Bobcat CT120 Compact Tractor Repair Service Manual - 6986523

(S/N: A59A11001 & Above) 
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This workshop repair service manual PDF download for the CT120 Bobcat Compact Tractor has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Bobcat Tractor CT120
S/N: A59A11001 & Above


TABLE OF CONTENTS :

SAFETY AND MAINTENANCE 
HYDRAULIC SYSTEM 
HYDROSTATIC SYSTEM 
DRIVE SYSTEM 
MAIN FRAME 
ELECTRICAL SYSTEM & ANALYSIS 
ENGINE SERVICE 
SPECIFICATIONS 
ALPHABETICAL INDEX 
SERVICE MANUAL REVISION


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6986523 (9-10)
Total Pages : 675


This Bobcat manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

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MAINTENANCE SAFETY
CONTENTS
FOREWORD
    FOREWORD
    SAFETY INSTRUCTIONS
        Use Safety Rules
        Safety Rules For Power Take-Off (PTO) Driven Implements
        Compact Tractor Requirements and Capabilities
    FIRE PREVENTION
        Maintenance
        Operation
        Electrical
        Hydraulic System
        Fueling
        Starting
        Spark Arrestor Exhaust System
        Welding And Grinding
        Fire Extinguishers
    SERIAL NUMBER LOCATIONS
        Compact Tractor Serial Number
        Engine Serial Number
        Loader Serial Number (Optional)
    DELIVERY REPORT
    COMPACT TRACTOR IDENTIFICATION
    COMPACT TRACTOR IDENTIFICATION (WITH OPTIONAL LOADER AND REAR BALLAST)
    COMPACT TRACTOR IDENTIFICATION (WITH OPTIONAL THREE-POINT IMPLEMENT AND FRONT BALLAST)
    
SAFETY AND MAINTENANCE
    SUPPORTING THE COMPACT TRACTOR ON JACKSTANDS
        Procedure
    ENGINE COVER
        Opening And Closing
    SEAT BELT
        Inspection And Maintenance
    TRANSPORTING THE COMPACT TRACTOR ON A TRAILER
        Loading And Unloading
        Fastening
    TOWING THE COMPACT TRACTOR
        Procedure
    AXLE TOE IN
        Inspection And Maintenance
    SERVICE SCHEDULE
        Chart
    AIR CLEANER SERVICE
        Replacing Filter Element
    ENGINE COOLING SYSTEM
        Checking Level
        Cleaning
        Hoses And Clamps
        Removing And Replacing Coolant
    FUEL SYSTEM
        Fuel Specifications
        Biodiesel Blend Fuel
        Filling The Fuel Tank
        Fuel Filter
        Removing Air From The Fuel System
        Filling A Portable Fuel Container
    ENGINE LUBRICATION SYSTEM
        Checking And Adding Engine Oil
        Engine Oil Chart
        Removing And Replacing Oil And Filter
    HYDRAULIC / HYDROSTATIC / TRANSMISSION SYSTEM
        Checking And Adding Fluid
        Transmission / Differential Fluid Chart
        Removing And Replacing Hydraulic / Hydrostatic / Transmission Filters
        Removing And Replacing Hydraulic / Transmission Fluid
        Hoses And Clamps
    FRONT AXLE
        Checking And Adding Lubricant
        Removing And Replacing Lubricant
        Axle Pivot
    SPARK ARRESTOR MUFFLER
        Cleaning Procedure
    COMPACT TRACTOR STORAGE AND RETURN TO SERVICE
        Storage
        Return To Service
    ALTERNATOR BELT
        Belt Adjustment
        Belt Replacement
    LUBRICATING THE COMPACT TRACTOR
        Lubrication Locations
    TIRE MAINTENANCE
        Front Wheel Nuts / Bolts
        Rear Wheel Nuts
        Mounting
        Wheel Spacing (AG Tires Only)
    PIVOT PINS
        Inspection And Maintenance
    SAFETY INTERLOCK SYSTEM - NEUTRAL START
        Inspection And Maintenance
    SAFETY INTERLOCK SYSTEM - OPERATING
        Inspection And Maintenance
    PARKING BRAKE SYSTEM
        Inspection And Maintenance
    BRAKE SYSTEM
        Inspection And Maintenance
        Adjusting
    TRAVEL CONTROL PEDAL
        Inspection And Maintenance
        Adjustment Procedure
    CLUTCH SYSTEM
        Inspection And Maintenance
        Adjusting
        Draining Water From Clutch Housing
    BOB-TACH (HAND LEVER)
        Inspection And Maintenance
        
