Service Manual Bobcat S205 Skid-Steer Loader 6904138 (7-09) PDF Download

Description

Bobcat S205 Skid-Steer Loader Service Manual 6904138 (7-09) – PDF DOWNLOAD

FILE DETAILS:

Bobcat S205 Skid-Steer Loader Service Manual 6904138 (7-09) – PDF DOWNLOAD

Language : English
Pages : 957
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S205 Skid-Steer Loader Service Manual 6904138 (7-09) – PDF DOWNLOAD

S/N 530511001 – 530559999
S/N 530611001 – 530659999

FOREWORD:

This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

A general inspection of the following items must be made after the loader has had service or repair:

TABLE OF CONTENTS:

Bobcat S205 Skid-Steer Loader Service Manual 6904138 (7-09) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 8
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrestor Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Loader Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
LOADER IDENTIFICATION 17
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE LOADER 23
Procedure 23
LIFT ARM SUPPORT DEVICE 25
Installing 25
Removing 26
OPERATOR CAB 27
Description 27
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 31
Loading And Unloading 31
Fastening 31
TOWING THE LOADER 33
Procedure 33
REMOTE START TOOL KIT-MEL1563 35
Remote Start Tool – MEL1563 35
Service Tool Harness Control – MEL1565 36
Service Tool Harness Communicator – MEL1566 37
Remote Start Procedure 38
REMOTE START TOOL (SERVICE TOOL) kIT – 6689779 41
Description 41
Remote Start Tool (Service Tool) – 6689778 42
Loader Service Tool Harness – 6689747 43
Computer Service Tool Harness – 6689746 44
Remote Start Procedure 45
SERVICE SCHEDULE 49
Chart 49
AIR CLEANER SERVICE 51
Replacing Filter Elements 51
ENGINE COOLING SYSTEM 53
Cleaning 53
Checking Level 54
Removing And Replacing Coolant 55
FUEL SYSTEM 57
Fuel Specifications 57
Biodiesel Blend Fuel 57
Filling the Fuel Tank 58
Fuel Filter 59
Removing Air From The Fuel System 59
ENGINE LUBRICATION SYSTEM 61
Checking And Adding Engine Oil 61
Engine Oil Chart 61
Removing And Replacing Oil And Filter 62
HYDRAULIC / HYDROSTATIC SYSTEM 63
Checking And Adding Fluid 63
Hydraulic / Hydrostatic Fluid Chart 63
Removing And Replacing Hydraulic Fluid 64
Removing And Replacing Hydraulic / Hydrostatic Filter 64
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders) 65
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders) 66
Removing And Replacing Hydraulic Charge Filter 68
Breather Cap 69
FINAL DRIVE TRANSMISSION (CHAINCASE) 71
Checking And Adding Oil 71
Removing And Replacing Oil 71
BOB-TACH (HAND LEVER) 73
Inspection And Maintenance 73
BOB-TACH (POWER) 75
Inspection And Maintenance 75
LUBRICATING THE LOADER 77
Lubrication Locations 77
TIRE MAINTENANCE 79
Wheel Nuts 79
Rotating 79
Mounting 79
SPARK ARRESTOR MUFFLER 81
Cleaning Procedure 81
PIVOT PINS 83
Inspection And Maintenance 83
LOADER STORAGE AND RETURN TO SERVICE 85
Storage 85
Return to Service 85
STOPPING THE ENGINE AND LEAVING THE LOADER 87
Procedure 87
Emergency Exit 88
HYDRAULIC SYSTEM 89
HYDRAULIC / HYDROSTATIC SCHEMATICS 93
HYDRAULIC SYSTEM INFORMATION 109
Glossary Of Hydraulic / Hydrostatic Symbols 109
Troubleshooting 113
CYLINDER (LIFT) 115
Testing 115
Removal And Installation 116
Parts Identification 119
Disassembly and Assembly 120
CYLINDER (TILT) 123
Testing 123
Removal And Installation 124
Base End Pivot Pin Removal And Installation 125
Rod End Pivot Pin Bushing And Seal Removal And Installation 126
Parts Identification 127
Disassembly And Assembly 128
CYLINDER (BOB-TACH) 131
Testing 131
Removal And Installation 132
Parts Identification 133
Disassembly and Assembly 134
MAIN RELIEF VALVE 137
Description 137
Testing 137
Adjusting 139
Removal and Installation 140
HYDRAULIC CONTROL VALVE (STANDARD) 141
Description 141
Removal And Installation 141
Identification Chart 146
Mount Bracket Removal And Installation 147
Lift Load Check Valve Removal And Installation 147
