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Service Manual for Bobcat T250 Compact Track Loader 6986682 (3-09) PDF
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Bobcat T250 Compact Track Loader Service Manual 6986682 (3-09) – PDF DOWNLOAD
S/N A5GS11001 – A5GS19999
S/N A5GT11001 – A5GT19999
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Description
Bobcat T250 Compact Track Loader Service Manual 6986682 (3-09) – PDF DOWNLOAD
FILE DETAILS:
Bobcat T250 Compact Track Loader Service Manual 6986682 (3-09) – PDF DOWNLOAD
Language : English
Pages : 885
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T250 Compact Track Loader Service Manual 6986682 (3-09) – PDF DOWNLOAD
S/N A5GS11001 – A5GS19999
S/N A5GT11001 – A5GT19999
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 6986682 (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............................................................. 21 Procedure............................................................................... 21 LIFT ARM SUPPORT DEVICE..................................................................... 23 Installing.............................................................................. 23 Removing................................................................................ 24 OPERATOR CAB................................................................................ 25 Description............................................................................. 25 Raising................................................................................. 26 Lowering................................................................................ 27 Cab Door Sensor (If Equipped)........................................................... 28 Special Applications Kit................................................................ 28 Special Applications Kit Inspection And Maintenance..................................... 28 TRANSPORTING THE LOADER ON A TRAILER........................................................ 29 Loading And Unloading................................................................... 29 Fastening............................................................................... 29 TOWING THE LOADER........................................................................... 31 Procedure............................................................................... 31 REMOTE START TOOL KIT-MEL1563............................................................... 33 Remote Start Tool - MEL1563............................................................. 33 Service Tool Harness Control - MEL1565.................................................. 34 Service Tool Harness Communicator - MEL1566............................................. 35 Remote Start Procedure.................................................................. 36 REMOTE START TOOL (SERVICE TOOL) KIT - 6689779.............................................. 39 Description............................................................................. 39 Remote Start Tool (Service Tool) - 6689778.............................................. 40 Loader Service Tool Harness - 6689747................................................... 41 Computer Service Tool Harness - 6689746................................................. 42 Remote Start Procedure.................................................................. 43 SERVICE SCHEDULE............................................................................ 47 Chart................................................................................... 47 AIR CLEANER SERVICE......................................................................... 49 Replacing Filter Elements............................................................... 49 ENGINE COOLING SYSTEM....................................................................... 51 Cleaning................................................................................ 51 Checking Level.......................................................................... 52 Removing And Replacing Coolant.......................................................... 52 FUEL SYSTEM................................................................................. 53 Fuel Specifications..................................................................... 53 Biodiesel Blend Fuel.................................................................... 53 Filling The Fuel Tank................................................................... 54 Fuel Filter............................................................................. 54 Removing Air From The Fuel System....................................................... 55 ENGINE LUBRICATION SYSTEM................................................................... 57 Checking And Adding Engine Oil.......................................................... 57 Engine Oil Chart........................................................................ 57 Removing And Replacing Oil And Filter................................................... 58 HYDRAULIC / HYDROSTATIC SYSTEM.............................................................. 59 Checking And Adding Fluid............................................................... 59 Hydraulic / Hydrostatic Fluid Chart..................................................... 59 Removing And Replacing Hydraulic Fluid.................................................. 60 Removing And Replacing Hydraulic / Hydrostatic Filter................................... 61 Removing And Replacing Case Drain Filters............................................... 62 Removing And Replacing Hydraulic Charge Filter.......................................... 63 Breather Cap............................................................................ 64 BOB-TACH (HAND LEVER)....................................................................... 65 Inspection And Maintenance.............................................................. 65 BOB-TACH (POWER)............................................................................ 67 Inspection And Maintenance.............................................................. 67 LUBRICATING THE LOADER...................................................................... 69 Lubrication Locations................................................................... 69 SPARK ARRESTOR MUFFLER...................................................................... 71 Cleaning Procedure...................................................................... 71 PIVOT PINS.................................................................................. 73 Inspection And Maintenance.............................................................. 73 LOADER STORAGE AND RETURN TO SERVICE........................................................ 75 Storage................................................................................. 75 Return to Service....................................................................... 75 STOPPING THE ENGINE AND LEAVING THE LOADER.................................................. 77 Procedure............................................................................... 77 Emergency Exit.......................................................................... 78 HYDRAULIC SYSTEM................................................................................ 79 HYDRAULIC / HYDROSTATIC SCHEMATICS.......................................................... 85 HYDRAULIC SYSTEM INFORMATION................................................................ 93 Glossary Of Hydraulic / Hydrostatic Symbols............................................. 93 Troubleshooting......................................................................... 97 CYLINDER (LIFT)............................................................................. 99 Testing................................................................................. 