Bobcat T2250 Telescopic Handler Service Manual (Version August 2012)

Bobcat T2250 Telescopic Handler Service Manual
S/N AC1911000 & Above

Type of machine: Telescopic Handler
Print No: 6987147, August 2012
Language and Format: English/PDF
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The Service Manual will give you complete information on repair, servicing and preventative maintenance, for your Bobcat T2250 Telescopic Handler.

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Table of contents:
1. Foreword
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrestor Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATION
VersaHANDLER Serial Number
Engine Serial Number
Other Serial Numbers
DELIVERY REPORT
BOBCAT VERSAHANDLER IDENTIFICATION

2. SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE TELESCOPIC HANDLER
Procedure
OPERATOR CAB (ROPS / FOPS)
Emergency Exit
Cab Door
Cab Door Window
TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER
Loading And Unloading
Fastening
TOWING THE TELESCOPIC HANDLER
Releasing The Brake Discs
Towing
Engaging The Brake Discs
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Replacing The Filter Element
ENGINE COOLING SYSTEM
Cleaning
Removing And Replacing The Coolant
Checking Level
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Fuel Filter
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Oil Chart
Replacing Oil And Filter
HYDRAULIC / HYDROSTATIC SYSTEM
Checking And Adding Fluid
Replacing The Hydraulic / Hydrostatic Filters
Replacing Hydraulic Fluid
ATTACHMENT CARRIER
Inspection And Maintenance
BOB-TACH (HAND LEVER) (IF EQUIPPED)
Inspection And Maintenance
AXLES (FRONT AND REAR)
Checking Oil Level (Planetary Carrier)
Draining Oil (Planetary Carrier)
Checking Oil Level (Rear Differential)
Draining Oil (Rear Differential)
Checking Oil Level (Front Differential)
Draining Oil (Front Differential)
LUBRICATING THE TELESCOPING HANDLER
Procedure
TIRE MAINTENANCE
Wheel Nuts
Tire Mounting
Tire Rotation
Tire Pressure
APPROVED BOOM STOP (IF EQUIPPED)
Installing The Approved Boom Stop
Removing The Approved Boom Stop
ENGINE COVER
Opening And Closing The Engine Cover
REMOTE START
Connecting to the Telescopic Handler
Remote Start Procedure (For Tools MEL1563
and MEL1565)
Remote Start Procedure (For Tool Kit P/N 6689779)
TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE
Storage
Return to Service
STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER
Procedure
EMERGENCY EXIT
Rear Window

3. HYDRAULIC SYSTEM
HYDRAULIC SYSTEM INFORMATION
Troubleshooting Chart
Tightening Procedures
LIFT CYLINDER
Removal And Installation
Parts Identification
Disassembly
Assembly
BUCKET POSITIONING CYLINDER
Removal And Installation
Parts Identification
Disassembly
Assembly
EXTENSION CYLINDER
Cylinder Group Removal And Installation
Upper Tubeline Removal
Upper Tubeline Installation
Extension Cylinder Removal And Installation
Tubeline Tray Disassembly
Tubeline Tray Assembly
Parts Identification
Disassembly
Assembly
TILT CYLINDER
Removal And Installation
Parts Identification
Disassembly
Assembly
STEERING CYLINDER (FRONT)
Removing the Steering Cylinder
Installing the Steering Cylinder
Parts Identification
Disassembling the Steering Cylinder
Assembling the Steering Cylinder
STEERING CYLINDER (REAR)
Removing The Steering Cylinder
Parts Identification
Disassembling the Steering Cylinder
Assembling the Steering Cylinder
DRIVE BOX
Parts Identification
Disassembly
Assembly
Special Tools
MAIN RELIEF VALVE
Testing And Adjustment
Removal And Installation
PORT RELIEF VALVES
Parts Identification
Adjustment Procedure
STEERING MODE VALVE BLOCK
Removal And Installation
Parts Identification
Disassembly
Solenoid Testing
Assembly
BRAKE VALVE
Removal And Installation
Disassembly And Assembly
GEAR PUMP
Removal And Installation
Parts Identification
Disassembly And Assembly
HYDRAULIC FLUID RESERVOIR
Removal And Installation
STEERING VALVE
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
HYDRAULIC CONTROL VALVE (FOR S/N AC1911001 – 11251)
Troubleshooting Chart (Controllers)
Telescoping Valve Section Troubleshooting
Auxiliary Valve Section Troubleshooting
Troubleshooting Chart (Control Valve)
Removal And Installation
Parts Identification
Disassembly And Assembly
End Housing Disassembly And Assembly
Telescoping and Auxiliary Valve Section Disassembly And Assembly
Lifting and Tilting Valve Section Disassembly And Assembly
Inlet-Outlet Valve Section Disassembly And Assembly
HYDRAULIC CONTROL VALVE (FOR S/N AC1911252 & ABOVE)
Troubleshooting Chart (Controllers)
Telescoping Valve Section Troubleshooting
Auxiliary Valve Section Troubleshooting
Troubleshooting Chart (Control Valve)
Removal And Installation
Parts Identification
Disassembly And Assembly
End Housing Disassembly And Assembly
Telescoping and Auxiliary Valve Section Disassembly And Assembly
Lifting and Tilting Valve Section Disassembly And Assembly
Inlet-Outlet Valve Section Disassembly And Assembly
JOYSTICK
Removal And Installation
PARKING BRAKE
Parking Brake Valve Removal And Installation
Parking Brake Valve Disassembly And Assembly
WORKGROUP LOCKOUT VALVE
Testing
Removal And Installation
Disassembly And Assembly
TOW VALVE
Removal And Installation
Disassembly And Assembly
FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE
Removal And Installation
Disassembly And Assembly
MANIFOLD (FOR S/N AC1911001 – 11251)
Removal And Installation
Disassembly
MANIFOLD (FOR S/N AC1911252 & ABOVE)
Removal And Installation
Disassembly

4. HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
Replenishing Valve Function
OIL COOLER
Removal And Installation
HYDROSTATIC DRIVE MOTOR
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
HYDROSTATIC PUMP (FOR S/N AC1911001 – 11999)
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
HYDROSTATIC PUMP (FOR S/N AC1912000 & ABOVE)
Removal And Installation
Parts Identification
Shaft Disassembly
Relief Valves Disassembly And Assembly
Charge Pump Disassembly
Piston Pump Disassembly
Solenoid Block Disassembly
Inspection
Piston Pump Assembly
Charge Pump Assembly
Solenoid Block Assembly
Shaft Assembly
DRIVE BELT
Description
Shield Removal And Installation
Belt Adjustment
Belt Removal And Installation
Tensioner Pulley Removal And Installation
Tensioner Pulley Parts Identification
Tensioner Pulley Disassembly And Assembly

5. DRIVE SYSTEM
TROUBLESHOOTING
Chart
AXLE AND DIFFERENTIAL (FRONT)
Description
Planetary Carrier And Wheel Hub Parts Identification
Planetary Carrier Disassembly
Wheel Hub Disassembly
Steering Knuckle And Drive Shaft Parts Identification
Steering Knuckle Disassembly
Axle Housing / Drive Shaft Disassembly
Brake Group Parts Identification
Brake Group Disassembly
Differential Parts Identification
Differential Disassembly
Pinion Group Parts Identification
Pinion Group Disassembly
Pinion Group Assembly
Differential Assembly
Brake Group Assembly
Axle Housing / Drive Shaft Assembly
Steering Knuckle Assembly
Wheel Hub Assembly
Planetary Carrier Assembly
Special Tools
AXLE AND DIFFERENTIAL (REAR)
Description
Planetary Carrier And Wheel Hub Parts Identification
Planetary Carrier Disassembly
Wheel Hub Disassembly
Steering Knuckle and Drive Shaft Parts Identification
Steering Knuckle Disassembly
Axle Housing / Drive Shaft Disassembly
Differential Parts Identification
Pinion Group Parts Identification
Pinion Group Disassembly
Pinion Group Assembly
Differential Assembly
Steering Knuckle Assembly
Planetary Carrier Assembly
Special Tools
FRONT AXLE
Removal
Installation
AXLE TOE-IN
Adjustment
PARKING BRAKE
Releasing The Brake Discs
Engaging The Brake Discs
STEERING ANGLE ADJUSTMENT
Adjustment
DRIVE SHAFT
Removal And Installation
SERVICE BRAKE
Description
Bleeding The Brake Circuit
REAR AXLE
Removal
Installation

