Complete workshop repair & service manual with electrical wiring diagrams for Bobcat T180 Compact Track Loader. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This Bobcat T180 Compact Track Loader service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

6902501 (12-06) - T180 Turbo, T180 Turbo High Flow Operation & Maintenance Manual.pdf
6902502 (7-09) - T180 Turbo, T180 Turbo High Flow Service Manual.pdf
6902820 (12-06) - T180 Turbo, T180 Turbo High Flow Operation & Maintenance Manual.pdf
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6903153 (2-06) - T140 Service Manual.pdf
6903153 (6-12) - T140 Service Manual.pdf
6904140 (4-08) - T180 Compact Track Loader Operation & Maintenance Manual.pdf
6904142 (11-10) - T180 Compact Track Loader Servicece Manual.pdf
6904148 (10-07) - T140 Compact Track Loader Operation & Maintenance Manual.pdf
6904150 (7-09) - T140 Compact Track Loader Service Manual.pdf
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6904978 (11-10) - T110 Compact Track Loader Operation & Maintenance Manual.pdf
6904979 (4-11) - T110 Compact Track Loader Service Manual.pdf
6904979 (7-10) - T110 Compact Track Loader Service Manual.pdf
6904979 (7-13) - T110 Compact Track Loader Service Manual.pdf
6986569 (11-10) - T140 Compact Track Loader Service Manual.pdf
6986968 (4-08) - T140 Compact Track Loader Operation & Maintenance Manual.pdf
6986997 (3-10) - T140 Compact Track Loader Operation & Maintenance Manual.pdf
6986999 (3-08) - T180 Compact Track Loader Operation & Maintenance Manual.pdf
6987015 (12-09) - T180 Compact Track Loader Operation & Maintenance Manual.pdf
6987041 (1-11) - T140 Compact Track Loader Service Manual.pdf
6987042 (11-10) - T180 Compact Track Loader Servicece Manual.pdf
6987051 (11-10) - T180 Compact Track Loader Servicece Manual.pdf
6989617 (3-11) - T180 Compact Track Loader Operation & Maintenance Manual.pdf
6989617 (11-10) - T180 Compact Track Loader Operation & Maintenance Manual.pdf

EXCERPT:
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
MAINFRAME . . .  . . .  . . .  . . . . . . . 50-01
ELECTRICAL SYSTEM & ANALYSIS . . .  . . . . . . 60-01
ENGINE SERVICE  . . .  . . .   . . . . . 70-01
HEATING, VENTILATION, AIR CONDITIONING  . . . . . . 80-01
SPECIFICATIONS . . .  . . .   . . . SPEC-01
…
HYDROSTATIC PUMP (SJC) (CONT'D)
Disassembly And Assembly (Cont'd)
Figure 30-41-37
Figure 30-41-38
Figure 30-41-39
Figure 30-41-40
Assembly: Align the timing pin (Item 1) [Figure 30-41-37] and [Figure 30-41-38] in the case housing with the notch (Item 1) [Figure 30-41-39] and [Figure 30-41-40] that does not go through the valve plate.
Align the shoulder of the roller bearing (Item 2) [Figure 30-41-37] and [Figure 30-41-38] with the beveled edge on the valve plate (Item 2) [Figure 30-41-39] and [Figure 30-41-40].
NOTE: Valve plate should sit FLUSH with the case housing when properly installed.
…

6902501 (12-06) - T180 Turbo, T180 Turbo High Flow Operation & Maintenance Manual...1
  OPERATOR SAFETY WARNINGS...3
  CONTENTS...5
  FOREWORD...7
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...9
    REGULAR MAINTENANCE ITEMS...9
    MOTOR OIL...9
    SERIAL NUMBER LOCATIONS...10
      Loader Serial Number...10
      Engine Serial Number...10
    DELIVERY REPORT...10
    MACHINE IDENTIFICATION...11
    FEATURES, ACCESSORIES AND ATTACHMENTS...12
      Standard Items...12
      Options and Accessories...12
      Buckets Available...13
      Attachments...13
  SAFETY...15
    SAFETY INSTRUCTIONS...17
      Before Operation...17
      Safe Operation Is The Operator’s Responsibility...18
      Safe Operation Needs A Qualified Operator...18
      Fire Prevention...19
    MACHINE SIGNS (DECALS)...20
    INSTRUMENT PANEL IDENTIFICATION...25
      Left Panel...25
      Right Panel (Standard - With Key Switch)...26
      Right Panel (Deluxe - With Keyless Start)...27
      Option And Field Accessory Panels (If Equipped)...29
      Cab Light...30
    LIFT ARM BY-PASS CONTROL...30
      Operation...30
    TRACTION LOCK OVERRIDE...30
      Operation...30
    ENGINE SPEED CONTROL...31
      Operation...31
    PARKING BRAKE...31
      Operation...31
    DRIVING AND STEERING THE LOADER...32
      Available Controls Configurations...32
      Operation (Standard and ACS)...32
    STOPPING THE BOBCAT LOADER...32
      Using The Steering Levers...32
    SEAT BAR RESTRAINT SYSTEM...33
      Operation...33
    HYDRAULIC CONTROLS...34
      Operation...34
      Standard Controls (Also ACS - Foot Pedal Selected)...34
      Advanced Control System (ACS) (HAND Control Selected)...35
      Quick Couplers...36
      Releasing Hydraulic Pressure (Loader and Attachment)...36
      Auxiliary Hydraulics Button - VARIABLE FLOW...37
      Auxiliary Hydraulics Button - MAXIMUM FLOW ONLY...37
      Auxiliary Hydraulics Button - DISENGAGE...37
      FRONT Auxiliary Hydraulics Operation - VARIABLE FLOW...37
      FRONT Auxiliary Hydraulics Operation - MAXIMUM FLOW...37
      FRONT Auxiliary Hydraulics Operation - CONTINUOUS FLOW...37
      REAR Auxiliary Hydraulics Operation (If Equipped)...38
      High-Flow Hydraulics Operation (If Equipped)...38
      Attachment Control Device (ACD) (If Equipped)...39
      Secondary Front Auxiliary Hydraulics (If Equipped)...39
      Bucket Position Valve Operation (If Equipped)...40
    DAILY INSPECTION...41
      Daily Inspection and Maintenance...41
    PRE-STARTING PROCEDURES...42
      Before Starting The Engine...42
    STARTING THE ENGINE (STANDARD PANEL, KEY SWITCH)...44
      Procedure...44
    STARTING THE ENGINE (DELUXE PANEL, KEYLESS START)...46
      Procedure...46
      Cold Temperature Starting...47
    WARMING THE HYDRAULIC/HYDROSTATIC SYSTEM...48
      Procedure...48
    STOPPING THE ENGINE...49
      Procedure...49
    MONITORING THE DISPLAY PANEL...50
      Standard Panel...50
      Deluxe Panel...50
      WARNING and SHUTDOWN...50
    ATTACHMENTS AND BUCKETS...51
      Choosing The Correct Bucket...51
      Pallet Forks...52
      Hand Lever Bob-Tach - Installing The Bucket Or Attachment...52
      Hand Lever Bob-Tach - Removing The Bucket Or Attachment...54
      Power Bob-Tach - Installing The Bucket Or Attachment...55
      Power Bob-Tach - Removing The Bucket Or Attachment...56
    OPERATING PROCEDURE...57
      Operating With A Full Bucket...57
      Operating With An Empty Bucket...58
      Compact Track Loader Operating Tips...59
      Foot Pedal Machines...60
      Hand Control Machines (ACS)...62
    PARKING THE BOBCAT LOADER...64
      Procedure...64
    TOWING THE LOADER...64
      Towing Procedure...64
    TRANSPORTING THE BOBCAT LOADER...65
      Loading Onto Transport Vehicle...65
      Fastening To Transport Vehicle...65
    LIFTING THE LOADER...66
      Single Point Lift...66
      Four Point Lift...66
  PREVENTIVE MAINTENANCE...67
    MAINTENANCE SAFETY...71
    SERVICE SCHEDULE...73
      Chart...73
    LIFT ARM SUPPORT DEVICE...74
      Engaging The Lift Arm Support Device...74
      Disengaging The Lift Arm Support Device...75
    HEATER AND AIR CONDITIONING...76
      Cleaning And Maintenance...76
      Adjusting The Air Conditioner Belt...77
    OPERATOR CAB...78
      Raising The Operator Cab...78
      Lowering The Operator Cab...79
      Cab Door Sensor...79
      Emergency Exit...80
    SEAT BELT...81
      Inspection and Maintenance...81
    SEAT BAR RESTRAINT SYSTEM...82
      Inspecting The Seat Bar...82
      Maintaining The Seat Bar...82
    BOCAT INTERLOCK CONTROL SYSTEM (BICS)...83
      Inspecting The BICS Controller (Engine Stopped - Key ON)...83
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...83
      Inspecting The Seat Bar Sensor (Engine RUNNING)...83
      Inspecting The Traction Lock (Engine RUNNING)...83
      Inspecting The Lift Arm By-Pass Control...83
      Inspecting Deactivation Of Lift And Tilt Functions (ACS)...83
    TRACK TENSION...84
      Adjusting (Increase Track Tension)...84
      Adjusting (Decrease Track Tension)...85
    TRACK SPROCKET MAINTENANCE...86
    HYDROSTATIC MOTOR CARRIER LUBRICATION...86
    TRACK ROLLER AND IDLER LUBRICATION...86
    REAR DOOR...87
      Opening And Closing The Rear Door...87
      Adjusting The Rear Door Latch...87
    REAR GRILL...88
      Removing...88
      Installing...88
    AIR CLEANER SERVICE...89
      Replacing Filter Elements...89
    FUEL SYSTEM...90
      Fuel Specifications...90
      Filling The Fuel Tank...90
      Fuel Filter...91
      Removing Air From The Fuel System...91
    ENGINE LUBRICATION SYSTEM...92
      Checking Engine Oil...92
      Replacing The Oil And Filter...92
    ENGINE COOLING SYSTEM...93
      Cleaning The Cooling System...93
      Checking Coolant Level And Adding Coolant...93
      Replacing The Coolant...94
    ALTERNATOR BELT...94
      Adjusting The Alternator Belt...94
    ELECTRICAL SYSTEM...95
      Description...95
      Cleaning Battery and Terminals...95
      Fuse Location...96
      Using A Booster Battery (Jump Starting)...97
      Removing And Installing The Battery...98
    HYDRAULIC / HYDROSTATIC SYSTEM...99
      Checking And Adding Fluid...99
      Replacing Hydraulic/Hydrostatic Filter...99
      Replacing Hydraulic Fluid and Case Drain Filters...100
      Hydraulic Breather...101
    FAN GEARBOX...101
      Checking And Maintaining...101
    DRIVE BELT...102
      Adjusting The Drive Belt...102
      Replacing The Drive Belt...102
    SPARK ARRESTOR MUFFLER...103
    LUBRICATING THE BOBCAT LOADER...104
      Lubrication Locations...104
    PIVOT PINS...105
      Inspection And Maintenance...105
    BOB-TACH (HAND LEVER)...106
      Inspection And Maintenance...106
    BOB-TACH (POWER) (OPTIONAL)...107
      Inspection And Maintenance...107
  SYSTEM SETUP & ANALYSIS...109
    BICS SYSTEM...111
      Troubleshooting Guide...111
    DIAGNOSTICS SERVICE CODES...112
      Display...112
      Number Codes List...113
    DELUXE INSTRUMENT PANEL SETUP...117
      Deluxe Panel Upgrade...117
      Deluxe Panel Setup...118
      Passwords (Deluxe)...118
    SHUTDOWN FEATURE...120
    SERVICE CLOCK RESET...120
  MACHINE SIGN TRANSLATIONS...121
    SERVICE SCHEDULE (6734534)...123
    WARNING (6728540)...124
    WARNING (6577754)...125
    WARNING (6718391)...125
    WARNING (6732696)...125
    DANGER (6718392)...126
    LIFT ARM SUPPORT DEVICE (6706558)...126
    DANGER (6718393)...126
    DANGER (6717343)...127
    IMPORTANT (6560573)...127
  SPECIFICATIONS...129
    LOADER SPECIFICATIONS (T180)...131
      Machine Dimensions...131
      Performance...132
      Controls...132
      Engine...132
      Hydraulic System...133
      Electrical...133
      Drive System...134
      Capacities...134
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS...135
  WARRANTY...137
6902502 (7-09) - T180 Turbo, T180 Turbo High Flow Service Manual...139
  MAINTENANCE SAFETY...141
  ALPHABETICAL INDEX...143
  CONTENTS...145
    FOREWORD...146
    SAFETY INSTRUCTIONS...149
    FIRE PREVENTION...151
      Maintenance...151
      Operation...151
      Electrical...151
      Hydraulic System...151
      Fueling...151
      Starting...151
      Spark Arrestor Exhaust System...151
      Welding And Grinding...152
      Fire Extinguishers...152
    SERIAL NUMBER LOCATION...153
      Loader Serial Number...153
      Engine Serial Number...153
    DELIVERY REPORT...154
    LOADER IDENTIFICATION...155
  SAFETY & MAINTENANCE...157
    LIFTING AND BLOCKING THE LOADER...159
      Procedure...159
    LIFT ARM SUPPORT DEVICE...161
      Installing Lift Arm Support Device...161
      Removing The Lift Arm Support Device...162
    OPERATOR CAB...163
      Description...163
      Raising The Operator Cab...163
      Lowering The Operator Cab...164
      Cab Door Sensor...165
      Emergency Exit...166
    TRANSPORTING THE BOBCAT LOADER...167
      Procedure...167
    TOWING THE LOADER...169
      Procedure...169
    REMOTE START...171
      Procedure...171
    SERVICE SCHEDULE...175
      Chart...175
    AIR CLEANER SERVICE...177
      Replacing Filter Element...177
    ENGINE COOLING SYSTEM...179
      Cleaning The Cooling System...179
      Checking The Coolant Level...180
      Replacing the Coolant...180
    FUEL SYSTEM...183
      Fuel Specifications...183
      Filling The Fuel Tank...183
      Fuel Filter...184
      Removing Air From The Fuel System...184
    ENGINE LUBRICATION SYSTEM...185
      Checking Engine Oil...185
      Oil Chart...185
      Replacing Oil And Filter...186
    HYDRAULIC/HYDROSTATIC SYSTEM...187
      Checking And Adding Fluid...187
      Replacing Hydraulic/Hydrostatic Filter...187
      Replacing Hydraulic Fluid...188
      Breather Cap...190
    FAN GEARBOX...191
      Checking And Maintaining...191
    BOB-TACH...193
      Inspection And Maintenance...193
    POWER BOB-TACH (OPTION)...195
      Inspection And Maintenance...195
    LUBRICATION OF THE BOBCAT LOADER...197
      Procedure...197
    SPARK ARRESTOR MUFFLER...199
      Cleaning Procedure...199
  HYDRAULIC SYSTEM...201
    HYDRAULIC / HYDROSTATIC SCHEMATICS...207
    HYDRAULIC SYSTEM INFORMATION...223
      Troubleshooting Chart...227
      Tighten Procedures...228
    CYLINDER (LIFT)...229
      Checking...229
      Removal And Installation...230
      Parts Identification...231
      Disassembly...232
      Assembly...233
    CYLINDER (TILT)...237
      Checking...237
      Removal And Installation...238
      Base End Pivot Pin Replacement...239
      Rod End Pivot Pin Bushing And Seal Replacement...240
      Parts Identification...241
      Disassembly...242
      Assembly...243
    CYLINDER (POWER BOB-TACH)...247
      Checking...247
      Removal And Installation...248
      Parts Identification...249
      Disassembly...250
      Assembly...251
    MAIN RELIEF VALVE...255
      Checking...255
      Adjustment...256
      Removal and Installation...257
    HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL)...259
      Identification...259
      Removal And Installation...259
      BICS Valve Removal And Installation...263
      BICS Valve, Lift Arm Bypass Orifice Disassembly And Assembly...264
      BICS Valve, Check Valve Disassembly And Assembly...265
      BICS Valve Lock Valve Disassembly And Assembly...266
      BICS Valve Solenoid Disassembly And Assembly...267
      BICS Valve Solenoid Testing...268
      Identification Chart...269
      Load Check Valve...270
      Main Relief Valve...271
      Port Relief Valve...272
      Anti-Cavitation Valve/Port Relief Valve...273
      Anti-Cavitation Valve...274
      Rubber Boot...275
      Lift And Tilt Lock Block...275
      Lift Spool and Detent...276
      Tilt Spool Removal And Installation...285
      Auxiliary Spool Removal And Installation...287
      Auxiliary Electric Solenoid Disassembly...288
      Port-Auxiliary Section Disassembly...289
      Cleaning And Inspection...289
    HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)...291
      Identification...291
      Removal and Installation...291
      BICS Valve Removal And Installation...295
      BICS Valve, Lift Arm Bypass Orifice Removal And Installation...297
      BICS Valve, Check Valve Removal And Installation...298
      BICS Valve Lock Valve Removal And Installation...299
      BICS Valve Solenoid Removal And Installation...300
      BICS Valve Solenoid Testing...301
      Actuator Removal And Installation...302
      Identification Chart (ACS)...304
      Lift Base End Restrictor...305
      Load Check Valve...305
      Main Relief Valve...306
      Port Relief Valve...307
      Anti-Cavitation Valve/Port Relief Valve...308
      Anti-Cavitation Valve...309
      Tilt Spool Removal And Installation...309
      Lift Spool Removal And Installation...310
      Lift and Tilt Spool Disassembly And Assembly...311
      Auxiliary Spool Removal And Installation...312
      Auxiliary Electric Solenoid...313
      Port-Auxiliary Section...314
      Cleaning And Inspection...314
    HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL)...315
      Identification...315
      Removal And Installation...315
      Identification Chart...321
      Mount Bracket Removal and Installation...322
      BICS Valve, Lift Load Check Valve Removal And Installation...322
      BICS Valve, Lift Load Check Valve Removal And Installation (Cont’d)...323
      Load Check Valve Removal And Installation (Tilt & Auxiliary)...323
      Anti-Cavitation Valve (Lift, Rod End)...324
      Port Relief/Anti-Cavitation Valve (Lift, Base End)...325
      Port Relief/Anti-Cavitation Valve (Tilt, Base End)...325
      Port Relief/Anti-Cavitation Valve (Tilt, Rod End)...326
      Port Relief Valve...326
      Port Relief Valve (Cont’d)...327
      Plug Removal...327
      Plug Removal (Cont’d)...328
      Rubber Boot Removal and Installation...328
      End Cap/Spool Lock Block Removal and Installation...329
      Lift Spool and Detent Removal and Installation...330
      Tilt Spool Removal and Installation...339
      Auxiliary Spool Removal And Installation...341
      Auxiliary Spool Removal And Installation (Cont’d)...342
      Auxiliary Solenoid Disassembly and Assembly...343
      BICS Valve Solenoid Disassembly And Assembly...344
      BICS Valve, Lock Valve Removal And Installation...345
      BICS Valve, Lock Valve Removal And Installation (Cont’d)...346
      BICS Valve, Check Valve Removal And Installation...347
      BICS Valve, Check Valve Removal And Installation (Cont’d)...347
      BICS Valve, Lift Arm Bypass Orifice Disassembly And Assembly...348
      Main Relief Valve...348
    HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)...349
      Identification...349
      Removal And Installation...349
      Actuator Removal And Installation (Out of Loader)...354
      Identification Chart (ACS)...357
      Mount Bracket Removal and Installation...358
      BICS Valve, Lift Load Check Valve Removal And Installation...358
      Load Check Valve Removal And Installation (Tilt & Auxiliary)...359
      Anti-Cavitation Valve (Lift, Rod End)...360
      Port Relief/Anti-Cavitation Valve (Lift, Base End)...361
      Port Relief/Anti-Cavitation Valve (Tilt, Base End)...361
      Port Relief/Anti-Cavitation Valve (Tilt, Rod End)...362
      Port Relief Valve...362
      Plug Removal...363
      End Cap Block Removal and Installation...364
      Lift Spool Removal and Installation...365
      Tilt Spool Removal and Installation...369
      Auxiliary Spool Removal And Installation...371
      Auxiliary Solenoid Disassembly and Assembly...372
      BICS Valve Solenoid Disassembly And Assembly...373
      BICS Valve, Lock Valve Removal And Installation...374
      BICS Valve, Check Valve Removal And Installation...376
      BICS Valve, Lift Arm Bypass Orifice Disassembly And Assembly...377
      Main Relief Valve...377
    LIFT ARM BYPASS CONTROL VALVE...379
      Inspecting...379
      Removal and Installation...379
      Disassembly And Assembly...380
    HYDRAULIC PUMP...381
      Check The Output Of The Hydraulic Pump Without Power Bob-Tach...381
      Check The Output Of The Hydraulic Pump With Power Bob-Tach...383
      Removal And Installation...385
      Identification...387
      Disassembly And Assembly...388
    HYDRAULIC PUMP (HIGH FLOW)...393
      Check The Output Of The Hydraulic Pump (Standard)...393
      Check The Output Of The Hydraulic Pump (High Flow)...395
      Removal And Installation...397
      Identification...399
      Disassembly And Assembly...400
    HYDRAULIC PUMP (SJC)...409
      Test The Output Of The Hydraulic Auxiliary Pump...409
      Test The Output Of The Hydraulic Charge Pump...410
      Removal And Installation...412
      Identification...414
      Disassembly And Assembly...415
    HYDRAULIC PUMP (HIGH FLOW) (SJC)...423
      Test The Output Of The Hydraulic Auxiliary Pump...423
      Test The Output Of The Hydraulic Charge Pump...424
      Test The Output Of The Hydraulic Pump (High Flow)...426
      Removal And Installation...428
      Identification...430
      Disassembly And Assembly...431
    HYDRAULIC/HYDROSTATIC FILTER HOUSING...443
      Removal And Installation...443
    HYDRAULIC FLUID RESERVOIR...445
      Removal And Installation...445
    BUCKET POSITION VALVE...449
      Solenoid Removal And Installation...449
      Solenoid Testing...450
      Removal And Installation...451
      Disassembly And Assembly...453
    HIGH FLOW VALVE...455
      Checking The High Flow Relief Valve...455
      High Flow Relief Valve Adjustment Procedure...457
      Removal And Installation...458
      Disassembly And Assembly...460
      Solenoid Testing...462
    REAR AUXILIARY DIVERTER VALVE...463
      Removal And Installation...463
      Disassembly And Assembly...466
      Solenoid Testing...471
      Inspection...471
    POWER BOB-TACH BLOCK...473
      Removal And Installation...473
      Disassembly And Assembly...475
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK...479
      Removal and Installation...479
      Disassembly And Assembly...479
  HYDROSTATIC SYSTEM...481
    HYDROSTATIC SYSTEM INFORMATION...483
      Troubleshooting Chart...483
      Replenishing Valve Function...484
    HYDROSTATIC MOTOR...485
      Replacing the Motor Oil...485
      Removal And Installation...486
      Parts Identification...488
      Disassembly...490
      Inspection...498
      Assembly...499
    HYDROSTATIC MOTOR (SJC)...509
      Replacing the Motor Oil...509
      Removal And Installation...510
      Parts Identification...512
      Disassembly and Assembly...514
    CHARGE PRESSURE...525
      Sender Removal And Installation (Non SJC Machines)...525
      Testing (Non SJC Machines)...525
      Adjusting (Non SJC Machines)...526
      Sender Removal And Installation (SJC Machines)...527
      Testing (SJC Machines)...527
      Adjusting (SJC Machines)...528
    HYDROSTATIC PUMP...529
      Replenishing/High Pressure Relief Valve...529
      Removal And Installation...530
      Parts Identification (Right Half)...532
      Parts Identification (Left Half)...534
      Hydraulic Pump Removal And Installation...536
      Pump Separation...536
      Disassembly...537
      Assembly...543
    HYDROSTATIC PUMP (SJC)...551
      Description...551
      Hydraulic Controller Removal And Installation...552
      Removal And Installation...554
      Parts Identification...556
      High Pressure Relief and Bypass Valve...557
      Charge Relief Valve...558
      Disassembly and Assembly...559
      Mechanical Neutral Adjustment...575
      Hydraulic Controller Neutral Adjustment...578
    DRIVE BELT...581
      Shield Removal And Installation...581
      Adjusting...581
      Drive Belt Replacement...583
      Tensioner Pulley Removal And Installation...584
      Tensioner Pulley Parts Identification...585
      Tensioner Pulley Disassembly...586
      Tensioner Pulley Assembly...587
    OIL COOLER...589
      Removal and Installation...589
  DRIVE SYSTEM...591
    BRAKE...593
      Pressure Relief Valve Test...593
      Right Motor Brake Test...594
      Left Motor Brake Test...595
      Block Removal And Installation...597
      Block Disassembly And Assembly...599
    DRIVE COMPONENTS...601
      Track Tension...601
      Track Tension Adjusting...601
      Track Removal And Installation...604
      Track Idler (Front) Removal And Installation...607
      Track Idler (Front) Parts Identification...609
      Track Idler (Front) Disassembly...610
      Track Idler (Front) Assembly...611
      Track Idler (Rear) End Play Specifications...614
      Track Idler (Rear) Parts Identification...614
      Track Idler (Rear) Removal And Installation...614
      Track Idler (Rear) Disassembly...615
      Track Idler (Rear) Assembly...616
      Track Roller Assembly End Play Specifications...618
      Track Roller Parts Identification...618
      Track Roller Removal And Installation...618
      Track Roller Disassembly...619
      Track Roller Assembly...620
      Track Housing Removal And Installation...622
      Track Damage Identification...623
  MAIN FRAME...635
    SEAT BAR...639
      Removal And Installation...639
      Assembling Components...641
      Compression Spring Disassembly And Assembly...643
    OPERATOR CAB...645
      Gas Cylinder Removal And Installation...645
      Gas Cylinder Disassembly...647
      Removal And Installation...648
    OPERATOR SEAT...651
      Removal And Installation...651
      Slide Rail Removal And Installation...652
      Cushion Removal And Installation...652
      Back Removal And Installation...653
      Shock Removal And Installation...654
    BOB-TACH...655
      Removal And Installation...655
      Bob-Tach Lever And Wedge...656
    POWER BOB-TACH...659
      Removal And Installation...659
      Power Bob-Tach Lever And Wedge...660
    LIFT ARMS...663
      Removal And Installation...663
    REAR GRILL...667
      Removal And Installation...667
    REAR DOOR...669
      Removal And Installation...669
      Striker Removal and Installation...670
      Striker Disassembly and Assembly...670
      Adjusting The Striker...670
      Latch Removal and Installation...671
    FUEL TANK...673
      Removal And Installation...673
      Fuel Level Sender...674
      Fuel Fill Screen...674
      Fuel Pickup Screen...675
    CONTROL PEDALS...677
      Removal And Installation...677
      Pedal Adjustment...677
      Crossbar Linkage Removal And Installation...678
      Lift Foot Pedal Linkage Removal And Installation...679
      Tilt Foot Pedal Linkage Removal And Installation...680
    CONTROL PEDALS (ACS)...681
      Foot Sensor Removal And Installation...681
      Foot Pedal Removal And Installation...682
      Foot Pedal Linkage Disassembly And Assembly...683
    CONTROL PANEL (NON-ADJUSTABLE PINTLES)...685
      Removal and Installation...685
      Shock Removal And Installation...688
      Shaft Removal And Installation...688
      Shaft Disassembly And Assembly...688
      Linkage Removal And Installation...689
      Linkage Adjustment...692
      Linkage Neutral Adjustment...696
    CONTROL PANEL (ADJUSTABLE PINTLES)...699
      Description...699
      Removal and Installation...700
      Shock Removal And Installation...703
      Shaft Removal And Installation...703
      Shaft Disassembly And Assembly...704
      Linkage Removal And Installation...705
      Pintle Arm Disassembly and Assembly...709
      Linkage Neutral Adjustment...711
      Linkage Travel Adjustment...715
    CONTROL PANEL (SELECTABLE JOYSTICK CONTROL) (SJC)...719
      Removal And Installation...719
    CONTROL HANDLE...721
      Control Lever Removal And Installation...721
      Control Lever Boot...721
    CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL...723
      Components Identification...723
      Handle Sensor Removal And Installation...724
      Control Handle Removal and Installation...727
      Control Handle Disassembly and Assembly...728
      Control Lever Removal and Installation...728
      Control Lever Boot...730
    CONTROL HANDLE (SELECTABLE JOYSTICK CONTROL) (SJC)...731
      Joystick Testing (Right & Left)...731
      Joystick Removal (Right & Left)...732
      Lever Assembly Removal (Right & Left)...733
  ELECTRICAL SYSTEM...735
    ELECTRICAL SCHEMATICS...739
    ELECTRICAL SYSTEM INFORMATION...750
      Troubleshooting Chart...752
      Description...753
      Fuse Location...754
      Relay Switch Location...754
      Solenoid Test...755
    BATTERY...756
      Removal And Installation...756
      Servicing...757
      Using A Booster Battery (Jump Starting)...758
    ALTERNATOR...760
      Adjusting The Alternator Belt...760
      Alternator Identification...760
      Charging System Check...761
      Alternator Voltage Test...762
      Low Voltage Test...763
      High Voltage Test...763
      Removal And Installation...763
      Rectifier Continuity (Diode) Test...764
      Alternator Regulator Test...765
      Disassembly...766
      Stator Continuity Test...767
      Stator Ground Test...767
      Rotor Continuity Test...767
      Rotor Ground Test...767
      Assembly...768
    STARTER...770
      Checking...770
      Removal And Installation...771
      Parts Identification...772
      Disassembly and Assembly...773
      Inspection And Repair...776
      No Load Test...778
    INSTRUMENT PANEL...780
      Left Panel...780
      Right Panel (Standard) (With Key Switch)...781
      Right Panel (Deluxe) (With Keyless Start)...782
      Right Panel Setup Display Options (Deluxe)...784
      Deluxe Panel Setup...785
      Passwords (Deluxe)...785
      Option And Field Accessory Panels (If Equipped)...787
      Standard Panel Removal And Installation (Right Side)...788
      Deluxe Panel Removal And Installation (Right Side)...789
      Standard & Deluxe Panel Removal And Installation (Left Side)...790
      Front Accessory Panel Removal And Installation...791
    LIGHTS...792
      Front Removal And Installation...792
      Rear Removal And Installation...793
    BOBCAT CONTROLLER...794
      Identification Chart...794
      Removal And Installation...796
    CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC)...798
      Removal and Installation...798
      Identification Chart...801
    DIAGNOSTICS SERVICE CODES...804
      Display...804
      Number Codes List...805
    BICS SYSTEM...812
      Inspecting The BICS Controller (Engine STOPPED - Key ON)...812
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...812
      Inspecting The Seat Bar Sensor (Engine RUNNING)...812
      Inspecting The Traction Lock (Engine RUNNING)...812
      Inspecting The Lift Arm Bypass Control...813
      Additional Inspection For Loaders With Advanced Control System (ACS)...813
      Troubleshooting Chart...814
      Troubleshooting Guide...815
    SEAT BAR SENSOR...816
      Troubleshooting Chart...816
      Test...817
      Removal And Installation...818
      BICS Circuit Test...819
    TRACTION LOCK...822
      Troubleshooting Chart...822
      Description Of The Control System...823
      Inspecting The Control System...823
    ADVANCED CONTROL SYSTEM (ACS)...824
      Components Identification...824
      Troubleshooting Guide...826
      Controller, Connector And Wire Identification...827
      ACS Controller Removal And Installation...828
      Handle Sensor Connector...829
      Switch Handle Removal...830
      Switch Handle Installation...832
      Actuators Disassembly and Assembly...835
      Handle Lock Solenoid Removal And Installation...836
      Handle Lock Solenoid Disassembly And Assembly...837
      Handle Lock Solenoid Connector...838
      Calibration Procedure...839
      Foot Sensor Disassembly And Assembly...841
      Foot Sensor Connector...841
      Foot Lock Solenoid Removal And Installation...842
      Foot Lock Solenoid Connector...843
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE...844
      Controls Identification Chart...844
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (selectable JOYstick control) (sjc)...846
      Controls Identification Chart...846
    FLYWHEEL RPM SENSOR...850
      Adjustment...850
    SERVICE PC (LAPTOP COMPUTER)...852
      Connecting The Service PC To Remote Start Tool...852
    CALIBRATION...854
      Description...854
      Actuator Testing...854
      Lift and Tilt Calibration Procedure (SJC)...857
      Hydrostatic Pump Calibration (SJC)...858
      Calibration Procedure (ACS)...864
    SPEED SENSOR (SELECTABLE JOYSTICK CONTROL) (SJC)...866
      Description...866
      Testing...866
      Removal and Installation...868
  ENGINE SERVICE...872
    TROUBLESHOOTING...874
      Chart...874
    ENGINE SPEED CONTROL...876
      Removal And Installation...876
      Disassembly...877
    ENGINE SPEED CONTROL (SELECTABLE JOYSTICK CONTROL) (SJC)...878
      Removal and Installation...878
      Disassembly and Assembly...880
    MUFFLER...882
      Removal And Installation...882
    AIR CLEANER...884
      Removal And Installation...884
    RADIATOR...886
      Removal And Installation...886
    COOLING FAN...890
      Drive Tension Pulley Removal And Installation...890
      Gearbox/Blower Housing Removal And Installation...891
      Blower Housing Grill Removal And Installation...893
      Blower Disassembly And Assembly...893
      Gearbox Parts Identification...895
      Gearbox Disassembly...896
      Gearbox Assembly...901
      Gearbox Checking Backlash...906
    ENGINE COMPONENTS AND TESTING...910
      Compression Checking...910
      Glow Plugs Checking...911
      Glow Plugs Removal And Installation...911
      Fuel Shut-Off Solenoid, Checking...912
      Fuel Shut-Off Solenoid Removal And Installation...913
      Fuel Injection Pump Removal And Installation...914
      Timing The Injection Pump...917
      Fuel Injector Removal And Installation...919
      Checking Nozzle Injection Pressure...920
      Nozzle Spraying Condition...921
      Valve Seat Tightness...921
      Valve Clearance Adjustment...922
      Valve Timing, Checking...923
    ENGINE...924
      Removal And Installation...924
      Engine Mount Replacement...932
    FLYWHEEL AND HOUSING...934
      Flywheel Removal And Installation...934
      Ring Gear Removal And Installation...934
      Housing Removal And Installation...935
    RECONDITIONING THE ENGINE...938
      Cylinder Head Removal And Installation...938
      Cylinder Head Disassembly And Assembly...941
      Cylinder Head Servicing...942
      Cylinder Head Top Clearance...942
      Valve Guide Checking...943
      Reconditioning The Valve And Valve Seat...945
      Valve Spring...946
      Rocker Arm And Shaft Checking...947
      Timing Gearcase Cover Removal And Installation...947
      Idler Gear And Camshaft Removal And Installation...950
      Camshaft Servicing...951
      Idler Gear And Shaft Servicing...952
      Timing Gears Checking Backlash...953
      Fuel Camshaft Removal And Installation...953
      Fuel Camshaft Governor...954
      Crankshaft Gear Removal And Installation...954
      Oil Pump Removal And Installation...955
      Oil Pump Service...955
      Checking Engine Oil Pressure...956
      Valve Tappets...957
      Piston And Connecting Rod Removal And Installation...957
      Piston And Connecting Rod Servicing...959
      Connecting Rod Alignment...962
      Crankshaft And Bearings Removal And Installation...962
      Crankshaft And Bearings, Servicing...964
      Cylinder Bore, Checking...968
      Water Pump Removal And Installation...969
      Water Pump Disassembly And Assembly...969
    TURBOCHARGER...970
      Checking...970
      Description...970
      Removal And Installation...971
  HEATING, VENTILATION, AIR CONDITIONING...974
    AIR CONDITIONING SYSTEM FLOW...977
      Principals...977
      Chart...978
    COMPONENTS...980
      Identification...980
    SAFETY...984
      Safety Equipment...984
    REGULAR MAINTENANCE...986
      Filter Elements Removal And Installation...986
      Compressor Drive Belt Inspection...987
      Cleaning The Condenser...988
    BASIC TROUBLESHOOTING...990
      Poor A/C Performance...990
      Cleaning The A/C Evaporator Coil & Heater Coil...990
      Compressor Drive Belt Inspection...991
      Checking The Electrical System...992
      Engine Coolant Bypassing The Heater Valve...999
      Heater Valve Not Opening Or Closing...1000
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...1002
      Compressor Oil...1002
      Compressor Oil Check...1003
      Component Replacement And Refrigeration Leaks...1004
    SYSTEM TROUBLESHOOTING CHART...1006
      Gauge Pressure Related Troubleshooting...1007
    TEMPERATURE/PRESSURE...1010
      Chart...1010
    AIR CONDITIONING SERVICE...1012
      Chart...1012
    SYSTEM CHARGING AND RECLAMATION...1014
      Reclamation Procedure...1014
      Charging Procedure With A Manifold Gauge Set...1017
      Charging Procedure...1018
    COMPRESSOR...1022
      Removal And Installation...1022
      Compressor Clutch Disassembly...1023
    CONDENSER...1028
      Removal And Installation...1028
    RECEIVER/DRIER...1030
      Removal And Installation...1030
    PRESSURE RELIEF VALVE...1032
      Removal And Installation...1032
    PRESSURE SWITCH...1034
      Removal And Installation...1034
    EVAPORATOR/HEATER UNIT...1036
      Removal And Installation...1036
      Disassembly And Assembly...1038
    THERMOSTAT...1040
      Removal And Installation...1040
    EXPANSION VALVE...1042
      Removal And Installation...1042
    EVAPORATOR...1044
      Removal And Installation...1044
    HEATER COIL...1046
      Removal And Installation With A/C...1046
      Removal And Installation Without A/C...1047
    HEATER/AC FAN...1048
      Removal And Installation...1048
      Disassembly And Assembly...1049
      Wire Connector Removal and Installation...1051
    HEATER VALVE...1054
      Removal And Installation...1054
      Disassembly And Assembly...1054
  SPECIFICATIONS...1056
    LOADER SPECIFICATIONS...1058
      Machine Dimensions...1058
      Performance...1059
      Controls...1059
      Engine...1060
      Hydraulic System...1061
      Electrical...1061
      Drive System...1062
      Capacities...1062
      Tracks...1062
      Ground Pressure...1062
    ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T...1064
      Fuel Injection Nozzles...1064
      Fuel Injection Pump...1064
      Cylinder Head...1064
      Valves...1064
      Valve Springs...1065
      Valve Timing...1065
      Rocker Arms...1065
      Camshaft...1065
      Tappet...1065
      Cylinder Liner...1066
      Piston Rings...1066
      Pistons...1066
      Connecting Rod...1066
      Oil Pump...1066
      Crankshaft...1067
      Timing Gear...1067
      Thermostat...1067
    ENGINE SPECIFICATIONS - KUBOTA V2403-M-DI-T...1068
      Fuel Injection Nozzles...1068
      Fuel Injection Pump...1068
      Cylinder Head...1068
      Valves...1068
      Valve Springs...1069
      Valve Timing...1069
      Rocker Arms...1069
      Camshaft...1069
      Tappet...1069
      Cylinder Liner...1070
      Piston Rings...1070
      Pistons...1070
      Connecting Rod...1070
      Oil Pump...1070
      Crankshaft...1071
      Timing Gear...1071
      Thermostat...1071
    TORQUE SPECIFICATIONS FOR BOLTS...1072
      Torque For General SAE Bolts...1072
      Torque For General Metric Bolts...1073
    HYDRAULIC CONNECTION SPECIFICATIONS...1074
      O-ring Face Seal Connection...1074
      Straight Thread O-ring Fitting...1075
      Tubelines And Hoses...1075
      Flare Fitting...1075
      O-ring Flare Fitting...1076
      Port Seal Fitting...1078
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...1080
      Specifications...1080
    CONVERSIONS...1082
      Decimal And Millimeter Equivalents...1082
      U.S. To Metric Conversion...1082
  SERVICE MANUAL REVISION...1084
    Revision No: T180 - 1...1084
    Revision No: T180 - 2...1086
    Revision No: T180 - 3...1088
    Revision No: T180 - 4...1090
    Revision No: T180 - 5...1092
    Revision No: T180 - 6...1094
    Revision No: T180 - 7...1096
    Revision No: T180 - 8...1098
6902820 (12-06) - T180 Turbo, T180 Turbo High Flow Operation & Maintenance Manual...1100
  OPERATOR SAFETY WARNINGS...1102
  CONTENTS...1104
  FOREWORD...1106
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...1108
    REGULAR MAINTENANCE ITEMS...1108
    MOTOR OIL...1108
    SERIAL NUMBER LOCATIONS...1109
      Loader Serial Number...1109
      Engine Serial Number...1109
    DELIVERY REPORT...1109
    MACHINE IDENTIFICATION...1110
    FEATURES, ACCESSORIES AND ATTACHMENTS...1111
      Standard Items...1111
      Options and Accessories...1111
      Buckets Available...1112
      Attachments...1112
  SAFETY...1114
    SAFETY INSTRUCTIONS...1116
      Before Operation...1116
      Safe Operation Is The Operator’s Responsibility...1117
      Safe Operation Needs A Qualified Operator...1117
      Fire Prevention...1118
    MACHINE SIGNS (DECALS)...1119
  OPERATING INSTRUCTIONS...1122
    INSTRUMENT PANEL IDENTIFICATION...1124
      Left Panel...1124
      Right Panel (Standard - With Key Switch)...1125
      Right Panel (Deluxe - With Keyless Start)...1126
      Option And Field Accessory Panels (If Equipped)...1128
      Cab Light...1129
    LIFT ARM BY-PASS CONTROL...1129
      Operation...1129
    TRACTION LOCK OVERRIDE...1129
      Operation...1129
    ENGINE SPEED CONTROL...1130
      Operation...1130
    PARKING BRAKE...1130
      Operation...1130
    INCHING CONTROL...1130
      Operation...1130
    DRIVING AND STEERING THE LOADER...1131
      Available Controls Configurations...1131
      Operation (Standard and ACS)...1131
      Operation (SJC in ‘H’ Control Pattern)...1132
      Operation (SJC in ‘ISO’ Control Pattern)...1133
    STOPPING THE BOBCAT LOADER...1134
      Using The Steering Levers Or Joysticks...1134
    SEAT BAR RESTRAINT SYSTEM...1134
      Operation...1134
    HYDRAULIC CONTROLS...1135
      Standard Controls (Also ACS in Foot Pedal Mode)...1135
      Advanced Control System (ACS) in HAND Control Mode...1136
      Selectable Joystick Control (SJC) - ‘H’ Control Pattern...1137
      Selectable Joystick Control (SJC) - ‘ISO’ Control Pattern...1137
      Quick Couplers...1138
      Releasing Hydraulic Pressure (Loader and Attachment)...1138
      Auxiliary Hydraulics Button - VARIABLE FLOW...1139
      Auxiliary Hydraulics Button - MAXIMUM FLOW ONLY...1139
      Auxiliary Hydraulics Button - DISENGAGE...1139
      FRONT Auxiliary Hydraulics Operation - VARIABLE FLOW...1139
      FRONT Auxiliary Hydraulics Operation - MAXIMUM FLOW...1139
      FRONT Auxiliary Hydraulics Operation - CONTINUOUS FLOW...1139
      REAR Auxiliary Hydraulics Operation (If Equipped)...1140
      High-Flow Hydraulics Operation (If Equipped)...1140
      Attachment Control Device (ACD) (If Equipped)...1141
      Secondary Front Auxiliary Hydraulics (If Equipped)...1141
      Bucket Position Valve Operation (If Equipped)...1142
    DAILY INSPECTION...1143
      Daily Inspection and Maintenance...1143
    PRE-STARTING PROCEDURES...1144
      Before Starting The Engine...1144
    STARTING THE ENGINE (STANDARD PANEL, KEY SWITCH)...1146
      Procedure...1146
    STARTING THE ENGINE (DELUXE PANEL, KEYLESS START)...1148
      Procedure...1148
      Cold Temperature Starting...1149
    WARMING THE HYDRAULIC/HYDROSTATIC SYSTEM...1150
      Procedure...1150
    STOPPING THE ENGINE...1151
      Procedure...1151
    MONITORING THE DISPLAY PANEL...1152
      Standard Panel...1152
      Deluxe Panel...1152
      WARNING and SHUTDOWN...1152
    ATTACHMENTS AND BUCKETS...1153
      Choosing The Correct Bucket...1153
      Pallet Forks...1154
      Hand Lever Bob-Tach - Installing The Bucket Or Attachment...1154
      Hand Lever Bob-Tach - Removing The Bucket Or Attachment...1156
      Power Bob-Tach - Installing The Bucket Or Attachment...1157
      Power Bob-Tach - Removing The Bucket Or Attachment...1158
