Bobcat S205 Skid-Steer Loaders Repair Service Manuals + Operation & Maintenance Manual
Complete repair service manual with electrical wiring diagrams for Bobcat S205 Skid-Steer Loaders, with all the workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Bobcat S205 Skid-Steer Loaders workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
6902839 (5-12) - S205 Turbo, S205 Turbo High Flow Operation & Maintenance Manual.pdf
6902839 (12-06) - S205 Turbo, S205 Turbo High Flow Operation & Maintenance Manual.pdf
6902917 (7-09) - S205 Turbo, S205 Turbo High Flow Service Manual.pdf
6904136 (4-08) - S205 Skid-Steer Loader Operation & Maintenance Manual.pdf
6904138 (7-09) - S205 Skid-Steer Loader Service Manual.pdf
6986987 (3-08) - S205 Skid-Steer Loader Operation & Maintenance Manual.pdf
6987013 (2-13) - S205 Skid-Steer Loader Operation & Maintenance Manual.pdf
6987013 (11-10) - S205 Skid-Steer Loader Operation & Maintenance Manual.pdf
6987037 (7-09) - S205 Skid-Steer Loader Service Manual.pdf
6987050 (2-11) - S205 Skid-Steer Loader Service Manual.pdf
6987050 (6-10) - S205 Skid-Steer Loader Service Manual.pdf
6987050 (7-14) - S205 Skid-Steer Loader Service Manual.pdf
Total Pages: 6,502 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
6987050 (2-11) - S205 Skid-Steer Loader Service Manual......2
MAINTENANCE SAFETY......4
ALPHABETICAL INDEX......6
CONTENTS......8
FOREWORD......9
SAFETY INSTRUCTIONS......12
FIRE PREVENTION......14
Maintenance......14
Operation......14
Electrical......14
Hydraulic System......14
Fueling......14
Starting......14
Spark Arrestor Exhaust System......14
Welding And Grinding......15
Fire Extinguishers......15
SERIAL NUMBER LOCATIONS......16
Loader Serial Number......16
Engine Serial Number......16
DELIVERY REPORT......17
LOADER IDENTIFICATION......18
SAFETY & MAINTENANCE......20
LIFTING AND BLOCKING THE LOADER......24
Procedure......24
LIFT ARM SUPPORT DEVICE......26
Installing......26
Removing......27
OPERATOR CAB......28
Description......28
Raising......28
Lowering......29
Cab Door Sensor......30
Special Applications Kit......30
Special Applications Kit Inspection And Maintenance......30
TRANSPORTING THE LOADER ON A TRAILER......32
Loading And Unloading......32
Fastening......32
TOWING THE LOADER......34
Procedure......34
REMOTE START TOOL KIT-MEL1563......36
Remote Start Tool - MEL1563......36
Service Tool Harness Control - MEL1565......37
Service Tool Harness Communicator - MEL1566......38
Remote Start Procedure......39
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031......42
Description......42
Remote Start Tool (Service Tool) - 7003030......43
Loader Service Tool Harness - 6689747......44
Computer Service Tool Harness - 6689746......45
Remote Start Procedure......46
SERVICE SCHEDULE......50
Chart......50
AIR CLEANER SERVICE......52
Replacing Filter Elements......52
ENGINE COOLING SYSTEM......54
Cleaning......54
Checking Level......55
Removing And Replacing Coolant......55
FUEL SYSTEM......56
Fuel Specifications......56
Biodiesel Blend Fuel......56
Filling The Fuel Tank......57
Fuel Filter......58
Removing Air From The Fuel System......58
ENGINE LUBRICATION SYSTEM......60
Checking And Adding Engine Oil......60
Engine Oil Chart......60
Removing And Replacing Oil And Filter......61
HYDRAULIC / HYDROSTATIC SYSTEM......62
Checking And Adding Fluid......62
Hydraulic / Hydrostatic Fluid Chart......62
Removing And Replacing Hydraulic Fluid......63
Removing And Replacing Hydraulic / Hydrostatic Filter......63
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)......64
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)......65
Removing And Replacing Hydraulic Charge Filter......67
Breather Cap......68
FINAL DRIVE TRANSMISSION (CHAINCASE)......70
Checking And Adding Oil......70
Removing And Replacing Oil......70
BOB-TACH (HAND LEVER)......72
Inspection And Maintenance......72
BOB-TACH (POWER)......74
Inspection And Maintenance......74
LUBRICATING THE LOADER......76
Lubrication Locations......76
TIRE MAINTENANCE......78
Wheel Nuts......78
Rotating......78
Mounting......78
SPARK ARRESTER MUFFLER......80
Cleaning Procedure......80
PIVOT PINS......82
Inspection And Maintenance......82
LOADER STORAGE AND RETURN TO SERVICE......84
Storage......84
Return To Service......84
STOPPING THE ENGINE AND LEAVING THE LOADER......86
Procedure......86
EMERGENCY EXIT......88
Rear Window......88
Front Door......88
SEAT BELT......90
Inspection And Maintenance......90
HYDRAULIC SYSTEM......92
HYDRAULIC / HYDROSTATIC SCHEMATICS......98
HYDRAULIC SYSTEM INFORMATION......114
Glossary Of Hydraulic / Hydrostatic Symbols......114
Troubleshooting......118
CYLINDER (LIFT)......120
Testing......120
Removal And Installation......121
Parts Identification......124
Disassembly And Assembly......125
CYLINDER (TILT)......128
Testing......128
Removal And Installation......129
Rod End Pivot Pin Bushing And Seal Removal And Installation......131
Base End Pivot Pin Removal And Installation......131
Parts Identification......132
Disassembly And Assembly......133
CYLINDER (BOB-TACH)......136
Testing......136
Removal And Installation......137
Parts Identification......138
Disassembly And Assembly......139
MAIN RELIEF VALVE......142
Description......142
Testing......142
Adjusting......144
Removal And Installation......145
HYDRAULIC CONTROL VALVE (STANDARD)......146
Description......146
Removal And Installation......147
Identification Chart......152
Mount Bracket Removal And Installation......153
Lift Load Check Valve Removal And Installation......153
Load Check Valve Removal And Installation (Tilt And Auxiliary)......154
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)......155
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)......156
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)......156
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)......157
Port Relief Valve Removal And Installation......157
Plug Removal And Installation......158
Rubber Boot Removal And Installation......159
End Cap / Spool Lock Block Removal And Installation......160
Lift Spool And Detent Removal And Installation......161
Tilt Spool Removal And Installation......171
Auxiliary Spool Removal And Installation......173
Auxiliary Solenoid Removal And Installation (S/N A3LJ34999 & Below And A3LK34999 & Below)......175
Auxiliary Solenoid Removal And Installation (S/N A3LJ35001 & Above And A3LK35001 & Above)......176
Solenoid Removal And Installation......177
Lock Valve Removal And Installation......178
Lift Arm Bypass Orifice Removal And Installation......180
Main Relief Valve Removal And Installation......180
Check Valve Removal And Installation......181
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)......182
Description......182
Removal And Installation......183
Actuator Removal And Installation (Out Of Loader)......187
Identification Chart......190
Mount Bracket Removal And Installation......191
Lift Load Check Valve Removal And Installation......191
Load Check Valve Removal And Installation (Tilt And Auxiliary)......192
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)......193
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)......194
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)......194
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)......195
Port Relief Valve Removal And Installation......195
Plug Removal And Installation......196
End Cap Block Removal And Installation......197
Lift Spool And Detent Removal And Installation......198
Tilt Spool Removal And Installation......203
Auxiliary Spool Removal And Installation......205
Auxiliary Solenoid Removal And Installation (S/N A3LJ34999 & Below And A3LK34999 & Below)......207
Auxiliary Solenoid Removal And Installation (S/N A3LJ35001 & Above And A3LK35001 & Above)......208
Solenoid Removal And Installation......209
Lock Valve Removal And Installation......210
Lift Arm Bypass Orifice Removal And Installation......212
Main Relief Valve Removal And Installation......212
Check Valve Removal And Installation......213
LIFT ARM BYPASS CONTROL VALVE......214
Description......214
Testing......214
Removal And Installation......214
Disassembly And Assembly......215
HYDRAULIC PUMP (STANDARD)......216
Description......216
Pump Test At Quick Couplers......216
Direct Pump Test (Standard Section)......217
Direct Pump Test (Charge Section)......219
Removal And Installation......221
Hydraulic Pump Startup......223
Parts Identification......224
Disassembly And Assembly......225
HYDRAULIC PUMP (STANDARD) (HIGH FLOW)......234
Description......234
Pump Test At Quick Couplers......234
Direct Pump Test (Standard Section)......235
Direct Pump Test (Charge Section)......237
Direct Pump Test (High Flow Section)......239
Removal And Installation......241
Hydraulic Pump Startup......243
Parts Identification......244
Disassembly And Assembly......245
HYDRAULIC PUMP (SJC)......258
Description......258
Pump Test At Quick Couplers......258
Direct Pump Test (Standard Section)......259
Direct Pump Test (Charge Section)......261
Removal And Installation......263
Hydraulic Pump Startup......265
Parts Identification......266
Disassembly And Assembly......267
HYDRAULIC PUMP (SJC) (HIGH FLOW)......276
Description......276
Pump Test At Quick Couplers......276
Direct Pump Test (Standard Section)......277
Direct Pump Test (Charge Section)......279
Direct Pump Test (High Flow Section)......281
Removal And Installation......283
Hydraulic Pump Startup......285
Parts Identification......286
Disassembly And Assembly......287
HYDRAULIC / HYDROSTATIC FILTERS......300
Description......300
Housing Removal And Installation......300
Charge Filter Housing Removal And Installation......302
HYDRAULIC FLUID RESERVOIR......304
Description......304
Removal And Installation......304
Hydraulic Fluid Screen......307
OIL COOLER......308
Description......308
Removal And Installation......308
BUCKET POSITION VALVE......310
Description......310
Solenoid Removal And Installation......310
Solenoid Testing......311
Removal And Installation......312
Disassembly And Assembly......313
REAR AUXILIARY DIVERTER VALVE......316
Description......316
Solenoid Testing......316
Removal And Installation......317
Disassembly And Assembly......320
BOB-TACH (POWER) BLOCK......326
Description......326
Removal And Installation......326
Disassembly And Assembly......328
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK......332
Description......332
Removal And Installation......332
Disassembly And Assembly......332
HIGH FLOW VALVE......334
Description......334
High Flow Relief Valve Testing......334
High Flow Relief Valve Adjustment......335
Solenoid Testing......336
Removal And Installation......337
Disassembly And Assembly......338
HYDROSTATIC SYSTEM......342
HYDROSTATIC SYSTEM INFORMATION......344
Troubleshooting......344
Description......345
HYDROSTATIC DRIVE MOTOR......346
Description......346
Removal And Installation......346
Parts Identification......349
Disassembly And Assembly......350
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)......356
Description......356
Removal And Installation (Left Side)......357
Removal And Installation (Right Side)......360
Parts Identification......363
Disassembly......364
Assembly......374
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH MANUAL CONTROLS)......386
Description......386
Shaft Seal Removal And Installation......387
Removal And Installation......389
Parts Identification......391
Disassembly And Assembly......392
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH SJC CONTROLS)......398
Description......398
Shaft Seal Removal And Installation......399
Removal And Installation......401
Parts Identification......403
Disassembly And Assembly......404
CHARGE PRESSURE......410
Description......410
Testing (S/N A3LJ29999 & Below And A3LK29999 & Below)......411
Sender Removal And Installation (S/N A3LJ29999 & Below And A3LK29999 & Below)......412
Testing (S/N A3LJ30001 & Above And A3LK30001 & Above)......413
Sender Removal And Installation (S/N A3LJ30001 & Above And A3LK30001 & Above)......414
Adjusting......415
HYDROSTATIC PUMP......418
Description......418
Replenishing / High Pressure Relief Valve Removal And Installation......418
Removal And Installation......419
Hydrostatic Pump Startup......420
Parts Identification (Left Half)......421
Parts Identification (Right Half)......422
Disassembly......423
Assembly......429
HYDROSTATIC PUMP (SJC)......436
Description......436
Hydraulic Controller Removal And Installation......437
Removal And Installation......439
Hydrostatic Pump Startup......441
Parts Identification......442
High Pressure Relief And Bypass Valve......443
Charge Relief Valve......444
Disassembly And Assembly......445
Mechanical Neutral Adjustment......461
Hydraulic Controller Neutral Adjustment......464
DRIVE BELT......468
Description......468
Shield Removal And Installation......468
Adjusting......468
Belt Removal And Installation......470
Tensioner Pulley Removal And Installation......471
Tensioner Pulley Parts Identification......472
Tensioner Pulley Disassembly......473
Tensioner Pulley Assembly......474
TWO-SPEED VALVE......476
Description......476
Valve Removal And Installation......477
Valve Disassembly And Assembly......479
CASE DRAIN FILTER......482
Description......482
Disassembly And Assembly......482
DRIVE SYSTEM......484
BRAKE (SINGLE SPEED)......486
Description......486
Disc Removal And Installation......486
BRAKE (TWO-SPEED)......488
Description......488
Disc Removal And Installation......488
Disc Disassembly And Assembly......489
DRIVE COMPONENTS......490
Description......490
Axle Seal Removal And Installation......491
Axle Sprocket And Bearings Removal And Installation......493
Chain Removal And Installation......498
CHAINCASE......500
Description......500
Front Cover Removal And Installation......500
Center Cover Removal And Installation......501
Rear Cover Removal And Installation......502
MAINFRAME......504
SEAT BAR......508
Description......508
Removal And Installation......508
Disassembly And Assembly......509
Compression Spring Disassembly And Assembly......510
OPERATOR CAB......512
Gas Cylinder Removal And Installation......512
Gas Cylinder Bracket Disassembly And Assembly......515
Removal And Installation......515
OPERATOR SEAT......518
Removal And Installation......518
Seat Belt Removal And Installation......518
OPERATOR SEAT (SUSPENSION)......520
Removal And Installation......520
Slide Rail Removal And Installation......521
Seat Belt Removal And Installation......521
Lower Cushion Removal And Installation......521
Back Cushion Removal And Installation......523
Shock Removal And Installation......523
3-Point Seat Belt Removal And Installation......524
BOB-TACH (HAND LEVER)......526
Description......526
Removal And Installation......526
Lever And Wedge Disassembly And Assembly......527
Pivot Pin Bushing And Seal Removal And Installation......528
BOB-TACH (POWER)......530
Description......530
Removal And Installation......530
Lever And Wedge Disassembly And Assembly......532
Pivot Pin Bushing And Seal Removal And Installation......533
LIFT ARMS......534
Stabilizer Bar Removal And Installation......534
Link Removal And Installation......535
Removal And Installation......536
REAR GRILLE......540
Removal And Installation......540
REAR DOOR (TAILGATE)......542
Removal And Installation......542
Striker Removal And Installation......543
Striker Disassembly And Assembly......543
Striker (Adjusting)......543
Latch Removal And Installation......544
FUEL TANK......546
Removal And Installation......546
Fuel Level Sender Removal And Installation......547
Fuel Fill Screen Removal And Installation......548
CONTROL PEDALS AND LINKAGES......550
Description......550
Pedal Removal And Installation......550
Linkage Removal And Installation......551
Pedal (Adjusting)......553
CONTROL PEDALS (ACS)......554
Description......554
Foot Sensor Removal And Installation......554
Foot Pedal Removal And Installation......555
Foot Pedal Linkage Disassembly And Assembly......556
CONTROL PANEL......558
Description......558
Removal And Installation......559
Shock Removal And Installation......562
Shaft Removal And Installation......562
Shaft Disassembly And Assembly......563
Linkage Removal And Installation......564
Pintle Arm Disassembly And Assembly......568
Linkage Neutral (Adjusting)......570
Linkage Travel (Adjusting)......574
CONTROL PANEL (SJC)......578
Description......578
Removal And Installation......578
CONTROL HANDLE / LEVER......580
Description......580
Lever Removal And Installation......580
Boot Removal And Installation......581
CONTROL HANDLE / LEVER (ACS)......582
Description......582
Handle Sensor Removal And Installation......582
Handle Removal And Installation......585
Handle Disassembly And Assembly......586
Lever Removal And Installation......586
Boot Removal And Installation......588
CONTROL HANDLE / LEVER (SJC)......590
Description......590
Joystick Testing......590
Joystick Removal And Installation......591
Joystick Mount Removal And Installation......592
ACCESS PANEL (INSIDE)......594
Removal And Installation (Left)......594
Removal And Installation (Right)......594
ACCESS PANEL (INSIDE) (SJC)......596
Removal And Installation (Left)......596
Removal And Installation (Right)......597
WINDOW (REAR)......600
Removal......600
Installation (Split Molding)......600
Installation (Continuous Molding)......602
WINDOW (TOP)......604
Removal And Installation......604
WINDOW (SIDE)......606
Removal And Installation......606
WINDOW (CAB DOOR)......608
Removal (Standard Window)......608
Installation (Standard Window)......609
Removal And Installation (Special Applications Window)......611
CAB DOOR......612
Description......612
Removal And Installation......612
Aligning......613
Adjusting......614
Checking Operation......614
ELECTRICAL SYSTEM & ANALYSIS......616
ELECTRICAL SCHEMATICS......622
ELECTRICAL SYSTEM INFORMATION......628
Glossary Of Electrical Symbols......628
Standard Cab Harness Connectors......631
Deluxe Cab Harness Connectors......632
Mainframe Harness Connectors......633
Description......634
Troubleshooting......635
Fuse And Relay Location / Identification......636
Solenoid Testing......637
BATTERY......638
Removal And Installation......638
Servicing......639
Using A Booster Battery (Jump Starting)......640
ALTERNATOR......642
Belt Adjustment......642
Belt Replacement......642
Charging System Inspection......643
Alternator Voltage Testing......644
Low Voltage Testing......644
High Voltage Testing......645
Removal And Installation......646
Parts Identification......647
STARTER......648
Testing......648
Removal And Installation......649
Parts Identification......650
INSTRUMENT PANELS......652
Left Panel......652
Standard Key Panel......654
Keyless Start Panel......654
Deluxe Instrumentation Panel......655
Side Panel......656
Front Panel......656
Front Panel Removal And Installation......657
Removal And Installation (Left And Right)......658
Key Switch Removal And Installation......659
Alarm Removal And Installation......659
LIGHTS......660
Front Removal And Installation......660
Rear Removal And Installation......661
Cab Light Removal And Installation......661
BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)......662
Description......662
Connector Identification......663
Removal And Installation......669
BOBCAT CONTROLLER (ACS)......672
Description......672
Connector And Wire Identification......673
Removal And Installation......674
BOBCAT CONTROLLER (SJC) (DRIVE)......676
Description......676
Connector Identification......677
Removal And Installation......679
SPEED SENSORS (SJC)......680
Description......680
Testing......680
Removal And Installation......682
DIAGNOSTIC SERVICE CODES......684
Viewing Service Codes......684
Service Codes List......685
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)......690
Description......690
Inspecting The BICS™ (Engine STOPPED - Key ON)......691
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)......691
Inspecting The Seat Bar Sensor (Engine RUNNING)......691
Inspecting The Traction Lock (Engine RUNNING)......691
Inspecting The Lift Arm Bypass Control......691
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)......691
Troubleshooting......692
SEAT BAR SENSOR......694
Description......694
Troubleshooting......694
Testing......695
Removal And Installation......696
Bobcat Interlock Control System (BICS™) Circuit Test......699
TRACTION LOCK......702
Description......702
Troubleshooting......702
Removal And Installation......703
Inspecting......707
CONTROL SYSTEM (ACS)......708
Description......708
Troubleshooting......709
Handle Sensor Connector Disassembly And Assembly......710
Switch Handle Removal......711
Switch Handle Installation......713
Actuator Connector Disassembly And Assembly......716
Handle Lock Solenoid Removal And Installation......717
Handle Lock Solenoid Disassembly And Assembly......717
Foot Sensor Disassembly And Assembly......718
Foot Lock Solenoid Removal And Installation......719
ELECTRICAL / HYDRAULIC CONTROLS......720
Identification Chart......720
Description......721
Identification Chart ACD Group 0......722
Identification Chart ACD Group 1......723
Identification Chart ACD Group 2......724
Identification Chart ACD Group 3......725
ELECTRICAL / HYDRAULIC CONTROLS (ACS)......726
Identification Chart......726
Description......727
Identification Chart ACD Group 0......728
Identification Chart ACD Group 1......729
Identification Chart ACD Group 2......730
Identification Chart ACD Group 3......731
ELECTRICAL / HYDRAULIC CONTROLS (SJC)......732
Identification Chart......732
Description......733
Identification Chart ACD Group 0......734
Identification Chart ACD Group 1......735
Identification Chart ACD Group 2......736
Identification Chart ACD Group 3......737
SERVICE PC (LAPTOP COMPUTER)......738
Connecting Remote Start Tool......738
Connecting Remote Start Tool (Service Tool)......738
CALIBRATION......740
Description......740
Actuator Testing......740
Lift And Tilt Calibration (SJC)......743
Hydrostatic Pump Calibration (SJC)......745
Lift And Tilt Calibration (ACS)......750
STEERING DRIFT COMPENSATION......752
Description......752
Operation......752
FLYWHEEL RPM SENSOR......754
Description......754
Adjusting......754
CONTROL PANEL SETUP......756
Right Panel Setup (Deluxe Instrumentation Panel)......756
Attachment Control Information (Deluxe Instrumentation Panel)......757
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)......758
Password Description......758
Changing The Owner Password......758
Changing The User Passwords......759
Password Lockout Feature......759
PASSWORD SETUP (KEYLESS START PANEL)......760
Password Description......760
Changing The Owner Password......760
Password Lockout Feature......760
MAINTENANCE CLOCK......762
Description......762
Setup......763
Reset......766
BACK-UP ALARM SYSTEM......768
Description......768
Inspecting......768
Adjusting Switch Position......769
Troubleshooting (Standard And ACS)......770
Troubleshooting (Joystick)......771
Alarm Removal And Installation......772
Switch Removal And Installation......772
ENGINE SERVICE......774
ENGINE INFORMATION......778
Description......778
Specifications......779
Torque Values......783
Troubleshooting......783
Engine Removal And Installation......785
Engine Mount Replacement......792
Compression - Checking......793
ENGINE SPEED CONTROL......794
Removal And Installation......794
ENGINE SPEED CONTROL (SJC)......796
Removal And Installation......796
Disassembly And Assembly......798
MUFFLER......800
Removal And Installation......800
AIR CLEANER......802
Housing Removal And Installation......802
ENGINE COOLING SYSTEM......804
Radiator Removal And Installation......804
Hydraulic Fan Description (S/N A3LJ29999 & Below And A3LK29999 & Below)......807
Hydraulic Fan Disassembly And Assembly (S/N A3LJ29999 & Below And A3LK29999 & Below)......807
Blower Housing Removal And Installation (S/N A3LJ29999 & Below And A3LK29999 & Below)......808
Fan Removal And Installation (S/N A3LJ29999 & Below And A3LK29999 & Below)......810
Hydraulic Fan Motor Removal And Installation (S/N A3LJ29999 & Below And A3LK29999 & Below)......810
Hydraulic Fan Description (S/N A3LJ30001 & Above And A3LK30001 & Above)......811
Hydraulic Fan Disassembly And Assembly (S/N A3LJ30001 & Above And A3LK30001 & Above)......811
Blower Housing Removal And Installation (S/N A3LJ30001 & Above And A3LK30001 & Above)......813
Fan Removal And Installation (S/N A3LJ30001 & Above And A3LK30001 & Above)......815
Hydraulic Fan Motor Removal And Installation (S/N A3LJ30001 & Above And A3LK30001 & Above)......815
Water Pump Removal And Installation......816
Water Pump Disassembly And Assembly......816
Thermostat Housing Removal And Installation......817
Thermostat - Checking......818
LUBRICATION SYSTEM......820
Oil Pan Removal And Installation......820
Oil Pump Removal And Installation......820
Relief Valve - Testing......821
Oil Pump Inspection......821
Oil Filter Cooler Removal And Installation......822
Engine Oil Pressure - Testing......823
FUEL SYSTEM......824
Fuel Shutoff Solenoid - Checking......824
Fuel Shutoff Solenoid Removal And Installation......824
Fuel Injection Pump - Checking......825
Fuel Injection Pump Assembly Removal And Installation......826
Governor Housing Disassembly And Assembly......829
Governor Disassembly And Assembly......831
Fuel Camshaft Removal And Installation......832
Fuel Injection Pump Removal And Installation......834
Fuel Injection Pump - Timing......837
Fuel Injector Removal And Installation......839
Fuel Injector Nozzle Pressure - Checking......840
Nozzle Spray Condition......841
Valve Seat Tightness......841
CYLINDER HEAD......842
Glow Plugs - Testing......842
Glow Plugs Removal And Installation......842
Valve Clearance Adjustment......843
Valve Timing - Checking......844
Cylinder Head Removal And Installation......845
Cylinder Head Disassembly And Assembly......848
Cylinder Head - Servicing......848
Cylinder Head Top Clearance......849
Valve Guide - Checking......849
Valve Guide Removal And Installation......850
Reconditioning The Valve And Valve Seat......850
Valve Spring......852
Valve Tappets......853
Rocker Arm And Shaft - Checking......854
Bridge Arm And Bridge Arm Shaft - Checking......854
Bridge Arm Shaft Removal And Installation......855
Push Rod Alignment - Checking......856
CRANKSHAFT AND PISTONS......858
Piston And Connecting Rod Removal And Installation......858
Piston And Connecting Rod - Servicing......859
Cylinder Bore - Checking......863
Connecting Rod Alignment......864
Crankshaft Gear Removal And Installation......864
Crankshaft And Bearings Removal And Installation......865
Crankshaft And Bearings - Servicing......868
CAMSHAFT AND TIMING GEARS......872
Timing Gearcase Cover Removal......872
Timing Gearcase Cover Installation......873
Timing Gears Backlash - Checking......876
Idler Gear And Camshaft Removal And Installation......876
Camshaft - Servicing......877
Idler Gear And Shaft - Servicing......878
TURBOCHARGER......880
Description......880
Testing......880
Removal And Installation......881
FLYWHEEL AND HOUSING......882
Flywheel Removal And Installation......882
Ring Gear Removal And Installation......883
Housing Removal And Installation......884
EXHAUST GAS RECIRCULATION (EGR) SYSTEM......886
Description......886
Testing......887
Removal And Installation......890
Disassembly And Assembly......891
HEATING, VENTILATION, AIR CONDITIONING......892
AIR CONDITIONING SYSTEM FLOW......895
Description......895
Chart......896
Components......897
Safety Equipment......900
REGULAR MAINTENANCE......902
Filters......902
Compressor Drive Belt Adjustment......902
Compressor Drive Belt Replacement......903
Condenser......903
Air Conditioning Lubrication......903
Air Conditioning Service Chart......904
Evaporator / Heater Coil......905
TROUBLESHOOTING......906
Blower Motor Does Not Operate......906
Blower Motor Operates Normally, But Air Flow Is Insufficient......906
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal......906
The Compressor Does Not Operate At All, Or Operates Improperly......906
Gauge Pressure Related Troubleshooting......907
Troubleshooting Tree......909
Temperature / Pressure Chart......913
Poor A/C Performance......914
HVAC Repair And Leaks......915
Electrical System......916
Engine Coolant Bypassing The Heater Valve......923
Heater Valve Not Opening Or Closing......924
SYSTEM CHARGING AND RECLAMATION......926
Refrigerant Identification......926
Reclamation And Charging With Recovery / Charging Unit......927
Charging With A Manifold Gauge Set......929
COMPRESSOR......932
Removal And Installation......932
Oil......934
