Service Manual

S205 Skid-Steer Loader

S/N 530560001 & Above

S/N 530660001 & Above

EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS)

6987037 (5-08) Printed in U.S.A. © Bobcat Company 2008

 MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.

CORRECT CORRECT CORRECT

B-10731a B-15535 B-15524

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG

B-15734 B-15732 B-15525

Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an approved attachments not approved by
Avoid exhaust fume leaks which lift arm support device. Replace it Bobcat Company.
can kill without warning. Exhaust if damaged.
system must be tightly sealed.
WRONG WRONG WRONG

B-15733 B-15523 B-6589

B-16102 B-16102
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW07-0805
 ALPHABETICAL INDEX

ACCESS PANEL (INSIDE) ..................................... 50-01 ENGINE SPEED CONTROL ...................................70-01

ACCESS PANEL (INSIDE) (SJC) ........................... 50-01 ENGINE SPEED CONTROL (SJC) .........................70-01
AIR CLEANER ........................................................ 70-01 EVAPORATOR ........................................................80-01
AIR CLEANER SERVICE ....................................... 10-01 EVAPORATOR/HEATER UNIT................................80-01
AIR CONDITIONING SYSTEM FLOW ................... 80-01 EXPANSION VALVE ................................................80-01
ALTERNATOR ........................................................ 60-01
FLYWHEEL AND HOUSING ...................................70-01
BACK-UP ALARM SYSTEM ................................... 60-01 FLYWHEEL RPM SENSOR ....................................60-01
BATTERY................................................................ 60-01 FRONT AUXILIARY HYDRAULIC
BLOWER FAN ........................................................ 80-01 COUPLER BLOCK ...............................................20-01
BOBCAT INTERLOCK CONTROL FUEL SYSTEM.............................................10-01, 70-01
SYSTEM (BICS) ................................................... 60-01 FUEL TANK .............................................................50-01
BOBCAT CONTROLLER (ACS) ............................ 60-01
BOBCAT CONTROLLER (MAIN)............................ 60-01 HEATER COIL .........................................................80-01
BOBCAT CONTROLLER (SJC) (DRIVE) ............... 60-01 HEATER VALVE ......................................................80-01
BOB-TACH.............................................................. 10-01 HIGH FLOW VALVE ................................................20-01
BOB-TACH (HAND LEVER) ........................ 10-01, 50-01 HYDRAULIC CONNECTION SPECS ............... SPEC-01
BOB-TACH (POWER).................................. 10-01, 50-01 HYDRAULIC CONTROL VALVE (ACS) OR (SJC) ..20-01
BOB-TACH (POWER) BLOCK................................ 20-01 HYDRAULIC CONTROL VALVE (STANDARD) ......20-01
BRAKE (SINGLE SPEED) ...................................... 40-01 HYDRAULIC/HYDROSTATIC FILTERS ..................20-01
BRAKE (TWO-SPEED)........................................... 40-01 HYDRAULIC FLUID RESERVOIR ..........................20-01
BUCKET POSITION VALVE.................................. 20-01 HYDRAULIC/HYDROSTATIC
FLUID SPECIFICATIONS................................ SPEC-01
CAB DOOR ............................................................. 50-01 HYDRAULIC/HYDROSTATIC SYSTEM..................10-01
CALIBRATION ........................................................ 60-01 HYDRAULIC PUMP (STANDARD)..........................20-01
CAMSHAFT AND TIMING GEARS......................... 70-01 HYDRAULIC PUMP (STANDARD) (HIGH FLOW)..20-01
CHARGE PRESSURE ........................................... 30-01 HYDRAULIC PUMP (SJC) ......................................20-01
COMPRESSOR ...................................................... 80-01 HYDRAULIC PUMP (SJC) (HIGH FLOW)...............20-01
CONDENSER ......................................................... 80-01 HYDRAULIC SYSTEM INFORMATION ..................20-01
CONTROL HANDLE/LEVER .................................. 50-01 HYDROSTATIC MOTOR .........................................30-01
CONTROL HANDLE/LEVER (ACS) ....................... 50-01 HYDROSTATIC MOTOR (TWO-SPEED) ................30-01
CONTROL HANDLE/LEVER (SJC) ........................ 50-01 HYDROSTATIC MOTOR CARRIER
CONTROL PANEL .................................................. 50-01 (SINGLE ANDTWO-SPEED WITH MANUAL
CONTROL PANEL (SJC)........................................ 50-01 CONTROLS) .........................................................30-01
CONTROL PANEL SETUP ..................................... 60-01 HYDROSTATIC MOTOR CARRIER
CONTROL PEDALS AND LINKAGE ...................... 50-01 (SINGLE ANDTWO-SPEED WITH SJC
CONTROL PEDALS (ACS) .................................... 50-01 CONTROLS) .........................................................30-01
CONTROL SYSTEM (ACS) .................................... 60-01 HYDROSTATIC PUMP ............................................30-01
CONVERSIONS ................................................SPEC-01 HYDROSTATIC PUMP (SJC) ..................................30-01
CRANKSHAFT AND PISTONS ............................. 70-01 HYDROSTATIC SYSTEM INFORMATION..............30-01
CYLINDER (LIFT) ................................................... 20-01
CYLINDER (BOB-TACH) ........................................ 20-01 INSTRUMENT PANELS .........................................60-01
CYLINDER (TILT) ................................................... 20-01
CYLINDER HEAD ................................................... 70-01 LIFT ARMS ..............................................................50-01
LIFT ARM BYPASS CONTROL VALVE ..................20-01
DIAGNOSTICS SERVICE CODES......................... 60-01 LIFT ARM SUPPORT DEVICE................................10-01
DRIVE BELT ........................................................... 30-01 LIFTING AND BLOCKING THE LOADER...............10-01
LIGHTS....................................................................60-01
ELECTRICAL/HYD. CONTROLS ........................... 60-01 S205 LOADER SPECIFICATIONS.................... SPEC-01
ELECTRICAL/HYD. CONTROLS LOADER STORAGE AND RETURN TO SERVICE 10-01
REFERENCE (SJC).............................................. 60-01 LUBRICATING THE LOADER.................................10-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01 LUBRICATION SYSTEM .........................................70-01
ENGINE COOLING SYSTEM ................................. 10-01
ENGINE LUBRICATION SYSTEM ......................... 10-01 MAIN RELIEF VALVE ..............................................20-01
ENGINE COOLING SYSTEM ................................. 70-01 MAINTENANCE CLOCK .........................................60-01
ENGINE INFORMATION ........................................ 70-01 MUFFLER................................................................70-01

