Bobcat S250 Turbo S300 Turbo High Flow Loader Service Manual 6901926 (6-12) – PDF DOWNLOAD

Description

Bobcat S250 Turbo S300 Turbo High Flow Loader Service Manual 6901926 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat S250 Turbo S300 Turbo High Flow Loader Service Manual 6901926 (6-12) – PDF DOWNLOAD

Language : English
Pages : 1050
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S250 Turbo S300 Turbo High Flow Loader Service Manual 6901926 (6-12) – PDF DOWNLOAD

S250
S/N 521311001 & Above
S/N 521411001 & Above
S300
S/N 521511001 & Above
S/N 521611001 & Above

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:

TABLE OF CONTENTS:

Bobcat S250 Turbo S300 Turbo High Flow Loader Service Manual 6901926 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 8
SAFETY INSTRUCTIONS 11
Fire Prevention 13
SERIAL NUMBER LOCATION 15
Loader Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
BOBCAT LOADER IDENTIFICATION 17
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE LOADER 21
Procedure 21
LIFT ARM SUPPORT DEVICE 23
Installing The Lift Arm Support Device 23
Removing The Lift Arm Support Device 24
OPERATOR CAB 25
Description 25
Raising The Operator Cab 25
Lowering The Operator Cab 26
Emergency Exit 26
TRANSPORTING THE BOBCAT LOADER 29
Procedure 29
TOWING THE LOADER 31
Procedure For Non-Two-Speeds 31
REMOTE START 33
Procedure For Loader W/O Attachments Control Harness 33
Procedure For Loader With Attachments Control Harness 34
Procedure 35
SERVICE SCHEDULE 37
Chart 37
AIR CLEANER SERVICE 39
Replacing Filter Element 39
ENGINE COOLING SYSTEM 41
Cleaning Cooling System 41
FUEL SYSTEM 43
Fuel Specifications 43
Filling The Fuel Tank 43
Fuel Filter 43
Removing Air From The Fuel System 44
ENGINE LUBRICATION SYSTEM 45
Checking Engine Oil 45
Oil Chart 45
Replacing Oil And Filter 45
HYDRAULIC/HYDROSTATIC SYSTEM 47
Checking And Adding Fluid 47
Hydraulic/Hydrostatic Filter Replacement 47
Replacing Hydraulic Fluid And Case Drain Filters 48
FINAL DRIVE TRANSMISSION (CHAINCASE) 51
Checking And Adding Oil 51
Replacing The Oil 51
FAN GEARBOX 53
Checking And Adding Oil 53
BOB-TACH 55
Inspection And Maintenance 55
POWER BOB-TACH 57
Inspection And Maintenance 57
LUBRICATING THE LOADER 59
Procedure 59
TIRE MAINTENANCE 63
Wheel Nuts 63
Tire Rotation 63
Tire Mounting 63
HYDRAULIC SYSTEM 65
HYDRAULIC/HYDROSTATIC SCHEMATICS 71
HYDRAULIC SYSTEM INFORMATION 111
Troubleshooting 115
Tightening Procedure 116
CYLINDER (LIFT) 117
Checking 117
Removal And Installation 117
Parts Identification 119
Disassembly 120
Assembly 121
CYLINDER (TILT) 125
Checking 125
Removal And Installation 125
Base Pin Removal And Installation 127
Parts Identification 128
Disassembly 129
Assembly 130
CYLINDER (POWER BOB-TACH) 133
Checking 133
Removal And Installation 134
Parts Identification 135
Disassembly 136
Assembly 137
MAIN RELIEF VALVE (FOOT CONTROL) 141
Checking The Main Relief Valve At Front Aux Hyd 141
Removal And Installation 142
Adjustment 142
MAIN RELIEF VALVE (ACS) 143
Checking The Main Relief Valve At Front Aux Hyd 143
Removal And Installation 144
Adjustment 145
MAIN RELIEF VALVE (SELECTABLE JOYSTICK CONTROL) (SJC) 147
Checking The Main Relief Valve At Front Auxiliary Hydraulics 147
Removal and Installation 148
Adjustment 149
HYDRAULIC CONTROL VALVE (FOOT CONTROL) 151
Removal And Installation 151
BICS™ Valve, Removal And Installation 155
BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation 156
BICS™ Valve, Check Valve Removal And Installation 157
Backslide, Lock Valve Removal And Installation 158
BICS™ Valve, Solenoid Removal And Installation 159
BICS™ Valve, Solenoid Testing 160
