Bobcat S205 Skid-Steer Loader Preventive Maintenance

Inspecting The BICS Controller (Engine STOPPED - Key ON)

• Sit in operator’s seat

• Turn key ON (Key Switch Panel)

• Press RUN / ENTER Button (Keyless Panel)

• Lower seat bar and disengage parking brake

• Press the PRESS TO OPERATE LOADER Button

• Three BICS lights (1, 2 and 3) [PRESS TO OPERATE LOADER, SEAT BAR, AND LIFT & TILT VALVE] on left instrument panel should be ON

Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)

• Sit in operator’s seat

• Lower seat bar

• Press the PRESS TO OPERATE LOADER Button

• Press the auxiliary hydraulics FLOW Button

• The auxiliary FLOW Button light will come ON. Raise the seat bar

• The light should be OFF

Inspecting The Seat Bar Sensor (Engine RUNNING)

• Sit in operator’s seat,

• Lower seat bar

• Engage parking brake

• Fasten seat belt

• Start engine and operate at low idle

• Press the PRESS TO OPERATE LOADER Button

• While raising the lift arms, raise the seat bar fully

• The lift arms should stop

• Repeat using the tilt function

Inspecting The Traction Lock (Engine RUNNING)

• Fasten seat belt

• Disengage parking brake

• Press the PRESS TO OPERATE LOADER Button and raise seat bar fully

• Move steering levers slowly forward and backward. The TRACTION lock should be engaged

• Lower the seat bar

• Press the PRESS TO OPERATE LOADER Button

• Engage parking brake and move steering levers slowly forward and backward. The TRACTION lock should be engaged

• The TRACTION light on the left instrument panel will remain OFF until the engine is started, the PRESS TO OPERATE LOADER Button is pressed and the parking brake is disengaged

Inspecting The Lift Arm By-Pass Control

• Raise the lift arms 2 meters off the ground.

• Stop engine

• Turn lift arm by-pass control knob clockwise 1/4 turn

• Pull up and hold lift arm by-pass control knob until lift arms slowly lower

Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)

• Sit in operator’s seat and fasten seat belt.

• Lower seat bar, start engine and press the PRESS TO OPERATE LOADER Button.

• Raise lift arms about 2 meters off the ground

• Turn key to OFF (Key Switch Panel), press STOP Button (Keyless Panel), and wait for the engine to come to a complete stop

• Turn key to ON (Key Switch Panel)

• Press RUN / ENTER Button (Keyless Panel)

• Press the PRESS TO OPERATE LOADER Button, move hand control or joystick to lower the lift arms. Lift arms should not lower

• Move the control (foot pedal, hand control or joystick) to tilt the bucket (or attachment) forward. The bucket (or attachment) should not tilt forward

Inspecting The Seat Bar Restraint System

• Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine. Press the PRESS TO OPERATE LOADER Button

• Operate the hydraulic controls to check that both the lift and tilt functions operate correctly

• Raise the lift arms until the attachment is about 600 mm off the ground

• Raise the seat bar. Move the hydraulic controls. Pedals and handles (if equipped) must be firmly locked in the NEUTRAL position (except joysticks). There must be no motion of the lift arms or tilt (attachment) when the controls are moved

• Lower the seat bar, press the PRESS TO OPERATE LOADER Button, lower the lift arms. Operate the lift control. While the lift arms are going up, raise the seat bar. The lift arms must stop

• Lower the seat bar, press the PRESS TO OPERATE LOADER Button, lower the lift arms and put the attachment flat on the ground. Stop the engine. Raise the seat bar. Operate the foot pedals and handles (if equipped) to be sure they are firmly locked in the NEUTRAL position (except joysticks)

• Use compressed air to clean any debris or dirt from the pivot parts. Do not lubricate

• Inspect all mounting hardware. The correct bolt torque is 35Nm

• If the seat bar system does not function correctly, replace parts that are worn or damaged. Use only genuine Bobcat replacement parts

Seat Belt Inspection & Maintenance

• Check the webbing. If the system is equipped with a retractor, pull the webbing completely our and inspect the full length of the webbing. Look for cuts, wear, fraying, dirt and stiffness.

