Bobcat S250 S300 Repair Manual [Skid Steer Loader] (A5GM20001-…)

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Description

Revised Factory [6987039] Workshop Repair Service Manual For Bobcat S250, S300 Skid Steer Loader. Detailed Step by Step Instructions, diagrams, illustrations make easy any repair, Overhaul, Disassembly and Assembly, Testing, Adjustment, Replacement and Change, Inspection and Adjustment, etc.

= Printable,
= Zoom able,
= Clickable index,
= Bookmarks,
= Searchable Text

MODELS Covered

Bobcat S250, S300

Serial Number A5GM20001 & Above
Serial Number A5GN20001 & Above
Serial Number A5GP20001 & Above
Serial Number A5GR20001 & Above

SECTIONS covered

* Safety And Maintenance

Air Cleaner Service
Replacing Filter Elements
Bob-Tach (Hand Lever)
Inspection And Maintenance
Bob-Tach (Power)
Inspection And Maintenance
Engine Cooling System
Checking Level
Cleaning
Removing And Replacing Coolant
Engine Lubrication System
Checking And Adding Engine Oil
Engine Oil Chart
Removing And Replacing Oil And Filter
Final Drive Transmission (Chaincase)
Checking And Adding Oil
Removing And Replacing Oil
Fuel System
Biodiesel Blend Fuel
Filling The Fuel Tank
Fuel Filter
Fuel Specifications
Removing Air From The Fuel System
Hydraulic / Hydrostatic System
Breather Cap
Checking And Adding Fluid
Hydraulic / Hydrostatic Fluid Chart
Removing And Replacing Hydraulic Charge Filter
Removing And Replacing Hydraulic Fluid
Removing And Replacing Case Drain Filters
Removing And Replacing Hydraulic / Hydrostatic Filter
Lift Arm Support Device
Installing
Removing
Lifting And Blocking The Loader
Procedure
Loader Storage And Return To Service
Return To Service
Storage
Lubricating The Loader
Lubrication Locations
Operator Cab
Cab Door Sensor
Description
Forestry Door And Window Kit
Forestry Door And Window Kit Inspection And Maintenance
Lowering
Raising
Special Applications Kit
Special Applications Kit Inspection And Maintenance
Pivot Pins
Inspection And Maintenance
Remote Start Tool Kit-Mel
Remote Start Procedure
Remote Start Tool – Mel
Service Tool Harness Communicator – Mel
Service Tool Harness Control – Mel
Remote Start Tool (Service Tool) Kit –
Computer Service Tool Harness –
Description
Loader Service Tool Harness –
Computer Service Tool Harness –
Remote Start Tool (Service Tool) –
Service Schedule
Chart
Spark Arrestor Muffler
Cleaning Procedure
Stopping The Engine And Leaving The Loader
Emergency Exit
Procedure
Tire Maintenance
Mounting
Rotating
Wheel Nuts
Towing The Loader
Procedure
Transporting The Loader On A Trailer
Fastening
Loading And Unloading

