Bobcat S220 Skid-Steer Loaders Repair Service Manuals + Operation & Maintenance Manuals

Complete repair service manual with electrical wiring diagrams for Bobcat S220 Skid-Steer Loaders, with workshop information to maintain, diagnose, repair, and service like professional mechanics.

Bobcat S220 Skid-Steer Loaders workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

6902446 (12-06) - S220 Turbo, S220 Turbo High Flow Operation & Maintenance Manual.pdf
6902447 (3-06) - S220 Turbo, S220 Turbo High Flow Service Manual.pdf
6902447 (6-12) - S220 Turbo, S220 Turbo High Flow Service Manual.pdf
6902696 (5-12) - S220 Turbo, S220 Turbo High Flow Operation & Maintenance Manual.pdf
6902696 (12-06) - S220 Turbo, S220 Turbo High Flow Operation & Maintenance Manual.pdf
6902722 (2-06) - S220 Turbo, S220 Turbo High Flow Service Manual.pdf
6902722 (06-12) - S220 Turbo, S220 Turbo High Flow Service Manual.pdf
6904152 (5-08) - S220 Skid-Steer Loader Operation & Maintenance Manual.pdf
6904154 (3-09) - S220 Skid-Steer Loader Service Manual.pdf
6904176 (5-12) - S220 Turbo, S220 Turbo High Flow Operation & Maintenance Manual.pdf
6904176 (12-06) - S220 Turbo, S220 Turbo High Flow Operation & Maintenance Manual.pdf
6986679 (3-09) - S220 Skid-Steer Loader Service Manual.pdf
6986970 (4-08) - S220 Skid-Steer Loader Operation & Maintenance Manual.pdf
6986989 (4-10) - S220 Skid-Steer Loader Operation & Maintenance Manual.pdf
6987038 (7-14) - S220 Skid-Steer Loader Service Manual.pdf
6987038 (11-10) - S220 Skid-Steer Loader Service Manual.pdf

Total Pages: 9,123 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

6902446 (12-06) - S220 Turbo, S220 Turbo High Flow Operation & Maintenance Manual....2
  OPERATOR SAFETY WARNINGS....4
  CONTENTS....6
  FOREWORD....8
    BOBCAT COMPANY IS ISO9001:2000 CERTIFIED....10
    MOTOR OIL....10
    SERIAL NUMBER LOCATIONS....11
      Loader Serial Number....11
      Engine Serial Number....11
    DELIVERY REPORT....11
    MACHINE IDENTIFICATION....12
    FEATURES, ACCESSORIEs and attachments....13
      Standard Items....13
      Options and Accessories....13
      Buckets Available....14
      Attachments....14
  SAFETY....16
    SAFETY INSTRUCTIONS....18
      Before Operation....18
      Safe Operation Is The Operator?s Responsibility....19
      Safe Operation Needs A Qualified Operator....19
      Fire Prevention....20
    MACHINE SIGNS (DECALS)....21
  OPERATING INSTRUCTIONS....24
    INSTRUMENT PANEL IDENTIFICATION....28
      Left Panel....28
      Right Panel (Standard - With Key Switch)....29
      Right Panel (Deluxe - With Keyless Start)....30
      Option And Field Accessory Panels (If Equipped)....32
      Cab Light....33
    LIFT ARM BY-PASS CONTROL....33
      Operation....33
    TRACTION LOCK OVERRIDE....33
      Operation....33
    ENGINE SPEED CONTROL....34
      Operation....34
    PARKING BRAKE....34
      Operation....34
    DRIVING AND STEERING THE LOADER....35
      Available Controls Configurations....35
      Operation (Standard and ACS)....35
      Operation (SJC in ?H? Control Pattern)....36
      Operation (SJC in ?ISO? Control Pattern)....37
    STOPPING THE BOBCAT LOADER....38
      Using The Steering Levers Or Joysticks....38
    SEAT BAR RESTRAINT SYSTEM....38
      Operation....38
    HYDRAULIC CONTROLS....39
      Operation....39
      Standard Controls (Also ACS in Foot Pedal Mode)....39
      Advanced Control System (ACS) in HAND Control Mode....40
      Selectable Joystick Control (SJC) - ?H? Control Pattern....41
      Selectable Joystick Control (SJC) - ?ISO? Control Pattern....41
      Quick Couplers....42
      Releasing Hydraulic Pressure (Loader and Attachment)....42
      Auxiliary Hydraulics Button - VARIABLE FLOW....42
      Auxiliary Hydraulics Button - MAXIMUM FLOW ONLY....42
      Auxiliary Hydraulics Button - DISENGAGE....42
      FRONT Auxiliary Hydraulics Operation - VARIABLE FLOW....43
      FRONT Auxiliary Hydraulics Operation - MAXIMUM FLOW....43
      FRONT Auxiliary Hydraulics Operation - CONTINUOUS FLOW....43
      REAR Auxiliary Hydraulics Operation (If Equipped)....43
      High-Flow Hydraulics Operation (If Equipped)....44
      Attachment Control Device (ACD) (If Equipped)....44
      Bucket Position Valve Operation (If Equipped)....45
    DAILY INSPECTION....46
      Daily Inspection and Maintenance....46
    PRE-STARTING PROCEDURES....47
      Before Starting The Engine....47
    STARTING THE ENGINE (STANDARD PANEL, KEY SWITCH)....49
      Procedure....49
    STARING THE ENGINE (DELUXE PANEL, KEYLESS START)....51
      Procedure....51
      Cold Temperature Starting....52
    WARMING THE HYDRAULIC/HYDROSTATIC SYSTEM....53
      Procedure....53
    STOPPING THE ENGINE....53
      Procedure....53
    MONITORING THE DISPLAY PANEL....54
      Standard Panel....54
      Deluxe Panel....54
      WARNING and SHUTDOWN....54
    ATTACHMENTS AND BUCKETS....55
      Choosing The Correct Bucket....55
      Pallet Forks....56
      Hand Lever Bob-Tach - Installing The Bucket Or Attachment....56
      Hand Lever Bob-Tach - Removing The Bucket Or Attachment....58
      Power Bob-Tach - Installing The Bucket Or Attachment....59
      Power Bob-Tach - Removing The Bucket Or Attachment....60
    OPERATING PROCEDURE....61
      Operating With A Full Bucket....61
      Operating With An Empty Bucket....62
      Foot Pedal Machines....63
      Hand Control Machines (Includes ACS)....65
      Selectable Joystick Control (SJC) with ?ISO? Pattern Selected....67
    PARKING THE BOBCAT LOADER....69
      Procedure....69
    TRANSPORTING THE BOBCAT LOADER....70
      Loading Onto Transport Vehicle....70
      Fastening To Transport Vehicle....70
    TOWING THE LOADER....71
      Towing Procedure....71
  PREVENTIVE MAINTENANCE....72
    MAINTENANCE SAFETY....74
    SERVICE SCHEDULE....76
      Chart....76
    LIFT ARM SUPPORT DEVICE....77
      Engaging The Lift Arm Support Device....77
      Disengaging The Lift Arm Support Device....78
    OPERATOR CAB....79
      Raising The Operator Cab....79
      Lowering The Operator Cab....80
      Cab Door Sensor (If Equipped)....80
      Emergency Exit....81
    SEAT BELT....82
      Inspection and Maintenance....82
    SEAT BAR RESTRAINT SYSTEM....83
      Inspecting The Seat Bar....83
      Maintaining The Seat Bar....83
    BOCAT INTERLOCK CONTROL SYSTEM (BICS)....84
      Inspecting The BICS Controller (Engine Stopped - Key ON)....84
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....84
      Inspecting The Seat Bar Sensor (Engine RUNNING)....84
      Inspecting The Traction Lock (Engine RUNNING)....84
      Inspecting The Lift Arm By-Pass Control....84
      Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....84
    REAR DOOR....85
      Opening And Closing The Rear Door....85
      Adjusting The Rear Door Latch....85
    REAR GRILL....86
      Removing....86
      Installing....86
    HEATING SYSTEM....86
      Cleaning And Maintenance....86
    AIR CLEANER SERVICE....87
      Replacing Filter Elements....87
    FUEL SYSTEM....88
      Fuel Specifications....88
      Filling The Fuel Tank....88
      Fuel Filter....89
      Removing Air From The Fuel System....89
    ENGINE LUBRICATION SYSTEM....90
      Checking Engine Oil....90
      Replacing The Oil And Filter....90
    ENGINE COOLING SYSTEM....91
      Cleaning The Cooling System....91
    ELECTRICAL SYSTEM....92
      Description....92
      Cleaning Battery and Terminals....92
      Fuse Location....92
      Using A Booster Battery (Jump Starting)....93
      Removing And Installing The Battery....95
    HYDRAULIC / HYDROSTATIC SYSTEM....96
      Checking And Adding Fluid....96
      Replacing Hydraulic/Hydrostatic Filter....96
      Replacing Hydraulic Fluid and Case Drain Filters....97
      Breather Cap....98
    TIRE MAINTENANCE....99
      Wheel Nuts....99
      Rotating....99
      Mounting....99
    FINAL DRIVE TRANSMISSION (CHAINCASE)....100
      Checking And Adding Oil....100
      Removing Oil From The Chaincase....100
    FAN GEARBOX....101
      Checking And Maintaining....101
    DRIVE BELT....101
      Adjusting The Drive Belt....101
      Replacing The Drive Belt....101
    BELT ADJUSTMENTS....102
      Adjusting The Alternator Belt....102
      Adjusting the Air Conditioner Belt....102
    LUBRICATING THE BOBCAT LOADER....103
      Lubrication Locations....103
    PIVOT PINS....104
      Inspection And Maintenance....104
    BOB-TACH (HAND LEVER)....105
      Inspection And Maintenance....105
    BOB-TACH (POWER) (OPTIONAL)....106
      Inspection And Maintenance....106
  SYSTEM SETUP & ANALYSIS....108
    BICS SYSTEM....110
      Troubleshooting Guide....110
    DIAGNOSTICS SERVICE CODES....111
      Display....111
      Number Codes List....112
    DELUXE INSTRUMENT PANEL SETUP....116
      Deluxe Panel Upgrade....116
      Deluxe Panel Setup....117
      Passwords (Deluxe)....117
    SHUTDOWN FEATURE....119
    SERVICE CLOCK RESET....119
  MACHINE SIGN TRANSLATIONS....120
    SERVICE SCHEDULE (6734534)....122
    WARNING (6728539)....123
    WARNING (6715944)....124
    DANGER (6702301)....125
    WARNING (6577754)....125
    DANGER (6702302)....125
    WARNING (6579528)....125
    WARNING (6717343)....126
    WARNING (6708941)....126
    IMPORTANT (6560573)....126
    WARNING (6732696)....126
  SPECIFICATIONS....128
    LOADER SPECIFICATIONS (S220)....130
      Machine Dimensions....130
      Performance....131
      Controls....131
      Engine....131
      Hydraulic System....132
      Electrical....132
      Drive System....133
      Capacities....133
      Tires....133
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS....134
  WARRANTY....136
6902447 (3-06) - S220 Turbo, S220 Turbo High Flow Service Manual....138
  MAINTENANCE SAFETY....140
  ALPHABETICAL INDEX....142
  CONTENTS....144
    FOREWORD....145
    SAFETY INSTRUCTIONS....148
      Fire Prevention....150
    SERIAL NUMBER LOCATION....152
      Loader Serial Number....152
      Engine Serial Number....152
    DELIVERY REPORT....153
    BOBCAT LOADER IDENTIFICATION....154
  SAFETY AND MAINTENANCE....156
    LIFTING AND BLOCKING THE LOADER....158
      Procedure....158
    LIFT ARM SUPPORT DEVICE....160
      Engaging The Lift Arm Support Device....160
      Disengaging The Lift Arm Support Device....161
    OPERATOR CAB....162
      Description....162
      Raising The Operator Cab....162
      Lowering The Operator Cab....163
      Emergency Exit....163
    TRANSPORTING THE BOBCAT LOADER....166
      Procedure....166
    TOWING THE LOADER....168
      Procedure For Non-Two-Speeds....168
    REMOTE START....170
      Procedure For Loader W/O Attachments Control Harness....170
      Procedure For Loader With Attachments Control Harness....171
      Procedure....172
    SERVICE SCHEDULE....174
      Chart....174
    AIR CLEANER SERVICE....176
      Replacing Filter Element....176
    ENGINE COOLING SYSTEM....178
      Cleaning Cooling System....178
    FUEL SYSTEM....180
      Fuel Specifications....180
      Filling The Fuel Tank....180
      Fuel Filter....180
      Removing Air From The Fuel System....181
    ENGINE LUBRICATION SYSTEM....182
      Checking Engine Oil....182
      Oil Chart....182
      Replacing Oil And Filter....182
    HYDRAULIC/HYDROSTATIC SYSTEM....184
      Checking And Adding Fluid....184
      Hydraulic/Hydrostatic Filter Replacement....184
      Replacing Hydraulic Fluid And Case Drain Filters....185
    FINAL DRIVE TRANSMISSION (CHAINCASE)....188
      Checking And Adding Oil....188
      Replacing The Oil....188
    FAN GEARBOX....190
      Checking And Adding Oil....190
    BOB-TACH....192
      Inspection And Maintenance....192
    POWER BOB-TACH....194
      Inspection And Maintenance....194
    LUBRICATING THE LOADER....196
      Procedure....196
    TIRE MAINTENANCE....198
      Wheel Nuts....198
      Tire Rotation....198
      Tire Mounting....198
  HYDRAULIC SYSTEM....200
    HYDRAULIC/HYDROSTATIC SCHEMATICS....206
    HYDRAULIC SYSTEM INFORMATION....222
      Troubleshooting....226
      Tightening Procedure....227
    CYLINDER (LIFT)....228
      Checking....228
      Removal And Installation....228
      Parts Identification....230
      Disassembly....231
      Assembly....232
    CYLINDER (TILT)....236
      Checking....236
      Removal And Installation....236
      Base Pin Removal And Installation....238
      Parts Identification....239
      Disassembly....240
      Assembly....241
    CYLINDER (POWER BOB-TACH)....244
      Checking....244
      Removal And Installation....245
      Parts Identification....246
      Disassembly....247
      Assembly....248
    MAIN RELIEF VALVE (FOOT CONTROL)....252
      Checking The Main Relief Valve At Front Aux. Hyd...252
      Removal And Installation....253
      Adjustment....253
    MAIN RELIEF VALVE (ACS)....254
      Checking The Main Relief Valve At Front Aux. Hyd...254
      Removal And Installation....255
      Adjustment....256
    MAIN RELIEF VALVE (SELECTABLE JOYSTICK CONTROL) (SJC)....258
      Checking The Main Relief Valve At Front Auxiliary Hydraulics....258
      Removal and Installation....259
      Adjustment....260
    HYDRAULIC CONTROL VALVE (FOOT CONTROL)....262
      Removal And Installation....262
      BICS? Valve, Removal And Installation....266
      BICS? Valve, Lift Arm By-Pass Orifice Removal And Installation....267
      BICS? Valve, Check Valve Removal And Installation....268
      Backslide, Lock Valve Removal And Installation....269
      BICS? Valve, Solenoid Removal And Installation....270
      BICS? Valve, Solenoid Testing....271
      Identification Chart....271
      Load Check Valve....272
      Main Relief Valve....273
      Port Relief Valve, Tilt Spool....273
      Port Relief Valve, Lift Spool....274
      Anti-Cavitation Valve/Port Relief Valve, Tilt Spool....274
      Anti-Cavitation Valve, Lift Spool....275
      Rubber Boot....275
      Lift And Tilt Lock Block....276
      Lift Spool And Detent Removal....277
      Lift Spool And Detent Disassembly....279
      Lift Spool And Detent Assembly....281
      Lift Spool And Detent Installation....285
      Tilt Spool Removal And Installation....285
      Tilt Spool Disassembly And Assembly....286
      Auxiliary Spool Removal And Installation....287
      Auxiliary Plug Removal And Installation....289
      Auxiliary Electric Solenoid Disassembly....290
      Port-Auxiliary Section Removal And Installation....291
      Cleaning And Inspection....291
    HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)....292
      Actuator Removal And Installation (In Loader)....292
      Actuator Removal And Installation (Out Of Loader)....295
      Removal And Installation....296
      BICS? Valve, Removal And Installation....300
      BICS? Valve, Lift Arm By-Pass Orifice Disassembly And Assembly....302
      BICS? Valve, Check Valve Disassembly And Assembly....303
      BICS? Valve, Lock Valve Disassembly And Assembly....304
      BICS? Valve, Solenoid Disassembly And Assembly....305
      BICS? Valve, Solenoid Testing....306
      Identification Chart....307
      Lift Base End Restrictor....308
      Load Check Valve....308
      Main Relief Valve....309
      Port Relief Valve....310
      Anti-Cavitation Valve/Port Relief Valve....311
      Anti-Cavitation Valve....312
      Lift Spool Removal....313
      Lift Spool Removal And Installation....314
      Lift and Tilt Spool Disassembly And Assembly....315
      Auxiliary Spool Removal And Installation....316
      Auxiliary Electric Solenoid Disassembly....317
      Port-Auxiliary Section Disassembly....318
      Cleaning And Inspection....318
    HYDRAULIC CONTROL VALVE (SELECTABLE JOYSTICK CONTROL) (SJC)....320
      Actuator Removal And Installation (In Loader)....320
      Actuator Removal And Installation (Out Of Loader)....323
      Removal And Installation....324
      BICS? Valve, Removal And Installation....328
      BICS? Valve, Lift Arm By-Pass Orifice Disassembly And Assembly....330
      BICS? Valve, Check Valve Disassembly And Assembly....331
      BICS? Valve, Lock Valve Disassembly And Assembly....332
      BICS? Valve, Solenoid Disassembly And Assembly....333
      BICS? Valve, Solenoid Testing....334
      Identification Chart....335
      Lift Base End Restrictor....336
      Load Check Valve....336
      Main Relief Valve....337
      Port Relief Valve....338
      Anti-Cavitation Valve/Port Relief Valve....339
      Anti-Cavitation Valve....340
      Lift Spool Removal....341
      Lift Spool Removal And Installation....342
      Lift and Tilt Spool Disassembly And Assembly....343
      Auxiliary Spool Removal And Installation....344
      Auxiliary Electric Solenoid Disassembly....345
      Port-Auxiliary Section Disassembly....346
      Cleaning And Inspection....346
    LIFT ARM BY-PASS CONTROL VALVE....348
      Inspecting....348
      Additional Inspection For Loaders W/Advanced Hand Controls....348
      Removal And Installation....348
      Disassembly And Assembly....349
    HYDRAULIC PUMP....350
      Check The Output Of The Hydraulic Pump....350
      Removal And Installation....351
      Identification....353
      Disassembly And Assembly....354
    HYDRAULIC PUMP (CHARGE)....362
      Check The Output Of The Hydraulic Pump....362
      Removal And Installation....365
      Disassembly And Assembly....365
    HYDRAULIC PUMP (HI FLOW)....366
      Hydraulic Pump Test....366
      Inline Hydraulic Pump Test (Standard)....367
      Inline Hydraulic Pump Test (High Flow)....369
      High Flow Relief Adjustment Procedure....371
      High Flow Relief Valve Removal and Installation....373
      Removal And Installation....375
      Identification....377
      Disassembly And Assembly....378
    HYDRAULIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC)....392
      Check The Output Of The Hydraulic Pump....392
      Removal And Installation....393
      Identification....395
      Disassembly And Assembly....396
    HYDRAULIC PUMP (HI-FLOW) (SELECTABLE JOYSTICK CONTROL) (SJC)....402
      Hydraulic Pump Test....402
      Inline Hydraulic Pump Test (Standard)....403
      Inline Hydraulic Pump Test (High Flow)....405
      High Flow Relief Adjustment Procedure....407
      High Flow Relief Valve Removal and Installation....409
      Removal And Installation....411
      Identification....413
      Disassembly And Assembly....414
    HYDRAULIC/HYDROSTATIC FILTER....424
      Housing Removal And Installation....424
      Mount Removal And Installation....425
    HYDRAULIC FLUID RESERVOIR....426
      Fluid Removal....426
      Removal And Installation....426
      Hydraulic Fluid Screen....429
    BUCKET POSITION VALVE....432
      Solenoid Removal And Installation....432
      Solenoid Testing....432
      Removal And Installation....433
      Disassembly And Assembly....433
    REAR AUXILIARY DIVERTER....436
      Removal and Installation....436
    REAR AUXILIARY DIVERTER (CONT?D)....437
      Disassembly And Assembly....438
      Solenoid Testing....443
      Inspection....443
    POWER BOB-TACH BLOCK (EARLY MODELS)....444
      Removal And Installation....444
      Disassembly And Assembly....445
    POWER BOB-TACH BLOCK (LATER MODELS)....454
      Removal And Installation....454
      Disassembly And Assembly....455
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....460
      Removal and Installation....460
      Disassembly And Assembly....460
  HYDROSTATIC SYSTEM....462
    HYDROSTATIC SYSTEM INFORMATION....464
      Troubleshooting....464
      Replenishing Valve Function....465
    HYDROSTATIC MOTOR....466
      Removal And Installation....466
      Parts Identification....467
      Disassembly....468
      Inspection....470
      Assembly....471
    HYDROSTATIC MOTOR (TWO-SPEED)....476
      Removal And Installation....476
      Parts Identification....478
      Disassembly....480
      Inspection....487
      Assembly....488
    HYDROSTATIC MOTOR CARRIER....496
      Removal and Installation....496
      Parts Identification....498
      Disassembly....499
      Assembly....500
    HYDROSTATIC MOTOR CARRIER (SELECTABLE JOYSTICK CONTROL) (SJC)....502
      Removal And Installation....502
      Parts Identification....503
      Assembly....506
    CHARGE PRESSURE SENDER....510
      Testing....510
    CHARGE PRESSURE SENDER (CONT?D)....511
      Removal and Installation....511
      Setting Charge Pressure....512
    HYDROSTATIC PUMP....514
      Removal And Installation....514
      Replenishing/High Pressure Relief Valve....516
      Parts Identification (Right Half)....517
      Parts Identification (Left Half)....519
      Hydraulic Pump Removal And Installation....521
      Pump Separation....521
      Disassembly....522
      Assembly....528
    HYDROSTATIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC)....536
      Pump Controller Removal And Installation....536
      Hydrostatic Pump Calibration....539
      Removal And Installation....543
      Parts Identification (Right Half)....546
      Parts Identification (Left Half)....548
      System Check Relief Valves (High Pressure Relief, Charge Check & By-Pass Valve)....550
      Charge Relief Valve....551
      Pump Separation....553
      Shaft Seal And Shaft Replacement....554
      Shaft Seal And Shaft Installation....556
      Charge Pump Removal....558
      Charge Pump Inspection....560
      Charge Pump Installation....561
      Disassembly....563
      Inspection....570
      Assembly....574
      Pump Neutral Adjustment....583
      Pump Controller Neutral Adjustment....586
    DRIVE BELT....590
      Shield Removal And Installation....590
      Adjustment....590
      Replacement....590
      Tensioner Pulley Removal And Installation....591
      Tensioner Pulley Tension Spring....593
    OIL COOLER (SEAL TO CONNECT) (STC)....594
      Hydraulic Oil Cooler Removal and Installation....594
    OIL COOLER (SEAL TO CONNECT) (STC) (CONT?D)....595
      Hydraulic Oil Cooler Removal and Installation (Cont,d)....595
  DRIVE SYSTEM....596
    BRAKE....598
      Disc Removal And Installation....598
    BRAKE (TWO-SPEED)....602
      Block Removal And Installation....602
      Block Disassembly And Assembly....603
    DRIVE COMPONENTS....608
      Axle Seal Removal And Installation....608
      Axle, Sprocket And Bearings Removal And Installation....610
      Drive Chain Removal And Installation....614
    CHAINCASE....616
      Front Chaincase Cover Removal And Installation....616
      Rear Chaincase Cover Removal And Installation....616
  MAIN FRAME....618
    SEAT BAR....620
      Removal And Installation....620
      Assembling Components....621
      Compression Spring Disassembly And Assembly....622
    OPERATOR CAB....624
      Gas Cylinder Removal And Installation (Dual Gas Spring)....624
      Gas Cylinder Removal And Installation (3rd Gas Spring)....626
      Gas Cylinder Bracket Disassembly And Assembly....628
      Removal And Installation....628
    OPERATOR SEAT....632
      Removal And Installation....632
      Seat Belt Removal And Installation....632
    OPERATOR SEAT (SUSPENSION)....634
      Removal And Installation....634
      Slide Rail Removal And Installation....635
      Cushion Removal And Installation....635
      Back Removal And Installation....636
      Shock Removal And Installation....637
      3-Point Seat Belt Removal And Installation....638
    BOB-TACH....640
      Removal And Installation....640
      Bob-Tach Lever And Wedge....642
    POWER BOB-TACH....644
      Removal And Installation....644
      Power Bob-Tach Lever And Wedge....646
      Pivot Pin Bushing And Seal Replacement....648
    LIFT ARMS....650
      Removal And Installation....650
    REAR GRILL....654
      Removal And Installation....654
    REAR DOOR....656
      Removal And Installation....656
      Adjusting The Rear Door Latch....657
    FUEL TANK....658
      Removal And Installation....658
      Fuel Level Sender....659
    CONTROL PEDALS....660
      Removal And Installation....660
      Pedal Adjustment....660
    CONTROL PEDALS (ACS)....662
      Foot Sensor Removal And Installation....662
      Foot Pedal Removal And Installation....663
      Foot Pedal Linkage Disassembly And Assembly....663
    CONTROL PANEL....664
      Removal And Installation....664
      Shock Removal And Installation....666
      Shaft Removal And Installation....666
      Shaft Disassembly And Assembly....666
      Linkage Removal And Installation....668
      Linkage Neutral Adjustment....671
    CONTROL PANEL (SELECTABLE JOYSTICK CONTROL) (SJC)....678
      Removal And Installation....678
    CONTROL HANDLE....682
      Lever Removal And Installation....682
      Steering Lever Boot....682
    CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL....684
      Components Identification....684
      Handle Sensor Removal And Installation....684
      Control Handle Removal And Installation....687
      Control Handle Disassembly And Assembly....688
      Control Lever Removal And Installation....689
      Control Lever Boot....690
    CONTROL HANDLE (SELECTABLE JOYSTICK CONTROL) (SJC)....692
      Joystick Testing (Right & Left)....692
      Joystick Removal (Right & Left)....693
      Joystick Boot Removal (Right & Left)....694
      Lever Assembly Removal (Right & Left)....694
    INSIDE ACCESS PANEL....696
      Removal And Installation (Left)....696
      Removal And Installation (Right)....696
    INSIDE ACCESS PANEL (SELECTABLE JOYSTICK CONTROL) (SJC)....698
      Panel Removal (Right)....698
      Panel Removal (Left)....701
  ELECTRICAL SYSTEM & ANALYSIS....702
    ELECTRICAL SCHEMATICS....706
    ELECTRICAL SYSTEM INFORMATION....711
      Troubleshooting....713
      Description....714
      Fuse Location....716
      Relay Switch Location....716
      Solenoid Test....717
    BATTERY....719
      Removal And Installation....719
      Servicing The Electrical System....721
      Using A Booster Battery (Jump Starting)....722
    ALTERNATOR....723
      Adjusting The Alternator Belt....723
      Alternator Identification....723
      Charging System Check....724
      Alternator Voltage Test....725
      Low Voltage Test....725
      High Voltage Test....726
      Removal And Installation....726
      Rectifier Continuity (Diode) Test....727
      Alternator Regulator Test....728
      Disassembly....729
      Stator Continuity Test....729
      Stator Ground Test....729
      Rotor Continuity Test....730
      Rotor Ground Test....730
      Assembly....730
    STARTER....731
      Removal And Installation....731
      Parts Identification....732
      Checking....733
      Disassembly And Assembly....734
      Inspection And Repair....737
      No Load Test....740
    INSTRUMENT PANEL....741
      Left Panel....741
      Right Panel (Standard) (With Key Switch)....742
      Right Panel (Deluxe) (With Keyless Start)....743
      Right Panel Setup Display Options (Deluxe)....745
      Deluxe Panel Setup....746
      Passwords (Deluxe)....746
      Option And Field Accessory Panels (If Equipped)....748
      Standard Panel Removal And Installation (Right Side)....749
      Deluxe Panel Removal And Installation (Right Side)....750
      Standard & Deluxe Panel Removal And Installation (Left Side)....751
      Front Accessory Panel Removal And Installation....752
    LIGHTS....753
      Front Removal And Installation....753
      Rear Removal And Installation....753
    CONTROLLER (BOBCAT)....756
      Identification Chart....756
      Removal And Installation....758
    CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC)....759
      Removal....759
      Identification Chart....762
    SPEED SENSOR (SELECTABLE JOYSTICK CONTROL) (SJC)....765
      Testing....765
      Removal....766
    DIAGNOSTICS SERVICE CODES....769
      Display....769
      Number Codes List....770
    BICS? SYSTEM....775
      Inspecting The fBICS? Controller (Engine STOPPED - Key ON)....775
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....775
      Inspecting The Seat Bar Sensor (Engine RUNNING)....775
      Inspecting The Traction Lock (Engine RUNNING)....775
      Inspecting The Lift Arm By-Pass Control....776
      Additional Inspection For Loaders With Advanced Controls System (ACS) or Selectable Joystick Control (SJC)....776
      Troubleshooting....777
      Troubleshooting Guide....778
    SEAT BAR SENSOR....779
      Troubleshooting Chart....779
      Test....780
      Removal And Installation....781
      BICS? Circuit Test....782
    TRACTION LOCK....783
      Troubleshooting....783
      Removal And Installation (Single Speed)....784
      Description Of The Control System (Two Speed)....785
      Inspecting The Control System (Two Speed)....785
    ADVANCED CONTROL SYSTEM (ACS)....787
      Components Identification....787
      Troubleshooting Guide....789
      Controller, Connector And Wire Identification....790
      ACS Controller Removal And Installation....791
      Handle Sensor Connector....792
      Switch Handle Removal....793
      Switch Handle Installation....795
      Actuators Disassembly And Assembly....798
      Handle Lock Solenoid Removal And Installation....799
      Handle Lock Solenoid Disassembly And Assembly....799
      Handle Lock Solenoid Connector....800
      Calibration Of The ACS System....800
      Switchable Hand/Foot Controls Calibration Procedure....801
      Hand Controls Only Calibration Procedure....802
      Foot Sensor Disassembly And Assembly....803
      Foot Sensor Connector....804
      Foot Lock Solenoid Removal And Installation....804
      Foot Lock Solenoid Connector....805
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE....807
      Controls Identification Chart....807
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC)....809
      Controls Identification Chart....809
    SERVICE PC (LAPTOP COMPUTER)....813
      Connecting The Service PC To Remote Start Tool....813
    LIFT AND TILT ACTUATOR CALIBRATION (SELECTABLE JOYSTICK CONTROL) (SJC)....815
      Procedure....815
    FLYWHEEL RPM SENSOR....817
      Adjustment....817
  ENGINE SERVICE....819
    TROUBLESHOOTING....823
      Chart....823
    ENGINE SPEED CONTROL....825
      Removal And Installation....825
      Speed Control Cable....826
    ENGINE SPEED CONTROL (SELECTABLE JOYSTICK CONTROL) (SJC)....829
      Removal....829
      Disassembly....831
      Speed Control Cable....832
    MUFFLER....833
      Removal And Installation....833
    AIR CLEANER....835
      Housing Removal And Installation....835
    RADIATOR....837
      Removal And Installation....837
      Mount Removal....839
    COOLING FAN....841
      Drive Tension Pulley Removal And Installation....841
      Gearbox/Blower Housing Removal And Installation....842
      Blower Removal And Installation....843
      Gearbox Parts Identification....845
      Gearbox Disassembly....846
      Gearbox Assembly....851
      Gearbox, Checking Backlash....856
    ENGINE....859
      Removal And Installation....859
      Mount Replacement....866
      Removal And Installation Tools....867
    FLYWHEEL AND HOUSING....869
      Flywheel Removal And Installation....869
      Ring Gear Removal And Installation....869
      Flywheel Housing Removal And Installation....869
    RECONDITIONING THE ENGINE....871
      Engine Tools Identification Chart....871
      Compression Pressure....875
      Cylinder Head Clearance....875
      Valve Cover And Injector Nozzle Removal And Installation....876
      Rocker Arm And Push Rod Disassembly And Assembly....878
      Valve Clearance....878
      Cylinder Head And Tappet Disassembly And Assembly....879
      Selecting Cylinder Head Gasket Disassembly And Assembly....880
      Valve Disassembly And Assembly....881
      Engine Timing (TDC)....882
      Injection Pump Assembly Removal....883
      Injection Pump Assembly Installation....886
      Injection Pump Removal and Installation....889
      Injection Pump Timing....891
      Fan Drive Pulley Disassembly And Assembly....894
      Water Pump Disassembly And Assembly....894
      Gearcase Cover Disassembly And Assembly....895
      Idle Gear And Camshaft Disassembly And Assembly....895
      Gearcase Plate Disassembly And Assembly....896
      Oil Pan And Oil Strainer Disassembly And Assembly....896
      Connecting Rod Cap Disassembly And Assembly....897
      Piston Disassembly And Assembly....898
      Piston Ring And Connecting Rod Disassembly And Assembly....899
      Bearing Case Cover Disassembly And Assembly....901
      Flywheel Housing Disassembly And Assembly....902
      Crankcase No. 2 Disassembly And Assembly....902
      Crankcase No. 1 And No. 2 Disassembly And Assembly....903
      Crankshaft Disassembly And Assembly....903
      Cylinder Head Surface Flatness....903
      Cylinder Head Flaw....904
      Valve Recessing....904
      Valve Lapping....905
      Clearance Between Valve Stem And Valve Guide....905
      Replacing Valve Guide....906
      Correcting Valve And Valve Seat....906
      Free Length And Tilt Of Valve Spring....907
      Valve Spring Setting Load....907
      Oil Clearance Between Rocker Arm Shaft And Bearing....908
      Oil Clearance Between Tappet And Tappet Guide Bore....908
      Timing Gear Backlash....909
      Idler Gear Side Clearance....909
      Camshaft Side Clearance....910
      Camshaft Alignment....910
      Cam Height....910
      Oil Clearance Of Camshaft Journal....911
      Oil Clearance Between Idler Gear Shaft And Idler Gearing Bushing....911
      Replacing Idler Gear Bushing....912
      Piston Pin Bore I.D...913
      Oil Clearance Between Piston Pin And Small End Bushing....913
      Replacing Small End Bushing....914
      Clearance Between Piston Ring And Groove....914
      Piston Ring Gap....915
      Connecting Rod Alignment....915
      Crankshaft Side Clearance....916
      Crankshaft Alignment....917
      Oil Clearance Between Crankpin And Crankpin Bearing....917
      Oil Clearance Between Crankshaft Journal And Crankshaft Bearing....919
      Replacing Crankshaft Sleeve....920
      Cylinder Bore I.D...920
      Correcting Cylinder (Oversize +0.5 mm)....921
      Engine Oil Pressure....921
      Rotor Lobe Clearance....922
      Clearance Between Outer Rotor And Pump Body....922
      Thermostat Valve Opening Temperature....922
      Radiator Water Leakage....923
      Radiator Cap Air Leakage....923
      Thermostat Assembly....923
      Intake Air Heater....924
      Checking the Turbo Charger....925
      Compressor Side....925
      Wheel Shaft....925
      Axial Clearance....926
      Radial Clearance....926
      Air Cleaner, Intake Pipe, Inlet Pipe And Muffler....926
      Oil Pipe....927
      Turbocharger....927
  HEATING, VENTILATION, AIR CONDITIONING....929
    AIR CONDITIONING SYSTEM FLOW....932
      Principles....932
      Chart....933
    COMPONENTS....935
      Identification....935
    SAFETY....939
      Safety Equipment....939
    REGULAR MAINTENANCE....941
      Filter Elements Removal And Installation....941
      Compressor Drive Belt Inspection....942
      Cleaning The Condenser....943
    BASIC TROUBLESHOOTING....945
      Poor A/C Performance....945
      Cleaning The A/C Evaporator Coil & Heater Coil....946
      Compressor Drive Belt Inspection....946
      Checking The Electrical System....947
      Engine Coolant By-Passing The Heater Valve....955
      Heater Valve Not Opening Or Closing....956
    GENERAL AIR CONDITIONING SERVICE GUIDELINES....957
      Compressor Oil....957
      Compressor Oil Check....958
      Component Replacement And Refrigeration Leaks....959
    SYSTEM TROUBLESHOOTING CHART....961
      Gauge Pressure Related Troubleshooting....962
      Troubleshooting Tree....964
    TEMPERATURE/PRESSURE....969
      Chart....969
    AIR CONDITIONING SERVICE....971
      Chart....971
    SYSTEM CHARGING AND RECLAMATION....973
      Reclamation Procedure....973
      Charging Procedure With A Manifold Gauge Set....975
      Charging Procedure....976
    COMPRESSOR....979
      Removal And Installation....979
      Compressor Clutch Disassembly....980
    CONDENSER....985
      Removal And Installation....985
    RECEIVER/DRIER....987
      Removal And Installation....987
    PRESSURE RELIEF VALVE....989
      Removal And Installation....989
    PRESSURE SWITCH....991
      Removal And Installation....991
    EVAPORATOR/HEATER UNIT....993
      Removal And Installation....993
      Disassembly And Assembly....994
    THERMOSTAT....995
      Removal And Installation....995
    EXPANSION VALVE....997
      Removal And Installation....997
    EVAPORATOR....999
      Removal And Installation....999
    HEATER COIL....1001
      Removal And Installation With A/C....1001
      Removal And Installation Without A/C....1002
    BLOWER FAN....1003
      Removal And Installation....1003
      Disassembly And Assembly....1004
      Wire Connector Removal and Installation....1006
    HEATER VALVE....1009
      Removal and Installation....1009
      Disassembly And Assembly....1010
  SPECIFICATIONS....1013
    LOADER SPECIFICATIONS (S220)....1015
      Machine Dimensions....1015
      Performance....1016
      Controls....1016
      Engine....1016
      Hydraulic System....1017
      Electrical....1017
      Drive System....1018
      Capacities....1018
      Tires....1018
    ENGINE SPECIFICATIONS....1019
      General....1019
      Fuel System....1019
      Valve And Valve Timing....1019
      Valve Spring....1020
      Piston And Piston Ring....1020
      Connecting Rod....1020
      Cylinder Head....1021
      Crankshaft....1021
      Cylinder Bore....1021
      Oil Pump....1021
      Rocker Arm....1022
      Tappet....1022
      Camshaft....1022
      Thermostat....1022
      Timing Gear....1023
      Intake Air Heater....1023
    TORQUE SPECIFICATIONS FOR BOLTS....1025
      Torque For General SAE Bolts....1025
      Torque For General Metric Bolts....1026
      Torque For Kubota Metric Engine Bolts....1027
      Tightening Torques For General Use Screws, Bolts And Nuts....1027
    HYDRAULIC CONNECTION SPECIFICATIONS....1029
      O-ring Face Seal Connection....1029
      Straight Thread O-ring Fitting....1030
      Tubelines And Hoses....1030
      Flare Fitting....1030
      O-ring Flare Fitting....1031
      Port Seal Fitting....1033
    HYDRAULIC FLUID SPECIFICATIONS....1035
      Specifications....1035
    CONVERSIONS....1037
      Decimal And Millimeter Equivalents....1037
  SMR....1039
    S220-1....1039
    S220-2....1041
    S220-3....1043
6902447 (6-12) - S220 Turbo, S220 Turbo High Flow Service Manual....1045
  MAINTENANCE SAFETY....1047
  ALPHABETICAL INDEX....1049
  CONTENTS....1051
    FOREWORD....1052
    SAFETY INSTRUCTIONS....1055
      Fire Prevention....1057
    SERIAL NUMBER LOCATION....1059
      Loader Serial Number....1059
      Engine Serial Number....1059
    DELIVERY REPORT....1060
    BOBCAT LOADER IDENTIFICATION....1061
  SAFETY AND MAINTENANCE....1063
    LIFTING AND BLOCKING THE LOADER....1065
      Procedure....1065
    LIFT ARM SUPPORT DEVICE....1067
      Engaging The Lift Arm Support Device....1067
      Disengaging The Lift Arm Support Device....1068
    OPERATOR CAB....1069
      Description....1069
      Raising The Operator Cab....1069
      Lowering The Operator Cab....1070
      Emergency Exit....1070
    TRANSPORTING THE BOBCAT LOADER....1073
      Procedure....1073
    TOWING THE LOADER....1075
      Procedure For Non-Two-Speeds....1075
    REMOTE START....1077
      Procedure For Loader W/O Attachments Control Harness....1077
      Procedure For Loader With Attachments Control Harness....1078
      Procedure....1079
    SERVICE SCHEDULE....1081
      Chart....1081
    AIR CLEANER SERVICE....1083
      Replacing Filter Element....1083
    ENGINE COOLING SYSTEM....1085
      Cleaning Cooling System....1085
    FUEL SYSTEM....1087
      Fuel Specifications....1087
      Filling The Fuel Tank....1087
      Fuel Filter....1087
      Removing Air From The Fuel System....1088
    ENGINE LUBRICATION SYSTEM....1089
      Checking Engine Oil....1089
      Oil Chart....1089
      Replacing Oil And Filter....1089
    HYDRAULIC/HYDROSTATIC SYSTEM....1091
      Checking And Adding Fluid....1091
      Hydraulic/Hydrostatic Filter Replacement....1091
      Replacing Hydraulic Fluid And Case Drain Filters....1092
    FINAL DRIVE TRANSMISSION (CHAINCASE)....1095
      Checking And Adding Oil....1095
      Replacing The Oil....1095
    FAN GEARBOX....1097
      Checking And Adding Oil....1097
    BOB-TACH....1099
      Inspection And Maintenance....1099
    POWER BOB-TACH....1101
      Inspection And Maintenance....1101
    LUBRICATING THE LOADER....1103
      Procedure....1103
    TIRE MAINTENANCE....1105
      Wheel Nuts....1105
      Tire Rotation....1105
      Tire Mounting....1105
  HYDRAULIC SYSTEM....1107
    HYDRAULIC/HYDROSTATIC SCHEMATICS....1113
    HYDRAULIC SYSTEM INFORMATION....1129
      Troubleshooting....1133
      Tightening Procedure....1134
    CYLINDER (LIFT)....1135
      Checking....1135
      Removal And Installation....1135
      Parts Identification....1137
      Disassembly....1138
      Assembly....1139
    CYLINDER (TILT)....1143
      Checking....1143
      Removal And Installation....1143
      Base Pin Removal And Installation....1145
      Parts Identification....1146
      Disassembly....1147
      Assembly....1148
    CYLINDER (POWER BOB-TACH)....1151
      Checking....1151
      Removal And Installation....1152
      Parts Identification....1153
      Disassembly....1154
      Assembly....1155
