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Bobcat T180 Compact Track Loader Service Manual 6904142 (11-10) – PDF DOWNLOAD
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Bobcat T180 Compact Track Loader Service Manual 6904142 (11-10) – PDF DOWNLOAD
S/N 531411001 – 531459999
S/N 531511001 – 531559999
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Description
Bobcat T180 Compact Track Loader Service Manual 6904142 (11-10) – PDF DOWNLOAD
FILE DETAILS:
Bobcat T180 Compact Track Loader Service Manual 6904142 (11-10) – PDF DOWNLOAD
Language : English
Pages : 900
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T180 Compact Track Loader Service Manual 6904142 (11-10) – PDF DOWNLOAD
S/N 531411001 – 531459999
S/N 531511001 – 531559999
FOREWORD:
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS (Including side screens) is in good condition and is not modified.
2. Check that ROPS mounting hardware is tightened and is Bobcat approved.
3. The seat belt must be correctly installed, functional and in good condition.
4. The seat bar must be correctly adjusted, clean and lubricated.
5. Check lift arm support device, replace if damaged.
6. Machine signs (decals) must be legible and in the correct location.
7. Steering levers, hand controls and foot pedals must return to neutral (as applicable).
8. Check for correct function of the work lights.
9. The parking brake must function correctly.
10. Enclosure door latches must open and close freely.
11. Bob-Tach wedges and linkages must function correctly and be in good condition.
12. Safety treads must be in good condition.
13. Check for correct function of indicator lamps.
14. Check hydraulic fluid level, engine oil level and fuel supply.
15. Inspect for fuel, oil or hydraulic fluid leaks.
SAFETY INSTRUCTIONS:
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
• The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
• Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
• An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
• The AEM Safety Manual delivered with the machine gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Bobcat T180 Compact Track Loader Service Manual 6904142 (11-10) – PDF DOWNLOAD
MAINTENANCE SAFETY.................................................................................. 3 ALPHABETICAL INDEX.................................................................................. 5 CONTENTS............................................................................................ 7 FOREWORD........................................................................................ 8 SAFETY INSTRUCTIONS............................................................................. 11 FIRE PREVENTION................................................................................. 13 Maintenance................................................................................. 13 Operation................................................................................... 13 Electrical.................................................................................. 13 Hydraulic System............................................................................ 13 Fueling..................................................................................... 13 Starting.................................................................................... 13 Spark Arrestor Exhaust System............................................................... 13 Welding And Grinding........................................................................ 14 Fire Extinguishers.......................................................................... 14 SERIAL NUMBER LOCATION.......................................................................... 15 Loader Serial Number........................................................................ 15 Engine Serial Number........................................................................ 15 DELIVERY REPORT................................................................................. 16 LOADER IDENTIFICATION........................................................................... 17 SAFETY & MAINTENANCE................................................................................ 19 LIFTING AND BLOCKING THE LOADER................................................................. 23 Procedure................................................................................... 23 LIFT ARM SUPPORT DEVICE......................................................................... 25 Installing.................................................................................. 25 Removing.................................................................................... 26 OPERATOR CAB.................................................................................... 27 Description................................................................................. 27 Raising..................................................................................... 28 Lowering.................................................................................... 29 Cab Door Sensor............................................................................. 30 Special Applications Kit.................................................................... 30 Special Applications Kit Inspection And Maintenance......................................... 30 TRANSPORTING THE LOADER ON A TRAILER............................................................ 31 Loading And Unloading....................................................................... 31 Fastening................................................................................... 31 TOWING THE LOADER............................................................................... 33 Procedure................................................................................... 33 REMOTE START TOOL KIT-MEL1563................................................................... 35 Remote Start Tool - MEL1563................................................................. 35 Service Tool Harness Control - MEL1565...................................................... 36 Service Tool Harness Communicator - MEL1566................................................. 37 Remote Start Procedure...................................................................... 38 REMOTE START TOOL (SERVICE TOOL) KIT - 6689779.................................................. 41 Description................................................................................. 41 Remote Start Tool (Service Tool) - 6689778.................................................. 42 Loader Service Tool Harness - 6689747....................................................... 43 Computer Service Tool Harness - 6689746..................................................... 44 Remote Start Procedure...................................................................... 45 SERVICE SCHEDULE................................................................................ 49 Chart....................................................................................... 49 AIR CLEANER SERVICE............................................................................. 51 Replacing Filter Elements................................................................... 51 ENGINE COOLING SYSTEM........................................................................... 53 Cleaning.................................................................................... 53 Checking Level.............................................................................. 54 Removing And Replacing Coolant.............................................................. 54 FUEL SYSTEM..................................................................................... 55 Fuel Specifications......................................................................... 55 Biodiesel Blend Fuel........................................................................ 55 Filling The Fuel Tank....................................................................... 56 Fuel Filter................................................................................. 57 Removing Air From The Fuel System........................................................... 57 ENGINE LUBRICATION SYSTEM....................................................................... 59 Checking And Adding Engine Oil.............................................................. 59 Engine Oil Chart............................................................................ 59 Removing And Replacing Oil And Filter....................................................... 59 HYDRAULIC/HYDROSTATIC SYSTEM.................................................................... 61 Checking And Adding Fluid................................................................... 61 Hydraulic / Hydrostatic Fluid Chart......................................................... 