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Bobcat T250 Compact Track Loader Service Manual 6904164 (3-09) PDF File Download
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Bobcat T250 Compact Track Loader Service Manual 6904164 (3-09) – PDF DOWNLOAD
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Description
Bobcat T250 Compact Track Loader Service Manual 6904164 (3-09) – PDF DOWNLOAD
FILE DETAILS:
Bobcat T250 Compact Track Loader Service Manual 6904164 (3-09) – PDF DOWNLOAD
Language : English
Pages : 963
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T250 Compact Track Loader Service Manual 6904164 (3-09) – PDF DOWNLOAD
S/N 531811001 & Above
S/N 531911001 & 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:
1. Check that the ROPS/FOPS (Including side screens) is in good condition and is not modified.
2. Check that ROPS mounting hardware is tightened and is Bobcat approved.
3. The seat belt must be correctly installed, functional and in good condition.
4. The seat bar must be correctly adjusted, clean and lubricated.
5. Check lift arm support device, replace if damaged.
6. Machine signs (decals) must be legible and in the correct location.
7. Steering levers, hand controls and foot pedals must return to neutral (as applicable).
8. Check for correct function of the work lights.
9. The parking brake must function correctly.
10. Enclosure door latches must open and close freely.
11. Bob-Tach wedges and linkages must function correctly and be in good condition.
12. Safety treads must be in good condition.
13. Check for correct function of indicator lamps.
14. Check hydraulic fluid level, engine oil level and fuel supply.
15. Inspect for fuel, oil or hydraulic fluid leaks.
SAFETY INSTRUCTIONS:
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
• 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 be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
• Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
• An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the 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.
• The AEM Safety Manual delivered with the machine gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Bobcat T250 Compact Track Loader Service Manual 6904164 (3-09) – PDF DOWNLOAD
MAINTENANCE SAFETY.......................................................................................... 3 ALPHABETICAL INDEX.......................................................................................... 5 CONTENTS.................................................................................................... 7 FOREWORD................................................................................................ 8 SAFETY INSTRUCTIONS..................................................................................... 11 FIRE PREVENTION......................................................................................... 13 Maintenance......................................................................................... 13 Operation........................................................................................... 13 Electrical.......................................................................................... 13 Hydraulic System.................................................................................... 13 Fueling............................................................................................. 13 Starting............................................................................................ 13 Spark Arrestor Exhaust System....................................................................... 13 Welding And Grinding................................................................................ 14 Fire Extinguishers.................................................................................. 14 SERIAL NUMBER LOCATIONS................................................................................. 15 Loader Serial Number................................................................................ 15 Engine Serial Number................................................................................ 15 DELIVERY REPORT......................................................................................... 16 LOADER IDENTIFICATION................................................................................... 17 SAFETY AND MAINTENANCE...................................................................................... 19 LIFTING AND BLOCKING THE LOADER......................................................................... 23 Procedure........................................................................................... 23 LIFT ARM SUPPORT DEVICE................................................................................. 25 Installing.......................................................................................... 25 Removing............................................................................................ 26 OPERATOR CAB............................................................................................ 27 Description......................................................................................... 27 Raising............................................................................................. 28 Lowering............................................................................................ 29 Cab Door Sensor (If Equipped)....................................................................... 30 Special Applications Kit............................................................................ 30 Special Applications Kit Inspection And Maintenance................................................. 30 TRANSPORTING THE LOADER ON A TRAILER.................................................................... 31 Loading And Unloading............................................................................... 31 Fastening........................................................................................... 31 TOWING THE LOADER....................................................................................... 33 Procedure........................................................................................... 33 REMOTE START TOOL KIT-MEL1563........................................................................... 35 Remote Start Tool - MEL1563......................................................................... 35 Service Tool Harness Control - MEL1565.............................................................. 36 Service Tool Harness Communicator - MEL1566......................................................... 37 Remote Start Procedure.............................................................................. 38 REMOTE START TOOL (SERVICE TOOL) KIT - 6689779.......................................................... 41 Description......................................................................................... 41 Remote Start Tool (Service Tool) - 6689778.......................................................... 42 Loader Service Tool Harness - 6689747............................................................... 43 Computer Service Tool Harness - 6689746............................................................. 44 Remote Start Procedure.............................................................................. 45 SERVICE SCHEDULE........................................................................................ 49 Chart............................................................................................... 49 AIR CLEANER SERVICE..................................................................................... 51 Replacing Filter Elements........................................................................... 51 ENGINE COOLING SYSTEM................................................................................... 53 Cleaning............................................................................................ 53 Checking Level...................................................................................... 54 Removing And Replacing Coolant...................................................................... 54 FUEL SYSTEM............................................................................................. 55 Fuel Specifications................................................................................. 55 Biodiesel Blend Fuel................................................................................ 55 Filling The Fuel Tank............................................................................... 56 Fuel Filter......................................................................................... 56 Removing Air From The Fuel System................................................................... 57 ENGINE LUBRICATION SYSTEM............................................................................... 59 Checking And Adding Engine Oil...................................................................... 59 Engine Oil Chart.................................................................................... 59 Removing And Replacing Oil And Filter............................................................... 60 HYDRAULIC / HYDROSTATIC SYSTEM.......................................................................... 61 Checking And Adding Fluid........................................................................... 61 Hydraulic / Hydrostatic Fluid Chart................................................................. 61 Removing And Replacing Hydraulic Fluid.............................................................. 62 Removing And Replacing Hydraulic / Hydrostatic Filter............................................... 63 Removing And Replacing Case Drain Filters........................................................... 64 Removing And Replacing Hydraulic Charge Filter...................................................... 65 Breather Cap........................................................................................ 66 BOB-TACH (HAND LEVER)................................................................................... 