T2250

S/N A859 11001 &

Above

SERVICE
MANUAL

6986740-EN (07-08) © Bobcat Europe, 2008

Printed in Europe
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING 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

CORRECT

Safety Alert Symbol: This symbol with a warning statement,

means: “Warning, be alert! Your safety
is involved!” Carefully read the
message that follows.

B-10731a
Never service the Bobcat Telescopic
Handler without instructions.

CORRECT WRONG WRONG

B-16082 B-16080 B-16079

Cleaning and maintenance are Disconnecting or loosening any Never work on Telescopic
required daily. hydraulic tubeline, hose, fitting, Handler with boom up unless
component or a part failure can boom is held by an approved
cause boom to drop. Do not go boom stop. Replace if damaged.
under boom when raised unless Never modify equipment or add
supported by an approved boom attachments not approved by
stop. Replace if damaged. Bobcat Company.

WRONG WRONG WRONG

B-16081 B-16078 B-6589

Have good ventilation when Keep body, jewelry and clothing Lead-acid batteries produce
welding or grinding painted away from moving parts, flammable and explosive gases.
parts. electrical contact, hot parts and Keep arcs, sparks, flames and
Wear dust mask when grinding exhaust. lighted tobacco away from
painted parts. Toxic dust and gas Wear eye protection to guard batteries.
can be produced. from battery acid, compressed Batteries contain acid which
Avoid exhaust fume leaks which springs, fluids under pressure burns eyes or skin on contact.
can kill without warning. Exhaust and flying debris when engines Wear protective clothing. If acid
system must be tightly sealed. are running or tools are used. contacts body, flush well with
Use eye protection approved for water. For eye contact flush well
type of welding. and get immediate medical
attention.

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.
MSW12-0805
 ALPHABETICAL INDEX

ACCUMULATOR .............................................. 20-210-01 GEAR PUMP...................................................... 20-130-1

AIR CLEANER ................................................... 70-40-01 GENERAL AIR CONDITIONING SERVICE GUIDELINES .. 80-60-1
AIR CLEANER SERVICE................................... 10-60-01
AIR CONDITIONING SERVICE ........................... 80-90-1
AIR CONDITIONING SYSTEM FLOW................. 80-10-1 HEATER ASSEMBLY ......................................... 80-170-1
ALTERNATOR ...................................................... 60-30-1 HYDRAULIC CONNECTION SPECIFICATIONS ..... SPEC-50-1
APPROVED BOOM STOP................................. 10-150-1 HYDRAULIC CONTROL VALVE ........................ 20-170-1
AXLE AND DIFFERENTIAL (FRONT) ........................... 40-20-1 HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS.. SPEC-60-1
AXLE AND DIFFERENTIAL (REAR).............................. 40-21-1 HYDRAULIC / HYDROSTATIC SYSTEM ........... 10-100-1
AXLE TOE-IN ....................................................... 40-40-1 HYDRAULIC RESERVOIR................................. 20-150-1
AXLES (FRONT AND REAR) ............................ 10-110-1 HYDRAULIC SYSTEM INFORMATION ............... 20-10-1
HYDROSTATIC DRIVE MOTOR .......................... 30-30-1
HYDROSTATIC PUMP ......................................... 30-40-1
HYDROSTATIC SYSTEM INFORMATION ........... 30-10-1
BASIC TROUBLESHOOTING ............................. 80-50-1
BATTERY ............................................................. 60-20-1
BOOM ASSEMBLY .............................................. 50-30-1 INCHING SWITCH ............................................. 60-150-1
BRAKE VALVE ................................................... 20-120-1 INNER BOOM ...................................................... 50-40-1
BUCKET POSITIONING CYLINDER ................... 20-30-1 INSTRUMENT PANEL ......................................... 60-80-1

CAMSHAFT AND TIMING GEARS.................... 70-100-1 JOYSTICK .......................................................... 20-180-1

COMPONENTS ................................................... 80-20-1 JOYSTICK PANEL.............................................. 50-120-1
COMPRESSOR ................................................. 80-110-1
CONDENSER .................................................... 80-120-1
CONVERSIONS............................................. SPEC-70-1 LIFT CYLINDER................................................... 20-20-1
CRANKSHAFT AND PISTONS............................ 70-90-1 LIFTING AND BLOCKING THE TELESCOPIC HANDLER . 10-10-1
CYLINDER HEAD ................................................ 70-80-1 LIGHTS ................................................................ 60-60-1
LUBRICATION.................................................... 10-120-1
LUBRICATION SYSTEM...................................... 70-60-1
DASH COVER/STEERING COLUMN COVER .. 50-130-1
DRIVE BOX ...............................................................20-70-1

ELECTRICAL SYSTEM INFORMATION ............. 60-10-1

ENGINE AND ENGINE MOUNTS ....................... 70-11-1
ENGINE AND HYDROSTAT ASSEMBLY............. 70-12-1
ENGINE COOLING SYSTEM .............................. 10-70-1
ENGINE COOLING SYSTEM .............................. 70-50-1
ENGINE COVER................................................ 10-160-1
ENGINE COVER.................................................. 50-70-1
ENGINE LUBRICATION SYSTEM ....................... 10-90-1
ENGINE SPECIFICATIONS...............................SPEC-01
ENGINE SPEED CONTROL................................ 70-20-1
EVAPORATOR/BLOWER UNIT ......................... 80-150-1
EXPANSION VALVE........................................... 80-160-1
EXTENSION CYLINDER ..................................... 20-40-1

FENDER ............................................................ 50-110-1

FUEL SYSTEM .................................................... 70-70-1
FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE
........................................................................................... 20-230-1
FRONT AXLE....................................................... 40-30-1
FRONT WIPER MOTOR .................................... 60-110-1
FUEL SYSTEM .................................................... 10-80-1
FUEL TANK.......................................................... 50-80-1

6986740-EN (07-08) ALPHA-01 Bobcat T2250

SERVICE MANUAL
 ALPHABETICAL INDEX (CONT’D)

MACHINE TORQUE SPECIFICATIONS ........ SPEC-30-1

MAIN RELIEF VALVE........................................... 20-80-1
MANIFOLD......................................................... 20-240-1 WEAR PADS (FRONT)......................................... 50-50-1
MUFFLER ............................................................ 70-30-1 WEAR PADS (REAR)........................................... 50-60-1

OIL COOLER ....................................................... 30-20-1

OPERATOR CAB ................................................. 10-20-1
OPERATOR CAB ................................................. 50-10-1
OPERATOR SEAT................................................ 50-20-1

PARKING BRAKE .............................................. 20-190-1

PARKING BRAKE ................................................ 40-50-1
PEDAL ASSEMBLY............................................ 60-140-1
PORT RELIEF VALVES...................................... 20-100-1
WORKGROUP LOCKOUT VALVE ..................... 20-200-1
PRESSURE SWITCH ........................................ 80-140-1

BOB-TACH ........................................................... 50-90-1

BOB-TACH CYLINDER ........................................ 20-90-1

REAR AXLE ......................................................... 40-90-1

REAR WEIGHTS................................................ 50-100-1
REAR WIPER MOTOR ...................................... 60-130-1
RECEIVER / DRIER........................................... 80-130-1
REGULAR MAINTENANCE................................. 80-40-1
REMOTE START................................................ 10-180-1

SAFETY ............................................................... 80-30-1

SERVICE BRAKE .......................................................... 40-80-1
SERVICE SCHEDULE ......................................... 10-50-1
SERVICE SOFTWARE ...................................... 60-160-1
STARTER ............................................................. 60-40-1
STEERING ANGLE ADJUSTMENT .............................. 40-60-1
STEERING CYLINDER (FRONT).................................. 20-60-1
STEERING CYLINDER (REAR) .................................... 20-61-1
STEERING MODE VALVE BLOCK .................... 20-110-1
STEERING VALVE ............................................. 20-160-1
SYSTEM CHARGING AND RECLAMATION ..... 80-100-1
SYSTEM TROUBLESHOOTING CHART ............ 80-70-1

TEMPERATURE AND PRESSURE ..................... 80-80-1

TIRE MAINTENANCE ........................................ 10-130-1
TILT CYLINDER ................................................... 20-50-1
TOP WIPER MOTOR ......................................... 60-120-1
TORQUE SPECIFICATIONS FOR BOLTS..... SPEC-40-1
TOW VALVE ....................................................... 20-220-1
TOWING THE TELESCOPIC HANDLER............. 10-40-1
TRANSPORTING THE TELESCOPIC HANDLER10-30-1
TRAVEL LEVER................................................... 60-70-1
TROUBLESHOOTING ......................................... 40-10-1

TELESCOPIC HANDLER TELESCOPIC TOOL

CARRIER (TTC) SPECIFICATIONS .............. SPEC-10-1

6986740-EN (07-08) ALPHA-02 Bobcat T2250

SERVICE MANUAL
 CONTENTS SAFETY &
MAINTENANCE
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III HYDRAULIC

SYSTEM
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V

SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII

HYDROSTATIC
BOBCAT TELESCOPIC HANDLER IDENTIFICATION . . . . . . . . . X SYSTEM

SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 10-01

DRIVE
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 SYSTEM

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01 MAIN FRAME

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

ELECTRICAL
ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . 60-01 SYSTEM &
ANALYSIS
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . 80-01 ENGINE

SERVICE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01

HVAC

SPECIFICATION

SPECIFICATION

6986740-EN (07-08) I Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) II Bobcat T2250
SERVICE MANUAL
 FOREWORD
This manual is for the Bobcat Telescopic Handler mechanic. It provides necessary servicing and
adjustment procedures for the Bobcat Telescopic Handler 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 Telescopic Handler has had
service or repair:
1. Check that ROPS/FOPS 8. The parking brake must
(including right side window) function correctly.
is in good condition and is not
modified.

2. Check that ROPS mounting 9. Enclosure door latches must

hardware is tightened and is open and close freely.
Bobcat approved.

3. The seat belt must be 10. Attachment locking pins must

correctly installed, functional function correctly and be in
and in good condition. good condition. Bob-Tach
wedges and linkages (if
equipped) must function
correctly and be in good
condition.
4. Check boom stop, replace if 11. Safety treads must be in good
damaged. condition.

5. Machine signs (decals) must 12. Check for correct function of

be legible and in the correct indicator lamps and gauges.
location.

6. Joystick control lever and foot 13. Check hydraulic fluid level,
pedals must return to neutral. engine oil level and fuel
supply.

7. Check for correct function of 14. Inspect for fuel, oil or

the work lights. hydraulic fluid leaks.

FW VH-0308 SM

6986740-EN (07-08) III Bobcat T2250

SERVICE MANUAL
 15. Lubricate the Telescopic 20. Inspect for loose or broken
Handler. parts or connections.

16. Check the condition of the 21. Check for any field
battery and cables. modification not completed.

17. Inspect the air cleaner for 22. Operate the machine and
damage or leaks. Check the check all functions.
condition of the element.

18. Check the electrical charging 23. Check function or condition of

system. all equipped options and
accessories (examples: back-
up alarm, fire extinguisher,
rotating beacon, front
stabilizers, etc.).
19. Check tires for wear and 24. Recommend to the owner
pressure. Use only approved that all necessary corrections
tires. be made before the machine
is returned to service.

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.

FW VH-0308 SM

6986740-EN (07-08) IV Bobcat T2250

SERVICE MANUAL
SAFETY INSTRUCTIONS • The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
Safety Alert Symbol service procedures. It is a part of the machine and can
be stored in a container provided on the machine.
This symbol with a warning statement means: Replacement Operation & Maintenance Manuals can
“Warning, be alert! Your safety is involved!” be ordered from your Bobcat dealer.
Carefully read the message that follows.
• Machine signs (decals) instruct on the safe operation
and care of your Bobcat machine or attachment. The
signs and their locations are shown in the Operation &
Maintenance Manual. Replacement signs are
WARNING available from your Bobcat dealer.

• The Service Manual and Parts Manual are available

Instructions are necessary before operating or from your dealer for use by mechanics to do shop-type
servicing machine. Read and understand the service and repair work.
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow The dealer and owner / operator review the recommended
warnings and instructions in the manuals when uses of the product when delivered. If the owner / operator
making repairs, adjustments or servicing. Check for will be using the machine for a different application(s) he
correct function after adjustments, repairs or service. or she must ask the dealer for recommendations on the
Untrained operators and failure to follow instructions new use.
can cause injury or death.
W-2003-0903

IMPORTANT
This notice identifies procedures which must be
followed to avoid damage to the machine.
I-2019-0284

Cutting or drilling concrete containing sand or rock

containing quartz may result in exposure to silica dust.
DANGER
SI VH-0308 SM
The signal word DANGER on the machine and in the
manuals indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
D-1002-1107

WARNING
The signal word WARNING on the machine and in the
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107

The following publications provide information on the safe

use and maintenance of the Bobcat machine and
attachments:

• The Delivery Report is used to assure that complete

instructions have been given to the new owner and
that the machine is in safe operating condition.

6986740-EN (07-08) V Bobcat T2250

SERVICE MANUAL
FIRE PREVENTION Hydraulic System

Check hydraulic tubes, hoses and fittings for damage and

leakage. Never use open flame or bare skin to check for
leaks. Hydraulic tubes and hoses must be properly routed
and have adequate support and secure clamps. Tighten
or replace any parts that show leakage.

Maintenance Always clean fluid spills. Do not use gasoline or diesel fuel
for cleaning parts. Use commercial nonflammable
The machine and some attachments have components
solvents.
that are at high temperatures under normal operating
conditions. The primary source of high temperatures is
Fueling
the engine and exhaust system. The electrical system, if
damaged or incorrectly maintained, can be a source of
arcs or sparks.

Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard. Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
The operator’s area, engine compartment and engine sparks. Fill the fuel tank outdoors.
cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Starting

All fuels, most lubricants and some coolants mixtures are Do not use ether or starting fluids on any engine that has
flammable. Flammable fluids that are leaking or spilled glow plugs. These starting aids can cause explosion and
onto hot surfaces or onto electrical components can injure you or bystanders.
cause a fire.
Use the procedure in the Operation & Maintenance
Operation Manual for connecting the battery and for jump starting.

Do not use the machine where exhaust, arcs, sparks or

hot components can contact flammable material,
explosive dust or gases.

Electrical

SI VH-0308 SM
Check all electrical wiring and connections for damage.
Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed.

Battery gas can explode and cause serious injury. Use the
procedure in the Operation & Maintenance Manual for
connecting the battery and for jump starting. Do not jump
start or charge a frozen or damaged battery. Keep any
open flames or sparks away from batteries. Do not smoke
in battery charging area.

6986740-EN (07-08) VI Bobcat T2250

SERVICE MANUAL
FIRE PREVENTION (CONT’D)

Welding And Grinding

Always clean the machine and attachment, disconnect

the battery, and disconnect the wiring from the Bobcat
controllers before welding. Cover rubber hoses, battery
and all other flammable parts. Keep a fire extinguisher
near the machine when welding.

Have good ventilation when grinding or welding painted

parts. Wear dust mask when grinding painted parts. Toxic
dust or gas can be produced.

Dust generated from repairing nonmetallic parts such as

hoods, fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away
from open flames or sparks.

Fire Extinguishers

Know where fire extinguishers and first aid kits are located
and how to use them. Inspect the fire extinguisher and
service the fire extinguisher regularly. Obey the
recommendations on the instructions plate.

Sl VH-0208

6986740-EN (07-08) VII Bobcat T2250

SERVICE MANUAL
SERIAL NUMBER LOCATION Explanation of Telescopic Handler Serial Number:
XXXX XXXXX
Always use the serial number of the Telescopic Handler
when requesting service information or when ordering Module 2. - Production
parts. Early or later models (identification made by serial Sequence (Series)
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service Module 1. - Model/Engine
operation. Combination

Figure 1 1. The four digit Model/Engine Combination Module

number identifies the model number and engine
combination.

2. The five digit Production Sequence Number identifies

the order which the Telescopic Handler is produced.

Engine Serial Number

1 Figure 3

S2291

Figure 2
1

S3502

The engine serial number can be found on top of the

cylinder block (Item 1) [Figure 3]. Always use the full
number when ordering replacement parts.

S7082

The Telescopic Handler serial number plate is located on

the right front side of the chassis (Item 1) [Figure 1] &
[Figure 2].

6986740-EN (07-08) VIII Bobcat T2250

SERVICE MANUAL
DELIVERY REPORT

Figure 4

B-16315

The Delivery Report must be filled out by the dealer and

signed by the owner or operator when the Telescopic
Handler is delivered. An explanation of the form must be
given to the owner. Make sure it is filled out completely
[Figure 4].

6986740-EN (07-08) IX Bobcat T2250

SERVICE MANUAL
BOBCAT TELESCOPIC HANDLER IDENTIFICATION

OPERATOR HANDBOOK &

LOAD CAPACITY CHARTS
MIRROR
● OPERATOR
BOOM CAB (ROPS/
FOPS)

TELESCOPING
BOOM

COUPLERS BOOM
STOP
BOB-TACH

SEAT
BELT

† BUCKET
* TIRES (Use only approved
tires at correct pressure.)
SAFETY TREAD
(Under Boom, on top of Frame)
LIGHTS
LIGHT MIRROR

REAR
LIGHTS

ENGINE
COVER
S4926
S4927

* TIRES - Tires shown may not be standard. The machine is factory equipped with standard tires. Other tires are available.
● ROPS, FOPS - Roll Over Protective Structure, per ISO 3471, and Falling Object Protective Structure, per ISO 3449, Level I.
Level II is available.
† Bucket - Many Buckets and other Attachments are available.

6986740-EN (07-08) X Bobcat T2250

SERVICE MANUAL
 SAFETY AND MAINTENANCE SAFETY AND
MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-60-1
Replacing The Filter Element . . . . . . . . . . . . . . . . . . . . . .10-60-1

APPROVED BOOM STOP . . . . . . . . . . . . . . . . . . . . . . . . . .10-150-1

Installing The Approved Boom Stop . . . . . . . . . . . . . . . .10-150-1
Removing The Approved Boom Stop . . . . . . . . . . . . . . .10-150-1

AXLES (FRONT AND REAR). . . . . . . . . . . . . . . . . . . . . . . .10-110-1

Checking Oil Level (Front Differential) . . . . . . . . . . . . . . .10-110-3
Checking Oil Level (Planetary Carrier) . . . . . . . . . . . . . .10-110-1
Checking Oil Level (Rear Differential) . . . . . . . . . . . . . . .10-110-2
Draining Oil (Front Differential) . . . . . . . . . . . . . . . . . . . .10-110-3
Draining Oil (Planetary Carrier). . . . . . . . . . . . . . . . . . . .10-110-1
Draining Oil (Rear Differential) . . . . . . . . . . . . . . . . . . . .10-110-2

ENGINE COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . .10-70-1

Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . .10-70-1
Cleaning The Cooling System. . . . . . . . . . . . . . . . . . . . . .10-70-1
Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . .10-70-2

ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-160-1

Opening And Closing The Engine Cover. . . . . . . . . . . . .10-160-1

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . .10-90-1

Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-90-1
Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-90-1
Replacing Oil And Filter. . . . . . . . . . . . . . . . . . . . . . . . . . .10-90-1

FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-80-1

Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-80-1
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-80-2
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-80-1

HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . .10-100-1

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . .10-100-1
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . .10-100-2
Replacing The Hydraulic / Hydrostatic Filters . . . . . . . . .10-100-1

LIFTING AND BLOCKING THE TELESCOPIC HANDLER . .10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-1

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-120-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-120-1

Continued On Next Page

6986740-EN (07-08) 10-01 Bobcat T2250

SERVICE MANUAL
 SAFETY AND MAINTENANCE (CONT’D)

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-1

Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-2
Cab Door Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-2
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-1

REMOTE START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-180-1

Connecting to the Telescopic Handler . . . . . . . . . . . . . . . . .10-180-1

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

TIRE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Tire Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

TOWING THE TELESCOPIC HANDLER . . . . . . . . . . . . . . . . . .10-40-1

Engaging The Brake Discs . . . . . . . . . . . . . . . . . . . . . . . . . .10-40-2
Releasing The Brake Discs . . . . . . . . . . . . . . . . . . . . . . . . . .10-40-1
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-40-2

TRANSPORTING THE TELESCOPIC HANDLER . . . . . . . . . . .10-30-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-30-1

6986740-EN (07-08) 10-02 Bobcat T2250

SERVICE MANUAL
LIFTING AND BLOCKING THE TELESCOPIC Figure 10-10-2
HANDLER

Procedure

WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to fall
or move and cause injury or death.
W-2017-0286

S7202
Figure 10-10-1

Put the floor jack under the center of the rear axle. Lift the
Telescopic Handler and install jackstands [Figure 10-10-
2].

S7203

Always park the machine on a level surface.

STOP the engine. Put the floor jack under the center of
the front axle. Lift the Telescopic Handler and install
jackstands [Figure 10-10-1].

6986740-EN (07-08) 10-10-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 10-10-2 Bobcat T2250
SERVICE MANUAL
OPERATOR CAB Emergency Exit

Figure 10-20-1 Figure 10-20-2

S6549 S6552

The Telescopic Handler has an operator cab (ROPS and Pull the tag on top of the rear window (Item 1) [Figure 10-
FOPS) (Item 1) [Figure 10-20-1] to protect the operator 20-2] to remove the rubber cord.
from rollover and falling objects. Check with your dealer if
the operator cab has been damaged. Never operate Push the rear window out of the rear of the operator cab.
without right window. The seat belt must be worn for roll (Models with enclosed cab only.)
over protection.
Exit through the rear of the operator cab.
ROPS/FOPS - Roll Over Protective Structure per SAE
J1040 and ISO 3471, and Falling Object Protective
Structure per SAE J1043 and ISO 3449.

WARNING
Never modify operator cab or canopy by welding,
grinding, drilling holes or adding attachments unless
instructed to do so by Bobcat. Do not operate without
right window. Changes to the cab or canopy can
cause loss of operator protection from rollover and
falling objects, and result in serious injury or death.
W-2396-1202

6986740-EN (07-08) 10-20-1 Bobcat T2250

SERVICE MANUAL
OPERATOR CAB (CONT’D) Cab Door Window

Cab Door Figure 10-20-5

Figure 10-20-3

2 1

P-47202

S6522
Turn the handle (Item 1) [Figure 10-20-5] (as shown).
Push the window open fully until it latches against the cab.
The cab door can be locked (Item 1) [Figure 10-20-3]
with the start key. Figure 10-20-6

Figure 10-20-4

1
1

S3344

P-47201
Pull up the lever (Item 1) [Figure 10-20-6] inside the cab
to disengage the latch and close the window.
The cab door can be opened from the outside of the cab
using the latch (Item 2) [Figure 10-20-3] and from the
inside of the cab by squeezing the latch (Item 1) [Figure
10-20-4] (as shown).

6986740-EN (07-08) 10-20-2 Bobcat T2250

SERVICE MANUAL
TRANSPORTING THE TELESCOPIC HANDLER

Procedure

Always drive the Telescopic Handler backwards (heavy

end up) onto the transport vehicle.

Figure 10-30-1

3
4
2

1 1

S3519

The rear of the trailer must be blocked or supported

[Figure 10-30-1] when loading or unloading the
Telescopic Handler to prevent the front end of the trailer
from raising up.

Be sure the transport and towing vehicles are of adequate

size and capacity. For the weight of Telescopic Handler,
(See TELESCOPIC HANDLER TELESCOPIC TOOL
CARRIER (TTC) SPECIFICATIONS on Page SPEC-10-
1.) Fasten the Telescopic Handler to the transport vehicle
to prevent if from moving during sudden stops or when
going up or down slopes.

Block the wheels (Item 1) [Figure 10-30-1].

Fasten the machine frame to the transport vehicle (Items

2 & 3) [Figure 10-30-1].

Attach the forks or bucket attachment to the transport

vehicle (Item 4) [Figure 10-30-1].

WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0807

6986740-EN (07-08) 10-30-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 10-30-2 Bobcat T2250
SERVICE MANUAL
TOWING THE TELESCOPIC HANDLER Figure 10-40-1

The Telescopic Handler can be towed a short distance

such as removing it from mud or loading it onto a 2
transport vehicle.
2
1

S6519

Loosen the four bolts (Item 1) until the slotted spacers

(Item 2) [Figure 10-40-1] can be removed from under the
bolt heads (the bolts and spacers are located on both the
front and rear side of the front axle).

Remove the spacers (Item 2) [Figure 10-40-1] and save

for reuse.

Figure 10-40-2

ACTIVE POSITION RELEASED POSITION

Block the wheels to prevent the machine from rolling. 1

2
Releasing The Brake Discs

The brakes are engaged by spring pressure and released

by hydraulic pressure. The parking brake must be
released manually before towing (if the engine can not be
started to release the brakes or there is no hydraulic
pressure). Only the front axle has brakes.

The following procedure describes how to release the

brakes: P-68946

After removing the spacers, evenly tighten the front and

rear bolts (Item 1) to hold the parking brake piston (Item 2)
[Figure 10-40-2] in the released position.

6986740-EN (07-08) 10-40-1 Bobcat T2250

SERVICE MANUAL
TOWING THE TELESCOPIC HANDLER (CONT’D) Figure 10-40-4

Towing
2
Figure 10-40-3

1 1

Operating
position

Towing
S2711
position

Loosen the four bolts (Item 1) until the spacers (Item 2)

S2696 [Figure 10-40-4] can be installed under the bolt heads
(the bolts and washers are located on both the front and
rear side of front axle).
Raise the engine cover.
Figure 10-40-5
Turn the tow valve (Item 1) [Figure 10-40-3]
counterclockwise 90 degrees to TOWING POSITION. ACTIVE POSITION RELEASED POSITION

Tow the Telescopic Handler at a slow speed. 1

3
NOTE: The vehicle will not be able to brake until the
four bolts (Item 1) [Figure 10-40-3] & [Figure
10-40-3] are returned to their original position.

2
P-68946

Evenly tighten the front and rear bolts (Item 1) to hold the
spacers (Item 2) [Figure 10-40-4] & [Figure 10-40-5].

Tighten the bolts to 70-85 ft.-lb. (95-115 N•m) torque.

This will allow the parking brake piston (Item 3) [Figure

10-40-5] to be active again.

Block the wheels to prevent the machine from rolling.

After towing is completed, turn the tow valve (Item 1)

[Figure 10-40-3] clockwise 90 degrees to the
OPERATING POSITION.

NOTE:If the tow valve is not returned to the operating

position, the machine will not be able to be driven forward
or backward.

Engaging The Brake Discs

6986740-EN (07-08) 10-40-2 Bobcat T2250

SERVICE MANUAL
 SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service
schedule is a guide for correct maintenance of the Bobcat Telescopic Handler.

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
WARNING 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

SERVICE SHEDULE HOURS

ITEM SERVICE REQUIRED ❏ ■
10 50 100 250 500 1000
Engine Oil Check the oil level and add as needed. Do not overfill.
Hydraulic Fluid Check the fluid level and add as needed.
Safety Signs, Safety Tread and Check for damaged signs (decals), safety treads, load charts and mirrors. Replace if
Mirrors damaged or missing.
Fuel Filter Remove the trapped water.
Tires Check for damaged tires and correct air pressure. Inflate to MAXIMUM pressure shown on
sidewall of the tire.
Seat Belt & Restraint Bar Check the condition of the seat belt. Check the restraint bar (If equipped). Clean dirt and
(LORS™) (If Equipped) debris from moving parts.
Brakes and Controls Check for function. Service as necessary.
Gauges, Horn and Backup Alarm Check for function. Repair or replace as necessary.
General Check for loose or broken parts, damaged cab, seat belt and instrument operations. Check
for installation of right hand cab window. Clean mirrors and windows. Repair or replace as
needed.
Engine Cooling System Clean debris from oil cooler, radiator and air conditioner condenser. Check coolant level
COLD in reservoir and add 50% ethylene glycol premixed with 50% water as needed.
Check cooling system for leaks.
Engine Air Filter Check condition indicator. Service only when required. Do not use compressed air to clean
elements. Empty dust cup.
Engine Air Intake System Check for leaks and damaged components.
Bob-Tach Pivot, Wedges, Lubricate with multi-purpose lithium based grease.
Cylinder and Link Pin Pivots
Axle Steering Pivot Points Lubricate with multi-purpose lithium based grease.
Rear Axle Pivot Lubricate with multi-purpose lithium based grease.
Boom and Cylinder Pivot Lubricate with multi-purpose lithium based grease.
Hydraulic Hoses and Tubelines Check condition of hoses, tubelines and connections. Repair or replace as needed
Universal Joints and Slip Yoke on Lubricate with multi-purpose lithium based grease.
Drive Shaft
Cab Filter Clean dust out of the cab filter. Replace every 500 hours.
Battery Check electrolyte level. Add distilled water as needed.
Wheel Nuts Check wheel nut torque. Tighten as needed [265 ft.-lb. (360 N•m)]. †
Fuel Filter Replace the fuel filter element. Use the genuine Bobcat Filter. ●
Engine / Hydro. Drive Belt Check for wear or damage. Check tension and adjust or replace as needed.
Alt. & Air Cond. Belt (If Equipped) Check belt tension and adjust as needed.
LORS™ or door hinges (If Lubricate restraint bar spring pivot or door hinges with multi-purpose lithium based grease.
Equipped)
Hydraulic/Hydrostatic Oil Filters Replace the hydraulic/hydrostatic oil filter elements. Use a genuine Bobcat filter. ●
Engine Oil and Filter Replace the engine oil and filter. Use a genuine Bobcat filter. ●
Cab Filter Replace the cab filter.
Axle Fluids Check all fluid levels. ♦
Front & Rear Axle Fluid Replace the axle oil in the central casings. ♦ ❍
Gear Box Fluid Replace the gear box (drive box) fluid. ♦ ❍
Wheel Gear Fluid Replace the wheel gear fluid. ♦ ❍
Hydraulic Fluid Replace the hydraulic fluid.
Engine Coolant Flush cooling system and replace coolant with 50% ethylene glycol premixed with 50%
water. Check freeze protection of antifreeze -34°F (-30°F)
Telescopic Boom Wear Blocks Check for wear and adjust as needed. Replace if necessary.
Pivot Pins and Bushings Check for wear on the pivot pins and bushings.
Breathers Clean gear box, axle housing, and hydraulic tank breathers. Replace as needed.

† Check wheel nut torque every 8 hours for the first 24 hours.
● Perform service first time at 50 hours, then as indicated in chart.
♦ Perform fluid level check first time at 100 hours, then as indicated in chart.
❍ Replace fluid first at 500 hours, then as indicated in chart.
❏ or every 6 months.
■ or every 12 months.

6986740-EN (07-08) 10-50-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 10-50-2 Bobcat T2250
SERVICE MANUAL
AIR CLEANER SERVICE Figure 10-60-3

Replacing The Filter Element

Outer filter

Figure 10-60-1

2
1

S3272

Pull the element straight out [Figure 10-60-3].

NOTE: Make sure all sealing surfaces are free of dirt

and debris. Do not use compressed air to
S3269
remove dirt or debris.

Replace the large (outer) filter element only when the red Install a new outer element.
ring shows in the window of the condition indicator
(Item 1) [Figure 10-60-1]. Figure 10-60-4

NOTE: Before replacing the filter element, push the 2

button on the condition indicator (Item 2)
[Figure 10-60-1]. Start the engine. If the red
ring does not show, do not replace the filter
element.

Replace the inner filter every third time the outer filter is
replaced or when the red ring still shows in the indicator
window after the outer filter has been replaced. 1
Figure 10-60-2

1 2
S3271

Install the dust cover (Item 1) [Figure 10-60-4] and fasten.

Connect the filter housing clamps (Item 2) [Figure 10-60-4].

1
S3271

Loosen the filter housing clamps (Item 1) [Figure 10-60-

2].

Release the fastener and remove the cover (Item 2)

[Figure 10-60-2].

6986740-EN (07-08) 10-60-1 Bobcat T2250

SERVICE MANUAL
AIR CLEANER SERVICE (CONT’D)

Replacing The Filter Element (Cont’d)

Inner Filter

Remove the outer element.

NOTE: Make sure all sealing surfaces are free of dirt

and debris. Do not use compressed air to
remove dirt or debris

Figure 10-60-5

S3273

Remove the inner filter (Item 1) [Figure 10-60-5] and

install a new element.

Install the outer element.

Figure 10-60-6

2 S3271

Install the dust cover (Item 1) [Figure 10-60-6] and fasten.

Connect the filter housing clamps (Item 2) [Figure 10-60-

6].

6986740-EN (07-08) 10-60-2 Bobcat T2250

SERVICE MANUAL
ENGINE COOLING SYSTEM Checking The Coolant Level

Check the cooling system every day to prevent over- Open the engine cover.
heating, loss of performance or engine damage.
Figure 10-70-3

WARNING
Wear safety glasses to prevent eye injury when any of
the following conditions exist:
• When fluids are under pressure.
1
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285

Cleaning The Cooling System

S7479
Figure 10-70-1

When the engine is cold, the coolant level must be at least

at the MIN mark (Item 1) [Figure 10-70-3] on the overflow
bottle.
1

IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.

Too much antifreeze reduces cooling system

S2690 efficiency and may cause serious premature engine
damage.
Open the engine cover (Item 1) [Figure 10-70-1]. Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
Figure 10-70-2 boiling point and freeze protection of the system.

Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
1 engine damage.
I-2124-0497

S2691

Use low air pressure or water pressure to clean the

radiator (Item 1) and oil cooler (Item 2) [Figure 10-70-2].

6986740-EN (07-08) 10-70-1 Bobcat T2250

SERVICE MANUAL
ENGINE COOLING SYSTEM (CONT’D) NOTE: The Telescopic Handler is factory filled with
ethylene glycol coolant.
Replacing The Coolant
Add premixed coolant, 50% water and 50% ethylene
glycol to the reservoir if the coolant level is low.

WARNING One gallon (3,8 L) of ethylene glycol mixed with one

gallon (3,8 L) of water is the correct mixture of coolant to
provide a -34° F (-37° C) freeze protection.
AVOID BURNS
Do not remove radiator cap when the engine is hot. Use a refractometer to check the condition of ethylene
You can be seriously burned. glycol in your cooling system.
W-2070-1203
Add coolant to the radiator. The coolant level must be right
Open the engine cover. below the connection with the overflow bottle (Item 2)
[Figure 10-70-4].
Figure 10-70-4
Install the radiator cap.

Add coolant to the overflow bottle as needed.

1 Run the engine until it is at operating temperature.

2 Stop the engine.

Check the coolant level when the engine is cold and add
as needed.

S6529
IMPORTANT
AVOID ENGINE DAMAGE
Remove the radiator cap (Item 1) [Figure 10-70-4]. Always use the correct ratio of water to antifreeze.
Figure 10-70-5 Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
damage.

Too little antifreeze reduces the additives which

protect the internal engine components; reduces the
boiling point and freeze protection of the system.

Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
1 engine damage.
I-2124-0497

S6568

Open the drain valve (Item 1) [Figure 10-70-5] at the

bottom of the engine compartment.

Drain the coolant into a container. Recycle or dispose of

coolant in an environmentally safe manner.

Close the drain valve (Item 1) [Figure 10-70-5].

Mix the coolant in a separate container.

6986740-EN (07-08) 10-70-2 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM Filling The Fuel Tank

Fuel Specifications

Use only clean, high quality diesel fuel, Grade No. 2 or

Grade No. 1. WARNING
The following is one suggested blending guideline which AVOID INJURY OR DEATH
should prevent fuel gelling problems in cold temperatures: Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
TEMP. F° (C°) NO. 2 NO. 1 explosion or fire.
W-2063-0807
+15° (9°) 100% 0%
Down to -20° (-29°) 50% 50%
Figure 10-80-1
Below -20° (-29°) 0% 100%

At a minimum, Low Sulfur (500 ppm sulfur) Diesel Fuel

must be used in this machine.

The following fuels may also be used in this machine: S6555

• Ultra Low Sulfur (15 ppm sulfur) Diesel Fuel.

Remove the fuel fill cap (Item 1) [Figure 10-80-1].
• Biodiesel Blend Fuel - Must contain no more than five
percent biodiesel mixed with low sulfur or ultra low Use a clean, approved safety container to add fuel of the
sulfur petroleum based diesel. This is commonly correct specifications. Add fuel only in an area that has
marketed as B5 blended diesel fuel. free movement of air and no open flames or sparks. NO
SMOKING!

Install and tighten the fuel fill cap [Figure 10-80-1].

6986740-EN (07-08) 10-80-1 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D)

Fuel Filter

Figure 10-80-2

S3276

For the correct service interval. (See SERVICE

SCHEDULE on Page 10-50-1.)

Loosen the drain (Item 1) [Figure 10-80-2] at the bottom

of the filter element to remove water from the filter.

Remove the filter element (Item 2) [Figure 10-80-2].

Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter, and
hand tighten.

WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-0807

6986740-EN (07-08) 10-80-2 Bobcat T2250

SERVICE MANUAL
ENGINE LUBRICATION SYSTEM Replacing Oil And Filter

Checking Engine Oil For the correct service interval for replacing the engine oil
and filter. (See SERVICE SCHEDULE on Page 10-50-1.)
Check the engine oil level every day before starting the
engine for the work shift. Run the engine until it is at operating temperature. Stop
the engine.
Figure 10-90-1
Figure 10-90-3

1 1

S2320
S6568

Open the engine cover and remove the dipstick (Item 1)

[Figure 10-90-1]. Remove the oil plug (Item 1) [Figure 10-90-3] at the
bottom of the engine compartment.
Keep the oil level between the marks on the dipstick.
Drain the oil into a container and recycle or dispose of
Oil Chart used oil in an environmentally safe manner.

Figure 10-90-2 NOTE: Oil at engine operating temperature is

extremely hot. Take all necessary precautions
to avoid injury and make sure the container is
heat resistant.

Install the oil plug (Item 1) [Figure 10-90-3].

WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-0807

Use good quality motor oil that meets API Service

Classification of CI-4 or better (See Oil Chart, [Figure 10-
90-2]).

6986740-EN (07-08) 10-90-1 Bobcat T2250

SERVICE MANUAL
ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-90-6

Replacing Oil And Filter (Cont’d)

Figure 10-90-4
1

S3281

Remove the fill cap (Item 1) [Figure 10-90-6].

S2690
Put oil in the engine. (See Capacities on Page SPEC-10-
3.) (See Oil Chart on Page 10-90-1.)
Open the engine cover (Item 1) [Figure 10-90-4].
Install the fill cap, start the engine and let it run for several
Figure 10-90-5 minutes.

Stop the engine, and check for leaks at the oil filter.

Let the engine cool.

Figure 10-90-7

S3278

Remove the oil filter (Item 1) [Figure 10-90-5].

Clean the filter housing surface.

Put clean oil on the new oil filter gasket. Install the filter S2320

and hand tighten.

Remove the dipstick (Item 1) [Figure 10-90-7] and check
the oil level. Add oil as needed if it is not at the top mark
on the dipstick.

Recycle or dispose of the fluid in an environmentally safe

manner. Reinstall the dipstick.

6986740-EN (07-08) 10-90-2 Bobcat T2250

SERVICE MANUAL
HYDRAULIC / HYDROSTATIC SYSTEM Replacing The Hydraulic / Hydrostatic Filters

Checking And Adding Fluid For the correct service interval for replacing the hydraulic /
hydrostatic filters. (See SERVICE SCHEDULE on Page
Use only recommended fluid in the hydraulic system. (See 10-50-1.)
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
on Page SPEC-60-1.) Figure 10-100-3

Stop the machine on a level surface. Lower the boom all

the way and tilt the Bob-Tach fully back.

Stop the engine.

Figure 10-100-1

1 S2695

Stop the engine and open the engine cover.

Remove the two filter elements (Items 1 & 2) [Figure 10-

100-3].
S3322
Clean the surface of the filter housings where the filter
seals contacts the housings.
Check the fluid level at the sight gauge (Item 1) [Figure
10-100-1] behind the front left wheel.
Put clean oil on the seals of the new filters. Install and
hand tighten the two new filter elements.
Figure 10-100-2

WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
S7162

Clean the area around the hydraulic fill cap.

Remove the fill cap (Item 1) [Figure 10-100-2] at the front

left side of the Telescopic Handler and add hydraulic fluid
until visible in the sight gauge.

Install the fill cap.

6986740-EN (07-08) 10-100-1 Bobcat T2250

SERVICE MANUAL
HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)

Replacing Hydraulic Fluid

WARNING
Use only recommended fluid in the hydraulic system. (See
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
AVOID INJURY OR DEATH
on Page SPEC-60-1.)
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Stop the machine on a level surface. Lower the boom all
Failure to use care around combustibles can cause
the way and tilt the Bob-Tach fully back.
explosion or fire which can result in injury or death.
W-2103-0807
Stop the engine.

Figure 10-100-4 Figure 10-100-5

S2373
S6545

Remove the fill cap (Item 1) [Figure 10-100-4] at the front Remove the reservoir drain plug (Item 1) [Figure 10-100-
left side of the Telescopic Handler. 5] behind the right front tire and drain the fluid into a
container. Recycle or dispose of the fluid in an
environmentally safe manner. Reinstall the drain plug and
tighten.

WARNING Figure 10-100-6

AVOID INJURY OR DEATH

Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention 1
from a physician familiar with this injury.
W-2072-0807

S3322

Add fluid until visible in the sight gauge (Item 1) [Figure

10-100-6] behind the front left tire.

Install the fill cap (Item 1) [Figure 10-100-4].

6986740-EN (07-08) 10-100-2 Bobcat T2250

SERVICE MANUAL
AXLES (FRONT AND REAR) Draining Oil (Planetary Carrier)

Checking Oil Level (Planetary Carrier) Figure 10-110-2

Figure 10-110-1

1 1

S3296

S3297
For the correct service interval. (See SERVICE
SCHEDULE on Page 10-50-1.)
Put the machine on a level surface with the plug (Item 1)
[Figure 10-110-1] positioned as shown. Put the machine on a level surface with the plug (Item 1)
[Figure 10-110-2] positioned as shown.
Remove the plug (Item 1) [Figure 10-110-1]. The oil level
should be at the bottom edge of the plug hole. Remove the plug (Item 1) [Figure 10-110-2] and drain
into a container. Recycle or dispose of the used lubricant
Add gear lube through the hole if the oil level is below the in an environmentally safe manner.
hole. (See Capacities on Page SPEC-10-3.)
Reposition the plug hole (Item 1) [Figure 10-110-1] and
Install and tighten the plug. add gear lube until the lube level is at the bottom edge of
the plug hole.
Repeat the procedure for the other side.
Install and tighten the plug.

Repeat the procedure for the other side.

6986740-EN (07-08) 10-110-1 Bobcat T2250

SERVICE MANUAL
AXLES (FRONT AND REAR) (CONT'D) Draining Oil (Rear Differential)

Checking Oil Level (Rear Differential) For the correct service interval. (See SERVICE
SCHEDULE on Page 10-50-1.)
Figure 10-110-3
Figure 10-110-4

1
1

S3299
S1842

With the machine on a level surface, remove the fill plug

(Item 1) [Figure 10-110-3]. The oil level should be at the With the machine on a level surface remove the drain plug
bottom edge of the plug hole. (Item 1) [Figure 10-110-4] and drain into a container.

Add oil through the hole if the oil level is at the bottom Recycle or dispose of the used lubricant in an
edge of the hole. (See Capacities on Page SPEC-10-3.) environmentally safe manner.

Install and tighten the fill plug. Install and tighten the drain plug.

Remove the fill plug (Item 1) [Figure 10-110-3].

Add oil through the hole until the oil level is at the bottom
edge of the plug hole.

Install and tighten the fill plug.

6986740-EN (07-08) 10-110-2 Bobcat T2250

SERVICE MANUAL
AXLES (FRONT AND REAR) (CONT'D) Draining Oil (Front Differential)

Checking Oil Level (Front Differential) For the correct service interval. (See SERVICE
SCHEDULE on Page 10-50-1.)
Figure 10-110-5
Figure 10-110-7

1
S3295

S3295

Figure 10-110-6
Figure 10-110-8

1
S3689

S3689
With the machine on a level surface, remove the fill plugs
(Item 1) [Figure 10-110-5] & [Figure 10-110-6]. The oil With the machine on a level surface, remove the drain
level should be at the bottom edge of the plug holes. plugs (Item 1) [Figure 10-110-7] & [Figure 10-110-8] and
drain into a container.
Add oil through the holes if the oil level is below the holes.
(See Capacities on Page SPEC-10-3.) Recycle or dispose of the used lubricant in an
environmentally safe manner.
Install and tighten the fill plugs.
Install and tighten the drain plugs.

Remove the fill plugs (Item 1) [Figure 10-110-5] &

[Figure 10-110-6].

Add oil through the holes until the oil level is at the bottom
edge of the plug holes.

Install and tighten the fill plugs.

6986740-EN (07-08) 10-110-3 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 10-110-4 Bobcat T2250
SERVICE MANUAL
LUBRICATION Figure 10-120-3

Procedure
4
Lubricate as specified (See SERVICE SCHEDULE on
Page 10-50-1.) for the best performance of the machine.

Record the operating hours each time you lubricate so

4
that it is performed at the correct interval.

Always use a good quality lithium based multi-purpose 3

grease. Apply lubricant until extra grease shows.

Lubricate the following locations on the Telescopic

Handler: 3
S6558

Figure 10-120-1

3. Bob-Tach Frame Pivot - Both sides (2) [Figure 10-

120-3].

4. Tilt Cylinder, Rod End - Both sides and middle (3)

[Figure 10-120-3].

Figure 10-120-4
1

5
P24167

Ref. Description (# of Fittings)

7
1. Axle Pivots - Top and bottom (2) [Figure 10-120-1] of
all four wheels. 6

Figure 10-120-2 7
S6534

5. Link Pivot - Both sides and middle (3) [Figure 10-120-

4].

6. Link Pivot - Middle (1) [Figure 10-120-4].

2 2 7. Link Pivot - Both sides and middle (3) [Figure 10-120-

4].

S2000 S1998

2. Axle Oscillation, Rear Axle - Front and Back (2)

[Figure 10-120-2].

6986740-EN (07-08) 10-120-1 Bobcat T2250

SERVICE MANUAL
LUBRICATION (CONT’D) Figure 10-120-7

Figure 10-120-5

11
10

12

8 S2694

S0003
NOTE: Raise the boom and install the approved Boom
Stop (See Installing The Approved Boom Stop
8. Bob-Tach Wedge - Both sides (2) [Figure 10-120-5]. on Page 10-150-1.) before lubricating the Lift
and Slave Cylinders.
Figure 10-120-6
10. Slave Cylinder, Rod End (1) [Figure 10-120-7].

11. Lift Cylinder, Rod End (1) [Figure 10-120-7].

12. Lift Cylinder, Pivot (1) [Figure 10-120-7].

Figure 10-120-8

S3307

9. Tilt Cylinder, Base End (1) [Figure 10-120-6].

13 14
S2693

13. Slave Cylinder, Base End (1) [Figure 10-120-8].

14. Lift Cylinder, Base End (1) [Figure 10-120-8].

6986740-EN (07-08) 10-120-2 Bobcat T2250

SERVICE MANUAL
LUBRICATION (CONT’D) Figure 10-120-11

Figure 10-120-9

17
15
15

15

17

S3300
17. Cab Door Hinges - Upper (17) [Figure 10-120-11].

15. Boom Pivot (3) [Figure 10-120-9]. Figure 10-120-12

Figure 10-120-10

16
18

18

16

S0001

S3306
18. Cab Door Hinges - Lower (18) [Figure 10-120-12].
16. Boom Slide - Both sides, top, and bottom (8) [Figure
10-120-10].

6986740-EN (07-08) 10-120-3 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 10-120-4 Bobcat T2250
SERVICE MANUAL
TIRE MAINTENANCE Tire Rotation

Wheel Nuts Check the tires regularly for wear, damage and pressure.
For the correct tire pressure, (See Tires on Page SPEC-
Figure 10-130-1 10-3.)

Rear tires usually wear faster than front tires. To keep the
wear even, move the front tires to the rear and rear tires to
the front.

It is important to keep the same size tires on each side of

the Telescopic Handler. If different sizes are used, each
tire will be turning at a different rate and cause excessive
wear and loss of stability. The tread bars of all the tires
must face the same direction.

Recommended tire pressure must be maintained to avoid

excessive tire wear and loss of stability and handling
capacity. Check for the correct pressure before operating
S2004 the Telescopic Handler.

Tire Pressure
For the correct service interval to check the wheel nuts
(See SERVICE SCHEDULE on Page 10-50-1.). For correct inflation: (See Tires on Page SPEC-10-3.)
The correct torque is 265 ft.-lb. (360 N•m) torque [Figure
10-130-1].

Tire Mounting

Tires are to be repaired only by an authorized person

using the correct procedures and type of equipment.

Tires and rims must always be checked for correct size

before mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire
bead and rim flange must be lubricated with a rubber
lubricant before mounting the tire.

Avoid excessive pressure which can rupture the tire and

cause serious injury or death.

During inflation of the tire, check the tire pressure

frequently to avoid over inflation.

6986740-EN (07-08) 10-130-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 10-130-2 Bobcat T2250
SERVICE MANUAL
APPROVED BOOM STOP Removing The Approved Boom Stop

If the boom is raised for service or maintenance, use the • Start the engine and raise the boom. Stop the engine.
following procedure to install and remove the approved
boom stop. • Remove the fasteners, pins and boom stop.

Installing The Approved Boom Stop

• Put the Telescopic Handler on a flat, solid and level

surface.
• With the operator in the seat, the seat belt fastened,
Travel Direction Control in neutral and the parking
brake engaged, start the engine and raise the boom
fully. Stop the engine.
Figure 10-150-1

S6553

• Remove the boom stop (Item 1) [Figure 10-150-1]

from the storage position.

Figure 10-150-2

1
S2658

• Position the boom stop over the boom cylinder rod and
install the pins and secure with fasteners (Item 1)
[Figure 10-150-2].

• Start the engine and lower the boom slowly [Figure

10-150-2] so that the boom stop is held securely.

6986740-EN (07-08) 10-150-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 10-150-2 Bobcat T2250
SERVICE MANUAL
ENGINE COVER Figure 10-160-2

Opening And Closing The Engine Cover

WARNING
AVOID INJURY OR DEATH
Never service or adjust the machine when the engine 1
is running unless instructed to do so in the manual.
W-2012-0497

Figure 10-160-1
S7218

Raise the engine cover until the hold open latch (Item 1)
[Figure 10-160-2] is in the secure position.
1
To make sure the latch (Item 1) [Figure 10-160-2] is fully
engaged into secure position, push forward on the bottom
of the latch while holding the engine cover up.

Close the engine cover before operating the Telescopic

Handler.

S6554

Pull the latch handle (Item 1) [Figure 10-160-1] out and

rotate it counterclockwise. Raise the engine cover to
provide access for maintenance.

Close the engine cover before operating the Telescopic

Handler.

6986740-EN (07-08) 10-160-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 10-160-2 Bobcat T2250
SERVICE MANUAL
REMOTE START Figure 10-180-1

Connecting to the Telescopic Handler Tools P/N 6689778

and P/N 6689747
Tools that will be needed to complete the following steps
are:

Order from Bobcat Parts P/N: 6689779 - Remote Start

Tool (Service Tool) Kit

Kit P/N 6689779 Includes: 2

6689778 - Remote Start Tool (Service Tool)
6689747 - Service Tool Harness 1
6689746 - Computer Service Tool Harness
6689745 - BOSS® Service Tool Harness

S7313
OR, instead of kit P/N 6689779, the following two tools
can be used: Tools MEL1563
and MEL1565
MEL1563 - Remote Start Tool
MEL1565 - Service Tool Harness Control

S7314

The service tool harness control (Item 1) is used to

connect the remote start tool (Item 2) [Figure 10-180-1]
to the electrical system on the Telescopic Handler.

6986740-EN (07-08) 10-180-1 Bobcat T2250

SERVICE MANUAL
REMOTE START (CONT’D) Figure 10-180-3

Connecting to the Telescopic Handler (Cont’d)

Figure 10-180-2 2

1
1

3
S7089

Connect the main connector (Item 1) of the Service Tool

S5046 Harness Control to the machine frame harness connector
(Item 2) [Figure 10-180-3], located in the rear of the
machine.
Remove the rear cover (Item 1) [Figure 10-180-2] from
the Telescopic Handler. For machines with an attachment control harness, the
attachment harness must first be disconnected from the
Telescopic Handler harness.

NOTE: The remote start tool connection harness has

two connectors (Item 1) and (Item 3). The main
connector (Item 1) is always used for
connection to the engine harness [Figure 10-
180-3].

The second connector (Item 3) [Figure 10-180-

3] is used for attachment ACD upgrades or
attachment operational diagnostics only. This
connector has a cap attached to it to prevent
damage or corrosion when not in use.

NOTE: The key switch on the machine operator panel

must be in the off position or the Remote Start
Kit will not operate.

6986740-EN (07-08) 10-180-2 Bobcat T2250

SERVICE MANUAL
Remote Start Procedure (For Tools MEL1563 Figure 10-180-5
and MEL1565)

Figure 10-180-4

2
3 1

P16118

P16116 The traction lock switch (Item 1) [Figure 10-180-5] is

used to turn traction lock on or off. Push the switch to the
override position. The switch will illuminate to indicate
The remote start tool (Item 1) [Figure 10-180-4] has three traction lock OVERRIDE, in this position the wheels are
rocker switches. able to turn.

The maximum flow/variable flow switch (Item 2) [Figure

10-180-5] is used to activate the auxiliary hydraulics.
Pressing the switch once will activate variable flow.
Pressing the switch again will activate maximum flow. The
switch will illuminate to indicate which flow rate is active.
Pressing the switch a third time will turn the flow OFF. The
switch is used when checking pressures and flow rate.

The auxiliary pressure release (Item 3) [Figure 10-180-5]

is used to release hydraulic pressure to the front and/or
rear auxiliary couplers. To release pressure; push and
hold the switch for three seconds.

NOTE: With the engine running; pushing and holding

the pressure release switch will cause the
engine to stop in three seconds. To relieve the
pressure; continue to press the switch after
the engine has stopped.

6986740-EN (07-08) 10-180-3 Bobcat T2250

SERVICE MANUAL
Remote Start Procedure (For Tool Kit P/N 6689779) Figure 10-180-7

Figure 10-180-6

5 3
1 2
6 4

P-76441

P-76439
The gear icon with the left facing arrows (Item 1) [Figure
10-180-7] will illuminate and blink when the RUN key is
The Remote Start Tool (Service Tool) (Item 1) [Figure 10- pressed and the Telescopic Handler is communicating
180-6] has five buttons. with the service tool.

The STOP button (Item 2) [Figure 10-180-6] is used to The computer icon with the right facing arrows (Item 2)
stop the Remote Start Tool (Service Tool) from [Figure 10-180-7] will illuminate and blink when the
communicating and stop the Telescopic Handler engine. Remote Start Tool (Service Tool) is transmitting data to
and from the computer.
The RUN button (Item 3) [Figure 10-180-6] is used to turn
the Remote Start Tool (Service Tool) on and activates the NOTE: To relieve the pressure at the rear or
ignition power. The button will illuminate to indicate the secondary front auxiliary, (if equipped) press
service tool is active. the RUN button on the remote start tool. Then
press the auxiliary (AUX) hydraulics button on
The START button (Item 4) [Figure 10-180-6] is used to the remote start tool and move the AUXILIARY
start the engine. Hydraulic Switch on the Telescopic Handler to
the right and left several times.
The traction lock button (Item 5) [Figure 10-180-6] is
used to turn traction lock ON or OFF. Push the button and
the button will illuminate indicating the traction lock is
disabled in which the wheels or tracks are able to turn.

The auxiliary button (Item 6) [Figure 10-180-6] is used to

activate the auxiliary hydraulics. The button will illuminate
to indicate the auxiliary hydraulics are active. Pressing the
button a second time will turn the flow OFF. The button is
used when checking pressures and flow rate.

6986740-EN (07-08) 10-180-4 Bobcat T2250

SERVICE MANUAL
 HYDRAULIC SYSTEM

BOB-TACH CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Not available at time of printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
HYDRAULIC
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1 SYSTEM
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-2
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

BUCKET POSITIONING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-6
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-5
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

DRIVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-2
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-9

EXTENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Cylinder Group Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Extension Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . . 20-40-5
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-10
Tubeline Tray Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-8
Tubeline Tray Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
Upper Tubeline Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-4
Upper Tubeline Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-3

FRONT AUXILIARY HYDRAULIC PRESSURE RELEASE VALVE . . . . . 20-230-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230-2
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230-1

GEAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-4
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-3
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Continued On Next Page

6986740-EN (07-08) 20-01 Bobcat T2250

SERVICE MANUAL
 HYDRAULIC SYSTEM (CONT’D)

HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1

Auxiliary Valve Section Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-6
End Housing Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-170-16
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-16
Inlet-Outlet Valve Section Disassembly And Assembly . . . . . . . . . . . . . . 20-170-20
Lifting and Tilting Valve Section Disassembly And Assembly . . . . . . . . . 20-170-19
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-15
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-11
Telescoping and Auxiliary Valve Section Disassembly And Assembly . . 20-170-17
Telescoping Valve Section Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . 20-170-2
Troubleshooting Chart (Controllers). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1
Troubleshooting Chart (Control Valve). . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-10

HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Tightening Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-4

JOYSTICK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-1

LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-2
Testing And Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-240-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-240-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-240-1

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-190-1

Parking Brake Valve Disassembly And Assembly . . . . . . . . . . . . . . . . . . . 20-190-2
Parking Brake Valve Removal And Installation20-190-1

PORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Continued On Next Page

6986740-EN (07-08) 20-02 Bobcat T2250

SERVICE MANUAL
 HYDRAULIC SYSTEM (CONT’D)

STEERING CYLINDER (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Assembling the Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-5
Disassembling the Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Installing the Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Removing the Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

STEERING CYLINDER (REAR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1

Assembling The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-6
Disassembling The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-4
Removing The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1

STEERING MODE VALVE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-3
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-5

STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-6
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-2
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1

TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-4
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

TOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-2
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-1

WORKGROUP LOCKOUT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-3
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-1

6986740-EN (07-08) 20-03 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 20-04 Bobcat T2250
SERVICE MANUAL
HYDRAULIC SYSTEM INFORMATION

mc-2340

Bobcat T2250
20-10-1 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)

mc-2340-2

6986740-EN (07-08) 20-10-2 Bobcat T2250

SERVICE MANUAL
HYDRAULIC SYSTEM INFORMATION (CONT’D)

mc-2340-3

6986740-EN (07-08) 20-10-3 Bobcat T2250

SERVICE MANUAL
HYDRAULIC SYSTEM INFORMATION (CONT’D)

Troubleshooting Chart WARNING

The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285

PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 6
The hydraulic oil temperature warning light comes ON when hydraulics are operating. 1, 2
Slow hydraulic system action. 1, 2, 4, 8
Hydraulic action is not smooth. 1, 3, 4, 5
Boom goes up slowly at full engine RPM. 1, 2, 4, 5, 6, 7
The boom comes down with the lever in neutral position. 7, 8, 9

KEY TO CORRECT THE CAUSE

1. The fluid level is not correct..
2. The hydraulic pump has damage.
3. Relief valve is not at the correct pressure.
4. Suction leak on the inlet side of the hydraulic pump.
5. Fluid is cold. Wrong viscosity fluid. ((See HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS on
Page SPEC-60-1.))
6. Using the machine for more than its rated capacity.
7. Internal leak in the lift cylinder.
8. External leak from the cylinder(s).
9. Damaged lift spool.

6986740-EN (07-08) 20-10-4 Bobcat T2250

SERVICE MANUAL
HYDRAULIC SYSTEM INFORMATION (CONT’D)

Tightening Procedures

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

To tighten the hydraulic fittings, tubelines etc. (See

HYDRAULIC CONNECTION SPECIFICATIONS on Page
SPEC-50-1.), for the correct procedure and torque.

WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290

6986740-EN (07-08) 20-10-5 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 20-10-6 Bobcat T2250
SERVICE MANUAL
LIFT CYLINDER Figure 20-20-3

Removal And Installation

Figure 20-20-1

S7229

Place a wood block (Item 1) [Figure 20-20-3] under the lift

S7231 cylinder / bucket positioning cylinder.

Figure 20-20-4
Lower the boom onto adequate stands or blocks as shown
[Figure 20-20-1].

Figure 20-20-2

S7232

Support the two cylinders using a cinch strap (Item 1)

S5046 [Figure 20-20-4].

Remove the rear cover (Item 1) [Figure 20-20-2] from the

Telescopic Handler.

6986740-EN (07-08) 20-20-1 Bobcat T2250

SERVICE MANUAL
LIFT CYLINDER (CONT'D)

Removal And Installation (Cont'd)

IMPORTANT
Figure 20-20-5
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure 20-20-7
1

S7235 1

Remove the pivot pin retainer bolt (Item 1) [Figure 20-20-

5] from the lift cylinder / bucket positioning cylinder.

Figure 20-20-6

S7234

Lift and support the cylinders using a hoist and lifting strap
(Item 1). Remove the cinch strap (Item 2) [Figure 20-20-
7].

Figure 20-20-8

S7233

Remove the upper pivot pin using a pin removal tool (Item
1) [Figure 20-20-6].

1
S5027

Lower the two cylinders onto the wood block (Item 1)

[Figure 20-20-8].

6986740-EN (07-08) 20-20-2 Bobcat T2250

SERVICE MANUAL
LIFT CYLINDER (CONT'D) Figure 20-20-10

Removal And Installation (Cont'd)

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all 2
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

1
Figure 20-20-9 S5029

Remove the Load Lock Solenoid (Item 1) [Figure 20-20-

10].
1
Remove the base end pivot pin retainer bolt (Item 2)
[Figure 20-20-10]..

Figure 20-20-11

1
2

S5028

Remove the two hoses (Item 1) [Figure 20-20-9] from the 1

load lock.

Remove the two hoses (Item 2) [Figure 20-20-9] from the

bucket positioning cylinder.

NOTE: Mark the hoses for correct installation. S5030

Remove the base end pivot pin (Item 1) [Figure 20-20-

11].

Carefully remove the two cylinders.

6986740-EN (07-08) 20-20-3 Bobcat T2250

SERVICE MANUAL
LIFT CYLINDER (CONT'D)

Removal And Installation (Cont'd)

Figure 20-20-12

S5039

Remove the bolt and nut (Item 1) [Figure 20-20-12] and

separate the lift cylinder and bucket positioning cylinder.

6986740-EN (07-08) 20-20-4 Bobcat T2250

SERVICE MANUAL
LIFT CYLINDER (CONT'D)

Parts Identification

1. Bushing
2. Grease Fitting
3. Housing
4. Wear Ring
5. Expander O-ring
6. Set Screw
7. Piston
8. Backup Ring
9. O-Ring
10. Backup Ring
11. Rod
12. Head Gland
13. Wiper
1
2

1
5

3
4
11

7
8 6
9
8

13
10
1 10
9
12
4
45

2 1

S7307

6986740-EN (07-08) 20-20-5 Bobcat T2250

SERVICE MANUAL
LIFT CYLINDER (CONT'D) Figure 20-20-15

Disassembly

Use the following tools to disassemble the cylinder:

MEL1074-O-ring Seal Hook

MEL1033-Rod Seal Installation Tool
MEL1353-Cylinder Gland Nut Wrench

Clean the outside of the lift cylinder before disassembly. 1

Clean all parts in solvent and dry with compressed air.

Figure 20-20-13
S5032

Carefully peen the lock ring from the head gland [Figure
20-20-15].

Figure 20-20-16

S2843

Put the cylinder in a vise [Figure 20-20-13].

Figure 20-20-14

P-32340

1 Loosen the head gland [Figure 20-20-16].

1 1
2

S5031

Remove the four bolts (Item 1) and remove the load lock
(Item 2) [Figure 20-20-14].

6986740-EN (07-08) 20-20-6 Bobcat T2250

SERVICE MANUAL
LIFT CYLINDER (CONT'D) Figure 20-20-19

Disassembly (Cont'd)

Figure 20-20-17

1 1

S5033

Remove the two wear rings (Item 1) [Figure 20-20-19]

S5051 from the piston.

Figure 20-20-20
Remove the rod assembly (Item 1) [Figure 20-20-17]
from the housing.

Figure 20-20-18

S5034

Remove the set screw (Item 1) [Figure 20-20-20] from

S5036 the piston.

Put the rod end of the cylinder rod in a vise [Figure 20-20-
18].

6986740-EN (07-08) 20-20-7 Bobcat T2250

SERVICE MANUAL
LIFT CYLINDER (CONT'D) Figure 20-20-23

Disassembly (Cont'd)

Figure 20-20-21

S5035

Remove the expander O-ring (Item 1) [Figure 20-20-23].

S5054
Figure 20-20-24

Support the cylinder rod on a wood block and remove the

piston [Figure 20-20-21].

Figure 20-20-22

1 2

1 S5035

Remove the black O-ring (Item 1) and two backup rings

(Item 2) [Figure 20-20-24] from the piston.
S5052

Remove the seal (Item 1) [Figure 20-20-22] from the

piston.

6986740-EN (07-08) 20-20-8 Bobcat T2250

SERVICE MANUAL
LIFT CYLINDER (CONT'D) Figure 20-20-27

Disassembly (Cont'd)

Figure 20-20-25

1 1

S5042
1

Remove the wear rings (Item 1) [Figure 20-20-27].

S5037
Figure 20-20-28

Remove the head gland (Item 1) [Figure 20-20-25] from

the rod.

Figure 20-20-26

1
3
S5053

1
Remove the seal (Item 1), backup ring (Item 2) and wear
ring (Item 3) [Figure 20-20-28].
S5038

Remove the wiper seal (Item 1) [Figure 20-20-26] from

the head gland.

6986740-EN (07-08) 20-20-9 Bobcat T2250

SERVICE MANUAL
LIFT CYLINDER (CONT'D) Figure 20-20-31

Assembly

Use the following tools to assemble the cylinder:

MEL1074-O-ring Seal Hook

MEL1033-Rod Seal Installation Tool
MEL1353-Cylinder Gland Nut Wrench

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts. 1

Always install new seals and O-rings. Lubricate all seals

S5038
and O-rings with clean hydraulic fluid before installation.

Figure 20-20-29 Install the wiper seal (Item 1) [Figure 20-20-31] from the
head gland.

Figure 20-20-32

2
3
S5053 1

Install the backup ring (Item 1), seal (Item 2) and wear S5037
ring (Item 3) [Figure 20-20-29].

Figure 20-20-30 Install the head gland (Item 1) [Figure 20-20-32] onto the
rod.

Figure 20-20-33

1 1
1

1
S5042
2

Install the wear rings (Item 1) [Figure 20-20-30]. S5035

Install the two backup rings (Item 1) and black O-ring

(Item 2) [Figure 20-20-33] onto the piston.

6986740-EN (07-08) 20-20-10 Bobcat T2250

SERVICE MANUAL
LIFT CYLINDER (CONT'D) Figure 20-20-36

Assembly (Cont'd)

Figure 20-20-34

1
P-32047

Clean off any old residue, and apply LOCTITE 242 or

S5035 equivalent to the threads on the rod [Figure 20-20-36].

Figure 20-20-37
Install the expander O-ring (Item 1) [Figure 20-20-34].

Figure 20-20-35

S5054

S5052 Use the cylinder wrench to install the piston [Figure 20-
20-37].

Install the seal (Item 1) [Figure 20-20-35] onto the piston.

6986740-EN (07-08) 20-20-11 Bobcat T2250

SERVICE MANUAL
LIFT CYLINDER (CONT'D) Figure 20-20-40

Assembly (Cont'd)

Figure 20-20-38

1 1

S5033

Install the two wear rings (Item 1) [Figure 20-20-40] onto

P-29887 the piston.

Figure 20-20-41
Apply LOCTITE 242 or equivalent to the set screw (Item
1) [Figure 20-20-38].

Figure 20-20-39

1 S5051

Install the rod assembly (Item 1) [Figure 20-20-41] into

S5034 the housing.

Install the set screw (Item 1) [Figure 20-20-39] from the

piston.

6986740-EN (07-08) 20-20-12 Bobcat T2250

SERVICE MANUAL
LIFT CYLINDER (CONT'D) Figure 20-20-44

Assembly (Cont'd)

Figure 20-20-42
2

2 2
1

S5031

Install the load lock (Item 1) and install the four bolts (Item
P-29925 2) [Figure 20-20-44].

Use the spanner wrench to tighten the head gland

[Figure 20-20-42].

Figure 20-20-43

P-29926

Peen the lock ring into the groove in the head gland
[Figure 20-20-43].

6986740-EN (07-08) 20-20-13 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 20-20-14 Bobcat T2250
SERVICE MANUAL
BUCKET POSITIONING CYLINDER Figure 20-30-3

Removal And Installation

Figure 20-30-1

S7229

Place a wood block (Item 1) [Figure 20-30-3] under the lift

S7231 cylinder/bucket positioning cylinder.

Figure 20-30-4
Lower the boom onto adequate stands or blocks as shown
[Figure 20-30-1].

Figure 20-30-2

S7232

Support the two cylinders using a cinch strap (Item 1)

S5046 [Figure 20-30-4].

Remove the rear cover (Item 1) [Figure 20-30-2] from the

Telescopic Handler.

6986740-EN (07-08) 20-30-1 Bobcat T2250

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D)

Removal And Installation (Cont'd)

IMPORTANT
Figure 20-30-5
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure 20-30-7
1

S7235 1

Remove the pivot pin retainer bolt (Item 1) [Figure 20-30-

5] from the lift cylinder/bucket positioning cylinder.

Figure 20-30-6

S7234

Lift and support the cylinders using a hoist and lifting strap
(Item 1). Remove the cinch strap (Item 2) [Figure 20-30-
7].

Figure 20-30-8

S7233

Remove the upper pivot pin using a pin removal tool (Item
1) [Figure 20-30-6].

S5027

Lower the two cylinders onto the wood block (Item 1)

[Figure 20-30-8].

6986740-EN (07-08) 20-30-2 Bobcat T2250

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-10

Removal And Installation (Cont'd)

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
2
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

1
Figure 20-30-9 S5029

Remove the Load Lock Solenoid (Item 1) [Figure 20-30-

10].
1
Remove the base end pivot pin retainer bolt (Item 2)
[Figure 20-30-10]..

Figure 20-30-11

1
1

S5028

Remove the two hoses (Item 1) [Figure 20-30-9] from the 1

load lock.

Remove the two hoses (Item 1) [Figure 20-30-9] from the

cylinder.

NOTE: Mark the hoses for correct installation. S5030

Remove the base end pivot pin (Item 1) [Figure 20-30-

11].

Carefully remove the two cylinders.

6986740-EN (07-08) 20-30-3 Bobcat T2250

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D)

Removal And Installation (Cont'd)

Figure 20-30-12

S5039

Remove the bolt and nut (Item 1) [Figure 20-30-12] and

separate the lift cylinder and bucket positioning cylinder.

6986740-EN (07-08) 20-30-4 Bobcat T2250

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D)

Parts Identification

1. Bushing
2. Grease Fitting
3. Housing
4. Wear Ring
5. Seal
6. Seal
7. Set Screw
8. Piston
9. O-ring
10. Backup Ring 2
11. Head Gland
12. Wiper Seal
13. Rod 1

4
7
3

4 9 8

10
11
6
1 12

13

2
1

B-16230

6986740-EN (07-08) 20-30-5 Bobcat T2250

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-15

Disassembly

Use the following tools to disassemble the cylinder:

MEL1074-O-ring Seal Hook

MEL1353-Cylinder Gland Nut Wrench

Clean the outside of the bucket positioning cylinder before

disassembly.

Figure 20-30-13

P-32350

Remove the head gland [Figure 20-30-15].

Figure 20-30-16

S5055

Put the cylinder in a vise [Figure 20-30-13].

Figure 20-30-14

S5057

1 Remove the rod assembly (Item 1) [Figure 20-30-16]

from the housing.

S5056

Carefully peen the lock from the head gland (Item 1)

[Figure 20-30-14].

6986740-EN (07-08) 20-30-6 Bobcat T2250

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-19

Disassembly (Cont'd)

Figure 20-30-17

S5060

Support the cylinder rod on a wood block and remove the

S5058
set screw (Item 1) [Figure 20-30-19] from the piston.

Figure 20-30-20
Put the rod end of the cylinder in a vise [Figure 20-30-
17].

Figure 20-30-18

P-32354
1

Remove the piston assembly (Item 1) [Figure 20-30-20]

S5056 from the rod.

Remove the wear ring (Item 1) [Figure 20-30-18] from the

piston.

6986740-EN (07-08) 20-30-7 Bobcat T2250

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-23

Disassembly (Cont'd)
3
Figure 20-30-21

2
1 2

2
S5063

Remove the center seal (Item 1), the O-rings (Item 2) and
S5061 the backup ring (Item 2) [Figure 20-30-23].

Figure 20-30-24
Remove the seal (Item 1) and the wear ring (Item 2)
[Figure 20-30-21].

Figure 20-30-22

1 2

1 2 S5064

Remove the central seal (Item 1) and wipers (Item 2)

S5062 [Figure 20-30-24], one on either side...

Remove any residue from the threads on the cylinder rod.

Remove the expander O-ring (Item 1) [Figure 20-30-22]
from the piston.

Remove the internal O-ring and its backup rings (Item 2)

[Figure 20-30-22].

Remove the head gland from the rod.

6986740-EN (07-08) 20-30-8 Bobcat T2250

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-27

Assembly

Use the following tool to assemble the cylinder: 1

MEL1033-Rod Seal Installation Tool

MEL1353-Cylinder Gland Nut Wrench

Wash the cylinder parts in solvent and dry with

compressed air.

Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts.

Lubricate all O-rings and seals with hydraulic oil during P-29883
installation.

Figure 20-30-25 Install the wear ring (Item 1) [Figure 20-30-27].

1 Figure 20-30-28

P-29882

Install the two O-rings (Item 1) [Figure 20-30-25] onto the

head gland. P-29885

Figure 20-30-26 Install the center seal (Item 1) [Figure 20-30-28].

NOTE: The groove in the seal must point away from

1 the wiper seal (Item 1) [Figure 20-30-26].

P-29884

Install the wiper (Item 1) and wear ring (Item 2) [Figure

20-30-26].

6986740-EN (07-08) 20-30-9 Bobcat T2250

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-31

Assembly (Cont'd)
1
Figure 20-30-29

1 2

S5061

Install the seal (Item 1) and the wear ring (Item 2) [Figure
P-29881 20-30-21].

Figure 20-30-32
Install the head gland (Item 1) [Figure 20-30-29] onto the
rod.

Figure 20-30-30

2 P-29886
1

Apply LOCTITE 242 or equivalent to the threads on the

S5062 rod [Figure 20-30-32].

Install the expander O-ring (Item 1) [Figure 20-30-22]

onto the piston.

Install the internal O-ring and its backup rings (Item 2)

[Figure 20-30-22].

6986740-EN (07-08) 20-30-10 Bobcat T2250

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-35

Assembly (Cont'd)

Figure 20-30-33

S5060

Install the set screw (Item 1) [Figure 20-30-19] into the

P-32354 piston and tighten.

Figure 20-30-36
Install the piston assembly (Item 1) [Figure 20-30-20]
onto the rod.

Figure 20-30-34

S5057

Install the rod assembly (Item 1) [Figure 20-30-16] into

P-29887 the housing.

Apply LOCTITE 242 or equivalent to the set screw (Item

1) [Figure 20-30-34].

6986740-EN (07-08) 20-30-11 Bobcat T2250

SERVICE MANUAL
BUCKET POSITIONING CYLINDER (CONT'D)

Assembly (Cont'd)

Figure 20-30-37

P-32350

Use the spanner wrench to tighten the head gland

[Figure 20-30-15].

Figure 20-30-38

P-29868

Carefully peen the lock ring over and into the nut [Figure
20-30-38].

6986740-EN (07-08) 20-30-12 Bobcat T2250

SERVICE MANUAL
EXTENSION CYLINDER Figure 20-40-3

Cylinder Group Removal And Installation

Figure 20-40-1

2
1

S7247

Remove the two bolts (Item 1) [Figure 20-40-3] from the

P-23866 top of the inner boom.

