Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Bobcat T180 Turbo T180 Turbo High Flow Loader Service Manual 6902502 (7-09) – PDF DOWNLOAD
$33.95
Bobcat T180 Turbo T180 Turbo High Flow Loader Service Manual 6902502 (7-09) – PDF DOWNLOAD
(S/N 524211001 & Above)
(S/N 524311001 & Above)
(S/N 527511001 & Above)
(S/N 527611001 & Above)
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Bobcat T180 Turbo T180 Turbo High Flow Loader Service Manual 6902502 (7-09) – PDF DOWNLOAD
FILE DETAILS:
Bobcat T180 Turbo T180 Turbo High Flow Loader Service Manual 6902502 (7-09) – PDF DOWNLOAD
Language : English
Pages : 961
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T180 Turbo T180 Turbo High Flow Loader Service Manual 6902502 (7-09) – PDF DOWNLOAD
(S/N 524211001 & Above)
(S/N 524311001 & Above)
(S/N 527511001 & Above)
(S/N 527611001 & 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 Turbo T180 Turbo High Flow Loader Service Manual 6902502 (7-09) – 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 Lift Arm Support Device...................................................... 23 Removing The Lift Arm Support Device.................................................... 24 OPERATOR CAB................................................................................ 25 Description............................................................................. 25 Raising The Operator Cab................................................................ 25 Lowering The Operator Cab............................................................... 26 Cab Door Sensor......................................................................... 27 Emergency Exit.......................................................................... 28 TRANSPORTING THE BOBCAT LOADER.............................................................. 29 Procedure............................................................................... 29 TOWING THE LOADER........................................................................... 31 Procedure............................................................................... 31 REMOTE START................................................................................ 33 Procedure............................................................................... 33 SERVICE SCHEDULE............................................................................ 37 Chart................................................................................... 37 AIR CLEANER SERVICE......................................................................... 39 Replacing Filter Element................................................................ 39 ENGINE COOLING SYSTEM....................................................................... 41 Cleaning The Cooling System............................................................. 41 Checking The Coolant Level.............................................................. 42 Replacing the Coolant................................................................... 42 FUEL SYSTEM................................................................................. 45 Fuel Specifications..................................................................... 45 Filling The Fuel Tank................................................................... 45 Fuel Filter............................................................................. 46 Removing Air From The Fuel System....................................................... 46 ENGINE LUBRICATION SYSTEM................................................................... 47 Checking Engine Oil..................................................................... 47 Oil Chart............................................................................... 47 Replacing Oil And Filter................................................................ 48 HYDRAULIC/HYDROSTATIC SYSTEM................................................................ 49 Checking And Adding Fluid............................................................... 49 Replacing Hydraulic/Hydrostatic Filter.................................................. 49 Replacing Hydraulic Fluid............................................................... 50 Breather Cap............................................................................ 52 FAN GEARBOX................................................................................. 53 Checking And Maintaining................................................................ 53 BOB-TACH.................................................................................... 55 Inspection And Maintenance.............................................................. 55 POWER BOB-TACH (OPTION)..................................................................... 57 Inspection And Maintenance.............................................................. 57 LUBRICATION OF THE BOBCAT LOADER............................................................ 59 Procedure............................................................................... 59 SPARK ARRESTOR MUFFLER...................................................................... 61 Cleaning Procedure...................................................................... 61 HYDRAULIC SYSTEM................................................................................ 63 HYDRAULIC / HYDROSTATIC SCHEMATICS.......................................................... 69 HYDRAULIC SYSTEM INFORMATION................................................................ 85 Troubleshooting Chart................................................................... 89 Tighten Procedures...................................................................... 90 CYLINDER (LIFT)............................................................................. 91 Checking................................................................................ 91 Removal And Installation................................................................ 92 Parts Identification.................................................................... 93 Disassembly............................................................................. 94 Assembly................................................................................ 95 CYLINDER (TILT)............................................................................. 99 Checking................................................................................ 99 Removal And Installation................................................................100 Base End Pivot Pin Replacement..........................................................101 Rod End Pivot Pin Bushing And Seal Replacement..........................................102 Parts Identification....................................................................103 Disassembly.............................................................................104 Assembly................................................................................105 CYLINDER (POWER BOB-TACH)...................................................................109 Checking................................................................................109 Removal And Installation................................................................110 Parts Identification....................................................................111 Disassembly.............................................................................112 Assembly................................................................................113 MAIN RELIEF VALVE...........................................................................117 Checking................................................................................117 Adjustment..............................................................................118 Removal and Installation................................................................119 HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL)....................................121 Identification..........................................................................121 Removal And Installation................................................................121 BICS Valve Removal And Installation.....................................................125 BICS Valve, Lift Arm Bypass Orifice Disassembly And