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Bobcat T250 Turbo T250 High Flow Loader Service Manual 6902451 (10-12) – PDF DOWNLOAD
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Bobcat T250 Turbo T250 High Flow Loader Service Manual 6902451 (10-12) – PDF DOWNLOAD
S/N 523111001 & Above
S/N 523011001 & Above
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Description
Bobcat T250 Turbo T250 High Flow Loader Service Manual 6902451 (10-12) – PDF DOWNLOAD
FILE DETAILS:
Bobcat T250 Turbo T250 High Flow Loader Service Manual 6902451 (10-12) – PDF DOWNLOAD
Language : English
Pages : 732
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T250 Turbo T250 High Flow Loader Service Manual 6902451 (10-12) – PDF DOWNLOAD
S/N 523111001 & Above
S/N 523011001 & 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 Turbo T250 High Flow Loader Service Manual 6902451 (10-12) – PDF DOWNLOAD
MAINTENANCE SAFETY.................................................................................................... 3 ALPHABETICAL INDEX.................................................................................................... 5 CONTENTS.............................................................................................................. 7 FOREWORD.......................................................................................................... 8 SAFETY INSTRUCTIONS............................................................................................... 11 Fire Prevention............................................................................................... 13 SERIAL NUMBER LOCATION............................................................................................ 15 Loader Serial Number.......................................................................................... 15 Engine Serial Number.......................................................................................... 15 DELIVERY REPORT................................................................................................... 16 BOBCAT LOADER IDENTIFICATION...................................................................................... 17 SAFETY AND MAINTENANCE................................................................................................ 19 LIFTING AND BLOCKING THE LOADER................................................................................... 21 Procedure..................................................................................................... 21 LIFT ARM SUPPORT DEVICE........................................................................................... 23 Engaging The Lift Arm Support Device.......................................................................... 23 Disengaging The Lift Arm Support Device....................................................................... 24 OPERATOR CAB...................................................................................................... 25 Description................................................................................................... 25 Raising The Operator Cab...................................................................................... 25 Lowering The Operator Cab..................................................................................... 26 Emergency Exit................................................................................................ 26 TRANSPORTING THE BOBCAT LOADER.................................................................................... 29 Procedure..................................................................................................... 29 REMOTE START...................................................................................................... 31 Procedure For Loader W/O Attachments Control Harness.......................................................... 31 Procedure For Loader With Attachments Control Harness......................................................... 32 Procedure..................................................................................................... 33 SERVICE SCHEDULE.................................................................................................. 35 Chart......................................................................................................... 35 AIR CLEANER SERVICE............................................................................................... 37 Replacing Filter Element...................................................................................... 37 ENGINE COOLING SYSTEM............................................................................................. 39 Cleaning Cooling System....................................................................................... 39 FUEL SYSTEM....................................................................................................... 41 Fuel Specifications........................................................................................... 41 Filling The Fuel Tank......................................................................................... 41 Fuel Filter................................................................................................... 42 Removing Air From The Fuel System............................................................................. 42 ENGINE LUBRICATION SYSTEM......................................................................................... 43 Checking Engine Oil........................................................................................... 43 Oil Chart..................................................................................................... 43 Replacing Oil And Filter...................................................................................... 43 HYDRAULIC/HYDROSTATIC SYSTEM...................................................................................... 45 Checking And Adding Fluid..................................................................................... 45 Hydraulic/Hydrostatic Filter Replacement...................................................................... 45 Replacing Hydraulic Fluid And Case Drain Filters.............................................................. 46 FAN GEARBOX....................................................................................................... 49 Checking And Adding Oil....................................................................................... 49 BOB-TACH.......................................................................................................... 51 Inspection And Maintenance.................................................................................... 51 POWER BOB-TACH.................................................................................................... 53 Inspection And Maintenance.................................................................................... 53 LUBRICATING THE LOADER............................................................................................ 55 Procedure..................................................................................................... 55 HYDRAULIC SYSTEM...................................................................................................... 57 HYDRAULIC/HYDROSTATIC SCHEMATICS.................................................................................. 61 HYDRAULIC SYSTEM INFORMATION...................................................................................... 65 Troubleshooting............................................................................................... 69 Tightening Procedure.......................................................................................... 70 CYLINDER (LIFT)................................................................................................... 71 Checking...................................................................................................... 71 Removal And Installation...................................................................................... 71 Parts Identification.......................................................................................... 73 Disassembly................................................................................................... 74 Assembly...................................................................................................... 75 CYLINDER (TILT)................................................................................................... 79 Checking...................................................................................................... 79 Removal And Installation...................................................................................... 79 Base Pin Removal And Installation............................................................................. 