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Bobcat T250 Compact Track Loader Service Manual 6987044 (5-13) – PDF DOWNLOAD
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Bobcat T250 Compact Track Loader Service Manual 6987044 (5-13) – PDF DOWNLOAD
S/N A5GS20001 & Above
S/N A5GT20001 & Above
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Description
Bobcat T250 Compact Track Loader Service Manual 6987044 (5-13) – PDF DOWNLOAD
FILE DETAILS:
Bobcat T250 Compact Track Loader Service Manual 6987044 (5-13) – PDF DOWNLOAD
Language : English
Pages : 1020
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T250 Compact Track Loader Service Manual 6987044 (5-13) – PDF DOWNLOAD
S/N A5GS20001 & Above
S/N A5GT20001 & 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 6987044 (5-13) – PDF DOWNLOAD
MAINTENANCE SAFETY...................................................................................... 3 CONTENTS................................................................................................ 5 FOREWORD................................................................................................ 7 FOREWORD............................................................................................ 9 SAFETY INSTRUCTIONS................................................................................. 12 FIRE PREVENTION..................................................................................... 14 Maintenance..................................................................................... 14 Operation....................................................................................... 14 Electrical...................................................................................... 14 Hydraulic System................................................................................ 14 Fueling......................................................................................... 14 Starting........................................................................................ 14 Spark Arrester Exhaust System................................................................... 14 Welding And Grinding............................................................................ 15 Fire Extinguishers.............................................................................. 15 SERIAL NUMBER LOCATIONS............................................................................. 16 Loader Serial Number............................................................................ 16 Engine Serial Number............................................................................ 16 DELIVERY REPORT..................................................................................... 17 LOADER IDENTIFICATION............................................................................... 18 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................................................................................. 30 Special Applications Kit........................................................................ 30 Special Applications Kit Inspection And Maintenance............................................. 30 Forestry Door And Window Kit.................................................................... 31 Forestry Door And Window Kit Inspection And Maintenance......................................... 31 TRANSPORTING THE LOADER ON A TRAILER................................................................ 33 Loading And Unloading........................................................................... 33 Fastening....................................................................................... 33 TOWING THE LOADER................................................................................... 35 Procedure....................................................................................... 35 REMOTE START TOOL KIT-MEL1563....................................................................... 37 Remote Start Tool - MEL1563..................................................................... 37 Service Tool Harness Control - MEL1565.......................................................... 38 Service Tool Harness Communicator - MEL1566..................................................... 39 Remote Start Procedure.......................................................................... 40 REMOTE START TOOL (SERVICE TOOL) KIT - 7217666...................................................... 45 Description..................................................................................... 45 Remote Start Tool (Service Tool) - 7022042...................................................... 46 Loader Service Tool Harness - 6689747........................................................... 47 Computer Service Tool Harness - 6689746......................................................... 48 Remote Start Procedure.......................................................................... 49 SERVICE SCHEDULE.................................................................................... 53 Chart........................................................................................... 53 AIR CLEANER SERVICE................................................................................. 55 Replacing Filter Elements....................................................................... 55 ENGINE COOLING SYSTEM............................................................................... 57 Maintenance Platform............................................................................ 57 Description..................................................................................... 57 Cleaning (Earlier Models)....................................................................... 57 Cleaning (Later Models)......................................................................... 58 Removing And Replacing Coolant.................................................................. 60 Checking Level.................................................................................. 60 FUEL SYSTEM......................................................................................... 61 Fuel Specifications............................................................................. 61 Biodiesel Blend Fuel............................................................................ 61 Filling The Fuel Tank........................................................................... 62 Fuel Filter..................................................................................... 63 Removing Air From The Fuel System............................................................... 63 ENGINE LUBRICATION SYSTEM........................................................................... 65 Checking And Adding Engine Oil.................................................................. 65 Engine Oil Chart................................................................................ 65 Removing And Replacing Oil And Filter........................................................... 66 HYDRAULIC / HYDROSTATIC SYSTEM...................................................................... 67 Checking And Adding Fluid....................................................................... 67 Hydraulic / Hydrostatic Fluid Chart............................................................. 67 Removing And Replacing Hydraulic Fluid.......................................................... 68 Removing And Replacing Hydraulic / Hydrostatic Filter........................................... 69 Removing And Replacing Case Drain Filters....................................................... 70 Removing And Replacing Hydraulic Charge Filter.................................................. 71 Breather Cap.................................................................................... 72 BOB-TACH (HAND LEVER)............................................................................... 73 Inspection And Maintenance...................................................................... 73 BOB-TACH (POWER).................................................................................... 75 Inspection And Maintenance...................................................................... 75 LUBRICATING THE LOADER.............................................................................. 77 Lubrication Locations........................................................................... 77 SPARK ARRESTER MUFFLER.............................................................................. 79 Cleaning Procedure.............................................................................. 79 PIVOT PINS.......................................................................................... 81 Inspection And Maintenance...................................................................... 81 LOADER STORAGE AND RETURN TO SERVICE................................................................ 83 Storage......................................................................................... 83 Return To Service............................................................................... 83 STOPPING THE ENGINE AND LEAVING THE LOADER.......................................................... 85 Procedure....................................................................................... 85 EMERGENCY EXIT...................................................................................... 87 Rear Window..................................................................................... 87 Front Door...................................................................................... 87 SEAT BELT........................................................................................... 89 Inspection And Maintenance...................................................................... 89 HYDRAULIC SYSTEM........................................................................................ 91 HYDRAULIC / HYDROSTATIC SCHEMATICS.................................................................. 97 HYDRAULIC SYSTEM INFORMATION........................................................................ 105 Glossary Of Hydraulic / Hydrostatic Symbols..................................................... 105 Troubleshooting................................................................................. 