BOBCAT B250 B Series SN 572911001 Service Manual PDF DOWNLOAD
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TABLE OF CONTENTS:
BOBCAT B250 B Series SN 572911001 Service Manual PDF DOWNLOAD
MAINTENANCE SAFETY……………………………………… 3
ALPHABETICAL INDEX……………………………………… 5
CONTENTS………………………………………………. 7
FOREWORD…………………………………………… 8
SAFETY INSTRUCTIONS…………………………………. 11
Fire Prevention…………………………………. 15
SERIAL NUMBER LOCATION………………………………. 17
Loader Backhoe Serial Number……………………… 17
Engine Serial Number…………………………….. 17
DELIVERY REPORT…………………………………….. 18
BOBCAT LOADER IDENTIFICATION…………………………. 19
SAFETY & MAINTENANCE……………………………………. 21
LIFTING AND BLOCKING THE LOADER BACKHOE……………….. 23
Procedure………………………………………. 23
APPROVED LIFT ARM SUPPORT DEVICE……………………… 25
Installing The Approved Lift Arm Support Device…….. 25
Removing The Approved Lift Arm Support Device………. 26
ENGINE COVER……………………………………….. 27
TRANSPORTING THE LOADER BACKHOE………………………. 29
Procedure………………………………………. 29
TOWING THE LOADER BACKHOE……………………………. 31
Procedure………………………………………. 31
AXLE TOE-IN………………………………………… 33
Adjustment……………………………………… 33
SERVICE SCHEDULE……………………………………. 35
Chart………………………………………….. 35
AIR CLEANER SERVICE…………………………………. 37
Daily Check…………………………………….. 37
Replacing The Air Filter Element………………….. 37
ENGINE COOLING SYSTEM……………………………….. 39
Cleaning The Cooling System………………………. 39
Checking Coolant Level…………………………… 39
Coolant Replacement……………………………… 40
FUEL SYSTEM………………………………………… 43
Fuel Specifications……………………………… 43
Filling The Fuel Tank……………………………. 43
Fuel Filter…………………………………….. 43
Removing Air From The Fuel System…………………. 45
ENGINE LUBRICATION SYSTEM……………………………. 47
Checking Engine Oil……………………………… 47
Oil Chart………………………………………. 47
Replacing The Oil And Filter……………………… 48
HYDRAULIC/HYDROSTATIC SYSTEM…………………………. 51
Checking And Adding Fluid………………………… 51
Cleaning The Cooler……………………………… 52
Replacing Hydraulic/Hydrostatic Filter…………….. 52
Replacing Hydraulic Fluid………………………… 53
REAR AXLE………………………………………….. 55
Checking Oil Level………………………………. 55
Draining Oil……………………………………. 55
FRONT AXLE…………………………………………. 55
Checking Oil Level………………………………. 55
Draining Oil……………………………………. 55
BOOM LOCK PIN………………………………………. 57
Engaging And Disengaging The Pin………………….. 57
BOB-TACH…………………………………………… 59
Inspection And Maintenance……………………….. 59
ALTERNATOR BELT…………………………………….. 61
Adjusting The Alternator Belt…………………….. 61
LUBRICATING THE LOADER BACKHOE……………………….. 63
TIRE MAINTENANCE……………………………………. 69
Wheel Nuts……………………………………… 69
Tire Mounting…………………………………… 69
Tire Pressure…………………………………… 69
SWING LOCK PIN……………………………………… 71
Engaging The Swing Lock Pin………………………. 71
HYDRAULIC SYSTEM……………………………………….. 73
HYDRAULIC/HYDROSTATIC SCHEMATICS……………………… 12
HYDRAULIC SYSTEM INFORMATION…………………………. 77
Glossary Of Hydraulic / Hydrostatic Symbols………… 77
Troubleshooting…………………………………. 81
Description…………………………………….. 82
ARM CYLINDER……………………………………….. 83
Checking……………………………………….. 83
Removal And Installation…………………………. 84
Parts Identification…………………………….. 87
Disassembly…………………………………….. 88
Assembly……………………………………….. 90
BOOM CYLINDER………………………………………. 93
Checking……………………………………….. 93
Removal And Installation…………………………. 95
Parts Identification…………………………….. 98
Disassembly…………………………………….. 99
Assembly………………………………………..101
SWING CYLINDER………………………………………103
Checking………………………………………..103
Removal And Installation………………………….104
Parts Identification……………………………..106
Disassembly……………………………………..107
Assembly………………………………………..109
Bushing Removal And Installation…………………..111
BUCKET CYLINDER……………………………………..113
Checking………………………………………..113
Removal And Installation………………………….115
Parts Identification……………………………..118
Disassembly……………………………………..119
Assembly………………………………………..121
STABILIZER CYLINDER………………………………….123
Checking………………………………………..123
Removal And Installation………………………….124
Parts Identification……………………………..127
Disassembly……………………………………..128
Assembly………………………………………..132
SIDE SHIFT LOCK CYLINDER……………………………..135
Removal And Installation………………………….135
Parts Identification……………………………..137
Disassembly……………………………………..138
Assembly………………………………………..139
