BOBCAT B250 B Series SN 572211001 Service Manual PDF DOWNLOAD

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BOBCAT B250 B Series SN 572211001 Service Manual PDF DOWNLOAD

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TABLE OF CONTENTS:

BOBCAT B250 B Series SN 572211001 Service Manual PDF DOWNLOAD

MAINTENANCE SAFETY……………………………………… 3
ALPHABETICAL INDEX……………………………………… 5
CONTENTS………………………………………………. 7
FOREWORD…………………………………………… 8
SAFETY INSTRUCTIONS…………………………………. 11
Fire Prevention…………………………………. 13
SERIAL NUMBER LOCATION………………………………. 15
Loader Backhoe Serial Number……………………… 15
Engine Serial Number…………………………….. 15
DELIVERY REPORT…………………………………….. 15
BOBCAT LOADER IDENTIFICATION…………………………. 16
SAFETY & MAINTENANCE……………………………………. 17
LIFTING AND BLOCKING THE LOADER BACKHOE……………….. 19
Procedure………………………………………. 19
APPROVED LIFT ARM SUPPORT DEVICE……………………… 21
Installing The Approved Lift Arm Support Device…….. 21
Removing The Approved Lift Arm Support Device………. 22
ENGINE COVER……………………………………….. 23
TRANSPORTING THE LOADER BACKHOE………………………. 25
Procedure………………………………………. 25
TOWING THE LOADER BACKHOE……………………………. 27
Procedure………………………………………. 27
AXLE TOE-IN………………………………………… 29
Adjustment……………………………………… 29
SERVICE SCHEDULE……………………………………. 31
Chart………………………………………….. 31
AIR CLEANER SERVICE…………………………………. 33
Replacing The Filter…………………………….. 33
ENGINE COOLING SYSTEM……………………………….. 35
Coolant Replacement……………………………… 35
FUEL SYSTEM………………………………………… 37
Fuel Specifications……………………………… 37
Filling The Fuel Tank……………………………. 37
Fuel Filter…………………………………….. 37
Removing Air From The Fuel System…………………. 38
ENGINE LUBRICATION SYSTEM……………………………. 39
Checking Engine Oil……………………………… 39
Oil Chart………………………………………. 39
Replacing The Oil And Filter……………………… 39
HYDRAULIC/HYDROSTATIC SYSTEM…………………………. 41
Checking And Adding Fluid………………………… 41
Cleaning The Cooler……………………………… 42
Replacing Hydraulic/Hydrostatic Filter…………….. 42
Replacing Hydraulic Fluid………………………… 43
REAR AXLE………………………………………….. 45
Checking Oil Level………………………………. 45
Draining Oil……………………………………. 45
FRONT AXLE…………………………………………. 47
Checking Oil Level………………………………. 47
Draining Oil……………………………………. 47
BOOM LOCK PIN………………………………………. 49
Engaging And Disengaging The Pin………………….. 49
BOB-TACH…………………………………………… 51
Inspection And Maintenance……………………….. 51
ALTERNATOR BELT…………………………………….. 53
Adjusting The Alternator Belt…………………….. 53
LUBRICATING THE LOADER BACKHOE……………………….. 55
TIRE MAINTENANCE……………………………………. 61
Wheel Nuts……………………………………… 61
Tire Mounting…………………………………… 61
Tire Pressure…………………………………… 61
SWING LOCK PIN……………………………………… 63
Engaging The Swing Lock Pin………………………. 63
HYDRAULIC SYSTEM……………………………………….. 65
HYDRAULIC/HYDROSTATIC SCHEMATIC………………………. 69
HYDRAULIC SYSTEM INFORMATION…………………………. 71
Troubleshooting…………………………………. 75
Description…………………………………….. 76
ARM CYLINDER……………………………………….. 77
Checking……………………………………….. 77
Removal And Installation…………………………. 78
Parts Identification…………………………….. 81
Disassembly…………………………………….. 82
Assembly……………………………………….. 84
BOOM CYLINDER………………………………………. 87
Checking……………………………………….. 87
Removal And Installation…………………………. 89
Parts Identification…………………………….. 92
Disassembly…………………………………….. 93
Assembly……………………………………….. 95
SWING CYLINDER……………………………………… 97
Checking……………………………………….. 97
Removal And Installation…………………………. 98
Parts Identification……………………………..100
Disassembly……………………………………..101
Assembly………………………………………..103
Bushing Removal And Installation…………………..105
BUCKET CYLINDER……………………………………..107
Checking………………………………………..107
Removal And Installation………………………….109