109 CYLINDER (LIFT)..................................................................................... 111 Testing......................................................................................... 111 Removal And Installation........................................................................ 112 Parts Identification............................................................................ 114 Disassembly..................................................................................... 115 Assembly........................................................................................ 117 CYLINDER (TILT)..................................................................................... 119 Testing......................................................................................... 119 Removal And Installation........................................................................ 120 Base End Pivot Pin Removal And Installation..................................................... 122 Parts Identification............................................................................ 123 Disassembly..................................................................................... 124 Assembly........................................................................................ 126 CYLINDER (BOB-TACH)................................................................................. 129 Testing......................................................................................... 129 Removal And Installation........................................................................ 130 Parts Identification............................................................................ 131 Disassembly..................................................................................... 132 Assembly........................................................................................ 133 MAIN RELIEF VALVE................................................................................... 137 Description..................................................................................... 137 Testing......................................................................................... 138 Adjusting....................................................................................... 140 Removal And Installation........................................................................ 141 HYDRAULIC CONTROL VALVE (STANDARD).................................................................. 143 Description..................................................................................... 143 Removal And Installation........................................................................ 144 Identification Chart............................................................................ 148 Mount Bracket Removal And Installation.......................................................... 149 Lift Load Check Valve Removal And Installation.................................................. 149 Load Check Valve Removal And Installation (Tilt And Auxiliary).................................. 150 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).................................. 150 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................... 151 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................... 152 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................... 152 Port Relief Valve Removal And Installation...................................................... 153 Plug Removal And Installation................................................................... 154 Rubber Boot Removal And Installation............................................................ 155 End Cap Block Removal And Installation.......................................................... 156 Lift Spool And Detent Removal And Installation.................................................. 157 Tilt Spool Removal And Installation............................................................. 167 Auxiliary Spool Removal And Installation........................................................ 169 Auxiliary Solenoid Removal And Installation (S/N A5GS34999 & Below And A5GT34999 & Below)....... 171 Auxiliary Solenoid Removal And Installation (S/N A5GS35001 & Above And A5GT35001& Above)........ 172 Solenoid Removal And Installation............................................................... 173 Lock Valve Removal And Installation............................................................. 174 Lift Arm Bypass Orifice Removal And Installation................................................ 176 Main Relief Valve Removal And Installation...................................................... 176 Check Valve Removal And Installation............................................................ 177 HYDRAULIC CONTROL VALVE (ACS) OR (SJC).............................................................. 179 Description..................................................................................... 179 Removal And Installation........................................................................ 180 Actuator Removal And Installation (In Loader)................................................... 184 Actuator Removal And Installation (Out Of Loader)............................................... 186 Identification Chart............................................................................ 189 Mount Bracket Removal And Installation.......................................................... 190 Lift Load Check Valve Removal And Installation.................................................. 190 Load Check Valve Removal And Installation (Tilt And Auxiliary).................................. 191 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).................................. 192 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................... 193 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................... 193 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................... 194 Port Relief Valve Removal And Installation...................................................... 194 Plug Removal And Installation................................................................... 195 End Cap Block Removal And Installation.......................................................... 196 Lift Spool And Detent Removal And Installation.................................................. 197 Tilt Spool Removal And Installation............................................................. 202 Auxiliary Spool Removal And Installation........................................................ 204 Auxiliary Solenoid Removal And Installation (S/N A5GS34999 & Below And A5GT34999 & Below)....... 206 Auxiliary Solenoid Removal And Installation (S/N A5GS35001 & Above And A5GT35001& Above)........ 207 Solenoid Removal And Installation............................................................... 208 Lock Valve Removal And Installation............................................................. 209 Lift Arm Bypass Orifice Removal And Installation................................................ 211 Main Relief Valve Removal And Installation...................................................... 211 Check Valve Removal And Installation............................................................ 212 LIFT ARM BYPASS CONTROL VALVE....................................................................... 213 Description..................................................................................... 213 Testing......................................................................................... 213 Removal And Installation........................................................................ 214 Disassembly And Assembly........................................................................ 215 HYDRAULIC PUMP (STANDARD)........................................................................... 217 Description..................................................................................... 217 Pump Test At Quick Couplers..................................................................... 218 Direct Pump Test (Standard Section)............................................................. 219 Direct Pump Test (Charge Section)............................................................... 221 Removal And Installation........................................................................ 225 Hydraulic Pump Startup.......................................................................... 227 Parts Identification............................................................................ 228 Disassembly And Assembly........................................................................ 229 HYDRAULIC PUMP (STANDARD) (HIGH FLOW)............................................................... 231 Description..................................................................................... 231 Pump Test At Quick Couplers..................................................................... 232 Direct Pump Test (Standard Section)............................................................. 233 Direct Pump Test (Charge Section)............................................................... 235 Direct Pump Test (High Flow Section)............................................................ 239 High Flow Relief Valve Adjustment............................................................... 241 High Flow Relief Valve Removal And Installation................................................. 243 Solenoid Removal And Installation............................................................... 244 Removal And Installation........................................................................ 245 Hydraulic Pump Startup.......................................................................... 247 Parts Identification............................................................................ 248 Disassembly And Assembly........................................................................ 249 HYDRAULIC PUMP (SJC)................................................................................ 251 Description..................................................................................... 251 Pump Test At Quick Couplers..................................................................... 