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Bobcat T180 Compact Track Loader Service Manual SN A3LL11001 & Above – PDF DOWNLOAD
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Bobcat T180 Compact Track Loader Service Manual SN A3LL11001 & Above – PDF DOWNLOAD
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Description
Bobcat T180 Compact Track Loader Service Manual SN A3LL11001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat T180 Compact Track Loader Service Manual SN A3LL11001 & Above – PDF DOWNLOAD
Language : English
Pages : 1000
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T180 Compact Track Loader Service Manual SN A3LL11001 & Above – PDF DOWNLOAD
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 SN A3LL11001 & Above – PDF DOWNLOAD
MAINTENANCE SAFETY.............................................................................. 3 CONTENTS........................................................................................ 5 FOREWORD........................................................................................ 7 FOREWORD.................................................................................... 9 SAFETY INSTRUCTIONS......................................................................... 11 FIRE PREVENTION............................................................................. 13 Maintenance............................................................................. 13 Operation............................................................................... 13 Electrical.............................................................................. 13 Hydraulic System........................................................................ 13 Fueling................................................................................. 13 Starting................................................................................ 13 Spark Arrester 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 AND 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 Communicator - MEL1566............................................. 35 Remote Start Procedure.................................................................. 36 REMOTE START TOOL (SERVICE TOOL) KIT - 7003031.............................................. 39 Description............................................................................. 39 Remote Start Tool (Service Tool) - 7003030.............................................. 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................................................... 58 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............................................................................ 64 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 ARRESTER 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.............................................................................. 79 Rear Window............................................................................. 79 Front Door.............................................................................. 79 SEAT BELT................................................................................... 81 Inspection And Maintenance.............................................................. 81 HYDRAULIC SYSTEM................................................................................ 83 HYDRAULIC/HYDROSTATIC SCHEMATICS............................................................ 89 HYDRAULIC SYSTEM INFORMATION................................................................ 97 Glossary Of Hydraulic / Hydrostatic Symbols............................................. 97 Troubleshooting.........................................................................101 CYLINDER (LIFT).............................................................................103 Testing.................................................................................103 Removal And Installation................................................................104 Parts Identification....................................................................105 Disassembly And Assembly................................................................106 CYLINDER (TILT).............................................................................109 Testing.................................................................................109 Removal And Installation................................................................110 Rod End Pivot Pin Bushing And Seal Removal And Installation.............................112 Base End Pivot Pin Removal And Installation.............................................112 Parts Identification....................................................................113 Disassembly And Assembly................................................................114 CYLINDER (BOB-TACH).........................................................................117 Testing.................................................................................117 Removal And Installation................................................................118 Parts Identification....................................................................119 Disassembly And Assembly................................................................120 MAIN RELIEF VALVE...........................................................................123 Description.............................................................................123 Testing.................................................................................123 Adjusting...............................................................................125 Removal And Installation................................................................126 HYDRAULIC CONTROL VALVE (STANDARD)..........................................................127 Description.............................................................................127 Removal And Installation................................................................128 Identification Chart....................................................................133 Mount Bracket Removal And Installation..................................................134 Lift Load Check Valve Removal And Installation..........................................134 Load Check Valve Removal And Installation (Tilt And Auxiliary)..........................135 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................136 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........137 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........137 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............138 Port Relief Valve Removal And Installation..............................................138 Plug Removal And Installation...........................................................139 Rubber Boot Removal And Installation....................................................140 End Cap / Spool Lock Block Removal And Installation.....................................141 Lift Spool And Detent Removal And Installation..........................................142 Tilt Spool Removal And Installation.....................................................152 Auxiliary Spool Removal And Installation................................................154 Auxiliary Solenoid Removal And Installation (S/N A3LL34999 & Below).....................156 Auxiliary Solenoid Removal And Installation (S/N A3LL35001 & Above).....................157 Solenoid Removal And Installation.......................................................158 Lock Valve Removal And Installation.....................................................159 Lift Arm Bypass Orifice Removal And Installation........................................161 Main Relief Valve Removal And Installation..............................................161 Check Valve Removal And Installation....................................................162 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)......................................................163 Description.............................................................................163 Removal And Installation................................................................164 Actuator Removal And Installation (Out of Loader).......................................168 Identification Chart....................................................................171 Mount Bracket Removal And Installation..................................................172 Lift Load Check Valve Removal And Installation..........................................172 