Bobcat CT2025, CT2035, CT2040, CT2535, CT2540 7371865 (11-19) (Preview)
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TABLE OF CONTENTS
SAFETY FIRST
FOR SAFETY
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 MATERIALS
HANDLING OF ROTATING BLADE, SHAFT AND DRIVING BELT
PREVENTION OF SCALD
DISPOSAL OF ENVIRONMENTAL WASTE
CAUTIONS WHEN HANDLING TIRES
SAFETY FIRST
GENERAL
DESCRIPTION FOR SYMBOLS AND ABBREVIATIONS
TRACTOR SERIAL NUMBER
TRACTOR EXTERIOR VIEW
IDENTIFICATION NUMBER
ENGINE SERIAL NUMBER
TRANSMISSION SERIAL NUMBER
DIMENSIONS
SPECIFICATIONS
DRIVING SPEED
GEAR ARRANGEMENT
ARRANGEMENT OF MAIN SHIFT GEAR AND REAR AXLE GEARS
MAINTENANCE SCHEDULE
MAINTENANCE
LUBRICATION LIST
TIGHTENING TORQUES
GENERAL USE SCREWS, BOLTS, AND NUTS
STUD BOLTS
AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS
SPRING PIN AND SNAP RING INSTALLATION
SPRING PIN TYPE
SNAP RING INSTALLATION
UNIT CONVERSION TABLE
ENGINE
ENGINE IDENTIFICATION
ENGINE EPA DECAL (A)
ENGINE NUMBER (B)
SPECIFICATIONS
GENERAL SPECIFICATIONS
ENGINE DIMENSION
COMPONENTS
ENGINE PERFORMANCE CURVE
TORQUE
BRAKE HORSE POWER (HP)
ENGINE PERFORMANCE CURVE ANALYSIS
S.F.C (SPECIFIC FUEL CONSUMPTION)
ENGINE BODY
SERVICING SPECIFICATIONS
LUBRICATING SYSTEM
COOLING SYSTEM
TIGHTENING TORQUES FOR ENGINE
OPERATING PRINCIPLE
CRDI (COMMON RAIL DIRECT INJECTION) SYSTEM
ECU
HIGH PRESSURE FUEL PUMP (FOR INJECTION)
FUEL RAIL(COMMON RAIL)
INJECTOR [C3I]
CYLINDER HEAD
CYLINDER BLOCK
CYLINDER HONING
BODY AND POWER TRAIN SYSTEM
CRANKSHAFT
PISTON AND PISTON RING
CONNECTING ROD
CAMSHAFT
ROCKER ARM ASSEMBLY
INTAKE AND EXHAUST VALVES
TIMING GEAR
FLYWHEEL
MLS CYLINDER HEAD GASKET
ENGINE OIL FLOW
LUBRICATING SYSTEM
ENGINE OIL FLOW CHART
FUNCTION OF LUBRICATING SYSTEM
COOLANT FLOW ROUTE
COOLING SYSTEM
WATER PUMP
THERMOSTAT
RADIATOR
RADIATOR CAP
FUEL SYSTEM
OVERVIEW FOR FUEL SUPPLY
FUEL FLOW ROUTE
FUEL FILTER
BLEEDING THE FUEL SYSTEM
HIGH PRESSURE FUEL PUMP
COMMON RAIL (FUEL RAIL)
INJECTOR [C3I (CALIBRATION IMPROVED INDIVIDUAL INJECTOR)]
FUEL COOLER
ACCELERATION SYSTEM
OVERVIEW
INTAKE & EXHAUST SYSTEM
EGR COOLER
EGR VALVE
AIR CONTROL VAVLE
CCRT (CATALYZED CONTINUOUSLY REGENERATING TRAP)
SENSOR
SENSORS AS INPUT/OUTPUT FOR ECU
TROUBLESHOOTING
MEASUREMENT AND ADJUSTMENT
VALVE CLEARANCE
CLEARANCE ADJUSTMENT
VALVE LIFT (DEFLECTION AND WORN CONDITION OF VALVE CAM, TAPPET, PUSH ROD, ROCKER ARM, ETC.)
