Bobcat S250 Turbo S300 Turbo High Flow Loader Service Manual 6902711 (6-12) – PDF DOWNLOAD

Description

Bobcat S250 Turbo S300 Turbo High Flow Loader Service Manual 6902711 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat S250 Turbo S300 Turbo High Flow Loader Service Manual 6902711 (6-12) – PDF DOWNLOAD

Language : English
Pages : 1076
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S250 Turbo S300 Turbo High Flow Loader Service Manual 6902711 (6-12) – PDF DOWNLOAD

S250
S/N 526011001 & Above
S/N 526111001 & Above
S300
S/N 525811001 & Above
S/N 525911001 & 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 6902711 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
Fire Prevention 13
SERIAL NUMBER LOCATION 15
Loader Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 15
BOBCAT LOADER IDENTIFICATION 16
SAFETY AND MAINTENANCE 17
LIFTING AND BLOCKING THE LOADER 19
Procedure 19
LIFT ARM SUPPORT DEVICE 21
Installing The Lift Arm Support Device 21
Removing The Lift Arm Support Device 22
OPERATOR CAB 23
Description 23
Raising The Operator Cab 23
Lowering The Operator Cab 24
Emergency Exit 24
TRANSPORTING THE BOBCAT LOADER 27
Procedure 27
TOWING THE LOADER 29
Procedure 29
REMOTE START 31
Procedure For Loader W/O Attachments Control Harness 31
Procedure For Loader With Attachments Control Harness 32
Procedure 33
SERVICE SCHEDULE 35
Chart 35
AIR CLEANER SERVICE 37
Replacing Filter Element 37
ENGINE COOLING SYSTEM 39
Cleaning Cooling System 39
Checking The Coolant Level 41
Adding The Coolant 42
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 Fluid Chart 47
Hydraulic/Hydrostatic Filter Replacement 48
Replacing Hydraulic Fluid And Case Drain Filters 49
FINAL DRIVE TRANSMISSION (CHAINCASE) 51
Checking And Adding Oil 51
Removing 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
Pivot Pins 61
TIRE MAINTENANCE 63
Wheel Nuts 63
Tire Rotation 63
Tire Mounting 63
HYDRAULIC SYSTEM 65
HYDRAULIC/HYDROSTATIC SCHEMATICS 71
HYDRAULIC SYSTEM INFORMATION 103
Troubleshooting 107
Tightening Procedure 108
CYLINDER (LIFT) 109
Checking 109
Removal And Installation 109
Parts Identification 111
Disassembly 112
Assembly 113
CYLINDER (TILT) 117
Checking 117
Removal And Installation 117
Base Pin Removal And Installation 119
Parts Identification 120
Disassembly 121
Assembly 122
CYLINDER (POWER BOB-TACH) 125
Checking 125
Removal And Installation 126
Parts Identification 127
Disassembly 128
Assembly 129
MAIN RELIEF VALVE 133
Checking Main Relief 133
Adjustment 135
Removal And Installation 136
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL) 137
Identification 137
Removal And Installation 137
BICS™ Valve, Removal And Installation 141
BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation 143
BICS™ Valve, Check Valve Removal And Installation 144
Backslide, Lock Valve Removal And Installation 145
BICS™ Valve, Solenoid Removal And Installation 146
BICS™ Valve, Solenoid Testing 147
Identification Chart 148
Load Check Valve 149
Main Relief Valve 150
Port Relief Valve, Tilt Spool 150
Port Relief Valve, Lift Spool 151
Anti-Cavitation Valve/Port Relief Valve, Tilt Spool 151
Anti-Cavitation Valve, Lift Spool 152
Rubber Boot 152
Lift And Tilt Lock Block 153
Lift Spool And Detent Removal 154
Lift Spool And Detent Disassembly 156
Lift Spool And Detent Assembly 159
Lift Spool And Detent Installation 163
Tilt Spool Removal And Installation 164
Tilt Spool Disassembly And Assembly 165