Installation: Tighten the bolts to 18 ft.-lb. (24 N•m)

Remove the inner boom. (See Removal on Page 50-40- torque.
1.)
Figure 20-40-4
Remove the bolt (Item 1) and washer (Item 2) [Figure 20-
40-1] from one side of the cylinder pin.

Installation: Tighten the bolt to 188-210 ft.-lb. (255-285 1

N•m) torque.

Figure 20-40-2

S3684

Remove the cover (Item 1) [Figure 20-40-4] from the

boom head.

P-23866

Remove the pin assembly (Item 1) [Figure 20-40-2] from

the opposite side.

6986740-EN (07-08) 20-40-1 Bobcat T2250

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Figure 20-40-7

Cylinder Group Removal And Installation (Cont'd)

Figure 20-40-5

1
1
S7298

Disassemble the electrical connector (Item 1) [Figure 20-

2 S7306 40-7].

NOTE: Mark the connector wirings housing for

Remove the two hoses (Item 1) and fittings (Item 2) correct installation.
[Figure 20-40-5] from the tubelines.
Pull the electrical harness into the boom.
Remove the two hoses (Item 3) [Figure 20-40-5] from the
bulkhead fittings. Installation: For ease of installation temporarily tie a rope
onto the two hoses and electrical harness.
Figure 20-40-6
Figure 20-40-8

S7248

S7256

Remove the retainer ring (Item 1) [Figure 20-40-6] (if

equipped) from the support. Remove the extension cylinder assembly from the boom
[Figure 20-40-8].

6986740-EN (07-08) 20-40-2 Bobcat T2250

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Figure 20-40-11

Upper Tubeline Removal

1
Figure 20-40-9

S7257

Remove the four hoses (Item 1) [Figure 20-40-11] from

S7250 the tubelines.

NOTE: Mark the hoses for correct assembly.

With the extension cylinder group supported on a work
surface, remove the tie straps from the electrical harness Figure 20-40-12
[Figure 20-40-9].

Figure 20-40-10 1
2

1 S7252
1

S7251 Remove the bolt (Item 1) from the tubeline clamps (Item
2) [Figure 20-40-12] on the rod end of the cylinder.

Loosen the tubeline clamp mounting bolts (Item 1) Lift and remove the tubelines from the top of the cylinder.
[Figure 20-40-10].

NOTE: Mark the location of the tubelines for correct

assembly.

6986740-EN (07-08) 20-40-3 Bobcat T2250

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Figure 20-40-15

Upper Tubeline Installation

Set the tubeline assembly onto the extension cylinder.

1
Figure 20-40-13

2
1

2
2

S7251
1

Install the tubeline clamp (Item 1) and mounting bolts

(Item 2) [Figure 20-40-15] on the base end of the
cylinder.
S7252
Figure 20-40-16

Install the tubeline clamps (Item 1) and bolt (Item 2)

[Figure 20-40-13] on the rod end of the cylinder.

Figure 20-40-14
51,2 inches
(1300 mm)
1

1 1

S7253

Measure the distance from the center of the tubeline nut

(Item 1) to the center of the tubeline clamp (Item 2)
S7257 [Figure 20-40-16].

The correct distance between clamps must be 51.2

Install the four hoses (Item 1) [Figure 20-40-14] on the inches (1300 mm) for all four tubelines.
tubelines.

6986740-EN (07-08) 20-40-4 Bobcat T2250

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Extension Cylinder Removal And Installation

Upper Tubeline Installation (Cont’d) Figure 20-40-19

Figure 20-40-17

1 1 1
1 S7254

S7251
S7252
Remove the two tubelines (Item 1) from the load lock
(Item 2) [Figure 20-40-19].
Loosen the bolts (Item 1) [Figure 20-40-17] to move and
adjust the tubeline clamps. Figure 20-40-20

When the tubeline clamps are in the correct position

tighten the bolts.

Figure 20-40-18

2 1

S7258

Remove the two tubelines (Item 1) and two hoses (Item 2)

[Figure 20-40-20] from both sides of the cylinder.
S7250

Secure the electrical harness to the inner tubeline using

tie straps [Figure 20-40-18] approximately every 6-8
inches (152-203 mm).

6986740-EN (07-08) 20-40-5 Bobcat T2250

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Tubeline Tray Disassembly

Extension Cylinder Removal And Installation (Cont’d) Figure 20-40-22

Figure 20-40-21

1
1 1
1
1

P-47489

S7255
Remove the tie straps (Item 1) [Figure 20-40-22]
securing the electrical harness to the hoses.
Install a hoist (Item 1) [Figure 20-40-21] to lift and
support the extension cylinder. Figure 20-40-23

Slide the extension cylinder through the tubelines [Figure

20-40-21] and remove the cylinder.

2
P-47490

Remove the two bolts (Item 1) and tubeline mounting

brackets (Item 2) [Figure 20-40-23].

6986740-EN (07-08) 20-40-6 Bobcat T2250

SERVICE MANUAL
EXTENSION CYLINDER (CONT’D) Figure 20-40-26

Tubeline Tray Disassembly (Cont’d)

Figure 20-40-24

1
2

P-27932

Remove the tie strap (Item 1) from both ends of the

P-47491 electrical harness (Item 2) [Figure 20-40-26]. Remove
the electrical harness.

Remove the four hoses (Item 1) [Figure 20-40-24] from Figure 20-40-27
the tubelines.

NOTE: Mark the hoses for correct assembly.

Figure 20-40-25
1

1
1
2
1
P-27930

Remove the tubelines (Item 1) [Figure 20-40-27].

P-47492

Straighten the two tabs (Item 1) (both ends) and remove

the cover (Item 2) [Figure 20-40-25].

6986740-EN (07-08) 20-40-7 Bobcat T2250

SERVICE MANUAL
EXTENSION CYLINDER (CONT’D) Figure 20-40-30

Tubeline Tray Assembly

Figure 20-40-28

1
1
3

6
5
P-27932
2

Place the electrical harness (Item 1) in the center of the

4
P-27930 two tubelines on the left side and secure using a tie strap
(Item 2) [Figure 20-40-30] on each end of the tubelines.

Figure 20-40-29 Figure 20-40-31

1
5
1

2 4

2
6
2

P-27931 P-27933

Place the tubelines (Item 1) and (Item 2) next to each With the tubelines held in position, install the tray cover
other on the right side of the tray (Item 6) [Figure 20-40- (Item 1) on the tray. Bend the two tabs (Item 2) [Figure
28] & [Figure 20-40-29]. 20-40-31] on each end of the tray cover.

NOTE: The notch (Item 3) [Figure 20-40-28] represents

the front of the tray.

Place the tubelines (Item 4) and (Item 5) next to each

other on the left side of the tray (Item 6) [Figure 20-40-28]
& [Figure 20-40-29].

6986740-EN (07-08) 20-40-8 Bobcat T2250

SERVICE MANUAL
EXTENSION CYLINDER (CONT’D) Figure 20-40-33

Tubeline Tray Assembly (Cont’d) 4

2
Figure 20-40-32 3

1
5
4
1
6

P-27935
5
2
3 Install the hose assembly (Item 1) [Figure 20-40-33] on
P-27934 the two tubelines on the right side of the tray.

NOTE: The hose (Item 2) must be connected to the

Install the hose/harness assembly (Item 1) [Figure 20-40- inside tubeline (Item 3) [Figure 20-40-33].
32] on the tubelines on the left side of the tray.
Apply LOCTITE #271 on the bolt (Item 4) and install the
NOTE: The hose (Item 2) must be connected to the hose bracket (Item 5) [Figure 20-40-33].
outside tubeline (Item 3) [Figure 20-40-32].
NOTE: Do not overtighten the bolt or damage will be
Apply LOCTITE #271 onto the bolt (Item 4) and install the done to the tubelines below.
hose bracket (Item 5) [Figure 20-40-32].
Figure 20-40-34
NOTE: Do not overtighten the bolt or damage will be
done to the tubelines below.

Install a tie strap (Item 6) [Figure 20-40-32] on the 1 1

electrical harness.
1

P-47489

Install tie straps (Item 1) [Figure 20-40-34] approximately

every 6-8 inches (152-203 mm) to secure the electrical
harness to the hose.

6986740-EN (07-08) 20-40-9 Bobcat T2250

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D)

Parts Identification

1. Housing
2. Relief Valve
3. O-Ring
4. Expander O-Ring
2
5. Wear Ring
6. O-Ring
7. Rod
8. Backup Ring 2
9. Piston
10. Head Gland
11. Wiper
12. Wear Ring
13 Set Screw

1
55
9
6
4
8 13
7
3
3
10

4
11 8

12

S7274

6986740-EN (07-08) 20-40-10 Bobcat T2250

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Figure 20-40-37

Disassembly

Use the following tool to disassemble the cylinder:

MEL1074-O-ring Seal Hook

Clean the outside of the extension cylinder before

disassembly.

Mark the outside of the extension cylinder for ease of

assembly.

Figure 20-40-35
S7261

Carefully peen the lock ring from the head gland [Figure
20-40-37].

Figure 20-40-38

S7259

Put the cylinder in a vise [Figure 20-40-35].

Figure 20-40-36

S7262

2
Loosen the head gland [Figure 20-40-38].

S7260

Remove the two fittings (Item 1) and relief valves (Item 2)

[Figure 20-40-36].

6986740-EN (07-08) 20-40-11 Bobcat T2250

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Figure 20-40-41

Disassembly (Cont'd)

Figure 20-40-39

S7265

Support the cylinder rod on a wood block [Figure 20-40-

S7263 41].

Figure 20-40-42
Remove the rod assembly (Item 1) [Figure 20-40-39]
from the housing.

Figure 20-40-40

1
S7266

Remove the two wear rings (Item 1) [Figure 20-40-42]

S7264 from the piston.

Put the rod end of the cylinder in a vise [Figure 20-40-

40].

6986740-EN (07-08) 20-40-12 Bobcat T2250

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Figure 20-40-45

Disassembly (Cont'd)

Figure 20-40-43

1 1
S7269

Remove the expander O-ring (Item 1) [Figure 20-40-45]

S7267 from the piston.

Figure 20-40-46
Loosen the set screw (Item 1) [Figure 20-40-43].

Figure 20-40-44 2

2
1 1

P-25007
S7270

1
S7268 Remove the seal (Item 1) and two backup rings (Item 2)
[Figure 20-40-46] from the piston.

Remove the piston assembly (Item 1) [Figure 20-40-44]

from the rod.

6986740-EN (07-08) 20-40-13 Bobcat T2250

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Figure 20-40-49

Disassembly (Cont'd)

Figure 20-40-47

2
1 S7273

Remove the two O-rings (Item 1) and backup ring (Item 2)

S7271 [Figure 20-40-49].

Remove the head gland (Item 1) [Figure 20-40-47] from

the rod.

Figure 20-40-48

2
3

S7272

Remove the wiper (Item 1), two wear rings (top & bottom)
(Item 2) and seal (Item 3) [Figure 20-40-48] from the
head gland.

6986740-EN (07-08) 20-40-14 Bobcat T2250

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Figure 20-40-52

Assembly

Clean all parts in solvent and dry with compressed air. 1

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

Figure 20-40-50

S7271

Install the head gland (Item 1) [Figure 20-40-52] onto the

cylinder rod.

Figure 20-40-53

1
2
2
1 S7273

2
Install the two O-rings (Item 1) and backup ring (Item 2) 1 1
[Figure 20-40-50] on the head gland.

Figure 20-40-51
1

1 P-25007
S7270

Install the O-ring (Item 1) and two backup rings (Item 2)

2 [Figure 20-40-53] in the piston.
3

S7272

Install the wiper (Item 1), two wear rings (top & bottom)
(Item 2) and seal (Item 3) [Figure 20-40-51].

6986740-EN (07-08) 20-40-15 Bobcat T2250

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Figure 20-40-56

Assembly (Cont'd)

Figure 20-40-54

1
S7266

Install the two wear rings (Item 1) [Figure 20-40-56] onto

1 the piston.
S7269

Figure 20-40-57
Install the expander O-ring (Item 1) [Figure 20-40-54].

Figure 20-40-55
1

2
S7263
1

S7267 Install the rod assembly (Item 1) [Figure 20-40-57] into

the housing.

Install the piston (Item 1) [Figure 20-40-55] onto the rod

and hand tighten.

Tighten the set screw (Item 2) [Figure 20-40-55].

6986740-EN (07-08) 20-40-16 Bobcat T2250

SERVICE MANUAL
EXTENSION CYLINDER (CONT'D) Figure 20-40-60

Assembly (Cont'd)

Figure 20-40-58 2

S7260

Install the two fittings (Item 1) and two relief valves (Item
S7262 2) [Figure 20-40-60].

Tighten the head gland [Figure 20-40-58].

Figure 20-40-59

S7261

Using a punch seat the lock ring to keep the head gland
from turning [Figure 20-40-59].

6986740-EN (07-08) 20-40-17 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 20-40-18 Bobcat T2250
SERVICE MANUAL
TILT CYLINDER Figure 20-50-3

Removal And Installation

Fully lower and retract the boom.

IMPORTANT 1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
S7281

Figure 20-50-1
Install a lifting ring (Item 1) [Figure 20-50-3] and hoist to
the top of the cylinder.

1 Figure 20-50-4

S7301

2 3
Remove the cover (Item 1) [Figure 20-50-1].
S7282
Figure 20-50-2

Remove the snap ring (Item 1) and washer (Item 2) and

remove the pivot pin (Item 3) [Figure 20-50-4].

S7306

Remove the two hoses (Item 1) [Figure 20-50-2] from the

tubelines.

NOTE: Mark the hoses for correct installation.

6986740-EN (07-08) 20-50-1 Bobcat T2250

SERVICE MANUAL
TILT CYLINDER (CONT'D) Figure 20-50-7

Removal And Installation (Cont'd)

Figure 20-50-5

S7285

Lift the cylinder from the boom and remove [Figure 20-
S7283 50-7].

Remove the pivot pin retainer bolt (Item 1) [Figure 20-50-

5].

Figure 20-50-6

S7284

Remove the pivot pin [Figure 20-50-6].

6986740-EN (07-08) 20-50-2 Bobcat T2250

SERVICE MANUAL
TILT CYLINDER (CONT'D)

Parts Identification

1. Bushing
2. Grease Fitting
3. Housing
4. Relief Cartridge
5. Wear Ring
6. Expander O-ring
7. Set Screw
8. Piston
9. Backup Ring
10. O-Ring
11. Backup Ring
12. Rod
13. Head Gland
14. Wiper

1
2

4
1 6

3
5
12

8
9 7
10
9

1 14
10
11
10
13
5 65

S7286

6986740-EN (07-08) 20-50-3 Bobcat T2250

SERVICE MANUAL
TILT CYLINDER (CONT'D) Figure 20-50-10

Disassembly

Use the following tools to disassemble the cylinder:

MEL1074-O-ring Seal Hook

MEL1353-Cylinder Gland Nut Wrench

Clean the outside of the tilt cylinder before disassembly.

Figure 20-50-8

S7289

Carefully peen the lock ring from the head gland [Figure
20-50-10].

Figure 20-50-11

S7287

Put the cylinder in a vise [Figure 20-50-8].

Figure 20-50-9

S7290

1
Loosen the head gland [Figure 20-50-11].

S7288

Remove the relief cartridge (Item 1) [Figure 20-50-9].

6986740-EN (07-08) 20-50-4 Bobcat T2250

SERVICE MANUAL
TILT CYLINDER (CONT'D) Figure 20-50-14

Disassembly (Cont'd)

Figure 20-50-12 1
1

S7293

Support the cylinder rod on a wood block [Figure 20-50-

S7291 14].

Remove the two wear rings (Item 1) [Figure 20-50-14].

Remove the rod assembly (Item 1) [Figure 20-50-12].
Figure 20-50-15
Figure 20-50-13

S7294
S7292

Loosen the set screw (Item 1) [Figure 20-50-15].

Put the rod end of the cylinder in a vise [Figure 20-50-
13].

6986740-EN (07-08) 20-50-5 Bobcat T2250

SERVICE MANUAL
TILT CYLINDER (CONT'D) Figure 20-50-18

Disassembly (Cont'd)

Figure 20-50-16
1 2

S7299

Remove the seal (Item 1) and two backup rings (Item 2)

S7295 [Figure 20-50-18] from the piston.

Figure 20-50-19
Remove the piston (Item 1) [Figure 20-50-16] from the
rod. 2

Figure 20-50-17
1

S7297

Remove the two O-rings (Item 1) and backup ring (Item 2)

S7296 [Figure 20-50-19] from the head gland.

Remove the expander O-ring (Item 1) [Figure 20-50-17]

from the piston.

6986740-EN (07-08) 20-50-6 Bobcat T2250

SERVICE MANUAL
TILT CYLINDER (CONT'D) Assembly

Disassembly (Cont'd) Use the following tool to assemble the cylinder:

Figure 20-50-20 MEL1353-Cylinder Gland Nut Wrench

Clean all parts in solvent and dry with compressed air.

2 Inspect all parts for wear or damage. Replace any worn or

damaged parts.
3
1 Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation.

Figure 20-50-21

2
2
S7297

3
1
Remove the wiper (Item 1), two wear rings (Item 2) and
seal (Item 3) [Figure 20-50-20] from the head gland.

S7297

Install the wiper (Item 1), two wear rings (Item 2) and seal
(Item 3) [Figure 20-50-21] into the head gland.

Figure 20-50-22
2

S7297

Install the two O-rings (Item 1) and backup ring (Item 2)

[Figure 20-50-22] onto the head gland.

6986740-EN (07-08) 20-50-7 Bobcat T2250

SERVICE MANUAL
TILT CYLINDER (CONT'D) Figure 20-50-25

Assembly (Cont'd)

Figure 20-50-23

1 2

S7292

Install the head gland on the rod and put the rod end of
S7299 the cylinder in a vise [Figure 20-50-25].

Figure 20-50-26
Install the seal (Item 1) and two backup rings (Item 2)
[Figure 20-50-23] into the piston.

Figure 20-50-24

P-32047

Clean off any old residue, and apply LOCTITE 242 or

S7296 equivalent to the threads on the rod [Figure 20-50-26].

Install the expander O-ring (Item 1) [Figure 20-50-24]

onto the piston.

6986740-EN (07-08) 20-50-8 Bobcat T2250

SERVICE MANUAL
TILT CYLINDER (CONT'D) Figure 20-50-29

Assembly (Cont'd)

Figure 20-50-27 1
1

S7293

Install the two wear rings (Item 1) [Figure 20-50-29].

S7295
Figure 20-50-30

Install the piston (Item 1) [Figure 20-50-27] onto the rod.

Figure 20-50-28 1

S7291

1
Install the rod assembly (Item 1) [Figure 20-50-30] in the
S7294 cylinder.

Tighten the set screw (Item 1) [Figure 20-50-28].

6986740-EN (07-08) 20-50-9 Bobcat T2250

SERVICE MANUAL
TILT CYLINDER (CONT'D) Figure 20-50-33

Assembly (Cont'd)

Figure 20-50-31

S7288

Install the relief cartridge (Item 1) [Figure 20-50-33].

S7290

Install the head gland [Figure 20-50-31].

Figure 20-50-32

S7289

Carefully lock the head gland ring [Figure 20-50-32].

6986740-EN (07-08) 20-50-10 Bobcat T2250

SERVICE MANUAL
STEERING CYLINDER (FRONT) Figure 20-60-3

Removing the Steering Cylinder

Figure 20-60-1 2

2 1

S2211
1

Remove the tie rod (Item 1) from the steering case

(Item 2) [Figure 20-60-3] by means of a puller.
S1483

Figure 20-60-4
Remove the three bolts (Item 1) and remove the centering
sensor (Item 2) [Figure 20-60-1].

NOTE: The axle is shown removed from the machine

for photo clarity.

Figure 20-60-2

2
S2443
2

Disconnect the left and right tie rods (Item 1) from the
piston (Item 2) [Figure 20-60-4].

S2211

Loosen and remove the tie rod nut (Item 1) from the tie
rod end (Item 2) [Figure 20-60-2] .

6986740-EN (07-08) 20-60-1 Bobcat T2250

SERVICE MANUAL
STEERING CYLINDER (FRONT) (CONT’D) Installing the Steering Cylinder

Removing the Steering Cylinder (Cont’d) Figure 20-60-7

Figure 20-60-5

S5045

S2444
Lubricate the seats of the seals and fit the steering
cylinder (Item 1) [Figure 20-60-7] into its seat.
Remove the four bolts (Item 1) from the steering cylinder
(Item 2) [Figure 20-60-5]. Figure 20-60-8

Figure 20-60-6

1
1

S2447

S2445
Tighten the four bolts (Item 1) [Figure 20-60-8] to 66-74
ft.-Ib. (90-100 N•m) torque.
Extract the cylinder (Item 1) [Figure 20-60-6] using a
plastic hammer.

6986740-EN (07-08) 20-60-2 Bobcat T2250

SERVICE MANUAL
STEERING CYLINDER (FRONT) (CONT’D) Figure 20-60-11

Installing the Steering Cylinder (Cont’d)

Figure 20-60-9
1

S1483
1
2
Install the centering sensor (Item 1) [Figure 20-60-11] for
S2443 checking piston centering.

Tighten the three bolts (Item 2) [Figure 20-60-11] to 2-4

Connect the left and right tie rods (Item 1) by screwing ft.-Ibs. (5 - 6 N•m) torque.
them onto the piston (Item 2) [Figure 20-60-9] using a
torque wrench setting of 177-200 ft.-Ibs. (240 - 270 N•m). Perform the axle toe-in procedure. (See AXLE TOE-IN on
page 40-40-1.)
Figure 20-60-10

1 4
2

3
S2454

Insert the tapered pins of the tie rod (Item 1) in the

steering case (Item 2) and tighten the tie rod nut (Item 3)
[Figure 20-60-10] to 200-222 ft.-Ibs (270-300 N•m)
torque.

NOTE: Check that the rubber guards (Item 4) [Figure

20-60-10] are intact.

6986740-EN (07-08) 20-60-3 Bobcat T2250

SERVICE MANUAL
STEERING CYLINDER (FRONT) (CONT’D) Figure 20-60-14

Disassembling the Steering Cylinder

IMPORTANT
Before disassembling the unit, drain the oil in the
cylinder chambers completely. 1

Figure 20-60-12

S1518
1

With the help of a drift, apply pressure to the stop ring

(Item 1) that is placed inside the cylinder (Item 2) [Figure
20-60-14] and extract the ring using a screwdriver.

Figure 20-60-15
2

S1516

Remove the snap ring (Item 1) from the cylinder head

(Item 2) [Figure 20-60-12],

Figure 20-60-13
1
3

2
S1519
2

Hammer the piston (Item 1) on the rear of the head

(Item 2) [Figure 20-60-15] using a plastic hammer.
1
Continue hammering until the head (Item 2) is ejected
from the cylinder (Item 3) [Figure 20-60-15].

S1517

With the help of a plastic hammer, push the head

(Item 1) inside the cylinder (Item 2) [Figure 20-60-13],

NOTE: The head should line up with the edge of the

cylinder.

6986740-EN (07-08) 20-60-4 Bobcat T2250

SERVICE MANUAL
STEERING CYLINDER (FRONT) (CONT’D) Assembling the Steering Cylinder

Disassembling the Steering Cylinder (Cont’d) Figure 20-60-18

Figure 20-60-16

1 2 3
3

S1521
A
S1520
After applying grease, install the sealing ring (Item 1) on
the cylinder housing, the anti-extrusion ring (Item 2) and
Disassemble the cylinder unit (Item 1) by extracting first the scraper ring (Item 3) inside the cylinder
the rod (Item 2) then the piston (Item 3) [Figure 20-60- (Item 3) [Figure 20-60-18].
16].
NOTE: Make sure the anti extrusion ring (Item 2) is
NOTE: Note the assembly side of the piston (Item 3). positioned on the correct side of the sealing
The bevelled part “A” of the piston is oriented ring (Item 1) [Figure 20-60-18], as shown.
towards the head (Item 2) [Figure 20-60-16].
Figure 20-60-19
Figure 20-60-17

3 2 1

S1522
S2499

After applying grease, install the sealing ring (Item 1) on

Remove all seals, anti-extrusion rings and scraper rings the housing, the anti-extrusion ring (Item 2) and the
from head, cylinder and piston. scraper ring (Item 3) [Figure 20-60-19] in the head
(Item 2) [Figure 20-60-16].
NOTE: 1) All seals must be replaced every time the
unit is disassembled. NOTE: Make sure the anti extrusion ring (Item 2) is
2) Particular attention must be paid not to positioned on the correct side of the sealing
damage the seats of both seals and piston ring (Item 1) [Figure 20-60-19], as shown.
slide.

6986740-EN (07-08) 20-60-5 Bobcat T2250

SERVICE MANUAL
STEERING CYLINDER (FRONT) (CONT’D) Figure 20-60-22

Assembling the Steering Cylinder (Cont’d)

Figure 20-60-20
1

S1525

Install the rod (Item 1) into the cilinder housing (Item 2)

S1523 [Figure 20-60-22].

NOTE: Apply a little grease to seals and cylinder.

Fit the seal (Item 1) [Figure 20-60-20] onto the outside of
the head. Figure 20-60-23

NOTE: In order to facilitate assembly, apply grease to

the outer surface of the head.
Do not roll the seal (Item 1) [Figure 20-60-20].

Figure 20-60-21
1

5 3 2

1
2

4
S1526

Push the rod (Item 1) into the cylinder (Item 2) [Figure 20-
60-23] for 3.93 inch (100 mm) using a plastic hammer.

S1524

Prepare the piston (Item 1) by fitting it with the guide ring

(Item 2), the magnetic ring (Item 3), the O-ring
(Item 4) and the seal (Item 5) [Figure 20-60-21].

NOTE: In order to facilitate assembly, apply grease.

6986740-EN (07-08) 20-60-6 Bobcat T2250

SERVICE MANUAL
STEERING CYLINDER (FRONT) (CONT’D) Figure 20-60-26

Assembling the Steering Cylinder (Cont’d)

Figure 20-60-24

2
1

S1530

Apply pressure to the head using two screwdrivers or

S1527 levers until the head is fastened onto the stop ring (Item 1)
[Figure 20-60-26].

Apply grease to head seals (Item 1), fit the head onto the Figure 20-60-27
piston and push in into the cylinder (Item 2) [Figure 20-
60-24] using a plastic hammer. 2

Figure 20-60-25

S1531

2
Fit the snap ring (Item 1) on the head (Item 2) [Figure 20-
S1529 60-27].

NOTE: Make sure that the snap ring (Item 1) [Figure

Insert the stop ring (Item 1) ensuring that it fits into the 20-60-27] is securely fastened in its seat. If
seat of the cylinder (Item 2) [Figure 20-60-25]. necessary, force it into its seat using a drift
and a hammer.

6986740-EN (07-08) 20-60-7 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 20-60-8 Bobcat T2250
SERVICE MANUAL
STEERING CYLINDER (REAR) Figure 20-61-3

Removing The Steering Cylinder

2
Figure 20-61-1

S2211

Disconnect the tapered pins of the tie rod (Item 1) from

S2471
the steering case (Item 2) [Figure 20-61-3] by means of
a puller.

Remove the centering sensor (Item 1) [Figure 20-61-1] Figure 20-61-4

of the steering piston.

Figure 20-61-2

2 1

1 S2472

S2210 Disconnect the left and right steering bars (Item 1) from
the piston (Item 2) [Figure 20-61-4].

Remove the nuts (Item 1) that lock the pivot pins

(Item 2) [Figure 20-61-2].

6986740-EN (07-08) 20-61-1 Bobcat T2250

SERVICE MANUAL
STEERING CYLINDER (REAR) (CONT’D) Installing The Steering Cylinder

Removing The Steering Cylinder (Cont’d) Figure 20-61-7

Figure 20-61-5

S2475

S2473
Lubricate the seats of the seals and fit the steering
cylinder (Item 1) [Figure 20-61-7] into its seat.
Remove the four securing bolts (Item 1) from the steering
cylinder (Item 2) [Figure 20-61-5]. Figure 20-61-8

Figure 20-61-6

S2476

S2474
Lock the cylinder by cross-tightening the four bolts
(Item 1) [Figure 20-61-8], apply a torque of 66-74 ft.-Ib.
Extract the cylinder (Item 1) [Figure 20-61-6] using a (90 - 100 N•m).
plastic hammer.

NOTE: For cylinder disassembly, See “Disassembling

The Steering Cylinder” on page 20-61-4.

6986740-EN (07-08) 20-61-2 Bobcat T2250

SERVICE MANUAL
STEERING CYLINDER (REAR) (CONT’D) Figure 20-61-11

Installing The Steering Cylinder (Cont’d)

Figure 20-61-9

S2471

Install the proximity sensor (Item 1) for checking piston

S2477 centering.

Tighten the bolts (Item 2) [Figure 20-61-11] to 2-4 ft.-Ibs.

Connect the left and right tie rods (Item 1) by screwing (5 - 6 N•m) torque.
them onto the piston (Item 2) [Figure 20-61-9] using a
torque wrench setting of 177-200 ft.-Ibs. (240 - 270 N•m). Perform the axle toe-in procedure. (See AXLE TOE-IN on
page 40-40-1.)
Figure 20-61-10

1
2

S2478

Insert the pins (Item 1) in the steering case

(Item 2) [Figure 20-61-10] and lock into position using a
torque wrench setting of 200-224 ft.-Ibs. (270 - 300 N•m).

NOTE: Check that the rubber guards (Item 3) [Figure

20-61-10] are intact.

6986740-EN (07-08) 20-61-3 Bobcat T2250

SERVICE MANUAL
STEERING CYLINDER (REAR) (CONT’D) Figure 20-61-14

Disassembling The Steering Cylinder

Figure 20-61-12 2

2
S1518

With the help of a drift, apply pressure to the stop ring

S1516 (Item 1) that is placed inside the cylinder
(Item 2) [Figure 20-61-14] and extract the ring using a
screwdriver.
NOTE: Before disassembling the unit, drain the oil in
the cylinder chambers completely. Figure 20-61-15

Remove the snap ring (Item 1) from the cylinder head

(Item 2) [Figure 20-61-12],

Figure 20-61-13

3 1
1
2
S1519

Hammer the piston (Item 1) on the rear of the head

(Item 2) [Figure 20-61-15] using a plastic hammer.
S1517
Continue hammering until the head (Item 2) is ejected
from the cylinder (Item 3) [Figure 20-61-15].
With the help of a plastic hammer, push the head (Item 1)
inside the cylinder (Item 2) [Figure 20-61-13],

NOTE: The head should line up with the edge of the

cylinder.

6986740-EN (07-08) 20-61-4 Bobcat T2250

SERVICE MANUAL
STEERING CYLINDER (REAR) (CONT’D)

Disassembling The Steering Cylinder (Cont’d)

Figure 20-61-16

A
S1520

Disassemble the cylinder unit (Item 1) by extracting first

the rod (Item 2) then the piston (Item 3) [Figure 20-61-
16].

NOTE: Mark the assembly side of the piston

(Item 3) [Figure 20-61-16]. The bevelled part
“A” of the piston is oriented towards the head
(Item 2) [Figure 20-61-16].

Figure 20-61-17

S2499

Remove all seals, anti-extrusion rings and scraper rings

from head (Item 1), cylinder (Item 2) and piston (Item 3)
[Figure 20-61-17].

NOTE: 1) All seals must be replaced every time the

unit is disassembled.
2) Particular attention must be paid not to
damage the seats of both seals and piston
slide.

6986740-EN (07-08) 20-61-5 Bobcat T2250

SERVICE MANUAL
STEERING CYLINDER (REAR) (CONT’D) Figure 20-61-20

Assembling The Steering Cylinder

2 1
Figure 20-61-18

1 2 3

S1523

Fit the seal (Item 1) onto the outside of the head

S1521 (Item 2) [Figure 20-61-20].

NOTE: In order to facilitate assembly, apply grease to

After applying grease, install the sealing ring (Item 1) on the outer surface of the head.
the cylinder housing, the anti-extrusion ring (Item 2) and
the scraper ring (Item 3) inside the cylinder NOTE: Do not roll the seal (Item 1) [Figure 20-61-20]
(Item 3) [Figure 20-61-18].
Figure 20-61-21
NOTE: Make sure the anti extrusion ring (Item 2) is
positioned on the correct side of the sealing
ring (Item 1) [Figure 20-61-18], as shown. 5 3 2

Figure 20-61-19 1

3 2 4
1

S1524

Prepare the piston (Item 1) by fitting it with the guide ring

(Item 2), the magnetic ring (Item 3), the O-ring
S1522 (Item 4) and the seal (Item 5) [Figure 20-61-21].

NOTE: In order to facilitate assembly, apply grease to

After applying grease, install the sealing ring (Item 1) on the seals.
the head, the anti-extrusion ring (Item 2) and the scraper
ring (Item 3) [Figure 20-61-19]. NOTE: If a centring sensor is not fitted, then the
magnetic ring (Item 3) [Figure 20-61-21]
NOTE: Make sure the anti extrusion ring (Item 2) is should be replaced by another guide ring
positioned on the correct side of the sealing (Item 2) [Figure 20-61-21].
ring (Item 1) [Figure 20-61-19], as shown.

6986740-EN (07-08) 20-61-6 Bobcat T2250

SERVICE MANUAL
STEERING CYLINDER (REAR) (CONT’D) Figure 20-61-24

Assembling The Steering Cylinder (Cont’d)

2
Figure 20-61-22 1

1
S1527

Apply grease to head seals (Item 1), fit the head onto the
S1525 piston and push in into the cylinder (Item 2) [Figure 20-
61-24] using a plastic hammer.

Center the shaft on the cylinder (Item 1) so that it fits into Figure 20-61-25
the piston (Item 2) [Figure 20-61-22].

NOTE: Apply a little grease to seals and cylinder.

1
Figure 20-61-23

2
S1529

2
Insert the stop ring (Item 1) ensuring that it fits into the
seat of the cylinder (Item 3) [Figure 20-61-25].
S1526

Push the piston (Item 1) into the cylinder (Item 2) [Figure

20-61-23] for 100 mm. using a plastic hammer.

6986740-EN (07-08) 20-61-7 Bobcat T2250

SERVICE MANUAL
STEERING CYLINDER (REAR) (CONT’D)

Assembling The Steering Cylinder (Cont’d)

Figure 20-61-26

S1530

Apply pressure to the head using two screwdrivers or

levers until the head is fastened onto the stop ring (Item 1)
[Figure 20-61-26].

Figure 20-61-27

S1531

Fit the snap ring (Item 1) on the head (Item 2) [Figure 20-
61-27].

NOTE: Make sure that the snap ring (Item 1) [Figure

20-61-27] is securely fastened in its seat.
If necessary, force it into its seat using a drift
and a hammer.

6986740-EN (07-08) 20-61-8 Bobcat T2250

SERVICE MANUAL
DRIVE BOX

Parts Identification

Figure 20-70-1

5
1. Gear
4
2. Snap ring 3
3. Ball bearing 2
1
4. Snap ring
5. Vent
6. Nut 27
26
7. Bearing
9
8. Shim 8
7
9. Spacer
6
10. Seal
11. Ball bearing
12. Gear

24 25
10
23
11

12
13
14 13. Snap ring
15 14. Ball bearing
22
15. Seal
16. Plug
17. Lock washer
18. Bolt
20 17 16
21 19. Magnet plug
19 18
20. Dowel
21. Plug
22. Flange
23. O-ring
24. Bolt
25. Cover
26. Shim
27. Bearing

S2500

6986740-EN (07-08) 20-70-1 Bobcat T2250

SERVICE MANUAL
DRIVE BOX (CONT’D) Figure 20-70-4

Disassembly

Remove the front axle (See Removal on Page 40-31-1.).

Remove the drive motor. (See Removal And Installation 1

on Page 30-30-1.).

Figure 20-70-2

S2463
1

Take off the drive side flange cover (Item 1) [Figure 20-
70-4] by alternatively forcing a screwdriver into the
appropriate slots.

NOTE: Look out not to damage the surfaces.

S2461 Figure 20-70-5

Loosen the securing bolts (Item 1) [Figure 20-70-2] only

so that later when you pry the drive side flange cover
1
loose, it does not fall.

Figure 20-70-3

S2464
1

Remove the securing bolts and lift off the cover (Item 1)
[Figure 20-70-5].

S2462

Loosen the drive side flange cover (Item 1) [Figure 20-70-

3] using a plastic hammer.

6986740-EN (07-08) 20-70-2 Bobcat T2250

SERVICE MANUAL
DRIVE BOX (CONT’D) Figure 20-70-8

Disassembly (Cont’d) 1

Figure 20-70-6

S2432

Remove the snap ring (Item 1) [Figure 20-70-8].

S2486 Figure 20-70-9

To remove the drive side shaft (Item 1), remove the snap
ring (Item 2) [Figure 20-70-6].
2
Figure 20-70-7

1
S2433

With a puller, remove the bearing (Item 1) from the input

shaft (Item 2) [Figure 20-70-9].

S2487

Using two levers, remove the drive side shaft (Item 1)

[Figure 20-70-7].

6986740-EN (07-08) 20-70-3 Bobcat T2250

SERVICE MANUAL
DRIVE BOX (CONT’D) Figure 20-70-12

Disassembly (Cont’d)
1
Figure 20-70-10

2 S2490

Remove the secondary gear (Item 1) [Figure 20-70-12]

S2434 using two levers.

Figure 20-70-13
Remove the bearing (Item 1) and the snap ring (Item 2)
[Figure 20-70-10].

Figure 20-70-11

2
1

S2435

1 Remove the snap ring (Item 1) [Figure 20-70-13].

S2489

With a puller, remove the bearing (Item 1) from the flange

shaft (Item 2) [Figure 20-70-11].

6986740-EN (07-08) 20-70-4 Bobcat T2250

SERVICE MANUAL
DRIVE BOX (CONT’D) Figure 20-70-16

Disassembly (Cont’d)

Figure 20-70-14

S2493

1
Remove the seal (Item 1) by using a drift (Item 2) [Figure
20-70-16].
S2491

Figure 20-70-17
Remove the flange (Item 1) [Figure 20-70-14] by means
of a plastic hammer.

Figure 20-70-15 1

S2488
1

Using a lever, remove the flange sealing ring (Item 1)

S2492 [Figure 20-70-17].

Remove the internal bearing (Item 1) [Figure 20-70-15].

6986740-EN (07-08) 20-70-5 Bobcat T2250

SERVICE MANUAL
DRIVE BOX (CONT’D) Figure 20-70-20

Assembly

Figure 20-70-18

S2494

1
Fit the flange (Item 1) [Figure 20-70-20] in the cover.
S2483
Figure 20-70-21
Insert the sealing ring using a seal installation tool
(Bobcat part number 6912179) (Item 1) [Figure 20-70-
18].

NOTE: Bring the sealing ring just to the end stop,

apply grease to the sealing lips.

Figure 20-70-19

S2495

Insert the bearing (Item 1) [Figure 20-70-21].

S2436

Insert the sealing ring (Item 1) [Figure 20-70-19] with a

normal tool.

NOTE: Bring the sealing ring just to the end stop,

apply grease to the sealing lips.

6986740-EN (07-08) 20-70-6 Bobcat T2250

SERVICE MANUAL
DRIVE BOX (CONT’D) Figure 20-70-24

Assembly (Cont’d)

Figure 20-70-22

S2437 / S2438

1
2 Using a normal tool insert the bearing (Item 1) [Figure
20-70-24].
S2496

Figure 20-70-25
Using a normal tool insert the bearing (Item 1) and snap
ring (Item 2) [Figure 20-70-22].

Figure 20-70-23

1
2

S2439 / S2440

Insert the snap ring (Item 1) and using a normal tool insert
the bearing (Item 2) [Figure 20-70-25].
S2497

Install the secondary gear (Item 1) [Figure 20-70-23] with

a plastic hammer.

6986740-EN (07-08) 20-70-7 Bobcat T2250

SERVICE MANUAL
DRIVE BOX (CONT’D) Figure 20-70-28

Assembly (Cont’d)

Figure 20-70-26
1

S2484

Apply sealant tot the drive side flange cover.

S2441
Install drive side flange cover, apply LOCTITE 510 to the
bolts [Figure 20-70-28].
Fix the bearing with the snap ring (Item 1) [Figure 20-70-
26]. Figure 20-70-29

Figure 20-70-27

S2485

S2498
Tighten the alignment bolts with a torque wrench setting
of 59-66.4 ft.-lb. (80-90 N•m) [Figure 20-70-29].
Hold the drive side shaft (Item 1) [Figure 20-70-27] using
a plier and install the drive side shaft with a plastic
hammer.

6986740-EN (07-08) 20-70-8 Bobcat T2250

SERVICE MANUAL
DRIVE BOX (CONT’D)

Special Tools

BOBCAT PN IMAGE DESCRIPTION

6912179 Seal installation tool

6986740-EN (07-08) 20-70-9 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 20-70-10 Bobcat T2250
SERVICE MANUAL
MAIN RELIEF VALVE Figure 20-80-2

Testing And Adjustment

The following tool will be needed to do the following

procedure:

MEL10003-Hydraulic Tester.

Figure 20-80-1

1 2

S2731
3
2
Fasten the seat belt, lower the restraint bar (if equipped),
then start the engine and run at low idle RPM. Press the
hydraulic control lockout Button (Item 1) and front auxiliary
hydraulics button (Item 2) [Figure 20-80-2]. Make sure
1 the tester is connected correctly. If no flow is indicated on
4
the tester, the hoses are connected wrong. with the hoses
S7303 connected correctly, increase the engine speed to 2400
RPM.

Connect the inlet hose (Item 1) from the tester to the front Warm the fluid to 140° F (60° C) by turning the restrictor
coupler (Item 2) [Figure 20-80-1]. control (Item 5) [Figure 20-80-1] on the tester to about
1000 PSI (69 bar). DO NOT exceed system relief
Connect the outlet hose (Item 3) from the tester to the pressure. Open the restrictor control knob and record the
rear coupler (Item 4) [Figure 20-80-1]. free flow (GPM) at 2400 RPM.

There should be at least 13 GPM (55 L/min) free flow.

Turn the restrictor control (Item 5) [Figure 20-80-1] on the
IMPORTANT tester until the main relief opens. The correct pressure
should be 3626 PSI (235 bar).

The hydraulic tester must be in the fully open position If adjustment is needed, (See Testing And Adjustment on
before you start the engine. Page 20-80-1.).
I-2024-0284

6986740-EN (07-08) 20-80-1 Bobcat T2250

SERVICE MANUAL
MAIN RELIEF VALVE (CONT’D) Removal And Installation

Testing And Adjustment (Cont’d)

Remove the rear left side cover.

IMPORTANT
Figure 20-80-3
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
1 I-2003-0888

Remove the rear left side cover.

Locate the main relief valve (Item 1) [Figure 20-80-3] on

the rear left side of the control valve.

Clean the area around the control valve.

S7304 Remove the main relief valve (Item 1) [Figure 20-80-4].

Installation: Tighten the main relief valve to 33 ft.-lb. (45

Locate the main relief valve (Item 1) [Figure 20-80-3] on
N•m) torque.
the rear left side of the control valve.

Figure 20-80-4

1 2

S5462

Loosen the lock nut (Item 1) and turn the adjustment

screw (Item 2) [Figure 20-80-4] clockwise to increase the
pressure or counterclockwise to decrease the pressure.

NOTE: A 1/4 of a turn = 150 psi (10.34 bar).

Retest the main relief valve after adjustment.

6986740-EN (07-08) 20-80-2 Bobcat T2250

SERVICE MANUAL
BOB-TACH CYLINDER

Not available at time of printing

6986740-EN (07-08) 20-90-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 20-90-2 Bobcat T2250
SERVICE MANUAL
PORT RELIEF VALVES

Parts Identification

1. Inlet-Outlet Valve Section A Port Relief Valve (3771 PSI (260 bar))
2. Lifting Valve Section B Port Relief Valve (3191 PSI (220 bar))
3. Tilting Valve Section C Port Relief Valve (2756 PSI (190 bar))
4. Telescoping Valve Section D Port Relief Valve (3554 PSI (245 bar))
5. Auxiliary Valve Section E Port Relief Valve (2538 PSI (175 bar))
6. End Housing F Port Relief Valve (3046 PSI (210bar))
G Port Relief Valve (3191 PSI (220 bar))
H Port Relief Valve (3191 PSI (220 bar))

A
C
E
B G

D
F

2
3
4
5

S5481

6986740-EN (07-08) 20-100-1 Bobcat T2250

SERVICE MANUAL
PORT RELIEF VALVES (CONT’D) Test results:

Adjustment Procedure
PORT RELIEF
PRESSURE
VALVE
A 3771 PSI (260 bar)
IMPORTANT B 3191 PSI (220 bar)
C 2756 PSI (190 bar)
When repairing hydrostatic and hydraulic systems, D 3554 PSI (245 bar)
clean the work area before disassembly and keep all
E 2538 PSI (175 bar)
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly F 3046 PSI (210 bar)
damage the system. G 3191 PSI (220 bar)
I-2003-0888
H 3191 PSI (220 bar)

A portable pressurized hydraulic pump will be used to test If the port relief pressure reading is not according to
the work port relief valves. Use only Bobcat hydraulic fluid specifications, replace the spring on the port relief valve.
in the pressurized pump.

NOTE: The valve is shown removed from the machine

for photo clarity.

Figure 20-100-1

S3682

Install the pressurized pump, hose and a pressure gauge

minimum of 5000 PSI (345 bar) into the valve section
work port in which the port relief valve is located [Figure
20-100-1]. Pressurize this section with the pump until the
port relief valve opens and record the pressure reading.

6986740-EN (07-08) 20-100-2 Bobcat T2250

SERVICE MANUAL
STEERING MODE VALVE BLOCK Figure 20-110-2

Removal And Installation

WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290 1 1
S5071

Remove the four Allen screws (Item 1) [Figure 20-110-2].

IMPORTANT Figure 20-110-3

When repairing hydrostatic and hydraulic systems,

clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Remove the rear cover from the machine.

Figure 20-110-1 2 2 1
1 3

S5072

Remove the hydraulic hoses (Item 1) [Figure 20-110-3]

from the block.

Remove the four Allen screws (Item 2) [Figure 20-110-3].

Installation: Install bolts with torque of of 80-90 in.-Ib.

(9,0-10,2 N•m).
1
1 2
S5073
NOTE: Mark the location of the valve on the block.

Remove the block (Item 3) [Figure 20-110-3].

Remove the solenoids (Item 1) [Figure 20-110-1].

NOTE: Mark the location of the wire connectors for

correct installation.

Remove the housing (Item 2) [Figure 20-110-1].

6986740-EN (07-08) 20-110-1 Bobcat T2250

SERVICE MANUAL
STEERING MODE VALVE BLOCK (CONT'D)

Parts Identification

S5074

6986740-EN (07-08) 20-110-2 Bobcat T2250

SERVICE MANUAL
STEERING MODE VALVE BLOCK (CONT'D)

Disassembly
IMPORTANT
Clean the outside of the valve block before disassembly.
When repairing hydrostatic and hydraulic systems,
Mark the outside of the valve block for ease of assembly. clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
Figure 20-110-4 tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

1
Figure 20-110-6

1
1

P-42291

Remove the four O-rings (Item 1) [Figure 20-110-4] from

the housing.
P-42294

Figure 20-110-5
Remove the solenoids (Item 1) [Figure 20-110-6] from
the solenoid shafts.

Figure 20-110-7

1 1

P-42292

Remove the nut (Item 1) [Figure 20-110-5] from each

solenoid.
P-42295

NOTE: Mark the location of the solenoids.

Remove the O-ring (Item 1) [Figure 20-110-7] from the
two shafts.

6986740-EN (07-08) 20-110-3 Bobcat T2250

SERVICE MANUAL
STEERING MODE VALVE BLOCK (CONT'D) Figure 20-110-10

Disassembly (Cont'd)

Figure 20-110-8

1 1

P-42299

Remove the O-ring (Item 1) [Figure 20-110-10] from each

P-42296 shaft.

Figure 20-110-11
Loosen the shafts (Item 1) [Figure 20-110-8].

Figure 20-110-9

5
1
4
2
1

3
P-42300

P-42297 Carefully remove the spool (Item 1) [Figure 20-110-11]

from the housing.

Remove the shaft (Item 1), pin (Item 2), spring (Item 3)
and spring retainer (Item 4) from the housing (Item 5)
[Figure 20-110-9] (both sides).

6986740-EN (07-08) 20-110-4 Bobcat T2250

SERVICE MANUAL
STEERING MODE VALVE BLOCK (CONT'D) Figure 20-110-14

Solenoid Testing

Figure 20-110-12

P-42299

Install a new O-ring (Item 1) [Figure 20-110-14] on each

P-42301 shaft.

Figure 20-110-15
Use a circuit tester, touch one probe to the prong and the
other probe to the other prong [Figure 20-110-12], there
must be continuity. If there is no continuity, replace the
solenoid. 5
2
Assembly

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts. 1
3
Always install new seals and O-rings. Lubricate all seals 4
and O-rings with clean hydraulic fluid before installation.
P-42297
Figure 20-110-13

Install the spring retainer (Item 1), spring (Item 2), pin
(Item 3) and shaft (Item 4) in the housing (Item 5) [Figure
20-110-15] (both sides).

P-42300

Carefully install the spool (Item 1) [Figure 20-110-13].

6986740-EN (07-08) 20-110-5 Bobcat T2250

SERVICE MANUAL
STEERING MODE VALVE BLOCK (CONT'D) Figure 20-110-18

Assembly (Cont'd)

Figure 20-110-16

1 1

P-42293

Install the O-ring (Item 1) [Figure 20-110-18] on the two

P-42296 solenoids.

Figure 20-110-19
Tighten each shaft (Item 1) [Figure 20-110-16].

Figure 20-110-17 1

2
1 1

P-42294

P-42295 Install the solenoids (Item 1) on the shafts (Item 2)

[Figure 20-110-19].

Install an O-ring (Item 1) [Figure 20-110-17] on each

shaft.

6986740-EN (07-08) 20-110-6 Bobcat T2250

SERVICE MANUAL
STEERING MODE VALVE BLOCK (CONT'D)

Assembly (Cont'd)

Figure 20-110-20

1 1

P-42292

Install the nuts (Item 1) [Figure 20-110-20] on each shaft

and hand tighten.

NOTE: Do not overtighten the nuts.

Figure 20-110-21

P-42291

Install the four O-rings (Item 1) [Figure 20-110-21] on the

housing

6986740-EN (07-08) 20-110-7 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 20-110-8 Bobcat T2250
SERVICE MANUAL
BRAKE VALVE Figure 20-120-3

Removal And Installation

Figure 20-120-1

1 1

S2968

Remove the three hoses (Item 1) [Figure 20-120-3] from

S2965 the brake valve.

NOTE: Mark hoses for correct installation.

Remove the dash cover / column cover. (See “Removal
And Installation” on page 50-130-1.)

Disconnect the harness connector (Item 1) [Figure 20-

120-1] from the inching switch. IMPORTANT
Figure 20-120-2 When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
1 I-2003-0888

S2967

Remove the accelerator cable (Item 1) from the pedal and

mounting bracket (Item 2) [Figure 20-120-2].

6986740-EN (07-08) 20-120-1 Bobcat T2250

SERVICE MANUAL
BRAKE VALVE (CONT’D) Disassembly And Assembly

Removal And Installation (Cont’d) Figure 20-120-5

Figure 20-120-4
1 2

1
1

1 1
P-42869

S2969
Remove the bolt (Item 1) and spring (Item 2) [Figure 20-
120-5].
Remove the mounting bolts (Item 1) [Figure 20-120-4].
Figure 20-120-6
Remove the pedal assembly.

P-42870

Remove the roll pin (Item 1) and pedal (Item 2) [Figure

20-120-6].

6986740-EN (07-08) 20-120-2 Bobcat T2250

SERVICE MANUAL
BRAKE VALVE (CONT’D) Figure 20-120-9

Disassembly And Assembly (Cont’d)

1
Figure 20-120-7

1
1
1

P-42874

Remove the three bolts (Item 1) [Figure 20-120-9] from

P-42871 both bearing flanges.

Figure 20-120-10
Assembly: Align the hole (Item 1) in the pedal with the
hole (Item 2) [Figure 20-120-7] in the shaft.

Figure 20-120-8

P-42875

Remove the shaft and bearing assembly [Figure 20-120-

P-42872 10].

Loosen the two set screws (Item 1) [Figure 20-120-8] on

the two bearings.

6986740-EN (07-08) 20-120-3 Bobcat T2250

SERVICE MANUAL
BRAKE VALVE (CONT’D) Figure 20-120-13

Disassembly And Assembly (Cont’d)

Figure 20-120-11

1 2 1

2
P-42877

2 Remove the four bolts (Item 1), spacers (Item 2) [Figure

P-42876 20-120-13] and nuts from the brake valve.

Figure 20-120-14
Remove the flanges (Item 1) and bearings (Item 2)
[Figure 20-120-11].

Figure 20-120-12

P-42879

Remove the brake valve (Item 1) [Figure 20-120-14].

P-42878
Inspect the brake valve assembly for wear or damage.
Replace the brake valve assembly if necessary.
Remove the three fittings (Item 1) [Figure 20-120-12]
from the brake valve. Note: The brake valve assembly is not serviceable.

6986740-EN (07-08) 20-120-4 Bobcat T2250

SERVICE MANUAL
GEAR PUMP

Removal And Installation

IMPORTANT
Raise the boom and install the boom stop. (See “Installing
The Approved Boom Stop” on page 10-150-1.) When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Figure 20-130-1 parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

NOTE: Mark all electrical connectors, hoses and

tubelines for correct assembly.

Figure 20-130-3

1
1

S7204

Rotate the battery disconnect switch (Item 1) [Figure 20- 2

130-1] to the right, to disconnect the power supply from
the battery.

Drain the hydraulic reservoir.

3 S7200
Figure 20-130-2

Remove the inlet tube (Item 1) [Figure 20-130-3] by

removing the four flange bolts.

Remove the two hoses (Item 2) [Figure 20-130-3] from

1
the gear pump.
1
Remove the small diameter hose at the bottom side of the
gear pump (Item 3) [Figure 20-130-3].

S6342

Remove the covers by removing the bolts (Item 1) [Figure

20-130-2].

6986740-EN (07-08) 20-130-1 Bobcat T2250

SERVICE MANUAL
GEAR PUMP (CONT’D)

Removal And Installation (Cont’d)

Figure 20-130-4

1
1

S7201

For easier access to the gear pump, loosen the three

hoses connections (Item 1) [Figure 20-130-4] from the
hydrostatic pump.

Figure 20-130-5

1
1

S7106

Remove the two gear pump mounting hex bolts (Item 1)

[Figure 20-130-5]. Remove the gear pump.

Installation: Tighten the mounting bolts to 52 - 59 ft.-lb.

(70,8 - 80 N•m) torque.

6986740-EN (07-08) 20-130-2 Bobcat T2250

SERVICE MANUAL
GEAR PUMP (CONT’D)

Parts Identification

1. Snap Ring 7 6
2. Seal Ring
3. Mount Plate 3 7
6
4. Set Screw
5. Bearing
6. Backup Ring 4
7. Seal Ring 2
1
8. Thrust Plate
9. Gear
10. Seal Ring
11. Bushing
12. Plug
13. Housing 5
14. Screw 8
15. O-ring 9
5 8
16. Fitting
17. Spring
18. Spring Seat
19. End Cover
20. Set Screw
21. Spool
22. Screen 16
23. O-ring
24. Adjustment Screw
15
25. Plug
26. Screw
17

14 18
12
26
15

20 19
21

22
13 23
10
24
11
15

25

S4968

6986740-EN (07-08) 20-130-3 Bobcat T2250

SERVICE MANUAL
GEAR PUMP (CONT'D) Figure 20-130-7

Disassembly And Assembly

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or 2

damaged parts. 1

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

Clean the outside of the gear pump before disassembly.

Mark the outside of the gear pump for ease of assembly.

P-25294

IMPORTANT Remove the plug (Item 1) and O-ring (Item 2) [Figure 20-
130-7] from the housing.

When repairing hydrostatic and hydraulic systems, Figure 20-130-8

clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. 6
I-2003-0888
4
Figure 20-130-6 3

5
2

1
S5412

1 Remove the plug (Item 1), O-ring (Item 2), spring (Item 3),
spring seat (Item 4), set screw (Item 5), spool assembly
1 (Item 6) and O-ring from the housing (Item 7) [Figure 20-
130-8].
S5412
NOTE: Always use new O-rings.

Remove the four bolts (Item 1) [Figure 20-130-6] and

remove the end cover from the housing.

Assembly: Tighten the bolts to 51 ft.-lb. (70 N•m) torque.

6986740-EN (07-08) 20-130-4 Bobcat T2250

SERVICE MANUAL
GEAR PUMP (CONT'D) Figure 20-130-11

Disassembly And Assembly (Cont’d)

Figure 20-130-9
1 2

Cut

0.550” dia.
2.0”

P-25295

1.500”
Remove the screen (Item 1) from the orifice (Item 2)
B-14674 [Figure 20-130-11] and clean.

Figure 20-130-12
Figure 20-130-10

P-55053
P-25296

Turn the housing over and remove the mount plate

To remove the orifice assembly (Item 6) [Figure 20-130-8] [Figure 20-130-12].
from the spool, a holding fixture will have to be made from
a 0.750 inch thick x 1.500 inches wide x 2.0 inches long
(19 mm) thick x 38 mm wide x 50 mm long) piece of
hardwood. Drill a 0.550 inch (14 mm) hole in the center of
the hardwood block. Cut the block lengthwise [Figure 20-
130-9].

Place both halves of the hardwood block around the

spool. Clamp the blocks in a vise [Figure 20-130-10].

NOTE: Do not use anything other than hardwood

blocks to grip the spool, or the spool will be
damaged.

Remove the orifice assembly.

6986740-EN (07-08) 20-130-5 Bobcat T2250

SERVICE MANUAL
GEAR PUMP (CONT'D) Figure 20-130-15

Disassembly And Assembly (Cont’d) 2

Figure 20-130-13
1

1
3

4
P-55056

Remove the O-ring (Item 1) and gear assembly (Item 2)

P-55054 [Figure 20-130-15] from the housing.

Assembly: The position of the V portion (Item 3) on the

Remove the snap ring (Item 1) [Figure 20-130-13]. thrust plate must point towards the larger port (Item 4)
[Figure 20-130-15] on the housing.
Figure 20-130-14
Figure 20-130-16

2 2
1

3 1 3
1
P-55055

P-25313

Remove the shaft seal (Item 1) [Figure 20-130-14].

Remove the two thrust plates (Item 1), seal ring (Item 2)
and backup ring (Item 3) [Figure 20-130-16] from the
gears.

Assembly: The seal ring (Item 2) will be installed on the

thrust plate (Item 1) first followed by the backup ring (Item
3) [Figure 20-130-16].

6986740-EN (07-08) 20-130-6 Bobcat T2250

SERVICE MANUAL
HYDRAULIC RESERVOIR Figure 20-150-3

Removal And Installation

Drain the oil reservoir. (See “Replacing Hydraulic Fluid”

on page 10-100-2.)

Remove the operator cab/canopy. (Cab: See “Removal

And Installation” on page 50-10-1 ; Canopy: See
“Removal And Installation” on page 50-111.) 1

Remove the front axle. (See “Removal” on page 50-111.)

Figure 20-150-1

S7280

Remove all hydraulic connections (Item 1) [Figure 20-

150-3] from the side of the tank (inside the frame).
1
Figure 20-150-4

S7278

Remove the vent (Item 1) [Figure 20-150-1] from the 1

tank. 1

Figure 20-150-2

S7277

1
Remove the four tank mounting bolts (Item 1) [Figure 20-
150-4].

Installation: Torque bolts to 35-40 ft.-lb. (47-54 N•m).

Tip the hydraulic reservoir over on its side and remove

through the frame opening where the axle/hydrostatic
2 motor assembly was installed.

S7279

Remove the hydraulic connection (Item 1) [Figure 20-

150-2] from the tank.

Remove the two hoses (Item 2) [Figure 20-150-2] from

the tank.

6986740-EN (07-08) 20-150-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 20-150-2 Bobcat T2250
SERVICE MANUAL
STEERING VALVE Figure 20-160-2

Removal And Installation

Remove the Dash / Steering cover. 1

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
S5104
I-2003-0888

Figure 20-160-1 Remove the four hoses (Item 1) [Figure 20-160-2] from
the steering valve.

NOTE: Mark hoses for correct installation.

Figure 20-160-3

1
S5102

Remove the four bolts (Item 1) [Figure 20-160-1] and

1
remove the cover.
S5101

Remove the four bolts (Item 1) [Figure 20-160-3] and

remove the steering valve.

Installation: Torque bolts to 22 ft.-lb. (30 Nm).

6986740-EN (07-08) 20-160-1 Bobcat T2250

SERVICE MANUAL
STEERING VALVE (CONT'D)

Parts Identification

1. Bolt 13. Springs

2. End Cap 14. Pin
3. Spacer 15. Check Ball (.250”)
4. O-ring 16. Spring
5. Wear Ring 17. Pin
6. Gerotor assembly 18. Check Ball (.187”)
7. Drive Shaft 19. O-ring
8. O-ring 20. Housing
9. Spacer Plate 21. Thrust Washer
10. Spool 22. Thrust Bearing
11. Sleeve 23. Seal
12. Drive Pin 24. Gland Bushing
25. Seal

S4721

6986740-EN (07-08) 20-160-2 Bobcat T2250

SERVICE MANUAL
STEERING VALVE (CONT'D) Figure 20-160-6

Disassembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

S0200
Remove the hydraulic fittings from the steering valve.

Figure 20-160-4 Remove the gerotor assembly (Item 1) [Figure 20-160-6]

and the O-ring beneath.

Figure 20-160-7

S4962

Remove the seven end cap bolts [Figure 20-160-4]. S0202

Figure 20-160-5
Remove the spacer plate (Item 1) [Figure 20-160-7].

2 3 1

S0198

Remove the O-ring (Item 1), spacer (Item 2) and wear ring
(Item 3) [Figure 20-160-5].

6986740-EN (07-08) 20-160-3 Bobcat T2250

SERVICE MANUAL
STEERING VALVE (CONT'D) Figure 20-160-10

Disassembly (Cont'd)
1
Figure 20-160-8

1 2

S4728

Tip the housing onto the port face and remove the spool
S0203 and sleeve assembly (Item 1) [Figure 20-160-10].

NOTE: Do not bind spool and sleeve in housing.

Remove the O-ring (Item 1) [Figure 20-160-8]. Rotate spool and sleeve assembly slowly
when removing it from housing.
Remove the drive shaft (Item 2) [Figure 20-160-8], while
holding the steering valve upright. Figure 20-160-11

Figure 20-160-9

4
3
1

4
2

1 2
S4726

S4722
Remove the two bearing washers (Item 1) and thrust
bearing (Item 2) [Figure 20-160-11].
Carefully remove the two springs (Item 1), two pins (Item
2), pin (Item 3) and balls (Item 4) [Figure 20-160-9] from
each port.

6986740-EN (07-08) 20-160-4 Bobcat T2250

SERVICE MANUAL
STEERING VALVE (CONT'D) Figure 20-160-14

Disassembly (Cont'd)

Figure 20-160-12 1

2 1

S4731
1
The housing valves (Item 1) [Figure 20-160-14] are
S5361
factory adjusted and are not to be changed. The housing
with specified valve pressure settings, the mating spool
and sleeve are not practical replacement parts.
Remove the pin (Item 1), then remove the six springs
(Item 2) by partially sliding out the spool. [Figure 20-160- Figure 20-160-15
12].

Figure 20-160-13

3 1

S4731
2
3 Remove the seals (Items 1 and 2) [Figure 20-160-15]
S5360
from the gland bushing.

Remove the control spool (Item 1) from the sleeve NOTE: Gland bushing removal requires a special 4-
(Item 2) [Figure 20-160-13]. pin tool. Do not attempt to remove without this
tool as damage to the bushing could occur.
Check the condition of the six (two sets of three) springs It is not required to remove the bushing for
(Item 3) [Figure 20-160-13]. seal replacement.

6986740-EN (07-08) 20-160-5 Bobcat T2250

SERVICE MANUAL
STEERING VALVE (CONT'D) Assembly

Inspection Figure 20-160-18

Figure 20-160-16

2 S4738

S4738
Assemble the spool (Item 1) and sleeve (Item 2) [Figure
20-160-18] carefully so that spring slots line up at the
Inspect the spool (Item 1) and sleeve (Item 2) [Figure 20- same end. Rotate the spool while sliding parts together.
160-16] for any damage or wear. Replace as needed.
NOTE: Test for free rotation. The spool should rotate
Figure 20-160-17 smoothly in the sleeve with fingertip force
applied at splined end.

Figure 20-160-19

1
S4737

Inspect the drive shaft (Item 1) [Figure 20-160-17] for any

S5360
damage or wear. Replace as needed.

Install the six springs (Item 1) [Figure 20-160-19] onto the

spool and sleeve.
Center spring set in spring slots. Seat springs down
evenly and flush with upper surface of spool and sleeve.

NOTE: There are six springs and should be

positioned three per side and back to back.

6986740-EN (07-08) 20-160-6 Bobcat T2250

SERVICE MANUAL
STEERING VALVE (CONT'D) Figure 20-160-22

Assembly (Cont’d)

Figure 20-160-20

S4731

1
Install the seal (Item 1) [Figure 20-160-22] in the gland
bushing, with smooth side of the seal facing towards
S5361
bushing.

Insert pin (Item 1) [Figure 20-160-20] through the spool Figure 20-160-23
and sleeve assembly until the pin is flush at both sides of
the sleeve.

Figure 20-160-21
1

1
3

S4731

Install the seal (Item 1) [Figure 20-160-23] in the gland

2 bushing.
S4726

Install the big diameter bearing washer (Item 1) [Figure

20-160-21] with the chamfered side towards the sleeve.

Install the thrust bearing (Item 2) [Figure 20-160-21].

Install the small diameter bearing washer (Item 3) [Figure

20-160-21] with the chamfered side facing the outside of
the bearing assembly.

6986740-EN (07-08) 20-160-7 Bobcat T2250

SERVICE MANUAL
STEERING VALVE (CONT'D) Assembly (Cont’d)

Assembly (Cont’d) Figure 20-160-26

Figure 20-160-24
5

2
1

4 6

1
3

S4728

Put some clean oil on the spool and sleeve assembly

(Item 1) and fully insert it into the housing (Item 2) [Figure
20-160-24] such that the splined end of the spool enters
S4732
the housing first. Mind the correct position of the bearing
and washers inside the housing.
Install the two .187” balls (Item 1), .250” ball (Item 2), pin
NOTE: To prevent the cross pin from dropping into the (Item 3), two pins (Item 4) and springs (Item 5) [Figure
discharge groove of the housing, do not pull 20-160-26] in the holes as shown.
the spool assembly beyond this point. With the
spool assembly in this flush position, check Install the spacer plate (Item 6) [Figure 20-160-26]. Align
for free rotation within housing by turning the bolt holes in the spacer plate with tapped holes in the
assembly with fingertip force at the splined housing.
end.
Figure 20-160-27
Figure 20-160-25
2

S4733
S4742

Rotate the spool and sleeve assembly until the pin (Item
Install the O-ring (Item 1) [Figure 20-160-25] into the 1) is parallel with the port face (Item 2) [Figure 20-160-
housing. 27].
Install the drive (Item 3) [Figure 20-160-27] making sure
the drive is engaged with the pin.
Mark the drive according to the parallel line.

6986740-EN (07-08) 20-160-8 Bobcat T2250

SERVICE MANUAL
STEERING VALVE (CONT'D) Figure 20-160-30

Assembly (Cont’d)

Figure 20-160-28 1
2 3

1
S0198

Install the O-ring (Item 1), spacer (Item 2) and wear ring
S4734 (Item 3) [Figure 20-160-30].

Figure 20-160-31
Install the O-ring (Item 1) [Figure 20-160-28] in the
gerotor (on the spacer plate side).

Figure 20-160-29

S4962

2
Install the seven end cap bolts [Figure 20-160-31].
Pretighten to 12.5 ft.-lb. (17 N•m), then torque screws to
19-22 in.-lb.(26-30 N•m).

S4735

Align the star valleys (Items 1) (Reference A) to the

marked drive (Item 2) (Reference B) [Figure 20-160-29].
This way the valleys are aligned with the pin.

NOTE: Keep in mind the parallel relationship of

reference lines A, B, C, and D in [Figure 20-160-
29].

6986740-EN (07-08) 20-160-9 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 20-160-10 Bobcat T2250
SERVICE MANUAL
HYDRAULIC CONTROL VALVE

Troubleshooting Chart (Controllers) WARNING

The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel. adjustments can cause injury or death.
W-2004-1285

PROBLEM CAUSE CORRECTION

None of the controllers work Insufficient power supply Check battery voltage
Insufficient pilot pressure Check pilot pressure
Only one controller works No actuation signal Check diagnostic service codes
Unsuitable actuation signal Check diagnostic service codes
One controller not working or jerky Friction or jamming of the plunger Replace controller
One controller not working or jerky Contamination of the proportional Replace controller
in one direction valve in the controller
Controller creeps Neutral position incorrect Calibrate neutral adjustment
Oil leakage between control valve Faulty seals Replace seal
and controller
Oil leakage between controllers Faulty controller couplers Replace controller couplers

6986740-EN (07-08) 20-170-1 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-3

Telescoping Valve Section Troubleshooting

Remove the rear cover from machine.

1. Check for diagnostic service codes. (See “Viewing

Service Codes” on page 60-180-1.)
When no service code is read, go to step 11.

2. If code 50-02 or 50-03 appears: error in joystick or 1

wiring of joystick to main controller device.
Code 50-04 requires joystick (re)calibration.

Figure 20-170-1

S6542

1
6. With adequate room in front of the machine, start the
engine, lower the restraint bar (if equipped) and run
the engine at 2200 RPM. Move the telescopic control
switch (Item 1) [Figure 20-170-3] forward and back to
see if this function works. Stop the engine.
1 Figure 20-170-4
S4963
S5481

3. If code 50-66 or 50-67 appears: error on boom 1

extension valve (base), which is located at the back
side of the control valve. (Item 1) [Figure 20-170-1]

Figure 20-170-2
2
1
2

S4963

7. Unplug the connector (extension controller connector

shown in picture) (Item 1) [Figure 20-170-4] of the
valve controller which controls the diagnosed valve.

S4963 8. Remove the two screws (extension controller shown in

S5481 picture) (Item 2) [Figure 20-170-4] and pull out the
controller.
4. If code 50-45 or 50-46 appears: error on boom
retraction valve (rod), which is located at the front side NOTE: Install a cap on the valve opening to prevent
of the control valve. (Item 1) [Figure 20-170-2] dust penetration.

5. Unplug the valve controller connector of the valve

which has been diagnosed and plug back in.

6986740-EN (07-08) 20-170-2 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Checking Pilot Pressure

Telescoping Valve Section Troubleshooting (Cont’d) Figure 20-170-6

Figure 20-170-5

1
1

S7102

S7170
11. Locate the test fitting (Item 1) [Figure 20-170-6],
through the right side frame hole, below the control
9. Use an ohmmeter to check the controller solenoid. valve and remove the cap.
The reading between both electrical connector
terminals must be approximately 5.8 ohms (Item 1) Figure 20-170-7
[Figure 20-170-5].

If the controller solenoid measurement is correct, the error

could be located in wiring/connectors to the valve
controller.

10. Reinstall the controller.

S7103

12. Install a 1000 PSI (70 bar) gauge on the test fitting
[Figure 20-170-7].

13. Start the engine, lower the restraint bar (if equipped)
and run the engine at 2200 RPM. Record the pressure.
The pressure at the gauge should be 508 PSI (35 bar)
maximum.

14. Remove the gauge.

6986740-EN (07-08) 20-170-3 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-10

Telescoping Valve Section Troubleshooting (Cont’d)

Checking Drain Pressure

Figure 20-170-8

S6542

19. With adequate room in front of the machine, start the

S7104 engine, lower the restraint bar (if equipped) and run
the engine at 2200 RPM. Move the telescopic control
switch (Item 1) [Figure 20-170-10] forward and back
15. Locate the test fitting (Item 1) [Figure 20-170-8] to see if this function works. Stop the engine.
behind the control valve and remove the cap.
Figure 20-170-11
Figure 20-170-9

S4963
S7105

20. If the telescopic function does not work, remove the

16. Install a 500 PSI (35 bar) gauge on the test fitting two screws (Item 1) [Figure 20-170-11] on each
[Figure 20-170-9]. controller (front and back) and remove them.
17. Start the engine, lower the restraint bar (if equipped) NOTE: Install a cap on each valve opening to prevent
and run the engine at 2200 RPM. Record the pressure. dust penetration.
The pressure at the gauge should be 22 PSI (1,5 bar)
maximum.

18. Remove the gauge.

6986740-EN (07-08) 20-170-4 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D)

Telescoping Valve Section Troubleshooting (Cont’d)

Figure 20-170-12

S7171

21. Turn the ignition key switch ON, but DO NOT start the
engine. Check the function of each controller by
having another person move the telescopic control
switch (Item 1) [Figure 20-170-10]. The controller
piston, which can be seen through the controller
orifices (Item 1) [Figure 20-170-12] must be moving
according to the switch movement.

22. If a controller does not function properly, the controller

must be replaced.

Figure 20-170-13

S7309

23. Check the seals (Item 1) [Figure 20-170-13] of each

controller. Clean or replace if necessary.

24. Put clean oil onto the seals and reinstall the two
controllers.

6986740-EN (07-08) 20-170-5 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-16

Auxiliary Valve Section Troubleshooting

Remove the rear cover from machine.

1. Check for diagnostic service codes. (See “Viewing

Service Codes” on page 60-180-1.)
When no service code is read, go to step 11. 1

2. If code 50-05 or 50-06 appears: error in joystick or

wiring of joystick to main controller device.
Code 50-07 requires joystick (re)calibration.

Figure 20-170-14

S6542

1
6. With adequate room in front of the machine, start the
engine, lower the restraint bar (if equipped) and run
the engine at 2200 RPM. Move the auxiliary control
switch (Item 1) [Figure 20-170-16] forward and back
to see if this function works. Stop the engine.

1 Figure 20-170-17
S4963
S5481

3. If code 50-72 or 50-73 appears: error on auxiliary valve 1

(rod), which is located at the back side of the control
valve. (Item 1) [Figure 20-170-14]

Figure 20-170-15 2

1
2

1
S4963

7. Unplug the connector (auxiliary controller connector

shown in picture) (Item 1) [Figure 20-170-17] of the
valve controller which controls the diagnosed valve.

S4963
8. Remove the two screws (auxiliary controller shown in
S5481 picture) (Item 2) [Figure 20-170-17] and pull out the
controller.
4. If code 50-45 or 50-46 appears: error on auxiliary valve
NOTE: Install a cap on the valve opening to prevent
(base), which is located at the front side of the control
dust penetration.
valve. (Item 1) [Figure 20-170-15]

5. Unplug the valve controller connector of the valve

which has been diagnosed and plug back in.

6986740-EN (07-08) 20-170-6 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Checking Pilot Pressure

Auxiliary Valve Section Troubleshooting (Cont’d) Figure 20-170-19

Figure 20-170-18

1
1

S7102

S7170
11. Locate the test fitting (Item 1) [Figure 20-170-19],
through the right side frame hole, below the control
9. Use an ohmmeter to check the controller solenoid. valve and remove the cap.
The reading between both electrical connector
terminals must be approximately 5.8 ohms (Item 1) Figure 20-170-20
[Figure 20-170-18].

If the controller solenoid measurement is correct, the error

could be located in wiring/connectors to the valve
controller.

10. Reinstall the controller.

S7103

12. Install a 1000 PSI (70 bar) gauge on the test fitting
[Figure 20-170-20].

13. Start the engine, lower the restraint bar (if equipped)
and run the engine at 2200 RPM. Record the pressure.
The pressure at the gauge should be 508 PSI (35 bar)
maximum.

