Bobcat S205 Skid Steer Loader Service Manual 6902917-21416B320133.pdf -Bookmark created by https://wimanual.com MAINTENANCE SAFETY ALPHABETICAL INDEX CONTENTS FOREWORD SAFETY INSTRUCTIONS Fire Prevention SERIAL NUMBER LOCATION Loader Serial Number Engine Serial Number DELIVERY REPORT BOBCAT LOADER IDENTIFICATION SAFETY AND MAINTENANCE LIFTING AND BLOCKING THE LOADER Procedure LIFT ARM SUPPORT DEVICE Installing Lift Arm Support Device Removing Lift Arm Support Device OPERATOR CAB Description Raising The Operator Cab Lowering The Operator Cab Emergency Exit TRANSPORTING THE BOBCAT LOADER Procedure TOWING THE LOADER Procedure REMOTE START Procedure SERVICE SCHEDULE Chart AIR CLEANER SERVICE Checking Replacing Filter Element(s) ENGINE COOLING SYSTEM Cleaning The Cooling System Checking The Coolant Level Replacing the Coolant FUEL SYSTEM Fuel Specifications Filling The Fuel Tank Fuel Filter Removing Air From The Fuel System ENGINE LUBRICATION SYSTEM Checking Engine Oil Oil Chart Replacing Oil And Filter HYDRAULIC Checking And Adding Fluid Replacing Hydraulic Replacing Hydraulic Fluid Breather Cap FINAL DRIVE TRANSMISSION (CHAINCASE) Checking And Adding Oil Removing Oil From The Chaincase FAN GEARBOX Checking And Maintaining BOB-TACH Inspection And Maintenance POWER BOB-TACH (OPTION) Inspection And Maintenance LUBRICATION OF THE BOBCAT LOADER Procedure TIRE MAINTENANCE Wheel Nuts Rotating Mounting SPARK ARRESTOR MUFFLER Cleaning Procedure HYDRAULIC SYSTEM HYDRAULIC HYDRAULIC SYSTEM INFORMATION Troubleshooting Chart CYLINDER (LIFT) Checking Removal And Installation Identification Disassembly Assembly CYLINDER (TILT) Checking Removal And Installation Base End Pivot Pin Replacement Rod End Pivot Pin Bushing And Seal Replacement Parts Identification Disassembly Assembly CYLINDER (POWER BOB-TACH) Checking Removal And Installation Identification Disassembly Assembly MAIN RELIEF VALVE Checking Adjustment Removal and Installation HYDRAULIC CONTROL VALVE (FOOT CONTROL) Identification Removal And Installation Identification Chart Mount Bracket Removal and Installation BICS� Valve, Lift Load Check Valve Removal And Installation Load Check Valve Removal And Installation (Tilt & Auxiliary) Anti-Cavitation Valve (Lift, Rod End) Port Relief Port Relief Port Relief Port Relief Valve Plug Removal Rubber Boot Removal and Installation End Cap Lift Spool and Detent Removal and Installation Tilt Spool Removal and Installation Auxiliary Spool Removal And Installation Auxiliary Solenoid Disassembly and Assembly BICS� Valve Solenoid Disassembly And Assembly BICS� Valve, Lock Valve Removal And Installation BICS� Valve, Check Valve Removal And Installation BICS� Valve, Lift Arm By-Pass Orifice Disassembly And Assembly Main Relief Valve HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS) Identification Removal And Installation Actuator Removal And Installation (Out of Loader) Identification Chart (ACS) Mount Bracket Removal and Installation BICS� Valve, Lift Load Check Valve Removal And Installation Load Check Valve Removal And Installation (Tilt & Auxiliary) Anti-Cavitation Valve (Lift, Rod End) Port Relief Port Relief Port Relief Port Relief Valve Plug Removal End Cap Block Removal and Installation Lift Spool Removal and Installation Tilt Spool Removal and Installation Auxiliary Spool Removal And Installation Auxiliary Solenoid Disassembly and Assembly BICS� Valve Solenoid Disassembly And Assembly BICS� Valve, Lock Valve Removal And Installation BICS� Valve, Check Valve Removal And Installation BICS� Valve, Lift Arm By-Pass Orifice Disassembly And Assembly Main Relief Valve LIFT ARM BY-PASS CONTROL VALVE Removal and Installation Disassembly And Assembly HYDRAULIC PUMP Check The Output Of The Hydraulic Pump Without Rear Auxiliary. Check The Output Of The Hydraulic Pump With Rear Auxiliary. Removal And Installation Identification Disassembly And Assembly HYDRAULIC PUMP (HIGH FLOW) Check The Output Of The Hydraulic Pump Without Rear Auxiliary. Check The Output Of The Hydraulic Pump With Rear Auxiliary. Removal And Installation Identification Disassembly And Assembly HYDRAULIC