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Bobcat T250 Turbo T250 Turbo High Flow Loader Service Manual 6902724 (6-12) – PDF DOWNLOAD
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Bobcat T250 Turbo T250 Turbo High Flow Loader Service Manual 6902724 (6-12) – PDF DOWNLOAD
S/N 525611001 & Above
S/N 525711001 & Above
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Description
Bobcat T250 Turbo T250 Turbo High Flow Loader Service Manual 6902724 (6-12) – PDF DOWNLOAD
FILE DETAILS:
Bobcat T250 Turbo T250 Turbo High Flow Loader Service Manual 6902724 (6-12) – PDF DOWNLOAD
Language : English
Pages : 1066
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T250 Turbo T250 Turbo High Flow Loader Service Manual 6902724 (6-12) – PDF DOWNLOAD
S/N 525611001 & Above
S/N 525711001 & 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 Turbo High Flow Loader Service Manual 6902724 (6-12) – 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 TOWING THE LOADER................................................................................................. 31 Procedure..................................................................................................... 31 REMOTE START...................................................................................................... 33 Procedure For Loader W/O Attachments Control Harness.......................................................... 33 Procedure For Loader With Attachments Control Harness......................................................... 34 Procedure..................................................................................................... 35 SERVICE SCHEDULE.................................................................................................. 37 Chart......................................................................................................... 37 AIR CLEANER SERVICE............................................................................................... 39 Replacing Filter Element...................................................................................... 39 ENGINE COOLING SYSTEM............................................................................................. 41 Cleaning Cooling System....................................................................................... 41 Checking The Coolant Level.................................................................................... 43 Adding The Coolant............................................................................................ 44 FUEL SYSTEM....................................................................................................... 45 Fuel Specifications........................................................................................... 45 Filling The Fuel Tank......................................................................................... 45 Fuel Filter................................................................................................... 46 Removing Air From The Fuel System............................................................................. 46 ENGINE LUBRICATION SYSTEM......................................................................................... 47 Checking Engine Oil........................................................................................... 47 Oil Chart..................................................................................................... 47 Replacing Oil And Filter...................................................................................... 47 HYDRAULIC/HYDROSTATIC SYSTEM...................................................................................... 49 Checking And Adding Fluid..................................................................................... 49 Hydraulic Fluid Chart......................................................................................... 49 Hydraulic/Hydrostatic Filter Replacement...................................................................... 50 Replacing Hydraulic Fluid And Case Drain Filters.............................................................. 51 FAN GEARBOX....................................................................................................... 53 Checking And Adding Oil....................................................................................... 53 BOB-TACH.......................................................................................................... 55 Inspection And Maintenance.................................................................................... 55 POWER BOB-TACH.................................................................................................... 57 Inspection And Maintenance.................................................................................... 57 LUBRICATING THE LOADER............................................................................................ 59 Procedure..................................................................................................... 59 HYDRAULIC SYSTEM...................................................................................................... 61 HYDRAULIC/HYDROSTATIC SCHEMATICS.................................................................................. 67 HYDRAULIC SYSTEM INFORMATION...................................................................................... 83 Troubleshooting............................................................................................... 87 Tightening Procedure.......................................................................................... 88 CYLINDER (LIFT)................................................................................................... 89 Checking...................................................................................................... 89 Removal And Installation...................................................................................... 89 Parts Identification.......................................................................................... 91 Disassembly................................................................................................... 92 Assembly...................................................................................................... 93 CYLINDER (TILT)................................................................................................... 97 Checking...................................................................................................... 97 Removal And Installation...................................................................................... 97 Base Pin Removal And Installation............................................................................. 99 Parts Identification.......................................................................................... 100 Disassembly................................................................................................... 101 Assembly...................................................................................................... 102 CYLINDER (POWER BOB-TACH)......................................................................................... 105 Checking...................................................................................................... 105 Removal And Installation...................................................................................... 106 Parts Identification.......................................................................................... 107 Disassembly................................................................................................... 108 Assembly...................................................................................................... 109 MAIN RELIEF VALVE................................................................................................. 113 Checking Main Relief.......................................................................................... 113 Adjustment.................................................................................................... 115 Removal And Installation...................................................................................... 116 HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL).......................................................... 117 Identification................................................................................................ 117 Removal And Installation...................................................................................... 117 BICS™ Valve, Removal And Installation......................................................................... 121 BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation................................................ 123 BICS™ Valve, Check Valve Removal And Installation............................................................. 124 Backslide, Lock Valve Removal And Installation................................................................ 125 BICS™ Valve, Solenoid Removal And Installation................................................................ 126 BICS™ Valve, Solenoid Testing................................................................................. 127 Identification Chart.......................................................................................... 128 Load Check Valve.............................................................................................. 129 Main Relief Valve............................................................................................. 130 Port Relief Valve, Tilt Spool................................................................................. 130 Port Relief Valve, Lift Spool................................................................................. 131 Anti-Cavitation Valve/Port Relief Valve, Tilt Spool........................................................... 131 Anti-Cavitation Valve, Lift Spool............................................................................. 132 Rubber Boot................................................................................................... 132 Lift And Tilt Lock Block...................................................................................... 133 Lift Spool And Detent Removal................................................................................. 134 Lift Spool And Detent Disassembly............................................................................. 136 Lift Spool And Detent Assembly................................................................................ 139 Lift Spool And Detent Installation............................................................................ 143 Tilt Spool Removal And Installation........................................................................... 144 Tilt Spool Disassembly And Assembly........................................................................... 145 Auxiliary Spool Removal And Installation...................................................................... 146 Auxiliary Plug Removal And Installation....................................................................... 148 Auxiliary Electric Solenoid Disassembly....................................................................... 149 Port-Auxiliary Section Removal And Installation............................................................... 