Bobcat S250 S300 Turbo Skid Steer Loader Complete Workshop Service Repair Manual

6904158 (1-08) Printed in U.S.A. © Bobcat Company 2008 Service Manual S250, S300 Skid-Steer Loader S/N 530911001 & Above S/N 531011001 & Above S/N 531111001 & Above S/N 531211001 & Above EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICS)

MAINTENANCE SAFETY Never service the Bobcat Skid- Steer Loader without instructions. Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced. Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed. Stop, cool and clean engine of flammable materials before checking fluids. Never service or adjust loader with the engine running unless instructed to do so in the manual. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes. Never fill fuel tank with engine running, while smoking or when near open flame. Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device. Replace it if damaged. Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust. Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding. Keep rear door closed except for service. Close and latch door before operating the loader. Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged. Never modify equipment or add attachments not approved by Bobcat Company. Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention. Use the correct procedure to lift or lower operator cab. Cleaning and maintenance are required daily. MSW14-0805 WRONG B-16102 B-6589 B-10731a CORRECT CORRECT B-16264 B-16261 CORRECT WRONG B-16272 B-16260 WRONG WRONG B-16263 B-16102 WRONG B-16270 B-16271 WRONG WARNING Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. W-2003-0903 Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer. Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

S250, S300 Service Manual ALPHABETICAL INDEX ACCESS PANEL (LEFT)......................................... 50-01 ACCESS PANEL (INSIDE) SJC) ............................ 50-01 ADVANCED CONTROL SYSTEM (ACS) ............... 60-01 AIR CLEANER ........................................................ 70-01 AIR CLEANER SERVICE ....................................... 10-01 AIR CONDITIONING SYSTEM FLOW ................... 80-01 ALTERNATOR ........................................................ 60-01 BACK-UP ALARM SYSTEM ................................... 60-01 BATTERY ................................................................ 60-01 BLOWER FAN ........................................................ 80-01 BOBCAT CONTROLLER (ACS) ............................. 60-01 BOBCAT CONTROLLER (MAIN)............................ 60-01 BOBCAT CONTROLLER (SJC) (DRIVE) ............... 60-01 BOBCAT INTERLOCK CONTROL SYSTEM (BICS) ................................................... 60-01 BOB-TACH (HAND LEVER) .................... 10-01, 50-01 BOB-TACH (POWER) BLOCK ............................ 20-01 BOB-TACH (POWER-OPTION) ................ 10-01, 50-01 BRAKE .................................................................... 40-01 BRAKE (TWO-SPEED) ........................................... 40-01 BUCKET POSITION VALVE ................................ 20-01 CAB DOOR ............................................................. 50-01 CALIBRATION ........................................................ 60-01 CAMSHAFT AND TIMING GEARS......................... 70-01 CASE DRAIN FILTER ............................................. 30-01 CHAINCASE ........................................................... 40-01 CHARGE PRESSURE ............................................ 30-01 COMPRESSOR ...................................................... 80-01 CONDENSER ......................................................... 80-01 CONTROL HANDLE / LEVER ................................ 50-01 CONTROL HANDLE / LEVER (ACS) ..................... 50-01 CONTROL HANDLE (ACS) .................................... 50-01 CONTROL HANDLE (SJC) ..................................... 50-01 CONTROL PANEL .................................................. 50-01 CONTROL PANEL (SJC) ........................................ 50-01 CONTROL PANEL SETUP ..................................... 60-01 CONTROL PEDALS (ACS) .................................... 