PUMP (SJC) Test The Output Of The Hydraulic Auxiliary Pump Test The Output Of The Hydraulic Charge Pump Removal And Installation Identification Disassembly And Assembly HYDRAULIC PUMP (HIGH FLOW) (SJC) Test The Output Of The Hydraulic Auxiliary Pump Test The Output Of The Hydraulic Charge Pump Test The Output Of The Hydraulic Pump (High Flow) Removal And Installation Identification Disassembly And Assembly HYDRAULIC Removal And Installation HYDRAULIC FLUID RESERVOIR Fluid Removal Removal And Installation BUCKET POSITION VALVE Solenoid Removal And Installation Solenoid Testing Removal And Installation Disassembly And Assembly HIGH FLOW VALVE Checking The High Flow Relief Valve High Flow Relief Valve Adjustment Procedure Removal And Installation Disassembly And Assembly Solenoid Testing REAR AUXILIARY DIVERTER VALVE Removal And Installation Disassembly And Assembly Solenoid Testing Inspection POWER BOB-TACH BLOCK Removal And Installation Disassembly And Assembly FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Removal and Installation Disassembly And Assembly HYDROSTATIC SYSTEM HYDROSTATIC SYSTEM INFORMATION Troubleshooting Chart Replenishing Valve Function HYDROSTATIC MOTOR Description Removal And Installation Parts Identification (Wet Bolt) Disassembly (Wet Bolt) Assembly (Wet Bolt) Parts Identification (Dry Bolt) Dissassembly and Assembly (Dry Bolt) HYDROSTATIC MOTOR CARRIER Shaft Seal Replacement Removal And Installation Parts Identification Disassembly and Assembly HYDROSTATIC MOTOR CARRIER (SJC) Shaft Seal Replacement Removal And Installation Parts Identification Disassembly and Assembly CHARGE PRESSURE Sender Removal And Installation (Non SJC Machines) Testing (Non SJC Machines) Adjusting (Non SJC Machines) Sender Removal And Installation (SJC Machines) Testing (SJC Machines) Adjusting (SJC Machines) HYDROSTATIC PUMP Replenishing Removal And Installation Parts Identification (Right Half) Parts Identification (Left Half) Hydraulic Pump Removal And Installation Pump Separation Disassembly Assembly HYDROSTATIC PUMP (SJC) Description Hydraulic Controller Removal And Installation Removal And Installation Parts Identification High Pressure Relief and By-Pass Valve Charge Relief Valve Disassembly and Assembly Mechanical Neutral Adjustment Hydraulic Controller Neutral Adjustment DRIVE BELT Shield Removal And Installation Adjusting Drive Belt Replacement Tensioner Pulley Removal And Installation Tensioner Pulley Parts Identification Tensioner Pulley Disassembly Tensioner Pulley Assembly OIL COOLER Removal and Installation DRIVE SYSTEM BRAKE Disk Removal And Installation Switch Operated Parking Brake DRIVE COMPONENTS Axle Seal Removal And Installation Axle Sprocket And Bearings Removal And Installation Chain Removal And Installation CHAINCASE Checking And Adding Oil Removing The Oil General Information Front Cover Removal And Installation Center Cover Removal And Installation Rear Cover Removal And Installation MAIN FRAME SEAT BAR Removal And Installation Assembling Components Compression Spring Disassembly And Assembly OPERATOR CAB Gas Cylinder Removal And Installation Gas Cylinder Disassembly Removal And Installation OPERATOR SEAT Removal And Installation Seat Belt Removal And Installation OPERATOR SEAT (SUSPENSION) Removal And Installation Slide Rail Removal And Installation Cushion Removal And Installation Back Removal And Installation Shock Removal And Installation 3-Point Seat Belt Removal And Installation BOB-TACH Removal And Installation Bob-Tach Lever And Wedge POWER BOB-TACH Removal And Installation Power Bob-Tach Lever And Wedge LIFT ARM Removal And Installation Link Removal And Installation Stabilizer Bar Removal And Installation REAR GRILL Removal And Installation REAR DOOR Removal And Installation Striker Removal and Installation Striker Disassembly and Assembly Adjusting The Striker Latch Removal and Installation FUEL TANK Removal And Installation Fuel Level Sender Fuel Fill Screen CONTROL PEDALS Removal And Installation Pedal Adjustment Crossbar Linkage Removal and Installation Lift Foot Pedal Linkage Removal and Installation Tilt Foot