81 Parts Identification.......................................................................................... 82 Disassembly................................................................................................... 83 Assembly...................................................................................................... 84 CYLINDER (POWER BOB-TACH)......................................................................................... 87 Checking...................................................................................................... 87 Removal And Installation...................................................................................... 88 Parts Identification.......................................................................................... 89 Disassembly................................................................................................... 90 Assembly...................................................................................................... 91 MAIN RELIEF VALVE (FOOT CONTROL).................................................................................. 95 Checking The Main Relief Valve At Front Aux. Hyd.............................................................. 95 Removal And Installation...................................................................................... 96 Adjustment.................................................................................................... 96 MAIN RELIEF VALVE (ACS)........................................................................................... 97 Checking The Main Relief Valve At Front Aux. Hyd.............................................................. 97 Removal And Installation...................................................................................... 98 Adjustment.................................................................................................... 99 HYDRAULIC CONTROL VALVE (FOOT CONTROL)............................................................................101 Removal And Installation......................................................................................101 BICS™ Valve, Removal And Installation.........................................................................105 BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation................................................106 BICS™ Valve, Check Valve Removal And Installation.............................................................107 BICS™ Valve, Lock Valve Removal And Installation..............................................................108 BICS™ Valve, Solenoid Removal And Installation................................................................109 BICS™ Valve, Solenoid Testing.................................................................................110 Identification Chart..........................................................................................111 Load Check Valve..............................................................................................111 Main Relief Valve.............................................................................................112 Port Relief Valve, Tilt Spool.................................................................................113 Port Relief Valve, Lift Spool.................................................................................113 Anti-Cavitation Valve/Port Relief Valve, Tilt Spool...........................................................114 Anti-Cavitation Valve, Lift Spool.............................................................................114 Rubber Boot...................................................................................................115 Lift And Tilt Lock Block......................................................................................115 Lift Spool And Detent Removal.................................................................................116 Tilt Spool Removal And Installation...........................................................................125 Auxiliary Spool Removal And Installation......................................................................127 Auxiliary Plug Removal And Installation.......................................................................129 Auxiliary Electric Solenoid Disassembly.......................................................................130 Port-Auxiliary Section Removal And Installation...............................................................131 Cleaning And Inspection.......................................................................................132 HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)...........................................................133 Actuator Removal And Installation (In Loader).................................................................133 Actuator Removal And Installation (Out Of Loader).............................................................136 Removal And Installation......................................................................................137 BICS™ Valve, Removal And Installation.........................................................................141 BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly................................................143 BICS™ Valve, Check Valve Disassembly And Assembly.............................................................144 BICS™ Valve, Lock Valve Disassembly And Assembly..............................................................145 BICS™ Valve, Solenoid Disassembly And Assembly................................................................146 BICS™ Valve, Solenoid Testing.................................................................................147 Identification Chart..........................................................................................148 Lift Base End Restrictor......................................................................................149 Load Check Valve..............................................................................................149 Main Relief Valve.............................................................................................150 Port Relief Valve.............................................................................................151 Anti-Cavitation Valve/Port Relief Valve.......................................................................152 Anti-Cavitation Valve.........................................................................................153 Lift Spool Removal............................................................................................154 Lift Spool Removal And Installation...........................................................................155 Lift and Tilt Spool Disassembly And Assembly..................................................................156 Auxiliary Spool Removal And Installation......................................................................157 Auxiliary Electric Solenoid Disassembly.......................................................................158 Port-Auxiliary Section Disassembly............................................................................159 Cleaning And Inspection.......................................................................................159 LIFT ARM BY-PASS CONTROL VALVE....................................................................................161 Inspecting....................................................................................................161 Additional Inspection For Loaders W/Advanced Hand Controls....................................................161 Removal And Installation......................................................................................161 Disassembly And Assembly......................................................................................162 HYDRAULIC PUMP....................................................................................................163 Check The Output Of The Hydraulic Pump........................................................................163 Removal And Installation......................................................................................164 Identification................................................................................................166 Disassembly And Assembly......................................................................................167 HYDRAULIC PUMP (CHARGE)...........................................................................................175 Check The Output Of The Hydraulic Pump........................................................................175 Removal and Installation......................................................................................178 Disassembly and Assembly......................................................................................178 