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Bobcat CT2540 Compact Tractor Service Manual (SN B4W111001-B4W199999)

Format: PDF (Printable Document)

File Language: English

File Pages: 777

File Size: 70.99 MB (Speed Download Link)

Brand: Bobcat

Model: CT2540 Compact Tractor

Book No: 7392929

Serial No: SN B4W111001-B4W199999

Type of Document: Service Manual

Categories: ,

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Bobcat CT2540 Compact Tractor Service Manual (SN B4W111001-B4W199999)

This CT2540 is a compact tractor you'll see mowing, running a loader, auger, or box blade on small farms and acreage, kind of Bobcat's answer to the Deere and Kubota compacts. The service manual is what a mechanic, field tech, or serious owner grabs when something's broken, not just for maintenance. They're looking for wiring diagrams, hydraulic schematics, torque references, and step-by-step teardown so they don't guess and break something expensive.

What this manual helps you do

  • Diagnose electrical faults using wiring diagrams and step sequences instead of chasing wires blindly
  • Check and set hydraulic and hydrostatic system pressures with the right test ports and adjustment points
  • Follow teardown and reassembly of the engine, front axle, transmission, and 3-point / loader hydraulics
  • Replace and adjust clutches, brakes, steering, and linkage with the correct order and specs in front of you
  • Troubleshoot PTO, 3-point hitch, and loader issues using symptom charts and flow checks

Who this is for

This is for anyone working specifically on a Bobcat CT2540 in the serial range B4W111001 to B4W199999 who wants shop-level repair info, same idea as a Cat SIS or Deere TM book. If you just need how to drive it, service intervals, or fluid types, you want the operator's handbook, not this manual.

FAQ

Q: Is this a searchable PDF and are the wiring diagrams readable?

A: These manuals are normally text searchable and the wiring diagrams are scanned clearly enough to zoom and trace circuits.

Q: How do I know if it fits my exact tractor?

A: Check your serial number plate. If it falls between B4W111001 and B4W199999, this is the right service manual for your machine.

Q: Is this what I need for repairs, or is there another book?

A: For diagnostics and repairs, this service manual is the right one. The parts catalog and operator's manual are separate documents.

Bottom line, if your tractor is a CT2540 in that B4W111001-B4W199999 range and you're doing your own repairs, this is the manual you want. If your serial is outside that range, skip it.

📘 Show Index

Table of Contents:

