t180 6902502 SM 7-09

Service
Manual
Dealer Copy -- Not for Resale

(S/N 524211001 & Above)
(S/N 524311001 & Above)
(S/N 527511001 & Above)
(S/N 527611001 & Above)
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6902502 (7-09) Printed in U.S.A. ©Bobcat Company 2009
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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
P-90216 B-15659 B-15660

Never service the Bobcat Compact Use the correct procedure to lift or Cleaning and maintenance are
Track Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG

B-15664 B-15661 B-15662
Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted parts. hydraulic tubeline, hose, fitting, arms up unless lift arms are held
Wear dust mask when grinding component or a part failure can by an approved lift arm support
painted parts. Toxic dust and gas cause lift arms to drop. Do not go device. Replace if damaged.
can be produced. under lift arms when raised Never modify equipment or add
Avoid exhaust fume leaks which unless supported by an attachments not approved by
can kill without warning. Exhaust approved lift arm support device. Bobcat Company.
system must be tightly sealed. Replace it if damaged.
WRONG WRONG WRONG
B-15665 B-15663 B-6589
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW09-0409
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ALPHABETICAL INDEX
ADVANCED CONTROL SYSTEM (ACS) .............. 60-01 FAN GEARBOX .......................................................10-01

AIR CLEANER ........................................................70-01 FLYWHEEL AND HOUSING ...................................70-01
AIR CLEANER SERVICE .......................................10-01 FLYWHEEL RPM SENSOR ....................................60-01
AIR CONDITIONING SERVICE.............................. 80-01 FRONT AUXILIARY HYDRAULIC
AIR CONDITIONING SYSTEM FLOW ................... 80-01 COUPLER BLOCK ...............................................20-01
ALTERNATOR ........................................................ 60-01 FUEL SYSTEM........................................................10-01
FUEL TANK .............................................................50-01
BASIC TROUBLESHOOTING ................................ 80-01
BATTERY................................................................ 60-01 GENERAL AIR CONDITIONING
BICS SYSTEM ........................................................ 60-01 SERVICE GUIDELINES ........................................80-01
BOBCAT CONTROLLER ....................................... 60-01
BOB-TACH................................................... 10-01, 50-01 HEATER COIL .........................................................80-01
BRAKE .................................................................... 40-01 HEATER/AC FAN ...................................................80-01
BUCKET POSITION VALVE.................................. 20-01 HEATER VALVE ......................................................80-01
HIGH FLOW VALVE ................................................20-01
CHARGE PRESSURE ........................................... 30-01 HYDRAULIC CONNECTION SPECS ............... SPEC-01
COMPONENTS ..................................................... 80-01 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
COMPRESSOR ...................................................... 80-01 (ADVANCEDCONTROL SYSTEM) (ACS) ...........20-01
CONDENSER ......................................................... 80-01 HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
CONTROL HANDLE ............................................... 50-01 (FOOT CONTROL)...............................................20-01
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
(ACS) SELECTABLE HAND/FOOT CONTROL... 50-01 (FOOT CONTROL)...............................................20-01

CONTROL PANEL .................................................. 50-01 HYDRAULIC CONTROL VALVE (1 PIECE CASTING)
CONTROL PEDALS ............................................... 50-01 (ADVANCEDCONTROL SYSTEM) (ACS) ...........20-01
CONTROL PEDALS (ACS) .................................... 50-01 HYDRAULIC CONTROL VALVE
CONVERSIONS ................................................SPEC-01 (FOOT CONTROL)................................................20-01
COOLING FAN ...................................................... 70-01 HYDRAULIC FILTER HOUSING .............................20-01
CYLINDER (LIFT) ................................................... 20-01 HYDRAULIC FLUID RESERVOIR ..........................20-01
CYLINDER (POWER BOB-TACH).......................... 20-01 HYDRAULIC/HYDROSTATIC
CYLINDER (TILT) ................................................... 20-01 FLUID SPECIFICATIONS................................ SPEC-01
HYDRAULIC/HYDROSTATIC SYSTEM..................10-01
DIAGNOSTICS SERVICE CODES......................... 60-01 HYDRAULIC SYSTEM INFORMATION ..................20-01
DRIVE BELT ........................................................... 30-01 HYDRAULIC PUMP ................................................20-01
DRIVE COMPONENTS .......................................... 40-01 HYDRAULIC PUMP (HIGH FLOW).........................20-01
HYDROSTATIC MOTOR .........................................30-01
ELECTRICAL/HYD. CONTROLS REFERENCE .... 60-01 HYDROSTATIC PUMP ............................................30-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01 HYDROSTATIC SYSTEM INFORMATION..............30-01
ENGINE .................................................................. 70-01
ENGINE COMPONENTS AND TESTING .............. 70-01 INSTRUMENT PANEL ............................................60-01
ENGINE COOLING SYSTEM ................................. 10-01
ENGINE LUBRICATION SYSTEM ......................... 10-01 LIFT ARMS ..............................................................50-01
ENGINE SPECIFICATIONS - LIFT ARM BYPASS CONTROL VALVE ..................20-01
KUBOTA V2003-M-DI-T................................. SPEC-01 LIFT ARM SUPPORT DEVICE................................10-01
ENGINE SPECIFICATIONS - LIFTING AND BLOCKING THE LOADER...............10-01
KUBOTA V2403-M-DI-T..................................SPEC-01 LIGHTS....................................................................60-01
ENGINE SPEED CONTROL .................................. 70-01 LOADER SPECIFICATIONS ............................. SPEC-01
EVAPORATOR........................................................ 80-01 LUBRICATION OF THE BOBCAT LOADER ...........10-01
EVAPORATOR/HEATER UNIT ............................... 80-01
MAIN RELIEF VALVE ..............................................20-01
MUFFLER................................................................70-01
OIL COOLER...........................................................30-01
OPERATOR CAB .........................................10-01, 50-01
OPERATOR SEAT...................................................50-01
Continued On Next Page
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ALPHABETICAL INDEX (CONT’D)
POWER BOB-TACH ................................................10-01

POWER BOB-TACH BLOCK...............................20-01
PRESSURE RELIEF VALVE ...............................80-01
PRESSURE SWITCH..........................................80-01
RADIATOR...............................................................70-01
REAR AUXILIARY DIVERTER VALVE ....................20-01
REAR DOOR ..........................................................50-01
REAR GRILL ..........................................................50-01
RECEIVER/DRIER ..................................................80-01
RECONDITIONING THE ENGINE ..........................70-01
REGULAR MAINTENANCE ....................................80-01
REMOTE START .....................................................10-01
RPM SENSOR.........................................................70-01
SAFETY.................................................................. 80-01
SEAT BAR............................................................... 50-01
SEAT BAR SENSOR............................................... 60-01
SELECT VALVE ......................................................20-01
SERVICE SCHEDULE.............................................10-01
SPARK ARRESTOR MUFFLER ..............................10-01
STARTER ................................................................60-01

SYSTEM CHARGING AND RECLAMATION ..........80-01
SYSTEM TROUBLESHOOTING CHART ...............80-01
TEMPERATURE/PRESSURE .................................80-01
THERMOSTAT.........................................................80-01
TORQUE SPECIFICATIONS FOR BOLTS........ SPEC-01
TOWING THE LOADER ..........................................10-01
TRACTION LOCK....................................................60-01
TRANSPORTING THE LOADER ............................10-01
TROUBLESHOOTING.............................................70-01
TURBOCHARGER ..................................................70-01
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SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

SYSTEM
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX HYDROSTATIC

SYSTEM
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI DRIVE

SYSTEM
SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

MAIN FRAME
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL
SYSTEM &
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ANALYSIS
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 SERVICE
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 HVAC
SPECIFICATIONS
SPECIFICATIONS
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FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including side screens) is in function correctly.
good condition and is not
modified.
2. Check that ROPS mounting 10. Enclosure door latches must

hardware is tightened and is open and close freely.
Bobcat approved.
3. The seat belt must be 11. Bob-Tach wedges and

correctly installed, functional linkages must function
and in good condition. correctly and be in good

condition.
4. The seat bar must be 12. Safety treads must be in good

correctly adjusted, clean and condition.
lubricated.
5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps.
6. Machine signs (decals) must 14. Check hydraulic fluid level,

be legible and in the correct engine oil level and fuel
location. supply.
7. Steering levers, hand controls 15. Inspect for fuel, oil or

and foot pedals must return to hydraulic fluid leaks.
neutral (as applicable).
8. Check for correct function of 16. Lubricate the loader.

the work lights.
FW SSL-1008 SM
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17. Check the condition of the 23. Operate the machine and
battery and cables. check all functions.
18. Inspect the air cleaner for 24. Check for correct function of
damage or leaks. Check the the Bobcat Interlock Control
condition of the element. System (BICS™) before the
machine is returned to the
customer.
19. Check the electrical charging 25. Check for proper function of
system. front horn and back-up alarm
(if equipped).
20. Check tires for wear and 26. Check function or condition of
pressure. Check tracks for all equipped options and
wear and tension. Use only accessories (examples: fire

approved tires or tracks. extinguisher, rotating beacon,
lift kits, etc.).
21. Inspect for loose or broken 27. Recommend to the owner
parts or connections. that all necessary corrections
be made before the machine
is returned to service.
22. Check for any field

modification not completed.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects and other
reproductive harm.
FW SSL-1008 SM
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III Service Manual
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T180 Bobcat Loader

IV Service Manual
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SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions • An Operator’s Handbook fastened to the operator
can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903

operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
IMPORTANT
• The AEM Safety Manual delivered with the machine
This notice identifies procedures which must be gives general safety information.
followed to avoid damage to the machine.
I-2019-0284 • The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shop-
type service and repair work.
• The Skid-Steer Loader Operator Training Course is
DANGER available through your local dealer or at

www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
The signal word DANGER on the machine and in the of correct operation of the Skid-Steer Loader. The
manuals indicates a hazardous situation which, if not course is available in English and Spanish versions.
avoided, will result in death or serious injury.
D-1002-1107 • Service Safety Training Courses are available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com. They provide information for
safe and correct service procedures.
WARNING • The Skid-Steer Loader Safety Video is available from

your Bobcat dealer or at www.training.bobcat.com
The signal word WARNING on the machine and in the or www.bobcat.com.
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
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SAFETY INSTRUCTIONS (CONT’D)
The dealer and owner / operator review the

recommended uses of the product when delivered. If the
owner / operator will be using the machine for a different
application(s) he or she must ask the dealer for
recommendations on the new use.
Cutting or drilling concrete containing sand or rock

containing quartz may result in exposure to silica dust.
Do not exceed Permissible Exposure Limits (PEL) to
silica dust as determined by OSHA or other job site Rules
and Regulations. Use a respirator, water spray or other
means to control dust. Silica dust can cause lung disease
and is known to the state of California to cause cancer.
Call Before You Dig

Dial 811 (USA Only)

1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in your
state / province, or city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.).
SI SSL-1008 SM
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FIRE PREVENTION Hydraulic System
Check hydraulic tubes, hoses and fittings for damage

and leakage. Never use open flame or bare skin to check
for leaks. Hydraulic tubes and hoses must be properly
routed and have adequate support and secure clamps.
Tighten or replace any parts that show leakage.
Maintenance Always clean fluid spills. Do not use gasoline or diesel

fuel for cleaning parts. Use commercial nonflammable
The machine and some attachments have components
solvents.
that are at high temperatures under normal operating
conditions. The primary source of high temperatures is
Fueling
the engine and exhaust system. The electrical system, if
damaged or incorrectly maintained, can be a source of
arcs or sparks.
Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard. Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
The operator’s area, engine compartment and engine sparks. Fill the fuel tank outdoors.

cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Starting
All fuels, most lubricants and some coolants mixtures are Do not use ether or starting fluids on any engine that has
flammable. Flammable fluids that are leaking or spilled glow plugs or air intake heater. These starting aids can
onto hot surfaces or onto electrical components can cause explosion and injure you or bystanders.
cause a fire.
Use the procedure in the Operation & Maintenance
Operation Manual for connecting the battery and for jump starting.
Do not use the machine where exhaust, arcs, sparks or

hot components can contact flammable material, Spark Arrestor Exhaust System
explosive dust or gases. The spark arrestor exhaust system is designed to control
the emission of hot particles from the engine and exhaust
Electrical system, but the muffler and the exhaust gases are still
hot.
Check the spark arrestor exhaust system regularly to

make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
cleaning the spark arrestor muffler (if equipped).
Check all electrical wiring and connections for damage.
Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed.
Battery gas can explode and cause serious injury. Use

the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
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T180 Bobcat Loader

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FIRE PREVENTION (CONT’D)
Welding And Grinding
Always clean the machine and attachment, disconnect

the battery, and disconnect the wiring from the Bobcat
controllers before welding. Cover rubber hoses, battery
and all other flammable parts. Keep a fire extinguisher
near the machine when welding.
Have good ventilation when grinding or welding painted

parts. Wear dust mask when grinding painted parts.
Toxic dust or gas can be produced.
Dust generated from repairing nonmetallic parts such as

hoods, fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away
from open flames or sparks.
Fire Extinguishers

Know where fire extinguishers and first aid kits are
located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.
SI SSL-1008 SM
T180 Bobcat Loader
VIII Service Manual
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SERIAL NUMBER LOCATION Engine Serial Number
Always use the serial number of the loader when Figure 2

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Loader Serial Number
Figure 1
P-48002
The engine serial number is in the location shown

[Figure 2].

P-45263
The loader serial number plate is located on the outside

of the loader frame [Figure 1].
Explanation of loader Serial Number:
XXXX XXXXX
Model 1.-Model/ Engine Model 2.-Production
Combination Sequence (Series)
1. The four digit Model/Engine Combination Module

number identifies the model number and engine
combination.
2. The five digit Production Sequence Number identifies

the order which the loader is produced.
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DELIVERY REPORT
Figure 3
B-16315
The Delivery Report must be filled out by the dealer and

signed by the owner or operator when the Bobcat loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [Figure

3].
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LOADER IDENTIFICATION
SEAT BAR FRONT

LIGHTS
OPERATOR SEAT
with SEAT BELT
GRAB
HANDLES
STEERING
LEVERS
TILT
CYLINDERS
FRONT AUXILIARY
QUICK COUPLERS

BUCKET
STEPS STEPS WITH
SAFETY TREAD
B-19882A
† BUCKET
◆ REAR WINDOW ● OPERATOR CAB

(ROPS / FOPS)
◆ REAR AUXILIARY LIFT ARM

QUICK COUPLERS SUPPORT DEVICE
LIFT ARM
REAR
GRILL LIFT
CYLINDER
REAR
DOOR
◆ REAR
LIGHT
◆ TAIL
LIGHT ❒ TRACKS B-19883
◆ OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)

❒ TRACKS - Optional tracks are available.
† Bucket - Several different buckets and other attachments are available for this machine.
● ROPS, FOPS - Roll Over Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective Structure
per ISO 3449, Level I. Level II is available. Extra insulated cab is available as an option (Reduced noise level).
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SAFETY &
SAFETY & MAINTENANCE MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-140-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
Replacing the Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 10-110-1

Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2
FAN GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Checking And Maintaining . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . 10-100-2
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . 10-120-1

Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-4
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Replacing Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . . 10-120-1
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Installing Lift Arm Support Device . . . . . . . . . . . . . . . . . . . 10-20-1
Removing The Lift Arm Support Device. . . . . . . . . . . . . . . 10-20-2
LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
LUBRICATION OF THE BOBCAT LOADER. . . . . . . . . . . . . 10-150-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
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SAFETY & MAINTENANCE (CONT’D)
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Cab Door Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
POWER BOB-TACH (OPTION) . . . . . . . . . . . . . . . . . . . . . . 10-141-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-141-1
REMOTE START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . 10-40-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD

TORQUE SPECIFICATIONS FOR BOLTS, SPEC SECTION) UNLESS
OTHERWISE SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD

ITEMS MAY VARY.
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LIFTING AND BLOCKING THE LOADER Figure 10-10-2
WARNING
AVOID INJURY OR DEATH
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions
P-31849A
can cause injury or death.
W-2003-0807
Always park the loader on a level surface.

Figure 10-10-1
Put floor jack under the rear of the loader [Figure 10-10-
2].
Lift the rear of the loader and install jackstands [Figure

10-10-2].
Figure 10-10-3
B-7023A
Procedure
WARNING P-24646
Put jackstands under the front axles and rear corners

Put the floor jack under the front of the loader [Figure 10-
of the frame before running the engine for service.
10-3].
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
Lift the front of the loader and put jackstands under the
W-2017-0286
axle tubes [Figure 10-10-3].
NOTE: Make sure the jackstands do not touch the

tracks. Make sure tracks clear the floor or any
obstacles.
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LIFT ARM SUPPORT DEVICE
Installing Lift Arm Support Device

DANGER
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
P-90328
to fall and cause injury or death.
W-2059-0598 AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
WARNING • Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
Repair the support device if damaged or if parts are D-1009-0409
missing. Using a damaged support device or with
missing parts can cause lift arms or boom to fall Figure 10-20-2

causing serious injury or death.
W-2271-1007
Figure 10-20-1
P-45252
1
Lower the lift arm support device on top of the lift cylinder.
P-45251
Hook the free end of the spring (Item 1) [Figure 10-20-2]
to the lift arm support device so there will be no
interference with the support device engagement.
Disconnect the spring from the lift arm support device
retaining pin (Item 1). Support the lift arm support device With the operator in the seat, seat belt fastened and seat
(Item 2) with your hand and remove the retaining pin bar lowered, start the engine.
[Figure 10-20-1].
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LIFT ARM SUPPORT DEVICE (CONT'D) Removing The Lift Arm Support Device
Installing Lift Arm Support Device (Cont’d) Figure 10-20-4
Figure 10-20-3
P-45486
1
N-20524
Remove the pin from the lift arm support device.
Raise the lift arms, until the lift arm support device drops Connect the spring (Item 1) [Figure 10-20-4] from the lift
onto the lift cylinder rod [Figure 10-20-3]. arm support device to the bracket below the lift arms.

Lower the lift arms slowly until the support device is held With the operator in the seat, seat belt fastened and seat
between the lift arm and the lift cylinder. Stop the engine. bar lowered, start the engine.
Raise the seat bar and move pedals until both pedals
lock. Raise the lift arms a small amount and the spring will lift
the support device off the lift cylinder rod. Lower the lift
Install pin (Item 1) [Figure 10-20-3] into the rear of the lift arms. Stop the engine.
arm support device below the cylinder rod.
Raise the seat bar and move pedals until both pedals
lock.
Disconnect the spring from the bracket.
Figure 10-20-5
1
2
P-45251
Raise the support device into storage position and insert

pin (Item 1) through lift arm support device (Item 2) and
bracket [Figure 10-20-5]. Connect spring to pin.
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OPERATOR CAB Figure 10-30-1
Description
The Bobcat loader has an operator cab (ROPS and

FOPS) as standard equipment to protect the operator
from rollover and falling objects. Check with your dealer if
the operator cab has been damaged. The seat belt must
be worn for roll over protection.
ROPS/FOPS - Roll Over Protective Structure per SAE

J1040 and ISO 3471, and Falling Object Protective
Structure per SAE J1043 and ISO 3449, Level I. Level II
is available.
Level I - Protection from falling bricks, small concrete P-31849A

blocks, and hand tools encountered in operations such
as highway maintenance, landscaping, and other
construction site services. Always stop the engine before raising or lowering the
cab.
Level II - Protection from falling trees, rocks; for
machines involved in site clearing, overhead demolition Stop the loader on a level surface. Lower the lift arms. If
or forestry. the lift arms must be up while raising the operator cab,
install the lift arm support device. (See Installing Lift Arm

Raising The Operator Cab Support Device on Page 10-20-1.)
Install jackstands under the rear of the loader frame

[Figure 10-30-1].
WARNING Figure 10-30-2
UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT

MOVEMENT CAUSED BY CAB CONTACT WITH
CONTROLS CAN CAUSE SERIOUS
INJURY OR DEATH
• STOP ENGINE before raising or lowering cab.
W-2758-0908
WARNING
Never modify operator cab by welding, grinding,
P10564 P10563
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from Loosen the nut (both sides) at the front corners of the
rollover and falling objects, and result in injury or operator cab [Figure 10-30-2].
death.
W-2069-0200 Remove the nuts and plates [Figure 10-30-2] (both
sides).
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OPERATOR CAB (CONT'D)
Raising The Operator Cab (Cont’d)

DANGER
Figure 10-30-3
P-90328
AVOID DEATH
• Keep out of this area when lift arms are raised
P-45261
D-1009-0409
Lift on the grab handle and bottom of the operator cab
slowly until the cab is all the way up and the latching
Figure 10-30-5

mechanism engages [Figure 10-30-3].
Lowering The Operator Cab
Figure 10-30-4
P-24482
P10564 P10563
Install the plates and nuts [Figure 10-30-5] (both sides).
P-45262 Tighten the nuts to 40 - 50 ft.-lb. (54 - 68 N•m) torque.
Always stop the engine before raising or lowering the

cab.
NOTE: Make sure the seat bar is fully raised or

lowered when lowering the cab. Always use
the grab handles to lower the cab.
Pull down on the bottom of the operator cab until it stops

at the latching mechanism [Figure 10-30-4].
Release the latching mechanism (Inset) [Figure 10-30-4]

and pull the cab all the way down.
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OPERATOR CAB (CONT'D)
Cab Door Sensor
Figure 10-30-6
1 2
P-31202 P-34171
The cab door (option) has a sensor (Item 1) [Figure 10-

30-6] which deactivates the lift and tilt valves when the
door is open.

A decal (Item 2) [Figure 10-30-6] on the door handle
indicates if door is equipped with the sensor.
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OPERATOR CAB (CONT'D) Figure 10-30-9
Emergency Exit
Figure 10-30-7
N-20171
Front Door (If Equipped)

N-19385
NOTE: When an Operator Cab Enclosure Kit is
installed, the window of the front door can be
The front opening on the operator cab and rear window used as an emergency exit. [Figure 10-30-9]
provide exits.

NOTE: If the loader has a Special Application Door
Rear Window (If Equipped) Kit installed, the window of the front door is
NOT an emergency exit.
Pull on the tag on the top of the rear window to remove
the rubber cord [Figure 10-30-7]. Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [Figure 10-30-9].
Figure 10-30-8
Figure 10-30-10
P-45260
P-24472
Push the rear window out of the rear of the operator cab.
Push the window out with your foot [Figure 10-30-10] at
Exit through the rear of the operator cab [Figure 10-30- any corner of the window.
8].
Exit through the front door.
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TRANSPORTING THE BOBCAT LOADER Figure 10-40-2
Procedure
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are P-45989 P-24785
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0807
Figure 10-40-1

P-45217
6718401
1 Use the following procedure to fasten the Bobcat loader

P-45216
to the transport vehicle to prevent the loader from moving
during sudden stops or when going up or down slopes
Be sure the transport and towing vehicles are of [Figure 10-40-2].
adequate size and capacity (See Performance on Page
SPEC-10-2 for weight of loader.). • Lower the bucket or attachment to the floor.
A loader with an empty bucket or no attachment must be • Stop the engine.

loaded backward onto the transport vehicle [Figure 10-
40-1]. • Engage the parking brake.
The rear of the trailer must be blocked or supported (Item • Install chains at the front and rear loader tie down
1) [Figure 10-40-1] when loading or unloading the loader positions (Inset) [Figure 10-40-2].
to prevent the front end of the trailer from raising up.
• Fasten each end of the chain to the transport vehicle.
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TOWING THE LOADER
Procedure
Because of the design of the loader, there is not a

recommended towing procedure.
• The loader can be lifted onto a transport vehicle.
• The loader can be skidded a short distance to move

for service (EXAMPLE: Move onto a transport
vehicle.) without damage to the hydrostatic system.
(The tires/tracks will not turn.) There might be slight
wear to the tires/tracks when the loader is skidded.
The towing chain (or cable) must be rated at 1 & 1/2

times the weight of the loader (See Performance on
Page SPEC-10-2.).
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REMOTE START Figure 10-60-2
Procedure
WARNING
With the 7-pin connector plugged into the loader and 1
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the P-24651
service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899 Figure 10-60-3
Figure 10-60-1

1
1
P-24653
P16115 Lift and block the loader. (See Procedure on Page 10-10-
1.)
The tool listed will be need to do the following procedure: Raise the lift arms (if required by the procedure) and
install an approved lift arm support device. (See Installing
MEL1563 - Remote Start Tool Kit Lift Arm Support Device on Page 10-20-1.)
The remote start (Item 1) [Figure 10-60-1] is required Raise the operator cab (if required by the procedure).
when the operator cab is in the raised position for service (See Raising The Operator Cab on Page 10-30-1.)
and the service technician needs to turn the key switch
on or start the engine. Example: Control Handle: linkage Open the rear door of the loader.
neutral adjustment.
Remove the plug (Item 1) [Figure 10-60-2] or disconnect
the attachment control harness (Item 1) [Figure 10-60-3]
if connected.
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REMOTE START (CONT'D)
Procedure (Cont'd)
WARNING
Figure 10-60-4
• Use traction lock override switch for service
work with seat bar raised.
• Traction lock is engaged when light is OFF.
• Lift and block the loader. Check that wheels are
clear.
• Traction lock is disengaged when light is ON.
• See Service Manual for more instruction.
W-2785-0209
1
Figure 10-60-6
P-24652
Connect the remote start tool to the engine harness

connector (Item 1) [Figure 10-60-4].

NOTE: The key switch on the right-hand side
operator panel must be in the off position or 2
the Remote Start Kit will not operate. 3 1
Figure 10-60-5
P16118
The traction lock switch (Item 1) [Figure 10-60-6] is used

to turn traction lock on or off. Push the switch to the
override position. The switch will illuminate to indicate
1 traction lock OVERRIDE, in this position the wheels are
able to turn.
The maximum flow/variable flow switch (Item 2) [Figure

10-60-6] is used to activate the auxiliary hydraulics.
Pressing the switch once will activate variable flow.
Pressing the switch again will activate maximum flow.
P16116
The switch will illuminate to indicate which flow rate is
active. Pressing the switch a third time will turn the flow
OFF. The switch is used when checking pressures and
The remote start tool (Item 1) [Figure 10-60-5] has three flow rate.
rocker switches.
The auxiliary pressure release (Item 3) [Figure 10-60-6]
is used to release hydraulic pressure to the rear auxiliary
couplers. To release pressure; push and hold the switch
for three seconds.
NOTE: With the engine running; pushing and holding

the pressure release switch will cause the
engine to stop in three seconds. To relieve the
pressure; continue to press the switch after
the engine has stopped.
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REMOTE START (CONT'D)
Procedure (Cont'd)
Figure 10-60-7
P-34661
Push the couplers on the front auxiliary block toward the

block and hold for five seconds to release the front

auxiliary pressure [Figure 10-60-7].
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SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader
Instructions are necessary before operating or servicing machine. Read and

understand the Operation & Maintenance Manual, Operator’s Handbook and signs
WARNING (decals) on machine. Follow warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
SERVICE SCHEDULE HOURS
■ ■ ■
ITEM SERVICE REQUIRED
8-10 50 100 250 500 1000
Engine Oil Check the oil level and add oil as needed.
Engine Air Filter and Air Check display panel. Service only when required. Check for leaks and
System damaged components.
Engine Cooling System Clean debris from oil cooler, radiator and grill. Check coolant level in recovery
tank. Add coolant as needed.
Seat Belt, Seat Bar and Check the condition of seat belt. Check the seat bar and control interlocks.
Control Interlocks Clean dirt and debris from moving parts.
Safety Signs and Safety Tread Check for damaged signs (decals) and safety treads. Replace any signs or

safety treads that are damaged or worn.
Indicators & Lights (Opt.) Check for correct operation of all indicators & lights.
Operator Cab Check the fastening bolts, washers & nuts. Check the condition of cab.
Lift Arms, Cylinders, Bob-Tach Lubricate with multi-purpose lithium based grease.
Pivot Pins and Wedges
Fuel Filter Remove the trapped water.
Bobcat Interlock Control Check that four BICS indicator lights and functions are activated. See details in
System (BICS) this Operation & Maintenance Manual.
Heater and A/C Filters Clean or replace filters as needed during heating/cooling season.
Tracks Check for damaged or worn tracks and correct tension. ‡
Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and leaks. Repair or
Tubelines replace as needed.
Foot Pedals or Hand Controls, Check for correct operation. Repair or adjust as needed.
and Steering Levers
Parking Brake Check operation.
Track Sprocket Bolts Check torque. Tighten as needed. See procedure in this manual. ◆
Spark Arrestor Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Steering Shaft Grease two fittings.
Engine/Hydros. Drive Belt Check for wear or damage. Adjust as needed. •
Fan Drive Gearbox Check gear lube level. Add as needed.
Alternator Belt & Air Check belt tension and adjust as needed.
Conditioner Belt (If Equipped)
Engine Oil and Filter Replace oil and filter. Use CD or better grade oil and Bobcat filter. †
Fuel Filter Replace the filter element.
Bobcat Interlock Control Check the function of the lift arm bypass control.
System (BICS)
Hydraulic Reservoir Breather Replace the reservoir breather cap.
Cap
Hydraulic/Hydrostatic Filter Replace the filter element. •
Hydraulic Reservoir Replace the fluid.
Case Drain Filters Replace the filters. ■
Hydrostatic Motor Carrier Replace Oil with High Performance Synthetic Oil P/N 6682546.
■ Or every 12 months.
† First oil and filter change must occur at 50 hours; 250 hours thereafter.
* Inspect the new belt after first 50 hours.
• Replace filter element after the first 50 hours and when the transmission warning light comes ON.
‡ Check every 8-10 hours for the first 50 hours. Then at 50 hour intervals.
◆ Check after the first 50 hours of operation only.
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AIR CLEANER SERVICE Figure 10-80-3
Replacing Filter Element
Figure 10-80-1
P-31836
Outer Filter
B-15552B
B-15553B
Remove the wing nut and remove the dust cover [Figure
10-80-3].
It is important to change the air filter element only when
the Air Cleaner Icon in the right panel is ON (Item 1) Figure 10-80-4

[Figure 10-80-1] and you hear three beeps from the
alarm.
Replace the inner filter every third time the outer filter is
replaced or as indicated.
Figure 10-80-2
1
2
P-31837
1
Remove the wing nut and remove the outer filter element
(Item 1) [Figure 10-80-4].
NOTE: Make sure all sealing surfaces are free of dirt

B-15551 and debris.
Install a new outer element.

Press and hold the LIGHT Button (Item 1) [Figure 10-80-
2] for two seconds. Install the dust cover and the wing nut [Figure 10-80-3]
(Be sure the evacuator is down).
If the filter element needs replacement, the CODE [01-
17] (Air Filter Plugged) will show in the HOURMETER / Check the air intake hose and the air cleaner housing for
CODE DISPLAY (Item 2) [Figure 10-80-2]. damage. Make sure all connections are tight.
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AIR CLEANER SERVICE (CONT'D) Figure 10-80-6
Replacing Filter Element (Cont'd)
Figure 10-80-5
P-31836
Install the dust cover and the wing nut [Figure 10-80-6]
P-31838 (Be sure the evacuator is down).
Inner Filter

Only replace the inner filter element under the following
conditions:
Replace the inner filter element every third time the outer
filter is replaced.
After the outer element has been replaced, start the

engine and run at full RPM. If the HOURMETER / CODE
DISPLAY shows [01-17] (Air Filter Plugged), replace
the inner filter element.
Remove the wing nut and remove the inner filter element
[Figure 10-80-5].
Install the new inner element.
Install the outer element.
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ENGINE COOLING SYSTEM
Cleaning The Cooling System

IMPORTANT
WARNING AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
AVOID INJURY OR DEATH Too much antifreeze reduces cooling system

Wear safety glasses to prevent eye injury when any efficiency and may cause serious premature engine
of the following conditions exist: damage.
• When fluids are under pressure.
• Flying debris or loose material is present. Too little antifreeze reduces the additives which
• Engine is running. protect the internal engine components; reduces the
• Tools are being used. boiling point and freeze protection of the system.
W-2019-0907
Always add a premixed solution. Adding full strength
concentrated coolant can cause serious premature
Figure 10-90-1
engine damage.
I-2124-0497
Figure 10-90-2

P-45101
Check the cooling system every day to prevent over-

heating, loss of performance or engine damage. P-45103
Open the rear door and remove the rear grill. (See
Removal And Installation on Page 50-60-1.) Raise the air conditioning condenser (If equipped) and
the oil cooler and clean the top of the radiator [Figure 10-
Use air pressure or water pressure to clean the top of the 90-2].
oil cooler [Figure 10-90-1].
Lower the oil cooler on the loader frame.
Check cooling system for leaks.
WARNING Replace the rear grill and close the rear door.

DO NOT operate the utility work machine with the
tow bolts installed. By-passing the parking brake can
cause machine roll away.
W-2460-0403
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ENGINE COOLING SYSTEM (CONT'D) Replacing the Coolant
Checking The Coolant Level
Figure 10-90-3 WARNING

MAX AVOID BURNS
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1203
MIN P-45106
Figure 10-90-4
P-45102
Open the rear door and remove the rear grill.

Check the coolant level [Figure 10-90-3]. The level
markers are on the outside of the tank. Coolant must be
between the bottom marker and the top marker when the
engine is cold.
P-45102
Replace the rear grill and close the rear door before
operating the loader. Open the rear door and remove the rear grill.
Remove the radiator cap (Item 1) [Figure 10-90-4].
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system

efficiency and may cause serious premature engine
damage.
Too little antifreeze reduces the additives which

protect the internal engine components; reduces the
boiling point and freeze protection of the system.
Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
engine damage.
I-2124-0497
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ENGINE COOLING SYSTEM (CONT'D)
Replacing the Coolant (Cont’d)
Figure 10-90-5
P-48075
Turn the valve (Item 1) [Figure 10-90-5] 90 degrees

and drain the coolant into a container.

Recycle or dispose of used coolant in an environmentally
safe manner. Close the drain valve and remove the hose.
NOTE: The loader is factory filled with propylene

glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.
Add premixed coolant, 47% water and 53% propylene

glycol to the recovery tank if the coolant level is low.
One gallon and one pint (4,3 L) of propylene glycol mixed

with one gallon (3,8 L) of water is the correct mixture of
coolant to provide a -34° F (-37° C) freeze protection.
Use a refractometer to check the condition of propylene

glycol in your cooling system.
Fill the radiator with the premixed coolant. Install the

radiator cap.
Remove the cover from the coolant recovery tank. Fill the
tank until it is at the lower marker (inside the tank).
Run the engine until it is at operating temperature.
Stop the engine.
Check the coolant level in the recovery tank when cool.
Add coolant as needed.
Replace the rear grill and close the rear door.
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FUEL SYSTEM Filling The Fuel Tank
Fuel Specifications
Figure 10-100-1
WARNING
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
1 WARNING
P-48074 Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
Use only clean, high quality diesel fuel, Grade No. 2 or
explosion or fire.
Grade No. 1. W-2103-0508

The following is one suggested blending guideline which
should prevent fuel gelling during cold temperatures: Open the rear door.
Remove the fuel fill cap (Item 1) [Figure 10-100-1].

Temp. F° (C°) No. 2 No. 1
+15° (9°) 100% 0% Figure 10-100-2
Down to -20° (-29°) 50% 50%
WRONG
Below -20° (-29°) 0% 100%
Contact your fuel supplier for local recommendations.
B-19883A
Use a clean, approved safety container to add fuel of the

correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING! [Figure 10-100-2].
Install and tighten the fuel fill cap (Item 1) [Figure 10-
100-1].
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FUEL SYSTEM (CONT’D) Figure 10-100-4
Fuel Filter
Figure 10-100-3 3
1
2
2
1
P-48076
Open the vent (Item 1) [Figure 10-100-4] on the fuel filter

P-48077
housing.
(See Removing Air From The Fuel System on Page 10- Squeeze the hand pump (priming bulb) (Item 2) [Figure
100-2.) for the service interval for removing water from, 10-100-4] until fuel flows from the vent with no air
or replacing the fuel filter. bubbles.

Removing Water Close the vent (Item 1) [Figure 10-100-4] on the fuel
filter housing.
Loosen the drain (Item 1) [Figure 10-100-3] at the
bottom of the filter element to remove water from the Open the vent (Item 3) [Figure 10-100-4] on the fuel
filter. injection pump.
Replacing Element Squeeze the hand pump (priming bulb) (Item 2) [Figure
10-100-4] until the pump feels solid.
Remove the filter element (Item 2) [Figure 10-100-3].
Tighten the vent plug (Item 3) [Figure 10-100-4].
Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter, and Start the engine.
hand tighten.
It may be necessary to open the vent plug (Item 3)
Remove the air from the fuel system. (See Removing Air [Figure 10-100-4] briefly while the engine is running.
From The Fuel System on Page 10-100-2.) Close the vent when the engine runs smoothly.
Removing Air From The Fuel System
After replacing the filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel
system before starting the engine.
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
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ENGINE LUBRICATION SYSTEM Oil Chart
Checking Engine Oil
Check the engine oil level every day before starting the
engine for the work shift.
Figure 10-110-1
P-48079

Park the loader on level ground.
Open the rear door and remove the dipstick (Item 1)

[Figure 10-110-1].
Keep the oil level between the marks on the dipstick. DO

NOT OVERFILL.
Use a good quality motor oil that meets API Service

Classification of CD or better. (See Oil Chart on Page 10-
110-1.)
Install the dipstick and close the rear door.
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ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-110-3
Replacing Oil And Filter
(See SERVICE SCHEDULE on Page 10-70-1.) for the

service interval for replacing the engine oil and filter. 1
Run the engine until it is at operating temperature. Park

the loader on level ground and stop the engine.
Open the rear door.
Figure 10-110-2
P-1575
3
Put oil in the engine. (See Capacities on Page SPEC-10-
5 for capacity.) [Figure 10-110-3] (See Oil Chart on Page
10-110-1.)
2
Start the engine and let it run for several minutes.

Stop the engine and check for leaks at the oil filter.
1 Remove the dipstick and check the oil level.

P-48078
Add oil until it reaches the top mark (Item 1) [Figure 10-
110-3] on the dipstick. DO NOT OVERFILL.
Remove the drain plug (Item 1) [Figure 10-110-2].
Install the dipstick and the fill plug.
Drain the oil into a container and dispose of used oil in an
environmentally safe manner. Close the rear door.
Remove the oil filter (Item 2) [Figure 10-110-2].
Clean the filter housing surface.
Put clean oil on the new oil filter gasket.
Install the filter and hand tighten.
Install and tighten the drain plug.
Remove the fill cap (Item 3) [Figure 10-110-2].
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
explosion or fire.
W-2103-0508
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HYDRAULIC/HYDROSTATIC SYSTEM Replacing Hydraulic/Hydrostatic Filter
Checking And Adding Fluid (See SERVICE SCHEDULE on Page 10-70-1.) for the
correct service intervals.
Figure 10-120-1
Open the rear door.
Figure 10-120-3
1
P-24478A P-45228A
Use only recommended fluid in the hydraulic system.

P-45244
(See Specifications on Page SPEC-50-1.)

Stop the loader on a level surface, Remove the filter element (Item 1) [Figure 10-120-3]
Lower the lift arms and tilt the Bob-Tach fully back. Clean the surface of the filter housing where the seal
contacts the housing.
Stop the engine.
Put clean oil on the seal of the new filter element.
Check the fluid level in the sight gauge [Figure 10-120-1]
Install and hand tighten the filter element.
on the left side of the loader, above the track.
Close the rear door before operating the loader.
Figure 10-120-2
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
1
physician familiar with this injury is not received
immediately.
W-2145-0290
P-45245
WARNING
Open the rear door and remove the rear grill.
Remove the fill cap (Item 1) [Figure 10-120-2] Always clean up spilled fuel or oil. Keep heat, flames,
Add the fluid as needed to bring the level to the center of Failure to use care around combustibles can cause
the sight gauge [Figure 10-120-1]and install the fill cap. explosion or fire.
W-2103-0508
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HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D) Figure 10-120-5
Replacing Hydraulic Fluid

1
Figure 10-120-4
P-24751
Raise the operator cab. (See Raising The Operator Cab

P-45245 on Page 10-30-1.)
Remove plug (Item 1) [Figure 10-120-5] from hydraulic

(See SERVICE SCHEDULE on Page 10-70-1.) for the reservoir and pump the hydraulic fluid into a container.
service interval.

Figure 10-120-6
The fluid must be replaced if it becomes contaminated or
after major repairs. If the fluid is replaced, the hydrostatic RIGHT CASE
DRAIN FILTER
filter and both case drain filters must be replaced.
Remove the rear grill. [Figure 10-120-4]
Remove the reservoir fill cap (Item 1) [Figure 10-120-4] 2
P-24683 P-48429
Disconnect the hoses (Item 1) [Figure 10-120-6] from

the case drain filter located under the control valve. Cap
and plug the hoses and case drain filter to prevent
leakage.
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HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D) Figure 10-120-8
Replacing Hydraulic Fluid (Cont’d)
Figure 10-120-7
LEFT CASE
DRAIN FILTER 2
1
P-64316
The hydrostatic charge pressure filter shown [Figure 10-

P-24734 120-8] is located behind the control panel and in front of
the fuel tank.
Disconnect the hose (Item 1) [Figure 10-120-7] from the Remove and replace the hydrostatic charge pressure
case drain filter located on the reservoir. Cap and plug filter (Item 1) [Figure 10-120-8].

the hose and case drain filter to prevent leakage.
Remove the case drain filters (Item 2) [Figure 10-120-6]

& [Figure 10-120-7] and drain the fluid into a container.
Replace the hydraulic/hydrostatic filter. (See Replacing

Hydraulic/Hydrostatic Filter on Page 10-120-1.)
Replace both hydrostatic motor case drain filters (Item 2)

[Figure 10-120-6] & [Figure 10-120-7].
When the fluid is removed from the reservoir, reconnect

the hose to case drain filters.
Add the correct fluid to the reservoir until the fluid level is
at the center of the sight gauge (Do not overfill) with lift
arms lowered.
Lower the operator cab. (See Lowering The Operator

Cab on Page 10-30-2.)
Start the engine and operate the loader hydraulic

controls. Stop the engine and check for leaks.
Check the fluid level in the reservoir and add as needed.
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HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D)
Breather Cap
Figure 10-120-9
P-24687
See service schedule for the correct service replacement

interval. (See SERVICE SCHEDULE on Page 10-70-1.)

on Page 10-30-1.)
Remove the breather cap (Item 1) and discard.[Figure

10-120-9]
Install new cap.

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FAN GEARBOX
Checking And Maintaining
Figure 10-130-1
P-24688
(See SERVICE SCHEDULE on Page 10-70-1.) for the

correct service interval.

on Page 10-30-1.)
Remove the plug (Item 1) [Figure 10-130-1] to check the

lubricant level.
If the level is low, add SAE 90W gear lubricant through

the check plug hole until lubricant flows from the hole.
Install and tighten the plug.

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BOB-TACH Figure 10-140-3
Inspection And Maintenance

Bob-Tach
Wedge
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death. Wedge Must Contact
W-2102-0497 Lower Edge Of Hole
In the Attachment
Figure 10-140-1 B-15177
The spring loaded wedge (Item 1) [Figure 10-140-1]

must contact the lower edge of the hole in the attachment
(Item 1) [Figure 10-140-2] and [Figure 10-140-3].
1
If the wedge does not contact the lower edge of the hole
[Figure 10-140-2] and [Figure 10-140-3], the

attachment will be loose and can come off the Bob-Tach.
Figure 10-140-4
P-24695
Move the Bob-Tach levers to engage the wedges [Figure

10-140-1]. The levers and wedges must move freely.
The wedges must extend through the holes in the

attachment mounting frame (Item 1) [Figure 10-140-1].
Figure 10-140-2
B-17460
Inspect the mounting frame on the attachment and the

Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-140-4]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
1
Look for cracked welds. Contact your Bobcat dealer for
repair or replacement parts.
Lubricate the wedges. (See Procedure on Page 10-150-

1.)
P-24696
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POWER BOB-TACH (OPTION) Figure 10-141-3
Inspection And Maintenance
Figure 10-141-1
Front Accessory Panel

1
B-15177
Wedge Must Contact Lower Edge

Of Hole In The Attachment P-24487
If the wedge does not contact the lower edge of the hole
B-15891 [Figure 10-141-3], the attachment will be loose and can
come off the Bob-Tach.
Push and hold the BOB-TACH “WEDGES UP” switch Figure 10-141-4
[Figure 10-141-1] until wedges are fully raised. Push and

hold the BOB-TACH “WEDGES DOWN” switch [Figure
10-141-1] until the wedges are fully down. The wedges
must move freely.
Figure 10-141-2
B-17460
Inspect the mounting frame on the attachment and the

1 Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-141-4]. Replace any parts including
P-24487 decals and lever that are damaged, bent, or missing.
Keep all fasteners tight. Inspect the hoses and fittings for
leaks.
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-141-2] Look for cracked welds. Contact your Bobcat dealer for
and must contact the lower edge of the hole in the repair or replacement parts.
attachment [Figure 10-141-2] and (Item 1) [Figure 10-
141-3]. Lubricate the wedges. (See Procedure on Page 10-150-
1.)
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LUBRICATION OF THE BOBCAT LOADER Figure 10-150-3
Procedure
Figure 10-150-1
3
1
N-18510
3. Tilt Cylinder Base End (Both Sides) [Figure 10-150-

P-45255 3].
Figure 10-150-4
Lubricate the loader as specified in the Service
Schedule. (See SERVICE SCHEDULE on Page 10-70-1

for the best performance of the loader.)
Record the operating hours each time you lubricate the

Bobcat loader.
Always use a good quality lithium based multi-purpose

grease when you lubricate the loader. Apply lubricant 4
until extra grease shows.
5
Lubricate the following locations on the loader:
1. Lift Cylinder Rod End (Both Sides) [Figure 10-150-1].

P-48104
Figure 10-150-2
4. Tilt Cylinder Rod End [Figure 10-150-4].
5. Bob-Tach Pivot Pin (Both Sides) [Figure 10-150-4].
P-45257
2. Lift Cylinder Base End (Both Sides) [Figure 10-150-

2].
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LUBRICATION OF THE BOBCAT LOADER (CONT'D) Figure 10-150-7
Procedure (Cont’d)
Figure 10-150-5
9
P-24699
P-24703
9. 250 Hours: Steering Lever Shaft (2) [Figure 10-150-

7 P16045 7].
6. Bob-Tach Wedge (Both Sides) [Figure 10-150-5].

7. Power Bob-Tach Cylinder (Both Sides) [Figure 10-
150-5].
Figure 10-150-6
P-45253
8. Lift Arm Pivot Pin (Both Sides) [Figure 10-150-6].
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SPARK ARRESTOR MUFFLER
Cleaning Procedure
WARNING
(See SERVICE SCHEDULE on Page 10-70-1.) for
service interval for cleaning the spark arrestor muffler.
When the engine is running during service, the
steering levers must be in neutral and the parking
Do not operate the loader with a defective exhaust
brake engaged. Failure to do so can cause injury or
system.
death.
W-2006-0284
Start the engine and run for about ten seconds while a
IMPORTANT second person, wearing safety glasses, holds a piece of
wood over the outlet of the muffler.
This loader is factory equipped with a U.S.D.A.
This will force contaminants out through the cleanout
Forestry Service approved spark arrestor muffler. It
hole.
is necessary to do maintenance on this spark
arrestor muffler to keep it in working condition. The
Stop the engine.
spark arrestor muffler must be serviced by dumping
the spark chamber every 100 hours of operation.
Install and tighten the plug.
If this machine is operated on flammable forest,
Close the rear door.
brush or grass covered land, it must be equipped

with a spark arrestor attached to the exhaust system
and maintained in working order. Failure to do so will
be in violation of California State Law, Section 4442
PRC. WARNING
Consult local laws and regulations for spark arrestor AVOID INJURY OR DEATH
requirements When an engine is running in an enclosed area, fresh
I-2022-0807 air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
Figure 10-160-1 outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-0807
WARNING
1 Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285
P-45498
Stop the engine. Open the rear door.

WARNING
Remove the plug (Item 1) [Figure 10-160-1] from the Never use machine in atmosphere with explosive
bottom of the muffler. dust or gases or where exhaust can contact
flammable material. Failure to obey warnings can
cause injury or death.
W-2068-1285
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HYDRAULIC SYSTEM
BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-90-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-3 HYDRAULIC
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . 20-90-1 SYSTEM
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-2
CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2
CYLINDER (POWER BOB-TACH) . . . . . . . . . . . . . . . . . . . . . 20-22-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4

CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-7
Base End Pivot Pin Replacement . . . . . . . . . . . . . . . . . . . 20-21-3
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6
Rod End Pivot Pin Bushing And Seal Replacement . . . . . 20-21-4
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK. . . . . 20-130-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 20-130-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
HIGH FLOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Checking The High Flow Relief Valve . . . . . . . . . . . . . . . 20-100-1
High Flow Relief Valve Adjustment Procedure . . . . . . . . 20-100-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-8
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HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL

SYSTEM) (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-12
Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-19
Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . 20-41-18
Auxiliary Electric Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-23
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . 20-41-22
BICS Valve, Check Valve Removal And Installation . . . . . . . . . . . . . 20-41-8
BICS Valve, Lift Arm Bypass Orifice Removal And Installation . . . . . 20-41-7
BICS Valve Lock Valve Removal And Installation . . . . . . . . . . . . . . . 20-41-9
BICS Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-41-5
BICS Valve Solenoid Removal And Installation . . . . . . . . . . . . . . . . 20-41-10
BICS Valve Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-11
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Identification Chart (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-14
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-20
Lift and Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . 20-41-21
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15

Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-16
Port-Auxiliary Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-19
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) 20-40-1

Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Auxiliary Electric Solenoid Disassembly . . . . . . . . . . . . . . . . . . . . . 20-40-30
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . 20-40-29
BICS Valve, Check Valve Disassembly And Assembly . . . . . . . . . . . 20-40-7
BICS Valve, Lift Arm Bypass Orifice Disassembly And Assembly . . . 20-40-6
BICS Valve Lock Valve Disassembly And Assembly . . . . . . . . . . . . . 20-40-8
BICS Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
BICS Valve Solenoid Disassembly And Assembly. . . . . . . . . . . . . . . 20-40-9
BICS Valve Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-10
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Lift And Tilt Lock Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17
Lift Spool and Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-18
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
Port-Auxiliary Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Rubber Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL). 20-42-1

Anti-Cavitation Valve (Lift, Rod End) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-10
Auxiliary Solenoid Disassembly and Assembly . . . . . . . . . . . . . . . . . . . 20-42-29
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . 20-42-27
BICS Valve, Lift Load Check Valve Removal And Installation . . . . . . . . . 20-42-8
BICS Valve, Lock Valve Removal And Installation. . . . . . . . . . . . . . . . . 20-42-31
BICS Valve Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . 20-42-30
BICS Valve, Check Valve Removal And Installation . . . . . . . . . . . . . . . 20-42-33
BICS Valve, Lift Arm Bypass Orifice Disassembly And Assembly . . . . . 20-42-34
End Cap/Spool Lock Block Removal and Installation . . . . . . . . . . . . . . 20-42-15
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-7
Lift Spool and Detent Removal and Installation . . . . . . . . . . . . . . . . . . . 20-42-16
Load Check Valve Removal And Installation (Tilt & Auxiliary) . . . . . . . . . 20-42-9
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-34
Mount Bracket Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-8
Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-13
Port Relief/Anti-Cavitation Valve (Lift, Base End) . . . . . . . . . . . . . . . . . 20-42-11
Port Relief/Anti-Cavitation Valve (Tilt, Base End) . . . . . . . . . . . . . . . . . 20-42-11

Port Relief/Anti-Cavitation Valve (Tilt, Rod End) . . . . . . . . . . . . . . . . . . 20-42-12
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-12
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-1
Rubber Boot Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-14
Tilt Spool Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42-25
T180 Bobcat Loader

65 of 961
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL

SYSTEM) (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1
Anti-Cavitation Valve (Lift, Rod End) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-12
Auxiliary Solenoid Disassembly and Assembly . . . . . . . . . . . . . . . . . . . 20-43-24
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . 20-43-23
BICS Valve, Check Valve Removal And Installation . . . . . . . . . . . . . . . 20-43-28
BICS Valve, Lift Arm Bypass Orifice Disassembly And Assembly . . . . . 20-43-29
BICS Valve, Lift Load Check Valve Removal And Installation . . . . . . . . 20-43-10
BICS Valve, Lock Valve Removal And Installation. . . . . . . . . . . . . . . . . 20-43-26
BICS Valve Solenoid Disassembly And Assembly. . . . . . . . . . . . . . . . . 20-43-25
End Cap Block Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-43-16
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-1
Identification Chart (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-9
Lift Spool Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-17
Load Check Valve Removal And Installation (Tilt & Auxiliary) . . . . . . . . 20-43-11
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-29
Mount Bracket Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-43-10
Plug Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-15
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-14

Port Relief/Anti-Cavitation Valve (Lift, Base End) . . . . . . . . . . . . . . . . . 20-43-13
Port Relief/Anti-Cavitation Valve (Tilt, Base End) . . . . . . . . . . . . . . . . . 20-43-13
Port Relief/Anti-Cavitation Valve (Tilt, Rod End) . . . . . . . . . . . . . . . . . . 20-43-14
Tilt Spool Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43-21
HYDRAULIC/HYDROSTATIC FILTER HOUSING . . . . . . . . . . . . . . . . . . . 20-70-1

HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Check The Output Of The Hydraulic Pump With Power Bob-Tach. . . . . . 20-60-3
Check The Output Of The Hydraulic Pump Without Power Bob-Tach . . . 20-60-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-7
HYDRAULIC PUMP (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1

Check The Output Of The Hydraulic Pump (High Flow) . . . . . . . . . . . . . 20-61-3
Check The Output Of The Hydraulic Pump (Standard) . . . . . . . . . . . . . . 20-61-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-8
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-7
T180 Bobcat Loader

66 of 961
HYDRAULIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-1

Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-6
Test The Output Of The Hydraulic Auxiliary Pump . . . . . . 20-62-1
Test The Output Of The Hydraulic Charge Pump . . . . . . . 20-62-2
HYDRAULIC PUMP (HIGH FLOW) (SJC) . . . . . . . . . . . . . . . 20-63-1

Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-8
Test The Output Of The Hydraulic Auxiliary Pump . . . . . . 20-63-1
Test The Output Of The Hydraulic Charge Pump . . . . . . . 20-63-2
Test The Output Of The Hydraulic Pump (High Flow) . . . . 20-63-4
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . 20-10-1

Tighten Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-6
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5

LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . 20-50-1
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-2
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
POWER BOB-TACH BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . 20-110-1

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-9
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-9


ITEMS MAY VARY.
T180 Bobcat Loader

67 of 961
T180 Bobcat Loader

68 of 961
HYDRAULIC/HYDROSTATIC SCHEMATIC
T180 (S/N 524211001 AND ABOVE)
(S/N 524311001 AND ABOVE)
Printable Version Click Here
(PRINTED MARCH 2005)

V-0416legend
LEGEND
1 RESERVOIR:
Capacity . . . . . . . 19.2 Qt. (18,2 L) 15 LIFT CYLINDER SPOOL - MADE TO 29 RESTRICTOR - 0.031 inch (0,8 mm) 43 RELIEF/ANTICAVITATION VALVE -
RESTRICT FLOW DURING BOOM PORT (TILT BASE END)
2 SPRING LOADED FILTER BY-PASS DOWN BUT NOT DURING BOOM UP 3500 PSI (241,3 Bar)
30 RELIEF VALVE: 3300 PSI (228 Bar)
VALVE: 45-55 PSI (3,1-3,8 Bar)
16 SOLENOID ACTIVATED DIRECTIONAL 44 PILOT ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: 31 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE - HYDRAULIC
CONTROL VALVE - BICS CONTROL
36-44 PSI (2,5-3,0 Bar) POWERED BOB-TACH
Normally Closed 17 PILOTED ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 45 RESTRICTION - 0.089 inch (2,26 mm)
4 DRIVE MOTOR SHUTTLE VALVE CONTROL VALVE - TILT CONTROL
BRONZE)
18 PILOTED ACTIVATED DIRECTIONAL 46 RESTRICTION - 0.025 inch (0,6 mm)
5 RELIEF/REPLENISHING VALVE - HIGH 333 FILTER - BICS CONTROL VALVE
CONTROL VALVE - LIFT CONTROL
PRESSURE: 5000 PSI (345 Bar) (SCREEN) 47
19 PULL BUTTON ACTIVATED RELIEF VALVE - 2000 PSI (137 Bar)
6 RELIEF VALVE - CHARGE INLET:
DIRECTIONAL CONTROL VALVE - LIFT 34 CHECK VALVE - BUCKET POSITION
220-270 PSI (15,1-18,6 Bar) 48 RELIEF VALVE - 1200 PSI (83 Bar)
ARM BY-PASS VALVE
at High Engine Idle Dealer Copy -- Not for Resale
With 140 degrees F. (60 degrees C.) Fluid 20 PILOTED ACTIVATED DIRECTIONAL 49 SOLENOID ACTIVATED DIRECTIONAL
35 RESTRICTION
CONTROL VALVE - UNLOADING CONTROL VALVE (TWO COIL)
SPOOL
7 FRONT AUXILIARY MANUAL PRESSURE 36 VARIABLE CAPACITY DISPLACEMENT 50 CHECK VALVE - With 300 PSI (20,7 Bar)
BLEED-OFF VALVE 1 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP Spring with 0.016 inch (0,40 mm) orifice
8 CONTROL VALVE - FLOW CONTROL
HYDRAULIC PUMP . . . . . . . Gear Type 16.9 37 SHUTTLE RELIEF VALVE 51 HYDRAULIC BRAKE - SPRING APPLIED
SPOOL
GPM (64 L/min.) at 3000 Engine RPM (Not Adjustable - Factory Set) - PRESSURE RELEASE
at 1150 PSI (79,3 Bar) 2 FLOW DIVIDER ADJUSTMENT VALVE 65 PSI (4,5 Bar) 52 CHECK VALVE
9 RELIEF VALVE - MAIN:
3250-3350 PSI (224-231 Bar) 23 SOLENOID ACTIVATED DIRECTIONAL 38 FIXED CAPACITY DISPLACEMENT 53 RELIEF VALVE - BRAKE PRESSURE
at Front Quick Couplers CONTROL VALVE - BASE BIDIRECTIONAL HYDROSTATIC 500 PSI (34,5 Bar)
MOTOR
10 RELIEF VALVE - PORT: . . . . . (Optional) 24 SOLENOID ACTIVATED DIRECTIONAL 54 SOLENOID ACTIVATED DIRECTIONAL
3100 PSI (241,3 Bar) CONTROL VALVE - ROD 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring CONTROL VALVE
11 ANTICAVITATION VALVE
25 LOAD SHUTTLE VALVE - BLEED OFF 40 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BUCKET POSITION
12 SOLENOID ACTIVATED DIRECTIONAL 26 SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF)
CONTROL VALVE - AUXILIARY CONTROL VALVE - TWO COIL
13 RELIEF VALVE - PORT: . . . . . (Optional) 41 CHECK VALVE - BICS CONTROL VALVE
27 PILOT ACTIVATED DIRECTIONAL
3500 PSI (213,7 Bar)
CONTROL VALVE - REAR AUXILIARY 42 RELIEF VALVE - PORT:
14 LOAD CHECK VALVE 3500 PSI (241,3 Bar)
28 RESTRICTOR - 0.140 inch (3,6 mm)
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
Printed in U.S.A. V-0416legend (3-10-05)

69 of 961
(REAR QUICK
FEMALE COUPLERS) MALE
T180 (S/N 524211001 AND ABOVE)
BASE ROD REAR AUX VALVE (OPTIONAL)
INTEGRATED QUICK
23 24 COUPLER BLOCK
(PRINTED MARCH 2005) MALE
25
V-0416 26
28 7 (FRONT AUXILIARY
MALE
7 LEFT SIDE LIFT ARM)
DRIVE MOTOR
29
1 30
FEMALE
27
4 37
P-OUT P-IN T
51
32 BUCKET POSITION VALVE (OPTIONAL)
D
38 HYDRAULIC FILTER 34
31
OIL
2 22
COOLER
B HYDROSTATIC PUMPS A
5 36
5
A
6 3 40 C
HYDRAULIC CONTROL VAVLE 21
20

12 12
13 B
CHARGE
INLET B A
AUXILIARY
SPOOL
14
36
43 TILT CYLINDERS
BOB-TACH BICS CONTROL VALVE
5 5 CYLINDER
D C (OPTIONAL)
HYDRAULIC
POWERED
8 BOB-TACH
(OPTIONAL)
INLET OUTLET
BRAKE VALVE 39 47
B A 17
DR 42 TILT
T 53 52 CYLINDER
SPOOL
IN 50 11
48
DRIVE MOTOR 46 14
38 LIFT CYLINDERS
49 10
45
PP 18
54
P2 B A
P1 LIFT
44 CYLINDER
B1 A1 51
SPOOL 35
B2 A2 15
14
4 37
9 16 WORKING CIRCUITS
33 41 33 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
LIFT ARM BY PASS VALVE

32
19
Printed in U.S.A. V-0416 (3-10-05)
70 of 961
WITH HIGH FLOW OPTION
T180 (S/N 524211001 AND ABOVE)

V-0417legend
LEGEND
1 RESERVOIR:
VALVE: 45-55 PSI (3,1-3,8 Bar)
BRONZE)
6 RELIEF VALVE - CHARGE INLET: DIRECTIONAL CONTROL VALVE - LIFT 34 CHECK VALVE - BUCKET POSITION
220-270 PSI (15,1-18,6 Bar) ARM BY-PASS 48 RELIEF VALVE - 1200 PSI (83 Bar)
VALVE
20 PILOTED ACTIVATED DIRECTIONAL 35 49 SOLENOID ACTIVATED DIRECTIONAL
With 140 degrees F. (60 degrees C.) Fluid RESTRICTION
SPOOL
7 FRONT AUXILIARY MANUAL PRESSURE 36 VARIABLE CAPACITY DISPLACEMENT 50 RELIEF VALVE - 3300 PSI (228 Bar)
BLEED-OFF VALVE 21 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - FLOW CONTROL 51 DUMP VALVE - (ON/OFF)
8 HYDRAULIC PUMP . . . . . . . Gear Type 16.9 SPOOL 37 SHUTTLE RELIEF VALVE
GPM (64 L/min.) at 3000 Engine RPM (Not Adjustable - Factory Set) 52 CHECK VALVE
22 FLOW DIVIDER ADJUSTMENT VALVE 65 PSI (4,5 Bar)
9 RELIEF VALVE - MAIN: 53 AUXILIARY HYDRAULIC PUMP -
3250-3350 PSI (224-231 Bar) 23 SOLENOID ACTIVATED DIRECTIONAL 38 FIXED CAPACITY DISPLACEMENT 9.5 GPM (36 L/min) at High Engine Idle
at Front Quick Couplers CONTROL VALVE - BASE BIDIRECTIONAL HYDROSTATIC
MOTOR 54 CHECK VALVE - With 300 PSI (20,7 Bar) Spring
10 RELIEF VALVE - PORT: . . . . . (Optional) 24 SOLENOID ACTIVATED DIRECTIONAL with 0.016 inch (0,40 mm) orifice
3100 PSI (241,3 Bar) CONTROL VALVE - ROD 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring 55 HYDRAULIC BRAKE - SPRING APPLIED -
11 ANTICAVITATION VALVE PRESSURE RELEASE
25 LOAD SHUTTLE VALVE - BLEED OFF 40 SOLENOID ACTIVATED DIRECTIONAL 56 CHECK VALVE
12 SOLENOID ACTIVATED DIRECTIONAL 26 SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF) 57 RELIEF VALVE - BRAKE PRESSURE
41 500 PSI (34,5 Bar)
13 RELIEF VALVE - PORT: . . . . . (Optional) CHECK VALVE - BICS CONTROL VALVE
27 PILOT ACTIVATED DIRECTIONAL 58 SOLENOID ACTIVATED DIRECTIONAL
3500 PSI (213,7 Bar)
CONTROL VALVE - REAR AUXILIARY 42 RELIEF VALVE - PORT: CONTROL VALVE
NOTE: Unless otherwise specified
springs have NO significant
pressure value.