Load Check Valve Removal And Installation (Tilt And Auxiliary)..........................173 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................174 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........175 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........175 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............176 Port Relief Valve Removal And Installation..............................................176 Plug Removal And Installation...........................................................177 End Cap Block Removal And Installation..................................................178 Lift Spool And Detent Removal And Installation..........................................179 Tilt Spool Removal And Installation.....................................................184 Auxiliary Spool Removal And Installation................................................186 Auxiliary Solenoid Removal And Installation (S/N A3LL34999 & Below).....................188 Auxiliary Solenoid Removal And Installation (S/N A3LL35001 & Above).....................189 Solenoid Removal And Installation.......................................................190 Lock Valve Removal And Installation.....................................................191 Lift Arm Bypass Orifice Removal And Installation........................................193 Main Relief Valve Removal And Installation..............................................193 Check Valve Removal And Installation....................................................194 LIFT ARM BYPASS CONTROL VALVE...............................................................195 Description.............................................................................195 Testing.................................................................................195 Removal And Installation................................................................195 Disassembly And Assembly................................................................196 HYDRAULIC PUMP (STANDARD)...................................................................197 Description.............................................................................197 Pump Test At Quick Couplers.............................................................197 Direct Pump Test (Standard Section).....................................................198 Direct Pump Test (Charge Section).......................................................200 Removal And Installation................................................................202 Hydraulic Pump Startup..................................................................204 Parts Identification....................................................................205 Disassembly And Assembly................................................................206 HYDRAULIC PUMP (STANDARD) (HIGH FLOW).......................................................215 Description.............................................................................215 Pump Test At Quick Couplers.............................................................215 Direct Pump Test (Standard Section).....................................................216 Direct Pump Test (Charge Section).......................................................218 Direct Pump Test (High Flow Section)....................................................220 Removal And Installation................................................................222 Hydraulic Pump Startup..................................................................224 Parts Identification....................................................................225 Disassembly And Assembly................................................................226 HYDRAULIC PUMP (SJC)........................................................................239 Description.............................................................................239 Pump Test At Quick Couplers.............................................................239 Direct Pump Test (Standard Section).....................................................240 Direct Pump Test (Charge Section).......................................................242 Removal And Installation................................................................244 Hydraulic Pump Startup..................................................................246 Parts Identification....................................................................247 Disassembly And Assembly................................................................248 HYDRAULIC PUMP (SJC) (HIGH FLOW)............................................................257 Description.............................................................................257 Pump Test At Quick Couplers.............................................................257 Direct Pump Test (Standard Section).....................................................258 Direct Pump Test (Charge Section).......................................................260 Direct Pump Test (High Flow Section)....................................................262 Removal And Installation................................................................264 Hydraulic Pump Startup..................................................................266 Parts Identification....................................................................267 Disassembly And Assembly................................................................268 HYDRAULIC / HYDROSTATIC FILTERS.............................................................281 Description.............................................................................281 Housing Removal And Installation........................................................281 Charge Filter Housing Removal And Installation..........................................283 HYDRAULIC FLUID RESERVOIR...................................................................285 Description.............................................................................285 Removal And Installation................................................................285 Hydraulic Fluid Screen..................................................................287 OIL COOLER..................................................................................289 Description.............................................................................289 Removal And Installation................................................................289 BUCKET POSITION VALVE.......................................................................291 Description.............................................................................291 Solenoid Removal And Installation.......................................................291 Solenoid Testing........................................................................292 Removal And Installation................................................................293 Disassembly And Assembly................................................................294 REAR AUXILIARY DIVERTER VALVE...............................................................297 Description.............................................................................297 Solenoid Testing........................................................................297 Removal And Installation................................................................298 Disassembly And Assembly................................................................301 BOB-TACH (POWER) BLOCK......................................................................307 Description.............................................................................307 Removal And Installation................................................................307 Disassembly And Assembly................................................................309 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK.....................................................313 Description.............................................................................313 Removal And Installation................................................................313 Disassembly And Assembly................................................................313 HIGH FLOW VALVE.............................................................................315 Description.............................................................................315 High Flow Relief Valve Testing..........................................................315 High Flow Relief Valve