150 Cleaning And Inspection....................................................................................... 150 HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)......................................... 151 Identification................................................................................................ 151 Actuator Removal And Installation (In Loader)................................................................. 152 Actuator Removal And Installation (Out Of Loader)............................................................. 154 Removal And Installation...................................................................................... 156 BICS™ Valve, Removal And Installation......................................................................... 160 BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly................................................ 163 BICS™ Valve, Check Valve Disassembly And Assembly............................................................. 164 BICS™ Valve, Lock Valve Disassembly And Assembly.............................................................. 165 BICS™ Valve, Solenoid Disassembly And Assembly................................................................ 166 BICS™ Valve, Solenoid Testing................................................................................. 167 Identification Chart.......................................................................................... 168 Lift Base End Restrictor...................................................................................... 169 Load Check Valve.............................................................................................. 170 Main Relief Valve............................................................................................. 171 Port Relief Valve............................................................................................. 173 Anti-Cavitation Valve/Port Relief Valve....................................................................... 174 Anti-Cavitation Valve......................................................................................... 175 Lift Spool Removal............................................................................................ 176 Lift Spool Removal And Installation........................................................................... 177 Lift And Tilt Spool Disassembly And Assembly.................................................................. 178 Auxiliary Spool Removal And Installation...................................................................... 179 Auxiliary Electric Solenoid Disassembly....................................................................... 180 Port-Auxiliary Section Disassembly............................................................................ 181 Cleaning And Inspection....................................................................................... 181 HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (selectable joystick control) (sjc)..................................... 183 Identification................................................................................................ 183 Actuator Removal And Installation (In Loader)................................................................. 184 Actuator Removal And Installation (Out Of Loader)............................................................. 186 Actuator Removal And Installation (Out Of Loader) (Cont’d).................................................... 187 Removal And Installation...................................................................................... 188 BICS™ Valve, Removal And Installation......................................................................... 192 BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly................................................ 195 BICS™ Valve, Check Valve Disassembly And Assembly............................................................. 196 BICS™ Valve, Lock Valve Disassembly And Assembly.............................................................. 197 BICS™ Valve, Solenoid Disassembly And Assembly................................................................ 198 BICS™ Valve, Solenoid Testing................................................................................. 199 Identification Chart.......................................................................................... 200 Lift Base End Restrictor...................................................................................... 201 Load Check Valve.............................................................................................. 202 Main Relief Valve............................................................................................. 203 Port Relief Valve............................................................................................. 205 Anti-Cavitation Valve/Port Relief Valve....................................................................... 206 Anti-Cavitation Valve......................................................................................... 207 Lift Spool Removal............................................................................................ 208 Lift Spool Removal And Installation........................................................................... 209 Lift And Tilt Spool Disassembly And Assembly.................................................................. 210 Auxiliary Spool Removal And Installation...................................................................... 211 Auxiliary Electric Solenoid Disassembly....................................................................... 212 Port-Auxiliary Section Disassembly............................................................................ 213 Cleaning And Inspection....................................................................................... 213 hYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL).......................................................... 215 Identification................................................................................................ 215 Removal And Installation...................................................................................... 215 Identification Chart.......................................................................................... 219 BICS™ Valve, Lift Load Check Valve Removal And Installation................................................... 220 Load Check Valve Removal And Installation (Tilt & Auxiliary).................................................. 221 Anti-Cavitation Valve (Lift, Rod End)......................................................................... 221 Port Relief/Anti-Cavitation Valve (Lift, Base End)............................................................ 222 Port Relief/Anti-Cavitation Valve (Tilt, Base End)............................................................ 223 Port Relief/Anti-Cavitation Valve (Tilt, Rod End)............................................................. 223 Port Relief Valve............................................................................................. 224 Plug Removal.................................................................................................. 225 Rubber Boot Removal and Installation.......................................................................... 226 End Cap/Spool Lock Block Removal and Installation............................................................. 227 Lift Spool and Detent Removal and Installation................................................................ 228 Auxiliary Spool Removal And Installation...................................................................... 240 Auxiliary Solenoid Disassembly and Assembly................................................................... 242 BICS™ Valve Solenoid Disassembly And Assembly................................................................. 243 BICS™ Valve, Lock Valve Removal And Installation.............................................................. 244 BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly................................................ 246 Main Relief Valve............................................................................................. 247 BICS™ Valve, Check Valve Removal and Installation............................................................. 248 HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)......................................... 249 Identification................................................................................................ 249 Removal And Installation...................................................................................... 250 Actuator Removal And Installation (In Loader)................................................................. 254 Actuator Removal And Installation (Out of Loader)............................................................. 256 Identification Chart.......................................................................................... 259 BICS™ Valve, Lift Load Check Valve Removal And Installation................................................... 260 Load Check Valve Removal And Installation (Tilt & Auxiliary).................................................. 261 Anti-Cavitation Valve (Lift, Rod End)......................................................................... 261 Port Relief/Anti-Cavitation Valve (Lift, Base End)............................................................ 262 Port Relief/Anti-Cavitation Valve (Tilt, Base End)............................................................ 263 Port Relief/Anti-Cavitation Valve (Tilt, Rod End)............................................................. 263 Port Relief Valve............................................................................................. 264 Plug Removal.................................................................................................. 265 End Cap Block Removal And Installation........................................................................ 266 Lift Spool Removal And Installation........................................................................... 267 Tilt Spool Removal And Installation........................................................................... 271 Auxiliary Spool Removal And Installation...................................................................... 273 Auxiliary Solenoid Disassembly And Assembly................................................................... 275 BICS™ Valve Solenoid Disassembly And Assembly................................................................. 276 BICS™ Valve, Lock Valve Removal And Installation.............................................................. 277 BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly................................................ 279 Main Relief Valve............................................................................................. 279 BICS™ Valve, Check Valve Removal And Installation............................................................. 280 HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (SELECTABLE JOYSTICK CONTROL) (SJC)..................................... 281 Identification................................................................................................ 