Bobcat S250, S300 Skid-Steer Loader Repair Service Manual – 6904158

(S/N: 530911001 & Above – S/N: 531011001 & Above – S/N: 531111001 & Above – S/N: 531211001 & Above)
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This workshop repair service manual PDF download for the S250, S300 Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

Bobcat Loader S250, S300
S/N: 530911001 & Above
S/N: 531011001 & Above
S/N: 531111001 & Above
S/N: 531211001 & Above

TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
SERIAL NUMBER LOCATION
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE
HEATING, VENTILATION, AIR CONDITIONING
SPECIFICATIONS
SERVICE MANUAL REVISION

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6904158 (3-09)
Total Pages : 1019

This Bobcat Skid-Steer Loader Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrestor Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATION
Loader Serial Number
Engine Serial Number
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION

SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE LOADER
Procedure
LIFT ARM SUPPORT DEVICE
Installing
Removing
OPERATOR CAB
Description
Raising
Lowering
Cab Door Sensor
Special Applications Kit Inspection And Maintenance
TRANSPORTING THE LOADER ON A TRAILER
Loading And Unloading
Fastening
TOWING THE LOADER
Procedure
REMOTE START TOOL KIT-MEL1563
Remote Start Tool – MEL1563
Service Tool Harness Control – MEL1565
Service Tool Harness Communicator – MEL1566
Remote Start Procedure
REMOTE START TOOL (SERVICE TOOL) KIT – 6689779
Description
Remote Start Tool (Service Tool) – 6689778
Loader Service Tool Harness – 6689747
Computer Service Tool Harness – 6689746
Remote Start Procedure
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Replacing Filter Elements
ENGINE COOLING SYSTEM
Cleaning
Removing And Replacing Coolant
Checking Level
FUEL SYSTEM
Fuel Specifications
Biodiesel Blend Fuel
Filling The Fuel Tank
Fuel Filter
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Engine Oil Chart
Removing And Replacing Oil And Filter
HYDRAULIC / HYDROSTATIC SYSTEM
Checking And Adding Fluid
Hydraulic / Hydrostatic Fluid Chart
Removing And Replacing Hydraulic Fluid
Removing And Replacing Hydraulic / Hydrostatic Filter
Removing And Replacing Case Drain Filters
Removing And Replacing Hydraulic Charge Filter
Breather Cap
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
Removing And Replacing Oil
BOB-TACH (HAND LEVER)
Inspection And Maintenance
BOB-TACH (POWER)
Inspection And Maintenance
LUBRICATING THE LOADER
Lubrication Locations
TIRE MAINTENANCE
Wheel Nuts
Rotating
Mounting
SPARK ARRESTOR MUFFLER
Cleaning Procedure
PIVOT PINS
Inspection And Maintenance
LOADER STORAGE AND RETURN TO SERVICE
Storage
Return to Service
STOPPING THE ENGINE AND LEAVING THE LOADER
Procedure
Emergency Exit

HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
Troubleshooting
CYLINDER (LIFT)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (TILT)
Testing
Removal And Installation
Base End Pivot Pin Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (BOB-TACH)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
MAIN RELIEF VALVE
Description
Testing
Adjusting
Removal And Installation
HYDRAULIC CONTROL VALVE (STANDARD)
Description
Removal And Installation
Identification Chart
Mount Bracket Removal And Installation
Lift Load Check Valve Removal And Installation
Load Check Valve Removal And Installation (Tilt & Auxiliary)
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)
Port Relief Valve Removal And Installation
Plug Removal And Installation
Rubber Boot Removal And Installation
End Cap Block Removal And Installation
Lift Spool And Detent Removal And Installation
Tilt Spool Removal And Installation
Auxiliary Spool Removal And Installation
Auxiliary Solenoid Removal And Installation
Solenoid Removal And Installation
Lock Valve Removal And Installation
Lift Arm By-Pass Orifice Removal And Installation
Main Relief Valve Removal And Installation
Check Valve Removal And Installation
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
Description
Removal And Installation
Actuator Removal And Installation (In Loader)
Actuator Removal And Installation (Out Of Loader)
Identification Chart
Mount Bracket Removal And Installation
Lift Load Check Valve Removal And Installation
Load Check Valve Removal And Installation (Tilt & Auxiliary)
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)
Port Relief Valve Removal And Installation
Plug Removal And Installation
End Cap Block Removal And Installation
Lift Spool And Detent Removal And Installation
Tilt Spool Removal And Installation
Auxiliary Spool Removal And Installation
Auxiliary Solenoid Removal And Installation
Solenoid Removal And Installation
Lock Valve Removal And Installation
Lift Arm By-Pass Orifice Removal And Installation
Main Relief Valve Removal And Installation
Check Valve Removal And Installation
LIFT ARM BYPASS CONTROL VALVE
Description
Testing
Removal And Installation
Disassembly And Assembly
HYDRAULIC PUMP (STANDARD)
Description
Pump Test at Quick Couplers
Direct Pump Test (Standard Section)
Direct Pump Test (Charge Section)
Removal And Installation
Hydraulic Pump Start Up
Parts Identification
Disassembly And Assembly
HYDRAULIC PUMP (STANDARD) (HIGH FLOW)
Description
Pump Test At Quick Couplers
Direct Pump Test (Standard Section)
Direct Pump Test (Charge Section)
Direct Pump Test (High Flow Section)
High Flow Relief Valve Adjustment
High Flow Relief Valve Removal And Installation
Solenoid Removal And Installation
Removal And Installation
Hydraulic Pump Start Up
Parts Identification
Disassembly And Assembly
HYDRAULIC PUMP (SJC)
Description
Pump Test At Quick Couplers
Direct Pump Test (Standard Section)
Direct Pump Test (Charge Section)
Removal And Installation
Hydraulic Pump Start Up
Parts Identification
Disassembly And Assembly
HYDRAULIC PUMP (SJC) (HIGH FLOW)
Description
Pump Test At Quick Couplers
Direct Pump Test (Standard Section)
Direct Pump Test (Charge Section)
Direct Pump Test (High Flow Section)
High Flow Relief Valve Adjustment
High Flow Relief Valve Removal And Installation
Solenoid Removal And Installation
Removal And Installation
Hydraulic Pump Start Up
Parts Identification
Disassembly And Assembly
HYDRAULIC/HYDROSTATIC FILTERS
Description
Housing Removal And Installation
Charge Filter Housing Removal And Installation
HYDRAULIC FLUID RESERVOIR
Description
Removal And Installation
Hydraulic Fluid Screen
OIL COOLER
Description
Removal And Installation
BUCKET POSITION VALVE
Description
Solenoid Removal And Installation
Solenoid Testing
Removal And Installation
Disassembly And Assembly
REAR AUXILIARY DIVERTER VALVE
Description
Solenoid Testing
Removal And Installation
Disassembly And Assembly
BOB-TACH (POWER) BLOCK
Description
Removal And Installation
Disassembly And Assembly
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
Description
Removal and Installation
Disassembly And Assembly

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting
Description
HYDROSTATIC MOTOR
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
HYDROSTATIC MOTOR (TWO-SPEED)
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
HYDROSTATIC MOTOR CARRIER
Description
Removal and Installation
Parts Identification
Disassembly
Assembly
HYDROSTATIC MOTOR CARRIER (SJC)
Description
Removal and Installation
Parts Identification
Disassembly
Assembly
CHARGE PRESSURE
Description
Testing
Sender Removal And Installation
Adjusting
HYDROSTATIC PUMP
Description
Removal And Installation
Hydrostatic Pump Start Up
Replenishing / High Pressure Relief Valve Removal And Installation
Parts Identification (Left Half)
Parts Identification (Right Half)
Disassembly
Assembly
HYDROSTATIC PUMP (SJC)
Description
Hydraulic Controller Removal And Installation
Removal And Installation
Hydrostatic Pump Start Up
Parts Identification
High Pressure Relief And By-Pass Valve
Charge Relief Valve
Disassembly And Assembly
Mechanical Neutral Adjustment
Hydraulic Controller Neutral Adjustment
DRIVE BELT
Description
Drive Belt Shield Removal And Installation
Adjusting
Belt Removal And Installation
Tensioner Pulley Removal And Installation
Tensioner Pulley Tension Spring Removal And Installation
CASE DRAIN FILTER
Description
Disassembly And Assembly