14. Remove the gauge.

6986740-EN (07-08) 20-170-7 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-23

Auxiliary Valve Section Troubleshooting (Cont’d)

Checking Drain Pressure

Figure 20-170-21
1

S6542

19. With adequate room in front of the machine, start the

S7104 engine, lower the restraint bar (if equipped) and run
the engine at 2200 RPM. Move the auxiliary control
switch (Item 1) [Figure 20-170-23] forward and back
15. Locate the test fitting (Item 1) [Figure 20-170-21] to see if this function works. Stop the engine.
behind the control valve and remove the cap.
Figure 20-170-24
Figure 20-170-22

S4963
S7105

20. If the auxiliary function does not work, remove the two
16. Install a 500 PSI (35 bar) gauge on the test fitting screws (Item 1) [Figure 20-170-24] on each controller
[Figure 20-170-22]. (front and back) and remove them.
17. Start the engine, lower the restraint bar (if equipped) NOTE: Install a cap on each valve opening to prevent
and run the engine at 2200 RPM. Record the pressure. dust penetration.
The pressure at the gauge should be 22 PSI (1,5 bar)
maximum.

18. Remove the gauge.

6986740-EN (07-08) 20-170-8 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D)

Auxiliary Valve Section Troubleshooting (Cont’d)

Figure 20-170-25

S7171

21. Turn the ignition key switch ON, but DO NOT start the
engine. Check the function of each controller by
having another person move the auxiliary control
switch (Item 1) [Figure 20-170-23]. The controller
piston, which can be seen through the controller
orifices (Item 1) [Figure 20-170-25] must be moving
according to the switch movement.

22. If a controller does not function properly, the controller

must be replaced.

Figure 20-170-26

S7309

23. Check the seals (Item 1) [Figure 20-170-26] of each

controller. Clean or replace if necessary.

24. Put clean oil onto the seals and reinstall the two
controllers.

6986740-EN (07-08) 20-170-9 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D)

Troubleshooting Chart (Control Valve) WARNING

The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
W-2004-1285

PROBLEM CAUSE CORRECTION

Lack of strength at all actuators Load sense relief cartridge defective Replace relief cartridge
Load sense relief cartridge out of Make necessary adjustments
adjustment
Lack of force on one actuator only Secondary relief valve out of adjust- Reset to original pressure
ment
Secondary relief valve blocked open Replace relief valve
Lack of load hold Load check valve failure Replace load check valve
Excessive clearance between housing Replace housing and spool
and spool
Simultaneous movement of con- Blockage of individual compensator Remove and clean orifice
trols orifice
Individual pressure compensator Replace housing and compensator
blocked
Load sense line leakage Replace load sense regulator
Engine remains under load after Flow regulator blocked Replace flow regulator
spools are returned to neutral Flow regulator filter clogged Replace filter
Detent malfunction Controller defective Replace controller
Spool return difficult Tie rod bolts too tight Re-torque tie rod bolts
Spool leaking oil Defective spool seal Replace spool seal
Oil leakage between valve section Defective seals Replace seals

6986740-EN (07-08) 20-170-10 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-27

Removal And Installation

Relieve hydraulic pressure. Drain the hydraulic reservoir.

(See Contents Page 10-01.) 2

WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury 1 1
and possible death if proper medical treatment by a
S5488
physician familiar with this injury is not received
immediately.
W-2145-0290
Remove the electric connectors (Item 1) as well as the
ones on the other side of the tubelines (Item 2) [Figure
20-170-27].

IMPORTANT Remove the tubeline (Item 2) [Figure 20-170-27].

NOTE: Mark all hoses and tubelines for correct

When making repairs on hydraulic system, clean the installation.
work area before disassemble and keep all parts
clean. Always use caps and plugs on hoses, tubelines Figure 20-170-28
and ports to keep dirt out. Dirt can quickly damage
the system.
I-2056-0793

Remove the fuel tank. (See Contents, Page 50-01.)

NOTE: Rear Weights have been removed for picture 2

clarity.

S5495

Remove the hoses (Item 1 and 2) [Figure 20-170-28].

6986740-EN (07-08) 20-170-11 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-31

Removal And Installation (Cont’d)

Figure 20-170-29
1

S5492

Remove the hoses (Item 1) [Figure 20-170-31] from the

S5494 control valve.

Figure 20-170-32
Remove the hose and tee fitting (Item 1) [Figure 20-170-
29].

Figure 20-170-30 1

1 1

S5496

2
2 Remove the tubeline (Item 1) [Figure 20-170-32].
S5493

Remove the hoses (Item 1) and (Item 2) [Figure 20-170-

30].

6986740-EN (07-08) 20-170-12 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-35

Removal And Installation (Cont’d)

Figure 20-170-33

2 1
S5489

Remove the hose (Item 1) [Figure 20-170-35] from the

S5490 front right hand side of the control valve.

Figure 20-170-36
Remove hoses (Item 1 and 2) [Figure 20-170-33].

Figure 20-170-34

1
1 1

S5487

S5491 Remove the hoses (Item 1) [Figure 20-170-36].

Disconnect the hoses (Item 1 and 2) [Figure 20-170-34].

NOTE: Mark the location of the connectors for correct

installation.

6986740-EN (07-08) 20-170-13 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D)

Removal And Installation (Cont’d)

Figure 20-170-37

1 1

2
2
2
2
S5483

Attach a chain to the lifting holes (Item 1) [Figure 20-170-

37] of the control valve.

Remove the bolts (Item 2) [Figure 20-170-37].

Installation: Tighten the mounting bolts to 18-19 ft.-lb.ft.-

lb. (24-26 N•m) torque.

Figure 20-170-38

S5482

Remove the control valve from the machine [Figure 20-

170-38].

6986740-EN (07-08) 20-170-14 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D)

Parts Identification

1. Inlet-Outlet Valve Section

2. Lifting Valve Section
3. Tilting Valve Section
4. Telescoping Valve Section
5. Auxiliary Valve Section
6. End Housing

2
3
4
5

S5481

6986740-EN (07-08) 20-170-15 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) End Housing Disassembly And Assembly

Disassembly And Assembly Figure 20-170-40

IMPORTANT
When making repairs on hydraulic system, clean the 1
work area before disassemble and keep all parts
clean. Always use caps and plugs on hoses, tubelines
and ports to keep dirt out. Dirt can quickly damage
the system.
I-2056-0793
1

Figure 20-170-39
1 S5480

Loosen the three nuts from the tie bolts (Item 1) [Figure
20-170-40].

Installation: Tighten the nuts to 31 ft.-lb. (42 N•m) torque.

Figure 20-170-41

S5481

Clean the outside of the control valve [Figure 20-170-39]

before disassembly. 2

Mark the outside of the control valve [Figure 20-170-39] 1

for ease of assembly. 4
3
NOTE: Plugs have been installed on all tubeline ports. S5479

NOTE: Sections will be processed from right to left as

depicted in [Figure 20-170-39]. Remove the relief cartridge (Item 1) [Figure 20-170-41].

Remove the plug (Item 2), spring (Item 3) and spool

(Item 4) [Figure 20-170-41].

Installation: Tighten cartridge to 31 ft.-lb. (42 N•m)

torque.

Replace all O-rings.

6986740-EN (07-08) 20-170-16 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-44

Telescoping and Auxiliary Valve Section Disassembly

And Assembly

Figure 20-170-42

1
2
2 S5478

2 Remove the spool [Figure 20-170-44].

S5467 For Auxiliary Valve Section:

Figure 20-170-45
Loosen the two bolts (Item 1) [Figure 20-170-42] and
remove the controller. AUXILIARY VALVE
SECTION
Loosen the four bolts (Item 2) [Figure 20-170-42] and
remove the port block.

Installation: Tighten the bolts to 4.9 ft.-lb. (6,6 N•m)

torque.

Figure 20-170-43 1

1 S5474

Remove the two plugs (Item 1) [Figure 20-170-45] on the

top side of the valve section.

Replace all O-rings.

Installation: Tighten the plugs to 17.7 ft.-lb. (24 N•m)

torque.
S5478

Replace all O-rings [Figure 20-170-43].

6986740-EN (07-08) 20-170-17 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D)

Telescoping and Auxiliary Valve Section Disassembly

And Assembly (Cont’d)

For Telescoping Valve Section:

Figure 20-170-46

TELESCOPING
VALVE SECTION

3 2 1

3
2 S5473

Remove the two plugs (Item 1), two springs (Item 2) and
two port relief valves (Item 3) [Figure 20-170-46] on the
top side of the valve section.

Replace all O-rings.

Installation: Tighten the plugs to 17.7 ft.-lb. (24 N•m)

torque.

6986740-EN (07-08) 20-170-18 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) For Lifting Valve Section:

Lifting and Tilting Valve Section Disassembly And Figure 20-170-49

Assembly
LIFTING VALVE
For Tilting Valve Section: SECTION

Figure 20-170-47

TILTING VALVE 3
SECTION

3
2 1

3 2 S5471

3 Remove the plug (Item 1), spring (Item 2) and two relief
2 valves (Item 3) [Figure 20-170-49].
S5472
Installation: Tighten the plugs to 17.7 ft.-lb. (24 N•m)
torque.
Remove the two plugs (Item 1), two springs (Item 2) and
two port relief valves (Item 3) [Figure 20-170-47] on top
side of the valve section.

Installation: Tighten the plugs to 17.7 ft.-lb. (24 N•m)

torque.

Figure 20-170-48

1
4

3
2 6
6
3
4 S5476

Loosen the front and rear cover (Item 1), and remove the
rod (Item 2), springs (Item 3), spring retainers (Item 4)
and washers (Item 6) [Figure 20-170-48].

Replace all O-rings.

Installation: Tighten the cover bolts to 4.9 ft.-lb. (6,6 N•m)

torque.

6986740-EN (07-08) 20-170-19 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-52

Inlet-Outlet Valve Section Disassembly And Assembly

Figure 20-170-50 2

1
1

S5469

Remove the plugs (Item 1 and 2) [Figure 20-170-52] from

S4965 the valve section.

Installation: Tighten the plugs to 17.7 ft.-lb. (24 N•m)

Remove and disassemble the main relief valve (Item 1) torque.
[Figure 20-170-50] from the valve section.

Installation: Tighten the valve to 17.7 ft.-lb. (24 N•m)

torque.

Figure 20-170-51

S5470

Replace all O-rings in the main relief valve [Figure 20-

170-51].

6986740-EN (07-08) 20-170-20 Bobcat T2250

SERVICE MANUAL
JOYSTICK

Removal And Installation WARNING

Remove the joystick panel. (See “JOYSTICK PANEL” on
page 50-120-1.) Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
NOTE: The joystick is not serviceable and must be penetrating the skin. This can cause serious injury
replaced as a complete unit. and possible death if proper medical treatment by a
physician familiar with this injury is not received
Figure 20-180-1 immediately.
W-2145-0290

IMPORTANT
When making repairs on hydraulic system, clean the
work area before disassemble and keep all parts
clean. Always use caps and plugs on hoses, tubelines
and ports to keep dirt out. Dirt can quickly damage
the system.
I-2056-0793

1
S5044 Figure 20-180-3

Remove the bracket (Item 1) [Figure 20-180-1]

Figure 20-180-2 2
1
1

1 1
S3702

Remove the four mounting bolts (Item 1) [Figure 20-180-

3].
1 2 S5043
Installation: Tighten the bolts to 7.5 ft.-lb. (10 N•m)
torque.
Disconnect the electrical connector (Item 1) [Figure 20-
180-2]. Remove the joystick assembly.
Mark the five hydraulic hoses (Item 2) [Figure 20-180-2] Installation: The joystick harness (Item 2) [Figure 20-
for correct assembly. Remove the hoses from the joystick. 180-3] must spiral around the joystick base as shown.
Raise the dust boot (Item 3) [Figure 20-180-2].

6986740-EN (07-08) 20-180-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 20-180-2 Bobcat T2250
SERVICE MANUAL
PARKING BRAKE Figure 20-190-2

Parking Brake Valve Removal And Installation

1
Remove the battery access cover. (See “Removal And
Installation” on page 60-20-1).

Relieve the hydraulic pressure.

WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by S4520
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received Remove the two screws (Item 1) [Figure 20-190-2] in
immediately. order to loosen the parking brake lever.
W-2145-0290
Figure 20-190-3

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. 1
I-2003-0888

Mark all hoses and electrical connectors for correct

installation. S4521

Figure 20-190-1 Lift the parking brake lever and valve (Item 1) [Figure 20-
190-3] out the frame.

2
S3699

Remove the three hoses (Item 1). Unplug the electrical

connector (Item 2) [Figure 20-190-1].

6986740-EN (07-08) 20-190-1 Bobcat T2250

SERVICE MANUAL
PARKING BRAKE (CONT’D) Figure 20-190-6

Parking Brake Valve Disassembly And Assembly

Figure 20-190-4
3

2
1
1
1

P-44440

Remove the collar (Item 1), spring (Item 2) and shaft (Item
S3700 3) [Figure 20-190-6] from the housing.

Figure 20-190-7
Remove the fittings (Item 1) [Figure 20-190-4].

Figure 20-190-5

P-44441

P-44439 Remove the washer (Item 1) [Figure 20-190-7] from the

housing.

Loosen the collar (Item 1) [Figure 20-190-5].

NOTE: Use care removing the collar. The collar is

under spring pressure.

6986740-EN (07-08) 20-190-2 Bobcat T2250

SERVICE MANUAL
PARKING BRAKE (CONT’D)

Parking Brake Valve Disassembly And Assembly

(Cont’d)

Figure 20-190-8

P-44442

Remove the electrical connector (Item 1) [Figure 20-190-

8] from the housing.

6986740-EN (07-08) 20-190-3 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 20-190-4 Bobcat T2250
SERVICE MANUAL
WORKGROUP LOCKOUT VALVE Figure 20-200-3

Testing

Raise the boom and install the boom stop. (See Installing
The Approved Boom Stop on Page 10-150-1.)

Figure 20-200-1

S7103

Install a 1000 PSI (70 bar) gauge on the test fitting

[Figure 20-200-3].

Start the engine, lower the restraint bar (if equipped) and
S3691 run engine at 2400 RPM.

Record the pressure. The pressure at the gauge should

Remove the rear cover (Item 1) [Figure 20-200-1]. be 435 PSI (30 bar).

Figure 20-200-2 The workgroup lockout valve is not adjustable. If the

pressure is incorrect, replace the workgroup lockout valve.
(See Removal And Installation on Page 20-200-2.)

S7102

Locate the test fitting (Item 1) [Figure 20-200-2], through

the right side frame hole, below the control valve and
remove the cap

6986740-EN (07-08) 20-200-1 Bobcat T2250

SERVICE MANUAL
WORKGROUP LOCKOUT VALVE (CONT’D) Figure 20-200-6

Removal And Installation

Relieve hydraulic pressure. Drain the hydraulic reservoir.

(See Replacing Hydraulic Fluid on Page 10-100-2.)

Figure 20-200-4

1
1

S7110

Remove the solenoid (Item 1) [Figure 20-200-6] from the

valve.

Mark the hoses and electrical connectors for correct

S5046 installation.

Remove the rear cover (Item 1) [Figure 20-200-4].

Remove the fuel tank (See Removal And Installation on

WARNING
Page 50-80-1.).
Hydraulic fluid escaping under pressure can have
Figure 20-200-5 sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290

1
IMPORTANT
When making repairs on hydraulic system, clean the
work area before disassemble and keep all parts
1
clean. Always use caps and plugs on hoses, tubelines
S7109 and ports to keep dirt out. Dirt can quickly damage
the system.
I-2056-0793
Remove the tie straps (Item 1) [Figure 20-200-5] from the
harness.

6986740-EN (07-08) 20-200-2 Bobcat T2250

SERVICE MANUAL
WORKGROUP LOCKOUT VALVE (CONT’D) Disassembly And Assembly

Removal And Installation (Cont’d) Figure 20-200-8

Figure 20-200-7

1 1

1
2 S7113
3
S7111
Remove the spool (Item 1) [Figure 20-200-8].

Remove the four hoses (Item 1) [Figure 20-200-7]. Figure 20-200-9

Remove the two mounting bolts (Item 2) and remove the

workgroup lockout valve (Item 3) [Figure 20-200-7].

2 1

1 2
1
2
P-44340

Remove the three O-rings (Item 1) and four backup rings

(Item 2) [Figure 20-200-9] from the spool.

6986740-EN (07-08) 20-200-3 Bobcat T2250

SERVICE MANUAL
WORKGROUP LOCKOUT VALVE (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 20-200-10

S7112

Remove the fittings (Item 1) [Figure 20-200-10].

Wash the valve in clean solvent and dry with compressed

air. Check the components for wear or damage. Replace
any worn or damaged components. Always use new O-
rings and backup rings.

Apply clean hydraulic fluid to the components during

assembly.

6986740-EN (07-08) 20-200-4 Bobcat T2250

SERVICE MANUAL
TOW VALVE Figure 20-220-2

Removal And Installation

Open the engine cover.

3
Figure 20-220-1

Operating 1
position
2

S4967

2 Towing Remove the two nuts, bolts (Item 1) and strap (Item 2).
position Remove the tow valve (Item 3) [Figure 20-220-2].

S4966

Position the tow valve (Item 1) [Figure 20-220-1] to

towing position to relieve hydraulic pressure.

Mark the hoses for correct installation. Remove the two

hoses (Item 2) [Figure 20-220-1].

WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

6986740-EN (07-08) 20-220-1 Bobcat T2250

SERVICE MANUAL
TOW VALVE (CONT’D) Figure 20-220-5

Disassembly And Assembly

Clean the outside of the tow valve before disassembly.

Mark the outside of the tow valve for ease of assembly.

Figure 20-220-3
1

P-46750

Remove the retainer (Item 1) and stop plate (Item 2)

2 [Figure 20-220-5].

NOTE: Record the position of the stop plate for proper

1 assembly.
P-46747
Figure 20-220-6

Remove the screw (Item 1) and washer (Item 2) [Figure

20-220-3].

Figure 20-220-4

1
1 1

P-46752

Remove the two fittings (Item 1) [Figure 20-220-6].

P-46749

Remove the handle (Item 1) [Figure 20-220-4].

6986740-EN (07-08) 20-220-2 Bobcat T2250

SERVICE MANUAL
TOW VALVE (CONT’D) Figure 20-220-9

Disassembly And Assembly (Cont’d)

Figure 20-220-7 1

P-46755
1

Remove the O-ring (Item 1) [Figure 20-220-9] from the

P-46753 adapters.

Remove the O-ring (Item 1) [Figure 20-220-7] from the

fittings.

Figure 20-220-8

1 1

P-46754

Remove the two adapters (Item 1) [Figure 20-220-8].

6986740-EN (07-08) 20-220-3 Bobcat T2250

SERVICE MANUAL
TOW VALVE (CONT’D) Figure 20-220-12

Disassembly And Assembly (Cont’d)

Figure 20-220-10
1

P-46759

Figure 20-220-13
P-46756

Figure 20-220-11
1

1
P-46760

Assembly: Align the slot (Item 1) [Figure 20-220-12]

P-46758 with the notch (Item 1) [Figure 20-220-13] in the shaft.

Remove the seal (Item 1) [Figure 20-220-10] from the

valve. (Both sides)

Assembly: The concave side of the seal (Item 1) [Figure

20-220-10] fits over the ball (Item 2) [Figure 20-220-11].

Turn the shaft (Item 1) until the shaft and ball (Item 2)
[Figure 20-220-11] are in the position shown. Remove
the ball.

Assembly: Record the position of the shaft and ball for

proper assembly.

6986740-EN (07-08) 20-220-4 Bobcat T2250

SERVICE MANUAL
TOW VALVE (CONT’D) Figure 20-220-16

Disassembly And Assembly (Cont’d)

Figure 20-220-14

1
1

P-46762

Remove the seal (Item 1) [Figure 20-220-16] from the

P-46763 housing.

Clean all parts in solvent and dry with compressed air.

Remove the shaft (Item 1) [Figure 20-220-14] by pressing
the shaft into the housing. Inspect all parts for wear or damage. Replace any worn or
damaged parts.
Figure 20-220-15
Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation.

P-46761

Remove the O-ring (Item 1) [Figure 20-220-15] from the

shaft.

6986740-EN (07-08) 20-220-5 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 20-220-6 Bobcat T2250
SERVICE MANUAL
FRONT AUXILIARY HYDRAULIC PRESSURE Figure 20-230-2
RELEASE VALVE

Removal And Installation 3 3

Stop the engine.

Engage the parking brake.

1 1
Exit the machine.
2
Figure 20-230-1

S5865

Remove the two nuts (Item 1), strap (Item 2) and two bolts
(Item 3) [Figure 20-230-2].
CLOSED
OPEN Figure 20-230-3
(pressure relief
position) 1

S4140

Turn the handle (Item 1) [Figure 20-230-1] to relieve

hydraulic pressure (OPEN position). 1

WARNING
Hydraulic fluid escaping under pressure can have S5866
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a Mark and remove the two hoses (Item 1) [Figure 20-230-
physician familiar with this injury is not received 3] from the valve.
immediately.
W-2145-0290 Remove the valve.

6986740-EN (07-08) 20-230-1 Bobcat T2250

SERVICE MANUAL
FRONT AUXILIARY HYDRAULIC PRESSURE Figure 20-230-6
RELEASE VALVE (CONT’D)

Disassembly And Assembly

IMPORTANT
1
When making repairs on hydraulic system, clean the
work area before disassemble and keep all parts
clean. Always use caps and plugs on hoses, tubelines 2
and ports to keep dirt out. Dirt can quickly damage
the system.
I-2056-0793
P-46750

Clean the outside of the pressure release valve before

disassembly. Remove the retainer (Item 1) and stop plate (Item 2)
[Figure 20-230-6].
Mark the outside of the pressure release valve for ease of
assembly. NOTE: Record the position of the stop plate for proper
assembly.
Figure 20-230-4

1
P-46747

Remove the screw (Item 1) and washer (Item 2) [Figure

20-230-4].

Figure 20-230-5

P-46749

Remove the handle (Item 1) [Figure 20-230-5].

6986740-EN (07-08) 20-230-2 Bobcat T2250

SERVICE MANUAL
FRONT AUXILIARY HYDRAULIC PRESSURE Figure 20-230-9
RELEASE VALVE (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 20-230-7

1 1

P-46754

1 1
Remove the two adapters (Item 1) [Figure 20-230-9].

P-46752 Figure 20-230-10

Remove the two fittings (Item 1) [Figure 20-230-7].

1
Figure 20-230-8

P-46755

1
Remove the O-ring (Item 1) [Figure 20-230-10] from the
adapters.
P-46753

Remove the O-ring (Item 1) [Figure 20-230-8] from the

fittings.

6986740-EN (07-08) 20-230-3 Bobcat T2250

SERVICE MANUAL
FRONT AUXILIARY HYDRAULIC PRESSURE Figure 20-230-13
RELEASE VALVE (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 20-230-11 1

P-46759

Figure 20-230-14

P-46756

Remove the seal (Item 1) [Figure 20-230-11] from the 1

valve. (Both sides)

Assembly: The concave side of the seal (Item 1) [Figure

20-230-11] fits over the ball (Item 2) [Figure 20-230-12].

Figure 20-230-12

P-46760

2
Assembly: Align the slot (Item 1) [Figure 20-230-13]
with the notch (Item 1) [Figure 20-230-14] in the shaft.

P-46758

Turn the shaft (Item 1) until the shaft and ball (Item 2)
[Figure 20-230-12] are in the position shown.

Gently push the ball (Item 2) [Figure 20-230-12] out of

the housing.

6986740-EN (07-08) 20-230-4 Bobcat T2250

SERVICE MANUAL
FRONT AUXILIARY HYDRAULIC PRESSURE Figure 20-230-17
RELEASE VALVE (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 20-230-15

1 1

P-46762

Remove the seal (Item 1) [Figure 20-230-17] from the

housing.
P-46763
Wash the components in clean solvent and dry with
compressed air.
Remove the shaft (Item 1) [Figure 20-230-15] by pressing
the shaft into the housing. Check the components for wear or damage. Replace any
worn or damaged components. Always use new O-rings
Figure 20-230-16 and seals.

Apply clean hydraulic fluid to the O-rings and seals during

assembly.
1

P-46761

Remove the O-ring (Item 1) [Figure 20-230-16] from the

shaft.

6986740-EN (07-08) 20-230-5 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 20-230-6 Bobcat T2250
SERVICE MANUAL
MANIFOLD Figure 20-240-2

Removal And Installation

The manifold is located below the hydraulic control valve.

Relieve hydraulic pressure. (Refer to the Operation &

Maintenance Manual for the correct procedure.)

1
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
S5092
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received Remove the hose (Item 1) [Figure 20-240-2] on the
immediately. manifold located towards the backside of the machine.
W-2145-0290
Figure 20-240-3

IMPORTANT
When making repairs on hydraulic system, clean the
work area before disassemble and keep all parts
clean. Always use caps and plugs on hoses, tubelines
and ports to keep dirt out. Dirt can quickly damage 1
the system.
I-2056-0793

Figure 20-240-1
S5094

1 Remove, mark and cap the hoses on the left of the

manifold, starting from the back of the machine to the
front, beginning with the first (Item 1) [Figure 20-240-3].

S5093

Remove the hose (Item 1) [Figure 20-240-1] on the

manifold located towards the front of the machine.

6986740-EN (07-08) 20-240-1 Bobcat T2250

SERVICE MANUAL
MANIFOLD (CONT’D) Figure 20-240-6

Removal And Installation (Cont’d)

Figure 20-240-4

1
S5097

Remove the last hose (Item 1) [Figure 20-240-6].

S5095
Figure 20-240-7

Remove the next hose (Item 1) [Figure 20-240-4].

Figure 20-240-5

1
S5098

Remove the hose (Item 1) [Figure 20-240-7] on the right

S5096 side of the manifold.

Remove the third hose (Item 1) [Figure 20-240-5].

6986740-EN (07-08) 20-240-2 Bobcat T2250

SERVICE MANUAL
MANIFOLD (CONT’D) Disassembly

Removal And Installation (Cont’d) Figure 20-240-9

Figure 20-240-8

1
1
1

S2889

S5097
Remove all check valves (Item 1) [Figure 20-240-9].

Remove the two bolts (Item 1) [Figure 20-240-8] and Figure 20-240-10
remove the manifold from the machine.

4 5 2
1
3

S5498

Each check valve consists of a plug (Item 1), seal

(Item 2), spring (Item 3), ball (Item 4) and ball seat
(Item 5) [Figure 20-240-10]. Check for wear and replace
if necessary.

6986740-EN (07-08) 20-240-3 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 20-240-4 Bobcat T2250
SERVICE MANUAL
 HYDROSTATIC SYSTEM

DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-2
Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . 30-50-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . 30-50-1
Tensioner Pulley Disassembly And Assembly. . . . . . . . . 30-50-6
Tensioner Pulley Parts Identification . . . . . . . . . . . . . . . . 30-50-5
Tensioner Pulley Removal And Installation . . . . . . . . . . . 30-50-4 HYDROSTATIC
SYSTEM
HYDROSTATIC DRIVE MOTOR. . . . . . . . . . . . . . . . . . . . . . 30-30-1
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-18
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-16
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-2
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-24
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-20
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-3
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . 30-10-1

Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . 30-10-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

6986740-EN (07-08) 30-01 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 30-02 Bobcat T2250
SERVICE MANUAL
HYDROSTATIC SYSTEM INFORMATION

Troubleshooting Chart WARNING

The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285

PROBLEM CAUSE
The Telescopic Handler does not move 1, 2
The Telescopic Handler does not move in a straight line. 3, 4
The hydrostatic system is overheating. 5, 6, 7, 8
Warning light comes ON. 5, 8, 9, 10, 11

KEY TO CORRECT THE CAUSE

1. The hydrostatic pump has damage.
2. The hydrostatic motor has damage.
3. The tires do not have the correct tire pressure.
4. The tires are not the same size.
5. The hydrostatic fluid is not at the correct level.
6. The oil cooler has a restriction.
7. The temperature sending switch is not operating correctly.
8. The Telescopic Handler is not being operated at the correct RPM.
9. The sender is defective.
10. Pump is defective or worn hydrostatics
11. Hydraulic filter is plugged.

6986740-EN (07-08) 30-10-1 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC SYSTEM INFORMATION (CONT’D)

Replenishing Valve Function

IMPORTANT
Figure 30-10-1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

The functions of the replenishing valves are:

1. To give replacement fluid to the low pressure side of

the hydrostatic circuit. Replacement fluid is needed
Valve Moves For because of normal internal leakage and the controlled
Function 1 Charge Oil flow to the oil cooler for cooling; Function 1 [Figure 30-
Replacement 10-1].

2. To keep high pressure fluid out of the low pressure

side of the hydrostatic circuitry; Function 2 [Figure 30-
10-1].

Valve Stays on Seat

to Hold High
Pressure for
Drive
Function 2 B-2804

6986740-EN (07-08) 30-10-2 Bobcat T2250

SERVICE MANUAL
OIL COOLER Figure 30-20-3

Removal And Installation

Remove the condenser if equipped. (See “Removal And 1

Installation” on page 180-120-1.)
1
Figure 30-20-1

S5436

1
Remove the two screws (Item 1) [Figure 30-20-3] and
remove the oil cooler.

Installation: Tighten the bolts to 18 ft.-lb. (25 N•m)

S5399 torque.

Remove the hydraulic hose (Item 1) [Figure 30-20-1] at

the bottom of the oil cooler.

Figure 30-20-2

S5022

Remove the hydraulic hose (Item 1) [Figure 30-20-2] at

the top of the oil cooler.

6986740-EN (07-08) 30-20-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 30-20-2 Bobcat T2250
SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR

Removal And Installation

Remove the front axle (See Removal on Page 40-31-1.)

Figure 30-30-1

1
1

P-22325

Install a chain hoist and lifting strap to lift and support the
drive motor [Figure 30-30-1].

Remove the four mounting bolts (Item 1) [Figure 30-30-1]

from the drive motor.

Assembly: Tighten the mounting bolts to 140-155 ft.-lb.

(190-210 N•m) torque.

Remove the hydrostatic drive motor from the axle

housing.

6986740-EN (07-08) 30-30-1 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D)

Parts Identification

1. Plug
2. O-ring
3. Spring
4. Poppet
5. Housing
6. Bolt
7. Spring Seat
8. Spool
9. Gasket
10. Spacer
11. Backup Ring
12. Shaft
13. Housing

13

6986740-EN (07-08) 30-30-2 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D)

Parts Identification (Cont’d)

6986740-EN (07-08) 30-30-3 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D)

Parts Identification (Cont’d)

6986740-EN (07-08) 30-30-4 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-4

Disassembly

Clean the outside of the drive motor before disassembly.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
P-22328
I-2003-0888

Figure 30-30-2 Remove the solenoid nut (Item 1) [Figure 30-30-4].

Figure 30-30-5

P-22326

P-22329
Place the hydrostatic drive motor on a work surface, mark
the sections for correct assembly [Figure 30-30-2].
Remove the solenoid (Item 1) [Figure 30-30-5] from the
Figure 30-30-3 shaft.

1 1

P-22327

Remove the four bolts (Item 1) [Figure 30-30-3] and

remove the solenoid housing.

6986740-EN (07-08) 30-30-5 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-8

Disassembly (Cont'd)

Figure 30-30-6 3

P-22333

1 Remove the O-ring (Item 1) and pin (Item 2) from the

P-22330 solenoid shaft (Item 3) [Figure 30-30-8].

Figure 30-30-9
Remove and discard the O-ring (Item 1) [Figure 30-30-6]
from the solenoid.

Figure 30-30-7

2
P-22335
2

Loosen the large nut (Item 1) [Figure 30-30-9] on the

P-22331 compensator valve.

Do not loosen the small nut (Item 2) [Figure 30-30-9].

Remove the solenoid shaft (Item 1) and O-ring (Item 2)
[Figure 30-30-7] from the housing.

6986740-EN (07-08) 30-30-6 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-12

Disassembly (Cont'd)

Figure 30-30-10

3
2
1 1

P-22338

Remove the plug (Item 1) [Figure 30-30-12] from the

P-22336 housing.

Figure 30-30-13
Remove the adjusting screw (Item 1), valve spring (Item
2) and spool assembly (Item 3) [Figure 30-30-10] from
the housing.

Figure 30-30-11

1
1

P-22339

Remove and discard the O-ring (Item 1) [Figure 30-30-

13] from the plug.
P-22337

Remove and discard the O-ring (Item 1) [Figure 30-30-

11] from the adjustment screw.

6986740-EN (07-08) 30-30-7 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-16

Disassembly (Cont'd)

Figure 30-30-14

1
P-27537

Remove the spool (Item 1) [Figure 30-30-16].

P-27534
Figure 30-30-17

Remove the two fittings (Item 1) [Figure 30-30-14] from

the housing.
1
Figure 30-30-15

P-22344

1
Remove and discard the six O-rings (Item 1) [Figure 30-
30-17] from the housing.
P-27536

Remove the two spool limiters (Item 1) [Figure 30-30-15].

6986740-EN (07-08) 30-30-8 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-20

Disassembly (Cont'd)

Figure 30-30-18 1

1
1

P-22347

1
1
Remove the gasket (Item 1) [Figure 30-30-20] from the
P-22345 end cap.

Figure 30-30-21
Remove the eight bolts (Item 1) [Figure 30-30-18] from
the end cap.

Figure 30-30-19

P-22348

Remove the piston (Item 1) [Figure 30-30-21] from the

P-22346 end cap.

Lift and remove the end cap (Item 1) [Figure 30-30-19]

from the housing.

6986740-EN (07-08) 30-30-9 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-24

Disassembly (Cont'd)

Figure 30-30-22

4
1 3

P-22377

Remove the plug (Item 1), spring (Item 2), spring seat
P-22375 (Item 3) and spool (Item 4) [Figure 30-30-24] from the
housing.

Remove the seal (Item 1) [Figure 30-30-22] from the Figure 30-30-25
piston.

Figure 30-30-23

P-22378

P-22376 Remove and discard the O-ring (Item 1) [Figure 30-30-

25] from the plug.

Loosen the plug (Item 1) [Figure 30-30-23].

6986740-EN (07-08) 30-30-10 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-28

Disassembly (Cont'd)

Figure 30-30-26
1

P-22378

Remove and discard the O-ring (Item 1) [Figure 30-30-

P-22379 28] from the plug.

Figure 30-30-29
Loosen the plug (Item 1) [Figure 30-30-26].

Figure 30-30-27 1

2 P-22381

3
P-22380 Loosen and remove the relief valve (Item 1) [Figure 30-
30-29] from the housing.

Remove the plug (Item 1), spring (Item 2) and spring seat
(Item 3) [Figure 30-30-27] from the housing.

6986740-EN (07-08) 30-30-11 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-32

Disassembly (Cont'd) 2

Figure 30-30-30 2 1

1 2 3 4 5 2

2
P-22386

Remove and discard the O-ring (Item 1). Remove eight

P-22501 mounting bolts (Item 2) [Figure 30-30-32] from the
mounting plate.

Remove the plug (Item 1), O-rings (Item 2), spring (Item Figure 30-30-33
3) and poppet (Item 4) from the relief valve housing (Item
5) [Figure 30-30-30].

Figure 30-30-31

P-22504

Remove the mounting plate (Item 1) [Figure 30-30-33]

P-22384 using a suitable puller.

Remove the valve segment (Item 1) [Figure 30-30-31]

from the cylinder.

6986740-EN (07-08) 30-30-12 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-36

Disassembly (Cont'd)
1
Figure 30-30-34

P-22459

Remove the bearing plate (Item 1) [Figure 30-30-36] from

P-22378 the cylinder block.

Figure 30-30-37
Remove and discard the seal (Item 1) [Figure 30-30-34]
from the mounting plate.

Figure 30-30-35

1
2

P-22458

Remove the bearing from the cylinder block [Figure 30-

P-22503 30-37].

DO NOT damage the bearing plate surface of the cylinder

Remove the cylinder block (Item 1) and synchronizing block.
shaft assembly (Item 2) [Figure 30-30-35] from the
housing.

NOTE: It is not important that the pistons are installed

in their original position.

6986740-EN (07-08) 30-30-13 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-40

Disassembly (Cont'd)

Figure 30-30-38

1
P-22505

Pry up the peened notch (Item 1) [Figure 30-30-40] in the

P-22388 ring nut.

Figure 30-30-41
Remove the O-ring (Item 1) [Figure 30-30-38] from the
housing.

Figure 30-30-39

P-22506

Remove the ring nut (Item 1) [Figure 30-30-41] from the

P-22390 shaft.

Press the piston/shaft assembly from the housing [Figure

30-30-39].

DO NOT damage the pistons.

6986740-EN (07-08) 30-30-14 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-44

Disassembly (Cont'd)

Figure 30-30-42
2
3

2
1

3
1 P-22447

Remove the pin (Item 1), spring (Item 2) and spring seat
P-22507 (Item 3) [Figure 30-30-44] from the shaft assembly.

Figure 30-30-45
Remove the large bearing and race (Item 1), small
bearing and race (Item 2) and spacer (Item 3) [Figure 30-
30-42] from the shaft.
1
Figure 30-30-43

1
P-22508

Remove the piston rings (Item 1) [Figure 30-30-45] from

the pistons.
P-22446
NOTE: If any portion of the shaft assembly, bearings
or races must be replaced, the complete shaft/
Using a clamp, compress the spring seat and spring, and bearing assembly must be replaced. The only
drive the pin (Item 1) [Figure 30-30-43] inwards. Release serviceable part is the piston rings (Item 1)
the clamp. [Figure 30-30-45].

6986740-EN (07-08) 30-30-15 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-48

Inspection

Clean all parts in solvent and use air pressure to dry 1

them. DO NOT use cloth or paper as small pieces of
material can get into the system and cause damage.

Figure 30-30-46

2
1

P-22375

Inspect the piston (Item 1) [Figure 30-30-48] for wear or

damage.

2 Figure 30-30-49

P-22461
1

Inspect the running (bronze) surface of the bearing plate

1
(Item 1) and locating pin holes (Item 2) [Figure 30-30-46]
for wear. Replace if damaged or worn.

Figure 30-30-47

P-22349

2 Inspect the swash plate running surface (Item 1) [Figure

30-30-49] in the end cap for wear or damage.

P-22462

Inspect the cylinder block assembly for wear or damage.

The piston bores (Item 1) must be smooth. The races for
the synchronizing shaft rollers (Item 2) [Figure 30-30-47]
must not be worn.

If there is any defect in the cylinder block or pistons, the

complete rotating group must be replaced.

6986740-EN (07-08) 30-30-16 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D)

Inspection (Cont'd)

Figure 30-30-50

B-15936

Inspect the valve segment for damage or wear on the

sealing surface (Item 1) [Figure 30-30-50].

Check that the spindle is located correctly in the valve

segment by measuring distance "A" [Figure 30-30-50]. If
this dimension is not within 1.36 to 1.37 inch (34.5 to 34.7
mm) the assembly must be replaced.

6986740-EN (07-08) 30-30-17 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-52

Assembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-22446
Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or Using a clamp, compress the spring and spring seat
damaged parts. [Figure 30-30-52].

Always install new seals and O-rings. Lubricate all seals Figure 30-30-53
and O-rings with clean hydraulic fluid before installation.

Figure 30-30-51

1
2 1

P-22441

P-22447
Install the pin (Item 1) [Figure 30-30-53] as shown.

NOTE: Clamp is removed for photo clarity.

Install the spring (Item 1) and spring seat (Item 2) into the
shaft assembly (Item 3) [Figure 30-30-51].

6986740-EN (07-08) 30-30-18 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-56

Assembly (Cont'd)

Figure 30-30-54

2
P-22509

1
Using a punch seat the ring nut into the groove in the
P-22453 shaft. [Figure 30-30-56].

Figure 30-30-57
Support the shaft assembly in a press without causing
damage to the pistons, install the large bearing and race
(Item 1), spacer (Item 2) and small bearing and race (Item
3) [Figure 30-30-54] into the shaft assembly.

NOTE: Be sure not to over press the bearings, they

should be able to roll freely.

Figure 30-30-55

P-22455

1 Press the piston/shaft assembly into the housing [Figure

30-30-57].

DO NOT DAMAGE THE PISTONS.

P-22505

Install the ring nut (Item 1) [Figure 30-30-55] onto the

shaft.

NOTE: Do not over tighten the ring nut and that there
is no noticeable looseness in the bearing.

6986740-EN (07-08) 30-30-19 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-60

Assembly (Cont'd)

Figure 30-30-58 1
1

1
1

P-22387

Install the mounting plate onto the housing, install the

P-22450 eight mounting bolts (Item 1) [Figure 30-30-60] and
tighten to 46 ft.-lb. (63 N•m) torque.

Install a new seal (Item 1) [Figure 30-30-58] into the Figure 30-30-61
mounting plate until it is fully seated.

Figure 30-30-59
1

P-22386

P-22388 Install a new O-ring (Item 1) [Figure 30-30-61] onto the

mounting plate.

Install a new O-ring (Item 1) [Figure 30-30-59] onto the

housing.

6986740-EN (07-08) 30-30-20 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-63

Assembly (Cont'd) 2

Figure 30-30-62
1

0.53 to 0.55 inch

(13.5 to 14.0 mm)

P-22440

Figure 30-30-64
B-15933

Piston End

Press a new bearing into the cylinder block until it is

located 0.53 to 0.55 inch (13.5 to 14.0 mm) below the 2
bearing plate surface [Figure 30-30-62].

B-15935

Install new piston rings (Item 1) [Figure 30-30-63] onto

the pistons, make sure the spherical surface (Item 1)
[Figure 30-30-64] conforms to the shape of the piston.

An identification mark (Item 2) [Figure 30-30-63] &

[Figure 30-30-64] is on the "outer" side of the piston ring.

The ends of the piston rings must NOT overlap each

other.

6986740-EN (07-08) 30-30-21 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-67

Assembly (Cont'd)

Figure 30-30-65

1 1

P-22511

Install the synchronizing shaft support pin (Item 1)

P-22459 [Figure 30-30-67] into the cylinder block and retain with
grease.

Install the bearing plate (Item 1) [Figure 30-30-65] with Figure 30-30-68
the bronze surface facing up onto the cylinder block.

Figure 30-30-66
1

P-22499

P-22464 Install the six synchronizing shaft rollers (Item 1) [Figure

30-30-68] onto the synchronizing shaft and retain with
grease.
Position the housing on end, tip the three pistons (Item 1)
[Figure 30-30-66] closest to the minimum angle stop out
toward the housing.

6986740-EN (07-08) 30-30-22 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-71

Assembly (Cont'd)

Figure 30-30-69 1
2 2
1

P-22513

Install the synchronizing shaft and rollers (Item 1) [Figure

B-15935 30-30-71] into the motor shaft races. When properly
installed the synchronizing shaft should move freely in all
directions.
NOTE: The recess (Item 1) [Figure 30-30-69] on each
roller MUST face the synchronizing shaft. NOTE: The motor shaft end of the synchronizing shaft
is smaller than the cylinder end.
Figure 30-30-70
Figure 30-30-72

1 2

3 1
1

P-22512

P-22511

Install the synchronizing shaft support pin (Item 1)

[Figure 30-30-70] into the motor shaft assembly and When installing the cylinder block, the races (Item 1)
retain with grease. [Figure 30-30-72] in the cylinder block must be positioned
so the synchronizing shaft rollers (Item 2) [Figure 30-30-
72] and pistons (Item 3) [Figure 30-30-71] and their
bores (Item 2) [Figure 30-30-72] are aligned.

Install the six pistons (Item 3) [Figure 30-30-71] into the

cylinder bores, tilt the block so the synchronizing shaft
rollers enter their races in the block and the support pin
(Item 3) [Figure 30-30-72] enter the recess.

Lift the cylinder block slightly and guide the three

remaining pistons in position.

6986740-EN (07-08) 30-30-23 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-75

Assembly (Cont'd)

Figure 30-30-73

1
1

P-22375

Install a new seal (Item 1) [Figure 30-30-75] onto the

P-22500
piston.

If the cylinder block (Item 1) [Figure 30-30-73] is properly Figure 30-30-76

installed, there should be very little rotational free-play
between the block and the motor shaft.

NOTE: A brass rod may be used to guide the pistons 1

into their bores.

Lubricate the pistons and cylinder block bores with

hydraulic oil.

Figure 30-30-74

P-22348

Lubricate and install the piston (Item 1) [Figure 30-30-76]

into the end cap.
2

4 P-22511

Install a new gasket (Item 1) [Figure 30-30-74] onto the

housing.

Install the valve segment (Item 2) [Figure 30-30-74] onto

the cylinder block and retain with heavy grease.

NOTE: The hole (Item 3) in the valve segment should

be opposite the minimum displacement
adjustment screw (Item 4) [Figure 30-30-74].

6986740-EN (07-08) 30-30-24 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-79

Assembly (Cont'd)
1
Figure 30-30-77

P-22381

Install the relief valve (Item 1) [Figure 30-30-79] into the

P-22349 housing and tighten to 38 ft.-lb. (52 N•m) torque.

Figure 30-30-80
NOTE: Note the position of the hole (Item 1) [Figure
30-30-77] in the end cap.

Figure 30-30-78
1

3
5 1 4
4 2

P-22378

Install a new O-ring (Item 1) [Figure 30-30-80] onto the

P-22501 plug.

Assemble the poppet (Item 1) and spring (Item 2) into the

relief valve housing (Item 3) install O-rings (Item 4) and
plug (Item 5) [Figure 30-30-78].

6986740-EN (07-08) 30-30-25 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-83

Assembly (Cont'd)

Figure 30-30-81

1
2
2
3
3 P-22380

4
Install the spring seat (Item 1), spring (Item 2) and plug
P-22377 (Item 3) [Figure 30-30-83] into the housing and tighten to
30 ft.-lb. (41 N•m) torque.

Install the spool (Item 1), spring seat (Item 2), spring (Item Figure 30-30-84
3) and plug (Item 4) [Figure 30-30-81] into the housing
and tighten to 30 ft.-lb. (41 N•m) torque.

Figure 30-30-82 2

1
1

P-22346

Align the hole in the piston (Item 1) and the valve segment
P-22378 (Item 2) [Figure 30-30-84].

Install a new O-ring (Item 1) [Figure 30-30-82] onto the

plug.

6986740-EN (07-08) 30-30-26 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-87

Assembly (Cont'd)

Figure 30-30-85

1
1

P-22339

1
1
Install a new O-ring (Item 1) [Figure 30-30-87] onto the
P-22345 plug.

Figure 30-30-88
Install the end cap housing and tighten the eight bolts
(Item 1) [Figure 30-30-85] to 85 ft.-lb. (115 N•m) torque.

Figure 30-30-86

P-22338
1
Install the plug (Item 1) [Figure 30-30-88] into the
P-22344 housing.

Install six new O-rings (Item 1) [Figure 30-30-86] onto the

housing.

6986740-EN (07-08) 30-30-27 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-91

Assembly (Cont'd)

Figure 30-30-89

1
1
2

P-22333

Install a new O-ring (Item 1) [Figure 30-30-91] onto the

P-22337 solenoid shaft.

Lightly lubricate the pin (Item 2) [Figure 30-30-91] and

Install a new O-ring (Item 1) [Figure 30-30-89] onto the install into the solenoid shaft.
adjustment screw.
Figure 30-30-92
Figure 30-30-90

1
2
3 1

P-22340
P-22336

Install a new O-ring (Item 1) and solenoid shaft assembly

Install the spool (Item 1), spring (Item 2) and adjusting (Item 2) [Figure 30-30-92] into the housing.
screw (Item 3) [Figure 30-30-90] into the housing and
tighten to 7 ft.-lb. (9 N•m) torque.

6986740-EN (07-08) 30-30-28 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-95

Assembly (Cont'd)

Figure 30-30-93

1 1

P-22327

2
Install the solenoid housing assembly (Item 1) with four
bolts (Item 2) [Figure 30-30-95]. Tighten the bolts to 58
P-22342
ft.-lb. (78 N•m) torque.

Install the solenoid housing (Item 1) onto the shaft and

install a new O-ring (Item 2) [Figure 30-30-93].

Figure 30-30-94

P-22343

Install the solenoid nut (Item 1) [Figure 30-30-94] and

hand tighten.

6986740-EN (07-08) 30-30-29 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 30-30-30 Bobcat T2250
SERVICE MANUAL
HYDROSTATIC PUMP Figure 30-40-3

Removal And Installation

Remove the engine / hydrostat assembly. (See “Removal

And Installation” on page 70-30-1.)

Figure 30-40-1
1

S6359
1

Remove the nut (Item 1) [Figure 30-40-3] from the pulley.

Figure 30-40-4

S6357

Loosen the bolt and nut (Item 1) [Figure 30-40-1].

Figure 30-40-2
1
2

S6360

Install a chain hoist and lifting strap to lift and support the
pump assembly.

S6358

Loosen the bolt (Item 1) and move the tensioner pulley

(Item 2) [Figure 30-40-2] up to loosen tension on the the
drive belt.

Remove the drive belt.

6986740-EN (07-08) 30-40-1 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT’D) Figure 30-40-7

Removal And Installation (Cont’d)

Figure 30-40-5

S6362

Figure 30-40-8
S7161

Remove the pulley (Item 1) [Figure 30-40-5] from the

pump assembly.

Figure 30-40-6
1

S6363

Remove the bolts (Item 1) [Figure 30-40-7] and [Figure

30-40-8] to separate the hydrostatic pump from the
hydraulic pump.

S6361 Assembly: Tighten the bolts to 52-59 ft.-lb. (70,8-80 N•m)

torque.

Remove the two pump assembly mounting bolts (Item 1)

[Figure 30-40-6].

Assembly: Tighten the mounting bolts to 69-78 ft.-lb. (94-

106 N•m) torque.

Remove the pump assembly.

6986740-EN (07-08) 30-40-2 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT’D)

Parts Identification

1. Multi-Function Valve Assembly

2. O-Ring
3. Plug
4. Plug
5. Nut
6. Charge Relief
7. O-Ring
8. Spring
9. Poppet
10. O-Ring
11. Control Filter Screen
12. Bolt
13. Lip Seal
14. Cover
15. O-Ring
16. Retainer Plate
17. Manifold (connections to/from filter)
18. Tube
19. Nut
5 3
3
6 10 12
1

7 4
10
8
17
9

10 2
3 16
19 13
10 14
18 15
1

10
3

S2940

6986740-EN (07-08) 30-40-3 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT’D)

Parts Identification (Cont’d)

1. Bolt 1 8
2. Bolt
3. Bolt
7
4. Solenoid 2
5. Gasket
6. Orifice Plug
7. Orifice Plug
8. Plug

6
5

S2939

6986740-EN (07-08) 30-40-4 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT’D)

Parts Identification (Cont’d)

1. Valve Plate
2. Retainer Ring
3. Spring Retainer
4. Spring
5. Spring Seat
6. Cylinder
7. Bolt
8. Slipper Guide Bearing
9. Spacer
10. Slipper Guide
11. Piston
12. Bolt 11
13. Bolt
14. Block 10
15. Spring 8 9
16. Servo Arm
17. Pin
7
18. Washer
19. Swash Plate Guide
20. Pin 6
21. Locator Link
22. Swash Plate
23. Bearing Assembly 5
24. Pin 4
25. Housing
3
2
1

25

14

17
18 20
13 24
12 21
16

15

24

23
19

22

S2936

6986740-EN (07-08) 30-40-5 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT’D)

Parts Identification (Cont’d)

1. Key
2. Charge Pump Shaft
3. Pin
4. Wear Plate
5. Gears
6. Coupling
7. Seal
8. Charge Pump Cover
9. Retaining Plate
10. Bolt
11. O-Ring 19
12. Flange Adaptor
13. Washer
14. Bolt
15. O-Ring
16. Bushing 16
17. Plug
18. O-Ring
19. Gasket
20. Charge Pump Housing 18 17

1
3 2
20

10
6
4
7
5 8
13
9

11
14
12
15

S2937

6986740-EN (07-08) 30-40-6 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT’D)

Parts Identification (Cont’d)

2
1
4
5
7 9
10
3 11
6 12
8

20
19
18

13
14

15 21
16
1. Nut 17
2. Screw
3. Servo Adjustment Cover
4. O-Ring
5. Nut
6. Nut 22
8. Snap Ring 23
9. Spring Guide
10. Spring
24
11. Spring Guide 23
12. Bolt 29 22
13. Bolt 29
14. Servo Spring Housing 30
15. Servo Cylinder 31
16. O-Ring 32
17. O-Ring 33 25
18. Bearing
19. Spacer 34
20. Snap Ring
28
26
21. Shaft 26
22. Piston Ring 35 27
23. O-Ring
24. Servo Piston
40 36
25. Block
26. O-Ring
27. Servo Cylinder/End Cap 41 37
28. Bolt
29. Guide Post 38
39
30. Spring Seat
31. Spring
32. Shim
33. Leveler
34. Inserts
35. O-Ring
36. Side Cover
37. Washer
38. Bolt
39. Nut
40. O-Ring S2938
41 Plug

6986740-EN (07-08) 30-40-7 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT’D) Figure 30-40-10

Disassembly

Clean the outside of the pump before disassembly.

Mark the outside of the pump for ease of assembly.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
S7139
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 Remove the shaft and bearing assembly from the housing
[Figure 30-40-10].
Figure 30-40-9
NOTE: If the shaft or bearing assembly become stuck
in the housing, lightly tap on the shaft.

Figure 30-40-11

2
1
1

S7138

Remove the three bolts (Item 1) [Figure 30-40-9].

S7140
Remove the retainer plate (Item 2) [Figure 30-40-9] from
the pump housing.
Remove the shaft seal (Item 1) [Figure 30-40-11] from
the shaft.

6986740-EN (07-08) 30-40-8 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-14

Disassembly (Cont'd)

Figure 30-40-12

1
1

S7143

2
Remove the relief valve lock nut (Item 1) and the plug
S7141 (Item 2) [Figure 30-40-14].

Figure 30-40-15
Remove the snap ring (Item 1) and spacer washer (Item
2) [Figure 30-40-12] from the shaft.

Figure 30-40-13

S7144

Remove the spring and relief poppet from the charge

S7142 pump housing [Figure 30-40-15].

Remove the bearing (Item 1) [Figure 30-40-13] from the

shaft.

Place the pump on the work surface with the charge pump
up.

Mark the pump housings for correct assembly.

Before removing the relief valve mark the plug, lock nut
and housing for approximate assembly adjustment.

6986740-EN (07-08) 30-40-9 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-18

Disassembly (Cont'd)

Figure 30-40-16
1

P-18584

1
Lift and remove the charge pump housing (incl. charge
S7146 pump) (Item 1) [Figure 30-40-18] from the pump housing.

Figure 30-40-19
Remove the mounting bolt (Item 1) [Figure 30-40-16].

NOTE: Remove the lifting bracket (Item 2) [Figure 30- 1

40-16] from the pump.

Figure 30-40-17 1

2
1 1
1 1
2

P-18726

Remove the six bolts (Item 1) and remove the retaining

plate (Item 2) [Figure 30-40-19] from the charge pump
housing.
P-18724

Remove the four mounting bolts (Item 1) [Figure 30-40-

17] from the flange adapter.

Remove the flange adapter (Item 2) [Figure 30-40-17].

6986740-EN (07-08) 30-40-10 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-22

Disassembly (Cont'd)

Figure 30-40-20
1

P-18728

Remove the coupler (Item 1) [Figure 30-40-22].

P-18727
Figure 30-40-23

Remove the charge pump cover (Item 1) [Figure 30-40-

20].

Figure 30-40-21 1

2
1

2 P-18729

Remove the charge pump shaft (Item 1) and key (Item 2)

[Figure 30-40-23] from the pump.
P-18558

Only if wear marks are present, remove the bushing (Item

1) from the charge pump cover (Item 2) [Figure 30-40-
21].

6986740-EN (07-08) 30-40-11 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-26

Disassembly (Cont'd)

Figure 30-40-24 1

1
2

P-18732

Remove the charge pump wear plate (Item 1) [Figure 30-

P-18730 40-26].

Remove the O-ring (Item 2) [Figure 30-40-26].

Remove the charge pump gears (Item 1) [Figure 30-40-
24]. Figure 30-40-27

Figure 30-40-25

2 1

2 1

P-18585

P-18731
Remove the swash plate leveler spring shims (Item 1)
[Figure 30-40-27] from the spring pockets.
Remove the eccentric ring (Item 1) and alignment pin
(Item 2) [Figure 30-40-25] from the pump. Inspect the journal bearing (Item 2) [Figure 30-40-27].
Replace as needed.
Note the position of the alignment pin.

6986740-EN (07-08) 30-40-12 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-30

Disassembly (Cont'd)
3 1
Figure 30-40-28

2 2 2

1 3

P-18586

Remove the gasket (Item 1) and the valve plate (Item 2)

P-18734 from the housing. Note the direction of the arrows (Item 3)
[Figure 30-40-30] on the valve plate for proper assembly.

For proper operation, if the plugs are removed from the Figure 30-40-31
housing they must be returned to their original position
[Figure 30-40-28].
1
Installation: Tighten the servo relief valve plug (Item 1) to
9 ft.-lb. (12 N•m) torque. Tighten the rotation pipe plugs
(Item 2) [Figure 30-40-28] to 4 ft.-lb. (5.4 N•m) torque.
1
Figure 30-40-29

P-18588

1
Remove the two leveler springs (Item 1) [Figure 30-40-
1 31].

P-18735

Remove the multi-function valve assemblies (Item 1)

[Figure 30-40-29] from the housing.

6986740-EN (07-08) 30-40-13 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-34

Disassembly (Cont'd)

Figure 30-40-32

1 1

1
P-18596

Mark the position of the side cover.

P-18589
Remove the six bolts (Item 1) [Figure 30-40-34] from the
side cover.
Remove both spring seats (Item 1) [Figure 30-40-32]
from the swash plate leveler. Figure 30-40-35

Figure 30-40-33

1
1

P-18597

P-18590
Remove the side cover/swash plate leveler assembly from
the housing [Figure 30-40-35].
Remove the swash plate hold down spring (Item 1)
[Figure 30-40-33].

6986740-EN (07-08) 30-40-14 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-38

Disassembly (Cont'd)
2
Figure 30-40-36

2
1

2 1

1
P-18601

1 Remove the six solenoid manifold mounting bolts (Item 1).

P-18598 Remove the manifold (Item 2) [Figure 30-40-38].

Figure 30-40-39
Remove and discard the O-ring (Item 1). Loosen and
remove both guide posts (Item 2) [Figure 30-40-36].

Figure 30-40-37
1

P-18602

Remove the gasket (Item 1) [Figure 30-40-39] from the

P-18599 manifold.

Remove the leveler (Item 1) and slide inserts (Item 2)

[Figure 30-40-37] from the side cover.

Inspect the slide inserts for wear or damage.

Replace if needed.

6986740-EN (07-08) 30-40-15 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-42

Disassembly (Cont'd)

Figure 30-40-40

1
1
1

P-18605
1

Remove and discard the three O-rings (Item 1) [Figure

P-18603 30-40-42] from the solenoid.

Figure 30-40-43
Remove the four solenoid mounting bolts (Item 1) [Figure
30-40-40].

Figure 30-40-41

P-18606

Remove the anchor pin (Item 1) [Figure 30-40-43].

P-18604

Remove the solenoids (Item 1) [Figure 30-40-41] from

the manifold.

6986740-EN (07-08) 30-40-16 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-46

Disassembly (Cont'd)

Figure 30-40-44
1

P-18610

Remove the swash plate/piston assembly (Item 1) [Figure

P-18607 30-40-46] from the pump housing.

Figure 30-40-47
Remove the cage locator link (Item 1) [Figure 30-40-44]
from the swash plate.
1
Figure 30-40-45

P-18611

Remove the four slipper guide bearing retainer bolts (Item

P-18609 1) [Figure 30-40-47].

Remove the cylinder block (Item 1) [Figure 30-40-45]

through the housing end opening. The swash plate and
piston assembly will remain in the housing.

6986740-EN (07-08) 30-40-17 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-50

Disassembly (Cont'd)

Figure 30-40-48

P-18617

Remove the bronze slider block (Item 1) [Figure 30-40-

P-18615 50] from the servo piston.

Mark the position of the servo end covers.

Remove the swash plate bearings (Item 1) [Figure 30-40-
48] from the housing. Figure 30-40-51

Figure 30-40-49

1 1

P-18777

P-18616
Remove the three bolts and remove the servo end cover.
Remove and discard both O-rings (Item 1) [Figure 30-40-
Remove the swash plate bearing races (Item 1) [Figure 51].
30-40-49] from the housing.

6986740-EN (07-08) 30-40-18 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-54

Disassembly (Cont'd)
2
Figure 30-40-52 3

1
P-18622

Remove the servo piston (Item 1) from the housing (Item

P-18778 2) [Figure 30-40-54].

Remove and discard the O-ring (Item 3) [Figure 30-40-

Remove the three bolts (Item 1) [Figure 30-40-52] and 54].
remove the servo adjustment cover.

Figure 30-40-53

P-18620

Measure and record the adjustment setting for

approximate installation adjustment [Figure 30-40-53].

6986740-EN (07-08) 30-40-19 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-57

Inspection

Figure 30-40-55 1 1

1
2

P-18628

Inspect the servo piston and seal rings (Item 1) [Figure

P-18769 30-40-57] for wear. If worn, remove the seal rings and
expander O-rings from the piston.

Clean all parts in solvent and use air pressure to dry Install new expander O-rings into the grooves in the servo
them. DO NOT use cloth or paper as small pieces of piston. Carefully install the piston seal rings over the
material can get into the system and cause damage. expander rings. Do not overstretch the piston seal rings.

Check the wear plate (Item 1) and charge pump gears Figure 30-40-58
(Item 2) [Figure 30-40-55] for damage or wear.

Figure 30-40-56 2

1 P-18622

P-18770 Lubricate the seal rings and carefully slide the servo
piston (Item 1) into the cylinder (Item 2) [Figure 30-40-
58]. Allow the assembly to set for 5 minutes to allow the
Check the valve plate [Figure 30-40-56], the surface must seal rings to return to their original size.
be smooth and free of scratches. If scratches can be felt
with a finger nail, replace the part.

6986740-EN (07-08) 30-40-20 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-61

Inspection (Cont'd)

Figure 30-40-59 1

3
2

P-18739

Servo arm (Item 1) [Figure 30-40-61] alignment is critical

P-18736 for proper pump operation. For this reason, removal of the
servo arm from the swash plate is not recommended.

Check the swash plate assembly surface, it must be If the servo arm must be removed from the swash plate.
smooth and free of scratches [Figure 30-40-59]. Remove the swash plate guide bolt (Item 2) and the servo
arm mounting bolt (Item 3) [Figure 30-40-61].
Figure 30-40-60
Installation: The servo arm (Item 1) [Figure 30-40-61]
must be carefully aligned with the slot and threaded holes
in the swash plate while installing, and must be pressed
completely into the swash plate slot.

Tighten the swash plate guide bolt and servo arm bolt to
24 ft.-lb. (32 N•m) torque.
1
Figure 30-40-62

1
P-18737

1
Inspect the swash plate guide (Item 1) [Figure 30-40-60]
for wear. Replace as needed.

1
P-18738

The threaded holes (Item 1) [Figure 30-40-62] in the

swash plate must be cleaned prior to assembly.

6986740-EN (07-08) 30-40-21 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-65

Inspection (Cont'd)

Figure 30-40-63

P-18773
S2880

1
Check the swash plate bearings (Item 1) [Figure 30-40-
P-18739 65] for wear and damage. Replace as needed.

Figure 30-40-66
Figure 30-40-64

2
1

P-18771
S2880
S2880

Check each piston (Item 1) and piston shoe (Item 2)

If the headed roll pin and flat washer (Item 1) [Figure 30- [Figure 30-40-66] for wear or scratches.
40-63] must be installed in the swash plate, the distance
between the washer and the side of the swash plate must
be .21 inch (5,33 mm) [Figure 30-40-64].

6986740-EN (07-08) 30-40-22 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-69

Inspection (Cont'd)

Figure 30-40-67
1

P-18568

Inspect the shaft seal (Item 1) [Figure 30-40-69]. Replace

P-18772 if needed.

Remove and discard the O-ring (Item 2) [Figure 30-40-

Check the cylinder block bores for wear or scratches 69].
[Figure 30-40-67].
Inspect the multi-function valve cartridge for damage to
If there is any defect in the cylinder block or pistons, the parts or O-rings.
complete rotating group must be replaced.
Figure 30-40-70
Figure 30-40-68

1
P-18741
S7145

Replace O-rings as needed [Figure 30-40-70].

Check the shaft for wear or damage in the spline and
bearing areas [Figure 30-40-68].

Check the bearing for correct operation. Remove the race

(Item 1) [Figure 30-40-68] from the shaft only if it is
necessary to replace the bearing.

6986740-EN (07-08) 30-40-23 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-72

Assembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-18755
Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or Lubricate the slipper running surface on the swash plate,
damaged parts. center the piston and guide on the swash plate [Figure
30-40-72].
Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation. Figure 30-40-73

Figure 30-40-71
1
2
1

1 2
3
P-18611

P-18754
Apply LOCTITE #242 to four NEW retainer bolts (Item 1).
Install the slipper guide bearings (Item 2) and spacers
Put the piston assemblies into the slipper guide [Figure (Item 3) [Figure 30-40-73].
30-40-71].
Tighten the four bolts to 10 ft.-lb. (13,5 N•m) torque.

NOTE: Always use NEW retainer bolts with proper

locking compound.

NOTE: The slipper guides and piston slippers must

slide freely on the swash plate.

6986740-EN (07-08) 30-40-24 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-76

Assembly (Cont'd)

Figure 30-40-74

P-18615

Assemble and lubricate the bearing cage (Item 1) [Figure

P-18756 30-40-76], and install it on the bearing races.

Figure 30-40-77
Lubricate the pistons and cylinder block bores. Install the
assembled swash plate and pistons into the cylinder block
[Figure 30-40-74].

NOTE: The pistons and bores are not selectively

fitted. 1

Figure 30-40-75

P-18757

Install the bronze slider block (Item 1) [Figure 30-40-77]

1 on the swash plate servo arm.

P-18616

Install the swash plate bearing races (Item 1) [Figure 30-

40-75] into the housing. Note the locating pins are offset
in the housing to assure proper assembly.

6986740-EN (07-08) 30-40-25 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-80

Assembly (Cont'd)

Figure 30-40-78

P-18760

Lower the cylinder block and swash plate assembly until

P-18758 the swash plate is properly located on the bearings
[Figure 30-40-80].

Carefully lower the cylinder block and swash plate Figure 30-40-81
assembly into the housing [Figure 30-40-78].

Figure 30-40-79

1
1

P-18595

P-18758 Install new O-rings (Item 1) [Figure 30-40-81] on the

servo end cap.

Holding the cylinder block and swash plate assembly Lightly lubricate the O-rings and the inner surface of the
approximately 1/2" (12 mm) above the bearings. Position end cap.
the servo piston (Item 1) on the bronze slider block (Item
2) [Figure 30-40-79]. Take care not to wedge the block,
the parts should slide freely.

6986740-EN (07-08) 30-40-26 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-84

Assembly (Cont'd)

Figure 30-40-82

P-18762

Install the servo adjustment cover over the servo piston

P-18594 until the piston adjustment screw touches the cover. Using
a hex wrench, turn the adjustment screw
counterclockwise while holding the cover until it is in
Hold the servo piston in position and install the servo end position [Figure 30-40-84].
cap [Figure 30-40-82].
NOTE: Do not install the bolts at this time.
Figure 30-40-83
Figure 30-40-85

1
1

3
1

P-18761

P-18763

Install the three end cap mounting bolts (Item 1) [Figure

30-40-83]. Tighten to 10 ft.-lb. (13,5 N•m) torque. Align the slot in the swash plate bearing cage (Item 1) with
the pin (Item 2) in the swash plate and the pin hole (Item
Lightly lubricate the O-rings and inner surface of the 3) [Figure 30-40-85] in the housing.
adjustment cover.

6986740-EN (07-08) 30-40-27 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-88

Assembly (Cont'd)

Figure 30-40-86 2

2
3

1 1
P-18765
3

Position the two side cover inserts (Item 1) and

P-18606 swashplate leveler (Item 2) on the side cover. Note the
orientation of the leveler and the notch (Item 3) [Figure
30-40-88] in the cover.
Hook the cage locator link (Item 1) over the pin (Item 2)
[Figure 30-40-86] between the swash plate and washer. Figure 30-40-89
Rotate the link into the slot in the bearing cage.

Install the anchor pin (Item 3) [Figure 30-40-86] through

the locator link and into the housing. 1

Figure 30-40-87

P-18598

Install the two guide post bolts (Item 1) [Figure 30-40-89]

through the leveler and inserts. Install the sealing nuts
and tighten to 17 ft.-lb. (23 N•m) torque.
P-18764
Install a new O-ring (Item 2) [Figure 30-40-89] on the
cover.
Push the swashplate assembly toward the servo piston
until the swash plate guide contacts the bearing races.
Check for clearance between the servo arm and the slider
block [Figure 30-40-87]. If no clearance is present,
recheck the assembly of the bearing cage and races.

6986740-EN (07-08) 30-40-28 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-92

Assembly (Cont'd)

Figure 30-40-90

P-18744

Use a depth micrometer to measure the distance from the

P-18742 end cap to the swash plate surface. Take a second
measurement at a point 90° (Item 1) [Figure 30-40-92]
from the first point of measurement. These
Lift the swash plate leveler and install the side cover measurements must not vary more than .001 inches
[Figure 30-40-90]. (0,025 mm).

Figure 30-40-91 Figure 30-40-93

1 1

P-18743 P-18745

Install the two side cover bolts (Item 1) [Figure 30-40-91] Rotate the side cover [Figure 30-40-93] (which will also
finger tight. rotate the leveler and swash plate) until the zero angle
position is established, as determined by a second depth
Apply a force of 5 - 10 ft.-lb. (22 - 44 N•m) to the swash measurement.
plate leveler to make sure both leveler arms contact the
swash plate.

Make sure the swash plate assembly is seated correctly

on the bearings.

6986740-EN (07-08) 30-40-29 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-96

Assembly (Cont'd)

Figure 30-40-94

1
1

1 1
P-18746

Install the three servo adjustment cover mounting bolts

P-18743 (Item 1) [Figure 30-40-96]. Tighten to 10 ft.-lb. (13,5 N•m)
torque.

After the zero angle position has been established, tighten Figure 30-40-97
the two side cover bolts (Item 1) [Figure 30-40-94].

Figure 30-40-95

2
2

P-18747

1 P-18596 Turn the adjustment screw on the servo, which will rotate
the swash plate assembly until a zero angle position is
established [Figure 30-40-97].
Install the four remaining side cover bolts, apply LOCTITE
#242 to the threads of the "thru" bolts (Item 1) [Figure 30-
40-95].

First tighten the four side cover bolts (Item 2) to 24 ft.-lb.

(32,5 N•m) torque. Tighten the two remaining side cover
bolts (Item 1) [Figure 30-40-95] to 18.5 ft.-lb. (25 N•m)
torque.

6986740-EN (07-08) 30-40-30 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-100

Assembly (Cont'd)

Figure 30-40-98

P-18605

Install new O-rings (Item 1) [Figure 30-40-100] on the

P-18748 solenoid spool.

Figure 30-40-101
Use a depth micrometer to measure the distance from the
end cap to the swash plate surface [Figure 30-40-98].
Take a second measurement at a point 180° from the first
point of measurement. These measurements must not
1
vary more than .001 inch (0,025 mm).

Figure 30-40-99 1

1
P-18603

Lightly lubricate both solenoid spools and install into the

manifold housing and retain with the four screws (Item 1)
1 [Figure 30-40-101].

P-18749

Without turning the servo adjustment screw, install the

sealed nut (Item 1) [Figure 30-40-99] and tighten.

6986740-EN (07-08) 30-40-31 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-104

Assembly (Cont'd)

Figure 30-40-102
1

P-18590

Install the spring (Item 1) [Figure 30-40-104] on the servo

P-18602 arm link.

Figure 30-40-105
Apply assembly lube on the gasket (Item 1) [Figure 30-
40-102] and install on the manifold housing.

Figure 30-40-103 1

P-18589
2
2
Install the spring seats (Item 1) [Figure 30-40-105] on the
P18601 leveler arms.

Install the manifold assembly (Item 1) on the pump with

the six screws (Item 2) [Figure 30-40-103].

6986740-EN (07-08) 30-40-32 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-108

Assembly (Cont'd)
1
Figure 30-40-106

1
2

P-18586

Install a new gasket (Item 1) [Figure 30-40-108] on the

P-18588 housing.

Figure 30-40-109
Install both springs (Item 1) [Figure 30-40-106] on the
leveler spring seats.

Lubricate the running surface of the cylinder (Item 2) 2

1
[Figure 30-40-106].

Figure 30-40-107

2
1

P-18585

Lubricate the charge pump journal bearing (Item 1). Install

the hardened shims (Item 2) [Figure 30-40-109] in the
1 charge pump pockets for the swash plate leveler springs.
Retain the shims with assembly lube.
P-18588
Turn the charge pump housing over.

Install the valve plate (Item 1) [Figure 30-40-107] on the

alignment pins.

NOTE: The direction of the arrow cut outs (Item 2)

[Figure 30-40-107] in the valve plate.

6986740-EN (07-08) 30-40-33 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-112

Assembly (Cont'd)

Figure 30-40-110
2 1

P-18731

Install the eccentric ring (Item 1) in the charge pump and

P-18750 align with the alignment pin (Item 2) [Figure 30-40-112].

Figure 30-40-113
Lightly lubricate the alignment pin (Item 1) [Figure 30-40-
110] and install into the charge pump housing, in the
position marked at time of disassembly. This will properly
align the wear plate and eccentric ring.
2
Install a new O-ring (Item 2) [Figure 30-40-110]. 1

Figure 30-40-111

3
1
2

P-18729

Apply assembly lube and install the charge pump gears

(Item 1), charge pump shaft (Item 2) and key (Item 3)
[Figure 30-40-113] into the pump.

P-18751

Lubricate both sides of the wear plate (Item 1) and install

in the charge pump. Align the wear plate with the
alignment pin (Item 2) [Figure 30-40-111].

6986740-EN (07-08) 30-40-34 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-116

Assembly (Cont'd)
2
Figure 30-40-114

P-18726

Install the retaining plate cover (Item 1) and six bolts (Item
P-18728 2) [Figure 30-40-116]. Tighten the bolts to 10 ft.-lb. (13,5
N•m) torque.

Install the coupler (Item 1) [Figure 30-40-114]. Figure 30-40-117

Figure 30-40-115

P-18752

P-18727
Lower the charge pump onto the pump housing while
positioning the three springs in their pockets [Figure 30-
Install the charge pump cover (Item 1) [Figure 30-40- 40-117].
115].
When properly installed, the charge pump will engage the
Rotate until the pin hole in the cover aligns with the pin. alignment pins, but the springs will hold the charge pump
housing 1/8 to 1/4 (3 to 8 mm) away from the pump
housing.

6986740-EN (07-08) 30-40-35 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-120

Assembly (Cont'd)

Figure 30-40-118

1
2 2
2 2

S7144

Install the spring and relief poppet into the charge pump
P-18724 [Figure 30-40-120].

Figure 30-40-121
Install the flange adapter (Item 1) and four bolts (Item 2)
[Figure 30-40-118]. Tighten the bolts to 90 ft.-lb.
(122 N•m) torque.

Figure 30-40-119

2 1

S7143

1 Install the plug with lock nut (Item 1) [Figure 30-40-121],

align the marks made at disassembly. Tighten the lock nut
S7146 to 38 ft.-lb. (52 N•m) torque.

Install the mounting bolt (Item 1) [Figure 30-40-119] and

tighten to 28 ft.-lb. (38 N•m) torque.

NOTE: Install the lifting bracket (Item 2) [Figure 30-40-

119].

