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Bobcat T180 Compact Track Loader Service Manual 6987042 (11-10) – PDF DOWNLOAD
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Bobcat T180 Compact Track Loader Service Manual 6987042 (11-10) – PDF DOWNLOAD
S/N 531460001 & Above
S/N 531560001 & Above
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Description
Bobcat T180 Compact Track Loader Service Manual 6987042 (11-10) – PDF DOWNLOAD
FILE DETAILS:
Bobcat T180 Compact Track Loader Service Manual 6987042 (11-10) – PDF DOWNLOAD
Language : English
Pages : 884
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T180 Compact Track Loader Service Manual 6987042 (11-10) – PDF DOWNLOAD
S/N 531460001 & Above
S/N 531560001 & Above
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 6987042 (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............................................................. 21 Procedure............................................................................... 21 LIFT ARM SUPPORT DEVICE..................................................................... 23 Installing.............................................................................. 23 Removing................................................................................ 24 OPERATOR CAB................................................................................ 25 Description............................................................................. 25 Raising................................................................................. 26 Lowering................................................................................ 27 Cab Door Sensor......................................................................... 28 Special Applications Kit................................................................ 28 Special Applications Kit Inspection And Maintenance..................................... 28 TRANSPORTING THE LOADER ON A TRAILER........................................................ 29 Loading And Unloading................................................................... 29 Fastening............................................................................... 29 TOWING THE LOADER........................................................................... 31 Procedure............................................................................... 31 REMOTE START TOOL KIT-MEL1563............................................................... 33 Remote Start Tool - MEL1563............................................................. 33 Service Tool Harness Control - MEL1565.................................................. 34 Service Tool Harness Communicator - MEL1566............................................. 35 Remote Start Procedure.................................................................. 36 REMOTE START TOOL (SERVICE TOOL) KIT - 6689779.............................................. 39 Description............................................................................. 39 Remote Start Tool (Service Tool) - 6689778.............................................. 40 Loader Service Tool Harness - 6689747................................................... 41 Computer Service Tool Harness - 6689746................................................. 42 Remote Start Procedure.................................................................. 43 SERVICE SCHEDULE............................................................................ 47 Chart................................................................................... 47 AIR CLEANER SERVICE......................................................................... 49 Replacing Filter Elements............................................................... 49 ENGINE COOLING SYSTEM....................................................................... 51 Cleaning................................................................................ 51 Checking Level.......................................................................... 52 Removing And Replacing Coolant.......................................................... 52 FUEL SYSTEM................................................................................. 53 Fuel Specifications..................................................................... 53 Biodiesel Blend Fuel.................................................................... 53 Filling The Fuel Tank................................................................... 54 Fuel Filter............................................................................. 55 Removing Air From The Fuel System....................................................... 55 ENGINE LUBRICATION SYSTEM................................................................... 57 Checking And Adding Engine Oil.......................................................... 57 Engine Oil Chart........................................................................ 57 Removing And Replacing Oil And Filter................................................... 57 HYDRAULIC / HYDROSTATIC SYSTEM.............................................................. 59 Checking And Adding Fluid............................................................... 59 Hydraulic / Hydrostatic Fluid Chart..................................................... 59 Removing And Replacing Hydraulic Fluid.................................................. 60 Removing And Replacing Hydraulic / Hydrostatic Filter................................... 61 Removing And Replacing Case Drain Filters............................................... 62 Removing And Replacing Hydraulic Charge Filter.......................................... 63 Breather Cap............................................................................ 63 BOB-TACH (HAND LEVER)....................................................................... 65 Inspection And Maintenance.............................................................. 65 BOB-TACH (POWER)............................................................................ 67 Inspection And Maintenance.............................................................. 67 LUBRICATING THE LOADER...................................................................... 69 Lubrication Locations................................................................... 69 SPARK ARRESTOR MUFFLER...................................................................... 71 Cleaning Procedure...................................................................... 71 PIVOT PINS.................................................................................. 73 Inspection And Maintenance.............................................................. 73 LOADER STORAGE AND RETURN TO SERVICE........................................................ 75 Storage................................................................................. 75 Return To Service....................................................................... 75 STOPPING THE ENGINE AND LEAVING THE LOADER.................................................. 77 Procedure............................................................................... 77 Emergency Exit.......................................................................... 78 HYDRAULIC SYSTEM................................................................................ 79 HYDRAULIC / HYDROSTATIC SCHEMATICS.......................................................... 83 HYDRAULIC SYSTEM INFORMATION................................................................ 91 Glossary Of Hydraulic / Hydrostatic Symbols............................................. 91 Troubleshooting......................................................................... 95 CYLINDER (LIFT)............................................................................. 97 Testing................................................................................. 97 Removal And Installation................................................................ 98 Parts Identification.................................................................... 