HYDRAULIC SYSTEM
    HYDRAULIC / HYDRAULIC SCHEMATICS
    HYDRAULIC SYSTEM INFORMATION
        Glossary Of Hydraulic / Hydrostatic Symbols For Compact Tractors
        Troubleshooting The Hydraulic Circuit
        Troubleshooting The Joystick Valve Circuit
        Troubleshooting The Power Lift Circuit
        Troubleshooting The Steering Circuit
    MAIN RELIEF VALVE
        Testing Information
        Testing And Adjusting The Main Relief Valve
    HYDRAULIC PUMP
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    STEERING VALVE
        Removal And Installation
        Parts Identification
        Disassembly
        Inspection
        Assembly
    STEERING CYLINDER
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
    RIGHT JOYSTICK (IF EQUIPPED)
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
        Adjustment
    RIGHT JOYSTICK VALVE (IF EQUIPPED)
        Removal And Installation
        Parts Identification
        Disassembly
        Inspection
        Assembly
    HYDRAULIC FILTER
        Description
        Filter Bracket Removal And Installation
    OIL COOLER
        Removal And Installation
    THREE POINT HITCH HOUSING
        Removal And Installation
    AUXILIARY CONTROL VALVE
        Valve End Cap Removal And Installation
        Valve Section Parts Identification
        Valve Section Disassembly And Assembly
    ROCK SHAFT
        Removal And Installation
        Inspection
    MLS VALVE
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
        Adjustment
    THREE POINT CYLINDER
        Removal And Installation
        Disassembly And Assembly
        Inspection
    THREE POINT CYLINDER CONTROL
        Removal And Installation
    FRONT WHEEL DRIVE CASE
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    ROCK SHAFT LIFT ARMS
        Removal And Installation
    FLOW CONTROL VALVE
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
    CYLINDER (LIFT) (EARLY MODELS)
        Testing
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    CYLINDER (LIFT) (LATE MODELS)
        Testing
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    CYLINDER (TILT) (EARLY MODELS)
        Testing
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    CYLINDER (TILT) (LATE MODELS)
        Testing
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
        
HYDROSTATIC SYSTEM
    HYDROSTATIC SYSTEM INFORMATION
        Troubleshooting Chart
    HYDROSTATIC PUMP
        Removal And Installation
        Parts Identification
        Disassembly
        Inspection
        Assembly
        Hydrostatic Pump Start-Up
    HYDROSTATIC PUMP TESTING
        Charge Pressure Testing
        Forward Drive Relief Testing
        Reverse Drive Relief Testing
        