6986740-EN (07-08) 30-40-36 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D) Figure 30-40-124

Assembly (Cont'd)

Figure 30-40-122

1 1

S7147

Install the shaft and bearing assembly, aligning the shaft

P-18753 spline with the cylinder block spline. Continue to lower the
shaft and align with the charge pump journal bearing and
charge pump coupler [Figure 30-40-124].
Lightly lubricate and install both multi-function valve
assemblies (Item 1) [Figure 30-40-122] in the charge Figure 30-40-125
pump. Tighten to 66 ft.-lb. (89 N•m) torque.

Figure 30-40-123

S7148
2

S7141 Install a new O-ring (Item 1) [Figure 30-40-125].

Lubricate the seal with assembly lube and install the seal
Install the bearing (Item 1), the spacer washer (Item 2) assembly on the drive shaft and in the housing.
and the snap ring (Item 3) [Figure 30-40-123] on the drive
shaft.

Position the pump on the charge pump end.

6986740-EN (07-08) 30-40-37 Bobcat T2250

SERVICE MANUAL
HYDROSTATIC PUMP (CONT'D)

Assembly (Cont'd)

Figure 30-40-126

2
2

S7149

Install the retainer plate (Item 1) and three bolts (Item 2)

[Figure 30-40-126]. Tighten the bolts in a sequenced
pattern to 12 ft.-lb. (16 N•m) torque.

6986740-EN (07-08) 30-40-38 Bobcat T2250

SERVICE MANUAL
DRIVE BELT Shield Removal And Installation

Description Stop the engine.

The drive belt connects the engine to the hydrostatic Figure 30-50-1
pumps. The drive belt is tightened by a spring tensioner
and is covered by a shield to protect operator.

The drive belt is located on the flywheel side of the

engine.

S7204

Rotate the battery disconnect switch (Item 1) [Figure 30-

50-1] to the right, to disconnect the power supply from the
battery.

Open the engine cover. (See “Opening And Closing The

Engine Cover” on page 10-160-1)

Figure 30-50-2

2
1

S2933

Remove the cover (Item 1) [Figure 30-50-2] at the rear of

the engine compartment.

Remove the three belt shield holddown clips (Item 2)

[Figure 30-50-2].

Remove the belt shield (Item 3) [Figure 30-50-2] from the

drive belt housing.

6986740-EN (07-08) 30-50-1 Bobcat T2250

SERVICE MANUAL
DRIVE BELT (CONT’D) Figure 30-50-4

Adjusting 2

Figure 30-50-3
1

S2934

S2932
3

Loosen the bolt (Item 1) [Figure 30-50-3] on the spring

loaded tensioner.

S2935

Loosen the lock nut (Item 1) [Figure 30-50-4].

Adjust drive belt tension by tightening the bolt (Item 2)

until the idler indicator (pointer) (Item 3) [Figure 30-50-4]
is at twelve o’clock position.

When belt tension is correct, tighten the lock nut (Item 1)

[Figure 30-50-4].

6986740-EN (07-08) 30-50-2 Bobcat T2250

SERVICE MANUAL
DRIVE BELT (CONT’D) Belt Removal And Installation

Adjusting (Cont’d) Remove the belt shield (See Shield Removal And
Installation on Page 30-50-1.)
Figure 30-50-5
Figure 30-50-7

1
1

S2932

S2932

Tighten the mounting bolt (Item 1) [Figure 30-50-5] to 81

ft.-lb. (110 N•m) torque. Loosen the bolt (Item 1) [Figure 30-50-3] on the spring
loaded tensioner.
Figure 30-50-6
Figure 30-50-8

1 1
2

S2933

S7114

Reinstall the drive belt cover (Item 1) and the cover

(Item 2) [Figure 30-50-6] at the rear of the engine Loosen the lock nut (Item 1) [Figure 30-50-8].
compartment
Release belt tension by fully loosening the bolt (Item 2)
Turn battery disconnect switch to the ON position. [Figure 30-50-8].

Remove the drive belt from the pump pulley and flywheel.

Remove the drive belt.

6986740-EN (07-08) 30-50-3 Bobcat T2250

SERVICE MANUAL
DRIVE BELT (CONT’D) Figure 30-50-11

Tensioner Pulley Removal And Installation

2
Stop the engine.
1
Figure 30-50-9

S7114

1
Loosen the lock nut (Item 1) and fully loosen the bolt
(Item 2) [Figure 30-50-11]

S7204 Figure 30-50-12

Rotate the battery disconnect switch (Item 1) [Figure 30-

50-9] to the right, to disconnect the power supply from the
battery.

Open the engine cover. (See “Opening And Closing The

Engine Cover” on page 10-160-1)

Figure 30-50-10 1

2
3
S2932

2
1
Loosen the bolt (Item 1) [Figure 30-50-12] on the spring
loaded tensioner.

Remove the drive belt (Item 2) [Figure 30-50-12].

S2933

Remove the cover (Item 1) [Figure 30-50-10] at the rear

of the engine compartment.

Remove the three belt shield holddown clips (Item 2)

[Figure 30-50-10].

Remove the belt shield (Item 3) [Figure 30-50-10] from

the drive belt housing.

6986740-EN (07-08) 30-50-4 Bobcat T2250

SERVICE MANUAL
DRIVE BELT (CONT’D) Figure 30-50-15

Tensioner Pulley Removal And Installation (Cont’d)

Figure 30-50-13

1 1
1

1 1
2 S7341

Remove the four engine mount bolts through the four

S2932 openings (Item 1) [Figure 30-50-15] in the bottom side of
the engine/hydrostat assembly.

Remove the seven bolts (Item 1) from the flywheel The engine can now be slightly shifted to create the extra
(Item 2) [Figure 30-50-13]. space which is needed to remove the tensioner pulley.

Remove the flywheel from its flange, but leave it in the Figure 30-50-16
engine compartment.

Figure 30-50-14

1
1

S2932

S2932 Remove the tensioner pulley assembly (Item 1) [Figure

30-50-16].

Remove the bolt and washer (Item 1) [Figure 30-50-14] Installation: After re-installation of the tensioner pulley,
from the tensioner pulley assembly. flywheel and belt, perform the belt tension adjusting
procedure. (See Adjusting on Page 30-50-2.)

6986740-EN (07-08) 30-50-5 Bobcat T2250

SERVICE MANUAL
DRIVE BELT (CONT’D)

Tensioner Pulley Parts Identification

1. Cover
2. Bolt
3. Washer 1
4. Pins
5. Washer
6. Spring
2
7. Snap Ring
8. Snap Ring
9. Bearing
10. Dust Shield 11
11. Pulley 3
12. Bushing
13. Hub 12
4
14. Washer
15. Seal
16. Arrow Indicator Plate 5
17. Spring
18. Shaft
19. Bracket 6 13

NOTE: Belt tensioner parts are not all 5 14

available individually. Consult
parts catalog for available 15
sub-assemblies. 7

8 16

17
10

18

19

S7151

6986740-EN (07-08) 30-50-6 Bobcat T2250

SERVICE MANUAL
DRIVE BELT (CONT’D) Figure 30-50-19

Tensioner Pulley Disassembly And Assembly

Figure 30-50-17

1
S7117

Remove the retainer washer (Item 1) [Figure 30-50-19].

S7115
Figure 30-50-20

Remove the dust cap (Item 1) [Figure 30-50-17] from the

pulley.

Figure 30-50-18
1

1
S7118

Remove the spring washer (Item 1) [Figure 30-50-20].

S7116

Remove the bolt (Item 1) and washer (Item 2) [Figure 30-

50-18].

6986740-EN (07-08) 30-50-7 Bobcat T2250

SERVICE MANUAL
DRIVE BELT (CONT’D) Figure 30-50-23

Tensioner Pulley Disassembly And Assembly (Cont’d)

Figure 30-50-21

1
S7121

Lift the pulley from the hub (Item 1) [Figure 30-50-23].

S7119
Figure 30-50-24

Remove the retainer washer (Item 1) [Figure 30-50-21].

3
Figure 30-50-22

2 1

2
S7122

2
Lift and remove the hub (Item 1) from the bracket (Item 2)
S7120
while tapping on the shaft (Item 3) [Figure 30-50-24] with
a plastic hammer.

Remove the snap ring (Item 1) [Figure 30-50-22].

NOTE: Remove the two pins (Item 2) [Figure 30-50-22]

from the hub assembly only if they have been
damaged.

6986740-EN (07-08) 30-50-8 Bobcat T2250

SERVICE MANUAL
DRIVE BELT (CONT’D) Figure 30-50-27

Tensioner Pulley Disassembly And Assembly (Cont’d)

2
Figure 30-50-25

1 1
S7127

Assembly: Install the spring (Item 1) on the hub (Item 2)

S7126 [Figure 30-50-27] as shown.
Figure 30-50-28
Remove the arrow indicator plate (Item 1) [Figure 30-50-
25].
3
Figure 30-50-26
2

1
1

S7128

2
Assembly: Install the hub and spring on the bracket and
S7123 align the spring (Item 1) [Figure 30-50-28] over the
alignment pin on the bracket.

Remove the spring (Item 1) from the bracket (Item 2) Assembly: Rotate the hub until it snaps into place. The
[Figure 30-50-26]. pin (Item 2) must be positioned in the bracket cutaway
(Item 3) [Figure 30-50-28] as shown.

6986740-EN (07-08) 30-50-9 Bobcat T2250

SERVICE MANUAL
DRIVE BELT (CONT’D) Figure 30-50-31

Tensioner Pulley Disassembly And Assembly (Cont’d)

Figure 30-50-29 1

S7129

2
Remove the snap ring (Item 1) [Figure 30-50-31] from the
S7124 pulley.

Figure 30-50-32
If needed, replace the copper bushing (Item 1) from the
hub (Item 2) [Figure 30-50-29].

Figure 30-50-30

1
S7130

Turn the pulley upside down and replace the bearing

S7125 (Item 1) [Figure 30-50-32] from the pulley.

Remove the seal (Item 1) [Figure 30-50-30] from the hub.

6986740-EN (07-08) 30-50-10 Bobcat T2250

SERVICE MANUAL
 DRIVE SYSTEM

AXLE AND DIFFERENTIAL (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Axle Housing / Drive Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . 40-20-12
Brake Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-36
Brake Group Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-15
Brake Group Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Differential Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-33
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-21
Differential Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-20
Pinion Group Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-24
Pinion Group Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-25
Pinion Group Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-27
Planetary Carrier And Wheel Hub Parts Identification . . . . . . . . . . . . 40-20-1
Planetary Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-50
Planetary Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
DRIVE
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-53
Steering Knuckle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-43 SYSTEM
Steering Knuckle And Drive Shaft Parts Identification . . . . . . . . . . . . 40-20-7
Steering Knuckle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-8
Wheel Hub Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-4

AXLE AND DIFFERENTIAL (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1

Axle Housing / Drive Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . 40-21-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
Differential Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-33
Differential Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-15
Pinion Group Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-25
Pinion Group Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-21
Pinion Group Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-20
Planetary Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-43
Planetary Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-2
Planetary Carrier And Wheel Hub Parts Identification . . . . . . . . . . . . 40-21-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-48
Steering Knuckle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-37
Steering Knuckle and Drive Shaft Parts Identification. . . . . . . . . . . . . 40-21-7
Steering Knuckle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-8
Wheel Hub Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-4

AXLE TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

DRIVESHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1

FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

Continued On Next Page

6986740-EN (07-08) 40-01 Bobcat T2250

SERVICE MANUAL
 DRIVE SYSTEM (CONT’D)

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

Engaging The Brake Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-2
Releasing The Brake Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-4
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1

SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

Bleeding The Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

STEERING ANGLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1

6986740-EN (07-08) 40-02 Bobcat T2250

SERVICE MANUAL
TROUBLESHOOTING

Chart

The following Troubleshooting Chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.

PROBLEM CAUSE
Pinion or Ring gear tooth broken 1, 2, 3, 4, 5, 6
Pinion teeth pitted 5, 11
Axle housing bent 12, 13
Worn or pitted bearings 3, 5, 6, 11, 14
Oil leakage 6, 9, 14
Excessive wear on input shaft splines 3, 16, 17, 19
Pinion teeth fatigue 7, 12, 17, 19
Side gear spline worn 17, 19
Thrust washer surface worn 5, 6, 7
Inner diameter of tapered roller bearing worn 5, 6, 18, 19
Bent or broken half shaft 19
Half shaft broken at wheel side 20, 21

KEY TO CORRECT THE CAUSE

1. Excessive gear load
2. Incorrect gear adjustment (excessive play)
3. Pinion nut loose
4. Incorrect gear adjustment (insufficient play)
5. Insufficient lubrication
6. Contaminated oil
7. Incorrect lubrication
8. Worn bearings
9. Operation at high temperature
10. Low oil level
11. Excessive use
12. Overloaded
13. Accident
14. Normal Wear
15. Lip seal damaged
16. Pinion axle play
17. Continuous overload
18. Excessive pinion axle play
19. Vehicle intensively operated or overloaded
20. Wheel loose
21. Beam housing bent

6986740-EN (07-08) 40-10-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 40-10-2 Bobcat T2250
SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT)

Description

For photo clarity, the following axle procedures are done Drive motor removal. See “Removal And Installation” on
with the complete axle assembly removed from the page -30-30-1.
machine, although the planetary carrier, wheel hub,
steering knuckle and drive shaft procedures may be done Drive box removal. See “Disassembly” on page -20-71-2.
with the axle assembly installed in the machine. For
complete axle repair, the following must be done. Steering cylinder removal. See “Removing the Steering
Cylinder” on page -61-1
Front axle removal. See “Removal” on page -30-1.

Planetary Carrier And Wheel Hub Parts Identification

1. Seal
2. Bearing
3. Wheel stud
4. Wheel hub
5. Nut
6. O-ring
7. Bearing
8. Snap ring
9. Ring gear
10. Ring gear support

11. Locking plate

12. Thrust washer
13. Snap ring
14. Snap ring
15. Planet gear
16. Bearing
17. Planet gear carrier
18. O-ring
19. Plug
20. Countersunk bolt
21. Planet gear carrier
22. Stud
23. Nut
24. Ring Gear Support
S2190

6986740-EN (07-08) 40-20-1 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-2

Planetary Carrier Disassembly 1

1

Clean the outside of the planetary carrier before

disassembly.

Mark the outside of the planetary carrier for ease of

assembly. 1

1
IMPORTANT
S2190
When repairing hydrostatic and hydraulic systems, S2190
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly Remove the two screws (Item 1) [Figure 40-20-2] from
damage the system. the planetary carrier.
I-2003-0888
Figure 40-20-3
Figure 40-20-1
2

S2191

S5320
Remove the planetary gear carrier (Item 1) from the wheel
hub (Item 2) [Figure 40-20-3] by alternately forcing a
With the drain plug (Item 1) [Figure 40-20-1] in the
screwdriver into the appropriate slots.
position shown, place a drain pan under the hub and
remove the plug.

6986740-EN (07-08) 40-20-2 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-6

Planetary Carrier Disassembly (Cont'd)

Figure 40-20-4

1
1

1
1

S2194

With the help of a puller, remove the planet wheel gears

S2192
(Item 1) [Figure 40-20-6].

NOTE: Note the assembly side of the planetary gears.

Remove the securing bolts and the complete planet gear
carrier (Item 1) [Figure 40-20-4]. Figure 40-20-7

Figure 40-20-5

S2195 / S2196

S5194
NOTE: Note down the direction of assembly of planet
wheel gears [Figure 40-20-7].
Remove the snap ring (Item 1) [Figure 40-20-5] from the
planetary carrier.

6986740-EN (07-08) 40-20-3 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-10

Wheel Hub Disassembly

Figure 40-20-8

1 1

S5291

Remove the thrust washer (Item 1) [Figure 40-20-10].

S5290
Figure 40-20-11

Remove the snap ring (Item 1) [Figure 40-20-8].

Figure 40-20-9

1 1
2

S5292

Remove the plate (Item 1) [Figure 40-20-11].

S2198X

Remove the eight nuts (Item 1) from the ring gear (Item 2)
[Figure 40-20-9].

6986740-EN (07-08) 40-20-4 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-14

Wheel Hub Disassembly (Cont'd)

Figure 40-20-12
1

S2203X

Remove the bearing (Item 1) [Figure 40-20-14].

S5293
Figure 40-20-15

Remove the ring gear from the shaft [Figure 40-20-12].

1
Figure 40-20-13

S2204X

Remove the complete wheel hub (Item 1) [Figure 40-20-

S5321
15] by hand.

NOTE: Use care while removing, as the assembly may

Loosen the hub with a plastic hammer [Figure 40-20-13]. come off easily.

NOTE: Alternately hammer on several equidistant

points.

6986740-EN (07-08) 40-20-5 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D)

Wheel Hub Disassembly (Cont'd)

Figure 40-20-16

S5325 S5325

Remove the seals from the hub [Figure 40-20-16].

NOTE: Hammer in an alternate sequence to prevent

crawling and deformation of the bearing races.

Figure 40-20-17

S2207

Remove the sealing ring from the steering knuckle (Item

1) [Figure 40-20-17] from the ring gear assembly.

6986740-EN (07-08) 40-20-6 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D)

Steering Knuckle And Drive Shaft Parts Identification

19. Nut
20. Bolt
21. Steering adjust bolt
22. Articulated tie rod
23. Ring
24. Cylinder
25. Cylinder bolt
26. Bolt
27. Electronic sensor
28. O-ring
29. Pivot

1. Thrust bushing
2. Seal
3. Joint
4. Nut
5. Washer
6. Stud
7. Cap
8. Grease fitting
9. Cap
10. Shim
11. Seal
12. Bushing
13. Steering knuckle
14. Steering knuckle
15. Articulation
16. Bolt
17. Cap
18. Pivot pin

S1389

6986740-EN (07-08) 40-20-7 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-20

Steering Knuckle Disassembly

Clean the outside of the steering knuckle before 1

disassembly.

Mark the outside of the steering knuckle for ease of

assembly.

Figure 40-20-18

S5197
1

Remove the tapered end of the tie rod (Item 1) [Figure

40-20-20] from the steering knuckle.

NOTE: Be careful as the bolt may come out with great

force.

Figure 40-20-21
S2208

Measure and note the protrusion of the screw (Item 1) for

reassembly [Figure 40-20-18] before removing the screw.

Figure 40-20-19

S5196

1 Remove six screws from the bottom pivot (Item 1) [Figure

40-20-21].

Remove the pivot (Item 1) [Figure 40-20-21].

S2210

NOTE: Screws can not be re-used.

Remove the steering cylinder nut (Item 1) [Figure 40-20-
19].

6986740-EN (07-08) 40-20-8 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-24

Steering Knuckle Disassembly (Cont'd)

Figure 40-20-22
1
2

3
S2428A

Using two levers, remove the top pivot pin (Item 1)

S5300 complete with front seal (Item 2) and shims (Item 3)
[Figure 40-20-24].

Remove the seal from the bottom pivot (Item 1) [Figure Figure 40-20-25
40-20-22].

Figure 40-20-23
2

1
3
2

S1393

S5291 Configuration of the upper (Item 1) pivot pin with shims

(Item 2) and the lower pivot pin (Item 3) [Figure 40-20-
25].
Remove the four screws (Item 1) [Figure 40-20-23] from
the upper pivot.

6986740-EN (07-08) 40-20-9 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-28

Steering Knuckle Disassembly (Cont'd)

Figure 40-20-26
1

S2212

Remove the bushing from the steering knuckle (Item 1)

S2431 [Figure 40-20-28].

NOTE: Note down the orientation of bushing.

Remove the steering knuckle (Item 1) [Figure 40-20-26]
from the axle. Figure 40-20-29

Figure 40-20-27

S2214 / S2215

S5327
Using a puller for inner parts, remove the top bush
(Item 1) and the bottom ball-bush (Item 2) [Figure 40-20-
Use a puller to remove the seal from the steering knuckle 29].
(Item 1) [Figure 40-20-27].

Installation: Use special tool (Bobcat part number

6912178) to install the seal.

6986740-EN (07-08) 40-20-10 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D)

Steering Knuckle Disassembly (Cont’d)

Figure 40-20-30

S2216

Remove the pivot pins (Item 1) and the front sealing rings
(Item 2) [Figure 40-20-30].

NOTE: Note down the side for assembly

Figure 40-20-31

S2217

If the ball cover (Item 1) [Figure 40-20-31] needs

replacing, remove it from the bottom pivot pin.

6986740-EN (07-08) 40-20-11 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-34

Axle Housing / Drive Shaft Disassembly

Clean the outside of the axle housing before disassembly.

Mark the outside of the axle housing for ease of assembly.

Figure 40-20-32 1

P-23016

Remove the two snap rings (Item 1) [Figure 40-20-34]

across from each other.

Figure 40-20-35

P-22855

Remove the drive shaft from the axle housing [Figure 40-
20-32].

Figure 40-20-33

P-23017

Drive the upper bearing cup down to push the opposite

bearing cup partially through the yoke [Figure 40-20-35].

NOTE: The bottom bearing cup will not be completely

removed.
S2218

Remove seal ring (Item 1) [Figure 40-20-33] and the

bushing from the arm.

NOTE: Note down the side for assembly

Check the position of the anti-extrusion and O-rings.

6986740-EN (07-08) 40-20-12 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-38

Axle Housing / Drive Shaft Disassembly (Cont'd)

Figure 40-20-36

2
P-23019

Turn the shaft over and remove the bearing cup (Item 1).
P-23021 Remove the drive shaft (Item 2) [Figure 40-20-38] from
the yoke.
Turn the shaft over and remove the bearing cup (Item 1) Figure 40-20-39
[Figure 40-20-36].

Figure 40-20-37

1 1

P-23022

P-23020 Remove the two snap rings (Item 1) [Figure 40-20-39]

from the yoke.

Drive the cross (Item 1) [Figure 40-20-37] down to push

the opposite bearing cup through the yoke.

NOTE: The drive shaft end (Item 2) [Figure 40-20-37]

may fall out of the yoke.

6986740-EN (07-08) 40-20-13 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-42

Axle Housing / Drive Shaft Disassembly (Cont'd)

Figure 40-20-40

P-23025

Press the second bearing cup through the yoke [Figure

P-23023 40-20-42].

Figure 40-20-43
Using two different size sockets and a vice, and press one
bearing cup into the yoke while pushing the opposite
bearing cup through the yoke [Figure 40-20-40].

Figure 40-20-41

P-23026

Remove the bearing cup (Item 1) and cross (Item 2)

[Figure 40-20-43] from the yoke.
P-23024

Remove the bearing cup (Item 1) [Figure 40-20-41].

6986740-EN (07-08) 40-20-14 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D)

Brake Group Parts Identification

Picture to be updated. 1

8
3 6
7
17
9
10 2

1. Friction Plates 4
2. Separator Plates 5

3. Coupler 8
4. Bolt
5. Service Brake Piston 11
6. Spring 12
13
7. Bolt
8. O-Ring
9. Bolt 14
8
10. Pin
11. Pin
12. Parking Brake Piston
13. Belleville Springs
14. Slotted Nut
15. Bolt
16. U-shaped Stop Washer 16
15
17. Cap S5319

6986740-EN (07-08) 40-20-15 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-46

Brake Group Disassembly

Figure 40-20-44

S2380
2
1
Connect an external pump to the park brake port (Item 1)
S2220 / S2163 [Figure 40-20-46] of the negative brake and introduce a
pressure of 218 - 435 ft-lb. (15-30 bar) in order to
compress the Belleville springs.
Loosen the unlocking screws (Item 1) and remove the two
U-shaped stop washers (Item 2) [Figure 40-20-44]. Figure 40-20-47

Figure 40-20-45

S1429
S2220 / S2222

S2164
Insert block screws to end stroke and release pression.

P1 = Park brake port. Release pressure 15-30 bar. If the screws are to be replaced, mark down the different
P2 = service brake port. colors for the different brake gaps.
P3 = Hydraulic diff. lock port.
Working pressure 217,5 - 362,5 ft-lb. (15-25 bar).

B1 = Park brake bleeding screw.

B2 = Service brake bleeding screw.

6986740-EN (07-08) 40-20-16 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-50

Brake Group Disassembly (Cont'd)

Figure 40-20-48
1

S5174

Remove the first friction plate (Item 1) [Figure 40-20-50].

S5363
Remove the remaining plates and the flange (Item 2)
[Figure 40-20-50]. Do not mix up the sequence.
Remove the 16 axle housing mounting bolts (Item 1)
[Figure 40-20-48]. Figure 40-20-51

Remove the axle housing.

2
Clean the outside of the brake group before disassembly.

Mark the outside of the brake group for ease of assembly. 3

Figure 40-20-49 1

1
1
2
S5175

Install two screws (Item 1) [Figure 40-20-51] in order to

compress the belleville springs of the negative brake
preloaded.

Remove the 2 unlocking screws (Item 2) [Figure 40-20-

S5173 51] from the brake housing.

Remove the piston (Item 3) [Figure 40-20-51].

Remove the first brake separator plate (Item 1) [Figure
40-20-49] from the brake housing.

NOTE: For friction plate replacement only it is not

necessary to remove the brake housing.

6986740-EN (07-08) 40-20-17 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-54

Brake Group Disassembly (Cont'd)

Figure 40-20-52

S5180

Turn the module upside down again and remove the three
1 pins (Item 1) [Figure 40-20-54].
S5176

Figure 40-20-55
Turn the brake module upside down and use a pin driver
to remove the locking pin (Item 1) from the slotted nut
1
(Item 2) [Figure 40-20-52].

Mark the position of the slotted nut for reassembly.

Figure 40-20-53

S5181

1
Use a new screw (Item 1) to remove the three caps (Item
2) [Figure 40-20-55].

S5177

Put the brake module under a press to compress the

belleville springs [Figure 40-20-53] and remove the
slotted nut.

Carefully release the pressure and remove the brake

housing from the press. Remove the belleville springs
(Item 1) [Figure 40-20-53].

6986740-EN (07-08) 40-20-18 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-58

Brake Group Disassembly (Cont'd)

Figure 40-20-56
2

1
1

S5179
1

Turn the brake module upside down and carefully apply

S5294 air pressure to the upper hole (Item 1) to remove the
S5295
service brake piston (Item 2) [Figure 40-20-58].

Remove the three spring mounted bolts (Item 1) [Figure Figure 40-20-59
40-20-56].

Note: Be careful. The bolts are under spring pressure.

Figure 40-20-57 2

S5178

Remove the parking brake piston (Item 1) [Figure 40-20-

57] from the brake module by carefully applying air
pressure to the upper side hole.
S2891
Put the oil into a container. S2892

Remove the O-Rings and anti extrusion rings from the

service brake, parking brake and piston housing [Figure
40-20-59].

6986740-EN (07-08) 40-20-19 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D)

Differential Parts Identification

10 1
9 3 2
11
6

4
5
7 6
8
5

4
1. Washer
12
2. Gear
3. Spindle
9
4. Friction washer 3 6
10
5. Gear (pinion) 2
6. Pin
1
7. Spindle Retainer
8. Spindle
9. Bearing
10. Shim
11. Ring Gear
12. Housing

S5317

6986740-EN (07-08) 40-20-20 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-62

Differential Disassembly

Clean the outside of the differential before disassembly.

Mark the outside of the differential for ease of assembly.

Remove the differential assembly from the axle housing.

Figure 40-20-60
1

S5308

1 Turn the differential around and remove the top gear (Item
1) [Figure 40-20-63].

Figure 40-20-63

S5306

If the bearing needs replacing, extract it with a puller (Item

1) [Figure 40-20-60].

Figure 40-20-61

S5309

1 Use a pin driver to remove the three pins (Item 1) [Figure

40-20-63].

3
S5330

Remove the bearing (Item 1) [Figure 40-20-61].

Remove the 12 bolts (Item 2) [Figure 40-20-61].

Remove the ring gear (Item 3) [Figure 40-20-61].

6986740-EN (07-08) 40-20-21 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-66

Differential Disassembly (Cont'd)

Figure 40-20-64

S5312

1
Remove the short spindles (Item 1) [Figure 40-20-66].
S5310
Figure 40-20-67

Push the two opposite mounted short pins to the outside

(Item 1) [Figure 40-20-64].

Figure 40-20-65

1 S5314

Lift the retainer (Item 1) [Figure 40-20-67]. Remove the

washers and the gears.
S5311

Remove the long spindle (Item 1) [Figure 40-20-65] .

Remove the washers and satellite gears.

6986740-EN (07-08) 40-20-22 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D)

Differential Disassembly (Cont'd)

Figure 40-20-68

S5312

Lift the gear (Item 1) [Figure 40-20-68]. Remove the shim

washer below.

6986740-EN (07-08) 40-20-23 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D)

Pinion Group Parts Identification

1. Bevel pinion
2. Bearing
3. Shim “S1”
4. Spacer
5. Shim “S2”
6. Bearing
7. Bolt

S2503

6986740-EN (07-08) 40-20-24 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-71

Pinion Group Disassembly

Clean the outside of the pinion group before disassembly.

Figure 40-20-69

S5312

Pull the internal bearing from the pinion if necessary

[Figure 40-20-71].

S5298
Figure 40-20-72

Use the pinion ring nut (Bobcat part number 6912173) to

remove the nut [Figure 40-20-69].

Figure 40-20-70

S5312

Remove the bearing race of the external bearing [Figure

40-20-72].

S5299

Remove the pinion, the shims and the spacer [Figure 40-
20-70].

6986740-EN (07-08) 40-20-25 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D)

Pinion Group Disassembly (Cont'd)

Figure 40-20-73

S5304

Insert a drift in the appropriate holes [Figure 40-20-73].

Figure 40-20-74

P-25691

Remove the bearing race (Item 1) of the internal bearing

as well as the shim washer(s) (Item 2) [Figure 40-20-74].

6986740-EN (07-08) 40-20-26 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D)

Pinion Group Assembly

Figure 40-20-75

S2919

6986740-EN (07-08) 40-20-27 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-77

Pinion Group Assembly (Cont'd)

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts if necessary.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

D 1
IMPORTANT
S5335
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all Measure the inner bearing (Item 1), complete with bearing
parts clean. Always use caps and plugs on hoses, race, under comparator “DG” [Figure 40-20-77]. Press
tubelines and ports to keep dirt out. Dirt can quickly the bearing race centrally and carry out several
damage the system. measurements by rotating the bearing race. The
I-2003-0888
measurement is called D.

Figure 40-20-76 EXAMPLE: 30 - 0,55 = 29,45 = “D”.

Figure 40-20-78

1 2

S5312

S5337 S5338
Using a faceplate, reset a centesimal comparator “DG” on
a calibrated block (whose known thickness is 30mm).
Preload the comparator by about 3 mm [Figure 40-20- Check nominal dimension “INT” as marked on the pinion
76]. (Item 1) (eg 98). Add or subtract the variation indicated on
the pinion (Item 2) [Figure 40-20-78] to “INT” to obtain the
actual centre distance “I”.

I=INT±Y.

6986740-EN (07-08) 40-20-28 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-81

Pinion Group Assembly (Cont'd)

Figure 40-20-79

S5344

Insert the bearing race of the bearings and shims using a

driver (Item 1) [Figure 40-20-81].
S5340

Figure 40-20-82
Calculate the shim “S1” [Figure 40-20-79] for insertion
under the bearing race of the inner bearing using the
following formula:

S1 = X - (I + D) where X= 5.04” (128 mm) (a fixed

dimension, see [Figure 40-20-79]). I is the actual pinion
center distance (as determined above). D is the total
bearing thickness (as determined above).

Figure 40-20-80
1 1
2 2

1
1 2
2

S5342

Make sure the bearing race has been completely inserted

into its seat [Figure 40-20-80]. S5347
S2304

Insert tool the dummy pinion (Item 1) (Bobcat part number

6912176) complete with bearings (Item 2) [Figure 40-20-
82].

6986740-EN (07-08) 40-20-29 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-84

Pinion Group Assembly (Cont'd)

Figure 40-20-83
1

S5340

Remove the dummy pinion (Item 1) [Figure 40-20-84],

remove the bearings, and re-arrange the bearings, with
the tool shim and the largest calibrated shim in between.
Put the dummy pinion on top. Use the depth comparator
to measure the depth “B” in either side hole of the dummy
pinion.

Figure 40-20-85

1 S5340
S2177

Use a depth comparator “DDG” into either side hole of the

dummy pinion (Item 1) [Figure 40-20-83]. Reset the
comparator with a preload of about 3 mm.
S5350
Measure value A.

Calculate the shim S2 to be inserted:

Calculate H = A - B. S2 = H + Q where Q is fixed value to

obtain = 0.07...0.08 mm [Figure 40-20-85].

6986740-EN (07-08) 40-20-30 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-88

Pinion Group Assembly (Cont'd)

Figure 40-20-86

S5354

Heat the external bearing to 100°C and fit it on the pinion

S5351 [Figure 40-20-88].

Figure 40-20-89
Heat the bearing to 100°C and assemble it to the pinion
shaft [Figure 40-20-86].

Figure 40-20-87

S5356

2
Apply Loctite 270 to the thread of the nut and screw the
S5353 nut onto the pinion [Figure 40-20-89].

Fit the pinion and bearing assembly (Item 1), the

spacer (Item 2) and shim S2 (Item 3) [Figure 40-20-87].

6986740-EN (07-08) 40-20-31 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D)

Pinion Group Assembly (Cont'd)

Figure 40-20-90

S5355

Use the pinion ring nut (Bobcat part number 6912173) to

tighten the nut. Use a torque wrench set to 500 - 700 N•m.
If the torque exceeds the maximum value, the size of shim
S1 needs to be increased. If the value does not reach the
set value, the shim S1 needs to be reduced [Figure 40-
20-90].

6986740-EN (07-08) 40-20-32 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-93

Differential Assembly

Figure 40-20-91

1 2

2 S2895

Partially install a washer (Item 1), a gear (Item 2) and the

S2893
long spindle (Item 3) [Figure 40-20-93] in the housing.

Figure 40-20-94
Lubricate and install the shim washer and pinion gear
(Item 1) [Figure 40-20-91].

Figure 40-20-92

1 S2896
1
2
Insert the two short spindles (Item 1) [Figure 40-20-94],
S2894 washers and gears.

Lubricate the four washers and four gears (Item 1)

[Figure 40-20-92].

6986740-EN (07-08) 40-20-33 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-97

Differential Assembly (Cont'd)

Figure 40-20-95

1 1

S2899

Center the pin holes and insert the three locking pins
1 (Item 1) [Figure 40-20-97].
S2897

NOTE: Check the free rotation of the sattelite wheels

Insert the retainer (Item 1) [Figure 40-20-95] and on the spindles.
completely insert the long spindle.
Figure 40-20-98
Figure 40-20-96

S2914
S2898

Lubricate the gear (Item 1) [Figure 40-20-98].

Fully insert the two short spindles (Item 1) [Figure 40-20-
96].

6986740-EN (07-08) 40-20-34 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-101

Differential Assembly (Cont'd)

Figure 40-20-99

1
1

S5330

Install the 12 bolts (Item 1) [Figure 40-20-101] and torque

S2915 to 85.5- 94.5 ft.-lb. (116-128 N•m).

Figure 40-20-102
Install the gear (Item 1) [Figure 40-20-99].

Figure 40-20-100

1 1

S5330

S2915
Install the bearing (Item 1) [Figure 40-20-102].

NOTE: Heat the bearing to 212°F (100°C) before

Position the shim washer (Item 1) on the gear (Item 2) assembling.
[Figure 40-20-100].

6986740-EN (07-08) 40-20-35 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D)

Brake Group Assembly

Figure 40-20-103

S2920

6986740-EN (07-08) 40-20-36 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-106

Brake Group Assembly (Cont'd)

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn or

damaged parts.

Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

Figure 40-20-104

S5307

Measure the distance B between the disc support plane

and the arm support plane [Figure 40-20-106]. Subtract
B from A to obtain value C.

Figure 40-20-107

S5301

Measure the height U of the center ring to the support

plane [Figure 40-20-104].

Figure 40-20-105

S5313

Bring the pack beneath a press, load with 2200 lb.

(1000 kg) and measure the distance D [Figure 40-20-
107] between the top and bottom disc. Add G, the brake
discs gap and F (fixed value of 0.2 mm) to obtain D1.

S5331

Measure distance V between the center ring and the

piston pack stop [Figure 40-20-105]. Subtract U from V to
obtain value A.

6986740-EN (07-08) 40-20-37 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-109

Brake Group Assembly (Cont'd)

Subtract D1 from C to obtain E, the piston pack quote.

A=V-U

C=A-B

D1 = D + G + F

E = C - D1

Figure 40-20-108

S5351

Insert the slotted nut, and with respecting the value E,

determine the distance H between the top of the brake
group and the top of the slotted nut [Figure 40-20-109].

Then install the Belleville springs and make sure the

slotted nut is tighten to the same distance H as measured
above.

NOTE: Make sure the Belleville springs are centered in

the housing.

S5333 Install the piston.

Assemble the brake group in reverse order as described

in the disassembly section, but without the Belleville
springs. Tighten the cylinder until the measured value is
equal to the calculated value E [Figure 40-20-108] .

6986740-EN (07-08) 40-20-38 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-112

Brake Group Assembly (Cont'd)

Figure 40-20-110

2 1

S5173
1
Install the first brake separator plate (Item 1) [Figure 40-
S5175 20-112] on the brake housing.

Install two screws (Item 1) [Figure 40-20-110] in order to

keep the disc springs of the negative brake preloaded.

Install the two unlocking screws (Item 2) [Figure 40-20-

110] on the brake housing.

Figure 40-20-111

S5174

Install the first friction plate (Item 1) [Figure 40-20-111].

Install the remaining plates and the flange (Item 2)

[Figure 40-20-111]. Do not mix up the sequence.

6986740-EN (07-08) 40-20-39 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-115

Axle Housing / Drive Shaft Assembly

Figure 40-20-113

S5365

Press the bearing cup into the yoke [Figure 40-20-115].

S5375
Figure 40-20-116

Partially install a new bearing cup (Item 1) [Figure 40-20-

113] into the yoke.

Figure 40-20-114

S5366

Install the second bearing cup into the yoke and press
onto the cross [Figure 40-20-116].
S5364
NOTE: Use care not to lose or drop any needle
bearings out of position.
Install the cross (Item 1) [Figure 40-20-114] into the
bearing cup.

6986740-EN (07-08) 40-20-40 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-119

Axle Housing / Drive Shaft Assembly (Cont'd)

Figure 40-20-117

S5369

Partially install a new bearing cup (Item 1) [Figure 40-20-

119] into the yoke.
S5367

Figure 40-20-120
Fully press the two bearing cups into the drive shaft yoke
[Figure 40-20-117].

Figure 40-20-118

S5370

Install the cross / shaft assembly into the bearing cup

S5375 [Figure 40-20-120].

Install the two snap rings (Item 1) [Figure 40-20-118].

6986740-EN (07-08) 40-20-41 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-123

Axle Housing / Drive Shaft Assembly (Cont'd)

Figure 40-20-121

S5375

Install a new bushing (Item 1) and seal (Item 2) [Figure

S5375
40-20-123] into the axle housing.

Lightly lubricate the new seal and bushing.

Install the second bearing cup into the yoke and press
onto the cross [Figure 40-20-121]. Figure 40-20-124

NOTE: Use care not to lose or drop any needle

bearings out of position.

Figure 40-20-122

S5375

Install the drive shaft into the axle housing aligning the
shaft with the splines.
S5375
NOTE: Use care not to damage the seal.
Make sure the bearing cups are fully seated and install
the two snap rings [Figure 40-20-122].

6986740-EN (07-08) 40-20-42 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-127

Steering Knuckle Assembly

Figure 40-20-125

S2383
1

Lubricate the outer surface of the sealing ring (Item 1)

S2382 [Figure 40-20-127]. Fit them into their seat using a
special tool (Bobcat part number 6912181) [Figure 40-
20-127].
Lubricate the bushing (Item 1) [Figure 40-20-125] and
the seat of the steering knuckle. Install the bushing, using
a special tool (Bobcat part number 6912180) .

Figure 40-20-126

Top

Neutral

Axis

Bottom

S1497

6986740-EN (07-08) 40-20-43 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-130

Steering Knuckle Assembly (Cont’d)

Figure 40-20-128

1
S2386

2 If the bottom pivot pin has been extracted, position the pin
S1499 under a press and fit the ball cover (Item 1) [Figure 40-
20-130].
Figure 40-20-129 Figure 40-20-131

S2387
S2384 / S2385
S2189

Using the wheel hub seal tool (Bobcat part number

Fit the front sealing rings onto the pivot pins.
6912182) apply a repositionable jointing compound for
seals to the outer surface of the sealing ring (Item 1)
NOTE: Carefully check that the rings are properly
[Figure 40-20-128] & [Figure 40-20-129]. Position the
oriented.
sealing ring in the steering knuckle (Item 2) [Figure 40-
20-128] & [Figure 40-20-129].

NOTE: Check that the ring (Item 1) [Figure 40-20-128]

& [Figure 40-20-129] is correctly oriented.

6986740-EN (07-08) 40-20-44 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-134

Steering Knuckle Assembly (Cont’d)

Figure 40-20-132

S2392

Lubricate and fit the sealing ring onto a special tool

S2388 (Bobcat part number 6912181); install the rings into the
S2389 arm.

Lubricate the top bush or the bottom ball bush and fit them NOTE: Pay particular attention to the direction of
into the fulcrum holes of the arm. assembly of the rings (flat side facing out).

Figure 40-20-133 Figure 40-20-135

1
2

S2390
S2391 S2393

Lubricate the bushing (Item 1) and the seat of the steering Insert the u-joint (Item 1) [Figure 40-20-135].
knuckle (Item 2). Install the bushing (Item 2) [Figure 40-
20-133], using a special tool (Bobcat part number
6912180).

6986740-EN (07-08) 40-20-45 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-138

Steering Knuckle Assembly (Cont’d)

Figure 40-20-136

1 S2396X
2
Lubricate with grease and install the unit in the steering
S2431 knuckle.

Figure 40-20-139
Lubricate the splined shaft (Item 1) of the u-joint (Item 2)
and install the steering knuckle (Item 3) [Figure 40-20-
136].

Pay due attention not to damage the dust cover rings and
the sealing rings.

Figure 40-20-137

S2397
2
Lubricate the steering knuckle.

1
S2395

Prepare a series of shims (Item 1) [Figure 40-20-137] of

0,4 up to 0,7 mm.

To be assembled under the upper pin (Item 2) [Figure 40-

20-137].

6986740-EN (07-08) 40-20-46 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-142

Steering Knuckle Assembly (Cont’d)

Figure 40-20-140

2 1

S2400

1 Tighten the new fitting screws (Item 1) [Figure 40-20-142]

S2398X
of bottom pivot pins in sequence using the cross
tightening method.

Fit the unit (Item 1) in the steering knuckle (Item 2) Tighten the bolts to 66-74 ft.-lb. (90 - 100 N•m) torque.
[Figure 40-20-140]. Position the screws and tightly
tighten. Figure 40-20-143

Figure 40-20-141

S2401

S2399 Check by means of a lever that there is no vertical gap.

Tighten the new fitting screws (Item 1) [Figure 40-20-141] In case there is any gap, determine the width and reduce
of top pivot pins in sequence using the cross tightening it by removing shims.
method.

Tighten the bolts to 66-74 ft.-lb. (90 - 100 N•m) torque.

6986740-EN (07-08) 40-20-47 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-146

Steering Knuckle Assembly (Cont’d)

Figure 40-20-144

S2404

Set the screw to the length of protrusion previously noted

during disassembly.
S2402

Check the torque of the pins, which has to be 30-60 ft-lb.

(40 - 80 N•m). If the preliminary measured value is too
high, the shims have to be increased.

Figure 40-20-145

S2403

Make certain that the notch is aligned with the cotter pin
hole when the nut is finally locked down to max 222 ft-lb.
(300 N•m).

6986740-EN (07-08) 40-20-48 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-149

Wheel Hub Assembly

Figure 40-20-147

1
2
S2409

1
Install the external bearing (Item 1) [Figure 40-20-149].
S2405 / S2406
NOTE: Move the bearing to the limit stop by
hammering lightly all around the edge.
Position the bearing race (Item 1) [Figure 40-20-147] on
the proper tool. Figure 40-20-150

Lubricate the seats of the bearings and position the hub

(Item 2) [Figure 40-20-147] on the tool with bearing race.

Figure 40-20-148

1 1 S2410

Install the wheel hub (Item 1) [Figure 40-20-150].

S2408 / S2408

Position the bearing race (Item 1) of the internal bearing

(Item 2) [Figure 40-20-148].

NOTE: Check that the bearing race is correctly

oriented.

6986740-EN (07-08) 40-20-49 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-153

Planetary Carrier Assembly

Figure 40-20-151

1
S2413

Install the flange (Item 1) [Figure 40-20-153]. Using

1 Tecno Lube /101, grease the surface of the flange that
S2411
touches the ring gear.

Install the ring gear (Item 1) [Figure 40-20-151]. Figure 40-20-154

Figure 40-20-152

S2414

S2412
Coat the nuts (Item 1) [Figure 40-20-154] with Loctite 242
and screw them.
Fit the complete ring gear (Item 1) [Figure 40-20-152].

NOTE: In order to fasten the flange, use a plastic

hammer and alternately hammer on several
equidistant points.

6986740-EN (07-08) 40-20-50 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-157

Planetary Carrier Assembly (Cont’d)

Figure 40-20-155

S2417

Install the snap ring (Item 1) [Figure 40-20-157].

S2415
Figure 40-20-158
Tighten nuts (Item 1) [Figure 40-20-155] in two stages,
using the criss-cross method.

Initial torque wrench setting: 66 ft.-lb. (90 N•m).

Final torque wrench setting: 74 ft.-lb. (100 N•m).

Figure 40-20-156

S2418

Check the continuous rolling torque on the hub (Item 1)

1 [Figure 40-20-158]: torque 5-15 ft.-lb. (7 - 20 N•m).

If torque is too high, loosen the nuts (Item 1) [Figure 40-

20-155], and re-tighten using a lower final torque setting.
S2416

If torque is too low, torque the nuts (Item 1) [Figure 40-

20-155] using a higher final torque setting.
Install the distance piece (Item 1) [Figure 40-20-156].

6986740-EN (07-08) 40-20-51 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D) Figure 40-20-161

Planetary Carrier Assembly (Cont’d)

NOTE: Check the condition and position of the O-ring. 1 2

Figure 40-20-159

S2423
1

Face down
Fit the planetary gear cover (Item 1) onto the wheel hub
(Item 2) [Figure 40-20-161].
2
S2420 / S2421 Figure 40-20-162

1
Fit the planetary gear (Item 1) [Figure 40-20-159] onto
the planetary gear cover.

NOTE: The jointed portion (Item 2) [Figure 40-20-159]

of the internal ring of the bearings must face
the bottom of the pin.

Figure 40-20-160

S2190

Fasten the bolts using a torque wrench setting of 29-37 ft.-

Ibs. (40-50 N•m).

S2422

Lock into position the planetary gears with the snap rings
[Figure 40-20-160].

6986740-EN (07-08) 40-20-52 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (FRONT) (CONT'D)

Special Tools

BOBCAT PN IMAGE DESCRIPTION

6912173 PINION RING NUT

6912176 DUMMY PINION

6912178 INPUT FLANGE SEAL

6912180 U-JOINT ARM &

STEERING KNUCKLE BUSHING

6912181 U-JOINT SEAL, ARM SIDE

6912182 WHEEL HUB SEAL

6986740-EN (07-08) 40-20-53 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 40-20-54 Bobcat T2250
SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR)

Description

For photo clarity, the following axle procedures are done • Rear Axle removal. (See REAR AXLE on Page 90-1.)
with the complete axle assembly removed from the
machine, although the planetary carrier, wheel hub, • Rear steering cylinder removal. (See Removing The
steering knuckle and drive shaft procedures may be done Steering Cylinder on Page 61-1.)
with the axle assembly installed in the machine. For
complete axle repair, the following must be done.

Planetary Carrier And Wheel Hub Parts Identification

1. Seal
2. Bearing
3. Wheel stud
4. Wheel hub
5. Nut
6. O-ring
7. Bearing
8. Snap ring
9. Ring gear
10. Ring gear support

11. Locking plate

12. Thrust washer
13. Snap ring
14. Snap ring
15. Planet gear
16. Bearing
17. Planet gear carrier
18. O-ring
19. Plug
20. Countersunk bolt
21. Planet gear carrier
22. Stud
23. Nut
24. Ring Gear Support S2190

6986740-EN (07-08) 40-21-1 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-2

Planetary Carrier Disassembly

Clean the outside of the planetary carrier before

disassembly.
1
Mark the outside of the planetary carrier for ease of
assembly.

IMPORTANT
When repairing hydrostatic and hydraulic systems, S2190
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly Remove the two screws (Item 1) [Figure 40-21-2] from
damage the system. the planetary carrier.
I-2003-0888
Figure 40-21-3
Figure 40-21-1
2

S2191

S5320
Remove the planetary gear carrier (Item 1) from the wheel
hub (Item 2) [Figure 40-21-3] by alternately forcing a
With the drain plug (Item 1) [Figure 40-21-1] in the screwdriver into the appropriate slots.
position shown, place a drain pan under the hub and
remove the plug.

6986740-EN (07-08) 40-21-2 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-6

Planetary Carrier Disassembly (Cont’d)

Figure 40-21-4

S2194

With the help of a puller, remove the planetary wheel

S2192 gears (Item 1) [Figure 40-21-6].

NOTE: Note the assembly side of the planetary gears.

Remove the securing bolts and the complete planetary
gear carrier (Item 1) [Figure 40-21-4]. Figure 40-21-7
Figure 40-21-5

1
1

S2195 / S2196

S2193

NOTE: Note down the direction of assembly of

planetary gears.
Remove the snap rings (Item 1) [Figure 40-21-5] from the
planetary carrier.

6986740-EN (07-08) 40-21-3 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-10

Wheel Hub Disassembly

Figure 40-21-8

S5291

Remove the thrust washer (Item 1) [Figure 40-21-10].

S2197
Figure 40-21-11
Remove the snap ring (Item 1) [Figure 40-21-8].

Figure 40-21-9

1
2 1

S5292

Remove the plate (Item 1) [Figure 40-21-11].

S2198X

Remove the eight nuts (Item 1) from the ring gear (Item 2)
[Figure 40-21-9].

6986740-EN (07-08) 40-21-4 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-14

Wheel Hub Disassembly (Cont'd)

Figure 40-21-12
1

S2203X

Remove the bearing (Item 1) [Figure 40-21-14].

S5293
Figure 40-21-15
1
Remove the ring gear from the shaft [Figure 40-21-12].

Figure 40-21-13

S2204X

Remove the complete wheel hub (Item 1) [Figure 40-21-

15] by hand.
S5321

NOTE: Use care while removing, as the assembly may

Loosen the hub with a plastic hammer [Figure 40-21-13]. come off easily.

NOTE: Alternately hammer on several equidistant

points.

6986740-EN (07-08) 40-21-5 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D)

Wheel Hub Disassembly (Cont'd)

Figure 40-21-16

S5324 S5325

Remove the seals from the hub [Figure 40-21-16].

NOTE: Hammer in an alternate sequence to prevent

crawling and deformation of the bearing races.

Figure 40-21-17

S2207

Remove the sealing ring from the steering knuckle

(Item 1) [Figure 40-21-17]. Pay due attention not to
damage the seat of bearing.

6986740-EN (07-08) 40-21-6 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D)

Steering Knuckle and Drive Shaft Parts Identification

19. Nut
20. Bolt
21. Steering adjust bolt
22. Articulated tie rod
23. Ring
24. Cylinder
25. Cylinder bolt
26. Bolt
27. Electronic sensor
28. O-ring
29. Pivot

1. Thrust bushing
2. Seal
3. Drive shaft
4. Nut
5. Washer
6. Stud
7. Cap
8. Grease fitting
9. Cap
10. Shim
11. Seal
12. Bushing
13. Steering knuckle
14. Steering knuckle
15. Articulation
16. Bolt
17. Cap
18. Pivot pin

S1389

6986740-EN (07-08) 40-21-7 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-20

Steering Knuckle Disassembly 1

Clean the outside of the steering knuckle before
disassembly.

Mark the outside of the steering knuckle for ease of

assembly.

Figure 40-21-18

S5197
1

Remove the tapered end of the tie rod (Item 1) [Figure

40-21-20] from the steering knuckle.

NOTE: Be careful as the bolt may come out with great

force.

Figure 40-21-21
S2208

Measure and note the protrusion of the screw (Item 1)

[Figure 40-21-18] and remove the screw.

Figure 40-21-19

S5196

Remove six screws from the bottom cap of the knuckle

assembly [Figure 40-21-21].

S2210
Remove the pivot (Item 1) [Figure 40-21-21].

NOTE: Screws can not be re-used.

Remove the steering cylinder nut (Item 1) [Figure 40-21-
19].

6986740-EN (07-08) 40-21-8 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-24

Steering Knuckle Disassembly (Cont’d)

Figure 40-21-22
1 2

3
S2428A

Using two levers, remove the top pivot pin (Item 1)

S5300 complete with front seal (Item 2) and shims (Item 3)
[Figure 40-21-24].

Remove the seal from the bottom pivot (Item 1) [Figure Figure 40-21-25
40-21-22].

Figure 40-21-23
2
1
3

S1393

S5291
Configuration of the upper (Item 1) pivot pin with shims
(Item 2) and the lower pivot pin (Item 3) [Figure 40-21-
25].
Remove the four screws (Item 1) [Figure 40-21-23] from
the upper pivot.

6986740-EN (07-08) 40-21-9 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-28

Steering Knuckle Disassembly (Cont’d)

Figure 40-21-26
1

S2212

Remove the bushing from the steering knuckle (Item 1)

S2431 [Figure 40-21-28].

NOTE: Note down the orientation of bushing.

Remove the steering knuckle (Item 1) [Figure 40-21-26]
from the axle. Figure 40-21-29

Figure 40-21-27

S2214 / S2215

S5327
Using a puller for inner parts, remove the top bush
(Item 1) and the bottom ball-bush (Item 2) [Figure 40-21-
29].
Use a puller to remove the seal from the steering knuckle
(Item 1) [Figure 40-21-27].

Installation: Use special tool (Bobcat part number

6912178) to install the seal.

6986740-EN (07-08) 40-21-10 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D)

Steering Knuckle Disassembly (Cont’d)

Figure 40-21-30

S2216

Remove the pivot pins (Item 1) and the front sealing rings
(Item 2) [Figure 40-21-30].

NOTE: Note down the side for assembly

Figure 40-21-31

S2217

If the ball cover (Item 1) [Figure 40-21-31] need

replacing, remove it from the bottom pivot pin.

6986740-EN (07-08) 40-21-11 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-34

Axle Housing / Drive Shaft Disassembly

Clean the outside of the axle housing before disassembly.

Mark the outside of the axle housing for ease of assembly.

Figure 40-21-32 1

P-23016

Remove the two snap rings (Item 1) [Figure 40-21-34]

across from each other.

Figure 40-21-35

P-22855

Remove the drive shaft from the axle housing [Figure 40-
21-32].

Figure 40-21-33

P-23017

Drive the upper bearing cup down to push the opposite

bearing cup partially through the yoke [Figure 40-21-35].

NOTE: The bottom bearing cup will not be completely

S2218
removed.

Remove sealing ring (Item 1) [Figure 40-21-33] and the

bushing from the arm.

NOTE: Note down the side for assembly

Check the position of the anti-extrusion and O-rings.

6986740-EN (07-08) 40-21-12 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-38

Axle Housing / Drive Shaft Disassembly (Cont'd)

Figure 40-21-36

2
P-23019

Turn the shaft over and remove the bearing cup (Item 1).
P-23021 Remove the drive shaft (Item 2) [Figure 40-21-38] from
the yoke.

Turn the shaft over and remove the bearing cup (Item 1) Figure 40-21-39
[Figure 40-21-36].

Figure 40-21-37

1 1

P-23022

P-23020 Remove the two snap rings (Item 1) [Figure 40-21-39]

from the yoke.
Drive the cross (Item 1) [Figure 40-21-37] down to push
the opposite bearing cup through the yoke.

NOTE: The drive shaft end (Item 2) [Figure 40-21-37]

may fall out of the yoke.

6986740-EN (07-08) 40-21-13 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-42

Axle Housing / Drive Shaft Disassembly (Cont'd)

Figure 40-21-40

P-23025

Press the second bearing cup through the yoke [Figure

P-23023 40-21-42].

Figure 40-21-43
Using two different size sockets and a vice, and press one
bearing cup into the yoke while pushing the opposite
bearing cup through the yoke [Figure 40-21-40].

Figure 40-21-41

P-23026

Remove the bearing cup (Item 1) and cross (Item 2)

[Figure 40-21-43] from the yoke.
P-23024

Remove the bearing cup (Item 1) [Figure 40-21-41].

6986740-EN (07-08) 40-21-14 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D)

Differential Parts Identification

1. Nut
2. O-ring
3. Flange
4. Coverplate
5. Seal
6. Spacer
7. Bearing
8. Ring
9. Plug
10. Shim
11. Gear
12. Shim
13. Bearing
14. Bolt
15. Differential housing
16. Friction washer
17. Gear
18. Friction washer
19. Gear
20. Spindle
21. Pin
22. Spindle
23. Cover
24. Hexagon Bolt
25. Retainer
25. Ring gear

S2512

6986740-EN (07-08) 40-21-15 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-46

Differential Disassembly (Cont’d)

Figure 40-21-44

S2260

Pull out the differential assembly (Item 1) [Figure 40-21-

S2256 46].

Figure 40-21-47
Remove the brake side arm (Item 1) [Figure 40-21-44].

Figure 40-21-45

S2266

Open the snap ring (Item 1) [Figure 40-21-47] and place

S2257 a bit further for later removal from the differential housing.

Sling the arm to be removed and connect it to a hoist,

remove screws of the ring gear side arm [Figure 40-21-
45].

6986740-EN (07-08) 40-21-16 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-50

Differential Disassembly (Cont’d)

Figure 40-21-48 2

1
1

S2269
S2270

2
Remove the ring gear (Item 1) [Figure 40-21-50] from the
S2268
differential unit.

Using a puller, remove the bearing (Item 2) [Figure 40-

Remove the bearing (Item 2) from the differential housing 21-50] of the ring gear side.
(Item 1) [Figure 40-21-48].
Figure 40-21-51
Figure 40-21-49

S2271 / S2272

S2267

Remove the cover (Item 1) [Figure 40-21-51] from the

Remove fixing screws (Item 1) of the ring gear (Item 2) blocking side of the differential unit.
[Figure 40-21-49]; exchange each time when removed.

6986740-EN (07-08) 40-21-17 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-54

Differential Disassembly (Cont’d)

Figure 40-21-52
2

1
2 3
3

S2275
S2276

With a pin-driver, remove the long spindle (Item 1) and

S2273 then the gears and washers (Item 2) [Figure 40-21-54].

Remove the short spindles (Item 3), gears and washers

Remove the shim washer (Item 1) and the planetary gear (Item 2) [Figure 40-21-54].
(Item 2) [Figure 40-21-52].
Figure 40-21-55
Figure 40-21-53

S2278
S2274

Remove the shim washer (Item 1) [Figure 40-21-55].

Remove the pins (Item 1) [Figure 40-21-53] of the
differential cross spindles.

6986740-EN (07-08) 40-21-18 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D)

Differential Disassembly (Cont’d)

Figure 40-21-56

S4778

Remove the planetary gear (Item 1) [Figure 40-21-56].

Figure 40-21-57

S2279B

Remove the shim washer (Item 1) and the planetary gear

(Item 2) [Figure 40-21-57].

6986740-EN (07-08) 40-21-19 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D)

Pinion Group Parts Identification

1. Nut
2. O-ring
3. Flange
4. Coverplate
5. Seal
6. Spacer
7. Bearing
8. Shim “S2”
9. Plug 7 11
10
10. Shim “S1” 9
11. Taper roller Bearing 8
7
6
5
4
3
2
1

S2174

6986740-EN (07-08) 40-21-20 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-60

Pinion Group Disassembly

Figure 40-21-58

1 1
2

S2283

Remove the flange (Item 1) [Figure 40-21-60] by means

S2280 of a puller.

Figure 40-21-61
Make positional marks across nut (Item 1) and pinion
(Item 2) tang; If disassembly is awkward, heat the check
nut (Item 1) [Figure 40-21-58] of the flange at 80C°.

NOTE: Heating is meant to loosen the setting of

Loctite on the nut (Item 1) [Figure 40-21-58]. 1

Figure 40-21-59

S2287

Remove the mount (Item 1) [Figure 40-21-61].

S2281X

Lock the pinion with a wrench (Item 1) [Figure 40-21-59]

to avoid rotation. Unloose and remove the nut; also
remove the O-ring [Figure 40-21-59].

6986740-EN (07-08) 40-21-21 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-64

Pinion Group Disassembly (Cont’d)

Figure 40-21-62

S2286X

Remove the pinion (Item 1) [Figure 40-21-64], shims and

S2284X distance piece. Refer and keep to the positions marked
during disassembly.

Remove the sealing ring (Item 1) [Figure 40-21-62]. Figure 40-21-65

Figure 40-21-63

1
2

1 S2288

S2285X

Using a puller and a press, remove the inner bearing

Remove the sealing ring (Item 1) and spacer (Item 2) (Item 1) from the pinion (Item 2) [Figure 40-21-65].
[Figure 40-21-63].

NOTE: Sealing rings must be replaced each time the

unit is disassembled.

6986740-EN (07-08) 40-21-22 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-68

Pinion Group Disassembly (Cont’d)

Figure 40-21-66

1
1
S2292

1
Remove the bearing race of the internal bearing (Item 1)
S2289 as well as the shim washer(s) (Item 2) [Figure 40-21-68].

Figure 40-21-69
Remove the bearing race of the external bearing (Item 1)
[Figure 40-21-66].

Figure 40-21-67

S2293

Remove the snap ring (Item 1) [Figure 40-21-69].

S2290 / S2291

Insert a drift in the appropriate holes.

6986740-EN (07-08) 40-21-23 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D)

Pinion Group Disassembly (Cont’d)

Figure 40-21-70

S2294

Remove the cap (Item 1) [Figure 40-21-70].

6986740-EN (07-08) 40-21-24 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D)

Pinion Group Assembly

Figure 40-21-71

S2723

6986740-EN (07-08) 40-21-25 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-74

Pinion Group Assembly (Cont’d) I = 98 mm Y = -0.1 mm

Figure 40-21-72

1
2

S2297 / S2298

30 mm Check nominal dimension “INT” as marked on the pinion

S2295 (Item 1) (eg 98). Add or subtract the variation indicated on
the pinion (Item 2) [Figure 40-21-74] to “INT” to obtain the
actual centre distance “I”.
CALCULATING PINION CENTRE DISTANCE
EXAMPLE: I =INT ± Y = 98-0,1=97,9mm
Using a faceplate, reset a centesimal comparator “DG” on
a calibrated block (whose known thickness is 30 mm). NOTE: C61 =Match part number

Preload the comparator by about 3 mm. Figure 40-21-75

Figure 40-21-73

1
D S2299

S2296
C61 = bevel gear set matching number

Bring inner bearing (Item 1) [Figure 40-21-73], complete (-0,1) = Y variation from the theoretical I =98
with bearing race, under comparator “DG”. Press the
bearing race centrally and carry out several
measurements by rotating the bearing race. The
measurement is called D.

EXAMPLE: 30 - 0,55 = 29,45 = “D”.

6986740-EN (07-08) 40-21-26 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-78

Pinion Group Assembly (Cont’d)

Figure 40-21-76

S2302

Figure 40-21-79
S2300

Calculate shims “S1” for insertion under the bearing race

of the inner bearing using the following formula:

S1 = X - (I + D) where: X = 128 (this is a fixed dimension,

see figure [Figure 40-21-71])

I = actual pinion centre distance

D = Total bearing thickness;

EXAMPLE: S1 = 128 - (97,9+29,45) = 0,65 mm

NOTE: If needed, more shims can be used to obtain S2303

the required thickness.

Figure 40-21-77 Connect the tension rod to the press and move the
bearing race of bearings into the seats.

Disconnect the press and remove the tension rod.

NOTE: Before starting the next stage, make sure that

the bearing race has been completely inserted
into its seat.

1
S2301

Using a proper tool, partially insert the bearing race

(Item 1) and the selected shim(s) (Item 2) [Figure 40-21-
77], together with the other bearing race.

The figure below [Figure 40-21-78] gives an idea of the

internal setup.

6986740-EN (07-08) 40-21-27 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-81

Pinion Group Assembly (Cont’d)

Figure 40-21-80

S2176
1
2 3
Figure 40-21-82
S2304

CALCULATING PINION BEARINGS ROLLING TORQUE

Introduce a dummy pinion (Item 1) (Bobcat part number

6912176) complete with bearings (Item 2 and 3) [Figure
40-21-80] into the main body; tighten by hand until a
rolling torque is definitely obtained.

S2305

Introduce the tracer of a depth comparator “DDG” into

either side hole of the dummy pinion (Item 1) [Figure 40-
21-81] & [Figure 40-21-82].

Reset the comparator with a preload of about 3 mm.

Measure value A.

6986740-EN (07-08) 40-21-28 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-85

Pinion Group Assembly (Cont’d)

Figure 40-21-83

S2309

Calculate the shim S2 to be inserted:

1 S2177
Calculate H = A - B. S2 = H + Q where Q is fixed value to
obtain = 0.07...0.08 mm [Figure 40-21-85].
Figure 40-21-84
Figure 40-21-86

S5348
S5349
S2310B

Remove the dummy pinion (Item 1), remove the bearings,

and re-arrange the bearings, with the tool shim and the Measure the difference H using a dial gauge DDG
largest calibrated shim in between. Put the dummy pinion
(Item 1) on top. Use the depth comparator to measure the E.g. H = A -B = 2.93 mm
depth “B” in either side hole of the dummy pinion (Item 1)
[Figure 40-21-83] & [Figure 40-21-84].

6986740-EN (07-08) 40-21-29 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-89

Pinion Group Assembly (Cont’d)

Figure 40-21-87

1
1 3 4 2 5

S2313

Insert the spacer (Item 1) [Figure 40-21-89].

S2311
Figure 40-21-90
Fit the pinion (Item 1), shim “S1” (Item 2) and distance
piece (Item 3 and 4) in the main body (Item 3) [Figure 40-
21-87].

NOTE: The finer shims must be placed in-between the

thicker ones.
1
Figure 40-21-88

100°C 1

S2287

Install the mount bracket (Item 1) [Figure 40-21-90]

S2508

Heat the external bearing (Item 1) [Figure 40-21-88] to a

temperature of about 100 C°

NOTE: Lightly lubricate bearing with SAE85W90 oil.

6986740-EN (07-08) 40-21-30 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-93

Pinion Group Assembly (Cont’d)

Figure 40-21-91

S2317X

Rolling Torque 60-89 ft.-lb. (80 -120 N•m).

S2315
Figure 40-21-94
Install the flange (Item 1) onto the pinion without sealing
ring and install the nut (Item 2) [Figure 40-21-91] without
LOCTITE 270.

Figure 40-21-92 1
2

1 1

S2280

Make positional marks across nut (Item 1) and pinion

(Item 2) tang; then remove nut and flange (Item 3) [Figure
40-21-94].
S2316

Lock the wrench (Item 1) [Figure 40-21-92], rotate the

pinion using a dynamometric wrench, up to a minimum
required torque setting of 192-222 ft.-lb. (260 - 300 N•m).

6986740-EN (07-08) 40-21-31 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-97

Pinion Group Assembly (Cont’d)

Figure 40-21-95
1

1
2

S2316

Lock the wrench (Item 1) [Figure 40-21-97], rotate the

S2314 pinion using adynamometric wrench, up to a minimum
required torque setting of 192-222 ft.-lb. (260-300 N•m).

Fit ring (Item 1) in the main body using driver (Item 2)

[Figure 40-21-95].

Figure 40-21-96

S2283

Oil seal ring lips and install flange (Item 1). Mount O-ring
(Item 2) and apply Loctite 270 to pinion tang; tighten nut
(Item 3) [Figure 40-21-96].

6986740-EN (07-08) 40-21-32 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-100

Differential Assembly 3

Figure 40-21-98

2 1
1

S2323

Insert the gear wheel (Item 1) with the spherical washer

S2321 (Item 2) and the bolt (Item 3) [Figure 40-21-100] to keep
them in position.
Insert the washer (Item 1) and the gear wheel (Item 2)
Figure 40-21-101
[Figure 40-21-98] on the ring gear side.
1
Figure 40-21-99
2
3 2
3

2
1

S2324

S2322 Insert the gear wheels (Item 1) with the spherical washers
(Item 2) and the bolt (Item 3) [Figure 40-21-101].
Insert the gear wheel (Item 1) with the spherical washer
(Item 2) and the bolt (Item 3) [Figure 40-21-99] to keep
them in position.

6986740-EN (07-08) 40-21-33 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-104

Differential Assembly (Cont’d)

1
Figure 40-21-102

S2326

Bring the pin holes in line with the help of a pin-driver

S2323 (Item 1) [Figure 40-21-104].

Figure 40-21-105
Insert the crossbolt (Item 1) [Figure 40-21-102] in the
correct position.

Figure 40-21-103

1
1

S2327

Insert pins (Item 1) [Figure 40-21-105] to end of stroke.

S2325

Insert the bolts in their position (Item 1) [Figure 40-21-

103].

6986740-EN (07-08) 40-21-34 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-108

Differential Disassembly (Cont’d)

Figure 40-21-106

2
1

S2330

Tighten the bolts to 43 ft.-lb. (58 N•m) torque.

S2328
Figure 40-21-109

Insert planetary gear

(Item 1) together with washer (Item 2) [Figure 40-21-

106].

Figure 40-21-107
2

1
1
S2331

Install the ring gear (Item 1). Fix the screws (Item 2)
[Figure 40-21-109] of the ring gear.

NOTE: Use LOCTITE 270 on screws not treated with

DRILOC.
S2329

Coat the nuts (Item 1) [Figure 40-21-107] with Loctite 270

and screw them.

6986740-EN (07-08) 40-21-35 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D)

Differential Disassembly (Cont’d)

Figure 40-21-110

S2332

Tighten the screws of the ring gear using the criss cross
method.

Tighten the bolts to 95-105 ft.-lb. (128-142 N•m) torque.

Figure 40-21-111

110°C

S2333

Heat up the roll bearings (Item 1) [Figure 40-21-111] to

110°C and insert it onto the differential.

6986740-EN (07-08) 40-21-36 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-114

Steering Knuckle Assembly

Figure 40-21-112

1
S2383
1

Lubricate the outer surface of the sealing ring (Item 1)

S2382 [Figure 40-21-114]. Fit them into their seat using a
special tool (Bobcat part number 6912181) (Item
2) [Figure 40-21-114].
Lubricate the bushing (Item 1) [Figure 40-21-112] and the
seat of the steering knuckle. Install the bushing, using a
special tool (Bobcat part number 6912180).

Figure 40-21-113

Top

Neutral

Axis

Bottom

S1497

6986740-EN (07-08) 40-21-37 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-117

Steering Knuckle Assembly (Cont’d)

Figure 40-21-115

1
1

S2386

2
If the bottom pivot pin (Item 1) [Figure 40-21-117] has
S1499
been extracted, position the pin under a press and fit the
ball cover.
Figure 40-21-116
Figure 40-21-118

1
3

2
1

S2384 / S2385 S2387

S2189

Using the wheel hub seal tool (Bobcat part number

6912182) apply a repositionable jointing compound for
seals to the outer surface of the sealing ring (Item 1) Fit the front sealing rings (Item 1) onto the pivot pins (Item
[Figure 40-21-115] & [Figure 40-21-116]. Position the 2) [Figure 40-21-118].
sealing ring in the steering knuckle (Item 2) [Figure 40-
21-115] & [Figure 40-21-116]. NOTE: Carefully check that the rings are properly
oriented (Item 3) [Figure 40-21-118].
NOTE: Check that the ring (Item 1) [Figure 40-21-115]
& [Figure 40-21-116] is correctly oriented.

6986740-EN (07-08) 40-21-38 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-121

Steering Knuckle Assembly (Cont’d)

Figure 40-21-119

S2392

Lubricate and fit the sealing ring onto the special tool
S2388 / S2389 (Bobcat part number 6912181); install the rings into the
arm.

Lubricate the top bush or the bottom ball bush and fit them Figure 40-21-122
into the fulcrum holes of the arm.

Figure 40-21-120

S2393X

S2390 / S2391
Insert the u-joint (Item 1) [Figure 40-21-122].

Lubricate the bushing and the seat of the steering

knuckle. Install the bushing, using a special tool (Bobcat
part number 6912180).

6986740-EN (07-08) 40-21-39 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-125

Steering Knuckle Assembly (Cont’d)

Figure 40-21-123

S2396

Lubricate and install the unit in the steering knuckle.

S2394
Figure 40-21-126
Lubricate the terminal of the u-joint and install the steering
knuckle.

Pay due attention not to damage the dust cover rings and
the sealing rings.

Figure 40-21-124

S2397

1
Lubricate the steering knuckle.

S2395

Prepare a series of shims (Item 1) [Figure 40-21-124] of

0,4 up to 0,7 mm.

To be assembled under the upper pin (Item 2) [Figure 40-

21-124].

6986740-EN (07-08) 40-21-40 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-129

Steering Knuckle Assembly (Cont’d)

Figure 40-21-127

2
1
1
S2400

Tighten the new fittin screws (Item 1) [Figure 40-21-129]

S2398 of bottom pivot pins in sequence using the cross
tightening method.

Fit the unit (Item 1) in the steering knuckle (Item 2) Tighten the bolts to 66-74 ft.-lb. (90 - 100 N•m) torque.
[Figure 40-21-127]. Position the screws and tightly
tighten. Figure 40-21-130

Figure 40-21-128

S2401

S2399
Check by means of a lever that there is no vertical gap.

Tighten the new fitting screws (Item 1) [Figure 40-21-128] In case there is any gap, determine the width and reduce
of top pivot pins in sequence using the cross tightening it by removing shims.
method.

Tighten the screws to 66-74 ft.-lb. (90 - 100 N•m) torque.

6986740-EN (07-08) 40-21-41 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-133

Steering Knuckle Assembly (Cont’d)

Figure 40-21-131

S2404

Set the screw to the length of protrusion previously noted

S2402
during disassembly.

Check the torque of the pins, which has to be between

30 ft.-lb. (40 N•m) and 60 ft.-lb. (80 N•m). If the
preliminary measured value is too high, the shims have to
be increased.

Figure 40-21-132

S2403

Make certain that the notch is aligned with the cotter pin
hole when the nut is finally locked down to max 222 ft-lb.
(300 N•m).

6986740-EN (07-08) 40-21-42 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-136

Planetary Carrier Assembly

1
Figure 40-21-134

2
S2409
1

Install the external bearing (Item 1) [Figure 40-21-136].

S2405 / S2406
NOTE: Move the bearing to the limit stop by
hammering lightly all around the edge.
Position the bearing race (Item 1) [Figure 40-21-134] on
the proper tool. Figure 40-21-137
Lubricate the seats of the bearings and position the hub
(Item 2) [Figure 40-21-134] on the tool with bearing race. 1
Figure 40-21-135

S2410

1
Install the wheel hub (Item 1) [Figure 40-21-137].

S2407 / S2408

Position the bearing race (Item 1) of the internal bearing

(Item 2) [Figure 40-21-135].

NOTE: Check that the bearing race is correctly

oriented.

6986740-EN (07-08) 40-21-43 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-140

Planetary Carrier Assembly (Cont’d)

Figure 40-21-138

1 1

S2413

Install the security flange (Item 1) [Figure 40-21-140].

S2411
Using Tecno Lube /101, grease the surface of the flange
that touches the ring gear.
Install the ring gear (Item 1) [Figure 40-21-138].
Figure 40-21-141
Figure 40-21-139

S2414

S2412
Coat the nuts (Item 1) [Figure 40-21-141] with Loctite 242
and screw them.
Fit the complete crown flange (Item 1) [Figure 40-21-
139].

NOTE: In order to fasten the flange, use a plastic

hammer and alternately hammer on several
equidistant points.

6986740-EN (07-08) 40-21-44 Bobcat T2250

SERVICE MANUAL
.AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-144

Planetary Carrier Assembly (Cont’d)

Figure 40-21-142 1

S2417

Install the snap ring (Item 1) [Figure 40-21-144].

