A Bobcat S250 skid-steer is a mid-size loader you'll see loading trucks, running forks, or feeding a mixer all day on a small site or farm. The service manual is what I grab when I'm in a tight driveway with my truck stock and I need the right teardown order, test procedure, or spec to finish the job without a parts run. People use this manual when they're chasing hydraulic issues, electrical gremlins, or doing real engine and drive work on an out-of-warranty S250.
What this manual helps you do
- Diagnose hydraulic problems, then check pressures and flow on the S250's hydraulic and hydrostatic systems in the right sequence
- Trace and repair wiring faults using proper diagrams for this exact serial range, so you're not guessing at connectors and colors
- Follow step-by-step removal and install procedures for components like drive motors, pumps, cylinders, and Bob-Tach parts
- Rebuild and adjust major assemblies such as the chaincase, axles, and control linkages so they go back together correctly
- Set and verify adjustments after repairs, like control response, safety interlocks, and system checks, before you put it back to work
Who this is for
This manual is for anyone working on a Bobcat S250 loader in the 520811001-520899999 serial range: small contractors, owner-operators, shop mechanics, rental fleets, and field techs. If you just need basic operating tips, daily checks, or safety info, you want the operator's handbook instead.
FAQ
Q: Is this a searchable PDF with readable wiring diagrams?
A: These manuals are usually supplied as searchable PDFs, and the wiring diagrams are designed to be zoomed on a laptop or tablet so you can read pin labels.
Q: Will it cover my exact S250?
A: It's written for S250 loaders in the 520811001-520899999 serial number range. If your plate falls in that window, this is the right one.
Q: Is this the right document for repairs, not just maintenance?
A: Yes, this is the workshop-level service manual, the one you use for diagnostics, teardown, and reassembly, not just fluid changes.
Bottom line, if your S250's serial tag lands between 520811001 and 520899999 and you're planning to wrench on it yourself, this is the manual you want.
📘 Show Index
Table of Contents:
- MAINTENANCE SAFETY
- ALPHABETICAL INDEX
- CONTENTS
- FOREWORD
- SAFETY INSTRUCTIONS
- FIRE PREVENTION
- Maintenance
- Operation
- Electrical
- Hydraulic System
- Fueling
- Starting
- Spark Arrestor Exhaust System
- Welding And Grinding
- Fire Extinguishers
- SERIAL NUMBER LOCATION
- Loader Serial Number
- Engine Serial Number
- DELIVERY REPORT
- BOBCAT LOADER IDENTIFICATION
- SAFETY AND MAINTENANCE
- LIFTING AND BLOCKING THE LOADER
- LIFT ARM SUPPORT DEVICE
- Installing The Lift Arm Support Device
- Removing The Lift Arm Support Device
- OPERATOR CAB
- Description
- Raising The Operator Cab
- Lowering The Operator Cab
- Emergency Exit
- TRANSPORTING THE BOBCAT LOADER
- TOWING THE LOADER
- Procedure For Non-Two-Speeds
- REMOTE START
- Procedure For Loader W/O Attachments Control Harness
- Procedure For Loader With Attachments Control Harness
- Procedure
- SERVICE SCHEDULE
- AIR CLEANER SERVICE
- ENGINE COOLING SYSTEM
- FUEL SYSTEM
- Fuel Specifications
- Filling The Fuel Tank
- Fuel Filter
- Removing Air From The Fuel System
- Fuel Lift Pump Strainer
- ENGINE LUBRICATION SYSTEM
- Checking Engine Oil
- Oil Chart
- Replacing Oil And Filter
- HYDRAULIC / HYDROSTATIC SYSTEM
- Checking And Adding Fluid
- Hydraulic / Hydrostatic Filter Replacement
- Replacing Hydraulic Fluid
- FINAL DRIVE TRANSMISSION (CHAINCASE)
- Checking And Adding Oil
- Replacing The Oil
- FAN GEARBOX
- BOB-TACH
- Inspection And Maintenance
- POWER BOB-TACH
- Inspection And Maintenance
- LUBRICATING THE LOADER
- TIRE MAINTENANCE
- Wheel Nuts
- Tire Rotation
- Tire Mounting
- HYDRAULIC SYSTEM
- HYDRAULIC / HYDROSTATIC SCHEMATICS
- HYDRAULIC SYSTEM INFORMATION
- Troubleshooting
- Tightening Procedure
- CYLINDER (LIFT)
- Checking
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- CYLINDER (TILT)
- Checking
- Removal And Installation
- Base Pin Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- CYLINDER (POWER BOB-TACH)
- Checking
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- MAIN RELIEF VALVE (FOOT CONTROL)
- Checking The Main Relief Valve At Front Aux. Hyd.