DRIVE SYSTEM
BRAKE (S/N 530917348 & BELOW, 531012023 & BELOW, 531116712 & BELOW AND 531211918 & BELOW)
Description
Disc Removal And Installation
BRAKE (S/N 530917349 & ABOVE, 531012024 & ABOVE, 531116713 & ABOVE AND 531211919 & ABOVE)
Description
Disc Removal And Installation
BRAKE (TWO-SPEED)
Description
Block Removal And Installation
Block Disassembly And Assembly
DRIVE COMPONENTS
Description
Axle Seal Removal And Installation
Axle, Sprocket And Bearings Removal And Installation
Chain Removal And Installation
CHAINCASE
Description
Front Cover Removal And Installation
Center Cover Removal And Installation
Rear Cover Removal And Installation

MAIN FRAME
SEAT BAR
Description
Removal And Installation
Disassembly And Assembly
Compression Spring Disassembly And Assembly
OPERATOR CAB
Gas Cylinder Removal And Installation
Gas Cylinder Bracket Disassembly And Assembly
Removal And Installation
OPERATOR SEAT
Removal And Installation
Seat Belt Removal And Installation
OPERATOR SEAT (SUSPENSION)
Removal And Installation
Slide Rail Removal And Installation
Seat Belt Removal And Installation
Cushion Removal And Installation
Back Removal And Installation
Shock Removal And Installation
3-Point Seat Belt Removal And Installation
BOB-TACH (HAND LEVER)
Description
Removal And Installation
Lever And Wedge Disassembly And Assembly
Pivot Pin Bushing And Seal Removal And Installation
BOB-TACH (POWER – OPTION)
Description
Removal And Installation
Lever And Wedge Disassembly And Assembly
Pivot Pin Bushing And Seal Removal And Installation
LIFT ARMS
Stabilizer Bar Removal And Installation
Link Removal And Installation
Removal And Installation
REAR GRILL
Removal And Installation
REAR DOOR
Removal And Installation
Striker Removal And Installation
Striker Disassembly And Assembly
Striker (Adjusting)
Latch Removal And Installation
FUEL TANK
Removal And Installation
Fuel Level Sender Removal And Installation
Fuel Fill Screen Removal And Installation
CONTROL PEDALS AND LINKAGES
Description
Pedal Removal And Installation
Linkage Removal And Installation
Pedal (Adjusting)
CONTROL PEDALS (ACS)
Description
Foot Sensor Removal And Installation
Foot Pedal Removal And Installation
Foot Pedal Linkage Disassembly And Assembly
CONTROL PANEL (S/N 531011925 & BELOW, 530917134 & BELOW, 531116513 & BELOW, AND 531211869 & BELOW)
Description
Removal And Installation
Shock Removal And Installation
Shaft Removal And Installation
Shaft Disassembly And Assembly
Linkage Removal And Installation
Pintle Arm Disassembly and Assembly
Linkage Neutral (Adjusting)
Linkage Travel (Adjusting)
CONTROL PANEL (S/N 531011926 & ABOVE, 530917135 & ABOVE, 531116514 & ABOVE, AND 531211870 & ABOVE)
Description
Removal And Installation
Shock Removal And Installation
Shaft Removal And Installation
Linkage Removal And Installation
Pintle Arm Disassembly and Assembly
Linkage Neutral (Adjusting)
Linkage Travel (Adjusting)
CONTROL PANEL (S/N 531011925 & BELOW, 530917134 & BELOW, 531116513 & BELOW, AND 531211869 & BELOW) (SJC)
Description
Removal And Installation
CONTROL PANEL (S/N 531011926 & ABOVE, 530917135 & ABOVE, 531116514 & ABOVE, AND 531211870 & ABOVE) (SJC)
Description
Removal And Installation
CONTROL HANDLE / LEVER
Description
Lever Removal And Installation
Boot Removal And Installation
CONTROL HANDLE / LEVER (ACS)
Description
Handle Sensor Removal And Installation
Handle Removal And Installation
Handle Disassembly And Assembly
Lever Removal And Installation
Boot Removal And Installation
JOYSTICK CONTROL
Description (Earlier Models And Later Models)
Testing (Earlier Models And Later Models)
Removal And Installation (Earlier Models)
Removal And Installation (Later Models)
Boot Removal And Installation (Earlier Models)
Joystick Mount Removal And Installation (Earlier Models)
Joystick Mount Removal And Installation (Earlier Models) (Cont’d)
Joystick Mount Removal And Installation (Later Models)
ACCESS PANEL (INSIDE)
Removal And Installation (Left)
Removal And Installation (Right)
ACCESS PANEL (INSIDE) (SJC)
Removal And Installation (Left)
Removal And Installation (Right)
WINDOW (REAR)
Removal
Installation
WINDOW (TOP)
Removal And Installation
WINDOW (SIDE)
Removal And Installation
WINDOW (FRONT DOOR)
Removal (Standard Window)
Installation (Standard Window)
Removal And Installation (Special Applications Window)
CAB DOOR
Description
Removal And Installation
Aligning
Adjusting
Checking Operation