50-01 CONTROL PEDALSAND LINKAGES..................... 50-01 CONTROL SYSTEM (ACS) .................................... 60-01 CONVERSIONS ............................................ SPEC-01 CRANKSHAFT AND PISTONS .............................. 70-01 CYLINDER HEAD ................................................... 70-01 CYLINDER (LIFT) ................................................... 20-01 CYLINDER (BOB-TACH) ........................................ 20-01 CYLINDER (TILT) ................................................ 20-01 DIAGNOSTICS SERVICE CODES ..................... 60-01 DRIVE BELT ........................................................... 30-01 DRIVE COMPONENTS .......................................... 40-01 ELECTRICAL / HYDRAULIC CONTROLS ............. 60-01 ELECTRICAL/HYDRAULIC CONTROLS (SJC) ..... 60-01 ELECTRICAL SYSTEM INFORMATION ................ 60-01 ENGINE COOLING SYSTEM ...................... 10-01, 70-01 ENGINE INFORMATION ........................................ 70-01 ENGINE LUBRICATION SYSTEM.......................... 10-01 ENGINE SPEED CONTROL .................................. 70-01 ENGINE SPEED CONTROL (SJC) ......................... 70-01 EVAPORATOR ........................................................ 80-01 EVAPORATOR / HEATER UNIT.............................. 80-01 EXPANSION VALVE ................................................ 80-01 FAN GEARBOX ....................................................... 10-01 FINAL DRIVE TRANSMISSION (CHAINCASE) .. 10-01 FLYWHEEL AND HOUSING ................................ 70-01 FLYWHEEL RPM SENSOR ................................. 60-01 FRONT AUXILIARY HYD. COUPLER BLOCK ....... 20-01 FUEL SYSTEM............................................. 10-01, 70-01 FUEL TANK ............................................................. 50-01 HEATER COIL ......................................................... 80-01 HEATER VALVE ...................................................... 80-01 HYDRAULIC CONNECTION SPECS ............... SPEC-01 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)..20-01 HYDRAULIC CONTROL VALVE (STANDARD) ...... 20-01 HYDRAULIC FLUID RESERVOIR .......................... 20-01 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS ........................................... SPEC-01 HYDRAULIC / HYDROSTATIC FILTERS ................ 20-01 HYDRAULIC / HYDROSTATIC SYSTEM ................ 10-01 HYDRAULIC PUMP (STANDARD) (HIGH FLOW)..20-01 HYDRAULIC PUMP (STANDARD) ........................ 20-01 HYDRAULIC PUMP (SJC) (HIGH FLOW)............... 20-01 HYDRAULIC PUMP (SJC) ...................................... 20-01 HYDRAULIC SYSTEM INFORMATION .................. 20-01 HYDROSTATIC MOTOR ..................................... 30-01 HYDROSTATIC MOTOR (TWO SPEED) ................ 30-01 HYDROSTATIC MOTOR CARRIER ........................ 30-01 HYDROSTATIC MOTOR CARRIER (SJC) .............. 30-01 HYDROSTATIC PUMP ......................................... 30-01 HYDROSTATIC PUMP (SJC) ............................. 30-01 HYDROSTATIC SYSTEM INFORMATION .......... 30-01 INSTRUMENT PANELS .......................................... 60-01 JOYSTICK CONTROL ............................................ 50-01 LIFT ARMS .............................................................. 50-01 LIFT ARM BYPASS CONTROL VALVE .............. 20-01 LIFT ARM SUPPORT DEVICE ........................... 10-01 LIFTING AND BLOCKING THE LOADER............... 10-01 LIGHTS ................................................................ 60-01 S250 LOADER SPECIFICATIONS .................... SPEC-01 S300 LOADER SPECIFICATIONS .................... SPEC-01 LOADER STORAGE AND RETURN TO SERVICE 10-01 LUBRICATION SYSTEM .............................. 10-01, 70-01 LUBRICATING THE LOADER ................................. 10-01 MAIN RELIEF VALVE .............................................. 20-01 MAIN RELIEF VALVE (FOOT CONTROL) .............. 20-01 MAIN RELIEF VALVE (SELECTABLE JOYSTICK CONTROL) (SJC) ...... 20-01 MAINTENANCE CLOCK ......................................... 60-01 MUFFLER................................................................ 70-01