    MAIN RELIEF VALVE (FOOT CONTROL)....1159
      Checking The Main Relief Valve At Front Aux. Hyd...1159
      Removal And Installation....1160
      Adjustment....1160
    MAIN RELIEF VALVE (ACS)....1161
      Checking The Main Relief Valve At Front Aux. Hyd...1161
      Removal And Installation....1162
      Adjustment....1163
    MAIN RELIEF VALVE (SELECTABLE JOYSTICK CONTROL) (SJC)....1165
      Checking The Main Relief Valve At Front Auxiliary Hydraulics....1165
      Removal and Installation....1166
      Adjustment....1167
    HYDRAULIC CONTROL VALVE (FOOT CONTROL)....1169
      Removal And Installation....1169
      BICS? Valve, Removal And Installation....1173
      BICS? Valve, Lift Arm By-Pass Orifice Removal And Installation....1174
      BICS? Valve, Check Valve Removal And Installation....1175
      Backslide, Lock Valve Removal And Installation....1176
      BICS? Valve, Solenoid Removal And Installation....1177
      BICS? Valve, Solenoid Testing....1178
      Identification Chart....1178
      Load Check Valve....1179
      Main Relief Valve....1180
      Port Relief Valve, Tilt Spool....1180
      Port Relief Valve, Lift Spool....1181
      Anti-Cavitation Valve/Port Relief Valve, Tilt Spool....1181
      Anti-Cavitation Valve, Lift Spool....1182
      Rubber Boot....1182
      Lift And Tilt Lock Block....1183
      Lift Spool And Detent Removal....1184
      Lift Spool And Detent Disassembly....1186
      Lift Spool And Detent Assembly....1188
      Lift Spool And Detent Installation....1192
      Tilt Spool Removal And Installation....1192
      Tilt Spool Disassembly And Assembly....1193
      Auxiliary Spool Removal And Installation....1194
      Auxiliary Plug Removal And Installation....1196
      Auxiliary Electric Solenoid Disassembly....1197
      Port-Auxiliary Section Removal And Installation....1198
      Cleaning And Inspection....1198
    HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)....1199
      Actuator Removal And Installation (In Loader)....1199
      Actuator Removal And Installation (Out Of Loader)....1202
      Removal And Installation....1203
      BICS? Valve, Removal And Installation....1207
      BICS? Valve, Lift Arm By-Pass Orifice Disassembly And Assembly....1209
      BICS? Valve, Check Valve Disassembly And Assembly....1210
      BICS? Valve, Lock Valve Disassembly And Assembly....1211
      BICS? Valve, Solenoid Disassembly And Assembly....1212
      BICS? Valve, Solenoid Testing....1213
      Identification Chart....1214
      Lift Base End Restrictor....1215
      Load Check Valve....1215
      Main Relief Valve....1216
      Port Relief Valve....1217
      Anti-Cavitation Valve/Port Relief Valve....1218
      Anti-Cavitation Valve....1219
      Lift Spool Removal....1220
      Lift Spool Removal And Installation....1221
      Lift and Tilt Spool Disassembly And Assembly....1222
      Auxiliary Spool Removal And Installation....1223
      Auxiliary Electric Solenoid Disassembly....1224
      Port-Auxiliary Section Disassembly....1225
      Cleaning And Inspection....1225
    HYDRAULIC CONTROL VALVE (SELECTABLE JOYSTICK CONTROL) (SJC)....1227
      Actuator Removal And Installation (In Loader)....1227
      Actuator Removal And Installation (Out Of Loader)....1230
      Removal And Installation....1231
      BICS? Valve, Removal And Installation....1235
      BICS? Valve, Lift Arm By-Pass Orifice Disassembly And Assembly....1237
      BICS? Valve, Check Valve Disassembly And Assembly....1238
      BICS? Valve, Lock Valve Disassembly And Assembly....1239
      BICS? Valve, Solenoid Disassembly And Assembly....1240
      BICS? Valve, Solenoid Testing....1241
      Identification Chart....1242
      Lift Base End Restrictor....1243
      Load Check Valve....1243
      Main Relief Valve....1244
      Port Relief Valve....1245
      Anti-Cavitation Valve/Port Relief Valve....1246
      Anti-Cavitation Valve....1247
      Lift Spool Removal....1248
      Lift Spool Removal And Installation....1249
      Lift and Tilt Spool Disassembly And Assembly....1250
      Auxiliary Spool Removal And Installation....1251
      Auxiliary Electric Solenoid Disassembly....1252
      Port-Auxiliary Section Disassembly....1253
      Cleaning And Inspection....1253
    LIFT ARM BY-PASS CONTROL VALVE....1255
      Inspecting....1255
      Additional Inspection For Loaders W/Advanced Hand Controls....1255
      Removal And Installation....1255
      Disassembly And Assembly....1256
    HYDRAULIC PUMP....1257
      Check The Output Of The Hydraulic Pump....1257
      Removal And Installation....1258
      Identification....1260
      Disassembly And Assembly....1261
    HYDRAULIC PUMP (CHARGE)....1269
      Check The Output Of The Hydraulic Pump....1269
      Removal And Installation....1272
      Disassembly And Assembly....1272
    HYDRAULIC PUMP (HI FLOW)....1273
      Hydraulic Pump Test....1273
      Inline Hydraulic Pump Test (Standard)....1274
      Inline Hydraulic Pump Test (High Flow)....1276
      High Flow Relief Adjustment Procedure....1278
      High Flow Relief Valve Removal and Installation....1280
      Removal And Installation....1282
      Identification....1284
      Disassembly And Assembly....1285
    HYDRAULIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC)....1299
      Check The Output Of The Hydraulic Pump....1299
      Removal And Installation....1300
      Identification....1302
      Disassembly And Assembly....1303
    HYDRAULIC PUMP (HI-FLOW) (SELECTABLE JOYSTICK CONTROL) (SJC)....1309
      Hydraulic Pump Test....1309
      Inline Hydraulic Pump Test (Standard)....1310
      Inline Hydraulic Pump Test (High Flow)....1312
      High Flow Relief Adjustment Procedure....1314
      High Flow Relief Valve Removal and Installation....1316
      Removal And Installation....1318
      Identification....1320
      Disassembly And Assembly....1321
    HYDRAULIC/HYDROSTATIC FILTER....1331
      Housing Removal And Installation....1331
      Mount Removal And Installation....1332
    HYDRAULIC FLUID RESERVOIR....1333
      Fluid Removal....1333
      Removal And Installation....1333
      Hydraulic Fluid Screen....1336
    BUCKET POSITION VALVE....1339
      Solenoid Removal And Installation....1339
      Solenoid Testing....1339
      Removal And Installation....1340
      Disassembly And Assembly....1340
    REAR AUXILIARY DIVERTER....1343
      Removal and Installation....1343
    REAR AUXILIARY DIVERTER (CONT?D)....1344
      Disassembly And Assembly....1345
      Solenoid Testing....1350
      Inspection....1350
    POWER BOB-TACH BLOCK (EARLY MODELS)....1351
      Removal And Installation....1351
      Disassembly And Assembly....1352
    POWER BOB-TACH BLOCK (LATER MODELS)....1361
      Removal And Installation....1361
      Disassembly And Assembly....1362
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....1367
      Removal and Installation....1367
      Disassembly And Assembly....1367
  HYDROSTATIC SYSTEM....1369
    HYDROSTATIC SYSTEM INFORMATION....1371
      Troubleshooting....1371
      Replenishing Valve Function....1372
    HYDROSTATIC MOTOR....1373
      Removal And Installation....1373
      Parts Identification....1374
      Disassembly....1375
      Inspection....1377
      Assembly....1378
    HYDROSTATIC MOTOR (TWO-SPEED)....1383
      Removal And Installation....1383
      Parts Identification....1385
      Disassembly....1387
      Inspection....1394
      Assembly....1395
    HYDROSTATIC MOTOR CARRIER....1403
      Removal and Installation....1403
      Parts Identification....1405
      Disassembly....1406
      Assembly....1407
    HYDROSTATIC MOTOR CARRIER (SELECTABLE JOYSTICK CONTROL) (SJC)....1409
      Removal And Installation....1409
      Parts Identification....1410
      Assembly....1413
    CHARGE PRESSURE SENDER....1417
      Testing....1417
    CHARGE PRESSURE SENDER (CONT?D)....1418
      Removal and Installation....1418
      Setting Charge Pressure....1419
    HYDROSTATIC PUMP....1421
      Removal And Installation....1421
      Replenishing/High Pressure Relief Valve....1423
      Parts Identification (Right Half)....1424
      Parts Identification (Left Half)....1426
      Hydraulic Pump Removal And Installation....1428
      Pump Separation....1428
      Disassembly....1429
      Assembly....1435
    HYDROSTATIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC)....1443
      Pump Controller Removal And Installation....1443
      Hydrostatic Pump Calibration....1446
      Removal And Installation....1450
      Parts Identification (Right Half)....1453
      Parts Identification (Left Half)....1455
      System Check Relief Valves (High Pressure Relief, Charge Check & By-Pass Valve)....1457
      Charge Relief Valve....1458
      Pump Separation....1460
      Shaft Seal And Shaft Replacement....1461
      Shaft Seal And Shaft Installation....1463
      Charge Pump Removal....1465
      Charge Pump Inspection....1467
      Charge Pump Installation....1468
      Disassembly....1470
      Inspection....1477
      Assembly....1481
      Pump Neutral Adjustment....1490
      Pump Controller Neutral Adjustment....1493
    DRIVE BELT....1497
      Shield Removal And Installation....1497
      Adjustment....1497
      Replacement....1497
      Tensioner Pulley Removal And Installation....1498
      Tensioner Pulley Tension Spring....1500
    OIL COOLER (SEAL TO CONNECT) (STC)....1501
      Hydraulic Oil Cooler Removal and Installation....1501
    OIL COOLER (SEAL TO CONNECT) (STC) (CONT?D)....1502
      Hydraulic Oil Cooler Removal and Installation (Cont,d)....1502
  DRIVE SYSTEM....1503
    BRAKE....1505
      Disc Removal And Installation....1505
    BRAKE (TWO-SPEED)....1509
      Block Removal And Installation....1509
      Block Disassembly And Assembly....1510
    DRIVE COMPONENTS....1515
      Axle Seal Removal And Installation....1515
      Axle, Sprocket And Bearings Removal And Installation....1517
      Drive Chain Removal And Installation....1521
    CHAINCASE....1523
      Front Chaincase Cover Removal And Installation....1523
      Rear Chaincase Cover Removal And Installation....1523
  MAIN FRAME....1525
    SEAT BAR....1527
      Removal And Installation....1527
      Assembling Components....1528
      Compression Spring Disassembly And Assembly....1529
    OPERATOR CAB....1531
      Gas Cylinder Removal And Installation (Dual Gas Spring)....1531
      Gas Cylinder Removal And Installation (3rd Gas Spring)....1533
      Gas Cylinder Bracket Disassembly And Assembly....1535
      Removal And Installation....1535
    OPERATOR SEAT....1539
      Removal And Installation....1539
      Seat Belt Removal And Installation....1539
    OPERATOR SEAT (SUSPENSION)....1541
      Removal And Installation....1541
      Slide Rail Removal And Installation....1542
      Cushion Removal And Installation....1542
      Back Removal And Installation....1543
      Shock Removal And Installation....1544
      3-Point Seat Belt Removal And Installation....1545
    BOB-TACH....1547
      Removal And Installation....1547
      Bob-Tach Lever And Wedge....1549
    POWER BOB-TACH....1551
      Removal And Installation....1551
      Power Bob-Tach Lever And Wedge....1553
      Pivot Pin Bushing And Seal Replacement....1555
    LIFT ARMS....1557
      Removal And Installation....1557
    REAR GRILL....1561
      Removal And Installation....1561
    REAR DOOR....1563
      Removal And Installation....1563
      Adjusting The Rear Door Latch....1564
    FUEL TANK....1565
      Removal And Installation....1565
      Fuel Level Sender....1566
    CONTROL PEDALS....1567
      Removal And Installation....1567
      Pedal Adjustment....1567
    CONTROL PEDALS (ACS)....1569
      Foot Sensor Removal And Installation....1569
      Foot Pedal Removal And Installation....1570
      Foot Pedal Linkage Disassembly And Assembly....1570
    CONTROL PANEL....1571
      Removal And Installation....1571
      Shock Removal And Installation....1573
      Shaft Removal And Installation....1573
      Shaft Disassembly And Assembly....1573
      Linkage Removal And Installation....1575
      Linkage Neutral Adjustment....1578
    CONTROL PANEL (SELECTABLE JOYSTICK CONTROL) (SJC)....1585
      Removal And Installation....1585
    CONTROL HANDLE....1589
      Lever Removal And Installation....1589
      Steering Lever Boot....1589
    CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL....1591
      Components Identification....1591
      Handle Sensor Removal And Installation....1591
      Control Handle Removal And Installation....1594
      Control Handle Disassembly And Assembly....1595
      Control Lever Removal And Installation....1596
      Control Lever Boot....1597
    CONTROL HANDLE (SELECTABLE JOYSTICK CONTROL) (SJC)....1599
      Joystick Testing (Right & Left)....1599
      Joystick Removal (Right & Left)....1600
      Joystick Boot Removal (Right & Left)....1601
      Lever Assembly Removal (Right & Left)....1601
    INSIDE ACCESS PANEL....1603
      Removal And Installation (Left)....1603
      Removal And Installation (Right)....1603
    INSIDE ACCESS PANEL (SELECTABLE JOYSTICK CONTROL) (SJC)....1605
      Panel Removal (Right)....1605
      Panel Removal (Left)....1608
  ELECTRICAL SYSTEM & ANALYSIS....1609
    ELECTRICAL SCHEMATICS....1613
    ELECTRICAL SYSTEM INFORMATION....1619
      Troubleshooting....1621
      Description....1622
      Fuse Location....1624
      Relay Switch Location....1624
      Solenoid Test....1625
    BATTERY....1627
      Removal And Installation....1627
      Servicing The Electrical System....1629
      Using A Booster Battery (Jump Starting)....1630
    ALTERNATOR....1631
      Adjusting The Alternator Belt....1631
      Alternator Identification....1631
      Charging System Check....1632
      Alternator Voltage Test....1633
      Low Voltage Test....1633
      High Voltage Test....1634
      Removal And Installation....1634
      Rectifier Continuity (Diode) Test....1635
      Alternator Regulator Test....1636
      Disassembly....1637
      Stator Continuity Test....1637
      Stator Ground Test....1637
      Rotor Continuity Test....1638
      Rotor Ground Test....1638
      Assembly....1638
    STARTER....1639
      Removal And Installation....1639
      Parts Identification....1640
      Checking....1641
      Disassembly And Assembly....1642
      Inspection And Repair....1645
      No Load Test....1648
    INSTRUMENT PANEL....1649
      Left Panel....1649
      Right Panel (Standard) (With Key Switch)....1650
      Right Panel (Deluxe) (With Keyless Start)....1651
      Right Panel Setup Display Options (Deluxe)....1653
      Deluxe Panel Setup....1654
      Passwords (Deluxe)....1654
      Option And Field Accessory Panels (If Equipped)....1656
      Standard Panel Removal And Installation (Right Side)....1657
      Deluxe Panel Removal And Installation (Right Side)....1658
      Standard & Deluxe Panel Removal And Installation (Left Side)....1659
      Front Accessory Panel Removal And Installation....1660
    LIGHTS....1661
      Front Removal And Installation....1661
      Rear Removal And Installation....1661
    CONTROLLER (BOBCAT)....1664
      Identification Chart....1664
      Removal And Installation....1666
    CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC)....1667
      Removal....1667
      Identification Chart....1670
    SPEED SENSOR (SELECTABLE JOYSTICK CONTROL) (SJC)....1673
      Testing....1673
      Removal....1674
    DIAGNOSTICS SERVICE CODES....1677
      Display....1677
      Number Codes List....1678
    BICS? SYSTEM....1683
      Inspecting The fBICS? Controller (Engine STOPPED - Key ON)....1683
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....1683
      Inspecting The Seat Bar Sensor (Engine RUNNING)....1683
      Inspecting The Traction Lock (Engine RUNNING)....1683
      Inspecting The Lift Arm By-Pass Control....1684
      Additional Inspection For Loaders With Advanced Controls System (ACS) or Selectable Joystick Control (SJC)....1684
      Troubleshooting....1685
      Troubleshooting Guide....1686
    SEAT BAR SENSOR....1687
      Troubleshooting Chart....1687
      Test....1688
      Removal And Installation....1689
      BICS? Circuit Test....1690
    TRACTION LOCK....1691
      Troubleshooting....1691
      Removal And Installation (Single Speed)....1692
      Description Of The Control System (Two Speed)....1693
      Inspecting The Control System (Two Speed)....1693
    ADVANCED CONTROL SYSTEM (ACS)....1695
      Components Identification....1695
      Troubleshooting Guide....1697
      Controller, Connector And Wire Identification....1698
      ACS Controller Removal And Installation....1699
      Handle Sensor Connector....1700
      Switch Handle Removal....1701
      Switch Handle Installation....1703
      Actuators Disassembly And Assembly....1706
      Handle Lock Solenoid Removal And Installation....1707
      Handle Lock Solenoid Disassembly And Assembly....1707
      Handle Lock Solenoid Connector....1708
      Calibration Of The ACS System....1708
      Switchable Hand/Foot Controls Calibration Procedure....1709
      Hand Controls Only Calibration Procedure....1710
      Foot Sensor Disassembly And Assembly....1711
      Foot Sensor Connector....1712
      Foot Lock Solenoid Removal And Installation....1712
      Foot Lock Solenoid Connector....1713
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE....1715
      Controls Identification Chart....1715
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC)....1717
      Controls Identification Chart....1717
    SERVICE PC (LAPTOP COMPUTER)....1721
      Connecting The Service PC To Remote Start Tool....1721
    LIFT AND TILT ACTUATOR CALIBRATION (SELECTABLE JOYSTICK CONTROL) (SJC)....1723
      Procedure....1723
    FLYWHEEL RPM SENSOR....1725
      Adjustment....1725
  ENGINE SERVICE....1727
    TROUBLESHOOTING....1731
      Chart....1731
    ENGINE SPEED CONTROL....1733
      Removal And Installation....1733
      Speed Control Cable....1734
    ENGINE SPEED CONTROL (SELECTABLE JOYSTICK CONTROL) (SJC)....1737
      Removal....1737
      Disassembly....1739
      Speed Control Cable....1740
    MUFFLER....1741
      Removal And Installation....1741
    AIR CLEANER....1743
      Housing Removal And Installation....1743
    RADIATOR....1745
      Removal And Installation....1745
      Mount Removal....1747
    COOLING FAN....1749
      Drive Tension Pulley Removal And Installation....1749
      Gearbox/Blower Housing Removal And Installation....1750
      Blower Removal And Installation....1751
      Gearbox Parts Identification....1753
      Gearbox Disassembly....1754
      Gearbox Assembly....1759
      Gearbox, Checking Backlash....1764
    ENGINE....1767
      Removal And Installation....1767
      Mount Replacement....1774
      Removal And Installation Tools....1775
    FLYWHEEL AND HOUSING....1777
      Flywheel Removal And Installation....1777
      Ring Gear Removal And Installation....1777
      Flywheel Housing Removal And Installation....1777
    RECONDITIONING THE ENGINE....1779
      Engine Tools Identification Chart....1779
      Compression Pressure....1783
      Cylinder Head Clearance....1783
      Valve Cover And Injector Nozzle Removal And Installation....1784
      Rocker Arm And Push Rod Disassembly And Assembly....1786
      Valve Clearance....1786
      Cylinder Head And Tappet Disassembly And Assembly....1787
      Selecting Cylinder Head Gasket Disassembly And Assembly....1788
      Valve Disassembly And Assembly....1789
      Engine Timing (TDC)....1790
      Injection Pump Assembly Removal....1791
      Injection Pump Assembly Installation....1794
      Injection Pump Removal and Installation....1797
      Injection Pump Timing....1799
      Fan Drive Pulley Disassembly And Assembly....1802
      Water Pump Disassembly And Assembly....1802
      Gearcase Cover Disassembly And Assembly....1803
      Idle Gear And Camshaft Disassembly And Assembly....1803
      Gearcase Plate Disassembly And Assembly....1804
      Oil Pan And Oil Strainer Disassembly And Assembly....1804
      Connecting Rod Cap Disassembly And Assembly....1805
      Piston Disassembly And Assembly....1806
      Piston Ring And Connecting Rod Disassembly And Assembly....1807
      Bearing Case Cover Disassembly And Assembly....1809
      Flywheel Housing Disassembly And Assembly....1810
      Crankcase No. 2 Disassembly And Assembly....1810
      Crankcase No. 1 And No. 2 Disassembly And Assembly....1811
      Crankshaft Disassembly And Assembly....1811
      Cylinder Head Surface Flatness....1811
      Cylinder Head Flaw....1812
      Valve Recessing....1812
      Valve Lapping....1813
      Clearance Between Valve Stem And Valve Guide....1813
      Replacing Valve Guide....1814
      Correcting Valve And Valve Seat....1814
      Free Length And Tilt Of Valve Spring....1815
      Valve Spring Setting Load....1815
      Oil Clearance Between Rocker Arm Shaft And Bearing....1816
      Oil Clearance Between Tappet And Tappet Guide Bore....1816
      Timing Gear Backlash....1817
      Idler Gear Side Clearance....1817
      Camshaft Side Clearance....1818
      Camshaft Alignment....1818
      Cam Height....1818
      Oil Clearance Of Camshaft Journal....1819
      Oil Clearance Between Idler Gear Shaft And Idler Gearing Bushing....1819
      Replacing Idler Gear Bushing....1820
      Piston Pin Bore I.D...1821
      Oil Clearance Between Piston Pin And Small End Bushing....1821
      Replacing Small End Bushing....1822
      Clearance Between Piston Ring And Groove....1822
      Piston Ring Gap....1823
      Connecting Rod Alignment....1823
      Crankshaft Side Clearance....1824
      Crankshaft Alignment....1825
      Oil Clearance Between Crankpin And Crankpin Bearing....1825
      Oil Clearance Between Crankshaft Journal And Crankshaft Bearing....1827
      Replacing Crankshaft Sleeve....1828
      Cylinder Bore I.D...1828
      Correcting Cylinder (Oversize +0.5 mm)....1829
      Engine Oil Pressure....1829
      Rotor Lobe Clearance....1830
      Clearance Between Outer Rotor And Pump Body....1830
      Thermostat Valve Opening Temperature....1830
      Radiator Water Leakage....1831
      Radiator Cap Air Leakage....1831
      Thermostat Assembly....1831
      Intake Air Heater....1832
      Checking the Turbo Charger....1833
      Compressor Side....1833
      Wheel Shaft....1833
      Axial Clearance....1834
      Radial Clearance....1834
      Air Cleaner, Intake Pipe, Inlet Pipe And Muffler....1834
      Oil Pipe....1835
      Turbocharger....1835
  HEATING, VENTILATION, AIR CONDITIONING....1837
    AIR CONDITIONING SYSTEM FLOW....1840
      Principles....1840
      Chart....1841
    COMPONENTS....1843
      Identification....1843
    SAFETY....1847
      Safety Equipment....1847
    REGULAR MAINTENANCE....1849
      Filter Elements Removal And Installation....1849
      Compressor Drive Belt Inspection....1850
      Cleaning The Condenser....1851
    BASIC TROUBLESHOOTING....1853
      Poor A/C Performance....1853
      Cleaning The A/C Evaporator Coil & Heater Coil....1854
      Compressor Drive Belt Inspection....1854
      Checking The Electrical System....1855
      Engine Coolant By-Passing The Heater Valve....1863
      Heater Valve Not Opening Or Closing....1864
    GENERAL AIR CONDITIONING SERVICE GUIDELINES....1865
      Compressor Oil....1865
      Compressor Oil Check....1866
      Component Replacement And Refrigeration Leaks....1867
    SYSTEM TROUBLESHOOTING CHART....1869
      Gauge Pressure Related Troubleshooting....1870
      Troubleshooting Tree....1872
    TEMPERATURE/PRESSURE....1877
      Chart....1877
    AIR CONDITIONING SERVICE....1879
      Chart....1879
    SYSTEM CHARGING AND RECLAMATION....1881
      Reclamation Procedure....1881
      Charging Procedure With A Manifold Gauge Set....1883
      Charging Procedure....1884
    COMPRESSOR....1887
      Removal And Installation....1887
      Compressor Clutch Disassembly....1888
    CONDENSER....1893
      Removal And Installation....1893
    RECEIVER/DRIER....1895
      Removal And Installation....1895
    PRESSURE RELIEF VALVE....1897
      Removal And Installation....1897
    PRESSURE SWITCH....1899
      Removal And Installation....1899
    EVAPORATOR/HEATER UNIT....1901
      Removal And Installation....1901
      Disassembly And Assembly....1902
    THERMOSTAT....1903
      Removal And Installation....1903
    EXPANSION VALVE....1905
      Removal And Installation....1905
    EVAPORATOR....1907
      Removal And Installation....1907
    HEATER COIL....1909
      Removal And Installation With A/C....1909
      Removal And Installation Without A/C....1910
    BLOWER FAN....1911
      Removal And Installation....1911
      Disassembly And Assembly....1912
      Wire Connector Removal and Installation....1914
    HEATER VALVE....1917
      Removal and Installation....1917
      Disassembly And Assembly....1918
  SPECIFICATIONS....1921
    LOADER SPECIFICATIONS (S220)....1923
      Machine Dimensions....1923
      Performance....1924
      Controls....1924
      Engine....1924
      Hydraulic System....1925
      Electrical....1925
      Drive System....1926
      Capacities....1926
      Tires....1926
    ENGINE SPECIFICATIONS....1927
      General....1927
      Fuel System....1927
      Valve And Valve Timing....1927
      Valve Spring....1928
      Piston And Piston Ring....1928
      Connecting Rod....1928
      Cylinder Head....1929
      Crankshaft....1929
      Cylinder Bore....1929
      Oil Pump....1929
      Rocker Arm....1930
      Tappet....1930
      Camshaft....1930
      Thermostat....1930
      Timing Gear....1931
      Intake Air Heater....1931
    TORQUE SPECIFICATIONS FOR BOLTS....1933
      Torque For General SAE Bolts....1933
      Torque For General Metric Bolts....1934
      Torque For Kubota Metric Engine Bolts....1935
      Tightening Torques For General Use Screws, Bolts And Nuts....1935
    HYDRAULIC CONNECTION SPECIFICATIONS....1937
      O-ring Face Seal Connection....1937
      Straight Thread O-ring Fitting....1938
      Tubelines And Hoses....1938
      Flare Fitting....1938
      O-ring Flare Fitting....1939
      Port Seal Fitting....1941
    HYDRAULIC FLUID SPECIFICATIONS....1943
      Specifications....1943
    CONVERSIONS....1945
      Decimal And Millimeter Equivalents....1945
  SMR....1947
    S220-1....1947
    S220-2....1949
    S220-3....1951
    S220-4....1953
6902696 (12-06) - S220 Turbo, S220 Turbo High Flow Operation & Maintenance Manual....1955
  OPERATOR SAFETY WARNINGS....1957
  CONTENTS....1959
  FOREWORD....1961
    BOBCAT COMPANY IS ISO9001:2000 CERTIFIED....1963
    REGULAR MAINTENANCE ITEMS....1963
    MOTOR OIL....1963
    SERIAL NUMBER LOCATIONS....1964
      Loader Serial Number....1964
      Engine Serial Number....1964
    DELIVERY REPORT....1964
    MACHINE IDENTIFICATION....1965
    FEATURES, ACCESSORIES AND ATTACHMENTS....1966
      Standard Items....1966
      Options and Accessories....1966
      Buckets Available....1967
      Attachments....1967
  SAFETY....1969
    SAFETY INSTRUCTIONS....1971
      Before Operation....1971
      Safe Operation Is The Operator?s Responsibility....1972
      Safe Operation Needs A Qualified Operator....1972
      Fire Prevention....1973
    MACHINE SIGNS (DECALS)....1974
  OPERATING INSTRUCTIONS....1977
    INSTRUMENT PANEL IDENTIFICATION....1981
      Left Panel....1981
      Right Panel (Standard - With Key Switch)....1982
      Right Panel (Deluxe - With Keyless Start)....1983
      Option And Field Accessory Panels (If Equipped)....1985
      Cab Light....1986
    LIFT ARM BY-PASS CONTROL....1986
      Operation....1986
    TRACTION LOCK OVERRIDE....1986
      Operation....1986
    ENGINE SPEED CONTROL....1987
      Operation....1987
    TWO-SPEED CONTROL....1987
    INCHING CONTROL....1987
      Operation....1987
    DRIVING AND STEERING THE LOADER....1988
      Available Controls Configurations....1988
      Operation (Standard and ACS)....1988
      Operation (SJC in ?H? Control Pattern)....1989
      Operation (SJC in ?ISO? Control Pattern)....1990
    STOPPING THE BOBCAT LOADER....1991
      Using The Steering Levers Or Joysticks....1991
    SEAT BAR RESTRAINT SYSTEM....1991
      Operation....1991
    HYDRAULIC CONTROLS....1992
      Standard Controls (Also ACS in Foot Pedal Mode)....1992
      Advanced Control System (ACS) in HAND Control Mode....1993
      Selectable Joystick Control (SJC) - ?H? Control Pattern....1994
      Selectable Joystick Control (SJC) - ?ISO? Control Pattern....1994
      Quick Couplers....1995
      Releasing Hydraulic Pressure (Loader and Attachment)....1995
      Auxiliary Hydraulics Button - VARIABLE FLOW....1996
      Auxiliary Hydraulics Button - MAXIMUM FLOW ONLY....1996
      Auxiliary Hydraulics Button - DISENGAGE....1996
      FRONT Auxiliary Hydraulics Operation - VARIABLE FLOW....1996
      FRONT Auxiliary Hydraulics Operation - MAXIMUM FLOW....1996
      FRONT Auxiliary Hydraulics Operation - CONTINUOUS FLOW....1996
      REAR Auxiliary Hydraulics Operation (If Equipped)....1997
      Secondary Front Auxiliary Hydraulics (If Equipped)....1997
      High-Flow Hydraulics Operation (If Equipped)....1998
      Attachment Control Device (ACD) (If Equipped)....1998
      Bucket Position Valve Operation (If Equipped)....1999
    PARKING BRAKE....1999
      Operation....1999
    DAILY INSPECTION....2000
      Daily Inspection and Maintenance....2000
    PRE-STARTING PROCEDURES....2001
      Before Starting The Engine....2001
    STARTING THE ENGINE (STANDARD PANEL, KEY SWITCH)....2003
      Procedure....2003
    STARTING THE ENGINE (DELUXE PANEL, KEYLESS START)....2005
      Procedure....2005
      Cold Temperature Starting....2006
    WARMING THE HYDRAULIC/HYDROSTATIC SYSTEM....2007
      Procedure....2007
    STOPPING THE ENGINE....2007
      Procedure....2007
    MONITORING THE DISPLAY PANEL....2008
      Standard Panel....2008
      Deluxe Panel....2008
      WARNING and SHUTDOWN....2008
    ATTACHMENTS AND BUCKETS....2009
      Choosing The Correct Bucket....2009
      Pallet Forks....2010
      Hand Lever Bob-Tach - Installing The Bucket Or Attachment....2010
      Hand Lever Bob-Tach - Removing The Bucket Or Attachment....2012
      Power Bob-Tach - Installing The Bucket Or Attachment....2013
      Power Bob-Tach - Removing The Bucket Or Attachment....2014
    OPERATING PROCEDURE....2015
      Operating With A Full Bucket....2015
      Operating With An Empty Bucket....2016
      Foot Pedal Machines....2017
      Hand Control Machines (Includes ACS and SJC with H-Pattern Selected)....2019
      Selectable Joystick Control (SJC) with ?ISO? Pattern Selected....2021
    PARKING THE BOBCAT LOADER....2023
      Procedure....2023
    TRANSPORTING THE BOBCAT LOADER....2024
      Loading Onto Transport Vehicle....2024
      Fastening To Transport Vehicle....2024
    TOWING THE LOADER....2025
      Towing Procedure....2025
    LIFTING THE LOADER....2026
      Single Point Lift....2026
      Four Point Lift....2026
  PREVENTIVE MAINTENANCE....2027
    MAINTENANCE SAFETY....2029
    SERVICE SCHEDULE....2031
      Chart....2031
    LIFT ARM SUPPORT DEVICE....2032
      Engaging The Lift Arm Support Device....2032
      Disengaging The Lift Arm Support Device....2033
    OPERATOR CAB....2034
      Description....2034
      Raising The Operator Cab....2034
      Lowering The Operator Cab....2035
      Cab Door Sensor (If Equipped)....2035
      Emergency Exit....2036
    SEAT BELT....2037
      Inspection and Maintenance....2037
    SEAT BAR RESTRAINT SYSTEM....2038
      Inspecting The Seat Bar....2038
      Maintaining The Seat Bar....2038
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....2039
      Inspecting The BICS Controller (Engine Stopped - Key ON)....2039
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....2039
      Inspecting The Seat Bar Sensor (Engine RUNNING)....2039
      Inspecting The Traction Lock (Engine RUNNING)....2039
      Inspecting The Lift Arm By-Pass Control....2039
      Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....2039
    REAR DOOR....2040
      Opening And Closing The Rear Door....2040
      Adjusting The Rear Door Latch....2040
    REAR GRILL....2041
      Removing....2041
      Installing....2041
    HEATING SYSTEM....2041
      Cleaning And Maintenance....2041
    AIR CLEANER SERVICE....2042
      Replacing Filter Elements....2042
    FUEL SYSTEM....2043
      Fuel Specifications....2043
      Filling The Fuel Tank....2043
      Fuel Filter....2044
      Removing Air From The Fuel System....2044
    ENGINE LUBRICATION SYSTEM....2045
      Checking Engine Oil....2045
      Replacing The Oil And Filter....2045
    ENGINE COOLING SYSTEM....2046
      Cleaning The Cooling System....2046
    ELECTRICAL SYSTEM....2047
      Description....2047
      Cleaning Battery and Terminals....2047
      Fuse Location....2048
      Using A Booster Battery (Jump Starting)....2049
      Removing And Installing The Battery....2050
    HYDRAULIC / HYDROSTATIC SYSTEM....2051
      Checking And Adding Fluid....2051
      Replacing Hydraulic/Hydrostatic Filter....2051
      Replacing Hydraulic Fluid and Case Drain Filters....2052
      Breather Cap....2053
    TIRE MAINTENANCE....2054
      Wheel Nuts....2054
      Rotating....2054
      Mounting....2054
    FINAL DRIVE TRANSMISSION (CHAINCASE)....2055
      Checking And Adding Oil....2055
      Removing Oil From The Chaincase....2055
    FAN GEARBOX....2056
      Checking And Maintaining....2056
    DRIVE BELT....2056
      Adjusting The Drive Belt....2056
      Replacing The Drive Belt....2056
    BELT ADJUSTMENTS....2057
      Adjusting The Alternator Belt....2057
      Adjusting the Air Conditioner Belt....2057
    LUBRICATING THE BOBCAT LOADER....2058
      Lubrication Locations....2058
    PIVOT PINS....2060
      Inspection And Maintenance....2060
    BOB-TACH (HAND LEVER)....2061
      Inspection And Maintenance....2061
    BOB-TACH (POWER) (OPTIONAL)....2062
      Inspection And Maintenance....2062
  SYSTEM SETUP & ANALYSIS....2063
    BICS SYSTEM....2065
      Troubleshooting Guide....2065
    DIAGNOSTICS SERVICE CODES....2066
      Display....2066
      Number Codes List....2067
    DELUXE INSTRUMENT PANEL SETUP....2071
      Deluxe Panel Upgrade....2071
      Deluxe Panel Setup....2072
      Passwords (Deluxe)....2072
      Viewing Service Codes....2074
    SHUTDOWN FEATURE....2075
    SERVICE CLOCK RESET....2075
  MACHINE SIGN TRANSLATIONS....2077
    SERVICE SCHEDULE (6734534)....2079
    WARNING (6728539)....2080
    WARNING (6715944)....2081
    DANGER (6702301)....2082
    WARNING (6577754)....2082
    DANGER (6702302)....2082
    WARNING (6579528)....2082
    WARNING (6717343)....2083
    WARNING (6708941)....2083
    IMPORTANT (6560573)....2083
    WARNING (6732696)....2083
    LIFT ARM SUPPORT DEVICE (6732774)....2084
  SPECIFICATIONS....2085
    LOADER SPECIFICATIONS (S220)....2087
      Machine Dimensions....2087
      Performance....2088
      Controls....2088
      Engine....2088
      Hydraulic System....2089
      Electrical....2089
      Drive System....2090
      Capacities....2090
      Tires....2090
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS....2091
  WARRANTY....2093
6902696 (5-12) - S220 Turbo, S220 Turbo High Flow Operation & Maintenance Manual....2095
  OPERATOR SAFETY WARNINGS....2097
  CONTENTS....2099
  FOREWORD....2101
    BOBCAT COMPANY IS ISO9001:2000 CERTIFIED....2103
    REGULAR MAINTENANCE ITEMS....2103
    MOTOR OIL....2103
    SERIAL NUMBER LOCATIONS....2104
      Loader Serial Number....2104
      Engine Serial Number....2104
    DELIVERY REPORT....2104
    MACHINE IDENTIFICATION....2105
    FEATURES, ACCESSORIES AND ATTACHMENTS....2106
      Standard Items....2106
      Options and Accessories....2106
      Buckets Available....2107
      Attachments....2107
  SAFETY....2109
    SAFETY INSTRUCTIONS....2111
      Before Operation....2111
      Safe Operation Is The Operator?s Responsibility....2112
      Safe Operation Needs A Qualified Operator....2112
      Fire Prevention....2113
    MACHINE SIGNS (DECALS)....2114
  OPERATING INSTRUCTIONS....2117
    INSTRUMENT PANEL IDENTIFICATION....2121
      Left Panel....2121
      Right Panel (Standard - With Key Switch)....2122
      Right Panel (Deluxe - With Keyless Start)....2123
      Option And Field Accessory Panels (If Equipped)....2125
      Cab Light....2126
    LIFT ARM BY-PASS CONTROL....2126
      Operation....2126
    TRACTION LOCK OVERRIDE....2126
      Operation....2126
    ENGINE SPEED CONTROL....2127
      Operation....2127
    TWO-SPEED CONTROL....2127
    INCHING CONTROL....2127
      Operation....2127
    DRIVING AND STEERING THE LOADER....2128
      Available Controls Configurations....2128
      Operation (Standard and ACS)....2128
      Operation (SJC in ?H? Control Pattern)....2129
      Operation (SJC in ?ISO? Control Pattern)....2130
    STOPPING THE BOBCAT LOADER....2131
      Using The Steering Levers Or Joysticks....2131
    SEAT BAR RESTRAINT SYSTEM....2131
      Operation....2131
    HYDRAULIC CONTROLS....2132
      Standard Controls (Also ACS in Foot Pedal Mode)....2132
      Advanced Control System (ACS) in HAND Control Mode....2133
      Selectable Joystick Control (SJC) - ?H? Control Pattern....2134
      Selectable Joystick Control (SJC) - ?ISO? Control Pattern....2134
      Quick Couplers....2135
      Releasing Hydraulic Pressure (Loader and Attachment)....2135
      Auxiliary Hydraulics Button - VARIABLE FLOW....2136
      Auxiliary Hydraulics Button - MAXIMUM FLOW ONLY....2136
      Auxiliary Hydraulics Button - DISENGAGE....2136
      FRONT Auxiliary Hydraulics Operation - VARIABLE FLOW....2136
      FRONT Auxiliary Hydraulics Operation - MAXIMUM FLOW....2136
      FRONT Auxiliary Hydraulics Operation - CONTINUOUS FLOW....2136
      REAR Auxiliary Hydraulics Operation (If Equipped)....2137
      Secondary Front Auxiliary Hydraulics (If Equipped)....2137
      High-Flow Hydraulics Operation (If Equipped)....2138
      Attachment Control Device (ACD) (If Equipped)....2138
      Bucket Position Valve Operation (If Equipped)....2139
    PARKING BRAKE....2139
      Operation....2139
    DAILY INSPECTION....2140
      Daily Inspection and Maintenance....2140
    PRE-STARTING PROCEDURES....2141
      Before Starting The Engine....2141
    STARTING THE ENGINE (STANDARD PANEL, KEY SWITCH)....2143
      Procedure....2143
    STARTING THE ENGINE (DELUXE PANEL, KEYLESS START)....2145
      Procedure....2145
      Cold Temperature Starting....2146
    WARMING THE HYDRAULIC/HYDROSTATIC SYSTEM....2147
      Procedure....2147
    STOPPING THE ENGINE....2147
      Procedure....2147
    MONITORING THE DISPLAY PANEL....2148
      Standard Panel....2148
      Deluxe Panel....2148
      WARNING and SHUTDOWN....2148
    ATTACHMENTS AND BUCKETS....2149
      Choosing The Correct Bucket....2149
      Pallet Forks....2150
      Hand Lever Bob-Tach - Installing The Bucket Or Attachment....2150
      Hand Lever Bob-Tach - Removing The Bucket Or Attachment....2152
      Power Bob-Tach - Installing The Bucket Or Attachment....2153
      Power Bob-Tach - Removing The Bucket Or Attachment....2154
    OPERATING PROCEDURE....2155
      Operating With A Full Bucket....2155
      Operating With An Empty Bucket....2156
      Foot Pedal Machines....2157
      Hand Control Machines (Includes ACS and SJC with H-Pattern Selected)....2159
      Selectable Joystick Control (SJC) with ?ISO? Pattern Selected....2161
    PARKING THE BOBCAT LOADER....2163
      Procedure....2163
    TRANSPORTING THE BOBCAT LOADER....2164
      Loading Onto Transport Vehicle....2164
      Fastening To Transport Vehicle....2164
    TOWING THE LOADER....2165
      Towing Procedure....2165
    LIFTING THE LOADER....2166
      Single Point Lift....2166
      Four Point Lift....2166
  PREVENTIVE MAINTENANCE....2167
    MAINTENANCE SAFETY....2169
    SERVICE SCHEDULE....2171
      Chart....2171
    LIFT ARM SUPPORT DEVICE....2172
      Engaging The Lift Arm Support Device....2172
      Disengaging The Lift Arm Support Device....2173
    OPERATOR CAB....2174
      Description....2174
      Raising The Operator Cab....2174
      Lowering The Operator Cab....2175
      Cab Door Sensor (If Equipped)....2175
      Emergency Exit....2176
    SEAT BELT....2177
      Inspection and Maintenance....2177
    SEAT BAR RESTRAINT SYSTEM....2178
      Inspecting The Seat Bar....2178
      Maintaining The Seat Bar....2178
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....2179
      Inspecting The BICS Controller (Engine Stopped - Key ON)....2179
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....2179
      Inspecting The Seat Bar Sensor (Engine RUNNING)....2179
      Inspecting The Traction Lock (Engine RUNNING)....2179
      Inspecting The Lift Arm By-Pass Control....2179
      Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....2179
    REAR DOOR....2180
      Opening And Closing The Rear Door....2180
      Adjusting The Rear Door Latch....2180
    REAR GRILL....2181
      Removing....2181
      Installing....2181
    HEATING SYSTEM....2181
      Cleaning And Maintenance....2181
    AIR CLEANER SERVICE....2182
      Replacing Filter Elements....2182
    FUEL SYSTEM....2183
      Fuel Specifications....2183
      Filling The Fuel Tank....2183
      Fuel Filter....2184
      Removing Air From The Fuel System....2184
    ENGINE LUBRICATION SYSTEM....2185
      Checking Engine Oil....2185
      Replacing The Oil And Filter....2185