- Removal And Installation
- Adjustment
- MAIN RELIEF VALVE (AHC)
- Checking The Main Relief Valve At Front Aux. Hyd.
- Removal And Installation
- Adjustment
- HYDRAULIC CONTROL VALVE (FOOT CONTROL)
- Removal And Installation
- BICS™ Valve, Removal And Installation
- BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation
- BICS™ Valve, Check Valve Removal And Installation
- Backslide, Lock Valve Removal And Installation
- BICS™ Valve, Solenoid Removal And Installation
- BICS™ Valve, Solenoid Testing
- Identification Chart
- Load Check Valve
- Main Relief Valve
- Port Relief Valve, Tilt Spool
- Port Relief Valve, Lift Spool
- Anti-Cavitation Valve / Port Relief Valve, Tilt Spool
- Anti-Cavitation Valve, Lift Spool
- Rubber Boot
- Lift And Tilt Lock Block
- Lift Spool And Detent Removal
- Lift Spool And Detent Disassembly
- Lift Spool And Detent Assembly
- Lift Spool And Detent Installation
- Tilt Spool Removal And Installation
- Tilt Spool Disassembly And Assembly
- Auxiliary Spool Removal And Installation
- Auxiliary Plug Removal And Installation
- Auxiliary Electric Solenoid Disassembly
- Port-Auxiliary Section Removal And Installation
- Cleaning And Inspection
- HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)
- LIFT ARM BYPASS CONTROL VALVE
- Inspecting
- Additional Inspection For Loaders W/ Advanced Hand Controls
- Removal And Installation
- Disassembly And Assembly
- HYDRAULIC PUMP
- Check The Output Of The Hydraulic Pump W/O Power Bob-Tach
- Check The Output Of The Hydraulic Pump W/ Power Bob-Tach.
- Removal And Installation
- Identification
- Disassembly And Assembly
- HYDRAULIC PUMP (HI FLOW)
- HYDRAULIC / HYDROSTATIC FILTER
- Housing Removal And Installation
- Mount Removal And Installation
- HYDRAULIC FLUID RESERVOIR
- Fluid Removal
- Removal And Installation
- Hydraulic Fluid Screen
- BUCKET POSITION VALVE
- Solenoid Removal And Installation
- Solenoid Testing
- Removal And Installation
- Disassembly And Assembly
- SELECT VALVE
- REAR AUXILIARY DIVERTER
- POWER BOB-TACH BLOCK
- Removal And Installation
- Disassembly And Assembly
- FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
- Removal and Installation
- Disassembly And Assembly
- HYDROSTATIC SYSTEM
- HYDROSTATIC SYSTEM INFORMATION
- Troubleshooting
- Replenishing Valve Function
- HYDROSTATIC MOTOR
- Removal And Installation
- Parts Identification
- Disassembly
- Inspection
- Assembly
- HYDROSTATIC MOTOR (TWO-SPEED)
- Removal And Installation
- Parts Identification
- Disassembly
- Inspection
- Assembly
- HYDROSTATIC MOTOR CARRIER
- Removal and Installation
- Parts Identification
- Disassembly
- Assembly
- CHARGE PRESSURE
- Sender Removal And Installation
- HYDROSTATIC PUMP
- Replenishing / High Pressure Relief Valve
- Charge Pressure Relief Valve
- Removal And Installation
- Parts Identification (Right Half)
- Parts Identification (Left Half)
- Hydraulic Pump Removal
- Disassembly
- Assembly
- OIL COOLER (SEAL TO CONNECT) (STC)
- Hydraulic Oil Cooler Removal and Installation
- DRIVE BELT
- Shield Removal And Installation
- Adjustment
- Replacement
- Tensioner Pulley Removal And Installation
- Tensioner Pulley Tension Spring
- DRIVE SYSTEM
- BRAKE