OIL PRESSURE MEASUREMENT
BUBBLE TEST FOR RADIATOR
EXPLODED VIEW
GEAR CASE
CYLINDER HEAD COVER
CRANK SHAFT
PISTON & CONNECTING ROD
CAMSHAFT
IDLE GEAR
ROCKER ARM & VALVE
EH3-G131002 INTAKE MANIFOLD
EH3-G141001 OIL PUMP
EH3-G142001 OIL PAN
EH3-G144001 OIL FILTER
FUEL EQUIPMENT
WATER FLANGE
EH3-G163001 WATER PUMP
EGR
EH3-G172001 EGR COOLER
EGR COOLER
TC2-G115001 AFTERTREATMENT
TC2-G117005 FUEL FILTER
TC2-G119001 ECU
DISASSEMBLY, SERVICE AND ASSEMBLY
ENGINE REMOVAL
ENGINE COMPONENT REMOVAL
HEAD COVER
ENGINE DISASSEMBLY
GLOW PLUG AND INJECTOR
ROCKER ARM ASSEMBLY
CYLINDER HEAD
INTAKE AND EXHAUST VALVES
HIGH PRESSURE FUEL PUMP
GEAR CASE
GEARS IN GEAR CASE
PISTON AND CONNECTING ROD
FLYWHEEL AND CRANKSHAFT
OIL FILTER
OIL PUMP
THERMOSTAT
WATER PUMP
FUEL FILTER
ENGINE IDENTIFICATION
ENGINE EPA DECAL (A)
SPECIFICATIONS
GENERAL SPECIFICATIONS
CYLINDER HEAD
VALVES
VALVE TIMING
ENGINE BODY
CYLINDER BORE
VALVE SPRING
ROCKER ARM
TAPPET
CAMSHAFT
TIMING GEAR
PISTON RING
CONNECTING ROD
CRANKSHAFT
OIL PUMP
LUBRICATING SYSTEM
COOLING SYSTEM
FUEL SYSTEM
THERMOSTAT
RADIATOR
INJECT PUMP
INJECTION NOZZLE
TIGHTENING TORQUES
SEPERATING PRINCIPLE
LUBRICATING SYSTEM
COOLING SYSTEM
FUEL SYSTEM
FUEL FLOW ROUTE
FUEL FILTER
BLEEDING THE FUEL SYSTEM
FUEL FEED PUMP
FUEL INJECTION PUMP
BASIC PRINCIPLE OF GOVERNOR SYSTEM
GOVERNOR SYSTEM
OPERATION OF GOVERNOR
PCV (POSITIVE CRANKCASES VENTILATION)
AIR HEATER
PCV VALVE
INTAKE & EXHAUST SYSTEM
TROUBLESHOOTING
MEASUREMENT AND ADJUSTMENT
FAN BELT
ENGINE BODY
CHECKING AND ADJUSTING
VALVE CLEARANCE
INJECTION TIMING MEASUREMENT AND ADJUSTMENT
ENGINE OIL PRESSURE
EXPLODED VIEW
CYLINDER BLOCK GROUP
OIL PAN GROUP
GEAR CASE GROUP
MAIN BEARING CASE GROUP
VALVE ROCKER ARM GROUP
CYLINDER HEAD COVER GROUP
CAMSHAFT GROUP
PISTON & CAMSHAFT GROUP
NOZZLE HOLDER GROUP
FUEL CAMSHAFT GROUP
SPEED CONTROL LEVER GROUP
GOVERNOR GROUP
WATER PUMP GROUP
WATER HOSE GROUP
ENGINE DISASSEMBLY AND SERVICING
REMOVAL AND REASSEMBLY
DISASSEMBLING OTHER ENGINE PARTS
CYLINDER HEAD COVER, GLOW PLUGS AND FUEL OVERFLOW PIPES
HEAT SEAL REMOVAL PROCEDURE
ROCKER ARM ASSEMBLY
CYLINDER HEAD
VALVE
INJECTION PUMP