67 Inspection And Maintenance.......................................................................... 67 BOB-TACH (POWER)........................................................................................ 69 Inspection And Maintenance.......................................................................... 69 LUBRICATING THE LOADER.................................................................................. 71 Lubrication Locations............................................................................... 71 SPARK ARRESTOR MUFFLER.................................................................................. 73 Cleaning Procedure.................................................................................. 73 PIVOT PINS.............................................................................................. 75 Inspection And Maintenance.......................................................................... 75 LOADER STORAGE AND RETURN TO SERVICE.................................................................... 77 Storage............................................................................................. 77 Return to Service................................................................................... 77 STOPPING THE ENGINE AND LEAVING THE LOADER.............................................................. 79 Procedure........................................................................................... 79 Emergency Exit...................................................................................... 80 HYDRAULIC SYSTEM............................................................................................ 81 HYDRAULIC / HYDROSTATIC SCHEMATICS...................................................................... 87 HYDRAULIC SYSTEM INFORMATION............................................................................103 Glossary Of Hydraulic / Hydrostatic Symbols.........................................................103 Troubleshooting.....................................................................................107 CYLINDER (LIFT).........................................................................................109 Testing.............................................................................................109 Removal And Installation............................................................................110 Parts Identification................................................................................112 Disassembly.........................................................................................113 Assembly............................................................................................115 CYLINDER (TILT).........................................................................................117 Testing.............................................................................................117 Removal And Installation............................................................................118 Base End Pivot Pin Removal And Installation.........................................................120 Parts Identification................................................................................121 Disassembly.........................................................................................122 Assembly............................................................................................124 CYLINDER (BOB-TACH).....................................................................................127 Testing.............................................................................................127 Removal And Installation............................................................................128 Parts Identification................................................................................129 Disassembly.........................................................................................130 Assembly............................................................................................131 MAIN RELIEF VALVE.......................................................................................135 Description.........................................................................................135 Testing.............................................................................................136 Adjusting...........................................................................................138 Removal And Installation............................................................................139 HYDRAULIC CONTROL VALVE (STANDARD)......................................................................141 Description.........................................................................................141 Removal And Installation............................................................................142 Identification Chart................................................................................146 Mount Bracket Removal And Installation..............................................................147 Lift Load Check Valve Removal And Installation......................................................147 Load Check Valve Removal And Installation (Tilt & Auxiliary)........................................148 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)......................................148 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End).......................149 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End).......................150 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)........................150 Port Relief Valve Removal And Installation..........................................................151 Plug Removal And Installation.......................................................................152 Rubber Boot Removal and Installation................................................................153 End Cap Block Removal and Installation..............................................................154 Lift Spool And Detent Removal And Installation......................................................155 Tilt Spool Removal And Installation.................................................................165 Auxiliary Spool Removal And Installation............................................................167 Auxiliary Solenoid Removal And Installation.........................................................169 Solenoid Removal And Installation...................................................................170 Lock Valve Removal And Installation.................................................................171 Lift Arm Bypass Orifice Removal And Installation....................................................173 Main Relief Valve Removal And Installation..........................................................173 Check Valve Removal And Installation................................................................174 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)..................................................................175 Description.........................................................................................175 Removal And Installation............................................................................176 Actuator Removal And Installation (In Loader).......................................................180 Actuator Removal And Installation (Out of Loader)...................................................182 Identification Chart................................................................................185 Mount Bracket Removal And Installation..............................................................186 Lift Load Check Valve Removal And Installation......................................................186 Load Check Valve Removal And Installation (Tilt & Auxiliary)........................................187 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)......................................187 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End).......................188 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End).......................189 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)........................189 Port Relief Valve Removal And Installation..........................................................190 Plug Removal And Installation.......................................................................191 End Cap Block Removal And Installation..............................................................192 Lift Spool And Detent Removal And Installation......................................................193 Tilt Spool Removal And Installation.................................................................198 Auxiliary Spool Removal And Installation............................................................200 Auxiliary Solenoid Removal And Installation.........................................................202 Solenoid Removal And Installation...................................................................203 Lock Valve Removal And Installation.................................................................204 Lift Arm Bypass Orifice Removal And Installation....................................................206 Main Relief Valve Removal And Installation..........................................................206 Check Valve Removal And Installation................................................................207 LIFT ARM BYPASS CONTROL VALVE...........................................................................209 Description.........................................................................................209 Testing.............................................................................................209 Removal And Installation............................................................................209 Disassembly And Assembly............................................................................210 HYDRAULIC PUMP (STANDARD)...............................................................................211 Description.........................................................................................211 Pump Test at Quick Couplers.........................................................................212 Direct Pump Test (Standard Section).................................................................213 Direct Pump Test (Charge Section)...................................................................215 Removal And Installation............................................................................219 Hydraulic Pump Start Up.............................................................................221 Parts Identification................................................................................222 Disassembly And Assembly............................................................................223 HYDRAULIC PUMP (STANDARD) (HIGH FLOW)...................................................................225 Description.........................................................................................225 Pump Test At Quick Couplers.........................................................................226 Direct Pump Test (Standard Section).................................................................227 Direct Pump Test (Charge Section)...................................................................229 Direct Pump Test (High Flow Section)................................................................233 High Flow Relief Valve Adjustment...................................................................235 High Flow Relief Valve Removal And Installation.....................................................237 Solenoid Removal And Installation...................................................................238 Removal And Installation............................................................................239 Hydraulic Pump Start Up.............................................................................241 Parts Identification................................................................................242 Disassembly And Assembly............................................................................243 HYDRAULIC PUMP (SJC)....................................................................................245 Description.........................................................................................245 Pump Test At Quick Couplers.........................................................................246 Direct Pump Test (Standard Section).................................................................247 Direct Pump Test (Charge Section)...................................................................249 Removal And Installation............................................................................253 Hydraulic Pump Start Up.............................................................................255 Parts Identification................................................................................256 Disassembly And Assembly............................................................................257 HYDRAULIC PUMP (SJC) (HIGH FLOW)........................................................................259 Description.........................................................................................259 Pump Test At Quick Couplers.........................................................................260 Direct Pump Test (Standard Section).................................................................261 Direct Pump Test (Charge Section)...................................................................263 Direct Pump Test (High Flow Section)................................................................267 High Flow Relief Valve Adjustment...................................................................269 High Flow Relief Valve Removal And Installation.....................................................271 Solenoid Removal And Installation...................................................................272 Removal And Installation............................................................................273 Hydraulic Pump Start Up.............................................................................275 Parts Identification................................................................................276 Disassembly And Assembly............................................................................277 HYDRAULIC/HYDROSTATIC FILTERS...........................................................................279 Description.........................................................................................279 Housing Removal And Installation....................................................................279 Charge Filter Housing Removal And Installation......................................................281 HYDRAULIC FLUID RESERVOIR...............................................................................283 Description.........................................................................................283 Removal And Installation............................................................................283 Hydraulic Fluid Screen..............................................................................286 OIL COOLER..............................................................................................287 Description.........................................................................................287 Removal And Installation............................................................................287 BUCKET POSITION VALVE...................................................................................289 Description.........................................................................................289 Solenoid Removal And Installation...................................................................290 Solenoid Testing....................................................................................291 Removal And Installation............................................................................291 Disassembly And Assembly............................................................................292 REAR AUXILIARY DIVERTER VALVE...........................................................................295 Description.........................................................................................295 Solenoid Testing....................................................................................295 Removal And Installation............................................................................296 Disassembly And Assembly............................................................................298 BOB-TACH (POWER) BLOCK..................................................................................305 Description.........................................................................................305 Removal And Installation............................................................................305 Disassembly And Assembly............................................................................307 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK.................................................................311 Description.........................................................................................311 Removal and Installation............................................................................311 Disassembly And Assembly............................................................................312 HYDROSTATIC SYSTEM..........................................................................................315 HYDROSTATIC SYSTEM INFORMATION..........................................................................317 Troubleshooting.....................................................................................317 Description.........................................................................................318 HYDROSTATIC MOTOR.......................................................................................319 Description.........................................................................................319 Removing And Replacing Oil..........................................................................319 Removal And Installation............................................................................320 Parts Identification................................................................................322 Disassembly And Assembly............................................................................324 CHARGE PRESSURE.........................................................................................337 Description.........................................................................................337 Testing.............................................................................................338 Sender Removal And Installation.....................................................................340 Adjusting...........................................................................................341 HYDROSTATIC PUMP........................................................................................343 Description.........................................................................................343 Removal And Installation............................................................................344 Hydrostatic Pump Start Up...........................................................................346 Replenishing / High Pressure Relief Valve Removal And Installation..................................347 Parts Identification (Left Half)....................................................................348 Parts Identification (Right Half)...................................................................349 Disassembly.........................................................................................350 Assembly............................................................................................357 HYDROSTATIC PUMP (SJC)..................................................................................363 Description.........................................................................................363 Hydraulic Controller Removal And Installation.......................................................364 Removal And Installation............................................................................366 Hydrostatic Pump Start Up...........................................................................368 Parts Identification................................................................................369 High Pressure Relief And Bypass Valve...............................................................370 Charge Relief Valve.................................................................................371 Disassembly And Assembly............................................................................372 Mechanical Neutral Adjustment.......................................................................389 Hydraulic Controller Neutral Adjustment.............................................................392 DRIVE BELT..............................................................................................395 Description.........................................................................................395 Drive Belt Shield Removal And Installation..........................................................395 Adjusting...........................................................................................396 Belt Adjustment.....................................................................................396 Drive Belt Removal And Installation.................................................................396 Tensioner Pulley Removal And Installation...........................................................397 Disassembly And Assembly............................................................................398 Tensioner Pulley Tension Spring Removal And Installation............................................399 CASE DRAIN FILTER.......................................................................................401 Description.........................................................................................401 Disassembly And Assembly............................................................................401 DRIVE SYSTEM................................................................................................403 BRAKE...................................................................................................405 Description.........................................................................................405 Block Removal And Installation......................................................................406 Block Disassembly And Assembly......................................................................407 TRACK CARRIAGE COMPONENTS...............................................................................409 Description.........................................................................................409 Checking Tension....................................................................................410 Adjusting Tension...................................................................................411 Track Removal And Installation......................................................................412 Idler (Front) Removal And Installation..............................................................415 Idler (Rear) Removal And Installation...............................................................418 Roller Removal And Installation.....................................................................418 Sprocket Removal And Installation...................................................................419 Track Housing Removal And Installation..............................................................420 Track Damage Identification.........................................................................421 MAIN FRAME..................................................................................................431 SEAT BAR................................................................................................435 Description.........................................................................................435 Removal And Installation............................................................................435 Disassembly And Assembly............................................................................437 Compression Spring Disassembly And Assembly.........................................................438 OPERATOR CAB............................................................................................439 Gas Cylinder Removal And Installation...............................................................439 Gas Cylinder Bracket Disassembly And Assembly.......................................................441 Removal And Installation............................................................................442 OPERATOR SEAT (SUSPENSION)..............................................................................445 Removal And Installation............................................................................445 Slide Rail Removal And Installation.................................................................446 Seat Belt Removal And Installation..................................................................446 Lower Cushion Removal And Installation..............................................................447 Back Cushion Removal And Installation...............................................................448 Shock Removal And Installation......................................................................448 3-Point Seat Belt Removal And Installation..........................................................449 BOB-TACH (HAND LEVER)...................................................................................451 Description.........................................................................................451 Removal And Installation............................................................................451 Lever And Wedge Disassembly And Assembly............................................................454 Pivot Pin Bushing And Seal Removal And Installation.................................................455 BOB-TACH (POWER)........................................................................................457 Description.........................................................................................457 Removal And Installation............................................................................457 Lever And Wedge Disassembly And Assembly............................................................460 Pivot Pin Bushing And Seal Removal And Installation.................................................462 LIFT ARMS...............................................................................................463 Removal And Installation............................................................................463 REAR GRILL..............................................................................................467 Removal And Installation............................................................................467 REAR DOOR...............................................................................................469 Removal And Installation............................................................................469 Striker Removal And Installation....................................................................470 Striker Disassembly And Assembly....................................................................470 Striker (Adjusting).................................................................................471 Latch Removal And Installation......................................................................472 FUEL TANK...............................................................................................473 Removal And Installation............................................................................473 Fuel Level Sender Removal And Installation..........................................................475 Fuel Fill Screen Removal And Installation...........................................................475 CONTROL PEDALS AND LINKAGES.............................................................................477 Description.........................................................................................477 Pedal Removal And Installation......................................................................478 Linkage Removal And Installation....................................................................479 Pedal (Adjusting)...................................................................................480 CONTROL PEDALS (ACS)....................................................................................481 Description.........................................................................................481 Foot Sensor Removal And Installation................................................................482 Foot Pedal Removal And Installation.................................................................483 Foot Pedal Linkage Disassembly And Assembly.........................................................484 CONTROL PANEL (S/N 531813473 & BELOW AND 531911429 & BELOW).............................................485 Description.........................................................................................485 Removal And Installation............................................................................486 Shock Removal And Installation......................................................................488 Shaft Removal And Installation......................................................................488 Shaft Disassembly And Assembly......................................................................489 Linkage Removal And Installation....................................................................490 