Bobcat T250 TURBO – HIGH FLOW Compact Track Loader Repair Service Manual – 6902451

(S/N: 523111001 & Above – S/N: 523011001 & Above)
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This workshop repair service manual PDF download for the T250 Bobcat Compact Track 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 T250
TURBO – HIGH FLOW
S/N: 523111001 & Above
S/N: 523011001 & Above

TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
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 : 6902451 (3-06)
Total Pages : 729

This service manual / repair manual / 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
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
Engaging The Lift Arm Support Device
Disengaging The Lift Arm Support Device
OPERATOR CAB
Description
Raising The Operator Cab
Lowering The Operator Cab
Emergency Exit
TRANSPORTING THE BOBCAT LOADER
Procedure
REMOTE START
Procedure For Loader W/O Attachments Control Harness
Procedure For Loader With Attachments Control Harness
Procedure
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Replacing Filter Element
ENGINE COOLING SYSTEM
Cleaning Cooling System
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Fuel Filter
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Oil Chart
Replacing Oil And Filter
HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid
Hydraulic/Hydrostatic Filter Replacement
Replacing Hydraulic Fluid And Case Drain Filters
FAN GEARBOX
Checking And Adding Oil
BOB-TACH
Inspection And Maintenance
POWER BOB-TACH
Inspection And Maintenance
LUBRICATING THE LOADER
Procedure

HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Troubleshooting
Tightening Procedure
CYLINDER (LIFT)
Checking
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (TILT)
Checking
Removal And Installation
Base Pin Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (POWER BOB-TACH)
Checking
Removal And Installation
Parts Identification
Disassembly
Assembly
MAIN RELIEF VALVE (FOOT CONTROL)
Checking The Main Relief Valve At Front Aux. Hyd.
Removal And Installation
Adjustment
MAIN RELIEF VALVE (ACS)
Checking The Main Relief Valve At Front Aux. Hyd.
Removal And Installation
Adjustment
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
Removal And Installation
BICS™ Valve, Removal And Installation
BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation
BICS™ Valve, Check Valve Removal And Installation
BICS™ Valve, Lock Valve Removal And Installation
BICS™ Valve, Solenoid Removal And Installation
BICS™ Valve, Solenoid Testing
Identification Chart
Load Check Valve
Main Relief Valve
Port Relief Valve, Tilt Spool
Port Relief Valve, Lift Spool
Anti-Cavitation Valve/Port Relief Valve, Tilt Spool
Anti-Cavitation Valve, Lift Spool
Rubber Boot
Lift And Tilt Lock Block
Lift Spool And Detent Removal
Tilt Spool Removal And Installation
Auxiliary Spool Removal And Installation
Auxiliary Plug Removal And Installation
Auxiliary Electric Solenoid Disassembly
Port-Auxiliary Section Removal And Installation
Cleaning And Inspection
HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)
Actuator Removal And Installation (In Loader)
Actuator Removal And Installation (Out Of Loader)
Removal And Installation
BICS™ Valve, Removal And Installation
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly
BICS™ Valve, Check Valve Disassembly And Assembly
BICS™ Valve, Lock Valve Disassembly And Assembly
BICS™ Valve, Solenoid Disassembly And Assembly
BICS™ Valve, Solenoid Testing
Identification Chart
Lift Base End Restrictor
Load Check Valve
Main Relief Valve
Port Relief Valve
Anti-Cavitation Valve/Port Relief Valve
Anti-Cavitation Valve
Lift Spool Removal
Lift Spool Removal And Installation
Lift and Tilt Spool Disassembly And Assembly
Auxiliary Spool Removal And Installation
Auxiliary Electric Solenoid Disassembly
Port-Auxiliary Section Disassembly
Cleaning And Inspection
LIFT ARM BY-PASS CONTROL VALVE
Inspecting
Additional Inspection For Loaders W/Advanced Hand Controls
Removal And Installation
Disassembly And Assembly
HYDRAULIC PUMP
Check The Output Of The Hydraulic Pump
Removal And Installation
Identification
Disassembly And Assembly
HYDRAULIC PUMP (CHARGE)
Check The Output Of The Hydraulic Pump
Removal and Installation
Disassembly and Assembly
HYDRAULIC PUMP (HI FLOW)
Hydraulic Pump Test
Inline Hydraulic Pump Test (Standard)
Inline Hydraulic Pump Test (High Flow)
High Flow Relief Adjustment Procedure
High Flow Relief Valve Removal and Installation
Removal And Installation
Identification
Disassembly And Assembly
HYDRAULIC/HYDROSTATIC FILTER
Housing Removal And Installation
Mount Removal And Installation
HYDRAULIC FLUID RESERVOIR
Fluid Removal
Removal And Installation
Hydraulic Fluid Screen
BUCKET POSITION VALVE
Solenoid Removal And Installation
Solenoid Testing
Removal And Installation
Disassembly And Assembly
REAR AUXILIARY DIVERTER
Removal and Installation
Disassembly And Assembly
Solenoid Testing
Inspection
POWER BOB-TACH BLOCK (EARLY MODELS)
Removal And Installation
Disassembly And Assembly
POWER BOB-TACH BLOCK
Removal And Installation
Disassembly And Assembly
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
Removal and Installation
Disassembly And Assembly