Assembly............................126 BICS Valve, Check Valve Disassembly And Assembly........................................127 BICS Valve Lock Valve Disassembly And Assembly..........................................128 BICS Valve Solenoid Disassembly And Assembly............................................129 BICS Valve Solenoid Testing.............................................................130 Identification Chart....................................................................131 Load Check Valve........................................................................132 Main Relief Valve.......................................................................133 Port Relief Valve.......................................................................134 Anti-Cavitation Valve/Port Relief Valve.................................................135 Anti-Cavitation Valve...................................................................136 Rubber Boot.............................................................................137 Lift And Tilt Lock Block................................................................137 Lift Spool and Detent...................................................................138 Tilt Spool Removal And Installation.....................................................147 Auxiliary Spool Removal And Installation................................................149 Auxiliary Electric Solenoid Disassembly.................................................150 Port-Auxiliary Section Disassembly......................................................151 Cleaning And Inspection.................................................................151 HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)...................153 Identification..........................................................................153 Removal and Installation................................................................153 BICS Valve Removal And Installation.....................................................157 BICS Valve, Lift Arm Bypass Orifice Removal And Installation............................159 BICS Valve, Check Valve Removal And Installation........................................160 BICS Valve Lock Valve Removal And Installation..........................................161 BICS Valve Solenoid Removal And Installation............................................162 BICS Valve Solenoid Testing.............................................................163 Actuator Removal And Installation.......................................................164 Identification Chart (ACS)..............................................................166 Lift Base End Restrictor................................................................167 Load Check Valve........................................................................167 Main Relief Valve.......................................................................168 Port Relief Valve.......................................................................169 Anti-Cavitation Valve/Port Relief Valve.................................................170 Anti-Cavitation Valve...................................................................171 Tilt Spool Removal And Installation.....................................................171 Lift Spool Removal And Installation.....................................................172 Lift and Tilt Spool Disassembly And Assembly............................................173 Auxiliary Spool Removal And Installation................................................174 Auxiliary Electric Solenoid.............................................................175 Port-Auxiliary Section..................................................................176 Cleaning And Inspection.................................................................176 HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL)....................................177 Identification..........................................................................177 Removal And Installation................................................................177 Identification Chart....................................................................183 Mount Bracket Removal and Installation..................................................184 BICS Valve, Lift Load Check Valve Removal And Installation..............................184 BICS Valve, Lift Load Check Valve Removal And Installation (Cont’d).....................185 Load Check Valve Removal And Installation (Tilt & Auxiliary)............................185 Anti-Cavitation Valve (Lift, Rod End)...................................................186 Port Relief/Anti-Cavitation Valve (Lift, Base End)......................................187 Port Relief/Anti-Cavitation Valve (Tilt, Base End)......................................187 Port Relief/Anti-Cavitation Valve (Tilt, Rod End).......................................188 Port Relief Valve.......................................................................188 Port Relief Valve (Cont’d)..............................................................189 Plug Removal............................................................................189 Plug Removal (Cont’d)...................................................................190 Rubber Boot Removal and Installation....................................................190 End Cap/Spool Lock Block Removal and Installation.......................................191 Lift Spool and Detent Removal and Installation..........................................192 Tilt Spool Removal and Installation.....................................................201 Auxiliary Spool Removal And Installation................................................203 Auxiliary Spool Removal And Installation (Cont’d).......................................204 Auxiliary Solenoid Disassembly and Assembly.............................................205 BICS Valve Solenoid Disassembly And Assembly............................................206 BICS Valve, Lock Valve Removal And Installation.........................................207 BICS Valve, Lock Valve Removal And Installation (Cont’d)................................208 BICS Valve, Check Valve Removal And Installation........................................209 BICS Valve, Check Valve Removal And Installation (Cont’d)...............................209 BICS Valve, Lift Arm Bypass Orifice Disassembly And Assembly............................210 Main Relief Valve.......................................................................210 HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)...................211 Identification..........................................................................211 Removal And Installation................................................................211 Actuator Removal And Installation (Out of Loader).......................................216 Identification Chart (ACS)..............................................................219 Mount Bracket Removal and Installation..................................................220 BICS Valve, Lift Load Check Valve Removal And Installation..............................220 Load Check Valve Removal And Installation (Tilt & Auxiliary)............................221 Anti-Cavitation Valve (Lift, Rod End)...................................................222 Port Relief/Anti-Cavitation Valve (Lift, Base End)......................................223 Port Relief/Anti-Cavitation Valve (Tilt, Base End)......................................223 Port Relief/Anti-Cavitation Valve (Tilt, Rod End).......................................224 Port Relief Valve.......................................................................224 Plug Removal............................................................................225 End Cap Block Removal and Installation..................................................226 Lift Spool Removal and Installation.....................................................227 Tilt Spool Removal and Installation.....................................................231 Auxiliary Spool Removal And Installation................................................233 Auxiliary Solenoid Disassembly and Assembly.............................................234 BICS Valve Solenoid Disassembly And