281 Removal And Installation...................................................................................... 282 Actuator Removal And Installation (In Loader)................................................................. 286 Actuator Removal And Installation (Out of Loader)............................................................. 288 Identification Chart.......................................................................................... 291 BICS™ Valve, Lift Load Check Valve Removal And Installation................................................... 292 Load Check Valve Removal And Installation (Tilt & Auxiliary).................................................. 293 Anti-Cavitation Valve (Lift, Rod End)......................................................................... 293 Port Relief/Anti-Cavitation Valve (Lift, Base End)............................................................ 294 Port Relief/Anti-Cavitation Valve (Tilt, Base End)............................................................ 295 Port Relief/Anti-Cavitation Valve (Tilt, Rod End)............................................................. 295 Port Relief Valve............................................................................................. 296 Plug Removal.................................................................................................. 297 End Cap Block Removal And Installation........................................................................ 298 Lift Spool Removal And Installation........................................................................... 299 Tilt Spool Removal And Installation........................................................................... 303 Auxiliary Spool Removal And Installation...................................................................... 305 Auxiliary Solenoid Disassembly And Assembly................................................................... 307 BICS™ Valve Solenoid Disassembly And Assembly................................................................. 308 BICS™ Valve, Lock Valve Removal And Installation.............................................................. 309 BICS™ Valve, Check Valve Removal And Installation............................................................. 311 BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly................................................ 312 Main Relief Valve............................................................................................. 312 LIFT ARM BY-PASS CONTROL VALVE.................................................................................... 313 Inspecting.................................................................................................... 313 Additional Inspection For Loaders W/Advanced Hand Controls.................................................... 313 Removal And Installation...................................................................................... 313 Disassembly And Assembly...................................................................................... 314 HYDRAULIC PUMP.................................................................................................... 315 Check The Output Of The Hydraulic Pump........................................................................ 315 Removal And Installation...................................................................................... 316 Identification................................................................................................ 318 Disassembly And Assembly...................................................................................... 319 HYDRAULIC PUMP (CHARGE)........................................................................................... 327 Check The Output Of The Hydraulic Pump........................................................................ 327 Removal And Installation...................................................................................... 330 Disassembly And Assembly...................................................................................... 330 HYDRAULIC PUMP (HIGH FLOW)........................................................................................ 331 Hydraulic Pump Test (30 GPM).................................................................................. 331 Hydraulic Pump Test (40 GPM).................................................................................. 332 Inline Hydraulic Pump Test (Standard)......................................................................... 333 Inline Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM).................................................... 335 High Flow Relief Adjustment Procedure (30 GPM And 40 GPM)..................................................... 337 High Flow Relief Valve Removal And Installation (30 GPM And 40 GPM)........................................... 339 Removal And Installation (30 GPM And 40 GPM).................................................................. 340 Identification (30 GPM) (S/N 525613399 & Below)............................................................... 342 Identification (40 GPM) (S/N 525613400 & Above)............................................................... 343 Disassembly And Assembly (30 GPM And 40 GPM).................................................................. 344 HYDRAULIC PUMP (SLECTABLE JOYSTICK CONTROL) (SJC)................................................................. 357 Check The Output Of The Hydraulic Pump........................................................................ 357 Removal And Installation...................................................................................... 358 Identification................................................................................................ 360 Disassembly And Assembly...................................................................................... 361 HYDRAULIC PUMP (HIGH FLOW) (SELECTABLE JOYSTICK CONTROL) (SJC).................................................... 367 Hydraulic Pump Test (30 GPM).................................................................................. 367 Hydraulic Pump Test (40 GPM).................................................................................. 368 Inline Hydraulic Pump Test (Standard)......................................................................... 369 Inline Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM).................................................... 371 High Flow Relief Adjustment Procedure (30 GPM And 40 GPM)..................................................... 373 High Flow Relief Valve Removal And Installation (30 GPM And 40 GPM)........................................... 375 Removal And Installation (30 GPM And 40 GPM).................................................................. 376 Identification (30 GPM) (S/N 525613399 & Below)............................................................... 378 Identification (40 GPM) (S/N 525613400 & Above)............................................................... 379 Disassembly And Assembly (30 GPM And 40 GPM).................................................................. 380 HYDRAULIC/HYDROSTATIC FILTER...................................................................................... 389 Housing Removal And Installation.............................................................................. 389 Mount Removal And Installation................................................................................ 390 HYDRAULIC FLUID RESERVOIR......................................................................................... 391 Fluid Removal................................................................................................. 391 Removal And Installation...................................................................................... 391 Hydraulic Fluid Screen........................................................................................ 394 BUCKET POSITION VALVE............................................................................................. 395 Solenoid Removal And Installation............................................................................. 395 Solenoid Testing.............................................................................................. 395 Removal And Installation...................................................................................... 396 Disassembly And Assembly...................................................................................... 396 REAR AUXILIARY DIVERTER........................................................................................... 399 Removal And Installation...................................................................................... 399 Disassembly And Assembly...................................................................................... 401 Solenoid Testing.............................................................................................. 406 Inspection.................................................................................................... 406 POWER BOB-TACH BLOCK.............................................................................................. 407 Removal And Installation...................................................................................... 407 Disassembly And Assembly...................................................................................... 408 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK........................................................................... 413 Removal and Installation...................................................................................... 413 Disassembly And Assembly...................................................................................... 413 HYDROSTATIC SYSTEM.................................................................................................... 415 HYDROSTATIC SYSTEM INFORMATION.................................................................................... 417 Troubleshooting Chart......................................................................................... 417 Replenishing Valve Function................................................................................... 418 HYDROSTATIC MOTOR................................................................................................. 419 Removal And Installation...................................................................................... 419 Parts Identification.......................................................................................... 422 Disassembly................................................................................................... 424 Inspection.................................................................................................... 432 Assembly...................................................................................................... 433 Filling....................................................................................................... 441 HYDROSTATIC MOTOR (SELECTABLE JOYSTICK CONTROL) (SJC)............................................................. 443 Removal And Installation...................................................................................... 443 Parts Identification.......................................................................................... 