252 Direct Pump Test (Standard Section)............................................................. 253 Direct Pump Test (Charge Section)............................................................... 255 Removal And Installation........................................................................ 259 Hydraulic Pump Startup.......................................................................... 261 Parts Identification............................................................................ 262 Disassembly And Assembly........................................................................ 263 HYDRAULIC PUMP (SJC) (HIGH FLOW).................................................................... 265 Description..................................................................................... 265 Pump Test At Quick Couplers..................................................................... 266 Direct Pump Test (Standard Section)............................................................. 267 Direct Pump Test (Charge Section)............................................................... 269 Direct Pump Test (High Flow Section)............................................................ 273 High Flow Relief Valve Adjustment............................................................... 275 High Flow Relief Valve Removal And Installation................................................. 277 Solenoid Removal And Installation............................................................... 278 Removal And Installation........................................................................ 279 Hydraulic Pump Startup.......................................................................... 281 Parts Identification............................................................................ 282 Disassembly And Assembly........................................................................ 283 HYDRAULIC / HYDROSTATIC FILTERS..................................................................... 285 Description..................................................................................... 285 Housing Removal And Installation................................................................ 285 HYDRAULIC FLUID RESERVOIR........................................................................... 287 Description..................................................................................... 287 Removal And Installation........................................................................ 287 Hydraulic Fluid Screen.......................................................................... 290 OIL COOLER.......................................................................................... 291 Description..................................................................................... 291 Removal And Installation........................................................................ 291 BUCKET POSITION VALVE............................................................................... 295 Description..................................................................................... 295 Solenoid Removal And Installation............................................................... 296 Solenoid Testing................................................................................ 297 Removal And Installation........................................................................ 297 Disassembly And Assembly........................................................................ 298 REAR AUXILIARY DIVERTER VALVE....................................................................... 301 Description..................................................................................... 301 Solenoid Testing................................................................................ 301 Removal And Installation........................................................................ 302 Disassembly And Assembly........................................................................ 304 BOB-TACH (POWER) BLOCK.............................................................................. 311 Description..................................................................................... 311 Removal And Installation........................................................................ 311 Disassembly And Assembly........................................................................ 313 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK............................................................. 317 Description..................................................................................... 317 Removal And Installation........................................................................ 317 Disassembly And Assembly........................................................................ 318 HYDROSTATIC SYSTEM...................................................................................... 321 HYDROSTATIC SYSTEM INFORMATION...................................................................... 323 Description..................................................................................... 323 Troubleshooting................................................................................. 324 HYDROSTATIC DRIVE MOTOR............................................................................. 325 Description..................................................................................... 325 Removing And Replacing Oil...................................................................... 325 Removal And Installation........................................................................ 326 Parts Identification............................................................................ 328 Disassembly And Assembly........................................................................ 330 CHARGE PRESSURE..................................................................................... 343 Description..................................................................................... 343 Testing......................................................................................... 343 Sender Removal And Installation................................................................. 345 Adjusting....................................................................................... 346 HYDROSTATIC PUMP.................................................................................... 349 Description..................................................................................... 349 Removal And Installation........................................................................ 350 Hydrostatic Pump Startup........................................................................ 352 Replenishing / High Pressure Relief Valve Removal And Installation.............................. 353 Parts Identification (Left Half)................................................................ 354 Parts Identification (Right Half)............................................................... 355 Disassembly..................................................................................... 356 Assembly........................................................................................ 363 HYDROSTATIC PUMP (SJC) (S/N A5GS20001 - A5GS35021 AND A5GT20001 - A5GT35001)........................ 369 Description..................................................................................... 369 Hydraulic Controller Removal And Installation................................................... 370 Removal And Installation........................................................................ 372 Hydrostatic Pump Startup........................................................................ 374 Parts Identification............................................................................ 375 High Pressure Relief And ByPass Valve........................................................... 376 Charge Relief Valve............................................................................. 377 Disassembly And Assembly........................................................................ 378 Mechanical Neutral Adjustment................................................................... 395 Hydraulic Controller Neutral Adjustment......................................................... 398 HYDROSTATIC PUMP (SJC) (S/N A5GS35022 & ABOVE AND A5GT35002 & ABOVE)................................ 401 Description..................................................................................... 401 Hydraulic Controller Removal And Installation................................................... 402 Removal And Installation........................................................................ 404 Hydrostatic Pump Startup........................................................................ 405 Parts Identification............................................................................ 406 High Pressure Relief And Bypass Valve........................................................... 407 Charge Relief Valve............................................................................. 408 Disassembly And Assembly........................................................................ 409 Mechanical Neutral Adjustment................................................................... 422 Hydraulic Controller Neutral Adjustment......................................................... 425 DRIVE BELT.......................................................................................... 429 Description..................................................................................... 429 Shield Removal And Installation................................................................. 429 Adjusting....................................................................................... 430 Belt Removal And Installation................................................................... 430 Tensioner Pulley Removal And Installation....................................................... 431 Tensioner Pulley Disassembly And Assembly....................................................... 432 Tensioner Pulley Tension Spring Removal And Installation........................................ 433 Tensioner Pulley Tension Spring Disassembly And Assembly........................................ 