Pintle Arm Disassembly and Assembly.................................................................494 Linkage Neutral (Adjusting).........................................................................495 Linkage Travel (Adjusting)..........................................................................499 CONTROL PANEL (S/N 531813474 & ABOVE AND 531911430 & ABOVE).............................................503 Description.........................................................................................503 Removal And Installation............................................................................504 Shock Removal And Installation......................................................................506 Shaft Removal And Installation......................................................................507 Linkage Removal And Installation....................................................................508 Pintle Arm Disassembly and Assembly.................................................................512 Linkage Neutral (Adjusting).........................................................................513 Linkage Travel (Adjusting)..........................................................................517 CONTROL PANEL (S/N 531813473 & BELOW AND 531911429 & BELOW) (SJC).......................................521 Description.........................................................................................521 Removal And Installation............................................................................522 CONTROL PANEL (S/N 531813474 & ABOVE AND 531911430 & ABOVE) (SJC).......................................525 Description.........................................................................................525 Removal And Installation............................................................................526 CONTROL HANDLE / LEVER..................................................................................529 Description.........................................................................................529 Lever Removal And Installation......................................................................529 Boot Removal And Installation.......................................................................530 CONTROL HANDLE / LEVER (ACS)............................................................................531 Description.........................................................................................531 Handle Sensor Removal And Installation..............................................................531 Handle Removal And Installation.....................................................................534 Handle Disassembly And Assembly.....................................................................535 Lever Removal And Installation......................................................................536 Boot Removal And Installation.......................................................................537 JOYSTICK CONTROL........................................................................................539 Description (Earlier Models And Later Models).......................................................539 Testing (Earlier Models And Later Models)...........................................................540 Removal And Installation (Earlier Models)...........................................................541 Removal And Installation (Later Models).............................................................542 Boot Removal And Installation (Earlier Models)......................................................543 Joystick Mount Removal And Installation (Earlier Models)............................................543 Joystick Mount Removal And Installation (Earlier Models) (Cont’d)...................................544 Joystick Mount Removal And Installation (Later Models)..............................................544 ACCESS PANEL (INSIDE)...................................................................................545 Removal And Installation (Left).....................................................................545 Removal And Installation (Right)....................................................................545 ACCESS PANEL (INSIDE) (SJC).............................................................................547 Removal And Installation (Left).....................................................................547 Removal And Installation (Right)....................................................................548 WINDOW (REAR)...........................................................................................551 Removal.............................................................................................551 Installation........................................................................................551 WINDOW (TOP)............................................................................................553 Removal And Installation............................................................................553 WINDOW (SIDE)...........................................................................................555 Removal And Installation............................................................................555 WINDOW (FRONT DOOR).....................................................................................557 Removal (Standard Window)...........................................................................557 Installation (Standard Window)......................................................................558 Removal And Installation (Special Applications Window)..............................................560 CAB DOOR................................................................................................561 Description.........................................................................................561 Removal And Installation............................................................................561 Aligning............................................................................................562 Adjusting...........................................................................................563 Checking Operation..................................................................................563 ELECTRICAL SYSTEM & ANALYSIS................................................................................565 ELECTRICAL SCHEMATICS...................................................................................569 ELECTRICAL SYSTEM INFORMATION...........................................................................582 Glossary Of Electrical Symbols......................................................................582 Cab Harness Connectors..............................................................................585 Mainframe Harness Connectors........................................................................586 Description.........................................................................................588 Troubleshooting.....................................................................................590 Fuse And Relay Location / Identification............................................................591 Solenoid Testing....................................................................................592 BATTERY.................................................................................................594 Servicing...........................................................................................594 Using A Booster Battery (Jump Starting).............................................................594 Removal And Installation............................................................................596 ALTERNATOR..............................................................................................598 Belt Adjustment.....................................................................................598 Belt Replacement....................................................................................598 Charging System Inspection..........................................................................599 Alternator Voltage Testing..........................................................................600 Low Voltage Testing.................................................................................600 High Voltage Testing................................................................................601 Removal And Installation............................................................................602 Parts Identification................................................................................603 STARTER.................................................................................................604 Testing.............................................................................................604 Removal And Installation............................................................................605 Parts Identification................................................................................606 INSTRUMENT PANELS.......................................................................................608 Left Panel..........................................................................................608 Right Panel (Key Switch)............................................................................609 Right Panel (Keyless)...............................................................................610 Side And Front Panels...............................................................................612 Removal And Installation (Left And Right)...........................................................613 Bulb Removal And Installation (Left Only)...........................................................616 Key Switch Removal And Installation.................................................................617 Alarm Removal And Installation......................................................................618 Front Panel Removal And