99 Disassembly And Assembly................................................................100 CYLINDER (TILT).............................................................................103 Testing.................................................................................103 Removal And Installation................................................................104 Rod End Pivot Pin Bushing And Seal Removal And Installation.............................106 Base End Pivot Pin Removal And Installation.............................................106 Parts Identification....................................................................107 Disassembly And Assembly................................................................108 CYLINDER (BOB-TACH).........................................................................111 Testing.................................................................................111 Removal And Installation................................................................112 Parts Identification....................................................................113 Disassembly And Assembly................................................................114 MAIN RELIEF VALVE...........................................................................117 Description.............................................................................117 Testing.................................................................................117 Adjusting...............................................................................119 Removal and Installation................................................................120 HYDRAULIC CONTROL VALVE (STANDARD)..........................................................121 Description.............................................................................121 Removal And Installation................................................................121 Identification Chart....................................................................126 Mount Bracket Removal And Installation..................................................127 Lift Load Check Valve Removal And Installation..........................................127 Load Check Valve Removal And Installation (Tilt & Auxiliary)............................128 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................129 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........130 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........130 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............131 Port Relief Valve Removal And Installation..............................................131 Plug Removal And Installation...........................................................132 Rubber Boot Removal And Installation....................................................133 End Cap / Spool Lock Block Removal And Installation.....................................134 Lift Spool And Detent Removal And Installation..........................................135 Tilt Spool Removal And Installation.....................................................145 Auxiliary Spool Removal And Installation................................................147 Auxiliary Solenoid Removal And Installation.............................................148 Solenoid Removal And Installation.......................................................149 Lock Valve Removal And Installation.....................................................151 Lift Arm Bypass Orifice Removal And Installation........................................153 Main Relief Valve Removal And Installation..............................................153 Check Valve Removal And Installation....................................................154 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)......................................................155 Description.............................................................................155 Removal And Installation................................................................155 Actuator Removal And Installation (Out of Loader).......................................160 Identification Chart....................................................................163 Mount Bracket Removal And Installation..................................................164 Lift Load Check Valve Removal And Installation..........................................164 Load Check Valve Removal And Installation (Tilt & Auxiliary)............................165 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................166 Port Relief/Anti-Cavitation Valve Removal And Installation (Lift, Base End).............167 Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Base End).............167 Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)..............168 Port Relief Valve Removal And Installation..............................................168 Plug Removal And Installation...........................................................169 End Cap Block Removal And Installation..................................................170 Lift Spool And Detent Removal And Installation..........................................171 Tilt Spool Removal And Installation.....................................................176 Auxiliary Spool Removal And Installation................................................178 Auxiliary Solenoid Removal And Installation.............................................179 Solenoid Removal And Installation.......................................................180 Lock Valve Removal And Installation.....................................................182 Lift Arm Bypass Orifice Removal And Installation........................................184 Main Relief Valve Removal And Installation..............................................185 Check Valve Removal And Installation....................................................186 LIFT ARM BYPASS CONTROL VALVE...............................................................187 Description.............................................................................187 Testing.................................................................................187 Removal and Installation................................................................187 Disassembly And Assembly................................................................188 HYDRAULIC PUMP (STANDARD)...................................................................189 Description.............................................................................189 Pump Test at Quick Couplers.............................................................189 Direct Pump Test (Standard Section).....................................................190 Direct Pump Test (Charge Section).......................................................192 Removal And Installation................................................................194 Hydraulic Pump Startup..................................................................196 Parts Identification....................................................................197 Disassembly And Assembly................................................................198 HYDRAULIC PUMP (STANDARD) (HIGH FLOW).......................................................207 Description.............................................................................207 Pump Test at Quick Couplers.............................................................207 Direct Pump Test (Standard Section).....................................................208 Direct Pump Test (Charge Section).......................................................210 Direct Pump Test (High Flow Section)....................................................212 Removal And Installation................................................................214 Hydraulic Pump Startup..................................................................216 Parts Identification....................................................................217 Disassembly And Assembly................................................................218 HYDRAULIC PUMP (SJC)........................................................................231 Description.............................................................................231 Pump Test At Quick Couplers.............................................................231 Direct Pump Test (Standard Section).....................................................232 Direct Pump Test (Charge Section).......................................................234 Removal And Installation................................................................236 Hydraulic Pump Startup..................................................................238 Parts Identification....................................................................239 Disassembly And Assembly................................................................240 HYDRAULIC PUMP (SJC) (HIGH FLOW)............................................................249 Description.............................................................................249 Pump Test at Quick Couplers.............................................................249 Direct Pump Test (Standard Section).....................................................250 Direct Pump Test (Charge Section).......................................................252 Direct Pump Test (High Flow Section)....................................................254 Removal And Installation................................................................256 Hydraulic Pump Startup..................................................................258 Parts Identification....................................................................259 Disassembly And Assembly................................................................260 