* Hydraulic System

Bob-Tach (Power) Block
Description
Disassembly And Assembly
Removal And Installation
Bucket Position Valve
Description
Disassembly And Assembly
Removal And Installation
Solenoid Removal And Installation
Solenoid Testing
Cylinder (Bob-Tach)
Assembly
Disassembly
Parts Identification
Removal And Installation
Testing
Cylinder (Lift)
Assembly
Disassembly
Parts Identification
Removal And Installation
Testing
Cylinder (Tilt)
Assembly
Base End Pivot Pin Removal And Installation
Disassembly
Parts Identification
Removal And Installation
Testing
Front Auxiliary Hydraulic Coupler Block
Description
Disassembly And Assembly
Removal And Installation
Hydraulic Control Valve (Acs) Or (Sjc)
Actuator Removal And Installation (In Loader)
Actuator Removal And Installation (Out Of Loader)
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)
Auxiliary Solenoid Removal And Installation
Auxiliary Spool Removal And Installation
Check Valve Removal And Installation
Description
End Cap Block Removal And Installation
Identification Chart
Lift Arm By-Pass Orifice Removal And Installation
Lift Load Check Valve Removal And Installation
Lift Spool And Detent Removal And Installation
Load Check Valve Removal And Installation (Tilt & Auxiliary)
Lock Valve Removal And Installation
Main Relief Valve Removal And Installation
Mount Bracket Removal And Installation
Plug Removal And Installation
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
Removal And Installation
Solenoid Removal And Installation
Tilt Spool Removal And Installation
Hydraulic Control Valve (Standard)
Auxiliary Solenoid Removal And Installation
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)
Auxiliary Spool Removal And Installation
Check Valve Removal And Installation
Description
End Cap Block Removal And Installation
Identification Chart
Lift Arm By-Pass Orifice Removal And Installation
Lift Load Check Valve Removal And Installation
Lift Spool And Detent Removal And Installation
Load Check Valve Removal And Installation (Tilt & Auxiliary)
Lock Valve Removal And Installation
Main Relief Valve Removal And Installation
Mount Bracket Removal And Installation
Plug Removal And Installation
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
Removal And Installation
Rubber Boot Removal And Installation
Solenoid Removal And Installation
Tilt Spool Removal And Installation
Hydraulic Fluid Reservoir
Description
Hydraulic Fluid Screen
Removal And Installation
Hydraulic Pump (Sjc)
Description
Direct Pump Test (Charge Section)
Direct Pump Test (Standard Section)
Disassembly And Assembly
Hydraulic Pump Startup
Parts Identification
Pump Test At Quick Couplers
Removal And Installation
Hydraulic Pump (Sjc) (High Flow)
Description
Direct Pump Test (Charge Section)
Direct Pump Test (High Flow Section)
Direct Pump Test (Standard Section)
Disassembly And Assembly
High Flow Relief Valve Adjustment
High Flow Relief Valve Removal And Installation
Hydraulic Pump Startup
Parts Identification
Pump Test At Quick Couplers
Solenoid Removal And Installation
Removal And Installation
Hydraulic Pump (Standard)
Description
Direct Pump Test (Charge Section)
Direct Pump Test (Standard Section)
Disassembly And Assembly
Hydraulic Pump Startup
Parts Identification
Pump Test At Quick Couplers
Removal And Installation
Hydraulic Pump (Standard) (High Flow)
Description
Direct Pump Test (Charge Section)
Direct Pump Test (High Flow Section)
Direct Pump Test (Standard Section)
Disassembly And Assembly
High Flow Relief Valve Adjustment
High Flow Relief Valve Removal And Installation
Hydraulic Pump Startup
Parts Identification
Pump Test At Quick Couplers
Removal And Installation
Solenoid Removal And Installation
Hydraulic System Information
Glossary Of Hydraulic / Hydrostatic Symbols
Troubleshooting
Hydraulic/Hydrostatic Filters
Description
Housing Removal And Installation
Lift Arm Bypass Control Valve
Description
Disassembly And Assembly
Removal And Installation
Testing
Main Relief Valve
Adjusting
Description
Removal And Installation
Testing
Oil Cooler
Description
Removal And Installation
Rear Auxiliary Diverter Valve
Description
Disassembly And Assembly
Removal And Installation
Solenoid Testing
* Hydrostatic System

Case Drain Filter
Description
Disassembly And Assembly
Charge Pressure
Adjusting
Description
Sender Removal And Installation
Testing
Drive Belt
Adjusting
Belt Removal And Installation
Description
Shield Removal And Installation
Tensioner Pulley Disassembly And Assembly
Tensioner Pulley Removal And Installation
Tensioner Pulley Tension Disassembly And Assembly
Tensioner Pulley Tension Spring Removal And Installation
Hydrostatic Motor
Description
Disassembly And Assembly
Parts Identification
Removal And Installation
Hydrostatic Motor Carrier
Assembly
Description
Disassembly
Parts Identification
Removal And Installation
Hydrostatic Motor Carrier (Sjc)
Assembly
Description
Disassembly
Parts Identification
Removal And Installation
Hydrostatic Motor (Two-Speed)
Assembly
Description
Disassembly
Parts Identification
Removal And Installation
Hydrostatic Pump
Assembly
Description
Disassembly
Hydrostatic Pump Startup
Parts Identification (Left Half)
Parts Identification (Right Half)
Replenishing / High Pressure Relief Valve Removal And Installation
Hydrostatic Pump (Sjc)
Charge Relief Valve
Description
Disassembly And Assembly
High Pressure Relief And Bypass Valve
Hydraulic Controller Neutral Adjustment
Hydraulic Controller Removal And Installation
Hydrostatic Pump Startup
Mechanical Neutral Adjustment
Parts Identification
Removal And Installation
Hydrostatic System Information
Description
Troubleshooting