- Disc Removal And Installation
- BRAKE (TWO-SPEED)
- Block Removal And Installation
- Block Disassembly And Assembly
- DRIVE COMPONENTS
- Axle Seal Removal And Installation
- Axle, Sprocket And Bearings Removal And Installation
- Drive Chain Removal And Installation
- CHAINCASE
- Front Chaincase Cover Removal And Installation
- Rear Chaincase Cover Removal And Installation
- MAIN FRAME
- SEAT BAR
- Removal And Installation
- Assembling Components
- Compression Spring Disassembly And Assembly
- OPERATOR CAB
- Gas Cylinder Removal And Installation
- Gas Cylinder Bracket Disassembly And Assembly
- Removal And Installation
- OPERATOR SEAT
- Removal And Installation
- Seat Belt Removal And Installation
- OPERATOR SEAT (SUSPENSION)
- Removal And Installation
- Slide Rail Removal And Installation
- Cushion Removal And Installation
- Back Removal And Installation
- Shock Removal And Installation
- BOB-TACH
- Removal And Installation
- Bob-Tach Lever And Wedge
- POWER BOB-TACH
- Removal And Installation
- Power Bob-Tach Lever And Wedge
- Pivot Pin Bushing And Seal Replacement
- LIFT ARMS
- Stabilizer Bar Removal And Installation
- Link Removal And Installation
- Removal And Installation
- Installation Of Lift Arms
- REAR GRILL
- REAR DOOR
- Removal And Installation
- Adjusting The Rear Door Latch
- FUEL TANK
- Removal And Installation
- Fuel Level Sender
- CONTROL PEDALS
- Removal And Installation
- Pedal Adjustment
- CONTROL PEDALS (ACS)
- Foot Sensor Removal And Installation
- Foot Pedal Removal And Installation
- Foot Pedal Linkage Disassembly And Assembly
- CONTROL PANEL
- Removal And Installation
- Steering Lever Boot
- CONTROL HANDLE
- Shock Removal And Installation
- Shaft Removal And Installation
- Shaft Disassembly And Assembly
- Lever Removal And Installation
- Steering Lever Boot
- Linkage Removal And Installation
- Linkage Neutral Adjustment
- CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) ADVANCED HAND CONTROL
- Components Identification
- Handle Sensor Removal And Installation
- Control Handle Removal And Installation
- Control Handle Disassembly And Assembly
- Control Lever Removal And Installation
- Control Lever Boot
- CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL
- Components Identification
- Handle Sensor Removal And Installation
- Control Handle Removal And Installation
- Control Handle Disassembly And Assembly
- Control Lever Removal And Installation
- Control Lever Boot
- ELECTRICAL SYSTEM & ANALYSIS
- ELECTRICAL SCHEMATICS
- ELECTRICAL SYSTEM INFORMATION
- Troubleshooting
- Description
- Fuse Location
- Relay Switch Location
- Solenoid Test
- BATTERY
- Removal And Installation
- Servicing The Electrical System
- Using A Booster Battery (Jump Starting)
- ALTERNATOR
- Adjusting The Alternator Belt
- Alternator Identification
- Charging System Check
- Alternator Voltage Test
- Low Voltage Test
- High Voltage Test
- Removal And Installation
- Rectifier Continuity (Diode) Test
- Alternator Regulator Test
- Disassembly
- Stator Continuity Test
- Stator Ground Test
- Rotor Continuity Test
- Rotor Ground Test
- Assembly
- STARTER
- Removal And Installation
- Parts Identification
- Checking
- Disassembly And Assembly