    ENGINE COOLING SYSTEM....2186
      Cleaning The Cooling System....2186
    ELECTRICAL SYSTEM....2187
      Description....2187
      Cleaning Battery and Terminals....2187
      Fuse Location....2188
      Using A Booster Battery (Jump Starting)....2189
      Removing And Installing The Battery....2190
    HYDRAULIC / HYDROSTATIC SYSTEM....2191
      Checking And Adding Fluid....2191
      Replacing Hydraulic/Hydrostatic Filter....2191
      Replacing Hydraulic Fluid and Case Drain Filters....2192
      Breather Cap....2193
    TIRE MAINTENANCE....2194
      Wheel Nuts....2194
      Rotating....2194
      Mounting....2194
    FINAL DRIVE TRANSMISSION (CHAINCASE)....2195
      Checking And Adding Oil....2195
      Removing Oil From The Chaincase....2195
    FAN GEARBOX....2196
      Checking And Maintaining....2196
    DRIVE BELT....2196
      Adjusting The Drive Belt....2196
      Replacing The Drive Belt....2196
    BELT ADJUSTMENTS....2197
      Adjusting The Alternator Belt....2197
      Adjusting the Air Conditioner Belt....2197
    LUBRICATING THE BOBCAT LOADER....2198
      Lubrication Locations....2198
    PIVOT PINS....2200
      Inspection And Maintenance....2200
    BOB-TACH (HAND LEVER)....2201
      Inspection And Maintenance....2201
    BOB-TACH (POWER) (OPTIONAL)....2202
      Inspection And Maintenance....2202
  SYSTEM SETUP & ANALYSIS....2203
    BICS SYSTEM....2205
      Troubleshooting Guide....2205
    DIAGNOSTICS SERVICE CODES....2206
      Display....2206
      Number Codes List....2207
    DELUXE INSTRUMENT PANEL SETUP....2211
      Deluxe Panel Upgrade....2211
      Deluxe Panel Setup....2212
      Passwords (Deluxe)....2212
      Viewing Service Codes....2214
    SHUTDOWN FEATURE....2215
    SERVICE CLOCK RESET....2215
  MACHINE SIGN TRANSLATIONS....2217
    SERVICE SCHEDULE (6734534)....2219
    WARNING (6728539)....2220
    WARNING (6715944)....2221
    DANGER (6702301)....2222
    WARNING (6577754)....2222
    DANGER (6702302)....2222
    WARNING (6579528)....2222
    WARNING (6717343)....2223
    WARNING (6708941)....2223
    IMPORTANT (6560573)....2223
    WARNING (6732696)....2223
    LIFT ARM SUPPORT DEVICE (6732774)....2224
  SPECIFICATIONS....2225
    LOADER SPECIFICATIONS (S220)....2227
      Machine Dimensions....2227
      Performance....2228
      Controls....2228
      Engine....2228
      Hydraulic System....2229
      Electrical....2229
      Drive System....2230
      Capacities....2230
      Tires....2230
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS....2231
  WARRANTY....2233
6902722 (06-12) - S220 Turbo, S220 Turbo High Flow Service Manual....2235
  MAINTENANCE SAFETY....2237
  ALPHABETICAL INDEX....2239
  CONTENTS....2241
    FOREWORD....2242
    SAFETY INSTRUCTIONS....2245
      Fire Prevention....2247
    SERIAL NUMBER LOCATION....2249
      Loader Serial Number....2249
      Engine Serial Number....2249
    DELIVERY REPORT....2250
    BOBCAT LOADER IDENTIFICATION....2251
  SAFETY AND MAINTENANCE....2253
    LIFTING AND BLOCKING THE LOADER....2255
      Procedure....2255
    LIFT ARM SUPPORT DEVICE....2257
      Engaging The Lift Arm Support Device....2257
      Disengaging The Lift Arm Support Device....2258
    OPERATOR CAB....2259
      Description....2259
      Raising The Operator Cab....2259
      Lowering The Operator Cab....2260
      Emergency Exit....2260
    TRANSPORTING THE BOBCAT LOADER....2263
      Procedure....2263
    TOWING THE LOADER....2265
      Procedure....2265
    REMOTE START....2267
      Procedure For Loader W/O Attachments Control Harness....2267
      Procedure For Loader With Attachments Control Harness....2268
      Procedure....2269
    SERVICE SCHEDULE....2271
      Chart....2271
    AIR CLEANER SERVICE....2273
      Replacing Filter Element....2273
    ENGINE COOLING SYSTEM....2275
      Cleaning Cooling System....2275
      Checking The Coolant Level....2277
      Adding The Coolant....2278
    FUEL SYSTEM....2279
      Fuel Specifications....2279
      Filling The Fuel Tank....2279
      Fuel Filter....2279
      Removing Air From The Fuel System....2280
    ENGINE LUBRICATION SYSTEM....2281
      Checking Engine Oil....2281
      Oil Chart....2281
      Replacing Oil And Filter....2281
    HYDRAULIC/HYDROSTATIC SYSTEM....2283
      Checking And Adding Fluid....2283
      Hydraulic Fluid Chart....2283
      Hydraulic/Hydrostatic Filter Replacement....2284
      Replacing Hydraulic Fluid And Case Drain Filters....2285
    FINAL DRIVE TRANSMISSION (CHAINCASE)....2287
      Checking And Adding Oil....2287
      Removing The Oil....2287
    FAN GEARBOX....2289
      Checking And Adding Oil....2289
    BOB-TACH....2291
      Inspection And Maintenance....2291
    POWER BOB-TACH....2293
      Inspection And Maintenance....2293
    LUBRICATING THE LOADER....2295
      Procedure....2295
    TIRE MAINTENANCE....2297
      Wheel Nuts....2297
      Tire Rotation....2297
      Tire Mounting....2297
  HYDRAULIC SYSTEM....2299
    HYDRAULIC/HYDROSTATIC SCHEMATICS....2305
    HYDRAULIC SYSTEM INFORMATION....2337
      Troubleshooting....2341
      Tightening Procedure....2342
    CYLINDER (LIFT)....2343
      Checking....2343
      Removal And Installation....2343
      Parts Identification....2345
      Disassembly....2346
      Assembly....2347
    CYLINDER (TILT)....2351
      Checking....2351
      Removal And Installation....2351
      Base Pin Removal And Installation....2353
      Parts Identification....2354
      Disassembly....2355
      Assembly....2356
    CYLINDER (POWER BOB-TACH)....2359
      Checking....2359
      Removal And Installation....2360
      Parts Identification....2361
      Disassembly....2362
      Assembly....2363
    MAIN RELIEF VALVE....2367
      Checking Main Relief....2367
      Adjustment....2369
      Removal And Installation....2370
    MAIN RELIEF VALVE (ACS)....2371
      Checking The Main Relief Valve At Front Aux. Hyd...2371
      Removal And Installation....2372
      Adjustment....2373
    MAIN RELIEF VALVE (Selectable JOYSTICK Control) (Sjc)....2375
      Checking The Main Relief Valve At Front Auxiliary Hydraulics....2375
      Removal and Installation....2376
      Adjustment....2377
    HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL)....2379
      Identification....2379
      Removal And Installation....2379
      BICS? Valve, Removal And Installation....2383
      BICS? Valve, Lift Arm By-Pass Orifice Removal And Installation....2385
      BICS? Valve, Check Valve Removal And Installation....2386
      Backslide, Lock Valve Removal And Installation....2387
      BICS? Valve, Solenoid Removal And Installation....2388
      BICS? Valve, Solenoid Testing....2389
      Identification Chart....2390
      Load Check Valve....2391
      Main Relief Valve....2392
      Port Relief Valve, Tilt Spool....2392
      Port Relief Valve, Lift Spool....2393
      Anti-Cavitation Valve/Port Relief Valve, Tilt Spool....2393
      Anti-Cavitation Valve, Lift Spool....2394
      Rubber Boot....2394
      Lift And Tilt Lock Block....2395
      Lift Spool And Detent Removal....2396
      Lift Spool And Detent Disassembly....2398
      Lift Spool And Detent Assembly....2401
      Lift Spool And Detent Installation....2405
      Tilt Spool Removal And Installation....2406
      Tilt Spool Disassembly And Assembly....2407
      Auxiliary Spool Removal And Installation....2408
      Auxiliary Plug Removal And Installation....2410
      Auxiliary Electric Solenoid Disassembly....2411
      Port-Auxiliary Section Removal And Installation....2412
      Cleaning And Inspection....2412
    HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)....2413
      Identification....2413
      Actuator Removal And Installation (In Loader)....2414
      Actuator Removal And Installation (Out Of Loader)....2417
      Removal And Installation....2419
      BICS? Valve, Removal And Installation....2423
      BICS? Valve, Lift Arm By-Pass Orifice Disassembly And Assembly....2426
      BICS? Valve, Check Valve Disassembly And Assembly....2427
      BICS? Valve, Lock Valve Disassembly And Assembly....2428
      BICS? Valve, Solenoid Disassembly And Assembly....2429
      BICS? Valve, Solenoid Testing....2430
      Identification Chart....2431
      Lift Base End Restrictor....2432
      Load Check Valve....2433
      Main Relief Valve....2434
      Port Relief Valve....2436
      Anti-Cavitation Valve/Port Relief Valve....2437
      Anti-Cavitation Valve....2438
      Lift Spool Removal....2439
      Lift Spool Removal And Installation....2440
      Lift and Tilt Spool Disassembly And Assembly....2441
      Auxiliary Spool Removal And Installation....2442
      Auxiliary Electric Solenoid Disassembly....2443
      Port-Auxiliary Section Disassembly....2444
      Cleaning And Inspection....2444
    HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (selectable joystick control) (sjc)....2445
      Identification....2445
      Actuator Removal And Installation (In Loader)....2446
      Actuator Removal And Installation (Out Of Loader)....2449
      Removal And Installation....2451
      BICS? Valve, Removal And Installation....2455
      BICS? Valve, Lift Arm By-Pass Orifice Disassembly And Assembly....2458
      BICS? Valve, Check Valve Disassembly And Assembly....2459
      BICS? Valve, Lock Valve Disassembly And Assembly....2460
      BICS? Valve, Solenoid Disassembly And Assembly....2461
      BICS? Valve, Solenoid Testing....2462
      Identification Chart....2463
      Lift Base End Restrictor....2464
      Load Check Valve....2464
      Main Relief Valve....2465
      Port Relief Valve....2466
      Anti-Cavitation Valve/Port Relief Valve....2467
      Anti-Cavitation Valve....2468
      Lift Spool Removal....2469
      Lift Spool Removal And Installation....2470
      Lift and Tilt Spool Disassembly And Assembly....2471
      Auxiliary Spool Removal And Installation....2472
      Auxiliary Electric Solenoid Disassembly....2473
      Port-Auxiliary Section Disassembly....2474
      Cleaning And Inspection....2474
    HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL)....2475
      Removal And Installation....2475
      Identification Chart....2480
      BICS? Valve, Lift Load Check Valve Removal And Installation....2481
      Load Check Valve Removal And Installation (Tilt & Auxiliary)....2482
      Anti-Cavitation Valve (Lift, Rod End)....2482
      Port Relief/Anti-Cavitation Valve (Lift, Base End)....2483
      Port Relief/Anti-Cavitation Valve (Tilt, Base End)....2484
      Port Relief/Anti-Cavitation Valve (Tilt, Rod End)....2484
      Port Relief Valve....2485
      Plug Removal....2486
      Rubber Boot Removal and Installation....2487
      End Cap/Spool Lock Block Removal and Installation....2488
      Lift Spool and Detent Removal and Installation....2489
      Auxiliary Spool Removal And Installation....2501
      Auxiliary Solenoid Disassembly and Assembly....2503
      BICS? Valve Solenoid Disassembly And Assembly....2504
      BICS? Valve, Lock Valve Removal And Installation....2505
      BICS? Valve, Lift Arm By-Pass Orifice Disassembly And Assembly....2507
      Main Relief Valve....2507
      BICS? Valve, Check Valve Removal and Installation....2508
    HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)....2509
      Identification....2509
      Removal And Installation....2510
      Actuator Removal And Installation (In Loader)....2514
      Identification Chart....2519
      BICS? Valve, Lift Load Check Valve Removal And Installation....2520
      Load Check Valve Removal And Installation (Tilt & Auxiliary)....2521
      Anti-Cavitation Valve (Lift, Rod End)....2521
      Port Relief/Anti-Cavitation Valve (Lift, Base End)....2522
      Port Relief/Anti-Cavitation Valve (Tilt, Base End)....2523
      Port Relief/Anti-Cavitation Valve (Tilt, Rod End)....2523
      Port Relief Valve....2524
      Plug Removal....2525
      End Cap Block Removal And Installation....2526
      Lift Spool Removal And Installation....2527
      Auxiliary Spool Removal And Installation....2533
      Auxiliary Solenoid Disassembly And Assembly....2535
      BICS? Valve Solenoid Disassembly And Assembly....2536
      BICS? Valve, Lock Valve Removal And Installation....2537
      BICS? Valve, Lift Arm By-Pass Orifice Disassembly And Assembly....2539
      Main Relief Valve....2539
      BICS? Valve, Check Valve Removal And Installation....2540
    HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (SELECTABLE JOYSTICK CONTROL) (SJC)....2541
      Identification....2541
      Removal And Installation....2542
      Actuator Removal And Installation (In Loader)....2546
      Identification Chart....2551
      BICS? Valve, Lift Load Check Valve Removal And Installation....2552
      Load Check Valve Removal And Installation (Tilt & Auxiliary)....2553
      Anti-Cavitation Valve (Lift, Rod End)....2553
      Port Relief/Anti-Cavitation Valve (Lift, Base End)....2554
      Port Relief/Anti-Cavitation Valve (Tilt, Base End)....2555
      Port Relief/Anti-Cavitation Valve (Tilt, Rod End)....2555
      Port Relief Valve....2556
      Plug Removal....2557
      End Cap Block Removal And Installation....2558
      Lift Spool Removal And Installation....2559
      Auxiliary Spool Removal And Installation....2565
      Auxiliary Solenoid Disassembly And Assembly....2567
      BICS? Valve Solenoid Disassembly And Assembly....2568
      BICS? Valve, Lock Valve Removal And Installation....2569
      BICS? Valve, Lift Arm By-Pass Orifice Disassembly And Assembly....2571
      Main Relief Valve....2571
      BICS? Valve, Check Valve Removal And Installation....2572
    LIFT ARM BY-PASS CONTROL VALVE....2573
      Inspecting....2573
      Additional Inspection For Loaders W/Advanced Hand Controls....2573
      Removal And Installation....2573
      Disassembly And Assembly....2574
    HYDRAULIC PUMP....2575
      Check The Output Of The Hydraulic Pump....2575
      Removal And Installation....2576
      Identification....2578
      Disassembly And Assembly....2579
    HYDRAULIC PUMP (CHARGE)....2587
      Check The Output Of The Hydraulic Pump....2587
      Removal And Installation....2590
      Disassembly And Assembly....2590
    HYDRAULIC PUMP (HIGH FLOW)....2591
      Hydraulic Pump Test (30 GPM)....2591
      Hydraulic Pump Test (40 GPM)....2592
      Inline Hydraulic Pump Test (Standard)....2593
      Inline Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM)....2595
      High Flow Relief Adjustment Procedure (30 GPM And 40 GPM)....2597
      High Flow Relief Valve Removal And Installation (30 GPM And 40 GPM)....2599
      Removal And Installation (30 GPM And 40 GPM)....2600
      Identification (30 GPM) (S/N 526214399 & Below)....2602
      Identification (40 GPM) (S/N 526214400 & Above)....2603
      Disassembly And Assembly (30 GPM And 40 GPM)....2604
    HYDRAULIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC)....2617
      Check The Output Of The Hydraulic Pump....2617
      Removal And Installation....2618
      Identification....2620
      Disassembly And Assembly....2621
    HYDRAULIC PUMP (HIGH FLOW) (SELECTABLE JOYSTICK CONTROL) (SJC)....2627
      Hydraulic Pump Test (30 GPM)....2627
      Hydraulic Pump Test (40 GPM)....2628
      Inline Hydraulic Pump Test (Standard)....2629
      Inline Hydraulic Pump Test (High Flow) (30 GPM and 40 GPM)....2631
      High Flow Relief Adjustment Procedure (30 GPM and 40 GPM)....2633
      High Flow Relief Valve Removal and Installation (30 GPM and 40 GPM)....2635
      Removal And Installation (30 GPM and 40 GPM)....2637
      Identification (30 GPM) (S/N 526214399 and Below)....2639
      Identification (40 GPM) (S/N 526214400 and Above)....2640
      Disassembly And Assembly (30 GPM and 40 GPM)....2641
    HYDRAULIC/HYDROSTATIC FILTER....2651
      Housing Removal And Installation....2651
      Mount Removal And Installation....2652
    HYDRAULIC FLUID RESERVOIR....2653
      Fluid Removal....2653
      Removal And Installation....2653
      Hydraulic Fluid Screen....2656
    BUCKET POSITION VALVE....2659
      Solenoid Removal And Installation....2659
      Solenoid Testing....2659
      Removal And Installation....2660
      Disassembly And Assembly....2660
    REAR AUXILIARY DIVERTER....2663
      Removal and Installation....2663
      Disassembly And Assembly....2665
      Solenoid Testing....2670
      Inspection....2670
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....2677
      Removal and Installation....2677
      Disassembly And Assembly....2677
  HYDROSTATIC SYSTEM....2679
    HYDROSTATIC SYSTEM INFORMATION....2681
      Troubleshooting....2681
      Replenishing Valve Function....2682
    HYDROSTATIC MOTOR....2683
      Removal And Installation....2683
      Parts Identification....2684
      Disassembly....2685
      Inspection....2687
      Assembly....2688
    HYDROSTATIC MOTOR (TWO-SPEED)....2693
      Removal And Installation....2693
      Parts Identification....2695
      Disassembly....2697
      Inspection....2704
      Assembly....2705
    HYDROSTATIC MOTOR CARRIER....2713
      Removal and Installation....2713
      Parts Identification....2715
      Disassembly....2716
      Assembly....2717
    HYDROSTATIC MOTOR CARRIER (SELECTABLE JOYSTICK CONTROL) (SJC)....2719
      Removal And Installation....2719
      Parts Identification....2720
      Disassembly....2721
      Assembly....2723
    CHARGE PRESSURE....2727
      Testing....2727
      Removal And Installation....2729
      Setting Charge Pressure....2730
    HYDROSTATIC PUMP....2731
      Removal And Installation....2731
      Replenishing/High Pressure Relief Valve....2733
      Parts Identification (Right Half)....2734
      Parts Identification (Left Half)....2736
      Hydraulic Pump Removal And Installation....2738
      Pump Separation....2738
      Disassembly....2739
      Assembly....2745
    HYDROSTATIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC)....2753
      Pump Controller Removal And Installation....2753
      Hydrostatic Pump Calibration....2756
      Removal And Installation....2761
      Parts Identification (Right Half)....2763
      Parts Identification (Left Half)....2765
      System Check Relief Valves (High Pressure Relief, Charge Check & By-Pass Valve)....2767
      Charge Relief Valve....2768
      Pump Separation....2770
      Shaft Seal And Shaft Replacement....2771
      Shaft Seal And Shaft Installation....2773
      Charge Pump Removal....2775
      Charge Pump Inspection....2777
      Charge Pump Installation....2778
      Disassembly....2780
      Inspection....2787
      Assembly....2791
      Pump Neutral Adjustment....2800
      Pump Controller Neutral Adjustment....2803
    DRIVE BELT....2807
      Shield Removal And Installation....2807
      Adjustment....2807
      Replacement....2807
      Tensioner Pulley Removal And Installation....2808
      Tensioner Pulley Tension Spring....2810
    OIL COOLER (SEAL TO CONNECT) (STC)....2811
      Hydraulic Oil Cooler Removal And Installation....2811
  DRIVE SYSTEM....2813
    BRAKE....2815
      Disc Removal And Installation....2815
    BRAKE (TWO-SPEED)....2819
      Block Removal And Installation....2819
      Block Disassembly And Assembly....2820
    DRIVE COMPONENTS....2825
      Axle Seal Removal And Installation....2825
      Axle, Sprocket And Bearings Removal And Installation....2827
      Drive Chain Removal And Installation....2832
    CHAINCASE....2833
      Front Chaincase Cover Removal And Installation....2833
      Rear Chaincase Cover Removal And Installation....2833
  MAIN FRAME....2835
    SEAT BAR....2839
      Removal And Installation....2839
      Assembling Components....2840
      Compression Spring Disassembly And Assembly....2841
    OPERATOR CAB....2843
      Gas Cylinder Removal And Installation (Dual Gas Spring)....2843
      Gas Cylinder Removal And Installation (3rd Gas Spring)....2845
      Gas Cylinder Bracket Disassembly And Assembly....2846
      Removal And Installation....2847
    OPERATOR SEAT....2851
      Removal And Installation....2851
      Seat Belt Removal And Installation....2851
    OPERATOR SEAT (SUSPENSION)....2853
      Removal And Installation....2853
      Slide Rail Removal And Installation....2854
      Seat Belt Removal and Installation....2854
      Cushion Removal And Installation....2855
      Back Removal And Installation....2856
      Shock Removal And Installation....2856
      3-Point Seat Belt Removal And Installation....2857
    BOB-TACH....2859
      Removal And Installation....2859
      Bob-Tach Lever And Wedge....2861
    POWER BOB-TACH....2863
      Removal And Installation....2863
      Power Bob-Tach Lever And Wedge....2865
      Pivot Pin Bushing And Seal Replacement....2867
    LIFT ARMS....2869
      Removal And Installation....2869
    REAR GRILL....2873
      Removal And Installation....2873
    REAR DOOR....2875
      Removal And Installation....2875
      Striker Removal and Installation....2876
      Striker Disassembly and Assembly....2876
      Door Latch and Catch Adjustment....2876
      Latch Removal And Installation....2877
    FUEL TANK....2879
      Removal And Installation....2879
      Fuel Level Sender....2880
    CONTROL PEDALS....2881
      Removal And Installation....2881
      Pedal Adjustment....2881
    CONTROL PEDALS (ACS)....2883
      Foot Sensor Removal And Installation....2883
      Foot Pedal Removal And Installation....2884
      Foot Pedal Linkage Disassembly And Assembly....2884
    CONTROL PANEL (NON-ADJUSTABLE PINTLES)....2885
      Removal And Installation....2885
      Shock Removal And Installation....2887
      Shaft Removal And Installation....2887
      Shaft Disassembly And Assembly....2887
      Linkage Removal And Installation....2889
      Linkage Neutral Adjustment....2892
    CONTROL PANEL (ADJUSTABLE PINTLES)....2899
      Description....2899
      Removal And Installation....2900
      Shock Removal And Installation....2902
      Shaft Removal And Installation....2902
      Shaft Disassembly And Assembly....2903
      Linkage Removal And Installation....2904
      Pintle Arm Disassembly and Assembly....2909
      Linkage Neutral Adjustment....2910
      Linkage Travel Adjustment....2914
    CONTROL PANEL (SELECTABLE JOYSTICK CONTROL) (SJC)....2919
      Removal And Installation....2919
    CONTROL HANDLE....2923
      Lever Removal And Installation....2923
      Steering Lever Boot....2923
    CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL....2925
      Components Identification....2925
      Handle Sensor Removal And Installation....2925
      Control Handle Removal And Installation....2928
      Control Handle Disassembly And Assembly....2929
      Control Lever Removal And Installation....2930
      Control Lever Boot....2931
    CONTROL HANDLE (SELECTABLE JOYSTICK CONTROL) (SJC)....2933
      Joystick Testing (Right & Left)....2933
      Joystick Removal (Right & Left)....2934
      Joystick Boot Removal (Right & Left)....2935
      Lever Assembly Removal (Right & Left)....2935
    INSIDE ACCESS PANEL....2937
      Removal And Installation (Left)....2937
      Removal And Installation (Right)....2937
    INSIDE ACCESS PANEL (SELECTABLE JOYSTICK CONTROL) (SJC)....2939
      Panel Removal (Right)....2939
      Panel Removal (Left)....2942
  ELECTRICAL SYSTEM & ANALYSIS....2943
    ELECTRICAL SCHEMATICS....2947
    ELECTRICAL SYSTEM INFORMATION....2955
      Troubleshooting....2957
      Description....2958
      Fuse Location....2960
      Relay Switch Location....2960
      Solenoid Test....2961
    BATTERY....2963
      Removal And Installation....2963
      Servicing The Electrical System....2965
      Using A Booster Battery (Jump Starting)....2966
    ALTERNATOR....2967
      Adjusting The Alternator Belt....2967
      Alternator Identification....2967
      Charging System Check....2968
      Alternator Voltage Test....2969
      Low Voltage Test....2969
      High Voltage Test....2970
      Removal And Installation....2970
      Rectifier Continuity (Diode) Test....2971
      Alternator Regulator Test....2972
      Disassembly....2973
      Stator Continuity Test....2973
      Stator Ground Test....2973
      Rotor Continuity Test....2974
      Rotor Ground Test....2974
      Assembly....2974
    STARTER....2975
      Checking....2975
      Removal And Installation....2976
      Parts Identification....2977
      Disassembly And Assembly....2978
      Inspection And Repair....2981
      No Load Test....2984
    INSTRUMENT PANEL....2985
      Left Panel....2985
      Right Panel (Standard) (With Key Switch)....2986
      Right Panel (Deluxe) (With Keyless Start)....2987
      Right Panel Setup Display Options (Deluxe)....2989
      Deluxe Panel Setup....2990
      Passwords (Deluxe)....2990
      Option And Field Accessory Panels (If Equipped)....2992
      Standard Panel Removal And Installation (Right Side)....2993
      Deluxe Panel Removal And Installation (Right Side)....2994
      Standard & Deluxe Panel Removal And Installation (Left Side)....2995
      Front Accessory Panel Removal And Installation....2996
    LIGHTS....2997
      Front Removal And Installation....2997
      Rear Removal And Installation....2997
    CONTROLLER (BOBCAT)....3000
      Identification Chart....3000
      Removal And Installation....3002
    CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC)....3003
      Removal....3003
      Identification Chart....3006
    SPEED SENSOR (SELECTABLE JOYSTICK CONTROL) (SJC)....3009
      Testing....3009
      Removal....3010
    DIAGNOSTICS SERVICE CODES....3013
      Display....3013
      Number Codes List....3014
    BICS? SYSTEM....3019
      Inspecting The BICS? Controller (Engine STOPPED - Key ON)....3019
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....3019
      Inspecting The Seat Bar Sensor (Engine RUNNING)....3019
      Inspecting The Traction Lock (Engine RUNNING)....3019
      Inspecting The Lift Arm By-Pass Control....3020
      Additional Inspection For Loaders With Advanced Controls System (ACS) or Selectable Joystick Control (SJC)....3020
      Troubleshooting....3021
      Troubleshooting Guide....3022
    SEAT BAR SENSOR....3023
      Troubleshooting Chart....3023
      Test....3024
      Removal And Installation....3025
      BICS? Circuit Test....3026
    TRACTION LOCK....3027
      Troubleshooting....3027
      Removal And Installation (Single Speed)....3028
      Description Of The Control System (Two Speed)....3029
      Inspecting The Control System (Two Speed)....3029
    ADVANCED CONTROL SYSTEM (ACS)....3031
      Components Identification....3031
      Troubleshooting Guide....3033
      Controller, Connector And Wire Identification....3034
      ACS Controller Removal And Installation....3035
      Handle Sensor Connector....3036
      Switch Handle Removal....3037
      Switch Handle Installation....3039
      Actuators Disassembly And Assembly....3042
      Handle Lock Solenoid Removal And Installation....3043
      Handle Lock Solenoid Disassembly And Assembly....3044
      Handle Lock Solenoid Connector....3044
      Foot Sensor Disassembly And Assembly....3045
      Foot Sensor Connector....3046
      Foot Lock Solenoid Removal And Installation....3047
      Foot Lock Solenoid Connector....3048
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE....3049
      Controls Identification Chart....3049
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC)....3051
      Controls Identification Chart....3051
    SERVICE PC (LAPTOP COMPUTER)....3055
      Connecting The Service PC To Remote Start Tool....3055
    CALIBRATION....3057
      Lift and Tilt Calibration Procedure (Selectable Joystick Control) (SJC)....3057
      Hydrostatic Pump Calibration (Selectable Joystick Control) (SJC)....3059
      Calibration Procedure (Advanced Control System) (ACS)....3064
    FLYWHEEL RPM SENSOR....3067
      Adjustment....3067
  ENGINE SERVICE....3069
    TROUBLESHOOTING....3073
      Chart....3073
    ENGINE SPEED CONTROL....3075
      Removal And Installation....3075
      Speed Control Cable....3076
    ENGINE SPEED CONTROL (SELECTABLE JOYSTICK CONTROL) (SJC)....3079
      Removal....3079
      Disassembly....3081
      Speed Control Cable....3082
    MUFFLER....3083
      Removal And Installation....3083
    AIR CLEANER....3085
      Housing Removal And Installation....3085
    RADIATOR....3087
      Removal And Installation....3087
      Mount Removal (Early Loaders)....3089
      Mount Removal (Later Loaders)....3089
    COOLING FAN....3091
      Drive Tension Pulley Removal And Installation....3091
      Gearbox/Blower Housing Removal And Installation....3092
      Blower Removal And Installation....3093
      Gearbox Parts Identification....3095
      Gearbox Disassembly....3096
      Gearbox Assembly....3101
      Gearbox, Checking Backlash....3106
    ENGINE....3109
      Removal And Installation....3109
      Mount Replacement....3116
      Removal And Installation Tools....3117
    FLYWHEEL AND HOUSING....3119
      Flywheel Removal And Installation....3119
      Ring Gear Removal And Installation....3119
      Flywheel Housing Removal And Installation....3119
    RECONDITIONING THE ENGINE....3121
      Engine Tools Identification Chart....3121
      Compression Pressure....3126
      Cylinder Head Clearance....3126
      Valve Cover, Injector Nozzle And Seal Removal And Installation....3127
      Checking Nozzle Injection Pressure....3129
      Nozzle Spraying Condition....3130
      Valve Seat Tightness....3130
      Rocker Arm And Push Rod Disassembly And Assembly....3131
      Valve Clearance....3131
      Cylinder Head And Tappet Disassembly And Assembly....3132
      Selecting Cylinder Head Gasket Disassembly And Assembly....3133
      Valve Disassembly And Assembly....3135
      Engine Timing (TDC)....3135
      Injection Pump Housing Removal....3136
      Injection Pump Governor Housing Removal And Installation....3139
      Injection Pump Governor Fork Lever Removal And Installation....3141
      Injection Pump Governor Lever Removal And Installation....3141
      Injection Pump Stop Lever Removal And Installation....3142
      Injection Pump Fuel Camshaft And Governor Weight Removal And Installation....3142
      Injection Pump Removal and Installation....3144
      Injection Pump Housing Installation....3151
      Injection Pump Timing....3154
      Fan Drive Pulley Disassembly And Assembly....3156
      Water Pump Disassembly And Assembly....3157
      Oil Cooler And Water Pipe Disassembly And Assembly....3157
      Gearcase Cover Disassembly And Assembly....3158
      Idle Gear And Camshaft Disassembly And Assembly....3159
      Oil Pan And Oil Strainer Disassembly And Assembly....3159
      Connecting Rod Cap Disassembly And Assembly....3160
      Piston Disassembly And Assembly....3160
      Piston Ring And Connecting Rod Disassembly And Assembly....3161
      Flywheel And Crankshaft Disassembly And Assembly....3162
      Bearing Case Cover Disassembly And Assembly....3163
      Flywheel Housing Disassembly And Assembly....3164
      Crankcase No. 2 Disassembly And Assembly....3164
      Crankcase No. 1 And No. 2 Disassembly And Assembly....3165
      Crankshaft Disassembly And Assembly....3165
      Cylinder Head Surface Flatness....3166
      Cylinder Head Flaw....3167
      Valve Recessing....3167
      Valve Lapping....3168
      Clearance Between Valve Stem And Valve Guide....3168
      Replacing Valve Guide....3169
      Correcting Valve And Valve Seat....3169
      Free Length And Tilt Of Valve Spring....3170
      Valve Spring Setting Load....3170
      Oil Clearance Between Rocker Arm Shaft And Bearing....3171
      Oil Clearance Between Tappet And Tappet Guide Bore....3171
      Timing Gear Backlash....3172
      Idler Gear Side Clearance....3172
      Camshaft Side Clearance....3173
      Camshaft Alignment....3173
      Cam Height....3173
      Oil Clearance Between Idler Gear Shaft And Idler Gearing Bushing....3174
      Replacing Idler Gear Bushing....3175
      Piston Pin Bore I.D...3176
      Oil Clearance Between Piston Pin And Small End Bushing....3176
      Replacing Small End Bushing....3177
      Clearance Between Piston Ring And Groove....3177
      Piston Ring Gap....3178
      Connecting Rod Alignment....3178
      Crankshaft Side Clearance....3179
      Crankshaft Alignment....3180
      Oil Clearance Between Crankpin And Crankpin Bearing....3180
      Oil Clearance Between Crankshaft Journal And Crankshaft Bearing....3182
      Replacing Crankshaft Sleeve....3183
      Cylinder Bore I.D...3183
      Correcting Cylinder (Oversize +0.5 mm)....3184
      Engine Oil Pressure....3184
      Rotor Lobe Clearance....3185
      Clearance Between Outer Rotor And Pump Body....3185
      Clearance Between Rotor And Cover....3185
      Relief Valve....3186
      Thermostat Valve Opening Temperature....3186
      Radiator Water Leakage....3186
      Radiator Cap Air Leakage....3187
      Thermostat Assembly....3187
      Intake Air Heater....3188
      Air Cleaner, Intake Pipe, Inlet Pipe And Muffler....3189
      Oil Pipe....3189
      Turbocharger....3190
  HEATING, VENTILATION, AIR CONDITIONING....3191
    AIR CONDITIONING SYSTEM FLOW....3194
      Principals....3194
      Chart....3195
    COMPONENTS....3197
      Identification....3197
    SAFETY....3201
      Safety Equipment....3201
    REGULAR MAINTENANCE....3203
      Filter Elements Removal And Installation....3203
      Compressor Drive Belt Inspection....3204
      Cleaning The Condenser....3205
    BASIC TROUBLESHOOTING....3207
      Poor A/C Performance....3207
      Cleaning The A/C Evaporator Coil & Heater Coil....3208
      Compressor Drive Belt Inspection....3208
      Checking The Electrical System....3209
      Engine Coolant By-Passing The Heater Valve....3217
      Heater Valve Not Opening Or Closing....3218
    GENERAL AIR CONDITIONING SERVICE GUIDELINES....3219
      Compressor Oil....3219
      Compressor Oil Check....3220
      Component Replacement And Refrigeration Leaks....3221
    SYSTEM TROUBLESHOOTING CHART....3223
      Gauge Pressure Related Troubleshooting....3224
      Troubleshooting Tree....3226
    TEMPERATURE/PRESSURE....3231
      Chart....3231
    AIR CONDITIONING SERVICE....3233
      Chart....3233
    SYSTEM CHARGING AND RECLAMATION....3235
      Reclamation Procedure....3235
      Charging Procedure With A Manifold Gauge Set....3237
      Charging Procedure....3238
    COMPRESSOR....3241
      Removal And Installation....3241
      Compressor Clutch Disassembly....3242
    CONDENSER....3247
      Removal And Installation....3247
    RECEIVER/DRIER....3249
      Removal And Installation....3249
    PRESSURE RELIEF VALVE....3251
      Removal And Installation....3251
    PRESSURE SWITCH....3253
      Removal And Installation....3253
    EVAPORATOR/HEATER UNIT....3255
      Removal And Installation....3255
      Disassembly And Assembly....3256
    THERMOSTAT....3257
      Removal And Installation....3257
    EXPANSION VALVE....3259
      Removal And Installation....3259
    EVAPORATOR....3261
      Removal And Installation....3261
    HEATER COIL....3263
      Removal And Installation With A/C....3263
    BLOWER FAN....3265
      Removal And Installation....3265
      Disassembly And Assembly....3266
      Wire Connector Removal And Installation....3268
    HEATER VALVE....3271
      Removal And Installation....3271
      Disassembly And Assembly....3272
  SPECIFICATIONS....3275
    LOADER SPECIFICATIONS (S220)....3277
      Machine Dimensions....3277
      Performance....3278
      Controls....3278
      Engine....3278
      Hydraulic System....3279
      Electrical....3280
      Drive System....3280
      Capacities....3280
      Tires....3280
    ENGINE SPECIFICATIONS....3281
      General....3281
      Fuel System....3281
      Valve And Valve Timing....3281
      Valve Spring....3282
      Piston And Piston Ring....3282
      Connecting Rod....3282
      Cylinder Head....3283
      Crankshaft....3283
      Cylinder Bore....3283
      Oil Pump....3283
      Rocker Arm....3284
      Tappet....3284
      Camshaft....3284
      Thermostat....3284
      Timing Gear....3285
      Intake Air Heater....3285
      Turbocharger Compressor Shaft....3285
    TORQUE SPECIFICATIONS FOR BOLTS....3287
      Torque For General SAE Bolts....3287
      Torque For General Metric Bolts....3288
      Torque For Kubota Metric Engine Bolts....3289
      Tightening Torques For General Use Screws, Bolts And Nuts....3289
    HYDRAULIC CONNECTION SPECIFICATIONS....3291
      O-ring Face Seal Connection....3291
      Straight Thread O-ring Fitting....3292
      Tubelines And Hoses....3292
      Flare Fitting....3292
      O-ring Flare Fitting....3293
      Port Seal Fitting....3295
    HYDRAULIC FLUID SPECIFICATIONS....3297
      Specifications....3297
    CONVERSIONS....3299
      Decimal And Millimeter Equivalents....3299
  SMR....3301
    Revision No: S220-1....3301
    Revision No: S220-2....3303
    Revision No: S220-3....3305
    Revision No: S220-4....3307
    Revision No: S220-5....3309
6902722 (2-06) - S220 Turbo, S220 Turbo High Flow Service Manual....3311
  MAINTENANCE SAFETY....3313
  ALPHABETICAL INDEX....3315
  CONTENTS....3317
    FOREWORD....3318
    SAFETY INSTRUCTIONS....3321
      Fire Prevention....3323
    SERIAL NUMBER LOCATION....3325
      Loader Serial Number....3325
      Engine Serial Number....3325
    DELIVERY REPORT....3326
    BOBCAT LOADER IDENTIFICATION....3327
  SAFETY AND MAINTENANCE....3329
    LIFTING AND BLOCKING THE LOADER....3331
      Procedure....3331
    LIFT ARM SUPPORT DEVICE....3333
      Engaging The Lift Arm Support Device....3333
      Disengaging The Lift Arm Support Device....3334
    OPERATOR CAB....3335
      Description....3335
      Raising The Operator Cab....3335
      Lowering The Operator Cab....3336
      Emergency Exit....3336
    TRANSPORTING THE BOBCAT LOADER....3339
      Procedure....3339
    TOWING THE LOADER....3341
      Procedure....3341
    REMOTE START....3343
      Procedure For Loader W/O Attachments Control Harness....3343
      Procedure For Loader With Attachments Control Harness....3344
      Procedure....3345
    SERVICE SCHEDULE....3347
      Chart....3347
    AIR CLEANER SERVICE....3349
      Replacing Filter Element....3349
    ENGINE COOLING SYSTEM....3351
      Cleaning Cooling System....3351
      Checking The Coolant Level....3353
      Adding The Coolant....3354
    FUEL SYSTEM....3355
      Fuel Specifications....3355
      Filling The Fuel Tank....3355
      Fuel Filter....3355
      Removing Air From The Fuel System....3356
    ENGINE LUBRICATION SYSTEM....3357
      Checking Engine Oil....3357
      Oil Chart....3357
      Replacing Oil And Filter....3357
    HYDRAULIC/HYDROSTATIC SYSTEM....3359
      Checking And Adding Fluid....3359
      Hydraulic Fluid Chart....3359
      Hydraulic/Hydrostatic Filter Replacement....3360
      Replacing Hydraulic Fluid And Case Drain Filters....3361
    FINAL DRIVE TRANSMISSION (CHAINCASE)....3363
      Checking And Adding Oil....3363
      Removing The Oil....3363
    FAN GEARBOX....3365
      Checking And Adding Oil....3365
    BOB-TACH....3367
      Inspection And Maintenance....3367
    POWER BOB-TACH....3369
      Inspection And Maintenance....3369
    LUBRICATING THE LOADER....3371
      Procedure....3371
    TIRE MAINTENANCE....3373
      Wheel Nuts....3373
      Tire Rotation....3373
      Tire Mounting....3373
  HYDRAULIC SYSTEM....3375
    HYDRAULIC/HYDROSTATIC SCHEMATICS....3381
    HYDRAULIC SYSTEM INFORMATION....3413
      Troubleshooting....3417
      Tightening Procedure....3418
    CYLINDER (LIFT)....3419
      Checking....3419
      Removal And Installation....3419
      Parts Identification....3421
      Disassembly....3422
      Assembly....3423
    CYLINDER (TILT)....3427
      Checking....3427
      Removal And Installation....3427
      Base Pin Removal And Installation....3429
      Parts Identification....3430
      Disassembly....3431
      Assembly....3432
    CYLINDER (POWER BOB-TACH)....3435
      Checking....3435
      Removal And Installation....3436
      Parts Identification....3437
      Disassembly....3438
      Assembly....3439
    MAIN RELIEF VALVE....3443
      Checking Main Relief....3443
      Adjustment....3445
      Removal And Installation....3446
    MAIN RELIEF VALVE (ACS)....3447
      Checking The Main Relief Valve At Front Aux. Hyd...3447
      Removal And Installation....3448
      Adjustment....3449
    MAIN RELIEF VALVE (Selectable JOYSTICK Control) (Sjc)....3451
      Checking The Main Relief Valve At Front Auxiliary Hydraulics....3451
      Removal and Installation....3452
      Adjustment....3453
    HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL)....3455
      Identification....3455
      Removal And Installation....3455
      BICS? Valve, Removal And Installation....3459
      BICS? Valve, Lift Arm By-Pass Orifice Removal And Installation....3461
      BICS? Valve, Check Valve Removal And Installation....3462
      Backslide, Lock Valve Removal And Installation....3463
      BICS? Valve, Solenoid Removal And Installation....3464
      BICS? Valve, Solenoid Testing....3465
      Identification Chart....3466
      Load Check Valve....3467
      Main Relief Valve....3468
      Port Relief Valve, Tilt Spool....3468
      Port Relief Valve, Lift Spool....3469
      Anti-Cavitation Valve/Port Relief Valve, Tilt Spool....3469
      Anti-Cavitation Valve, Lift Spool....3470
      Rubber Boot....3470