Pedal Linkage Removal and Installation CONTROL PEDALS (ACS) Foot Sensor Removal And Installation Foot Pedal Removal And Installation Foot Pedal Linkage Disassembly And Assembly CONTROL PANEL Description Removal and Installation Shock Removal And Installation Shaft Removal And Installation Shaft Disassembly And Assembly Linkage Removal And Installation Pintle Arm Disassembly and Assembly Linkage Neutral Adjustment Linkage Travel Adjustment CONTROL PANEL (SJC) Removal And Installation CONTROL HANDLE Control Lever Removal And Installation Control Lever Boot CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) Components Identification Handle Sensor Removal And Installation Control Handle Removal and Installation Control Handle Disassembly and Assembly Control Lever Removal and Installation Control Lever Boot CONTROL HANDLE (SJC) Joystick Testing (Right & Left) Joystick Removal (Right & Left) Lever Assembly Removal (Right & Left) ELECTRICAL SYSTEM ELECTRICAL SCHEMATICS ELECTRICAL SYSTEM INFORMATION Troubleshooting Chart Description Fuse Location Relay Switch Location BATTERY Removal And Installation Servicing Using A Booster Battery (Jump Starting) ALTERNATOR Adjusting The Alternator Belt Alternator Identification Charging System Check Alternator Voltage Test Low Voltage Test High Voltage Test Removal And Installation Rectifier Continuity (Diode) Test Alternator Regulator Test Disassembly Stator Continuity Test Stator Ground Test Rotor Continuity Test Rotor Ground Test Assembly STARTER Checking Removal And Installation Parts Identification Disassembly and Assembly Inspection And Repair No Load Test INSTRUMENT PANEL Left Panel Right Panel (Standard) (With Key Switch) Right Panel (Deluxe) (With Keyless Start) Right Panel Setup Display Options (Deluxe) Deluxe Panel Setup Passwords (Deluxe) Option And Field Accessory Panels (If Equipped) Standard Panel Removal And Installation (Right Side) Deluxe Panel Removal And Installation (Right Side) Standard & Deluxe Panel Removal And Installation (Left Side) Front Accessory Panel Removal And Installation LIGHTS Front Removal And Installation Rear Removal And Installation BOBCAT CONTROLLER Identification Chart Removal And Installation CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC) Removal and Installation Identification Chart DIAGNOSTICS SERVICE CODES Display Number Codes List BICS� SYSTEM Inspecting The BICS� Controller (Engine STOPPED - Key ON) Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON) Inspecting The Seat Bar Sensor (Engine RUNNING) Inspecting The Traction Lock (Engine RUNNING) Inspecting The Lift Arm By-Pass Control Additional Inspection For Loaders With Advanced Hand Controls (ACS) Troubleshooting Chart Troubleshooting Guide SEAT BAR SENSOR Troubleshooting Chart Test Removal And Installation BICS� Circuit Test TRACTION LOCK Troubleshooting Chart Description Of The Control System Inspecting The Control System Inspecting Solenoid Removal And Installation Guide Removal Guide Installation ADVANCED CONTROL SYSTEM (ACS) Components Identification Troubleshooting Guide Controller, Connector And Wire Identification ACS Controller Removal And Installation Handle Sensor Connector Switch Handle Removal Switch Handle Installation Actuators Disassembly and Assembly Handle Lock Solenoid Removal And Installation Handle Lock Solenoid Disassembly And Assembly Handle Lock Solenoid Connector Calibration Procedure Foot Sensor Disassembly And Assembly Foot Sensor Connector Foot Lock Solenoid Removal And Installation Foot Lock Solenoid Connector ELECTRICAL Controls Identification Chart ELECTRICAL Controls Identification Chart FLYWHEEL RPM SENSOR Adjustment SERVICE PC (LAPTOP COMPUTER) Connecting The Service PC To Remote Start Tool CALIBRATION Description Actuator Testing Lift and Tilt Calibration Procedure (SJC) Hydrostatic Pump Calibration (SJC) Calibration Procedure (ACS) SPEED SENSOR Description Testing Removal and Installation ENGINE SERVICE TROUBLESHOOTING Chart ENGINE SPEED CONTROL Removal And Installation Disassembly MUFFLER Removal And Installation AIR CLEANER Removal And Installation RADIATOR Removal