- Inspection And Repair
- No Load Test
- INSTRUMENT PANEL
- Left Panel
- Right Panel (Standard) (With Key Switch)
- Deluxe Panel Setup
- Passwords (Deluxe)
- Option And Field Accessory Panels (If Equipped)
- Standard Panel Removal And Installation (Right Side)
- Deluxe Panel Removal And Installation (Right Side)
- Standard & Deluxe Panel Removal And Installation (Left Side)
- Front Accessory Panel Removal And Installation
- LIGHTS
- Front Removal And Installation
- Rear Removal And Installation
- BOBCAT CONTROLLER
- Identification Chart
- Removal And Installation
- DIAGNOSTICS SERVICE CODES
- BICS™ SYSTEM
- Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
- Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
- Inspecting The Seat Bar Sensor (Engine RUNNING)
- Inspecting The Traction Lock (Engine RUNNING)
- Inspecting The Lift Arm Bypass Control
- Additional Inspection For Loaders With Advanced Hand Controls (AHC)
- Troubleshooting
- Troubleshooting Guide
- SEAT BAR SENSOR
- Troubleshooting Chart
- Test
- Removal And Installation
- BICS™ Circuit Test
- TRACTION LOCK
- Troubleshooting
- Removal And Installation (Single Speed)
- Description Of The Control System (Two Speed)
- Inspecting The Control System (Two Speed)
- ADVANCED CONTROL SYSTEM (ACS)
- Components Identification
- Troubleshooting Guide
- Controller, Connector And Wire Identification
- ACS Controller Removal And Installation
- Handle Sensor Connector
- Switch Handle Removal
- Switch Handle Installation
- Actuators Disassembly And Assembly
- Handle Lock Solenoid Removal And Installation
- Handle Lock Solenoid Disassembly And Assembly
- Handle Lock Solenoid Connector
- Calibration Of The ACS System
- Switchable Hand / Foot Controls Calibration Procedure
- Hand Controls Only Calibration Procedure
- Foot Sensor Disassembly And Assembly
- Foot Sensor Connector
- Foot Lock Solenoid Removal And Installation
- Foot Lock Solenoid Connector
- ELECTRICAL / HYDRAULIC CONTROLS REFERENCE
- Controls Identification Chart
- ENGINE SERVICE
- TROUBLESHOOTING
- ENGINE SPEED CONTROL
- Removal And Installation
- Speed Control Cable
- Speed Control Linkage
- MUFFLER
- AIR CLEANER
- Housing Removal And Installation
- RADIATOR
- COOLING FAN
- Drive Tension Pulley Removal And Installation
- Gearbox / Blower Housing Removal And Installation
- Gearbox Parts Identification
- Gearbox Disassembly
- Gearbox Assembly
- Gearbox, Checking Backlash
- ENGINE COMPONENTS AND TESTS
- Engine Compression, Checking
- Glow Plug, Checking
- Fuel Shut-Off Solenoid Checking
- Fuel Shut-Off Solenoid Removal And Installation
- Fuel Injection Pump Removal
- Fuel Injection Pump Timing
- Fuel Injection Pump Installation
- Fuel Injector Removal And Installation
- Fuel Injector, Checking
- Fuel Injector Disassembly
- Fuel Injector Assembly
- Timing Belt Inspection
- Timing Belt Removal
- Timing Belt Installation
- Timing Belt, Replacement In The Loader
- Valve Clearance Adjustment
- Valve Timing, Checking
- Thermostat, Oil Pressure Control Valves & Heater Connections
- ENGINE
- Removal And Installation
- Mount Replacement
- FLYWHEEL AND HOUSING
- Flywheel Removal And Installation
- Ring Gear Removal And Installation