Adjustment.......................................................316 Solenoid Testing........................................................................317 Removal And Installation................................................................318 Disassembly And Assembly................................................................319 HYDROSTATIC SYSTEM..............................................................................323 HYDROSTATIC SYSTEM INFORMATION..............................................................325 Description.............................................................................325 Troubleshooting.........................................................................326 HYDROSTATIC DRIVE MOTOR (A3LL35027 & BELOW).................................................327 Description.............................................................................327 Removing And Replacing Oil..............................................................328 Removal And Installation................................................................330 Parts Identification....................................................................332 Disassembly And Assembly................................................................334 HYDROSTATIC DRIVE MOTOR (A3LL35028 - A3LL36499).............................................345 Description.............................................................................345 Removing And Replacing Oil..............................................................346 Removal And Installation................................................................348 Parts Identification....................................................................350 Disassembly And Assembly................................................................352 HYDROSTATIC DRIVE MOTOR (A3LL36500 & ABOVE).................................................363 Description.............................................................................363 Removing And Replacing Oil..............................................................364 Removal And Installation................................................................366 Parts Identification....................................................................368 Disassembly And Assembly................................................................370 CHARGE PRESSURE.............................................................................381 Description.............................................................................381 Testing (S/N A3LL29999 & Below).........................................................382 Sender Removal And Installation (S/N A3LL29999 & Below).................................383 Testing (S/N A3LL30001 & Above).........................................................384 Sender Removal And Installation (S/N A3LL30001 & Above).................................385 Adjusting...............................................................................386 HYDROSTATIC PUMP............................................................................389 Description.............................................................................389 Replenishing / High Pressure Relief Valve Removal And Installation......................390 Removal And Installation................................................................391 Hydrostatic Pump Startup................................................................393 Parts Identification (Left Half)........................................................394 Parts Identification (Right Half).......................................................395 Disassembly.............................................................................396 Assembly................................................................................402 HYDROSTATIC PUMP (SJC)......................................................................409 Description.............................................................................409 Hydraulic Controller Removal And Installation...........................................410 Removal And Installation................................................................412 Hydrostatic Pump Startup................................................................414 Parts Identification....................................................................415 High Pressure Relief And Bypass Valve...................................................416 Charge Relief Valve.....................................................................417 Disassembly And Assembly................................................................418 Mechanical Neutral Adjustment...........................................................434 Hydraulic Controller Neutral Adjustment.................................................437 DRIVE BELT..................................................................................441 Description.............................................................................441 Shield Removal And Installation.........................................................441 Adjusting...............................................................................442 Belt Removal And Installation...........................................................443 Tensioner Pulley Removal And Installation...............................................444 Tensioner Pulley Parts Identification...................................................445 Tensioner Pulley Disassembly............................................................446 Tensioner Pulley Assembly...............................................................447 CASE DRAIN FILTER...........................................................................449 Description.............................................................................449 Disassembly And Assembly................................................................449 DRIVE SYSTEM....................................................................................451 BRAKE.......................................................................................453 Description.............................................................................453 Right Motor Brake Test..................................................................453 Left Motor Brake Test...................................................................454 Block Removal And Installation..........................................................455 Block Disassembly And Assembly..........................................................457 TRACK UNDERCARRIAGE (SOLID-MOUNTED) (S/N A3LL35032 & BELOW).................................459 Description.............................................................................459 Checking Tension........................................................................460 Adjusting Tension.......................................................................460 Track Removal And Installation..........................................................462 Idler (Front) Removal And Installation..................................................465 Track Tensioner Disassembly And Assembly................................................467 Idler (Rear) Removal And Installation...................................................468 Roller Removal And Installation.........................................................469 Sprocket Removal And Installation.......................................................469 Track Housing Removal And Installation..................................................470 TRACK UNDERCARRIAGE (SOLID-MOUNTED) (S/N A3LL35033 & ABOVE).................................473 Description.............................................................................473 Checking Tension........................................................................474 Adjusting Tension.......................................................................475 Track Removal And Installation..........................................................476 Idler (Front) Removal And Installation..................................................478 Idler (Rear) Removal And Installation...................................................483 Roller Removal And Installation.........................................................483 Sprocket Removal And Installation.......................................................484 Track Housing Removal And Installation..................................................485 TRACK UNDERCARRIAGE (ROLLER SUSPENSION).....................................................487 