Oil Check......934
Clutch Disassembly And Assembly......936
CONDENSER......940
Removal And Installation......940
RECEIVER / DRIER......942
Receiver / Drier Removal And Installation......942
Pressure Relief Valve Removal And Installation......943
Pressure Switch Removal And Installation......944
Schraeder Valve Removal And Installation......945
EVAPORATOR / HEATER UNIT......946
Removal And Installation......946
THERMOSTAT......948
Description......948
Removal And Installation......949
EXPANSION VALVE......950
Removal And Installation......950
EVAPORATOR COIL......952
Removal And Installation......952
HEATER COIL......954
Removal And Installation With A/C......954
Removal And Installation Without A/C......956
BLOWER FAN......958
Removal And Installation......958
Disassembly And Assembly......959
Connector Identification......961
HEATER VALVE......962
Removal And Installation......962
Disassembly And Assembly......963
SPECIFICATIONS......964
(S205) LOADER SPECIFICATIONS......966
Machine Dimensions......966
Performance......967
Engine......967
Drive System......967
Controls......968
Hydraulic System......968
Electrical......969
Capacities......969
Tires......969
TORQUE SPECIFICATIONS FOR BOLTS......970
Torque For General SAE Bolts......970
Torque For General Metric Bolts......971
HYDRAULIC CONNECTION SPECIFICATIONS......972
O-ring Face Seal Connection......972
Straight Thread O-ring Fitting......973
Tubelines And Hoses......973
Flare Fitting......974
Port Seal Fitting......975
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS......976
Specifications......976
CONVERSIONS......978
Decimal And Millimeter Equivalent Chart......978
U.S. To Metric Conversion Chart......978
SERVICE MANUAL REVISION......980
Revision No: S205 - 1......980
Revision No: S205 - 2......982
Revision No: S205 - 3......984
Revision No: S205 - 4......986
Revision No: S205 - 5......988
Revision No: S205 - 6......990
Revision No: S205 - 7......992
Revision No: S205 - 8......994
Revision No: S205 - 9......996
Revision No: S205 - 10......998
Revision No: S205 - 11......1000
Revision No: S205 - 12......1002
Revision No: S205 - 13......1004
Revision No: S205 - 14......1006
Revision No: S205 - 15......1008
6987050 (6-10) - S205 Skid-Steer Loader Service Manual......1010
MAINTENANCE SAFETY......1012
ALPHABETICAL INDEX......1014
CONTENTS......1016
FOREWORD......1017
SAFETY INSTRUCTIONS......1020
FIRE PREVENTION......1022
Maintenance......1022
Operation......1022
Electrical......1022
Hydraulic System......1022
Fueling......1022
Starting......1022
Spark Arrestor Exhaust System......1022
Welding And Grinding......1023
Fire Extinguishers......1023
SERIAL NUMBER LOCATIONS......1024
Loader Serial Number......1024
Engine Serial Number......1024
DELIVERY REPORT......1025
LOADER IDENTIFICATION......1026
SAFETY & MAINTENANCE......1028
LIFTING AND BLOCKING THE LOADER......1032
Procedure......1032
LIFT ARM SUPPORT DEVICE......1034
Installing......1034
Removing......1035
OPERATOR CAB......1036
Description......1036
Raising......1036
Lowering......1037
Cab Door Sensor......1038
Special Applications Kit......1038
Special Applications Kit Inspection And Maintenance......1038
TRANSPORTING THE LOADER ON A TRAILER......1040
Loading And Unloading......1040
Fastening......1040
TOWING THE LOADER......1042
Procedure......1042
REMOTE START TOOL KIT-MEL1563......1044
Remote Start Tool - MEL1563......1044
Service Tool Harness Control - MEL1565......1045
Service Tool Harness Communicator - MEL1566......1046
Remote Start Procedure......1047
REMOTE START TOOL (SERVICE TOOL) KIT - 6689779......1050
Description......1050
Remote Start Tool (Service Tool) - 6689778......1051
Loader Service Tool Harness - 6689747......1052
Computer Service Tool Harness - 6689746......1053
Remote Start Procedure......1054
SERVICE SCHEDULE......1058
Chart......1058
AIR CLEANER SERVICE......1060
Replacing Filter Elements......1060
ENGINE COOLING SYSTEM......1062
Cleaning......1062
Checking Level......1063
Removing And Replacing Coolant......1063
FUEL SYSTEM......1064
Fuel Specifications......1064
Biodiesel Blend Fuel......1064
Filling the Fuel Tank......1065
Fuel Filter......1066
Removing Air From The Fuel System......1066
ENGINE LUBRICATION SYSTEM......1068
Checking And Adding Engine Oil......1068
Engine Oil Chart......1068
Removing And Replacing Oil And Filter......1069
HYDRAULIC / HYDROSTATIC SYSTEM......1070
Checking And Adding Fluid......1070
Hydraulic / Hydrostatic Fluid Chart......1070
Removing And Replacing Hydraulic Fluid......1071
Removing And Replacing Hydraulic / Hydrostatic Filter......1071
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)......1072
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)......1073
Removing And Replacing Hydraulic Charge Filter......1075
Breather Cap......1075
FINAL DRIVE TRANSMISSION (CHAINCASE)......1076
Checking And Adding Oil......1076
Removing And Replacing Oil......1076
BOB-TACH (HAND LEVER)......1078
Inspection And Maintenance......1078
BOB-TACH (POWER)......1080
Inspection And Maintenance......1080
LUBRICATING THE LOADER......1082
Lubrication Locations......1082
TIRE MAINTENANCE......1084
Wheel Nuts......1084
Rotating......1084
Mounting......1084
SPARK ARRESTOR MUFFLER......1086
Cleaning Procedure......1086
PIVOT PINS......1088
Inspection And Maintenance......1088
LOADER STORAGE AND RETURN TO SERVICE......1090
Storage......1090
Return To Service......1090
STOPPING THE ENGINE AND LEAVING THE LOADER......1092
Procedure......1092
EMERGENCY EXIT......1094
Rear Window......1094
Front Door......1094
HYDRAULIC SYSTEM......1096
HYDRAULIC / HYDROSTATIC SCHEMATICS......1102
HYDRAULIC SYSTEM INFORMATION......1118
Glossary Of Hydraulic / Hydrostatic Symbols......1118
Troubleshooting......1122
CYLINDER (LIFT)......1124
Testing......1124
Removal And Installation......1125
Parts Identification......1128
Disassembly And Assembly......1129
CYLINDER (TILT)......1132
Testing......1132
Removal And Installation......1133
Rod End Pivot Pin Bushing And Seal Removal And Installation......1135
Base End Pivot Pin Removal And Installation......1135
Parts Identification......1136
Disassembly And Assembly......1137
CYLINDER (BOB-TACH)......1140
Testing......1140
Removal And Installation......1141
Parts Identification......1142
Disassembly And Assembly......1143
MAIN RELIEF VALVE......1146
Description......1146
Testing......1146
Adjusting......1148
Removal And Installation......1149
HYDRAULIC CONTROL VALVE (STANDARD)......1150
Description......1150
Removal And Installation......1151
Identification Chart......1156
Mount Bracket Removal And Installation......1157
Lift Load Check Valve Removal And Installation......1157
Load Check Valve Removal And Installation (Tilt & Auxiliary)......1158
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)......1159
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)......1160
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)......1160
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)......1161
Port Relief Valve Removal And Installation......1161
Plug Removal And Installation......1162
Rubber Boot Removal And Installation......1163
End Cap / Spool Lock Block Removal And Installation......1164
Lift Spool And Detent Removal And Installation......1165
Tilt Spool Removal And Installation......1175
Auxiliary Spool Removal And Installation......1177
Auxiliary Solenoid Removal And Installation (S/N A3LJ34999 & Below And A3LK34999 & Below)......1179
Auxiliary Solenoid Removal And Installation (S/N A3LJ35001 & Above And A3LK35001 & Above)......1180
Solenoid Removal And Installation......1181
Lock Valve Removal And Installation......1182
Lift Arm Bypass Orifice Removal And Installation......1184
Main Relief Valve Removal And Installation......1184
Check Valve Removal And Installation......1185
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)......1186
Description......1186
Removal And Installation......1187
Actuator Removal And Installation (Out of Loader)......1191
Identification Chart......1194
Mount Bracket Removal And Installation......1195
Lift Load Check Valve Removal And Installation......1195
Load Check Valve Removal And Installation (Tilt & Auxiliary)......1196
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)......1197
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)......1198
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)......1198
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)......1199
Port Relief Valve Removal And Installation......1199
Plug Removal And Installation......1200
End Cap Block Removal And Installation......1201
Lift Spool And Detent Removal And Installation......1202
Tilt Spool Removal And Installation......1207
Auxiliary Spool Removal And Installation......1209
Auxiliary Solenoid Removal And Installation (S/N A3LJ34999 & Below And A3LK34999 & Below)......1211
Auxiliary Solenoid Removal And Installation (S/N A3LJ35001 & Above And A3LK35001 & Above)......1212
Solenoid Removal And Installation......1213
Lock Valve Removal And Installation......1214
Lift Arm Bypass Orifice Removal And Installation......1216
Main Relief Valve Removal And Installation......1216
Check Valve Removal And Installation......1217
LIFT ARM BYPASS CONTROL VALVE......1218
Description......1218
Testing......1218
Removal And Installation......1218
Disassembly And Assembly......1219
HYDRAULIC PUMP (STANDARD)......1220
Description......1220
Pump Test At Quick Couplers......1220
Direct Pump Test (Standard Section)......1221
Direct Pump Test (Charge Section)......1223
Removal And Installation......1225
Hydraulic Pump Startup......1227
Parts Identification......1228
Disassembly And Assembly......1229
HYDRAULIC PUMP (STANDARD) (HIGH FLOW)......1238
Description......1238
Pump Test At Quick Couplers......1238
Direct Pump Test (Standard Section)......1239
Direct Pump Test (Charge Section)......1241
Direct Pump Test (High Flow Section)......1243
Removal And Installation......1245
Hydraulic Pump Startup......1247
Parts Identification......1248
Disassembly And Assembly......1249
HYDRAULIC PUMP (SJC)......1262
Description......1262
Pump Test At Quick Couplers......1262
Direct Pump Test (Standard Section)......1263
Direct Pump Test (Charge Section)......1265
Removal And Installation......1267
Hydraulic Pump Startup......1269
Parts Identification......1270
Disassembly And Assembly......1271
HYDRAULIC PUMP (SJC) (HIGH FLOW)......1280
Description......1280
Pump Test At Quick Couplers......1280
Direct Pump Test (Standard Section)......1281
Direct Pump Test (Charge Section)......1283
Direct Pump Test (High Flow Section)......1285
Removal And Installation......1287
Hydraulic Pump Startup......1289
Parts Identification......1290
Disassembly And Assembly......1291
HYDRAULIC / HYDROSTATIC FILTERS......1304
Description......1304
Housing Removal And Installation......1304
Charge Filter Housing Removal And Installation......1306
HYDRAULIC FLUID RESERVOIR......1308
Description......1308
Removal And Installation......1308
Hydraulic Fluid Screen......1311
OIL COOLER......1312
Description......1312
Removal And Installation......1312
BUCKET POSITION VALVE......1314
Description......1314
Solenoid Removal And Installation......1314
Solenoid Testing......1315
Removal And Installation......1316
Disassembly And Assembly......1317
REAR AUXILIARY DIVERTER VALVE......1320
Description......1320
Solenoid Testing......1320
Removal And Installation......1321
Disassembly And Assembly......1324
BOB-TACH (POWER) BLOCK......1330
Description......1330
Removal And Installation......1330
Disassembly And Assembly......1332
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK......1336
Description......1336
Removal And Installation......1336
Disassembly And Assembly......1336
HIGH FLOW VALVE......1338
Description......1338
High Flow Relief Valve Testing......1338
High Flow Relief Valve Adjustment......1339
Solenoid Testing......1340
Removal And Installation......1341
Disassembly And Assembly......1342
HYDROSTATIC SYSTEM......1346
HYDROSTATIC SYSTEM INFORMATION......1348
Troubleshooting......1348
Description......1349
HYDROSTATIC DRIVE MOTOR......1350
Description......1350
Removal And Installation......1350
Parts Identification......1353
Disassembly And Assembly......1354
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)......1360
Description......1360
Removal And Installation (Left Side)......1361
Removal And Installation (Right Side)......1364
Parts Identification......1367
Disassembly......1368
Assembly......1378
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH MANUAL CONTROLS)......1390
Description......1390
Shaft Seal Removal And Installation......1391
Removal And Installation......1393
Parts Identification......1395
Disassembly And Assembly......1396
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH SJC CONTROLS)......1402
Description......1402
Shaft Seal Removal And Installation......1403
Removal And Installation......1405
Parts Identification......1407
Disassembly And Assembly......1408
CHARGE PRESSURE......1414
Description......1414
Testing (S/N A3LJ29999 & Below And A3LK29999 & Below)......1415
Sender Removal And Installation (S/N A3LJ29999 & Below And A3LK29999 & Below)......1416
Testing (S/N A3LJ30001 & Above And A3LK30001 & Above)......1417
Sender Removal And Installation (S/N A3LJ30001 & Above And A3LK30001 & Above)......1418
Adjusting......1419
HYDROSTATIC PUMP......1422
Description......1422
Replenishing / High Pressure Relief Valve Removal And Installation......1422
Removal And Installation......1423
Hydrostatic Pump Startup......1424
Parts Identification (Left Half)......1425
Parts Identification (Right Half)......1426
Disassembly......1427
Assembly......1433
HYDROSTATIC PUMP (SJC)......1440
Description......1440
Hydraulic Controller Removal And Installation......1441
Removal And Installation......1443
Hydrostatic Pump Startup......1445
Parts Identification......1446
High Pressure Relief And Bypass Valve......1447
Charge Relief Valve......1448
Disassembly And Assembly......1449
Mechanical Neutral Adjustment......1465
Hydraulic Controller Neutral Adjustment......1468
DRIVE BELT......1472
Description......1472
Shield Removal And Installation......1472
Adjusting......1472
Belt Removal And Installation......1474
Tensioner Pulley Removal And Installation......1475
Tensioner Pulley Parts Identification......1476
Tensioner Pulley Disassembly......1477
Tensioner Pulley Assembly......1478
TWO-SPEED VALVE......1480
Description......1480
Valve Removal And Installation......1481
Valve Disassembly And Assembly......1483
CASE DRAIN FILTER......1486
Description......1486
Disassembly And Assembly......1486
DRIVE SYSTEM......1488
BRAKE (SINGLE SPEED)......1490
Description......1490
Disc Removal And Installation......1490
BRAKE (TWO-SPEED)......1492
Description......1492
Disc Removal And Installation......1492
Disc Disassembly And Assembly......1493
DRIVE COMPONENTS......1494
Description......1494
Axle Seal Removal And Installation......1495
Axle Sprocket And Bearings Removal And Installation......1497
Chain Removal And Installation......1502
CHAINCASE......1504
Description......1504
Front Cover Removal And Installation......1504
Center Cover Removal And Installation......1505
Rear Cover Removal And Installation......1506
MAINFRAME......1508
SEAT BAR......1512
Description......1512
Removal And Installation......1512
Disassembly And Assembly......1513
Compression Spring Disassembly And Assembly......1514
OPERATOR CAB......1516
Gas Cylinder Removal And Installation......1516
Gas Cylinder Bracket Disassembly And Assembly......1519
Removal And Installation......1519
OPERATOR SEAT......1522
Removal And Installation......1522
Seat Belt Removal And Installation......1522
OPERATOR SEAT (SUSPENSION)......1524
Removal And Installation......1524
Slide Rail Removal And Installation......1525
Seat Belt Removal And Installation......1525
Lower Cushion Removal And Installation......1525
Back Cushion Removal And Installation......1527
Shock Removal And Installation......1527
3-Point Seat Belt Removal And Installation......1528
BOB-TACH (HAND LEVER)......1530
Description......1530
Removal And Installation......1530
Lever And Wedge Disassembly And Assembly......1531
Pivot Pin Bushing And Seal Removal And Installation......1532
BOB-TACH (POWER)......1534
Description......1534
Removal And Installation......1534
Lever And Wedge Disassembly And Assembly......1536
Pivot Pin Bushing And Seal Removal And Installation......1537
LIFT ARMS......1538
Stabilizer Bar Removal And Installation......1538
Link Removal And Installation......1539
Removal And Installation......1540
REAR GRILL......1544
Removal And Installation......1544
REAR DOOR (TAILGATE)......1546
Removal And Installation......1546
Striker Removal And Installation......1547
Striker Disassembly And Assembly......1547
Striker (Adjusting)......1547
Latch Removal And Installation......1548
FUEL TANK......1550
Removal And Installation......1550
Fuel Level Sender Removal And Installation......1551
Fuel Fill Screen Removal And Installation......1552
CONTROL PEDALS AND LINKAGES......1554
Description......1554
Pedal Removal And Installation......1554
Linkage Removal And Installation......1555
Pedal (Adjusting)......1557
CONTROL PEDALS (ACS)......1558
Description......1558
Foot Sensor Removal And Installation......1558
Foot Pedal Removal And Installation......1559
Foot Pedal Linkage Disassembly And Assembly......1560
CONTROL PANEL......1562
Description......1562
Removal And Installation......1563
Shock Removal And Installation......1566
Shaft Removal And Installation......1566
Shaft Disassembly And Assembly......1567
Linkage Removal And Installation......1568
Pintle Arm Disassembly And Assembly......1572
Linkage Neutral (Adjusting)......1574
Linkage Travel (Adjusting)......1578
CONTROL PANEL (SJC)......1582
Description......1582
Removal And Installation......1582
CONTROL HANDLE / LEVER......1584
Description......1584
Lever Removal And Installation......1584
Boot Removal And Installation......1585
CONTROL HANDLE / LEVER (ACS)......1586
Description......1586
Handle Sensor Removal And Installation......1586
Handle Removal And Installation......1589
Handle Disassembly And Assembly......1590
Lever Removal And Installation......1590
Boot Removal And Installation......1592
CONTROL HANDLE / LEVER (SJC)......1594
Description......1594
Joystick Testing......1594
Joystick Removal And Installation......1595
Joystick Mount Removal And Installation......1596
ACCESS PANEL (INSIDE)......1598
Removal And Installation (Left)......1598
Removal And Installation (Right)......1598
ACCESS PANEL (INSIDE) (SJC)......1600
Removal And Installation (Left)......1600
Removal And Installation (Right)......1601
WINDOW (REAR)......1604
Removal......1604
Installation (Split Molding)......1604
Installation (Continuous Molding)......1606
WINDOW (TOP)......1608
Removal And Installation......1608
WINDOW (SIDE)......1610
Removal And Installation......1610
WINDOW (CAB DOOR)......1612
Removal (Standard Window)......1612
Installation (Standard Window)......1613
Removal And Installation (Special Applications Window)......1615
CAB DOOR......1616
Description......1616
Removal And Installation......1616
Aligning......1617
Adjusting......1618
Checking Operation......1618
ELECTRICAL SYSTEM & ANALYSIS......1620
ELECTRICAL SCHEMATICS......1626
ELECTRICAL SYSTEM INFORMATION......1632
Glossary Of Electrical Symbols......1632
Standard Cab Harness Connectors......1635
Deluxe Cab Harness Connectors......1636
Mainframe Harness Connectors......1637
Description......1638
Troubleshooting......1639
Fuse And Relay Location / Identification......1640
Solenoid Testing......1641
BATTERY......1642
Removal And Installation......1642
Servicing......1643
Using A Booster Battery (Jump Starting)......1644
ALTERNATOR......1646
Belt Adjustment......1646
Belt Replacement......1646
Charging System Inspection......1647
Alternator Voltage Testing......1648
Low Voltage Testing......1648
High Voltage Testing......1649
Removal And Installation......1650
Parts Identification......1651
STARTER......1652
Testing......1652
Removal And Installation......1653
Parts Identification......1654
INSTRUMENT PANELS......1656
Left Panel......1656
Standard Key Panel......1658
Keyless Start Panel......1658
Deluxe Instrumentation Panel......1659
Side Panel......1660
Front Panel......1660
Front Panel Removal And Installation......1661
Removal And Installation (Left And Right)......1662
Key Switch Removal And Installation......1663
Alarm Removal And Installation......1663
LIGHTS......1664
Front Removal And Installation......1664
Rear Removal And Installation......1665
Cab Light Removal And Installation......1665
BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)......1666
Description......1666
Connector Identification......1667
Removal And Installation......1673
BOBCAT CONTROLLER (ACS)......1676
Description......1676
Connector And Wire Identification......1677
Removal And Installation......1678
BOBCAT CONTROLLER (SJC) (DRIVE)......1680
Description......1680
Connector Identification......1681
Removal And Installation......1683
SPEED SENSORS (SJC)......1684
Description......1684
Testing......1684
Removal And Installation......1686
DIAGNOSTIC SERVICE CODES......1688
Viewing Service Codes......1688
Service Codes List......1689
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)......1694
Description......1694
Inspecting The BICS (Engine STOPPED - Key ON)......1695
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)......1695
Inspecting The Seat Bar Sensor (Engine RUNNING)......1695
Inspecting The Traction Lock (Engine RUNNING)......1695
Inspecting The Lift Arm Bypass Control......1695
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)......1695
Troubleshooting......1696
SEAT BAR SENSOR......1698
Description......1698
Troubleshooting......1698
Testing......1699
Removal And Installation......1700
Bobcat Interlock Control System (BICS) Circuit Test......1702
TRACTION LOCK......1704
Description......1704
Troubleshooting......1704
Removal And Installation......1705
Inspecting......1709
CONTROL SYSTEM (ACS)......1710
Description......1710
Troubleshooting......1711
Handle Sensor Connector Disassembly And Assembly......1712
Switch Handle Removal......1713
Switch Handle Installation......1715
Actuator Connector Disassembly And Assembly......1718
Handle Lock Solenoid Removal And Installation......1719
Handle Lock Solenoid Disassembly And Assembly......1719
Foot Sensor Disassembly And Assembly......1720
Foot Lock Solenoid Removal And Installation......1721
ELECTRICAL / HYDRAULIC CONTROLS......1722
Identification Chart......1722
Description......1723
Identification Chart ACD Group 0......1724
Identification Chart ACD Group 1......1725
Identification Chart ACD Group 2......1726
Identification Chart ACD Group 3......1727
ELECTRICAL / HYDRAULIC CONTROLS (ACS)......1728
Identification Chart......1728
Description......1729
Identification Chart ACD Group 0......1730
Identification Chart ACD Group 1......1731
Identification Chart ACD Group 2......1732
Identification Chart ACD Group 3......1733
ELECTRICAL / HYDRAULIC CONTROLS (SJC)......1734
Identification Chart......1734
Description......1735
Identification Chart ACD Group 0......1736
Identification Chart ACD Group 1......1737
Identification Chart ACD Group 2......1738
Identification Chart ACD Group 3......1739
SERVICE PC (LAPTOP COMPUTER)......1740
Connecting Remote Start Tool......1740
Connecting Remote Start Tool (Service Tool)......1740
CALIBRATION......1742
Description......1742
Actuator Testing......1742
Lift And Tilt Calibration (SJC)......1745
Hydrostatic Pump Calibration (SJC)......1747
Lift And Tilt Calibration (ACS)......1752
STEERING DRIFT COMPENSATION......1754
Description......1754
Operation......1754
FLYWHEEL RPM SENSOR......1756
Description......1756
Adjusting......1756
CONTROL PANEL SETUP......1758
Right Panel Setup (Deluxe Instrumentation Panel)......1758
Attachment Control Information (Deluxe Instrumentation Panel)......1759
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)......1760
Password Description......1760
Changing The Owner Password......1760
Changing The User Passwords......1761
Password Lockout Feature......1761
PASSWORD SETUP (KEYLESS START PANEL)......1762
Password Description......1762
Changing The Owner Password......1762
Password Lockout Feature......1762
MAINTENANCE CLOCK......1764
Description......1764
Setup......1765
Reset......1768
BACK-UP ALARM SYSTEM......1770
Description......1770
Inspecting......1770
Adjusting Switch Position......1771
Troubleshooting (Standard And ACS)......1772
Troubleshooting (Joystick)......1773
Alarm Removal And Installation......1774
Switch Removal And Installation......1774
ENGINE SERVICE......1776
ENGINE INFORMATION......1780
Description......1780
Specifications......1781
Torque Values......1785
Troubleshooting......1785
Engine Removal And Installation......1787
Engine Mount Replacement......1794
Compression - Checking......1795
ENGINE SPEED CONTROL......1796
Removal And Installation......1796
ENGINE SPEED CONTROL (SJC)......1798
Removal And Installation......1798
Disassembly And Assembly......1800
MUFFLER......1802
Removal And Installation......1802
AIR CLEANER......1804
Housing Removal And Installation......1804
ENGINE COOLING SYSTEM......1806
Radiator Removal And Installation......1806
Hydraulic Fan Description (S/N A3LJ29999 & Below And A3LK29999 & Below)......1809
Hydraulic Fan Disassembly And Assembly (S/N A3LJ29999 & Below And A3LK29999 & Below)......1809
Blower Housing Removal And Installation (S/N A3LJ29999 & Below And A3LK29999 & Below)......1810
Fan Removal And Installation (S/N A3LJ29999 & Below And A3LK29999 & Below)......1812
Hydraulic Fan Motor Removal And Installation (S/N A3LJ29999 & Below And A3LK29999 & Below)......1812
Hydraulic Fan Description (S/N A3LJ30001 & Above And A3LK30001 & Above)......1813
Hydraulic Fan Disassembly And Assembly (S/N A3LJ30001 & Above And A3LK30001 & Above)......1813
Blower Housing Removal And Installation (S/N A3LJ30001 & Above And A3LK30001 & Above)......1815
Fan Removal And Installation (S/N A3LJ30001 & Above And A3LK30001 & Above)......1817
Hydraulic Fan Motor Removal And Installation (S/N A3LJ30001 & Above And A3LK30001 & Above)......1817
Water Pump Removal And Installation......1818
Water Pump Disassembly And Assembly......1818
Thermostat Housing Removal And Installation......1819
Thermostat - Checking......1820
LUBRICATION SYSTEM......1822
Oil Pan Removal And Installation......1822
Oil Pump Removal And Installation......1822
Relief Valve - Testing......1823
Oil Pump Inspection......1823
Oil Filter Cooler Removal And Installation......1824
Engine Oil Pressure - Testing......1825
FUEL SYSTEM......1826
Fuel Shutoff Solenoid - Checking......1826
Fuel Shutoff Solenoid Removal And Installation......1826
Fuel Injection Pump - Checking......1827
Fuel Injection Pump Assembly Removal And Installation......1828
Governor Housing Disassembly And Assembly......1831
Governor Disassembly And Assembly......1833
Fuel Camshaft Removal And Installation......1835
Fuel Injection Pump Removal And Installation......1837
Fuel Injection Pump - Timing......1839
Fuel Injector Removal And Installation......1841
Fuel Injector Nozzle Pressure - Checking......1842
Nozzle Spray Condition......1843
Valve Seat Tightness......1843
CYLINDER HEAD......1844
Glow Plugs - Testing......1844
Glow Plugs Removal And Installation......1844
Valve Clearance Adjustment......1845
Valve Timing - Checking......1846
Cylinder Head Removal And Installation......1847
Cylinder Head Disassembly And Assembly......1850
Cylinder Head - Servicing......1850
Cylinder Head Top Clearance......1851
Valve Guide - Checking......1851
Valve Guide Removal And Installation......1852
Reconditioning The Valve And Valve Seat......1852
Valve Spring......1854
Valve Tappets......1855
Rocker Arm And Shaft - Checking......1856
Bridge Arm And Bridge Arm Shaft - Checking......1856
Bridge Arm Shaft Removal And Installation......1857
Push Rod Alignment - Checking......1858
CRANKSHAFT AND PISTONS......1860
Piston And Connecting Rod Removal And Installation......1860
Piston And Connecting Rod - Servicing......1861
Cylinder Bore - Checking......1865
Connecting Rod Alignment......1866
Crankshaft Gear Removal And Installation......1866
Crankshaft And Bearings Removal And Installation......1867
Crankshaft And Bearings - Servicing......1870
CAMSHAFT AND TIMING GEARS......1874
Timing Gearcase Cover Removal......1874
Timing Gearcase Cover Installation......1875
Timing Gears Backlash - Checking......1878
Idler Gear And Camshaft Removal And Installation......1878
Camshaft - Servicing......1879
Idler Gear And Shaft - Servicing......1880