6. MAIN FRAME
OPERATOR CAB (S/N AC1913000 & ABOVE)
Removal And Installation
OPERATOR CAB (S/N AC1912999 & BELOW)
Removal And Installation
OPERATOR SEAT
Removal And Installation
Assembly And Disassembly
BOOM ASSEMBLY
Removal And Installation
INNER BOOM
Removal
Installation
WEAR PADS (FRONT)
Removal And Installation
WEAR PADS (REAR)
Removal
Installation
ENGINE COVER
Locking Mechanism Removal And Installation
Removal And Installation
Lock
FUEL TANK
Removal And Installation
BOB-TACH
Removal And Installation
COUNTERWEIGHT
Removal And Installation
FENDER
Removal And Installation
JOYSTICK PANEL (S/N AC1912999 & BELOW)
Joystick Panel Cover Removal and Installation
JOYSTICK PANEL (S/N AC1913000 & ABOVE)
Joystick Panel Cover Removal and Installation
DASH COVER/STEERING COLUMN COVER (S/N AC1912999 & BELOW)
Steering Column Cover Removal And Installation
Dash Cover Removal And Installation
DASH COVER/STEERING COLUMN COVER (S/N AC1913000 & ABOVE)
Removal And Installation

7. ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SYSTEM INFORMATION (S/N AC1912999 & BELOW)
Troubleshooting Chart
Description
Fuses, Diodes And Relays
ELECTRICAL SYSTEM INFORMATION (S/N AC1913000 & ABOVE)
Troubleshooting Chart
Description
Fuses, Diodes And Relays
BATTERY
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
ALTERNATOR
Removal And Installation
Belt Adjustment
Belt Replacement
STARTER
Testing
Removal And Installation
LIGHTS
Rear Light Removal And Installation
Front Light Removal And Installation
TRAVEL LEVER (S/N AC1912999 & BELOW)
Removal And Installation
TRAVEL LEVER (S/N AC1913000 & ABOVE)
Removal And Installation
INSTRUMENT PANEL (S/N AC1912999 & BELOW)
Removal And Installation
INSTRUMENT PANEL (S/N AC1913000 & ABOVE)
Removal And Installation
SWITCH PANEL (S/N AC1913000 & ABOVE)
Removal And Installation
FRONT WIPER MOTOR
Removal And Installation
TOP WIPER MOTOR
Removal And Installation
REAR WIPER MOTOR
Removal And Installation
PEDAL ASSEMBLY
Removal And Installation
Disassembly And Assembly
INCHING SWITCH
Removal And Installation
Adjustment
Inching Control Calibration (Display Controller)
SERVICE SOFTWARE
Connecting Remote Start Tool to Laptop Computer
Connecting Remote Start Tool (Service Tool)
Connecting Remote Start Tool to Telescopic Handler
Entering The Service Software
Calibrate Inch Pedal
MAIN CONTROLLER
Removal And Installation
Connector Identification
DIAGNOSTIC SERVICE CODES
Viewing Service Codes
Service Codes List
LONGITUDINAL STABILITY INDICATOR CALIBRATION (S/N AC1911001-14999)
Fitting The Sensor
Calibration Procedure
LLMI / LLMC SYSTEM (S/N AC1915000 & ABOVE)
System Calibration
Calibration Test
System Failure Reports
System Components Identification
LLMS Removal
LLMS Installation
LLMC Controller Removal
LLMC Controller Installation

8. ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications
Troubleshooting
Compression – Checking
ENGINE AND ENGINE MOUNTS
Removal And Installation
ENGINE AND HYDROSTAT ASSEMBLY
Removal And Installation
ENGINE SPEED CONTROL
Removal And Installation
MUFFLER
Removal And Installation
AIR CLEANER
Removal And Installation
Air Intake Cowling Removal And Installation
ENGINE COOLING SYSTEM
Radiator Removal And Installation
Fan Removal And Installation
Water Pump Removal And Installation
Water Pump Disassembly And Assembly
Thermostat Housing Removal And Installation
LUBRICATION SYSTEM
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Inspection
Oil Filter Cooler Removal And Installation
Engine Oil Pressure – Testing
FUEL SYSTEM
Fuel Camshaft Removal And Installation
Injection Pump Governor Housing Removal And Installation
Injection Pump Governor Housing Disassembly And Assembly
Fuel Shutoff Solenoid – Checking
Fuel Shutoff Solenoid – Removal And Installation
Fuel Injection Pump Removal And Installation
Fuel Injection Pump Housing Removal
Fuel Injection Pump Housing Installation
Injection Pump Timing
Fuel Injector Removal and Installation
Fuel Injector Nozzle Pressure – Checking
Nozzle Spraying Condition
Valve Seat Tightness
CYLINDER HEAD
Intake Air Heater – Testing
Intake Air Heater Removal And Installation
Valve Clearance Adjustment
Valve Timing – Checking
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head – Servicing
Cylinder Head Top Clearance
Valve Guide – Checking
Reconditioning The Valve And Valve Seat
Valve Spring
Valve Tappets
Rocker Arm And Shaft – Checking
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod – Servicing
Cylinder Bore Checking
Connecting Rod Alignment
Crankshaft Gear Removal And Installation
Crankshaft And Bearings Removal and Installation
Crankshaft And Bearings – Servicing
CAMSHAFT AND TIMING GEARS
Timing Gearcase Cover Removal And Installation
Timing Gears Backlash – Checking
Camshaft – Servicing
Idle Gear And Shaft Removal And Installation
Idler Gear And Shaft – Servicing
Balancer Shaft Servicing
TURBOCHARGER
Description
Testing
Removal And Installation
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Housing Removal And Installation
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Checking The Function Of EGR System
Disassembly And Assembly

9. HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW
Description
Chart
Components
Safety Equipment
REGULAR MAINTENANCE
Filters
Compressor And Alternator Drive Belt Inspection
Cleaning The Condenser
Air Conditioning Lubrication
Air Conditioning Service Chart
TROUBLESHOOTING
Gauge Pressure Related Troubleshooting
Troubleshooting Tree
Temperature / Pressure Chart
Poor A/C Performance
HVAC Repair And Leaks
Checking The Electrical System
SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
Charging Procedure With A Manifold Gauge Set
COMPRESSOR
Removal And Installation
Compressor Oil
Compressor Oil Check
Compressor Clutch Disassembly And Assembly
CONDENSER (S/N AC1912999 & BELOW)
Removal And Installation
CONDENSER (S/N AC1913000 & ABOVE)
Removal And Installation
RECEIVER / DRIER
Removal And Installation
PRESSURE SWITCH
Removal And Installation
EVAPORATOR/BLOWER UNIT (S/N AC1912999 & BELOW)
Removal And Installation
EVAPORATOR/BLOWER UNIT (S/N AC1913000 & ABOVE)
Removal And Installation
EXPANSION VALVE (S/N AC1912999 & BELOW)
Removal And Installation
EXPANSION VALVE (S/N AC1913000 & ABOVE)
Removal And Installation
HEATER ASSEMBLY
Removal And Installation
Fan Removal And Installation
Core Removal And Installation

10. SPECIFICATIONS
(T2250) TELESCOPIC HANDLER SPECIFICATIONS
Machine Dimensions
Performance
Weights
Engine
Controls
Drive System
Traction
Steering
Brakes
Fluid Capacities
Hydraulic System
Electrical System
Instrument Panel
Environmental
Temperature Range
MACHINE TORQUE SPECIFICATIONS
Specifications
TORQUE SPECIFICATIONS FOR BOLTS
Torque for General SAE Bolts
Torque For General Metric Bolts
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/HYDROSTATIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion

ALPHABETICAL INDEX
(T2250) TELESCOPIC HANDLER
SPECIFICATIONS
AIR CLEANER SERVICE
AIR CLEANER
AIR CONDITIONING SYSTEM FLOW
ALTERNATOR
APPROVED BOOM STOP (IF EQUIPPED)
ATTACHMENT CARRIER
AXLE AND DIFFERENTIAL (FRONT)
AXLE AND DIFFERENTIAL (REAR)
AXLE TOE-IN
AXLES (FRONT AND REAR)
BATTERY
BOBCAT TELESCOPIC HANDLER
IDENTIFICATION
BOB-TACH (HAND LEVER) (IF EQUIPPED)
BOB-TACH
BOOM ASSEMBLY
BRAKE VALVE
BUCKET POSITIONING CYLINDER
CAMSHAFT AND TIMING GEARS
COMPRESSOR
CONDENSER (S/N AC1912999 & BELOW)
CONDENSER (S/N AC1913000 & ABOVE)
CONVERSIONS
COUNTERWEIGHT
CRANKSHAFT AND PISTONS
CYLINDER HEAD
DASH COVER/STEERING COLUMN COVER (S/
N AC1912999 & BELOW)
DASH COVER/STEERING COLUMN COVER (S/
N AC1913000 & ABOVE)
DELIVERY REPORT
DIAGNOSTIC SERVICE CODES
DRIVE BELT
DRIVE BOX
DRIVE SHAFT
ELECTRICAL SYSTEM INFORMATION (S/N
AC1912999 & BELOW)
ELECTRICAL SYSTEM INFORMATION (S/N
AC1913000 & ABOVE)
EMERGENCY EXIT
ENGINE AND ENGINE MOUNTS
ENGINE COOLING SYSTEM
ENGINE COOLING SYSTEM
ENGINE COVER
ENGINE COVER
ENGINE INFORMATION
ENGINE LUBRICATION SYSTEM
ENGINE SPEED CONTROL
ENGINE AND HYDROSTAT ASSEMBLY
EVAPORATOR/BLOWER UNIT (S/N AC1912999
& BELOW)
EVAPORATOR/BLOWER UNIT (S/N AC1913000
& ABOVE)
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM
EXPANSION VALVE (S/N AC1912999 & BELOW)
EXPANSION VALVE (S/N AC1913000 & ABOVE)
EXTENSION CYLINDER
FENDER
FIRE PREVENTION
FLYWHEEL AND HOUSING
FOREWORD
FRONT AUXILIARY HYDRAULIC PRESSURE
RELEASE VALVE
FRONT AXLE
FRONT WIPER MOTOR
FUEL SYSTEM
FUEL SYSTEM
FUEL TANK
GEAR PUMP
HEATER ASSEMBLY
HYDRAULIC / HYDROSTATIC SYSTEM
HYDRAULIC CONNECTION SPECIFICATIONS
HYDRAULIC CONTROL VALVE (FOR S/N AC1911001 – 11251)
HYDRAULIC CONTROL VALVE (FOR S/N AC1911252 & ABOVE)
HYDRAULIC FLUID RESERVOIR
HYDRAULIC SYSTEM INFORMATION
HYDRAULIC/HYDROSTATIC FLUID
SPECIFICATIONS
HYDROSTATIC DRIVE MOTOR
HYDROSTATIC PUMP (FOR S/N AC1911001 – 11999)
HYDROSTATIC PUMP (FOR S/N AC1912000 & ABOVE)
HYDROSTATIC SYSTEM INFORMATION
INCHING SWITCH
INNER BOOM
INSTRUMENT PANEL (S/N AC1912999 & BELOW)
INSTRUMENT PANEL (S/N AC1913000 & ABOVE)
JOYSTICK PANEL (S/N AC1912999 & BELOW)
JOYSTICK PANEL (S/N AC1913000 & ABOVE)
JOYSTICK
LIFT CYLINDER
LIFTING AND BLOCKING THE TELESCOPIC
HANDLER
LIGHTS
LLMI / LLMC SYSTEM (S/N AC1915000 & ABOVE)
LONGITUDINAL STABILITY INDICATOR
CALIBRATION (S/N AC1911001-14999)
LUBRICATING THE TELESCOPING HANDLER
LUBRICATION SYSTEM
MACHINE TORQUE SPECIFICATIONS
MAIN CONTROLLER
MAIN RELIEF VALVE
MAINTENANCE SAFETY
MANIFOLD (FOR S/N AC1911001 – 11251)
MANIFOLD (FOR S/N AC1911252 & ABOVE)
MUFFLER
OIL COOLER
OPERATOR CAB (ROPS / FOPS)
OPERATOR CAB (S/N AC1912999 & BELOW)
OPERATOR CAB (S/N AC1913000 & ABOVE)
OPERATOR SEAT
PARKING BRAKE
PARKING BRAKE
PEDAL ASSEMBLY
PORT RELIEF VALVES
PRESSURE SWITCH
REAR AXLE
REAR WIPER MOTOR
RECEIVER / DRIER
REGULAR MAINTENANCE
REMOTE START
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATION
SERVICE BRAKE
SERVICE SCHEDULE
SERVICE SOFTWARE
STARTER
STEERING ANGLE ADJUSTMENT
STEERING CYLINDER (FRONT)
STEERING CYLINDER (REAR)
STEERING MODE VALVE BLOCK
STEERING VALVE
STOPPING THE ENGINE AND LEAVING THE
TELESCOPIC HANDLER
SWITCH PANEL (S/N AC1913000 & ABOVE)
SYSTEM CHARGING AND RECLAMATION
TELESCOPIC HANDLER STORAGE AND
RETURN TO SERVICE
TILT CYLINDER
TIRE MAINTENANCE
TOP WIPER MOTOR
TORQUE SPECIFICATIONS FOR BOLTS
TOW VALVE
TOWING THE TELESCOPIC HANDLER
TRANSPORTING THE TELESCOPIC HANDLER
ON A TRAILER
TRAVEL LEVER (S/N AC1912999 & BELOW)
TRAVEL LEVER (S/N AC1913000 & ABOVE)
TROUBLESHOOTING
TROUBLESHOOTING
TURBOCHARGER
WEAR PADS (FRONT)
WEAR PADS (REAR)
WORKGROUP LOCKOUT VALVE