    OPERATING PROCEDURE...1159
      Operating With A Full Bucket...1159
      Operating With An Empty Bucket...1160
      Compact Track Loader Operating Tips...1161
      Foot Pedal Machines...1162
      Hand Control Machines (Includes ACS and SJC with H-Pattern Selected)...1164
      Selectable Joystick Control (SJC) with ‘ISO’ Pattern Selected...1166
    PARKING THE BOBCAT LOADER...1168
      Procedure...1168
    TOWING THE LOADER...1168
      Towing Procedure...1168
    TRANSPORTING THE BOBCAT LOADER...1169
      Loading Onto Transport Vehicle...1169
      Fastening To Transport Vehicle...1169
    LIFTING THE LOADER...1170
      Single Point Lift...1170
      Four Point Lift...1170
  PREVENTIVE MAINTENANCE...1172
    MAINTENANCE SAFETY...1176
    SERVICE SCHEDULE...1178
      Chart...1178
    LIFT ARM SUPPORT DEVICE...1179
      Engaging The Lift Arm Support Device...1179
      Disengaging The Lift Arm Support Device...1180
    HEATER AND AIR CONDITIONING...1181
      Cleaning And Maintenance...1181
      Adjusting The Air Conditioner Belt...1182
    OPERATOR CAB...1183
      Raising The Operator Cab...1183
      Lowering The Operator Cab...1184
      Cab Door Sensor...1184
      Emergency Exit...1185
    SEAT BELT...1186
      Inspection and Maintenance...1186
    SEAT BAR RESTRAINT SYSTEM...1187
      Inspecting The Seat Bar...1187
      Maintaining The Seat Bar...1187
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...1188
      Inspecting The BICS Controller (Engine Stopped - Key ON)...1188
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...1188
      Inspecting The Seat Bar Sensor (Engine RUNNING)...1188
      Inspecting The Traction Lock (Engine RUNNING)...1188
      Inspecting The Lift Arm By-Pass Control...1188
      Inspecting Deactivation Of Lift And Tilt Functions (ACS)...1188
    TRACK TENSION...1189
      Adjusting (Increase Track Tension)...1189
      Adjusting (Decrease Track Tension)...1190
    TRACK SPROCKET MAINTENANCE...1191
    HYDROSTATIC MOTOR CARRIER LUBRICATION...1191
    TRACK ROLLER AND IDLER LUBRICATION...1191
    REAR DOOR...1192
      Opening And Closing The Rear Door...1192
      Adjusting The Rear Door Latch...1192
    REAR GRILL...1193
      Removing...1193
      Installing...1193
    AIR CLEANER SERVICE...1194
      Replacing Filter Elements...1194
    FUEL SYSTEM...1195
      Fuel Specifications...1195
      Filling The Fuel Tank...1195
      Fuel Filter...1196
      Removing Air From The Fuel System...1196
    ENGINE LUBRICATION SYSTEM...1197
      Checking Engine Oil...1197
      Replacing The Oil And Filter...1197
    ENGINE COOLING SYSTEM...1198
      Cleaning The Cooling System...1198
      Checking Coolant Level And Adding Coolant...1198
      Replacing The Coolant...1199
    ALTERNATOR BELT...1199
      Adjusting The Alternator Belt...1199
    ELECTRICAL SYSTEM...1200
      Description...1200
      Cleaning Battery and Terminals...1200
      Fuse Location...1201
      Using A Booster Battery (Jump Starting)...1202
      Removing And Installing The Battery...1203
    HYDRAULIC / HYDROSTATIC SYSTEM...1204
      Checking And Adding Fluid...1204
      Replacing Hydraulic/Hydrostatic Filter...1204
      Replacing Hydraulic Fluid and Case Drain Filters...1205
      Hydraulic Breather...1206
    FAN GEARBOX...1206
      Checking And Maintaining...1206
    DRIVE BELT...1207
      Adjusting The Drive Belt...1207
      Replacing The Drive Belt...1207
    SPARK ARRESTOR MUFFLER...1208
    LUBRICATING THE BOBCAT LOADER...1209
      Lubrication Locations...1209
    PIVOT PINS...1210
      Inspection And Maintenance...1210
    BOB-TACH (HAND LEVER)...1211
      Inspection And Maintenance...1211
    BOB-TACH (POWER) (OPTIONAL)...1212
      Inspection And Maintenance...1212
  SYSTEM SETUP & ANALYSIS...1214
    BICS SYSTEM...1216
      Troubleshooting Guide...1216
    DIAGNOSTICS SERVICE CODES...1217
      Display...1217
      Number Codes List...1218
    DELUXE INSTRUMENT PANEL SETUP...1222
      Deluxe Panel Upgrade...1222
      Deluxe Panel Setup...1223
      Passwords (Deluxe)...1223
      Viewing Service Codes...1225
    SHUTDOWN FEATURE...1226
    SERVICE CLOCK RESET...1226
  MACHINE SIGN TRANSLATIONS...1228
    SERVICE SCHEDULE (6734534)...1230
    WARNING (6728540)...1231
    WARNING (6735255) (SJC)...1232
    OPERATION (6727926) (STANDARD AND ACS)...1233
    OPERATION (6735256) (SJC)...1234
    WARNING (6577754)...1235
    WARNING (6718391)...1235
    WARNING (6737189)...1235
    WARNING (6718396)...1235
    WARNING (6718397)...1235
    DANGER (6718392)...1236
    DANGER (6718393)...1236
    DANGER (6717343)...1236
    WARNING (6804114)...1236
    LIFT ARM SUPPORT DEVICE (6719018)...1237
    IMPORTANT (6560573)...1237
  SPECIFICATIONS...1238
    LOADER SPECIFICATIONS (T180)...1240
      Machine Dimensions...1240
      Performance...1241
      Controls...1241
      Engine...1241
      Hydraulic System...1242
      Electrical...1242
      Drive System...1243
      Capacities...1243
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS...1244
  WARRANTY...1246
6903138 (6-05) - T140 Operation & Maintenance Manual...1248
  OPERATOR SAFETY WARNINGS...1250
  CONTENTS...1252
  FOREWORD...1254
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...1256
    REGULAR MAINTENANCE ITEMS...1256
    MOTOR OIL...1256
    SERIAL NUMBER LOCATIONS...1257
    LOADER SERIAL NUMBER...1257
    ENGINE SERIAL NUMBER...1258
    DELIVERY REPORT...1258
    MACHINE IDENTIFICATION...1259
    FEATURES, ACCESSORIES AND ATTACHMENTS...1260
      Standard Items...1260
      Options and Accessories...1260
      Buckets Available...1261
      Attachments...1261
  SAFETY...1262
    SAFETY INSTRUCTIONS...1264
      Before Operation...1264
      Safe Operation Is The Operator’s Responsibility...1265
      Safe Operation Needs A Qualified Operator...1265
      Fire Prevention...1266
    MACHINE SIGNS (DECALS)...1267
  OPERATING INSTRUCTIONS...1270
    INSTRUMENT PANEL IDENTIFICATION...1272
      Left Panel...1272
      Right Panel (Standard - With Key Switch)...1273
      Right Panel (Deluxe - With Keyless Start)...1274
      Option And Field Accessory Panels (If Equipped)...1276
      Cab Light...1277
    LIFT ARM BY-PASS CONTROL...1277
      Operation...1277
    TRACTION LOCK OVERRIDE...1278
      Operation...1278
    ENGINE SPEED CONTROL...1278
      Operation...1278
    PARKING BRAKE...1278
      Operation...1278
    DRIVING AND STEERING THE LOADER...1279
      Available Controls Configurations...1279
      Operation (Standard and ACS)...1279
    STOPPING THE BOBCAT LOADER...1279
      Using The Steering Levers...1279
    SEAT BAR RESTRAINT SYSTEM...1280
      Operation...1280
    HYDRAULIC CONTROLS...1281
      Operation...1281
      Standard Controls (Also ACS in Foot Pedal Mode)...1281
      Advanced Control System (ACS) in HAND Control Mode...1282
      Quick Couplers...1283
      Releasing Hydraulic Pressure (Loader and Attachment)...1283
      Auxiliary Hydraulics Button - VARIABLE FLOW...1283
      Auxiliary Hydraulics Button - MAXIMUM FLOW ONLY...1284
      Auxiliary Hydraulics Button - DISENGAGE...1284
      FRONT Auxiliary Hydraulics Operation - VARIABLE FLOW...1284
      FRONT Auxiliary Hydraulics Operation - MAXIMUM FLOW...1284
      FRONT Auxiliary Hydraulics Operation - CONTINUOUS FLOW...1284
      REAR Auxiliary Hydraulics Operation (If Equipped)...1285
      Attachment Control Device (ACD) (If Equipped)...1285
      Bucket Position Valve Operation (If Equipped)...1285
    DAILY INSPECTION...1286
      Daily Inspection and Maintenance...1286
    PRE-STARTING PROCEDURES...1287
      Before Starting The Engine...1287
    STARTING THE ENGINE (STANDARD PANEL, KEY SWITCH)...1289
      Procedure...1289
    STARTING THE ENGINE (DELUXE PANEL, KEYLESS START)...1291
      Procedure...1291
      Cold Temperature Starting...1292
    WARMING THE HYDRAULIC/HYDROSTATIC SYSTEM...1292
      Procedure...1292
    STOPPING THE ENGINE...1293
      Procedure...1293
    MONITORING THE DISPLAY PANEL...1294
      Standard Panel...1294
      Deluxe Panel...1294
      WARNING and SHUTDOWN...1294
    ATTACHMENTS AND BUCKETS...1295
      Choosing The Correct Bucket...1295
      Pallet Forks...1296
      Hand Lever Bob-Tach™ - Installing The Bucket Or Attachment...1296
      Hand Lever Bob-Tach™ - Removing The Bucket Or Attachment...1298
      Power Bob-Tach™ - Installing The Bucket Or Attachment...1299
      Power Bob-Tach™ - Removing The Bucket Or Attachment...1300
    OPERATING PROCEDURE...1301
      Operating With A Full Bucket...1301
      Operating With An Empty Bucket...1302
      Compact Track Loader Operating Tips...1303
      Foot Pedal Machines...1304
      Hand Control Machines (Includes ACS)...1306
    PARKING THE BOBCAT LOADER...1308
      Procedure...1308
    TRANSPORTING THE BOBCAT LOADER...1309
      Loading Onto Transport Vehicle...1309
      Fastening To Transport Vehicle...1309
    TOWING THE LOADER...1309
      Towing Procedure...1309
    LIFTING THE LOADER...1310
      Single Point Lift...1310
      Four Point Lift...1310
  PREVENTIVE MAINTENANCE...1312
    MAINTENANCE SAFETY...1316
    SERVICE SCHEDULE...1318
      Chart...1318
    LIFT ARM SUPPORT DEVICE...1319
      Engaging The Lift Arm Support Device...1319
      Disengaging The Lift Arm Support Device...1320
    OPERATOR CAB...1321
      Raising The Operator Cab...1321
      Lowering The Operator Cab...1322
      Cab Door Sensor...1322
      Emergency Exit...1323
    SEAT BELT...1324
      Inspection and Maintenance...1324
    SEAT BAR RESTRAINT SYSTEM...1325
      Inspecting The Seat Bar...1325
      Maintaining The Seat Bar...1325
    BOCAT INTERLOCK CONTROL SYSTEM (BICS)...1326
      Inspecting The BICS Controller (Engine Stopped - Key ON)...1326
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...1326
      Inspecting The Seat Bar Sensor (Engine RUNNING)...1326
      Inspecting The Traction Lock (Engine RUNNING)...1326
      Inspecting The Lift Arm By-Pass Control...1326
      Inspecting Deactivation Of Lift And Tilt Functions (ACS)...1326
    TRACK TENSION...1327
      Adjusting (Increase Track Tension)...1328
      Adjusting (Decrease Track Tension)...1329
    TRACK SPROCKET MAINTENANCE...1330
    HYDROSTATIC MOTOR CARRIER LUBRICATION...1330
    TRACK ROLLER AND IDLER LUBRICATION...1330
    REAR DOOR...1331
      Opening And Closing The Rear Door...1331
      Adjusting The Rear Door Latch...1331
    REAR GRILL...1332
    HEATING SYSTEM...1332
      Cleaning And Maintenance...1332
    AIR CLEANER SERVICE...1333
      Replacing Filters...1333
    FUEL SYSTEM...1334
      Fuel Specifications...1334
      Filling The Fuel Tank...1334
      Fuel Filter...1335
      Removing Air From The Fuel System...1335
    ENGINE LUBRICATION SYSTEM...1336
      Checking Engine Oil...1336
      Replacing The Oil And Filter...1336
    ENGINE COOLING SYSTEM...1338
      Cleaning The Cooling System...1338
      Checking Coolant Level And Adding Coolant...1339
      Replacing The Coolant...1339
    ALTERNATOR BELT...1340
      Adjusting The Alternator Belt...1340
    ELECTRICAL SYSTEM...1340
      Description...1340
      Cleaning Battery and Terminals...1340
      Fuse Location...1341
      Using A Booster Battery (Jump Starting)...1342
      Removing And Installing The Battery...1343
    HYDRAULIC / HYDROSTATIC SYSTEM...1344
      Checking And Adding Fluid...1344
      Replacing Hydraulic/Hydrostatic Filter...1344
      Replacing Hydraulic Fluid and Case Drain Filters...1345
      Hydraulic Breather...1346
    FAN GEARBOX...1347
      Checking And Maintaining...1347
    DRIVE BELT...1348
      Adjusting The Drive Belt...1348
      Replacing The Drive Belt...1348
    SPARK ARRESTOR MUFFLER...1349
    LUBRICATING THE BOBCAT LOADER...1350
      Lubrication Locations...1350
    PIVOT PINS...1351
      Inspection And Maintenance...1351
    BOB-TACH™ (HAND LEVER)...1352
      Inspection And Maintenance...1352
    BOB-TACH™ (POWER) (OPTIONAL)...1353
      Inspection And Maintenance...1353
  SYSTEM SETUP & ANALYSIS...1354
    BICS SYSTEM...1356
      Troubleshooting Guide...1356
    DIAGNOSTICS SERVICE CODES...1357
      Display...1357
      Number Codes List...1358
    DELUXE INSTRUMENT PANEL SETUP...1362
      Deluxe Panel Upgrade...1362
      Deluxe Panel Setup...1363
      Passwords (Deluxe)...1363
      Viewing Service Codes...1365
  MACHINE SIGN TRANSLATIONS...1366
    SERVICE SCHEDULE (6734534)...1368
    WARNING (6728540)...1369
    WARNING (6718397)...1370
    WARNING (6718396)...1370
    DANGER (6718393)...1371
    DANGER (6718392)...1371
    WARNING (6718391)...1371
    WARNING (6717343)...1372
    WARNING (6577754)...1372
    IMPORTANT (6560573)...1372
    LIFT ARM SUPPORT DEVICE (6706558)...1373
  SPECIFICATIONS...1374
    LOADER SPECIFICATIONS (T140)...1376
      Machine Dimensions...1376
      Performance...1377
      Controls...1377
      Engine...1377
      Hydraulic System...1378
      Electrical...1378
      Drive System...1379
      Capacities...1379
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS...1380
  WARRANTY...1382
6903153 (2-06) - T140 Service Manual...1384
  MAINTENANCE SAFETY...1388
  ALPHABETICAL INDEX...1386
  CONTENTS...1390
    FOREWORD...1391
    SAFETY INSTRUCTIONS...1394
      Fire Prevention...1396
    SERIAL NUMBER LOCATIONS...1398
      Loader Serial Number...1398
      Engine Serial Number...1398
    DELIVERY REPORT...1399
    LOADER IDENTIFICATION...1400
  SAFETY AND MAINTENANCE...1402
    LIFTING AND BLOCKING THE LOADER...1404
      Procedure...1404
    LIFT ARM SUPPORT DEVICE...1406
      Installing Lift Arm Support Device...1406
      Removing The Lift Arm Support Device...1407
    OPERATOR CAB...1408
      Description...1408
      Raising The Operator Cab...1408
      Lowering The Operator Cab...1409
      Emergency Exit...1410
    TRANSPORTING THE BOBCAT LOADER...1412
      Procedure...1412
    TOWING THE LOADER...1414
      Procedure...1414
    REMOTE START...1416
      Procedure...1416
    SERVICE SCHEDULE...1420
      Chart...1420
    AIR CLEANER SERVICE...1422
      Checking...1422
      Replacing Filter Element(s)...1423
    ENGINE COOLING SYSTEM...1426
      Cleaning The Cooling System...1426
      Checking The Coolant Level...1427
      Replacing The Coolant...1428
    FUEL SYSTEM...1430
      Fuel Specifications...1430
      Filling The Fuel Tank...1430
      Fuel Filter...1431
      Removing Air From The Fuel System...1431
    ENGINE LUBRICATION SYSTEM...1432
      Checking Engine Oil...1432
      Oil Chart...1432
      Replacing Oil And Filter...1432
    HYDRAULIC/HYDROSTATIC SYSTEM...1434
      Checking And Adding Fluid...1434
      Replacing Hydraulic/Hydrostatic Filter...1434
      Replacing Hydrostatic Motor Case Drain Filter(s)...1435
      Replacing Hydraulic Fluid...1436
      Breather Cap...1437
    FAN GEARBOX...1438
      Checking And Maintaining...1438
    BOB-TACH™...1440
      Inspection And Maintenance...1440
    POWER BOB-TACH™...1442
      Inspection And Maintenance...1442
    LUBRICATION OF THE BOBCAT LOADER...1444
      Procedure...1444
    SPARK ARRESTOR MUFFLER...1448
      Servicing...1448
  HYDRAULIC SYSTEM...1450
    HYDRAULIC/HYDROSTATIC SCHEMATICS...1454
    HYDRAULIC SYSTEM INFORMATION...1456
      Glossary Of Hydraulic/Hydrostatic Symbols...1456
      Tighten Procedures...1460
      Troubleshooting Chart...1461
    CYLINDER (LIFT)...1462
      Checking...1462
      Removal And Installation...1463
      Identification...1464
      Disassembly...1465
      Assembly...1466
    CYLINDER (TILT)...1470
      Checking...1470
      Removal And Installation...1470
      Rod End Pivot Pin Bushing And Seal Replacement...1472
      Identification...1473
      Disassembly...1474
      Assembly...1475
    CYLINDER (POWER BOB-TACH™)...1478
      Checking...1478
      Removal And Installation...1479
      Parts Identification...1480
      Disassembly...1481
      Assembly...1482
    MAIN RELIEF VALVE...1486
      Checking...1486
      Adjustment...1488
    HYDRAULIC CONTROL VALVE (FOOT CONTROL)...1490
      Removal And Installation...1490
      Identification Chart...1495
      BICS Valve, Lift Load Check Valve Removal And Installation...1496
      Load Check Valve Removal And Installation (Tilt & Auxiliary)...1497
      Anti-Cavitation Valve (Lift, Rod End)...1498
      Port Relief/Anti-Cavitation Valve (Lift, Base End)...1499
      Port Relief/Anti-Cavitation Valve (Tilt, Base End)...1499
      Port Relief/Anti-Cavitation Valve (Tilt, Rod End)...1500
      Port Relief Valve...1501
      Plug Removal...1502
      Rubber Boot Removal and Installation...1503
      End Cap/Spool Lock Block Removal and Installation...1504
      Lift Spool and Detent Removal and Installation...1505
      Tilt Spool Removal and Installation...1515
      Auxiliary Spool Removal And Installation...1517
      Auxiliary Solenoid Disassembly and Assembly...1519
      BICS Valve Solenoid Disassembly And Assembly...1520
      BICS Valve, Lock Valve Removal And Installation...1521
      BICS Valve, Check Valve Removal And Installation...1523
      BICS Valve, Lift Arm By-Pass Orifice Disassembly And Assembly...1524
      Main Relief Valve...1524
    HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)...1526
      Removal And Installation...1526
      Actuator Removal And Installation (Out of Loader)...1530
      Identification Chart (ACS)...1533
      BICS Valve, Load Check Valve Removal And Installation (Lift)...1534
      Load Check Valve Removal And Installation (Tilt & Auxiliary)...1535
      Anti-Cavitation Valve (Lift, Rod End)...1536
      Port Relief/Anti-Cavitation Valve (Lift, Base End)...1537
      Port Relief/Anti-Cavitation Valve (Tilt, Base End)...1537
      Port Relief/Anti-Cavitation Valve (Tilt, Rod End)...1538
      Port Relief Valve...1539
      Plug Removal...1540
      End Cap Block Removal and Installation...1541
      Lift Spool Removal and Installation...1542
      Tilt Spool Removal and Installation...1546
      Auxiliary Spool Removal And Installation...1548
      Auxiliary Solenoid Disassembly and Assembly...1550
      BICS Valve Solenoid Disassembly And Assembly...1551
      BICS Valve, Lock Valve Removal And Installation...1552
      BICS Valve, Check Valve Removal And Installation...1554
      BICS Valve, Lift Arm By-Pass Orifice Disassembly And Assembly...1555
      Main Relief Valve...1555
    LIFT ARM BY-PASS CONTROL VALVE...1556
      Inspecting...1556
      Removal And Installation...1556
      Disassembly And Assembly...1557
    HYDRAULIC PUMP...1558
      Check The Output Of The Hydraulic Pump Without Rear Auxiliary...1558
      Removal And Installation...1561
      Identification...1565
      Disassembly And Assembly...1566
    HYDRAULIC/HYDROSTATIC FILTER...1572
      Housing Removal And Installation...1572
    HYDRAULIC FLUID RESERVOIR...1574
      Removal And Installation...1574
    BUCKET POSITION VALVE...1576
      Solenoid Removal And Installation...1576
      Solenoid Testing...1576
      Removal And Installation...1577
      Disassembly And Assembly...1578
    REAR AUXILIARY DIVERTER VALVE...1582
      Removal And Installation...1582
      Disassembly And Assembly...1584
      Inspection...1589
    POWER BOB-TACH™ BLOCK...1590
      Removal And Installation...1590
      Disassembly And Assembly...1592
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK...1596
      Removal and Installation...1596
      Disassembly And Assembly...1596
  HYDROSTATIC SYSTEM...1598
    HYDROSTATIC SYSTEM INFORMATION...1600
      Troubleshooting Chart...1600
      Replenishing Valve Function...1601
    HYDROSTATIC MOTOR...1602
      Replacing the Motor Oil...1602
      Removal And Installation...1603
      Parts Identification...1605
      Disassembly...1607
      Inspection...1615
      Assembly...1616
    CHARGE PRESSURE...1626
      Sender Removal And Installation...1626
      Checking Charge Pressure...1626
      Adjusting...1627
    HYDROSTATIC PUMP...1628
      Replenishing/High Pressure Relief Valve...1628
      Removal And Installation...1629
      Parts Identification (Right Half)...1631
      Parts Identification (Left Half)...1633
      Hydraulic Pump Removal And Installation...1635
      Pump Separation...1635
      Disassembly...1636
      Assembly...1642
    DRIVE BELT...1650
      Shield Removal And Installation...1650
      Adjusting...1650
      Drive Belt Replacement...1652
      Tensioner Pulley Removal And Installation...1653
      Tensioner Pulley Parts Identification...1654
      Tensioner Pulley Disassembly...1655
      Tensioner Pulley Assembly...1656
    OIL COOLER...1658
      Removal and Installation...1658
  DRIVE SYSTEM...1660
    BRAKE...1662
      Pressure Relief Valve Test...1662
      Right Motor Brake Test...1663
      Left Motor Brake Test...1664
      Block Removal And Installation...1666
      Block Disassembly And Assembly...1668
    DRIVE COMPONENTS...1670
      Track Tension...1670
      Track Tension Adjusting...1671
      Track Removal And Installation...1673
      Track Idler (Front) Removal And Installation...1676
      Track Idler (Front) Disassembly and Assembly...1678
      Track Idler (Rear) End Play Specifications...1679
      Track Idler (Rear) Removal And Installation...1679
      Track Idler (Rear) Disassembly and Assembly...1679
      Track Roller Assembly End Play Specifications...1680
      Track Roller Removal And Installation...1680
      Track Roller Disassembly and Assembly...1680
      Track Housing Removal And Installation...1681
      Track Damage Identification...1682
  MAIN FRAME...1694
    SEAT BAR...1696
      Removal And Installation...1696
      Assembling Components...1698
      Compression Spring Disassembly And Assembly...1700
    OPERATOR CAB...1702
      Gas Cylinder Removal And Installation...1702
      Gas Cylinder Disassembly...1704
      Removal And Installation...1705
    OPERATOR SEAT...1708
      Removal And Installation...1708
      Slide Rail Removal And Installation...1709
      Seat Belt Removal and Installation...1709
      Cushion Removal And Installation...1710
      Back Removal And Installation...1711
      Shock Removal And Installation...1711
      3-Point Seat Belt Removal And Installation...1712
    BOB-TACH™...1714
      Removal And Installation...1714
      Bob-Tach Lever And Wedge...1716
      Bob-Tach Stops...1717
    POWER BOB-TACH™...1718
      Removal And Installation...1718
      Power Bob-Tach Lever And Wedge...1720
    LIFT ARM...1722
      Removal And Installation...1722
    REAR GRILL...1726
      Removal And Installation...1726
    REAR DOOR...1728
      Removal And Installation...1728
      Striker Removal and Installation...1729
      Striker Disassembly and Assembly...1729
      Door Latch and Catch Adjustment...1729
      Latch Removal And Installation...1730
    FUEL TANK...1732
      Removal And Installation...1732
      Fuel Level Sender...1733
      Fuel Fill Screen...1733
      Fuel Pickup Screen...1734
    CONTROL PEDALS...1736
      Removal And Installation...1736
      Pedal Adjustment...1736
      Crossbar Linkage Removal And Installation...1737
      Lift Foot Pedal Linkage Removal And Installation...1738
      Tilt Foot Pedal Linkage Removal And Installation...1738
    CONTROL PEDALS (ACS)...1740
      Foot Sensor Removal And Installation...1740
      Foot Pedal Removal And Installation...1741
      Foot Pedal Linkage Disassembly And Assembly...1741
    CONTROL PANEL...1742
      Description...1742
      Removal and Installation...1743
      Shock Removal And Installation...1746
      Shaft Removal And Installation...1746
      Shaft Disassembly And Assembly...1747
      Linkage Removal And Installation...1748
      Pintle Arm Disassembly and Assembly...1752
      Linkage Neutral Adjustment...1754
      Linkage Travel Adjustment...1758
    CONTROL HANDLE...1762
      Control Lever Removal And Installation...1762
      Rubber Boot Replacement...1762
    CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL...1764
      Components Identification...1764
      Handle Sensor Removal And Installation...1764
      Control Handle Removal and Installation...1767
      Control Handle Disassembly and Assembly...1768
      Control Lever Removal and Installation...1768
      Control Lever Boot...1769
  ELECTRICAL SYSTEM & ANALYSIS...1770
    ELECTRICAL SCHEMATICS...1774
    ELECTRICAL SYSTEM INFORMATION...1778
      Troubleshooting Chart...1778
      Description...1779
      Relay Switch Location...1780
      Fuse Location...1780
    BATTERY...1782
      Removal And Installation...1782
      Servicing...1783
      Using A Booster Battery (Jump Starting)...1784
    ALTERNATOR...1786
      Adjusting The Alternator Belt...1786
      Alternator Identification...1786
      Charging System Check...1787
      Alternator Voltage Test...1788
      Low Voltage Test...1788
      High Voltage Test...1789
      Removal And Installation...1790
      Rectifier Continuity (Diode) Test...1791
      Alternator Regulator Test...1792
      Disassembly...1792
      Stator Continuity Test...1793
      Stator Ground Test...1793
      Rotor Continuity Test...1793
      Rotor Ground Test...1793
      Assembly...1794
    STARTER...1796
      Checking...1796
      Removal And Installation...1797
      Parts Identification...1798
      Disassembly and Assembly...1799
      Inspection And Repair...1802
      No Load Test...1804
    INSTRUMENT PANEL...1806
      Left Panel...1806
      Right Panel (Standard) (With Key Switch)...1807
      Right Panel - (Deluxe) (With Keyless Start)...1807
      Right Panel Setup Display Options (Deluxe)...1810
      Option And Field Accessory Panels (If Equipped)...1813
      Removal And Installation...1814
      Front Accessory Panel Removal And Installation...1815
    LIGHTS...1816
      Front Removal And Installation...1816
      Rear Removal And Installation...1817
    BOBCAT CONTROLLER...1818
      Identification Chart...1818
      Removal And Installation...1820
    DIAGNOSTIC SERVICE CODES...1822
      Display...1822
      Number Codes List...1823
    BICS SYSTEM...1828
      Inspecting The BICS Controller (Engine STOPPED - Key ON)...1828
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...1828
      Inspecting The Seat Bar Sensor (Engine RUNNING)...1828
      Inspecting The Traction Lock (Engine RUNNING)...1828
      Inspecting The Lift Arm By-Pass Control...1828
      Troubleshooting Chart...1829
      Troubleshooting Guide...1830
    SEAT BAR SENSOR...1832
      Troubleshooting Chart...1832
      Test...1833
      Removal And Installation...1834
      BICS Circuit Test...1835
    TRACTION LOCK...1836
      Troubleshooting Chart...1836
      Description Of The Control System...1837
      Inspecting The Control System...1837
    ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND/FOOT CONTROL...1838
      Components Identification...1838
      Troubleshooting Guide...1840
      Controller, Connector And Wire Identification...1841
      ACS Controller Removal And Installation...1842
      Handle Sensor Connector...1842
      Switch Handle Removal...1843
      Switch Handle Installation...1845
      Actuators Disassembly And Assembly...1848
      Handle Lock Solenoid Removal And Installation...1849
      Handle Lock Solenoid Disassembly And Assembly...1849
      Handle Lock Solenoid Connector...1850
      Calibration Of The ACS System...1851
      Switchable Hand/Foot Controls Calibration Procedure...1851
      Foot Sensor Disassembly And Assembly...1853
      Foot Sensor Connector...1853
      Foot Lock Solenoid Removal And Installation...1854
      Foot Lock Solenoid Connector...1854
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE...1856
      Controls Identification Chart...1856
    FLYWHEEL RPM SENSOR...1858
      Adjustment...1858
  ENGINE SERVICE...1860
    TROUBLESHOOTING...1862
      Chart...1862
    ENGINE SPEED CONTROL...1864
      Removal And Installation...1864
      Disassembly...1864
    MUFFLER...1866
      Removal And Installation...1866
    AIR CLEANER...1868
      Removal And Installation...1868
    RADIATOR...1870
      Removal And Installation...1870
    COOLING FAN...1872
      Drive Tension Pulley Removal And Installation...1872
      Gearbox/Blower Housing Removal And Installation...1873
      Blower Housing Grill Removal And Installation...1875
      Blower Disassembly And Assembly...1875
      Gearbox Parts Identification...1877
      Gearbox Disassembly...1878
      Gearbox Assembly...1883
      Gearbox Checking Backlash...1887
    ENGINE COMPONENTS AND TESTING...1892
      Compression Checking...1892
      Glow Plugs Checking...1893
      Glow Plugs Removal And Installation...1893
      Fuel Shutoff Solenoid, Checking...1894
      Fuel Shutoff Solenoid Removal And Installation...1895
      Fuel Injection Pump Removal And Installation...1896
      Timing The Injection Pump...1900
      Fuel Injector Removal And Installation...1901
      Checking Nozzle Injection Pressure...1903
      Nozzle Spraying Condition...1903
      Valve Seat Tightness...1904
      Valve Clearance Adjustment...1904
      Valve Timing, Checking...1905
    ENGINE...1906
      Removal And Installation...1906
      Engine Mount Replacement...1912
    FLYWHEEL AND HOUSING...1914
      Flywheel Removal And Installation...1914
      Ring Gear Removal And Installation...1914
      Housing Removal And Installation...1915
    RECONDITIONING THE ENGINE...1918
      Cylinder Head Removal And Installation...1918
      Cylinder Head Disassembly And Assembly...1921
      Cylinder Head Servicing...1922
      Cylinder Head Top Clearance...1922
      Valve Guide Checking...1923
      Reconditioning The Valve And Valve Seat...1925
      Valve Spring...1926
      Rocker Arm And Shaft Checking...1927
      Timing Gearcase Cover Removal And Installation...1927
      Idler Gear And Camshaft Removal And Installation...1930
      Camshaft Servicing...1931
      Idler Gear And Shaft Servicing...1932
      Timing Gears Checking Backlash...1933
      Fuel Camshaft Removal And Installation...1933
      Fuel Camshaft Governor...1934
      Crankshaft Gear Removal And Installation...1934
      Oil Pump Removal And Installation...1935
      Oil Pump Service...1935
      Checking Engine Oil Pressure...1936
      Valve Tappets...1937
      Piston And Connecting Rod Removal And Installation...1937
      Piston And Connecting Rod Servicing...1939
      Connecting Rod Alignment...1941
      Crankshaft And Bearings Removal And Installation...1942
      Crankshaft And Bearings, Servicing...1944
      Cylinder Bore, Checking...1948
      Water Pump Removal And Installation...1948
      Water Pump Disassembly And Assembly...1949
  HEATER...1950
    COMPONENTS...1952
      Identification...1952
    REGULAR MAINTENANCE...1954
      Filter Elements Removal And Installation...1954
    BASIC TROUBLESHOOTING...1956
      Cleaning The Heater Coil...1956
      Checking The Electrical System...1957
      Engine Coolant By-Passing The Heater Valve...1961
      Heater Valve Not Opening Or Closing...1962
    SYSTEM TROUBLESHOOTING CHART...1964
      Blower Motor Does Not Operate...1964
      Blower motor operators normally, but air flow is insufficient...1964
    HEATER UNIT...1966
      Removal And Installation...1966
      Disassembly And Assembly...1967
    HEATER COIL...1968
      Removal And Installation...1968
    HEATER FAN...1970
      Removal And Installation...1970
      Disassembly And Assembly...1970
      Wire Connector Removal and Installation...1972
    HEATER VALVE...1974
      Removal and Installation...1974
      Disassembly And Assembly...1975
  SPECIFICATIONS...1976
    LOADER SPECIFICATIONS (T140)...1978
      Machine Dimensions...1978
      Performance...1979
      Controls...1979
      Engine...1979
      Hydraulic System...1980
      Electrical...1981
      Drive System...1981
      Capacities...1981
      Tracks...1981
      Ground Pressure...1981
    ENGINE SPECIFICATIONS...1982
      Fuel Injection Nozzles...1982
      Fuel Injection Pump...1982
      Cylinder Head...1982
      Valves...1982
      Valve Springs...1983
      Valve Timing...1983
      Rocker Arms...1983
      Camshaft...1983
      Tappet...1983
      Cylinders...1984
      Piston Rings...1984
      Pistons...1984
      Connecting Rod...1984
      Oil Pump...1984
      Crankshaft...1985
      Timing Gear...1985
      Thermostat...1985
    TORQUE SPECIFICATIONS FOR BOLTS...1986
      Torque For General SAE Bolts...1986
      Torque For General Metric Bolts...1987
      Torque For Kubota Metric Bolts...1987
    HYDRAULIC CONNECTION SPECIFICATIONS...1988
      O-ring Face Seal Connection...1988
      Straight Thread O-ring Fitting...1989
      Tubelines And Hoses...1989
      Flare Fitting...1989
      O-ring Flare Fitting...1990
      Port Seal Fitting...1992
    HYDRAULIC FLUID SPECIFICATIONS...1994
      Specifications...1994
    CONVERSIONS...1996
      Decimal And Millimeter Equivalents...1996
      U.S. To Metric Conversion...1996
  SMR...1998
    T140-1...1998
6903153 (6-12) - T140 Service Manual...2000
  MAINTENANCE SAFETY...2004
  ALPHABETICAL INDEX...2002
  CONTENTS...2006
    FOREWORD...2007
    SAFETY INSTRUCTIONS...2010
      Fire Prevention...2012
    SERIAL NUMBER LOCATIONS...2014
      Loader Serial Number...2014
      Engine Serial Number...2014
    DELIVERY REPORT...2015
    LOADER IDENTIFICATION...2016
  SAFETY AND MAINTENANCE...2018
    LIFTING AND BLOCKING THE LOADER...2020
      Procedure...2020
    LIFT ARM SUPPORT DEVICE...2022
      Installing Lift Arm Support Device...2022
      Removing The Lift Arm Support Device...2023
    OPERATOR CAB...2024
      Description...2024
      Raising The Operator Cab...2024
      Lowering The Operator Cab...2025
      Emergency Exit...2026
    TRANSPORTING THE BOBCAT LOADER...2028
      Procedure...2028
    TOWING THE LOADER...2030
      Procedure...2030
    REMOTE START...2032
      Procedure...2032
    SERVICE SCHEDULE...2036
      Chart...2036
    AIR CLEANER SERVICE...2038
      Checking...2038
      Replacing Filter Element(s)...2039
    ENGINE COOLING SYSTEM...2042
      Cleaning The Cooling System...2042
      Checking The Coolant Level...2043
      Replacing The Coolant...2044
    FUEL SYSTEM...2046
      Fuel Specifications...2046
      Filling The Fuel Tank...2046
      Fuel Filter...2047
      Removing Air From The Fuel System...2047
    ENGINE LUBRICATION SYSTEM...2048
      Checking Engine Oil...2048
      Oil Chart...2048
      Replacing Oil And Filter...2048
    HYDRAULIC/HYDROSTATIC SYSTEM...2050
      Checking And Adding Fluid...2050
      Replacing Hydraulic/Hydrostatic Filter...2050
      Replacing Hydrostatic Motor Case Drain Filter(s)...2051
      Replacing Hydraulic Fluid...2052
      Breather Cap...2053
    FAN GEARBOX...2054
      Checking And Maintaining...2054
    BOB-TACH™...2056
      Inspection And Maintenance...2056
    POWER BOB-TACH™...2058
      Inspection And Maintenance...2058
    LUBRICATION OF THE BOBCAT LOADER...2060
      Procedure...2060
    SPARK ARRESTOR MUFFLER...2064
      Servicing...2064
  HYDRAULIC SYSTEM...2066
    HYDRAULIC/HYDROSTATIC SCHEMATICS...2070
    HYDRAULIC SYSTEM INFORMATION...2072
      Glossary Of Hydraulic/Hydrostatic Symbols...2072
      Tighten Procedures...2076
      Troubleshooting Chart...2077
    CYLINDER (LIFT)...2078
      Checking...2078
      Removal And Installation...2079
      Identification...2080
      Disassembly...2081
      Assembly...2082
    CYLINDER (TILT)...2086
      Checking...2086
      Removal And Installation...2086
      Rod End Pivot Pin Bushing And Seal Replacement...2088
      Identification...2089
      Disassembly...2090
      Assembly...2091
    CYLINDER (POWER BOB-TACH™)...2094
      Checking...2094
      Removal And Installation...2095
      Parts Identification...2096
      Disassembly...2097
      Assembly...2098
    MAIN RELIEF VALVE...2102
      Checking...2102
      Adjustment...2104
    HYDRAULIC CONTROL VALVE (FOOT CONTROL)...2106
      Removal And Installation...2106
      Identification Chart...2111
      BICS Valve, Lift Load Check Valve Removal And Installation...2112
      Load Check Valve Removal And Installation (Tilt & Auxiliary)...2113
      Anti-Cavitation Valve (Lift, Rod End)...2114
      Port Relief/Anti-Cavitation Valve (Lift, Base End)...2115
      Port Relief/Anti-Cavitation Valve (Tilt, Base End)...2115
      Port Relief/Anti-Cavitation Valve (Tilt, Rod End)...2116
      Port Relief Valve...2117
      Plug Removal...2118
      Rubber Boot Removal and Installation...2119
      End Cap/Spool Lock Block Removal and Installation...2120
      Lift Spool and Detent Removal and Installation...2121
      Tilt Spool Removal and Installation...2131
      Auxiliary Spool Removal And Installation...2133
      Auxiliary Solenoid Disassembly and Assembly...2135
      BICS Valve Solenoid Disassembly And Assembly...2136
      BICS Valve, Lock Valve Removal And Installation...2137
      BICS Valve, Check Valve Removal And Installation...2139
      BICS Valve, Lift Arm By-Pass Orifice Disassembly And Assembly...2140
      Main Relief Valve...2140
    HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)...2142
      Removal And Installation...2142
      Actuator Removal And Installation (Out of Loader)...2146
      Identification Chart (ACS)...2149
      BICS Valve, Load Check Valve Removal And Installation (Lift)...2150
      Load Check Valve Removal And Installation (Tilt & Auxiliary)...2151
      Anti-Cavitation Valve (Lift, Rod End)...2152
      Port Relief/Anti-Cavitation Valve (Lift, Base End)...2153
      Port Relief/Anti-Cavitation Valve (Tilt, Base End)...2153
      Port Relief/Anti-Cavitation Valve (Tilt, Rod End)...2154
      Port Relief Valve...2155
      Plug Removal...2156
      End Cap Block Removal and Installation...2157
      Lift Spool Removal and Installation...2158
      Tilt Spool Removal and Installation...2162
      Auxiliary Spool Removal And Installation...2164
      Auxiliary Solenoid Disassembly and Assembly...2166
      BICS Valve Solenoid Disassembly And Assembly...2167
      BICS Valve, Lock Valve Removal And Installation...2168
      BICS Valve, Check Valve Removal And Installation...2170
      BICS Valve, Lift Arm By-Pass Orifice Disassembly And Assembly...2171
      Main Relief Valve...2171
    LIFT ARM BY-PASS CONTROL VALVE...2172
      Inspecting...2172
      Removal And Installation...2172
      Disassembly And Assembly...2173
    HYDRAULIC PUMP...2174
      Check The Output Of The Hydraulic Pump Without Rear Auxiliary...2174
      Removal And Installation...2177
      Identification...2181
      Disassembly And Assembly...2182
    HYDRAULIC/HYDROSTATIC FILTER...2188
      Housing Removal And Installation...2188
    HYDRAULIC FLUID RESERVOIR...2190
      Removal And Installation...2190
    BUCKET POSITION VALVE...2192
      Solenoid Removal And Installation...2192
      Solenoid Testing...2192
      Removal And Installation...2193
      Disassembly And Assembly...2194
    REAR AUXILIARY DIVERTER VALVE...2198
      Removal And Installation...2198
      Disassembly And Assembly...2200
      Inspection...2205
    POWER BOB-TACH™ BLOCK...2206
      Removal And Installation...2206
      Disassembly And Assembly...2208
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK...2212
      Removal and Installation...2212
      Disassembly And Assembly...2212
  HYDROSTATIC SYSTEM...2214
    HYDROSTATIC SYSTEM INFORMATION...2216
      Troubleshooting Chart...2216
      Replenishing Valve Function...2217
    HYDROSTATIC MOTOR...2218
      Replacing the Motor Oil...2218
      Removal And Installation...2219
      Parts Identification...2221
      Disassembly...2223
      Inspection...2231
      Assembly...2232
    CHARGE PRESSURE...2242
      Sender Removal And Installation...2242
      Checking Charge Pressure...2242
      Adjusting...2243
    HYDROSTATIC PUMP...2244
      Replenishing/High Pressure Relief Valve...2244
      Removal And Installation...2245
      Parts Identification (Right Half)...2247
      Parts Identification (Left Half)...2249
      Hydraulic Pump Removal And Installation...2251
      Pump Separation...2251
      Disassembly...2252
      Assembly...2258
    DRIVE BELT...2266
      Shield Removal And Installation...2266
      Adjusting...2266
      Drive Belt Replacement...2268
      Tensioner Pulley Removal And Installation...2269
      Tensioner Pulley Parts Identification...2270
      Tensioner Pulley Disassembly...2271
      Tensioner Pulley Assembly...2272
    OIL COOLER...2274
      Removal and Installation...2274
  DRIVE SYSTEM...2276
    BRAKE...2278
      Pressure Relief Valve Test...2278
      Right Motor Brake Test...2279
      Left Motor Brake Test...2280
      Block Removal And Installation...2282
      Block Disassembly And Assembly...2284
    DRIVE COMPONENTS...2286
      Track Tension...2286
      Track Tension Adjusting...2287
      Track Removal And Installation...2289
      Track Idler (Front) Removal And Installation...2292
      Track Idler (Front) Disassembly and Assembly...2294
      Track Idler (Rear) End Play Specifications...2295
      Track Idler (Rear) Removal And Installation...2295
      Track Idler (Rear) Disassembly and Assembly...2295
      Track Roller Assembly End Play Specifications...2296
      Track Roller Removal And Installation...2296
      Track Roller Disassembly and Assembly...2296
      Track Housing Removal And Installation...2297
      Track Damage Identification...2298
  MAIN FRAME...2310
    SEAT BAR...2312
      Removal And Installation...2312
      Assembling Components...2314
      Compression Spring Disassembly And Assembly...2316
    OPERATOR CAB...2318
      Gas Cylinder Removal And Installation...2318
      Gas Cylinder Disassembly...2320
      Removal And Installation...2321
    OPERATOR SEAT...2324
      Removal And Installation...2324
      Slide Rail Removal And Installation...2325
      Seat Belt Removal and Installation...2325
      Cushion Removal And Installation...2326
      Back Removal And Installation...2327
      Shock Removal And Installation...2327
      3-Point Seat Belt Removal And Installation...2328
    BOB-TACH™...2330
      Removal And Installation...2330
      Bob-Tach Lever And Wedge...2332
      Bob-Tach Stops...2333
    POWER BOB-TACH™...2334
      Removal And Installation...2334
      Power Bob-Tach Lever And Wedge...2336
    LIFT ARM...2338
      Removal And Installation...2338
    REAR GRILL...2342
      Removal And Installation...2342
    REAR DOOR...2344
      Removal And Installation...2344
      Striker Removal and Installation...2345
      Striker Disassembly and Assembly...2345
      Door Latch and Catch Adjustment...2345
      Latch Removal And Installation...2346