CRANKCASE
IDLE GEAR AND CRANK GEAR
VALVE CAMSHAFT
FUEL CAMSHAFT
CONNECTING ROD AND PISTON
CRANKSHAFT
INSPECTION FOR OVERHAUL
CYLINDER HEAD AND VALVE
VALVE SPRING
CHECKING OIL CLEARANCE BETWEEN ROCKER ARM SHAFT AND BUSHING
TIMING GEARS AND CAMSHAFTS
CONNECTING ROD AND PISTON
CRANKSHAFT
CYLINDER BORE
LUBRICATING SYSTEM
COOLING SYSTEM
FUEL SYSTEM
CLUTCH
SPECIFICATION
GENERAL SPECIFICATIONS
TIGHTENING TORQUES
SEALANT
OPERATIONAL PRINCIPLE
TROUBLESHOOTING
MEASUREMENT AND ADJUSTMENT
CLUTCH PEDAL PLAY ADJUSTMENT
CLUTCH STOPPER BOLT ADJUSTMENT
SAFETY START SWITCH ADJUSTMENT
CLUTCH DISC SPLINE BOSS AND GEAR SHAFT END PLAY
CLUTCH DISC WEAR INSPECTION
PRESSURE PLATE INSPECTION
THRUST BALL BEARING INSPECTION
FLYWHEEL SURFACE AND DEFLECTION OF ENGINE CRANKSHAFT
EXPLODED VIEW
CLUTCH LEVER
CLUTCH
CLUTCH PEDAL
CLUTCH DISASSEMBLY (CLUTCH DISC REPLACEMENT)
DISASSEMBLY, SERVICE AND ASSEMBLY
CLUTCH ASSEMBLY
TRANSMISSION
SPECIFICATIONS
GENERAL SPECIFICATIONS
TIGHTENING TORQUE FOR MAJOR COMPONENTS
SEALANT AND ADHESIVE SPECIFICATIONS
STRUCTURE AND OPERATING PRINCIPLE
MAIN GEAR SHIFT SECTION
OPERATING PRINCIPLE OF SYNCHRONIZER
RANGE SHIFT SECTION
PTO GEAR SHIFT SECTION
FRONT WHEEL DRIVE SECTION
INSPECTION AND ADJUSTMENT
SYNCHRONIZER GEAR INSPECTION
TROUBLESHOOTING
EXPLODED VIEW
MAIN SHAFT
SHAFT 1
SHAFT 2
REVERSE SHAFT
RANGE SHAFT
PTO DRIVE SHAFT
FRONT DRIVE SYSTEM
RANGE FORK
PTO SHIFT FORK
FRONT DRIVE FORK
PROPELLER SHAFT
PTO SHAFT
MAIN SPEED FORK
MAIN SHAFT
HST PROPER SHAFT
RANGE SHAFT
PTO DRIVE SHAFT
CLUTCH HOUSING REMOVAL
DISASSEMBLY, SERVICE AND ASSEMBLY
CLUTCH HOUSING ASSEMBLY DISASSEMBLY
TRANSMISSION CASE MAIN SHIFT, RANGE SHIFT SECTION DISASSEMBLY
FRONT WHEEL DRIVE SECTION DISASSEMBLY
TRANSMISSION CASE SHIFT SECTION ASSEMBLY
PTO SHAFT DISASSEMBLY
HST (HST MODEL)
SPECIFICATIONS
GENERAL
HST
MAJOR TIGHTENING TORQUE
HST STRUCTURE & COMPONENTS
EXTERIOR
COMPONENTS
OPERATING PRINCIPLE
STRUCTURE AND FUNCTION OF HST
BASIC PRINCIPLE OF HST
FUNCTION HST CHARGE PUMP
CHARGE RELIEF VALVE
HIGH PRESSURE RELIEF VALVE
Operation of HST
NEUTRAL STATUS
FORWARD DRIVING
REVERSE DRIVING
TROUBLESHOOTING
MEASUREMENT AND ADJUSTMENT