Identification Chart 160
Load Check Valve 161
Main Relief Valve 162
Port Relief Valve, Tilt Spool 162
Port Relief Valve, Lift Spool 163
Anti-Cavitation Valve/Port Relief Valve, Tilt Spool 163
Anti-Cavitation Valve, Lift Spool 164
Rubber Boot 164
Lift And Tilt Lock Block 165
Lift Spool And Detent Removal 166
Lift Spool And Detent Disassembly 168
Lift Spool And Detent Assembly 170
Lift Spool And Detent Installation 174
Tilt Spool Removal And Installation 174
Tilt Spool Disassembly And Assembly 175
Auxiliary Spool Removal And Installation 176
Auxiliary Plug Removal And Installation 178
Auxiliary Electric Solenoid Disassembly 179
Port-Auxiliary Section Removal And Installation 180
Cleaning And Inspection 180
HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS) 181
Actuator Removal And Installation (In Loader) 181
Actuator Removal And Installation (Out Of Loader) 184
Removal And Installation 185
BICS™ Valve, Removal And Installation 189
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly 191
BICS™ Valve, Check Valve Disassembly And Assembly 192
BICS™ Valve, Lock Valve Disassembly And Assembly 193
BICS™ Valve, Solenoid Disassembly And Assembly 194
BICS™ Valve, Solenoid Testing 195
Identification Chart 196
Lift Base End Restrictor 197
Load Check Valve 197
Main Relief Valve 198
Port Relief Valve 199
Anti-Cavitation Valve/Port Relief Valve 200
Anti-Cavitation Valve 201
Lift Spool Removal 202
Lift Spool Removal And Installation 203
Lift and Tilt Spool Disassembly And Assembly 204
Auxiliary Spool Removal And Installation 205
Auxiliary Electric Solenoid Disassembly 206
Port-Auxiliary Section Disassembly 207
Cleaning And Inspection 207
HYDRAULIC CONTROL VALVE (SELECTABLE JOYSTICK CONTROL) (SJC) 209
Actuator Removal And Installation (In Loader) 209
Actuator Removal And Installation (Out Of Loader) 212
Removal And Installation 213
BICS™ Valve, Removal And Installation 217
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly 219
BICS™ Valve, Check Valve Disassembly And Assembly 220
BICS™ Valve, Lock Valve Disassembly And Assembly 221
BICS™ Valve, Solenoid Disassembly And Assembly 222
BICS™ Valve, Solenoid Testing 223
Identification Chart 224
Lift Base End Restrictor 225
Load Check Valve 225
Main Relief Valve 226
Port Relief Valve 227
Anti-Cavitation Valve/Port Relief Valve 228
Anti-Cavitation Valve 229
Lift Spool Removal 230
Lift Spool Removal And Installation 231
Lift and Tilt Spool Disassembly And Assembly 232
Auxiliary Spool Removal And Installation 233
Auxiliary Electric Solenoid Disassembly 234
Port-Auxiliary Section Disassembly 235
Cleaning And Inspection 235
LIFT ARM BY-PASS CONTROL VALVE 237
Inspecting 237
Additional Inspection For Loaders W/Advanced Hand Controls 237
Removal And Installation 237
Disassembly And Assembly 238
HYDRAULIC PUMP (BOBCAT P/N 6678224, 6681596) (VENDOR P/N 163D1185, 163D1301) 239
Check The Output Of The Hydraulic Pump W/O Power Bob-Tach 239
Check The Output Of The Hydraulic Pump W/Power Bob-Tach 240
Removal And Installation 242
Identification 244
Disassembly And Assembly 245
HYDRAULIC PUMP (HI FLOW) (BOBCAT P/N 6680295, 6681600) (VENDOR P/N 163D1275, 163D1304) 251
Hydraulic Pump Test 251
Inline Hydraulic Pump Test (Standard) 252
Inline Hydraulic Pump Test (High Flow) 254
High Flow Relief Adjustment Procedure 256
High Flow Relief Valve Removal and Installation 258
Removal And Installation 260
Identification 262
Disassembly And Assembly 263
HYDRAULIC PUMP (BOBCAT P/N 6683236) (VENDOR P/N 163D1298) 273
Check The Output Of The Hydraulic Pump 273
Removal And Installation 274
Identification 276
Disassembly And Assembly 277
HYDRAULIC PUMP (CHARGE) 285