99 Removal And Installation................................................................100 Parts Identification....................................................................102 Disassembly.............................................................................103 Assembly................................................................................105 CYLINDER (TILT).............................................................................107 Testing.................................................................................107 Removal And Installation................................................................108 Base End Pivot Pin Removal And Installation.............................................110 Parts Identification....................................................................111 Disassembly.............................................................................112 Assembly................................................................................114 CYLINDER (BOB-TACH).........................................................................117 Testing.................................................................................117 Removal And Installation................................................................118 Parts Identification....................................................................119 Disassembly.............................................................................120 Assembly................................................................................121 MAIN RELIEF VALVE...........................................................................125 Description.............................................................................125 Testing.................................................................................126 Adjusting...............................................................................128 Removal And Installation................................................................129 HYDRAULIC CONTROL VALVE (STANDARD)..........................................................131 Description.............................................................................131 Removal And Installation................................................................132 Identification Chart....................................................................136 Mount Bracket Removal And Installation..................................................137 Lift Load Check Valve Removal And Installation..........................................137 Load Check Valve Removal And Installation (Tilt & Auxiliary)............................138 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................138 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........139 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........140 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............140 Port Relief Valve Removal And Installation..............................................141 Plug Removal And Installation...........................................................142 Rubber Boot Removal and Installation....................................................143 End Cap Block Removal and Installation..................................................144 Lift Spool And Detent Removal And Installation..........................................145 Tilt Spool Removal And Installation.....................................................155 Auxiliary Spool Removal And Installation................................................157 Auxiliary Solenoid Removal And Installation.............................................159 Solenoid Removal And Installation.......................................................160 Lock Valve Removal And Installation.....................................................161 Lift Arm Bypass Orifice Removal And Installation........................................163 Main Relief Valve Removal And Installation..............................................163 Check Valve Removal And Installation....................................................164 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)......................................................165 Description.............................................................................165 Removal And Installation................................................................166 Actuator Removal And Installation (In Loader)...........................................170 Actuator Removal And Installation (Out of Loader).......................................172 Identification Chart....................................................................175 Mount Bracket Removal And Installation..................................................176 Lift Load Check Valve Removal And Installation..........................................176 Load Check Valve Removal And Installation (Tilt & Auxiliary)............................177 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................177 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........178 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........179 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............179 Port Relief Valve Removal And Installation..............................................180 Plug Removal And Installation...........................................................181 End Cap Block Removal And Installation..................................................182 Lift Spool And Detent Removal And Installation..........................................183 Tilt Spool Removal And Installation.....................................................188 Auxiliary Spool Removal And Installation................................................190 Auxiliary Solenoid Removal And Installation.............................................192 Solenoid Removal And Installation.......................................................193 Lock Valve Removal And Installation.....................................................194 Lift Arm Bypass Orifice Removal And Installation........................................196 Main Relief Valve Removal And Installation..............................................196 Check Valve Removal And Installation....................................................197 LIFT ARM BYPASS CONTROL VALVE...............................................................199 Description.............................................................................199 Testing.................................................................................199 Removal And Installation................................................................199 Disassembly And Assembly................................................................200 HYDRAULIC PUMP (STANDARD)...................................................................201 Description.............................................................................201 Pump Test at Quick Couplers.............................................................202 Direct Pump Test (Standard Section).....................................................203 Direct Pump Test (Charge Section).......................................................205 Removal And Installation................................................................209 Hydraulic Pump Start Up.................................................................211 Parts Identification....................................................................212 Disassembly And Assembly................................................................213 HYDRAULIC PUMP (STANDARD) (HIGH FLOW).......................................................215 Description.............................................................................215 Pump Test At Quick Couplers.............................................................216 Direct Pump Test (Standard Section).....................................................217 Direct Pump Test (Charge Section).......................................................219 Direct Pump Test (High Flow Section)....................................................223 High Flow Relief Valve Adjustment.......................................................225 High Flow Relief Valve Removal And Installation.........................................227 Solenoid Removal And Installation.......................................................228 Removal And Installation................................................................229 