TILT CYLINDER……………………………………….141
Checking………………………………………..141
Removal And Installation………………………….142
Parts Identification……………………………..144
Disassembly……………………………………..145
Assembly………………………………………..147
LIFT CYLINDER……………………………………….149
Checking………………………………………..149
Removal And Installation………………………….150
Parts Identification……………………………..152
Disassembly……………………………………..153
Assembly………………………………………..155
STEERING CYLINDER (FRONT)…………………………….157
Removal And Installation………………………….157
Parts Identification……………………………..161
Disassembly And Assembly………………………….162
Inspection………………………………………165
STEERING CYLINDER (REAR)……………………………..167
Removal And Installation………………………….167
Parts Identification……………………………..170
Disassembly And Assembly………………………….171
Inspection………………………………………174
MAIN RELIEF VALVE……………………………………177
Description……………………………………..177
Testing…………………………………………177
Adjustment………………………………………178
PORT RELIEF VALVE (BACKHOE CONTROL VALVE)………………179
Testing And Adjusting (Arm Control)………………..179
Testing And Adjusting (Bucket Control)……………..180
Testing And Adjusting (Boom Control)……………….182
Testing And Adjusting (Boom Swing Control)………….183
PORT RELIEF VALVE (LOADER CONTROL VALVE)……………….185
Testing And Adjusting (Bucket Tilt)………………..185
Testing And Adjusting (Front Auxiliary)…………….187
LOADER CONTROL VALVE…………………………………189
Removal And Installation………………………….189
Parts Identification……………………………..191
Disassembly And Assembly………………………….192
Inlet/Outlet Valve Section………………………..193
Lift Arm Valve Section……………………………195
Tilt Valve Section……………………………….198
Auxiliary Valve Section…………………………..202
BACKHOE CONTROL VALVE………………………………..207
Removal And Installation………………………….207
Parts Identification……………………………..209
Disassembly And Assembly………………………….210
Inlet/Outlet Valve Section………………………..211
Arm Valve Section………………………………..214
Bucket Valve Section……………………………..217
Right Stabilizer Valve Section…………………….220
Left Stabilizer Valve Section……………………..223
Boom Valve Section……………………………….227
Boom Swing Valve Section………………………….230
Outlet Valve Section……………………………..233
HYDRAULIC FLUID RESERVOIR…………………………….235
Removal And Installation………………………….235
Strainer Removal And Installation………………….237
HYDRAULIC FILTER HOUSING……………………………..239
Removal And Installation………………………….239
Disassembly……………………………………..240
Assembly………………………………………..241
GEAR PUMP…………………………………………..243
Removal And Installation………………………….243
Parts Identification……………………………..244
Disassembly And Assembly………………………….245
Inspection………………………………………247
STEERING PUMP……………………………………….249
Removal And Installation………………………….249
Parts Identification……………………………..250
Disassembly……………………………………..251
Inspection………………………………………260
Assembly………………………………………..260
TRAVEL PEDAL………………………………………..269
Removal And Installation………………………….269
Parts Identification……………………………..270
Disassembly And Assembly………………………….271
Neutral Adjustment……………………………….275
STEERING VALVE………………………………………277
Removal And Installation………………………….277
Description……………………………………..278
Wheel Alignment Procedure…………………………278
SAPR BRAKE CYLINDER………………………………….279
Removal And Installation………………………….279
Parts Identification……………………………..281
Disassembly……………………………………..282
Assembly………………………………………..284
SAPR BRAKE CONTROL VALVE……………………………..287
Removal And Installation………………………….287
Parts Identification……………………………..288
Disassembly And Assembly………………………….289
AUXILIARY CONTROL VALVE………………………………291
Removal And Installation………………………….291
Parts Identification……………………………..292
Disassembly And Assembly………………………….293
HYDROSTATIC SYSTEM………………………………………297
HYDROSTATIC SYSTEM INFORMATION………………………..299
Troubleshooting Chart…………………………….299
Replenishing Valve Function……………………….300
OIL COOLER………………………………………….301
Removal And Installation………………………….301
Parts Identification……………………………..302
HYDROSTATIC DRIVE MOTOR………………………………303
Description……………………………………..303
Removal And Installation………………………….303
Parts Identification……………………………..304
Disassembly……………………………………..305
Inspection………………………………………311
Assembly………………………………………..313
HYDROSTATIC PUMP…………………………………….321
Description……………………………………..321