71 of 961
(REAR QUICK
T180 (S/N 524211001 AND ABOVE) BASE ROD REAR AUX VALVE (OPTIONAL)

Printable Version Click Here INTEGRATED QUICK
23 24 COUPLER BLOCK
(PRINTED MARCH 2005) MALE
25
V-0417 26
MALE
DRIVE MOTOR
29
1 30
FEMALE
27
4 37
P-OUT P-IN T
55
D
31
OIL
2 22
COOLER
5 36
5
A
6 3 40 C
HYDRAULIC CONTROL VAVLE 21
20

12 12
13 B
CHARGE
INLET B A
AUXILIARY
SPOOL
14
36
43 TILT CYLINDERS
BICS CONTROL VALVE
5 5 HIGH FLOW VALVE
D C
8 51
50
52
INLET OUTLET
BRAKE VALVE B A 17
42 TILT
T 57 56 53 CYLINDER
BOB-TACH SPOOL
CYLINDER
IN (OPTIONAL) 11
HYDRAULIC
DRIVE MOTOR POWERED 14
38 BOB-TACH LIFT CYLINDERS
(OPTIONAL) 10
18
58 39 47
DR B A
LIFT
55 CYLINDER
B1 A1
SPOOL 35
54
B2 A2 48 15
46
14
37 49 45
4
PP
9 16 WORKING CIRCUITS
P1 P2 33 41 33 PILOT CIRCUITS
DRAIN CIRCUITS
44 COMPONENTS

32
19
Printed in U.S.A. V-0417 (3-10-05)
72 of 961
T180 (S/N 527511001 - 527512999)

(S/N 527611001 - 527612999)
V-0493legend
LEGEND
1 RESERVOIR:
VALVE: 45-55 PSI (3,1-3,8 Bar)
BRONZE)
VALVE
SPOOL
7 FRONT AUXILIARY MANUAL 36 VARIABLE CAPACITY DISPLACEMENT 50 CHECK VALVE - With 300 PSI (20,7 Bar)
PRESSURE BLEED-OFF VALVE 21 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP Spring with 0.016 inch (0,40 mm) orifice
CONTROL VALVE - FLOW CONTROL
8 HYDRAULIC PUMP . . . . . . . Gear Type 16.3 SPOOL 37 SHUTTLE RELIEF VALVE 51 HYDRAULIC BRAKE - SPRING APPLIED
GPM (61,7 L/min.) at High Engine Idle (Not Adjustable - Factory Set) - PRESSURE RELEASE
22 FLOW DIVIDER ADJUSTMENT VALVE 65 PSI (4,5 Bar) 52 CHECK VALVE
MOTOR
10 RELIEF VALVE - PORT: . . . . . (Optional) 24 SOLENOID ACTIVATED DIRECTIONAL 54 SOLENOID ACTIVATED DIRECTIONAL
3500 PSI (241,3 Bar) CONTROL VALVE - ROD 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring CONTROL VALVE
3100 PSI (213,8 Bar)
28 RESTRICTOR - 0.140 inch (3,6 mm) NOTE: Unless otherwise specified, springs have
NO significant pressure value.
73 of 961
(REAR QUICK
T180 (S/N 527511001 - 527512999) BASE ROD REAR AUX VALVE (OPTIONAL)
(S/N 527611001 - 527612999) WORKING CIRCUITS

(PRINTED MARCH 2005) PILOT CIRCUITS
INTEGRATED QUICK DRAIN CIRCUITS
(V-0493) COUPLER BLOCK COMPONENTS
23 24
Printable Version Click Here 25 MALE
26
MALE
DRIVE MOTOR
29
1 30
FEMALE
27
4 37
P-OUT P-IN T
51
D
OIL
31 COOLER
2 22
5 36
5
HYDRAULIC CONTROL VAVLE A
6 3 40 C
21
13
20
12
12 AUXILIARY
CHARGE SPOOL B
INLET B A
14
36
43 TILT CYLINDERS
BICS CONTROL VALVE
5 5
D C
INLET OUTLET
TILT
BRAKE VALVE B A 17
SPOOL
T 53 52
BOB-TACH 42
CYLINDER
IN (OPTIONAL) 11
HYDRAULIC
(OPTIONAL)
42
18
54 39 47
DR B A LIFT
SPOOL
B1 A1 51
35
50 15
B2 A2 48
46
37 49 45 14
4
PP
33 41 33 16
9
P1 P2
44

32
19
Printed in U.S.A.
V-0493 (3-10-05)
74 of 961
T180 (S/N 527511001 - 527512999)
(S/N 527611001 - 527612999)
V-0494legend
LEGEND
1 RESERVOIR:
VALVE: 45-55 PSI (3,1-3,8 Bar)
BRONZE)
VALVE
With 140 degrees F. (49 degrees C.) Fluid 20 PILOTED ACTIVATED DIRECTIONAL 35 49 SOLENOID ACTIVATED DIRECTIONAL
RESTRICTION
SPOOL
7 FRONT AUXILIARY MANUAL 36 VARIABLE CAPACITY DISPLACEMENT 50 RELIEF VALVE - 3300 PSI (228 Bar)
PRESSURE BLEED-OFF VALVE 21 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP
GPM (61,7 L/min.) at High Engine Idle (Not Adjustable - Factory Set) 52 CHECK VALVE
3250-3350 PSI (224-231 Bar) 23 SOLENOID ACTIVATED DIRECTIONAL 38 FIXED CAPACITY DISPLACEMENT 9.2 GPM (34,8 L/min) at High Engine Idle
54 CHECK VALVE - With 300 PSI (20,7 Bar)
MOTOR
10 RELIEF VALVE - PORT: . . . . . (Optional) 24 SOLENOID ACTIVATED DIRECTIONAL Spring with 0.016 inch (0,40 mm) orifice
3500 PSI (241,3 Bar) CONTROL VALVE - ROD 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring 55 HYDRAULIC BRAKE - SPRING APPLIED
- PRESSURE RELEASE
12 SOLENOID ACTIVATED DIRECTIONAL 26 57
SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF) RELIEF VALVE - BRAKE PRESSURE
CONTROL VALVE - AUXILIARY CONTROL VALVE - TWO COIL 500 PSI (34,5 Bar)
27 PILOT ACTIVATED DIRECTIONAL 58 SOLENOID ACTIVATED DIRECTIONAL
3100 PSI (213,8 Bar) CONTROL VALVE
28 RESTRICTOR - 0.140 inch (3,6 mm) NOTE: Unless otherwise specified, springs have
75 of 961
(REAR QUICK
WORKING CIRCUITS
T180 (S/N 527511001 - 527512999) BASE ROD REAR AUX VALVE (OPTIONAL) PILOT CIRCUITS
DRAIN CIRCUITS
(S/N 527611001 - 527612999) COMPONENTS
INTEGRATED QUICK
(V-0494) COUPLER BLOCK
23 24
26
MALE
DRIVE MOTOR
29
1 30
FEMALE
27
4 37
P-OUT P-IN T
55
D
OIL
31 COOLER
2 22
5 36
5
HYDRAULIC CONTROL VAVLE A
6 3 40 C
21
13
20
12
12 AUXILIARY
CHARGE SPOOL B
INLET B A
14
36
43 TILT CYLINDERS
BICS CONTROL VALVE
5 5 HIGH FLOW VALVE
D C
8 51
50
52
INLET OUTLET
TILT
BRAKE VALVE B A 17
SPOOL
T 57 56 53
BOB-TACH 42
CYLINDER
IN (OPTIONAL) 11
HYDRAULIC
(OPTIONAL)
42
18
58 39 47
DR B A LIFT
SPOOL
B1 A1 55
35
54 15
B2 A2 48
46
37 49 45 14
4
PP 33 41
33 16
9
P1 P2
44

32
19
Printed in U.S.A.
V-0494 (3-10-05)
76 of 961
T180 (S/N 527513000 AND ABOVE)

V-0561legend
LEGEND
1 RESERVOIR:
Capacity . . . . . . . 19.2 Qts. (18,2 L) 15 LIFT CYLINDER SPOOL - MADE TO 29 RESTRICTOR - 0.031 inch (0,8 mm) 43 PORT RELIEF/ANTICAVITATION VALVE
RESTRICT FLOW DURING BOOM 3500 PSI (241,3 Bar)
2 SPRING LOADED FILTER BY-PASS DOWN BUT NOT DURING BOOM UP 30 RELIEF VALVE: 3300 PSI (228 Bar)
VALVE: 45-55 PSI (3,1-3,8 Bar)
BRONZE)
VALVE
SPOOL
7 FRONT AUXILIARY MANUAL 36 VARIABLE CAPACITY DISPLACEMENT 50 CHECK VALVE - With 300 PSI (20,7 Bar)
PRESSURE BLEED-OFF VALVE 21 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP Spring with 0.016 inch (0,40 mm) orifice
8 HYDRAULIC PUMP . . . . . . . Gear Type 16.3 SPOOL 37 SHUTTLE RELIEF VALVE 51 HYDRAULIC BRAKE - SPRING APPLIED
GPM (61,7 L/min.) at High Engine Idle (Not Adjustable - Factory Set) - PRESSURE RELEASE
22 FLOW DIVIDER ADJUSTMENT VALVE 65 PSI (4,5 Bar) 52 CHECK VALVE
MOTOR
10 RELIEF VALVE - PORT: . . . . . (Optional) 24 SOLENOID ACTIVATED DIRECTIONAL 54 FILTER - Bob-Tach Valve
3500 PSI (241,3 Bar) CONTROL VALVE - ROD 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring (S/N 527513389 & Above Only)
(S/N 527613032 & Above Only)
3100 PSI (213,8 Bar)
CONTROL VALVE - REAR AUXILIARY
42 SOLENOID ACTIVATED DIRECTIONAL
14 LOAD CHECK VALVE
28 RESTRICTOR - 0.140 inch (3,6 mm) CONTROL VALVE NOTE: Unless otherwise specified, springs have
77 of 961
(REAR QUICK
(S/N 527613000 AND ABOVE) WORKING CIRCUITS

(PRINTED MARCH 2005) PILOT CIRCUITS
INTEGRATED QUICK DRAIN CIRCUITS
(V-0561) COUPLER BLOCK COMPONENTS
23 24
26
MALE
DRIVE MOTOR
29
1 30
FEMALE
27
4 37
P-OUT P-IN T
51
D
OIL
31 COOLER
2 22
5 36
5
A
HYDRAULIC CONTROL VAVLE
6 3 40 C
21
13
20
12
12 AUXILIARY
CHARGE SPOOL B
INLET B A
14
36
43 TILT CYLINDERS
BICS CONTROL VALVE
5 5
D C
INLET OUTLET
TILT
BRAKE VALVE B A 17
SPOOL
T 53 52
BOB-TACH
CYLINDER 43
IN (OPTIONAL) 11
HYDRAULIC
(OPTIONAL) 43
18
42 39 47
DR B A LIFT
SPOOL
B1 A1 51
35
50 15
B2 A2 48
46
49 33 41
4 37 45 14
PP
54 33
9 16
P1 P2
44

32
19
Printed in U.S.A.
V-0561 (3-10-05)
78 of 961
T180 (S/N 527513000 AND ABOVE)
V-0562legend
LEGEND
1 RESERVOIR:
Capacity . . . . . . . 19.2 Qt. (18,2 L) 15 LIFT CYLINDER SPOOL - MADE TO 29 RESTRICTOR - 0.031 inch (0,8 mm) 43 PORT RELIEF/ANTICAVITATION VALVE
RESTRICT FLOW DURING BOOM 3500 PSI (241,3 Bar)
2 SPRING LOADED FILTER BY-PASS DOWN BUT NOT DURING BOOM UP 30 RELIEF VALVE: 3300 PSI (228 Bar)
VALVE: 45-55 PSI (3,1-3,8 Bar)
BRONZE)
VALVE
With 140 degrees F. (49 degrees C.) Fluid 20 PILOTED ACTIVATED DIRECTIONAL 35 49 SOLENOID ACTIVATED DIRECTIONAL
RESTRICTION
SPOOL
7 FRONT AUXILIARY MANUAL 36 VARIABLE CAPACITY DISPLACEMENT 50 RELIEF VALVE - 3300 PSI (228 Bar)
PRESSURE BLEED-OFF VALVE 21 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP
GPM (61,7 L/min.) at High Engine Idle (Not Adjustable - Factory Set) 52 CHECK VALVE
3250-3350 PSI (224-231 Bar) 23 SOLENOID ACTIVATED DIRECTIONAL 38 FIXED CAPACITY DISPLACEMENT 9.2 GPM (34,8 L/min) at High Engine Idle
54 CHECK VALVE - With 300 PSI (20,7 Bar)
MOTOR
10 RELIEF VALVE - PORT: . . . . . (Optional) 24 SOLENOID ACTIVATED DIRECTIONAL Spring with 0.016 inch (0,40 mm) orifice
3500 PSI (241,3 Bar) CONTROL VALVE - ROD 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring 55 HYDRAULIC BRAKE - SPRING APPLIED
- PRESSURE RELEASE
12 SOLENOID ACTIVATED DIRECTIONAL 26 57
SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF) RELIEF VALVE - BRAKE PRESSURE
CONTROL VALVE - AUXILIARY CONTROL VALVE - TWO COIL 500 PSI (34,5 Bar)
27 PILOT ACTIVATED DIRECTIONAL 58 FILTER - Bob-Tach Valve
3100 PSI (213,8 Bar)
CONTROL VALVE - REAR AUXILIARY (S/N 527513389 & Above Only)
42 SOLENOID ACTIVATED DIRECTIONAL
14 LOAD CHECK VALVE (S/N 527613032 & Above Only)
28 RESTRICTOR - 0.140 inch (3,6 mm) CONTROL VALVE
NOTE: Unless otherwise specified, springs have

79 of 961
(REAR QUICK
WORKING CIRCUITS
T180 (S/N 527513000 AND ABOVE) BASE ROD REAR AUX VALVE (OPTIONAL) PILOT CIRCUITS
DRAIN CIRCUITS
(S/N 527613000 AND ABOVE) COMPONENTS
INTEGRATED QUICK
23 24
26
MALE
DRIVE MOTOR
29
1 30
FEMALE
27
4 37
P-OUT P-IN T
55
D
OIL
31 COOLER
2 22
5 36
5
A
HYDRAULIC CONTROL VAVLE
6 3 40 C
21
13
20
12
12 AUXILIARY
CHARGE SPOOL B
INLET B A
14
36
43 TILT CYLINDERS
BICS CONTROL VALVE
5 5 HIGH FLOW VALVE
D C
8 51
50
52
INLET OUTLET
TILT
BRAKE VALVE B A 17
SPOOL
T 57 56 53
BOB-TACH
CYLINDER 43
IN (OPTIONAL) 11
HYDRAULIC
(OPTIONAL) 43
18
42 39 47
DR B A LIFT
SPOOL
B1 A1 55
35
54 15
B2 A2 48
46
49 33 41
4 37 45 14
PP
58
33 16
9
P1 P2
44

32
19
Printed in U.S.A.
V-0562 (3-10-05)
80 of 961
With SJC Option
T180 (S/N 527513000 AND ABOVE)
(PRINTED MAY 2005)

V-0697legend
LEGEND
1 RESERVOIR:
Capacity . . . . . . . 19.2 qt. (18,2 L) 15 LIFT CYLINDER SPOOL - MADE TO 29 RESTRICTOR - 0.031 inch (0,8 mm) 43 PORT RELIEF/ANTICAVITATION VALVE
RESTRICT FLOW DURING BOOM 3500 PSI (241,3 bar)
2 SPRING LOADED FILTER BY-PASS DOWN BUT NOT DURING BOOM UP 30 RELIEF VALVE: 3300 PSI (228 bar)
VALVE: 45-55 PSI (3,1-3,8 bar)
36-44 PSI (2,5-3,0 bar) POWERED BOB-TACH
BRONZE)
PRESSURE: 5250 PSI (362 bar) (SCREEN) 47
19 PULL BUTTON ACTIVATED RELIEF VALVE - 2000 PSI (137 bar)
360 PSI (24,8 bar) ARM BY-PASS 48 RELIEF VALVE - 1200 PSI (83 bar)
VALVE
SPOOL
7 FRONT AUXILIARY MANUAL 36 VARIABLE CAPACITY DISPLACEMENT 50 CHECK VALVE - With 300 PSI (20,7 bar) Spring
PRESSURE BLEED-OFF VALVE 21 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP with 0.016 inch (0,40 mm) orifice
8 HYDRAULIC PUMP . . . . . . . Gear Type SPOOL 37 SHUTTLE RELIEF VALVE 51 HYDRAULIC BRAKE - SPRING APPLIED
16.3 GPM (61,7 L/min.) at High Engine Idle (Not Adjustable - Factory Set) - PRESSURE RELEASE
22 FLOW DIVIDER ADJUSTMENT VALVE 65 PSI (4,5 bar) 52 CHECK VALVE
3250-3350 PSI (224-231 bar) 23 SOLENOID ACTIVATED DIRECTIONAL 38 FIXED CAPACITY DISPLACEMENT 53 RELIEF VALVE - BRAKE PRESSURE
at Front Quick Couplers CONTROL VALVE - BASE BIDIRECTIONAL HYDROSTATIC 500 PSI (34,5 bar)
MOTOR
10 RELIEF VALVE - PORT: . . . . . (Optional) 24 SOLENOID ACTIVATED DIRECTIONAL 54 FILTER - Bob-Tach Valve
3500 PSI (241,3 bar) CONTROL VALVE - ROD 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring
55 CHARGE PUMP . . . . . . . Gear Type
11 ANTICAVITATION VALVE 12.8 GPM (48,5 L/min.) at High Engine Idle
CONTROL VALVE - BUCKET POSITION 56 SOLENOID ACTIVATED CONTROL
12 SOLENOID ACTIVATED DIRECTIONAL 26 SOLENOID ACTIVATED DIRECTIONAL VALVE (ON/OFF) VALVE - FORWARD/REVERSE
41 CHECK VALVE - BICS CONTROL VALVE 57 SERVO PISTON - Swash Plate
13 RELIEF VALVE - PORT: . . . . . (Optional)
3100 PSI (213,8 bar)
CONTROL VALVE - REAR AUXILIARY 42 SOLENOID ACTIVATED DIRECTIONAL 58 POSITION SENSOR - Swash Plate
14 LOAD CHECK VALVE CONTROL VALVE
28 RESTRICTOR - 0.140 inch (3,6 mm) 59 CHARGE PRESSURE SWITCH
NOTE: Unless otherwise specified, springs have

81 of 961
(REAR QUICK
WITH SJC OPTION

(PRINTED MAY 2005)
INTEGRATED QUICK
23 24
26
MALE
DRIVE MOTOR 29
1 30
FEMALE
27
4 37
P-OUT P-IN T
51
D
31
B HYDROSTATIC PUMPS A OIL

22
2 COOLER
56
57 A
HYDRAULIC CONTROL VALVE
5 5 3 40 C
58
21
6 36 13
20
12
12 AUXILIARY
CHARGE
SPOOL B
INLET B A
59
58 14
2 31 36
43 TILT CYLINDERS
BICS CONTROL VALVE
5 57 5
56
3
TILT
B A 17
SPOOL
D C
8
43 11
INLET 14
LIFT CYLINDERS
55 43
18
OUTLET HYDRAULIC
53 POWERED
IN B A LIFT
T BOB-TACH
52 SPOOL
(OPTIONAL)
38
35
39 47
15
DR
14
54
51
42 48 33 41
46 33 16
9
49 45
B1 A1 PP
4 37 58
B2 A2
P2 LIFT ARM BY PASS VALVE
BRAKE VALVE P1
32 44 19
Printed in U.S.A.
DRIVE MOTOR
V-0697 (5-5-05)
82 of 961
WITH SJC AND HIGH FLOW OPTION
T180 (S/N 527513000 AND ABOVE)
(PRINTED MAY 2005)
V-0698legend
LEGEND
1 RESERVOIR: 16 SOLENOID ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 47 RELIEF VALVE - 2000 PSI (137 bar)
Capacity . . . . . . . 19.2 qt. (18,2 L) CONTROL VALVE - BICS CONTROL BRONZE)
2 SPRING LOADED FILTER BY-PASS 48 RELIEF VALVE - 1200 PSI (83 bar)
17 PILOTED ACTIVATED DIRECTIONAL 33 FILTER - BICS CONTROL VALVE
VALVE: 45-55 PSI (3,1-3,8 bar)
CONTROL VALVE - TILT CONTROL (SCREEN) 49 SOLENOID ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE (TWO COIL)
36-44 PSI (2,5-3,0 bar) 18 PILOTED ACTIVATED DIRECTIONAL 34 CHECK VALVE - BUCKET POSITION
Normally Closed CONTROL VALVE - LIFT CONTROL VALVE 50 RELIEF VALVE - 3300 PSI (228 bar)
4 DRIVE MOTOR SHUTTLE VALVE 19 PULL BUTTON ACTIVATED 51

35 RESTRICTION DUMP VALVE - (ON/OFF)
DIRECTIONAL CONTROL VALVE -
5 RELIEF/REPLENISHING VALVE - HIGH LIFT ARM BY-PASS 52 CHECK VALVE
36 VARIABLE CAPACITY DISPLACEMENT
PRESSURE: 5250 PSI (362 bar) 20 PILOTED ACTIVATED DIRECTIONAL BI-DIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - UNLOADING 53 AUXILIARY HYDRAULIC PUMP -
6 RELIEF VALVE - CHARGE INLET: SPOOL 37 SHUTTLE RELIEF VALVE 9.5 GPM (36 L/min) at High Engine Idle
360 PSI (24,8 bar) (Not Adjustable - Factory Set) 54
21 PILOTED ACTIVATED DIRECTIONAL CHECK VALVE - With 300 PSI (20,7 bar) Spring
at High Engine Idle 65 PSI (4,5 bar)
CONTROL VALVE - FLOW CONTROL with 0.016 inch (0,40 mm) orifice
With 140 degrees F. (60 degrees C.) Fluid
SPOOL Dealer Copy 38
-- Not for Resale
FIXED CAPACITY DISPLACEMENT 55 HYDRAULIC BRAKE - SPRING APPLIED
7 FRONT AUXILIARY MANUAL BI-DIRECTIONAL HYDROSTATIC - PRESSURE RELEASE
22 FLOW DIVIDER ADJUSTMENT VALVE
PRESSURE BLEED-OFF VALVE MOTOR 56 CHECK VALVE
8 HYDRAULIC PUMP . . . . . . . Gear Type 16.3 23 SOLENOID ACTIVATED DIRECTIONAL 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring 57 RELIEF VALVE - BRAKE PRESSURE
GPM (61,7 L/min.) at High Engine Idle
CONTROL VALVE - BASE 500 PSI (34,5 bar)
24 SOLENOID ACTIVATED DIRECTIONAL 40 SOLENOID ACTIVATED DIRECTIONAL 58
9 RELIEF VALVE - MAIN: FILTER - Bob-Tach Valve
CONTROL VALVE - ROD CONTROL VALVE - BUCKET POSITION
3250-3350 PSI (224-231 bar)
VALVE (ON/OFF) 59
at Front Quick Couplers CHARGE PUMP -
25 LOAD SHUTTLE VALVE - BLEED OFF 41 CHECK VALVE - BICS CONTROL VALVE 12.8 GPM (48,5 L/min) at High Engine Idle
10 RELIEF VALVE - PORT: . . . . . (Optional)
3500 PSI (241,3 bar) 26 SOLENOID ACTIVATED DIRECTIONAL 60 SOLENOID ACTIVATED CONTROL
42 SOLENOID ACTIVATED DIRECTIONAL VALVE - FORWARD/REVERSE
11 ANTICAVITATION VALVE CONTROL VALVE - TWO COIL
CONTROL VALVE
27 PILOT ACTIVATED DIRECTIONAL 61 SERVO PISTON -Swash Plate
12 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY 43 PORT RELIEF/ANTICAVITATION VALVE
3500 PSI (241,3 bar) 62 POSITION SENSOR -Swash Plate
CONTROL VALVE - AUXILIARY
13 RELIEF VALVE - PORT: . . . . . (Optional) 44 PILOT ACTIVATED DIRECTIONAL 63 CHARGE PRESSURE SWITCH
3100 PSI (213,8 bar) 29 RESTRICTOR - 0.031 inch (0,8 mm) CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH
14 LOAD CHECK VALVE
30 RELIEF VALVE: 3300 PSI (228 bar) 45 RESTRICTION - 0.089 inch (2,26 mm)
15 LIFT CYLINDER SPOOL - MADE TO NOTE: Unless otherwise specified, springs have
31 FILTER - HYDRAULIC (CANISTER) 46 RESTRICTION - 0.025 inch (0,6 mm)
RESTRICT FLOW DURING BOOM NO significant pressure value.
DOWN BUT NOT DURING BOOM UP
V-0698legend (5-5-05)
Printed in U.S.A.
83 of 961
(REAR QUICK
WITH SJC AND HIGH FLOW OPTION

(PRINTED MAY 2005)
INTEGRATED QUICK
23 24
26
MALE
DRIVE MOTOR 29
1 30
FEMALE
27
4 37
P-OUT P-IN T
55
D
31
B HYDROSTATIC PUMPS A OIL

22
2 COOLER
60
61 A
HYDRAULIC CONTROL VALVE
5 5 3 40 C
62
21
6 36 13
20
12
12 AUXILIARY
CHARGE
SPOOL B
INLET B A
63
62 14
2 31 36
43 TILT CYLINDERS
BICS CONTROL VALVE
HIGH FLOW VALVE
5 61 5
60 51
50
3 52
TILT
B A 17
SPOOL
D C
8
43 11
INLET 14
LIFT CYLINDERS
59 43
18
HYDRAULIC
57 OUTLET
IN 53 POWERED B
T A LIFT
BOB-TACH
56 SPOOL
(OPTIONAL)
38
35
39 47
15
DR
14
54
55
42 48 33 41
46 33 16
9
49 45
B1 A1 PP
4 37 58
B2 A2
P2 LIFT ARM BY PASS VALVE
BRAKE VALVE P1
32 44 19
Printed in U.S.A.
DRIVE MOTOR
V-0698 (5-5-05)
84 of 961
HYDRAULIC SYSTEM INFORMATION
T180 Bobcat Loader

85 of 961
HYDRAULIC SYSTEM INFORMATION (CONT’D)
T180 Bobcat Loader

86 of 961
HYDRAULIC SYSTEM INFORMATION (CONT'D)
T180 Bobcat Loader

87 of 961
T180 Bobcat Loader

88 of 961
Troubleshooting Chart WARNING

The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
The transmission warning light come ON when hydraulics are operating. 1, 3
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine RPM 1, 3, 4, 5, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position 4
The lift arms come down with the pedal is in neutral position 4, 9, 10, 11
Bypass valve stuck 12
Bypass valve stem bent or broke 13

KEY TO CORRECT CAUSE
1. The fluid level is not correct.

2. The pedal linkage is disconnected.
3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.
5. Relief valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid. (See Specifications on Page SPEC-50-1.)
8. Using the loader for more than its rated capacity.
9. Internal leak in the lift cylinder(s).
10. External leak from the cylinder(s).
11. Damaged lift spool.
12. Rotate shaft.
13. Replace manual spool cartridge.
T180 Bobcat Loader

89 of 961
Tighten Procedures
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
For tightening torques for hydraulic fittings, tubelines etc.,

(See HYDRAULIC CONNECTION SPECIFICATIONS on
Page SPEC-40-1.)
T180 Bobcat Loader

90 of 961
CYLINDER (LIFT) Figure 20-20-2
Checking
WARNING
Failure to use care around combustibles can cause 2
explosion or fire. 1
W-2103-0508
P-45266
WARNING Install a plug in the hose (Item 1) [Figure 20-20-2] and

tighten.
AVOID INJURY OR DEATH Engage the parking brake. Lower the seat bar. Start the
Diesel fuel or hydraulic fluid under pressure can engine. Press the PRESS TO OPERATE BUTTON. Push
penetrate skin or eyes, causing serious injury or the top (toe) of the lift pedal or move left hand lever

death. Fluid leaks under pressure may not be visible. towards the operator.
not use your bare hand. Wear safety goggles. If fluid If there is any leakage from the base end cylinder port
enters skin or eyes, get immediate medical attention (Item 2) [Figure 20-20-2], remove the lift cylinder for
from a physician familiar with this injury. repair.
W-2072-0807
Repeat the procedure to check the other lift cylinder.
Figure 20-20-1
P-45265
Lower the lift arms. Stop the engine. Pull up on the lift
arm bypass control. Raise the seat bar.
Check only one cylinder at a time.
Disconnect the hose (Item 1) [Figure 20-20-1] from the

lift cylinder base end port.
T180 Bobcat Loader

91 of 961
CYLINDER (LIFT) (CONT’D) Figure 20-20-5
Removal And Installation
Figure 20-20-3
P-45268
Remove the lift arm pivot pin (Item 1) [Figure 20-20-5]

P-45265 (both sides).
Figure 20-20-6
Stop the engine. Pull up on the lift arm bypass control
and move the lift pedal to release the hydraulic pressure.
1

Disconnect the hoses (Item 1) [Figure 20-20-3] from the
lift cylinder.
Install plugs in the hoses and tighten.

2
Figure 20-20-4
3
1
P-45258
Remove the retainer bolt (Item 1) [Figure 20-20-6] and

nut from the lift cylinder rod end pivot pin (both sides).
Installation: Tighten the bolt and nut to 25 - 28 ft.-lb. (35

- 38 N•m) torque.
P-45267 Remove the lift cylinder rod end pivot pin (Item 2) [Figure
20-20-6].
Remove the retainer bolt (Item 1) [Figure 20-20-4] and Remove the lift cylinder (Item 3) [Figure 20-20-6] from
nut from the lift arm pin (both sides). the loader.

- 38 N•m) torque.
NOTE: Remove the air cleaner (See AIR CLEANER

SERVICE on Page 10-80-1.) to remove the left
rear pivot pin. The pin must be driven out from
the engine compartment.
T180 Bobcat Loader

92 of 961
CYLINDER (LIFT) (CONT'D)
Parts Identification
1. Plug 9. Spacer
2. O-ring 10. Seal
3. Cylinder 11. O-ring
4. O-ring 12. Head
5. Nut 13. Rod Seal
6. Piston 14. Wiper Seal
7. Seal 15. Rod
8. O-ring

7 8
15
1 6
2
5
14
1 13
3
2 12
11
10
B-13593A
B-13593
T180 Bobcat Loader

93 of 961
CYLINDER (LIFT) (CONT'D) Figure 20-20-9
Disassembly
2
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook 1

Spanner Wrench
Hold the hydraulic cylinder over a drain pan and move

the rod in and out slowly to remove the fluid from the
cylinder.
Put the base end of the cylinder in a vise. 3
Figure 20-20-7 P-48038
1 Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-

20-9] from the piston.
NOTE: If the fiber surface (Item 3) [Figure 20-20-9] on

the piston head, becomes damaged, the
complete piston head must be replaced.

Figure 20-20-10
P-48033
Use a spanner wrench to loosen the head (Item 1)

[Figure 20-20-7] from the cylinder case.
2
Figure 20-20-8
4
3 P-48039
2
1 Remove the two O-rings (Item 1) and the back-up washer

(Item 2) [Figure 20-20-10] from the cylinder head.
P-48036
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-8].
T180 Bobcat Loader

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CYLINDER (LIFT) (CONT'D) Assembly
Disassembly (Cont'd) Use the following tools to assemble the cylinder:
Figure 20-20-11 MEL1396 - Seal Installation Tool

MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
1 Figure 20-20-13
P-48040
Remove the wiper seal (Item 1) [Figure 20-20-11] from

the cylinder head.

P7424
Figure 20-20-12
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts.
Always install new O-rings and seals during assembly.

1
Lubricate all O-rings and seals with hydraulic oil during
installation.
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-20-13].
P-48042 Allow the seal to stretch for 30 seconds before installing it

on the piston.
Remove the rod seal (Item 1) [Figure 20-20-12] from the
cylinder head.
T180 Bobcat Loader

95 of 961
CYLINDER (LIFT) (CONT'D) Figure 20-20-16
Assembly (Cont'd)
Figure 20-20-14
1
2
P7425
Install the rod seal in the head [Figure 20-20-16].

P-48038
Figure 20-20-17
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-

20-14] on the cylinder piston.

2
Figure 20-20-15
P-48041 P-48042
Install the wiper seal, with the wiper side of the seal (Item
1) toward the outside of the head (Item 2) [Figure 20-20-
P-48043 P7427 17].
Install the rod seal on the rod seal tool [Figure 20-20-15].
NOTE: During installation the spring side of the seal

(Item 1) [Figure 20-20-15] must be installed
toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 20-

20-15].
T180 Bobcat Loader

96 of 961
CYLINDER (LIFT) (CONT'D)
Assembly (Cont'd)
Figure 20-20-18
1
2 3
P-48036
NOTE: Clean and dry the threads before installing the

nut. Install the new nut from the kit.

Install the head (Item 1), spacer (Item 2) piston (Item 3),
and nut (Item 4) [Figure 20-20-18].
Tighten the nut (Item 4) [Figure 20-20-18] to 600 ft.-lb.

(814 N•m) torque.
Figure 20-20-19
P-48035
Put the base end of the hydraulic cylinder in a vise.
Tighten the head (Item 1) [Figure 20-20-19] using a

spanner wrench.
T180 Bobcat Loader

97 of 961
T180 Bobcat Loader

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CYLINDER (TILT) Remove the attachment. Roll the Bob-Tach fully back.
Stop the engine. Raise the seat bar.
Checking
Disconnect the hose (Item 1) [Figure 20-21-1] which
goes to the base end of the tilt cylinder.
WARNING Install a cap (Item 1) [Figure 20-21-2] on the fitting and

tighten.
Hydraulic fluid escaping under pressure can have Engage the parking brake. Lower the seat bar.
penetrating the skin. This can cause serious injury Start the engine and push the Press to Operate button.
and possible death if proper medical treatment by a Push the bottom (heel) of the tilt pedal.
immediately. If there is leakage from the open port, remove the tilt
W-2145-0290 cylinder for repair.
Figure 20-21-1

1
N-18801
Figure 20-21-2
N-18802
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CYLINDER (TILT) (CONT'D) Figure 20-21-4
WARNING 1

explosion or fire.
W-2103-0508
N-18545
Figure 20-21-3
Use a drift pin and hammer, remove the rod end pivot pin
(Item 1) [Figure 20-21-4].
Figure 20-21-5

1
N-18544 3 2
Remove the attachment. Roll the Bob-Tach forward. Stop

the engine. Raise the seat bar.
Remove the retainer bolt (Item 1) [Figure 20-21-3] and P-34137

nut from the rod end pin.
Installation: Tighten the bolt and nut to standard torque. Remove the retainer bolt (Item 1) [Figure 20-21-5] from
the tilt cylinder rod end pivot pin.
Installation: Tighten the bolt and nut to 125 - 140 ft.-lb.

(170 - 190 N•m) torque.
Remove the step (Item 2) [Figure 20-21-5].

cylinders.
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CYLINDER (TILT) (CONT'D) Base End Pivot Pin Replacement
Removal And Installation (Cont’d) Figure 20-21-7
Figure 20-21-6
2
P-24709
P-34228
Remove the tilt cylinder from the Bob-Tach. (See
Removal And Installation on Page 20-22-2.)
cylinder. Loosen the retainer bolt (Item 1) [Figure 20-21-7] from

the tilt cylinder rod base end pin.
Remove the cylinder (Item 2) [Figure 20-21-6] from the
rod end pivot pin. Installation: Tighten the retainer bolt to 175 - 190 ft.-lb.
(240 - 260 N•m) torque.
Remove the cylinder from the loader.
Strike the head of the bolt (Item 1) [Figure 20-21-7] to
push the pivot pin out.
Reverse the removal procedure to install the pivot pin.
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Rod End Pivot Pin Bushing And Seal Replacement
Figure 20-21-8
1
1
N-18554
Reverse the removal procedure to install the pivot pin

N-18556 bushing and seal.
Remove the rod end of the tilt cylinder from the Bob-
Tach. (See Rod End Pivot Pin Bushing And Seal

Replacement on Page 20-21-4.)
Use a seal pick to remove the seals (Item 1) [Figure 20-

21-8] on both sides of the pivot bushing.
Figure 20-21-9
N-18555
Remove and replace bushing with a driver tool and

hammer [Figure 20-21-9].
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CYLINDER (TILT) (CONT'D)
1. Case 9. Washer
2. Plug 10. O-ring
3. O-ring 11. Head
4. Nut 12. Seal
5. Piston 13. Seal
6. Seal 14. Rod
7. O-ring 15. Seal MC-1688B
8. O-ring 16. Bushing
3
MC-01688A

9
4
10
7
12
6 13
5 11
MC-01688D
14
MC-01688C
15
16
15
PE-1056A
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Disassembly
2

Spanner Wrench

the rod in and out slowly to remove the fluid from the
cylinder.
Put the base end of the cylinder in a vise.
Figure 20-21-11 P-48073
Remove the seal (Item 1), and O-ring (Item 2) [Figure

20-21-13] from the piston.
1
Figure 20-21-14

2
P-48034
Use a spanner wrench to loosen the head (Item 1)

[Figure 20-21-11] from the cylinder case.
Figure 20-21-12 P-48039
3 Remove the two O-rings (Item 1) and the back-up washer

2 (Item 2) [Figure 20-21-14] from the cylinder head.
P-48071
Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-12].
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CYLINDER (TILT) (CONT'D) Assembly
Disassembly (Cont'd) Use the following tools to assemble the cylinder:
Figure 20-21-15 MEL1396 - Seal Installation Tool

MEL1033 - Rod Seal Installation Tool
Spanner Wrench
1 Figure 20-21-17
P-48040
Remove the wiper seal (Item 1) [Figure 20-21-15] from

the cylinder head.

P7424
Figure 20-21-16


1
installation.
fits the piston [Figure 20-21-17].
P-48042 Allow the seal to stretch for 30 seconds before installing it

on the piston.
Remove the rod seal (Item 1) [Figure 20-21-16] from the
cylinder head.
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Assembly (Cont'd)
Figure 20-21-18
P7425

P-48073
Figure 20-21-21
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-

21-18] on the cylinder piston.

2
Figure 20-21-19
P-48041 P-48042
Install the wiper seal, with the wiper side of the seal (Item
1) toward the outside of the head (Item 2) [Figure 20-21-
P-48043 P7427 21].
Install the rod seal on the rod seal tool [Figure 20-21-19].
NOTE: During installation the spring side of the seal

(Item 1) [Figure 20-21-19] must be installed
toward the inside of the cylinder.

21-19].
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Assembly (Cont'd)
Figure 20-21-22
1
1
2
P-48070

P-48071
Tighten the head (Item 1) [Figure 20-21-24] using a
spanner wrench.
NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit.

Install the head (Item 1), piston (Item 2) and nut (Item 3)
[Figure 20-21-22].
Tighten the nut (Item 3) [Figure 20-21-22] to 100 ft.-lb.

(136 N•m) torque.
Figure 20-21-23
P-48088 P-48089
Mark the end of the shaft and nut. Tighten the nut an
additional 135 degrees or 2-1/4 flats [Figure 20-21-23].
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CYLINDER (POWER BOB-TACH) Figure 20-22-2
Checking
WARNING
explosion or fire.
W-2103-0508 1
P16330
WARNING Disconnect the hose (Item 1) [Figure 20-22-2] from the

power Bob-Tach cylinder base end port.
AVOID INJURY OR DEATH Figure 20-22-3


not use your bare hand. Wear safety goggles. If fluid 2
W-2072-0807
Figure 20-22-1
P16332
Install a plug in the hose (Item 1) [Figure 20-22-3] and

tighten.
Engage the parking brake. Lower the seat bar. Start the
engine.
Push and hold the BOB-TACH “WEDGES UP” Switch

(Front Accessory Panel).
N-21401
If there is any leakage from the base end cylinder port

Tilt the Bob-Tach forward, so it is parallel to the floor (Item 2) [Figure 20-22-3], remove the lift cylinder for
[Figure 20-22-1]. repair.
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CYLINDER (POWER BOB-TACH) (CONT'D)
Figure 20-22-4
1 2
N-21401
Disconnect the hoses from the cylinder fittings (Item 1 &

2) [Figure 20-22-4].

Install plugs and cap on fittings.
NOTE: Connect the hose with the 45° end (Item 1)

[Figure 20-22-4] to the base end fitting on the
cylinder.
Figure 20-22-5
1 1
N-21400
Remove the bolts (Item 1) [Figure 20-22-5].
Installation: Tighten the bolts to 25 - 28 ft.-lb. (34 - 38

N•m) torque.
Remove the washers and cylinder from the lever pivots.
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1. Cylinder 8. Ring
2. Nut 9. O-ring
3. Piston 10. Head
4. O-ring 11. Seal
5. Ring 12. Seal
6. Spacer 13. Rod
7. O-ring

3
4
5
6
7 8
9
10
11
12
13
B-16276
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CYLINDER (POWER BOB-TACH) (CONT'D) Figure 20-22-8
Disassembly
3
Figure 20-22-6 2
1
P16295
Piston: Remove the O-ring (Item 1), and seal (Item 2)

P16293 from the piston (Item 3) [Figure 20-22-8].
Figure 20-22-9

3
Spanner Wrench 4

the rod in and out slowly to remove the fluid from the 2
cylinder. 1
Put the base end of the cylinder in a vise.
Use a spanner wrench to loosen the head [Figure 20-22-

6].
Figure 20-22-7 N-20611
Remove the wiper seal (Item 1), and rod seal (Item 2),
4 3 2
the back up washer (Item 3) the thin O-ring (Item 4) and
1 the thick O-ring (Item 5) from the head [Figure 20-22-9].
P16294
Remove the head and rod assembly from the cylinder

[Figure 20-22-7]. Put the rod end in a vise.
Remove the nut (Item 1), piston (Item 2), spacer (Item 3),
and head (Item 4) from the rod [Figure 20-22-7].
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Assembly
3
1
Figure 20-22-10
2
P16295
Install the O-ring (Item 1) and seal (Item 2) on the piston

P7424 (Item 3) [Figure 20-22-11].
NOTE: The piston center hole (Item 4) [Figure 20-22-

Use the following tools to assembly the cylinder: 11] has a bevel on one end. The bevel goes
toward the rod.

MEL1396 - Seal Installation Tool
MEL1033 - Rod Seal Installation Tool Figure 20-22-12
Spanner Wrench


installation.
fits the piston [Figure 20-22-10]. N-20612
Allow the seal to stretch for 30 seconds before installing it

on the piston. Install the rod seal on the rod seal tool [Figure 20-22-12].
NOTE: During installation the O-ring side of the seal

must be toward the inside of the cylinder.
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Assembly (Cont'd)
Figure 20-22-13
1
2
3
P7422
Install the thin O-ring (Item 1) [Figure 20-22-15].

N-20613
Install the back-up washer (Item 2) and thick O-ring (Item
3) into the groove on the head [Figure 20-22-15].
22-13]. NOTE: Clean and dry the threads before installing the

nut. Install the new nut from the seal kit.
Figure 20-22-14
Figure 20-22-16
3
1 2 4
P7425
P16294

Install the head (Item 1) and spacer (Item 2) [Figure 20-
Install the wiper seal with the wiper toward the outside of 22-16].
the head.
Install the piston (Item 3) [Figure 20-22-16].
Grease the piston where the nut contacts the piston. Do

not get grease on the threads. Install the new nut (Item 4)
[Figure 20-22-16].
Tighten the nut to 90 ft.-lb. (122 N•m) torque.
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Assembly (Cont'd)
Figure 20-22-17
P16293

Tighten the head using a spanner wrench [Figure 20-22-
17].
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MAIN RELIEF VALVE Figure 20-30-1
Checking
2
1
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
P-34480
WARNING
Connect the IN port (Item 1) [Figure 20-30-1] of the
When the engine is running during service, the hydraulic tester to the bottom (female) quick coupler on
steering levers must be in neutral and the parking the loader.
brake engaged. Failure to do so can cause injury or
death. Connect the OUT port (Item 2) [Figure 20-30-1] of the
W-2006-0284 hydraulic tester to the top (male) quick coupler on the

loader.
Figure 20-30-2
WARNING
W-2017-0286
The tools listed will be needed to do the following 1

procedure:
MEL10003 - Hydraulic Tester

MEL10006 - Hydraulic Test Kit
N-18409
Turn the key switch to the OFF position. To release the
hydraulic pressure at the front auxiliary quick couplers
push the couplers into the coupler block and hold for Start the engine and run at low idle.
three seconds.
• Press the AUXILIARY HYDRAULICS Button (Item 1)
Lift and block the loader. (See Procedure on Page 10-10- [Figure 20-30-2] twice and the light beside Maximum
1.) Flow comes on.
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MAIN RELIEF VALVE (CONT’D) Adjustment
Checking (Cont’d) Figure 20-30-4
Figure 20-30-3
Right
Steering
Lever O-ring
Control
Back-up
B-6764
1
P-31833
If the pressure is not correct, adjust the main relief valve.
Remove the end cap (Item 1) [Figure 20-30-4] if
• Push the front switch (Item 1) [Figure 20-30-3] to give equipped.
the front quick couplers a constant flow of fluid.

Turn the adjusting screw in or out until the pressure is
• To release from continuous operation, press the front correct.
switch (Item 1) [Figure 20-30-3] a second time.
NOTE: If the correct pressure can not be reached,
Watch the flow meter on the hydraulic tester to make replace the main relief valve. Check the
sure the flow is correct. Increase the engine speed to full pressure setting of the new relief valve.
RPM.
Refer to Specifications, for both flow and pressure

specifications of the hydraulic system. (See LOADER
SPECIFICATIONS on Page SPEC-10-1.)
Check the free flow specification.
Turn the restrictor control, on the tester, until the main

relief valve opens. Check the relief pressure.
If the relief pressure is not correct, stop the engine and

adjust the main relief valve.
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MAIN RELIEF VALVE (CONT’D)
Removal and Installation
IMPORTANT
damage the system.
I-2003-0888
Figure 20-30-5

P-24710
P-48430
Clean the area around the control valve. Loosen and

remove the main relief valve (Item 1) [Figure 20-30-5].
Remove the O-rings and back-up washers [Figure 20-

30-4].
Clean the main relief valve in clean solvent. Use air

pressure to dry the valve.
Install new O-rings and back-up washers. Install the main

relief valve (Item 1) [Figure 20-30-5] and tighten. Check
the pressure again. (See Checking on Page 20-30-1.)
Installation: Tighten the main relief valve to 35 - 40 ft.-lb.

(47 - 54 N•m) torque.
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T180 Bobcat Loader

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HYDRAULIC CONTROL VALVE (2 PIECE CASTING)
(FOOT CONTROL)
Identification
WARNING
Figure 20-40-1 Never work on a machine with the lift arms up unless
W-2059-0598
IMPORTANT
1
N-18695
damage the system.
The hydraulic control valve (2 piece casting) (foot control) I-2003-0888
has a removable BICS section (Item 1) [Figure 20-40-1].

Lift and block the loader. (See Procedure on Page 10-10-
The BICS section and main control valve are in two 1.)
separate castings.
Raise the lift arms and install an approved lift arm support
For identification of the hydraulic control valve (1 piece device (See Installing Lift Arm Support Device on Page
casting) (foot control), (See Identification on Page 20-42- 10-20-1.)
1.) Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Clean the area around the control valve.
Drain the hydraulic reservoir. (See Replacing Hydraulic
Fluid on Page 10-120-2.)
DANGER Remove the control panel. (See Removal and Installation
on Page 50-101-2 [adjustable pintles] or See Removal
and Installation on Page 50-100-1 [non-adjustable
pintles])
P-90328
AVOID DEATH
D-1009-0409
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HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Figure 20-40-4
(FOOT CONTROL) (CONT’D)
1
Removal and Installation (Cont’d)
Figure 20-40-2 4
2
P-48288
1
Mark and disconnect the four electric solenoid
connectors for correct installation (Item 1) [Figure 20-40-
4].
P-48286
Remove the outlet tubeline (Item 2) [Figure 20-40-4]
from the control valve to the hydraulic oil cooler.
Mark all tubelines and hoses for correct installation. Disconnect and cap the brake block hose (Item 3)

The fixed end main valve hose assembly (Item 1) [Figure 20-40-4] from the control valve.
[Figure 20-40-2] is connected to a fixed end fitting on the
control valve. The hose is routed to the back upright
Remove the wire harness clamp bolt (Item 4) [Figure 20-
where the hose is connected to a tee fitting that feeds the
40-4].
base end of both lift cylinders. The hose must be
removed at the back tee fitting, located in the right side Figure 20-40-5
upright.
1
NOTE: Remember the hose routing for ease of
control valve installation.
Figure 20-40-3
2
4 3
1
P-48289
Mark all tubelines and hoses for correct installation.
Disconnect and cap the tubeline (Item 1) [Figure 20-40-

5] from the lift lock valve.
P-31999
Disconnect and remove the BICS valve drain tubeline
(Item 2) [Figure 20-40-5] from the control valve.
Remove the tie - strap (Item 1) [Figure 20-40-3] from the
fixed end main valve hose. Disconnect and remove the hose (Item 3) [Figure 20-40-
5] from the lift arm bypass valve to the drain on the
control valve.
Disconnect the drive motor case drain hose (Item 4)

[Figure 20-40-5].
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(FOOT CONTROL) (CONT'D)
Removal And Installation (Cont'd)
Figure 20-40-6
1
P-48291A
1

40-8].
P-48287
Remove the control pedal crossbar linkage and tilt
linkage. (See Crossbar Linkage Removal And Installation
Remove the connector pins (Item 1) [Figure 20-40-6]. on Page 50-90-2.)

Figure 20-40-7
Figure 20-40-9
1 1
1
P-48290
P-48292A
Remove the two lift arm bypass valve mounting bolts

(Item 1) [Figure 20-40-7] Remove and cap both tubelines (Item 1) [Figure 20-40-
9] from the auxiliary section of the control valve.
Disconnect and cap the hose (Item 2) [Figure 20-40-9]

from the hydraulic reservoir.
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1
Figure 20-40-10
2 P-48295
Connect a hoist to the control valve (Item 1) [Figure 20-

40-12].
P-34390A
Figure 20-40-13
Disconnect and cap the tubeline (Item 1) & (Item 2)
[Figure 20-40-10] from the tilt section of the control

valve.
1
10] from the lift section of the control valve. 1 P-26062
Figure 20-40-11
P-26095 P-26061
1
2 Remove the two mounting bolts (Item 1) [Figure 20-40-
13] fastening the control valve and bracket to the side of
the loader.
Remove the control valve from the loader [Figure 20-40-

13].
P-48294
Reverse procedure for installation.
Disconnect and cap the pump hose (Item 1) [Figure 20-

40-11] at the bottom of the control valve.
Mark and disconnect the BICS electric solenoid

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BICS Valve Removal And Installation
Figure 20-40-14
1 1
1 1
2
1 1
N-18697
1
1
Remove the four large O-rings (Item 1) [Figure 20-40-
16] and the small O-ring (Item 2) [Figure 20-40-16] from
N-18679 the top of the control valve.
Install the four large O-rings (Item 1) [Figure 20-40-16]

Remove the control valve. (See BICS Valve Removal and the small O-ring (Item 2) [Figure 20-40-16] on the
And Installation on Page 20-40-5.)

top of the control valve.
To remove the BICS from the control valve loosen and Figure 20-40-17
remove the six mounting bolts (Item 1) [Figure 20-40-
14].
Figure 20-40-15
6
3
1 2
4
5
N-18679
Install the six mounting bolts [Figure 20-40-17].

N-18695
The chart below lists the correct torque specifications
and tightening sequence when reinstalling the BICS
Remove the BICS valve assembly from the top of the valve assembly to the control valve. Thoroughly clean
control valve [Figure 20-40-15]. and dry bolts and threads in valve. Use liquid adhesive
Loctite® #242 or equivalent.
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BICS Valve Removal And Installation (Cont’d)
STEP TORQUE SEQUENCE

1 110 - 130 in.-lb.
(12,4 - 14,7 N•m)
1
2 190 - 210 in-lb.
(21,5 - 23,7 N•m) 1, 2, 3, 4, 5 & 6
3* 190 - 210 in.-lb.
(21,5 - 23,7 N•m)
*Torque must be 190 - 210 in.-lb. (21,5 - 23,7 N•m) for

every bolt or repeat step 3. N-18687
BICS Valve, Lift Arm Bypass Orifice Disassembly

And Assembly Figure 20-40-20
Figure 20-40-18

1
1
N-18685
N-18686
Using a flat blade screw driver, remove the lift arm
bypass orifice (Item 1) [Figure 20-40-19] & [Figure 20-
Remove the fitting (Item 1) [Figure 20-40-18] from the 40-20].
valve.
Orifice size is 0.078 in.
Reverse the removal procedure to install the lift arm

bypass orifice.
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BICS Valve, Check Valve Disassembly And Assembly
Figure 20-40-21 1
P-8956
1
Clean and inspect the screen (Item 1) [Figure 20-40-23]
on the end of the valve.
N-18683
Reverse the removal procedure to install the BICS check
valve.
Remove the check valve (Item 1) [Figure 20-40-21].

Installation: Tighten the valve to 20 ft.-lb. (27 N•m)
torque.
Figure 20-40-22
2
1
N-18684
Remove and install with new O-rings (Item 1) and back-

up ring (Item 2) [Figure 20-40-22].
Check valve (Item 3) [Figure 20-40-22] has a rating of 5 -

10 PSI.
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BICS Valve Lock Valve Disassembly And Assembly
Figure 20-40-24
1
1 1
N-18689
Remove the lock valves (Item 1) [Figure 20-40-24],

[Figure 20-40-25] & [Figure 20-40-26] from the BICS
N-18682 valve.
Installation: Tighten the lock valves to 25 ft.-lb. (34 N•m)

Figure 20-40-25 torque.

Figure 20-40-27
1 1
2
N-18688
2
2
N-18690
Remove the O-rings (Item 1) [Figure 20-40-27] and

back-up rings (Item 2) [Figure 20-40-27] from both the tilt
and lift lock valves.
Install new O-rings (Item 1) [Figure 20-40-27] and back-

up rings (Item 2) [Figure 20-40-27] on the tilt and lift lock
valves.
Reverse the removal procedure to install the lock valve.
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BICS Valve Solenoid Disassembly And Assembly

1
Figure 20-40-28
N-18692
Remove the solenoid cartridge (Item 1) [Figure 20-40-

30].
N-18691
Installation: Tighten the cartridge to 20 ft.-lb. (27 N•m)
torque.
Remove the mounting nut (Item 1) [Figure 20-40-28]
from the solenoid cartridge.

Installation: Tighten the mounting nut to 53 in.-lb. (6
N•m) torque.
Remove the solenoid (Item 2) [Figure 20-40-28].
Figure 20-40-29
N-18693A
Remove the O-rings (Item 1) [Figure 20-40-29] from

both ends of the solenoid.
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HYDRAULIC CONTROL VALVE (2 PIECE CASTING) BICS Valve Solenoid Testing
Figure 20-40-32
(Cont’d)
Figure 20-40-31
3
2
P9175
1
Use an ohm meter to measure coil resistance [Figure
N-18694 20-40-32].
Coil wires do not have polarity.

Remove the O-rings (Item 1) [Figure 20-40-31] and

back-up rings (Item 2) [Figure 20-40-31] from the Correct resistance for the auxiliary, lift and tilt lock coils
cartridge. are 7 - 10 ohm.
Clean all parts in solvent and dry with compressed air. The other coils (BICS, diverter, select valve) are 5 - 8
ohm.
Inspect all parts for wear and replace any showing
excessive wear.
NOTE: The screen (Item 3) [Figure 20-40-31] may be

cleaned with solvent. If it is torn or worn it
needs to be replaced.
Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-40-29] & [Figure

20-40-31] and new back-up rings (Item 2) [Figure 20-40-
31] on the solenoid cartridge.
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H3 H2 H1
Identification Chart
ITEM T180 LOADER C4

A1 Lift Cylinder Base End/Restrictor G3 B3 A3 D3
A2 Tilt Cylinder Base End
C3
A3 Auxiliary Hydraulics B2 A2
G2 E2 D2
B1 Lift Cylinder Rod End
F2 C2
B2 Tilt Cylinder Rod End G1 B1 A1 E1 D1
B3 Auxiliary Hydraulics F1 C1
C1 Load Check Valve/Lift Function MR
C2 Load Check Valve/Tilt Function
TS-1918
C3 Orificed Load Check Valve/Auxiliary Function
C4 Outlet Fluid Flow
D1 Lift Spool Detent
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool/Centering Springs
E1 Port Relief Valve – 3500 PSI
E2 Anti–Cavitation/Port Relief Valve – 3500 PSI

F1 Anti-Cavitation Valve
F2 Port Relief Valve – 3500 PSI
G1 LIft Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H1 Auxiliary Electric Solenoid
H2 Plug/Port Relief (Optional) – 3100 PSI
MR Main Relief Valve – 3300 PSI
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Load Check Valve
Figure 20-40-34
1 1
1
1
1
N-18698
2
Mark each valve section, spool and related parts so that
they will be returned to its original valve section during
N-18697 assembly.
Use bolts to fasten the control valve to a work bench for

Remove the BICS valve assembly from the control valve. easier disassembly and assembly procedures.
(See BICS Valve Removal And Installation on Page 20-

40-5.) Loosen the load check valve plugs (Item 1) [Figure 20-
40-35].
Remove the four large O-rings (Item 1) [Figure 20-40-
34] and small O-ring (Item 2) [Figure 20-40-34]. Always Installation: Always use new O-ring. Tighten the plug to
replace these O-rings before installing the BICS valve 35 - 40 ft.-lb. (47 - 54 N•m) torque.
assembly.
Figure 20-40-36
IMPORTANT
1
damage the system.
I-2003-0888
3
2 N-18699
Remove the load check plugs (Item 1) [Figure 20-40-36].
Remove the spring (Item 2) [Figure 20-40-36] and

poppet (Item 3) [Figure 20-40-36].
T180 Bobcat Loader

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Load Check Valve (Cont’d)
Figure 20-40-37
N-19031
2 Remove the main relief valve (Item 1) [Figure 20-40-39].
N-18700 Figure 20-40-40
2 3
The auxiliary section (Item 1) [Figure 20-40-37] uses an 4 5
orifice load check poppet (Item 2) [Figure 20-40-37].

1
NOTE: For correct port locations and valve
component values. (See BICS Valve Removal
Main Relief Valve 1. Relief Valve

2. O-ring
3. Sleeve
Figure 20-40-38 4. Glide Ring
5. O-ring
CD-15092
Remove the O-rings, sleeve, and glide ring from the main
relief valve [Figure 20-40-40].
Installation: Always use new O-rings. sleeve, and glide

ring. Tighten to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
1
N-18923
Loosen the main relief valve (Item 1) [Figure 20-40-38].
T180 Bobcat Loader

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Port Relief Valve
Figure 20-40-41
N-18977
Remove the port relief valve (Item 1) [Figure 20-40-43].
N-18976 Figure 20-40-44
4
Figure 20-40-42

3
2
1
1
1. O-ring
2. Backup Washer
3. O-ring
4. Relief Valve
N-18844
N-18923 Remove the O-rings and back-up washer from the port
Loosen the port relief valve (Item 1) [Figure 20-40-41] &

[Figure 20-40-42] (Port E1 or F2).
Installation: Always use new O-rings and back-up

washers. Tighten to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
T180 Bobcat Loader

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Anti-Cavitation Valve/Port Relief Valve
Figure 20-40-45 1
N-18843
Remove the O-rings (Item 1) [Figure 20-40-47] from the

anti-cavitation/port relief valve.
N-18976
Loosen the anti-cavitation valve (Item 1) [Figure 20-40-

45].

Figure 20-40-46
N-18978
Remove the anti-cavitation/port relief valve (Item 1)

[Figure 20-40-46] from the control valve for the tilt
section.
T180 Bobcat Loader

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2
1 3 4
Anti-Cavitation Valve
Figure 20-40-48
E-01509
2
1. Anti-Cavitation Valve
2. O-ring
3. Backup Washer
4. O-ring
N-18839
1
Remove the O-rings and back-up washer from the anti-
cavitation valve [Figure 20-40-50].
N-18923
Figure 20-40-49

2
N-19032
Remove the lift lock solenoid (Item 1) [Figure 20-40-48]

& [Figure 20-40-49].
Remove the anti-cavitation valve (Item 2) [Figure 20-40-

48] & [Figure 20-40-49] from the control valve for the lift
section.
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HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Lift And Tilt Lock Block
Figure 20-40-53
Rubber Boot
Figure 20-40-51
1
N-18923
N-18923 Figure 20-40-54
Remove the two screws (Item 1) [Figure 20-40-51] on

the rubber boot retainer.

1
Installation: Tighten the screws to 90 - 100 in.-lb. (10,2 -
11,3 N•m) torque.
Figure 20-40-52
2 2
1 1
2
N-18925
Remove the lock solenoids (Item 1) [Figure 20-40-53] &

1 2 [Figure 20-40-54] from the lock block.
Remove the rubber boot (Item 2) [Figure 20-40-53] &

N-18924 [Figure 20-40-54]. (See Rubber Boot on Page 20-40-
17.)
Remove the rubber boot (Item 1) [Figure 20-40-52] and

retainer (Item 2) [Figure 20-40-52].
T180 Bobcat Loader

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Lift And Tilt Lock Block (Cont’d)
Figure 20-40-55
2
1
N-18927
Remove the spacer (Item 1) [Figure 20-40-57] and O-

ring (Item 2) [Figure 20-40-57] from the lift spool.
N-18926
Figure 20-40-58
Remove the block [Figure 20-40-55].

NOTE: The lock block must be clean and oil free. (Oil
can cause the solenoids not to function
properly.)
Lift Spool and Detent
Figure 20-40-56
1
N-18976
Remove the end cap (Item 1) [Figure 20-40-58].
1
N-18923
The tool listed will be needed to do the following

procedure:
MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool
Remove the lift and tilt lock block (Item 1) [Figure 20-40-
56] from the control valve. (See Lift And Tilt Lock Block
on Page 20-40-17.)
T180 Bobcat Loader

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Lift Spool and Detent (Cont’d)

WARNING
Figure 20-40-59 The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
Figure 20-40-61
N-18971
Use a screwdriver to remove the snap ring (Item 1)

[Figure 20-40-59].

N-18973
Remove the washer (Item 2) [Figure 20-40-59].
Figure 20-40-60 Put a rag around the detent assembly [Figure 20-40-61].
This will prevent the detent balls and spring from being
lost when the detent sleeve is removed.
Figure 20-40-62
3 2
2 1
1 N-18972
2
Remove the screws (Item 1) [Figure 20-40-60] from the
detent bonnet.
N-18974
Remove the detent bonnet (Item 2) [Figure 20-40-60].

Remove the detent sleeve (Item 1) [Figure 20-40-62],
detent balls (Item 2) [Figure 20-40-62] and spring (Item
3) [Figure 20-40-62].
T180 Bobcat Loader

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Lift Spool and Detent (Cont'd)
Figure 20-40-63
P-8988
1
Clamp the linkage end of the spool in a vise [Figure 20-
40-65].
N-18975
NOTE: Protect spool before clamping in vise.
Remove the spool assembly and seal (Item 1) [Figure Figure 20-40-66
20-40-63] from the control valve.

2
Figure 20-40-64
1
3
1
N-18915
N-18930 Install the spring tool (Item 1) [Figure 20-40-66] over the
centering spring.
Remove the spool seal (Item 1) [Figure 20-40-64] from NOTE: Be careful when removing the detent adapter
the linkage end of the valve. (Item 2) [Figure 20-40-66] from the centering
spring, as it is under spring pressure.
NOTE: The centering spring (Item 3) [Figure 20-40-66]

is white on all 700 series loaders.
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Lift Spool and Detent (Cont'd) 1
Figure 20-40-67
N-19009
1 Remove spring tool (Item 1) [Figure 20-40-69] from the

2
spring assembly.
N-18916
Figure 20-40-70
Put a rag around the detent assembly [Figure 20-40-67].
This will prevent the detent balls and spring from being 1

2
lost when the detent adapter is removed.
3
Remove the detent adapter with an Allen wrench.
Remove the back-up washer (Item 1) [Figure 20-40-67]

4
and spool seal (Item 2) [Figure 20-40-67].
Figure 20-40-68
N-18919A
Inspect the adapter (Item 1) [Figure 20-40-70], collar

(Item 2) [Figure 20-40-70], spring (Item 3) [Figure 20-
40-70], and washer (Item 4) [Figure 20-40-70].
N-19004
Remove the detent adapter (Item 1) [Figure 20-40-68]

from the spring assembly.
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Figure 20-40-71 2
1
N-18961
Install the O-ring (Item 1) [Figure 20-40-73] over the

nipple on the plastic plug (Item 2) [Figure 20-40-73].
N-18918
Figure 20-40-74
Remove the stud from the end of the spool [Figure 20-
40-71].

Figure 20-40-72
N-18963
1
Install the plastic plug and O-ring in the spool [Figure 20-
40-74].
N-18920
Removal of the plastic plug:
Make a center point in the plug using a 1/16 inch drill.
Drill a hole all the way through the plug using a 7/64 inch
tap drill
Turn a 6-32 tap (Item 1) [Figure 20-40-72] into the plug.

Pull the tap and plug out of the spool. Be careful, do not
break the tap.
Clean all the debris from inside the spool bore.
NOTE: DO NOT USE Loctite® ON THE STUD

THREADS.
T180 Bobcat Loader

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Figure 20-40-75 2
O-ring
1 3
2
Plastic N-18958
Plug
0.60 in.
(15,2 mm)
Apply grease on all the detent component surfaces
before assembly [Figure 20-40-77].
B-14712
Install the spring (Item 1) [Figure 20-40-77] and detent
balls (Item 2) [Figure 20-40-77] into the adapter (Item 3)
Install the stud and tighten until the other end of the stud [Figure 20-40-77] and compress with the detent pliers
is out about 0.600 in. (15,2 mm) from the spool [Figure

(Item 1) [Figure 20-40-78].
20-40-75].
Figure 20-40-78
Figure 20-40-76
N-18968
N-18967
Install the detent adapter to the collar [Figure 20-40-78].

Clamp the collar (Item 1) [Figure 20-40-76] in a vice.
NOTE: The collar and the detent adapter are held
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.
T180 Bobcat Loader

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Figure 20-40-79
N-19005
Install the spring assembly to the lift spool hand tight

[Figure 20-40-81].
N-19004
Remove the spring tool.
Install the spring tool (Item 1) [Figure 20-40-79] over the Check the alignment of the detent adapter and the
washer, spring, collar and detent adapter.

washer.
Figure 20-40-80 Tighten the adapter to 90 - 100 in.-lb. (10,2 - 11,3 N•m).
NOTE: The adapter must fit in the center of the

washer (Item 1) [Figure 20-40-81].
2 Figure 20-40-82
N-18917
Install the spool seal (Item 1) [Figure 20-40-80] and

back-up washer (Item 2) [Figure 20-40-80].
CD-15051
Install the detent balls and spring [Figure 20-40-82].
T180 Bobcat Loader

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Figure 20-40-83
2
N-18972
Install the lift spool assembly in the spool bore [Figure

20-40-85].
N-19007
Install the detent bonnet (Item 1) [Figure 20-40-85].
Hold the detent balls in place with the detent pliers Install the mounting screws (Item 2) [Figure 20-40-85].
[Figure 20-40-83].

Installation: Tighten the screws to 90 - 100 in.-lb. (10,2 -
Figure 20-40-84 11,3 N•m) torque.
Figure 20-40-86
N-19008
1
N-18971
Install the detent sleeve (Item 1) [Figure 20-40-84] to the
detent adapter.
Install the washer (Item 1) [Figure 20-40-86] and snap
ring (Item 2) [Figure 20-40-86].
T180 Bobcat Loader

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Figure 20-40-87
1 2
1 N-18927
Install the spacer (Item 1) [Figure 20-40-89] and O-ring

(Item 2) [Figure 20-40-89] on the linkage end of the lift
N-18976 spool.
Figure 20-40-90
Install the end cap (Item 1) [Figure 20-40-87].

Figure 20-40-88
1
1
N-18923
N-18930 Install the lift and tilt lock block (Item 1) [Figure 20-40-
90]. (See Lift And Tilt Lock Block on Page 20-40-17.)
Install the spool seal (Item 1) [Figure 20-40-88] on the

linkage end of the valve.
T180 Bobcat Loader

146 of 961
Tilt Spool Removal And Installation
Figure 20-40-91
N-18686
1 Remove the screws (Item 1) [Figure 20-40-93] from the

end cap.
N-18923
Installation: Tighten the bolt to 90 - 100 in.-lb. (10,2 -
11,3 N•m) torque.
Remove the lift and tilt lock block (Item 1) [Figure 20-40-
91] from the control valve. (See Lift And Tilt Lock Block

Figure 20-40-94
on Page 20-40-17.)
Figure 20-40-92
2
1
N-18816
N-18928 Remove the spool, centering spring, back-up washer and

spool seal [Figure 20-40-94].
Remove the spacer (Item 1) [Figure 20-40-92] and O- Assembly: Always use a new spool seal.
ring (Item 2) [Figure 20-40-92] from the tilt spool.
T180 Bobcat Loader

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Tilt Spool Removal And Installation (Cont'd)

2 1
Figure 20-40-95
3
4
1
N-18944A

(Item 2) [Figure 20-40-97], spring (Item 3) [Figure 20-
N-18942 40-97], and washer (Item 4) [Figure 20-40-97].
Figure 20-40-98
Put the linkage end of the spool in the vice [Figure 20-
40-95].

2
Install the spool tool (Item 1) [Figure 20-40-95] over the 1
centering spring.
Figure 20-40-96
1 1
N-18930 N-18943
Remove the spool seal(s) (Item 1) [Figure 20-40-98] and

the back-up washer (Item 2) [Figure 20-40-98].
Assembly: Always use a new spool seal.

N-19014
Remove the bolt (Item 1) [Figure 20-40-96] holding the

centering spring to the spool.

11,3 N•m) torque.
Remove spring tool from the spring assembly.
T180 Bobcat Loader

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Auxiliary Spool Removal And Installation

1
Figure 20-40-99
1 N-18989
Remove the spool (Item 1) [Figure 20-40-101].
N-18976 Assembly: Put grease on all the centering spring

component parts.
end cap (both sides).

11,3 N•m) torque.
Figure 20-40-100
N-18990
Remove the end cap, O-ring, springs and center spring

retainer (both sides) [Figure 20-40-100].
NOTE: If the centering spring retainer (Item 1) [Figure

20-40-100] must be replaced, replace the
retainer on the opposite end also.
T180 Bobcat Loader

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Auxiliary Electric Solenoid Disassembly
Figure 20-40-102
2
3
1
1 N-18992
1 Remove the coil (Item 1) [Figure 20-40-104] and end

plate (Item 2) [Figure 20-40-104].
N-18822
Remove the solenoid valve (Item 3) [Figure 20-40-104].
Remove the nut (Item 1) [Figure 20-40-102] from both Installation: Tighten valve to 8 - 12 ft.-lb. (11 - 16 N•m)
solenoids.

torque.
Installation: Tighten the nut to 8 - 12 ft.-lb. (11 - 16 N•m) Figure 20-40-105
torque.
Figure 20-40-103
2
1
1
N-18795
N-18823 Remove the O-rings (Item 1) [Figure 20-40-105] from

the solenoid valves.
Remove the end plate (Item 1) [Figure 20-40-103] and

housing (Item 2) [Figure 20-40-103].
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Port Relief (Optional)
Port-Auxiliary Section Disassembly
Figure 20-40-106
1 2
N-18843
1
Remove the O-rings (Item 1) [Figure 20-40-107] &

[Figure 20-40-108] and back-up ring (Item 2) [Figure 20-
N-18993 40-107] & [Figure 20-40-108] from the plug.
Cleaning And Inspection

Remove the plug (Item 1) [Figure 20-40-106] or optional
port relief valve from the control valve.

Clean all components with clean solvent and dry with
compressed air.
NOTE: Optional port relief (Item 1) [Figure 20-40-106]
is set at 3500 PSI. Check the spools for wear or scratches.
Figure 20-40-107 Check that the spools are not loose in their bore.
Plug
Check that the centering springs are not broken.
Check that the load check valve seats are not worn.
2
Check the load check poppets for damage.
Check the rubber boots and retainers.
Replace the parts as needed.

1
Use new O-rings and back-up rings.
1
Apply oil to all new O-rings and back-up rings before
N-18800 installation.
T180 Bobcat Loader

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T180 Bobcat Loader

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(ADVANCED CONTROL SYSTEM) (ACS)
Identification
WARNING
W-2059-0598
IMPORTANT
1 When repairing hydrostatic and hydraulic systems,
N-18695
damage the system.
The hydraulic control valve (2 piece casting) (Advance I-2003-0888
Control System) (ACS) has a removable BICS section

(Item 1) [Figure 20-41-1]. Lift and block the loader. (See Procedure on Page 10-10-
1.)
The BICS section and main control valve are in two
separate castings. Raise the lift arms and install an approved lift arm support
device (See Installing Lift Arm Support Device on Page
For identification of the hydraulic control valve (1 piece 10-20-1.)
casting) (Advanced Control System) (ACS), (See Raise the operator cab. (See Raising The Operator Cab
Identification on Page 20-42-1.) on Page 10-30-1.)
Removal and Installation Clean the area around the control valve.

pintles])
P-90328
AVOID DEATH
D-1009-0409
T180 Bobcat Loader

153 of 961
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D)
Figure 20-41-2
1
1
P-48881
Remove the tubeline clamp (Item 1) [Figure 20-41-4].

This will allow room to move the auxiliary tubelines away
P-31998 from the control valve.
Figure 20-41-5

The fixed end main valve hose assembly (Item 1) [Figure
20-41-2] is connected to a fixed end fitting on the control 4
valve. The hose is routed to the back upright where the
hose is connected to a tee fitting that feeds the base end
of both lift cylinders. The hose must be removed at the
back tee fitting, located in the right side upright. 1

Figure 20-41-3 2
3
P-48894
Disconnect the tubeline (Item 1) [Figure 20-41-5] from

the lift arm bypass valve.
1
Disconnect the drain hose (Item 2) [Figure 20-41-5] from
the control valve.
Disconnect the motor case drain hose (Item 3) [Figure

20-41-5] from the lift arm bypass valve.
P-31999 Remove the bolts (Item 4) [Figure 20-41-5] from the lift
arm bypass control valve. After removing the lift arm
bypass valve mounting bolts move the wire harness and
Remove the tie - strap (Item 1) [Figure 20-41-3] from the
bypass valve towards the engine to give more room for
fixed end main valve hose.
control valve removal.
T180 Bobcat Loader

154 of 961
Figure 20-41-6
2
1
1 4 1
2
P-48896
3
Label and disconnect the actuator electrical connectors

(Item 1) [Figure 20-41-7].
P-48895
Remove the bolt (Item 2) [Figure 20-41-7] from the wire
harness clamp.
Label and disconnect the electrical connectors (Item 1)
[Figure 20-41-6].

