EN Operation & Maintenance Manual S/N 530611001 & Above EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICS) 6904136-EN (09-06) Printed in Europe © Bobcat Europe 2006
OPERATOR SAFETY WARNINGS CORRECT WARNING Operator must have instructions before running the machine. Untrained operators can cause injury or death. W-2001-1285 Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows. CORRECT WRONG B-16245 Always use the seat bar and fasten seat belt snugly. Always keep feet on the foot pedals or foot rest when operating loader.
FOREWORD CONTENTS FOREWORD ..............................................................................................III SAFETY .................................................................................................... XI Safety & SAFETY OPERATING INSTRUCTIONS....................................................................1 PREVENTIVE MAINTENANCE ................................................................59 SYSTEM SETUP & ANALYSIS ...................................................
S205 Skid-Steer Loader Operation & Maintenance Manual II
FOREWORD FOREWORD This Operation & Maintenance Manual was written to give the owner / operator instructions on the safe operation and maintenance of the Bobcat Loader. READ AND UNDERSTAND THIS OPERATION & MAINTENANCE MANUAL BEFORE OPERATING YOUR MACHINE. If you have any questions, see your Bobcat dealer. BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED................................. V DELIVERY REPORT .................................................................................
S205 Skid-Steer Loader Operation & Maintenance Manual IV
BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED ISO 9001:2000 is an international standard that controls the processes and procedures which we use to design, develop, manufacture and distribute Bobcat products. British Standards Institute (BSI) is the Certified Registrar Bobcat Company chose to assess the Company’s compliance with the ISO 9001:2000 standard.
SERIAL NUMBER LOCATIONS Engine Serial Number Always use the serial number of the loader when 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. Figure 2 Figure 1 P-48387 The engine serial number is located on the side of the engine [Figure 2] above the oil filter.
LOADER IDENTIFICATION FRONT LIGHTS OPERATOR SEAT WITH SEAT BELT SEAT BAR GRAB HANDLES REAR AUXILIARY QUICK COUPLERS STEERING LEVER STABILIZER ROD TILT CYLINDERS † BUCKET FRONT AUXILIARY QUICK COUPLERS SAFETY TREAD BUCKET STEPS z OPERATOR CAB (ROPS & FOPS) REAR WINDOW LIFT ARM LINK LIFT ARM REAR GRILL LIFT CYLINDER TAIL LIGHT LIFT ARM SUPPORT DEVICE REAR LIGHT REAR DOOR * TIRES B-16604C B-16605B ◆ Optional or Field Accessory (Not Standard Equipment) * TIRES - Tires shown may not be standard.
FEATURES, ACCESSORIES AND ATTACHMENTS Standard Items Options and Accessories Model S205 Bobcat Loaders are equipped with the following standard items: Below is a list of some equipment available from your Bobcat Loader dealer as Dealer and / or Factory Installed Accessories and Factory Installed Options. See your Bobcat dealer for other available options, accessories and attachments.
Buckets Available FEATURES, ACCESSORIES AND ATTACHMENTS (CONT’D) These and other attachments are approved for use on this model loader. Do not use unapproved attachments. Attachments not manufactured by Bobcat may not be approved. The versatile Bobcat Loader quickly turns into a multi-job machine with a tight-fit attachment hook-up . . . from bucket to grapple to pallet fork to backhoe and a variety of other attachments.
Special Applications Kit Inspection And Maintenance FEATURES, ACCESSORIES AND ATTACHMENTS (CONT’D) • • • Special Applications Kit • • • B-25286A Available for special applications to restrict material from entering cab openings. Kit includes 12 mm Lexan™ front door, top and rear windows. See your Bobcat dealer for availability. S205 Skid-Steer Loader Operation & Maintenance Manual X Inspect for cracks or damage. Replace if required. Pre-rinse with water to remove gritty materials.
SAFETY MACHINE SIGNS (DECALS) ..................................................................XVI SAFETY INSTRUCTIONS....................................................................... XIII Before Operation................................................................................ XIII Fire Prevention....................................................................................XV Safe Operation Is The Operator’s Responsibility ...............................
S205 Skid-Steer Loader Operation & Maintenance Manual XII
• SAFETY INSTRUCTIONS Before Operation Carefully follow the operating instructions in this manual. and maintenance The Bobcat Loader is highly maneuverable and compact. It is rugged and useful under a wide variety of conditions. This presents an operator with hazards associated with off highway, rough terrain applications, common with Bobcat Loader usage. An Operator’s Handbook is fastened to the operator cab of the Loader. It’s brief instructions are convenient to the operator.
SAFETY INSTRUCTIONS (CONT’D) A Qualified Operator Must Do The Following: Safe Operation Is The Operator’s Responsibility Understand the Written Instructions, Rules and Regulations Safety Alert Symbol This symbol with a warning statement means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows. • The written instructions from Bobcat Company include the Delivery Report, Operation & Maintenance Manual, Operator’s Handbook and machine signs (decals).
• SAFETY INSTRUCTIONS (CONT’D) Fire Prevention The machines and some attachments have components that are at high temperatures under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks. Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler (if equipped). Figure 4 Flammable debris (leaves, straw, etc.
MACHINE SIGNS (DECALS) Follow the instructions on all the Machine Signs (Decals) that are on the loader. Replace any damaged machine signs and be sure they are in the correct locations. Machine signs are available from your Bobcat Loader dealer. SJC - 7131519 Standard and ACS - 6727926 Shoulder Belt Opt. - 6735370 6902600 Door Opt. - 6707852 SJC - 7131518 ACS Only 6718706 6735140 6734179 Inside Cab Door Opt.
MACHINE SIGNS (DECALS) (CONT’D) Follow the instructions on all the Machine Signs (Decals) that are on the loader. Replace any damaged machine signs and be sure they are in the correct locations. Machine signs are available from your Bobcat Loader dealer. 6708929 6733996 Under Rear Grill 6565990 6577754 (2) 6578368 6560573 6719018 6809511 (2) (On Hose & Tubeline) 6717343 (2) Under Cab 6727595 (2) Ref.
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OPERATING INSTRUCTIONS ATTACHMENTS ........................................................................................38 Choosing The Correct Bucket ..............................................................38 Installing And Removing The Attachment (Hand Lever Bob-Tach)......39 Installing And Removing The Attachment (Power Bob-Tach Option)...41 Pallet Forks ..........................................................................................38 BOBCAT INTERLOCK CONTROL SYSTEM (BICS) ...........
OPERATING INSTRUCTIONS (CONT’D) LIFTING THE LOADER ............................................................................ 56 Four Point Lift ...................................................................................... 56 Single Point Lift.................................................................................... 56 MONITORING THE DISPLAY PANELS .................................................... 34 Left Panel..........................................................................