And Installation COOLING FAN Drive Tension Pulley Removal And Installation Gearbox Blower Housing Grill Removal And Installation Blower Disassembly And Assembly Gearbox Parts Identification Gearbox Disassembly Gearbox Assembly Gearbox Checking Backlash ENGINE COMPONENTS AND TESTING Compression Checking Glow Plugs Checking Glow Plugs Removal And Installation Fuel Shut-Off Solenoid, Checking Fuel Shut-Off Solenoid Removal And Installation Fuel Injection Pump Removal And Installation Timing The Injection Pump Fuel Injector Removal And Installation Checking Nozzle Injection Pressure Nozzle Spraying Condition Valve Seat Tightness Valve Clearance Adjustment Valve Timing, Checking ENGINE Removal And Installation Engine Mount Replacement FLYWHEEL AND HOUSING Flywheel Removal And Installation Ring Gear Removal And Installation Housing Removal And Installation RECONDITIONING THE ENGINE Cylinder Head Removal And Installation Cylinder Head Disassembly And Assembly Cylinder Head Servicing Cylinder Head Top Clearance Valve Guide Checking Reconditioning The Valve And Valve Seat Valve Spring Rocker Arm And Shaft Checking Timing Gearcase Cover Removal And Installation Idler Gear And Camshaft Removal And Installation Camshaft Servicing Idler Gear And Shaft Servicing Timing Gears Checking Backlash Fuel Camshaft Removal And Installation Fuel Camshaft Governor Crankshaft Gear Removal And Installation Oil Pump Removal And Installation Oil Pump Service Checking Engine Oil Pressure Valve Tappets Piston And Connecting Rod Removal And Installation Piston And Connecting Rod Servicing Connecting Rod Alignment Crankshaft And Bearings Removal And Installation Crankshaft And Bearings, Servicing Cylinder Bore, Checking Water Pump Removal And Installation Water Pump Disassembly And Assembly TURBOCHARGER Checking Description Removal And Installation HEATING, VENTILATION, AIR CONDITIONING AIR CONDITIONING SYSTEM FLOW Principals Chart COMPONENTS Identification SAFETY Safety Equipment REGULAR MAINTENANCE Filter Elements Removal And Installation Compressor Drive Belt Inspection Cleaning The Condenser BASIC TROUBLESHOOTING Poor A Cleaning The A Compressor Drive Belt Inspection Checking The Electrical System Engine Coolant By-Passing The Heater Valve Heater Valve Not Opening Or Closing GENERAL AIR CONDITIONING SERVICE GUIDELINES Compressor Oil Compressor Oil Check Component Replacement And Refrigeration Leaks SYSTEM TROUBLESHOOTING CHART Gauge Pressure Related Troubleshooting TEMPERATURE Chart AIR CONDITIONING SERVICE Chart SYSTEM CHARGING AND RECLAMATION Reclamation Procedure Charging Procedure With A Manifold Gauge Set Charging Procedure COMPRESSOR Removal And Installation Compressor Clutch Disassembly CONDENSER Removal And Installation RECEIVER Removal And Installation PRESSURE RELIEF VALVE Removal And Installation PRESSURE SWITCH Removal And Installation EVAPORATOR Removal And Installation Disassembly And Assembly THERMOSTAT Removal And Installation EXPANSION VALVE Removal And Installation EVAPORATOR Removal And Installation HEATER COIL Removal And Installation With A Removal And Installation Without A HEATER Removal And Installation Disassembly And Assembly Wire Connector Removal and Installation HEATER VALVE Removal And Installation Disassembly And Assembly SPECIFICATIONS LOADER SPECIFICATIONS Machine Dimensions Performance Controls Engine Hydraulic System Electrical Drive System Capacities Tires ENGINE SPECIFICATIONS - KUBOTA V2403-M-DI-T Fuel Injection Nozzles Fuel Injection Pump Cylinder Head Valves Valve Springs Valve Timing Rocker Arms Camshaft Tappet Cylinder Liner Piston Rings Pistons Connecting Rod Oil Pump Crankshaft Timing Gear Thermostat TORQUE SPECIFICATIONS FOR BOLTS Torque For General SAE Bolts Torque For General Metric Bolts HYDRAULIC CONNECTION SPECIFICATIONS O-ring Face Seal Connection Straight Thread O-ring Fitting Tubelines And Hoses Flare Fitting O-ring Flare Fitting Port Seal Fitting HYDRAULIC Specifications CONVERSIONS Decimal And Millimeter Equivalents U.S. To Metric Conversion SMR S205-1 S205-2 S205-3 . 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