Bobcat S205 Skid-Steer Loader Technical Service Manual 6987037 (7-09) PDF

Description

Bobcat S205 Skid-Steer Loader Service Manual 6987037 (7-09) – PDF DOWNLOAD

FILE DETAILS:

Bobcat S205 Skid-Steer Loader Service Manual 6987037 (7-09) – PDF DOWNLOAD

Language : English
Pages : 932
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S205 Skid-Steer Loader Service Manual 6987037 (7-09) – PDF DOWNLOAD

S/N 530560001 & Above
S/N 530660001 & Above

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 6987037 (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 54
FUEL SYSTEM 55
Fuel Specifications 55
Biodiesel Blend Fuel 55
Filling the Fuel Tank 56
Fuel Filter 57
Removing Air From The Fuel System 57
ENGINE LUBRICATION SYSTEM 59
Checking And Adding Engine Oil 59
Engine Oil Chart 59
Removing And Replacing Oil And Filter 60
HYDRAULIC / HYDROSTATIC SYSTEM 61
Checking And Adding Fluid 61
Hydraulic / Hydrostatic Fluid Chart 61
Removing And Replacing Hydraulic Fluid 62
Removing And Replacing Hydraulic / Hydrostatic Filter 62
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders) 63
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders) 64
Removing And Replacing Hydraulic Charge Filter 66
Breather Cap 67
FINAL DRIVE TRANSMISSION (CHAINCASE) 69
Checking And Adding Oil 69
Removing And Replacing Oil 69
BOB-TACH (HAND LEVER) 71
Inspection And Maintenance 71
BOB-TACH (POWER) 73
Inspection And Maintenance 73
LUBRICATING THE LOADER 75
Lubrication Locations 75
TIRE MAINTENANCE 77
Wheel Nuts 77
Rotating 77
Mounting 77
SPARK ARRESTOR MUFFLER 79
Cleaning Procedure 79
PIVOT PINS 81
Inspection And Maintenance 81
LOADER STORAGE AND RETURN TO SERVICE 83
Storage 83
Return to Service 83
STOPPING THE ENGINE AND LEAVING THE LOADER 85
Procedure 85
Emergency Exit 86
HYDRAULIC SYSTEM 87
HYDRAULIC / HYDROSTATIC SCHEMATICS 91
HYDRAULIC SYSTEM INFORMATION 107
Glossary Of Hydraulic / Hydrostatic Symbols 107
Troubleshooting 111
CYLINDER (LIFT) 113
Testing 113
Removal And Installation 114
Parts Identification 117
Disassembly and Assembly 118
CYLINDER (TILT) 121
Testing 121
Removal And Installation 122
Rod End Pivot Pin Bushing And Seal Removal And Installation 124
Base End Pivot Pin Removal And Installation 124
Parts Identification 125
Disassembly And Assembly 126
CYLINDER (BOB-TACH) 129
Testing 129
Removal And Installation 130
Parts Identification 131
Disassembly and Assembly 132
MAIN RELIEF VALVE 135
Description 135
Testing 135
Adjusting 137
Removal and Installation 138
HYDRAULIC CONTROL VALVE (STANDARD) 139
Description 139
Removal And Installation 139
Identification Chart 144
Mount Bracket Removal And Installation 145
Lift Load Check Valve Removal And Installation 145
Load Check Valve Removal And Installation (Tilt & Auxiliary) 146
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 147
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 148
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 148
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 149
Port Relief Valve Removal And Installation 149
Plug Removal And Installation 150
Rubber Boot Removal And Installation 151
End Cap / Spool Lock Block Removal And Installation 152
Lift Spool And Detent Removal And Installation 153
Tilt Spool Removal And Installation 163
Auxiliary Spool Removal And Installation 165
Auxiliary Solenoid Removal And Installation 166
Solenoid Removal And Installation 167
Lock Valve Removal And Installation 169
Lift Arm Bypass Orifice Removal And Installation 171
Main Relief Valve Removal And Installation 171
Check Valve Removal And Installation 172
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 173
Description 173
Removal And Installation 173
Actuator Removal And Installation (Out of Loader) 178
Identification Chart 181
Mount Bracket Removal And Installation 182
Lift Load Check Valve Removal And Installation 182
Load Check Valve Removal And Installation (Tilt & Auxiliary) 183
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 184
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 185
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 185