DRIVE SYSTEM
    SERVICE BRAKE
        Troubleshooting Chart
        Description
        Brake Pedal Clearance Adjustment
    BRAKE PEDAL ASSEMBLY
        Removal And Installation
    DRIVESHAFT
        Removal And Installation
    AXLE CASE
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
    BRAKE CASE
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
        Inspection
    TRANSMISSION
        Troubleshooting Chart
        Middle Case / Output Shaft Group Parts Identification
        Middle Case / Output Shaft Group Disassembly
        Middle Case / Output Shaft Group Inspection
        PTO Driving Shaft Group Parts Identification
        PTO Driving Shaft Group Disassembly
        PTO Driving Shaft Group Inspection
        Differential Parts Identification
        Differential Disassembly
        Differential Inspection
        Pinion Shaft Parts Identification
        Pinion Shaft Disassembly
        Pinion Shaft Inspection
        Range Shifter Shaft Group Parts Identification
        Range Shifter Shaft Group Disassembly
        Range Shifter Shaft Group Inspection
        Mid PTO Shaft Group Parts Identification
        Mid PTO Shaft Group Disassembly
        Mid PTO Shaft Group Inspection
        Rear PTO Group Parts Identification
        Rear PTO Group Disassembly
        Rear PTO Group Inspection
        Rear PTO Group Assembly
        Mid PTO Shaft Group Assembly
        Range Shifter Shaft Group Assembly
        Pinion Shaft Assembly
        Differential Assembly
        PTO Driving Shaft Group Assembly
        Middle Case / Output Shaft Group Assembly
    FRONT AXLE
        Removal And Installation
    AXLE AND DIFFERENTIAL
        Troubleshooting Chart
        Gear Case Cover Parts Identification
        Gear Case Cover Disassembly
        Gear Case Cover Inspection
        Axle Case Group Parts Identification
        Axle Case Group Disassembly
        Axle Case Group Inspection
        Axle Support Removal
        Pinion Shaft Removal
        Pinion Shaft Parts Identification
        Pinion Shaft Disassembly
        Pinion Shaft Inspection
        Differential Removal
        Differential Parts Identification
        Differential Disassembly
        Differential Inspection
        Differential Assembly
        Differential Installation
        Pinion Shaft Assembly
        Pinion Shaft Installation
        Axle Support Installation
        Axle Case Group Assembly
    STEERING AXLE ADJUSTMENT
        Toe-In Checking
        Toe-In Adjustment
        Rocking Force
        Steering Angle Adjustment
    SEPARATING THE TRACTOR
        Procedure
        
MAIN FRAME
    OPERATOR SEAT
        Removal And Installation
    CONSOLE COVER
        Left Side Removal And Installation
        Right Side Removal And Installation
    HYDROSTATIC TRANSMISSION CASE
        Removal And Installation
    REAR PTO CONTROL
        Linkage Removal And Installation
        Disassembly And Assembly
    MID PTO CONTROL
        Linkage Removal And Installation
        Linkage Disassembly And Assembly
    UPPER COVER
        Removal And Installation
    FLOOR MAT
        Removal And Installation (Right Side)
        Removal And Installation (Left Side)
    FLOOR PLATE
        Removal And Installation (Left Side)
        Removal And Installation (Right Side)
    ENGINE COVER
        Removal And Installation
    ENGINE SIDE COVER
        Removal And Installation
    FENDER
        Removal And Installation (Right Side)
        Removal And Installation (Left Side)
    FIREWALL
        Removal And Installation
    ROPS
        Removal And Installation
        Bracket Removal And Installation
    PTO SAFETY SHIELD
        Removal And Installation
    DRAW BAR
        Removal And Installation
    DRAW BAR ASSEMBLY
        Removal And Installation
    THREE POINT HITCH LOWER LINK
        Left Side Removal And Installation
        Right Side Removal And Installation
        Top Link Assembly Removal And Installation
    FUEL TANK
        Removal And Installation
    BOB-TACH (HAND LEVER)
        Description
        Removal And Installation
        Parts Identification
        Lever And Wedge Disassembly And Assembly
        
ELECTRICAL SYSTEM & ANALYSIS
    ELECTRICAL SCHEMATIC
    ELECTRICAL SYSTEM INFORMATION
        Glossary Of Electrical Symbols
        Electrical Component Location
        Troubleshooting
        Description
        Fuse And Relay Location - Engine Compartment
        Fuse And Relay Location - Instrument Panel
    BATTERY
        Removing And Installing Battery
        Battery Maintenance
        Using A Booster Battery (Jump Starting)
    ALTERNATOR
        Belt Adjustment
        Belt Replacement
        Charging System Inspection
        Alternator Voltage Testing
        Low Voltage Testing
        High Voltage Testing
        Removal And Installation
        Parts Identification
    STARTER
        Testing
        Removal And Installation
        Parts Identification
    HOOD LIGHTS
        Removal And Installation
        Bulb Removal And Installation
    REAR LIGHTS
        Removal And Installation
        Bulb Removal And Installation
    TURN INDICATORS
        Removal And Installation
        Bulb Removal And Installation
    SEAT SENSOR
        Removal And Installation
    FUEL LEVEL SENDER
        Removal And Installation
    INSTRUMENT PANEL
        Removal And Installation
    CENTER CONSOLE COVER
        Removal And Installation
    PTO SWITCHES
        Removal And Installation
        Adjustment
    HORN
        Removal And Installation
    CRUISE CONTROL
        Inspection And Maintenance
        Adjusting The Cruise Control Tension
        