    FUEL TANK...2348
      Removal And Installation...2348
      Fuel Level Sender...2349
      Fuel Fill Screen...2349
      Fuel Pickup Screen...2350
    CONTROL PEDALS...2352
      Removal And Installation...2352
      Pedal Adjustment...2352
      Crossbar Linkage Removal And Installation...2353
      Lift Foot Pedal Linkage Removal And Installation...2354
      Tilt Foot Pedal Linkage Removal And Installation...2354
    CONTROL PEDALS (ACS)...2356
      Foot Sensor Removal And Installation...2356
      Foot Pedal Removal And Installation...2357
      Foot Pedal Linkage Disassembly And Assembly...2357
    CONTROL PANEL...2358
      Description...2358
      Removal and Installation...2359
      Shock Removal And Installation...2362
      Shaft Removal And Installation...2362
      Shaft Disassembly And Assembly...2363
      Linkage Removal And Installation...2364
      Pintle Arm Disassembly and Assembly...2368
      Linkage Neutral Adjustment...2370
      Linkage Travel Adjustment...2374
    CONTROL HANDLE...2378
      Control Lever Removal And Installation...2378
      Rubber Boot Replacement...2378
    CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL...2380
      Components Identification...2380
      Handle Sensor Removal And Installation...2380
      Control Handle Removal and Installation...2383
      Control Handle Disassembly and Assembly...2384
      Control Lever Removal and Installation...2384
      Control Lever Boot...2385
  ELECTRICAL SYSTEM & ANALYSIS...2386
    ELECTRICAL SCHEMATICS...2390
    ELECTRICAL SYSTEM INFORMATION...2394
      Troubleshooting Chart...2394
      Description...2395
      Relay Switch Location...2396
      Fuse Location...2396
    BATTERY...2398
      Removal And Installation...2398
      Servicing...2399
      Using A Booster Battery (Jump Starting)...2400
    ALTERNATOR...2402
      Adjusting The Alternator Belt...2402
      Alternator Identification...2402
      Charging System Check...2403
      Alternator Voltage Test...2404
      Low Voltage Test...2404
      High Voltage Test...2405
      Removal And Installation...2406
      Rectifier Continuity (Diode) Test...2407
      Alternator Regulator Test...2408
      Disassembly...2408
      Stator Continuity Test...2409
      Stator Ground Test...2409
      Rotor Continuity Test...2409
      Rotor Ground Test...2409
      Assembly...2410
    STARTER...2412
      Checking...2412
      Removal And Installation...2413
      Parts Identification...2414
      Disassembly and Assembly...2415
      Inspection And Repair...2418
      No Load Test...2420
    INSTRUMENT PANEL...2422
      Left Panel...2422
      Right Panel (Standard) (With Key Switch)...2423
      Right Panel - (Deluxe) (With Keyless Start)...2423
      Right Panel Setup Display Options (Deluxe)...2426
      Option And Field Accessory Panels (If Equipped)...2429
      Removal And Installation...2430
      Front Accessory Panel Removal And Installation...2431
    LIGHTS...2432
      Front Removal And Installation...2432
      Rear Removal And Installation...2433
    BOBCAT CONTROLLER...2434
      Identification Chart...2434
      Removal And Installation...2436
    DIAGNOSTIC SERVICE CODES...2438
      Display...2438
      Number Codes List...2439
    BICS SYSTEM...2444
      Inspecting The BICS Controller (Engine STOPPED - Key ON)...2444
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...2444
      Inspecting The Seat Bar Sensor (Engine RUNNING)...2444
      Inspecting The Traction Lock (Engine RUNNING)...2444
      Inspecting The Lift Arm By-Pass Control...2444
      Troubleshooting Chart...2445
      Troubleshooting Guide...2446
    SEAT BAR SENSOR...2448
      Troubleshooting Chart...2448
      Test...2449
      Removal And Installation...2450
      BICS Circuit Test...2451
    TRACTION LOCK...2452
      Troubleshooting Chart...2452
      Description Of The Control System...2453
      Inspecting The Control System...2453
    ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND/FOOT CONTROL...2454
      Components Identification...2454
      Troubleshooting Guide...2456
      Controller, Connector And Wire Identification...2457
      ACS Controller Removal And Installation...2458
      Handle Sensor Connector...2458
      Switch Handle Removal...2459
      Switch Handle Installation...2461
      Actuators Disassembly And Assembly...2464
      Handle Lock Solenoid Removal And Installation...2465
      Handle Lock Solenoid Disassembly And Assembly...2465
      Handle Lock Solenoid Connector...2466
      Calibration Of The ACS System...2467
      Switchable Hand/Foot Controls Calibration Procedure...2467
      Foot Sensor Disassembly And Assembly...2469
      Foot Sensor Connector...2469
      Foot Lock Solenoid Removal And Installation...2470
      Foot Lock Solenoid Connector...2470
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE...2472
      Controls Identification Chart...2472
    FLYWHEEL RPM SENSOR...2474
      Adjustment...2474
  ENGINE SERVICE...2476
    TROUBLESHOOTING...2478
      Chart...2478
    ENGINE SPEED CONTROL...2480
      Removal And Installation...2480
      Disassembly...2480
    MUFFLER...2482
      Removal And Installation...2482
    AIR CLEANER...2484
      Removal And Installation...2484
    RADIATOR...2486
      Removal And Installation...2486
    COOLING FAN...2488
      Drive Tension Pulley Removal And Installation...2488
      Gearbox/Blower Housing Removal And Installation...2489
      Blower Housing Grill Removal And Installation...2491
      Blower Disassembly And Assembly...2491
      Gearbox Parts Identification...2493
      Gearbox Disassembly...2494
      Gearbox Assembly...2499
      Gearbox Checking Backlash...2503
    ENGINE COMPONENTS AND TESTING...2508
      Compression Checking...2508
      Glow Plugs Checking...2509
      Glow Plugs Removal And Installation...2509
      Fuel Shutoff Solenoid, Checking...2510
      Fuel Shutoff Solenoid Removal And Installation...2511
      Fuel Injection Pump Removal And Installation...2512
      Timing The Injection Pump...2516
      Fuel Injector Removal And Installation...2517
      Checking Nozzle Injection Pressure...2519
      Nozzle Spraying Condition...2519
      Valve Seat Tightness...2520
      Valve Clearance Adjustment...2520
      Valve Timing, Checking...2521
    ENGINE...2522
      Removal And Installation...2522
      Engine Mount Replacement...2528
    FLYWHEEL AND HOUSING...2530
      Flywheel Removal And Installation...2530
      Ring Gear Removal And Installation...2530
      Housing Removal And Installation...2531
    RECONDITIONING THE ENGINE...2534
      Cylinder Head Removal And Installation...2534
      Cylinder Head Disassembly And Assembly...2537
      Cylinder Head Servicing...2538
      Cylinder Head Top Clearance...2538
      Valve Guide Checking...2539
      Reconditioning The Valve And Valve Seat...2541
      Valve Spring...2542
      Rocker Arm And Shaft Checking...2543
      Timing Gearcase Cover Removal And Installation...2543
      Idler Gear And Camshaft Removal And Installation...2546
      Camshaft Servicing...2547
      Idler Gear And Shaft Servicing...2548
      Timing Gears Checking Backlash...2549
      Fuel Camshaft Removal And Installation...2549
      Fuel Camshaft Governor...2550
      Crankshaft Gear Removal And Installation...2550
      Oil Pump Removal And Installation...2551
      Oil Pump Service...2551
      Checking Engine Oil Pressure...2552
      Valve Tappets...2553
      Piston And Connecting Rod Removal And Installation...2553
      Piston And Connecting Rod Servicing...2555
      Connecting Rod Alignment...2557
      Crankshaft And Bearings Removal And Installation...2558
      Crankshaft And Bearings, Servicing...2560
      Cylinder Bore, Checking...2564
      Water Pump Removal And Installation...2564
      Water Pump Disassembly And Assembly...2565
  HEATER...2566
    COMPONENTS...2568
      Identification...2568
    REGULAR MAINTENANCE...2570
      Filter Elements Removal And Installation...2570
    BASIC TROUBLESHOOTING...2572
      Cleaning The Heater Coil...2572
      Checking The Electrical System...2573
      Engine Coolant By-Passing The Heater Valve...2577
      Heater Valve Not Opening Or Closing...2578
    SYSTEM TROUBLESHOOTING CHART...2580
      Blower Motor Does Not Operate...2580
      Blower motor operators normally, but air flow is insufficient...2580
    HEATER UNIT...2582
      Removal And Installation...2582
      Disassembly And Assembly...2583
    HEATER COIL...2584
      Removal And Installation...2584
    HEATER FAN...2586
      Removal And Installation...2586
      Disassembly And Assembly...2586
      Wire Connector Removal and Installation...2588
    HEATER VALVE...2590
      Removal and Installation...2590
      Disassembly And Assembly...2591
  SPECIFICATIONS...2592
    LOADER SPECIFICATIONS (T140)...2594
      Machine Dimensions...2594
      Performance...2595
      Controls...2595
      Engine...2595
      Hydraulic System...2596
      Electrical...2597
      Drive System...2597
      Capacities...2597
      Tracks...2597
      Ground Pressure...2597
    ENGINE SPECIFICATIONS...2598
      Fuel Injection Nozzles...2598
      Fuel Injection Pump...2598
      Cylinder Head...2598
      Valves...2598
      Valve Springs...2599
      Valve Timing...2599
      Rocker Arms...2599
      Camshaft...2599
      Tappet...2599
      Cylinders...2600
      Piston Rings...2600
      Pistons...2600
      Connecting Rod...2600
      Oil Pump...2600
      Crankshaft...2601
      Timing Gear...2601
      Thermostat...2601
    TORQUE SPECIFICATIONS FOR BOLTS...2602
      Torque For General SAE Bolts...2602
      Torque For General Metric Bolts...2603
      Torque For Kubota Metric Bolts...2603
    HYDRAULIC CONNECTION SPECIFICATIONS...2604
      O-ring Face Seal Connection...2604
      Straight Thread O-ring Fitting...2605
      Tubelines And Hoses...2605
      Flare Fitting...2605
      O-ring Flare Fitting...2606
      Port Seal Fitting...2608
    HYDRAULIC FLUID SPECIFICATIONS...2610
      Specifications...2610
    CONVERSIONS...2612
      Decimal And Millimeter Equivalents...2612
      U.S. To Metric Conversion...2612
  SMR...2614
    T140-1...2614
    T140-2...2616
6904140 (4-08) - T180 Compact Track Loader Operation & Maintenance Manual...2618
  OPERATOR SAFETY WARNINGS...2620
  CONTENTS...2622
  FOREWORD...2624
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...2626
    REGULAR MAINTENANCE ITEMS...2626
    SERIAL NUMBER LOCATIONS...2627
      Loader Serial Number...2627
      Engine Serial Number...2627
    DELIVERY REPORT...2627
    LOADER IDENTIFICATION...2628
    FEATURES, ACCESSORIES AND ATTACHMENTS...2629
      Standard Items...2629
      Options and Accessories...2629
      Options and Accessories...2629
      Buckets Available...2630
      Attachments...2630
      High-Flow Attachments...2630
      Special Applications Kit...2631
      Special Applications Kit Inspection And Maintenance...2631
  SAFETY & TRAINING RESOURCES...2632
    SAFETY INSTRUCTIONS...2634
      Before Operation...2634
      Safe Operation Is The Operator’s Responsibility...2635
      Safe Operation Needs A Qualified Operator...2635
      Avoid Silica Dust...2636
    FIRE PREVENTION...2636
      Maintenance...2636
      Operation...2636
      Electrical...2636
      Hydraulic System...2637
      Fueling...2637
      Starting...2637
      Spark Arrestor Exhaust System...2637
      Welding And Grinding...2637
      Fire Extinguishers...2637
    MACHINE SIGNS (DECALS)...2639
    PUBLICATIONS AND TRAINING RESORCES...2641
  OPERATING INSTRUCTIONS...2642
    INSTRUMENT PANEL IDENTIFICATION...2646
      Left Panel...2646
      Right Panel (Key Switch)...2647
      Right Panel (Keyless)...2648
      Cab Light...2649
      Side And Front Panels...2650
    SEAT BAR RESTRAINT SYSTEM...2651
      Operation...2651
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...2652
      Operation...2652
    LIFT ARM BYPASS CONTROL...2653
      Operation...2653
    PARKING BRAKE...2653
      Operation...2653
    TRACTION LOCK OVERRIDE...2653
      Operation...2653
    BACK-UP ALARM SYSTEM...2654
      Operation...2654
    ENGINE SPEED CONTROL...2654
      Operation...2654
    DRIVING AND STEERING THE LOADER...2655
      Available Control Configurations...2655
      Operation (Standard and ACS)...2655
      Operation (SJC) In ‘H’ Control Pattern...2656
      Operation (SJC) In ‘ISO’ Control Pattern...2657
    STOPPING THE LOADER...2657
      Using The Control Levers Or Joysticks...2657
    SPEED MANAGEMENT...2658
      Operation...2658
    STEERING DRIFT COMPENSATION...2659
      Description...2659
      Selecting And Adjusting...2659
      Exiting And Saving...2660
    HYDRAULIC CONTROLS...2661
      Description...2661
      Standard Controls (Also ACS In FOOT Pedal Mode)...2661
      Advanced Control System (ACS) In HAND Control Mode...2662
      Selectable Joystick Control (SJC) In ‘H’ Control Pattern...2662
      Selectable Joystick Control (SJC) In ‘ISO’ Control Pattern...2663
      Hydraulic Bucket Positioning...2663
      FRONT Auxiliary Hydraulics Operation (VARIABLE FLOW)...2664
      FRONT Auxiliary Hydraulics Operation (MAXIMUM FLOW)...2664
      FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)...2665
      REAR Auxiliary Hydraulics Operation...2665
      Quick Couplers...2666
      Relieve Hydraulic Pressure (Loader And Attachment)...2666
      High-Flow Hydraulics Operation...2667
      Secondary Front Auxiliary Hydraulics...2668
    ATTACHMENT CONTROL DEVICE (ACD)...2669
      Description...2669
    DAILY INSPECTION...2670
      Daily Inspection and Maintenance...2671
    PRE-STARTING PROCEDURE...2672
      Entering The Loader...2672
      Operation & Maintenance Manual And Operator’s Handbook Locations...2672
      Seat Adjustment...2673
      Seat Belt Adjustment...2673
      Seat Bar...2674
    STARTING THE ENGINE...2675
      Key Switch...2675
      Keyless...2677
      Cold Temperature Starting...2678
      Warming The Hydraulic / Hydrostatic System...2679
    MONITORING THE DISPLAY PANELS...2680
      Left Panel...2680
      Right Panel (Key Switch)...2680
      Right Panel (Keyless)...2680
      Warning And Shutdown...2680
    STOPPING THE ENGINE AND LEAVING THE LOADER...2681
      Procedure...2681
      Emergency Exit...2682
    ATTACHMENTS...2683
      Choosing The Correct Bucket...2683
      Pallet Forks...2683
      Installing And Removing The Attachment (Hand Lever Bob-Tach)...2684
      Installing And Removing The Attachment (Power Bob-Tach)...2687
    TRACK CARRIAGE SYSTEM...2689
      Introduction...2689
      Compact Track Loader Operating And Maintenance Tips...2689
    OPERATING PROCEDURE...2691
      Inspect The Work Area...2691
      Operating With A Full Bucket...2691
      Operating With An Empty Bucket...2692
      Filling And Emptying The Bucket (Foot Pedals)...2693
      Leveling The Ground Using Float (Foot Pedals)...2694
      ...
      Removal And Installation...3375
      Parts Identification...3376
    INSTRUMENT PANELS...3378
      Left Panel...3378
      Right Panel (Key Switch)...3379
      Right Panel (Keyless)...3380
      Side And Front Panels...3382
      Removal And Installation (Left And Right)...3383
      Bulb Removal And Installation (Left Only)...3386
      Key Switch Removal And Installation...3387
      Alarm Removal And Installation...3388
      Front Panel Removal And Installation...3388
    LIGHTS...3390
      Front Removal And Installation...3390
      Rear Removal And Installation...3391
      Cab Light Removal And Installation...3391
    BOBCAT CONTROLLER (MAIN)...3392
      Description...3392
      Connector Identification...3393
      Removal And Installation...3395
    BOBCAT CONTROLLER (ACS)...3396
      Description...3396
      Connector Identification...3398
      Removal And Installation...3399
    BOBCAT CONTROLLER (SJC) (DRIVE)...3400
      Description...3400
      Connector Identification...3401
      Removal and Installation...3403
    SPEED SENSOR (SJC)...3406
      Description...3406
      Testing...3406
      Removal And Installation...3408
    DIAGNOSTIC SERVICE CODES...3412
      Viewing Service Codes (Key Switch)...3412
      Viewing Service Codes (Keyless)...3412
      Service Codes List...3413
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...3418
      Description...3418
      Inspecting The BICS Controller (Engine STOPPED - Key ON)...3419
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...3419
      Inspecting The Seat Bar Sensor (Engine RUNNING)...3419
      Inspecting The Traction Lock (Engine RUNNING)...3419
      Inspecting The Lift Arm Bypass Control...3419
      Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)...3419
      Troubleshooting...3420
      Troubleshooting Chart...3421
    SEAT BAR SENSOR...3422
      Description...3422
      Troubleshooting...3422
      Testing...3423
      Removal And Installation...3424
      Bobcat Interlock Control System (BICS) Circuit Test...3426
    TRACTION LOCK...3428
      Description...3428
      Troubleshooting...3429
      Inspecting...3430
    CONTROL SYSTEM (ACS)...3432
      Description...3432
      Troubleshooting Chart...3433
      Handle Sensor Connector Disassembly And Assembly...3434
      Switch Handle Removal...3435
      Switch Handle Installation...3437
      Actuator Connector Disassembly And Assembly...3440
      Handle Lock Solenoid Removal And Installation...3441
      Handle Lock Solenoid Disassembly And Assembly...3441
      Foot Sensor Disassembly And Assembly...3442
      Foot Lock Solenoid Removal And Installation...3443
    ELECTRICAL/HYDRAULIC CONTROLS...3444
      Identification Chart...3444
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SJC)...3446
      Identification Chart...3446
    SERVICE PC (LAPTOP COMPUTER)...3450
      Connecting Remote Start Tool...3450
      Connecting Remote Start Tool (Service Tool)...3450
    CALIBRATION...3452
      Description...3452
      Actuator Testing...3452
      Lift And Tilt Calibration (ACS)...3454
      Lift And Tilt Calibration (SJC)...3456
      Hydrostatic Pump Calibration (SJC)...3458
    STEERING DRIFT COMPENSATION...3464
      Description...3464
      Selecting And Adjusting...3464
      Exiting And Saving...3465
    FLYWHEEL RPM SENSOR...3466
      Description...3466
      Adjusting...3466
    CONTROL PANEL SETUP...3468
      Right Panel Setup (Keyless)...3468
      Attachment Control Information (Keyless)...3469
    PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START)...3470
      Password Description...3470
      Changing The Owner And User Passwords...3471
      Password Lockout Feature...3472
    MAINTENANCE CLOCK...3474
      Description...3474
      Setup...3475
      Reset...3479
    BACK-UP ALARM SYSTEM...3480
      Description...3480
      Inspecting...3480
      Adjusting Switch Position...3481
      Troubleshooting (Standard and ACS)...3482
      Troubleshooting (Joystick)...3483
      Alarm Removal And Installation...3484
      Switch Removal And Installation...3484
  ENGINE SERVICE...3486
    ENGINE INFORMATION...3490
      Description...3490
      Specifications...3491
      Torque Values...3495
      Troubleshooting...3495
      Engine Removal And Installation...3497
      Engine Mount Replacement...3504
      Compression - Checking...3505
    ENGINE SPEED CONTROL...3506
      Removal And Installation...3506
    ENGINE SPEED CONTROL (SJC)...3508
      Removal And Installation...3508
      Disassembly And Assembly...3510
    MUFFLER...3512
      Removal And Installation...3512
    AIR CLEANER...3514
      Housing Removal And Installation...3514
    ENGINE COOLING SYSTEM...3516
      Radiator Removal And Installation...3516
      Blower Housing Removal And Installation...3519
      Hydraulic Fan Removal And Installation...3521
      Hydraulic Fan Description...3522
      Hydraulic Fan Disassembly And Assembly...3522
      Water Pump Removal And Installation...3523
      Water Pump Disassembly And Assembly...3523
      Thermostat Housing Removal And Installation...3524
    LUBRICATION SYSTEM...3526
      Oil Pan Removal And Installation...3526
      Oil Pump Removal And Installation...3526
      Oil Pump Inspection...3527
      Engine Oil Pressure - Testing...3528
    FUEL SYSTEM...3530
      Fuel Camshaft Removal And Installation...3530
      Fuel Camshaft Governor Disassembly And Assembly...3531
      Fuel Shutoff Solenoid - Checking...3532
      Fuel Shutoff Solenoid Removal And Installation...3532
      Fuel Injection Pump Removal And Installation...3533
      Injection Pump - Timing...3536
      Fuel Injector Removal And Installation...3538
      Fuel Injector Nozzle Pressure - Checking...3540
      Nozzle Spraying Condition...3540
      Valve Seat Tightness...3541
    CYLINDER HEAD...3542
      Glow Plugs - Testing...3542
      Glow Plugs Removal And Installation...3542
      Valve Clearance Adjustment...3543
      Valve Timing, Checking...3544
      Cylinder Head Removal And Installation...3545
      Cylinder Head Disassembly and Assembly...3548
      Cylinder Head - Servicing...3548
      Cylinder Head Top Clearance...3549
      Valve Guide-Checking...3549
      Reconditioning The Valve And Valve Seat...3550
      Valve Spring...3552
      Valve Tappets...3553
      Rocker Arm And Shaft Checking...3553
    CRANKSHAFT AND PISTONS...3554
      Piston And Connecting Rod Removal And Installation...3554
      Piston And Connecting Rod - Servicing...3555
      Cylinder Bore - Checking...3558
      Connecting Rod Alignment...3558
      Crankshaft Gear Removal And Installation...3559
      Crankshaft And Bearings Removal And Installation...3559
      Crankshaft And Bearings - Servicing...3561
    CAMSHAFT AND TIMING GEARS...3566
      Timing Gearcase Cover Removal And Installation...3566
      Timing Gears Backlash-Checking...3568
      Idler Gear And Camshaft Removal And Installation...3569
      Camshaft - Servicing...3570
      Idler Gear And Shaft Servicing...3571
    TURBOCHARGER...3572
      Description...3572
      Testing...3572
      Removal And Installation...3573
    FLYWHEEL AND HOUSING...3576
      ...
    ELECTRICAL/HYDRAULIC CONTROLS...4452
      Identification Chart...4452
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SJC)...4454
      Identification Chart...4454
    SERVICE PC (LAPTOP COMPUTER)...4458
      Connecting To The Remote Start Tool...4458
      Connecting Remote Start Tool (Service Tool)...4458
    CALIBRATION...4460
      Description...4460
      Actuator Testing...4460
      Lift And Tilt Calibration (ACS)...4462
      Lift And Tilt Calibration (SJC)...4464
      Hydrostatic Pump Calibration (SJC)...4466
    STEERING DRIFT COMPENSATION...4472
      Description...4472
      Selecting And Adjusting...4472
      Exiting And Saving...4473
    FLYWHEEL RPM SENSOR...4474
      Description...4474
      Adjusting...4474
    CONTROL PANEL SETUP...4476
      Right Panel Setup (Keyless)...4476
      Attachment Control Information (Keyless)...4477
    PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START)...4478
      Password Description...4478
      Changing The Owner And User Passwords...4479
      Password Lockout Feature...4480
    MAINTENANCE CLOCK...4482
      Description...4482
      Setup...4483
      Reset...4487
    BACK-UP ALARM SYSTEM...4488
      Description...4488
      Inspecting...4488
      Adjusting Switch Position...4489
      Troubleshooting (Standard And ACS)...4490
      Troubleshooting (Joystick)...4491
      Alarm Removal And Installation...4492
      Switch Removal And Installation...4492
  ENGINE SERVICE...4494
    ENGINE INFORMATION...4496
      Description...4496
      Specifications...4497
      Engine Torque Values...4501
      Troubleshooting...4501
      Engine Removal And Installation...4503
      Engine Mount Replacement...4510
      Compression - Checking...4511
    ENGINE SPEED CONTROL...4512
      Removal And Installation...4512
    ENGINE SPEED CONTROL (SJC)...4514
      Removal And Installation...4514
      Disassembly And Assembly...4516
    MUFFLER...4518
      Removal And Installation...4518
    AIR CLEANER...4520
      Housing Removal And Installation...4520
    ENGINE COOLING SYSTEM...4522
      Radiator Removal And Installation...4522
      Hydraulic Fan Description...4524
      Hydraulic Fan Disassembly And Assembly...4524
      Blower Housing Removal And Installation...4525
      Fan Removal And Installation...4527
      Hydraulic Fan Motor Removal And Installation...4527
      Water Pump Removal And Installation...4528
      Water Pump Disassembly And Assembly...4528
      Thermostat Housing Removal And Installation...4529
    LUBRICATION SYSTEM...4530
      Oil Pan Removal And Installation...4530
      Oil Pump Removal And Installation...4530
      Oil Pump Inspection...4531
      Engine Oil Pressure-Testing...4532
    FUEL SYSTEM...4534
      Fuel Camshaft Removal And Installation...4534
      Fuel Camshaft Governor Disassembly And Assembly...4535
      Fuel Shutoff Solenoid - Checking...4536
      Fuel Shutoff Solenoid Removal And Installation...4536
      Fuel Injection Pump Removal And Installation...4537
      Injection Pump - Timing...4541
      Fuel Injector Removal And Installation...4543
      Fuel Injector Nozzle Pressure - Checking...4544
      Nozzle Spray Condition...4545
      Valve Seat Tightness...4545
    CYLINDER HEAD...4546
      Glow Plugs - Testing...4546
      Glow Plugs Removal And Installation...4546
      Valve Clearance Adjustment...4547
      Valve Timing - Checking...4548
      Cylinder Head Removal And Installation...4549
      Cylinder Head Disassembly and Assembly...4552
      Cylinder Head - Servicing...4552
      Cylinder Head Top Clearance...4553
      Valve Guide-Checking...4553
      Reconditioning The Valve And Valve Seat...4554
      Valve Spring...4556
      Valve Tappets...4557
      Rocker Arm And Shaft Checking...4557
    CRANKSHAFT AND PISTONS...4558
      Piston And Connecting Rod Removal And Installation...4558
      Piston And Connecting Rod - Servicing...4560
      Cylinder Bore- Checking...4562
      Connecting Rod Alignment...4563
      Crankshaft And Bearings Removal And Installation...4563
      Crankshaft And Bearings - Servicing...4565
    CAMSHAFT AND TIMING GEARS...4570
      Timing Gearcase Cover Removal And Installation...4570
      Timing Gears Backlash - Checking...4572
      Idler Gear And Shaft Removal And Installation...4573
      Camshaft - Servicing...4574
      Idler Gear And Shaft Servicing...4575
    FLYWHEEL AND HOUSING...4576
      Flywheel Removal And Installation...4576
      Ring Gear Removal And Installation...4576
      Housing Removal And Installation...4577
  HEATING SYSTEM...4580
    HEATING SYSTEM...4582
      Description...4582
    REGULAR MAINTENANCE...4584
      Filter Elements Removal And Installation...4584
      Heater Coil...4585
      Troubleshooting...4585
    TROUBLESHOOTING...4586
      Blower Motor Does Not Operate...4586
      Blower Motor Operators Normally, But Air Flow Is Insufficient...4586
      Electrical System...4587
      Engine Coolant Bypassing The Heater Valve...4591
      Heater Valve Not Opening Or Closing...4592
    HEATER UNIT...4594
      Removal And Installation...4594
    HEATER COIL...4596
      Removal And Installation...4596
    HEATER FAN...4598
      Blower Removal And Installation...4598
      Disassembly And Assembly...4599
      Connector Identification...4601
    HEATER VALVE...4602
      Removal and Installation...4602
      Disassembly And Assembly...4603
  SPECIFICATIONS...4604
    (T140) LOADER SPECIFICATIONS...4606
      Dimensions...4606
      Performance...4607
      Controls...4607
      Engine...4607
      Hydraulic System...4608
      Electrical...4608
      Drive System...4609
      Capacities...4609
      Tracks...4609
    TORQUE SPECIFICATIONS FOR BOLTS...4610
      Torque For General SAE Bolts...4610
      Torque For General Metric Bolts...4611
    HYDRAULIC CONNECTION SPECIFICATIONS...4612
      O-ring Face Seal Connection...4612
      Straight Thread O-ring Fitting...4613
      Tubelines And Hoses...4613
      Flare Fitting...4614
      Port Seal Fitting...4615
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...4616
      Specifications...4616
    CONVERSIONS...4618
      Decimal And Millimeter Equivalents...4618
      U.S. To Metric Conversion Chart...4618
  SERVICE MANUAL REVISION...4620
    Revision No: T140 - 1...4620
    Revision No: T140 - 2...4622
    Revision No: T140 - 3...4624
    Revision No: T140 - 4...4626
    Revision No: T140 - 5...4628
    Revision No: T140 - 6...4630
    Revision No: T140 - 7...4632
    Revision No: T140 - 8...4634
    Revision No: T140 - 9...4636
    Revision No: T140 - 10...4638
    Revision No: T140 - 11...4640
    Revision No: T140 - 12...4642
    Revision No: T140 - 13...4644
6904978 (11-10) - T110 Compact Track Loader Operation & Maintenance Manual...4646
  OPERATOR SAFETY WARNINGS...4648
  CONTENTS...4650
  FOREWORD...4652
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...4654
    REGULAR MAINTENANCE ITEMS...4654
    SERIAL NUMBER LOCATIONS...4655
      Loader Serial Number...4655
      Engine Serial Number...4655
    DELIVERY REPORT...4655
    LOADER IDENTIFICATION...4656
    FEATURES, ACCESSORIES AND ATTACHMENTS...4657
      Standard Items...4657
      Options And Accessories...4657
      Buckets Available...4658
      Attachments...4658
      Special Applications Kit...4659
      Special Applications Kit Inspection And Maintenance...4659
  SAFETY & TRAINING RESOURCES...4660
    SAFETY INSTRUCTIONS...4662
      Before Operation...4662
      Safe Operation Is The Operator’s Responsibility...4663
      Safe Operation Needs A Qualified Operator...4663
      Avoid Silica Dust...4664
    FIRE PREVENTION...4664
      Maintenance...4664
      Operation...4664
      Electrical...4664
      Hydraulic System...4665
      Fueling...4665
      Starting...4665
      Spark Arrestor Exhaust System...4665
      Welding And Grinding...4665
      Fire Extinguishers...4665
    MACHINE SIGNS (DECALS)...4667
    PUBLICATIONS AND TRAINING RESOURCES...4669
  OPERATING INSTRUCTIONS...4670
    INSTRUMENT PANEL IDENTIFICATION...4674
      Cab Light...4674
      Left Panel...4675
      Display Screen...4677
      Standard Key Panel...4678
      Keyless Start Panel...4678
      Deluxe Instrumentation Panel...4679
      Side Panel...4680
      Front Panel...4680
    CONTROL IDENTIFICATION...4681
      Standard Controls...4681
      Selectable Joystick Controls (SJC)...4682
    SEAT BAR RESTRAINT SYSTEM...4683
      Operation...4683
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...4684
      Operation...4684
    LIFT ARM BYPASS CONTROL...4685
      Operation...4685
    PARKING BRAKE...4685
      Operation...4685
    TRACTION LOCK OVERRIDE...4685
      Operation...4685
    EMERGENCY EXIT...4686
      Rear Window...4686
      Front Door...4686
    BACK-UP ALARM SYSTEM...4687
      Description...4687
      Operation...4687
    ENGINE SPEED CONTROL...4688
      Operation...4688
    DRIVING AND STEERING THE LOADER...4689
      Available Control Configurations...4689
      Operation (Standard)...4689
      Operation (SJC) In ‘ISO’ Control Pattern...4690
      Operation (SJC) In ‘H’ Control Pattern...4691
    STOPPING THE LOADER...4691
      Using The Control Levers Or Joysticks...4691
    TWO-SPEED CONTROL...4692
      Description...4692
      Operation (SJC)...4692
    SPEED MANAGEMENT...4693
      Operation...4693
      Changing The Factory Default Setting...4694
    DRIVE RESPONSE...4695
      Description...4695
      Operation...4695
    STEERING DRIFT COMPENSATION...4697
      Description...4697
      Operation...4697
    HYDRAULIC CONTROLS...4699
      Description...4699
      Standard Controls...4699
      Selectable Joystick Controls (SJC) In ‘ISO’ Control Pattern...4699
      Selectable Joystick Controls (SJC) In ‘H’ Control Pattern...4700
      Hydraulic Bucket Positioning...4700
      Front Auxiliary Hydraulic Control Lockout...4700
      FRONT Auxiliary Hydraulics Operation (Variable Flow)...4701
      FRONT Auxiliary Hydraulics Operation (Continuous Flow)...4702
      Quick Couplers...4703
      Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)...4704
    ATTACHMENT CONTROL DEVICE (ACD)...4705
      Description...4705
    DAILY INSPECTION...4706
      Daily Inspection And Maintenance...4707
    PRE-STARTING PROCEDURE...4708
      Entering The Loader...4708
      Operation & Maintenance Manual And Operator’s Handbook Locations...4708
      Seat Adjustment...4709
      Seat Belt Adjustment...4710
      Seat Bar...4710
    STARTING THE ENGINE...4711
      Standard Key Panel...4711
      Keyless Start Panel...4713
      Deluxe Instrumentation Panel...4715
      Cold Temperature Starting...4717
      Warming The Hydraulic / Hydrostatic System...4717
    MONITORING THE DISPLAY PANELS...4718
      Left Panel...4718
      Warning And Shutdown...4718
    STOPPING THE ENGINE AND LEAVING THE LOADER...4719
      Procedure...4719
    ATTACHMENTS...4720
      Choosing The Correct Bucket...4720
      Pallet Forks...4720
      Installing And Removing The Attachment...4721
    TRACK UNDERCARRIAGE SYSTEM...4724
      Introduction...4724
      Compact Track Loader Operating And Maintenance Tips...4724
    OPERATING PROCEDURE...4726
      Inspect The Work Area...4726
      Basic Operating Instructions...4726
      Driving On Public Roads...4726
      Operating With A Full Bucket...4727
      Operating With An Empty Bucket...4727
      Filling And Emptying The Bucket (Foot Pedals)...4728
      Leveling The Ground Using Float (Foot Pedals)...4729
      Digging And Filling A Hole (Foot Pedals)...4730
      Filling And Emptying The Bucket (SJC - ‘H’ Pattern)...4731
      Leveling The Ground Using Float (SJC - ‘H’ Pattern)...4732
      Digging And Filling A Hole (SJC - ‘H’ Pattern)...4732
      Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)...4733
      Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)...4734
      Digging And Filling A Hole (SJC - ‘ISO’ Pattern)...4734
    TOWING THE LOADER...4735
      Procedure...4735
    LIFTING THE LOADER...4735
      Single-Point Lift...4735
    TRANSPORTING THE LOADER ON A TRAILER...4736
      Loading And Unloading...4736
      Fastening...4736
  PREVENTIVE MAINTENANCE...4738
    MAINTENANCE SAFETY...4742
    SERVICE SCHEDULE...4744
      Chart...4744
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...4745
      Inspecting The BICS (Engine STOPPED - Key ON)...4745
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...4745
      Inspecting The Seat Bar Sensor (Engine RUNNING)...4745
      Inspecting The Traction Lock (Engine RUNNING)...4745
      Inspecting The Lift Arm Bypass Control...4745
      Inspecting Deactivation Of Lift And Tilt Functions (SJC)...4745
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine RUNNING)...4746
    SEAT BAR RESTRAINT SYSTEM...4747
      Description...4747
      Inspecting...4747
      Maintaining...4747
    SEAT BELT...4748
      Inspection And Maintenance...4748
    LIFT ARM SUPPORT DEVICE...4749
      Installing...4749
      Removing...4750
    BACK-UP ALARM SYSTEM...4751
      Description...4751
      Inspecting...4751
      Adjusting Switch Position...4751
    OPERATOR CAB...4752
      Description...4752
      Raising...4752
      Lowering...4753
      Cab Door Sensor...4754
    REAR DOOR (TAILGATE)...4755
      Opening And Closing...4755
      Adjusting...4755
    REAR GRILLE...4755
      Removing...4755
      Installing...4755
    HEATING SYSTEM...4756
      Cleaning And Maintenance...4756
      Filters...4756
      Heater Coil...4756
      Troubleshooting...4756
    AIR CLEANER SERVICE...4757
      Replacing Filter Elements...4757
    FUEL SYSTEM...4758
      Fuel Specifications...4758
      Biodiesel Blend Fuel...4758
      Filling The Fuel Tank...4759
      Fuel Filter...4760
      Removing Air From The Fuel System...4760
    ENGINE LUBRICATION SYSTEM...4761
      Checking And Adding Engine Oil...4761
      Engine Oil Chart...4761
      Removing And Replacing Oil And Filter...4762
    ENGINE COOLING SYSTEM...4763
      Cleaning...4763
      Checking Level...4763
      Removing And Replacing Coolant...4764
    ELECTRICAL SYSTEM...4765
      Description...4765
      Fuse And Relay Location / Identification...4765
      Battery Maintenance...4766
      Using A Booster Battery (Jump Starting)...4767
      Removing And Installing Battery...4768
    HYDRAULIC / HYDROSTATIC SYSTEM...4769
      Checking And Adding Fluid...4769
      Hydraulic / Hydrostatic Fluid Chart...4769
      Removing And Replacing Hydraulic Fluid...4770
      Removing And Replacing Hydraulic / Hydrostatic Filter...4771
      Removing And Replacing Case Drain Filters...4771
      Removing And Replacing Hydraulic Charge Filter...4772
      Breather Cap...4772
    SPARK ARRESTER MUFFLER...4773
      Cleaning Procedure...4773
    TRACK TENSION...4774
      Description...4774
      Checking...4774
      Adjusting...4775
    HYDROSTATIC DRIVE MOTOR...4776
      Removing And Replacing Oil...4776
    TRACK SPROCKET MAINTENANCE...4776
      Tightening Procedure...4776
    ALTERNATOR BELT...4777
      Belt Adjustment...4777
      Belt Replacement...4777
    DRIVE BELT...4778
      Belt Adjustment...4778
      Belt Replacement...4778
    LUBRICATING THE LOADER...4779
      Lubrication Locations...4779
    TRACK ROLLER AND IDLER LUBRICATION...4780
      Procedure...4780
    PIVOT PINS...4781
      Inspection And Maintenance...4781
    BOB-TACH...4782
      Inspection And Maintenance...4782
    LOADER STORAGE AND RETURN TO SERVICE...4783
      Storage...4783
      Return To Service...4783
  SYSTEM SETUP & ANALYSIS...4784
    DIAGNOSTIC SERVICE CODES...4786
      Viewing Service Codes...4786
      Service Codes List...4787
    CONTROL PANEL SETUP...4792
      Right Panel Setup (Deluxe Instrumentation Panel)...4792
      Attachment Control Information (Deluxe Instrumentation Panel)...4793
    PASSWORD SETUP (KEYLESS START PANEL)...4794
      Password Description...4794
      Changing The Owner Password...4794
      Password Lockout Feature...4794
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...4795
      Password Description...4795
      Changing The Owner Password...4795
      Changing The User Passwords...4796
      Password Lockout Feature...4796
    MAINTENANCE CLOCK...4797
      Description...4797
      Setup...4797
      Reset...4797
  MACHINE SIGN TRANSLATIONS...4798
    MACHINE SIGN TRANSLATIONS...4800
      Service Schedule (6734534)...4800
      Warning (6728540)...4803
      Warning (6718396)...4804
      Danger (6809511)...4804
      Warning (6737189)...4804
      Warning (6725370)...4805
      Warning (6704786)...4805
      Warning (6737248)...4805
      Lift Arm Support Device (6706558)...4806
      Danger (6717343)...4807
      Warning (6804114)...4807
      Important (6560573)...4807
      Warning (7131520)...4808
      Danger (6718392)...4809
      Danger (6718393)...4809
      Warning (7131521)...4810
      Warning (6577754)...4811
      Warning (6718391)...4811
  SPECIFICATIONS...4812
    (T110) LOADER SPECIFICATIONS...4814
      Machine Dimensions...4814
      Performance...4815
      Engine...4815
      Controls...4815
      Drive System...4816
      Hydraulic System...4816
      Electrical...4817
      Capacities...4817
      Tracks...4817
      Ground Pressure...4817
  WARRANTY...4818
    WARRANTY...4820
  ALPHABETICAL INDEX...4822
6904978 (3-11) - T110 Compact Track Loader Operation & Maintenance Manual...4824
  OPERATOR SAFETY WARNINGS...4826
  CONTENTS...4828
  FOREWORD...4830
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...4832
    REGULAR MAINTENANCE ITEMS...4832
    SERIAL NUMBER LOCATIONS...4833
      Loader Serial Number...4833
      Engine Serial Number...4833
    DELIVERY REPORT...4833
    LOADER IDENTIFICATION...4834
    FEATURES, ACCESSORIES AND ATTACHMENTS...4835
      Standard Items...4835
      Options And Accessories...4835
      Buckets Available...4836
      Attachments...4836
      Special Applications Kit...4837
      Special Applications Kit Inspection And Maintenance...4837
  SAFETY & TRAINING RESOURCES...4838
    SAFETY INSTRUCTIONS...4840
      Before Operation...4840
      Safe Operation Is The Operator’s Responsibility...4841
      Safe Operation Needs A Qualified Operator...4841
      Avoid Silica Dust...4842
    FIRE PREVENTION...4842
      Maintenance...4842
      Operation...4842
      Electrical...4842
      Hydraulic System...4843
      Fueling...4843
      Starting...4843
      Spark Arrestor Exhaust System...4843
      Welding And Grinding...4843
      Fire Extinguishers...4843
    MACHINE SIGNS (DECALS)...4845
    PUBLICATIONS AND TRAINING RESOURCES...4847
  OPERATING INSTRUCTIONS...4848
    INSTRUMENT PANEL IDENTIFICATION...4852
      Cab Light...4852
      Left Panel...4853
      Display Screen...4855
      Standard Key Panel...4856
      Keyless Start Panel...4856
      Deluxe Instrumentation Panel...4857
      Side Panel...4858
      Front Panel...4858
    CONTROL IDENTIFICATION...4859
      Standard Controls...4859
      Selectable Joystick Controls (SJC)...4860
    SEAT BAR RESTRAINT SYSTEM...4861
      Operation...4861
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...4862
      Operation...4862
    LIFT ARM BYPASS CONTROL...4863
      Operation...4863
    PARKING BRAKE...4863
      Operation...4863
    TRACTION LOCK OVERRIDE...4863
      Operation...4863
    EMERGENCY EXIT...4864
      Rear Window...4864
      Front Door...4864
    BACK-UP ALARM SYSTEM...4865
      Description...4865
      Operation...4865
    ENGINE SPEED CONTROL...4866
      Operation...4866
    DRIVING AND STEERING THE LOADER...4867
      Available Control Configurations...4867
      Operation (Standard)...4867
      Operation (SJC) In ‘ISO’ Control Pattern...4868
      Operation (SJC) In ‘H’ Control Pattern...4869
    STOPPING THE LOADER...4869
      Using The Control Levers Or Joysticks...4869
    TWO-SPEED CONTROL...4870
      Description...4870
      Operation (SJC)...4870
    SPEED MANAGEMENT...4871
      Operation...4871
      Changing The Factory Default Setting...4872
    DRIVE RESPONSE...4873
      Description...4873
      Operation...4873
    STEERING DRIFT COMPENSATION...4875
      Description...4875
      Operation...4875
    HYDRAULIC CONTROLS...4877
      Description...4877
      Standard Controls...4877
      Selectable Joystick Controls (SJC) In ‘ISO’ Control Pattern...4877
      Selectable Joystick Controls (SJC) In ‘H’ Control Pattern...4878
      Hydraulic Bucket Positioning...4878
      Front Auxiliary Hydraulic Control Lockout...4878
      FRONT Auxiliary Hydraulics Operation (Variable Flow)...4879