Auxiliary Spool Removal And Installation 166
Auxiliary Plug Removal And Installation 168
Auxiliary Electric Solenoid Disassembly 169
Port-Auxiliary Section Removal And Installation 170
Cleaning And Inspection 170
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) 171
Identification 171
Actuator Removal And Installation (In Loader) 172
Actuator Removal And Installation (Out Of Loader) 175
Removal And Installation 177
BICS™ Valve, Removal And Installation 181
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly 184
BICS™ Valve, Check Valve Disassembly And Assembly 185
BICS™ Valve, Lock Valve Disassembly And Assembly 186
BICS™ Valve, Solenoid Disassembly And Assembly 187
BICS™ Valve, Solenoid Testing 188
Identification Chart 189
Lift Base End Restrictor 190
Load Check Valve 191
Main Relief Valve 192
Port Relief Valve 194
Anti-Cavitation Valve/Port Relief Valve 195
Anti-Cavitation Valve 196
Lift Spool Removal 197
Lift Spool Removal And Installation 198
Lift and Tilt Spool Disassembly And Assembly 199
Auxiliary Spool Removal And Installation 200
Auxiliary Electric Solenoid Disassembly 201
Port-Auxiliary Section Disassembly 202
Cleaning And Inspection 202
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (selectable joystick control) (sjc) 203
Identification 203
Actuator Removal And Installation (In Loader) 204
Actuator Removal And Installation (Out Of Loader) 207
Removal And Installation 209
BICS™ Valve, Removal And Installation 213
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly 216
BICS™ Valve, Check Valve Disassembly And Assembly 217
BICS™ Valve, Lock Valve Disassembly And Assembly 218
BICS™ Valve, Solenoid Disassembly And Assembly 219
BICS™ Valve, Solenoid Testing 220
Identification Chart 221
Lift Base End Restrictor 222
Load Check Valve 222
Main Relief Valve 223
Port Relief Valve 224
Anti-Cavitation Valve/Port Relief Valve 225
Anti-Cavitation Valve 226
Lift Spool Removal 227
Lift Spool Removal And Installation 228
Lift and Tilt Spool Disassembly And Assembly 229
Auxiliary Spool Removal And Installation 230
Auxiliary Electric Solenoid Disassembly 231
Port-Auxiliary Section Disassembly 232
Cleaning And Inspection 232
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL) 233
Identification 233
Removal And Installation 233
Identification Chart 238
BICS™ Valve, Lift Load Check Valve Removal And Installation 239
Load Check Valve Removal And Installation (Tilt & Auxiliary) 240
Anti-Cavitation Valve (Lift, Rod End) 240
Port Relief/Anti-Cavitation Valve (Lift, Base End) 241
Port Relief/Anti-Cavitation Valve (Tilt, Base End) 242
Port Relief/Anti-Cavitation Valve (Tilt, Rod End) 242
Port Relief Valve 243
Plug Removal 244
Rubber Boot Removal and Installation 245
End Cap/Spool Lock Block Removal and Installation 246
Lift Spool and Detent Removal and Installation 247
Auxiliary Spool Removal And Installation 259
Auxiliary Solenoid Disassembly and Assembly 261
BICS™ Valve Solenoid Disassembly And Assembly 262
BICS™ Valve, Lock Valve Removal And Installation 263
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly 265
Main Relief Valve 265
BICS™ Valve, Check Valve Removal and Installation 266
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS) 267
Identification 267
Removal And Installation 268
Actuator Removal And Installation (In Loader) 272
Identification Chart 277
BICS™ Valve, Lift Load Check Valve Removal And Installation 278