TURBOCHARGER......1882
Description......1882
Testing......1882
Removal And Installation......1883
FLYWHEEL AND HOUSING......1884
Flywheel Removal And Installation......1884
Ring Gear Removal And Installation......1885
Housing Removal And Installation......1886
EXHAUST GAS RECIRCULATION (EGR) SYSTEM......1888
Description......1888
Testing......1889
Removal And Installation......1892
Disassembly And Assembly......1893
HEATING, VENTILATION, AIR CONDITIONING......1894
AIR CONDITIONING SYSTEM FLOW......1897
Description......1897
Chart......1898
Components......1899
Safety Equipment......1902
REGULAR MAINTENANCE......1904
Filters......1904
Compressor Drive Belt Adjustment......1904
Compressor Drive Belt Replacement......1905
Condenser......1905
Air Conditioning Lubrication......1905
Air Conditioning Service Chart......1906
Evaporator / Heater Coil......1907
TROUBLESHOOTING......1908
Blower Motor Does Not Operate......1908
Blower Motor Operates Normally, But Air Flow Is Insufficient......1908
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal......1908
The Compressor Does Not Operate At All, Or Operates Improperly......1908
Gauge Pressure Related Troubleshooting......1909
Troubleshooting Tree......1911
Temperature / Pressure Chart......1915
Poor A/C Performance......1916
HVAC Repair And Leaks......1917
Electrical System......1918
Engine Coolant Bypassing The Heater Valve......1925
Heater Valve Not Opening Or Closing......1926
SYSTEM CHARGING AND RECLAMATION......1928
Refrigerant Identification......1928
Reclamation And Charging With Recovery / Charging Unit......1929
Charging With A Manifold Gauge Set......1931
COMPRESSOR......1934
Removal And Installation......1934
Oil......1936
Oil Check......1936
Clutch Disassembly And Assembly......1938
CONDENSER......1942
Removal And Installation......1942
RECEIVER / DRIER......1944
Receiver / Drier Removal And Installation......1944
Pressure Relief Valve Removal And Installation......1945
Pressure Switch Removal And Installation......1946
Schraeder Valve Removal And Installation......1947
EVAPORATOR / HEATER UNIT......1948
Removal And Installation......1948
THERMOSTAT......1950
Description......1950
Removal And Installation......1951
EXPANSION VALVE......1952
Removal And Installation......1952
EVAPORATOR COIL......1954
Removal And Installation......1954
HEATER COIL......1956
Removal And Installation With A/C......1956
Removal And Installation Without A/C......1958
BLOWER FAN......1960
Removal And Installation......1960
Disassembly And Assembly......1961
Connector Identification......1963
HEATER VALVE......1964
Removal And Installation......1964
Disassembly And Assembly......1965
SPECIFICATIONS......1966
(S205) LOADER SPECIFICATIONS......1968
Machine Dimensions......1968
Performance......1969
Engine......1969
Drive System......1969
Controls......1970
Hydraulic System......1970
Electrical......1971
Capacities......1971
Tires......1971
TORQUE SPECIFICATIONS FOR BOLTS......1972
Torque For General SAE Bolts......1972
Torque For General Metric Bolts......1973
HYDRAULIC CONNECTION SPECIFICATIONS......1974
O-ring Face Seal Connection......1974
Straight Thread O-ring Fitting......1975
Tubelines And Hoses......1975
Flare Fitting......1976
Port Seal Fitting......1977
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS......1978
Specifications......1978
CONVERSIONS......1980
Decimal And Millimeter Equivalent Chart......1980
U.S. To Metric Conversion Chart......1980
SERVICE MANUAL REVISION......1982
Revision No: S205 - 1......1982
Revision No: S205 - 2......1984
Revision No: S205 - 3......1986
Revision No: S205 - 4......1988
Revision No: S205 - 5......1990
Revision No: S205 - 6......1992
Revision No: S205 - 7......1994
Revision No: S205 - 8......1996
Revision No: S205 - 9......1998
Revision No: S205 - 10......2000
Revision No: S205 - 11......2002
Revision No: S205 - 12......2004
Revision No: S205 - 13......2006
Revision No: S205 - 14......2008
6902839 (12-06) - S205 Turbo; S205 Turbo High Flow Operation & Maintenance Manual......2010
OPERATOR SAFETY WARNINGS......2012
CONTENTS......2014
FOREWORD......2016
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED......2018
REGULAR MAINTENANCE ITEMS......2018
MOTOR OIL......2018
SERIAL NUMBER LOCATIONS......2019
Loader Serial Number......2019
Engine Serial Number......2019
DELIVERY REPORT......2019
MACHINE IDENTIFICATION......2020
FEATURES, ACCESSORIES AND ATTACHMENTS......2021
Standard Items......2021
Options and Accessories......2021
Buckets Available......2022
Attachments......2022
SAFETY......2024
SAFETY INSTRUCTIONS......2026
Before Operation......2026
Safe Operation Is The Operator’s Responsibility......2027
Safe Operation Needs A Qualified Operator......2027
Fire Prevention......2028
MACHINE SIGNS (DECALS)......2029
OPERATING INSTRUCTIONS......2032
INSTRUMENT PANEL IDENTIFICATION......2034
Left Panel-Standard and Deluxe Instrument Panels......2034
Right Panel (Standard - With Key Switch)......2035
Right Panel (Deluxe - With Keyless Start)......2036
Option And Field Accessory Panels (If Equipped)......2038
Cab Light......2039
LIFT ARM BY-PASS CONTROL......2039
TRACTION LOCK OVERRIDE......2039
Operation......2039
ENGINE SPEED CONTROL......2040
PARKING BRAKE......2040
DRIVING AND STEERING THE LOADER......2041
Available Controls Configurations......2041
Operation (Standard and ACS)......2041
Operation (SJC in ‘H’ Control Pattern)......2042
Operation (SJC in ‘ISO’ Control Pattern)......2043
STOPPING THE BOBCAT LOADER......2044
Using The Steering Levers Or Joysticks......2044
SEAT BAR RESTRAINT SYSTEM......2044
Operation......2044
HYDRAULIC CONTROLS......2045
Standard Operation (Foot Pedal)......2045
Standard Controls (Also ACS in Foot Pedal Mode)......2045
Advanced Control System (ACS) in HAND Control Mode......2046
Selectable Joystick Control (SJC) - ‘H’ Control Pattern......2047
Selectable Joystick Control (SJC) - ‘ISO’ Control Pattern......2047
Quick Couplers......2048
Releasing Hydraulic Pressure (Loader and Attachment)......2048
Auxiliary Hydraulics Button - VARIABLE FLOW......2049
Auxiliary Hydraulics Button - MAXIMUM FLOW ONLY......2049
Auxiliary Hydraulics Button - DISENGAGE......2049
FRONT Auxiliary Hydraulics Operation - VARIABLE FLOW......2049
FRONT Auxiliary Hydraulics Operation - MAXIMUM FLOW......2049
FRONT Auxiliary Hydraulics Operation - CONTINUOUS FLOW......2050
REAR Auxiliary Hydraulics Operation (If Equipped)......2050
High-Flow Hydraulics Operation (If Equipped)......2050
Attachment Control Device (ACD) (If Equipped)......2051
Secondary Front Auxiliary Hydraulics (If Equipped)......2051
Bucket Position Valve Operation (If Equipped)......2052
DAILY INSPECTION......2053
Daily Inspection and Maintenance:......2053
PRE-STARTING PROCEDURE......2054
Before Starting The Engine......2054
STARTING THE ENGINE (STANDARD PANEL, KEY SWITCH)......2056
Procedure......2056
STARTING THE ENGINE (DELUXE PANEL, KEYLESS START)......2058
Procedure......2058
Cold Temperature Starting......2059
WARMING THE HYDRAULIC/HYDROSTATIC SYSTEM......2060
Procedure......2060
STOPPING THE ENGINE......2060
Procedure......2060
MONITORING THE DISPLAY PANEL......2061
Standard Panel......2061
Deluxe Panel......2061
WARNING and SHUTDOWN......2061
ATTACHMENTS AND BUCKETS......2062
Choosing The Correct Bucket......2062
Pallet Forks......2063
Hand Lever Bob-Tach - Installing The Bucket Or Attachment......2063
Hand Lever Bob-Tach - Removing The Bucket Or Attachment......2065
Power Bob-Tach - Installing The Bucket Or Attachment......2066
Power Bob-Tach - Removing The Bucket Or Attachment......2067
OPERATING PROCEDURE......2068
Operating With A Full Bucket......2068
Operating With An Empty Bucket......2068
Foot Pedal Machines......2069
Hand Control Machines (Includes ACS and SJC with H-Pattern Selected)......2071
Selectable Joystick Control (SJC) with ‘ISO’ Pattern Selected......2073
PARKING THE BOBCAT LOADER......2075
Procedure......2075
TOWING THE LOADER......2075
Towing Procedure......2075
TRANSPORTING THE BOBCAT LOADER......2076
Loading Onto Transport Vehicle......2076
Fastening To Transport Vehicle......2076
LIFTING THE LOADER......2077
Single Point Lift......2077
Four Point Lift......2077
PREVENTIVE MAINTENANCE......2078
MAINTENANCE SAFETY......2082
SERVICE SCHEDULE......2084
Chart......2084
LIFT ARM SUPPORT DEVICE......2085
Installing Lift Arm Support Device......2085
Removing Lift Arm Support Device......2086
HEATING AND AIR CONDITIONING......2087
Cleaning and Maintenance......2087
OPERATOR CAB......2088
Raising The Operator Cab......2088
Lowering The Operator Cab......2090
Cab Door Sensor......2090
Emergency Exit......2091
SEAT BELT......2092
Inspection and Maintenance......2092
SEAT BAR RESTRAINT SYSTEM......2093
Inspecting the Seat Bar......2093
Maintaining the Seat Bar......2093
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)......2094
Inspecting The BICS Controller (Engine Stopped - Key ON)......2094
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)......2094
Inspecting The Seat Bar Sensor (Engine RUNNING)......2094
Inspecting The Traction Lock (Engine RUNNING)......2094
Inspecting The Lift Arm By-Pass Control......2094
Inspecting Deactivation Of Lift And Tilt Functions (ACS)......2094
REAR DOOR......2095
Opening And Closing The Rear Door......2095
Adjusting The Rear Door......2095
REAR GRILL......2096
Removing......2096
Installing......2096
AIR CLEANER SERVICE......2097
Replacing Filter Element......2097
FUEL SYSTEM......2099
Fuel Specifications......2099
Filling the Fuel Tank......2099
Fuel Filter......2100
Removing Air From The Fuel System......2100
ENGINE LUBRICATION SYSTEM......2101
Checking Engine Oil......2101
Replacing Oil And Filter......2101
ENGINE COOLING SYSTEM......2102
Cleaning The Cooling System......2102
Checking The Coolant Level......2102
Replacing the Coolant......2103
ALTERNATOR BELT......2104
Adjusting The Alternator Belt......2104
ELECTRICAL SYSTEM......2105
Description......2105
Cleaning Battery Terminals......2105
Fuse Location......2105
Using A Booster Battery (Jump Starting)......2106
Removing And Installing The Battery......2108
HYDRAULIC/HYDROSTATIC SYSTEM......2109
Checking And Adding Fluid......2109
Replacing Hydraulic/Hydrostatic Filter......2109
Replacing Hydraulic Fluid And Case Drain Filters......2110
Breather Cap......2111
SPARK ARRESTOR MUFFLER......2112
TIRE MAINTENANCE......2113
Wheel Nuts......2113
Rotating......2113
Mounting......2113
FINAL DRIVE TRANSMISSION (CHAINCASE)......2114
Checking And Adding Oil......2114
Removing Oil From The Chaincase......2114
FAN GEARBOX......2115
Checking And Maintaining......2115
DRIVE BELT......2116
Adjusting The Drive Belt......2116
Replacing The Drive Belt......2116
LUBRICATION OF THE BOBCAT LOADER......2117
Lubrication Locations......2117
PIVOT PINS......2119
Inspection And Maintenance......2119
BOB-TACH (HAND LEVER)......2120
Inspection And Maintenance......2120
BOB-TACH (POWER - OPTION)......2121
Inspection And Maintenance......2121
SYSTEM SETUP & ANALYSIS......2122
BICS SYSTEM......2124
Troubleshooting Guide......2124
DIAGNOSTICS SERVICE CODES......2125
Display......2125
Number Codes List......2126
DELUXE INSTRUMENT PANEL SETUP......2130
Deluxe Panel Upgrade......2130
Deluxe Panel Setup......2131
Passwords (Deluxe)......2131
Viewing Service Codes......2133
SHUTDOWN FEATURE......2134
SERVICE CLOCK RESET......2134
MACHINE SIGN TRANSLATIONS......2136
SERVICE SCHEDULE (6734534)......2138
WARNING (6728539)......2139
OPERATING INSTRUCTIONS (6727926)......2140
WARNING (6725370)......2140
DANGER (6702301)......2141
WARNING (6577754)......2141
DANGER (6702302)......2141
WARNING (6579528)......2141
DANGER (6717343)......2142
WARNING (6718706)......2142
WARNING (6710358)......2143
IMPORTANT (6560573)......2143
LIFT ARM SUPPORT DEVICE (6719018)......2144
WARNING (6737189)......2145
IMPORTANT (6733996)......2145
SPECIFICATIONS......2146
LOADER SPECIFICATIONS (S205)......2150
Loader Dimensions......2150
Performance......2151
Engine......2151
Hydraulic System......2151
Electrical......2152
Drive System......2152
Capacities......2152
Controls......2153
ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS......2154
WARRANTY......2156
6987013 (11-10) - S205 Skid-Steer Loader Operation & Maintenance Manual......2158
OPERATOR SAFETY WARNINGS......2160
CONTENTS......2162
FOREWORD......2164
BOBCAT COMPANY IS IS0 9001 CERTIFIED......2166
REGULAR MAINTENANCE ITEMS......2166
SERIAL NUMBER LOCATIONS......2167
Loader Serial Number......2167
Engine Serial Number......2167
DELIVERY REPORT......2167
LOADER IDENTIFICATION......2168
FEATURES, ACCESSORIES AND ATTACHMENTS......2169
Standard Items......2169
Options And Accessories......2169
Buckets Available......2170
Attachments......2170
High-Flow Attachments......2170
Special Applications Kit......2171
Special Applications Kit Inspection And Maintenance......2171
SAFETY & TRAINING RESOURCES......2172
SAFETY INSTRUCTIONS......2174
Before Operation......2174
Safe Operation Is The Operator’s Responsibility......2175
Safe Operation Needs A Qualified Operator......2175
Avoid Silica Dust......2176
FIRE PREVENTION......2176
Maintenance......2176
Operation......2176
Electrical......2176
Hydraulic System......2177
Fueling......2177
Starting......2177
Spark Arrestor Exhaust System......2177
Welding And Grinding......2177
Fire Extinguishers......2177
MACHINE SIGNS (DECALS)......2179
PUBLICATIONS AND TRAINING RESOURCES......2181
OPERATING INSTRUCTIONS......2182
INSTRUMENT PANEL IDENTIFICATION......2186
Cab Light......2186
Left Panel......2187
Display Screen......2189
Standard Key Panel......2190
Keyless Start Panel......2190
Deluxe Instrumentation Panel......2191
Side Panel......2192
Front Panel......2192
CONTROL IDENTIFICATION......2193
Standard Controls......2193
Advanced Control System (ACS)......2194
Selectable Joystick Controls (SJC)......2195
SEAT BAR RESTRAINT SYSTEM......2196
Operation......2196
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)......2197
Operation......2197
LIFT ARM BYPASS CONTROL......2198
Operation......2198
PARKING BRAKE......2198
Operation......2198
TRACTION LOCK OVERRIDE......2198
Operation......2198
EMERGENCY EXIT......2199
Rear Window......2199
Front Door......2199
BACK-UP ALARM SYSTEM......2200
Description......2200
Operation......2200
ENGINE SPEED CONTROL......2201
Operation......2201
DRIVING AND STEERING THE LOADER......2202
Available Control Configurations......2202
Operation (Standard And ACS)......2202
Operation (SJC) In ‘ISO’ Control Pattern......2203
Operation (SJC) In ‘H’ Control Pattern......2204
STOPPING THE LOADER......2204
Using The Control Levers Or Joysticks......2204
TWO-SPEED CONTROL......2205
Description......2205
Operation (Standard And ACS) (If Equipped)......2205
Operation (SJC) (If Equipped)......2205
SPEED MANAGEMENT......2206
Operation......2206
Changing The Factory Default Setting......2207
DRIVE RESPONSE......2208
Description......2208
Operation......2208
STEERING DRIFT COMPENSATION......2210
Description......2210
Operation......2210
HYDRAULIC CONTROLS......2212
Description......2212
Standard Controls (Also ACS In FOOT Pedal Mode)......2212
Advanced Control System (ACS) In HAND Control Mode......2213
Selectable Joystick Controls (SJC) In ‘ISO’ Control Pattern......2213
Selectable Joystick Controls (SJC) In ‘H’ Control Pattern......2214
Hydraulic Bucket Positioning......2214
FRONT Auxiliary Hydraulics Operation......2215
FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)......2216
REAR Auxiliary Hydraulics Operation......2216
Secondary Front Auxiliary Hydraulics Operation......2217
High-Flow Hydraulics Operation......2218
Quick Couplers......2218
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)......2219
ATTACHMENT CONTROL DEVICE (ACD)......2220
Description......2220
DAILY INSPECTION......2221
Daily Inspection And Maintenance......2222
PRE-STARTING PROCEDURE......2223
Entering The Loader......2223
Operation & Maintenance Manual And Operator’s Handbook Locations......2223
Seat Adjustment......2224
Seat Belt Adjustment......2225
Seat Bar......2225
STARTING THE ENGINE......2226
Standard Key Panel......2226
Keyless Start Panel......2228
Deluxe Instrumentation Panel......2230
Cold Temperature Starting......2232
Warming The Hydraulic / Hydrostatic System......2233
MONITORING THE DISPLAY PANELS......2234
Left Panel......2234
Warning And Shutdown......2234
STOPPING THE ENGINE AND LEAVING THE LOADER......2235
Procedure......2235
COUNTERWEIGHTS......2236
Description......2236
Effect On The Loader And Loader Operation......2236
When To Consider Using Counterweights......2236
When To Consider Removing Counterweights......2236
Accessories That Affect Machine Weight......2236
ATTACHMENTS......2237
Choosing The Correct Bucket......2237
Pallet Forks......2237
Installing And Removing The Attachment (Hand Lever Bob-Tach)......2238
Installing And Removing The Attachment (Power Bob-Tach)......2240
OPERATING PROCEDURE......2243
Inspect The Work Area......2243
Basic Operating Instructions......2243
Driving On Public Roads......2243
Operating With A Full Bucket......2244
Operating With An Empty Bucket......2244
Filling And Emptying The Bucket (Foot Pedals)......2245
Leveling The Ground Using Float (Foot Pedals)......2246
Digging And Filling A Hole (Foot Pedals)......2246
Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)......2247
Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)......2248
Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)......2249
Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)......2250
Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)......2251
Digging And Filling A Hole (SJC - ‘ISO’ Pattern)......2251
TOWING THE LOADER......2252
Procedure......2252
LIFTING THE LOADER......2253
Single-Point Lift......2253
Four-Point Lift......2253
TRANSPORTING THE LOADER ON A TRAILER......2254
Loading And Unloading......2254
Fastening......2254
PREVENTIVE MAINTENANCE......2256
MAINTENANCE SAFETY......2260
SERVICE SCHEDULE......2262
Chart......2262
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)......2263
Inspecting The BICS (Engine STOPPED - Key ON)......2263
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)......2263
Inspecting The Seat Bar Sensor (Engine RUNNING)......2263
Inspecting The Traction Lock (Engine RUNNING)......2263
Inspecting The Lift Arm Bypass Control......2263
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)......2263
SEAT BAR RESTRAINT SYSTEM......2264
Description......2264
Inspecting......2264
Maintaining......2264
SEAT BELT......2265
Inspection And Maintenance......2265
LIFT ARM SUPPORT DEVICE......2266
Installing......2266
Removing......2267
BACK-UP ALARM SYSTEM......2268
Description......2268
Inspecting......2268
Adjusting Switch Position......2268
OPERATOR CAB......2269
Description......2269
Raising......2269
Lowering......2270
Cab Door Sensor......2271
REAR DOOR (TAILGATE)......2272
Opening And Closing......2272
Adjusting......2272
REAR GRILLE......2272
Removing......2272
Installing......2272
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)......2273
Cleaning And Maintenance......2273
Filters......2273
Evaporator / Heater Coil......2273
Condenser......2273
Air Conditioning Lubrication......2273
Troubleshooting......2273
AIR CLEANER SERVICE......2274
Replacing Filter Elements......2274
FUEL SYSTEM......2276
Fuel Specifications......2276
Biodiesel Blend Fuel......2276
Filling The Fuel Tank......2277
Fuel Filter......2278
Removing Air From The Fuel System......2278
ENGINE LUBRICATION SYSTEM......2279
Checking And Adding Engine Oil......2279
Engine Oil Chart......2279
Removing And Replacing Oil And Filter......2279
ENGINE COOLING SYSTEM......2280
Cleaning......2280
Removing And Replacing Coolant......2281
Checking Level......2281
ELECTRICAL SYSTEM......2282
Description......2282
Fuse And Relay Location / Identification......2282
Battery Maintenance......2283
Using A Booster Battery (Jump Starting)......2284
Removing And Installing Battery......2285
HYDRAULIC / HYDROSTATIC SYSTEM......2286
Checking And Adding Fluid......2286
Hydraulic / Hydrostatic Fluid Chart......2286
Removing And Replacing Hydraulic Fluid......2287
Removing And Replacing Hydraulic / Hydrostatic Filter......2287
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)......2288
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)......2289
Removing And Replacing Hydraulic Charge Filter......2291
Breather Cap......2292
SPARK ARRESTER MUFFLER......2293
Cleaning Procedure......2293
TIRE MAINTENANCE......2294
Wheel Nuts......2294
Rotating......2294
Mounting......2294
FINAL DRIVE TRANSMISSION (CHAINCASE)......2295
Checking And Adding Oil......2295
Removing And Replacing Oil......2295
ALTERNATOR BELT......2296
Belt Adjustment......2296
Belt Replacement......2296
AIR CONDITIONING BELT......2297
Belt Adjustment......2297
Belt Replacement......2297
DRIVE BELT......2298
Belt Adjustment......2298
Belt Replacement......2300
LUBRICATING THE LOADER......2301
Lubrication Locations......2301
PIVOT PINS......2303
Inspection And Maintenance......2303
BOB-TACH (HAND LEVER)......2304
Inspection And Maintenance......2304
BOB-TACH (POWER)......2305
Inspection And Maintenance......2305
LOADER STORAGE AND RETURN TO SERVICE......2306
Storage......2306
Return To Service......2306
SYSTEM SETUP & ANALYSIS......2308
DIAGNOSTIC SERVICE CODES......2310
Viewing Service Codes......2310
Service Codes List......2311
CONTROL PANEL SETUP......2316
Right Panel Setup (Deluxe Instrumentation Panel)......2316
Attachment Control Information (Deluxe Instrumentation Panel)......2317
PASSWORD SETUP (KEYLESS START PANEL)......2318
Password Description......2318
Changing The Owner Password......2318
Password Lockout Feature......2318
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)......2319
Password Description......2319
Changing The Owner Password......2319
Changing The User Passwords......2320
Password Lockout Feature......2320
MAINTENANCE CLOCK......2321
Description......2321
Setup......2321
Reset......2321
MACHINE SIGN TRANSLATIONS......2322
SERVICE SCHEDULE (6734534)......2324
DANGER (6702301)......2327
WARNING (6577754)......2327
DANGER (6702302)......2327
DANGER (6717343)......2327
IMPORTANT (6560573)......2328
WARNING (7160879)......2328
WARNING (6728539)......2329
WARNING (6718706)......2330
WARNING (6710358)......2330
DANGER (6809511)......2330
WARNING (6725370)......2331
WARNING (6737189)......2331
WARNING (6737248)......2331
LIFT ARM SUPPORT DEVICE (6719018)......2332
WARNING (7131518)......2333
WARNING (7131519)......2335
WARNING (6704786)......2337
WARNING (6579528)......2337
SPECIFICATIONS......2338
(S205) LOADER SPECIFICATIONS......2340
Machine Dimensions......2340
Performance......2341
Engine......2341
Drive System......2341
Controls......2342
Hydraulic System......2342
Electrical......2343
Capacities......2343
Tires......2343
WARRANTY......2344
WARRANTY......2346
ALPHABETICAL INDEX......2348
6902839 (5-12) - S205 Turbo; S205 Turbo High Flow Operation & Maintenance Manual......2352
OPERATOR SAFETY WARNINGS......2354
CONTENTS......2356
FOREWORD......2358
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED......2360
REGULAR MAINTENANCE ITEMS......2360
MOTOR OIL......2360
SERIAL NUMBER LOCATIONS......2361
Loader Serial Number......2361
Engine Serial Number......2361
DELIVERY REPORT......2361
MACHINE IDENTIFICATION......2362
FEATURES, ACCESSORIES AND ATTACHMENTS......2363
Standard Items......2363
Options and Accessories......2363
Buckets Available......2364
Attachments......2364
SAFETY......2366
SAFETY INSTRUCTIONS......2368
Before Operation......2368
Safe Operation Is The Operator’s Responsibility......2369
Safe Operation Needs A Qualified Operator......2369
Fire Prevention......2370
MACHINE SIGNS (DECALS)......2371
OPERATING INSTRUCTIONS......2374
INSTRUMENT PANEL IDENTIFICATION......2376
Left Panel-Standard and Deluxe Instrument Panels......2376
Right Panel (Standard - With Key Switch)......2377
Right Panel (Deluxe - With Keyless Start)......2378
Option And Field Accessory Panels (If Equipped)......2380
Cab Light......2381
LIFT ARM BY-PASS CONTROL......2381
TRACTION LOCK OVERRIDE......2381
Operation......2381
ENGINE SPEED CONTROL......2382
PARKING BRAKE......2382
DRIVING AND STEERING THE LOADER......2383
Available Controls Configurations......2383
Operation (Standard and ACS)......2383
Operation (SJC in ‘H’ Control Pattern)......2384
Operation (SJC in ‘ISO’ Control Pattern)......2385
STOPPING THE BOBCAT LOADER......2386
Using The Steering Levers Or Joysticks......2386
SEAT BAR RESTRAINT SYSTEM......2386
Operation......2386
HYDRAULIC CONTROLS......2387
Standard Operation (Foot Pedal)......2387
Standard Controls (Also ACS in Foot Pedal Mode)......2387
Advanced Control System (ACS) in HAND Control Mode......2388
Selectable Joystick Control (SJC) - ‘H’ Control Pattern......2389
Selectable Joystick Control (SJC) - ‘ISO’ Control Pattern......2389
Quick Couplers......2390
Releasing Hydraulic Pressure (Loader and Attachment)......2390
Auxiliary Hydraulics Button - VARIABLE FLOW......2391
Auxiliary Hydraulics Button - MAXIMUM FLOW ONLY......2391
Auxiliary Hydraulics Button - DISENGAGE......2391
FRONT Auxiliary Hydraulics Operation - VARIABLE FLOW......2391
FRONT Auxiliary Hydraulics Operation - MAXIMUM FLOW......2391
FRONT Auxiliary Hydraulics Operation - CONTINUOUS FLOW......2392
REAR Auxiliary Hydraulics Operation (If Equipped)......2392
High-Flow Hydraulics Operation (If Equipped)......2392
Attachment Control Device (ACD) (If Equipped)......2393
Secondary Front Auxiliary Hydraulics (If Equipped)......2393
Bucket Position Valve Operation (If Equipped)......2394
DAILY INSPECTION......2395
Daily Inspection and Maintenance:......2395
PRE-STARTING PROCEDURE......2396
Before Starting The Engine......2396
STARTING THE ENGINE (STANDARD PANEL, KEY SWITCH)......2398
Procedure......2398
STARTING THE ENGINE (DELUXE PANEL, KEYLESS START)......2400
Procedure......2400
Cold Temperature Starting......2401
WARMING THE HYDRAULIC/HYDROSTATIC SYSTEM......2402
Procedure......2402
STOPPING THE ENGINE......2402
Procedure......2402
MONITORING THE DISPLAY PANEL......2403
Standard Panel......2403
Deluxe Panel......2403
WARNING and SHUTDOWN......2403
ATTACHMENTS AND BUCKETS......2404
Choosing The Correct Bucket......2404
Pallet Forks......2405
Hand Lever Bob-Tach - Installing The Bucket Or Attachment......2405
Hand Lever Bob-Tach - Removing The Bucket Or Attachment......2407
Power Bob-Tach - Installing The Bucket Or Attachment......2408
Power Bob-Tach - Removing The Bucket Or Attachment......2409
OPERATING PROCEDURE......2410
Operating With A Full Bucket......2410
Operating With An Empty Bucket......2410
Foot Pedal Machines......2411
Hand Control Machines (Includes ACS and SJC with H-Pattern Selected)......2413
Selectable Joystick Control (SJC) with ‘ISO’ Pattern Selected......2415
PARKING THE BOBCAT LOADER......2417
Procedure......2417
TOWING THE LOADER......2417
Towing Procedure......2417
TRANSPORTING THE BOBCAT LOADER......2418
Loading Onto Transport Vehicle......2418
Fastening To Transport Vehicle......2418
LIFTING THE LOADER......2419
Single Point Lift......2419
Four Point Lift......2419
PREVENTIVE MAINTENANCE......2420
MAINTENANCE SAFETY......2424
SERVICE SCHEDULE......2426
Chart......2426
LIFT ARM SUPPORT DEVICE......2427
Installing Lift Arm Support Device......2427
Removing Lift Arm Support Device......2428
HEATING AND AIR CONDITIONING......2429
Cleaning and Maintenance......2429
OPERATOR CAB......2430
Raising The Operator Cab......2430
Lowering The Operator Cab......2432
Cab Door Sensor......2432
Emergency Exit......2433
SEAT BELT......2434
Inspection and Maintenance......2434
SEAT BAR RESTRAINT SYSTEM......2435
Inspecting the Seat Bar......2435
Maintaining the Seat Bar......2435
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)......2436
Inspecting The BICS Controller (Engine Stopped - Key ON)......2436
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)......2436
Inspecting The Seat Bar Sensor (Engine RUNNING)......2436
Inspecting The Traction Lock (Engine RUNNING)......2436
Inspecting The Lift Arm By-Pass Control......2436
Inspecting Deactivation Of Lift And Tilt Functions (ACS)......2436
REAR DOOR......2437
Opening And Closing The Rear Door......2437
Adjusting The Rear Door......2437
REAR GRILL......2438
Removing......2438
Installing......2438
AIR CLEANER SERVICE......2439
Replacing Filter Element......2439
FUEL SYSTEM......2441
Fuel Specifications......2441
Filling the Fuel Tank......2441
Fuel Filter......2442
Removing Air From The Fuel System......2442
ENGINE LUBRICATION SYSTEM......2443
Checking Engine Oil......2443
Replacing Oil And Filter......2443