Hydraulic Pump Startup..................................................................272 HYDRAULIC / HYDROSTATIC FILTERS.............................................................273 Description.............................................................................273 Housing Removal And Installation........................................................273 Charge Filter Housing Removal And Installation..........................................275 HYDRAULIC FLUID RESERVOIR...................................................................277 Description.............................................................................277 Removal And Installation................................................................277 Hydraulic Fluid Screen..................................................................279 OIL COOLER..................................................................................281 Description.............................................................................281 Removal And Installation................................................................281 BUCKET POSITION VALVE.......................................................................283 Description.............................................................................283 Solenoid Removal And Installation.......................................................283 Solenoid Testing........................................................................284 Removal And Installation................................................................285 Disassembly And Assembly................................................................286 REAR AUXILIARY DIVERTER VALVE...............................................................289 Description.............................................................................289 Solenoid Testing........................................................................289 Removal And Installation................................................................290 Disassembly And Assembly................................................................293 BOB-TACH (POWER) BLOCK......................................................................299 Description.............................................................................299 Removal And Installation................................................................299 Disassembly And Assembly................................................................301 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK.....................................................305 Description.............................................................................305 Removal And Installation................................................................305 Disassembly And Assembly................................................................305 HIGH FLOW VALVE.............................................................................307 Description.............................................................................307 High Flow Relief Valve Testing..........................................................307 High Flow Relief Valve Adjustment.......................................................308 Solenoid Testing........................................................................309 Removal And Installation................................................................310 Disassembly And Assembly................................................................311 HYDROSTATIC SYSTEM..............................................................................315 HYDROSTATIC SYSTEM INFORMATION..............................................................317 Description.............................................................................317 Troubleshooting.........................................................................318 HYDROSTATIC MOTOR...........................................................................319 Description.............................................................................319 Removing And Replacing Oil..............................................................320 Removal And Installation................................................................322 Parts Identification....................................................................324 Disassembly And Assembly................................................................326 CHARGE PRESSURE.............................................................................337 Description.............................................................................337 Testing.................................................................................337 Sender Removal And Installation.........................................................339 Adjusting...............................................................................340 HYDROSTATIC PUMP............................................................................343 Description.............................................................................343 Replenishing / High Pressure Relief Valve Removal And Installation......................344 Removal And Installation................................................................345 Hydrostatic Pump Startup................................................................347 Parts Identification (Left Half)........................................................348 Parts Identification (Right Half).......................................................349 Disassembly.............................................................................350 Assembly................................................................................356 HYDROSTATIC PUMP (SJC)......................................................................363 Description.............................................................................363 Hydraulic Controller Removal And Installation...........................................364 Removal And Installation................................................................366 Hydrostatic Pump Startup................................................................368 Parts Identification....................................................................369 High Pressure Relief And Bypass Valve...................................................370 Charge Relief Valve.....................................................................371 Disassembly And Assembly................................................................372 Mechanical Neutral Adjustment...........................................................388 Hydraulic Controller Neutral Adjustment.................................................391 DRIVE BELT..................................................................................395 Description.............................................................................395 Shield Removal And Installation.........................................................395 Adjusting...............................................................................396 Belt Removal And Installation...........................................................397 Tensioner Pulley Removal And Installation...............................................398 Tensioner Pulley Parts Identification...................................................399 Tensioner Pulley Disassembly............................................................400 Tensioner Pulley Assembly...............................................................401 CASE DRAIN FILTER...........................................................................403 Description.............................................................................403 Disassembly And Assembly................................................................403 DRIVE SYSTEM....................................................................................405 BRAKE.......................................................................................407 Description.............................................................................407 Right Motor Brake Test..................................................................407 Left Motor Brake Test...................................................................408 Block Removal And Installation..........................................................409 Block Disassembly And Assembly..........................................................411 TRACK CARRIAGE COMPONENTS...................................................................413 Description.............................................................................413 Checking Tension........................................................................414 Adjusting Tension.......................................................................415 Track Removal And Installation..........................................................417 