Bobcat T2250 Telescopic Handler Service Manual (Version 2008)

Bobcat T2250 Telescopic Handler Service Manual
S/N A859 11001 & Above

Type of machine: Telehandler
Print No: 6986740-EN (07-08), 2008
Language and Format: English/PDF
Instant Download after payment. Please make sure your email address is correct.

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:
DELIVERY REPORT
FOREWORD

1. SAFETY AND MAINTENANCE
AIR CLEANER SERVICE
Replacing The Filter Element
APPROVED BOOM STOP
Installing The Approved Boom Stop
Removing The Approved Boom Stop
AXLES (FRONT AND REAR)
Checking Oil Level (Front Differential)
Checking Oil Level (Planetary Carrier)
Checking Oil Level (Rear Differential)
Draining Oil (Front Differential)
Draining Oil (Planetary Carrier)
Draining Oil (Rear Differential)
ENGINE COOLING SYSTEM
Checking The Coolant Level
Cleaning The Cooling System
Replacing The Coolant
ENGINE COVER
Opening And Closing The Engine Cover
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Oil Chart
Replacing Oil And Filter
FUEL SYSTEM
Filling The Fuel Tank
Fuel Filter
Fuel Specifications
HYDRAULIC / HYDROSTATIC SYSTEM
Checking And Adding Fluid
Replacing Hydraulic Fluid
Replacing The Hydraulic / Hydrostatic Filters
LIFTING AND BLOCKING THE TELESCOPIC HANDLER
Procedure
LUBRICATION
Procedure
OPERATOR CAB
Cab Door
Cab Door Window
Emergency Exit
REMOTE START
Connecting to the Telescopic Handler
SERVICE SCHEDULE
TIRE MAINTENANCE
Tire Mounting
Tire Pressure
Tire Rotation
Wheel Nuts
TOWING THE TELESCOPIC HANDLER
Engaging The Brake Discs
Releasing The Brake Discs
Towing
TRANSPORTING THE TELESCOPIC HANDLER
Procedure

2. HYDRAULIC SYSTEM
BOB-TACH CYLINDER
Not available at time of printing
BRAKE VALVE
Disassembly And Assembly
Removal And Installation
BUCKET POSITIONING CYLINDER
Assembly
Disassembly
Parts Identification
Removal And Installation
DRIVE BOX
Assembly
Disassembly
Parts Identification
Special Tools
EXTENSION CYLINDER
Assembly
Cylinder Group Removal And Installation
Disassembly
Extension Cylinder Removal And Installation
Parts Identification
Tubeline Tray Assembly
Tubeline Tray Disassembly
Upper Tubeline Installation
Upper Tubeline Removal
FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE
Disassembly And Assembly
Removal And Installation
GEAR PUMP
Disassembly And Assembly
Parts Identification
Removal And Installation
HYDRAULIC CONTROL VALVE
Auxiliary Valve Section Troubleshooting
End Housing Disassembly And Assembly
Disassembly And Assembly
Inlet-Outlet Valve Section Disassembly And Assembly
Lifting and Tilting Valve Section Disassembly And Assembly
Parts Identification
Removal And Installation
Telescoping and Auxiliary Valve Section Disassembly And Assembly
Telescoping Valve Section Troubleshooting
Troubleshooting Chart (Controllers)
Troubleshooting Chart (Control Valve)
HYDRAULIC RESERVOIR
Removal And Installation
HYDRAULIC SYSTEM INFORMATION
Tightening Procedures
Troubleshooting Chart
JOYSTICK
Removal And Installation
LIFT CYLINDER
Disassembly
Parts Identification
Removal And Installation
MAIN RELIEF VALVE
Removal And Installation
Testing And Adjustment
MANIFOLD
Disassembly
Removal And Installation
PARKING BRAKE
Parking Brake Valve Disassembly And Assembly
Parking Brake Valve Removal And Installation
PORT RELIEF VALVES
Adjustment Procedure
Parts Identification
STEERING CYLINDER (FRONT)
Assembling the Steering Cylinder
Disassembling the Steering Cylinder
Installing the Steering Cylinder
Removing the Steering Cylinder
STEERING CYLINDER (REAR)
Assembling The Steering Cylinder
Disassembling The Steering Cylinder
Removing The Steering Cylinder
STEERING MODE VALVE BLOCK
Assembly
Disassembly
Parts Identification
Removal And Installation
Solenoid Testing
STEERING VALVE
Assembly
Disassembly
Inspection
Parts Identification
Removal And Installation
TILT CYLINDER
Assembly
Disassembly
Parts Identification
Removal And Installation
TOW VALVE
Disassembly And Assembly
Removal And Installation
WORKGROUP LOCKOUT VALVE
Disassembly And Assembly
Removal And Installation
Testing

3. HYDROSTATIC SYSTEM
DRIVE BELT
Adjusting
Belt Removal And Installation
Description
Shield Removal And Installation
Tensioner Pulley Disassembly And Assembly
Tensioner Pulley Parts Identification
Tensioner Pulley Removal And Installation
HYDROSTATIC DRIVE MOTOR
Assembly
Disassembly
Inspection
Parts Identification
Removal And Installation
HYDROSTATIC PUMP
Assembly
Disassembly
Inspection
Parts Identification
Removal And Installation
HYDROSTATIC SYSTEM INFORMATION
Replenishing Valve Function
Troubleshooting Chart
OIL COOLER
Removal And Installation