Check The Output Of The Hydraulic Pump 285
HYDRAULIC PUMP (HI FLOW) (BOBCAT P/N 6683237) (VENDOR P/N 163D1299) 289
Hydraulic Pump Test 289
Inline Hydraulic Pump Test (Standard) 290
Inline Hydraulic Pump Test (High Flow) 292
High Flow Relief Adjustment Procedure 294
High Flow Relief Valve Removal and Installation 296
Removal And Installation 298
Identification 300
Disassembly And Assembly 301
HYDRAULIC PUMP (HI FLOW) (BOBCAT P/N 6684635) (VENDOR P/N 163D1372) 315
Hydraulic Pump Test 315
Inline Hydraulic Pump Test (Standard) 316
Inline Hydraulic Pump Test (High Flow) 318
High Flow Relief Adjustment Procedure 320
High Flow Relief Valve Removal and Installation 322
Removal And Installation 324
Identification 326
Disassembly And Assembly 327
HYDRAULIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC) (BOBCAT P/N 6684386) (VENDOR P/N 163D1357) 341
Check The Output Of The Hydraulic Pump 341
Removal And Installation 342
Identification 344
Disassembly And Assembly 345
HYDRAULIC PUMP (HI FLOW) (SELECTABLE JOYSTICK CONTROL) (SJC) (BOBCAT P/N 6684387) (VENDOR P/N 163D1358) 351
Hydraulic Pump Test 351
Inline Hydraulic Pump Test (Standard) 352
Inline Hydraulic Pump Test (High Flow) 354
High Flow Relief Adjustment Procedure 356
High Flow Relief Valve Removal and Installation 358
Removal And Installation 360
Identification 362
Disassembly And Assembly 363
HYDRAULIC/HYDROSTATIC FILTER 373
Housing Removal And Installation 373
Mount Removal And Installation 374
HYDRAULIC FLUID RESERVOIR 375
Fluid Removal 375
Removal And Installation 375
Hydraulic Fluid Screen 378
BUCKET POSITION VALVE 381
Solenoid Removal And Installation 381
Solenoid Testing 381
Removal And Installation 382
Disassembly And Assembly 382
REAR AUXILIARY DIVERTER VALVE (EARLY MODELS) 385
Removal and Installation 385
REAR AUXILIARY DIVERTER VALVE (EARLY MODELS) (CONT’D) 386
REAR AUXILIARY DIVERTER VALVE (EARLY MODELS) (CONT’D) 387
Disassembly and Assembly 387
Inspection 387
Solenoid Testing 388
Assembly 388
REAR AUXILIARY DIVERTER (LATER MOTELS) 389
Removal and Installation 389
Disassembly And Assembly 391
Solenoid Testing 396
Inspection 396
POWER BOB-TACH BLOCK (EARLY MODELS) 397
Removal And Installation 397
Disassembly And Assembly 398
POWER BOB-TACH BLOCK (LATER MODELS) 407
Removal And Installation 407
Disassembly And Assembly 408
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 415
Removal and Installation 415
Disassembly And Assembly 415
HYDROSTATIC SYSTEM 417
HYDROSTATIC SYSTEM INFORMATION 419
Troubleshooting 419
Replenishing Valve Function 420
HYDROSTATIC MOTOR 421
Removal And Installation 421
Parts Identification 422
Disassembly 423
Inspection 425
Assembly 426
HYDROSTATIC MOTOR (TWO-SPEED) 431
Removal And Installation 431
Parts Identification 433
Disassembly 435
Inspection 442
Assembly 443
HYDROSTATIC MOTOR CARRIER 451
Removal and Installation 451
Parts Identification 453
Disassembly 454
Assembly 455
HYDROSTATIC MOTOR CARRIER (SELECTABLE JOYSTICK CONTROL) (SJC) 457
Removal And Installation 457
Parts Identification 458
Disassembly 459
Assembly 461
CHARGE PRESSURE 467
Sender Removal And Installation 467
HYDROSTATIC PUMP (S250 S/N 521313912 & BELOW) (S300 S/N 521512099 & BELOW) 469
Replenishing/High Pressure Relief Valve 469
Charge Pressure Relief Valve 469
Removal And Installation 470
Parts Identification (Right Half) 472
Parts Identification (Left Half) 474
Hydraulic Pump Removal 476
Disassembly 476
Assembly 484
HYDROSTATIC PUMP (S250 S/N 521313913 & ABOVE) (S300 S/N 521512100 & ABOVE) 493
Removal And Installation 493
Replenishing/High Pressure Relief Valve 495
Parts Identification (Right Half) 496
Parts Identification (Left Half) 498