S205 Service Manual

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 ALPHABETICAL INDEX (CONT’D)

OIL COOLER .......................................................... 20-01

OPERATOR CAB......................................... 10-01, 50-01
OPERATOR SEAT .................................................. 50-01
OPERATOR SEAT (SUSPENSION) ....................... 50-01

PASSWORD SETUP (IF EQUIPPED WITH

KEYLESS START) ................................................ 60-01
PIVOT PINS ............................................................ 10-01

REAR AUXILIARY DIVERTER VALVE ................... 20-01

REAR DOOR ..........................................................50-01
REAR GRILL ..........................................................50-01
RECEIVER/DRIER ................................................. 80-01
REGULAR MAINTENANCE ................................... 80-01
REMOTE START TOOL KIT-MEL1563 .............. 10-01
REMOTE START TOOL (SERVICE TOOL)
KIT-6689779 ......................................................... 10-01

SEAT BAR............................................................... 50-01

SEAT BAR SENSOR............................................... 60-01
SERVICE PC (LAPTOP COMPUTER) ................... 60-01
SERVICE SCHEDULE.............................................10-01
SPARK ARRESTOR MUFFLER ............................. 10-01
SPEED SENSOR (SJC) ......................................... 60-01
STARTER................................................................ 60-01
STEERING DRIFT COMPENSATION .................... 60-01
STOPPING THE ENGINE AND
LEAVING THE LOADER....................................... 10-01
SYSTEM CHARGING AND RECLAMATION.......... 80-01

TEMPERATURE/PRESSURE ................................ 80-01

THERMOSTAT........................................................ 80-01
TORQUE SPECIFICATIONS FOR BOLTS ........SPEC-01
TOWING THE LOADER ......................................... 10-01
TRACK CARRIAGE COMPONENTS ..................... 40-01
TRACTION LOCK ................................................... 60-01
TRANSPORTING THE BOBCAT LOADER ............ 10-01
TROUBLESHOOTING ............................................ 80-01
TURBOCHARGER ................................................. 70-01
TWO-SPEED VALVE .............................................. 30-01