61 Removing And Replacing Hydraulic Fluid...................................................... 62 Removing And Replacing Hydraulic / Hydrostatic Filter....................................... 63 Removing And Replacing Case Drain Filters................................................... 64 Removing And Replacing Hydraulic Charge Filter.............................................. 65 Breather Cap................................................................................ 66 BOB-TACH (HAND LEVER)........................................................................... 67 Inspection And Maintenance.................................................................. 67 BOB-TACH (POWER)................................................................................ 69 Inspection And Maintenance.................................................................. 69 LUBRICATING THE LOADER.......................................................................... 71 Lubrication Locations....................................................................... 71 SPARK ARRESTOR MUFFLER.......................................................................... 73 Cleaning Procedure.......................................................................... 73 PIVOT PINS...................................................................................... 75 Inspection And Maintenance.................................................................. 75 LOADER STORAGE AND RETURN TO SERVICE............................................................ 77 Storage..................................................................................... 77 Return To Service........................................................................... 77 STOPPING THE ENGINE AND LEAVING THE LOADER...................................................... 79 Procedure................................................................................... 79 Emergency Exit.............................................................................. 80 HYDRAULIC SYSTEM.................................................................................... 81 HYDRAULIC / HYDROSTATIC SCHEMATICS.............................................................. 85 HYDRAULIC SYSTEM INFORMATION.................................................................... 93 Glossary Of Hydraulic / Hydrostatic Symbols................................................. 93 Troubleshooting............................................................................. 97 CYLINDER (LIFT)................................................................................. 99 Testing..................................................................................... 99 Removal And Installation....................................................................100 Parts Identification........................................................................101 Disassembly And Assembly....................................................................102 CYLINDER (TILT).................................................................................105 Testing.....................................................................................105 Removal And Installation....................................................................106 Base End Pivot Pin Removal And Installation.................................................107 Rod End Pivot Pin Bushing And Seal Removal And Installation.................................108 Parts Identification........................................................................109 Disassembly And Assembly....................................................................110 CYLINDER (BOB-TACH).............................................................................113 Testing.....................................................................................113 Removal And Installation....................................................................114 Parts Identification........................................................................115 Disassembly And Assembly....................................................................116 MAIN RELIEF VALVE...............................................................................119 Description.................................................................................119 Testing.....................................................................................119 Adjusting...................................................................................121 Removal and Installation....................................................................122 HYDRAULIC CONTROL VALVE (STANDARD)..............................................................123 Description.................................................................................123 Removal And Installation....................................................................123 Identification Chart........................................................................128 Mount Bracket Removal And Installation......................................................129 Lift Load Check Valve Removal And Installation..............................................129 Load Check Valve Removal And Installation (Tilt & Auxiliary)................................130 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..............................131 Port Relief/Anti-Cavitation Valve Removal And Installation (Lift, Base End).................132 Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Base End).................132 Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)..................133 Port Relief Valve Removal And Installation..................................................133 Plug Removal And Installation...............................................................134 Rubber Boot Removal And Installation........................................................135 End Cap/Spool Lock Block Removal And Installation...........................................136 Lift Spool And Detent Removal And Installation..............................................137 Tilt Spool Removal And Installation.........................................................147 Auxiliary Spool Removal And Installation....................................................149 Auxiliary Solenoid Removal And Installation.................................................150 Solenoid Removal And Installation...........................................................151 Lock Valve Removal And Installation.........................................................153 Lift Arm Bypass Orifice Removal And Installation............................................155 Main Relief Valve Removal And Installation..................................................155 Check Valve Removal And Installation........................................................156 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)..........................................................157 Description.................................................................................157 Removal And Installation....................................................................157 Actuator Removal And Installation (Out of Loader)...........................................162 Identification Chart........................................................................165 Mount Bracket Removal And Installation......................................................166 Lift Load Check Valve Removal And Installation..............................................166 Load Check Valve Removal And Installation (Tilt & Auxiliary)................................167 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..............................168 Port Relief/Anti-Cavitation Valve Removal And Installation (Lift, Base End).................169 Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Base End).................169 Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)..................170 Port Relief Valve Removal And Installation..................................................170 Plug Removal And Installation...............................................................171 End Cap Block Removal And Installation......................................................172 Lift Spool And Detent Removal And Installation..............................................173 Tilt Spool Removal And Installation.........................................................178 Auxiliary Spool Removal And Installation....................................................180 Auxiliary Solenoid Removal And Installation.................................................181 Solenoid Removal And Installation...........................................................182 Lock Valve Removal And Installation.........................................................184 Lift Arm Bypass Orifice Removal And Installation............................................186 