Installation: Tighten the bolt to 25 - 28 ft.-lb. (34 - 38
N•m) torque.
Disconnect the outlet tubeline (Item 2) [Figure 20-41-6]
from the control valve. Figure 20-41-8
Disconnect and cap the brake block hose (Item 3)
[Figure 20-41-6] from the control valve.
1 2
41-6].
P-48884
Remove the drain tubeline (Item 1) [Figure 20-41-8] from

the control valve and BICS valve.
Disconnect the auxiliary tubelines (Item 2) [Figure 20-41-

8].
Disconnect the drain hose (Item 3) [Figure 20-41-8] from

the control valve.
T180 Bobcat Loader

155 of 961

1
Figure 20-41-9
P-48884
1
Connect a hoist (Item 1) [Figure 20-41-11] to the control

valve.
P-48899
Disconnect the lift tubeline (Item 1) [Figure 20-41-9].

Disconnect the tilt tubeline (Item 2) [Figure 20-41-9].
Disconnect the tilt tubeline (Item 3) [Figure 20-41-9].
Figure 20-41-10
Figure 20-41-12
1
2
1 P-26062
P-48898
P-26095 P-26061
Disconnect the inlet hose (Item 1) [Figure 20-41-10]
from the bottom of the control valve.
Remove the two mounting bolts (Item 1) [Figure 20-41-
Disconnect the BICS valve electrical connector (Item 2)
the loader.
[Figure 20-41-10].
12].
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156 of 961
BICS Valve Removal And Installation
Figure 20-41-13
1 1
1
1
2
1 1
N-18697
1
1 Remove the four large O-rings (Item 1) and the small O-
ring (Item 2) [Figure 20-41-15] from the top of the control
N-18679 valve.
Install the four large O-rings (Item 1) and the small O-ring
Remove the control valve. (See BICS Valve Removal (Item 2) [Figure 20-41-15] on the top of the control valve.

To remove the BICS from the control valve loosen and
remove the six mounting bolts (Item 1) [Figure 20-41-
13].
Figure 20-41-14
N-18695
Remove the BICS valve assembly from the top of the

control valve [Figure 20-41-14].
T180 Bobcat Loader

157 of 961
BICS Valve Removal And Installation (Cont’d)
Figure 20-41-16
3 6
1 2
5 4
N-18679
Install the six mounting bolts [Figure 20-41-16].

The chart below lists the correct torque specifications
and tightening sequence when reinstalling the BICS
valve assembly to the control valve. Thoroughly clean
and dry bolts and threads in valve. Use liquid adhesive
Loctite® #242 or equivalent.
STEP TORQUE SEQUENCE

1 110 - 130 in.-lb.
(12,4 - 14,7 N•m)
2 190 - 210 in.-lb. 1,2,3,4,5 & 6
(21,5 - 23,7 N•m)
3 190 - 210 in.-lb.
(21,5 - 23,7 N•m)
*Torque must be 190 - 210 in.-lb. (21,5 - 23,7 N•m) for

every bolt or repeat step 3.
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BICS Valve, Lift Arm Bypass Orifice Removal And

Installation
Figure 20-41-17
N-18687
1
Figure 20-41-19
N-18686
Remove the fitting (Item 1) [Figure 20-41-17] from the

valve.
N-18685
Using a flat blade screw driver, remove the lift arm

bypass orifice (Item 1) [Figure 20-41-18] & [Figure 20-
41-19].
Orifice size is 0.078 in.
Reverse the removal procedure to install the lift arm

bypass orifice.
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BICS Valve, Check Valve Removal And Installation
Figure 20-41-20 1
1 P-8956
Clean and inspect the screen (Item 1) [Figure 20-41-22]

on the end of the valve.
N-18683
Reverse the removal procedure to install the BICS check
valve.
Remove the check valve (Item 1) [Figure 20-41-20].

Installation: Tighten the valve to 20 ft.-lb. (27 N•m)
torque.
Figure 20-41-21
2
1
N-18684
Remove the O-rings (Item 1) and back-up ring (Item 2)

[Figure 20-41-21].
Install new O-rings (Item 1) and back-up ring (Item 2)

[Figure 20-41-21] on the check valve.
Check valve (Item 3) [Figure 20-41-21] has a rating of 5 -

10 PSI.
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BICS Valve Lock Valve Removal And Installation
Figure 20-41-23
1
1
1
N-18689
Remove the lock valves (Item 1) [Figure 20-41-23],

[Figure 20-41-24] & [Figure 20-41-25] from the BICS
N-18682 valve.
Installation: Tighten the lock valves to 25 ft.-lb. (34 N•m)

Figure 20-41-24 torque.

1
N-18688
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BICS Valve Lock Valve Removal And Installation

(Cont’d) 1
Figure 20-41-26 1
N-18693
2 Remove the O-rings (Item 1) [Figure 20-41-28] from

2 both ends of the solenoid.
2
N-18690 Figure 20-41-29
Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-41-26] from both the tilt and lift lock valves. 1
Install new O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-41-26] on the tilt and lift lock valves.
Reverse the removal procedure to install the lock valve.
BICS Valve Solenoid Removal And Installation
Figure 20-41-27
1 N-18692
Remove the solenoid cartridge (Item 1) [Figure 20-41-

29].
2 Installation: Tighten the cartridge to 20 ft.-lb. (27 N•m)

torque.
N-18691

from the solenoid cartridge.
Installation: Tighten the mounting nut to 53 in.-lb. (6

N•m) torque.
Remove the solenoid (Item 2) [Figure 20-41-27].
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HYDRAULIC CONTROL VALVE (2 PIECE CASTING) BICS Valve Solenoid Testing
Figure 20-41-31
BICS Valve Solenoid Removal And Installation
(Cont’d)
Figure 20-41-30
3
2
P9175
1
Use an ohm meter to measure coil resistance [Figure
N-18694 20-41-31].
Coil wires do not have polarity.


[Figure 20-41-30] from the cartridge. Correct resistance for the BICS is 9.7 ± 1 ohm at 20° C.
Clean all parts in solvent and dry with compressed air. Correct resistance for the tilt and lift lock coils is 7.7 ± 1
ohm at 20° C.
excessive wear.

back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-41-28] & [Figure

20-41-30] and new back-up rings (Item 2) [Figure 20-41-
30] on the solenoid cartridge.
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HYDRAULIC CONTROL VALVE (2 PIECE CASTING) NOTE: There are two types of sealing designs used
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) on the actuators and the actuator adapters.
Actuator Removal And Installation Figure 20-41-34
NOTE: Actuators can be removed with the control

EARLIER SEALING STYLE
valve in the loader. Remove the lift arm
bypass valve and the control panel to allow
room for actuator removal in the loader.
Figure 20-41-32
1
3
1
2
P-51830
The earlier style holds the O-ring (Item 1) in the actuator

adapter (Item 2). The actuator sealing face (Item 3)
[Figure 20-41-34] has a flat face and no O-ring.
1

2 N-19112 Figure 20-41-35
Remove the two screws (Item 1) [Figure 20-41-32] on LATER SEALING STYLE
the actuator retainer.
Installation: Tighten the bolt and nut to 90 - 100 in.-lb.

(10,2 - 11,3 N•m) torque.
Pull the actuator (Item 2) [Figure 20-41-32] away from

the control valve.
Figure 20-41-33 1
2
3
P-51831
The later style holds the O-ring (Item 1) in the actuator

sealing face (Item 2). The actuator adapter (Item 3)
[Figure 20-41-35] has no O-ring.
1 NOTE: The later style actuator can replace the earlier

style actuator as long as the actuator adapter
is changed to the later style.
N-19113
Use a drift pin and hammer to remove the actuator pin

(Item 1) [Figure 20-41-33] from the actuator and the lift
or tilt spool.
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Actuator Removal And Installation (Cont’d)
Figure 20-41-36
3
2
1 N-19114
Remove the actuator (Item 1) [Figure 20-41-36].

Remove the O-ring (Item 2) [Figure 20-41-36].
Remove the actuator adapter (Item 3) [Figure 20-41-36].
Figure 20-41-37
N-18940
Repeat removal for the other actuator [Figure 20-41-37].
NOTE: The calibration procedure must be followed

when replacing handle sensor, actuator or
ACS controller. (See Calibration Procedure on
Page 60-120-16.)
T180 Bobcat Loader

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H1
H3 H2
Identification Chart (ACS)
ITEM T180 ACS LOADER

C4
A1 Lift Cylinder Base End/Restrictor B3
G3 A3 D3
A2 Tilt Cylinder Base End
C3
G2 B2 D2
A3 Auxiliary Hydraulics A2 E2
C2
B1 Lift Cylinder Rod End F2 G1 D1
B1 A1 E1
B2 Tilt Cylinder Rod End C1
F1
MR
B3 Auxiliary Hydraulics
C1 Load Check Valve/Lift Function
PE1339
C2 Load Check Valve/Tilt Function
C3 Orificed Load Check Valve/Auxiliary Function
C4 Outlet Fluid Flow
D1 Lift Spool Centering Spring
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool/Centering Springs

E1 Port Relief Valve-3500 PSI
E2 Anti-Cavitation/Port Relief Valve-3500 PSI
F1 Anti-Cavitation Valve
F2 Port Relief Valve-3500 PSI
G1 Lift Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H2 Plug/Port Relief (Optional)-3100 PSI
MR Main Relief Valve-3300 PSI
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Lift Base End Restrictor

IMPORTANT
Figure 20-41-39
damage the system.
1 I-2003-0888
Figure 20-41-41
N-21159
1
Remove the BICS valve assembly from the control valve.

41-5.)
Remove the restrictor (Item 1) [Figure 20-41-39] from

the lift section base end port.
N-19100
Load Check Valve

Mark each valve section, spool and related parts so that
Figure 20-41-40 they will be returned to their original valve section during
assembly.
Use bolts to fasten the control valve to a work bench for

easier disassembly and assembly procedures.
1 1
Loosen the load check valve plugs (Item 1) [Figure 20-
41-41].
1
1 Installation: Always use new O-ring. tighten the plug to
35 - 40 ft.-lb. (47 - 54 N•m) torque.
N-19099
Remove the BICS valve assembly from the control valve.

41-5.)
Remove the four large O-rings (Item 1) and small O-ring

(Item 2) [Figure 20-41-40]. Always replace these O-rings
before installing the BICS valve assembly
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HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Main Relief Valve
Figure 20-41-44
Load Check Valve (Cont’d)
Figure 20-41-42
1 1
N-19034
3
2 N-19101 Loosen the main relief valve (Item 1) [Figure 20-41-44].
Figure 20-41-45
Remove the load check plugs (Item 1) [Figure 20-41-42].

Remove the spring (Item 2) and poppet (Item 3) [Figure
20-41-42].
Figure 20-41-43
1
1
N-19035
Remove the main relief valve (Item 1) [Figure 20-41-45].
2 N-19102
The auxiliary section (Item 1) uses an orifice load check

poppet (Item 2) [Figure 20-41-43].
T180 Bobcat Loader

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Main Relief Valve (Cont’d)
Figure 20-41-46
1
2
3 4 5
B-06764
1. Relief Valve N-19034

2. O-ring
3. Sleeve
4. Glide Ring Loosen the port relief valve (Item 1) [Figure 20-41-47] &
5. O-ring [Figure 20-41-48] (Port E1 or F2). (See Identification
CD-15092 Chart (ACS) on Page 20-41-14.)

Remove the O-rings, sleeve, and glide ring from the main washers. Tighten to 35 - 40 ft.-lb. (47 - 54 N•m) torque.

Figure 20-41-49
Installation: Always use new O-rings, sleeve, and glide
ring. TIghten to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
Port Relief Valve
Figure 20-41-47
N-18981
Remove the port relief valve (Item 1) [Figure 20-41-49].
N-19000
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Port Relief Valve (Cont’d)
Figure 20-41-50
4 1
2
1
1. O-ring N-18980
2. Backup Washer
3. O-ring
Remove the anti-cavitation/port relief valve (Item 1) from
4. Relief Valve
the control valve for the tilt section [Figure 20-41-52].
N-18844
Remove the O-rings and back-up washer from the port

Figure 20-41-53
Anti-Cavitation Valve/Port Relief Valve
Figure 20-41-51
N-18843

N-19003 anti-cavitation/port relief valve.
Loosen the anti-cavitation valve (Item 1) [Figure 20-41-

51].
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1 2 4
Anti-Cavitation Valve 3
Figure 20-41-54
E-1509A
1
1. Anti-Cavitation Valve
2. O-ring
3. Backup Washer
4. O-ring
N-18839
Remove the O-rings and back-up washer from the anti-

cavitation valve [Figure 20-41-56].
N-19034
Tilt Spool Removal And Installation
Figure 20-41-55 Figure 20-41-57

1
N-19036
N-19112
Remove the anti-cavitation valve (Item 1) [Figure 20-41- Remove the actuator (Item 1) [Figure 20-41-57] from the
54] & [Figure 20-41-55] from the control valve. control valve. (See Actuator Removal And Installation on
Page 20-41-12.)
T180 Bobcat Loader

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HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Lift Spool Removal And Installation
Figure 20-41-60
Tilt Spool Removal And Installation (Cont’d)
Figure 20-41-58
1 1
N-19112
N-19003 Remove the actuator (Item 1) [Figure 20-41-60] from the

control valve. (See Actuator Removal And Installation on
Page 20-41-12.)
cap.

Figure 20-41-61
11,3 N•m) torque.
Figure 20-41-59
1
1
1 N-19003

end cap.
N-18983
11,3 N•m) torque.
Remove the spool assembly (Item 1) [Figure 20-41-59]
and seal from the control valve.
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Lift Spool Removal And Installation (Cont’d)
Figure 20-41-62 1
N-19014

N-18985
11,3 N•m) torque.
Remove the spool assembly (Item 1) [Figure 20-41-62]
and seal from the control valve.

Assembly: Always use a new spool seal. Figure 20-41-65
Lift and Tilt Spool Disassembly And Assembly
2 1
Figure 20-41-63 3
4
1
N-18944A

N-18942 (Item 2) [Figure 20-41-65], spring (Item 3) [Figure 20-
41-65], and washer (Item 4) [Figure 20-41-65].
41-63].
Install the spool tool (Item 1) [Figure 20-41-63] over the

centering spring.
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Lift and Tilt Spool Disassembly And Assembly

(Cont’d)
4
3
Figure 20-41-66
2
1
2
1
N-18987
1
Remove the end cap (Item 1), O-ring (Item 2) springs

(Item 3) and washer (Item 4) [Figure 20-41-68] (both
sides).
N-18930 N-18943
Remove the spool seal(s) (Item 1) and the back-up

Figure 20-41-69
Auxiliary Spool Removal And Installation 1
Figure 20-41-67
1 N-18988
Assembly: Put grease on all the centering spring

component parts.
N-19003

end cap (both sides).

11,3 N•m) torque.
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Auxiliary Electric Solenoid
Figure 20-41-70
3
2
1 N-18992
Remove the coil (Item 1) and end plate (Item 2) [Figure

1 20-41-72].
N-18996
Remove the solenoid valve (Item 3) [Figure 20-41-72].
Remove the nut (Item 1) [Figure 20-41-70] from both Installation: Tighten valve to 96 - 144 in.-lb. (11 - 16
solenoids.

N•m) torque.
Installation: Tighten the nut to 96 - 144 in.-lb. (11 - 16 Figure 20-41-73
N•m) torque.
Figure 20-41-71
2
1
1
N-18795
N-18823 Remove the O-rings (Item 1) [Figure 20-41-73] from the

solenoid valves.
Remove the end plate (Item 1) and housing (Item 2) Installation: Always use new O-rings and apply oil to the
[Figure 20-41-71]. O-rings prior to installation.
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Port-Auxiliary Section
Figure 20-41-74
2 1
N-18843
1
Remove the O-rings (Item 1) [Figure 20-41-75] &

[Figure 20-41-76] and back-up ring (Item 2) [Figure 20-
N-18996 41-75] & [Figure 20-41-76] from the plug.
Cleaning And Inspection

Remove the plug (Item 1) [Figure 20-41-74] or optional
port relief valve from the control valve.

Clean all components with clean solvent and dry with
compressed air.
Figure 20-41-75
Check the spools for wear or scratches.
Plug
Check that the spools are not loose in their bore.
Check that the centering springs are not broken.

2
Check that the load check valve seats are not worn.
Check the load check poppets for damage.
1 Check the rubber boots and retainers.
1 Replace the parts as needed.
N-18800 Use new O-rings and back-up rings.
Apply oil to all new O-rings and back-up rings before

installation.
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(FOOT CONTROL)
Identification
WARNING
W-2059-0598
IMPORTANT
P-51436
damage the system.
The hydraulic control valve (1 piece casting) (foot control) I-2003-0888
(Item 1) [Figure 20-42-1] does not have a removable

BICS section. Lift and block the loader. (See Procedure on Page 10-10-
1.)
The BICS section and main control valve are in one
casting. Raise the lift arms and install an approved lift arm support
casting) (foot control), (See Identification on Page 20-40- Raise the operator cab. (See Raising The Operator Cab
1.) on Page 10-30-1.)
Removal And Installation Clean the area around the control valve.
Drain the hydraulic reservoir. Replacing Hydraulic Fluid
10-120-2

pintles])
P-90328
AVOID DEATH
D-1009-0409
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4
Figure 20-42-2 2 1
3
1
1
P-51714
Mark and disconnect the four electric solenoid

connectors for correct installation (Item 1) [Figure 20-42-
4].
P-51710
from the control valve to the hydraulic oil cooler.

The fixed end main valve hose (Item 1) [Figure 20-42-2] Disconnect and cap the supply hose (Item 3) and the
is connected to a fixed end fitting on the control valve. supply hose clamp (Item 4) [Figure 20-42-4].
The hose is routed to the back upright where the hose is
connected to a tee fitting that feeds the base end of both Figure 20-42-5
lift cylinders. The hose must be removed at the back tee
fitting, located in the right side upright.
Figure 20-42-3
1
P-51725

P-51711
Remove the tie-strap (Item 1) [Figure 20-42-3] from the

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Figure 20-42-6
2
2 P-51724
Disconnect the wire harness tie-strap mounts (Item 1)

[Figure 20-42-8] from the lift arm bypass bracket.
P-51715
Remove the lift arm bypass tubeline (Item 2) [Figure 20-
42-8] from the control valve drain.
6] from the lift arm bypass valve to the control valve.

Figure 20-42-9
from the lift arm bypass valve to the drive motor case
drain.
Figure 20-42-7 1
1
1
P-48287
Remove the connector pins (Item 1) [Figure 20-42-9].
P-51719

main valve mounting bracket.
T180 Bobcat Loader

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1
Figure 20-42-10
P-51727
Remove tubeline clamp bolt (Item 1) [Figure 20-42-12]

from the auxiliary tubelines in the left rear upright.
P-51723
Installation: Tighten bolt to 15 - 20 ft.-lb. (20 - 27 N•m)
torque.
NOTE: Skid loader transmission shown, procedure is
the same.

Figure 20-42-13
42-10].
Remove the control pedal crossbar linkage and tilt

linkage. (See Crossbar Linkage Removal And Installation 2
1 1
on Page 50-90-2.)
Figure 20-42-11
1
P-51714
Remove and cap both tubelines (Item 1) [Figure 20-42-

Disconnect and cap the drain hose (Item 2) [Figure 20-

42-13] from the control valve.
P-51721

(Item 1) [Figure 20-42-11].
Remove the lift arm bypass valve and mounting bracket.
T180 Bobcat Loader

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Figure 20-42-14
1 1
2 P-51722
3
Mark and disconnect the BICS electric solenoid
P-51729
Figure 20-42-17
Disconnect and cap the tubelines (Item 1) and (Item 2)
[Figure 20-42-14] from the tilt section of the control

valve.
1 1
14] from the lift section of the control valve.
Figure 20-42-15
P-51726
Connect a hoist to the lifting brackets (Item 1) [Figure 20-

42-17] on the control valve.
P-51728
Remove the fixed-end main valve hose (Item 1) [Figure

20-42-15] from the main control valve fitting.
T180 Bobcat Loader

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Figure 20-42-18
1 P-26095A
1
1P-51713
P-26062A P-51713
P-51713


the loader.

18].
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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) (CONT'D)
Identification Chart
Figure 20-42-19
C2 J2 C3
J4
D5 B3
E3
E3
G1 G2
F2 A3 D3
B2
D4 F4 E2
A2
D1
D2
A1
E1
F1 H2 B1
F3

H3
MR C1
H1 J3
J1
MS1926
ITEM T180 LOADER ITEM T180 LOADER

A1 Lift Cylinder Base End E1 Lift Spool Detent
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool/Centering Springs
B1 Lift Cylinder Rod End F1 LIft Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End F3 Lift Spool Lock Solenoid
C1 Load Check/BICS Valve F4 Tilt Spool Lock Solenoid
Lift G1 Auxiliary Solenoid Stem
C2 Load Check Valve Tilt Function G2 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function H1 BICS Valve Solenoid
D1 Anti-Cavitation Valve
H2 BICS Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief/Anti-Cavitation Valve – 3500 PSI H3 BICS Lock Valve (Lift)
Lift (Base End) J1 Inlet Fluid Flow (From Pump)
D3 Port Relief/Anti-Cavitation Valve – 3500 PSI J2 Outlet Fluid Flow (Return to Tank)
Tilt (Base End)
J3 Lift Arm Bypass Orifice
D4 Port Relief/Anti-Cavitation Valve – 3500 PSI
J4 Drain (Case)
Tilt (Rod End)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary) MR Main Relief Valve – 3300 PSI
3500 PSI (Optional)
T180 Bobcat Loader

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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) BICS Valve, Lift Load Check Valve Removal And
(FOOT CONTROL) (CONT'D) Installation
Mount Bracket Removal and Installation Figure 20-42-22
Figure 20-42-20
1 P-51438
P-51690
Remove the lift load check valve (Item 1) [Figure 20-42-
22].
Remove the control valve and mount bracket (Item 1)
[Figure 20-42-20] from the loader.

Installation: Lubricate the o-ring and tighten the valve to
55 - 65 ft.-lb. (75 - 88 N•m) torque.
Figure 20-42-21
Figure 20-42-23
2 1
2
2
P-51435
P-51439

the inlet fitting on the control valve. Remove and install new O-rings (Item 1) and back-up
Remove the two mount bolts (Item 2) [Figure 20-42-21]
from the control valve mount plate. Remove the mount
plate and tubeline.
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BICS Valve, Lift Load Check Valve Removal And

Installation (Cont’d)
4
Figure 20-42-24
1 1
3
2
P-51453

20-42-26].
P-51440 Check the orifice (Item 3) [Figure 20-42-26] in the

poppet to be sure it is not plugged.
Check for free movement of the load check valve (Item 1)

Installation: Install a new O-ring (Item 4) [Figure 20-42-
[Figure 20-42-24]. 26] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 38 - 45 ft.-lb. (52 - 61 N•m)
Load Check Valve Removal And Installation (Tilt & torque.
Auxiliary)
Figure 20-42-25
P-51691
At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-42-25].
At the front side of the control valve locate the auxiliary

section load check valve (Item 2) [Figure 20-42-25].
NOTE: The tilt and auxiliary load check valves are

interchangeable.
T180 Bobcat Loader

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Anti-Cavitation Valve (Lift, Rod End)

4
Figure 20-42-27
1
3
2
1 P-51453

20-42-29].
P-51692
Check the orifice (Item 3) [Figure 20-42-29] in the
At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-42-27].

29] on the plug and lightly lubricate with oil before
torque.
IMPORTANT
damage the system.
I-2003-0888
Figure 20-42-28
P-51693
Installation: Always use new O-ring (Item 1) [Figure 20-

42-28] on the anti-cavitation valve plug.
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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief/Anti-Cavitation Valve (Tilt, Base End)
Figure 20-42-32
Port Relief/Anti-Cavitation Valve (Lift, Base End)
Figure 20-42-30
P-51692
P-51692 Remove the tilt port relief/anti cavitation valve (Item 1)

[Figure 20-42-32] from the base end of the tilt section.
Loosen the lift circuit port relief/anti cavitation valve (Item Figure 20-42-33
1) [Figure 20-42-30].

Figure 20-42-31
P-51454
1
Replace the O-ring (Item 1) [Figure 20-42-33] before
P-51451
installation.
Replace the O-ring (Item 1) [Figure 20-42-31] before Installation: Tighten to 38 - 45 ft.-lb. (52 - 61 N•m)
torque.
installation.
Installation: Tighten to 38 - 45 ft.-lb. (52 - 61 N•m)

torque.
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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief Valve
Figure 20-42-36
Port Relief/Anti-Cavitation Valve (Tilt, Rod End)
Figure 20-42-34
P-51692
P-51692 Remove the port relief plug (Item 1) [Figure 20-42-36]

from the auxiliary circuit of the control valve.
Remove the tilt port relief/anti cavitation valve (Item 1) Figure 20-42-37
[Figure 20-42-34] from the rod end of the tilt section.

Figure 20-42-35
1 P-51695
P-51694 Installation: Always use new O-rings (Item 1) [Figure

20-42-37]. Tighten to 38 - 45 ft.-lb. (52 - 61 N•m) torque.

installation.

torque.
T180 Bobcat Loader

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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Plug Removal
Figure 20-42-40
Figure 20-42-38
1 1
P-51459
P-51696 At the top side of the control valve, remove the plug (Item
1) [Figure 20-42-40].
The control valve may be equipped with an optional Figure 20-42-41
auxiliary port relief valve (Item 1) [Figure 20-42-38].

Remove the auxiliary port relief valve.
Figure 20-42-39
1
P-51460
Installation: Always use new O-rings (Item 1) [Figure

20-42-41]. Tighten to 40 ft.-lb. (54 N•m) torque.
P-51640

20-42-39]. Tighten to 38 - 45 ft.-lb. (52 - 61 N•m) torque.
T180 Bobcat Loader

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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Rubber Boot Removal and Installation
Figure 20-42-44
Plug Removal (Cont’d)
1
Figure 20-42-42
P-51506
1
P-51461 Remove the three screws (Item 1) [Figure 20-42-44] on
the rubber boot retainer plate.
At the bottom side of the control valve remove the plug Installation: Tighten the screws to 90 - 100 in.-lb. (10 -
(Item 1) [Figure 20-42-42].

11,3 N•m) torque.
Figure 20-42-43 Figure 20-42-45
1
2
1
P-51462
P-51701
Installation: Always use new O-rings (Item 1) [Figure Remove the rubber boots (Item 1) from the retainer plate
20-42-43]. Tighten to 40 ft.-lb. (54 N•m) torque. (Item 2) [Figure 20-42-45].
T180 Bobcat Loader

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End Cap/Spool Lock Block Removal and Installation
Figure 20-42-46
1 1
P-51699
1
Remove the four end cap/spool lock block mount screws

(Item 1) [Figure 20-42-48].
P-51697
Installation: Tighten the screws to 90 - 100 in.-lb. (10 -
11,3 N•m) torque.
Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-42-46] from the

Remove the rubber boots and retainer plate from the lift
end cap/spool lock block. and tilt spools.
Figure 20-42-47 Figure 20-42-49
1
P-51698
P-51700
Disconnect the tube line (Item 1) [Figure 20-42-47] from Remove the end cap/spool lock block (Item 1) [Figure
the end cap/spool lock block. 20-42-49] from the control valve.
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Lift Spool and Detent Removal and Installation

procedure:
MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool 1
Remove the end cap/spool lock block from the control

valve.
Figure 20-42-50
P-51513
Remove the end cap (Item 1) [Figure 20-42-52].
Figure 20-42-53
1

P-51511
1
Remove the O-ring (Item 1) [Figure 20-42-50]. 2
Installation: Replace the O-ring, and lubricate lightly

with oil before installation of the end cap/spool lock block.
P-51514
Figure 20-42-51
Use a screwdriver to remove the snap ring (Item 1)
[Figure 20-42-53].
Remove the washer (Item 2) [Figure 20-42-53].
P-51512
Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-42-51] from the lift spool.
T180 Bobcat Loader

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(Cont'd)
Figure 20-42-54
2 1
3
1
2 P-51517
Remove the detent sleeve (Item 1), detent balls (Item 2)

and spring (Item 3) [Figure 20-42-56].
1 2
P-51515
Figure 20-42-57

detent bonnet.
Remove the detent bonnet (Item 2) [Figure 20-42-54].
Installation: Lubricate the screws and tighten to 90 - 100
in.-lb. (10 - 11,3 N•m) torque.
WARNING
The detent assembly has small springs and balls. Do 1
not lose these parts during disassembly and
assembly.
P-51518
Figure 20-42-55 Remove the lift spool assembly and seal (Item 1) [Figure
P-51516
Put a rag around the detent assembly [Figure 20-42-55].

lost when the detent sleeve is removed.
T180 Bobcat Loader

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2
(Cont'd)
Figure 20-42-58 1
3
N-18915
1 Install the spring tool (Item 1) [Figure 20-42-60] over the

centering spring.
P-51519 NOTE: Be careful when removing the detent adapter

(Item 2) [Figure 20-42-60] from the centering
spring, as it is under spring pressure.
Remove the lift spool seal (Item 1) [Figure 20-42-58]

from the linkage end of the valve. NOTE: The centering spring (Item 3) [Figure 20-42-60]
is white on all 700 series loaders.
Figure 20-42-59
Figure 20-42-61
1
P-8988 2
N-18916
Clamp the linkage end of the spool in a vise [Figure 20-

42-59]. Put a rag around the detent assembly [Figure 20-42-61].
NOTE: Protect spool before clamping in vise. lost when the detent adapter is removed.
Remove the detent adapter with an Alan wrench.
Remove the back-up washer (Item 1) and spool seal

(Item 2) [Figure 20-42-61].
T180 Bobcat Loader

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Lift Spool and Detent Removal and Installation 1

2
(Cont'd)
3
Figure 20-42-62
1 4
N-18919A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-42-64].
N-19004 Figure 20-42-65
Remove the detent adapter (Item 1) [Figure 20-42-62]

from the spring assembly.
Figure 20-42-63
N-18918
Remove the stud from the end of the spool [Figure 20-
42-65].
N-19009
Remove spring tool (Item 1) [Figure 20-42-63] from the

spring assembly.
T180 Bobcat Loader

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(Cont'd)
Figure 20-42-66
N-18963
1
Install the plastic plug and O-ring in the spool [Figure 20-
42-68].
N-18920 Figure 20-42-69
Removal of the plastic plug:

O-ring
Make a center point in the plug using a 1/16 inch drill.
Drill a hole all the way through the plug using a 7/64 inch
tap drill
Turn a 6-32 tap (Item 1) [Figure 20-42-66] into the plug.

Pull the tap and plug out of the spool. Be careful, do not
Plastic
break the tap.
Plug
0.60 in.
Clean all the debris from inside the spool bore. (15,2 mm)
NOTE: DO NOT USE Loctite® ON THE STUD

B-14712
THREADS.
Figure 20-42-67
Install the stud and tighten until the other end of the stud
is out about 0.600 in. (15,2 mm) from the spool [Figure
20-42-69].
2
1
N-18961
Install the O-ring (Item 1) over the nipple on the plastic

plug (Item 2) [Figure 20-42-67].
T180 Bobcat Loader

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(Cont'd)
Figure 20-42-70
1
1
N-18968
Install the detent adapter to the collar [Figure 20-42-72].
NOTE: The collar and the detent adapter are held

N-18967 together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
Clamp the collar (Item 1) [Figure 20-42-70] in a vice.

the detent balls and spring from falling out.
Figure 20-42-71 Figure 20-42-73
1 3
2
N-18958
N-19004
Apply grease on all the detent component surfaces Install the spring tool (Item 1) [Figure 20-42-73] over the
before assembly [Figure 20-42-71]. washer, spring, collar and detent adapter.
Install the spring (Item 1) and detent balls (Item 2) into

the adapter (Item 3) [Figure 20-42-71] and compress
with the detent pliers (Item 1) [Figure 20-42-72].
T180 Bobcat Loader

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(Cont'd)
Figure 20-42-74
CD-15051
1
Install the detent balls and spring [Figure 20-42-76].
Figure 20-42-77
N-18917
Install the spool seal (Item 1) and back-up washer (Item

2) [Figure 20-42-74].
Figure 20-42-75
1
N-19007
Hold the detent balls in place with the detent pliers

[Figure 20-42-77].
N-19005
Install the spring assembly to the lift spool hand tight

[Figure 20-42-75].
Remove the spring tool.
Check the alignment of the detent adapter and the

washer.
Tighten the adapter to 90 - 100 in.-lb. (10,2 - 11,3 N•m).
NOTE: The adapter must fit in the center of the

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(Cont'd)
Figure 20-42-78
1
P-51514
Install the washer (Item 1) and snap ring (Item 2) [Figure

20-42-80].
N-19008 Figure 20-42-81
Install the detent sleeve (Item 1) [Figure 20-42-78] to the

detent adapter.
Figure 20-42-79
2
P-51513
1
2
P-51515
Install the lift spool assembly in the spool bore [Figure

20-42-79].
Install the detent bonnet (Item 1) [Figure 20-42-79].
Install the mounting screws (Item 2) [Figure 20-42-79].

in.-lb. (10 - 11,3 N•m) torque.
T180 Bobcat Loader

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(Cont'd)
Figure 20-42-82 1
P-51511
Install the O-ring (Item 1) [Figure 20-42-80] on the

control valve.
P-51520 Figure 20-42-85

linkage end of the valve. 2
Figure 20-42-83
1 4
P-51701
2 Install the end cap/spool lock block (Item 1) and the

mount bolt (Item 2) [Figure 20-42-85].
P-51512 Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-42-85].
Install the O-ring (Item 1) and bushing (Item 2) [Figure
20-42-83] on the lift spool. Installation: Tighten the screws to 90 - 100 in.-lb. (10 -
11,3 N•m) torque.
T180 Bobcat Loader

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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Tilt Spool Removal and Installation
Remove the lift and tilt end cap/spool lock block. (See
Lift Spool and Detent Removal and Installation End Cap/Spool Lock Block Removal and Installation on
(Cont'd) Page 20-42-15.)
Figure 20-42-86 Figure 20-42-88
1 2
P-51698
P-51521
Connect the tubeline (Item 1) [Figure 20-42-86].

20-42-88] from the tilt spool.
Figure 20-42-87
Figure 20-42-89
1
P-51697
P-51522
Use an ohm meter to measure the lock solenoid coils

resistance. Remove the three screws (Item 1) [Figure 20-42-89]
from the spool centering block.
The correct resistance for the coil is 5.5 ± 0.28 ohm.
Installation: Tighten the bolt to 90 - 100 in.-lb. (10 - 11,3
Installation: Install the lift spool (Item 1) and tilt spool N•m) torque.
(Item 2) [Figure 20-42-87] lock solenoids and tighten to
35 - 45 ft.-lb. (52 - 61 N•m) torque.
T180 Bobcat Loader

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1
Figure 20-42-90
N-18942
1 Put the linkage end of the spool in the vice [Figure 20-
42-92].
P-51543
Install the spool tool (Item 1) [Figure 20-42-92] over the
centering spring.
Remove the spool centering block (Item 1) [Figure 20-

Figure 20-42-93
Check and replace the O-ring (Item 2) [Figure 20-42-90]
before replacing the spool centering block.
1
Figure 20-42-91
N-19014

P-51544
11,3 N•m) torque.
Remove the tilt spool, centering spring, back-up washer
and spool seal [Figure 20-42-91]. Remove spring tool from the spring assembly.
T180 Bobcat Loader

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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Auxiliary Spool Removal And Installation
Figure 20-42-96
Figure 20-42-94
2 1
3 1
P-51522
N-18944A Remove the three screws (Item 1) [Figure 20-42-96]

Inspect the adapter (Item 1), collar (Item 2), spring (Item Installation: Tighten the bolt to 90 - 100 in.-lb. (10 - 11,3

N•m) torque.
Figure 20-42-95 Remove the spool centering block (Item 2) [Figure 20-
2
1 Figure 20-42-97
1 2
1
P-51545 N-18943
Remove the spool seal(s) (Item 1) [Figure 20-42-95] and

P-51546
the back-up washer (Item 2) [Figure 20-42-95].
Assembly: Always use a new spool seal. Remove the spring (Item 1) and center spring retainer
(Item 2) [Figure 20-42-97] from the auxiliary spool.
Note: If the centering spring retainer (Item 2) [Figure

T180 Bobcat Loader

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Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-42-98
1 2
1
2 P-51550

20-42-100] from the auxiliary spool.
P-51547
Figure 20-42-101

Figure 20-42-99
2 1
P-51551
P-51549
Remove the spring (Item 1) and center spring retainer


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Auxiliary Solenoid Disassembly and Assembly
Figure 20-42-102
1
P-51703
Remove the solenoid stem (Item 1) [Figure 20-42-104].
P-51702 Installation: Tighten the stem to 10 - 14 ft.-lb. (14 - 19

N•m) torque.
Remove the nut (Item 1) [Figure 20-42-102] from both Figure 20-42-105
solenoids.

Installation: Tighten the nut to 48 - 72 in.-lb. (5 - 8 N•m)
torque.
Figure 20-42-103
1
2
2
P-51555

the solenoid stem.
P-51553 Check and clean the screen (Item 2) [Figure 20-42-105].
Remove the nut (Item 1) and solenoid coil (Item 2)

[Figure 20-42-103].
Use an ohm meter to measure the solenoid coil

resistance.
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Figure 20-42-106
2
P-51445
P-51444 Installation: Lubricate the O-rings and tighten the stem

to 20 - 24 ft.-lb. (27 - 33 N•m) torque.
Remove the nut (Item 1) [Figure 20-42-106] from the Figure 20-42-109
solenoid stem.

Installation: Tighten the nut to 53 in.-lb. (6 N•m) torque.
Remove the solenoid coil (Item 2) [Figure 20-42-106]. 3

2
Figure 20-42-107
N-18694

[Figure 20-42-109] from the cartridge.
Clean all parts in solvent and dry with compressed air.

N-18693A
excessive wear.
both ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-42-109] may be
Use an ohm meter to measure the solenoid coil needs to be replaced.
resistance.
The correct resistance for the coil is 9.79 ± 0.29 ohm. back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-42-107] &

[Figure 20-42-109] and new back-up rings (Item 2)
[Figure 20-42-109] on the solenoid stem.
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BICS Valve, Lock Valve Removal And Installation
Figure 20-42-110 1
1
1
1 2
1
2
2
2
P-51564

[Figure 20-42-112] from the lift lock valve, and replace
P-51704 with new.
Locate the two BICS lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-42-110] is for the lift

circuit.
Figure 20-42-111
P-51443
Remove the lift lock valve (Item 1) [Figure 20-42-111]

from the back of the control valve.
Installation: Lightly lubricate the lock valve o-rings and

tighten to 20 - 24 ft.-lb. (27 - 33 N•m) torque.
T180 Bobcat Loader

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(Cont’d)
Figure 20-42-113
1
P-51706
Remove the tilt lock valve (Item 1) [Figure 20-42-115]

from the front of the control valve.
P-51705 Installation: Lightly lubricate the lock valve o-rings and

Locate the tilt circuit lock valve (Item 1) [Figure 20-42-

Figure 20-42-116
113].
Figure 20-42-114
1
1
2 1
1
2
1
2
2
P-51564
P-51697 Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-42-116] from the tilt lock valve, and replace
with new.
Remove the lift spool lock solenoid (Item 1) [Figure 20-
42-114].
Remove the tilt spool lock solenoid (Item 2) [Figure 20-

42-114].
Installation: Lubricate the O-rings and tighten the spool

lock solenoids to 38 - 45 ft.-lb. (52 - 61 N•m) torque.
T180 Bobcat Loader

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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) BICS Valve, Check Valve Removal And Installation
(FOOT CONTROL) (CONT'D) (Cont’d)
BICS Valve, Check Valve Removal And Installation Figure 20-42-119
Figure 20-42-117
1
3
1
4
P-51447
P-51438
Check that there is no blockage in the orifice (Item 1)
[Figure 20-42-119].
Remove the BICS valve (Item 1) [Figure 20-42-117].

Inspect the check valve (Item 2) and spring (Item 3)
Installation: Lubricate the o-ring and tighten the valve to [Figure 20-42-119].
55 - 65 ft.-lb. (75 - 88 N•m) torque.
Replace the O-ring (Item 4) [Figure 20-42-119] on the
Figure 20-42-118 plug before installation.
P-51446
Remove the plug (Item 1) [Figure 20-42-118] from the

top of the BICS valve.
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Figure 20-42-122
And Assembly
Figure 20-42-120
1 P-51707
Remove the main relief valve (Item 1) [Figure 20-42-

P-51436 122].
Figure 20-42-123

valve.
Figure 20-42-121
1
1
P-51463
Remove the O-rings from the main relief valve (Item 1)

P-51437 [Figure 20-42-123].
Installation: Always use new O-rings. Tighten to 38 - 45

Check the lift arm bypass orifice (Item 1) [Figure 20-42- ft.-lb. (52 - 61 N•m) torque.
121].
NOTE: This orifice is not removable from the valve

casting.
T180 Bobcat Loader

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(ADVANCED CONTROL SYSTEM) (ACS)
Identification
WARNING
W-2059-0598
IMPORTANT
P-51730
damage the system.
The hydraulic control valve (1 piece casting) (ACS) (Item I-2003-0888
1) [Figure 20-43-1] does not have a removable BICS

section. Lift and block the loader. (See Procedure on Page 10-10-
1.)
The BICS section and main control valve are in one
casting. Raise the lift arms and install an approved lift arm support
casting) (ACS), (See Identification on Page 20-41-1.) Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Clean the area around the control valve.
DANGER Fluid on Page 10-120-2.)
Remove the control panel. (See Removal and Installation

pintles])
P-90328
AVOID DEATH
D-1009-0409
T180 Bobcat Loader

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Removal and Installation (Cont’d) 4
Figure 20-43-2 1
2
1 3
1
P-51975
Mark and disconnect the two auxiliary electric solenoid

connectors (Item 1) [Figure 20-43-4] for correct
P-51710 installation.

Mark all tubelines and hoses for correct installation. from the control valve to the hydraulic oil cooler.

The fixed end main valve hose (Item 1) [Figure 20-43-2]
is connected to a fixed end fitting on the control valve. Disconnect and cap the supply hose (Item 3) and the
The hose is routed to the back upright where the hose is supply hose clamp (Item 4) [Figure 20-43-4].
connected to a tee fitting that feeds the base end of both
lift cylinders. The hose must be removed at the back tee Figure 20-43-5
fitting, located in the right side upright.
Figure 20-43-3
P-51725

P-51711

T180 Bobcat Loader

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Figure 20-43-6
2 P-51977
Disconnect the wire harness tie-strap mounts (Item 1)

[Figure 20-43-8] from the lift arm bypass bracket.
P-51976
Figure 20-43-9
6] from the lift arm bypass valve to the control valve.

from the lift arm bypass valve to the drive motor case
drain.
Remove the lift arm bypass tubeline (Item 3) [Figure 20-

43-6] from the control valve drain.
Figure 20-43-7
1
P-51983
1 Disconnect the connectors (Item 1) [Figure 20-43-9]

from the lift and tilt actuators.
P-51719

main valve mounting bracket.
T180 Bobcat Loader

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Figure 20-43-10
2 1
1
P-51980
Remove and cap both tubelines (Item 1) [Figure 20-43-

P-51721
Disconnect and cap the drain hose (Item 2) [Figure 20-
(Item 1) [Figure 20-43-10].

Figure 20-43-13
Remove the lift arm bypass valve and mounting bracket.
Figure 20-43-11
2
1
1
P-51982
Disconnect and cap the tubelines (Item 1) and (Item 2)

P-51727 [Figure 20-43-13] from the tilt section of the control
valve.
Remove tubeline clamp bolt (Item 1) [Figure 20-43-11] Disconnect and cap the tubeline (Item 3) [Figure 20-43-
from the auxiliary tubelines in the left rear upright. 13] from the lift section of the control valve.
Installation: Tighten bolt to 15 - 20 ft.-lb. (20 - 27 N•m)

torque.
T180 Bobcat Loader

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Figure 20-43-14 1
1
P-51726
1
Connect a hoist to the lifting brackets (Item 1) [Figure 20-
43-16] on the control valve.
P-51728
Figure 20-43-17
Remove the fixed-end main valve hose (Item 1) [Figure
20-43-14] from the main control valve fitting.

Figure 20-43-15
1 P-26095A
1
1P-51713
1 P-26062A P-51713
P-51713

P-51722 the loader.

Mark and disconnect the BICS electric solenoid 17].
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Actuator Removal And Installation (Out of Loader)
Remove the control valve from the loader.
Figure 20-43-18
1
1
P-51734
1
Using a drift pin and a hammer, remove the actuator
linkage pin (Item 1) [Figure 20-43-20] from the actuator
and the tilt spool.
P-51732 Remove the actuator and linkage pin from the valve.

Figure 20-43-21
from the tilt actuator.
Installation: Tighten the mounting bolts to 90 - 100 in.-lb.

(10,2 - 11,3 N•m) torque.
Figure 20-43-19 1
1 P-51736
Inspect the O-ring (Item 1) [Figure 20-43-21] on the face

of the actuator, and replace as needed.
Check the linkage pin (Item 2) [Figure 20-43-21] and

P-51733 replace as needed.
Slide the actuator mount bracket (Item 1) [Figure 20-43-

19] away from the control valve.
Pull the actuator away from the control valve [Figure 20-
43-19].
T180 Bobcat Loader

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(Cont’d)
Figure 20-43-22
P-51800
Using a drift pin and a hammer, remove the actuator

1 linkage pin (Item 1) [Figure 20-43-24] from the actuator
and the tilt spool.
P-51737
Remove the actuator and linkage pin from the valve.

Figure 20-43-25
from the lift actuator.

(10,2 - 11,3 N•m) torque.
Figure 20-43-23
1
1
2
P-51736
Inspect the O-ring (Item 1) [Figure 20-43-25] on the face

of the actuator, and replace as needed.
P-51799 Check the linkage pin (Item 2) [Figure 20-43-25] and

replace as needed.
Slide the actuator mount bracket (Item 1) [Figure 20-43-

23] away from the control valve.
Pull the actuator away from the control valve [Figure 20-
43-23].
T180 Bobcat Loader

217 of 961

(Cont’d)
Figure 20-43-26
1 2
3
P-51738
NOTE: The two longer bolts (Item 1) are used to

mount the lift actuator and end cap (Item 2)
[Figure 20-43-26] to the control valve.
The two shorter mount bolts (Item 3) are used
to mount the tilt actuator to the end cap (Item
4) [Figure 20-43-26].

(10,2 - 11,3 N•m) torque (Item 1) [Figure 20-43-26]
T180 Bobcat Loader

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Identification Chart (ACS)
Figure 20-43-27
J2 C3
C2
J4
D5 B3
E3
E3
G1 G2
F2 A3 D3
B2
D4 E2
A2
D1
D2
A1
E1
F1 H2 B1
H3

MR C1
H1 J3
J1
MS1929
ITEM T180 LOADER ITEM T180 LOADER

A1 Lift Cylinder Base End E1 Lift Spool Centering Spring
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool/Centering Springs
B1 Lift Cylinder Rod End F1 LIft Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End G1 Auxiliary Solenoid Stem
C1 Load Check/BICS Valve G2 Auxiliary Solenoid Stem
Lift H1 BICS Valve Solenoid
C2 Load Check Valve Tilt Function
H2 BICS Lock Valve (Tilt)
C3 Load Check Valve Auxiliary Function
D1 Anti-Cavitation Valve H3 BICS Lock Valve (Lift)
Lift (Rod End) J1 Inlet Fluid Flow (From Pump)
D2 Port Relief/Anti-Cavitation Valve – 3500 PSI J2 Outlet Fluid Flow (Return to Tank)
Lift (Base End) J3 Lift Arm Bypass Orifice
D3 Port Relief/Anti-Cavitation Valve – 3500 PSI J4 Drain (Case)
Tilt (Base End)
MR Main Relief Valve – 3300 PSI
D4 Port Relief/Anti-Cavitation Valve – 3500 PSI
Tilt (Rod End)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary)
3500 PSI (Optional)
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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) BICS Valve, Lift Load Check Valve Removal And
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) Installation
Mount Bracket Removal and Installation Figure 20-43-30
Figure 20-43-28
1 P-51740
P-51730
Remove the lift load check valve (Item 1) [Figure 20-43-
30].
Remove the control valve and mount bracket (Item 1)
[Figure 20-43-28] from the loader.

Installation: Lubricate the o-ring and tighten the valve to
55 - 65 ft.-lb. (75 - 88 N•m) torque.
Figure 20-43-29
Figure 20-43-31
P-51731
P-51439

the inlet fitting on the control valve. Remove and install new O-rings (Item 1) and back-up
from the control valve mount plate. Remove the mount
plate and tubeline.
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BICS Valve, Lift Load Check Valve Removal And

Installation (Cont’d)
4
Figure 20-43-32
1 1
3
2
P-51453

20-43-34].
P-51440 Check the orifice (Item 3) [Figure 20-43-34] in the

Check for free movement of the load check valve (Item 1)

[Figure 20-43-32]. 34] on the plug and lightly lubricate with oil before
Load Check Valve Removal And Installation (Tilt & torque.
Auxiliary)
Figure 20-43-33
P-51741
At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-43-33].
At the front side of the control valve locate the auxiliary

section load check valve (Item 2) [Figure 20-43-33].
NOTE: The tilt and auxiliary load check valves are

interchangeable.
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Anti-Cavitation Valve (Lift, Rod End)

4
Figure 20-43-35
1
3
2
P-51453
1

20-43-37].
P-51742
Check the orifice (Item 3) [Figure 20-43-37] in the
At the back side of the control valve, remove the lift
section anti-cavitation valve (Item 1) [Figure 20-43-35]. Installation: Install a new O-ring (Item 4) [Figure 20-43-

37] on the plug and lightly lubricate with oil before
torque.
IMPORTANT
damage the system.
I-2003-0888
Figure 20-43-36
P-51452
Always use new O-ring (Item 1) [Figure 20-43-36] on the

anti-cavitation valve plug.
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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief/Anti-Cavitation Valve (Tilt, Base End)
Figure 20-43-40
Port Relief/Anti-Cavitation Valve (Lift, Base End)
Figure 20-43-38
1
P-51742
P-51742 Remove the tilt port relief/anti cavitation valve (Item 1)

[Figure 20-43-40] from the base end of the tilt section.
Loosen the lift circuit port relief/anti cavitation valve (Item Figure 20-43-41
1) [Figure 20-43-38].

Figure 20-43-39
1 P-51454
P-51451 Replace the O-ring (Item 1) [Figure 20-43-41] before

installation.
Replace the O-ring (Item 1) [Figure 20-43-39] before Installation: Lightly lubricate with oil and tighten to 38 -
installation. 45 ft.-lb. (52 - 61 N•m) torque.
Installation: Lightly lubricate with oil and tighten to 38 -

45 ft.-lb. (52 - 61 N•m) torque.
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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Port Relief Valve
Figure 20-43-44
Port Relief/Anti-Cavitation Valve (Tilt, Rod End)
Figure 20-43-42
P-51742
P-51742 Remove the port relief plug (Item 1) [Figure 20-43-44]

from the auxiliary circuit of the control valve.
Remove the tilt port relief/anti cavitation valve (Item 1) Figure 20-43-45
[Figure 20-43-42] from the rod end of the tilt section.

Figure 20-43-43
1 P-51801
P-51455 Installation: Always use new O-rings (Item 1) [Figure

20-43-45]. Lightly lubricate with oil and tighten to 38 - 45
ft.-lb. (52 - 61 N•m) torque.
installation.
Installation: Lightly lubricate with oil and tighten to 38 -

45 ft.-lb. (52 - 61 N•m) torque.
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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Plug Removal
Figure 20-43-48
Figure 20-43-46
1
1
P-51459
P-51743 At the top side of the control valve, remove the plug (Item
1) [Figure 20-43-48].
The control valve may be equipped with an optional Figure 20-43-49
auxiliary port relief valve (Item 1) [Figure 20-43-46].

Remove the auxiliary port relief valve.
Figure 20-43-47
1
P-51460

P-51640

20-43-47]. Lightly lubricate with oil and tighten to 38 - 45
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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) End Cap Block Removal and Installation
Remove the lift and tilt actuators from the control valve.
Plug Removal (Cont’d) (See Actuator Removal And Installation (Out of Loader)
on Page 20-43-6.)
Figure 20-43-50
Figure 20-43-52
1
P-51461 2
P-51744
At the bottom side of the control valve remove the plug

(Item 1) [Figure 20-43-50].

Disconnect the tube line (Item 1) [Figure 20-43-52] from
the end cap block.
Figure 20-43-51
Remove the two end cap block mount screws (Item 2)
[Figure 20-43-52].

11,3 N•m) torque.
Figure 20-43-53
1
P-51462 1

P-51745
Remove the end cap block (Item 1) [Figure 20-43-53]

from the control valve.
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Lift Spool Removal and Installation
The tool listed will be needed to do the following 1

procedure:
MEL 1285 - Spring Tool
Remove the end cap block from the control valve.
Figure 20-43-54
1
P-51748
Remove the two screws (Item 1) [Figure 20-43-56] from

the lift spool end cap.
1
in.-lb. (10 - 11,3 N•m) torque.

Figure 20-43-57
P-51746
Installation: Replace the O-ring, and lubricate lightly

with oil before installation of the end cap block.
Figure 20-43-55 1
P-51749
Remove the lift spool end cap (Item 1) [Figure 20-43-57]

2 from the control valve.
1
P-51747

20-43-55] from the lift spool.
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Lift Spool Removal and Installation (Cont'd)
Figure 20-43-58
P-51772
1 Clamp the linkage end of the spool in a vise [Figure 20-

43-60].
P-51770
NOTE: Protect spool before clamping in vise.
Remove the lift spool assembly and seal (Item 1) [Figure Figure 20-43-61

Figure 20-43-59
1
P-51773
P-51771 Install the spring tool (Item 1) [Figure 20-43-61] over the
centering spring.
Remove the lift spool seal (Item 1) [Figure 20-43-59]

from the linkage end of the valve.
T180 Bobcat Loader

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2
1
Figure 20-43-62
P-51771 P-51775

N-190146
Remove the bolt (Item 1) [Figure 20-43-62] holding the Figure 20-43-65

11,3 N•m) torque. 1
Figure 20-43-63
2
3
3 3
4 1 P-51749
Install the lift spool assembly (Item 1) [Figure 20-43-65]

in the spool bore.
P-51776 Install the mounting screws (Item 3) [Figure 20-43-65].

Inspect the adapter (Item 1), collar (Item 2), spring (Item in.-lb. (10 - 11,3 N•m) torque.
T180 Bobcat Loader

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Figure 20-43-66
P-51746
Install the O-ring (Item 1) [Figure 20-43-68] on the

control valve.
P-51777
Figure 20-43-69
linkage end of the valve.

Figure 20-43-67
3
2
1 1
2
P-51744
2
Install the end cap block (Item 1) and the two mount bolts
(Item 2) [Figure 20-43-69].
P-51747
11,3 N•m) torque.
Install the O-ring (Item 1) and bushing (Item 2) [Figure
20-43-67] on the lift spool. Connect the tube line (Item 3) [Figure 20-43-69] to the
end cap block.
Install the lift and tilt actuators to the control valve.
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Tilt Spool Removal and Installation
Remove the end cap block. (See End Cap Block

Removal and Installation on Page 20-43-16.)
Figure 20-43-70 2
P-51780
Remove the spool centering block (Item 1) [Figure 20-

2 43-72] from the control valve.
1
Check and replace the O-ring (Item 2) [Figure 20-43-72]
before replacing the spool centering block.
P-51778

Figure 20-43-73
20-43-70] from the tilt spool.
Figure 20-43-71
2
P-51781
Remove the tilt spool, centering spring, back-up washer

2 and spool seal (Item 1) [Figure 20-43-73].
P-51779
Disconnect the tubeline (Item 1) [Figure 20-43-71].
Remove the three screws (Item 2) [Figure 20-43-71]


N•m) torque.
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2 1
Figure 20-43-74
3
4
1
N-18944A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
N-18942
Figure 20-43-77
43-74]. 2

1
Install the spring tool (Item 1) [Figure 20-43-74] over the
centering spring.
Figure 20-43-75
1
1
P-51545 N-18943

N-19014


11,3 N•m) torque.
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Auxiliary Spool Removal And Installation
Figure 20-43-78
1 1
2
P-51783

2 P-51779
Figure 20-43-81
the spool centering block.

Remove the three screws (Item 2) [Figure 20-43-78]

N•m) torque.
1
Remove the spool centering block from the control valve.
Figure 20-43-79 2
P-51784


2
1
P-51782

Note: If the centering spring retainer (Item 2) [Figure

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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Auxiliary Solenoid Disassembly and Assembly
Figure 20-43-84
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-43-82
1
2
P-51552
P-51785 Remove the nut (Item 1) [Figure 20-43-84] from both

solenoids.
Remove the spacer (Item 1) and O-ring (Item 2) [Figure Installation: Tighten the nut to 48 - 72 in.-lb. (5 - 8 N•m)

torque.
Figure 20-43-83 Figure 20-43-85
P-51786
P-51553
Remove the auxiliary spool (Item 1) [Figure 20-43-83]. Remove the nut (Item 1) and solenoid coil (Item 2)
[Figure 20-43-85].
Use an ohm meter to measure the solenoid coil

resistance.
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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) BICS Valve Solenoid Disassembly And Assembly
Figure 20-43-88
Auxiliary Solenoid Disassembly and Assembly
(Cont’d)
Figure 20-43-86
1
1
2
P-51788
Remove the nut (Item 1) [Figure 20-43-88] from the

P-51787 solenoid stem.
Installation: Tighten the nut to 53 in.-lb. (6 N•m) torque.


Remove the solenoid coil (Item 2) [Figure 20-43-88].
Installation: Tighten the stem to 10 - 14 ft.-lb. (14 - 19
N•m) torque. Figure 20-43-89
Figure 20-43-87
1
2
N-18693A
P-51555
both ends of the solenoid coil.
solenoid stem. Use an ohm meter to measure the solenoid coil
resistance.
Check and clean the screen (Item 2) [Figure 20-43-87].
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HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Use only new O-rings and apply oil to all O-rings and
(ADVANCED CONTROL SYSTEM) (ACS) (CONT’D) back-up rings before installation.
BICS Valve Solenoid Disassembly And Assembly Install new O-rings (Item 1) [Figure 20-43-89] & [Figure
(Cont’d) 20-43-91] and new back-up rings (Item 2) [Figure 20-43-
91] on the solenoid stem.
Figure 20-43-90
Figure 20-43-92
1
2
1
P-51789

P-51790
Installation: Lubricate the O-rings and tighten the stem

to 20 - 24 ft.-lb. (27 - 33 N•m) torque. Locate the two BICS lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-43-92] is for the lift circuit.
Figure 20-43-91
Figure 20-43-93
3
2
1
1
N-18694
P-51791

[Figure 20-43-91] from the stem. Remove the lift lock valve (Item 1) [Figure 20-43-93]
Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear and replace any showing tighten to 20 - 24 ft.-lb. (27 - 33 N•m) torque.
excessive wear.

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(Cont’d)
1
Figure 20-43-94
1
1
1 1
1 2
1 2
2
P-51564
1
2
2 [Figure 20-43-96] from the tilt lock valve, and replace
2 with new.
P-51564

[Figure 20-43-94] from the lift lock valve, and replace
with new.
Figure 20-43-95
P-51792
Remove the tilt lock valve (Item 1) [Figure 20-43-95]


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BICS Valve, Check Valve Removal And Installation 1
Figure 20-43-97
4
P-51447
1
Check that there is no blockage in the orifice (Item 1)

[Figure 20-43-99].
P-51788
Inspect the check valve (Item 2) and spring (Item 3)
[Figure 20-43-99].
Remove the BICS valve (Item 1) [Figure 20-43-97].

Replace the O-ring (Item 4) [Figure 20-43-99] on the
Installation: Lubricate the o-ring and tighten the valve to plug before installation.
55 - 65 ft.-lb. (75 - 88 N•m) torque.
Figure 20-43-98
P-51446
Remove the plug (Item 1) [Figure 20-43-98] from the top

of the BICS valve.
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Figure 20-43-102
And Assembly
Figure 20-43-100
1
P-51794
Remove the main relief valve (Item 1) [Figure 20-43-

P-51793 102].
Figure 20-43-103

valve.
Figure 20-43-101
1
1
P-51463
Remove the O-rings from the main relief valve (Item 1)

P-51437 [Figure 20-43-103].
Installation: Always use new O-rings. Tighten to 38 - 45

Check the lift arm bypass orifice (Item 1) [Figure 20-43- ft.-lb. (52 - 61 N•m) torque.
101].
NOTE: This orifice is not removable from the valve

casting.
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LIFT ARM BYPASS CONTROL VALVE Figure 20-50-1
Inspecting
Raise the lift arms 6 feet (2 m) off the ground. Stop the 1
engine. Turn the Lift Arm Bypass Control Knob clockwise
1/4 turn. Then pull the Lift Arm Bypass Control Knob until
the lift arms slowly lower. 4
3
DANGER 1
P-31990A
The Lift Arm Bypass valve (Item 1) [Figure 20-50-1] is

located under the right side of the control panel.
Hold the Lift Arm Bypass Control knob (Item 2) and

loosen the jam nut (Item 3) on the Lift Arm Bypass valve
P-90328 shaft [Figure 20-50-1].

AVOID DEATH Remove the Lift Arm Bypass Control knob (Item 2) and
• Disconnecting or loosening any hydraulic the jam nut (Item 3) from the Lift Arm Bypass valve shaft
tubeline, hose, fitting, component or a part failure [Figure 20-50-1].
• Keep out of this area when lift arms are raised Remove the rubber washer (Item 4) [Figure 20-50-1].
D-1009-0409
WARNING
W-2059-0598
Install jack stands under the rear corners of the loader.
Start the engine. Raise the lift arms and install an

approved lift arm support device. (See Installing Lift Arm
Support Device on Page 10-20-1.)

on Page 10-30-1.)
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LIFT ARM BYPASS CONTROL VALVE (CONT'D) Disassembly And Assembly
Removal And Installation (Cont’d) Figure 20-50-3
Figure 20-50-2
1
1
4
2
3
P-26065
P-48431
Remove the bypass valve (Item 1) [Figure 20-50-3] from
the valve block. Inspect the bypass valve for damage and
Disconnect the base end lift tubeline (Item 1) [Figure 20- replace if necessary.
50-2] from the Lift Arm Bypass valve.

Installation: Tighten the valve to 33 - 37 ft.-lb. (45 - 50
Disconnect the drain hose (Item 2) [Figure 20-50-2] from N•m) torque.
the Lift Arm Bypass valve.
Inspect the hydraulic fittings on the valve block for
Disconnect the motor case drain hose (Item 3) [Figure damage and replace if necessary.
20-50-2].
Remove the two mounting bolt/nuts (Item 4) [Figure 20-

50-2].
Installation: Tighten the mounting bolts to 180 - 200 in.-

lb. (21 - 23 N•m) torque.
Remove the lift arm bypass control valve.
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HYDRAULIC PUMP Figure 20-60-1
Check The Output Of The Hydraulic Pump Without

Power Bob-Tach
2
WARNING
W-2017-0286
1
P-26071
WARNING Disconnect the OUTLET hose (Item 1) [Figure 20-60-1]

from the pump.
Figure 20-60-2

W-2059-0598
The tools listed will be needed to do the following

2 1
procedure:
MEL1563 - Remote Start Tool


1.) P-48256
device. (See Installing Lift Arm Support Device on Page Connect the INLET hose (Item 1) [Figure 20-60-2] from
10-20-1.) the tester to the OUTLET fitting (Item 2) [Figure 20-60-1]
of the pump. Connect the OUTLET hose (Item 2) [Figure
Raise the operator cab. (See Raising The Operator Cab 20-60-2] from the tester to the hose (Item 1) [Figure 20-
on Page 10-30-1.) 60-1] which was disconnected from the pump.
Open the rear door of the loader.
Connect the remote start tool. (See Procedure on Page

10-60-1.) IMPORTANT
I-2024-0284
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HYDRAULIC PUMP (CONT'D)
Check The Output Of The Hydraulic Pump Without

Power Bob-Tach (Cont'd)
Figure 20-60-3
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
Hydraulic Control
Valve
1
B-16277
Sample tester connection shown [Figure 20-60-3].

Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Warm the fluid to 140° F (60° C) by turning the restrictor

control (Item 1) [Figure 20-60-3] on the tester to about
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free
flow (GPM) at full RPM.
Push the maximum/variable flow switch (on the remote

start tool) to engage the front auxiliary hydraulics. The
light will come ON. Push the button (on the right control
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the highest pressure (PSI)
and flow (GPM). The high pressure flow must be at least
80% of free flow.
HIGH PRESSURE FLOW (GPM)

%= X100
FREE FLOW (GPM)
A low percentage may indicate a failed pump.
*Refer to SPECIFICATIONS Section for system relief

pressure and full RPM. (See LOADER
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HYDRAULIC PUMP (CONT'D) Figure 20-60-5
Check The Output Of The Hydraulic Pump With

Power Bob-Tach.
WARNING 2 1

W-2017-0286
P-48256
Figure 20-60-4
Connect the INLET hose (Item 1) [Figure 20-60-5] from

the tester to the OUTLET fitting (Item 2) [Figure 20-60-4]
on the top of the Power Bob-Tach block. Connect the
1 OUTLET hose (Item 2) [Figure 20-60-5] from the tester
to the hose (Item 1) [Figure 20-60-4] which was
2
disconnected from the Power Bob-Tach block.

IMPORTANT
P-48255 position before you start the engine.
I-2024-0284

procedure:


1.)
device. (See Installing Lift Arm Support Device on Page
10-20-1.)

on Page 10-30-1.)

10-60-1.)
Disconnect the OUTLET hose (Item 1) [Figure 20-60-4]

from the top of the Power Bob-Tach block.
T180 Bobcat Loader

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Check The Output Of The Hydraulic Pump With

Power Bob-Tach. (Cont'd)
Figure 20-60-6
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
Hydraulic Control
Valve
1
B-16277

RPM*.


start tool) to engage the front auxiliary hydraulics. The
80% of free flow.

%= X100
FREE FLOW (GPM)
*Refer to the Specifications section for system relief

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HYDRAULIC PUMP (CONT'D) Raise the lift arms and install an approved lift arm support
Removal And Installation 10-20-1.)
on Page 10-30-1.)
DANGER Drain the hydraulic fluid from the reservoir. (See
Replacing Hydraulic Fluid on Page 10-120-2.)
Remove the Power Bob-Tach block if equipped. (See
Disconnect and cap the outlet hose (Item 1) [Figure 20-
60-7] from the back of the hydraulic pump.
AVOID DEATH
P-90328
WARNING
W-2059-0598

D-1009-0409
Figure 20-60-8
IMPORTANT
damage the system.
I-2003-0888
Figure 20-60-7
1
P-26068
Disconnect and cap the inlet hose (Item 1) [Figure 20-

60-8] from the front of the hydraulic pump.
P-26071
Lift and block the rear of the loader. (See Procedure on

Page 10-10-1.)
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Removal And Installation (Cont’d)
Figure 20-60-9
P-26347
1 2
1
2
P-26347

P-26069
Remove the coupler (Item 2) [Figure 20-60-10] from the
hydraulic pump shaft.
9] from the hydraulic pump. Reverse the removal procedure to install the hydraulic

pump.
Installation: Tighten the mounting bolts to 27 - 37 ft.-lb.
(37 - 50 N•m) torque. Installation: Use a new O-ring (Item 1) [Figure 20-60-10]
when installing the hydraulic pump. (See Disassembly
Remove the hydraulic pump (Item 2) [Figure 20-60-9] And Assembly on Page 20-60-8.)
from the hydrostatic pump.
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Identification
15

8
7
6
14
12 13
11
10
9 1. Retaining Ring
7
1 4 5 2. Pump End Section
3 3. Pre-Load Seal
4. Load Seal
2 5. Section Seal
6. Wear Plate
7. Pins
8. Drive Gear
9. Idler Gear
10. Pump Center Section
11. Wear Plate
12. Section Seal
13. Pump End Section
14. Bolt (4)
15. Bolt (4)
B-16050A
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Disassembly And Assembly

1
Figure 20-60-11
P-26352
2
2
P-26353
1
Remove the pump end section (Item 1) [Figure 20-60-

P-26351 12].
Mark the pump sections for correct assembly [Figure 20-

60-11].