433 CASE DRAIN FILTER................................................................................... 435 Description..................................................................................... 435 Disassembly And Assembly........................................................................ 435 DRIVE SYSTEM............................................................................................ 437 BRAKE............................................................................................... 439 Description..................................................................................... 439 Block Removal And Installation.................................................................. 439 Block Disassembly And Assembly.................................................................. 441 TRACK UNDERCARRIAGE (SOLID-MOUNTED) (RUBBER TRACK) (S/N A5GS20261 & BELOW AND A5GT20079 & BELOW).... 443 Description..................................................................................... 443 Checking Tension................................................................................ 444 Adjusting Tension............................................................................... 445 Track Removal And Installation.................................................................. 446 Idler (Front) Removal And Installation (S/N A5GS20167 & Below And A5GT20064 & Below)............ 448 Idler (Front) Removal And Installation (S/N A5GS20168 & Above And A5GT20065 & Above)............ 450 Idler (Rear) Removal And Installation........................................................... 456 Roller Removal And Installation................................................................. 456 Sprocket Removal And Installation............................................................... 457 Track Housing Removal And Installation.......................................................... 458 TRACK UNDERCARRIAGE (SOLID-MOUNTED) (RUBBER TRACK) (S/N A5GS20262 & ABOVE AND A5GT20080 & ABOVE).... 459 Description..................................................................................... 459 Checking Tension................................................................................ 460 Adjusting Tension............................................................................... 461 Track Removal And Installation.................................................................. 462 Idler (Front) Removal And Installation.......................................................... 464 Idler (Rear) Removal And Installation........................................................... 469 Roller Removal And Installation................................................................. 469 Sprocket Removal And Installation............................................................... 470 Track Housing Removal And Installation.......................................................... 471 TRACK UNDERCARRIAGE (ROLLER SUSPENSION) (RUBBER TRACK).............................................. 473 Description..................................................................................... 473 Checking Tension................................................................................ 474 Adjusting Tension............................................................................... 475 Track Removal And Installation.................................................................. 476 Idler (Front) Removal And Installation (S/N A5GS20084 & Below And A5GT20050 & Below)............ 478 Idler (Front) Removal And Installation (S/N A5GS20085 & Above And A5GT20051 & Above)............ 480 Track Tensioner Disassembly And Assembly (S/N A5GS20084 & Below And A5GT20050 & Below).......... 483 Track Tensioner Disassembly And Assembly (S/N A5GS20085 & Above And A5GT20051 & Above).......... 485 Idler (Rear) Removal And Installation........................................................... 486 Roller Removal And Installation................................................................. 486 Leaf Spring Removal And Installation............................................................ 487 Sprocket Removal And Installation............................................................... 488 Track Housing Removal And Installation.......................................................... 489 TRACK UNDERCARRIAGE (STEEL TRACK)................................................................... 491 Description..................................................................................... 491 Checking Tension................................................................................ 492 Adjusting Tension............................................................................... 493 Track Shoe Removal And Installation............................................................. 494 Track Removal................................................................................... 494 Track Installation.............................................................................. 496 Idler (Front) Removal And Installation.......................................................... 498 Track Tensioner Removal......................................................................... 498 Track Tensioner Installation.................................................................... 499 Track Tensioner Disassembly And Assembly........................................................ 500 Idler (Rear) Removal And Installation........................................................... 501 Roller Removal And Installation................................................................. 502 Top Roller Removal And Installation............................................................. 502 Sprocket Removal And Installation............................................................... 503 Track Housing Removal And Installation.......................................................... 504 TRACK MAINTENANCE (RUBBER TRACK).................................................................... 505 Track Damage Identification..................................................................... 505 MAINFRAME............................................................................................... 517 SEAT BAR............................................................................................ 521 Description..................................................................................... 521 Removal And Installation........................................................................ 521 Disassembly And Assembly........................................................................ 522 Compression Spring Disassembly And Assembly..................................................... 523 OPERATOR CAB........................................................................................ 525 Gas Cylinder Removal And Installation........................................................... 525 Gas Cylinder Bracket Disassembly And Assembly................................................... 527 Removal And Installation........................................................................ 528 OPERATOR SEAT (SUSPENSION).......................................................................... 531 Removal And Installation........................................................................ 531 Slide Rail Removal And Installation............................................................. 532 Seat Belt Removal And Installation.............................................................. 532 Lower Cushion Removal And Installation.......................................................... 533 Back Cushion Removal And Installation........................................................... 534 Shock Removal And Installation.................................................................. 534 3-Point Seat Belt Removal And Installation...................................................... 535 BOB-TACH (HAND LEVER)............................................................................... 537 Description..................................................................................... 537 Removal And Installation........................................................................ 537 Lever And Wedge Disassembly And Assembly........................................................ 539 Pivot Pin Bushing And Seal Removal And Installation............................................. 540 BOB-TACH (POWER).................................................................................... 541 Description..................................................................................... 541 Removal And Installation........................................................................ 541 Lever And Wedge Disassembly And Assembly........................................................ 544 Pivot Pin Bushing And Seal Removal And Installation............................................. 546 LIFT ARMS........................................................................................... 547 Removal And Installation........................................................................ 547 REAR GRILLE......................................................................................... 551 Removal And Installation........................................................................ 551 REAR DOOR (TAILGATE)................................................................................ 553 Removal And Installation........................................................................ 553 Striker Removal And Installation................................................................ 554 Striker Disassembly And Assembly................................................................ 554 Striker (Adjusting)............................................................................. 555 Latch Removal And Installation.................................................................. 556 FUEL TANK........................................................................................... 557 Removal And Installation........................................................................ 557 Fuel Level Sender Removal And Installation...................................................... 559 Fuel Fill Screen Removal And Installation....................................................... 