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 186
Port Relief Valve Removal And Installation 186
Plug Removal And Installation 187
End Cap Block Removal And Installation 188
Lift Spool And Detent Removal And Installation 189
Tilt Spool Removal And Installation 194
Auxiliary Spool Removal And Installation 196
Auxiliary Solenoid Removal And Installation 197
Solenoid Removal And Installation 198
Lock Valve Removal And Installation 200
Lift Arm Bypass Orifice Removal And Installation 202
Main Relief Valve Removal And Installation 203
Check Valve Removal And Installation 204
LIFT ARM BYPASS CONTROL VALVE 205
Description 205
Testing 205
Removal and Installation 205
Disassembly And Assembly 206
HYDRAULIC PUMP (STANDARD) 207
Description 207
Pump Test at Quick Couplers 207
Direct Pump Test (Standard Section) 208
Direct Pump Test (Charge Section) 210
Removal And Installation 212
Hydraulic Pump Startup 214
Parts Identification 215
Disassembly And Assembly 216
HYDRAULIC PUMP (STANDARD) (HIGH FLOW) 225
Description 225
Pump Test at Quick Couplers 225
Direct Pump Test (Standard Section) 226
Direct Pump Test (Charge Section) 228
Direct Pump Test (High Flow Section) 230
Removal And Installation 232
Hydraulic Pump Startup 234
Parts Identification 235
Disassembly And Assembly 236
HYDRAULIC PUMP (SJC) 249
Description 249
Pump Test at Quick Couplers 249
Direct Pump Test (Standard Section) 250
Direct Pump Test (Charge Section) 252
Removal And Installation 254
Hydraulic Pump Startup 256
Parts Identification 258
Disassembly And Assembly 259
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
Hydraulic Pump Startup 278
Parts Identification 279
Disassembly And Assembly 280
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 Removal And Installation 405
Removal And Installation 406
Hydrostatic Pump Startup 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 Startup 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
Tensioner Pulley Removal And Installation 458
Tensioner Pulley Parts Identification 459
Tensioner Pulley Disassembly 460
Tensioner Pulley 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) 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 (Adjusting) 557
Linkage Travel (Adjusting) 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 578
Joystick Mount Removal And Installation 579
ACCESS PANEL (INSIDE) 581
Removal And Installation (Left) 581
Removal And Installation (Right) 581
ACCESS PANEL (INSIDE) (SJC) 583
Removal And Installation (Left) 583
Removal And Installation (Right) 584
WINDOW (REAR) 587
Removal 587
Installation (Split Molding) 587
Installation (Continuous Molding) 589
WINDOW (TOP) 591
Removal And Installation 591
WINDOW (SIDE) 593
Removal And Installation 593
WINDOW (CAB DOOR) 595
Removal (Standard Window) 595
Installation (Standard Window) 596
Removal And Installation (Special Applications Window) 598
CAB DOOR 599
Description 599
Removal And Installation 599
Aligning 600
Adjusting 601
Checking Operation 601
ELECTRICAL SYSTEM & ANALYSIS 603
ELECTRICAL SCHEMATICS 607
ELECTRICAL SYSTEM INFORMATION 613
Glossary Of Electrical Symbols 613
Standard Cab Harness Connectors 616
Deluxe Cab Harness Connectors 617
Mainframe Harness Connectors 618
Description 619
Troubleshooting 620
Fuse And Relay Location / Identification 621
Solenoid Testing 622
BATTERY 623
Removal And Installation 623
Servicing 624
Using A Booster Battery (Jump Starting) 624
ALTERNATOR 627
Belt Adjustment 627
Belt Replacement 627
Charging System Inspection 628
Alternator Voltage Testing 629
Low Voltage Testing 630
High Voltage Testing 630
Removal And Installation 631
Parts Identification 632
STARTER 633
Testing 633
Removal And Installation 634
Parts Identification 635
INSTRUMENT PANELS 637
Left Panel 637
Standard Key Panel 639
Deluxe Instrumentation Panel 640
Side Panel 641
Front Panel 641
Front Panel Removal And Installation 642
Removal And Installation (Left And Right) 643
Key Switch Removal And Installation 644
Alarm Removal And Installation 644
LIGHTS 645
Front Removal And Installation 645
Rear Removal And Installation 646