Main Relief Valve Removal And Installation..................................................187 Check Valve Removal And Installation........................................................188 LIFT ARM BYPASS CONTROL VALVE...................................................................189 Description.................................................................................189 Testing.....................................................................................189 Removal and Installation....................................................................189 Disassembly And Assembly....................................................................190 HYDRAULIC PUMP (STANDARD).......................................................................191 Description.................................................................................191 Pump Test at Quick Couplers.................................................................191 Direct Pump Test (Standard Section).........................................................192 Direct Pump Test (Charge Section)...........................................................194 Removal And Installation....................................................................196 Hydraulic Pump Start Up.....................................................................198 Parts Identification........................................................................199 Disassembly And Assembly....................................................................200 HYDRAULIC PUMP (STANDARD) (HIGH FLOW)...........................................................209 Description.................................................................................209 Pump Test at Quick Couplers.................................................................209 Direct Pump Test (Standard Section).........................................................210 Direct Pump Test (Charge Section)...........................................................212 Direct Pump Test (High Flow Section)........................................................214 Removal And Installation....................................................................216 Hydraulic Pump Start Up.....................................................................218 Parts Identification........................................................................219 Disassembly And Assembly....................................................................220 HYDRAULIC PUMP (SJC)............................................................................233 Description.................................................................................233 Pump Test At Quick Couplers.................................................................233 Direct Pump Test (Standard Section).........................................................234 Direct Pump Test (Charge Section)...........................................................236 Removal And Installation....................................................................238 Hydraulic Pump Start Up.....................................................................240 Parts Identification........................................................................241 Disassembly And Assembly....................................................................242 HYDRAULIC PUMP (SJC) (HIGH FLOW)................................................................251 Description.................................................................................251 Pump Test at Quick Couplers.................................................................251 Direct Pump Test (Standard Section).........................................................252 Direct Pump Test (Charge Section)...........................................................254 Direct Pump Test (High Flow Section)........................................................256 Removal And Installation....................................................................258 Hydraulic Pump Start Up.....................................................................260 Parts Identification........................................................................261 Disassembly And Assembly....................................................................262 Hydraulic Pump Start Up.....................................................................274 HYDRAULIC/HYDROSTATIC FILTERS...................................................................275 Description.................................................................................275 Gear Pump Filter Housing Removal And Installation...........................................275 Charge Filter Housing Removal And Installation..............................................277 HYDRAULIC FLUID RESERVOIR.......................................................................279 Description.................................................................................279 Removal And Installation....................................................................279 Hydraulic Fluid Screen......................................................................281 OIL COOLER......................................................................................283 Description.................................................................................283 Removal And Installation....................................................................283 BUCKET POSITION VALVE...........................................................................285 Description.................................................................................285 Solenoid Removal And Installation...........................................................285 Solenoid Testing............................................................................286 Removal And Installation....................................................................287 Disassembly And Assembly....................................................................288 REAR AUXILIARY DIVERTER VALVE...................................................................291 Description.................................................................................291 Removal And Installation....................................................................291 Disassembly And Assembly....................................................................294 Solenoid Testing............................................................................300 BOB-TACH (POWER) BLOCK..........................................................................301 Description.................................................................................301 Removal And Installation....................................................................301 Disassembly And Assembly....................................................................303 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK.........................................................307 Description.................................................................................307 Removal And Installation....................................................................307 Disassembly And Assembly....................................................................307 HIGH FLOW VALVE.................................................................................309 Description.................................................................................309 High Flow Relief Valve Testing..............................................................309 High Flow Relief Valve Adjustment...........................................................310 Solenoid Testing............................................................................311 Removal And Installation....................................................................312 Disassembly And Assembly....................................................................313 HYDROSTATIC SYSTEM..................................................................................317 HYDROSTATIC SYSTEM INFORMATION..................................................................319 Troubleshooting.............................................................................319 Description.................................................................................320 HYDROSTATIC MOTOR...............................................................................321 Description.................................................................................321 Removing And Replacing Oil..................................................................322 Removal And Installation....................................................................324 Parts Identification........................................................................326 Disassembly And Assembly....................................................................328 