S2415
Figure 40-21-145
Tighten nuts (Item 1) [Figure 40-21-142] in two stages,
using the criss-cross method.
1
Initial torque wrench setting: 66 ft.-lb. (90 N•m).
Final torque wrench setting: 74 ft.-lb. (100 N•m).

Figure 40-21-143

1
S2418

Check the continuous rolling torque on the hub (Item 1)

[Figure 40-21-145]: torque 5-15 ft.-lb. (7 - 20 N•m).

If torque is too high, loosen the nuts (Item 1) [Figure 40-

21-142], and re-tighten using a lower final torque setting.
S2416
If torque is too low, torque the nuts (Item 1) [Figure 40-
21-142] using a higher final torque setting.
Install the distance piece (Item 1) [Figure 40-21-143].

6986740-EN (07-08) 40-21-45 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D) Figure 40-21-148

Planetary Carrier Assembly (Cont’d)

Figure 40-21-146
2

1
1

S2422

Lock into position the planetary gears (Item 1) with the

S2419 snap rings (Item 2) [Figure 40-21-148].

Figure 40-21-149
Make sure the O-ring (Item 1) [Figure 40-21-146] is fully
seated in the groove.
1 2
Figure 40-21-147

S2423
2 Face

Fit the planetary gear cover (Item 1) onto the wheel hub
S2420 / S2421
(Item 2) [Figure 40-21-149].

Fit the planetary gear (Item 1) onto the planetary gear

cover (Item 2) [Figure 40-21-147].

NOTE: The jointed portion (Item 2) [Figure 40-21-147]

of the internal ring of the bearings must face
the bottom of the pin.

6986740-EN (07-08) 40-21-46 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D)

Planetary Carrier Assembly (Cont’d)

Figure 40-21-150

S2190

Install the two bolts (Item 1) [Figure 40-21-150]. Torque

wrench 30-37 ft.-lb. (40-50 N•m).

6986740-EN (07-08) 40-21-47 Bobcat T2250

SERVICE MANUAL
AXLE AND DIFFERENTIAL (REAR) (CONT'D)

Special Tools

BOBCAT PN IMAGE DESCRIPTION

6912173 PINION RING NUT

6912176 DUMMY PINION

6912178 INPUT FLANGE SEAL

6912180 U-JOINT ARM &

STEERING KNUCKLE BUSHING

6912181 U-JOINT SEAL, ARM SIDE

6912182 WHEEL HUB SEAL

6986740-EN (07-08) 40-21-48 Bobcat T2250

SERVICE MANUAL
FRONT AXLE Figure 40-30-3

Removal

Fully retract the telescoping boom and install a boomstop

(See Installing The Approved Boom Stop on Page 10-
150-1.) to allow the front axle to be removed from under
the frame. 1

Figure 40-30-1
2

S4461
1

Remove the two hydraulic hoses (Item 1 & 2) [Figure 40-

30-3] at the front left of the Telescopic Handler.

NOTE: Mark all hoses for correct installation.

S4458

IMPORTANT
Rotate the battery disconnect switch (Item 1) [Figure 40-
30-1] to the right, to disconnect the power supply from the When repairing hydrostatic and hydraulic systems,
battery. clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
Drain the hydraulic reservoir (See “Replacing Hydraulic tubelines and ports to keep dirt out. Dirt can quickly
Fluid” on page 10-100-2). damage the system.
I-2003-0888
Figure 40-30-2
Figure 40-30-4

2 1
1

S4458

S4462

Disconnect the two harness connectors (Item 1 & 2)

[Figure 40-30-2] at the front of the Telescopic Handler
Remove the hydraulic hose (Item 1) [Figure 40-30-4] at
from the main harness.
the front right of the Telescopic Handler.
NOTE: Mark all connectors for correct assembly.
NOTE: Mark all hoses for correct installation.

6986740-EN (07-08) 40-30-1 Bobcat T2250

SERVICE MANUAL
FRONT AXLE (CONT'D) Figure 40-30-7

Removal (Cont'd)

Figure 40-30-5
2

1 2

2 S4485

Remove the two flange hoses (Item 1) [Figure 40-30-7]

S4455 by removing the four bolts (Item 2) of each flange hose.

Figure 40-30-8
Remove the cover (Item 1) [Figure 40-30-5] by removing
the two screws (Item 2).

Figure 40-30-6
1 2

1
2

S4478

Remove the solenoid (Item 1) [Figure 40-30-8].

S4460
Remove the four hydraulic hoses (Item 2) [Figure 40-30-
8] from the top and bottom of the drive motor.
Remove the four driveshaft mounting bolts and nuts (Item
1) [Figure 40-30-6]. Lower the driveshaft.

6986740-EN (07-08) 40-30-2 Bobcat T2250

SERVICE MANUAL
FRONT AXLE (CONT'D) Figure 40-30-11

Removal (Cont'd)

Figure 40-30-9

S4483

Using a floor jack, apply upward pressure to lift and

S2923 support the front axle [Figure 40-30-11].

Figure 40-30-12
Lift the front of the machine and place jack stands under
the frame as shown [Figure 40-30-9].

Figure 40-30-10

S3692

Remove the two remaining mounting plate bolts and nuts

S3297 (Item 1) [Figure 40-30-12] on both sides.

Loosen the eight wheel nuts (Item 1) [Figure 40-30-10] of

the two wheels.

Remove both front wheels.

6986740-EN (07-08) 40-30-3 Bobcat T2250

SERVICE MANUAL
FRONT AXLE (CONT'D)

Removal (Cont'd)
IMPORTANT
Figure 40-30-13
When repairing hydrostatic and hydraulic systems,
1 clean the work area before disassembly and keep all
1
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
1 damage the system.
I-2003-0888

2
S3690

Remove the two mounting bolts and nuts (Item 1) [Figure

40-30-13] on each side.

Remove the mounting plate (Item 2) [Figure 40-30-13].

Have an assistant balance the axle on the floor jack and

lower the floor jack slowly. Roll out the axle from under the
frame.

Use a hoist and strap to put the axle well-supported in an

appropriate place.

Figure 40-30-14

S4486

Remove the two hydraulic tubelines (Item 1 & 2) [Figure

40-30-14].

NOTE: Mark all hoses for correct installation.

6986740-EN (07-08) 40-30-4 Bobcat T2250

SERVICE MANUAL
FRONT AXLE (CONT'D) Figure 40-30-17

Installation 2
2
Figure 40-30-15
2

1 S3690

1
Install the mounting plate (Item 1) and two mounting bolts
S4486 and nuts (Item 2) [Figure 40-30-17] on each side.

Tighten the nuts to 275-300 ft-lb. (370-410 N•m) torque.

Install the two hydraulic tubelines (Item 1) [Figure 40-30-
15]. Figure 40-30-18

Figure 40-30-16

S3692

S4483
Install the two mounting plate bolts and nuts (Item 1)
[Figure 40-30-18] on each side.
Using a floor jack, position the axle and apply upward
pressure to lift and support the front axle [Figure 40-30- Tighten the nuts to 275-300 ft-lb. (370-410 N•m) torque.
16].

6986740-EN (07-08) 40-30-5 Bobcat T2250

SERVICE MANUAL
FRONT AXLE (CONT'D) Figure 40-30-21

Installation (Cont'd)

Figure 40-30-19
2

1 2

S4485

Install the two flange hoses (Item 1) by removing the four

S3297 bolts (Item 2) [Figure 40-30-21] of each flange hose.

Figure 40-30-22
Install the two front wheels.

Install the eight wheel nuts (Item 1) [Figure 40-30-19] of

both wheels. Tighten to 265 ft.-lb. (360 N•m) torque.
1
Fill the hydraulic reservoir. (See “Replacing Hydraulic
Fluid” on page 10-100-2)
1
Figure 40-30-20

2
1
S4460

Install the four driveshaft mounting bolts and nuts (Item 1)

2 [Figure 40-30-22].

S4478

Install the solenoid (Item 1) [Figure 40-30-20].

Install the hydraulic hoses (Item 2 & 3) [Figure 40-30-20].

6986740-EN (07-08) 40-30-6 Bobcat T2250

SERVICE MANUAL
FRONT AXLE (CONT'D) Figure 40-30-25

Installation (Cont'd)

Figure 40-30-23

2
1

S4458

Connect the two harness connectors (Item 1 & 2) [Figure

S4455 40-30-25] at the front of the Telescopic Handler.

Secure the electrical harness (Item 1) [Figure 40-30-25]

Install the cover (Item 1) [Figure 40-30-23].
to the steering hoses with tie straps.
Figure 40-30-24
Remove the jackstands from the machine.

S4461

Install the two hydraulic hoses (Item 1 & 2) [Figure 40-30-

24] at the front left of the Telescopic Handler.

6986740-EN (07-08) 40-30-7 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 40-30-8 Bobcat T2250
SERVICE MANUAL
AXLE TOE-IN Figure 40-40-1

Adjustment

The axle is removed from the machine for photo clarity,

but this procedure may be completed with the axle
installed in the machine.
2
3
Turn the steering wheel until the steering cylinder rod is
positioned in the center. Measure the exposed part of the
cylinder rod on each side of the cylinder housing making
sure they are the same length.
1
Figure 40-40-1

S2058

If measurement is not the same, adjust the two tie rod

ends (Item 1) by loosening or tightening the track rods
(Item 2) [Figure 40-40-1] of the two tie rods until the
measurement is the same.

Tighten the nut (Item 3) [Figure 40-40-1] to 221 ft-lb. (300

N•m) torque.

S2056

Install two identical, straight bars [Figure 40-40-1] onto

the wheel hub and secure them using lug nuts.

NOTE: The two bars must be perpendicular to the

ground.

Figure 40-40-2

S2057

Measure the distance between the ends of the two bars

[Figure 40-40-2]. The measurement must be equal.

6986740-EN (07-08) 40-40-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 40-40-2 Bobcat T2250
SERVICE MANUAL
PARKING BRAKE Releasing The Brake Discs

The Telescopic Handler can be towed a short distance The brakes are engaged by spring pressure and released
such as removing it from mud or loading it onto a by hydraulic pressure. The parking brake must be
transport vehicle. released manually before towing (if the engine can not be
started to release the brakes or there is no hydraulic
pressure). Only the front axle has brakes.

The following procedure describes how to release the

brakes:

Figure 40-50-1

2
1

S6519

Loosen the four bolts (Item 1) until the slotted spacers

Block the wheels to prevent the machine from rolling. (Item 2) [Figure 40-50-1] can be removed from under the
bolt heads (the bolts and spacers are located on both the
front and rear side of the front axle).

Remove the spacers (Item 2) [Figure 40-50-1] and save

for reuse.

Figure 40-50-2

ACTIVE POSITION RELEASED POSITION

1
2

P-68946

After removing the spacers, evenly tighten the front and

rear bolts (Item 1) to hold the parking brake piston (Item 2)
[Figure 40-50-2] in the released position.

6986740-EN (07-08) 40-50-1 Bobcat T2250

SERVICE MANUAL
PARKING BRAKE (CONT'D) Engaging The Brake Discs

Releasing The Brake Discs (Cont’d) Figure 40-50-4

Figure 40-50-3
2

1 1

1
Operating
position

Towing 2
position
S2711

S2696
Loosen the four bolts (Item 1) until the spacers (Item 2)
[Figure 40-50-4] can be installed under the bolt heads
Raise the engine cover. (the bolts and washers are located on both the front and
rear side of front axle).
Turn the tow valve counterclockwise 90° (Item 1) [Figure
40-50-3] to TOWING POSITION. Figure 40-50-5
Tow the Telescopic Handler at a slow speed. ACTIVE POSITION RELEASED POSITION
NOTE: The vehicle will not be able to brake until the
four bolts (Item 1) [Figure 40-50-4] & [Figure 1
40-50-5] are returned to their original position. 3

2
P-68946

Evenly tighten the front and rear bolts (Item 1) to hold the
spacers (Item 2) [Figure 40-50-4] & [Figure 40-50-5].

Tighten the bolts to 70-85 ft.-lb. (95-115 N•m) torque.

This will allow the parking brake piston (Item 3) [Figure

40-50-5] to be active again.
Block the wheels to prevent the machine from rolling.

After towing is completed, turn the tow valve (Item 1)

[Figure 40-50-3] clockwise 90° to the OPERATING
POSITION.

NOTE: If the tow valve is not returned to the operating

position, the machine will not be able to be
driven forward or backward.

6986740-EN (07-08) 40-50-2 Bobcat T2250

SERVICE MANUAL
STEERING ANGLE ADJUSTMENT Figure 40-60-3

Adjustment

The axle is removed from the machine for photo clarity,

1
but this procedure may be completed with the axle
installed in the machine.

Figure 40-60-1

S2061

Adjust the stop (Item 1) [Figure 40-60-3] as needed.

Tighten the lock nut to 110 ft-lb. (150 N•m) torque.

2 Figure 40-60-4

S2059
1
Install a straight bar (Item 1) onto the wheel hub and
secure using lug nuts. Turn the steering wheel completely
to one side. Place a straight bar (Item 2) [Figure 40-60-1]
on the pinion shaft.

Figure 40-60-2

S2062

Turn the steering wheel completely to the other side

[Figure 40-60-4] and repeat above procedure.

32-35
Degrees

S2060

Use an angle gauge, to obtain a reading of 32-35 degrees

[Figure 40-60-2].

6986740-EN (07-08) 40-60-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 40-60-2 Bobcat T2250
SERVICE MANUAL
DRIVESHAFT

Removal And Installation

Figure 40-70-1

1 1

S5458

Remove the four drive shaft mounting bolts (Item 1)

[Figure 40-70-1] from both ends of the drive shaft.

Slide the drive shaft out of the machine.

6986740-EN (07-08) 40-70-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 40-70-2 Bobcat T2250
SERVICE MANUAL
SERVICE BRAKE Figure 40-80-2

Description

There are two bleed screws located on each side of the

front axle differential housing. 1

Air trapped in the brake lines may cause a spongy feel

and/or delayed activation of the service brake.

Use the following procedure to remove air from the brake

circuit.

Bleeding The Brake Circuit

The machine will need to be operational so that the S6543

engine and the hydraulic system functions properly.

Block the wheels to prevent the machine from moving. Engage the parking brake switch (Item 1) [Figure 40-80-
2] by pressing it to the bottom position.
Figure 40-80-1
Figure 40-80-3

1 1
1

S7302
S2731

The parking brake will be bled using the bleed screws

(Items 1) [Figure 40-80-1] at the top of the front axle (B1 The red light (Item 1) [Figure 40-80-3] will turn on when
port). Install a hose on the bleed screw and route the the parking brake switch is engaged.
opposite end of the hose to a drain pan.

2 people will be needed to perform this procedure.

Enter the Telescopic Handler, put the Travel Direction

Control in the neutral position, fasten the seat belt and
start the engine.

6986740-EN (07-08) 40-80-1 Bobcat T2250

SERVICE MANUAL
SERVICE BRAKE (CONT’D) Move the Travel Direction Control to the forward position.
Increase RPM to 1500. The parking brake must not allow
Bleeding The Brake Circuit (Cont’d) the Telescopic Handler to move.

Figure 40-80-4 Decrease RPM to low idle.

Move the Travel Direction Control in the reverse position.

Increase RPM to 1500. The parking brake must not allow
the Telescopic Handler to move.

Decrease RPM to low idle.

1 1
Move the Travel Direction Control in the neutral position.

If the brakes allowed the machine to move, repeat the

park brake bleed procedure and then retest the park
brake.

S7302

Have the second person open the parking brake bleed

screw (Item 1) [Figure 40-80-4] and bleed the system
until hydraulic fluid, with no air bubbles, flows from the
end of the bleed hose at the drain pan. Close the brake
bleed screw. Remove the hose from the bleed screw that
was used in the bleeding procedure.

Have the second person move away from the machine.

Figure 40-80-5

S6543

Disengage the parking brake by pressing the switch (Item

1) [Figure 40-80-5] to the top position. The red light (Item
1) [Figure 40-80-3] will turn off when the parking brake
switch is moved to the disengaged position.

Slowly move the machine to an open and clear area to

test the parking brake. Keep all by-standers away while
testing.

Engage the parking brake switch (Item 1) [Figure 40-80-

5] by pressing it to the bottom position. The red light (Item
1) [Figure 40-80-3] will turn on when the parking brake
switch is engaged.

6986740-EN (07-08) 40-80-2 Bobcat T2250

SERVICE MANUAL
REAR AXLE Figure 40-90-2

Removal

Position the machine on the work surface.

Relieve hydraulic pressure.

WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
S7310
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
Lift the rear of the machine and place jackstands under
the frame as shown.

Figure 40-90-1 Place a block in front and behind the front wheel [Figure
40-90-2].

Figure 40-90-3

1 1

P18440

Rotate the battery disconnect switch (Item 1) [Figure 40-

S5070
90-1] to the right, to disconnect the power supply from the
battery.
Remove the eight lug nuts and washers (Item 1) [Figure
Drain the hydraulic reservoir. (See “Replacing Hydraulic 40-90-3] from each rear wheel.
Fluid” on page 10-100-2)
Remove both rear wheels.

6986740-EN (07-08) 40-90-1 Bobcat T2250

SERVICE MANUAL
REAR AXLE (CONT’D) Figure 40-90-5

Removal (Cont’d)

Figure 40-90-4

1
1

S2928

1
Remove the hoses (Item 1) [Figure 40-90-5] from the
S1951 steering cylinder.

NOTE: Mark all hoses for correct installation.

Remove the four bolts (Item 1) [Figure 40-90-4] and
remove the rear fenders. Figure 40-90-6

Remove the driveshaft. (See “DRIVESHAFT” on page 40-

70-1.)

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
S7202

Install two jackstands (Item 1) [Figure 40-90-6] under the

axle.

6986740-EN (07-08) 40-90-2 Bobcat T2250

SERVICE MANUAL
REAR AXLE (CONT’D) Figure 40-90-9

Removal (Cont’d)

Figure 40-90-7

1
1
S2925

1 Remove the jackstands (Item 1) [Figure 40-90-9] from the

S2927 axle.

Figure 40-90-10
Remove the two bolts (Item 1) [Figure 40-90-7] from the
front mount bracket.

Figure 40-90-8

1 S2924

Have an assistant balance the axle on the floor jack and

S2926 lower the floor jack slowly. Roll the axle out from under the
frame [Figure 40-90-10].

Remove the two bolts (Item 1) [Figure 40-90-8] from the

rear mount bracket.

6986740-EN (07-08) 40-90-3 Bobcat T2250

SERVICE MANUAL
REAR AXLE (CONT’D) Figure 40-90-13

Installation

Have an assistant balance the axle on the floor jack and

roll the axle under the frame .

Figure 40-90-11
1

S2926

Install the two bolts (Item 1) [Figure 40-90-13] in the rear

mount bracket.

Figure 40-90-14
S2924

Raise the floor jack, lifting the axle upward and into
position [Figure 40-90-11].

Figure 40-90-12

1
S2927

Install the two bolts (Item 1) [Figure 40-90-14] in the front

1 mounting bracket.
1

S2925

Install jackstands (Item 1) [Figure 40-90-12] under the

axle.

6986740-EN (07-08) 40-90-4 Bobcat T2250

SERVICE MANUAL
REAR AXLE (CONT’D) Figure 40-90-17

Installation (Cont’d)

Figure 40-90-15

1 2

P-44942

Install the driveshaft (Item 1) with four bolts (Item 2)

P-44951 [Figure 40-90-17]. Tighten the bolts to 87 ft-lb. (118 N•m)
torque.

Plug the wire connector (Item 1) [Figure 40-90-15] into Figure 40-90-18
the wire harness.

Figure 40-90-16
1

1 1
1
S1951

S2928 Install the rear fenders (Item 1) with two bolts (Item 2)
[Figure 40-90-18].

Install the hoses (Item 1) [Figure 40-90-16] on the

steering cylinder.

6986740-EN (07-08) 40-90-5 Bobcat T2250

SERVICE MANUAL
REAR AXLE (CONT’D)

Installation (Cont’d)

Figure 40-90-19

P-22280

Install the rear tires with eight nuts (Item 1) [Figure 40-90-
19] and washers.

Tighten the nuts to 221 ft-lb. (300 N•m) torque.

Raise the machine and remove the jackstands. Lower the

machine and remove the blocks from the front tire .

Figure 40-90-20

P18440

Rotate the battery disconnect switch (Item 1) [Figure 40-

90-20] to the left, to restore the power supply from the
battery.

Fill the hydraulic reservoir. See “Replacing Hydraulic

Fluid” on page 10-100-2

6986740-EN (07-08) 40-90-6 Bobcat T2250

SERVICE MANUAL
 MAIN FRAME

BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-90-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . .50-90-1

BOOM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-30-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . .50-30-1

DASH COVER/STEERING COLUMN COVER. . . . . . . . . . .50-130-1

Dash Cover Removal And Installation . . . . . . . . . . . . . . .50-130-2
Steering Column Cover Removal And Installation . . . . .50-130-1

ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-70-1

Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-70-2
Locking Mechanism Removal And Installation . . . . . . . . .50-70-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . .50-70-1

FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-110-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . .50-110-1 MAIN FRAME

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-80-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . .50-80-1

INNER BOOM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-40-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-40-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-40-1

JOYSTICK PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-120-1

Joystick Panel Cover Removal and Installation . . . . . . . .50-120-1

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-10-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . .50-10-1

OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-20-1

Assembly And Disassembly . . . . . . . . . . . . . . . . . . . . . . .50-20-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . .50-20-1

REAR WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-100-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . .50-100-1

WEAR PADS (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-50-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . .50-50-1

WEAR PADS (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-60-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-60-1
Removal50-60-1

6986740-EN (07-08) 50-01 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 50-02 Bobcat T2250
SERVICE MANUAL
OPERATOR CAB Figure 50-10-3

Removal And Installation

Figure 50-10-1

1
S2970

Remove the tie straps (Item 1) [Figure 50-10-3] that

S7226 attach the harness to the cab frame.

Figure 50-10-4
Raise the boom and install the boom stop (Item 1) [Figure
50-10-1].

Relieve hydraulic pressure.

Figure 50-10-2
2

S2971

1 Remove the tie straps (Item 1) from the connector.

Disconnect the connector (Item 2) [Figure 50-10-4].

S7204 Remove the tie straps (Item 3) [Figure 50-10-4] from the
harnesses.

Rotate the battery disconnect switch (Item 1) [Figure 50-

10-2] to the right, to disconnect the power supply from the
battery.

Remove the battery access cover and battery (See

Removal And Installation on Page 60-20-1.).

NOTE: Mark all hoses and electrical connectors for

correct installation.

6986740-EN (07-08) 50-10-1 Bobcat T2250

SERVICE MANUAL
OPERATOR CAB (CONT’D) Figure 50-10-7

Removal And Installation (Cont’d)

Figure 50-10-5 1

S7208

Unplug the two electrical connectors (Item 1) [Figure 50-

S2972 10-7].

Figure 50-10-8
Disconnect the parking brake connector (Item 1) [Figure
50-10-5].

Figure 50-10-6

1 1

1 S2973

Remove the tie straps (Item 1) [Figure 50-10-8] from the

S7207 parking brake hydraulic hoses.

Loosen the screws (Item 1) and disconnect the three

electrical connectors (Item 2) [Figure 50-10-6].

6986740-EN (07-08) 50-10-2 Bobcat T2250

SERVICE MANUAL
OPERATOR CAB (CONT’D)

Removal And Installation (Cont’d)

WARNING
Figure 50-10-9
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
1 immediately.
W-2145-0290

IMPORTANT
S7209
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Mark the wires and remove the two nuts (Item 1) [Figure parts clean. Always use caps and plugs on hoses,
50-10-9] and wirings from the battery disconnect switch. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 50-10-10

Figure 50-10-11

2
1

S7210

S4595
Remove the nut (Item 1), and bolt. Remove the grounding
strap (Item 2) [Figure 50-10-10].
Remove the three hydraulic hoses (Item 1) [Figure 50-10-
11].

Remove any necessary nylon ties.

6986740-EN (07-08) 50-10-3 Bobcat T2250

SERVICE MANUAL
OPERATOR CAB (CONT’D) Figure 50-10-14

Removal And Installation (Cont’d)

1 1
Figure 50-10-12

1
S7107

Remove the three screws (Item 1) and remove the cover

S7214 (Item 2) [Figure 50-10-14].

Figure 50-10-15
Mark and remove the five hydraulic hoses [Figure 50-10-
12]. 1

Figure 50-10-13

1
S5881

Remove the knobs (Item 1) and raise the fuse box cover
S7215 (Item 2) [Figure 50-10-15] gently.

Remove, mark and cap the seven hoses on the right side
of the cab [Figure 50-10-13].

If machine is equipped with air conditioning, remove the

refrigerant from the A/C system. (See “Reclamation
Procedure” on page 80-100-1.)

6986740-EN (07-08) 50-10-4 Bobcat T2250

SERVICE MANUAL
OPERATOR CAB (CONT’D) Figure 50-10-18

Removal And Installation (Cont’d)

Figure 50-10-16
1

P-53573

Temporarily remove the protective covering (Item 1)

S5882 [Figure 50-10-18] from the A/C hoses and
expansion valve.

Remove the main wire harness connector (Item 1) from Figure 50-10-19
the A/C fan switch (Item 2) [Figure 50-10-16].

Remove the fuse box cover (Item 3) [Figure 50-10-16].

Figure 50-10-17
1

2
1

P-53574
1

Remove the bolt (Item 1) and plate (Item 2)) [Figure 50-
10-19]. Remove the A/C hoses from the valve.
S5885
NOTE: Plug the A/C hoses to prevent contamination.

Remove two screws (Item 1) to remove the side cover

(Item 2) [Figure 50-10-17].

6986740-EN (07-08) 50-10-5 Bobcat T2250

SERVICE MANUAL
OPERATOR CAB (CONT’D) Figure 50-10-22

Removal And Installation (Cont’d)

Figure 50-10-20

S7150
2 S2929
1 1
Install a hoist to lift and support the cab [Figure 50-10-
S2975 22].

Apply light lifting pressure to the hoist to support the cab

Loosen the bolts (Item 1) and remove the A/C hoses while the mounting hardware is being removed.
(Item 2) [Figure 50-10-20] from the cab by pulling them
into the battery compartment. Figure 50-10-23

Open the engine cover.

Figure 50-10-21

2 1 S2979

Remove the cab mount bolt (Item 1) and washer (Item 2)

S7216 [Figure 50-10-23] from the front of the cab.

Remove the engine speed control cable (Item 1) [Figure

50-10-21] from the linkage.

Remove the engine speed control cable from the

mounting bracket (Item 2) [Figure 50-10-21].

Remove any necessary nylon ties, carefully remove the

speed control cable from the engine compartment.

NOTE: Adjust the engine speed control cable during

installation. (See Removal And Installation on
Page 70-20-1.)

Close the engine cover.

6986740-EN (07-08) 50-10-6 Bobcat T2250

SERVICE MANUAL
OPERATOR CAB (CONT’D) Figure 50-10-26

Removal And Installation (Cont’d)

Figure 50-10-24

S7150

Lift and remove the cab [Figure 50-10-26].

S2977

Loosen the rear mounting bolt (Item 1) [Figure 50-10-24]

remove the nut.

NOTE: The bolt cannot be removed from the mount.

Figure 50-10-25

1
2

S2976

Remove the two bolts (Item 1) and plastic cushions (Item

2) [Figure 50-10-25].

6986740-EN (07-08) 50-10-7 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 50-10-8 Bobcat T2250
SERVICE MANUAL
OPERATOR SEAT Assembly And Disassembly

Removal And Installation Back Cushion removal

Figure 50-20-1 Figure 50-20-2

1
1
2

S5138 S4139

Remove the bolt covers and the bolts beneath (Item 1) Remove the seat belt mounting bolt cover and the bolt
[Figure 50-20-1] on both sides of the seat. beneath (Item 1) on both sides. Remove the retainers by
removing the bolt (Item 1) [Figure 50-20-2].
Installation: Tighten to 18 ft.-lb. (25 N•m) torque.
Installation: Tighten to 18 ft.-lb. (25 N•m) torque.
Remove the seat.
Figure 50-20-3

1 1

S5142

Remove the three cushion mount bolts (Item 1) [Figure

50-20-3] from the back of the seat to remove the back
cushion.

6986740-EN (07-08) 50-20-1 Bobcat T2250

SERVICE MANUAL
OPERATOR SEAT (CONT’D) Figure 50-20-6
1
Assembly And Disassembly (Cont’d)

Back cushion pivoting mechanism removal 2

Figure 50-20-4

S4145

1 Remove the bolt (Item 1). Remove the back cushion pivot
mechanism (Item 2) [Figure 50-20-6].

S4143 Operator Seat Frame removal

Figure 50-20-7
Remove the two screws (Item 1) [Figure 50-20-4].

Figure 50-20-5

1 1

2 S4146

S4144 Remove the plastic pins that secure the Frame cover
(Item 1) [Figure 50-20-7].

Carefully remove the bolt (Item 1) . Make sure you guard

the spring (Item 2) [Figure 50-20-5] to avoid it causing
damage when released.

6986740-EN (07-08) 50-20-2 Bobcat T2250

SERVICE MANUAL
OPERATOR SEAT (CONT’D) Figure 50-20-10

Assembly And Disassembly (Cont’d)

Figure 50-20-8

S4149

Remove the bolt (Item 1)[Figure 50-20-10] to remove the

S4147 cushion seat from the seat frame (Four bolts require
loosening).

Remove the bolt (Item 1) [Figure 50-20-8] to remove the Installation: Tighten to 18 ft.-lb. (25N•m) torque.
slide rail from the seat frame (Two bolts per rail).
Figure 50-20-11
Remove the Frame Cover.

Figure 50-20-9

1
1

1
1
1

S4150

S4148
Remove the screws (Item 1)[Figure 50-20-11] to remove
the cushion seat from the seat frame.

Remove the bolt (Item 1)[Figure 50-20-9] to remove the

slide rail from the seat mounting frame (Two bolts per rail).

6986740-EN (07-08) 50-20-3 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 50-20-4 Bobcat T2250
SERVICE MANUAL
BOOM ASSEMBLY Figure 50-30-3

Removal And Installation

Figure 50-30-1

S7229

Place a wood block (Item 1) [Figure 50-30-3] under the lift

S7231 cylinder / bucket positioning cylinder.

Figure 50-30-4
Lower the boom onto adequate stands or blocks as shown
[Figure 50-30-1].

Figure 50-30-2

S7232

Support the two cylinders using a cinch strap (Item 1)

S5046 [Figure 50-30-4].

Remove the rear cover (Item 1) [Figure 50-30-2] from the

machine.

6986740-EN (07-08) 50-30-1 Bobcat T2250

SERVICE MANUAL
BOOM ASSEMBLY (CONT'D)

Removal And Installation (Cont'd)

IMPORTANT
Figure 50-30-5
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure 50-30-7
1

S7235 1

Remove the pivot pin retainer bolt (Item 1) [Figure 50-30-

5] from the lift cylinder/bucket positioning cylinder.

Figure 50-30-6

S7234

Lift and support the cylinders using a hoist and lifting strap
(Item 1). Remove the cinch strap (Item 2) [Figure 50-30-
7].

Figure 50-30-8

S7233

Remove the upper pivot pin using a pin removal tool (Item
1) [Figure 50-30-6].

S5027

Lower the two cylinders onto a wood block (Item 1)

[Figure 50-30-8].

6986740-EN (07-08) 50-30-2 Bobcat T2250

SERVICE MANUAL
BOOM ASSEMBLY (CONT'D) Figure 50-30-10

Removal And Installation (Cont'd)

IMPORTANT 1

When repairing hydrostatic and hydraulic systems,

clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

S7237
Figure 50-30-9

Install a lifting chain (Item 1) [Figure 50-30-10] on the

front of the boom.

Figure 50-30-11
2
2

1
1
1
S7236

Disconnect the electrical connector(s) (Item 1) [Figure

50-30-9] (if equipped).
S7238
Disconnect the six hydraulic hoses (Item 2) [Figure 50-
30-9] from the tubelines.
Install a lifting chain (Item 1) [Figure 50-30-11] at the rear
NOTE: Mark the hoses for correct installation. Cap of the boom.
and plug the hoses and tubelines.

6986740-EN (07-08) 50-30-3 Bobcat T2250

SERVICE MANUAL
BOOM ASSEMBLY (CONT'D) Figure 50-30-14

Removal And Installation (Cont'd)

Figure 50-30-12

S7241
1
2
Lift and remove the boom assembly [Figure 50-30-14].
S7239

Remove the bolt (Item 1) and washer (Item 2) [Figure 50-

30-12] from the boom pin.

Figure 50-30-13

S7240

Remove the boom pin [Figure 50-30-13].

6986740-EN (07-08) 50-30-4 Bobcat T2250

SERVICE MANUAL
INNER BOOM Figure 50-40-3

Removal

Figure 50-40-1

2
2

1
1
S7236

Disconnect the electrical connector(s) (Item 1) [Figure

S7305 50-40-3] (if equipped).

Disconnect the six hydraulic hoses (Item 2) [Figure 50-

Install a wood block (Item 1) [Figure 50-40-1] under the 40-3] from the tubelines.
boom, such that it is in a more horizontal position.
NOTE: Mark the hoses for correct installation.
Figure 50-40-2

1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

S5046

Remove the rear cover (Item 1) [Figure 50-40-2].

Remove the front wear pads. (See Removal And

Installation on Page 50-50-1.)

6986740-EN (07-08) 50-40-1 Bobcat T2250

SERVICE MANUAL
INNER BOOM (CONT’D) Figure 50-40-6

Removal (Cont’d)
1
Figure 50-40-4

2 1

1 S7245

Remove the four side wear pads [Figure 50-40-6] at the

S7242 rear of the boom.

Figure 50-40-7
Place a wood block (Item 1) under the cylinder for
support. Remove the bolt (Item 2) [Figure 50-40-4] from
the cylinder.

Figure 50-40-5

S7244

Begin sliding the inner boom from the main boom. Before
the inner boom is completely removed, position a hoist
S7249 and lifting strap on the inner boom. Carefully continue to
remove the inner boom completely [Figure 50-40-7].

Remove the three tubeline clamps (Item 1) and remove

the tubeline bracket (Item 2) [Figure 50-40-5].

6986740-EN (07-08) 50-40-2 Bobcat T2250

SERVICE MANUAL
INNER BOOM (CONT'D) Figure 50-40-10

Installation
1
Figure 50-40-8

S7245

Install the four side wear pads [Figure 50-40-10] at the

S7275 rear of the boom.

Figure 50-40-11
Apply grease to the inside top and bottom corners of the
main boom [Figure 50-40-8].

Figure 50-40-9

2 2
1

S7242

Install the bolt (Item 1) [Figure 50-40-11] through the

S7244 support pin and into the cylinder. Tighten the bolt to 221
ft.-lb. (300 N•m) torque.

Install the end of the inner boom (Item 1) into the main Remove the wood block (Item 2) [Figure 50-40-11].
boom (Item 2) [Figure 50-40-9] approximately 2 ft. (610
mm).

Install the front wear pads. (See Removal And Installation

on Page 50-50-1.)

Remove the lifting strap and slide the inner boom fully into
the main boom.

6986740-EN (07-08) 50-40-3 Bobcat T2250

SERVICE MANUAL
INNER BOOM (CONT'D)

Installation (Cont’d)

Figure 50-40-12

1
1

2
S7236

Install the six hoses (Item 1) [Figure 50-40-12] on the

tubelines.

Install the electrical connector(s) (Item 1) [Figure 50-40-

12] (if equipped).

Figure 50-40-13

S5046

Install the rear cover (Item 1) [Figure 50-40-13].

6986740-EN (07-08) 50-40-4 Bobcat T2250

SERVICE MANUAL
WEAR PADS (FRONT) Figure 50-50-3

Removal And Installation

Figure 50-50-1

1 1

1
S7223

1 Remove the side wear pads [Figure 50-50-3].

S7220
Repeat the side wear pad removal steps for the other
side.
Extend the inner boom approximately 2 ft. (610 mm) and
mark the location of the eight wear pads (Item 1) [Figure Installation: Use Loctite 243 or equivalent. Tighten the
50-50-1]. bolts first by hand, then tighten an extra 1/8th turn.

Figure 50-50-2 Figure 50-50-4

1
1

S7221
S7221

Remove the four bolts (Item 1) [Figure 50-50-2] from the Remove the six bolts (Item 1) [Figure 50-50-4] from the
boom. boom.

Installation: Use Loctite 243 or equivalent. Tighten the

bolts to 15 ft.-lb. (20 N•m).

6986740-EN (07-08) 50-50-1 Bobcat T2250

SERVICE MANUAL
WEAR PADS (FRONT) (CONT’D)

Removal And Installation (Cont’d)

Figure 50-50-5

S7222

Remove the wear pad (Item 1) and spacer plate(s) (Item

2) [Figure 50-50-5].

With the two upper wear pads removed, use a hoist and
lifting strap at the end of the boom, apply upwards
pressure, lifting the inner boom off the bottom wear pads.

Remove the bottom wear pads.

6986740-EN (07-08) 50-50-2 Bobcat T2250

SERVICE MANUAL
WEAR PADS (REAR) Installation

Removal Figure 50-60-2

Remove the inner boom. (See Removal on Page 50-40-

1.)

Figure 50-60-1

1 1
Inner height H
2 2

S7275

2 2 Measure and note down the inner height (H) of the outer
boom [Figure 50-60-2].
1 1 S7276
Figure 50-60-3

With the inner boom supported, remove the wear pads 1 1

(Item 1) and spacer plates (Item 2) [Figure 50-60-1].

During inner boom removal, the side wear pads were

removed.

MUST EQUAL MUST EQUAL

OUTER BOOM OUTER BOOM
INSIDE INSIDE
HEIGHT H HEIGHT H
MINUS 0.0394” MINUS 0.0394”
(1MM) (1MM)

1 1 S7276

Using the appropriate spacer plates to come to height H

minus 0.0394” (1mm) of clearance, install the new wear
pads (Item 1) [Figure 50-60-3].

Tighten the bolts to 15 ft.-lb. (20 N•m). Use Loctite 243 or

equivalent.

NOTE: Spacer plates can be ordered in 0.0394”

(1mm), 0.0787” (2mm) and 0.1181” (3mm) of
thickness.

NOTE: Left and right side height should be exactly the

same.

Apply grease to the wear pads.

Install the inner boom. (See Installation on Page 50-40-

3.).

6986740-EN (07-08) 50-60-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 50-60-2 Bobcat T2250
SERVICE MANUAL
ENGINE COVER Removal And Installation

Locking Mechanism Removal And Installation Figure 50-70-2

Lift the engine cover. Add a support to prevent the cover 1

from closing when the lockingmechanism is removed.

Figure 50-70-1

S5118

Figure 50-70-3

1 1
S5065

Remove the retainer clips (Item 1) [Figure 50-70-1] at

both of the ball joints ends. Remove the ball joints from
the ends.

S5119

Remove the four hinge mounting bolts (Item 1) [Figure

50-70-2] and [Figure 50-70-3].

Remove the engine cover.

6986740-EN (07-08) 50-70-1 Bobcat T2250

SERVICE MANUAL
ENGINE COVER (CONT’D)

Lock

Figure 50-70-4

S5107

Loosen the four bolts (Item 1) [Figure 50-70-4].

6986740-EN (07-08) 50-70-2 Bobcat T2250

SERVICE MANUAL
FUEL TANK Figure 50-80-3

Removal And Installation

Figure 50-80-1

1 2
1

S5167

Disconnect the electrical connector (Item 1) [Figure 50-

S5046 80-3].

Figure 50-80-4
Remove the fuel cap (Item 1) [Figure 50-80-1].

Drain all fuel from the tank. Reinstall the fuel cap.

Remove the rear cover (Item 2) [Figure 50-80-1].

Figure 50-80-2

1
1 1
S5166

Remove the fitting (Item 1) [Figure 50-80-4].

P-52893

Remove the bolts (Item 1) and bar (Item 2) [Figure 50-80-

2].

6986740-EN (07-08) 50-80-1 Bobcat T2250

SERVICE MANUAL
FUEL TANK (CONT’D)

Removal And Installation (Cont’d)

Figure 50-80-5

S5169

Remove the fuel line (Item 1) [Figure 50-80-5].

Figure 50-80-6

S2984

Lift the fuel tank out.

If necessary, a bar can be used to help lifting the tank

(Item 1) [Figure 50-80-6].

6986740-EN (07-08) 50-80-2 Bobcat T2250

SERVICE MANUAL
BOB-TACH Figure 50-90-3

Removal And Installation

Figure 50-90-1

S5131

1
1 Remove grease fitting from the top (Item 1) [Figure 50-
S5129 90-3].

Figure 50-90-4
Lower the boom onto a wood block (Item 1) [Figure 50-
90-1].

Figure 50-90-2

1
S5132
1

Remove the grease fittings on both sides (Item 1) [Figure

S5130 50-90-4].

Remove the grease fitting caps (Item 1). Remove the

snap ring on both sides (Item 2) [Figure 50-90-2].

6986740-EN (07-08) 50-90-1 Bobcat T2250

SERVICE MANUAL
BOB-TACH (CONT'D)

Removal And Installation (Cont'd)

Figure 50-90-5

1
S5133

Drive the pivot pin out (Item 1) [Figure 50-90-5].

Start the engine, lower the restraint bar and retract the tilt
cylinder by moving the joystick to the right.

Stop the engine.

Figure 50-90-6

1 2
3

S5134

Remove the nut (Item 1) and bolt (Item 2) from the Bob-
Tach base pin, on both sides. Drive the pin (Item 3)
through [Figure 50-90-6].

Start the engine, lower the restraint bar, raise the boom
and remove the Bob-Tach.

6986740-EN (07-08) 50-90-2 Bobcat T2250

SERVICE MANUAL
REAR WEIGHTS Figure 50-100-3

Removal And Installation

Figure 50-100-1

S5170

Loosen the top bolts (Item 1) [Figure 50-100-3] on both

S5046 sides.

Figure 50-100-4
Remove the rear cover (Item 1) [Figure 50-100-1].

Remove the tail lights (See Rear Light Removal And

Installation on Page 60-60-1.).

Remove the fuel tank (See Removal And Installation on

Page 50-80-1.).

Figure 50-100-2

1
2
S5172

Remove the two mounting bolts (Item 1) [Figure 50-100-

4].

Lift and remove the weight.

1
1
S7084

Install brackets (Item 1) [Figure 50-100-2] in the threaded

holes on both sides to lift the weight.

Install a hoist (Item 2) [Figure 50-100-2] to lift and

support the weight (approx. 2204 lbs. (1000 kg)).

6986740-EN (07-08) 50-100-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 50-100-2 Bobcat T2250
SERVICE MANUAL
FENDER Rear Fender

Removal And Installation Figure 50-110-2

Front Fender
1
Figure 50-110-1

1 1
S5461

Remove the four nuts and washers (Item 1) [Figure 50-

1 110-2] from the tire. Remove the tire.
S5461

Remove the two fender mount bolts (Item 1) [Figure 50-

110-1]. Remove the fender.

Installation: Tighten the bolts to 90-100 ft.-lb. (125-140

N•m) torque.

6986740-EN (07-08) 50-110-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 50-110-2 Bobcat T2250
SERVICE MANUAL
6986740-EN (07-08) 50-110-3 Bobcat T2250
SERVICE MANUAL
6986740-EN (07-08) 50-110-4 Bobcat T2250
SERVICE MANUAL
JOYSTICK PANEL Figure 50-120-3

Joystick Panel Cover Removal and Installation

2
Figure 50-120-1

S5882
1

Remove the main wire harness connector (Item 1) from

S7204 the A/C fan switch (Item 2) [Figure 50-120-3].

Remove the fuse box cover (Item 3) [Figure 50-120-3].

Rotate the battery disconnect switch (Item 1) [Figure 50-
120-1] to the right, to disconnect the power supply from Figure 50-120-4
the battery.

Figure 50-120-2 2

S2946

1
S5880 Remove the connector (Item 1) from the cigarette lighter
(Item 2) [Figure 50-120-4].

Remove the knobs (Item 1) and raise the fuse box cover
(Item 2) [Figure 50-120-2] gently.

6986740-EN (07-08) 50-130-1 Bobcat T2250

SERVICE MANUAL
JOYSTICK PANEL (CONT’D) Figure 50-120-7

Joystick Panel Cover Removal and Installation 2

(Cont’d)
1
Figure 50-120-5

1
1
1

2 1
1
1
S5888

Remove the five screws (Item 1) and remove the joystick

1 1 panel cover (Item 2) [Figure 50-120-7].
S5853

Remove the four screws (Item 1) from the joystick base

plate (Item 2) [Figure 50-120-5].

Figure 50-120-6

S5892

Remove the joystick base plate (Item 1) [Figure 50-120-

6] by pulling it over the joystick.

6986740-EN (07-08) 50-120-2 Bobcat T2250

SERVICE MANUAL
DASH COVER/STEERING COLUMN COVER

Steering Column Cover Removal And Installation

Figure 50-130-1

1
S2946

Remove the five screws (Item 1) and remove the steering

column cover [Figure 50-130-1].

6986740-EN (07-08) 50-130-1 Bobcat T2250

SERVICE MANUAL
DASH COVER/STEERING COLUMN COVER (CONT’D) Figure 50-130-4

Dash Cover Removal And Installation

Remove the Steering Column Cover. (See Steering

Column Cover Removal And Installation on Page 50-130-
1.)
1
Remove the Instrument Panel. (See Removal And
Installation on Page 60-80-1.)

Figure 50-130-2
2
1

1 S2988

1
Remove the six screws (Item 1) [Figure 50-130-4] from
the dash cover.

Remove the plastic plug (Item 2) [Figure 50-130-4] from

the dash cover.

Figure 50-130-5

S2986

Remove the cap (Item 1) [Figure 50-130-2] from the

steering wheel.
1
Figure 50-130-3

1
S2989

Remove the two plastic plugs (Item 1) [Figure 50-130-5]

from the front top of the dash cover.

Remove the dash cover.

S2987

Remove the nut (Item 1) [Figure 50-130-3] from the

steering wheel.

Remove the steering wheel.

6986740-EN (07-08) 50-130-2 Bobcat T2250

SERVICE MANUAL
 ELECTRICAL SYSTEM AND ANALYSIS

ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . 60-20-3

DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . 60-180-1

Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . 60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Fuses, Diodes And Relays . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

FRONT WIPER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

INCHING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1 ELECTRICAL
Inching Control Calibration (Display Controller) . . . . . . . .60-150-2 SYSTEM &
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1 ANALYSIS

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Light Removal And Installation. . . . . . . . . . . . . . . . . . 60-60-2
Rear Light Removal And Installation . . . . . . . . . . . . . . . . . . 60-60-1

MAIN CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1

Connector Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-2
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1

PEDAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . 60-140-2
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

REAR WIPER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

SERVICE SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1

Calibrate Inch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-4
Connecting Remote Start Tool to Laptop Computer . . . . . 60-160-1
Connecting Remote Start Tool to Telescopic Handler . . . . 60-160-2
Entering The Service Software . . . . . . . . . . . . . . . . . . . . . 60-160-3

Continued On Next Page

6986740-EN (07-08) 60-01 Bobcat T2250

SERVICE MANUAL
 ELECTRICAL SYSTEM AND ANALYSIS (CONT’D)

STARTER 60-40-1
Parts Identification 60-40-4
Removal And Installation 60-40-2
Testing 60-40-1

TOP WIPER MOTOR 60-120-1

Removal And Installation 60-120-1

TRAVEL LEVER 60-70-1

Removal And Installation 60-70-1

6986740-EN (07-08) 60-02 Bobcat T2250

SERVICE MANUAL
ELECTRICAL SYSTEM INFORMATION

Troubleshooting Chart WARNING

The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Instructions are necessary before operating or
most common. Many of the recommended procedures servicing machine. Read and understand the
must be done by authorized Bobcat Service Personnel Operation & Maintenance Manual, Handbook and
only. 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-2003-0199

PROBLEM CAUSE
Battery will not take charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9

KEY TO CORRECT THE CAUSE

1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.

6986740-EN (07-08) 60-10-1 Bobcat T2250

SERVICE MANUAL
ELECTRICAL SYSTEM INFORMATION (CONT’D) Fuses, Diodes And Relays

Description Figure 60-10-2

Figure 60-10-1
1
1

S6532
1

S5880 Remove the covers from the rows of fuses/relays/diodes

(Item 1) [Figure 60-10-2] to check or replace fuses,
diodes or relays.
The Telescopic Handler has a 12 volt, negative ground
alternator charging system. The electrical system is
protected by fuses located in the cab in the right console
(Item 1) [Figure 60-10-1].

The fuses will protect the electrical system when there is

an electrical overload. The reason of the overload must be
found before starting the engine again.

6986740-EN (07-08) 60-10-2 Bobcat T2250

SERVICE MANUAL
 ELECTRICAL SYSTEM INFORMATION (CONT’D)

Fuses, Diodes & Relays (Cont’d)

Figure 60-10-3

39
35 40
17
30 36 41
1 18
29 37 42
9 13 19
14 28 38
8 20
15
7
16 34
6
24 33
12
25
32
2 11 26
22 31
3
10 27
4
5 23
21

S6559

The locations and descriptions are shown below and in [Figure 60-10-3].
FUSES RELAYS
Ref. Description. Amps Ref. Description Amps Ref. Description
2 Starter Relay & Alternator 25 A 26 Drive Controller & Key Switch 25 A 1 Flasher Relay Unit
3 ♦Rear Washer & Top Wiper & 25 A 27 Low Beam Headlights 15 A 6 AC Fan
Rear Wiper & Radio
4 Boom Float & ACD Supply 25 A 35 ACD Attachment 25 A 7 AC Compressor
5 ♦Heater Blower & AC Fan 20 A 36 Cigar Lighter 10 A 8 Glow Plugs
Relay
13 Hazard Lights 7.5 A 37 Ceiling Light & Horn Relay & 7.5 A 9 Starter
Radio
14 Joystick & ACD Switches & 6/2 7.5 A 38 Right Park Lights 10 Boom Float
Way Valve Switch
15 ♦Front Wiper/ Washer & Horn 15 A 39 Head Light SW & Turn Signal & 10 A 11 Back Up Alarm
Switch Horn
16 Left Park Lights & License 7.5 A 40 ISL & Shunt Key & Boom Angle 15 A 12 Stop Lights
Plate Light Sensor
17 FNR Lever & Drive Controller 10 A 41 Front Work Lights 15 A 21 Ignition
18 Steering Mode 10 A 42 Rear & Boom Work Lights 15 A 28 Rear & Boom Work Lights
19 Power Bob-Tach Switch & 15 A 29 Front Work Lights
Parking Brake Switch & Bea-
con
20 Stop Lights & Rear Auxiliaries 15 A 30 Blue Work Lights
& Brake Fail Pressure Switch
22 ♦Air Conditioner Fan 20 A 31 Low Speed
23 ♦Air Condition Compressor 7.5 A * + Battery 50 A 32 Low Beam Headlights
24 Display Controller 25 A * Ignition Relay & Glow Plug Relay 50 A 33 Horn
25 Fuel Pull Relay & Low Speed 25 A * Hazard Lights 7.5 A 34 Fuel Pull
Relay

* Located under the cab, close to the battery.

♦ Not used on Canopy models.

6986740-EN (07-08) 60-10-3 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 60-10-4 Bobcat T2250
SERVICE MANUAL
BATTERY Figure 60-20-2

Removal And Installation

WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and rubber
gloves to keep acid off body.In case of acid contact, 1
wash immediately with water.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
1
minutes.
S3703
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get prompt
medical attention. Remove the two nuts (Item 1) [Figure 60-20-2] from the
W-2065-1296
bottom of the battery access cover.

Figure 60-20-1 Remove the battery access cover.

1 Figure 60-20-3
1

2
S7205
S3701 1

S3704
Remove the two screws (Item 1) from the battery access
cover (Item 2) [Figure 60-20-1] located on the back of the
cab. Remove the bolts (Item 1) [Figure 60-20-3] on both sides
of the battery. The nuts have already been removed for
battery cover removal.

Always disconnect the negative cable first to prevent

sparks.

Remove the positive battery cable.

Remove the battery.

6986740-EN (07-08) 60-20-1 Bobcat T2250

SERVICE MANUAL
BATTERY (CONT'D) Figure 60-20-5

Servicing

WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and rubber
gloves to keep acid off body.In case of acid contact,
wash immediately with water.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
P-09590
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get prompt
medical attention. Always clean the terminals and cable ends when installing
W-2065-1296
a new battery [Figure 60-20-4] and [Figure 60-20-5].

Figure 60-20-4 When installing the battery in the Telescopic Handler, do

not touch any metal parts with the battery terminal posts.

Connect and tighten the battery cables. Connect the

negative (-) cable last to prevent sparks.

Figure 60-20-6

P-09589

P-09588

The battery cables must be clean and the connections

tight. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate (baking soda) and
water solution [Figure 60-20-6].

Check the electrolyte level in the battery. Add distilled

water as needed.

Put Battery Saver (P/N 6664458) or grease on the battery

terminals and cable ends to prevent corrosion.

6986740-EN (07-08) 60-20-2 Bobcat T2250

SERVICE MANUAL
BATTERY (CONT'D)

Using A Booster Battery (Jump Starting)

WARNING
If it is necessary to use a booster battery to start the
engine, BE CAREFUL! There must be one person in the
operator’s seat and one person to connect and disconnect Keep arcs, sparks flames and lighted tobacco away
the battery cables. from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
The key switch must be OFF. The booster battery must be
12 volt. Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F (16°C) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
IMPORTANT lean over battery while boosting, testing or charging.

Battery gas can explode and cause serious injury.

Damage to the alternator can occur if: W-2066-0705
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the VersaHANDLER.
(Remove both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2228-0304

WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and rubber
gloves to keep acid off body.

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.

If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get prompt
medical attention.
W-2065-0807

6986740-EN (07-08) 60-20-3 Bobcat T2250

SERVICE MANUAL
BATTERY (CONT'D)

Using A Booster Battery (Jump Starting) (Cont’d)

Figure 60-20-7

S3345

1 3

S3336

Connect the end of the first cable to the positive (+)

terminal of the booster battery (Item 1) [Figure 60-20-7].
Connect the other end of the same cable to the positive
terminal (Item 2) [Figure 60-20-7] on the Telescopic
Handler starter.

Connect the end of the second cable to the negative (-)

terminal of the booster battery (Item 3) [Figure 60-20-7].
Connect the other end of the same cable to one of the
bolts that connect the engine to the belt shield (Item 4)
[Figure 60-20-7] or to the ground cables of the engine
(beneath the alternator).

Keep cables away from moving parts. Start the engine.

After the engine has started, remove the ground (-) cable
(Item 4) [Figure 60-20-7] first.

Remove the cable from the positive terminal (Item 2)

[Figure 60-20-7].

6986740-EN (07-08) 60-20-4 Bobcat T2250

SERVICE MANUAL
ALTERNATOR Figure 60-30-3

Removal And Installation

Figure 60-30-1

2
1 2

S3686

1
Remove the bolt (Item 1) and the nut (Item 2) [Figure 60-
S5154 30-3].

Remove the alternator.

Open the engine cover.

Remove the connector (Item 1) and the bolt (Item 2)

[Figure 60-30-1].

Figure 60-30-2

1
1

S3685

Loosen the two bolts (Item 1) [Figure 60-30-2] from the

bottom of the alternator.

6986740-EN (07-08) 60-30-1 Bobcat T2250

SERVICE MANUAL
ALTERNATOR (CONT’D)

Adjusting The Alternator Belt

Stop the engine.

Open the engine cover.

Figure 60-30-4

1 2

S5156

Loosen the bolt (Item 1) and nut (Item 2) [Figure 60-30-4]

at the top of the alternator.

Figure 60-30-5

S5188

Loosen the alternator mounting bolt (Item 1) [Figure 60-

30-5] at the bottom of the alternator.

Move the alternator until the belt has 5/16 inch (8,0 mm)
movement at the middle of the belt span (Item 1) [Figure
60-30-5] with 15 lbs. (20 N•m) of force.

Tighten the adjustment and mounting bolts.

6986740-EN (07-08) 60-30-2 Bobcat T2250

SERVICE MANUAL
STARTER Figure 60-40-3

Testing

Figure 60-40-1

2
1
Bat
S
M

Cranking
Motor
P-34673

Disconnect the negative cable from the battery. (See

A-1992 Removal And Installation on Page 60-20-1.)

Disconnect the S terminal on the starter (Item 1) [Figure

The key switch must be in the OFF position. 60-40-3].
The battery must be at full charge. Hold-In Test: Use circuit tester, touch one probe to the S
terminal (Item 1) and one probe to the mounting bolt (Item
The cable connections on the battery must be clean and
tight. 2) [Figure 60-40-3] on the magnetic switch (solenoid). If
there is no continuity replace the magnetic switch
Connect a jumper wire between S terminal and BAT (solenoid).
terminal [Figure 60-40-1].
Figure 60-40-4
If the starter turns but does not turn the engine, the starter
drive has a defect.
2
Figure 60-40-2
1
P-34675
Bat
1
S
M

2
Cranking
Motor
P-34674

Disconnect the negative cable from the battery. (See

A-1991 Removal And Installation on Page 60-20-1.)

Disconnect the S terminal on the starter (Item 1) [Figure

Connect a jumper wire (of at least 4 gauge in size) 60-40-4].
between the M terminal and the BAT terminal [Figure 60-
40-2]. Pull-In Test: Use circuit tester, touch one probe to the S
terminal (Item 1) and one probe to the starter motor
If the starter turns, the defect is in the solenoid. terminal (Item 2) [Figure 60-40-4]. If there is no continuity
replace the magnetic switch (solenoid).
If the starter does not turn, the starter is defective.

6986740-EN (07-08) 60-40-1 Bobcat T2250

SERVICE MANUAL
STARTER (CONT’D) Figure 60-40-7

Removal And Installation

Figure 60-40-5 2

2
S5159

Loosen the bolt (Item 1) to remove the electrical wire

S5157 (Item 2) [Figure 60-40-7] from the starter.

Figure 60-40-8
Loosen the bolt (Item 1) to remove the electrical wire
(Item 2) [Figure 60-40-5].

Figure 60-40-6

1
2

S5160

Remove the bolt (Item 1) and the electrical wire (Item 2)

S5158 [Figure 60-40-8] from the starter.

Remove the small bolt (Item 1) and remove the electrical

wire (Item 2) [Figure 60-40-6].

6986740-EN (07-08) 60-40-2 Bobcat T2250

SERVICE MANUAL
STARTER (CONT’D)

Removal And Installation (Cont’d)

Figure 60-40-9

1 S5161

Remove the three bolts (Item 1) [Figure 60-40-9] from the

magnetic switch.

Remove the starter from the engine.

Installation: Tighten to 40-45 ft.-lb. (54-61 N•m) torque

6986740-EN (07-08) 60-40-3 Bobcat T2250

SERVICE MANUAL
STARTER (CONT'D)

Parts Identification

1. Starter 30 13. Lever

2. Shaft 14. Gear
3. Gear 15. Bracket
4. Washer 16. Spring
5. Shaft 17. Gear
6. Stop Ring 34 18. Stop
33
7. Lever 19. Stop Ring
8. Holder 13 20. Ball
9. Spring 21. Armature
10. Spring 36 22. Washer
11. Plate 8 23. Seal
11
12. Seal 9
10
31
32 7
21

15
12 37
16
14
17 20
19 18

14

6
29
1 4
3
28
2
27

24. Yoke
35 25. Holder
26. Bracket
27. Ring
22 26
28. Bolt
29. Bolt
23 25 30. Switch
31. Seal
23 32. Bolt
33. Washer
34. Nut
24 35. Boot
36. Bracket
37. Bearing
B-19824

6986740-EN (07-08) 60-40-4 Bobcat T2250

SERVICE MANUAL
LIGHTS Figure 60-60-3

Rear Light Removal And Installation

Figure 60-60-1

S5123

Now replace all lightbulbs that need replacing. [Figure

1 S5121 60-60-3].

Remove the electrical connector (Item 1). Remove the tow

mounting bolts (Item 1) [Figure 60-60-1]. Remove the
lightharness.

Figure 60-60-2

S5122

Loosen the screws (Item 1) [Figure 60-60-2] of the cover

from the electrical harness.

6986740-EN (07-08) 60-60-1 Bobcat T2250

SERVICE MANUAL
LIGHTS (CONT'D)

Front Light Removal And Installation

Figure 60-60-4

S5112

Disconnect the light harness connector (Item 1) [Figure

60-60-4] from the light.

Figure 60-60-5

S5113

Remove the two bolts (Item 1) [Figure 60-60-5] and

remove the light.

6986740-EN (07-08) 60-60-2 Bobcat T2250

SERVICE MANUAL
TRAVEL LEVER Figure 60-70-3

Removal And Installation

Remove the instrument panel. (See “Removal And

Installation” on page 60-80-1)

Figure 60-70-1

1
2

S2955

Disconnect the travel control wire harness connector

(Item 1) and signal control wire connector (cab only) (Item
1 2) [Figure 60-70-3].

S7204 Figure 60-70-4

Rotate the battery disconnect switch (Item 1) [Figure 60-

70-1] to the right, to disconnect the power supply from the
battery.
1
Figure 60-70-2

1
1
S2956

1
Remove the two screws (Item 1) [Figure 60-70-4] from
the travel lever.

1
S2946

Remove the five screws (Item 1) and remove the steering

column cover [Figure 60-70-2].

6986740-EN (07-08) 60-70-1 Bobcat T2250

SERVICE MANUAL
TRAVEL LEVER (CONT’D) Figure 60-70-7

Removal And Installation (Cont’d)

Figure 60-70-5

3
1

S2958

Installation: Align the pin (Item 1) in the travel lever with

S2959 the hole (Item 2) [Figure 60-70-7] in the steering column.

NOTE: For the canopy, the lever must be slightly

Remove the signal lever (cab version only) (Item 1) angled up in order to let the operator restraint
[Figure 60-70-5]. bar pass. Therefore an extra hole (Item 3)
[Figure 60-70-7] is provided.
Figure 60-70-6

S2957

Remove the travel lever (Item 1) [Figure 60-70-6].

6986740-EN (07-08) 60-70-2 Bobcat T2250

SERVICE MANUAL
INSTRUMENT PANEL Figure 60-80-3

Removal And Installation

Figure 60-80-1

S2949

1
Remove the temperature control knob (Item 1) [Figure
S7204 60-80-3] (If Equipped).

Figure 60-80-4
Rotate the battery disconnect switch (Item 1) [Figure 60-
80-1] to the right, to disconnect the power supply from the
battery.

Figure 60-80-2

1
1

1
S2948

1
Remove the nut (Item 1) [Figure 60-80-4] letting the
temperature controller fall inward.
S6364

Remove the nine instrument panel mounting bolts (Item 1)

[Figure 60-80-2].

6986740-EN (07-08) 60-80-1 Bobcat T2250

SERVICE MANUAL
INSTRUMENT PANEL Figure 60-80-7

Removal And Installation (Cont’d)

Figure 60-80-5 2

S2952

Remove the tie straps (Item 1) and unplug the connector

S2950 (Item 2) [Figure 60-80-7].

Remove the fuse box cover.

Tilt the instrument panel forward and unplug all
connectors [Figure 60-80-5]. Figure 60-80-8

NOTE: Mark the connectors for correct installation.

Remove the battery cover. (See “Removal And

Installation” on page 60-20-1.)

Figure 60-80-6

1
1

S2953
1

Pull the harness and connector (Item 1) [Figure 60-80-8]

into the cab. Then continue pulling the harness and
connector to the instrument panel.

S2951 Remove the instrument panel.

Remove the tie straps (Item 1) [Figure 60-80-6] that

connect the harness to the frame.

6986740-EN (07-08) 60-80-2 Bobcat T2250

SERVICE MANUAL
FRONT WIPER MOTOR Figure 60-110-3

Removal And Installation

Figure 60-110-1

1
S2981
1

Remove the spray tube (Item 1) [Figure 60-110-3].

S7204
Figure 60-110-4

Rotate the battery disconnect switch (Item 1) [Figure 60-

110-1] to the right, to disconnect the power supply from
the battery.
2
Remove the dash cover/steering column cover. (See
Removal And Installation on Page 50-130-1.) 2

Figure 60-110-2

1 1

S2982

Flip open the wiper covers and remove the two nuts
(Item 1) [Figure 60-110-4].

Remove the wiper arms ( Item 2) [Figure 60-110-4] from

the wiper motor shafts.

S2980

Disconnect the front wiper connector (Item 1) [Figure 60-

110-2] from the main harness.

Reposition the main wire harness to the right side of the

cab.

6986740-EN (07-08) 60-110-1 Bobcat T2250

SERVICE MANUAL
FRONT WIPER MOTOR (CONT'D) Figure 60-110-7

Removal And Installation (Cont'd)

Figure 60-110-5

1
1

S2997

Remove the wiper motor from inside the cab [Figure 60-
S2983 110-7].

Remove both outer nuts (Item 1) [Figure 60-110-5].

Figure 60-110-6

S2996

Remove both inner nuts (Item 1) and washers (Item 2)

[Figure 60-110-6].

6986740-EN (07-08) 60-110-2 Bobcat T2250

SERVICE MANUAL
TOP WIPER MOTOR Figure 60-120-3

Removal And Installation

Figure 60-120-1

S5872
1

Remove the cover (Item 1) [Figure 60-120-3] from the

S7204 interior light.

Figure 60-120-4
Rotate the battery disconnect switch (Item 1) [Figure 60-
120-1] to the right, to disconnect the power supply from 1
the battery.

Figure 60-120-2

1
1

S5873
1 1

Mark and disconnect electrical connectors (Item 1)

[Figure 60-120-4] from the interior light.
S5874
Remove the roof cowling.

Remove the four bolts (Item 1) [Figure 60-120-2].

Gently lower the roof cowling.

6986740-EN (07-08) 60-120-1 Bobcat T2250

SERVICE MANUAL
TOP WIPER MOTOR (CONT'D) Figure 60-120-7

Removal And Installation (Cont'd)

Figure 60-120-5

1 S5876

Have an assistant support the wiper motor [Figure 60-

S5875 120-7].

Figure 60-120-8
Disconnect the top wiper connector (Item 1) [Figure 60-
120-5] from the main harness.

Figure 60-120-6

S5878
3

Remove the plastic cover (Item 1) [Figure 60-120-8].

2
S5877

Flip open the wiper cover and remove the nut

(Item 1) [Figure 60-120-6].

Disconnect the spray tube (Item 2) [Figure 60-120-6].

Remove the wiper arm (Item 3) [Figure 60-120-6] from

the wiper motor shaft.

6986740-EN (07-08) 60-120-2 Bobcat T2250

SERVICE MANUAL
TOP WIPER MOTOR (CONT'D)

Removal And Installation (Cont'd)

Figure 60-120-9

1 1

S5879

Remove the two nuts (Item 1) [Figure 60-120-9].

Remove the wiper motor.

6986740-EN (07-08) 60-120-3 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 60-120-4 Bobcat T2250
SERVICE MANUAL
REAR WIPER MOTOR Figure 60-130-3

Removal And Installation

Figure 60-130-1

S5872
1

Remove the cover (Item 1) [Figure 60-130-3] from the

S7204 interior light.

Figure 60-130-4
Rotate the battery disconnect switch (Item 1) [Figure 60-
130-1] to the right, to disconnect the power supply from 1
the battery.

Figure 60-130-2

1
1

S5873
1 1

Mark and disconnect electrical connectors (Item 1)

[Figure 60-130-4] from the interior light.
S5874
Remove the roof cowling.

Remove the four bolts (Item 1) [Figure 60-130-2].

Gently lower the roof cowling.

6986740-EN (07-08) 60-130-1 Bobcat T2250

SERVICE MANUAL
REAR WIPER MOTOR (CONT'D) Figure 60-130-7

Removal And Installation (Cont'd)

Figure 60-130-5

S5869

Have an assistant support the wiper motor [Figure 60-

S5867 130-7].

Figure 60-130-8
Disconnect the rear wiper connector (Item 1) [Figure 60-
130-5] from the main harness.

Figure 60-130-6

S5870

Remove the plastic cover (Item 1) [Figure 60-130-8].

S5868

Flip open the wiper cover and remove the nut

(Item 1) [Figure 60-130-6].

Remove the wiper arm (Item 2) [Figure 60-130-6].

6986740-EN (07-08) 60-130-2 Bobcat T2250

SERVICE MANUAL
REAR WIPER MOTOR (CONT'D)

Removal And Installation (Cont'd)

Figure 60-130-9

1 1

S5871

Remove the two nuts (Item 1) [Figure 60-130-9].

Remove the wiper motor.

6986740-EN (07-08) 60-130-3 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 60-130-4 Bobcat T2250
SERVICE MANUAL
PEDAL ASSEMBLY Figure 60-140-3

Removal And Installation

Figure 60-140-1
1

S2967

1
Remove the accelerator cable (Item 1) from the pedal and
S7204 mounting bracket (Item 2) [Figure 60-140-3].

Figure 60-140-4
Rotate the battery disconnect switch (Item 1) [Figure 60-
140-1] to the right, to disconnect the power supply from
the battery.

Remove the dash cover/column cover. (See “DASH

COVER/STEERING COLUMN COVER” on page -50-130-
1)

Figure 60-140-2
1

S2968
1

Remove the three hoses (Item 1) [Figure 60-140-4] from

the brake valve.

NOTE: Mark hoses for correct installation.

S2965

IMPORTANT
Disconnect the connector (Item 1) [Figure 60-140-2] from
the inching switch. When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

6986740-EN (07-08) 60-140-1 Bobcat T2250

SERVICE MANUAL
PEDAL ASSEMBLY (CONT’D) Disassembly And Assembly

Removal And Installation (Cont’d) Figure 60-140-6

Figure 60-140-5
1 2

1
1

1 1
P-42869

S2969
Remove the bolt (Item 1) and spring (Item 2) [Figure 60-
140-6].
Remove the mounting nuts (Item 1) [Figure 60-140-5].
Figure 60-140-7
Remove the pedal assembly.

Installation: Tighten the nuts to 18 ft-lb. (25 N•m) torque.

P-42870

Remove the roll pin (Item 1) and pedal (Item 2) [Figure

60-140-7].

6986740-EN (07-08) 60-140-2 Bobcat T2250

SERVICE MANUAL
PEDAL ASSEMBLY (CONT’D) Figure 60-140-10

Disassembly And Assembly (Cont’d)

1
Figure 60-140-8

1
1
1

P-42874

Remove the three bolts (Item 1) [Figure 60-140-10] from

P-42871 the two bearing flanges.

Figure 60-140-11
Installation: Align the hole (Item 1) in the pedal with the
hole (Item 2) [Figure 60-140-8] in the shaft.

Figure 60-140-9

P-42875

Remove the shaft and bearing assembly [Figure 60-140-

P-42872 11].

Loosen the two set screws (Item 1) [Figure 60-140-9] on

the two bearings.

6986740-EN (07-08) 60-140-3 Bobcat T2250

SERVICE MANUAL
PEDAL ASSEMBLY (CONT’D) Figure 60-140-14

Disassembly And Assembly (Cont’d)

Figure 60-140-12

1 2 1

2
P-42877

2 Remove the four bolts (Item 1) spacers (Item 2) [Figure

P-42876 60-140-14] and nuts from the brake valve.

Figure 60-140-15
Remove the flanges (Item 1) and bearings (Item 2)
[Figure 60-140-12].

Figure 60-140-13

P-42879

Remove the brake valve (Item 1) [Figure 60-140-15].

P-42878

Remove the three fittings (Item 1) [Figure 60-140-13]

from the brake valve.

6986740-EN (07-08) 60-140-4 Bobcat T2250

SERVICE MANUAL
PEDAL ASSEMBLY (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 60-140-16

P-42880

Remove the retainer pin (Item 1) and washer (Item 2)

[Figure 60-140-16].

Figure 60-140-17

P-42881

Remove the pedal (Item 1) [Figure 60-140-17].

6986740-EN (07-08) 60-140-5 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 60-140-6 Bobcat T2250
SERVICE MANUAL
INCHING SWITCH Adjustment

Removal And Installation Remove the dash cover/column cover. (See “DASH
COVER/STEERING COLUMN COVER” on page -50-130
Remove the dash cover/column cover. (See “DASH 1.)
COVER/STEERING COLUMN COVER” on page -50-130
1.) Figure 60-150-2

Figure 10-150-1 0.31”

(8 mm)

2
1

3
S2965

1
Remove the tie strap and unplug the switch connector
(Item 1) [Figure 10-150-1] from the harness.

Figure 60-150-1

MS-01215

1 With the brake pedal in the rest position, turn the

adjustment bolt (Item 1) so that it is 0.31 in. (8 mm) away
from the switch body (Item 2) [Figure 60-150-2].
1
Check that the potentiometer rod (Item 3) [Figure 60-150-
2] is in contact with the center of the adjusting bolt.
S2966

When adjustment is complete, tighten the nut (Item 4)

Remove the two mounting bolts and nuts (Item 1) [Figure [Figure 60-150-2] without turning the adjusting bolt.
60-150-1].

Installation: Be sure the switch is on the front side of the

mounting bracket.

Remove the switch.

6986740-EN (07-08) 60-150-1 Bobcat T2250

SERVICE MANUAL
INCHING SWITCH (CONT’D) Figure 60-150-5

Inching Control Calibration (Display Controller)

Description

The Inching Control is used to slow the Telescopic

Handler while maintaining high engine RPM.

The Inching Control will have to be recalibrated if an

Inching Control fault occurs, or if the Drive Controller is
replaced.

The Inching Control Calibration Display Controller

procedure shows how to calibrate the Inching Control
through the display panel. S7192

Procedure
Once the toal machine hours are displayed, press and
Connect the remote start tool to the Telescopic Handler. hold the Hours/jobs/RPM button (Item 1) [Figure 60-150-
(See “REMOTE START” on page -10-170-1.) 3] for approximately 5 seconds until CAL is displayed
(Item 1) [Figure 60-150-5].
Figure 60-150-3
Figure 60-150-6

S7190
S7193

Figure 60-150-4
After approximately 3 seconds the display will change to
inch (Item 1) [Figure 60-150-6].

S7191

To enter Inching Control calibration from the Display

Controller, press the Hours/Job/RPM button (Item 1)
[Figure 60-150-3] until HRS is displayed (Item 1) [Figure
60-150-4] .

6986740-EN (07-08) 60-150-2 Bobcat T2250

SERVICE MANUAL
INCHING SWITCH (CONT’D) Figure 60-150-9

Inching Control Calibration (Display Controller)

(Cont’d)

Figure 60-150-7

S7196

PdLdn [Figure 60-150-9] will be displayed indicating that

the brake pedal needs to be depressed.
S7194

Press the up arrow (Item 1) [Figure 60-150-7] to enter

Inching Control Calibration.

Figure 60-150-8

S7195

PdLUP [Figure 60-150-8] will be displayed indicating that

the brake pedal needs to be released.

6986740-EN (07-08) 60-150-3 Bobcat T2250

SERVICE MANUAL
INCHING SWITCH (CONT’D) Figure 60-150-12

Inching Control Calibration (Display Controller)

(Cont’d)

Figure 60-150-10

S7190

If the Inching Control calibration passed, then press and

hold the Hours/Job/RPM button (Item 1) [Figure 60-150-
S7197 12] until the display powers down. The calibration
procedure is now complete.

Figure 60-150-11

S7198

After approximately 3 pedal cycles of depressing and

releasing the brake pedal, the LCD display will display
either a Pass (Item 1) [Figure 60-150-10] or a fail (Item 1)
[Figure 60-150-11], indicating whether the Inching
Control has been successfully calibrated.

If the Inching Control calibration failed, then the power will

need to be cycled, and this process will need to be
restarted from the beginning.

6986740-EN (07-08) 60-150-4 Bobcat T2250

SERVICE MANUAL
SERVICE SOFTWARE

Connecting Remote Start Tool to Laptop Computer

Figure 60-160-1

1 2

P16119

Tools that will be needed to complete the following steps

are:

MEL1563 - Remote Start Tool

MEL1565 - Service Tool Harness Control
MEL1566 -Service Tool Harness Communicator
(Computer Interface)

NOTE: Make all connections with the key in the OFF

position.