Load Check Valve Removal And Installation (Tilt & Auxiliary) 279
Anti-Cavitation Valve (Lift, Rod End) 279
Port Relief/Anti-Cavitation Valve (Lift, Base End) 280
Port Relief/Anti-Cavitation Valve (Tilt, Base End) 281
Port Relief/Anti-Cavitation Valve (Tilt, Rod End) 281
Port Relief Valve 282
Plug Removal 283
End Cap Block Removal And Installation 284
Lift Spool Removal And Installation 285
Auxiliary Spool Removal And Installation 291
Auxiliary Solenoid Disassembly And Assembly 293
BICS™ Valve Solenoid Disassembly And Assembly 294
BICS™ Valve, Lock Valve Removal And Installation 295
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly 297
Main Relief Valve 297
BICS™ Valve, Check Valve Removal And Installation 298
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (SELECTABLE JOYSTICK CONTROL) (SJC) 299
Identification 299
Removal And Installation 300
Actuator Removal And Installation (In Loader) 304
Actuator Removal And Installation (Out of Loader) 306
Identification Chart 309
BICS™ Valve, Lift Load Check Valve Removal And Installation 310
Load Check Valve Removal And Installation (Tilt & Auxiliary) 311
Anti-Cavitation Valve (Lift, Rod End) 311
Port Relief/Anti-Cavitation Valve (Lift, Base End) 312
Port Relief/Anti-Cavitation Valve (Tilt, Base End) 313
Port Relief/Anti-Cavitation Valve (Tilt, Rod End) 313
Port Relief Valve 314
Plug Removal 315
End Cap Block Removal And Installation 316
Lift Spool Removal And Installation 317
Auxiliary Spool Removal And Installation 323
Auxiliary Solenoid Disassembly And Assembly 325
BICS™ Valve Solenoid Disassembly And Assembly 326
BICS™ Valve, Lock Valve Removal And Installation 327
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly 329
Main Relief Valve 329
BICS™ Valve, Check Valve Removal And Installation 330
LIFT ARM BY-PASS CONTROL VALVE 331
Inspecting 331
Additional Inspection For Loaders W/Advanced Hand Controls 331
Removal And Installation 331
Disassembly And Assembly 332
HYDRAULIC PUMP 333
Check The Output Of The Hydraulic Pump 333
Removal And Installation 334
Identification 336
Disassembly And Assembly 337
HYDRAULIC PUMP (CHARGE) 345
Check The Output Of The Hydraulic Pump 345
Removal And Installation 348
Disassembly And Assembly 348
HYDRAULIC PUMP (HIGH FLOW) 349
Hydraulic Pump Test (30 GPM) 349
Hydraulic Pump Test (40 GPM) 350
Inline Hydraulic Pump Test (Standard) 351
Inline Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM) 353
High Flow Relief Adjustment Procedure (30 GPM And 40 GPM) 355
High Flow Relief Valve Removal and Installation (30 GPM And 40 GPM) 357
Removal And Installation (30 GPM And 40 GPM) 358
Identification (30 GPM) (S/N 526016699 & Below) (S/N 525815599 & Below) 360
Identification (40 GPM) (S/N 526016700 & Above) (S/N 525815600 & Above) 361
Disassembly And Assembly (30 GPM And 40 GPM) 362
HYDRAULIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC) 375
Check The Output Of The Hydraulic Pump 375
Removal And Installation 376
Identification 378
Disassembly And Assembly 379
HYDRAULIC PUMP (HIGH FLOW) (SELECTABLE JOYSTICK CONTROL) (SJC) 385
Hydraulic Pump Test (30 GPM) 385
Hydraulic Pump Test (40 GPM) 386
Inline Hydraulic Pump Test (Standard) 387
Inline Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM) 389
High Flow Relief Adjustment Procedure (30 GPM And 40 GPM) 391
High Flow Relief Valve Removal And Installation (30 GPM And 40 GPM) 393
Removal And Installation (30 GPM And 40 GPM) 395