Idler (Front) Removal And Installation..................................................420 Idler (Rear) Removal And Installation...................................................422 Roller Removal And Installation.........................................................422 Sprocket Removal And Installation.......................................................423 Track Housing Removal And Installation..................................................424 Track Damage Identification.............................................................426 MAIN FRAME......................................................................................439 SEAT BAR....................................................................................443 Description.............................................................................443 Removal And Installation................................................................443 Disassembly And Assembly................................................................444 Compression Spring Disassembly And Assembly.............................................446 OPERATOR CAB................................................................................447 Gas Cylinder Removal And Installation...................................................447 Gas Cylinder Bracket Disassembly And Assembly...........................................449 Removal And Installation................................................................450 OPERATOR SEAT (SUSPENSION)..................................................................453 Removal And Installation................................................................453 Slide Rail Removal And Installation.....................................................454 Seat Belt Removal and Installation......................................................454 Lower Cushion Removal And Installation..................................................455 Back Cushion Removal And Installation...................................................456 Shock Removal And Installation..........................................................456 3-Point Seat Belt Removal And Installation..............................................457 BOB-TACH (HAND LEVER).......................................................................459 Description.............................................................................459 Removal And Installation................................................................459 Lever And Wedge Disassembly And Assembly................................................460 Pivot Pin Bushing And Seal Removal And Installation.....................................462 BOB-TACH (POWER)............................................................................463 Description.............................................................................463 Removal And Installation................................................................463 Lever And Wedge Disassembly And Assembly................................................465 Pivot Pin Bushing And Seal Removal And Installation.....................................466 LIFT ARMS...................................................................................467 Removal And Installation................................................................467 REAR GRILL..................................................................................471 Removal And Installation................................................................471 REAR DOOR...................................................................................473 Removal And Installation................................................................473 Striker Removal And Installation........................................................474 Striker Disassembly And Assembly........................................................474 Striker (Adjusting).....................................................................474 Latch Removal And Installation..........................................................475 FUEL TANK...................................................................................477 Removal And Installation................................................................477 Fuel Level Sender Removal And Installation..............................................478 Fuel Fill Screen Removal And Installation...............................................478 CONTROL PEDALS AND LINKAGES.................................................................479 Description.............................................................................479 Pedal Removal And Installation..........................................................479 Linkage Removal And Installation........................................................480 Pedal (Adjusting).......................................................................482 CONTROL PEDALS (ACS)........................................................................483 Description.............................................................................483 Foot Sensor Removal And Installation....................................................483 Foot Pedal Removal And Installation.....................................................484 Foot Pedal Linkage Disassembly And Assembly.............................................485 CONTROL PANEL...............................................................................487 Description.............................................................................487 Removal And Installation................................................................488 Shock Removal And Installation..........................................................491 Shaft Removal And Installation..........................................................491 Shaft Disassembly And Assembly..........................................................492 Linkage Removal And Installation........................................................493 Pintle Arm Disassembly And Assembly.....................................................497 Linkage Neutral (Adjusting).............................................................499 Linkage Travel (Adjusting)..............................................................503 CONTROL PANEL (SJC).........................................................................507 Description.............................................................................507 Removal And Installation................................................................507 CONTROL HANDLE / LEVER......................................................................509 Description.............................................................................509 Lever Removal And Installation..........................................................509 Boot Removal And Installation...........................................................510 CONTROL HANDLE / LEVER (ACS)................................................................511 Description.............................................................................511 Handle Sensor Removal And Installation..................................................511 Handle Removal And Installation.........................................................514 Handle Disassembly And Assembly.........................................................515 Lever Removal And Installation..........................................................515 Boot Removal And Installation...........................................................517 CONTROL HANDLE / LEVER (SJC)................................................................519 Description.............................................................................519 Joystick Testing........................................................................519 Joystick Removal And Installation.......................................................520 Joystick Mount Removal And Installation.................................................521 ACCESS PANEL (INSIDE).......................................................................523 Removal And Installation (Left).........................................................523 Removal And Installation (Right)........................................................523 ACCESS PANEL (INSIDE) (SJC).................................................................525 Removal And Installation (Left).........................................................525 Removal And Installation (Right)........................................................526 WINDOW (REAR)...............................................................................529 Removal.................................................................................529 Installation (Split Molding)............................................................529 Installation (Continuous Molding).......................................................531 WINDOW (TOP)................................................................................533 Removal And Installation................................................................533 WINDOW (SIDE)...............................................................................535 Removal And Installation................................................................535 WINDOW (CAB DOOR)...........................................................................537 Removal (Standard Window)...............................................................537 Installation (Standard Window)..........................................................538 Removal And Installation (Special Applications Window)..................................540 CAB DOOR....................................................................................541 Description.............................................................................541 Removal And Installation................................................................541 Aligning................................................................................542 Adjusting...............................................................................543 Checking Operation......................................................................543 ELECTRICAL SYSTEM & ANALYSIS....................................................................545 ELECTRICAL SCHEMATICS.......................................................................549 ELECTRICAL SYSTEM INFORMATION...............................................................555 Glossary Of Electrical Symbols..........................................................555 Standard Cab Harness Connectors.........................................................558 Deluxe Cab Harness Connectors...........................................................559 Mainframe Harness Connectors............................................................560 Description.............................................................................561 Troubleshooting.........................................................................562 Fuse And Relay Location / Identification................................................563 Solenoid Testing........................................................................564 BATTERY.....................................................................................565 Removal And Installation................................................................565 Servicing...............................................................................566 Using A Booster Battery (Jump Starting).................................................567 ALTERNATOR..................................................................................569 Belt Adjustment.........................................................................569 Belt Replacement........................................................................569 Charging System Inspection..............................................................570 Alternator Voltage Testing..............................................................571 Low Voltage Testing.....................................................................571 High Voltage Testing....................................................................572 Removal And Installation................................................................573 Parts Identification....................................................................574 STARTER.....................................................................................575 Testing.................................................................................575 Removal And Installation................................................................576 Parts Identification....................................................................577 INSTRUMENT PANELS...........................................................................579 Left Panel..............................................................................579 Standard Key Panel......................................................................581 Deluxe Instrumentation Panel............................................................582 Side Panel..............................................................................583 Front Panel.............................................................................583 Front Panel Removal And Installation....................................................584 Removal And Installation (Left And Right)...............................................585 Key Switch Removal And Installation.....................................................586 Alarm Removal And Installation..........................................................587 LIGHTS......................................................................................589 Front Removal And Installation..........................................................589 Rear Removal And Installation...........................................................590 Cab Light Removal And Installation......................................................590 BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)...................................................591 Description.............................................................................591 Connector Identification................................................................592 Removal and Installation................................................................598 BOBCAT CONTROLLER (ACS).....................................................................601 Description.............................................................................601 Connector And Wire Identification.......................................................602 Removal And Installation................................................................603 BOBCAT CONTROLLER (SJC) (DRIVE).............................................................605 Description.............................................................................605 Connector Identification................................................................606 Removal and Installation................................................................608 SPEED SENSOR (SJC)..........................................................................609 Description.............................................................................609 Testing.................................................................................609 Removal And Installation................................................................611 DIAGNOSTIC SERVICE CODES....................................................................615 Viewing Service Codes (Standard Key Panel)..............................................615 Viewing Service Codes (Deluxe Instrumentation Panel)....................................615 Service Codes List......................................................................616 BOBCAT INTERLOCK CONTROL SYSTEM (BICS)......................................................621 Description.............................................................................621 Inspecting The BICS Controller (Engine STOPPED - Key ON)................................622 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....622 Inspecting The Seat Bar Sensor (Engine RUNNING).........................................622 Inspecting The Traction Lock (Engine RUNNING)...........................................622 Inspecting The Lift Arm Bypass Control..................................................622 Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)........................622 Troubleshooting.........................................................................623 SEAT BAR SENSOR.............................................................................625 Description.............................................................................625 Troubleshooting.........................................................................625 Testing.................................................................................626 Removal And Installation................................................................627 Bobcat Interlock Control System (BICS) Circuit Test.....................................629 TRACTION LOCK...............................................................................631 Description.............................................................................631 Troubleshooting.........................................................................632 Inspecting..............................................................................633 CONTROL SYSTEM (ACS)........................................................................635 Description.............................................................................635 Troubleshooting.........................................................................636 Handle