Removal And Installation………………………….321
Parts Identification……………………………..324
Disassembly……………………………………..326
Inspection………………………………………342
Assembly………………………………………..344
HYDROSTATIC PUMP TESTING AND ADJUSTMENT………………..359
Hydrostatic Pump Work Sheet……………………….359
Pump Testing…………………………………….362
DRIVE SYSTEM……………………………………………367
PARKING BRAKE……………………………………….369
Lever Removal And Installation…………………….369
Cable Removal And Installation…………………….370
Adjustment………………………………………372
BRAKE CALIPER……………………………………….373
Removal And Installation………………………….373
Parts Identification……………………………..375
Disassembly And Assembly………………………….376
Adjustment………………………………………378
REAR AXLE…………………………………………..381
Removal…………………………………………381
Installation…………………………………….384
AXLE AND DIFFERENTIAL (REAR)………………………….387
Troubleshooting Chart…………………………….387
General Information………………………………388
Wheel Hub/Spindle Parts Identification……………..388
Wheel Hub/Spindle Disassembly……………………..389
Drive Axle Parts identification……………………393
Drive Axle Disassembly……………………………394
Steering Knuckle Parts identification………………397
Steering Knuckle Disassembly………………………398
Differential Parts identification………………….401
Differential Disassembly………………………….402
Differential Inspection…………………………..408
Pinion Group Parts identification………………….409
Pinion Group Disassembly………………………….410
Pinion Group Inspection…………………………..413
Pinion Group Assembly…………………………….414
Differential Assembly…………………………….421
Steering Knuckle Assembly…………………………430
Drive Axle Assembly………………………………433
Wheel Hub/Spindle Assembly………………………..436
STEERING ANGLE ADJUSTMENT (REAR AXLE)………………….441
Adjustment………………………………………441
FRONT AXLE………………………………………….443
Removal…………………………………………443
Installation…………………………………….445
AXLE AND DIFFERENTIAL (FRONT)…………………………447
Troubleshooting Chart…………………………….447
General Information………………………………448
Wheel Hub/Spindle Parts Identification……………..448
Wheel Hub/Spindle Disassembly……………………..449
Drive Axle Parts identification……………………453
Drive Axle Disassembly……………………………454
Steering Knuckle Parts identification………………457
Steering Knuckle Disassembly………………………458
Differential Parts Identification………………….461
Differential Disassembly………………………….462
Differential Inspection…………………………..468
Pinion Group Parts identification………………….469
Pinion Group Disassembly………………………….470
Pinion Group Inspection…………………………..473
Pinion Group Assembly…………………………….474
Differential Assembly…………………………….481
Steering Knuckle Assembly…………………………490
Drive Axle Assembly………………………………493
Wheel Hub/Spindle Assembly………………………..496
STEERING ANGLE ADJUSTMENT (FRONT AXLE)…………………501
Adjustment………………………………………501
DRIVESHAFT………………………………………….503
Removal And Installation………………………….503
DROP BOX……………………………………………505
Removal And Installation………………………….505
Parts Identification……………………………..508
Disassembly……………………………………..509
Inspection………………………………………516
Assembly………………………………………..516
MAIN FRAME……………………………………………..521
OPERATOR CAB………………………………………..523
Removal And Installation………………………….523
Cab Mount Removal And Installation…………………531
ENCLOSED CAB………………………………………..533
Removal And Installation………………………….533
Cab Mount Removal And Installation…………………541
OPERATOR SEAT……………………………………….543
Removal And Installation………………………….543
FLOOR PANELS………………………………………..545
Left Front Panel Removal And Installation…………..545
Right Front Panel Removal And Installation………….545
Rear Panel Removal And Installation………………..546
GRILL………………………………………………547
Removal And Installation………………………….547
GRILL FRAME…………………………………………549
Removal And Installation………………………….549
ENGINE SIDE COVERS…………………………………..551
Removal And Installation………………………….551
FENDER……………………………………………..553
Removal And Installation………………………….553
ENGINE COVER………………………………………..555
Removal And Installation………………………….555
FUEL TANK…………………………………………..557
Removal And Installation………………………….557
Fuel Fill Screen Removal And Installation…………..558
LIFT ARMS…………………………………………..559
Removal And Installation………………………….559
BOB-TACH……………………………………………563
Removal And Installation………………………….563
Bob-Tach Lever And Wedge………………………….565
Pivot Pin Bushing Removal And Installation………….567