Cab Light Removal And Installation 646
BOBCAT CONTROLLER (GATEWAY AND AUXILIARY) 647
Description 647
Connector Identification 648
Removal and Installation 654
BOBCAT CONTROLLER (ACS) 657
Description 657
Connector Identification 658
Removal and Installation 659
BOBCAT CONTROLLER (SJC) (DRIVE) 661
Description 661
Connector Identification 662
Removal and Installation 664
SPEED SENSORS (SJC) 665
Description 665
Testing 665
Removal And Installation 667
DIAGNOSTIC SERVICE CODES 669
Viewing Service Codes (Standard Key Panel) 669
Viewing Service Codes (Deluxe Instrumentation Panel) 669
Service Codes List 670
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) 675
Description 675
Inspecting The BICS Controller (Engine STOPPED – Key ON) 676
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 676
Inspecting The Seat Bar Sensor (Engine RUNNING) 676
Inspecting The Traction Lock (Engine RUNNING) 676
Inspecting The Lift Arm Bypass Control 676
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC) 676
Troubleshooting 677
SEAT BAR SENSOR 679
Description 679
Troubleshooting 679
Testing 680
Removal And Installation 681
Bobcat Interlock Control System (BICS) Circuit Test 683
TRACTION LOCK 685
Description 685
Troubleshooting 685
Removal And Installation 686
Inspecting 690
CONTROL SYSTEM (ACS) 691
Description 691
Troubleshooting 692
Handle Sensor Connector Disassembly And Assembly 693
Switch Handle Removal 694
Switch Handle Installation 696
Actuator Connector Disassembly And Assembly 699
Handle Lock Solenoid Removal And Installation 700
Handle Lock Solenoid Disassembly And Assembly 700
Foot Sensor Disassembly And Assembly 701
Foot Lock Solenoid Removal And Installation 702
ELECTRICAL / HYDRAULIC CONTROLS 703
Identification Chart 703
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 705
Identification Chart 705
SERVICE PC (LAPTOP COMPUTER) 709
Connecting Remote Start Tool 709
Connecting Remote Start Tool (Service Tool) 709
CALIBRATION 711
Description 711
Actuator Testing 711
Lift And Tilt Calibration (ACS) 713
Lift And Tilt Calibration (SJC) 715
Hydrostatic Pump Calibration (SJC) 717
STEERING DRIFT COMPENSATION 723
Description 723
Operation 723
FLYWHEEL RPM SENSOR 725
Description 725
Adjusting 725
CONTROL PANEL SETUP 727
Right Panel Setup (Deluxe Instrumentation Panel) 727
Right Panel Setup (Deluxe Instrumentation Panel) 728
Attachment Control Information (Deluxe Instrumentation Panel) 728
PASSWORD SETUP 729
Password Description 729
Changing The Owner Password 729
Changing The User Passwords 730
Password Lockout Feature 730
MAINTENANCE CLOCK 731
Description 731
Setup 732
Reset 735
BACK-UP ALARM SYSTEM 737
Description 737
Inspecting 737
Adjusting Switch Position 738
Troubleshooting (Standard and ACS) 739
Troubleshooting (Joystick) 740
Alarm Removal And Installation 741
Switch Removal And Installation 741
ENGINE SERVICE 743
ENGINE INFORMATION 747
Description 747
Specifications – Kubota V2403-M-DI-T 748
Torque Values 752
Troubleshooting 752
Engine Removal And Installation 754
Engine Mount Replacement 761
Compression – Checking 762
ENGINE SPEED CONTROL 763
Removal And Installation 763
ENGINE SPEED CONTROL (SJC) 765
Removal And Installation 765
Disassembly And Assembly 767
MUFFLER 769
Removal And Installation 769
AIR CLEANER 771
Housing Removal And Installation 771
ENGINE COOLING SYSTEM 773
Radiator Removal And Installation 773
Hydraulic Fan Description 776
Hydraulic Fan Disassembly And Assembly 776
Blower Housing Removal And Installation 777
Fan Removal And Installation 779
Hydraulic Fan Motor Removal And Installation 779
Water Pump Removal And Installation 780
Water Pump Disassembly And Assembly 780
Thermostat Housing Removal And Installation 781
Thermostat – Checking 782
LUBRICATION SYSTEM 783
Oil Pan Removal And Installation 783
Oil Pump Removal And Installation 783
Oil Pump Inspection 784
Engine Oil Pressure – Testing 785
FUEL SYSTEM 787
Fuel Shutoff Solenoid – Checking 787
Fuel Shutoff Solenoid Removal And Installation 787
Fuel Injection Pump – Checking 788
Fuel Injection Pump Removal And Installation 789