Remove the four smaller pump housing bolts (Item 1)
[Figure 20-60-11].
Remove the four larger pump housing bolts (Item 2)

[Figure 20-60-11].
Installation: Tighten the four smaller bolts (Item 1)

[Figure 20-60-11] to 30 ft.-lb. (40,7 N•m) torque. Tighten
the four larger bolts (Item 2) [Figure 20-60-11] to 54 ft.-
lb. (73,2 N•m) torque.
IMPORTANT
damage the system.
I-2003-0888
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Disassembly And Assembly (Cont'd)
Figure 20-60-13 1
P-26358
2
Figure 20-60-16
P-26354
1
Figure 20-60-14

4
3
1
P-26359
2 Remove the pump center section (Item 1) [Figure 20-60-

P-26355 15] & [Figure 20-60-16] from the pump end section.
NOTE: Inspect the pump center section (Item 1)

Remove the wear plate (Item 1) [Figure 20-60-13] & [Figure 20-60-16]. If excessive wear or
[Figure 20-60-14] and section seal (Item 2) [Figure 20- damage is visible, the pump must be
60-13] & [Figure 20-60-14] from the pump end section. replaced.
NOTE: Position wear plate (Item 1) [Figure 20-60-14]

inlets and traps as shown with bronze side
toward gears.
NOTE: Inspect the pump end section (Item 3) [Figure

20-60-14] and bushings (Item 4) [Figure 20-60-
14]. If excessive wear or damage is visible, the
pump must be replaced.
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Figure 20-60-17
1
P-26391
Figure 20-60-20
P-26389
Figure 20-60-18

1
P-26362
1
1
P-26362
To remove the drive gear (Item 1) [Figure 20-60-19] from

P-26390 the pump end section, locate and remove the retaining
ring (Item 1) [Figure 20-60-20] from the spline end of the
drive gear.
Remove the idler gear (Item 1) [Figure 20-60-17] &
[Figure 20-60-18].
NOTE: Inspect the idler gear (Item 1) [Figure 20-60-

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Figure 20-60-21
P-26394

P-26392 inlets and traps as shown with bronze side
toward gears.
Remove the drive gear (Item 1) [Figure 20-60-21] from Figure 20-60-24
the pump end section.

NOTE: Inspect the drive gear (Item 1) [Figure 20-60- 1
P-26396
Figure 20-60-22
1
1 P-26395
Remove the load seal (Item 1) [Figure 20-60-24].

2
P-26393
Remove the wear plate (Item 1) [Figure 20-60-22] &

[Figure 20-60-23] and section seal (Item 2) [Figure 20-
60-22] & [Figure 20-60-23] from the pump end section.
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Figure 20-60-25
P-26398
P-26397
Remove the pre-load seal (Item 1) [Figure 20-60-25].

Figure 20-60-26
P-26374

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HYDRAULIC PUMP (HIGH FLOW) Figure 20-61-1
Check The Output Of The Hydraulic Pump (Standard)
WARNING 2

W-2017-0286
1
P-26753
WARNING Disconnect the OUTLET hose (Item 1) [Figure 20-61-1]

from the pump.
Figure 20-61-2

W-2059-0598
2 1
IMPORTANT
I-2024-0284
P-48256
procedure:
MEL1563 - Remote Start Tool the tester to the OUTLET fitting (Item 2) [Figure 20-61-1]
MEL10103 - Hydraulic Tester of the pump. Connect the OUTLET hose (Item 2) [Figure
MEL10106 - Hydraulic Test Kit 20-61-2] from the tester to the hose (Item 1) [Figure 20-
61-1] which was disconnected from the pump.
1.)
10-20-1.)

on Page 10-30-1.)

10-60-1.)
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255 of 961
HYDRAULIC PUMP (HIGH FLOW)) (CONT'D)
Check The Output Of The Hydraulic Pump (Standard)

(Cont'd)
Figure 20-61-3
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In
Hydraulic Control
Valve
1
B-16277

RPM*.


start tool) to engage the front auxiliary hydraulics, the
80% of free flow.
%= HIGH PRESSURE FLOW (GPM) X100

FREE FLOW (GPM)
*Refer to the Specification Section for system relief

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HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-4
Check The Output Of The Hydraulic Pump (High

Flow)
WARNING
W-2017-0286
P-48463
WARNING Install a jumper hose (Item 1) [Figure 20-61-4] onto the

front auxiliary quick couplers.
10-20-1.)

W-2059-0598
IMPORTANT
I-2024-0284

procedure:


1.)

on Page 10-30-1.)

10-60-1.)
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Check The Output Of The Hydraulic Pump (High EXAMPLE: TESTER

Flow) (Cont'd) CONNECTION
Reservoir
Figure 20-61-5
Hydraulic Pump
Out In
High Flow Valve
1
1 B-16277

2
P-48235 Start the engine and run at low idle RPM. Press the front
auxiliary button. Press the High Flow button. Push the
button (on the right control lever) for fluid flow to the quick
Disconnect the OUTLET hose (Item 1) [Figure 20-61-5] coupler. Make sure the tester is connected correctly. If no

from the High Flow valve. flow is indicated on the tester, the hoses are connected
wrong. With the hoses connected correctly, increase the
Figure 20-61-6 engine speed to full RPM*.

1000 PSI (6895 kPa).
NOTE: DO NOT EXCEED 3300 PSI.

2 1
Open the restrictor control and record the free flow
(GPM) at full RPM. Turn the restrictor control on the
tester to 3300 PSI and the flow should go to zero GPM.
If pressure readings are not obtained go to the High Flow

Valve, relief valve adjustment procedure (See
Adjustment on Page 20-30-2.)
P-48256
Record the highest pressure (PSI) and flow (GPM). The

high pressure flow must be at least 80% of free flow.
the tester to the OUTLET hose (Item 1) [Figure 20-61-5]
on the High Flow valve. Connect the OUTLET hose (Item %= HIGH PRESSURE FLOW (GPM) X100
2) [Figure 20-61-6] from the tester to the fitting (Item 2) FREE FLOW (GPM)
[Figure 20-61-5] on the High Flow valve.
Lower the cab.
*Refer to Hydraulic Schematics Legend for system relief
pressure and full RPM.
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HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Remove the Power Bob-Tach block if equipped. (See
Disconnect and cap the outlet hoses (Item 1) [Figure 20-
DANGER
WARNING
W-2059-0598
P-90328
AVOID DEATH Figure 20-61-9


D-1009-0409
Figure 20-61-8
1
1
P-26739
Disconnect and cap the inlet hoses (Item 1) [Figure 20-

P-26741
10-20-1.)

Page 10-10-1.)

on Page 10-30-1.)
Drain the hydraulic fluid from the reservoir. (See

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Figure 20-61-10
P-26684
1 2
1
2
P-26684

P-26740
Remove the coupler (Item 2) [Figure 20-61-11] from the
hydraulic pump shaft.
10] from the hydraulic pump. Reverse the removal procedure to install the hydraulic

pump.
(37 - 50 N•m) torque. Installation: Use a new O-ring (Item 1) [Figure 20-61-
11] when installing the hydraulic pump. (See
Remove the hydraulic pump (Item 2) [Figure 20-61-10] Disassembly And Assembly on Page 20-61- 8.)
T180 Bobcat Loader

260 of 961
HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
Identification
26
22 23
19
27
24 25
23
18 20 21
16 17
15
7 8
14

13
11 12
1
6 7 9 10
5
3 4
1. Retaining Ring 15. Pre-Load Seal

2. Pump End Section 16. Load Seal
3. Pre-Load Seal 17. Section Seal
4. Load Seal 18. Wear Plate
5. Section Seal 19. Drive Gear
6. Wear Plate 20. Idler Gear
7. Pins 21. Pump Section
8. Drive Gear 22. Wear Plate
9. Idler Gear 23. Pins
10. Pump Section 24. Section Seal
11. Wear Plate 25. Pump End Section
12. Section Seal 26. Bolt (4)
13. Spline Section 27. Bolt (4)
B-16051A
T180 Bobcat Loader

261 of 961

1
Figure 20-61-12
1
P-26622
2
P-26624
2

1 P-26622 13].

61-12].

Remove the four smaller pump housing bolts (Item 1)
[Figure 20-61-12].
Remove the four larger pump housing bolts (Item 2)

[Figure 20-61-12].
Installation: Tighten the four smaller bolts (Item 1)

[Figure 20-61-12] to 30 ft.-lb. (40,7 N•m) torque. Tighten
the four larger bolts (Item 2) [Figure 20-61-12] to 54 ft.-
lb. (73,2 N•m) torque.
IMPORTANT
damage the system.
I-2003-0888
T180 Bobcat Loader

262 of 961
Figure 20-61-14
1 1
P-26627
2 Figure 20-61-17
P-26625
Figure 20-61-15

4
1
3
1 P-26628
Remove the pump section (Item 1) [Figure 20-61-16] &

2
P-26626 [Figure 20-61-17] from the pump center section.
NOTE: Inspect the pumps center section (Item 1)

Remove the wear plate (Item 1) [Figure 20-61-14] & [Figure 20-61-17]. If excessive wear or
[Figure 20-61-15] and section seal (Item 2) [Figure 20- damage is visible, the pump must be
61-14] & [Figure 20-61-15] from the pump end section. replaced.

toward gears.

T180 Bobcat Loader

263 of 961
Figure 20-61-18
P-26631
Figure 20-61-21
P-26629

[Figure 20-61-19].

Figure 20-61-19
P-26632
1
Remove the drive gear (Item 1) [Figure 20-61-20] &
[Figure 20-61-21].
NOTE: Inspect the drive gear (Item 1) [Figure 20-61-

P-26630 21]. If excessive wear or damage is visible, the

T180 Bobcat Loader

264 of 961

1
Figure 20-61-22
P-26635
1
1
P-26635
2
P-26633
Figure 20-61-25
Figure 20-61-23

P-26638
P-26637
P-26634

61-22] & [Figure 20-61-23] from the pump center
section.

toward gears.
T180 Bobcat Loader

265 of 961
Disassembly And Assembly (Cont'd) 3
Figure 20-61-26
2
P-26657

toward gears.
Remove the pump center section (Item 1) [Figure 20-61- NOTE: Inspect the pump center section (Item 3) and
26] from the pump sections. bushings (Item 4) [Figure 20-61-28]. If

excessive wear or damage is visible, the
Figure 20-61-27 pump must be replaced.
Figure 20-61-29
1
2
P-26655
P-26659
61-27] & [Figure 20-61-28] from the pump section. Remove the pump section (Item 1) [Figure 20-61-29]
from the pump end section.
T180 Bobcat Loader

266 of 961
Figure 20-61-30
P-26662

P-26660 32]. If excessive wear or damage is visible, the
NOTE: Inspect the pump section (Item 1) [Figure 20-

61-30]. If excessive wear or damage is visible,

the pump must be replaced.
Figure 20-61-31
P-26661

[Figure 20-61-32].
T180 Bobcat Loader

267 of 961
Figure 20-61-33
P-26666
Remove the drive gear (Item 1) [Figure 20-61-35] from

P-26663 the pump end section.

Figure 20-61-34 35]. If excessive wear or damage is visible, the

Figure 20-61-36
1
P-26665
1
1
P-26664
To remove the drive gear (Item 1) [Figure 20-61-33] from

P-26674
the pump end section, locate and remove the retaining
ring (Item 1) [Figure 20-61-34] from the spline end of the
drive gear. Remove the spline shaft (Item 1) [Figure 20-61-36] from
the end of the drive gear.
NOTE: Inspect the spline shaft (Item 1) [Figure 20-61-

T180 Bobcat Loader

268 of 961
Figure 20-61-37
P-26670
P-26669
2
P-26667
Figure 20-61-40
Figure 20-61-38
1

P-26672
1
1
P-26671
P-26668

61-37] & [Figure 20-61-38] from the pump end section.

toward gears.
T180 Bobcat Loader

269 of 961
HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
Figure 20-61-41
P-26673


T180 Bobcat Loader

270 of 961
HYDRAULIC PUMP (SJC) Figure 20-62-2
Test The Output Of The Hydraulic Auxiliary Pump
WARNING
2 1
W-2017-0286
Figure 20-62-1 P-48256

the tester, to the OUTLET hose (Item 1) [Figure 20-62-1]
coming from the gear pump. Connect the OUTLET hose
1 (Item 2) [Figure 20-62-2] from the tester, to the INLET
tubeline (Item 2) [Figure 20-62-1] leading to the control
valve.

2
IMPORTANT
P-64570 The hydraulic tester must be in the fully open
I-2024-0284
procedure:


1.)
10-20-1.)

on Page 10-30-1.)

10-60-1.)
Disconnect the OUTLET hose (Item 1) [Figure 20-62-1].
T180 Bobcat Loader

271 of 961
HYDRAULIC PUMP (SJC) (CONT'D) Test The Output Of The Hydraulic Charge Pump

(Cont'd)
Figure 20-62-3
WARNING
EXAMPLE: TESTER Put jackstands under the front axles and rear corners
CONNECTION of the frame before running the engine for service.
Reservoir
W-2017-0286
Figure 20-62-4
Hydraulic Pump
Out In
Hydraulic Control
Valve
1 1
B-16277

2
P-64315
RPM*.
Warm the fluid to 140° F (60° C) by turning the restrictor The tools listed will be needed to do the following
control (Item 1) [Figure 20-62-3] on the tester to about procedure:
pressure. Open the restrictor control and record the free MEL1563 - Remote Start Tool
flow (GPM) at full RPM. MEL10103 - Hydraulic Tester
start tool) to engage the front auxiliary hydraulics. The Lift and block the loader. (See Procedure on Page 10-10-
light will come ON. Push the button (on the right control 1.)
go over main relief). Record the highest pressure (PSI) Raise the lift arms and install an approved lift arm support
and flow (GPM). The high pressure flow must be at least device. (See Installing Lift Arm Support Device on Page
80% of free flow. 10-20-1.)
HIGH PRESSURE FLOW (GPM) Raise the operator cab. (See Raising The Operator Cab
%= X100 on Page 10-30-1.)
FREE FLOW (GPM)
*Refer to the Specifications Section for system relief
10-60-1.)
Disconnect the charge pump OUTLET hose (Item 1) from
the INLET fitting (Item 2) [Figure 20-62-4] at the charge
filter housing.
T180 Bobcat Loader

272 of 961
HYDRAULIC PUMP (SJC) (CONT'D) Turn the restrictor down to 2000 PSI. DO NOT EXCEED
2000 PSI. The high pressure flow must be at least 80% of
Test The Output Of The Hydraulic Charge Pump free flow.
(Cont’d)
Figure 20-62-5 %= X100
FREE FLOW (GPM)
*Refer to Hydraulic Schematics for pump flow and full

RPM.
2 1
P-48256

the tester, to the charge pump OUTLET hose (Item 1)
[Figure 20-62-4] coming from the gear pump. Connect
the OUTLET hose (Item 2) [Figure 20-62-5] from the
tester, to the INLET fitting (Item 2) [Figure 20-62-4] at
the charge filter housing.
IMPORTANT
I-2024-0284
RPM*.

1000 PSI (6895 kPa). DO NOT exceed 2000 PSI.

(GPM) at full RPM.
T180 Bobcat Loader

273 of 961
HYDRAULIC PUMP (SJC) (CONT'D) Raise the lift arms and install an approved lift arm support
Removal And Installation 10-20-1.)
on Page 10-30-1.)
DANGER Drain the hydraulic fluid from the reservoir. (See
Disconnect and cap the outlet hose (Item 1) [Figure 20-
Remove the Power Bob-Tach block (Item 2) [Figure 20-
62-6] if equipped. (See Removal And Installation on
Page 20-120-1.)
P-90328
•
AVOID DEATH
Disconnecting or loosening any hydraulic
WARNING
can cause lift arms to drop. Never work on a machine with the lift arms up unless
• Keep out of this area when lift arms are raised the lift arms are secured by an approved lift arm
unless supported by an approved lift arm support device. Failure to use an approved lift arm
support. Replace if damaged. support device can allow the lift arms or attachment

D-1009-0409 to fall and cause injury or death.
W-2059-0598
Figure 20-62-7
IMPORTANT
parts clean. Always use caps and plugs on hoses, 1
damage the system.
I-2003-0888
Figure 20-62-6 1
P-64547
Disconnect and cap the inlet hoses (Item 1) [Figure 20-

1
P-64546

Page 10-10-1.)
T180 Bobcat Loader

274 of 961
HYDRAULIC PUMP (SJC) (CONT'D) Remove the hydraulic pump (Item 3) [Figure 20-62-9]
Figure 20-62-10
Figure 20-62-8
P-64446
P-64549
Replace the O-ring (Item 1) [Figure 20-62-10] in the

Remove the two mounting bolts (Item 1) [Figure 20-62- hydrostatic pump.
8] from the hydraulic pump.

Reverse the removal procedure to install the hydraulic
Installation: Tighten the mounting bolts to 55 - 60 ft.-lb. pump.
(75 - 85 N•m) torque.
Figure 20-62-9
3
1
P-64343
Remove the bracket mounting bolt (Item 1) from the

pump mounting bracket (Item 2) [Figure 20-62-9].
Note: The mounting bolt is a special purpose bolt.

Only replace with original Bobcat Parts.
Installation: Apply a medium strength threadlocker to

mounting bolt and tighten to 90 - 100 ft.-lb. (122 - 136
N•m) torque.
Remove the mounting bracket (Item 2) [Figure 20-62-9].
T180 Bobcat Loader

275 of 961
HYDRAULIC PUMP (SJC) (CONT'D)
Identification
15
14
7 5
12
8
5 6
4
12 3

9
8
7
11
5
6
10
9
7
3 4 5 6
1 1. Shaft Seal
2 2. Pump Flange Section
3. Pre-Load Seal
4. Load Seal
5. O-ring
6. Wear Plate
7. Pins
8. Drive Gear
9. Idler Gear
10. Auxiliary Pump Section
11. Spline Shaft
13. Charge Pump Section
14. Pump End Section
15. Bolt (8)
B-21259A
T180 Bobcat Loader

276 of 961
HYDRAULIC PUMP (SJC) (CONT'D) Figure 20-62-12
Disassembly And Assembly 1
Figure 20-62-11
P-26352
P-64507
1
1 P-64509
1
P-64508 12].

62-11].

Remove the eight pump housing bolts (Item 1) [Figure
20-62-11].
Installation: Tighten the bolts (Item 2) [Figure 20-62-11]

to 54 ft.-lb. (73,2 N•m) torque.
IMPORTANT
damage the system.
I-2003-0888
T180 Bobcat Loader

277 of 961
Figure 20-62-13 1
P-64511
2
Figure 20-62-16
P-64509
1
Figure 20-62-14

3
4
1
P-64512
2 Remove the charge pump section (Item 1) [Figure 20-

P-64510 62-15] & [Figure 20-62-16] from the pump center
section.
Remove the wear plate (Item 1) and section seal (Item 2) NOTE: Inspect the pump section (Item 1) [Figure 20-
[Figure 20-62-13] & [Figure 20-62-14] from the pump 62-16]. If excessive wear or damage is visible,
end section. the pump must be replaced.

toward gears.

T180 Bobcat Loader

278 of 961
Figure 20-62-17
P-64515
Figure 20-62-20
P-64513
Figure 20-62-18

1
P-64516

P-64514 [Figure 20-62-20] from the pump center section.

Remove the drive gear (Item 1) [Figure 20-62-17] & 20]. If excessive wear or damage is visible, the
[Figure 20-62-18]. pump must be replaced.

T180 Bobcat Loader

279 of 961
Figure 20-62-21
1
P-64519
1
2 Figure 20-62-24
P-64517
2
Figure 20-62-22

1
2 1
P-64520
Remove the load seal (Item 1) [Figure 20-62-23] &

P-64518 [Figure 20-62-24]. Inspect for damage and replace as
needed.
Remove the wear plate (Item 1) and O-ring (Item 2) Remove the pre-load seal (Item 2) [Figure 20-62-24].
[Figure 20-62-21] & [Figure 20-62-22] from the pump
center section. Inspect for damage and replace as
needed.

toward gears.
T180 Bobcat Loader

280 of 961
Figure 20-62-25
2
1
1
P-64526
Figure 20-62-28
P-64521
3
Inspect the pre-load seal (Item 1) [Figure 20-62-25] for

damage and replace as needed. 4

NOTE: Inspect the pump center section (Item 2) and
bushings (Item 3) [Figure 20-62-25]. If
pump must be replaced. 1
Figure 20-62-26
2
1
P-64527
Remove the wear plate (Item 1) and O-ring (Item 2)

needed.

toward gears.
P-64525 NOTE: Inspect the pump center section (Item 3) and

Remove the pump center section (Item 1) [Figure 20-62- pump must be replaced.
26].
T180 Bobcat Loader

281 of 961
Figure 20-62-29
1
P-64530
1
P-64528 the pump flange section.
Figure 20-62-32
Figure 20-62-30

1
P-64531
P-64529

Remove the auxiliary pump section (Item 1) [Figure 20- 32]. If excessive wear or damage is visible, the
62-29] & [Figure 20-62-30] from the pump flange pump must be replaced.
section.
NOTE: Inspect the pump section (Item 1) [Figure 20-

62-30]. If excessive wear or damage is visible,
the pump must be replaced.
T180 Bobcat Loader

282 of 961
Figure 20-62-33
2
P-64535
Figure 20-62-36
P-64532
Remove the spline shaft (Item 1) [Figure 20-62-33] from

the end of the drive gear.

Remove the idler gear (Item 2) [Figure 20-62-33].
Figure 20-62-34
2
P-64536

1 [Figure 20-62-35] & [Figure 20-62-36] from the pump
flange section. Inspect for damage and replace as
needed.

toward gears.

T180 Bobcat Loader

283 of 961
Figure 20-62-37
3
2
1
P-64540

P-64537 damage and replace as needed.
NOTE: Inspect the pump flange section (Item 2) and

Figure 20-62-38 bushings (Item 3) [Figure 20-62-39]. If

Figure 20-62-40
1
2
2
1 P-30188A
P-64538

[Figure 20-62-38]. Inspect for damage and replace as
P-64541
needed.
Remove the pre-load seal (Item 2) [Figure 20-62-38]. Remove the shaft seal (Item 1) [Figure 20-62-40] from
the pump flange section.
Installation: The shaft seal flush surface (Item 2)

[Figure 20-62-40] must be facing out away from the
pump.
T180 Bobcat Loader

284 of 961
HYDRAULIC PUMP (HIGH FLOW) (SJC) Figure 20-63-2
WARNING
2 1
W-2017-0286
Figure 20-63-1 P-48256

the tester, to the OUTLET hose (Item 1) [Figure 20-63-1]
coming from the gear pump. Connect the OUTLET hose
1 (Item 2) [Figure 20-63-2] from the tester, to the INLET
tubeline (Item 2) [Figure 20-63-1] leading to the
hydraulic control valve.

2
IMPORTANT
P-64570 The hydraulic tester must be in the fully open
I-2024-0284
procedure:


1.)
10-20-1.)

on Page 10-30-1.)

10-60-1.)
Disconnect the OUTLET hose (Item 1) [Figure 20-63-1].
T180 Bobcat Loader

285 of 961
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Test The Output Of The Hydraulic Charge Pump

(Cont'd)
Figure 20-63-3
WARNING
EXAMPLE: TESTER Put jackstands under the front axles and rear corners
CONNECTION of the frame before running the engine for service.
Reservoir
W-2017-0286
Figure 20-63-4
Hydraulic Pump
Out In
Hydraulic Control
Valve
1 1
B-16277

2
P-64315
RPM*.
Warm the fluid to 140° F (60° C) by turning the restrictor The tools listed will be needed to do the following
control (Item 1) [Figure 20-63-3] on the tester to about procedure:
pressure. Open the restrictor control and record the free MEL1563 - Remote Start Tool
flow (GPM) at full RPM. MEL10103 - Hydraulic Tester
start tool) to engage the front auxiliary hydraulics. The Lift and block the loader. (See Procedure on Page 10-10-
light will come ON. Push the button (on the right control 1.)
go over main relief). Record the highest pressure (PSI) Raise the lift arms and install an approved lift arm support
and flow (GPM). The high pressure flow must be at least device. (See Installing Lift Arm Support Device on Page
80% of free flow. 10-20-1.)
%= HIGH PRESSURE FLOW (GPM) X100 Raise the operator cab. (See Raising The Operator Cab
FREE FLOW (GPM) on Page 10-30-1.)

*Refer to the Specifications Section for system relief
10-60-1.)
Disconnect the charge pump OUTLET hose (Item 1) from
the INLET fitting (Item 2) [Figure 20-63-4] at the charge
filter housing.
T180 Bobcat Loader

286 of 961
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Turn the restrictor down to 2000 PSI. DO NOT EXCEED
2000 PSI. The high pressure flow must be at least 80% of
Test The Output Of The Hydraulic Charge Pump free flow.
(Cont’d)
%= HIGH PRESSURE FLOW (GPM) X100
Figure 20-63-5 FREE FLOW (GPM)
*Refer to Hydraulic Schematics for pump flow and full

RPM.
2 1
P-48256

the tester, to the charge pump OUTLET hose (Item 1)
[Figure 20-63-4] coming from the gear pump. Connect
the OUTLET hose (Item 2) [Figure 20-63-5] from the
tester, to the INLET fitting (Item 2) [Figure 20-63-4] at
the charge filter housing.
IMPORTANT
I-2024-0284
RPM*.

1000 PSI (6895 kPa). DO NOT exceed 2000 PSI.

(GPM) at full RPM.
T180 Bobcat Loader

287 of 961
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D) Figure 20-63-6
Test The Output Of The Hydraulic Pump (High Flow)
1
WARNING
W-2017-0286
P-48463
WARNING Install a jumper hose (Item 1) [Figure 20-63-6] onto the

front auxiliary quick couplers.
10-20-1.)

W-2059-0598
IMPORTANT
I-2024-0284

procedure:


1.)

on Page 10-30-1.)

10-60-1.)
T180 Bobcat Loader

288 of 961
Test The Output Of The Hydraulic Pump (High Flow) EXAMPLE: TESTER
(Cont'd) CONNECTION
Reservoir
Figure 20-63-7
Hydraulic Pump
Out In
High Flow Valve
1
1 B-16277

2
P-48235 Start the engine and run at low idle RPM. Press the front
auxiliary button. Press the High Flow button. Push the
button (on the right control lever) for fluid flow to the quick
Disconnect the high flow pump OUTLET hose (Item 1) coupler. Make sure the tester is connected correctly. If no

from the high flow valve INLET fitting (Item 2) [Figure 20- flow is indicated on the tester, the hoses are connected
63-7]. wrong. With the hoses connected correctly, increase the
engine speed to full RPM*.
Figure 20-63-8
1000 PSI (6895 kPa).
2 1 Open the restrictor control and record the free flow

(GPM) at full RPM. Turn the restrictor control on the
tester to 3300 PSI and the flow should go to zero GPM.
If pressure readings are not obtained go to the High Flow

Valve, relief valve adjustment procedure (See
Adjustment on Page 20-30-2.)
P-48256 Record the highest pressure (PSI) and flow (GPM). The
high pressure flow must be at least 80% of free flow.
the tester, to the high flow pump OUTLET hose (Item 1) %= HIGH PRESSURE FLOW (GPM) X100
[Figure 20-63-7]. Connect the OUTLET hose (Item 2) FREE FLOW (GPM)
[Figure 20-63-8] from the tester, to the high flow valve
INLET fitting (Item 2) [Figure 20-63-7] on the High Flow A low percentage may indicate a failed pump.
valve.
*Refer to Hydraulic Schematics Legend for system relief
Lower the cab. pressure and full RPM.
T180 Bobcat Loader

289 of 961
DANGER
P-64545
P-90328
AVOID DEATH Figure 20-63-11


D-1009-0409
1
10-20-1.) 2

Page 10-10-1.) P-64546

on Page 10-30-1.) Disconnect and cap the outlet hoses (Item 1) [Figure 20-
63-10] and [Figure 20-63-11] from the back of the
Drain the hydraulic fluid from the reservoir. (See hydraulic pump.
Remove the Power Bob-Tach block (Item 2) [Figure 20-
Open the rear door of the loader. 63-11] if equipped. (See Removal And Installation on
Page 20-120-1.)
WARNING
W-2059-0598
T180 Bobcat Loader

290 of 961
Figure 20-63-12
3
1
1
2
1 P-64343
Remove the bracket mounting bolt (Item 1) from the

P-64544 pump mounting bracket (Item 2) [Figure 20-63-14].
Note: The mounting bolt is a special purpose bolt.

Disconnect and cap the inlet hoses (Item 1) [Figure 20- Only replace with original Bobcat Parts.

Installation: Apply a medium strength threadlocker to
Figure 20-63-13 mounting bolt and tighten to 90 - 100 ft.-lb. (122 - 136
N•m) torque.
Remove the mounting bracket (Item 2) [Figure 20-63-

14].
Remove the hydraulic pump (Item 3) [Figure 20-63-14]

1
Figure 20-62-15
P-64549

13] from the hydraulic pump.

(75 - 85 N•m) torque.
P-64446
Replace the O-ring (Item 1) [Figure 20-62-15] in the

hydrostatic pump.
Reverse the removal procedure to install the hydraulic

pump.
T180 Bobcat Loader

291 of 961
HYDRAULIC PUMP (HIGH FLOW) (SJC) (CONT'D)
Identification
17
16
8 4
12 15 2
7
14 3 4 5
7
8 13 6 5
9
6
7
12

7
8
7
9 6
5
3 4
6 5 11
6 9
5 10
1 3 4
1. Shaft Seal
2. Pump Flange Section
2
3. Pre-Load Seal
4. Load Seal
5. O-Ring
6. Valve Plate
7. Pin
8. Drive Gear
9. Idler Gear
10. Auxiliary Pump Section
11. Auxiliary Center Section
12. Splined Shaft
13. Charge Pump Section
14. Charge Center Section
15. High Flow Pump Section
16. High Flow End Section
17. Bolt
B-18248
T180 Bobcat Loader

292 of 961
Disassembly And Assembly 1
Figure 20-63-16
1
P-64553
P-64554
1
1
Remove the high flow end section (Item 1) [Figure 20-
P-64552 63-17].

63-16].

Remove the eight pump housing bolts (Item 1) [Figure
20-63-16].
Installation: Tighten the bolts (Item 2) [Figure 20-63-16]

to 54 ft.-lb. (73,2 N•m) torque.
IMPORTANT
damage the system.
I-2003-0888
T180 Bobcat Loader

293 of 961
Figure 20-63-18 1
P-64556
2
Figure 20-63-21
P-64554
1
Figure 20-63-19

3
4
1
P-64557
2
Remove the high flow pump section (Item 1) [Figure 20-
P-64555 63-20] & [Figure 20-63-21] from the charge center
section.
Remove the wear plate (Item 1) and O-ring (Item 2) NOTE: Inspect the high flow pump section (Item 1)
[Figure 20-63-18] & [Figure 20-63-19] from the high flow [Figure 20-63-21]. If excessive wear or
end section. damage is visible, the pump must be
replaced.
toward gears.
NOTE: Inspect the high flow end section (Item 3) and

T180 Bobcat Loader

294 of 961
Figure 20-63-22
P-64560
Figure 20-63-25
P-64558
Figure 20-63-23

1
P-64561

P-64559 [Figure 20-63-25] from the charge center section.

Remove the drive gear (Item 1) [Figure 20-63-22] & 25]. If excessive wear or damage is visible, the
[Figure 20-63-23]. pump must be replaced.

T180 Bobcat Loader

295 of 961
Figure 20-63-26
P-64564
2
Figure 20-63-29
P-64562
2
Figure 20-63-27

1
2
1
P-64565

needed.
Remove the wear plate (Item 1) and O-ring (Item 2) Remove the pre-load seal (Item 2) [Figure 20-63-29].
[Figure 20-63-26] & [Figure 20-63-27] from the charge
needed.

toward gears.
T180 Bobcat Loader

296 of 961
Figure 20-63-30 2
3
1
1
P-64569
Figure 20-63-33
P-64567
3

damage and replace as needed. 4

NOTE: Inspect the charge center section (Item 2) and
1
Figure 20-63-31
2
1 P-64571

[Figure 20-63-32] & [Figure 20-63-33] from the charge
needed.

toward gears.
P-64568 NOTE: Inspect the charge center section (Item 3) and

Remove the charge center section (Item 1) [Figure 20- pump must be replaced.
63-31].
T180 Bobcat Loader

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Figure 20-63-34
1 1
P-64574

P-64572 the auxiliary center section.
Figure 20-63-37
Figure 20-63-35

1
P-64575
P-64573

Remove the charge pump section (Item 1) [Figure 20- 37]. If excessive wear or damage is visible, the
63-34] & [Figure 20-63-35] from the auxiliary pump pump must be replaced.
center section.
NOTE: Inspect the charge pump section (Item 1)

[Figure 20-63-35]. If excessive wear or
damage is visible, the pump must be
replaced.
T180 Bobcat Loader

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Figure 20-63-38
1 2
2
P-64578
Figure 20-63-41
P-64576

the end of the drive gear. Inspect for damage and replace

as needed.
Remove the idler gear (Item 2) [Figure 20-63-38]. 1
Figure 20-63-39 2
P-64579
1
[Figure 20-63-40] & [Figure 20-63-41] from the auxiliary
needed.

P-64577 toward gears.

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Disassembly And Assembly (Cont'd) 2
Figure 20-63-42
1
1
P-64521

P-64519 damage and replace as needed.
NOTE: Inspect the auxiliary center section (Item 2)

Figure 20-63-43 and bushings (Item 3) [Figure 20-63-44]. If

2
Figure 20-63-45
1
P-64520

[Figure 20-63-43]. Inspect for damage and replace as
P-64525
needed.
Remove the pre-load seal (Item 2) [Figure 20-63-43]. Remove the auxiliary center section (Item 1) [Figure 20-
63-45].
T180 Bobcat Loader

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Figure 20-63-46
P-64528
1
Figure 20-63-49
P-64526
Figure 20-63-47

3
4
1
1
P-64529
2 Remove the auxiliary pump section (Item 1) [Figure 20-

P-64527 63-48] & [Figure 20-63-49] from the pump flange
section.
Remove the wear plate (Item 1) and O-ring (Item 2) NOTE: Inspect the auxiliary pump section (Item 1)
[Figure 20-63-46] & [Figure 20-63-47] from the auxiliary [Figure 20-63-49]. If excessive wear or
center section. Inspect for damage and replace as damage is visible, the pump must be
needed. replaced.

toward gears.
NOTE: Inspect the auxiliary center section (Item 3)

and bushings (Item 4) [Figure 20-63-47]. If
T180 Bobcat Loader

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Figure 20-63-50
1
1
P-64532

P-64530 the end of the drive gear.
Remove the idler gear (Item 2) [Figure 20-63-52].

the pump flange section. Figure 20-63-53

Figure 20-63-51
1
1
P-64534
P-64531
Remove the idler gear (Item 1) [Figure 20-63-53] from
the pump flange section.
51]. If excessive wear or damage is visible, the NOTE: Inspect the idler gear (Item 1) [Figure 20-63-
pump must be replaced. 53]. If excessive wear or damage is visible, the
T180 Bobcat Loader

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Figure 20-63-54
P-64537
Figure 20-63-57
P-64535
Figure 20-63-55

2
1 P-64538

2
needed.
Remove the wear plate (Item 1) and section seal (Item 2) Remove the pre-load seal (Item 2) [Figure 20-63-57].
flange section. Inspect for damage and replace as
needed.

toward gears.
T180 Bobcat Loader

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Figure 20-63-58
1
2
P-30188A
3
2
P-64541
Remove the shaft seal (Item 1) [Figure 20-63-59] from

1
P-64540 the pump flange section.
Installation: The shaft seal flush surface (Item 2)

Inspect the pre-load seal (Item 1) [Figure 20-63-58] for [Figure 20-63-59] must be facing out away from the
damage and replace as needed. pump.

NOTE: Inspect the pump flange section (Item 2) and
T180 Bobcat Loader

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HYDRAULIC/HYDROSTATIC FILTER HOUSING Figure 20-70-2
IMPORTANT 1

2
damage the system.
3
P-48260
Implement Filter Housing
Figure 20-70-1 Disconnect the wires from the charge pressure sender
(Item 1) [Figure 20-70-2] from the filter housing.
Disconnect the temperature sender connector (Item 2)

[Figure 20-70-2] from the filter housing.

Disconnect the wire connector (Item 3) [Figure 20-70-2]
from the differential pressure switch on the filter housing.
1
Figure 20-70-3
P-48259
1
Stop the engine and open the rear door.
Drain the hydraulic fluid. (See Replacing Hydraulic Fluid

on Page 10-120-2.)
Remove the two mounting bolts (Item 1) and remove the

hydraulic filter drip pan (Item 2) [Figure 20-70-1]. P-48257

the filter housing. Using MEL 1558 tool disconnect the oil cooler tubeline
(Item 1) [Figure 20-70-3] from the filter housing.
T180 Bobcat Loader

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HYDRAULIC/HYDROSTATIC FILTER HOUSING Charge Filter Housing
(CONT’D)
Stop the engine and open the rear door.
Drain the hydraulic fluid. (See Replacing Hydraulic Fluid
Figure 20-70-4 on Page 10-120-2.)
Figure 20-70-5
1
P-48258
1
P-64315
Remove the two mounting screws (Item 1) [Figure 20-
70-4] from the filter housing mounting bracket.

Disconnect the tubeline (Item 1 [Figure 20-70-5] from
Installation: Tighten the mounting screws to 15 - 20 ft.- the filter housing.
Remove the hydraulic filter housing and filter. filter housing.
Reverse the removal procedure to install the filter Figure 20-70-6
housing and filter.
1
2
P-64315
Disconnect the wire connector (Item 1) [Figure 20-70-6]

from the differential pressure switch on the filter housing.
Remove the four mounting bolts (Item 2) [Figure 20-70-

6] from the filter housing.
Remove the hydraulic filter housing and filter.
Reverse the removal procedure to install the filter

housing and filter.
T180 Bobcat Loader
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HYDRAULIC FLUID RESERVOIR Remove bucket position valve if equipped. (See Removal
Figure 20-80-1
DANGER
1 2
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic P-48379

can cause lift arms to drop. Remove the two bolts (Item 1) and the reservoir bracket
• Keep out of this area when lift arms are raised (Item 2) [Figure 20-80-1].

Figure 20-80-2
D-1009-0409
WARNING
the lift arms are secured by an approved lift arm 2
support device can allow the lift arms or attachment 1
W-2059-0598
P-48380
10-20-1.) Disconnect the reservoir vent hose (Item 1) [Figure 20-
80-2] from the hydraulic reservoir.
on Page 10-30-1.) Disconnect the hydraulic fill hose (Item 2) [Figure 20-80-
2] from the hydraulic fluid reservoir.
pintles])
Remove the crossbar linkage. (See Crossbar Linkage

Drain the hydraulic fluid reservoir. (See Replacing

Hydraulic Fluid on Page 10-120-2.)
T180 Bobcat Loader

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HYDRAULIC FLUID RESERVOIR (CONT'D) Figure 20-80-5
Figure 20-80-3
2 P-48465
Remove the front hydraulic reservoir bracket bolt (Item 1)

P-48378 [Figure 20-80-5].
Figure 20-80-6
Mark, disconnect and cap the two hoses (Item 1) [Figure
20-80-3] from the hydraulic fluid reservoir tee fitting. 1

Mark, disconnect and cap the hoses (Item 2) [Figure 20-
2
80-3] to the case drain filter.
Figure 20-80-4
1 P-24827 P-24768
Remove the three bolts (Item 1) from the side access

plate (Item 2) [Figure 20-80-6].
Remove side access plate.

P-48377
Remove the bolt from the wire harness clamp (Item 1)

[Figure 20-80-4].
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HYDRAULIC FLUID RESERVOIR (CONT'D)
Figure 20-80-7
P-24749
P-24748
Disconnect and cap the hose (Item 1) from the fitting

(Item 2) [Figure 20-80-7] at the bottom of the reservoir.

Figure 20-80-8
P-48381
Tilt the front of the hydraulic reservoir bracket down, by

pushing down on the hydraulic reservoir.
Roll the hydraulic reservoir (Item 1) [Figure 20-80-8] out

from under the fender and remove from the front of the
loader.
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BUCKET POSITION VALVE Figure 20-90-3
Solenoid Removal And Installation
Figure 20-90-1
1 2
1
P-26312A
Remove the solenoid stem (Item 1) [Figure 20-90-3]

P-26310A from the bucket position valve.
Installation: Put oil on O-rings and back-up washers and

Disconnect the wire harness connector (Item 1) [Figure tighten the solenoid stem to 30 - 35 ft.-lb. (40,8 - 47,6
20-90-1] from the bucket position shut-off solenoid. N•m) torque.

NOTE: Loosening the two mounting bolts (Item 2) Figure 20-90-4
[Figure 20-90-1] on the Bucket Positioning
Valve Bracket may aid in the solenoid
removal.
Figure 20-90-2
1
2
N-18191
1 Inspect the solenoid stem and replace the O-rings (Item

1) [Figure 20-90-4] and the back-up washer (Item 2)
P-26311A [Figure 20-90-4].
Remove the solenoid nut (Item 1) [Figure 20-90-2].
Installation: Tighten the solenoid nut to 4 - 6 ft.-lb. max.

(5 - 8 N•m max.) torque. Overtightening may cause valve
failure.
Remove the solenoid coil (Item 2) [Figure 20-90-2].
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BUCKET POSITION VALVE (CONT'D)
Solenoid Testing
Figure 20-90-5
P9175
Use a test meter to measure coil resistance [Figure 20-

90-5]. Coil wires do not have polarity. Correct resistance

for the coil is 9.8 ohm.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
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BUCKET POSITION VALVE (CONT'D) Figure 20-90-6
DANGER 1
P-26310A
P-90328
AVOID DEATH Start the engine. Raise the lift arms and install an
• Disconnecting or loosening any hydraulic approved lift arm support device. (See Installing Lift Arm
tubeline, hose, fitting, component or a part failure Support Device on Page 10-20-1.)
• Keep out of this area when lift arms are raised Stop the engine.

D-1009-0409 on Page 10-30-1.)
Disconnect the electric solenoid connector (Item 1)

[Figure 20-90-6].
WARNING
W-2059-0598
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Figure 20-90-7
1
P-26313A
1
Disconnect the two tubelines (Item 1) [Figure 20-90-9]
P-26311A from the tee fitting.
Figure 20-90-10
Figure 20-90-8

1
4
1 2
3
P-26314
P-26312A
Remove the tubeline (Item 1) [Figure 20-90-10] from the

Remove the solenoid nut (Item 1) [Figure 20-90-7]. B port to the control valve.
Installation: Tighten the nut to 4 - 6 ft.-lb. max. (5 - 8 Disconnect the tubeline (Item 2) [Figure 20-90-10] from
N•m max.) torque. Overtightening may cause valve the C port (tilt rod end) on the BPV.
failure.
Remove the solenoid (Item 2) [Figure 20-90-7] and the the D port (tilt base end) on the BPV.
solenoid stem (Item 1) [Figure 20-90-8].
Remove the mounting screws (Item 4) [Figure 20-90-
Installation: Put oil on the O-rings and back-up washers 10].
and tighten the solenoid stem to 30 - 35 ft.-lb. (40,8 - 47,6
N•m) torque. Installation: Tighten the mounting screws to 15 ft.-lb. (20
N•m) torque.
Remove the bucket position valve and bracket from the

loader.
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Figure 20-90-11
1
N-19072
Remove the flow adjustment valve and O-ring (Item 1)

N-19069 [Figure 20-90-13]
NOTE: Always install new O-rings before any parts

Remove the solenoid nut (Item 1) [Figure 20-90-11]. are installed into the valve. Check the parts
for wear or damage and replace as needed.

Installation: Tighten the nut to 4 - 6 ft.-lb. max. (5 - 8
N•m max.) torque. Overtighten may cause valve failure. Figure 20-90-14
Figure 20-90-12
1 1
N-19041
N-19070
Remove the plug (Item 1) [Figure 20-90-14].
Remove the solenoid (Item 1) and the solenoid stem

(Item 2) [Figure 20-90-12].
Installation: Tighten the solenoid stem to 30 - 35 ft.-lb.

(40,8 - 47,6 N•m) torque.
T180 Bobcat Loader

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Figure 20-90-15
1
N-19045
Remove the plug [Figure 20-90-17].

N-18339
Figure 20-90-18
Remove the plug (Item 1), and flow control spool (Item 2)
[Figure 20-90-15].

Check the flow control spool for wear, check the O-ring
on the plug and replace as needed.
Figure 20-90-16 3
N-19046
1
Remove the plug (Item 1), spring (Item 2) and unloading
2 spool (Item 3) [Figure 20-90-18].
Check all parts and replace as needed. Install a new O-

3 ring on the plug before installing.
N-19042
Remove the tilt cylinder check valve (item 1) spring (Item

2) and plug (Item 3) [Figure 20-90-16]. Check for wear,
check the O-ring and replace as needed.
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HIGH FLOW VALVE
Checking The High Flow Relief Valve WARNING

Figure 20-100-1
1
2 fall or move and cause injury or death.
W-2017-0286
Figure 20-100-2
3
1
P-34480
2

procedure:

N-18409

1.) Start the engine and run at low idle RPM. Push the flow
switch (Item 1) once (on the instrument panel) to engage
NOTE: Check the Main Relief Valve (See Checking on the front auxiliary hydraulics variable flow, the light (Item
Page 20-30-1.) for proper flow and pressure 2) will come ON [Figure 20-100-2].
before checking the High Flow Relief Valve.
Push the high flow switch (Item 3) [Figure 20-100-2] and
Connect the IN port of the hydraulic tester to the female the High Flow light will come ON.
quick coupler (Item 1) [Figure 20-100-1] on the loader.
Connect the OUT port of the hydraulic tester to the male

quick coupler (Item 2) [Figure 20-100-1] on the loader.
IMPORTANT
I-2024-0284
T180 Bobcat Loader

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HIGH FLOW VALVE (CONT'D)
Checking The High Flow Relief Valve (Cont’d)
Figure 20-100-3
Right
Steering
Lever
Control
1
P-31833
• Push the front switch (Item 1) [Figure 20-100-3] to

give the front quick couplers a constant flow of fluid.

• To release from continuous operation, press the front
switch (Item 1) [Figure 20-100-3] a second time.
Watch the flow meter on the hydraulic tester to make

sure the flow is correct. Increase the engine speed to full
RPM.

control on the tester to about 1000 PSI (6895 kPa). DO
NOT exceed system relief pressure.
Turn the restrictor control on the tester counter clockwise,

to obtain free flow, the flow should be at 27 GPM. Start
turning the restrictor clockwise, causing more restriction
on the flow. The GPM should drop off slightly until the
pressure reaches approximately 3100 PSI. At
approximately 3100 PSI the flow should start decreasing
rapidly until the pressure reaches 3250 - 3300 PSI. At
3250 - 3300 PSI the flow should be at 0 GPM. Turn the
restrictor control counter clockwise to free flow. Shut the
front auxiliary hydraulics off.
If the specs from above are reached, the high flow relief
valve is OK.
If the high flow relief pressure is not correct, stop the

engine and adjust the high flow relief valve. (See
Disassembly And Assembly on Page 20-100-6.)
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HIGH FLOW VALVE (CONT'D) Figure 20-100-5
High Flow Relief Valve Adjustment Procedure
NOTE: The high flow relief valve is located between

the control valve and the hydraulic reservoir.
Figure 20-100-4
1 P-45469
To increase the high flow relief valve PSI turn the screw
(Item 1) [Figure 20-100-5] clockwise a 1/4 turn and
recheck the high flow relief valve. (1/4 turn equals
approximately 200 PSI.)
P-48231
To decrease the high flow relief valve PSI turn the screw

(Item 1) [Figure 20-100-5] counterclockwise a 1/4 turn
If the relief pressure is not correct, stop the engine and and recheck the high flow relief valve. (1/4 turn equals
raise the operator cab. (See Checking The High Flow approximately 200 PSI.)
Relief Valve on Page 20-100-1.)
NOTE: If the relief screw (Item 1) [Figure 20-100-5]
Remove the high flow relief valve adjustment plug (Item has been turned in 1/4 turn and the pressure
1) [Figure 20-100-4]. remains the same, remove and inspect the
high flow relief valve, replace as needed.
Install the plug into the high flow relief valve.
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Figure 20-100-6
2 2
1
1
P-48236
1
Disconnect the electrical connector (Item 1) [Figure 20-
P-48235 100-7] from the solenoid.
Figure 20-100-8
Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 20-100-6] which are connected to the

steering shaft on the control panel.
Remove the four steering linkage mounting bolts (Item 2)

[Figure 20-100-6].
2
Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage mounting bolts to 25 -
28 ft.-lb. (34 - 38 N•m) torque.
The high flow valve is located between the control valve

1
and the hydraulic reservoir.
P-48238
IMPORTANT Mark all tubelines and hoses for correct installation.

from the pump outlet to the high flow valve.
from the high flow valve to the pump inlet.
damage the system.
I-2003-0888
T180 Bobcat Loader

320 of 961
Figure 20-100-9
1
2
P-48232
Disconnect and cap the tubelines (Item 1) [Figure 20-

100-9] to the tilt cylinders.

9].

(34 - 38 N•m) torque.
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321 of 961
Figure 20-100-10
2 1
1
P-48110
Inspect O-rings (Item 1) and back-up washer (Item 2) on

P-48108 the solenoid stem [Figure 20-100-12].
Installation: Put oil on O-rings and back-up washer.

Remove the solenoid nut (Item 1) and solenoid (Item 2) Install and tighten to 25 ft.-lb. (39,9 N•m) torque.
from the solenoid valve [Figure 20-100-10].

Figure 20-100-13
Installation: Tighten to 4 - 6 ft.-lb. (5 - 8 N•m) torque.
Figure 20-100-11
1
P-48111
P-48109 Remove the relief valve (Item 1) [Figure 20-100-13].
Installation: Apply to oil to the O-rings and back-up

Remove the solenoid valve (Item 1) [Figure 20-100-11] washers. Tighten to 30 - 35 ft.-lb. (41 - 47 N•m) torque.
from the valve.

torque.
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Figure 20-100-14
1
P-48113
2
Remove the check valve (Item 1) [Figure 20-100-16]
P-48112 from the high flow valve.
Figure 20-100-17
Inspect the relief valve and replace the two O-rings (Item
1) and back-up washer (Item 2) [Figure 20-100-14].

Figure 20-100-15
1
P-48114
Inspect the check valve, O-rings (Item 1) & back-up

P-45469 washers (Item 2) for wear and replace as needed [Figure
20-100-17].
Inspect the O-ring (Item 1) [Figure 20-100-15] on the Installation: Apply to oil to the O-rings and back-up
relief valve adjustment plug for damage and replace as washers. Tighten to 30 - 35 ft.-lb. (41 - 47 N•m) torque.
needed.
Installation: Tighten to 20 ft.-lb. (27,1 N•m) torque.
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Solenoid Testing
Figure 20-100-18
P9175

100-18]. Coil terminals do not have polarity. Correct

resistance for the pressure relief coil is 7.5 ohm.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
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REAR AUXILIARY DIVERTER VALVE Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Disconnect the negative battery cable. (See Removal
DANGER Remove the speed control lever. (See Removal and

Installation on Page 70-21-1.)

pintles])
Figure 20-110-1
P-90328
AVOID DEATH
support. Replace if damaged. 1

D-1009-0409
WARNING P-48301
Never work on a machine with the lift arms up unless The rear auxiliary valve (Item 1) [Figure 20-110-1] is
the lift arms are secured by an approved lift arm located between the control valve and the gear pump on
support device. Failure to use an approved lift arm the right side of the loader.
W-2059-0598
IMPORTANT
WARNING When repairing hydrostatic and hydraulic systems,
AVOID INJURY OR DEATH parts clean. Always use caps and plugs on hoses,
Always clean up spilled fuel or oil. Keep heat, flames, tubelines and ports to keep dirt out. Dirt can quickly
sparks or lighted tobacco away from fuel and oil. damage the system.
I-2003-0888
explosion or fire.
W-2103-0508

1.)
10-20-1.)
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REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-110-4
Figure 20-110-2
1 P-48304
Disconnect the drain tubeline (Item 1) [Figure 20-110-4]

P-48302 from the lift arm by pass valve.
Figure 20-110-5
Disconnect the base and rod end tubelines (Item 1)
[Figure 20-110-2].

Figure 20-110-3
1
P-48303
Disconnect and remove the drain tubeline (Item 1)

P-48300 [Figure 20-110-5] from the rear auxiliary valve.
Disconnect the four solenoid connectors (Item 1) [Figure

20-110-3] from the rear auxiliary valve.
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Figure 20-110-6
2
P-48361
1
Remove the rear auxiliary valve (Item 1) [Figure 20-110-
P-48305 8] by lowering the valve to the drivecase which allows the
valve to be brought forward and removed from the loader.
Disconnect the pump outlet hose (Item 1) [Figure 20-

110-6] from the rear auxiliary valve.

the bottom of the control valve.
Figure 20-110-7
1 1
P-48306
Loosen and remove the two bolts and nuts (Item 1)

[Figure 20-110-7]
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REAR AUXILIARY DIVERTER VALVE (CONT'D)
Figure 20-110-9
IMPORTANT
damage the system.
I-2003-0888
Figure 20-110-11
1
1
P-48751
1
Figure 20-110-10

1 P-48755
Figure 20-110-12
2 2
P-48752 2
1
Clean the diverter valve to remove dirt before
disassembly. Valve ports are labeled for correct
assembly.
Several plugs (Item 1) [Figure 20-110-9] & [Figure 20-

110-10] are located all over the diverter valve and can be
removed for cleanout purposes. P-48756
Installation: Put oil on O-rings and back-up

washers.Tighten to 10 ft.-lb. (13,6 N•m) torque. Remove the shuttle valve (Item 1) [Figure 20-110-11] &
[Figure 20-110-12] from diverter valve and inspect the
O-rings and back-up washers (Item 2) [Figure 20-110-
12] for damage.
Installation: Put oil on the O-rings and back-up washers.

Tighten to 10 - 12 ft.-lb. (14 - 16 N•m) torque.
T180 Bobcat Loader

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Figure 20-110-13
P-48753
1
Figure 20-110-16
P-48755
Figure 20-110-14 1

2
2
2
1
P-48754
Remove the relief valve (Item 1) [Figure 20-110-15] &

P-48757 [Figure 20-110-16] from the diverter valve and inspect
the O-rings and back-up washers (Item 2) [Figure 20-
110-16] for damage.
Remove the differential sensing valve (Item 1) [Figure
20-110-13] & [Figure 20-110-14] from diverter valve and Installation: Put oil on O-ring and back-up washers.
inspect the O-rings and back-up washers (Item 2) Tighten to 20 - 25 ft.-lb. (27 - 34 N•m) torque.
[Figure 20-110-14] for damage.
Installation: Put oil on O-ring and back-up washers.

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Figure 20-110-17
1
P-48761
NOTE: Before removing the solenoid coils mark the

P-48759 coils for proper alignment.
Remove the nuts (Item 1) [Figure 20-110-19] from the

Figure 20-110-18 solenoid valve stems.

Installation: Tighten the nut to 4 - 6 ft.-lb. (5 - 8 N•m)
torque.
1
2
P-48760
NOTE: Before removing the solenoid coils mark the

coils for proper alignment.
Remove the nut (Item 1) [Figure 20-110-17] & [Figure

20-110-18] from the solenoid valve stem.
Installation: Tighten the nut to 4 - 6 ft.-lb. (5 - 8 N•m)

torque.
Remove the spacer (Item 2) and solenoid valve coils

(Item 3) [Figure 20-110-18].
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Figure 20-110-20 1
P-48763A
Figure 20-110-23
P-48762
Figure 20-110-21

1 2
2 2
1 1 P-48764
Remove the solenoid valve stem (Item 1) [Figure 20-

P-48763 110-22] & [Figure 20-110-23] and inspect the O-rings
and back-up washers (Item 2) [Figure 20-110-23] for
damage.
Remove the solenoid valve stem (Item 1) [Figure 20-
110-21] & [Figure 20-110-22] and inspect the O-rings Installation: Put oil on O-rings and back-up washers.
and back-up washers (Item 2) [Figure 20-110-22] for Tighten to 30 - 35 ft.-lb. (41 - 47 N•m) torque.
damage.
Installation: Put oil on O-rings and back-up washers.

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Figure 20-110-24
P-48765

P-48765
Installation: Tighten the plug to 10 ft.-lb. (13,6 N•m)
torque.
Figure 20-110-27

Installation: Tighten the plug to 38 ft.-lb. (51,5 N•m)
torque.
Figure 20-110-25
P-48786
1 Remove the orifice (Item 1) [Figure 20-110-24].

P-48766
Installation: Tighten the orifice to 3.3 ft.-lb. (4,5 N•m)
torque.
Remove and inspect the orifice (Item 1) [Figure 20-110-
25] for dirt and debris.
Installation: Tighten the orifice to 22 ft.-lb. (29,8 N•m)

torque.
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REAR AUXILIARY DIVERTER VALVE (CONT'D) Solenoid Testing
Disassembly And Assembly (Cont'd) Figure 20-110-29
Figure 20-110-28
P9137
P-48758
110-29]. Coil wires do not have polarity. Correct
Remove the plugs (Item 1) [Figure 20-110-28]. resistance is 8.6 - 9.5 ohm @ 68° F.

Installation: Tighten the plug to 14 ft.-lb. (19 N•m) Replace the test meter with 12 volt power. You can see
torque. and hear the spool shift.
Inspection
Inspect cartridges, check valves, solenoid valves and

sealing washers for contamination or damage. Wash all
parts in clean solvent. Use air pressure for drying them.
Install new O-rings and back-up washers.
Inspect diverter valve cavities for contamination. Wash

valve in clean solvent. Use air pressure to dry.
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T180 Bobcat Loader

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POWER BOB-TACH BLOCK Figure 20-120-1

3
WARNING
Never work on a machine with the lift arms up unless 1
2
W-2059-0598
3
P-48229
DANGER Lift and block the loader. (See Procedure on Page 10-10-
1.)
10-20-1.)

on Page 10-30-1.)
P-90328 Open the rear door.

AVOID DEATH
Remove the nut from the speed control linkage (Item 1)
and unplug the rear lights electrical connector (Item 2)
[Figure 20-120-1].
D-1009-0409
Remove the fuel fill bracket mounting bolts (Item 3)
[Figure 20-120-1].
IMPORTANT
damage the system.
I-2003-0888
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POWER BOB-TACH BLOCK (CONT'D) Figure 20-120-4
Figure 20-120-2
P-48227

P-48230 4].

Installation: The harness connectors are marked with (34 - 38 N•m) torque.
Red or Black tie straps. Be sure the connectors with the

same color are connected. Remove the power Bob-Tach block.
Disconnect the power Bob-Tach harness from the NOTE: There is an O-ring in-between the power Bob-
solenoid connectors (Item 1) [Figure 20-120-2] by the Tach block and the hydraulic pump. Inspect
hydraulic pump. and replace as needed.
Figure 20-120-3
P-48226

“DR” port fitting on the block.

power Bob-Tach cylinder rod end fitting on the block.

power Bob-Tach cylinder base end fitting on the block.
Disconnect the outlet hose (Item 4) [Figure 20-120-3]

from the fitting on top of the block.
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Figure 20-120-5
1 3
2
2
1
P-48120
Remove the spring guide (Item 1), spring (Item 2) and the
P-48115 spool (Item 3) [Figure 20-120-6].
Check the O-ring (Item 4) [Figure 20-120-6] on the plug

Clean the block (Item 1) [Figure 20-120-5] to remove dirt and replace as needed.
before disassembly. Block ports are labeled for correct

assembly. Figure 20-120-7
Installation: Tighten the plug to 25 - 30 ft.-lb. (34 - 40,6

N•m) torque.
IMPORTANT 1

tubelines and ports to keep dirt out. Dirt can quickly P-48116
damage the system.

I-2003-0888
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-120-7].
Installation: Tighten the plug to 12 - 14 ft.-lb. (16,3 - 19

N•m) torque.
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Figure 20-120-8
1
1
P-48122
Do not remove the plugs (Item 1) [Figure 20-120-10].

P-48382
NOTE: Do not remove plugs. If the plugs are removed
the internal pressure relieving spring setting
Remove the check valve (Item 1) [Figure 20-120-8]. will be altered.

Installation: Oil the check valve and O-rings and tighten Figure 20-120-11
the check valve to 20 - 25 ft.-lb. (27,1 - 34 N•m) torque.
Figure 20-120-9
1
2
1
P-48384
3
P-48119 Remove the plug (Item 1) [Figure 20-120-11], inspect

the O-ring and replace as needed.
Inspect the check valve (Item 1) and piston assembly Installation: Tighten the plug (Item 1) [Figure 20-120-
(Item 2) [Figure 20-120-9]. 11] to 12 - 14 ft.-lb. (16,3 - 19 N•m) torque.
Check the O-rings and back up washers (Item 3) [Figure

20-120-9] on the check valve and piston assembly and
replace as needed.
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Figure 20-120-12 3
2
1
P-48106
Remove the first solenoid coil (Item 1), spacer (Item 2)

P-48664 and the second solenoid coil (Item 3) [Figure 20-120-
14].
Remove the orifice screw (Item 2) located behind the NOTE: Remember the solenoid coil orientation for
plug (Item 1) [Figure 20-120-12]. ease of installation.

Installation: Tighten the orifice screw (Item 2) [Figure Figure 20-120-15
20-120-12] to 6 - 8 ft.-lb. (8,1 - 10,8 N•m) torque.
Figure 20-120-13
1 1
P-48386
P-48127 Remove the solenoid stem (Item 1) [Figure 20-120-15].
Installation: Tighten the solenoid stem to 20 - 25 ft.-lb.

NOTE: This plug is a zero leak plug and should not be (27,1 - 34 N•m) torque.
removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-120-13].
Remove the solenoid nut (Item 2) [Figure 20-120-13].
Installation: Tighten the solenoid valve stem nut to 15 -

45 in.-lb. (1,7 - 5,1 N•m) torque.
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Figure 20-120-16
1
P-48174
1
Remove the screened orifice plug (Item 1) [Figure 20-

P-48175 120-18].
Installation: Tighten the screened orifice plug to 11 - 12

Remove the armature rod assembly (Item 1) [Figure 20- ft.-lb. (14,9 - 16,3 N•m) torque.
120-16].

Figure 20-120-19
Figure 20-120-17
2 2
1 1
P-48138
P-48173
Inspect the screened orifice plug (Item 1) [Figure 20-

Inspect the solenoid stem (Item 1), armature assembly 120-19] for damage replace as needed. If the screened
(Item 2) and the spool (Item 3) for damage [Figure 20- orifice plug is blocked replace with a new plug.
120-17].
Check the O-ring (Item 2) [Figure 20-120-19] and
NOTE: If the solenoid stem is damaged (Item 1) check replace as needed.
the armature assembly (Item 2) for damage.
The armature assembly (Item 2) and spool

(Item 3) are non-serviceable parts. If they are
damaged, order a new power Bob-Tach block
assembly from Bobcat parts [Figure 20-120-
17].
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FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly
Removal and Installation Figure 20-130-2
1
IMPORTANT
clean the work area before disassembly and keep all 2
parts clean. Always use caps and plugs on hoses, 4
damage the system. 3
I-2003-0888
Figure 20-130-1
P-34661
Figure 20-130-3
2

1
3
6 2
4
5 3
P-48464
Disconnect the auxiliary tubelines (Item 1) and drain

P-34760
tubeline (Item 2) from the coupler block [Figure 20-130-
1].
Remove the male coupler (Item 1) [Figure 20-130-2] &
Remove the two mounting bolts (Item 3) [Figure 20-130- [Figure 20-130-3].
1].
Installation: Tighten the male coupler (Item 1) [Figure
20-130-2] & [Figure 20-130-3] to 59 ft.-lb. (80 N•m)
Remove the drain coupler (Item 2) [Figure 20-130-2] &

[Figure 20-130-3].
Installation: Tighten the drain coupler (Item 2) [Figure

20-130-2] & [Figure 20-130-3] to 37 ft.-lb. (50 N•m)
Remove the female coupler (Item 3) [Figure 20-130-2] &

[Figure 20-130-3].
Installation: Tighten the female coupler (Item 3) [Figure

20-130-2] & [Figure 20-130-3] to 59 ft.-lb. (80 N•m)
Remove the fittings (Item 4) [Figure 20-130-2] & [Figure

20-130-3] check the O-rings (Item 5) [Figure 20-130-3]
and replace as needed.
Remove the springs (Item 6) [Figure 20-130-3].
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FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-130-6
(CONT’D)
Disassembly And Assembly (Cont’d)

1
Figure 20-130-4
1
2
P-34665
Check the O-rings (Item 1) backup O-rings (Item 2) for

damage and replace as needed [Figure 20-130-6].
P-34663
Figure 20-130-7
Check the O-ring (Item 1) [Figure 20-130-4] for damage
and replace as needed.

1
Figure 20-130-5
P-34664
Check the O-rings (Item 1) backup O-rings (Item 2) for

damage and replace as needed [Figure 20-130-7].
P-34701
Press center of male couplers down and check the O-ring

(Item 1) [Figure 20-130-5] for damage and replace as
needed.
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HYDROSTATIC SYSTEM
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Adjusting (Non SJC Machines) . . . . . . . . . . . . . . . . . . . . . 30-30-2
Adjusting (SJC Machines) . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-4 HYDROSTATIC
Sender Removal And Installation (Non SJC Machines) . . 30-30-1 SYSTEM
Sender Removal And Installation (SJC Machines) . . . . . . 30-30-3
Testing (Non SJC Machines) . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Testing (SJC Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-3
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-3 DRIVE
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . 30-50-1 SYSTEM
Tensioner Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . 30-50-7
Tensioner Pulley Disassembly . . . . . . . . . . . . . . . . . . . . . . 30-50-6
Tensioner Pulley Parts Identification . . . . . . . . . . . . . . . . . 30-50-5
Tensioner Pulley Removal And Installation . . . . . . . . . . . . 30-50-4
HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-15

ELECTRICAL
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-6 SYSTEM &
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-14 ANALYSIS
Replacing the Motor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 ENGINE
SERVICE
HYDROSTATIC MOTOR (SJC). . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . 30-21-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-2 SPECIFICATIONS
Replacing the Motor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-15
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-9
Hydraulic Pump Removal And Installation. . . . . . . . . . . . . 30-40-8
Parts Identification (Left Half). . . . . . . . . . . . . . . . . . . . . . . 30-40-6
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . 30-40-4
Pump Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-8
Replenishing/High Pressure Relief Valve . . . . . . . . . . . . . 30-40-1
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HYDROSTATIC SYSTEM (CONT’D)
HYDROSTATIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1

Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . 30-41-9
High Pressure Relief and Bypass Valve. . . . . . . . . . . . . . . 30-41-7
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . 30-41-25
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . 30-41-28
Hydraulic Controller Removal And Installation. . . . . . . . . . 30-41-2
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . 30-10-1

Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1



ITEMS MAY VARY.
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HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart WARNING

The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4
The loader does not move in a straight line. 2, 3, 4, 5
The hydrostatic system is overheating. 6,7,8
KEY TO CORRECT THE CAUSE

1. The hydrostatic pump replenishing valves not seating.
2. The steering linkage needs adjustment.

3. The hydrostatic pump has damage.
4. The hydrostatic motor has damage.
5. Track tension is to tight, on one side.
6. The hydrostatic fluid is not at the correct level.
7. The oil cooler has a restriction.
8. The loader is not being operated at the correct RPM.
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HYDROSTATIC SYSTEM INFORMATION (CONT’D)
Replenishing Valve Function
Figure 30-10-1
CHARGE OIL
Valve Moves for Charge

FUNCTION 1 Oil Replacement

Valve Stays on Seat to
Hold High Pressure for Drive
FUNCTION 2
B-2804
The functions of the replenishing valves are:
1. To give replacement fluid to the low pressure side of

the hydrostatic circuit. Replacement fluid is needed
because of normal internal leakage and the controlled
flow to the oil cooler for cooling; Function 1 [Figure
30-10-1].
2. To keep high pressure fluid out of the low pressure

side of the hydrostatic circuitry; Function 2 [Figure
30-10-1].
(See HYDROSTATIC SYSTEM INFORMATION on Page

30-10-1.) for valve location and repair information.)
IMPORTANT
damage the system.
I-2003-0888
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HYDROSTATIC MOTOR Figure 30-20-1
Replacing the Motor Oil
DANGER 1 1
1
A
D F
1
1
B C
1
E
P-28206
P-90328
AVOID DEATH Loosen the six mounting bolts (Item 1) [Figure 30-20-1]
• Disconnecting or loosening any hydraulic and remove the drive sprocket from the motor.
can cause lift arms to drop. Installation: Tighten the mount bolts to 300 - 330 ft.-lb.
• Keep out of this area when lift arms are raised (410 - 450 N•m) torque. Use a cross pattern sequence
unless supported by an approved lift arm (A-B-C, D-E-F) [Figure 30-20-1] to tighten bolts.

D-1009-0409 Figure 30-20-2
WARNING 1

W-2059-0598

1.) 1 P-28207
Raise the lift arms and install an approved lift arm support Remove the plug (Item 1) [Figure 30-20-2] from the
device. (See Installing Lift Arm Support Device on Page bottom of the motor and drain the oil.
10-20-1.)
Remove the track. (See Track Removal And Installation

on Page 40-20-4.)
NOTE: Hydrostatic motor oil should be changed with

any track removal.
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HYDROSTATIC MOTOR (CONT’D)
Replacing the Motor Oil (Cont’d) WARNING

Figure 30-20-3
1 1 W-2059-0598
Figure 30-20-4
1 1
P-28207
1
A
Install the bottom plug into the motor. D F
1
1

Remove the top plug (Item 1) [Figure 30-20-3] from the
B C
motor.
1
E
Fill the motor with 1.5 oz. (45 ml) of high performance
P-28206
synthetic oil, Bobcat p/n 6682546. The motor will be
approximately 1/2 to 2/3 full.
1.)
DANGER 10-20-1.)
on Page 40-20-4.)
Loosen the six mounting bolts (Item 1) [Figure 30-20-4]

and remove the drive sprocket from the motor.
Installation: Tighten the mount bolts to 300 - 330 ft.-lb.
(410 - 450 N•m) torque. Use a cross pattern sequence
(A-B-C, D-E-F) [Figure 30-20-4] to tighten bolts.
P-90328
AVOID DEATH
D-1009-0409
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HYDROSTATIC MOTOR (CONT'D) Figure 30-20-7
Figure 30-20-5
1 1
P-28209
Mark and remove the brake power assist hose (Item 1)

P-28207 [Figure 30-20-7].
Cap and plug all hydraulic lines and hoses.