Hydraulic Pump Start Up.................................................................231 Parts Identification....................................................................232 Disassembly And Assembly................................................................233 HYDRAULIC PUMP (SJC)........................................................................235 Description.............................................................................235 Pump Test At Quick Couplers.............................................................236 Direct Pump Test (Standard Section).....................................................237 Direct Pump Test (Charge Section).......................................................239 Removal And Installation................................................................243 Hydraulic Pump Start Up.................................................................245 Parts Identification....................................................................246 Disassembly And Assembly................................................................247 HYDRAULIC PUMP (SJC) (HIGH FLOW)............................................................249 Description.............................................................................249 Pump Test At Quick Couplers.............................................................250 Direct Pump Test (Standard Section).....................................................251 Direct Pump Test (Charge Section).......................................................253 Direct Pump Test (High Flow Section)....................................................257 High Flow Relief Valve Adjustment.......................................................259 High Flow Relief Valve Removal And Installation.........................................261 Solenoid Removal And Installation.......................................................262 Removal And Installation................................................................263 Hydraulic Pump Start Up.................................................................265 Parts Identification....................................................................266 Disassembly And Assembly................................................................267 HYDRAULIC/HYDROSTATIC FILTERS...............................................................269 Description.............................................................................269 Housing Removal And Installation........................................................269 HYDRAULIC FLUID RESERVOIR...................................................................271 Description.............................................................................271 Removal And Installation................................................................271 Hydraulic Fluid Screen..................................................................274 OIL COOLER..................................................................................275 Description.............................................................................275 Removal And Installation................................................................275 BUCKET POSITION VALVE.......................................................................277 Description.............................................................................277 Solenoid Removal And Installation.......................................................278 Solenoid Testing........................................................................279 Removal And Installation................................................................279 Disassembly And Assembly................................................................280 REAR AUXILIARY DIVERTER VALVE...............................................................283 Description.............................................................................283 Solenoid Testing........................................................................283 Removal And Installation................................................................284 Disassembly And Assembly................................................................286 BOB-TACH (POWER) BLOCK......................................................................293 Description.............................................................................293 Removal And Installation................................................................293 Disassembly And Assembly................................................................295 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK.....................................................299 Description.............................................................................299 Removal and Installation................................................................299 Disassembly And Assembly................................................................300 HYDROSTATIC SYSTEM..............................................................................303 HYDROSTATIC SYSTEM INFORMATION..............................................................305 Troubleshooting.........................................................................305 Description.............................................................................306 HYDROSTATIC MOTOR...........................................................................307 Description.............................................................................307 Removing And Replacing Oil..............................................................307 Removal And Installation................................................................308 Parts Identification....................................................................310 Disassembly And Assembly................................................................312 CHARGE PRESSURE.............................................................................325 Description.............................................................................325 Testing.................................................................................325 Sender Removal And Installation.........................................................327 Adjusting...............................................................................328 HYDROSTATIC PUMP............................................................................331 Description.............................................................................331 Removal And Installation................................................................332 Hydrostatic Pump Start Up...............................................................334 Replenishing / High Pressure Relief Valve Removal And Installation......................335 Parts Identification (Left Half)........................................................336 Parts Identification (Right Half).......................................................337 Disassembly.............................................................................338 Assembly................................................................................345 HYDROSTATIC PUMP (SJC)......................................................................351 Description.............................................................................351 Hydraulic Controller Removal And Installation...........................................352 Removal And Installation................................................................354 Hydrostatic Pump Start Up...............................................................356 Parts Identification....................................................................357 High Pressure Relief And Bypass Valve...................................................358 Charge Relief Valve.....................................................................359 Disassembly And Assembly................................................................360 Mechanical Neutral Adjustment...........................................................377 Hydraulic Controller Neutral Adjustment.................................................380 DRIVE