CHARGE PRESSURE.................................................................................339 Description.................................................................................339 Testing.....................................................................................339 Sender Removal And Installation.............................................................341 Adjusting...................................................................................342 HYDROSTATIC PUMP................................................................................345 Description.................................................................................345 Removal And Installation....................................................................346 Hydrostatic Pump Start Up...................................................................348 Replenishing/High Pressure Relief Valve.....................................................348 Parts Identification (Left Half)............................................................350 Parts Identification (Right Half)...........................................................351 Disassembly.................................................................................352 Assembly....................................................................................358 HYDROSTATIC PUMP (SJC)..........................................................................365 Description.................................................................................365 Hydraulic Controller Removal And Installation...............................................366 Removal And Installation....................................................................368 Hydrostatic Pump Start Up...................................................................370 Parts Identification........................................................................371 High Pressure Relief And Bypass Valve.......................................................372 Charge Relief Valve.........................................................................373 Disassembly And Assembly....................................................................374 Mechanical Neutral Adjustment...............................................................390 Hydraulic Controller Neutral Adjustment.....................................................393 DRIVE BELT......................................................................................397 Description.................................................................................397 Shield Removal And Installation.............................................................397 Adjusting...................................................................................398 Belt Removal And Installation...............................................................399 Belt Tensioner Removal And Installation.....................................................400 Belt Tensioner Parts Identification.........................................................401 Belt Tensioner Disassembly..................................................................402 Belt Tensioner Assembly.....................................................................403 CASE DRAIN FILTER...............................................................................405 Description.................................................................................405 Disassembly And Assembly....................................................................405 DRIVE SYSTEM........................................................................................407 BRAKE...........................................................................................409 Description.................................................................................409 Right Motor Brake Test......................................................................409 Left Motor Brake Test.......................................................................410 Block Removal And Installation..............................................................411 Block Disassembly And Assembly..............................................................413 TRACK CARRIAGE COMPONENTS.......................................................................415 Description.................................................................................415 Checking Tension............................................................................416 Adjusting Tension...........................................................................417 Track Removal And Installation..............................................................419 Idler (Front) Removal And Installation......................................................422 Idler (Rear) Removal And Installation.......................................................424 Roller Removal And Installation.............................................................424 Sprocket Removal And Installation...........................................................425 Carriage Removal And Installation...........................................................426 Track Damage Identification.................................................................428 MAIN FRAME..........................................................................................441 SEAT BAR........................................................................................445 Description.................................................................................445 Removal And Installation....................................................................445 Disassembly And Assembly....................................................................446 Compression Spring Disassembly And Assembly.................................................448 OPERATOR CAB....................................................................................449 Gas Cylinder Removal And Installation.......................................................449 Gas Cylinder Bracket Disassembly And Assembly...............................................451 Removal And Installation....................................................................452 OPERATOR SEAT (SUSPENSION)......................................................................455 Removal And Installation....................................................................455 Slide Rail Removal And Installation.........................................................456 Seat Belt Removal and Installation..........................................................456 Lower Cushion Removal And Installation......................................................456 Back Cushion Removal And Installation.......................................................458 Shock Removal And Installation..............................................................458 3-Point Seat Belt Removal And Installation..................................................459 BOB-TACH (HAND LEVER)...........................................................................461 Description.................................................................................461 Removal And Installation....................................................................461 Lever And Wedge Disassembly And Assembly....................................................462 Pivot Pin Bushing And Seal Removal And Installation.........................................464 BOB-TACH (POWER-OPTION).........................................................................465 Description.................................................................................465 Removal And Installation....................................................................465 Lever And Wedge Disassembly And Assembly....................................................467 Pivot Pin Bushing And Seal Removal And Installation.........................................468 LIFT ARMS.......................................................................................469 Removal And Installation....................................................................469 REAR GRILL......................................................................................473 Removal And Installation....................................................................473 REAR DOOR.......................................................................................475 Removal And Installation....................................................................475 Striker Removal And Installation............................................................476 Striker Disassembly And Assembly............................................................476 Striker (Adjusting).........................................................................476 Latch Removal And Installation..............................................................477 