Identification (30 GPM) (S/N 525815599 & Below) (S/N 526016699 & Below) 397
Identification (40 GPM) (S/N 525815600 & Above) (S/N 526016700 & Above) 398
Disassembly And Assembly (30 GPM And 40 GPM) 399
HYDRAULIC/HYDROSTATIC FILTER 409
Housing Removal And Installation 409
Mount Removal And Installation 410
HYDRAULIC FLUID RESERVOIR 411
Fluid Removal 411
Removal And Installation 411
Hydraulic Fluid Screen 414
BUCKET POSITION VALVE 417
Solenoid Removal And Installation 417
Solenoid Testing 417
Removal And Installation 418
Disassembly And Assembly 418
REAR AUXILIARY DIVERTER 421
Removal and Installation 421
Disassembly And Assembly 423
Solenoid Testing 428
Inspection 428
POWER BOB-TACH BLOCK 429
Removal And Installation 429
Disassembly And Assembly 430
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 435
Removal and Installation 435
Disassembly And Assembly 435
HYDROSTATIC SYSTEM 437
HYDROSTATIC SYSTEM INFORMATION 439
Troubleshooting 439
Replenishing Valve Function 440
HYDROSTATIC MOTOR 441
Removal And Installation 441
Parts Identification 442
Disassembly 443
Inspection 445
Assembly 446
HYDROSTATIC MOTOR (TWO-SPEED) 451
Removal And Installation 451
Parts Identification 453
Disassembly 455
Inspection 462
Assembly 463
HYDROSTATIC MOTOR CARRIER 471
Removal and Installation 471
Parts Identification 473
Disassembly 474
Assembly 475
HYDROSTATIC MOTOR CARRIER (SELECTABLE JOYSTICK CONTROL) (SJC) 477
Removal And Installation 477
Parts Identification 478
Disassembly 479
Assembly 481
CHARGE PRESSURE 485
Testing 485
Removal And Installation 487
Setting Charge Pressure 488
HYDROSTATIC PUMP 489
Removal And Installation 489
Replenishing/High Pressure Relief Valve 491
Parts Identification (Right Half) 492
Parts Identification (Left Half) 494
Hydraulic Pump Removal And Installation 496
Pump Separation 496
Disassembly 497
Assembly 503
HYDROSTATIC PUMP (SELECTABLE JOYSTICK CONTROL) 511
Pump Controller Removal And Installation 511
Hydrostatic Pump Calibration 514
Removal And Installation 519
Parts Identification (Right Half) 521
Parts Identification (Left Half) 523
System Check Relief Valves (High Pressure Relief, Charge Check & By-Pass Valve) 525
Charge Relief Valve 526
Pump Separation 528
Shaft Seal And Shaft Replacement 529
Shaft Seal And Shaft Installation 531
Charge Pump Removal 533
Charge Pump Inspection 535
Charge Pump Installation 536
Disassembly 538
Inspection 545
Assembly 549
Pump Neutral Adjustment 558
Pump Controller Neutral Adjustment 561
DRIVE BELT 565
Shield Removal And Installation 565
Adjustment 565
Replacement 565
Tensioner Pulley Removal And Installation 566
Tensioner Pulley Tension Spring 568
OIL COOLER (SEAL TO CONNECT) (STC) 569
Hydraulic Oil Cooler Removal And Installation 569
DRIVE SYSTEM 571
BRAKE 573
Disc Removal And Installation 573
BRAKE (TWO-SPEED) 577
Block Removal And Installation 577
Block Disassembly And Assembly 578
DRIVE COMPONENTS 583
Axle Seal Removal And Installation 583
Axle, Sprocket And Bearings Removal And Installation 585
Drive Chain Removal And Installation 590
CHAINCASE 591
Front Chaincase Cover Removal And Installation 591
Rear Chaincase Cover Removal And Installation 591
MAIN FRAME 593
SEAT BAR 597
Removal And Installation 597
Assembling Components 598
Compression Spring Disassembly And Assembly 599
OPERATOR CAB 601
Gas Cylinder Removal And Installation 601
Gas Cylinder Bracket Disassembly And Assembly 603
Removal And Installation 603
OPERATOR SEAT 607
Removal And Installation 607