WINDOW (FRONT DOOR)..................................... 50-01

WINDOW (REAR) ................................................... 50-01
WINDOW (SIDE) .................................................... 50-01
WINDOW (TOP)...................................................... 50-01

S205 Service Manual

 SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

SYSTEM
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX HYDROSTATIC

SYSTEM
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI DRIVE

SYSTEM
SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

MAIN FRAME
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01 ELECTRICAL

SYSTEM &
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ANALYSIS
ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 SERVICE

HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 HVAC

SPECIFICATIONS

SPECIFICATIONS

i S205 Service Manual

 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:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including side screens) is in function correctly.
good condition and is not
modified.

2. Check that ROPS mounting 10. Enclosure door latches must

hardware is tightened and is open and close freely.
Bobcat approved.

3. The seat belt must be 11. Bob-Tach wedges and

correctly installed, functional linkages must function
and in good condition. correctly and be in good
condition.

4. The seat bar must be 12. Safety treads must be in good

correctly adjusted, clean and condition.
lubricated.

5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps.

6. Machine signs (decals) must 14. Check hydraulic fluid level,

be legible and in the correct engine oil level and fuel
location. supply.

7. Steering levers, hand controls 15. Inspect for fuel, oil or

and foot pedals must return to hydraulic fluid leaks.
neutral (as applicable).

8. Check for correct function of 16. Lubricate the loader.

the work lights.

FW SSL-0308 SM

ii S205 Service Manual

17. Check the condition of the 22. Check for any field
battery and cables. modification not completed.

18. Inspect the air cleaner for 23. Operate the machine and
damage or leaks. Check the check all functions.
condition of the element.

19. Check the electrical charging 24. Check for correct function of
system. the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.
20. Check tires for wear and 25. Check function or condition of
pressure. Check tracks for all equipped options and
wear and tension. Use only accessories (examples: back-
approved tires or tracks. up alarm, fire extinguisher,
rotating beacon, lift kits, etc.).
21. Inspect for loose or broken 26. Recommend to the owner
parts or connections. that all necessary corrections
be made before the machine
is returned to service.

CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects and other
reproductive harm.

FW SSL-0308 SM

iii S205 Service Manual

SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions • An Operator’s Handbook fastened to the operator
can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903
operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
IMPORTANT
• The AEM Safety Manual delivered with the machine
This notice identifies procedures which must be gives general safety information.
followed to avoid damage to the machine.
I-2019-0284 • The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shop-
type service and repair work.

• The Skid-Steer Loader Operator Training Course is

DANGER available through your local dealer or at

www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
The signal word DANGER on the machine and in the of correct operation of the Skid-Steer Loader. The
manuals indicates a hazardous situation which, if not course is available in English and Spanish versions.
avoided, will result in death or serious injury.
D-1002-1107 • Service Safety Training Courses are available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com. They provide information for
safe and correct service procedures.

WARNING • The Skid-Steer Loader Safety Video is available from

your Bobcat dealer or at www.training.bobcat.com
The signal word WARNING on the machine and in the or www.bobcat.com.
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107

SI SSL-0308 SM

v S205 Service Manual

FIRE PREVENTION Hydraulic System

Check hydraulic tubes, hoses and fittings for damage

and leakage. Never use open flame or bare skin to check
for leaks. Hydraulic tubes and hoses must be properly
routed and have adequate support and secure clamps.
Tighten or replace any parts that show leakage.

Maintenance Always clean fluid spills. Do not use gasoline or diesel

fuel for cleaning parts. Use commercial nonflammable
The machine and some attachments have components
solvents.
that are at high temperatures under normal operating
conditions. The primary source of high temperatures is
Fueling
the engine and exhaust system. The electrical system, if
damaged or incorrectly maintained, can be a source of
arcs or sparks.

Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard. Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
The operator’s area, engine compartment and engine sparks. Fill the fuel tank outdoors.
cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Starting

All fuels, most lubricants and some coolants mixtures are Do not use ether or starting fluids on any engine that has
flammable. Flammable fluids that are leaking or spilled glow plugs. These starting aids can cause explosion and
onto hot surfaces or onto electrical components can injure you or bystanders.
cause a fire.
Use the procedure in the Operation & Maintenance
Operation Manual for connecting the battery and for jump starting.