  • FORWARD
  • 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 DECALS
      • LOCATION OF DECALS
  • GENERAL
    • DESCRIPTION FOR SYMBOLS AND ABBREVIATIONS
    • TRACTOR EXTERIOR VIEW
    • IDENTIFICATION NUMBER
      • TRACTOR SERIAL NUMBER
      • ENGINE SERIAL NUMBER
      • TRANSMISSION SERIAL NUMBER
    • DIMENSIONS
    • SPECIFICATIONS
    • DRIVING SPEED
      • GEAR ARRANGEMENT
        • ARRANGEMENT OF MAIN SHIFT GEAR AND REAR AXLE GEARS
    • RELATIVE SPEED RATIO OF FRONT WHEELS
      • CALCULATION FOR RELATIVE SPEED RATIO OF FRONT WHEELS
      • METHOD OF MEASURING CIRCUMFERENCE
    • MAINTENANCE
      • MAINTENANCE SCHEDULE CHART
      • LUBRICATION LIST
    • TIRE MAINTENANCE
      • PROPER INFLATION PRESSURE
      • WHEEL BOLT TORQUE
    • 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)
      • ASSIGNMENT STANDARD FOR ENGINE MODEL CODE
    • SPECIFICATION
      • GENERAL SPECIFICATIONS
      • ENGINE DIMENSION
      • COMPONENTS
      • ENGINE PERFORMANCE CURVE
        • TORQUE
        • BRAKE HORSE POWER (HP)
      • ENGINE PERFORMANCE CURVE ANALYSIS
        • S.F.C (SPECIFIC FUEL CONSUMPTION) (FOR REFERENCE ONLY)
        • 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
      • 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
      • IDLE GEAR
      • ROCKER ARM VALVE
      • EGR
      • EGR COOLER
      • ECU
      • CYLINDER BLOCK
      • GEAR CASE
      • CRANK SHAFT
      • PISTON CONNECTING ROD
      • FUEL EQUIPMENT
      • CYLINDER HEAD COVER
      • AFTER TREATMENT
      • ELECTRICAL PARTS
    • ENGINE DISASSEMBLY AND SERVICING
      • ENGINE COMPONENT REMOVAL
      • ENGINE DISASSEMBLY
        • HEAD COVER
        • 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)
      • ENGINE NUMBER (B)
      • ASSIGNMENT STANDARD FOR ENGINE MODEL CODE
    • SPECIFICATIONS
      • GENERAL SPECIFICATIONS
      • ENGINE PERFORMANCE CURVE
      • ENGINE PERFORMANCE CURVE ANALYSIS
      • SERVICING SPECIFICATIONS
    • OPERATING PRINCIPLE
      • BODY AND POWER TRAIN SYSTEM
      • LUBRICATING SYSTEM
      • COOLING SYSTEM
        • FUEL FLOW ROUTE
      • FUEL SYSTEM
        • FUEL FILTER
        • BLEEDING THE FUEL SYSTEM
        • FUEL FEED PUMP
        • FUEL INJECTION PUMP
        • INJECTION NOZZLE
      • GOVERNOR AND STOP SYSTEM
        • BASIC PRINCIPLE OF GOVERNOR SYSTEM
        • OPERATION OF GOVERNOR
      • PCV VALVE
    • TROUBLESHOOTING
    • MEASUREMENT AND ADJUSTMENT
      • VALVE CLEARANCE
      • VALVE LIFT (DEFLECTION AND WORN CONDITION OF VALVE CAM, TAPPET, PUSH ROD, ROCKER ARM, ETC.)
      • INJECTION TIMING MEASUREMENT AND ADJUSTMENT
      • OIL PRESSURE MEASUREMENT
      • BUBBLE TEST FOR RADIATOR
      • INJECTION NOZZLE INSPECTION
    • EXPLODED VIEW
      • CYLINDER BLOCK
      • GEAR CASE
      • MAIN BEARING CASE
      • VALVE ROCKER ARM
      • CAMSHAFT
      • PISTON & CRANKSHAFT
      • NOZZLE HOLDER