Parts Identification……………………………..112
Disassembly……………………………………..113
Assembly………………………………………..115
STABILIZER CYLINDER………………………………….117
Checking………………………………………..117
Removal And Installation………………………….118
Parts Identification……………………………..121
Disassembly……………………………………..122
Assembly………………………………………..126
SIDE SHIFT LOCK CYLINDER……………………………..129
Removal And Installation………………………….129
Parts Identification……………………………..131
Disassembly……………………………………..132
Assembly………………………………………..133
TILT CYLINDER……………………………………….135
Checking………………………………………..135
Removal And Installation………………………….136
Parts Identification……………………………..138
Disassembly……………………………………..139
Assembly………………………………………..141
LIFT CYLINDER……………………………………….143
Checking………………………………………..143
Removal And Installation………………………….144
Parts Identification……………………………..146
Disassembly……………………………………..147
Assembly………………………………………..149
STEERING CYLINDER (FRONT)…………………………….151
Removal And Installation………………………….151
Parts Identification……………………………..155
Disassembly And Assembly………………………….156
Inspection………………………………………159
STEERING CYLINDER (REAR)……………………………..161
Removal And Installation………………………….161
Parts Identification……………………………..164
Disassembly And Assembly………………………….165
Inspection………………………………………168
MAIN RELIEF VALVE……………………………………171
Testing The Main Relief Valve……………………..171
Adjustment………………………………………172
PORT RELIEF VALVE (BACKHOE CONTROL VALVE)………………173
Testing And Adjusting (Arm Control)………………..173
Testing And Adjusting (Boom Control)……………….175
Testing And Adjusting (Boom Swing Control)………….177
PORT RELIEF VALVE (LOADER CONTROL VALVE)……………….179
Testing And Adjusting (Bucket Tilt)………………..179
Testing And Adjusting (Front Auxiliary)…………….181
LOADER CONTROL VALVE…………………………………183
Removal And Installation………………………….183
Parts Identification……………………………..185
Disassembly And Assembly………………………….186
Inlet/Outlet Valve Section………………………..187
Lift Arm Valve Section……………………………189
Tilt Valve Section……………………………….192
Auxiliary Valve Section…………………………..196
BACKHOE CONTROL VALVE………………………………..201
Removal And Installation………………………….201
Parts Identification……………………………..203
Disassembly And Assembly………………………….204
Inlet/Outlet Valve Section………………………..205
Arm Valve Section………………………………..208
Tilt Valve Section……………………………….211
Right Stabilizer Valve Section…………………….214
Left Stabilizer Valve Section……………………..217
Boom Valve Section……………………………….221
Boom Swing Valve Section………………………….224
Outlet Valve Section……………………………..227
HYDRAULIC FLUID RESERVOIR…………………………….229
Removal And Installation………………………….229
Strainer Removal And Installation………………….231
HYDRAULIC FILTER HOUSING……………………………..233
Removal And Installation………………………….233
Disassembly……………………………………..234
Assembly………………………………………..235
GEAR PUMP…………………………………………..237
Removal And Installation………………………….237
Parts Identification……………………………..238
Disassembly And Assembly………………………….239
Inspection………………………………………241
STEERING PUMP……………………………………….243
Removal And Installation………………………….243
Parts Identification……………………………..244
Disassembly……………………………………..245
Inspection………………………………………254
Assembly………………………………………..254
TRAVEL PEDAL………………………………………..263
Removal And Installation………………………….263
Parts Identification……………………………..264
Disassembly And Assembly………………………….265
STEERING VALVE………………………………………271
Removal And Installation………………………….271
Description……………………………………..272
Wheel Alignment Procedure…………………………272
SAPR BRAKE CYLINDER………………………………….273
Removal And Installation………………………….273
Parts Identification……………………………..275
Disassembly……………………………………..276
Assembly………………………………………..278