ARM………………………………………………..569
Removal And Installation………………………….569
Arm Pivot Bushing Removal And Installation………….571
BOOM……………………………………………….573
Removal And Installation………………………….573
Boom Pivot Bushing Removal And Installation…………574
SWING FRAME…………………………………………575
Removal And Installation………………………….575
Bushing Removal And Installation…………………..577
X-CHANGE®…………………………………………..579
Removal And Installation………………………….579
BUCKET……………………………………………..581
Backhoe Bucket Teeth Removal And Installation……….581
Loader Bucket Teeth Removal And Installation………..581
STABILIZER FRAME…………………………………….583
Removal And Installation………………………….583
FRONT AXLE PIVOT FRAME……………………………….587
Removal…………………………………………587
Installation…………………………………….588
Bushing Removal And Installation…………………..589
REAR WINDOW…………………………………………591
Removal And Installation………………………….591
CAB DOOR……………………………………………595
Removal And Installation………………………….595
ELECTRICAL SYSTEM AND ANALYSIS……………………………597
ELECTRICAL SCHEMATIC…………………………………599
ELECTRICAL SYSTEM INFORMATION…………………………601
Troubleshooting Chart…………………………….601
Description……………………………………..602
Fuse And Relay Location…………………………..602
BATTERY…………………………………………….603
Removal And Installation………………………….603
Servicing The Electrical System……………………604
Using A Booster Battery (Jump Starting)…………….605
ALTERNATOR………………………………………….607
Adjusting The Alternator Belt……………………..607
Description……………………………………..607
Tests…………………………………………..608
Alternator Output Test……………………………608
Full Field Test………………………………….609
Alternator Regulator Test…………………………609
Alternator Regulator Test With Voltmeter……………610
Removal And Installation………………………….611
Parts Identification……………………………..612
Pulley Removal And Installation……………………613
Disassembly And Assembly………………………….614
Rotor Continuity Test…………………………….617
Stator Continuity Test……………………………617
Rectifier Continuity (Diode) Test………………….618
Brush Length…………………………………….618
STARTER…………………………………………….619
Removal And Installation………………………….619
Checking The Starter In The Loader…………………619
Parts Identification……………………………..621
Disassembly……………………………………..622
Inspection And Repair…………………………….627
No Load Test…………………………………….631
Assembly………………………………………..632
FRONT LIGHTS………………………………………..639
Bulb Removal And Installation……………………..639
Housing Removal And Installation…………………..641
TURN INDICATOR LIGHTS (FRONT)…………………………643
Bulb Removal And Installation……………………..643
TURN INDICATOR LIGHTS (REAR)………………………….645
Bulb Removal And Installation……………………..645
CAB LIGHTS………………………………………….647
Bulb Removal And Installation……………………..647
Housing Removal And Installation…………………..649
FUEL LEVEL SENDER……………………………………651
Removal And Installation………………………….651
Testing…………………………………………652
INSTRUMENT PANEL…………………………………….653
Removal And Installation………………………….653
FRONT WIPER…………………………………………655
Removal And Installation………………………….655
REAR WIPER………………………………………….659
Removal And Installation………………………….659
ENGINE SERVICE………………………………………….661
TROUBLESHOOTING……………………………………..665
Chart…………………………………………..665
ENGINE SPEED CONTROL…………………………………667
Removal And Installation………………………….667
Cable Removal And Installation…………………….668
MUFFLER…………………………………………….669
Removal And Installation………………………….669
AIR CLEANER…………………………………………671
Removal And Installation………………………….671
RADIATOR……………………………………………673
Removal And Installation………………………….673
ENGINE COMPONENTS AND TESTING…………………………675
Checking Engine Compression……………………….675
Checking Glow Plugs………………………………676
Glow Plug Removal And Installation…………………677
Fuel Shut-Off Solenoid Removal And Installation……..678
Checking Fuel Injection Pump………………………679
Fuel Injection Pump Removal And Installation………..680
Fuel Injection Pump Timing………………………..682
Fuel Injector Nozzles Removal And Installation………683
Checking Fuel Injector, Nozzles……………………685
Thermostat Removal And Installation………………..686
Water Pump Removal And Installation………………..687
ENGINE……………………………………………..689
Removal And Installation………………………….689
Mount Replacement………………………………..693
RECONDITIONING THE ENGINE…………………………….695
Timing Gear Case Cover Removal And Installation……..695