HYDRAULIC PUMP (HI FLOW)..........................................................................................179 Hydraulic Pump Test...........................................................................................179 Inline Hydraulic Pump Test (Standard).........................................................................180 Inline Hydraulic Pump Test (High Flow)........................................................................182 High Flow Relief Adjustment Procedure.........................................................................184 High Flow Relief Valve Removal and Installation...............................................................186 Removal And Installation......................................................................................188 Identification................................................................................................190 Disassembly And Assembly......................................................................................191 HYDRAULIC/HYDROSTATIC FILTER......................................................................................205 Housing Removal And Installation..............................................................................205 Mount Removal And Installation................................................................................206 HYDRAULIC FLUID RESERVOIR.........................................................................................207 Fluid Removal.................................................................................................207 Removal And Installation......................................................................................207 Hydraulic Fluid Screen........................................................................................210 BUCKET POSITION VALVE.............................................................................................211 Solenoid Removal And Installation.............................................................................211 Solenoid Testing..............................................................................................211 Removal And Installation......................................................................................212 Disassembly And Assembly......................................................................................212 REAR AUXILIARY DIVERTER...........................................................................................215 Removal and Installation......................................................................................215 Disassembly And Assembly......................................................................................217 Solenoid Testing..............................................................................................222 Inspection....................................................................................................222 POWER BOB-TACH BLOCK (EARLY MODELS)...............................................................................223 Removal And Installation......................................................................................223 Disassembly And Assembly......................................................................................224 POWER BOB-TACH BLOCK..............................................................................................233 Removal And Installation......................................................................................233 Disassembly And Assembly......................................................................................234 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK...........................................................................239 Removal and Installation......................................................................................239 Disassembly And Assembly......................................................................................239 HYDROSTATIC SYSTEM....................................................................................................241 HYDROSTATIC SYSTEM INFORMATION....................................................................................243 Troubleshooting Chart.........................................................................................243 Replenishing Valve Function...................................................................................244 HYDROSTATIC MOTOR.................................................................................................245 Removal And Installation......................................................................................245 Parts Identification..........................................................................................248 Disassembly...................................................................................................250 Inspection....................................................................................................258 Assembly......................................................................................................259 Filling.......................................................................................................267 CHARGE PRESSURE SENDER............................................................................................269 Testing.......................................................................................................269 Removal and Installation......................................................................................270 Setting Charge Pressure.......................................................................................271 HYDROSTATIC PUMP..................................................................................................273 Removal And Installation......................................................................................273 Replenishing/High Pressure Relief Valve.......................................................................275 Parts Identification (Right Half).............................................................................276 Parts Identification (Left Half)..............................................................................278 Hydraulic Pump Removal And Installation.......................................................................280 Pump Separation...............................................................................................280 Disassembly...................................................................................................281 Assembly......................................................................................................287 DRIVE BELT........................................................................................................295 Shield Removal And Installation...............................................................................295 Adjustment....................................................................................................295 Replacement...................................................................................................295 Tensioner Pulley Removal And Installation.....................................................................296 Tensioner Pulley Tension Spring...............................................................................298 OIL COOLER (SEAL TO CONNECT) (STC)................................................................................299 Hydraulic Oil Cooler Removal and Installation.................................................................299 DRIVE SYSTEM..........................................................................................................301 BRAKE.............................................................................................................303 Switch Operated Parking Brake.................................................................................303 Block Removal And Installation................................................................................303 Block Disassembly And Assembly................................................................................304 DRIVE COMPONENTS..................................................................................................305 Track Checking................................................................................................305 Track Adjustment..............................................................................................306 Track Removal And Installation................................................................................307 Track Idler (Front) End Play Specifications...................................................................309 Track Idler (Front) Removal And Installation..................................................................309 