Description.............................................................................487 Checking Tension........................................................................488 Adjusting Tension.......................................................................489 Track Removal And Installation..........................................................490 Idler (Front) Removal And Installation..................................................492 Track Tensioner Disassembly And Assembly................................................495 Idler (Rear) Removal And Installation...................................................497 Roller Removal And Installation.........................................................497 Leaf Spring Removal And Installation....................................................498 Sprocket Removal And Installation.......................................................499 Track Housing Removal And Installation..................................................500 TRACK MAINTENANCE...........................................................................503 Track Damage Identification.............................................................503 MAINFRAME.......................................................................................515 SEAT BAR....................................................................................519 Description.............................................................................519 Removal And Installation................................................................519 Disassembly And Assembly................................................................520 Compression Spring Disassembly And Assembly.............................................521 OPERATOR CAB................................................................................523 Gas Cylinder Removal And Installation...................................................523 Gas Cylinder Bracket Disassembly And Assembly...........................................525 Removal And Installation................................................................526 OPERATOR SEAT (SUSPENSION)..................................................................529 Removal And Installation................................................................529 Slide Rail Removal And Installation.....................................................530 Seat Belt Removal And Installation......................................................530 Lower Cushion Removal And Installation..................................................531 Back Cushion Removal And Installation...................................................532 Shock Removal And Installation..........................................................532 3-Point Seat Belt Removal And Installation..............................................533 BOB-TACH (HAND LEVER).......................................................................535 Description.............................................................................535 Removal And Installation................................................................535 Lever And Wedge Disassembly And Assembly................................................536 Pivot Pin Bushing And Seal Removal And Installation.....................................538 BOB-TACH (POWER)............................................................................539 Description.............................................................................539 Removal And Installation................................................................539 Lever And Wedge Disassembly And Assembly................................................541 Pivot Pin Bushing And Seal Removal And Installation.....................................542 LIFT ARMS...................................................................................543 Removal And Installation................................................................543 REAR GRILLE.................................................................................547 Removal And Installation................................................................547 REAR DOOR (TAILGATE)........................................................................549 Removal And Installation................................................................549 Striker Removal And Installation........................................................550 Striker Disassembly And Assembly........................................................550 Striker (Adjusting).....................................................................551 Latch Removal And Installation..........................................................552 FUEL TANK...................................................................................553 Removal And Installation................................................................553 Fuel Level Sender Removal And Installation..............................................554 Fuel Fill Screen Removal And Installation...............................................554 CONTROL PEDALS AND LINKAGES.................................................................555 Description.............................................................................555 Pedal Removal And Installation..........................................................555 Linkage Removal And Installation........................................................556 Pedal (Adjusting).......................................................................558 CONTROL PEDALS (ACS)........................................................................559 Description.............................................................................559 Foot Sensor Removal And Installation....................................................559 Foot Pedal Removal And Installation.....................................................560 Foot Pedal Linkage Disassembly And Assembly.............................................561 CONTROL PANEL...............................................................................563 Description.............................................................................563 Removal And Installation................................................................564 Shock Removal And Installation..........................................................567 Shaft Removal And Installation..........................................................567 Shaft Disassembly And Assembly..........................................................568 Linkage Removal And Installation........................................................569 Pintle Arm Disassembly And Assembly.....................................................573 Linkage Neutral (Adjusting).............................................................575 Linkage Travel (Adjusting)..............................................................579 CONTROL PANEL (SJC).........................................................................583 Description.............................................................................583 Removal And Installation................................................................583 CONTROL HANDLE / LEVER......................................................................585 Description.............................................................................585 Lever Removal And Installation..........................................................585 Boot Removal And Installation...........................................................586 CONTROL HANDLE / LEVER (ACS)................................................................587 Description.............................................................................587 Handle Sensor Removal And Installation..................................................587 Handle Removal And Installation.........................................................590 Handle Disassembly And Assembly.........................................................591 Lever Removal And Installation..........................................................591 Boot Removal And Installation...........................................................593 CONTROL HANDLE / LEVER (SJC)................................................................595 Description.............................................................................595 Joystick Testing........................................................................595 Joystick Removal And Installation.......................................................596 Joystick Mount Removal And