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Cab Harness Connectors
Mainframe Harness Connectors
Troubleshooting
Description
Fuse And Relay Location / Identification
Solenoid Testing
BATTERY
Servicing
Using A Booster Battery (Jump Starting)
Removal And Installation
ALTERNATOR
Belt Adjustment
Belt Replacement
Charging System Inspection
Alternator Voltage Testing
Low Voltage Testing
High Voltage Testing
Removal And Installation
Parts Identification
STARTER
Testing
Removal And Installation
Parts Identification
INSTRUMENT PANELS
Left Panel
Right Panel (Key Switch)
Right Panel (Keyless)
Side And Front Panels
Removal And Installation (Left And Right)
Bulb Removal And Installation (Left Only)
Key Switch Removal And Installation
Alarm Removal And Installation
Front Panel Removal And Installation
LIGHTS
Front Removal And Installation
Rear Removal And Installation
Cab Light Removal And Installation
BOBCAT CONTROLLER (MAIN)
Description
Connector Identification
Removal And Installation
BOBCAT CONTROLLER (ACS)
Description
Connector And Wire Identification
Removal And Installation
BOBCAT CONTROLLER (SJC) (DRIVE)
Description
Connector Identification
Removal And Installation
SPEED SENSOR (SJC)
Description
Testing
Removal And Installation
DIAGNOSTIC SERVICE CODES
Viewing Service Codes (Key Switch)
Viewing Service Codes (Keyless)
Service Codes List
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)
Description
Inspecting The BICS Controller (Engine Stopped – Key ON)
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
Inspecting The Seat Bar Sensor (Engine RUNNING)
Inspecting The Traction Lock (Engine RUNNING)
Inspecting The Lift Arm Bypass Control
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)
Troubleshooting
Troubleshooting Chart
SEAT BAR SENSOR
Description
Troubleshooting
Testing
Removal And Installation
Bobcat Interlock Control System (BICS) Circuit Test
TRACTION LOCK
Description
Troubleshooting
Removal And Installation (Single Speed)
Inspecting (Single and Two Speed)
CONTROL SYSTEM (ACS)
Description
Troubleshooting Chart
Handle Sensor Connector Disassembly And Assembly
Switch Handle Removal
Switch Handle Installation
Actuator Connector Disassembly And Assembly
Handle Lock Solenoid Removal And Installation
Handle Lock Solenoid Disassembly And Assembly
Foot Sensor Disassembly And Assembly
Foot Lock Solenoid Removal And Installation
ELECTRICAL / HYDRAULIC CONTROLS
Identification Chart
ELECTRICAL / HYDRAULIC CONTROLS (SJC)
Identification Chart
SERVICE PC (LAPTOP COMPUTER)
Connecting Remote Start Tool
Connecting Remote Start Tool (Service Tool)
CALIBRATION
Description
Actuator Testing
Lift And Tilt Calibration (ACS)
Lift And Tilt Calibration (SJC)
Hydrostatic Pump Calibration (SJC)
STEERING DRIFT COMPENSATION
Description
Selecting And Adjusting
Exiting And Saving
FLYWHEEL RPM SENSOR
Description
Adjustment
CONTROL PANEL SETUP
Right Panel Setup (Keyless)
Attachment Control Information (Keyless)
PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START)
Password Description
Changing The Owner Password
Changing The User Passwords
Password Lockout Feature
MAINTENANCE CLOCK
Description
Setup
Reset
BACK-UP ALARM SYSTEM
Description
Inspecting
Adjusting Switch Position
Troubleshooting (Standard And ACS)
Troubleshooting (Joystick)
Alarm Removal And Installation
Switch Removal And Installation

ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications
Torque Values
Troubleshooting
Engine Removal And Installation
Engine Mount Replacement
Compression -Checking
ENGINE SPEED CONTROL
Removal And Installation
Cable Removal And Installation
ENGINE SPEED CONTROL (SJC)
Removal And Installation
Disassembly And Assembly
Speed Control Cable Removal And Installation
MUFFLER
Removal And Installation
AIR CLEANER
Housing Removal And Installation
ENGINE COOLING SYSTEM
Radiator Removal And Installation (S/N 530915315 & Below, 531011742 & Below, 531115050 & Below, 531211660 & Below)
Radiator Removal And Installation (S/N 530915316 & Above, 531011743 & Above, 531115051 & Above, 531211661 & Above)
Radiator Mount Removal And Installation
Hydraulic Fan Motor Description (S/N 530915315 & Below, 531011742 & Below, 531115050 & Below, 531211660 & Below)
Blower Housing Removal And Installation (S/N 530915315 & Below, 531011742 & Below, 531115050 & Below, 531211660 & Below)
Fan Removal And Installation (S/N 530915315 & Below, 531011742 & Below, 531115050 & Below, 531211660 & Below)
Hydraulic Fan Motor Removal And Installation (S/N 530915315 & Below, 531011742 & Below, 531115050 & Below, 531211660 & Below)
Hydraulic Fan Motor Disassembly And Assembly (S/ N 530915315 & Below, 531011742 & Below, 531115050 & Below, 531211660 & Below)
Hydraulic Fan Motor Description (S/N 530915316 – 530940000, 531011743 – 531040000, 531115051 – 531140000, 531211661 – 531240000)
Axial Fan Housing Removal And Installation (S/N 530915316 – 530940000, 531011743 – 531040000, 531115051 – 531140000, & 531211661 – 531240000)
Axial Fan Removal And Installation (S/N 530915316 – 530940000, 531011743 – 531040000, 531115051 – 531140000, & 531211661 – 531240000)
Hydraulic Fan Motor Removal And Installation (S/N 530915316 – 530940000, 531011743 – 531040000, 531115051 – 531140000, & 531211661 – 531240000)
Hydraulic Fan Motor Disassembly And Assembly (S/ N 530915316 – 530940000, 531011743 – 531040000, 531115051 – 531140000, & 531211661 – 531240000)
Hydraulic Fan Motor Description (S/N 530940001 & Above, 531040001 & Above, 531140001 & Above, 531240001 & Above)
Axial Fan Housing Removal And Installation (S/N 530940001 & Above, 531040001 & Above, 531140001 & Above, 531240001 & Above)
Axial Fan Removal And Installation (S/N 530940001 & Above, 531040001 & Above, 531140001 & Above, 531240001 & Above)
Hydraulic Fan Motor Removal And Installation (S/N 530940001 & Above, 531040001 & Above, 531140001 & Above, 531240001 & Above)
Hydraulic Fan Motor Disassembly And Assembly (S/ N 530940001 & Above, 531040001 & Above, 531140001 & Above, 531240001 & Above)
Water Pump Removal And Installation
Water Pump Disassembly And Assembly
Thermostat Housing Removal And Installation
LUBRICATION SYSTEM
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Inspection
Oil Filter Cooler Removal And Installation
Engine Oil Pressure – Testing
FUEL SYSTEM
Fuel Camshaft Removal And Installation
Injection Pump Governor Housing Removal And Installation
Injection Pump Governor Housing Disassembly And Assembly
Fuel Shutoff Solenoid – Checking
Fuel Shutoff Solenoid – Removal And Installation
Fuel Injection Pump Removal And Installation
Fuel Injection Pump Housing Removal
Fuel Injection Pump Housing Installation
Injection Pump Timing
Fuel Injector Removal and Installation
Fuel Injector Nozzle Pressure – Checking
Nozzle Spraying Condition
Valve Seat Tightness
CYLINDER HEAD
Intake Air Heater – Testing
Intake Air Heater Removal And Installation
Valve Clearance Adjustment
Valve Timing – Checking
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head – Servicing
Cylinder Head Top Clearance
Valve Guide – Checking
Reconditioning The Valve And Valve Seat
Valve Spring
Valve Tappets
Rocker Arm And Shaft – Checking
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod – Servicing
Cylinder Bore Checking
Connecting Rod Alignment
Crankshaft Gear Removal And Installation
Crankshaft And Bearings Removal and Installation
Crankshaft And Bearings – Servicing
CAMSHAFT AND TIMING GEArS
Timing Gearcase Cover Removal And Installation
Timing Gears Backlash – Checking
Camshaft – Servicing
Idle Gear And Shaft Removal And Installation
Idler Gear And Shaft – Servicing
TURBOCHARGER
Description
Testing
Removal And Installation
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Housing Removal And Installation

HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW
Description
Chart
Components
Safety Equipment
REGULAR MAINTENANCE
Filter Elements Removal And Installation
Compressor Drive Belt Inspection
Condenser
Air Conditioning Lubrication
Air Conditioning Service Chart
A/C Evaporator Coil & Heater Coil
TROUBLESHOOTING
Blower Motor Does Not Operate
Blower Motor Operates Normally, But Air Flow Is Insufficient
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
The Compressor Does Not Operate At All, Or Operates Improperly
Gauge Pressure Related Troubleshooting
Troubleshooting Tree
Temperature / Pressure Chart
Poor A/C Performance
HVAC Repair And Leaks
Electrical System
Engine Coolant By-Passing The Heater Valve
Heater Valve Not Opening Or Closing
SYSTEM CHARGING AND RECLAMATION
Refrigerant Identification
Reclamation And Charging With Recovery / Charging Unit
Charging With A Manifold Gauge Set
COMPRESSOR
Belt Adjustment
Removal And Installation
Oil
Oil Check
Clutch Disassembly And Assembly
CONDENSER
Removal And Installation
RECEIVER / DRIER
Receiver / Drier Removal And Installation
Pressure Relief Valve Removal And Installation
Pressure Switch Removal And Installation
Schraeder Valve Removal And Installation
EVAPORATOR / HEATER UNIT
Removal And Installation
THERMOSTAT
Removal And Installation
EXPANSION VALVE
Removal And Installation
EVAPORATOR
Removal And Installation
HEATER COIL
Removal And Installation With A/C
Removal And Installation Without A/C
BLOWER FAN
Removal And Installation
Disassembly And Assembly
Connector Identification
HEATER VALVE
Removal and Installation
Disassembly And Assembly

SPECIFICATIONS
(S250) LOADER SPECIFICATIONS
Dimensions
Performance
Controls
Engine
Hydraulic System
Electrical
Drive System
Capacities
Tires
(S300) LOADER SPECIFICATIONS
Dimensions
Performance
Controls
Engine
Hydraulic System
Electrical
Drive System
Capacities
Tires
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General Metric Bolts
HYDRAULIC CONNECTION SPECIFICATIONS
O-ring Face Seal Connection
Straight Thread O-ring Fitting
Tubelines And Hoses
Flare Fitting
Port Seal Fitting
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion Chart

SERVICE MANUAL REVISION
Revision No: S250 / S300 – 1
Revision No: S250 / S300 – 2
Revision No: S250 / S300 – 3
Revision No: S250 / S300 – 4
Revision No: S250 / S300 – 5
Revision No: S250 / S300 – 6
Revision No: S250 / S300 – 7
Revision No: S250 / S300 – 8
Revision No: S250 / S300 – 9
Revision No: S250 / S300 – 10
Revision No: S250 / S300 – 11

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