SAPR BRAKE CONTROL VALVE……………………………..281
Removal And Installation………………………….281
Parts Identification……………………………..282
Disassembly And Assembly………………………….283
HYDROSTATIC SYSTEM………………………………………285
HYDROSTATIC SYSTEM INFORMATION………………………..287
Troubleshooting Chart…………………………….287
Replenishing Valve Function……………………….288
OIL COOLER………………………………………….289
Removal And Installation………………………….289
Parts Identification……………………………..290
HYDROSTATIC DRIVE MOTOR………………………………291
Removal And Installation………………………….291
Parts Identification……………………………..292
Disassembly……………………………………..293
Inspection………………………………………297
Assembly………………………………………..299
HYDROSTATIC PUMP…………………………………….305
Removal And Installation………………………….305
Parts Identification……………………………..308
Disassembly……………………………………..310
Inspection………………………………………326
Assembly………………………………………..328
HYDROSTATIC TESTING………………………………….343
Pump Adjustment………………………………….343
DRIVE SYSTEM……………………………………………347
PARKING BRAKE……………………………………….349
Lever Removal And Installation…………………….349
Cable Removal And Installation…………………….350
Adjustment………………………………………352
BRAKE CALIPER……………………………………….353
Removal And Installation………………………….353
Parts Identification……………………………..355
Disassembly And Assembly………………………….356
Adjustment………………………………………358
REAR AXLE…………………………………………..361
Removal…………………………………………361
Installation…………………………………….364
AXLE AND DIFFERENTIAL (REAR)………………………….367
Troubleshooting Chart…………………………….367
General Information………………………………368
Wheel Hub/Spindle Parts Identification……………..368
Wheel Hub/Spindle Disassembly……………………..369
Drive Axle Parts Identification……………………373
Drive Axle Disassembly……………………………374
Steering Knuckle Parts Identification………………377
Steering Knuckle Disassembly………………………378
Differential Parts Identification………………….381
Differential Disassembly………………………….382
Differential Inspection…………………………..388
Pinion Group Parts Identification………………….389
Pinion Group Disassembly………………………….390
Pinion Group Inspection…………………………..393
Pinion Group Assembly…………………………….394
Differential Assembly…………………………….401
Steering Knuckle Assembly…………………………410
Drive Axle Assembly………………………………413
Wheel Hub/Spindle Assembly………………………..416
STEERING ANGLE ADJUSTMENT (REAR AXLE)………………….421
Adjustment………………………………………421
FRONT AXLE………………………………………….423
Removal…………………………………………423
Installation…………………………………….425
AXLE AND DIFFERENTIAL (FRONT)…………………………427
Troubleshooting Chart…………………………….427
General Information………………………………428
Wheel Hub/Spindle Parts Identification……………..428
Wheel Hub/Spindle Disassembly……………………..429
Drive Axle Parts Identification……………………433
Drive Axle Disassembly……………………………434
Steering Knuckle Parts Identification………………437
Steering Knuckle Disassembly………………………438
Differential Parts Identification………………….441
Differential Disassembly………………………….442
Differential Inspection…………………………..448
Pinion Group Parts Identification………………….449
Pinion Group Disassembly………………………….450
Pinion Group Inspection…………………………..453
Pinion Group Assembly…………………………….454
Differential Assembly…………………………….461
Steering Knuckle Assembly…………………………470
Drive Axle Assembly………………………………473
Wheel Hub/Spindle Assembly………………………..476
STEERING ANGLE ADJUSTMENT (FRONT AXLE)…………………481
Adjustment………………………………………481
DRIVESHAFT………………………………………….483
Removal And Installation………………………….483
DROP BOX……………………………………………485
Removal And Installation………………………….485
Parts Identification……………………………..488
Disassembly……………………………………..489
Inspection………………………………………496
Assembly………………………………………..496
MAIN FRAME……………………………………………..501
OPERATOR CAB………………………………………..503
