BOBCAT B250 570311001 Service Manual PDF DOWNLOAD
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TABLE OF CONTENTS:
BOBCAT B250 570311001 Service Manual PDF DOWNLOAD
MAINTENANCE SAFETY……………………………………… 3
ALPHABETICAL INDEX……………………………………… 5
CONTENTS………………………………………………. 7
SAFETY INSTRUCTIONS…………………………………. 11
Fire Prevention…………………………………. 13
SERIAL NUMBER LOCATION………………………………. 15
Loader Backhoe Serial Number……………………… 15
Engine Serial Number…………………………….. 15
DELIVERY REPORT…………………………………….. 15
BOBCAT LOADER IDENTIFICATION…………………………. 16
SAFETY & MAINTENANCE……………………………………. 17
LIFTING AND BLOCKING THE LOADER BACKHOE……………….. 19
Procedure………………………………………. 19
LIFT ARM SUPPORT DEVICE……………………………… 21
Installing The Lift Arm Support Device…………….. 21
Removing The Lift Arm Support Device………………. 22
ENGINE COVER……………………………………….. 23
TRANSPORTING THE LOADER BACKHOE………………………. 25
Procedure………………………………………. 25
TOWING THE LOADER BACKHOE……………………………. 27
Procedure………………………………………. 27
AXLE TOE-IN………………………………………… 29
Adjustment……………………………………… 29
SERVICE SCHEDULE……………………………………. 31
Chart………………………………………….. 31
AIR CLEANER SERVICE…………………………………. 33
Replacing Filter Element…………………………. 33
ENGINE COOLING SYSTEM……………………………….. 35
Coolant Replacement……………………………… 35
FUEL SYSTEM………………………………………… 37
Fuel Specifications……………………………… 37
Filling The Fuel Tank……………………………. 37
Fuel Filter…………………………………….. 38
Removing Air From The Fuel System…………………. 38
ENGINE LUBRICATION SYSTEM……………………………. 39
Checking Engine Oil……………………………… 39
Oil Chart………………………………………. 39
Replacing Oil And Filter…………………………. 40
HYDRAULIC/HYDROSTATIC SYSTEM…………………………. 43
Checking And Adding Fluid………………………… 43
Cleaning The Cooler……………………………… 43
Replacing Hydraulic/Hydrostatic Filter…………….. 44
Replacing Hydraulic Fluid………………………… 45
REAR AXLE………………………………………….. 47
Checking Oil Level………………………………. 47
Draining Oil……………………………………. 47
FRONT AXLE…………………………………………. 48
Checking Oil Level………………………………. 48
Draining Oil……………………………………. 48
BACKHOE BOOM LOCK…………………………………… 49
Disengaging The Boom Lock………………………… 49
Engaging Boom Lock………………………………. 50
BOB-TACH HAND LEVER…………………………………. 51
Inspection And Maintenance……………………….. 51
ALTERNATOR BELT…………………………………….. 53
Adjusting The Alternator Belt…………………….. 53
LUBRICATING THE LOADER BACKHOE……………………….. 55
TIRE MAINTENANCE……………………………………. 61
Wheel Nuts……………………………………… 61
Mounting……………………………………….. 61
Tire Pressure…………………………………… 61
HYDRAULIC SYSTEM……………………………………….. 63
HYDRAULIC/HYDROSTATIC SCHEMATICS……………………… 67
HYDRAULIC SYSTEM INFORMATION…………………………. 69
Troubleshooting…………………………………. 73
Description…………………………………….. 74
ARM CYLINDER……………………………………….. 75
Checking……………………………………….. 75
Removal And Installation…………………………. 77
Parts Identification…………………………….. 79
Disassembly…………………………………….. 80
Assembly……………………………………….. 83
BOOM CYLINDER………………………………………. 87
Checking……………………………………….. 87
Removal And Installation…………………………. 88
Parts Identification…………………………….. 90
Disassembly…………………………………….. 91
Assembly……………………………………….. 94
SWING CYLINDER……………………………………… 97
Removal And Installation…………………………. 97
Parts Identification (Left Side)………………….. 99
Parts Identification (Right Side)………………….100
Disassembly……………………………………..101
Assembly………………………………………..104
BUCKET CYLINDER……………………………………..107
Checking………………………………………..107
Removal And Installation………………………….109
Parts Identification……………………………..111
Disassembly……………………………………..112
Assembly………………………………………..115
STABILIZER CYLINDER………………………………….119
Checking………………………………………..119
Removal And Installation………………………….120
Parts Identification……………………………..122
Disassembly……………………………………..123
Assembly………………………………………..130
SIDE SHIFT LOCK CYLINDER……………………………..137
Disassembly……………………………………..137
Inspection………………………………………140
Assembly………………………………………..141
Parts Identification……………………………..144
TILT CYLINDER……………………………………….145
Checking………………………………………..145
Removal And Installation………………………….146
Parts Identification (Left Side)…………………..148
Parts Identification (Right Side)………………….149
Disassembly……………………………………..150
Assembly………………………………………..153
LIFT CYLINDER……………………………………….157
Checking………………………………………..157
Removal And Installation………………………….158
Parts Identification……………………………..159