Hydraulic Pump Removal And Installation 500
Pump Separation 500
Disassembly 501
Assembly 507
HYDROSTATIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC) 515
Pump Controller Removal And Installation 515
Hydrostatic Pump Calibration 518
Removal And Installation 522
Parts Identification (Right Half) 525
Parts Identification (Left Half) 527
System Check Relief Valves (High Pressure Relief, Charge Check & By-Pass Valve) 529
Charge Relief Valve 530
Pump Separation 532
Shaft Seal And Shaft Replacement 533
Shaft Seal And Shaft Installation 535
Charge Pump Removal 537
Charge Pump Inspection 539
Charge Pump Installation 540
Disassembly 542
Inspection 549
Assembly 553
Pump Neutral Adjustment 562
Pump Controller Neutral Adjustment 565
DRIVE BELT 569
Shield Removal And Installation 569
Adjustment 569
Replacement 569
Tensioner Pulley Removal And Installation 570
Tensioner Pulley Tension Spring 572
OIL COOLER (SEAL TO CONNECT) (STC) 573
Hydraulic Oil Cooler Removal and Installation 573
OIL COOLER (SEAL TO CONNECT) (STC) (CONT’D) 574
Hydraulic Oil Cooler Removal and Installation (Cont,d) 574
DRIVE SYSTEM 575
BRAKE 579
Disc Removal And Installation 579
BRAKE (TWO-SPEED) 583
Block Removal And Installation 583
Block Disassembly And Assembly 584
DRIVE COMPONENTS 589
Axle Seal Removal And Installation 589
Axle, Sprocket And Bearings Removal And Installation 591
Drive Chain Removal And Installation 595
CHAINCASE 599
Front Chaincase Cover Removal And Installation 599
Rear Chaincase Cover Removal And Installation 599
MAIN FRAME 601
SEAT BAR 605
Removal And Installation 605
Assembling Components 606
Compression Spring Disassembly And Assembly 607
OPERATOR CAB 609
Gas Cylinder Removal And Installation (Early Models) 609
Gas Cylinder Removal And Installation (Later Models) 611
Gas Cylinder Bracket Disassembly And Assembly 613
Removal And Installation 613
OPERATOR SEAT 617
Removal And Installation 617
Seat Belt Removal And Installation 617
OPERATOR SEAT (SUSPENSION) 619
Removal And Installation 619
Slide Rail Removal And Installation 620
Cushion Removal And Installation 620
Back Removal And Installation 621
Shock Removal And Installation 622
BOB-TACH 623
Removal And Installation 623
Bob-Tach Lever And Wedge 625
POWER BOB-TACH 627
Removal And Installation 627
Power Bob-Tach Lever And Wedge 629
Pivot Pin Bushing And Seal Replacement 631
LIFT ARMS 633
Stabilizer Bar Removal And Installation 633
Link Removal And Installation 634
Removal And Installation 635
Installation Of Lift Arms 637
REAR GRILL 639
Removal And Installation 639
REAR DOOR 641
Removal And Installation 641
Adjusting The Rear Door Latch 642
FUEL TANK 643
Removal And Installation 643
Fuel Level Sender 644
CONTROL PEDALS 645
Removal And Installation 645
Pedal Adjustment 645
CONTROL PEDALS (ACS) 647
Foot Sensor Removal And Installation 647
Foot Pedal Removal And Installation 648
Foot Pedal Linkage Disassembly And Assembly 648
CONTROL PANEL 649
Removal And Installation 649
Shock Removal And Installation 651
Shaft Removal And Installation 651
Shaft Disassembly And Assembly 651
Linkage Removal And Installation 653
Linkage Neutral Adjustment 656
CONTROL PANEL (SELECTABLE JOYSTICK CONTROL) (SJC) 663
Removal And Installation 663
CONTROL HANDLE 667
Lever Removal And Installation 667
Steering Lever Boot 667
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL 669
Components Identification 669
Handle Sensor Removal And Installation 669
Control Handle Removal And Installation 672
Control Handle Disassembly And Assembly 673
Control Lever Removal And Installation 674
Control Lever Boot 675
CONTROL HANDLE (SELECTABLE JOYSTICK CONTROL) (SJC) 677