      FRONT Auxiliary Hydraulics Operation (Continuous Flow)...4880
      Quick Couplers...4881
      Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)...4882
    ATTACHMENT CONTROL DEVICE (ACD)...4883
      Description...4883
    DAILY INSPECTION...4884
      Daily Inspection And Maintenance...4885
    PRE-STARTING PROCEDURE...4886
      Entering The Loader...4886
      Operation & Maintenance Manual And Operator’s Handbook Locations...4886
      Seat Adjustment...4887
      Seat Belt Adjustment...4888
      Seat Bar...4888
    STARTING THE ENGINE...4889
      Standard Key Panel...4889
      Keyless Start Panel...4891
      Deluxe Instrumentation Panel...4893
      Cold Temperature Starting...4895
      Warming The Hydraulic / Hydrostatic System...4895
    MONITORING THE DISPLAY PANELS...4896
      Left Panel...4896
      Warning And Shutdown...4896
    STOPPING THE ENGINE AND LEAVING THE LOADER...4897
      Procedure...4897
    ATTACHMENTS...4898
      Choosing The Correct Bucket...4898
      Pallet Forks...4898
      Installing And Removing The Attachment...4899
    TRACK UNDERCARRIAGE SYSTEM...4902
      Introduction...4902
      Compact Track Loader Operating And Maintenance Tips...4902
    OPERATING PROCEDURE...4904
      Inspect The Work Area...4904
      Basic Operating Instructions...4904
      Driving On Public Roads...4904
      Operating With A Full Bucket...4905
      Operating With An Empty Bucket...4905
      Filling And Emptying The Bucket (Foot Pedals)...4906
      Leveling The Ground Using Float (Foot Pedals)...4907
      Digging And Filling A Hole (Foot Pedals)...4908
      Filling And Emptying The Bucket (SJC - ‘H’ Pattern)...4909
      Leveling The Ground Using Float (SJC - ‘H’ Pattern)...4910
      Digging And Filling A Hole (SJC - ‘H’ Pattern)...4910
      Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)...4911
      Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)...4912
      Digging And Filling A Hole (SJC - ‘ISO’ Pattern)...4912
    TOWING THE LOADER...4913
      Procedure...4913
    LIFTING THE LOADER...4913
      Single-Point Lift...4913
    TRANSPORTING THE LOADER ON A TRAILER...4914
      Loading And Unloading...4914
      Fastening...4914
  PREVENTIVE MAINTENANCE...4916
    MAINTENANCE SAFETY...4920
    SERVICE SCHEDULE...4922
      Chart...4922
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...4923
      Inspecting The BICS™ (Engine STOPPED - Key ON)...4923
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...4923
      Inspecting The Seat Bar Sensor (Engine RUNNING)...4923
      Inspecting The Traction Lock (Engine RUNNING)...4923
      Inspecting The Lift Arm Bypass Control...4923
      Inspecting Deactivation Of Lift And Tilt Functions (SJC)...4923
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine RUNNING)...4924
    SEAT BAR RESTRAINT SYSTEM...4925
      Description...4925
      Inspecting...4925
      Maintaining...4925
    SEAT BELT...4926
      Inspection And Maintenance...4926
    LIFT ARM SUPPORT DEVICE...4927
      Installing...4927
      Removing...4928
    BACK-UP ALARM SYSTEM...4929
      Description...4929
      Inspecting...4929
      Adjusting Switch Position...4929
    OPERATOR CAB...4930
      Description...4930
      Raising...4930
      Lowering...4931
      Cab Door Sensor...4932
    REAR DOOR (TAILGATE)...4933
      Opening And Closing...4933
      Adjusting...4933
    REAR GRILLE...4933
      Removing...4933
      Installing...4933
    HEATING SYSTEM...4934
      Cleaning And Maintenance...4934
      Filters...4934
      Heater Coil...4934
      Troubleshooting...4934
    AIR CLEANER SERVICE...4935
      Replacing Filter Elements...4935
    FUEL SYSTEM...4936
      Fuel Specifications...4936
      Biodiesel Blend Fuel...4936
      Filling The Fuel Tank...4937
      Fuel Filter...4938
      Removing Air From The Fuel System...4938
    ENGINE LUBRICATION SYSTEM...4939
      Checking And Adding Engine Oil...4939
      Engine Oil Chart...4939
      Removing And Replacing Oil And Filter...4940
    ENGINE COOLING SYSTEM...4941
      Cleaning...4941
      Checking Level...4941
      Removing And Replacing Coolant...4942
    ELECTRICAL SYSTEM...4943
      Description...4943
      Fuse And Relay Location / Identification...4943
      Battery Maintenance...4944
      Using A Booster Battery (Jump Starting)...4945
      Removing And Installing Battery...4946
    HYDRAULIC / HYDROSTATIC SYSTEM...4947
      Checking And Adding Fluid...4947
      Hydraulic / Hydrostatic Fluid Chart...4947
      Removing And Replacing Hydraulic Fluid...4948
      Removing And Replacing Hydraulic / Hydrostatic Filter...4949
      Removing And Replacing Case Drain Filters...4949
      Removing And Replacing Hydraulic Charge Filter...4950
      Breather Cap...4950
    SPARK ARRESTER MUFFLER...4951
      Cleaning Procedure...4951
    TRACK TENSION...4952
      Description...4952
      Checking...4952
      Adjusting...4953
    HYDROSTATIC DRIVE MOTOR...4954
      Removing And Replacing Oil...4954
    TRACK SPROCKET MAINTENANCE...4954
      Tightening Procedure...4954
    ALTERNATOR BELT...4955
      Belt Adjustment...4955
      Belt Replacement...4955
    DRIVE BELT...4956
      Belt Adjustment...4956
      Belt Replacement...4956
    LUBRICATING THE LOADER...4957
      Lubrication Locations...4957
    TRACK ROLLER AND IDLER LUBRICATION...4958
      Procedure...4958
    PIVOT PINS...4959
      Inspection And Maintenance...4959
    BOB-TACH...4960
      Inspection And Maintenance...4960
    LOADER STORAGE AND RETURN TO SERVICE...4961
      Storage...4961
      Return To Service...4961
  SYSTEM SETUP & ANALYSIS...4962
    DIAGNOSTIC SERVICE CODES...4964
      Viewing Service Codes...4964
      Service Codes List...4965
    CONTROL PANEL SETUP...4970
      Right Panel Setup (Deluxe Instrumentation Panel)...4970
      Attachment Control Information (Deluxe Instrumentation Panel)...4971
    PASSWORD SETUP (KEYLESS START PANEL)...4972
      Password Description...4972
      Changing The Owner Password...4972
      Password Lockout Feature...4972
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...4973
      Password Description...4973
      Changing The Owner Password...4973
      Changing The User Passwords...4974
      Password Lockout Feature...4974
    MAINTENANCE CLOCK...4975
      Description...4975
      Setup...4975
      Reset...4975
  MACHINE SIGN TRANSLATIONS...4976
    MACHINE SIGN TRANSLATIONS...4978
      Service Schedule (6734534)...4978
      Warning (6728540)...4981
      Warning (6718396)...4982
      Danger (6809511)...4982
      Warning (6737189)...4982
      Warning (6725370)...4983
      Warning (6704786)...4983
      Warning (6737248)...4983
      Lift Arm Support Device (6706558)...4984
      Danger (6717343)...4985
      Important (6560573)...4985
      Warning (7131520)...4986
      Danger (6718392)...4987
      Danger (6718393)...4987
      Warning (7131521)...4988
      Warning (6577754)...4989
      Warning (6718391)...4989
  SPECIFICATIONS...4990
    (T110) LOADER SPECIFICATIONS...4992
      Machine Dimensions...4992
      Performance...4993
      Engine...4993
      Controls...4993
      Drive System...4994
      Hydraulic System...4994
      Electrical...4995
      Capacities...4995
      Tracks...4995
      Ground Pressure...4995
  WARRANTY...4996
    WARRANTY...4998
  ALPHABETICAL INDEX...5000
6904979 (4-11) - T110 Compact Track Loader Service Manual...5002
  MAINTENANCE SAFETY...5004
  CONTENTS...5006
  FOREWORD...5008
    FOREWORD...5010
    SAFETY INSTRUCTIONS...5013
    FIRE PREVENTION...5015
      Maintenance...5015
      Operation...5015
      Electrical...5015
      Hydraulic System...5015
      Fueling...5015
      Starting...5015
      Spark Arrestor Exhaust System...5015
      Welding And Grinding...5016
      Fire Extinguishers...5016
    SERIAL NUMBER LOCATIONS...5017
      Loader Serial Number...5017
      Engine Serial Number...5017
    DELIVERY REPORT...5018
    LOADER IDENTIFICATION...5019
  SAFETY & MAINTENANCE...5020
    LIFTING AND BLOCKING THE LOADER...5022
      Procedure...5022
    LIFT ARM SUPPORT DEVICE...5024
      Installing...5024
      Removing...5025
    OPERATOR CAB...5026
      Description...5026
      Raising...5026
      Lowering...5027
      Cab Door Sensor...5028
      Special Applications Kit...5028
      Special Applications Kit Inspection And Maintenance...5028
    TRANSPORTING THE LOADER ON A TRAILER...5030
      Loading And Unloading...5030
      Fastening...5030
    TOWING THE LOADER...5032
      Procedure...5032
    REMOTE START TOOL KIT-MEL1563...5034
      Remote Start Tool - MEL1563...5034
      Service Tool Harness Control - MEL1565...5035
      Service Tool Harness Communicator - MEL1566...5036
      Remote Start Procedure...5037
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031...5040
      Description...5040
      Remote Start Tool (Service Tool) - 7003030...5041
      Loader Service Tool Harness - 6689747...5042
      Computer Service Tool Harness - 6689746...5043
      Remote Start Procedure...5044
    SERVICE SCHEDULE...5048
      Chart...5048
    AIR CLEANER SERVICE...5050
      Replacing Filter Elements...5050
    ENGINE COOLING SYSTEM...5052
      Cleaning...5052
      Checking Level...5052
      Removing And Replacing Coolant...5053
    FUEL SYSTEM...5054
      Fuel Specifications...5054
      Biodiesel Blend Fuel...5054
      Filling The Fuel Tank...5055
      Fuel Filter...5056
      Removing Air From The Fuel System...5056
    ENGINE LUBRICATION SYSTEM...5058
      Checking And Adding Engine Oil...5058
      Engine Oil Chart...5058
      Removing And Replacing Oil And Filter...5059
    HYDRAULIC / HYDROSTATIC SYSTEM...5060
      Checking And Adding Fluid...5060
      Hydraulic / Hydrostatic Fluid Chart...5060
      Removing And Replacing Hydraulic Fluid...5061
      Removing And Replacing Hydraulic / Hydrostatic Filter...5062
      Removing And Replacing Case Drain Filters...5062
      Removing And Replacing Hydraulic Charge Filter...5063
      Breather Cap...5063
    BOB-TACH (HAND LEVER)...5064
      Inspection And Maintenance...5064
    BOB-TACH (POWER) (S/N AE0J11001 & ABOVE)...5066
      Inspection And Maintenance...5066
    LUBRICATING THE LOADER...5068
      Lubrication Locations...5068
    SPARK ARRESTER MUFFLER...5070
      Cleaning Procedure...5070
    PIVOT PINS...5072
      Inspection And Maintenance...5072
    LOADER STORAGE AND RETURN TO SERVICE...5074
      Storage...5074
      Return To Service...5074
    STOPPING THE ENGINE AND LEAVING THE LOADER...5076
      Procedure...5076
    EMERGENCY EXIT...5078
      Rear Window...5078
      Front Door...5078
    SEAT BELT...5080
      Inspection And Maintenance...5080
  HYDRAULIC SYSTEM...5082
    HYDRAULIC / HYDROSTATIC SCHEMATICS...5086
    HYDRAULIC SYSTEM INFORMATION...5094
      Glossary Of Hydraulic / Hydrostatic Symbols...5094
      Troubleshooting...5098
    CYLINDER (LIFT)...5100
      Testing...5100
      Removal And Installation...5101
      Parts Identification...5102
      Disassembly And Assembly...5103
    CYLINDER (TILT)...5106
      Testing...5106
      Removal And Installation...5106
      Rod End Pivot Pin Bushing And Seal Removal And Installation...5107
      Base End Pivot Pin Removal And Installation...5108
      Parts Identification...5109
      Disassembly And Assembly...5110
    CYLINDER (BOB-TACH) (S/N AE0J11001 & ABOVE)...5114
      Testing...5114
      Removal And Installation...5115
      Parts Identification...5116
      Disassembly And Assembly...5117
    MAIN RELIEF VALVE...5120
      Description...5120
      Testing...5120
      Adjusting...5121
      Removal And Installation...5122
    HYDRAULIC CONTROL VALVE...5124
      Description...5124
      Removal And Installation...5124
      Identification Chart...5127
      BICS™ Load Check Valve Removal And Installation...5128
      Load Check Valve Removal And Installation (Tilt And Auxiliary)...5129
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)...5130
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...5131
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...5131
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)...5132
      Port Relief Valve Removal And Installation...5132
      Plug Removal And Installation...5133
      Rubber Boot Removal And Installation...5133
      End Cap / Spool Lock Block Removal And Installation...5134
      Lift Spool And Detent Removal And Installation...5134
      Tilt Spool Removal And Installation...5143
      Auxiliary Spool Removal And Installation...5146
      Solenoid Removal And Installation...5153
      Lock Valve Removal And Installation...5155
      Lift Arm Bypass Orifice Removal And Installation...5157
      Main Relief Valve Removal And Installation...5157
    HYDRAULIC CONTROL VALVE (SJC)...5158
      Description...5158
      Removal And Installation...5158
      Actuator Removal And Installation...5162
      Identification Chart...5165
      BICS™ Load Check Valve Removal And Installation...5166
      Load Check Valve Removal And Installation (Tilt And Auxiliary)...5167
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)...5168
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...5169
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...5169
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)...5170
      Port Relief Valve Removal And Installation...5170
      Plug Removal And Installation...5171
      End Cap Block Removal And Installation...5172
      Lift Spool And Detent Removal And Installation...5173
      Tilt Spool Removal And Installation...5177
      Auxiliary Spool Removal And Installation...5179
      Auxiliary Solenoid Removal And Installation...5181
      Solenoid Removal And Installation...5182
      Lock Valve Removal And Installation...5183
      Lift Arm Bypass Orifice Removal And Installation...5184
      Main Relief Valve Removal And Installation...5185
      Check Valve Removal And Installation...5185
    LIFT ARM BYPASS CONTROL VALVE...5188
      Description...5188
      Testing...5188
      Removal And Installation...5188
      Disassembly And Assembly...5190
    HYDRAULIC PUMP...5192
      Description...5192
      Pump Test At Quick Couplers...5192
      Direct Pump Test (Standard Section)...5193
      Direct Pump Test (Charge Section)...5195
      Removal And Installation...5197
      Parts Identification...5201
      Disassembly And Assembly...5202
      Hydraulic Pump Startup...5206
    HYDRAULIC PUMP (SJC)...5208
      Description...5208
      Pump Test At Quick Couplers...5208
      Direct Pump Test (Standard Section)...5209
      Removal And Installation...5210
      Hydraulic Pump Startup...5211
      Parts Identification...5212
      Disassembly And Assembly...5213
    HYDRAULIC / HYDROSTATIC FILTERS...5218
      Description...5218
      Housing Removal And Installation...5218
      Charge Filter Housing Removal And Installation...5219
    HYDRAULIC FLUID RESERVOIR...5220
      Description...5220
      Removal And Installation...5220
      Hydraulic Fluid Screen...5222
    OIL COOLER...5224
      Description...5224
      Removal And Installation...5224
    BUCKET POSITION VALVE...5226
      Description...5226
      Solenoid Removal And Installation...5226
      Solenoid Testing...5227
      Removal And Installation...5227
      Disassembly And Assembly...5230
    AUXILIARY HYDRAULIC INTERLOCK VALVE...5232
      Description...5232
      Removal And Installation...5232
      Disassembly And Assembly...5233
    BOB-TACH (POWER) BLOCK (S/N AE0J11001 & ABOVE)...5234
      Description...5234
      Removal And Installation...5234
      Disassembly And Assembly...5236
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK...5240
      Description...5240
      Removal And Installation...5240
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK (SJC)...5242
      Description...5242
      Removal And Installation...5242
      Disassembly And Assembly...5242
  HYDROSTATIC SYSTEM...5244
    HYDROSTATIC SYSTEM INFORMATION...5246
      Description...5246
      Troubleshooting...5247
    HYDROSTATIC DRIVE MOTOR...5248
      Description...5248
      Removing And Replacing Oil...5248
      Removal And Installation...5248
      Parts Identification...5250
      Disassembly And Assembly...5251
    CHARGE PRESSURE...5260
      Description...5260
      Testing...5260
      Sender Removal And Installation...5261
      Adjusting...5262
    HYDROSTATIC PUMP...5264
      Description...5264
      Replenishing / High Pressure Relief Valve Removal And Installation...5264
      Removal And Installation...5265
      Hydrostatic Pump Startup...5267
      Parts Identification...5268
      Disassembly...5269
      Assembly...5274
    HYDROSTATIC PUMP (SJC)...5280
      Description...5280
      High Pressure Relief And Bypass Valve...5281
      Removal And Installation...5282
      Hydrostatic Pump Startup...5284
      Hydraulic Controller Removal And Installation...5285
      Parts Identification...5287
      Disassembly And Assembly...5288
      Mechanical Neutral Adjustment...5303
      Hydraulic Controller Neutral Adjustment...5306
    DRIVE BELT...5310
      Description...5310
      Shield Removal And Installation...5310
      Adjusting...5310
      Belt Removal And Installation...5311
      Tensioner Pulley Removal And Installation...5311
      Tensioner Pulley Disassembly And Assembly...5311
    CASE DRAIN FILTER...5312
      Description...5312
      Disassembly And Assembly...5312
  DRIVE SYSTEM...5314
    BRAKE...5316
      Description...5316
      Right Motor Brake Test...5317
      Left Motor Brake Test...5318
      Block Removal And Installation...5319
      Block Disassembly And Assembly...5320
    TRACK UNDERCARRIAGE COMPONENTS...5322
      Description...5322
      Checking Tension...5323
      Adjusting Tension...5324
      Track Removal And Installation...5326
      Idler (Front) Removal And Installation...5329
      Track Tensioner Disassembly And Assembly...5330
      Idler (Rear) Removal And Installation...5331
      Roller Removal And Installation...5331
      Sprocket Removal And Installation...5332
    TRACK MAINTENANCE...5334
      Track Damage Identification...5334
  MAINFRAME...5346
    SEAT BAR...5350
      Description...5350
      Removal And Installation...5350
      Disassembly And Assembly...5352
      Compression Spring Disassembly And Assembly...5353
    OPERATOR CAB...5354
      Gas Cylinder Removal And Installation...5354
      Gas Cylinder Bracket Disassembly And Assembly...5356
      Removal And Installation...5357
    OPERATOR SEAT (SUSPENSION)...5360
      Removal And Installation...5360
      Slide Rail Removal And Installation...5361
      Seat Belt Removal And Installation...5361
      Lower Cushion Removal And Installation...5362
      Back Cushion Removal And Installation...5362
      Shock Removal And Installation...5363
      3-Point Seat Belt Removal And Installation...5363
    BOB-TACH (HAND LEVER)...5366
      Description...5366
      Removal And Installation...5366
      Lever And Wedge Disassembly And Assembly...5368
      Bob-Tach Stops...5369
      Pivot Pin Bushing And Seal Removal And Installation...5370
    BOB-TACH (POWER) (S/N AE0J11001 & ABOVE)...5372
      Description...5372
      Removal And Installation...5372
      Lever And Wedge Disassembly And Assembly...5374
      Bob-Tach Stops...5375
      Pivot Pin Bushing And Seal Removal And Installation...5376
    LIFT ARMS...5378
      Removal And Installation...5378
    REAR GRILLE...5384
      Removal And Installation...5384
    REAR DOOR (TAILGATE)...5386
      Removal And Installation...5386
      Striker Removal And Installation...5387
      Striker Disassembly And Assembly...5387
      Striker (Adjusting)...5389
      Latch Removal And Installation...5390
    FUEL TANK...5392
      Removal And Installation...5392
      Fuel Level Sender Removal And Installation...5393
      Fuel Fill Screen Removal And Installation...5393
      Fuel Pickup Screen...5393
    CONTROL PEDALS AND LINKAGES...5394
      Description...5394
      Pedal Removal And Installation...5394
      Linkage Removal And Installation...5395
      Pedal (Adjusting)...5395
    CONTROL PANEL...5398
      Description...5398
      Removal And Installation...5399
      Shaft Removal And Installation...5402
      Shaft Disassembly And Assembly...5403
      Shock Removal And Installation...5403
      Linkage Removal And Installation...5404
      Pintle Arm Removal And Installation...5405
      Pintle Arm Disassembly And Assembly...5408
      Linkage Neutral (Adjusting)...5409
      Linkage Travel (Adjusting)...5412
    CONTROL PANEL (SJC)...5418
      Description...5418
      Removal And Installation...5418
    CONTROL HANDLE / LEVER...5420
      Description...5420
      Lever Removal And Installation...5420
      Boot Removal And Installation...5420
    CONTROL HANDLE / LEVER (SJC)...5422
      Description...5422
      Joystick Testing...5422
      Joystick Removal And Installation...5424
      Joystick Mount Removal And Installation...5425
    WINDOW (REAR)...5426
      Removal...5426
      Installation (Split Molding)...5426
      Installation (Continuous Molding)...5427
    WINDOW (TOP)...5430
      Removal And Installation...5430
    WINDOW (SIDE)...5432
      Removal And Installation...5432
    WINDOW (CAB DOOR)...5434
      Removal (Standard Window)...5434
      Installation (Standard Window)...5435
      Removal And Installation (Special Applications Window)...5436
    CAB DOOR...5438
      Description...5438
      Removal And Installation...5438
      Aligning...5439
      Adjusting...5440
      Checking Operation...5440
    CAB DOOR (SPECIAL APPLICATIONS KIT DOOR)...5442
      Description...5442
      Removal And Installation...5442
      Aligning...5443
      Adjusting...5444
      Checking Operation...5444
  ELECTRICAL SYSTEM & ANALYSIS...5446
    ELECTRICAL SCHEMATICS...5450
    ELECTRICAL SYSTEM INFORMATION...5454
      Glossary Of Electrical Symbols...5454
      Standard Cab Harness Connectors...5457
      Deluxe Cab Harness Connectors...5458
      Mainframe Harness Connectors...5459
      Description...5460
      Troubleshooting...5461
      Fuse And Relay Location / Identification...5462
      Solenoid Testing...5462
    BATTERY...5464
      Removal And Installation...5464
      Servicing...5465
      Using A Booster Battery (Jump Starting)...5466
    ALTERNATOR...5468
      Belt Adjustment...5468
      Belt Replacement...5468
      Charging System Inspection...5469
      Alternator Voltage Testing...5470
      Low Voltage Testing...5471
      High Voltage Testing...5471
      Removal And Installation...5472
      Parts Identification...5473
    STARTER...5474
      Testing...5474
      Removal And Installation...5475
      Parts Identification...5476
    INSTRUMENT PANELS...5478
      Left Panel...5478
      Standard Key Panel...5481
      Keyless Start Panel...5481
      Deluxe Instrumentation Panel...5482
      Side Panel...5483
      Front Panel...5483
      Front Panel Removal And Installation...5484
      Removal And Installation (Left And Right)...5484
      Key Switch Removal And Installation...5485
      Alarm Removal And Installation...5486
    LIGHTS...5488
      Front Removal And Installation...5488
      Rear Removal And Installation...5488
      Cab Light Removal And Installation...5489
    BOBCAT CONTROLLER (GATEWAY)...5490
      Description...5490
      Connector Identification...5491
      Removal And Installation...5494
    BOBCAT CONTROLLER (ACS) (SJC)...5496
      Description...5496
      Connector And Wire Identification...5497
      Removal And Installation...5498
    BOBCAT CONTROLLER (DRIVE) (SJC)...5500
      Description...5500
      Connector Identification...5501
      Removal And Installation...5503
    BOBCAT CONTROLLER (AUXILIARY) (SJC)...5506
      Description...5506
      Connector Identification...5507
      Removal And Installation...5510
    DIAGNOSTIC SERVICE CODES...5512
      Viewing Service Codes...5512
      Service Codes List...5513
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...5518
      Description...5518
      Inspecting The BICS™ (Engine STOPPED - Key ON)...5518
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...5518
      Inspecting The Seat Bar Sensor (Engine RUNNING)...5518
      Inspecting The Traction Lock (Engine RUNNING)...5519
      Inspecting The Lift Arm Bypass Control...5519
      Inspecting Deactivation Of Lift And Tilt Functions (SJC)...5519
      Troubleshooting...5520
    SEAT BAR SENSOR...5522
      Description...5522
      Troubleshooting...5522
      Testing...5523
      Removal And Installation...5524
      Bobcat Interlock Control System (BICS™) Circuit Test...5527
    TRACTION LOCK...5530
      Description...5530
      Troubleshooting...5530
      Inspecting...5531
      Parking Brake Solenoid Removal And Installation...5532
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)...5534
      Identification Chart...5534
    SERVICE PC (LAPTOP COMPUTER)...5538
      Connecting Remote Start Tool...5538
      Connecting Remote Start Tool (Service Tool)...5538
    CALIBRATION...5540
      Description...5540
      Actuator Testing...5540
      Lift And Tilt Calibration (SJC)...5542
      Hydrostatic Pump Calibration (SJC)...5544
    STEERING DRIFT COMPENSATION...5550
      Description...5550
      Operation...5550
    FLYWHEEL RPM SENSOR...5552
      Description...5552
      Adjusting...5552
    CONTROL PANEL SETUP...5554
      Right Panel Setup (Deluxe Instrumentation Panel)...5554
      Attachment Control Information (Deluxe Instrumentation Panel)...5555
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...5556
      Password Description...5556
      Changing The Owner Password...5556
      Changing The User Passwords...5557
      Password Lockout Feature...5557
    PASSWORD SETUP (KEYLESS START PANEL)...5558
      Password Description...5558
      Changing The Owner Password...5558
      Password Lockout Feature...5558
    MAINTENANCE CLOCK...5560
      Description...5560
      Setup...5561
      Reset...5564
    BACK-UP ALARM SYSTEM...5566
      Description...5566
      Inspecting...5566
      Adjusting Switch Position...5567
      Troubleshooting...5568
      Troubleshooting (Joystick)...5569
      Alarm Removal And Installation...5570
      Switch Removal And Installation...5570
  ENGINE SERVICE...5572
    ENGINE INFORMATION...5574
      Description...5574
      Specifications...5575
      Torque Values...5580
      Troubleshooting...5581
      Engine Removal And Installation...5583
      Engine Mount Replacement...5593
      Compression - Checking...5594
    ENGINE SPEED CONTROL...5596
      Removal And Installation...5596
    ENGINE SPEED CONTROL (SJC)...5598
      Removal And Installation...5598
      Disassembly And Assembly...5600
    MUFFLER...5602
      Removal And Installation...5602
    AIR CLEANER...5604
      Housing Removal And Installation...5604
    ENGINE COOLING SYSTEM...5606
      Radiator Removal And Installation...5606
      Fan Removal And Installation...5607
      Water Pump Removal And Installation...5607
      Water Pump Disassembly And Assembly...5608
      Thermostat Housing Removal And Installation...5609
      Thermostat - Checking...5610
    LUBRICATION SYSTEM...5612
      Oil Pan Removal And Installation...5612
      Oil Pump Removal And Installation...5612
      Oil Pump Inspection...5613
      Engine Oil Pressure - Testing...5614
    FUEL SYSTEM...5616
      Fuel Shutoff Solenoid - Checking...5616
      Fuel Shutoff Solenoid Removal And Installation...5616
      Fuel Injection Pump - Checking...5617
      Fuel Injection Pump Removal And Installation...5618
      Governor Disassembly And Assembly...5621
      Fuel Camshaft Removal And Installation...5622
      Fuel Injection Pump - Timing...5622
      Fuel Injector Removal And Installation...5624
      Fuel Injector Nozzle Pressure - Checking...5626
      Nozzle Spray Condition...5627
      Valve Seat Tightness...5627
    CYLINDER HEAD...5628
      Glow Plugs - Testing...5628
      Glow Plugs Removal And Installation...5629
      Valve Clearance Adjustment...5630
      Valve Timing - Checking...5631
      Cylinder Head Removal And Installation...5632
      Cylinder Head Disassembly And Assembly...5635
      Cylinder Head - Servicing...5635
      Cylinder Head Top Clearance...5636
      Valve Guide - Checking...5636
      Reconditioning The Valve And Valve Seat...5637
      Valve Spring...5639
      Valve Tappets...5640
      Rocker Arm And Shaft - Checking...5640
      Push Rod Alignment - Checking...5641
    CRANKSHAFT AND PISTONS...5642
      Piston And Connecting Rod Removal And Installation...5642
      Piston And Connecting Rod - Servicing...5644
      Cylinder Bore - Checking...5646
      Connecting Rod Alignment...5646
      Crankshaft Gear Removal And Installation...5647
      Crankshaft And Bearings Removal And Installation...5647
      Crankshaft And Bearings - Servicing...5649
    CAMSHAFT AND TIMING GEARS...5654
      Timing Gearcase Cover Removal And Installation...5654
      Timing Gears Backlash - Checking...5656
      Idler Gear And Camshaft Removal And Installation...5657
      Camshaft - Servicing...5658
      Idler Gear And Shaft Servicing...5659
      Balancer Shaft Servicing...5660
    FLYWHEEL AND HOUSING...5662
      Flywheel Removal And Installation...5662
      Ring Gear Removal And Installation...5662
      Housing Removal And Installation...5663
  HEATER...5666
    HEATER SYSTEM...5668
      Description...5668
    REGULAR MAINTENANCE...5670
      Filters...5670
      Heater Coil...5670
    TROUBLESHOOTING...5672
      Blower Motor Does Not Operate...5672
      Blower Motor Operates Normally, But Air Flow Is Insufficient...5672
      Electrical System...5673
      Engine Coolant Bypassing The Heater Valve...5677
      Heater Valve Not Opening Or Closing...5678
    HEATER UNIT...5680
      Removal And Installation...5680
    HEATER COIL...5682
      Removal And Installation...5682
    BLOWER FAN...5684
      Removal And Installation...5684
      Disassembly And Assembly...5685
      Connector Identification...5687
    HEATER VALVE...5688
      Removal And Installation...5688
      Disassembly And Assembly...5689
  SPECIFICATIONS...5690
    (T110) LOADER SPECIFICATIONS...5692
      Machine Dimensions...5692
      Performance...5693
      Engine...5693
      Controls...5693
      Drive System...5694
      Hydraulic System...5694
      Electrical...5695
      Capacities...5695
      Tracks...5695
      Ground Pressure...5695
    TORQUE SPECIFICATION FOR BOLTS...5696
      Torque For General SAE Bolts...5696
      Torque For General Metric Bolts...5697
    HYDRAULIC CONNECTION SPECIFICATIONS...5698
      O-ring Face Seal Connection...5698
      Straight Thread O-ring Fitting...5699
      Tubelines And Hoses...5699
      Flare Fitting...5699
      Port Seal Fitting...5700
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...5702
      Specifications...5702
    CONVERSIONS...5704
      Decimal And Millimeter Equivalent Chart...5704
      U.S. To Metric Conversion Chart...5704
  ALPHABETICAL INDEX...5706
  SERVICE MANUAL REVISION...5708
    Revision No: T110 - 1...5708
    Revision No: T110 - 2...5710
    Revision No: T110 - 3...5712
    Revision No: T110 - 4...5714
    Revision No: T110 - 5...5716
    Revision No: T110 - 6...5718
6904979 (7-10) - T110 Compact Track Loader Service Manual...5720
  MAINTENANCE SAFETY...5722
  CONTENTS...5724
  FOREWORD...5726
    FOREWORD...5728
    SAFETY INSTRUCTIONS...5731
    FIRE PREVENTION...5733
      Maintenance...5733
      Operation...5733
      Electrical...5733
      Hydraulic System...5733
      Fueling...5733
      Starting...5733
      Spark Arrester Exhaust System...5733
      Welding And Grinding...5734
      Fire Extinguishers...5734
    SERIAL NUMBER LOCATIONS...5735
      Loader Serial Number...5735
      Engine Serial Number...5735
    DELIVERY REPORT...5735
    LOADER IDENTIFICATION...5736
  SAFETY & MAINTENANCE...5738
    LIFTING AND BLOCKING THE LOADER...5740
      Procedure...5740
    LIFT ARM SUPPORT DEVICE...5742
      Installing...5742
      Removing...5743
    OPERATOR CAB...5744
      Description...5744
      Raising...5744
      Lowering...5745
      Cab Door Sensor...5746
      Special Applications Kit...5746
      Special Applications Kit Inspection And Maintenance...5746
    TRANSPORTING THE LOADER ON A TRAILER...5748
      Loading And Unloading...5748
      Fastening...5748
    TOWING THE LOADER...5750
      Procedure...5750
    REMOTE START TOOL KIT-MEL1563...5752
      Remote Start Tool - MEL1563...5752
      Service Tool Harness Control - MEL1565...5753
      Service Tool Harness Communicator - MEL1566...5754
      Remote Start Procedure...5755
    REMOTE START TOOL (SERVICE TOOL) KIT - 6689779...5758
      Description...5758
      Remote Start Tool (Service Tool) - 6689778...5759
      Loader Service Tool Harness - 6689747...5760
      Computer Service Tool Harness - 6689746...5761
      Remote Start Procedure...5762
    SERVICE SCHEDULE...5766
      Chart...5766
    AIR CLEANER SERVICE...5768
      Replacing Filter Elements...5768
    ENGINE COOLING SYSTEM...5770
      Cleaning...5770
      Checking Level...5770
      Removing And Replacing Coolant...5771
    FUEL SYSTEM...5772
      Fuel Specifications...5772
      Biodiesel Blend Fuel...5772
      Filling The Fuel Tank...5773
      Fuel Filter...5774
      Removing Air From The Fuel System...5774
    ENGINE LUBRICATION SYSTEM...5776
      Checking And Adding Engine Oil...5776
      Engine Oil Chart...5776
      Removing And Replacing Oil And Filter...5776
    HYDRAULIC / HYDROSTATIC SYSTEM...5778
      Checking And Adding Fluid...5778
      Hydraulic / Hydrostatic Fluid Chart...5778
      Removing And Replacing Hydraulic Fluid...5779
      Removing And Replacing Hydraulic / Hydrostatic Filter...5780
      Removing And Replacing Case Drain Filters...5780
      Removing And Replacing Hydraulic Charge Filter...5781
      Breather Cap...5781
    BOB-TACH (HAND LEVER)...5782
      Inspection And Maintenance...5782
    BOB-TACH (POWER) (S/N AE0J11001 & ABOVE)...5784
      Inspection And Maintenance...5784
    LUBRICATING THE LOADER...5786
      Lubrication Locations...5786
    SPARK ARRESTER MUFFLER...5788
      Cleaning Procedure...5788
    PIVOT PINS...5790
      Inspection And Maintenance...5790
    LOADER STORAGE AND RETURN TO SERVICE...5792
      Storage...5792
      Return To Service...5792
    STOPPING THE ENGINE AND LEAVING THE LOADER...5794
      Procedure...5794
    EMERGENCY EXIT...5796
      Rear Window...5796
      Front Door...5796
  HYDRAULIC SYSTEM...5798
    HYDRAULIC / HYDROSTATIC SCHEMATICS...5802
    HYDRAULIC SYSTEM INFORMATION...5810
      Glossary Of Hydraulic / Hydrostatic Symbols...5810
      Troubleshooting...5814
    CYLINDER (LIFT)...5816
      Testing...5816
      Removal And Installation...5817
      Parts Identification...5818
      Disassembly And Assembly...5819
    CYLINDER (TILT)...5822
      Testing...5822
      Removal And Installation...5822
      Rod End Pivot Pin Bushing And Seal Removal And Installation...5823
      Base End Pivot Pin Removal And Installation...5824
      Parts Identification...5825
      Disassembly And Assembly...5826
    CYLINDER (BOB-TACH) (S/N AE0J11001 & ABOVE)...5830
      Testing...5830
      Removal And Installation...5831
      Parts Identification...5832
      Disassembly And Assembly...5833
    MAIN RELIEF VALVE...5836
      Description...5836
      Testing...5836
      Adjusting...5837
      Removal And Installation...5838
    HYDRAULIC CONTROL VALVE...5840
      Description...5840
      Removal And Installation...5840
      Identification Chart...5843
      BICS Load Check Valve Removal And Installation...5844
      Load Check Valve Removal And Installation (Tilt & Auxiliary)...5845
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)...5846
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...5847
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...5847
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)...5848
      Port Relief Valve Removal And Installation...5848
      Plug Removal And Installation...5849
      Rubber Boot Removal And Installation...5849
      End Cap / Spool Lock Block Removal And Installation...5850
      Lift Spool And Detent Removal And Installation...5850
      Tilt Spool Removal And Installation...5859
      Auxiliary Spool Removal And Installation...5862
      Solenoid Removal And Installation...5869
      Lock Valve Removal And Installation...5871
      Lift Arm Bypass Orifice Removal And Installation...5873
      Main Relief Valve Removal And Installation...5873
    HYDRAULIC CONTROL VALVE (SJC)...5874
      Description...5874
      Removal And Installation...5874
      Actuator Removal And Installation...5878
      Identification Chart...5881
      BICS Load Check Valve Removal And Installation...5882
      Load Check Valve Removal And Installation (Tilt & Auxiliary)...5883
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)...5884
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...5885
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...5885
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)...5886
      Port Relief Valve Removal And Installation...5886
      Plug Removal And Installation...5887
      End Cap Block Removal And Installation...5888
      Lift Spool And Detent Removal And Installation...5889
      Tilt Spool Removal And Installation...5893
      Auxiliary Spool Removal And Installation...5895
      Auxiliary Solenoid Removal And Installation...5897
      Solenoid Removal And Installation...5898
      Lock Valve Removal And Installation...5899
      Lift Arm Bypass Orifice Removal And Installation...5900
      Main Relief Valve Removal And Installation...5901
      Check Valve Removal And Installation...5901
    LIFT ARM BYPASS CONTROL VALVE...5904
      Description...5904
      Testing...5904
      Removal And Installation...5904
      Disassembly And Assembly...5906
    HYDRAULIC PUMP...5908
      Description...5908
      Pump Test at Quick Couplers...5908
      Direct Pump Test (Standard Section)...5909
      Direct Pump Test (Charge Section)...5911
      Removal And Installation...5913
      Parts Identification...5917
      Disassembly And Assembly...5918
      Hydraulic Pump Startup...5922
    HYDRAULIC PUMP (SJC)...5924
      Description...5924
      Pump Test At Quick Couplers...5924
      Direct Pump Test (Standard Section)...5925
      Removal And Installation...5926
      Hydraulic Pump Startup...5927
      Parts Identification...5928
      Disassembly And Assembly...5929
    HYDRAULIC / HYDROSTATIC FILTERS...5934
      Description...5934
      Housing Removal And Installation...5934
      Charge Filter Housing Removal And Installation...5935
    HYDRAULIC FLUID RESERVOIR...5936
      Description...5936
      Removal And Installation...5936
      Hydraulic Fluid Screen...5938
    OIL COOLER...5940
      Description...5940
      Removal And Installation...5940
    BUCKET POSITION VALVE...5942
      Description...5942
      Solenoid Removal And Installation...5942
      Solenoid Testing...5943
      Removal And Installation...5943
      Disassembly And Assembly...5946
    AUXILIARY HYDRAULIC INTERLOCK VALVE...5948
      Description...5948
      Removal And Installation...5948
      Disassembly And Assembly...5949
    BOB-TACH (POWER) BLOCK (S/N AE0J11001 & ABOVE)...5950
      Description...5950
      Removal And Installation...5950
      Disassembly And Assembly...5952
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK...5956
      Description...5956
      Removal And Installation...5956
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK (SJC)...5958
      Description...5958
      Removal And Installation...5958
      Disassembly And Assembly...5958
  HYDROSTATIC SYSTEM...5960
    HYDROSTATIC SYSTEM INFORMATION...5962
      Description...5962
      Troubleshooting...5963
    HYDROSTATIC DRIVE MOTOR...5964
      Description...5964
      Removing And Replacing Oil...5964
      Removal And Installation...5964
      Parts Identification...5966
      Disassembly And Assembly...5967
    CHARGE PRESSURE...5976
      Description...5976
      Testing...5976
      Sender Removal And Installation...5977
      Adjusting...5978
    HYDROSTATIC PUMP...5980
      Description...5980
      Replenishing / High Pressure Relief Valve Removal And Installation...5980
      Removal And Installation...5981
      Hydrostatic Pump Startup...5983
      Parts Identification...5984
      Disassembly...5985
      Assembly...5990
    HYDROSTATIC PUMP (SJC)...5996
      Description...5996
      High Pressure Relief And Bypass Valve...5997
      Removal And Installation...5998
      Hydrostatic Pump Startup...6000
      Hydraulic Controller Removal And Installation...6001
      Parts Identification...6003
      Disassembly And Assembly...6004
      Mechanical Neutral Adjustment...6019
      Hydraulic Controller Neutral Adjustment...6022
    DRIVE BELT...6026
      Description...6026
      Shield Removal And Installation...6026
      Adjusting...6026
      Belt Removal And Installation...6027
      Tensioner Pulley Removal And Installation...6027
      Tensioner Pulley Disassembly And Assembly...6027
    CASE DRAIN FILTER...6028
      Description...6028
      Disassembly And Assembly...6028
  DRIVE SYSTEM...6030
    BRAKE...6032
      Description...6032
      Right Motor Brake Test...6033
      Left Motor Brake Test...6034
      Block Removal And Installation...6035
      Block Disassembly And Assembly...6036
    TRACK UNDERCARRIAGE COMPONENTS...6038
      Description...6038
      Checking Tension...6039
      Adjusting Tension...6040
      Track Removal And Installation...6042
      Idler (Front) Removal And Installation...6045
      Track Tensioner Disassembly And Assembly...6046
      Idler (Rear) Removal And Installation...6047
      Roller Removal And Installation...6047
      Sprocket Removal And Installation...6048
    TRACK MAINTENANCE...6050
      Track Damage Identification...6050
  MAINFRAME...6062
    SEAT BAR...6066
      Description...6066
      Removal And Installation...6066
      Disassembly And Assembly...6068
      Compression Spring Disassembly And Assembly...6069
    OPERATOR CAB...6070
      Gas Cylinder Removal And Installation...6070
      Gas Cylinder Bracket Disassembly And Assembly...6072
      Removal And Installation...6073
    OPERATOR SEAT (SUSPENSION)...6076
      Removal And Installation...6076
      Slide Rail Removal And Installation...6077
      Seat Belt Removal and Installation...6077
      Lower Cushion Removal And Installation...6078
      Back Cushion Removal And Installation...6078
