(S/N: 519611001 & Above - S/N: 519711001 & Above)
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This workshop repair service manual PDF download for the A220 Bobcat All-Wheel Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
APPLICABLE MODELS :
Bobcat Loader A220
TURBO - HIGH FLOW
S/N: 519611001 & Above
S/N: 519711001 & Above
TABLE OF CONTENTS :
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
SERIAL NUMBER LOCATION
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
SAFETY & MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAINFRAME
ELECTRICAL SYSTEM ANALYSIS
ENGINE SERVICE
HEATING, VENTILATION, AIR CONDITIONING
SPECIFICATIONS
SERVICE MANUAL REVISION
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6901245 (7-10)
Total Pages : 990
This A220 Bobcat Loader Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
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ALPHABETICAL INDEX
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrestor Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATION
Loader Serial Number
Engine Serial Number
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
SAFETY & MAINTENANCE
LIFTING AND BLOCKING THE LOADER
Procedure
LIFT ARM SUPPORT DEVICE
Engaging The Lift Arm Support Device
Disengaging The Lift Arm Support Device
OPERATOR CAB
Raising The Operator Cab
Lowering The Operator Cab
Emergency Exit
TRANSPORTING THE LOADER
Procedure
TOWING THE LOADER
Procedure For Non-Two-Speeds
Procedure For Two-Speeds
REMOTE START
Procedure For Loader Without Attachment Control Harness
Procedure For Loader With Attachment Control Harness
Procedure
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Replacing Filter Element
ENGINE COOLING SYSTEM
Cleaning The Cooling System
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Fuel Filter
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Replacing Oil And Filter
HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid
Hydraulic/Hydrostatic Filter Replacement
Replacing Hydraulic Fluid
Steering Filter Replacement
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
Replacing The Oil
FAN GEARBOX
Checking And Adding Oil
BOB-TACH
Inspection And Maintenance
POWER BOB-TACH (OPTION)
Inspection And Maintenance
LUBRICATING THE LOADER
Procedure
TIRE MAINTENANCE
Wheel Nuts
Tire Rotation
Tire Mounting
HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Troubleshooting
Tighten Procedures
CYLINDER (LIFT)
Checking
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (TILT)
Checking
Removal And Installation
Rod End Seal
Parts Identification
Disassembly
Assembly
CYLINDER (POWER BOB-TACH)
Checking
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (STEERING)
Removal (Front)
Removal (Rear)
MAIN RELIEF VALVE
Checking The Main Relief Valve At Front Auxiliary Hydraulics
Removal And Installation
Adjustment
HYDRAULIC CONTROL VALVE
Actuator Removal And Installation (In Loader)
Removal And Installation
Actuator Removal And Installation (Out Of Loader)
BICS™ Valve Removal And Installation
BICS™ Valve Lift Arm Bypass Orifice Removal And Installation
BICS™ Valve Check Valve Removal And Installation
BICS™ Valve Lock Valve Removal And Installation
BICS™ Valve Solenoid Removal And Installation
BICS™ Valve Solenoid Testing
Identification Chart
Lift Base End Restrictor
Load Check Valve
Main Relief Valve
Port Relief Valve
Anti-Cavitation Valve/Port Relief Valve
Anti-Cavitation Valve
Lift Spool Removal And Installation
Tilt Spool Removal And Installation
Lift And Tilt Spool Disassembly And Assembly
Auxiliary Spool Removal And Installation
Auxiliary Electric Solenoid Disassembly And Assembly
Port-Auxiliary Section Disassembly
Cleaning And Inspection
LIFT ARM BYPASS CONTROL VALVE
Inspecting
Removal And Installation
Disassembly And Assembly
HYDRAULIC PUMP