ENGINE COOLING SYSTEM......2444
Cleaning The Cooling System......2444
Checking The Coolant Level......2444
Replacing the Coolant......2445
ALTERNATOR BELT......2446
Adjusting The Alternator Belt......2446
ELECTRICAL SYSTEM......2447
Description......2447
Cleaning Battery Terminals......2447
Fuse Location......2447
Using A Booster Battery (Jump Starting)......2448
Removing And Installing The Battery......2450
HYDRAULIC/HYDROSTATIC SYSTEM......2451
Checking And Adding Fluid......2451
Replacing Hydraulic/Hydrostatic Filter......2451
Replacing Hydraulic Fluid And Case Drain Filters......2452
Breather Cap......2453
SPARK ARRESTOR MUFFLER......2454
TIRE MAINTENANCE......2455
Wheel Nuts......2455
Rotating......2455
Mounting......2455
FINAL DRIVE TRANSMISSION (CHAINCASE)......2456
Checking And Adding Oil......2456
Removing Oil From The Chaincase......2456
FAN GEARBOX......2457
Checking And Maintaining......2457
DRIVE BELT......2458
Adjusting The Drive Belt......2458
Replacing The Drive Belt......2458
LUBRICATION OF THE BOBCAT LOADER......2459
Lubrication Locations......2459
PIVOT PINS......2461
Inspection And Maintenance......2461
BOB-TACH (HAND LEVER)......2462
Inspection And Maintenance......2462
BOB-TACH (POWER - OPTION)......2463
Inspection And Maintenance......2463
SYSTEM SETUP & ANALYSIS......2464
BICS SYSTEM......2466
Troubleshooting Guide......2466
DIAGNOSTICS SERVICE CODES......2467
Display......2467
Number Codes List......2468
DELUXE INSTRUMENT PANEL SETUP......2472
Deluxe Panel Upgrade......2472
Deluxe Panel Setup......2473
Passwords (Deluxe)......2473
Viewing Service Codes......2475
SHUTDOWN FEATURE......2476
SERVICE CLOCK RESET......2476
MACHINE SIGN TRANSLATIONS......2478
SERVICE SCHEDULE (6734534)......2480
WARNING (6728539)......2481
OPERATING INSTRUCTIONS (6727926)......2482
WARNING (6725370)......2482
DANGER (6702301)......2483
WARNING (6577754)......2483
DANGER (6702302)......2483
WARNING (6579528)......2483
DANGER (6717343)......2484
WARNING (6718706)......2484
WARNING (6710358)......2485
IMPORTANT (6560573)......2485
LIFT ARM SUPPORT DEVICE (6719018)......2486
WARNING (6737189)......2487
IMPORTANT (6733996)......2487
SPECIFICATIONS......2488
LOADER SPECIFICATIONS (S205)......2492
Loader Dimensions......2492
Performance......2493
Engine......2493
Hydraulic System......2493
Electrical......2494
Drive System......2494
Capacities......2494
Controls......2495
ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS......2496
WARRANTY......2498
6902917 (7-09) - S205 Turbo; S205 Turbo High Flow Service Manual......2500
MAINTENANCE SAFETY......2501
ALPHABETICAL INDEX......2503
CONTENTS......2505
FOREWORD......2506
SAFETY INSTRUCTIONS......2509
FIRE PREVENTION......2511
Maintenance......2511
Operation......2511
Electrical......2511
Hydraulic System......2511
Fueling......2511
Starting......2511
Spark Arrestor Exhaust System......2511
Welding And Grinding......2512
Fire Extinguishers......2512
SERIAL NUMBER LOCATION......2514
Loader Serial Number......2514
Engine Serial Number......2514
DELIVERY REPORT......2515
BOBCAT LOADER IDENTIFICATION......2516
SAFETY AND MAINTENANCE......2517
LIFTING AND BLOCKING THE LOADER......2519
Procedure......2519
LIFT ARM SUPPORT DEVICE......2521
Installing Lift Arm Support Device......2521
Removing Lift Arm Support Device......2522
OPERATOR CAB......2523
Description......2523
Raising The Operator Cab......2523
Lowering The Operator Cab......2524
Emergency Exit......2525
TRANSPORTING THE BOBCAT LOADER......2527
Procedure......2527
TOWING THE LOADER......2529
Procedure......2529
REMOTE START......2531
Procedure......2531
SERVICE SCHEDULE......2535
Chart......2535
AIR CLEANER SERVICE......2537
Checking......2537
Replacing Filter Element(s)......2537
ENGINE COOLING SYSTEM......2539
Cleaning The Cooling System......2539
Checking The Coolant Level......2540
Replacing the Coolant......2540
FUEL SYSTEM......2543
Fuel Specifications......2543
Filling The Fuel Tank......2543
Fuel Filter......2544
Removing Air From The Fuel System......2544
ENGINE LUBRICATION SYSTEM......2545
Checking Engine Oil......2545
Oil Chart......2545
Replacing Oil And Filter......2546
HYDRAULIC/HYDROSTATIC SYSTEM......2547
Checking And Adding Fluid......2547
Replacing Hydraulic/Hydrostatic Filter......2547
Replacing Hydraulic Fluid......2547
Breather Cap......2549
FINAL DRIVE TRANSMISSION (CHAINCASE)......2551
Checking And Adding Oil......2551
Removing Oil From The Chaincase......2551
FAN GEARBOX......2553
Checking And Maintaining......2553
BOB-TACH......2555
Inspection And Maintenance......2555
POWER BOB-TACH (OPTION)......2557
Inspection And Maintenance......2557
LUBRICATION OF THE BOBCAT LOADER......2559
Procedure......2559
TIRE MAINTENANCE......2563
Wheel Nuts......2563
Rotating......2563
Mounting......2563
SPARK ARRESTOR MUFFLER......2565
Cleaning Procedure......2565
HYDRAULIC SYSTEM......2567
HYDRAULIC/HYDROSTATIC SCHEMATICS......2573
HYDROSTATIC SYSTEM......2785
HYDROSTATIC SYSTEM INFORMATION......2787
Troubleshooting Chart......2787
Replenishing Valve Function......2788
HYDROSTATIC MOTOR......2789
Description......2789
Removal And Installation......2789
Parts Identification (Wet Bolt)......2791
Disassembly (Wet Bolt)......2792
Assembly (Wet Bolt)......2797
Parts Identification (Dry Bolt)......2803
Disassembly and Assembly (Dry Bolt)......2804
HYDROSTATIC MOTOR CARRIER......2809
Shaft Seal Replacement......2809
Removal And Installation......2811
Parts Identification......2813
Disassembly and Assembly......2814
HYDROSTATIC MOTOR CARRIER (SJC)......2819
Shaft Seal Replacement......2819
Removal And Installation......2821
Parts Identification......2823
Disassembly and Assembly......2824
CHARGE PRESSURE......2829
Sender Removal And Installation (Non SJC Machines)......2829
Testing (Non SJC Machines)......2829
Adjusting (Non SJC Machines)......2830
Sender Removal And Installation (SJC Machines)......2831
Testing (SJC Machines)......2831
Adjusting (SJC Machines)......2832
HYDROSTATIC PUMP......2833
Replenishing/High Pressure Relief Valve......2833
Removal And Installation......2834
Parts Identification (Right Half)......2836
Parts Identification (Left Half)......2838
Hydraulic Pump Removal And Installation......2840
Pump Separation......2840
Disassembly......2841
Assembly......2847
HYDROSTATIC PUMP (SJC)......2855
Description......2855
Hydraulic Controller Removal And Installation......2856
Removal And Installation......2858
Parts Identification......2860
High Pressure Relief and Bypass Valve......2861
Charge Relief Valve......2862
Disassembly and Assembly......2863
Mechanical Neutral Adjustment......2879
Hydraulic Controller Neutral Adjustment......2882
DRIVE BELT......2885
Shield Removal And Installation......2885
Adjusting......2885
Drive Belt Replacement......2887
Tensioner Pulley Removal And Installation......2888
Tensioner Pulley Parts Identification......2889
Tensioner Pulley Disassembly......2890
Tensioner Pulley Assembly......2891
OIL COOLER......2893
Removal and Installation......2893
HYDRAULIC SYSTEM INFORMATION......2581
Troubleshooting Chart......2585
CYLINDER (LIFT)......2587
Checking......2587
Removal And Installation......2588
Identification......2591
Disassembly......2592
Assembly......2593
CYLINDER (TILT)......2597
Checking......2597
Removal And Installation......2598
Base End Pivot Pin Replacement......2599
Rod End Pivot Pin Bushing And Seal Replacement......2600
Parts Identification......2601
Disassembly......2602
Assembly......2603
CYLINDER (POWER BOB-TACH)......2607
Checking......2607
Removal And Installation......2608
Identification......2609
Disassembly......2610
Assembly......2611
MAIN RELIEF VALVE......2615
Checking......2615
Adjustment......2616
Removal and Installation......2617
HYDRAULIC CONTROL VALVE (FOOT CONTROL)......2619
Identification......2619
Removal And Installation......2619
Identification Chart......2624
Mount Bracket Removal and Installation......2625
BICS Valve, Lift Load Check Valve Removal And Installation......2625
Load Check Valve Removal And Installation (Tilt & Auxiliary)......2626
Anti-Cavitation Valve (Lift, Rod End)......2627
Port Relief/Anti-Cavitation Valve (Lift, Base End)......2628
Port Relief/Anti-Cavitation Valve (Tilt, Base End)......2628
Port Relief/Anti-Cavitation Valve (Tilt, Rod End)......2629
Port Relief Valve......2629
Plug Removal......2630
Rubber Boot Removal and Installation......2631
End Cap/Spool Lock Block Removal and Installation......2632
Lift Spool and Detent Removal and Installation......2633
Tilt Spool Removal and Installation......2642
Auxiliary Spool Removal And Installation......2644
Auxiliary Solenoid Disassembly and Assembly......2646
BICS Valve Solenoid Disassembly And Assembly......2647
BICS Valve, Lock Valve Removal And Installation......2648
BICS Valve, Check Valve Removal And Installation......2650
BICS Valve, Lift Arm Bypass Orifice Disassembly And Assembly......2651
Main Relief Valve......2651
HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)......2653
Identification......2653
Removal And Installation......2653
Actuator Removal And Installation (Out of Loader)......2658
Identification Chart (ACS)......2661
Mount Bracket Removal and Installation......2662
BICS Valve, Lift Load Check Valve Removal And Installation......2662
Load Check Valve Removal And Installation (Tilt & Auxiliary)......2663
Anti-Cavitation Valve (Lift, Rod End)......2664
Port Relief/Anti-Cavitation Valve (Lift, Base End)......2665
Port Relief/Anti-Cavitation Valve (Tilt, Base End)......2665
Port Relief/Anti-Cavitation Valve (Tilt, Rod End)......2666
Port Relief Valve......2666
Plug Removal......2667
End Cap Block Removal and Installation......2668
Lift Spool Removal and Installation......2669
Tilt Spool Removal and Installation......2673
Auxiliary Spool Removal And Installation......2675
Auxiliary Solenoid Disassembly and Assembly......2676
BICS Valve Solenoid Disassembly And Assembly......2677
BICS Valve, Lock Valve Removal And Installation......2678
BICS Valve, Check Valve Removal And Installation......2680
BICS Valve, Lift Arm Bypass Orifice Disassembly And Assembly......2681
Main Relief Valve......2681
LIFT ARM BYPASS CONTROL VALVE......2683
Removal and Installation......2683
Disassembly And Assembly......2684
HYDRAULIC PUMP......2685
Check The Output Of The Hydraulic Pump Without Rear Auxiliary.....2685
Check The Output Of The Hydraulic Pump With Rear Auxiliary.....2687
Removal And Installation......2689
Identification......2691
Disassembly And Assembly......2692
HYDRAULIC PUMP (HIGH FLOW)......2697
Check The Output Of The Hydraulic Pump Without Rear Auxiliary.....2697
Check The Output Of The Hydraulic Pump With Rear Auxiliary.....2699
Removal And Installation......2701
Identification......2703
Disassembly And Assembly......2704
HYDRAULIC PUMP (SJC)......2713
Test The Output Of The Hydraulic Auxiliary Pump......2713
Test The Output Of The Hydraulic Charge Pump......2714
Removal And Installation......2716
Identification......2718
Disassembly And Assembly......2719
HYDRAULIC PUMP (HIGH FLOW) (SJC)......2727
Test The Output Of The Hydraulic Auxiliary Pump......2727
Test The Output Of The Hydraulic Charge Pump......2728
Test The Output Of The Hydraulic Pump (High Flow)......2730
Removal And Installation......2732
Identification......2734
Disassembly And Assembly......2735
HYDRAULIC/HYDROSTATIC FILTER HOUSING......2747
Removal And Installation......2747
HYDRAULIC FLUID RESERVOIR......2749
Fluid Removal......2749
Removal And Installation......2749
BUCKET POSITION VALVE......2753
Solenoid Removal And Installation......2753
Solenoid Testing......2754
Removal And Installation......2755
Disassembly And Assembly......2757
HIGH FLOW VALVE......2759
Checking The High Flow Relief Valve......2759
High Flow Relief Valve Adjustment Procedure......2761
Removal And Installation......2762
Disassembly And Assembly......2764
Solenoid Testing......2766
REAR AUXILIARY DIVERTER VALVE......2767
Removal And Installation......2767
Disassembly And Assembly......2770
Solenoid Testing......2775
Inspection......2775
POWER BOB-TACH BLOCK......2777
Removal And Installation......2777
Disassembly And Assembly......2779
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK......2783
Removal and Installation......2783
Disassembly And Assembly......2783
DRIVE SYSTEM......2895
BRAKE......2897
Disk Removal And Installation......2897
Switch Operated Parking Brake......2898
DRIVE COMPONENTS......2899
Axle Seal Removal And Installation......2899
Axle Sprocket And Bearings Removal And Installation......2901
Chain Removal And Installation......2906
CHAINCASE......2909
Checking And Adding Oil......2909
Removing The Oil......2909
General Information......2910
Front Cover Removal And Installation......2910
Center Cover Removal And Installation......2911
Rear Cover Removal And Installation......2912
MAIN FRAME......2913
SEAT BAR......2915
Removal And Installation......2915
Assembling Components......2916
Compression Spring Disassembly And Assembly......2918
OPERATOR CAB......2919
Gas Cylinder Removal And Installation......2919
Gas Cylinder Disassembly......2922
Removal And Installation......2922
OPERATOR SEAT......2925
Removal And Installation......2925
Seat Belt Removal And Installation......2925
OPERATOR SEAT (SUSPENSION)......2927
Removal And Installation......2927
Slide Rail Removal And Installation......2928
Cushion Removal And Installation......2928
Back Removal And Installation......2930
Shock Removal And Installation......2930
3-Point Seat Belt Removal And Installation......2931
BOB-TACH......2933
Removal And Installation......2933
Bob-Tach Lever And Wedge......2934
POWER BOB-TACH......2937
Removal And Installation......2937
Power Bob-Tach Lever And Wedge......2938
LIFT ARM......2941
Removal And Installation......2941
Link Removal And Installation......2945
Stabilizer Bar Removal And Installation......2946
REAR GRILL......2947
Removal And Installation......2947
REAR DOOR......2949
Removal And Installation......2949
Striker Removal and Installation......2950
Striker Disassembly and Assembly......2950
Adjusting The Striker......2950
Latch Removal and Installation......2951
FUEL TANK......2953
Removal And Installation......2953
Fuel Level Sender......2954
Fuel Fill Screen......2954
CONTROL PEDALS......2957
Removal And Installation......2957
Pedal Adjustment......2957
Crossbar Linkage Removal and Installation......2957
Lift Foot Pedal Linkage Removal and Installation......2959
Tilt Foot Pedal Linkage Removal and Installation......2959
CONTROL PEDALS (ACS)......2961
Foot Sensor Removal And Installation......2961
Foot Pedal Removal And Installation......2962
Foot Pedal Linkage Disassembly And Assembly......2963
CONTROL PANEL......2965
Description......2965
Removal and Installation......2966
Shock Removal And Installation......2969
Shaft Removal And Installation......2969
Shaft Disassembly And Assembly......2970
Linkage Removal And Installation......2971
Pintle Arm Disassembly and Assembly......2975
Linkage Neutral Adjustment......2977
Linkage Travel Adjustment......2981
CONTROL PANEL (SJC)......2985
Removal And Installation......2985
CONTROL HANDLE......2987
Control Lever Removal And Installation......2987
Control Lever Boot......2987
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS)......2989
Components Identification......2989
Handle Sensor Removal And Installation......2990
Control Handle Removal and Installation......2992
Control Handle Disassembly and Assembly......2993
Control Lever Removal and Installation......2994
Control Lever Boot......2995
CONTROL HANDLE (SJC)......2997
Joystick Testing (Right & Left)......2997
Joystick Removal (Right & Left)......2998
Lever Assembly Removal (Right & Left)......2999
ELECTRICAL SYSTEM......3001
ELECTRICAL SCHEMATICS......3005
ELECTRICAL SYSTEM INFORMATION......3012
Troubleshooting Chart......3014
Description......3015
Fuse Location......3016
Relay Switch Location......3016
BATTERY......3018
Removal And Installation......3018
Servicing......3019
Using A Booster Battery (Jump Starting)......3020
ALTERNATOR......3022
Adjusting The Alternator Belt......3022
Alternator Identification......3022
Charging System Check......3023
Alternator Voltage Test......3024
Low Voltage Test......3025
High Voltage Test......3025
Removal And Installation......3025
Rectifier Continuity (Diode) Test......3026
Alternator Regulator Test......3027
Disassembly......3028
Stator Continuity Test......3029
Stator Ground Test......3029
Rotor Continuity Test......3029
Rotor Ground Test......3029
Assembly......3030
STARTER......3032
Checking......3032
Removal And Installation......3033
Parts Identification......3034
Disassembly and Assembly......3035
Inspection And Repair......3038
No Load Test......3040
INSTRUMENT PANEL......3042
Left Panel......3042
Right Panel (Standard) (With Key Switch)......3043
Right Panel (Deluxe) (With Keyless Start)......3044
Right Panel Setup Display Options (Deluxe)......3046
Deluxe Panel Setup......3047
Passwords (Deluxe)......3047
Option And Field Accessory Panels (If Equipped)......3049
Standard Panel Removal And Installation (Right Side)......3050
Deluxe Panel Removal And Installation (Right Side)......3051
Standard & Deluxe Panel Removal And Installation (Left Side)......3052
Front Accessory Panel Removal And Installation......3053
LIGHTS......3054
Front Removal And Installation......3054
Rear Removal And Installation......3055
BOBCAT CONTROLLER......3056
Identification Chart......3056
Removal And Installation......3058
CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC)......3060
Removal and Installation......3060
Identification Chart......3063
DIAGNOSTICS SERVICE CODES......3066
Display......3066
Number Codes List......3067
BICS SYSTEM......3074
Inspecting The BICS Controller (Engine STOPPED - Key ON)......3074
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)......3074
Inspecting The Seat Bar Sensor (Engine RUNNING)......3074
Inspecting The Traction Lock (Engine RUNNING)......3074
Inspecting The Lift Arm Bypass Control......3074
Additional Inspection For Loaders With Advanced Hand Controls (ACS)......3075
Troubleshooting Chart......3076
Troubleshooting Guide......3077
SEAT BAR SENSOR......3078
Troubleshooting Chart......3078
Test......3079
Removal And Installation......3080
BICS Circuit Test......3082
TRACTION LOCK......3084
Troubleshooting Chart......3084
Description Of The Control System......3085
Inspecting The Control System......3085
Inspecting......3086
Solenoid Removal And Installation......3086
Guide Removal......3088
Guide Installation......3090
ADVANCED CONTROL SYSTEM (ACS)......3092
Components Identification......3092
Troubleshooting Guide......3094
Controller, Connector And Wire Identification......3095
ACS Controller Removal And Installation......3096
Handle Sensor Connector......3097
Switch Handle Removal......3098
Switch Handle Installation......3100
Actuators Disassembly and Assembly......3103
Handle Lock Solenoid Removal And Installation......3105
Handle Lock Solenoid Disassembly And Assembly......3105
Handle Lock Solenoid Connector......3106
Calibration Procedure......3107
Foot Sensor Disassembly And Assembly......3109
Foot Sensor Connector......3109
Foot Lock Solenoid Removal And Installation......3110
Foot Lock Solenoid Connector......3111
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE......3112
Controls Identification Chart......3112
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SLECTABLE JOYSTICK CONTROL) (SJC)......3114
Controls Identification Chart......3114
FLYWHEEL RPM SENSOR......3118
Adjustment......3118
SERVICE PC (LAPTOP COMPUTER)......3120
Connecting The Service PC To Remote Start Tool......3120
CALIBRATION......3122
Description......3122
Actuator Testing......3122
Lift and Tilt Calibration Procedure (SJC)......3125
Hydrostatic Pump Calibration (SJC)......3126
Calibration Procedure (ACS)......3132
SPEED SENSOR......3134
Description......3134
Testing......3134
Removal and Installation......3136
ENGINE SERVICE......3138
TROUBLESHOOTING......3140
Chart......3140
ENGINE SPEED CONTROL......3142
Removal And Installation......3142
Disassembly......3143
MUFFLER......3144
Removal And Installation......3144
AIR CLEANER......3146
Removal And Installation......3146
RADIATOR......3148
Removal And Installation......3148
COOLING FAN......3152
Drive Tension Pulley Removal And Installation......3152
Gearbox/Blower Housing Removal And Installation......3153
Blower Housing Grill Removal And Installation......3155
Blower Disassembly And Assembly......3155
Gearbox Parts Identification......3157
Gearbox Disassembly......3158
Gearbox Assembly......3163
Gearbox Checking Backlash......3168
ENGINE COMPONENTS AND TESTING......3172
Compression Checking......3172
Glow Plugs Checking......3173
Glow Plugs Removal And Installation......3173
Fuel Shut-Off Solenoid, Checking......3174
Fuel Shut-Off Solenoid Removal And Installation......3175
Fuel Injection Pump Removal And Installation......3176
Timing The Injection Pump......3179
Fuel Injector Removal And Installation......3181
Checking Nozzle Injection Pressure......3182
Nozzle Spraying Condition......3183
Valve Seat Tightness......3183
Valve Clearance Adjustment......3184
Valve Timing, Checking......3185
ENGINE......3186
Removal And Installation......3186
Engine Mount Replacement......3194
FLYWHEEL AND HOUSING......3196
Flywheel Removal And Installation......3196
Ring Gear Removal And Installation......3196
Housing Removal And Installation......3197
RECONDITIONING THE ENGINE......3200
Cylinder Head Removal And Installation......3200
Cylinder Head Disassembly And Assembly......3203
Cylinder Head Servicing......3204
Cylinder Head Top Clearance......3204
Valve Guide Checking......3205
Reconditioning The Valve And Valve Seat......3207
Valve Spring......3208
Rocker Arm And Shaft Checking......3209
Timing Gearcase Cover Removal And Installation......3209
Idler Gear And Camshaft Removal And Installation......3212
Camshaft Servicing......3213
Idler Gear And Shaft Servicing......3214
Timing Gears Checking Backlash......3215
Fuel Camshaft Removal And Installation......3215
Fuel Camshaft Governor......3216
Crankshaft Gear Removal And Installation......3216
Oil Pump Removal And Installation......3217
Oil Pump Service......3217
Checking Engine Oil Pressure......3218
Valve Tappets......3219
Piston And Connecting Rod Removal And Installation......3219
Piston And Connecting Rod Servicing......3221
Connecting Rod Alignment......3224
Crankshaft And Bearings Removal And Installation......3224
Crankshaft And Bearings, Servicing......3226
Cylinder Bore, Checking......3230
Water Pump Removal And Installation......3231
Water Pump Disassembly And Assembly......3231
TURBOCHARGER......3232
Checking......3232
Description......3232
Removal And Installation......3233
HEATING, VENTILATION, AIR CONDITIONING......3236
AIR CONDITIONING SYSTEM FLOW......3239
Principals......3239
Chart......3240
COMPONENTS......3242
Identification......3242
SAFETY......3246
Safety Equipment......3246
REGULAR MAINTENANCE......3248
Filter Elements Removal And Installation......3248
Compressor Drive Belt Inspection......3249
Cleaning The Condenser......3250
BASIC TROUBLESHOOTING......3252
Poor A/C Performance......3252
Cleaning The A/C Evaporator Coil & Heater Coil......3252
Compressor Drive Belt Inspection......3253
Checking The Electrical System......3254
Engine Coolant Bypassing The Heater Valve......3261
Heater Valve Not Opening Or Closing......3262
GENERAL AIR CONDITIONING SERVICE GUIDELINES......3264
Compressor Oil......3264
Compressor Oil Check......3265
Component Replacement And Refrigeration Leaks......3266
SYSTEM TROUBLESHOOTING CHART......3268
Gauge Pressure Related Troubleshooting......3269
TEMPERATURE/PRESSURE......3272
Chart......3272
AIR CONDITIONING SERVICE......3274
Chart......3274
SYSTEM CHARGING AND RECLAMATION......3276
Reclamation Procedure......3276
Charging Procedure With A Manifold Gauge Set......3279
Charging Procedure......3280
COMPRESSOR......3284
Removal And Installation......3284
Compressor Clutch Disassembly......3285
CONDENSER......3290
Removal And Installation......3290
RECEIVER/DRIER......3292
Removal And Installation......3292
PRESSURE RELIEF VALVE......3294
Removal And Installation......3294
PRESSURE SWITCH......3296
Removal And Installation......3296
EVAPORATOR/HEATER UNIT......3298
Removal And Installation......3298
Disassembly And Assembly......3300
THERMOSTAT......3302
Removal And Installation......3302
EXPANSION VALVE......3304
Removal And Installation......3304
EVAPORATOR......3306
Removal And Installation......3306
HEATER COIL......3308
Removal And Installation With A/C......3308
Removal And Installation Without A/C......3310
HEATER/AC FAN......3312
Removal And Installation......3312
Disassembly And Assembly......3313
Wire Connector Removal and Installation......3315
HEATER VALVE......3318
Removal And Installation......3318
Disassembly And Assembly......3318
SPECIFICATIONS......3320
LOADER SPECIFICATIONS......3322
Machine Dimensions......3322
Performance......3323
Controls......3323
Engine......3323
Hydraulic System......3324
Electrical......3324
Drive System......3325
Capacities......3325
Tires......3325
ENGINE SPECIFICATIONS - KUBOTA V2403-M-DI-T......3326
Fuel Injection Nozzles......3326
Fuel Injection Pump......3326
Cylinder Head......3326
Valves......3326
Valve Springs......3327
Valve Timing......3327
Rocker Arms......3327
Camshaft......3327
Tappet......3327
Cylinder Liner......3328
Piston Rings......3328
Pistons......3328
Connecting Rod......3328
Oil Pump......3328
Crankshaft......3329
Timing Gear......3329
Thermostat......3329
TORQUE SPECIFICATIONS FOR BOLTS......3330
Torque For General SAE Bolts......3330
Torque For General Metric Bolts......3331
HYDRAULIC CONNECTION SPECIFICATIONS......3332
O-ring Face Seal Connection......3332
Straight Thread O-ring Fitting......3333
Tubelines And Hoses......3333
Flare Fitting......3333
O-ring Flare Fitting......3334
Port Seal Fitting......3336
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS......3338
Specifications......3338
CONVERSIONS......3340
Decimal And Millimeter Equivalents......3340
U.S. To Metric Conversion......3340
PARTS MANAGER......3342
SERVICE MANAGER X......3342
SALES MANAGER......3342
Revision No: S205-1......3342
Date: 15 April 2005......3342
Product: Bobcat Loader......3342
Model: S205......3342
Manual No: 6902917 (8-04)......3342
PARTS MANAGER......3344
SERVICE MANAGER X......3344
SALES MANAGER......3344
Revision No: S205-2......3344
Date: 7 July 2005......3344
Product: Bobcat Loader......3344
Model: S205......3344
Manual No: 6902917 (8-04)......3344
PARTS MANAGER......3346
SERVICE MANAGER X......3346
SALES MANAGER......3346
Revision No: S205-3......3346
Date: 23 March 2006......3346
Product: Bobcat Loader......3346
Model: S205......3346
Manual No: 6902917 (8-04)......3346
SERVICE MANUAL REVISION......3342
Revision No: S205 - 1......3342
Revision No: S205 - 2......3344
Revision No: S205 - 3......3346
Revision No: S205 - 4......3348
6904136 (4-08) - S205 Skid-Steer Loader Operation & Maintenance Manual......3350
OPERATOR SAFETY WARNINGS......3352
CONTENTS......3354
FOREWORD......3356
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED......3358
REGULAR MAINTENANCE ITEMS......3358
SERIAL NUMBER LOCATIONS......3359
Loader Serial Number......3359
Engine Serial Number......3359
DELIVERY REPORT......3359
LOADER IDENTIFICATION......3360
FEATURES, ACCESSORIES AND ATTACHMENTS......3361
Standard Items......3361
Options and Accessories......3361
Buckets Available......3362
Attachments......3362
High-Flow Attachments......3362
Special Applications Kit......3363
Special Applications Kit Inspection And Maintenance......3363
SAFETY & TRAINING RESOURCES......3364
SAFETY INSTRUCTIONS......3366
Before Operation......3366
Safe Operation Is The Operator’s Responsibility......3367
Safe Operation Needs A Qualified Operator......3367
Avoid Silica Dust......3368
FIRE PREVENTION......3368
Maintenance......3368
Operation......3368
Electrical......3368
Hydraulic System......3369
Fueling......3369
Starting......3369
Spark Arrestor Exhaust System......3369
Welding And Grinding......3369
Fire Extinguishers......3369
MACHINE SIGNS (DECALS)......3371
PUBLICATIONS AND TRAINING RESORCES......3373
OPERATING INSTRUCTIONS......3374
INSTRUMENT PANEL IDENTIFICATION......3378
Left Panel......3378
Right Panel (Key Switch)......3379
Right Panel (Keyless)......3380
Cab Light......3381
Side And Front Panels......3382
SEAT BAR RESTRAINT SYSTEM......3383
Operation......3383
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)......3384
Operation......3384
LIFT ARM BYPASS CONTROL......3385