      Shock Removal And Installation...6079
      3-Point Seat Belt Removal And Installation...6079
    BOB-TACH (HAND LEVER)...6082
      Description...6082
      Removal And Installation...6082
      Lever And Wedge Disassembly And Assembly...6084
      Bob-Tach Stops...6085
      Pivot Pin Bushing And Seal Removal And Installation...6086
    BOB-TACH (POWER) (S/N AE0J11001 & ABOVE)...6088
      Description...6088
      Removal And Installation...6088
      Lever And Wedge Disassembly And Assembly...6090
      Bob-Tach Stops...6091
      Pivot Pin Bushing And Seal Removal And Installation...6092
    LIFT ARMS...6094
      Removal And Installation...6094
    REAR GRILL...6100
      Removal And Installation...6100
    REAR DOOR (TAILGATE)...6102
      Removal And Installation...6102
      Striker Removal And Installation...6103
      Striker Disassembly And Assembly...6103
      Striker (Adjusting)...6105
      Latch Removal And Installation...6106
    FUEL TANK...6108
      Removal And Installation...6108
      Fuel Level Sender Removal And Installation...6109
      Fuel Fill Screen Removal And Installation...6109
      Fuel Pickup Screen...6109
    CONTROL PEDALS AND LINKAGES...6110
      Description...6110
      Pedal Removal And Installation...6110
      Linkage Removal And Installation...6111
      Pedal (Adjusting)...6111
    CONTROL PANEL...6114
      Description...6114
      Removal And Installation...6115
      Shaft Removal And Installation...6118
      Shaft Disassembly And Assembly...6119
      Shock Removal And Installation...6119
      Linkage Removal And Installation...6120
      Pintle Arm Removal And Installation...6121
      Pintle Arm Disassembly And Assembly...6124
      Linkage Neutral (Adjusting)...6125
      Linkage Travel (Adjusting)...6128
    CONTROL PANEL (SJC)...6134
      Description...6134
      Removal And Installation...6134
    CONTROL HANDLE / LEVER...6136
      Description...6136
      Lever Removal And Installation...6136
      Boot Removal And Installation...6136
    CONTROL HANDLE / LEVER (SJC)...6138
      Description...6138
      Joystick Testing...6138
      Joystick Removal And Installation...6140
      Joystick Mount Removal And Installation...6141
    WINDOW (REAR)...6142
      Removal...6142
      Installation (Split Molding)...6142
      Installation (Continuous Molding)...6143
    WINDOW (TOP)...6146
      Removal And Installation...6146
    WINDOW (SIDE)...6148
      Removal And Installation...6148
    WINDOW (CAB DOOR)...6150
      Removal (Standard Window)...6150
      Installation (Standard Window)...6151
      Removal And Installation (Special Applications Window)...6152
    CAB DOOR...6154
      Description...6154
      Removal And Installation...6154
      Aligning...6155
      Adjusting...6156
      Checking Operation...6156
    CAB DOOR (SPECIAL APPLICATIONS KIT DOOR)...6158
      Description...6158
      Removal And Installation...6158
      Aligning...6159
      Adjusting...6160
      Checking Operation...6160
  ELECTRICAL SYSTEM & ANALYSIS...6162
    ELECTRICAL SCHEMATICS...6166
    ELECTRICAL SYSTEM INFORMATION...6170
      Glossary Of Electrical Symbols...6170
      Standard Cab Harness Connectors...6173
      Deluxe Cab Harness Connectors...6174
      Mainframe Harness Connectors...6175
      Description...6176
      Troubleshooting...6177
      Fuse And Relay Location / Identification...6178
      Solenoid Testing...6178
    BATTERY...6180
      Removal And Installation...6180
      Servicing...6181
      Using A Booster Battery (Jump Starting)...6182
    ALTERNATOR...6184
      Belt Adjustment...6184
      Belt Replacement...6184
      Charging System Inspection...6185
      Alternator Voltage Testing...6186
      Low Voltage Testing...6187
      High Voltage Testing...6187
      Removal And Installation...6188
      Parts Identification...6189
    STARTER...6190
      Testing...6190
      Removal And Installation...6191
      Parts Identification...6192
    INSTRUMENT PANELS...6194
      Left Panel...6194
      Standard Key Panel...6197
      Keyless Start Panel...6197
      Deluxe Instrumentation Panel...6198
      Side Panel...6199
      Front Panel...6199
      Front Panel Removal And Installation...6200
      Removal And Installation (Left And Right)...6200
      Key Switch Removal And Installation...6201
      Alarm Removal And Installation...6202
    LIGHTS...6204
      Front Removal And Installation...6204
      Rear Removal And Installation...6204
      Cab Light Removal And Installation...6205
    BOBCAT CONTROLLER (GATEWAY)...6206
      Description...6206
      Connector Identification...6207
      Removal And Installation...6210
    BOBCAT CONTROLLER (ACS) (SJC)...6212
      Description...6212
      Connector And Wire Identification...6213
      Removal And Installation...6214
    BOBCAT CONTROLLER (DRIVE) (SJC)...6216
      Description...6216
      Connector Identification...6217
      Removal And Installation...6219
    BOBCAT CONTROLLER (AUXILIARY) (SJC)...6222
      Description...6222
      Connector Identification...6223
      Removal And Installation...6226
    DIAGNOSTIC SERVICE CODES...6228
      Viewing Service Codes (Standard Key Panel And Keyless Start Panel)...6228
      Viewing Service Codes (Deluxe Instrumentation Panel)...6228
      Service Codes List...6229
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...6234
      Description...6234
      Inspecting The BICS (Engine STOPPED - Key ON)...6234
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...6234
      Inspecting The Seat Bar Sensor (Engine RUNNING)...6234
      Inspecting The Traction Lock (Engine RUNNING)...6235
      Inspecting The Lift Arm Bypass Control...6235
      Inspecting Deactivation Of Lift And Tilt Functions (SJC)...6235
      Troubleshooting...6236
    SEAT BAR SENSOR...6238
      Description...6238
      Troubleshooting...6238
      Testing...6239
      Removal And Installation...6240
      Bobcat Interlock Control System (BICS) Circuit Test...6241
    TRACTION LOCK...6242
      Description...6242
      Troubleshooting...6242
      Inspecting...6243
      Parking Brake Solenoid Removal And Installation...6244
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)...6246
      Identification Chart...6246
    SERVICE PC (LAPTOP COMPUTER)...6250
      Connecting Remote Start Tool...6250
      Connecting Remote Start Tool (Service Tool)...6250
    CALIBRATION...6252
      Description...6252
      Actuator Testing...6252
      Lift And Tilt Calibration (SJC)...6254
      Hydrostatic Pump Calibration (SJC)...6256
    STEERING DRIFT COMPENSATION...6262
      Description...6262
      Operation...6262
    FLYWHEEL RPM SENSOR...6264
      Description...6264
      Adjusting...6264
    CONTROL PANEL SETUP...6266
      Right Panel Setup (Deluxe Instrumentation Panel)...6266
      Attachment Control Information (Deluxe Instrumentation Panel)...6267
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...6268
      Password Description...6268
      Changing The Owner Password...6268
      Changing The User Passwords...6269
      Password Lockout Feature...6269
    PASSWORD SETUP (KEYLESS START PANEL)...6270
      Password Description...6270
      Changing The Owner Password...6270
      Password Lockout Feature...6270
    MAINTENANCE CLOCK...6272
      Description...6272
      Setup...6273
      Reset...6276
    BACK-UP ALARM SYSTEM...6278
      Description...6278
      Inspecting...6278
      Adjusting Switch Position...6279
      Troubleshooting...6280
      Troubleshooting (Joystick)...6281
      Alarm Removal And Installation...6282
      Switch Removal And Installation...6282
  ENGINE SERVICE...6284
    ENGINE INFORMATION...6286
      Description...6286
      Specifications...6287
      Torque Values...6292
      Troubleshooting...6293
      Engine Removal And Installation...6295
      Engine Mount Replacement...6305
      Compression - Checking...6306
    ENGINE SPEED CONTROL...6308
      Removal And Installation...6308
    ENGINE SPEED CONTROL (SJC)...6310
      Removal And Installation...6310
      Disassembly And Assembly...6312
    MUFFLER...6314
      Removal And Installation...6314
    AIR CLEANER...6316
      Housing Removal And Installation...6316
    ENGINE COOLING SYSTEM...6318
      Radiator Removal And Installation...6318
      Fan Removal And Installation...6319
      Water Pump Removal And Installation...6319
      Water Pump Disassembly And Assembly...6320
      Thermostat Housing Removal And Installation...6321
      Thermostat - Checking...6322
    LUBRICATION SYSTEM...6324
      Oil Pan Removal And Installation...6324
      Oil Pump Removal And Installation...6324
      Oil Pump Inspection...6325
      Engine Oil Pressure - Testing...6326
    FUEL SYSTEM...6328
      Fuel Shutoff Solenoid - Checking...6328
      Fuel Shutoff Solenoid Removal And Installation...6328
      Fuel Injection Pump - Checking...6329
      Fuel Injection Pump Removal And Installation...6330
      Governor Disassembly And Assembly...6333
      Fuel Camshaft Removal And Installation...6334
      Fuel Injection Pump - Timing...6334
      Fuel Injector Removal And Installation...6336
      Fuel Injector Nozzle Pressure - Checking...6338
      Nozzle Spray Condition...6339
      Valve Seat Tightness...6339
    CYLINDER HEAD...6340
      Glow Plugs - Testing...6340
      Glow Plugs Removal And Installation...6341
      Valve Clearance Adjustment...6342
      Valve Timing - Checking...6343
      Cylinder Head Removal And Installation...6344
      Cylinder Head Disassembly And Assembly...6347
      Cylinder Head - Servicing...6347
      Cylinder Head Top Clearance...6348
      Valve Guide - Checking...6348
      Reconditioning The Valve And Valve Seat...6349
      Valve Spring...6351
      Valve Tappets...6352
      Rocker Arm And Shaft - Checking...6352
      Push Rod Alignment - Checking...6353
    CRANKSHAFT AND PISTONS...6354
      Piston And Connecting Rod Removal And Installation...6354
      Piston And Connecting Rod - Servicing...6356
      Cylinder Bore - Checking...6358
      Connecting Rod Alignment...6358
      Crankshaft Gear Removal And Installation...6359
      Crankshaft And Bearings Removal And Installation...6359
      Crankshaft And Bearings - Servicing...6361
    CAMSHAFT AND TIMING GEARS...6366
      Timing Gearcase Cover Removal And Installation...6366
      Timing Gears Backlash - Checking...6368
      Idler Gear And Camshaft Removal And Installation...6369
      Camshaft - Servicing...6370
      Idler Gear And Shaft Servicing...6371
      Balancer Shaft Servicing...6372
    FLYWHEEL AND HOUSING...6374
      Flywheel Removal And Installation...6374
      Ring Gear Removal And Installation...6374
      Housing Removal And Installation...6375
  HEATER...6378
    HEATER SYSTEM...6380
      Description...6380
    REGULAR MAINTENANCE...6382
      Filters...6382
      Heater Coil...6382
    TROUBLESHOOTING...6384
      Blower Motor Does Not Operate...6384
      Blower Motor Operates Normally, But Air Flow Is Insufficient...6384
      Electrical System...6385
      Engine Coolant Bypassing The Heater Valve...6389
      Heater Valve Not Opening Or Closing...6390
    HEATER UNIT...6392
      Removal And Installation...6392
    HEATER COIL...6394
      Removal And Installation...6394
    BLOWER FAN...6396
      Removal And Installation...6396
      Disassembly And Assembly...6397
      Connector Identification...6399
    HEATER VALVE...6400
      Removal and Installation...6400
      Disassembly And Assembly...6401
  SPECIFICATIONS...6402
    (T110) LOADER SPECIFICATIONS...6404
      Machine Dimensions...6404
      Performance...6405
      Engine...6405
      Controls...6405
      Drive System...6406
      Hydraulic System...6406
      Electrical...6407
      Capacities...6407
      Tracks...6407
      Ground Pressure...6407
    TORQUE SPECIFICATION FOR BOLTS...6408
      Torque For General SAE Bolts...6408
      Torque For General Metric Bolts...6409
    HYDRAULIC CONNECTION SPECIFICATIONS...6410
      O-ring Face Seal Connection...6410
      Straight Thread O-ring Fitting...6411
      Tubelines And Hoses...6411
      Flare Fitting...6411
      Port Seal Fitting...6412
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...6414
      Specifications...6414
    CONVERSIONS...6416
      Decimal And Millimeter Equivalent Chart...6416
      U.S. To Metric Conversion Chart...6416
  ALPHABETICAL INDEX...6418
  SERVICE MANUAL REVISION...6420
    Revision No: T110 - 1...6420
    Revision No: T110 - 2...6422
    Revision No: T110 - 3...6424
6904979 (7-13) - T110 Compact Track Loader Service Manual...6426
  MAINTENANCE SAFETY...6428
  CONTENTS...6430
  FOREWORD...6432
    FOREWORD...6434
    SAFETY INSTRUCTIONS...6436
    FIRE PREVENTION...6438
      Maintenance...6438
      Operation...6438
      Electrical...6438
      Hydraulic System...6438
      Fueling...6438
      Starting...6438
      Spark Arrester Exhaust System...6438
      Welding And Grinding...6439
      Fire Extinguishers...6439
    SERIAL NUMBER LOCATIONS...6440
      Loader Serial Number...6440
      Engine Serial Number...6440
    DELIVERY REPORT...6441
    LOADER IDENTIFICATION...6442
  SAFETY AND MAINTENANCE...6444
    LIFTING AND BLOCKING THE LOADER...6446
      Procedure...6446
    LIFT ARM SUPPORT DEVICE...6448
      Installing...6448
      Removing...6449
    OPERATOR CAB...6450
      Description...6450
      Raising...6450
      Lowering...6451
      Cab Door Sensor...6452
      Special Applications Kit...6453
      Special Applications Kit Inspection And Maintenance...6453
    TRANSPORTING THE LOADER ON A TRAILER...6454
      Loading And Unloading...6454
      Fastening...6454
    TOWING THE LOADER...6456
      Procedure...6456
    REMOTE START TOOL KIT-MEL1563...6458
      Remote Start Tool - MEL1563...6458
      Service Tool Harness Control - MEL1565...6459
      Service Tool Harness Communicator - MEL1566...6460
      Remote Start Procedure...6461
    REMOTE START TOOL (SERVICE TOOL) KIT - 7217666...6464
      Description...6464
      Remote Start Tool (Service Tool) - 7022042...6465
      Loader Service Tool Harness - 6689747...6466
      Computer Service Tool Harness - 6689746...6467
      Remote Start Procedure...6468
    SERVICE SCHEDULE...6472
      Chart...6472
    AIR CLEANER SERVICE...6474
      Replacing Filter Elements...6474
    ENGINE COOLING SYSTEM...6476
      Cleaning...6476
      Checking Level...6476
      Removing And Replacing Coolant...6477
    FUEL SYSTEM...6478
      Fuel Specifications...6478
      Biodiesel Blend Fuel...6478
      Filling The Fuel Tank...6479
      Fuel Filter...6480
      Removing Air From The Fuel System...6480
    ENGINE LUBRICATION SYSTEM...6482
      Checking And Adding Engine Oil...6482
      Engine Oil Chart...6482
      Removing And Replacing Oil And Filter...6483
    HYDRAULIC / HYDROSTATIC SYSTEM...6484
      Checking And Adding Fluid...6484
      Hydraulic / Hydrostatic Fluid Chart...6484
      Removing And Replacing Hydraulic Fluid...6485
      Removing And Replacing Hydraulic / Hydrostatic Filter...6486
      Removing And Replacing Case Drain Filters...6486
      Removing And Replacing Hydraulic Charge Filter...6487
      Breather Cap...6487
    BOB-TACH (HAND LEVER)...6488
      Inspection And Maintenance...6488
    BOB-TACH (POWER)...6490
      Inspection And Maintenance...6490
    LUBRICATING THE LOADER...6492
      Lubrication Locations...6492
    SPARK ARRESTER MUFFLER...6494
      Cleaning Procedure...6494
    PIVOT PINS...6496
      Inspection And Maintenance...6496
    LOADER STORAGE AND RETURN TO SERVICE...6498
      Storage...6498
      Return To Service...6498
    STOPPING THE ENGINE AND LEAVING THE LOADER...6500
      Procedure...6500
    EMERGENCY EXIT...6502
      Rear Window...6502
      Front Door...6502
    SEAT BELT...6504
      Inspection And Maintenance...6504
  HYDRAULIC SYSTEM...6506
    HYDRAULIC / HYDROSTATIC SCHEMATICS...6510
    HYDRAULIC SYSTEM INFORMATION...6514
      Glossary Of Hydraulic / Hydrostatic Symbols...6514
      Troubleshooting...6518
    CYLINDER (LIFT)...6520
      Testing...6520
      Removal And Installation...6521
      Parts Identification...6522
      Disassembly And Assembly...6523
    CYLINDER (TILT)...6526
      Testing...6526
      Removal And Installation...6526
      Rod End Pivot Pin Bushing And Seal Removal And Installation...6527
      Base End Pivot Pin Removal And Installation...6528
      Parts Identification...6529
      Disassembly And Assembly...6530
    CYLINDER (BOB-TACH)...6534
      Testing...6534
      Removal And Installation...6535
      Parts Identification...6536
      Disassembly And Assembly...6537
    MAIN RELIEF VALVE...6540
      Description...6540
      Testing...6540
      Adjusting...6541
      Removal And Installation...6542
    HYDRAULIC CONTROL VALVE...6544
      Description...6544
      Removal And Installation...6544
      Identification Chart...6547
      BICS™ Load Check Valve Removal And Installation...6548
      Load Check Valve Removal And Installation (Tilt And Auxiliary)...6549
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)...6550
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...6551
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...6551
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)...6552
      Port Relief Valve Removal And Installation...6552
      Plug Removal And Installation...6553
      Rubber Boot Removal And Installation...6553
      End Cap / Spool Lock Block Removal And Installation...6554
      Lift Spool And Detent Removal And Installation...6554
      Tilt Spool Removal And Installation...6563
      Auxiliary Spool Removal And Installation...6566
      Solenoid Removal And Installation...6573
      Lock Valve Removal And Installation...6575
      Lift Arm Bypass Orifice Removal And Installation...6577
      Main Relief Valve Removal And Installation...6577
    HYDRAULIC CONTROL VALVE (SJC)...6578
      Description...6578
      Removal And Installation...6578
      Actuator Removal And Installation...6582
      Identification Chart...6585
      BICS™ Load Check Valve Removal And Installation...6586
      Blower Motor Does Not Operate...7857
      Blower Motor Operators Normally, But Air Flow Is Insufficient...7857
      Electrical System...7858
      Engine Coolant Bypassing The Heater Valve...7862
      Heater Valve Not Opening Or Closing...7863
    HEATER UNIT...7865
      Removal And Installation...7865
    HEATER COIL...7867
      Removal And Installation...7867
    HEATER FAN...7869
      Blower Removal And Installation...7869
      Disassembly And Assembly...7870
      Connector Identification...7872
    HEATER VALVE...7873
      Removal and Installation...7873
      Disassembly And Assembly...7874
  SPECIFICATIONS...7875
    (T140) LOADER SPECIFICATIONS...7877
      Dimensions...7877
      Performance...7878
      Controls...7878
      Engine...7878
      Hydraulic System...7879
      Electrical...7879
      Drive System...7880
      Capacities...7880
      Tracks...7880
    TORQUE SPECIFICATIONS FOR BOLTS...7881
      Torque For General SAE Bolts...7881
      Torque For General Metric Bolts...7882
    HYDRAULIC CONNECTION SPECIFICATIONS...7883
      O-ring Face Seal Connection...7883
      Straight Thread O-ring Fitting...7884
      Tubelines And Hoses...7884
      Flare Fitting...7885
      Port Seal Fitting...7886
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...7887
      Specifications...7887
    CONVERSIONS...7889
      Decimal And Millimeter Equivalents...7889
      U.S. To Metric Conversion Chart...7889
  SERVICE MANUAL REVISION...7891
    Revision No: T140 - 1...7891
    Revision No: T140 - 2...7893
    Revision No: T140 - 3...7895
    Revision No: T140 - 4...7897
    Revision No: T140 - 5...7899
6986968 (4-08) - T140 Compact Track Loader Operation & Maintenance Manual...7901
  OPERATOR SAFETY WARNINGS...7903
  CONTENTS...7905
  FOREWORD...7907
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...7909
    REGULAR MAINTENANCE ITEMS...7909
    SERIAL NUMBER LOCATIONS...7910
      Loader Serial Number...7910
      Engine Serial Number...7910
    DELIVERY REPORT...7910
    LOADER IDENTIFICATION...7911
    FEATURES, ACCESSORIES AND ATTACHMENTS...7912
      Standard Items...7912
      Options and Accessories...7912
      Buckets Available...7913
      Attachments...7913
      Special Applications Kit...7914
      Special Applications Kit Inspection And Maintenance...7914
  SAFETY & TRAINING RESOURCES...7915
    SAFETY INSTRUCTIONS...7917
      Before Operation...7917
      Safe Operation Is The Operator’s Responsibility...7918
      Safe Operation Needs A Qualified Operator...7918
      Avoid Silica Dust...7919
    FIRE PREVENTION...7919
      Maintenance...7919
      Operation...7919
      Electrical...7919
      Hydraulic System...7920
      Fueling...7920
      Starting...7920
      Spark Arrestor Exhaust System...7920
      Welding And Grinding...7920
      Fire Extinguishers...7920
    MACHINE SIGNS (DECALS)...7922
    PUBLICATIONS AND TRAINING RESOURCES...7924
  OPERATING INSTRUCTIONS...7925
    INSTRUMENT PANEL IDENTIFICATION...7929
      Left Panel...7929
      Right Panel (Key Switch)...7930
      Right Panel (Keyless)...7931
      Cab Light...7932
      Side And Front Panels...7933
    SEAT BAR RESTRAINT SYSTEM...7934
      Operation...7934
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...7935
      Operation...7935
    LIFT ARM BYPASS CONTROL...7936
      Operation...7936
    PARKING BRAKE...7936
      Operation...7936
    TRACTION LOCK OVERRIDE...7936
      Operation...7936
    BACK-UP ALARM SYSTEM...7937
      Operation...7937
    ENGINE SPEED CONTROL...7937
      Operation...7937
    DRIVING AND STEERING THE LOADER...7938
      Available Control Configurations...7938
      Operation (Standard and ACS)...7938
      Operation (SJC) In ‘H’ Control Pattern...7939
      Operation (SJC) In ‘ISO’ Control Pattern...7940
    STOPPING THE LOADER...7940
      Using The Control Levers Or Joysticks...7940
    SPEED MANAGEMENT...7941
      Operation...7941
    STEERING DRIFT COMPENSATION...7942
      Description...7942
      Operation...7942
    HYDRAULIC CONTROLS...7944
      Description...7944
      Standard Controls (Also ACS in Foot Pedal Mode)...7944
      Advanced Control System (ACS) in HAND Control Mode...7945
      Selectable Joystick Control (SJC) In ‘H’ Control Pattern...7945
      Selectable Joystick Control (SJC) In ‘ISO’ Control Pattern...7946
      Hydraulic Bucket Positioning...7946
      FRONT Auxiliary Hydraulics Operation (VARIABLE FLOW)...7947
      FRONT Auxiliary Hydraulics Operation (MAXIMUM FLOW)...7947
      FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)...7948
      REAR Auxiliary Hydraulics Operation...7948
      Quick Couplers...7949
      Relieve Hydraulic Pressure (Loader and Attachment)...7949
      Secondary Front Auxiliary Hydraulics...7950
    ATTACHMENT CONTROL DEVICE (ACD)...7951
      Description...7951
    DAILY INSPECTION...7952
      Daily Inspection and Maintenance...7953
    PRE-STARTING PROCEDURE...7954
      Entering The Loader...7954
      Operation & Maintenance Manual And Operator’s Handbook Locations...7954
      Seat Adjustment...7955
      Seat Belt Adjustment...7955
      Seat Bar...7956
    STARTING THE ENGINE...7957
      Key Switch...7957
      Keyless...7959
      Cold Temperature Starting...7960
      Warming The Hydraulic / Hydrostatic System...7961
    MONITORING THE DISPLAY PANELS...7962
      Left Panel...7962
      Right Panel (Key Switch)...7962
      Right Panel (Keyless)...7962
      Warning And Shutdown...7962
    STOPPING THE ENGINE AND LEAVING THE LOADER...7963
      Procedure...7963
      Emergency Exit...7964
    ATTACHMENTS...7965
      Choosing The Correct Bucket...7965
      Pallet Forks...7965
      Installing And Removing The Attachment (Hand Lever Bob-Tach)...7966
      Installing And Removing The Attachment (Power Bob-Tach)...7968
    TRACK CARRIAGE SYSTEM...7971
      Introduction...7971
      Compact Track Loader Operating And Maintenance Tips...7971
    OPERATING PROCEDURE...7973
      Inspect The Work Area...7973
      Operating With A Full Bucket...7973
      Operating With An Empty Bucket...7974
      Filling And Emptying The Bucket (Foot Pedals)...7975
      Leveling The Ground Using Float (Foot Pedals)...7976
      Digging And Filling A Hole (Foot Pedals)...7976
      Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)...7977
      Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)...7978
      Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)...7979
      Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)...7980
      Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)...7981
      Digging And Filling A Hole (SJC - ‘ISO’ Pattern)...7981
    TOWING THE LOADER...7982
      Procedure...7982
    LIFTING THE LOADER...7983
      Single Point Lift...7983
      Four Point Lift...7983
    TRANSPORTING THE LOADER On A TRAILER...7984
      Loading And Unloading...7984
      Fastening...7984
  PREVENTIVE MAINTENANCE...7985
    MAINTENANCE SAFETY...7989
    SERVICE SCHEDULE...7991
      Chart...7991
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...7992
      Inspecting The BICS Controller (Engine STOPPED - Key ON)...7992
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...7992
      Inspecting The Seat Bar Sensor (Engine RUNNING)...7992
      Inspecting The Traction Lock (Engine RUNNING)...7992
      Inspecting The Lift Arm Bypass Control...7992
      Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)...7992
    SEAT BAR RESTRAINT SYSTEM...7993
      Description...7993
      Inspecting...7993
      Maintaining...7993
    SEAT BELT...7994
      Inspection and Maintenance...7994
    LIFT ARM SUPPORT DEVICE...7995
      Installing...7995
      Removing...7996
    BACK-UP ALARM SYSTEM...7997
      Description...7997
      Inspecting...7997
      Adjusting Switch Position...7997
    OPERATOR CAB...7998
      Description...7998
      Raising...7998
      Lowering...7999
      Cab Door Sensor...8000
    REAR DOOR...8001
      Opening And Closing...8001
      Adjusting...8001
    REAR GRILL...8002
      Removing...8002
      Installing...8002
    HEATING SYSTEM...8003
      Cleaning And Maintenance...8003
      Filters...8003
      Heater Coil...8003
      Troubleshooting...8003
    AIR CLEANER SERVICE...8004
      Replacing Filter Elements...8004
    FUEL SYSTEM...8006
      Fuel Specifications...8006
      Biodiesel Blend Fuel...8006
      Filling The Fuel Tank...8007
      Fuel Filter...8008
      Removing Air From The Fuel System...8008
    ENGINE LUBRICATION SYSTEM...8009
      Checking And Adding Engine Oil...8009
      Engine Oil Chart...8009
      Removing And Replacing Oil And Filter...8009
    ENGINE COOLING SYSTEM...8010
      Cleaning...8010
      Checking Level...8011
      Removing And Replacing Coolant...8011
    ELECTRICAL SYSTEM...8012
      Description...8012
      Fuse And Relay Location / Identification...8012
      Battery Maintenance...8013
      Using A Booster Battery (Jump Starting)...8013
      Removing And Installing The Battery...8015
    HYDRAULIC / HYDROSTATIC SYSTEM...8016
      Checking And Adding Fluid...8016
      Hydraulic / Hydrostatic Fluid Chart...8016
      Removing And Replacing Hydraulic Fluid...8016
      Removing And Replacing Hydraulic / Hydrostatic Filter...8017
      Removing And Replacing Case Drain Filters...8018
      Removing And Replacing Hydraulic Charge Filter...8018
      Breather Cap...8019
    SPARK ARRESTOR MUFFLER...8020
      Cleaning Procedure...8020
    TRACK TENSION...8021
      Adjusting...8021
    TRACK SPROCKET MAINTENANCE...8023
      Tightening Procedure...8023
    HYDROSTATIC MOTOR CARRIER...8023
      Removing And Replacing Oil...8023
    TRACK ROLLER AND IDLER LUBRICATION...8023
      Procedure...8023
    ALTERNATOR BELT...8024
      Belt Adjustment...8024
      Belt Replacement...8024
    DRIVE BELT...8025
      Belt Adjustment...8025
      Belt Replacement...8025
    LUBRICATING THE LOADER...8026
      Lubrication Locations...8026
    PIVOT PINS...8028
      Inspection And Maintenance...8028
    BOB-TACH (HAND LEVER)...8029
      Inspection And Maintenance...8029
    BOB-TACH (POWER)...8030
      Inspection And Maintenance...8030
    LOADER STORAGE AND RETURN TO SERVICE...8031
      Storage...8031
      Return to Service...8031
  SYSTEM SETUP & ANALYSIS...8033
    BOBCAT INTERLOCK CONROL SYSTEM (BICS)...8035
      Troubleshooting Chart...8035
    DIAGNOSTIC SERVICE CODES...8036
      Viewing Service Codes (Key Switch)...8036
      Viewing Service Codes (Keyless)...8036
      Service Codes List...8037
    CONTROL PANEL SETUP...8042
      Right Panel Setup (Keyless)...8042
      Attachment Control Information (Keyless)...8043
    PASSWORD SETUP...8044
      Password Description...8044
      Changing The Owner Password...8044
      Changing The User Passwords...8045
      Password Lockout Feature...8045
    MAINTENANCE CLOCK...8046
      Description...8046
      Setup...8046
      Reset...8046
  MACHINE SIGN TRANSLATIONS...8047
    SERVICE SCHEDULE (6734534)...8049
    WARNING (6728540)...8052
    WARNING (7131520)...8053
    WARNING (6737248)...8054
    WARNING (7131521)...8055
    WARNING (6718397)...8057
    WARNING (6718396)...8057
    DANGER (6718393)...8057
    DANGER (6718392)...8057
    WARNING (6718391)...8058
    DANGER (6717343)...8058
    WARNING (6577754)...8058
    IMPORTANT (6560573)...8059
    WARNING (6804114)...8059
    WARNING (6708941)...8059
    WARNING (6737189)...8059
    LIFT ARM SUPPORT DEVICE (6706558)...8060
    DANGER (6809511)...8060
    WARNING (6733996)...8061
    WARNING (6726423)...8061
    WARNING (6704786)...8061
  SPECIFICATIONS...8063
    (T140) LOADER SPECIFICATIONS...8065
      Dimensions...8065
      Performance...8066
      Controls...8066
      Drive System...8066
      Engine...8067
      Hydraulic System...8067
      Electrical...8068
      Capacities...8068
      Tracks...8068
  WARRANTY...8069
  ALPHABETICAL INDEX...8073
6986997 (3-10) - T140 Compact Track Loader Operation & Maintenance Manual...8075
  OPERATOR SAFETY WARNINGS...8077
  CONTENTS...8079
  FOREWORD...8081
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...8083
    REGULAR MAINTENANCE ITEMS...8083
    SERIAL NUMBER LOCATIONS...8084
      Loader Serial Number...8084
      Engine Serial Number...8084
    DELIVERY REPORT...8084
    LOADER IDENTIFICATION...8085
    FEATURES, ACCESSORIES AND ATTACHMENTS...8086
      Standard Items...8086
      Options And Accessories...8086
      Buckets Available...8087
      Attachments...8087
      Special Applications Kit...8088
      Special Applications Kit Inspection And Maintenance...8088
  SAFETY & TRAINING RESOURCES...8089
    SAFETY INSTRUCTIONS...8091
      Before Operation...8091
      Safe Operation Is The Operator’s Responsibility...8092
      Safe Operation Needs A Qualified Operator...8092
      Avoid Silica Dust...8093
    FIRE PREVENTION...8093
      Maintenance...8093
      Operation...8093
      Electrical...8093
      Hydraulic System...8094
      Fueling...8094
      Starting...8094
      Spark Arrestor Exhaust System...8094
      Welding And Grinding...8094
      Fire Extinguishers...8094
    MACHINE SIGNS (DECALS)...8096
    PUBLICATIONS AND TRAINING RESOURCES...8098
  OPERATING INSTRUCTIONS...8099
    INSTRUMENT PANEL IDENTIFICATION...8103
      Cab Light...8103
      Left Panel...8104
      Display Screen...8106
      Standard Key Panel...8107
      Keyless Start Panel...8107
      Deluxe Instrumentation Panel...8108
      Side Panel...8109
      Front Panel...8109
    CONTROL IDENTIFICATION...8110
      Standard Controls...8110
      Advanced Control System (ACS)...8111
      Selectable Joystick Controls (SJC)...8112
    SEAT BAR RESTRAINT SYSTEM...8113
      Operation...8113
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...8114
      Operation...8114
    LIFT ARM BYPASS CONTROL...8115
      Operation...8115
    PARKING BRAKE...8115
      Operation...8115
    TRACTION LOCK OVERRIDE...8115
      Operation...8115
    EMERGENCY EXIT...8116
      Rear Window...8116
      Front Door...8116
    BACK-UP ALARM SYSTEM...8117
      Description...8117
      Operation...8117
    ENGINE SPEED CONTROL...8118
      Operation...8118
    DRIVING AND STEERING THE LOADER...8119
      Available Control Configurations...8119
      Operation (Standard And ACS)...8119
      Operation (SJC) In ‘ISO’ Control Pattern...8120
      Operation (SJC) In ‘H’ Control Pattern...8121
    STOPPING THE LOADER...8121
      Using The Control Levers Or Joysticks...8121
    SPEED MANAGEMENT...8122
      Operation...8122
      Changing The Factory Default Setting...8123
    DRIVE RESPONSE...8124
      Description...8124
      Operation...8124
    STEERING DRIFT COMPENSATION...8126
      Description...8126
      Operation...8126
    HYDRAULIC CONTROLS...8128
      Description...8128
      Standard Controls (Also ACS In FOOT Pedal Mode)...8128
      Advanced Control System (ACS) In HAND Control Mode...8129
      Selectable Joystick Controls (SJC) In ‘ISO’ Control Pattern...8129
      Selectable Joystick Controls (SJC) In ‘H’ Control Pattern...8130
      Hydraulic Bucket Positioning...8130
      FRONT Auxiliary Hydraulics Operation...8131
      FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)...8132
      REAR Auxiliary Hydraulics Operation...8132
      Secondary Front Auxiliary Hydraulics Operation...8133
      Quick Couplers...8134
      Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)...8135
    ATTACHMENT CONTROL DEVICE (ACD)...8136
      Description...8136
    DAILY INSPECTION...8137
      Daily Inspection And Maintenance...8138
    PRE-STARTING PROCEDURE...8139
      Entering The Loader...8139
      Operation & Maintenance Manual And Operator’s Handbook Locations...8139
      Seat Adjustment...8140
      Seat Belt Adjustment...8141
      Seat Bar...8141
    STARTING THE ENGINE...8142
      Standard Key Panel...8142
      Keyless Start Panel...8144
      Deluxe Instrumentation Panel...8146
      Cold Temperature Starting...8148
      Warming The Hydraulic / Hydrostatic System...8148
    MONITORING THE DISPLAY PANELS...8149
      Left Panel...8149
      Warning And Shutdown...8149
    STOPPING THE ENGINE AND LEAVING THE LOADER...8150
      Procedure...8150
    ATTACHMENTS...8151
      Choosing The Correct Bucket...8151
      Pallet Forks...8151
      Installing And Removing The Attachment (Hand Lever Bob-Tach)...8152
      Installing And Removing The Attachment (Power Bob-Tach)...8154
    TRACK UNDERCARRIAGE SYSTEM...8157
      Introduction...8157
      Compact Track Loader Operating And Maintenance Tips...8157
    OPERATING PROCEDURE...8159
      Inspect The Work Area...8159
      Basic Operating Instructions...8159
      Driving On Public Roads...8159
      Operating With A Full Bucket...8160
      Operating With An Empty Bucket...8160
      Filling And Emptying The Bucket (Foot Pedals)...8161
      Leveling The Ground Using Float (Foot Pedals)...8162
      Digging And Filling A Hole (Foot Pedals)...8162
      Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)...8163
      Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)...8164
      Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)...8165
      Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)...8166
      Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)...8167
      Digging And Filling A Hole (SJC - ‘ISO’ Pattern)...8167
    TOWING THE LOADER...8168
      Procedure...8168
    LIFTING THE LOADER...8169
      Single-Point Lift...8169
      Four-Point Lift...8169
    TRANSPORTING THE LOADER ON A TRAILER...8170
      Loading And Unloading...8170
      Fastening...8170
  PREVENTIVE MAINTENANCE...8171
    MAINTENANCE SAFETY...8175
    SERVICE SCHEDULE...8177
      Chart...8177
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...8178
      Inspecting The BICS (Engine STOPPED - Key ON)...8178
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...8178
      Inspecting The Seat Bar Sensor (Engine RUNNING)...8178
      Inspecting The Traction Lock (Engine RUNNING)...8178
      Inspecting The Lift Arm Bypass Control...8178
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)...8178
    SEAT BAR RESTRAINT SYSTEM...8179
      Description...8179
      Inspecting...8179
      Maintaining...8179
    SEAT BELT...8180
      Inspection And Maintenance...8180
    LIFT ARM SUPPORT DEVICE...8181
      Installing...8181
      Removing...8182
    BACK-UP ALARM SYSTEM...8183
      Description...8183
      Inspecting...8183
      Adjusting Switch Position...8183
    OPERATOR CAB...8184
      Description...8184
      Raising...8184
      Lowering...8185
      Cab Door Sensor...8186
    REAR DOOR (TAILGATE)...8187
      Opening And Closing...8187
      Adjusting...8187
    REAR GRILL...8187
      Removing...8187
      Installing...8187
    HEATING SYSTEM...8188
      Cleaning And Maintenance...8188
      Filters...8188
      Heater Coil...8188
      Troubleshooting...8188
    AIR CLEANER SERVICE...8189
      Replacing Filter Elements...8189
    FUEL SYSTEM...8191
      Fuel Specifications...8191
      Biodiesel Blend Fuel...8191
      Filling The Fuel Tank...8192
      Fuel Filter...8193
      Removing Air From The Fuel System...8193
    ENGINE LUBRICATION SYSTEM...8194
      Checking And Adding Engine Oil...8194
      Engine Oil Chart...8194
      Removing And Replacing Oil And Filter...8194
    ENGINE COOLING SYSTEM...8195
      Cleaning...8195
      Removing And Replacing Coolant...8196
      Checking Level...8196
    ELECTRICAL SYSTEM...8197
      Description...8197
      Fuse And Relay Location / Identification...8197
      Battery Maintenance...8198
      Using A Booster Battery (Jump Starting)...8199
      Removing And Installing Battery...8200
    HYDRAULIC / HYDROSTATIC SYSTEM...8201
      Checking And Adding Fluid...8201
      Hydraulic / Hydrostatic Fluid Chart...8201
      Removing And Replacing Hydraulic Fluid...8202
      Removing And Replacing Hydraulic / Hydrostatic Filter...8203
      Removing And Replacing Case Drain Filters...8203
      Removing And Replacing Hydraulic Charge Filter...8204
      Breather Cap...8204
    SPARK ARRESTER MUFFLER...8205
      Cleaning Procedure...8205
    TRACK TENSION...8206
      Checking...8206
      Adjusting...8206
    HYDROSTATIC DRIVE MOTOR...8208
      Removing And Replacing Oil...8208
    TRACK SPROCKET MAINTENANCE...8208
      Tightening Procedure...8208
    ALTERNATOR BELT...8209
      Belt Adjustment...8209
      Belt Replacement...8209
    DRIVE BELT...8210
      Belt Adjustment...8210
      Belt Replacement...8210
    LUBRICATING THE LOADER...8211
      Lubrication Locations...8211
    TRACK ROLLER AND IDLER LUBRICATION...8213
      Procedure...8213
    PIVOT PINS...8213
      Inspection And Maintenance...8213
    BOB-TACH (HAND LEVER)...8214
      Inspection And Maintenance...8214
    BOB-TACH (POWER)...8215
      Inspection And Maintenance...8215
    LOADER STORAGE AND RETURN TO SERVICE...8216
      Storage...8216
      Return To Service...8216
  SYSTEM SETUP & ANALYSIS...8217
    DIAGNOSTIC SERVICE CODES...8219
      Viewing Service Codes...8219
      Service Codes List...8220
    CONTROL PANEL SETUP...8225
      Right Panel Setup (Deluxe Instrumentation Panel)...8225
      Attachment Control Information (Deluxe Instrumentation Panel)...8226
    PASSWORD SETUP (KEYLESS START PANEL)...8227
      Password Description...8227
      Changing The Owner Password...8227
      Password Lockout Feature...8227
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...8228
      Password Description...8228
      Changing The Owner Password...8228
      Changing The User Passwords...8229
      Password Lockout Feature...8229
    MAINTENANCE CLOCK...8230
      Description...8230
      Setup...8230
      Reset...8230
  MACHINE SIGN TRANSLATIONS...8231
    SERVICE SCHEDULE (6734534)...8233
    WARNING (6728540)...8236
    WARNING (6718396)...8237
    DANGER (6809511)...8237
    WARNING (6718397)...8237
    WARNING (6737189)...8238
    WARNING (6725370)...8238
    LIFT ARM SUPPORT DEVICE (6706558)...8239
    WARNING (7131520)...8240
    WARNING (6737248)...8241
    WARNING (7131521)...8242
    WARNING (6726423)...8244
    WARNING (6704786)...8244
    DANGER (6718392)...8245
    DANGER (6718393)...8245
    WARNING (6577754)...8245
    WARNING (6718391)...8245
    DANGER (6717343)...8246
    WARNING (6804114)...8246
    IMPORTANT (6560573)...8246
  SPECIFICATIONS...8247
    (T140) LOADER SPECIFICATIONS...8249
      Machine Dimensions...8249
      Performance...8250
      Engine...8250
      Controls...8250
      Drive System...8251
      Hydraulic System...8251
      Electrical...8252
      Capacities...8252
      Tracks...8252
      Ground Pressure...8252
  WARRANTY...8253
    WARRANTY...8255
  ALPHABETICAL INDEX...8257
6986999 (3-08) - T180 Compact Track Loader Operation & Maintenance Manual...8261
  OPERATOR SAFETY WARNINGS...8263
  CONTENTS...8265
  FOREWORD...8267
    BOBCAT COMANY IS IS0 9001:2000 CERTIFIED...8269
    REGULAR MAINTENANCE ITEMS...8269
    SERIAL NUMBER LOCATIONS...8270
      Loader Serial Number...8270
      Engine Serial Number...8270
    DELIVERY REPORT...8270
    LOADER IDENTIFICATION...8271
    FEATURES, ACCESSORIES AND ATTACHMENTS...8272
      Standard Items...8272
      Options And Accessories...8272
      Buckets Available...8273
      Attachments...8273
      High-Flow Attachments...8273
      Special Applications Kit...8274
      Special Applications Kit Inspection And Maintenance...8274
  SAFETY & TRAINING RESOURCES...8275
    SAFETY INSTRUCTIONS...8277
      Before Operation...8277
      Safe Operation Is The Operator’s Responsibility...8278
      Safe Operation Needs A Qualified Operator...8278
      Avoid Silica Dust...8279
    FIRE PREVENTION...8279
      Maintenance...8279
      Operation...8279
      Electrical...8279
      Hydraulic System...8280
      Fueling...8280
      Starting...8280
      Spark Arrestor Exhaust System...8280
      Welding And Grinding...8280
      Fire Extinguishers...8280
    MACHINE SIGNS (DECALS)...8282
    PUBLICATIONS AND TRAINING RESOURCES...8284
  OPERATING INSTRUCTIONS...8285
    INSTRUMENT PANEL IDENTIFICATION...8289
      Cab Light...8289
      Left Panel...8290
      Display Screen...8292
      Standard Key Panel...8292
      Deluxe Instrumentation Panel...8293
      Side Panel...8294
      Front Panel...8294
    SEAT BAR RESTRAINT SYSTEM...8295
      Operation...8295
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...8296
      Operation...8296
    LIFT ARM BYPASS CONTROL...8297
      Operation...8297
    PARKING BRAKE...8297
      Operation...8297
