Caterpillar cat el180 hydraulic excavator (prefix 1 rf) service repair manual (1rf00001 and up)

Service Repair Manual
Models
E180 EL180 HYDRAULIC
EXCAVATOR

Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: E180 EXCAVATOR 1RF
Configuration: E180 EL180 HYDRAULIC EXCAVATORS 1RF00001-UP (MACHINE) POWERED BY 3204 ENGINE
Disassembly and Assembly
3204 VEHICULAR ENGINES
Media Number -SENR3230-00 Publication Date -01/10/1985 Date Updated -30/11/2001
Exhaust Manifold
SMCS - 1059-011; 1059-012
Remove Exhaust Manifold
START BY:
a. remove turbocharger
1. Remove eight bolts (2), exhaust manifold (1) and the gasket from the cylinder head assembly.
2. Inspect studs (3). Remove them if they are loose or damaged.
Install Exhaust Manifold
1. If the exhaust manifold studs were removed, put 5P3931 Anti-Seize Compound on the threads
of the studs, and tighten them to a torque of 30 ± 5 N·m (22 ± 4 lb.ft.).
1/2E180 EL180 HYDRAULIC EXCAVATORS 1RF00001-UP (MACHINE) POWERE...
2019/11/23https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

2. Put gasket (1) and manifold (2) in position on the cylinder head assembly.
3. Put 5P3931 Anti-Seize Compound on the threads of the bolts. Install the bolts that hold the
manifold in place.
END BY:
a. install turbocharger
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Nov 23 09:31:08 UTC+0800 2019

Shutdown SIS
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Product: EXCAVATOR
Fuel Transfer Pump
SMCS - 1256-015; 1256-016
Disassemble Fuel Transfer Pump
START BY:
a. remove fuel transfer pump
1. Remove connector (1) and the O-ring seal. Remove connector (2) and the O-ring seal from the
pump housing.
2. Remove spring (3), valve (4) and the seal from the pump housing.

Cover (6) is under spring tension. To prevent personal injury, carefully
remove bolts (5) to release the spring tension.
3. Carefully remove bolts (5), cover (6), the seal and spring from the pump housing.
4. Remove plate (7), the valve and seal from the pump housing.
5. Remove snap ring (8) that holds tappet (9) in position. Remove tappet (9) from the pump
housing.
Assemble Fuel Transfer Pump

1. Put tappet (2) in position in the pump housing, and install snap ring (1) that holds it in place.
2. Install seal (6), valve (3) and plate (4) in piston (5) as shown.
3. Install piston assembly (7) and spring (8) in the pump housing as shown.
4. Install seal (10) in cover (9), and put clean diesel fuel on the O-ring seal.
5. Put cover (10) in position on the pump housing, and install the bolts that hold it in place.

6. Install seal (11) in the bore of the pump housing.
7. Install valve (13) and spring (12) in the pump housing.
8. Be sure the O-ring seals are in position on connector (14) and connector (15), and put clean
diesel fuel on the O-ring seals.
9. Install connector (14) and connector (15) in the pump housing.
END BY:
a. install fuel transfer pump
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Nov 23 09:32:04 UTC+0800 2019

Shutdown SIS
Previous Screen
Product: EXCAVATOR
Governor
SMCS - 1264-015; 1264-016
Disassemble Governor
START BY:
a. remove fuel injection pump housing and governor
NOTE: If it is desired to remove only the governor so the fuel injection pump housing can be
disassembled, only do steps. 1, 2, 16, 23, 27, 28, 29, 33, 34, 35, 36 and 39.
1. Remove two bolts (2) and fuel transfer pump (3).
2. Remove two bolts (1) from the fuel system.

3. Remove six bolts (4), governor housing (5) and the gasket.
4. Remove governor spring (10), two wave washers (7) and (9), one flatwasher (8) and seat (6) from
the guide.
5. Remove bolts (12) and cover assembly (11) from the housing.
6. Remove seal (13) from cover (11) with tooling (B).