Track Idler (Front) Parts Identification......................................................................312 Track Idler (Front) Disassembly...............................................................................313 Track Idler (Front) Assembly..................................................................................314 Track Idler (Rear) End Play Specifications....................................................................317 Track Idler (Rear) Parts Identification.......................................................................317 Track Idler (Rear) Removal And Installation...................................................................317 Track Idler (Rear) Disassembly................................................................................318 Track Idler (Rear) Assembly...................................................................................320 Track Roller Assembly End Play Specifications.................................................................321 Track Roller Parts Identification.............................................................................321 Track Roller Removal And Installation.........................................................................321 Track Roller Disassembly......................................................................................322 Track Roller Assembly.........................................................................................323 Track Housing Removal And Installation........................................................................325 Track Damage Identification...................................................................................326 MAIN FRAME............................................................................................................337 SEAT BAR..........................................................................................................339 Removal And Installation......................................................................................339 Assembling Components.........................................................................................340 Compression Spring Disassembly And Assembly...................................................................341 OPERATOR CAB......................................................................................................343 Gas Cylinder Removal And Installation (Dual Gas Spring).......................................................343 Gas Cylinder Removal And Installation (3rd Gas Spring)........................................................345 Gas Cylinder Bracket Disassembly And Assembly.................................................................347 Removal And Installation......................................................................................347 OPERATOR SEAT.....................................................................................................351 Removal And Installation......................................................................................351 Seat Belt Removal And Installation............................................................................351 OPERATOR SEAT (SUSPENSION)........................................................................................353 Removal And Installation......................................................................................353 Slide Rail Removal And Installation...........................................................................354 Cushion Removal And Installation..............................................................................354 Back Removal And Installation.................................................................................355 Shock Removal And Installation................................................................................356 3-Point Seat Belt Removal And Installation....................................................................357 BOB-TACH..........................................................................................................359 Removal And Installation......................................................................................359 Bob-Tach Lever And Wedge......................................................................................361 POWER BOB-TACH....................................................................................................363 Removal And Installation......................................................................................363 Power Bob-Tach Lever And Wedge................................................................................365 Pivot Pin Bushing And Seal Replacement........................................................................367 LIFT ARMS.........................................................................................................369 Removal And Installation......................................................................................369 REAR GRILL........................................................................................................373 Removal And Installation......................................................................................373 REAR DOOR.........................................................................................................375 Removal And Installation......................................................................................375 Adjusting The Rear Door Latch.................................................................................376 FUEL TANK.........................................................................................................377 Removal And Installation......................................................................................377 Fuel Level Sender.............................................................................................379 CONTROL PEDALS....................................................................................................381 Removal And Installation......................................................................................381 Pedal Adjustment..............................................................................................381 CONTROL PEDALS (ACS)..............................................................................................383 Foot Sensor Removal And Installation..........................................................................383 Foot Pedal Removal And Installation...........................................................................384 Foot Pedal Linkage Disassembly And Assembly...................................................................384 CONTROL PANEL.....................................................................................................385 Removal And Installation......................................................................................385 Shock Removal And Installation................................................................................387 Shaft Removal And Installation................................................................................387 Shaft Disassembly And Assembly................................................................................387 Linkage Removal And Installation..............................................................................389 Linkage Neutral Adjustment....................................................................................392 CONTROL HANDLE....................................................................................................399 Lever Removal And Installation................................................................................399 Steering Lever Boot...........................................................................................399 CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL.......................................401 Components Identification.....................................................................................401 Handle Sensor Removal And Installation........................................................................401 Control Handle Removal And Installation.......................................................................404 Control Handle Disassembly And Assembly.......................................................................405 Control Lever Removal And Installation........................................................................406 Control Lever Boot............................................................................................407 INSIDE ACCESS PANEL...............................................................................................409 Removal And Installation (Left)...............................................................................409 Removal And Installation (Right)..............................................................................409 ELECTRICAL SYSTEM & ANALYSIS..........................................................................................411 ELECTRICAL SCHEMATICS.............................................................................................415 ELECTRICAL SYSTEM INFORMATION.....................................................................................421 Troubleshooting...............................................................................................423 Description...................................................................................................424 Fuse Location.................................................................................................426 Relay Switch Location.........................................................................................426 Solenoid Test.................................................................................................427 BATTERY...........................................................................................................429 Removal And Installation......................................................................................429 Servicing The Electrical System...............................................................................431 Using A Booster Battery (Jump Starting).......................................................................432 ALTERNATOR........................................................................................................433 Adjusting The Alternator Belt.................................................................................433 Alternator Identification.....................................................................................433 Charging System Check.........................................................................................434 Alternator Voltage Test.......................................................................................435 Low Voltage Test..............................................................................................435 High Voltage Test.............................................................................................436 Removal And Installation......................................................................................436 Rectifier Continuity (Diode) Test.............................................................................437 Alternator Regulator Test.....................................................................................438 Disassembly...................................................................................................439 Stator Continuity Test........................................................................................439 Stator Ground Test............................................................................................439 Rotor Continuity Test.........................................................................................440 Rotor Ground Test.............................................................................................440 Assembly......................................................................................................440 STARTER...........................................................................................................441 Removal And Installation......................................................................................441 Parts Identification..........................................................................................442 Checking......................................................................................................443 Disassembly And Assembly......................................................................................444 Inspection And Repair.........................................................................................447 No Load Test..................................................................................................450 INSTRUMENT PANEL..................................................................................................451 Left Panel....................................................................................................451 Right Panel (Standard) (With Key Switch)......................................................................452 Right Panel (Deluxe) (With Keyless Start).....................................................................453 Right Panel Setup Display Options (Deluxe)....................................................................455 Deluxe Panel Setup............................................................................................456 Passwords (Deluxe)............................................................................................456 Option And Field Accessory Panels (If Equipped)...............................................................458 Standard Panel Removal And Installation (Right Side)..........................................................459 Deluxe Panel Removal And Installation (Right Side)............................................................460 Standard & Deluxe Panel Removal And Installation (Left Side)..................................................461 Front Accessory Panel Removal And Installation................................................................462 LIGHTS............................................................................................................463 Front Removal And Installation................................................................................463 Rear Removal And Installation.................................................................................463 BOBCAT CONTROLLER.................................................................................................466 Identification Chart..........................................................................................466 Removal And Installation......................................................................................468 DIAGNOSTICS SERVICE CODES.........................................................................................469 Display.......................................................................................................469 Number Codes List.............................................................................................470 BICS™ SYSTEM......................................................................................................475 Inspecting The BICS™ Controller (Engine STOPPED - Key ON).....................................................475 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)..........................475 Inspecting The Seat Bar Sensor (Engine RUNNING)...............................................................475 Inspecting The Traction Lock (Engine RUNNING).................................................................475 Inspecting The Lift Arm By-Pass Control.......................................................................476 Additional Inspection For Loaders With Advanced Controls System (ACS) or Selectable Joystick Control (SJC)....476 Troubleshooting...............................................................................................477 Troubleshooting Guide.........................................................................................478 SEAT BAR SENSOR...................................................................................................479 Troubleshooting Chart.........................................................................................479 Test..........................................................................................................480 Removal And Installation......................................................................................481 BICS™ Circuit Test............................................................................................482 TRACTION LOCK.....................................................................................................483 Troubleshooting Chart.........................................................................................483 Description Of The Control System.............................................................................484 Inspecting The Control System.................................................................................484 Parking Brake Solenoid Removal And Installation...............................................................485 ADVANCED CONTROL SYSTEM (ACS).....................................................................................487 Components Identification.....................................................................................487 Troubleshooting Guide.........................................................................................489 Controller, Connector And