* Drive System

Brake
Description
Disc Removal And Installation
Brake (Two-Speed)
Block Disassembly And Assembly
Block Removal And Installation
Description
Chaincase
Center Cover Removal And Installation
Description
Front Cover Removal And Installation
Rear Cover Removal And Installation
Drive Components
Axle Seal Removal And Installation
Axle, Sprocket And Bearings Removal And Installation
Chain Removal And Installation
Description

* Main Frame

Access Panel (Inside)
Removal And Installation (Left)
Removal And Installation (Right)
Access Panel (Inside) (Sjc)
Removal And Installation (Left)
Removal And Installation (Right)
Bob-Tach (Hand Lever)
Description
Lever And Wedge Disassembly And Assembly
Pivot Pin Bushing And Seal Removal And Installation
Removal And Installation
Bob-Tach (Power)
Description
Lever And Wedge Disassembly And Assembly
Pivot Pin Bushing And Seal Removal And Installation
Removal And Installation
Cab Door
Adjusting
Aligning
Checking Operation
Description
Removal And Installation
Control Handle / Lever
Boot Removal And Installation
Description
Lever Removal And Installation
Control Handle / Lever (Acs)
Boot Removal And Installation
Description
Handle Disassembly And Assembly
Handle Removal And Installation
Handle Sensor Removal And Installation
Lever Removal And Installation
Control Handle / Lever (Sjc)
Description
Joystick Mount Removal And Installation
Joystick Removal And Installation
Joystick Testing
Control Panel
Description
Linkage Neutral (Adjusting)
Linkage Removal And Installation
Linkage Travel (Adjusting)
Removal And Installation
Pintle Arm Disassembly And Assembly
Shaft Removal And Installation
Shock Removal And Installation
Control Panel (Sjc)
Description
Removal And Installation
Control Pedals (Acs)
Description
Foot Pedal Linkage Disassembly And Assembly
Foot Pedal Removal And Installation
Foot Sensor Removal And Installation
Control Pedals And Linkages
Description
Linkage Removal And Installation
Pedal (Adjusting)
Pedal Removal And Installation
Fuel Tank
Fuel Fill Screen Removal And Installation
Fuel Level Sender Removal And Installation
Removal And Installation
Lift Arms
Link Removal And Installation
Removal And Installation
Stabilizer Bar Removal And Installation
Operator Cab
Gas Cylinder Bracket Disassembly And Assembly
Gas Cylinder Removal And Installation
Removal And Installation
Operator Seat
Removal And Installation
Seat Belt Removal And Installation
Operator Seat (Suspension)
Back Cushion Removal And Installation
Lower Cushion Removal And Installation
Removal And Installation
Seat Belt Removal And Installation
Shock Removal And Installation
Slide Rail Removal And Installation
-Point Seat Belt Removal And Installation
Rear Door
Latch Removal And Installation
Removal And Installation
Striker (Adjusting)
Striker Disassembly And Assembly
Striker Removal And Installation
Rear Grill
Removal And Installation
Seat Bar
Compression Spring Disassembly And Assembly
Description
Disassembly And Assembly
Removal And Installation
Window (Cab Door)
Installation (Standard Window)
Removal (Standard Window)
Removal And Installation (Special Applications Window)
Window (Rear)
Installation
Removal
Window (Side)
Removal And Installation
Window (Top)
Removal And Installation