    TRACTION LOCK OVERRIDE...8297
      Operation...8297
    BACK-UP ALARM SYSTEM...8298
      Operation...8298
    ENGINE SPEED CONTROL...8298
      Operation...8298
    DRIVING AND STEERING THE LOADER...8299
      Available Control Configurations...8299
      Operation (Standard And ACS)...8299
      Operation (SJC) in ‘ISO’ Control Pattern...8300
      Operation (SJC) in ‘H’ Control Pattern...8301
    STOPPING THE LOADER...8301
      Using The Control Levers Or Joysticks...8301
    SPEED MANAGEMENT...8302
      Operation...8302
    STEERING DRIFT COMPENSATION...8303
      Description...8303
      Operation...8303
    HYDRAULIC CONTROLS...8305
      Description...8305
      Standard Controls (Also ACS In FOOT Pedal Mode)...8305
      Advanced Control System (ACS) In HAND Control Mode...8306
      Selectable Joystick Controls (SJC) In ‘ISO’ Control Pattern...8306
      Selectable Joystick Controls (SJC) In ‘H’ Control Pattern...8307
      Hydraulic Bucket Positioning...8307
      FRONT Auxiliary Hydraulics Operation...8308
      FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)...8309
      REAR Auxiliary Hydraulics Operation...8309
      Secondary Front Auxiliary Hydraulics Operation...8310
      High-Flow Hydraulics Operation...8311
      Quick Couplers...8311
      Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)...8312
    ATTACHMENT CONTROL DEVICE (ACD)...8313
      Description...8313
    DAILY INSPECTION...8314
      Daily Inspection And Maintenance...8315
    PRE-STARTING PROCEDURE...8316
      Entering The Loader...8316
      Operation & Maintenance Manual And Operator’s Handbook Locations...8316
      Seat Adjustment...8317
      Seat Belt Adjustment...8318
      Seat Bar...8318
    STARTING THE ENGINE...8319
      Standard Key Panel...8319
      Deluxe Instrumentation Panel...8321
      Cold Temperature Starting...8323
      Warming The Hydraulic / Hydrostatic System...8323
    MONITORING THE DISPLAY PANELS...8324
      Left Panel...8324
      Warning And Shutdown...8324
    STOPPING THE ENGINE AND LEAVING THE LOADER...8325
      Procedure...8325
      Emergency Exit...8326
    ATTACHMENTS...8327
      Choosing The Correct Bucket...8327
      Pallet Forks...8327
      Installing And Removing The Attachment (Hand Lever Bob-Tach)...8328
      Installing And Removing The Attachment (Power Bob-Tach)...8330
    TRACK CARRIAGE SYSTEM...8333
      Introduction...8333
      Compact Track Loader Operating And Maintenance Tips...8333
    OPERATING PROCEDURE...8335
      Inspect The Work Area...8335
      Operating With A Full Bucket...8335
      Operating With An Empty Bucket...8336
      Filling And Emptying The Bucket (Foot Pedals)...8337
      Leveling The Ground Using Float (Foot Pedals)...8338
      Digging And Filling A Hole (Foot Pedals)...8338
      Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)...8339
      Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)...8340
      Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)...8341
      Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)...8342
      Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)...8343
      Digging And Filling A Hole (SJC - ‘ISO’ Pattern)...8343
    TOWING THE LOADER...8344
      Procedure...8344
    LIFTING THE LOADER...8345
      Single Point Lift...8345
      Four Point Lift...8345
    TRANSPORTING THE LOADER ON A TRAILER...8346
      Loading And Unloading...8346
      Fastening...8346
  PREVENTIVE MAINTENANCE...8347
    MAINTENANCE SAFETY...8351
    SERVICE SCHEDULE...8353
      Chart...8353
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...8354
      Inspecting The BICS (Engine STOPPED - Key ON)...8354
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...8354
      Inspecting The Seat Bar Sensor (Engine RUNNING)...8354
      Inspecting The Traction Lock (Engine RUNNING)...8354
      Inspecting The Lift Arm Bypass Control...8354
      Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)...8354
    SEAT BAR RESTRAINT SYSTEM...8355
      Description...8355
      Inspecting...8355
      Maintaining...8355
    SEAT BELT...8356
      Inspection And Maintenance...8356
    LIFT ARM SUPPORT DEVICE...8357
      Installing...8357
      Removing...8358
    BACK-UP ALARM SYSTEM...8359
      Description...8359
      Inspecting...8359
      Adjusting Switch Position...8359
    OPERATOR CAB...8360
      Description...8360
      Raising...8360
      Lowering...8361
      Cab Door Sensor...8362
    REAR DOOR...8363
      Opening And Closing...8363
      Adjusting...8363
    REAR GRILL...8363
      Removing...8363
      Installing...8363
    HEATING, VENTILATION AND AIR CONDITIONING (HVAC)...8364
      Cleaning And Maintenance...8364
      Filters...8364
      Evaporator / Heater Coil...8364
      Condenser...8364
      Air Conditioning Lubrication...8364
      Troubleshooting...8364
    AIR CLEANER SERVICE...8365
      Replacing Filter Elements...8365
    FUEL SYSTEM...8367
      Fuel Specifications...8367
      Biodiesel Blend Fuel...8367
      Filling The Fuel Tank...8368
      Fuel Filter...8369
      Removing Air From The Fuel System...8369
    ENGINE LUBRICATION SYSTEM...8370
      Checking And Adding Engine Oil...8370
      Engine Oil Chart...8370
      Removing And Replacing Oil And Filter...8370
    ENGINE COOLING SYSTEM...8371
      Cleaning...8371
      Removing And Replacing Coolant...8372
      Checking Level...8372
    ELECTRICAL SYSTEM...8373
      Description...8373
      Fuse And Relay Location / Identification...8373
      Battery Maintenance...8374
      Using A Booster Battery (Jump Starting)...8375
      Removing And Installing Battery...8376
    HYDRAULIC / HYDROSTATIC SYSTEM...8377
      Checking And Adding Fluid...8377
      Hydraulic / Hydrostatic Fluid Chart...8377
      Removing And Replacing Hydraulic Fluid...8378
      Removing And Replacing Hydraulic / Hydrostatic Filter...8378
      Removing And Replacing Case Drain Filters...8379
      Removing And Replacing Hydraulic Charge Filter...8380
      Breather Cap...8381
    SPARK ARRESTOR MUFFLER...8382
      Cleaning Procedure...8382
    TRACK TENSION...8383
      Checking...8383
      Adjusting...8383
    HYDROSTATIC MOTOR CARRIER...8385
      Removing And Replacing Oil...8385
    TRACK SPROCKET MAINTENANCE...8385
      Tightening Procedure...8385
    ALTERNATOR BELT...8385
      Belt Adjustment...8385
      Belt Replacement...8385
    AIR CONDITIONING BELT...8386
      Belt Adjustment...8386
      Belt Replacement...8386
    DRIVE BELT...8387
      Belt Adjustment...8387
      Belt Replacement...8387
    LUBRICATING THE LOADER...8388
      Lubrication Locations...8388
    TRACK ROLLER AND IDLER LUBRICATION...8389
      Procedure...8389
    PIVOT PINS...8389
      Inspection And Maintenance...8389
    BOB-TACH (hand lever)...8390
      Inspection And Maintenance...8390
    BOB-TACH (POWER)...8391
      Inspection And Maintenance...8391
    LOADER STORAGE AND RETURN TO SERVICE...8392
      Storage...8392
      Return To Service...8392
  SYSTEM SETUP & ANALYSIS...8393
    DIAGNOSTIC SERVICE CODES...8395
      Viewing Service Codes (Standard Key Panel)...8395
      Viewing Service Codes (Deluxe Instrumentation Panel)...8395
      Service Codes List...8396
    CONTROL PANEL SETUP...8400
      Right Panel Setup (Deluxe Instrumentation Panel)...8400
      Attachment Control Information (Deluxe Instrumentation Panel)...8401
    PASSWORD SETUP...8402
      Password Description...8402
      Changing The Owner Password...8402
      Changing The User Passwords...8403
      Password Lockout Feature...8403
    MAINTENANCE CLOCK...8404
      Description...8404
      Setup...8404
      Reset...8404
  MACHINE SIGN TRANSLATIONS...8405
    SERVICE SCHEDULE (6734534)...8407
    WARNING (6728540)...8410
    WARNING (6718396)...8411
    DANGER (6809511)...8411
    WARNING (6718397)...8411
    WARNING (6733996)...8412
    WARNING (6737189)...8412
    WARNING (6725370)...8412
    LIFT ARM SUPPORT DEVICE (6706558)...8413
    WARNING (7131520)...8414
    WARNING (6737248)...8415
    WARNING (7131521)...8416
    WARNING (6726423)...8418
    WARNING (6704786)...8418
    DANGER (6718392)...8419
    DANGER (6718393)...8419
    WARNING (6577754)...8419
    WARNING (6718391)...8419
    DANGER (6717343)...8420
    WARNING (6804114)...8420
    IMPORTANT (6560573)...8420
  SPECIFICATIONS...8421
    (T180) LOADER SPECIFICATIONS...8423
      Machine Dimensions...8423
      Performance...8424
      Engine...8424
      Controls...8424
      Drive System...8425
      Hydraulic System...8425
      Electrical...8426
      Capacities...8426
      Tracks...8426
      Ground Pressure...8426
  WARRANTY...8427
  ALPHABETICAL INDEX...8431
6987015 (12-09) - T180 Compact Track Loader Operation & Maintenance Manual...8433
  OPERATOR SAFETY WARNINGS...8435
  CONTENTS...8437
  FOREWORD...8439
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...8441
    REGULAR MAINTENANCE ITEMS...8441
    SERIAL NUMBER LOCATIONS...8442
      Loader Serial Number...8442
      Engine Serial Number...8442
    DELIVERY REPORT...8442
    LOADER IDENTIFICATION...8443
    FEATURES, ACCESSORIES AND ATTACHMENTS...8444
      Standard Items...8444
      Options And Accessories...8444
      Buckets Available...8445
      Attachments...8445
      High-Flow Attachments...8445
      Special Applications Kit...8446
      Special Applications Kit Inspection And Maintenance...8446
  SAFETY & TRAINING RESOURCES...8447
    SAFETY INSTRUCTIONS...8449
      Before Operation...8449
      Safe Operation Is The Operator’s Responsibility...8450
      Safe Operation Needs A Qualified Operator...8450
      Avoid Silica Dust...8451
    FIRE PREVENTION...8451
      Maintenance...8451
      Operation...8451
      Electrical...8451
      Hydraulic System...8452
      Fueling...8452
      Starting...8452
      Spark Arrestor Exhaust System...8452
      Welding And Grinding...8452
      Fire Extinguishers...8452
    MACHINE SIGNS (DECALS)...8454
    PUBLICATIONS AND TRAINING RESOURCES...8456
  OPERATING INSTRUCTIONS...8457
    INSTRUMENT PANEL IDENTIFICATION...8461
      Cab Light...8461
      Left Panel...8462
      Display Screen...8464
      Standard Key Panel...8465
      Keyless Start Panel...8465
      Deluxe Instrumentation Panel...8466
      Side Panel...8467
      Front Panel...8467
    CONTROL IDENTIFICATION...8468
      Standard Controls...8468
      Advanced Control System (ACS)...8469
      Selectable Joystick Controls (SJC)...8470
    SEAT BAR RESTRAINT SYSTEM...8471
      Operation...8471
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...8472
      Operation...8472
    LIFT ARM BYPASS CONTROL...8473
      Operation...8473
    PARKING BRAKE...8473
      Operation...8473
    TRACTION LOCK OVERRIDE...8473
      Operation...8473
    EMERGENCY EXIT...8474
      Rear Window...8474
      Front Door...8474
    BACK-UP ALARM SYSTEM...8475
      Description...8475
      Operation...8475
    ENGINE SPEED CONTROL...8476
      Operation...8476
    DRIVING AND STEERING THE LOADER...8477
      Available Control Configurations...8477
      Operation (Standard And ACS)...8477
      Operation (SJC) In ‘ISO’ Control Pattern...8478
      Operation (SJC) In ‘H’ Control Pattern...8479
    STOPPING THE LOADER...8479
      Using The Control Levers Or Joysticks...8479
    SPEED MANAGEMENT...8480
      Operation...8480
      Changing The Factory Default Setting...8481
    DRIVE RESPONSE...8482
      Description...8482
      Operation...8482
    STEERING DRIFT COMPENSATION...8484
      Description...8484
      Operation...8484
    HYDRAULIC CONTROLS...8486
      Description...8486
      Standard Controls (Also ACS In FOOT Pedal Mode)...8486
      Advanced Control System (ACS) In HAND Control Mode...8487
      Selectable Joystick Controls (SJC) In ‘ISO’ Control Pattern...8487
      Selectable Joystick Controls (SJC) In ‘H’ Control Pattern...8488
      Hydraulic Bucket Positioning...8488
      FRONT Auxiliary Hydraulics Operation...8489
      FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)...8490
      REAR Auxiliary Hydraulics Operation...8490
      Secondary Front Auxiliary Hydraulics Operation...8491
      High-Flow Hydraulics Operation...8492
      Quick Couplers...8492
      Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)...8493
    ATTACHMENT CONTROL DEVICE (ACD)...8494
      Description...8494
    DAILY INSPECTION...8495
      Daily Inspection And Maintenance...8496
    PRE-STARTING PROCEDURE...8497
      Entering The Loader...8497
      Operation & Maintenance Manual And Operator’s Handbook Locations...8497
      Seat Adjustment...8498
      Seat Belt Adjustment...8499
      Seat Bar...8499
    STARTING THE ENGINE...8500
      Standard Key Panel...8500
      Keyless Start Panel...8502
      Deluxe Instrumentation Panel...8504
      Cold Temperature Starting...8506
      Warming The Hydraulic / Hydrostatic System...8506
    MONITORING THE DISPLAY PANELS...8507
      Left Panel...8507
      Warning And Shutdown...8507
    STOPPING THE ENGINE AND LEAVING THE LOADER...8508
      Procedure...8508
    COUNTERWEIGHTS...8509
      Description...8509
      Effect On The Loader And Loader Operation...8509
      When To Consider Using Counterweights...8509
      When To Consider Removing Counterweights...8509
      Accessories That Affect Machine Weight...8509
    ATTACHMENTS...8510
      Choosing The Correct Bucket...8510
      Pallet Forks...8510
      Installing And Removing The Attachment (Hand Lever Bob-Tach)...8511
      Installing And Removing The Attachment (Power Bob-Tach)...8513
    TRACK UNDERCARRIAGE SYSTEM...8516
      Introduction...8516
      Compact Track Loader Operating And Maintenance Tips...8516
    OPERATING PROCEDURE...8518
      Inspect The Work Area...8518
      Basic Operating Instructions...8518
      Driving On Public Roads...8518
      Operating With A Full Bucket...8519
      Operating With An Empty Bucket...8519
      Filling And Emptying The Bucket (Foot Pedals)...8520
      Leveling The Ground Using Float (Foot Pedals)...8521
      Digging And Filling A Hole (Foot Pedals)...8521
      Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)...8522
      Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)...8523
      Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)...8524
      Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)...8525
      Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)...8526
      Digging And Filling A Hole (SJC - ‘ISO’ Pattern)...8526
    TOWING THE LOADER...8527
      Procedure...8527
    LIFTING THE LOADER...8528
      Single Point Lift...8528
      Four Point Lift...8528
    TRANSPORTING THE LOADER ON A TRAILER...8529
      Loading And Unloading...8529
      Fastening...8529
  PREVENTIVE MAINTENANCE...8531
    MAINTENANCE SAFETY...8535
    SERVICE SCHEDULE...8537
      Chart...8537
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...8538
      Inspecting The BICS (Engine STOPPED - Key ON)...8538
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...8538
      Inspecting The Seat Bar Sensor (Engine RUNNING)...8538
      Inspecting The Traction Lock (Engine RUNNING)...8538
      Inspecting The Lift Arm Bypass Control...8538
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)...8538
    SEAT BAR RESTRAINT SYSTEM...8539
      Description...8539
      Inspecting...8539
      Maintaining...8539
    SEAT BELT...8540
      Inspection And Maintenance...8540
    LIFT ARM SUPPORT DEVICE...8541
      Installing...8541
      Removing...8542
    BACK-UP ALARM SYSTEM...8543
      Description...8543
      Inspecting...8543
      Adjusting Switch Position...8543
    OPERATOR CAB...8544
      Description...8544
      Raising...8544
      Lowering...8545
      Cab Door Sensor...8546
    REAR DOOR (TAILGATE)...8547
      Opening And Closing...8547
      Adjusting...8547
    REAR GRILL...8547
      Removing...8547
      Installing...8547
    HEATING, VENTILATION AND AIR CONDITIONING (HVAC)...8548
      Cleaning And Maintenance...8548
      Filters...8548
      Evaporator / Heater Coil...8548
      Condenser...8548
      Air Conditioning Lubrication...8548
      Troubleshooting...8548
    AIR CLEANER SERVICE...8549
      Replacing Filter Elements...8549
    FUEL SYSTEM...8551
      Fuel Specifications...8551
      Biodiesel Blend Fuel...8551
      Filling The Fuel Tank...8552
      Fuel Filter...8553
      Removing Air From The Fuel System...8553
    ENGINE LUBRICATION SYSTEM...8554
      Checking And Adding Engine Oil...8554
      Engine Oil Chart...8554
      Removing And Replacing Oil And Filter...8554
    ENGINE COOLING SYSTEM...8555
      Cleaning...8555
      Removing And Replacing Coolant...8556
      Checking Level...8556
    ELECTRICAL SYSTEM...8557
      Description...8557
      Fuse And Relay Location / Identification...8557
      Battery Maintenance...8558
      Using A Booster Battery (Jump Starting)...8559
      Removing And Installing Battery...8560
    HYDRAULIC / HYDROSTATIC SYSTEM...8561
      Checking And Adding Fluid...8561
      Hydraulic / Hydrostatic Fluid Chart...8561
      Removing And Replacing Hydraulic Fluid...8562
      Removing And Replacing Hydraulic / Hydrostatic Filter...8562
      Removing And Replacing Case Drain Filters...8563
      Removing And Replacing Hydraulic Charge Filter...8564
      Breather Cap...8565
    SPARK ARRESTER MUFFLER...8566
      Cleaning Procedure...8566
    TRACK TENSION...8567
      Description...8567
      Checking (Earlier Model Solid-Mounted Undercarriage)...8568
      Adjusting (Earlier Model Solid-Mounted Undercarriage)...8568
      Checking (Later Model Solid-Mounted Undercarriage)...8570
      Adjusting (Later Model Solid-Mounted Undercarriage)...8571
      Checking (Roller Suspension Undercarriage)...8572
      Adjusting (Roller Suspension Undercarriage)...8573
    HYDROSTATIC DRIVE MOTOR...8574
      Removing And Replacing Oil...8574
    TRACK SPROCKET MAINTENANCE...8574
      Tightening Procedure...8574
    ALTERNATOR BELT...8575
      Belt Adjustment...8575
      Belt Replacement...8575
    AIR CONDITIONING BELT...8576
      Belt Adjustment...8576
      Belt Replacement...8576
    DRIVE BELT...8577
      Belt Adjustment...8577
      Belt Replacement...8579
    LUBRICATING THE LOADER...8580
      Lubrication Locations...8580
    TRACK ROLLER AND IDLER LUBRICATION...8581
      Procedure...8581
    PIVOT PINS...8581
      Inspection And Maintenance...8581
    BOB-TACH (HAND LEVER)...8582
      Inspection And Maintenance...8582
    BOB-TACH (POWER)...8583
      Inspection And Maintenance...8583
    LOADER STORAGE AND RETURN TO SERVICE...8584
      Storage...8584
      Return To Service...8584
  SYSTEM SETUP & ANALYSIS...8585
    DIAGNOSTIC SERVICE CODES...8587
      Viewing Service Codes (Standard Key Panel And Keyless Start Panel)...8587
      Viewing Service Codes (Deluxe Instrumentation Panel)...8587
      Service Codes List...8588
    CONTROL PANEL SETUP...8592
      Right Panel Setup (Deluxe Instrumentation Panel)...8592
      Attachment Control Information (Deluxe Instrumentation Panel)...8593
    PASSWORD SETUP (KEYLESS START PANEL)...8594
      Password Description...8594
      Changing The Owner Password...8594
      Password Lockout Feature...8594
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...8595
      Password Description...8595
      Changing The Owner Password...8595
      Changing The User Passwords...8596
      Password Lockout Feature...8596
    MAINTENANCE CLOCK...8597
      Description...8597
      Setup...8597
      Reset...8597
  MACHINE SIGN TRANSLATIONS...8599
    SERVICE SCHEDULE (6734534)...8601
    WARNING (6728540)...8604
    WARNING (6718396)...8605
    DANGER (6809511)...8605
    WARNING (6718397)...8605
    WARNING (6733996)...8606
    WARNING (6737189)...8606
    WARNING (6725370)...8606
    LIFT ARM SUPPORT DEVICE (6706558)...8607
    WARNING (7131520)...8608
    WARNING (6726423)...8609
    WARNING (7131521)...8610
    WARNING (7160879)...8611
    WARNING (6704786)...8612
    WARNING (6577754)...8612
    WARNING (6737248)...8612
    DANGER (6718392)...8613
    DANGER (6718393)...8613
    WARNING (6718391)...8613
    IMPORTANT (6709030)...8613
    DANGER (6717343)...8614
    WARNING (6804114)...8614
    IMPORTANT (6560573)...8614
  SPECIFICATIONS...8615
    (T180) LOADER SPECIFICATIONS...8617
      Machine Dimensions...8617
      Performance...8618
      Engine...8618
      Drive System...8618
      Controls...8619
      Hydraulic System...8619
      Electrical...8620
      Capacities...8620
      Tracks...8620
      Ground Pressure...8620
  WARRANTY...8621
    WARRANTY...8623
  ALPHABETICAL INDEX...8625
6987041 (1-11) - T140 Compact Track Loader Service Manual...8629
  MAINTENANCE SAFETY...8631
  ALPHABETICAL INDEX...8633
  CONTENTS...8635
    FOREWORD...8636
    SAFETY INSTRUCTIONS...8639
    FIRE PREVENTION...8641
      Maintenance...8641
      Operation...8641
      Electrical...8641
      Hydraulic System...8641
      Fueling...8641
      Starting...8641
      Spark Arrestor Exhaust System...8641
      Welding And Grinding...8642
      Fire Extinguishers...8642
    SERIAL NUMBER LOCATIONS...8643
      Loader Serial Number...8643
      Engine Serial Number...8643
    DELIVERY REPORT...8644
    LOADER IDENTIFICATION...8645
  SAFETY AND MAINTENANCE...8647
    LIFTING AND BLOCKING THE LOADER...8651
      Procedure...8651
    LIFT ARM SUPPORT DEVICE...8653
      Installing...8653
      Removing...8654
    OPERATOR CAB...8655
      Description...8655
      Raising...8656
      Lowering...8657
      Cab Door Sensor...8658
      Special Applications Kit...8658
      Special Applications Kit Inspection And Maintenance...8658
    TRANSPORTING THE LOADER ON A TRAILER...8659
      Loading And Unloading...8659
      Fastening...8659
    TOWING THE LOADER...8661
      Procedure...8661
    REMOTE START TOOL KIT-MEL1563...8663
      Remote Start Tool - MEL1563...8663
      Service Tool Harness Control - MEL1565...8664
      Service Tool Harness Communicator - MEL1566...8665
      Remote Start Procedure...8666
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031...8669
      Description...8669
      Remote Start Tool (Service Tool) - 7003030...8670
      Loader Service Tool Harness - 6689747...8671
      Computer Service Tool Harness - 6689746...8672
      Remote Start Procedure...8673
    SERVICE SCHEDULE...8677
      Chart...8677
    AIR CLEANER SERVICE...8679
      Replacing Filter Elements...8679
    ENGINE COOLING SYSTEM...8681
      Cleaning...8681
      Checking Level...8682
      Removing And Replacing The Coolant...8682
    FUEL SYSTEM...8683
      Fuel Specifications...8683
      Biodiesel Blend Fuel...8683
      Filling The Fuel Tank...8684
      Fuel Filter...8685
      Removing Air From The Fuel System...8685
    ENGINE LUBRICATION SYSTEM...8687
      Checking And Adding Engine Oil...8687
      Engine Oil Chart...8687
      Removing And Replacing Oil And Filter...8688
    HYDRAULIC / HYDROSTATIC SYSTEM...8689
      Checking And Adding Fluid...8689
      Hydraulic / Hydrostatic Fluid Chart...8689
      Removing And Replacing Hydraulic Fluid...8690
      Removing And Replacing Hydraulic / Hydrostatic Filter...8691
      Removing And Replacing Case Drain Filters...8691
      Removing And Replacing Hydraulic Charge Filter...8692
      Breather Cap...8692
    BOB-TACH (HAND LEVER)...8693
      Inspection And Maintenance...8693
    BOB-TACH (POWER)...8695
      Inspection And Maintenance...8695
    LUBRICATING THE LOADER...8697
      Lubrication Locations...8697
    SPARK ARRESTER MUFFLER...8699
      Cleaning Procedure...8699
    PIVOT PINS...8701
      Inspection And Maintenance...8701
    LOADER STORAGE AND RETURN TO SERVICE...8703
      Storage...8703
      Return To Service...8703
    STOPPING THE ENGINE AND LEAVING THE LOADER...8705
      Procedure...8705
    EMERGENCY EXIT...8707
      Rear Window...8707
      Front Door...8707
    SEAT BELT...8709
      Inspection And Maintenance...8709
  HYDRAULIC SYSTEM...8711
    HYDRAULIC / HYDROSTATIC SCHEMATICS...8715
    HYDRAULIC SYSTEM INFORMATION...8719
      Glossary Of Hydraulic / Hydrostatic Symbols...8719
      Troubleshooting...8723
    CYLINDER (LIFT)...8725
      Testing...8725
      Removal And Installation...8726
      Parts Identification...8727
      Disassembly And Assembly...8728
    CYLINDER (TILT)...8731
      Testing...8731
      Removal And Installation...8731
      Rod End Pivot Pin Bushing And Seal Removal And Installation...8733
      Base End Pivot Pin Removal And Installation...8733
      Parts Identification...8734
      Disassembly And Assembly...8735
    CYLINDER (BOB-TACH)...8739
      Testing...8739
      Removal And Installation...8740
      Parts Identification...8741
      Disassembly And Assembly...8742
    MAIN RELIEF VALVE...8745
      Description...8745
      Testing...8746
      Adjusting...8748
      Removal And Installation...8749
    HYDRAULIC CONTROL VALVE (STANDARD)...8751
      Description...8751
      Removal And Installation...8752
      Identification Chart...8756
      Lift Load Check Valve Removal And Installation...8757
      Load Check Valve Removal And Installation (Tilt And Auxiliary)...8758
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)...8759
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...8760
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...8760
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)...8761
      Port Relief Valve Removal And Installation...8762
      Plug Removal And Installation...8763
      Rubber Boot Removal And Installation...8764
      End Cap / Spool Lock Block Removal And Installation...8764
      Lift Spool And Detent Removal And Installation...8765
      Tilt Spool Removal And Installation...8775
      Auxiliary Spool Removal And Installation...8777
      Auxiliary Solenoid Removal And Installation (S/N A3L734999 & Below And A3L834999 & Below)...8779
      Auxiliary Solenoid Removal And Installation (S/N A3L735001 & Above And A3L835001 & Above)...8780
      Solenoid Removal And Installation...8781
      Lock Valve Removal And Installation...8782
      Lift Arm Bypass Orifice Removal And Installation...8784
      Main Relief Valve Removal And Installation...8784
      Check Valve Removal And Installation...8785
    HYDRAULIC CONTROL VALVE (ACS) OR (SJC)...8787
      Description...8787
      Removal And Installation...8788
      Actuator Removal And Installation (Out Of Loader)...8792
      Identification Chart...8795
      Lift Load Check Valve Removal And Installation...8796
      Load Check Valve Removal And Installation (Tilt And Auxiliary)...8797
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)...8798
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...8799
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...8799
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)...8800
      Port Relief Valve Removal And Installation...8800
      Plug Removal And Installation...8801
      End Cap Block Removal And Installation...8802
      Lift Spool And Detent Removal And Installation...8803
      Tilt Spool Removal And Installation...8808
      Auxiliary Spool Removal And Installation...8810
      Auxiliary Solenoid Removal And Installation (S/N A3L734999 & Below And A3L834999 & Below)...8812
      Auxiliary Solenoid Removal And Installation (S/N A3L735001 & Above And A3L835001 & Above)...8813
      Solenoid Removal And Installation...8814
      Lock Valve Removal And Installation...8815
      Lift Arm Bypass Orifice Removal And Installation...8817
      Main Relief Valve Removal And Installation...8817
      Check Valve Removal And Installation...8818
    LIFT ARM BYPASS CONTROL VALVE...8819
      Description...8819
      Testing...8819
      Removal And Installation...8819
      Disassembly And Assembly...8820
    HYDRAULIC PUMP (STANDARD)...8821
      Description...8821
      Pump Test At Quick Couplers...8821
      Direct Pump Test (Standard Section)...8822
      Direct Pump Test (Charge Section)...8823
      Removal And Installation...8827
      Hydraulic Pump Startup...8829
      Parts Identification...8830
      Disassembly And Assembly...8831
    HYDRAULIC PUMP (SJC)...8839
      Description...8839
      Pump Test At Quick Couplers...8839
      Direct Pump Test (Standard Section)...8840
      Direct Pump Test (Charge Section)...8842
      Removal And Installation...8844
      Hydraulic Pump Startup...8844
      Parts Identification...8845
      Disassembly And Assembly...8846
    HYDRAULIC / HYDROSTATIC FILTERS...8847
      Description...8847
      Housing Removal And Installation...8847
      Charge Filter Housing Removal And Installation...8849
    HYDRAULIC FLUID RESERVOIR...8851
      Description...8851
      Removal And Installation...8851
      Hydraulic Fluid Screen...8852
    OIL COOLER...8853
      Description...8853
      Removal And Installation...8853
    BUCKET POSITION VALVE...8855
      Description...8855
      Solenoid Removal And Installation...8855
      Solenoid Testing...8856
      Removal And Installation...8856
      Disassembly And Assembly...8858
    REAR AUXILIARY DIVERTER VALVE...8861
      Description...8861
      Solenoid Testing...8861
      Removal And Installation...8862
      Disassembly And Assembly...8864
    BOB-TACH (POWER) BLOCK...8871
      Description...8871
      Removal And Installation...8871
      Disassembly And Assembly...8873
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK...8877
      Description...8877
      Removal And Installation...8877
      Disassembly And Assembly...8877
  HYDROSTATIC SYSTEM...8879
    HYDROSTATIC SYSTEM INFORMATION...8881
      Description...8881
      Troubleshooting...8882
    HYDROSTATIC DRIVE MOTOR (A3L735013 & BELOW, A3L835001 & BELOW)...8883
      Description...8883
      Removing And Replacing Oil...8884
      Removal And Installation...8886
      Parts Identification...8888
      Disassembly And Assembly...8890
    HYDROSTATIC DRIVE MOTOR (A3L735014 & ABOVE, A3L835002 & ABOVE)...8901
      Description...8901
      Removing And Replacing Oil...8902
      Removal And Installation...8904
      Parts Identification...8906
      Disassembly And Assembly...8908
    CHARGE PRESSURE...8919
      Description...8919
      Testing...8919
      Sender Removal And Installation...8921
      Adjusting...8922
    HYDROSTATIC PUMP...8925
      Description...8925
      Replenishing / High Pressure Relief Valve Removal And Installation...8926
      Removal And Installation...8927
      Hydrostatic Pump Startup...8929
      Parts Identification (Left Half)...8930
      Parts Identification (Right Half)...8931
      Disassembly...8932
      Assembly...8938
    HYDROSTATIC PUMP (SJC)...8945
      Description...8945
      Hydraulic Controller Removal And Installation...8946
      Removal And Installation...8948
      Hydrostatic Pump Startup...8949
      Parts Identification...8950
      High Pressure Relief And Bypass Valve...8951
      Charge Relief Valve...8952
      Disassembly And Assembly...8953
      Mechanical Neutral Adjustment...8969
      Hydraulic Controller Neutral Adjustment...8972
    DRIVE BELT...8975
      Description...8975
      Shield Removal And Installation...8975
      Adjusting...8976
      Belt Removal And Installation...8978
      Tensioner Pulley Removal And Installation...8979
      Tensioner Pulley Parts Identification...8980
      Tensioner Pulley Disassembly...8981
      Tensioner Pulley Assembly...8982
    CASE DRAIN FILTER...8985
      Description...8985
      Disassembly And Assembly...8985
  DRIVE SYSTEM...8987
    BRAKE...8989
      Description...8989
      Right Motor Brake Test...8989
      Left Motor Brake Test...8990
      Block Removal And Installation...8991
      Block Disassembly And Assembly...8993
    TRACK UNDERCARRIAGE COMPONENTS...8995
      Description...8995
      Checking Tension...8996
      Adjusting Tension...8997
      Track Removal And Installation...8999
      Idler (Front) Removal And Installation...9002
      Track Tensioner Disassembly And Assembly (S/N A3L735017 & Below And A3L835001 & Below)...9004
      Track Tensioner Disassembly And Assembly (S/N A3L735018 & Above And A3L835002 & Above)...9005
      Idler (Rear) Removal And Installation...9006
      Roller Removal And Installation...9006
      Sprocket Removal And Installation...9007
      Track Housing Removal And Installation...9008
    TRACK MAINTENANCE...9011
      Track Damage Identification...9011
  MAINFRAME...9023
    SEAT BAR...9027
      Description...9027
      Removal And Installation...9027
      Disassembly And Assembly...9028
      Compression Spring Disassembly And Assembly...9029
    OPERATOR CAB...9031
      Gas Cylinder Removal And Installation...9031
      Gas Cylinder Bracket Disassembly And Assembly...9033
      Removal And Installation...9034
    OPERATOR SEAT (SUSPENSION)...9037
      Removal And Installation...9037
      Slide Rail Removal And Installation...9038
      Seat Belt Removal And Installation...9038
      Lower Cushion Removal And Installation...9038
      Back Cushion Removal And Installation...9040
      Shock Removal And Installation...9040
      3-Point Seat Belt Removal And Installation...9041
    BOB-TACH (HAND LEVER)...9043
      Description...9043
      Removal And Installation...9043
      Lever And Wedge Disassembly And Assembly...9046
      Bob-Tach Stops...9047
      Pivot Pin Bushing And Seal Removal And Installation...9048
    BOB-TACH (POWER)...9049
      Description...9049
      Removal And Installation...9049
      Lever And Wedge Disassembly And Assembly...9051
      Bob-Tach Stops...9052
      Pivot Pin Bushing And Seal Removal And Installation...9053
    LIFT ARMS...9055
      Removal And Installation...9055
    REAR GRILLE...9061
      Removal And Installation...9061
    REAR DOOR (TAILGATE)...9063
      Removal And Installation...9063
      Striker Removal And Installation...9064
      Striker Disassembly And Assembly...9064
      Striker (Adjusting)...9065
      Latch Removal And Installation...9066
    FUEL TANK...9067
      Removal And Installation...9067
      Fuel Level Sender Removal And Installation...9068
      Fuel Fill Screen Removal And Installation...9068
    CONTROL PEDALS AND LINKAGES...9069
      Description...9069
      Pedal Removal And Installation...9069
      Linkage Removal And Installation...9070
      Pedal (Adjusting)...9072
    CONTROL PEDALS (ACS)...9073
      Description...9073
      Foot Sensor Removal And Installation...9073
      Foot Pedal Removal And Installation...9074
      Foot Pedal Linkage Disassembly And Assembly...9075
    CONTROL PANEL...9077
      Description...9077
      Removal And Installation...9078
      Shock Removal And Installation...9081
      Shaft Removal And Installation...9081
      Shaft Disassembly And Assembly...9082
      Linkage Removal And Installation...9083
      Pintle Arm Disassembly And Assembly...9087
      Linkage Neutral (Adjusting)...9089
      Linkage Travel (Adjusting)...9093
    CONTROL PANEL (SJC)...9097
      Description...9097
      Removal And Installation...9097
    CONTROL HANDLE / LEVER...9099
      Description...9099
      Lever Removal And Installation...9099
      Boot Removal And Installation...9099
    CONTROL HANDLE / LEVER (ACS)...9101
      Description...9101
      Handle Sensor Removal And Installation...9101
      Handle Removal And Installation...9104
      Handle Disassembly And Assembly...9105
      Lever Removal And Installation...9105
      Boot Removal And Installation...9107
    CONTROL HANDLE / LEVER (SJC)...9109
      Description...9109
      Joystick Testing...9109
      Joystick Removal And Installation...9110
      Joystick Mount Removal And Installation...9111
    WINDOW (REAR)...9113
      Removal...9113
      Installation (Split Molding)...9113
      Installation (Continuous Molding)...9115
    WINDOW (TOP)...9117
      Removal And Installation...9117
    WINDOW (SIDE)...9119
      Removal And Installation...9119
    WINDOW (CAB DOOR)...9121
      Removal (Standard Window)...9121
      Installation (Standard Window)...9122
      Removal And Installation (Special Applications Window)...9124
    CAB DOOR...9125
      Description...9125
      Removal And Installation...9125
      Aligning...9126
      Adjusting...9127
      Checking Operation...9127
  ELECTRICAL SYSTEM & ANALYSIS...9129
    ELECTRICAL SCHEMATICS...9133
    ELECTRICAL SYSTEM INFORMATION...9140
      Glossary Of Electrical Symbols...9140
      Standard Cab Harness Connectors...9143
      Deluxe Cab Harness Connectors...9144
      Mainframe Harness Connectors...9145
      Description...9146
      Troubleshooting...9147
      Fuse And Relay Location / Identification...9148
      Solenoid Testing...9149
    BATTERY...9150
      Removal And Installation...9150
      Servicing...9151
      Using A Booster Battery (Jump Starting)...9152
    ALTERNATOR...9154
      Belt Adjustment...9154
      Belt Replacement...9154
      Charging System Inspection...9155
      Alternator Voltage Testing...9156
      Low Voltage Testing...9156
      High Voltage Testing...9157
      Removal And Installation...9158
      Parts Identification...9159
    STARTER...9160
      Testing...9160
      Removal And Installation...9161
      Parts Identification...9162
    INSTRUMENT PANELS...9164
      Left Panel...9164
      Standard Key Panel...9166
      Keyless Start Panel...9166
      Deluxe Instrumentation Panel...9167
      Side Panel...9168
      Front Panel...9168
      Front Panel Removal And Installation...9169
      Removal And Installation (Left And Right)...9169
      Key Switch Removal And Installation...9171
      Alarm Removal And Installation...9172
    LIGHTS...9174
      Front Removal And Installation...9174
      Rear Removal And Installation...9175
      Cab Light Removal And Installation...9175
    BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)...9176
      Description...9176
      Connector Identification...9177
      Removal And Installation...9183
    BOBCAT CONTROLLER (ACS)...9184
      Description...9184
      Connector And Wire Identification...9185
      Removal And Installation...9186
    BOBCAT CONTROLLER (SJC) (DRIVE)...9188
      Description...9188
      Connector Identification...9189
      Removal And Installation...9191
    SPEED SENSORS (SJC)...9192
      Description...9192
      Testing...9192
      Removal And Installation...9194
    DIAGNOSTIC SERVICE CODES...9198
      Viewing Service Codes...9198
      Service Codes List...9199
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...9204
      Description...9204
      Inspecting The BICS™ (Engine STOPPED - Key ON)...9205
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...9205
      Inspecting The Seat Bar Sensor (Engine RUNNING)...9205
      Inspecting The Traction Lock (Engine RUNNING)...9205
      Inspecting The Lift Arm Bypass Control...9205
      Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)...9205
      Troubleshooting...9206
    SEAT BAR SENSOR...9208
      Description...9208
      Troubleshooting...9208
      Testing...9209
      Removal And Installation...9210
      Bobcat Interlock Control System (BICS™) Circuit Test...9213
    TRACTION LOCK...9216
      Description...9216
      Troubleshooting...9216
      Inspecting...9217
      Parking Brake Solenoid Removal And Installation...9218
    CONTROL SYSTEM (ACS)...9220
      Description...9220
      Troubleshooting...9221
      Handle Sensor Connector Disassembly And Assembly...9222
      Switch Handle Removal...9223
      Switch Handle Installation...9225
      Actuator Connector Disassembly And Assembly...9228
      Handle Lock Solenoid Removal And Installation...9229
      Handle Lock Solenoid Disassembly And Assembly...9229
      Foot Sensor Disassembly And Assembly...9230
      Foot Lock Solenoid Removal And Installation...9231
    ELECTRICAL / HYDRAULIC CONTROLS...9232
      Identification Chart...9232
      Description...9233
      Identification Chart ACD Group 0...9234
      Identification Chart ACD Group 1...9235
      Identification Chart ACD Group 2...9236
      Identification Chart ACD Group 3...9237
    ELECTRICAL / HYDRAULIC CONTROLS (ACS)...9238
      Identification Chart...9238
      Description...9239
      Identification Chart ACD Group 0...9240
      Identification Chart ACD Group 1...9241
      Identification Chart ACD Group 2...9242
      Identification Chart ACD Group 3...9243
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)...9244
      Identification Chart...9244
      Description...9245
      Identification Chart ACD Group 0...9246
      Identification Chart ACD Group 1...9247
      Identification Chart ACD Group 2...9248
      Identification Chart ACD Group 3...9249
    SERVICE PC (LAPTOP COMPUTER)...9250
      Connecting Remote Start Tool...9250
      Connecting Remote Start Tool (Service Tool)...9250
    CALIBRATION...9252
      Description...9252
      Actuator Testing...9252
      Lift And Tilt Calibration (SJC)...9255
      Hydrostatic Pump Calibration (SJC)...9257
      Lift And Tilt Calibration (ACS)...9262
    STEERING DRIFT COMPENSATION...9264
      Description...9264
      Operation...9264
    FLYWHEEL RPM SENSOR...9266
      Description...9266
      Adjusting...9266
    CONTROL PANEL SETUP...9268
      Right Panel Setup (Deluxe Instrumentation Panel)...9268
      Attachment Control Information (Deluxe Instrumentation Panel)...9269
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...9270
      Password Description...9270
      Changing The Owner Password...9270
      Changing The User Passwords...9271
      Password Lockout Feature...9271
    PASSWORD SETUP (KEYLESS START PANEL)...9272
      Password Description...9272
      Changing The Owner Password...9272
      Password Lockout Feature...9272
    MAINTENANCE CLOCK...9274
      Description...9274
      Setup...9275
      Reset...9278
    BACK-UP ALARM SYSTEM...9280
      Description...9280
      Inspecting...9280
      Adjusting Switch Position...9281
      Troubleshooting (Standard And ACS)...9282
      Troubleshooting (Joystick)...9283
      Alarm Removal And Installation...9284
      Switch Removal And Installation...9284
  ENGINE SERVICE...9286
    ENGINE INFORMATION...9290
      Description...9290
      Specifications...9291
      Torque Values...9295
      Troubleshooting...9296
      Engine Removal And Installation...9298
      Engine Mount Replacement...9304
      Compression - Checking...9305
    ENGINE SPEED CONTROL...9306
      Removal And Installation...9306
    ENGINE SPEED CONTROL (SJC)...9308
      Removal And Installation...9308
      Disassembly And Assembly...9310
    MUFFLER...9312
      Removal And Installation...9312
    AIR CLEANER...9314
      Housing Removal And Installation...9314
      ...