Load Check Valve Removal And Installation (Tilt & Auxiliary) 148
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 149
Port Relief/Anti-Cavitation Valve Removal And Installation (Lift, Base End) 150
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 150
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 151
Port Relief Valve Removal And Installation 151
Plug Removal And Installation 152
Rubber Boot Removal And Installation 153
End Cap/Spool Lock Block Removal And Installation 154
Lift Spool And Detent Removal And Installation 155
Tilt Spool Removal And Installation 165
Auxiliary Spool Removal And Installation 167
Auxiliary Solenoid Removal And Installation 168
Solenoid Removal And Installation 169
Lock Valve Removal And Installation 171
Lift Arm Bypass Orifice Removal And Installation 173
Main Relief Valve Removal And Installation 173
Check Valve Removal And Installation 174
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 175
Description 175
Removal And Installation 175
Actuator Removal And Installation (Out of Loader) 180
Identification Chart 183
Mount Bracket Removal And Installation 184
Lift Load Check Valve Removal And Installation 184
Load Check Valve Removal And Installation (Tilt & Auxiliary) 185
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 186
Port Relief/Anti-Cavitation Valve Removal And Installation (Lift, Base End) 187
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 187
Port Relief/Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 188
Port Relief Valve Removal And Installation 188
Plug Removal And Installation 189
End Cap Block Removal And Installation 190
Lift Spool And Detent Removal And Installation 191
Tilt Spool Removal And Installation 196
Auxiliary Spool Removal And Installation 198
Auxiliary Solenoid Removal And Installation 199
Solenoid Removal And Installation 200
Lock Valve Removal And Installation 202
Lift Arm Bypass Orifice Removal And Installation 204
Main Relief Valve Removal And Installation 205
Check Valve Removal And Installation 206
LIFT ARM BYPASS CONTROL VALVE 207
Description 207
Testing 207
Removal and Installation 207
Disassembly And Assembly 208
HYDRAULIC PUMP (STANDARD) 209
Description 209
Pump Test at Quick Couplers 209
Direct Pump Test (Standard Section) 210
Direct Pump Test (Charge Section) 212
Removal And Installation 214
Parts Identification 216
Disassembly And Assembly 217
Hydraulic Pump Start Up 225
HYDRAULIC PUMP (STANDARD) (HIGH FLOW) 227
Description 227
Pump Test at Quick Couplers 227
Direct Pump Test (Standard Section) 228
Direct Pump Test (Charge Section) 230
Direct Pump Test (High Flow Section) 232
Removal And Installation 234
Parts Identification 236
Disassembly And Assembly 237
Hydraulic Pump Start Up 249
HYDRAULIC PUMP (SJC) 251
Description 251
Pump Test at Quick Couplers 251
Direct Pump Test (Standard Section) 252
Direct Pump Test (Charge Section) 254
Removal And Installation 256
Parts Identification 258
Disassembly And Assembly 259
Hydraulic Pump Start Up 267
HYDRAULIC PUMP (SJC) (HIGH FLOW) 269
Description 269
Pump Test at Quick Couplers 269
Direct Pump Test (Standard Section) 270
Direct Pump Test (Charge Section) 272
Direct Pump Test (High Flow Section) 274
Removal And Installation 276
Parts Identification 278
Disassembly And Assembly 279
Hydraulic Pump Start Up 290
HYDRAULIC/HYDROSTATIC FILTERS 293
Description 293
Housing Removal And Installation 293
Charge Filter Housing Removal And Installation 295
HYDRAULIC FLUID RESERVOIR 297
Description 297
Removal And Installation 297
Hydraulic Fluid Screen 300
OIL COOLER 301
Description 301
Removal and Installation 301
BUCKET POSITION VALVE 303
Description 303
Solenoid Removal And Installation 303
Solenoid Testing 304
Removal And Installation 305
Disassembly And Assembly 306
REAR AUXILIARY DIVERTER VALVE 309
Description 309
Removal And Installation 309
Disassembly And Assembly 312
Solenoid Testing 318
BOB-TACH (POWER) BLOCK 319