Do not use the machine where exhaust, arcs, sparks or

hot components can contact flammable material, Spark Arrestor Exhaust System
explosive dust or gases. The spark arrestor exhaust system is designed to control
the emission of hot particles from the engine and exhaust
Electrical system, but the muffler and the exhaust gases are still
hot.

Check the spark arrestor exhaust system regularly to

make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
cleaning the spark arrestor muffler (if equipped).
Check all electrical wiring and connections for damage.
Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed.

Battery gas can explode and cause serious injury. Use

the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.

SI SSL-0308 SM

vii S205 Service Manual

FIRE PREVENTION (CONT’D)

Welding And Grinding

Always clean the machine and attachment, disconnect

the battery, and disconnect the wiring from the Bobcat
controllers before welding. Cover rubber hoses, battery
and all other flammable parts. Keep a fire extinguisher
near the machine when welding.

Have good ventilation when grinding or welding painted

parts. Wear dust mask when grinding painted parts.
Toxic dust or gas can be produced.

Dust generated from repairing nonmetallic parts such as

hoods, fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away
from open flames or sparks.

Fire Extinguishers

Know where fire extinguishers and first aid kits are

located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.

SI SSL-0308 SM

viii S205 Service Manual

SERIAL NUMBER LOCATIONS Engine Serial Number

Always use the serial number of the loader when Figure 2

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.

Loader Serial Number

Figure 1

P-48705

The engine serial number is in the location shown

[Figure 2].

P-31843B

The loader serial number plate is located on the outside

of the loader frame [Figure 1].

Explanation of loader Serial Number:

XXXX XXXXX
Model 1.-Model/ Engine Model 2.-Production
Combination Sequence (Series)

1. The four digit Model/Engine Combination Module

number identifies the model number and engine
combination.

2. The five digit Production Sequence Number identifies

the order which the loader is produced.

ix S205 Service Manual

DELIVERY REPORT

Figure 3

B-16315

The Delivery Report must be filled out by the dealer and

signed by the owner or operator when the Bobcat Loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [Figure
3].

x S205 Service Manual

LOADER IDENTIFICATION

FRONT LIGHTS OPERATOR SEAT

WITH SEAT BELT

SEAT BAR

‹REAR AUXILIARY
GRAB HANDLES QUICK COUPLERS
STEERING
LEVER
TILT CYLINDER
STABILIZER ROD

† BUCKET
FRONT AUXILIARY
QUICK COUPLERS

BUCKET STEPS SAFETY TREAD

zOPERATOR CAB
REAR WINDOW (ROPS & FOPS)

LIFT ARM LINK

REAR GRILL
LIFT ARM

TAIL LIGHT LIFT CYLINDER

LIFT ARM
SUPPORT DEVICE

REAR
LIGHT

REAR DOOR

* TIRES
B-16604C
B-16605B
‹ OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)
* TIRES - The Bobcat Loader is factory equipped with heavy duty flotation tires. See Specifications Section and your
Bobcat dealer for available tires.
† BUCKET - Several different buckets and other attachments are available for the Bobcat Loader.
z ROPS, FOPS - Roll Over Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective Structure
per SAEJ1043 and ISO 3449, Level I. Level II is available. The Bobcat Loader is base-equipped with a standard operator
cab as shown. Extra insulated cab is available as an option (Reduced noise level).

xi S205 Service Manual

 SAFETY &
SAFETY AND MAINTENANCE MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
SAFETY &
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1 MAINTENANCE
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2 DRIVE
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1 SYSTEM
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . 10-90-2

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

Checking And Adding Engine Oil. . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Engine Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Removing And Replacing Oil And Filter. . . . . . . . . . . . . . . . . . 10-110-2
ELECTRICAL
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . 10-130-1 SYSTEM &
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1 ANALYSIS
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 ENGINE

Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 SERVICE
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . 10-100-3 SPECIFICATIONS

HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . 10-120-1

Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-7
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . 10-120-1
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed
Loaders). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-4
Removing And Replacing Hydraulic Case Drain Filters (Single Speed
Loaders). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-3
Removing And Replacing Hydraulic Charge Filter. . . . . . 10-120-6
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . 10-120-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . 10-120-2