      Hydraulic Pump Startup...9659
      Parts Identification...9660
      Disassembly And Assembly...9661
    HYDRAULIC PUMP (SJC)...9674
      Description...9674
      Pump Test At Quick Couplers...9674
      Direct Pump Test (Standard Section)...9675
      Direct Pump Test (Charge Section)...9677
      Removal And Installation...9679
      Hydraulic Pump Startup...9681
      Parts Identification...9682
      Disassembly And Assembly...9683
    HYDRAULIC PUMP (SJC) (HIGH FLOW)...9692
      Description...9692
      Pump Test at Quick Couplers...9692
      Direct Pump Test (Standard Section)...9693
      Direct Pump Test (Charge Section)...9695
      Direct Pump Test (High Flow Section)...9697
      Removal And Installation...9699
      Hydraulic Pump Startup...9701
      Parts Identification...9702
      Disassembly And Assembly...9703
      Hydraulic Pump Startup...9715
    HYDRAULIC / HYDROSTATIC FILTERS...9716
      Description...9716
      Housing Removal And Installation...9716
      Charge Filter Housing Removal And Installation...9718
    HYDRAULIC FLUID RESERVOIR...9720
      Description...9720
      Removal And Installation...9720
      Hydraulic Fluid Screen...9722
    OIL COOLER...9724
      Description...9724
      Removal And Installation...9724
    BUCKET POSITION VALVE...9726
      Description...9726
      Solenoid Removal And Installation...9726
      Solenoid Testing...9727
      Removal And Installation...9728
      Disassembly And Assembly...9729
    REAR AUXILIARY DIVERTER VALVE...9732
      Description...9732
      Solenoid Testing...9732
      Removal And Installation...9733
      Disassembly And Assembly...9736
    BOB-TACH (POWER) BLOCK...9742
      Description...9742
      Removal And Installation...9742
      Disassembly And Assembly...9744
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK...9748
      Description...9748
      Removal And Installation...9748
      Disassembly And Assembly...9748
    HIGH FLOW VALVE...9750
      Description...9750
      High Flow Relief Valve Testing...9750
      High Flow Relief Valve Adjustment...9751
      Solenoid Testing...9752
      Removal And Installation...9753
      Disassembly And Assembly...9754
  HYDROSTATIC SYSTEM...9758
    HYDROSTATIC SYSTEM INFORMATION...9760
      Description...9760
      Troubleshooting...9761
    HYDROSTATIC MOTOR...9762
      Description...9762
      Removing And Replacing Oil...9763
      Removal And Installation...9765
      Parts Identification...9767
      Disassembly And Assembly...9769
    CHARGE PRESSURE...9780
      Description...9780
      Testing...9780
      Sender Removal And Installation...9782
      Adjusting...9783
    HYDROSTATIC PUMP...9786
      Description...9786
      Replenishing / High Pressure Relief Valve Removal And Installation...9787
      Removal And Installation...9788
      Hydrostatic Pump Startup...9790
      Parts Identification (Left Half)...9791
      Parts Identification (Right Half)...9792
      Disassembly...9793
      Assembly...9799
    HYDROSTATIC PUMP (SJC)...9806
      Description...9806
      Hydraulic Controller Removal And Installation...9807
      Removal And Installation...9809
      Hydrostatic Pump Startup...9811
      Parts Identification...9812
      High Pressure Relief And Bypass Valve...9813
      Charge Relief Valve...9814
      Disassembly And Assembly...9815
      Mechanical Neutral Adjustment...9831
      Hydraulic Controller Neutral Adjustment...9834
    DRIVE BELT...9838
      Description...9838
      Shield Removal And Installation...9838
      Adjusting...9839
      Belt Removal And Installation...9840
      Tensioner Pulley Removal And Installation...9841
      Tensioner Pulley Parts Identification...9842
      Tensioner Pulley Disassembly...9843
      Tensioner Pulley Assembly...9844
    CASE DRAIN FILTER...9846
      Description...9846
      Disassembly And Assembly...9846
  DRIVE SYSTEM...9848
    BRAKE...9850
      Description...9850
      Right Motor Brake Test...9850
      Left Motor Brake Test...9851
      Block Removal And Installation...9852
      Block Disassembly And Assembly...9854
    TRACK CARRIAGE COMPONENTS...9856
      Description...9856
      Checking Tension...9857
      Adjusting Tension...9858
      Track Removal And Installation...9860
      Idler (Front) Removal And Installation...9863
      Idler (Rear) Removal And Installation...9865
      Roller Removal And Installation...9865
      Sprocket Removal And Installation...9866
      Track Housing Removal And Installation...9867
      Track Damage Identification...9869
  MAIN FRAME...9882
    SEAT BAR...9886
      Description...9886
      Removal And Installation...9886
      Disassembly And Assembly...9887
      Compression Spring Disassembly And Assembly...9889
    OPERATOR CAB...9890
      Gas Cylinder Removal And Installation...9890
      Gas Cylinder Bracket Disassembly And Assembly...9892
      Removal And Installation...9893
    OPERATOR SEAT (SUSPENSION)...9896
      Removal And Installation...9896
      Slide Rail Removal And Installation...9897
      Seat Belt Removal and Installation...9897
      Lower Cushion Removal And Installation...9898
      Back Cushion Removal And Installation...9899
      Shock Removal And Installation...9899
      3-Point Seat Belt Removal And Installation...9900
    BOB-TACH (HAND LEVER)...9902
      Description...9902
      Removal And Installation...9902
      Lever And Wedge Disassembly And Assembly...9903
      Pivot Pin Bushing And Seal Removal And Installation...9905
    BOB-TACH (POWER)...9906
      Description...9906
      Removal And Installation...9906
      Lever And Wedge Disassembly And Assembly...9908
      Pivot Pin Bushing And Seal Removal And Installation...9909
    LIFT ARMS...9910
      Removal And Installation...9910
    REAR GRILL...9914
      Removal And Installation...9914
    REAR DOOR...9916
      Removal And Installation...9916
      Striker Removal And Installation...9917
      Striker Disassembly And Assembly...9917
      Striker (Adjusting)...9917
      Latch Removal And Installation...9918
    FUEL TANK...9920
      Removal And Installation...9920
      Fuel Level Sender Removal And Installation...9921
      Fuel Fill Screen Removal And Installation...9921
    CONTROL PEDALS AND LINKAGES...9922
      Description...9922
      Pedal Removal And Installation...9922
      Linkage Removal And Installation...9923
      Pedal (Adjusting)...9925
    CONTROL PEDALS (ACS)...9926
      Description...9926
      Foot Sensor Removal And Installation...9926
      Foot Pedal Removal And Installation...9927
      Foot Pedal Linkage Disassembly And Assembly...9928
    CONTROL PANEL...9930
      Description...9930
      Removal And Installation...9931
      Shock Removal And Installation...9934
      Shaft Removal And Installation...9934
      Shaft Disassembly And Assembly...9935
      Linkage Removal And Installation...9936
      Pintle Arm Disassembly And Assembly...9940
      Linkage Neutral (Adjusting)...9942
      Linkage Travel (Adjusting)...9946
    CONTROL PANEL (SJC)...9950
      Description...9950
      Removal And Installation...9950
    CONTROL HANDLE / LEVER...9952
      Description...9952
      Lever Removal And Installation...9952
      Boot Removal And Installation...9953
    CONTROL HANDLE / LEVER (ACS)...9954
      Description...9954
      Handle Sensor Removal And Installation...9954
      Handle Removal And Installation...9957
      Handle Disassembly And Assembly...9958
      Lever Removal And Installation...9958
      Boot Removal And Installation...9960
    CONTROL HANDLE / LEVER (SJC)...9962
      Description...9962
      Joystick Testing...9962
      Joystick Removal And Installation...9963
      Joystick Mount Removal And Installation...9964
    ACCESS PANEL (INSIDE)...9966
      Removal And Installation (Left)...9966
      Removal And Installation (Right)...9966
    ACCESS PANEL (INSIDE) (SJC)...9968
      Removal And Installation (Left)...9968
      Removal And Installation (Right)...9969
    WINDOW (REAR)...9972
      Removal...9972
      Installation (Split Molding)...9972
      Installation (Continuous Molding)...9974
    WINDOW (TOP)...9976
      Removal And Installation...9976
    WINDOW (SIDE)...9978
      Removal And Installation...9978
    WINDOW (CAB DOOR)...9980
      Removal (Standard Window)...9980
      Installation (Standard Window)...9981
      Removal And Installation (Special Applications Window)...9983
    CAB DOOR...9984
      Description...9984
      Removal And Installation...9984
      Aligning...9985
      Adjusting...9986
      Checking Operation...9986
  ELECTRICAL SYSTEM & ANALYSIS...9988
    ELECTRICAL SCHEMATICS...9992
    ELECTRICAL SYSTEM INFORMATION...9998
      Glossary Of Electrical Symbols...9998
      Standard Cab Harness Connectors...10001
      Deluxe Cab Harness Connectors...10002
      Mainframe Harness Connectors...10003
      Description...10004
      Troubleshooting...10005
      Fuse And Relay Location / Identification...10006
      Solenoid Testing...10007
    BATTERY...10008
      Removal And Installation...10008
      Servicing...10009
      Using A Booster Battery (Jump Starting)...10010
    ALTERNATOR...10012
      Belt Adjustment...10012
      Belt Replacement...10012
      Charging System Inspection...10013
      Alternator Voltage Testing...10014
      Low Voltage Testing...10014
      High Voltage Testing...10015
      Removal And Installation...10016
      Parts Identification...10017
    STARTER...10018
      Testing...10018
      Removal And Installation...10019
      Parts Identification...10020
    INSTRUMENT PANELS...10022
      Left Panel...10022
      Standard Key Panel...10024
      Deluxe Instrumentation Panel...10025
      Side Panel...10026
      Front Panel...10026
      Front Panel Removal And Installation...10027
      Removal And Installation (Left And Right)...10028
      Key Switch Removal And Installation...10029
      Alarm Removal And Installation...10030
    LIGHTS...10032
      Front Removal And Installation...10032
      Rear Removal And Installation...10033
      Cab Light Removal And Installation...10033
    BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)...10034
      Description...10034
      Connector Identification...10035
      Removal and Installation...10041
    BOBCAT CONTROLLER (ACS)...10044
      Description...10044
      Connector And Wire Identification...10045
      Removal And Installation...10046
    BOBCAT CONTROLLER (SJC) (DRIVE)...10048
      Description...10048
      Connector Identification...10049
      Removal and Installation...10051
    SPEED SENSOR (SJC)...10052
      Description...10052
      Testing...10052
      Removal And Installation...10054
    DIAGNOSTIC SERVICE CODES...10058
      Viewing Service Codes (Standard Key Panel)...10058
      Viewing Service Codes (Deluxe Instrumentation Panel)...10058
      Service Codes List...10059
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...10064
      Description...10064
      Inspecting The BICS Controller (Engine STOPPED - Key ON)...10065
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...10065
      Inspecting The Seat Bar Sensor (Engine RUNNING)...10065
      Inspecting The Traction Lock (Engine RUNNING)...10065
      Inspecting The Lift Arm Bypass Control...10065
      Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)...10065
      Troubleshooting...10066
    SEAT BAR SENSOR...10068
      Description...10068
      Troubleshooting...10068
      Testing...10069
      Removal And Installation...10070
      Bobcat Interlock Control System (BICS) Circuit Test...10072
    TRACTION LOCK...10074
      Description...10074
      Troubleshooting...10075
      Inspecting...10076
    CONTROL SYSTEM (ACS)...10078
      Description...10078
      Troubleshooting...10079
      Handle Sensor Connector Disassembly And Assembly...10080
      Switch Handle Removal...10081
      Switch Handle Installation...10083
      Actuator Connector Disassembly And Assembly...10086
      Handle Lock Solenoid Removal And Installation...10087
      Handle Lock Solenoid Disassembly And Assembly...10087
      Foot Sensor Disassembly And Assembly...10088
      Foot Lock Solenoid Removal And Installation...10089
    ELECTRICAL / HYDRAULIC CONTROLS...10090
      Identification Chart...10090
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)...10092
      Identification Chart...10092
    SERVICE PC (LAPTOP COMPUTER)...10096
      Connecting Remote Start Tool...10096
      Connecting Remote Start Tool (Service Tool)...10096
    CALIBRATION...10098
      Description...10098
      Actuator Testing...10098
      Lift And Tilt Calibration (ACS)...10100
      Lift And Tilt Calibration (SJC)...10102
      Hydrostatic Pump Calibration (SJC)...10104
    STEERING DRIFT COMPENSATION...10110
      Description...10110
      Operation...10110
    FLYWHEEL RPM SENSOR...10112
      Description...10112
      Adjusting...10112
    CONTROL PANEL SETUP...10114
      Right Panel Setup (Deluxe Instrumentation Panel)...10114
      Attachment Control Information (Deluxe Instrumentation Panel)...10115
    PASSWORD SETUP...10116
      Password Description...10116
      Changing The Owner Password...10116
      Changing The User Passwords...10117
      Password Lockout Feature...10117
    MAINTENANCE CLOCK...10118
      Description...10118
      Setup...10119
      Reset...10122
    BACK-UP ALARM SYSTEM...10124
      Description...10124
      Inspecting...10124
      Adjusting Switch Position...10125
      Troubleshooting (Standard and ACS)...10126
      Troubleshooting (Joystick)...10127
      Alarm Removal And Installation...10128
      Switch Removal And Installation...10128
  ENGINE SERVICE...10130
    ENGINE INFORMATION...10134
      Description...10134
      Specifications...10135
      Torque Values...10139
      Troubleshooting...10139
      Engine Removal And Installation...10141
      Engine Mount Replacement...10148
      Compression - Checking...10149
    ENGINE SPEED CONTROL...10150
      Removal And Installation...10150
    ENGINE SPEED CONTROL (SJC)...10152
      Removal And Installation...10152
      Disassembly And Assembly...10154
    MUFFLER...10156
      Removal And Installation...10156
    AIR CLEANER...10158
      Housing Removal And Installation...10158
    ENGINE COOLING SYSTEM...10160
      Radiator Removal And Installation...10160
      Hydraulic Fan Description...10163
      Hydraulic Fan Disassembly And Assembly...10163
      Blower Housing Removal And Installation...10164
      Fan Removal And Installation...10166
      Hydraulic Fan Motor Removal And Installation...10166
      Water Pump Removal And Installation...10167
      Water Pump Disassembly And Assembly...10167
      Thermostat Housing Removal And Installation...10168
      Thermostat - Checking...10169
    LUBRICATION SYSTEM...10170
      Oil Pan Removal And Installation...10170
      Oil Pump Removal And Installation...10170
      Oil Pump Inspection...10171
      Engine Oil Pressure - Testing...10172
    FUEL SYSTEM...10174
      Fuel Shutoff Solenoid - Checking...10174
      Fuel Shutoff Solenoid Removal And Installation...10174
      Fuel Injection Pump - Checking...10175
      Fuel Injection Pump Removal And Installation...10176
      Governor Disassembly And Assembly...10180
      Fuel Camshaft Removal And Installation...10181
      Injection Pump - Timing...10182
      Fuel Injector Removal And Installation...10184
      Fuel Injector Nozzle Pressure - Checking...10185
      Nozzle Spray Condition...10186
      Valve Seat Tightness...10186
    CYLINDER HEAD...10188
      Glow Plugs - Testing...10188
      Glow Plugs Removal And Installation...10188
      Valve Clearance Adjustment...10189
      Valve Timing - Checking...10190
      Cylinder Head Removal And Installation...10191
      Cylinder Head Disassembly and Assembly...10194
      Cylinder Head - Servicing...10194
      Cylinder Head Top Clearance...10195
      Valve Guide - Checking...10195
      Reconditioning The Valve And Valve Seat...10196
      Valve Spring...10198
      Valve Tappets...10199
      Rocker Arm And Shaft Checking...10199
      Push Rod Alignment - Checking...10200
    CRANKSHAFT AND PISTONS...10202
      Piston And Connecting Rod Removal And Installation...10202
      Piston And Connecting Rod - Servicing...10203
      Cylinder Bore - Checking...10206
      Connecting Rod Alignment...10206
      Crankshaft Gear Removal And Installation...10207
      Crankshaft And Bearings Removal And Installation...10207
      Crankshaft And Bearings - Servicing...10209
    CAMSHAFT AND TIMING GEARS...10214
      Timing Gearcase Cover Removal And Installation...10214
      Timing Gears Backlash - Checking...10216
      Idler Gear And Camshaft Removal And Installation...10217
      Camshaft - Servicing...10218
      Idler Gear And Shaft Servicing...10219
    TURBOCHARGER...10220
      Description...10220
      Testing...10220
      Removal And Installation...10221
    FLYWHEEL AND HOUSING...10224
      Flywheel Removal And Installation...10224
      Ring Gear Removal And Installation...10224
      Housing Removal And Installation...10225
  HEATING, VENTILATION, AIR CONDITIONING...10228
    AIR CONDITIONING SYSTEM FLOW...10231
      Description...10231
      Chart...10232
      Components...10233
      Safety Equipment...10236
    REGULAR MAINTENANCE...10238
      Filters...10238
      Compressor Drive Belt Adjustment...10239
      Compressor Drive Belt Replacement...10239
      Condenser...10239
      Air Conditioning Lubrication...10239
      Air Conditioning Service Chart...10240
      Evaporator / Heater Coil...10241
    TROUBLESHOOTING...10242
      Blower Motor Does Not Operate...10242
      Blower Motor Operates Normally, But Air Flow Is Insufficient...10242
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...10242
      The Compressor Does Not Operate At All, Or Operates Improperly...10242
      Gauge Pressure Related Troubleshooting...10243
      Troubleshooting Tree...10245
      Temperature / Pressure Chart...10249
      Poor A/C Performance...10250
      HVAC Repair And Leaks...10251
      Electrical System...10252
      Engine Coolant Bypassing The Heater Valve...10259
      Heater Valve Not Opening Or Closing...10260
    SYSTEM CHARGING AND RECLAMATION...10262
      Refrigerant Identification...10262
      Reclamation And Charging With Recovery / Charging Unit...10263
      Charging With A Manifold Gauge Set...10265
    COMPRESSOR...10268
      Removal And Installation...10268
      Oil...10269
      Oil Check...10270
      Clutch Disassembly And Assembly...10272
    CONDENSER...10276
      Removal And Installation...10276
    RECEIVER / DRIER...10278
      Receiver / Drier Removal And Installation...10278
      Pressure Relief Valve Removal And Installation...10280
      Pressure Switch Removal And Installation...10281
      Schraeder Valve Removal And Installation...10281
    EVAPORATOR / HEATER UNIT...10282
      Removal And Installation...10282
    THERMOSTAT...10284
      Removal And Installation...10284
    EXPANSION VALVE...10286
      Removal And Installation...10286
    EVAPORATOR COIL...10288
      Removal And Installation...10288
    HEATER COIL...10290
      Removal And Installation With A/C...10290
      Removal And Installation Without A/C...10292
    BLOWER FAN...10294
      Removal And Installation...10294
      Disassembly And Assembly...10295
      Connector Identification...10297
    HEATER VALVE...10298
      Removal And Installation...10298
      Disassembly And Assembly...10299
  SPECIFICATIONS...10300
    T180 LOADER SPECIFICATIONS...10302
      Dimensions...10302
      Performance...10303
      Controls...10303
      Engine...10304
      Hydraulic System...10305
      Electrical...10305
      Drive System...10306
      Capacities...10306
      Tracks...10306
      Ground Pressure...10306
    TORQUE SPECIFICATIONS FOR BOLTS...10308
      Torque For General SAE Bolts...10308
      Torque For General Metric Bolts...10309
    HYDRAULIC CONNECTION SPECIFICATIONS...10310
      O-ring Face Seal Connection...10310
      Straight Thread O-ring Fitting...10311
      Tubelines And Hoses...10311
      Flare Fitting...10312
      Port Seal Fitting...10313
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...10314
      Specifications...10314
    CONVERSIONS...10316
      Decimal And Millimeter Equivalents...10316
      U.S. To Metric Conversion Chart...10316
  SERVICE MANUAL REVISION...10318
    Revision No: T180 - 1...10318
    Revision No: T180 - 2...10320
    Revision No: T180 - 3...10322
    Revision No: T180 - 4...10324
    Revision No: T180 - 5...10326
6987051 (11-10) - T180 Compact Track Loader Servicece Manual...10328
  MAINTENANCE SAFETY...10330
  ALPHABETICAL INDEX...10332
  CONTENTS...10334
    FOREWORD...10335
    SAFETY INSTRUCTIONS...10338
    FIRE PREVENTION...10340
      Maintenance...10340
      Operation...10340
      Electrical...10340
      Hydraulic System...10340
      Fueling...10340
      Starting...10340
      Spark Arrestor Exhaust System...10340
      Welding And Grinding...10341
      Fire Extinguishers...10341
    SERIAL NUMBER LOCATION...10342
      Loader Serial Number...10342
      Engine Serial Number...10342
    DELIVERY REPORT...10343
    LOADER IDENTIFICATION...10344
  SAFETY & MAINTENANCE...10346
    LIFTING AND BLOCKING THE LOADER...10350
      Procedure...10350
    LIFT ARM SUPPORT DEVICE...10352
      Installing...10352
      Removing...10353
    OPERATOR CAB...10354
      Description...10354
      Raising...10355
      Lowering...10356
      Cab Door Sensor...10357
      Special Applications Kit...10357
      Special Applications Kit Inspection And Maintenance...10357
    TRANSPORTING THE LOADER ON A TRAILER...10358
      Loading And Unloading...10358
      Fastening...10358
    TOWING THE LOADER...10360
      Procedure...10360
    REMOTE START TOOL KIT-MEL1563...10362
      Remote Start Tool - MEL1563...10362
      Service Tool Harness Control - MEL1565...10363
      Service Tool Harness Communicator - MEL1566...10364
      Remote Start Procedure...10365
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031...10368
      Description...10368
      Remote Start Tool (Service Tool) - 7003030...10369
      Loader Service Tool Harness - 6689747...10370
      Computer Service Tool Harness - 6689746...10371
      Remote Start Procedure...10372
    SERVICE SCHEDULE...10376
      Chart...10376
    AIR CLEANER SERVICE...10378
      Replacing Filter Elements...10378
    ENGINE COOLING SYSTEM...10380
      Cleaning...10380
      Checking Level...10381
      Removing And Replacing Coolant...10381
    FUEL SYSTEM...10382
      Fuel Specifications...10382
      Biodiesel Blend Fuel...10382
      Filling The Fuel Tank...10383
      Fuel Filter...10384
      Removing Air From The Fuel System...10384
    ENGINE LUBRICATION SYSTEM...10386
      Checking And Adding Engine Oil...10386
      Engine Oil Chart...10386
      Removing And Replacing Oil And Filter...10387
    HYDRAULIC / HYDROSTATIC SYSTEM...10388
      Checking And Adding Fluid...10388
      Hydraulic / Hydrostatic Fluid Chart...10388
      Removing And Replacing Hydraulic Fluid...10389
      Removing And Replacing Hydraulic / Hydrostatic Filter...10390
      Removing And Replacing Case Drain Filters...10391
      Removing And Replacing Hydraulic Charge Filter...10392
      Breather Cap...10393
    BOB-TACH (HAND LEVER)...10394
      Inspection And Maintenance...10394
    BOB-TACH (POWER)...10396
      Inspection And Maintenance...10396
    LUBRICATING THE LOADER...10398
      Lubrication Locations...10398
    SPARK ARRESTOR MUFFLER...10400
      Cleaning Procedure...10400
    PIVOT PINS...10402
      Inspection And Maintenance...10402
    LOADER STORAGE AND RETURN TO SERVICE...10404
      Storage...10404
      Return To Service...10404
    STOPPING THE ENGINE AND LEAVING THE LOADER...10406
      Procedure...10406
    EMERGENCY EXIT...10408
      Rear Window...10408
      Front Door...10408
    SEAT BELT...10410
      Inspection And Maintenance...10410
  HYDRAULIC SYSTEM...10412
    HYDRAULIC / HYDROSTATIC SCHEMATICS...10418
    HYDRAULIC SYSTEM INFORMATION...10426
      Glossary Of Hydraulic / Hydrostatic Symbols...10426
      Troubleshooting...10430
    CYLINDER (LIFT)...10432
      Testing...10432
      Removal And Installation...10433
      Parts Identification...10434
      Disassembly And Assembly...10435
    CYLINDER (TILT)...10438
      Testing...10438
      Removal And Installation...10439
      Rod End Pivot Pin Bushing And Seal Removal And Installation...10441
      Base End Pivot Pin Removal And Installation...10441
      Parts Identification...10442
      Disassembly And Assembly...10443
    CYLINDER (BOB-TACH)...10446
      Testing...10446
      Removal And Installation...10447
      Parts Identification...10448
      Disassembly And Assembly...10449
    MAIN RELIEF VALVE...10452
      Description...10452
      Testing...10452
      Adjusting...10454
      Removal And Installation...10455
    HYDRAULIC CONTROL VALVE (STANDARD)...10456
      Description...10456
      Removal And Installation...10457
      Identification Chart...10462
      Mount Bracket Removal And Installation...10463
      Lift Load Check Valve Removal And Installation...10463
      Load Check Valve Removal And Installation (Tilt And Auxiliary)...10464
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)...10465
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...10466
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...10466
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)...10467
      Port Relief Valve Removal And Installation...10467
      Plug Removal And Installation...10468
      Rubber Boot Removal And Installation...10469
      End Cap / Spool Lock Block Removal And Installation...10470
      Lift Spool And Detent Removal And Installation...10471
      Tilt Spool Removal And Installation...10481
      Auxiliary Spool Removal And Installation...10483
      Auxiliary Solenoid Removal And Installation (S/N A3LL34999 & Below)...10485
      Auxiliary Solenoid Removal And Installation (S/N A3LL35001 & Above)...10486
      Solenoid Removal And Installation...10487
      Lock Valve Removal And Installation...10488
      Lift Arm Bypass Orifice Removal And Installation...10490
      Main Relief Valve Removal And Installation...10490
      Check Valve Removal And Installation...10491
    HYDRAULIC CONTROL VALVE (ACS) OR (SJC)...10492
      Description...10492
      Removal And Installation...10493
      Actuator Removal And Installation (Out of Loader)...10497
      Identification Chart...10500
      Mount Bracket Removal And Installation...10501
      Lift Load Check Valve Removal And Installation...10501
      Load Check Valve Removal And Installation (Tilt And Auxiliary)...10502
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)...10503
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...10504
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...10504
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)...10505
      Port Relief Valve Removal And Installation...10505
      Plug Removal And Installation...10506
      End Cap Block Removal And Installation...10507
      Lift Spool And Detent Removal And Installation...10508
      Tilt Spool Removal And Installation...10513
      Auxiliary Spool Removal And Installation...10515
      Auxiliary Solenoid Removal And Installation (S/N A3LL34999 & Below)...10517
      Auxiliary Solenoid Removal And Installation (S/N A3LL35001 & Above)...10518
      Solenoid Removal And Installation...10519
      Lock Valve Removal And Installation...10520
      Lift Arm Bypass Orifice Removal And Installation...10522
      Main Relief Valve Removal And Installation...10522
      Check Valve Removal And Installation...10523
    LIFT ARM BYPASS CONTROL VALVE...10524
      Description...10524
      Testing...10524
      Removal And Installation...10524
      Disassembly And Assembly...10525
    HYDRAULIC PUMP (STANDARD)...10526
      Description...10526
      Pump Test At Quick Couplers...10526
      Direct Pump Test (Standard Section)...10527
      Direct Pump Test (Charge Section)...10529
      Removal And Installation...10531
      Hydraulic Pump Startup...10533
      Parts Identification...10534
      Disassembly And Assembly...10535
    HYDRAULIC PUMP (STANDARD) (HIGH FLOW)...10544
      Description...10544
      Pump Test At Quick Couplers...10544
      Direct Pump Test (Standard Section)...10545
      Direct Pump Test (Charge Section)...10547
      Direct Pump Test (High Flow Section)...10549
      Removal And Installation...10551
      Hydraulic Pump Startup...10553
      Parts Identification...10554
      Disassembly And Assembly...10555
    HYDRAULIC PUMP (SJC)...10568
      Description...10568
      Pump Test At Quick Couplers...10568
      Direct Pump Test (Standard Section)...10569
      Direct Pump Test (Charge Section)...10571
      Removal And Installation...10573
      Hydraulic Pump Startup...10575
      Parts Identification...10576
      Disassembly And Assembly...10577
    HYDRAULIC PUMP (SJC) (HIGH FLOW)...10586
      Description...10586
      Pump Test At Quick Couplers...10586
      Direct Pump Test (Standard Section)...10587
      Direct Pump Test (Charge Section)...10589
      Direct Pump Test (High Flow Section)...10591
      Removal And Installation...10593
      Hydraulic Pump Startup...10595
      Parts Identification...10596
      Disassembly And Assembly...10597
    HYDRAULIC / HYDROSTATIC FILTERS...10610
      Description...10610
      Housing Removal And Installation...10610
      Charge Filter Housing Removal And Installation...10612
    HYDRAULIC FLUID RESERVOIR...10614
      Description...10614
      Removal And Installation...10614
      Hydraulic Fluid Screen...10616
    OIL COOLER...10618
      Description...10618
      Removal And Installation...10618
    BUCKET POSITION VALVE...10620
      Description...10620
      Solenoid Removal And Installation...10620
      Solenoid Testing...10621
      Removal And Installation...10622
      Disassembly And Assembly...10623
    REAR AUXILIARY DIVERTER VALVE...10626
      Description...10626
      Solenoid Testing...10626
      Removal And Installation...10627
      Disassembly And Assembly...10630
    BOB-TACH (POWER) BLOCK...10636
      Description...10636
      Removal And Installation...10636
      Disassembly And Assembly...10638
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK...10642
      Description...10642
      Removal And Installation...10642
      Disassembly And Assembly...10642
    HIGH FLOW VALVE...10644
      Description...10644
      High Flow Relief Valve Testing...10644
      High Flow Relief Valve Adjustment...10645
      Solenoid Testing...10646
      Removal And Installation...10647
      Disassembly And Assembly...10648
  HYDROSTATIC SYSTEM...10652
    HYDROSTATIC SYSTEM INFORMATION...10654
      Description...10654
      Troubleshooting...10655
    HYDROSTATIC DRIVE MOTOR (A3LL35027 & BELOW)...10656
      Description...10656
      Removing And Replacing Oil...10657
      Removal And Installation...10659
      Parts Identification...10661
      Disassembly And Assembly...10663
    HYDROSTATIC DRIVE MOTOR (A3LL35028 - A3LL36499)...10674
      Description...10674
      Removing And Replacing Oil...10675
      Removal And Installation...10677
      Parts Identification...10679
      Disassembly And Assembly...10681
    HYDROSTATIC DRIVE MOTOR (A3LL36500 & ABOVE)...10692
      Description...10692
      Removing And Replacing Oil...10693
      Removal And Installation...10695
      Parts Identification...10697
      Disassembly And Assembly...10699
    CHARGE PRESSURE...10710
      Description...10710
      Testing (S/N A3LL29999 & Below)...10711
      Sender Removal And Installation (S/N A3LL29999 & Below)...10712
      Testing (S/N A3LL30001 & Above)...10713
      Sender Removal And Installation (S/N A3LL30001 & Above)...10714
      Adjusting...10715
    HYDROSTATIC PUMP...10718
      Description...10718
      Replenishing / High Pressure Relief Valve Removal And Installation...10719
      Removal And Installation...10720
      Hydrostatic Pump Startup...10722
      Parts Identification (Left Half)...10723
      Parts Identification (Right Half)...10724
      Disassembly...10725
      Assembly...10731
    HYDROSTATIC PUMP (SJC)...10738
      Description...10738
      Hydraulic Controller Removal And Installation...10739
      Removal And Installation...10741
      Hydrostatic Pump Startup...10743
      Parts Identification...10744
      High Pressure Relief And Bypass Valve...10745
      Charge Relief Valve...10746
      Disassembly And Assembly...10747
      Mechanical Neutral Adjustment...10763
      Hydraulic Controller Neutral Adjustment...10766
    DRIVE BELT...10770
      Description...10770
      Shield Removal And Installation...10770
      Adjusting...10771
      Belt Removal And Installation...10772
      Tensioner Pulley Removal And Installation...10773
      Tensioner Pulley Parts Identification...10774
      Tensioner Pulley Disassembly...10775
      Tensioner Pulley Assembly...10776
    CASE DRAIN FILTER...10778
      Description...10778
      Disassembly And Assembly...10778
  DRIVE SYSTEM...10780
    BRAKE...10782
      Description...10782
      Right Motor Brake Test...10782
      Left Motor Brake Test...10783
      Block Removal And Installation...10784
      Block Disassembly And Assembly...10786
    TRACK UNDERCARRIAGE (SOLID-MOUNTED) (S/N A3LL35032 & BELOW)...10788
      Description...10788
      Checking Tension...10789
      Adjusting Tension...10789
      Track Removal And Installation...10791
      Track Tensioner Disassembly And Assembly...10796
      Idler (Rear) Removal And Installation...10797
      Roller Removal And Installation...10797
      Sprocket Removal And Installation...10798
      Track Housing Removal And Installation...10799
    TRACK UNDERCARRIAGE (SOLID-MOUNTED) (S/N A3LL35033 & ABOVE)...10802
      Description...10802
      Checking Tension...10803
      Adjusting Tension...10804
      Track Removal And Installation...10805
      Idler (Front) Removal And Installation...10807
      Idler (Rear) Removal And Installation...10812
      Roller Removal And Installation...10812
      Sprocket Removal And Installation...10813
      Track Housing Removal And Installation...10814
    TRACK UNDERCARRIAGE (ROLLER SUSPENSION)...10816
      Description...10816
      Checking Tension...10817
      Adjusting Tension...10818
      Track Removal And Installation...10819
      Idler (Front) Removal And Installation...10821
      Track Tensioner Disassembly And Assembly...10825
      Idler (Rear) Removal And Installation...10826
      Roller Removal And Installation...10826
      Leaf Spring Removal And Installation...10827
      Sprocket Removal And Installation...10828
      Track Housing Removal And Installation...10829
    TRACK MAINTENANCE...10832
      Track Damage Identification...10832
  MAINFRAME...10844
    SEAT BAR...10848
      Description...10848
      Removal And Installation...10848
      Disassembly And Assembly...10849
      Compression Spring Disassembly And Assembly...10850
    OPERATOR CAB...10852
      Gas Cylinder Removal And Installation...10852
      Gas Cylinder Bracket Disassembly And Assembly...10854
      Removal And Installation...10855
    OPERATOR SEAT (SUSPENSION)...10858
      Removal And Installation...10858
      Slide Rail Removal And Installation...10859
      Seat Belt Removal And Installation...10859
      Lower Cushion Removal And Installation...10860
      Back Cushion Removal And Installation...10861
      Shock Removal And Installation...10861
      3-Point Seat Belt Removal And Installation...10862
    BOB-TACH (HAND LEVER)...10864
      Description...10864
      Removal And Installation...10864
      Lever And Wedge Disassembly And Assembly...10865
      Pivot Pin Bushing And Seal Removal And Installation...10867
    BOB-TACH (POWER)...10868
      Description...10868
      Removal And Installation...10868
      Lever And Wedge Disassembly And Assembly...10870
      Pivot Pin Bushing And Seal Removal And Installation...10871
    LIFT ARMS...10872
      Removal And Installation...10872
    REAR GRILLE...10876
      Removal And Installation...10876
    REAR DOOR (TAILGATE)...10878
      Removal And Installation...10878
      Striker Removal And Installation...10879
      Striker Disassembly And Assembly...10879
      Striker (Adjusting)...10880
      Latch Removal And Installation...10881
    FUEL TANK...10882
      Removal And Installation...10882
      Fuel Level Sender Removal And Installation...10883
      Fuel Fill Screen Removal And Installation...10883
    CONTROL PEDALS AND LINKAGES...10884
      Description...10884
      Pedal Removal And Installation...10884
      Linkage Removal And Installation...10885
      Pedal (Adjusting)...10887
    CONTROL PEDALS (ACS)...10888
      Description...10888
      Foot Sensor Removal And Installation...10888
      Foot Pedal Removal And Installation...10889
      Foot Pedal Linkage Disassembly And Assembly...10890
    CONTROL PANEL...10892
      Description...10892
      Removal And Installation...10893
      Shock Removal And Installation...10896
      Shaft Removal And Installation...10896
      Shaft Disassembly And Assembly...10897
      Linkage Removal And Installation...10898
      Pintle Arm Disassembly And Assembly...10902
      Linkage Neutral (Adjusting)...10904
      Linkage Travel (Adjusting)...10908
    CONTROL PANEL (SJC)...10912
      Description...10912
      Removal And Installation...10912
    CONTROL HANDLE / LEVER...10914
      Description...10914
      Lever Removal And Installation...10914
      Boot Removal And Installation...10915
    CONTROL HANDLE / LEVER (ACS)...10916
      Description...10916
      Handle Sensor Removal And Installation...10916
      Handle Removal And Installation...10919
      Handle Disassembly And Assembly...10920
      Lever Removal And Installation...10920
      Boot Removal And Installation...10922
    CONTROL HANDLE / LEVER (SJC)...10924
      Description...10924
      Joystick Testing...10924
      Joystick Removal And Installation...10925
      Joystick Mount Removal And Installation...10926
    ACCESS PANEL (INSIDE)...10928
      Removal And Installation (Left)...10928
      Removal And Installation (Right)...10928
    ACCESS PANEL (INSIDE) (SJC)...10930
      Removal And Installation (Left)...10930
      Removal And Installation (Right)...10931
    WINDOW (REAR)...10934
      Removal...10934
      Installation (Split Molding)...10934
      Installation (Continuous Molding)...10936
    WINDOW (TOP)...10938
      Removal And Installation...10938