Governor Disassembly And Assembly 793
Fuel Camshaft Removal And Installation 794
Injection Pump – Timing 795
Fuel Injector Removal And Installation 797
Fuel Injector Nozzle Pressure – Checking 798
Nozzle Spray Condition 799
Valve Seat Tightness 799
CYLINDER HEAD 801
Glow Plugs – Testing 801
Glow Plugs Removal And Installation 801
Valve Clearance Adjustment 802
Valve Timing – Checking 803
Cylinder Head Removal And Installation 804
Cylinder Head Disassembly and Assembly 807
Cylinder Head – Servicing 807
Cylinder Head Top Clearance 808
Valve Guide – Checking 808
Reconditioning The Valve And Valve Seat 809
Valve Spring 811
Valve Tappets 812
Rocker Arm And Shaft Checking 812
CRANKSHAFT AND PISTONS 813
Piston And Connecting Rod Removal And Installation 813
Piston And Connecting Rod – Servicing 814
Cylinder Bore – Checking 817
Connecting Rod Alignment 817
Crankshaft Gear Removal And Installation 818
Crankshaft And Bearings Removal And Installation 818
Crankshaft And Bearings – Servicing 820
CAMSHAFT AND TIMING GEARS 825
Timing Gearcase Cover Removal And Installation 825
Timing Gears Backlash-Checking 827
Idler Gear And Camshaft Removal And Installation 828
Camshaft – Servicing 829
Idler Gear And Shaft Servicing 830
TURBOCHARGER 831
Description 831
Testing 831
Removal And Installation 832
FLYWHEEL AND HOUSING 835
Flywheel Removal And Installation 835
Ring Gear Removal And Installation 835
Housing Removal And Installation 836
HEATING, VENTILATION, AIR CONDITIONING 839
AIR CONDITIONING SYSTEM FLOW 842
Description 842
Chart 843
Components 844
Safety Equipment 847
REGULAR MAINTENANCE 849
Filters 849
Compressor Drive Belt Adjustment 849
Compressor Drive Belt Replacement 849
Condenser 850
Air Conditioning Lubrication 850
Air Conditioning Service Chart 851
Evaporator / Heater Coil 852
TROUBLESHOOTING 853
Blower Motor Does Not Operate 853
Blower Motor Operates Normally, But Air Flow Is Insufficient 853
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 853
The Compressor Does Not Operate At All, Or Operates Improperly 853
Gauge Pressure Related Troubleshooting 854
Troubleshooting Tree 856
Temperature / Pressure Chart 860
Poor A/C Performance 861
HVAC Repair And Leaks 862
Electrical System 863
Engine Coolant Bypassing The Heater Valve 870
Heater Valve Not Opening Or Closing 871
SYSTEM CHARGING AND RECLAMATION 873
Refrigerant Identification 873
Reclamation And Charging With Recovery / Charging Unit 874
Charging With A Manifold Gauge Set 876
COMPRESSOR 879
Removal And Installation 879
Oil 880
Oil Check 881
Clutch Disassembly And Assembly 883
CONDENSER 887
Removal And Installation 887
RECEIVER/DRIER 889
Receiver/Drier Removal And Installation 889
Pressure Relief Valve Removal And Installation 890
Pressure Switch Removal And Installation 891
Schraeder Valve Removal And Installation 892
EVAPORATOR / HEATER UNIT 893
Removal And Installation 893
THERMOSTAT 895
Removal And Installation 895
EXPANSION VALVE 897
Removal And Installation 897
EVAPORATOR COIL 899
Removal And Installation 899
HEATER COIL 901
Removal And Installation With A/C 901
Removal And Installation Without A/C 903
BLOWER FAN 905
Removal And Installation 905
Disassembly And Assembly 906
Connector Identification 908
HEATER VALVE 909
Removal and Installation 909
Disassembly And Assembly 910
SPECIFICATIONS 911
S205 LOADER SPECIFICATIONS 913
Dimensions 913
Performance 914
Controls 914
Engine 914
Hydraulic System 915
Electrical 915
Drive System 916
Capacities 916
Tires 916
TORQUE SPECIFICATIONS FOR BOLTS 917
Torque For General SAE Bolts 917
Torque For General Metric Bolts 918
HYDRAULIC CONNECTION SPECIFICATIONS 919
O-ring Face Seal Connection 919
Straight Thread O-ring Fitting 920
Tubelines And Hoses 920
Flare Fitting 921
Port Seal Fitting 922
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 923
Specifications 923
CONVERSIONS 925
Decimal And Millimeter Equivalents 925
U S To Metric Conversion Chart 925
SERVICE MANUAL REVISION 927
Revision No: S205 – 1 927
Revision No: S205 – 2 929
Revision No: S205 – 3 931

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