Installation.................................................597 ACCESS PANEL (INSIDE).......................................................................599 Removal And Installation (Left).........................................................599 Removal And Installation (Right)........................................................599 ACCESS PANEL (INSIDE) (SJC).................................................................601 Removal And Installation (Left).........................................................601 Removal And Installation (Right)........................................................602 WINDOW (REAR)...............................................................................605 Removal.................................................................................605 Installation (Split Molding)............................................................605 Installation (Continuous Molding).......................................................607 WINDOW (TOP)................................................................................609 Removal And Installation................................................................609 WINDOW (SIDE)...............................................................................611 Removal And Installation................................................................611 WINDOW (CAB DOOR)...........................................................................613 Removal (Standard Window)...............................................................613 Installation (Standard Window)..........................................................614 Removal And Installation (Special Applications Window)..................................616 CAB DOOR....................................................................................617 Description.............................................................................617 Removal And Installation................................................................617 Aligning................................................................................618 Adjusting...............................................................................619 Checking Operation......................................................................619 ELECTRICAL SYSTEM AND ANALYSIS..................................................................621 ELECTRICAL SCHEMATICS.......................................................................625 ELECTRICAL SYSTEM INFORMATION...............................................................631 Glossary Of Electrical Symbols..........................................................631 Standard Cab Harness Connectors.........................................................634 Deluxe Cab Harness Connectors...........................................................635 Mainframe Harness Connectors............................................................636 Description.............................................................................637 Troubleshooting.........................................................................638 Fuse And Relay Location / Identification................................................639 Solenoid Testing........................................................................640 BATTERY.....................................................................................641 Removal And Installation................................................................641 Servicing...............................................................................642 Using A Booster Battery (Jump Starting).................................................643 ALTERNATOR..................................................................................645 Belt Adjustment.........................................................................645 Belt Replacement........................................................................645 Charging System Inspection..............................................................646 Alternator Voltage Testing..............................................................647 Low Voltage Testing.....................................................................647 High Voltage Testing....................................................................648 Removal And Installation................................................................649 Parts Identification....................................................................650 STARTER.....................................................................................651 Testing.................................................................................651 Removal And Installation................................................................652 Parts Identification....................................................................653 INSTRUMENT PANELS...........................................................................655 Left Panel..............................................................................655 Standard Key Panel......................................................................657 Keyless Start Panel.....................................................................657 Deluxe Instrumentation Panel............................................................658 Side Panel..............................................................................659 Front Panel.............................................................................659 Front Panel Removal And Installation....................................................660 Removal And Installation (Left And Right)...............................................661 Key Switch Removal And Installation.....................................................662 Alarm Removal And Installation..........................................................663 LIGHTS......................................................................................665 Front Removal And Installation..........................................................665 Rear Removal And Installation...........................................................666 Cab Light Removal And Installation......................................................666 BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)...................................................667 Description.............................................................................667 Connector Identification................................................................668 Removal And Installation................................................................674 BOBCAT CONTROLLER (ACS).....................................................................677 Description.............................................................................677 Connector And Wire Identification.......................................................678 Removal And Installation................................................................679 BOBCAT CONTROLLER (SJC) (DRIVE).............................................................681 Description.............................................................................681 Connector Identification................................................................682 Removal And Installation................................................................684 SPEED SENSORS (SJC).........................................................................685 Description.............................................................................685 Testing.................................................................................685 Removal And Installation................................................................687 DIAGNOSTIC SERVICE CODES....................................................................691 Viewing Service Codes...................................................................691 Service Codes List......................................................................692 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™).....................................................697 Description.............................................................................697 Inspecting The BICS™ (Engine STOPPED - Key ON)..........................................698 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....698 Inspecting The Seat Bar Sensor (Engine RUNNING).........................................698 Inspecting The Traction Lock (Engine RUNNING)...........................................698 Inspecting The Lift Arm Bypass Control..................................................698 