7. Loosen low idle adjustment screw (14), and remove spring (15) from the housing.
8. Remove shaft (16) and lever (17) from the housing. Remove the ring from the shaft if necessary.
9. On later engines, remove the control shaft assembly from the housing as follows:
a. Remove two screws (19), plate (18) and the washer located under plate (18).
b. Remove stop (20) and the plate located under the stop.

c. Remove shaft assembly (21), lever (22) and lever (23) from the housing.
d. Remove plate (25) from the shaft assembly.
e. Remove pin (26), pin (27) and spring (24) from the shaft assembly.
10. On earlier engines, remove shaft assembly (28), lever (29) and lever (30) from the housing.
11. On earlier engines, disassemble the control shaft assembly as follows:
a. Remove the two snap rings from pins (33), and remove the pins. Remove plates (31) and stop (32)
from the shaft assembly.

b. Remove pin (36), pin (34) and spring (35) from the shaft assembly.
NOTICE
Remove check valve (37) only if a replacement is necessary because the
check valve will be damaged during removal.
12. Remove check valve (37) if a replacement is necessary.
13. Remove two bolts (38), cover (39) and the gasket from the housing.

14. Remove insulator (42) and body (41) for the governor dashpot adjustment screw.
15. Remove seal (43) and high idle adjustment screw (40).
16. Remove two bolts (45), housing (44) and the gasket from the fuel injection pump housing.
17. Remove bolts (46) and torque control group (47) as a unit.
18. Disassemble the torque control group. Inspect insulator (48), shim (49), spring (50), contact (51)
and spacer (52) for wear or damage.

19. Remove bolts (53) and block (54) for the full load stop.
20. Remove bolt (57) that holds collar (58) to bolt (55). Remove collar (58) and spring (56) from
bolt (55).
21. Remove bolt (55) from the block.
22. Loosen nuts (59), and remove power adjustment screw (60) and torque rise adjustment screw
(61) from collar (58) if a replacement is necessary.
23. Remove bolts (63) and governor servo (62) from the fuel injection pump housing.

24. Remove lockring (68), seat (67), spring (broken link spring) (66) and sleeve (65) from valve
(64). Remove the other lockring (68) from the groove in the center of valve (65).
NOTE: The groove in the bottom of valve (64) must be in alignment with the servo body to permit
removal from the fuel rack.
25. Remove valve (64), sleeve (69) and piston (71) from the governor servo. Remove the O-ring seal
from sleeve (69).
26. Remove pin (70) and lever (72) from the governor servo.
27. Use tool (D) to hold spring (74) under compression so ring (73) can be removed. Spring (74) is
used to put a preload on the thrust bearing for the camshaft in the fuel injection pump housing.
28. Remove ring (73); then remove tool (D).

29. Remove bearing (75), sleeves (76) and spring (74) from the governor shaft.
30. Remove ring (77) and dashpot assembly (78) from the governor shaft.
31. Use tool (C) to remove snap ring (84) from seat (81). Remove ring (83) and spool (82) from seat
(81).
32. Remove seat (81) from spring (80), and remove spring (80) from seat (79).
33. Remove spring (overfueling spring) (85) and riser (86) from the governor shaft.
34. Remove ring (88), races (87) and bearing (89) from the riser.

NOTE: Make a replacement of shield (90) any time it is removed.
35. Use a screwdriver to remove shield (90) as shown.
36. Remove bolts (91) and carrier (92) for the governor flyweights.
37. Remove dowels (93) and flyweights (95) from the carrier.
38. Remove shaft (94) from the carrier. Remove the dowel from shaft (94).
39. Remove races (96) and bearing (97) from the camshaft in the fuel injection pump housing.
10/22E180 EL180 HYDRAULIC EXCAVATORS 1RF00001-UP (MACHINE) POWER...

Assemble Governor
NOTE: If the governor was removed only to permit repair of the fuel injection pump housing, do
only Steps 1, 4, 5, 7, 9, 10, 11, 16, 23, 42, 43, 44 and 45.
NOTE: Put clean engine oil on all parts before assembly. Be sure all oil passages are clear.

1. Install one race (1), bearing (2) and the other race (1) on the camshaft in the fuel injection pump
housing.
2. Put flyweights (3) in position on carrier (4), and install the dowels to hold the flyweights in place.
The flyweights must move freely on the dowels and have 0.010 to 0.23 mm (0.0004 to 0.009 in.)
end play.
3. Install dowel (5) in governor shaft (6), and install the governor shaft in the carrier as shown.
4. Put the carrier in position on the camshaft, and install the bolts that hold the carrier in place.