Seat Belt Removal And Installation 607
OPERATOR SEAT (SUSPENSION) 609
Removal And Installation 609
Slide Rail Removal And Installation 610
Seat Belt Removal and Installation 610
Cushion Removal And Installation 611
Back Removal And Installation 612
Shock Removal And Installation 612
3-Point Seat Belt Removal And Installation 613
BOB-TACH 615
Removal And Installation 615
Bob-Tach Lever And Wedge 617
POWER BOB-TACH 619
Removal And Installation 619
Power Bob-Tach Lever And Wedge 621
Pivot Pin Bushing And Seal Replacement 623
LIFT ARMS 625
Stabilizer Bar Removal And Installation 625
Link Removal And Installation 626
Removal And Installation 627
Installation Of Lift Arms 629
REAR GRILL 631
Removal And Installation 631
REAR DOOR 633
Removal And Installation 633
Striker Removal and Installation 634
Striker Disassembly and Assembly 634
Door Latch and Catch Adjustment 634
Latch Removal And Installation 635
FUEL TANK 637
Removal And Installation 637
Fuel Level Sender 638
CONTROL PEDALS 639
Removal And Installation 639
Pedal Adjustment 639
CONTROL PEDALS (ACS) 641
Foot Sensor Removal And Installation 641
Foot Pedal Removal And Installation 642
Foot Pedal Linkage Disassembly And Assembly 642
CONTROL PANEL (NON-ADJUSTABLE PINTLES) 643
Removal And Installation 643
Shock Removal And Installation 645
Shaft Removal And Installation 645
Shaft Disassembly And Assembly 645
Linkage Removal And Installation 647
Linkage Neutral Adjustment 650
CONTROL PANEL (ADJUSTABLE PINTLES) 657
Description 657
Removal And Installation 658
Shock Removal And Installation 660
Shaft Removal And Installation 660
Shaft Disassembly And Assembly 661
Linkage Removal And Installation 662
Pintle Arm Disassembly and Assembly 667
Linkage Neutral Adjustment 668
Linkage Travel Adjustment 672
CONTROL PANEL (SELECTABLE JOYSTICK CONTROL) (SJC) 677
Removal And Installation 677
CONTROL HANDLE 681
Lever Removal And Installation 681
Steering Lever Boot 681
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL 683
Components Identification 683
Handle Sensor Removal And Installation 683
Control Handle Removal And Installation 686
Control Handle Disassembly And Assembly 687
Control Lever Removal And Installation 688
Control Lever Boot 689
CONTROL HANDLE (SELECTABLE JOYSTICK CONTROL) (SJC) 691
Joystick Testing (Right & Left) 691
Joystick Removal (Right & Left) 692
Joystick Boot Removal (Right & Left) 693
Lever Assembly Removal (Right & Left) 693
INSIDE ACCESS PANEL 695
Removal And Installation (Left) 695
Removal And Installation (Right) 695
INSIDE ACCESS PANEL (SELECTABLE JOYSTICK CONTROL) (SJC) 697
Panel Removal (Right) 697
Panel Removal (Left) 700
ELECTRICAL SYSTEM & ANALYSIS 701
ELECTRICAL SCHEMATICS 705
ELECTRICAL SYSTEM INFORMATION 713
Troubleshooting 715
Description 716
Fuse Location 718
Relay Switch Location 718
Solenoid Test 719
BATTERY 721
Removal And Installation 721
Servicing The Electrical System 723
Using A Booster Battery (Jump Starting) 724
ALTERNATOR 725
Adjusting The Alternator Belt 725
Alternator Identification 725
Charging System Check 726
Alternator Voltage Test 727
Low Voltage Test 727
High Voltage Test 728
Removal And Installation 728
Rectifier Continuity (Diode) Test 729
Alternator Regulator Test 730
Disassembly 731
Stator Continuity Test 731
Stator Ground Test 731
Rotor Continuity Test 732
Rotor Ground Test 732
Assembly 732
STARTER 733
Checking 733
Removal And Installation 734
Parts Identification 735