Operation......3385
PARKING BRAKE......3385
Operation......3385
TRACTION LOCK OVERRIDE......3385
Operation......3385
BACK-UP ALARM SYSTEM......3386
Operation......3386
ENGINE SPEED CONTROL......3386
Operation......3386
DRIVING AND STEERING THE LOADER......3387
Available Control Configurations......3387
Operation (Standard and ACS)......3387
Operation (SJC) in ‘H’ Control Pattern......3388
Operation (SJC) in ‘ISO’ Control Pattern......3389
STOPPING THE LOADER......3389
Using The Control Levers Or Joysticks......3389
TWO-SPEED CONTROL......3390
Description......3390
Operation......3390
SPEED MANAGEMENT......3391
Operation......3391
STEERING DRIFT COMPENSATION......3392
Description......3392
Selecting And Adjusting......3392
Exiting And Saving......3393
HYDRAULIC CONTROLS......3394
Description......3394
Standard Controls (Also ACS In FOOT Pedal Mode)......3394
Advanced Control System (ACS) In HAND Control Mode......3395
Selectable Joystick Control (SJC) In ‘H’ Control Pattern......3395
Selectable Joystick Control (SJC) In ‘ISO’ Control Pattern......3396
Hydraulic Bucket Positioning......3396
FRONT Auxiliary Hydraulics Operation (VARIABLE FLOW)......3397
FRONT Auxiliary Hydraulics Operation (MAXIMUM FLOW)......3397
FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)......3398
REAR Auxiliary Hydraulics Operation......3398
Quick Couplers......3399
Relieve Hydraulic Pressure (Loader and Attachment)......3399
High-Flow Hydraulics Operation......3400
Secondary Front Auxiliary Hydraulics......3401
ATTACHMENT CONTROL DEVICE (ACD)......3402
Description......3402
DAILY INSPECTION......3403
Daily Inspection and Maintenance......3404
PRE-STARTING PROCEDURE......3405
Entering The Loader......3405
Operation & Maintenance Manual And Operator’s Handbook Locations......3405
Seat Adjustment......3406
Seat Belt Adjustment......3407
Seat Bar......3407
STARTING THE ENGINE......3408
Key Switch......3408
Keyless......3410
Cold Temperature Starting......3411
Warming The Hydraulic / Hydrostatic System......3412
MONITORING THE DISPLAY PANELS......3413
Left Panel......3413
Right Panel (Key Switch)......3413
Right Panel (Keyless)......3413
Warning And Shutdown......3413
STOPPING THE ENGINE AND LEAVING THE LOADER......3414
Procedure......3414
Emergency Exit......3415
ATTACHMENTS......3416
Choosing The Correct Bucket......3416
Pallet Forks......3416
Installing And Removing The Attachment (Hand Lever Bob-Tach)......3417
Installing And Removing The Attachment (Power Bob-Tach)......3419
OPERATING PROCEDURE......3422
Inspect The Work Area......3422
Operating With A Full Bucket......3422
Operating With An Empty Bucket......3423
Filling And Emptying The Bucket (Foot Pedals)......3424
Leveling The Ground Using Float (Foot Pedals)......3425
Digging And Filling A Hole (Foot Pedals)......3426
Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)......3427
Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)......3428
Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)......3429
Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)......3430
Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)......3431
Digging And Filling A Hole (SJC - ‘ISO’ Pattern)......3432
TOWING THE LOADER......3433
Procedure......3433
LIFTING THE LOADER......3434
Single Point Lift......3434
Four Point Lift......3434
TRANSPORTING THE LOADER ON A TRAILER......3435
Loading And Unloading......3435
Fastening......3435
PREVENTIVE MAINTENANCE......3436
MAINTENANCE SAFETY......3440
SERVICE SCHEDULE......3442
Chart......3442
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)......3443
Inspecting The BICS Controller (Engine STOPPED - Key ON)......3443
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)......3443
Inspecting The Seat Bar Sensor (Engine RUNNING)......3443
Inspecting The Traction Lock (Engine RUNNING)......3443
Inspecting The Lift Arm By-Pass Control......3443
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)......3443
SEAT BAR RESTRAINT SYSTEM......3444
Description......3444
Inspecting......3444
Maintaining......3444
SEAT BELT......3445
Inspection and Maintenance......3445
LIFT ARM SUPPORT DEVICE......3446
Installing......3446
Removing......3447
BACK-UP ALARM SYSTEM......3448
Description......3448
Inspecting......3448
Adjusting Switch Position......3448
OPERATOR CAB......3449
Description......3449
Raising......3449
Lowering......3450
Cab Door Sensor......3451
REAR DOOR......3451
Opening And Closing......3451
Adjusting......3452
REAR GRILL......3452
Removing......3452
Installing......3452
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)......3453
Cleaning And Maintenance......3453
Filters......3453
Evaporator / Heater Coil......3453
Condenser......3453
Air Conditioning Lubrication......3453
Troubleshooting......3453
AIR CLEANER SERVICE......3454
Replacing Filter Elements......3454
FUEL SYSTEM......3456
Fuel Specifications......3456
Biodiesel Blend Fuel......3456
Filling the Fuel Tank......3457
Fuel Filter......3458
Removing Air From The Fuel System......3458
ENGINE LUBRICATION SYSTEM......3459
Checking And Adding Engine Oil......3459
Engine Oil Chart......3459
Removing And Replacing Oil And Filter......3459
ENGINE COOLING SYSTEM......3460
Cleaning......3460
Checking Level......3461
Removing And Replacing Coolant......3462
ELECTRICAL SYSTEM......3463
Description......3463
Fuse And Relay Location / Identification......3463
Battery Maintenance......3464
Using A Booster Battery (Jump Starting)......3464
Removing And Installing Battery......3466
HYDRAULIC / HYDROSTATIC SYSTEM......3467
Checking And Adding Fluid......3467
Hydraulic / Hydrostatic Fluid Chart......3467
Removing And Replacing Hydraulic Fluid......3467
Removing And Replacing Hydraulic / Hydrostatic Filter......3468
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)......3468
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)......3469
Removing And Replacing Hydraulic Charge Filter......3471
Breather Cap......3472
SPARK ARRESTOR MUFFLER......3473
Cleaning Procedure......3473
TIRE MAINTENANCE......3474
Wheel Nuts......3474
Rotating......3474
Mounting......3474
FINAL DRIVE TRANSMISSION (CHAINCASE)......3475
Checking And Adding Oil......3475
Removing And Replacing Oil......3475
ALTERNATOR BELT......3476
Belt Adjustment......3476
Belt Replacement......3476
AIR CONDITIONING BELT......3476
Belt Adjustment......3476
Belt Replacement......3476
DRIVE BELT......3477
Belt Adjustment......3477
Belt Replacement......3477
LUBRICATING THE LOADER......3478
Lubrication Locations......3478
PIVOT PINS......3480
Inspection And Maintenance......3480
BOB-TACH (HAND LEVER)......3481
Inspection And Maintenance......3481
BOB-TACH (POWER)......3482
Inspection And Maintenance......3482
LOADER STORAGE AND RETURN TO SERVICE......3483
Storage......3483
Return to Service......3483
SYSTEM SETUP & ANALYSIS......3484
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)......3486
Troubleshooting Chart......3486
DIAGNOSTIC SERVICE CODES......3487
Viewing Service Codes (Key Switch)......3487
Viewing Service Codes (Keyless)......3487
Service Codes List......3488
CONTROL PANEL SETUP......3493
Right Panel Setup (Keyless)......3493
Right Panel Setup (Keyless)......3494
Attachment Control Information (Keyless)......3494
PASSWORD SETUP......3495
Password Description......3495
Changing The Owner Password......3495
Changing The User Passwords......3496
Password Lockout Feature......3496
MAINTENANCE CLOCK......3497
Description......3497
Setup......3497
Reset......3497
MACHINE SIGN TRANSLATION......3498
SERVICE SCHEDULE (6734534)......3500
DANGER (6702301)......3503
DANGER (6702302)......3503
DANGER (6717343)......3503
WARNING (6579528)......3503
WARNING (6577754)......3504
IMPORTANT (6560573)......3504
WARNING (6728539)......3505
WARNING (6718706)......3506
DANGER (6809511)......3506
WARNING (6732696)......3506
WARNING (6733996)......3507
WARNING (6725370)......3507
WARNING (6737189)......3507
LIFT ARM SUPPORT DEVICE (6719018)......3508
WARNING (7131518)......3509
WARNING (7131519)......3511
WARNING (6737248)......3512
WARNING (6726423)......3513
WARNING (6704786)......3513
SPECIFICATIONS......3514
(S205) LOADER SPECIFICATIONS......3516
Loader Dimensions......3516
Performance......3517
Controls......3517
Engine......3517
Hydraulic System......3518
Electrical......3518
Drive System......3519
Capacities......3519
Tires......3519
WARRANTY......3520
6904138 (7-09) - S205 Skid-Steer Loader Service Manual......3526
MAINTENANCE SAFETY......3528
ALPHABETICAL INDEX......3530
CONTENTS......3532
FOREWORD......3533
SAFETY INSTRUCTIONS......3536
FIRE PREVENTION......3538
Maintenance......3538
Operation......3538
Electrical......3538
Hydraulic System......3538
Fueling......3538
Starting......3538
Spark Arrestor Exhaust System......3538
Welding And Grinding......3539
Fire Extinguishers......3539
SERIAL NUMBER LOCATIONS......3540
Loader Serial Number......3540
Engine Serial Number......3540
DELIVERY REPORT......3541
LOADER IDENTIFICATION......3542
SAFETY AND MAINTENANCE......3544
LIFTING AND BLOCKING THE LOADER......3548
Procedure......3548
LIFT ARM SUPPORT DEVICE......3550
Installing......3550
Removing......3551
OPERATOR CAB......3552
Description......3552
Raising......3553
Lowering......3554
Cab Door Sensor......3555
Special Applications Kit......3555
Special Applications Kit Inspection And Maintenance......3555
TRANSPORTING THE LOADER ON A TRAILER......3556
Loading And Unloading......3556
Fastening......3556
TOWING THE LOADER......3558
Procedure......3558
REMOTE START TOOL KIT-MEL1563......3560
Remote Start Tool - MEL1563......3560
Service Tool Harness Control - MEL1565......3561
Service Tool Harness Communicator - MEL1566......3562
Remote Start Procedure......3563
REMOTE START TOOL (SERVICE TOOL) kIT - 6689779......3566
Description......3566
Remote Start Tool (Service Tool) - 6689778......3567
Loader Service Tool Harness - 6689747......3568
Computer Service Tool Harness - 6689746......3569
Remote Start Procedure......3570
SERVICE SCHEDULE......3574
Chart......3574
AIR CLEANER SERVICE......3576
Replacing Filter Elements......3576
ENGINE COOLING SYSTEM......3578
Cleaning......3578
Checking Level......3579
Removing And Replacing Coolant......3580
FUEL SYSTEM......3582
Fuel Specifications......3582
Biodiesel Blend Fuel......3582
Filling the Fuel Tank......3583
Fuel Filter......3584
Removing Air From The Fuel System......3584
ENGINE LUBRICATION SYSTEM......3586
Checking And Adding Engine Oil......3586
Engine Oil Chart......3586
Removing And Replacing Oil And Filter......3587
HYDRAULIC / HYDROSTATIC SYSTEM......3588
Checking And Adding Fluid......3588
Hydraulic / Hydrostatic Fluid Chart......3588
Removing And Replacing Hydraulic Fluid......3589
Removing And Replacing Hydraulic / Hydrostatic Filter......3589
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)......3590
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)......3591
Removing And Replacing Hydraulic Charge Filter......3593
Breather Cap......3594
FINAL DRIVE TRANSMISSION (CHAINCASE)......3596
Checking And Adding Oil......3596
Removing And Replacing Oil......3596
BOB-TACH (HAND LEVER)......3598
Inspection And Maintenance......3598
BOB-TACH (POWER)......3600
Inspection And Maintenance......3600
LUBRICATING THE LOADER......3602
Lubrication Locations......3602
TIRE MAINTENANCE......3604
Wheel Nuts......3604
Rotating......3604
Mounting......3604
SPARK ARRESTOR MUFFLER......3606
Cleaning Procedure......3606
PIVOT PINS......3608
Inspection And Maintenance......3608
LOADER STORAGE AND RETURN TO SERVICE......3610
Storage......3610
Return to Service......3610
STOPPING THE ENGINE AND LEAVING THE LOADER......3612
Procedure......3612
Emergency Exit......3613
HYDRAULIC SYSTEM......3614
HYDRAULIC / HYDROSTATIC SCHEMATICS......3618
HYDRAULIC SYSTEM INFORMATION......3634
Glossary Of Hydraulic / Hydrostatic Symbols......3634
Troubleshooting......3638
CYLINDER (LIFT)......3640
Testing......3640
Removal And Installation......3641
Parts Identification......3644
Disassembly and Assembly......3645
CYLINDER (TILT)......3648
Testing......3648
Removal And Installation......3649
Base End Pivot Pin Removal And Installation......3650
Rod End Pivot Pin Bushing And Seal Removal And Installation......3651
Parts Identification......3652
Disassembly And Assembly......3653
CYLINDER (BOB-TACH)......3656
Testing......3656
Removal And Installation......3657
Parts Identification......3658
Disassembly and Assembly......3659
MAIN RELIEF VALVE......3662
Description......3662
Testing......3662
Adjusting......3664
Removal and Installation......3665
HYDRAULIC CONTROL VALVE (STANDARD)......3666
Description......3666
Removal And Installation......3666
Identification Chart......3671
Mount Bracket Removal And Installation......3672
Lift Load Check Valve Removal And Installation......3672
Load Check Valve Removal And Installation (Tilt & Auxiliary)......3673
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)......3674
Port Relief/Anti-Cavitation Valve Removal And Installation (Lift, Base End)......3675
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Base End)......3675
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)......3676
Port Relief Valve Removal And Installation......3676
Plug Removal And Installation......3677
Rubber Boot Removal And Installation......3678
End Cap/Spool Lock Block Removal And Installation......3679
Lift Spool And Detent Removal And Installation......3680
Tilt Spool Removal And Installation......3690
Auxiliary Spool Removal And Installation......3692
Auxiliary Solenoid Removal And Installation......3693
Solenoid Removal And Installation......3694
Lock Valve Removal And Installation......3696
Lift Arm Bypass Orifice Removal And Installation......3698
Main Relief Valve Removal And Installation......3698
Check Valve Removal And Installation......3699
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)......3700
Description......3700
Removal And Installation......3700
Actuator Removal And Installation (Out of Loader)......3705
Identification Chart......3708
Mount Bracket Removal And Installation......3709
Lift Load Check Valve Removal And Installation......3709
Load Check Valve Removal And Installation (Tilt & Auxiliary)......3710
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)......3711
Port Relief/Anti-Cavitation Valve Removal And Installation (Lift, Base End)......3712
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Base End)......3712
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)......3713
Port Relief Valve Removal And Installation......3713
Plug Removal And Installation......3714
End Cap Block Removal And Installation......3715
Lift Spool And Detent Removal And Installation......3716
Tilt Spool Removal And Installation......3721
Auxiliary Spool Removal And Installation......3723
Auxiliary Solenoid Removal And Installation......3724
Solenoid Removal And Installation......3725
Lock Valve Removal And Installation......3727
Lift Arm Bypass Orifice Removal And Installation......3729
Main Relief Valve Removal And Installation......3730
Check Valve Removal And Installation......3731
LIFT ARM BYPASS CONTROL VALVE......3732
Description......3732
Testing......3732
Removal and Installation......3732
Disassembly And Assembly......3733
HYDRAULIC PUMP (STANDARD)......3734
Description......3734
Pump Test at Quick Couplers......3734
Direct Pump Test (Standard Section)......3735
Direct Pump Test (Charge Section)......3737
Removal And Installation......3739
Parts Identification......3741
Disassembly And Assembly......3742
Hydraulic Pump Start Up......3750
HYDRAULIC PUMP (STANDARD) (HIGH FLOW)......3752
Description......3752
Pump Test at Quick Couplers......3752
Direct Pump Test (Standard Section)......3753
Direct Pump Test (Charge Section)......3755
Direct Pump Test (High Flow Section)......3757
Removal And Installation......3759
Parts Identification......3761
Disassembly And Assembly......3762
Hydraulic Pump Start Up......3774
HYDRAULIC PUMP (SJC)......3776
Description......3776
Pump Test at Quick Couplers......3776
Direct Pump Test (Standard Section)......3777
Direct Pump Test (Charge Section)......3779
Removal And Installation......3781
Parts Identification......3783
Disassembly And Assembly......3784
Hydraulic Pump Start Up......3792
HYDRAULIC PUMP (SJC) (HIGH FLOW)......3794
Description......3794
Pump Test at Quick Couplers......3794
Direct Pump Test (Standard Section)......3795
Direct Pump Test (Charge Section)......3797
Direct Pump Test (High Flow Section)......3799
Removal And Installation......3801
Parts Identification......3803
Disassembly And Assembly......3804
Hydraulic Pump Start Up......3815
HYDRAULIC/HYDROSTATIC FILTERS......3818
Description......3818
Housing Removal And Installation......3818
Charge Filter Housing Removal And Installation......3820
HYDRAULIC FLUID RESERVOIR......3822
Description......3822
Removal And Installation......3822
Hydraulic Fluid Screen......3825
OIL COOLER......3826
Description......3826
Removal and Installation......3826
BUCKET POSITION VALVE......3828
Description......3828
Solenoid Removal And Installation......3828
Solenoid Testing......3829
Removal And Installation......3830
Disassembly And Assembly......3831
REAR AUXILIARY DIVERTER VALVE......3834
Description......3834
Removal And Installation......3834
Disassembly And Assembly......3837
Solenoid Testing......3843
BOB-TACH (POWER) BLOCK......3844
Description......3844
Removal And Installation......3844
Disassembly And Assembly......3846
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK......3850
Description......3850
Removal and Installation......3850
Disassembly And Assembly......3850
HIGH FLOW VALVE......3852
Description......3852
High Flow Relief Valve Testing......3852
High Flow Relief Valve Adjustment......3853
Solenoid Testing......3854
Removal And Installation......3855
Disassembly And Assembly......3856
HYDROSTATIC SYSTEM......3860
HYDROSTATIC SYSTEM INFORMATION......3862
Troubleshooting......3862
Description......3863
HYDROSTATIC MOTOR......3864
Description......3864
Removal And Installation......3864
Parts Identification......3867
Disassembly and Assembly......3868
HYDROSTATIC MOTOR (TWO-SPEED)......3874
Description......3874
Removal And Installation (Left Side)......3875
Removal And Installation (Right Side)......3878
Parts Identification......3881
Disassembly......3882
Assembly......3892
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH MANUAL CONTROLS)......3904
Description......3904
Shaft Seal Removal And Installation......3904
Removal And Installation......3906
Parts Identification......3908
Disassembly and Assembly......3909
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH SJC CONTROLS)......3914
Description......3914
Shaft Seal Removal And Installation......3914
Removal And Installation......3916
Parts Identification......3918
Disassembly and Assembly......3919
CHARGE PRESSURE......3924
Description......3924
Testing......3924
Sender Removal And Installation......3926
Adjusting......3926
HYDROSTATIC PUMP......3930
Description......3930
Replenishing/High Pressure Relief Valve......3930
Removal And Installation......3931
Hydrostatic Pump Start Up......3932
Parts Identification (Left Half)......3933
Parts Identification (Right Half)......3934
Disassembly......3935
Assembly......3941
HYDROSTATIC PUMP (SJC)......3948
Description......3948
Hydraulic Controller Removal And Installation......3949
Removal And Installation......3951
Hydrostatic Pump Start Up......3953
Parts Identification......3954
High Pressure Relief and Bypass Valve......3955
Charge Relief Valve......3956
Disassembly and Assembly......3957
Mechanical Neutral Adjustment......3973
Hydraulic Controller Neutral Adjustment......3976
DRIVE BELT......3980
Description......3980
Shield Removal And Installation......3980
Adjusting......3980
Belt Removal And Installation......3982
Belt Tensioner Removal And Installation......3983
Belt Tensioner Parts Identification......3984
Belt Tensioner Disassembly......3985
Belt Tensioner Assembly......3986
TWO-SPEED VALVE......3988
Description......3988
Valve Removal And Installation......3989
Valve Disassembly And Assembly......3991
CASE DRAIN FILTER......3994
Description......3994
Disassembly And Assembly......3994
DRIVE SYSTEM......3996
BRAKE (SINGLE SPEED)......3998
Description......3998
Disc Removal And Installation......3998
BRAKE (TWO-SPEED)......4000
Description......4000
Disc Removal And Installation......4000
Disc Disassembly and Assembly......4001
DRIVE COMPONENTS......4002
Description......4002
Axle Seal Removal And Installation......4003
Axle Sprocket And Bearings Removal And Installation......4005
Chain Removal And Installation......4010
CHAINCASE......4012
Description......4012
Front Cover Removal And Installation......4012
Center Cover Removal And Installation......4013
Rear Cover Removal And Installation......4014
MAIN FRAME......4016
SEAT BAR......4020
Description......4020
Removal And Installation......4020
Disassembly And Assembly......4021
Compression Spring Disassembly And Assembly......4023
OPERATOR CAB......4024
Gas Cylinder Removal And Installation......4024
Gas Cylinder Bracket Disassembly And Assembly......4027
Removal And Installation......4027
OPERATOR SEAT......4030
Removal And Installation......4030
Seat Belt Removal And Installation......4030
OPERATOR SEAT (SUSPENSION)......4032
Removal And Installation......4032
Slide Rail Removal And Installation......4033
Seat Belt Removal and Installation......4033
Lower Cushion Removal And Installation......4033
Back Cushion Removal And Installation......4035
Shock Removal And Installation......4035
3-Point Seat Belt Removal And Installation......4036
BOB-TACH (HAND LEVER)......4038
Description......4038
Removal And Installation......4038
Lever And Wedge Disassembly And Assembly......4039
Pivot Pin Bushing And Seal Removal And Installation......4040
BOB-TACH (POWER-OPTION)......4042
Description......4042
Removal And Installation......4042
Lever And Wedge Disassembly And Assembly......4044
Pivot Pin Bushing And Seal Removal And Installation......4045
LIFT ARMS......4046
Stabilizer Bar Removal And Installation......4046
Link Removal And Installation......4047
Removal And Installation......4048
REAR GRILL......4052
Removal And Installation......4052
REAR DOOR......4054
Removal And Installation......4054
Striker Removal and Installation......4055
Striker Disassembly and Assembly......4055
Striker (Adjusting)......4055
Latch Removal and Installation......4056
FUEL TANK......4058
Removal And Installation......4058
Fuel Level Sender Removal And Installation......4059
Fuel Fill Screen Removal And Installation......4060
CONTROL PEDALS AND LINKAGES......4062
Description......4062
Pedal Removal And Installation......4062
Linkage Removal And Installation......4063
Pedal (Adjusting)......4065
CONTROL PEDALS (ACS)......4066
Description......4066
Foot Sensor Removal And Installation......4066
Foot Pedal Removal And Installation......4067
Foot Pedal Linkage Disassembly And Assembly......4068
CONTROL PANEL......4070
Description......4070
Removal and Installation......4071
Shock Removal And Installation......4074
Shaft Removal And Installation......4074
Shaft Disassembly And Assembly......4075
Linkage Removal And Installation......4076
Pintle Arm Disassembly and Assembly......4080
Linkage Neutral Adjustment......4082
Linkage Travel Adjustment......4086
CONTROL PANEL (SJC)......4090
Description......4090
Removal And Installation......4090
CONTROL HANDLE/LEVER......4092
Description......4092
Lever Removal And Installation......4092
Boot Removal And Installation......4093
CONTROL HANDLE/LEVER (ACS)......4094
Description......4094
Handle Sensor Removal And Installation......4094
Handle Removal and Installation......4097
Handle Disassembly and Assembly......4098
Lever Removal and Installation......4098
Boot Removal And Installation......4100
CONTROL HANDLE/LEVER (SJC)......4102
Description......4102
Joystick Testing......4102
Joystick Removal And Installation (S/N 530511001 - 530512551, S/N 530611001 - 530611153)......4103
Joystick Removal And Installation (S/N 530512552 & Above, S/N 530611154 & Above)......4105
Removal And Installation (S/N 530511001 - 530512551, S/N 530611001 - 530611153)......4106
Removal And Installation (S/N 530512552 & Above, S/ N 530611154 & Above)......4107
ACCESS PANEL (INSIDE)......4108
Removal And Installation (Left)......4108
Removal And Installation (Right)......4108
ACCESS PANEL (INSIDE) (SJC)......4110
Removal And Installation (Left)......4110
Removal And Installation (Right)......4111
WINDOW (REAR)......4114
Removal......4114
Installation......4114
WINDOW (TOP)......4116
Removal And Installation......4116
WINDOW (SIDE)......4118
Removal And Installation......4118
WINDOW (FRONT DOOR)......4120
Removal (Standard Window)......4120
Installation (Standard Window)......4121
Removal And Installation (Special Applications Window)......4123
ELECTRICAL SYSTEM & ANALYSIS......4124
ELECTRICAL SCHEMATICS......4128
ELECTRICAL SYSTEM INFORMATION......4141
Glossary Of Electrical Symbols......4141
Cab Harness Connectors......4144
Mainframe Harness Connectors......4145
Description......4146
Troubleshooting......4147
Fuse And Relay Location / Identification......4148
Solenoid Testing......4149
BATTERY......4151
Removal And Installation......4151
Servicing......4152
Using A Booster Battery (Jump Starting)......4153
ALTERNATOR......4155
Belt Adjustment......4155
Belt Replacement......4155
Charging System Inspection......4156
Alternator Voltage Testing......4157
Low Voltage Testing......4157
High Voltage Testing......4158
Removal And Installation......4159
Parts Identification......4160
STARTER......4161
Testing......4161
Removal And Installation......4162
Parts Identification......4163
INSTRUMENT PANELS......4165
Left Panel......4165
Right Panel (Key Switch)......4166
Right Panel (Keyless)......4167
Side And Front Panels......4169
Removal And Installation (Left And Right)......4170
Bulb Removal And Installation (Left Only)......4173
Key Switch Removal And Installation......4174
Alarm Removal And Installation......4175
Front Panel Removal And Installation......4175
LIGHTS......4177
Front Removal And Installation......4177
Rear Removal And Installation......4178
Cab Light Removal And Installation......4178
BOBCAT CONTROLLER (MAIN)......4179
Description......4179
Connector Identification......4180
Removal And Installation......4182
BOBCAT CONTROLLER (ACS)......4183
Description......4183
Connector Identification......4185
Removal and Installation......4186
BOBCAT CONTROLLER (SJC) (DRIVE)......4187
Description......4187
Connector Identification......4188
Removal and Installation......4190
WHEEL SPEED SENSORS (SJC)......4193
Description......4193
Testing......4193
Removal And Installation......4195
DIAGNOSTIC SERVICE CODES......4197
Viewing Service Codes (Key Switch)......4197
Viewing Service Codes (Keyless)......4197
Service Codes List......4198
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)......4203
Description......4203
Inspecting The BICS Controller (Engine STOPPED - Key ON)......4204
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)......4204
Inspecting The Seat Bar Sensor (Engine RUNNING)......4204
Inspecting The Traction Lock (Engine RUNNING)......4204
Inspecting The Lift Arm Bypass Control......4204
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)......4204
Troubleshooting......4205
Troubleshooting Chart......4206
SEAT BAR SENSOR......4207
Description......4207
Troubleshooting......4207
Testing......4208
Removal And Installation......4209
Bobcat Interlock Control System (BICS) Circuit Test......4211
TRACTION LOCK......4213
Description......4213
Troubleshooting......4213
Removal And Installation......4214
Inspecting......4218
CONTROL SYSTEM (ACS)......4219
Description......4219
Troubleshooting Chart......4220
Handle Sensor Connector Disassembly And Assembly......4221
Switch Handle Removal......4222
Switch Handle Installation......4224
Actuator Connector Disassembly And Assembly......4227
Handle Lock Solenoid Removal And Installation......4228
Handle Lock Solenoid Disassembly And Assembly......4228
Foot Sensor Disassembly And Assembly......4229
Foot Lock Solenoid Removal And Installation......4230
ELECTRICAL/HYDRAULIC CONTROLS......4231
Identification Chart......4231
ELECTRICAL/HYDRAULIC CONTROLS (SJC)......4233
Identification Chart......4233
SERVICE PC (LAPTOP COMPUTER)......4237
Connecting Remote Start Tool......4237
Connecting Remote Start Tool (Service Tool)......4237
CALIBRATION......4239
Description......4239
Actuator Testing......4239
Lift And Tilt Calibration (ACS)......4241
Lift And Tilt Calibration (SJC)......4243
Hydrostatic Pump Calibration (SJC)......4245