      • ENGINE STOP LEVER
      • WATER PUMP
      • WATER HOSE
      • FUEL CAMSHAFT
      • SPEED CONTROL PLATE
    • ENGINE DISASSEMBLY AND SERVICING
      • ENGINE REMOVAL
        • PCV VALVE
        • HEAD COVER INSTALLATION
      • ENGINE COMPONENTS DISASSAMBLY AND ASSEMBLY
        • GLOW PLUG AND FUEL OVERFLOW PIPE
        • HEAT SEAL REMOVAL
        • ROCKER ARM ASSEMBLY
        • CYLINDER HEAD
        • INTAKE AND EXHAUST VALVES
        • INJECTION PUMP
        • GOVERNOR SPRING AND STOP SOLENOID
        • GEAR CASE
        • IDLE GEAR AND CRANK GEAR
        • VALVE CAMSHAFT
        • FUEL CAMSHAFT
        • CRANK GEARS AND SHAFTS CHECK
        • PISTON AND CONNECTING ROD
        • PISTON AND CONNECTING ROD CHECK
        • PISTON RING MEASUREMENT
        • CRANKSHAFT AND FLYWHEEL
        • METAL JOURNAL BEARINGS
        • FLYWHEEL AND CRANKSHAFT CHECK
        • CYLINDER BORE CHECK
        • OIL PUMP, OIL FILTER, RELIEF VALVE AND OIL STRAINER
        • THERMOSTAT
        • WATER PUMP
  • 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
      • CLUTCH RELEASE
      • CLUTCH PEDAL
    • DISASSEMBLY, SERVICE AND ASSEMBLY
      • CLUTCH DISASSEMBLY (CLUTCH DISC REPLACEMENT)
      • CLUTCH ASSEMBLY
  • TRANSMISSION
    • SPECIFICATIONS
      • GENERAL SPECIFICATIONS
      • TIGHTENING TORQUE FOR MAJOR COMPONENTS
      • SEALANT AND ADHESIVE SPECIFICATIONS
    • STRUCTURE AND OPERATING PRINCIPLE
      • MAIN GEAR SHIFT SECTION
      • RANGE SHIFT SECTION
      • PTO GEAR SHIFT SECTION
      • FRONT WHEEL DRIVE SECTION
    • TROUBLESHOOTING
    • EXPLODED VIEW
      • PTO CLUTCH
      • DRIVE SHAFT
      • RANGE SHIFT SHAFT
      • RANGE SHIFT FORK
      • PTO SHAFT
      • PTO SHIFT FORK
      • MID PTO LEVER (IND. PTO)
      • FRONT WHEEL DRIVE SHAFT
      • PTO INPUT SHAFT
      • PTO CLUTCH
      • PROPELLER SHAFT
      • CLUTCH HOUSING REMOVAL
    • DISASSEMBLY, SERVICE AND ASSEMBLY
      • CLUTCH HOUSING ASSEMBLY DISASSEMBLY
      • MIDDLE CASE DISASSEMBLY
      • TRANSMISSION CASE RANGE SHIFT SECTION DISASSEMBLY
      • FRONT WHEEL DRIVE SECTION DISASSEMBLY
      • PTO SHAFT DISASSEMBLY
  • HST
    • 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 NEUTRAL POSITION ADJUSTMENT
        • HST PEDAL LINK ADJUSTMENT
        • HST PEDAL ADJUSTMENT
      • CRUISE MAGNETIC CLEARANCE
        ADJUSTMENT (OPTIONAL)
      • BLEEDING AIR FROM HST COMPONENT
    • EXPLODED VIEW
      • HST PEDAL
      • HST CONTROL (IND. PTO)
      • RPM LINKED
      • HST ASSY
    • SERVICING
      • HST DISASSEMBLY AND ASSEMBLY
      • HST COMPONENTS DISASSEMBLY AND ASSEMBLY
  • REAR AXLE
    • SPECIFICATIONS
      • TRANSMISSION FLUID
      • TIGHTENING TORQUES
    • OPERATING PRINCIPLE
      • POWER TRAIN OF REAR AXLE
      • PRINCIPLE OF DIFFERENTIAL SYSTEM
      • DIFFERENTIAL LOCK SYSTEM
    • TROUBLESHOOTING
    • INSPECTION AND ADJUSTMENT
      • BACKLASH FOR DIFFERENTIAL PINION AND SIDE GEAR
