PDF Service Manual Bobcat S205 Turbo Skid Steer Loader - 6 MB
This comprehensive service manual provides all the information needed to repair and maintain the Bobcat S205 Turbo and S205 Turbo High Flow Skid Steer Loaders.
It covers everything from preventative maintenance to complete tear-down and rebuild of major components like the engine and hydraulic system.
With detailed specifications, step-by-step instructions, and clear diagrams, this manual is essential for any technician working on an S205.
Keep your Bobcat performing at its best by using the factory-approved repair procedures.
This guide is a must-have for minimizing downtime and ensuring quality repairs.
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--- Page 1 ---
Service
Manual
S/N 528411001 & Above
S/N 528511001 & Above
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6902917 (7-09) Printed in U.S.A. © Bobcat Company 2009
--- Page 3 ---
SAFETY INSTRUCTIONS (CONT’D)
The dealer and owner / operator review the
recommended uses of the product when delivered. If the
owner / operator will be using the machine for a different
application(s) he or she must ask the dealer for
recommendations on the new use.
Cutting or drilling concrete containing sand or rock
containing quartz may result in exposure to silica dust.
Do not exceed Permissible Exposure Limits (PEL) to
silica dust as determined by OSHA or other job site Rules
and Regulations. Use a respirator, water spray or other
means to control dust. Silica dust can cause lung disease
and is known to the state of California to cause cancer.
Call Before You Dig
Dial 811 (USA Only)
1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in your
state / province, or city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.).
SI SSL-1008 SM
S205 Bobcat Loader
VI Service Manual
--- Page 4 ---
S205 Bobcat Loader
10-10-2 Service Manual
--- Page 5 ---
S205 Bobcat Loader
10-50-2 Service Manual
--- Page 6 ---
ENGINE COOLING SYSTEM (CONT'D) Replacing the Coolant
Checking The Coolant Level
Figure 10-90-3 WARNING
MAX AVOID BURNS
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1203
MIN P-45106
Figure 10-90-4
1
P-45102
Open the rear door and raise the rear grill.
Check the coolant level [Figure 10-90-3]. The level
markers are on the outside of the tank. Coolant must be
between the bottom marker and the top marker when the
engine is cold.
P-45102
Close the rear door before operating the loader.
Open the rear door and remove the rear grill.
Remove the radiator cap (Item 1) [Figure 10-90-4].
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
damage.
Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
boiling point and freeze protection of the system.
Always add a premixed solution. Adding full strength
concentrated coolant can cause serious premature
engine damage.
I-2124-0497
S205 Bobcat Loader
10-90-2 Service Manual
--- Page 7 ---
S205 Bobcat Loader
10-120-4 Service Manual
--- Page 8 ---
LUBRICATION OF THE BOBCAT LOADER (CONT’D) Figure 10-160-6
Procedure (Cont’d)
Figure 10-160-4
10
6 7
N-18508
10. Lift Arm Pivot Pin (Both Sides) [Figure 10-160-6].
P-48104
Figure 10-160-7
6. Tilt Cylinder Rod End. [Figure 10-160-4].
7. Bob-Tach Pivot Pin (Both Sides) [Figure 10-160-4].
Figure 10-160-5
8 11
N-18511
P-31839
11. Lift Arm Link Pivot Pin (Both Sides) [Figure 10-160-
9 7].
P16045
8. Bob-Tach Wedge (Both Sides) [Figure 10-160-5].
9. Power Bob-Tach Cylinder (Both Sides) [Figure 10-
160-5].
S205 Bobcat Loader
10-160-2 Service Manual
--- Page 9 ---
HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC/HYDROSTATIC FILTER HOUSING . . . . . . . . . . . . . . . . . . . . 20-70-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Fluid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Check The Output Of The Hydraulic Pump With Rear Auxiliary. . . . . . . . 20-60-3
Check The Output Of The Hydraulic Pump Without Rear Auxiliary. . . . . 20-60-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-7
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-5
HYDRAULIC PUMP (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Check The Output Of The Hydraulic Pump With Rear Auxiliary. . . . . . . . 20-61-3
Check The Output Of The Hydraulic Pump Without Rear Auxiliary. . . . . 20-61-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-8
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-7
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-5
HYDRAULIC PUMP (HIGH FLOW) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-9
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-8
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63-6
Test The Output Of The Hydraulic Auxiliary Pump . . . . . . . . . . . . . . . . . 20-63-1
Test The Output Of The Hydraulic Charge Pump . . . . . . . . . . . . . . . . . . 20-63-2
Test The Output Of The Hydraulic Pump (High Flow) . . . . . . . . . . . . . . . 20-63-4
HYDRAULIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-7
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62-4
Test The Output Of The Hydraulic Auxiliary Pump . . . . . . . . . . . . . . . . . 20-62-1
Test The Output Of The Hydraulic Charge Pump . . . . . . . . . . . . . . . . . . 20-62-2
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-2
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Continued On Next Page
S205 Bobcat Loader
20-04 Service Manual
--- Page 10 ---
(REAR QUICK
FEMALE COUPLERS) MALE
HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH SJC AND HIGH FLOW OPTION
S205 (S/N 528411001 AND ABOVE) BASE ROD REAR AUX VALVE (OPTIONAL)
(S/N 528511001 AND ABOVE)
(PRINTED JULY 2005)
INTEGRATED QUICK
(V-0721) COUPLER BLOCK
23 24
25 MALE
26
28 7 (FRONT AUXILIARY
MALE
7 LEFT SIDE LIFT ARM)
DRIVE MOTOR 29
1 30
FEMALE
27
4 37
P-OUT P-IN T
32 BUCKET POSITION VALVE (OPTIONAL)
D
38 HYDRAULIC FILTER 34
31
B HYDROSTATIC PUMPS A OIL
22
2 COOLER
55
56 A
HYDRAULIC CONTROL VALVE
5 5 3 40 C
57
21
6 36 13
20
12
12 AUXILIARY
CHARGE
SPOOL B
INLET B A
42
58
57 14
2 31 36
10 TILT CYLINDERS
BICS CONTROL VALVE
HIGH FLOW VALVE
5 56 5
55 51
50
3 52
TILT
B A 17
SPOOL
D C
8
10 11
INLET 14
LIFT CYLINDERS
59 10
18
HYDRAULIC
OUTLET
53 POWERED B A LIFT
BOB-TACH
(OPTIONAL) SPOOL
38
35
39 47
15
DR
14
54
48 33 41
46 33 16
9
49 45
37 PP
4 43
P2 LIFT ARM BY PASS VALVE
P1
32 44 19
Printed in U.S.A.