Assembly............................................235 BICS Valve, Lock Valve Removal And Installation.........................................236 BICS Valve, Check Valve Removal And Installation........................................238 BICS Valve, Lift Arm Bypass Orifice Disassembly And Assembly............................239 Main Relief Valve.......................................................................239 LIFT ARM BYPASS CONTROL VALVE...............................................................241 Inspecting..............................................................................241 Removal and Installation................................................................241 Disassembly And Assembly................................................................242 HYDRAULIC PUMP..............................................................................243 Check The Output Of The Hydraulic Pump Without Power Bob-Tach...........................243 Check The Output Of The Hydraulic Pump With Power Bob-Tach..............................245 Removal And Installation................................................................247 Identification..........................................................................249 Disassembly And Assembly................................................................250 HYDRAULIC PUMP (HIGH FLOW)..................................................................255 Check The Output Of The Hydraulic Pump (Standard).......................................255 Check The Output Of The Hydraulic Pump (High Flow)......................................257 Removal And Installation................................................................259 Identification..........................................................................261 Disassembly And Assembly................................................................262 HYDRAULIC PUMP (SJC)........................................................................271 Test The Output Of The Hydraulic Auxiliary Pump.........................................271 Test The Output Of The Hydraulic Charge Pump............................................272 Removal And Installation................................................................274 Identification..........................................................................276 Disassembly And Assembly................................................................277 HYDRAULIC PUMP (HIGH FLOW) (SJC)............................................................285 Test The Output Of The Hydraulic Auxiliary Pump.........................................285 Test The Output Of The Hydraulic Charge Pump............................................286 Test The Output Of The Hydraulic Pump (High Flow).......................................288 Removal And Installation................................................................290 Identification..........................................................................292 Disassembly And Assembly................................................................293 HYDRAULIC/HYDROSTATIC FILTER HOUSING........................................................305 Removal And Installation................................................................305 HYDRAULIC FLUID RESERVOIR...................................................................307 Removal And Installation................................................................307 BUCKET POSITION VALVE.......................................................................311 Solenoid Removal And Installation.......................................................311 Solenoid Testing........................................................................312 Removal And Installation................................................................313 Disassembly And Assembly................................................................315 HIGH FLOW VALVE.............................................................................317 Checking The High Flow Relief Valve.....................................................317 High Flow Relief Valve Adjustment Procedure.............................................319 Removal And Installation................................................................320 Disassembly And Assembly................................................................322 Solenoid Testing........................................................................324 REAR AUXILIARY DIVERTER VALVE...............................................................325 Removal And Installation................................................................325 Disassembly And Assembly................................................................328 Solenoid Testing........................................................................333 Inspection..............................................................................333 POWER BOB-TACH BLOCK........................................................................335 Removal And Installation................................................................335 Disassembly And Assembly................................................................337 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK.....................................................341 Removal and Installation................................................................341 Disassembly And Assembly................................................................341 HYDROSTATIC SYSTEM..............................................................................343 HYDROSTATIC SYSTEM INFORMATION..............................................................345 Troubleshooting Chart...................................................................345 Replenishing Valve Function.............................................................346 HYDROSTATIC MOTOR...........................................................................347 Replacing the Motor Oil.................................................................347 Removal And Installation................................................................348 Parts Identification....................................................................350 Disassembly.............................................................................352 Inspection..............................................................................360 Assembly................................................................................361 HYDROSTATIC MOTOR (SJC).....................................................................371 Replacing the Motor Oil.................................................................371 Removal And Installation................................................................372 Parts Identification....................................................................374 Disassembly and Assembly................................................................376 CHARGE PRESSURE.............................................................................387 Sender Removal And Installation (Non SJC Machines)......................................387 Testing (Non SJC Machines)..............................................................387 Adjusting (Non SJC Machines)............................................................388 Sender Removal And Installation (SJC Machines)..........................................389 Testing (SJC Machines)..................................................................389 Adjusting (SJC Machines)................................................................390 HYDROSTATIC PUMP............................................................................391 Replenishing/High Pressure Relief Valve.................................................391 Removal And Installation................................................................392 Parts Identification (Right Half).......................................................394 Parts Identification (Left Half)........................................................396 Hydraulic Pump Removal And Installation.................................................398 Pump Separation.........................................................................398 Disassembly.............................................................................399 