Description 319
Removal And Installation 319
Disassembly And Assembly 321
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 325
Description 325
Removal and Installation 325
Disassembly And Assembly 325
HIGH FLOW VALVE 327
Description 327
High Flow Relief Valve Testing 327
High Flow Relief Valve Adjustment 328
Solenoid Testing 329
Removal And Installation 330
Disassembly And Assembly 331
HYDROSTATIC SYSTEM 335
HYDROSTATIC SYSTEM INFORMATION 337
Troubleshooting 337
Description 338
HYDROSTATIC MOTOR 339
Description 339
Removal And Installation 339
Parts Identification 342
Disassembly and Assembly 343
HYDROSTATIC MOTOR (TWO-SPEED) 349
Description 349
Removal And Installation (Left Side) 350
Removal And Installation (Right Side) 353
Parts Identification 356
Disassembly 357
Assembly 367
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH MANUAL CONTROLS) 379
Description 379
Shaft Seal Removal And Installation 379
Removal And Installation 381
Parts Identification 383
Disassembly and Assembly 384
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH SJC CONTROLS) 389
Description 389
Shaft Seal Removal And Installation 389
Removal And Installation 391
Parts Identification 393
Disassembly and Assembly 394
CHARGE PRESSURE 399
Description 399
Testing 399
Sender Removal And Installation 401
Adjusting 401
HYDROSTATIC PUMP 405
Description 405
Replenishing/High Pressure Relief Valve 405
Removal And Installation 406
Hydrostatic Pump Start Up 407
Parts Identification (Left Half) 408
Parts Identification (Right Half) 409
Disassembly 410
Assembly 416
HYDROSTATIC PUMP (SJC) 423
Description 423
Hydraulic Controller Removal And Installation 424
Removal And Installation 426
Hydrostatic Pump Start Up 428
Parts Identification 429
High Pressure Relief and Bypass Valve 430
Charge Relief Valve 431
Disassembly and Assembly 432
Mechanical Neutral Adjustment 448
Hydraulic Controller Neutral Adjustment 451
DRIVE BELT 455
Description 455
Shield Removal And Installation 455
Adjusting 455
Belt Removal And Installation 457
Belt Tensioner Removal And Installation 458
Belt Tensioner Parts Identification 459
Belt Tensioner Disassembly 460
Belt Tensioner Assembly 461
TWO-SPEED VALVE 463
Description 463
Valve Removal And Installation 464
Valve Disassembly And Assembly 466
CASE DRAIN FILTER 469
Description 469
Disassembly And Assembly 469
DRIVE SYSTEM 471
BRAKE (SINGLE SPEED) 473
Description 473
Disc Removal And Installation 473
BRAKE (TWO-SPEED) 475
Description 475
Disc Removal And Installation 475
Disc Disassembly and Assembly 476
DRIVE COMPONENTS 477
Description 477
Axle Seal Removal And Installation 478
Axle Sprocket And Bearings Removal And Installation 480
Chain Removal And Installation 485
CHAINCASE 487
Description 487
Front Cover Removal And Installation 487
Center Cover Removal And Installation 488
Rear Cover Removal And Installation 489
MAIN FRAME 491
SEAT BAR 495
Description 495
Removal And Installation 495
Disassembly And Assembly 496
Compression Spring Disassembly And Assembly 498
OPERATOR CAB 499
Gas Cylinder Removal And Installation 499
Gas Cylinder Bracket Disassembly And Assembly 502
Removal And Installation 502
OPERATOR SEAT 505
Removal And Installation 505
Seat Belt Removal And Installation 505
OPERATOR SEAT (SUSPENSION) 507
Removal And Installation 507
Slide Rail Removal And Installation 508
Seat Belt Removal and Installation 508
Lower Cushion Removal And Installation 508
Back Cushion Removal And Installation 510
Shock Removal And Installation 510
3-Point Seat Belt Removal And Installation 511
BOB-TACH (HAND LEVER) 513
Description 513
Removal And Installation 513
Lever And Wedge Disassembly And Assembly 514
Pivot Pin Bushing And Seal Removal And Installation 515
BOB-TACH (POWER-OPTION) 517
Description 517
Removal And Installation 517
Lever And Wedge Disassembly And Assembly 519
Pivot Pin Bushing And Seal Removal And Installation 520
LIFT ARMS 521
Stabilizer Bar Removal And Installation 521