OPERATING INSTRUCTIONS (CONT’D) TOWING THE LOADER ............................................................................55 Procedure ............................................................................................55 TRACTION LOCK OVERRIDE..................................................................12 Operation .............................................................................................12 TRANSPORTING THE LOADER ON A TRAILER ....................................
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The left instrument panel is the same for both the Key Switch and Keyless Instrument Panels [Figure 5]. INSTRUMENT PANEL IDENTIFICATION Left Panel The table below shows the DESCRIPTION and FUNCTION / OPERATION for each of the components of the left panel. Figure 5 2 1 3 4 6 5 13 9 7 10 8 11 12 14 B-15551 REF. NO DESCRIPTION FUNCTION / OPERATION 1 TEMPERATURE GAUGE Shows the engine coolant temperature.
The right instrument panel shown [Figure 6] is the Key Switch Panel. INSTRUMENT PANEL IDENTIFICATION (CONT’D) Right Panel (Key Switch) The table below shows the Icons and other components of the Right Key Switch Panel. Figure 6 15 17 19 21 23 25 27 16 18 20 22 24 26 28 29 B-15552B REF. FUNCTION ICON / LIGHT Advanced ON Control System 15 (ACS) (Opt.
Figure 8 INSTRUMENT PANEL IDENTIFICATION (CONT’D) Right Panel (Keyless) Figure 7 3 1 2 B-16165 4 6 5 The first screen you will see on your new loader will be as shown in [Figure 8]. B-15553B When this screen is on the display you can enter the password and start the engine or change the Display Panel setup features. The right instrument panel shown [Figure 7] is the Keyless Panel. 2. Function Icons: The lower left area of the Keyless Panel has the same Icons as the Key Switch Panel.
INSTRUMENT PANEL IDENTIFICATION (CONT’D) Cab Light Right Panel (Keyless) (Cont’d) Figure 10 Figure 9 1 N-22015 B-16655 Push the button (1) [Figure 10] to turn the light ON. Push the button again to turn OFF. Use the Keypad to select the number of the language [Figure 9]. Press EXIT. The screen will return to [Figure 8]. You can then enter the password and start the engine. (See DISPLAY CONTROLLER PANEL SETUP on Page 111) for further description of screens to setup the system for your use.
Side Accessory Panel [Figure 11] INSTRUMENT PANEL IDENTIFICATION (CONT’D) REF. NO. Option And Field Accessory Panels Figure 11 SIDE ACCESSORY PANEL 1 2 3 4 5 6 7 8 DESCRIPTION 1 POWER PLUG 2 NOT USED --- 3 FRONT WIPER Press the top of the switch to start the front wiper (press and hold for washer fluid). Press the bottom of the switch to stop the wiper. 4 REAR WIPER Press the bottom of the switch to start the rear wiper.
SEAT BAR RESTRAINT SYSTEM WARNING Operation Figure 13 Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground. • Stop the engine. • Engage the parking brake. • Raise seat bar. • (Foot Pedal Controls) Move pedals until both lock. • (Advanced Control system - ACS) Move the hydraulic controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated.
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) Figure 15 Operation 1 WARNING 2 3 4 B-15551G AVOID INJURY OR DEATH The Bobcat Interlock Control System (BICS) must deactivate the lift, tilt and traction drive functions. If it does not, contact your dealer for service. DO NOT modify the system. W-2151-0394 N-18409 Figure 14 There are display lights (1, 2, 3 and 4) [Figure 15] located on the left instrument panel that must be ON to operate the machine.
LIFT ARM BY-PASS CONTROL TRACTION LOCK OVERRIDE Figure 16 Operation Figure 17 1 2 P-54406 1 The lift arm by-pass control (1) [Figure 16] is used to lower the lift arms if the lift arms cannot be lowered during normal operations. • Sit in the operator's seat. • Fasten the seat belt and lower the seat bar. • Turn the knob (1) [Figure 16] clockwise 1/4 turn. • Pull up and hold the knob until the lift arms slowly lower.
ENGINE SPEED CONTROL PARKING BRAKE Operation Figure 19 Figure 18 1 1 2 B-15993C P-31864 Press the top of the switch (1) [Figure 19] to engage the parking brake. The traction drive system will be locked. The speed control lever is at the right side of the operator's seat (1) [Figure 18]. Press the bottom of the switch (2) [Figure 19] to disengage the parking brake. The traction drive system will be unlocked. Move the lever forward to increase engine speed. Move backward to decrease engine speed.
DRIVING AND STEERING THE LOADER Figure 21 Standard and ACS Available Controls Configurations The loader has three configurations available: • Standard Controls - Two Steering Levers control drive and steering functions. • Advanced Control System (ACS) (Option or Field Accessory) - Two Steering Levers control drive and steering functions. • Selectable Joystick Controls (SJC) (Option) (‘ISO’ Pattern) Left joystick controls the drive and steering functions.
Figure 24 DRIVING AND STEERING THE LOADER (CONT’D) Operation (SJC) in ‘H’ Control Pattern Left Joystick Right Joystick N N FORWARD N N BACKWARD N N LEFT TURN N RIGHT TURN SJC in ‘H’ Control Pattern 1 Figure 22 2 3 1 B-15993H Select the ‘H’ control pattern by pressing the bottom of the switch (1) [Figure 22]. 4 N WARNING 5 N AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly. • The seat bar must be lowered.
DRIVING AND STEERING THE LOADER (CONT’D) Figure 27 SJC in ‘ISO’ Control Pattern LEFT JOYSTICK Operation (SJC) in ‘ISO’ Control Pattern Figure 25 N N FORWARD LEFT TURN FORWARD RIGHT TURN 1 N N B-15993H BACKWARD LEFT TURN Select the ‘ISO’ control pattern by pressing the top of the switch (1) [Figure 25]. BACKWARD RIGHT TURN N N WARNING LEFT FAST TURN AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly. • The seat bar must be lowered.
SPEED MANAGEMENT (SJC OPTION) The system will retain the speed percentage as long as the key remains ON (Key Switch Panel) or the STOP button has not been pressed (Keyless Panel). Operation Speed Management allows the loader to be maneuvered at slow travel speed for installing attachments, loading or unloading, and work applications such as trenching, tilling and landscaping.