The Service PC (Item 1) with the remote start tool (Item 2)

[Figure 60-160-1]. When connected to the Telescopic
Handler, the Service PC is used to monitor, conduct
diagnostic and load software.

Connect the Service Tool Harness Communicator

(MEL1566) (Item 3) [Figure 60-160-1] to the designated
serial port on the Service PC.

NOTE: The recommended serial cable length should

not exceed 15 feet. A serial cable longer than
15 feet will create a degraded signal causing
communication errors.

Connect the other end to the connector on the remote

start tool.

Connect the remote start tool to the Telescopic Handler.

(See Connecting Remote Start Tool to Telescopic Handler
on Page 60-160-2.)

6986740-EN (07-08) 60-160-1 Bobcat T2250

SERVICE MANUAL
SERVICE SOFTWARE (CONT’D) NOTE: The remote start tool connection harness has
two connectors (Item 1) and (Item 3). The main
Connecting Remote Start Tool to Telescopic Handler connector (Item 1) is always used for
connection to the engine harness [Figure 60-
Figure 60-160-2 160-3].

The second connector (Item 3) [Figure 60-160-

1 3] is used for attachment ACD upgrades or
attachment operational diagnostics only. This
connector has a cap attached to it to prevent
damage or corrosion when not in use.

NOTE: The key switch on the machine operator panel

must be in the off position or the Remote Start
Kit will not operate.

S5046

Remove the rear cover (Item 1) [Figure 60-160-2] from

the Telescopic Handler.

Figure 60-160-3

3
S7089

Connect the MEL1565 main connector (Item 1) to the

machine frame harness connector (Item 2) [Figure 60-
160-3], located in the rear of the machine.

For machines with an attachment control harness, the

attachment harness must first be disconnected from the
Telescopic Handler harness.

6986740-EN (07-08) 60-160-2 Bobcat T2250

SERVICE MANUAL
SERVICE SOFTWARE (CONT’D) Figure 60-160-6

Entering The Service Software

Position the laptop such that its screen can be read from
the operator seat.

Start the program by clicking the “Factory Analyzer” icon

on the desktop.

Figure 60-160-4

S7100

This is the Main Screen of the Telescopic Handler

analyzer program [Figure 60-160-6].

S7098

The “select port” screen will appear when entering the

Telescopic Handler service analyzer [Figure 60-160-4].
The com port can be changed, if com port 1 is already
being used.

Figure 60-160-5

S7099

The above screen [Figure 60-160-5] will appear if:

• The remote start tool is not connected to the machine.

• The service tool ignition key is not in ON position.

6986740-EN (07-08) 60-160-3 Bobcat T2250

SERVICE MANUAL
SERVICE SOFTWARE (CONT’D) Figure 60-160-9

Calibrate Inch Pedal

Figure 60-160-7

S7092

Read the warning and make sure the situation is conform

S7090 with its content. Click OK (Item 1) [Figure 60-160-9].

Figure 60-160-10
Select the Diagnostics icon (Item 1) [Figure 60-160-7].

Figure 60-160-8

1
1

S7093

S7091 In the Diagnostic Screen, click on the Inch Pedal Button

(Item 1) [Figure 60-160-10].

Select System Diagnostics (Item 1) [Figure 60-160-8].

6986740-EN (07-08) 60-160-4 Bobcat T2250

SERVICE MANUAL
SERVICE SOFTWARE (CONT’D) Figure 60-160-13

Calibrate Inch Pedal (Cont’d)

Figure 60-160-11

S7097

If the procedure was succesfull, the above screen will

S7094 appear [Figure 60-160-13].

Before pressing OK, power cycle the machine by turning

Enter the cab, and keep the inching pedal released for at the machine contact key to ON and then again to OFF.
least 5 seconds, as instructed on the screen [Figure 60- Then press OK to return to the Diagnostic Screen.
160-11].
Figure 60-160-14
Figure 60-160-12

S7096
S7095

If the procedure was not succesfull, the above screen will

Follow the new instruction on the screen and keep the appear [Figure 60-160-14].
inching pedal pressed for at least 5 seconds [Figure 60-
160-12]. Before pressing OK, power cycle the machine by turning
the machine contact key to ON and then again to OFF.
Follow further instructions on the screen. The above steps Then press OK to return to the Diagnostic Screen.
will recur several times.
Repeat the Calibrate Inch Pedal procedure until
succesfull.

6986740-EN (07-08) 60-160-5 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 60-160-6 Bobcat T2250
SERVICE MANUAL
MAIN CONTROLLER

Removal And Installation

Figure 60-170-1

S7204

Rotate the battery disconnect switch (Item 1) [Figure 60-

170-1] to the right, to disconnect the power supply from
the battery.

Remove the dash cover / column cover. See “DASH

COVER/STEERING COLUMN COVER” on page -50-130-
1.

The main controller (drive controller) is located under the

dash cover, on the right hand side in front of the joystick.

Figure 60-170-2

1
2

S7083

Disconnect the electrical connector (Item 1) [Figure 60-

170-2].

Remove the three bolts (Item 2) [Figure 60-170-2] from

the main controller.

Remove the main controller.

6986740-EN (07-08) 60-170-1 Bobcat T2250

SERVICE MANUAL
MAIN CONTROLLER (CONT’D)

Connector Identification

Harness Connector View

Controller

S7164
S7165

6986740-EN (07-08) 60-170-2 Bobcat T2250

SERVICE MANUAL
DIAGNOSTIC SERVICE CODES

Viewing Service Codes

Figure 60-180-1

2 3

S2731

Press and hold the Work Lights button (Item 1) for three
seconds to consult the service codes on the display
screen (Item 2). Use the Up and Down buttons (Items 2 &
3) [Figure 60-180-1] to scroll if there are multiple service
codes.

NOTE: Corroded or loose grounds can cause multiple

service codes and/or abnormal symptoms. All
instrument panel lights flashing, alarm
sounding, headlights and taillights flashing,
could indicate a bad ground. The same
symptoms could apply if the voltage is low,
such as loose or corroded battery cables. If
you observe these symptoms, check grounds
and positive leads first.

Service Codes List

COD
FUNCTION FAILURES ICON BUZZER COMMENT
E
03-09 Battery Voltage Low solid battery icon triple display will power down if
beep in limited function mode -
lights operate normally
03-10 Battery Voltage High solid battery icon triple machine able to start - if
beep engine is running it will not
shut off
03-11 Battery Voltage Extremely High flashing battery icon - solid beep display backlight is off -
all other icons disabled machine able to start -
lights operate normally
03-14 Battery Voltage Extremely Low solid battery icon solid beep error code is created
03-15 Battery Voltage In Shutdown solid battery icon no beep engine is shut down
03-22 Battery Voltage Out Of Range Low flashing battery icon triple
beep
04-14 Engine Oil Pressure Extremely Low flashing engine oil no beep
pressure icon
04-15 Engine Oil Pressure In Shutdown flashing engine oil no beep engine is shut down
pressure icon
06-10 Engine Speed High solid general warning triple
icon beep

6986740-EN (07-08) 60-180-1 Bobcat T2250

SERVICE MANUAL
 COD
FUNCTION FAILURES ICON BUZZER COMMENT
E
06-11 Engine Speed Extremely High flashing general solid beep
warning icon
06-13 Engine Speed No Signal flashing general solid beep
warning icon
06-15 Engine Speed In Shutdown flashing general solid beep
warning icon
06-18 Engine Speed Out Of Range solid general warning triple
icon beep
07-10 Hydraulic Oil High solid hydraulic oil triple
Temperature temperature icon beep
07-11 Hydraulic Oil Extremely High flashing hydraulic oil solid beep
Temperature temperature icon
07-15 Hydraulic Oil In Shutdown flashing hydraulic oil no beep
Temperature temperature icon
07-21 Hydraulic Oil Out Of Range High solid hydraulic oil triple
Temperature temperature icon beep
07-22 Hydraulic Oil Out Of Range Low solid hydraulic oil triple
Temperature temperature icon beep
08-10 Engine Coolant High solid engine coolant triple
Temperature temperature icon beep
08-11 Engine Coolant Extremely High flashing engine coolant solid beep
Temperature temperature icon
08-15 Engine Coolant In Shutdown flashing engine coolant no beep
Temperature temperature icon
08-21 Engine Coolant Out Of Range High solid engine coolant triple
Temperature temperature icon beep
08-22 Engine Coolant Out Of Range Low solid engine coolant triple
Temperature temperature icon beep
09-21 Fuel Level Out Of Range High solid general warning triple
icon beep
09-22 Fuel Level Out Of Range Low flashing general triple
warning icon beep
13-05 Fuel Hold Short To Battery solid general warning triple
icon beep
13-06 Fuel Hold Short To Ground solid general warning triple
icon beep
13-07 Fuel Hold Open Circuit solid general warning triple
icon beep
14-02 Fuel Pull Error On solid general warning triple
icon beep
14-03 Fuel Pull Error Off solid general warning triple
icon beep
21-02 Preheater Error On flashing preheater icon triple
beep
21-03 Preheater Error Off flashing preheater icon triple
beep
22-02 Starter Output Error On solid general warning triple
icon beep
22-03 Starter Output Error Off solid general warning triple
icon beep
30-28 Watchdog Failure

6986740-EN (07-08) 60-180-2 Bobcat T2250

SERVICE MANUAL
 COD
FUNCTION FAILURES ICON BUZZER COMMENT
E
31-28 Recovery Mode Failure
33-23 Constant Data Not Calibrated solid general warning triple
icon beep
36-48 ACD (Attachment Multiple Controllers solid general warning triple
Control Device) Present icon beep
50-02 Extend / Retract Out Of Range High flashing joystick triple
Control lockout icon beep
50-03 Extend / Retract Out Of Range Low flashing joystick triple
Control lockout icon beep
50-04 Extend / Retract Not Calibrated flashing joystick triple
Control lockout icon beep
50-05 Auxiliary Control Out Of Range High flashing auxiliary triple
hydraulic icon beep
50-06 Auxiliary Control Out Of Range Low flashing auxiliary triple
hydraulic icon beep
50-07 Auxiliary Control Not Calibrated flashing auxiliary triple
hydraulic icon beep
50-14 Inching Control Out Of Range High solid general warning triple
icon beep
50-15 Inching Control Out Of Range Low solid general warning triple
icon beep
50-16 Inching Control Not Calibrated solid general warning triple still present after
icon beep calibration
50-20 Boom Pressure Out Of Range High solid general warning triple
icon beep
50-21 Boom Pressure Out Of Range Low solid general warning triple
icon beep
50-23 Constant Data Not Calibrated solid general warning triple
icon beep
50-24 Stability Valve Error On solid general warning triple
icon beep
50-25 Stability Valve Error Off solid general warning triple
icon beep
50-26 Recovery Mode Failure only visible with the
service analyzer
50-28 FPR No Inputs Active solid general warning triple
icon beep
50-29 FPR More Than One Input solid general warning triple
Active icon beep
50-30 Rear Light Relay Error On solid general warning triple
icon beep
50-31 Rear Light Relay Error Off solid general warning triple
icon beep
50-33 Brake Control System Error On solid general warning triple
Valve icon beep
50-34 Brake Control System Error Off solid general warning triple
Valve icon beep
50-36 Brake Light Relay Error On solid general warning triple
icon beep
50-37 Brake Light Relay Error Off solid general warning triple
icon beep

6986740-EN (07-08) 60-180-3 Bobcat T2250

SERVICE MANUAL
 COD
FUNCTION FAILURES ICON BUZZER COMMENT
E
50-42 Secondary Auxiliary Error On solid general warning triple
Hydraulic Valve icon beep
50-43 Secondary Auxiliary Error Off solid general warning triple
Hydraulic Valve icon beep
50-45 Extend / Retract Base Error On solid general warning triple
icon beep
50-46 Extend / Retract Base Error Off solid general warning triple
icon beep
50-48 V Sensor 1 Out Of Range Low solid general warning triple
icon beep
50-49 V Sensor 1 Out Of Range High solid general warning triple
icon beep
50-50 V Sensor 2 Out Of Range Low solid general warning triple
icon beep
50-51 V Sensor 2 Out Of Range High solid general warning triple
icon beep
50-54 Switched Battery Over Voltage solid general warning triple
icon beep
50-55 Switched Battery Under Voltage solid general warning triple
icon beep
50-56 CAN Communication Fault solid general warning triple
icon beep
50-57 Drive Controller Not Calibrated solid general warning triple
icon beep
50-58 CAN RPM Message Stale solid general warning triple
icon beep
50-60 Drive Pump Forward Error On solid general warning triple
icon beep
50-61 Drive Pump Forward Error Off solid general warning triple
icon beep
50-63 Drive Pump Reverse Error On solid general warning triple
icon beep
50-64 Drive Pump Reverse Error Off solid general warning triple
icon beep
50-66 Extend / Retract Rod Error On solid general warning triple
icon beep
50-67 Extend / Retract Rod Error Off solid general warning triple
icon beep
50-69 Auxiliary Hydraulics Error On solid general warning triple
Base icon beep
50-70 Auxiliary Hydraulics Error Off solid general warning triple
Base icon beep
50-72 Auxiliary Hydraulics Error On solid general warning triple
Rod icon beep
50-73 Auxiliary Hydraulics Error Off solid general warning triple
Rod icon beep
50-78 Float Valve Error On flashing boom float triple
icon beep
50-79 Float Valve Error Off flashing boom float triple
icon beep

6986740-EN (07-08) 60-180-4 Bobcat T2250

SERVICE MANUAL
 COD
FUNCTION FAILURES ICON BUZZER COMMENT
E
50-80 Two Speed Relay Error On flashing two speed triple
icon beep
50-81 Two Speed Relay Error Off flashing two speed triple
icon beep
50-82 EEPROM Error solid general warning triple
icon beep
63-05 Operator Presence Short To Battery triple
Switch beep
63-06 Operator Presence Short To Ground triple
Switch beep
64-05 Accessory Relay Short To Battery solid general warning triple
icon beep
64-06 Accessory Relay Short To Ground solid general warning triple
icon beep
64-07 Accessory Relay Open Circuit solid general warning triple
icon beep
65-05 Joystick Lockout Short To Battery flashing joystick triple
lockout icon beep
65-06 Joystick Lockout Short To Ground flashing joystick triple
lockout icon beep
65-07 Joystick Lockout Open Circuit flashing joystick triple
lockout icon beep
70-28 Brake Pressure Failure flashing parking brake triple
icon beep
77-48 Multiple Key Alarm machine will shut down

6986740-EN (07-08) 60-180-5 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 60-180-6 Bobcat T2250
SERVICE MANUAL
 ENGINE SERVICE

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Air Intake Cowling Removal And Installation. . . . . . . . . . . . . . . . 70-40-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

CAMSHAFT AND TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1

Camshaft - Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-3
Idle Gear And Shaft Removal And Installation . . . . . . . . . . . . . 70-100-5
Idler Gear And Shaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . 70-100-6
Timing Gearcase Cover Removal And Installation . . . . . . . . . . 70-100-1
Timing Gears Backlash - Checking . . . . . . . . . . . . . . . . . . . . . . 70-100-2

CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-9
Crankshaft Gear Removal And Installation . . . . . . . . . . . . . . . . . 70-90-9
Crankshaft And Bearings Removal and Installation . . . . . . . . . 70-90-10
Crankshaft And Bearings - Servicing . . . . . . . . . . . . . . . . . . . . 70-90-14
Cylinder Bore Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-8
Piston And Connecting Rod Removal And Installation . . . . . . . . 70-90-1
Piston And Connecting Rod - Servicing . . . . . . . . . . . . . . . . . . . 70-90-3

CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . . . 70-80-4
Cylinder Head Disassembly And Assembly . . . . . . . . . . . . . . . . 70-80-7
Cylinder Head - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8 ENGINE
Intake Air Heater - Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1 SERVICE
Intake Air Heater Removal And Installation. . . . . . . . . . . . . . . . . 70-80-1
Reconditioning The Valve And Valve Seat . . . . . . . . . . . . . . . . 70-80-11
Rocker Arm And Shaft - Checking . . . . . . . . . . . . . . . . . . . . . . 70-80-15
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-2
Valve Guide - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-9
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-13
Valve Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-14
Valve Timing - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-3

ENGINE AND ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . 70-11-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-11-1

ENGINE AND HYDROSTAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 70-12-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-12-1

ENGINE COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-3
Radiator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Thermostat Housing Removal And Installation . . . . . . . . . . . . . . 70-50-4
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . 70-50-3
Water Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . 70-50-4

Continued On Next Page

6986740-EN (07-08) 70-01 Bobcat T2250

SERVICE MANUAL
 ENGINE SERVICE (CONT’D)

ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Compression - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-9
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-7
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2

ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

FLYWHEEL AND HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1

Fuel Camshaft Removal And Installation. . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Injection Pump Removal And Installation . . . . . . . . . . . . . . . 70-70-8
Fuel Injection Pump Housing Removal . . . . . . . . . . . . . . . . . . . . 70-70-16
Fuel Injection Pump Housing Installation . . . . . . . . . . . . . . . . . . 70-70-20
Fuel Injector Removal and Installation. . . . . . . . . . . . . . . . . . . . . 70-70-26
Fuel Injector Nozzle Pressure - Checking . . . . . . . . . . . . . . . . . . 70-70-28
Fuel Shutoff Solenoid - Checking . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-7
Fuel Shutoff Solenoid - Removal And Installation . . . . . . . . . . . . . 70-70-7
Injection Pump Governor Housing Removal And Installation . . . . 70-70-3
Injection Pump Governor Housing Disassembly And Assembly . . 70-70-5
Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-23
Nozzle Spraying Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-28
Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-29

LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

Engine Oil Pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-5
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Oil Filter Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . 70-60-4

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1

TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1

6986740-EN (07-08) 70-02 Bobcat T2250

SERVICE MANUAL
ENGINE INFORMATION

Description

The T2250 has the Kubota direct injected V3300 Turbo

diesel engine with a displacement of 202.5 cu.in. (3,3 L).

The engine has 4 cylinders and the rotation is counter-

clockwise (viewed from the flywheel side). It is also
equipped with an air intake heater for assisting in cold
starts. Engine block heaters are also available from
Bobcat Parts.

The engine serial number is stamped on the engine and is

located near the injection pump. The model number is
located on the valve cover. Use these numbers to obtain
the correct service parts.

The engine is liquid cooled with a propylene glycol/water

mixture. The cooling fan is driven by a hydraulic motor.
The speed of the fan is determined by the engine coolant
temperature sensor and the hydraulic/hydrostatic fluid
temperature sensor.

6986740-EN (07-08) 70-10-1 Bobcat T2250

SERVICE MANUAL
ENGINE INFORMATION (CONT’D)

Specifications

All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by parentheses.

Fuel System

Injection Timing 12°-13° before T.D.C. 0.21 to 0.23 rad.

Fuel Injection Pressure - 1st Stage 18,63-19,61 MPa 2702-2845 PSI 190-200 kgf/cm²
Fuel Injection Pressure - 2nd Stage 23,54-24,52 MPa 3414-3556 PSI 240-250 kgf/cm²
Fuel Tightness of Nozzle Valve Seat When the pressure is 16,67 MPa (170 kgf/cm², 2418 PSI), the
valve seat must be fuel tightness

Valves

Valve Seat Width (Intake) 1,524 mm (0.06 in.)

Valve Seat Width (Exhaust) 2,286 mm (0.09 in.)
Valve Seat and Face Angle (Intake) 60° 1.047 rad.
Valve Seat and Face Angle (Exhaust) 45° 0.785 rad.
Valve Stem O.D. 6,960 to 6,975 mm (0.2740 to 0.2764 in.)
Valve Guide I.D. 7,030 to 7,045 mm (0.2768 to 0.2774 in.)
Clearance Between Valve Stem And Valve Guide 0,055 to 0,085 mm (0.0022 to 0.0033 in.)
(Intake and Exhaust)
Allowable Limit 0,1 mm (0.0039 in.)
Valve Clearance (Cold) 0,23 to 0,27 mm (0.0091 to 0.0106 in.)
Valve Recessing (Intake) 0,6 to 0,8 mm (0.0236 to 0.0315 in.)
Allowable Limit 1,2 mm (0.0472 in.)
Valve Recessing (Exhaust) 0,85 to 1,05 mm (0.0335 to 0.0413 in.)
Allowable Limit 1,2 mm (0.0472 in.)

Valve Springs

Valve Spring (Intake) 35,1 to 35,6 mm (1.3819 to 1.4016 in.)

Allowable Limit 34,6 mm (1.3622 in.)
Valve Spring (Exhaust) 35,1 to 35,6 mm (1.3819 to 1.4016 in.)
Allowable Limit 34,6 mm (1.3622 in.)
Setting Load/Setting Length (Intake) 63,547 N / 31,5 mm (14.256 lbs / 1.2401 in.)
(6,48 kgf / 31,5 mm)
Allowable Limit 45,864 N / 31,5 mm (10.296 lbs /1.2401 in.)
(4.68 kgf / 31.5 mm)
Setting Load/Setting Length (Exhaust) 63,547 N / 31,5 mm (14.256 lbs / 1.2401 in.)
(6.48 kgf / 31.5 mm)
Allowable Limit 45,864 N / 31,5 mm (10.296 lbs /1.2401 in.)
(4.68 kgf / 31.5 mm)
Tilt - Allowable Limit 1,0 mm (0.039 in.)
Valve Tappets

Clearance Between Tappet And Guide 0,020 to 0,062 mm (0.0008 to 0.0024 in.)
Allowable Limit 0,07 mm (0.0028 in.)
Tappet Guide I.D. 24,000 to 24,021 mm (0.9449 to 0.9457 in.)
Tappet O.D. 23,959 to 23,980 mm (0.9433 to 0.9441 in.)

6986740-EN (07-08) 70-10-2 Bobcat T2250

SERVICE MANUAL
ENGINE INFORMATION (CONT’D)

Specifications (Cont’d)

All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by parentheses.
Valve Timing

Intake Valve - Open 14° before T.D.C. 0.24 rad.

Closed 36° after B.D.C. 0.61 rad.
Exhaust Valve - Open 45° before B.D.C. 0.76 rad.
Closed 17° after T.D.C. 0.29 rad.

Rocker Arm

Clearance Between Valve Arm Bridge And Valve Arm 0,018 to 0,042 mm (0.0007 to 0.0026 in.)
Bridge Shaft
Allowable Limit 0,15 mm (0.0059 in.)
Valve Arm Bridge I.D. 9,050 to 9,065 mm (0.3563 to 0.3569 in.)
Valve Arm Bridge Shaft O.D. 9,023 to 9,032 mm (0.3552 to 0.3566 in.)
Clearance Between Rocker Arm Shaft And Rocker Arm 0,016 to 0,045 mm (0.0006 to 0.0018 in.)
Allowable Limit 0,15 mm (0.0059 in.)
Rocker Arm Shaft O.D. 15,973 to 15,984 mm (0.6289 to 0.6293 in.)
Rocker Arm I.D. For Shaft 16,000 to 16,018 mm (0.6299 to 0.6306 in.)

Camshaft

Clearance Between Tappet And Guide 0,020 to 0,062 mm (0.0008 to 0.0024 in.)
Allowable Limit 0,07 mm (0.0028 in.)
Tappet Guide I.D. 24,000 to 24,021 mm (0.9449 to 0.9457 in.)
Tappet O.D. 23,959 to 23,980 mm (0.9433 to 0.9441 in.)

Timing Gear

Timing Gear Backlash

Crank Gear - Idler Gear 0,049 to 0,193 mm (0.0019 to 0.0076 in.)
Allowable Limit 0,22 mm (0.0087 in.)
Idler Gear - Cam Gear 0,049 to 0,189 mm (0.0019 to 0.0074 in.)
Allowable Limit 0,22 mm (0.0087 in.)
Idle Gear - Injection Pump Gear 0,030 to 0,165 mm (0.0012 to 0.0065 in.)
Allowable Limit 0,22 mm (0.0087 in.)
Clearance Between Idle Gear Shaft And Idle Gear 0,05 to 0,091 mm (0.0020 to 0.0036 in.)
Bushing
Allowable Limit 0,10 mm (0.0039 in.)
Idle Gear Bushing I.D. 45,025 to 45,050 mm (1.7726 to 1.7736 in.)
Idle Gear Shaft O.D. 44,959 to 44,975 mm (1.7700 to 1.7707 in.)
Idle Gear Side Clearance 0,15 to 0,30 mm (0.0059 to 0.0118 in.)
Allowable Limit 0,9 mm (0.0354 in.)

6986740-EN (07-08) 70-10-3 Bobcat T2250

SERVICE MANUAL
ENGINE INFORMATION (CONT’D)

Specifications (Cont’d)

All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by parentheses.
Cylinder Head

Cylinder Head Surface Flatness - Allowable Limit 0,05 mm (0.0019 in.)

Compression Pressure 498 to 526 PSI / 250 RPM 3.43 to 3.63 MPa / 250 RPM 35 to
37 kgf/cm² / 250 RPM
Compression Ratio 19.3
Variance Among Cylinder - Allowable Limit 10% or less
Firing Order 1-3-4-2

Piston And Piston Ring

Piston Pin Bore I.D. 30,000 to 30,013 mm (1.1811 to 1.1816 in.)

Allowable Limit 30,05 mm (1.1831 in.)
Clearance Between Compression Ring 1 and Ring 0,05 to 0,07 mm (0.0020 to 0.0028 in.)
Groove
Allowable Limit 0,15 mm (0.0059 in.)
Clearance Between Compression Ring 2 and Ring 0,093 to 0,120 mm (0.0037 to 0.0047 in.)
Groove
Allowable Limit 0,20 mm (0.0079 in.)
Clearance Between Oil Ring And Ring Groove 0,02 to 0,06 mm (0.0008 to 0.0023 in.)
Allowable Limit 0,15 mm (0.0059 in.)
Ring Gap
Compression Ring 1 0,30 to 0,45 mm (0.0118 to 0.0177 in.)
Allowable Limit 1,25 mm (0.0492 in.)
Compression Ring 2 0,30 to 0,45 mm (0.0118 to 0.0177 in.)
Allowable Limit 1,25 mm (0.0492 in.)
Oil Ring 0,25 to 0,45 mm (0.0098 to 0.0177 in.)
Allowable Limit 1,25 mm (0.0492 in.)
Connecting Rod

Connecting Rod Alignment - Allowable Limit 0,05 mm (0.0020 in.)

Clearance Between Piston Pin And Small End Bushing 0,02 to 0,040 mm (0.0008 to 0.0016 in.)
Allowable Limit 0,15 mm (0.0059 in.)
Piston Pin O.D. 30,006 to 30,011 mm (1.1813 to 1.1815 in.)
Small End Busing I.D. 30,031 to 30,046 mm (1.1823 to 1.1829 in.)
Cylinder Bore

Cylinder Bore I.D. 98,000 to 98,022 mm (3.8582 to 3.8591 in.)

Allowable Limit 98,15 mm (3.8642 in.)
Oversized Cylinder Liner I.D. 98,500 to 98,522 mm (3.8780 to 3.8788 in.)
Allowable Limit 98,65 mm (3.8839 in.)

6986740-EN (07-08) 70-10-4 Bobcat T2250

SERVICE MANUAL
ENGINE INFORMATION (CONT’D)

Specifications (Cont’d)

All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by parentheses.
Crankshaft

Crankshaft Alignment - Allowable Limit 0,02 mm (0.00079 in.)

Crankpin O.D. 52,977 to 52,990 mm (2.0857 to 2.0862 in.)
Crankshaft Journal O.D. 74,977 to 74,990 mm (2.9518 to 2.9548 in.)
Oil Clearance Between Crankshaft Journal And 0,018 to 0,062 mm (0.0007 to 0.0024 in.)
Crankshaft Bearing
Allowable Limit 0,20 mm (0.0079 in.)
Oil Clearance Between Crank Pin And Pin Bearing 0,018 to 0,051 mm (0.0007 to 0.0020 in.)
Allowable Limit 0,20 mm (0.0079 in.)
Crankshaft Side Clearance 0,015 to 0,31 mm (0.0059 to 0.0122 in.)
Allowable Limit 0,50 mm (0.0197 in.)
Oil Pump

Engine Oil Pressure - At Idle Speed 98 kPa (14 PSI) 1,0 kgf/cm²
Allowable Limit 49 kPa (7 PSI) 0,5 kgf/cm²
Engine Oil Pressure - At Rated Speed 196 to 392 kPa (28 to 56 PSI) 2,0 to 4,0 kgf/cm²
Allowable Limit 147,1 kPa (21.3 PSI) 1,5 kgf/cm²
Engine Oil Pressure Switch Working Pressure 39,2 to 58,8 kPa (5.6 to 8.4 PSI) 0,4 to 0,6 kgf/cm²
Clearance Between Inner Rotor And Outer Rotor 0,04 to 0,16 mm (0.0016 to 0.0063 in.)
Clearance Between Outer Rotor And Pump Body 0,100 to 0,184 mm (0.0039 to 0.0072 in.)
Clearance Between Rotor And Cover 0,025 to 0,075 mm (0.0010 to 0.0030 in.)
Allowable Limit 0,225 mm (0.0089 in.)
Relief Valve Working Pressure 885 kPa (129 PSI) 9,04 kgf/cm²

Thermostat

Thermostat Valve Opening Temperature 74,5 to 78,5°C (166.1 to 173.3°F)

Temperature At Which Thermostat Completely Opens 90°C (194°F)

Intake Air Heater

Intake Air Heater Resistance (at cold occasion) Approximately 0.3Ω

6986740-EN (07-08) 70-10-5 Bobcat T2250

SERVICE MANUAL
ENGINE INFORMATION (CONT’D)

Torque Values

Kubota Metric Engine Bolts

Thread Size Material

(Dia. x Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M5 x 0.8 4-5 N•m (3-4 ft.-lb.)
M6 x 1.0 8-9 N•m (6-7 ft.-lb.) 8-12 N•m (6-9 ft.-lb.)
M8 x 1.25 8-12 N•m (6-9 ft.-lb.) 15-22 N•m (11-16 ft.-lb.) 24-34 N•m (18-25 ft.-lb.)
M10 x 1.25 18-24 N•m (13-18 ft.-lb.) 30-41 N•m (22-30 ft.-lb.) 49-68 N•m (36-50 ft.-lb.)
M12 x 1.25 30-41 N•m (22-30 ft.-lb.) 54-73 N•m (40-54 ft.-lb.) 94-118 N•m (69-87 ft.-lb.)
M14 x 1.5 49-68 N•m (36-50 ft.-lb.) 79-108 N•m (58-80 ft.-lb.) 157-186 N•m (116-137 ft.-lb.)

Tightening Torques For General Use Screws, Bolts And Nuts

Grade Standard Screw and Bolt Special Screw and Bolt (7)

Nominal Unit (4)

Diameter N•m kg•fm ft-lbs N•m kg•fm ft-lbs
M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.9 9.8 to 11.3 1.00 to 1.15 7.23 to 8.32
M8 17.7 to 20.6 1.8 to 2.1 13.0 to 15.2 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
M10 39.2 to 45.1 4.0 to 4.6 28.9 to 33.3 49.0 to 55.9 5.0 to 5.7 36.2 to 41.2
M12 62.8 to 72.6 6.4 to 7.4 46.3 to 53.5 77.5 to 90.2 7.9 to 9.2 57.1 to 66.5

Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to tightening,
be sure to check out the numbers as shown below.

Punched number Screw and bolt material grade

None or 4 Standard screw and bolt SS400, S20C
7 Special screw and bolt S43C, S48C (Refined)

6986740-EN (07-08) 70-10-6 Bobcat T2250

SERVICE MANUAL
ENGINE INFORMATION (CONT’D)

Troubleshooting

The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.

PROBLEM CAUSE
Slow cranking speed. 1, 2, 3
Engine will not start. 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 19, 27, 28, 29
Difficult to start. 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29, 54
No power for engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is mis-firing. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue/white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration. 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure warning. 4, 33, 36
Overheating. 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure. 22, 27, 29, 30, 40, 49
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop. 9, 10, 11

6986740-EN (07-08) 70-10-7 Bobcat T2250

SERVICE MANUAL
ENGINE INFORMATION (CONT’D)

Troubleshooting (Cont’d)

KEY TO CORRECT THE CAUSE

1. Alternator belt is loose or damaged. 28. Worn valve and seats.
2. Bad electrical connections. 29. Broken or worn piston rings.
3. Faulty starter motor. 30. Worn valve stems or guides.
4. Incorrect grade of oil. 31. Worn or damaged bearings.
5. Low cranking speed. 32. Not enough oil in the crankcase.
6. Fuel tank empty. 33. Switch/sensor is defective.
7. Faulty stop control operation. 34. Oil pump worn.
8. Plugged fuel line. 35. Relief valve is sticking open.
9. Plugged fuel filter. 36. Relief valve is sticking closed.
10. Restriction in the air cleaner. 37. Broken relief valve spring.
11. Air in the fuel system. 38. Faulty suction pipe.
12. Faulty fuel injection pump. 39. Plugged oil filter.
13. Faulty fuel injectors. 40. Piston seizure.
14. Broken injection pump drive. 41. Incorrect piston height.
15. Incorrect injection pump timing. 42. Faulty engine mounting.
16. Incorrect valve timing. 43. Incorrect flywheel alignment.
17. Poor compression. 44. Faulty thermostat.
18. Plugged fuel tank vent. 45. Restriction in water jacket.
19. Incorrect grade of fuel. 46. Loose alternator belt.
20. Exhaust pipe restriction. 47. Plugged radiator.
21. Cylinder head gasket leaking. 48. Faulty water pump.
22. Overheating. 49. Plugged breather pipe.
23. Cold running. 50. Damaged valve stem deflectors.
24. Incorrect tappet adjustment. 51. Coolant level to low.
25. Sticking valves. 52. Plugged oil pump pipe strainer.
26. Incorrect fuel lines. 53. Broken valve spring.
27. Worn cylinder bores. 54. Damaged Battery

6986740-EN (07-08) 70-10-8 Bobcat T2250

SERVICE MANUAL
ENGINE INFORMATION (CONT’D)

Compression - Checking Compression Factory spec. 3,43 to 3,63 MPa /

pressure 250 RPM
Figure 70-10-1 35 to 37 kgf/cm² /
250 RPM
1 498 to 526 PSI /
250 RPM
Allowable limit 2,60 MPa / 250
RPM
26,5 kgf/cm² / 250
RPM
377 PSI / 250 RPM

Tightening Nozzle holder 17,7 to 20,6

Torque clamp nut N•m
1,8 to 2,1 kgf·m
13.0 to 15.2 ft.-
P-37196 lb.
Overflow pipe 9,8 to 11,3 N•m
After warming up the engine, stop it and remove the air assembly 1,0 to 1,15
cleaner, the muffler, high pressure pipes, cylinder head retaining screw kgf·m
cover, overflow pipe, all nozzle holders and all nozzle 7.23 to 8.32 ft.-
gaskets. lb.
Cylinder head 1,6 to 2,3 N•m
Install a compression tester and nozzle adaptor MEL1614 cover screw 0,15 to 0,23
for diesel engines to nozzle holder hole (Item 1) [Figure kgf·m
70-10-1]. 1.15 to 1.66 ft.-
lb.
After making sure that the speed control lever is set at the
Injection pipe 22,6 to 36,3
stop position (Non-injection), run the engine at 200 to 300
retaining nut N•m
RPM with the starter.
2,3 to 3,7 kgf·m
16.6 to 26.8 ft.-
Read the maximum pressure. Measure the pressure more
lb.
than twice.

If the measurement is below the allowable limit, apply a

small amount of oil to the cylinder wall through the nozzle
hole and measure the compression pressure again.

If the compression pressure increase after applying oil.

check the cylinder wall and piston rings.

If the compression pressure is still less than the allowable

limit, check the top clearance, valve and cylinder head.

NOTE: Check the compression pressure with the

specified valve clearance.

Always use a fully charged battery for

performing this test.

Variances in cylinder compression values

should be under 10%.

6986740-EN (07-08) 70-10-9 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 70-10-10 Bobcat T2250
SERVICE MANUAL
ENGINE AND ENGINE MOUNTS Figure 70-11-3

Removal And Installation

Remove the engine / hydrostat assembly. (See Removal

And Installation on Page 70-12-1.)

Remove the radiator. (See Radiator Removal And

Installation on Page 70-50-1.) 1
Figure 70-11-1 2

S7134

Disconnect the water temperature sender connector (Item

1 1) [Figure 70-11-3].

Remove the tie strap (Item 2) [Figure 70-11-3] from the

wiring harness clamp.

Figure 70-11-4
S7132

Disconnect the electrical connector (Item 1) [Figure 70-

11-1] from the A/C compressor (if machine is equipped
with air conditioning).

Figure 70-11-2 3
2

S7135

Remove the L & S terminal (Item 1) and B+ terminal (Item

2) [Figure 70-11-4] from the alternator.
1
Remove the wire harness clamp (Item 2) [Figure 70-11-
4].
S7133

Remove the two hoses (Item 1) [Figure 70-11-2] from the

A/C compressor (if machine is equipped with air
conditioning).

6986740-EN (07-08) 70-11-1 Bobcat T2250

SERVICE MANUAL
ENGINE AND ENGINE MOUNTS (CONT'D) Figure 70-11-7

Removal And Installation (Cont’d)

Figure 70-11-5
3

2
1

S7155

1
Remove the tie strap (Item 1) [Figure 70-11-7].
S7156
Disconnect the fuel shutoff solenoid connector (Item 2)
[Figure 70-11-7].
Remove the ground cable (Item 1) [Figure 70-11-5] from
the alternator. Disconnect the wiring harness (Item 3) [Figure 70-11-7]
from the air intake heater.
Figure 70-11-6
Figure 70-11-8

2
1

1
3

4
S7131

S7156

Remove the bracket (Item 1) [Figure 70-11-6].

Disconnect the positive (+) wires (Item 1) [Figure 70-11-
8] from the starter.

Disconnect the wire connector (Item 2) [Figure 70-11-8]

from the engine speed sensor

Disconnect the wire (Item 3) [Figure 70-11-8] from the

starter solenoid.

Remove the ground cable (Item 4) [Figure 70-11-8].

Remove the wire harness clamp (Item 5) [Figure 70-11-

8].

6986740-EN (07-08) 70-11-2 Bobcat T2250

SERVICE MANUAL
ENGINE AND ENGINE MOUNTS (CONT'D) Figure 70-11-11

Removal And Installation (Cont’d)

Figure 70-11-9

S7136

1
Install a hoist and chain to the lifting brackets [Figure 70-
S7156 11-11] as shown.

Figure 70-11-12
Disconnect the wire connector (Item 1) [Figure 70-11-9]
from the oil pressure sender.

Figure 70-11-10

S7160

Remove the three engine mount bolts (Item 1) [Figure 70-

S7156 11-12] through the three openings in the bottom side of
the engine / hydrostat assembly.

Remove the radiator hose (Item 1) [Figure 70-11-10] from Installation: Tighten the engine mount bolts to 61-69 ft.-
the engine. lb. (83-94 N•m) torque.

6986740-EN (07-08) 70-11-3 Bobcat T2250

SERVICE MANUAL
ENGINE AND ENGINE MOUNTS (CONT'D)

Removal And Installation (Cont’d)

Figure 70-11-13

S7136

Lift the engine [Figure 70-11-13].

6986740-EN (07-08) 70-11-4 Bobcat T2250

SERVICE MANUAL
ENGINE AND HYDROSTAT ASSEMBLY Figure 70-12-3

Removal And Installation

1
Raise the boom and install the boom stop. (See Installing
The Approved Boom Stop on Page 10-150-1.)

Figure 70-12-1
1

S6342

Remove the two covers by removing the bolts (Item 1)

1 [Figure 70-12-3].

Figure 70-12-4
S7204

Rotate the battery disconnect switch (Item 1) [Figure 70-

12-1] to the right, to disconnect the power supply from the
battery. 1
2
Figure 70-12-2

S2974

1 Remove the engine speed cable (Items 1 and 2) [Figure

2
70-12-4].
2

S6341

Remove the support (Item 1) [Figure 70-12-2] from the

bracket on the engine cover.

Remove the engine cover by disconnecting it from the

hinges (Item 2) [Figure 70-12-2].

Remove the muffler (See “Removal And Installation” on

page 70-30-1).

Drain the hydraulic reservoir (See “Replacing Hydraulic

Fluid” on page -10-100-2).

Drain the radiator (See Replacing The Coolant on Page

10-70-2.).

6986740-EN (07-08) 70-12-1 Bobcat T2250

SERVICE MANUAL
ENGINE AND HYDROSTAT ASSEMBLY (CONT’D) Figure 70-12-7

Removal And Installation (Cont’d) 1

Figure 70-12-5

S6345

1
Figure 70-12-8
S6343
1

Disconnect the two hoses (Item 1) [Figure 70-12-5] of the

towing valve.
1
NOTE: Mark hoses for ease of installation.

Figure 70-12-6

S6346

Disconnect the twelve hydraulic hoses and tubelines (Item

1) [Figure 70-12-7] and [Figure 70-12-8]. Do this through
the hole under the boom and through the hole in the
1
bottom side of the machine.

S6344

Disconnect the hose (Item 1) [Figure 70-12-6] from the

radiator.

6986740-EN (07-08) 70-12-2 Bobcat T2250

SERVICE MANUAL
ENGINE AND HYDROSTAT ASSEMBLY (CONT’D) Figure 70-12-11

Removal And Installation (Cont’d)

Figure 70-12-9
1

1
1

S6349

Disconnect the two wire harness connectors (Item 1)

S6347 [Figure 70-12-11] from the pump assembly.

Figure 70-12-12
Remove the tie straps (Item 1) [Figure 70-12-9] from the
cables.

Figure 70-12-10

1
1

S6350

Disconnect the electrical connector (Item 1) [Figure 70-

S6348 12-12] through the front hole under the boom.

Remove the cables (Item 1) [Figure 70-12-10] from the

main switch.

6986740-EN (07-08) 70-12-3 Bobcat T2250

SERVICE MANUAL
ENGINE AND HYDROSTAT ASSEMBLY (CONT’D) If equipped with air conditioning, perform the following
steps:
Removal And Installation (Cont’d)
Remove the refrigerant from the A/C system (See
Remove the battery access cover and battery . “Reclamation Procedure” on page 80-100-1).

Figure 70-12-13 Figure 70-12-15

1 1
2

2
1

S7207
1
S7107

Loosen the screw (Item 1) and disconnect the electrical Remove the three screws (Item 1) and remove the cover
connector (Item 2) [Figure 70-12-13]. (Item 2) [Figure 70-12-15].

Disconnect the grey electrical connector (Item 3) [Figure Figure 70-12-16

70-12-13].
1
Figure 70-12-14

2
2

1
S5881

S6351 Remove the knobs (Item 1) and raise the fuse box cover
(Item 2) [Figure 70-12-16] gently.

Remove the ground cable (Item 1) [Figure 70-12-14] from

the frame.

Remove the tie straps (Item 2) [Figure 70-12-14] from the

harness.

6986740-EN (07-08) 70-12-4 Bobcat T2250

SERVICE MANUAL
ENGINE AND HYDROSTAT ASSEMBLY (CONT’D) Figure 70-12-19

Removal And Installation (Cont’d)

Figure 70-12-17

1
2

P-53574

Remove the bolt (Item 1) and plate (Item 2)) [Figure 70-
S5882 12-19]. Remove the A/C hoses from the valve (if
equipped).

Remove the main wire harness connector (Item 1) from NOTE: Plug the A/C hoses to prevent contamination.
the blower fan switch (Item 2) [Figure 70-12-17].
Figure 70-12-20
Remove the fuse box cover (Item 3) [Figure 70-12-17].

Figure 70-12-18

2
1 1

S2975

P-53573 Loosen the bolts (Item 1) and remove the A/C hoses
(Item 2) [Figure 70-12-20] (if equipped) from the cab by
pulling them into the battery compartment.
Temporarily remove the protective covering (Item 1)
[Figure 70-12-18] from the A/C hoses and
expansion valve (if equipped).

6986740-EN (07-08) 70-12-5 Bobcat T2250

SERVICE MANUAL
ENGINE AND HYDROSTAT ASSEMBLY (CONT’D)

Removal And Installation (Cont’d)

Figure 70-12-21

1
S5048

Disconnect and plug the fuel lines (Item 1) [Figure 70-12-

21].

Figure 70-12-22

S7108

Remove the engine mounting bolt (Item 1) [Figure 70-12-

22] on the bottom of the frame, below the drive belt cast
housing.

6986740-EN (07-08) 70-12-6 Bobcat T2250

SERVICE MANUAL
ENGINE AND HYDROSTAT ASSEMBLY (CONT’D)

Removal And Installation (Cont’d)

Figure 70-12-23

S7163

A tool needs to be fabricated to use in the removal procedure. This tool allows the engine/hydrostatic pump assembly to
be lifted evenly for easier removal. Use the dimensions shown in [Figure 70-12-23] to make the engine removal tool.

6986740-EN (07-08) 70-12-7 Bobcat T2250

SERVICE MANUAL
ENGINE AND HYDROSTAT ASSEMBLY (CONT’D) Figure 70-12-26

Removal And Installation (Cont’d)

Figure 70-12-24

1
1

S7152

Remove the two mounting bolts (Item 1) [Figure 70-12-

S6353
S6354 26] on the front side of the engine / hydrostat assembly.

Figure 70-12-27
Attach chains to the lifting tool and attach to the frame
[Figure 70-12-24].

Figure 70-12-25
1
1

S7153

Remove the mounting bolt (Item 1) [Figure 70-12-27] on

S6352 the rear side of the engine / hydrostat assembly.

Properly attach the chains (Item 1) [Figure 70-12-25] to a

lifting device.

6986740-EN (07-08) 70-12-8 Bobcat T2250

SERVICE MANUAL
ENGINE AND HYDROSTAT ASSEMBLY (CONT’D)

Removal And Installation (Cont’d)

Figure 70-12-28

S7154

Remove the two mounting bolts (Item 1) [Figure 70-12-

28] on the boom side of the engine / hydrostat assembly.

Figure 70-12-29

S6356

Lift the engine / hydrostat assembly away from the

machine [Figure 70-12-29].

6986740-EN (07-08) 70-12-9 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 70-12-10 Bobcat T2250
SERVICE MANUAL
ENGINE SPEED CONTROL

Removal And Installation

Figure 70-20-1

S2967

Remove the accelerator cable (Item 1) from the pedal and

mounting bracket (Item 2) [Figure 70-20-1].

Remove the battery box cover.

Carefully pull the speed control cable through the cab and
into the battery box.

Open the engine cover.

Figure 70-20-2

1
2

S2974

Remove small clip to remove ball joint (Item 1) [Figure

70-20-2].

Loosen the nut (Item 2) [Figure 70-20-2] to remove the

speed control cable from the mounting bracket.

Remove any necessary tie straps and carefully remove

the speed control cable.

6986740-EN (07-08) 70-20-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 70-20-2 Bobcat T2250
SERVICE MANUAL
MUFFLER Figure 70-30-3

Removal And Installation

Open the Engine Cover.

Figure 70-30-1

1 S5136

Remove the two bolts (Item1) [Figure 70-30-3].

S5137

Remove the tightening bracket (Item 1) [Figure 70-30-1].

Figure 70-30-2

1
S5135

Remove the two bolts (Item 1) [Figure 70-30-2] securing

the muffler to the frame.

6986740-EN (07-08) 70-30-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 70-30-2 Bobcat T2250
SERVICE MANUAL
AIR CLEANER Figure 70-40-3

Removal And Installation

Open the Engine Cover.

Figure 70-40-1

1 S5136

1
Remove the bolts (Item 1) [Figure 70-40-3] and remove
the air cleaner.

S5106 Installation: perform the actions for removal in

reverse order.

Remove the hose clamp (Item 1) [Figure 70-40-1]. Air Intake Cowling Removal And Installation

Figure 70-40-2 Figure 70-40-4

1
1
S5104 S5136

Remove the two nuts and bolts (Item 1) [Figure 70-40-2] Loosen the bolt (Item 1) [Figure 70-40-4] and remove the
securing the air cleaner frame to engine cover frame. air intake cowling.

6986740-EN (07-08) 70-40-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 70-40-2 Bobcat T2250
SERVICE MANUAL
ENGINE COOLING SYSTEM Figure 70-50-3

Radiator Removal And Installation

Drain the fluid from the radiator. (See Replacing The 1

Coolant on Page 10-70-2.)

Remove the condenser (if equipped). (See Removal And

Installation on Page 80-120-1.)

Remove the hydraulic oil cooler. (See Removal And

Installation on Page 10-90-1.)

NOTE: The procedure is described with the cradle

removed from the engine, for clarity.
S7088
Figure 70-50-1
1 Remove the bolts (Item 1) [Figure 70-50-3] and remove
the hydraulic fluid reservoir.
1
2 Figure 70-50-4

1
1

1
S6530

Remove the four bolts (Item 1) and the belt shield (Item 2)
[Figure 70-50-1] for easier access.
Figure 70-50-2 S7087

Remove the hose (Item 1) [Figure 70-50-4] from the

radiator hose mounting bracket.

S7085

Remove the cooling fluid hose (Item 1) [Figure 70-50-2]

from the radiator.

6986740-EN (07-08) 70-50-1 Bobcat T2250

SERVICE MANUAL
ENGINE COOLING SYSTEM (CONT’D) Figure 70-50-7

Radiator Removal And Installation (Cont’d)

1
Figure 70-50-5

1 S7101

Loosen the fan cover (Item 1) [Figure 70-50-7].

S7086
Figure 70-50-8

Remove the hose clamp (Item 1) [Figure 70-50-5] from

the radiator hose mounting bracket. 2
2
Figure 70-50-6

1 1
1

2
S3674
1

Remove the radiator (Item 1) [Figure 70-50-8].

1
S7101 Use proper support (Item 2) [Figure 70-50-8].

NOTE: Take care not to damage the drain valve

Remove the four bolts (Item 1) [Figure 70-50-6]. underneath the radiator upon removal.

6986740-EN (07-08) 70-50-2 Bobcat T2250

SERVICE MANUAL
ENGINE COOLING SYSTEM (CONT’D) Water Pump Removal And Installation

Fan Removal And Installation Figure 70-50-10

Remove the radiator.

1 3
Figure 70-50-9

1
P-66743

1 1
Drain the fluid from the radiator. (See Replacing The
Coolant on Page 10-70-2.)
1
S5443
Loosen the four bolts (Item 2) from the water pump pulley
(Item 3) [Figure 70-50-10].
Remove the four bolts (Item 1) [Figure 70-50-9] and
remove the fan. Remove the alternator belt (Item 1) [Figure 70-50-10].
(See Removal And Installation on Page 60-30-1.)

Remove the four bolts (Item 2) from the water pump pulley
(Item 3) [Figure 70-50-10].

Remove the water pump pulley (Item 3) [Figure 70-50-10]

Remove the six water pump bolts (Item 4) [Figure 70-50-

10].

Figure 70-50-11

3EEABAC1P120A

Remove the water pump (Item 1) [Figure 70-50-11] from

the gearcase.

When mounting the water pump, use the new gasket

(Item 2) [Figure 70-50-11].

6986740-EN (07-08) 70-50-3 Bobcat T2250

SERVICE MANUAL
ENGINE COOLING SYSTEM (CONT’D) Thermostat Housing Removal And Installation

Water Pump Disassembly And Assembly Figure 70-50-13

Figure 70-50-12

2
1

P-37151

B-22926A
Figure 70-50-14

Remove the water pump assembly.

NOTE: The seal (Item 1) and the gasket (Item 2)

[Figure 70-50-12] are available for replacement
parts .

P-37152

Remove the thermostat cover mounting screws, and

remove the thermostat cover (Item 1) [Figure 70-50-13].

Remove the thermostat assembly (Item 3) [Figure 70-50-

13].

Apply a liquid gasket (Three Bond 1215 or equivalent)

only at the thermostat cover side of the gasket (Item 2)
[Figure 70-50-13].

Attach the thermostat (Item 3) with its hole (Item 4) facing

toward the air suction side [Figure 70-50-14].

6986740-EN (07-08) 70-50-4 Bobcat T2250

SERVICE MANUAL
ENGINE COOLING SYSTEM (CONT’D)

Thermostat Housing Removal And Installation

(Cont’d)

Thermostat Checking

Figure 70-50-15

P-37172

Push down the thermostat valve and insert a string

between the valve and the valve seat.

Place the thermostat and a thermometer in a container

with water and gradually heat the water [Figure 70-50-
15].

Hold the string to suspend the thermostat in the water.

When the water temperature rises, the thermostat valve
will open, allowing it to fall down from the string.

Continue heating the water and read the temperature

when the valve has risen by about 8 mm (0.315 in.).

If the measurement is not acceptable, replace the

thermostat.

Thermostat’s valve Factory spec. 74.5 to 78.5°C

opening 166.1 to
temperature 173.3°F
Temperature at Factory spec. 90°C
which thermostat 194°F
completely opens

6986740-EN (07-08) 70-50-5 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 70-50-6 Bobcat T2250
SERVICE MANUAL
LUBRICATION SYSTEM Figure 70-60-2

Oil Pan Removal And Installation

Remove the engine/hydrostatic pump package from the

Telescopic Handler. (See Removal And Installation on
Page 70-11-1.)

Figure 70-60-1

P-37126

Figure 70-60-3

P-37125

Unscrew the oil pan mounting screws and remove the oil
pan (Item 1) [Figure 70-60-1].

P-37127

Unscrew the oil strainer mounting screw, and remove the

oil strainer (Item 2) [Figure 70-60-3].

Install the oil strainer, using care not to damage the O-

ring.

Apply liquid gasket to the oil pan (Item 3) [Figure 70-60-

2].

Confirm that the liquid gasket coating surface is free of

water, dust and oil in order to maintain sealing effect.

Carefully apply the adhesive evenly.

NOTE: When mounting the adhesive-applied parts,

take care to fit them to the mating parts.
Assemble the adhesive-applied parts within
ten minutes.
To avoid uneven tightening, tighten mounting
screws in diagonal order from the center.
After cleaning the oil strainer, install it.
Attach the oil pan with its central drain plug
facing toward the air suction side.

6986740-EN (07-08) 70-60-1 Bobcat T2250

SERVICE MANUAL
LUBRICATION SYSTEM (CONT’D) Oil Pump Inspection

Oil Pump Removal And Installation Figure 70-60-5

Figure 70-60-4

P-37220

3EEABAC1P089A
Measure the clearance between lobes of the inner rotor
and the outer rotor with a feeler gauge [Figure 70-60-5].
Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 70- If the clearance exceeds the factory specifications,
100-1.) replace the oil pump rotor assembly.

Remove the oil pump cover (Item 1) [Figure 70-60-4]. Clearance Factory spec. 0.04 to 0.16 mm
between 0.0016 to 0.0063 in.
inner rotor
and outer
rotor

Figure 70-60-6

P-37218

Measure the clearance between the outer rotor and the

pump body with a feeler gauge [Figure 70-60-6].

If the clearance exceeds the factory specifications,

replace the oil pump rotor assembly.

Clearance Factory spec. 0.100 to 0.184

between outer mm
rotor and pump 0.0039 to 0.0072
body in.
Allowable 0.3 mm
limit 0.0118 in.

6986740-EN (07-08) 70-60-2 Bobcat T2250

SERVICE MANUAL
LUBRICATION SYSTEM (CONT’D) Relief Valve

Oil Pump Inspection (Cont’d) Figure 70-60-8

Figure 70-60-7

3EEABAC1P107A

3EEABAB1P225A
Remove the bolt (Item 1) [Figure 70-60-8].

Put a strip of plastigage (Code No. 07909-30241) onto the Remove the relief valve (Item 2), the spring (Item 3) and
rotor face with grease [Figure 70-60-7]. the packing (Item 4) [Figure 70-60-8].

Install the cover and tighten the screws with the specified Tightening Relief valve 68.6 to 78.4 N•m
torque. torque 7.0 to 8.0 kgf·m
50.6 to 57.9 ft.-lb.
Remove the cover carefully, and measure the amount of
the flattening with the scale and get the clearance.

If the clearance exceeds the allowable limit, replace oil

pump rotor assembly and the cover.

Clearance Factory spec. 0.025 to 0.075 mm

between 0.0010 to 0.0030 in.
rotor and Allowable 0.225 mm
cover limit 0.0089 in.

Tightening Oil pump 7.9 to 9.3 N•m

torque cover screw 0.80 to 0.95 kgf·m
5.8 to 6.9 ft.-lb.

6986740-EN (07-08) 70-60-3 Bobcat T2250

SERVICE MANUAL
Oil Pipe Oil Filter Cooler Removal And Installation

Figure 70-60-9 Figure 70-60-10

3EEABAC1P053B 3EEABAC1P090A

Remove the joint bolt (Item 1) and take off the pipe (Item Remove the water pipe (Item 1) [Figure 70-60-10].
2) [Figure 70-60-9].
Remove the oil filter cartridge (Item 2) [Figure 70-60-10].
Remove the bolts (Item 3) and release the clamp (Item 4)
[Figure 70-60-9]. Figure 70-60-11

Remove the oil pipe 2 (Item 5) [Figure 70-60-9].

Before installation pour fresh engine oil through the oil

supply port of the turbocharger.

Replace the gasket with new one.

Be careful not to allow dust, dirt and other foreign matters

in the oil pipes.

NOTE: Tape or plug all openings to prevent foreign

matters from damaging the oil cavities in the
turbocharger.
3EEABAC1P091A

Remove the oil cooler joint bolt (Item 3) [Figure 70-60-11]

& [Figure 70-60-12].

Installation: Tighten the oil cooler joint bolt to 29 - 32.5

ft.-lb. (39,2 - 44,1 N•m).

6986740-EN (07-08) 70-60-4 Bobcat T2250

SERVICE MANUAL
LUBRICATION SYSTEM (CONT’D) Engine Oil Pressure - Testing

Oil Filter Cooler Removal And Installation (Cont’d) Figure 70-60-13

Figure 70-60-12

P-37150

3EEABAC1P092A
Remove the oil switch and set a pressure tester (Code
No. 07916-32031) [Figure 70-60-13].
Remove the oil cooler (Item 4) [Figure 70-60-12].
Start the engine. After warming up, measure the oil
pressure of both idling and rated speeds.

If the oil pressure is less than the allowable limit, check

the following:

Engine oil insufficient

Oil pump defective
Oil strainer clogged
Oil filter cartridge
Oil gallery clogged
Excessive oil clearance of bearing
Foreign matter in the relief valve

After checking the engine oil pressure, tighten the engine

oil pressure switch to the specified torque.

At idle speed Allowable limit 0,49 bar

0.5 kgf/cm²
7 PSI

At rated speed Factory spec. 1,93 to 3,86 bar

2.0 to 4.0 kgf/cm²
28 to 56 PSI
Allowable limit 1,47 bar
1.5 kgf/cm²
21.3 PSI

6986740-EN (07-08) 70-60-5 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 70-60-6 Bobcat T2250
SERVICE MANUAL
FUEL SYSTEM Figure 70-70-3

Fuel Camshaft Removal And Installation

Figure 70-70-1

3EEABAC1P028A

Secure the fuel camshaft with open end wrench (Item 3),
and remove the governor weight mounting nut and the
3EEABAB1P217A
governor weight (Item 4) [Figure 70-70-3].

Separate the governor housing assembly from the Figure 70-70-4

injection pump unit.

Remove the fuel feed pump from the injection pump unit.

Remove the governor sleeve (Item 1) [Figure 70-70-1].

Figure 70-70-2

3EEABAB1P221B

Loosen the fuel camshaft stopper mounting screws and

remove the fuel camshaft stopper (Item 5) [Figure 70-70-
4].

3EEABAB1P218A

Remove the injection pump assembly (Item 2) [Figure 70-

70-2].

Remove the fuel camshaft lock bolts.

6986740-EN (07-08) 70-70-1 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D) Figure 70-70-6

Fuel Camshaft Removal And Installation (Cont’d)

Figure 70-70-5

3EEABAB1P223B

Secure the fuel camshaft with lock bolts as the key way to
fuel camshaft (Item 9) [Figure 70-70-6] is right-
3EEABAB1P222B
downward.

Pull out the fuel camshaft (Item 6) and bearings (Item 7) Install the injection pump assembly to the injection pump
[Figure 70-70-5] together. housing.

After removing the bearing’s cir-clip (Item 8) [Figure 70- Attach the O-ring and the cover and tighten the cover
70-5], press out the bearings. mounting bolts.

NOTE: Do not use the fuel camshaft lock bolts, when Install the governor sleeve to the fuel camshaft.
remove the governor weight mounting nut.
Otherwise, the lock bolts or injection pump Check the movement of the governor sleeve.
housing might get damaged.
NOTE: Be careful not to damage the O-ring.
Press the bearings into the fuel camshaft.
NOTE: Be careful the direction of the governor sleeve.
Set the cir-clip at the gear side’s bearing.
NOTE: When reassembling the inside parts, slightly
Install the fuel camshaft and bearings to the injection lubricate each inside part with oil.
pump housing.
Tightening Fuel camshaft 7.9 to 9.3 N•m
Attach the fuel camshaft stopper and tighten the fuel torque stopper 0.80 to 0.95 kgf·m
camshaft stopper mounting screws with the specified
torque. mounting screw 5.8 to 6.9 ft.-lb.
Governor weight 62.8 to 72.6 N•m
Attach the governor weight to the fuel camshaft and mounting screw 6.4 to 7.4 kgf·m
tighten the governor weight mounting nut with specified 46.3 to 53.5 ft.-lb.
torque.

6986740-EN (07-08) 70-70-2 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D) Figure 70-70-9

Injection Pump Governor Housing Removal And

Installation

Figure 70-70-7

3EEABAB1P205A

Slide off the governor connecting rod (Item 7) [Figure 70-

70-9] from the rack pin of the injection pump assembly.

3EEABAC1P077A
For convenience, temporarily hook the start spring on the
rack pin hole of the governor connecting rod.
Remove the injection pump unit from the engine.
Remove the governor housing mounting bolts.
Remove the governor lubricating pipe (Item 1) [Figure 70-
70-7].

Remove the stop solenoid (Item 2) [Figure 70-70-7].

Detach the sight cover (Item 3) [Figure 70-70-7] from the

injection pump unit.

Figure 70-70-8

3EEABAB1P078B

Unhook the start spring (Item 4) from the rack pin (Item 5)
[Figure 70-70-8] of the injection pump assembly.

Remove the nut (Item 6) [Figure 70-70-8].

NOTE: Be careful not to drop the nut inside.

NOTE: (See Fuel Injection Pump Removal And

Installation on Page 70-70-8.) for proper
alignment of the governor connection rod
procedure. The procedure will require a
special tool part number MEL1637.

6986740-EN (07-08) 70-70-3 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D) Figure 70-70-11

Injection Pump Governor Housing Removal And

Installation (Cont’d)

Figure 70-70-10

3EEABAC1P079A

When reassembling the inside parts, lightly lubricate each

inside part with oil.

3EEABAC1P078A
After sliding on the governor connecting rod to the rack
pin, tighten the nut with the specified torque with using the
Detach the governor housing assembly (Item 8) [Figure jig for keeping the control rod horizontal.
70-70-10] from the injection pump unit.
After tightening the nut, hook the start spring on the rack
NOTE: The injection pump unit is lubricated with pin.
engine oil. Oil will leak when the governor
housing is removed from the injection pump. Check the movement of control rack of injection pump
assembly by the stop lever.

NOTE: When installing the governor housing

assembly to the injection pump unit, be careful
not to damage O-ring (Item 9) [Figure 70-70-
11].

NOTE: When linking the control rod to the rack pin of

injection pump, use the jig for keeping the
control rod horizontal. Otherwise the control
rack may be stuck, and causes to be difficult to
start the engine or hunting of governor.

Tightening Governor 9.8 to 11.3 N•m

torque housing 1.00 to 1.15 kgf·m
mounting bolt 7.23 to 8.32 ft.-lb.
Anti-rotation 3.43 N•m
nut 0.35 kgf·m
2.5 ft.-lb.

6986740-EN (07-08) 70-70-4 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D) Figure 70-70-14

Injection Pump Governor Housing Disassembly And

Assembly

Fork Lever

Figure 70-70-12

3EEABAC1P082A

Remove the governor fork lever assembly from the

governor housing (Item 5) [Figure 70-70-14].

After reassembling the governor housing assembly, check

the movement of the governor fork lever assembly, the
3EEABAC1P080A
speed control lever and the stop lever.

Pull off the governor for lever shaft (Item 1) with the extra NOTE: When assembling the inside parts, lightly
bolt (Dia.: 4 mm, Pitch: 0.7 mm, Length: more than 25 lubricate each inside part with oil.
mm) (Item 2) [Figure 70-70-12].
NOTE: Be careful not to deform the start spring.
Figure 70-70-13
Speed Lever

Figure 70-70-15

3EEABAC1P081A

Unhook the governor spring (Item 3) at the governor fork

lever (Item 4) [Figure 70-70-13] side. 3EEABAC1P083A

Remove the speed control lever (Item 1) and the return

spring (Item 2) [Figure 70-70-15].

6986740-EN (07-08) 70-70-5 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D) Stop Lever

Injection Pump Governor Housing Disassembly And Figure 70-70-18

Assembly (Cont’d)

Governor Fork

Figure 70-70-16

3EEABAC1P086A

Remove the stop lever (Item 1) and the return spring (Item
2) [Figure 70-70-18].

3EEABAC1P084A
Remove the stop lever shaft (Item 3) [Figure 70-70-18].

Remove the governor lever assembly (Item 3) [Figure 70-

70-16] from the governor housing.

Figure 70-70-17

3EEABAC1P085A

Remove the start spring (Item 4) and the stop spring (Item
5) [Figure 70-70-17]

6986740-EN (07-08) 70-70-6 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D) Fuel Shutoff Solenoid - Removal And Installation

Fuel Shutoff Solenoid - Checking Figure 70-70-21

Figure 70-70-19

1
S8579

S8579
Stop the engine. The fuel shutoff solenoid connector is
located between the fuel filter and the oil filter.
Stop the engine. The fuel shutoff solenoid connector is
located between the fuel filter and the oil filter. Remove the tie strap and disconnect the fuel shutoff
solenoid connector (Item 1) [Figure 70-70-21].
Remove the tie strap and disconnect the fuel shutoff
solenoid connector (Item 1) [Figure 70-70-19]. Figure 70-70-22

Use an ohmmeter to check the fuel shutoff solenoid.

Figure 70-70-20

1
S8581

Remove the two mounting bolts (Item 1) [Figure 70-70-

22] from the fuel stop solenoid. Remove the solenoid from
S8580
the injection pump.

The reading between electrical connector terminal C and

terminal A must be approximately 15.6 ohms [Figure 70-
70-20].

The reading between electrical connector terminal C and

terminal B must be approximately .35 to .40 ohms.

6986740-EN (07-08) 70-70-7 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D) Figure 70-70-25

Fuel Injection Pump Removal And Installation

Figure 70-70-23

2
3

3 1

1 2
S8579

Remove the tie strap and disconnect the electrical

connector (Item 1) from the fuel stop solenoid. Then
S8582
remove the two mounting bolts (Item 2) [Figure 70-70-25]
from the fuel stop solenoid. Remove the solenoid from the
NOTE: The injection pump must be removed as a injection pump.
complete unit. Do Not remove individual pump
barrels. If individual pump barrels are Figure 70-70-26
removed, the pump must be recalibrated in a
certified injection shop.

NOTE: The injection pump can be replaced with the

engine crankshaft in any position.

Disconnect and plug the fuel hose (Item 1) and fuel 1

overflow hose (Item 2) [Figure 70-70-23].

Disconnect the four injection lines (Item 3) [Figure 70-70-

23] at the injection pump.

Figure 70-70-24

P-37523

1 Remove the sight cover (Item 1) [Figure 70-70-26] from

the injection pump unit.
1

S8583

Disconnect the four injection lines (Item 1) [Figure 70-70-

24] at the injectors.

Remove the injection lines from the engine.

6986740-EN (07-08) 70-70-8 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D) Figure 70-70-29

Fuel Injection Pump Removal And Installation 1

(Cont’d)

Figure 70-70-27

P-37526

Disconnect the governor connecting rod (Item 1) [Figure

70-70-29] from the injection pump.

P-37524
Figure 70-70-30

Disconnect the starter spring hook (Item 1) [Figure 70-70-

27]. (Be careful to not deform the starter spring.) 1 1 2

Figure 70-70-28

1
1
2

P-37528

Remove the five injection pump mounting bolts (Item 1)

[Figure 70-70-30].

P-37525
Remove the three injection pump mounting nuts (Item 2)
[Figure 70-70-30].
Remove the anti-rotation nut (Item 1) [Figure 70-70-28].
Installation: Tighten the injection pump mounting bolts to
Installation: Tighten the anti-rotation nut to 24-36 in.-lb. 17-20 ft.-lb. (24-28 N•m) torque. Tighten the injection
(3-4 N•m) torque. pump mounting nuts to 13-15 ft.-lb. (18-21 N•m) torque.

NOTE: Be careful not to drop the anti-rotation nut

inside.

6986740-EN (07-08) 70-70-9 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D)

Fuel Injection Pump Removal And Installation

(Cont’d)

Figure 70-70-31

P-37527

With the injection pump mounting bolts and nuts loose, be

sure the governor connecting rod (Item 1) [Figure 70-70-
31] clears the rack pin on the injection pump.

Figure 70-70-32

P-37529

Align the pin on the injection pump (Item 1) [Figure 70-

70-32] with the notch in the housing.

Remove the injection pump from the injection pump

housing.

6986740-EN (07-08) 70-70-10 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D) Figure 70-70-35

Fuel Injection Pump Removal And Installation

(Cont’d)

Figure 70-70-33

3EEABAB1P224A

Remove the injection pump mounting bolts and nuts

completely and take out the injection pump assembly
(Item 9) [Figure 70-70-35].
3EEABAC1P029B

NOTE: Be careful not to deform the start spring.

Slightly loosen the injection pump assembly mounting
bolts and nuts so that they tilt the injection pump assembly NOTE: When taking out the injection pump assembly,
(Item 9) [Figure 70-70-33]. be careful not to hit it against the governor
connecting rod.
Figure 70-70-34
Figure 70-70-36

3EEABAB1P205A

3EEABAB1P224B
Slide off the governor connecting rod (Item 7) [Figure 70-
70-34] from the rack pin of the injection pump assembly. Install the injection pump assembly (Item 1) in the unit,
and tighten the mounting bolts and nuts that keep the
injection pump assembly (Item 1) [Figure 70-70-36] tilted.

6986740-EN (07-08) 70-70-11 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D) Figure 70-70-39

Fuel Injection Pump Removal And Installation

(Cont’d)

Figure 70-70-37

3EEABAC1P110A

Figure 70-70-40

3EEABAC1P029C

Figure 70-70-38

3EEABAC1P111A

Place the jig (Item 3) [Figure 70-70-39] & [Figure 70-70-

40] in the stop solenoid mounting hole of the injection
pump unit.
3EEABAB1P205B

NOTE: The tool (JIG) part number is MEL1637 for the

Hook the governor connecting rod (Item 2) [Figure 70-70- governor connection rod alignment tool (Item
38] to the rack pin of the injection pump assembly (Item 1) 3) [Figure 70-70-39].
[Figure 70-70-37].

Tighten the mounting bolts and nuts with the specified

torque, not to slide off the governor connecting rod (Item
2) [Figure 70-70-38] from the rack pin.

6986740-EN (07-08) 70-70-12 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D) Figure 70-70-43

Fuel Injection Pump Removal And Installation

(Cont’d)

Figure 70-70-41

3EEABAC1P114A

Make sure the permanent magnet at the top of the jig

(Item 3) is attracted to the governor connecting rod (Item
2). To do this, turn the jig a little clockwise and
3EEABAC1P112A
counterclockwise and look into the sight cover hole to see
if the governor connecting rod (Item 2) [Figure 70-70-41]
Figure 70-70-42 moves right and left accordingly [Figure 70-70-42] &
[Figure 70-70-43].

3EEABAC1P113A

6986740-EN (07-08) 70-70-13 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D) Figure 70-70-46

Fuel Injection Pump Removal And Installation

(Cont’d)

Figure 70-70-44

3EEABAC1P117A

Figure 70-70-47

3EEABAC1P116A

Slightly tighten the anti-rotation nut (Item 4) [Figure 70-

70-44] of the governor connecting rod.

Holding down the jig by hand, tighten up the anti-rotation

nut to the specified torque.

Figure 70-70-45

3EEABAC1P119A

Move the stop lever (Item 6) [Figure 70-70-46] and

visually check to see if the fuel injection pump control rack
comes smoothly back to the start position by the counter
force of the start spring. At the same time, visually check
to see if there is no twist in the sliding point (Item 7)
[Figure 70-70-47] between the governor fork lever and
the governor connecting rod from the stop solenoid
mounting hole.

3EEABAB1P078C
If the control rack fails to move back smoothly, remove the
start spring and the anti-rotation nut, and go through the
Hook the start spring (Item 5) [Figure 70-70-45] to the procedure above starting with [Figure 70-70-39].
rack pin.

6986740-EN (07-08) 70-70-14 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D)

Fuel Injection Pump Removal And Installation

(Cont’d)

Finally fit the sight cover and the stop solenoid back into
place.

Tightening Injection Bolt 23.5 to 27.5

torque pump N•m
mounting bolt 2.4 to 2.8
and nut kgf·m
17.4 to 20.3 ft.-
lb.
Nut 17.7 to 20.6
N•m
1.8 to 2.1
kgf·m
13.0 to 15.2 ft.-
lbs
Anti-rotation nut 3.43 N•m
0.35 kgf·m
2.5 ft.-lb.

6986740-EN (07-08) 70-70-15 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D) Figure 70-70-49

Fuel Injection Pump Housing Removal

Figure 70-70-48

P-37517

Place the piston of the 4th cylinder at the top dead center
in the compression stroke. Fix the flywheel with the
flywheel stopper bolt.

Look for a timing mark on the idler gear (Item 1), if one is
P-37116 not present, mark the engaged tooth (Item 2) [Figure 70-
70-49] with a white marking pin to aid in reassembly.
Injection Pump Gear Puller
Application: Use this puller for removing the injection If the timing marks are present and aligned the gears do
pump gear from the governor shaft. not need to be marked.
A 10 mm (0.39 in. dia.)
Figure 70-70-50
B M16 x Pitch 1.5
C 19 mm (0.75 in.)
D 0.5 mm radius (0.02 in. radius)
E 0.89 rad. (50°)
F 10 mm dia. (0.39 in.)
G 20 mm (0.79 in.)
H 5 mm (0.20 in.)
I 95 mm (3.74 in.)
J 125 mm (4.93 in.) 1
K 5 mm (0.20 in.)
L M16 x Pitch 1.5
M 30 mm (1.18 in.)
N 9.5 mm (0.3740 in.)
O 11 mm (0.4331 in.)
P 9.5 mm (0.3740 in.) P-37513
Q 15.5 mm (0.6102 in.)
R 4.5 mm radius (0.18 in. radius) Unscrew the two flange bolts (Item 1) [Figure 70-70-50]
S 20 mm (0.79 in.) from the injection pump unit. Have the fuel cam shaft lock
T 20 mm (0.79 in.) bolts at hand.
U 80 mm (3.1496 in.)
W 12 mm (0.47 in.)
C2 Chamfer 2.0 mm (0.079 in.)

6986740-EN (07-08) 70-70-16 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D) Figure 70-70-53

Fuel Injection Pump Housing Removal (Cont’d)

Figure 70-70-51

P-37533

Loosen the injection pump gear mounting nut (Item 1)

[Figure 70-70-53].
P-37555

Figure 70-70-54
The fuel cam shaft lock bolts (Item 1) [Figure 70-70-51]
are M8 X P1.25 X L30 mm.

Figure 70-70-52 1

1
1
2

P-37534

Install two bolts (M10 X P1.25 X L80 mm) into the two
threaded holes (Item 1) [Figure 70-70-54] in the injection
P-37532
pump cam gear.