      Lift And Tilt Lock Block....3471
      Lift Spool And Detent Removal....3472
      Lift Spool And Detent Disassembly....3474
      Lift Spool And Detent Assembly....3477
      Lift Spool And Detent Installation....3481
      Tilt Spool Removal And Installation....3482
      Tilt Spool Disassembly And Assembly....3483
      Auxiliary Spool Removal And Installation....3484
      Auxiliary Plug Removal And Installation....3486
      Auxiliary Electric Solenoid Disassembly....3487
      Port-Auxiliary Section Removal And Installation....3488
      Cleaning And Inspection....3488
    HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)....3489
      Identification....3489
      Actuator Removal And Installation (In Loader)....3490
      Actuator Removal And Installation (Out Of Loader)....3493
      Removal And Installation....3495
      BICS? Valve, Removal And Installation....3499
      BICS? Valve, Lift Arm By-Pass Orifice Disassembly And Assembly....3502
      BICS? Valve, Check Valve Disassembly And Assembly....3503
      BICS? Valve, Lock Valve Disassembly And Assembly....3504
      BICS? Valve, Solenoid Disassembly And Assembly....3505
      BICS? Valve, Solenoid Testing....3506
      Identification Chart....3507
      Lift Base End Restrictor....3508
      Load Check Valve....3509
      Main Relief Valve....3510
      Port Relief Valve....3512
      Anti-Cavitation Valve/Port Relief Valve....3513
      Anti-Cavitation Valve....3514
      Lift Spool Removal....3515
      Lift Spool Removal And Installation....3516
      Lift and Tilt Spool Disassembly And Assembly....3517
      Auxiliary Spool Removal And Installation....3518
      Auxiliary Electric Solenoid Disassembly....3519
      Port-Auxiliary Section Disassembly....3520
      Cleaning And Inspection....3520
    HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (selectable joystick control) (sjc)....3521
      Identification....3521
      Actuator Removal And Installation (In Loader)....3522
      Actuator Removal And Installation (Out Of Loader)....3525
      Removal And Installation....3527
      BICS? Valve, Removal And Installation....3531
      BICS? Valve, Lift Arm By-Pass Orifice Disassembly And Assembly....3534
      BICS? Valve, Check Valve Disassembly And Assembly....3535
      BICS? Valve, Lock Valve Disassembly And Assembly....3536
      BICS? Valve, Solenoid Disassembly And Assembly....3537
      BICS? Valve, Solenoid Testing....3538
      Identification Chart....3539
      Lift Base End Restrictor....3540
      Load Check Valve....3540
      Main Relief Valve....3541
      Port Relief Valve....3542
      Anti-Cavitation Valve/Port Relief Valve....3543
      Anti-Cavitation Valve....3544
      Lift Spool Removal....3545
      Lift Spool Removal And Installation....3546
      Lift and Tilt Spool Disassembly And Assembly....3547
      Auxiliary Spool Removal And Installation....3548
      Auxiliary Electric Solenoid Disassembly....3549
      Port-Auxiliary Section Disassembly....3550
      Cleaning And Inspection....3550
    HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL)....3551
      Removal And Installation....3551
      Identification Chart....3556
      BICS? Valve, Lift Load Check Valve Removal And Installation....3557
      Load Check Valve Removal And Installation (Tilt & Auxiliary)....3558
      Anti-Cavitation Valve (Lift, Rod End)....3558
      Port Relief/Anti-Cavitation Valve (Lift, Base End)....3559
      Port Relief/Anti-Cavitation Valve (Tilt, Base End)....3560
      Port Relief/Anti-Cavitation Valve (Tilt, Rod End)....3560
      Port Relief Valve....3561
      Plug Removal....3562
      Rubber Boot Removal and Installation....3563
      End Cap/Spool Lock Block Removal and Installation....3564
      Lift Spool and Detent Removal and Installation....3565
      Auxiliary Spool Removal And Installation....3577
      Auxiliary Solenoid Disassembly and Assembly....3579
      BICS? Valve Solenoid Disassembly And Assembly....3580
      BICS? Valve, Lock Valve Removal And Installation....3581
      BICS? Valve, Lift Arm By-Pass Orifice Disassembly And Assembly....3583
      Main Relief Valve....3583
      BICS? Valve, Check Valve Removal and Installation....3584
    HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)....3585
      Identification....3585
      Removal And Installation....3586
      Actuator Removal And Installation (In Loader)....3590
      Identification Chart....3595
      BICS? Valve, Lift Load Check Valve Removal And Installation....3596
      Load Check Valve Removal And Installation (Tilt & Auxiliary)....3597
      Anti-Cavitation Valve (Lift, Rod End)....3597
      Port Relief/Anti-Cavitation Valve (Lift, Base End)....3598
      Port Relief/Anti-Cavitation Valve (Tilt, Base End)....3599
      Port Relief/Anti-Cavitation Valve (Tilt, Rod End)....3599
      Port Relief Valve....3600
      Plug Removal....3601
      End Cap Block Removal And Installation....3602
      Lift Spool Removal And Installation....3603
      Auxiliary Spool Removal And Installation....3609
      Auxiliary Solenoid Disassembly And Assembly....3611
      BICS? Valve Solenoid Disassembly And Assembly....3612
      BICS? Valve, Lock Valve Removal And Installation....3613
      BICS? Valve, Lift Arm By-Pass Orifice Disassembly And Assembly....3615
      Main Relief Valve....3615
      BICS? Valve, Check Valve Removal And Installation....3616
    HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (SELECTABLE JOYSTICK CONTROL) (SJC)....3617
      Identification....3617
      Removal And Installation....3618
      Actuator Removal And Installation (In Loader)....3622
      Identification Chart....3627
      BICS? Valve, Lift Load Check Valve Removal And Installation....3628
      Load Check Valve Removal And Installation (Tilt & Auxiliary)....3629
      Anti-Cavitation Valve (Lift, Rod End)....3629
      Port Relief/Anti-Cavitation Valve (Lift, Base End)....3630
      Port Relief/Anti-Cavitation Valve (Tilt, Base End)....3631
      Port Relief/Anti-Cavitation Valve (Tilt, Rod End)....3631
      Port Relief Valve....3632
      Plug Removal....3633
      End Cap Block Removal And Installation....3634
      Lift Spool Removal And Installation....3635
      Auxiliary Spool Removal And Installation....3641
      Auxiliary Solenoid Disassembly And Assembly....3643
      BICS? Valve Solenoid Disassembly And Assembly....3644
      BICS? Valve, Lock Valve Removal And Installation....3645
      BICS? Valve, Lift Arm By-Pass Orifice Disassembly And Assembly....3647
      Main Relief Valve....3647
      BICS? Valve, Check Valve Removal And Installation....3648
    LIFT ARM BY-PASS CONTROL VALVE....3649
      Inspecting....3649
      Additional Inspection For Loaders W/Advanced Hand Controls....3649
      Removal And Installation....3649
      Disassembly And Assembly....3650
    HYDRAULIC PUMP....3651
      Check The Output Of The Hydraulic Pump....3651
      Removal And Installation....3652
      Identification....3654
      Disassembly And Assembly....3655
    HYDRAULIC PUMP (CHARGE)....3663
      Check The Output Of The Hydraulic Pump....3663
      Removal And Installation....3666
      Disassembly And Assembly....3666
    HYDRAULIC PUMP (HIGH FLOW)....3667
      Hydraulic Pump Test (30 GPM)....3667
      Hydraulic Pump Test (40 GPM)....3668
      Inline Hydraulic Pump Test (Standard)....3669
      Inline Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM)....3671
      High Flow Relief Adjustment Procedure (30 GPM And 40 GPM)....3673
      High Flow Relief Valve Removal And Installation (30 GPM And 40 GPM)....3675
      Removal And Installation (30 GPM And 40 GPM)....3676
      Identification (30 GPM) (S/N 526214399 & Below)....3678
      Identification (40 GPM) (S/N 526214400 & Above)....3679
      Disassembly And Assembly (30 GPM And 40 GPM)....3680
    HYDRAULIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC)....3693
      Check The Output Of The Hydraulic Pump....3693
      Removal And Installation....3694
      Identification....3696
      Disassembly And Assembly....3697
    HYDRAULIC PUMP (HIGH FLOW) (SELECTABLE JOYSTICK CONTROL) (SJC)....3703
      Hydraulic Pump Test (30 GPM)....3703
      Hydraulic Pump Test (40 GPM)....3704
      Inline Hydraulic Pump Test (Standard)....3705
      Inline Hydraulic Pump Test (High Flow) (30 GPM and 40 GPM)....3707
      High Flow Relief Adjustment Procedure (30 GPM and 40 GPM)....3709
      High Flow Relief Valve Removal and Installation (30 GPM and 40 GPM)....3711
      Removal And Installation (30 GPM and 40 GPM)....3713
      Identification (30 GPM) (S/N 526214399 and Below)....3715
      Identification (40 GPM) (S/N 526214400 and Above)....3716
      Disassembly And Assembly (30 GPM and 40 GPM)....3717
    HYDRAULIC/HYDROSTATIC FILTER....3727
      Housing Removal And Installation....3727
      Mount Removal And Installation....3728
    HYDRAULIC FLUID RESERVOIR....3729
      Fluid Removal....3729
      Removal And Installation....3729
      Hydraulic Fluid Screen....3732
    BUCKET POSITION VALVE....3735
      Solenoid Removal And Installation....3735
      Solenoid Testing....3735
      Removal And Installation....3736
      Disassembly And Assembly....3736
    REAR AUXILIARY DIVERTER....3739
      Removal and Installation....3739
      Disassembly And Assembly....3741
      Solenoid Testing....3746
      Inspection....3746
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....3753
      Removal and Installation....3753
      Disassembly And Assembly....3753
  HYDROSTATIC SYSTEM....3755
    HYDROSTATIC SYSTEM INFORMATION....3757
      Troubleshooting....3757
      Replenishing Valve Function....3758
    HYDROSTATIC MOTOR....3759
      Removal And Installation....3759
      Parts Identification....3760
      Disassembly....3761
      Inspection....3763
      Assembly....3764
    HYDROSTATIC MOTOR (TWO-SPEED)....3769
      Removal And Installation....3769
      Parts Identification....3771
      Disassembly....3773
      Inspection....3780
      Assembly....3781
    HYDROSTATIC MOTOR CARRIER....3789
      Removal and Installation....3789
      Parts Identification....3791
      Disassembly....3792
      Assembly....3793
    HYDROSTATIC MOTOR CARRIER (SELECTABLE JOYSTICK CONTROL) (SJC)....3795
      Removal And Installation....3795
      Parts Identification....3796
      Disassembly....3797
      Assembly....3799
    CHARGE PRESSURE....3803
      Testing....3803
      Removal And Installation....3805
      Setting Charge Pressure....3806
    HYDROSTATIC PUMP....3807
      Removal And Installation....3807
      Replenishing/High Pressure Relief Valve....3809
      Parts Identification (Right Half)....3810
      Parts Identification (Left Half)....3812
      Hydraulic Pump Removal And Installation....3814
      Pump Separation....3814
      Disassembly....3815
      Assembly....3821
    HYDROSTATIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC)....3829
      Pump Controller Removal And Installation....3829
      Hydrostatic Pump Calibration....3832
      Removal And Installation....3837
      Parts Identification (Right Half)....3839
      Parts Identification (Left Half)....3841
      System Check Relief Valves (High Pressure Relief, Charge Check & By-Pass Valve)....3843
      Charge Relief Valve....3844
      Pump Separation....3846
      Shaft Seal And Shaft Replacement....3847
      Shaft Seal And Shaft Installation....3849
      Charge Pump Removal....3851
      Charge Pump Inspection....3853
      Charge Pump Installation....3854
      Disassembly....3856
      Inspection....3863
      Assembly....3867
      Pump Neutral Adjustment....3876
      Pump Controller Neutral Adjustment....3879
    DRIVE BELT....3883
      Shield Removal And Installation....3883
      Adjustment....3883
      Replacement....3883
      Tensioner Pulley Removal And Installation....3884
      Tensioner Pulley Tension Spring....3886
    OIL COOLER (SEAL TO CONNECT) (STC)....3887
      Hydraulic Oil Cooler Removal And Installation....3887
  DRIVE SYSTEM....3889
    BRAKE....3891
      Disc Removal And Installation....3891
    BRAKE (TWO-SPEED)....3895
      Block Removal And Installation....3895
      Block Disassembly And Assembly....3896
    DRIVE COMPONENTS....3901
      Axle Seal Removal And Installation....3901
      Axle, Sprocket And Bearings Removal And Installation....3903
      Drive Chain Removal And Installation....3908
    CHAINCASE....3909
      Front Chaincase Cover Removal And Installation....3909
      Rear Chaincase Cover Removal And Installation....3909
  MAIN FRAME....3911
    SEAT BAR....3915
      Removal And Installation....3915
      Assembling Components....3916
      Compression Spring Disassembly And Assembly....3917
    OPERATOR CAB....3919
      Gas Cylinder Removal And Installation (Dual Gas Spring)....3919
      Gas Cylinder Removal And Installation (3rd Gas Spring)....3921
      Gas Cylinder Bracket Disassembly And Assembly....3922
      Removal And Installation....3923
    OPERATOR SEAT....3927
      Removal And Installation....3927
      Seat Belt Removal And Installation....3927
    OPERATOR SEAT (SUSPENSION)....3929
      Removal And Installation....3929
      Slide Rail Removal And Installation....3930
      Seat Belt Removal and Installation....3930
      Cushion Removal And Installation....3931
      Back Removal And Installation....3932
      Shock Removal And Installation....3932
      3-Point Seat Belt Removal And Installation....3933
    BOB-TACH....3935
      Removal And Installation....3935
      Bob-Tach Lever And Wedge....3937
    POWER BOB-TACH....3939
      Removal And Installation....3939
      Power Bob-Tach Lever And Wedge....3941
      Pivot Pin Bushing And Seal Replacement....3943
    LIFT ARMS....3945
      Removal And Installation....3945
    REAR GRILL....3949
      Removal And Installation....3949
    REAR DOOR....3951
      Removal And Installation....3951
      Striker Removal and Installation....3952
      Striker Disassembly and Assembly....3952
      Door Latch and Catch Adjustment....3952
      Latch Removal And Installation....3953
    FUEL TANK....3955
      Removal And Installation....3955
      Fuel Level Sender....3956
    CONTROL PEDALS....3957
      Removal And Installation....3957
      Pedal Adjustment....3957
    CONTROL PEDALS (ACS)....3959
      Foot Sensor Removal And Installation....3959
      Foot Pedal Removal And Installation....3960
      Foot Pedal Linkage Disassembly And Assembly....3960
    CONTROL PANEL (NON-ADJUSTABLE PINTLES)....3961
      Removal And Installation....3961
      Shock Removal And Installation....3963
      Shaft Removal And Installation....3963
      Shaft Disassembly And Assembly....3963
      Linkage Removal And Installation....3965
      Linkage Neutral Adjustment....3968
    CONTROL PANEL (ADJUSTABLE PINTLES)....3975
      Description....3975
      Removal And Installation....3976
      Shock Removal And Installation....3978
      Shaft Removal And Installation....3978
      Shaft Disassembly And Assembly....3979
      Linkage Removal And Installation....3980
      Pintle Arm Disassembly and Assembly....3985
      Linkage Neutral Adjustment....3986
      Linkage Travel Adjustment....3990
    CONTROL PANEL (SELECTABLE JOYSTICK CONTROL) (SJC)....3995
      Removal And Installation....3995
    CONTROL HANDLE....3999
      Lever Removal And Installation....3999
      Steering Lever Boot....3999
    CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL....4001
      Components Identification....4001
      Handle Sensor Removal And Installation....4001
      Control Handle Removal And Installation....4004
      Control Handle Disassembly And Assembly....4005
      Control Lever Removal And Installation....4006
      Control Lever Boot....4007
    CONTROL HANDLE (SELECTABLE JOYSTICK CONTROL) (SJC)....4009
      Joystick Testing (Right & Left)....4009
      Joystick Removal (Right & Left)....4010
      Joystick Boot Removal (Right & Left)....4011
      Lever Assembly Removal (Right & Left)....4011
    INSIDE ACCESS PANEL....4013
      Removal And Installation (Left)....4013
      Removal And Installation (Right)....4013
    INSIDE ACCESS PANEL (SELECTABLE JOYSTICK CONTROL) (SJC)....4015
      Panel Removal (Right)....4015
      Panel Removal (Left)....4018
  ELECTRICAL SYSTEM & ANALYSIS....4019
    ELECTRICAL SCHEMATICS....4023
    ELECTRICAL SYSTEM INFORMATION....4031
      Troubleshooting....4033
      Description....4034
      Fuse Location....4036
      Relay Switch Location....4036
      Solenoid Test....4037
    BATTERY....4039
      Removal And Installation....4039
      Servicing The Electrical System....4041
      Using A Booster Battery (Jump Starting)....4042
    ALTERNATOR....4043
      Adjusting The Alternator Belt....4043
      Alternator Identification....4043
      Charging System Check....4044
      Alternator Voltage Test....4045
      Low Voltage Test....4045
      High Voltage Test....4046
      Removal And Installation....4046
      Rectifier Continuity (Diode) Test....4047
      Alternator Regulator Test....4048
      Disassembly....4049
      Stator Continuity Test....4049
      Stator Ground Test....4049
      Rotor Continuity Test....4050
      Rotor Ground Test....4050
      Assembly....4050
    STARTER....4051
      Checking....4051
      Removal And Installation....4052
      Parts Identification....4053
      Disassembly And Assembly....4054
      Inspection And Repair....4057
      No Load Test....4060
    INSTRUMENT PANEL....4061
      Left Panel....4061
      Right Panel (Standard) (With Key Switch)....4062
      Right Panel (Deluxe) (With Keyless Start)....4063
      Right Panel Setup Display Options (Deluxe)....4065
      Deluxe Panel Setup....4066
      Passwords (Deluxe)....4066
      Option And Field Accessory Panels (If Equipped)....4068
      Standard Panel Removal And Installation (Right Side)....4069
      Deluxe Panel Removal And Installation (Right Side)....4070
      Standard & Deluxe Panel Removal And Installation (Left Side)....4071
      Front Accessory Panel Removal And Installation....4072
    LIGHTS....4073
      Front Removal And Installation....4073
      Rear Removal And Installation....4073
    CONTROLLER (BOBCAT)....4076
      Identification Chart....4076
      Removal And Installation....4078
    CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC)....4079
      Removal....4079
      Identification Chart....4082
    SPEED SENSOR (SELECTABLE JOYSTICK CONTROL) (SJC)....4085
      Testing....4085
      Removal....4086
    DIAGNOSTICS SERVICE CODES....4089
      Display....4089
      Number Codes List....4090
    BICS? SYSTEM....4095
      Inspecting The BICS? Controller (Engine STOPPED - Key ON)....4095
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....4095
      Inspecting The Seat Bar Sensor (Engine RUNNING)....4095
      Inspecting The Traction Lock (Engine RUNNING)....4095
      Inspecting The Lift Arm By-Pass Control....4096
      Additional Inspection For Loaders With Advanced Controls System (ACS) or Selectable Joystick Control (SJC)....4096
      Troubleshooting....4097
      Troubleshooting Guide....4098
    SEAT BAR SENSOR....4099
      Troubleshooting Chart....4099
      Test....4100
      Removal And Installation....4101
      BICS? Circuit Test....4102
    TRACTION LOCK....4103
      Troubleshooting....4103
      Removal And Installation (Single Speed)....4104
      Description Of The Control System (Two Speed)....4105
      Inspecting The Control System (Two Speed)....4105
    ADVANCED CONTROL SYSTEM (ACS)....4107
      Components Identification....4107
      Troubleshooting Guide....4109
      Controller, Connector And Wire Identification....4110
      ACS Controller Removal And Installation....4111
      Handle Sensor Connector....4112
      Switch Handle Removal....4113
      Switch Handle Installation....4115
      Actuators Disassembly And Assembly....4118
      Handle Lock Solenoid Removal And Installation....4119
      Handle Lock Solenoid Disassembly And Assembly....4120
      Handle Lock Solenoid Connector....4120
      Foot Sensor Disassembly And Assembly....4121
      Foot Sensor Connector....4122
      Foot Lock Solenoid Removal And Installation....4123
      Foot Lock Solenoid Connector....4124
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE....4125
      Controls Identification Chart....4125
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC)....4127
      Controls Identification Chart....4127
    SERVICE PC (LAPTOP COMPUTER)....4131
      Connecting The Service PC To Remote Start Tool....4131
    CALIBRATION....4133
      Lift and Tilt Calibration Procedure (Selectable Joystick Control) (SJC)....4133
      Hydrostatic Pump Calibration (Selectable Joystick Control) (SJC)....4135
      Calibration Procedure (Advanced Control System) (ACS)....4140
    FLYWHEEL RPM SENSOR....4143
      Adjustment....4143
  ENGINE SERVICE....4145
    TROUBLESHOOTING....4149
      Chart....4149
    ENGINE SPEED CONTROL....4151
      Removal And Installation....4151
      Speed Control Cable....4152
    ENGINE SPEED CONTROL (SELECTABLE JOYSTICK CONTROL) (SJC)....4155
      Removal....4155
      Disassembly....4157
      Speed Control Cable....4158
    MUFFLER....4159
      Removal And Installation....4159
    AIR CLEANER....4161
      Housing Removal And Installation....4161
    RADIATOR....4163
      Removal And Installation....4163
      Mount Removal (Early Loaders)....4165
      Mount Removal (Later Loaders)....4165
    COOLING FAN....4167
      Drive Tension Pulley Removal And Installation....4167
      Gearbox/Blower Housing Removal And Installation....4168
      Blower Removal And Installation....4169
      Gearbox Parts Identification....4171
      Gearbox Disassembly....4172
      Gearbox Assembly....4177
      Gearbox, Checking Backlash....4182
    ENGINE....4185
      Removal And Installation....4185
      Mount Replacement....4192
      Removal And Installation Tools....4193
    FLYWHEEL AND HOUSING....4195
      Flywheel Removal And Installation....4195
      Ring Gear Removal And Installation....4195
      Flywheel Housing Removal And Installation....4195
    RECONDITIONING THE ENGINE....4197
      Engine Tools Identification Chart....4197
      Compression Pressure....4202
      Cylinder Head Clearance....4202
      Valve Cover, Injector Nozzle And Seal Removal And Installation....4203
      Checking Nozzle Injection Pressure....4205
      Nozzle Spraying Condition....4206
      Valve Seat Tightness....4206
      Rocker Arm And Push Rod Disassembly And Assembly....4207
      Valve Clearance....4207
      Cylinder Head And Tappet Disassembly And Assembly....4208
      Selecting Cylinder Head Gasket Disassembly And Assembly....4209
      Valve Disassembly And Assembly....4211
      Engine Timing (TDC)....4211
      Injection Pump Housing Removal....4212
      Injection Pump Governor Housing Removal And Installation....4215
      Injection Pump Governor Fork Lever Removal And Installation....4217
      Injection Pump Governor Lever Removal And Installation....4217
      Injection Pump Stop Lever Removal And Installation....4218
      Injection Pump Fuel Camshaft And Governor Weight Removal And Installation....4218
      Injection Pump Removal and Installation....4220
      Injection Pump Housing Installation....4227
      Injection Pump Timing....4230
      Fan Drive Pulley Disassembly And Assembly....4232
      Water Pump Disassembly And Assembly....4233
      Oil Cooler And Water Pipe Disassembly And Assembly....4233
      Gearcase Cover Disassembly And Assembly....4234
      Idle Gear And Camshaft Disassembly And Assembly....4235
      Oil Pan And Oil Strainer Disassembly And Assembly....4235
      Connecting Rod Cap Disassembly And Assembly....4236
      Piston Disassembly And Assembly....4236
      Piston Ring And Connecting Rod Disassembly And Assembly....4237
      Flywheel And Crankshaft Disassembly And Assembly....4238
      Bearing Case Cover Disassembly And Assembly....4239
      Flywheel Housing Disassembly And Assembly....4240
      Crankcase No. 2 Disassembly And Assembly....4240
      Crankcase No. 1 And No. 2 Disassembly And Assembly....4241
      Crankshaft Disassembly And Assembly....4241
      Cylinder Head Surface Flatness....4242
      Cylinder Head Flaw....4243
      Valve Recessing....4243
      Valve Lapping....4244
      Clearance Between Valve Stem And Valve Guide....4244
      Replacing Valve Guide....4245
      Correcting Valve And Valve Seat....4245
      Free Length And Tilt Of Valve Spring....4246
      Valve Spring Setting Load....4246
      Oil Clearance Between Rocker Arm Shaft And Bearing....4247
      Oil Clearance Between Tappet And Tappet Guide Bore....4247
      Timing Gear Backlash....4248
      Idler Gear Side Clearance....4248
      Camshaft Side Clearance....4249
      Camshaft Alignment....4249
      Cam Height....4249
      Oil Clearance Between Idler Gear Shaft And Idler Gearing Bushing....4250
      Replacing Idler Gear Bushing....4251
      Piston Pin Bore I.D...4252
      Oil Clearance Between Piston Pin And Small End Bushing....4252
      Replacing Small End Bushing....4253
      Clearance Between Piston Ring And Groove....4253
      Piston Ring Gap....4254
      Connecting Rod Alignment....4254
      Crankshaft Side Clearance....4255
      Crankshaft Alignment....4256
      Oil Clearance Between Crankpin And Crankpin Bearing....4256
      Oil Clearance Between Crankshaft Journal And Crankshaft Bearing....4258
      Replacing Crankshaft Sleeve....4259
      Cylinder Bore I.D...4259
      Correcting Cylinder (Oversize +0.5 mm)....4260
      Engine Oil Pressure....4260
      Rotor Lobe Clearance....4261
      Clearance Between Outer Rotor And Pump Body....4261
      Clearance Between Rotor And Cover....4261
      Relief Valve....4262
      Thermostat Valve Opening Temperature....4262
      Radiator Water Leakage....4262
      Radiator Cap Air Leakage....4263
      Thermostat Assembly....4263
      Intake Air Heater....4264
      Air Cleaner, Intake Pipe, Inlet Pipe And Muffler....4265
      Oil Pipe....4265
      Turbocharger....4266
  HEATING, VENTILATION, AIR CONDITIONING....4267
    AIR CONDITIONING SYSTEM FLOW....4270
      Principals....4270
      Chart....4271
    COMPONENTS....4273
      Identification....4273
    SAFETY....4277
      Safety Equipment....4277
    REGULAR MAINTENANCE....4279
      Filter Elements Removal And Installation....4279
      Compressor Drive Belt Inspection....4280
      Cleaning The Condenser....4281
    BASIC TROUBLESHOOTING....4283
      Poor A/C Performance....4283
      Cleaning The A/C Evaporator Coil & Heater Coil....4284
      Compressor Drive Belt Inspection....4284
      Checking The Electrical System....4285
      Engine Coolant By-Passing The Heater Valve....4293
      Heater Valve Not Opening Or Closing....4294
    GENERAL AIR CONDITIONING SERVICE GUIDELINES....4295
      Compressor Oil....4295
      Compressor Oil Check....4296
      Component Replacement And Refrigeration Leaks....4297
    SYSTEM TROUBLESHOOTING CHART....4299
      Gauge Pressure Related Troubleshooting....4300
      Troubleshooting Tree....4302
    TEMPERATURE/PRESSURE....4307
      Chart....4307
    AIR CONDITIONING SERVICE....4309
      Chart....4309
    SYSTEM CHARGING AND RECLAMATION....4311
      Reclamation Procedure....4311
      Charging Procedure With A Manifold Gauge Set....4313
      Charging Procedure....4314
    COMPRESSOR....4317
      Removal And Installation....4317
      Compressor Clutch Disassembly....4318
    CONDENSER....4323
      Removal And Installation....4323
    RECEIVER/DRIER....4325
      Removal And Installation....4325
    PRESSURE RELIEF VALVE....4327
      Removal And Installation....4327
    PRESSURE SWITCH....4329
      Removal And Installation....4329
    EVAPORATOR/HEATER UNIT....4331
      Removal And Installation....4331
      Disassembly And Assembly....4332
    THERMOSTAT....4333
      Removal And Installation....4333
    EXPANSION VALVE....4335
      Removal And Installation....4335
    EVAPORATOR....4337
      Removal And Installation....4337
    HEATER COIL....4339
      Removal And Installation With A/C....4339
    BLOWER FAN....4341
      Removal And Installation....4341
      Disassembly And Assembly....4342
      Wire Connector Removal And Installation....4344
    HEATER VALVE....4347
      Removal And Installation....4347
      Disassembly And Assembly....4348
  SPECIFICATIONS....4351
    LOADER SPECIFICATIONS (S220)....4353
      Machine Dimensions....4353
      Performance....4354
      Controls....4354
      Engine....4354
      Hydraulic System....4355
      Electrical....4356
      Drive System....4356
      Capacities....4356
      Tires....4356
    ENGINE SPECIFICATIONS....4357
      General....4357
      Fuel System....4357
      Valve And Valve Timing....4357
      Valve Spring....4358
      Piston And Piston Ring....4358
      Connecting Rod....4358
      Cylinder Head....4359
      Crankshaft....4359
      Cylinder Bore....4359
      Oil Pump....4359
      Rocker Arm....4360
      Tappet....4360
      Camshaft....4360
      Thermostat....4360
      Timing Gear....4361
      Intake Air Heater....4361
      Turbocharger Compressor Shaft....4361
    TORQUE SPECIFICATIONS FOR BOLTS....4363
      Torque For General SAE Bolts....4363
      Torque For General Metric Bolts....4364
      Torque For Kubota Metric Engine Bolts....4365
      Tightening Torques For General Use Screws, Bolts And Nuts....4365
    HYDRAULIC CONNECTION SPECIFICATIONS....4367
      O-ring Face Seal Connection....4367
      Straight Thread O-ring Fitting....4368
      Tubelines And Hoses....4368
      Flare Fitting....4368
      O-ring Flare Fitting....4369
      Port Seal Fitting....4371
    HYDRAULIC FLUID SPECIFICATIONS....4373
      Specifications....4373
    CONVERSIONS....4375
      Decimal And Millimeter Equivalents....4375
  SMR....4377
    Revision No: S220-1....4377
    Revision No: S220-2....4379
    Revision No: S220-3....4381
    Revision No: S220-4....4383
6904152 (5-08) - S220 Skid-Steer Loader Operation & Maintenance Manual....4385
  OPERATOR SAFETY WARNINGS....4387
  CONTENTS....4389
  FOREWORD....4391
    BOBCAT COMPANY IS ISO9001:2000 CERTIFIED....4393
    REGULAR MAINTENANCE ITEMS....4393
    SERIAL NUMBER LOCATIONS....4394
      Loader Serial Number....4394
      Engine Serial Number....4394
    DELIVERY REPORT....4394
    LOADER IDENTIFICATION....4395
    FEATURES, ACCESSORIEs and attachments....4396
      Standard Items....4396
      Options and Accessories....4396
      Buckets Available....4397
      Attachments....4397
      40 GPM Attachments....4397
      Special Applications Kit....4398
      Special Applications Kit Inspection And Maintenance....4398
  SAFETY & TRAINING RESOURCES....4399
    SAFETY INSTRUCTIONS....4401
      Before Operation....4401
      Safe Operation Is The Operator?s Responsibility....4402
      Safe Operation Needs A Qualified Operator....4402
      Avoid Silica Dust....4403
    FIRE PREVENTION....4403
      Maintenance....4403
      Operation....4403
      Electrical....4403
      Hydraulic System....4404
      Fueling....4404
      Starting....4404
      Spark Arrestor Exhaust System....4404
      Welding And Grinding....4404
      Fire Extinguishers....4404
    MACHINE SIGNS (DECALS)....4406
    PUBLICATIONS AND TRAINING RESOURCES....4408
  OPERATING INSTRUCTIONS....4409
    INSTRUMENT PANEL IDENTIFICATION....4413
      Left Panel....4413
      Right Panel (Key Switch)....4414
      Right Panel (Keyless)....4415
      Cab Light....4416
      Side And Front Panels....4417
    SEAT BAR RESTRAINT SYSTEM....4418
      Operation....4418
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....4419
      Operation....4419
    LIFT ARM BYPASS CONTROL....4420
      Operation....4420
    PARKING BRAKE....4420
      Operation....4420
    TRACTION LOCK OVERRIDE....4420
      Operation....4420
    BACK-UP ALARM SYSTEM....4421
      Operation....4421
    ENGINE SPEED CONTROL....4421
      Operation....4421
    DRIVING AND STEERING THE LOADER....4422
      Available Control Configurations....4422
      Operation (Standard and ACS)....4422
      Operation (SJC) in ?H? Control Pattern....4423
      Operation (SJC) in ?ISO? Control Pattern....4424
    STOPPING THE LOADER....4424
      Using The Control Levers Or Joysticks....4424
    TWO-SPEED CONTROL....4425
      Description....4425
      Operation (Standard And ACS) (If Equipped)....4425
      Operation (SJC) (If Equipped)....4425
    SPEED MANAGEMENT....4426
      Operation....4426
    STEERING DRIFT COMPENSATION....4427
      Description....4427
      Selecting And Adjusting....4427
      Exiting And Saving....4428
    HYDRAULIC CONTROLS....4429
      Description....4429
      Standard Controls (Also ACS In Foot Pedal Mode)....4429
      Advanced Control System (ACS) in HAND Control Mode....4430
      Selectable Joystick Control (SJC) - ?H? Control Pattern....4430
      Selectable Joystick Control (SJC) - ?ISO? Control Pattern....4431
      Hydraulic Bucket Positioning....4431
      FRONT Auxiliary Hydraulics Operation (VARIABLE FLOW)....4432
      FRONT Auxiliary Hydraulics Operation (MAXIMUM FLOW)....4432
      FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....4433
      REAR Auxiliary Hydraulics Operation....4433
      Quick Couplers....4434
      Relieve Hydraulic Pressure (Loader and Attachment)....4434
      High-Flow Hydraulics Operation....4435
      Secondary Front Auxiliary Hydraulics....4436
    ATTACHMENT CONTROL DEVICE (ACD)....4437
      Description....4437
    DAILY INSPECTION....4438
      Daily Inspection and Maintenance....4439
    PRE-STARTING PROCEDURE....4440
      Entering The Loader....4440
      Operation & Maintenance Manual And Operator?s Handbook Locations....4440
      Seat Adjustment....4441
      Seat Belt Adjustment....4441
      Seat Bar....4442
    STARTING THE ENGINE....4443
      Key Switch....4443
      Keyless....4445
      Cold Temperature Starting....4446
      Warming The Hydraulic / Hydrostatic System....4447
    MONITORING THE DISPLAY PANELS....4448
      Left Panel....4448
      Right Panel (Key Switch)....4448
      Right Panel (Keyless)....4448
      Warning and Shutdown....4448
    STOPPING THE ENGINE AND LEAVING THE LOADER....4449
      Procedure....4449
      Emergency Exit....4450
    ATTACHMENTS....4451
      Choosing The Correct Bucket....4451
      Pallet Forks....4451
      Installing And Removing The Attachment (Hand Lever Bob-Tach)....4452
      Installing And Removing The Attachment (Power Bob-Tach)....4454
    OPERATING PROCEDURE....4457
      Inspect The Work Area....4457
      Operating With A Full Bucket....4457
      Operating With An Empty Bucket....4458
      Filling And Emptying The Bucket (Foot Pedals)....4459
      Leveling The Ground Using Float (Foot Pedals)....4460
      Digging And Filling A Hole (Foot Pedals)....4461
      Filling And Emptying The Bucket (ACS - Handles, SJC - ?H? Pattern)....4462
      Leveling The Ground Using Float (ACS - Handles, SJC - ?H? Pattern)....4463
      Digging And Filling A Hole (ACS - Handles, SJC - ?H? Pattern)....4464
      Filling And Emptying The Bucket (SJC - ?ISO? Pattern)....4465
      Leveling The Ground Using Float (SJC - ?ISO? Pattern)....4466
      Digging And Filling A Hole (SJC - ?ISO? Pattern)....4467
    TOWING THE LOADER....4468
      Procedure....4468
    LIFTING THE LOADER....4469
      Single Point Lift....4469
      Four Point Lift....4469
    TRANSPORTING THE LOADER ON A TRAILER....4470
      Loading And Unloading....4470
      Fastening....4470
  PREVENTIVE MAINTENANCE....4471
    MAINTENANCE SAFETY....4475
    SERVICE SCHEDULE....4477
      Chart....4477
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....4478
      Inspecting The BICS Controller (Engine STOPPED - Key ON)....4478
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....4478
      Inspecting The Seat Bar Sensor (Engine RUNNING)....4478
      Inspecting The Traction Lock (Engine RUNNING)....4478
      Inspecting The Lift Arm By-Pass Control....4478
      Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....4478
    SEAT BAR RESTRAINT SYSTEM....4479
      Description....4479
      Inspecting....4479
      Maintaining....4479
    SEAT BELT....4480
      Inspection and Maintenance....4480
    LIFT ARM SUPPORT DEVICE....4481
      Installing....4481
      Removing....4482
    BACK-UP ALARM SYSTEM....4483
      Description....4483
      Inspecting....4483
      Adjusting Switch Position....4483
    OPERATOR CAB....4484
      Description....4484
      Raising....4484
      Lowering....4485
      Cab Door Sensor....4486
    REAR DOOR....4487
      Opening And Closing....4487
      Adjusting....4487
    REAR GRILL....4488
      Removing....4488
      Installing....4488
    HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....4489
      Cleaning And Maintenance....4489
      Filters....4489
      Evaporator / Heater Coil....4489
      Condenser....4489
      Air Conditioning Lubrication....4489
      Troubleshooting....4489
    AIR CLEANER SERVICE....4490
      Replacing Filter Elements....4490
    FUEL SYSTEM....4492
      Fuel Specifications....4492
      Biodiesel Blend Fuel....4492
      Filling The Fuel Tank....4493
      Fuel Filter....4494
      Removing Air From The Fuel System....4494
    ENGINE LUBRICATION SYSTEM....4495
      Checking And Adding Engine Oil....4495
      Engine Oil Chart....4495
      Removing And Replacing Oil And Filter....4495
    ENGINE COOLING SYSTEM....4496
      Cleaning....4496
      Checking Level....4497
      Removing And Replacing Coolant....4497
    ELECTRICAL SYSTEM....4498
      Description....4498
      Fuse And Relay Location / Identification....4498
      Battery Maintenance....4499
      Using A Booster Battery (Jump Starting)....4499
      Removing And Installing Battery....4501
    HYDRAULIC / HYDROSTATIC SYSTEM....4502
      Checking And Adding Fluid....4502
      Hydraulic / Hydrostatic Fluid Chart....4502
      Removing And Replacing Hydraulic Fluid....4502
      Removing And Replacing Hydraulic / Hydrostatic Filter....4504
      Removing And Replacing Case Drain Filters....4504
      Removing And Replacing Hydraulic Charge Filter....4506
      Breather Cap....4507
    SPARK ARRESTOR MUFFLER....4508
      Cleaning Procedure....4508
    TIRE MAINTENANCE....4509
      Wheel Nuts....4509
      Rotating....4509
      Mounting....4509
    FINAL DRIVE TRANSMISSION (CHAINCASE)....4510
      Checking And Adding Oil....4510
      Removing And Replacing Oil....4510
    ALTERNATOR BELT....4511
      Belt Adjustment....4511
      Belt Replacement....4511
    AIR CONDITIONING BELT....4511
      Belt Adjustment....4511
      Belt Replacement....4511
    drive belt....4512
      Belt Adjustment....4512
      Belt Replacement....4512
    LUBRICATING THE LOADER....4515
      Lubrication Locations....4515
    PIVOT PINS....4517
      Inspection And Maintenance....4517
    BOB-TACH (hand lever)....4518
      Inspection And Maintenance....4518
    BOB-TACH (POWER)....4519
      Inspection And Maintenance....4519
    LOADER STORAGE AND RETURN TO SERVICE....4520
      Storage....4520
      Return to Service....4520
  SYSTEM SETUP & ANALYSIS....4521
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....4523
      Troubleshooting Chart....4523
    DIAGNOSTIC SERVICE CODES....4524
      Viewing Service Codes (Key Switch)....4524
      Viewing Service Codes (Keyless)....4524
      Service Codes List....4525
    CONTROL PANEL SETUP....4530
      Right Panel Setup (Keyless)....4530
      Right Panel Setup (Keyless)....4531
      Attachment Control Information (Keyless)....4531
    PASSWORD SETUP....4532
      Password Description....4532
      Changing The Owner Password....4532
      Changing The User Passwords....4533
      Password Lockout Feature....4533
    MAINTENANCE CLOCK....4534
      Description....4534
      Setup....4534
      Reset....4534
  MACHINE SIGN TRANSLATIONS....4535
    SERVICE SCHEDULE (6734534)....4537
    DANGER (6702301)....4540
    DANGER (6702302)....4540
    DANGER (6717343)....4540
    WARNING (6579528)....4540
    WARNING (6577754)....4541
    IMPORTANT (6560573)....4541
    WARNING (6728539)....4542
    WARNING (6718706)....4543
    WARNING (6732696)....4543
    DANGER (6809511)....4543
    WARNING (6733996)....4544
    WARNING (6725370)....4544
    WARNING (6737189)....4544
    LIFT ARM SUPPORT DEVICE (6732774)....4545
    warning (7131518)....4546
    warning (7131519)....4548
    WARNING (6737248)....4550
    WARNING (6708941)....4550
    WARNING (6726423)....4550
    WARNING (6704786)....4551
  SPECIFICATIONS....4553
    (S220) LOADER SPECIFICATIONS....4555
      Dimensions....4555
      Performance....4556
      Controls....4556
      Engine....4556
      Hydraulic System....4557
      Electrical....4557
      Drive System....4558
      Capacities....4558
      Tires....4558
  WARRANTY....4559
  ALPHABETICAL INDEX....4563
6904154 (3-09) - S220 Skid-Steer Loader Service Manual....4565
  MAINTENANCE SAFETY....4567
  ALPHABETICAL INDEX....4569
  CONTENTS....4571
    FOREWORD....4572
    SAFETY INSTRUCTIONS....4575
    FIRE PREVENTION....4577
      Maintenance....4577
      Operation....4577
      Electrical....4577
      Hydraulic System....4577
      Fueling....4577
      Starting....4577
      Spark Arrestor Exhaust System....4577
      Welding And Grinding....4578
      Fire Extinguishers....4578
    SERIAL NUMBER LOCATIONS....4579
      Loader Serial Number....4579