Disassembly……………………………………..160
Assembly………………………………………..163
STEERING CYLINDER (FRONT)…………………………….167
Removal And Installation………………………….167
STEERING CYLINDER (FRONT) (CONT’D)…………………….171
Parts Identification……………………………..171
Disassembly And Assembly………………………….172
Inspection………………………………………175
STEERING CYLINDER (REAR)……………………………..177
Removal And Installation………………………….177
Parts Identification……………………………..180
Disassembly And Assembly………………………….181
Inspection………………………………………184
MAIN RELIEF VALVE……………………………………187
Testing The Main Relief Valve……………………..187
Adjustment………………………………………188
PORT RELIEF VALVE (BACKHOE CONTROL VALVE)………………189
Testing And Adjusting (Arm Control)………………..189
Testing And Adjusting (Boom Control)……………….191
Testing And Adjusting (Boom Swing Control)………….193
PORT RELIEF VALVE (LOADER CONTROL VALVE)……………….195
Testing And Adjusting (Bucket Tilt)………………..195
Testing And Adjusting (Front Auxiliary)…………….197
LOADER CONTROL VALVE…………………………………199
Removal And Installation………………………….199
Parts Identification……………………………..201
Disassembly And Assembly………………………….202
Inlet/Outlet Valve Section………………………..203
Lift Arm Valve Section……………………………205
Tilt Valve Section……………………………….208
Auxiliary Valve Section…………………………..212
BACKHOE CONTROL VALVE………………………………..217
Removal And Installation………………………….217
Parts Identification……………………………..219
Disassembly And Assembly………………………….220
Inlet/Outlet Valve Section………………………..222
Arm Valve Section………………………………..224
Tilt Valve Section……………………………….227
Right Stabilizer Valve Section…………………….230
Left Stabilizer Valve Section……………………..233
Boom Valve Section……………………………….237
Boom Swing Valve Section………………………….240
Outlet Valve Section……………………………..243
HYDRAULIC FLUID RESERVOIR…………………………….245
Removal And Installation………………………….245
Filter Removal And Installation……………………247
HYDRAULIC FILTER HOUSING……………………………..249
Removal And Installation………………………….249
Disassembly……………………………………..250
Assembly………………………………………..251
GEAR PUMP…………………………………………..253
Removal And Installation………………………….253
Parts Identification……………………………..254
Disassembly And Assembly………………………….255
Inspection………………………………………257
STEERING PUMP……………………………………….259
Removal And Installation………………………….259
Parts Identification……………………………..262
Disassembly……………………………………..263
Inspection………………………………………272
Assembly………………………………………..272
TRAVEL PEDAL………………………………………..281
Removal And Installation………………………….281
Parts Identification……………………………..282
Disassembly And Assembly………………………….283
STEERING VALVE………………………………………289
Removal And Installation………………………….289
Description……………………………………..290
Wheel Alignment Procedure…………………………290
HYDROSTATIC SYSTEM………………………………………291
HYDROSTATIC SYSTEM INFORMATION………………………..293
Troubleshooting Chart…………………………….293
Replenishing Valve Function……………………….294
OIL COOLER………………………………………….295
Removal And Installation………………………….295
Parts Identification……………………………..297
Disassembly……………………………………..298
Assembly………………………………………..300
HYDROSTATIC DRIVE MOTOR………………………………303
Removal And Installation………………………….303
Parts Identification……………………………..305
Disassembly……………………………………..306
Inspection………………………………………310
Assembly………………………………………..312
HYDROSTATIC PUMP…………………………………….317
Removal And Installation………………………….317
Parts Identification……………………………..320
Disassembly……………………………………..322
Inspection………………………………………338
Assembly………………………………………..340
HYDROSTATIC TESTING………………………………….355
Pump Adjustment………………………………….355
DRIVE SYSTEM……………………………………………359
PARKING BRAKE……………………………………….361
Lever Removal And Installation…………………….361
Cable Removal And Installation…………………….362
Adjustment………………………………………365
BRAKE CALIPER……………………………………….367
Removal And Installation………………………….367
Parts Identification……………………………..370
Disassembly And Assembly………………………….371
BRAKE CALIPER……………………………………….377
Removal And Installation………………………….377
Parts Identification……………………………..380
Disassembly And Assembly………………………….381
REAR AXLE…………………………………………..387
Removal…………………………………………387
Installation…………………………………….390
AXLE AND DIFFERENTIAL (REAR)………………………….393
Troubleshooting Chart…………………………….393
General Information………………………………394
Wheel Hub/Spindle Parts Identification……………..394