Figure 31 HYDRAULIC CONTROLS Description Two foot pedals (or optional hand controls) control the hydraulic cylinders for the lift and tilt functions. 2 Put your feet on the pedals (or footrests) and KEEP THEM THERE any time you operate the loader. 1 B-15518 Standard Controls (Also ACS In FOOT Pedal Mode) B-15973 Tilt Operation - (Right Pedal) Figure 30 Push the heel (1) [Figure 31] of the pedal to tilt the bucket backward. 2 Push the toe (2) [Figure 31] of the pedal to tilt the bucket forward.
Selectable Joystick Control (SJC) In ‘H’ Control Pattern HYDRAULIC CONTROLS (CONT’D) Advanced Control System (ACS) In HAND Control Mode Figure 34 Figure 32 Left Joystick Right Joystick 1 2 1 2 3 3 B-19873 B-19874 B-15541 B-15541 B-15781 Lift Arm Operation - (Left Hand Joystick) Lift Arm Operation - (Left Hand Lever) Move the joystick outward (1) [Figure 34] to raise the lift arms. Move the lever outward (1) [Figure 32] to raise the lift arms.
HYDRAULIC CONTROLS (CONT’D) Bucket Position Valve Operation (If Equipped) Selectable Joystick Control (SJC) In ‘ISO’ Control Pattern The function of the bucket position valve is to keep the bucket in the same approximate position it is in before you begin raising the lift arms. Figure 36 Figure 38 2 5 4 1 3 B-155541 2 Right Joystick B-15781 Lift Arm Operation - (Right Hand Joystick) 1 Move the joystick backward (1) [Figure 36] to raise the lift arms.
Auxiliary Hydraulics Operation (MAXIMUM FLOW ONLY) HYDRAULIC CONTROLS (CONT’D) Auxiliary Hydraulics Operation (VARIABLE FLOW) MAXIMUM FLOW ONLY allows for fast movement only. If you move the auxiliary switch (1 or 3) [Figure 40], the auxiliary functions move at fast speed; release the switch to stop auxiliary functions. Figure 39 3 Press the auxiliary hydraulics button (1) [Figure 39] two times. 2 The light (3) [Figure 39] will be ON.
Quick Couplers HYDRAULIC CONTROLS (CONT’D) FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW) WARNING After selecting VARIABLE or MAXIMUM FLOW, press the front switch (2) [Figure 40] to give the front quick couplers a constant flow of fluid with the female coupler being pressurized. (EXAMPLE: Operate a backhoe.) Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible.
HYDRAULIC CONTROLS (CONT’D) High-Flow Hydraulics Operation (If Equipped) Relieve Hydraulic Pressure (Loader and Attachment) Figure 44 WARNING AVOID BURNS Hydraulic fluid, tubes, fittings and quick couplers can get hot when running machine and attachments. Be careful when connecting and disconnecting quick couplers.
HYDRAULIC CONTROLS (CONT’D) Secondary Front Auxiliary Hydraulics (If Equipped) High-Flow Hydraulics Operation (If Equipped) (Cont’d) Figure 48 SECONDARY COUPLERS Figure 46 1 1 3 2 P-16537 P-13254 P16291A You can use additional switches (1, 2, and 3) [Figure 46] on the right and left control handles for functions which control some attachments. See the appropriate Attachment Maintenance Manual for control details.
DAILY INSPECTION Figure 50 6734534B-V 25 S205 Skid-Steer Loader Operation & Maintenance Manual
DAILY INSPECTION (CONT’D) WARNING Daily Inspection and Maintenance Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The Service Schedule [Figure 50] is a guide for correct maintenance of the Bobcat Loader. It is located inside the rear door of the loader.
PRE-STARTING PROCEDURE Seat Adjustment Entering The Loader Figure 52 Figure 51 1 2 1 2 1 N-20299 N-20299 P-31865 N-18529A Release the seat lever (1) [Figure 52] and adjust the seat position for comfortable operation of the loader controls. Use the bucket or attachment steps, grab handles and safety treads (on top of the loader lift arms and frame) to get on and off the loader [Figure 51]. Do not jump.
PRE-STARTING PROCEDURE (CONT’D) Seat Belt Adjustment IMPORTANT Figure 54 Check the seat belt and shoulder belt retractors for correct operation. Keep retractors clean and replace as necessary. I-2199-0200 P-16041 Seat Bar Figure 56 P-16038 Squeeze both seat belt adjusters to release and lengthen each half of the seat belt [Figure 54]. Fasten the seat belt. Pull the ends of the belt through the belt adjusters so that the seat belt is snug and the buckle is centered between your hips [Figure 54].
If the temperature is cold, the glow plugs will automatically cycle. The Icon light (1) [Figure 58] will be ON and the cycle time remaining will show in the hourmeter. STARTING THE ENGINE Key Switch When the Icon light goes OFF, turn the key switch to START [Figure 58]. Release the key when the engine starts. It will return to the RUN position. WARNING • • AVOID INJURY OR DEATH Engines can have hot parts and hot exhaust gas. Keep flammable material away.
NOTE: (SJC) The pending mode will flash which will indicate PRESS TO OPERATE LOADER is required. The light will flash when key is ON and continue to flash until the PRESS TO OPERATE LOADER button is pressed and thereafter it will light solid. If the mode (ISO / H) is changed while driving, the active mode will be solid and the pending mode will flash.
Figure 62 STARTING THE ENGINE (CONT’D) 3 Keyless WARNING 5 • • AVOID INJURY OR DEATH Engines can have hot parts and hot exhaust gas. Keep flammable material away. Do not use machines in atmosphere containing explosive gas. 1 6 W-2051-1086 2 4 B-15553B B-22153 Perform the PRE-STARTING PROCEDURE. (See PRESTARTING PROCEDURE on Page 27.) Use the numeric keypad (1) [Figure 62] to enter the password, then press the RUN / ENTER Button (2) [Figure 62].
NOTE: (SJC) The pending mode will flash which will indicate PRESS TO OPERATE LOADER is required. The light will flash when key is ON and continue to flash until the PRESS TO OPERATE LOADER button is pressed and thereafter it will light solid. If the mode (ISO / H) is changed while driving, the active mode will be solid and the pending mode will flash.
STARTING THE ENGINE (CONT’D) Warming The Hydraulic / Hydrostatic System IMPORTANT When the temperature is below -30°C (-20°F), hydrostatic oil must be warmed before starting. The hydrostatic system will not get enough oil at low temperatures and will be damaged. Park the machine in an area where the temperature will be above -18°C (0°F) if possible. I-2007-1285 Let the engine run for a minimum of 5 minutes to warm the engine and hydrostatic transmission fluid before operating the loader.