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

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

6. ELECTRICAL SYSTEM AND ANALYSIS
ALTERNATOR
Adjusting The Alternator Belt
Removal And Installation
BATTERY
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
DIAGNOSTIC SERVICE CODES
Service Codes List
Viewing Service Codes
ELECTRICAL SYSTEM INFORMATION
Description
Fuses, Diodes And Relays
Troubleshooting Chart
FRONT WIPER MOTOR
Removal And Installation
INCHING SWITCH
Adjustment
Inching Control Calibration (Display Controller)
Removal And Installation
INSTRUMENT PANEL
Removal And Installation
LIGHTS
Front Light Removal And Installation
Rear Light Removal And Installation
MAIN CONTROLLER
Connector Identification
Removal And Installation
PEDAL ASSEMBLY
Disassembly And Assembly
Removal And Installation
REAR WIPER MOTOR
Removal And Installation
SERVICE SOFTWARE
Calibrate Inch Pedal
Connecting Remote Start Tool to Laptop Computer
Connecting Remote Start Tool to Telescopic Handler
Entering The Service Software
STARTER
Parts Identification
Removal And Installation
Testing
TOP WIPER MOTOR
Removal And Installation
TRAVEL LEVER
Removal And Installation

7. ENGINE SERVICE
AIR CLEANER
Air Intake Cowling Removal And Installation
Removal And Installation
CAMSHAFT AND TIMING GEARS
Camshaft – Servicing
Idle Gear And Shaft Removal And Installation
Idler Gear And Shaft – Servicing
Timing Gearcase Cover Removal And Installation
Timing Gears Backlash – Checking
CRANKSHAFT AND PISTONS
Connecting Rod Alignment
Crankshaft Gear Removal And Installation
Crankshaft And Bearings Removal and Installation
Crankshaft And Bearings – Servicing
Cylinder Bore Checking
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod – Servicing
CYLINDER HEAD
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head – Servicing
Cylinder Head Top Clearance
Intake Air Heater – Testing
Intake Air Heater Removal And Installation
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 AND ENGINE MOUNTS
Removal And Installation
ENGINE AND HYDROSTAT ASSEMBLY
Removal And Installation
ENGINE COOLING SYSTEM
Fan Removal And Installation
Radiator Removal And Installation
Thermostat Housing Removal And Installation
Water Pump Removal And Installation
Water Pump Disassembly And Assembly
ENGINE INFORMATION
Compression – Checking
Description
Torque Values
Troubleshooting
Specifications
ENGINE SPEED CONTROL
Removal And Installation
FLYWHEEL AND HOUSING
Description
Removal And Installation
Testing
FUEL SYSTEM
Fuel Camshaft Removal And Installation
Fuel Injection Pump Removal And Installation
Fuel Injection Pump Housing Removal
Fuel Injection Pump Housing Installation
Fuel Injector Removal and Installation
Fuel Injector Nozzle Pressure – Checking
Fuel Shutoff Solenoid – Checking
Fuel Shutoff Solenoid – Removal And Installation
Injection Pump Governor Housing Removal And Installation
Injection Pump Governor Housing Disassembly And Assembly
Injection Pump Timing
Nozzle Spraying Condition
Valve Seat Tightness
LUBRICATION SYSTEM
Engine Oil Pressure – Testing
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Inspection
Oil Filter Cooler Removal And Installation
MUFFLER
Removal And Installation
TURBOCHARGER
Description
Removal And Installation
Testing

8. HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SERVICE
Chart
AIR CONDITIONING SYSTEM FLOW
Chart
Description
BASIC TROUBLESHOOTING
Checking The Electrical System
Compressor And Alternator Drive Belt Inspection
Poor A/C Performance
COMPONENTS
Identification
COMPRESSOR
Compressor Clutch Disassembly And Assembly
Removal And Installation
CONDENSER
Removal And Installation
EVAPORATOR/BLOWER UNIT
Removal And Installation
EXPANSION VALVE
Removal And Installation
GENERAL AIR CONDITIONING SERVICE GUIDELINES
Component Replacement And Refrigeration Leaks
Compressor Oil
Compressor Oil Check
HEATER ASSEMBLY
Core Removal And Installation
Fan Removal And Installation
Removal And Installation
PRESSURE SWITCH
Removal And Installation
RECEIVER / DRIER
Removal And Installation
REGULAR MAINTENANCE
Cleaning The Condenser
Compressor And Alternator Drive Belt Inspection
Filter Element Removal And Installation
SAFETY
Safety Equipment
SYSTEM CHARGING AND RECLAMATION
Charging Procedure With A Manifold Gauge Set
Reclamation Procedure
SYSTEM TROUBLESHOOTING CHART
Chart
Gauge Pressure Related Troubleshooting
TEMPERATURE AND PRESSURE
Chart

9. SPECIFICATIONS
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion
ENGINE SPECIFICATIONS
Camshaft And Thrust Washer
Connecting Rods And Bearings
Crankshaft
Crankshaft Re-Grind Data
Cylinder Block
Cylinder Head
Cylinder Liners
Engine Torque Component
Exhaust Valves
Flywheel
Fuel Injection Pump
Fuel Injectors
Fuel Lift Pump
General
Intake Valves
Main Bearings
Oil Pump, Gear And Relief Valve
Pistons And Piston Rings
Rocker Shaft, Rockers And Bushings
Thrust Washers
Timing Case And Timing Gears
Turbocharger
Valve Guides
Valve Springs
Water Pump And Thermostat
HYDRAULIC CONNECTION SPECIFICATIONS
Flare Fitting
O-ring Face Seal Connection
O-ring Flare Fitting
Port Seal Fitting
Straight Thread O-ring Fitting
Tubelines And Hoses
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
Specifications
MACHINE TORQUE SPECIFICATIONS
Specifications
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General Metric Bolts
Torque for General SAE Bolts
TELESCOPIC HANDLER TELESCOPIC TOOL CARRIER (TTC)
SPECIFICATIONS
Capacities
Controls
Machine Dimensions
Drive System
Electrical System
Engine
Hydraulic System
Instrument Panel
Performance
Tires