Link Removal And Installation 522
Removal And Installation 523
REAR GRILL 527
Removal And Installation 527
REAR DOOR 529
Removal And Installation 529
Striker Removal and Installation 530
Striker Disassembly and Assembly 530
Striker (Adjusting) 530
Latch Removal and Installation 531
FUEL TANK 533
Removal And Installation 533
Fuel Level Sender Removal And Installation 534
Fuel Fill Screen Removal And Installation 535
CONTROL PEDALS AND LINKAGES 537
Description 537
Pedal Removal And Installation 537
Linkage Removal And Installation 538
Pedal (Adjusting) 540
CONTROL PEDALS (ACS) 541
Description 541
Foot Sensor Removal And Installation 541
Foot Pedal Removal And Installation 542
Foot Pedal Linkage Disassembly And Assembly 543
CONTROL PANEL 545
Description 545
Removal and Installation 546
Shock Removal And Installation 549
Shaft Removal And Installation 549
Shaft Disassembly And Assembly 550
Linkage Removal And Installation 551
Pintle Arm Disassembly and Assembly 555
Linkage Neutral Adjustment 557
Linkage Travel Adjustment 561
CONTROL PANEL (SJC) 565
Description 565
Removal And Installation 565
CONTROL HANDLE/LEVER 567
Description 567
Lever Removal And Installation 567
Boot Removal And Installation 568
CONTROL HANDLE/LEVER (ACS) 569
Description 569
Handle Sensor Removal And Installation 569
Handle Removal and Installation 572
Handle Disassembly and Assembly 573
Lever Removal and Installation 573
Boot Removal And Installation 575
CONTROL HANDLE/LEVER (SJC) 577
Description 577
Joystick Testing 577
Joystick Removal And Installation (S/N 530511001 – 530512551, S/N 530611001 – 530611153) 578
Joystick Removal And Installation (S/N 530512552 & Above, S/N 530611154 & Above) 580
Removal And Installation (S/N 530511001 – 530512551, S/N 530611001 – 530611153) 581
Removal And Installation (S/N 530512552 & Above, S/ N 530611154 & Above) 582
ACCESS PANEL (INSIDE) 583
Removal And Installation (Left) 583
Removal And Installation (Right) 583
ACCESS PANEL (INSIDE) (SJC) 585
Removal And Installation (Left) 585
Removal And Installation (Right) 586
WINDOW (REAR) 589
Removal 589
Installation 589
WINDOW (TOP) 591
Removal And Installation 591
WINDOW (SIDE) 593
Removal And Installation 593
WINDOW (FRONT DOOR) 595
Removal (Standard Window) 595
Installation (Standard Window) 596
Removal And Installation (Special Applications Window) 598
ELECTRICAL SYSTEM & ANALYSIS 599
ELECTRICAL SCHEMATICS 603
ELECTRICAL SYSTEM INFORMATION 616
Glossary Of Electrical Symbols 616
Cab Harness Connectors 619
Mainframe Harness Connectors 620
Description 621
Troubleshooting 622
Fuse And Relay Location / Identification 623
Solenoid Testing 624
BATTERY 626
Removal And Installation 626
Servicing 627
Using A Booster Battery (Jump Starting) 628
ALTERNATOR 630
Belt Adjustment 630
Belt Replacement 630
Charging System Inspection 631
Alternator Voltage Testing 632
Low Voltage Testing 632
High Voltage Testing 633
Removal And Installation 634
Parts Identification 635
STARTER 636
Testing 636
Removal And Installation 637
Parts Identification 638
INSTRUMENT PANELS 640
Left Panel 640
Right Panel (Key Switch) 641
Right Panel (Keyless) 642
Side And Front Panels 644
Removal And Installation (Left And Right) 645
Bulb Removal And Installation (Left Only) 648
Key Switch Removal And Installation 649
Alarm Removal And Installation 650
Front Panel Removal And Installation 650
LIGHTS 652
Front Removal And Installation 652
Rear Removal And Installation 653
Cab Light Removal And Installation 653
BOBCAT CONTROLLER (MAIN) 654
Description 654
Connector Identification 655
Removal And Installation 657
BOBCAT CONTROLLER (ACS) 658
Description 658
Connector Identification 660
Removal and Installation 661
BOBCAT CONTROLLER (SJC) (DRIVE) 662
Description 662
Connector Identification 663
Removal and Installation 665
WHEEL SPEED SENSORS (SJC) 668
Description 668
Testing 668
Removal And Installation 670
DIAGNOSTIC SERVICE CODES 672