559 CONTROL PEDALS AND LINKAGES......................................................................... 561 Description..................................................................................... 561 Pedal Removal And Installation.................................................................. 562 Linkage Removal And Installation................................................................ 563 Pedal (Adjusting)............................................................................... 564 CONTROL PEDALS (ACS)................................................................................ 565 Description..................................................................................... 565 Foot Sensor Removal And Installation............................................................ 566 Foot Pedal Removal And Installation............................................................. 567 Foot Pedal Linkage Disassembly And Assembly..................................................... 568 CONTROL PANEL....................................................................................... 569 Description..................................................................................... 569 Removal And Installation........................................................................ 570 Shock Removal And Installation.................................................................. 572 Shaft Removal And Installation.................................................................. 573 Linkage Removal And Installation................................................................ 574 Pintle Arm Disassembly And Assembly............................................................. 578 Linkage Neutral (Adjusting)..................................................................... 579 Linkage Travel (Adjusting)...................................................................... 583 CONTROL PANEL (SJC)................................................................................. 587 Description..................................................................................... 587 Removal And Installation........................................................................ 588 CONTROL HANDLE / LEVER.............................................................................. 591 Description..................................................................................... 591 Lever Removal And Installation.................................................................. 591 Boot Removal And Installation................................................................... 592 CONTROL HANDLE / LEVER (ACS)........................................................................ 593 Description..................................................................................... 593 Handle Sensor Removal And Installation.......................................................... 593 Handle Removal And Installation................................................................. 596 Handle Disassembly And Assembly................................................................. 597 Lever Removal And Installation.................................................................. 598 Boot Removal And Installation................................................................... 599 CONTROL HANDLE / LEVER (SJC)........................................................................ 601 Description..................................................................................... 601 Joystick Testing................................................................................ 602 Joystick Removal And Installation............................................................... 603 Joystick Mount Removal And Installation......................................................... 604 ACCESS PANEL (INSIDE)............................................................................... 605 Removal And Installation (Left)................................................................. 605 Removal And Installation (Right)................................................................ 605 ACCESS PANEL (INSIDE) (SJC)......................................................................... 607 Removal And Installation (Left)................................................................. 607 Removal And Installation (Right)................................................................ 608 WINDOW (REAR)....................................................................................... 611 Removal......................................................................................... 611 Installation (Split Molding).................................................................... 611 Installation (Continuous Molding)............................................................... 613 WINDOW (TOP)........................................................................................ 615 Removal And Installation........................................................................ 615 WINDOW (SIDE)....................................................................................... 617 Removal And Installation........................................................................ 617 WINDOW (CAB DOOR)................................................................................... 619 Removal (Standard Window)....................................................................... 619 Installation (Standard Window).................................................................. 620 Removal And Installation (Special Applications Window).......................................... 622 CAB DOOR............................................................................................ 623 Description..................................................................................... 623 Removal And Installation........................................................................ 623 Aligning........................................................................................ 624 Adjusting....................................................................................... 625 Checking Operation.............................................................................. 625 ELECTRICAL SYSTEM AND ANALYSIS.......................................................................... 627 ELECTRICAL SCHEMATICS............................................................................... 631 ELECTRICAL SYSTEM INFORMATION....................................................................... 637 Glossary Of Electrical Symbols.................................................................. 637 Cab Harness Connectors.......................................................................... 640 Mainframe Harness Connectors.................................................................... 641 Description..................................................................................... 643 Troubleshooting................................................................................. 644 Fuse And Relay Location / Identification........................................................ 645 Solenoid Testing................................................................................ 646 BATTERY............................................................................................. 647 Removal And Installation........................................................................ 647 Servicing....................................................................................... 648 Using A Booster Battery (Jump Starting)......................................................... 649 ALTERNATOR.......................................................................................... 651 Belt Adjustment................................................................................. 651 Belt Replacement................................................................................ 651 Charging System Inspection...................................................................... 652 Alternator Voltage Testing...................................................................... 653 Low Voltage Testing............................................................................. 653 High Voltage Testing............................................................................ 654 Removal And Installation........................................................................ 655 Parts Identification............................................................................ 656 STARTER............................................................................................. 657 Testing......................................................................................... 657 Removal And Installation........................................................................ 658 Parts Identification............................................................................ 659 INSTRUMENT PANELS................................................................................... 661 Left Panel...................................................................................... 661 Standard Key Panel.............................................................................. 663 Keyless Start Panel............................................................................. 663 Deluxe Instrumentation Panel.................................................................... 664 Side Panel...................................................................................... 665 Front Panel..................................................................................... 665 Front Panel Removal And Installation............................................................ 666 Removal And Installation (Left And Right)....................................................... 666 Key Switch Removal And Installation............................................................. 668 Alarm Removal And Installation.................................................................. 669 LIGHTS.............................................................................................. 671 Front Removal And Installation.................................................................. 