Installation................................................................618 LIGHTS..................................................................................................620 Front Removal And Installation......................................................................620 Rear Removal And Installation.......................................................................621 Cab Light Removal And Installation..................................................................621 BOBCAT CONTROLLER (MAIN)................................................................................622 Description.........................................................................................622 Connector Identification............................................................................623 Removal And Installation............................................................................625 BOBCAT CONTROLLER (ACS).................................................................................626 Description.........................................................................................626 Connector And Wire Identification...................................................................627 Removal And Installation............................................................................628 BOBCAT CONTROLLER (SJC) (DRIVE).........................................................................630 Description.........................................................................................630 Connector Identification............................................................................631 Removal And Installation............................................................................633 SPEED SENSORS (SJC).....................................................................................634 Description.........................................................................................634 Testing.............................................................................................634 Removal and Installation............................................................................636 DIAGNOSTIC SERVICE CODES................................................................................638 Viewing Service Codes (Key Switch)..................................................................638 Viewing Service Codes (Keyless).....................................................................638 Service Codes List..................................................................................639 BOBCAT INTERLOCK CONTORL SYSTEM (BICS)..................................................................644 Description.........................................................................................644 Inspecting The BICS Controller (Engine Stopped - Key ON)............................................645 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)................645 Inspecting The Seat Bar Sensor (Engine RUNNING).....................................................645 Inspecting The Traction Lock (Engine RUNNING).......................................................645 Inspecting The Lift Arm Bypass Control..............................................................645 Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....................................645 Troubleshooting.....................................................................................646 Troubleshooting Chart...............................................................................647 SEAT BAR SENSOR.........................................................................................648 Description.........................................................................................648 Troubleshooting.....................................................................................649 Testing.............................................................................................650 Removal And Installation............................................................................651 Bobcat Interlock Control System (BICS) Circuit Test.................................................652 TRACTION LOCK...........................................................................................654 Description.........................................................................................654 Troubleshooting.....................................................................................655 Inspecting..........................................................................................656 Parking Brake Solenoid Removal And Installation.....................................................657 CONTROL SYSTEM (ACS)....................................................................................658 Description.........................................................................................658 Troubleshooting Chart...............................................................................659 Handle Sensor Connector Disassembly And Assembly....................................................660 Switch Handle Removal...............................................................................661 Switch Handle Installation..........................................................................663 Actuator Connector Disassembly And Assembly.........................................................666 Handle Lock Solenoid Removal And Installation.......................................................667 Handle Lock Solenoid Disassembly And Assembly.......................................................668 Foot Sensor Disassembly And Assembly................................................................668 Foot Lock Solenoid Removal And Installation.........................................................669 ELECTRICAL / HYDRAULIC CONTROLS.........................................................................670 Identification Chart................................................................................670 ELECTRICAL / HYDRAULIC CONTROLS (SJC)...................................................................672 Identification Chart................................................................................672 SERVICE PC (LAPTOP COMPUTER)............................................................................676 Connecting Remote Start Tool........................................................................676 Connecting Remote Start Tool (Service Tool).........................................................676 CALIBRATION.............................................................................................678 Description.........................................................................................678 Actuator Testing....................................................................................678 Lift And Tilt Calibration (ACS).....................................................................680 Lift And Tilt Calibration (SJC).....................................................................682 Hydrostatic Pump Calibration (SJC)..................................................................684 STEERING DRIFT COMPENSATION.............................................................................690 Description.........................................................................................690 Selecting And Adjusting.............................................................................690 Exiting And Saving..................................................................................691 FLYWHEEL RPM SENSOR.....................................................................................692 Description.........................................................................................692 Adjustment..........................................................................................693 CONTROL PANEL SETUP.....................................................................................694 Right Panel Setup (Keyless).........................................................................694 Attachment Control Information (Keyless)............................................................695 PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START).........................................................696 Password Description................................................................................696 Changing The Owner Password.........................................................................696 Changing The User Passwords.........................................................................697 Password Lockout Feature............................................................................697 MAINTENANCE CLOCK.......................................................................................698 Description.........................................................................................698 Setup...............................................................................................699 Reset...............................................................................................703 BACK-UP ALARM SYSTEM....................................................................................704 Description.........................................................................................704 Inspecting..........................................................................................704 Adjusting Switch Position...........................................................................705 Troubleshooting (Standard And ACS)..................................................................706 Troubleshooting (Joystick)..........................................................................707 Alarm Removal And Installation......................................................................708 Switch Removal And Installation.....................................................................708 ENGINE SERVICE..............................................................................................710 ENGINE