Oil Pump Removal And Installation………………….697
Crankshaft Front Seal Removal And Installation………699
Engine Speed Control Plate Removal And Installation….700
Idle Limit And Fuel Limit Adjustment……………….701
Exhaust Manifold Removal And Installation…………..701
Valve Cover Removal And Installation……………….702
Rocker Arm Removal And Installation………………..703
Push Rod Removal And Installation………………….704
Tappet Removal And Installation……………………705
Water Flange Removal And Installation………………705
Cylinder Head Removal And Installation……………..706
Checking Piston Top Clearance……………………..707
Cylinder Head Disassembly And Assembly……………..708
Servicing The Cylinder Head……………………….709
Combustion Chamber Removal And Installation…………712
Idler Gear Removal And Installation………………..713
Camshaft Removal And Installation………………….714
Fuel Camshaft Removal And Installation……………..716
Oil Pan Removal And Installation…………………..718
Governor Shaft Removal And Installation…………….719
Governor Fork Lever Removal And Installation………..722
Piston Removal And Installation……………………724
Checking The Piston And Connecting Rod……………..724
Connecting Rod Alignment………………………….725
Piston Ring Gap………………………………….725
Piston Ring Installation………………………….726
Connecting Rod Installation……………………….727
Checking Engine Cylinder Bore……………………..727
Crankshaft Removal And Installation………………..728
Checking Crankshaft Journal And Block Bearing……….730
Checking Crankshaft Journal And Main Bearing………..731
Connecting Rod Journal……………………………732
Checking The End Play Of The Crankshaft…………….733
Crankshaft Alignment……………………………..733
Engine Timing Installation………………………..734
Timing Gear Backlash, Idler Gear And Crankshaft……..734
Idler Gear And Camshaft Gear………………………735
Idler Gear And Fuel Camshaft Gear………………….735
Fuel Camshaft Gear And Governor Shaft Gear………….735
FLYWHEEL HOUSING…………………………………….737
Removal And Installation………………………….737
FLYWHEEL……………………………………………739
Removal And Installation………………………….739
Ring Gear Removal And Installation…………………739
RUBBER DRIVE COUPLER…………………………………741
Removal And Installation………………………….741
Disassembly……………………………………..741
TURBOCHARGER………………………………………..743
Checking………………………………………..743
Description……………………………………..743
Removal And Installation………………………….743
HEATER…………………………………………………747
COMPONENTS………………………………………….749
Identification…………………………………..749
HEATER FAN………………………………………….751
Removal And Installation………………………….751
HEATER UNIT…………………………………………753
Removal And Installation………………………….753
Disassembly And Assembly………………………….754
SPECIFICATIONS………………………………………….757
LOADER BACKHOE SPECIFICATIONS…………………………760
Loader Backhoe Dimensions…………………………760
Backhoe Rated Load Capacity (Per SAE J31)…………..761
Loader Performance……………………………….762
Backhoe Performance………………………………762
Controls………………………………………..762
Drive System…………………………………….762
Engine………………………………………….763
Electrical………………………………………763
Capacities………………………………………763
Tires…………………………………………..763
ENGINE SPECIFICATIONS………………………………..765
Engine Compression……………………………….765
Fuel Injection Nozzles……………………………765
Fuel Injection Pump………………………………765
Cylinder Head……………………………………765
Valves………………………………………….765
Valve Springs……………………………………766
Rocker Arms……………………………………..766
Camshaft………………………………………..766
Cylinders……………………………………….766
Piston Rings…………………………………….767
Pistons…………………………………………767
Crankshaft………………………………………767
Oil Pump………………………………………..768
Thermostat………………………………………768
Grinding Specifications for the Crankshaft………….769
LOADER BACKHOE TORQUE………………………………..771
Specifications…………………………………..771
TORQUE SPECIFICATIONS FOR BOLTS……………………….773
Torque For General Metric Bolts……………………773
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS……………..775
Specifications…………………………………..775
CONVERSIONS…………………………………………777
Decimal And Millimeter Equivalents…………………777
U.S. To Metric Conversion…………………………777
SMR……………………………………………………779
B250-1……………………………………………..779
B250-2 …………………………………………….781
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DESCRIPTION:
BOBCAT B250 B Series SN 572911001 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 loosen 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