NOTE: Make a replacement of shield (7) any time it is removed.
5. Install shield (7) on the carrier, and use tool (A) to push the shield against its seat. Use a hammer
and punch to move the metal (stake) two places on the side of the shield 180° ± 5° apart next to the
holes in the shield.
6. Install one race (9), bearing (10), the other race (9), and use tool (B) to install the ring on riser (8)
as shown.
7. Install riser (8) and the spring (overfueling spring) on the governor shaft as shown.
8. Assemble the dashpot as follows:
a. Install spring (12) on seat (11), and install seat (13) in spring (12).

b. Put spool (14) and ring (15) in position on seat (13), and use tool (B) to install snap ring (16) to
hold them in place.
9. Install dashpot assembly (17) on the governor shaft as shown.
NOTE: Spring (19) is used to put a preload on the thrust bearing on the camshaft in the fuel
injection pump housing.
10. Install ring (21) in the lower groove in the governor shaft. Install one sleeve (20), spring (19), the
other sleeve (20) and bearing (18) on the governor shaft as shown.
11. Use tool (C) to hold spring (19) under compression, and install ring (22) in the groove in the
governor shaft. Remove tool (C).

12. Put lever (27) in position on governor servo (23), and install pin (24) to hold the lever in place.
Use a hammer and chisel to move the metal (stake) four places 90 ° apart on the outside surface on
both legs of the governor servo to hold pin (24) in place.
13. Install the O-ring seal on sleeve (25). Install piston (26) and sleeve (25) in the governor servo as
shown.
14. Install valve (28) in the governor servo as shown.
15. Install one lockring (32) in the groove near the center of valve (28). Put sleeve (29), spring
(broken link spring) (30) and seat (31) in position on valve (28), and install the other lockring (32) to
hold them in place.
16. Put the governor servo in position on the fuel injection pump housing with piston (26) engaged
over rack (33), and install the bolts that hold the governor servo in place.

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17. Install torque rise adjustment screw (35) and power adjustment screw (34) in collar (36) as
shown. Install nuts (37) on the screws.
18. Put bolt (39) in position in block assembly (40), and install spring (38) on the bolt as shown.
19. Put collar (36) in position on bolt (39). Be sure the cutout (slot) in the collar is engaged with
dowel (41). Install bolt (42) to hold the collar in place. Be sure bolt (42) fits in the groove of bolt
(39).
20. Put block (40) in position on housing (44). Be sure the holes in the block are engaged with
dowels (43). Install the bolts that hold the block in place.

21. Assemble the torque control group as follows:
a. Install shim (46), spring (50), contact (47) and spacer (51) on insulator (49) as shown.
b. Install bolts (53) through retainer (52), bar (48), the insulator assembly and bar (45).
22. Install torque control group (54) on block (40) as shown.
If housing (44) is installed with the flange on bolt (39) (see illustration
B86569X1) on the wrong side of the dashpot, the riser in the governor
will be held in the maximum fuel delivery position. To prevent possible
personal injury, make sure housing (44) is installed on the fuel injection
pump housing with the flange on bolt (39) behind seat (55).
23. Install gasket (56) on fuel injection pump housing (44). Put housing (44) in position on the fuel
injection pump housing with bolt (39) behind dashpot (seat) (55). Install the two bolts that hold the
housing in place.

24. Use tooling (D) to install lip type seal (57) in the governor outer housing. Install the seal with the
lip facing in as shown.
25. Install insulator (fuel setting contact) (58) in the housing. Tighten the insulator to a torque of 4.5
± 0.5 N·m (40 ± 4 lb.in.).
26. Install adjustment screw (59) and the locknut for the high idle adjustment.
27. Install the O-ring seal on body (60) for the governor dashpot adjustment. Install body (60) in the
housing.
28. Install the gasket and cover (61) on the housing.
29. If it was necessary to replace check valve (62), install a new check valve as shown.
30. Install spring (65) in shaft assembly (63). Install pin (64) in shaft assembly (63) with the tip of
the pin engaged in the hole in spring (63). Install pin (66) in the shaft assembly to hold pin (64) in
place.

31. On earlier machines, put stop (69) and plates (67) in position on shaft assembly (63). Install pins
(68) to hold the plates and stop in place. Install snap rings (70) to hold pins (68) in place.
32. On later engines, assemble the control shaft as follows:
a. Put plate (71) and (73) in position on the shaft assembly as shown.
b. Put plate (72), stop (75) and washer (76) in position between plate (71) and (73). Install two
screws (74) that hold them in place. Do not tighten the screws at this time.
33. On earlier machines, put levers (77) and (78) in position in the housing as shown. Install shaft
assembly (63) to hold the levers in place.

Caterpillar cat el180 hydraulic excavator (prefix 1 rf) service repair manual (1rf00001 and up)

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