S250, S300 Service Manual ALPHABETICAL INDEX (CONT’D) OIL COOLER ........................................................... 30-01 OPERATOR CAB..........................................10-01, 50-01 OPERATOR SEAT ................................................... 50-01 OPERATOR SEAT (SUSPENSION) ........................ 50-01 PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START) ................................................................. 60-01 PIVOT PINS............................................................. 10-01 REAR AUXILIARY DIVERTER VALVE .................... 20-01 REAR DOOR ...................................................... 50-01 REAR GRILL ....................................................... 50-01 RECEIVER / DRIER ................................................80-01 REGULAR MAINTENANCE .................................... 80-01 REMOTE START ................................................ 10-01 REMOTE START (SERVICE TOOL) ...................... 10-01 SEAT BAR ............................................................... 50-01 SEAT BAR SENSOR ............................................... 60-01 SRVICE PC (LAPTOP COMPUTER) ...................... 60-01 SERVICE SCHEDULE ........................................... 10-01 SPEED SENSOR (SJC) .......................................... 60-01 SPARK ARRESTOR MUFFLER .............................. 10-01 STARTER ................................................................ 60-01 STEERING DRIFT COMPENSATION ..................... 60-01 STOPPING THE ENGINE AND LEAVING THE LOADER ........................................................ 10-01 SYSTEM CHARGING AND RECLAMATION .......... 80-01 THERMOSTAT......................................................... 80-01 TIRE MAINTENANCE ............................................. 10-01 TORQUE SPECIFICATIONS FOR BOLTS .... SPEC-01 TOWING THE LOADER .......................................... 10-01 TRACTION LOCK.................................................... 60-01 TRANSPORTING THE LOADER ON A TRAILER ..10-01 TROUBLESHOOTING............................................. 80-01 TURBOCHARGER .................................................. 70-01 WINDOW (FRONT DOOR) .................................... 50-01 WINDOW (REAR).................................................... 50-01 WINDOW (SIDE) ..................................................... 50-01 WINDOW (TOP) ...................................................... 50-01

i S250, S300 Service Manual CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . X SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01 MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 SPECIFICATIONS SAFETY & HYDROSTATIC MAIN FRAME SYSTEM SYSTEM DRIVE ELECTRICAL MAINTENANCE SYSTEM & ANALYSIS SERVICE ENGINE SPECIFICATIONS HVAC HYDRAULIC SYSTEM

ii S250, S300 Service Manual

iii S250, S300 Service Manual FOREWORD 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: 1. Check that the ROPS/FOPS (Including side screens) is in good condition and is not modified. 9. The parking brake must function correctly. 2. Check that ROPS mounting hardware is tightened and is Bobcat approved. 10. Enclosure door latches must open and close freely. 3. The seat belt must be correctly installed, functional and in good condition. 11. Bob-Tach wedges and linkages must function correctly and be in good condition. 4. The seat bar must be correctly adjusted, clean and lubricated. 12. Safety treads must be in good condition. 5. Check lift arm support device, replace if damaged. 13. Check for correct function of indicator lamps (Optional on some models). 6. Machine signs must be legible and in the correct location. 14. Check hydraulic fluid level, engine oil level and fuel supply. 7. Steering levers and foot pedals must return to neutral. 15. Inspect for fuel, oil or hydraulic fluid leaks. 8. Check for correct function of the work lights 16. Lubricate the loader.

iv S250, S300 Service Manual 17. Check the condition of the battery and cables. 22. Operate the loader and check all functions. 18. Inspect the air cleaner for damage or leaks. Check the condition of the element. 23. Check for any field modification not completed. 19. Check the electrical charging system. 24. Check for correct function of the Bobcat Interlock Control System (BICS™) before the machine is returned to the customer. 20. Check tires for wear and pressure. 25. Recommend to the owner that all necessary corrections be made before the machine is returned to service. 21. Inspect for loose or broken parts or connections. CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects and other reproductive harm.

Bobcat S250 S300 Turbo Skid Steer Loader Complete Workshop Service Repair Manual

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