Tighten the upper fuel cam shaft lock bolt (Item 1) [Figure
70-70-52] until it comes into contact with the fuel cam
shaft. Make sure the cam shaft does not move.

Tighten the lower fuel cam shaft lock bolt (Item 2) [Figure
70-70-52] until it comes into contact with the fuel
camshaft.

Do not over tighten the lock bolts when they have come in
contact with the cam shaft.

6986740-EN (07-08) 70-70-17 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D) Figure 70-70-57

Fuel Injection Pump Housing Removal (Cont’d) 1

Figure 70-70-55

P-37540

Remove the two mounting bolts (Item 1) [Figure 70-70-

57] and move the fuel filter to allow clearance for the
P-37535
injection pump assembly to be removed.

Install a gear puller (Item 1) [Figure 70-70-55] and Disconnect the throttle linkage from the injection pump.
remove the gear.
Figure 70-70-58
Remove the key from the key way on the injection pump
shaft.
1
Figure 70-70-56

1 1

S8585

Remove the three injection pump unit mounting flange

nuts (Item 1) [Figure 70-70-58]. (Two on the front side
S8584
and one on the back side of the injection pump.)

Disconnect the lubricating oil pipe (Item 1) [Figure 70-70-

56].

6986740-EN (07-08) 70-70-18 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D)

Fuel Injection Pump Housing Removal (Cont’d)

Figure 70-70-59

P-37541

Remove the two injection pump unit support bolts (Item 1)

[Figure 70-70-59].

Remove the injection pump unit from the engine.

6986740-EN (07-08) 70-70-19 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D) Figure 70-70-62

Fuel Injection Pump Housing Installation

Figure 70-70-60

P-37533
2 3
Hand tighten the injection pump gear mounting nut (Item
1) [Figure 70-70-62].
P-37616

Figure 70-70-63
Place the injection pump gear (Item 1) back into the gear
case. Align the marks of the injection pump gear (Item 2)
and the idle gear (Item 3) [Figure 70-70-60].

Figure 70-70-61

2
1

P-37541

Install the two rear mount bolts (Item 1) [Figure 70-70-63]

and tighten.

P-37534
Loosen the two injection pump adjustment bolts (Item 2)
[Figure 70-70-63].
Install the injection pump unit into the injection pump gear
(Item 1) [Figure 70-70-61].

NOTE: When installing the injection pump unit to the

injection pump gear, make sure that the key is
fit in the keyway of injection pump gear.

6986740-EN (07-08) 70-70-20 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D) Figure 70-70-66

Fuel Injection Pump Housing Installation (Cont’d)

Figure 70-70-64

P-37532

Remove the two fuel camshaft lock bolts (Item 1) [Figure

70-70-66].
S8585

Figure 70-70-67
Install the three mounting flange nuts (Item 1) [Figure 70-
70-64] and hand tighten. (Two on the front side and one
on the back side of the injection pump.)

Figure 70-70-65

P-37513

Install the two flange bolts (Item 1) [Figure 70-70-67] and

tighten to 17-20 ft.-lb. (24-28 N•m) torque.

P-37533

Tighten the injection pump gear nut (Item 1) [Figure 70-

70-65] to 54 - 62 ft.-lb. (74 - 83 N•m) torque.

6986740-EN (07-08) 70-70-21 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D) Figure 70-70-70

Fuel Injection Pump Housing Installation (Cont’d)

Figure 70-70-68

1 S8584

Reconnect the lubricating oil pipe (Item 1) [Figure 70-70-

70].
P-37538

Figure 70-70-71
Move the injection pump unit clockwise (viewed from
gearcase side), align the injection timing marks (Item 1)
[Figure 70-70-68] on the injection pump unit and on the
engine gearcase. 1

Figure 70-70-69

P-37516
1
Install the injection pump gear cover and throttle cable
mount bracket, and tighten the eight bolts (Item 1) [Figure
70-70-71] to 17- 20 ft.-lb. (24-28 N•m) torque.

S8585

Tighten the three injection pump unit mounting flange nuts

(Item 1) [Figure 70-70-69] to 17-20 ft.-lb. (24-28 N•m)
torque. (Two on the front side and one on the back side of
the injection pump.)

6986740-EN (07-08) 70-70-22 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT’D) Injection Pump Timing

Fuel Injection Pump Housing Installation (Cont’d) Figure 70-70-73

Figure 70-70-72

P-37538

P-37519
Align the timing mark on the injection pump (Item 1)
[Figure 70-70-73] with the timing mark on the gearcase
Remove the flywheel pin (Item 1) [Figure 70-70-72] from housing.
the engine flywheel and flywheel casting.
Figure 70-70-74
Check the injection timing. (See Injection Pump Timing on
Page 70-70-23.)

Install the flywheel cover on the flywheel casting.

1
1

S8582

Disconnect the four injection lines (Item 1) [Figure 70-70-

74] from the injection pump.

6986740-EN (07-08) 70-70-23 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT'D) Figure 70-70-77

Injection Pump Timing (Cont’d)

Figure 70-70-75 1

P-37543

Install a short plastic tube (Item 1) [Figure 70-70-77] in

the number one cylinder port of the injection pump. The
S8583
tube should fit securely and point upward.

Disconnect the four injection lines (Item 1) [Figure 70-70- Figure 70-70-78
75] from the injector.

Remove the injector lines from the engine.

Figure 70-70-76 1

2 S8586

1 Disconnect the wiring connector (Item 1) [Figure 70-70-

78] from the engine speed control sensor.

S8579
Remove the speed sensor (Item 2) [Figure 70-70-78]
from the engine.
Remove the tie strap and disconnect the electrical
connector (Item 1) [Figure 70-70-76] from the fuel shutoff
solenoid.

Remove the two mount bolts (Item 2) [Figure 70-70-76]

from the fuel shutoff solenoid.

Remove the fuel shutoff solenoid from the engine.

6986740-EN (07-08) 70-70-24 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT'D) Figure 70-70-81

Injection Pump Timing (Cont’d)

Figure 70-70-79

S8587

Check the location of the engine timing mark, by looking

in the engine speed sensor hole on the engine flywheel
P-37543
casting (Item 1) [Figure 70-70-81].

Turn the engine counterclockwise (viewed from flywheel Figure 70-70-82

end) until the fuel partially fills the plastic tube (Item 1)
[Figure 70-70-79].

Figure 70-70-80
2
1

P-37542

The timing mark (Item 1) [Figure 70-70-82] should be

located in the center of the engine speed sensor hole.
P-37543

NOTE: The T.D.C. hole (Item 2) [Figure 70-70-82] in the

After there is fuel rise seen in the plastic tube, rotate the flywheel will not be visible by looking in the
engine back (clockwise) at least 90 degrees. speed sensor hole.

Slowly rotate the engine counterclockwise (viewed from If the timing mark is not located in the center of the hole,
flywheel end) and stop turning when the fuel begins to rise rotate the injection pump unit until the injection timing is
in the plastic tube (Item 1) [Figure 70-70-80]. adjusted.

The injection timing is 12 to 13 degrees before T.D.C.

(0.21 to 0.23 rad.).

6986740-EN (07-08) 70-70-25 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT'D) Figure 70-70-85

Fuel Injector Removal and Installation

Figure 70-70-83

1
1

3EEABAC1P064A

Remove the injection nozzle oil seal (Item 1) from the

cylinder head cover (Item 2) [Figure 70-70-85].
S8582

Installation: Install new injection nozzle oil seals.

Disconnect the four injection lines (Item 1) [Figure 70-70-
83] from the injection pump. Installation: Tighten the valve cover bolts to 14-20 in.-lb.
(1.6 to 2.3 N•m) torque.
Figure 70-70-84
Figure 70-70-86

1
1
1

S8583

P-37578
Disconnect the four injection lines (Item 1) [Figure 70-70-
84] from the injector. Remove the five over flow pipe retaining bolts (Item 1)
[Figure 70-70-86].
Remove the injector lines from the engine.
Installation: Tighten the retaining bolts to 85-96 in.-lb.
(9.6-10.8 N•m) torque.

Remove the nozzle holder clamps (Item 1) [Figure 70-70-

88] from the injector nozzle.

6986740-EN (07-08) 70-70-26 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT'D) Figure 70-70-89

Fuel Injector Removal and Installation (Cont'd)

Figure 70-70-87

P-37581

Remove the injector nozzle (Item 1) [Figure 70-70-89]

from the engine.
P-37579

Figure 70-70-90
Remove the nut (Item 1) [Figure 70-70-87] from the
injector nozzle holder clamp.

Installation: Tighten the injector nozzle holder clamp nut

to 13-15 ft.-lb. (18-21 N•m) torque. 1

Figure 70-70-88 2

1
P-37583

Check the injector nozzle O-rings (Item 1) and nozzle

washer (Item 2) [Figure 70-70-90].

Always replace the injector O-rings and washer before

installation.
P-37580

Remove the injector nozzle holder clamp (Item 1) [Figure

70-70-88].

6986740-EN (07-08) 70-70-27 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT'D) Nozzle Spraying Condition

Fuel Injector Nozzle Pressure - Checking Figure 70-70-92

Figure 70-70-91

3EEABAC1P013A

3EEABAC1P012A
Set the injection nozzle to a nozzle tester (Code No.
07909-31361), and check the nozzle spraying condition.
Set the injection nozzle to the nozzle tester (Code No.:
07909-31361). If the spraying condition is defective, replace the injection
nozzle assembly or repair at Denso service shop.
Slowly move the tester handle to measure the pressure at
which fuel begins jetting out from the nozzle.

If the measurement is not within the factory specifications,

replace the injection nozzle assembly or repair at Denso
service shop.

NOTE: Injection nozzle gasket must be replaced when

the injection nozzle is removed for checking.

Injection Factory 1st 18.63 to 19.61 MPa

pressure spec. stage 190 to 200 kgf/cm²
2702 to 2845 PSI

6986740-EN (07-08) 70-70-28 Bobcat T2250

SERVICE MANUAL
FUEL SYSTEM (CONT'D)

Valve Seat Tightness

Figure 70-70-93

3EEABAC1P014A

Set the injection nozzle to a nozzle tester (Code No.

07909-31361).

Raise the fuel pressure, and keep at 16.67 MPa (170 kgf/
cm², 2418 PSI) for 10 seconds.

If any fuel leak is found, replace the injection nozzle

assembly or repair at Denso service shop.

Valve seat Factory No fuel leak at 16.67 MPa

tightness spec. 170 kgf/cm²
2418 PSI

6986740-EN (07-08) 70-70-29 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 70-70-30 Bobcat T2250
SERVICE MANUAL
CYLINDER HEAD Intake Air Heater Removal And Installation

Intake Air Heater - Testing Figure 70-80-3

Figure 70-80-1

1
1 2
2

P-37559

P-37557
Disconnect the electrical wire from the intake heater lead
(Item 1) [Figure 70-80-3]
Disconnect the electrical wire (Item 1) [Figure 70-80-1]
from the air intake heater. Remove the four mount bolts (Item 2) [Figure 70-80-3]
from the intake air heater housing.
Figure 70-80-2
Installation: Tighten the bolts to 17-20 ft.-lb. (24-28 N•m)
torque.

Figure 70-80-4

1
1

P-37558

Measure the resistance between + terminal (Item 1) and

intake air heater body (Item 2) [Figure 70-80-2].
P-37560

If the resistance is open, the intake air heater is faulty.

NOTE: When installing the intake air heater in the
Intake air Factory spec. Approx. 0.3 Ohms. housing, install the intake air heater so the
heater (At cold occasion) heater lines (Item 1) [Figure 70-80-4] are
resistance vertical, to prevent a short-circuit in the
system.

6986740-EN (07-08) 70-80-1 Bobcat T2250

SERVICE MANUAL
CYLINDER HEAD (CONT’D) Figure 70-80-6

Valve Clearance Adjustment

NOTE: Valve clearance must be checked and

adjusted when engine is cold.

Remove the high pressure pipes and the head cover.

Put the engine in Top Dead Center. (See Valve Timing -

Checking on Page 70-80-3.)

Before adjusting the valve clearance, adjust the bridge to

set the height of valves.

Figure 70-80-5 P-37195

Loosen the lock nut (Item 4) of adjusting screw (Item 3)

[Figure 70-80-6] (push rod side) and insert the thickness
gauge between the rocker arm and the bridge head. Set
the adjusting screw to the specified value, then tighten
the lock nut.

Valve Factory spec. 0.23 to 0.27 mm

clearance 0.0091 to 0.0106 in.

NOTE: After adjusting, tighten the lock nut (Item 4)

[Figure 70-80-6] securely.

P-37194
Valve arrangement IN. EX.
Adjustment cylinder
Loosen the lock nut (Item 2) and return the adjusting Location of piston
screw (Item 1) [Figure 70-80-5]. When No. 1 piston is 1st * *
compression top dead 2nd *
Push the rocker arm by your fingers and screw in the center
adjusting screw slowly until you feel the screw touch the 3rd *
top of valve stem, then tighten the lock nut. 4th
When No. 1 piston is 1st
overlap position 2nd *
3rd *
4th * *

6986740-EN (07-08) 70-80-2 Bobcat T2250

SERVICE MANUAL
CYLINDER HEAD (CONT’D) Figure 70-80-9

Valve Timing - Checking

Figure 70-80-7

2
2

P-37577

Any time the timing mark (Item 1) on the fuel cam gear is
P-37516 meshed with the idler gear (Item 2) [Figure 70-80-9] the
engine is on top dead center of the compression stroke on
number four cylinder.
Remove the two bolts (Item 1) [Figure 70-80-7] from the
throttle linkage mount and the injection pump gear cover. Figure 70-80-10

Remove the six remaining mount bolts (Item 2) [Figure

70-80-7] from the injection pump gear cover.

Remove the injection pump gear cover from the engine.

1
Figure 70-80-8

P-37599

Install a .375 in. (9,525 mm) bolt through the hole in the
flywheel casting (Item 1) [Figure 70-80-10].
1

2 P-37576

Rotate the engine, until the timing mark on the injection

pump fuel cam gear (Item 1) is meshed with the idler gear
(Item 2) [Figure 70-80-8].

6986740-EN (07-08) 70-80-3 Bobcat T2250

SERVICE MANUAL
CYLINDER HEAD (CONT’D) Cylinder Head Removal And Installation

Valve Timing - Checking (Cont’d) Remove the fuel injectors. (See Fuel Injector Removal
and Installation on Page 70-70-26.)
Figure 70-80-11
Figure 70-80-12

P-37519

P-37201

Remove the flywheel cover from the engine flywheel

housing. Remove the rocker arm assembly (Item 1) [Figure 70-80-
12].
Check to see that the bolt (Item 1) [Figure 70-80-11] is
completely through the flywheel. Remove the push rods (Item 2) [Figure 70-80-12].

The engine is now pinned on Top Dead Center. Remove the bridge arm (Item 4) [Figure 70-80-12].

Figure 70-80-13

P-37158

Putting the push rods onto the tappets (Item 3) [Figure

70-80-13], check to see if their ends are properly engaged
with the grooves.

NOTE: After reassembling the rocker arm, be sure to

adjust the valve clearance.

6986740-EN (07-08) 70-80-4 Bobcat T2250

SERVICE MANUAL
CYLINDER HEAD (CONT’D) Be sure to adjust the valve clearance. (See Valve
Clearance Adjustment on Page 70-80-2.)
Cylinder Head Removal And Installation (Cont’d)
It is not necessary to retighten the cylinder head screw
Figure 70-80-14 after running the engine for 30 minutes.

NOTE: When replacing the piston, piston pin bushing,

connecting rod or crank pin bearing, select the
cylinder head gasket thickness to meet with
the top clearance.

P-37228A

Loosen the hose clamps and remove the water return

hose (Item 1) [Figure 70-80-14].

Figure 70-80-15

P-37266

Remove the cylinder head screw in the order of (18) to (1)

[Figure 70-80-15], and remove the cylinder head.

Remove the cylinder head gasket. (O-ring is not attached

to because of metal type cylinder head gasket.)

The cylinder head should be free of scratches and dust.

Take care for handling the gasket not to damage it.

Install the cylinder head.

Tightening Cylinder head 98.1 to 107.9 N•m

torque screw 10.0 to 11.0 kgf·m
72.3 to 79.6 ft.-lb.

Tighten the cylinder head screw gradually in the order of

(1) to (18) after applying engine oil.

6986740-EN (07-08) 70-80-5 Bobcat T2250

SERVICE MANUAL
CYLINDER HEAD (CONT’D) Figure 70-80-17

Cylinder Head Removal And Installation (Cont’d)

Figure 70-80-16

P-37203

Figure 70-80-18
P-37156

Make sure to not the notch (a), (b) or (c) of cylinder head
gasket (Item 1) [Figure 70-80-16] in advance.

Replace the same notch (a), (b) or (c) as the original

cylinder head gasket (Item 1) [Figure 70-80-16].

Select the cylinder head gasket (Item 1) [Figure 70-80-

16] thickness to meet with the top clearance when
replacing the piston, piston pin bushing, connecting rod or
crank pin bearing.

3EEABAC1P026A

Measure the piston head’s recessing or protrusion from

the crankcase cylinder face 4 spots per each piston
[Figure 70-80-18] and (average of four pistons) using the
dial gauge as shown in [Figure 70-80-17].

Select the suitable cylinder head gasket refer to the table

below.

6986740-EN (07-08) 70-80-6 Bobcat T2250

SERVICE MANUAL
CYLINDER HEAD (CONT’D) Cylinder Head Disassembly And Assembly

Cylinder Head Removal And Installation (Cont’d) Figure 70-80-19

Notch of Thickness of Part Piston Head’s

Cylinder cylinder head Code recessing or
Head gasket protrusion
Gasket Before After from the level
tighten tighten of crankcase
ing ing cylinder face.
(average of 4
pistons)
2 0.90 0.80 1C02 -0.07 to
notches mm mm 0- +0.0490 mm
(a) 0.0354 0.0315 0331 -0.0028 to
in. in. 0 +0.0019 in.
1 notch 1.00 0.90 1C02 +0.050 to P-37204
(b) mm mm 0- +0.149 mm
0.0394 0.0354 0360 +0.0020 to
in. in. 0 +0.0058 in. Figure 70-80-20
Without 1.05 0.95 1C02 +0.150 to
notch mm mm 0- +0.20 mm
(c) 0.0413 0.0374 0361 +0.0059 to
in. in. 0 +0.0078 in.

P-37118

Remove the valve spring collets (Item 1) after

compressing the valve spring (Item 3) with the valve
spring retainer (Item 2) [Figure 70-80-19].

Install the valve spring [Figure 70-80-20] with its small-

pitch end downward (at the head side).

Wash the valve stem and valve guide hole, and apply
engine oil sufficiently.

After installing the valve spring collets, lightly tap the stem
to assure proper fit with a plastic hammer.

6986740-EN (07-08) 70-80-7 Bobcat T2250

SERVICE MANUAL
Cylinder Head - Servicing CYLINDER HEAD (CONT’D)

Figure 70-80-21 Cylinder Head Top Clearance

Figure 70-80-23

P-37212

P-37197
Figure 70-80-22

Remove the cylinder head (remove the cylinder head

gasket completely).

Bring the piston to its top dead center fasten 1.5 mm dia.
5 to 7 mm long fuse wires to 3 to 4 spots (Item 1) [Figure
70-80-23] on the piston top with grease so as to avoid the
intake and exhaust valves.

Bring the piston to its middle position, install the cylinder

head, and tighten the cylinder head screws to
specification. (Head gasket must be changed to new one).

Turn the crankshaft until the piston exceeds its top dead
center.
P-37162

Remove the cylinder head, and measure squeezed fuse

wires for thickness.
Thoroughly clean the cylinder head surface.
If the measurement is not within the specified value,
Place a straightedge on the cylinder head’s four sides and
check the oil clearance of the crank pin journal and the
two diagonal [Figure 70-80-22]. Measure the clearance
piston pin.
with a feeler gauge [Figure 70-80-21].

If the measurement exceeds the allowable limit, correct it Top Factory spec. 0.72 to 0.90 mm
with a surface grinder. (See Specifications on Page 70- clearance 0.0283 to 0.0354 in.
10-2.) Tightening Cylinder head 98.1 to 107.9 N•m
torque screw 10.0 to 11.0 kgf·m
NOTE: Be sure to check the valve recessing after 72.3 to 79.6 ft.-lb.
correcting.

6986740-EN (07-08) 70-80-8 Bobcat T2250

SERVICE MANUAL
CYLINDER HEAD (CONT’D) Figure 70-80-25

Valve Guide - Checking

The tool described below is not provided. The tool is used

for inserting and removing the valve guides.Use the
dimensions below [Figure 70-80-24] and [Figure 70-80-
25] to make this tool.

Figure 70-80-24

P-37188

A 20 mm dia. (0.79 in. dia.)

B 11.7 to 11.9 mm dia. (0.460 to 0.468 in. dia.)
C 6.5 to 6.6 mm dia. (0.256 to 0.259 in. dia.)
D 225 mm (8.86 in.)
E 70 mm (2.76 in.)
F 45 mm (1.77 in.)
G 25 mm (0.98 in.)
P-37187 H 5 mm (0.197 in.)
I 6.7 to 7.0 mm dia. (0.263 to 0.275 in. dia.)
J 20 mm dia. (0.787 in. dia.)
K 12.5 to 12.8 mm dia. (0.492 to 0.504 in. dia.)
L 8.9 to 9.1 mm (0.350 to 0.3578 in. dia.)
C1 Chamfer 1.0 mm (0.039 in.)
C2 Chamfer 2.0 mm (0.079 in.)
C0.3 Chamfer 0.3 mm (0.012 in.)

6986740-EN (07-08) 70-80-9 Bobcat T2250

SERVICE MANUAL
CYLINDER HEAD (CONT’D) If the clearance exceeds the allowable limit, replace the
valves. If it still exceeds the allowable limit, replace the
Valve Guide - Checking (Cont’d) valve guide.

Figure 70-80-26 Clearance Factory Intake 0.055 to 0.085

between spec. valve mm
valve 0.0022 to 0.0033
stem and in.
guide Exhaust 0.055 to 0.085
valve mm
0.0022 to 0.0033
in.
Allowable 0.1 mm
limit 0.0039 in.

Valve stem Factor Intake 6.960 to 6.975

O.D. y spec. valve mm
0.2740 to 0.2746
P-37138
in.
Exhaust 6.960 to 6.975
Remove carbon from the valve guide section. valve mm
0.2740 to 0.2746
Measure the valve stem O.D. with an outside micrometer in.
[Figure 70-80-26].
Valve guide Factory Intake 7.030 to 7.045
Figure 70-80-27
I.D. spec. valve mm
0.2768 to 0.2774
in.
Exhaust 7.030 to 7.045
valve mm
0.2768 to 0.2774
in.

P-37139

Measure the valve guide I.D. of the cylinder head at the

most wear part as shown in [Figure 70-80-27] with a
small hole gauge and calculate the clearance.

6986740-EN (07-08) 70-80-10 Bobcat T2250

SERVICE MANUAL
CYLINDER HEAD (CONT’D) Figure 70-80-29

Reconditioning The Valve And Valve Seat

Figure 70-80-28

P-37256

Figure 70-80-30
P-37168

NOTE: Before correcting the valve and seat, check the

valve stem and the I.D. of valve guide section,
and repair them if necessary.
After correcting the valve seat, be sure to
check the valve recessing [Figure 70-80-28].

Correct the valve with a valve refacer.

P-37257

Slightly correct the seat surface with a 1.047 rad. (60°)

(intake valve) or 0.785 rad. (45°) (exhaust valve) seat
cutter (Code No. 07909-33102) [Figure 70-80-29].

Resurface the seat surface with a 0.523 rad. (30°) valve

seat cutter to intake valve seat and with a 0.262 rad. (15°)
valve seat cutter to exhaust valve seat so that the width is
close to specified valve seat width (2.12 mm, 0.0835 in.)
[Figure 70-80-30].

After resurfacing the seat, inspect for even valve seating,

apply a thin film of compound between the valve face and
valve seat, and fit them with valve lapping tool.

Check the valve seating with prussian blue. The valve

seating surface should show good contact all the way
around.

6986740-EN (07-08) 70-80-11 Bobcat T2250

SERVICE MANUAL
CYLINDER HEAD (CONT’D) Valve Lapping

Reconditioning The Valve And Valve Seat (Cont’d) Figure 70-80-32

Valve Recessing

Figure 70-80-31

P-37214

Apply compound evenly to the valve lapping surface.

P-37213
Insert the valve into the valve guide. Lap the valve onto its
seat with a valve flapper or screwdriver [Figure 70-80-
Clean the cylinder head, the valve face and seat. 32].
Insert the valve into the valve guide.
After lapping the valve, wash the compound away and
Measure the valve recessing with a depth gauge [Figure apply oil, then repeat valve lapping with oil.
70-80-31].
Apply prussian blue to the contact surface to check the
If the measurement exceeds the allowable limit, replace seated rate. If it is less than 70%, repeat valve lapping
the valve. again.
If it still exceeds the allowable limit after replacing the
valve, correct the valve seat face of the cylinder head with NOTE: When valve lapping is performed, be sure to
a valve seat cutter or valve seat grinder. check the valve recessing and adjust the valve
Then, correct the cylinder head surface with a surface clearance after assembling the valve.
grinder, or replace the cylinder head.

Valve Factory Intake (recessing)

recessing spec. valve 0.6 to 0.8 mm
(0.0236 to
0.0315 in.)
Exhaust (recessing)
valve 0.85 to 1.05 mm
(0.0335 to
0.0413 in.)
Allowable (recessing)
limit 1.2 mm (0.0472 in.)

6986740-EN (07-08) 70-80-12 Bobcat T2250

SERVICE MANUAL
CYLINDER HEAD (CONT’D) Figure 70-80-34

Valve Spring

Figure 70-80-33

P-37254

Measure the free length (A) with vernier calipers [Figure

P-37255 70-80-34]. If the measurement is less than the allowable
limit, replace it.

Place the valve spring on a tester and compress it to the Put the spring on a surface plate, place a square on the
same length it is actually compressed in the engine side of the spring, and check to see if the entire side is
[Figure 70-80-33]. contact with the square. Rotate the spring and measure
the maximum (B) [Figure 70-80-34]. If the measurement
Read the compression load on the gauge. exceeds the allowable limit, replace.

If the measurement is less than the allowable limit, Check the entire surface of the spring for scratches.
replace it. Replace it, if any.

Setting Factory Intake 63.547 N / 31.5 Free Factory Intake 35.1 to 35.6 mm
load/ spec. valve mm length (A) spec. valve 1.3819 to 1.4016
setting 6.48 kgf / 31.5 mm in.
length 14.256 lbs. /
Exhau 35.1 to 35.6 mm
1,2401 in.
st 1.3819 to 1.4016
Exhaus 63.547 N / 31.5 valve in.
t valve mm
Allowable Intake 34.6 mm
6.48 kgf / 31.5 mm
limit valve 1.3622 in.
14.256 lbs. /
1,2401 in. Exhau 34.6 mm
st 1.3622 in.
Allowable Intake 45.864 N / 31.5
valve
limit valve mm
4.68 kgf / 31.5 mm Tilt (B) Allowable 1.0 mm
10.296 lbs. / limit 0.039 in.
1,2401 in.
Exhaus 45.864 N / 31.5
t valve mm
4.68 kgf / 31.5 mm
10.296 lbs. /
1,2401 in.

6986740-EN (07-08) 70-80-13 Bobcat T2250

SERVICE MANUAL
CYLINDER HEAD (CONT’D) If the oil clearance exceeds the allowable limit or the
tappet is damaged, replace the tappet.
Valve Tappets
Oil clearance Factory 0.020 to 0.062 mm
Figure 70-80-35 between spec. 0.0008 to 0.0024 in.
tappet and Allowable 0.07 mm
guide limit 0.0028 in.

Tappet O.D. Factory 23.959 to 23.980 mm

spec. 0.9433 to 0.9411 in.
Tappet guide Factory 24.000 to 24.021 mm
I.D. spec. 0.9449 to 0.9457 in.

P-37202

Remove the tappets (Item 4) [Figure 70-80-35] from the

crankcase.

When reassembling replace the head gasket with a new

one.

Before installing the tappets (Item 4) [Figure 70-80-35],

apply engine oil thinly around them.

NOTE: Mark the cylinder number to the tappets to

prevent interchanging.

Figure 70-80-36

P-37174

Measure the tappet O.D. with an outside micrometer

[Figure 70-80-36].

Measure the I.D. of the tappet guide bore with a cylinder

gauge, and calculate the oil clearance [Figure 70-80-36].

6986740-EN (07-08) 70-80-14 Bobcat T2250

SERVICE MANUAL
CYLINDER HEAD (CONT’D)

Rocker Arm And Shaft - Checking

Figure 70-80-37

P-37173

Measure the rocker arm bearing I.D. with an inside

micrometer [Figure 70-80-37].

Measure the rocker arm shaft O.D. with an outside

micrometer, and then calculate the oil clearance [Figure
70-80-37].

If the clearance exceeds the allowable limit, replace the

rocker arm and measure the oil clearance again. If it still
exceeds the allowable limit, replace also the rocker arm
shaft.

Oil clearance Factory 0.016 to 0.045 mm

or rocker arm spec. 0.0006 to 0.0018 in.
shaft and Allowable 0.15 mm
bearing limit 0.0059 in.

Rocker arm Factory 15.973 to 15.984 mm

shaft O.D. spec. 0.6289 to 0.6293 in.
Rocker arm Factory 16.000 to 16.018 mm
I.D. for shaft spec. 0.6299 to 0.6306 in.

6986740-EN (07-08) 70-80-15 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 70-80-16 Bobcat T2250
SERVICE MANUAL
CRANKSHAFT AND PISTONS Figure 70-90-2

Piston And Connecting Rod Removal And Installation

Remove the oil pan. (See Oil Pan Removal And
Installation on Page 70-60-1.)

Remove the cylinder head. (See Cylinder Head Removal

And Installation on Page 70-80-4.)

Figure 70-90-1

P-37159

Align the marks (a) [Figure 70-90-2] with each other.

(Face the marks toward the injection pump.)

Apply engine oil to the connecting rod screws and lightly

screw it in by hand, then tighten it to the specified torque.
If the connecting rod screw won’t be screwed in smoothly,
clean the threads. If the connecting rod screw is still hard
P-37128
to screw in, replace it.
When using the existing crank pin metal again, put tally
Remove the connecting rod screws (Item 1) [Figure 70- marks on the crank pin metal and the connecting rod in
90-1] from connecting rod cap. order to keep their positioning.
Remove the connecting rod caps. Fit the crank pin metal in place.

Tightening Connecting rod 78.5 to 83.4 N•m

torque screw 8.0 to 8.5 kgf·m
57.9 to 61.5 ft.-lb.

6986740-EN (07-08) 70-90-1 Bobcat T2250

SERVICE MANUAL
CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-5

Piston And Connecting Rod Removal And Installation

(Cont’d)

Figure 70-90-3 Top Ring Gap Oil Ring

Gap
0.79 rad. (45°)
Piston
Pin Hole

Second Ring
Gap Oil Ring Gap

P-37209

Completely clean carbon in the cylinders.

P-37208 Turn the flywheel and set a piston to the top dead center.

Pull out the piston upward by lightly tapping it from the

Figure 70-90-4 bottom of the crankcase with the grip of a hammer.

Before inserting the piston into the cylinder, apply enough

engine oil to the cylinder.

When inserting the piston into the cylinder, face the mark
(Item 3) [Figure 70-90-4] on the connecting rod to the
injection pump.

NOTE: Do not change the combination of cylinder and

piston.
Make sure of the position of each piston by
marking. For example, mark “1” on the No. 1
position.
When inserting the piston into the cylinder,
P-37233 place the gap of the compression ring 1 on the
opposite side of the combustion chamber and
stagger the gaps of the compression ring 2
and oil ring marking a right angle from the gap
of the compression ring 1.
Carefully insert the pistons using a piston ring
compressor (Item 1) [Figure 70-90-3].
Otherwise, their chrome-plated section of
piston rings may be scratched, causing
trouble inside the liner.

When inserting the piston in place, be careful

not to get the molybdenum disulfide coating
(Item 2) [Figure 70-90-4] torn off its skirt. This
coating is useful in minimizing the clearance
with the cylinder liner. Just after the piston pin
has been press-fitted, in particular, the piston
is still hot and the coating is easy to peel off.
Wait until the piston cools down.

6986740-EN (07-08) 70-90-2 Bobcat T2250

SERVICE MANUAL
CRANKSHAFT AND PISTONS (CONT'D) The Small End Bushing Replacing Tool can be made
using the dimensions below. One set of dimensions is for
Piston And Connecting Rod - Servicing the press out tool and one for press fit.

The Connecting Rod Alignment Tool is not provided. Figure 70-90-6

Order this tool using the code below.

Code No: 07909-31661

Application: Use for checking the connecting rod alignment.
Application Connecting rod big end I.D. 30 to 75 mm (1.18
Range: to 2.95 in. dia.) Connecting rod length 65 to 330
mm (2.56 to 12.99 in.)

P-37189

Small End Bushing Replacing Tool

Application: Use to press out and to press fit the small end
bushing in the connection rod.

(Press out)

A 157 mm dia. (6.181 in.)

B 14.5 mm (0.571 in.)
C 120 mm (4.7244 in.)
D 30.101 to 30.156 mm dia.
(1.1851 to 1.187 in. dia.)
E 33.075 to 33.100 mm dia.
(1.3021 to 1.3031 in. dia.)
F 20 mm (0.7874 in.)
a 0.0000063 mm (0.00025 in.)
b 0.0000063 mm (0.00025 in.)
C1 Chamfer 1.0 mm (0.039 in.)
C2 Chamfer 2.0 mm (0.079 in.)

(Press fit)

A 157 mm dia. (6.181 in.)

B 14.5 mm (0.571 in.)
C 120 mm (4.7244 in.)
D 30.101 to 30.156 mm dia.
(1.1851 to 1.187 in. dia.)
E 42.000 mm dia. (1.6535 in. dia.)
F 20 mm (0.7874 in.)
a 0.0000063 mm (0.00025 in.)
b 0.0000063 mm (0.00025 in.)
C1 Chamfer 1.0 mm (0.039 in.)
C2 Chamfer 2.0 mm (0.079 in.)

6986740-EN (07-08) 70-90-3 Bobcat T2250

SERVICE MANUAL
CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-9

Piston And Connecting Rod - Servicing (Cont’d)

Figure 70-90-7

P-37160

Figure 70-90-10
P-37210

Figure 70-90-8

P-37161

When installing the ring, assemble the rings so that the

manufacture’s mark (Item 12) [Figure 70-90-10] near the
P-37211 gap faces the top of the piston.

When installing the oil ring onto the piston, place the
Remove the piston rings using a piston ring tool. expander joint (Item 10) on the opposite side of the oil ring
gap (Item 11) [Figure 70-90-9].
Remove the piston pin (Item 1), and separate the
connecting rod (Item 7) from the piston (Item 2) [Figure Apply engine oil to the piston pin (Item 1) [Figure 70-90-
70-90-7]. 7].

Be sure to fix the crank pin bearing and the connecting Assemble the piston to the connecting rod with the ↑
rod are same I.D. colors. mark (Item 8) and the connecting rod numbering mark
(Item 9) [Figure 70-90-8] facing same side.
When installing the piston pin, immerse the piston in 80°C
The end faces of the oil ring are plated with hard chrome.
(176°F) oil for 10 to 15 minutes and insert the piston pin to In putting the piston into the cylinder, be careful not to get
the piston. the oil ring scratched by the cylinder. Use the piston ring
fitter to tighten up the oil ring. If the ring’s planted is
scratched, it may get stuck on the cylinder wall, causing a
serious trouble.

NOTE: Mark the same number on the connecting rod

and the piston so as not to change the
combination.

6986740-EN (07-08) 70-90-4 Bobcat T2250

SERVICE MANUAL
CRANKSHAFT AND PISTONS (CONT'D) If the clearance exceeds the allowable limit, replace the
bushing. If it still exceeds the allowable limit, replace the
Piston And Connecting Rod - Servicing (Cont’d) piston pin.

Figure 70-90-11 Oil clearance Factory 0.020 to 0.040 mm

between piston pin spec. 0.0008 to 0.0016 in.
and small end
Allowable 0.15 mm
bushing
limit 0.0059 in.

Piston pin O.D. Factory 30.006 to 30.011 mm

spec. 1.1813 to 1.1815 in.
Small end Factory 30.031 to 30.046 mm
bushing I.D. spec. 1.1823 to 1.1829 in.

P-37253

Measure the piston pin bore I.D. in both the horizontal and
vertical directions with a cylinder gauge [Figure 70-90-
11].

If the measurement exceeds the allowable limit, replace

the piston.

Piston pin bore Factory 30.000 to 30.013 mm

I.D. spec. 1.1811 to 1.1816 in.
Allowable 30.05 mm
limit 1.1831 in.

Figure 70-90-12

P-37178

Measure the O.D. of the piston pin where it contacts the

bushing with an outside micrometer [Figure 70-90-12].

Measure the I.D. of the piston pin bushing at the

connecting rod small end with a cylinder gauge [Figure
70-90-12].

6986740-EN (07-08) 70-90-5 Bobcat T2250

SERVICE MANUAL
CRANKSHAFT AND PISTONS (CONT'D) Piston Ring Groove

Piston And Connecting Rod - Servicing (Cont’d) Figure 70-90-15

Figure 70-90-13

P-37215

P-37179
Remove carbon from the ring grooves.

Figure 70-90-14 Measure the clearance between the ring and the groove
with a feeler gauge [Figure 70-90-15].

If the clearance exceeds allowable limit, check the new

rings on an old piston and if it is out of spec, replace the
piston.

Factory spec. Compression 0.05 to 0.07 mm

ring 1 0.0020 to 0.0028 in.
Compression 0.093 to 0.120 mm
ring 2 0.0037 to 0.0047 in.
Oil Ring 0.020 to 0.060 mm
0.0008 to 0.0023 in.
Allowable limit Compression 0.15 mm
ring 1 0.0059 in.
P-37142 Compression 0.20 mm
ring 2 0.0079 in.
Oil ring 0.15 mm
Press out the used bushing using a small end bushing
0.0059 in.
replacing tool [Figure 70-90-13].

Clean a new small end bushing and bore, and apply

engine oil to them.

Insert a new bushing onto the tool and press-fit it with a

press so that the seam (Item 1) [Figure 70-90-14] of the
bushing is flush with the connecting rod.

6986740-EN (07-08) 70-90-6 Bobcat T2250

SERVICE MANUAL
CRANKSHAFT AND PISTONS (CONT'D)

Piston And Connecting Rod - Servicing (Cont’d)

Piston Ring Gap

Figure 70-90-16

P-37180

Insert the piston ring into the lower part of the liner (the
least worn out part) with the piston.

Measure the ring gap with a feeler gauge [Figure 70-90-

16].

If the gap exceeds the allowable limit, replace the piston

ring.

Compression Factory spec. 0.30 to 0.45 mm

ring 1, 2 0.0118 to 0.0177 in.
Allowable limit 1.25 mm
0.0492 in.

Oil Ring Factory spec. 0.25 to 0.45 mm

0.0098 to 0.0177 in.
Allowable limit 1.25 mm
0.0492 in.

6986740-EN (07-08) 70-90-7 Bobcat T2250

SERVICE MANUAL
CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-19

Cylinder Bore Checking

Figure 70-90-17

P-37164

When the cylinder is worn beyond the allowable limit, bore

P-37169 and hone it to the specified dimension [Figure 70-90-19].

Cylinder I.D. (2) Oversize 98.500 to 98.522 mm

Figure 70-90-18 (+ 0.5 mm) Spec. 3.8780 to 3.8788 in.
Maximum wear Allowable limit 98.65 mm
3.8839 in.
Finishing Hone to 1.2 to 2.0 μR max.
———
(0.000047 to 0.0079 in.R max.

Replace the piston and piston rings with oversize (0.5

mm) ones.

Part Name Part Code Marking

Piston 1C050-21910 05 OS
Piston Ring Assembly 1C020-21090 05 OS

P-37163
NOTE: When the oversize cylinder is worn beyond the
allowable limit, replace the cylinder block with
a new one.
Measure the six points with a cylinder gauge to find out
the maximum wear [Figure 70-90-17]. Generally, position
(1) in the (a, b) direction (at about 20 mm (0.79 in.) from
the top) shows the maximum wear [Figure 70-90-18].
Since position (3) at the lower part of the bore will show
the minimum wear, find these difference.

Cylinder bore Factory spec. 98.000 to 98.022 mm

I.D. 3.8582 to 3.8591 in.
Allowable limit 98.15 mm
3.8642 in.

6986740-EN (07-08) 70-90-8 Bobcat T2250

SERVICE MANUAL
CRANKSHAFT AND PISTONS (CONT'D) Crankshaft Gear Removal And Installation

Connecting Rod Alignment Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 70-
Figure 70-90-20 100-1.)

Remove the idler gear. (See Idle Gear And Shaft Removal
And Installation on Page 70-100-5.)

Figure 70-90-21

P-37181

(See Piston And Connecting Rod - Servicing on Page 70-

90-3.) for the code to order this tool [Figure 70-90-20]
from the engine manufacturer.
B-3686

NOTE: Since the I.D. of the connecting rod small end

bushing is the basis of this check, check the Remove the crankshaft gear with a puller [Figure 70-90-
bushing for wear beforehand. 21].

Remove the piston pin in the connecting rod. Remove the crankshaft key.

Install the piston pin in the connecting rod.

Install the connecting rod on the connecting rod alignment

tool.

Put a gauge over the piston pin, and move it against the
face plate [Figure 70-90-20].

If the gauge does not fit squarely against the face plate,
measure the space between the pin of the gauge and the
face plate.

If the measurement exceeds the allowable limit, replace

the connecting rod.

Connecting rod Allowable limit 0.05 mm

alignment 0.0020 in.

6986740-EN (07-08) 70-90-9 Bobcat T2250

SERVICE MANUAL
CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-23

Crankshaft And Bearings Removal and Installation

Figure 70-90-22

P-37131

NOTE: In case of replacing the oil seal, use caution

P-37130 when installing the seal in the bearing case
cover as not to install it tilted. The seal should
be flush with the cover.
NOTE: Before disassembling, check the side Confirm that the liquid gasket coating surface
clearance of crankshaft. Also check it during is free of water, dust and oil in order to
reassembly. maintain sealing effect.
Apply liquid gasket (Item 2) [Figure 70-90-23]
Remove the bearing case cover mounting screws. to the bearing case cover evenly.

Screw two removed screws into the screw hole (Item 3) Before installing the bearing case cover / oil
[Figure 70-90-22] of bearing case cover to remove it. seal assembly, lube the seal and be careful not
to damage the seal while installing the
assembly.
Install the bearing case cover/oil seal
assembly to the position the casting mark
“UP” on it upward (Item 1) [Figure 70-90-23].

Tighten the bearing case cover mounting

screws with even force on the diagonal line.
When mounting the adhesive-applied parts,
take care to fit them to the mating parts.
Assemble the adhesive-applied parts within
ten minutes.
Tightening Bearing Case 23.5 to 27.5 N•m
torque Cover mounting 2.4 to 2.8 kgf·m
screw 17.4 to 20.3 ft.-lb.

6986740-EN (07-08) 70-90-10 Bobcat T2250

SERVICE MANUAL
CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-25

Crankshaft And Bearings Removal and Installation

(Cont’d)

Figure 70-90-24

3EEABAB1P108B

Figure 70-90-26

P-37231

Install the engine flywheel pin.

Remove the crankshaft screw (Item 1) [Figure 70-90-24].

Remove the fan drive pulley (Item 2) [Figure 70-90-24].

NOTE: Clean the crankshaft screw and the alternator

drive pulley sleeve surface thoroughly and
tighten the screw securely to specified torque.

Tightening Crankshaft 255.0 to 274.6 N•m 3EEABAC1P096A

torque screw 26.0 to 28.0 kgf·m
188.1 to 202.5 ft.-lb.
Match the crankcase 1 (Item 1)and crankcase 2 (Item 2),
[Figure 70-90-25] referring to the flywheel’s contoured
face.

Tighten the crankcase 2 mounting bolts loosely.

Tighten up the jig (Item 5) [Figure 70-90-26] to the

specified torque same as the flywheel housing screw
(Item 4) [Figure 70-90-25]. This helps to minimize the
level difference between the crankcase 1 and the
crankcase 2 (at the flywheel side). Possible gap must be
0.05 mm or smaller (Item 3) [Figure 70-90-25].

Tightening Crankcase 2 49.0 to 55.9 N•m

torque mounting screw 5.0 to 5.7 kgf·m
36.2 to 41.3 ft.-lb.
Flywheel 77.5 to 90.2 N•m
housing screw 7.9 to 9.2 kgf·m
57.1 to 66.5 ft.-lb.

6986740-EN (07-08) 70-90-11 Bobcat T2250

SERVICE MANUAL
CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-29

Crankshaft And Bearings Removal and Installation

(Cont’d)

Figure 70-90-27

P-37136

Remove the main bearing case.

P-37133 Remove the crankshaft.

Reassemble the main bearing case having the same
Remove the crankcase 2 [Figure 70-90-27]. number as the one engraved on the crankcase, and set
the casting mark “F / W SIDE” (Item 1) [Figure 70-90-29]
Figure 70-90-28 on the main bearing case facing towards the flywheel
side.

P-37134

NOTE: Make sure the crankcase 1 and 2 are clean.

Apply liquid gasket (Item 1) [Figure 70-90-28]
to the crankcase 2 as shown in the figure.

Tighten the crankcase 2 mounting screws with

even force on the diagonal line.
Confirm that the liquid gasket coating surface
is free of water, dust and oil in order to
maintain sealing effect.
Carefully apply the adhesive evenly.
Tightening Crankcase 2 49.0 to 55.9 N•m
torque mounting screw 5.0 to 5.7 kgf·m
36.2 to 41.3 ft.-lb.

6986740-EN (07-08) 70-90-12 Bobcat T2250

SERVICE MANUAL
CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-32

Crankshaft And Bearings Removal and Installation

(Cont’d)

Figure 70-90-30

3EEABAC1P098A

Figure 70-90-33

P-37137

Figure 70-90-31

3EEABAC1P099A

Reassemble the thrust bearing (Item 2) [Figure 70-90-

31], with the oil groove facing outside, into both side of the
fourth main bearing case.
3EEABAC1P097A
Apply oil to the bearing case screws and tighten them to
the specified torque.

Tightening Main bearing 137.3 to 147.1 N•m

torque case screw 14.0 to 15.0 kgf·m
101.3 to 108.5 ft.-lb.

6986740-EN (07-08) 70-90-13 Bobcat T2250

SERVICE MANUAL
CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-35

Crankshaft And Bearings - Servicing

The following special tools are not provided, so make

them referring to [Figure 70-90-34], [Figure 70-90-35] &
[Figure 70-90-36].

Figure 70-90-34

P-37114

P-37115
Gearcase Oil Seal Replacing Tool
Application: Use to press fit the oil seal.
A 148.8 mm (5.8582 in.) Auxiliary Socket For Fixing Crankshaft Sleeve
B 50 mm (1.9685 in.)
Application: Use to fix the crankshaft sleeve of the diesel
C 18.8 mm (0.7401 in.)
D 13.7 to 13.9 mm (0.5394 to 0.5472 in.)
engine.
E 11 mm (0.433 in.)
F 18 mm dia. (0.7087 in. dia.) A Rmax = 12.5 S
G 38 mm dia. (1.4961 in. dia.) B 94.5 to 95.0 mm (3.7205 to 3.7402 in.)
H 45 mm dia. (1.7716 in. dia.) C 40 mm (1.5748 in.)
I 57.9 to 58.1 mm (2.2795 to 2.2874 in.) D 30 mm (1.1811 in.)
J 79.5 mm dia. (3.1299 in. dia.) E 12 mm (0.4724 in.)
K 87 mm (3.452 in.) F 7.9 to 8.1 mm (0.3110 to 0.3189 in.)
L 12 mm (0.4724 in.) G 20 mm (0.0787 in.)
M 40 mm (1.5748 in.) H 130 mm (5.1181 in.)
N 120 mm (4.7244 in.) I 99.4 to 99.6 mm (3.9134 to 3.9213 in.)
J 95.05 to 95.20 mm (3.7421 to 3.7480 in.)
K 3 mm dia. (0.1181 in. dia.)
L 15 mm (0.5905 in.)
M 10 mm (0.3937 in.)
N 90 mm (3.5433 in.)
O 115 mm (4.5275 in.)
P 16.9 to 17.1 mm (0.6654 to 0.6732 in.)
C1 Chamfer 1.0 mm (0.039 in.)
C3 Chamfer 3.0 mm (0.1181 in.)
C5 Chamfer 5.0 mm (0.1969 in.)
C0.2 Chamfer 0.2 mm (0.0079 in.)
C0.3 Chamfer 0.3 mm (0.0118 in.

6986740-EN (07-08) 70-90-14 Bobcat T2250

SERVICE MANUAL
CRANKSHAFT AND PISTONS (CONT'D)

Crankshaft And Bearings - Servicing (Cont’d)

Figure 70-90-36

3EEABAC1P115A

Application: Use for aligning the crankcase 1 and 2.

A 115 mm (4.5276 in.)

B 56 mm (2.2047 in.)
C 17 mm (0.6693 in.)
D 20 mm (0.7874 in.)
E f14 mm (0.5512 in. dia.)
F f11 mm (0.4331 in. dia.)
G f14 mm (0.5512 in. dia.)
H 17.5 mm (0.6890 in.)
I 17.5 mm (0.6890 in.)
J 35 mm (1.3780 in.)
K 19mm (0.7480 in.)

6986740-EN (07-08) 70-90-15 Bobcat T2250

SERVICE MANUAL
CRANKSHAFT AND PISTONS (CONT'D) Oversize thrust bearing

Crankshaft And Bearings - Servicing (Cont’d) Oversize Bearing Code Number Marking
0.2 mm Thrust bearing 1C010-23951 020 OS
Crankshaft Side Clearance 0.008 in. 1 02
Thrust bearing 1C010-23971 020 OS
Figure 70-90-37 2 02
0.4 mm Thrust bearing 1C010-23961 040 OS
0.016 in. 1 04
Thrust 1C010-23981 040 OS
bearing1 04

Oversize dimensions of crankshaft journal.

Oversize 0.2 mm 0.4 mm

0.008 in. 0.016 in.
Dimension A 29.20 to 29.25 mm 29.40 to 29.45 mm
1.1496 to 1.1515 in. 1.1574 to 1.1594 in.
Dimension B 169.1 to 169.15 mm 169.2 to 169.25 mm
6.6575 to 6.6594 in. 6.6614 to 6.6634 in.
Dimension C 2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
3EEABAC1P105A
0.1102 to 0.1260 in. 0.1102 to 0.1260 in.
radius radius

Figure 70-90-38 (0.8-S)

The crankshaft journal must be fine-finished to higher than ————

Figure 70-90-39

P-37144

Set a dial indicator with its tip on the end of the crankshaft P-37182
[Figure 70-90-37].

Measure the side clearance by moving the crankshaft to Support the crankshaft with V block on the surface plate
the front and rear. and set a dial indicator with its tip on the intermediate
journal at right angle [Figure 70-90-39].
If the measurement exceeds the allowable limit, replace
the thrust bearings. Rotate the crankshaft on the V block and get the
misalignment (half of the measurement).
If the same size bearing is useless because of the
crankshaft journal wear, replace it with an oversize one If the misalignment exceeds the allowable limit, replace
referring to the table and [Figure 70-90-38]. the crankshaft.

Crankshaft side Factory spec. 0.15 to 0.31 mm Crankshaft Allowable limit 0.02 mm
clearance 0.0059 to 0.0122 in. alignment 0.00079 in.

Allowable limit 0.50 mm

0.0197 in.

6986740-EN (07-08) 70-90-16 Bobcat T2250

SERVICE MANUAL
CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-41

Crankshaft And Bearings - Servicing (Cont’d)

Figure 70-90-40

P-37147

NOTE: STD size crank pin bearing for V3300. To

P-37145 replace it with a specific STD service part,
make sure the crank pin bearing has the same
ID color as the connecting rod [Figure 70-90-
Clean the crank pin and crank pin bearing. 41].

Put a strip of plastigage (Code No. 07909-30241) [Figure ID Connecting rod Crank pin bearing
70-90-40] on the center of the crank pin. Color
Large-end in. Clas Part Center wall thick
dia. s code
Install the connecting rod cap and tighten the connecting
Blue 56.01 to 56.02 L 1C020- 1.496 to 1.501
rod screws to the specified torque, and remove the cap mm 22311 mm
again. 2.2051 to 2.2055 0.0589 to 0.0591
in. in.
Measure the amount of the flattening with the scale, and Yellow 56.00 to 56.01 S 1C020- 1.491 to 1.496
get the oil clearance. or No mm 22331 mm
Color 2.2047 to 2.2051 0.0587 to 0.0589
If the oil clearance exceeds the allowable limit, replace in. in.
the crank pin bearing.
Undersize crank pin bearing.
If the same size bearing is useless because of the crank
pin wear, replace it with an undersize one referring to the Undersize Bearing Code Number Marking
table and figure. 0.2 mm Crank pin bearing 1C020-22960 020 US
0.008 in. 02
NOTE: Never insert the plastigage into the crank pin 0.4 mm Crank pin bearing 1C020-22970 040 US
oil hole. Be sure not to move the crankshaft 0.016 in. 04
while the connecting rod screws are tightened.
Crank pin O.D. Factory spec. 52.977 to 52.990 mm
2.0857 to 2.0862 in.

Oil clearance Factory spec. 0.018 to 0.051 mm

between crank 0.0007 to 0.0020 in.
pin and crank
Allowable limit 0.20 mm
pin bearing
0.0079 in.

6986740-EN (07-08) 70-90-17 Bobcat T2250

SERVICE MANUAL
CRANKSHAFT AND PISTONS (CONT'D) Install the main bearing case and tighten the screws to the
specified torque, and remove the cases again.
Crankshaft And Bearings - Servicing (Cont’d)
Measure the amount of the flattening with the scale and
Figure 70-90-42 get the oil clearance.

If the clearance exceeds the allowable limit, replace the

crankshaft bearing.

Crank pin O.D. Factory spec. 74.977 to 74.990 mm

2.9518 to 2.9548 in.

Oil clearance Factory spec. 0.018 to 0.062 mm

between 0.0007 to 0.0020 in.
crankshaft
Allowable limit 0.20 mm
journal and
0.0079 in.
crankshaft
bearing

Undersize crank pin bearing.

P-37146

Undersize Bearing Code Number Marking

Undersize dimensions of crank pin. 0.2 mm Crankshaft 1C020-23910 020 US
0.008 in. bearing 02
Undersize 0.2 mm 0.4 mm 0.4 mm Crankshaft 1C020-22920 040 US
0.008 in. 0.016 in. 0.016 in. bearing 04
Dimension A 2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
0.1102 to 0.1260 in. 0.1102 to 0.1260 in.
radius radius
Dimension B 1.0 to 1.5 mm radius 1.0 to 1.5 mm radius
0.0394 to 0.0591 in. 0.0394 to 0.0591 in.
radius radius
Dimension C 52.777 to 52.790 mm 52.577 to 52.590 mm
2.0778 to 2.0783 in. 2.0700 to 2.0705 in.
(0.8-S)
The crank pin must be fine-finished to higher than ————

Figure 70-90-43

P-37149

Clean the crankshaft journal and crankshaft bearing.

Put a strip of press gauge (Code No.: 07909-30241) on

the center of the journal [Figure 70-90-43].

NOTE: Never insert the press gauge into the oil hole
of the journal.

6986740-EN (07-08) 70-90-18 Bobcat T2250

SERVICE MANUAL
CRANKSHAFT AND PISTONS (CONT'D) Crankshaft Sleeve

Crankshaft And Bearings - Servicing (Cont’d) Figure 70-90-45

Figure 70-90-44

P-37148

P-37269
Remove the used crankshaft sleeve (Item 1) [Figure 70-
90-45] using a special-use puller set (Code No.: 07916-
Undersize dimensions of crank pin [Figure 70-90-44]. 09032).

Undersize 0.2 mm 0.4 mm Set the sleeve guide (Item 4) to the crankshaft (Item 2)
0.008 in. 0.016 in. [Figure 70-90-45].
Dimension A 2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
0.1102 to 0.1260 in. 0.1102 to 0.1260 in. Heat a new sleeve to a temperature between 150 and
200°C (302 and 392°F), and fix the sleeve to the
radius radius
Dimension B 1.0 to 1.5 mm radius 1.0 to 1.5 mm radius
crankshaft.
0.0394 to 0.0591 in. 0.0394 to 0.0591 in.
radius radius
Press fit the sleeve using the auxiliary socket for pushing
Dimension C 74.777 to 74.790 mm 74.577 to 74.590 mm
2.9440 to 2.9445 in. 2.9361 to 2.9366 in.
(Item 3) [Figure 70-90-45].
(0.8-S)
The crank pin must be fine-finished to higher than ————
NOTE: Mount the sleeve with its largely chamfered
surface facing outward.

6986740-EN (07-08) 70-90-19 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 70-90-20 Bobcat T2250
SERVICE MANUAL
CAMSHAFT AND TIMING GEARS Figure 70-100-3

Timing Gearcase Cover Removal And Installation

Figure 70-100-1

3EEABAC1P094A

Be careful not to damage the water pipe (Item 2) [Figure

3EEABAC1P093A 70-100-3].

NOTE: When mounting the adhesive-applied parts,

Remove the gearcase cover (Item 1) [Figure 70-100-1]. take care to fit them to the mating parts.

Figure 70-100-2 NOTE: Assemble the adhesive-applied parts within

ten minutes.

NOTE: Apply a liquid gasket to the gearcase cover.

NOTE: Use the new O-rings when attaching gearcase

cover.

3EEABAC1P089A

Confirm that the liquid gasket coating surface is free of

water, dust and oil in order to maintain sealing effect.

Carefully apply the adhesive evenly [Figure 70-100-2].

6986740-EN (07-08) 70-100-1 Bobcat T2250

SERVICE MANUAL
CAMSHAFT AND TIMING GEARS (CONT’D)

Timing Gears Backlash - Checking

Figure 70-100-4

3EEABAC1P100A

Set a dial indicator (lever type) with its tip on the gear
tooth [Figure 70-100-4].

Move the gear to measure the backlash, holding its

mating gear.

If the backlash exceeds the allowable limit, check the oil

clearance of the shafts and the gear.

If the oil clearance is proper, replace the gear.

Crank gear Factory 0.049 to 0.193 mm

Idle gear spec. 0.0019 to 0.0076 in.
Allowable 0.22 mm
limit 0.0087 in.
Idle gear Factory 0.049 to 0.189 mm
Cam gear spec. 0.0019 to 0.0074 in.
Allowable 0.22 mm
limit 0.0087 in.
Idle gear 2 Factory 0.030 to 0.165 mm
spec. 0.0012 to 0.0065 in.
Injection Allowable 0.22 mm
pump gear limit 0.0087 in.

6986740-EN (07-08) 70-100-2 Bobcat T2250

SERVICE MANUAL
CAMSHAFT AND TIMING GEARS (CONT’D) Alignment

Camshaft - Servicing Figure 70-100-6

Side Clearance

Figure 70-100-5

P-37175

Support the camshaft with V block on the surface plate

3EEABAC1P102A and set a dial indicator with its tip on the intermediate
journal at right angle [Figure 70-100-6].

Set a dial indicator with its tip on the camshaft [Figure 70- Rotate the camshaft on the V blocks and get the
100-5]. misalignment (half of the measurement).

Measure the side clearance by moving the cam gear to If the misalignment exceeds the allowable limit, replace
the front and rear. the camshaft.

If the measurement exceeds the allowable limit, replace Camshaft Allowable 0.01 mm
the camshaft stopper. alignment limit 0.00039 in.

Side Factory 0.07 to 0.22 mm

clearance spec. 0.0028 to 0.0087 in.
Allowable 0.03 mm
limit 0.0118 in.

6986740-EN (07-08) 70-100-3 Bobcat T2250

SERVICE MANUAL
CAMSHAFT AND TIMING GEARS (CONT’D) Figure 70-100-9

Camshaft - Servicing (Cont’d)

Figure 70-100-7

P-37140

Measure the camshaft journal O.D. with an outside

P-37176 micrometer [Figure 70-100-9].

If the clearance exceeds the allowable limit, replace the

Measure the height of the cam at its highest point with an camshaft.
outside micrometer [Figure 70-100-7].
Oil clearance Factory 0.050 to 0.091 mm
If the measurement is less than the allowable limit, of camshaft spec. 0.0020 to 0.0035 in.
replace the camshaft. journal Allowable 0.15 mm
limit 0.0059 in.
Intake and Factory Intake 37.63 mm
exhaust spec. valve 1.4815 in.
cam height Camshaft Factory 45.934 to 45.950 mm
Exhaust 38.96 mm
journal O.D. spec. 1.8084 to 1.8091 in.
valve 1.5338 in.
Camshaft Factory 46.000 to 46.025 mm
Allowable Intake 37.13 mm
journal I.D. spec. 1.8110 to 1.8120 in.
limit valve 1.4618 in.
Exhaust 38.46 mm
valve 1.5141 in.

Figure 70-100-8

3EEABAC1P103A

Measure the cylinder block bore I.D. for camshaft with an

inside micrometer [Figure 70-100-8].

6986740-EN (07-08) 70-100-4 Bobcat T2250

SERVICE MANUAL
CAMSHAFT AND TIMING GEARS (CONT’D)

Idle Gear And Shaft Removal And Installation

Figure 70-100-10

3EEABAC1P095A

Remove three set screws of the idle gear and draw out
the idle gear 1, 2 [Figure 70-100-10].

Remove two set screws of the camshaft stopper and draw

out the camshaft.

Set the crankshaft at the top dead center of No. 1 and 4

cylinder and the camshaft key to the top position and align
the marks of idle gear and cam gear and crank gear to
assemble them [Figure 70-100-10].

6986740-EN (07-08) 70-100-5 Bobcat T2250

SERVICE MANUAL
CAMSHAFT AND TIMING GEARS (CONT’D) Side Clearance

Idler Gear And Shaft - Servicing Figure 70-100-12

Figure 70-100-11

3EEABAC1P101A

P-37189
Set a dial indicator with its tip on the idle gear [Figure 70-
100-12].
Bushing Replacing Tool
Application: Use to press out and press fit the bushing. Measure the side clearance by moving the idle gear to the
1. For idle gear bushing. front and rear.

A 196 mm (7.7165 in.) If the measurement exceeds the allowable limit, replace
B 37.5 to 1.476 mm the idle gear collar.
C 150 mm (5.9055 in.)
D 46.325 to 46.500 mm dia. Side Factory 0.15 to 0.30 mm
(1.8238 to 1.8307 in. dia.) clearance spec. 0.0059 to 0.0118 in.
E 48.100 to 48.075 mm dia.
Allowable 0.9 mm
(1.8937 to 1.8927 in. dia.)
limit 0.0354 in.
F 20 mm (0.7874 in.)
a 0.0000063 mm (0.00025 in.)
b 0.0000063 mm (0.00025 in.)
C1 Chamfer 1.0 mm (0.039 in.)
C2 Chamfer 2.0 mm (0.079 in.)

6986740-EN (07-08) 70-100-6 Bobcat T2250

SERVICE MANUAL
CAMSHAFT AND TIMING GEARS (CONT’D) If the oil clearance exceeds the allowable limit, replace
the bushing.
Idler Gear And Shaft Servicing (Cont’d)
Clearance Factory 0.050 to 0.091 mm
Figure 70-100-13 between idle spec. 0.0020 to 0.0036 in.
gear shaft Allowable 0.10 mm
and idle gear limit 0.0039 in.
bushing

Idle gear Factory 45.025 to 45.050 mm

bushing I.D. spec. 1.7726 to 1.7736 in.
Idle gear Factory 44.959 to 44.945 mm
shaft O.D. spec. 1.7700 to 1.7707 in.

Figure 70-100-15

3EEABAC1P104A

Measure the idle gear shaft O.D. with an outside

micrometer [Figure 70-100-13].

Figure 70-100-14

P-37177

Using an idle gear bushing replacing tool, press out the

used bushing. (See Idler Gear And Shaft - Servicing on
Page 70-100-6.)

Clean a new idle gear bushing and idle gear bore, and
apply engine oil to them.

P-37141 Using an idle gear bushing replacing tool, press in a new

bushing (service parts) to the specified dimension [Figure
70-100-15].
Measure the idle gear bushings I.D. with an inside
micrometer, and calculate the oil clearance [Figure 70-
100-14].

6986740-EN (07-08) 70-100-7 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 70-100-8 Bobcat T2250
SERVICE MANUAL
TURBOCHARGER Testing

Description Inspect the turbine fins and the turbo housing for damage.

Figure 70-110-1 Spin turbine by hand. Turbine should spin freely.

If the turbine is damaged replace the turbocharger.

Check the oil tubelines for leaks.

S5447

The turbocharger is placed between the exhaust and

intake manifolds. It is driven by hot exhaust gases and
supplies air at more than atmospheric pressure to the
intake. It is lubricated by oil from the main galley. The
location of the turbo is between the engine and the blower
housing.

The oil flows to the turbo by a tubeline (Item 1) and

returns to the engine block through another tubeline (Item
2) [Figure 70-110-1].

The turbocharger internal components are not

serviceable.

6986740-EN (07-08) 70-110-1 Bobcat T2250

SERVICE MANUAL
TURBOCHARGER (CONT’D) Figure 70-110-4

Removal And Installation

2
1 1 2

WARNING 2

Turbochargers, operate at high speed and high

temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact 1
with hot surfaces. 2
W-2257-1196

Figure 70-110-2 S5448

Remove the exhaust four tube bolts (Item 1) [Figure 70-

110-4].

Remove the seven turbocharger mounting bolts (Item 2)

[Figure 70-110-4].

Take off the turbocharger assembly.

Installation: During installation replace all gaskets with

2 new ones.

1
S5447

Remove the bolts (Item 1) and tubeline [Figure 70-110-2].

Figure 70-110-3

S5446

Loosen the intake hose clamps (Item 1) [Figure 70-110-

3] and remove the intake hose.

Loosen the air cleaner hose clamps (Item 2) [Figure 70-

110-3] and remove the air cleaner hose.

6986740-EN (07-08) 70-110-2 Bobcat T2250

SERVICE MANUAL
FLYWHEEL AND HOUSING Ring Gear Removal And Installation

Flywheel Removal And Installation NOTE: The lead chamfer on ring gear tooth must face
the starter.
Figure 70-120-1
The ring gear (Item 1) [Figure 70-120-2] on the flywheel
is an interference fit. Heat the ring gear enough to expand
it and hit it with a hammer to remove it evenly.

Clean the outer surface of the flywheel to give it a smooth

fit.

1 Clean the new ring gear and heat it to a maximum

temperature of 428°F (220°C).

Fit the ring gear over the flywheel. Make sure the gear is
on the seat correctly.

P-37364

NOTE: To avoid damage to the RPM sensor, remove

the RPM sensor before removing the flywheel.

Remove the drive belt. (See Belt Removal And Installation

on Page 30-50-3.)

Remove the bolts (Item 1) [Figure 70-120-1] from the

flywheel.

Installation: Tighten the flywheel bolts to 75-80 ft.-lb.

(101,7-108,4 N•m) torque.

Installation: There are two alignment pins on the

crankshaft that are used to install the flywheel in the
proper position for timing purposes.

Figure 70-120-2

P-37365

Remove the flywheel from the engine crankshaft [Figure

70-120-2].

6986740-EN (07-08) 70-120-1 Bobcat T2250

SERVICE MANUAL
FLYWHEEL AND HOUSING (CONT’D) Figure 70-120-4

Housing Removal And Installation

Figure 70-120-3

1 1

1
1
1

1 P-37367

Installation: Install the flywheel housing on the engine.

1
P-37366
Install two alignment studs (Item 1) [Figure 70-120-4] into
the engine crankshaft to help align the flywheel.
Remove the drive belt. (See Belt Removal And Installation
on Page 30-50-3.) The two studs are M12 x 1.25 Pitch x 76 mm (3 in.) long.

Remove the hydrostatic pump. (See Removal And

Installation on Page 30-40-1.)

Remove the belt tension pulley assembly. (See Tensioner

Pulley Removal And Installation on Page 30-50-4.)

Remove the starter. (See Removal And Installation on

Page 60-40-2.)

Remove the ten flywheel housing mounting bolts (Item 1)

[Figure 70-120-3].

Installation: Tighten the mounting bolts to 65-75 ft.-lb.

(88,1-101,7 N•m) torque.

Remove the flywheel housing from the engine.

6986740-EN (07-08) 70-120-2 Bobcat T2250

SERVICE MANUAL
 HEATING, VENTILATION, AIR CONDITIONING

AIR CONDITIONING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1

AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . 80-10-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1

Checking The Electrical System . . . . . . . . . . . . . . . . . . . . . . . . 80-50-2
Compressor And Alternator Drive Belt Inspection. . . . . . . . . . . 80-50-1
Poor A/C Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1

COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1
Compressor Clutch Disassembly And Assembly . . . . . . . . . . 80-110-2
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1

CONDENSER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1

EVAPORATOR/BLOWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1

EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-160-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-160-1

GENERAL AIR CONDITIONING SERVICE GUIDELINES. . . . . . . 80-60-1 HVAC

Component Replacement And Refrigeration Leaks . . . . . . . . . 80-60-3
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
Compressor Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1

HEATER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1

Core Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 80-170-2
Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-2
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1

PRESSURE SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1

RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1

Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1

REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Cleaning The Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-2
Compressor And Alternator Drive Belt Inspection. . . . . . . . . . . 80-40-2
Filter Element Removal And Installation . . . . . . . . . . . . . . . . . . 80-40-1

Contined On Next Page

6986740-EN (07-08) 80-01 Bobcat T2250

SERVICE MANUAL
 HEATING, VENTILATION, AIR CONDITIONING (CONT’D)

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1

SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . . 80-100-1

Charging Procedure With A Manifold Gauge Set . . . . . . . . . . . . 80-100-4
Reclamation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1

SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . 80-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1
Gauge Pressure Related Troubleshooting. . . . . . . . . . . . . . . . . . . 80-70-2

TEMPERATURE AND PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1

6986740-EN (07-08) 80-02 Bobcat T2250

SERVICE MANUAL
AIR CONDITIONING SYSTEM FLOW

Description

In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed
circuit. At these five points in the system the refrigerant goes through pressure and temperature changes.

The compressor (Item 1) (See Chart on Page 80-10-2) takes in heated, low pressure refrigerant gas through the suction
valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the
discharge valve (high pressure side) on the condenser (Item 2) (See Chart on Page 80-10-2).

Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.

The liquid refrigerant moves on to the receiver/drier (Item 3) (See Chart on Page 80-10-2) where impurities such as
moisture and dirt are filtered out. The receiver/drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) (See Chart on Page 80-10-2).

The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) (See Chart on Page 80-10-2). As
the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature,
low-pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the evaporator fan
(blower) (Item 6) (See Chart on Page 80-10-2). Since the refrigerant is colder than the air, it absorbs the heat from the
air and produces cooled air, which is pushed into the cab by the fan. The moisture in the air condenses on the evaporator
coil and drips into the drain pan, which directs the water out of the cab.

The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.

6986740-EN (07-08) 80-10-1 Bobcat T2250

SERVICE MANUAL
AIR CONDITIONING SYSTEM FLOW (CONT'D)

Chart

6986740-EN (07-08) 80-10-2 Bobcat T2250

SERVICE MANUAL
COMPONENTS Figure 80-20-3

Identification
1
Figure 80-20-1

S4971

Receiver / Drier: The receiver / drier (Item 1) [Figure 80-

S4972 20-3] is the unit that receives the liquid refrigerant from
the condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
Compressor: The compressor (Item 1) [Figure 80-20-1] is extra liquid refrigerant until it is needed by the evaporator.
the pump that circulates the refrigerant throughout the
system. It raises the pressure of the refrigerant for heat Figure 80-20-4
transfer through the condenser and evaporator.

NOTE: The A/C System (compressor) is

recommended to be turned on for at least 5 1
minutes weekly throughout the year to
lubricate the internal components.

Figure 80-20-2

P-27595

1
Pressure Switch: The pressure switch (Item 1) [Figure
80-20-4] is located on the receiver / drier assembly (Item
2) [Figure 80-20-3]. It will disengage the compressor
clutch if the pressure readings are too low or too high,
which indicates loss of refrigerant.
S4970

Condenser: The condenser (Item 1) [Figure 80-20-2] is

the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.

6986740-EN (07-08) 80-20-1 Bobcat T2250

SERVICE MANUAL
COMPONENTS (CONT'D) Figure 80-20-7

Identification (Cont'd)

Figure 80-20-5

1 1

S7836

Blower Fan Switch: This is a three position switch (Item 1)

S4969 [Figure 80-20-7]. When the blower fan switch is in the
OFF position the A/C will not engage.

Evaporator Unit: The evaporator unit (Item 1) [Figure 80-

20-5] is located behind the operator seat inside the cab.
The unit delivers the cold air for the A/C into the cab. The
unit also contains the blower fan, evaporator coil and
thermostat which are not serviceable.

Figure 80-20-6

P-27596

Expansion Valve: The expansion valve (Item 1) [Figure

80-20-6] controls the amount of refrigerant entering the
evaporator coil.

6986740-EN (07-08) 80-20-2 Bobcat T2250

SERVICE MANUAL
SAFETY Figure 80-30-1

Safety Equipment

WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500

WARNING In servicing A/C and heater systems you will be exposed

to high pressures, temperatures and several chemical
HFC 134A refrigerant can be dangerous if not hazards. Moving belts and pulleys are normal shop
properly handled. Liquid 134A may cause blindness if hazards.
it contacts the eyes and may cause serious frostbite if
it contacts the skin. In addition to exercising caution in your work, DO WEAR
• Gaseous 134A becomes lethal (phosgene) gas SAFETY GLASSES OR A FACE SHIELD [Figure 80-30-
when it contacts open flame or very hot 1] when you are using R-134a or a leak detector,
substances. adjusting service valves or the manifold gage set
• NEVER SMOKE when there is the possibility of connectors. Safety glasses or a transparent face shield
even small amounts of 134A in the air. are practical safety items and one or the other is
Any servicing work that involves release or addition absolutely required.
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment, Figure 80-30-2
knowledge, and experience to service refrigeration
equipment.
W-2373-0500

R-134a inside a canister or in an A/C system is a liquid

under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO 21.6 F DEGREES
"INSTANTLY". If it spills on your skin or in your eyes you
should flood the area with cool water and SEEK
MEDICAL ATTENTION FAST! It is a good idea to wear
gloves [Figure 80-30-2] to prevent frost bite if you should
get refrigerant on your hands.

6986740-EN (07-08) 80-30-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 80-30-2 Bobcat T2250
SERVICE MANUAL
REGULAR MAINTENANCE Figure 80-40-3

Filter Element Removal And Installation

Figure 80-40-1 2

P-27657

1
Remove the filter (Item 1) and backup screen (Item 2)
S4974 [Figure 80-40-3].

Figure 80-40-4
Remove the four mount bolts (Item 1) [Figure 80-40-1]
from the fresh air filter cover at the front of the cab.

Figure 80-40-2

P-27658

The fresh air filter [Figure 80-40-4] is made of open cell

S4975 foam and should be cleaned with water. A mild detergent
may also be used.

Remove the two filter mount bolts (Item 1) [Figure 80-40-

2].

6986740-EN (07-08) 80-40-1 Bobcat T2250

SERVICE MANUAL
REGULAR MAINTENANCE (CONT'D) Cleaning The Condenser

Compressor And Alternator Drive Belt Inspection Open the engine cover.

It is a good rule to regularly inspect (weekly) the Temporarily remove the air cleaner. (See Filter Element
compressor / alternator drive belt for tension and wear. Removal And Installation on Page 80-40-1.)