    WINDOW (SIDE)...10940
      Removal And Installation...10940
    WINDOW (CAB DOOR)...10942
      Removal (Standard Window)...10942
      Installation (Standard Window)...10943
      Removal And Installation (Special Applications Window)...10945
    CAB DOOR...10946
      Description...10946
      Removal And Installation...10946
      Aligning...10947
      Adjusting...10948
      Checking Operation...10948
  ELECTRICAL SYSTEM & ANALYSIS...10950
    ELECTRICAL SCHEMATICS...10954
    ELECTRICAL SYSTEM INFORMATION...10960
      Glossary Of Electrical Symbols...10960
      Standard Cab Harness Connectors...10963
      Deluxe Cab Harness Connectors...10964
      Mainframe Harness Connectors...10965
      Description...10966
      Troubleshooting...10967
      Fuse And Relay Location / Identification...10968
      Solenoid Testing...10969
    BATTERY...10970
      Removal And Installation...10970
      Servicing...10971
      Using A Booster Battery (Jump Starting)...10972
    ALTERNATOR...10974
      Belt Adjustment...10974
      Belt Replacement...10974
      Charging System Inspection...10975
      Alternator Voltage Testing...10976
      Low Voltage Testing...10976
      High Voltage Testing...10977
      Removal And Installation...10978
      Parts Identification...10979
    STARTER...10980
      Testing...10980
      Removal And Installation...10981
      Parts Identification...10982
    INSTRUMENT PANELS...10984
      Left Panel...10984
      Standard Key Panel...10986
      Keyless Start Panel...10986
      Deluxe Instrumentation Panel...10987
      Side Panel...10988
      Front Panel...10988
      Front Panel Removal And Installation...10989
      Removal And Installation (Left And Right)...10990
      Key Switch Removal And Installation...10991
      Alarm Removal And Installation...10992
    LIGHTS...10994
      Front Removal And Installation...10994
      Rear Removal And Installation...10995
      Cab Light Removal And Installation...10995
    BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)...10996
      Description...10996
      Connector Identification...10997
      Removal And Installation...11003
    BOBCAT CONTROLLER (ACS)...11006
      Description...11006
      Connector And Wire Identification...11007
      Removal And Installation...11008
    BOBCAT CONTROLLER (SJC) (DRIVE)...11010
      Description...11010
      Connector Identification...11011
      Removal And Installation...11013
    SPEED SENSORS (SJC)...11014
      Description...11014
      Testing...11014
      Removal And Installation...11016
    DIAGNOSTIC SERVICE CODES...11020
      Viewing Service Codes...11020
      Service Codes List...11021
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...11026
      Description...11026
      Inspecting The BICS (Engine STOPPED - Key ON)...11027
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...11027
      Inspecting The Seat Bar Sensor (Engine RUNNING)...11027
      Inspecting The Traction Lock (Engine RUNNING)...11027
      Inspecting The Lift Arm Bypass Control...11027
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)...11027
      Troubleshooting...11028
    SEAT BAR SENSOR...11030
      Description...11030
      Troubleshooting...11030
      Testing...11031
      Removal And Installation...11032
      Bobcat Interlock Control System (BICS) Circuit Test...11034
    TRACTION LOCK...11036
      Description...11036
      Troubleshooting...11037
      Inspecting...11038
    CONTROL SYSTEM (ACS)...11040
      Description...11040
      Troubleshooting...11041
      Handle Sensor Connector Disassembly And Assembly...11042
      Switch Handle Removal...11043
      Switch Handle Installation...11045
      Actuator Connector Disassembly And Assembly...11048
      Handle Lock Solenoid Removal And Installation...11049
      Handle Lock Solenoid Disassembly And Assembly...11049
      Foot Sensor Disassembly And Assembly...11050
      Foot Lock Solenoid Removal And Installation...11051
    ELECTRICAL / HYDRAULIC CONTROLS...11052
      Identification Chart...11052
      Description...11053
      Identification Chart ACD Group 0...11054
      Identification Chart ACD Group 1...11055
      Identification Chart ACD Group 2...11056
      Identification Chart ACD Group 3...11057
    ELECTRICAL / HYDRAULIC CONTROLS (ACS)...11058
      Identification Chart...11058
      Description...11059
      Identification Chart ACD Group 0...11060
      Identification Chart ACD Group 1...11061
      Identification Chart ACD Group 2...11062
      Identification Chart ACD Group 3...11063
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)...11064
      Identification Chart...11064
      Description...11065
      Identification Chart ACD Group 0...11066
      Identification Chart ACD Group 1...11067
      Identification Chart ACD Group 2...11068
      Identification Chart ACD Group 3...11069
    SERVICE PC (LAPTOP COMPUTER)...11070
      Connecting Remote Start Tool...11070
      Connecting Remote Start Tool (Service Tool)...11070
    CALIBRATION...11072
      Description...11072
      Actuator Testing...11072
      Lift And Tilt Calibration (SJC)...11075
      Hydrostatic Pump Calibration (SJC)...11077
      Lift And Tilt Calibration (ACS)...11082
    STEERING DRIFT COMPENSATION...11084
      Description...11084
      Operation...11084
    FLYWHEEL RPM SENSOR...11086
      Description...11086
      Adjusting...11086
    CONTROL PANEL SETUP...11088
      Right Panel Setup (Deluxe Instrumentation Panel)...11088
      Attachment Control Information (Deluxe Instrumentation Panel)...11089
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...11090
      Password Description...11090
      Changing The Owner Password...11090
      Changing The User Passwords...11091
      Password Lockout Feature...11091
    PASSWORD SETUP (KEYLESS START PANEL)...11092
      Password Description...11092
      Changing The Owner Password...11092
      Password Lockout Feature...11092
    MAINTENANCE CLOCK...11094
      Description...11094
      Setup...11095
      Reset...11098
    BACK-UP ALARM SYSTEM...11100
      Description...11100
      Inspecting...11100
      Adjusting Switch Position...11101
      Troubleshooting (Standard and ACS)...11102
      Troubleshooting (Joystick)...11103
      Alarm Removal And Installation...11104
      Switch Removal And Installation...11104
  ENGINE SERVICE...11106
    ENGINE INFORMATION...11110
      Description...11110
      Specifications...11111
      Torque Values...11115
      Troubleshooting...11115
      Engine Removal And Installation...11117
      Engine Mount Replacement...11124
      Compression - Checking...11125
    ENGINE SPEED CONTROL...11126
      Removal And Installation...11126
    ENGINE SPEED CONTROL (SJC)...11128
      Removal And Installation...11128
      Disassembly And Assembly...11130
    MUFFLER...11132
      Removal And Installation...11132
    AIR CLEANER...11134
      Housing Removal And Installation...11134
    ENGINE COOLING SYSTEM...11136
      Radiator Removal And Installation...11136
      Hydraulic Fan Description (S/N A3LL29999 & Below)...11139
      Hydraulic Fan Disassembly And Assembly (S/N A3LL29999 & Below)...11139
      Blower Housing Removal And Installation (S/N A3LL29999 & Below)...11140
      Fan Removal And Installation (S/N A3LL29999 & Below)...11142
      Hydraulic Fan Motor Removal And Installation (S/N A3LL29999 & Below)...11142
      Hydraulic Fan Description (S/N A3LL30001 & Above)...11143
      Hydraulic Fan Disassembly And Assembly (S/N A3LL30001 & Above)...11143
      Blower Housing Removal And Installation (S/N A3LL30001 & Above)...11145
      Fan Removal And Installation (S/N A3LL30001 & Above)...11147
      Hydraulic Fan Motor Removal And Installation (S/N A3LL30001 & Above)...11147
      Water Pump Removal And Installation...11148
      Water Pump Disassembly And Assembly...11148
      Thermostat Housing Removal And Installation...11149
      Thermostat - Checking...11150
    LUBRICATION SYSTEM...11152
      Oil Pan Removal And Installation...11152
      Oil Pump Removal And Installation...11152
      Relief Valve - Testing...11153
      Oil Pump Inspection...11153
      Oil Filter Cooler Removal And Installation...11154
      Engine Oil Pressure - Testing...11155
    FUEL SYSTEM...11156
      Fuel Shutoff Solenoid - Checking...11156
      Fuel Shutoff Solenoid Removal And Installation...11156
      Fuel Injection Pump - Checking...11157
      Fuel Injection Pump Assembly Removal And Installation...11158
      Governor Housing Disassembly And Assembly...11161
      Governor Disassembly And Assembly...11163
      Fuel Camshaft Removal And Installation...11165
      Fuel Injection Pump Removal And Installation...11167
      Fuel Injection Pump - Timing...11170
      Fuel Injector Removal And Installation...11172
      Fuel Injector Nozzle Pressure - Checking...11173
      Nozzle Spray Condition...11174
      Valve Seat Tightness...11174
    CYLINDER HEAD...11176
      Glow Plugs - Testing...11176
      Glow Plugs Removal And Installation...11176
      Valve Clearance Adjustment...11177
      Valve Timing - Checking...11178
      Cylinder Head Removal And Installation...11179
      Cylinder Head Disassembly And Assembly...11182
      Cylinder Head - Servicing...11182
      Cylinder Head Top Clearance...11183
      Valve Guide - Checking...11183
      Valve Guide Removal And Installation...11184
      Reconditioning The Valve And Valve Seat...11184
      Valve Spring...11186
      Valve Tappets...11187
      Rocker Arm And Shaft - Checking...11188
      Bridge Arm And Bridge Arm Shaft - Checking...11188
      Bridge Arm Shaft Removal And Installation...11189
      Push Rod Alignment - Checking...11190
    CRANKSHAFT AND PISTONS...11192
      Piston And Connecting Rod Removal And Installation...11192
      Piston And Connecting Rod - Servicing...11193
      Cylinder Bore - Checking...11197
      Connecting Rod Alignment...11198
      Crankshaft Gear Removal And Installation...11198
      Crankshaft And Bearings Removal And Installation...11199
      Crankshaft And Bearings - Servicing...11202
    CAMSHAFT AND TIMING GEARS...11206
      Timing Gearcase Cover Removal...11206
      Timing Gearcase Cover Installation...11207
      Timing Gears Backlash - Checking...11210
      Idler Gear And Camshaft Removal And Installation...11210
      Camshaft - Servicing...11211
      Idler Gear And Shaft - Servicing...11212
    TURBOCHARGER...11214
      Description...11214
      Testing...11214
      Removal And Installation...11215
    FLYWHEEL AND HOUSING...11216
      Flywheel Removal And Installation...11216
      Ring Gear Removal And Installation...11217
      Housing Removal And Installation...11218
    EXHAUST GAS RECIRCULATION (EGR) SYSTEM...11220
      Description...11220
      Testing...11221
      Removal And Installation...11224
      Disassembly And Assembly...11225
  HEATING, VENTILATION, AIR CONDITIONING...11226
    AIR CONDITIONING SYSTEM FLOW...11229
      Description...11229
      Chart...11230
      Components...11231
      Safety Equipment...11234
    REGULAR MAINTENANCE...11236
      Filters...11236
      Compressor Drive Belt Adjustment...11237
      Compressor Drive Belt Replacement...11238
      Condenser...11238
      Air Conditioning Lubrication...11238
      Air Conditioning Service Chart...11239
      Evaporator / Heater Coil...11240
    TROUBLESHOOTING...11242
      Blower Motor Does Not Operate...11242
      Blower Motor Operates Normally, But Air Flow Is Insufficient...11242
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...11242
      The Compressor Does Not Operate At All, Or Operates Improperly...11242
      Gauge Pressure Related Troubleshooting...11243
      Troubleshooting Tree...11245
      Temperature / Pressure Chart...11249
      Poor A/C Performance...11250
      HVAC Repair And Leaks...11251
      Electrical System...11252
      Engine Coolant Bypassing The Heater Valve...11259
      Heater Valve Not Opening Or Closing...11260
    SYSTEM CHARGING AND RECLAMATION...11262
      Refrigerant Identification...11262
      Reclamation And Charging With Recovery / Charging Unit...11263
      Charging With A Manifold Gauge Set...11265
    COMPRESSOR...11268
      Removal And Installation...11268
      Oil...11270
      Oil Check...11270
      Clutch Disassembly And Assembly...11272
    CONDENSER...11276
      Removal And Installation...11276
    RECEIVER / DRIER...11278
      Receiver / Drier Removal And Installation...11278
      Pressure Relief Valve Removal And Installation...11280
      Pressure Switch Removal And Installation...11281
      Schraeder Valve Removal And Installation...11281
    EVAPORATOR / HEATER UNIT...11282
      Removal And Installation...11282
    THERMOSTAT...11284
      Description...11284
      Removal And Installation...11285
    EXPANSION VALVE...11286
      Removal And Installation...11286
    EVAPORATOR COIL...11288
      Removal And Installation...11288
    HEATER COIL...11290
      Removal And Installation With A/C...11290
      Removal And Installation Without A/C...11292
    BLOWER FAN...11294
      Removal And Installation...11294
      Disassembly And Assembly...11295
      Connector Identification...11297
    HEATER VALVE...11298
      Removal And Installation...11298
      Disassembly And Assembly...11299
  SPECIFICATIONS...11300
    (T180) LOADER SPECIFICATIONS...11302
      Machine Dimensions...11302
      Performance...11303
      Engine...11303
      Drive System...11303
      Controls...11304
      Hydraulic System...11304
      Electrical...11305
      Capacities...11305
      Tracks...11305
      Ground Pressure...11305
    TORQUE SPECIFICATIONS FOR BOLTS...11306
      Torque For General SAE Bolts...11306
      Torque For General Metric Bolts...11307
    HYDRAULIC CONNECTION SPECIFICATIONS...11308
      O-ring Face Seal Connection...11308
      Straight Thread O-ring Fitting...11309
      Tubelines And Hoses...11309
      Flare Fitting...11310
      Port Seal Fitting...11311
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...11312
      Specifications...11312
    CONVERSIONS...11314
      Decimal And Millimeter Equivalent Chart...11314
      U.S. To Metric Conversion Chart...11314
  SERVICE MANUAL REVISION...11316
    Revision No: T180 - 1...11316
    Revision No: T180 - 2...11318
    Revision No: T180 - 3...11320
    Revision No: T180 - 4...11322
    Revision No: T180 - 5...11324
    Revision No: T180 - 6...11326
    Revision No: T180 - 7...11328
    Revision No: T180 - 8...11330
    Revision No: T180 - 9...11332
    Revision No: T180 - 10...11334
    Revision No: T180 - 11...11336
    Revision No: T180 - 12...11338
    Revision No: T180 - 13...11340
    Revision No: T180 - 14...11342
6989617 (11-10) - T180 Compact Track Loader Operation & Maintenance Manual...11344
  OPERATOR SAFETY WARNINGS...11346
  CONTENTS...11348
  FOREWORD...11350
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...11352
    REGULAR MAINTENANCE ITEMS...11352
    SERIAL NUMBER LOCATIONS...11353
      Loader Serial Number...11353
      Engine Serial Number...11353
    DELIVERY REPORT...11353
    LOADER IDENTIFICATION...11354
    FEATURES, ACCESSORIES AND ATTACHMENTS...11355
      Standard Items...11355
      Options And Accessories...11355
      Buckets Available...11356
      Attachments...11356
      High-Flow Attachments...11356
      Special Applications Kit...11357
      Special Applications Kit Inspection And Maintenance...11357
  SAFETY & TRAINING RESOURCES...11358
    SAFETY INSTRUCTIONS...11360
      Before Operation...11360
      Safe Operation Is The Operator’s Responsibility...11361
      Safe Operation Needs A Qualified Operator...11361
      Avoid Silica Dust...11362
    FIRE PREVENTION...11362
      Maintenance...11362
      Operation...11362
      Electrical...11362
      Hydraulic System...11363
      Fueling...11363
      Starting...11363
      Spark Arrestor Exhaust System...11363
      Welding And Grinding...11363
      Fire Extinguishers...11363
    MACHINE SIGNS (DECALS)...11365
    PUBLICATIONS AND TRAINING RESOURCES...11367
  OPERATING INSTRUCTIONS...11368
    INSTRUMENT PANEL IDENTIFICATION...11372
      Cab Light...11372
      Left Panel...11373
      Display Screen...11375
      Standard Key Panel...11376
      Keyless Start Panel...11376
      Deluxe Instrumentation Panel...11377
      Side Panel...11378
      Front Panel...11378
    CONTROL IDENTIFICATION...11379
      Standard Controls...11379
      Advanced Control System (ACS)...11380
      Selectable Joystick Controls (SJC)...11381
    SEAT BAR RESTRAINT SYSTEM...11382
      Operation...11382
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...11383
      Operation...11383
    LIFT ARM BYPASS CONTROL...11384
      Operation...11384
    PARKING BRAKE...11384
      Operation...11384
    TRACTION LOCK OVERRIDE...11384
      Operation...11384
    EMERGENCY EXIT...11385
      Rear Window...11385
      Front Door...11385
    BACK-UP ALARM SYSTEM...11386
      Description...11386
      Operation...11386
    ENGINE SPEED CONTROL...11387
      Operation...11387
    DRIVING AND STEERING THE LOADER...11388
      Available Control Configurations...11388
      Operation (Standard And ACS)...11388
      Operation (SJC) In ‘ISO’ Control Pattern...11389
      Operation (SJC) In ‘H’ Control Pattern...11390
    STOPPING THE LOADER...11390
      Using The Control Levers Or Joysticks...11390
    SPEED MANAGEMENT...11391
      Operation...11391
      Changing The Factory Default Setting...11392
    DRIVE RESPONSE...11393
      Description...11393
      Operation...11393
    STEERING DRIFT COMPENSATION...11395
      Description...11395
      Operation...11395
    HYDRAULIC CONTROLS...11397
      Description...11397
      Standard Controls (Also ACS In FOOT Pedal Mode)...11397
      Advanced Control System (ACS) In HAND Control Mode...11398
      Selectable Joystick Controls (SJC) In ‘ISO’ Control Pattern...11398
      Selectable Joystick Controls (SJC) In ‘H’ Control Pattern...11399
      Hydraulic Bucket Positioning...11399
      FRONT Auxiliary Hydraulics Operation...11400
      FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)...11401
      REAR Auxiliary Hydraulics Operation...11402
      Secondary Front Auxiliary Hydraulics Operation...11403
      High-Flow Hydraulics Operation...11404
      Quick Couplers...11404
      Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)...11405
    ATTACHMENT CONTROL DEVICE (ACD)...11406
      Description...11406
    DAILY INSPECTION...11407
      Daily Inspection And Maintenance...11408
    PRE-STARTING PROCEDURE...11409
      Entering The Loader...11409
      Operation & Maintenance Manual And Operator’s Handbook Locations...11409
      Seat Adjustment...11410
      Seat Belt Adjustment...11411
      Seat Bar...11411
    STARTING THE ENGINE...11412
      Standard Key Panel...11412
      Keyless Start Panel...11414
      Deluxe Instrumentation Panel...11416
      Cold Temperature Starting...11418
      Warming The Hydraulic / Hydrostatic System...11418
    MONITORING THE DISPLAY PANELS...11419
      Left Panel...11419
      Warning And Shutdown...11419
    STOPPING THE ENGINE AND LEAVING THE LOADER...11420
      Procedure...11420
    COUNTERWEIGHTS...11421
      Description...11421
      Effect On The Loader And Loader Operation...11421
      When To Consider Using Counterweights...11421
      When To Consider Removing Counterweights...11421
      Accessories That Affect Machine Weight...11421
    ATTACHMENTS...11422
      Choosing The Correct Bucket...11422
      Pallet Forks...11422
      Installing And Removing The Attachment (Hand Lever Bob-Tach)...11423
      Installing And Removing The Attachment (Power Bob-Tach)...11425
    TRACK UNDERCARRIAGE SYSTEM...11428
      Introduction...11428
      Compact Track Loader Operating And Maintenance Tips...11428
    OPERATING PROCEDURE...11430
      Inspect The Work Area...11430
      Basic Operating Instructions...11430
      Driving On Public Roads...11430
      Operating With A Full Bucket...11431
      Operating With An Empty Bucket...11431
      Filling And Emptying The Bucket (Foot Pedals)...11432
      Leveling The Ground Using Float (Foot Pedals)...11433
      Digging And Filling A Hole (Foot Pedals)...11433
      Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)...11434
      Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)...11435
      Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)...11436
      Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)...11437
      Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)...11438
      Digging And Filling A Hole (SJC - ‘ISO’ Pattern)...11438
    TOWING THE LOADER...11439
      Procedure...11439
    LIFTING THE LOADER...11440
      Single-Point Lift...11440
      Four-Point Lift...11440
    TRANSPORTING THE LOADER ON A TRAILER...11441
      Loading And Unloading...11441
      Fastening...11441
  PREVENTIVE MAINTENANCE...11442
    MAINTENANCE SAFETY...11446
    SERVICE SCHEDULE...11448
      Chart...11448
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...11449
      Inspecting The BICS (Engine STOPPED - Key ON)...11449
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...11449
      Inspecting The Seat Bar Sensor (Engine RUNNING)...11449
      Inspecting The Traction Lock (Engine RUNNING)...11449
      Inspecting The Lift Arm Bypass Control...11449
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)...11449
    SEAT BAR RESTRAINT SYSTEM...11450
      Description...11450
      Inspecting...11450
      Maintaining...11450
    SEAT BELT...11451
      Inspection And Maintenance...11451
    LIFT ARM SUPPORT DEVICE...11452
      Installing...11452
      Removing...11453
    BACK-UP ALARM SYSTEM...11454
      Description...11454
      Inspecting...11454
      Adjusting Switch Position...11454
    OPERATOR CAB...11455
      Description...11455
      Raising...11455
      Lowering...11456
      Cab Door Sensor...11457
    REAR DOOR (TAILGATE)...11458
      Opening And Closing...11458
      Adjusting...11458
    REAR GRILLE...11458
      Removing...11458
      Installing...11458
    HEATING, VENTILATION AND AIR CONDITIONING (HVAC)...11459
      Cleaning And Maintenance...11459
      Filters...11459
      Evaporator / Heater Coil...11459
      Condenser...11459
      Air Conditioning Lubrication...11459
      Troubleshooting...11459
    AIR CLEANER SERVICE...11460
      Replacing Filter Elements...11460
    FUEL SYSTEM...11462
      Fuel Specifications...11462
      Biodiesel Blend Fuel...11462
      Filling The Fuel Tank...11463
      Fuel Filter...11464
      Removing Air From The Fuel System...11464
    ENGINE LUBRICATION SYSTEM...11465
      Checking And Adding Engine Oil...11465
      Engine Oil Chart...11465
      Removing And Replacing Oil And Filter...11465
    ENGINE COOLING SYSTEM...11466
      Cleaning...11466
      Removing And Replacing Coolant...11467
      Checking Level...11467
    ELECTRICAL SYSTEM...11468
      Description...11468
      Fuse And Relay Location / Identification...11468
      Battery Maintenance...11469
      Using A Booster Battery (Jump Starting)...11470
      Removing And Installing Battery...11471
    HYDRAULIC / HYDROSTATIC SYSTEM...11472
      Checking And Adding Fluid...11472
      Hydraulic / Hydrostatic Fluid Chart...11472
      Removing And Replacing Hydraulic Fluid...11473
      Removing And Replacing Hydraulic / Hydrostatic Filter...11473
      Removing And Replacing Case Drain Filters...11474
      Removing And Replacing Hydraulic Charge Filter...11475
      Breather Cap...11476
    SPARK ARRESTER MUFFLER...11477
      Cleaning Procedure...11477
    TRACK TENSION...11478
      Description...11478
      Checking (Solid-Mounted Undercarriage)...11479
      Adjusting (Solid-Mounted Undercarriage)...11480
      Checking (Roller Suspension Undercarriage)...11481
      Adjusting (Roller Suspension Undercarriage)...11482
    HYDROSTATIC DRIVE MOTOR...11483
      Removing And Replacing Oil...11483
    TRACK SPROCKET MAINTENANCE...11483
      Tightening Procedure...11483
    ALTERNATOR BELT...11484
      Belt Adjustment...11484
      Belt Replacement...11484
    AIR CONDITIONING BELT...11485
      Belt Adjustment...11485
      Belt Replacement...11485
    DRIVE BELT...11486
      Belt Adjustment...11486
      Belt Replacement...11488
    LUBRICATING THE LOADER...11489
      Lubrication Locations...11489
    TRACK ROLLER AND IDLER LUBRICATION...11490
      Procedure...11490
    PIVOT PINS...11490
      Inspection And Maintenance...11490
    BOB-TACH (HAND LEVER)...11491
      Inspection And Maintenance...11491
    BOB-TACH (POWER)...11492
      Inspection And Maintenance...11492
    LOADER STORAGE AND RETURN TO SERVICE...11493
      Storage...11493
      Return To Service...11493
  SYSTEM SETUP & ANALYSIS...11494
    DIAGNOSTIC SERVICE CODES...11496
      Viewing Service Codes...11496
      Service Codes List...11497
    CONTROL PANEL SETUP...11502
      Right Panel Setup (Deluxe Instrumentation Panel)...11502
      Attachment Control Information (Deluxe Instrumentation Panel)...11503
    PASSWORD SETUP (KEYLESS START PANEL)...11504
      Password Description...11504
      Changing The Owner Password...11504
      Password Lockout Feature...11504
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...11505
      Password Description...11505
      Changing The Owner Password...11505
      Changing The User Passwords...11506
      Password Lockout Feature...11506
    MAINTENANCE CLOCK...11507
      Description...11507
      Setup...11507
      Reset...11507
  MACHINE SIGN TRANSLATIONS...11508
    MACHINE SIGN TRANSLATIONS...11510
      Service Schedule (6734534)...11510
      Warning (6728540)...11513
      Warning (6718396)...11514
      Danger (6809511)...11514
      Warning (6718397)...11514
      Warning (6737189)...11515
      Warning (6725370)...11515
      Warning (6737248)...11515
      Lift Arm Support Device (6706558)...11516
      Warning (7131520)...11517
      Warning (6726423)...11518
      Warning (7131521)...11519
      Warning (7160879)...11520
      Warning (6704786)...11521
      Warning (6577754)...11521
      Danger (6718392)...11522
      Danger (6718393)...11522
      Warning (6718391)...11522
      Danger (6717343)...11523
      Warning (6804114)...11523
      Important (6560573)...11523
  SPECIFICATIONS...11524
    (T180) LOADER SPECIFICATIONS...11526
      Machine Dimensions...11526
      Performance...11527
      Engine...11527
      Drive System...11527
      Controls...11528
      Hydraulic System...11528
      Electrical...11529
      Capacities...11529
      Tracks...11529
      Ground Pressure...11529
  WARRANTY...11530
    WARRANTY...11532
  ALPHABETICAL INDEX...11534
6989617 (3-11) - T180 Compact Track Loader Operation & Maintenance Manual...11536
  OPERATOR SAFETY WARNINGS...11538
  CONTENTS...11540
  FOREWORD...11542
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...11544
    REGULAR MAINTENANCE ITEMS...11544
    SERIAL NUMBER LOCATIONS...11545
      Loader Serial Number...11545
      Engine Serial Number...11545
    DELIVERY REPORT...11545
    LOADER IDENTIFICATION...11546
    FEATURES, ACCESSORIES AND ATTACHMENTS...11547
      Standard Items...11547
      Options And Accessories...11547
      Buckets Available...11548
      Attachments...11548
      High-Flow Attachments...11548
      Special Applications Kit...11549
      Special Applications Kit Inspection And Maintenance...11549
  SAFETY & TRAINING RESOURCES...11550
    SAFETY INSTRUCTIONS...11552
      Before Operation...11552
      Safe Operation Is The Operator’s Responsibility...11553
      Safe Operation Needs A Qualified Operator...11553
      Avoid Silica Dust...11554
    FIRE PREVENTION...11554
      Maintenance...11554
      Operation...11554
      Electrical...11554
      Hydraulic System...11555
      Fueling...11555
      Starting...11555
      Spark Arrestor Exhaust System...11555
      Welding And Grinding...11555
      Fire Extinguishers...11555
    MACHINE SIGNS (DECALS)...11557
    PUBLICATIONS AND TRAINING RESOURCES...11559
  OPERATING INSTRUCTIONS...11560
    INSTRUMENT PANEL IDENTIFICATION...11564
      Cab Light...11564
      Left Panel...11565
      Display Screen...11567
      Standard Key Panel...11568
      Keyless Start Panel...11568
      Deluxe Instrumentation Panel...11569
      Side Panel...11570
      Front Panel...11570
    CONTROL IDENTIFICATION...11571
      Standard Controls...11571
      Advanced Control System (ACS)...11572
      Selectable Joystick Controls (SJC)...11573
    SEAT BAR RESTRAINT SYSTEM...11574
      Operation...11574
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...11575
      Operation...11575
    LIFT ARM BYPASS CONTROL...11576
      Operation...11576
    PARKING BRAKE...11576
      Operation...11576
    TRACTION LOCK OVERRIDE...11576
      Operation...11576
    EMERGENCY EXIT...11577
      Rear Window...11577
      Front Door...11577
    BACK-UP ALARM SYSTEM...11578
      Description...11578
      Operation...11578
    ENGINE SPEED CONTROL...11579
      Operation...11579
    DRIVING AND STEERING THE LOADER...11580
      Available Control Configurations...11580
      Operation (Standard And ACS)...11580
      Operation (SJC) In ‘ISO’ Control Pattern...11581
      Operation (SJC) In ‘H’ Control Pattern...11582
    STOPPING THE LOADER...11582
      Using The Control Levers Or Joysticks...11582
    SPEED MANAGEMENT...11583
      Operation...11583
      Changing The Factory Default Setting...11584
    DRIVE RESPONSE...11585
      Description...11585
      Operation...11585
    STEERING DRIFT COMPENSATION...11587
      Description...11587
      Operation...11587
    HYDRAULIC CONTROLS...11589
      Description...11589
      Standard Controls (Also ACS In FOOT Pedal Mode)...11589
      Advanced Control System (ACS) In HAND Control Mode...11590
      Selectable Joystick Controls (SJC) In ‘ISO’ Control Pattern...11590
      Selectable Joystick Controls (SJC) In ‘H’ Control Pattern...11591
      Hydraulic Bucket Positioning...11591
      FRONT Auxiliary Hydraulics Operation...11592
      FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)...11593
      REAR Auxiliary Hydraulics Operation...11594
      Secondary Front Auxiliary Hydraulics Operation...11595
      High-Flow Hydraulics Operation...11596
      Quick Couplers...11596
      Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)...11597
    ATTACHMENT CONTROL DEVICE (ACD)...11598
      Description...11598
    DAILY INSPECTION...11599
      Daily Inspection And Maintenance...11600
    PRE-STARTING PROCEDURE...11601
      Entering The Loader...11601
      Operation & Maintenance Manual And Operator’s Handbook Locations...11601
      Seat Adjustment...11602
      Seat Belt Adjustment...11603
      Seat Bar...11603
    STARTING THE ENGINE...11604
      Standard Key Panel...11604
      Keyless Start Panel...11606
      Deluxe Instrumentation Panel...11608
      Cold Temperature Starting...11610
      Warming The Hydraulic / Hydrostatic System...11610
    MONITORING THE DISPLAY PANELS...11611
      Left Panel...11611
      Warning And Shutdown...11611
    STOPPING THE ENGINE AND LEAVING THE LOADER...11612
      Procedure...11612
    COUNTERWEIGHTS...11613
      Description...11613
      Effect On The Loader And Loader Operation...11613
      When To Consider Using Counterweights...11613
      When To Consider Removing Counterweights...11613
      Accessories That Affect Machine Weight...11613
    ATTACHMENTS...11614
      Choosing The Correct Bucket...11614
      Pallet Forks...11614
      Installing And Removing The Attachment (Hand Lever Bob-Tach)...11615
      Installing And Removing The Attachment (Power Bob-Tach)...11617
    TRACK UNDERCARRIAGE SYSTEM...11620
      Introduction...11620
      Compact Track Loader Operating And Maintenance Tips...11620
    OPERATING PROCEDURE...11622
      Inspect The Work Area...11622
      Basic Operating Instructions...11622
      Driving On Public Roads...11622
      Operating With A Full Bucket...11623
      Operating With An Empty Bucket...11623
      Filling And Emptying The Bucket (Foot Pedals)...11624
      Leveling The Ground Using Float (Foot Pedals)...11625
      Digging And Filling A Hole (Foot Pedals)...11625
      Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)...11626
      Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)...11627
      Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)...11628
      Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)...11629
      Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)...11630
      Digging And Filling A Hole (SJC - ‘ISO’ Pattern)...11630
    TOWING THE LOADER...11631
      Procedure...11631
    LIFTING THE LOADER...11632
      Single-Point Lift...11632
      Four-Point Lift...11632
    TRANSPORTING THE LOADER ON A TRAILER...11633
      Loading And Unloading...11633
      Fastening...11633
  PREVENTIVE MAINTENANCE...11634
    MAINTENANCE SAFETY...11638
    SERVICE SCHEDULE...11640
      Chart...11640
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...11641
      Inspecting The BICS™ (Engine STOPPED - Key ON)...11641
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...11641
      Inspecting The Seat Bar Sensor (Engine RUNNING)...11641
      Inspecting The Traction Lock (Engine RUNNING)...11641
      Inspecting The Lift Arm Bypass Control...11641
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)...11641
    SEAT BAR RESTRAINT SYSTEM...11642
      Description...11642
      Inspecting...11642
      Maintaining...11642
    SEAT BELT...11643
      Inspection And Maintenance...11643
    LIFT ARM SUPPORT DEVICE...11644
      Installing...11644
      Removing...11645
    BACK-UP ALARM SYSTEM...11646
      Description...11646
      Inspecting...11646
      Adjusting Switch Position...11646
    OPERATOR CAB...11647
      Description...11647
      Raising...11647
      Lowering...11648
      Cab Door Sensor...11649
    REAR DOOR (TAILGATE)...11650
      Opening And Closing...11650
      Adjusting...11650
    REAR GRILLE...11650
      Removing...11650
      Installing...11650
    HEATING, VENTILATION AND AIR CONDITIONING (HVAC)...11651
      Cleaning And Maintenance...11651
      Filters...11651
      Evaporator / Heater Coil...11651
      Condenser...11651
      Air Conditioning Lubrication...11651
      Troubleshooting...11651
    AIR CLEANER SERVICE...11652
      Replacing Filter Elements...11652
    FUEL SYSTEM...11654
      Fuel Specifications...11654
      Biodiesel Blend Fuel...11654
      Filling The Fuel Tank...11655
      Fuel Filter...11656
      Removing Air From The Fuel System...11656
    ENGINE LUBRICATION SYSTEM...11657
      Checking And Adding Engine Oil...11657
      Engine Oil Chart...11657
      Removing And Replacing Oil And Filter...11657
    ENGINE COOLING SYSTEM...11658
      Cleaning...11658
      Removing And Replacing Coolant...11659
      Checking Level...11659
    ELECTRICAL SYSTEM...11660
      Description...11660
      Fuse And Relay Location / Identification...11660
      Battery Maintenance...11661
      Using A Booster Battery (Jump Starting)...11662
      Removing And Installing Battery...11663
    HYDRAULIC / HYDROSTATIC SYSTEM...11664
      Checking And Adding Fluid...11664
      Hydraulic / Hydrostatic Fluid Chart...11664
      Removing And Replacing Hydraulic Fluid...11665
      Removing And Replacing Hydraulic / Hydrostatic Filter...11665
      Removing And Replacing Case Drain Filters...11666
      Removing And Replacing Hydraulic Charge Filter...11667
      Breather Cap...11668
    SPARK ARRESTER MUFFLER...11669
      Cleaning Procedure...11669
    TRACK TENSION...11670
      Description...11670
      Checking (Solid-Mounted Undercarriage)...11671
      Adjusting (Solid-Mounted Undercarriage)...11672
      Checking (Roller Suspension Undercarriage)...11673
      Adjusting (Roller Suspension Undercarriage)...11674
    HYDROSTATIC DRIVE MOTOR...11675
      Removing And Replacing Oil...11675
    TRACK SPROCKET MAINTENANCE...11675
      Tightening Procedure...11675
    ALTERNATOR BELT...11676
      Belt Adjustment...11676
      Belt Replacement...11676
    AIR CONDITIONING BELT...11677
      Belt Adjustment...11677
      Belt Replacement...11677
    DRIVE BELT...11678
      Belt Adjustment...11678
      Belt Replacement...11680
    LUBRICATING THE LOADER...11681
      Lubrication Locations...11681
    TRACK ROLLER AND IDLER LUBRICATION...11682
      Procedure...11682
    PIVOT PINS...11682
      Inspection And Maintenance...11682
    BOB-TACH (HAND LEVER)...11683
      Inspection And Maintenance...11683
    BOB-TACH (POWER)...11684
      Inspection And Maintenance...11684
    LOADER STORAGE AND RETURN TO SERVICE...11685
      Storage...11685
      Return To Service...11685
  SYSTEM SETUP & ANALYSIS...11686
    DIAGNOSTIC SERVICE CODES...11688
      Viewing Service Codes...11688
      Service Codes List...11689
    CONTROL PANEL SETUP...11694
      Right Panel Setup (Deluxe Instrumentation Panel)...11694
      Attachment Control Information (Deluxe Instrumentation Panel)...11695
    PASSWORD SETUP (KEYLESS START PANEL)...11696
      Password Description...11696
      Changing The Owner Password...11696
      Password Lockout Feature...11696
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...11697
      Password Description...11697
      Changing The Owner Password...11697
      Changing The User Passwords...11698
      Password Lockout Feature...11698
    MAINTENANCE CLOCK...11699
      Description...11699
      Setup...11699
      Reset...11699
  MACHINE SIGN TRANSLATIONS...11700
    MACHINE SIGN TRANSLATIONS...11702
      Service Schedule (6734534)...11702
      Warning (6728540)...11705
      Warning (6718396)...11706
      Danger (6809511)...11706
      Warning (6718397)...11706
      Warning (6737189)...11707
      Warning (6725370)...11707
      Warning (6737248)...11707
      Lift Arm Support Device (6706558)...11708
      Warning (7131520)...11709
      Important (6560573)...11710
      Warning (7131521)...11711
      Warning (7160879)...11712
      Warning (6577754)...11713
      Danger (6718392)...11714
      Danger (6718393)...11714
      Warning (6718391)...11714
      Danger (6717343)...11714
      Warning (7168019)...11715
      Warning (7142141)...11716
  SPECIFICATIONS...11718
    (T180) LOADER SPECIFICATIONS...11720
      Machine Dimensions...11720
      Performance...11721
      Engine...11721
      Drive System...11721
      Controls...11722
      Hydraulic System...11722
      Electrical...11723
      Capacities...11723
      Tracks...11723
      Ground Pressure...11723
  WARRANTY...11724
    WARRANTY...11726
  ALPHABETICAL INDEX...11728