Wheel Hub/Spindle Disassembly……………………..395
Drive Axle Parts Identification……………………399
Drive Axle Disassembly……………………………400
Steering Knuckle Parts Identification………………403
Steering Knuckle Disassembly………………………404
Differential Parts Identification………………….407
Differential Disassembly………………………….408
Differential Inspection…………………………..414
Pinion Group Parts Identification………………….415
Pinion Group Disassembly………………………….416
Pinion Group Inspection…………………………..419
Pinion Group Assembly…………………………….420
Differential Assembly…………………………….427
Steering Knuckle Assembly…………………………436
Drive Axle Assembly………………………………439
Wheel Hub/Spindle Assembly………………………..442
STEERING ANGLE ADJUSTMENT (REAR AXLE)………………….447
Adjustment………………………………………447
FRONT AXLE………………………………………….449
Removal…………………………………………449
Installation…………………………………….451
AXLE AND DIFFERENTIAL (FRONT)…………………………453
Troubleshooting Chart…………………………….453
General Information………………………………454
Wheel Hub/Spindle Parts Identification……………..454
Wheel Hub/Spindle Disassembly……………………..455
Drive Axle Parts Identification……………………459
Drive Axle Disassembly……………………………460
Steering Knuckle Parts Identification………………463
Steering Knuckle Disassembly………………………464
Differential Parts Identification………………….467
Differential Disassembly………………………….468
Differential Inspection…………………………..474
Pinion Group Parts Identification………………….475
Pinion Group Disassembly………………………….476
Pinion Group Inspection…………………………..479
Pinion Group Assembly…………………………….480
Differential Assembly…………………………….487
Steering Knuckle Assembly…………………………496
Drive Axle Assembly………………………………499
Wheel Hub/Spindle Assembly………………………..502
STEERING ANGLE ADJUSTMENT (FRONT AXLE)…………………507
Adjustment………………………………………507
DRIVESHAFT………………………………………….509
Removal And Installation………………………….509
DROP BOX……………………………………………511
Removal And Installation………………………….511
Parts Identification……………………………..514
Disassembly……………………………………..515
Inspection………………………………………522
Assembly………………………………………..522
MAIN FRAME……………………………………………..527
OPERATOR CAB………………………………………..529
Not Available At Time Of Printing………………….529
ENCLOSED CAB………………………………………..531
Removal And Installation………………………….531
Cab Mount Removal And Installation…………………539
OPERATOR SEAT……………………………………….541
Removal And Installation………………………….541
FLOOR PANELS………………………………………..543
Left Front Panel Removal And Installation…………..543
Right Front Panel Removal And Installation………….543
Rear Panel Removal And Installation………………..544
GRILL………………………………………………545
Removal And Installation………………………….545
GRILL FRAME…………………………………………547
Removal And Installation………………………….547
ENGINE SIDE COVERS…………………………………..549
Removal And Installation………………………….549
FENDER……………………………………………..551
Removal And Installation………………………….551
ENGINE COVER………………………………………..553
Removal And Installation………………………….553
FUEL TANK…………………………………………..555
Removal And Installation………………………….555
Fuel Fill Screen Removal And Installation…………..556
LIFT ARMS…………………………………………..557
Removal And Installation………………………….557
BOB-TACH……………………………………………561
Removal And Installation………………………….561
Bob-Tach Lever And Wedge………………………….563
Pivot Pin Bushing Removal And Installation………….565
ARM………………………………………………..567
Removal And Installation………………………….567
Arm Pivot Bushing Removal And Installation………….568
BOOM……………………………………………….569
Removal And Installation………………………….569
SWING FRAME…………………………………………573
Removal And Installation………………………….573
Bushing Removal And Installation…………………..574
X-CHANGE™…………………………………………..575
Removal And Installation………………………….575
BUCKET……………………………………………..577
Backhoe Bucket Teeth Removal And Installation……….577
Loader Bucket Teeth Removal And Installation………..577
STABILIZER FRAME…………………………………….579
Removal And Installation………………………….579
FRONT AXLE PIVOT FRAME……………………………….589
Removal…………………………………………589
Installation…………………………………….590
Bushing Removal And Installation…………………..591
REAR WINDOW…………………………………………593
Removal And Installation………………………….593
CAB DOOR……………………………………………597
Removal And Installation………………………….597
ELECTRICAL SYSTEM AND ANALYSIS……………………………599
ELECTRICAL SCHEMATICS………………………………..601
ELECTRICAL SYSTEM INFORMATION…………………………603