      Engine Serial Number....4579
    DELIVERY REPORT....4579
    LOADER IDENTIFICATION....4580
  SAFETY AND MAINTENANCE....4581
    LIFTING AND BLOCKING THE LOADER....4585
      Procedure....4585
    LIFT ARM SUPPORT DEVICE....4587
      Installing....4587
      Removing....4588
    OPERATOR CAB....4589
      Description....4589
      Raising....4589
      Lowering....4590
      Cab Door Sensor....4591
    TRANSPORTING LOADER ON A TRAILER....4593
      Loading And Unloading....4593
      Fastening....4593
    TOWING THE LOADER....4595
      Procedure....4595
    REMOTE START TOOL KIT-MEL1563....4597
      Remote Start Tool - MEL1563....4597
      Service Tool Harness Control - MEL1565....4598
      Service Tool Harness Communicator - MEL1566....4599
      Remote Start Procedure....4600
    REMOTE START TOOL (SERVICE TOOL) KIT - 6689779....4603
      Description....4603
      Remote Start Tool (Service Tool) - 6689778....4604
      Loader Service Tool Harness - 6689747....4605
      Computer Service Tool Harness - 6689746....4606
      Remote Start Procedure....4607
    SERVICE SCHEDULE....4611
      Chart....4611
    AIR CLEANER SERVICE....4613
      Replacing Filter Elements....4613
    ENGINE COOLING SYSTEM....4615
      Cleaning....4615
      Checking Level....4616
      Removing And Replacing Coolant....4616
    FUEL SYSTEM....4617
      Fuel Specifications....4617
      Biodiesel Blend Fuel....4617
      Filling The Fuel Tank....4618
      Fuel Filter....4618
      Removing Air From The Fuel System....4619
    ENGINE LUBRICATION SYSTEM....4621
      Checking And Adding Engine Oil....4621
      Engine Oil Chart....4621
      Removing And Replacing Oil And Filter....4622
    HYDRAULIC / HYDROSTATIC SYSTEM....4623
      Checking And Adding Fluid....4623
      Hydraulic / Hydrostatic Fluid Chart....4623
      Removing And Replacing Hydraulic Fluid....4624
      Removing And Replacing Hydraulic / Hydrostatic Filter....4625
      Removing And Replacing Case Drain Filters....4626
      Removing And Replacing Hydraulic Charge Filter....4627
      Breather Cap....4628
    FINAL DRIVE TRANSMISSION (CHAINCASE)....4629
      Checking And Adding Oil....4629
      Removing And Replacing Oil....4629
    BOB-TACH (HAND LEVER)....4631
      Inspection And Maintenance....4631
    BOB-TACH (POWER - OPTION)....4633
      Inspection And Maintenance....4633
    LUBRICATING THE LOADER....4635
      Lubrication Locations....4635
    TIRE MAINTENANCE....4637
      Wheel Nuts....4637
      Rotating....4637
      Mounting....4638
    SPARK ARRESTOR MUFFLER....4639
      Cleaning Procedure....4639
    PIVOT PINS....4641
      Inspection And Maintenance....4641
    LOADER STORAGE AND RETURN TO SERVICE....4643
      Storage....4643
      Return to Service....4643
    STOPPING THE ENGINE AND LEAVING THE LOADER....4645
      Procedure....4645
      Emergency Exit....4646
  HYDRAULIC SYSTEM....4647
    HYDRAULIC / HYDROSTATIC SCHEMATICS....4653
    HYDRAULIC SYSTEM INFORMATION....4685
      Glossary Of Hydraulic / Hydrostatic Symbols....4685
      Troubleshooting....4689
    CYLINDER (LIFT)....4691
      Testing....4691
      Removal And Installation....4692
      Parts Identification....4694
      Disassembly....4695
      Assembly....4697
    CYLINDER (TILT)....4699
      Testing....4699
      Removal And Installation....4700
      Base End Pivot Pin Removal And Installation....4702
      Parts Identification....4703
      Disassembly....4704
      Assembly....4706
    CYLINDER (BOB-TACH)....4709
      Testing....4709
      Removal And Installation....4710
      Parts Identification....4711
      Disassembly....4712
      Assembly....4713
    MAIN RELIEF VALVE....4717
      Description....4717
      Testing....4718
      Adjusting....4720
      Removal And Installation....4721
    HYDRAULIC CONTROL VALVE (STANDARD)....4723
      Description....4723
      Removal And Installation....4724
      Identification Chart....4728
      Mount Bracket Removal And Installation....4729
      Lift Load Check Valve Removal And Installation....4729
      Load Check Valve Removal And Installation (Tilt & Auxiliary)....4730
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....4730
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....4731
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....4732
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....4732
      Port Relief Valve Removal And Installation....4733
      Plug Removal And Installation....4734
      Rubber Boot Removal and Installation....4735
      End Cap Block Removal and Installation....4736
      Lift Spool And Detent Removal And Installation....4737
      Tilt Spool Removal And Installation....4747
      Auxiliary Spool Removal And Installation....4749
      Auxiliary Solenoid Removal And Installation....4751
      Solenoid Removal And Installation....4752
      Lock Valve Removal And Installation....4753
      Lift Arm Bypass Orifice Removal And Installation....4755
      Main Relief Valve Removal And Installation....4755
      Check Valve Removal And Installation....4756
    HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....4757
      Description....4757
      Removal And Installation....4758
      Actuator Removal And Installation (In Loader)....4762
      Actuator Removal And Installation (Out Of Loader)....4764
      Identification Chart....4767
      Mount Bracket Removal And Installation....4768
      Lift Load Check Valve Removal And Installation....4768
      Load Check Valve Removal And Installation (Tilt & Auxiliary)....4769
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....4769
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....4770
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....4771
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....4771
      Port Relief Valve Removal And Installation....4772
      Plug Removal And Installation....4773
      End Cap Block Removal And Installation....4774
      Lift Spool And Detent Removal And Installation....4775
      Tilt Spool Removal And Installation....4780
      Auxiliary Spool Removal And Installation....4782
      Auxiliary Solenoid Removal And Installation....4784
      Solenoid Removal And Installation....4785
      Lock Valve Removal And Installation....4786
      Lift Arm Bypass Orifice Removal And Installation....4788
      Main Relief Valve Removal And Installation....4788
      Check Valve Removal And Installation....4789
    LIFT ARM BYPASS CONTROL VALVE....4791
      Description....4791
      Testing....4791
      Removal And Installation....4792
      Disassembly And Assembly....4793
    HYDRAULIC PUMP (STANDARD)....4795
      Description....4795
      Pump Test at Quick Couplers....4796
      Direct Pump Test (Standard Section)....4797
      Direct Pump Test (Charge Section)....4799
      Removal And Installation....4803
      Hydraulic Pump Start Up....4805
      Parts Identification....4806
      Disassembly And Assembly....4807
    HYDRAULIC PUMP (STANDARD) (HIGH FLOW)....4809
      Description....4809
      Pump Test At Quick Couplers....4810
      Direct Pump Test (Standard Section)....4811
      Direct Pump Test (Charge Section)....4813
      Direct Pump Test (High Flow Section)....4817
      High Flow Relief Valve Adjustment....4819
      High Flow Relief Valve Removal And Installation....4822
      Solenoid Removal And Installation....4823
      Removal And Installation....4824
      Hydraulic Pump Start Up....4826
      Parts Identification....4828
      Disassembly And Assembly....4829
    HYDRAULIC PUMP (SJC)....4831
      Description....4831
      Pump Test At Quick Couplers....4832
      Direct Pump Test (Standard Section)....4833
      Direct Pump Test (Charge Section)....4835
      Removal And Installation....4839
      Hydraulic Pump Start Up....4841
      Parts Identification....4842
      Disassembly And Assembly....4843
    HYDRAULIC PUMP (SJC) (HIGH FLOW)....4845
      Description....4845
      Pump Test At Quick Couplers....4846
      Direct Pump Test (Standard Section)....4847
      Direct Pump Test (Charge Section)....4849
      Direct Pump Test (High Flow Section)....4853
      High Flow Relief Valve Adjustment....4855
      High Flow Relief Valve Removal And Installation....4858
      Solenoid Removal And Installation....4859
      Removal And Installation....4860
      Hydraulic Pump Start Up....4862
      Parts Identification....4864
      Disassembly And Assembly....4865
    HYDRAULIC/HYDROSTATIC FILTERS....4867
      Description....4867
      Housing Removal And Installation....4867
      Charge Filter Housing Removal And Installation....4869
    HYDRAULIC FLUID RESERVOIR....4871
      Description....4871
      Removal And Installation....4871
      Hydraulic Fluid Screen....4874
    OIL COOLER....4875
      Description....4875
      Removal And Installation....4875
    BUCKET POSITION VALVE....4877
      Description....4877
      Solenoid Removal And Installation....4878
      Solenoid Testing....4879
      Removal And Installation....4879
      Disassembly And Assembly....4880
    REAR AUXILIARY DIVERTER VALVE....4883
      Description....4883
      Solenoid Testing....4883
      Removal And Installation....4884
      Disassembly And Assembly....4886
    BOB-TACH (POWER) BLOCK....4893
      Description....4893
      Removal And Installation....4893
      Disassembly And Assembly....4895
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....4899
      Description....4899
      Removal and Installation....4899
      Disassembly And Assembly....4900
  HYDROSTATIC SYSTEM....4903
    HYDROSTATIC SYSTEM INFORMATION....4905
      Troubleshooting....4905
      Description....4906
    HYDROSTATIC MOTOR....4907
      Description....4907
      Removal And Installation....4908
      Parts Identification....4910
      Disassembly And Assembly....4911
    HYDROSTATIC MOTOR (TWO-SPEED)....4915
      Description....4915
      Removal And Installation....4916
      Parts Identification....4919
      Disassembly....4921
      Assembly....4927
    HYDROSTATIC MOTOR CARRIER....4931
      Description....4931
      Removal and Installation....4932
      Parts Identification....4933
      Disassembly....4934
      Assembly....4935
    HYDROSTATIC MOTOR CARRIER (SJC)....4937
      Description....4937
      Removal and Installation....4938
      Parts Identification....4939
      Disassembly....4940
      Assembly....4942
    CHARGE PRESSURE....4945
      Description....4945
      Testing....4946
      Sender Removal And Installation....4948
      Adjusting....4949
    HYDROSTATIC PUMP....4951
      Description....4951
      Removal And Installation....4952
      Hydrostatic Pump Start Up....4954
      Replenishing / High Pressure Relief Valve Removal And Installation....4955
      Parts Identification (Left Half)....4956
      Parts Identification (Right Half)....4957
      Disassembly....4958
      Assembly....4965
    HYDROSTATIC PUMP (SJC)....4971
      Description....4971
      Hydraulic Controller Removal And Installation....4972
      Removal And Installation....4974
      Hydrostatic Pump Start Up....4976
      Parts Identification....4977
      High Pressure Relief And ByPass Valve....4978
      Charge Relief Valve....4979
      Disassembly And Assembly....4980
      Mechanical Neutral Adjustment....4997
      Hydraulic Controller Neutral Adjustment....5000
    DRIVE BELT....5003
      Description....5003
      Drive Belt Shield Removal And Installation....5003
      Adjusting....5004
      Belt Removal And Installation....5004
      Tensioner Pulley Removal And Installation....5005
      Tensioner Pulley Tension Spring Removal And Installation....5007
    CASE DRAIN FILTER....5009
      Description....5009
      Disassembly And Assembly....5009
  DRIVE SYSTEM....5011
    BRAKE (S/N 530714318 & BELOW AND 530811605 & BELOW)....5013
      Description....5013
      Disc Removal And Installation....5014
    BRAKE (S/N 530714319 & ABOVE AND 530811606 & ABOVE)....5017
      Description....5017
      Disc Removal And Installation....5018
    BRAKE (TWO-SPEED)....5021
      Description....5021
      Block Removal And Installation....5022
      Block Disassembly And Assembly....5024
    DRIVE COMPONENTS....5029
      Description....5029
      Axle Seal Removal And Installation....5030
      Axle, Sprocket And Bearings Removal And Installation....5032
      Chain Removal And Installation....5037
      Description....5038
      Axle Seal Removal And Installation....5039
      Axle, Sprocket And Bearings Removal And Installation....5041
      Chain Removal And Installation....5046
    CHAINCASE....5049
      Description....5049
      Front Cover Removal And Installation....5049
      Center Cover Removal And Installation....5050
      Rear Cover Removal And Installation....5051
  MAIN FRAME....5053
    SEAT BAR....5057
      Description....5057
      Removal And Installation....5057
      Disassembly And Assembly....5059
      Compression Spring Disassembly And Assembly....5060
    OPERATOR CAB....5061
      Gas Cylinder Removal And Installation....5061
      Gas Cylinder Bracket Disassembly And Assembly....5063
      Removal And Installation....5064
    OPERATOR SEAT....5067
      Removal And Installation....5067
      Seat Belt Removal And Installation....5067
    OPERATOR SEAT (SUSPENSION)....5069
      Removal And Installation....5069
      Slide Rail Removal And Installation....5070
      Seat Belt Removal And Installation....5070
      Cushion Removal And Installation....5071
      Back Removal And Installation....5072
      Shock Removal And Installation....5072
      3-Point Seat Belt Removal And Installation....5073
    BOB-TACH (HAND LEVER)....5075
      Description....5075
      Removal And Installation....5075
      Lever And Wedge Disassembly And Assembly....5078
      Pivot Pin Bushing And Seal Removal And Installation....5079
    BOB-TACH (POWER - OPTION)....5081
      Description....5081
      Removal And Installation....5081
      Lever And Wedge Disassembly And Assembly....5084
      Pivot Pin Bushing And Seal Removal And Installation....5086
    LIFT ARMS....5087
      Removal And Installation....5087
    REAR GRILL....5091
      Removal And Installation....5091
    REAR DOOR....5093
      Removal And Installation....5093
      Striker Removal And Installation....5094
      Striker Disassembly And Assembly....5094
      Striker (Adjusting)....5095
      Latch Removal And Installation....5096
    FUEL TANK....5097
      Removal And Installation....5097
      Fuel Level Sender Removal And Installation....5099
      Fuel Fill Screen Removal And Installation....5099
    CONTROL PEDALS AND LINKAGES....5101
      Description....5101
      Pedal Removal And Installation....5102
      Linkage Removal And Installation....5103
      Pedal (Adjusting)....5104
    CONTROL PEDALS (ACS)....5105
      Description....5105
      Foot Sensor Removal And Installation....5106
      Foot Pedal Removal And Installation....5107
      Foot Pedal Linkage Disassembly And Assembly....5108
    CONTROL PANEL (S/N 530714202 & BELOW AND 530811539 & BELOW)....5109
      Description....5109
      Removal And Installation....5110
      Shock Removal And Installation....5112
      Shaft Removal And Installation....5112
      Shaft Disassembly And Assembly....5113
      Linkage Removal And Installation....5114
      Pintle Arm Disassembly and Assembly....5118
      Linkage Neutral (Adjusting)....5119
      Linkage Travel (Adjusting)....5123
    CONTROL PANEL (S/N 530714203 & ABOVE AND 530811540 & ABOVE)....5127
      Description....5127
      Removal And Installation....5128
      Shock Removal And Installation....5130
      Shaft Removal And Installation....5131
      Linkage Removal And Installation....5132
      Pintle Arm Disassembly and Assembly....5136
      Linkage Neutral (Adjusting)....5137
      Linkage Travel (Adjusting)....5141
    CONTROL PANEL (S/N 530714202 & BELOW AND 530811539 & BELOW) (SJC)....5145
      Description....5145
      Removal And Installation....5146
    CONTROL PANEL (S/N 530714203 & ABOVE AND 530811540 & ABOVE) (SJC)....5149
      Description....5149
      Removal And Installation....5150
    CONTROL HANDLE / LEVER....5153
      Description....5153
      Lever Removal And Installation....5153
      Boot Removal And Installation....5154
    CONTROL HANDLE / LEVER (ACS)....5155
      Description....5155
      Handle Sensor Removal And Installation....5155
      Handle Removal And Installation....5158
      Handle Disassembly And Assembly....5159
      Lever Removal And Installation....5160
      Boot Removal And Installation....5161
    JOYSTICK CONTROL....5163
      Description (Earlier Models And Later Models)....5163
      Testing (Earlier Models And Later Models)....5164
      Removal And Installation (Earlier Models)....5165
      Removal And Installation (Later Models)....5166
      Boot Removal And Installation (Earlier Models)....5167
      Joystick Mount Removal And Installation (Earlier Models)....5167
      Joystick Mount Removal And Installation (Earlier Models) (Cont?d)....5168
      Joystick Mount Removal And Installation (Later Models)....5168
    ACCESS PANEL (INSIDE)....5169
      Removal And Installation (Left)....5169
      Removal And Installation (Right)....5169
    ACCESS PANEL (INSIDE) (SJC)....5171
      Removal And Installation (Left)....5171
      Removal And Installation (Right)....5172
    WINDOW (REAR)....5175
      Removal....5175
      Installation....5175
    WINDOW (TOP)....5177
      Removal And Installation....5177
    WINDOW (SIDE)....5179
      Removal And Installation....5179
    WINDOW (FRONT DOOR)....5181
      Removal (Standard Window)....5181
      Installation (Standard Window)....5182
      Removal And Installation (Special Applications Window)....5184
    CAB DOOR....5185
      Description....5185
      Removal And Installation....5185
      Aligning....5186
      Adjusting....5187
      Checking Operation....5187
  ELECTRICAL SYSTEM & ANALYSIS....5189
    ELECTRICAL SCHEMATICS....5193
    ELECTRICAL SYSTEM INFORMATION....5206
      Glossary Of Electrical Symbols....5206
      Cab Harness Connectors....5209
      Mainframe Harness Connectors....5210
      Description....5212
      Troubleshooting....5214
      Fuse And Relay Location / Identification....5215
      Solenoid Testing....5216
    BATTERY....5218
      Removal And Installation....5218
      Servicing....5219
      Using A Booster Battery (Jump Starting)....5219
    ALTERNATOR....5222
      Belt Adjustment....5222
      Charging System Inspection....5223
      Alternator Voltage Testing....5224
      Low Voltage Testing....5224
      High Voltage Testing....5225
      Removal And Installation....5226
      Parts Identification....5227
    STARTER....5228
      Testing....5228
      Removal And Installation....5229
      Parts Identification....5230
    INSTRUMENT PANELS....5232
      Left Panel....5232
      Right Panel (Key Switch)....5233
      Right Panel (Keyless)....5234
      Side And Front Panels....5236
      Removal And Installation (Left And Right)....5237
      Bulb Removal And Installation (Left Only)....5240
      Key Switch Removal And Installation....5241
      Alarm Removal And Installation....5242
      Front Panel Removal And Installation....5242
    LIGHTS....5244
      Front Removal And Installation....5244
      Rear Removal And Installation....5245
      Cab Light Removal And Installation....5245
    BOBCAT CONTROLLER (MAIN)....5246
      Description....5246
      Connector Identification....5247
      Removal And Installation....5249
    BOBCAT CONTROLLER (ACS)....5250
      Description....5250
      Connector And Wire Identification....5251
      Removal And Installation....5252
    BOBCAT CONTROLLER (SJC) (DRIVE)....5254
      Description....5254
      Connector Identification....5255
      Removal And Installation....5257
    SPEED SENSOR (SJC)....5258
      Description....5258
      Testing....5259
      Removal And Installation....5260
    DIAGNOSTIC SERVICE CODES....5262
      Description....5262
      Service Codes List....5263
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....5270
      Description....5270
      Inspecting The BICS Controller (Engine STOPPED - Key ON)....5271
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....5271
      Inspecting The Seat Bar Sensor (Engine RUNNING)....5271
      Inspecting The Traction Lock (Engine RUNNING)....5271
      Inspecting The Lift Arm Bypass Control....5271
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....5271
      Troubleshooting....5272
      Troubleshooting Chart....5273
    SEAT BAR SENSOR....5274
      Description....5274
      Troubleshooting....5275
      Testing....5276
      Removal And Installation....5277
      Bobcat Interlock Control System (BICS) Circuit Test....5278
    TRACTION LOCK....5280
      Description....5280
      Troubleshooting....5281
      Removal And Installation (Single Speed)....5282
      Inspecting (Single And Two Speed)....5286
    CONTROL SYSTEM (ACS)....5288
      Description....5288
      Troubleshooting Chart....5289
      Handle Sensor Connector Disassembly And Assembly....5290
      Switch Handle Removal....5291
      Switch Handle Installation....5293
      Actuator Connector Disassembly And Assembly....5296
      Handle Lock Solenoid Removal And Installation....5297
      Handle Lock Solenoid Disassembly And Assembly....5298
      Foot Sensor Disassembly And Assembly....5298
      Foot Lock Solenoid Removal And Installation....5299
    ELECTRICAL / HYDRAULIC CONTROLS....5300
      Identification Chart....5300
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)....5302
      Identification Chart....5302
    SERVICE PC (LAPTOP COMPUTER)....5306
      Connecting Remote Start Tool....5306
      Connecting Remote Start Tool (Service Tool)....5306
    CALIBRATION....5308
      Description....5308
      Actuator Testing....5308
      Lift And Tilt Calibration (ACS)....5310
      Lift And Tilt Calibration (SJC)....5312
      Hydrostatic Pump Calibration (SJC)....5314
    STEERING DRIFT COMPENSATION....5320
      Description....5320
      Selecting And Adjusting....5320
      Exiting And Saving....5321
    FLYWHEEL RPM SENSOR....5322
      Description....5322
      Adjustment....5323
    CONTROL PANEL SETUP....5324
      Right Panel Setup (Keyless)....5324
      Attachment Control Information (Keyless)....5325
    PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START)....5326
      Password Description....5326
      Changing The Owner And User Passwords....5327
      Password Lockout Feature....5328
    MAINTENANCE CLOCK....5330
      Description....5330
      Setup....5331
      Reset....5335
    BACK-UP ALARM SYSTEM....5336
      Description....5336
      Inspecting....5336
      Adjusting Switch Position....5337
      Troubleshooting (Standard And ACS)....5338
      Troubleshooting (Joystick)....5339
      Alarm Removal And Installation....5340
      Switch Removal And Installation....5340
  ENGINE SERVICE....5342
    ENGINE INFORMATION....5346
      Description....5346
      Specifications....5347
      Torque Values....5351
      Troubleshooting....5352
      Engine Removal And Installation....5354
      Engine Mount Replacement....5363
      Compression -Checking....5364
    ENGINE SPEED CONTROL....5366
      Removal And Installation....5366
      Cable Removal And Installation....5367
    ENGINE SPEED CONTROL (SJC)....5368
      Removal And Installation....5368
      Disassembly And Assembly....5371
      Speed Control Cable Removal And Installation....5373
    MUFFLER....5374
      Removal And Installation....5374
    AIR CLEANER....5376
      Housing Removal And Installation....5376
    ENGINE COOLING SYSTEM....5378
      Radiator Removal And Installation (S/N 530713065 & Below, 530811453 & Below)....5378
      Radiator Removal And Installation (S/N 530713066 & Above, 530811454 & Above)....5380
      Radiator Mount Removal And Installation....5382
      Hydraulic Fan Motor Description (S/N 530713065 & Below, 530811453 & Below)....5383
      Blower Housing Removal And Installation (S/N 530713065 & Below, 530811453 & Below)....5383
      Fan Removal And Installation (S/N 530713065 & Below, 530811453 & Below)....5385
      Hydraulic Fan Motor Removal And Installation (S/N 530713065 & Below, 530811453 & Below)....5386
      Hydraulic Fan Motor Disassembly And Assembly (S/ N 530713065 & Below, 530811453 & Below)....5386
      Hydraulic Fan Motor Description (S/N 530713066 - 530740000, 530811454 - 530840000)....5387
      Axial Fan Housing Removal And Installation (S/N 530713066 - 530740000, 530811454 - 530840000)....5387
      Axial Fan Removal And Installation (S/N 530713066 - 530740000, 530811454 - 530840000)....5389
      Hydraulic Fan Motor Removal And Installation (S/N 530713066 - 530740000, 530811454 - 530840000)....5391
      Hydraulic Fan Motor Disassembly And Assembly (S/ N 530713066 - 530740000, 530811454 - 530840000)....5391
      Hydraulic Fan Motor Description (S/N 530740001 & Above, 530840001 & Above)....5392
      Axial Fan Housing Removal And Installation (S/N 530740001 & Above, 530840001 & Above)....5392
      Axial Fan Removal And Installation (S/N 530740001 & Above, 530840001 & Above)....5395
      Hydraulic Fan Motor Removal And Installation (S/N 530740001 & Above, 530840001 & Above)....5396
      Hydraulic Fan Motor Disassembly And Assembly (S/ N 530740001 & Above, 530840001 & Above)....5397
      Water Pump Removal And Installation....5398
      Water Pump Disassembly And Assembly....5399
      Thermostat Housing Removal And Installation....5399
    LUBRICATION SYSTEM....5402
      Oil Pan Removal And Installation....5402
      Oil Pump Removal And Installation....5403
      Oil Pump Inspection....5404
      Oil Filter Cooler Removal And Installation....5407
      Engine Oil Pressure - Testing....5408
    FUEL SYSTEM....5410
      Fuel Camshaft Removal And Installation....5410
      Injection Pump Governor Housing Removal And Installation....5412
      Injection Pump Governor Housing Disassembly And Assembly....5414
      Fuel ShutOff Solenoid - Checking....5416
      Fuel ShutOff Solenoid - Removal And Installation....5416
      Fuel Injection Pump Removal And Installation....5417
      Fuel Injection Pump Housing Removal....5425
      Fuel Injection Pump Housing Installation....5429
      Injection Pump Timing....5432
      Fuel Injector Removal and Installation....5435
      Fuel Injector Nozzle Pressure - Checking....5436
      Nozzle Spraying Condition....5437
      Valve Seat Tightness....5437
    CYLINDER HEAD....5438
      Intake Air Heater - Testing....5438
      Intake Air Heater Removal And Installation....5438
      Valve Clearance Adjustment....5439
      Valve Timing - Checking....5440
      Cylinder Head Removal And Installation....5441
      Cylinder Head Disassembly And Assembly....5444
      Cylinder Head - Servicing....5444
      Cylinder Head Top Clearance....5445
      Valve Guide - Checking....5446
      Reconditioning The Valve And Valve Seat....5448
      Valve Spring....5450
      Valve Tappets....5451
      Rocker Arm And Shaft - Checking....5452
    CRANKSHAFT AND PISTONS....5454
      Piston And Connecting Rod Removal And Installation....5454
      Piston And Connecting Rod - Servicing....5456
      Cylinder Bore Checking....5461
      Connecting Rod Alignment....5462
      Crankshaft Gear Removal And Installation....5462
      Crankshaft And Bearings Removal and Installation....5463
      Crankshaft And Bearings - Servicing....5467
    CAMSHAFT AND TIMING GEArS....5474
      Timing Gearcase Cover Removal And Installation....5474
      Timing Gears Backlash - Checking....5475
      Camshaft - Servicing....5476
      Idle Gear And Shaft Removal And Installation....5478
      Idler Gear And Shaft - Servicing....5479
    TURBOCHARGER....5482
      Description....5482
      Testing....5482
      Removal And Installation....5483
    FLYWHEEL AND HOUSING....5484
      Flywheel Removal And Installation....5484
      Ring Gear Removal And Installation....5484
      Housing Removal And Installation....5485
  HEATING, VENTILATION, AIR CONDITIONING....5486
    AIR CONDITIONING SYSTEM FLOW....5489
      Description....5489
      Chart....5490
      Components....5491
      Safety Equipment....5494
    REGULAR MAINTENANCE....5496
      Filter Elements Removal And Installation....5496
      Compressor Drive Belt Inspection....5497
      Condenser....5498
      Air Conditioning Service Chart....5499
      A/C Evaporator Coil & Heater Coil....5500
    TROUBLESHOOTING....5502
      Blower Motor Does Not Operate....5502
      Blower Motor Operates Normally, But Air Flow Is Insufficient....5502
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....5502
      The Compressor Does Not Operate At All, Or Operates Improperly....5502
      Gauge Pressure Related Troubleshooting....5503
      Troubleshooting Tree....5505
      Temperature / Pressure Chart....5509
      Poor A/C Performance....5511
      HVAC Repair And Leaks....5512
      Electrical System....5513
      Engine Coolant Bypassing The Heater Valve....5520
      Heater Valve Not Opening Or Closing....5521
    SYSTEM CHARGING AND RECLAMATION....5522
      Refrigerant Identification....5522
      Reclamation And Charging With Recovery / Charging Unit....5523
      Charging With A Manifold Gauge Set....5525
    COMPRESSOR....5528
      Belt Adjustment....5528
      Removal And Installation....5528
      Oil....5529
      Oil Check....5530
      Clutch Disassembly And Assembly....5531
    CONDENSER....5536
      Removal And Installation....5536
    RECEIVER / DRIER....5538
      Receiver / Drier Removal And Installation....5538
      Pressure Relief Valve Removal And Installation....5539
      Pressure Switch Removal And Installation....5539
      Schraeder Valve Removal And Installation....5540
    EVAPORATOR / HEATER UNIT....5542
      Removal And Installation....5542
    THERMOSTAT....5544
      Removal And Installation....5544
    EXPANSION VALVE....5546
      Removal And Installation....5546
    EVAPORATOR....5548
      Removal And Installation....5548
    HEATER COIL....5550
      Removal And Installation With A/C....5550
      Removal And Installation Without A/C....5552
    BLOWER FAN....5554
      Removal And Installation....5554
      Disassembly And Assembly....5555
      Connector Identification....5557
    HEATER VALVE....5558
      Removal and Installation....5558
      Disassembly And Assembly....5559
  SPECIFICATIONS....5560
    (S220) LOADER SPECIFICATIONS....5562
      Dimensions....5562
      Performance....5563
      Controls....5563
      Engine....5563
      Hydraulic System....5564
      Electrical....5564
      Drive System....5565
      Capacities....5565
      Tires....5565
    TORQUE SPECIFICATIONS FOR BOLTS....5566
      Torque For General SAE Bolts....5566
      Torque For General Metric Bolts....5567
    HYDRAULIC CONNECTION SPECIFICATIONS....5568
      O-ring Face Seal Connection....5568
      Straight Thread O-ring Fitting....5569
      Tubelines And Hoses....5569
      Flare Fitting....5570
      Port Seal Fitting....5571
    HYDRAULIC FLUID SPECIFICATIONS....5572
      Specifications....5572
    CONVERSIONS....5574
      Decimal And Millimeter Equivalents....5574
      U.S. To Metric Conversion Chart....5574
  SERVICE MANUAL REVISION....5576
    Revision No: S220 - 1....5576
    Revision No: S220 - 2....5578
    Revision No: S220 - 3....5580
    Revision No: S220 - 4....5582
    Revision No: S220 - 5....5584
    Revision No: S220 - 6....5586
    Revision No: S220 - 7....5588
    Revision No: S220 - 8....5590
    Revision No: S220 - 9....5592
    Revision No: S220 - 10....5594
    Revision No: S220 - 11....5596
    Revision No: S220 - 12....5598
6904176 (12-06) - S220 Turbo, S220 Turbo High Flow Operation & Maintenance Manual....5600
  OPERATOR SAFETY WARNINGS....5602
  CONTENTS....5604
  FOREWORD....5606
    BOBCAT COMPANY IS ISO9001:2000 CERTIFIED....5608
    REGULAR MAINTENANCE ITEMS....5608
    MOTOR OIL....5608
    SERIAL NUMBER LOCATIONS....5609
      Loader Serial Number....5609
      Engine Serial Number....5609
    DELIVERY REPORT....5609
    MACHINE IDENTIFICATION....5610
    FEATURES, ACCESSORIES AND ATTACHMENTS....5611
      Standard Items....5611
      Options and Accessories....5611
      Buckets Available....5612
      Attachments....5612
      40 GPM Attachments....5612
  SAFETY....5614
    SAFETY INSTRUCTIONS....5616
      Before Operation....5616
      Safe Operation Is The Operator?s Responsibility....5617
      Safe Operation Needs A Qualified Operator....5617
      Fire Prevention....5618
    MACHINE SIGNS (DECALS)....5619
  OPERATING INSTRUCTIONS....5622
    INSTRUMENT PANEL IDENTIFICATION....5626
      Left Panel....5626
      Right Panel (Standard - With Key Switch)....5627
      Right Panel (Deluxe - With Keyless Start)....5628
      Option And Field Accessory Panels (If Equipped)....5630
      Cab Light....5631
    LIFT ARM BY-PASS CONTROL....5631
      Operation....5631
    TRACTION LOCK OVERRIDE....5631
      Operation....5631
    ENGINE SPEED CONTROL....5632
      Operation....5632
    TWO-SPEED CONTROL....5632
    INCHING CONTROL....5632
      Operation....5632
    DRIVING AND STEERING THE LOADER....5633
      Available Controls Configurations....5633
      Operation (Standard and ACS)....5633
      Operation (SJC in ?H? Control Pattern)....5634
      Operation (SJC in ?ISO? Control Pattern)....5635
    STOPPING THE BOBCAT LOADER....5636
      Using The Steering Levers Or Joysticks....5636
    SEAT BAR RESTRAINT SYSTEM....5636
      Operation....5636
    HYDRAULIC CONTROLS....5637
      Standard Controls (Also ACS in Foot Pedal Mode)....5637
      Advanced Control System (ACS) in HAND Control Mode....5638
      Selectable Joystick Control (SJC) - ?H? Control Pattern....5639
      Selectable Joystick Control (SJC) - ?ISO? Control Pattern....5639
      Quick Couplers....5640
      Releasing Hydraulic Pressure (Loader and Attachment)....5640
      Auxiliary Hydraulics Button - VARIABLE FLOW....5641
      Auxiliary Hydraulics Button - MAXIMUM FLOW ONLY....5641
      Auxiliary Hydraulics Button - DISENGAGE....5641
      FRONT Auxiliary Hydraulics Operation - VARIABLE FLOW....5641
      FRONT Auxiliary Hydraulics Operation - MAXIMUM FLOW....5641
      FRONT Auxiliary Hydraulics Operation - CONTINUOUS FLOW....5641
      REAR Auxiliary Hydraulics Operation (If Equipped)....5642
      Secondary Front Auxiliary Hydraulics (If Equipped)....5642
      High-Flow Hydraulics Operation (If Equipped)....5643
      Attachment Control Device (ACD) (If Equipped)....5643
      Bucket Position Valve Operation (If Equipped)....5644
    PARKING BRAKE....5644
      Operation....5644
    DAILY INSPECTION....5645
      Daily Inspection and Maintenance....5645
    PRE-STARTING PROCEDURES....5646
      Before Starting The Engine....5646
    STARTING THE ENGINE (STANDARD PANEL, KEY SWITCH)....5648
      Procedure....5648
    STARTING THE ENGINE (DELUXE PANEL, KEYLESS START)....5650
      Procedure....5650
      Cold Temperature Starting....5651
    WARMING THE HYDRAULIC/HYDROSTATIC SYSTEM....5652
      Procedure....5652
    STOPPING THE ENGINE....5652
      Procedure....5652
    MONITORING THE DISPLAY PANEL....5653
      Standard Panel....5653
      Deluxe Panel....5653
      WARNING and SHUTDOWN....5653
    ATTACHMENTS AND BUCKETS....5654
      Choosing The Correct Bucket....5654
      Pallet Forks....5655
      Hand Lever Bob-Tach - Installing The Bucket Or Attachment....5655
      Hand Lever Bob-Tach - Removing The Bucket Or Attachment....5657
      Power Bob-Tach - Installing The Bucket Or Attachment....5658
      Power Bob-Tach - Removing The Bucket Or Attachment....5659
    OPERATING PROCEDURE....5660
      Operating With A Full Bucket....5660
      Operating With An Empty Bucket....5661
      Foot Pedal Machines....5662
      Hand Control Machines (Includes ACS and SJC with H-Pattern Selected)....5664
      Selectable Joystick Control (SJC) with ?ISO? Pattern Selected....5666
    PARKING THE BOBCAT LOADER....5668
      Procedure....5668
    TRANSPORTING THE BOBCAT LOADER....5669
      Loading Onto Transport Vehicle....5669
      Fastening To Transport Vehicle....5669
    TOWING THE LOADER....5670
      Towing Procedure....5670
    LIFTING THE LOADER....5671
      Single Point Lift....5671
      Four Point Lift....5671
  PREVENTIVE MAINTENANCE....5672
    MAINTENANCE SAFETY....5674
    SERVICE SCHEDULE....5676
      Chart....5676
    LIFT ARM SUPPORT DEVICE....5677
      Engaging The Lift Arm Support Device....5677
      Disengaging The Lift Arm Support Device....5678
    OPERATOR CAB....5679
      Description....5679
      Raising The Operator Cab....5679
      Lowering The Operator Cab....5680
      Cab Door Sensor (If Equipped)....5680
      Emergency Exit....5681
    SEAT BELT....5682
      Inspection and Maintenance....5682
    SEAT BAR RESTRAINT SYSTEM....5683
      Inspecting The Seat Bar....5683
      Maintaining The Seat Bar....5683
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....5684
      Inspecting The BICS Controller (Engine Stopped - Key ON)....5684
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....5684
      Inspecting The Seat Bar Sensor (Engine RUNNING)....5684
      Inspecting The Traction Lock (Engine RUNNING)....5684
      Inspecting The Lift Arm By-Pass Control....5684
      Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....5684
    REAR DOOR....5685
      Opening And Closing The Rear Door....5685
      Adjusting The Rear Door Latch....5685
    REAR GRILL....5686
      Removing....5686
      Installing....5686
    HEATING SYSTEM....5686
      Cleaning And Maintenance....5686
    AIR CLEANER SERVICE....5687
      Replacing Filter Elements....5687
    FUEL SYSTEM....5688
      Fuel Specifications....5688
      Filling The Fuel Tank....5688
      Fuel Filter....5689
      Removing Air From The Fuel System....5689
    ENGINE LUBRICATION SYSTEM....5690
      Checking Engine Oil....5690
      Replacing The Oil And Filter....5690
    ENGINE COOLING SYSTEM....5691
      Cleaning The Cooling System....5691
      Checking Level....5692
      Removing And Replacing Coolant....5692
    ELECTRICAL SYSTEM....5693
      Description....5693
      Cleaning Battery and Terminals....5693
      Fuse Location....5694
      Using A Booster Battery (Jump Starting)....5695
      Removing And Installing The Battery....5696
    HYDRAULIC / HYDROSTATIC SYSTEM....5697
      Checking And Adding Fluid....5697
      Replacing Hydraulic/Hydrostatic Filter....5697
      Replacing Hydraulic Fluid and Case Drain Filters....5698
      Breather Cap....5699
    TIRE MAINTENANCE....5700
      Wheel Nuts....5700
      Rotating....5700
      Mounting....5700
    FINAL DRIVE TRANSMISSION (CHAINCASE)....5701
      Checking And Adding Oil....5701
      Removing Oil From The Chaincase....5701
    FAN GEARBOX....5702
      Checking And Maintaining....5702
    DRIVE BELT....5702
      Adjusting The Drive Belt....5702
      Replacing The Drive Belt....5702
    BELT ADJUSTMENTS....5703
      Adjusting The Alternator Belt....5703
      Adjusting the Air Conditioner Belt....5703
    LUBRICATING THE BOBCAT LOADER....5704
      Lubrication Locations....5704
    PIVOT PINS....5705
      Inspection And Maintenance....5705
    BOB-TACH (HAND LEVER)....5706
      Inspection And Maintenance....5706
    BOB-TACH (POWER) (OPTIONAL)....5707
      Inspection And Maintenance....5707
  SYSTEM SETUP & ANALYSIS....5708
    BICS SYSTEM....5710
      Troubleshooting Guide....5710
    DIAGNOSTICS SERVICE CODES....5711
      Display....5711
      Service Codes List....5712
    DELUXE INSTRUMENT PANEL SETUP....5716
      Deluxe Panel Upgrade....5716
      Deluxe Panel Setup....5717
      Passwords (Deluxe)....5717
      Viewing Service Codes....5719
    SHUTDOWN FEATURE....5720
    SERVICE CLOCK RESET....5720
  MACHINE SIGN TRANSLATIONS....5722
    SERVICE SCHEDULE (6734534)....5724
    WARNING (6728539)....5725
    WARNING (6715944)....5726
    DANGER (6702301)....5727
    WARNING (6577754)....5727
    DANGER (6702302)....5727
    WARNING (6579528)....5727
    WARNING (6717343)....5728
    WARNING (6708941)....5728
    IMPORTANT (6560573)....5728
    WARNING (6732696)....5728
    LIFT ARM SUPPORT DEVICE (6732774)....5729
  SPECIFICATIONS....5730
    LOADER SPECIFICATIONS (S220)....5732
      Machine Dimensions....5732
      Performance....5733
      Controls....5733
      Engine....5733
      Hydraulic System....5734
      Electrical....5734
      Drive System....5735
      Capacities....5735
      Tires....5735
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS....5736
  WARRANTY....5738
6904176 (5-12) - S220 Turbo, S220 Turbo High Flow Operation & Maintenance Manual....5740
  OPERATOR SAFETY WARNINGS....5742
  CONTENTS....5744
  FOREWORD....5746
    BOBCAT COMPANY IS ISO9001:2000 CERTIFIED....5748
    REGULAR MAINTENANCE ITEMS....5748
    MOTOR OIL....5748
    SERIAL NUMBER LOCATIONS....5749
      Loader Serial Number....5749
      Engine Serial Number....5749
    DELIVERY REPORT....5749
    MACHINE IDENTIFICATION....5750
    FEATURES, ACCESSORIES AND ATTACHMENTS....5751
      Standard Items....5751
      Options and Accessories....5751
      Buckets Available....5752
      Attachments....5752
      40 GPM Attachments....5752
  SAFETY....5754
    SAFETY INSTRUCTIONS....5756
      Before Operation....5756
      Safe Operation Is The Operator?s Responsibility....5757
      Safe Operation Needs A Qualified Operator....5757