• Check the buckle and latch for correct operation. Make sure latch plate is not excessively worn, deformed or buckle is not damaged or casing broken.

• Check the retractor web storage device (if equipped) by extending webbing to determine if it looks correct and that it spools out and retracts webbing correctly.

• Check webbing in areas exposed to ultraviolet (UV) rays from the sun or extreme dust or dirt. If the original color of the webbing in these areas is extremely faded and / or the webbing is packed with dirt, the webbing strength may have deteriorated.

Heating & Air Conditioning Cleaning and Maintenance

• The Fresh Air Filter is located below the rear window of the cab. Remove the bolts and remove the filter housing.

• Shake the filter or use low air pressure to remove dirt. Replace after cleaning three times or if filter becomes too dirty to clean.

• Reinstall the filter, housing and bolts.

• The Recirculation Filter is located in front of the rear window inside the cab. Remove the clamping knobs, grill and filter.

• Clean the filter with water and mild detergent. Reinstall the filter. Replace after cleaning three times, or if filter becomes too dirty to clean.

• Raise the cab and remove the evaporator cover.

• Use low pressure water or air to remove debris from the evaporator fins.

• Install the cover.

• Run the air conditioner for about 5 minutes every week to lubricate the internal components.

Air Cleaner Service Maintenance

• Remove the wing nut and remove the dust cover

• Remove the wing nut and remove the outer filter element

• Make sure all sealing surfaces are free of dirt and debris. Do not use air pressure to clean

• Install a new outer element

• Install the dust cover and the wing nut (Be sure the evacuator is down)

• Check the air intake hose and the air cleaner housing for damage. Make sure all connections are tight.

Removing Air From The Fuel System

• Open the vent on the fuel filter housing

• Squeeze the hand pump (priming bulb) until fuel flows from the vent with no air bubbles.

• Close the vent on the fuel filter housing.

• Open the vent on the fuel injection pump

• Squeeze the hand pump (priming bulb) until the pump feels solid

• Tighten the vent plug

• Start the engine

Checking And Adding Engine Oil

• Check the engine oil level every day before starting the engine for the work shift

• Park the machine on level ground. Open the rear door and remove the dipstick

• Keep the oil level between the marks on the dipstick. Do not overfill

• Install the dipstick and close the rear door

Install the dipstick and close the rear door

• Run the engine until it is at operating temperature

• Stop the engine

• Open the rear door

• Remove the drain hose from the storage position

• Remove the drain plug

• Drain the oil into a container and dispose of used oil in an environmentally safe manner

• Remove the oil filter

• Clean the filter housing surface

• Put clean oil on the new oil filter gasket

• Install the filter and hand tighten

• Install and tighten the drain plug

• Remove the fill cap

• Put oil in the engine. Do not overfill

• Start the engine and let it run for several minutes

• Stop the engine and check for leaks at the oil filter

• Remove the dipstick and check the oil level

• Add oil as needed if it is not at the top mark on the dipstick

• Install the dipstick and close the rear door

Engine Cooling System Cleaning Procedure

• Open the rear door and raise the rear grill

• Use low air pressure or water pressure to clean the top of the oil cooler

• Raise the oil cooler and use low air pressure or water pressure to clean the top of the radiator

• Lower the oil cooler

• Check cooling system for leaks

• Lower the rear grill and close the rear door

Checking the Engine Cooling System Level

• Open the rear door and raise the rear grill

• Remove the coolant fill cap

• Check the coolant level. The level markers are inside the tank

• Coolant must be at the bottom marker when the engine is cold; top marker when hot

• Close the rear door before operating the loader

Removing And Replacing the Coolant

• Open the rear door and remove the rear grill

• Remove the coolant fill cap

• Connect a hose to the engine block drain valve

• Open the drain valve and drain the coolant into a container

• After all the coolant is removed, close the drain valve and remove the hose

• Recycle or dispose of coolant in an environmentally safe manner

• Mix the coolant in a separate container

• Add premixed coolant, 47% water and 53% propylene glycol to the recovery tank. 4,3 L of propylene glycol mixed with 3,8 L of water is the correct mixture of coolant to provide a -37°C (-34°F) freeze protection

• Remove the coolant fill cap. Fill the tank until it is at the lower marker on the tank.