* Electrical System & Analysis

Alternator
Alternator Voltage Testing
Belt Adjustment
Belt Replacement
Charging System Inspection
High Voltage Testing
Low Voltage Testing
Parts Identification
Removal And Installation
Back-Up Alarm System
Adjusting Switch Position
Alarm Removal And Installation
Description
Inspecting
Switch Removal And Installation
Troubleshooting (Joystick)
Troubleshooting (Standard And Acs)
Battery
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
Bobcat Controller (Acs)
Connector And Wire Identification
Description
Removal And Installation
Bobcat Controllers (Gateway And Auxiliary)
Connector Identification
Description
Removal And Installation
Bobcat Controller (Sjc) (Drive)
Connector Identification
Description
Removal And Installation
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
Calibration
Actuator Testing
Description
Hydrostatic Pump Calibration (Sjc)
Lift And Tilt Calibration (Acs)
Lift And Tilt Calibration (Sjc)
Control Panel Setup
Attachment Control Information (Deluxe Instrumentation Panel)
Right Panel Setup (Deluxe Instrumentation Panel)
Control System (Acs)
Actuator Connector Disassembly And Assembly
Description
Foot Lock Solenoid Removal And Installation
Foot Sensor Disassembly And Assembly
Handle Lock Solenoid Disassembly And Assembly
Handle Lock Solenoid Removal And Installation
Handle Sensor Connector Disassembly And Assembly
Switch Handle Installation
Switch Handle Removal
Troubleshooting
Diagnostic Service Codes
Viewing Service Codes (Deluxe Instrumentation Panel)
Viewing Service Codes (Standard Key Panel)
Service Codes List
Electrical / Hydraulic Controls
Identification Chart
Electrical / Hydraulic Controls (Sjc)
Identification Chart
Electrical System Information
Cab Harness Connectors
Description
Fuse And Relay Location / Identification
Glossary Of Electrical Symbols
Mainframe Harness Connectors
Solenoid Testing
Troubleshooting
Flywheel Rpm Sensor
Adjusting
Description
Instrument Panels
Alarm Removal And Installation
Deluxe Instrumentation Panel
Front Panel
Front Panel Removal And Installation
Key Switch Removal And Installation
Left Panel
Removal And Installation (Left And Right)
Side Panel
Standard Key Panel
Lights
Cab Light Removal And Installation
Front Removal And Installation
Rear Removal And Installation
Maintenance Clock
Description
Reset
Setup
Password Setup
Changing The Owner Password
Changing The User Passwords
Password Description
Password Lockout Feature
Seat Bar Sensor
Bobcat Interlock Control System (Bics) Circuit Test
Description
Removal And Installation
Testing
Troubleshooting
Service Pc (Laptop Computer)
Connecting Remote Start Tool
Connecting Remote Start Tool (Service Tool)
Speed Sensor (Sjc)
Description
Removal And Installation
Testing
Starter
Parts Identification
Removal And Installation
Testing
Steering Drift Compensation
Description
Operation
Traction Lock
Description
Inspecting (Single And Two Speed)
Removal And Installation (Single Speed)
Troubleshooting