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)........................698 Troubleshooting.........................................................................699 SEAT BAR SENSOR.............................................................................701 Description.............................................................................701 Troubleshooting.........................................................................701 Testing.................................................................................702 Removal And Installation................................................................703 Bobcat Interlock Control System (BICS™) Circuit Test....................................706 TRACTION LOCK...............................................................................709 Description.............................................................................709 Troubleshooting.........................................................................710 Inspecting..............................................................................711 CONTROL SYSTEM (ACS)........................................................................713 Description.............................................................................713 Troubleshooting.........................................................................714 Handle Sensor Connector Disassembly And Assembly........................................715 Switch Handle Removal...................................................................716 Switch Handle Installation..............................................................718 Actuator Connector Disassembly And Assembly.............................................721 Handle Lock Solenoid Removal And Installation...........................................722 Handle Lock Solenoid Disassembly And Assembly...........................................722 Foot Sensor Disassembly And Assembly....................................................723 Foot Lock Solenoid Removal And Installation.............................................724 ELECTRICAL / HYDRAULIC CONTROLS.............................................................725 Identification Chart....................................................................725 Description.............................................................................726 Identification Chart ACD Group 0........................................................727 Identification Chart ACD Group 1........................................................728 Identification Chart ACD Group 2........................................................729 Identification Chart ACD Group 3........................................................730 ELECTRICAL / HYDRAULIC CONTROLS (ACS).......................................................731 Identification Chart....................................................................731 Description.............................................................................732 Identification Chart ACD Group 0........................................................733 Identification Chart ACD Group 1........................................................734 Identification Chart ACD Group 2........................................................735 Identification Chart ACD Group 3........................................................736 ELECTRICAL / HYDRAULIC CONTROLS (SJC).......................................................737 Identification Chart....................................................................737 Description.............................................................................738 Identification Chart ACD Group 0........................................................739 Identification Chart ACD Group 1........................................................740 Identification Chart ACD Group 2........................................................741 Identification Chart ACD Group 3........................................................742 SERVICE PC (LAPTOP COMPUTER)................................................................743 Connecting Remote Start Tool............................................................743 Connecting Remote Start Tool (Service Tool).............................................743 CALIBRATION.................................................................................745 Description.............................................................................745 Actuator Testing........................................................................745 Lift And Tilt Calibration (SJC).........................................................748 Hydrostatic Pump Calibration (SJC)......................................................750 Lift And Tilt Calibration (ACS).........................................................755 STEERING DRIFT COMPENSATION.................................................................757 Description.............................................................................757 Operation...............................................................................757 FLYWHEEL RPM SENSOR.........................................................................759 Description.............................................................................759 Adjusting...............................................................................759 CONTROL PANEL SETUP.........................................................................761 Right Panel Setup (Deluxe Instrumentation Panel)........................................761 Attachment Control Information (Deluxe Instrumentation Panel)...........................762 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...............................................763 Password Description....................................................................763 Changing The Owner Password.............................................................763 Changing The User Passwords.............................................................764 Password Lockout Feature................................................................764 PASSWORD SETUP (KEYLESS START PANEL)........................................................765 Password Description....................................................................765 Changing The Owner Password.............................................................765 Password Lockout Feature................................................................765 MAINTENANCE CLOCK...........................................................................767 Description.............................................................................767 Setup...................................................................................768 Reset...................................................................................771 BACK-UP ALARM SYSTEM........................................................................773 Description.............................................................................773 Inspecting..............................................................................773 Adjusting Switch Position...............................................................774 Troubleshooting (Standard and ACS)......................................................775 Troubleshooting (Joystick)..............................................................776 Alarm Removal And Installation..........................................................777 Switch Removal And Installation.........................................................777 ENGINE SERVICE..................................................................................779 ENGINE INFORMATION..........................................................................783 Description.............................................................................783 Specifications..........................................................................784 Torque Values...........................................................................788 Troubleshooting.........................................................................788 Engine Removal And Installation.........................................................790 Engine Mount Replacement................................................................797 Compression - Checking..................................................................798 ENGINE SPEED CONTROL........................................................................799 Removal And