INFORMATION......................................................................................714 Description.........................................................................................714 Specifications......................................................................................715 Torque Values.......................................................................................719 Troubleshooting.....................................................................................720 Engine Removal And Installation.....................................................................722 Engine Mount Replacement............................................................................731 Compression -Checking...............................................................................732 ENGINE SPEED CONTROL....................................................................................734 Removal And Installation............................................................................734 Cable Removal And Installation......................................................................735 ENGINE SPEED CONTROL (SJC)..............................................................................736 Removal And Installation............................................................................736 Disassembly And Assembly............................................................................739 Speed Control Cable Removal And Installation........................................................741 MUFFLER.................................................................................................742 Removal And Installation............................................................................742 AIR CLEANER.............................................................................................744 Housing Removal And Installation....................................................................744 ENGINE COOLING SYSTEM...................................................................................746 Radiator Removal And Installation (S/N 531812825 & Below, 531911354 & Below)........................746 Radiator Removal And Installation (S/N 531812826 & Above, 531911355 & Above)........................748 Radiator Mount Removal And Installation.............................................................750 Hydraulic Fan Motor Description (S/N 531812825 & Below, 531911354 & Below)..........................751 Blower Housing Removal And Installation (S/N 531812825 & Below, 531911354 & Below)..................751 Fan Removal And Installation (S/N 531812825 & Below, 531911354 & Below).............................753 Hydraulic Fan Motor Removal And Installation (S/N 531812825 & Below, 531911354 & Below).............754 Hydraulic Fan Motor Disassembly And Assembly (S/ N 531812825 & Below, 531911354 & Below)............754 Hydraulic Fan Motor Description (S/N 531812826 - 531840000, 531911355 - 531940000)..................755 Axial Fan Housing Removal And Installation (S/N 531812826 - 531840000, 531911355 - 531940000).......755 Axial Fan Removal And Installation (S/N 531812826 - 531840000, 531911355 - 531940000)...............757 Hydraulic Fan Motor Removal And Installation (S/N 531812826 - 531840000, 531911355 - 531940000).....759 Hydraulic Fan Motor Disassembly And Assembly (S/ N 531812826 - 531840000, 531911355 - 531940000)....759 Hydraulic Fan Motor Description (S/N 531840001 & Above, 531940001 & Above)..........................760 Axial Fan Housing Removal And Installation (S/N 531840001 & Above, 531940001 & Above)...............760 Axial Fan Removal And Installation (S/N 531840001 & Above, 531940001 & Above).......................763 Hydraulic Fan Motor Removal And Installation (S/N 531840001 & Above, 531940001 & Above).............764 Hydraulic Fan Motor Disassembly And Assembly (S/ N 531840001 & Above, 531940001 & Above)............765 Water Pump Removal And Installation.................................................................766 Water Pump Disassembly And Assembly.................................................................767 Thermostat Housing Removal And Installation.........................................................767 LUBRICATION SYSTEM......................................................................................770 Oil Pan Removal And Installation....................................................................770 Oil Pump Removal And Installation...................................................................771 Oil Pump Inspection.................................................................................772 Oil Filter Cooler Removal And Installation..........................................................775 Engine Oil Pressure - Testing.......................................................................776 FUEL SYSTEM.............................................................................................778 Fuel Camshaft Removal And Installation..............................................................778 Injection Pump Governor Housing Removal And Installation............................................780 Injection Pump Governor Housing Disassembly And Assembly............................................782 Fuel Shutoff Solenoid - Checking....................................................................784 Fuel Shutoff Solenoid - Removal And Installation....................................................784 Fuel Injection Pump Removal And Installation........................................................785 Fuel Injection Pump Housing Removal.................................................................793 Fuel Injection Pump Housing Installation............................................................797 Injection Pump Timing...............................................................................800 Fuel Injector Removal and Installation..............................................................803 Fuel Injector Nozzle Pressure - Checking............................................................804 Nozzle Spraying Condition...........................................................................805 Valve Seat Tightness................................................................................805 CYLINDER HEAD...........................................................................................806 Intake Air Heater - Testing.........................................................................806 Intake Air Heater Removal And Installation..........................................................806 Valve Clearance Adjustment..........................................................................807 Valve Timing - Checking.............................................................................808 Cylinder Head Removal And Installation..............................................................809 Cylinder Head Disassembly And Assembly..............................................................812 Cylinder Head - Servicing...........................................................................812 Cylinder Head Top Clearance.........................................................................813 Valve Guide - Checking..............................................................................814 Reconditioning The Valve And Valve Seat.............................................................816 Valve Spring........................................................................................818 Valve Tappets.......................................................................................819 Rocker Arm And Shaft - Checking.....................................................................820 CRANKSHAFT AND PISTONS..................................................................................822 Piston And Connecting Rod Removal And Installation..................................................822 Piston And Connecting Rod - Servicing...............................................................824 Cylinder Bore Checking..............................................................................829 Connecting Rod Alignment............................................................................830 Crankshaft Gear Removal And Installation............................................................830 Crankshaft And Bearings Removal and Installation....................................................831 Crankshaft And Bearings - Servicing.................................................................835 CAMSHAFT AND TIMING GEArS...............................................................................842 Timing Gearcase Cover Removal And Installation......................................................842 Timing Gears Backlash - Checking....................................................................843 Camshaft - Servicing................................................................................844 Idle Gear And Shaft Removal And Installation........................................................846 Idler Gear And Shaft - Servicing....................................................................847 TURBOCHARGER............................................................................................850 Description.........................................................................................850 Testing.............................................................................................850 Removal And Installation............................................................................851 FLYWHEEL AND HOUSING....................................................................................852 Flywheel Removal And Installation...................................................................852 Ring Gear Removal And Installation..................................................................852 Housing Removal And Installation....................................................................853 HEATING, VENTILATION, AIR CONDITIONING......................................................................854 AIR CONDITIONING SYSTEM