Troubleshooting Chart…………………………….603
Description……………………………………..604
Fuse Location……………………………………604
BATTERY…………………………………………….605
Removal And Installation………………………….605
Servicing The Electrical System……………………606
Using A Booster Battery (Jump Starting)…………….607
ALTERNATOR………………………………………….609
Adjusting The Alternator Belt……………………..609
Description……………………………………..609
Tests…………………………………………..610
Alternator Output Test……………………………610
Full Field Test………………………………….611
Alternator Regulator Test…………………………611
Alternator Regulator Test With Voltmeter……………612
Removal And Installation………………………….613
Parts Identification……………………………..614
Pulley Removal And Installation……………………615
Disassembly And Assembly………………………….616
Rotor Continuity Test…………………………….619
Stator Continuity Test……………………………619
Rectifier Continuity (Diode) Test………………….620
Brush Length…………………………………….620
STARTER…………………………………………….621
Removal And Installation………………………….621
Checking The Starter In The Loader…………………621
Parts Identification……………………………..623
Disassembly……………………………………..624
Inspection And Repair…………………………….629
No Load Test…………………………………….633
Assembly………………………………………..634
FRONT LIGHTS………………………………………..641
Bulb Removal And Installation……………………..641
Housing Removal And Installation…………………..643
TURN INDICATOR LIGHTS (FRONT)…………………………645
Bulb Removal And Installation……………………..645
TURN INDICATOR LIGHTS (REAR)………………………….647
Bulb Removal And Installation……………………..647
CAB LIGHTS………………………………………….649
Bulb Removal And Installation……………………..649
Housing Removal And Installation…………………..651
FUEL LEVEL SENDER……………………………………653
Removal And Installation………………………….653
INSTRUMENT PANEL…………………………………….655
Removal And Installation………………………….655
FRONT WIPER…………………………………………657
Removal And Installation………………………….657
REAR WIPER………………………………………….661
Removal And Installation………………………….661
ENGINE SERVICE………………………………………….663
TROUBLESHOOTING……………………………………..667
Chart…………………………………………..667
ENGINE SPEED CONTROL…………………………………669
Removal And Installation………………………….669
Cable Removal And Installation…………………….670
MUFFLER…………………………………………….671
Removal And Installation………………………….671
AIR CLEANER…………………………………………673
Removal And Installation………………………….673
RADIATOR……………………………………………675
Removal And Installation………………………….675
ENGINE COMPONENTS AND TESTING…………………………677
Checking Engine Compression……………………….677
Checking Glow Plugs………………………………678
Glow Plug Removal And Installation…………………679
Fuel Shut-Off Solenoid Removal And Installation……..680
Checking Fuel Injection Pump………………………681
Fuel Injection Pump Removal And Installation………..682
Fuel Injection Pump Timing………………………..684
Fuel Injector Nozzles Removal And Installation………685
Checking Fuel Injector, Nozzles……………………687
Thermostat Removal And Installation………………..688
Water Pump Removal And Installation………………..689
ENGINE……………………………………………..691
Removal And Installation………………………….691
Mount Replacement………………………………..695
RECONDITIONING THE ENGINE…………………………….697
Timing Gear Case Cover Removal And Installation……..697
Oil Pump Removal And Installation………………….699
Crankshaft Front Seal Removal And Installation………701
Engine Speed Control Plate Removal And Installation….702
Idle Limit And Fuel Limit Adjustment……………….703
Exhaust Manifold Removal And Installation…………..703
Valve Cover Removal And Installation……………….704
Rocker Arm Removal And Installation………………..705
Push Rod Removal And Installation………………….706
Tappet Removal And Installation……………………707
Water Flange Removal And Installation………………707
Cylinder Head Removal And Installation……………..708
Checking Piston Top Clearance……………………..709
Cylinder Head Disassembly And Assembly……………..710
Servicing The Cylinder Head……………………….711
Combustion Chamber Removal And Installation…………714
Idler Gear Removal And Installation………………..715
Camshaft Removal And Installation………………….716
Fuel Camshaft Removal And Installation……………..718
Oil Pan Removal And Installation…………………..720
Governor Shaft Removal And Installation…………….721
Governor Fork Lever Removal And Installation………..724
Piston Removal And Installation……………………726
Checking The Piston And Connecting Rod……………..726
Connecting Rod Alignment………………………….727