Disassembly And Assembly 736
Inspection And Repair 739
No Load Test 742
INSTRUMENT PANEL 743
Left Panel 743
Right Panel (Standard) (With Key Switch) 744
Right Panel (Deluxe) (With Keyless Start) 745
Right Panel Setup Display Options (Deluxe) 747
Deluxe Panel Setup 748
Passwords (Deluxe) 748
Option And Field Accessory Panels (If Equipped) 750
Standard Panel Removal And Installation (Right Side) 751
Deluxe Panel Removal And Installation (Right Side) 752
Standard & Deluxe Panel Removal And Installation (Left Side) 753
Front Accessory Panel Removal And Installation 754
LIGHTS 755
Front Removal And Installation 755
Rear Removal And Installation 755
BOBCAT CONTROLLER 758
Identification Chart 758
Removal And Installation 760
CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC) 761
Removal 761
Identification Chart 764
SPEED SENSOR (SELECTABLE JOYSTICK CONTROL) (SJC) 767
Testing 767
Removal 768
DIAGNOSTICS SERVICE CODES 771
Display 771
Number Codes List 772
BICS™ SYSTEM 777
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 777
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 777
Inspecting The Seat Bar Sensor (Engine RUNNING) 777
Inspecting The Traction Lock (Engine RUNNING) 777
Inspecting The Lift Arm By-Pass Control 778
Additional Inspection For Loaders With Advanced Controls System (ACS) or Selectable Joystick Control (SJC) 778
Troubleshooting 779
Troubleshooting Guide 780
SEAT BAR SENSOR 781
Troubleshooting Chart 781
Test 782
Removal And Installation 783
BICS™ Circuit Test 784
TRACTION LOCK 785
Troubleshooting 785
Removal And Installation (Single Speed) 786
Description Of The Control System (Two Speed) 787
Inspecting The Control System (Two Speed) 787
ADVANCED CONTROL SYSTEM (ACS) 789
Components Identification 789
Troubleshooting Guide 791
Controller, Connector And Wire Identification 792
ACS Controller Removal And Installation 794
Handle Sensor Connector 795
Switch Handle Removal 796
Switch Handle Installation 798
Actuators Disassembly And Assembly 801
Handle Lock Solenoid Removal And Installation 802
Handle Lock Solenoid Disassembly And Assembly 803
Handle Lock Solenoid Connector 803
Foot Sensor Disassembly And Assembly 804
Foot Sensor Connector 805
Foot Lock Solenoid Removal And Installation 806
Foot Lock Solenoid Connector 807
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE 809
Controls Identification Chart 809
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (selectable JOYstick control) (sjc) 811
Controls Identification Chart 811
SERVICE PC (LAPTOP COMPUTER) 815
Connecting The Service PC To Remote Start Tool 815
CALIBRATION 817
Lift and Tilt Calibration Procedure (Selectable Joystick Control) (SJC) 817
Hydrostatic Pump Calibration (Selectable Joystick Control) (SJC) 819
Calibration Procedure (Advanced Control System) (ACS) 824
FLYWHEEL RPM SENSOR 827
Adjustment 827
ENGINE SERVICE 829
TROUBLESHOOTING 833
Chart 833
ENGINE SPEED CONTROL 835
Removal And Installation 835
Speed Control Cable 836
ENGINE SPEED CONTROL (SELECTABLE JOYSTICK CONTROL) (SJC) 839
Removal 839
Disassembly 841
Speed Control Cable 842
MUFFLER 843
Removal And Installation 843
AIR CLEANER 845
Housing Removal And Installation 845
RADIATOR 847
Removal And Installation 847
Mount Removal (Early Loaders) 849
Mount Removal (Later Loaders) 849
COOLING FAN 851
Drive Tension Pulley Removal And Installation 851
Gearbox/Blower Housing Removal And Installation 852
Blower Removal And Installation 853