MONITORING THE DISPLAY PANELS Right Panel (Key Switch) Left Panel Figure 67 Figure 66 1 2 1 B-15553B B-15552B After the engine is running, frequently monitor the right instrument panel [Figure 67] for error conditions. B-15553B The associated icon will be ON if there is an error condition. Frequently monitor the temperature and fuel gauges and BICS lights (all must be ON to operate loader) [Figure 66].
MONITORING THE DISPLAY PANELS (CONT’D) Warning And Shutdown Right Panel (Keyless) When a WARNING condition exists, the associated Icon light will come ON and there will be 3 beeps from the alarm. Be aware that, if this condition is allowed to continue, there may be damage to the engine or loader hydraulic systems.
Figure 71 STOPPING THE ENGINE AND LEAVING THE LOADER Procedure Figure 69 1 2 B-15553B B-15552 Engage the parking brake. P-66659 Turn the key switch to the STOP position (1) [Figure 71] (Key Switch) or press the STOP Button (2) [Figure 71] (Keyless). P-66660 Stop the Bobcat Loader on level ground. Lift the seat bar and make sure the lift and tilt functions are deactivated. Lower the lift arms fully and put the attachment flat on the ground [Figure 69]. Unbuckle the seat belt.
Front Door (If Equipped) STOPPING THE ENGINE AND LEAVING THE LOADER (CONT’D) NOTE: When an Operator Cab Enclosure Kit is installed, the window of the front door can be used as an emergency exit [Figure 74]. Emergency Exit The front opening on the operator cab and rear window provide exits. Rear Window (If Equipped) NOTE: If the loader has a Special Application Door Kit installed, the window of the front door is NOT an emergency exit.
Use the correct size bucket for the type and density of material being handled. For safe handling of materials and avoiding machine damage, the attachment (or bucket) should handle a full load without going over the Rated Operating Capacity for the loader. Partial loads make steering more difficult. ATTACHMENTS Choosing The Correct Bucket WARNING Never use attachments or buckets which are not approved by Bobcat Company.
Stop the engine and exit the loader. ATTACHMENTS (CONT’D) Installing And Removing The Attachment (Hand Lever Bob-Tach) WARNING The Bob-Tach is used for fast changing of buckets and attachments. See the appropriate Attachment Operation & Maintenance Manual to install other attachments. Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground. • Stop the engine. • Engage the parking brake. • Raise seat bar. • (Foot Pedal Controls) Move pedals until both lock.
ATTACHMENTS (CONT’D) WARNING Installing And Removing The Attachment (Hand Lever Bob-Tach) (Cont’d) Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground. • Stop the engine. • Engage the parking brake. • Raise seat bar. • (Foot Pedal Controls) Move pedals until both lock. • (Advanced Control system - ACS) Move the hydraulic controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated.
Installing And Removing The Attachment (Power Bob-Tach Option) ATTACHMENTS (CONT’D) Installing And Removing The Attachment (Hand Lever Bob-Tach) (Cont’d) Installing The Bob-Tach is used for fast changing of buckets and attachments. See the appropriate Attachment Operation & Maintenance Manual to install other attachments. Removing (Cont’d) Enter the loader. Perform the PRE-STARTING PROCEDURE. (See PRESTARTING PROCEDURE on Page 27.) Perform the PRE-STARTING PROCEDURE on Page 27. Start the engine.
ATTACHMENTS (CONT’D) Installing And Removing The Attachment (Power Bob-Tach Option) (Cont’d) WARNING Installing (Cont’d) Bob-Tach wedges must extend through the holes in attachment. Levers must be fully down and locked. Failure to secure wedges can allow attachment to come off and cause injury or death. Figure 85 W-2102-0588 NOTE: The Power Bob-Tach system has continuous pressurized hydraulic oil to keep the wedges in the engaged position and prevent attachment disengagement.
Figure 88 ATTACHMENTS (CONT’D) Installing And Removing The Attachment (Power Bob-Tach Option) (Cont’d) Removing Lower the lift arms and put the attachment flat on the ground and lower or close the hydraulic equipment. • If the attachment is hydraulically (combination bucket, backhoe, etc.): controlled Stop the engine and relieve hydraulic pressure in the auxiliary circuit. (See Relieve Hydraulic Pressure (Loader and Attachment) on Page 23.
OPERATING PROCEDURE Inspect The Work Area WARNING Before beginning operation, inspect the work area for unsafe conditions. AVOID INJURY OR DEATH • Keep the lift arms as low as possible. • Do not travel or turn with the lift arms up. • Turn on level ground. • Go up and down slopes, not across them. • Keep the heavy end of the machine uphill. • Do not overload the machine. Failure to obey warnings can cause the machine to tip or roll over and cause injury or death.
OPERATING PROCEDURE (CONT’D) Operating With An Empty Bucket Figure 91 WITH BUCKET EMPTY Going Down Slope B-15540 Figure 92 WITH BUCKET EMPTY Going Up Slope B-15517 With empty bucket, go down or up the slope with the heavy end toward the top of the slope [Figure 91] and [Figure 92].
OPERATING PROCEDURE (CONT’D) Emptying Filling And Emptying The Bucket (Foot Pedals) Figure 95 Filling Figure 93 2 1 1 2 B-15973 B-15534 Keep the bucket low when moving to the area where you want to empty the bucket. B-15973 B-15520 Raise the lift arms (1) [Figure 95]. Level the bucket (2) [Figure 95] while raising the lift arms to help prevent material from falling off the back of the bucket. Figure 94 Drive forward slowly until the bucket is over the top of the truck box or bin.
OPERATING PROCEDURE (CONT’D) Leveling The Ground Using Float (Foot Pedals) IMPORTANT Figure 96 Never drive forward when the hydraulic control for lift arms is in float position. I-2005-1285 1 2 3 B-15522 B-15973 Put the lift arms in float position by pushing the pedal all the way forward (1) [Figure 96] until the pedal is locked in the forward position. Tilt the bucket forward (2) [Figure 96] to change the position of the cutting edge of the bucket.
OPERATING PROCEDURE (CONT’D) Filling Digging And Filling A Hole (Foot Pedals) Figure 99 Digging Figure 97 1 1 2 3 B-15539 B-15537 B-15973 Tilt the bucket forward (2) [Figure 99] as soon as it is past the edge of the hole. Drive forward slowly and continue to tilt the bucket down (2) [Figure 97] until it enters the ground. If necessary, raise the lift arms to empty the bucket. Raise the cutting edge a small amount (3) [Figure 97] to increase traction and keep an even digging depth.
OPERATING PROCEDURE (CONT’D) Emptying Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern) Figure 102 Filling 2 Figure 100 1 2 B-15781 B-15534 1 Keep the bucket low when moving to the area where you want to empty the bucket. B-15781 B-15520 Raise the lift arms (1) [Figure 102]. Level the bucket (2) [Figure 102] while raising the lift arms to help prevent material from falling off the back of the bucket.