FUEL TANK.......................................................................................479 Removal And Installation....................................................................479 Fuel Level Sender Removal And Installation..................................................480 Fuel Fill Screen Removal And Installation...................................................480 CONTROL PEDALS AND LINKAGES.....................................................................481 Description.................................................................................481 Pedal Removal And Installation..............................................................481 Linkage Removal And Installation............................................................482 Pedal (Adjusting)...........................................................................484 CONTROL PEDALS (ACS)............................................................................485 Description.................................................................................485 Foot Sensor Removal And Installation........................................................485 Foot Pedal Removal And Installation.........................................................486 Foot Pedal Linkage Disassembly And Assembly.................................................487 CONTROL PANEL...................................................................................489 Description.................................................................................489 Removal And Installation....................................................................490 Shock Removal And Installation..............................................................493 Shaft Removal And Installation..............................................................493 Shaft Disassembly And Assembly..............................................................494 Linkage Removal And Installation............................................................495 Pintle Arm Disassembly And Assembly.........................................................499 Linkage Neutral Adjustment..................................................................501 Linkage Travel Adjustment...................................................................505 CONTROL PANEL (SJC).............................................................................509 Description.................................................................................509 Removal And Installation....................................................................509 CONTROL HANDLE/LEVER............................................................................511 Description.................................................................................511 Lever Removal And Installation..............................................................511 Boot Removal And Installation...............................................................512 CONTROL HANDLE/LEVER (ACS)......................................................................513 Description.................................................................................513 Handle Sensor Removal And Installation......................................................513 Handle Removal And Installation.............................................................516 Handle Disassembly And Assembly.............................................................517 Lever Removal And Installation..............................................................517 Boot Removal And Installation...............................................................519 CONTROL HANDLE/LEVER (SJC)......................................................................521 Description.................................................................................521 Joystick Testing............................................................................521 Joystick Removal And Installation (S/N 531411001 - 531411692, S/N 531511001 - 531511108)....522 Joystick Removal And Installation (S/N 531411693 & Above, S/N 531511109 & Above)............524 Removal And Installation (S/N 531411001 - 531411692, S/N 531511001 - 531511108).............525 Removal And Installation (S/N 531411693 & Above, S/N 531511109 & Above).....................526 ACCESS PANEL (INSIDE)...........................................................................527 Removal And Installation (Left).............................................................527 Removal And Installation (Right)............................................................527 ACCESS PANEL (INSIDE) (SJC).....................................................................529 Removal And Installation (Left).............................................................529 Removal And Installation (Right)............................................................530 WINDOW (REAR)...................................................................................533 Removal.....................................................................................533 Installation................................................................................533 WINDOW (TOP)....................................................................................535 Removal And Installation....................................................................535 WINDOW (SIDE)...................................................................................537 Removal And Installation....................................................................537 WINDOW (FRONT DOOR).............................................................................539 Removal (Standard Window)...................................................................539 Installation (Standard Window)..............................................................540 Removal And Installation (Special Applications Window)......................................542 ELECTRICAL SYSTEM & ANALYSIS........................................................................543 ELECTRICAL SCHEMATICS...........................................................................547 ELECTRICAL SYSTEM INFORMATION...................................................................559 Glossary Of Electrical Symbols..............................................................559 Cab Harness Connectors......................................................................562 Mainframe Harness Connectors................................................................563 Description.................................................................................564 Troubleshooting.............................................................................565 Fuse And Relay Location / Identification....................................................566 Solenoid Testing............................................................................567 BATTERY.........................................................................................569 Removal And Installation....................................................................569 Servicing...................................................................................570 Using A Booster Battery (Jump Starting).....................................................571 ALTERNATOR......................................................................................573 Belt Adjustment.............................................................................573 Belt Replacement............................................................................573 Charging System Inspection..................................................................574 Alternator Voltage Testing..................................................................575 Low Voltage Testing.........................................................................575 High Voltage Testing........................................................................576 Removal And Installation....................................................................577 Parts Identification........................................................................578 STARTER.........................................................................................579 Testing.....................................................................................579 Removal And Installation....................................................................580 Parts Identification........................................................................581 INSTRUMENT PANELS...............................................................................583 Left Panel..................................................................................583 Right Panel (Key Switch)....................................................................584 Right Panel (Keyless).......................................................................585 