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Installing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Removing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Continued On Next Page

10-01 S205 Service Manual

 SAFETY AND MAINTENANCE (CONT’D)

LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

LOADER STORAGE AND RETURN TO SERVICE . . . . . . . 10-190-1

Return to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Cab Door Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Special Applications Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Special Applications Kit Inspection And Maintenance . . . . 10-30-4

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-180-1

REMOTE START TOOL KIT-MEL1563. . . . . . . . . . . . . . . . . . 10-60-1

Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-4
Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Service Tool Harness Communicator - MEL1566 . . . . . . . 10-60-3
Service Tool Harness Control - MEL1565 . . . . . . . . . . . . . 10-60-2

REMOTE START TOOL (SERVICE TOOL) KIT - 6689779 . . 10-61-1

Computer Service Tool Harness - 6689746 . . . . . . . . . . . . 10-61-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1
Loader Service Tool Harness - 6689747 . . . . . . . . . . . . . . 10-61-3
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-5
Remote Start Tool (Service Tool) - 6689778 . . . . . . . . . . . 10-61-2

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

STOPPING THE ENGINE AND LEAVING THE LOADER . . 10-200-1

Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-2
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

Continued On Next Page

10-02 S205 Service Manual

 SAFETY AND MAINTENANCE (CONT’D)

TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

TRANSPORTING THE LOADER ON A TRAILER . . . . . . . . . 10-40-1

Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE

STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SPEC
SECTION) UNLESS OTHERWISE SPECIFIED.

10-03 S205 Service Manual

LIFTING AND BLOCKING THE LOADER Figure 10-10-2

WARNING
AVOID INJURY OR DEATH
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions P-45482
can cause injury or death.
W-2003-0807
Put the floor jack under the front of the loader.
Figure 10-10-1 Lift the front of the loader and put jackstands under the
axle tubes [Figure 10-10-2].

NOTE: Make sure the jackstands do not touch the

tires. Make sure tires clear floor or any
obstacles.

Figure 10-10-3

B-7023A

Procedure

Always park the loader on a level surface.

P-31849

WARNING Put the floor jack under the rear of the loader [Figure 10-
10-3].
Put jackstands under the front axles and rear corners
of the frame before running the engine for service. Lift the rear of the loader and install jackstands [Figure
Failure to use jackstands can allow the machine to 10-10-3].
fall or move and cause injury or death.
W-2017-0286

10-10-1 S205 Service Manual

LIFT ARM SUPPORT DEVICE The operator must be in the operator's seat, with the seat
belt fastened and seat bar lowered, until the lift arm
Installing support device is installed.

Start the engine, and raise the lift arms all the way up.
WARNING
Figure 10-20-2
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.

Service lift arm support device if damaged or if parts

are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death.
W-2572-0407

P-31857B

Have a second person install the lift arm support device

over the rod of one of the lift cylinders [Figure 10-20-2].

The lift arm support device must be tight against the

cylinder rod.
Remove attachment from the loader. (See BOB-TACH
(HAND LEVER) on Page 50-40-1.) OR (See BOB-TACH Figure 10-20-3
(POWER) on Page 50-41-1.)

Figure 10-20-1

P-10136

P-31856C

Lower the lift arms slowly until the lift arm support device
P-43747 P-31266
is held between the lift arms and the lift cylinder [Figure
10-20-3]. The tabs of the lift arm support device must go
Put jackstands under the rear corners of the loader frame past the end of the cylinder (Inset) [Figure 10-20-3].
(Inset) [Figure 10-20-1].

Remove the lift arm support device (Item 1) [Figure 10-

20-1] from storage position.

10-20-1 S205 Service Manual

LIFT ARM SUPPORT DEVICE (CONT’D)

Removing

The operator must be in the operator's seat, with the seat

belt fastened and seat bar lowered, until the lift arm
support device is removed and the lift arms are lowered
all the way.

Start the engine, raise the lift arms all the way up.

Have a second person remove the lift arm support

device.

Lower the lift arms all the way and stop the engine.

Return the lift arm support device to storage position and

secure with clamping knobs.

Remove the jackstands.

