A Service Manual (sometimes referred to as a Repair, Technical, Workshop
or Shop Manual) is often
large and broken down in to sections for different parts of your equipment.
Service
manuals cover absolutely every aspect of your machine unless mentioned
otherwise. Sometimes, the
engine is covered in a separate service manual that is written specifically for
the
engine. Most of the time though, it’s included in the main service manual. A
service manual will
arm you with the same exact information that your local service center has and
includes
electrical and hydraulic diagrams and which are usually color and or large
foldout pages.
Most OEM service manuals will also include troubleshooting flow charts, error
codes and
exploded views of components which are a great help for disassembly and
re-assembly.

An Operator’s Manual typically describes basic equipment operation and
maintenance. This
is the manual distributed with your equipment at the time of purchase from the
dealer.

• 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