ENGINE SERVICE
    ENGINE INFORMATION
        Description
        Specifications (Engine Model C3093B1)
        Troubleshooting
        Engine Removal And Installation
        Compression - Checking
    ENGINE SPEED CONTROL
        Cable Removal And Installation
        Lever Removal And Installation
    SPARK ARRESTOR MUFFLER
        Removal And Installation
    AIR CLEANER
        Removal And Installation
        Bracket Removal And Installation
    ENGINE COOLING SYSTEM
        Description
        Radiator Removal And Installation
        Water Pump Removal And Installation
        Water Pump Disassembly And Assembly
        Thermostat Housing Removal And Installation
        Testing The Thermostat
    LUBRICATION SYSTEM
        Description
        Oil Pan Removal And Installation
        Oil Pump Removal And Installation
        Oil Pump Inspection
        Engine Oil Pressure - Testing
        Oil Filter
    FUEL SYSTEM
        Description
        Fuel Camshaft Removal And Installation
        Fuel Shutoff Solenoid Checking
        Fuel Shutoff Solenoid Removal And Installation
        Fuel Injection Pump Removal And Installation
        Fuel Injection Pump Timing
        Fuel Injector Removal And Installation
        Fuel Injector Nozzle Pressure - Checking
        Nozzle Spray Condition
        Valve Seat Tightness
        Bleeding The Fuel System
    CYLINDER HEAD
        Glow Plug - Testing
        Glow Plug Removal And Installation
        Valve Clearance Adjustment
        Valve Timing - Checking
        Cylinder Head Removal And Installation
        Cylinder Head Disassembly And Assembly
        Cylinder Head Servicing
        Cylinder Head Top Clearance
        Valve Guide - Checking
        Reconditioning The Valve And Valve Seat
        Valve Spring
        Valve Tappets
        Rocker Arm And Shaft - Checking
    CRANKSHAFT AND PISTONS
        Piston And Connecting Rod Removal And Installation
        Piston And Connecting Rod - Servicing
        Cylinder Bore - Checking
        Connecting Rod - Alignment
        Crankshaft And Bearings Removal And Installation
        Crankshaft And Bearings - Servicing
    CAMSHAFT AND TIMING GEARS
        Timing Gearcase Cover Removal And Installation
        Timing Gears Backlash - Checking
        Idler Gear And Shaft Removal And Installation
        Camshaft - Servicing
        Idler Gear And Shaft - Servicing
    FLYWHEEL AND HOUSING
        Flywheel Removal And Installation
    FAN
        Removal And Installation
    CLUTCH ASSEMBLY
        Removal And Installation
        Clutch Disc Inspection
        Pressure Plate Inspection
        Clutch Pedal Play Adjustment
        Clutch Pedal Stop Bolt Adjustment
    CLUTCH HOUSING
        Removal And Installation
        Parts Identification
        Disassembly
        Inspection
        Assembly
        
SPECIFICATIONS
    CT120 COMPACT TRACTOR SPECIFICATIONS
        Dimensions (Standard Machine)
        Dimensions (With Optional Loader)
        Performance
        Controls
        Engine
        Hydraulic System
        Electrical
        Power Take-Off (PTO) System (Rear-PTO)
        Power Take-Off (PTO) System (Mid-PTO Optional)
        Drive System
        Steering
        Capacities
        Tires
        Loader (If Equipped)
    TORQUE SPECIFICATIONS FOR BOLTS
        Torque For General SAE Bolts
        Torque For General Metric Bolts
    TRANSMISSION / DIFFERENTIAL FLUID SPECIFICATIONS
        Specifications
    CONVERSIONS
        Decimal And Millimeter Equivalent Chart
        U.S. To Metric Conversion Chart
        
ALPHABETICAL INDEX

SERVICE MANUAL REVISION
    Revision No: CT120-1
    Revision No: CT120-2
    Revision No: CT120-3
    Revision No: CT120-4
    
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