Remove the three mounting bolts (Item 1) [Figure 30-20-
5] from the access cover and remove the cover from the Figure 30-20-8

loader.
Figure 30-20-6
3 1 1
1
P-28210
1
P-28208 With an arm hoist support the hydraulic motor.
Remove the eight hydraulic motor mounting bolts (Item

Mark and remove the main drive hoses (Item 1) [Figure 1) [Figure 30-20-8].
30-20-6] from the motor.
Installation: Tighten the motor mounting bolts to 175 -
Mark and remove the brake release hose (Item 2) 190 ft.-lb. (240 - 260 N•m) torque. Apply thread locker
[Figure 30-20-6] from the motor. equivalent to (Loctite® 242).
Mark and remove the case drain hose (Item 3) [Figure Remove the hydrostatic motor from the loader.
30-20-6].
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HYDROSTATIC MOTOR (CONT'D)
10
9
7 8
57
5
6
56
4
3
2
1
16
15
57
10 14

13
11
12 41 46
40 45 43
44
43
24
25
35 42
29 28
26
27 39
36 37 38
OR
18 34 58
17
33
54
32 53
19 31 52
51
30 50 55
23
49
22 48
21 47
20
B-16112C
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Parts Identification (Cont’d)
Ref. Description Ref. Description

1. Shaft 29. Spring
2. Bushing 30. Case, rear
3. Seal 31. Bolt
4. Bearing 32. Bolt
5. Case, front 33. Quad Ring
6. Seal 34. Washer
7. Bearing 35. Housing
8. Washer 36. Roll Pin (Earlier Models)*
9. Rings 37. Roll Pin (Earlier Models)*
10. Quad Ring 38. O-ring
11. Cam 39. Plug
12. Rotor 40. Washer
13. Piston 41. Bolt
14. Spring 42. Shaft
15. Seal 43. Disc
16. Seal 44. Shim
17. Seal 45. Shim
18. Seal 46. Disc

19. Pin 47. Bushing
20. Plug 48. Seal
21. O-ring 49. Snap Ring
22. Spring 50. Piston
23. Poppet 51. O-Ring
24. Plug 52. Washer
25. O-ring 53. O-ring
26. Spring 54. Cover
27. Washer 55. Bolt
28. Spool 56. O-ring
57. Plug
58. Machined Pin (Later Models)*
* Earlier model hydrostatic motors used a double roll alignment pin, later models use a machined
1 piece alignment pin.
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HYDROSTATIC MOTOR (CONT’D) Figure 30-20-11
Disassembly
Figure 30-20-9
P-28349
Check the O-ring (Item 1) [Figure 30-20-11] on the brake

P-28347 cover plate and replace.
Figure 30-20-12
NOTE: Mark the motor, brake and motor carrier
housings for proper alignment for ease of

assembly [Figure 30-20-9]. 1
Drain the oil from the motor casing.
Check for vendor motor serial numbers at (Item 1)

[Figure 30-20-9], these serial numbers will be needed
when ordering replacement parts.
Figure 30-20-10
1 P-28350
Remove the disc spring (Item 1) [Figure 30-20-12] from

the brake housing.
NOTE: Mark the top side of the disk spring for proper
installation.
NOTE: Remove any grease on or around the disc

spring. The disc spring does not need to be
P-28348 greased.
Remove the twenty four mounting bolts (Item 1) [Figure

30-20-10] from the brake cover plate.
NOTE: Unscrew the bolts alternately, one turn at a

time to release the preload on the end cap.
Remove the cover plate and O-ring from the brake

housing.
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Disassembly (Cont'd) 1
Figure 30-20-13
P-28357A
1
1
2
1 P-28356
Alignment pins (Item 1) [Figure 30-20-15] aid in

P-28351 alignment of the brake housing to the rear housing.
Remove the brake housing (Item 2) [Figure 30-20-15]

Remove the piston from the brake housing [Figure 30- from the rear housing.
20-13].

Figure 30-20-16
NOTE: The use of air pressure through the brake line
connection (Item 1) [Figure 30-20-13] will aid
in piston removal.
Figure 30-20-14 1
2
2
1
P-28354
2 P-28564
Remove snap ring (Item 1) [Figure 30-20-16].

1
P-28353 Remove piston seal (Item 2) [Figure 30-20-16].
Remove the six mounting bolts (Item 1) [Figure 30-20-

14] from the brake housing.
The two plugs (Item 2) [Figure 30-20-14] cover the

alignment pins which aid in alignment of the motor parts.
If plugs are removed check and replace O-rings.
Note: Alignment pins were a double roll pin design

in earlier loaders. Later, the alignment pins
were changed to a solid machined pin.
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Disassembly (Cont'd)
1
Figure 30-20-17 2
P-28408
Remove the brake shaft (Item 1) [Figure 30-20-19] from

P-28405 the rear housing.
Check alignment pins (Item 2) [Figure 30-20-19] for

Remove the brake disks (Item 1) [Figure 30-20-17] and damage. See assembly for replacement.
shims from the brake shaft.

Figure 30-20-20
Figure 30-20-18
1
1
2
2
P-28412 P-28411
P-28406
Remove the flushing valve plug (Item 1) [Figure 30-20-

Remove the brake washer (Item 1) [Figure 30-20-18]. 20] from the rear housing assembly.
Remove O-ring (Item 2) [Figure 30-20-18] and replace. Check O-ring (Item 2) [Figure 30-20-20] and replace.
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Figure 30-20-21 2
3 4
1 2 3
4
P-28436

P-28414 30-20-23].
Inspect all parts and replace as needed.

Remove spring (Item 1), washer (Item 2), spool (Item 3)
and rear spring (Item 4) [Figure 30-20-21]. Figure 30-20-24

Inspect all parts and replace as needed. 1 1
Figure 30-20-22
2
1
2
2
P-28434
1 1
1 1
P-28410
1
Remove the ten mounting bolts (Item 1) [Figure 30-20-

P-28433 24] from the rear housing.
NOTE: Bolts (Item 2) [Figure 30-20-24] must be

Remove rear housing mount bolts (Item 1) [Figure 30- returned to original holes.
20-22].
NOTE: Bolts (Item 1) [Figure 30-20-22] are shorter

than the other ten rear housing mount bolts.
Remove the flushing relief valve plug (Item 2) [Figure 30-

20-22] & [Figure 30-20-23] and replace O-ring.
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1
Figure 30-20-25
P-28489
Remove and replace the two seals and back-up O-rings

P-28437 (Item 1) [Figure 30-20-27] under the seals, from the
distributor.
Remove the O-ring (Item 1) [Figure 30-20-25] and Figure 30-20-28

replace.

Remove the distributor (Item 2) [Figure 30-20-25] from 1
the rear housing.
Figure 30-20-26
1
2
P-28488
1
Remove the nine springs (Item 1) [Figure 30-20-28] from

the distributor.
P-28487
Remove the two seals and back-up O-rings (Item 1)

[Figure 30-20-26] under the seals, from the rear
housing.
Remove the alignment pin (Item 2) [Figure 30-20-26].
T180 Bobcat Loader

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Figure 30-20-29
1
P-28439
Figure 30-20-32
P-28438
Remove the cam ring (Item 1) [Figure 30-20-29] from the

front housing assembly.

Figure 30-20-30
2
P-28440
1 Remove the snap ring (Item 1) [Figure 30-20-31] &

[Figure 30-20-32] from the rotating group.
Remove the retainer ring (Item 2) [Figure 30-20-31] &

P-28442 [Figure 30-20-32] from the rotating group.
Remove the O-ring (Item 1) [Figure 30-20-30] from the

front housing assembly and replace.
Remove the rotating group (Item 2) [Figure 30-20-30]

from the front housing assembly.
T180 Bobcat Loader

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Figure 30-20-33
1
P-28444
Remove the washer (Item 1) [Figure 30-20-35] from

P-28441 under the split ring.
Figure 30-20-36
Use low air pressure to remove the roller/piston
assembly (Item 1) [Figure 30-20-33] from the cylinder
2

block.
NOTE: Put all roller/piston assembles back in the

original bore.
NOTE: The roller/piston assembly (Item 1) [Figure 30- 1

20-33] is not a serviceable part.
Figure 30-20-34
P-28445
1 Install the bearing puller (Item 1) [Figure 30-20-36]

under the front housing and support the puller and
housing with blocks.
Press the shaft (Item 2) [Figure 30-20-36] from the

housing.
P-28443
With a hammer and punch remove the split ring (Item 1)

[Figure 30-20-34].
T180 Bobcat Loader

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Figure 30-20-37 1
2 2
3
P-28450
4
Remove the shaft seal (Item 1) [Figure 30-20-39].
P-48471
Remove the bearing cup (Item 2) [Figure 30-20-39] if it
needs replacement.
Use a bearing puller to remove the bearing from the shaft
[Figure 30-20-37].

NOTE: The bearing will be destroyed during the
removal procedure. Be sure to have a new
bearing on hand before removing the old
bearing.
Replace the O-ring (Item 1), bearing (Item 2), face seal
(Item 3) and the bushing (Item 4) [Figure 30-20-37].
Figure 30-20-38
P-28448
Remove and inspect the bearing (Item 1) [Figure 30-20-

38].
Replace the bearing if worn or damaged.
T180 Bobcat Loader

359 of 961
Figure 30-20-40
2
1
P-28493
Check the piston surface (Item 1) and the bushing

P-28451 surface (Item 2) [Figure 30-20-42] in the brake shaft.
NOTE: The bushing (Item 2) [Figure 30-20-42] can be

Remove bearing cup (Item 1) [Figure 30-20-40] and replaced in the brake shaft. When bushing is
replace. replaced, install flush with the top of the brake

shaft.
Inspection
Figure 30-20-43
Figure 30-20-41
2
P-28489
N-18298
Check the distributor surfaces for scratches [Figure 30-

Clean all parts in clean solvent and use air pressure to 20-43].
dry them. Do Not use cloth or paper because small
pieces of material can get into the system and cause
damage.
Before the motor is assembled, check the following

items:
Check the brake piston (Item 1) and seal (Item 2) and

replace[Figure 30-20-41].
T180 Bobcat Loader

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HYDROSTATIC MOTOR (CONT'D) Assembly
Inspection (Cont'd) Figure 30-20-46
Figure 30-20-44
P-28441
P-28492
NOTE: Always use new O-rings and seals when
assembling the motor and brake assemblies.
Check the cam ring inside surface for wear and scratches
[Figure 30-20-44]. Dip the roller/piston assembly (Item 1) [Figure 30-20-46]

in oil and replace back its original bore.
Figure 30-20-45
Repeat procedure for each roller/piston assembly.
NOTE: The roller/piston assembly (Item 1) [Figure 30-

Figure 30-20-47
1
3
2
1
N-18335
Check all rollers (Item 1) [Figure 30-20-45], pistons (Item

2) [Figure 30-20-45] and piston rings (Item 3) [Figure
30-20-45] for wear and replace as needed. 2
P-28439
NOTE: Put all roller/piston assembly back in their
original position.
Install the retainer ring (Item 1) [Figure 30-20-47] and
NOTE: The roller/piston assembly is not a snap ring (Item 2) [Figure 30-20-47] on the cylinder
serviceable part. block (both sides).
NOTE: The roller/piston assembly is not a

serviceable part.
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Assembly (Cont'd)
Figure 30-20-48 2
1
2
4
1
4
3
P-28451
Replace the shaft seal (Item 1) [Figure 30-20-50] and fill

P-48471 lips of seal with Bobcat multipurpose grease.
Replace the bearing cup (Item 2) [Figure 30-20-50].

Install the bushing (Item 1), face seal (Item 2), the new
bearing (Item 3) and on to the shaft (Item 4) [Figure 30- Install a new O-ring (Item 4) [Figure 30-20-48] & [Figure

20-48]. 30-20-50].
Figure 30-20-49
P-28450
Replace the bearing cup (Item 1) [Figure 30-20-49] as

needed.
T180 Bobcat Loader

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Assembly (Cont'd)
Figure 30-20-51 1
P-28444
Release the pressure from the bearing. Remove the tool

P-28448 from the bearing.
Install a new bearing (Item 1) [Figure 30-20-51] into the Add one pre-load washer (Item 1) [Figure 30-20-53] that
front housing. is closest to the measurement between the bearing race
and split ring with the additional 0.002 - 0.004 in. (0.05 -

Figure 30-20-52 0.1 mm).
Figure 30-20-54
2
P-30728
Place the shaft on a hydraulic press table. P-30730
Install the front housing (Item 1) [Figure 30-20-52] and

bearing over the shaft. Install the special tool (MEL 1612) Install the tool and press the bearing to 4400 lb. of
(Item 2) [Figure 30-20-52] over the bearing and press pressure.
the bearing onto the shaft. Apply 4400 lb. of pressure to
set the bearing. Rotate the housing to check for free Install the split rings (Item 1) [Figure 30-20-54].
travel.
NOTE: The 4400 lb. of force, is NOT the amount of

pressure required by the press. It is the amount of
downward force applied by the press.
Install the split ring (Item 3) [Figure 30-20-52] and

measure the distance between the split ring and the top
of the bearing inner race with a feeler gauge. Add 0.002 -
0.004 in. (0.05 - 0.1 mm) to get the correct washer
thickness for the preload.
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Assembly (Cont'd)
Figure 30-20-55
P-28438
1
Install the cam ring (Item 1) [Figure 30-20-57] on the
P-28443 front housing.
Align the marks (Item 2) [Figure 30-20-57] on the cam

Remove from press. ring to the front housing.

Install a new O-ring on the front housing assembly (Item Figure 30-20-58
1) [Figure 30-20-55] and lightly smear with grease.
Figure 30-20-56
P-28488
P-28442 Using a small amount of grease, install the nine springs

into the distributor valve [Figure 30-20-58].
Install the rotating group on the front housing [Figure 30-

20-56].
T180 Bobcat Loader

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Assembly (Cont'd)
Figure 30-20-59
P-28491
Install the distributor into the rear housing.

P-28489
Align the pin (Item 1) with the hole in the distributor (Item
2) [Figure 30-20-61].
Install new O-rings and new seals (Item 1) [Figure 30-
20-59] on the distributor. When the distributor is aligned correctly, The distributor

can be depressed slightly.
Lightly smear oil over seals and O-rings.
Figure 30-20-62
Figure 30-20-60
1
1
P-28486
P-28487
Install a new O-ring (Item 1) [Figure 30-20-62] on the

Install new O-rings and new seals (Item 1) [Figure 30- rear housing and lightly smear with oil.
20-60] on the rear housing.
Install alignment pin into the rear housing (Item 2)

[Figure 30-20-60].
Lightly smear oil over seals and O-rings.
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Assembly (Cont'd) 1 1
Figure 30-20-63
2
1
2
1
1 1
1 1
3 4 P-28410
Use Loctite® #243 on the bolt threads and install the ten
P-28411 P-28539 mounting bolts (Item 1) [Figure 30-20-64].
Tighten the bolts to 111 - 114 ft.-lb. (150 - 155 N•m)

Install the rear housing (Item 1) [Figure 30-20-63] on the torque.
cam ring/front housing assembly.

Use Loctite® #243 on the bolt threads and install the two
Align the marks. mounting bolts (Item 2) [Figure 30-20-64]. Tighten the
bolts to 111 - 114 ft.-lb. (150 - 155 N•m) torque.
Note: Alignment pins were a double roll pin design
in earlier loaders. Later, the alignment pins
were changed to a solid machined pin.
When installing roll pins (Item 2), install large outer roll
pin (Item 3) with split face pointed outwards away from
brake shaft. Install small inner roll pin (Item 4) [Figure
30-20-63] with split face pointed toward brake shaft hole.
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Assembly (Cont'd)
Figure 30-20-65 1
1
3 2
3
P-28406
Install the brake shaft (Item 1) [Figure 30-20-67] through

N-18348 the rear housing into the cylinder block.
NOTE: Be sure shaft seats fully into the cylinder

Assemble the brake discs into a pack making sure the block.
inner discs, alternate with the outer disc and an outer

disc is placed at each end of the disc pack (Item 1) Install brake washer (Item 2) [Figure 30-20-67] on rear
[Figure 30-20-65]. housing.
Figure 30-20-66 Install a new O-ring on the rear housing (Item 3) [Figure
30-20-67] and lightly coat with oil.
1
P-28407
P-28464
Clamp the disc pack in a vice and check the disc pack
height, make sure to include brake washer (Item 1)
[Figure 30-20-66].
The correct disc pack specifications is 1.44 ± 0.002 in.

(36,50 ± 0,05 mm).
Extra outer discs (Item 2) are used to reduce the number

of required shims (Item 3) to make up the required
thickness for the brake pack [Figure 30-20-65].
T180 Bobcat Loader

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Assembly (Cont'd)
Figure 30-20-68
2 1
2
3
3
2 2
P-28519
Install the needed amount of outer discs (Item 1) [Figure

P-28518 30-20-70] to act as shims.
Figure 30-20-71
Align the reference marks. Install the brake housing on
the rear housing assembly.

Install new washers (Item 1) in the brake housing mount
bolts (Item 2) [Figure 30-20-68].
Apply Loctite® #243 to bolts and install bolts and

washers into the rear case. Start each bolt by hand,
tighten opposite bolts to maintain squareness.
Tighten bolts to 52 - 57 ft.-lb. (70 - 77 N•m) torque.
Install plugs (Item 3) [Figure 30-20-68] and tighten to 18 1

- 22 ft.-lb. (25 - 30 N•m) torque.
P-28521
Figure 30-20-69
Install the disc pack (Item 1) [Figure 30-20-71] starting

with an outer and alternating every other disc with an
inner disc.
P-28520
Install the needed amount of shims (Item 1) [Figure 30-

20-69].
T180 Bobcat Loader

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Assembly (Cont'd)
Figure 30-20-72 1
2
2
1 P-28350
Put a slight amount of oil on the piston seal.

P-28565
Install the piston (Item 1) [Figure 30-20-74] in the brake
housing.
Install a new piston inner seal (Item 1) [Figure 30-20-72].
Install disc spring (Item 2) on the top of the piston. Disc

NOTE: Install seal with metal case end towards the spring will fit flush with piston center shoulder (Item 3)
brake pack. [Figure 30-20-74].
Install snap ring (Item 2) [Figure 30-20-72]. Figure 30-20-75
Figure 30-20-73
1
1
P-28349
N-18298
Replace O-ring on cover (Item 1) [Figure 30-20-75] and
slightly coat with oil.
Install a new piston seal (Item 1) [Figure 30-20-73] on
the piston.
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Assembly (Cont'd)
Figure 30-20-76
P-28348
Align the marks on the end cover and install on the brake

Install the twenty four socket head bolts (Item 2) [Figure
30-20-76] into the end cover and finger tighten only.
NOTE: Tighten the bolts alternately one turn at a time

until the end cover is fully seated.
Tighten the bolts to 26 - 29 ft.-lb. (35 - 39 N•m) torque.
T180 Bobcat Loader

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HYDROSTATIC MOTOR (SJC) Figure 30-21-1
Replacing the Motor Oil
DANGER 1 1
1
A
D F
1
1
B C
1
E
P-28206
P-90328
AVOID DEATH Loosen the six mounting bolts (Item 1) [Figure 30-21-1]
• Disconnecting or loosening any hydraulic and remove the drive sprocket from the motor.
can cause lift arms to drop. Installation: Tighten the mount bolts to 300 - 330 ft.-lb.
• Keep out of this area when lift arms are raised (410 - 450 N•m) torque. Use a cross pattern sequence
unless supported by an approved lift arm (A-B-C, D-E-F) [Figure 30-21-1] to tighten bolts.

Figure 30-21-2
D-1009-0409
WARNING 1

W-2059-0598
Lift and block the loader. (See Procedure on Page 10-10- 1 P-28207
1.)
Raise the lift arms and install an approved lift arm support Remove the plug (Item 1) [Figure 30-21-2] from the
device. (See Installing Lift Arm Support Device on Page bottom of the motor and drain the oil.
10-20-1.)

on Page 40-20-4.)
NOTE: Hydrostatic motor oil should be changed with

any track removal.
T180 Bobcat Loader

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HYDROSTATIC MOTOR (SJC) (CONT’D)
Replacing the Motor Oil (Cont’d) WARNING

Figure 30-21-3
1 1 W-2059-0598
Figure 30-21-4
1 1
P-28207 1
A
D F
Install the bottom plug into the motor. 1
1

Remove the top plug (Item 1) [Figure 30-21-3] from the B C
motor. 1
E
Fill the motor with high performance synthetic oil p/n P-28206
6682546.
Removal And Installation 1.)
DANGER 10-20-1.)
on Page 10-30-1.)
on Page 40-20-4.)
Loosen the six mounting bolts (Item 1) [Figure 30-21-4]
and remove the drive sprocket from the motor.
Installation: Tighten the mount bolts to 300 - 330 ft.-lb.
(410 - 450 N•m) torque. Use a cross pattern sequence
P-90328 (A-B-C, D-E-F) [Figure 30-21-4] to tighten bolts.
AVOID DEATH
D-1009-0409
T180 Bobcat Loader

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HYDROSTATIC MOTOR (SJC) (CONT'D) Mark and remove the case drain hose (Item 3) [Figure
30-21-6].
Figure 30-21-5
Figure 30-21-7
1 1
P-28207
P-28209
Remove the three mounting bolts (Item 1) [Figure 30-21-

5] from the access cover and remove the cover from the Mark and remove the brake power assist hose (Item 1)

loader. [Figure 30-21-7].
Remove speed sensor. Removal and Installation60-170- Cap and plug all hydraulic lines and hoses.
3
Figure 30-21-8
NOTE: Speed sensor removal is recommended too
prevent damage while removing the
hydrostatic motor from the track carriage.
Figure 30-21-6
2
1
3 1
1
P-28210
1 With an arm hoist support the hydraulic motor.
P-28208 Remove the eight hydraulic motor mounting bolts (Item

1) [Figure 30-21-8].
Mark and remove the main drive hoses (Item 1) [Figure Installation: Tighten the motor mounting bolts to 175 -
30-21-6] from the motor. 190 ft.-lb. (240 - 260 N•m) torque. Apply thread locker
equivalent to (Loctite® 242).
Mark and remove the brake release hose (Item 2)
[Figure 30-21-6] from the motor. Remove the hydrostatic motor from the loader.
T180 Bobcat Loader

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HYDROSTATIC MOTOR (SJC) (CONT'D)
10
9
7 8
54
5
6
53
4
3
2
1
16
15
54
10 14

13
11
12 38 43
37 42 40
41
40
24 36
25
35 39
29 28
26
27
18 34
17
33
36 51
32 50
19 31 49
48
30 47 52
23
46
22 45
21 44
20
B-16112D
T180 Bobcat Loader

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HYDROSTATIC MOTOR (SJC) (CONT'D)
Parts Identification (Cont’d)

1. Shaft 29. Spring
2. Bushing 30. Case, rear
3. Seal 31. Bolt
4. Bearing 32. Bolt
5. Case, front 33. Quad Ring
6. Seal 34. Washer
7. Bearing 35. Housing
8. Washer 36. Pin
9. Rings 37. Washer
10. Quad Ring 38. Bolt
11. Cam 39. Shaft
12. Rotor 40. Disc
13. Piston 41. Shim
14. Spring 42. Shim
15. Seal 43. Disc
16. Seal 44. Bushing
17. Seal 45. Seal
18. Seal 46. Snap Ring

19. Pin 47. Piston
20. Plug 48. O-Ring
21. O-ring 49. Washer
22. Spring 50. O-ring
23. Poppet 51. Cover
24. Plug 52. Bolt
26. Spring 54. Plug
27. Washer
28. Spool
T180 Bobcat Loader

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HYDROSTATIC MOTOR (SJC) (CONT’D) Figure 30-21-10
Disassembly and Assembly
Figure 30-21-9
1
P-28348
Remove the twenty four mounting bolts (Item 1) and

P-28347 cover plate (Item 2) [Figure 30-21-10].
NOTE: The bolts should be removed and/or

NOTE: Mark the motor, brake and motor carrier tightened, one turn at a time to maintain equal
housings for proper alignment for ease of preload on the end cap.

assembly [Figure 30-21-9].
Assembly: Replace the O-ring on the end cap and
Drain the oil from the motor casing. slightly coat with oil.
Check for vendor motor serial numbers at (Item 1) Assembly: Tighten the bolts to 26 - 29 ft.-lb. (35 - 39
[Figure 30-21-9], these serial numbers will be needed N•m) torque.
when ordering replacement parts.
Figure 30-21-11
P-28350
Remove the disc spring (Item 1) [Figure 30-21-11] from

the brake housing.
NOTE: Mark the top side of the disk spring for proper
installation.
NOTE: Remove any grease on or around the disc

spring. The disc spring does not need to be
greased.
T180 Bobcat Loader

376 of 961
HYDROSTATIC MOTOR (SJC) (CONT'D) Figure 30-21-14
Disassembly and Assembly (Cont'd)

1
Figure 30-21-12
2 3
1
1 P-64411
Remove the six mounting bolts (Item 1) [Figure 30-21-

P-28351 14] from the brake housing.
Remove the brake housing (Item 2) [Figure 30-21-14]

Remove the piston from the brake housing [Figure 30- from the rear housing.
21-12].

Remove snap ring (Item 3) [Figure 30-21-14].
NOTE: The use of air pressure through the brake line
connection (Item 1) [Figure 30-21-12] will aid Remove inner piston seal (Item 4) [Figure 30-21-14].
in piston removal.
NOTE: Install seal with metal case end towards the
Figure 30-21-13 brake pack.
Assembly: Use the alignment pins and reference marks

1 to install the brake housing on the rear housing.
Assembly: Install new washers on the brake housing

mount bolts (Item 1) [Figure 30-21-14].
Assembly: Apply Loctite® #243 or equivalent

threadlocker to the bolts and install bolts and washers
into the rear housing. Start each bolt by hand, tighten
opposite bolts to maintain squareness.
2 Assembly: Tighten bolts to 52 - 57 ft.-lb. (70 - 77 N•m)

torque.
N-18298
Check the brake piston (Item 1) [Figure 30-21-13] for

damage including the surface that contacts the brake
shaft.
Replace the seal (Item 2) [Figure 30-21-13].
Assembly: Apply oil to the seal (Item 2) [Figure 30-21-

13] for added protection when installing the brake piston.
T180 Bobcat Loader

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Figure 30-21-15
1
3 2
1 N-18348
Assembly: Assemble the brake discs into a pack making

P-28519A sure the inner discs, alternate with the outer disc and an
outer disc is placed at each end of the disc pack (Item 1)
[Figure 30-21-17].
Assembly: Install the needed amount of shims (Item 1)
[Figure 30-21-15]. Outer discs can also be used as Figure 30-21-18

shims.
Figure 30-21-16
1 1
P-28407
1 P-64413
P-28464 Disassembly: Remove the brake disks (Item 1) [Figure

30-21-18] and shims from the brake shaft.
Assembly: Lightly clamp the disc pack in a vice and

check the disc pack height, make sure to include brake
Assembly: The correct disc pack specifications is 1.44 ±

0.002 in. (36,50 ± 0,05 mm).
Assembly: Extra outer discs (Item 2) are used to reduce

the number of required shims (Item 3) to make up the
required thickness for the brake pack [Figure 30-21-17].
T180 Bobcat Loader

378 of 961
Figure 30-21-19
4
3
5 1
5
2
1
2
P-28412 P-28411
Remove the flushing valve plug (Item 1) [Figure 30-21-

P-64414 20] from the rear housing assembly.
Check O-ring (Item 2) [Figure 30-21-20] and replace.

Remove the brake washer (Item 1) [Figure 30-21-19].
Figure 30-21-21

Remove and replace the O-ring (Item 2) [Figure 30-21-
19].
Assembly: Slightly coat the O-ring (Item 2) [Figure 30-

21-19] with a layer of oil. 1 2 3
4
Remove the brake shaft (Item 3) [Figure 30-21-19] from
the rear housing.
NOTE: The bushing (Item 4) [Figure 30-21-19] can be

replaced in the brake shaft. When bushing is
replaced, install flush with the top of the brake
shaft.
Check the alignment pins (Item 5) [Figure 30-21-19] for P-28414

damage and replace as needed.
Remove spring (Item 1), washer (Item 2), spool (Item 3)

and rear spring (Item 4) [Figure 30-21-21].
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Disassembly and Assembly (Cont'd) 1 1
Figure 30-21-22
2
1
1
P-28434
1 1
1 1
1
P-64415
Remove the twelve mounting bolts (Item 1) and (Item 2)

P-28433 [Figure 30-21-24] from the rear housing.
NOTE: The bolts (Item 2) [Figure 30-21-24] are shorter

Figure 30-21-23 bolts and must be returned to their original
holes.

Assembly: Use Loctite® #243 or equivalent threadlocker
1 on the bolt threads and install the twelve mounting bolts
2 3 (Item 1) and (Item 2) [Figure 30-21-24].
Assembly: Tighten the bolts to 111 - 114 ft.-lb. (150 - 155

N•m) torque.
P-28436
Remove the flushing relief valve plug (Item 1) [Figure 30-

21-22] & [Figure 30-21-23] and replace O-ring.

30-21-23].
T180 Bobcat Loader

380 of 961

1
Figure 30-21-25
P-28489
Remove and replace the two seals (Item 1) [Figure 30-

P-64416 21-27] and the back-up O-rings under the seals on the
distributor.
Remove and replace the O-ring (Item 1) [Figure 30-21- Assembly: Apply a slight amount of oil to the o-rings and
25]. seals (Item 1) [Figure 30-21-27]

Remove the distributor (Item 2) [Figure 30-21-25] from Check the distributor surfaces for scratches.
the rear housing.
Figure 30-21-28
Assembly: Install the distributor (Item 2) [Figure 30-21-
25] by using the alignment pin (Item 2) [Figure 30-21-
26]. 1
Figure 30-21-26
2 1
1
P-28488
Remove and inspect the nine springs (Item 1) [Figure

30-21-28] from the distributor. Replace as necessary.
P-28487
Remove and replace the two seals and back-up O-rings

(Item 1) [Figure 30-21-26] on the rear housing.
Assembly: Apply a slight amount of oil to the O-rings

and seals (Item 1) [Figure 30-21-26]
Remove and inspect the alignment pin (Item 2) [Figure

30-21-26].
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Figure 30-21-29
1
P-48690
2
Remove the snap ring (Item 1) [Figure 30-21-31] from
P-64418 the bottom side of the rotating group.
Figure 30-21-32
Remove the cam ring (Item 1) [Figure 30-21-29] from the
front housing assembly.

Check the cam ring inside surface for wear and
scratches.
Assembly: Align the marks (Item 2) [Figure 30-21-30]

on the cam ring to the front housing.
Figure 30-21-30
2
1
P-48691
Remove the retainer ring (Item 1) [Figure 30-21-32] from

the bottom side of the rotating group.
1
P-64419

30] from the front housing assembly.
Assembly: Slightly smear the O-ring (Item 1) [Figure

30-21-30] with grease to hold in place.

from the front housing assembly.
T180 Bobcat Loader

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Figure 30-21-33
P-48695
1 Lift the retaining ring (Item 1) [Figure 30-21-35].

P-48689
Use low air pressure and remove the roller/piston
assembly (Item 2) [Figure 30-21-35] from the cylinder
Remove the snap ring (Item 1) [Figure 30-21-33] from block.
the top side of the rotating group.

Check the roller/piston assembly (Item 2) [Figure 30-21-
Figure 30-21-34 35] for wear and replace as needed.
NOTE: Soak the roller/piston assembly (Item 2)

[Figure 30-21-35] in oil and put all roller/piston
assembles back in the original bore.
NOTE: The roller/piston assembly (Item 2) [Figure 30-

1
Figure 30-21-36
P-48694
1
The retainer ring (Item 1) [Figure 30-21-34] cannot be

removed from the top side of the rotating group, because
the RPM target disk is attached directly to the rotating
group.
P-28443
Disassembly: With a hammer and punch remove the

split ring (Item 1) [Figure 30-21-36].
T180 Bobcat Loader

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Figure 30-21-37
1
3
P-28444
Disassembly: Remove the washer (Item 1) [Figure 30-

P-30728 21-38] from under the split ring.
Figure 30-21-39
Assembly: Place the shaft on a hydraulic press table.
2

Assembly: Install the front housing (Item 1) [Figure 30-
21-37] and bearing over the shaft.
Assembly: Install the special tool (MEL 1612) (Item 2)

[Figure 30-21-37] over the bearing and press the
bearing onto the shaft. Apply 4400 lb. of pressure to set 1
the bearing. Rotate the housing to check for free travel.
NOTE: The 4400 lb. of force, is NOT the amount of

pressure required by the press. It is the
amount of downward force applied by the
press.
P-28445
Assembly: Install the split ring (Item 3) [Figure 30-21-
37] and measure the distance between the split ring and
the top of the bearing inner race with a feeler gauge. Add Disassembly: Install the bearing puller (Item 1) [Figure
0.002 - 0.004 in. (0.05 - 0.1 mm) to get the correct 30-21-39] under the front housing and support the puller
washer thickness for the preload. and housing with blocks.
Assembly: Add one pre-load washer (Item 1) below the Disassembly: Press the shaft (Item 2) [Figure 30-21-39]
split ring (Item 3) that is closest to the measurement from the housing.
between the bearing race and split ring with the
additional 0.002 - 0.004 in. (0.05 - 0.1 mm) [Figure 30-
21-38].
Assembly: Release the pressure from the bearing.

Remove the tool from the bearing.
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Figure 30-21-40 1
2 2
3
P-28450
4
Remove the shaft seal (Item 1) [Figure 30-21-42].
P-48471
Remove and replace the bearing cup (Item 2) [Figure
30-21-42].
Use a bearing puller to remove the bearing from the shaft
[Figure 30-21-40]. Figure 30-21-43

NOTE: The bearing will be destroyed during the
removal procedure. Be sure to have a new 1
bearing on hand before removing the old
bearing. 2
Replace the O-ring (Item 1), bearing (Item 2), face seal
(Item 3) and the bushing (Item 4) [Figure 30-21-40].
Figure 30-21-41
P-28451
Remove and replace the bearing cup (Item 1) [Figure

30-21-43].

43].
Reverse procedure for assembly.

P-28448
Remove and inspect the bearing (Item 1) [Figure 30-21-

41].
Replace the bearing if worn or damaged.
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CHARGE PRESSURE Figure 30-30-2
Sender Removal And Installation (Non SJC

Machines)
2
WARNING
1
W-2017-0286
P-28590
Figure 30-30-1
Disconnect the wires (Item 1) [Figure 30-30-2] from the

charge pressure sender.
Remove the charge pressure sender (Item 2) [Figure 30-

30-2] from the fitting.
1

Installation: Tighten the sender to 7.4 - 8.1 ft.-lb. (10 - 11
N•m) torque.
2 Testing (Non SJC Machines)

1.)
P-48580
Remove the two mounting bolts (Item 1) to remove the oil
filter drip shield (Item 2) [Figure 30-30-1].
Open the rear door.
Remove the two mounting bolts (Item 1) to remove the oil charge pressure sender.
filter drip shield (Item 2) [Figure 30-30-1].
Installation: Tighten the mounting bolts and nuts to 15 30-2] from the fitting.
ft.-lb. (20 N•m) torque.
N•m) torque.
Install a tee fitting into the charge pressure sender fitting.
Install a hose with a pressure gauge of at least 500 PSI

on one end of the tee fitting and the charge pressure
sender into the other end.
Reconnect the wires to the charge pressure sender.
Start the engine.
The gauge must read as follows:
220 - 270 PSI (15,1 - 18,6 bar) with approximately 140° F

(60° C) fluid @ High Idle.
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CHARGE PRESSURE (CONT'D) Figure 30-30-4
Adjusting (Non SJC Machines)
IMPORTANT
damage the system.
I-2003-0888
N-17231
Figure 30-30-3
Remove the plug, spring and poppet [Figure 30-30-4].
Check the poppet and spring for wear or damage.
1 Figure 30-30-5

N-19567
1
If the charge pressure is not correct loosen the charge
relief valve plug (Item 1) [Figure 30-30-3].
N-19568
Assemble: Always use a new O-ring. Tighten the plug to
30 - 50 ft.-lb. (41 - 68 N•m) torque.
There are several different thickness of the shims (Item
1) [Figure 30-30-5] and are used to adjust the charge
pressure.
NOTE: 0.010 in. (0,254 mm) is 8 PSI (55.16 kPa)

increase in pressure.
The charge pressure should be set at 220 - 270 PSI (15,1

- 18,6 bar).
T180 Bobcat Loader

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CHARGE PRESSURE (CONT'D) Testing (SJC Machines)
Sender Removal And Installation (SJC Machines) Lift and block the loader. (See Procedure on Page 10-10-
1.)
WARNING device (See Installing Lift Arm Support Device on Page
10-20-1.)
on Page 10-30-1.)
W-2017-0286
Figure 30-30-6 Remove the charge pressure sender (Item 2) [Figure 30-

N•m) torque.
1
2 Install a tee fitting into the charge pressure sender fitting.
Install a hose with a pressure gauge of at least 500 PSI

on one end of the tee fitting and the charge pressure
sender into the other end.
Reconnect the wires to the charge pressure sender.
Start the engine.

P-64580
The gauge must read as follows:
360 PSI (24,8 bar) with approximately 140° F (60° C)
10-20-1.) fluid @ High Idle.

on Page 10-30-1.)



N•m) torque.
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CHARGE PRESSURE (CONT'D) Figure 30-30-8
Adjusting (SJC Machines)
IMPORTANT
1
damage the system.
I-2003-0888
P-64435
Figure 30-30-7
Check the poppet and spring for wear or damage.
There are several different thickness of the shims (Item

1) [Figure 30-30-8] and are used to adjust the charge
pressure.

The charge pressure should be set at 360 PSI (24,8 bar).
1
P-64431
If the charge pressure is not correct remove the charge

relief valve (Item 1) [Figure 30-30-7].
NOTE: The pump has been removed for photo clarity.

The charge pressure relief valve is located on
the engine side of the hydrostatic pump when
installed in the loader.
Assemble: Always use a new O-ring. Tighten the plug to

30 - 50 ft.-lb. (41 - 68 N•m) torque.
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HYDROSTATIC PUMP Figure 30-40-2
Replenishing/High Pressure Relief Valve
Figure 30-40-1 1
2
1
3
N-19566
Remove the high pressure relief valve (Items 1) [Figure

N-19565 30-40-2] from the pump.
Assemble: Tighten the plug to 30 - 50 ft.-lb. (41 - 68

There are four replenishing/high pressure relief valves N•m) torque.
(Item 1) [Figure 30-40-1] in the hydrostatic pump

assembly. Two are located at the top of the pumps and Check for damage and replace as needed.
two at the bottom of the pumps.
Check the O-rings (Items 2 & 3) [Figure 30-40-2] for
(See HYDROSTATIC SYSTEM INFORMATION on Page damage and replace as needed.
30-10-1.) for valve function.
If the high pressure relief valve must be replaced, it must
NOTE: The two top valves are for the reverse drive be replaced as a complete unit.
loop and the two bottom valves are for the
forward drive loop. The pressure setting for a new high pressure relief valve
is 5000 PSI (34475 kPa).
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HYDROSTATIC PUMP (CONT’D) Figure 30-40-4

1
IMPORTANT
clean the work area before disassembly and keep all 2
damage the system.
I-2003-0888
P-34567
Remove the engine/hydrostatic pump assembly from the

loader. (See Removal And Installation on Page 70-80-1.) Loosen the drive belt tensioner (Item 1) [Figure 30-40-4]
and remove the drive belt.
Remove the control handle linkage from the hydrostatic
pump. (See Linkage Removal And Installation on Page Remove the hydrostatic pump drive pulley mounting nut
50-100-5.) (Item 2) [Figure 30-40-4] and washer.

Remove the hydraulic pump from the hydrostatic pump. Installation: Tighten the pump pulley mounting nut to
(See Removal And Installation on Page 20-60-5 or See 175 - 200 ft.-lb. (237 - 271 N•m) torque.
Removal And Installation on Page 20-61-5 [High Flow
pump] or See Removal And Installation on Page 20-62-4 Figure 30-40-5
[SJC pump] or See Removal And Installation on Page
20-63-6 [High Flow SJC pump])
Figure 30-40-3
P-4235
1 Install a puller on the hydrostatic pump drive pulley and

P-34568 remove the pulley from the pump shaft [Figure 30-40-5].
Remove the hydrostatic pump mounting bolt (Item 1)

[Figure 30-40-3] and washer(s).
Installation: Tighten the mounting bolt to 65 - 70 ft.-lb.

(88 - 95 N•m) torque.
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HYDROSTATIC PUMP (CONT’D)
Removal And Installation (Cont’d) WARNING

Figure 30-40-6
1 explosion or fire.
W-2103-0508
Reverse the removal procedure to install the hydrostatic

pump assembly.
P-48650
Installation: Install the key in the hydrostatic pump shaft

(Item 1) [Figure 30-40-6] before installing the pump drive

pulley.
Figure 30-40-7
P-28850
Hold the nut (Item 1) [Figure 30-40-7] on the two

hydrostatic pump mounting bolts (Item 2) [Figure 30-40-
6].
Remove the two hydrostatic pump mounting bolts from

the pump and drive belt housing.
Installation: Tighten the pump mounting bolts to 65 - 70

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HYDROSTATIC PUMP (CONT'D)
Parts Identification (Right Half)
5
4
8
3
7
6
2
9 1
13 14
10 15
11 12
17
19

16
21
18
23 20
25
27
22
24
29
26
28
30 38
33
36
34 32
31
37
35
49 46
47 48
40 45
42
39 44
49
41
43
D-2427
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Parts Identification (Right Half) (Cont'd)

1. Bolt 26. Retainer
2. End Cap 27. Retainer
3. Plug 28. Piston Assembly
4. O-ring 29. Plate
5. Plug 30. Swash Plate
6. O-ring 31. Pin
7. O-ring 32. Housing
8. Relief Valve 33. Plug
9. Bolt 34. Bearing
10. Gasket 35. Seal
11. Bearing 36. O-ring
12. Plug 37. Cover
13. O-ring 38. Bolt
14. O-ring 39. Shaft
15. Relief Valve 40. Snap Ring
16. Pin 41. Bearing
17. Valve Plate 42. Snap Ring
18. Retainer 43. Snap Ring

19. Washer 44. Plug
20. Spring 45. O-ring
21. Washer 46. Bearing
22. Block 47. O-ring
23. Retainer 48. Plate
24. Pin 49. Bolt
25. Washer
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Parts Identification (Left Half)
17 6
16 1
8 2
11 3
14 13 10 5
12 7
15 9
22
23
18 19 21
20
24
26

28
30 25
32 27
29
34 31
36
38
33
35
37 47
39 46
45
44
48 43
49 40
42
50
51
41 58
52
53
57
53 52
59
55
54 56
D-2428
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Parts Identification (Left Half) (Cont'd)

1. Snap Ring 31. Pin
2. Washer 32. Retainer
3. Seal 33. Block
4. Snap Ring 34. Washer
5. Snap Ring 35. Spring
6. Bearing 36. Washer
7. Snap Ring 37. Washer
8. Key 38. Valve Plate
9. Shaft 39. Pin
10. Housing 40. Gasket
11. Plug 41. Bearing
12. O-ring 42. Plug
13. Bearing 43. Poppet
14. Seal 44. Spring
15. O-ring 45. Shim
16. Cover 46. O-ring
17. Bolt 47. Plug
18. Pin 48. Relief Valve

20. Plug 50. O-ring
21. Bearing 51. Plug
22. O-ring 52. Pin
23. Plate 53. O-ring
24. Bolt 54. Coupler
25. Swash Plate 55. O-ring
26. Wear Plate 56. Bolt
27. Piston Assembly 57. O-ring
28. Piston Retainer 58. O-ring
29. Retainer 59. Relief Valve
30. Washer
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HYDROSTATIC PUMP (CONT'D) Pump Separation
Hydraulic Pump Removal And Installation Figure 30-40-10
Figure 30-40-8
1
2
1 1
N-19569
N-21967
10].
Remove the pump mounting bolts (Item 1) [Figure 30-
40-8] (both sides). Figure 30-40-11

(34 - 37 N•m) torque.
Remove the hydraulic pump (Item 2) [Figure 30-40-8]

from the hydrostatic pumps.
Figure 30-40-9
1 N-19570
2
Separate the two hydrostatic pumps [Figure 30-40-11].
N-21969
Remove the O-ring (Item 1) [Figure 30-40-9] and coupler

(Item 2) [Figure 30-40-9] with the hydraulic pump.
T180 Bobcat Loader

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HYDROSTATIC PUMP (CONT'D) Figure 30-40-14
Pump Separation (Cont’d)
Figure 30-40-12
1
3
1
N-19551
2 3
Remove the pump housing end cap (Item 1) [Figure 30-
N-19571 40-14].
Remove the gasket (Item 2) [Figure 30-40-14].

Remove the pump coupler (Item 1) [Figure 30-40-12].
Figure 30-40-15

Remove the large O-ring (Item 2) [Figure 30-40-12].
Remove the two small O-rings (Item 3) [Figure 30-40- 1

12].
Disassembly
Figure 30-40-13
1 1
N-17193
Remove the valve plate (Item 1) [Figure 30-40-15].
Check the valve plate for wear. (Both Sides.)
N-19550
Remove the four bolts (Item 1) [Figure 30-40-13] from

the pump housing end cap.
T180 Bobcat Loader

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1
Figure 30-40-16
2
1
N-17198
Remove the slipper guide and pistons (Item 1) [Figure

N-17194 30-40-18] from the cylinder block.
Check all the pistons (Item 2) [Figure 30-40-18] for wear

Check the valve plate locating pin (Item 1) [Figure 30-40- and replace the rotating group as needed.
16] for wear and replace if needed.

Figure 30-40-19
Check the needle bearing (Item 2) [Figure 30-40-16] for
wear and replace if needed. 1
Figure 30-40-17
N-17199
Remove the ball guide retainer (Item 1) [Figure 30-40-

N-17197 19] from the cylinder block.

from the pump.
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Figure 30-40-20
1
3 3
2
3 3 2 1
3
N-17481
Remove the driveshaft key (Item 1) the snap ring (Item 2)

N-17200 and the support washer (Item 3) from the drive shaft end
of the pump [Figure 30-40-22].
Check the ball guide retainer (Item 1) and washer (Item Figure 30-40-23
2) for wear and replace as needed [Figure 30-40-20].

Remove the four pins (Item 3) [Figure 30-40-20] from the
cylinder block. 1
Check the cylinder block for wear and replace as needed.
Check pins (Item 3) [Figure 30-40-20] to see if they are

all the same length.
Figure 30-40-21
N-17239
Use a seal puller and remove the seal (Item 1) [Figure

30-40-23] from the pump housing.
1
N-17201
Remove the thrust plate (Item 1) [Figure 30-40-21] from

the pump housing.
T180 Bobcat Loader

401 of 961
Figure 30-40-24 1
1
N-17242
Check the pump shaft (Item 1) [Figure 30-40-26] for

N-17240 wear and replace if needed.
Figure 30-40-27
the pump housing and remove the driveshaft and bearing

from the housing.
Figure 30-40-25
1 1
N-17243
1
Remove the four mount bolts (Item 1) [Figure 30-40-27]
from the lower trunnion cover. Remove the cover.
N-17241

the driveshaft and remove the bearing.
Check the bearing for wear and replace if worn.
T180 Bobcat Loader

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Figure 30-40-28
2
2
1 1
1 N-17246
Remove the four mount bolts (Item 1) from the pump

N-17244 housing and remove the linkage bracket (Item 2) [Figure
30-40-30].
Remove the O-ring (Item 1) and bearing race (Item 2) Figure 30-40-31
from the pump housing [Figure 30-40-28].

Figure 30-40-29
1
2
N-17247
N-17245 Remove the upper trunnion cover (Item 1) [Figure 30-40-

31].
Check the bearing race (Item 1) and O-ring (Item 2) for

wear and replace as needed [Figure 30-40-29].
T180 Bobcat Loader

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Figure 30-40-32
1 N-17249
Inspect the bearing race (Item 1) and O-ring (Item 2)

N-17250 [Figure 30-40-34] and replace as needed.
Figure 30-40-35
Inspect the seal (Item 1) [Figure 30-40-32] in the upper
trunnion cover and replace if needed.

Figure 30-40-33
1 N-17251
2
Slide the swash plate from side to side and remove the
N-17248 tapered roller bearing (Item 1) [Figure 30-40-35] from
the swash plate shaft.
Remove the O-ring (Item 1) [Figure 30-40-33] and

bearing race (Item 2) [Figure 30-40-33] from the pump
housing.
T180 Bobcat Loader

404 of 961
Assembly
Figure 30-40-36
N-17252
Install the swash plate and bearing into the pump

N-17252 housing [Figure 30-40-38].
Figure 30-40-39
Tilt the swash plate (Item 1) [Figure 30-40-36] and
remove the swash plate and lower bearing from the

pump housing.
Figure 30-40-37
1
1
N-17249
Install the tapered bearing (Item 1) [Figure 30-40-39] on

the swash plate shaft.
N-17253
Install the lower bearing (Item 1) [Figure 30-40-37] on

the swash plate.
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Assembly (Cont'd)
Figure 30-40-40
2
N-17246
1
Install the linkage bracket (Item 1) [Figure 30-40-42] and
N-17248 the four mounting bolts and tighten to 18 - 22 ft.-lb. (24 -
30 N•m) torque.
Install the bearing race (Item 1) and O-ring (Item 2) as

shown in [Figure 30-40-40].

Figure 30-40-41
N-17247
Install the upper trunnion seal (Item 1) [Figure 30-40-41]

and cover.
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Assembly (Cont'd)
Figure 30-40-43
2
N-17243
Align the marks on the lower trunnion cover and pump

N-17245 housing as shown in [Figure 30-40-45].
Install the four mounting bolts and tighten to 18 - 22 ft.-lb.

Figure 30-40-44 (24 - 30 N•m) torque.

Figure 30-40-46
N-17244
N-17242
Install the bearing race (Item 1) [Figure 30-40-43] and O-
ring (Item 2) [Figure 30-40-43] at the lower trunnion as
shown in [Figure 30-40-44]. Install the snap ring (Item 1) [Figure 30-40-46] on the
pump shaft.
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Assembly (Cont'd) 1 1
Figure 30-40-47
3
2
1 1
1 N-17200
Install the four slipper pins (Item 1) [Figure 30-40-49]

N-17241 into the cylinder block.
Apply a small amount of grease to the washer (Item 2)

Install the bearing and snap ring (Item 1) [Figure 30-40- and install into the ball guide retainer (Item 3) [Figure 30-
47] on the pump shaft. 40-49].

Figure 30-40-48 Figure 30-40-50
N-17240 N-17199
Install the pump shaft into the pump housing [Figure 30- Install the ball guide retainer and washer (Item 1) [Figure
40-48]. 30-40-50] onto the slipper holddown pins.
Install the snap ring (Item 1) [Figure 30-40-48].
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Assembly (Cont'd)
1
2
Figure 30-40-51
N-17194
Replace the needle bearing (Item 1) and valve plate

N-17198 locating pin (Item 2) in the charge pump [Figure 30-40-
53].
Assemble the piston assemblies into the slipper guide. Figure 30-40-54
Lubricate the pistons and cylinder block bores and insert

the piston assemblies into the cylinder bores [Figure 30-
40-51].
Figure 30-40-52
2 1
N-17196
The bearing cage (Item 1) [Figure 30-40-54] will

protrude from 0.08 - 0.10 in. (2,0 - 2,5 mm) from the
N-17197 surface of the charge pump.
The valve plate locating spring pin (Item 2) [Figure 30-

Lay the pump housing on its side and install the cylinder 40-54] will protrude from 1.65 - 0.185 in. (4,19 - 4,70 mm)
block, piston assembly into the housing. from the surface of the charge pump.
Place the pump on a work surface with the end cap

opening up [Figure 30-40-52].
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Assembly (Cont'd)
1 1
Figure 30-40-55
N-19550
Install the valve plate and end cap on the pump housing.
N-17193 Tighten the bolts (Item 1) [Figure 30-40-57] to 35 - 45 ft.-
Coat the backside of the valve plate with petroleum jelly Figure 30-40-58
to hold it in position and install the valve plate onto the

charge pump, bronze face up [Figure 30-40-55].
The notch (Item 1) [Figure 30-40-55] on the valve plate

must engage the locating pin.
Figure 30-40-56 1
2
1
N-19571
1 Install the two small O-rings (Item 1) [Figure 30-40-58].
Install the large new O-ring (Item 2) [Figure 30-40-58].
N-19551 Install the pump coupler (Item 3) [Figure 30-40-58].
Coat a new end cap gasket (Item 1) [Figure 30-40-56]

with petroleum jelly and install onto the end cap.
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Assembly (Cont'd)
Figure 30-40-59
N-19570
Install the two pumps together [Figure 30-40-59].

Figure 30-40-60
1
N-19569
Tighten the four bolts (Item 1) [Figure 30-40-60] to 35 -

45 ft.-lb. (47 - 61 N•m) torque.
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T180 Bobcat Loader

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HYDROSTATIC PUMP (SJC) The servo piston strokes the swash plate in the rotating
group. The rotating group generates flow to the A or B
Description ports on the hydrostatic pump. The flow from the A and B
ports is sent to the hydrostatic drive motors where
The SJC hydrostatic pump is a fully proportional dual forward or reverse drive motor rotation is obtained.
piston pump in one pump casing. The endcaps are
removable to gain access to the rotating assemblies. There are swash plate angle sensors on the bottom of
the pump that monitor swash plate movement.
The hydraulic controllers are fed charge pressure from
an external charge pump. 12 volt electrical solenoids shift Ports are labeled on the hydrostatic pump casting.
a spool in the hydraulic controller that directs flow to a
servo piston.
Figure 30-41-1

P-64943
A,B Service Line Ports (High Pressure Outlet Ports to Drive Motors)
T1 Case Drain Port
MA Operating Pressure of “A” Port
MB Operating Pressure of “B” Port
R Air Bleed Port
X1,X2 Control Pressure Gauge Port
G Charge Pressure Inlet Port
MG Gauge Port For Charge Pressure
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HYDROSTATIC PUMP (SJC) (CONT'D) Figure 30-41-3
Hydraulic Controller Removal And Installation
The loader’s right hand side hydraulic controller can be

removed with the hydrostatic pump still in the loader. The
loader’s left hand side hydraulic controller can only be
removed when the hydrostatic pump is separated from
the engine/hydrostatic pump cast mount.
Controller solenoids can be bled of trapped air in the 1

controller. This should be performed when hydraulic
controllers are replaced, removed or uncommanded
oscillations in the controls are present.
Raise the lift arms and install and approved lift arm P-64460
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)
Disconnect all of the electrical harness connectors (Item
Place the loader on jack stands. (See Procedure on Page 1) [Figure 30-41-3] from the loader harness.
10-10-1.)
Removal:
WARNING

IMPORTANT
Failure to use jackstands can allow the machine to When repairing hydrostatic and hydraulic systems,
fall or move and cause injury or death. clean the work area before disassembly and keep all
W-2017-0286 parts clean. Always use caps and plugs on hoses,
damage the system.
Raise the operator cab. (See Raising The Operator Cab I-2003-0888
on Page 10-30-1.)
Figure 30-41-2 Figure 30-41-4
P-64425 P-64426
Locate the two hydraulic controllers (Item 1) [Figure 30- Remove the four mount bolts (Item 1) [Figure 30-41-4]
41-2] on the hydrostatic pumps. from the hydraulic controller.
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Hydraulic Controller Removal And Installation 1

(Cont'd)
Figure 30-41-5
1
2
2 P-64427
3
Alternately tighten bolts (Item 1) [Figure 30-41-7] to 7.7
ft.-lb. (10,4 N•m) torque. Ensure bolts are tight to
P-64427 specifications.
NOTE: When a hydraulic controller is replaced, the

Remove the controller (Item 1) [Figure 30-41-5] from the hydrostatic pumps must be calibrated. (See

pump. Hydraulic Controller Neutral Adjustment on
Page 30-41-28.)
Remove the controller gaskets (Item 2) [Figure 30-41-5]
from the pump. Figure 30-41-8
Installation:
Figure 30-41-6
P-64978
With the engine running and the loader on jack stands:

P-64444 Bleed the trapped air in the controller by loosening the
small set screw (Item 1) [Figure 30-41-8] a maximum of
2 turns. Leave the screw loose until oil comes dripping
Be sure the feedback lever (Item 3) [Figure 30-41-5] is in out of the set screw. Tighten set screw to 18 in.-lb. (2
the center of the servo piston groove (Item 1) [Figure 30- N•m) torque.
41-6].
Repeat the bleeding procedure for all of the solenoids.
Use a small amount of grease on a new gasket and
install the gasket on the hydraulic controller (Item 1)
[Figure 30-41-5].
Be sure the pump surface is clean.
T180 Bobcat Loader

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Remove the hydrostatic pump/engine assembly from the

loader. (See Removal And Installation on Page 70-80-1.)
IMPORTANT 1

tubelines and ports to keep dirt out. Dirt can quickly P-64345
damage the system.

I-2003-0888
Loosen the washer and nut (Item 1) [Figure 30-41-10] on
the hydrostatic pump drive shaft.
Figure 30-41-9
Installation: Tighten the nut to 175 - 200 ft.-lb. (237 - 271
N•m) torque

1 Figure 30-41-11
P-64344 1
Loosen the tensioner mount bolt (Item 1) [Figure 30-41-

9].
P-64346
Remove the drive belt (Item 2) [Figure 30-41-9].

Use a puller (Item 1) [Figure 30-41-11] to loosen the
Installation: (See Drive Belt Replacement on Page 30- pulley from the pump drive shaft.
50-3.)
NOTE: DO NOT strike puller or pump shaft with a
hammer. Internal pump damage may result.
Remove the nut and washer from the pump drive shaft.
Remove the pump pulley from the pump drive shaft.
T180 Bobcat Loader

416 of 961
Figure 30-41-12
1 1 1 P-64343
Remove the mounting bolt (Item 1) [Figure 30-41-14] at

P-64348 the hydraulic pump mounting bracket.
Remove the hydrostatic pump from the mounting bracket

Figure 30-41-13 and drive belt housing.

NOTE: The mounting bolt is a special purpose bolt.
Only replace with original Bobcat Parts.
1 1 Figure 30-41-15
P-64337 P-64338 1

12] and nuts (Item 1) [Figure 30-41-13].
P-64458
Installation: Tighten the mounting bolts and nuts to 65 -
70 ft.-lb. (88 - 95 N•m) torque.
Remove the air bleed plugs (Item 1) [Figure 30-41-15].
Make sure the key (Item 2) [Figure 30-41-12] is installed.
BEFORE START UP: Fill one of the air bleed ports with
new hydraulic oil until the hydraulic oil flows out of the
other air bleed port. This will remove trapped air in the
hydrostatic pumps before start up.
Assembly: Tighten plugs to 18 ft.-lb. (25 N•m) torque.
T180 Bobcat Loader

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HYDROSTATIC PUMP (SJC) (CONT'D)
3 1
1. O-ring 5 4
2. Bolt
3. End Housing
4. O-ring 7 6
5. Right Rotating Assembly 8
6. Timing Pin
7. Bearing
8. Spacer/Coupler
9. Pin
10. Positioning Pin
11. O-ring 10
12. Snap Ring 11 9
13. Position Sensor 2
14. Washer 12 13
15. Bolt 14
15
16
19 17
21
24 23 22 26

20
25
18
26
18
27
32 19 29
28
31 16. Steel Cover
17. Bolt
18. Hydraulic Controller
19. High Pressure Relief
20. Case Housing
21. Bolt
6 22. Plug
2
7 23. Screen
24. Plug
25. Orifice
30 26. Dowel Pin
27. Charge Pressure Relief
4 28. Left Servo
29. Right Servo
30. Left Rotating Assembly
31. Key
32. End Housing
B25010
T180 Bobcat Loader

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High Pressure Relief and Bypass Valve
Figure 30-41-16
1
1
P-64437
Check the valve seat surface (Item 1) [Figure 30-41-18]

P-64431 for scratches and replace as needed.
Inspect the spring (Item 2) [Figure 30-41-18] for

There are four system check relief valves (Item 1) breakage.
[Figure 30-41-16] in the back of the hydrostatic pump.

Inspect seats inside case housing.
Remove the relief valve cap (Item 1) [Figure 30-41-16].
Do not disassemble the relief valve assembly. If
Assembly: Tighten cap to 111 - 125 ft.-lb. (150 - 170 replacement is required, replace as an assembly.
N•m) torque.
Factory setting on the relief valve is 5250 PSI (362 bar).
Figure 30-41-17
4
3
2 1
P-64436
Check the valve cap O-ring (Item 1) and back-up ring

(Item 2) [Figure 30-41-17], replace as needed.
Remove relief valve assembly (Item 3) [Figure 30-41-17]

from the valve cap.
Check the conical spring (Item 4) [Figure 30-41-17] to

ensure it is not broken or flattened.
T180 Bobcat Loader

419 of 961
Charge Relief Valve
Figure 30-41-19 3 4
2 5
1
1 P-64435
Inspect the poppet (Item 1) and the mating seat (Item 2)

P-64431 [Figure 30-41-21] for damage or foreign material. Ensure
the poppet moves freely in it’s bore.
The charge relief valve (Item 1) [Figure 30-41-19] is Inspect the sealing ring (Item 3) [Figure 30-41-21] and
located on the back of the hydrostatic pump. the mating seat in the pump housing for damage or

foreign material.
Remove the charge relief valve.
Inspect the spring (Item 4) and the charge relief valve
Assembly: Tighten charge relief valve to 52 ft.-lb. (70 shims (Item 5) [Figure 30-41-21].
N•m) torque.
NOTE: 1.0 mm shim (Item 5) [Figure 30-41-21] = 43.5
Figure 30-41-20 PSI (3 bar) in pressure change. Adding shims
increases charge pressure. Removing shims
decreases charge pressure.
1
P-64435
Check and replace the O-ring (Item 1) [Figure 30-41-20].
T180 Bobcat Loader

420 of 961
Disassembly and Assembly
Remove the hydrostatic pump/engine assembly from the

2
Figure 30-41-22
1
1
P-64439
Remove the bolts (Item 1) mounting the steel covers

(Item 2) [Figure 30-41-24].
Assembly: Tighten bolts to 38 ft.-lb. (51 N•m) torque.

P-64458
Figure 30-41-25

Remove the hydraulic controllers (Item 1) [Figure 30-41-
22]. (See Hydraulic Controller Removal And Installation
on Page 30-41-2.) 1
Figure 30-41-23
2 2
1 1 1
P-64440
Remove the mounting bolts and washers for the swash

plate angle sensor (Item 1) [Figure 30-41-25].
P-64438 Assembly: Tighten bolts to 27.4 in.-lb. (3,1 N•m) torque.
Swash plate angle sensors (Item 1) are mounted on the

bottom of the hydrostatic pump. They are protected by
steel covers (Item 2) [Figure 30-41-23].
Note the connectors facing each other.
Note the steel covers facing direction.
T180 Bobcat Loader

421 of 961
Figure 30-41-26
P-64442
Both swash plate angle sensors and associated

P-64441 hardware removed from the hydrostatic pump. [Figure
30-41-28].
Assembly: Note the slotted portion (Item 1) of the

positioning pin tightly fits the machined section on the

swash plate angle sensor shaft (Item 2) [Figure 30-41-
26].
Note the machined section of the swash plate angle

sensor shaft faces the center of the hydrostatic pump.
Figure 30-41-27
P-64453
NOTE: Improperly installing the swash plate angle

sensor, with the shaft facing toward the
outside of the hydrostatic pump, will make it
hard to install the sensor mounting bolts and
also destroy the seal (Item 1) [Figure 30-41-
27].
T180 Bobcat Loader

422 of 961
Right End Housing
Figure 30-41-29
3
1
2
P-64464
Pull the end housings from the case housing [Figure 30-
41-31].
1
P-64445

Left End Housing
Figure 30-41-30
3 1
P-64447
Remove the four mount bolts (Item 1) securing the end

housing (Item 2) to the main case housing (Item 3)
[Figure 30-41-29] and [Figure 30-41-30].
Assembly: Alternately, tighten mount bolts to 96 ft.-lb.

(130 N•m) torque.
T180 Bobcat Loader

423 of 961
Figure 30-41-32
1 2
1
2
P-64463
Assembly: Ensure dowel pin (Item 1) is aligned with hole

P-64465 in case housing (Item 2) [Figure 30-41-34] before
tightening screws.
Replace O-ring (Item 1) [Figure 30-41-32].

Figure 30-41-33
P-64466
Ensure servo follower (Item 2) [Figure 30-41-32] is

swung out for proper engagement with the notch in the
servo piston (Item 1) [Figure 30-41-33].
T180 Bobcat Loader

424 of 961
HYDROSTATIC PUMP (SJC) (CONT'D)
Figure 30-41-35
RIGHT SIDE
P-64454
Figure 30-41-36

LEFT SIDE
P-64501
Remove valve plate (Item 1) [Figure 30-41-35] and

[Figure 30-41-36] from the case housing.
Inspect valve plate for scratches or scoring. Replace a

valve plate if the scratches are deep enough to catch with
a fingernail.
NOTE: Pay attention to the notches (Item 2) [Figure

30-41-35] and [Figure 30-41-36] in the valve
plate for assembly reasons. There are
different valve plates for the left and right
side. The valve plates are NOT
interchangeable.
T180 Bobcat Loader

425 of 961

RIGHT SIDE
Figure 30-41-37
1
2
RIGHT SIDE
1 P-64456
2
Figure 30-41-40
P-64455
LEFT SIDE
Figure 30-41-38 1
2

LEFT SIDE
P-64503
1
2
Assembly: Align the timing pin (Item 1) [Figure 30-41-
P-64502 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.
T180 Bobcat Loader

426 of 961
Figure 30-41-41
1
P-64469
Remove the piston assembly (Item 1) [Figure 30-41-43].

B25012
Figure 30-41-44
Right Side Rotating Group [Figure 30-41-41].

Figure 30-41-42
1
P-64475
Remove the pistons (Item 1) [Figure 30-41-44] from the

B25011 rotating block.
Left Side Rotating Group [Figure 30-41-42].
T180 Bobcat Loader

427 of 961

1
Figure 30-41-45
P-64471
Remove the spherical washer (Item 1) [Figure 30-41-

P-64476 47].
Figure 30-41-48
Inspect the pistons, look for scoring and scratches.
Ensure the holes (Item 1) [Figure 30-41-45] in the
1

slippers, are not plugged.
Figure 30-41-46
1
P-64472
Inspect the pins (Item 1) [Figure 30-41-48]. They should

be all the same length. Do not remove.
P-64477
Inspect the mating surface of the spherical washer for

scoring or scratches (Item 1) [Figure 30-41-46].
T180 Bobcat Loader

428 of 961

3
Figure 30-41-49
1
1
P-64479
Inspect mating surface for the slippers on the swash

P-64474 plate (Item 1) [Figure 30-41-51].
Remove the swash plate from the endcap housing (Item

Inspect the spherical washer for scoring and wear (Item 2) [Figure 30-41-51].
1) [Figure 30-41-49].

Remove the slide ring (Item 3) [Figure 30-41-51], ensure
Figure 30-41-50 it pivots freely.
Figure 30-41-52
1
3 1
P-64478
P-64480
Inspect the back surface of the rotating block (Item 1)
[Figure 30-41-50] where the valve plate seals. Ensure
there is no scratches or scoring. Assembly: Carefully align bearing pin eyelets (Item 1)
into holes in endcap housing (Item 2) [Figure 30-41-52].
Visually ensure spring (Item 2) and c-clip (Item 3) [Figure
30-41-50] are not bent or damaged.
T180 Bobcat Loader

429 of 961
Disassembly and Assembly (Cont'd) 2

1 1
Figure 30-41-53
1 P-64483
Remove the shell bearing races (Item 1) [Figure 30-41-

P-64481 55].
Assembly: Note shell bearing races have an edge (Item

Assembly: Ensure bearing pins are in the holes of the 2) [Figure 30-41-55] on them. The edges face towards
swash plate (Item 1) [Figure 30-41-53]. the outside of the endcap housing

Figure 30-41-54 Inspect bearing surfaces for scratches or scoring.
P-64482
Remove the shell bearing (Item 1) [Figure 30-41-54].
Inspect individual roller bearings and machined surfaces

(Item 2) [Figure 30-41-54] on swash plate.
T180 Bobcat Loader

430 of 961
Disassembly and Assembly (Cont'd) LEFT SIDE

Figure 30-41-56
1
2
1
P-64486
Figure 30-41-59
P-64484
RIGHT SIDE
Remove the snap ring (Item 1) from the positioning pin 1
(Item 2) [Figure 30-41-56].

Figure 30-41-57
2 1
P-64523
Remove the snap ring (Item 1) [Figure 30-41-58] and

[Figure 30-41-59] from the end housing.
Figure 30-41-60
P-64485
Pull the positioning pin from the end housing.
Replace O-ring (Item 1) [Figure 30-41-57].
Inspect wear surfaces (Item 2) [Figure 30-41-57] for

scratches or scoring. Ensure positioning pin can rotate
smoothly in the end housing without excessive play.
1
P-64524
The pump seal (Item 1) [Figure 30-41-60] is removed by

inserting a screw into the seal and prying out.
T180 Bobcat Loader

431 of 961
Figure 30-41-61
P-64488
The drive shaft can be tapped out of the end housing with
B25013
a rubber mallet.