Viewing Service Codes (Key Switch) 672
Viewing Service Codes (Keyless) 672
Service Codes List 673
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) 678
Description 678
Inspecting The BICS Controller (Engine STOPPED – Key ON) 679
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 679
Inspecting The Seat Bar Sensor (Engine RUNNING) 679
Inspecting The Traction Lock (Engine RUNNING) 679
Inspecting The Lift Arm Bypass Control 679
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC) 679
Troubleshooting 680
Troubleshooting Chart 681
SEAT BAR SENSOR 682
Description 682
Troubleshooting 682
Testing 683
Removal And Installation 684
Bobcat Interlock Control System (BICS) Circuit Test 686
TRACTION LOCK 688
Description 688
Troubleshooting 688
Removal And Installation 689
Inspecting 693
CONTROL SYSTEM (ACS) 694
Description 694
Troubleshooting Chart 695
Handle Sensor Connector Disassembly And Assembly 696
Switch Handle Removal 697
Switch Handle Installation 699
Actuator Connector Disassembly And Assembly 702
Handle Lock Solenoid Removal And Installation 703
Handle Lock Solenoid Disassembly And Assembly 703
Foot Sensor Disassembly And Assembly 704
Foot Lock Solenoid Removal And Installation 705
ELECTRICAL/HYDRAULIC CONTROLS 706
Identification Chart 706
ELECTRICAL/HYDRAULIC CONTROLS (SJC) 708
Identification Chart 708
SERVICE PC (LAPTOP COMPUTER) 712
Connecting Remote Start Tool 712
Connecting Remote Start Tool (Service Tool) 712
CALIBRATION 714
Description 714
Actuator Testing 714
Lift And Tilt Calibration (ACS) 716
Lift And Tilt Calibration (SJC) 718
Hydrostatic Pump Calibration (SJC) 720
STEERING DRIFT COMPENSATION 726
Description 726
Selecting And Adjusting 726
Exiting And Saving 727
FLYWHEEL RPM SENSOR 728
Description 728
Adjusting 728
CONTROL PANEL SETUP 730
Right Panel Setup (Keyless) 730
Attachment Control Information (Keyless) 731
PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START) 732
Password Description 732
Changing The Owner And User Passwords 733
Password Lockout Feature 734
MAINTENANCE CLOCK 736
Description 736
Setup 737
Reset 741
BACK-UP ALARM SYSTEM 742
Description 742
Inspecting 742
Adjusting Switch Position 743
Troubleshooting (Standard and ACS) 744
Troubleshooting (Joystick) 745
Alarm Removal And Installation 746
Switch Removal And Installation 746
ENGINE SERVICE 748
ENGINE INFORMATION 750
Description 750
Engine Specifications – Kubota V2403-M-DI-T 751
Engine Torque Values 755
Troubleshooting 755
Engine Removal And Installation 757
Engine Mount Replacement 764
Compression – Checking 765
ENGINE SPEED CONTROL 766
Removal And Installation 766
ENGINE SPEED CONTROL (SJC) 768
Removal And Installation 768
Disassembly And Assembly 770
MUFFLER 772
Removal And Installation 772
AIR CLEANER 774
Housing Removal And Installation 774
ENGINE COOLING SYSTEM 776
Radiator Removal And Installation 776
Blower Housing Removal And Installation 779
Hydraulic Fan Removal And Installation 781
Hydraulic Fan Description 782
Hydraulic Fan Disassembly And Assembly 782
Water Pump Removal And Installation 783
Water Pump Disassembly And Assembly 783
Thermostat Housing Removal And Installation 784
LUBRICATION SYSTEM 786
Oil Pan Removal And Installation 786
Oil Pump Removal And Installation 786
Oil Pump Inspection 787
Engine Oil Pressure – Testing 788
FUEL SYSTEM 790
Fuel Camshaft Removal And Installation 790
Fuel Camshaft Governor Disassembly And Assembly 791
Fuel Shutoff Solenoid – Checking 792
Fuel Shutoff Solenoid Removal And Installation 792
Fuel Injection Pump Removal And Installation 793
Injection Pump – Timing 796
Fuel Injector Removal And Installation 798
Fuel Injector Nozzle Pressure – Checking 800
Nozzle Spraying Condition 800
Valve Seat Tightness 801
CYLINDER HEAD 802
Glow Plugs – Testing 802
Glow Plugs Removal And Installation 802
Valve Clearance Adjustment 803
Valve Timing, Checking 804
Cylinder Head Removal And Installation 805
Cylinder Head Disassembly and Assembly 808
