Bobcat T180 Compact Track Loader OEM Service & Repair Manual

6904142 (11-10) Printed in U.S.A. © Bobcat Company 2010 Service Manual T180 Compact Track Loader S/N 531411001 - 531459999 S/N 531511001 - 531559999 EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

MAINTENANCE SAFETY WARNING Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. W-2003-0807 Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer. Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows. Never service the Bobcat Compact Track Loader without instructions. Stop, cool and clean engine of flammable materials before checking fluids. Never service or adjust loader with the engine running unless instructed to do so in the manual. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes. Never fill fuel tank with engine running, while smoking or when near open flame. Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device. Replace it if damaged. Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust. Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding. Keep rear door closed except for service. Close and latch door before operating the loader. Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention. Use the correct procedure to lift or lower operator cab. Cleaning and maintenance are required daily. B-15659 CORRECT P-90216 CORRECT B-15660 CORRECT B-15664 WRONG WRONG B-15661 WRONG B-15662 WRONG B-6589 B-15663 WRONG WRONG B-15665 MSW09-0409 Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged. Never modify equipment or add attachments not approved by Bobcat Company. Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced. Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.

ALPHABETICAL INDEX ACCESS PANEL (INSIDE) ..................................... 50-01 ACCESS PANEL (INSIDE) (SJC) ........................... 50-01 AIR CLEANER ........................................................ 70-01 AIR CLEANER SERVICE ....................................... 10-01 AIR CONDITIONING SYSTEM FLOW ................... 80-01 ALTERNATOR ........................................................ 60-01 BACK-UP ALARM SYSTEM ................................... 60-01 BATTERY ................................................................ 60-01 BLOWER FAN ........................................................ 80-01 BOBCAT INTERLOCK CONTROL SYSTEM (BICS) ................................................... 60-01 BOBCAT CONTROLLER (ACS) ............................. 60-01 BOBCAT CONTROLLER (MAIN)............................ 60-01 BOBCAT CONTROLLER (SJC) (DRIVE) ............... 60-01 BOB-TACH (HAND LEVER) ........................ 10-01, 50-01 BOB-TACH (POWER) ............................................. 50-01 BOB-TACH (POWER) BLOCK................................ 20-01 BRAKE .................................................................... 40-01 BUCKET POSITION VALVE.................................. 20-01 CALIBRATION ........................................................ 60-01 CAMSHAFT AND TIMING GEARS......................... 70-01 CASE DRAIN FILTER ............................................. 30-01 CHARGE PRESSURE ........................................... 30-01 COMPRESSOR ...................................................... 80-01 CONDENSER ......................................................... 80-01 CONTROL HANDLE/LEVER .................................. 50-01 CONTROL HANDLE/LEVER (ACS) ....................... 50-01 CONTROL HANDLE/LEVER (SJC) ........................ 50-01 CONTROL PANEL .................................................. 50-01 CONTROL PANEL (SJC) ........................................ 50-01 CONTROL PANEL SETUP ..................................... 60-01 CONTROL PEDALS AND LINKAGE ...................... 50-01 CONTROL PEDALS (ACS) .................................... 50-01 CONTROL SYSTEM (ACS) .................................... 60-01 CONVERSIONS ................................................ SPEC-01 CRANKSHAFT AND PISTONS ............................. 70-01 CYLINDER (LIFT) ................................................... 20-01 CYLINDER (BOB-TACH) ........................................ 20-01 CYLINDER (TILT) ................................................... 20-01 CYLINDER HEAD ................................................... 70-01 DIAGNOSTICS SERVICE CODES ......................... 60-01 DRIVE BELT ........................................................... 30-01 ELECTRICAL/HYD. CONTROLS ............................ 60-01 ELECTRICAL/HYD. CONTROLS REFERENCE (SJC) .............................................. 60-01 ELECTRICAL SYSTEM INFORMATION ................. 60-01 ENGINE COOLING SYSTEM ................................. 10-01 ENGINE LUBRICATION SYSTEM ......................... 10-01 ENGINE COOLING SYSTEM ................................. 70-01 ENGINE INFORMATION ......................................... 70-01 ENGINE SPEED CONTROL ...................................70-01 ENGINE SPEED CONTROL (SJC) .........................70-01 EVAPORATOR ........................................................80-01 EVAPORATOR/HEATER UNIT................................80-01 EXPANSION VALVE ................................................ 80-01 FLYWHEEL AND HOUSING ................................... 70-01 FLYWHEEL RPM SENSOR ....................................60-01 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK ............................................... 20-01 FUEL SYSTEM............................................. 10-01, 70-01 FUEL TANK ............................................................. 50-01 HEATER COIL ......................................................... 80-01 HEATER VALVE ...................................................... 80-01 HIGH FLOW VALVE ................................................20-01 HYDRAULIC CONNECTION SPECS ............... SPEC-01 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)..20-01 HYDRAULIC CONTROL VALVE (STANDARD) ...... 20-01 HYDRAULIC/HYDROSTATIC FILTERS ..................20-01 HYDRAULIC FLUID RESERVOIR .......................... 20-01 HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS................................ SPEC-01 HYDRAULIC/HYDROSTATIC SYSTEM .................. 10-01 HYDRAULIC PUMP (STANDARD).......................... 20-01 HYDRAULIC PUMP (STANDARD) (HIGH FLOW)..20-01 HYDRAULIC PUMP (SJC) ...................................... 20-01 HYDRAULIC PUMP (SJC) (HIGH FLOW)............... 20-01 HYDRAULIC SYSTEM INFORMATION .................. 20-01 HYDROSTATIC MOTOR ......................................... 30-01 HYDROSTATIC PUMP ............................................ 30-01 HYDROSTATIC PUMP (SJC) .................................. 30-01 HYDROSTATIC SYSTEM INFORMATION.............. 30-01 INSTRUMENT PANELS ......................................... 60-01 LIFT ARMS .............................................................. 50-01 LIFT ARM BYPASS CONTROL VALVE .................. 20-01 LIFT ARM SUPPORT DEVICE................................ 10-01 LIFTING AND BLOCKING THE LOADER............... 10-01 LIGHTS.................................................................... 60-01 T180 LOADER SPECIFICATIONS .................... SPEC-01 LOADER STORAGE AND RETURN TO SERVICE 10-01 LUBRICATING THE LOADER ................................. 10-01 LUBRICATION SYSTEM ......................................... 70-01