446 Disassembly................................................................................................... 448 Inspection.................................................................................................... 457 Assembly...................................................................................................... 458 Filling....................................................................................................... 467 CHARGE PRESSURE................................................................................................... 469 Testing....................................................................................................... 469 Removal And Installation...................................................................................... 471 Setting Charge Pressure....................................................................................... 472 HYDROSTATIC PUMP.................................................................................................. 473 Removal And Installation...................................................................................... 473 Replenishing/High Pressure Relief Valve....................................................................... 475 Parts Identification (Right Half)............................................................................. 476 Parts Identification (Left Half).............................................................................. 478 Hydraulic Pump Removal And Installation....................................................................... 480 Pump Separation............................................................................................... 480 Disassembly................................................................................................... 481 Assembly...................................................................................................... 487 HYDROSTATIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC).............................................................. 495 Pump Controller Removal And Installation...................................................................... 495 Hydrostatic Pump Calibration.................................................................................. 498 Removal And Installation...................................................................................... 503 Parts Identification (Right Half)............................................................................. 505 Parts Identification (Left Half).............................................................................. 507 System Check Relief Valves (High Pressure Relief, Charge Check & By-Pass Valve)............................... 509 Charge Relief Valve........................................................................................... 510 Pump Separation............................................................................................... 512 Shaft Seal And Shaft Replacement.............................................................................. 513 Shaft Seal And Shaft Installation............................................................................. 515 Charge Pump Removal........................................................................................... 517 Charge Pump Inspection........................................................................................ 519 Charge Pump Installation...................................................................................... 520 Disassembly................................................................................................... 522 Inspection.................................................................................................... 529 Assembly...................................................................................................... 533 Pump Neutral Adjustment....................................................................................... 542 Pump Controller Neutral Adjustment............................................................................ 545 DRIVE BELT........................................................................................................ 549 Shield Removal And Installation............................................................................... 549 Adjustment.................................................................................................... 549 Replacement................................................................................................... 549 Tensioner Pulley Removal And Installation..................................................................... 550 Tensioner Pulley Tension Spring............................................................................... 552 OIL COOLER (SEAL TO CONNECT) (STC)................................................................................ 553 Hydraulic Oil Cooler Removal And Installation................................................................. 553 DRIVE SYSTEM.......................................................................................................... 555 BRAKE............................................................................................................. 557 Switch Operated Parking Brake................................................................................. 557 Block Removal And Installation................................................................................ 557 Block Disassembly And Assembly................................................................................ 558 DRIVE COMPONENTS.................................................................................................. 559 Track Checking................................................................................................ 559 Track Adjustment.............................................................................................. 560 Track Removal And Installation................................................................................ 561 Track Idler (Front) End Play Specifications................................................................... 563 Track Idler (Front) Removal And Installation.................................................................. 563 Track Idler (Front) Parts Identification (Early Version)...................................................... 566 Track Idler (Front) Identification............................................................................ 567 Track Idler (Front) Disassembly (Early Version)............................................................... 568 Track Idler (Front) Assembly (Early Version).................................................................. 569 Track Idler (Rear) End Play Specifications.................................................................... 572 Track Idler (Rear) Parts Identification (Early Version)....................................................... 572 Track Idler (Rear) Removal And Installation................................................................... 572 Track Idler (Rear) Identification............................................................................. 573 Track Idler (Rear) Disassembly (Early Version)................................................................ 574 Track Idler (Rear) Assembly (Early Version)................................................................... 576 Track Roller Assembly End Play Specifications................................................................. 577 Track Roller Parts Identification (Early Version)............................................................. 577 Track Roller Removal And Installation......................................................................... 577 Track Roller Identification................................................................................... 578 Track Roller Disassembly (Early Version)...................................................................... 579 Track Roller Assembly (Early Version)......................................................................... 580 Track Housing Removal And Installation........................................................................ 582 Track Damage Identification................................................................................... 583 MAIN FRAME............................................................................................................ 593 SEAT BAR.......................................................................................................... 595 Removal And Installation...................................................................................... 595 Assembling Components......................................................................................... 596 Compression Spring Disassembly And Assembly................................................................... 597 OPERATOR CAB...................................................................................................... 599 Gas Cylinder Removal And Installation (Dual Gas Spring)....................................................... 599 Gas Cylinder Removal And Installation (3rd Gas Spring)........................................................ 601 Gas Cylinder Bracket Disassembly And Assembly................................................................. 603 Removal And Installation...................................................................................... 603 OPERATOR SEAT..................................................................................................... 607 Removal And Installation...................................................................................... 607 Slide Rail Removal And Installation........................................................................... 608 Seat Belt Removal And Installation............................................................................ 608 Cushion Removal And Installation.............................................................................. 609 Back Removal And Installation................................................................................. 610 Shock Removal And Installation................................................................................ 610 3-Point Seat Belt Removal And Installation.................................................................... 611 BOB-TACH.......................................................................................................... 613 Removal And Installation...................................................................................... 613 Bob-Tach Lever And Wedge...................................................................................... 615 POWER BOB-TACH.................................................................................................... 617 Removal And Installation...................................................................................... 617 Power Bob-Tach Lever And Wedge................................................................................ 619 Pivot Pin Bushing And Seal Replacement........................................................................ 621 LIFT ARMS......................................................................................................... 623 Removal And Installation...................................................................................... 