BELT..................................................................................383 Description.............................................................................383 Drive Belt Shield Removal And Installation..............................................383 Adjusting...............................................................................384 Belt Removal And Installation...........................................................384 Tensioner Pulley Removal And Installation...............................................385 Tensioner Pulley Disassembly And Assembly...............................................386 Tensioner Pulley Tension Spring Removal And Installation................................387 Tensioner Pulley Tension Disassembly And Assembly.......................................387 CASE DRAIN FILTER...........................................................................389 Description.............................................................................389 Disassembly And Assembly................................................................389 DRIVE SYSTEM....................................................................................391 BRAKE.......................................................................................393 Description.............................................................................393 Block Removal And Installation..........................................................394 Block Disassembly And Assembly..........................................................395 TRACK CARRIAGE COMPONENTS...................................................................397 Description.............................................................................397 Checking Tension........................................................................398 Adjusting Tension.......................................................................399 Track Removal And Installation..........................................................400 Idler (Front) Removal And Installation..................................................403 Idler (Rear) Removal And Installation...................................................406 Roller Removal And Installation.........................................................406 Sprocket Removal And Installation.......................................................407 Track Housing Removal And Installation..................................................408 Track Damage Identification.............................................................409 MAIN FRAME......................................................................................419 SEAT BAR....................................................................................423 Description.............................................................................423 Removal And Installation................................................................423 Disassembly And Assembly................................................................425 Compression Spring Disassembly And Assembly.............................................426 OPERATOR CAB................................................................................427 Gas Cylinder Removal And Installation...................................................427 Gas Cylinder Bracket Disassembly And Assembly...........................................429 Removal And Installation................................................................430 OPERATOR SEAT (SUSPENSION)..................................................................433 Removal And Installation................................................................433 Slide Rail Removal And Installation.....................................................434 Seat Belt Removal And Installation......................................................434 Lower Cushion Removal And Installation..................................................435 Back Cushion Removal And Installation...................................................436 Shock Removal And Installation..........................................................436 3-Point Seat Belt Removal And Installation..............................................437 BOB-TACH (HAND LEVER).......................................................................439 Description.............................................................................439 Removal And Installation................................................................439 Lever And Wedge Disassembly And Assembly................................................442 Pivot Pin Bushing And Seal Removal And Installation.....................................443 BOB-TACH (POWER)............................................................................445 Description.............................................................................445 Removal And Installation................................................................445 Lever And Wedge Disassembly And Assembly................................................448 Pivot Pin Bushing And Seal Removal And Installation.....................................450 LIFT ARMS...................................................................................451 Removal And Installation................................................................451 REAR GRILL..................................................................................455 Removal And Installation................................................................455 REAR DOOR...................................................................................457 Removal And Installation................................................................457 Striker Removal And Installation........................................................458 Striker Disassembly And Assembly........................................................458 Striker (Adjusting).....................................................................459 Latch Removal And Installation..........................................................460 FUEL TANK...................................................................................461 Removal And Installation................................................................461 Fuel Level Sender Removal And Installation..............................................463 Fuel Fill Screen Removal And Installation...............................................463 CONTROL PEDALS AND LINKAGES.................................................................465 Description.............................................................................465 Pedal Removal And Installation..........................................................466 Linkage Removal And Installation........................................................467 Pedal (Adjusting).......................................................................468 CONTROL PEDALS (ACS)........................................................................469 Description.............................................................................469 Foot Sensor Removal And Installation....................................................470 Foot Pedal Removal And Installation.....................................................471 Foot Pedal Linkage Disassembly And Assembly.............................................472 CONTROL PANEL...............................................................................473 Description.............................................................................473 Removal And Installation................................................................474 Shock Removal And Installation..........................................................476 Shaft Removal And Installation..........................................................476 Shaft Disassembly And Assembly..........................................................477 Linkage Removal And Installation........................................................478 Pintle Arm Disassembly and Assembly.....................................................482 Linkage Neutral (Adjusting).............................................................483 Linkage Travel (Adjusting)..............................................................487 CONTROL PANEL (SJC).........................................................................491 Description.............................................................................491 Removal And Installation................................................................492 CONTROL HANDLE / LEVER......................................................................495 Description.............................................................................495 Lever Removal And Installation..........................................................495 Boot Removal And Installation...........................................................496 CONTROL HANDLE / LEVER (ACS)................................................................497 Description.............................................................................497 Handle Sensor Removal And Installation..................................................497 Handle Removal And Installation.........................................................500 Handle Disassembly And Assembly.........................................................501 Lever Removal And Installation..........................................................502 Boot Removal And Installation...........................................................503 JOYSTICK CONTROL............................................................................505 Description.............................................................................505 Testing.................................................................................506 Removal And Installation................................................................507 Joystick Mount Removal And Installation.................................................508 ACCESS PANEL (INSIDE).......................................................................509 Removal And Installation (Left).........................................................509 Removal And Installation (Right)........................................................509 ACCESS PANEL (INSIDE) (SJC).................................................................511 Removal And Installation (Left).........................................................511 Removal And Installation (Right)........................................................512 WINDOW (REAR)...............................................................................515 Removal.................................................................................515 Installation............................................................................515 WINDOW (TOP)................................................................................517 Removal And Installation................................................................517 WINDOW (SIDE)...............................................................................519 Removal And Installation................................................................519 WINDOW (FRONT DOOR).........................................................................521 Removal (Standard Window)...............................................................521 Installation (Standard Window)..........................................................522 Removal And Installation (Special Applications Window)..................................524 CAB DOOR....................................................................................525 Description.............................................................................525 Removal And Installation................................................................525 Aligning................................................................................526 Adjusting...............................................................................527 Checking Operation......................................................................527 ELECTRICAL SYSTEM & ANALYSIS....................................................................529 ELECTRICAL SCHEMATICS.......................................................................533 ELECTRICAL SYSTEM INFORMATION...............................................................540 Glossary Of Electrical Symbols..........................................................540 Cab Harness Connectors..................................................................543 Mainframe Harness Connectors............................................................544 Description.............................................................................546 Troubleshooting.........................................................................548 Fuse And Relay Location / Identification................................................549 Solenoid Testing........................................................................550 BATTERY.....................................................................................552 Servicing...............................................................................552 Using A Booster Battery (Jump Starting).................................................552 Removal And Installation................................................................554 ALTERNATOR..................................................................................556 Belt Adjustment.........................................................................556 Belt Replacement........................................................................556 Charging System Inspection..............................................................557 Alternator Voltage Testing..............................................................558 Low Voltage Testing.....................................................................558 High Voltage Testing....................................................................559 Removal And Installation................................................................560 Parts Identification....................................................................561 STARTER.....................................................................................562 Testing.................................................................................562 Removal And Installation................................................................563 Parts Identification....................................................................564 INSTRUMENT PANELS...........................................................................566 Left Panel..............................................................................566 Right Panel (Key Switch)................................................................567 Right Panel (Keyless)...................................................................568 Side And Front Panels...................................................................570 Removal And Installation (Left And Right)...............................................571 Bulb Removal And Installation (Left Only)...............................................574 Key Switch Removal And Installation.....................................................575 Alarm Removal And Installation..........................................................576 Front Panel Removal And Installation....................................................576 LIGHTS......................................................................................578 Front Removal And Installation..........................................................578 Rear Removal And Installation...........................................................579 Cab Light Removal And Installation......................................................579 BOBCAT CONTROLLER (MAIN)....................................................................580 Description.............................................................................580 Connector Identification................................................................581 Removal And Installation................................................................583 BOBCAT CONTROLLER (ACS).....................................................................584 Description.............................................................................584 