Inspect wear surfaces for scratches, and inspect splines
Servo Piston Assembly [Figure 30-41-62].
for excessive wear.
Figure 30-41-63
Inspect bearing (Item 1); if bearing needs replacement,
remove snap ring (Item 2) [Figure 30-41-61] and remove
bearing.
The Servo Piston Assembly [Figure 30-41-62] cannot be

removed unless the hydraulic controller and rotating
group is removed first.
1 1
P-64489
Remove servo piston mounting bolts (Item 1) [Figure 30-

41-63].
Installation: Tighten bolts to 7.7 ft.-lb. (10,4 N•m) torque.
T180 Bobcat Loader

432 of 961
Figure 30-41-64
P-64492
Slide the servo piston assembly out of the bore. [Figure

P-64490 30-41-66].
Measure and record servo piston depth at the adjustment

screw [Figure 30-41-64].

Figure 30-41-65
P-64491
Use a rubber mallet to rotate servo piston cover (Item 1)

[Figure 30-41-65].
T180 Bobcat Loader

433 of 961
Figure 30-41-67 1
2
1
P-64493
Remove the bushings (Item 1), seals and O-rings (Item

P-64467 2) [Figure 30-41-69] from the pump housing.
Figure 30-41-70
Figure 30-41-68

1
3
P-64494
P-64466
Assembly: Align the servo piston so the guide slot Each servo has a pair of bushings (Item 1), O-rings (Item
(Item 1) [Figure 30-41-68] is parallel to the driveshaft 2) and square-cut seals (Item 3) [Figure 30-41-70].
centerline. Measure with a straight-edge [Figure 30-41-
67].
T180 Bobcat Loader

434 of 961
Figure 30-41-71
P-64497
1
Remove snap ring (Item 1) [Figure 30-41-73] from the
P-64495 servo piston.
Figure 30-41-74
Remove the lock nut (Item 1) [Figure 30-41-71] from the
servo piston.
1

Assembly: Tighten lock nut to 22 ft.-lb. (30 N•m) torque. 2
Figure 30-41-72
P-64498
Remove the piston stop adjustment mechanism (Item 1)

[Figure 30-41-74] from the servo piston.
P-64496 Inspect mechanism for broken parts.
Replace O-ring (Item 2) [Figure 30-41-74]

Remove the servo cover (Item 1) [Figure 30-41-72] from
the servo piston.
T180 Bobcat Loader

435 of 961
Figure 30-41-75
1
1
2 1
3
P-64499
Remove the four control pressure plugs (Item 1) [Figure

P-64461 30-41-77] at the top of the case housing to gain access to
the four orifices (Item 1) [Figure 30-41-78].
Remove the plug (Item 1) from the top center of the case Replace O-rings on plugs.
housing. Replace O-ring (Item 2) [Figure 30-41-75].

Assembly: Tighten plugs to 18 ft.-lb. (25 N•m) torque.
Assembly: Tighten plug to 45 ft.-lb. (10 N•m) torque.
Figure 30-41-78
Remove internal screen (Item 3) [Figure 30-41-75].
Assembly: Tighten internal screen to 7.4 ft.-lb. (62 N•m)

1
torque.
Figure 30-41-76
P-64500
Ensure the four orifices (Item 1) [Figure 30-41-78] in

case housing are clean and not plugged.
P-64462
Ensure screen is clean [Figure 30-41-76].
T180 Bobcat Loader

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HYDROSTATIC PUMP (SJC) (CONT'D) Mechanical Neutral Adjustment
Disassembly and Assembly (Cont'd) The pump mechanical neutral adjustment sets the
position of the servo piston and pump swash plate
Figure 30-41-79 relative to the hydraulic controller. This procedure should
be followed if the hydrostatic pump has been
disassembled for servicing the servo piston and the
setting has been disrupted.
Place the loader on jackstands. (See Procedure on Page

10-10-1.)
2
1
WARNING
P-64502
W-2017-0286
Bearings (Item 1) [Figure 30-41-79] in case housing are
replaced by using a press and bearing driver. Raise the lift arms, and install an approved lift arm

support device. (See Installing Lift Arm Support Device
Inspect center coupler (Item 2) [Figure 30-41-79]. on Page 10-20-1.)

on Page 10-30-1.)

10-60-1.)
Disconnect the swash plate angle sensors in the

electrical harness. This prevents unwanted swash plate
movement error codes from occurring during
adjustments. Disconnecting the sensors does not have to
be done directly at the sensor, follow the harness back to
find an accessible connector to disconnect.
Disconnect the speed sensors located on the top of the

motor carriers. This prevents uncommanded wheel
movement error codes from occurring during
adjustments.
WARNING
immediately.
W-2145-0290
T180 Bobcat Loader

437 of 961
Mechanical Neutral Adjustment (Cont’d)
Figure 30-41-80
1
P-64438
Remove the plugs (Item 1) [Figure 30-41-82] from the

P-64973 MA ports on the bottom of the pump, and install 7500 PSI
pressure gauges.
Connect a hydraulic hose (Item 1) [Figure 30-41-80] Figure 30-41-83

between port X1 and port X2 on each side of the

hydrostatic pump, to equalize the pressures on both ends
of the servo pistons.
Figure 30-41-81
1
1
1 1
P-64977
Remove drive hoses from the A and B ports (Item 1)

[Figure 30-41-83]. Plug the ports with metal caps. The
P-64425 caps must be able to handle at least 7500 PSI. Plugging
the A and B ports eliminates leakage at the drive motors
from causing errors in the pump mechanical neutral
Remove the plugs (Item 1) [Figure 30-41-81] from the setting.
MB ports on the front side of the pump, and install 7500
PSI (241 bar) pressure gauges.
T180 Bobcat Loader

438 of 961
Mechanical Neutral Adjustment (Cont’d)
Figure 30-41-84
1
P-64457
Turn the adjustment screw (Item 1) [Figure 30-41-86]

P-64457 counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the
adjustment screw.
Loosen the pump neutral adjustment lock nut (Item 1)
[Figure 30-41-84]. Figure 30-41-87

Start the loader using the remote start tool and run at an
idle.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
1
Figure 30-41-85
P-64457

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
P-64457

clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.
T180 Bobcat Loader

439 of 961
HYDROSTATIC PUMP (SJC) (CONT'D) Hydraulic Controller Neutral Adjustment
Mechanical Neutral Adjustment (Cont’d) The hydraulic controller neutral adjustment, aligns the
pump swash plate and the control spool so that a zero
Figure 30-41-88 angle control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are
adjusted or removed or after the pump mechanical
neutral setting is adjusted. Ensure the pump mechanical
neutral setting is correct before performing hydraulic
controller neutral adjustments.
NOTE: Procedure is shown for the left side hydraulic

2
controller. Procedure is the same for the right
side hydraulic controller, except you
disconnect the electrical connectors for the
right side hydraulic controller and connect
1 pressure gauges in the X1 and X2 ports on the
right side of the pump.
P-64457
Place the loader on jack stands. (See Procedure on Page
10-10-1.)
While holding the adjustment screw (Item 1) in position,
tighten the lock nut (Item 2) [Figure 30-41-88] to 22 ft.-lb.

(30 N•m) torque.
Shut loader OFF.

WARNING
Remove the hydraulic hose from the X1 and X2 ports on
the pump. Install the plugs and tighten to 18 ft.-lb. (25
N•m) torque.
Remove the pressure gauges from the MA and MB ports fall or move and cause injury or death.
on the pump. Install the plugs and tighten to 18 ft.-lb. (25 W-2017-0286
N•m) torque.
Raise the lift arms, and install an approved lift arm
NOTE: The Hydraulic Controller Neutral Adjustment support device. (See Installing Lift Arm Support Device
must be performed whenever the Mechanical on Page 10-20-1.)
Neutral Adjustment is done. (See Hydraulic
Controller Neutral Adjustment on Page 30-41- Raise the operator cab. (See Raising The Operator Cab
28.) on Page 10-30-1.)

10-60-1.)
WARNING
immediately.
W-2145-0290
T180 Bobcat Loader

440 of 961
Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-41-89
2
1
P-64975
1
Install 500 PSI pressure gauges in the X1 and X2 ports

P-64460 pertaining to the side of the hydrostatic pump you are
adjusting.
Disconnect the hydraulic controller connectors (Item 1) Figure 30-41-92

[Figure 30-41-89] from the loader wiring harness for the

hydraulic controller you are adjusting.
Figure 30-41-90
1 1
P-64459
Loosen the locking screw (Item 1) [Figure 30-41-92].

P-64458
Start the loader using the remote start tool and run at an
idle.
Remove the X1 plug (Item 1) and X2 plug (Item 2)
[Figure 30-41-90] pertaining to the side of the hydrostatic
pump you are adjusting.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
T180 Bobcat Loader

441 of 961
Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-41-93
P-64459

P-64459 clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
clockwise, until one of the gauges registers an increase Figure 30-41-96

in system pressure. Mark the position of the adjustment
screw.
2
Figure 30-41-94
P-64459
While holding the adjustment screw (Item 1) in position,

P-64459 tighten the locking screw (Item 2) [Figure 30-41-96] to
4.5 ft.-lb. (6,1 N•m) torque.
Turn the adjustment screw (Item 1) [Figure 30-41-94] Shut loader OFF.
counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the Remove the pressure gauges from the X1 and X2 ports
adjustment screw. on the pump. Install the plugs and tighten to 18 ft.-lb. (25
N•m) torque.
Connect the hydraulic controller wire connectors to the

loader wiring harness.
Perform a controller calibration procedure. (See

Hydrostatic Pump Calibration (SJC) on Page 60-160-5.)
T180 Bobcat Loader

442 of 961
DRIVE BELT Adjusting
Shield Removal And Installation To adjust the drive belt between the flywheel and the
hydrostatic pump pulley, use the following procedure:
Figure 30-50-1
Disconnect the negative (-) battery cable.
Remove the belt shield. (See Shield Removal And

The pulley tensioner is located between the flywheel and

1 pump pulley.
Figure 30-50-3
P-48001 1
2
Remove the three drive belt shield mounting clips
(Item 1) [Figure 30-50-1].

Figure 30-50-2
1 P-48478
Loosen the bolt (Item 1) [Figure 30-50-3] on the spring

loaded drive idler.
NOTE: The pointer (Item 2) [Figure 30-50-3] will be at

the 1 o'clock position when the idler is not
under spring tension.
P-48000
Remove the belt shield (Item 1) [Figure 30-50-2].
T180 Bobcat Loader

443 of 961
DRIVE BELT (CONT’D) Figure 30-50-5
Adjusting (Cont’d)
Figure 30-50-4
P-48480
Raise the idler assembly slightly so that the pulley is

P-48479 operating on spring tension and not against the stop.
Tighten the mounting bolt (Item 1) [Figure 30-50-5] to 25

Using the Belt Tensioner Bar (MEL1405) or a pry bar - 28 ft.-lb. (34 - 38 N•m) torque.
push the idler assembly against the belt, the pointer (Item

1) [Figure 30-50-4] will be at the 3 o'clock position when NOTE: Do not set the idler against the travel stop in
the idler stop is bottomed out. Do not pry directly on the the 3 o'clock position.
pulley, pry on the tensioner bracket the pulley is mounted
on. Run the engine for a few minutes.
Note: If the pointer does not move when prying on Stop the engine and recheck the pointer position.
the tensioner mounting bracket, manually
move the arrow towards the 3 o’clock position Readjust if necessary.
with a screwdriver while putting tension on
the bracket to help get it started. After the idler has been in service, readjust when the
pointer reaches the 1 o'clock position.
Install the belt shield using the fasteners.
Reconnect the negative (-) battery cable.
T180 Bobcat Loader

444 of 961
Drive Belt Replacement
Figure 30-50-6
P-48481
Remove the drive belt from the pump pulley and flywheel.
P-48000 Remove the drive belt from the loader [Figure 30-50-8].
Install the new drive belt. Install the belt tensioner

assembly.

on Page 10-30-1.) Install the fan drive belt.
Remove the negative (-) cable from the battery. The Adjust the drive belt. (See Adjusting on Page 30-50-1.)
battery may be removed for additional working clearance.
(See Removal And Installation on Page 60-20-1.) Reinstall belt shield and connect the negative (-) cable to
the battery.
Remove the belt shield [Figure 30-50-6]. (See Shield
Figure 30-50-7
P-48478
Remove the fan drive belt (Item 1) [Figure 30-50-7].
Remove the air conditioner belt if so equipped.
The belt tensioner is located between the flywheel and

pump pulley. Loosen and remove the bolt (Item 2)
[Figure 30-50-7] from the belt tensioner.
Remove the belt tensioner assembly.
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Tensioner Pulley Removal And Installation
Figure 30-50-9
1
P-48478
Loosen and remove the tensioner pulley mounting bolt

P-48000 (Item 1) [Figure 30-50-10].
Installation: Tighten the bolt to 25 - 28 ft.-lb. (34 - 38

Stop the engine. Open rear door. N•m) torque.

Remove the negative (-) cable from the battery. the Remove the belt tensioner pulley from the housing.
battery may be removed for additional working clearance.
(See Removal And Installation on Page 60-20-1.) Reverse the removal procedure to install the drive belt
tensioner.
Remove the belt shield [Figure 30-50-9]. (See Shield
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DRIVE BELT (CONT’D)
Tensioner Pulley Parts Identification
1. Cover
2. Bolt 1
3. Washer
4. Pins
5. Washer
6. Spring
2
7. Snap Ring
8. Snap Ring
9. Bearing
10. Dust Shield 11
11. Pulley 3
12. Bushing
13. Hub 12
4
14. Washer
15. Seal
16. Arrow Indicator Plate 5
17. Locating Pin
18. Spring

19. Shaft 6 13
20. Bracket
NOTE: Drive idler parts are not 5 14

available individually. Consult
parts catalog for available 15
sub-assemblies. 7
8 16
17
9
18
10
19
20
E-2296
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Tensioner Pulley Disassembly
Figure 30-50-11
3
1
1
4
P-8861
Remove the two pins (Item 1) from the hub assembly

P-8858 (Item 2) [Figure 30-50-13] only if they have been
damaged.
Remove the grease cover (Item 1) [Figure 30-50-11]. Remove the bracket assembly (Item 3) by tapping on the
shaft (Item 4) [Figure 30-50-13] with a plastic hammer.

Figure 30-50-12
Figure 30-50-14
2
3 2
1 4
P-8859
P-8862
Remove the bolt (Item 1), the flat washer (Item 2), the
retainer washer (Item 3), the spring washer (Item 4) and Remove the spring (Item 1) from the bracket (Item 2)
the second retainer washer (Item 3) from the pulley [Figure 30-50-14].
assembly (Item 5) [Figure 30-50-12].
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Tensioner Pulley Assembly
Figure 30-50-15
1
1
P-8873
2
Turn the pulley assembly over and install the two pins
P-8871 (Item 1) [Figure 30-50-17] into the hub.
Figure 30-50-18
Install the spring (Item 1) on the pulley (Item 2) [Figure
30-50-15] as shown.

Figure 30-50-16
2
3
P-8874
Install a punch as shown and turn clockwise while

P-8872 applying down pressure on the pulley.
Turn until the pulley snaps down into place; this

Install the shaft from the bracket assembly (Item 1) into procedure winds the spring and retains the end of the
the pulley assembly (Item 2) and align the spring (Item 3) spring in proper location [Figure 30-50-18].
[Figure 30-50-16] over the alignment pin on the bracket.
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Tensioner Pulley Assembly (Cont'd)
Figure 30-50-19
1
1
P-8877
Press the grease cap (Item 1) onto the pulley assembly

P-8875 (Item 2) [Figure 30-50-21]. Press on the outer formed
edge of the grease cap.
Install the first retainer washer (Item 1) and spring NOTE: When pressing the grease cap onto the pulley
washer (Item 2) over the roll pins [Figure 30-50-19]. assembly, do not press down on the arrow

indicator plate. Support the hub assembly so
Figure 30-50-20 that it contacts only the hub and not the arrow
indicator plate.
2
1
P-8876
Install the second retainer washer (Item 1), the washer

(Item 2) and the bolt (Item 3) [Figure 30-50-20]. Tighten
the bolt to 28 - 32 ft.-lb. (38 - 45 N•m) torque.
Fill the grease cap 1/4 full (approximately 1/2 - 3/4 oz.) of
grease.
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OIL COOLER Figure 30-60-2
IMPORTANT
damage the system.
I-2003-0888
N-19346
Remove the rear grill from the loader. (See Removal And
Installation on Page 50-60-1.) Figure 30-60-3
Figure 30-60-1

1
2
P-45242
N-19345
Slide the rubber sleeve in toward the radiator. The
connector will release [Figure 30-60-2] & [Figure 30-60-
Install tool MEL 1558 (Item 1) to outside of rubber sleeve 3].
(Item 2) [Figure 30-60-1].
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OIL COOLER (CONT’D)
Figure 30-60-4
1
2
1
P-45101
Disconnect the inlet and outlet hoses (Item 1) [Figure 30-

60-4] from the oil cooler (Item 2) [Figure 30-60-4].

NOTE: When installing the cooler hoses, the fittings
should make a clicking sound when pushed
together.
Lift up the oil cooler and remove the cooler from the
loader.
Reverse the removal procedure to install the oil cooler.
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DRIVE SYSTEM
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Block Disassembly And Assembly. . . . . . . . . . . . . . . . . . . 40-10-7
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-10-5
Left Motor Brake Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-3
Pressure Relief Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Right Motor Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-2
DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Track Damage Identification . . . . . . . . . . . . . . . . . . . . . . 40-20-23
Track Housing Removal And Installation . . . . . . . . . . . . . 40-20-22
Track Idler (Front) Assembly . . . . . . . . . . . . . . . . . . . . . . 40-20-11 DRIVE
Track Idler (Front) Disassembly. . . . . . . . . . . . . . . . . . . . 40-20-10 SYSTEM
Track Idler (Front) Removal And Installation . . . . . . . . . . . 40-20-7
Track Idler (Front) Parts Identification . . . . . . . . . . . . . . . . 40-20-9
Track Idler (Rear) Assembly . . . . . . . . . . . . . . . . . . . . . . 40-20-16
Track Idler (Rear) Disassembly . . . . . . . . . . . . . . . . . . . . 40-20-15
Track Idler (Rear) End Play Specifications . . . . . . . . . . . 40-20-14
Track Idler (Rear) Parts Identification . . . . . . . . . . . . . . . 40-20-14
Track Idler (Rear) Removal And Installation . . . . . . . . . . 40-20-14

Track Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-20-4
Track Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-20
Track Roller Assembly End Play Specifications. . . . . . . . 40-20-18
Track Roller Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 40-20-19
Track Roller Parts Identification . . . . . . . . . . . . . . . . . . . . 40-20-18
Track Roller Removal And Installation . . . . . . . . . . . . . . . 40-20-18
Track Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Track Tension Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1


ITEMS MAY VARY.
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BRAKE Figure 40-10-2
Pressure Relief Valve Test
WARNING
1
AVOID INJURY OR DEATH 2
enters skin or eyes, get immediate medical attention P-43987
W-2072-0807
Install a cap (Item 1) [Figure 40-10-2] onto the A1 fitting
on the brake block.
WARNING Connect the port-a-power to the A2 port (Item 2) [Figure

40-10-2] on the brake block.

AVOID INJURY OR DEATH Pump the port-a-power up to 500 PSI or more and verify
Always clean up spilled fuel or oil. Keep heat, flames, that the pressure relief valve will open at approximately
sparks or lighted tobacco away from fuel and oil. 500 PSI.
explosion or fire. If the pressure relief valve does not open at
W-2103-0508 approximately 500 PSI, replace. If the pressure relief
valve does open, continue with the following to check if
Figure 40-10-1 the pressure relief valve will hold pressure.
Release pressure and pump the port-a-power up to 400

PSI and verify that the pressure relief valve will hold
pressure. Pressure should not drop more than 80 PSI in
2 minutes.
If the pressure relief valve does not hold pressure,

replace. If the pressure relief valve holds pressure,
continue to check the right and left brakes in the motors.
1
2
P-43982

A2 port on the brake block.

from the A1 port on the brake block.
NOTE: Pressure relief valve is set to 500 PSI.
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BRAKE (CONT’D) Figure 40-10-4
Right Motor Brake Test
Figure 40-10-3 1
1 2
P-43984
2
Connect the port-a-power and gauge to the right motor
P-43982 power assist hose (Item 1) [Figure 40-10-4].
Drain the right motor brake release hose (Item 2) [Figure

Mark and disconnect the right motor brake release hose 40-10-4] into a container.
(Item 1) [Figure 40-10-3] from the A2 fitting on the brake

block. Pump the port-a-power up to 400 PSI (Max. 435 PSI).
Verify that the power assist holds pressure and hydraulic
Mark and disconnect the right motor power assist hose fluid flows from the brake release hose.
block. If the brake does not hold pressure and/or hydraulic fluid
does not flow, the motor needs to be removed and
serviced.
WARNING If the power assist holds pressure and hydraulic fluid

flows from brake release hose, then brake is okay.

W-2072-0807
WARNING
explosion or fire.
W-2103-0508
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BRAKE (CONT’D) Left Motor Brake Test
Right Motor Brake Test (Cont'd)
Figure 40-10-5
WARNING
1 penetrate skin or eyes, causing serious injury or
2 W-2072-0807
P-43983
WARNING
Connect the port-a-power and gauge to the right motor
brake release hose (Item 1) [Figure 40-10-5].

Drain the right motor power assist hose (Item 2) [Figure
40-10-5] into a container.
explosion or fire.
W-2103-0508
Pump the port-a-power up to 400 PSI (Max. 435 PSI).
Verify that the brake release holds pressure and Figure 40-10-6
hydraulic fluid flows from the power assist hose.
If the brake does not hold pressure and/or hydraulic fluid

serviced.
If the brake holds pressure and hydraulic fluid flows from

power assist hose, then brake is okay. 2
1
P-43982
Mark and disconnect the left motor power assist host

block.
Mark and disconnect the left motor brake release (Item 2)

[Figure 40-10-6] from the B2 fitting on the brake block.
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BRAKE (CONT’D)
Left Motor Brake Test (Cont'd) WARNING

Figure 40-10-7
explosion or fire.
W-2103-0508
Figure 40-10-8
1
1
2
P-43985
Connect the port-a-power and gauge to the left motor

power assist hose (Item 1) [Figure 40-10-7].

Drain the left motor brake release hose (Item 2) [Figure
40-10-7] into a container. 2
P-43986
Pump the port-a-power up to 400 PSI (Max. 435 PSI).
Verify that the power assist holds pressure and hydraulic
fluid flows from the brake release hose. Connect the port-a-power and gauge to the left motor
brake release hose (Item 1) [Figure 40-10-8].
If the brake does not hold pressure and/or hydraulic fluid
does not flow, the motor needs to be removed and Drain the left motor power assist hose (Item 2) [Figure
serviced. 40-10-8] into a container.
If the power assist holds pressure and hydraulic fluid Pump the port-a-power up to 400 PSI (Max. 435 PSI).
flows from brake release hose, then brake is okay.
Verify that the brake release holds pressure and
hydraulic fluid flows from the power assist hose.
WARNING If the brake does not hold pressure and/or hydraulic fluid
serviced.
Diesel fuel or hydraulic fluid under pressure can If the brake release holds pressure and hydraulic fluid
penetrate skin or eyes, causing serious injury or flows from power assist hose, then brake is okay.
W-2072-0807
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BRAKE (CONT’D)
Block Removal And Installation

WARNING
DANGER Diesel fuel or hydraulic fluid under pressure can
W-2072-0807
P-90328
•
AVOID DEATH
Disconnecting or loosening any hydraulic
WARNING
can cause lift arms to drop. AVOID INJURY OR DEATH
• Keep out of this area when lift arms are raised Always clean up spilled fuel or oil. Keep heat, flames,
unless supported by an approved lift arm sparks or lighted tobacco away from fuel and oil.
support. Replace if damaged. Failure to use care around combustibles can cause

explosion or fire.
D-1009-0409
W-2103-0508
WARNING
W-2059-0598
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Block Removal And Installation (Cont’d)
Figure 40-10-9 1
5 6
4
1
P-43999
3
7 Remove the bolts (Item 1) [Figure 40-10-10] from the
2 P-43982 bracket and remove the brake block.

10-20-1.)

on Page 10-30-1.)
Drain the hydraulic reservoir. (See Removal And

Disconnect the electrical wire harness connector (Item 1)

[Figure 40-10-9].
Mark the hydraulic hoses on the brake block for proper

installation.
Remove and cap the charge pressure hose (Item 2)

[Figure 40-10-9] from the brake block.
Remove and cap the case drain hose (Item 3) [Figure

40-10-9] from the brake block.
Remove and cap the right power assist hose (Item 4)

Remove and cap the right brake release hose (Item 5)

Remove and cap the left brake release hose (Item 6)

Remove and cap the left power assist hose (Item 7)

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Block Disassembly And Assembly
Figure 40-10-11
P-43995
1
Inspect the O-rings and back-up washers on the solenoid
P-43993 valve and replace as needed [Figure 40-10-13].
Assembly: Tighten the solenoid valve to 20 ft.-lb. (27,1

Loosen the electrical brake solenoid nut (Item 1) [Figure N•m) torque.
40-10-11].

Figure 40-10-14
Assembly: Tighten the solenoids nut to 5 ft.-lb. (6,8 N•m)
torque.
Figure 40-10-12
1
3
2
1
P-43996
2
Remove the relief valve (Item 1) and the check valve
P-43994 (Item 2) [Figure 40-10-14] from the brake block.
Remove the solenoid nut (Item 1) [Figure 40-10-12] and

solenoid coil (Item 2) [Figure 40-10-12].
Remove the solenoid valve (Item 3) [Figure 40-10-12]

from the block.
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Block Disassembly And Assembly (Cont’d)
Figure 40-10-15
P-43998
Inspect the O-rings and back-up washers on the check

P-43997 valve and replace as needed [Figure 40-10-16].
Assembly: Tighten the check valve to 12 - 14 ft.-lb. (16 -

Inspect the O-rings and back-up washers on the relief 19 N•m) torque.
valve and replace as needed [Figure 40-10-15].

Assembly: Tighten the relief valve to 20 ft.-lb. (27,1 N•m)
torque.
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DRIVE COMPONENTS Lift and block the loader. (See Procedure on Page 10-10-
1.) Be sure the jackstands do not touch the tracks.
Track Tension
NOTE: When the loader is on jackstands be sure the
bottom of the track clears the floor by at least
3 in. (76 mm).
WARNING Measure the track sag at the middle track roller [Figure
40-20-1]. DO NOT put your fingers into the pinch points
AVOID INJURY between the track and the roller. Use a 1/2 to 5/8 in. bolt,
Keep fingers and hands out of pinch points when dowel or block to check the gap (Item 1) [Figure 40-20-
checking the track tension. 1], & [Figure 40-20-2].
W-2142-0903
Track Tension Adjusting
Figure 40-20-1
Increase Track Tension
1 Figure 40-20-3
P-28176A

P-45250
Figure 40-20-2 N-18491

procedure:
MEL1560- Bleed Tool [Figure 40-20-3].
1/2-5/8 in. Track

(13-16 mm) Roller
Track P-13810A
Track tension is important for good performance and to

prevent the tracks from derailing.
NOTE: The wear of track rollers vary with the working

conditions and different types of soil
conditions.
Park the loader on a level surface.
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DRIVE COMPONENTS (CONT'D) Figure 40-20-5
Track Tension Adjusting (Cont'd) Right Side Shown
Increase Track Tension (Cont'd)
Figure 40-20-4
P-28179
1
NOTE: The grease cylinder used on the left side of
the loader is identical to the cylinder on the
right side. When the cylinder is located on the
P-28178 left side, the adjustment fitting is the lower
fitting; on the right side it is the upper fitting.

Loosen the two mount bolts (Item 1) [Figure 40-20-4] Add grease to the adjustment fitting (Item 1) [Figure 40-
from the covers. 20-5] (lower fitting on left side, upper fitting on right
side) until the track adjustment is correct [Figure 40-20-
1] & [Figure 40-20-2].
NOTE: Do not remove adjustment fitting (Item 1)

[Figure 40-20-5] unless pressure is released.
(See Track Tension Adjusting on Page 40-20-
1.)
NOTE: If replacement is necessary, always replace

adjustment fitting (Item 1) [Figure 40-20-5]
with genuine Bobcat Parts. It is a special
fitting designed for high pressure.
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Track Tension Adjusting (Cont'd)
Figure 40-20-6
1
Right Side
P-28182
Pivot the track cover (Item 1) [Figure 40-20-8] against

P-26945 the MEL tool and lock the mount bolt (Item 2) [Figure 40-
20-8].
NOTE: There are stop blocks (Item 1) [Figure 40-20-6] Turn the tool 1/4 turn counterclockwise and let the grease
that keep the cylinders from turning. If the flow into a container. Turn the tool one additional turn to

cylinders turn, the fittings will not be continue to release pressure.
accessible. Check the stop block bolts to be
sure they are tight. Raise the loader. Remove the jackstands.
Decrease Track Tension Repeat the procedure for the other track.
Figure 40-20-7 Dispose of the grease in an environmentally safe

manner.
P-28179
Pressure must be released from the spring and

adjustment cylinder to decrease track tension.
Install the bleed tool (MEL1560) on the bleed fitting (Item

1) [Figure 40-20-7] (upper fitting on left side, lower
fitting on right side), adjust and tighten the collar to fit
behind the edge of the access hole and the cover.
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Track Removal And Installation
Figure 40-20-9
P-28180
Pivot the covers downward [Figure 40-20-11].

N-18491
Figure 40-20-12

procedure:

MEL1560- Bleed Tool [Figure 40-20-9].
Figure 40-20-10 1
P-28181
1 Install the MEL1560 tool on the bleed fitting [Figure 40-

1 20-12].
Be sure the collar (Item 1) [Figure 40-20-12] is

P-28178 positioned behind the track housing plate.

1.)
NOTE: When the loader is on jackstands be sure the

bottom of the track clears the floor by at least
3 in. (76 mm).
Loosen the four mount bolts (Item 1) [Figure 40-20-10]

from the covers.
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Track Removal And Installation (Cont'd)
Figure 40-20-13
P-28183
2
With a bar pry, move the front idler assembly toward the
P-28182 rear of the track assembly until all track tension has been
released [Figure 40-20-14].
Pivot the track cover (Item 1) [Figure 40-20-13] against Figure 40-20-15
the MEL tool and lock the mount bolt (Item 2) [Figure 40-

20-13].
Give the MEL tool/bleed fitting a 1/4 turn,

counterclockwise to release the pressure from the spring
assembly.
Turn the MEL tool/bleed fitting one more complete turn

counterclockwise.
IMPORTANT
P-28184A
Fluid such as engine oil, hydraulic fluid, coolants,
grease, etc. must be disposed of in an
environmentally safe manner. Some regulations With pry bars, pry the track up and over the front idler
require that certain spills and leaks on the ground [Figure 40-20-15].
must be cleaned in a specific manner. See local, state
and federal regulations for the correct disposal. Turn the MEL tool/Bleed fitting clockwise to close fitting.
I-2067-0499
Remove the MEL1560 tool.
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Track Removal And Installation (Cont'd)
Figure 40-20-16
P-45328
With a chain hoist or arm hoist lift the track clear of the
P-28186 drive sprocket and remove the track from the loader
[Figure 40-20-18].
NOTE: To protect your hands from injury always NOTE: Hydrostatic motor oil should be changed with
wear gloves before removal or installation of any track removal. (See Replacing the Motor

the track. Oil on Page 30-20-1 or See Replacing the
Motor Oil on Page 30-21-1 [SJC])
Completely remove the track from the front track
assembly [Figure 40-20-16]. To install the rubber track:
Figure 40-20-17 Completely retract the front idler/spring assembly.
Put the track over the rear drive sprocket lugs.
Put the track over the rear idler.
Slide the track under the rollers.
Put the track on the front idler wheel.
Adjust the track to the proper tension.(See Track Tension

Adjusting on Page 40-20-1.)
1
NOTE: The grease cylinder must be completely
retracted against the spring assembly block
P-28187 before adding grease, to prevent air from
being trapped in the grease cylinder.
With a pry bar slide the track clear of the rear idler (Item
1) [Figure 40-20-17].
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Track Idler (Front) Removal And Installation
Figure 40-20-19
P-28194
1 Remove the track tensioner [Figure 40-20-21] from the

P-28191 track housing.
NOTE: When installing the track tensioner, make

Lift and block the loader. (See Procedure on Page 10-10- sure the grease fittings are pointed to the
1.) outside of the track frame.

on Page 40-20-4.)
Install a chain hoist on the front idler.
Slide the front track idler out of the track frame [Figure
40-20-19].
NOTE: The short side of the block (Item 1) [Figure 40-

20-19] is toward the bottom of the track
housing for installation.
Figure 40-20-20
P-28190
Installation: Make sure the tabs (Item 1) [Figure 40-20-

20] engage the holes (Item 2) [Figure 40-20-20] and
(Item 1) [Figure 40-20-21] on the track tensioner block.
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Track Idler (Front) Removal And Installation (Cont'd)
WARNING 2
3
1
N-18079
P-62574
Remove the seal (Item 1), O-ring (Item 2) and back-up

AVOID INJURY OR DEATH ring (Item 3) from the cylinder [Figure 40-20-23].
• Spring loaded components under pressure can
cause serious injury or death. Installation: Apply oil to the O-ring, back-up ring and
• Do not disassemble the coil spring assembly. seal before installation.
W-2617-1004

Figure 40-20-24
Figure 40-20-22
P-28196
P-28195
NOTE: The grease cylinder (Item 1) [Figure 40-20-22]

Remove the cylinder (Item 1) [Figure 40-20-22] from the must be completely retracted against the
shaft. spring assembly block (Item 2) [Figure 40-20-
22] before adding grease, to prevent air from
being trapped in the grease cylinder.
DO NOT DISASSEMBLE OR REPAIR THE COIL

SPRING ASSEMBLY. THE COMPRESSION FORCE OF
THE SPRING EXCEEDS 10,000 LB.
The coil spring assembly (Item 1) [Figure 40-20-24] is

only sold as a complete unit from Bobcat Parts.
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DRIVE COMPONENTS (CONT'D)
Track Idler (Front) Parts Identification
1 2
8
3

4
5 6
7 5 4 8 1
3
TRACK IDLER (Front)
1. Block
2. Idler
3. Seal
4. Snap Ring
5. Bearing
6. Roll Pin
7. Axle
8. Cover
PE1221
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Track Idler (Front) Disassembly
Figure 40-20-25
1
P-37967
Remove the seal (Item 1) [Figure 40-20-27] using a

N-18373 screwdriver. (Both sides of the idler.)
Figure 40-20-28
Drive the roll pin (Item 1) [Figure 40-20-25] into the
block. Remove the roll pin. (Both sides of the idler.)

Remove the block (Item 2) [Figure 40-20-25] from the
axle shaft. (Both sides of the idler.) 1
Figure 40-20-26
P-37968
Remove the snap ring (Item 1) [Figure 40-20-28]. (Both

sides of the idler.)
P-37966
Remove the seal cover (Item 1) [Figure 40-20-26] from

the idler. (Both sides of the idler.)
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DRIVE COMPONENTS (CONT'D) Track Idler (Front) Assembly
Track Idler (Front) Disassembly (Cont'd) Figure 40-20-31
Figure 40-20-29
N-18378
N-18376
Press a new bearing into the idler [Figure 40-20-31].
In a press, press the idler axle shaft (Item 1) [Figure 40- Figure 40-20-32
20-29] and one bearing from the idler.

Remove the bearing from the axle shaft.
2
Check axle shaft for wear and replace if needed.
1
Figure 40-20-30
P-37968
Install a snap ring (Item 1) [Figure 40-20-32] to retain the

bearing.
Install the axle shaft (Item 2) [Figure 40-20-32] into the

N-18377 bearing from the opposite side of the idler.
Turn the idler over and press the other bearing out, using
a bearing driver tool [Figure 40-20-30].
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Track Idler (Front) Assembly (Cont'd)
Figure 40-20-33
P-37969
With a seal driver, install the seal (Item 1) [Figure 40-20-

N-18380 35] into the idler. (Both sides.)
NOTE: The seals must be installed, so they are

Place the idler, bearing, and axle shaft assembly in a seated against the hub of the idler without
press. distorting the seal surface.

Using a bearing driver tool, press a new bearing over the Figure 40-20-36
axle shaft into the front idler [Figure 40-20-33].
Figure 40-20-34
P-37966
P-37968 Install the seal cover (Item 1) [Figure 40-20-36] on the

idler axle shaft. (Both sides of the idler.)
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Track Idler (Front) Assembly (Cont'd)
Figure 40-20-37
N-18383
Install the block (Item 1) [Figure 40-20-37] on the idler

axle shaft and drive the roll pin (Item 2) [Figure 40-20-

37] through the axle shaft. (Both sides of the idler.)
The two blocks must point in the same direction.
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DRIVE COMPONENTS (CONT'D) Track Idler (Rear) Removal And Installation
Track Idler (Rear) End Play Specifications Remove the track. (See Track Removal And Installation
on Page 40-20-4.)
LIft and block the loader. (See Procedure on Page 10-10-
1.) Figure 40-20-38

on Page 40-20-4.)
Attach a dial indicator to the track housing frame and

measure the rear idler end play. The specifications are as
follows:
1
Min:.006 1
Nominal:.027
Max:.048
2 3
P-37965 P-37964
Remove the two mount bolts (Item 1) [Figure 40-20-38].

Remove the rear idler from the loader.
Installation: Align the square sides of the idler shaft

(Item 2) [Figure 40-20-38] with the notches in the track
Align the holes in the frame with the holes in the shaft.
Install the bolts and tighten to 190 ft.-lb. (257,6 N•m)

torque.
Track Idler (Rear) Parts Identification
5
1
2
3 4
TRACK IDLER (Rear)
1. Cover 6
2. Seal 4
3 2
3. Snap Ring 1
4. Bearing
5. Idler
6. Axle
PE1569
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Track Idler (Rear) Disassembly
Figure 40-20-39
1
P-37972
Remove the snap ring (Item 1) [Figure 40-20-41]. (Both

P-37970 sides of the rear idler.)
Figure 40-20-42
the rear idler. (Both sides of the rear idler.)

Figure 40-20-40
N-18386
In a press, press the axle shaft and one bearing from the
P-37971 rear idler [Figure 40-20-42].
Remove seal (Item 1) [Figure 40-20-40]. (Both sides of

the rear idler.)
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Track Idler (Rear) Disassembly (Cont’d)

2
Figure 40-20-43
P-37972
Install a snap ring (Item 1) [Figure 40-20-45].

N-18387
Install the axle shaft (Item 2) [Figure 40-20-45] into the
idler from the opposite side.
Turn the rear idler over and press the old bearing out
[Figure 40-20-43]. Figure 40-20-46

Check the idler and replace as needed.
Track Idler (Rear) Assembly
Figure 40-20-44 1
N-18390
Place the idle, bearing and axle shaft assembly in a

press.
N-18388 Press a new bearing (Item 1) [Figure 40-20-46] over the

axle shaft into the rear idler.
Install a new bearing into the rear idler using a press and
bearing driver tool [Figure 40-20-44].
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Track Idler (Rear) Assembly (Cont’d)
Figure 40-20-47
1
P-37970
Install the seal cover (Item 1) [Figure 40-20-49].

P-37972
Install the rear idler assembly in the track housing and
install the two mount bolts.
Install a snap ring (Item 1) [Figure 40-20-47].

Figure 40-20-48
P-37973

48] in the rear idler. (Both sides of the rear idler.)

seated against the hub of the idler without
distorting the seal surface.
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DRIVE COMPONENTS (CONT'D) Track Roller Removal And Installation
Track Roller Assembly End Play Specifications Lift and block the loader. (See Procedure on Page 10-10-
1.)
LIft and block the loader. (See Procedure on Page 10-10-
1.) Remove the track. (See Track Removal And Installation
on Page 40-20-4.)
on Page 40-20-4.) Figure 40-20-50
Attach a dial indicator to the track housing frame and

measure the front idler end play. The specifications are
as follows:
Min:.006 1
1 1
Nominal:.027
Max:.048
N-18082

Remove the nuts (Item 1) [Figure 40-20-50] from the
roller shaft. (Both ends of the roller shaft.)
Installation: Tighten the nuts to 300 - 330 ft.-lb. (406,8 -

443,5 N•m) torque.
Remove the roller from the track assembly.

Track Roller Parts Identification
1
2 5
3 4
TRACK ROLLER
1. Cover
2. Seal
3. Snap Ring
6
4. Bearing 4
3 2 1
5. Roller
6. Axle
PE1570
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Track Roller Disassembly
Figure 40-20-51
P-37976

P-37974 the roller. (Both sides of the roller.)
Figure 40-20-54
the roller.

Figure 40-20-52
N-18360
Place the mounting nut (Item 1) [Figure 40-20-54] on the

P-37975 shaft.
With a press, press the axle shaft and one bearing from
Remove the seal from the roller (Item 1) [Figure 40-20- the roller [Figure 40-20-54].
52]. (Both sides of the roller.)
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Track Roller Disassembly (Cont'd)
Figure 40-20-55
P-37976
Install a new snap ring (Item 1) [Figure 40-20-57] into

N-18361 the roller.
Install the axle shaft into the bearing from the opposite
Turn the roller to the opposite end. side [Figure 40-20-57].

With a bearing driver tool press the remaining bearing out Figure 40-20-58
of the roller [Figure 40-20-55].
Track Roller Assembly
Figure 40-20-56
N-18363
Set in press with axle shaft up [Figure 40-20-58].
N-18362
Check the roller for wear and replace as needed.
Press a new bearing into the roller [Figure 40-20-56].
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Track Roller Assembly (Cont'd)
Figure 40-20-59
P-37976

P-37978
Figure 40-20-62
Install a new bearing (Item 1) [Figure 40-20-59] over the

axle shaft.

Figure 40-20-60
P-37977

62] into the roller. (Both sides of the roller.)
N-18365
seated against the hub of the roller without
With a bearing driver tool and a press, press a new distorting the seal surface. [Figure 40-20-62]
bearing into the roller [Figure 40-20-60].
Install the seal cover on the roller. (Both sides of the
roller.)
Install the roller assembly in the track housing.
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DRIVE COMPONENTS (CONT'D) Remove the four rear mounting bolts (Item 1) [Figure 40-
20-64] from the track housing mount plate.
Track Housing Removal And Installation
Figure 40-20-65
Figure 40-20-63
2
1
2
P-28211
P-28199
At the rear of the loader remove the two mount bolts

Lift and block the loader. (See Procedure on Page 10-10- (Item 1) [Figure 40-20-65].
1.)

Installation: Tighten the two mounting bolts to 300 - 330
NOTE: Position the jackstand (Item 1) [Figure 40-20-
ft.-lb. (410 - 450 N•m) torque.
63] at the front of the loader to allow for track
housing removal.
Figure 40-20-66
Remove the track from the loader. (See Track Removal
1
Remove the hydrostatic motor from the track housing.
(See Removal And Installation on Page 30-20-2 or See
Removal And Installation on Page 30-21-2 [SJC])
Support the track housing.
Remove the four front mounting bolts (Item 2) [Figure

40-20-63] from the track housing mount plate.
Figure 40-20-64
P-28201
1 At the front of the loader remove the two mounting bolts

(Item 1) [Figure 40-20-66].
Remove the track housing from the loader.
Installation: Tighten the two mounting bolts to 300 - 330

ft.-lb. (410 - 450 N•m) torque.
1
P-28200
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Track Damage Identification
Cutting Of Steel Cords
Figure 40-20-67
PI-13035
Causes of the damage:
When applied to rubber tracks under the following

P-3864 circumstances, tension in excess of the breaking strength
of the embedded steel cords causes steel cords to be
cut:

Figure 40-20-68
When the rubber track is detracking, the idler or
sprocket rides on the projections of the embedded
metal [Figure 40-20-69].
When the rubber track is detracked, projections of

rubber tracks get stuck between the frame of the
undercarriage.
The rubber track is clogged with stones or foreign

obstacles.
Furthermore, when moisture invades through a cut on

the lug side rubber surface, the embedded steel cords
Steel Cords will corrode. The deterioration of the design strength may
PI-13034 lead to the breaking off of the steel cords.
Prevention:
The following pages show photos and illustrations of
track damage and the probable cause of the damage. It The following preventions should be taken to minimize
is intended to be used for identifying the reason for track the risk of this damage:
damage and how to avoid future track damage.
Periodical checking on site of the recommended track
Damage: tension. (See Track Tension on Page 40-20-1.)
Embedded steel cords are cut off [Figure 40-20-67] Avoiding quick turns on bumpy and rocky fields.
& [Figure 40-20-68].
Drive carefully to avoid having stones and other
Replacement: articles clog the rubber tracks.
Replacement is required [Figure 40-20-67] & [Figure Driving over sharp objects should be avoided. If this
40-20-68]. is impossible, do not make turns while driving over
sharp objects.
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Track Damage Identification (Cont'd)
Abrasion Of Embedded Metals

Abrasion
Figure 40-20-70
D D1=0.67D
PI-13037
Replacement:
Replacement is required when the width of the

P-3865 embedded metals (D1) becomes 67% of their original
width (D) [Figure 40-20-71].

Damage: Causes of the damage:
In proportion to the service time, embedded metals When the track rollers, sprockets and idler gears roll over
will gradually wear away by friction [Figure 40-20-70]. the embedded metals, abrasion of embedded metals is
inevitable. The following cases sometimes accelerate
their abrasion:
Rubber tracks are driven with an extraordinary heavy

load on them.
Rubber tracks are used on sandy fields.
Prevention:
As long as rubber tracks are used under normal

operating conditions, abnormal abrasion is unlikely to
occur. The level of abrasion should be carefully checked
when the machines are used for dozing which generate a
heavy load for rubber tracks, and when they are operated
under a sandy field condition for a long time.
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Separation Of Embedded Metals

Guide
Figure 40-20-72
PI-13040
When a rubber track is detracked, it becomes stuck

between the guide or the undercarriage frame,
causing the separation of embedded metals [Figure
P-4379 40-20-74].

Damage:
Extraordinary outer forces applied to embedded
metals cause their separation from the rubber track's
body [Figure 40-20-72].
Replacement:
Even a partial separation of embedded metals
requires replacement of the track.
Figure 40-20-73
Idler
Rubber
track
PI-13039

Embedded metals are adhered between the steel cords
and the rubber body. The following cases generate
external forces greater than the adhesion strength,
causing separation of the embedded metals:
When the idler continually rides on the projections of

embedded metals, the embedded metals will
eventually peel off [Figure 40-20-73].
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DRIVE COMPONENTS (CONT'D) Separation Of Embedded Metals Due To Corrosion
Track Damage Identification (Cont'd) Figure 40-20-76
Separation Of Embedded Metals (Cont’d)
Figure 40-20-75
Abrasion
P-4378
Damage:
PI-13041
Due to corrosion of embedded metals, the adhesion
to the rubber body deteriorates, resulting in complete

Abnormally worn sprockets as shown will pull separation [Figure 40-20-76].
embedded metals out [Figure 40-20-75].
Replacement:
Prevention:
Even a partial separation of embedded metals
Similar to the prevention against the cutting of the steel requires a rubber track replacement.
cords:
Recommended track tension should be periodically

checked. (See Track Tension on Page 40-20-1.)
Quick turns on bumpy and rocky fields should be

avoided.
If abnormal wear of sprockets is observed, they

should be immediately replaced.
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DRIVE COMPONENTS (CONT'D) Cuts On The Lug Side Rubber
Track Damage Identification (Cont'd) Figure 40-20-78
Figure 40-20-77
Embedded metal
Good
Separation of
bonded rubber
cover P-4377
PI-13043
Damage:
Causes of the damage: Cuts on the lug side rubber often occurs as one of the
most typical failure modes [Figure 40-20-78].

Embedded metals are bonded to the rubber body. The
following operating conditions cause embedded metals Replacement:
to corrode, causing deterioration of the bonding, and
finally resulting in separation of the embedded metals When a cut on the lug side rubber reaches the
from the rubber body [Figure 40-20-77]. embedded steel cords, it should be immediately
repaired with cold vulcanization rubber.
Excessively salty fields, like the sea shore
Strong acidic or alkali soil conditions
Compost spread grounds
On tracks that are out of adjustment, the track rollers,

idlers and sprockets will gradually wear the rubber
surface at track roller side, causing exposure of the
embedded metals. Consequently the embedded metals
will corrode resulting in their separation from the rubber
body.
Prevention:
If rubber tracks are used under such field conditions as

described under (Causes of the damage), they should be
washed with plenty of water. After being completely
dried, they should be stored correctly.
When the bonded rubber cover is separated from the

embedded metal projections and the metals in the rubber
body become loose, it is time to consider replacement of
the rubber track.
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Figure 40-20-79
Cuts
PI-13045

When rubber tracks drive over projections or sharp
stones in the fields, the concentrated forces applied
cause cuts on the lug side rubber surface. In case of
making turns on projections, the lug side rubber surface
will have an even higher chance to be cut. If the cuts run
through the embedded steel cords, it might result in the
steel cords' breakage due to their corrosion. It is highly
recommended to repair the cuts with cold vulcanization
rubber as soon as they are observed [Figure 40-20-79].
Prevention:
Machine operators are requested to drive with great

attention to the ground's surface especially in terrains of
the following type:
Construction sites
Demolition sites
Paths covered with rocks and wood
Concrete ridges
Stumpy fields
When operating on terrains as mentioned above, high

speed, quick turns and overloading should be avoided.
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DRIVE COMPONENTS (CONT'D) Causes of the damage:
Track Damage Identification (Cont'd) Because of wound stress applied to rubber tracks around
the undercarriage parts during operation, the fatigue
Cracks On The Lug Side Rubber Due To Fatigue especially causes cracks on the lug side rubber surface.
Once the cracks occur, they gradually deteriorate with
Figure 40-20-80 even small external cracks. Also when operating near
seashores or under cold temperatures, rubber tracks are
more likely to suffer from ozone cracks.
Prevention:
Rubber tracks are designed with special rubber

compounds to prevent cracks due to fatigue. However,
external injuries on the lug side rubber sometimes cause
more chance of cracking. Machine operators should
observe soil conditions when driving, so as not to cause
external injuries to the lug side rubber. In order to
minimize the occurrence of ozone cracks, attention
should be paid to the following instructions for
maintenance:
P-4382
Avoid exposing stored tracks to direct sun light.

Figure 40-20-81 Avoid exposing stored tracks to direct rain and snow
fall.
Store tracks in well ventilated warehouses.
Use the tracks at least once a month.
P-4380
Damage:
Small cracks around the root of the lug as a result from

operation fatigue [Figure 40-20-80] & [Figure 40-20-81].
Replacement:
When the cracks reach so deep that they expose the

steel cords, track replacement is required.
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DRIVE COMPONENTS (CONT'D) Replacement:
Track Damage Identification (Cont'd) No replacement is required.
Lug Abrasion Causes of the damage:
Figure 40-20-82 Lug abrasion is more or less inevitable. Even if lug

abrasion is proceeding, the rubber track can be used.
However, as the traction performance deteriorates
accordingly, it is highly recommended to replace the
abraded tracks with new ones when the lug height
becomes less than 5 MM.
Prevention:
In order to prevent the rubber track from abnormal or

premature abrasion, the following operating conditions
should be avoided:
Making quick and repeated turns on concrete and

asphalt roads
P-4381
Driving up and down hilly paths with slippage

Figure 40-20-83 Making frequent turns on paths covered with rocks
and wood
Lug abrasion
PI-13049
Damage:
As its service time proceeds, the lug side inevitably

undergoes abrasion [Figure 40-20-82] & [Figure 40-
20-83].
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Cracks And Cuts On The Lug Side Rubber

Crack at the edge of Cut on lug side
Figure 40-20-84 embedded metal rubber
PI-13051
When rubber tracks drive over sharp projections,

CD-13050 intensive stress is applied to the lug side rubber surface,
especially at the edges of embedded metals, causing
cracks and cuts in the area around the embedded metals

Damage: [Figure 40-20-85].
Sometimes cracks and cuts on the lug side rubber at Prevention:

the edges of the embedded metals can be observed
[Figure 40-20-84]. To avoid extensive stress applied to the lug root where
metals are embedded, machine operators are requested
Replacement: to avoid driving over stumps and ridges.
Basically, no replacement is required unless the cuts on

the lug side rubber are discovered all around the edges
of the embedded metals, as this will result in a complete
cut off.
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Abrasion Of The Track Roller Side

Track roller
Figure 40-20-86
Abrasion
PI-13053
The abrasion of the track roller side rubber surface

P-4383 occurs because of sand and gravel being clogged
between the rubber and the outside surface of the track
rollers. The stress pushes the sand and gravel against

Damage: the side of the rubber track to cause the abrasion [Figure
40-20-87].
The rubber surface on which track rollers run is
gradually abraded. It will end in the exposure of the The level of abrasion is highly dependent on terrain
embedded metals [Figure 40-20-86]. conditions. A higher level of abrasion will occur when the
rubber tracks are operated in fields covered with many
Replacement: stones and gravel. Small stones hardened with mud,
stuck to the track rollers increase the abrasion level. After
It is recommended to replace the rubber track when an extended period of abrasion, it will be more likely for
more than half of the embedded metals are exposed embedded metals to catch moisture through the
completely exposed. inside steel cords, which can cause breakage of steel
cords and separation of the metals from the rubber body.
Prevention:
After operation in wet fields containing many small

stones, wash off the mud that is stuck to the track rollers
completely. When operating on gravel paths and stony
grounds, machines should be driven slowly and the
turning radius should be big enough to prevent stones
and gravel from getting stuck to the track roller side
rubber.
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494 of 961
Cuts On The Edges Of Track Roller Side
Figure 40-20-88
PI-13056
This damage is caused by objects on the field or by

P-4384 interference with the machine frame.
In case of damage by objects on the operating ground:

Figure 40-20-89
The edges of rubber track are often deformed largely
due to a bumpy ground surface, stones and other
objects, which cause extensive stress on the edges
resulting in the damage. Especially, when a machine
drives over concrete ridges, this type of damage
Edge Edge easily occurs [Figure 40-20-90].
PI-13055
Damage:
Both edges of a rubber track have no special

reinforcements. It sometimes occurs during operation
that they are cut or torn off [Figure 40-20-88] &
[Figure 40-20-89].
Replacement:
In such case, the rubber track does not have to be

replaced.
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495 of 961
Cuts On The Edges Of Track Roller Side
Figure 40-20-91
Cut
Tear
PI-13057

In case of damage by interference with the machine
frame
If a machine continues operating with rubber tracks

being detracked, the rubber tracks may get caught up
in the machine frame or undercarriage parts resulting
in damage. Furthermore, when a machine travels
along side slopes, the rubber tracks are deformed so
much that they come into contact with the machine
frame and undercarriage parts, which causes cutting,
gouging and rubbing of rubber tracks in the end
[Figure 40-20-91].
Prevention:
When traveling, a machine operator should be careful not

to drive over any projections on the ground. He should
also prevent rubber tracks from coming into contact with
concrete walls, ditches and ridges. If rubber tracks are
detracked, the machine should be stopped immediately
for retracting.
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MAIN FRAME
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1 SAFETY &
MAINTENANCE
CONTROL HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Control Lever Removal And Installation. . . . . . . . . . . . . . . . . . . . . 50-110-1
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE

HAND/FOOT CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1 DRIVE
Control Handle Disassembly and Assembly . . . . . . . . . . . . . . . . . 50-111-6 SYSTEM
Control Handle Removal and Installation. . . . . . . . . . . . . . . . . . . . 50-111-5
Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-8
Control Lever Removal and Installation . . . . . . . . . . . . . . . . . . . . . 50-111-6
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . 50-111-2 MAIN FRAME
CONTROL HANDLE (SELECTABLE JOYSTICK CONTROL) (SJC) . 50-112-1

Joystick Removal (Right & Left). . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-2

ELECTRICAL
Joystick Testing (Right & Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1 SYSTEM &
Lever Assembly Removal (Right & Left) . . . . . . . . . . . . . . . . . . . . 50-112-3 ANALYSIS
CONTROL PANEL (ADJUSTABLE PINTLES) . . . . . . . . . . . . . . . . . . 50-101-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1 ENGINE
Linkage Neutral Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-13 SERVICE
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-7
Linkage Travel Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-17
Pintle Arm Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . 50-101-11
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-2 SPECIFICATIONS
Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-6
Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-5
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-5
CONTROL PANEL (NON-ADJUSTABLE PINTLES). . . . . . . . . . . . . . 50-100-1

Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-8
Linkage Neutral Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-12
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-4
Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-4
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-4
CONTROL PANEL (SELECTABLE JOYSTICK CONTROL) (SJC). . . 50-102-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-102-1
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MAIN FRAME (CONT’D)
CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Crossbar Linkage Removal And Installation . . . . . . . . . . . 50-90-2
Lift Foot Pedal Linkage Removal And Installation . . . . . . . 50-90-3
Pedal Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Tilt Foot Pedal Linkage Removal And Installation . . . . . . . 50-90-4
CONTROL PEDALS (ACS). . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1

Foot Pedal Linkage Disassembly And Assembly. . . . . . . . 50-91-3
Foot Pedal Removal And Installation . . . . . . . . . . . . . . . . . 50-91-2
Foot Sensor Removal And Installation. . . . . . . . . . . . . . . . 50-91-1
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Fuel Fill Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
Fuel Pickup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Cylinder Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . 50-20-3
Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . 50-20-1
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Back Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-30-3
Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . 50-30-2
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . 50-30-4
Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . 50-30-2
POWER BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Power Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . 50-41-2
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MAIN FRAME (CONT’D)
REAR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Adjusting The Striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Latch Removal and Installation . . . . . . . . . . . . . . . . . . . . . 50-70-3
Striker Disassembly and Assembly . . . . . . . . . . . . . . . . . . 50-70-2
Striker Removal and Installation . . . . . . . . . . . . . . . . . . . . 50-70-2
REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

SEAT BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Assembling Components . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-3
Compression Spring Disassembly And Assembly . . . . . . . 50-10-5


ITEMS MAY VARY.
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T180 Bobcat Loader

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SEAT BAR Figure 50-10-3
Figure 50-10-1
P10564 P10563
Loosen the nut (both sides) at the front corners of the

N-19225 operator cab [Figure 50-10-3].
Remove the nuts and plates (both sides) [Figure 50-10-

Raise the seat bar (Item 1) [Figure 50-10-1]. 3].

Figure 50-10-2 Installation: Tighten the nuts to 40 - 50 ft.-lb. (54 - 68
N•m) torque.
Figure 50-10-4
N-18463
Disconnect the seat bar sensor (Item 1) [Figure 50-10-2]

P-45261
from the cab harness.
Lower the seat bar. Lift on the grab handle and bottom of the operator cab
slowly until the cab is all the way up and the latching
mechanism engages [Figure 50-10-4].
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501 of 961
SEAT BAR (CONT'D) Figure 50-10-6
Figure 50-10-5
N-19224
Remove the seat bar (Item 1) [Figure 50-10-6] from the

P-24791 operator cab.
Reverse the above procedure to install the seat bar into

Remove the seat bar mounting nuts (Item 1) [Figure 50- the operator cab.
10-5] (both sides).

Installation: Tighten the nuts to 28 ft.-lb. (38 N•m)
torque.

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Assembling Components
Figure 50-10-7
5 6
4 8
4 9
5
7 3
3 6
2 10
2 9 8
10
1 7
1
N-19383

N-19219
Assemble the parts as shown for the left side of the seat
bar pivot assembly [Figure 50-10-7] & [Figure 50-10-8].
Seat Bar Mount (Item 1)

Mounting Bolt (Item 2)
Keyed Plastic Bushing (Item 3)
Seat Bar (Item 4)
Magnetic Bushing Assembly (Item 5)
Pivot Bushing (Item 6)
Sensor Bracket (Item 7)
Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9)
Mounting Nut (Item 10)
Installation: Tighten the mounting bolt (Item 2) [Figure

50-10-7] & [Figure 50-10-8] to 50 - 70 in.-lb. (5,6 - 7,9
N•m) torque.
T180 Bobcat Loader

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Assembling Components (Cont'd)
Figure 50-10-9
5
6
4
4
5
3 3
2 6
2 7 7
1
1
N-19340

N-19220
Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-9] & [Figure 50-10-
10].
Seat Bar Mount (Item 1)

Mounting Nut (Item 2)
Pivot Bushing (Item 3)
Spacer Bushing (Item 4)
Seat Bar (Item 5)
Keyed Plastic Bushing (Item 6)
Mounting Bolt (Item 7)
Installation: Tighten the mounting bolt (Item 7) [Figure

50-10-9] & [Figure 50-10-10] to 50 - 70 in.-lb. (5,6 - 7,9
N•m) torque.
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Compression Spring Disassembly And Assembly 7

6
Figure 50-10-11
5
4 6
2
1
N-19384
Turn the bolt (Item 1) [Figure 50-10-11] & [Figure 50-10-

12] out of the clevis.
Assembly: Apply Loctite® #518 adhesive to the bolt

threads. Adjust the compression spring by turning the
bolt in past the end of the clevis three turns.

NOTE: For procedures requiring the use of Loctite®
#518 adhesive, thoroughly clean and dry
affected parts before the application of
Loctite® #518.
Disassemble and assemble the seat bar compression

N-19222 spring and parts as shown in Fig. [Figure 50-10-12].
Bolt (Item 1)
Bushing (Item 2)
Spring (Item 3)
Clevis (Item 4)
Retaining Pin (Item 5)
Pin (Item 6)
Bushing (Item 7)
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T180 Bobcat Loader

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OPERATOR CAB Figure 50-20-2
Gas Cylinder Removal And Installation
WARNING 1
Cylinder contains high pressure gas. Do not open.

Opening cylinder can release rod and cause injury or
death.
W-2113-0288
P1518 P1528
WARNING
Remove the cab nut and holddown plate (Item 1) [Figure
Never work on a machine with the lift arms up unless 50-20-2] (both sides).
support device. Failure to use an approved lift arm Installation: Tighten the nut to 40 - 50 ft.-lb. (54 - 68
support device can allow the lift arms or attachment N•m) torque.

W-2059-0598 Figure 50-20-3
Figure 50-20-1
1
P-48261
P-48265
Remove the operator cab stop (Item 1) (both sides)

[Figure 50-20-1]. Install a strap (Item 1) [Figure 50-20-3] to the cab
handles to prevent the cab from falling forward.
Raise the operator cab (See Raising The Operator Cab

on Page 10-30-1.) to release the tension on the gas
cylinder.
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OPERATOR CAB (CONT’D) Figure 50-20-6
Gas Cylinder Removal And Installation (Cont'd)
Figure 50-20-4
SINGLE GAS CYLINDER
N-19184
1
P-48262A Rotate the mounting bracket forward to relieve any

remaining tension on the gas cylinder(s) [Figure 50-20-
6].
Figure 50-20-5
Remove the front bolt (Item 1) [Figure 50-20-6] from the

DUAL GAS CYLINDER gas cylinder mounting bracket.
Installation: Tighten the bolts to 100 - 130 in.-lb. (11,3 -

14,7 N•m) torque.
1 2
P-43354A
Loosen the front bolt (Item 1) and remove the rear bolt
(Item 2) [Figure 50-20-4] and [Figure 50-20-5] from the
gas cylinder mounting bracket.
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OPERATOR CAB (CONT’D) Gas Cylinder Disassembly
Gas Cylinder Removal And Installation (Cont'd) Figure 50-20-9
Figure 50-20-7
SINGLE GAS CYLINDER
1 2
1
P1008
N-20618
Remove the clevis (Item 1) and washer (Item 2) [Figure
50-20-9] from the end of the gas cylinder.
Figure 50-20-8
Remove the gas cylinder from the outer housing.

DUAL GAS CYLINDER
Figure 50-20-10
P-39601
Remove the retaining pin(s) (Item 1) [Figure 50-20-7]

P1006
and [Figure 50-20-8] from the top pivot pin(s).
Remove the gas cylinder(s) (Item 2) [Figure 50-20-7] Assembly: Install a replacement cylinder inside the
and [Figure 50-20-8] from the operator cab. cylinder housing.
Reverse the above procedure to install the gas cylinders Apply a small amount of Loctite® 242 on the threads of
onto the operator cab. the cylinder rod [Figure 50-20-10].
Reinstall the washer and clevis on the cylinder rod.
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WARNING
1
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
cylinders. If the operator cab is tilted forward without
the gas cylinders operational, the cab will fall and
could cause injury or death.
W-2245-0796 P-43362
Figure 50-20-11
Remove bolt (Item 1) [Figure 50-20-12] from the cab
ground.
Remove any sta-straps connected to the harness

[Figure 50-20-12].

P-48265A
Remove the operator cab gas cylinder(s). (See Gas

Cylinder Removal And Installation on Page 50-20-1.)
Remove the heater unit from the cab (if equipped). (See
Use the hoist connected to the operator cab grab handles

to lower or (raise) the operator cab when the gas
cylinders are disconnected [Figure 50-20-11].
T180 Bobcat Loader

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Figure 50-20-13
1 1
P-39601
Remove the operator cab gas cylinder(s) (Item 1)

P-48263 [Figure 50-20-15]. (See Gas Cylinder Removal And
Figure 50-20-14 Lower the cab.

Figure 50-20-16
P-48264
P-48267
Disconnect all harness(s) (Item 1) [Figure 50-20-13]
[Figure 50-20-14] that connects the mainframe to the
cab. The number of connectors will vary depending on Remove the rear mounting nut and bolt (Item 1) [Figure
the options equipped on your loader. 50-20-16] (both sides) and nut from the operator cab.

- 47 N•m) torque.
T180 Bobcat Loader

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OPERATOR CAB (CONT’D)
Figure 50-20-17
1 2 3
N-20627A P-48266A
Connect the slings (Items 1, 2 and 3) [Figure 50-20-17]

to a chain hoist.

Remove the operator cab from the loader.
Reverse the above procedure to install the operator cab.
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OPERATOR SEAT Figure 50-30-3
Figure 50-30-1
1
1
1 2
N-20974
NOTE: Assure seat tethers are securely fastened to

N-20647 seatbelt studs (Item 1) and seat rail studs
(Item 2) [Figure 50-30-3].
Raise the operator cab. (See Raising The Operator Cab Figure 50-30-4
on Page 10-30-1.)

Remove the four seat mounting nuts (Item 1) [Figure 50-
30-1] and washers from the operator seat mounting
studs.
Installation: Tighten the mounting nuts to 20 ft.-lb. (27

N•m) torque.
Figure 50-30-2
N-20973
NOTE: Verify the front two seat rail studs have

washers attached (Item 1) [Figure 50-30-4].
P10564 P10563
Lower the cab and install one of the mounting washer

and nut [Figure 50-30-2].
NOTE: With the seat removed the cab will raise.
Reverse the removal procedure to install the operator

seat.
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OPERATOR SEAT (CONT'D) Cushion Removal And Installation
Slide Rail Removal And Installation Figure 50-30-6
Figure 50-30-5
1 1
2 2
1
1
N-18579
N-18587
Figure 50-30-7
Raise the operator cab. (See Raising The Operator Cab 2

on Page 10-30-1.)
1 1

Remove the operator seat. (See Removal And
Remove the two slide rail mounting bolts (Item 1) [Figure

50-30-5].
Remove the slide rail (Item 2) [Figure 50-30-5] from the

bottom of the seat frame.

seat slide rail. N-18582
Press the two buttons (Item 1) [Figure 50-30-6] &

[Figure 50-30-7] and lift the seat cushion.
T180 Bobcat Loader

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OPERATOR SEAT (CONT'D) Back Removal And Installation
Cushion Removal And Installation (Cont’d) Figure 50-30-10
Figure 50-30-8
1
N-18583
N-18581
Pull the seat back adjustment lever (Item 1) [Figure 50-
30-10] and tilt the seat back all the way forward.
Remove the cushion (Item 2) [Figure 50-30-7] from the
seat frame (Item 1) [Figure 50-30-8]. Figure 50-30-11

Figure 50-30-9
1 1
N-18578
N-18580
Remove the two mounting screws (Item 1) [Figure 50-
30-11] from the seat back and remove the back.
Inspect the seat ride adjustment [Figure 50-30-9].
Reverse the removal procedure to install the operator seat back.
seat back.
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OPERATOR SEAT (CONT'D)
Shock Removal And Installation
Figure 50-30-12
1
2
P-43118

on Page 10-30-1.)

Remove the operator seat. (See Removal And
Remove the seat shock mounting bolts (Item 1) [Figure

50-30-12] (Both ends.)
Remove the seat shock (Item 2) [Figure 50-30-12].

seat shock.
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BOB-TACH Figure 50-40-3
Figure 50-40-1
P-48132
Remove the grease fitting (Item 1) (both sides)

N-18544 [Figure 50-40-3] out of the Bob-Tach frame. This allows
grease to escape when driving the pivot pins into the
Bob-Tach frame.
Tilt the Bob-Tach forward, so it is parallel to the floor. Put
blocks (approximately 3 inches) under each side of the
Bob-Tach [Figure 50-40-1]. Figure 50-40-4

Lower the Bob-Tach onto the blocks.
nut from the tilt cylinder rod end pin (both sides).
Installation: Tighten the retainer bolt and nut to 25 - 30

Figure 50-40-2
1
N-18547
1
2
Strike the head of the bolt (Item 1) [Figure 50-40-4] to
push the pivot pin into the Bob-Tach frame.
Remove the bolt.
Use a long punch to push the pivot pin all the way into the
N-18545 Bob-Tach.
Remove the Bob-Tach from the lift arms.