      Fire Prevention....5758
    MACHINE SIGNS (DECALS)....5759
  OPERATING INSTRUCTIONS....5762
    INSTRUMENT PANEL IDENTIFICATION....5766
      Left Panel....5766
      Right Panel (Standard - With Key Switch)....5767
      Right Panel (Deluxe - With Keyless Start)....5768
      Option And Field Accessory Panels (If Equipped)....5770
      Cab Light....5771
    LIFT ARM BY-PASS CONTROL....5771
      Operation....5771
    TRACTION LOCK OVERRIDE....5771
      Operation....5771
    ENGINE SPEED CONTROL....5772
      Operation....5772
    TWO-SPEED CONTROL....5772
    INCHING CONTROL....5772
      Operation....5772
    DRIVING AND STEERING THE LOADER....5773
      Available Controls Configurations....5773
      Operation (Standard and ACS)....5773
      Operation (SJC in ?H? Control Pattern)....5774
      Operation (SJC in ?ISO? Control Pattern)....5775
    STOPPING THE BOBCAT LOADER....5776
      Using The Steering Levers Or Joysticks....5776
    SEAT BAR RESTRAINT SYSTEM....5776
      Operation....5776
    HYDRAULIC CONTROLS....5777
      Standard Controls (Also ACS in Foot Pedal Mode)....5777
      Advanced Control System (ACS) in HAND Control Mode....5778
      Selectable Joystick Control (SJC) - ?H? Control Pattern....5779
      Selectable Joystick Control (SJC) - ?ISO? Control Pattern....5779
      Quick Couplers....5780
      Releasing Hydraulic Pressure (Loader and Attachment)....5780
      Auxiliary Hydraulics Button - VARIABLE FLOW....5781
      Auxiliary Hydraulics Button - MAXIMUM FLOW ONLY....5781
      Auxiliary Hydraulics Button - DISENGAGE....5781
      FRONT Auxiliary Hydraulics Operation - VARIABLE FLOW....5781
      FRONT Auxiliary Hydraulics Operation - MAXIMUM FLOW....5781
      FRONT Auxiliary Hydraulics Operation - CONTINUOUS FLOW....5781
      REAR Auxiliary Hydraulics Operation (If Equipped)....5782
      Secondary Front Auxiliary Hydraulics (If Equipped)....5782
      High-Flow Hydraulics Operation (If Equipped)....5783
      Attachment Control Device (ACD) (If Equipped)....5783
      Bucket Position Valve Operation (If Equipped)....5784
    PARKING BRAKE....5784
      Operation....5784
    DAILY INSPECTION....5785
      Daily Inspection and Maintenance....5785
    PRE-STARTING PROCEDURES....5786
      Before Starting The Engine....5786
    STARTING THE ENGINE (STANDARD PANEL, KEY SWITCH)....5788
      Procedure....5788
    STARTING THE ENGINE (DELUXE PANEL, KEYLESS START)....5790
      Procedure....5790
      Cold Temperature Starting....5791
    WARMING THE HYDRAULIC/HYDROSTATIC SYSTEM....5792
      Procedure....5792
    STOPPING THE ENGINE....5792
      Procedure....5792
    MONITORING THE DISPLAY PANEL....5793
      Standard Panel....5793
      Deluxe Panel....5793
      WARNING and SHUTDOWN....5793
    ATTACHMENTS AND BUCKETS....5794
      Choosing The Correct Bucket....5794
      Pallet Forks....5795
      Hand Lever Bob-Tach - Installing The Bucket Or Attachment....5795
      Hand Lever Bob-Tach - Removing The Bucket Or Attachment....5797
      Power Bob-Tach - Installing The Bucket Or Attachment....5798
      Power Bob-Tach - Removing The Bucket Or Attachment....5799
    OPERATING PROCEDURE....5800
      Operating With A Full Bucket....5800
      Operating With An Empty Bucket....5801
      Foot Pedal Machines....5802
      Hand Control Machines (Includes ACS and SJC with H-Pattern Selected)....5804
      Selectable Joystick Control (SJC) with ?ISO? Pattern Selected....5806
    PARKING THE BOBCAT LOADER....5808
      Procedure....5808
    TRANSPORTING THE BOBCAT LOADER....5809
      Loading Onto Transport Vehicle....5809
      Fastening To Transport Vehicle....5809
    TOWING THE LOADER....5810
      Towing Procedure....5810
    LIFTING THE LOADER....5811
      Single Point Lift....5811
      Four Point Lift....5811
  PREVENTIVE MAINTENANCE....5812
    MAINTENANCE SAFETY....5814
    SERVICE SCHEDULE....5816
      Chart....5816
    LIFT ARM SUPPORT DEVICE....5817
      Engaging The Lift Arm Support Device....5817
      Disengaging The Lift Arm Support Device....5818
    OPERATOR CAB....5819
      Description....5819
      Raising The Operator Cab....5819
      Lowering The Operator Cab....5820
      Cab Door Sensor (If Equipped)....5820
      Emergency Exit....5821
    SEAT BELT....5822
      Inspection and Maintenance....5822
    SEAT BAR RESTRAINT SYSTEM....5823
      Inspecting The Seat Bar....5823
      Maintaining The Seat Bar....5823
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....5824
      Inspecting The BICS Controller (Engine Stopped - Key ON)....5824
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....5824
      Inspecting The Seat Bar Sensor (Engine RUNNING)....5824
      Inspecting The Traction Lock (Engine RUNNING)....5824
      Inspecting The Lift Arm By-Pass Control....5824
      Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....5824
    REAR DOOR....5825
      Opening And Closing The Rear Door....5825
      Adjusting The Rear Door Latch....5825
    REAR GRILL....5826
      Removing....5826
      Installing....5826
    HEATING SYSTEM....5826
      Cleaning And Maintenance....5826
    AIR CLEANER SERVICE....5827
      Replacing Filter Elements....5827
    FUEL SYSTEM....5828
      Fuel Specifications....5828
      Filling The Fuel Tank....5828
      Fuel Filter....5829
      Removing Air From The Fuel System....5829
    ENGINE LUBRICATION SYSTEM....5830
      Checking Engine Oil....5830
      Replacing The Oil And Filter....5830
    ENGINE COOLING SYSTEM....5831
      Cleaning The Cooling System....5831
      Checking Level....5832
      Removing And Replacing Coolant....5832
    ELECTRICAL SYSTEM....5833
      Description....5833
      Cleaning Battery and Terminals....5833
      Fuse Location....5834
      Using A Booster Battery (Jump Starting)....5835
      Removing And Installing The Battery....5836
    HYDRAULIC / HYDROSTATIC SYSTEM....5837
      Checking And Adding Fluid....5837
      Replacing Hydraulic/Hydrostatic Filter....5837
      Replacing Hydraulic Fluid and Case Drain Filters....5838
      Breather Cap....5839
    TIRE MAINTENANCE....5840
      Wheel Nuts....5840
      Rotating....5840
      Mounting....5840
    FINAL DRIVE TRANSMISSION (CHAINCASE)....5841
      Checking And Adding Oil....5841
      Removing Oil From The Chaincase....5841
    FAN GEARBOX....5842
      Checking And Maintaining....5842
    DRIVE BELT....5842
      Adjusting The Drive Belt....5842
      Replacing The Drive Belt....5842
    BELT ADJUSTMENTS....5843
      Adjusting The Alternator Belt....5843
      Adjusting the Air Conditioner Belt....5843
    LUBRICATING THE BOBCAT LOADER....5844
      Lubrication Locations....5844
    PIVOT PINS....5845
      Inspection And Maintenance....5845
    BOB-TACH (HAND LEVER)....5846
      Inspection And Maintenance....5846
    BOB-TACH (POWER) (OPTIONAL)....5847
      Inspection And Maintenance....5847
  SYSTEM SETUP & ANALYSIS....5848
    BICS SYSTEM....5850
      Troubleshooting Guide....5850
    DIAGNOSTICS SERVICE CODES....5851
      Display....5851
      Service Codes List....5852
    DELUXE INSTRUMENT PANEL SETUP....5856
      Deluxe Panel Upgrade....5856
      Deluxe Panel Setup....5857
      Passwords (Deluxe)....5857
      Viewing Service Codes....5859
    SHUTDOWN FEATURE....5860
    SERVICE CLOCK RESET....5860
  MACHINE SIGN TRANSLATIONS....5862
    SERVICE SCHEDULE (6734534)....5864
    WARNING (6728539)....5865
    WARNING (6715944)....5866
    DANGER (6702301)....5867
    WARNING (6577754)....5867
    DANGER (6702302)....5867
    WARNING (6579528)....5867
    WARNING (6717343)....5868
    WARNING (6708941)....5868
    IMPORTANT (6560573)....5868
    WARNING (6732696)....5868
    LIFT ARM SUPPORT DEVICE (6732774)....5869
  SPECIFICATIONS....5870
    LOADER SPECIFICATIONS (S220)....5872
      Machine Dimensions....5872
      Performance....5873
      Controls....5873
      Engine....5873
      Hydraulic System....5874
      Electrical....5874
      Drive System....5875
      Capacities....5875
      Tires....5875
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS....5876
  WARRANTY....5878
6986679 (3-09) - S220 Skid-Steer Loader Service Manual....5880
  MAINTENANCE SAFETY....5882
  ALPHABETICAL INDEX....5884
  CONTENTS....5886
    FOREWORD....5887
    SAFETY INSTRUCTIONS....5890
    FIRE PREVENTION....5892
      Maintenance....5892
      Operation....5892
      Electrical....5892
      Hydraulic System....5892
      Fueling....5892
      Starting....5892
      Spark Arrestor Exhaust System....5892
      Welding And Grinding....5893
      Fire Extinguishers....5893
    SERIAL NUMBER LOCATIONS....5894
      Loader Serial Number....5894
      Engine Serial Number....5894
    DELIVERY REPORT....5894
    LOADER IDENTIFICATION....5895
  SAFETY AND MAINTENANCE....5896
    LIFTING AND BLOCKING THE LOADER....5900
      Procedure....5900
    LIFT ARM SUPPORT DEVICE....5902
      Installing....5902
      Removing....5903
    OPERATOR CAB....5904
      Description....5904
      Raising....5905
      Lowering....5906
      Cab Door Sensor....5907
      Special Applications Kit Inspection And Maintenance....5907
    TRANSPORTING LOADER ON A TRAILER....5908
      Loading And Unloading....5908
      Fastening....5908
    TOWING THE LOADER....5910
      Procedure....5910
    REMOTE START TOOL KIT-MEL1563....5912
      Remote Start Tool - MEL1563....5912
      Service Tool Harness Control - MEL1565....5913
      Service Tool Harness Communicator - MEL1566....5914
      Remote Start Procedure....5915
    REMOTE START TOOL (SERVICE TOOL) KIT - 6689779....5918
      Description....5918
      Remote Start Tool (Service Tool) - 6689778....5919
      Loader Service Tool Harness - 6689747....5920
      Computer Service Tool Harness - 6689746....5921
      Remote Start Procedure....5922
    SERVICE SCHEDULE....5926
      Chart....5926
    AIR CLEANER SERVICE....5928
      Replacing Filter Elements....5928
    ENGINE COOLING SYSTEM....5930
      Cleaning....5930
      Removing And Replacing Coolant....5931
      Checking Level....5931
    FUEL SYSTEM....5932
      Fuel Specifications....5932
      Biodiesel Blend Fuel....5932
      Filling The Fuel Tank....5933
      Fuel Filter....5934
      Removing Air From The Fuel System....5934
    ENGINE LUBRICATION SYSTEM....5936
      Checking And Adding Engine Oil....5936
      Engine Oil Chart....5936
      Removing And Replacing Oil And Filter....5937
    HYDRAULIC / HYDROSTATIC SYSTEM....5938
      Checking And Adding Fluid....5938
      Hydraulic / Hydrostatic Fluid Chart....5938
      Removing And Replacing Hydraulic Fluid....5939
      Removing And Replacing Hydraulic / Hydrostatic Filter....5940
      Removing And Replacing Case Drain Filters....5941
      Removing And Replacing Hydraulic Charge Filter....5942
      Breather Cap....5943
    FINAL DRIVE TRANSMISSION (CHAINCASE)....5944
      Checking And Adding Oil....5944
      Removing And Replacing Oil....5944
    BOB-TACH (HAND LEVER)....5946
      Inspection And Maintenance....5946
    BOB-TACH (POWER - OPTION)....5948
      Inspection And Maintenance....5948
    LUBRICATING THE LOADER....5950
      Lubrication Locations....5950
    TIRE MAINTENANCE....5952
      Wheel Nuts....5952
      Rotating....5952
      Mounting....5953
    SPARK ARRESTOR MUFFLER....5954
      Cleaning Procedure....5954
    PIVOT PINS....5956
      Inspection And Maintenance....5956
    LOADER STORAGE AND RETURN TO SERVICE....5958
      Storage....5958
      Return to Service....5958
    STOPPING THE ENGINE AND LEAVING THE LOADER....5960
      Procedure....5960
      Emergency Exit....5961
  HYDRAULIC SYSTEM....5962
    HYDRAULIC / HYDROSTATIC SCHEMATICS....5968
    HYDRAULIC SYSTEM INFORMATION....5984
      Glossary Of Hydraulic / Hydrostatic Symbols....5984
      Troubleshooting....5988
    CYLINDER (LIFT)....5990
      Testing....5990
      Removal And Installation....5991
      Parts Identification....5993
      Disassembly....5994
      Assembly....5996
    CYLINDER (TILT)....5998
      Testing....5998
      Removal And Installation....5999
      Base End Pivot Pin Removal And Installation....6001
      Parts Identification....6002
      Disassembly....6003
      Assembly....6005
    CYLINDER (BOB-TACH)....6008
      Testing....6008
      Removal And Installation....6009
      Parts Identification....6010
      Disassembly....6011
      Assembly....6012
    MAIN RELIEF VALVE....6016
      Description....6016
      Testing....6017
      Adjusting....6019
      Removal And Installation....6020
    HYDRAULIC CONTROL VALVE (STANDARD)....6022
      Description....6022
      Removal And Installation....6023
      Identification Chart....6027
      Mount Bracket Removal And Installation....6028
      Lift Load Check Valve Removal And Installation....6028
      Load Check Valve Removal And Installation (Tilt & Auxiliary)....6029
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....6029
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....6030
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....6031
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....6031
      Port Relief Valve Removal And Installation....6032
      Plug Removal And Installation....6033
      Rubber Boot Removal and Installation....6034
      End Cap Block Removal and Installation....6035
      Lift Spool And Detent Removal And Installation....6036
      Tilt Spool Removal And Installation....6046
      Auxiliary Spool Removal And Installation....6048
      Auxiliary Solenoid Removal And Installation....6050
      Solenoid Removal And Installation....6051
      Lock Valve Removal And Installation....6052
      Lift Arm Bypass Orifice Removal And Installation....6054
      Main Relief Valve Removal And Installation....6054
      Check Valve Removal And Installation....6055
    HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....6056
      Description....6056
      Removal And Installation....6057
      Actuator Removal And Installation (In Loader)....6061
      Actuator Removal And Installation (Out Of Loader)....6063
      Identification Chart....6066
      Mount Bracket Removal And Installation....6067
      Lift Load Check Valve Removal And Installation....6067
      Load Check Valve Removal And Installation (Tilt & Auxiliary)....6068
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....6068
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....6069
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....6070
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....6070
      Port Relief Valve Removal And Installation....6071
      Plug Removal And Installation....6072
      End Cap Block Removal And Installation....6073
      Lift Spool And Detent Removal And Installation....6074
      Tilt Spool Removal And Installation....6079
      Auxiliary Spool Removal And Installation....6081
      Auxiliary Solenoid Removal And Installation....6083
      Solenoid Removal And Installation....6084
      Lock Valve Removal And Installation....6085
      Lift Arm Bypass Orifice Removal And Installation....6087
      Main Relief Valve Removal And Installation....6087
      Check Valve Removal And Installation....6088
    LIFT ARM BYPASS CONTROL VALVE....6090
      Description....6090
      Testing....6090
      Removal And Installation....6091
      Disassembly And Assembly....6092
    HYDRAULIC PUMP (STANDARD)....6094
      Description....6094
      Pump Test at Quick Couplers....6095
      Direct Pump Test (Standard Section)....6096
      Direct Pump Test (Charge Section)....6098
      Removal And Installation....6102
      Hydraulic Pump Start Up....6104
      Parts Identification....6105
      Disassembly And Assembly....6106
    HYDRAULIC PUMP (STANDARD) (HIGH FLOW)....6108
      Description....6108
      Pump Test At Quick Couplers....6109
      Direct Pump Test (Standard Section)....6110
      Direct Pump Test (Charge Section)....6112
      Direct Pump Test (High Flow Section)....6116
      High Flow Relief Valve Adjustment....6118
      High Flow Relief Valve Removal And Installation....6121
      Solenoid Removal And Installation....6122
      Removal And Installation....6123
      Hydraulic Pump Start Up....6125
      Parts Identification....6127
      Disassembly And Assembly....6128
    HYDRAULIC PUMP (SJC)....6130
      Description....6130
      Pump Test At Quick Couplers....6131
      Direct Pump Test (Standard Section)....6132
      Direct Pump Test (Charge Section)....6134
      Removal And Installation....6138
      Hydraulic Pump Start Up....6140
      Parts Identification....6141
      Disassembly And Assembly....6142
    HYDRAULIC PUMP (SJC) (HIGH FLOW)....6144
      Description....6144
      Pump Test At Quick Couplers....6145
      Direct Pump Test (Standard Section)....6146
      Direct Pump Test (Charge Section)....6148
      Direct Pump Test (High Flow Section)....6152
      High Flow Relief Valve Adjustment....6154
      High Flow Relief Valve Removal And Installation....6157
      Solenoid Removal And Installation....6158
      Removal And Installation....6159
      Hydraulic Pump Start Up....6161
      Parts Identification....6163
      Disassembly And Assembly....6164
    HYDRAULIC/HYDROSTATIC FILTERS....6166
      Description....6166
      Housing Removal And Installation....6166
    HYDRAULIC FLUID RESERVOIR....6168
      Description....6168
      Removal And Installation....6168
      Hydraulic Fluid Screen....6171
    OIL COOLER....6172
      Description....6172
      Removal And Installation....6172
    BUCKET POSITION VALVE....6174
      Description....6174
      Solenoid Removal And Installation....6175
      Solenoid Testing....6176
      Removal And Installation....6176
      Disassembly And Assembly....6177
    REAR AUXILIARY DIVERTER VALVE....6180
      Description....6180
      Solenoid Testing....6180
      Removal And Installation....6181
      Disassembly And Assembly....6183
    BOB-TACH (POWER) BLOCK....6190
      Description....6190
      Removal And Installation....6190
      Disassembly And Assembly....6192
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....6196
      Description....6196
      Removal and Installation....6196
      Disassembly And Assembly....6197
  HYDROSTATIC SYSTEM....6200
    HYDROSTATIC SYSTEM INFORMATION....6202
      Troubleshooting....6202
      Description....6203
    HYDROSTATIC MOTOR....6204
      Description....6204
      Removal And Installation....6205
      Parts Identification....6207
      Disassembly And Assembly....6208
    HYDROSTATIC MOTOR (TWO-SPEED)....6212
      Description....6212
      Removal And Installation....6213
      Parts Identification....6216
      Disassembly....6218
      Assembly....6224
    HYDROSTATIC MOTOR CARRIER....6228
      Description....6228
      Removal And Installation....6229
      Parts Identification....6230
      Disassembly....6231
      Assembly....6232
    HYDROSTATIC MOTOR CARRIER (SJC)....6234
      Description....6234
      Removal And Installation....6235
      Parts Identification....6236
      Disassembly....6237
      Assembly....6239
    CHARGE PRESSURE....6242
      Description....6242
      Testing....6243
      Sender Removal And Installation....6245
      Adjusting....6246
    HYDROSTATIC PUMP....6248
      Description....6248
      Removal And Installation....6249
      Hydrostatic Pump Startup....6251
      Replenishing / High Pressure Relief Valve Removal And Installation....6252
      Parts Identification (Left Half)....6253
      Parts Identification (Right Half)....6254
      Disassembly....6255
      Assembly....6262
    HYDROSTATIC PUMP (SJC)....6268
      Description....6268
      Hydraulic Controller Removal And Installation....6269
      Removal And Installation....6271
      Hydrostatic Pump Startup....6273
      Parts Identification....6274
      High Pressure Relief And ByPass Valve....6275
      Charge Relief Valve....6276
      Disassembly And Assembly....6277
      Mechanical Neutral Adjustment....6294
      Hydraulic Controller Neutral Adjustment....6297
    DRIVE BELT....6300
      Description....6300
      Shield Removal And Installation....6300
      Adjusting....6301
      Belt Removal And Installation....6301
      Tensioner Pulley Removal And Installation....6302
      Tensioner Pulley Disassembly And Assembly....6303
      Tensioner Pulley Tension Spring Removal And Installation....6304
      Tensioner Pulley Tension Spring Disassembly And Assembly....6304
    CASE DRAIN FILTER....6306
      Description....6306
      Disassembly And Assembly....6306
  DRIVE SYSTEM....6308
    BRAKE....6310
      Description....6310
      Disc Removal And Installation....6311
    BRAKE (TWO-SPEED)....6314
      Description....6314
      Block Removal And Installation....6315
      Block Disassembly And Assembly....6317
    DRIVE COMPONENTS....6322
      Description....6322
      Axle Seal Removal And Installation....6323
      Axle, Sprocket And Bearings Removal And Installation....6325
      Chain Removal And Installation....6330
      Description....6331
      Axle Seal Removal And Installation....6332
      Axle, Sprocket And Bearings Removal And Installation....6334
      Chain Removal And Installation....6339
    CHAINCASE....6342
      Description....6342
      Front Cover Removal And Installation....6342
      Center Cover Removal And Installation....6343
      Rear Cover Removal And Installation....6344
  MAIN FRAME....6346
    SEAT BAR....6350
      Description....6350
      Removal And Installation....6350
      Disassembly And Assembly....6352
      Compression Spring Disassembly And Assembly....6353
    OPERATOR CAB....6354
      Gas Cylinder Removal And Installation....6354
      Gas Cylinder Bracket Disassembly And Assembly....6356
      Removal And Installation....6357
    OPERATOR SEAT....6360
      Removal And Installation....6360
      Seat Belt Removal And Installation....6360
    OPERATOR SEAT (SUSPENSION)....6362
      Removal And Installation....6362
      Slide Rail Removal And Installation....6363
      Seat Belt Removal And Installation....6363
      Cushion Removal And Installation....6364
      Back Removal And Installation....6365
      Shock Removal And Installation....6365
      3-Point Seat Belt Removal And Installation....6366
    BOB-TACH (HAND LEVER)....6368
      Description....6368
      Removal And Installation....6368
      Lever And Wedge Disassembly And Assembly....6371
      Pivot Pin Bushing And Seal Removal And Installation....6372
    BOB-TACH (POWER - OPTION)....6374
      Description....6374
      Removal And Installation....6374
      Lever And Wedge Disassembly And Assembly....6377
      Pivot Pin Bushing And Seal Removal And Installation....6379
    LIFT ARMS....6380
      Removal And Installation....6380
    REAR GRILL....6384
      Removal And Installation....6384
    REAR DOOR....6386
      Removal And Installation....6386
      Striker Removal And Installation....6387
      Striker Disassembly And Assembly....6387
      Striker (Adjusting)....6388
      Latch Removal And Installation....6389
    FUEL TANK....6390
      Removal And Installation....6390
      Fuel Level Sender Removal And Installation....6393
      Fuel Fill Screen Removal And Installation....6393
    CONTROL PEDALS AND LINKAGES....6394
      Description....6394
      Pedal Removal And Installation....6395
      Linkage Removal And Installation....6396
      Pedal (Adjusting)....6397
    CONTROL PEDALS (ACS)....6398
      Description....6398
      Foot Sensor Removal And Installation....6399
      Foot Pedal Removal And Installation....6400
      Foot Pedal Linkage Disassembly And Assembly....6401
    CONTROL PANEL....6402
      Description....6402
      Removal And Installation....6403
      Shock Removal And Installation....6405
      Shaft Removal And Installation....6406
      Linkage Removal And Installation....6407
      Pintle Arm Disassembly and Assembly....6411
      Linkage Neutral (Adjusting)....6412
      Linkage Travel (Adjusting)....6416
    CONTROL PANEL (SJC)....6420
      Description....6420
      Removal And Installation....6421
    CONTROL HANDLE / LEVER....6424
      Description....6424
      Lever Removal And Installation....6424
      Boot Removal And Installation....6425
    CONTROL HANDLE / LEVER (ACS)....6426
      Description....6426
      Handle Sensor Removal And Installation....6426
      Handle Removal And Installation....6429
      Handle Disassembly And Assembly....6430
      Lever Removal And Installation....6431
      Boot Removal And Installation....6432
    JOYSTICK CONTROL....6434
      Description....6434
      Testing....6435
      Removal And Installation....6436
      Joystick Mount Removal And Installation....6437
    ACCESS PANEL (INSIDE)....6438
      Removal And Installation (Left)....6438
      Removal And Installation (Right)....6438
    ACCESS PANEL (INSIDE) (SJC)....6440
      Removal And Installation (Left)....6440
      Removal And Installation (Right)....6441
    WINDOW (REAR)....6444
      Removal....6444
      Installation....6444
    WINDOW (TOP)....6446
      Removal And Installation....6446
    WINDOW (SIDE)....6448
      Removal And Installation....6448
    WINDOW (FRONT DOOR)....6450
      Removal (Standard Window)....6450
      Installation (Standard Window)....6451
      Removal And Installation (Special Applications Window)....6453
    CAB DOOR....6454
      Description....6454
      Removal And Installation....6454
      Aligning....6455
      Adjusting....6456
      Checking Operation....6456
  ELECTRICAL SYSTEM & ANALYSIS....6458
    ELECTRICAL SCHEMATICS....6462
    ELECTRICAL SYSTEM INFORMATION....6469
      Glossary Of Electrical Symbols....6469
      Cab Harness Connectors....6472
      Mainframe Harness Connectors....6473
      Description....6475
      Troubleshooting....6477
      Fuse And Relay Location / Identification....6478
      Solenoid Testing....6479
    BATTERY....6481
      Removal And Installation....6481
      Servicing....6482
      Using A Booster Battery (Jump Starting)....6483
    ALTERNATOR....6485
      Belt Adjustment....6485
      Charging System Inspection....6486
      Alternator Voltage Testing....6487
      Low Voltage Testing....6487
      High Voltage Testing....6488
      Removal And Installation....6489
      Parts Identification....6490
    STARTER....6491
      Testing....6491
      Removal And Installation....6492
      Parts Identification....6493
    INSTRUMENT PANELS....6495
      Left Panel....6495
      Right Panel (Key Switch)....6496
      Right Panel (Keyless)....6497
      Side And Front Panels....6499
      Removal And Installation (Left And Right)....6500
      Bulb Removal And Installation (Left Only)....6503
      Key Switch Removal And Installation....6504
      Alarm Removal And Installation....6505
      Front Panel Removal And Installation....6505
    LIGHTS....6507
      Front Removal And Installation....6507
      Rear Removal And Installation....6508
      Cab Light Removal And Installation....6508
    BOBCAT CONTROLLER (MAIN)....6509
      Description....6509
      Connector Identification....6510
      Removal And Installation....6512
    BOBCAT CONTROLLER (ACS)....6513
      Description....6513
      Connector And Wire Identification....6514
      Removal And Installation....6515
    BOBCAT CONTROLLER (SJC) (DRIVE)....6517
      Description....6517
      Connector Identification....6518
      Removal And Installation....6520
    SPEED SENSOR (SJC)....6521
      Description....6521
      Testing....6522
      Removal And Installation....6523
    DIAGNOSTIC SERVICE CODES....6525
      Viewing Service Codes (Key Switch)....6525
      Viewing Service Codes (Keyless)....6525
      Service Codes List....6526
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....6531
      Description....6531
      Inspecting The BICS Controller (Engine STOPPED - Key ON)....6532
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....6532
      Inspecting The Seat Bar Sensor (Engine RUNNING)....6532
      Inspecting The Traction Lock (Engine RUNNING)....6532
      Inspecting The Lift Arm Bypass Control....6532
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....6532
      Troubleshooting....6533
      Troubleshooting Chart....6534
    SEAT BAR SENSOR....6535
      Description....6535
      Troubleshooting....6536
      Testing....6537
      Removal And Installation....6538
      Bobcat Interlock Control System (BICS) Circuit Test....6539
    TRACTION LOCK....6541
      Description....6541
      Troubleshooting....6542
      Removal And Installation (Single Speed)....6543
      Inspecting (Single And Two Speed)....6547
    CONTROL SYSTEM (ACS)....6549
      Description....6549
      Troubleshooting Chart....6550
      Handle Sensor Connector Disassembly And Assembly....6551
      Switch Handle Removal....6552
      Switch Handle Installation....6554
      Actuator Connector Disassembly And Assembly....6557
      Handle Lock Solenoid Removal And Installation....6558
      Handle Lock Solenoid Disassembly And Assembly....6559
      Foot Sensor Disassembly And Assembly....6559
      Foot Lock Solenoid Removal And Installation....6560
    ELECTRICAL / HYDRAULIC CONTROLS....6561
      Identification Chart....6561
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)....6563
      Identification Chart....6563
    SERVICE PC (LAPTOP COMPUTER)....6567
      Connecting Remote Start Tool....6567
      Connecting Remote Start Tool (Service Tool)....6567
    CALIBRATION....6569
      Description....6569
      Actuator Testing....6569
      Lift And Tilt Calibration (ACS)....6571
      Lift And Tilt Calibration (SJC)....6573
      Hydrostatic Pump Calibration (SJC)....6575
    STEERING DRIFT COMPENSATION....6581
      Description....6581
      Selecting And Adjusting....6581
      Exiting And Saving....6582
    FLYWHEEL RPM SENSOR....6583
      Description....6583
      Adjustment....6584
    CONTROL PANEL SETUP....6585
      Right Panel Setup (Keyless)....6585
      Attachment Control Information (Keyless)....6586
    PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START)....6587
      Password Description....6587
      Changing The Owner And User Passwords....6588
      Password Lockout Feature....6589
    MAINTENANCE CLOCK....6591
      Description....6591
      Setup....6592
      Reset....6596
    BACK-UP ALARM SYSTEM....6597
      Description....6597
      Inspecting....6597
      Adjusting Switch Position....6598
      Troubleshooting (Standard And ACS)....6599
      Troubleshooting (Joystick)....6600
      Alarm Removal And Installation....6601
      Switch Removal And Installation....6601
  ENGINE SERVICE....6603
    ENGINE INFORMATION....6607
      Description....6607
      Specifications....6608
      Torque Values....6613
      Troubleshooting....6614
      Engine Removal And Installation....6616
      Engine Mount Replacement....6622
      Compression - Checking....6623
    ENGINE SPEED CONTROL....6625
      Removal And Installation....6625
      Cable Removal And Installation....6625
    ENGINE SPEED CONTROL (SJC)....6627
      Removal And Installation....6627
      Disassembly And Assembly....6629
      Speed Control Cable Removal And Installation....6630
    MUFFLER....6631
      Removal And Installation....6631
    AIR CLEANER....6633
      Housing Removal And Installation....6633
    ENGINE COOLING SYSTEM....6635
      Radiator Removal And Installation....6635
      Radiator Mount Removal And Installation....6637
      Hydraulic Fan Motor Description....6638
      Axial Fan Housing Removal And Installation....6638
      Axial Fan Removal And Installation....6641
      Hydraulic Fan Motor Removal And Installation....6642
      Hydraulic Fan Motor Disassembly And Assembly....6643
      Water Pump Removal And Installation....6644
      Water Pump Disassembly And Assembly....6645
      Thermostat Housing Removal And Installation....6645
    LUBRICATION SYSTEM....6647
      Oil Pan Removal And Installation....6647
      Oil Pump Removal And Installation....6648
      Oil Pump Inspection....6648
      Oil Filter Cooler Removal And Installation....6650
      Engine Oil Pressure - Testing....6651
    FUEL SYSTEM....6653
      Fuel Shutoff Solenoid - Checking....6653
      Fuel Shutoff Solenoid - Removal And Installation....6653
      Fuel Injection Pump Assembly Removal....6654
      Fuel Injection Pump Assembly Installation....6658
      Governor Housing Disassembly And Assembly....6660
      Governor Disassembly And Assembly....6662
      Fuel Camshaft Removal And Installation....6664
      Fuel Injection Pump Removal....6666
      Injection Pump Timing....6673
      Fuel Injector Removal And Installation....6676
      Fuel Injector Nozzle Pressure - Checking....6677
      Nozzle Spraying Condition....6678
      Valve Seat Tightness....6678
    CYLINDER HEAD....6681
      Intake Air Heater - Testing....6681
      Intake Air Heater Removal And Installation....6681
      Valve Clearance Adjustment....6682
      Cylinder Head Removal And Installation....6684
      Cylinder Head Top Clearance....6686
      Cylinder Head Disassembly And Assembly....6687
      Cylinder Head - Servicing....6687
      Valve Guide - Checking....6688
      Reconditioning The Valve And Valve Seat....6690
      Valve Spring....6692
      Valve Tappets....6693
      Rocker Arm And Shaft - Checking....6694
      Push Rod Alignment - Checking....6694
    CRANKSHAFT AND PISTONS....6695
      Piston And Connecting Rod Removal And Installation....6695
      Piston And Connecting Rod - Servicing....6697
      Cylinder Bore Checking....6701
      Connecting Rod Alignment....6702
      Crankshaft Gear Removal And Installation....6702
      Crankshaft And Bearings Removal....6703
      Crankshaft And Bearings Installation....6705
      Crankshaft And Bearings - Servicing....6707
    CAMSHAFT AND TIMING GEArS....6713
      Timing Gearcase Cover Removal And Installation....6713
      Timing Gears Backlash - Checking....6714
      Idler Gear And Camshaft Removal and Installation....6714
      Camshaft - Servicing....6715
      Idler Gear And Shaft - Servicing....6717
    TURBOCHARGER....6719
      Description....6719
      Testing....6719
      Removal And Installation....6720
    FLYWHEEL AND HOUSING....6721
      Flywheel Removal And Installation....6721
      Ring Gear Removal And Installation....6721
      Housing Removal And Installation....6722
    EXHAUST GAS RECIRCULATION (EGR) SYSTEM....6723
      Description....6723
      Testing....6724
      Removal And Installation....6727
  HEATING, VENTILATION, AIR CONDITIONING....6729
    AIR CONDITIONING SYSTEM FLOW....6732
      Description....6732
      Chart....6733
      Components....6734
      Safety Equipment....6737
    REGULAR MAINTENANCE....6739
      Filter Elements Removal And Installation....6739
      Compressor Drive Belt Inspection....6739
      Condenser....6740
      Air Conditioning Service Chart....6741
      A/C Evaporator Coil & Heater Coil....6742
    TROUBLESHOOTING....6743
      Blower Motor Does Not Operate....6743
      Blower Motor Operates Normally, But Air Flow Is Insufficient....6743
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....6743
      The Compressor Does Not Operate At All, Or Operates Improperly....6743
      Gauge Pressure Related Troubleshooting....6744
      Troubleshooting Tree....6746
      Temperature / Pressure Chart....6750
      Poor A/C Performance....6752
      HVAC Repair And Leaks....6753
      Electrical System....6754
      Engine Coolant By Passing The Heater Valve....6761
      Heater Valve Not Opening Or Closing....6762
    SYSTEM CHARGING AND RECLAMATION....6763
      Refrigerant Identification....6763
      Reclamation And Charging With Recovery / Charging Unit....6764
      Charging With A Manifold Gauge Set....6766
    COMPRESSOR....6769
      Belt Adjustment....6769
      Removal And Installation....6769
      Oil....6770
      Oil Check....6771
      Clutch Disassembly And Assembly....6772
    CONDENSER....6777
      Removal And Installation....6777
    RECEIVER / DRIER....6779
      Receiver / Drier Removal And Installation....6779
      Pressure Relief Valve Removal And Installation....6780
      Pressure Switch Removal And Installation....6780
      Schraeder Valve Removal And Installation....6781
    EVAPORATOR / HEATER UNIT....6783
      Removal And Installation....6783
    THERMOSTAT....6785
      Removal And Installation....6785
    EXPANSION VALVE....6787
      Removal And Installation....6787
    EVAPORATOR....6789
      Removal And Installation....6789
    HEATER COIL....6791
      Removal And Installation With A/C....6791
      Removal And Installation Without A/C....6793
    BLOWER FAN....6795
      Removal And Installation....6795
      Disassembly And Assembly....6796
      Connector Identification....6798
    HEATER VALVE....6799
      Removal and Installation....6799
      Disassembly And Assembly....6800
  SPECIFICATIONS....6801
    (S220) LOADER SPECIFICATIONS....6803
      Dimensions....6803
      Performance....6804
      Controls....6804
      Engine....6804
      Hydraulic System....6805
      Electrical....6805
      Drive System....6806
      Capacities....6806
      Tires....6806
    TORQUE SPECIFICATIONS FOR BOLTS....6807
      Torque For General SAE Bolts....6807
      Torque For General Metric Bolts....6808
    HYDRAULIC CONNECTION SPECIFICATIONS....6809
      O-ring Face Seal Connection....6809
      Straight Thread O-ring Fitting....6810
      Tubelines And Hoses....6810
      Flare Fitting....6811
      Port Seal Fitting....6812
    HYDRAULIC FLUID SPECIFICATIONS....6813
      Specifications....6813
    CONVERSIONS....6815
      Decimal And Millimeter Equivalents....6815
      U.S. To Metric Conversion Chart....6815
  SERVICE MANUAL REVISION....6817
    Revision No: S220 - 1....6817
    Revision No: S220 - 2....6819
    Revision No: S220 - 3....6821
6986970 (4-08) - S220 Skid-Steer Loader Operation & Maintenance Manual....6823
  OPERATOR SAFETY WARNINGS....6825
  CONTENTS....6827
  FOREWORD....6829
    BOBCAT COMPANY IS ISO9001:2000 CERTIFIED....6831
    REGULAR MAINTENANCE ITEMS....6831
    SERIAL NUMBER LOCATIONS....6832
      Loader Serial Number....6832
      Engine Serial Number....6832
    DELIVERY REPORT....6832
    LOADER IDENTIFICATION....6833
    FEATURES, ACCESSORIEs and attachments....6834
      Standard Items....6834
      Options and Accessories....6834
      Buckets Available....6835
      Attachments....6835
      40 GPM Attachments....6835
      Special Applications Kit....6836
      Special Applications Kit Inspection And Maintenance....6836
  SAFETY & TRAINING RESOURCES....6837
    SAFETY INSTRUCTIONS....6839
      Before Operation....6839
      Safe Operation Is The Operator?s Responsibility....6840
      Safe Operation Needs A Qualified Operator....6840
      Avoid Silica Dust....6841
    FIRE PREVENTION....6841
      Maintenance....6841
      Operation....6841
      Electrical....6841
      Hydraulic System....6842
      Fueling....6842
      Starting....6842
      Spark Arrestor Exhaust System....6842
      Welding And Grinding....6842
      Fire Extinguishers....6842
    MACHINE SIGNS (DECALS)....6844
    PUBLICATIONS AND TRAINING RESOURCES....6846
  OPERATING INSTRUCTIONS....6847
    INSTRUMENT PANEL IDENTIFICATION....6851
      Left Panel....6851
      Right Panel (Key Switch)....6852
      Right Panel (Keyless)....6853
      Cab Light....6854
      Side And Front Panels....6855
    SEAT BAR RESTRAINT SYSTEM....6856
      Operation....6856
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....6857
      Operation....6857
    LIFT ARM BYPASS CONTROL....6858
      Operation....6858
    PARKING BRAKE....6858
      Operation....6858
    TRACTION LOCK OVERRIDE....6858
      Operation....6858
    BACK-UP ALARM SYSTEM....6859
      Operation....6859
    ENGINE SPEED CONTROL....6859
      Operation....6859
    DRIVING AND STEERING THE LOADER....6860
      Available Control Configurations....6860
      Operation (Standard and ACS)....6860
      Operation (SJC) in ?H? Control Pattern....6861
      Operation (SJC) in ?ISO? Control Pattern....6862
    STOPPING THE LOADER....6862
      Using The Control Levers Or Joysticks....6862
    TWO-SPEED CONTROL....6863
      Description....6863
      Operation (Standard And ACS) (If Equipped)....6863
      Operation (SJC) (If Equipped)....6863
    SPEED MANAGEMENT....6864
      Operation....6864
    STEERING DRIFT COMPENSATION....6865
      Description....6865
      Operation....6865
    HYDRAULIC CONTROLS....6867
      Description....6867
      Standard Controls (Also ACS In Foot Pedal Mode)....6867
      Advanced Control System (ACS) in HAND Control Mode....6868
      Selectable Joystick Control (SJC) - ?H? Control Pattern....6868
      Selectable Joystick Control (SJC) - ?ISO? Control Pattern....6869
      Hydraulic Bucket Positioning....6869
      FRONT Auxiliary Hydraulics Operation (VARIABLE FLOW)....6870
      FRONT Auxiliary Hydraulics Operation (MAXIMUM FLOW)....6870
      FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....6871
      REAR Auxiliary Hydraulics Operation....6871
      Quick Couplers....6872
      Relieve Hydraulic Pressure (Loader and Attachment)....6872
      High-Flow Hydraulics Operation....6873
      Secondary Front Auxiliary Hydraulics....6874
    ATTACHMENT CONTROL DEVICE (ACD)....6875
      Description....6875
    DAILY INSPECTION....6876
      Daily Inspection and Maintenance....6877
    PRE-STARTING PROCEDURE....6878
      Entering The Loader....6878