Side And Front Panels.......................................................................587 Removal And Installation (Left And Right)...................................................588 Bulb Removal And Installation (Left Only)...................................................591 Key Switch Removal And Installation.........................................................592 Alarm Removal And Installation..............................................................593 Front Panel Removal And Installation........................................................593 LIGHTS..........................................................................................595 Front Removal And Installation..............................................................595 Rear Removal And Installation...............................................................596 Cab Light Removal And Installation..........................................................596 BOBCAT CONTROLLER (MAIN)........................................................................597 Description.................................................................................597 Connector Identification....................................................................598 Removal And Installation....................................................................600 BOBCAT CONTROLLER (ACS).........................................................................601 Description.................................................................................601 Connector Identification....................................................................603 Removal And Installation....................................................................604 BOBCAT CONTROLLER (SJC) (DRIVE).................................................................605 Description.................................................................................605 Connector Identification....................................................................606 Removal and Installation....................................................................608 SPEED SENSOR (SJC)..............................................................................611 Description.................................................................................611 Testing.....................................................................................611 Removal And Installation....................................................................613 DIAGNOSTIC SERVICE CODES........................................................................617 Viewing Service Codes (Key Switch)..........................................................617 Viewing Service Codes (Keyless).............................................................617 Service Codes List..........................................................................618 BOBCAT INTERLOCK CONTROL SYSTEM (BICS)..........................................................623 Description.................................................................................623 Inspecting The BICS Controller (Engine STOPPED - Key ON)....................................624 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)........624 Inspecting The Seat Bar Sensor (Engine RUNNING).............................................624 Inspecting The Traction Lock (Engine RUNNING)...............................................624 Inspecting The Lift Arm Bypass Control......................................................624 Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)............................624 Troubleshooting.............................................................................625 Troubleshooting Chart.......................................................................626 SEAT BAR SENSOR.................................................................................627 Description.................................................................................627 Troubleshooting.............................................................................627 Testing.....................................................................................628 Removal And Installation....................................................................629 Bobcat Interlock Control System (BICS) Circuit Test.........................................631 TRACTION LOCK...................................................................................633 Description.................................................................................633 Troubleshooting.............................................................................634 Inspecting..................................................................................635 CONTROL SYSTEM (ACS)............................................................................637 Description.................................................................................637 Troubleshooting Chart.......................................................................638 Handle Sensor Connector Disassembly And Assembly............................................639 Switch Handle Removal.......................................................................640 Switch Handle Installation..................................................................642 Actuator Connector Disassembly And Assembly.................................................645 Handle Lock Solenoid Removal And Installation...............................................646 Handle Lock Solenoid Disassembly And Assembly...............................................646 Foot Sensor Disassembly And Assembly........................................................647 Foot Lock Solenoid Removal And Installation.................................................648 ELECTRICAL/HYDRAULIC CONTROLS...................................................................649 Identification Chart........................................................................649 ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SJC)...................................................651 Identification Chart........................................................................651 SERVICE PC (LAPTOP COMPUTER)....................................................................655 Connecting Remote Start Tool................................................................655 Connecting Remote Start Tool (Service Tool).................................................655 CALIBRATION.....................................................................................657 Description.................................................................................657 Actuator Testing............................................................................657 Lift And Tilt Calibration (ACS).............................................................659 Lift And Tilt Calibration (SJC).............................................................661 Hydrostatic Pump Calibration (SJC)..........................................................663 STEERING DRIFT COMPENSATION.....................................................................669 Description.................................................................................669 Selecting And Adjusting.....................................................................669 Exiting And Saving..........................................................................670 FLYWHEEL RPM SENSOR.............................................................................671 Description.................................................................................671 Adjusting...................................................................................671 CONTROL PANEL SETUP.............................................................................673 Right Panel Setup (Keyless).................................................................673 Attachment Control Information (Keyless)....................................................674 PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START).................................................675 Password Description........................................................................675 Changing The Owner And User Passwords.......................................................676 Password Lockout Feature....................................................................677 MAINTENANCE CLOCK...............................................................................679 Description.................................................................................679 Setup.......................................................................................680 Reset.......................................................................................684 BACK-UP ALARM SYSTEM............................................................................685 