• Use a refractometer to check the condition of propylene glycol in your cooling system

• Run the engine until it is at operating temperature.

• Stop the engine.

• Check the coolant level when cool. Add coolant as needed

• Install the rear grill and close the rear door

Battery Maintenance

• The battery cables must be clean and tight

• Check the electrolyte level in the battery

• Add distilled water as needed

• Remove acid or corrosion from the battery and cables with a sodium bicarbonate and water solution

• Put Battery Saver (6664458) or grease on the battery terminals and cable ends to prevent corrosion

Checking And Adding Fluid

• Stop the loader on a level surface

• Lower the lift arms and tilt the Bob-Tach fully back

• Stop the engine

• Check the fluid level in the sight gauge

• Open the rear door and raise the rear grill

• Remove the fill cap

• Add the fluid as needed to bring the level to the center of the sight gauge

• Install the fill cap

Removing And Replacing Hydraulic / Hydrostatic Filter

• Open the rear door

• Remove the filter element

• Clean the surface of the filter housing where the seal contacts the housing

• Put clean oil on the seal of the new filter element

• Install and hand tighten the filter element

• Close the rear door before operating the loader

• The fluid must be replaced if it becomes contaminated or after major repairs. If the fluid is replaced, the hydrostatic filter and both case drain filters must be replaced

• Raise the cab

• Open the rear door, remove the rear grill and remove the reservoir fill cap

• Remove the plug and use a pump to remove the oil from the reservoir. Install the plug again.

• Remove the motor access covers (Inset) from both sides of the loader.

• Disconnect the fittings and remove the case drain filter. Use a plug and cap to prevent leakage

• Replace the hydraulic / hydrostatic filter element

• Replace both hydrostatic motor case drain filters

• Add the correct fluid to the reservoir until the fluid level is at the center of the sight gauge (Do not overfill)

• Install the rear grill and close the rear door

• Lower the cab

• Start the engine and operate the loader hydraulic controls.

• Stop the engine and check for leaks

• Check the fluid level in the reservoir and add as needed

Removing And Replacing Charge Filter

• The charge filter is located under the cab

• Raise the cab

• Remove the filter

• Clean the surface of the filter housing where the filter seal contacts the housing

• Put clean oil on the seal of the new filter. Install and hand tighten the new filter

• Start the engine and operate the loader hydraulic controls

• Stop the engine and check for leaks at the filter

• Check the fluid level in the reservoir and add as needed

• Lower the cab

Breather Cap

• Raise the cab

• Remove the breather cap

• Install new cap

• Lower the cab

Spark Arrestor Muffler Cleaning Procedure

• Stop the engine. Open the rear door and raise the rear grill

• Remove the plug from the bottom of the muffler

• Start the engine and run for about 10 seconds while a second person, wearing safety glasses, holds a piece of wood over the outlet of the muffler

• This will force contaminants out through the cleanout hole.

• Stop the engine

• Install and tighten the plug

• Lower the rear grill and close the rear door

Tires wear, damage and pressure

• Pass
• Flag
• Fail

All tires should be the same size

• Pass
• Flag
• Fail

Tread bars facing the same direction

• Pass
• Flag
• Fail

Correct Tire Pressure

• Pass
• Flag
• Fail

Tire and rims correct size

• Pass
• Flag
• Fail

Rim and tire bead signs of damage

• Pass
• Flag
• Fail

Tire bead and rim flange lubricated properly before mounting

• Pass
• Flag
• Fail

Checking And Adding Oil

• Stop the loader on a level surface

• Stop the engine

• Remove the plug from the front of the chaincase housing.

• If oil can be reached with the tip of the your finger through the hole, the oil level is correct

• If the level is low, add oil through the check plug hole until the oil flows from the hole

• Install and tighten the plug

Removing Oil From The Chaincase

• Remove the check plug from the front of the chaincase housing.

• Remove the oil from the chaincase

• Recycle or dispose of the used oil in an environmentally safe manner

Belt Adjustment

• Stop the engine

• Raise the operator cab

• Loosen the alternator mounting bolt

• Loosen the adjustment bolt

• Move the alternator until the belt has 8,0 mm movement at the middle of the belt span with 66 N of force.