Checking The Output Of The Auxiliary Pump
Checking The Output Of The Steering Pump
Removal And Installation
Parts Identification
Disassembly And Assembly
HYDRAULIC PUMP (HI FLOW)
Checking The Output Of The High Flow Pump
Removal And Installation
Parts Identification
Disassembly And Assembly
HYDRAULIC/HYDROSTATIC FILTER
Housing Removal And Installation
HYDRAULIC FLUID RESERVOIR
Draining The Fluid Reservoir
Removal And Installation
Hydraulic Fluid Screen
BUCKET POSITION VALVE
Solenoid Removal And Installation
Solenoid Testing
Removal And Installation
Disassembly And Assembly
SELECT VALVE
Checking The High Flow Pump Relief Valve
Removal And Installation
Disassembly And Assembly
Solenoid Testing
REAR AUXILIARY DIVERTER VALVE
Disassembly
Inspection
Solenoid Testing
Assembly
POWER BOB-TACH BLOCK (EARLY MODELS)
Removal And Installation
Disassembly And Assembly
POWER BOB-TACH BLOCK (LATER MODELS)
Removal And Installation
Disassembly And Assembly
AUXILIARY PRESSURE RELEASE (ACCUMULATOR) (Early models)
Removal and Installation
FRONT AUXILARY HYDRAULIC COUPLER BLOCK (S/N 519611124 & Above)
Removal and Installation
Disassembly And Assembly
HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
Replenishing Valve Function
HYDROSTATIC MOTOR
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
HYDROSTATIC MOTOR (TWO-SPEED)
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
HYDROSTATIC MOTOR CARRIER
Removal And Installation
Parts Identification
Assembly
CHARGE PRESSURE
Testing
Removal And Installation
HYDROSTATIC PUMP
Pump Controller Removal And Installation
Hydrostatic Pump Calibration
Removal And Installation
Parts Identification (Right Half)
Parts Identification (Left Half)
System Check Relief Valves (High Pressure Relief, Charge Check & Bypass Valve)
Charge Relief Valve
Pump Separation
Shaft Seal And Shaft Replacement
Shaft Seal And Shaft Installation
Charge Pump Removal
Charge Pump Inspection
Charge Pump Installation
Disassembly
Inspection
Assembly
Pump Neutral Adjustment
Pump Controller Neutral Adjustment
DRIVE BELT
Shield Removal And Installation
Adjustment
Replacement
Tensioner Pulley Removal And Installation
Tensioner Pulley Tension Spring
OIL COOLER (SEAL TO CONNECT) (STC)
Hydraulic Oil Cooler Removal and Installation
DRIVE SYSTEM
BRAKE
Disc Removal And Installation
BRAKE (TWO-SPEED) (EARLY MODELS)
Block Removal And Installation
Block Disassembly And Assembly
BRAKE (TWO SPEED) (LATER MODELS)
Block Removal And Installation
Block Disassembly And Assembly
Wiring Diagram
Removal And Installation
DRIVE COMPONENTS
Axle Seal Removal And Installation
Axle, Sprocket And Bearings Removal And Installation
Drive Chain Removal And Installation
CHAINCASE
Front Chaincase Cover Removal And Installation
Rear Chaincase Cover Removal And Installation
HUB
Removal
Installation
Disassembly
Inspection
Assembly
MAINFRAME
SEAT BAR
Removal And Installation
Assembling Components
Compression Spring Disassembly And Assembly
OPERATOR CAB
Gas Cylinder Removal And Installation (Dual Gas Spring)
Gas Cylinder Removal And Installation (3rd Gas Spring)
Gas Cylinder Bracket Disassembly and Assembly
Removal And Installation
OPERATOR SEAT (STANDARD)
Removal And Installation
Seat Belt Removal And Installation
OPERATOR SEAT (SUSPENSION)
Removal And Installation
Slide Rail Removal And Installation
Cushion Removal And Installation
Back Removal And Installation
Shock Removal And Installation
BOB-TACH
Removal And Installation
Bob-Tach Lever And Wedge
Bob-Tach Stops
Pivot Pin Bushing And Seal Replacement
POWER BOB-TACH
Inspection And Maintenance
Power Bob-Tach Lever And Wedge
Removal And Installation
Pivot Pin Bushing And Seal Replacement
LIFT ARMS
Removal And Installation
REAR GRILL
Removal And Installation
REAR DOOR
Removal And Installation (Early Loaders)