Wire Identification.................................................................490 ACS Controller Removal And Installation.......................................................................491 Handle Sensor Connector.......................................................................................492 Switch Handle Removal.........................................................................................493 Switch Handle Installation....................................................................................495 Actuators Disassembly And Assembly............................................................................498 Handle Lock Solenoid Removal And Installation.................................................................499 Handle Lock Solenoid Disassembly And Assembly.................................................................499 Handle Lock Solenoid Connector................................................................................500 Calibration Of The ACS System.................................................................................500 Switchable Hand/Foot Controls Calibration Procedure...........................................................501 Hand Controls Only Calibration Procedure......................................................................502 Foot Sensor Disassembly And Assembly..........................................................................503 Foot Sensor Connector.........................................................................................504 Foot Lock Solenoid Removal And Installation...................................................................504 Foot Lock Solenoid Connector..................................................................................505 ELECTRICAL/HYDRAULIC CONTROLS REFERENCE...........................................................................507 Controls Identification Chart.................................................................................507 FLYWHEEL RPM SENSOR...............................................................................................509 Adjustment....................................................................................................509 ENGINE SERVICE........................................................................................................511 TROUBLESHOOTING...................................................................................................515 Chart.........................................................................................................515 ENGINE SPEED CONTROL..............................................................................................517 Removal And Installation......................................................................................517 Speed Control Cable...........................................................................................518 MUFFLER...........................................................................................................521 Removal And Installation......................................................................................521 AIR CLEANER.......................................................................................................523 Housing Removal And Installation..............................................................................523 RADIATOR..........................................................................................................525 Removal And Installation......................................................................................525 Mount Removal.................................................................................................527 COOLING FAN.......................................................................................................529 Drive Tension Pulley Removal And Installation.................................................................529 Gearbox/Blower Housing Removal And Installation...............................................................530 Gearbox Parts Identification..................................................................................533 Gearbox Disassembly...........................................................................................534 Gearbox Assembly..............................................................................................539 Gearbox, Checking Backlash....................................................................................544 ENGINE............................................................................................................547 Removal And Installation......................................................................................547 Mount Replacement.............................................................................................554 Removal And Installation Tools................................................................................555 FLYWHEEL AND HOUSING..............................................................................................557 Flywheel Removal And Installation.............................................................................557 Ring Gear Removal And Installation............................................................................557 Flywheel Housing Removal And Installation.....................................................................557 RECONDITIONING THE ENGINE.........................................................................................559 Engine Tools Identification Chart.............................................................................559 Compression Pressure..........................................................................................563 Cylinder Head Clearance.......................................................................................563 Valve Cover And Injector Nozzle Removal And Installation......................................................564 Rocker Arm And Push Rod Disassembly And Assembly..............................................................566 Valve Clearance...............................................................................................566 Cylinder Head And Tappet Disassembly And Assembly.............................................................567 Selecting Cylinder Head Gasket Disassembly And Assembly.......................................................568 Valve Disassembly And Assembly................................................................................569 Engine Timing (TDC)...........................................................................................570 Injection Pump Assembly Removal...............................................................................571 Injection Pump Assembly Installation..........................................................................574 Injection Pump Removal and Installation.......................................................................577 Injection Pump Timing.........................................................................................579 Fan Drive Pulley Disassembly And Assembly.....................................................................582 Water Pump Disassembly And Assembly...........................................................................582 Gearcase Cover Disassembly And Assembly.......................................................................583 Idle Gear And Camshaft Disassembly And Assembly...............................................................583 Gearcase Plate Disassembly And Assembly.......................................................................584 Oil Pan And Oil Strainer Disassembly And Assembly.............................................................584 Connecting Rod Cap Disassembly And Assembly...................................................................585 Piston Disassembly And Assembly...............................................................................586 Piston Ring And Connecting Rod Disassembly And Assembly.......................................................587 Bearing Case Cover Disassembly And Assembly...................................................................589 Flywheel Housing Disassembly And Assembly.....................................................................590 Crankcase No. 2 Disassembly And Assembly......................................................................590 Crankcase No. 1 And No. 2 Disassembly And Assembly............................................................591 Crankshaft Disassembly And Assembly...........................................................................591 Cylinder Head Surface Flatness................................................................................591 Cylinder Head Flaw............................................................................................592 