CHARGE RELIEF VALVE PRESSURE CHECK
HP RELIEF VALVE PRESSURE CHECK
HST PEDAL LINK ADJUSTMENT
HST PEDAL ADJUSTMENT
HST NEUTRAL POSITION ADJUSTMENT
CRUISE MAGNETICE CLEARANCE ADJUSTMENT (OPTIONAL)
BLEEDING AIR FROM HST COMPONENT
EXPLODED VIEW
TRANSMISSION CASE
HST ASSY
HST EXTERNAL HYDRAULIC LINE
HST PEDAL
CRUISE (OPTIONAL)
HST CONTROL
SERVICING
HST DISASSEMBLY AND ASSEMBLY
HST COMPONENTS DISASSEMBLY AND ASSEMBLY
REAR AXLE
SPECIFICATIONS
TRANSMISSION FLUID
TIGHTENING TORQUES
OPERATING PRINCIPLE
PRINCIPLE OF DIFFERENTIAL SYSTEM
DIFFERENTIAL LOCK SYSTEM
TROUBLESHOOTING
INSPECTION AND ADJUSTMENT
BACKLASH FOR SPIRAL BEVEL PINION AND RING GEAR
TOOTH CONTACT OF SPIRAL BEVEL
EXPLODED VIEW
REAR DIFFERENTIAL SYSTEM
DIFFERENTIAL LOCK FORK
REAR AXLE
DISASSEMBLY, SERVICING AND ASSEMBLY
REAR DIFFERENTIAL DISASSEMBLY
REAR DIFFERENTIAL SYSTEM COMPONENTS DISASSEMBLY
REAR DIFFERENTIAL SYSTEM ASSEMBLY
REAR DIFFERENTIAL INSTALLATION
BRAKE
SPECIFICATIONS
GENERAL SPECIFICATION
STRUCTURE AND OPERATION PRINCIPLE
TROUBLESHOOTING
INSPECTION AND ADJUSTMENT
BRAKE PEDAL FREE PLAY
CLEARANCE OF BRAKE LAMP SWITCH
BRAKE PEDAL STOPPER
BRAKE COMPONENTS INSPECTION
BRAKE DISC
BRAKE PLATE
CAM PLATE
CAM PLATE AND STEEL BALL
EXPLODED VIEW
BRAKE PEDAL
DISASSEMBLY, SERVICING AND ASSEMBLY
BRAKE SECTION DISASSEMBLY AND ASSEMBLY
FRONT AXLE
SPECIFICATIONS
GENERAL SPECIFICATIONS
SEALANT AND ADHESIVE
TIGHTENING TORQUE FOR MAJOR COMPONENTS
STRUCTURE AND OPERATING PRINCIPLE
POWER TRANSFER SYSTEM FOR FRONT AXLE
DIFFERENTIAL SYSTEM
LOAD TRANSFER
TROUBLESHOOTING
INSPECTION AND ADJUSTMENT
TOE-IN
STEERING ANGLE
SWAY RESISTANCE
PRELOAD OF TAPER ROLLER BEARING ON SPIRAL BEVEL PINION SHAFT
BACKLASH FOR DIFFERENTIAL PINION AND DIFFERENTIAL SIDE GEAR
BACKLASH FOR SPIRAL BEVEL PINION AND 23 SPIRAL BEVEL GEAR
TOOTH CONTACT OF SPIRAL BEVEL GEAR
TOOTH CONTACT FOR UPPER BEVEL GEARS AND FINAL DRIVE BEVEL GEARS
EXPLODED VIEW
FRONT DIFFERENTIAL
FRONT AXLE CASE
FRONT AXLE
FRONT AXLE BRACKET
BEVEL PINION SHAFT
DIFF GEAR SHAFT
DISASSEMBLY, SERVIE AND ASSEMBLY
FRONT AXLE OIL SEAL REPLACEMENT
BEVEL GEAR CASE AND FRONT AXLE CASE DISASSEMBLY AND ASSEMBLY