• Tighten the adjustment bolt and mounting bolt

• Lower the operator cab

Belt Replacement

• Loosen the alternator mounting and adjustment bolts

• Remove the belt and install a new belt

• Adjust the belt

Drive belt signs of wear

• Pass
• Flag
• Fail

Belt Adjustment

• Open the rear door

• Remove the drive belt cover

• Remove the compressor belt cover

• Loosen the mounting bolt and the adjustment bolt

• Move the compressor to the rear until the belt has 8,0 mm movement at the middle of the belt span with 66 N force

• Tighten the adjustment bolt and the mounting bolt

• Install the covers and close the rear door

Belt Replacement

• Open the rear door. Remove the drive belt cover and the compressor belt cover

• Loosen the mounting bolt and the adjustment bolt and move the compressor all the way forward

• Remove the belt and install a new belt

• Adjust the belt

Belt Adjustment

• Stop the engine

• Open the rear door and disconnect the negative (-) cable from the battery

• Remove three belt shield fasteners and remove the belt shield

• Loosen the bolt on the spring loaded drive idler

• Push the idler pulley against the belt, using a pry bar. The pointer will be at the 3 o'clock position when the idler pulley is against the stop (maximum movement).

• Raise the idler assembly slightly so that the pulley is operating on spring tension and not against the stop.

• Do not set the idler against the travel stop in the 3 o'clock position

• Tighten the mounting bolt to 34-38 Nm torque

• Run the engine for a few minutes. Stop the engine and recheck the pointer position

• Readjust if necessary

• After the idler has been in service, readjust when the pointer reaches the 1 o'clock position

• Install the belt shield and fasteners

• Connect the negative (-) battery cable

• Close the rear door

Belt Replacement

• Follow the steps above to loosen the drive belt tensioner

• Remove the bolt from the tensioner and remove the tensioner assembly

• Remove the fan drive belt

• Remove the drive belt from the pump pulley and flywheel and remove the belt from the loader

• Install the new drive belt

• Install the belt tensioner assembly

• Install the fan drive belt

• Adjust the drive belt, reinstall previously removed components and continue procedure from Belt Adjustment above

Lubrication Locations

• Record the operating hours each time you lubricate the Bobcat Loader

• Always use a good quality lithium based multi-purpose grease when you lubricate the loader. Apply lubricant until extra grease shows

Lubricate the following locations on the loader

• 1. Stabilizer Rod - Front (Both Sides)

• 2. Stabilizer Rod - Rear (Both Sides)

• 3. Lift Cylinder Rod End (Both Sides)

• 4. Lift Cylinder Base End (Both Sides)

• 5. Tilt Cylinder Base End (Both Sides)

• 6. Tilt Cylinder Rod End (Both Sides)

• 7. Bob-Tach Pivot Pin (Both Sides)

• 8. Bob-Tach Wedge (Both Sides)

• 9. Power Bob-Tach Cylinder (Both Sides)

• 10. Lift Arm Pivot Pin (Both Sides)

• 11. Lift Arm Link Pivot Pin (Both Sides)

• 12. 250 Hours: Steering Lever Shaft (2)

Lock nuts are tightened to 34-38 Nm torque

• Pass
• Flag
• Fail

Inspection And Maintenance

• Move the Bob-Tach levers down to engage the wedges

Levers move freely

• Pass
• Flag
• Fail

Wedges move freely

• Pass
• Flag
• Fail

Bob-Tach wedges must extend through the holes in attachment

• Pass
• Flag
• Fail

Levers must be fully down and locked. Failure to secure wedges can allow attachment to come off and cause injury or death

• Pass
• Flag
• Fail

The wedges must extend through the holes in the attachment mounting frame

• Pass
• Flag
• Fail

The spring loaded wedge must contact the lower edge of the hole in the attachment

• Pass
• Flag
• Fail

All fasteners tight

• Pass
• Flag
• Fail

Linkages OK

• Pass
• Flag
• Fail

Wedges OK

• Pass
• Flag
• Fail

Mounting frame OK

• Pass
• Flag
• Fail

Bob-tach OK

• Pass
• Flag
• Fail

Welds OK

• Pass
• Flag
• Fail

Wedges lubricated

• Pass
• Flag
• Fail