Cylinder Head – Servicing 808
Cylinder Head Top Clearance 809
Valve Guide-Checking 809
Reconditioning The Valve And Valve Seat 810
Valve Spring 812
Valve Tappets 813
Rocker Arm And Shaft Checking 813
CRANKSHAFT AND PISTONS 814
Piston And Connecting Rod Removal And Installation 814
Piston And Connecting Rod – Servicing 815
Cylinder Bore – Checking 818
Connecting Rod Alignment 818
Crankshaft Gear Removal And Installation 819
Crankshaft And Bearings Removal And Installation 819
Crankshaft And Bearings – Servicing 821
CAMSHAFT AND TIMING GEARS 826
Timing Gearcase Cover Removal And Installation 826
Timing Gears Backlash-Checking 828
Idler Gear And Camshaft Removal And Installation 829
Camshaft – Servicing 830
Idler Gear And Shaft Servicing 831
TURBOCHARGER 832
Description 832
Testing 832
Removal And Installation 833
FLYWHEEL AND HOUSING 836
Flywheel Removal And Installation 836
Ring Gear Removal And Installation 836
Housing Removal And Installation 837
HEATING, VENTILATION, AIR CONDITIONING 840
AIR CONDITIONING SYSTEM FLOW 843
Description 843
Chart 844
Components 845
Safety Equipment 848
REGULAR MAINTENANCE 850
Filter Elements Removal And Installation 850
Compressor Drive Belt Inspection 851
Condenser 852
Air Conditioning Lubrication 852
Air Conditioning Service Chart 853
Cleaning The A/C Evaporator Coil And Heater Coil 854
TROUBLESHOOTING 856
Blower Motor Does Not Operate 856
Blower Motor Operates Normally, But Air Flow Is Insufficient 856
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 856
The Compressor Does Not Operate At All, Or Operates Improperly 856
Gauge Pressure Related Troubleshooting 857
Troubleshooting Tree 859
Temperature/Pressure Chart 863
Poor A/C Performance 864
HVAC Repair And Leaks 865
Electrical System 866
Engine Coolant Bypassing The Heater Valve 873
Heater Valve Not Opening Or Closing 874
SYSTEM CHARGING AND RECLAMATION 876
Refrigerant Identification 876
Reclamation And Charging With Recovery / Charging Unit 877
Charging With A Manifold Gauge Set 879
COMPRESSOR 882
Belt Adjustment 882
Removal And Installation 883
Oil 884
Oil Check 885
Clutch Disassembly And Assembly 887
CONDENSER 892
Removal And Installation 892
RECEIVER/DRIER 894
Receiver/Drier Removal And Installation 894
Pressure Relief Valve Removal And Installation 895
Pressure Switch Removal And Installation 896
Schraeder Valve Removal And Installation 897
EVAPORATOR / HEATER UNIT 898
Removal And Installation 898
THERMOSTAT 900
Removal And Installation 900
EXPANSION VALVE 902
Removal And Installation 902
EVAPORATOR 904
Removal And Installation 904
HEATER COIL 906
Removal And Installation With A/C 906
Removal And Installation Without A/C 908
BLOWER FAN 910
Removal And Installation 910
Disassembly And Assembly 911
Connector Identification 913
HEATER VALVE 914
Removal and Installation 914
Disassembly And Assembly 915
SPECIFICATIONS 916
S205 LOADER SPECIFICATIONS 918
Dimensions 918
Performance 919
Controls 919
Engine 919
Hydraulic System 920
Electrical 920
Drive System 921
Capacities 921
Tires 921
TORQUE SPECIFICATIONS FOR BOLTS 922
Torque For General SAE Bolts 922
Torque For General Metric Bolts 923
HYDRAULIC CONNECTION SPECIFICATIONS 924
O-ring Face Seal Connection 924
Straight Thread O-ring Fitting 925
Tubelines And Hoses 925
Flare Fitting 926
Port Seal Fitting 927
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 928
Specifications 928
CONVERSIONS 930
Decimal And Millimeter Equivalents 930
U S To Metric Conversion Chart 930
SERVICE MANUAL REVISION 932
Revision No: S205 – 1 932
Revision No: S205 – 2 934
Revision No: S205 – 3 936
Revision No: S205 – 4 938
Revision No: S205 – 5 940
Revision No: S205 – 6 942
Revision No: S205 – 7 944
Revision No: S205 – 8 946
Revision No: S205 – 9 948
Revision No: S205 – 10 950
Revision No: S205 – 11 952
Revision No: S205 – 12 954
Revision No: S205 – 13 956

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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