Connector And Wire Identification.......................................................585 Removal And Installation................................................................586 BOBCAT CONTROLLER (SJC).....................................................................588 Description.............................................................................588 Connector Identification................................................................589 Removal And Installation................................................................591 SPEED SENSORS (SJC).........................................................................592 Description.............................................................................592 Testing.................................................................................592 Removal and Installation................................................................594 DIAGNOSTIC SERVICE CODES....................................................................596 Viewing Service Codes (Key Switch)......................................................596 Viewing Service Codes (Keyless).........................................................596 Service Codes List......................................................................597 BOBCAT INTERLOCK CONTORL SYSTEM (BICS)......................................................602 Description.............................................................................602 Inspecting The BICS Controller (Engine Stopped - Key ON)................................603 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....603 Inspecting The Seat Bar Sensor (Engine RUNNING).........................................603 Inspecting The Traction Lock (Engine RUNNING)...........................................603 Inspecting The Lift Arm Bypass Control..................................................603 Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)........................603 Troubleshooting.........................................................................604 Troubleshooting Chart...................................................................605 SEAT BAR SENSOR.............................................................................606 Description.............................................................................606 Troubleshooting.........................................................................607 Testing.................................................................................608 Removal And Installation................................................................609 Bobcat Interlock Control System (BICS) Circuit Test.....................................610 TRACTION LOCK...............................................................................612 Description.............................................................................612 Troubleshooting.........................................................................613 Inspecting..............................................................................614 Parking Brake Solenoid Removal And Installation.........................................615 CONTROL SYSTEM (ACS)........................................................................616 Description.............................................................................616 Troubleshooting Chart...................................................................617 Handle Sensor Connector Disassembly And Assembly........................................618 Switch Handle Removal...................................................................619 Switch Handle Installation..............................................................621 Actuator Connector Disassembly And Assembly.............................................624 Handle Lock Solenoid Removal And Installation...........................................625 Handle Lock Solenoid Disassembly And Assembly...........................................626 Foot Sensor Disassembly And Assembly....................................................626 Foot Lock Solenoid Removal And Installation.............................................627 ELECTRICAL / HYDRAULIC CONTROLS.............................................................628 Identification Chart....................................................................628 ELECTRICAL / HYDRAULIC CONTROLS (SJC).......................................................630 Identification Chart....................................................................630 SERVICE PC (LAPTOP COMPUTER)................................................................634 Connecting Remote Start Tool............................................................634 Connecting Remote Start Tool (Service Tool).............................................634 CALIBRATION.................................................................................636 Description.............................................................................636 Actuator Testing........................................................................636 Lift And Tilt Calibration (ACS).........................................................638 Lift And Tilt Calibration (SJC).........................................................640 Hydrostatic Pump Calibration (SJC)......................................................642 STEERING DRIFT COMPENSATION.................................................................648 Description.............................................................................648 Selecting And Adjusting.................................................................648 Exiting And Saving......................................................................649 FLYWHEEL RPM SENSOR.........................................................................650 Description.............................................................................650 Adjustment..............................................................................651 CONTROL PANEL SETUP.........................................................................652 Right Panel Setup (Keyless).............................................................652 Attachment Control Information (Keyless)................................................653 PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START).............................................654 Password Description....................................................................654 Changing The Owner Password.............................................................654 Changing The User Passwords.............................................................655 Password Lockout Feature................................................................655 MAINTENANCE CLOCK...........................................................................656 Description.............................................................................656 Setup...................................................................................657 Reset...................................................................................661 BACK-UP ALARM SYSTEM........................................................................662 Description.............................................................................662 Inspecting..............................................................................662 Adjusting Switch Position...............................................................663 Troubleshooting (Standard And ACS)......................................................664 Troubleshooting (Joystick)..............................................................665 Alarm Removal And Installation..........................................................666 Switch Removal And Installation.........................................................666 ENGINE SERVICE..................................................................................668 ENGINE INFORMATION..........................................................................672 Description.............................................................................672 