Assembly................................................................................405 HYDROSTATIC PUMP (SJC)......................................................................413 Description.............................................................................413 Hydraulic Controller Removal And Installation...........................................414 Removal And Installation................................................................416 Parts Identification....................................................................418 High Pressure Relief and Bypass Valve...................................................419 Charge Relief Valve.....................................................................420 Disassembly and Assembly................................................................421 Mechanical Neutral Adjustment...........................................................437 Hydraulic Controller Neutral Adjustment.................................................440 DRIVE BELT..................................................................................443 Shield Removal And Installation.........................................................443 Adjusting...............................................................................443 Drive Belt Replacement..................................................................445 Tensioner Pulley Removal And Installation...............................................446 Tensioner Pulley Parts Identification...................................................447 Tensioner Pulley Disassembly............................................................448 Tensioner Pulley Assembly...............................................................449 OIL COOLER..................................................................................451 Removal and Installation................................................................451 DRIVE SYSTEM....................................................................................453 BRAKE.......................................................................................455 Pressure Relief Valve Test..............................................................455 Right Motor Brake Test..................................................................456 Left Motor Brake Test...................................................................457 Block Removal And Installation..........................................................459 Block Disassembly And Assembly..........................................................461 DRIVE COMPONENTS............................................................................463 Track Tension...........................................................................463 Track Tension Adjusting.................................................................463 Track Removal And Installation..........................................................466 Track Idler (Front) Removal And Installation............................................469 Track Idler (Front) Parts Identification................................................471 Track Idler (Front) Disassembly.........................................................472 Track Idler (Front) Assembly............................................................473 Track Idler (Rear) End Play Specifications..............................................476 Track Idler (Rear) Parts Identification.................................................476 Track Idler (Rear) Removal And Installation.............................................476 Track Idler (Rear) Disassembly..........................................................477 Track Idler (Rear) Assembly.............................................................478 Track Roller Assembly End Play Specifications...........................................480 Track Roller Parts Identification.......................................................480 Track Roller Removal And Installation...................................................480 Track Roller Disassembly................................................................481 Track Roller Assembly...................................................................482 Track Housing Removal And Installation..................................................484 Track Damage Identification.............................................................485 MAIN FRAME......................................................................................497 SEAT BAR....................................................................................501 Removal And Installation................................................................501 Assembling Components...................................................................503 Compression Spring Disassembly And Assembly.............................................505 OPERATOR CAB................................................................................507 Gas Cylinder Removal And Installation...................................................507 Gas Cylinder Disassembly................................................................509 Removal And Installation................................................................510 OPERATOR SEAT...............................................................................513 Removal And Installation................................................................513 Slide Rail Removal And Installation.....................................................514 Cushion Removal And Installation........................................................514 Back Removal And Installation...........................................................515 Shock Removal And Installation..........................................................516 BOB-TACH....................................................................................517 Removal And Installation................................................................517 Bob-Tach Lever And Wedge................................................................518 POWER BOB-TACH..............................................................................521 Removal And Installation................................................................521 Power Bob-Tach Lever And Wedge..........................................................522 LIFT ARMS...................................................................................525 Removal And Installation................................................................525 REAR GRILL..................................................................................529 Removal And Installation................................................................529 REAR DOOR...................................................................................531 Removal And Installation................................................................531 Striker Removal and Installation........................................................532 Striker Disassembly and Assembly........................................................532 Adjusting The Striker...................................................................532 Latch Removal and Installation..........................................................533 FUEL TANK...................................................................................535 Removal And Installation................................................................535 Fuel Level Sender.......................................................................536 Fuel Fill Screen........................................................................536 Fuel Pickup Screen......................................................................537 CONTROL PEDALS..............................................................................539 Removal And Installation................................................................539 Pedal Adjustment........................................................................539 Crossbar Linkage Removal And Installation...............................................540 Lift Foot Pedal Linkage Removal And Installation........................................541 Tilt Foot Pedal Linkage Removal And Installation........................................542 CONTROL PEDALS (ACS)........................................................................543 Foot Sensor