STEERING DRIFT COMPENSATION......4251
Description......4251
Selecting And Adjusting......4251
Exiting And Saving......4252
FLYWHEEL RPM SENSOR......4253
Description......4253
Adjusting......4253
CONTROL PANEL SETUP......4255
Right Panel Setup (Keyless)......4255
Attachment Control Information (Keyless)......4256
PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START)......4257
Password Description......4257
Changing The Owner And User Passwords......4258
Password Lockout Feature......4259
MAINTENANCE CLOCK......4261
Description......4261
Setup......4262
Reset......4266
BACK-UP ALARM SYSTEM......4267
Description......4267
Inspecting......4267
Adjusting Switch Position......4268
Troubleshooting (Standard and ACS)......4269
Troubleshooting (Joystick)......4270
Alarm Removal And Installation......4271
Switch Removal And Installation......4271
ENGINE SERVICE......4273
ENGINE INFORMATION......4275
Description......4275
Engine Specifications - Kubota V2403-M-DI-T......4276
Engine Torque Values......4280
Troubleshooting......4280
Engine Removal And Installation......4282
Engine Mount Replacement......4289
Compression - Checking......4290
ENGINE SPEED CONTROL......4291
Removal And Installation......4291
ENGINE SPEED CONTROL (SJC)......4293
Removal And Installation......4293
Disassembly And Assembly......4295
MUFFLER......4297
Removal And Installation......4297
AIR CLEANER......4299
Housing Removal And Installation......4299
ENGINE COOLING SYSTEM......4301
Radiator Removal And Installation......4301
Blower Housing Removal And Installation......4304
Hydraulic Fan Removal And Installation......4306
Hydraulic Fan Description......4307
Hydraulic Fan Disassembly And Assembly......4307
Water Pump Removal And Installation......4308
Water Pump Disassembly And Assembly......4308
Thermostat Housing Removal And Installation......4309
LUBRICATION SYSTEM......4311
Oil Pan Removal And Installation......4311
Oil Pump Removal And Installation......4311
Oil Pump Inspection......4312
Engine Oil Pressure - Testing......4313
FUEL SYSTEM......4315
Fuel Camshaft Removal And Installation......4315
Fuel Camshaft Governor Disassembly And Assembly......4316
Fuel Shutoff Solenoid - Checking......4317
Fuel Shutoff Solenoid Removal And Installation......4317
Fuel Injection Pump Removal And Installation......4318
Injection Pump - Timing......4321
Fuel Injector Removal And Installation......4323
Fuel Injector Nozzle Pressure - Checking......4325
Nozzle Spraying Condition......4325
Valve Seat Tightness......4326
CYLINDER HEAD......4327
Glow Plugs - Testing......4327
Glow Plugs Removal And Installation......4327
Valve Clearance Adjustment......4328
Valve Timing, Checking......4329
Cylinder Head Removal And Installation......4330
Cylinder Head Disassembly and Assembly......4333
Cylinder Head - Servicing......4333
Cylinder Head Top Clearance......4334
Valve Guide-Checking......4334
Reconditioning The Valve And Valve Seat......4335
Valve Spring......4337
Valve Tappets......4338
Rocker Arm And Shaft Checking......4338
CRANKSHAFT AND PISTONS......4339
Piston And Connecting Rod Removal And Installation......4339
Piston And Connecting Rod - Servicing......4340
Cylinder Bore - Checking......4343
Connecting Rod Alignment......4343
Crankshaft Gear Removal And Installation......4344
Crankshaft And Bearings Removal And Installation......4344
Crankshaft And Bearings - Servicing......4346
CAMSHAFT AND TIMING GEARS......4351
Timing Gearcase Cover Removal And Installation......4351
Timing Gears Backlash-Checking......4353
Idler Gear And Camshaft Removal And Installation......4354
Camshaft - Servicing......4355
Idler Gear And Shaft Servicing......4356
TURBOCHARGER......4357
Description......4357
Testing......4357
Removal And Installation......4358
FLYWHEEL AND HOUSING......4361
Flywheel Removal And Installation......4361
Ring Gear Removal And Installation......4361
Housing Removal And Installation......4362
HEATING, VENTILATION, AIR CONDITIONING......4365
AIR CONDITIONING SYSTEM FLOW......4368
Description......4368
Chart......4369
Components......4370
Safety Equipment......4373
REGULAR MAINTENANCE......4375
Filter Elements Removal And Installation......4375
Compressor Drive Belt Inspection......4376
Condenser......4377
Air Conditioning Lubrication......4377
Air Conditioning Service Chart......4378
Cleaning The A/C Evaporator Coil And Heater Coil......4379
TROUBLESHOOTING......4381
Blower Motor Does Not Operate......4381
Blower Motor Operates Normally, But Air Flow Is Insufficient......4381
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal......4381
The Compressor Does Not Operate At All, Or Operates Improperly......4381
Gauge Pressure Related Troubleshooting......4382
Troubleshooting Tree......4384
Temperature/Pressure Chart......4388
Poor A/C Performance......4389
HVAC Repair And Leaks......4390
Electrical System......4391
Engine Coolant Bypassing The Heater Valve......4398
Heater Valve Not Opening Or Closing......4399
SYSTEM CHARGING AND RECLAMATION......4401
Refrigerant Identification......4401
Reclamation And Charging With Recovery / Charging Unit......4402
Charging With A Manifold Gauge Set......4404
COMPRESSOR......4407
Belt Adjustment......4407
Removal And Installation......4408
Oil......4409
Oil Check......4410
Clutch Disassembly And Assembly......4412
CONDENSER......4417
Removal And Installation......4417
RECEIVER/DRIER......4419
Receiver/Drier Removal And Installation......4419
Pressure Relief Valve Removal And Installation......4420
Pressure Switch Removal And Installation......4421
Schraeder Valve Removal And Installation......4422
EVAPORATOR / HEATER UNIT......4423
Removal And Installation......4423
THERMOSTAT......4425
Removal And Installation......4425
EXPANSION VALVE......4427
Removal And Installation......4427
EVAPORATOR......4429
Removal And Installation......4429
HEATER COIL......4431
Removal And Installation With A/C......4431
Removal And Installation Without A/C......4433
BLOWER FAN......4435
Removal And Installation......4435
Disassembly And Assembly......4436
Connector Identification......4438
HEATER VALVE......4439
Removal and Installation......4439
Disassembly And Assembly......4440
SPECIFICATIONS......4441
S205 LOADER SPECIFICATIONS......4443
Dimensions......4443
Performance......4444
Controls......4444
Engine......4444
Hydraulic System......4445
Electrical......4445
Drive System......4446
Capacities......4446
Tires......4446
TORQUE SPECIFICATIONS FOR BOLTS......4447
Torque For General SAE Bolts......4447
Torque For General Metric Bolts......4448
HYDRAULIC CONNECTION SPECIFICATIONS......4449
O-ring Face Seal Connection......4449
Straight Thread O-ring Fitting......4450
Tubelines And Hoses......4450
Flare Fitting......4451
Port Seal Fitting......4452
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS......4453
Specifications......4453
CONVERSIONS......4455
Decimal And Millimeter Equivalents......4455
U.S. To Metric Conversion Chart......4455
SERVICE MANUAL REVISION......4457
Revision No: S205 - 1......4457
Revision No: S205 - 2......4459
Revision No: S205 - 3......4461
Revision No: S205 - 4......4463
Revision No: S205 - 5......4465
Revision No: S205 - 6......4467
Revision No: S205 - 7......4469
Revision No: S205 - 8......4471
Revision No: S205 - 9......4473
Revision No: S205 - 10......4475
Revision No: S205 - 11......4477
Revision No: S205 - 12......4479
Revision No: S205 - 13......4481
6986987 (3-08) - S205 Skid-Steer Loader Operation & Maintenance Manual......4483
OPERATOR SAFETY WARNINGS......4485
CONTENTS......4487
FOREWORD......4489
BOBCAT COMANY IS IS0 9001:2000 CERTIFIED......4491
REGULAR MAINTENANCE ITEMS......4491
SERIAL NUMBER LOCATIONS......4492
Loader Serial Number......4492
Engine Serial Number......4492
DELIVERY REPORT......4492
LOADER IDENTIFICATION......4493
FEATURES, ACCESSORIES AND ATTACHMENTS......4494
Standard Items......4494
Options And Accessories......4494
Buckets Available......4495
Attachments......4495
High-Flow Attachments......4495
Special Applications Kit......4496
Special Applications Kit Inspection And Maintenance......4496
SAFETY & TRAINING RESOURCES......4497
SAFETY INSTRUCTIONS......4499
Before Operation......4499
Safe Operation Is The Operator’s Responsibility......4500
Safe Operation Needs A Qualified Operator......4500
Avoid Silica Dust......4501
FIRE PREVENTION......4501
Maintenance......4501
Operation......4501
Electrical......4501
Hydraulic System......4502
Fueling......4502
Starting......4502
Spark Arrestor Exhaust System......4502
Welding And Grinding......4502
Fire Extinguishers......4502
MACHINE SIGNS (DECALS)......4504
PUBLICATIONS AND TRAINING RESOURCES......4506
OPERATING INSTRUCTIONS......4507
INSTRUMENT PANEL IDENTIFICATION......4511
Cab Light......4511
Left Panel......4512
Display Screen......4514
Standard Key Panel......4514
Deluxe Instrumentation Panel......4515
Side Panel......4516
Front Panel......4516
SEAT BAR RESTRAINT SYSTEM......4517
Operation......4517
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)......4518
Operation......4518
LIFT ARM BYPASS CONTROL......4519
Operation......4519
PARKING BRAKE......4519
Operation......4519
TRACTION LOCK OVERRIDE......4519
Operation......4519
BACK-UP ALARM SYSTEM......4520
Operation......4520
ENGINE SPEED CONTROL......4520
Operation......4520
DRIVING AND STEERING THE LOADER......4521
Available Control Configurations......4521
Operation (Standard And ACS)......4521
Operation (SJC) in ‘ISO’ Control Pattern......4522
Operation (SJC) in ‘H’ Control Pattern......4523
STOPPING THE LOADER......4523
Using The Control Levers Or Joysticks......4523
TWO-SPEED CONTROL......4524
Description......4524
Operation (Standard And ACS) (If Equipped)......4524
Operation (SJC) (If Equipped)......4524
SPEED MANAGEMENT......4525
Operation......4525
STEERING DRIFT COMPENSATION......4526
Description......4526
Operation......4526
HYDRAULIC CONTROLS......4528
Description......4528
Standard Controls (Also ACS In FOOT Pedal Mode)......4528
Advanced Control System (ACS) In HAND Control Mode......4529
Selectable Joystick Controls (SJC) In ‘ISO’ Control Pattern......4529
Selectable Joystick Controls (SJC) In ‘H’ Control Pattern......4530
Hydraulic Bucket Positioning......4530
FRONT Auxiliary Hydraulics Operation......4531
FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)......4532
REAR Auxiliary Hydraulics Operation......4532
Secondary Front Auxiliary Hydraulics Operation......4533
High-Flow Hydraulics Operation......4534
Quick Couplers......4534
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)......4535
ATTACHMENT CONTROL DEVICE (ACD)......4536
Description......4536
DAILY INSPECTION......4537
Daily Inspection And Maintenance......4538
PRE-STARTING PROCEDURE......4539
Entering The Loader......4539
Operation & Maintenance Manual And Operator’s Handbook Locations......4539
Seat Adjustment......4540
Seat Belt Adjustment......4541
Seat Bar......4541
STARTING THE ENGINE......4542
Standard Key Panel......4542
Deluxe Instrumentation Panel......4544
Cold Temperature Starting......4546
Warming The Hydraulic / Hydrostatic System......4547
MONITORING THE DISPLAY PANELS......4548
Left Panel......4548
Warning And Shutdown......4548
STOPPING THE ENGINE AND LEAVING THE LOADER......4549
Procedure......4549
Emergency Exit......4550
ATTACHMENTS......4551
Choosing The Correct Bucket......4551
Pallet Forks......4551
Installing And Removing The Attachment (Hand Lever Bob-Tach)......4552
Installing And Removing The Attachment (Power Bob-Tach)......4554
OPERATING PROCEDURE......4557
Inspect The Work Area......4557
Operating With A Full Bucket......4557
Operating With An Empty Bucket......4558
Filling And Emptying The Bucket (Foot Pedals)......4559
Leveling The Ground Using Float (Foot Pedals)......4560
Digging And Filling A Hole (Foot Pedals)......4560
Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)......4561
Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)......4562
Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)......4563
Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)......4564
Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)......4565
Digging And Filling A Hole (SJC - ‘ISO’ Pattern)......4565
TOWING THE LOADER......4566
Procedure......4566
LIFTING THE LOADER......4567
Single Point Lift......4567
Four Point Lift......4567
TRANSPORTING THE LOADER ON A TRAILER......4568
Loading And Unloading......4568
Fastening......4568
PREVENTIVE MAINTENANCE......4569
MAINTENANCE SAFETY......4573
SERVICE SCHEDULE......4575
Chart......4575
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)......4576
Inspecting The BICS (Engine STOPPED - Key ON)......4576
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)......4576
Inspecting The Seat Bar Sensor (Engine RUNNING)......4576
Inspecting The Traction Lock (Engine RUNNING)......4576
Inspecting The Lift Arm Bypass Control......4576
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)......4576
SEAT BAR RESTRAINT SYSTEM......4577
Description......4577
Inspecting......4577
Maintaining......4577
SEAT BELT......4578
Inspection And Maintenance......4578
LIFT ARM SUPPORT DEVICE......4579
Installing......4579
Removing......4580
BACK-UP ALARM SYSTEM......4581
Description......4581
Inspecting......4581
Adjusting Switch Position......4581
OPERATOR CAB......4582
Description......4582
Raising......4582
Lowering......4583
Cab Door Sensor......4584
REAR DOOR......4585
Opening And Closing......4585
Adjusting......4585
REAR GRILL......4585
Removing......4585
Installing......4585
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)......4586
Cleaning And Maintenance......4586
Filters......4586
Evaporator / Heater Coil......4586
Condenser......4586
Air Conditioning Lubrication......4586
Troubleshooting......4586
AIR CLEANER SERVICE......4587
Replacing Filter Elements......4587
FUEL SYSTEM......4589
Fuel Specifications......4589
Biodiesel Blend Fuel......4589
Filling The Fuel Tank......4590
Fuel Filter......4591
Removing Air From The Fuel System......4591
ENGINE LUBRICATION SYSTEM......4592
Checking And Adding Engine Oil......4592
Engine Oil Chart......4592
Removing And Replacing Oil And Filter......4592
ENGINE COOLING SYSTEM......4593
Cleaning......4593
Removing And Replacing Coolant......4594
Checking Level......4594
ELECTRICAL SYSTEM......4595
Description......4595
Fuse And Relay Location / Identification......4595
Battery Maintenance......4596
Using A Booster Battery (Jump Starting)......4597
Removing And Installing Battery......4598
HYDRAULIC / HYDROSTATIC SYSTEM......4599
Checking And Adding Fluid......4599
Hydraulic / Hydrostatic Fluid Chart......4599
Removing And Replacing Hydraulic Fluid......4599
Removing And Replacing Hydraulic / Hydrostatic Filter......4600
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)......4600
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)......4601
Removing And Replacing Hydraulic Charge Filter......4603
Breather Cap......4603
SPARK ARRESTOR MUFFLER......4604
Cleaning Procedure......4604
TIRE MAINTENANCE......4605
Wheel Nuts......4605
Rotating......4605
Mounting......4605
FINAL DRIVE TRANSMISSION (CHAINCASE)......4606
Checking And Adding Oil......4606
Removing And Replacing Oil......4606
ALTERNATOR BELT......4607
Belt Adjustment......4607
Belt Replacement......4607
AIR CONDITIONING BELT......4607
Belt Adjustment......4607
Belt Replacement......4607
DRIVE BELT......4608
Belt Adjustment......4608
Belt Replacement......4608
LUBRICATING THE LOADER......4609
Lubrication Locations......4609
PIVOT PINS......4611
Inspection And Maintenance......4611
BOB-TACH (hand lever)......4612
Inspection And Maintenance......4612
BOB-TACH (POWER)......4613
Inspection And Maintenance......4613
LOADER STORAGE AND RETURN TO SERVICE......4614
Storage......4614
Return To Service......4614
SYSTEM SETUP & ANALYSIS......4615
DIAGNOSTIC SERVICE CODES......4617
Viewing Service Codes (Standard Key Panel)......4617
Viewing Service Codes (Deluxe Instrumentation Panel)......4617
Service Codes List......4618
CONTROL PANEL SETUP......4622
Right Panel Setup (Deluxe Instrumentation Panel)......4622
Attachment Control Information (Deluxe Instrumentation Panel)......4623
PASSWORD SETUP......4624
Password Description......4624
Changing The Owner Password......4624
Changing The User Passwords......4625
Password Lockout Feature......4625
MAINTENANCE CLOCK......4626
Description......4626
Setup......4626
Reset......4626
MACHINE SIGN TRANSLATIONS......4627
SERVICE SCHEDULE (6734534)......4629
DANGER (6702301)......4632
WARNING (6577754)......4632
DANGER (6702302)......4632
DANGER (6717343)......4632
IMPORTANT (6560573)......4633
WARNING (6579528)......4633
WARNING (6728539)......4634
WARNING (6718706)......4635
WARNING (6710358)......4635
DANGER (6809511)......4635
WARNING (6733996)......4636
WARNING (6725370)......4636
WARNING (6737189)......4636
WARNING (6737248)......4636
LIFT ARM SUPPORT DEVICE (6719018)......4637
WARNING (7131518)......4638
WARNING (7131519)......4640
WARNING (6726423)......4642
WARNING (6704786)......4642
SPECIFICATIONS......4643
(S205) LOADER SPECIFICATIONS......4645
Machine Dimensions......4645
Performance......4646
Engine......4646
Controls......4646
Drive System......4647
Hydraulic System......4647
Electrical......4648
Capacities......4648
Tires......4648
WARRANTY......4649
ALPHABETICAL INDEX......4653
6987013 (2-13) - S205 Skid-Steer Loader Operation & Maintenance Manual......4655
OPERATOR SAFETY WARNINGS......4657
CONTENTS......4659
FOREWORD......4661
BOBCAT COMPANY IS IS0 9001 CERTIFIED......4663
REGULAR MAINTENANCE ITEMS......4663
SERIAL NUMBER LOCATIONS......4664
Loader Serial Number......4664
Engine Serial Number......4664
DELIVERY REPORT......4664
LOADER IDENTIFICATION......4665
FEATURES, ACCESSORIES AND ATTACHMENTS......4666
Standard Items......4666
Options And Accessories......4666
Buckets Available......4667
Attachments......4667
High-Flow Attachments......4667
Special Applications Kit......4668
Special Applications Kit Inspection And Maintenance......4668
SAFETY & TRAINING RESOURCES......4669
SAFETY INSTRUCTIONS......4671
Before Operation......4671
Safe Operation Is The Operator’s Responsibility......4672
Safe Operation Needs A Qualified Operator......4672
Avoid Silica Dust......4673
FIRE PREVENTION......4673
Maintenance......4673
Operation......4673
Electrical......4673
Hydraulic System......4674
Fueling......4674
Starting......4674
Spark Arrester Exhaust System......4674
Welding And Grinding......4674
Fire Extinguishers......4674
PUBLICATIONS AND TRAINING RESOURCES......4675
MACHINE SIGNS (DECALS)......4676
OPERATING INSTRUCTIONS......4679
INSTRUMENT PANEL IDENTIFICATION......4683
Cab Light......4683
Left Panel......4684
Display Screen......4686
Standard Key Panel......4687
Keyless Start Panel......4687
Deluxe Instrumentation Panel......4688
Side Panel......4689
Front Panel......4689
CONTROL IDENTIFICATION......4690
Standard Controls......4690
Advanced Control System (ACS)......4691
Selectable Joystick Controls (SJC)......4692
SEAT BAR RESTRAINT SYSTEM......4693
Operation......4693
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)......4694
Operation......4694
LIFT ARM BYPASS CONTROL......4695
Operation......4695
PARKING BRAKE......4695
Operation......4695
TRACTION LOCK OVERRIDE......4695
Operation......4695
EMERGENCY EXIT......4696
Rear Window......4696
Front Door......4696
BACK-UP ALARM SYSTEM......4697
Description......4697
Operation......4697
ENGINE SPEED CONTROL......4698
Operation......4698
DRIVING AND STEERING THE LOADER......4699
Available Control Configurations......4699
Operation (Standard And ACS)......4699
Operation (SJC) In ‘ISO’ Control Pattern......4700
Operation (SJC) In ‘H’ Control Pattern......4701
STOPPING THE LOADER......4701
Using The Control Levers Or Joysticks......4701
TWO-SPEED CONTROL......4702
Description......4702
Operation (Standard And ACS) (If Equipped)......4702
Operation (SJC) (If Equipped)......4702
SPEED MANAGEMENT......4703
Operation......4703
Changing The Factory Default Setting......4704
DRIVE RESPONSE......4705
Description......4705
Operation......4705
STEERING DRIFT COMPENSATION......4707
Description......4707
Operation......4707
LIFT AND TILT COMPENSATION......4709
Description......4709
Operation......4709
Operation (ACS)......4710
Operation (SJC)......4711
HYDRAULIC CONTROLS......4712
Description......4712
Standard Controls (Also ACS In FOOT Pedal Mode)......4712
Advanced Control System (ACS) In HAND Control Mode......4713
Selectable Joystick Controls (SJC) In ‘ISO’ Control Pattern......4713
Selectable Joystick Controls (SJC) In ‘H’ Control Pattern......4714
Hydraulic Bucket Positioning......4714
FRONT Auxiliary Hydraulics Operation......4715
FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)......4716
REAR Auxiliary Hydraulics Operation......4716
Secondary Front Auxiliary Hydraulics Operation......4717
High-Flow Hydraulics Operation......4718
Quick Couplers......4718
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)......4719
ATTACHMENT CONTROL DEVICE (ACD)......4720
Description......4720
DAILY INSPECTION......4721
Daily Inspection And Maintenance......4722
PRE-STARTING PROCEDURE......4723
Entering The Loader......4723
Operation & Maintenance Manual And Operator’s Handbook Locations......4723
Seat Adjustment......4724
Seat Belt Adjustment......4725
Seat Bar......4725
STARTING THE ENGINE......4726
Standard Key Panel......4726
Keyless Start Panel......4728
Deluxe Instrumentation Panel......4730
Cold Temperature Starting......4732
Warming The Hydraulic / Hydrostatic System......4733
MONITORING THE DISPLAY PANELS......4734
Left Panel......4734
Warning And Shutdown......4734
STOPPING THE ENGINE AND LEAVING THE LOADER......4735
Procedure......4735
COUNTERWEIGHTS......4736
Description......4736
Effect On The Loader And Loader Operation......4736
When To Consider Using Counterweights......4736
When To Consider Removing Counterweights......4736
Accessories That Affect Machine Weight......4736
ATTACHMENTS......4737
Choosing The Correct Bucket......4737
Pallet Forks......4737
Installing And Removing The Attachment (Hand Lever Bob-Tach)......4738
Installing And Removing The Attachment (Power Bob-Tach)......4740
OPERATING PROCEDURE......4743
Inspect The Work Area......4743
Basic Operating Instructions......4743
Driving On Public Roads......4743
Operating With A Full Bucket......4744
Operating With An Empty Bucket......4744
Filling And Emptying The Bucket (Foot Pedals)......4745
Leveling The Ground Using Float (Foot Pedals)......4746
Digging And Filling A Hole (Foot Pedals)......4746
Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)......4747
Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)......4748
Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)......4749
Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)......4750
Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)......4751
Digging And Filling A Hole (SJC - ‘ISO’ Pattern)......4751
TOWING THE LOADER......4752
Procedure......4752
LIFTING THE LOADER......4753
Single-Point Lift......4753
Four-Point Lift......4753
TRANSPORTING THE LOADER ON A TRAILER......4754
Loading And Unloading......4754
Fastening......4754
PREVENTIVE MAINTENANCE......4755
MAINTENANCE SAFETY......4759
SERVICE SCHEDULE......4761
Chart......4761
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)......4762
Inspecting The BICS™ (Engine STOPPED - Key ON)......4762
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)......4762
Inspecting The Seat Bar Sensor (Engine RUNNING)......4762
Inspecting The Traction Lock (Engine RUNNING)......4762
Inspecting The Lift Arm Bypass Control......4762
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)......4762
SEAT BAR RESTRAINT SYSTEM......4763
Description......4763
Inspecting......4763
Maintaining......4763
SEAT BELT......4764
Inspection And Maintenance......4764
LIFT ARM SUPPORT DEVICE......4765
Installing......4765
Removing......4766
BACK-UP ALARM SYSTEM......4767
Description......4767
Inspecting......4767
Adjusting Switch Position......4767
OPERATOR CAB......4768
Description......4768
Raising......4768
Lowering......4769
Cab Door Sensor......4770
REAR DOOR (TAILGATE)......4771
Opening And Closing......4771
Adjusting......4771
REAR GRILLE......4771
Removing......4771
Installing......4771
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)......4772
Cleaning And Maintenance......4772
Filters......4772
Evaporator / Heater Coil......4772
Condenser......4772
Air Conditioning Lubrication......4772
Troubleshooting......4772
AIR CLEANER SERVICE......4773
Replacing Filter Elements......4773
FUEL SYSTEM......4775
Fuel Specifications......4775
Biodiesel Blend Fuel......4775
Filling The Fuel Tank......4776
Fuel Filter......4777
Removing Air From The Fuel System......4777
ENGINE LUBRICATION SYSTEM......4778
Checking And Adding Engine Oil......4778
Engine Oil Chart......4778
Removing And Replacing Oil And Filter......4778
ENGINE COOLING SYSTEM......4779
Cleaning......4779
Removing And Replacing Coolant......4780
Checking Level......4780
ELECTRICAL SYSTEM......4781
Description......4781
Fuse And Relay Location / Identification......4781
Battery Maintenance......4782
Using A Booster Battery (Jump Starting)......4783
Removing And Installing Battery......4784
HYDRAULIC / HYDROSTATIC SYSTEM......4785
Checking And Adding Fluid......4785
Hydraulic / Hydrostatic Fluid Chart......4785
Removing And Replacing Hydraulic Fluid......4786
Removing And Replacing Hydraulic / Hydrostatic Filter......4786
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)......4787
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)......4788
Removing And Replacing Hydraulic Charge Filter......4790
Breather Cap......4791
SPARK ARRESTER MUFFLER......4792
Cleaning Procedure......4792
TIRE MAINTENANCE......4793
Wheel Nuts......4793
Rotating......4793
Mounting......4793
FINAL DRIVE TRANSMISSION (CHAINCASE)......4794
Checking And Adding Oil......4794
Removing And Replacing Oil......4794
ALTERNATOR BELT......4795
Belt Adjustment......4795
Belt Replacement......4795
AIR CONDITIONING BELT......4796
Belt Adjustment......4796
Belt Replacement......4796
DRIVE BELT......4797
Belt Adjustment......4797
Belt Replacement......4799
LUBRICATING THE LOADER......4800
Lubrication Locations......4800
PIVOT PINS......4802
Inspection And Maintenance......4802
BOB-TACH (HAND LEVER)......4803
Inspection And Maintenance......4803
BOB-TACH (POWER)......4804
Inspection And Maintenance......4804
LOADER STORAGE AND RETURN TO SERVICE......4805
Storage......4805
Return To Service......4805
SYSTEM SETUP & ANALYSIS......4807
DIAGNOSTIC SERVICE CODES......4809
Viewing Service Codes......4809
Service Codes List......4810
CONTROL PANEL SETUP......4815
Right Panel Setup (Deluxe Instrumentation Panel)......4815
Attachment Control Information (Deluxe Instrumentation Panel)......4816
PASSWORD SETUP (KEYLESS START PANEL)......4817
Password Description......4817
Changing The Owner Password......4817
Password Lockout Feature......4817
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)......4818
Password Description......4818
Changing The Owner Password......4818
Changing The User Passwords......4819
Password Lockout Feature......4819
MAINTENANCE CLOCK......4820
Description......4820
Setup......4820
Reset......4820
MACHINE SIGN TRANSLATIONS......4821
MACHINE SIGN TRANSLATIONS......4823
Service Schedule (6734534)......4823
Danger (6702301)......4826
Warning (6577754)......4826
Danger (6702302)......4826
Danger (6717343)......4826
Important (6560573)......4827
Warning (7160879)......4827
Warning (6728539)......4828
Warning (6718706)......4829
Warning (6710358)......4829
Danger (6809511)......4829
Warning (6725370)......4830
Warning (6737189)......4830
Warning (6737248)......4830
Lift Arm Support Device (6719018)......4831
Warning (7131518)......4832
Warning (7131519)......4834
Warning (6579528)......4835
Warning (7168019)......4836
Warning (7142141)......4837
SPECIFICATIONS......4839
(S205) LOADER SPECIFICATIONS......4841
Machine Dimensions......4841
Performance......4842
Engine......4842
Drive System......4842
Controls......4843
Hydraulic System......4843
Electrical......4844
Capacities......4844
Tires......4844
WARRANTY......4845
WARRANTY......4847
ALPHABETICAL INDEX......4849
6987037 (7-09) - S205 Skid-Steer Loader Service Manual......4851
MAINTENANCE SAFETY......4853
ALPHABETICAL INDEX......4855
CONTENTS......4857
FOREWORD......4858
SAFETY INSTRUCTIONS......4861
FIRE PREVENTION......4863
Maintenance......4863
Operation......4863
Electrical......4863
Hydraulic System......4863
Fueling......4863
Starting......4863
Spark Arrestor Exhaust System......4863
Welding And Grinding......4864