OPERATING PROCEDURE (CONT’D) Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern) Figure 103 3 4 2 1 B-15522 1 B-15781 Press and hold the float button (1) [Figure 103] while the lever is in neutral. While lowering the lift arms (2) [Figure 103], release the float button. Tilt the bucket forward (3) [Figure 103] to change the position of the cutting edge of the bucket. With the bucket tilted farther forward, there is more force on the cutting edge and more loose material can be moved.
OPERATING PROCEDURE (CONT’D) Filling Digging And Filling A Hole (ACS - Handles, SJC ‘H’ Pattern) Figure 106 Digging 2 Figure 104 1 2 3 1 B-15537 Lower the lift arms (1) [Figure 106] and put the cutting edge of the bucket on the ground (2) [Figure 106]. Drive forward to the edge of the hole to push the material into the hole. B-15781A B-15781B B-15539 B-15781A B-15781B Tilt the bucket forward (2) [Figure 106] as soon as it is past the edge of the hole.
OPERATING PROCEDURE (CONT’D) Emptying Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern) Figure 109 Filling Figure 107 2 1 1 2 P-24820 P-24802 B-15534 Keep the bucket low when moving to the area where you want to empty the bucket. P-24820 P-24802 B-15520 Raise the lift arms (1) [Figure 109]. Level the bucket (2) [Figure 109] while raising the lift arms to help prevent material from falling off the back of the bucket.
OPERATING PROCEDURE (CONT’D) Leveling The Ground Using Float (SJC - ‘ISO’ Pattern) IMPORTANT Figure 110 Never drive forward when the hydraulic control for lift arms is in float position. 2 I-2005-1285 3 4 1 B-15522 P-24820 P-24802 Press and hold the float button (1) [Figure 110] while the joystick is in neutral. While lowering the lift arms (2) [Figure 110], release the float button. Tilt the bucket forward (3) [Figure 110] to change the position of the cutting edge of the bucket.
OPERATING PROCEDURE (CONT’D) Filling Digging And Filling A Hole (SJC - ‘ISO’ Pattern) Figure 112 Digging 1 Figure 111 2 1 2 3 B-15539 B-15537 Lower the lift arms (1) [Figure 112] and put the cutting edge of the bucket on the ground (2) [Figure 112]. Drive forward to the edge of the hole to push the material into the hole. P-24820 P-24802 Lower the lift arms all the way (1) [Figure 111]. Put the cutting edge of the bucket on the ground (2) [Figure 111].
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 / tracks will not turn.) There might be slight wear to the tires / tracks when the loader is skidded. The towing chain (or cable) must be rated at 1 & 1/2 times the weight of the loader.
Four Point Lift LIFTING THE LOADER Single Point Lift WARNING WARNING • • • • • AVOID INJURY OR DEATH Before lifting, check fasteners on single point lift and operator cab. Assemble front cab fasteners as shown in this manual. Never allow riders in the cab or bystanders within 5 meters while lifting the machine. AVOID INJURY OR DEATH Before lifting, check fasteners on four point lift. Never allow riders in the cab or bystanders within 5 meters while lifting the machine.
TRANSPORTING THE LOADER ON A TRAILER Fastening Loading And Unloading Figure 116 WARNING 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. W-2058-0494 N-19048A P-73276 Be sure the transport and towing vehicles are of adequate size and capacity. (See Fluid Capacities on Page 122.
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PREVENTIVE MAINTENANCE AIR CLEANER SERVICE..........................................................................77 Replacing Filter Elements ....................................................................77 AIR CONDITIONING BELT .......................................................................95 Belt Adjustment ....................................................................................95 Belt Replacement.................................................................................
PREVENTIVE MAINTENANCE (CONT’D) FINAL DRIVE TRANSMISSION (CHAINCASE) ....................................... 94 Checking And Adding Oil..................................................................... 94 Removing Oil From The Chaincase..................................................... 94 FUEL SYSTEM ......................................................................................... 79 Filling the Fuel Tank.............................................................................
PREVENTIVE MAINTENANCE (CONT’D) REAR GRILL .............................................................................................75 Installing...............................................................................................75 Removing .............................................................................................75 SEAT BAR RESTRAINT SYSTEM ............................................................67 Description ...........................................................
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MAINTENANCE SAFETY WARNING 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 can cause injury or death.
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SERVICE SCHEDULE Chart Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat loader. WARNING 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.
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) Inspecting The Traction Lock (Engine RUNNING) Inspecting The BICS Controller (Engine STOPPED Key ON) 6. 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. Figure 117 1 2 3 7. Engage parking brake and move steering levers slowly forward and backward.
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. SEAT BAR RESTRAINT SYSTEM Description The seat bar restraint system has a pivoting seat bar with arm rests. 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.
Figure 119 SEAT BELT Inspection and Maintenance WARNING Failure to properly inspect and maintain the seat belt can cause lack of operator restraint resulting in serious injury or death. W-2466-0703 Check the seat belt daily for correct function. Inspect the seat belt system thoroughly at least once each year or more often if the machine is exposed to severe environmental conditions or applications.
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 installed. LIFT ARM SUPPORT DEVICE Installing Start the engine, and raise the lift arms all the way up. WARNING Figure 121 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.
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.
Figure 124 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 SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level I. Level II is available.
NOTE: The weight of the cab increases when equipped with options and accessories such cab door, heater, air conditioning, etc. In these cases, the cab may need to be raised slightly from the latch to be able to release the latch. OPERATOR CAB (CONT’D) Raising (Cont’d) WARNING Support the cab and release the latching mechanism (Inset) [Figure 126]. Remove your hand from latching mechanism when the cab is past the latch stop. Use both hands to lower the cab all the way.
OPERATOR CAB (CONT’D) Cab Door Sensor (If Equipped) Figure 128 2 B-15551J 1 P-68116 P-68115 Cab doors have a sensor (1) [Figure 128] installed which deactivates the lift and tilt valves when the door is open. CLOSE DOOR TO OPERATE lift and tilt valves. The LIFT & TILT VALVE light (2) [Figure 128] will be ON when the door is closed and the PRESS TO OPERATE LOADER BUTTON is pressed.
REAR DOOR Opening And Closing WARNING WARNING Keep the rear door closed when operating the machine. Failure to do so could seriously injure a bystander. W-2020-1285 AVOID INJURY OR DEATH Never service or adjust the machine when the engine is running unless instructed to do so in the manual. W-2012-0497 Adjusting Figure 129 Figure 131 1 P-31848A P-30806 P-31126 Reach into the slot in the rear door and pull the latch handle [Figure 129].