Removal And Installation....................................................543 Foot Pedal Removal And Installation.....................................................544 Foot Pedal Linkage Disassembly And Assembly.............................................545 CONTROL PANEL (NON-ADJUSTABLE PINTLES)......................................................547 Removal and Installation................................................................547 Shock Removal And Installation..........................................................550 Shaft Removal And Installation..........................................................550 Shaft Disassembly And Assembly..........................................................550 Linkage Removal And Installation........................................................551 Linkage Adjustment......................................................................554 Linkage Neutral Adjustment..............................................................558 CONTROL PANEL (ADJUSTABLE PINTLES)..........................................................561 Description.............................................................................561 Removal and Installation................................................................562 Shock Removal And Installation..........................................................565 Shaft Removal And Installation..........................................................565 Shaft Disassembly And Assembly..........................................................566 Linkage Removal And Installation........................................................567 Pintle Arm Disassembly and Assembly.....................................................571 Linkage Neutral Adjustment..............................................................573 Linkage Travel Adjustment...............................................................577 CONTROL PANEL (SELECTABLE JOYSTICK CONTROL) (SJC)...........................................581 Removal And Installation................................................................581 CONTROL HANDLE..............................................................................583 Control Lever Removal And Installation..................................................583 Control Lever Boot......................................................................583 CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL.................585 Components Identification...............................................................585 Handle Sensor Removal And Installation..................................................586 Control Handle Removal and Installation.................................................589 Control Handle Disassembly and Assembly.................................................590 Control Lever Removal and Installation..................................................590 Control Lever Boot......................................................................592 CONTROL HANDLE (SELECTABLE JOYSTICK CONTROL) (SJC)..........................................593 Joystick Testing (Right & Left).........................................................593 Joystick Removal (Right & Left).........................................................594 Lever Assembly Removal (Right & Left)...................................................595 ELECTRICAL SYSTEM...............................................................................597 ELECTRICAL SCHEMATICS.......................................................................601 ELECTRICAL SYSTEM INFORMATION...............................................................612 Troubleshooting Chart...................................................................614 Description.............................................................................615 Fuse Location...........................................................................616 Relay Switch Location...................................................................616 Solenoid Test...........................................................................617 BATTERY.....................................................................................618 Removal And Installation................................................................618 Servicing...............................................................................619 Using A Booster Battery (Jump Starting).................................................620 ALTERNATOR..................................................................................622 Adjusting The Alternator Belt...........................................................622 Alternator Identification...............................................................622 Charging System Check...................................................................623 Alternator Voltage Test.................................................................624 Low Voltage Test........................................................................625 High Voltage Test.......................................................................625 Removal And Installation................................................................625 Rectifier Continuity (Diode) Test.......................................................626 Alternator Regulator Test...............................................................627 Disassembly.............................................................................628 Stator Continuity Test..................................................................629 Stator Ground Test......................................................................629 Rotor Continuity Test...................................................................629 Rotor Ground Test.......................................................................629 Assembly................................................................................630 STARTER.....................................................................................632 Checking................................................................................632 Removal And Installation................................................................633 Parts Identification....................................................................634 Disassembly and Assembly................................................................635 Inspection And Repair...................................................................638 No Load Test............................................................................640 INSTRUMENT PANEL............................................................................642 Left Panel..............................................................................642 Right Panel (Standard) (With Key Switch)................................................643 Right Panel (Deluxe) (With Keyless Start)...............................................644 Right Panel Setup Display Options (Deluxe)..............................................646 Deluxe Panel Setup......................................................................647 Passwords (Deluxe)......................................................................647 Option And Field Accessory Panels (If Equipped).........................................649 Standard Panel Removal And Installation (Right Side)....................................650 Deluxe Panel Removal And Installation (Right Side)......................................651 Standard & Deluxe Panel Removal And Installation (Left Side)............................652 Front Accessory Panel Removal And Installation..........................................653 LIGHTS......................................................................................654 Front Removal And Installation..........................................................654 Rear Removal And Installation...........................................................655 BOBCAT CONTROLLER...........................................................................656 Identification Chart....................................................................656 Removal And Installation................................................................658 CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC)..............................................660 Removal and