake Cam Lever Free Play
Brake Components Inspection
EXPLODED VIEW OF BRAKE
G250 Brake
G418 Brake Pedal
SERVICING
Brake Parts Removal
FRONT AXLE
SPECIFICATIONS
General Specifications
Sealant and Adhesive
Tightening Torque for Major Components
OPERATING PRINCIPLE
Power Transfer System for Front Axle
Differential System
Load Transfer
TROUBLESHOOTING
MEASUREMENT AND ADJUSTMENT
Toe In
Backlash for Spiral Bevel Pinion and Spiral Bevel Gear
Tooth Contact of Spiral Bevel Gear
EXPLODED VIEW OF FRONT AXLE
Front Axle Support
Bevel Gear Case
Front Axle Case
Front Axle
SERVICING
Front Axle Removal
Front Axle Disassembly and Assembly
Steering Cylinder Removal
Front Axle Cover Disassembly
Bevel Gear Case Disassembly
Front Differential System Disassembly
Bevel Pinion Shaft Removal
STEERING SYSTEM
SPECIFICATIONS
Steering Cylinder
Steering Unit
Tightening Torque for Main Components
OPERATING PRINCIPLE
Hydraulic Circuit for Steering Operation
Operating Principle
Operation
Structure
TROUBLESHOOTING
INSPECTION AND ADJUSTMENT
Steering Relief Opening Pressure
Relief Valve Pressure Adjustment
EXPLODED VIEW OF STEERING SYSTEM
G335 Steering Cylinder
G422 Steering & Hand Accel
G615 Power Steering Unit
SERVICING
Steering Cylinder
Steering Unit Removal
Disassembly of Power Steering Unit Components
Inspection
Installation
Steering Hydraulic Tube Location
HYDRAULIC SYSTEM
HYDRAULIC SCHEMATIC
SPECIFICATIONS
OPERATING PRINCIPLE
SCHEMATIC AND CIRCUIT DIAGRAM
HYDRAULIC SCHEMATIC AND BASIC OPERATION
CIRCUIT DIAGRAM
HYDRAULIC PUMP
COMPONENTS
OIL FILTER
AUXILIARY DOUBLE ACTING VALVE (OPTIONAL)
HPL VALVE (HYD. POWER LIFT)
MOWER LIFT LINKAGE
TROUBLESHOOTING
INSPECTION AND ADJUSTMENT
AUX. DOUBLE ACTING VALVE PRESSURE (OPTIONAL)
FEEDBACK PLATE ADJUSTMENT
HYD.CYLINDER
EXPLODED VIEW OF HYDRAULIC SYSTEM
FILTER AND PIPE
GEAR PUMP
CONTROL (HPL) VALVE
DOUBLE ACTING VALVE
REAR HYDRAULIC PIPE (Option)
FRONT HYDRAULIC PIPE (Option)
SHUT-OFF VALVE (Option)
SERVICING
DOUBLE ACTING VALVE (OPTIONAL) DISASSEMBLY AND ASSEMBLY
Double Acting Valve Components Removal and Installation
GEAR PUMP DISASSEMBLY
CONTROL VALVE DISASSEMBLY AND ASSEMBLY
Control Valve Components Disassembly
Assembly
ELECTRIC SYSTEM
ELECTRICAL SCHEMATICS
SPECIFICATIONS
GENERAL INFORMATION
SYMBOLS FOR ELECTRIC COMPONENTS
WIRING COLOR IDENTIFICATION
FUSE
INSPECTION
CAUSE FOR BLOWN FUSE
ELECTRIC DEVICE DIAGNOSIS
OPERATING PRINCIPLE
WHEN IGNITION SWITCH IS IN “OFF” POSITION
WHEN IGNITION SWITCH IS IN “ACC” POSITION
WHEN IGNITION SWITCH IS IN TURNED TO “ON” POSITION
WHEN IGNITION SWITCH IS IN TURNED TO “ST” POSITION
OPERATING PRINCIPLE OF PREHEAT CONTROLLER
ECU
CHECKING ELECTRICAL PARTS
KEY SWITCH
COMBINATION SWITCH
FLASHER UNIT
30/20A 5P RELAY
HAZARD WARNING FLASHER SWITCH
GLOW PLUG
ECU
ACTUATOR
PRESSURE SENSOR
SPEED SENSOR (MPU: MAGNET PICK UP)
PARKING BRAKE MICRO SWITCH
BRAKE SWITCH (OPTIONAL)
INSTRUMENT PANEL
COMPONENTS AND LOCATIONS
CIRCUIT DIAGRAM FOR INSTRUMENT PANEL
GAUGES AND INDICATORS
CLUSTER LAMP TEST
OIL PRESSURE SWITCH
DUAL TEMPERATURE SWITCH
FUEL SENSOR
ALTERNATOR
PREHEAT CONTROLLER
NEUTRAL SAFETY SWITCH
PTO CLUTCH SAFETY SWITCH
HEAD LAMP
TURN SIGNAL LAMP
TAIL LAMP
TROUBLESHOOTING
Exploded view OF ELECTRIC SYSTEm
TRANSMISSION ELECTRICAL SYSTEM
CHASSIS ELECTRICAL SYSTEM
CRUISE (OPTIONAL)
WIRE HARNESS
LIGHT
WORKING LAMP
WHEN THE ENGINE CANNOT BE STARTED
WHEN THE SYSTEM IS NOT CHARGED
WHEN THE SYSTEM IS NOT PREHEATED AUTOMATICALLY
WHEN THE CRUISE SYSTEM CANNOT BE OPERATED (OPTIONAL)
WHEN THE HEAD LAMP CANNOT BE OPERATED
TACHOMETER OPERATION WITH THE ENGINE RUNNING
FUEL GAUGE OPERATION
TEMPERATURE GAUGE OPERATION
HOUR METER OPERATION
INDEX
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