Specifications..........................................................................673 Torque Values...........................................................................678 Troubleshooting.........................................................................679 Engine Removal And Installation.........................................................681 Engine Mount Replacement................................................................687 Compression - Checking..................................................................688 ENGINE SPEED CONTROL........................................................................690 Removal And Installation................................................................690 Cable Removal And Installation..........................................................690 ENGINE SPEED CONTROL (SJC)..................................................................692 Removal And Installation................................................................692 Disassembly And Assembly................................................................694 Speed Control Cable Removal And Installation............................................695 MUFFLER.....................................................................................696 Removal And Installation................................................................696 AIR CLEANER.................................................................................698 Housing Removal And Installation........................................................698 ENGINE COOLING SYSTEM.......................................................................700 Radiator Removal And Installation.......................................................700 Radiator Mount Removal And Installation.................................................702 Hydraulic Fan Motor Description.........................................................703 Axial Fan Housing Removal And Installation..............................................703 Axial Fan Removal And Installation......................................................706 Hydraulic Fan Motor Removal And Installation............................................707 Hydraulic Fan Motor Disassembly And Assembly............................................708 Water Pump Removal And Installation.....................................................709 Water Pump Disassembly And Assembly.....................................................710 Thermostat Housing Removal And Installation.............................................710 LUBRICATION SYSTEM..........................................................................712 Oil Pan Removal And Installation........................................................712 Oil Pump Removal And Installation.......................................................713 Oil Pump Inspection.....................................................................713 Oil Filter Cooler Removal And Installation..............................................715 Engine Oil Pressure - Testing...........................................................716 FUEL SYSTEM.................................................................................718 Fuel Shutoff Solenoid - Checking........................................................718 Fuel Shutoff Solenoid - Removal And Installation........................................718 Fuel Injection Pump Assembly Removal....................................................719 Fuel Injection Pump Assembly Installation...............................................723 Governor Housing Disassembly And Assembly...............................................725 Governor Disassembly And Assembly.......................................................727 Fuel Camshaft Removal And Installation..................................................729 Fuel Injection Pump Removal.............................................................731 Injection Pump Timing...................................................................738 Fuel Injector Removal And Installation..................................................741 Fuel Injector Nozzle Pressure - Checking................................................742 Nozzle Spraying Condition...............................................................743 Valve Seat Tightness....................................................................743 CYLINDER HEAD...............................................................................744 Intake Air Heater - Testing.............................................................744 Intake Air Heater Removal And Installation..............................................744 Valve Clearance Adjustment..............................................................745 Cylinder Head Removal And Installation..................................................747 Cylinder Head Top Clearance.............................................................749 Cylinder Head Disassembly And Assembly..................................................750 Cylinder Head - Servicing...............................................................750 Valve Guide - Checking..................................................................751 Reconditioning The Valve And Valve Seat.................................................753 Valve Spring............................................................................755 Valve Tappets...........................................................................756 Rocker Arm And Shaft - Checking.........................................................757 Push Rod Alignment - Checking...........................................................757 CRANKSHAFT AND PISTONS......................................................................758 Piston And Connecting Rod Removal And Installation......................................758 Piston And Connecting Rod - Servicing...................................................760 Cylinder Bore Checking..................................................................764 Connecting Rod Alignment................................................................765 Crankshaft Gear Removal And Installation................................................765 Crankshaft And Bearings Removal.........................................................766 Crankshaft And Bearings Installation....................................................768 Crankshaft And Bearings - Servicing.....................................................770 CAMSHAFT AND TIMING GEArS...................................................................776 Timing Gearcase Cover Removal And Installation..........................................776 Timing Gears Backlash - Checking........................................................777 Idler Gear And Camshaft Removal and Installation........................................777 Camshaft - Servicing....................................................................778 Idler Gear And Shaft - Servicing........................................................780 TURBOCHARGER................................................................................782 Description.............................................................................782 Testing.................................................................................782 Removal And Installation................................................................783 FLYWHEEL AND HOUSING........................................................................784 Flywheel Removal And Installation.......................................................784 Ring Gear Removal And Installation......................................................784 Housing Removal And Installation........................................................785 EXHAUST GAS RECIRCULATION (EGR) SYSTEM......................................................786 Description.............................................................................786 Testing.................................................................................787 Removal And Installation................................................................790 HEATING, VENTILATION, AIR CONDITIONING..........................................................792 AIR