REAR GRILL Removing Open the rear door. Figure 132 P-66784 P-66783 Remove the rear grill [Figure 132]. Installing Align the tabs of the rear grill into the slots in the loader frame [Figure 132]. Lower the rear grill.
HEATING AND AIR CONDITIONING Evaporator Cleaning and Maintenance Figure 134 The heater and air conditioning system require regular inspection and maintenance. See your SERVICE SCHEDULE for intervals. (See SERVICE SCHEDULE on Page 65.) Filters Figure 133 1 2 P19427 Raise the cab and remove the evaporator cover (1) [Figure 134]. Use low pressure water or air to remove debris from the evaporator fins. 1 Install the cover.
AIR CLEANER SERVICE Outer Filter Replacing Filter Elements Figure 137 Figure 135 1 1 P-31836 B-15552B B-15553B Remove the wing nut and remove the dust cover [Figure 137]. It is important to change the air filter element only when the Air Cleaner Icon in the right panel is ON (1) [Figure 135] and you hear three beeps from the alarm. Figure 138 Replace the inner filter every third time the outer filter is replaced or as indicated.
Figure 140 AIR CLEANER SERVICE (CONT’D) Replacing Filter Elements (Cont’d) Inner Filter Only replace the inner filter element under the following conditions: • Replace the inner filter element every third time the outer filter is replaced. • After the outer element has been replaced, start the engine and run at full RPM. If the HOURMETER / CODE DISPLAY shows [01-17] (Air Filter Plugged), replace the inner filter element.
Figure 142 FUEL SYSTEM WRONG Fuel Specifications Use only clean, high quality diesel fuel, Grade No. 2 or Grade No. 1. The following is one suggested blending guideline which should prevent fuel gelling during cold temperatures: TEMPERATURE °C (°F) No. 2 No. 1 -9° (+15°) 100% 0% Down to -29° (-20°) 50% 50% Below -29° (-20°) 0% 100% B-15650 Contact your fuel supplier for local recommendations. Use a clean, approved safety container to add fuel of the correct specifications.
FUEL SYSTEM (CONT’D) Removing Air From The Fuel System Fuel Filter After replacing the filter element or when the fuel tank has run out of fuel, the air must be removed from the fuel system before starting the engine. See your SERVICE SCHEDULE for the service interval for removing water from, or replacing the fuel filter. (See SERVICE SCHEDULE on Page 65.) WARNING Removing Water Figure 143 Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death.
ENGINE LUBRICATION SYSTEM Removing And Replacing Oil And Filter Checking And Adding Engine Oil See your SERVICE SCHEDULE for the service interval for replacing the engine oil and filter. (See SERVICE SCHEDULE on Page 65.) Check the engine oil level every day before starting the engine for the work shift. Run the engine until it is at operating temperature. Stop the engine. Figure 145 Open the rear door. 1 P-48473 Remove the drain hose from the storage position (2) [Figure 145].
ENGINE COOLING SYSTEM Checking Level Check the cooling system every day to prevent overheating, loss of performance or engine damage. Open the rear door and raise the rear grill. Figure 148 Cleaning Figure 147 1 1 P-39967 2 Remove the coolant fill cap (1) [Figure 148]. 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. P-45101 Close the rear door before operating the loader.
ENGINE COOLING SYSTEM (CONT’D) NOTE: The loader is factory filled with propylene glycol coolant (purple color). DO NOT mix propylene glycol with ethylene glycol. Removing And Replacing the Coolant Open the rear door and remove the rear grill. Add premixed coolant, 47% water and 53% propylene glycol to the recovery tank. (See Checking Level on Page 82.) Figure 149 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.
Figure 152 ELECTRICAL SYSTEM Description 1 9 5 11 13 15 17 Figure 150 2 6 18 7 19 3 4 P-13849 8 12 10 14 16 20 7117407 P-24651 The loader has a 12 volt, negative ground alternator charging system. The electrical system is protected by fuses located in the cab on the steering control panel and a 100 amp. master fuse [Figure 150] in the engine compartment on the left side of the engine. The fuses will protect the electrical system when there is an electrical overload.
ELECTRICAL SYSTEM (CONT’D) Using A Booster Battery (Jump Starting) Battery Maintenance If it is necessary to use a booster battery to start the engine, BE CAREFUL! There must be one person in the operator's seat and one person to connect and disconnect the battery cables. Figure 153 The key switch must be OFF (Key Switch Panel) OR the STOP Button must be pressed (Keyless Panel). The booster battery must be 12 volts. WARNING Keep arcs, sparks flames and lighted tobacco away from batteries.
ELECTRICAL SYSTEM (CONT’D) IMPORTANT Using A Booster Battery (Jump Starting) (Cont’d) Figure 154 Damage to the alternator can occur if: • Engine is operated with battery cables disconnected. • Battery cables are connected when using a fast charger or when welding on the loader. (Remove both cables from the battery.) • Extra battery cables (booster cables) are connected wrong.
Figure 156 ELECTRICAL SYSTEM (CONT’D) Removing And Installing Battery WARNING 1 Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body. In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes. N-18458 If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting.
HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart Checking And Adding Fluid Figure 160 HYDRAULIC / HYDROSTATIC FLUID TEMPERATURE RANGE ANTICIPATED DURING MACHINE USE Use only recommended fluid in the hydraulic system. (See Hydraulic System on Page 121.) Stop the loader on a level surface. VG 100 Minimum VI 120 Lower the lift arms and tilt the Bob-Tach fully back. VG 46 Minimum VI 140 Stop the engine. SYNTHETIC HYDRAULIC FLUID Use recommendation from Synthetic Oil Mfr.
Figure 164 HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Removing And Replacing Hydraulic Fluid And Case Drain Filters See your SERVICE SCHEDULE for the service interval. (See SERVICE SCHEDULE on Page 65.) 2 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.
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Removing And Replacing Charge Filter Removing And Replacing Hydraulic Fluid And Case Drain Filters (Cont’d) The charge filter is located under the cab. Raise the cab (See Raising on Page 71). Figure 165 WARNING Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Breather Cap Removing And Replacing Charge Filter (Cont’d) See your SERVICE SCHEDULE for the correct replacement interval. (See SERVICE SCHEDULE on Page 65.) WARNING Raise the cab. (See Raising on Page 71.) Figure 166 Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. 1 W-2103-1285 Lower the cab.
SPARK ARRESTOR MUFFLER Cleaning Procedure WARNING See your SERVICE SCHEDULE for service the interval for cleaning the spark arrestor muffler. (See SERVICE SCHEDULE on Page 65.) When the engine is running during service, the steering levers must be in neutral and the parking brake engaged. Failure to do so can cause injury or death. Do not operate the loader with a defective exhaust system.