FRONT DIFFERENTIAL SYSTEM REMOVAL AND INSTALLATION
FRONT DIFFERENTIAL SYSTEM DISASSEMBLY AND ASSEMBLY COMPONENTS
STEERING SYSTEM
SPECIFCATIONS AND TIGHTENING TORQUE
SPECIFICATIONS FOR STEERING SYSTEM
TIGHTENING TORQUE FOR MAJOR COMPONENTS
HYDRAULIC PUMP
POWER STEERING UNIT
STEERING CYLINDER
OPERATING DIAGRAM
STRUCTURE AND OPERATING PRINCIPLE
STEERING UNIT
OPERATING PRINCIPLE
STRUCTURE AND SPECIFICATIONS
OPERATING PRINCIPLE OF STEERING SYSTEM
STRUCTURE AND OPERATING PRINCIPLE
TROUBLESHOOTING
INSPECTION AND ADJUSTMENT
EXPLODED VIEW
STEERING CYLINDER
POWER STEERING CYLINDER
STEERING COLUMN
DISASSEMBLY, SERVICE AND ASSEMBLY
STEERING UNIT (ORBITROL UNIT) COMPONENTS DISASSEMBLY
STEERING UNIT COMPONENTS ASSEMBLY
STEERING CYLINDER REMOVAL
RELIEF VALVE DISASSEMBLY AND ASSEMBLY
HYDRAULIC SYSTEM
HYDRAULIC SCHEMATICS
SPECIFCATIONS
GENERAL SPECIFICATIONS
TIGHTENING TORQUE
STRUCTURE AND OPERATING PRINCIPLE
COMPONENT ARRANGEMENT
OPERATING PRINCIPLE
OPERATING DIAGRAM
IMPLEMENT SECTION
MAIN SECTION
HYDRAULIC FILTER
HST FILTER [HST MODEL]
COMPONENTS
GEAR PUMP
REAR AUX. VALVE (REMOTE HYDRAULIC VALVE)
LIFT CONTROL VALVE (PCV VALVE)
HYDRAULIC BLOCK
LOADER JOYSTICK VALVE
OIL COOLER [HST MODEL]
HYDRAULIC LIFT CYLINDER
TROUBLESHOOTING
INSPECTION AND ADJUSTMENT
LEVER SETTING OF HYDRAULIC LIFT CYLINDER
PRE-INSPECTION
ADJUSTING THE POSITION CONTROL LEVER
SETTING THE JOYSTICK LEVER
HYD. CYLINDER
EXPLODED VIEW
LIFT CONTROL VALVE
HYDRAULIC 1
HYDRAULIC 2
EXTERNAL HYDRAULIC VALVE
HYDRAULIC BLOCK (T3)
SUCTION PIPE GROUP (T4)
GEAR PUMP
DISASSEMBLY, SERVICE AND ASSEMBLY
DISASSEMBLY OF GEAR PUMP
GEAR PUMP ASSEMBLY COMPONENTSASSEMBLY
AUX. HYDRAULIC VALVE (DOUBLE ACTING VALVE)
HYDRAULIC CYLINDER
HYDRAULIC CYLINDER ASSEMBLY DISASSEMBLY
HYDRAULIC CYLINDER ASSEMBLY REASSEMBLY
LIFT CONTROL VALVE
FLOW CONTROL VALVE
RELIEF VALVE
HYDRAULIC BLOCK
HYDRAULIC BLOCK ASSEMBLY COMPONENTS DISASSEMBLY
LOADER JOYSTICK VALVE
REMOVAL
DISASSEMBLY
ELECTRIC SYSTEM AND DIAGNOSIS
ELECTRICAL SCHEMATICS
SPECIFCATIONS
WIRING IDENTIFICATION
WIRING COLOR IDENTIFICATION
CROSS SECTIONAL AREA OF WIRING
SYMBOLS FOR ELECTRIC COMPONENTS
FUSE
INSPECTION