623 REAR GRILL........................................................................................................ 627 Removal And Installation...................................................................................... 627 REAR DOOR......................................................................................................... 629 Removal And Installation...................................................................................... 629 Striker Removal And Installation.............................................................................. 630 Striker Disassembly And Assembly.............................................................................. 630 Door Latch And Catch Adjustment............................................................................... 630 Latch Removal And Installation................................................................................ 631 FUEL TANK......................................................................................................... 633 Removal And Installation...................................................................................... 633 Fuel Level Sender............................................................................................. 635 CONTROL PEDALS.................................................................................................... 637 Removal And Installation...................................................................................... 637 Pedal Adjustment.............................................................................................. 637 CONTROL PEDALS (ACS).............................................................................................. 639 Foot Sensor Removal And Installation.......................................................................... 639 Foot Pedal Removal And Installation........................................................................... 640 Foot Pedal Linkage Disassembly And Assembly................................................................... 640 CONTROL PANEL (NON-ADJUSTABLE PINTLES)............................................................................ 641 Removal And Installation...................................................................................... 641 Shock Removal And Installation................................................................................ 643 Shaft Removal And Installation................................................................................ 643 Shaft Disassembly And Assembly................................................................................ 643 Linkage Removal And Installation.............................................................................. 645 Linkage Neutral Adjustment.................................................................................... 648 CONTROL PANEL (ADJUSTABLE PINTLES)................................................................................ 655 Description................................................................................................... 655 Removal And Installation...................................................................................... 656 Shock Removal And Installation................................................................................ 658 Shaft Removal And Installation................................................................................ 658 Shaft Disassembly And Assembly................................................................................ 659 Linkage Removal And Installation.............................................................................. 660 Pintle Arm Disassembly and Assembly........................................................................... 665 Linkage Neutral Adjustment.................................................................................... 666 Linkage Travel Adjustment..................................................................................... 670 CONTROL PANEL (SELECTABLE JOYSTICK CONTROL) (SJC)................................................................. 675 Removal And Installation...................................................................................... 675 CONTROL HANDLE.................................................................................................... 679 Lever Removal And Installation................................................................................ 679 Steering Lever Boot........................................................................................... 679 CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL....................................... 681 Components Identification..................................................................................... 681 Handle Sensor Removal And Installation........................................................................ 681 Control Handle Removal And Installation....................................................................... 684 Control Handle Disassembly And Assembly....................................................................... 685 Control Lever Removal And Installation........................................................................ 686 Control Lever Boot............................................................................................ 687 CONTROL HANDLE (SELECTABLE JOYSTICK CONTROL) (SJC)................................................................ 689 Joystick Testing (Right & Left)............................................................................... 689 Joystick Removal (Right & Left)............................................................................... 690 Joystick Boot Removal (Right & Left).......................................................................... 691 Lever Assembly Removal (Right & Left)......................................................................... 691 INSIDE ACCESS PANEL............................................................................................... 693 Removal And Installation (Left)............................................................................... 693 Removal And Installation (Right).............................................................................. 693 INSIDE ACCESS PANEL (SELECTABLE JOYSTICK CONTROL) (SJC)........................................................... 695 Panel Removal (Right)......................................................................................... 695 Panel Removal (Left).......................................................................................... 698 ELECTRICAL SYSTEM & ANALYSIS.......................................................................................... 699 ELECTRICAL SCHEMATICS............................................................................................. 703 ELECTRICAL SYSTEM INFORMATION..................................................................................... 711 Troubleshooting............................................................................................... 713 Description................................................................................................... 714 Fuse Location................................................................................................. 716 Relay Switch Location......................................................................................... 716 Solenoid Test................................................................................................. 717 BATTERY........................................................................................................... 719 Removal And Installation...................................................................................... 719 Servicing The Electrical System............................................................................... 721 Using A Booster Battery (Jump Starting)....................................................................... 722 ALTERNATOR........................................................................................................ 723 Adjusting The Alternator Belt................................................................................. 723 Alternator Identification..................................................................................... 723 Charging System Check......................................................................................... 724 Alternator Voltage Test....................................................................................... 725 Low Voltage Test.............................................................................................. 725 High Voltage Test............................................................................................. 726 Removal And Installation...................................................................................... 726 Rectifier Continuity (Diode) Test............................................................................. 727 Alternator Regulator Test..................................................................................... 728 Disassembly................................................................................................... 729 Stator Continuity Test........................................................................................ 729 Stator Ground Test............................................................................................ 729 Rotor Continuity Test......................................................................................... 730 Rotor Ground Test............................................................................................. 730 Assembly...................................................................................................... 730 STARTER........................................................................................................... 731 Checking...................................................................................................... 731 Removal And Installation...................................................................................... 732 Parts Identification.......................................................................................... 733 Disassembly And Assembly...................................................................................... 734 Inspection And Repair......................................................................................... 737 No Load Test.................................................................................................. 740 INSTRUMENT PANEL.................................................................................................. 741 Left Panel.................................................................................................... 741 Right Panel (Standard) (With Key Switch)...................................................................... 742 Right Panel (Deluxe) (With Keyless Start)..................................................................... 743 Right Panel Setup Display Options (Deluxe).................................................................... 745 Deluxe Panel Setup............................................................................................ 746 Passwords (Deluxe)............................................................................................ 