Gearbox Parts Identification 855
Gearbox Disassembly 856
Gearbox Assembly 861
Gearbox, Checking Backlash 866
ENGINE 869
Removal And Installation 869
Mount Replacement 876
Removal And Installation Tools 877
FLYWHEEL AND HOUSING 879
Flywheel Removal And Installation 879
Ring Gear Removal And Installation 879
Flywheel Housing Removal And Installation 879
RECONDITIONING THE ENGINE 881
Engine Tools Identification Chart 881
Compression Pressure 886
Cylinder Head Clearance 886
Valve Cover, Injector Nozzle And Seal Removal And Installation 887
Checking Nozzle Injection Pressure 889
Nozzle Spraying Condition 890
Valve Seat Tightness 890
Rocker Arm And Push Rod Disassembly And Assembly 891
Valve Clearance 891
Cylinder Head And Tappet Disassembly And Assembly 892
Selecting Cylinder Head Gasket Disassembly And Assembly 893
Valve Disassembly And Assembly 895
Engine Timing (TDC) 895
Injection Pump Housing Removal 896
Injection Pump Governor Housing Removal And Installation 899
Injection Pump Governor Fork Lever Removal And Installation 901
Injection Pump Governor Lever Removal And Installation 901
Injection Pump Stop Lever Removal And Installation 902
Injection Pump Fuel Camshaft And Governor Weight Removal And Installation 902
Injection Pump Removal and Installation 904
Injection Pump Housing Installation 911
Injection Pump Timing 914
Fan Drive Pulley Disassembly And Assembly 916
Water Pump Disassembly And Assembly 917
Oil Cooler And Water Pipe Disassembly And Assembly 917
Gearcase Cover Disassembly And Assembly 918
Idle Gear And Camshaft Disassembly And Assembly 919
Oil Pan And Oil Strainer Disassembly And Assembly 919
Connecting Rod Cap Disassembly And Assembly 920
Piston Disassembly And Assembly 920
Piston Ring And Connecting Rod Disassembly And Assembly 921
Flywheel And Crankshaft Disassembly And Assembly 922
Bearing Case Cover Disassembly And Assembly 923
Flywheel Housing Disassembly And Assembly 924
Crankcase No 2 Disassembly And Assembly 924
Crankcase No 1 And No 2 Disassembly And Assembly 925
Crankshaft Disassembly And Assembly 925
Cylinder Head Surface Flatness 926
Cylinder Head Flaw 927
Valve Recessing 927
Valve Lapping 928
Clearance Between Valve Stem And Valve Guide 928
Replacing Valve Guide 929
Correcting Valve And Valve Seat 929
Free Length And Tilt Of Valve Spring 930
Valve Spring Setting Load 930
Oil Clearance Between Rocker Arm Shaft And Bearing 931
Oil Clearance Between Tappet And Tappet Guide Bore 931
Timing Gear Backlash 932
Idler Gear Side Clearance 932
Camshaft Side Clearance 933
Camshaft Alignment 933
Cam Height 933
Oil Clearance Between Idler Gear Shaft And Idler Gearing Bushing 934
Replacing Idler Gear Bushing 935
Piston Pin Bore I D 936
Oil Clearance Between Piston Pin And Small End Bushing 936
Replacing Small End Bushing 937
Clearance Between Piston Ring And Groove 937
Piston Ring Gap 938
Connecting Rod Alignment 938
Crankshaft Side Clearance 939
Crankshaft Alignment 940
Oil Clearance Between Crankpin And Crankpin Bearing 940
Oil Clearance Between Crankshaft Journal And Crankshaft Bearing 942
Replacing Crankshaft Sleeve 943
Cylinder Bore I D 943
Correcting Cylinder (Oversize +0 5 mm) 944
Engine Oil Pressure 944
Rotor Lobe Clearance 945
Clearance Between Outer Rotor And Pump Body 945
Clearance Between Rotor And Cover 945
Relief Valve 946
Thermostat Valve Opening Temperature 946
Radiator Water Leakage 946
Radiator Cap Air Leakage 947
Thermostat Assembly 947