It is important to keep the same size tires on each side of the loader. If different sizes are used, each tire will be turning at a different rate and cause excessive wear. The tread bars of all the tires must face the same direction. TIRE MAINTENANCE Wheel Nuts Figure 168 Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capability. Check for the correct pressure before operating the loader.
FINAL DRIVE TRANSMISSION (CHAINCASE) Removing Oil From The Chaincase Checking And Adding Oil Remove the check plug (1) [Figure 170] from the front of the chaincase housing. The chaincase contains the final drive sprockets and chains. Use the same type of oil as the hydraulic / hydrostatic system. (See (S205) LOADER SPECIFICATIONS on Page 119.) Figure 171 Stop the loader on a level surface. Stop the engine. Figure 170 P-31287B 1 Remove the oil from the chaincase [Figure 171].
ALTERNATOR BELT AIR CONDITIONING BELT Belt Adjustment Belt Adjustment Stop the engine. Figure 173 Raise the operator cab. (See Raising on Page 71.) 2 Figure 172 2 1 P-24288 1 Inspect the drive belt regularly for wear. (See SERVICE SCHEDULE on Page 65.) P-24543 Open the rear door. Remove the drive belt cover. Remove the compressor belt cover. Loosen the alternator mounting bolt (1) [Figure 172]. Loosen the mounting bolt (1) and the adjustment bolt (2) [Figure 173].
NOTE: Do not set the idler against the travel stop in the 3 o'clock position. DRIVE BELT Belt Adjustment Stop the engine. Tighten the mounting bolt (1) [Figure 174] to 34-38 Nm torque. Open the rear door and disconnect the negative (-) cable from the battery. Run the engine for a few minutes. Stop the engine and recheck the pointer position. Remove three belt shield fasteners and remove the belt shield. Readjust if necessary.
Figure 178 LUBRICATING THE LOADER Lubrication Locations Lubricate the loader as specified for the best performance of the loader. (See SERVICE SCHEDULE on Page 65.) 5 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: N-18510 Figure 176 5. Tilt Cylinder Base End (Both Sides) [Figure 178].
Figure 182 LUBRICATING THE LOADER (CONT’D) Lubrication Locations (Cont’d) Figure 180 8 11 N-18511 P-31839 9 11. Lift Arm Link Pivot Pin (Both Sides) [Figure 182]. P-16045 Figure 183 8. Bob-Tach Wedge (Both Sides) [Figure 180]. 9. Power Bob-Tach Cylinder (Both Sides) [Figure 180]. Figure 181 10 12 P-24703 12. 250 Hours: Steering Lever Shaft (2) [Figure 183]. N-18508 10. Lift Arm Pivot Pin (Both Sides) [Figure 181].
PIVOT PINS Inspection And Maintenance Figure 184 1 1 P-31842A P-31842 All lift arm and cylinder pivots have a large pin held in position with a retainer bolt and lock nut (1) [Figure 184]. Check that the lock nuts are tightened to 34-38 Nm torque.
Inspection And Maintenance If the wedge does not contact the lower edge of the hole [Figure 186], the attachment will be loose and can come off the Bob-Tach. Figure 185 Figure 187 BOB-TACH (HAND LEVER) P-31693 TS-1062 Inspect the mounting frame on the attachment and the Bob-Tach, linkages and wedges for excessive wear or damage [Figure 187]. Replace any parts that are damaged, bent, or missing. Keep all fasteners tight. Move the Bob-Tach levers down to engage the wedges [Figure 185].
BOB-TACH (POWER - OPTION) The spring loaded wedge (1) [Figure 189] must contact the lower edge of the hole in the attachment (2) [Figure 189]. Inspection And Maintenance Figure 188 If the wedge does not contact the lower edge of the hole [Figure 189], the attachment will be loose and can come off the Bob-Tach. Figure 190 B-22965 B-15891 Push and hold the BOB-TACH “WEDGES UP” switch [Figure 188] until wedges are fully raised.
LOADER STORAGE AND RETURN TO SERVICE Return to Service Storage After the Bobcat Loader has been in storage, it is necessary to follow a list of items to return the loader to service. Sometimes it may be necessary to store your Bobcat Loader for an extend period of time. Below is a list of items to perform before storage. • Check the engine and hydraulic oil levels; check coolant level. • Install a fully charged battery. • Remove grease from exposed cylinder rods. • Check all belt tensions.
SYSTEM SETUP & ANALYSIS BOBCAT INTERLOCK CONTROL SYSTEM (BICS) ..............................105 Troubleshooting..................................................................................105 DIAGNOSTIC SERVICE CODES............................................................106 Service Codes List .............................................................................106 DISPLAY CONTROLLER PANEL SETUP...............................................111 Panel Setup..................................
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BOBCAT INTERLOCK CONTROL SYSTEM (BICS) Troubleshooting The following list shows the effects which can happen to the loader, and the probable causes when the BICS System lights are off or flashing and associated service code. Indicator Light 1 2 3 4 Light ON Light OFF PRESS TO OPERATE LOADER Button is pressed. PRESS TO OPERATE LOADER Button is not pressed. Seat Bar is down. Seat Bar is up.