10-20-2 S205 Service Manual

OPERATOR CAB

Description

The Bobcat Loader has an operator cab (ROPS and

FOPS) as standard equipment to protect the operator
from rollover and falling objects. Check with your dealer if
the operator cab has been damaged. The seat belt must
be worn for roll over protection.

ROPS/FOPS - Roll Over Protective Structure per ISO

3471, and Falling Object Protective Structure per SAE
J1043 and ISO 3449, Level I. Level II is available.

Level I
Protection from falling bricks, small concrete blocks,
and hand tools encountered in operations such as
highway maintenance, landscaping, and other
construction sites.

Level II
Protection from falling trees, rocks: for machines
involved in site clearing, overhead demolition or
forestry.

WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from
rollover and falling objects, and result in injury or
death.
W-2069-0200

10-30-1 S205 Service Manual

OPERATOR CAB (CONT’D)

Raising

Always stop the engine before raising or lowering the

cab.

Stop the loader on a level surface. Lower the lift arms. If

the lift arms must be up while raising the operator cab,
install the lift arm support device. (See Installing on Page
10-20-1.)

Figure 10-30-1

NOTE: On Advanced Control System (ACS) equipped

machines, the steering levers could contact
the cab frame while raising or lowering the
operator cab. The engine MUST be stopped
before raising or lowering the cab.
Figure 10-30-3

P-43747

Install jackstands under the rear of the loader frame

[Figure 10-30-1].

Figure 10-30-2

P-31858A

Lift on the grab handle and bottom of the operator cab

[Figure 10-30-3] slowly until the cab is all the way up and
the latching mechanism engages .

P-31288 P-31289

Remove the nuts and plates [Figure 10-30-2] (both

sides) at the front corners of the cab.

10-30-2 S205 Service Manual

OPERATOR CAB (CONT’D) Support the cab and release the latching mechanism
(Inset) [Figure 10-30-3]. Remove your hand from
Lowering latching mechanism when the cab is past the latch stop.
Use both hands to lower the cab all the way.
Always stop the engine before raising or lowering the
cab.

NOTE: Always use the grab handles to lower the cab.

WARNING
Figure 10-30-4
PINCH POINT CAN CAUSE INJURY
Remove your hand from the latching mechanism
when the cab is past the latch stop.
W-2469-0803

Figure 10-30-5

N-20120 P-31859A

Pull down on the bottom of the operator cab until it stops

at the latching mechanism [Figure 10-30-4].

NOTE: The weight of the cab increases when

equipped with options and accessories such P-31288 P-31289
cab door, heater, air conditioning, etc. In
these cases, the cab may need to be raised
Install the plates and nuts (both sides) [Figure 10-30-5].
slightly from the latch to be able to release the
latch.
Tighten the nuts to 40-45 ft.-lb. (54-61 N•m) torque.

NOTE: On Advanced Control System (ACS) equipped

machines, the steering levers could contact
the cab frame while raising or lowering the
operator cab. The engine MUST be stopped
before raising or lowering the cab.

10-30-3 S205 Service Manual

OPERATOR CAB (CONT’D) Special Applications Kit

Cab Door Sensor Figure 10-30-8

This machine may be equipped with a Cab Door Sensor.

Figure 10-30-6

S3999A

B-25286A

1
2 Available for special applications to restrict material from
entering cab openings. Kit includes 1/2 inch Lexan® front
P-68116
door, top and rear windows [Figure 10-30-8].
P-68115
See your Bobcat dealer for availability.

Cab doors have a sensor (Item 1) [Figure 10-30-6] Special Applications Kit Inspection And Maintenance
installed which deactivates the lift and tilt valves when the
door is open. • Inspect for cracks or damage. Replace if required.

A decal is located on the latch mechanism (Item 2) • Pre-rinse with water to remove gritty materials.
[Figure 10-30-6]. • Wash with a mild household detergent and warm
water.
The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6]
• Use a sponge or soft cloth. Rinse well with water and
will be OFF when the door is closed, the key switch is
dry with a clean soft cloth or rubber squeegee.
turned to RUN or the RUN / ENTER button is pressed,
the seat bar is lowered and the PRESS TO OPERATE • Do not use abrasive or highly alkaline cleaners.
LOADER button is pressed. • Do not clean with metal blades or scrapers.
Figure 10-30-7

The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6]

will be ON when the door is open, the key switch is
turned to RUN or the RUN / ENTER button is pressed,
the seat bar is lowered and the PRESS TO OPERATE
LOADER button is pressed.