CONDITIONING SYSTEM FLOW................................................................795 Description.............................................................................795 Chart...................................................................................796 Components..............................................................................797 Safety Equipment........................................................................800 REGULAR MAINTENANCE.........................................................................802 Filter Elements Removal And Installation................................................802 Compressor Drive Belt Inspection........................................................803 Condenser...............................................................................804 Air Conditioning Lubrication............................................................804 Air Conditioning Service Chart..........................................................805 Cleaning The A/C Evaporator Coil & Heater Coil..........................................806 TROUBLESHOOTING.............................................................................808 Blower Motor Does Not Operate...........................................................808 Blower Motor Operates Normally, But Air Flow Is Insufficient............................808 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..............808 The Compressor Does Not Operate At All, Or Operates Improperly..........................808 Gauge Pressure Related Troubleshooting..................................................809 Troubleshooting Tree....................................................................811 Temperature / Pressure Chart............................................................815 Poor A/C Performance....................................................................817 HVAC Repair And Leaks...................................................................818 Electrical System.......................................................................819 Engine Coolant Bypassing The Heater Valve...............................................826 Heater Valve Not Opening Or Closing.....................................................827 SYSTEM CHARGING AND RECLAMATION.............................................................828 Refrigerant Identification..............................................................828 Reclamation And Charging With Recovery / Charging Unit..................................829 Charging With A Manifold Gauge Set......................................................831 COMPRESSOR..................................................................................834 Belt Adjustment.........................................................................834 Removal And Installation................................................................834 Oil.....................................................................................835 Oil Check...............................................................................836 Clutch Disassembly And Assembly.........................................................837 CONDENSER...................................................................................842 Removal And Installation................................................................842 RECEIVER / DRIER............................................................................844 Receiver / Drier Removal And Installation...............................................844 Pressure Relief Valve Removal And Installation..........................................845 Pressure Switch Removal And Installation................................................845 Schraeder Valve Removal And Installation................................................846 EVAPORATOR / HEATER UNIT....................................................................848 Removal And Installation................................................................848 THERMOSTAT..................................................................................850 Removal And Installation................................................................850 EXPANSION VALVE.............................................................................852 Removal And Installation................................................................852 EVAPORATOR..................................................................................854 Removal And Installation................................................................854 HEATER COIL.................................................................................856 Removal And Installation With A/C.......................................................856 Removal And Installation Without A/C....................................................858 BLOWER FAN..................................................................................860 Removal And Installation................................................................860 Disassembly And Assembly................................................................861 Connector Identification................................................................863 HEATER VALVE................................................................................864 Removal And Installation................................................................864 Disassembly And Assembly................................................................865 SPECIFICATIONS..................................................................................866 (T250) LOADER SPECIFICATIONS................................................................868 Machine Dimensions......................................................................868 Performance.............................................................................869 Controls................................................................................869 Engine..................................................................................869 Hydraulic System........................................................................870 Electrical..............................................................................871 Drive System............................................................................871 Capacities..............................................................................871 Tracks..................................................................................871 Ground Pressure.........................................................................871 TORQUE SPECIFICATIONS FOR BOLTS.............................................................872 Torque For General SAE Bolts............................................................872 Torque For General Metric Bolts.........................................................873 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................874 O-ring Face Seal Connection.............................................................874 Straight Thread O-ring Fitting..........................................................875 Tubelines And Hoses.....................................................................875 Flare Fitting...........................................................................876 Port Seal Fitting.......................................................................877 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS................................................878 Specifications..........................................................................878 CONVERSIONS.................................................................................880 Decimal And Millimeter Equivalents......................................................880 U.S. To Metric Conversion Chart.........................................................880 SERVICE MANUAL REVISION.........................................................................882 Revision No: T250 - 1.......................................................................882 Revision No: T250 - 2.......................................................................884
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