Adjusting The Rear Door Latch
Striker Removal And Installation (Later Loaders)
Adjusting The Striker (Later Loaders)
Latch Removal And Installation (Later Loaders)
FUEL TANK
Removal And Installation
Fuel Level Sender
Fuel Pick-Up Screen/Check Valve
CONTROL
Joystick Testing (Right & Left)
Joystick Removal (Right & Left)
Joystick Boot Removal (Right & Left)
Lever Assembly Removal (Right & Left)
CONTROL PANEL
Removal And Installation
INSIDE ACCESS PANEL (EARLY MODELS)
Panel Removal (Right)
Panel Removal (Left)
INSIDE ACCESS PANEL (LATER MODELS)
Panel Removal (Right)
ELECTRICAL SYSTEM ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
Description
Fuse Location
Relay Switch Location
Solenoid Test
BATTERY
Removal And Installation
Servicing The Electrical System
Using A Booster Battery (Jump Starting)
ALTERNATOR
Adjusting The Alternator Belt
Alternator Identification
Charging System Check
Alternator Voltage Test
Low Voltage Test
High Voltage Test
Removal And Installation
Rectifier Continuity (Diode) Test
Alternator Regulator Test
Disassembly
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Assembly
STARTER (NIPPONDENSO)
Checking
Removal And Installation
Removal And Installation (Cont’d)
Parts Identification
Disassembly
Inspection And Repair
No Load Test
Assembly
STARTER (VALEO)
Checking
Removal And Installation
Removal And Installation (Cont’d)
Parts Identification
Disassembly And Assembly
Inspection And Repair
No Load Test
INSTRUMENT PANEL
Left Panel
Right Panel - (Standard) (With Key Switch)
Right Panel - (Deluxe) (With Keyless Start)
Right Panel Set Up Display Options (Deluxe)
Option and Field Accessory Panels (If Equipped)
Standard Panel Removal And Installation (Right Side)
Deluxe Panel Removal And Installation (Right Side)
Standard & Deluxe Panel Removal And Installation (Left Side)
LIGHTS
Front Removal And Installation
Rear Removal And Installation
BOBCAT 2001 CONTROLLER (EARLY MODELS)
Removal And Installation
Identification Chart
BOBCAT CONTROLLER
Identification Chart
Removal And Installation
AWS CONTROLLER
Removal
Identification Chart
SPEED SENSOR
Testing
Removal
DIAGNOSTICS SERVICE CODES
Display
Number Codes List
STEERING SOLENOID
Removal
BICS™ SYSTEM
Inspecting The BICS™ Controller (Engine STOPPED - Key ON)
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)
Inspecting The Seat Bar Sensor (Engine RUNNING)
Inspecting The Traction Lock (Engine RUNNING)
Inspecting The LIft Arm Bypass Control
Troubleshooting Chart
Troubleshooting Guide
SEAT BAR SENSOR
Troubleshooting Chart
Test
Removal And Installation
BICS™ Circuit Test
TRACTION LOCK
Troubleshooting Chart
Removal And Installation
Description Of The Control System
Inspecting The Control System
WHEEL POSITION SENSORS
Operation
Wheel Alignment (Failed Sensor)
Testing
Sensor Removal And Installation
Wheel Alignment (Field Adjustment)
Wheel Alignment (Calibration)
SERVICE PC (LAPTOP COMPUTER)
Connecting The Service PC To Remote Start Tool
LIFT AND TILT ACTUATOR CALIBRATION
Procedure
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
Controls Identification Chart
ENGINE SERVICE
TROUBLESHOOTING
Chart
ENGINE SPEED CONTROL (EARLY MODELS)
Removal
Speed Control Stop
Speed Control Cable
ENGINE SPEED CONTROL (LATER MODELS)
Removal
Disassembly
Speed Control Cable
MUFFLER
Removal And Installation
AIR CLEANER
Housing Removal And Installation
RADIATOR
Removal And Installation
COOLING FAN
Drive Tension Pulley Removal And Installation
Gearbox/Blower Housing Removal And Installation
Blower Removal And Installation
Gearbox Parts Identification
Gearbox Disassembly
Gearbox Assembly
Gearbox, Checking Backlash
ENGINE COMPONENTS AND TESTS
Engine Compression, Checking
Glow Plug, Checking
Fuel Shut-Off Solenoid Checking
Fuel Shut-Off Solenoid Removal And Installation