ALPHABETICAL INDEX (CONT’D) MAIN RELIEF VALVE .............................................. 20-01 MAINTENANCE CLOCK ......................................... 60-01 MUFFLER ................................................................ 70-01 OIL COOLER ........................................................... 20-01 OPERATOR CAB..........................................10-01, 50-01 OPERATOR SEAT (SUSPENSION) ........................ 50-01 PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START) ................................................. 60-01 PIVOT PINS............................................................. 10-01 REAR AUXILIARY DIVERTER VALVE .................... 20-01 REAR DOOR ..........................................................50-01 REAR GRILLE.........................................................50-01 RECEIVER/DRIER .................................................. 80-01 REGULAR MAINTENANCE .................................... 80-01 REMOTE STARTTOOL KIT-MEL1563 ....................10-01 REMOTE START TOOL (SERVICE TOOL) KIT-6689779 .......................................................... 10-01 SEAT BAR............................................................... 50-01 SEAT BAR SENSOR............................................... 60-01 SERVICE PC (LAPTOP COMPUTER) .................... 60-01 SERVICE SCHEDULE.............................................10-01 SPARK ARRESTOR MUFFLER .............................. 10-01 SPEED SENSOR (SJC) .......................................... 60-01 STARTER ................................................................ 60-01 STEERING DRIFT COMPENSATION ..................... 60-01 STOPPING THE ENGINE AND LEAVING THE LOADER ....................................... 10-01 SYSTEM CHARGING AND RECLAMATION .......... 80-01 TEMPERATURE/PRESSURE ................................. 80-01 THERMOSTAT......................................................... 80-01 TORQUE SPECIFICATIONS FOR BOLTS........ SPEC-01 TOWING THE LOADER .......................................... 10-01 TRACK CARRIAGE COMPONENTS ...................... 40-01 TRACTION LOCK.................................................... 60-01 TRANSPORTING THE LOADER ON A TRAILER ..10-01 TROUBLESHOOTING............................................. 80-01 TURBOCHARGER .................................................. 70-01 WINDOW (FRONT DOOR) ..................................... 50-01 WINDOW (REAR).................................................... 50-01 WINDOW (SIDE) ..................................................... 50-01 WINDOW (TOP) ...................................................... 50-01

I CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01 MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 SAFETY & HYDROSTATIC MAIN FRAME SYSTEM SYSTEM DRIVE ELECTRICAL MAINTENANCE SYSTEM & ANALYSIS ENGINE SERVICE ENGINE SPECIFICATIONS HVAC SPECIFICATIONS HYDRAULIC SYSTEM

II 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: FW SSL-1008 SM 1. Check that the ROPS/FOPS (Including side screens) is in good condition and is not modified. 9. The parking brake must function correctly. 2. Check that ROPS mounting hardware is tightened and is Bobcat approved. 10. Enclosure door latches must open and close freely. 3. The seat belt must be correctly installed, functional and in good condition. 11. Bob-Tach wedges and linkages must function correctly and be in good condition. 4. The seat bar must be correctly adjusted, clean and lubricated. 12. Safety treads must be in good condition. 5. Check lift arm support device, replace if damaged. 13. Check for correct function of indicator lamps. 6. Machine signs (decals) must be legible and in the correct location. 14. Check hydraulic fluid level, engine oil level and fuel supply. 7. Steering levers, hand controls and foot pedals must return to neutral (as applicable). 15. Inspect for fuel, oil or hydraulic fluid leaks. 8. Check for correct function of the work lights. 16. Lubricate the loader.

III FW SSL-1008 SM 17. Check the condition of the battery and cables. 23. Operate the machine and check all functions. 18. Inspect the air cleaner for damage or leaks. Check the condition of the element. 24. Check for correct function of the Bobcat Interlock Control System (BICS™) before the machine is returned to the customer. 19. Check the electrical charging system. 25. Check for proper function of front horn and back-up alarm (if equipped). 20. Check tires for wear and pressure. Check tracks for wear and tension. Use only approved tires or tracks. 26. Check function or condition of all equipped options and accessories (examples: fire extinguisher, rotating beacon, lift kits, etc.). 21. Inspect for loose or broken parts or connections. 27. Recommend to the owner that all necessary corrections be made before the machine is returned to service. 22. Check for any field modification not completed. CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects and other reproductive harm.

IV FW SSL-1008 SM

Bobcat T180 Compact Track Loader OEM Service & Repair Manual

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