Installation................................................................799 ENGINE SPEED CONTROL (SJC)..................................................................801 Removal And Installation................................................................801 Disassembly And Assembly................................................................803 MUFFLER.....................................................................................805 Removal And Installation................................................................805 AIR CLEANER.................................................................................807 Housing Removal And Installation........................................................807 ENGINE COOLING SYSTEM.......................................................................809 Radiator Removal And Installation.......................................................809 Hydraulic Fan Description (S/N A3LL29999 & Below).......................................812 Hydraulic Fan Disassembly And Assembly (S/N A3LL29999 & Below)..........................812 Blower Housing Removal And Installation (S/N A3LL29999 & Below).........................813 Fan Removal And Installation (S/N A3LL29999 & Below)....................................815 Hydraulic Fan Motor Removal And Installation (S/N A3LL29999 & Below)....................815 Hydraulic Fan Description (S/N A3LL30001 & Above).......................................816 Hydraulic Fan Disassembly And Assembly (S/N A3LL30001 & Above)..........................816 Blower Housing Removal And Installation (S/N A3LL30001 & Above).........................818 Fan Removal And Installation (S/N A3LL30001 & Above)....................................820 Hydraulic Fan Motor Removal And Installation (S/N A3LL30001 & Above)....................820 Water Pump Removal And Installation.....................................................821 Water Pump Disassembly And Assembly.....................................................821 Thermostat Housing Removal And Installation.............................................822 Thermostat - Checking...................................................................823 LUBRICATION SYSTEM..........................................................................825 Oil Pan Removal And Installation........................................................825 Oil Pump Removal And Installation.......................................................825 Relief Valve - Testing..................................................................826 Oil Pump Inspection.....................................................................826 Oil Filter Cooler Removal And Installation..............................................827 Engine Oil Pressure - Testing...........................................................828 FUEL SYSTEM.................................................................................829 Fuel Shutoff Solenoid - Checking........................................................829 Fuel Shutoff Solenoid Removal And Installation..........................................829 Fuel Injection Pump - Checking..........................................................830 Fuel Injection Pump Assembly Removal And Installation...................................831 Governor Housing Disassembly And Assembly...............................................834 Governor Disassembly And Assembly.......................................................836 Fuel Camshaft Removal And Installation..................................................838 Fuel Injection Pump Removal And Installation............................................840 Fuel Injection Pump - Timing............................................................843 Fuel Injector Removal And Installation..................................................845 Fuel Injector Nozzle Pressure - Checking................................................846 Nozzle Spray Condition..................................................................847 Valve Seat Tightness....................................................................847 CYLINDER HEAD...............................................................................849 Glow Plugs - Testing....................................................................849 Glow Plugs Removal And Installation.....................................................849 Valve Clearance Adjustment..............................................................850 Valve Timing - Checking.................................................................851 Cylinder Head Removal And Installation..................................................852 Cylinder Head Disassembly And Assembly..................................................855 Cylinder Head - Servicing...............................................................855 Cylinder Head Top Clearance.............................................................856 Valve Guide - Checking..................................................................856 Valve Guide Removal And Installation....................................................857 Reconditioning The Valve And Valve Seat.................................................857 Valve Spring............................................................................859 Valve Tappets...........................................................................860 Rocker Arm And Shaft - Checking.........................................................861 Bridge Arm And Bridge Arm Shaft - Checking..............................................861 Bridge Arm Shaft Removal And Installation...............................................862 Push Rod Alignment - Checking...........................................................863 CRANKSHAFT AND PISTONS......................................................................865 Piston And Connecting Rod Removal And Installation......................................865 Piston And Connecting Rod - Servicing...................................................866 Cylinder Bore - Checking................................................................870 Connecting Rod Alignment................................................................871 Crankshaft Gear Removal And Installation................................................871 Crankshaft And Bearings Removal And Installation........................................872 Crankshaft And Bearings - Servicing.....................................................875 CAMSHAFT AND TIMING GEARS...................................................................879 Timing Gearcase Cover Removal...........................................................879 Timing Gearcase Cover Installation......................................................880 Timing Gears Backlash - Checking........................................................883 Idler Gear And Camshaft Removal And Installation........................................883 Camshaft - Servicing....................................................................884 Idler Gear And Shaft - Servicing........................................................885 TURBOCHARGER................................................................................887 Description.............................................................................887 Testing.................................................................................887 Removal And Installation................................................................888 FLYWHEEL AND HOUSING........................................................................889 Flywheel Removal And Installation.......................................................889 Ring Gear Removal And Installation......................................................890 Housing Removal And Installation........................................................891 EXHAUST GAS RECIRCULATION (EGR) SYSTEM......................................................893 Description.............................................................................893 Testing.................................................................................894 Removal And Installation................................................................897 Disassembly And Assembly................................................................898 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)................................................899 AIR CONDITIONING SYSTEM FLOW................................................................901 Description.............................................................................901 