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
Replenishing Valve Function
HYDROSTATIC MOTOR
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
Filling
CHARGE PRESSURE SENDER
Testing
Removal and Installation
Setting Charge Pressure
HYDROSTATIC PUMP
Removal And Installation
Replenishing/High Pressure Relief Valve
Parts Identification (Right Half)
Parts Identification (Left Half)
Hydraulic Pump Removal And Installation
Pump Separation
Disassembly
Assembly
DRIVE BELT
Shield Removal And Installation
Adjustment
Replacement
Tensioner Pulley Removal And Installation
Tensioner Pulley Tension Spring
OIL COOLER (SEAL TO CONNECT) (STC)
Hydraulic Oil Cooler Removal and Installation

DRIVE SYSTEM
BRAKE
Switch Operated Parking Brake
Block Removal And Installation
Block Disassembly And Assembly
DRIVE COMPONENTS
Track Checking
Track Adjustment
Track Removal And Installation
Track Idler (Front) End Play Specifications
Track Idler (Front) Removal And Installation
Track Idler (Front) Parts Identification
Track Idler (Front) Disassembly
Track Idler (Front) Assembly
Track Idler (Rear) End Play Specifications
Track Idler (Rear) Parts Identification
Track Idler (Rear) Removal And Installation
Track Idler (Rear) Disassembly
Track Idler (Rear) Assembly
Track Roller Assembly End Play Specifications
Track Roller Parts Identification
Track Roller Removal And Installation
Track Roller Disassembly
Track Roller Assembly
Track Housing Removal And Installation
Track Damage Identification

MAIN FRAME
SEAT BAR
Removal And Installation
Assembling Components
Compression Spring Disassembly And Assembly
OPERATOR CAB
Gas Cylinder Removal And Installation (Dual Gas Spring)
Gas Cylinder Removal And Installation (3rd Gas Spring)
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
Cushion Removal And Installation
Back Removal And Installation
Shock Removal And Installation
3-Point Seat Belt Removal And Installation
BOB-TACH
Removal And Installation
Bob-Tach Lever And Wedge
POWER BOB-TACH
Removal And Installation
Power Bob-Tach Lever And Wedge
Pivot Pin Bushing And Seal Replacement
LIFT ARMS
Removal And Installation
REAR GRILL
Removal And Installation
REAR DOOR
Removal And Installation
Adjusting The Rear Door Latch
FUEL TANK
Removal And Installation
Fuel Level Sender
CONTROL PEDALS
Removal And Installation
Pedal Adjustment
CONTROL PEDALS (ACS)
Foot Sensor Removal And Installation
Foot Pedal Removal And Installation
Foot Pedal Linkage Disassembly And Assembly
CONTROL PANEL
Removal And Installation
Shock Removal And Installation
Shaft Removal And Installation
Shaft Disassembly And Assembly
Linkage Removal And Installation
Linkage Neutral Adjustment
CONTROL HANDLE
Lever Removal And Installation
Steering Lever Boot
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL
Components Identification
Handle Sensor Removal And Installation
Control Handle Removal And Installation
Control Handle Disassembly And Assembly
Control Lever Removal And Installation
Control Lever Boot
INSIDE ACCESS PANEL
Removal And Installation (Left)
Removal And Installation (Right)