Sensor Connector Disassembly And Assembly........................................637 Switch Handle Removal...................................................................638 Switch Handle Installation..............................................................640 Actuator Connector Disassembly And Assembly.............................................643 Handle Lock Solenoid Removal And Installation...........................................644 Handle Lock Solenoid Disassembly And Assembly...........................................644 Foot Sensor Disassembly And Assembly....................................................645 Foot Lock Solenoid Removal And Installation.............................................646 ELECTRICAL / HYDRAULIC CONTROLS.............................................................647 Identification Chart....................................................................647 ELECTRICAL / HYDRAULIC CONTROLS (SJC).......................................................649 Identification Chart....................................................................649 SERVICE PC (LAPTOP COMPUTER)................................................................653 Connecting Remote Start Tool............................................................653 Connecting Remote Start Tool (Service Tool).............................................653 CALIBRATION.................................................................................655 Description.............................................................................655 Actuator Testing........................................................................655 Lift And Tilt Calibration (ACS).........................................................657 Lift And Tilt Calibration (SJC).........................................................659 Hydrostatic Pump Calibration (SJC)......................................................661 STEERING DRIFT COMPENSATION.................................................................667 Description.............................................................................667 Operation...............................................................................667 FLYWHEEL RPM SENSOR.........................................................................669 Description.............................................................................669 Adjusting...............................................................................669 CONTROL PANEL SETUP.........................................................................671 Right Panel Setup (Deluxe Instrumentation Panel)........................................671 Attachment Control Information (Deluxe Instrumentation Panel)...........................672 PASSWORD SETUP..............................................................................673 Password Description....................................................................673 Changing The Owner Password.............................................................673 Changing The User Passwords.............................................................674 Password Lockout Feature................................................................674 MAINTENANCE CLOCK...........................................................................675 Description.............................................................................675 Setup...................................................................................676 Reset...................................................................................679 BACK-UP ALARM SYSTEM........................................................................681 Description.............................................................................681 Inspecting..............................................................................681 Adjusting Switch Position...............................................................682 Troubleshooting (Standard and ACS)......................................................683 Troubleshooting (Joystick)..............................................................684 Alarm Removal And Installation..........................................................685 Switch Removal And Installation.........................................................685 ENGINE SERVICE..................................................................................687 ENGINE INFORMATION..........................................................................691 Description.............................................................................691 Specifications..........................................................................692 Torque Values...........................................................................696 Troubleshooting.........................................................................696 Engine Removal And Installation.........................................................698 Engine Mount Replacement................................................................705 Compression - Checking..................................................................706 ENGINE SPEED CONTROL........................................................................707 Removal And Installation................................................................707 ENGINE SPEED CONTROL (SJC)..................................................................709 Removal And Installation................................................................709 Disassembly And Assembly................................................................711 MUFFLER.....................................................................................713 Removal And Installation................................................................713 AIR CLEANER.................................................................................715 Housing Removal And Installation........................................................715 ENGINE COOLING SYSTEM.......................................................................717 Radiator Removal And Installation.......................................................717 Hydraulic Fan Description...............................................................720 Hydraulic Fan Disassembly And Assembly..................................................720 Blower Housing Removal And Installation.................................................721 Fan Removal And Installation............................................................723 Hydraulic Fan Motor Removal And Installation............................................723 Water Pump Removal And Installation.....................................................724 Water Pump Disassembly And Assembly.....................................................724 Thermostat Housing Removal And Installation.............................................725 Thermostat - Checking...................................................................726 LUBRICATION SYSTEM..........................................................................727 Oil Pan Removal And Installation........................................................727 Oil Pump Removal And Installation.......................................................727 Oil Pump Inspection.....................................................................728 Engine Oil Pressure - Testing...........................................................729 FUEL SYSTEM.................................................................................731 Fuel Shutoff Solenoid - Checking........................................................731 Fuel Shutoff Solenoid Removal And Installation..........................................731 Fuel Injection Pump - Checking..........................................................732 Fuel Injection Pump Removal And Installation............................................733 Governor Disassembly And Assembly.......................................................737 Fuel Camshaft Removal And Installation..................................................738 Injection Pump - Timing.................................................................739 Fuel Injector Removal And Installation..................................................741 Fuel Injector Nozzle Pressure - Checking................................................742 Nozzle Spray Condition..................................................................743 Valve Seat Tightness....................................................................743 CYLINDER HEAD...............................................................................745 Glow Plugs - Testing....................................................................745 Glow Plugs Removal And Installation.....................................................745 Valve Clearance Adjustment..............................................................746 Valve Timing - Checking.................................................................747 Cylinder Head Removal And Installation..................................................748 Cylinder Head Disassembly and Assembly..................................................751 Cylinder Head - Servicing...............................................................751 Cylinder Head Top Clearance.............................................................752 Valve Guide - Checking..................................................................752 Reconditioning The Valve And Valve Seat.................................................753 Valve Spring............................................................................755 Valve Tappets...........................................................................756 Rocker Arm And Shaft Checking...........................................................756 Push Rod Alignment - Checking...........................................................757 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 Filters.................................................................................795 Compressor Drive Belt Adjustment........................................................796 Compressor Drive Belt Replacement.......................................................796 Condenser...............................................................................796 Air Conditioning Lubrication............................................................796 Air Conditioning Service Chart..........................................................797 Evaporator / Heater Coil................................................................798 TROUBLESHOOTING.............................................................................799 Blower Motor Does Not Operate...........................................................799 Blower Motor Operates Normally, But Air Flow Is Insufficient............................799 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..............799 The Compressor Does Not Operate At All, Or Operates Improperly..........................799 Gauge Pressure Related Troubleshooting..................................................800 Troubleshooting Tree....................................................................802 Temperature / Pressure Chart............................................................806 Poor A/C Performance....................................................................807 HVAC Repair And Leaks...................................................................808 Electrical System.......................................................................809 Engine Coolant Bypassing The Heater Valve...............................................816 Heater Valve Not Opening Or Closing.....................................................817 SYSTEM CHARGING AND RECLAMATION.............................................................819 Refrigerant Identification..............................................................819 Reclamation And Charging With Recovery / Charging Unit..................................820 Charging With A Manifold Gauge Set......................................................822 COMPRESSOR..................................................................................825 Removal And Installation................................................................825 Oil.....................................................................................826 Oil Check...............................................................................827 Clutch Disassembly And Assembly.........................................................829 CONDENSER...................................................................................833 Removal And Installation................................................................833 RECEIVER / DRIER............................................................................835 Receiver / Drier Removal And Installation...............................................835 Pressure Relief Valve Removal And Installation..........................................837 Pressure Switch Removal And Installation................................................838 Schraeder Valve Removal And Installation................................................838 EVAPORATOR / HEATER UNIT....................................................................839 Removal And Installation................................................................839 THERMOSTAT..................................................................................841 Removal And Installation................................................................841 EXPANSION VALVE.............................................................................843 Removal And Installation................................................................843 EVAPORATOR COIL.............................................................................845 Removal And Installation................................................................845 HEATER COIL.................................................................................847 Removal And Installation With A/C.......................................................847 Removal And Installation Without A/C....................................................849 BLOWER FAN..................................................................................851 Removal And Installation................................................................851 Disassembly And Assembly................................................................852 Connector Identification................................................................854 HEATER VALVE................................................................................855 Removal And Installation................................................................855 Disassembly And Assembly................................................................856 SPECIFICATIONS..................................................................................857 T180 LOADER SPECIFICATIONS..................................................................859 Dimensions..............................................................................859 Performance.............................................................................860 Controls................................................................................860 Engine..................................................................................861 Hydraulic System........................................................................862 Electrical..............................................................................862 Drive System............................................................................863 Capacities..............................................................................863 Tracks..................................................................................863 Ground Pressure.........................................................................863 TORQUE SPECIFICATIONS FOR BOLTS.............................................................865 Torque For General SAE Bolts............................................................865 Torque For General Metric Bolts.........................................................866 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................867 O-ring Face Seal Connection.............................................................867 Straight Thread O-ring Fitting..........................................................868 Tubelines And Hoses.....................................................................868 Flare Fitting...........................................................................869 Port Seal Fitting.......................................................................870 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS................................................871 Specifications..........................................................................871 CONVERSIONS.................................................................................873 Decimal And Millimeter Equivalents......................................................873 U.S. To Metric Conversion Chart.........................................................873 SERVICE MANUAL REVISION.........................................................................875 Revision No: T180 - 1.......................................................................875 Revision No: T180 - 2.......................................................................877 Revision No: T180 - 3.......................................................................879 Revision No: T180 - 4.......................................................................881 Revision No: T180 - 5.......................................................................883
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