- Flywheel Housing Removal And Installation
- RPM SENSOR
- RECONDITIONING THE ENGINE
- Deutz Engine Tools Identification Chart
- Disassembly
- Assembly
- Cylinder, Checking
- Camshaft Bearing, Checking
- Camshaft Bearing, Removal And Installation
- Control Rod Guide Bushing Removal
- Control Rod Guide Bushing Installation
- Rear Cover Seal Removal And Installation
- Crankshaft, Checking
- Connecting Rod, Checking
- Piston, Checking
- Piston Pin, Checking
- Piston Rings Installation
- Piston Installation On The Connecting Rod
- Cylinder Head Disassembly
- Valves, Checking
- Valve Seats, Checking
- Cylinder Head Assembly
- Rocker Arm And Bracket, Checking
- Front Cover Disassembly
- Front Cover Assembly
- Turbo Charger Removal and Installation
- Crankshaft Gear Mounting Bolt Torque Procedure
- HEATING, VENTILATION, AIR CONDITIONING
- AIR CONDITIONING SYSTEM FLOW
- COMPONENTS
- SAFETY
- REGULAR MAINTENANCE
- Filter Elements Removal And Installation
- Compressor Drive Belt Inspection
- Cleaning The Condenser
- BASIC TROUBLESHOOTING
- Poor A/C Performance
- Cleaning The A/C Evaporator Coil & Heater Coil
- Receiver / Drier Sight Glass Inspection
- Compressor Drive Belt Inspection
- Checking The Electrical System
- Engine Coolant Bypassing The Heater Valve
- Heater Valve Not Opening Or Closing
- GENERAL AIR CONDITIONING SERVICE GUIDELINES
- Compressor Oil
- Compressor Oil Check
- Component Replacement And Refrigeration Leaks
- SYSTEM TROUBLESHOOTING CHART
- Gauge Pressure Related Troubleshooting
- Troubleshooting Tree
- TEMPERATURE / PRESSURE
- AIR CONDITIONING SERVICE
- SYSTEM CHARGING AND RECLAMATION
- Reclamation Procedure
- Charging Procedure With A Manifold Gauge Set
- Charging Procedure
- COMPRESSOR
- Removal And Installation
- Compressor Clutch Disassembly
- CONDENSER
- RECEIVER / DRIER
- PRESSURE RELIEF VALVE
- PRESSURE SWITCH
- EVAPORATOR / HEATER UNIT
- Removal And Installation
- Disassembly And Assembly
- THERMOSTAT
- EXPANSION VALVE
- EVAPORATOR
- HEATER COIL
- Removal And Installation With A/C
- Removal And Installation Without A/C
- HEATER / AC FAN
- Removal And Installation
- Disassembly And Assembly
- Wire Connector Removal And Installation
- HEATER VALVE
- Removal And Installation
- Disassembly And Assembly
- SPECIFICATIONS
- LOADER SPECIFICATIONS (S250)
- Machine Dimensions
- Performance
- Controls
- Engine
- Hydraulic System
- Electrical
- Drive System
- Capacities
- Tires
- ENGINE SPECIFICATIONS
- General
- Fuel System
- Valve And Valve Guide And Seat Insert
- Piston And Rings
- Connecting Rod
- Cylinder Head And Block
- Crankshaft And Main Bearings
- Camshaft And Bearings
- Oil Pump
- LOADER TORQUE
- TORQUE SPECIFICATIONS FOR BOLTS
- Torque For General SAE Bolts
- Torque For General Metric Bolts
- Torque For Kubota Metric Engine Bolts
- HYDRAULIC CONNECTION SPECIFICATIONS
- O-ring Face Seal Connection
- Straight Thread O-ring Fitting
- Tubelines And Hoses
- Flare Fitting
- O-ring Flare Fitting
- Port Seal Fitting
- HYDRAULIC FLUID SPECIFICATIONS
- CONVERSIONS
- Decimal And Millimeter Equivalents
- U.S. To Metric Conversion
- SERVICE MANUAL REVISION
- S250-1
- S250-2
- S250-3
- S250-4
- S250-5
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