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Troubleshooting
Description
Fuse Location
Relay Switch Location
Solenoid Test
BATTERY
Removal And Installation
Servicing The Electrical System
Using A Booster Battery (Jump Starting)
ALTERNATOR
Adjusting The Alternator Belt
Alternator Identification
Charging System Check
Alternator Voltage Test
Low Voltage Test
High Voltage Test
Removal And Installation
Rectifier Continuity (Diode) Test
Alternator Regulator Test
Disassembly
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Assembly
STARTER
Removal And Installation
Parts Identification
Checking
Disassembly And Assembly
Inspection And Repair
No Load Test
INSTRUMENT PANEL
Left Panel
Right Panel (Standard) (With Key Switch)
Right Panel (Deluxe) (With Keyless Start)
Right Panel Setup Display Options (Deluxe)
Deluxe Panel Setup
Passwords (Deluxe)
Option And Field Accessory Panels (If Equipped)
Standard Panel Removal And Installation (Right Side)
Deluxe Panel Removal And Installation (Right Side)
Standard & Deluxe Panel Removal And Installation (Left Side)
Front Accessory Panel Removal And Installation
LIGHTS
Front Removal And Installation
Rear Removal And Installation
BOBCAT CONTROLLER
Identification Chart
Removal And Installation
DIAGNOSTICS SERVICE CODES
Display
Number Codes List
BICS™ SYSTEM
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 By-Pass Control
Additional Inspection For Loaders With Advanced Controls System (ACS) or Selectable Joystick Control (SJC)
Troubleshooting
Troubleshooting Guide
SEAT BAR SENSOR
Troubleshooting Chart
Test
Removal And Installation
BICS™ Circuit Test
TRACTION LOCK
Troubleshooting Chart
Description Of The Control System
Inspecting The Control System
Parking Brake Solenoid Removal And Installation
ADVANCED CONTROL SYSTEM (ACS)
Components Identification
Troubleshooting Guide
Controller, Connector And Wire Identification
ACS Controller Removal And Installation
Handle Sensor Connector
Switch Handle Removal
Switch Handle Installation
Actuators Disassembly And Assembly
Handle Lock Solenoid Removal And Installation
Handle Lock Solenoid Disassembly And Assembly
Handle Lock Solenoid Connector
Calibration Of The ACS System
Switchable Hand/Foot Controls Calibration Procedure
Hand Controls Only Calibration Procedure
Foot Sensor Disassembly And Assembly
Foot Sensor Connector
Foot Lock Solenoid Removal And Installation
Foot Lock Solenoid Connector
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
Controls Identification Chart
FLYWHEEL RPM SENSOR
Adjustment

