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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