Intake Air Heater 948
Air Cleaner, Intake Pipe, Inlet Pipe And Muffler 949
Oil Pipe 949
Turbocharger 950
HEATING, VENTILATION, AIR CONDITIONING 951
AIR CONDITIONING SYSTEM FLOW 954
Principals 954
Chart 955
COMPONENTS 957
Identification 957
SAFETY 961
Safety Equipment 961
REGULAR MAINTENANCE 963
Filter Elements Removal And Installation 963
Compressor Drive Belt Inspection 964
Cleaning The Condenser 965
BASIC TROUBLESHOOTING 967
Poor A/C Performance 967
Cleaning The A/C Evaporator Coil & Heater Coil 968
Compressor Drive Belt Inspection 968
Checking The Electrical System 969
Engine Coolant By-Passing The Heater Valve 977
Heater Valve Not Opening Or Closing 978
GENERAL AIR CONDITIONING SERVICE GUIDELINES 979
Compressor Oil 979
Compressor Oil Check 980
Component Replacement And Refrigeration Leaks 981
SYSTEM TROUBLESHOOTING CHART 983
Gauge Pressure Related Troubleshooting 984
Troubleshooting Tree 986
TEMPERATURE/PRESSURE 991
Chart 991
AIR CONDITIONING SERVICE 993
Chart 993
SYSTEM CHARGING AND RECLAMATION 995
Reclamation Procedure 995
Charging Procedure With A Manifold Gauge Set 997
Charging Procedure 998
COMPRESSOR 1001
Removal And Installation 1001
Compressor Clutch Disassembly 1002
CONDENSER 1007
Removal And Installation 1007
RECEIVER/DRIER 1009
Removal And Installation 1009
PRESSURE RELIEF VALVE 1011
Removal And Installation 1011
PRESSURE SWITCH 1013
Removal And Installation 1013
EVAPORATOR/HEATER UNIT 1015
Removal And Installation 1015
Disassembly And Assembly 1016
THERMOSTAT 1017
Removal And Installation 1017
EXPANSION VALVE 1019
Removal And Installation 1019
EVAPORATOR 1021
Removal And Installation 1021
HEATER COIL 1023
Removal And Installation With A/C 1023
Removal And Installation Without A/C 1024
BLOWER FAN 1025
Removal And Installation 1025
Disassembly And Assembly 1026
Wire Connector Removal and Installation 1028
HEATER VALVE 1031
Removal and Installation 1031
Disassembly And Assembly 1032
SPECIFICATIONS 1035
LOADER SPECIFICATIONS (S250) 1037
Machine Dimensions 1037
Performance 1038
Controls 1038
Engine 1038
Hydraulic System 1039
Electrical 1040
Drive System 1040
Capacities 1040
Tires 1040
LOADER SPECIFICATIONS (S300) 1041
Machine Dimensions 1041
Performance 1042
Controls 1042
Engine 1042
Hydraulic System 1043
Electrical 1044
Drive System 1044
Capacities 1044
Tires 1044
ENGINE SPECIFICATIONS 1045
General 1045
Fuel System 1045
Valve And Valve Timing 1045
Valve Spring 1046
Piston And Piston Ring 1046
Connecting Rod 1046
Cylinder Head 1047
Crankshaft 1047
Cylinder Bore 1047
Oil Pump 1047
Rocker Arm 1048
Tappet 1048
Camshaft 1048
Thermostat 1048
Timing Gear 1049
Intake Air Heater 1049
Turbocharger Compressor Shaft 1049
TORQUE SPECIFICATIONS FOR BOLTS 1051
Torque For General SAE Bolts 1051
Torque For General Metric Bolts 1052
Torque For Kubota Metric Engine Bolts 1053
Tightening Torques For General Use Screws, Bolts And Nuts 1053
HYDRAULIC CONNECTION SPECIFICATIONS 1055
O-ring Face Seal Connection 1055
Straight Thread O-ring Fitting 1056
Tubelines And Hoses 1056
Flare Fitting 1056
O-ring Flare Fitting 1057
Port Seal Fitting 1059
HYDRAULIC FLUID SPECIFICATIONS 1061
Specifications 1061
CONVERSIONS 1063
Decimal And Millimeter Equivalents 1063
SMR 1065
S250, S300-1 1065
S250, S300-2 1067
S250, S300-3 1069
S250, S300-4 1071
S250, S300-5 1073
S250, S300-6 1075

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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