Fuel Injection Pump Removal
Fuel Injection Pump Timing
Fuel Injection Pump Installation
Fuel Injector Removal And Installation
Fuel Injector, Checking
Fuel Injector Disassembly
Fuel Injector Assembly
Timing Belt Inspection
Timing Belt Removal
Timing Belt Installation
Timing Belt, Replacement In The Loader
Valve Clearance Adjustment
Valve Timing, Checking
Thermostat, Oil Pressure Control Valves & Heater Connections
ENGINE
Removal And Installation
Mount Replacement
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Flywheel Housing Removal And Installation
RECONDITIONING THE ENGINE
Deutz Engine Tools Identification Chart
Disassembly
Assembly
Cylinder, Checking
Camshaft Bearing, Checking
Camshaft Bearing, Removal And Installation
Control Rod Guide Bushing Removal
Control Rod Guide Bushing Installation
Rear Cover Seal Removal And Installation
Crankshaft, Checking
Connecting Rod, Checking
Piston, Checking
Piston Pin, Checking
Piston Rings Installation
Piston Installation On The Connecting Rod
Cylinder Head Disassembly
Valves, Checking
Valve Seats, Checking
Valve Spring, Checking
Cylinder Head Assembly
Rocker Arm And Bracket, Checking
Front Cover Disassembly
Front Cover Assembly
Turbo Charger Removal and Installation
Crankshaft Gear Mounting Bolt Torque Procedure
Governor Buffer Spring Adjustment
HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW
Principals
Chart
COMPONENTS
Identification
SAFETY
Safety Equipment
REGULAR MAINTENANCE
Filter Elements Removal And Installation
Compressor Drive Belt Inspection
Cleaning The Condenser
BASIC TROUBLESHOOTING
Poor A/C Performance
Cleaning The A/C Evaporator Coil & Heater Coil
Receiver/Drier Sight Glass Inspection
Compressor Drive Belt Inspection
Checking The Electrical System
Engine Coolant Bypassing The Heater Valve
Heater Valve Not Opening Or Closing
GENERAL AIR CONDITIONING SERVICE GUIDELINES
Compressor Oil
Compressor Oil Check
Component Replacement And Refrigeration Leaks
SYSTEM TROUBLESHOOTING CHART
Gauge Pressure Related Troubleshooting
Troubleshooting Tree
TEMPERATURE/PRESSURE
Chart
AIR CONDITIONING SERVICE
Chart
SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
Charging Procedure With A Manifold Gauge Set
Charging Procedure
COMPRESSOR
Removal And Installation
Compressor Clutch Disassembly
CONDENSER
Removal And Installation
RECEIVER/DRIER
Removal And Installation
PRESSURE RELIEF VALVE
Removal and Installation
PRESSURE SWITCH
Removal And Installation
EVAPORATOR/HEATER UNIT
Removal And Installation
Disassembly And Assembly
THERMOSTAT
Removal And Installation
EXPANSION VALVE
Removal And Installation
EVAPORATOR
Removal And Installation
HEATER COIL
Removal And Installation With A/C
Removal And Installation Without A/C
HEATER/AC FAN
Removal And Installation
Disassembly And Assembly
Wire Connector Removal And Installation
HEATER VALVE
Removal And Installation
Disassembly And Assembly
SPECIFICATIONS
LOADER SPECIFICATIONS
Machine Dimensions
Performance
Controls
Engine
Hydraulic System
Electrical
Drive System
Capacities
Tires
ENGINE SPECIFICATIONS
General
Fuel System
Valves, Valve Guide And Seat Insert
Piston And Rings
Connecting Rod
Cylinder Head And Block
Crankshaft And Main Bearings
Camshaft And Bearings
Oil Pump
LOADER TORQUE
Specifications
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General Metric Bolts
HYDRAULIC CONNECTION SPECIFICATIONS
O-ring Face Seal Connection
Straight Thread O-ring Fitting
Tubelines And Hoses
Flare Fitting
O-ring Flare Fitting
Port Seal Fitting
HYDRAULIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion
SERVICE MANUAL REVISION
A220-1
A220-2
A220-3
A220-4
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Bobcat A220 TURBO - HIGH FLOW Skid-Steer Loader Repair Service Manual - 6901245.pdf
Source : Sitelux.com