      • PRELOAD OF TAPER ROLLER BEARING IN DIFF.
      • BACKLASH FOR SPIRAL BEVEL PINION AND RING GEAR
      • TOOTH CONTACT OF SPIRAL BEVEL
    • EXPLODED VIEW
      • REAR AXLE
      • REAR DIFFERENTIAL
      • REAR DIFF LOCK
      • SPIRAL BEVEL GEAR
    • DISASSEMBLY, SERVICING AND ASSEMBLY
      • REAR AXLE COMPONENTS
      • REAR DIFFERENTIAL DISASSEMBLY
        • REAR DIFFERENTIAL SYSTEM COMPONENTS DISASSEMBLY
        • REAR DIFFERENTIAL SYSTEM ASSEMBLY
        • REAR DIFFERENTIAL INSTALLATION
  • BRAKE
    • SPECIFICATIONS
      • GENERAL SPECIFICATION
    • STRUCTURE AND OPERATING 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
      • BRAKE PEDAL (NONE CLUTCH)
      • BRAKE ROD
    • 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 21 SPIRAL BEVEL GEAR
      • TOOTH CONTACT OF SPIRAL BEVEL GEAR
      • TOOTH CONTACT FOR UPPER BEVEL GEARS AND FINAL DRIVE BEVEL GEARS
    • EXPLODED VIEW
      • FRONT DIFF SYSTEM
      • BEVEL PINION SHAFT
      • BEVEL GEAR CASE
      • FRONT AXLE CASE
      • FRONT AXLE
      • STEERING CYLINDER
      • PROPELLER SHAFT
      • FRONT AXLE BRACKET
    • DISASSEMBLY, SERVICING 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
    • SPECIFICATIONS AND TIGHTENING TORQUE
      • SPECIFICATIONS FOR STEERING SYSTEM
      • TIGHTENING TORQUE FOR MAJOR COMPONENTS
        • HYDRAULIC PUMP
        • POWER STEERING UNIT
        • STEERING CYLINDER
    • STRUCTURE AND OPERATING PRINCIPLE
      • OPERATING DIAGRAM
      • STEERING UNIT
        • OPERATING PRINCIPLE
        • STRUCTURE AND SPECIFICATIONS
      • OPERATING PRINCIPLE OF STEERING SYSTEM
      • STRUCTURE AND OPERATING PRINCIPLE
    • TROUBLESHOOTING
    • INSPECTION AND ADJUSTMENT
      • STEERING UNIT RELIEF VALVE PRESSURE CHECK
      • FRONT AXLE TOE-IN ADJUSTMENT
    • EXPLODED VIEW
      • POWER STEERING UNIT
      • STEERING COLUMN
    • DISASSEMBLY, SERVICING AND ASSEMBLY
      • STEERING UNIT REMOVAL
        • STEERING UNIT (ORBITROL UNIT) COMPONENTS DISASSEMBLY
        • STEERING UNIT COMPONENTS ASSEMBLY
      • STEERING CYLINDER REMOVAL
        • RELIEF VALVE DISASSEMBLY AND ASSEMBLY
  • HYDRAULIC SYSTEM
    • HYDRAULIC / HYDROSTATIC SCHEMATICS
    • SPECIFICATIONS
      • GENERAL SPECIFICATIONS
      • TIGHTENING TORQUE
    • STRUCTURE AND OPERATING PRINCIPLE
      • OPERATING PRINCIPLE
        • OPERATING DIAGRAM
        • IMPLEMENT SECTION
        • MAIN SECTION
      • COMPONENTS
        • GEAR PUMP
        • REAR AUX. VALVE (REMOTE HYDRAULIC VALVE)
        • LIFT CONTROL VALVE (PCV VALVE)
        • HYDRAULIC BLOCK
        • LOADER JOYSTICK VALVE
        • MODULATOR VALVE
        • OIL COOLER
        • HYDRAULIC LIFT CYLINDER
    • TROUBLESHOOTING
    • INSPECTION AND ADJUSTMENT
      • STEERING UNIT RELIEF PRESSURE INSPECTION
      • INSPECTION USING EXTERNAL HYDRAULIC VALVE COUPLER
      • MODULATOR VALVE (PTO CLUTCH) OPERATING PRESSURE INSPECTION