Description.................................................................................685 Inspecting..................................................................................685 Adjusting Switch Position...................................................................686 Troubleshooting (Standard and ACS)..........................................................687 Troubleshooting (Joystick)..................................................................688 Alarm Removal And Installation..............................................................689 Switch Removal And Installation.............................................................689 ENGINE SERVICE......................................................................................691 ENGINE INFORMATION..............................................................................695 Description.................................................................................695 Specifications..............................................................................696 Torque Values...............................................................................700 Troubleshooting.............................................................................700 Engine Removal And Installation.............................................................702 Engine Mount Replacement....................................................................709 Compression - Checking......................................................................710 ENGINE SPEED CONTROL............................................................................711 Removal And Installation....................................................................711 ENGINE SPEED CONTROL (SJC)......................................................................713 Removal And Installation....................................................................713 Disassembly And Assembly....................................................................715 MUFFLER.........................................................................................717 Removal And Installation....................................................................717 AIR CLEANER.....................................................................................719 Housing Removal And Installation............................................................719 ENGINE COOLING SYSTEM...........................................................................721 Radiator Removal And Installation...........................................................721 Blower Housing Removal And Installation.....................................................724 Hydraulic Fan Removal And Installation......................................................726 Hydraulic Fan Description...................................................................727 Hydraulic Fan Disassembly And Assembly......................................................727 Water Pump Removal And Installation.........................................................728 Water Pump Disassembly And Assembly.........................................................728 Thermostat Housing Removal And Installation.................................................729 LUBRICATION SYSTEM..............................................................................731 Oil Pan Removal And Installation............................................................731 Oil Pump Removal And Installation...........................................................731 Oil Pump Inspection.........................................................................732 Engine Oil Pressure - Testing...............................................................733 FUEL SYSTEM.....................................................................................735 Fuel Camshaft Removal And Installation......................................................735 Fuel Camshaft Governor Disassembly And Assembly.............................................736 Fuel Shutoff Solenoid - Checking............................................................737 Fuel Shutoff Solenoid Removal And Installation..............................................737 Fuel Injection Pump Removal And Installation................................................738 Injection Pump - Timing.....................................................................741 Fuel Injector Removal And Installation......................................................743 Fuel Injector Nozzle Pressure - Checking....................................................745 Nozzle Spraying Condition...................................................................745 Valve Seat Tightness........................................................................746 CYLINDER HEAD...................................................................................747 Glow Plugs - Testing........................................................................747 Glow Plugs Removal And Installation.........................................................747 Valve Clearance Adjustment..................................................................748 Valve Timing, Checking......................................................................749 Cylinder Head Removal And Installation......................................................750 Cylinder Head Disassembly and Assembly......................................................753 Cylinder Head - Servicing...................................................................753 Cylinder Head Top Clearance.................................................................754 Valve Guide-Checking........................................................................754 Reconditioning The Valve And Valve Seat.....................................................755 Valve Spring................................................................................757 Valve Tappets...............................................................................758 Rocker Arm And Shaft Checking...............................................................758 CRANKSHAFT AND PISTONS..........................................................................759 Piston And Connecting Rod Removal And Installation..........................................759 Piston And Connecting Rod - Servicing.......................................................760 Cylinder Bore - Checking....................................................................763 Connecting Rod Alignment....................................................................763 Crankshaft Gear Removal And Installation....................................................764 Crankshaft And Bearings Removal And Installation............................................764 Crankshaft And Bearings - Servicing.........................................................766 CAMSHAFT AND TIMING GEARS.......................................................................771 Timing Gearcase Cover Removal And Installation..............................................771 Timing Gears Backlash-Checking..............................................................773 Idler Gear And Camshaft Removal And Installation............................................774 Camshaft - Servicing........................................................................775 Idler Gear And Shaft Servicing..............................................................776 TURBOCHARGER....................................................................................777 Description.................................................................................777 Testing.....................................................................................777 Removal And Installation....................................................................778 FLYWHEEL AND HOUSING............................................................................781 Flywheel Removal And Installation...........................................................781 Ring Gear Removal And Installation..........................................................781 Housing Removal And Installation............................................................782 HEATING, VENTILATION, AIR CONDITIONING..............................................................785 AIR CONDITIONING SYSTEM FLOW....................................................................788 Description.................................................................................788 Chart.......................................................................................789 Components..................................................................................790 Safety Equipment............................................................................793 REGULAR MAINTENANCE.............................................................................795 Filter