Fire Extinguishers......4864
SERIAL NUMBER LOCATIONS......4865
Loader Serial Number......4865
Engine Serial Number......4865
DELIVERY REPORT......4866
LOADER IDENTIFICATION......4867
SAFETY AND MAINTENANCE......4869
LIFTING AND BLOCKING THE LOADER......4873
Procedure......4873
LIFT ARM SUPPORT DEVICE......4875
Installing......4875
Removing......4876
OPERATOR CAB......4877
Description......4877
Raising......4878
Lowering......4879
Cab Door Sensor......4880
Special Applications Kit......4880
Special Applications Kit Inspection And Maintenance......4880
TRANSPORTING THE LOADER ON A TRAILER......4881
Loading And Unloading......4881
Fastening......4881
TOWING THE LOADER......4883
Procedure......4883
REMOTE START TOOL KIT-MEL1563......4885
Remote Start Tool - MEL1563......4885
Service Tool Harness Control - MEL1565......4886
Service Tool Harness Communicator - MEL1566......4887
Remote Start Procedure......4888
REMOTE START TOOL (SERVICE TOOL) KIT - 6689779......4891
Description......4891
Remote Start Tool (Service Tool) - 6689778......4892
Loader Service Tool Harness - 6689747......4893
Computer Service Tool Harness - 6689746......4894
Remote Start Procedure......4895
SERVICE SCHEDULE......4899
Chart......4899
AIR CLEANER SERVICE......4901
Replacing Filter Elements......4901
ENGINE COOLING SYSTEM......4903
Cleaning......4903
Checking Level......4904
Removing And Replacing Coolant......4904
FUEL SYSTEM......4905
Fuel Specifications......4905
Biodiesel Blend Fuel......4905
Filling the Fuel Tank......4906
Fuel Filter......4907
Removing Air From The Fuel System......4907
ENGINE LUBRICATION SYSTEM......4909
Checking And Adding Engine Oil......4909
Engine Oil Chart......4909
Removing And Replacing Oil And Filter......4910
HYDRAULIC / HYDROSTATIC SYSTEM......4911
Checking And Adding Fluid......4911
Hydraulic / Hydrostatic Fluid Chart......4911
Removing And Replacing Hydraulic Fluid......4912
Removing And Replacing Hydraulic / Hydrostatic Filter......4912
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)......4913
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)......4914
Removing And Replacing Hydraulic Charge Filter......4916
Breather Cap......4917
FINAL DRIVE TRANSMISSION (CHAINCASE)......4919
Checking And Adding Oil......4919
Removing And Replacing Oil......4919
BOB-TACH (HAND LEVER)......4921
Inspection And Maintenance......4921
BOB-TACH (POWER)......4923
Inspection And Maintenance......4923
LUBRICATING THE LOADER......4925
Lubrication Locations......4925
TIRE MAINTENANCE......4927
Wheel Nuts......4927
Rotating......4927
Mounting......4927
SPARK ARRESTOR MUFFLER......4929
Cleaning Procedure......4929
PIVOT PINS......4931
Inspection And Maintenance......4931
LOADER STORAGE AND RETURN TO SERVICE......4933
Storage......4933
Return to Service......4933
STOPPING THE ENGINE AND LEAVING THE LOADER......4935
Procedure......4935
Emergency Exit......4936
HYDRAULIC SYSTEM......4937
HYDRAULIC / HYDROSTATIC SCHEMATICS......4941
HYDRAULIC SYSTEM INFORMATION......4957
Glossary Of Hydraulic / Hydrostatic Symbols......4957
Troubleshooting......4961
CYLINDER (LIFT)......4963
Testing......4963
Removal And Installation......4964
Parts Identification......4967
Disassembly and Assembly......4968
CYLINDER (TILT)......4971
Testing......4971
Removal And Installation......4972
Rod End Pivot Pin Bushing And Seal Removal And Installation......4974
Base End Pivot Pin Removal And Installation......4974
Parts Identification......4975
Disassembly And Assembly......4976
CYLINDER (BOB-TACH)......4979
Testing......4979
Removal And Installation......4980
Parts Identification......4981
Disassembly and Assembly......4982
MAIN RELIEF VALVE......4985
Description......4985
Testing......4985
Adjusting......4987
Removal and Installation......4988
HYDRAULIC CONTROL VALVE (STANDARD)......4989
Description......4989
Removal And Installation......4989
Identification Chart......4994
Mount Bracket Removal And Installation......4995
Lift Load Check Valve Removal And Installation......4995
Load Check Valve Removal And Installation (Tilt & Auxiliary)......4996
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)......4997
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)......4998
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)......4998
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)......4999
Port Relief Valve Removal And Installation......4999
Plug Removal And Installation......5000
Rubber Boot Removal And Installation......5001
End Cap / Spool Lock Block Removal And Installation......5002
Lift Spool And Detent Removal And Installation......5003
Tilt Spool Removal And Installation......5013
Auxiliary Spool Removal And Installation......5015
Auxiliary Solenoid Removal And Installation......5016
Solenoid Removal And Installation......5017
Lock Valve Removal And Installation......5019
Lift Arm Bypass Orifice Removal And Installation......5021
Main Relief Valve Removal And Installation......5021
Check Valve Removal And Installation......5022
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)......5023
Description......5023
Removal And Installation......5023
Actuator Removal And Installation (Out of Loader)......5028
Identification Chart......5031
Mount Bracket Removal And Installation......5032
Lift Load Check Valve Removal And Installation......5032
Load Check Valve Removal And Installation (Tilt & Auxiliary)......5033
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)......5034
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)......5035
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)......5035
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)......5036
Port Relief Valve Removal And Installation......5036
Plug Removal And Installation......5037
End Cap Block Removal And Installation......5038
Lift Spool And Detent Removal And Installation......5039
Tilt Spool Removal And Installation......5044
Auxiliary Spool Removal And Installation......5046
Auxiliary Solenoid Removal And Installation......5047
Solenoid Removal And Installation......5048
Lock Valve Removal And Installation......5050
Lift Arm Bypass Orifice Removal And Installation......5052
Main Relief Valve Removal And Installation......5053
Check Valve Removal And Installation......5054
LIFT ARM BYPASS CONTROL VALVE......5055
Description......5055
Testing......5055
Removal and Installation......5055
Disassembly And Assembly......5056
HYDRAULIC PUMP (STANDARD)......5057
Description......5057
Pump Test at Quick Couplers......5057
Direct Pump Test (Standard Section)......5058
Direct Pump Test (Charge Section)......5060
Removal And Installation......5062
Hydraulic Pump Startup......5064
Parts Identification......5065
Disassembly And Assembly......5066
HYDRAULIC PUMP (STANDARD) (HIGH FLOW)......5075
Description......5075
Pump Test at Quick Couplers......5075
Direct Pump Test (Standard Section)......5076
Direct Pump Test (Charge Section)......5078
Direct Pump Test (High Flow Section)......5080
Removal And Installation......5082
Hydraulic Pump Startup......5084
Parts Identification......5085
Disassembly And Assembly......5086
HYDRAULIC PUMP (SJC)......5099
Description......5099
Pump Test at Quick Couplers......5099
Direct Pump Test (Standard Section)......5100
Direct Pump Test (Charge Section)......5102
Removal And Installation......5104
Hydraulic Pump Startup......5106
Parts Identification......5108
Disassembly And Assembly......5109
HYDRAULIC PUMP (SJC) (HIGH FLOW)......5119
Description......5119
Pump Test at Quick Couplers......5119
Direct Pump Test (Standard Section)......5120
Direct Pump Test (Charge Section)......5122
Direct Pump Test (High Flow Section)......5124
Removal And Installation......5126
Hydraulic Pump Startup......5128
Parts Identification......5129
Disassembly And Assembly......5130
HYDRAULIC/HYDROSTATIC FILTERS......5143
Description......5143
Housing Removal And Installation......5143
Charge Filter Housing Removal And Installation......5145
HYDRAULIC FLUID RESERVOIR......5147
Description......5147
Removal And Installation......5147
Hydraulic Fluid Screen......5150
OIL COOLER......5151
Description......5151
Removal and Installation......5151
BUCKET POSITION VALVE......5153
Description......5153
Solenoid Removal And Installation......5153
Solenoid Testing......5154
Removal And Installation......5155
Disassembly And Assembly......5156
REAR AUXILIARY DIVERTER VALVE......5159
Description......5159
Removal And Installation......5159
Disassembly And Assembly......5162
Solenoid Testing......5168
BOB-TACH (POWER) BLOCK......5169
Description......5169
Removal And Installation......5169
Disassembly And Assembly......5171
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK......5175
Description......5175
Removal and Installation......5175
Disassembly And Assembly......5175
HIGH FLOW VALVE......5177
Description......5177
High Flow Relief Valve Testing......5177
High Flow Relief Valve Adjustment......5178
Solenoid Testing......5179
Removal And Installation......5180
Disassembly And Assembly......5181
HYDROSTATIC SYSTEM......5185
HYDROSTATIC SYSTEM INFORMATION......5187
Troubleshooting......5187
Description......5188
HYDROSTATIC MOTOR......5189
Description......5189
Removal And Installation......5189
Parts Identification......5192
Disassembly and Assembly......5193
HYDROSTATIC MOTOR (TWO-SPEED)......5199
Description......5199
Removal And Installation (Left Side)......5200
Removal And Installation (Right Side)......5203
Parts Identification......5206
Disassembly......5207
Assembly......5217
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH MANUAL CONTROLS)......5229
Description......5229
Shaft Seal Removal And Installation......5229
Removal And Installation......5231
Parts Identification......5233
Disassembly and Assembly......5234
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH SJC CONTROLS)......5239
Description......5239
Shaft Seal Removal And Installation......5239
Removal And Installation......5241
Parts Identification......5243
Disassembly and Assembly......5244
CHARGE PRESSURE......5249
Description......5249
Testing......5249
Sender Removal And Installation......5251
Adjusting......5251
HYDROSTATIC PUMP......5255
Description......5255
Replenishing/High Pressure Relief Valve Removal And Installation......5255
Removal And Installation......5256
Hydrostatic Pump Startup......5257
Parts Identification (Left Half)......5258
Parts Identification (Right Half)......5259
Disassembly......5260
Assembly......5266
HYDROSTATIC PUMP (SJC)......5273
Description......5273
Hydraulic Controller Removal And Installation......5274
Removal And Installation......5276
Hydrostatic Pump Startup......5278
Parts Identification......5279
High Pressure Relief and Bypass Valve......5280
Charge Relief Valve......5281
Disassembly and Assembly......5282
Mechanical Neutral Adjustment......5298
Hydraulic Controller Neutral Adjustment......5301
DRIVE BELT......5305
Description......5305
Shield Removal And Installation......5305
Adjusting......5305
Belt Removal And Installation......5307
Tensioner Pulley Removal And Installation......5308
Tensioner Pulley Parts Identification......5309
Tensioner Pulley Disassembly......5310
Tensioner Pulley Assembly......5311
TWO-SPEED VALVE......5313
Description......5313
Valve Removal And Installation......5314
Valve Disassembly And Assembly......5316
CASE DRAIN FILTER......5319
Description......5319
Disassembly And Assembly......5319
DRIVE SYSTEM......5321
BRAKE (SINGLE SPEED)......5323
Description......5323
Disc Removal And Installation......5323
BRAKE (TWO-SPEED)......5325
Description......5325
Disc Removal And Installation......5325
Disc Disassembly and Assembly......5326
DRIVE COMPONENTS......5327
Description......5327
Axle Seal Removal And Installation......5328
Axle Sprocket And Bearings Removal And Installation......5330
Chain Removal And Installation......5335
CHAINCASE......5337
Description......5337
Front Cover Removal And Installation......5337
Center Cover Removal And Installation......5338
Rear Cover Removal And Installation......5339
MAIN FRAME......5341
SEAT BAR......5345
Description......5345
Removal And Installation......5345
Disassembly And Assembly......5346
Compression Spring Disassembly And Assembly......5348
OPERATOR CAB......5349
Gas Cylinder Removal And Installation......5349
Gas Cylinder Bracket Disassembly And Assembly......5352
Removal And Installation......5352
OPERATOR SEAT......5355
Removal And Installation......5355
Seat Belt Removal And Installation......5355
OPERATOR SEAT (SUSPENSION)......5357
Removal And Installation......5357
Slide Rail Removal And Installation......5358
Seat Belt Removal and Installation......5358
Lower Cushion Removal And Installation......5358
Back Cushion Removal And Installation......5360
Shock Removal And Installation......5360
3-Point Seat Belt Removal And Installation......5361
BOB-TACH (HAND LEVER)......5363
Description......5363
Removal And Installation......5363
Lever And Wedge Disassembly And Assembly......5364
Pivot Pin Bushing And Seal Removal And Installation......5365
BOB-TACH (POWER)......5367
Description......5367
Removal And Installation......5367
Lever And Wedge Disassembly And Assembly......5369
Pivot Pin Bushing And Seal Removal And Installation......5370
LIFT ARMS......5371
Stabilizer Bar Removal And Installation......5371
Link Removal And Installation......5372
Removal And Installation......5373
REAR GRILL......5377
Removal And Installation......5377
REAR DOOR......5379
Removal And Installation......5379
Striker Removal and Installation......5380
Striker Disassembly and Assembly......5380
Striker (Adjusting)......5380
Latch Removal and Installation......5381
FUEL TANK......5383
Removal And Installation......5383
Fuel Level Sender Removal And Installation......5384
Fuel Fill Screen Removal And Installation......5385
CONTROL PEDALS AND LINKAGES......5387
Description......5387
Pedal Removal And Installation......5387
Linkage Removal And Installation......5388
Pedal (Adjusting)......5390
CONTROL PEDALS (ACS)......5391
Description......5391
Foot Sensor Removal And Installation......5391
Foot Pedal Removal And Installation......5392
Foot Pedal Linkage Disassembly And Assembly......5393
CONTROL PANEL......5395
Description......5395
Removal and Installation......5396
Shock Removal And Installation......5399
Shaft Removal And Installation......5399
Shaft Disassembly And Assembly......5400
Linkage Removal And Installation......5401
Pintle Arm Disassembly and Assembly......5405
Linkage Neutral (Adjusting)......5407
Linkage Travel (Adjusting)......5411
CONTROL PANEL (SJC)......5415
Description......5415
Removal And Installation......5415
CONTROL HANDLE / LEVER......5417
Description......5417
Lever Removal And Installation......5417
Boot Removal And Installation......5418
CONTROL HANDLE / LEVER (ACS)......5419
Description......5419
Handle Sensor Removal And Installation......5419
Handle Removal and Installation......5422
Handle Disassembly and Assembly......5423
Lever Removal and Installation......5423
Boot Removal And Installation......5425
CONTROL HANDLE / LEVER (SJC)......5427
Description......5427
Joystick Testing......5427
Joystick Removal And Installation......5428
Joystick Mount Removal And Installation......5429
ACCESS PANEL (INSIDE)......5431
Removal And Installation (Left)......5431
Removal And Installation (Right)......5431
ACCESS PANEL (INSIDE) (SJC)......5433
Removal And Installation (Left)......5433
Removal And Installation (Right)......5434
WINDOW (REAR)......5437
Removal......5437
Installation (Split Molding)......5437
Installation (Continuous Molding)......5439
WINDOW (TOP)......5441
Removal And Installation......5441
WINDOW (SIDE)......5443
Removal And Installation......5443
WINDOW (CAB DOOR)......5445
Removal (Standard Window)......5445
Installation (Standard Window)......5446
Removal And Installation (Special Applications Window)......5448
CAB DOOR......5449
Description......5449
Removal And Installation......5449
Aligning......5450
Adjusting......5451
Checking Operation......5451
ELECTRICAL SYSTEM & ANALYSIS......5453
ELECTRICAL SCHEMATICS......5457
ELECTRICAL SYSTEM INFORMATION......5463
Glossary Of Electrical Symbols......5463
Standard Cab Harness Connectors......5466
Deluxe Cab Harness Connectors......5467
Mainframe Harness Connectors......5468
Description......5469
Troubleshooting......5470
Fuse And Relay Location / Identification......5471
Solenoid Testing......5472
BATTERY......5473
Removal And Installation......5473
Servicing......5474
Using A Booster Battery (Jump Starting)......5474
ALTERNATOR......5477
Belt Adjustment......5477
Belt Replacement......5477
Charging System Inspection......5478
Alternator Voltage Testing......5479
Low Voltage Testing......5480
High Voltage Testing......5480
Removal And Installation......5481
Parts Identification......5482
STARTER......5483
Testing......5483
Removal And Installation......5484
Parts Identification......5485
INSTRUMENT PANELS......5487
Left Panel......5487
Standard Key Panel......5489
Deluxe Instrumentation Panel......5490
Side Panel......5491
Front Panel......5491
Front Panel Removal And Installation......5492
Removal And Installation (Left And Right)......5493
Key Switch Removal And Installation......5494
Alarm Removal And Installation......5494
LIGHTS......5495
Front Removal And Installation......5495
Rear Removal And Installation......5496
Cab Light Removal And Installation......5496
BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)......5497
Description......5497
Connector Identification......5498
Removal and Installation......5504
BOBCAT CONTROLLER (ACS)......5507
Description......5507
Connector Identification......5508
Removal and Installation......5509
BOBCAT CONTROLLER (SJC) (DRIVE)......5511
Description......5511
Connector Identification......5512
Removal and Installation......5514
SPEED SENSORS (SJC)......5515
Description......5515
Testing......5515
Removal And Installation......5517
DIAGNOSTIC SERVICE CODES......5519
Viewing Service Codes (Standard Key Panel)......5519
Viewing Service Codes (Deluxe Instrumentation Panel)......5519
Service Codes List......5520
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)......5525
Description......5525
Inspecting The BICS Controller (Engine STOPPED - Key ON)......5526
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)......5526
Inspecting The Seat Bar Sensor (Engine RUNNING)......5526
Inspecting The Traction Lock (Engine RUNNING)......5526
Inspecting The Lift Arm Bypass Control......5526
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)......5526
Troubleshooting......5527
SEAT BAR SENSOR......5529
Description......5529
Troubleshooting......5529
Testing......5530
Removal And Installation......5531
Bobcat Interlock Control System (BICS) Circuit Test......5533
TRACTION LOCK......5535
Description......5535
Troubleshooting......5535
Removal And Installation......5536
Inspecting......5540
CONTROL SYSTEM (ACS)......5541
Description......5541
Troubleshooting......5542
Handle Sensor Connector Disassembly And Assembly......5543
Switch Handle Removal......5544
Switch Handle Installation......5546
Actuator Connector Disassembly And Assembly......5549
Handle Lock Solenoid Removal And Installation......5550
Handle Lock Solenoid Disassembly And Assembly......5550
Foot Sensor Disassembly And Assembly......5551
Foot Lock Solenoid Removal And Installation......5552
ELECTRICAL / HYDRAULIC CONTROLS......5553
Identification Chart......5553
ELECTRICAL / HYDRAULIC CONTROLS (SJC)......5555
Identification Chart......5555
SERVICE PC (LAPTOP COMPUTER)......5559
Connecting Remote Start Tool......5559
Connecting Remote Start Tool (Service Tool)......5559
CALIBRATION......5561
Description......5561
Actuator Testing......5561
Lift And Tilt Calibration (ACS)......5563
Lift And Tilt Calibration (SJC)......5565
Hydrostatic Pump Calibration (SJC)......5567
STEERING DRIFT COMPENSATION......5573
Description......5573
Operation......5573
FLYWHEEL RPM SENSOR......5575
Description......5575
Adjusting......5575
CONTROL PANEL SETUP......5577
Right Panel Setup (Deluxe Instrumentation Panel)......5577
Right Panel Setup (Deluxe Instrumentation Panel)......5578
Attachment Control Information (Deluxe Instrumentation Panel)......5578
PASSWORD SETUP......5579
Password Description......5579
Changing The Owner Password......5579
Changing The User Passwords......5580
Password Lockout Feature......5580
MAINTENANCE CLOCK......5581
Description......5581
Setup......5582
Reset......5585
BACK-UP ALARM SYSTEM......5587
Description......5587
Inspecting......5587
Adjusting Switch Position......5588
Troubleshooting (Standard and ACS)......5589
Troubleshooting (Joystick)......5590
Alarm Removal And Installation......5591
Switch Removal And Installation......5591
ENGINE SERVICE......5593
ENGINE INFORMATION......5597
Description......5597
Specifications - Kubota V2403-M-DI-T......5598
Torque Values......5602
Troubleshooting......5602
Engine Removal And Installation......5604
Engine Mount Replacement......5611
Compression - Checking......5612
ENGINE SPEED CONTROL......5613
Removal And Installation......5613
ENGINE SPEED CONTROL (SJC)......5615
Removal And Installation......5615
Disassembly And Assembly......5617
MUFFLER......5619
Removal And Installation......5619
AIR CLEANER......5621
Housing Removal And Installation......5621
ENGINE COOLING SYSTEM......5623
Radiator Removal And Installation......5623
Hydraulic Fan Description......5626
Hydraulic Fan Disassembly And Assembly......5626
Blower Housing Removal And Installation......5627
Fan Removal And Installation......5629
Hydraulic Fan Motor Removal And Installation......5629
Water Pump Removal And Installation......5630
Water Pump Disassembly And Assembly......5630
Thermostat Housing Removal And Installation......5631
Thermostat - Checking......5632
LUBRICATION SYSTEM......5633
Oil Pan Removal And Installation......5633
Oil Pump Removal And Installation......5633
Oil Pump Inspection......5634
Engine Oil Pressure - Testing......5635
FUEL SYSTEM......5637
Fuel Shutoff Solenoid - Checking......5637
Fuel Shutoff Solenoid Removal And Installation......5637
Fuel Injection Pump - Checking......5638
Fuel Injection Pump Removal And Installation......5639
Governor Disassembly And Assembly......5643
Fuel Camshaft Removal And Installation......5644
Injection Pump - Timing......5645
Fuel Injector Removal And Installation......5647
Fuel Injector Nozzle Pressure - Checking......5648
Nozzle Spray Condition......5649
Valve Seat Tightness......5649
CYLINDER HEAD......5651
Glow Plugs - Testing......5651
Glow Plugs Removal And Installation......5651
Valve Clearance Adjustment......5652
Valve Timing - Checking......5653
Cylinder Head Removal And Installation......5654
Cylinder Head Disassembly and Assembly......5657
Cylinder Head - Servicing......5657
Cylinder Head Top Clearance......5658
Valve Guide - Checking......5658
Reconditioning The Valve And Valve Seat......5659
Valve Spring......5661
Valve Tappets......5662
Rocker Arm And Shaft Checking......5662
CRANKSHAFT AND PISTONS......5663
Piston And Connecting Rod Removal And Installation......5663
Piston And Connecting Rod - Servicing......5664
Cylinder Bore - Checking......5667
Connecting Rod Alignment......5667
Crankshaft Gear Removal And Installation......5668
Crankshaft And Bearings Removal And Installation......5668
Crankshaft And Bearings - Servicing......5670
CAMSHAFT AND TIMING GEARS......5675
Timing Gearcase Cover Removal And Installation......5675
Timing Gears Backlash-Checking......5677
Idler Gear And Camshaft Removal And Installation......5678
Camshaft - Servicing......5679
Idler Gear And Shaft Servicing......5680
TURBOCHARGER......5681
Description......5681
Testing......5681
Removal And Installation......5682
FLYWHEEL AND HOUSING......5685
Flywheel Removal And Installation......5685
Ring Gear Removal And Installation......5685
Housing Removal And Installation......5686
HEATING, VENTILATION, AIR CONDITIONING......5689
AIR CONDITIONING SYSTEM FLOW......5692
Description......5692
Chart......5693
Components......5694
Safety Equipment......5697
REGULAR MAINTENANCE......5699
Filters......5699
Compressor Drive Belt Adjustment......5699
Compressor Drive Belt Replacement......5699
Condenser......5700
Air Conditioning Lubrication......5700
Air Conditioning Service Chart......5701
Evaporator / Heater Coil......5702
TROUBLESHOOTING......5703
Blower Motor Does Not Operate......5703
Blower Motor Operates Normally, But Air Flow Is Insufficient......5703
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal......5703
The Compressor Does Not Operate At All, Or Operates Improperly......5703
Gauge Pressure Related Troubleshooting......5704
Troubleshooting Tree......5706
Temperature / Pressure Chart......5710
Poor A/C Performance......5711
HVAC Repair And Leaks......5712
Electrical System......5713
Engine Coolant Bypassing The Heater Valve......5720
Heater Valve Not Opening Or Closing......5721
SYSTEM CHARGING AND RECLAMATION......5723
Refrigerant Identification......5723
Reclamation And Charging With Recovery / Charging Unit......5724
Charging With A Manifold Gauge Set......5726
COMPRESSOR......5729
Removal And Installation......5729
Oil......5730
Oil Check......5731
Clutch Disassembly And Assembly......5733
CONDENSER......5737
Removal And Installation......5737
RECEIVER/DRIER......5739
Receiver/Drier Removal And Installation......5739
Pressure Relief Valve Removal And Installation......5740
Pressure Switch Removal And Installation......5741
Schraeder Valve Removal And Installation......5742
EVAPORATOR / HEATER UNIT......5743
Removal And Installation......5743
THERMOSTAT......5745
Removal And Installation......5745
EXPANSION VALVE......5747
Removal And Installation......5747
EVAPORATOR COIL......5749
Removal And Installation......5749
HEATER COIL......5751
Removal And Installation With A/C......5751
Removal And Installation Without A/C......5753
BLOWER FAN......5755
Removal And Installation......5755
Disassembly And Assembly......5756
Connector Identification......5758
HEATER VALVE......5759
Removal and Installation......5759
Disassembly And Assembly......5760
SPECIFICATIONS......5761
S205 LOADER SPECIFICATIONS......5763
Dimensions......5763
Performance......5764
Controls......5764
Engine......5764
Hydraulic System......5765
Electrical......5765
Drive System......5766
Capacities......5766
Tires......5766
TORQUE SPECIFICATIONS FOR BOLTS......5767
Torque For General SAE Bolts......5767
Torque For General Metric Bolts......5768
HYDRAULIC CONNECTION SPECIFICATIONS......5769
O-ring Face Seal Connection......5769
Straight Thread O-ring Fitting......5770
Tubelines And Hoses......5770
Flare Fitting......5771
Port Seal Fitting......5772
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS......5773
Specifications......5773
CONVERSIONS......5775
Decimal And Millimeter Equivalents......5775
U.S. To Metric Conversion Chart......5775
SERVICE MANUAL REVISION......5777
Revision No: S205 - 1......5777
Revision No: S205 - 2......5779
Revision No: S205 - 3......5781
6987050 (7-14) - S205 Skid-Steer Loader Service Manual......5783
MAINTENANCE SAFETY......5785
CONTENTS......5787
FOREWORD......5789
FOREWORD......5791
SAFETY INSTRUCTIONS......5793
FIRE PREVENTION......5795
Maintenance......5795
Operation......5795
Electrical......5795
Hydraulic System......5795
Fueling......5795
Starting......5795
Spark Arrester Exhaust System......5795
Welding And Grinding......5796
Fire Extinguishers......5796
SERIAL NUMBER LOCATIONS......5797
Loader Serial Number......5797
Engine Serial Number......5797
DELIVERY REPORT......5798
LOADER IDENTIFICATION......5799
SAFETY & MAINTENANCE......5801
LIFTING AND BLOCKING THE LOADER......5805
Procedure......5805
LIFT ARM SUPPORT DEVICE......5807
Installing......5807
Removing......5808
OPERATOR CAB......5809
Description......5809
Raising......5809
Lowering......5810
Cab Door Sensor......5812
Special Applications Kit......5813
Special Applications Kit Inspection And Maintenance......5813
TRANSPORTING THE LOADER ON A TRAILER......5815
Loading And Unloading......5815
Fastening......5815
TOWING THE LOADER......5817
Procedure......5817
REMOTE START TOOL KIT-MEL1563......5819
Remote Start Tool - MEL1563......5819
Service Tool Harness Control - MEL1565......5820
Service Tool Harness Communicator - MEL1566......5821
Remote Start Procedure......5822
REMOTE START TOOL (SERVICE TOOL) KIT - 7217666......5825
Description......5825
Remote Start Tool (Service Tool) - 7022042......5826
Loader Service Tool Harness - 6689747......5827
Computer Service Tool Harness - 6689746......5828
Remote Start Procedure......5829
SERVICE SCHEDULE......5833
Chart......5833
AIR CLEANER SERVICE......5835