Not Available At Time Of Printing………………….503
ENCLOSED CAB………………………………………..505
Removal And Installation………………………….505
Cab Mount Removal And Installation…………………512
OPERATOR SEAT……………………………………….513
Removal And Installation………………………….513
FLOOR PANELS………………………………………..515
Left Front Panel Removal And Installation…………..515
Right Front Panel Removal And Installation………….515
Rear Panel Removal And Installation………………..516
GRILL………………………………………………517
Removal And Installation………………………….517
GRILL FRAME…………………………………………519
Removal And Installation………………………….519
ENGINE SIDE COVERS…………………………………..521
Removal And Installation………………………….521
FENDER……………………………………………..523
Removal And Installation………………………….523
ENGINE COVER………………………………………..525
Removal And Installation………………………….525
FUEL TANK…………………………………………..527
Removal And Installation………………………….527
Fuel Fill Screen Removal And Installation…………..528
LIFT ARMS…………………………………………..529
Removal And Installation………………………….529
BOB-TACH……………………………………………533
Removal And Installation………………………….533
Bob-Tach Lever And Wedge………………………….535
Pivot Pin Bushing Removal And Installation………….537
ARM………………………………………………..539
Removal And Installation………………………….539
Arm Pivot Bushing Removal And Installation………….541
BOOM……………………………………………….543
Removal And Installation………………………….543
Boom Pivot Bushing Removal And Installation…………544
SWING FRAME…………………………………………545
Removal And Installation………………………….545
Bushing Removal And Installation…………………..547
X-CHANGE™…………………………………………..549
Removal And Installation………………………….549
BUCKET……………………………………………..551
Backhoe Bucket Teeth Removal And Installation……….551
Loader Bucket Teeth Removal And Installation………..551
STABILIZER FRAME…………………………………….553
Removal And Installation………………………….553
FRONT AXLE PIVOT FRAME……………………………….557
Removal…………………………………………557
Installation…………………………………….558
Bushing Removal And Installation…………………..559
REAR WINDOW…………………………………………561
Removal And Installation………………………….561
CAB DOOR……………………………………………565
Removal And Installation………………………….565
ELECTRICAL SYSTEM AND ANALYSIS……………………………567
ELECTRICAL SCHEMATIC…………………………………569
ELECTRICAL SYSTEM INFORMATION…………………………571
Troubleshooting Chart…………………………….571
Description……………………………………..572
Fuse Location……………………………………572
BATTERY…………………………………………….573
Removal And Installation………………………….573
Servicing The Electrical System……………………574
Using A Booster Battery (Jump Starting)…………….575
ALTERNATOR………………………………………….577
Adjusting The Alternator Belt……………………..577
Description……………………………………..577
Tests…………………………………………..578
Alternator Output Test……………………………578
Full Field Test………………………………….579
Alternator Regulator Test…………………………579
Alternator Regulator Test With Voltmeter……………580
Removal And Installation………………………….581
Parts Identification……………………………..582
Pulley Removal And Installation……………………583
Disassembly And Assembly………………………….584
Rotor Continuity Test…………………………….587
Stator Continuity Test……………………………587
Rectifier Continuity (Diode) Test………………….588
Brush Length…………………………………….588
STARTER…………………………………………….589
Removal And Installation………………………….589
Checking The Starter In The Loader…………………589
Parts Identification……………………………..591
Disassembly……………………………………..592
Inspection And Repair…………………………….597
No Load Test…………………………………….601
Assembly………………………………………..602
FRONT LIGHTS………………………………………..609
Bulb Removal And Installation……………………..609
Housing Removal And Installation…………………..611
TURN INDICATOR LIGHTS (FRONT)…………………………613
Bulb Removal And Installation……………………..613
TURN INDICATOR LIGHTS (REAR)………………………….615