DIAGNOSTIC SERVICE CODES Service Codes List CODE CODE 01-16 Air filter not connected 11-05 Seat bar sensor short to battery 01-17 Air filter plugged 11-06 Seat bar sensor short to ground 02-16 Hydraulic charge filter not connected 12-21 Front auxiliary PWM switch out of range high 02-17 Hydraulic charge filter plugged 12-22 Front auxiliary PWM switch out of range low 12-23 Front auxiliary PWM switch not in neutral 03-09 Battery voltage low 03-10 Battery voltage high 13-05 Fuel shut-
DIAGNOSTIC SERVICE CODES (CONT’D) Service Codes List (Cont’d) CODE CODE 25-02 Rear auxiliary relief solenoid error ON 32-61 Handle lock short to ground 25-03 Rear auxiliary relief solenoid error OFF 32-62 Handle lock short to battery 32-63 Pedal lock short to ground 26-02 Front base solenoid error ON 32-64 Pedal lock short to battery 26-03 Front base solenoid error OFF 32-65 Sensor supply voltage out of range 32-66 Battery voltage out of range 27-02 Front rod solenoid error ON 32-67
DIAGNOSTIC SERVICE CODES (CONT’D) Service Codes List (Cont’d) CODE CODE 38-04 No communication from joystick controller 38-53 Left forward drive solenoid error OFF 38-05 Left joystick X axis not in neutral 38-54 Left reverse drive solenoid error OFF 38-06 Right joystick X axis not in neutral 38-55 Right forward drive solenoid error OFF 38-07 Left joystick Y axis not in neutral 38-56 Right reverse drive solenoid error OFF 38-08 Right joystick Y axis not in neutral 38-57 Front right exten
DIAGNOSTIC SERVICE CODES (CONT’D) Service Codes List (Cont’d) CODE CODE 39-04 Left joystick no communication to Bobcat controller 75-22 Right Joystick Y-Axis Out of Range High (H-Pattern Only) 40-04 Right joystick no communication to Bobcat controller 75-27 Left Swash Plate Out of Position 75-28 Right Swash Plate Out of Position 75-29 Left Joystick X-Axis Out of Range Low 44-02 Horn error ON 75-31 Left Joystick Y-Axis Out of Range Low 44-03 Horn error OFF 75-32 Right Joystick Y-Axis Out
DIAGNOSTIC SERVICE CODES (CONT’D) Service Codes List (Cont’d) CODE CODE 77-48 Key Switch 78-74 Door / Transport Lock 80-02 ACD output ‘A’ error ON Door Transport Lock 80-03 ACD output ‘A’ error OFF 81-02 ACD output ‘B’ error ON 81-03 ACD output ‘B’ error OFF 82-02 ACD output ‘C’ error ON 82-03 ACD output ‘C’ error OFF 83-02 ACD output ‘D’ error ON 83-03 ACD output ‘D’ error OFF 84-02 ACD output ‘E’ error ON 84-03 ACD output ‘E’ error OFF 85-02 ACD output ‘F’ error ON 85-03 ACD o
DISPLAY CONTROLLER PANEL SETUP Panel Upgrade ICON DESCRIPTION LOCK / UNLOCK: Allows machine to be locked / unlocked. You must lock machine to activate security system. Icon Identification Figure 191 When system is unlocked, the user can press RUN / ENTER then press START to begin operation. SELECTION BUTTON A valid password will need to be entered at startup to run a locked machine. TOOL / SETUP: Access system options.
All new machines with Keyless Instrumentation arrive at Bobcat dealerships with the panel in locked mode. This means that a password must be used to start the engine [Figure 192]. DISPLAY CONTROLLER PANEL SETUP (CONT’D) Panel Setup Display Options Figure 192 Passwords For security purposes, your dealer may change the password and also set it in the locked mode. Your dealer will provide you with the password.
DISPLAY CONTROLLER PANEL SETUP (CONT’D) Passwords (Cont’d) Figure 193 Changing the Password - Right Instrument Panel Display Screen Press TOOL / SETUP B-16163 Press OWNER UTILITIES B-24288 Keypad Enter PASSWORD (owner or master) on Keypad then press ENTER to Continue.
DISPLAY CONTROLLER PANEL SETUP (CONT’D) Viewing Service Codes (Keyless) Viewing Service Codes (Key Switch) The Service Codes will aid your dealer in diagnosing conditions which can damage your machine. Figure 194 Figure 195 2 Press TOOL / SETUP 3 B-16163 1 Press OWNER UTILITIES 4 B-24288 Enter PASSWORD (owner or master) on Keypad then press ENTER to Continue.
DISPLAY CONTROLLER PANEL SETUP (CONT’D) SHUTDOWN FEATURE More EXAMPLES: Procedure Clocks Figure 196 TOOL / SETUP LOADER FEATURES DISPLAY OPTIONS CLOCKS SET CLOCK Use the keypad to set time. Press RUN / ENTER to set clock. Press EXIT to return to previous level menu. 2 RESET JOB CLOCK (Password required) Press CLEAR to reset job clock to zero. Press LOCK / UNLOCK to unlock. Enter Password and press RUN / ENTER.
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SPECIFICATIONS (S205) LOADER SPECIFICATIONS .......................................................119 Controls..............................................................................................122 Drive System......................................................................................121 Electrical ............................................................................................120 Engine........................................................................................
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(S205) LOADER SPECIFICATIONS Loader Dimensions • • Dimensions are given for loader equipped with standard dirt bucket and may vary with other bucket types. All dimensions are shown in millimeters. Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice. B-24268A (C) Angle of Departure ........................................................ Carry position ......................................................................
(S205) LOADER SPECIFICATIONS (CONT’D) Machine Rating Lift breakout force 1690 daN Tilt breakout force 1701 daN Rated operating capacity 930 kg Tipping load 2019 kg Axle torque 5423 Nm Function Time Raise lift arms 3,50 s Lower lift arms 2,30 s Bucket rollback 1,90 s Bucket dump 2,50 s Weights Operating weight 3023 kg Shipping weight 2658 kg Engine Make / Model Kubota / V2403-M-DI-TE2B-BC-I Fuel Diesel Cooling Liquid Power at 2700 RPM 45,5 kW Rated speed (EEC 80/1269, ISO 9249)
(S205) LOADER SPECIFICATIONS (CONT’D) Hydraulic System Pump type Engine driven, gear type Pump capacity at 3028 RPM 62,0 l/min Pump capacity at 3028 RPM high flow option 96,5 l/min System relief at Quick Couplers 22,4-23,1 MPa Control valve Three-spool, open-centre type with float detent on lift and electrically controlled auxiliary spool Hydraulic filter Full-flow replaceable - 3 µm synthetic media element Fluid lines SAE standard tubelines, hoses, and fittings Hydraulic Cylinders Lift cylinder
(S205) LOADER SPECIFICATIONS (CONT’D) Fluid Capacities Chaincase reservoir capacity 30,3 l Cooling system capacity with heater 11,4 l Cooling system capacity without heater 10,2 l Engine oil with filter capacity 8,7 l Fuel tank capacity 90,8 l Hydraulic reservoir capacity 18,2 l Hydraulic / Hydrostatic system capacity 34,1 l Fluid Specifications Engine coolant Polypropylene glycol/water mix (53% - 47%) with freeze protection to -37°C Engine oil Oil must meet API Service Classification of CD,
(S205) LOADER SPECIFICATIONS (CONT’D) Instrumentation The following loader functions are monitored by a combination of gauges and warning lights in the operator's line of sight. The system alerts the operator of monitored loader malfunctions by way of audible alarm and visual warning lights.
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WARRANTY BOBCAT LOADERS INGERSOLL RAND INTERNATIONAL warrants to its authorised dealers who in turn warrant to the end-user/owner that each new Bobcat loader will be free from proven defects in material and workmanship for twelve months from the date of delivery to the end-user/owner or 2000 hours of machine usage, whichever occurs first.