Valve Recessing...............................................................................................592 Valve Lapping.................................................................................................593 Clearance Between Valve Stem And Valve Guide..................................................................593 Replacing Valve Guide.........................................................................................594 Correcting Valve And Valve Seat...............................................................................594 Free Length And Tilt Of Valve Spring..........................................................................595 Valve Spring Setting Load.....................................................................................595 Oil Clearance Between Rocker Arm Shaft And Bearing............................................................596 Oil Clearance Between Tappet And Tappet Guide Bore............................................................596 Timing Gear Backlash..........................................................................................597 Idler Gear Side Clearance.....................................................................................597 Camshaft Side Clearance.......................................................................................598 Camshaft Alignment............................................................................................598 Cam Height....................................................................................................598 Oil Clearance Between Idler Gear Shaft And Idler Gearing Bushing..............................................599 Replacing Idler Gear Bushing..................................................................................600 Piston Pin Bore I.D...........................................................................................601 Oil Clearance Between Piston Pin And Small End Bushing........................................................601 Replacing Small End Bushing...................................................................................602 Clearance Between Piston Ring And Groove......................................................................602 Piston Ring Gap...............................................................................................603 Connecting Rod Alignment......................................................................................603 Crankshaft Side Clearance.....................................................................................604 Crankshaft Alignment..........................................................................................605 Oil Clearance Between Crankpin And Crankpin Bearing...........................................................605 Oil Clearance Between Crankshaft Journal And Crankshaft Bearing...............................................607 Replacing Crankshaft Sleeve...................................................................................608 Cylinder Bore I.D.............................................................................................608 Correcting Cylinder (Oversize +0.5 mm)........................................................................609 Engine Oil Pressure...........................................................................................609 Rotor Lobe Clearance..........................................................................................610 Clearance Between Outer Rotor And Pump Body...................................................................610 Thermostat Valve Opening Temperature..........................................................................610 Radiator Water Leakage........................................................................................611 Radiator Cap Air Leakage......................................................................................611 Thermostat Assembly...........................................................................................611 Intake Air Heater.............................................................................................612 Checking the Turbo Charger....................................................................................613 Compressor Side...............................................................................................613 Wheel Shaft...................................................................................................613 Axial Clearance...............................................................................................614 Radial Clearance..............................................................................................614 Air Cleaner, Intake Pipe, Inlet Pipe And Muffler..............................................................614 Oil Pipe......................................................................................................615 HEATING, VENTILATION, AIR CONDITIONING................................................................................617 AIR CONDITIONING SYSTEM FLOW......................................................................................620 Principals....................................................................................................620 Chart.........................................................................................................621 COMPONENTS........................................................................................................623 Identification................................................................................................623 SAFETY............................................................................................................627 Safety Equipment..............................................................................................627 REGULAR MAINTENANCE...............................................................................................629 Filter Elements Removal And Installation......................................................................629 Compressor Drive Belt Inspection..............................................................................630 Cleaning The Condenser........................................................................................631 BASIC TROUBLESHOOTING.............................................................................................633 Poor A/C Performance..........................................................................................633 Cleaning The A/C Evaporator Coil & Heater Coil................................................................634 Compressor Drive Belt Inspection..............................................................................634 Checking The Electrical System................................................................................635 Engine Coolant By-Passing The Heater Valve....................................................................643 Heater Valve Not Opening Or Closing...........................................................................644 GENERAL AIR CONDITIONING SERVICE GUIDELINES.......................................................................645 Compressor Oil................................................................................................645 Compressor Oil Check..........................................................................................646 Component Replacement And Refrigeration Leaks.................................................................647 SYSTEM TROUBLESHOOTING CHART......................................................................................649 Gauge Pressure Related Troubleshooting........................................................................650 Troubleshooting Tree..........................................................................................652 TEMPERATURE/PRESSURE..............................................................................................657 Chart.........................................................................................................657 AIR CONDITIONING SERVICE..........................................................................................659 Chart.........................................................................................................659 SYSTEM CHARGING AND RECLAMATION...................................................................................661 Reclamation Procedure.........................................................................................661 Charging Procedure With A Manifold Gauge Set..................................................................663 Charging Procedure............................................................................................664 