Remove the pivot pin (Item 1) [Figure 50-40-2] from the
tilt cylinder rod end (both sides).
Remove the Bob-Tach pivot pin (both sides).
Remove the tilt cylinder rod end from the Bob-Tach (both
sides).
Loosen the bolt (Item 2) [Figure 50-40-2] at the Bob-

Tach pivot pin.
Installation: Tighten the bolt to 175 - 190 ft.-lb. (240 -

260 N•m) torque.
T180 Bobcat Loader
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BOB-TACH (CONT’D) Figure 50-40-7
Bob-Tach Lever And Wedge
Figure 50-40-5
1
N-18560
1
Remove the Wedge (Item 1) [Figure 50-40-7].
N-18558
Always replace bent or broken wedges.
Use the following procedure to remove and install the Figure 50-40-8
Bob-Tach lever (Item 1) [Figure 50-40-5], spring and

wedge.
Figure 50-40-6
1
3
2
1
N-18561
Remove the lever mounting nut (Item 1), washer (Item 2),
N-18559 spring (Item 3) and lever (Item 4) [Figure 50-40-8].

Use a punch and hammer, remove the roll pin (Item 1) N•m) torque.
[Figure 50-40-6] from the Bob-Tach Wedge and spring
clevis.
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BOB-TACH (CONT’D)
Bob-Tach Lever And Wedge (Cont’d)
Figure 50-40-9
2 4
3
N-20625
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-40-9] are damaged, put the

assembly in a vise.
Remove the bolt and replace the damaged parts as

needed.
Figure 50-40-10
N-18563
Use a punch and hammer to drive the roll pin (Item 1)

[Figure 50-40-10] flush with the face of the Bob-Tach.
Reverse the removal procedure to install the Bob-Tach

lever and wedge [Figure 50-40-10].
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T180 Bobcat Loader

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POWER BOB-TACH Figure 50-41-2
Figure 50-41-1 1
2 3
P-48185
1
Remove the pivot pin (Item 1) [Figure 50-41-2] from the
P-48131
tilt cylinder rod end (both sides).
Remove the tilt cylinder rod end from the Bob-Tach (both
Tilt the Bob-Tach forward, so it is parallel to the floor. Put sides).
blocks (approximately 3 inches) under each side of the

Bob-Tach [Figure 50-41-1]. Loosen the bolt (Item 2) [Figure 50-41-2] at the Bob-
Tach pivot pin.
Lower the Bob-Tach onto the blocks.
Installation: Tighten the bolt to 175 - 190 ft.-lb. (240 -
Remove the hoses to the cylinder fittings 260 N•m) torque.
[Figure 50-41-1].
Figure 50-41-3
NOTE: The hose with the 45° end (Item 1)
[Figure 50-41-1] is connected to the base end
fitting on the cylinder.
Remove the hose clamp on the hoses and use the bolt
(Item 2) [Figure 50-41-1] on the tilt cylinder pivot pin to
secure the clamp.
1
nut from the tilt cylinder rod end pin (both sides).
Installation: Tighten the retainer bolt and nut to 25 - 28

P-48132
Remove the grease fitting (Item 1) (both sides)

[Figure 50-41-3] out of the Bob-Tach frame. This allows
the grease to escape when driving the pivot pins in to the
Bob-Tach frame.
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POWER BOB-TACH (CONT’D) Figure 50-41-6
Figure 50-41-4
1
1
N-18559
Use a punch and hammer, remove the roll pin (Item 1)

N-18547 [Figure 50-41-6] from the Bob-Tach Wedge and spring
clevis.
Strike the head of the bolt (Item 1) [Figure 50-41-4] to Figure 50-41-7
push the pivot pin into the Bob-Tach frame.

Remove the bolt.
Use a long punch to push the pivot pins all the way into
the Bob-Tach frame.
Remove the Bob-Tach from the lift arms. 1
Remove the Bob-Tach pivot pin (both sides).
Power Bob-Tach Lever And Wedge
Figure 50-41-5
N-18560
Remove the Wedge (Item 1) [Figure 50-41-7].
Always replace bent or broken wedges.
P-48135
Use the following procedure to remove and install the

Bob-Tach lever (Item 1) [Figure 50-41-5], spring and
wedge.
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POWER BOB-TACH (CONT’D) Figure 50-41-9
Power Bob-Tach Lever And Wedge (Cont’d)
Figure 50-41-8
4
1
2
3 2
N-20625
3
5 If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
4
P-48135 or clevis (Item 4) [Figure 50-41-9] are damaged, put the
assembly in a vise.
Remove the washers and bolts (Item 1) [Figure 50-41- Remove the bolt and replace the damaged parts as
8]. needed.

Installation: Tighten the bolts to 25 - 28 ft.-lb. (34 - 38 Figure 50-41-10
N•m) torque.
Remove the cylinder off the lever pivots. Position the rod
end to the left with the grease fitting holes to the top
[Figure 50-41-8].
Remove the lever mounting nut (Item 2), washer (Item 3),
spring (Item 4) and lever (Item 5) [Figure 50-41-8]. 1

N•m) torque.
N-18563
Use a punch and hammer to drive the roll pin (Item 1)

[Figure 50-41-10] flush with the face of the Bob-Tach.
Reverse the removal procedure to install the Power Bob-

Tach lever and wedge [Figure 50-41-10].
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T180 Bobcat Loader

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LIFT ARMS Remove the lift cylinder rod pin (Item 2) [Figure 50-50-2].
Removal And Installation Figure 50-50-3
Note: When installing new lift arms, It may be

necessary to spread the lift arms apart or pull
them closer together to get all of the pivot
pins in place.
1
Roll the Bob-Tach fully forward. Stop the engine.
2
Figure 50-50-1
P-45258
Remove the retainer bolt and nut (Item 1) [Figure 50-50-

1 3] from the left side, rod end, lift cylinder pin.
Installation: Tighten retainer bolt and nut to 25 - 28 ft.-lb.

(34 - 38 N•m) torque.
P-45367 Remove the lift cylinder rod pin (Item 2) [Figure 50-50-3].
Figure 50-50-4
At the right side of the loader, mark the two tilt hoses for
proper installation.
Disconnect and cap the two tilt hoses (Item 1) [Figure

50-50-1] from the tubelines (right side of machine).
Figure 50-50-2
P-45365
2
P-45363

2] from the right side, rod end lift cylinder.

(34 - 38 N•m) torque.
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LIFT ARMS (CONT'D) Figure 50-50-7
Figure 50-50-5
P-45366
Install a floor jack (Item 1) [Figure 50-50-7] under the

P-45364 front of the lift arms, and raise the lift arms 3 - 4 in.
Figure 50-50-8

Figure 50-50-6
P-45422
P-34360 Install two lift straps (Item 1) [Figure 50-50-8] on the lift
arms as shown.
Remove the front auxiliary coupler mounting bolts (Item NOTE: Position the lift straps as shown in [Figure 50-
1) [Figure 50-50-6] 50-8] to balance the lift arms for removal and
installation.
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LIFT ARMS (CONT'D)
Figure 50-50-9
P-45259

9]. (Both sides.)

(34 - 38 N•m) torque.
Remove the lift arm pivot pin (Item 2) [Figure 50-50-9].

(Both sides.)
Remove the lift arms from the loader.
Remove the Bob-Tach. (See Removal And Installation on

Page 50-40-1.)
Remove the tilt cylinders from the lift arms. (See

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T180 Bobcat Loader

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REAR GRILL Figure 50-60-3
Figure 50-60-1
2
P-48130
Installation: Line up the tab (Item 1) on the grill with the

P-48251 slot (Item 2) [Figure 50-60-3] on the loader mainframe.
Insert the tab fully and then push down.
Open the rear door. Reverse the removal procedure to install the grill.

Figure 50-60-2
P-48252
Lift up on the rear grill (Item 1) [Figure 50-60-1] and

[Figure 50-60-2].
Lift the grill away from the loader.
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T180 Bobcat Loader

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REAR DOOR Figure 50-70-2

2
Figure 50-70-1
3
2
P-24792
Disconnect the light harness connector (Item 1) [Figure

50-70-2] (if so equipped), from the engine harness.
Remove the top and bottom door hinge mounting bolts

(Item 2) [Figure 50-70-2] and nuts.
1

NOTE: Install the door stop (Item 3) [Figure 50-70-2]
in the top hinge as shown.
Installation: Tighten the mounting bolts and nuts to 25 -

28 ft.-lb. (34 - 38 N•m) torque.
Lift the door away from the loader frame and put the door
flat on the floor.
P-24829
Reverse the removal procedure to install the rear door.
Remove the light assembly from the door. (See Rear

Secure the chain hooks (Item 1) [Figure 50-70-1] to the

door as shown.
Connect a chain hoist (Item 2) [Figure 50-70-1] to the

lifting chain.
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REAR DOOR (CONT’D) Adjusting The Striker
Striker Removal and Installation
Figure 50-70-3 WARNING

1 Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 50-70-5
1
1
P-31126
Remove the two striker mount bolts (Item 1) [Figure 50-

70-3].

Remove the striker assembly from the loader. 1
Striker Disassembly and Assembly

P-31126
Figure 50-70-4
Loosen the striker assembly mount bolts (Item 1) [Figure
50-70-5].
2 2
3 Align the striker assembly in the center of the mounting
holes.
NOTE: Tighten the striker assembly, top mount bolt

only, until it will hold the striker assembly in
the center of the mounting slots.
4
1 Close the rear door. (This will align the striker assembly
to the correct position.)
Open the door.

P-31320
Tighten both striker mount bolts (Item 1) [Figure 50-70-
5].
Remove the lock nut (Item 1) [Figure 50-70-4].
Remove the rollers (Item 2) and the spacer (Item 3) from
the bolt (Item 4) [Figure 50-70-4].
Check the parts for wear and replace as needed.
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532 of 961
REAR DOOR (CONT’D) Figure 50-70-8
Latch Removal and Installation
Figure 50-70-6
1
P-31128
1 Remove the door handle (Item 1) [Figure 50-70-8] from

P-31125 the rear door.
Disconnect the spring (Item 1) [Figure 50-70-6] from the

rear door.

Remove the bolt and nut (Item 2) [Figure 50-70-6] from
the latch.
Figure 50-70-7
1
P-31127
Remove the spring (Item 1) [Figure 50-70-7] from the

door handle.
Remove the spring (Item 2) [Figure 50-70-7] from the

door latch.
Remove the door latch (Item 3) [Figure 50-70-7] from the

door handle.
T180 Bobcat Loader

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T180 Bobcat Loader

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FUEL TANK Figure 50-80-3

2
Figure 50-80-1
1 P-28143

P-28152 3] from the battery holder.
Remove the battery holder (Item 2) [Figure 50-80-3]

Remove left access cover (Item 1) [Figure 50-80-1] from the loader.
which is located from the rear of the machine below the

undercarriage. Figure 50-80-4
Figure 50-80-2
1
1 1
P-28144
P-28153
Remove the mounting bolts (Item 1) [Figure 50-80-4]
from the fuel tank retainer bracket.
Drain the fuel from the tank through the fuel drain (Item 1)
[Figure 50-80-2].
Remove the engine/hydrostatic pump assembly from the

T180 Bobcat Loader

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FUEL TANK (CONT'D) Fuel Fill Screen
Removal And Installation (Cont'd) Figure 50-80-7
Figure 50-80-5
1 2
1
P13874A
P-28145
Remove the clamp (Item 1) [Figure 50-80-7] and remove
the fuel fill hose (Item 2) [Figure 50-80-7] from the tank.
Disconnect fuel sender (Item 1) [Figure 50-80-5].
Disconnect fuel vent hose (Item 2) [Figure 50-80-5].

Disconnect fuel fill hose (Item 2) [Figure 50-80-7].
Remove tank from loader.
Fuel Level Sender
Figure 50-80-6
P-28145
Disconnect fuel level sender (Item 1) [Figure 50-80-6].
Loosen the fuel level sender (Item 2) [Figure 50-80-6]

with a wrench.
Turn the fuel level sender out and remove it from the fuel
tank. Check the fuel level sender for damage and replace
if necessary.
Installation: Tighten the fuel level sender to 50 - 60 in.-

lb. (5,7 - 6,8 N•m) torque.
T180 Bobcat Loader

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FUEL TANK (CONT'D) Figure 50-80-10
Fuel Fill Screen (Cont’d)
Figure 50-80-8
P-28150
Remove fuel supply screen (Item 1) [Figure 50-80-10]

P13875A from the hose. (If so equipped.)
Check screen for damage, and replace if necessary.

Remove the fuel fill screen (Item 1) [Figure 50-80-8]
from the tank. Check the screen for damage and replace

if necessary.
Fuel Pickup Screen
Figure 50-80-9
P-28149
Disconnect fuel hose (Item 1) [Figure 50-80-9] from

fitting (Item 2) [Figure 50-80-9].
Remove fitting (Item 2) [Figure 50-80-9] and grommet

from the tank.
Remove fuel supply hose assembly from the tank.
T180 Bobcat Loader

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T180 Bobcat Loader

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CONTROL PEDALS Figure 50-90-2
Figure 50-90-1 1
P-34375

P-26008 2] from the pedal mounting bracket.
Remove the pedal assembly from the loader.

Remove the bolt (Item 1) [Figure 50-90-1] and nut from
the pedal linkage. Pedal Adjustment

Installation: Tighten the bolt and nut to 21 - 25 ft.-lb. (28 After installing the pedal, adjust the pedal so that there is
- 34 N•m) torque. clearance under the rear of the pedal. The valve spool
must travel full stroke without the pedal hitting the floor
Check the rubber bushing in the pedal for wear and panel.
replace as needed.
T180 Bobcat Loader

539 of 961
CONTROL PEDALS (CONT'D) Raise the lift arms and install an approved lift arm support
Crossbar Linkage Removal And Installation 10-20-1.)

on Page 10-30-1.)
DANGER Remove the crossbar pivot bolt (Item 1) [Figure 50-90-
3].
Figure 50-90-4
P-90328 1
AVOID DEATH

D-1009-0409
P-24758
Remove the bolt and nut (Item 1) [Figure 50-90-4] to

WARNING disconnect the lift pedal linkage from crossbar.
Figure 50-90-5
W-2059-0598
Figure 50-90-3
1
P-24757
Remove the hairpin clip and cross-pin from the control

valve lift spool (Item 1) [Figure 50-90-5].
Disconnect the crossbar from the control valve.
P-24756
T180 Bobcat Loader

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CONTROL PEDALS (CONT'D) Lift Foot Pedal Linkage Removal And Installation
Crossbar Linkage Removal And Installation (Cont’d) Figure 50-90-7
Figure 50-90-6
1 P-24760
P-24763
Remove the bolt and nut (Item 1) [Figure 50-90-7] to
disconnect the lift foot pedal linkage from the crossbar
Remove the crossmember from the pivot [Figure 50-90- linkage.
6].

Figure 50-90-8
Installation: Check the nylon bushing (Item 1) [Figure
50-90-6] for wear and replace as needed.
1
P-24759

the pedal linkage.

- 34 N•m) torque.
T180 Bobcat Loader

541 of 961
CONTROL PEDALS (CONT'D) Figure 50-90-10
Tilt Foot Pedal Linkage Removal And Installation
Figure 50-90-9 1
1 P-26008

P-24761 the pedal linkage.

Remove the bolt and nut (Item 1) [Figure 50-90-9] to - 34 N•m) torque
disconnect the tilt foot pedal linkage from the control

valve.
T180 Bobcat Loader

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CONTROL PEDALS (ACS) Figure 50-91-3
Foot Sensor Removal And Installation
Figure 50-91-1
2 1
P-21936
P-21927
1 Remove the two bolts (Item 1) [Figure 50-91-3] from the

P-21938 foot sensor shield.
Installation: Tighten the bolts to 80 - 90 in.-lb. (9,0 - 10,2

Pull the pin (Item 1) [Figure 50-91-1] holding the foot N•m) torque.
pedal linkage to the sensor.

Disconnect the two connectors (Item 2) [Figure 50-91-1]
from the sensor and lock solenoid.
Figure 50-91-2
P-21935
Tilt the foot pedal up and remove the two nuts (Item 1)
[Figure 50-91-2].
Remove the foot pedal and sensor assembly from the

loader.
T180 Bobcat Loader

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CONTROL PEDALS (ACS) (CONT'D) Foot Pedal Removal And Installation
Foot Sensor Removal And Installation (Cont’d) Figure 50-91-5
Figure 50-91-4
1
P-21940
P-21924
Remove the pin (Item 1) [Figure 50-91-5] holding the
linkage to the sensor.
Remove foot lock solenoid (Item 1) [Figure 50-91-4].
Figure 50-91-6

Installation: Apply a drop of oil to the solenoid threads
and tighten the solenoid to 35 - 40 ft.-lb. (47 - 54 N•m)
lubed torque. 1
Remove the two bolts (Item 2) [Figure 50-91-4] from the

bracket and sensor assembly. P-21935A

N•m) torque.
Remove the sensor assembly.

when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See P-21934
Calibration Procedure on Page 60-120-16.)
Tip the foot pedal up and remove the two nuts (Item 1)
[Figure 50-91-6].
Remove the foot pedal assembly.
T180 Bobcat Loader

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CONTROL PEDALS (ACS) (CONT'D)
Foot Pedal Linkage Disassembly And Assembly
Figure 50-91-7
P-21931
Remove the bolt (Item 1) holding the linkage (Item 2) to

the side of the foot pedal [Figure 50-91-7].

Figure 50-91-8
2
3
1
P-21932
Remove the spacer (Item 1), linkage (Item 2), and nut
(Item 3) from the foot pedal [Figure 50-91-8].
T180 Bobcat Loader

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T180 Bobcat Loader

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CONTROL PANEL (NON-ADJUSTABLE PINTLES) Figure 50-100-1
DANGER 1
3
P-90328 P-48462
AVOID DEATH Loosen the jam nut (Item 1) from the bypass control knob
• Disconnecting or loosening any hydraulic (Item 2) [Figure 50-100-1].
can cause lift arms to drop. Remove the control knob (Item 2), jam nut (Item 1) and
• Keep out of this area when lift arms are raised rubber washer (Item 3) [Figure 50-100-1].
Disconnect the control harness connectors (Item 4)

[Figure 50-100-1] from right control levers.
D-1009-0409
WARNING
WARNING Put jackstands under the front axles and rear corners
support device. Failure to use an approved lift arm W-2017-0286
W-2059-0598 Figure 50-100-2
10-20-1.)
on Page 10-30-1.)
1
Remove the engine speed control. (See Removal And
P-48277

[Figure 50-100-2] from left control levers.
T180 Bobcat Loader

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(CONT’D)

3
Figure 50-100-3 1 1
2
2 2
1 1 P-26323
Remove the fuse/relay mounting bolts (Item 1) [Figure

50-100-4].
P-48235
Remove the fuse/relay shield (Item 2) [Figure 50-100-4].
Scribe a mark across the top of the steering linkage bars Remove the fuse/relay cover (Item 3) [Figure 50-100-4].

steering shaft on the control panel. Figure 50-100-5
[Figure 50-100-3].

28 ft.-lb. (34 - 38 N•m) torque.
P-26325
Remove the fuse/relay block [Figure 50-100-5].
T180 Bobcat Loader

548 of 961
(CONT’D)
Figure 50-100-6
1
1
1
1
1
P-26327
Remove the control panel mounting bolts (Item 1)

[Figure 50-100-6], [Figure 50-100-7] & [Figure 50-100-
P-34363 8] from both sides of the control panel.
Installation: Tighten the control panel mounting bolts to

Figure 50-100-7 15 - 20 ft.-lb. (20 - 27 N•m) torque.

Remove the control panel from the loader.
Reverse the removal procedure to install the control

panel.
P-26329
T180 Bobcat Loader

549 of 961
(CONT’D)
Shock Removal And Installation
Figure 50-100-9
1 3
2
3
1
P-4146
Remove Control Handle Lever (Item 1) [Figure 50-100-

2 10]. (See Control Lever Removal And Installation on
P-34365 Page 50-110-1.)
Remove the steering shaft pivot bolt (Item 2) [Figure 50-

Remove the mounting nut (Item 1) [Figure 50-100-9] 100-10] from both sides of the control panel.
from the end of the shock connected to the steering

linkage. Installation: Tighten the pivot bolts to 25 - 28 ft.-lb. (34 -
38 N•m) torque.
from the other end of the shock connected to the bracket Remove the steering shaft from the control panel.
on the control panel.
Shaft Disassembly And Assembly
(34 - 38 N•m) torque. Figure 50-100-11
Shaft Removal And Installation
NOTE: The steering shaft can be removed without

removing the control panel from the loader.
Photo [Figure 50-100-10] shows the control
panel removed for clarity purpose only. 1
1
Remove the steering linkage mounting bolts (Item 3)
[Figure 50-100-9].
Remove the steering shock mounting nuts (Item 2) 1

[Figure 50-100-9].
P-4154
Disassemble the right and left steering shafts from the

cross shaft assembly [Figure 50-100-11].
Assembly: Install new nylon bushings (Item 1) [Figure

50-100-11] as needed when assembling the steering
shaft. Be sure to apply grease on the cross shaft before
installing the right and left steering shaft.
T180 Bobcat Loader

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CONTROL PANEL (NON-ADJUSTABLE PINTLES) Linkage Removal And Installation
(CONT’D)
Figure 50-100-13
Shaft Disassembly And Assembly (Cont’d)
Figure 50-100-12
2 1
P-3729
1
P-26331 Remove the nut (Item 1) from the end of the centering
spring shoulder bolt (Item 2) [Figure 50-100-13].
To remove the steering shaft mounting bracket (Item 3) Remove the shoulder bolt/spring assembly.
[Figure 50-100-10], remove the three mounting bolts

(Item 1) [Figure 50-100-12] from the front of the control Installation: Tighten the centering spring shoulder bolt
panel. and a NEW lock nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
Remove the steering shaft mounting bracket from each Figure 50-100-14
side of the control panel.

(20 - 27 N•m) torque.
1
2
3 2
P-3736
Slide the plate (Item 1) to the right and remove it from the
two guide pins (Item 2) [Figure 50-100-14].
NOTE: The two guide bushings (Item 3) will be loose

and can fall out of the plate (Item 1) as soon as
it is removed from the guide pins (Item 2)
[Figure 50-100-14].
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CONTROL PANEL (NON-ADJUSTABLE PINTLES) If the centering blocks need replacement, remove the
(CONT’D) bolts (Item 2) [Figure 50-100-16]. Remove the centering
blocks.
Linkage Removal And Installation (Cont’d)
Installation: Tighten the centering block bolts to 25 - 28
Figure 50-100-15 ft.-lb. (34 - 38 N•m) torque.
Figure 50-100-17
5
6
4 2
1
1
2
2 1
2 3 N-15310
P-3733
The centering plate/centering spring assembly consists
of the following parts;

If the surface of any of the four pintle cams (Item 1) are
ITEM DESCRIPTION worn, loosen the bolt (Item 2) [Figure 50-100-17] and
rotate the cams 1/4 turn.
1 Shoulder Bolt
2 Bushings Tighten the bolts to 45 - 50 ft.-lb. (62 - 68 N•m) torque.
3 Spring
When replacing the old style pintle levers, wear cams
4 Lock Nut
and cam bolts, install the latest style parts.
5 Centering Plate
6 Guide Bushings
Figure 50-100-16
1
2
N-15312
Check the wear on the centering blocks (Item 1) [Figure

50-100-16].
T180 Bobcat Loader

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(CONT’D)
Figure 50-100-18
1
3
2 1
P-34365
Remove the nuts (Item 1) [Figure 50-100-20] from both

shock absorber ball joint ends.
P-3733
Remove the shock absorbers.
Remove the nut (Item 1) [Figure 50-100-18] from the Installation: Tighten the nuts to 25 - 28 ft.-lb. (34 - 38
torsion bushing/linkage bar. The bolt is threaded into the

N•m) torque.
linkage bar, remove the bolt from underneath the pintle
lever. Remove the nuts (Item 2) from the linkage bar mounting
bolt. The bolts (Item 3) are threaded into the linkage bars,
Installation: Tighten the bolt to 11 - 13 ft.-lb. (21 - 25 remove the bolts (Item 3) [Figure 50-100-20].
N•m) torque, then tighten the nut to 21 - 25 ft.-lb. (28 - 33
N•m) torque. The torsion bushings can now be removed from the
steering bell cranks.
Figure 50-100-19
N•m) torque, then tighten the nuts to 21 - 25 ft.-lb. (28 -
33 N•m) torque.
2 The linkage and the centering plate must be readjusted

for neutral after the components have been reassembled.
(See Linkage Neutral Adjustment on Page 50-100-12.)
P-3734
Remove the linkage bar (Item 1) and remove the torsion

bushing (Item 2) [Figure 50-100-19].
T180 Bobcat Loader

553 of 961
(CONT’D)
Linkage Adjustment
2
WARNING
1
the lift arms are secured by an approved lift arm 2
1
to fall and cause injury or death. 3
W-2059-0598
P-34365
device. (See Installing Lift Arm Support Device on Page Lift and block the loader. (See Procedure on Page 10-10-
10-20-1.) 1.)

on Page 10-30-1.)
WARNING

Connect the remote start tool (MEL1429). (See
Put jackstands under the front axles and rear corners Procedure on Page 10-60-1.)
Failure to use jackstands can allow the machine to Pre-load tension in the torsion bushings must be
fall or move and cause injury or death. removed before adjusting the steering linkage.
W-2017-0286
Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt
(Item 2). The bolt (Item 2) is threaded into the linkage bar
(Item 3). The bolt (Item 2) [Figure 50-100-21] must be
loosened enough to allow the torsion bushing to turn
freely between the steering bellcrank and the linkage bar.
Figure 50-100-22
2
3
4
P-3726

(Item 2). The bolt (Item 2) is threaded into the linkage bar
freely between the pintle arm and the linkage bar.
T180 Bobcat Loader
554 of 961
(CONT’D)
Linkage Adjustment (Cont’d)
Figure 50-100-23
1
1 3
P-3723
Move the right side steering lever forward and install a

15/16 in. (24 mm) thick spacer (Item 1) between the
P-37574 center plate (Item 2) and the mounting plate (Item 3)
[Figure 50-100-25].
Remove access plug from the top of the control valve. This will allow the pintle arms to move freely while

adjusting the steering linkage for full forward travel
Turn the control lever drift adjustment bolts (Item 1) speed.
[Figure 50-100-23] (one on each control lever) out until it
is flush with the bottom of the nut. Remove the 3/8 in. (10 mm) thick spacer (Item 1) [Figure
50-100-25].
Figure 50-100-24
Figure 50-100-26
4
2
1
3
3 1 2
4
P-3724
P-3730
Move the right side steering lever to the rear and install a
3/8 in. (10 mm) thick spacer (Item 1) between the pintle Before adjusting the linkage, check that the pintle arm
arm cam (Item 2) and the centering block (Item 3) mounting bolt (Item 1) is tight, 25 - 28 ft.-lb. (34 - 38 N•m)
[Figure 50-100-24]. torque and that there is no play between the pintle arm
(Item 2) and the square pump shaft (Item 3). Also check
that the cam mounting bolts (Item 4) [Figure 50-100-26]
are tight, 45 - 50 ft.-lb. (62 - 68 N•m) torque.
T180 Bobcat Loader

555 of 961
(CONT’D)
Linkage Adjustment (Cont’d)
Figure 50-100-27
P-3728
1
Move the left control lever to the full forward position,
then pull forward on the left rear linkage bar until the
P-3727 pintle arm is rotated to the front as far as possible
[Figure 50-100-28]. Use a locking plier and clamp the
two linkage bars together.
Loosen the two bolts and nuts (Item 1) [Figure 50-100-
27] on each steering linkage bar.

Installation: Tighten the nuts and bolts to 25 - 28 ft.-lb.
(34 - 38 N•m) torque.
Check the lever movement to make sure that the pintle

arm and the control lever are both at full stroke at the
same time. This will allow for maximum forward speed.
Repeat the procedure for the right side linkage.
After both sides of the linkage have been adjusted, the

feel of both levers at full stroke should be the same.
Readjust the linkage if necessary.
Figure 50-100-29
P-3723
Remove the spacer (Item 1) [Figure 50-100-29].
Disconnect the remote start tool.
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CONTROL PANEL (NON-ADJUSTABLE PINTLES)
(CONT'D)
Linkage Adjustment (Cont'd)
Figure 50-100-30
P-37574
Push the control lever to full stroke and turn drift

adjustment bolt (Item 1) [Figure 50-100-30] in until it

touches the U-bolt holding the control lever.
Repeat steps on the other control lever.
Drive the loader forward and check for drift.
The traditional benchmark for drift is less than 10 ft. of

“drift” in 100 ft. of travel distance.
If the drift is excessive to the left, turn the right

adjustment bolt (Item 1) [Figure 50-100-30] in.
If the drift is excessive to the right, turn the left

adjustment bolt in.
NOTE: When using the drift adjustment bolts, only

adjust one bolt for each test drive.
In addition only move each bolt a maximum of

one turn for each test drive. This will help
prevent over correction and excess reduction
in travel speed.
Drift adjustment is for forward travel only.
Adjust the drift to an acceptable level.
Re-install the plug in the drift bolt access hole after

adjustment.
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557 of 961
(CONT’D)
Linkage Neutral Adjustment
The following tool listed will be needed to do the following 2 1

1 2
procedure:
MEL1563 - Remote Start Tool Kit
Connect the remote start tool to the engine harness. (See

Procedure on Page 10-60-1.)
WARNING P-3731

Loosen the four bolts (Item 1) [Figure 50-100-32] holding
the two centering blocks. Move the right hand centering
block to the right as far as possible.
W-2017-0286
NOTE: Bolt holes (Item 2) [Figure 50-100-32] are
slotted for pintle arm centering adjustment.

Figure 50-100-31
Figure 50-100-33
2
3
4
P-3726
P-3725
Loosen the nut (Item 1) a couple of turns, then loosen the

bolt (Item 2). The bolt (Item 2) is threaded into the linkage Adjust the left centering block first [Figure 50-100-33].
bars (Items 3 & 4) [Figure 50-100-31].
The bolt (Item 2) [Figure 50-100-31] must be loose

enough to allow the torsion bushing to turn freely
between the pintle arm and the linkage bar.
T180 Bobcat Loader

558 of 961
(CONT’D)
Linkage Neutral Adjustment (Cont’d)
Figure 50-100-34
P-3732
Adjust the right centering block [Figure 50-100-35].
P16121 Move the right control lever until the tires do not turn
(neutral position).
Start the engine and run at high RPM. Move the right centering block to the left until it contacts

both pintle cams and the control lever is still in the neutral
Move the traction lock override switch (Item 1) [Figure position [Figure 50-100-35].
50-100-34] to the OFF position so the traction function is
unlocked. The wheels are now able to turn. Tighten the bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
Move the left control lever until the tires do not turn Test both levers by moving them backward and forward
(neutral position). and letting them return to neutral by the return spring
force.
Move the left centering block to the left until it contacts
both pintle cams and the control lever is still in the neutral If the levers do not return to neutral and the tires do not
position [Figure 50-100-33]. come to a complete stop, repeat the adjustment
procedure again.
Tighten the bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
Stop the engine.
NOTE: If the centering blocks are worn, they can be
removed and rotated 180 degrees and
reinstalled. If the cams are worn, they can be
loosened and rotated 90 degrees and
reinstalled.
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(CONT’D)
Figure 50-100-36
1
1
P-34365
2
3
4 Tighten the two bolts to 11 - 13 ft.-lb. (15 - 17 N•m)
torque, then tighten the two nuts to 21 - 25 ft.-lb. (28 - 33
P-3726 N•m) torque at the steering cross shaft (Items 1 & 2)
[Figure 50-100-37].
Tighten the two bolts (Item 1) to 11 - 13 ft.-lb. (15 - 17
N•m) torque, then tighten the two nuts (Item 2) [Figure

50-100-36] to 21 - 25 ft.-lb. (28 - 33 N•m) torque.
T180 Bobcat Loader

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CONTROL PANEL (ADJUSTABLE PINTLES)
Description
Figure 50-101-1

P-54658
The steering system [Figure 50-101-1] consists of Pintle arms are of a two-piece design that allow easy
independent steering levers the operator uses to provide adjustment of the neutral or “creep”. Earlier designs use
steering input to the loader. a “spring return” adjustment, later designs use a “thread
return” adjustment.
The steering levers are attached to pivoting bellcranks
that pivot on a steering shaft and plastic bushings. The The steering system returns the levers to their starting
bellcranks have grease fittings. position by means of the centering spring and the
returning force of the torsion bushings.
The forward travel is adjusted by drift adjustment bolts.
NOTE: Torsion bushings need to be replaced if torn
The bellcranks are attached to steering linkage bars with or rotating in the housing. Loosen torsion
rubber torsion bushings pressed into the bellcranks. bushing bolts slightly before adjustments are
Bellcranks mount to the control panel. made. Do not fully tighten torsion bushing
bolts again until all steering adjustments have
Steering linkage bars are a two-piece design. Steering been made first.
linkage bars are adjustable in length for “full travel
adjustment”. Sequence of steering adjustments:
1. Set neutral of pintle arms, “creep”
Steering linkage bars attach to the pintle arms where a
2. Set full travel at steering linkage bars
rubber torsion bushing is pressed into the pintle arms.
3. Set drift at drift adjustment bolts
T180 Bobcat Loader
561 of 961
CONTROL PANEL (ADJUSTABLE PINTLES) Figure 50-101-2
(CONT'D)
2 1
DANGER 3
P-48462
P-90328
AVOID DEATH
10-20-1.)
on Page 10-30-1.)

Remove the engine speed control. (See Removal And
D-1009-0409
Loosen the jam nut (Item 1) from the bypass control knob
(Item 2) [Figure 50-101-2].
WARNING Remove the control knob (Item 2), jam nut (Item 1) and
rubber washer (Item 3) [Figure 50-101-2].
the lift arms are secured by an approved lift arm Figure 50-101-3
W-2059-0598
WARNING 4

W-2017-0286
P-48277

[Figure 50-101-2] & [Figure 50-101-3] from the control
levers.
T180 Bobcat Loader

562 of 961
(CONT'D)
Removal and Installation (Cont'd)

2
Figure 50-101-4
1 1
2 2 3
P-26323
1 1
Remove the fuse/relay mounting bolts (Item 1) [Figure
50-101-5].
P-54609
Remove the fuse/relay cover (Item 2) and fuse/relay
block retaining bracket (Item 3) [Figure 50-101-5].

Figure 50-101-6

[Figure 50-101-4].

40 ft.-lb. (47,5 - 54,2 N•m) torque.
P-26325
Remove the fuse/relay block [Figure 50-101-6].
T180 Bobcat Loader

563 of 961
(CONT'D)
Removal and Installation (Cont'd) 1
Figure 50-101-7
11
P-26329
P-26328 P-26329
1
Remove the control panel mounting bolts (Item 1)
[Figure 50-101-7], [Figure 50-101-8] & [Figure 50-101-
P-26326 9] from both sides of the control panel.
Installation: Tighten the control panel mounting bolts to

Figure 50-101-8 15 - 20 ft.-lb. (20 - 27 N•m) torque.

Reverse the removal procedure to install the control

panel.
1
P-26327
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CONTROL PANEL (ADJUSTABLE PINTLES) Shaft Removal And Installation
(CONT’D)
NOTE: The steering shaft can be removed without
Shock Removal And Installation removing the control panel from the loader.
Photo [Figure 50-101-11] shows the control
Figure 50-101-10 panel removed for clarity purpose only.
Remove the steering linkage mounting bolts (Item 3)

[Figure 50-101-10].
1 Remove the steering shock mounting nuts (Item 2)

[Figure 50-101-10].
3
Figure 50-101-11
P-48275

from the end of the shock connected to the steering

3
linkage.
Remove the mounting nut (Item 2) [Figure 50-101-10] 1 2

from the other end of the shock connected to the bracket
P-48278
on the control panel.
Installation: Tighten the mounting bolts to 25 - 28 ft.-lb. Remove Control Handle Lever (Item 1) [Figure 50-101-
(34 - 38 N•m) torque. 11]. (See Control Lever Removal And Installation on
Page 50-110-1.)
Remove the steering shaft pivot bolt (Item 2) [Figure 50-

101-11] from both sides of the control panel.
Installation: Tighten the pivot bolts to 25 - 28 ft.-lb. (34 -

38 N•m) torque.
Remove the steering shaft from the control panel.
T180 Bobcat Loader

565 of 961
(CONT’D)
Shaft Disassembly And Assembly 1
Figure 50-101-12
2
2
1
1 P-26331
2
To remove the steering shaft mounting bracket (Item 3)
[Figure 50-101-11], remove the three mounting bolts
P-4154 (Item 1) [Figure 50-101-13] from the front of the control
panel.
Disassemble the right and left steering bellcranks Remove the steering shaft mounting bracket.
(Item 1) from the cross shaft assembly [Figure 50-101-

12]. Installation: Tighten the mounting bolts to 15 - 20 ft.-lb.
(20 - 27 N•m) torque.
Assembly: Install new nylon bushings (Item 2) [Figure
50-101-12] as needed when assembling the steering
shaft. Be sure to apply grease on the cross shaft before
installing the right and left bellcranks.
NOTE: The bellcranks should pivot freely on the

cross shaft when assembled correctly.
T180 Bobcat Loader

566 of 961
(CONT’D)
Linkage Removal And Installation
WARNING 2 2

1 1
W-2059-0598
P-54609

WARNING (Item 1) [Figure 50-101-14] which are connected to the
of the frame before running the engine for service. Remove the four steering linkage mounting bolts (Item 2)
Failure to use jackstands can allow the machine to [Figure 50-101-14].

W-2017-0286 Installation: Align the marks on the steering linkage
40 ft.-lb. (47,5 - 54,2 N•m) torque.
device. (See Installing Lift Arm Support Device on Page NOTE: After removal and installation of the linkage,
10-20-1.) the linkage neutral adjustment procedure
must be performed. (See Linkage Neutral
Lift and block the loader. (See Procedure on Page 10-10- Adjustment on Page 50-101-13.)
1.)
T180 Bobcat Loader

567 of 961
(CONT’D)
Linkage Removal And Installation (Cont’d) 7

6 8
Figure 50-101-15 3 1 4
2
5
2
P-48630
The centering plate/centering spring assembly consists

of the following parts:
2
P-48631
ITEM DESCRIPTION
Remove the nut (Item 1) from the end of the centering 1 Bolt
spring shoulder bolt (Item 2) [Figure 50-101-15]. 2 Bushings

3 Washer
Remove the bolt/spring assembly.
4 Bushing Spacer
Installation: Tighten the centering spring bolt and a 5 Spring
NEW lock nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
6 Lock Nut
Figure 50-101-16 7 Centering Plate
8 Guide Bushings
P-48632
Slide the centering plate (Item 1) [Figure 50-101-16] to

the right to remove it from the hydrostatic pumps.
NOTE: Directions are shown and stated as if you

were sitting in the operators seat.
T180 Bobcat Loader

568 of 961
(CONT’D)
SPRING RETURN STYLE
Figure 50-101-18 2
1
6 3
3
2
5
1
2 4
1
1 P-48627
2
If the surface of any of the four solid pintle cams (Item 1)
are worn, loosen the bolt (Item 2) and rotate the cams 1/4
P-48629 turn [Figure 50-101-19].
Remove the bolts and washers (Item 3) [Figure 50-101-

Check the wear on the centering blocks (Item 1) [Figure 19] from the pintle.
50-101-18].

Installation: Tighten the bolts to 35 - 40 ft.-lb. (47,5 -
If the centering blocks need replacement, remove the 54,2 N•m) torque.
bolts (Item 2) [Figure 50-101-18]. Remove the centering
blocks. Loosen the creep adjustment bolt (Item 4) [Figure 50-
101-19].
Installation: Tighten the centering block bolts to 35 - 40
ft.-lb. (47,5 - 54,2 N•m) torque. Remove the pintle arm (Item 5) from the pintle base.
(Item 6) [Figure 50-101-19].
NOTE: The washers go between the bolts and the
centering plate. Figure 50-101-20
NOTE: If the centering blocks are worn, they can be
removed and rotated 180 degrees and SPRING RETURN STYLE
reinstalled. If the solid cams are worn, they
can be loosened and rotated 90 degrees and
reinstalled. 1
3 4
P-48625
NOTE: When installing the pintle arm (Item 1) onto

the pintle base (Item 2) align the rear of pintle
arm (engine side) (Item 3) into the spring (Item
4) [Figure 50-101-20]. (Spring Return Style
Only)
T180 Bobcat Loader

569 of 961
(CONT’D)
SPRING RETURN STYLE
1
Figure 50-101-21
THREAD RETURN STYLE 3
2
2
P-48621
3
Remove and inspect the spring (Item 1) [Figure 50-101-
23]. Spring return style only.
P-54617
Figure 50-101-24
Remove the bolts and washers (Item 1) [Figure 50-101-
21] from the pintle.

THREAD RETURN STYLE

54,2 N•m) torque. 3
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-101-21].
Figure 50-101-22
1 2
P-54615
2
Loosen the bolt (Item 2) and remove the pintle base (Item
3) [Figure 50-101-23] and [Figure 50-101-24].
4
3
1
P-48624
Remove the bolt and nut (Item 1) [Figure 50-101-22].
Inspect the washers (Item 2), pintle arm (Item 3) and the
steering control link (Item 4) for damage and replace as
needed [Figure 50-101-22].
NOTE: The washers (Item 2) [Figure 50-101-22] are

hardened, and should only be replaced
through Bobcat Parts.
T180 Bobcat Loader

570 of 961
CONTROL PANEL (ADJUSTABLE PINTLES) Pintle Arm Disassembly and Assembly
(CONT’D)
Figure 50-101-26
2
Figure 50-101-25
2
1
3
P-54625
1
P-48659 Remove the bolt (Item 1) from the pintle solid cams (Item
2)_[Figure 50-101-26] and inspect the pintle solid cams
for damage or excessive wear.
NOTE: When installing the pintle base (Item 1) onto
the pump shaft, the cutouts on the pump shaft

will not line up with the bolt (Item 3) [Figure 54,2 N•m) torque.
50-101-25].
Figure 50-101-27
Installation: Install the pintle base (Item 1) onto the
pump shaft (Item 2) [Figure 50-101-25]. The top of the
2
pintle base should be level with the top of the pump shaft.
3
Tighten the bolt to 35 - 40 ft.-lb. (47,5 - 54,2 N•m) torque.
NOTE: After installing the linkage onto the

hydrostatic pumps the linkage neutral
adjustment procedure must be performed.
(See Linkage Neutral Adjustment on Page 50- 2
101-13.)
3
1
P-54624
NOTE: The pintle roller cams (Item 2) [Figure 50-101-

27] are used on ACS loaders only.
Remove the nut (Item 1) from the pintle roller cams (Item
2) and inspect the pintle roller cams and washers (Item 3)
for damage [Figure 50-101-27].
Inspect the torsion bushing (Item 3) [Figure 50-101-27]

for damage and replace as needed.
Installation: Tighten the nuts to 35 - 40 ft.-lb. (47,5 - 54,2

N•m) torque.
T180 Bobcat Loader

571 of 961
(CONT’D)
Pintle Arm Disassembly and Assembly (Cont’d)
Figure 50-101-28
1 3
4 2
2
P-48619
3
Using a bushing driver (Item 1) remove the torsion

bushing (Item 2) by pressing the bushing through the
P-54626 pintle arm into an oversized socket (Item 3) to catch the
torsion bushing [Figure 50-101-29].
Remove the base pintle (Item 1) [Figure 50-101-28] from Installation: Install the torsion bushing (Item 2) [Figure
the pump shaft.

50-101-29] into the pintle arm using the same procedure
as the removal.
Remove the retaining bolt (Item 2), adjusting screw (Item
3) and neoprene dampener (Item 4) [Figure 50-101-28] NOTE: When the torsion bushing is installed, the
from the base pintle. amount of bushing on each side of the pintle
arm should be the same.
Inspect parts for wear and damage, replace as needed
[Figure 50-101-28].
NOTE: Anti-seize should be used on the adjusting

screw to prevent corrosion and allow free
movement while adjusting.
T180 Bobcat Loader

572 of 961
(CONT’D)
Linkage Neutral Adjustment

1
The following tool listed will be needed to do the following
procedure:
MEL1563 - Remote Start Tool Kit
Connect the remote start tool to the engine harness. (See


1.)
P-48448
Figure 50-101-30
3 Loosen the bolt/nut (Item 1) [Figure 50-101-31] only until

the tension is released from the torsion bushing.
Figure 50-101-32

1
P-48450
2
Tool that may assist in the neutral adjustment [Figure 50-

101-30].
P-54612
To make this tool use a locking grip C-Clamp and grind
one edge flat (Item 1) and grind the other edge (Item 2)
[Figure 50-101-30] to a small rounded edge. Loosen the nut (Item 1) only until the tension is released
from the torsion bushing (Item 2) [Figure 50-101-32].
A steering centering block (Item 3) [Figure 50-101-30] is
also needed. The centering block can be placed as NOTE: The bolt must be loose enough to allow the
shown and welded to the C-clamp if desired. torsion bushing (Item 2) [Figure 50-101-32] to
turn freely between the torsion bushing and
the steering linkage bar.
WARNING
W-2017-0286
T180 Bobcat Loader

573 of 961
(CONT’D)
Figure 50-101-33
2
P16121
Using the remote start tool, turn the key (Item 1) [Figure
2 50-101-35] to the run position.
P-54614
Move the traction lock override switch (Item 2) [Figure
50-101-35] so the traction function is unlocked. (The
Loosen the two bolts (Item 1) holding the right centering traction lock override switch light will be ON.) On a
block. Move the right hand centering block (Item 2)

standard loader the wedge brake will unlock.
[Figure 50-101-33] until both pintle cams contact the
centering block. NOTE: When the engine is started, the wheels/tracks
may begin to move.
NOTE: The left centering block is not adjustable. By
adjusting the right centering block the left NOTE: In loaders equipped with manual steering and
centering block will also become aligned hydraulic brake, the steering levers may have
properly. to be moved during engine start-up to reduce
the amount of creep. This reduction in creep
Figure 50-101-34 will allow time for the engine to run and build
up hydraulic charge pressure, which will
release the hydraulic brake.
3
Using the remote start tool, turn the key (Item 1) [Figure
50-101-35] and start the engine and run at low idle.
1 Tighten bolts (Item 3) [Figure 50-101-34] to 35 - 40 ft.-lb.

(47,5 - 54,2 N•m).
2 NOTE: Check for slack between centering blocks and

pintle cams. If there is excessive slack repeat
above steps [Figure 50-101-33] & [Figure 50-
101-34].
P-48451
A modified locking grip C-Clamp and steering block

shown in [Figure 50-101-30] may be used to help in
aligning the centering blocks.
Install the centering block (Item 1) on the inside of the

pintle cams and the C-Clamp (Item 2) [Figure 50-101-
34] around both centering blocks.
Lock the C-Clamp in place.

T180 Bobcat Loader
574 of 961
(CONT’D)
Start the neutral adjustment procedure with the left

pump first and complete the neutral adjustment for
the left pump before adjusting the right pump.
Figure 50-101-36
1 1
2
P-54610
Move the engine speed control to high idle.
NOTE: The neutral range (dead-band) will vary

between the hydrostatic pumps.
NOTE: This procedure is shown for neutral

adjustment on the left side of the loader. The

P-48632 procedure is the same for the right side
neutral adjustment.
Loosen the left pump pintle adjustment lock bolts
(Item 1). (The right pump pintle adjustment lock bolts are
counterclockwise until forward creep is seen.
(Item 2) [Figure 50-101-36].) Loosen the bolts enough to
allow free movement between the pintle arm and the
pintle base.
counterclockwise to a point between forward and reverse
where there is zero creep.
NOTE: If the bolts are too loose or too tight, the
neutral adjustment may be affected.
Stroke the left steering lever to forward and allow the
lever to return to neutral. Stroke the left steering lever to
reverse and allow the lever to return to neutral. Check
that there is zero creep when the lever returns from either
direction, on the left side. Turn the adjustment screw (if
necessary) until zero creep is obtained.
T180 Bobcat Loader

575 of 961
CONTROL PANEL (ADJUSTABLE PINTLES)
(CONT’D)
Figure 50-101-38
2 1
2 1
P-48632
Torque the left pump pintle adjustment lock bolts (Item 1)

[Figure 50-101-38] to 35 - 40 ft.-lb. (47,5 - 54,2 N•m).

Repeat the adjustment procedure for the right pump.
Torque the right pump pintle adjustment lock bolts (Item

2) [Figure 50-101-38] to 35 - 40 ft.-lb. (47,5 - 54,2 N•m).
Test both levers by moving them backward and forward

and letting them return to neutral by the return spring
force.
If the levers do not return to neutral and the wheels/

tracks do not come to a complete stop, repeat the
adjustment procedure again.
Stop the engine.
Remove one pintle adjustment bolt (Item 1) [Figure 50-

101-38] at a time and apply Loctite® 242 or equivalent
thread locker to the bolt and re-install the bolt. Torque the
bolt to 35 - 40 ft.-lb. (47,5 - 54,2 N•m). Repeat for the
three remaining pintle adjustment lock bolts.
NOTE: To maintain proper adjustment setting,

remove and reinstall only one bolt at a time.
New bolts can be installed with pre applied
Loctite®.
Remove the loader remote start tool.
NOTE: After the neutral adjustment is completed on

both pumps, the linkage travel adjustment
MUST be completed. 50-101-17.)
T180 Bobcat Loader

576 of 961
(CONT’D)
Linkage Travel Adjustment

2
NOTE: When the linkage travel adjustment procedure
is being done as part of the loader neutral
adjustment procedure, check the torsion 1
bushings at the pump and at the bell cranks to
be sure they are not binding or too loose,
which will affect the procedure.
2
1
WARNING
P-48448

W-2059-0598
freely between the steering bellcrank and the linkage bar.
Figure 50-101-40

10-20-1.) 1
WARNING 2
W-2017-0286
P-54613
1.)
Loosen the nut (Item 1) only until the tension is released
Raise the operator cab. (See Raising The Operator Cab from the torsion bushing (Item 2) [Figure 50-101-40].
on Page 10-30-1.)
The bolt must be loose enough to allow the torsion
Pre-load tension in the torsion bushings must be bushing (Item 2) [Figure 50-101-40] to turn freely
removed before adjusting the steering linkage. between the torsion bushing and the linkage bar.
T180 Bobcat Loader

577 of 961
(CONT’D)
Linkage Travel Adjustment (Cont’d) 2
Figure 50-101-41
1 3 4
P-51174
Move the right side steering lever forward and install a

15/16 in. (24 mm) thick spacer (Item 1) between the
P-37574 center plate (Item 2) and the mounting plate (Item 3)
[Figure 50-101-43].
Remove access plug from the top of the control panel. This will allow the pintle arms to move freely while

adjusting the steering linkage for full forward travel
Turn the control lever drift adjustment bolts (Item 1) speed.
[Figure 50-101-41] (one on each control lever) out until it
is flush with the bottom of the nut. Remove the 3/8 in. (10 mm) thick spacer (Item 4) [Figure
50-101-43].
Figure 50-101-42
Figure 50-101-44
3 2
2
4
1
P-51173 1
P-51133
Move the right side steering lever to the rear and install a
3/8 in. (10 mm) thick spacer (Item 1) between the pintle Before adjusting the linkage, check that the base pintle
arm cam (Item 2) and the centering block (Item 3) arm mounting bolt (Item 1) and both of the upper pintle
[Figure 50-101-42]. mount bolts (Item 2) and tighten to 35 - 40 ft.-lb. (48 - 54
N•m) torque. There should be no play between the pintle
arm and the square pump shaft.
Also check that the cam mounting nuts or bolts (Item 4)

[Figure 50-101-44] are tight, 35 - 40 ft.-lb. (48 - 54 N•m)
torque.
T180 Bobcat Loader

578 of 961
(CONT'D)
Linkage Travel Adjustment (Cont'd)
Figure 50-101-45
1
1 1
P-51175
Remove the spacer (Item 1) [Figure 50-101-47].
P-54609
Disconnect the remote start tool. (See Procedure on
Page 10-60-1.)
Loosen the two bolts and nuts (Item 1) [Figure 50-101-
45] on each steering linkage bar. Figure 50-101-48

Figure 50-101-46 2
P-54613
P-51134
Tighten the two bolts (Item 1) and nuts (Item 2) to 35 - 40
ft.-lb. (47,5 - 54,2 N•m) [Figure 50-101-48].
Move the left control lever to the full forward position,
then pull forward on the left rear linkage bar until the
pintle arm is rotated to the front as far as possible
[Figure 50-101-46]. Use a locking plier, clamp the two
linkage bars together.
Installation: Tighten the nuts and bolts to 35 - 40 ft.-lb.

(47,5 - 54,2 N•m) torque.
Check the lever movement to make sure that the pintle

arm and the control lever are both at full stroke at the
same time. This will allow for maximum forward speed.
Repeat the linkage travel adjustment procedure for the

right side linkage.
T180 Bobcat Loader

579 of 961
(CONT'D)
Linkage Travel Adjustment (Cont'd)

1
Figure 50-101-49
1 P-37574
Push the control lever to full stroke and turn drift

adjustment bolt (Item 1) [Figure 50-101-50] in until it
P-48448 touches the U-bolt holding the control lever.
Repeat steps on the other control lever.

Tighten the two bolts and nuts (Items 1 & 2) [Figure 50-
101-49] to 35 - 40 ft.-lb. (47,5 - 54,2 N•m) torque at the

Drive the loader forward and check for drift.
steering bell cranks.
The traditional benchmark for drift is less than 10 ft. of
“drift” in 100 ft. of travel distance.
If the drift is excessive to the left, turn the right

adjustment bolt (Item 1) [Figure 50-101-50] in.
If the drift is excessive to the right, turn the left

adjustment bolt in.
NOTE: When using the drift adjustment bolts, only

adjust one bolt for each test drive.
In addition, only move each bolt a maximum

of one turn for each test drive. This will help
prevent over-correction and excessive
reduction in travel speed.
Drift adjustment is for forward travel only.
Adjust the drift to an acceptable level.
Re-install the plug in the drift bolt access hole after

adjustment.
T180 Bobcat Loader

580 of 961
CONTROL PANEL (SELECTABLE JOYSTICK Remove the engine speed control. (See Removal And
CONTROL) (SJC) Installation on Page 70-20-1.)
Removal And Installation Figure 50-102-1
WARNING
W-2017-0286
1
DANGER P-64311
Remove the lift arm bypass control knob and rubber


Figure 50-102-2
P-90328 2
1
1
AVOID DEATH
unless supported by an approved lift arm 4
D-1009-0409
3 3
P-64319
WARNING Remove the fuse cover mount screws (Item 1) [Figure

50-102-2].
the lift arms are secured by an approved lift arm Installation: Tighten screws to 8 - 11 ft.-lb. (11 - 15 N•m)
support device. Failure to use an approved lift arm torque.
to fall and cause injury or death. Remove the fuse/relay cover (Item 2) [Figure 50-102-2].
W-2059-0598
Remove the fuse/relay shield mounting screws (Item 3)
Raise the lift arms and install an approved lift arm support [Figure 50-102-2].
10-20-1.) Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27
N•m) torque.
on Page 10-30-1.) Remove the fuse/relay shield (Item 4) [Figure 50-102-2]
T180 Bobcat Loader

581 of 961
CONTROL PANEL (SELECTABLE JOYSTICK Figure 50-102-5
CONTROL) (SJC) (CONT’D)
Figure 50-102-3
1
1 1
P-64298
1
Disconnect the left joystick wire harness connector (Item
1) [Figure 50-102-5].
P-64309
Remove the control panel mount screws (Item 1) [Figure
50-102-3] from the both sides of the control panel.

Installation: Tighten the control panel mounting screws
to 15 - 20 ft.-lb. (20 - 27 N•m) torque.
Figure 50-102-4
P-64328
Disconnect the right joystick wire harness connector

(Item 1) [Figure 50-102-4].
T180 Bobcat Loader

582 of 961
CONTROL HANDLE Control Lever Boot
Control Lever Removal And Installation Figure 50-110-3
Figure 50-110-1
N-18884
1
P-48462
To replace the rubber boot (Item 1) [Figure 50-110-3] on
the control panel, remove the control lever (See above
Disconnect the electrical connectors (Item 1) [Figure 50- procedure).
110-1] from the control lever.

Drill out the four rivets (Item 2) [Figure 50-110-3] located
Figure 50-110-2 on the flange of the rubber boot and remove the old boot.
Install the new boot and reinstall the control lever.
N-22658
Remove the nuts from the two U-bolts (Item 1) [Figure

50-110-2] used to mount the control lever.
Remove the U-bolts from the control lever mount.
Remove the control lever (Item 2) [Figure 50-110-2] by

sliding the lever through the rubber boot (Item 1) [Figure
50-110-3] on the front of the control panel.
Installation: Tighten the U-bolts so the lever can not be

moved either right or left when seated in the operator
seat. Be sure the control lever does not interfere with the
operator cab when lowering or raising the cab.
T180 Bobcat Loader

583 of 961
T180 Bobcat Loader

584 of 961
CONTROL HANDLE (ADVANCED CONTROL Figure 50-111-2
SYSTEM) (ACS) SELECTABLE HAND/FOOT
CONTROL
Components Identification
Figure 50-111-1
1
1
P-21879
Handle Sensor (Item 1) [Figure 50-111-2].

sensor, actuator or ACS Controller.
Calibration Procedure60-120-16

P16572
Control Handle (Item 1) [Figure 50-111-1].
T180 Bobcat Loader

585 of 961
CONTROL (CONT'D)
Handle Sensor Removal And Installation 1
Figure 50-111-3
P-21836
1
Disconnect the harness connector (Item 1) [Figure 50-

111-5] from the handle sensor connector.
P-21864 Disconnect the harness connector (Item 2) [Figure 50-

111-5] from the handle lock solenoid connector.
Loosen the nuts (Item 1) [Figure 50-111-3].

Figure 50-111-6
Installation: Tighten the u-bolts so the lever can not be
seat. Be sure the control lever does not interfere with the 1
operator cab when lowering or raising the cab.
Figure 50-111-4
P-21861
1
Remove the handle sensor connector (Item 1) [Figure
50-111-6] from the clip.
NOTE: Pry out with a small screw driver and push the
P-21837 connector down.
Tilt the control handle (Item 1) [Figure 50-111-4] to the

center of the loader.
Lift the boot cover (Item 2) [Figure 50-111-4].
T180 Bobcat Loader

586 of 961
CONTROL (CONT'D)
Handle Sensor Removal And Installation (Cont'd)
Figure 50-111-7
P-21880
Remove one of the two mounting screws (Item 1) [Figure

50-111-9] from the handle sensor.
1
P-21860 Installation: Tighten bolt to 32 - 38 in.-lb. (3,6 - 4,3 N•m)
torque.
Remove the handle lock solenoid connector (Item1)

Figure 50-111-10
[Figure 50-111-7] from the clip.
NOTE: Pry out with a small screw driver and push the
connector down.
4
3 7
Figure 50-111-8 1
1 8
4
5 3
2 6
4 5
2
P-21882
3
Remove the handle sensor (Item 1) [Figure 50-111-10]
from the handle assembly.
1
P-21862 NOTE: The handle sensor (Item 1) [Figure 50-111-10]
can only be replaced as a complete assembly.
Remove one of the two mounting screws (Item 1) [Figure
Check the spacer (Item 2) and screws (Item 3), mounting
50-111-8] from the handle sensor.
pin (Item 4), spring (Item 5), washer (Item 6), bolt/nut
(Item 7), stop strap (Item 8) and replace as needed
Installation: Tighten screws to 32 - 38 in.-lb. (3,6 - 4,3
[Figure 50-111-10].
N•m) torque.
While removing the mounting pin (Item 2) [Figure 50-

111-8] from the handle sensor, remove the one plastic
spacer (Item 3) [Figure 50-111-8], the spring (Item 4)
[Figure 50-111-8] and washer (Item 5) [Figure 50-111-
8].
T180 Bobcat Loader

587 of 961
CONTROL HANDLE (ADVANCED CONTROL
CONTROL (CONT'D)
Handle Sensor Removal And Installation (Cont'd)
Figure 50-111-11
3
2
P-21878
Figure 50-111-12

3
2
1
P-21799
Installation: When installing the handle sensor into the

control handle, check the routing of the switch handle
wire harness (Item 1) [Figure 50-111-11] & [Figure 50-
111-12] to assure proper return of the control handle to
neutral and minimize harness movement.
NOTE: Route wires (Item 2) [Figure 50-111-11] &

[Figure 50-111-12] as shown away from stop
strap (Item 3) [Figure 50-111-11] & [Figure 50-
111-12] to avoid wire damage.

sensor, actuator or ACS Controller. (See
Calibration Procedure on Page 60-120-16.)
T180 Bobcat Loader

588 of 961
CONTROL (CONT'D)
Control Handle Removal and Installation

1
Figure 50-111-13
N-17384
1
Remove the rubber handle cover (Item 1) [Figure 50-
111-15] from the handle.
P-21879 Figure 50-111-16
Remove the handle sensor (Item 1) [Figure 50-111-13].

(See Handle Sensor Removal And Installation on Page
50-111-2.)
1
Figure 50-111-14
2 2
N-17385
Using a small screwdriver, hold the handle spacer (Item

1) [Figure 50-111-16] and remove the allen head screws
(Item 2) [Figure 50-111-16] from the handle assembly.
P16534 Installation: Tighten the allen head screws to 35 in.-lb.

(4 N•m) torque.
Remove the switch handle (Item 1) [Figure 50-111-14].
(See Switch Handle Removal on Page 60-120-7.)
T180 Bobcat Loader

589 of 961
CONTROL HANDLE (ADVANCED CONTROL Control Lever Removal and Installation
CONTROL (CONT'D) Figure 50-111-19
Control Handle Disassembly and Assembly
1
Figure 50-111-17
1
1
N-22667
2
1
Disconnect the electrical connectors (Item 1) [Figure 50-
N-17394 111-19] from the control lever switch handle.
Remove the electrical connectors from the control lever

Remove the handle sleeve (Item 1) [Figure 50-111-17]

switch handle. (See Controller, Connector And Wire
and bushings (Item 2) [Figure 50-111-17] from the
Identification on Page 60-120-4.)
handle.
Check all parts for wear and replace as needed.
Figure 50-111-18
N-22796
Check the mounting bolt (Item 1) [Figure 50-111-18] that

connects the handle to the handle sensor for wear,
replace as needed.
T180 Bobcat Loader

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CONTROL (CONT'D)
Control Lever Removal and Installation (Cont’d)
Figure 50-111-20
2
1
1
P13734
The control lever (Item 1) [Figure 50-111-22] must be

replaced as a complete unit.
N-22658 The connector clip (Item 2) [Figure 50-111-22] can be

replaced separately from the control lever.
Figure 50-111-21

18.25”
B-16618
Loosen the two u-clamps (Item 1) [Figure 50-111-20]

nuts.
Installation: Tighten the u-bolts so the lever can not be

seat. Control lever end (Item 2) [Figure 50-111-20]
should be flush with bellcrank. Be sure the control lever
does not interfere with the operator cab when lowering or
raising the cab. The distance between handles should be
18.25 in. [Figure 50-111-21].
Remove the control lever from the cross shaft and control
panel.
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CONTROL HANDLE (ADVANCED CONTROL
CONTROL (CONT'D)
Control Lever Boot
Figure 50-111-23
N-22659
To replace the rubber boot (Item 1) [Figure 50-111-23]

on the control panel, remove the control lever. (See
Control Lever Removal And Installation on Page 50-110-
1.)
Drill out the four rivets (Item 2) [Figure 50-111-23]

located on the flange of the rubber boot and remove the
old boot.
Install the new boot and reinstall the control lever. (See
Control Lever Boot on Page 50-110-1 and See Control
Lever Removal And Installation on Page 50-110-1)
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CONTROL HANDLE (SELECTABLE JOYSTICK Figure 50-112-3
CONTROL) (SJC)
Joystick Testing (Right & Left) 1

Figure 50-112-1
P-28312
Disconnect the joystick harness connector (Item 1) from

the loader wiring harness (Item 2) [Figure 50-112-3].
P-28301
Install the test harness (Item 3) [Figure 50-112-3]

The tools listed will be needed to do the following between the two connectors.
procedure:

Turn the remote start key to ON position without starting
MEL1608-Joystick Test Harness [Figure 50-112-1] the loader.
MEL1563-Remote Start Tool
Check the voltage between pin 3 and pin 5 on the joystick
Multimeter test harness (Item 3) [Figure 50-112-3].
Raise the lift arms and install an approved lift arm support The voltage should be between 2.45 and 2.55 volts.
10-20-1.) Figure 50-112-4
on Page 10-30-1.)
Connect the remote start tool to the loader. (See

Figure 50-112-2
P-64328
1
Repeat the procedure at the right joystick wiring harness

connector (Item 1) [Figure 50-112-4]. (If needed.)
P-64298
At the back side of the control panel, locate the left

joystick wire connector (Item 1) [Figure 50-112-2].
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CONTROL HANDLE (SELECTABLE JOYSTICK Figure 50-112-7
CONTROL) (SJC) (CONT'D)
Joystick Removal (Right & Left)
When replacing joystick assemblies, they are available

as a complete assembly with the boot and lever already 1
attached. This procedure is shown so the electrical
connections can be checked at the bottom of the joystick,
if suspected to be loose or disconnected.
10-20-1.)

P-26222
on Page 10-30-1.)
Figure 50-112-5 Remove the two outside joystick mount screws (Item 1)
[Figure 50-112-7].
Figure 50-112-8

1
P-26220A
Roll the joystick rubber boot (Item 1) [Figure 50-112-5]

P-26223A
down from the joystick handle.
Figure 50-112-6 Remove the joystick from the rubber boot [Figure 50-
112-8].
P-26221
Remove the two inside joystick mount bolts (Item 1)

[Figure 50-112-6].
T180 Bobcat Loader

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CONTROL HANDLE (SELECTABLE JOYSTICK Lever Assembly Removal (Right & Left)
Joystick Removal (Right & Left) (Cont'd) device. (See Installing Lift Arm Support Device on Page
10-20-1.)
Figure 50-112-9
on Page 10-30-1.)
1
Figure 50-112-10
P-26224
Disconnect the electrical harness (Item 1) [Figure 50-

112-9] from the joystick.

P-64328
Remove the joystick from the loader.

Disconnect the joystick wiring harness connectors (Item
1) on both the right and left hand joysticks [Figure 50-
112-10].
T180 Bobcat Loader

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CONTROL HANDLE (SELECTABLE JOYSTICK
Lever Assembly Removal (Right & Left) (Cont'd)
Figure 50-112-11
P-64303
Remove the two control lever mounting bolts (Item 1)

[Figure 50-112-11].