746 Option And Field Accessory Panels (If Equipped)............................................................... 748 Standard Panel Removal And Installation (Right Side).......................................................... 749 Deluxe Panel Removal And Installation (Right Side)............................................................ 750 Standard & Deluxe Panel Removal And Installation (Left Side).................................................. 751 Front Accessory Panel Removal And Installation................................................................ 752 LIGHTS............................................................................................................ 753 Front Removal And Installation................................................................................ 753 Rear Removal And Installation................................................................................. 753 BOBCAT CONTROLLER................................................................................................. 756 Identification Chart.......................................................................................... 756 Removal And Installation...................................................................................... 758 CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC).................................................................... 759 Removal....................................................................................................... 759 Identification Chart.......................................................................................... 762 SPEED SENSOR (SELECTABLE JOYSTICK CONTROL) (SJC).................................................................. 765 Testing....................................................................................................... 765 Removal....................................................................................................... 766 DIAGNOSTICS SERVICE CODES......................................................................................... 769 Display....................................................................................................... 769 Number Codes List............................................................................................. 770 BICS™ SYSTEM...................................................................................................... 775 Inspecting The BICS™ Controller (Engine STOPPED - Key ON)..................................................... 775 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON).......................... 775 Inspecting The Seat Bar Sensor (Engine RUNNING)............................................................... 775 Inspecting The Traction Lock (Engine RUNNING)................................................................. 775 Inspecting The Lift Arm By-Pass Control....................................................................... 776 Additional Inspection For Loaders With Advanced Controls System (ACS) or Selectable Joystick Control (SJC).... 776 Troubleshooting............................................................................................... 777 Troubleshooting Guide......................................................................................... 778 SEAT BAR SENSOR................................................................................................... 779 Troubleshooting Chart......................................................................................... 779 Test.......................................................................................................... 780 Removal And Installation...................................................................................... 781 BICS™ Circuit Test............................................................................................ 782 TRACTION LOCK..................................................................................................... 783 Troubleshooting Chart......................................................................................... 783 Description Of The Control System............................................................................. 784 Inspecting The Control System................................................................................. 784 Parking Brake Solenoid Removal And Installation............................................................... 785 ADVANCED CONTROL SYSTEM (ACS)..................................................................................... 787 Components Identification..................................................................................... 787 Troubleshooting Guide......................................................................................... 789 Controller, Connector And Wire Identification................................................................. 790 ACS Controller Removal And Installation....................................................................... 791 Handle Sensor Connector....................................................................................... 792 Switch Handle Removal......................................................................................... 793 Switch Handle Installation.................................................................................... 795 Actuators Disassembly And Assembly............................................................................ 798 Handle Lock Solenoid Removal And Installation................................................................. 799 Handle Lock Solenoid Disassembly And Assembly................................................................. 800 Handle Lock Solenoid Connector................................................................................ 800 Foot Sensor Disassembly And Assembly.......................................................................... 801 Foot Sensor Connector......................................................................................... 802 Foot Lock Solenoid Removal And Installation................................................................... 803 Foot Lock Solenoid Connector.................................................................................. 804 ELECTRICAL/HYDRAULIC CONTROLS REFERENCE........................................................................... 805 Controls Identification Chart................................................................................. 805 ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (selectable JOYstick control) (sjc)....................................... 807 Controls Identification Chart................................................................................. 807 SERVICE PC (LAPTOP COMPUTER)...................................................................................... 811 Connecting The Service PC To Remote Start Tool................................................................ 811 CALIBRATION....................................................................................................... 813 Lift And Tilt Calibration Procedure (Selectable Joystick Control) (SJC)....................................... 813 Hydrostatic Pump Calibration (Selectable Joystick Control) (SJC).............................................. 815 Calibration Procedure (Advanced Control System) (ACS)......................................................... 820 FLYWHEEL RPM SENSOR............................................................................................... 823 Adjustment.................................................................................................... 823 ENGINE SERVICE........................................................................................................ 825 TROUBLESHOOTING................................................................................................... 829 Chart......................................................................................................... 829 ENGINE SPEED CONTROL.............................................................................................. 831 Removal And Installation...................................................................................... 831 Speed Control Cable........................................................................................... 832 ENGINE SPEED CONTROL (SELECTABLE JOYSTICK CONTROL) (SJC).......................................................... 835 Removal....................................................................................................... 835 Disassembly................................................................................................... 837 Speed Control Cable........................................................................................... 838 MUFFLER........................................................................................................... 839 Removal And Installation...................................................................................... 839 AIR CLEANER....................................................................................................... 841 Housing Removal And Installation.............................................................................. 841 RADIATOR.......................................................................................................... 843 Removal And Installation...................................................................................... 843 Mount Removal (Early Loaders)................................................................................. 845 Mount Removal (Later Loaders)................................................................................. 845 COOLING FAN....................................................................................................... 847 Drive Tension Pulley Removal And Installation................................................................. 847 Gearbox/Blower Housing Removal And Installation............................................................... 848 Blower Removal And Installation............................................................................... 849 Gearbox Parts Identification.................................................................................. 851 Gearbox Disassembly........................................................................................... 852 Gearbox Assembly.............................................................................................. 857 Gearbox, Checking Backlash.................................................................................... 862 ENGINE............................................................................................................ 865 Removal And Installation...................................................................................... 865 Mount Replacement............................................................................................. 872 Removal And Installation Tools................................................................................ 873 FLYWHEEL AND HOUSING.............................................................................................. 875 Flywheel Removal And Installation............................................................................. 