COMPRESSOR........................................................................................................667 Removal And Installation......................................................................................667 Compressor Clutch Disassembly.................................................................................668 CONDENSER.........................................................................................................673 Removal And Installation......................................................................................673 RECEIVER/DRIER....................................................................................................675 Removal And Installation......................................................................................675 PRESSURE RELIEF VALVE.............................................................................................677 Removal And Installation......................................................................................677 PRESSURE SWITCH...................................................................................................679 Removal And Installation......................................................................................679 EVAPORATOR/HEATER UNIT............................................................................................681 Removal And Installation......................................................................................681 Disassembly And Assembly......................................................................................682 THERMOSTAT........................................................................................................683 Removal And Installation......................................................................................683 EXPANSION VALVE...................................................................................................685 Removal And Installation......................................................................................685 EVAPORATOR........................................................................................................687 Removal And Installation......................................................................................687 HEATER COIL.......................................................................................................689 Removal And Installation With A/C.............................................................................689 Removal And Installation Without A/C..........................................................................690 BLOWER FAN........................................................................................................691 Removal And Installation......................................................................................691 Disassembly And Assembly......................................................................................692 Wire Connector Removal and Installation.......................................................................694 HEATER VALVE......................................................................................................697 Removal and Installation......................................................................................697 Disassembly And Assembly......................................................................................698 SPECIFICATIONS........................................................................................................701 LOADER SPECIFICATIONS (T250)......................................................................................703 Machine Dimensions............................................................................................703 Performance...................................................................................................704 Controls......................................................................................................704 Engine........................................................................................................704 Hydraulic System..............................................................................................705 Electrical....................................................................................................705 Drive System..................................................................................................706 Capacities....................................................................................................706 Tracks........................................................................................................706 ENGINE SPECIFICATIONS.............................................................................................707 General.......................................................................................................707 Fuel System...................................................................................................707 Valve And Valve Timing........................................................................................707 Valve Spring..................................................................................................708 Piston And Piston Ring........................................................................................708 Connecting Rod................................................................................................708 Cylinder Head.................................................................................................709 Crankshaft....................................................................................................709 Cylinder Bore.................................................................................................709 Oil Pump......................................................................................................709 Rocker Arm....................................................................................................710 Tappet........................................................................................................710 Camshaft......................................................................................................710 Thermostat....................................................................................................710 Timing Gear...................................................................................................711 Intake Air Heater.............................................................................................711 TORQUE SPECIFICATIONS FOR BOLTS...................................................................................713 Torque For General SAE Bolts..................................................................................713 Torque For General Metric Bolts...............................................................................714 Torque For Kubota Metric Engine Bolts.........................................................................715 Tightening Torques For General Use Screws, Bolts And Nuts.....................................................715 HYDRAULIC CONNECTION SPECIFICATIONS...............................................................................717 O-ring Face Seal Connection...................................................................................717 Straight Thread O-ring Fitting................................................................................718 Tubelines And Hoses...........................................................................................718 Flare Fitting.................................................................................................718 O-ring Flare Fitting..........................................................................................719 Port Seal Fitting.............................................................................................721 HYDRAULIC FLUID SPECIFICATIONS....................................................................................723 Specifications................................................................................................723 CONVERSIONS.......................................................................................................725 Decimal And Millimeter Equivalents............................................................................725 SMR...................................................................................................................727 T250-1............................................................................................................727 T250-2............................................................................................................729 T250-3............................................................................................................731
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V