      Operation & Maintenance Manual And Operator?s Handbook Locations....6878
      Seat Adjustment....6879
      Seat Belt Adjustment....6879
      Seat Bar....6880
    STARTING THE ENGINE....6881
      Key Switch....6881
      Keyless....6883
      Cold Temperature Starting....6884
      Warming The Hydraulic / Hydrostatic System....6885
    MONITORING THE DISPLAY PANELS....6886
      Left Panel....6886
      Right Panel (Key Switch)....6886
      Right Panel (Keyless)....6886
      Warning and Shutdown....6886
    STOPPING THE ENGINE AND LEAVING THE LOADER....6887
      Procedure....6887
      Emergency Exit....6888
    ATTACHMENTS....6889
      Choosing The Correct Bucket....6889
      Pallet Forks....6889
      Installing And Removing The Attachment (Hand Lever Bob-Tach)....6890
      Installing And Removing The Attachment (Power Bob-Tach)....6892
    OPERATING PROCEDURE....6895
      Inspect The Work Area....6895
      Operating With A Full Bucket....6895
      Operating With An Empty Bucket....6896
      Filling And Emptying The Bucket (Foot Pedals)....6897
      Leveling The Ground Using Float (Foot Pedals)....6898
      Digging And Filling A Hole (Foot Pedals)....6899
      Filling And Emptying The Bucket (ACS - Handles, SJC - ?H? Pattern)....6900
      Leveling The Ground Using Float (ACS - Handles, SJC - ?H? Pattern)....6901
      Digging And Filling A Hole (ACS - Handles, SJC - ?H? Pattern)....6902
      Filling And Emptying The Bucket (SJC - ?ISO? Pattern)....6903
      Leveling The Ground Using Float (SJC - ?ISO? Pattern)....6904
      Digging And Filling A Hole (SJC - ?ISO? Pattern)....6905
    TOWING THE LOADER....6906
      Procedure....6906
    LIFTING THE LOADER....6907
      Single Point Lift....6907
      Four Point Lift....6907
    TRANSPORTING THE LOADER ON A TRAILER....6908
      Loading And Unloading....6908
      Fastening....6908
  PREVENTIVE MAINTENANCE....6909
    MAINTENANCE SAFETY....6913
    SERVICE SCHEDULE....6915
      Chart....6915
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....6916
      Inspecting The BICS Controller (Engine STOPPED - Key ON)....6916
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....6916
      Inspecting The Seat Bar Sensor (Engine RUNNING)....6916
      Inspecting The Traction Lock (Engine RUNNING)....6916
      Inspecting The Lift Arm By-Pass Control....6916
      Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....6916
    SEAT BAR RESTRAINT SYSTEM....6917
      Description....6917
      Inspecting....6917
      Maintaining....6917
    SEAT BELT....6918
      Inspection and Maintenance....6918
    LIFT ARM SUPPORT DEVICE....6919
      Installing....6919
      Removing....6920
    BACK-UP ALARM SYSTEM....6921
      Description....6921
      Inspecting....6921
      Adjusting Switch Position....6921
    OPERATOR CAB....6922
      Description....6922
      Raising....6922
      Lowering....6923
      Cab Door Sensor....6924
    REAR DOOR....6925
      Opening And Closing....6925
      Adjusting....6925
    REAR GRILL....6926
      Removing....6926
      Installing....6926
    HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....6927
      Cleaning And Maintenance....6927
      Filters....6927
      Evaporator / Heater Coil....6927
      Condenser....6927
      Air Conditioning Lubrication....6927
      Troubleshooting....6927
    AIR CLEANER SERVICE....6928
      Replacing Filter Elements....6928
    FUEL SYSTEM....6930
      Fuel Specifications....6930
      Biodiesel Blend Fuel....6930
      Filling The Fuel Tank....6931
      Fuel Filter....6932
      Removing Air From The Fuel System....6932
    ENGINE LUBRICATION SYSTEM....6933
      Checking And Adding Engine Oil....6933
      Engine Oil Chart....6933
      Removing And Replacing Oil And Filter....6933
    ENGINE COOLING SYSTEM....6934
      Cleaning....6934
      Removing And Replacing Coolant....6935
      Checking Level....6935
    ELECTRICAL SYSTEM....6936
      Description....6936
      Fuse And Relay Location / Identification....6936
      Battery Maintenance....6937
      Using A Booster Battery (Jump Starting)....6937
      Removing And Installing Battery....6939
    HYDRAULIC / HYDROSTATIC SYSTEM....6940
      Checking And Adding Fluid....6940
      Hydraulic / Hydrostatic Fluid Chart....6940
      Removing And Replacing Hydraulic Fluid....6940
      Removing And Replacing Hydraulic / Hydrostatic Filter....6942
      Removing And Replacing Case Drain Filters....6942
      Removing And Replacing Hydraulic Charge Filter....6944
      Breather Cap....6945
    SPARK ARRESTOR MUFFLER....6946
      Cleaning Procedure....6946
    TIRE MAINTENANCE....6947
      Wheel Nuts....6947
      Rotating....6947
      Mounting....6947
    FINAL DRIVE TRANSMISSION (CHAINCASE)....6948
      Checking And Adding Oil....6948
      Removing And Replacing Oil....6948
    ALTERNATOR BELT....6949
      Belt Adjustment....6949
      Belt Replacement....6949
    AIR CONDITIONING BELT....6950
      Belt Adjustment....6950
      Belt Replacement....6950
    DRIVE BELT....6951
      Belt Adjustment....6951
      Belt Replacement....6951
    LUBRICATING THE LOADER....6954
      Lubrication Locations....6954
    PIVOT PINS....6955
      Inspection And Maintenance....6955
    BOB-TACH (hand lever)....6956
      Inspection And Maintenance....6956
    BOB-TACH (POWER)....6957
      Inspection And Maintenance....6957
    LOADER STORAGE AND RETURN TO SERVICE....6958
      Storage....6958
      Return to Service....6958
  SYSTEM SETUP & ANALYSIS....6959
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....6961
      Troubleshooting Chart....6961
    DIAGNOSTIC SERVICE CODES....6962
      Viewing Service Codes (Key Switch)....6962
      Viewing Service Codes (Keyless)....6962
      Service Codes List....6963
    CONTROL PANEL SETUP....6968
      Right Panel Setup (Keyless)....6968
      Right Panel Setup (Keyless)....6969
      Attachment Control Information (Keyless)....6969
    PASSWORD SETUP....6970
      Password Description....6970
      Changing The Owner Password....6970
      Changing The User Passwords....6971
      Password Lockout Feature....6971
    MAINTENANCE CLOCK....6972
      Description....6972
      Setup....6972
      Reset....6972
  MACHINE SIGN TRANSLATIONS....6973
    SERVICE SCHEDULE (6734534)....6975
    DANGER (6702301)....6978
    DANGER (6702302)....6978
    DANGER (6717343)....6978
    WARNING (6579528)....6978
    WARNING (6577754)....6979
    IMPORTANT (6560573)....6979
    WARNING (6728539)....6980
    WARNING (6718706)....6981
    WARNING (6732696)....6981
    DANGER (6809511)....6981
    WARNING (6733996)....6982
    WARNING (6725370)....6982
    WARNING (6737189)....6982
    LIFT ARM SUPPORT DEVICE (6732774)....6983
    warning (7131518)....6984
    warning (7131519)....6986
    WARNING (6737248)....6988
    WARNING (6708941)....6988
    WARNING (6726423)....6988
    WARNING (6704786)....6989
  SPECIFICATIONS....6991
    (S220) LOADER SPECIFICATIONS....6993
      Dimensions....6993
      Performance....6994
      Controls....6994
      Engine....6994
      Hydraulic System....6995
      Electrical....6995
      Drive System....6996
      Capacities....6996
      Tires....6996
  WARRANTY....6997
6986989 (4-10) - S220 Skid-Steer Loader Operation & Maintenance Manual....7003
  OPERATOR SAFETY WARNINGS....7005
  CONTENTS....7007
  FOREWORD....7009
    BOBCAT COMPANY IS IS0 9001 CERTIFIED....7011
    REGULAR MAINTENANCE ITEMS....7011
    SERIAL NUMBER LOCATIONS....7012
      Loader Serial Number....7012
      Engine Serial Number....7012
    DELIVERY REPORT....7012
    LOADER IDENTIFICATION....7013
    FEATURES, ACCESSORIES AND ATTACHMENTS....7014
      Standard Items....7014
      Options And Accessories....7014
      Buckets Available....7015
      Attachments....7015
      40 GPM Attachments....7015
      Special Applications Kit....7016
      Special Applications Kit Inspection And Maintenance....7016
  SAFETY & TRAINING RESOURCES....7017
    SAFETY INSTRUCTIONS....7019
      Before Operation....7019
      Safe Operation Is The Operator?s Responsibility....7020
      Safe Operation Needs A Qualified Operator....7020
      Avoid Silica Dust....7021
    FIRE PREVENTION....7021
      Maintenance....7021
      Operation....7021
      Electrical....7021
      Hydraulic System....7022
      Fueling....7022
      Starting....7022
      Spark Arrestor Exhaust System....7022
      Welding And Grinding....7022
      Fire Extinguishers....7022
    MACHINE SIGNS (DECALS)....7024
    PUBLICATIONS AND TRAINING RESOURCES....7026
  OPERATING INSTRUCTIONS....7027
    INSTRUMENT PANEL IDENTIFICATION....7031
      Cab Light....7031
      Left Panel....7032
      Display Screen....7034
      Standard Key Panel....7035
      Keyless Start Panel....7035
      Deluxe Instrumentation Panel....7036
      Side Panel....7037
      Front Panel....7037
    CONTROL IDENTIFICATION....7038
      Standard Controls....7038
      Advanced Control System (ACS)....7039
      Selectable Joystick Controls (SJC)....7040
    SEAT BAR RESTRAINT SYSTEM....7041
      Operation....7041
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....7042
      Operation....7042
    LIFT ARM BYPASS CONTROL....7043
      Operation....7043
    PARKING BRAKE....7043
      Operation....7043
    TRACTION LOCK OVERRIDE....7043
      Operation....7043
    EMERGENCY EXIT....7044
      Rear Window....7044
      Front Door....7044
    BACK-UP ALARM SYSTEM....7045
      Description....7045
      Operation....7045
    ENGINE SPEED CONTROL....7046
      Operation....7046
    DRIVING AND STEERING THE LOADER....7047
      Available Control Configurations....7047
      Operation (Standard And ACS)....7047
      Operation (SJC) In ?ISO? Control Pattern....7048
      Operation (SJC) In ?H? Control Pattern....7049
    STOPPING THE LOADER....7049
      Using The Control Levers Or Joysticks....7049
    TWO-SPEED CONTROL....7050
      Description....7050
      Operation (Standard And ACS) (If Equipped)....7050
      Operation (SJC) (If Equipped)....7050
    SPEED MANAGEMENT....7051
      Operation....7051
      Changing The Factory Default Setting....7052
    DRIVE RESPONSE....7053
      Description....7053
      Operation....7053
    STEERING DRIFT COMPENSATION....7055
      Description....7055
      Operation....7055
    HYDRAULIC CONTROLS....7057
      Description....7057
      Standard Controls (Also ACS In FOOT Pedal Mode)....7057
      Advanced Control System (ACS) In HAND Control Mode....7058
      Selectable Joystick Controls (SJC) In ?ISO? Control Pattern....7058
      Selectable Joystick Controls (SJC) In ?H? Control Pattern....7059
      Hydraulic Bucket Positioning....7059
      FRONT Auxiliary Hydraulics Operation....7060
      FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....7061
      REAR Auxiliary Hydraulics Operation....7061
      Secondary Front Auxiliary Hydraulics Operation....7062
      High-Flow Hydraulics Operation....7063
      Quick Couplers....7063
      Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....7064
    ATTACHMENT CONTROL DEVICE (ACD)....7065
      Description....7065
    DAILY INSPECTION....7066
      Daily Inspection And Maintenance....7067
    PRE-STARTING PROCEDURE....7068
      Entering The Loader....7068
      Operation & Maintenance Manual And Operator?s Handbook Locations....7068
      Seat Adjustment....7069
      Seat Belt Adjustment....7070
      Seat Bar....7070
    STARTING THE ENGINE....7071
      Standard Key Panel....7071
      Keyless Start Panel....7073
      Deluxe Instrumentation Panel....7075
      Cold Temperature Starting....7077
      Warming The Hydraulic / Hydrostatic System....7077
    MONITORING THE DISPLAY PANELS....7078
      Left Panel....7078
      Warning And Shutdown....7078
    STOPPING THE ENGINE AND LEAVING THE LOADER....7079
      Procedure....7079
    COUNTERWEIGHTS....7080
      Description....7080
      Effect On The Loader And Loader Operation....7080
      When To Consider Using Counterweights....7080
      When To Consider Removing Counterweights....7080
      Accessories That Affect Machine Weight....7080
    ATTACHMENTS....7081
      Choosing The Correct Bucket....7081
      Pallet Forks....7081
      Installing And Removing The Attachment (Hand Lever Bob-Tach)....7082
      Installing And Removing The Attachment (Power Bob-Tach)....7084
    OPERATING PROCEDURE....7087
      Inspect The Work Area....7087
      Basic Operating Instructions....7087
      Driving On Public Roads....7087
      Operating With A Full Bucket....7088
      Operating With An Empty Bucket....7088
      Filling And Emptying The Bucket (Foot Pedals)....7089
      Leveling The Ground Using Float (Foot Pedals)....7090
      Digging And Filling A Hole (Foot Pedals)....7090
      Filling And Emptying The Bucket (ACS - Handles, SJC - ?H? Pattern)....7091
      Leveling The Ground Using Float (ACS - Handles, SJC - ?H? Pattern)....7092
      Digging And Filling A Hole (ACS - Handles, SJC - ?H? Pattern)....7093
      Filling And Emptying The Bucket (SJC - ?ISO? Pattern)....7094
      Leveling The Ground Using Float (SJC - ?ISO? Pattern)....7095
      Digging And Filling A Hole (SJC - ?ISO? Pattern)....7095
    TOWING THE LOADER....7096
      Procedure....7096
    LIFTING THE LOADER....7097
      Single-Point Lift....7097
      Four-Point Lift....7097
    TRANSPORTING THE LOADER ON A TRAILER....7098
      Loading And Unloading....7098
      Fastening....7098
  PREVENTIVE MAINTENANCE....7099
    MAINTENANCE SAFETY....7103
    SERVICE SCHEDULE....7105
      Chart....7105
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....7106
      Inspecting The BICS (Engine STOPPED - Key ON)....7106
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....7106
      Inspecting The Seat Bar Sensor (Engine RUNNING)....7106
      Inspecting The Traction Lock (Engine RUNNING)....7106
      Inspecting The Lift Arm Bypass Control....7106
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....7106
    SEAT BAR RESTRAINT SYSTEM....7107
      Description....7107
      Inspecting....7107
      Maintaining....7107
    SEAT BELT....7108
      Inspection And Maintenance....7108
    LIFT ARM SUPPORT DEVICE....7109
      Installing....7109
      Removing....7110
    BACK-UP ALARM SYSTEM....7111
      Description....7111
      Inspecting....7111
      Adjusting Switch Position....7111
    OPERATOR CAB....7112
      Description....7112
      Raising....7112
      Lowering....7113
      Cab Door Sensor....7114
    REAR DOOR (TAILGATE)....7115
      Opening And Closing....7115
      Adjusting....7115
    REAR GRILL....7115
      Removing....7115
      Installing....7115
    HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....7116
      Cleaning And Maintenance....7116
      Filters....7116
      Evaporator / Heater Coil....7116
      Condenser....7116
      Air Conditioning Lubrication....7116
      Troubleshooting....7116
    AIR CLEANER SERVICE....7117
      Replacing Filter Elements....7117
    FUEL SYSTEM....7119
      Fuel Specifications....7119
      Biodiesel Blend Fuel....7119
      Filling The Fuel Tank....7120
      Fuel Filter....7121
      Removing Air From The Fuel System....7121
    ENGINE LUBRICATION SYSTEM....7122
      Checking And Adding Engine Oil....7122
      Engine Oil Chart....7122
      Removing And Replacing Oil And Filter....7122
    ENGINE COOLING SYSTEM....7123
      Maintenance Platform....7123
      Description....7123
      Cleaning (Earlier Models)....7123
      Cleaning (Later Models)....7124
      Removing And Replacing Coolant....7126
      Checking Level....7126
    ELECTRICAL SYSTEM....7127
      Description....7127
      Fuse And Relay Location / Identification....7127
      Battery Maintenance....7128
      Using A Booster Battery (Jump Starting)....7129
      Removing And Installing Battery....7130
    HYDRAULIC / HYDROSTATIC SYSTEM....7131
      Checking And Adding Fluid....7131
      Hydraulic / Hydrostatic Fluid Chart....7131
      Removing And Replacing Hydraulic Fluid....7132
      Removing And Replacing Hydraulic / Hydrostatic Filter....7133
      Removing And Replacing Case Drain Filters....7134
      Removing And Replacing Hydraulic Charge Filter....7135
      Breather Cap....7135
    SPARK ARRESTER MUFFLER....7136
      Cleaning Procedure....7136
    TIRE MAINTENANCE....7137
      Wheel Nuts....7137
      Rotating....7137
      Mounting....7137
    FINAL DRIVE TRANSMISSION (CHAINCASE)....7138
      Checking And Adding Oil....7138
      Removing And Replacing Oil....7138
    ALTERNATOR BELT....7139
      Belt Adjustment....7139
      Belt Replacement....7139
    AIR CONDITIONING BELT....7140
      Belt Adjustment....7140
      Belt Replacement....7140
    DRIVE BELT....7141
      Belt Adjustment....7141
      Belt Replacement....7141
    LUBRICATING THE LOADER....7144
      Lubrication Locations....7144
    PIVOT PINS....7145
      Inspection And Maintenance....7145
    BOB-TACH (HAND LEVER)....7146
      Inspection And Maintenance....7146
    BOB-TACH (POWER)....7147
      Inspection And Maintenance....7147
    LOADER STORAGE AND RETURN TO SERVICE....7148
      Storage....7148
      Return To Service....7148
  SYSTEM SETUP & ANALYSIS....7149
    DIAGNOSTIC SERVICE CODES....7151
      Viewing Service Codes....7151
      Service Codes List....7152
    CONTROL PANEL SETUP....7157
      Right Panel Setup (Deluxe Instrumentation Panel)....7157
      Attachment Control Information (Deluxe Instrumentation Panel)....7158
    PASSWORD SETUP (KEYLESS START PANEL)....7159
      Password Description....7159
      Changing The Owner Password....7159
      Password Lockout Feature....7159
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....7160
      Password Description....7160
      Changing The Owner Password....7160
      Changing The User Passwords....7161
      Password Lockout Feature....7161
    MAINTENANCE CLOCK....7162
      Description....7162
      Setup....7162
      Reset....7162
  MACHINE SIGN TRANSLATIONS....7163
    SERVICE SCHEDULE (6734534)....7165
    DANGER (6702301)....7168
    WARNING (6577754)....7168
    WARNING (6708941)....7168
    DANGER (6702302)....7168
    DANGER (6717343)....7168
    IMPORTANT (6560573)....7169
    WARNING (6579528)....7169
    WARNING (6728539)....7170
    WARNING (6718706)....7171
    WARNING (6732696)....7171
    DANGER (6809511)....7171
    WARNING (6725370)....7172
    WARNING (6737189)....7172
    WARNING (6737248)....7172
    LIFT ARM SUPPORT DEVICE (6706558)....7173
    WARNING (7131518)....7174
    WARNING (6726423)....7175
    WARNING (7131519)....7176
    IMPORTANT (7120602)....7177
    WARNING (7142141)....7178
  SPECIFICATIONS....7179
    (S220) LOADER SPECIFICATIONS....7181
      Machine Dimensions....7181
      Performance....7182
      Hydraulic System....7182
      Engine....7183
      Controls....7183
      Drive System....7183
      Electrical....7184
      Capacities....7184
      Tires....7184
  WARRANTY....7185
    WARRANTY....7187
  ALPHABETICAL INDEX....7189
6987038 (11-10) - S220 Skid-Steer Loader Service Manual....7193
  MAINTENANCE SAFETY....7195
  ALPHABETICAL INDEX....7197
  CONTENTS....7199
    FOREWORD....7200
    SAFETY INSTRUCTIONS....7203
    FIRE PREVENTION....7205
      Maintenance....7205
      Operation....7205
      Electrical....7205
      Hydraulic System....7205
      Fueling....7205
      Starting....7205
      Spark Arrestor Exhaust System....7205
      Welding And Grinding....7206
      Fire Extinguishers....7206
    SERIAL NUMBER LOCATIONS....7207
      Loader Serial Number....7207
      Engine Serial Number....7207
    DELIVERY REPORT....7207
    LOADER IDENTIFICATION....7208
  SAFETY & MAINTENANCE....7209
    LIFTING AND BLOCKING THE LOADER....7213
      Procedure....7213
    LIFT ARM SUPPORT DEVICE....7215
      Installing....7215
      Removing....7216
    OPERATOR CAB....7217
      Description....7217
      Raising....7218
      Lowering....7219
      Cab Door Sensor....7220
      Special Applications Kit....7220
      Special Applications Kit Inspection And Maintenance....7220
    TRANSPORTING LOADER ON A TRAILER....7221
      Loading And Unloading....7221
      Fastening....7221
    TOWING THE LOADER....7223
      Procedure....7223
    REMOTE START TOOL KIT-MEL1563....7225
      Remote Start Tool - MEL1563....7225
      Service Tool Harness Control - MEL1565....7226
      Service Tool Harness Communicator - MEL1566....7227
      Remote Start Procedure....7228
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031....7231
      Description....7231
      Remote Start Tool (Service Tool) - 7003030....7232
      Loader Service Tool Harness - 6689747....7233
      Computer Service Tool Harness - 6689746....7234
      Remote Start Procedure....7235
    SERVICE SCHEDULE....7239
      Chart....7239
    AIR CLEANER SERVICE....7241
      Replacing Filter Elements....7241
    ENGINE COOLING SYSTEM....7243
      Maintenance Platform....7243
      Description....7243
      Cleaning (Earlier Models)....7243
      Cleaning (Later Models)....7244
      Removing And Replacing Coolant....7246
      Checking Level....7246
    FUEL SYSTEM....7247
      Fuel Specifications....7247
      Biodiesel Blend Fuel....7247
      Filling The Fuel Tank....7248
      Fuel Filter....7249
      Removing Air From The Fuel System....7249
    ENGINE LUBRICATION SYSTEM....7251
      Checking And Adding Engine Oil....7251
      Engine Oil Chart....7251
      Removing And Replacing Oil And Filter....7252
    HYDRAULIC / HYDROSTATIC SYSTEM....7253
      Checking And Adding Fluid....7253
      Hydraulic / Hydrostatic Fluid Chart....7253
      Removing And Replacing Hydraulic Fluid....7254
      Removing And Replacing Hydraulic / Hydrostatic Filter....7255
      Removing And Replacing Case Drain Filters....7256
      Removing And Replacing Hydraulic Charge Filter....7257
      Breather Cap....7258
    FINAL DRIVE TRANSMISSION (CHAINCASE)....7259
      Checking And Adding Oil....7259
      Removing And Replacing Oil....7259
    BOB-TACH (HAND LEVER)....7261
      Inspection And Maintenance....7261
    BOB-TACH (POWER)....7263
      Inspection And Maintenance....7263
    LUBRICATING THE LOADER....7265
      Lubrication Locations....7265
    TIRE MAINTENANCE....7267
      Wheel Nuts....7267
      Rotating....7267
      Mounting....7268
    SPARK ARRESTOR MUFFLER....7269
      Cleaning Procedure....7269
    PIVOT PINS....7271
      Inspection And Maintenance....7271
    LOADER STORAGE AND RETURN TO SERVICE....7273
      Storage....7273
      Return To Service....7273
    STOPPING THE ENGINE AND LEAVING THE LOADER....7275
      Procedure....7275
    EMERGENCY EXIT....7277
      Rear Window....7277
      Front Door....7277
    SEAT BELT....7279
      Inspection And Maintenance....7279
  HYDRAULIC SYSTEM....7281
    HYDRAULIC / HYDROSTATIC SCHEMATICS....7287
    HYDRAULIC SYSTEM INFORMATION....7303
      Glossary Of Hydraulic / Hydrostatic Symbols....7303
      Troubleshooting....7307
    CYLINDER (LIFT)....7309
      Testing....7309
      Removal And Installation....7310
      Parts Identification....7312
      Disassembly....7313
      Assembly....7315
    CYLINDER (TILT)....7317
      Testing....7317
      Removal And Installation....7318
      Base End Pivot Pin Removal And Installation....7320
      Parts Identification....7321
      Disassembly....7322
      Assembly....7324
    CYLINDER (BOB-TACH)....7327
      Testing....7327
      Removal And Installation....7328
      Parts Identification....7329
      Disassembly....7330
      Assembly....7331
    MAIN RELIEF VALVE....7335
      Description....7335
      Testing....7336
      Adjusting....7338
      Removal And Installation....7339
    HYDRAULIC CONTROL VALVE (STANDARD)....7341
      Description....7341
      Removal And Installation....7342
      Identification Chart....7346
      Mount Bracket Removal And Installation....7347
      Lift Load Check Valve Removal And Installation....7347
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....7348
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....7348
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....7349
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....7350
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....7350
      Port Relief Valve Removal And Installation....7351
      Plug Removal And Installation....7352
      Rubber Boot Removal And Installation....7353
      End Cap Block Removal And Installation....7354
      Lift Spool And Detent Removal And Installation....7355
      Tilt Spool Removal And Installation....7365
      Auxiliary Spool Removal And Installation....7367
      Auxiliary Solenoid Removal And Installation (S/N A5GK34999 & Below And A5GL34999 & Below)....7369
      Auxiliary Solenoid Removal And Installation (S/N A5GK35001 & Above And A5GL35001 & Above)....7370
      Solenoid Removal And Installation....7371
      Lock Valve Removal And Installation....7372
      Lift Arm Bypass Orifice Removal And Installation....7374
      Main Relief Valve Removal And Installation....7374
      Check Valve Removal And Installation....7375
    HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....7377
      Description....7377
      Removal And Installation....7378
      Actuator Removal And Installation (In Loader)....7382
      Actuator Removal And Installation (Out Of Loader)....7384
      Identification Chart....7387
      Mount Bracket Removal And Installation....7388
      Lift Load Check Valve Removal And Installation....7388
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....7389
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....7390
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....7391
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....7391
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....7392
      Port Relief Valve Removal And Installation....7392
      Plug Removal And Installation....7393
      End Cap Block Removal And Installation....7394
      Lift Spool And Detent Removal And Installation....7395
      Tilt Spool Removal And Installation....7400
      Auxiliary Spool Removal And Installation....7402
      Auxiliary Solenoid Removal And Installation (S/N A5GK34999 & Below And A5GL34999 & Below)....7404
      Auxiliary Solenoid Removal And Installation (S/N A5GK35001 & Above And A5GL35001 & Above)....7405
      Solenoid Removal And Installation....7406
      Lock Valve Removal And Installation....7407
      Lift Arm Bypass Orifice Removal And Installation....7409
      Main Relief Valve Removal And Installation....7409
      Check Valve Removal And Installation....7410
    LIFT ARM BYPASS CONTROL VALVE....7411
      Description....7411
      Testing....7411
      Removal And Installation....7412
      Disassembly And Assembly....7413
    HYDRAULIC PUMP (STANDARD)....7415
      Description....7415
      Pump Test At Quick Couplers....7416
      Direct Pump Test (Standard Section)....7417
      Direct Pump Test (Charge Section)....7419
      Removal And Installation....7423
      Hydraulic Pump Startup....7425
      Parts Identification....7426
      Disassembly And Assembly....7427
    HYDRAULIC PUMP (STANDARD) (HIGH FLOW)....7429
      Description....7429
      Pump Test At Quick Couplers....7430
      Direct Pump Test (Standard Section)....7431
      Direct Pump Test (Charge Section)....7433
      Direct Pump Test (High Flow Section)....7437
      High Flow Relief Valve Adjustment....7439
      High Flow Relief Valve Removal And Installation....7441
      Solenoid Removal And Installation....7442
      Removal And Installation....7443
      Hydraulic Pump Startup....7445
      Parts Identification....7446
      Disassembly And Assembly....7447
    HYDRAULIC PUMP (SJC)....7449
      Description....7449
      Pump Test At Quick Couplers....7450
      Direct Pump Test (Standard Section)....7451
      Direct Pump Test (Charge Section)....7453
      Removal And Installation....7457
      Hydraulic Pump Startup....7459
      Parts Identification....7460
      Disassembly And Assembly....7461
    HYDRAULIC PUMP (SJC) (HIGH FLOW)....7463
      Description....7463
      Pump Test At Quick Couplers....7464
      Direct Pump Test (Standard Section)....7465
      Direct Pump Test (Charge Section)....7467
      Direct Pump Test (High Flow Section)....7471
      High Flow Relief Valve Adjustment....7473
      High Flow Relief Valve Removal And Installation....7475
      Solenoid Removal And Installation....7476
      Removal And Installation....7477
      Hydraulic Pump Startup....7479
      Parts Identification....7480
      Disassembly And Assembly....7481
    HYDRAULIC / HYDROSTATIC FILTERS....7483
      Description....7483
      Housing Removal And Installation....7483
    HYDRAULIC FLUID RESERVOIR....7485
      Description....7485
      Removal And Installation....7485
      Hydraulic Fluid Screen....7488
    OIL COOLER....7489
      Description....7489
      Removal And Installation....7489
    BUCKET POSITION VALVE....7493
      Description....7493
      Solenoid Removal And Installation....7494
      Solenoid Testing....7495
      Removal And Installation....7495
      Disassembly And Assembly....7496
    REAR AUXILIARY DIVERTER VALVE....7499
      Description....7499
      Solenoid Testing....7499
      Removal And Installation....7500
      Disassembly And Assembly....7502
    BOB-TACH (POWER) BLOCK....7509
      Description....7509
      Removal And Installation....7509
      Disassembly And Assembly....7511
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....7515
      Description....7515
      Removal And Installation....7515
      Disassembly And Assembly....7516
  HYDROSTATIC SYSTEM....7519
    HYDROSTATIC SYSTEM INFORMATION....7521
      Troubleshooting....7521
      Description....7522
    HYDROSTATIC DRIVE MOTOR....7523
      Description....7523
      Removal And Installation....7524
      Parts Identification....7526
      Disassembly And Assembly....7527
    HYDROSTATIC DRIVE MOTOR (TWO-SPEED)....7531
      Description....7531
      Removal And Installation....7532
      Parts Identification....7535
      Disassembly....7537
      Assembly....7543
    HYDROSTATIC MOTOR CARRIER....7547
      Description....7547
      Removal And Installation....7548
      Parts Identification....7549
      Disassembly....7550
      Assembly....7551
    HYDROSTATIC MOTOR CARRIER (SJC)....7553
      Description....7553
      Removal And Installation....7554
      Parts Identification....7555
      Disassembly....7556
      Assembly....7558
    CHARGE PRESSURE....7561
      Description....7561
      Testing....7562
      Sender Removal And Installation....7564
      Adjusting....7565
    HYDROSTATIC PUMP....7567
      Description....7567
      Removal And Installation....7568
      Hydrostatic Pump Startup....7570
      Replenishing / High Pressure Relief Valve Removal And Installation....7571
      Parts Identification (Left Half)....7572
      Parts Identification (Right Half)....7573
      Disassembly....7574
      Assembly....7581
    HYDROSTATIC PUMP (SJC) (S/N A5GK20001 - A5GK35063 AND A5GL20001 - A5GL35004)....7587
      Description....7587
      Hydraulic Controller Removal And Installation....7588
      Removal And Installation....7590
      Hydrostatic Pump Startup....7592
      Parts Identification....7593
      High Pressure Relief And Bypass Valve....7594
      Charge Relief Valve....7595
      Disassembly And Assembly....7596
      Mechanical Neutral Adjustment....7613
      Hydraulic Controller Neutral Adjustment....7616
    HYDROSTATIC PUMP (SJC) (S/N A5GK35064 & ABOVE AND A5GL35005 & ABOVE)....7619
      Description....7619
      Hydraulic Controller Removal And Installation....7620
      Removal And Installation....7622
      Hydrostatic Pump Startup....7623
      Parts Identification....7624
      High Pressure Relief And Bypass Valve....7625
      Charge Relief Valve....7626
      Disassembly And Assembly....7627
      Mechanical Neutral Adjustment....7640
      Hydraulic Controller Neutral Adjustment....7643
    DRIVE BELT....7647
      Description....7647
      Shield Removal And Installation....7647
      Adjusting....7648
      Belt Removal And Installation....7648
      Tensioner Pulley Removal And Installation....7649
      Tensioner Pulley Disassembly And Assembly....7650
      Tensioner Pulley Tension Spring Removal And Installation....7651
      Tensioner Pulley Tension Spring Disassembly And Assembly....7651
    CASE DRAIN FILTER....7653
      Description....7653
      Disassembly And Assembly....7653
  DRIVE SYSTEM....7655
    BRAKE....7657
      Description....7657
      Disc Removal And Installation....7658
    BRAKE (TWO-SPEED)....7661
      Description....7661
      Block Removal And Installation....7662
      Block Disassembly And Assembly....7664
    DRIVE COMPONENTS....7669
      Description....7669
      Axle Seal Removal And Installation....7670
      Axle, Sprocket And Bearings Removal And Installation....7672
      Chain Removal And Installation....7677
    CHAINCASE....7679
      Description....7679
      Front Cover Removal And Installation....7679
      Center Cover Removal And Installation....7680
      Rear Cover Removal And Installation....7681
  MAINFRAME....7683
    SEAT BAR....7687
      Description....7687
      Removal And Installation....7687
      Disassembly And Assembly....7688
      Compression Spring Disassembly And Assembly....7689
    OPERATOR CAB....7691
      Gas Cylinder Removal And Installation....7691
      Gas Cylinder Bracket Disassembly And Assembly....7693
      Removal And Installation....7694
    OPERATOR SEAT....7697
      Removal And Installation....7697
      Seat Belt Removal And Installation....7697
    OPERATOR SEAT (SUSPENSION)....7699
      Removal And Installation....7699
      Slide Rail Removal And Installation....7700
      Seat Belt Removal And Installation....7700
      Lower Cushion Removal And Installation....7701
      Back Cushion Removal And Installation....7702
      Shock Removal And Installation....7702
      3-Point Seat Belt Removal And Installation....7703
    BOB-TACH (HAND LEVER)....7705
      Description....7705
      Removal And Installation....7705
      Lever And Wedge Disassembly And Assembly....7708
      Pivot Pin Bushing And Seal Removal And Installation....7709
    BOB-TACH (POWER)....7711
      Description....7711
      Removal And Installation....7711
      Lever And Wedge Disassembly And Assembly....7714
      Pivot Pin Bushing And Seal Removal And Installation....7716
    LIFT ARMS....7717
      Removal And Installation....7717
    REAR GRILLE....7721
      Removal And Installation....7721
    REAR DOOR (TAILGATE)....7723
      Removal And Installation....7723
      Striker Removal And Installation....7724
      Striker Disassembly And Assembly....7724
      Striker (Adjusting)....7725
      Latch Removal And Installation....7726
    FUEL TANK....7727
      Removal And Installation....7727
      Fuel Level Sender Removal And Installation....7730
      Fuel Fill Screen Removal And Installation....7730
    CONTROL PEDALS AND LINKAGES....7731
      Description....7731
      Pedal Removal And Installation....7732
      Linkage Removal And Installation....7733
      Pedal (Adjusting)....7734
    CONTROL PEDALS (ACS)....7735
      Description....7735
      Foot Sensor Removal And Installation....7736
      Foot Pedal Removal And Installation....7737
      Foot Pedal Linkage Disassembly And Assembly....7738
    CONTROL PANEL....7739
      Description....7739
      Removal And Installation....7740
      Shock Removal And Installation....7742
      Shaft Removal And Installation....7743
      Linkage Removal And Installation....7744
      Pintle Arm Disassembly And Assembly....7748
      Linkage Neutral (Adjusting)....7749
      Linkage Travel (Adjusting)....7753
    CONTROL PANEL (SJC)....7757
      Description....7757
      Removal And Installation....7758
    CONTROL HANDLE / LEVER....7761
      Description....7761
      Lever Removal And Installation....7761
      Boot Removal And Installation....7762
    CONTROL HANDLE / LEVER (ACS)....7763
      Description....7763
      Handle Sensor Removal And Installation....7763
      Handle Removal And Installation....7766
      Handle Disassembly And Assembly....7767
      Lever Removal And Installation....7768
      Boot Removal And Installation....7769
    CONTROL HANDLE / LEVER (SJC)....7771
      Description....7771
      Joystick Testing....7772
      Joystick Removal And Installation....7773
      Joystick Mount Removal And Installation....7774
    ACCESS PANEL (INSIDE)....7775
      Removal And Installation (Left)....7775
      Removal And Installation (Right)....7775
    ACCESS PANEL (INSIDE) (SJC)....7777
      Removal And Installation (Left)....7777
      Removal And Installation (Right)....7778
    WINDOW (REAR)....7781
      Removal....7781
      Installation (Split Molding)....7781
      Installation (Continuous Molding)....7783
    WINDOW (TOP)....7785
      Removal And Installation....7785
    WINDOW (SIDE)....7787
      Removal And Installation....7787
    WINDOW (CAB DOOR)....7789
      Removal (Standard Window)....7789
      Installation (Standard Window)....7790
      Removal And Installation (Special Applications Window)....7792
    CAB DOOR....7793
      Description....7793
      Removal And Installation....7793
      Aligning....7794
      Adjusting....7795
      Checking Operation....7795
  ELECTRICAL SYSTEM & ANALYSIS....7797
    ELECTRICAL SCHEMATICS....7803
    ELECTRICAL SYSTEM INFORMATION....7809
      Glossary Of Electrical Symbols....7809
      Cab Harness Connectors....7812
      Mainframe Harness Connectors....7813
      Description....7815
      Troubleshooting....7816
      Fuse And Relay Location / Identification....7817
      Solenoid Testing....7818
    BATTERY....7819
      Removal And Installation....7819
      Servicing....7820
      Using A Booster Battery (Jump Starting)....7820
    ALTERNATOR....7823
      Belt Adjustment....7823
      Belt Replacement....7823
      Charging System Inspection....7824
      Alternator Voltage Testing....7825
      Low Voltage Testing....7825
      High Voltage Testing....7826
      Removal And Installation....7827
      Parts Identification....7828
    STARTER....7829
      Testing....7829
      Removal And Installation....7830
      Parts Identification....7831
    INSTRUMENT PANELS....7834
      Left Panel....7834
      Standard Key Panel....7836
      Keyless Start Panel....7836
      Deluxe Instrumentation Panel....7837
      Side Panel....7838
      Front Panel....7838
      Front Panel Removal And Installation....7839
      Removal And Installation (Left And Right)....7839
      Key Switch Removal And Installation....7841
      Alarm Removal And Installation....7842
    LIGHTS....7843
      Front Removal And Installation....7843
      Rear Removal And Installation....7844
      Cab Light Removal And Installation....7844
    BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)....7845
      Description....7845
      Connector Identification....7846
      Removal And Installation....7852
    BOBCAT CONTROLLER (ACS)....7853
      Description....7853
      Connector And Wire Identification....7854
      Removal And Installation....7855
    BOBCAT CONTROLLER (SJC) (DRIVE)....7857
      Description....7857
      Connector Identification....7858
      Removal And Installation....7860
    SPEED SENSORS (SJC)....7861
      Description....7861
      Testing....7861
      Removal And Installation....7862
    DIAGNOSTIC SERVICE CODES....7865
      Viewing Service Codes (Standard Key Panel And Keyless Start Panel)....7865
      Viewing Service Codes (Deluxe Instrumentation Panel)....7865
      Service Codes List....7866
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....7871
      Description....7871
      Inspecting The BICS (Engine STOPPED - Key ON)....7872
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....7872
      Inspecting The Seat Bar Sensor (Engine RUNNING)....7872
      Inspecting The Traction Lock (Engine RUNNING)....7872
      Inspecting The Lift Arm Bypass Control....7872
      Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....7872
      Troubleshooting....7873
    SEAT BAR SENSOR....7875
      Description....7875
      Troubleshooting....7876
      Testing....7877
      Removal And Installation....7878
      Bobcat Interlock Control System (BICS) Circuit Test....7879
    TRACTION LOCK....7881
      Description....7881
      Troubleshooting....7882
      Removal And Installation (Single Speed)....7883
      Inspecting (Single And Two Speed)....7887
    CONTROL SYSTEM (ACS)....7889
      Description....7889
      Troubleshooting....7890
      Handle Sensor Connector Disassembly And Assembly....7891
      Switch Handle Removal....7892
      Switch Handle Installation....7894
      Actuator Connector Disassembly And Assembly....7897
      Handle Lock Solenoid Removal And Installation....7898
      Handle Lock Solenoid Disassembly And Assembly....7899
      Foot Sensor Disassembly And Assembly....7899
      Foot Lock Solenoid Removal And Installation....7900
    ELECTRICAL / HYDRAULIC CONTROLS....7901
      Identification Chart....7901
      Description....7902
      Identification Chart ACD Group 0....7903
      Identification Chart ACD Group 1....7904
      Identification Chart ACD Group 2....7905
      Identification Chart ACD Group 3....7906
    ELECTRICAL / HYDRAULIC CONTROLS (ACS)....7907
      Identification Chart....7907
      Description....7908
      Identification Chart ACD Group 0....7909