Installation................................................................660 Identification Chart....................................................................663 DIAGNOSTICS SERVICE CODES...................................................................666 Display.................................................................................666 Number Codes List.......................................................................667 BICS SYSTEM.................................................................................674 Inspecting The BICS Controller (Engine STOPPED - Key ON)................................674 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....674 Inspecting The Seat Bar Sensor (Engine RUNNING).........................................674 Inspecting The Traction Lock (Engine RUNNING)...........................................674 Inspecting The Lift Arm Bypass Control..................................................675 Additional Inspection For Loaders With Advanced Control System (ACS)....................675 Troubleshooting Chart...................................................................676 Troubleshooting Guide...................................................................677 SEAT BAR SENSOR.............................................................................678 Troubleshooting Chart...................................................................678 Test....................................................................................679 Removal And Installation................................................................680 BICS Circuit Test.......................................................................681 TRACTION LOCK...............................................................................684 Troubleshooting Chart...................................................................684 Description Of The Control System.......................................................685 Inspecting The Control System...........................................................685 ADVANCED CONTROL SYSTEM (ACS)...............................................................686 Components Identification...............................................................686 Troubleshooting Guide...................................................................688 Controller, Connector And Wire Identification...........................................689 ACS Controller Removal And Installation.................................................690 Handle Sensor Connector.................................................................691 Switch Handle Removal...................................................................692 Switch Handle Installation..............................................................694 Actuators Disassembly and Assembly......................................................697 Handle Lock Solenoid Removal And Installation...........................................698 Handle Lock Solenoid Disassembly And Assembly...........................................699 Handle Lock Solenoid Connector..........................................................700 Calibration Procedure...................................................................701 Foot Sensor Disassembly And Assembly....................................................703 Foot Sensor Connector...................................................................703 Foot Lock Solenoid Removal And Installation.............................................704 Foot Lock Solenoid Connector............................................................705 ELECTRICAL/HYDRAULIC CONTROLS REFERENCE.....................................................706 Controls Identification Chart...........................................................706 ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (selectable JOYstick control) (sjc).................708 Controls Identification Chart...........................................................708 FLYWHEEL RPM SENSOR.........................................................................712 Adjustment..............................................................................712 SERVICE PC (LAPTOP COMPUTER)................................................................714 Connecting The Service PC To Remote Start Tool..........................................714 CALIBRATION.................................................................................716 Description.............................................................................716 Actuator Testing........................................................................716 Lift and Tilt Calibration Procedure (SJC)...............................................719 Hydrostatic Pump Calibration (SJC)......................................................720 Calibration Procedure (ACS).............................................................726 SPEED SENSOR (SELECTABLE JOYSTICK CONTROL) (SJC)............................................728 Description.............................................................................728 Testing.................................................................................728 Removal and Installation................................................................730 ENGINE SERVICE..................................................................................734 TROUBLESHOOTING.............................................................................736 Chart...................................................................................736 ENGINE SPEED CONTROL........................................................................738 Removal And Installation................................................................738 Disassembly.............................................................................739 ENGINE SPEED CONTROL (SELECTABLE JOYSTICK CONTROL) (SJC)....................................740 Removal and Installation................................................................740 Disassembly and Assembly................................................................742 MUFFLER.....................................................................................744 Removal And Installation................................................................744 AIR CLEANER.................................................................................746 Removal And Installation................................................................746 RADIATOR....................................................................................748 Removal And Installation................................................................748 COOLING FAN.................................................................................752 Drive Tension Pulley Removal And Installation...........................................752 Gearbox/Blower Housing Removal And Installation.........................................753 Blower Housing Grill Removal And Installation...........................................755 Blower Disassembly And Assembly.........................................................755 Gearbox Parts Identification............................................................757 Gearbox Disassembly.....................................................................758 Gearbox Assembly........................................................................763 Gearbox Checking Backlash...............................................................768 ENGINE COMPONENTS AND TESTING...............................................................772 Compression Checking....................................................................772 Glow Plugs Checking.....................................................................773 Glow Plugs Removal And Installation.....................................................773 Fuel Shut-Off Solenoid, Checking........................................................774 Fuel Shut-Off Solenoid Removal And Installation.........................................775 Fuel Injection Pump Removal And Installation............................................776 Timing The Injection Pump...............................................................779 Fuel Injector Removal And Installation..................................................781 Checking Nozzle