Joystick Testing (Right & Left) 677
Joystick Removal (Right & Left) 678
Joystick Boot Removal (Right & Left) 679
Lever Assembly Removal (Right & Left) 680
INSIDE ACCESS PANEL 683
Removal And Installation (Left) 683
Removal And Installation (Right) 683
INSIDE ACCESS PANEL (SELECTABLE JOYSTICK CONTROL) (SJC) 685
Panel Removal (Right) 685
Panel Removal (Left) 688
ELECTRICAL SYSTEM & ANALYSIS 689
ELECTRICAL SCHEMATICS 693
ELECTRICAL SYSTEM INFORMATION 701
Troubleshooting 703
Description 704
Fuse Location 706
Relay Switch Location 706
Solenoid Test 707
BATTERY 709
Removal And Installation 709
Servicing The Electrical System 711
Using A Booster Battery (Jump Starting) 712
ALTERNATOR 713
Adjusting The Alternator Belt 713
Alternator Identification 713
Charging System Check 714
Alternator Voltage Test 715
Low Voltage Test 715
High Voltage Test 716
Removal And Installation 716
Rectifier Continuity (Diode) Test 717
Alternator Regulator Test 718
Disassembly 719
Stator Continuity Test 719
Stator Ground Test 719
Rotor Continuity Test 720
Rotor Ground Test 720
Assembly 720
STARTER 721
Removal And Installation 721
Parts Identification 722
Checking 723
Disassembly And Assembly 724
Inspection And Repair 727
No Load Test 730
INSTRUMENT PANEL 731
Left Panel 731
Right Panel (Standard) (With Key Switch) 732
Right Panel (Deluxe) (With Keyless Start) 733
Right Panel Setup Display Options (Deluxe) 735
Deluxe Panel Setup 736
Passwords (Deluxe) 736
Option And Field Accessory Panels (If Equipped) 738
Standard Panel Removal And Installation (Right Side) 739
Deluxe Panel Removal And Installation (Right Side) 740
Standard & Deluxe Panel Removal And Installation (Left Side) 741
Front Accessory Panel Removal And Installation 742
LIGHTS 743
Front Removal And Installation 743
Rear Removal And Installation 743
BOBCAT CONTROLLER 746
Identification Chart 746
Removal And Installation 748
CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC) 749
Removal 749
Identification Chart 752
SPEED SENSOR (SELECTABLE JOYSTICK CONTROL) (SJC) 755
Testing 755
Removal 756
DIAGNOSTICS SERVICE CODES 759
Display 759
Number Codes List 760
BICS™ SYSTEM 765
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 765
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 765
Inspecting The Seat Bar Sensor (Engine RUNNING) 765
Inspecting The Traction Lock (Engine RUNNING) 765
Inspecting The Lift Arm By-Pass Control 766
Additional Inspection For Loaders With Advanced Controls System (ACS) or Selectable Joystick Control (SJC) 766
Troubleshooting 767
Troubleshooting Guide 768
SEAT BAR SENSOR 769
Troubleshooting Chart 769
Test 770
Removal And Installation 771
BICS™ Circuit Test 772
TRACTION LOCK 773
Troubleshooting 773
Removal And Installation (Single Speed) 774
Description Of The Control System (Two Speed) 775
Inspecting The Control System (Two Speed) 775
ADVANCED CONTROL SYSTEM (ACS) 777
Components Identification 777
Troubleshooting Guide 779
Controller, Connector And Wire Identification 780
ACS Controller Removal And Installation 781
Handle Sensor Connector 782
Switch Handle Removal 783
Switch Handle Installation 785
Actuators Disassembly And Assembly 788
Handle Lock Solenoid Removal And Installation 789
Handle Lock Solenoid Disassembly And Assembly 789
Handle Lock Solenoid Connector 790
Calibration Of The ACS System 790
Switchable Hand/Foot Controls Calibration Procedure 791
Hand Controls Only Calibration Procedure 792
Foot Sensor Disassembly And Assembly 793
Foot Sensor Connector 794
Foot Lock Solenoid Removal And Installation 794
Foot Lock Solenoid Connector 795
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE 797