671 Rear Removal And Installation................................................................... 672 Cab Light Removal And Installation.............................................................. 672 BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)........................................................... 673 Description..................................................................................... 673 Connector Identification........................................................................ 674 Removal And Installation........................................................................ 680 BOBCAT CONTROLLER (ACS)............................................................................. 681 Description..................................................................................... 681 Connector And Wire Identification............................................................... 682 Removal And Installation........................................................................ 683 BOBCAT CONTROLLER (SJC) (DRIVE)..................................................................... 685 Description..................................................................................... 685 Connector Identification........................................................................ 686 Removal And Installation........................................................................ 688 SPEED SENSORS (SJC)................................................................................. 689 Description..................................................................................... 689 Testing......................................................................................... 689 Removal And Installation........................................................................ 691 DIAGNOSTIC SERVICE CODES............................................................................ 693 Viewing Service Codes (Standard Key Panel And Keyless Start Panel).............................. 693 Viewing Service Codes (Deluxe Instrumentation Panel)............................................ 693 Service Codes List.............................................................................. 694 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)............................................................. 699 Description..................................................................................... 699 Inspecting The BICS™ (Engine STOPPED - Key ON).................................................. 700 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)............ 700 Inspecting The Seat Bar Sensor (Engine RUNNING)................................................. 700 Inspecting The Traction Lock (Engine RUNNING)................................................... 700 Inspecting The Lift Arm Bypass Control.......................................................... 700 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)................................ 700 Troubleshooting................................................................................. 701 SEAT BAR SENSOR..................................................................................... 703 Description..................................................................................... 703 Troubleshooting................................................................................. 703 Testing......................................................................................... 704 Removal And Installation........................................................................ 705 Bobcat Interlock Control System (BICS™) Circuit Test............................................ 708 TRACTION LOCK....................................................................................... 709 Description..................................................................................... 709 Troubleshooting................................................................................. 710 Inspecting...................................................................................... 711 CONTROL SYSTEM (ACS)................................................................................ 713 Description..................................................................................... 713 Troubleshooting................................................................................. 714 Handle Sensor Connector Disassembly And Assembly................................................ 715 Switch Handle Removal........................................................................... 716 Switch Handle Installation...................................................................... 718 Actuator Connector Disassembly And Assembly..................................................... 721 Handle Lock Solenoid Removal And Installation................................................... 722 Handle Lock Solenoid Disassembly And Assembly................................................... 723 Foot Sensor Disassembly And Assembly............................................................ 723 Foot Lock Solenoid Removal And Installation..................................................... 724 ELECTRICAL / HYDRAULIC CONTROLS..................................................................... 725 Identification Chart............................................................................ 725 Description..................................................................................... 726 Identification Chart ACD Group 0................................................................ 727 Identification Chart ACD Group 1................................................................ 728 Identification Chart ACD Group 2................................................................ 729 Identification Chart ACD Group 3................................................................ 730 ELECTRICAL / HYDRAULIC CONTROLS (ACS)............................................................... 731 Identification Chart............................................................................ 731 Description..................................................................................... 732 Identification Chart ACD Group 0................................................................ 733 Identification Chart ACD Group 1................................................................ 734 Identification Chart ACD Group 2................................................................ 735 Identification Chart ACD Group 3................................................................ 736 ELECTRICAL / HYDRAULIC CONTROLS (SJC)............................................................... 737 Identification Chart............................................................................ 737 Description..................................................................................... 738 Identification Chart ACD Group 0................................................................ 739 Identification Chart ACD Group 1................................................................ 740 Identification Chart ACD Group 2................................................................ 741 Identification Chart ACD Group 3................................................................ 742 SERVICE PC (LAPTOP COMPUTER)........................................................................ 743 Connecting Remote Start Tool.................................................................... 743 Connecting Remote Start Tool (Service Tool)..................................................... 743 CALIBRATION......................................................................................... 745 Description..................................................................................... 745 Actuator Testing................................................................................ 745 Lift And Tilt Calibration (SJC)................................................................. 748 Hydrostatic Pump Calibration (SJC).............................................................. 750 Lift And Tilt Calibration (ACS)................................................................. 755 STEERING DRIFT COMPENSATION......................................................................... 757 Description..................................................................................... 757 Operation....................................................................................... 757 FLYWHEEL RPM SENSOR................................................................................. 759 Description..................................................................................... 759 Adjusting....................................................................................... 760 CONTROL PANEL SETUP................................................................................. 761 Right Panel Setup (Deluxe Instrumentation Panel)................................................ 761 Attachment Control Information (Deluxe Instrumentation Panel)................................... 762 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....................................................... 763 Password Description............................................................................ 763 Changing The Owner Password..................................................................... 763 Changing The User Passwords..................................................................... 764 Password Lockout Feature........................................................................ 764 PASSWORD SETUP (KEYLESS START PANEL)................................................................ 765 Password Description............................................................................ 765 Changing The Owner Password..................................................................... 765 Password Lockout Feature........................................................................ 765 MAINTENANCE CLOCK................................................................................... 767 Description..................................................................................... 767 Setup........................................................................................... 