Injection Pressure......................................................782 Nozzle Spraying Condition...............................................................783 Valve Seat Tightness....................................................................783 Valve Clearance Adjustment..............................................................784 Valve Timing, Checking..................................................................785 ENGINE......................................................................................786 Removal And Installation................................................................786 Engine Mount Replacement................................................................794 FLYWHEEL AND HOUSING........................................................................796 Flywheel Removal And Installation.......................................................796 Ring Gear Removal And Installation......................................................796 Housing Removal And Installation........................................................797 RECONDITIONING THE ENGINE...................................................................800 Cylinder Head Removal And Installation..................................................800 Cylinder Head Disassembly And Assembly..................................................803 Cylinder Head Servicing.................................................................804 Cylinder Head Top Clearance.............................................................804 Valve Guide Checking....................................................................805 Reconditioning The Valve And Valve Seat.................................................807 Valve Spring............................................................................808 Rocker Arm And Shaft Checking...........................................................809 Timing Gearcase Cover Removal And Installation..........................................809 Idler Gear And Camshaft Removal And Installation........................................812 Camshaft Servicing......................................................................813 Idler Gear And Shaft Servicing..........................................................814 Timing Gears Checking Backlash..........................................................815 Fuel Camshaft Removal And Installation..................................................815 Fuel Camshaft Governor..................................................................816 Crankshaft Gear Removal And Installation................................................816 Oil Pump Removal And Installation.......................................................817 Oil Pump Service........................................................................817 Checking Engine Oil Pressure............................................................818 Valve Tappets...........................................................................819 Piston And Connecting Rod Removal And Installation......................................819 Piston And Connecting Rod Servicing.....................................................821 Connecting Rod Alignment................................................................824 Crankshaft And Bearings Removal And Installation........................................824 Crankshaft And Bearings, Servicing......................................................826 Cylinder Bore, Checking.................................................................830 Water Pump Removal And Installation.....................................................831 Water Pump Disassembly And Assembly.....................................................831 TURBOCHARGER................................................................................832 Checking................................................................................832 Description.............................................................................832 Removal And Installation................................................................833 HEATING, VENTILATION, AIR CONDITIONING..........................................................836 AIR CONDITIONING SYSTEM FLOW................................................................839 Principals..............................................................................839 Chart...................................................................................840 COMPONENTS..................................................................................842 Identification..........................................................................842 SAFETY......................................................................................846 Safety Equipment........................................................................846 REGULAR MAINTENANCE.........................................................................848 Filter Elements Removal And Installation................................................848 Compressor Drive Belt Inspection........................................................849 Cleaning The Condenser..................................................................850 BASIC TROUBLESHOOTING.......................................................................852 Poor A/C Performance....................................................................852 Cleaning The A/C Evaporator Coil & Heater Coil..........................................852 Compressor Drive Belt Inspection........................................................853 Checking The Electrical System..........................................................854 Engine Coolant Bypassing The Heater Valve...............................................861 Heater Valve Not Opening Or Closing.....................................................862 GENERAL AIR CONDITIONING SERVICE GUIDELINES.................................................864 Compressor Oil..........................................................................864 Compressor Oil Check....................................................................865 Component Replacement And Refrigeration Leaks...........................................866 SYSTEM TROUBLESHOOTING CHART................................................................868 Gauge Pressure Related Troubleshooting..................................................869 TEMPERATURE/PRESSURE........................................................................872 Chart...................................................................................872 AIR CONDITIONING SERVICE....................................................................874 Chart...................................................................................874 SYSTEM CHARGING AND RECLAMATION.............................................................876 Reclamation Procedure...................................................................876 Charging Procedure With A Manifold Gauge Set............................................879 Charging Procedure......................................................................880 COMPRESSOR..................................................................................884 Removal And Installation................................................................884 Compressor Clutch Disassembly...........................................................885 CONDENSER...................................................................................890 Removal And Installation................................................................890 RECEIVER/DRIER..............................................................................892 Removal And Installation................................................................892 PRESSURE RELIEF VALVE.......................................................................894 Removal And Installation................................................................894 PRESSURE SWITCH.............................................................................896 Removal And Installation................................................................896 EVAPORATOR/HEATER UNIT......................................................................898 Removal And Installation................................................................898 