      Identification Chart ACD Group 1....7910
      Identification Chart ACD Group 2....7911
      Identification Chart ACD Group 3....7912
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)....7913
      Identification Chart....7913
      Description....7914
      Identification Chart ACD Group 0....7915
      Identification Chart ACD Group 1....7916
      Identification Chart ACD Group 2....7917
      Identification Chart ACD Group 3....7918
    SERVICE PC (LAPTOP COMPUTER)....7919
      Connecting Remote Start Tool....7919
      Connecting Remote Start Tool (Service Tool)....7919
    CALIBRATION....7921
      Description....7921
      Actuator Testing....7921
      Lift And Tilt Calibration (SJC)....7924
      Hydrostatic Pump Calibration (SJC)....7926
      Lift And Tilt Calibration (ACS)....7931
    STEERING DRIFT COMPENSATION....7933
      Description....7933
      Operation....7933
    FLYWHEEL RPM SENSOR....7935
      Description....7935
      Adjusting....7936
    CONTROL PANEL SETUP....7937
      Right Panel Setup (Deluxe Instrumentation Panel)....7937
      Attachment Control Information (Deluxe Instrumentation Panel)....7938
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....7939
      Password Description....7939
      Changing The Owner Password....7939
      Changing The User Passwords....7940
      Password Lockout Feature....7940
    PASSWORD SETUP (KEYLESS START PANEL)....7941
      Password Description....7941
      Changing The Owner Password....7941
      Password Lockout Feature....7941
    MAINTENANCE CLOCK....7943
      Description....7943
      Setup....7944
      Reset....7947
    BACK-UP ALARM SYSTEM....7949
      Description....7949
      Inspecting....7949
      Adjusting Switch Position....7950
      Troubleshooting (Standard And ACS)....7951
      Troubleshooting (Joystick)....7952
      Alarm Removal And Installation....7953
      Switch Removal And Installation....7953
  ENGINE SERVICE....7955
    ENGINE INFORMATION....7959
      Description....7959
      Specifications....7960
      Torque Values....7965
      Troubleshooting....7966
      Engine Removal And Installation....7968
      Engine Mount Replacement....7975
      Compression - Checking....7976
    ENGINE SPEED CONTROL....7977
      Removal And Installation....7977
      Cable Removal And Installation....7977
    ENGINE SPEED CONTROL (SJC)....7979
      Removal And Installation....7979
      Disassembly And Assembly....7981
      Cable Removal And Installation....7982
    MUFFLER....7983
      Removal And Installation....7983
    AIR CLEANER....7985
      Housing Removal And Installation....7985
    ENGINE COOLING SYSTEM....7987
      Radiator Removal And Installation....7987
      Radiator Mount Removal And Installation....7989
      Hydraulic Fan Motor Description....7990
      Axial Fan Housing Removal And Installation....7991
      Axial Fan Removal And Installation....7993
      Hydraulic Fan Motor Removal And Installation....7995
      Hydraulic Fan Motor Disassembly And Assembly....7995
      Water Pump Removal And Installation....7997
      Water Pump Disassembly And Assembly....7997
      Thermostat Housing Removal And Installation....7998
      Thermostat - Checking....7998
    LUBRICATION SYSTEM....7999
      Oil Pan Removal And Installation....7999
      Oil Pump Removal And Installation....8000
      Oil Pump Inspection....8000
      Oil Filter Cooler Removal And Installation....8002
      Engine Oil Pressure - Testing....8003
    FUEL SYSTEM....8005
      Fuel Shutoff Solenoid - Checking....8005
      Fuel Shutoff Solenoid Removal And Installation....8005
      Fuel Injection Pump Assembly Removal....8006
      Fuel Injection Pump Assembly Installation....8010
      Governor Housing Disassembly And Assembly....8012
      Governor Disassembly And Assembly....8014
      Fuel Camshaft Removal And Installation....8016
      Fuel Injection Pump Removal....8018
      Injection Pump - Timing....8025
      Fuel Injector Removal And Installation....8028
      Fuel Injector Nozzle Pressure - Checking....8029
      Nozzle Spraying Condition....8030
      Valve Seat Tightness....8030
    CYLINDER HEAD....8031
      Intake Air Heater - Testing....8031
      Intake Air Heater Removal And Installation....8031
      Valve Clearance Adjustment....8032
      Valve Timing - Checking....8034
      Cylinder Head Removal And Installation....8035
      Cylinder Head Disassembly And Assembly....8038
      Cylinder Head - Servicing....8038
      Cylinder Head Top Clearance....8039
      Valve Guide - Checking....8040
      Reconditioning The Valve And Valve Seat....8042
      Valve Spring....8044
      Valve Tappets....8045
      Rocker Arm And Shaft - Checking....8046
      Push Rod Alignment - Checking....8046
    CRANKSHAFT AND PISTONS....8047
      Piston And Connecting Rod Removal And Installation....8047
      Piston And Connecting Rod - Servicing....8049
      Cylinder Bore - Checking....8053
      Connecting Rod Alignment....8054
      Crankshaft Gear Removal And Installation....8054
      Crankshaft And Bearings Removal....8055
      Crankshaft And Bearings Installation....8057
      Crankshaft And Bearings - Servicing....8059
    CAMSHAFT AND TIMING GEArS....8065
      Timing Gearcase Cover Removal And Installation....8065
      Timing Gears Backlash - Checking....8066
      Idler Gear And Camshaft Removal and Installation....8066
      Camshaft - Servicing....8067
      Idler Gear And Shaft - Servicing....8069
    TURBOCHARGER....8071
      Description....8071
      Testing....8071
      Removal And Installation....8072
    FLYWHEEL AND HOUSING....8073
      Flywheel Removal And Installation....8073
      Ring Gear Removal And Installation....8073
      Housing Removal And Installation....8074
    EXHAUST GAS RECIRCULATION (EGR) SYSTEM....8075
      Description....8075
      Testing....8076
      Removal And Installation....8079
  HEATING, VENTILATION, AIR CONDITIONING....8081
    AIR CONDITIONING SYSTEM FLOW....8084
      Description....8084
      Chart....8085
      Components....8086
      Safety Equipment....8089
    REGULAR MAINTENANCE....8091
      Filters....8091
      Compressor Drive Belt Adjustment....8092
      Compressor Drive Belt Replacement....8092
      Condenser....8093
      Air Conditioning Lubrication....8093
      Air Conditioning Service Chart....8094
      Evaporator / Heater Coil....8095
    TROUBLESHOOTING....8097
      Blower Motor Does Not Operate....8097
      Blower Motor Operates Normally, But Air Flow Is Insufficient....8097
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....8097
      The Compressor Does Not Operate At All, Or Operates Improperly....8097
      Gauge Pressure Related Troubleshooting....8098
      Troubleshooting Tree....8100
      Temperature / Pressure Chart....8104
      Poor A/C Performance....8106
      HVAC Repair And Leaks....8107
      Electrical System....8108
      Engine Coolant Bypassing The Heater Valve....8115
      Heater Valve Not Opening Or Closing....8116
    SYSTEM CHARGING AND RECLAMATION....8117
      Refrigerant Identification....8117
      Reclamation And Charging With Recovery / Charging Unit....8118
      Charging With A Manifold Gauge Set....8120
    COMPRESSOR....8123
      Removal And Installation....8123
      Oil....8124
      Oil Check....8125
      Clutch Disassembly And Assembly....8126
    CONDENSER....8131
      Removal And Installation....8131
    RECEIVER / DRIER....8133
      Receiver / Drier Removal And Installation....8133
      Pressure Relief Valve Removal And Installation....8134
      Pressure Switch Removal And Installation....8134
      Schraeder Valve Removal And Installation....8135
    EVAPORATOR / HEATER UNIT....8137
      Removal And Installation....8137
    THERMOSTAT....8139
      Description....8139
      Removal And Installation....8140
    EXPANSION VALVE....8141
      Removal And Installation....8141
    EVAPORATOR COIL....8143
      Removal And Installation....8143
    HEATER COIL....8145
      Removal And Installation With A/C....8145
      Removal And Installation Without A/C....8147
    BLOWER FAN....8149
      Removal And Installation....8149
      Disassembly And Assembly....8150
      Connector Identification....8152
    HEATER VALVE....8153
      Removal And Installation....8153
      Disassembly And Assembly....8154
  SPECIFICATIONS....8155
    (S220) LOADER SPECIFICATIONS....8157
      Machine Dimensions....8157
      Performance....8158
      Hydraulic System....8158
      Engine....8159
      Controls....8159
      Drive System....8159
      Electrical....8160
      Capacities....8160
      Tires....8160
    TORQUE SPECIFICATIONS FOR BOLTS....8161
      Torque For General SAE Bolts....8161
      Torque For General Metric Bolts....8162
    HYDRAULIC CONNECTION SPECIFICATIONS....8163
      O-ring Face Seal Connection....8163
      Straight Thread O-ring Fitting....8164
      Tubelines And Hoses....8164
      Flare Fitting....8165
      Port Seal Fitting....8166
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....8167
      Specifications....8167
    CONVERSIONS....8169
      Decimal And Millimeter Equivalent Chart....8169
      U.S. To Metric Conversion Chart....8169
  SERVICE MANUAL REVISION....8171
    Revision No: S220 - 1....8171
    Revision No: S220 - 2....8173
    Revision No: S220 - 3....8175
    Revision No: S220 - 4....8177
    Revision No: S220 - 5....8179
    Revision No: S220 - 6....8181
    Revision No: S220 - 7....8183
    Revision No: S220 - 8....8185
    Revision No: S220 - 9....8187
    Revision No: S220 - 10....8189
6987038 (7-14) - S220 Skid-Steer Loader Service Manual....8191
  MAINTENANCE SAFETY....8193
  CONTENTS....8195
  FOREWORD....8197
    FOREWORD....8199
    SAFETY INSTRUCTIONS....8201
    FIRE PREVENTION....8203
      Maintenance....8203
      Operation....8203
      Electrical....8203
      Hydraulic System....8203
      Fueling....8203
      Starting....8203
      Spark Arrester Exhaust System....8203
      Welding And Grinding....8204
      Fire Extinguishers....8204
    SERIAL NUMBER LOCATIONS....8205
      Loader Serial Number....8205
      Engine Serial Number....8205
    DELIVERY REPORT....8205
    LOADER IDENTIFICATION....8206
  SAFETY AND MAINTENANCE....8207
    LIFTING AND BLOCKING THE LOADER....8211
      Procedure....8211
    LIFT ARM SUPPORT DEVICE....8213
      Installing....8213
      Removing....8214
    OPERATOR CAB....8215
      Description....8215
      Raising....8216
      Lowering....8217
      Cab Door Sensor....8218
      Special Applications Kit....8218
      Special Applications Kit Inspection And Maintenance....8218
    TRANSPORTING LOADER ON A TRAILER....8219
      Loading And Unloading....8219
      Fastening....8219
    TOWING THE LOADER....8221
      Procedure....8221
    REMOTE START TOOL KIT-MEL1563....8223
      Remote Start Tool - MEL1563....8223
      Service Tool Harness Control - MEL1565....8224
      Service Tool Harness Communicator - MEL1566....8225
      Remote Start Procedure....8226
    REMOTE START TOOL (SERVICE TOOL) KIT - 7217666....8229
      Description....8229
      Remote Start Tool (Service Tool) - 7022042....8230
      Loader Service Tool Harness - 6689747....8231
      Computer Service Tool Harness - 6689746....8232
      Remote Start Procedure....8233
    SERVICE SCHEDULE....8237
      Chart....8237
    AIR CLEANER SERVICE....8239
      Replacing Filter Elements....8239
    ENGINE COOLING SYSTEM....8241
      Maintenance Platform....8241
      Description....8241
      Cleaning (Earlier Models)....8241
      Cleaning (Later Models)....8242
      Removing And Replacing Coolant....8244
      Checking Level....8244
    FUEL SYSTEM....8245
      Fuel Specifications....8245
      Biodiesel Blend Fuel....8245
      Filling The Fuel Tank....8246
      Fuel Filter....8247
      Removing Air From The Fuel System....8247
    ENGINE LUBRICATION SYSTEM....8249
      Checking And Adding Engine Oil....8249
      Engine Oil Chart....8249
      Removing And Replacing Oil And Filter....8250
    HYDRAULIC / HYDROSTATIC SYSTEM....8251
      Checking And Adding Fluid....8251
      Hydraulic / Hydrostatic Fluid Chart....8251
      Removing And Replacing Hydraulic Fluid....8252
      Removing And Replacing Hydraulic / Hydrostatic Filter....8253
      Removing And Replacing Case Drain Filters....8254
      Removing And Replacing Hydraulic Charge Filter....8255
      Breather Cap....8256
    FINAL DRIVE TRANSMISSION (CHAINCASE)....8257
      Checking And Adding Oil....8257
      Removing And Replacing Oil....8257
    BOB-TACH (HAND LEVER)....8259
      Inspection And Maintenance....8259
    BOB-TACH (POWER)....8261
      Inspection And Maintenance....8261
    LUBRICATING THE LOADER....8263
      Lubrication Locations....8263
    TIRE MAINTENANCE....8265
      Wheel Nuts....8265
      Rotating....8265
      Mounting....8266
    PIVOT PINS....8267
      Inspection And Maintenance....8267
    SPARK ARRESTER MUFFLER....8269
      Cleaning Procedure....8269
    LOADER STORAGE AND RETURN TO SERVICE....8271
      Storage....8271
      Return To Service....8271
    STOPPING THE ENGINE AND LEAVING THE LOADER....8273
      Procedure....8273
    EMERGENCY EXIT....8275
      Rear Window....8275
      Front Door....8275
    SEAT BELT....8277
      Inspection And Maintenance....8277
  HYDRAULIC SYSTEM....8279
    HYDRAULIC/HYDROSTATIC SCHEMATICS....8285
    HYDRAULIC SYSTEM INFORMATION....8301
      Glossary Of Hydraulic / Hydrostatic Symbols....8301
      Troubleshooting....8305
    CYLINDER (LIFT)....8307
      Testing....8307
      Removal And Installation....8308
      Parts Identification....8310
      Disassembly....8311
      Assembly....8313
    CYLINDER (TILT)....8315
      Testing....8315
      Removal And Installation....8316
      Base End Pivot Pin Removal And Installation....8318
      Parts Identification....8319
      Disassembly....8320
      Assembly....8322
    CYLINDER (BOB-TACH)....8325
      Testing....8325
      Removal And Installation....8326
      Parts Identification....8327
      Disassembly....8328
      Assembly....8329
    MAIN RELIEF VALVE....8333
      Description....8333
      Testing....8334
      Adjusting....8336
      Removal And Installation....8337
    HYDRAULIC CONTROL VALVE (STANDARD)....8339
      Description....8339
      Removal And Installation....8340
      Identification Chart....8344
      Mount Bracket Removal And Installation....8345
      Lift Load Check Valve Removal And Installation....8345
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....8346
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....8346
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....8347
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....8348
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....8348
      Port Relief Valve Removal And Installation....8349
      Plug Removal And Installation....8350
      Rubber Boot Removal And Installation....8351
      End Cap Block Removal And Installation....8352
      Lift Spool And Detent Removal And Installation....8353
      Tilt Spool Removal And Installation....8363
      Auxiliary Spool Removal And Installation....8365
      Auxiliary Solenoid Removal And Installation (S/N A5GK34999 & Below And A5GL34999 & Below)....8367
      Auxiliary Solenoid Removal And Installation (S/N A5GK35001 & Above And A5GL35001 & Above)....8368
      Solenoid Removal And Installation....8369
      Lock Valve Removal And Installation....8370
      Lift Arm Bypass Orifice Removal And Installation....8372
      Main Relief Valve Removal And Installation....8372
      Check Valve Removal And Installation....8373
    HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....8375
      Description....8375
      Removal And Installation....8376
      Actuator Removal And Installation (In Loader)....8380
      Actuator Removal And Installation (Out Of Loader)....8382
      Identification Chart....8385
      Mount Bracket Removal And Installation....8386
      Lift Load Check Valve Removal And Installation....8386
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....8387
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....8388
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....8389
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....8389
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....8390
      Port Relief Valve Removal And Installation....8390
      Plug Removal And Installation....8391
      End Cap Block Removal And Installation....8392
      Lift Spool And Detent Removal And Installation....8393
      Tilt Spool Removal And Installation....8398
      Auxiliary Spool Removal And Installation....8400
      Auxiliary Solenoid Removal And Installation (S/N A5GK34999 & Below And A5GL34999 & Below)....8402
      Auxiliary Solenoid Removal And Installation (S/N A5GK35001 & Above And A5GL35001 & Above)....8403
      Solenoid Removal And Installation....8404
      Lock Valve Removal And Installation....8405
      Lift Arm Bypass Orifice Removal And Installation....8407
      Main Relief Valve Removal And Installation....8407
      Check Valve Removal And Installation....8408
    LIFT ARM BYPASS CONTROL VALVE....8409
      Description....8409
      Testing....8409
      Removal And Installation....8410
      Disassembly And Assembly....8411
    HYDRAULIC PUMP (STANDARD)....8413
      Description....8413
      Pump Test At Quick Couplers....8414
      Direct Pump Test (Standard Section)....8415
      Direct Pump Test (Charge Section)....8417
      Removal And Installation....8421
      Hydraulic Pump Startup....8423
      Parts Identification....8424
      Disassembly And Assembly....8425
    HYDRAULIC PUMP (STANDARD) (HIGH FLOW)....8427
      Description....8427
      Pump Test At Quick Couplers....8428
      Direct Pump Test (Standard Section)....8429
      Direct Pump Test (Charge Section)....8431
      Direct Pump Test (High Flow Section)....8435
      High Flow Relief Valve Adjustment....8437
      High Flow Relief Valve Removal And Installation....8439
      Solenoid Removal And Installation....8440
      Removal And Installation....8441
      Hydraulic Pump Startup....8443
      Parts Identification....8444
      Disassembly And Assembly....8445
    HYDRAULIC PUMP (SJC)....8447
      Description....8447
      Pump Test At Quick Couplers....8448
      Direct Pump Test (Standard Section)....8449
      Direct Pump Test (Charge Section)....8451
      Removal And Installation....8455
      Hydraulic Pump Startup....8457
      Parts Identification....8458
      Disassembly And Assembly....8459
    HYDRAULIC PUMP (SJC) (HIGH FLOW)....8461
      Description....8461
      Pump Test At Quick Couplers....8462
      Direct Pump Test (Standard Section)....8463
      Direct Pump Test (Charge Section)....8465
      Direct Pump Test (High Flow Section)....8469
      High Flow Relief Valve Adjustment....8471
      High Flow Relief Valve Removal And Installation....8473
      Solenoid Removal And Installation....8474
      Removal And Installation....8475
      Hydraulic Pump Startup....8477
      Parts Identification....8478
      Disassembly And Assembly....8479
    HYDRAULIC / HYDROSTATIC FILTERS....8481
      Description....8481
      Housing Removal And Installation....8481
    HYDRAULIC FLUID RESERVOIR....8483
      Description....8483
      Removal And Installation....8483
      Hydraulic Fluid Screen....8486
    OIL COOLER....8487
      Description....8487
      Removal And Installation....8487
    BUCKET POSITION VALVE....8491
      Description....8491
      Solenoid Removal And Installation....8492
      Solenoid Testing....8493
      Removal And Installation....8493
      Disassembly And Assembly....8494
    REAR AUXILIARY DIVERTER VALVE....8497
      Description....8497
      Solenoid Testing....8497
      Removal And Installation....8498
      Disassembly And Assembly....8500
    BOB-TACH (POWER) BLOCK....8507
      Description....8507
      Removal And Installation....8507
      Disassembly And Assembly....8509
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....8513
      Description....8513
      Removal And Installation....8513
      Disassembly And Assembly....8514
  HYDROSTATIC SYSTEM....8517
    HYDROSTATIC SYSTEM INFORMATION....8519
      Troubleshooting....8519
      Description....8520
    HYDROSTATIC DRIVE MOTOR....8521
      Description....8521
      Removal And Installation....8522
      Parts Identification....8524
      Disassembly And Assembly....8525
    HYDROSTATIC DRIVE MOTOR (TWO-SPEED)....8529
      Description....8529
      Removal And Installation....8530
      Parts Identification....8533
      Disassembly....8535
      Assembly....8541
    HYDROSTATIC MOTOR CARRIER....8545
      Description....8545
      Removal And Installation....8546
      Parts Identification....8547
      Disassembly....8548
      Assembly....8549
    HYDROSTATIC MOTOR CARRIER (SJC)....8551
      Description....8551
      Removal And Installation....8552
      Parts Identification....8553
      Disassembly....8554
      Assembly....8556
    CHARGE PRESSURE....8559
      Description....8559
      Testing....8560
      Sender Removal And Installation....8562
      Adjusting....8563
    HYDROSTATIC PUMP....8565
      Description....8565
      Removal And Installation....8566
      Hydrostatic Pump Startup....8568
      Replenishing / High Pressure Relief Valve Removal And Installation....8569
      Parts Identification (Left Half)....8570
      Parts Identification (Right Half)....8571
      Disassembly....8572
      Assembly....8579
    HYDROSTATIC PUMP (SJC) (S/N A5GK20001 - A5GK35063 AND A5GL20001 - A5GL35004)....8585
      Description....8585
      Hydraulic Controller Removal And Installation....8586
      Removal And Installation....8588
      Hydrostatic Pump Startup....8590
      Parts Identification....8591
      High Pressure Relief And Bypass Valve....8592
      Charge Relief Valve....8593
      Disassembly And Assembly....8594
      Mechanical Neutral Adjustment....8611
      Hydraulic Controller Neutral Adjustment....8614
    HYDROSTATIC PUMP (SJC) (S/N A5GK35064 & ABOVE AND A5GL35005 & ABOVE)....8617
      Description....8617
      Hydraulic Controller Removal And Installation....8618
      Removal And Installation....8620
      Hydrostatic Pump Startup....8621
      Parts Identification....8622
      High Pressure Relief And Bypass Valve....8623
      Charge Relief Valve....8624
      Disassembly And Assembly....8625
      Mechanical Neutral Adjustment....8638
      Hydraulic Controller Neutral Adjustment....8641
    DRIVE BELT....8645
      Description....8645
      Shield Removal And Installation....8645
      Adjusting....8646
      Belt Removal And Installation....8646
      Tensioner Pulley Removal And Installation....8647
      Tensioner Pulley Disassembly And Assembly....8648
      Tensioner Pulley Tension Spring Removal And Installation....8649
      Tensioner Pulley Tension Spring Disassembly And Assembly....8649
    CASE DRAIN FILTER....8651
      Description....8651
      Disassembly And Assembly....8651
  DRIVE SYSTEM....8653
    BRAKE....8655
      Description....8655
      Disc Removal And Installation....8656
    BRAKE (TWO-SPEED)....8659
      Description....8659
      Block Removal And Installation....8660
      Block Disassembly And Assembly....8662
    DRIVE COMPONENTS....8667
      Description....8667
      Axle Seal Removal And Installation....8668
      Axle, Sprocket And Bearings Removal And Installation....8670
      Chain Removal And Installation....8675
    CHAINCASE....8677
      Description....8677
      Front Cover Removal And Installation....8677
      Center Cover Removal And Installation....8678
      Rear Cover Removal And Installation....8679
  MAINFRAME....8681
    SEAT BAR....8685
      Description....8685
      Removal And Installation....8685
      Disassembly And Assembly....8686
      Compression Spring Disassembly And Assembly....8687
    OPERATOR CAB....8689
      Gas Cylinder Removal And Installation....8689
      Gas Cylinder Bracket Disassembly And Assembly....8691
      Removal And Installation....8692
    OPERATOR SEAT....8695
      Removal And Installation....8695
      Seat Belt Removal And Installation....8695
    OPERATOR SEAT (SUSPENSION)....8697
      Removal And Installation....8697
      Slide Rail Removal And Installation....8698
      Seat Belt Removal And Installation....8698
      Lower Cushion Removal And Installation....8699
      Back Cushion Removal And Installation....8700
      Shock Removal And Installation....8700
      3-Point Seat Belt Removal And Installation....8701
    BOB-TACH (HAND LEVER)....8703
      Description....8703
      Removal And Installation....8703
      Lever And Wedge Disassembly And Assembly....8706
      Pivot Pin Bushing And Seal Removal And Installation....8707
    BOB-TACH (POWER)....8709
      Description....8709
      Removal And Installation....8709
      Lever And Wedge Disassembly And Assembly....8712
      Pivot Pin Bushing And Seal Removal And Installation....8714
    LIFT ARMS....8715
      Removal And Installation....8715
    REAR GRILLE....8719
      Removal And Installation....8719
    REAR DOOR (TAILGATE)....8721
      Removal And Installation....8721
      Striker Removal And Installation....8722
      Striker Disassembly And Assembly....8722
      Striker (Adjusting)....8723
      Latch Removal And Installation....8724
    FUEL TANK....8725
      Removal And Installation....8725
      Fuel Level Sender Removal And Installation....8728
      Fuel Fill Screen Removal And Installation....8728
    CONTROL PEDALS AND LINKAGES....8729
      Description....8729
      Pedal Removal And Installation....8730
      Linkage Removal And Installation....8731
      Pedal (Adjusting)....8732
    CONTROL PEDALS (ACS)....8733
      Description....8733
      Foot Sensor Removal And Installation....8734
      Foot Pedal Removal And Installation....8735
      Foot Pedal Linkage Disassembly And Assembly....8736
    CONTROL PANEL....8737
      Description....8737
      Removal And Installation....8738
      Shock Removal And Installation....8740
      Shaft Removal And Installation....8741
      Linkage Removal And Installation....8742
      Pintle Arm Disassembly And Assembly....8746
      Linkage Neutral (Adjusting)....8747
      Linkage Travel (Adjusting)....8751
    CONTROL PANEL (SJC)....8755
      Description....8755
      Removal And Installation....8756
    CONTROL HANDLE / LEVER....8759
      Description....8759
      Lever Removal And Installation....8759
      Boot Removal And Installation....8760
    CONTROL HANDLE / LEVER (ACS)....8761
      Description....8761
      Handle Sensor Removal And Installation....8761
      Handle Removal And Installation....8764
      Handle Disassembly And Assembly....8765
      Lever Removal And Installation....8766
      Boot Removal And Installation....8767
    CONTROL HANDLE / LEVER (SJC)....8769
      Description....8769
      Joystick Testing....8770
      Joystick Removal And Installation....8771
      Joystick Mount Removal And Installation....8772
    ACCESS PANEL (INSIDE)....8773
      Removal And Installation (Left)....8773
      Removal And Installation (Right)....8773
    ACCESS PANEL (INSIDE) (SJC)....8775
      Removal And Installation (Left)....8775
      Removal And Installation (Right)....8776
    WINDOW (REAR)....8779
      Removal....8779
      Installation (Split Molding)....8779
      Installation (Continuous Molding)....8781
    WINDOW (TOP)....8783
      Removal And Installation....8783
    WINDOW (SIDE)....8785
      Removal And Installation....8785
    WINDOW (CAB DOOR)....8787
      Removal (Standard Window)....8787
      Installation (Standard Window)....8788
      Removal And Installation (Special Applications Window)....8790
    CAB DOOR....8791
      Description....8791
      Removal And Installation....8791
      Aligning....8792
      Adjusting....8793
      Checking Operation....8793
  ELECTRICAL SYSTEM AND ANALYSIS....8795
    ELECTRICAL SCHEMATICS....8799
    ELECTRICAL SYSTEM INFORMATION....8805
      Glossary Of Electrical Symbols....8805
      Cab Harness Connectors....8808
      Mainframe Harness Connectors....8809
      Description....8811
      Troubleshooting....8812
      Fuse And Relay Location / Identification....8813
      Solenoid Testing....8814
    BATTERY....8815
      Removal And Installation....8815
      Servicing....8816
      Using A Booster Battery (Jump Starting)....8817
    ALTERNATOR....8819
      Belt Adjustment....8819
      Belt Replacement....8819
      Charging System Inspection....8820
      Alternator Voltage Testing....8821
      Low Voltage Testing....8821
      High Voltage Testing....8822
      Removal And Installation....8823
      Parts Identification....8824
    STARTER....8825
      Testing....8825
      Removal And Installation....8826
      Parts Identification....8827
    INSTRUMENT PANELS....8829
      Left Panel....8829
      Standard Key Panel....8831
      Keyless Start Panel....8831
      Deluxe Instrumentation Panel....8832
      Side Panel....8833
      Front Panel....8833
      Front Panel Removal And Installation....8834
      Removal And Installation (Left And Right)....8834
      Key Switch Removal And Installation....8836
      Alarm Removal And Installation....8837
    LIGHTS....8839
      Front Removal And Installation....8839
      Rear Removal And Installation....8840
      Cab Light Removal And Installation....8840
    BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)....8841
      Description....8841
      Connector Identification....8842
      Removal And Installation....8848
    BOBCAT CONTROLLER (ACS)....8849
      Description....8849
      Connector And Wire Identification....8850
      Removal And Installation....8851
    BOBCAT CONTROLLER (SJC) (DRIVE)....8853
      Description....8853
      Connector Identification....8854
      Removal And Installation....8856
    SPEED SENSORS (SJC)....8857
      Description....8857
      Testing....8857
      Removal And Installation....8858
    DIAGNOSTIC SERVICE CODES....8861
      Viewing Service Codes (Standard Key Panel And Keyless Start Panel)....8861
      Viewing Service Codes (Deluxe Instrumentation Panel)....8861
      Service Codes List....8862
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....8867
      Description....8867
      Inspecting The BICS? (Engine STOPPED - Key ON)....8868
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....8868
      Inspecting The Seat Bar Sensor (Engine RUNNING)....8868
      Inspecting The Traction Lock (Engine RUNNING)....8868
      Inspecting The Lift Arm Bypass Control....8868
      Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....8868
      Troubleshooting....8869
    SEAT BAR SENSOR....8871
      Description....8871
      Troubleshooting....8872
      Testing....8873
      Removal And Installation....8874
      Bobcat Interlock Control System (BICS?) Circuit Test....8875
    TRACTION LOCK....8877
      Description....8877
      Troubleshooting....8878
      Removal And Installation (Single Speed)....8879
      Inspecting (Single And Two Speed)....8883
    CONTROL SYSTEM (ACS)....8885
      Description....8885
      Troubleshooting....8886
      Handle Sensor Connector Disassembly And Assembly....8887
      Switch Handle Removal....8888
      Switch Handle Installation....8890
      Actuator Connector Disassembly And Assembly....8893
      Handle Lock Solenoid Removal And Installation....8894
      Handle Lock Solenoid Disassembly And Assembly....8895
      Foot Sensor Disassembly And Assembly....8895
      Foot Lock Solenoid Removal And Installation....8896
    ELECTRICAL / HYDRAULIC CONTROLS....8897
      Identification Chart....8897
      Description....8898
      Identification Chart ACD Group 0....8899
      Identification Chart ACD Group 1....8900
      Identification Chart ACD Group 2....8901
      Identification Chart ACD Group 3....8902
    ELECTRICAL / HYDRAULIC CONTROLS (ACS)....8903
      Identification Chart....8903
      Description....8904
      Identification Chart ACD Group 0....8905
      Identification Chart ACD Group 1....8906
      Identification Chart ACD Group 2....8907
      Identification Chart ACD Group 3....8908
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)....8909
      Identification Chart....8909
      Description....8910
      Identification Chart ACD Group 0....8911
      Identification Chart ACD Group 1....8912
      Identification Chart ACD Group 2....8913
      Identification Chart ACD Group 3....8914
    SERVICE PC (LAPTOP COMPUTER)....8915
      Connecting Remote Start Tool....8915
      Connecting Remote Start Tool (Service Tool)....8915
    CALIBRATION....8917
      Description....8917
      Actuator Testing....8917
      Lift And Tilt Calibration (SJC)....8920
      Hydrostatic Pump Calibration (SJC)....8922
      Lift And Tilt Calibration (ACS)....8927
    STEERING DRIFT COMPENSATION....8929
      Description....8929
      Operation....8929
    FLYWHEEL RPM SENSOR....8931
      Description....8931
      Adjusting....8932
    CONTROL PANEL SETUP....8933
      Right Panel Setup (Deluxe Instrumentation Panel)....8933
      Attachment Control Information (Deluxe Instrumentation Panel)....8934
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....8935
      Password Description....8935
      Changing The Owner Password....8935
      Changing The User Passwords....8936
      Password Lockout Feature....8936
    PASSWORD SETUP (KEYLESS START PANEL)....8937
      Password Description....8937
      Changing The Owner Password....8937
      Password Lockout Feature....8937
    MAINTENANCE CLOCK....8939
      Description....8939
      Setup....8940
      Reset....8943
    BACK-UP ALARM SYSTEM....8945
      Description....8945
      Inspecting....8945
      Adjusting Switch Position....8946
      Troubleshooting (Standard And ACS)....8947
      Troubleshooting (Joystick)....8948
      Alarm Removal And Installation....8949
      Switch Removal And Installation....8949
  ENGINE SERVICE....8951
    ENGINE INFORMATION....8955
      Description....8955
      Specifications....8956
      Torque Values....8961
      Troubleshooting....8962
      Engine Removal And Installation....8964
      Engine Mount Replacement....8971
      Compression - Checking....8972
    ENGINE SPEED CONTROL....8973
      Removal And Installation....8973
      Cable Removal And Installation....8973
    ENGINE SPEED CONTROL (SJC)....8975
      Removal And Installation....8975
      Disassembly And Assembly....8977
      Cable Removal And Installation....8978
    MUFFLER....8979
      Removal And Installation....8979
    AIR CLEANER....8981
      Housing Removal And Installation....8981
    ENGINE COOLING SYSTEM....8983
      Radiator Removal And Installation....8983
      Radiator Mount Removal And Installation....8985
      Hydraulic Fan Motor Description....8986
      Axial Fan Housing Removal And Installation....8987
      Axial Fan Removal And Installation....8989
      Hydraulic Fan Motor Removal And Installation....8991
      Hydraulic Fan Motor Disassembly And Assembly....8991
      Water Pump Removal And Installation....8993
      Water Pump Disassembly And Assembly....8993
      Thermostat Housing Removal And Installation....8994
      Thermostat - Checking....8994
    LUBRICATION SYSTEM....8995
      Oil Pan Removal And Installation....8995
      Oil Pump Removal And Installation....8996
      Oil Pump Inspection....8996
      Oil Filter Cooler Removal And Installation....8998
      Engine Oil Pressure - Testing....8999
    FUEL SYSTEM....9001
      Fuel Shutoff Solenoid - Checking....9001
      Fuel Shutoff Solenoid Removal And Installation....9001
      Fuel Injection Pump Assembly Removal....9002
      Fuel Injection Pump Assembly Installation....9006
      Governor Housing Disassembly And Assembly....9008
      Governor Disassembly And Assembly....9010
      Fuel Camshaft Removal And Installation....9012
      Fuel Injection Pump Removal....9014
      Injection Pump - Timing....9021
      Fuel Injector Removal And Installation....9024
      Fuel Injector Nozzle Pressure - Checking....9025
      Nozzle Spraying Condition....9026
      Valve Seat Tightness....9026
    CYLINDER HEAD....9027
      Intake Air Heater - Testing....9027
      Intake Air Heater Removal And Installation....9027
      Valve Clearance Adjustment....9028
      Valve Timing - Checking....9030
      Cylinder Head Removal And Installation....9031
      Cylinder Head Disassembly And Assembly....9034
      Cylinder Head - Servicing....9034
      Cylinder Head Top Clearance....9035
      Valve Guide - Checking....9036
      Reconditioning The Valve And Valve Seat....9038
      Valve Spring....9040
      Valve Tappets....9041
      Rocker Arm And Shaft - Checking....9042
      Push Rod Alignment - Checking....9042
    CRANKSHAFT AND PISTONS....9043
      Piston And Connecting Rod Removal And Installation....9043
      Piston And Connecting Rod - Servicing....9045
      Cylinder Bore - Checking....9049
      Connecting Rod Alignment....9050
      Crankshaft Gear Removal And Installation....9050
      Crankshaft And Bearings Removal....9051
      Crankshaft And Bearings Installation....9053
      Crankshaft And Bearings - Servicing....9055
    CAMSHAFT AND TIMING GEARS....9061
      Timing Gearcase Cover Removal And Installation....9061
      Timing Gears Backlash - Checking....9062
      Idler Gear And Camshaft Removal and Installation....9062
      Camshaft - Servicing....9063
      Idler Gear And Shaft - Servicing....9065
    TURBOCHARGER....9067
      Description....9067
      Testing....9067
      Removal And Installation....9068
    FLYWHEEL AND HOUSING....9069
      Flywheel Removal And Installation....9069
      Ring Gear Removal And Installation....9069
      Housing Removal And Installation....9070
    EXHAUST GAS RECIRCULATION (EGR) SYSTEM....9071
      Description....9071
      Testing....9072
      Removal And Installation....9075
  HEATING, VENTILATION, AIR CONDITIONING....9077
    AIR CONDITIONING SYSTEM FLOW....9079
      Description....9079
      Chart....9080
      Components....9081
      Safety Equipment....9084
    REGULAR MAINTENANCE....9085
      Filters....9085
      Compressor Drive Belt Adjustment....9086
      Compressor Drive Belt Replacement....9086
      Condenser....9087
      Air Conditioning Lubrication....9087
      Air Conditioning Service Chart....9088
      Evaporator / Heater Coil....9089
    TROUBLESHOOTING....9091
      Blower Motor Does Not Operate....9091
      Blower Motor Operates Normally, But Air Flow Is Insufficient....9091
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....9091
      The Compressor Does Not Operate At All, Or Operates Improperly....9091
      Gauge Pressure Related Troubleshooting....9092
      Troubleshooting Tree....9094
      Temperature / Pressure Chart....9098
      Poor A/C Performance....9100
      HVAC Repair And Leaks....9101
      Electrical System....9102
      Engine Coolant Bypassing The Heater Valve....9110
      Heater Valve Not Opening Or Closing....9111
    SYSTEM CHARGING AND RECLAMATION....9113
      Refrigerant Identification....9113
      Reclamation And Charging With Recovery / Charging Unit....9114
      Charging With A Manifold Gauge Set....9116
    COMPRESSOR....9119
      Removal And Installation....9119
      Oil....9120
      Oil Check....9121
      Clutch Disassembly And Assembly....9122
    CONDENSER....9127
      Removal And Installation....9127
    RECEIVER / DRIER....9129
      Receiver / Drier Removal And Installation....9129
      Pressure Relief Valve Removal And Installation....9130
      Pressure Switch Removal And Installation....9130
      Schraeder Valve Removal And Installation....9131
    EVAPORATOR / HEATER UNIT....9133
      Removal And Installation....9133
    THERMOSTAT....9135
      Description....9135
      Removal And Installation....9136
    EXPANSION VALVE....9137
      Removal And Installation....9137
    EVAPORATOR COIL....9139
      Removal And Installation....9139
    HEATER COIL....9141
      Removal And Installation With A/C....9141
      Removal And Installation Without A/C....9143
    BLOWER FAN....9145
      Removal And Installation....9145
      Disassembly And Assembly....9146
      Connector Identification....9148
    HEATER VALVE....9149
      Removal And Installation....9149
      Disassembly And Assembly....9150
  SPECIFICATIONS....9151
    (S220) LOADER SPECIFICATIONS....9153
      Machine Dimensions....9153
      Performance....9154
      Hydraulic System....9154
      Engine....9155
      Controls....9155
      Drive System....9155
      Electrical....9156
      Capacities....9156
      Tires....9156
    TORQUE SPECIFICATIONS FOR BOLTS....9157
      Torque For General SAE Bolts....9157
      Torque For General Metric Bolts....9158
    HYDRAULIC CONNECTION SPECIFICATIONS....9159
      O-ring Face Seal Connection....9159
      Straight Thread O-ring Fitting....9160
      Tubelines And Hoses....9160
      Flare Fitting....9161
      Port Seal Fitting....9162
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....9163
      Specifications....9163
    CONVERSIONS....9165
      Decimal And Millimeter Equivalent Chart....9165
      U.S. To Metric Conversion Chart....9165
    SERVICE TOOLS REQUIRED....9167
      Remote Start Tools....9167
      Hydraulic Tools....9168
      Mainframe And Drive Tools....9170
      Electrical Tools....9171
      Engine Tools....9171
      HVAC Tools....9176
  ALPHABETICAL INDEX....9177