ENGINE SERVICE
TROUBLESHOOTING
Chart
ENGINE SPEED CONTROL
Removal And Installation
Speed Control Cable
MUFFLER
Removal And Installation
AIR CLEANER
Housing Removal And Installation
RADIATOR
Removal And Installation
Mount Removal
COOLING FAN
Drive Tension Pulley Removal And Installation
Gearbox/Blower Housing Removal And Installation
Gearbox Parts Identification
Gearbox Disassembly
Gearbox Assembly
Gearbox, Checking Backlash
ENGINE
Removal And Installation
Mount Replacement
Removal And Installation Tools
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Flywheel Housing Removal And Installation
RECONDITIONING THE ENGINE
Engine Tools Identification Chart
Compression Pressure
Cylinder Head Clearance
Valve Cover And Injector Nozzle Removal And Installation
Rocker Arm And Push Rod Disassembly And Assembly
Valve Clearance
Cylinder Head And Tappet Disassembly And Assembly
Selecting Cylinder Head Gasket Disassembly And Assembly
Valve Disassembly And Assembly
Engine Timing (TDC)
Injection Pump Assembly Removal
Injection Pump Assembly Installation
Injection Pump Removal and Installation
Injection Pump Timing
Fan Drive Pulley Disassembly And Assembly
Water Pump Disassembly And Assembly
Gearcase Cover Disassembly And Assembly
Idle Gear And Camshaft Disassembly And Assembly
Gearcase Plate Disassembly And Assembly
Oil Pan And Oil Strainer Disassembly And Assembly
Connecting Rod Cap Disassembly And Assembly
Piston Disassembly And Assembly
Piston Ring And Connecting Rod Disassembly And Assembly
Bearing Case Cover Disassembly And Assembly
Flywheel Housing Disassembly And Assembly
Crankcase No. 2 Disassembly And Assembly
Crankcase No. 1 And No. 2 Disassembly And Assembly
Crankshaft Disassembly And Assembly
Cylinder Head Surface Flatness
Cylinder Head Flaw
Valve Recessing
Valve Lapping
Clearance Between Valve Stem And Valve Guide
Replacing Valve Guide
Correcting Valve And Valve Seat
Free Length And Tilt Of Valve Spring
Valve Spring Setting Load
Oil Clearance Between Rocker Arm Shaft And Bearing
Oil Clearance Between Tappet And Tappet Guide Bore
Timing Gear Backlash
Idler Gear Side Clearance
Camshaft Side Clearance
Camshaft Alignment
Cam Height
Oil Clearance Between Idler Gear Shaft And Idler Gearing Bushing
Replacing Idler Gear Bushing
Piston Pin Bore I.D.
Oil Clearance Between Piston Pin And Small End Bushing
Replacing Small End Bushing
Clearance Between Piston Ring And Groove
Piston Ring Gap
Connecting Rod Alignment
Crankshaft Side Clearance
Crankshaft Alignment
Oil Clearance Between Crankpin And Crankpin Bearing
Oil Clearance Between Crankshaft Journal And Crankshaft Bearing
Replacing Crankshaft Sleeve
Cylinder Bore I.D.
Correcting Cylinder (Oversize +0.5 mm)
Engine Oil Pressure
Rotor Lobe Clearance
Clearance Between Outer Rotor And Pump Body
Thermostat Valve Opening Temperature
Radiator Water Leakage
Radiator Cap Air Leakage
Thermostat Assembly
Intake Air Heater
Checking the Turbo Charger
Compressor Side
Wheel Shaft
Axial Clearance
Radial Clearance
Air Cleaner, Intake Pipe, Inlet Pipe And Muffler
Oil Pipe

HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW
Principals
Chart
COMPONENTS
Identification
SAFETY
Safety Equipment
REGULAR MAINTENANCE
Filter Elements Removal And Installation
Compressor Drive Belt Inspection
Cleaning The Condenser
BASIC TROUBLESHOOTING
Poor A/C Performance
Cleaning The A/C Evaporator Coil & Heater Coil
Compressor Drive Belt Inspection
Checking The Electrical System
Engine Coolant By-Passing The Heater Valve
Heater Valve Not Opening Or Closing
GENERAL AIR CONDITIONING SERVICE GUIDELINES
Compressor Oil
Compressor Oil Check
Component Replacement And Refrigeration Leaks
SYSTEM TROUBLESHOOTING CHART
Gauge Pressure Related Troubleshooting
Troubleshooting Tree
TEMPERATURE/PRESSURE
Chart
AIR CONDITIONING SERVICE
Chart
SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
Charging Procedure With A Manifold Gauge Set
Charging Procedure
COMPRESSOR
Removal And Installation
Compressor Clutch Disassembly
CONDENSER
Removal And Installation
RECEIVER/DRIER
Removal And Installation
PRESSURE RELIEF VALVE
Removal And Installation
PRESSURE SWITCH
Removal And Installation
EVAPORATOR/HEATER UNIT
Removal And Installation
Disassembly And Assembly
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
Wire Connector Removal and Installation
HEATER VALVE
Removal and Installation
Disassembly And Assembly

SPECIFICATIONS
LOADER SPECIFICATIONS (T250)
Machine Dimensions
Performance
Controls
Engine
Hydraulic System
Electrical
Drive System
Capacities
Tracks
ENGINE SPECIFICATIONS
General
Fuel System
Valve And Valve Timing
Valve Spring
Piston And Piston Ring
Connecting Rod
Cylinder Head
Crankshaft
Cylinder Bore
Oil Pump
Rocker Arm
Tappet
Camshaft
Thermostat
Timing Gear
Intake Air Heater
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General Metric Bolts
Torque For Kubota Metric Engine Bolts
Tightening Torques For General Use Screws, Bolts And Nuts
HYDRAULIC CONNECTION SPECIFICATIONS
O-ring Face Seal Connection
Straight Thread O-ring Fitting
Tubelines And Hoses
Flare Fitting
O-ring Flare Fitting
Port Seal Fitting
HYDRAULIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalents

SERVICE MANUAL REVISION
T250-1
T250-2

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