The mounting bolts are secured with lock-nuts on the
back of the control panel. Once removed, they need to be
replaced with new.
Figure 50-112-12
P-64308
Remove the control lever from the loader [Figure 50-

112-12].
T180 Bobcat Loader

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ELECTRICAL SYSTEM
ADVANCED CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . 60-120-1

ACS Controller Removal And Installation . . . . . . . . . . . . 60-120-5
Actuators Disassembly and Assembly. . . . . . . . . . . . . . 60-120-12 SAFETY &
Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-16 MAINTENANCE
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Controller, Connector And Wire Identification . . . . . . . . . 60-120-4
Foot Lock Solenoid Connector. . . . . . . . . . . . . . . . . . . . 60-120-20
Foot Lock Solenoid Removal And Installation . . . . . . . . 60-120-19
Foot Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-18
Foot Sensor Disassembly And Assembly . . . . . . . . . . . 60-120-18
Handle Lock Solenoid Connector . . . . . . . . . . . . . . . . . 60-120-15 DRIVE
Handle Lock Solenoid Disassembly And Assembly. . . . 60-120-14 SYSTEM
Handle Lock Solenoid Removal And Installation . . . . . . 60-120-13
Handle Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . 60-120-6
Switch Handle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-7
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-120-9
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

ELECTRICAL
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . 60-30-1 SYSTEM
Alternator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-6
Alternator Voltage Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-9 ENGINE
Charging System Check . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2 SERVICE
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-7
High Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Low Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . 60-30-5 SPECIFICATIONS
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-8
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-8
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-8
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-8
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . 60-20-3
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ELECTRICAL SYSTEM (CONT’D)
BICS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Additional Inspection For Loaders With Advanced Control System (ACS) . . . . 60-90-2
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key
ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Inspecting The BICS Controller (Engine STOPPED - Key ON) . . . . . . . . . . . . . 60-90-1
Inspecting The Lift Arm Bypass Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . 60-90-1
Inspecting The Traction Lock (Engine RUNNING). . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-3
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-4
BOBCAT CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-3
CALIBRATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Calibration Procedure (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1

Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-5
Lift and Tilt Calibration Procedure (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-4
CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC) . . . . . . . . . . . . . . . 60-71-1

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-4
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1
DIAGNOSTICS SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Number Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-2
ELECTRICAL SYSTEM INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Relay Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-3
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE . . . . . . . . . . . . . . . . . . . 60-130-1

Controls Identification Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK

CONTROL) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-131-1
Controls Identification Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-131-1
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FLYWHEEL RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Deluxe Panel Removal And Installation (Right Side). . . . . . . . . . . . . . . 60-50-10
Deluxe Panel Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Front Accessory Panel Removal And Installation . . . . . . . . . . . . . . . . . 60-50-12
Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Option And Field Accessory Panels (If Equipped) . . . . . . . . . . . . . . . . . . 60-50-8
Passwords (Deluxe). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Standard & Deluxe Panel Removal And Installation (Left Side) 60-
50-11
Standard Panel Removal And Installation (Right Side) . . . . . . . . . . . . . . 60-50-9
Right Panel Setup Display Options (Deluxe) . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Right Panel (Deluxe) (With Keyless Start) . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Right Panel (Standard) (With Key Switch) . . . . . . . . . . . . . . . . . . . . . . . . 60-50-2
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1

Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
SEAT BAR SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

BICS Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Connecting The Service PC To Remote Start Tool . . . . . . . . . . . . . . . . 60-150-1
SPEED SENSOR (SELECTABLE JOYSTICK CONTROL) (SJC) . . . . . . . 60-170-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-3
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-7
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-9
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
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TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Description Of The Control System . . . . . . . . . . . . . . . . . 60-110-2
Inspecting The Control System . . . . . . . . . . . . . . . . . . . . 60-110-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1


ITEMS MAY VARY.
T180 Bobcat Loader

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PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH
COMPUTER POWER F
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
REAR ROD (NOT Used With AHC or ACS)
CLOCK/LATCH A
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm 1 1 4430 4370 1 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
12V 7.7 ohm
GROUND
2 2 2430 2370 2 2
GROUND
BROWN TIE STRAP (NOT Used With AHC or ACS) PWM
BUZZER
BUZZER
C422
START J
START
OPEN
1
DATA B
4380 1
DATA
7.7 ohm
PWM
REAR BASE 2380 2 2
C414
HIGH FLOW BICS HYDRAULIC LOCK
1 1 4440
G
C
D
E
B
A
K
E
F
J
7.5 ohm
WIRING SCHEMATIC
C415
12V
C420
7.5 ohm A A 4460 2 2 2440 WHITE TIE STRAP 4410 A A 9.8 ohm
12V B B 2460 BLUE TIE STRAP 2410 B B 12V
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
BUCKET POSITIONING FRONT ROD
C423
C418
(Without ACS Option) WIRES CONNECT BY LETTER
ACROSS CONNECTORS
9.8 ohm
12V
A
B
A
B
4420
2420
4330
2330
1
2
1
2
3.3 ohm
PWM FRONT BASE
C419 C106
4340 1 1 3.3 ohm
CAB 6727178
A B
T180 (S/N 524211001 AND ABOVE) B A
2340 2 2 PWM
(S/N 524311001 AND ABOVE) DIVERTER

3600 A A
C416
SPEED
SOME CONNECTOR 4450 A A 7.5 ohm SENSOR MAIN
3610 B B
(PRINTED OCTOBER 2003)
WORKLIGHTS
BODIES NOT SHOWN YELLOW TIE STRAP 2450 B B 12V FRAME
FRONT
FOR DRAWING CLARITY HYDRAULIC
V-0412
C108
3300 A A TEMPERATURE
SWITCH
SENDER
BRAKE
FRONT AUX RELIEF 3310 B B
1930
RED = RED 500-3000 ohm
2000
C424
RNG = ORANGE 4490 A A 11 ohm
BLK = BLACK GREEN TIE 12V
C435
2490 B B
RIGHT
LBL = LIGHT BLUE STRAP 2760 B B
RELAY GROUNDS 2000-2060 UNSWITCHED POWER 1000-1999 RED
FUSED, UNSWITCHED POWER 1000-1999 RED/WHT DBL = DARK BLUE A SEE C113 6120 A A
ARE CONNECTED IN SERIES LGN = LIGHT GREEN
SWITCHED POWER 1000-1999 RNG REAR AUX RELIEF
C405 C406
GROUND 2000-2999 BLK DGN = DARK GREEN SEAT
C417
CAB
2530 YEL = YELLOW A A 3700 A A
C434
GROUNDS MONITORING 3000-3999 LBL 4480 AIR FILTER BAR 6110 A A
LEFT
9.8 ohm
4330
PNK = PINK
4360
4340
4410
4440
4430
4420
2470 HYDRAULIC 4000-4999 LGN 12V B B SWITCH
2770
SEE J1 B 3710
3300
2480 B B
2110
3700
3200
B B
3600
ATTACHMENT CONTROLS 5000-5999 YEL WHT = WHITE 2750
4470
4460
4450
2460 LIGHTS 6000-6999 PNK BRN = BROWN 3110 B B FUEL
ACCESSORIES 7000-7999 WHT TAN = TAN SENDER - +8
2450 3100 A A 30-270 ohm 2910
ENGINE 8000-8999 TAN PUR = PURPLE
2440 2400 COMMUNICATION 9000-9999 PUR GRY = GRAY
J1 J2 2920 2900
C
2930
A
2430
18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2340 3100 2760
SPOOL SPARE FRONT COMPUTER SYSTEM LH AUX L HAND
COOLANT
PWM +8V ENG SPEED 28
LOCK ANALOG 1 TEMP SIGNAL SIGNAL
ROD GROUND Tx RIGHT SERIAL IN SUPPLY
2330 +
A 1 2 3 4 5 6 7 8 9 10
2520 A A 3400 3400 15 11 9110 D
C105
HYDRAULIC CHARGE C 4360 4330 2900 9100 4810 9210 3200 4300 3600 N K G L B R P S F E D C M A J H
2100 PRESSURE SENDER C C 3420 3420 47 7 9210 E
C408
- PROTECTED
0.5 - 7.5 V B R HAND REAR SPARE SYSTEM LH AUX SPARE AIR FILTER RH FRONT
3010 23
SERIAL IN BASE ANALOG 2 POWER Rx LEFT DIGITAL 1 SIGNAL
PWM - DETENT
9400 F See C492
B B 3410 23
11 12 13 14 15 16 17 18 19 20 N K G L B R P S F E D C M A J H
2420 3700 42 9410 G
B 9110 4440 1200 9200 4820 4310 4920
2410 REAR STATUS LH SKI FUEL PWM RH SKI
SEE J2 FRONT COMPUTER SEAT BAR
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
OPEN SIGNAL
BASE ROD IN DOWN SENDER DOWN
2380 2390
POWER +8v
J2
21 22 23 24 25 26 27 28 29 30
2370 4430 9400 1900 3900
P05 4830 3100 4320 4930
4340
35 3910 SEE FUSE/RELAY
2200 BUCKET
KEY/ENTER SEATBAR LH SKI RH SKI A
OPEN POSITION OPEN
SWITCH GROUND UP OPEN GROUND OPEN UP CENTER
2000 45 3920 (EUROPEAN
31 32 33 34 35 36 37 38
38 39 40
2240 4420 9350 3910 4840 2110 4940 25 3900 C407 LIGHTING)
C112
HYDRAULIC OIL A A 3430 3430 3 HYD LOCK STATUS 34 9350
HEADLIGHT SEATBAR BRAKE SW HYDRAULIC
FILTER (DIFFERENTIAL) SOLENOID OUT FLOAT
SWITCH SIGNAL IN
OPEN TEMP OPEN OPEN
2800 SWITCH B B 14 1200

41 42 43 44 45 46 47 48 49 50
3610 4410 9410 4640 9340 3920 4500 3300 24 1900
3510
2300 DIFFERENTIAL SWITCH RESERVED HYD FILTER TWO SPEED RESERVED TWO SPEED LEFT GLOW PLUG TRACTION LOCK 46 4500
OPEN SPARE RELAY
(AC INPUT) OPEN SIGNAL SWITCH (BOOTSTRAP) MAKE-UP BLINKER PULL / 963
OUTPUT 1
2600 HARNESS 6728626 1 2 3 4 5 66 7 8 9 10
5 9100
3430 4910 4390 6410 8510 4110

15 9200
2110
RESERVED STARTER UNSWITCHED CAN HYD CHARGE RIGHT TRACTION HIGH FLOW / REAR WKLT FUEL RELAY
44 9340
(hall) FEEDBACK BATTERY (1) HIGH PRESS +8V BLINKER LOCK HOLD 900 LOAD RELAY HOLD
2740 ENGINE OIL A A 3500 3500 37 4 2900
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C 4940
2730 C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
40
SENDER
2120 -
B 4930
2720 0.5-7.5 V B B 3510 TRACTION LOCK SENSOR TRAVEL F&R AUX RESERVED UNSWITCHED
30
SPARE
DIGITAL 2 PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 RELIEF (SENSOR GRND) BATTERY (2)
DIVERTER STARTER
RELAY
20 4920
2710 21 22 23 24 25 26 27 28 29 30
2350 4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
ENGINE HARNESS 7101311 TWO SPEED
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
43 4640
ENGINE t 4350 8150 1130 9700 8550 3500 2100 6320 8110
C104
COOLANT A A B A 36 4840
C113
3200 B 3200 SEE J2-8 HANDLE SWITCH PWR / RESERVED ATTACHMENT +5V
SPARE HYD CHARGE ENG OIL RESERVED
SENDER POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY
OUTPUT 2 PRESS SIGNAL HORN PRESS SIGNAL (FAN OUTPUT)
4830
500-3000 ohm B B 3210 26
41 42 43 44 45 46 47 48 49 50
180 16 4820
A A 1800
8000 9800 3420 7200 3520
SUPPLY 0 1400
1020
J1 6 4810
C110
G A A J2
D3
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
B
B B 1800
EXCITATION FUEL J1
SHUTOFF
ALTERNATOR 2010 6736515
4910
HOLD PULL
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
10.9 ohm C 2800
1480
4810
4820
4830
4840
4640
C
4300
4320
4310
4910
4920
4930
4940
4230
2530
2800
C101
1490
2520
4240
1010
STARTER 0.3 ohm
A
B
A
B
8800
8100
A
B
A
B
8800
8100
G
H
C
D
E
G
F
B
D
C
H
A
K
F
J
J
BATTERY CABLE M R
C109
8250 B B Traction Lock C410 C409

B 8250
S
8200 A A
G
H
C
D
G
E
D
C
H
F
K
8200
J
HOLD 10.9 ohm
4200 A A
C425
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
C C
WHT
2200
WHT
PUR
DGN
YEL
RGN
DBL
LGN
RGN
GLOW PLUGS 4100 B B PULL 0.3 ohm
1.0 ohm each
F
+ -
B 2600 HR HR HR HR
FLOAT
H 6200 PWM
SHIFT
SKI CTRL
SIDE
8590
8570
8560
8580
C103
TWO SPD
SKI CTRL
DETENT
TO OPTIONS A
FLOW
6310
(ACCESSORY
CONNECTOR) E 6400
D 6500
G 6600
8500
C404
SEE CAB
C 7100 A TO OPTIONS
CONNECTOR LEFT HANDLE RIGHT HANDLE
B (BACKUP ALARM
SWITCH) C407
TURN SIGNAL HORN
A
J 2730
P 6600
6000
M 6500
RNG/WHT
RNG/DBL
L 6400
DGN
BRN
YEL
F 4730
D 4235
D
E
B
A
C488
TO OPTIONS N 6300
(ACCESSORY
C 4275
CONNECTOR) C411 C412
E 4550
TO OPTIONS TO OPTIONS
S 1700 (ACCESSORY (ACCESSORY
1740 CONNECTOR) CONNECTOR)
A 1140
H 1150
R
B
G
K (ALTERNATOR
1800 & KITS)
FUSE 11 (ACS CONNECTOR)
25A
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1700 1055 4220 M M

7200 J J
C489
TO OPTIONS B 2720 SWITCHED MARKER REAR GLOW FUEL

(ACCESSORY POWER LIGHT LIGHT PLUG STARTER PULL TRACTION 4275 L L
CONNECTOR) A 1720 1720
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK
25A
6410 P P
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10 30 85 30 85 30 85 30 85 30 85 30 85 85 30
25A
MAINFRAME HARNESS 7101181 1730
4550 K K
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E
C492
(HEATER
) 9620 D D
FUSE 1 FUSE 2 FUSE 3 FUSE 6 FUSE 5
15A
G 9410 S S 9420
25A 15A 30A 30A
120
1140 F 9400 R R
E 9210 G G
1150 1160 9520 C C
1070 2240 H H
RELAY GROUNDS 2000-2060
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 1740 B B
FUSE / RELAY CENTER 25A
(UNSWITCHED
POWER)
25A
(ACS)
1170 A A
D 9110 F F
1080
1040
FUSE 5 FUSE 1 FUSE 9

TRACTION HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER 1160
1730
9800
9510
9610
9710
2710
FUSE 6 FUSE 2 LIGHT POWER FUSE 10
LIGHT
FUEL PULL FR & MK LT ATTCHMNT
30A 15A 25A 1050

G
-
D
C
E
A
B
1300
F
REAR LT ALT & KITS

+ TO OPTIONS
1060
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL)
COMPUTER ACS
ACD & REMOTE
1310 START CONNECTOR V-0412 (10-13-03)
25A 25A
1040
Printed in U.S.A. 1080
BATTERY
601 of 961
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH D
COMPUTER POWER F
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
CLOCK/LATCH A
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm 1 1 4430 4370 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
12V
GROUND
2 2 2430 2370 2
GROUND G
BROWN TIE STRAP (NOT Used With AHC or ACS)
BUZZER
BUZZER
C422
START J
START J
OPEN
1
DATA B
4380
DATA B
REAR BASE 2380 2
C414
1 1 4440
G
C
D
E
A
K
E
F
7.5 ohm
WIRING SCHEMATIC 12V
C415
C420
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
C423
C418
(With ACS Option) WIRES CONNECT BY LETTER
ACROSS CONNECTORS
9.8 ohm
12V
A
B
A
B
4420
2420
4330
2330
1
2
1
2
3.3 ohm
PWM FRONT BASE
C419 C106
4340 1 1 3.3 ohm
CAB 6727178
A B
T180 (S/N 524211001 AND ABOVE) B A
2340 2 2 PWM

3600 A A
C416
SPEED
3610 B B
(PRINTED OCTOBER 2003)
WORKLIGHTS
FRONT
V-0413
C108
SWITCH
SENDER
BRAKE
1930
500-3000 ohm
Printable Version Click Here RED = RED
2000
C424
C435
2490 B B
RIGHT
C405 C406
C417
CAB
C434
LEFT
9.8 ohm
4330
PNK = PINK
4360
4340
4410
4440
4430
4420
2770
SEE J1 B 3710
3300
2480 B B
2110
3700
3200
B B
3600
4470
4460
4450
2450 3100 A A 30-270 ohm 2910
J1 J2 2920 2900
C
2930
A
2430
18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2340 3100 2760
COOLANT
2330 +
A 1 2 3 4 5 6 7 8 9 10
2520 A 3400 15
C105
HYDRAULIC CHARGE C
A 3400 4360 4330 2900 9100 4810 9210 3200 4300 3600
11 9110 D N K G L B R P S F E D C M A J H
C408
- PROTECTED
0.5 - 7.5 V B R HAND
SERIAL IN
REAR SPARE
ANALOG 2 POWER
SYSTEM
Rx
LH AUX SPARE
DIGITAL 1
AIR FILTER
PWM -
RH FRONT
See C492
LEFT SIGNAL DETENT
B B 3410 3010 23 BASE
23 9400 F
2420 3700 42 9410 G
B 9110 4440 1200 9200 4820 4310 4920
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
OPEN SIGNAL
2380 2390
POWER +8v
J2
21 22 23 24 25 26 27 28 29 30
2370 4430 9400 1900 3900
P05 4830 3100 4320 4930
4340
2200 BUCKET
OPEN POSITION OPEN
2000 45 3920 (EUROPEAN
31 32 33 34 35 36 37 38
38 39 40
2240 4420 9350 3910 4840 2110 4940 25 3900 C407 LIGHTING)
C112
SWITCH SIGNAL IN
OPEN TEMP OPEN OPEN
2800 SWITCH B B 14 1200

41 42 43 44 45 46 47 48 49 50
3610 4410 9410 4640 9340 3920 4500 3300 24 1900
3510
OPEN SPARE RELAY
OUTPUT 1
2600 HARNESS 6728626 1 2 3 4 5 66 7 8 9 10
5 9100
3430 4910 4390 6410 8510 4110

15 9200
2110
44 9340
2740 ENGINE OIL A A 3500 3500 37 4 2900
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C 4940
2730 C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
40
SENDER
2120 -
B 4930
30
SPARE
CAN
DIVERTER STARTER
RELAY
20 4920
2710 21 22 23 24 25 26 27 28 29 30
2350 4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
4350 3500 6320 8110
43 4640
ENGINE t 8150 1130 9700 8550 2100
C104
C113
4830
500-3000 ohm B B 3210 26
41 42 43 44 45 46 47 48 49 50
180 16 4820
A A 1800
8000 9800 3420 7200 3520
SUPPLY 0 1400
1020
J1 6 4810
C110
G A A J2
D3
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
B
B B 1800
FUEL
EXCITATION
SHUTOFF
J1
ALTERNATOR 2010
6736515
4910
HOLD PULL
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
10.9 ohm 2800 C C 2800
1480
4810
4820
4830
4840
4640
4300
4320
4310
4910
4920
4930
4940
4230
2530
1490
C101
2520
4240
1010
STARTER 0.3 ohm
A
B
A
B
8800
8100
A
B
A
B
8800
8100
G
H
C
D
E
G
F
B
D
C
H
A
K
F
J
J
BATTERY CABLE M R
C109
8250 B B Traction Lock C410 C409

B 8250
S
8200 A A
G
H
C
D
G
E
D
C
H
F
K
8200
J
HOLD 10.9 ohm
4200 A A
C425
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
A
A
B
B
C C
WHT
2200
WHT
PUR
DGN
YEL
RGN
DBL
LGN
RGN
TO OPTIONS C465 C466
GLOW PLUGS 4100 B B PULL 0.3 ohm
A
B
B
(ACCESSORY 1.0 ohm each
CONNECTOR)
F
+ - HANDLE
B 2600 HANDLE LOCK
FLOAT
HR HR HR HR
SHIFT
SKI CTRL
SIDE
LOCK
H 6200 PWM
8590
8570
8560
8580
LEFT HANDLE
C103
TWO SPD
SKI CTRL
DETENT
A
FLOW
6310
HORN
E 6400
AHC LIFT
TURN SIGNAL
RIGHT
HALL SENSOR
6500 HANDLE
D AHC TILT
B
C
A
G 6600 HALL SENSOR
RNG/WHT
RNG/DBL
8500
C404
SEE CAB
C 7100 A TO OPTIONS C450
DGN
BRN
YEL
CONNECTOR
B
C
A
B (BACKUP ALARM
A
C
B
SWITCH) C407 C449
C
B
D
E
B
A
A
B
C
A
J 2730
C411
B
C
C412
A
P 6600 C469
6000
M 6500 C472
A
C
B
C
B
A
L 6400
(ACCESSORY (ACCESSORY
4750
1610
2750
F 4730 CONNECTOR) CONNECTOR)
1510
4650
2650
D 4235
C488
TO OPTIONS N 6300 13 ohm

(ACCESSORY 12V
C 4275
CONNECTOR) FOOT PEDAL LOCK TILT ACTUATOR LIFT ACTUATOR
E 4550
S 1700 M M
A 1140 1740
BLK
1150
DGN
H
RED
A B A B
RED
BLK
DGN
RED
RED
BLK
BLK
R
C467 C468
B
A B
8
7
6
5
4
3
2
1
A B
8
7
6
5
4
3
2
1
G C428
C429
4270
2500
4280
2510
K
8
7
5
4
3
2
1
(ALTERNATOR
6
1800 & KITS)
8
7
6
5
4
3
2
1
FUSE 11
1630
4770
2770
4790
4780
25A
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1530
4670
2670
4690
4680
1700 1055 4220 M M 4220
7200 J J
C489

(ACCESSORY POWER LIGHT LIGHT PLUG STARTER PULL TRACTION 4275 L L 4275
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK
25A
6410 P A 1170
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10
4680
4260
4220
4780
2270
2260
4790
4690
30 85 30 85 30 85 30 85 30 85 30 85 85 30
1180
1190
25A 4550 K K 4550
1730
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E 9720
(HEATER C B G E J H K A D F
9620 D D 9620
C492
) FUSE 2 FUSE 5
25A 15A 30A 30A
G 9410 S S 9420 4550 C GREY
15A
120
1140 F 9400 R R 9720 F J3
E 9210 G G 9620 E
1150 1160 9520 C C 9520 9520 D
1070 2240 H H 2240 2250 J1 ACS Controller
RELAY GROUNDS 2000-2060 G Advanced Control System
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 1740 B B 1740 2280 H
MAINFRAME HARNESS 7101181 FUSE / RELAY CENTER 25A
(UNSWITCHED
25A
1170 A F 1740 B
POWER) (ACS) P 1500 A
J2
D 9110 F
BLACK
A B C D K G F H
1080
J E
1040
4750
4650
4670
4770
FRONT &
MARKER 1160
1730
9800
9510
9610
9710
2710
LIGHT
FUEL PULL FR & MK LT ATTCHMNT A A 1620
C470
30A 15A 25A 1050 TILT C C 4760
FUSE 3 PEDAL
FUSE 7 FUSE 11 B
G
-
D
C
E
A
B
1300
F
+ B 2760
REAR LT ALT & KITS
1060 TO OPTIONS
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL) A A 1520
C471
ACD & REMOTE
COMPUTER
25A
ACS
25A
1310 START CONNECTOR LIFT
PEDAL
C C 4660 ACS HARNESS 6733292
1040 B B 2660
Printed in U.S.A. 1080 V-0413 (10-13-03)
BATTERY
602 of 961
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH
COMPUTER POWER F
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
CLOCK/LATCH A
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm 1 1 4430 4370 1 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
12V 7.7 ohm
GROUND
2 2 2430 2370 2 2
GROUND
BUZZER
BUZZER
C422
START J
START
OPEN
1
DATA B
4380 1
DATA
7.7 ohm
PWM
REAR BASE 2380 2 2
C414
1 1 4440
G
C
D
E
B
A
K
E
F
J
7.5 ohm
WIRING SCHEMATIC
C415
12V
C420
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
C423
C418
(Without Option) WIRES CONNECT BY LETTER
ACROSS CONNECTORS
9.8 ohm
12V
A
B
A
B
4420
2420
4330
2330
1
2
1
2
3.3 ohm
PWM FRONT BASE
C419 C106
4340 1 1 3.3 ohm
CAB 6727178
A B
T180 (S/N 527511001 - 527513826) B A
2340 2 2 PWM
(S/N 527611001 - 527613038) DIVERTER

3600 A A
C416
SPEED
3610 B B
(PRINTED JUNE 2005)
WORKLIGHTS
FRONT
V-0489
C108
SWITCH
SENDER
BRAKE
1930
2000
C424
C435
2490 B B
RIGHT
C405 C406
C417
CAB
C434
LEFT
9.8 ohm
4330
PNK = PINK
4360
4340
4410
4440
4430
4420
2770
SEE J1 B 3710
3300
2480 B B
2110
3700
3200
B B
3600
4470
4460
4450
2450 3100 A A 30-270 ohm 2910
J1 J2 2920 2900
C
2930
A
2430
18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2340 3100 2760
COOLANT
2330 +
A 1 2 3 4 5 6 7 8 9 10
2520 A A 3400 3400 15 11 9110 D
C105
HYDRAULIC CHARGE C 4360 4330 2900 9100 4810 9210 3200 4300 3600 N K G L B R P S F E D C M A J H
C408
- PROTECTED
0.5 - 7.5 V B R HAND REAR SPARE SYSTEM LH AUX SPARE AIR FILTER RH FRONT
3010 23
SERIAL IN BASE ANALOG 2 POWER Rx LEFT DIGITAL 1 SIGNAL
PWM - DETENT
9400 F See C492
B B 3410 23
2420 3700 42 9410 G
B 9110 4440 1200 9200 4820 4310 4920
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
OPEN SIGNAL
2380 2390
POWER +8v
J2
21 22 23 24 25 26 27 28 29 30
2370 4430 9400 1900 3900
P05 4830 3100 4320 4930
4340
2200 BUCKET
OPEN POSITION OPEN
2000 45 3920 (EUROPEAN
31 32 33 34 35 36 37 38
38 39 40
2240 4420 9350 3910 4840 2110 4940 25 3900 C407 LIGHTING)
C112
SWITCH SIGNAL IN
OPEN TEMP OPEN OPEN
2800 SWITCH B B 14 1200

41 42 43 44 45 46 47 48 49 50
3610 4410 9410 4640 9340 3920 4500 3300 24 1900
3510
OPEN SPARE RELAY
OUTPUT 1
2600 HARNESS 6728626 1 2 3 4 5 66 7 8 9 10
5 9100
3430 4910 4390 6410 8510 4110

15 9200
2110
44 9340
2740 ENGINE OIL A A 3500 3500 37 4 2900
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C 4940
2730 C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
40
SENDER
2120 -
B 4930
30
SPARE
CAN
DIVERTER STARTER
RELAY
20 4920
2710 21 22 23 24 25 26 27 28 29 30
2350 4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
43 4640
ENGINE t 4350 8150 1130 9700 8550 3500 2100 6320 8110
C104
C113
4830
500-3000 ohm B B 3210 26
41 42 43 44 45 46 47 48 49 50
180 16 4820
A A 1800
8000 9800 3420 7200 3520
SUPPLY 0 1400
1020
J1 6 4810
C110
G A A J2
D3
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
B
B B 1800
EXCITATION FUEL J1
SHUTOFF
4910
HOLD PULL
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
10.9 ohm C 2800
1480
4810
4820
4830
4840
4640
C
4300
4320
4310
4910
4920
4930
4940
4230
2530
2800
C101
1490
2520
4240
1010
STARTER 0.3 ohm
A
B
A
B
8800
8100
A
B
A
B
8800
8100
G
H
C
D
E
G
F
B
D
C
H
A
K
F
J
J
BATTERY CABLE M R
C109
B 8250 B B 8250 C410 C409

S Brake Valve
8200 A A 6732781
G
H
C
D
G
E
D
C
H
F
K
8200
J
4200 A A 4200 A A
C425
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
C C
WHT
2200 2200 B
WHT
PUR
DGN
B
YEL
RGN
DBL
LGN
RGN
GLOW PLUGS 4100 B B OPEN
1.0 ohm each
F
+ -
B 2600 HR HR HR HR
FLOAT
H 6200 PWM
SHIFT
SKI CTRL
SIDE
8590
8570
8560
8580
C103
TWO SPD
SKI CTRL
DETENT
TO OPTIONS A
FLOW
6310
(ACCESSORY
CONNECTOR) E 6400
D 6500
G 6600
8500
C404
SEE CAB
C 7100 A TO OPTIONS
B (BACKUP ALARM
SWITCH) C407
TURN SIGNAL HORN
A
J 2730
P 6600
6000
M 6500
RNG/WHT
RNG/DBL
L 6400
DGN
BRN
YEL
F 4730
D 4235
D
E
B
A
C488
TO OPTIONS N 6300
(ACCESSORY
C 4275
E 4550
A 1140
H 1150
R
B
G
K (ALTERNATOR
1800 & KITS)
25A
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1700 1055 4220 M M

7200 J J
C489

87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK
25A
6410 P P
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10 30 85 30 85 30 85 30 85 30 85 30 85 85 30
25A
4550 K K
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E
C492
(HEATER
) 9620 D D
15A
G 9410 S S 9420
25A 15A 30A 30A
120
1140 F 9400 R R
E 9210 G G
1150 1160 9520 C C
1070 2240 H H
(UNSWITCHED
POWER)
25A
(ACS)
1170 A A
D 9110 F F
1080
1040

FRONT &
MARKER 1160
1730
9800
9510
9610
9710
2710
LIGHT
30A 15A 25A 1050

G
-
D
C
E
A
B
1300
F
REAR LT ALT & KITS

+ TO OPTIONS
1060
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL)
COMPUTER ACS
ACD & REMOTE
25A 25A
1040
BATTERY
603 of 961
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH D
COMPUTER POWER F
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
CLOCK/LATCH A
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm 1 1 4430 4370 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
12V
GROUND
2 2 2430 2370 2
GROUND G
BUZZER
BUZZER
C422
START J
START J
OPEN
1
DATA B
4380
DATA B
REAR BASE 2380 2
C414
1 1 4440
G
C
D
E
A
K
E
F
7.5 ohm
C415
C420
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
C423
C418
ACROSS CONNECTORS
9.8 ohm
12V
A
B
A
B
4420
2420
4330
2330
1
2
1
2
3.3 ohm
PWM FRONT BASE
C419 C106
4340 1 1 3.3 ohm
CAB 6727178
A B
T180 (S/N 527511001 - 527513826) B A
2340 2 2 PWM
(S/N 527611001 - 527613038) DIVERTER

3600 A A
C416
SPEED
3610 B B
(PRINTED JUNE 2005)
WORKLIGHTS
FRONT
V-0490
C108
SWITCH
SENDER
BRAKE
1930
2000
C424
C435
2490 B B
RIGHT
C405 C406
C417
CAB
C434
LEFT
9.8 ohm
4330
PNK = PINK
4360
4340
4410
4440
4430
4420
2770
SEE J1 B 3710
3300
2480 B B
2110
3700
3200
B B
3600
4470
4460
4450
2450 3100 A A 30-270 ohm 2910
J1 J2 2920 2900
C
2930
A
2430
18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2340 3100 2760
COOLANT
2330 +
A 1 2 3 4 5 6 7 8 9 10
2520 A 3400 15
C105
HYDRAULIC CHARGE C
A 3400 4360 4330 2900 9100 4810 9210 3200 4300 3600
C408
- PROTECTED
0.5 - 7.5 V B R HAND
SERIAL IN
REAR SPARE
ANALOG 2 POWER
SYSTEM
Rx
LH AUX SPARE
DIGITAL 1
AIR FILTER
PWM -
RH FRONT
See C492
LEFT SIGNAL DETENT
B B 3410 3010 23 BASE
23 9400 F
2420 3700 42 9410 G
B 9110 4440 1200 9200 4820 4310 4920
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
OPEN SIGNAL
2380 2390
POWER +8v
J2
21 22 23 24 25 26 27 28 29 30
2370 4430 9400 1900 3900
P05 4830 3100 4320 4930
4340
2200 BUCKET
OPEN POSITION OPEN
2000 45 3920 (EUROPEAN
31 32 33 34 35 36 37 38
38 39 40
2240 4420 9350 3910 4840 2110 4940 25 3900 C407 LIGHTING)
C112
SWITCH SIGNAL IN
OPEN TEMP OPEN OPEN
2800 SWITCH B B 14 1200

41 42 43 44 45 46 47 48 49 50
3610 4410 9410 4640 9340 3920 4500 3300 24 1900
3510
OPEN SPARE RELAY
OUTPUT 1
2600 HARNESS 6728626 1 2 3 4 5 66 7 8 9 10
5 9100
3430 4910 4390 6410 8510 4110

15 9200
2110
44 9340
2740 ENGINE OIL A A 3500 3500 37 4 2900
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C 4940
2730 C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
40
SENDER
2120 -
B 4930
30
SPARE
CAN
DIVERTER STARTER
RELAY
20 4920
2710 21 22 23 24 25 26 27 28 29 30
2350 4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
4350 3500 6320 8110
43 4640
ENGINE t 8150 1130 9700 8550 2100
C104
C113
4830
500-3000 ohm B B 3210 26
41 42 43 44 45 46 47 48 49 50
180 16 4820
A A 1800
8000 9800 3420 7200 3520
SUPPLY 0 1400
1020
J1 6 4810
C110
G A A J2
D3
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
B
B B 1800
FUEL
EXCITATION
SHUTOFF
J1
ALTERNATOR 2010
6736515
4910
HOLD PULL
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
10.9 ohm 2800 C C 2800
1480
4810
4820
4830
4840
4640
4300
4320
4310
4910
4920
4930
4940
4230
2530
1490
C101
2520
4240
1010
STARTER 0.3 ohm
A
B
A
B
8800
8100
A
B
A
B
8800
8100
G
H
C
D
E
G
F
B
D
C
H
A
K
F
J
J
BATTERY CABLE M R
C109
B 8250 B B 8250 C410 C409

S Brake Valve
8200 A A
G
H
C
D
G
E
D
C
H
6732781
K
8200
J
4200 A A 4200 A A
C425
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
A
A
B
B
C
WHT
2200 C
WHT
PUR
DGN
YEL
2200
RGN
B
DBL
LGN
RGN
B C465 C466
TO OPTIONS GLOW PLUGS 4100 B B OPEN
A
B
B
CONNECTOR)
F
+ - HANDLE
B 2600 HANDLE LOCK
FLOAT
HR HR HR HR
SHIFT
SKI CTRL
SIDE
LOCK
H 6200 PWM
8590
8570
8560
8580
LEFT HANDLE
C103
TWO SPD
SKI CTRL
DETENT
A
FLOW
6310
HORN
E 6400
AHC LIFT
TURN SIGNAL
RIGHT
HALL SENSOR
6500 HANDLE
D AHC TILT
B
C
A
G 6600 HALL SENSOR
RNG/WHT
RNG/DBL
8500
C404
SEE CAB
DGN
BRN
YEL
CONNECTOR
B
C
A
B (BACKUP ALARM
A
C
B
SWITCH) C407 C449
C
B
D
E
B
A
A
B
C
A
J 2730
C411
B
C
C412
A
P 6600 C469
6000
M 6500 C472
A
C
B
C
B
A
L 6400
4750
1610
2750
1510
4650
2650
D 4235
C488

(ACCESSORY 12V
C 4275
E 4550
S 1700 M M
A 1140 1740
BLK
1150
DGN
H
RED
A B A B
RED
BLK
DGN
RED
RED
BLK
BLK
R
C467 C468
B
A B
8
7
6
5
4
3
2
1
A B
8
7
6
5
4
3
2
1
G C428
C429
4270
2500
4280
2510
K
8
7
5
4
3
2
1
(ALTERNATOR
6
1800 & KITS)
8
7
6
5
4
3
2
1
FUSE 11
1630
4770
2770
4790
4780
25A
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1530
4670
2670
4690
4680
1700 1055 4220 M M 4220
7200 J J
C489

87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK
25A
6410 P A 1170
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10
4680
4260
4220
4780
2270
2260
4790
4690
30 85 30 85 30 85 30 85 30 85 30 85 85 30
1180
1190
25A 4550 K K 4550
1730
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E 9720
9620 D D 9620
C492
) FUSE 2 FUSE 5
25A 15A 30A 30A
G 9410 S S 9420 4550 C GREY
15A
120
1140 F 9400 R R 9720 F J3
E 9210 G G 9620 E
1150 1160 9520 C C 9520 9520 D
(UNSWITCHED
25A
1170 A F 1740 B
J2
D 9110 F
BLACK
A B C D K G F H
1080
J E
1040
4750
4650
4670
4770
FRONT &
MARKER 1160
1730
9800
9510
9610
9710
2710
LIGHT
C470
30A 15A 25A 1050 TILT C C 4760
FUSE 3 PEDAL
FUSE 7 FUSE 11 B
G
-
D
C
E
A
B
1300
F
+ B 2760
REAR LT ALT & KITS
1060 TO OPTIONS
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL) A A 1520
C471
ACD & REMOTE
COMPUTER
25A
ACS
25A
PEDAL
1040 B B 2660
Printed in U.S.A. 1080 V-0490 (5-16-05)
BATTERY
604 of 961
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH
COMPUTER POWER F
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
CLOCK/LATCH A
CLOCK/LATCH
WIRING SCHEMATIC
C413
C421
HEADLIGHTS
1 1 4430 4370 1 1
Printable Version Click Here 7.5 ohm
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
WIRES CONNECT BY LETTER 12V 7.7 ohm
GROUND
2 2 2430 2370 2 2
GROUND
BUZZER
BUZZER
ACROSS CONNECTORS
C422
START J
START
OPEN
1
DATA B
4380 1
DATA
7.7 ohm
A B PWM
(Without Options) B A
REAR BASE 2380 2 2
C414
1 1 4440
G
C
D
E
B
A
K
E
F
J
7.5 ohm
C415
12V
C420
SOME CONNECTOR
T180 (S/N 527513827 AND ABOVE) BODIES NOT SHOWN
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
FOR DRAWING CLARITY BUCKET POSITIONING FRONT ROD
C423
C418
9.8 ohm A A 4420 4330 1 1 3.3 ohm
12V
PWM
(PRINTED JUNE 2005) B B 2420 2330 2 2 FRONT BASE
C419 C106
4340 1 1 3.3 ohm
CAB 6727178
UNSWITCHED POWER 1000-1999 RED RED = RED
V-0702 FUSED, UNSWITCHED POWER 1000-1999 RED/WHT RNG = ORANGE 2340 2 2 PWM
SWITCHED POWER 1000-1999 RNG BLK = BLACK

RELAY GROUNDS 2000-2060 GROUND 2000-2999 BLK LBL = LIGHT BLUE DIVERTER
3600 A A
C416
MONITORING 3000-3999 LBL DBL = DARK BLUE SPEED
ARE CONNECTED IN SERIES 4450 A A 7.5 ohm MAIN
HYDRAULIC 4000-4999 LGN LGN = LIGHT GREEN 3610 B B SENSOR
WORKLIGHTS
ATTACHMENT CONTROLS 5000-5999 YEL YELLOW TIE STRAP 2450 B B 12V FRAME
2530 DGN = DARK GREEN
GROUNDS LIGHTS 6000-6999 PNK
FRONT
YEL = YELLOW
2470 ACCESSORIES 7000-7999 WHT PNK = PINK
ENGINE 8000-8999 TAN WHT = WHITE
SWITCH
BRAKE
2460 COMMUNICATION 9000-9999 PUR FRONT AUX RELIEF
2800 BRN = BROWN
1930
2000
C424
2450 TAN = TAN 4490 A A H SEE C110
3610 11 ohm
2440 2400 2300 PUR = PURPLE GREEN TIE 12V
C435
2490 B B J SEE C110
RIGHT
3510 GRY = GRAY STRAP 2760 B B
2430
2600 A SEE C113 6120 A A
2340 REAR AUX RELIEF
C405 C406
2110 SEAT
C417
CAB
2330 3700 A A
A A
C434
4480 AIR FILTER BAR 6110 A A
LEFT
9.8 ohm
4330
2520
4360
4340
4410
4440
4430
4420
12V B B SWITCH
2770
B 3710
3300
2480 B B
2110
3700
2740
3200
B B
3600
2750
4470
4460
4450
2100 3110 FUEL
2730 B B
2120 SENDER - +8
2720 3100 A A 30-270 ohm 2910
2420 J1 J2 2920 2900
C
2710 2930
A
2410 18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2350 2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2380 2390 3100 2760
SPOOL SPARE COOLANT ENG SPEED 28
2370
HARNESS 7112802 LOCK ANALOG 1
FRONT
ROD
COMPUTER
GROUND
SYSTEM
Tx
LH AUX
RIGHT
L HAND
SERIAL IN
TEMP SIGNAL
PWM +8V
SUPPLY SIGNAL
HYDRAULIC 1 2 3 4 5 6 7 8 9 10
C105 C108
2200 TEMPERATURE A A 3300 1 1 3300 H SEE J2-48 4360 4330 2900 9100 4810 9210 3200 4300 3600
2000 SENDER
B B 3310 2 2 3310 J 7 9210 E
2240
500-3000 ohm
R HAND
SERIAL IN
REAR
BASE
SPARE
ANALOG 2
PROTECTED
POWER
SYSTEM
Rx
LH AUX
LEFT
SPARE
DIGITAL 1
AIR FILTER
SIGNAL
PWM -
RH FRONT
DETENT
23 9400 F See C492 C408
N K G L B R P S F E D C M A J H
+
A 11 12 13 14 15 16 17 18 19 20
G
C110
A A 3400 3 3 3400 15 1200 9200 4820 3700 4310 4920 42 9410
HYDRAULIC CHARGE C 9110 4440
PRESSURE SENDER - C C 3420 5 5 3420 47 FRONT REAR STATUS COMPUTER SEAT BAR LH SKI FUEL PWM RH SKI
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
0.5 - 7.5 V B BASE ROD IN DOWN
OPEN
SENDER SIGNAL DOWN
B B 3410 4 4 3410 3010 23
POWER +8v
J2
21 22 23 24 25 26 27 28 29 30
4430 9400 1900 3900
P05 4830 3100 4320 4930
B 4340
BUCKET 35 3910 SEE FUSE/RELAY
OPEN POSITION OPEN
KEY/ENTER SEATBAR
GROUND
LH SKI
UP OPEN GROUND OPEN
RH SKI
UP
A CENTER
SWITCH
45 3920 (EUROPEAN
31 32 33 34 35 36 37 38
38 39 40
4420 9350 3910 4840 2110 4940 25 3900 C407 LIGHTING)
C112
HYDRAULIC OIL A A 3440 34 9350
6 6 3430 3 HYD LOCK STATUS
HEADLIGHT BRAKE SW HYDRAULIC
SWITCH
SEATBAR
IN
OPEN TEMP OPEN OPEN
SWITCH B B SIGNAL
14 1200
41 42 43 44 45 46 47 48 49 50
4410 9410 4640 9340 3920 4500 3300 24 1900
RESERVED HYD FILTER TWO SPEED RESERVED TWO SPEED SPARE LEFT GLOW PLUG TRACTION LOCK 46 4500
(AC INPUT) OPEN SIGNAL (BOOTSTRAP) OPEN BLINKER RELAY PULL / 963
SWITCH MAKE-UP OUTPUT 1
5 9100
1 2 3 4 5 66 7 8 9 10
3430 4910 4390 6410 8510 4110
15 9200
44 9340
ENGINE OIL A A 3500 3500 37 4 2900
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C 4940
C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
40
SENDER -
B 4930
0.5-7.5 V B B 3510 TRACTION LOCK SENSOR TRAVEL F&R AUX RESERVED UNSWITCHED
30
SPARE
CAN
DIVERTER STARTER
RELAY
20 4920
21 22 23 24 25 26 27 28 29 30
4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
43 4640
ENGINE t 4350 8150 1130 9700 8550 3500 2100 6320 8110
C104
C113
4830
500-3000 ohm B B 3210 26
41 42 43 44 45 46 47 48 49 50
180 16 4820
A A 1800
8000 9800 3420 7200 3520
SUPPLY 0 1400
1020
J1 6 4810
C110
G A A J2
D3
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
B
B B 1800
EXCITATION FUEL J1
SHUTOFF
4910
HOLD PULL
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
10.9 ohm C 2800
1480
4810
4820
4830
4840
4640
C
4300
4320
4310
4910
4920
4930
4940
4230
2530
2800
C101
1490
2520
4240
1010
STARTER 0.3 ohm
A
B
A
B
8800
8100
A
B
A
B
8800
8100
G
H
C
D
E
G
F
B
D
C
H
A
K
F
J
J
BATTERY CABLE M R
C109
B 8250 B B 8250 C410 C409

S Brake Valve
8200 A A 6732781
G
H
C
D
G
E
D
C
H
F
K
8200
J
4200 A A 4200 A A
C425
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
C C
WHT
2200 2200 B
WHT
PUR
DGN
B
YEL
RGN
DBL
LGN
RGN
GLOW PLUGS 4100 B B OPEN
1.0 ohm each
F
+ -
B 2600 HR HR HR HR
FLOAT
H 6200 PWM
SHIFT
SKI CTRL
SIDE
8590
8570
8560
8580
C103
TWO SPD
SKI CTRL
DETENT
TO OPTIONS A
FLOW
6310
(ACCESSORY
CONNECTOR) E 6400
D 6500
G 6600
8500
C404
SEE CAB
C 7100 A TO OPTIONS
B (BACKUP ALARM
SWITCH) C407
TURN SIGNAL HORN
A
J 2730
P 6600
6000
M 6500
RNG/WHT
RNG/DBL
L 6400
DGN
BRN
YEL
F 4730
D 4235
D
E
B
A
C488
TO OPTIONS N 6300
(ACCESSORY
C 4275
E 4550
A 1140
H 1150
R
B
G
K (ALTERNATOR
1800 & KITS)
25A
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1700 1055 4220 M M

7200 J J
C489

87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK
25A
6410 P P
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10 30 85 30 85 30 85 30 85 30 85 30 85 85 30
25A
4550 K K
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E
C492
(HEATER
) 9620 D D
15A
G 9410 S S 9420
25A 15A 30A 30A
120
1140 F 9400 R R
E 9210 G G
1150 1160 9520 C C
1070 2240 H H
(UNSWITCHED
POWER)
25A
(ACS)
1170 A A
D 9110 F F
1080
1040

FRONT &
MARKER 1160
1730
9800
9510
9610
9710
2710
LIGHT
30A 15A 25A 1050

G
-
D
C
E
A
B
1300
F
REAR LT ALT & KITS

+ TO OPTIONS
1060
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL)
COMPUTER ACS
ACD & REMOTE
25A 25A
1040
BATTERY
605 of 961
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH D
COMPUTER POWER F
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
LEFT PANEL
CLOCK/LATCH A
CLOCK/LATCH
C413
C421
HEADLIGHTS
7.5 ohm 1 1 4430 4370 1
SYSTEM Rx K
SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK
SYSTEM Tx H
12V
GROUND
2 2 2430 2370 2
GROUND G
BUZZER
BUZZER
C422
START J
START J
OPEN
1
DATA B
4380
DATA B
REAR BASE 2380 2
C414
1 1 4440
G
C
D
E
A
K
E
F
7.5 ohm
C415
C420
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
C423
C418
ACROSS CONNECTORS
9.8 ohm
12V
A
B
A
B
4420
2420
4330
2330
1
2
1
2
3.3 ohm
PWM FRONT BASE
C419 C106
4340 1 1
Printable Version Click Here 3.3 ohm
CAB 6727178
A B
T180 (S/N 527513827 AND ABOVE) B A
2340 2 2 PWM

3600 A A
C416
SPEED
3610 B B
(PRINTED JUNE 2005)
WORKLIGHTS
FRONT
FOR DRAWING CLARITY
V-0703
SWITCH
BRAKE
FRONT AUX RELIEF
1930
RED = RED
2000
C424
RNG = ORANGE 4490 A A 11 ohm H SEE C110
C435
2490 B B J SEE C110
RIGHT
C405 C406
C417
CAB
C434
LEFT
9.8 ohm
4330
PNK = PINK
4360
4340
4410
4440
4430
4420
2770
B 3710
3300
2480 B B
2110
3700
3200
B B
3600
4470
4460
4450
2450 3100 A A 30-270 ohm 2910
J1 J2 2920 2900
C
2930
A
2430
18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2340 3100 2760
COOLANT
2330
1 2 3 4 5 6 7 8 9 10
2520 HARNESS 7112802 4360 4330 2900 9100 4810 9210 3200 4300 3600
2100 HYDRAULIC 9210 E
7
C105 C108
TEMPERATURE A A 3300 1 1 3300 H SEE J2-48 R HAND
SERIAL IN
REAR
BASE
SPARE
ANALOG 2
PROTECTED
POWER
SYSTEM
Rx
LH AUX
LEFT
SPARE
DIGITAL 1
AIR FILTER
SIGNAL
PWM -
RH FRONT
DETENT
23 9400 F
See C492 C408
SENDER B
B 3310 2 2 3310 J 11 12 13 14 15 16 17 18 19 20 N K G L B R P S F E D C M A J H
2420 500-3000 ohm 42 9410 G
+ 9110 4440 1200 9200 4820 3700 4310 4920
2410 A
C110
A A 3400 3 3 3400 15 FRONT REAR STATUS COMPUTER SEAT BAR LH SKI FUEL PWM RH SKI
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
HYDRAULIC CHARGE C BASE ROD IN DOWN
OPEN
SENDER SIGNAL DOWN
2380 2390 PRESSURE SENDER C 5 5
POWER +8v
J2
-
B C 3420 3420 47 21 22 23 24 25 26 27 28 29 30
2370 0.5 - 7.5 V
9400 1900 3900
P05 4830 3100 4320 4930
B B 3410 4 4 3410 3010 23 4340 4430
2200 BUCKET
B OPEN POSITION OPEN
2000 45 3920 (EUROPEAN
31 32 33 34 35 36 37 38
38 39 40
2240 4420 9350 3910 4840 2110 4940 25 3900 C407 LIGHTING)
HYD LOCK STATUS

34 9350
SOLENOID OUT FLOAT OPEN TEMP
SWITCH SIGNAL IN OPEN OPEN
14
C112
2800 HYDRAULIC OIL A A 3440 1200
6 6 3430 3 41 42 43 44 45 46 47 48 49 50
FILTER (DIFFERENTIAL)
3610 B B 4410 9410 4640 9340 3920 4500 3300 24 1900
SWITCH
2300
3510 RESERVED HYD FILTER TWO SPEED RESERVED TWO SPEED SPARE LEFT GLOW PLUG TRACTION LOCK 46 4500
(AC INPUT) OPEN SIGNAL (BOOTSTRAP) OPEN BLINKER RELAY PULL / 963
SWITCH MAKE-UP OUTPUT 1
2600 5 9100
1 2 3 4 5 66 7 8 9 10
3430 4910 4390 6410 8510 4110
15 9200
2110
44 9340
2740 ENGINE OIL A A 3500 3500 37 4 2900
C107
11 12 13 14 15 16 17 18 19 20
PRESSURE C 4940
2730 C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
40
SENDER
2120 -
B 4930
30
SPARE
CAN
DIVERTER STARTER
RELAY
20 4920
2710 21 22 23 24 25 26 27 28 29 30
2350 4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
4350 3500 6320 8110
43 4640
ENGINE t 8150 1130 9700 8550 2100
C104
C113
4830
500-3000 ohm B B 3210 26
41 42 43 44 45 46 47 48 49 50
180 16 4820
A A 1800
8000 9800 3420 7200 3520
SUPPLY 0 1400
1020
J1 6 4810
C110
G A A J2
D3
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
B
B B 1800
FUEL
EXCITATION
SHUTOFF
J1
ALTERNATOR 2010
6736515
4910
HOLD PULL
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
10.9 ohm 2800 C C 2800
1480
4810
4820
4830
4840
4640
4300
4320
4310
4910
4920
4930
4940
4230
2530
1490
C101
2520
4240
1010
STARTER 0.3 ohm
A
B
A
B
8800
8100
A
B
A
B
8800
8100
G
H
C
D
E
G
F
B
D
C
H
A
K
F
J
J
BATTERY CABLE M R
C109
B 8250 B B 8250 C410 C409

S Brake Valve
8200 A A
G
H
C
D
G
E
D
C
H
6732781
K
8200
J
4200 A A 4200 A A
C425
YEL/LGN
YEL/RED
WHT/RED
WHT/BLK
WHT/LGN
A
A
B
B
C
WHT
2200 C
WHT
PUR
DGN
YEL
2200
RGN
B
DBL
LGN
RGN
B C465 C466
TO OPTIONS GLOW PLUGS 4100 B B OPEN
A
B
B
CONNECTOR)
F
+ - HANDLE
B 2600 HANDLE LOCK
FLOAT
HR HR HR HR
SHIFT
SKI CTRL
SIDE
LOCK
H 6200 PWM
8590
8570
8560
8580
LEFT HANDLE
C103
TWO SPD
SKI CTRL
DETENT
A
FLOW
6310
HORN
E 6400
AHC LIFT
TURN SIGNAL
RIGHT
HALL SENSOR
6500 HANDLE
D AHC TILT
B
C
A
G 6600 HALL SENSOR
RNG/WHT
RNG/DBL
8500
C404
SEE CAB
DGN
BRN
YEL
CONNECTOR
B
C
A
B (BACKUP ALARM
A
C
B
SWITCH) C407 C449
C
B
D
E
B
A
A
B
C
A
J 2730
C411
B
C
C412
A
P 6600 C469
6000
M 6500 C472
A
C
B
C
B
A
L 6400
4750
1610
2750
1510
4650
2650
D 4235
C488

(ACCESSORY 12V
C 4275
E 4550
S 1700 M M
A 1140 1740
BLK
1150
DGN
H
RED
A B A B
RED
BLK
DGN
RED
RED
BLK
BLK
R
C467 C468
B
A B
8
7
6
5
4
3
2
1
A B
8
7
6
5
4
3
2
1
G C428
C429
4270
2500
4280
2510
K
8
7
5
4
3
2
1
(ALTERNATOR
6
1800 & KITS)
8
7
6
5
4
3
2
1
FUSE 11
1630
4770
2770
4790
4780
25A
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1530
4670
2670
4690
4680
1700 1055 4220 M M 4220
7200 J J
C489

87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK
25A
6410 P A 1170
(ATTACHMENT)
(COMPUTER)
6510 N N
FUSE 4
FUSE 10
4680
4260
4220
4780
2270
2260
4790
4690
30 85 30 85 30 85 30 85 30 85 30 85 85 30
1180
1190
25A 4550 K K 4550
1730
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E E 9720
9620 D D 9620
C492
) FUSE 2 FUSE 5
25A 15A 30A 30A
G 9410 S S 9420 4550 C GREY
15A
120
1140 F 9400 R R 9720 F J3
E 9210 G G 9620 E
1150 1160 9520 C C 9520 9520 D
(UNSWITCHED
25A
1170 A F 1740 B
J2
D 9110 F
BLACK
A B C D K G F H
1080
J E
1040
4750
4650
4670
4770
FRONT &
MARKER 1160
1730
9800
9510
9610
9710
2710
LIGHT
C470
30A 15A 25A 1050 TILT C C 4760
FUSE 3 PEDAL
FUSE 7 FUSE 11 B
G
-
D
C
E
A
B
1300
F
+ B 2760
REAR LT ALT & KITS
1060 TO OPTIONS
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL) A A 1520
C471
ACD & REMOTE
COMPUTER
25A
ACS
25A
PEDAL
1040 B B 2660
Printed in U.S.A. 1080 V-0703 (5-16-05)
BATTERY
606 of 961
PROTECTED POWER
PROTECTED POWER
RUN/ENTER SWITCH
COMPUTER POWER
COMPUTER POWER
TILT SPOOL LOCK
RIGHT PANEL
WIRING SCHEMATIC
LEFT PANEL
HIGH FLOW REAR ROD (NOT Used For This Model)
CLOCK/LATCH
CLOCK/LATCH A
C413
C421
HEADLIGHTS
1 1 1
C415
A A 4460 7.5 ohm 4430 4370
SYSTEM Rx
SYSTEM Rx
SYSTEM Tx
7.5 ohm LIFT SPOOL LOCK
SYSTEM Tx
12V
GROUND
12V 2 2 2430 2370 2
GROUND
B B 2460 BLUE TIE STRAP BROWN TIE STRAP (Not Use For This Model )
BUZZER
BUZZER
C422
START
(With SJC Option)
START
OPEN
1
DATA
4380
DATA B
REAR BASE 2380 2
C414
1 1 4440 BICS HYDRAULIC LOCK
G
C
D
E
K
A
B
E
F
F
J
J
7.5 ohm
T180 (S/N 527513827 AND ABOVE) 12V
C420
WIRES CONNECT BY LETTER 2 2 2440 WHITE TIE STRAP 4410 A A 9.8 ohm
ACROSS CONNECTORS 2410 B B 12V
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
A B BUCKET POSITIONING FRONT ROD
C423
C418
(PRINTED JUNE 2005) B A 9.8 ohm
12V
A
B
A
B
4420 4330 1 1 3.3 ohm
PWM
2420 2330 2 2 FRONT BASE
V-0704
C419 C106
SOME CONNECTOR 4340 1 1 3.3 ohm
CAB 6727178
BODIES NOT SHOWN 2340 2 2 PWM

ARE CONNECTED IN SERIES
Printable Version Click Here FOR DRAWING CLARITY
DIVERTER
A
3600 A
C416
RED = RED SPEED
UNSWITCHED POWER 1000-1999 RED
4450 A A 7.5 ohm SENSOR MAIN
RNG = ORANGE 3610 B B
WORKLIGHTS
2530 GROUNDS 12V FRAME
FUSED, UNSWITCHED POWER 1000-1999 RED/WHT BLK = BLACK YELLOW TIE STRAP 2450 B B
FRONT
2470 SWITCHED POWER 1000-1999 RNG LBL = LIGHT BLUE
GROUND 2000-2999 BLK DBL = DARK BLUE
2460 MONITORING 3000-3999 LBL LGN = LIGHT GREEN
SWITCH
BRAKE
2450 HYDRAULIC 4000-4999 LGN FRONT AUX RELIEF
DGN = DARK GREEN
1930
2000
C424
ATTACHMENT CONTROLS 5000-5999 YEL
2440 2400 2800 LIGHTS 6000-6999 PNK
YEL = YELLOW 4490 A A 11 ohm H SEE C110
PNK = PINK GREEN TIE 12V
C435
3610 ACCESSORIES 7000-7999 WHT 2490 B B 3310 J SEE C110
RIGHT
2430 WHT = WHITE STRAP 2760 B B
2300 ENGINE 8000-8999 TAN
2340 3510 COMMUNICATION 9000-9999 PUR BRN = BROWN A SEE C113 6120 A A
TAN = TAN REAR AUX RELIEF
2330 2600 PUR = PURPLE
C405 C406
SEAT
C417
CAB
2520 GRY = GRAY A A 3700 A A
C434
4480 AIR FILTER BAR 6110 A A
LEFT
9.8 ohm
2110
4330
4360
4340
4410
4440
4430
4420
12V B B SWITCH
2770
B 3710
3300
2480 B B
2110
2100
3700
3200
B B
3600
2750
4470
4460
4450
2740 3110 B B FUEL
SENDER - +8
2420 2730 3100 A A 30-270 ohm 2910
2120 J1 J2 2920 2900
C
2720 2930
A
2410
18 29 26 J1 J2 32 12 22 1 41 3 21 10 38 48 8 18 2770
2380 2390 2710 2740 2750
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
3100 2760
2370 2350 SPOOL SPARE FRONT COMPUTER SYSTEM LH AUX L HAND
COOLANT
2200 1 2 3 4 5 6 7 8 9 10
2000 HARNESS 7112800 4360 4330 2900 9100 4810 9210 3200 4300 3600
HYDRAULIC 7 9210 E
C408
C105 C108
R HAND SPARE PROTECTED SYSTEM SPARE

2240 TEMPERATURE A A 3300 1 1 3300 H SEE J2-48 SERIAL IN
REAR
ANALOG 2 POWER Rx
LH AUX
LEFT DIGITAL 1
AIR FILTER
PWM -
RH FRONT
DETENT See C492
BASE SIGNAL
23 9400 F
SENDER
B B 3310 2 2 3310 J 11 12 13 14 15 16 17 18 19 20 N K G L B R P S F E D C M A J H
500-3000 ohm 1200 9200 3700 4920 42 9410 G
9110 4440 4820 4310
+
A PWM RH SKI
C110
FRONT REAR STATUS COMPUTER SEAT BAR LH SKI FUEL
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
HYDRAULIC CHARGE A A 3400 3 3 3400 15 BASE ROD IN DOWN
OPEN
SENDER SIGNAL DOWN
C POWER +8v
J2
PRESSURE SENDER C C 3420 5 5 3420 47 21 22 23 24 25 26 27 28 29 30
0.5 - 7.5 V
-
B
4430 9400 1900 3900
P05 4830 3100 4320 4930
23 4340
B B 3410 4 4 3410 3010
BUCKET
LH SKI RH SKI 35 3910
A
OPEN POSITION OPEN
KEY/ENTER SEATBAR
GROUND UP OPEN GROUND OPEN UP
SEE FUSE/RELAY
SWITCH
B 45 3920 CENTER
31 32 33 34 35 36 37 38
38 39 40
C407
C112
HYDRAULIC OIL A A 3440 25 3900

4420 9350 3910 4840 2110 4940
FILTER (DIFFERENTIAL)
SWITCH B B HYD LOCK STATUS
34 9350
SOLENOID OUT FLOAT OPEN TEMP
SWITCH SIGNAL IN OPEN OPEN
14 1200
6 6 3430 3 41 42 43 44 45 46 47 48 49 50
4410 9410 4640 9340 3920 4500 3300 24 1900
C111
HYDRAULIC OIL B B 3440 GLOW PLUG TRACTION LOCK 46 4500

RESERVED HYD FILTER TWO SPEED RESERVED TWO SPEED SPARE LEFT
FILTER (DIFFERENTIAL) (AC INPUT) OPEN SIGNAL SWITCH (BOOTSTRAP) OPEN
MAKE-UP BLINKER RELAY PULL / 963
SWITCH A A 3430 OUTPUT 1

5 9100
1 2 3 4 5 66 7 8 9 10
3430 4910 4390 6410 8510 4110
15 9200
44 9340
4 2900
11 12 13 14 15 16 17 18 19 20
40 4940 2530 H
ENGINE OIL A A 3500 3500 37 8250 1110 9500 3400 6510 4200 4460 6210 8800
C107
PRESSURE C 30 4930 4930 J

C C 3520 3520 49 TRACTION LOCK SENSOR TRAVEL F&R AUX RESERVED UNSWITCHED
SENDER -
B
SPARE
CAN
DIVERTER STARTER
RELAY
20 4920 4920 E
0.5-7.5 V B B 3510 21 22 23 24 25 26 27 28 29 30
4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310 4310 C
29 4320 4320 D
C409
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300 4300 B
NOT USED FOR
THIS MODEL
31
31 32 33 34 35 36 37 38 39 40
4350 3500 6320 8110
43 4640 2530 K
ENGINE t 8150 1130 9700 8550 2100
C104
COOLANT A A B A 36 4840 4910 F

C113
4830 4230 G
500-3000 ohm B B 3210 26
41 42 43 44 45 46 47 48 49 50
180 16 4820 1490 A
A A 1800
8000 9800 3420 7200 3520
SUPPLY 0 1400
1020
J1 6 4810
C110
G A A J2 4640 D
D3
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
B
B B 1800 4840 C
FUEL
EXCITATION
SHUTOFF
J1 4830 B
ALTERNATOR 2010 4910 4820 G
6736515
HOLD PULL
4730
4110
7200
6510
6410
4200
8000
6320
6210
8550
8510
8250
8210
8800
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
1400 K
C410
10.9 ohm 2800 C C 2800
C101
NOT USED FOR

1010
STARTER 0.3 ohm
A
B
A
B
8800
8100
A
B
A
B
8800
8100
Dealer Copy -- Not for Resale 4200 A A
6732781
4200 A
Brake Valve
A
1480
4810
A
F
THIS MODEL
C425
2200 C C 2200 B B J
M R
C109
B 8250 B B 8250 4100 B B OPEN 4240 H

S
8200 A A 8200 2520 E
TO OPTIONS 6736808
GLOW PLUGS
BATTERY CABLE
(ACCESSORY 1.0 ohm each 2580 3 3 2580 3 3 GRD
C454
CONNECTOR) 1
C454
5 1540 1 1 1540 1 1 PWR LEFT SIDE
F 1
3
3020 2 2 3020 2 2 SIG WHEEL SPEED
B 2600 3 4 4
HR HR HR HR DRIVE 0
3080 4 3080 4 SIG
H 6200
8590
8570
8560
8580
CONTROLLER 9 2570 3 2570 3 GRD

C103
3 3
A 6310
C453
1
C453
7 1530 1 1 1530 1 1 PWR RIGHT SIDE
E 6400 1
3000 2 2 3000 2 SIG WHEEL SPEED
4 2
D 6500 2 4 4
9
2510 3070 4 3070 4 SIG
G 6600 3
8500
3020
C404
SEE CAB
FUSE 10
FUSE 11
FUSE 12
3
UNSWITCHED
FUSE 9
ATTCHMNT
ALT & KITS
C 7100 A TO OPTIONS 3 7114735

CONNECTOR
25A
25A
25A
25A
3080 1810 2 2
ACS
(BACKUP ALARM RED TIE

B 4
C407 4
C350
SWITCH) 1640 STRAPS
LEFT RIGHT 0 2810 4 4 2810 1 1 GRD
C356
SAFETY STEERING STEER SWASHPLATE SWASHPLATE 4 RIGHT SWASH PLATE
A IN OPEN OPEN MODE OPEN MODE 1 ANGLE ANGLE OPEN OPEN
9 4720 3 3 4720 3 3 SIG
POSITION SENSOR
J 2730 1 2 3 4 5 6 7 8 9 10 2
3000 1 1
STARTER
1710 1710 2 2 PWR

SWITCH
3
POWER
9400 4550 4220 4950 4720

P 6600 2 1820 2
LEFT
CAN HIGH LEFT LEFT 3070 2
6000
FORWARD STEER
4
C360
DRIVE OPEN OPEN OPEN OPEN JOYSTICK X JOYSTICK Y
M 6500 GND MODE 2 OPEN
4 4
1 4720 2860 2860 1 1 GRD
C355
11 12 13 15 16 17 18 19 20 8
4 LEFT SWASH PLATE
L 6400 9530 4275 4530 4540 3 3 4950
2670
LEFT BRAKE
7 4950 3 3 SIG
POSITION SENSOR
R QUAD
F 4730 FORWARD CAN LOW R QUAD TWO LIGHT DRIVE DRIVE MAIN SENSER
1770 1 1 1770 2 2 PWR
DRIVE DRIVE A DRIVE B DRIVE SPEED 1 OUTPUT GRND GRND GRND OPEN 3
D 4235 21 22 23
2
4
25 J5 26 27 28 29 30 4
C351 C352 C354 C353

TRACTION
4270 9630 3000 3070 4350 4210 2470 2490 2510 3

4260 1 1 4260 1 1
C488
RIGHT FORWARD DRIVE SOLENOID

LIGHT
TO OPTIONS N 6300
REAR
4
PULL
LEFT CAN SENSER

REVERSE SHIELD L QUAD L QUAD SAFETY BACK-UP SUPPLY 1 2660 2 2 2660 2 2
(ACCESSORY DRIVE DRIVE A DRIVE B DRIVE OUT ALARM OPEN OPEN OPEN +5V 2
C 4275 4
CONNECTOR) 31 32 33 34 35 36 37 38 39 40
4
4250 3 3 4250 1 1
C500
E 4550 4280 9730 3020 3080 9410 7100 1640 4 RIGHT REVERSE DRIVE SOLENOID
LEFT RIGHT RIGHT RIGHT RIGHT
5
2650 4 4 2650 2 2
REVERSE FORWARD FORWARD REVERSE REVERSE TWO UNSWITCHED UNSWITCHED SWITCHED
S 1700 OPEN 3
5 5
GND GND DRIVE DRIVE GND SPEED 2 BATTERY BATTERY BATTERY
1
4280 4280 1 1
1740 41 42 43 44 45 46 47 48 49 50 LEFT REVERSE DRIVE SOLENOID
A 1140 4
2680 6 6 2680 2 2
FRONT &
MARKER
2680 2660 4260 4250 2650 4390 1250 1260 1750 1

LIGHT
PULL
1150
FUEL
H 2
1
4270 7 7 4270 1 1
R J5 DRIVE 1 LEFT FORWARD DRIVE SOLENOID
1
2670 8 8 2670 2 2
B 2 2 4 4 3 1 3 2 1 5 1 2 2 3 3 4 3 3 1 1 2
1 4 6 2 5 4210
7 8 7 8 5 6 2 2 2 0 0 5 0 7 8 6 9 6 9 8 6
G
TO OPTIONS
A 6 6 6 6
2490
1250
1260
4275
4390
4540
4530
2470
9400
9410
4550
4220
9730
9630
9530
4350
7100
K
1750
(ALTERNATOR (BRAKE LIGHT)
& KITS) C474 4 4 4 4
GLOW
1800 9210 9010 HDL SW

PLUG

t180 6902502 SM 7-09

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t180 6902502 SM 7-09

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Service

Dealer Copy -- Not for Resale

CORRECT CORRECT CORRECT

P-90216 B-15659 B-15660

WRONG WRONG WRONG

Dealer Copy -- Not for Resale

WRONG WRONG WRONG

B-15665 B-15663 B-6589

ADVANCED CONTROL SYSTEM (ACS) .............. 60-01 FAN GEARBOX .......................................................10-01

Dealer Copy -- Not for Resale

Continued On Next Page

POWER BOB-TACH ................................................10-01

Dealer Copy -- Not for Resale

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX HYDROSTATIC

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI DRIVE

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

Dealer Copy -- Not for Resale

HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 HVAC

T180 Bobcat Loader

2. Check that ROPS mounting 10. Enclosure door latches must

3. The seat belt must be 11. Bob-Tach wedges and

Dealer Copy -- Not for Resale

4. The seat bar must be 12. Safety treads must be in good

6. Machine signs (decals) must 14. Check hydraulic fluid level,

7. Steering levers, hand controls 15. Inspect for fuel, oil or

8. Check for correct function of 16. Lubricate the loader.

Dealer Copy -- Not for Resale

22. Check for any field

T180 Bobcat Loader

T180 Bobcat Loader

Dealer Copy -- Not for Resale

• The Skid-Steer Loader Operator Training Course is

DANGER available through your local dealer or at

WARNING • The Skid-Steer Loader Safety Video is available from

T180 Bobcat Loader

The dealer and owner / operator review the

Cutting or drilling concrete containing sand or rock

Call Before You Dig

Dealer Copy -- Not for Resale

T180 Bobcat Loader

Check hydraulic tubes, hoses and fittings for damage

Maintenance Always clean fluid spills. Do not use gasoline or diesel

Flammable debris (leaves, straw, etc.) must be removed

Dealer Copy -- Not for Resale

Do not use the machine where exhaust, arcs, sparks or

Check the spark arrestor exhaust system regularly to

Battery gas can explode and cause serious injury. Use

T180 Bobcat Loader

Welding And Grinding

Always clean the machine and attachment, disconnect

Have good ventilation when grinding or welding painted

Dust generated from repairing nonmetallic parts such as

Dealer Copy -- Not for Resale

Always use the serial number of the loader when Figure 2

Loader Serial Number

The engine serial number is in the location shown

Dealer Copy -- Not for Resale

The loader serial number plate is located on the outside

Explanation of loader Serial Number:

1. The four digit Model/Engine Combination Module