      • LEVER SETTING OF HYDRAULIC LIFT CYLINDER
        • PRE-INSPECTION
        • ADJUSTING THE POSITION CONTROL LEVER
      • SETTING THE JOYSTICK LEVER
    • EXPLODED VIEW
      • MODULATE VALVE
      • HYDRAULIC CYLINDER
      • LIFT CYLINDER
      • JOYSTICK VALVE
      • EXTERNAL HYDRAULIC VALVE (DS)
      • HYDRAULIC SYSTEM (1)
      • HYDRAULIC SYSTEM
      • GEAR PUMP
      • DOUBLE ACTING VALVE LEVER
      • JOYSTICK LEVER
    • DISASSEMBLY, SERVICE AND ASSEMBLY
      • HYDRAULIC PUMP & HYDRAULIC FILTER REMOVAL AND REASSEMBLY
        • DISASSEMBLY OF GEAR PUMP
        • GEAR PUMP ASSEMBLY COMPONENTS ASSEMBLY
      • AUX. HYDRAULIC VALVE (DOUBLE ACTING VALVE)
        • AUX. HYDRAULIC (DOUBLE ACTING) VALVE ASSEMBLY COMPONENTS – DISASSEMBLY AND ASSEMBLY
      • HYDRAULIC CYLINDER
        • HYDRAULIC CYLINDER ASSEMBLY DISASSEMBLY
        • HYDRAULIC CYLINDER ASSEMBLY REASSEMBLY
      • LIFT CONTROL VALVE
      • FLOW CONTROL VALVE
      • RELIEF VALVE
      • HYDRAULIC BLOCK ASSEMBLY COMPONENTS DISASSEMBLY
        • REMOVAL
      • LOADER JOYSTICK VALVE
        • DISASSEMBLY
      • MODULATOR VALVE DISASSEMBLY
  • ELECTRIC SYSTEM AND DIAGNOSIS
    • ELECTRICAL SCHEMATICS
    • SPECIFICATIONS
    • CIRCUIT AND COMPONENT LOCATION
    • WIRING IDENTIFICATION
      • WIRING COLOR IDENTIFICATION
      • CROSS SECTIONAL AREA OF WIRING
      • SYMBOLS FOR ELECTRIC COMPONENTS
      • FUSE
        • INSPECTION
        • CAUSE FOR BLOWN FUSE
      • ELECTRIC DEVICE DIAGNOSIS
    • ELECTRIC COMPONENTS
      • FUSE
        • FUSE BOX
        • 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 OIL PRESSURE SWITCH
      • 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
        • CRUISE SWITCH [HST MODEL :OPTIONAL]
      • PARKING BRAKE SWITCH [EU]
      • SWITCHS
        • LINKED PEDAL SWITCH
        • DPF REGENERATION SWITCH
      • PREHEAT CONTROLLER [AU]
      • SAFETY CONTROL UNIT [EU]
      • INSTRUMENT PANEL
        • SYMBOLS AND COMPONENTS
        • CONNECTOR
        • GAUGES AND INDICATORS
        • HOUR METER
        • HEADLAMP
      • LAMPS
        • WORK LAMP
        • REAR COMBINATION LAMP
        • LICENSE LAMP (IF FITTED)
    • TROUBLESHOOTING
      • WHEN THE ENGINE CANNOT BE STARTED
      • WHEN THE SYSTEM IS NOT CHARGED
      • 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
    • EXPLODED VIEW
      • LIGHT CONTROL
      • WIRE HARNESS
      • ENGINE ELECTRICAL (1)
      • ENGINE ELECTRICAL (2)
      • ENGINE ELECTRICAL (3)
      • ALTERNATOR
      • FRONT WORKING LAMP
      • CABIN WIRE HARNESS
      • FUEL SENDER
      • TIER4 CONTROL
      • SPEAKER ANTENNA
      • REAR GLASS DEFOGGER
      • START CONTROL
      • PTO CONTROL
      • GLOW CONTROL
      • DISPLAY CONTROL
    • DIAGNOSIS
      • DIAGNOSTIC PROGRAM
      • DTC (DIAGNOSTIC TROUBLE CODE)
        • COMPOSITION
        • FAULT CODE &ACTION