875 Ring Gear Removal And Installation............................................................................ 875 Flywheel Housing Removal And Installation..................................................................... 875 RECONDITIONING THE ENGINE......................................................................................... 877 Engine Tools Identification Chart............................................................................. 877 Compression Pressure.......................................................................................... 882 Cylinder Head Clearance....................................................................................... 882 Valve Cover, Injector Nozzle And Seal Removal And Installation................................................ 883 Checking Nozzle Injection Pressure............................................................................ 885 Nozzle Spraying Condition..................................................................................... 886 Valve Seat Tightness.......................................................................................... 886 Rocker Arm And Push Rod Disassembly And Assembly.............................................................. 887 Valve Clearance............................................................................................... 887 Cylinder Head And Tappet Disassembly And Assembly............................................................. 888 Selecting Cylinder Head Gasket Disassembly And Assembly....................................................... 889 Valve Disassembly And Assembly................................................................................ 891 Engine Timing (TDC)........................................................................................... 891 Injection Pump Housing Removal................................................................................ 892 Injection Pump Governor Housing Removal And Installation...................................................... 895 Injection Pump Governor Fork Lever Removal And Installation................................................... 897 Injection Pump Governor Lever Removal And Installation........................................................ 897 Injection Pump Stop Lever Removal And Installation............................................................ 898 Injection Pump Fuel Camshaft And Governor Weight Removal And Installation..................................... 898 Injection Pump Removal and Installation....................................................................... 900 Injection Pump Housing Installation........................................................................... 907 Injection Pump Timing......................................................................................... 910 Fan Drive Pulley Disassembly And Assembly..................................................................... 912 Water Pump Disassembly And Assembly........................................................................... 913 Oil Cooler And Water Pipe Disassembly And Assembly............................................................ 913 Gearcase Cover Disassembly And Assembly....................................................................... 914 Idle Gear And Camshaft Disassembly And Assembly............................................................... 915 Oil Pan And Oil Strainer Disassembly And Assembly............................................................. 915 Connecting Rod Cap Disassembly And Assembly................................................................... 916 Piston Disassembly And Assembly............................................................................... 916 Piston Ring And Connecting Rod Disassembly And Assembly....................................................... 917 Flywheel And Crankshaft Disassembly And Assembly.............................................................. 918 Bearing Case Cover Disassembly And Assembly................................................................... 919 Flywheel Housing Disassembly And Assembly..................................................................... 920 Crankcase No. 2 Disassembly And Assembly...................................................................... 920 Crankcase No. 1 And No. 2 Disassembly And Assembly............................................................ 921 Crankshaft Disassembly And Assembly........................................................................... 921 Cylinder Head Surface Flatness................................................................................ 922 Cylinder Head Flaw............................................................................................ 923 Valve Recessing............................................................................................... 923 Valve Lapping................................................................................................. 924 Clearance Between Valve Stem And Valve Guide.................................................................. 924 Replacing Valve Guide......................................................................................... 925 Correcting Valve And Valve Seat............................................................................... 925 Free Length And Tilt Of Valve Spring.......................................................................... 926 Valve Spring Setting Load..................................................................................... 926 Oil Clearance Between Rocker Arm Shaft And Bearing............................................................ 927 Oil Clearance Between Tappet And Tappet Guide Bore............................................................ 927 Timing Gear Backlash.......................................................................................... 928 Idler Gear Side Clearance..................................................................................... 928 Camshaft Side Clearance....................................................................................... 929 Camshaft Alignment............................................................................................ 929 Cam Height.................................................................................................... 929 Oil Clearance Between Idler Gear Shaft And Idler Gearing Bushing.............................................. 930 Replacing Idler Gear Bushing.................................................................................. 931 Piston Pin Bore I.D........................................................................................... 932 Oil Clearance Between Piston Pin And Small End Bushing........................................................ 932 Replacing Small End Bushing................................................................................... 933 Clearance Between Piston Ring And Groove...................................................................... 933 Piston Ring Gap............................................................................................... 934 Connecting Rod Alignment...................................................................................... 934 Crankshaft Side Clearance..................................................................................... 935 Crankshaft Alignment.......................................................................................... 936 Oil Clearance Between Crankpin And Crankpin Bearing........................................................... 936 Oil Clearance Between Crankshaft Journal And Crankshaft Bearing............................................... 938 Replacing Crankshaft Sleeve................................................................................... 939 Cylinder Bore I.D............................................................................................. 939 Correcting Cylinder (Oversize +0.5 mm)........................................................................ 940 Engine Oil Pressure........................................................................................... 940 Rotor Lobe Clearance.......................................................................................... 941 Clearance Between Outer Rotor And Pump Body................................................................... 941 Clearance Between Rotor And Cover............................................................................. 941 Relief Valve.................................................................................................. 942 Thermostat Valve Opening Temperature.......................................................................... 942 Radiator Water Leakage........................................................................................ 942 Radiator Cap Air Leakage...................................................................................... 943 Thermostat Assembly........................................................................................... 943 Intake Air Heater............................................................................................. 944 Air Cleaner, Intake Pipe, Inlet Pipe And Muffler.............................................................. 945 Oil Pipe...................................................................................................... 945 Turbocharger.................................................................................................. 946 HEATING, VENTILATION, AIR CONDITIONING................................................................................ 947 AIR CONDITIONING SYSTEM FLOW...................................................................................... 950 Principals.................................................................................................... 950 Chart......................................................................................................... 951 COMPONENTS........................................................................................................ 953 Identification................................................................................................ 953 SAFETY............................................................................................................ 957 Safety Equipment.............................................................................................. 957 REGULAR MAINTENANCE............................................................................................... 959 Filter Elements Removal And Installation...................................................................... 959 Compressor Drive Belt Inspection.............................................................................. 960 Cleaning The Condenser........................................................................................ 961 BASIC TROUBLESHOOTING............................................................................................. 963 Poor A/C Performance.......................................................................................... 963 Cleaning The A/C Evaporator Coil & Heater Coil................................................................ 964 Compressor Drive Belt Inspection.............................................................................. 