Bulb Removal And Installation……………………..615
CAB LIGHTS………………………………………….617
Bulb Removal And Installation……………………..617
Housing Removal And Installation…………………..619
FUEL LEVEL SENDER……………………………………621
Removal And Installation………………………….621
INSTRUMENT PANEL…………………………………….623
Removal And Installation………………………….623
FRONT WIPER…………………………………………625
Removal And Installation………………………….625
REAR WIPER………………………………………….629
Removal And Installation………………………….629
ENGINE SERVICE………………………………………….631
TROUBLESHOOTING……………………………………..635
Chart…………………………………………..635
ENGINE SPEED CONTROL…………………………………637
Removal And Installation………………………….637
Cable Removal And Installation…………………….638
MUFFLER…………………………………………….639
Removal And Installation………………………….639
AIR CLEANER…………………………………………641
Removal And Installation………………………….641
RADIATOR……………………………………………643
Removal And Installation………………………….643
ENGINE COMPONENTS AND TESTING…………………………645
Checking Engine Compression……………………….645
Checking Glow Plugs………………………………646
Glow Plug Removal And Installation…………………647
Fuel Shut-Off Solenoid Removal And Installation……..648
Checking Fuel Injection Pump………………………649
Fuel Injection Pump Removal And Installation………..650
Fuel Injection Pump Timing………………………..652
Fuel Injector Nozzles Removal And Installation………653
Checking Fuel Injector, Nozzles……………………655
Thermostat Removal And Installation………………..656
Water Pump Removal And Installation………………..657
ENGINE……………………………………………..659
Removal And Installation………………………….659
Mount Replacement………………………………..663
RECONDITIONING THE ENGINE…………………………….665
Timing Gear Case Cover Removal And Installation……..665
Oil Pump Removal And Installation………………….667
Crankshaft Front Seal Removal And Installation………669
Engine Speed Control Plate Removal And Installation….670
Idle Limit And Fuel Limit Adjustment……………….671
Exhaust Manifold Removal And Installation…………..671
Valve Cover Removal And Installation……………….672
Rocker Arm Removal And Installation………………..673
Push Rod Removal And Installation………………….674
Tappet Removal And Installation……………………675
Water Flange Removal And Installation………………675
Cylinder Head Removal And Installation……………..676
Checking Piston Top Clearance……………………..677
Cylinder Head Disassembly And Assembly……………..678
Servicing The Cylinder Head……………………….679
Combustion Chamber Removal And Installation…………682
Idler Gear Removal And Installation………………..683
Camshaft Removal And Installation………………….684
Fuel Camshaft Removal And Installation……………..686
Oil Pan Removal And Installation…………………..688
Governor Shaft Removal And Installation…………….689
Governor Fork Lever Removal And Installation………..692
Piston Removal And Installation……………………694
Checking The Piston And Connecting Rod……………..694
Connecting Rod Alignment………………………….695
Piston Ring Gap………………………………….695
Piston Ring Installation………………………….696
Connecting Rod Installation……………………….697
Checking Engine Cylinder Bore……………………..697
Crankshaft Removal And Installation………………..698
Checking Crankshaft Journal And Block Bearing……….700
Checking Crankshaft Journal And Main Bearing………..701
Connecting Rod Journal……………………………702
Checking The End Play Of The Crankshaft…………….703
Crankshaft Alignment……………………………..703
Engine Timing Installation………………………..704
Timing Gear Backlash, Idler Gear And Crankshaft……..704
Idler Gear And Camshaft Gear………………………705
Idler Gear And Fuel Camshaft Gear………………….705
Fuel Camshaft Gear And Governor Shaft Gear………….705
FLYWHEEL HOUSING…………………………………….707
Removal And Installation………………………….707
FLYWHEEL……………………………………………709
Removal And Installation………………………….709