        • FAULT DIAGNOSIS CODE DESCRIPTION
  • CABIN
    • COMPONENTS
      • INTERIOR DEVICES
        • A/C CONTROLLER
        • INTERIOR LAMP
        • AIR INTAKE GRILL
        • SUN VISOR
        • SWITCH PANEL
        • CD PLAYER / BT PLAYER (OPTIONAL)
        • INTERIOR REAR VIEW MIRROR
        • WIPER MOTOR (FRONT)
        • WIPER MOTOR (REAR)
        • DOOR LATCH ASSEMBLY
        • REAR DOOR HANDLE
        • AIR CYLINDER
        • SPEAKER
      • EXTERNAL DEVICES
        • EXTERIOR FILTER ASSEMBLY
        • FRONT/REAR WORK LAMP
        • REAR COMBINATION LAMP
        • FRONT/REAR WIPERS
        • WASHER FLUID TANK
        • 7-PIN SOCKET
        • REAR VIEW MIRROR
        • ANTENNA
        • FRONT COMBINATION LAMP
        • LICENSE LAMP
    • EXPLODED VIEW
      • CABIN FRAME
      • ROOF
      • DOOR
      • FRONT GLASS
      • REAR GLASS
      • WIPER (FRONT)
      • WIPER (REAR)
    • CABIN DISASSEMBLY AND ASSEMBLY
      • CABIN REMOVAL
        • SEAT REMOVAL
      • COMPONENT REMOVAL
        • DOOR REMOVAL
        • DOOR GLASS REMOVAL
        • REAR GLASS HANDLE REMOVAL
        • ROOM MIRROR
        • WASHER FLUID TANK REMOVAL
        • INTERIOR LAMP
        • SWITCH PANEL (WORK LAMP AND WIPER SWITCH)
        • FRONT WIPER / MOTOR
        • REAR WIPER/MOTOR
        • ANTENNA
  • A/C AND HEATER
    • SPECIFICATION
      • AIR-CON/HEATER MAIN SPEC
    • PRINCIPLE OF COLLING SYSTEM
      • COOLING CYLCE
        • REFRIGERANT AND COMPRESSOR OIL
      • COMPRESSOR
      • RECEIVER-DRIER
        • INSPECTION
      • CONDENSER
        • INSPECTION
      • EXPANSION VALVE
      • EVAPORATOR
        • INSPECTION
        • INSPECTION
      • HEATER CORE
        • INSPECTION
      • AIR CONDITIONER/HEATER SYSTEM
        • AIR INLET AND VENT
        • AIR FLOW
        • ACTUATOR
      • COOLING SYSTEM
        • A/C ASSEMBLY
        • A/C ELECTRICAL CONNECTOR
        • A/C CONTROLLER
        • RESISTOR
    • CHECK AND ADJUSTMENT
      • TROUBLESHOOTING BY GAUGE
      • NORMAL CONDITION
      • INSUFFICIENT REFRIGERANT
      • EXCESSIVE REFRIGERANT, POOR
        CONDENSER COOLING
      • AIR INTRUSION INTO CYCLE
      • DEFECTIVE EXPANSION VALVE
      • POOR COMPRESSION
      • MOISTURE INTRUSION INTO COOLING CYCLE
      • POOR RECIRCULATION OF REFRIGERANT
      • INSPECTION AND ADJUSTMENT FOR CABIN SYSTEM
    • TROUBLESHOOTING
      • VISUAL INSPECTION
      • DIAGNOSIS BY SYMPTOM
      • TROUBLESHOOTING FOR POOR COOLING/HEATING PERFORMANCE
        • POOR COOLING
        • POOR HEATING
    • EXPLODED VIEW
      • AIR CONDITIONER HEATER
      • AIR CONDITIONER DRIVE
    • A/C RELATED COMPONENT DISSASSEMBLY AND ASSEMBLY
      • A/C FILTER REMOVAL
      • A/C ASSEMBLY REMOVAL
      • A/C ASSEMBLY COMPONENTS DISASSEMBLY
      • A/C CONTROLLER REMOVAL
      • COMPRESSOR REMOVAL
      • COMPRESSOR INSTALLATION
      • CONDERSER REMOVAL
  • INDEX

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