Controls Identification Chart 797
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC) 799
Controls Identification Chart 799
SERVICE PC (LAPTOP COMPUTER) 803
Connecting The Service PC To Remote Start Tool 803
LIFT AND TILT ACTUATOR CALIBRATION (SELECTABLE JOYSTICK CONTROL) (SJC) 805
Procedure 805
RPM SENSOR 807
Adjustment 807
ENGINE SERVICE 809
TROUBLESHOOTING 813
Chart 813
ENGINE SPEED CONTROL 815
Removal And Installation 815
Speed Control Cable 816
ENGINE SPEED CONTROL (SELECTABLE JOYSTICK CONTROL) (SJC) 819
Removal 819
Disassembly 821
Speed Control Cable 822
MUFFLER 825
Removal And Installation 825
AIR CLEANER 827
Housing Removal And Installation 827
RADIATOR 829
Removal And Installation 829
Mount Removal 831
COOLING FAN 833
Drive Tension Pulley Removal And Installation 833
Gearbox/Blower Housing Removal And Installation 834
Gearbox Parts Identification 837
Gearbox Disassembly 838
Gearbox Assembly 843
Gearbox, Checking Backlash 848
ENGINE 851
Removal And Installation 851
Mount Replacement 858
Removal And Installation Tools 859
FLYWHEEL AND HOUSING 861
Flywheel Removal And Installation 861
Ring Gear Removal And Installation 861
Flywheel Housing Removal And Installation 861
RECONDITIONING THE ENGINE 863
Engine Tools Identification Chart 863
Compression Pressure 867
Cylinder Head Clearance 867
Valve Cover And Injector Nozzle Removal And Installation 868
Rocker Arm And Push Rod Disassembly And Assembly 870
Valve Clearance 870
Cylinder Head And Tappet Disassembly And Assembly 871
Selecting Cylinder Head Gasket Disassembly And Assembly 872
Valve Disassembly And Assembly 873
Engine Timing (TDC) 874
Injection Pump Assembly Removal 875
Injection Pump Assembly Installation 878
Injection Pump Removal and Installation 881
Injection Pump Timing 883
Fan Drive Pulley Disassembly And Assembly 886
Water Pump Disassembly And Assembly 886
Gearcase Cover Disassembly And Assembly 887
Idle Gear And Camshaft Disassembly And Assembly 887
Gearcase Plate Disassembly And Assembly 888
Oil Pan And Oil Strainer Disassembly And Assembly 888
Connecting Rod Cap Disassembly And Assembly 889
Piston Disassembly And Assembly 890
Piston Ring And Connecting Rod Disassembly And Assembly 891
Bearing Case Cover Disassembly And Assembly 893
Flywheel Housing Disassembly And Assembly 894
Crankcase No 2 Disassembly And Assembly 894
Crankcase No 1 And No 2 Disassembly And Assembly 895
Crankshaft Disassembly And Assembly 895
Cylinder Head Surface Flatness 895
Cylinder Head Flaw 896
Valve Recessing 896
Valve Lapping 897
Clearance Between Valve Stem And Valve Guide 897
Replacing Valve Guide 898
Correcting Valve And Valve Seat 898
Free Length And Tilt Of Valve Spring 899
Valve Spring Setting Load 899
Oil Clearance Between Rocker Arm Shaft And Bearing 900
Oil Clearance Between Tappet And Tappet Guide Bore 900
Timing Gear Backlash 901
Idler Gear Side Clearance 901
Camshaft Side Clearance 902
Camshaft Alignment 902
Cam Height 902
Oil Clearance Between Idler Gear Shaft And Idler Gearing Bushing 903
Replacing Idler Gear Bushing 904
Piston Pin Bore I D 905
Oil Clearance Between Piston Pin And Small End Bushing 905
Replacing Small End Bushing 906
Clearance Between Piston Ring And Groove 906
Piston Ring Gap 907
Connecting Rod Alignment 907
Crankshaft Side Clearance 908
Crankshaft Alignment 909
Oil Clearance Between Crank pin And Crank pin Bearing 909
Oil Clearance Between Crankshaft Journal And Crankshaft Bearing 911
Replacing Crankshaft Sleeve 912
Cylinder Bore I D 912
Correcting Cylinder (Oversize +0 5 mm) 913
Engine Oil Pressure 913
Rotor Lobe Clearance 914
Clearance Between Outer Rotor And Pump Body 914