Ring Gear Removal And Installation…………………709
RUBBER DRIVE COUPLER…………………………………711
Removal And Installation………………………….711
Disassembly……………………………………..711
TURBOCHARGER………………………………………..713
Checking………………………………………..713
Description……………………………………..713
Removal And Installation………………………….713
HEATER…………………………………………………717
COMPONENTS………………………………………….719
Identification…………………………………..719
HEATER FAN………………………………………….721
Removal And Installation………………………….721
HEATER UNIT…………………………………………723
Removal And Installation………………………….723
Disassembly And Assembly………………………….725
SPECIFICATIONS………………………………………….727
LOADER BACKHOE SPECIFICATIONS…………………………729
Loader Backhoe Dimensions…………………………729
Backhoe Rated Load Capacity (Per SAE J31)…………..730
Performance……………………………………..731
Controls………………………………………..731
Engine………………………………………….731
Electrical………………………………………732
Drive System…………………………………….732
Capacities………………………………………732
Tires…………………………………………..732
ENGINE SPECIFICATIONS………………………………..733
Engine Compression……………………………….733
Fuel Injection Nozzles……………………………733
Fuel Injection Pump………………………………733
Cylinder Head……………………………………733
Valves………………………………………….733
Valve Springs……………………………………734
Rocker Arms……………………………………..734
Camshaft………………………………………..734
Cylinders……………………………………….734
Piston Rings…………………………………….735
Pistons…………………………………………735
Crankshaft………………………………………735
Oil Pump………………………………………..736
Thermostat………………………………………736
Grinding Specifications for the Crankshaft………….737
LOADER BACKHOE TORQUE………………………………..739
Specifications…………………………………..739
TORQUE SPECIFICATIONS FOR BOLTS……………………….741
Torque For General Metric Bolts……………………741
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS……………..743
Specifications…………………………………..743
CONVERSIONS…………………………………………745
Decimal And Millimeter Equivalents…………………745
U.S. To Metric Conversion…………………………745
SMR……………………………………………………747
B250-1……………………………………………..747
B250-2……………………………………………..749
B250-3……………………………………………..751
B250-4……………………………………………..753
B250-5……………………………………………..755

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DESCRIPTION:

BOBCAT B250 B Series SN 572211001 Service Manual PDF DOWNLOAD 

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 ROPS mounting hardware is tightened and is Bobcat approved.
2. The seat belt must be correctly installed, functional and in good condition.
3. Check lift arm support device, replace if damaged.
4. Machine signs must be legible and in the correct location.
5. Foot pedal must return to neutral.
6. Check for correct function of the work lights.
7. The parking brake must function correctly.
8. Enclosure door latches must open and close freely.
9. Bob-Tach wedges and linkages must function correctly and be in good condition.
10. Safety treads must be in good condition.
11. Check for correct function of indicator lamps (Optional on some models).
12. Check hydraulic fluid level, engine oil level, and fuel supply.
13. Inspect for fuel, oil, or hydraulic fluid leaks.
14. Lubricate the loader backhoe.
15. Check the condition of the battery and cables.
16. Inspect the air cleaner for damage or leaks. Check the condition of the element.
17. Check the electrical charging system.
18. Check tires for wear and pressure.
19. Inspect for loose or broken parts or connections.
20. Operate the loader and check all functions.
21. Check for any field modification not completed.
22. Recommend to the owner that all necessary corrections be made before the machine is returned to service

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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