Bobcat S205 Turbo, S205 Turbo High Flow Skid-Steer Loader Service Manual – 6902917

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(S/N: 528411001 & Above – S/N: 528511001 & Above)

This service manual PDF download for the Bobcat S205 Turbo, S205 Turbo High Flow Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

Bobcat Loader S205 Turbo, S205 Turbo High Flow
S/N: 528411001 & Above
S/N: 528511001 & Above

TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATION
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE
HEATING, VENTILATION, AIR CONDITIONING
SPECIFICATIONS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6902917 (7-09)
Total Pages : 850

This Bobcat Skid-Steer Loader Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrestor Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATION
Loader Serial Number
Engine Serial Number
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE LOADER
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/HYDROSTATIC SYSTEM
Checking And Adding Fluid
Replacing Hydraulic/Hydrostatic Filter
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/HYDROSTATIC SCHEMATICS
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)
Disassembly 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/High Pressure Relief Valve
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 Bypass 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
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/Anti-Cavitation Valve (Lift, Base End)
Port Relief/Anti-Cavitation Valve (Tilt, Base End)
Port Relief/Anti-Cavitation Valve (Tilt, Rod End)
Port Relief Valve
Plug Removal
Rubber Boot Removal and Installation
End Cap/Spool Lock Block Removal and Installation
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 Bypass 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/Anti-Cavitation Valve (Lift, Base End)
Port Relief/Anti-Cavitation Valve (Tilt, Base End)
Port Relief/Anti-Cavitation Valve (Tilt, Rod End)
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 Bypass Orifice Disassembly And Assembly
Main Relief Valve
LIFT ARM BYPASS 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/HYDROSTATIC FILTER HOUSING
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
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 Bypass 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/HYDRAULIC CONTROLS REFERENCE
Controls Identification Chart
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SLECTABLE JOYSTICK CONTROL) (SJC)
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 Removal And Installation
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/C Performance
Cleaning The A/C Evaporator Coil & Heater Coil
Compressor Drive Belt Inspection
Checking The Electrical System
Engine Coolant Bypassing The Heater Valve
Heater Valve Not Opening Or Closing
GENERAL AIR CONDITIONING SERVICE GUIDELINES
Compressor Oil
Compressor Oil Check
Component Replacement And Refrigeration Leaks
SYSTEM TROUBLESHOOTING CHART
Gauge Pressure Related Troubleshooting
TEMPERATURE/PRESSURE
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/DRIER
Removal And Installation
PRESSURE RELIEF VALVE
Removal And Installation
PRESSURE SWITCH
Removal And Installation
EVAPORATOR/HEATER UNIT
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/C
Removal And Installation Without A/C
HEATER/AC FAN
Removal And Installation
Disassembly And Assembly
Wire Connector Removal and Installation
HEATER VALVE
Removal And Installation
Disassembly And Assembly
SPECIFICATIONS
LOADER SPECIFICATIONS
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/HYDROSTATIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
Revision No: S205-1
Date: 15 April 2005
Product: Bobcat Loader
Model: S205
Manual No: 6902917 (8-04)
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
Revision No: S205-2
Date: 7 July 2005
Product: Bobcat Loader
Model: S205
Manual No: 6902917 (8-04)
PARTS MANAGER
SERVICE MANAGER X
SALES MANAGER
Revision No: S205-3
Date: 23 March 2006
Product: Bobcat Loader
Model: S205
Manual No: 6902917 (8-04)
SERVICE MANUAL REVISION
Revision No: S205 – 1
Revision No: S205 – 2
Revision No: S205 – 3
Revision No: S205 – 4

 

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Bobcat S205 Turbo, S205 Turbo High Flow Skid-Steer Loader Service Manual – 6902917.pdf

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