* Engine Service

Air Cleaner
Housing Removal And Installation
Camshaft And Timing Gears
Camshaft – Servicing
Idler Gear And Camshaft Removal And Installation
Idler Gear And Shaft – Servicing
Timing Gearcase Cover Removal And Installation
Timing Gears Backlash – Checking
Crankshaft And Pistons
Cylinder Bore – Checking
Connecting Rod Alignment
Crankshaft And Bearings Installation
Crankshaft And Bearings Removal
Crankshaft And Bearings – Servicing
Crankshaft Gear Removal And Installation
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod – Servicing
Cylinder Head
Cylinder Head Disassembly And Assembly
Cylinder Head Removal And Installation
Cylinder Head – Servicing
Cylinder Head Top Clearance
Intake Air Heater Removal And Installation
Intake Air Heater – Testing
Push Rod Alignment – Checking
Reconditioning The Valve And Valve Seat
Rocker Arm And Shaft – Checking
Valve Clearance Adjustment
Valve Guide – Checking
Valve Spring
Valve Tappets
Valve Timing – Checking
Engine Cooling System
Axial Fan Housing Removal And Installation
Axial Fan Removal And Installation
Hydraulic Fan Motor Description
Hydraulic Fan Motor Removal And Installation
Hydraulic Fan Motor Disassembly And Assembly
Hydraulic Fan Motor Description
Hydraulic Fan Motor Removal And Installation
Hydraulic Fan Motor Disassembly And Assembly
Radiator Removal And Installation
Radiator Mount Removal And Installation
Thermostat – Checking
Thermostat Housing Removal And Installation
Water Pump Disassembly And Assembly
Water Pump Removal And Installation
Engine Information
Compression – Checking
Description
Engine Mount Replacement
Engine Removal And Installation
Troubleshooting
Specifications
Torque Values
Engine Speed Control
Cable Removal And Installation
Removal And Installation
Engine Speed Control (Sjc)
Disassembly And Assembly
Removal And Installation
Cable Removal And Installation
Flywheel And Housing
Flywheel Removal And Installation
Housing Removal And Installation
Ring Gear Removal And Installation
Fuel System
Fuel Camshaft Removal And Installation
Fuel Injection Pump Assembly Installation
Fuel Injection Pump Assembly Removal
Fuel Injection Pump Removal
Fuel Injector Nozzle Pressure – Checking
Fuel Injector Removal And Installation
Fuel Shutoff Solenoid – Checking
Fuel Shutoff Solenoid – Removal And Installation
Governor Disassembly And Assembly
Governor Housing Disassembly And Assembly
Injection Pump – Timing
Nozzle Spraying Condition
Valve Seat Tightness
Lubrication System
Engine Oil Pressure – Testing
Oil Filter Cooler Removal And Installation
Oil Pan Removal And Installation
Oil Pump Inspection
Oil Pump Removal And Installation
Muffler
Removal And Installation
Turbocharger
Description
Removal And Installation
Testing

* Heating, Ventilation, Air Conditioning

Air Conditioning System Flow
Chart
Components
Description
Safety Equipment
Blower Fan
Connector Identification
Disassembly And Assembly
Removal And Installation
Compressor
Clutch Disassembly And Assembly
Oil
Oil Check
Removal And Installation
Condenser
Removal And Installation
Evaporator Coil
Removal And Installation
Evaporator / Heater Unit
Removal And Installation
Expansion Valve
Removal And Installation
Heater Coil
Removal And Installation With A/C
Removal And Installation Without A/C
Heater Valve
Disassembly And Assembly
Removal And Installation
Receiver / Drier
Pressure Relief Valve Removal And Installation
Pressure Switch Removal And Installation
Receiver / Drier Removal And Installation
Schraeder Valve Removal And Installation
Regular Maintenance
Evaporator / Heater Coil
Air Conditioning Lubrication
Air Conditioning Service Chart
Compressor Drive Belt Adjustment
Compressor Drive Belt Replacement
Condenser
Filters
System Charging And Reclamation
Charging With A Manifold Gauge Set
Reclamation And Charging With Recovery / Charging Unit
Refrigerant Identification
Thermostat
Removal And Installation
Troubleshooting
Blower Motor Does Not Operate
Blower Motor Operates Normally, But Air Flow Is Insufficient
Electrical System
Engine Coolant By-Passing The Heater Valve
Gauge Pressure Related Troubleshooting
Heater Valve Not Opening Or Closing
Hvac Repair And Leaks
Insufficient Cooling Although Air Flow And Compressor Operation Are
Normal
Poor A/C Performance
Temperature / Pressure Chart
The Compressor Does Not Operate At All, Or Operates Improperly
Troubleshooting Tree

* Specifications

Conversions
Decimal And Millimeter Equivalents
Us To Metric Conversion Chart
Hydraulic Connection Specifications
Flare Fitting
O-Ring Face Seal Connection
Port Seal Fitting
Straight Thread O-Ring Fitting
Tubelines And Hoses
Hydraulic / Hydrostatic Fluid Specifications
Specifications
(S) Loader Specifications
Capacities
Controls
Drive System
Electrical
Engine
Hydraulic System
Machine Dimensions
Performance
Tires
Loader Specifications
Capacities
Controls
Drive System
Electrical
Engine
Hydraulic System
Machine Dimensions
Performance
Tires
Torque Specifications For Bolts
Torque For General Metric Bolts
Torque For General Sae Bolts