CAUSE FOR BLOWN FUSE
ELECTRIC DEVICE DIAGNOSIS
OPERATING PRINCIPLE
WHEN IGNITION SWITCH IS IN “OFF” POSITION
WHEN IGNITION SWITCH IS TURNED TO “ACC” POSITION
OPERATING PRINCIPLE OF PREHEAT
WHEN IGNITION SWITCH IS TURNED TO “ST” POSITION
CHARGE WARNING LAMP OPERATION
ELECTRIC COMPONENTS
SLOW-BLOW FUSE
IGNITION SWITCH
IGNITION SWITCH OPERATION
KEY SWITCH TEST
START MOTOR
ALTERNATOR
COMBINATION SWITCH
FLASHER UNIT
GLOW RELAY
FUSE & RELAY BOX
5P RELAY
GLOW PLUG
MICRO 5P RELAY
MICRO 4P RELAY
COOLANT TEMPERATURE SENSOR
ENGINE STOP SOLENOID
ENGINE OIL PRESSURE SWITCH
PICKUP SENSOR
FUEL SENDER
HAZARD WARNING LAMP SWITCH
ECU
SENSORS AND RELAYS
CRANKSHAFT WHEEL SENSOR
FUEL RAIL PRESSURE SENSOR
ACCELERATION (KNOCK) SENSORS
HIGH-PRESSURE FUEL PUMP TEMPERATURE SENSOR
WATER-IN-FUEL SENSOR
EXHAUST GAS TEMP. SENSOR
CAMSHAFT WHEEL SENSOR
EGR VALVE SENSOR
MAF SENSOR
INTAKE AIR PRESSURE SENSOR/TEMPERATURE SENSOR
DPF DIFFERENTIAL PRESSURE SENSOR
THROTTLE POSITION SENSOR (TPS)
AIR CONTROL VALVE SENSOR
BRAKE SWITCH
PARKING BRAKE MICRO SWITCH
SAFETY START SWITCH
ONE SIDE BRAKE SWITCH
PTO SAFETY SWITCH
SWITCHS
CRUISE SWITCH [HST MODEL :OPTIONAL]
LINKED PEDAL SWITCH
DPF REGENERATION SWITCH [3H-TM(H)4 MODEL]
SAFETY CONTROL UNIT [EU]
PREHEAT CONTROLLER [CK2610(H)-US]
INSTRUMENT PANEL
SYBOMLS AND COMPONENTS
CONNECTOR
GAUGES AND INDICATORS
LAMPS
HEADLAMP
FRONT COMBINATION LAMP
WORK LAMP
REAR COMBINATION LAMP
WHEN THE ENGINE CANNOT BE STARTED
TROUBLESHOOTING
WHEN THE SYSTEM IS NOT CHARGED
WHEN THE SYSTEM IS NOT PREHEATED MANUALLY
WHEN THE SYSTEM IS NOT PREHEATED AUTOMATICALLY
WHEN THE HEAD LAMP CANNOT BE OPERATED
FUEL GAUGE OPERATION
TEMPERATURE GAUGE OPERATION
TACHOMETER OPERATION WITH THE ENGINE RUNNING
HOUR METER OPERATION
ENGINE ELECTRICAL
EXPLODED VIEW
ENGINE ELETRICAL (2)
START CONTROL
LIGHT CONTROL
WIRE HARNESS
DISPLAY CONTROL
ENGINE ELECTRICAL (3)
GLOW CONTROL
FUEL HEATER (WIRE)
FUEL SENDER
PTO CONTROL
TIER 4 CONTROL
DIAGNOSTIC PROGRAM
DIAGNOSIS
DTC (DIAGNOSTIC TROUBLE CODE)
COMPOSITION
ERORR CODE & ACTION
FAULT DIAGNOSIS CODE DESCRIPTION
INDEX
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