Thermostat Valve Opening Temperature 914
Radiator Water Leakage 915
Radiator Cap Air Leakage 915
Thermostat Assembly 915
Intake Air Heater 916
Checking the Turbo Charger 917
Compressor Side 917
Wheel Shaft 917
Axial Clearance 918
Radial Clearance 918
Air Cleaner, Intake Pipe, Inlet Pipe And Muffler 918
Oil Pipe 919
HEATING, VENTILATION, AIR CONDITIONING 921
AIR CONDITIONING SYSTEM FLOW 924
Principals 924
Chart 925
COMPONENTS 927
Identification 927
SAFETY 931
Safety Equipment 931
REGULAR MAINTENANCE 933
Filter Elements Removal And Installation 933
Compressor Drive Belt Inspection 934
Cleaning The Condenser 935
BASIC TROUBLESHOOTING 937
Poor A/C Performance 937
Cleaning The A/C Evaporator Coil & Heater Coil 938
Compressor Drive Belt Inspection 938
Checking The Electrical System 939
Engine Coolant By-Passing The Heater Valve 947
Heater Valve Not Opening Or Closing 948
GENERAL AIR CONDITIONING SERVICE GUIDELINES 951
Compressor Oil 951
Compressor Oil Check 952
Component Replacement And Refrigeration Leaks 953
SYSTEM TROUBLESHOOTING CHART 955
Gauge Pressure Related Troubleshooting 956
Troubleshooting Tree 958
TEMPERATURE/PRESSURE 963
Chart 963
AIR CONDITIONING SERVICE 965
Chart 965
SYSTEM CHARGING AND RECLAMATION 967
Reclamation Procedure 967
Charging Procedure With A Manifold Gauge Set 969
Charging Procedure 970
COMPRESSOR 973
Removal And Installation 973
Compressor Clutch Disassembly 974
CONDENSER 979
Removal And Installation 979
RECEIVER/DRIER 981
Removal And Installation 981
PRESSURE RELIEF VALVE 983
Removal And Installation 983
PRESSURE SWITCH 985
Removal And Installation 985
EVAPORATOR/HEATER UNIT 987
Removal And Installation 987
Disassembly And Assembly 988
THERMOSTAT 989
Removal And Installation 989
EXPANSION VALVE 991
Removal And Installation 991
EVAPORATOR 993
Removal And Installation 993
HEATER COIL 995
Removal And Installation With A/C 995
Removal And Installation Without A/C 996
BLOWER FAN 999
Removal And Installation 999
Disassembly And Assembly 1000
Wire Connector Removal and Installation 1002
HEATER VALVE 1005
Removal and Installation 1005
Disassembly And Assembly 1006
SPECIFICATIONS 1009
LOADER SPECIFICATIONS (S250) 1011
Machine Dimensions 1011
Performance 1012
Controls 1012
Engine 1012
Hydraulic System 1013
Electrical 1013
Drive System 1014
Capacities 1014
Tires 1014
LOADER SPECIFICATIONS (S300) 1015
Machine Dimensions 1015
Performance 1016
Controls 1016
Engine 1016
Hydraulic System 1017
Electrical 1017
Drive System 1018
Capacities 1018
Tires 1018
ENGINE SPECIFICATIONS 1019
General 1019
Fuel System 1019
Valve And Valve Timing 1019
Valve Spring 1020
Piston And Piston Ring 1020
Connecting Rod 1020
Cylinder Head 1021
Crankshaft 1021
Cylinder Bore 1021
Oil Pump 1021
Rocker Arm 1022
Tappet 1022
Camshaft 1022
Thermostat 1022
Timing Gear 1023
Intake Air Heater 1023
TORQUE SPECIFICATIONS FOR BOLTS 1025
Torque For General SAE Bolts 1025
Torque For General Metric Bolts 1026
Torque For Kubota Metric Engine Bolts 1027
Tightening Torques For General Use Screws, Bolts And Nuts 1027
HYDRAULIC CONNECTION SPECIFICATIONS 1029
O-ring Face Seal Connection 1029
Straight Thread O-ring Fitting 1030
Tubelines And Hoses 1030
Flare Fitting 1030
O-ring Flare Fitting 1031
Port Seal Fitting 1033
HYDRAULIC FLUID SPECIFICATIONS 1035
Specifications 1035
CONVERSIONS 1037
Decimal And Millimeter Equivalents 1037
SMR 1039
Revision No: S250/S300-1 1039
Revision No: S250/S300-2 1041
Revision No: S250/S300-3 1043
Revision No: S250/S300-4 1045
Revision No: S250/S300-5 1047
Revision No: S250/S300-6 1049

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PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.V