Elements Removal And Installation....................................................795 Compressor Drive Belt Inspection............................................................796 Condenser...................................................................................797 Air Conditioning Service Chart..............................................................798 Cleaning The A/C Evaporator Coil & Heater Coil..............................................799 TROUBLESHOOTING.................................................................................801 Blower Motor Does Not Operate...............................................................801 Blower Motor Operates Normally, But Air Flow Is Insufficient................................801 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..................801 The Compressor Does Not Operate At All, Or Operates Improperly..............................801 Gauge Pressure Related Troubleshooting......................................................802 Troubleshooting Tree........................................................................804 Temperature/Pressure Chart..................................................................808 Poor A/C Performance........................................................................809 HVAC Repair And Leaks.......................................................................810 Electrical System...........................................................................811 Engine Coolant Bypassing The Heater Valve...................................................818 Heater Valve Not Opening Or Closing.........................................................819 SYSTEM CHARGING AND RECLAMATION.................................................................821 Refrigerant Identification..................................................................821 Reclamation And Charging With Recovery / Charging Unit......................................822 Charging With A Manifold Gauge Set..........................................................824 COMPRESSOR......................................................................................827 Belt Adjustment.............................................................................827 Removal And Installation....................................................................828 Oil.........................................................................................829 Oil Check...................................................................................830 Clutch Disassembly And Assembly.............................................................832 CONDENSER.......................................................................................837 Removal And Installation....................................................................837 RECEIVER/DRIER..................................................................................839 Receiver/Drier Removal And Installation.....................................................839 Pressure Relief Valve Removal And Installation..............................................841 Pressure Switch Removal And Installation....................................................842 Schraeder Valve Removal And Installation....................................................842 EVAPORATOR / HEATER UNIT........................................................................843 Removal And Installation....................................................................843 THERMOSTAT......................................................................................845 Removal And Installation....................................................................845 EXPANSION VALVE.................................................................................847 Removal And Installation....................................................................847 EVAPORATOR......................................................................................849 Removal And Installation....................................................................849 HEATER COIL.....................................................................................851 Removal And Installation With A/C...........................................................851 Removal And Installation Without A/C........................................................853 BLOWER FAN......................................................................................855 Removal And Installation....................................................................855 Disassembly And Assembly....................................................................856 Connector Identification....................................................................858 HEATER VALVE....................................................................................859 Removal And Installation....................................................................859 Disassembly And Assembly....................................................................860 SPECIFICATIONS......................................................................................861 T180 LOADER SPECIFICATIONS......................................................................863 Dimensions..................................................................................863 Performance.................................................................................864 Controls....................................................................................864 Engine......................................................................................865 Hydraulic System............................................................................866 Electrical..................................................................................866 Drive System................................................................................867 Capacities..................................................................................867 Tracks......................................................................................867 Ground Pressure.............................................................................867 TORQUE SPECIFICATIONS FOR BOLTS.................................................................869 Torque For General SAE Bolts................................................................869 Torque For General Metric Bolts.............................................................870 HYDRAULIC CONNECTION SPECIFICATIONS.............................................................871 O-ring Face Seal Connection.................................................................871 Straight Thread O-ring Fitting..............................................................872 Tubelines And Hoses.........................................................................872 Flare Fitting...............................................................................873 Port Seal Fitting...........................................................................874 HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS......................................................875 Specifications..............................................................................875 CONVERSIONS.....................................................................................877 Decimal And Millimeter Equivalents..........................................................877 U.S. To Metric Conversion Chart.............................................................877 SERVICE MANUAL REVISION.............................................................................879 Revision No: T180 - 1...........................................................................879 Revision No: T180 - 2...........................................................................881 Revision No: T180 - 3...........................................................................883 Revision No: T180 - 4...........................................................................885 Revision No: T180 - 5...........................................................................887 Revision No: T180 - 6...........................................................................889 Revision No: T180 - 7...........................................................................891 Revision No: T180 - 8...........................................................................893 Revision No: T180 - 9...........................................................................895 Revision No: T180 - 10..........................................................................897 Revision No: T180 - 11..........................................................................899
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- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
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S.V