DRIVE MOTOR
V-0721 (7-12-05)
--- Page 11 ---
CYLINDER (LIFT) (CONT’D)
Removal And Installation (Cont’d)
Figure 20-20-9
1
P-54367
Remove the smaller pin (Item 1) [Figure 20-20-7] and lift
the lift cylinder (Item 1) [Figure 20-20-9] out from the
loader.
S205 Bobcat Loader
20-20-4 Service Manual
--- Page 12 ---
CYLINDER (TILT) (CONT'D) Figure 20-21-10
Rod End Pivot Pin Bushing And Seal Replacement
Figure 20-21-8
1
1
N-18554
Reverse the removal procedure to install the pivot pin
N-18556 bushing and seal.
Remove the rod end of the tilt cylinder from the Bob-
Tach. (See Removal And Installation, Page 20-20-2.)
Use a seal pick to remove the seals (Item 1) [Figure 20-
21-8] on both sides of the pivot bushing.
Figure 20-21-9
N-18555
Remove and replace bushing with a driver tool and
hammer [Figure 20-21-9].
S205 Bobcat Loader
20-21-4 Service Manual
--- Page 13 ---
CYLINDER (POWER BOB-TACH) (CONT’D) Figure 20-22-8
Disassembly
3
2
Use the following tools to disassemble the cylinder:
1
MEL1074 - O-ring Seal Hook
Spanner Wrench
Hold the hydraulic cylinder over a drain pan and move
the rod in and out slowly to remove the fluid from the
cylinder.
Figure 20-22-6
P16295
Piston: Remove the O-ring (Item 1) [Figure 20-22-8],
and seal (Item 2) [Figure 20-22-8] from the piston (Item
3) [Figure 20-22-8].
Figure 20-22-9
3 5
4
P16293
Put the base end of the cylinder in a vise. 2
1
Use a spanner wrench to loosen the head [Figure 20-22-
6].
Figure 20-22-7
N-20611
3 2
1 Remove the wiper seal (Item 1) [Figure 20-22-9], and
rod seal (Item 2) [Figure 20-22-9], the back up washer
(Item 3) [Figure 20-22-9] the thin O-ring (Item 4) [Figure
20-22-9] and the thick O-ring (Item 5) [Figure 20-22-9]
from the head.
P16294
Remove the head and rod assembly from the cylinder
[Figure 20-22-7]. Put the rod end in a vise.
Remove the nut (Item 1) [Figure 20-22-7], piston (Item 2)
[Figure 20-22-7] and head (Item 3) [Figure 20-22-7]
from the rod.
S205 Bobcat Loader
20-22-4 Service Manual
--- Page 14 ---
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-5
(CONT’D)
4
Removal and Installation (Cont’d)
Figure 20-40-3 2 1
3
1
1
P-51714
Mark and disconnect the four electric solenoid
connectors for correct installation (Item 1) [Figure 20-40-
5].
P-51710
Remove the outlet tubeline (Item 2) [Figure 20-40-5]
from the control valve to the hydraulic oil cooler.
Mark all tubelines and hoses for correct installation.
Disconnect and cap the supply hose (Item 3) and the
The fixed end main valve hose (Item 1) [Figure 20-40-3]
supply hose clamp (Item 4) [Figure 20-40-5].
is connected to a fixed end fitting on the control valve.
The hose is routed to the back upright where the hose is
Figure 20-40-6
connected to a tee fitting that feeds the base end of both
lift cylinders. The hose must be removed at the back tee
fitting, located in the right side upright. 1
NOTE: Remember the hose routing for ease of
control valve installation.
Figure 20-40-4
2
P-51715
1