964 Checking The Electrical System................................................................................ 965 Engine Coolant By-Passing The Heater Valve.................................................................... 973 Heater Valve Not Opening Or Closing........................................................................... 974 GENERAL AIR CONDITIONING SERVICE GUIDELINES....................................................................... 975 Compressor Oil................................................................................................ 975 Compressor Oil Check.......................................................................................... 976 Component Replacement And Refrigeration Leaks................................................................. 977 SYSTEM TROUBLESHOOTING CHART...................................................................................... 979 Gauge Pressure Related Troubleshooting........................................................................ 980 Troubleshooting Tree.......................................................................................... 982 TEMPERATURE/PRESSURE.............................................................................................. 987 Chart......................................................................................................... 987 AIR CONDITIONING SERVICE.......................................................................................... 989 Chart......................................................................................................... 989 SYSTEM CHARGING AND RECLAMATION................................................................................... 991 Reclamation Procedure......................................................................................... 991 Charging Procedure With A Manifold Gauge Set.................................................................. 993 Charging Procedure............................................................................................ 994 COMPRESSOR........................................................................................................ 997 Removal And Installation...................................................................................... 997 Compressor Clutch Disassembly................................................................................. 998 CONDENSER.........................................................................................................1003 Removal And Installation......................................................................................1003 RECEIVER/DRIER....................................................................................................1005 Removal And Installation......................................................................................1005 PRESSURE RELIEF VALVE.............................................................................................1007 Removal And Installation......................................................................................1007 PRESSURE SWITCH...................................................................................................1009 Removal And Installation......................................................................................1009 EVAPORATOR/HEATER UNIT............................................................................................1011 Removal And Installation......................................................................................1011 Disassembly And Assembly......................................................................................1012 THERMOSTAT........................................................................................................1013 Removal And Installation......................................................................................1013 EXPANSION VALVE...................................................................................................1015 Removal And Installation......................................................................................1015 EVAPORATOR........................................................................................................1017 Removal And Installation......................................................................................1017 HEATER COIL.......................................................................................................1019 Removal And Installation With A/C.............................................................................1019 Removal And Installation Without A/C..........................................................................1020 BLOWER FAN........................................................................................................1021 Removal And Installation......................................................................................1021 Disassembly And Assembly......................................................................................1022 Wire Connector Removal and Installation.......................................................................1024 HEATER VALVE......................................................................................................1027 Removal and Installation......................................................................................1027 Disassembly And Assembly......................................................................................1028 SPECIFICATIONS........................................................................................................1031 LOADER SPECIFICATIONS (T250)......................................................................................1033 Machine Dimensions............................................................................................1033 Performance...................................................................................................1034 Controls......................................................................................................1034 Engine........................................................................................................1034 Hydraulic System..............................................................................................1035 Electrical....................................................................................................1036 Drive System..................................................................................................1036 Capacities....................................................................................................1036 Tracks........................................................................................................1036 ENGINE SPECIFICATIONS.............................................................................................1037 General.......................................................................................................1037 Fuel System...................................................................................................1037 Valve And Valve Timing........................................................................................1037 Valve Spring..................................................................................................1038 Piston And Piston Ring........................................................................................1038 Connecting Rod................................................................................................1038 Cylinder Head.................................................................................................1039 Crankshaft....................................................................................................1039 Cylinder Bore.................................................................................................1039 Oil Pump......................................................................................................1039 Rocker Arm....................................................................................................1040 Tappet........................................................................................................1040 Camshaft......................................................................................................1040 Thermostat....................................................................................................1040 Timing Gear...................................................................................................1041 Intake Air Heater.............................................................................................1041 Turbocharger Compressor Shaft.................................................................................1041 TORQUE SPECIFICATIONS FOR BOLTS...................................................................................1043 Torque For General SAE Bolts..................................................................................1043 Torque For General Metric Bolts...............................................................................1044 Torque For Kubota Metric Engine Bolts.........................................................................1045 Tightening Torques For General Use Screws, Bolts And Nuts.....................................................1045 HYDRAULIC CONNECTION SPECIFICATIONS...............................................................................1047 O-ring Face Seal Connection...................................................................................1047 Straight Thread O-ring Fitting................................................................................1048 Tubelines And Hoses...........................................................................................1048 Flare Fitting.................................................................................................1048 O-ring Flare Fitting..........................................................................................1049 Port Seal Fitting.............................................................................................1051 HYDRAULIC FLUID SPECIFICATIONS....................................................................................1053 Specifications................................................................................................1053 CONVERSIONS.......................................................................................................1055 Decimal And Millimeter Equivalents............................................................................1055 SMR...................................................................................................................1057 T250-1............................................................................................................1057 T250-2............................................................................................................1059 T250-3............................................................................................................1061 T250-4............................................................................................................1063 T250-5 ...........................................................................................................1065
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