Replacing Filter Elements......5835
ENGINE COOLING SYSTEM......5837
Cleaning......5837
Checking Level......5838
Removing And Replacing Coolant......5839
FUEL SYSTEM......5841
Fuel Specifications......5841
Biodiesel Blend Fuel......5841
Filling The Fuel Tank......5842
Fuel Filter......5843
Removing Air From The Fuel System......5843
ENGINE LUBRICATION SYSTEM......5845
Checking And Adding Engine Oil......5845
Engine Oil Chart......5845
Removing And Replacing Oil And Filter......5846
HYDRAULIC / HYDROSTATIC SYSTEM......5847
Checking And Adding Fluid......5847
Hydraulic / Hydrostatic Fluid Chart......5847
Removing And Replacing Hydraulic Fluid......5848
Removing And Replacing Hydraulic / Hydrostatic Filter......5848
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders)......5849
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders)......5850
Removing And Replacing Hydraulic Charge Filter......5852
Breather Cap......5853
FINAL DRIVE TRANSMISSION (CHAINCASE)......5855
Checking And Adding Oil......5855
Removing And Replacing Oil......5856
BOB-TACH (HAND LEVER)......5857
Inspection And Maintenance......5857
BOB-TACH (POWER)......5859
Inspection And Maintenance......5859
LUBRICATING THE LOADER......5861
Lubrication Locations......5861
TIRE MAINTENANCE......5863
Wheel Nuts......5863
Rotating......5863
Mounting......5863
SPARK ARRESTER MUFFLER......5865
Cleaning Procedure......5865
PIVOT PINS......5867
Inspection And Maintenance......5867
LOADER STORAGE AND RETURN TO SERVICE......5869
Storage......5869
Return To Service......5869
STOPPING THE ENGINE AND LEAVING THE LOADER......5871
Procedure......5871
EMERGENCY EXIT......5873
Rear Window......5873
Front Door......5873
SEAT BELT......5875
Inspection And Maintenance......5875
HYDRAULIC SYSTEM......5877
HYDRAULIC/HYDROSTATIC SCHEMATICS......5883
HYDRAULIC SYSTEM INFORMATION......5899
Glossary Of Hydraulic / Hydrostatic Symbols......5899
Troubleshooting......5903
CYLINDER (LIFT)......5905
Testing......5905
Removal And Installation......5906
Parts Identification......5908
Disassembly And Assembly......5909
CYLINDER (TILT)......5913
Testing......5913
Removal And Installation......5914
Rod End Pivot Pin Bushing And Seal Removal And Installation......5915
Base End Pivot Pin Removal And Installation......5916
Parts Identification......5917
Disassembly And Assembly......5918
CYLINDER (BOB-TACH)......5921
Testing......5921
Removal And Installation......5922
Parts Identification......5923
Disassembly And Assembly......5924
MAIN RELIEF VALVE......5927
Description......5927
Testing......5927
Adjusting......5929
Removal And Installation......5930
HYDRAULIC CONTROL VALVE (STANDARD)......5931
Description......5931
Removal And Installation......5932
Identification Chart......5937
Mount Bracket Removal And Installation......5938
Lift Load Check Valve Removal And Installation......5938
Load Check Valve Removal And Installation (Tilt And Auxiliary)......5939
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)......5940
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)......5941
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)......5941
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)......5942
Port Relief Valve Removal And Installation......5942
Plug Removal And Installation......5943
Rubber Boot Removal And Installation......5944
End Cap / Spool Lock Block Removal And Installation......5945
Lift Spool And Detent Removal And Installation......5946
Tilt Spool Removal And Installation......5956
Auxiliary Spool Removal And Installation......5958
Auxiliary Solenoid Removal And Installation (S/N A3LJ34999 & Below And A3LK34999 & Below)......5960
Auxiliary Solenoid Removal And Installation (S/N A3LJ35001 & Above And A3LK35001 & Above)......5961
Solenoid Removal And Installation......5962
Lock Valve Removal And Installation......5963
Lift Arm Bypass Orifice Removal And Installation......5965
Main Relief Valve Removal And Installation......5965
Check Valve Removal And Installation......5966
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)......5967
Description......5967
Removal And Installation......5968
Actuator Removal And Installation (Out Of Loader)......5972
Identification Chart......5975
Mount Bracket Removal And Installation......5976
Lift Load Check Valve Removal And Installation......5976
Load Check Valve Removal And Installation (Tilt And Auxiliary)......5977
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)......5978
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)......5979
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)......5979
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)......5980
Port Relief Valve Removal And Installation......5980
Plug Removal And Installation......5981
End Cap Block Removal And Installation......5982
Lift Spool And Detent Removal And Installation......5983
Tilt Spool Removal And Installation......5988
Auxiliary Spool Removal And Installation......5990
Auxiliary Solenoid Removal And Installation (S/N A3LJ34999 & Below And A3LK34999 & Below)......5992
Auxiliary Solenoid Removal And Installation (S/N A3LJ35001 & Above And A3LK35001 & Above)......5993
Solenoid Removal And Installation......5994
Lock Valve Removal And Installation......5995
Lift Arm Bypass Orifice Removal And Installation......5997
Main Relief Valve Removal And Installation......5997
Check Valve Removal And Installation......5998
LIFT ARM BYPASS CONTROL VALVE......5999
Description......5999
Testing......5999
Removal And Installation......6000
Disassembly And Assembly......6001
HYDRAULIC PUMP (STANDARD)......6003
Description......6003
Pump Test At Quick Couplers......6003
Direct Pump Test (Standard Section)......6004
Direct Pump Test (Charge Section)......6006
Removal And Installation......6008
Hydraulic Pump Startup......6010
Parts Identification......6011
Disassembly And Assembly......6012
HYDRAULIC PUMP (STANDARD) (HIGH FLOW)......6021
Description......6021
Pump Test At Quick Couplers......6021
Direct Pump Test (Standard Section)......6022
Direct Pump Test (Charge Section)......6024
Direct Pump Test (High Flow Section)......6026
Removal And Installation......6028
Hydraulic Pump Startup......6030
Parts Identification......6031
Disassembly And Assembly......6032
HYDRAULIC PUMP (SJC)......6045
Description......6045
Pump Test At Quick Couplers......6045
Direct Pump Test (Standard Section)......6046
Direct Pump Test (Charge Section)......6048
Removal And Installation......6050
Hydraulic Pump Startup......6052
Parts Identification......6053
Disassembly And Assembly......6054
HYDRAULIC PUMP (SJC) (HIGH FLOW)......6063
Description......6063
Pump Test At Quick Couplers......6063
Direct Pump Test (Standard Section)......6064
Direct Pump Test (Charge Section)......6066
Direct Pump Test (High Flow Section)......6068
Removal And Installation......6070
Hydraulic Pump Startup......6072
Parts Identification......6073
Disassembly And Assembly......6074
HYDRAULIC / HYDROSTATIC FILTERS......6087
Description......6087
Housing Removal And Installation......6087
Charge Filter Housing Removal And Installation......6089
HYDRAULIC FLUID RESERVOIR......6091
Description......6091
Removal And Installation......6091
Hydraulic Fluid Screen......6094
OIL COOLER......6095
Description......6095
Removal And Installation......6095
BUCKET POSITION VALVE......6097
Description......6097
Solenoid Removal And Installation......6097
Solenoid Testing......6098
Removal And Installation......6099
Disassembly And Assembly......6101
REAR AUXILIARY DIVERTER VALVE......6103
Description......6103
Solenoid Testing......6103
Removal And Installation......6104
Disassembly And Assembly......6107
BOB-TACH (POWER) BLOCK......6113
Description......6113
Removal And Installation......6113
Disassembly And Assembly......6115
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK......6121
Description......6121
Removal And Installation......6121
Disassembly And Assembly......6122
HIGH FLOW VALVE......6125
Description......6125
High Flow Relief Valve Testing......6125
High Flow Relief Valve Adjustment......6127
Solenoid Testing......6127
Removal And Installation......6128
Disassembly And Assembly......6130
HYDROSTATIC SYSTEM......6133
HYDROSTATIC SYSTEM INFORMATION......6135
Troubleshooting......6135
Description......6136
HYDROSTATIC DRIVE MOTOR......6137
Description......6137
Removal And Installation......6138
Parts Identification......6140
Disassembly And Assembly......6141
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)......6147
Description......6147
Removal And Installation (Left Side)......6148
Removal And Installation (Right Side)......6150
Parts Identification......6154
Disassembly......6155
Assembly......6165
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH MANUAL CONTROLS)......6177
Description......6177
Shaft Seal Removal And Installation......6178
Removal And Installation......6180
Parts Identification......6182
Disassembly And Assembly......6183
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH SJC CONTROLS)......6189
Description......6189
Shaft Seal Removal And Installation......6190
Removal And Installation......6192
Parts Identification......6194
Disassembly And Assembly......6195
CHARGE PRESSURE......6201
Description......6201
Testing (S/N A3LJ29999 & Below And A3LK29999 & Below)......6202
Sender Removal And Installation (S/N A3LJ29999 & Below And A3LK29999 & Below)......6203
Testing (S/N A3LJ30001 & Above And A3LK30001 & Above)......6204
Sender Removal And Installation (S/N A3LJ30001 & Above And A3LK30001 & Above)......6205
Adjusting......6206
HYDROSTATIC PUMP......6209
Description......6209
Replenishing / High Pressure Relief Valve Removal And Installation......6209
Removal And Installation......6210
Hydrostatic Pump Startup......6211
Parts Identification (Left Half)......6212
Parts Identification (Right Half)......6213
Disassembly......6214
Assembly......6220
HYDROSTATIC PUMP (SJC)......6227
Description......6227
Hydraulic Controller Removal And Installation......6228
Removal And Installation......6230
Hydrostatic Pump Startup......6232
Parts Identification......6233
High Pressure Relief And Bypass Valve......6234
Charge Relief Valve......6235
Disassembly And Assembly......6236
Mechanical Neutral Adjustment......6251
Hydraulic Controller Neutral Adjustment......6254
DRIVE BELT......6257
Description......6257
Shield Removal And Installation......6257
Adjusting......6258
Belt Removal And Installation......6259
Tensioner Pulley Removal And Installation......6260
Tensioner Pulley Parts Identification......6261
Tensioner Pulley Disassembly......6262
Tensioner Pulley Assembly......6263
TWO-SPEED VALVE......6265
Description......6265
Valve Removal And Installation......6266
Valve Disassembly And Assembly......6268
CASE DRAIN FILTER......6271
Description......6271
Disassembly And Assembly......6271
DRIVE SYSTEM......6273
BRAKE (SINGLE SPEED)......6275
Description......6275
Disc Removal And Installation......6275
BRAKE (TWO-SPEED)......6277
Description......6277
Disc Removal And Installation......6278
Disc Disassembly And Assembly......6279
DRIVE COMPONENTS......6281
Description......6281
Axle Seal Removal And Installation......6282
Axle Sprocket And Bearings Removal And Installation......6284
Chain Removal And Installation......6289
CHAINCASE......6291
Description......6291
Front Cover Removal And Installation......6291
Center Cover Removal And Installation......6292
Rear Cover Removal And Installation......6293
MAINFRAME......6295
SEAT BAR......6299
Description......6299
Removal And Installation......6299
Disassembly And Assembly......6300
Compression Spring Disassembly And Assembly......6301
OPERATOR CAB......6303
Gas Cylinder Removal And Installation......6303
Gas Cylinder Bracket Disassembly And Assembly......6306
Removal And Installation......6306
OPERATOR SEAT......6309
Removal And Installation......6309
Seat Belt Removal And Installation......6310
OPERATOR SEAT (SUSPENSION)......6311
Removal And Installation......6311
Slide Rail Removal And Installation......6312
Seat Belt Removal And Installation......6312
Lower Cushion Removal And Installation......6313
Back Cushion Removal And Installation......6314
Shock Removal And Installation......6314
3-Point Seat Belt Removal And Installation......6315
BOB-TACH (HAND LEVER)......6317
Description......6317
Removal And Installation......6317
Lever And Wedge Disassembly And Assembly......6318
Pivot Pin Bushing And Seal Removal And Installation......6320
BOB-TACH (POWER)......6321
Description......6321
Removal And Installation......6321
Lever And Wedge Disassembly And Assembly......6323
Pivot Pin Bushing And Seal Removal And Installation......6324
LIFT ARMS......6325
Stabilizer Bar Removal And Installation......6325
Link Removal And Installation......6326
Removal And Installation......6327
REAR GRILLE......6331
Removal And Installation......6331
REAR DOOR (TAILGATE)......6333
Removal And Installation......6333
Striker Removal And Installation......6334
Striker Disassembly And Assembly......6334
Striker (Adjusting)......6334
Latch Removal And Installation......6335
FUEL TANK......6337
Removal And Installation......6337
Fuel Level Sender Removal And Installation......6338
Fuel Fill Screen Removal And Installation......6338
CONTROL PEDALS AND LINKAGES......6339
Description......6339
Pedal Removal And Installation......6339
Linkage Removal And Installation......6340
Pedal (Adjusting)......6342
CONTROL PEDALS (ACS)......6343
Description......6343
Foot Sensor Removal And Installation......6343
Foot Pedal Removal And Installation......6344
Foot Pedal Linkage Disassembly And Assembly......6344
CONTROL PANEL......6345
Description......6345
Removal And Installation......6346
Shock Removal And Installation......6349
Shaft Removal And Installation......6349
Shaft Disassembly And Assembly......6350
Linkage Removal And Installation......6351
Pintle Arm Disassembly And Assembly......6354
Linkage Neutral (Adjusting)......6356
Linkage Travel (Adjusting)......6360
CONTROL PANEL (SJC)......6365
Description......6365
Removal And Installation......6365
CONTROL HANDLE / LEVER......6367
Description......6367
Lever Removal And Installation......6367
Boot Removal And Installation......6368
CONTROL HANDLE / LEVER (ACS)......6369
Description......6369
Handle Sensor Removal And Installation......6369
Handle Removal And Installation......6372
Handle Disassembly And Assembly......6373
Lever Removal And Installation......6374
Boot Removal And Installation......6375
CONTROL HANDLE / LEVER (SJC)......6377
Description......6377
Joystick Testing......6378
Joystick Removal And Installation......6379
Joystick Mount Removal And Installation......6380
ACCESS PANEL (INSIDE)......6381
Removal And Installation (Left)......6381
Removal And Installation (Right)......6381
ACCESS PANEL (INSIDE) (SJC)......6383
Removal And Installation (Left)......6383
Removal And Installation (Right)......6384
WINDOW (REAR)......6387
Removal......6387
Installation (Split Molding)......6387
Installation (Continuous Molding)......6389
WINDOW (TOP)......6391
Removal And Installation......6391
WINDOW (SIDE)......6393
Removal And Installation......6393
WINDOW (CAB DOOR)......6395
Removal (Standard Window)......6395
Installation (Standard Window)......6396
Removal And Installation (Special Applications Window)......6397
CAB DOOR......6399
Description......6399
Removal And Installation......6399
Aligning......6400
Adjusting......6401
Checking Operation......6401
ELECTRICAL SYSTEM & ANALYSIS......6403
ELECTRICAL SCHEMATICS......6407
ELECTRICAL SYSTEM INFORMATION......6413
Glossary Of Electrical Symbols......6413
Standard Cab Harness Connectors......6416
Deluxe Cab Harness Connectors......6417
Mainframe Harness Connectors......6418
Description......6419
Troubleshooting......6420
Fuse And Relay Location / Identification......6421
Solenoid Testing......6422
BATTERY......6423
Removal And Installation......6423
Servicing......6424
Using A Booster Battery (Jump Starting)......6425
ALTERNATOR......6427
Belt Adjustment......6427
Belt Replacement......6427
Charging System Inspection......6428
Alternator Voltage Testing......6429
Low Voltage Testing......6429
High Voltage Testing......6430
Removal And Installation......6431
Parts Identification......6432
STARTER......6433
Testing......6433
Removal And Installation......6433
Parts Identification......6434
INSTRUMENT PANELS......6435
Left Panel......6435
Standard Key Panel......6437
Keyless Start Panel......6437
Deluxe Instrumentation Panel......6438
Side Panel......6439
Front Panel......6439
Front Panel Removal And Installation......6440
Removal And Installation (Left And Right)......6441
Key Switch Removal And Installation......6442
Alarm Removal And Installation......6442
LIGHTS......6443
Front Removal And Installation......6443
Rear Removal And Installation......6444
Cab Light Removal And Installation......6444
BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)......6445
Description......6445
Connector Identification......6446
Removal And Installation......6452
BOBCAT CONTROLLER (ACS)......6455
Description......6455
Connector And Wire Identification......6456
Removal And Installation......6457
BOBCAT CONTROLLER (SJC) (DRIVE)......6459
Description......6459
Connector Identification......6460
Removal And Installation......6462
SPEED SENSORS (SJC)......6463
Description......6463
Testing......6463
Removal And Installation......6465
DIAGNOSTIC SERVICE CODES......6467
Viewing Service Codes......6467
Service Codes List......6468
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)......6473
Description......6473
Inspecting The BICS™ (Engine STOPPED - Key ON)......6474
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)......6474
Inspecting The Seat Bar Sensor (Engine RUNNING)......6474
Inspecting The Traction Lock (Engine RUNNING)......6474
Inspecting The Lift Arm Bypass Control......6474
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)......6474
Troubleshooting......6475
SEAT BAR SENSOR......6477
Description......6477
Troubleshooting......6477
Testing......6478
Removal And Installation......6479
Bobcat Interlock Control System (BICS™) Circuit Test......6482
TRACTION LOCK......6485
Description......6485
Troubleshooting......6485
Removal And Installation......6486
Inspecting......6490
CONTROL SYSTEM (ACS)......6491
Description......6491
Troubleshooting......6492
Handle Sensor Connector Disassembly And Assembly......6493
Switch Handle Removal......6494
Switch Handle Installation......6496
Actuator Connector Disassembly And Assembly......6499
Handle Lock Solenoid Removal And Installation......6500
Handle Lock Solenoid Disassembly And Assembly......6500
Foot Sensor Disassembly And Assembly......6501
Foot Lock Solenoid Removal And Installation......6502
ELECTRICAL / HYDRAULIC CONTROLS......6503
Identification Chart......6503
Description......6504
Identification Chart ACD Group 0......6505
Identification Chart ACD Group 1......6506
Identification Chart ACD Group 2......6507
Identification Chart ACD Group 3......6508
ELECTRICAL / HYDRAULIC CONTROLS (ACS)......6509
Identification Chart......6509
Description......6510
Identification Chart ACD Group 0......6511
Identification Chart ACD Group 1......6512
Identification Chart ACD Group 2......6513
Identification Chart ACD Group 3......6514
ELECTRICAL / HYDRAULIC CONTROLS (SJC)......6515
Identification Chart......6515
Description......6516
Identification Chart ACD Group 0......6517
Identification Chart ACD Group 1......6518
Identification Chart ACD Group 2......6519
Identification Chart ACD Group 3......6520
SERVICE PC (LAPTOP COMPUTER)......6521
Connecting Remote Start Tool......6521
Connecting Remote Start Tool (Service Tool)......6521
CALIBRATION......6523
Description......6523
Actuator Testing......6523
Lift And Tilt Calibration (SJC)......6526
Hydrostatic Pump Calibration (SJC)......6528
Lift And Tilt Calibration (ACS)......6533
STEERING DRIFT COMPENSATION......6535
Description......6535
Operation......6535
FLYWHEEL RPM SENSOR......6537
Description......6537
Adjusting......6537
CONTROL PANEL SETUP......6539
Right Panel Setup (Deluxe Instrumentation Panel)......6539
Attachment Control Information (Deluxe Instrumentation Panel)......6540
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)......6541
Password Description......6541
Changing The Owner Password......6541
Changing The User Passwords......6542
Password Lockout Feature......6542
PASSWORD SETUP (KEYLESS START PANEL)......6543
Password Description......6543
Changing The Owner Password......6543
Password Lockout Feature......6543
MAINTENANCE CLOCK......6545
Description......6545
Setup......6546
Reset......6549
BACK-UP ALARM SYSTEM......6551
Description......6551
Inspecting......6551
Adjusting Switch Position......6552
Troubleshooting (Standard And ACS)......6553
Troubleshooting (Joystick)......6554
Alarm Removal And Installation......6555
Switch Removal And Installation......6555
ENGINE SERVICE......6557
ENGINE INFORMATION......6561
Description......6561
Specifications......6562
Torque Values......6566
Troubleshooting......6566
Engine Removal And Installation......6568
Engine Mount Replacement......6575
Compression - Checking......6576
ENGINE SPEED CONTROL......6577
Removal And Installation......6577
ENGINE SPEED CONTROL (SJC)......6579
Removal And Installation......6579
Disassembly And Assembly......6581
MUFFLER......6583
Removal And Installation......6583
AIR CLEANER......6585
Housing Removal And Installation......6585
ENGINE COOLING SYSTEM......6587
Radiator Removal And Installation......6587
Hydraulic Fan Description (S/N A3LJ29999 & Below And A3LK29999 & Below)......6590
Hydraulic Fan Disassembly And Assembly (S/N A3LJ29999 & Below And A3LK29999 & Below)......6590
Blower Housing Removal And Installation (S/N A3LJ29999 & Below And A3LK29999 & Below)......6591
Fan Removal And Installation (S/N A3LJ29999 & Below And A3LK29999 & Below)......6593
Hydraulic Fan Motor Removal And Installation (S/N A3LJ29999 & Below And A3LK29999 & Below)......6593
Hydraulic Fan Description (S/N A3LJ30001 & Above And A3LK30001 & Above)......6594
Hydraulic Fan Disassembly And Assembly (S/N A3LJ30001 & Above And A3LK30001 & Above)......6594
Blower Housing Removal And Installation (S/N A3LJ30001 & Above And A3LK30001 & Above)......6596
Fan Removal And Installation (S/N A3LJ30001 & Above And A3LK30001 & Above)......6598
Hydraulic Fan Motor Removal And Installation (S/N A3LJ30001 & Above And A3LK30001 & Above)......6598
Water Pump Removal And Installation......6599
Water Pump Disassembly And Assembly......6599
Thermostat Housing Removal And Installation......6600
Thermostat - Checking......6601
LUBRICATION SYSTEM......6603
Oil Pan Removal And Installation......6603
Oil Pump Removal And Installation......6603
Relief Valve - Testing......6604
Oil Pump Inspection......6604
Oil Filter Cooler Removal And Installation......6605
Engine Oil Pressure - Testing......6606
FUEL SYSTEM......6607
Fuel Shutoff Solenoid - Checking......6607
Fuel Shutoff Solenoid Removal And Installation......6607
Fuel Injection Pump - Checking......6608
Fuel Injection Pump Assembly Removal And Installation......6609
Governor Housing Disassembly And Assembly......6612
Governor Disassembly And Assembly......6614
Fuel Camshaft Removal And Installation......6615
Fuel Injection Pump Removal And Installation......6617
Fuel Injection Pump - Timing......6620
Fuel Injector Removal And Installation......6622
Fuel Injector Nozzle Pressure - Checking......6623
Nozzle Spray Condition......6624
Valve Seat Tightness......6624
CYLINDER HEAD......6625
Glow Plugs - Testing......6625
Glow Plugs Removal And Installation......6625
Valve Clearance Adjustment......6626
Valve Timing - Checking......6627
Cylinder Head Removal And Installation......6628
Cylinder Head Disassembly And Assembly......6631
Cylinder Head - Servicing......6631
Cylinder Head Top Clearance......6632
Valve Guide - Checking......6632
Valve Guide Removal And Installation......6633
Reconditioning The Valve And Valve Seat......6633
Valve Spring......6635
Valve Tappets......6636
Rocker Arm And Shaft - Checking......6637
Bridge Arm And Bridge Arm Shaft - Checking......6637
Bridge Arm Shaft Removal And Installation......6638
Push Rod Alignment - Checking......6639
CRANKSHAFT AND PISTONS......6641
Piston And Connecting Rod Removal And Installation......6641
Piston And Connecting Rod - Servicing......6642
Cylinder Bore - Checking......6646
Connecting Rod Alignment......6647
Crankshaft Gear Removal And Installation......6647
Crankshaft And Bearings Removal And Installation......6648
Crankshaft And Bearings - Servicing......6651
CAMSHAFT AND TIMING GEARS......6655
Timing Gearcase Cover Removal......6655
Timing Gearcase Cover Installation......6656
Timing Gears Backlash - Checking......6659
Idler Gear And Camshaft Removal And Installation......6659
Camshaft - Servicing......6660
Idler Gear And Shaft - Servicing......6661
TURBOCHARGER......6663
Description......6663
Testing......6663
Removal And Installation......6664
FLYWHEEL AND HOUSING......6665
Flywheel Removal And Installation......6665
Ring Gear Removal And Installation......6666
Housing Removal And Installation......6667
EXHAUST GAS RECIRCULATION (EGR) SYSTEM......6669
Description......6669
Testing......6670
Removal And Installation......6673
Disassembly And Assembly......6674
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)......6675
AIR CONDITIONING SYSTEM FLOW......6678
Description......6678
Chart......6679
Components......6680
Safety Equipment......6683
REGULAR MAINTENANCE......6685
Filters......6685
Compressor Drive Belt Adjustment......6685
Compressor Drive Belt Replacement......6686
Condenser......6686
Air Conditioning Lubrication......6686
Air Conditioning Service Chart......6687
Evaporator / Heater Coil......6688
TROUBLESHOOTING......6689
Blower Motor Does Not Operate......6689
Blower Motor Operates Normally, But Air Flow Is Insufficient......6689
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal......6689
The Compressor Does Not Operate At All, Or Operates Improperly......6689
Gauge Pressure Related Troubleshooting......6690
Troubleshooting Tree......6692
Temperature / Pressure Chart......6696
Poor A/C Performance......6697
HVAC Repair And Leaks......6698
Electrical System......6699
Engine Coolant Bypassing The Heater Valve......6706
Heater Valve Not Opening Or Closing......6707
SYSTEM CHARGING AND RECLAMATION......6709
Refrigerant Identification......6709
Reclamation And Charging With Recovery / Charging Unit......6710
Charging With A Manifold Gauge Set......6712
COMPRESSOR......6715
Removal And Installation......6715
Oil......6717
Oil Check......6717
Clutch Disassembly And Assembly......6719
CONDENSER......6723
Removal And Installation......6723
RECEIVER / DRIER......6725
Receiver / Drier Removal And Installation......6725
Pressure Relief Valve Removal And Installation......6726
Pressure Switch Removal And Installation......6727
Schraeder® Valve Removal And Installation......6728
EVAPORATOR / HEATER UNIT......6729
Removal And Installation......6729
THERMOSTAT......6731
Description......6731
Removal And Installation......6732
EXPANSION VALVE......6733
Removal And Installation......6733
EVAPORATOR COIL......6735
Removal And Installation......6735
HEATER COIL......6737
Removal And Installation With A/C......6737
Removal And Installation Without A/C......6739
BLOWER FAN......6741
Removal And Installation......6741
Disassembly And Assembly......6742
Connector Identification......6744
HEATER VALVE......6745
Removal And Installation......6745
Disassembly And Assembly......6746
SPECIFICATIONS......6747
(S205) LOADER SPECIFICATIONS......6749
Machine Dimensions......6749
Performance......6750
Engine......6750
Drive System......6750
Controls......6751
Hydraulic System......6751
Electrical......6752
Capacities......6752
Tires......6752
TORQUE SPECIFICATIONS FOR BOLTS......6753
Torque For General SAE Bolts......6753
Torque For General Metric Bolts......6754
HYDRAULIC CONNECTION SPECIFICATIONS......6755
O-ring Face Seal Connection......6755
Straight Thread O-ring Fitting......6756
Tubelines And Hoses......6756
Flare Fitting......6757
Port Seal Fitting......6758
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS......6759
Specifications......6759
CONVERSIONS......6761
Decimal And Millimeter Equivalent Chart......6761
U.S. To Metric Conversion Chart......6761
SERVICE TOOLS REQUIRED......6763
Remote Start Tools......6763
Hydraulic Tools......6764
Mainframe And Drive Tools......6766
Electrical Tools......6767
Engine Tools......6767
HVAC Tools......6772
ALPHABETICAL INDEX......6773
Bobcat S205 Skid-Steer Loaders Repair Service Manuals + Operation & Maintenance Manual