FLOW............................................................................857 Description.........................................................................................857 Chart...............................................................................................858 Components..........................................................................................859 Safety Equipment....................................................................................862 REGULAR MAINTENANCE.....................................................................................864 Filter Elements Removal And Installation............................................................864 Compressor Drive Belt Inspection....................................................................865 Condenser...........................................................................................866 Air Conditioning Lubrication........................................................................866 Air Conditioning Service Chart......................................................................867 Cleaning The A/C Evaporator Coil & Heater Coil......................................................868 TROUBLESHOOTING.........................................................................................870 Blower Motor Does Not Operate.......................................................................870 Blower Motor Operates Normally, But Air Flow Is Insufficient........................................870 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..........................870 The Compressor Does Not Operate At All, Or Operates Improperly......................................870 Gauge Pressure Related Troubleshooting..............................................................871 Troubleshooting Tree................................................................................873 Temperature / Pressure Chart........................................................................877 Poor A/C Performance................................................................................879 HVAC Repair And Leaks...............................................................................880 Electrical System...................................................................................881 Engine Coolant Bypassing The Heater Valve...........................................................888 Heater Valve Not Opening Or Closing.................................................................889 SYSTEM CHARGING AND RECLAMATION.........................................................................890 Refrigerant Identification..........................................................................890 Reclamation And Charging With Recovery / Charging Unit..............................................891 Charging With A Manifold Gauge Set..................................................................893 COMPRESSOR..............................................................................................896 Belt Adjustment.....................................................................................896 Removal And Installation............................................................................896 Oil.................................................................................................897 Oil Check...........................................................................................898 Clutch Disassembly And Assembly.....................................................................899 CONDENSER...............................................................................................904 Removal And Installation............................................................................904 RECEIVER / DRIER........................................................................................906 Receiver / Drier Removal And Installation...........................................................906 Pressure Relief Valve Removal And Installation......................................................907 Pressure Switch Removal And Installation............................................................907 Schraeder Valve Removal And Installation............................................................908 EVAPORATOR / HEATER UNIT................................................................................910 Removal And Installation............................................................................910 THERMOSTAT..............................................................................................912 Removal And Installation............................................................................912 EXPANSION VALVE.........................................................................................914 Removal And Installation............................................................................914 EVAPORATOR..............................................................................................916 Removal And Installation............................................................................916 HEATER COIL.............................................................................................918 Removal And Installation With A/C...................................................................918 Removal And Installation Without A/C................................................................920 BLOWER FAN..............................................................................................922 Removal And Installation............................................................................922 Disassembly And Assembly............................................................................923 Connector Identification............................................................................925 HEATER VALVE............................................................................................926 Removal And Installation............................................................................926 Disassembly And Assembly............................................................................927 SPECIFICATIONS..............................................................................................928 (T250) LOADER SPECIFICATIONS............................................................................930 Machine Dimensions..................................................................................930 Performance.........................................................................................931 Controls............................................................................................931 Engine..............................................................................................931 Hydraulic System....................................................................................932 Electrical..........................................................................................933 Drive System........................................................................................933 Capacities..........................................................................................933 Tracks..............................................................................................933 Ground Pressure.....................................................................................933 TORQUE SPECIFICATIONS FOR BOLTS.........................................................................934 Torque For General SAE Bolts........................................................................934 Torque For General Metric Bolts.....................................................................935 HYDRAULIC CONNECTION SPECIFICATIONS.....................................................................936 O-ring Face Seal Connection.........................................................................936 Straight Thread O-ring Fitting......................................................................937 Tubelines And Hoses.................................................................................937 Flare Fitting.......................................................................................938 Port Seal Fitting...................................................................................939 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS............................................................940 Specifications......................................................................................940 CONVERSIONS.............................................................................................942 Decimal And Millimeter Equivalents..................................................................942 U.S. To Metric Conversion Chart.....................................................................942 SERVICE MANUAL REVISION.....................................................................................944 Revision No: T250 - 1...................................................................................944 Revision No: T250 - 2...................................................................................946 Revision No: T250 - 3...................................................................................948 Revision No: T250 - 4...................................................................................950 Revision No: T250 - 5...................................................................................952 Revision No: T250 - 6...................................................................................954 Revision No: T250 - 7...................................................................................956 Revision No: T250 - 8...................................................................................958 Revision No: T250 - 9...................................................................................960 Revision No: T250 - 10..................................................................................962
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