Disassembly And Assembly................................................................900 THERMOSTAT..................................................................................902 Removal And Installation................................................................902 EXPANSION VALVE.............................................................................904 Removal And Installation................................................................904 EVAPORATOR..................................................................................906 Removal And Installation................................................................906 HEATER COIL.................................................................................908 Removal And Installation With A/C.......................................................908 Removal And Installation Without A/C....................................................909 HEATER/AC FAN...............................................................................910 Removal And Installation................................................................910 Disassembly And Assembly................................................................911 Wire Connector Removal and Installation.................................................913 HEATER VALVE................................................................................916 Removal And Installation................................................................916 Disassembly And Assembly................................................................916 SPECIFICATIONS..................................................................................918 LOADER SPECIFICATIONS.......................................................................920 Machine Dimensions......................................................................920 Performance.............................................................................921 Controls................................................................................921 Engine..................................................................................922 Hydraulic System........................................................................923 Electrical..............................................................................923 Drive System............................................................................924 Capacities..............................................................................924 Tracks..................................................................................924 Ground Pressure.........................................................................924 ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T.................................................926 Fuel Injection Nozzles..................................................................926 Fuel Injection Pump.....................................................................926 Cylinder Head...........................................................................926 Valves..................................................................................926 Valve Springs...........................................................................927 Valve Timing............................................................................927 Rocker Arms.............................................................................927 Camshaft................................................................................927 Tappet..................................................................................927 Cylinder Liner..........................................................................928 Piston Rings............................................................................928 Pistons.................................................................................928 Connecting Rod..........................................................................928 Oil Pump................................................................................928 Crankshaft..............................................................................929 Timing Gear.............................................................................929 Thermostat..............................................................................929 ENGINE SPECIFICATIONS - KUBOTA V2403-M-DI-T.................................................930 Fuel Injection Nozzles..................................................................930 Fuel Injection Pump.....................................................................930 Cylinder Head...........................................................................930 Valves..................................................................................930 Valve Springs...........................................................................931 Valve Timing............................................................................931 Rocker Arms.............................................................................931 Camshaft................................................................................931 Tappet..................................................................................931 Cylinder Liner..........................................................................932 Piston Rings............................................................................932 Pistons.................................................................................932 Connecting Rod..........................................................................932 Oil Pump................................................................................932 Crankshaft..............................................................................933 Timing Gear.............................................................................933 Thermostat..............................................................................933 TORQUE SPECIFICATIONS FOR BOLTS.............................................................934 Torque For General SAE Bolts............................................................934 Torque For General Metric Bolts.........................................................935 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................936 O-ring Face Seal Connection.............................................................936 Straight Thread O-ring Fitting..........................................................937 Tubelines And Hoses.....................................................................937 Flare Fitting...........................................................................937 O-ring Flare Fitting....................................................................938 Port Seal Fitting.......................................................................940 HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS..................................................942 Specifications..........................................................................942 CONVERSIONS.................................................................................944 Decimal And Millimeter Equivalents......................................................944 U.S. To Metric Conversion...............................................................944 SERVICE MANUAL REVISION.........................................................................946 Revision No: T180 - 1.......................................................................946 Revision No: T180 - 2.......................................................................948 Revision No: T180 - 3.......................................................................950 Revision No: T180 - 4.......................................................................952 Revision No: T180 - 5.......................................................................954 Revision No: T180 - 6.......................................................................956 Revision No: T180 - 7.......................................................................958 Revision No: T180 - 8.......................................................................960
Customer Support: [email protected]
https://vimeo.com/845518611?share=copy
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
S.V