768 Reset........................................................................................... 771 BACK-UP ALARM SYSTEM................................................................................ 773 Description..................................................................................... 773 Inspecting...................................................................................... 773 Adjusting Switch Position....................................................................... 774 Troubleshooting (Standard And ACS).............................................................. 775 Troubleshooting (Joystick)...................................................................... 776 Alarm Removal And Installation.................................................................. 777 Switch Removal And Installation................................................................. 777 ENGINE SERVICE.......................................................................................... 779 ENGINE INFORMATION.................................................................................. 783 Description..................................................................................... 783 Specifications.................................................................................. 784 Torque Values................................................................................... 789 Troubleshooting................................................................................. 790 Engine Removal And Installation................................................................. 792 Engine Mount Replacement........................................................................ 798 Compression - Checking.......................................................................... 799 ENGINE SPEED CONTROL................................................................................ 801 Removal And Installation........................................................................ 801 Cable Removal And Installation.................................................................. 801 ENGINE SPEED CONTROL (SJC).......................................................................... 803 Removal And Installation........................................................................ 803 Disassembly And Assembly........................................................................ 805 Cable Removal And Installation.................................................................. 806 MUFFLER............................................................................................. 807 Removal And Installation........................................................................ 807 AIR CLEANER......................................................................................... 809 Housing Removal And Installation................................................................ 809 ENGINE COOLING SYSTEM............................................................................... 811 Radiator Removal And Installation............................................................... 811 Radiator Mount Removal And Installation......................................................... 813 Hydraulic Fan Motor Description................................................................. 814 Axial Fan Housing Removal And Installation...................................................... 815 Axial Fan Removal And Installation.............................................................. 817 Hydraulic Fan Motor Removal And Installation.................................................... 819 Hydraulic Fan Motor Disassembly And Assembly.................................................... 819 Water Pump Removal And Installation............................................................. 821 Water Pump Disassembly And Assembly............................................................. 821 Thermostat Housing Removal And Installation..................................................... 822 Thermostat - Checking........................................................................... 822 LUBRICATION SYSTEM.................................................................................. 823 Oil Pan Removal And Installation................................................................ 823 Oil Pump Removal And Installation............................................................... 824 Oil Pump Inspection............................................................................. 824 Oil Filter Cooler Removal And Installation...................................................... 826 Engine Oil Pressure - Testing................................................................... 827 FUEL SYSTEM......................................................................................... 829 Fuel Shutoff Solenoid - Checking................................................................ 829 Fuel Shutoff Solenoid Removal And Installation.................................................. 829 Fuel Injection Pump Assembly Removal............................................................ 830 Fuel Injection Pump Assembly Installation....................................................... 834 Governor Housing Disassembly And Assembly....................................................... 836 Governor Disassembly And Assembly............................................................... 838 Fuel Camshaft Removal And Installation.......................................................... 840 Fuel Injection Pump Removal..................................................................... 842 Fuel Injection Pump Installation................................................................ 845 Fuel Injection Pump - Timing.................................................................... 849 Fuel Injector Removal And Installation.......................................................... 852 Fuel Injector Nozzle Pressure - Checking........................................................ 853 Nozzle Spraying Condition....................................................................... 854 Valve Seat Tightness............................................................................ 854 CYLINDER HEAD....................................................................................... 855 Intake Air Heater - Testing..................................................................... 855 Intake Air Heater Removal And Installation...................................................... 855 Valve Clearance Adjustment...................................................................... 856 Cylinder Head Removal And Installation.......................................................... 858 Cylinder Head Disassembly And Assembly.......................................................... 860 Cylinder Head - Servicing....................................................................... 860 Cylinder Head Top Clearance..................................................................... 861 Valve Guide - Checking.......................................................................... 862 Reconditioning The Valve And Valve Seat......................................................... 864 Valve Spring.................................................................................... 866 Valve Tappets................................................................................... 867 Rocker Arm And Shaft - Checking................................................................. 868 Push Rod Alignment - Checking................................................................... 868 CRANKSHAFT AND PISTONS.............................................................................. 869 Piston And Connecting Rod Removal And Installation.............................................. 869 Piston And Connecting Rod - Servicing........................................................... 871 Cylinder Bore - Checking........................................................................ 875 Connecting Rod Alignment........................................................................ 876 Crankshaft Gear Removal And Installation........................................................ 876 Crankshaft And Bearings Removal................................................................. 877 Crankshaft And Bearings Installation............................................................ 879 Crankshaft And Bearings - Servicing............................................................. 881 CAMSHAFT AND TIMING GEARS........................................................................... 887 Timing Gearcase Cover Removal And Installation.................................................. 887 Timing Gears Backlash - Checking................................................................ 888 Idler Gear And Camshaft Removal And Installation................................................ 888 Camshaft - Servicing............................................................................ 889 Idler Gear And Shaft - Servicing................................................................ 891 TURBOCHARGER........................................................................................ 893 Description..................................................................................... 893 Testing......................................................................................... 893 Removal And Installation........................................................................ 894 FLYWHEEL AND HOUSING................................................................................ 895 Flywheel Removal And Installation............................................................... 895 Ring Gear Removal And Installation.............................................................. 895 Housing Removal And Installation................................................................ 896 EXHAUST GAS RECIRCULATION (EGR) SYSTEM.............................................................. 897 Description..................................................................................... 897 Testing......................................................................................... 898 Removal And Installation........................................................................ 