Open the engine cover. Figure 80-40-6

Figure 80-40-5
1

1
2

1 1

1 S4973

S6530
Clean the condenser (Item 1) [Figure 80-40-6] using
water or air pressure.
Remove the four bolts (Item 1) and the belt shield (Item 2)
[Figure 80-40-5].
NOTE: Clean between the oil cooler and condenser.
Check the tension on the compressor / alternator belt.

6986740-EN (07-08) 80-40-2 Bobcat T2250

SERVICE MANUAL
BASIC TROUBLESHOOTING Check the A/C condenser for dirt or mud, and clean if
necessary. (See Cleaning The Condenser on Page 80-40-
Poor A/C Performance 2.)

Start the Telescopic Handler, engage the parking brake. Inspect the sight glass located on the receiver/drier for air
Engage the A/C system with the blower fan on high. Run bubbles. (See REGULAR MAINTENANCE on Page 80-
the Telescopic Handler at full RPM for approximately 15 40-1.)
minutes, with the cab door closed.
Compressor And Alternator Drive Belt Inspection
Figure 80-50-1
Regularly inspect (weekly) the compressor / alternator
drive belt for wear.

Open the engine cover.

Figure 80-50-3
1

1 1
2

S2931

1
Figure 80-50-2

1
S6530

Remove the four bolts (Item 1) and the belt shield (Item 2)
[Figure 80-50-3].
Check the tension on the compressor / alternator belt.

P-27746

Check the temperature at the louvers (Item 1) [Figure 80-

50-1] with a thermometer [Figure 80-50-2].

The louver temperature should be between 36-53°.F (2.2-

11,6° C) depending on the amount of humidity in the air.

If the louver temperature is too high. (See SYSTEM

TROUBLESHOOTING CHART on Page 80-70-1.)

Check the blower fan for proper operation or noise, and

replace if necessary. (See EVAPORATOR/BLOWER
UNIT on Page 80-150-1.)

Check the belt tension on the A/C compressor. (See

Compressor Drive Belt Inspection on Page 80-40-2.)

6986740-EN (07-08) 80-50-1 Bobcat T2250

SERVICE MANUAL
BASIC TROUBLESHOOTING (CONT'D) Figure 80-50-6

Checking The Electrical System

Figure 80-50-4

1
S6559

If the compressor clutch does not engage, check the air

S3670 condition compressor fuse (Item 1) [Figure 80-50-6].
Replace the fuse if needed.

Check to see if the compressor clutch (Item 1) [Figure 80- Figure 80-50-7
50-4] is engaging.

Turn the ignition key switch to the RUN position without

starting the machine.
1
Figure 80-50-5

S5887

1 Unplug the connector (Item 1) [Figure 80-50-7] from the

compressor.

S7836

Turn the blower fan switch (Item 1) [Figure 80-50-5] to the

first on position, the compressor clutch should make a
click sound, which indicates the clutch is engaging.

6986740-EN (07-08) 80-50-2 Bobcat T2250

SERVICE MANUAL
BASIC TROUBLESHOOTING (CONT'D) Figure 80-50-10

Checking The Electrical System (Cont'd) 1

Figure 80-50-8

S4979

Disconnect the machine harness (Item 1) [Figure 80-50-

S5860 10] from the pressure switch.

Figure 80-50-11
With a multimeter check the resistance to the compressor
clutch connector (Item 1) [Figure 80-50-8].

If there is no resistance value replace the compressor

clutch. (See COMPRESSOR on Page 80-110-1.)

Figure 80-50-9 1

S5862
1

With the key switch to the run position (engine off) and the
blower fan switch on the first position. Use a multimeter to
check the main harness (Item 1) [Figure 80-50-11] for
voltage.
S5861
There should be 12 volts. If there is no voltage, check the
harness for broken wires.
With a multimeter, check the voltage to the compressor
clutch at the main harness (Item 1) [Figure 80-50-9].

If there is no power at the clutch, check the wiring harness

for broken wires.

If there is no power at the clutch, reconnect the wiring

harness to the compressor clutch.

6986740-EN (07-08) 80-50-3 Bobcat T2250

SERVICE MANUAL
BASIC TROUBLESHOOTING (CONT'D) Figure 80-50-14

Checking The Electrical System (Cont'd)

Figure 80-50-12

1
1

P-27742

Check the main harness (Item 1) [Figure 80-50-14] for

S3688 voltage. The voltage should be 12 volts. If there is no
voltage, check the harness for broken wires.

If there is voltage at the harness, check the resistance at Figure 80-50-15

the pressure switch (Item 1) [Figure 80-50-12].

If there is no resistance value, check for a low refrigerant

level. (See SYSTEM CHARGING AND RECLAMATION
on Page 80-100-1.)

If good resistance value is observed, the pressure switch

is good.

Reconnect the main harness to the pressure switch.

Figure 80-50-13

P-27743

If there is voltage at the wiring harness, check the

thermostat wire (green) for resistance. The resistance
value should be 10 ohms at 20°C (68° F) [Figure 80-50-
15].

If there is no resistance, replace the entire blower fan unit.

1

P-27597

Disconnect the thermostat wiring connector (Item 1)

[Figure 80-50-13] from the main harness.

6986740-EN (07-08) 80-50-4 Bobcat T2250

SERVICE MANUAL
BASIC TROUBLESHOOTING (CONT'D) Figure 80-50-18
Checking The Electrical System (Cont'd)

Figure 80-50-16 1

P-27745

Check the main harness (Item 1) [Figure 80-50-18] for

voltage. The voltage should be 12 volts if there is no
voltage check the harness for broken wires.
S7841

Figure 80-50-19
Remove the fuse box cover (Item 1) [Figure 80-50-16].
H C
Figure 80-50-17

M B

1
L

N-22288

If there is voltage at the main harness check the blower

fan switch [Figure 80-50-19] for resistance.
P-27744
With the switch in the OFF position, there should be zero
resistance between all terminals.
Disconnect the main wire harness connectors (Item 1)
[Figure 80-50-17] from the switch. With the switch in the 1 position, there should be
resistance between C terminal and the B terminal. And
NOTE: Mark the wires for correct assembly. also between the C terminal and the L terminal frame
[Figure 80-50-19].

With the switch in the 2 position, there should be

resistance between C terminal and the B terminal. And
also between the C terminal and the M terminal frame
[Figure 80-50-19].

With the switch in the 3 position, there should be

resistance between C terminal and the B terminal. And
also between the C terminal and the H terminal frame
[Figure 80-50-19].

If any of the above resistance tests fail, replace the blower

fan switch.

6986740-EN (07-08) 80-50-5 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 80-50-6 Bobcat T2250
SERVICE MANUAL
GENERAL AIR CONDITIONING SERVICE GUIDELINES Compressor Oil Check

Compressor Oil The compressor oil should be checked as follows when oil
is being added to a machine in service.
Figure 80-60-1
There is a close affinity between oil and refrigerant.
During normal operation, part of the oil circulates with the
refrigerant in the system. Therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run in to insure
return of oil to the compressor.
1
If the amount of refrigerant in the system has decreased,
charge the system. (See SYSTEM CHARGING AND
RECLAMATION on Page 80-100-1.)

Open the cab door and windows.

Run the blower fan at maximum speed.

P-27538 Run the compressor for at least 20 minutes at 800-1200

RPM.
The compressor (Item 1) [Figure 80-60-1] is factory filled Remove the compressor from the machine. (See Removal
with 150-170 cc's of PAG oil (Poly Alkelene Glycol). And Installation on Page 80-110-1.)

Unlike engine oil, it is not necessary to frequently check or

change the compressor oil.

It is necessary to check, replenish or replace the

compressor oil in the following cases:

1. When the evaporator, condenser or receiver-drier is

replaced.

2. When refrigerant has leaked from the system.

3. When refrigerant is suddenly released from the

cooling cycle.

4. When any related problems occur in the cooling cycle.

When one of the components (the evaporator, condenser

or receiver-drier) is replaced, one ounce (30 cc) of PAG
oil should be added for each component replaced.

If the A/C compressor is changed, no oil should be added

to the system, because the compressor comes factory
filled with oil.

NOTE: Only PAG oil should be used. Never mix R-12

and R-134a Oils.

6986740-EN (07-08) 80-60-1 Bobcat T2250

SERVICE MANUAL
GENERAL AIR CONDITIONING SERVICE GUIDELINES Figure 80-60-4
(CONT'D)

Compressor Oil Check (Cont'd)

Figure 80-60-2

1
1

P-27542

NOTE: After draining the oil through the drain hole and
the connectors, extract the remaining oil
P-27539
through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-60-
4] several times by hand.
Figure 80-60-3
Measure the drained oil in a measuring cylinder.

Check the oil for contamination, dirt, metal shavings, or

varnish color, discard the oil if contaminated.

NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.

1 Figure 80-60-5

1
1
1

P-27545

Remove the oil drain plug (Item 1) [Figure 80-60-2] and

drain the oil through the connectors and the oil drain hole
(Item 1) [Figure 80-60-3].

Installation: Tighten the oil drain plug to 9.4-10.8 ft.-lb.

(13-15 N•m) torque.

P-27543

Add new compressor oil through the suction side

connector (Item 1) [Figure 80-60-5].

Installation: Add 150-170 cc's of PAG oil.

NOTE: The suction port on the compressor is marked

with an S and is the large port on the
compressor.

6986740-EN (07-08) 80-60-2 Bobcat T2250

SERVICE MANUAL
GENERAL AIR CONDITIONING SERVICE GUIDELINES
(CONT'D)

Component Replacement And Refrigeration Leaks

Figure 80-60-6

S4971

Whenever the A/C system is opened to the atmosphere or

there has been a leak in the system, the receiver / drier
(Item 1) [Figure 80-60-6] must be changed.

Never leave hose fittings, compressor fittings or

components uncapped while working on the A/C system.

6986740-EN (07-08) 80-60-3 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 80-60-4 Bobcat T2250
SERVICE MANUAL
SYSTEM TROUBLESHOOTING CHART

Chart

Blower motor does not operate

POSSIBLE CAUSE INSPECTION SOLUTION

1. Blown Fuse. Inspect the fuse/wiring. Replace fuse/repair wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or connector.
connection.
3. Fan motor malfunc- Check the lead wires from the motor with a circuit tester. Replace Evaporator/Blower
tion. Unit.
4. Fan motor switch Check power into and out of the fan switch. Replace Fan Switch.
malfunction.

Blower motor operates normally, but air flow is insufficient

Possible Cause Inspection Solution

1. Evaporator inlet Check evaporator for plugging. Remove obstruction and clean
obstruction evaporator fins with air or
water.
2. Defective thermo. Check thermostat using a circuit tester. Replace Evaporator/Blower
switch (frozen unit.
evaporator).

Insufficient cooling although air flow and compressor operation are normal

POSSIBLE CAUSE INSPECTION SOLUTION

1. System low on The high side pressure will be low and bubbles may be Repair any leaks and recharge
refrigerant. present in sight glass on receive drier. the refrigerant to the correct
level.
2. Excessive The high pressure side pressure will be high. Use refrigerant recovery
refrigerant. equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.

The compressor does not operate at all, or operates improperly

POSSIBLE CAUSE INSPECTION SOLUTION

1. Loose drive belt. The belt is vibrating or oscillating. Adjust tension.
2. Internal compressor The compressor is locked up and the belt slips. Replace compressor.
malfunction.
Magnetic clutch related
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic clutch.
5. Oil on the clutch Clutch slips. Replace or clean the clutch
surface. surface.
6. Open coil. Clutch does not engage and there is not reading when a Replace clutch.
circuit tester is connected between the coil and terminals.
7. Broken wiring or Clutch will not engage. Inspect the ground and connections. Repair.
poor ground.
8. Wiring harness Test the conductance of the pressure switch, thermostat, Check operation.
components. Relay, etc.

6986740-EN (07-08) 80-70-1 Bobcat T2250

SERVICE MANUAL
SYSTEM TROUBLESHOOTING CHART (CONT'D)

Gauge Pressure Related Troubleshooting

Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86-96 degrees F
(30-38 degrees C) and compressor speed of approximately 2000 RPM are:

High pressure side pressure: 210-265 PSI

Low pressure side pressure: 15-33 PSI
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure.

POSSIBLE CAUSE INSPECTION SOLUTION

Low pressure side The low pressure side pressure normally becomes too high
Too high. when the high pressure side pressure is too high. As this is
explained below, the following inspection is only used when
the low pressure side is too high.
1. Expansion valve Frost is present on the suction hose. Replace expansion valve
opens too far.
2. Defective The high and low pressure side gauge pressures equalize Replace compressor.
compressor when the magnetic clutch is disengaged.
Low pressure side
Too low.
1. Low refrigerant The high side pressure will be low and bubbles may be Repair any leaks and recharge
charge present in sight glass on receiver drier. the refrigerant to the correct
level.
2. Clogged or closed The expansion valve's inlet side is frosted. Moisture or other Clean or replace the expansion
expansion valve. Contaminants can be the cause. Valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion Negative low pressure reading may be shown.
valve.
4. Thermostat The evaporator is frozen. Replace Evaporator/Blower unit.
malfunction.
High pressure side
Too high.
1. Poor condenser Dirty or clogged condenser fins. Condenser fans not Clean fins, and/or repair the fan.
performance. Operating.
2. Excessive The high pressure side pressure will be high. Use refrigerant recovery
refrigerant. equipment to capture excess
refrigerant. Charge to the correct
refrigerant level.
3. Excessive oil The high pressure side will be high. Evacuate system. Remove oil
charge from condenser and compressor.
Measure oil from compressor
and add correct oil charge back
into compressor. Flush system
with nitrogen. Replace drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
Refrigerant.
5. Restriction in High pressure side will be high, and low pressure side will be Evacuate and flush system
drier,condenser or low. replacing defective parts.
high pressure line.

6986740-EN (07-08) 80-70-2 Bobcat T2250

SERVICE MANUAL
SYSTEM TROUBLESHOOTING CHART (CONT'D)

Gauge Pressure Related Troubleshooting (Cont'd)

POSSIBLE CAUSE INSPECTION SOLUTION

High pressure side
too low
1. Low refrigerant The high side pressure will be low and bubbles may be Repair any leaks and recharge
charge present in sight glass on receiver drier. the refrigerant to the correct
level.
System pressures
Equal
1. Clutch not operating See magnetic clutch related topics above.
2. Compressor not Equal high and low pressures. Replace compressor.
pumping.

6986740-EN (07-08) 80-70-3 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 80-70-4 Bobcat T2250
SERVICE MANUAL
TEMPERATURE AND PRESSURE
NORMAL CONDENSER RANGE
Chart TEMP F. PSIG
93 110.20
NORMAL EVAPORATOR RANGE
94 112.10
TEMP F. PSIG
95 114.10
16 15.69 100 124.30
18 17.04 102 128.50
20 18.43 104 132.90
22 19.87 106 137.30
24 21.35 108 141.90
26 22.88 110 146.50
28 24.47 112 151.30
30 26.10 114 156.10
32 27.79 116 161.10
34 29.52 118 166.10
36 31.32 120 171.30
38 33.17 122 176.60
40 35.07 124 182.00
42 37.03 126 187.50
44 39.05 128 193.10
45 40.09 130 198.90
50 45.48 135 213.70
55 51.27 140 229.40
60 57.47 145 245.80
65 64.10 150 263.00
70 71.19 155 281.10
75 78.75 160 300.10
80 86.80 165 320.10
85 95.40 170 340.80
90 104.40
91 106.30
92 108.20

Evaporator

Pressures represent gas temperatures inside the coil, not the coil surface. For an estimate of the temperature of the air
coming off the coil add 8-10 degrees F. to the temperature on the chart.

Condenser

Temperatures are not ambient temperatures but condensing temperatures. Add 40 degrees F. to the ambient
temperature to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for
ambient temperature.

Conditions and pressures will vary from system to system.

6986740-EN (07-08) 80-80-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 80-80-2 Bobcat T2250
SERVICE MANUAL
AIR CONDITIONING SERVICE

Chart

Service Company/Phone Number:

Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:

Explain services required:

Post Service Conditions 15 Minutes 30 Minutes Notes

Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:

6986740-EN (07-08) 80-90-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 80-90-2 Bobcat T2250
SERVICE MANUAL
SYSTEM CHARGING AND RECLAMATION

Reclamation Procedure WARNING

Open the engine cover.
In the event of a leakage, wear safety goggles.
Figure 80-100-1 Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500

NOTE: This test is run with the engine OFF, and the A/
1 C switch in the OFF position.

Figure 80-100-3

S5863

Figure 80-100-2

1 N-23024

NOTE: Before reclaiming a refrigeration system, it is

recommended to identify the type of refrigerant that is
in the A/C system and if it is pure enough to use. The
tool MEL1592, Refrigerant Identifier (Item 1) [Figure
80-100-3], will determine the kind of refrigerant and
any possible harmful or dangerous substances that
may be present in the system. Thus preventing
S5864 mixing of dangerous material with your reclaimed R-
134a in your reclaimer, and further contamination to
other A/C systems that are reclaimed and charged
Locate the low pressure port (Item 1) [Figure 80-100-1] from your MEL 1581 Recovery/Recycling/Recharging
and high pressure port (Item 1) [Figure 80-100-2] of the Machine.
compressor.
Remove the protective cap and connect the refrigerant
identifier to the low pressure hose (Item 1) [Figure 80-
100-1].

Connect the refrigerant identifier to its power source.

6986740-EN (07-08) 80-100-1 Bobcat T2250

SERVICE MANUAL
SYSTEM CHARGING AND RECLAMATION (CONT'D)

Reclamation Procedure (Cont'd) WARNING

Figure 80-100-4
HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness if
it contacts the eyes and may cause serious frostbite if
it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air.
Any servicing work that involves release or addition
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration
equipment.
W-2373-0500
S3683

Figure 80-100-5
Follow the steps displayed on the refrigerant identifier
screen [Figure 80-100-4].

Allow two minutes for the refrigerant identifier to display

the type of refrigerant and air content. An alarm will sound
if potentially flammable hydrocarbons are present and will
also indicate on the visual display.

Disconnect the refrigerant identifier from the A/C.

If the refrigerant is dangerous or flammable, it must be

evacuated from the A/C system into a separate container
and properly and safety disposed of.

If R134a is found, evacuate the system.

N-22291

Use an approved recovery/charging unit [Figure 80-100-

WARNING 5] to evacuate the system.

Connect the reclaimer to the A/C charge ports.

In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500

6986740-EN (07-08) 80-100-2 Bobcat T2250

SERVICE MANUAL
SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-100-8

Reclamation Procedure (Cont'd)

Figure 80-100-6

N-22292
1

Turn the reclaimer unit [Figure 80-100-8] to the ON

S5883 position and follow the on screen instructions.

Figure 80-100-9
Connect the Red hose (Item 1) to the high pressure port
(Item 2) [Figure 80-100-6] and open the valve.

Figure 80-100-7

2
N-22381

NOTE: The reclaimer unit, has a complete step by step

S5864 set of instructions [Figure 80-100-9] to follow
for reclamation and recharging of the A/C
system. a trained technician should follow
Connect the Blue hose (Item 1) to the low pressure port these instructions as they may very slightly
(Item 2) [Figure 80-100-7] and open the valve. depending on the model and brand of
reclaimer used.

6986740-EN (07-08) 80-100-3 Bobcat T2250

SERVICE MANUAL
SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-100-11

Charging Procedure With A Manifold Gauge Set

Open the hood.

2

WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
1
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
S5883

Figure 80-100-10
Connect the Red hose (Item 1) to the high pressure port
(Item 2) [Figure 80-100-11] and open the valve.

Figure 80-100-12

1
1

2
P-52622

Check to see that the hand valves (Item 1) [Figure 80-

100-10] are closed on the manifold gauge set. S5864

If there is any refrigerant in the A/C system, it must be

recovered by an approved A/C reclamation procedure. Connect the Blue hose (Item 1) to the low pressure port
(See Reclamation Procedure on Page 80-100-1.) (Item 2) [Figure 80-100-12] and open the valve.

Connect the gauges to the A/C charge ports.

6986740-EN (07-08) 80-100-4 Bobcat T2250

SERVICE MANUAL
SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-100-15

Charging Procedure With A Manifold Gauge Set

(Cont'd)

Figure 80-100-13
1

S3678

Note vacuum pressure indicated on the low pressure

(Blue) gauge (Item 1) [Figure 80-100-15]. Let stand for 5-
S3679 10 minutes and recheck the pressure for changes.

If the pressure drops, this may be an indication of a leak in

Connect the Yellow hose (Item 1) [Figure 80-100-13] to the A/C system.
the vacuum pump.
Determine the problem with the A/C system and repair it.
Figure 80-100-14
Figure 80-100-16

S3680
1
P-27485

Start the vacuum pump and open ISO-valve (Item 1)

[Figure 80-100-14] on the vacuum pump. A thermistor vacuum gauge (Item 1) [Figure 80-100-16]
can be used to determine the critical vacuum level during
Run the vacuum pump for at least 5-10 minutes to insure evacuation. It is a solid state instrument that constantly
that a vacuum has been pulled on the system. monitors and visually indicates the vacuum level.
Close the ISO-valve (Item 1) [Figure 80-100-14] (which
The thermistor vacuum gauge is used with the vacuum
isolates the vacuum pump from the A/C system) and turn
pump [Figure 80-100-16].
OFF the vacuum pump.
Start the vacuum pump and open ISO-valve on the
vacuum pump.

Be sure that both hand valves, and both charge port

valves are open.

6986740-EN (07-08) 80-100-5 Bobcat T2250

SERVICE MANUAL
SYSTEM CHARGING AND RECLAMATION (CONT'D) 80-100-18] on the manifold gauge set. Allow the vacuum
to pull in the refrigerant until the pressure stabilizes.
Charging Procedure With A Manifold Gauge Set
(Cont’d) Figure 80-100-19

Run the vacuum pump for at least 45 minutes to insure

that all the moisture is boiled out of the system.

Stop the vacuum pump and close the ISO-valve on the

vacuum pump.

Close both hand valves on the manifold gauge set and

remove the yellow hose from the vacuum pump that goes
to the manifold gauge set.

Remove the vacuum pump and thermistor vacuum gauge. 1

Figure 80-100-17
S7836

Turn the A/C fan switch (Item 1) [Figure 80-100-19] to

HIGH position.

Start the machine and run at medium speed.

Watch the scale and run system until the predetermined

amount of refrigerant is added to the A/C system.

The A/C system holds 1.76 lbs (0,800 Kg) of refrigerant.

1
2
Turn off the valve on the refrigerant container, and hand
S3677 valves on the manifold gauge set.

Turn off the engine and remove the A/C charging

Place a refrigerant container with R134a (Item 1) on a equipment from the machine.
charging scale (Item 2) [Figure 80-100-17] and zero out
the scale. Close the engine cover.

Connect the yellow hose (Item 3) [Figure 80-100-17] from

the manifold gauge set to the valve on the refrigerant tank.

Figure 80-100-18

S3681

Open the valve on the refrigerant container (Item 1) and

open the low pressure hand valve (Blue) (Item 2) [Figure

6986740-EN (07-08) 80-100-6 Bobcat T2250

SERVICE MANUAL
COMPRESSOR Figure 80-110-3

Removal And Installation

Evacuate the A/C system. (See SYSTEM CHARGING

AND RECLAMATION on Page 80-100-1.) 1
Figure 80-110-1

2
1

1
P-52608

1
Unplug the connector (Item 1) [Figure 80-110-3] from the
compressor.
1
1 Mark the compressor hoses for correct installation.
S3672

Remove the six bolts (Item 1) and remove the exhaust

pipe (Item 2) [Figure 80-110-1] for easier access to the
WARNING
compressor.
In the event of a leakage, wear safety goggles.
Figure 80-110-2 Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
1 a toxic gas.
W-2371-0500
1
2

1
S6530

Remove the four bolts (Item 1) and the belt shield (Item 2)
[Figure 80-110-2] for easier access to the compressor.

Remove the compressor belt.

6986740-EN (07-08) 80-110-1 Bobcat T2250

SERVICE MANUAL
COMPRESSOR (CONT'D) Compressor Clutch Disassembly And Assembly

Removal And Installation (Cont’d) Figure 80-110-6

Figure 80-110-4

1
1
P-27519

P-52609
Remove the center armature nut (Item 1) [Figure 80-110-
6].
Remove the compressor hoses (Item 1) [Figure 80-110-
4]. Assembly: Tighten the armature nut to 8 ft.-lb. (12 N•m).

Installation: Tighten the hoses to 22 ft.-lb. (29,8 N•m) Figure 80-110-7

torque.

Cap and plug the hoses and fittings with the proper A/C
caps and plugs. 1

Figure 80-110-5

P-27520

To remove the armature plate (Item 1) [Figure 80-110-7]

from the clutch face you must make an armature plate
puller.
P-52610

Remove the mount bolts (Item 1) [Figure 80-110-5].

NOTE: One mount bolt is hidden in the picture.

Remove the compressor.

6986740-EN (07-08) 80-110-2 Bobcat T2250

SERVICE MANUAL
COMPRESSOR (CONT'D) Figure 80-110-10

Compressor Clutch Disassembly And Assembly

(Cont'd)

Figure 80-110-8

1.25” 1.25”

P-27521

Attach a slide hammer puller to the armature puller tool

1.25” [Figure 80-110-10].
P-27524
Figure 80-110-11

The armature plate puller (Item 1) [Figure 80-110-8] can

be constructed by drilling three 0.315 inch (8 mm) holes in
a flat circular plate, located 1.25 inches (31,75 mm) apart.

Figure 80-110-9

2 1

P-27523

2 Remove the armature plate (Item 1) [Figure 80-110-11]

from the compressor clutch.

P-27522 Remove the shims (Item 2) [Figure 80-110-11] from the

armature shaft or armature plate.

Attach the armature puller plate (Item 1) to the armature Assembly: Insure that the clutch has the correct
plate using the three bolts (Item 2) [Figure 80-110-9]. clearance by adding the shims (Item 2) [Figure 80-110-
11].

The specified clearance for the clutch is 0.01-0.02 in. (0.3-

0.6 mm) adjusting shims are available in the following
thicknesses.

0.0039 in. (0.1 mm)

0.0118 in. (0.3 mm)
0.0197 in. (0.5 mm)

6986740-EN (07-08) 80-110-3 Bobcat T2250

SERVICE MANUAL
COMPRESSOR (CONT'D) Figure 80-110-14

Compressor Clutch Disassembly And Assembly

(Cont'd)

Figure 80-110-12

P-27527

The pulley assembly and bearing [Figure 80-110-14]

must be replaced as a complete unit.
P-27525
Figure 80-110-15

Remove the snap ring (Item 1) [Figure 80-110-12] from

the pulley assembly.

Figure 80-110-13
1
2

P-27528

Remove the lock (Item 1) and connector (Item 2) [Figure

80-110-15] from the compressor harness.
P-27526

Remove the pulley from the compressor [Figure 80-110-

13].

6986740-EN (07-08) 80-110-4 Bobcat T2250

SERVICE MANUAL
COMPRESSOR (CONT'D) Figure 80-110-18

Compressor Clutch Disassembly And Assembly

(Cont'd)

Figure 80-110-16

P-27531

Remove the coil from the compressor [Figure 80-110-18].

P-27529 Figure 80-110-19

Remove the harness retainer screw assembly (Item 1)

[Figure 80-110-16].

Figure 80-110-17

P-27527

1
The compressor [Figure 80-110-19] must be replaced as
a complete unit.

P-27530

Remove the snap ring (Item 1) [Figure 80-110-17] from

the coil.

6986740-EN (07-08) 80-110-5 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 80-110-6 Bobcat T2250
SERVICE MANUAL
CONDENSER Figure 80-120-2

Removal And Installation

Remove the refrigerant from the A/C system. (See

SYSTEM CHARGING AND RECLAMATION on Page 80-
100-1.) 1

WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
S4976
a toxic gas.
W-2371-0500

Remove the A/C hose (Item 1) [Figure 80-120-2] from the

Figure 80-120-1 condenser.

Figure 80-120-3

1
1

1
S4977

S5891
Remove the hose (Item 1) [Figure 80-120-1] from the
condenser.
Remove the two bolts and nuts (Item 1) [Figure 80-120-3]
NOTE: Install caps and plugs on all fittings. from each side of the condenser.

Tilt the condenser forward and remove.

6986740-EN (07-08) 80-120-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 80-120-2 Bobcat T2250
SERVICE MANUAL
RECEIVER / DRIER Figure 80-130-2

Removal And Installation 1 1

Open the engine cover.

Remove the refrigerant from the A/C system. (See

SYSTEM CHARGING AND RECLAMATION on Page 80-
100-1.)

Remove the air cleaner. (See AIR CLEANER on Page 70-

40-1.)
2

WARNING S4979

In the event of a leakage, wear safety goggles. Remove the two hoses (Item 1) [Figure 80-130-2] from
Escaping refrigerant can cause severe injuries to the Receiver / Drier.
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas. NOTE: Mark the hoses for correct installation.
W-2371-0500

NOTE: Install caps and plugs on all fittings.

Figure 80-130-1
Loosen the bolt (Item 2) [Figure 80-130-2] on the
mounting bracket.
1

S4971

Unplug the connector (Item 1) [Figure 80-130-1] from the

pressure switch.

6986740-EN (07-08) 80-130-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 80-130-2 Bobcat T2250
SERVICE MANUAL
PRESSURE SWITCH Figure 80-140-2

Removal And Installation

Open the engine cover.

Remove the refrigerant from the A/C system. (See

SYSTEM CHARGING AND RECLAMATION on Page 80-
100-1.)
1

WARNING
In the event of a leakage, wear safety goggles.
S4980
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas. Remove the pressure switch (Item 1) [Figure 80-140-2]
W-2371-0500
from the Receiver / Drier assembly.

Figure 80-140-1

S4979

Unplug the connector (Item 1) from the pressure switch

(Item 2) [Figure 80-140-1].

6986740-EN (07-08) 80-140-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 80-140-2 Bobcat T2250
SERVICE MANUAL
EVAPORATOR/BLOWER UNIT Figure 80-150-3

Removal And Installation

2

WARNING
3
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to 1
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500

Figure 80-150-1 S5882

1 1 Remove the main wire harness connector (Item 1) from

the blower fan switch (Item 2) [Figure 80-150-3].

Remove the fuse box cover (Item 3) [Figure 80-150-3].

Figure 80-150-4
2

1
1
S7107

Remove the three screws (Item 1) and remove the cover

(Item 2) [Figure 80-150-1].

Figure 80-150-2

1 P-25243

Temporarily remove the covering (Item 1) [Figure 80-150-

4] from the A/C hoses and expansion valve.

1
S5881

Remove the knobs (Item 1) and raise the fuse box cover
(Item 2) [Figure 80-150-2] gently.

6986740-EN (07-08) 80-150-1 Bobcat T2250

SERVICE MANUAL
EVAPORATOR/BLOWER UNIT (CONT'D) Figure 80-150-7

Removal And Installation (Cont'd)

Figure 80-150-5

1
2 2
1

P-27598

Remove the three mount bolts (Item 1) and ground wire

P-25244 (Item 2) [Figure 80-150-7] from the back of the
evaporator unit.

Remove the bolt (Item 1) and plate (Item 2) [Figure 80- Figure 80-150-8
150-5]. Remove the two A/C hoses.

NOTE: Plug the A/C hoses to avoid contamination.

Figure 80-150-6

P-27599

1 Remove the front mounting bolt (Item 1) [Figure 80-150-

8].
P-27597
Lay the evaporator/blower unit on the seat.

Disconnect the thermostat wiring connector (Item 1)

[Figure 80-150-6].

6986740-EN (07-08) 80-150-2 Bobcat T2250

SERVICE MANUAL
EVAPORATOR/BLOWER UNIT (CONT'D)

Removal And Installation (Cont'd)

Figure 80-150-9

P-27600

Remove the drain hose (Item 1) [Figure 80-150-9].

Remove the evaporator/blower unit from the machine.

6986740-EN (07-08) 80-150-3 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) 80-150-4 Bobcat T2250
SERVICE MANUAL
EXPANSION VALVE Figure 80-160-3

Removal And Installation

2

WARNING
3
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to 1
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500

Figure 80-160-1 S5882

1 1 Remove the main wire harness connector (Item 1) from

the blower fan switch (Item 2) [Figure 80-160-3].

Remove the fuse box cover (Item 3) [Figure 80-160-3].

Figure 80-160-4
2

1
1
S7107

Remove the three screws (Item 1) and remove the cover

(Item 2) [Figure 80-160-1].

Figure 80-160-2

1 P-25243

Temporarily remove the covering (Item 1) [Figure 80-160-

4] from the A/C hoses and expansion valve.

1
S5881

Remove the knobs (Item 1) and raise the fuse box cover
(Item 2) [Figure 80-160-2] gently.

6986740-EN (07-08) 80-160-1 Bobcat T2250

SERVICE MANUAL
EXPANSION VALVE (CONT'D) Figure 80-160-7

Removal And Installation (Cont'd)

1
Figure 80-160-5

P-27666

The expansion valve (Item 1) [Figure 80-160-7] is

P-25244 replaced as a complete unit.

Remove the bolt (Item 1) and plate (Item 2) [Figure 80-

160-5]. Remove the two A/C hoses.

NOTE: Plug the A/C hoses to avoid contamination.

Figure 80-160-6

P-27667

Remove the two mount bolts (Item 1) [Figure 80-160-6].

Remove the expansion valve.

6986740-EN (07-08) 80-160-2 Bobcat T2250

SERVICE MANUAL
HEATER ASSEMBLY Figure 80-170-3

Removal And Installation

Remove the travel/signal levers. (See TRAVEL/SIGNAL

LEVER on Page 60-70-1.)

Remove the instrument panel. (See INSTRUMENT

PANEL on Page 60-80-1.)

Remove the switch panel. (See SWITCH PANEL on Page

60-90-1.)

Remove the dash cover/steering column cover. (See

DASH COVER/STEERING COLUMN COVER on Page
50-130-1.) S2962

Figure 80-170-1
Clamp the heater hoses [Figure 80-170-3].

Figure 80-170-4

1
1

S2960

Disconnect the harness connector (Item 1) [Figure 80- S2963

170-1].

Figure 80-170-2 Remove the heater hoses (Item 1) [Figure 80-170-4] from
the heater assembly.

NOTE: Mark the hoses for correct installation.

1
1

S2961

Remove the vent hoses (Item 1) [Figure 80-170-2] from

the top of the assembly.

6986740-EN (07-08) 80-170-1 Bobcat T2250

SERVICE MANUAL
HEATER ASSEMBLY (CONT'D) Figure 80-170-7

Removal And Installation (Cont'd)

Figure 80-170-5
1

1
1

P-25595

1 Remove the blower fan mounting bolts (Item 1) [Figure

S2964 80-170-7] and remove the blower fan.

Core Removal And Installation

Remove the mounting bolts (Item 1) [Figure 80-170-5]
and remove the heater assembly. Figure 80-170-8

Fan Removal And Installation

Figure 80-170-6

1
1

P-25602

Remove the two flange mounting nuts (Item 1) [Figure

P-25594 80-170-8].

Carefully remove the clip (Item 1) and cable (Item 2)

[Figure 80-170-6].

6986740-EN (07-08) 80-170-2 Bobcat T2250

SERVICE MANUAL
HEATER ASSEMBLY (CONT'D) Figure 80-170-11

Core Removal And Installation (Cont'd) 1

1
Figure 80-170-9

1
1
P-25601

Remove the four screws (Item 1) [Figure 80-170-11] from

P-25603 the vent bracket.

Figure 80-170-12
Remove the flange / linkage assembly (Item 1) [Figure
80-170-9] from assembly.

Figure 80-170-10

1
1

P-25605

Remove the end bracket (Item 1) and spacer (Item 2)

P-25604 [Figure 80-170-12] from the assembly.

Remove the two bolts (Item 1) [Figure 80-170-10] and

save for later use.

6986740-EN (07-08) 80-170-3 Bobcat T2250

SERVICE MANUAL
HEATER ASSEMBLY (CONT'D)

Core Removal And Installation (Cont'd)

Figure 80-170-13

P-25606

Be sure to separate the bracket (Item 1) and tab (Item 2)

[Figure 80-170-13].

Figure 80-170-14

P-25607

Slide the core from the housing [Figure 80-170-14].

6986740-EN (07-08) 80-170-4 Bobcat T2250

SERVICE MANUAL
 SPECIFICATIONS

CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-70-1
Decimal And Millimeter Equivalents . . . . . . . . . . . . . . . . . . SPEC-70-1
U.S. To Metric Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-70-2

ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1

Camshaft And Thrust Washer . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6
Connecting Rods And Bearings . . . . . . . . . . . . . . . . . . . . . SPEC-20-4
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4
Crankshaft Re-Grind Data. . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-5
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-7
Engine Torque Component . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-11
Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-9
Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-7
Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-7
Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Intake Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6
Oil Pump, Gear And Relief Valve . . . . . . . . . . . . . . . . . . . . SPEC-20-9
Pistons And Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Rocker Shaft, Rockers And Bushings . . . . . . . . . . . . . . . . . SPEC-20-3
Thrust Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6
Timing Case And Timing Gears . . . . . . . . . . . . . . . . . . . . . SPEC-20-8
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-9
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Water Pump And Thermostat . . . . . . . . . . . . . . . . . . . . . . SPEC-20-10

HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . SPEC-50-1

Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-2
O-ring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
O-ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-3
Port Seal Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-5
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1 SPECIFICATIONS
Tubelines And Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1

HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS . . . . . SPEC-60-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1

MACHINE TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . SPEC-30-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1

6986740-EN (07-08) SPEC-01 Bobcat T2250

SERVICE MANUAL
 SPECIFICATIONS (CONT’D)

TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . SPEC-40-1

Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-2
Torque for General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-1

TELESCOPIC HANDLER TELESCOPIC TOOL CARRIER (TTC)

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3

6986740-EN (07-08) SPEC-02 Bobcat T2250

SERVICE MANUAL
TELESCOPIC HANDLER TELESCOPIC TOOL CARRIER (TTC) SPECIFICATIONS

Each attachment and each Telescopic Handler TTC have different Load
Capacity Charts. For example: An 84 inch bucket used on a V518 will have
WARNING its own chart; that same 84 inch bucket when used on a V723 will have a
different chart. Be sure you use the correct chart for your attachment and
Telescopic Handler TTC combination. W-2493-0204

Dimensions are given for machine equipped with standard tires and may vary with other tire types.

• All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

• Where applicable, specifications conform to SAE, ASME or ISO standards and are subject to change without notice.

Machine Dimensions

S4916

A 3984 mm (156.8 in.)

B 3585 mm (141.1 in.)
C 2185 mm (86.0 in.)
D 1985 mm (78.1 in.)
F 430 mm (16.9 in.)
G 1553 mm (61.1 in.)
H 2300 mm (90.6 in.)
I 1485 mm (58.5 in.)
J 1840 mm (72.4 in.)
K 4280 mm (168.5 in.)
L 3170 mm (124.8 in.)
M 1500 mm (59.0 in.)
N 5230 mm (206 in.)
O 1067 mm (42 in.) (24" load center)

6986740-EN (07-08) SPEC-10-1 Bobcat T2250

SERVICE MANUAL
TELESCOPIC HANDLER TELESCOPIC TOOL CARRIER (TTC) SPECIFICATIONS (CONT’D)

Performance

Operating Weight 4830 kg (10,648 lbs.)

Maximum Rated Capacity *2177 kg (4800 lbs.)
*Rated Load Capacity can change depending on which approved attachment is used
• Where applicable, specifications conform to SAE, ASME or ISO standards and are subject to change without notice.

Engine

Make/Model KUBOTA V3300-DI Turbo

Fuel/Cooling Diesel/Liquid
Horsepower (DIN 6271) 75 HP (56 kW)
Number of Cylinders Four
Lubrication Pressure System W/Filter
Air Cleaner Dry replaceable cartridge with safety element

Controls

Steering Proportional hydraulic steering via a conventional steering wheel

Hydraulics Electro-hydraulic joystick
Auxiliary Hydraulics Electric Switches on Joystick
Parking Brake (switch applied) Electric valve with switch activates spring applied, pressure release multi disc brake.

Drive System

Main Drive Hydrostatic 4 wheel drive

Transmission Infinitely variable hydrostatic piston pump, driving 1 fully reversing hydrostatic motor
Final Drive Front Differential with reduction gear box, Rear Differential, Planetary Axles with Oil
Lubrication.

Travel Speed Low Range High Range

0 - 7 kph (4.3 mph) 0 - 25 kph (15.5 mph)

6986740-EN (07-08) SPEC-10-2 Bobcat T2250

SERVICE MANUAL
TELESCOPIC HANDLER TELESCOPIC TOOL CARRIER (TTC) SPECIFICATIONS (CONT’D)

Tires

Type
Standard Tires Mitas 14 x 17.5 - 4.25 bar (62 PSI)
Optional Tires —

Capacities

Quantity Type
Fuel Tank 91 L (24 gal.) Diesel #2 or #1
Hyd./Hydros. System 70 L (18.5 gal.) 6903117
Hydraulic Reservoir 29 L (7.7 gal.) 6903117
Eng. Cooling System 11 L (2.9 gal.) Antifreeze mixture (Ethylene Glycol)

Engine Oil Change w/Filter 13.2 L (3.5 gal.) See Oil Chart
Front Axle W/ Reduction 8.9 L (2.35 gal.) 6687120
Gear
Rear Axle 5.6 L (1.48 gal) 6687120

Hydraulic System

Hydraulic Pump Engine driven, 85 L/min (22.4 GPM)

Hydraulic Pressure 250 bar (3626 PSI)
Auxiliary Flow @ High idle 0-85 L/min (0-22.4 GPM)

Electrical System

Alternator 12-Volt - 90 amp - open - belt driven

Starter 12 V - gear reduction type - 2.7 kW
Battery 12 V - 105 Ah - 950 cold cranking A at -18°C

Instrument Panel

Full compliment of instrumentation for engine, hydraulic and machine functions.

6986740-EN (07-08) SPEC-10-3 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) SPEC-10-4 Bobcat T2250
SERVICE MANUAL
ENGINE SPECIFICATIONS

All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.

General

Number Of Cylinders 4
Cylinder Arrangement In-line
Cycle 4 Stroke
Direction Of Rotation Clockwise From The Front
Intake System Turbocharged
Combustion System Direct Injection
Nominal Bore 100 (3.937)
Stroke 105 (4.134)
Compression Ratio 17.25:1
Displacement 4 liters (243 C.l.)
Firing Order 1-3-4-2

Cylinder Head

Head Thickness 117,95 - 118,05 (4.643 - 4.647)

Head Thickness After Machining (Minimum) 117,20 (4.614)
Valve Seat Angle 30°
Leak Test Pressure 2 bar (29 PSI)

Valve Guides

Inside Diameter 8,250-8,350 (0.3248-0.3287)

Outside Diameter 13,034-13,047 (0.5131-0.5137)
Valve Guide Bore 13,000-13,027 (0.5118-0.5129)
Valve Guide Clearance In The Cylinder Head (Interference) 0,007-0,047 (0.0003-0.00019)
Overall Length:
Intake 128,92-129,37 (5.076-5.093)
Exhaust 128,92-129,37 (5.075-5.093)
Protrusion From Bottom 12,35-12,65 (0.486-0.498)

6986740-EN (07-08) SPEC-20-1 Bobcat T2250

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.

Exhaust Valves

Valve Stem Diameter 8,93-8,96 (0.3515-0.3528)

Valve Guide Clearance 0,040-0,84 (0.0016-0.0033)
Maximum 15 (0.006)
Valve Head Diameter 41,51-41,75 (1.634-1.644)
Valve Face Angle 30°
Overall Length 128,92-129,37 (5.075-5.093)
Seal Type Stem seal with integral seating washer
Valve Seat Angle 30°
Valve Clearance 0,45 (0.018)
Exhaust Depth (Production) 1,53-1,81 (0.060-0.071)
Exhaust Depth (Service) 2,06 (0.081)

Intake Valves

Valve Stem Diameter 8,95-8,98 (0.3525-0.3535)

Valve Guide Clearance 0,025-0,069 (0.0010-0.0027)
Maximum 0,13 (0.005)
Valve Head Diameter 46,20-46,45 (1.819-1.829)
Valve Face Angle 30°
Overall Length 128,92-129,37 (5.076-5.093)
Seal Type Stem seal with integral seating washer
Valve Seat Angle 30°
Valve Clearance 0,20 (0.008)
Intake Depth (Production) 1,58-1,84 (0.062-0.072)
Intake Depth (Service) 2,09 (0.082)

Valve Springs

Installed Height 34,5 (1.358)

Installed Height Pressure 229 N (51 lbs.)
Number Of Active Coils 3.8

6986740-EN (07-08) SPEC-20-2 Bobcat T2250

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.

Rocker Shaft, Rockers And Bushings

Shaft Outside Diameter 24,962-24,987 (0.9828-0.9837)

Clearance Between Rocker Arm Bushing and Shaft 0,26-0,89 (0.0010-0.0035)
Maximum 0,17 (0.007)

Pistons And Piston Rings

Type Fastram combustion bowl inserted top ring groove,

graphite skirt
Piston Pin Bore Diameter 39,703-39,709 (1.5631-1.5633)
Piston Projection Above the Block Deck 0,21-0,35 (0.008-0.0137)
Top Ring Groove Width Tapered
Second Ring Groove Width 2,54-2,56 (0.0999-0.1007)
Third Ring Groove Width 3,52-3,54 (0.1385-0.1393)
Top Ring Barrel Face, Molybdenum insert, Keystone
Second Ring Taper Face, Cast Iron, Internal Bottom Step
Oil Control Ring Two Piece Coil Spring Loaded, Chromium Face
Top Ring Width Tapered
Second Ring Width 2,48-2,49 (0.097-0.098)
Third Ring Width 3,47-3,49 (0.1366-0.1374)
Top Ring Side Clearance Wedge
Second Ring Side Clearance 0,05-0,09 (0.002-0.003)
Third Ring Side Clearance 0,03-0,07 (0.0011-0.0027)
Top Ring End Gap 0,30-0,55 (0.011-0.021)
Second Ring End Gap 0,70-0,95 (0.027-0.037)
Third Ring End Gap 0,30-0,55 (0.0118-0.0216)
Piston Pin Type Full Floating
Piston Pin Outside Diameter 39,694-39,700 (1.5628-1.5630)
Piston Boss Clearance 0,003-0,015 (0.0001-0.0006)
Bushing Type Steel Back, Lead Bronze Tin Bearing Material
Bushing Outside Diameter 43,66-43,84 (1.7190-1.7259)
Bushing Inside Diameter (Reamed) 39,723-39,738 (1.5638-1.5645)
Piston Pin Bushing Clearance 0,023-0,044 (0.0009-0.0017)

6986740-EN (07-08) SPEC-20-3 Bobcat T2250

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.

Connecting Rods And Bearings

Connecting Rod Type H Section, Wedge Shape Small End

Connecting Rod Cap Location Flat joint face with dowels
Crank Pin End Diameter 67,21-67,22 (2.6460-2.6465)
Piston Pin End 43,01-43,03 (1.693-1.694)
Length Between Centers 219,05-219,10 (8.624-8.626)
Bearing Type Steel Back, Lead Bronze Bearing Material with Lead Finish
Bearing Width 31,55-31,88 (1.240-1.255)
Bearing Thickness At The Center 1,835-1,842 (0.0723-0.0725)
Bearing Clearance 0,03-0,081 (0.0012-0.0032)
Bearing Undersize Available -0,25 (-0.010); -0,50 (-0.020); - 0,75 (-0.030)

Crankshaft

Main Journals 76,16-76,18 (2.998-2.999)

Maximum Wear And Out Of Round Of The Journals And 0,04 (0.0016)
Crank Pins
Width Of Center Journal 44,15-44,22 (1.738-1.741)
Width Of Other Journals 39,24-39,34 (1.545-1.549)
Crank Pin Diameters 63,47-63,49 (2.499-2.500)
Width Of Crank Pins 40,35-40,42 (1.589-1.591)
Crankshaft End Play 0,05-0,38 (0.0002-0.015)
Thrust Washer Thickness: Std. 2,26-2,31 (0.089-0.091)
Oversize 2,45-2,50 (0.096-0.098)
Main Bearing Oil Clearance 0,057-0,117 (0.0022-0.0046)

6986740-EN (07-08) SPEC-20-4 Bobcat T2250

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.

Crankshaft (Cont'd)

Undersize Journals And Crank Pins 0,25 (0.010); 0,50 (0.020); 0,75 (0.030)

With the crankshaft on V-blocks check the maximum run-out of the journals. They must not exceed these specifications
below and the difference in run-out between journals must not exceed 0.004 (0,10)

Journal #1 Mounting
Journal #2 0,08 (0.003)
Journal #3 0,15 (0.006)
Journal #4 0,08 (0.003)
Journal #5 Mounting

Crankshaft Re-Grind Data

The finished sizes for crankshaft journals which have been ground undersize are given in the table below:

ITEM 0,25 (0.010) 0,51 (0.020) 0,76 (0.030)

1 75,909-75,930 75,649-75,670 (75,399-75,420
(2.9884-2.9892) (2.9784-2.96792) (2.9684-2.9692)
2 63,220-63,240 62,962-62,982 62,708-62,728
(2.488-2.4896) (2.4788-2.4796) (2.4688-2.4696)
3 39,47 (1.554) maximum - -
4 37,44 (1.474) maximum - -
5 44,68 (1.759) maximum - -
6 40,55 (1.596) maximum - -
7 Do not machine this diameter - -
8 Do not machine this diameter - -
9 3,68-3,69 (0.1448-0.1452) - -

Crankshaft Heat Treatment: 60 Hour Nitride

NOTE: Crankshafts that have been nitrided for 60 hours can be machined 0.010 (0,25) without the need to
harden again. Check the crankshaft for cracks before and after machining. Demagnetize the crankshaft
after it has been checked for cracks. Remove any sharp corners from the oil holes. Surface finish and
fillet radii must be maintained.

6986740-EN (07-08) SPEC-20-5 Bobcat T2250

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.

Main Bearings

Type Steel Back, 20% Tin Aluminium

All Others 31,62-31,88 (1.244-1.255)
Bearing Thickness (center) 2,083-2,089 (0.0820-0.0823)
Bearing Clearance 0,057-0,117 (0.0022-0.0046)
Bearing Undersize Available -0,25 (-0.010); -0,50 (-0.020); -0,75 (-0.030)

Thrust Washers

Type Steel back, bearing material

Position Each Side Of Center Main Bearing
Standard 2,26-2,31 (0.089-0.091)
Oversize 2,45-2,50 (0.096-0.098)

Camshaft And Thrust Washer

Journal #1 Diameter 50,71-50,74 (1.997-1.998)

Journal #2 Diameter 50,46-50,48 (1.987-1.988)
Journal #3 Diameter 49,95-49,98 (1.967-1.968)
Cam Lift (Intake) 7,03-7,13 (0.2768-0.2807)
Cam Lift (Exhaust) 7,963-8,063 (0.3135-0.3174)
Maximum Wear And Out Of Round 0,05 (0.02)
Camshaft End Play (Production) 0,10-0,55 (0.004-0.022)
Service Limits 0,60 (0.023)
Thrust Washer Type 360°
Thrust Washer Thickness 5,49-5,54 (0.216-0.218)
Thrust Washer Recess Depth 5,54-5,64 (0.218-0.222)

Cylinder Block

Cylinder Bore Diameter 105,000-105,025 (4.1338-4.1348)

Main Bearing Bore Diameter 80,416-80,442 (3.166-3.167)

6986740-EN (07-08) SPEC-20-6 Bobcat T2250

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.

Cylinder Liners

Production Dry, Interference Fit, Flanged, With Flame Ring

Service Dry, Interference Fit, Flanged, With Flame Ring
Production Liner Outside Diameter 104,25-104,28 (4.105-4.106)
Production Liner Clearance 0,03-0,08 (0.001-0.003)
Production Liner Inside Diameter 100,00-100,03 (3.937-3.938)
Service Liner Clearance ±0,03 (±0.001)
Inside Diameter Of Service Liner With Flame Ring 100,0-100,63 (3.937-3.961)
(Installed)
Maximum 0,25 (0.010)
Flange Thickness 3,81-3,86 (0.150-0.152)
Liner Projection From Deck Surface 0,10 (0.004) Above or 0,10 (0.004) Below
Hose Angle 30/35°
Piston Cooling Jets 9 N•m (7 ft.lbs.)

Fuel Injection Pump

Type DELPHI DP 210 with locking screw

Rotation From Drive End Clockwise
Fuel System Self Vent

Fuel Injectors

Working Pressure 294 bar (4263 PSI)

Fuel Lift Pump

Type Electrically operated

Method of Drive Electric Motor 12V/24V
Standard Pressure 0,41-0,69 bar (6-10 PSI)
Minimum Pressure 0,26 bar (3.75 PSI)

6986740-EN (07-08) SPEC-20-7 Bobcat T2250

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.

Timing Case And Timing Gears

Camshaft Gear Number Of Teeth 68

Camshaft Gear Bore Diameter 34,93-34,95 (1.375-1.376)
Camshaft Hub Outside Diameter 34,90-34,92 (1.374-1.375)
Fuel Pump Gear Number Of Teeth (Electronic) 68
Fuel Pump Gear Bore (Electronic) 29,99-30,02 (1.417-1.419)
Crankshaft Gear Number Of Teeth 34
Crankshaft Gear Bore Diameter 47,625-47,650 (1.875-1.8760)
Crankshaft Gear Hub Diameter 47,625-47,645 (1.875-1.8758)
Crankshaft Gear Clearance -0,020 - +0,020 (-0.0008 - +0.0008)
Idler Gear Number Of Teeth 73
Idler Gear Bore Diameter 57,14-57,18 (2.250-2.251)
(With Needle Bearings) 72,35-72,36 (2.848-2.849)
Width Of Idler Gear And Bushing Assembly (Fitted) 30,14-30,16 (1.186-1.187)
Flanged Bushing Inside Assembly (Fitted) 50,78-50,80 (1.999-2.000)
Idler Gear Hub Outside Diameter 50,70-50,74 (1.9990-1.9999)
(With Needle Bearings) 49,975-49,988 (1.967-1.968)
Idler Gear Hub Bushing Clearance 0,04-0,10 (0.0016-0.0039)
Gear End Play (Production Limits) 0,10-0,20 (0.004-0.008)
(With Needle Bearings) 0,10-0,75 (0.0039-0.0295)
Service Limit 0,38 (0.015)
Backlash For All Gears 0,08 (0.003) Minimum

6986740-EN (07-08) SPEC-20-8 Bobcat T2250

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.

Oil Pump, Gear And Relief Valve

Type of Oil Pump Gear Driven, Differential Rotor

Number Of Lobes Inner 5, Outer 6
Clearance Of Outer Rotor To Body 0,15-0,34 (0.006-0.013)
End Play
Inner Rotor 0,04-0,09 (0.001-0.004)
Outer Rotor 0,025-0,076 (0.0010-0.0029)
Oil Pump Idler Gear Bushing I.D. 16,012-16,038 (0.6303-0.6314)
Idler Shaft O.D. 15,966-15,984 (0.6285-0.5292)
Idler Gear Shaft Bushing Clearance 0,028-0,072 (0.0011-0.0028)
Oil Pump Idler Gear End Play 0,050-0,275 (0.0019-0.0108)
Relief Valve Plunger Bore Diameter 19,250-19,300 (0.7578-0.7598)
Relief Valve Plunger Outside Diameter 19,186-19,211 (0.7553-0.7563)
Clearance 0,039-0,114 (0.0015-0.0044)
Length Of The Spring (Installed) 59,8 (2.35)
Load On The Spring (Installed) 0,25 -0,36 bar (3.6-5.2 PSI)
Pressure To Open Pressure Relief Valve 4,14-4,69 bar (60-68 PSI)
Oil Filter Type Full Flow Screw-on Type Canister
Pressure To Open By-pass Valve In Oil Filter 0,55-0,83 bar (8-12 PSI)

Turbocharger

Type Garrett GT25

Flywheel

Run-Out Less than 0,30 (0.012)

Misalignment 0,03 (0.001) @ 25 (1.0)

6986740-EN (07-08) SPEC-20-9 Bobcat T2250

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

All dimensions are given in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.

Water Pump And Thermostat

Type Centrifugal, Gear Drive

Shaft Outside Diameter 21,425-21,438 (0.8435-0.8440)
Drive Gear Bore Diameter 21,375-21,400 (0.8415-0.8425)
Drive Gear Shaft Clearance 0,025-0,063 (0.0009-0.0024)
Impeller Bore Diameter 11,943-11,971 (0.4701-0.4712)
Impeller Shaft Outside Diameter 11,997-12,008 (0.4723-0.4727)
Impeller Clearance On Shaft 0,026-0,065 (0.0010-0.0025)
Bearing Bore Diameter 39,989-40,014 (1.5743-1.5753)
Bearing Diameter 39,989-40,000 (1.5743-1.5747)
Bearing Clearance In Pump Body +0,025/-0,011 (+0.0009/-0.0005)
Thermostat Type Wax Pellet, By-pass Blanking

NOMINAL TEMPERATURE
STAMPED ON START TO OPEN FULLY OPEN MINIMUM VALVE LIFT,
THERMOSTAT BY-PASS TEMPERATURE TEMPERATURE FULLY OPEN
VALVE
82° C (180° F) 77°/85° C (170°/185° F) 92°/98° C (198°/208° F) 9,0 (0.35)

6986740-EN (07-08) SPEC-20-10 Bobcat T2250

SERVICE MANUAL
ENGINE SPECIFICATIONS (CONT'D)

Engine Torque Component

COMPONENT FT.-LB. N•M

Bridge Piece To Block 12 16
Camshaft Gear Bolt 70 95
Connecting Rod Nuts
Step 1 13 18
Final 52 70
Crank Pulley Bolts 85 115
Cylinder Head Bolt
Step One 37 50
Step Two 74 100
Step Three 225°
Step Three - Long Bolts 270°
Engine Mounting Bridge To Frame 200 271
Exhaust Manifold Bolts 24 33
Flywheel Cover To Housing 45 61
Flywheel Housing To Cylinder Block 52 70
Flywheel To Crankshaft Bolts 77 105
Fuel Injector Nut 22 30
Fuel Injection Pump Gear Nut 18 24
Fuel Injection Pump Flange Nuts 18 24
Fuel Lift Pump Bolts 16 22
High Pressure Fuel Lines Fittings 22 30
Idler Gear Hub Bolts 33 44
Main Bearing Bolts
Step 1 65 88
Step 2 125 170
Step 3 185 250
Oil Pan Bolts 16 22
Oil Pan Plug 25 34
Oil Pump Cover 16 22
Oil Pump To Front Main Cap 16 22
Oil Transfer Plate Bolts 22 30
Piston Cooling Jets 7 9
Rear Oil Seal Housing Bolts 16 22
Rocker Cover Nuts (With Shim Washer) 7 9
Rocker Shaft Bracket Nuts 20 27
Timing Case To Block 16 22
Timing Case Cover To Timing Case Bolts 16 22
Turbocharger To Manifold Nuts 33 44
Water Pump To Timing Case Bolts & Nuts 16 22

6986740-EN (07-08) SPEC-20-11 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) SPEC-20-12 Bobcat T2250
SERVICE MANUAL
MACHINE TORQUE SPECIFICATIONS

Specifications

AXLE

FT.-LB. N•M
Axle To Frame Mounting Bolts 275-300 370-410
Brake Housing Hex Bolt 59 80
Brake Housing Spring Bolts 7 10
Brake Housing Stud 88 120
Differential Lock Retainer Bolt 10 13
Fender Mount Bolt 90-100 125-140
Housing Bolt 236 320
Housing Nut 140 190
King Pin Mount Bolts 140 190
Pinion Ring Gear Bolts 10 13
Planetary Cover Bolts 18 25
Planetary Gear Mount Bolts 88 120
Steering Cylinder Bolts 88 120
Tie Rod Jam Nut 185 250
Tie Rod Nut 160 220
Tie Rod Swivel End 300 406
Turn Stop Adjust Jam Nut 110 150
Wheel Nuts 221 300

BOOM

ft.-lb. NM
Extension Cylinder Base End 133 180
Extension Cylinder Rod End 188-210 255-285
Wear Pads Front 43 58
Wear Pads Rear 29 39

DRIVE BOX

ft.-lb. NM
Cover Bolts 44 60
Inner Housing Bolts 88 120
Mounting Flange Bolts 44 60

DRIVE MOTOR

ft.-lb. NM
End Cap Bolts 85 115
Mounting Bolts 155 210
Mounting Plate Bolts 46 63

6986740-EN (07-08) SPEC-30-1 Bobcat T2250

SERVICE MANUAL
MACHINE TORQUE SPECIFICATIONS (CONT’D)

Specifications (Cont’d)

ENGINE

ft.-lb. NM
A/C Compressor Mount Bolts 88 120
Alternator Mount Bolts 45 54
Starter Mount Bolts 45 54

HYDRAULIC PUMP

FT.-LB. N•M
Filter Head 90 122
Flange Adapter 90 122
Guide Post Bolts 17 23
Mounting Bolts 78 106
Retaining Plate 10 13
Servo End Cap 10 13
Side Cover Bolts 24 32

6986740-EN (07-08) SPEC-30-2 Bobcat T2250

SERVICE MANUAL
TORQUE SPECIFICATIONS FOR BOLTS

Torque for General SAE Bolts

The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Melroe that have zinc phosphate coating are specified by the letter H following the part number.

THREAD SIZE SAE GRADE 5 SAE GRADE 8

INCH. LBS.(N•m) .250 80-90 (9,0-10,2) 110-120 (12,4-13,6)
.3125 180-200 (20,3-22,6) 215-240 (24,2-27,1)
FOOT LBS.(N•m) .375 25-28 (34-38) 35-40 (47-54)
.4375 40-45 (54-61) 60-65 (81-88)
.500 65-70 (88-95) 90-100 (122-136)
.5625 90-100 (122-136) 125-140 (170-190)
.625 125-140 (170-190) 175-190 (240-260)
.750 220-245 (300-330) 300-330 (410-450)
.875 330-360 (450-490) 475-525 (645-710)
1.000 475-525 (645-710) 725-800 (985-1085)
1.125 650-720 (880-975) 1050-1175 (1425-1600)
1.250 900-1000 (1200-1360) 1475-1625 (2000-2200)
1.375 1200-1350 (1630-1830) 2000-2200 (2720-2980)
1.500 1500-1650 (2040-2240) 2600-2850 (3530-3870)
1.625 2000-2800 (2720-2980) 3450-3800 (4680-5150)
1.750 2500-2750 (3390-3730) 4300-4800 (5830-6500)
1.875 3150-3500 (4270-4750) 5500-6100 (5830-6500)
2.000 3800-4200 (5150-5700) 6500-7200 (8800-9800)

6986740-EN (07-08) SPEC-40-1 Bobcat T2250

SERVICE MANUAL
TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)

Torque For General Metric Bolts

THREAD SIZE MATERIAL

(DIA. X PITCH) HEAD MARK 4 HEAD MARK 7 HEAD MARK 10
M 5 x 0.8 4-5 N•m (3-4 ft.-lb.)
M 6 x 1.0 8-9 N•m (6-7 ft.-lb.) 8-12 N•m (6-9 ft.-lb.)
M 8 x 1.25 8-12 N•m (6-9 ft.-lb.) 15-22 N•m (11-16 24-34 N•m (18-25
ft.-lb.) ft.-lb.)
M 10 x 1.25 18-24 N•m (13-18 30-41 N•m (22-30 49-68 N•m (36-50
ft.-lb.) ft.-lb.) ft.-lb.)
M 12 x 1.25 30-41 N•m (22-30 54-73 N•m (40-54 94-118 N•m (69-87
ft.-lb.) ft.-lb.) ft.-lb.)
M 14 x 1.5 49-68 N•m (36-50 79-108 N•m (58-80 157-186 N•m (116-
ft.-lb.) ft.-lb.) 137 ft.-lb.)

6986740-EN (07-08) SPEC-40-2 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONNECTION SPECIFICATIONS Straight Thread O-ring Fitting

O-ring Face Seal Connection Figure Spec-50-2

IMPORTANT Nut Nut

When repairing hydrostatic and hydraulic systems, Washer

clean the work area before disassembly and keep all Washer
O-ring
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly O-ring
damage the system.
I-2003-0888

Figure Spec-50-1
A-1852

Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until
the washer is tight against the surface [Figure Spec-50-
2].

Tubelines And Hoses

Replace any tubelines that are bent or flattened. They will

restrict flow, which will slow hydraulic action and cause
heat.

Replace hoses which show signs of wear, damage or

B-07575
weather cracked rubber.

When the fitting is tightened, you can feel when the fitting Always use two wrenches when loosening and tightening
is tight to eliminate leakage caused by under or over hose or tubeline fittings.
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
Spec-50-1].

6986740-EN (07-08) SPEC-50-1 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONNECTION SPECIFICATIONS Use the following procedure to tighten the flare fitting:
(CONT'D)
Tighten the nut until it makes contact with the seat. Make
Flare Fitting a mark across the flats of both the male and female parts
of the connection (Item 1) [Figure Spec-50-3].
Figure Spec-50-3
Use the chart below to find the correct tightness needed
(Item 2) [Figure Spec-50-3]. If the fitting leaks after
tightening, disconnect it and inspect the seat area for
damage.
1

TS-1619

FLARE FITTING TIGHTENING TORQUE

TUBELINE NEW ROTATE RE-ASSEMBLY

TORQUE FT.-LB.
WRENCH SIZE OUTSIDE THREAD SIZE NO. OF HEX ROTATE NO. OF
(N•M)
DIAMETER FLATS HEX FLATS
5/8" 5/16" 1/2" - 20 17 (23) 2-1/2 1
11/16" 3/8" 9/16" - 18 22 (30) 2 1
7/8" 1/2" 3/4" - 16 40 (54) 2 1
1" 5/8" 7/8" - 14 60 (81) 1-1/2 1
1-1/4" 3/4" 1-1/16" - 12 84 (114) 1 3/4
1-3/8" 1" 1-5/16" - 12 118 (160) 3/4 3/4

6986740-EN (07-08) SPEC-50-2 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONNECTION SPECIFICATIONS Use the following procedure to tighten the O-ring flare
(CONT'D) fitting.

O-ring Flare Fitting Figure Spec-50-5

Figure Spec-50-4 Hex Flat Tightening Method

Primary O-ring Flare

Seal
1

Secondary
TS-1619
Seal
P-13009
Tighten the nut until it contacts with the seat. Make a mark
across the flats of both the male and female parts of the
The flare is the primary seal, the O-ring is the secondary
connection (Item 1) [Figure Spec-50-5].
seal and helps absorb vibration and pressure pulses at
the connection [Figure Spec-50-4].
Use the chart below to find the correct tightness needed
(Item 2) [Figure Spec-50-5]. If the fitting leaks after
If necessary, the O-ring-flare fitting can be used without
tightening, disconnect it and inspect the seat area for
an O-ring.
damage.

FLARE FITTING TIGHTENING TORQUE

** ***
TUBELINE *
NEW ROTATE RE-ASSEMBLY
WRENCH SIZE OUTSIDE THREAD SIZE TORQUE FT.-LB.
NO. OF HEX ROTATE NO. OF
DIAMETER (N•M)
FLATS HEX FLATS
5/8" 5/16" 1/2" - 20 17 (23) 2-1/2 1
11/16" 3/8" 9/16" - 18 22 (30) 2 1
7/8" 1/2" 3/4" - 16 40 (54) 2 1
1" 5/8" 7/8" - 14 60 (81) 1-1/2 1
1-1/4" 3/4" 1-1/16" - 12 84 (114) 1 3/4
1-3/8" 1" 1-5/16" - 12 118 (160) 3/4 3/4

* If a torque wrench is used to tighten a new fitting to a used hose/tubeline.

* If a torque wrench is used to tighten a used fitting to a new hose/tubeline.
* If a torque wrench is used to tighten a new fitting to a new hose/tubeline.
** If using the hex flat tightening method to tighten a new fitting to a new hose/tubeline.
** If using the hex flat tightening method to tighten a new fitting to a used hose/tubeline.
*** If using the hex flat tightening method to tighten a used fitting to a new hose/tubeline.

6986740-EN (07-08) SPEC-50-3 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONNECTION SPECIFICATIONS Figure Spec-50-7
(CONT'D)

O-ring Flare Fitting (Cont'd)

2
Figure Spec-50-6

Copper Bonnet Orifice

1
1 P-13573

Always remove the O-ring (Item 1) [Figure Spec-50-7]

from the flare face as shown.
P-13572
An O-ring (Item 2) [Figure Spec-50-7] is added to the flat
boss of the fitting to seal the connection in this application.
NOTE: O-ring flare fittings are not recommended in all
applications. Use the standard flare fittings in
these applications.

Do not use a O-ring flare fitting when a copper bonnet

orifice is used. When tightened the connection at the
bonnet may distort the flare face and prevent it from
sealing.

Use a standard flare fitting (Item 1) [Figure Spec-50-6] as

shown.

When a O-ring flare fitting is used as a straight thread port

adapter the O-ring flare face is not used to seal. The O-
ring may come off the fitting and enter the system.

6986740-EN (07-08) SPEC-50-4 Bobcat T2250

SERVICE MANUAL
HYDRAULIC CONNECTION SPECIFICATIONS NOTE: If a torque wrench cannot be used, use the hex
(CONT'D) flat tightening method as an approximate
guideline.
Port Seal Fitting
NOTE: Port seal fittings are not recommended in all
Figure Spec-50-8 applications. Use O-ring boss fittings in these
applications.

Figure Spec-50-9

1
Nut Seals
to Fitting

P-13571

Nut Seals
to Port Do not use port seal fittings when a thread in orifice (Item
1) [Figure Spec-50-9] is used in the port. The orifice may
interfere with the fitting and prevent it from sealing.

Use an O-ring boss fitting (Item 1) [Figure Spec-50-9] as

Secondary O-ring Seal shown.

PORT SEAL AND O-RING BOSS TIGHTENING

TORQUE
P-13008

FITTING NUT TORQUE

THREAD SIZE
The nut is the primary seal, the O-ring is the secondary WRENCH SIZE FT.LBS. (N•M)
seal and helps absorb vibration and pressure pulses at 11/16" 9/16" - 18 22 (30)
the connection [Figure Spec-50-8].
15/16" 3/4" - 16 40 (54)
The hex portion of the nut does not contact the surface of 1 - 1/8" 7/8" - 14 60 (81)
the component when the nut is tight. 1 - 1/4" 1 - 1/16" - 12 84 (114)
Use the following procedure to tighten the port seal fitting: 1 - 1/2" 1 - 5/16" - 12 118 (160)

Port seal and nut, washer and O-ring (O-ring Boss) fittings
use the same tightening torque valve chart.

If a torque wrench cannot be used, use the following

method.

Tighten the nut until it just makes metal to metal contact,

you can feel the resistance.

Tighten the nut with a wrench no more than one hex flat
maximum.

Do not over tighten the port seal fitting.

6986740-EN (07-08) SPEC-50-5 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) SPEC-50-6 Bobcat T2250
SERVICE MANUAL
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS When temperatures below zero degree F (-18°C) are
common, the machine must be kept in a warm building.
Specifications Extra warm-up time must be used each time the machine
is started during cold temperature conditions. Cold fluid
Use Bobcat axle fluid (P/N 100032-06A), for the drive box, will not flow easily and it makes action on the hydraulic
planetarys and axle housing. function slower. Loss of fluid flow to the hydrostatic pump
can cause hydraulic/hydrostatic system damage in less
Use Bobcat hydraulic/hydrostatic transmission fluid (P/N than 60 seconds.
6903117). If this fluid is not available, use 10W-30 or 10W-
40 SAE Motor Oil (5W-30 for 0°F [-18°C] and Below).

DO NOT use automatic transmission fluids in the

Telescopic Handler or permanent damage to the
WARNING
transmission will result.
During cold weather (32°F [0°C] and below), do not
operate machine until the engine has run for at least
five minutes at less than half throttle. This warm-up
WARNING period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or When temperatures are below -20°F (-30°C), the
death. Fluid leaks under pressure may not be visible. hydrostatic oil must be heated or kept warm. The
Use a piece of cardboard or wood to find leaks. Do hydrostatic system will not get enough oil at low
not use your bare hand. Wear safety goggles. If fluid temperatures. Park the machine in an area where the
enters skin or eyes, get immediate medical attention temperature will be above 0°F (-18°C) if possible.
from a physician familiar with this injury. W-2027-1285
W-2072-0496

6986740-EN (07-08) SPEC-60-1 Bobcat T2250

SERVICE MANUAL
6986740-EN (07-08) SPEC-60-2 Bobcat T2250
SERVICE MANUAL
CONVERSIONS

Decimal And Millimeter Equivalents

FRACTIONS DECIMALS MM FRACTIONS DECIMALS MM

1/64 0.015625 0.397 33/64 0.515625 13.097
1/32 0.03125 0.794 17/32 0.53125 13.494
3/64 0.046875 1.191 35/64 0.546875 13.891
1/16 0.0625 1.588 9/16 0.5625 14.288
5/64 0.078125 1.984 37/64 0.578125 14.684
3/32 0.09375 2.381 19/32 0.59375 15.081
7/64 0.109375 2.778 39/64 0.609375 15.478
1/8 0.1250 3.175 5/8 0.6250 15.875
9/64 0.140625 3.572 41/64 0.640625 16.272
5/32 0.15625 3.969 21/32 0.65625 16.669
11/64 0.171875 4.366 43/64 0.671875 17.066
3/16 0.1876 4.762 11/16 0.6875 17.462
13/64 0.203125 5.159 45/64 0.703125 17.859
7/32 0.21875 5.556 23/32 0.71875 18.256
15/64 0.234375 5.953 47/64 0.734375 18.653
1/4 0.2500 6.350 3/4 0.7500 19.050
17/64 0.265625 6.747 49/64 0.765625 19.447
9/32 0.28125 7.144 25/32 0.78125 19.844
19/64 0.296875 7.541 51/64 0.796875 20.241
5/16 0.3125 7.938 13/16 0.8125 20.638
21/64 0.328125 8.334 53/64 0.828125 21.034
11/32 0.34375 8.731 27/32 0.84375 21.431
23/64 0.359375 9.128 55/64 0.859375 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.390625 9.922 57/64 0.890625 22.622
13/32 0.40625 10.319 29/32 0.90625 23.019
27/64 0.421875 10.716 59/64 0.921875 23.416
7/16 0.4375 11.112 15/16 0.9375 23.812
29/64 0.453125 11.509 61/64 0.953125 24.209
15/32 0.46875 11.906 31/32 0.96875 24.606
31/64 0.484375 12.303 63/64 0.984375 25.003
1/2 0.5000 12.700 1 1.000 25.400
1 mm = 0.001" =
0.03937" 0.0254 mm

6986740-EN (07-08) SPEC-70-1 Bobcat T2250

SERVICE MANUAL
CONVERSION (CONT’D)

U.S. To Metric Conversion

TO CONVERT INTO MULTIPLY BY

LINEAR MEASUREMENT Miles Kilometers 1.609
Yards Meters 0.9144
Feet Meters 0.3048
Feet Centimeters 30.48
Inches Meters 0.0254
Inches Centimeters 2.54
Inches Millimeters 25.4
AREA Square Miles Square Kilometers 2.59
Square Feet Square Meters 0.0929
Square Inches Square Centimeters 6.452
Acre Hectare 0.4047
VOLUME Cubic Yards Cubic Meters 0.7646
Cubic Feet Cubic Meters 0.02832
Cubic Inches Cubic Centimeters 16.39
WEIGHT Tons (Short) Metric Tons 0.9078
Pounds Kilograms 0.4536
Ounces (Avdp.) Grams 28.3495
PRESSURE Bar Pounds/Square Inch 14,5
WORK Foot-Pounds Newton-Metre 1.356
LIQUID VOLUME Quarts Liters 0.9463
Gallons Liters 3.785
LIQUID FLOW Gallons/Minute Liters/Minute 3.785
TEMPERATURE Fahrenheit Celsius 1.Subtract 32°
2. Multiply by 5/9

6986740-EN (07-08) SPEC-70-2 Bobcat T2250

SERVICE MANUAL