Piston Ring Gap………………………………….727
Piston Ring Installation………………………….728
Connecting Rod Installation……………………….729
Checking Engine Cylinder Bore……………………..729
Crankshaft Removal And Installation………………..730
Checking Crankshaft Journal And Block Bearing……….732
Checking Crankshaft Journal And Main Bearing………..733
Connecting Rod Journal……………………………734
Checking The End Play Of The Crankshaft…………….735
Crankshaft Alignment……………………………..735
Engine Timing Installation………………………..736
Timing Gear Backlash, Idler Gear And Crankshaft……..736
Idler Gear And Camshaft Gear………………………737
Idler Gear And Fuel Camshaft Gear………………….737
Fuel Camshaft Gear And Governor Shaft Gear………….737
FLYWHEEL HOUSING…………………………………….739
Removal And Installation………………………….739
FLYWHEEL……………………………………………741
Removal And Installation………………………….741
Ring Gear Removal And Installation…………………741
RUBBER DRIVE COUPLER…………………………………743
Removal And Installation………………………….743
Disassembly……………………………………..743
TURBOCHARGER………………………………………..745
HEATER…………………………………………………747
COMPONENTS………………………………………….749
Identification…………………………………..749
HEATER FAN………………………………………….751
Removal And Installation………………………….751
HEATER UNIT…………………………………………753
Removal And Installation………………………….753
Disassembly And Assembly………………………….755
SPECIFICATIONS………………………………………….757
LOADER SPECIFICATIONS………………………………..759
Loader Backhoe Dimensions…………………………759
Performance……………………………………..760
Controls………………………………………..760
Engine………………………………………….760
Electrical………………………………………761
Drive System…………………………………….761
Capacities………………………………………761
Tires…………………………………………..761
ENGINE SPECIFICATIONS………………………………..763
Engine Compression……………………………….763
Fuel Injection Nozzles……………………………763
Fuel Injection Pump………………………………763
Cylinder Head……………………………………763
Valves………………………………………….763
Valve Springs……………………………………764
Rocker Arms……………………………………..764
Camshaft………………………………………..764
Cylinders……………………………………….764
Piston Rings…………………………………….765
Pistons…………………………………………765
Crankshaft………………………………………765
Oil Pump………………………………………..766
Thermostat………………………………………766
Grinding Specifications for the Crankshaft………….767
LOADER BACKHOE TORQUE………………………………..769
Specifications…………………………………..769
TORQUE SPECIFICATIONS FOR BOLTS……………………….771
Torque For General Metric Bolts……………………771
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS……………..773
Specifications…………………………………..773
CONVERSIONS…………………………………………775
Decimal And Millimeter Equivalents…………………775
U.S. To Metric Conversion…………………………775
SMR……………………………………………………777
B250-1……………………………………………..777
B250-2……………………………………………..779
B250-3……………………………………………..781
B250-4……………………………………………..783
B250-5……………………………………………..785
B250-6……………………………………………..787
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DESCRIPTION:
BOBCAT B250 570311001 Service Manual PDF DOWNLOAD
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:
- Check that ROPS mounting hardware is tightened and is Bobcat approved.
- The seat belt must be correctly installed, functional and in good condition.
- Check lift arm support device, replace if damaged.
- Machine signs must be legible and in the correct location.
- Foot pedal must return to neutral.
- Check for correct function of the work lights.
- The parking brake must function correctly.
- Enclosure door latches must open and close freely.
- Bob-Tach wedges and linkages must function correctly and be in good condition.
- Safety treads must be in good condition.
- Check for correct function of indicator lamps (Optional on some models).
- Check hydraulic fluid level, engine oil level, and fuel supply.
- Inspect for fuel, oil, or hydraulic fluid leaks.
- Lubricate the loader backhoe.
- Check the condition of the battery and cables.
- Inspect the air cleaner for damage or leaks. Check the condition of the element.
- Check the electrical charging system.
- Check tires for wear and pressure.
- Inspect for loose or broken parts or connections.
- Operate the loader and check all functions.
- Check for any field modification not completed.
- Recommend to the owner that all necessary corrections be made before the machine is returned to service.
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
G.P