Chart...................................................................................902 Components..............................................................................903 Safety Equipment........................................................................906 REGULAR MAINTENANCE.........................................................................907 Filters.................................................................................907 Compressor Drive Belt Adjustment........................................................908 Compressor Drive Belt Replacement.......................................................909 Condenser...............................................................................909 Air Conditioning Lubrication............................................................909 Air Conditioning Service Chart..........................................................910 Evaporator / Heater Coil................................................................911 TROUBLESHOOTING.............................................................................913 Blower Motor Does Not Operate...........................................................913 Blower Motor Operates Normally, But Air Flow Is Insufficient............................913 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..............913 The Compressor Does Not Operate At All, Or Operates Improperly..........................913 Gauge Pressure Related Troubleshooting..................................................914 Troubleshooting Tree....................................................................916 Temperature / Pressure Chart............................................................920 Poor A/C Performance....................................................................921 HVAC Repair And Leaks...................................................................922 Electrical System.......................................................................923 Engine Coolant Bypassing The Heater Valve...............................................930 Heater Valve Not Opening Or Closing.....................................................931 SYSTEM CHARGING AND RECLAMATION.............................................................933 Refrigerant Identification..............................................................933 Reclamation And Charging With Recovery / Charging Unit..................................934 Charging With A Manifold Gauge Set......................................................936 COMPRESSOR..................................................................................939 Removal And Installation................................................................939 Oil.....................................................................................941 Oil Check...............................................................................941 Clutch Disassembly And Assembly.........................................................943 CONDENSER...................................................................................947 Removal And Installation................................................................947 RECEIVER / DRIER............................................................................949 Receiver / Drier Removal And Installation...............................................949 Pressure Relief Valve Removal And Installation..........................................951 Pressure Switch Removal And Installation................................................952 Schraeder® Valve Removal And Installation...............................................952 EVAPORATOR / HEATER UNIT....................................................................953 Removal And Installation................................................................953 THERMOSTAT..................................................................................955 Description.............................................................................955 Removal And Installation................................................................956 EXPANSION VALVE.............................................................................957 Removal And Installation................................................................957 EVAPORATOR COIL.............................................................................959 Removal And Installation................................................................959 HEATER COIL.................................................................................961 Removal And Installation With A/C.......................................................961 Removal And Installation Without A/C....................................................963 BLOWER FAN..................................................................................965 Removal And Installation................................................................965 Disassembly And Assembly................................................................966 Connector Identification................................................................968 HEATER VALVE................................................................................969 Removal And Installation................................................................969 Disassembly And Assembly................................................................970 SPECIFICATIONS..................................................................................971 (T180) LOADER SPECIFICATIONS................................................................973 Machine Dimensions......................................................................973 Performance.............................................................................974 Engine..................................................................................974 Drive System............................................................................974 Controls................................................................................975 Hydraulic System........................................................................975 Electrical..............................................................................976 Capacities..............................................................................976 Tracks..................................................................................976 Ground Pressure.........................................................................976 TORQUE SPECIFICATIONS FOR BOLTS.............................................................977 Torque For General SAE Bolts............................................................977 Torque For General Metric Bolts.........................................................978 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................979 O-ring Face Seal Connection.............................................................979 Straight Thread O-ring Fitting..........................................................980 Tubelines And Hoses.....................................................................980 Flare Fitting...........................................................................981 Port Seal Fitting.......................................................................982 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS................................................983 Specifications..........................................................................983 CONVERSIONS.................................................................................985 Decimal And Millimeter Equivalent Chart.................................................985 U.S. To Metric Conversion Chart.........................................................985 SERVICE TOOLS REQUIRED......................................................................987 Remote Start Tools......................................................................987 Hydraulic Tools.........................................................................988 Mainframe And Drive Tools...............................................................990 Electrical Tools........................................................................991 Engine Tools............................................................................991 HVAC Tools..............................................................................996 ALPHABETICAL INDEX..............................................................................997
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