901 HEATING, VENTILATION, AIR CONDITIONING.................................................................. 903 AIR CONDITIONING SYSTEM FLOW........................................................................ 906 Description..................................................................................... 906 Chart........................................................................................... 907 Components...................................................................................... 908 Safety Equipment................................................................................ 911 REGULAR MAINTENANCE................................................................................. 913 Filters......................................................................................... 913 Compressor Drive Belt Adjustment................................................................ 914 Compressor Drive Belt Replacement............................................................... 914 Condenser....................................................................................... 915 Air Conditioning Lubrication.................................................................... 915 Air Conditioning Service Chart.................................................................. 916 Evaporator / Heater Coil........................................................................ 917 TROUBLESHOOTING..................................................................................... 919 Blower Motor Does Not Operate................................................................... 919 Blower Motor Operates Normally, But Air Flow Is Insufficient.................................... 919 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...................... 919 The Compressor Does Not Operate At All, Or Operates Improperly.................................. 919 Gauge Pressure Related Troubleshooting.......................................................... 920 Troubleshooting Tree............................................................................ 922 Temperature / Pressure Chart.................................................................... 926 Poor A/C Performance............................................................................ 928 HVAC Repair And Leaks........................................................................... 929 Electrical System............................................................................... 930 Engine Coolant Bypassing The Heater Valve....................................................... 937 Heater Valve Not Opening Or Closing............................................................. 938 SYSTEM CHARGING AND RECLAMATION..................................................................... 939 Refrigerant Identification...................................................................... 939 Reclamation And Charging With Recovery / Charging Unit.......................................... 940 Charging With A Manifold Gauge Set.............................................................. 942 COMPRESSOR.......................................................................................... 945 Removal And Installation........................................................................ 945 Oil............................................................................................. 946 Oil Check....................................................................................... 947 Clutch Disassembly And Assembly................................................................. 948 CONDENSER........................................................................................... 953 Removal And Installation........................................................................ 953 RECEIVER / DRIER.................................................................................... 955 Receiver / Drier Removal And Installation....................................................... 955 Pressure Relief Valve Removal And Installation.................................................. 956 Pressure Switch Removal And Installation........................................................ 956 Schraeder Valve Removal And Installation........................................................ 957 EVAPORATOR / HEATER UNIT............................................................................ 959 Removal And Installation........................................................................ 959 THERMOSTAT.......................................................................................... 961 Description..................................................................................... 961 Removal And Installation........................................................................ 962 EXPANSION VALVE..................................................................................... 963 Removal And Installation........................................................................ 963 EVAPORATOR COIL..................................................................................... 965 Removal And Installation........................................................................ 965 HEATER COIL......................................................................................... 967 Removal And Installation With A/C............................................................... 967 Removal And Installation Without A/C............................................................ 969 BLOWER FAN.......................................................................................... 971 Removal And Installation........................................................................ 971 Disassembly And Assembly........................................................................ 972 Connector Identification........................................................................ 974 HEATER VALVE........................................................................................ 975 Removal And Installation........................................................................ 975 Disassembly And Assembly........................................................................ 976 SPECIFICATIONS.......................................................................................... 977 (T250) LOADER SPECIFICATIONS........................................................................ 979 Machine Dimensions.............................................................................. 979 Performance..................................................................................... 980 Hydraulic System................................................................................ 980 Engine.......................................................................................... 981 Controls........................................................................................ 981 Drive System.................................................................................... 981 Electrical...................................................................................... 982 Capacities...................................................................................... 982 Tracks.......................................................................................... 982 Ground Pressure................................................................................. 982 TORQUE SPECIFICATIONS FOR BOLTS..................................................................... 983 Torque For General SAE Bolts.................................................................... 983 Torque For General Metric Bolts................................................................. 984 HYDRAULIC CONNECTION SPECIFICATIONS................................................................. 985 O-ring Face Seal Connection..................................................................... 985 Straight Thread O-ring Fitting.................................................................. 986 Tubelines And Hoses............................................................................. 986 Flare Fitting................................................................................... 987 Port Seal Fitting............................................................................... 988 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS........................................................ 989 Specifications.................................................................................. 989 CONVERSIONS......................................................................................... 991 Decimal And Millimeter Equivalent Chart......................................................... 991 U.S. To Metric Conversion Chart................................................................. 991 ALPHABETICAL INDEX...................................................................................... 993 SERVICE MANUAL REVISION................................................................................. 997 Revision No: T250 - 1............................................................................... 997 Revision No: T250 - 2............................................................................... 999 Revision No: T250 - 3...............................................................................1001 Revision No: T250 - 4...............................................................................1003 Revision No: T250 - 5...............................................................................1005 Revision No: T250 - 6...............................................................................1007 Revision No: T250 - 7...............................................................................1009 Revision No: T250 - 8...............................................................................1011 Revision No: T250 - 9...............................................................................1013 Revision No: T250 - 10..............................................................................1015 Revision No: T250 - 11..............................................................................1017 Revision No: T250 - 12..............................................................................1019
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