[DOOR] will appear in the data display [Figure 10-30-7].

10-30-4 S205 Service Manual

TRANSPORTING THE LOADER ON A TRAILER Fastening

Loading And Unloading Figure 10-40-2

WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury. P-31228 P-64082
W-2058-0807

Be sure the transport and towing vehicles are of

adequate size and capacity for weight of loader. (See
Performance on Page SPEC-10-2.)

Figure 10-40-1

P-54214A

Use the following procedure to fasten the Bobcat Loader

to the transport vehicle to prevent the loader from moving
during sudden stops or when going up or down slopes
[Figure 10-40-2].
1
P-54213A
• Lower the bucket or attachment to the floor.
• Stop the engine.
A loader with an empty bucket or no attachment must be
• Engage the parking brake.
loaded backward onto the transport vehicle [Figure 10-
40-1]. • Install chains at the front and rear loader tie down
positions [Figure 10-40-2].
The rear of the trailer must be blocked or supported (Item • Fasten each end of the chain to the transport vehicle.
1) [Figure 10-40-1] when loading or unloading the loader
to prevent the front end of the trailer from raising up.

10-40-1 S205 Service Manual

TOWING THE LOADER

Procedure

Because of the design of the loader, there is not a

recommended towing procedure.

• The loader can be lifted onto a transport vehicle.

• The loader can be skidded a short distance to move

for service (EXAMPLE: Move onto a transport
vehicle.) without damage to the hydrostatic system.
(The tires will not turn.) There might be slight wear to
the tires when the loader is skidded.

The towing chain (or cable) must be rated at one and

one-half times the weight of the loader. (See
Performance on Page SPEC-10-2.)

10-50-1 S205 Service Manual

REMOTE START TOOL KIT-MEL1563 Figure 10-60-2

Remote Start Tool - MEL1563

Tools that will be needed to complete the following steps

are:
2
MEL1563 - Remote Start Tool 3
MEL1565 - Service Tool Harness Control 1
MEL1566 - Service Tool Harness Communicator
(Computer Interface)

Figure 10-60-1

P16117
1

The traction lock switch (Item 1) [Figure 10-60-2] is used

to turn traction lock ON or OFF. Push the switch to the
override postion. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
able to turn.

The maximum flow/variable flow switch (Item 2) [Figure

10-60-2] is used to activate the auxiliary hydraulics.
Pressing the switch once will activate maximum flow.
P16114 Pressing the switch again will activate variable flow. The
switch will illuminate to indicate which flow rate is active.
Pressing the switch a third time will turn the flow OFF.
The remote start tool (Item 1) [Figure 10-60-1] is The switch is used when checking pressures and flow
required when the service technician is checking the rate.
hydraulic/hydrostatic system or adjusting the steering
linkage. The auxiliary pressure release (Item 3) [Figure 10-60-2]
is used to release hydraulic pressure to the front and/or
rear auxiliary couplers. To release pressure; push and
hold the switch for a few seconds.

NOTE: With the engine running; pushing and holding

the pressure release switch will cause the
engine to stop. To relieve the pressure; press
the switch until the engine stops.

10-60-1 S205 Service Manual

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REMOTE START TOOL-MEL1563 (CONT'D) Service Tool Harness Control - MEL1565

Remote Start Tool - MEL1563 (Cont’d) Figure 10-60-5

Figure 10-60-3
2

1 1

P16114

P16116
The service tool harness control (Item 1) [Figure 10-60-
5] is used to connect the remote start tool (Item 2)
Figure 10-60-4 [Figure 10-60-5] to the electrical system on the loader.

1 Figure 10-60-6

P16120

N-19561
The 10-pin rectangular connector (Item 1) [Figure 10-60-
3] is used to update software in the Deluxe
Instrumentation Panel (Item 1) [Figure 10-60-4]. Remove the plug (Item 1) [Figure 10-60-6] from the
loader harness connector.
NOTE: The Service PC must be connected to the
remote start tool to update the deluxe panel Connect the service tool harness control to the loader
software. harness connector.

The panel must be removed from inside the operator cab

and plugged into this connector [Figure 10-60-3].

10-60-2 S205 Service Manual

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