Bobcat A220 TURBO - HIGH FLOW Skid-Steer Loader Repair Service Manual - 6901245

(S/N: 519611001 & Above - S/N: 519711001 & Above) 
- 
This workshop repair service manual PDF download for the A220 Bobcat All-Wheel Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Bobcat Loader A220 
TURBO - HIGH FLOW
S/N: 519611001 & Above
S/N: 519711001 & Above


TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION 
SERIAL NUMBER LOCATION 
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
SAFETY & MAINTENANCE 
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM 
DRIVE SYSTEM 
MAINFRAME
ELECTRICAL SYSTEM ANALYSIS 
ENGINE SERVICE 
HEATING, VENTILATION, AIR CONDITIONING 
SPECIFICATIONS
SERVICE MANUAL REVISION


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6901245 (7-10)
Total Pages : 990


This A220 Bobcat Loader Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

-

ALPHABETICAL INDEX
CONTENTS
    FOREWORD
    SAFETY INSTRUCTIONS
    FIRE PREVENTION
        Maintenance
        Operation
        Electrical
        Hydraulic System
        Fueling
        Starting
        Spark Arrestor Exhaust System
        Welding And Grinding
        Fire Extinguishers
    SERIAL NUMBER LOCATION
        Loader Serial Number
        Engine Serial Number
    DELIVERY REPORT
    BOBCAT LOADER IDENTIFICATION
    
SAFETY & MAINTENANCE
    LIFTING AND BLOCKING THE LOADER
        Procedure
    LIFT ARM SUPPORT DEVICE
        Engaging The Lift Arm Support Device
        Disengaging The Lift Arm Support Device
    OPERATOR CAB
        Raising The Operator Cab
        Lowering The Operator Cab
        Emergency Exit
    TRANSPORTING THE LOADER
        Procedure
    TOWING THE LOADER
        Procedure For Non-Two-Speeds
        Procedure For Two-Speeds
    REMOTE START
        Procedure For Loader Without Attachment Control Harness
        Procedure For Loader With Attachment Control Harness
        Procedure
    SERVICE SCHEDULE
        Chart
    AIR CLEANER SERVICE
        Replacing Filter Element
    ENGINE COOLING SYSTEM
        Cleaning The Cooling System
    FUEL SYSTEM
        Fuel Specifications
        Filling The Fuel Tank
        Fuel Filter
        Removing Air From The Fuel System
    ENGINE LUBRICATION SYSTEM
        Checking Engine Oil
        Replacing Oil And Filter
    HYDRAULIC/HYDROSTATIC SYSTEM
        Checking And Adding Fluid
        Hydraulic/Hydrostatic Filter Replacement
        Replacing Hydraulic Fluid
        Steering Filter Replacement
    FINAL DRIVE TRANSMISSION (CHAINCASE)
        Checking And Adding Oil
        Replacing The Oil
    FAN GEARBOX
        Checking And Adding Oil
    BOB-TACH
        Inspection And Maintenance
    POWER BOB-TACH (OPTION)
        Inspection And Maintenance
    LUBRICATING THE LOADER
        Procedure
    TIRE MAINTENANCE
        Wheel Nuts
        Tire Rotation
        Tire Mounting
        
HYDRAULIC SYSTEM
    HYDRAULIC / HYDROSTATIC SCHEMATICS
    HYDRAULIC SYSTEM INFORMATION
        Troubleshooting
        Tighten Procedures
    CYLINDER (LIFT)
        Checking
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    CYLINDER (TILT)
        Checking
        Removal And Installation
        Rod End Seal
        Parts Identification
        Disassembly
        Assembly
    CYLINDER (POWER BOB-TACH)
        Checking
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    CYLINDER (STEERING)
        Removal (Front)
        Removal (Rear)
    MAIN RELIEF VALVE
        Checking The Main Relief Valve At Front Auxiliary Hydraulics
        Removal And Installation
        Adjustment
    HYDRAULIC CONTROL VALVE
        Actuator Removal And Installation (In Loader)
        Removal And Installation
        Actuator Removal And Installation (Out Of Loader)
        BICS™ Valve Removal And Installation
        BICS™ Valve Lift Arm Bypass Orifice Removal And Installation
        BICS™ Valve Check Valve Removal And Installation
        BICS™ Valve Lock Valve Removal And Installation
        BICS™ Valve Solenoid Removal And Installation
        BICS™ Valve Solenoid Testing
        Identification Chart
        Lift Base End Restrictor
        Load Check Valve
        Main Relief Valve
        Port Relief Valve
        Anti-Cavitation Valve/Port Relief Valve
        Anti-Cavitation Valve
        Lift Spool Removal And Installation
        Tilt Spool Removal And Installation
        Lift And Tilt Spool Disassembly And Assembly
        Auxiliary Spool Removal And Installation
        Auxiliary Electric Solenoid Disassembly And Assembly
        Port-Auxiliary Section Disassembly
        Cleaning And Inspection
    LIFT ARM BYPASS CONTROL VALVE
        Inspecting
        Removal And Installation
        Disassembly And Assembly
    HYDRAULIC PUMP
        Checking The Output Of The Auxiliary Pump
        Checking The Output Of The Steering Pump
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
    HYDRAULIC PUMP (HI FLOW)
        Checking The Output Of The High Flow Pump
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
    HYDRAULIC/HYDROSTATIC FILTER
        Housing Removal And Installation
    HYDRAULIC FLUID RESERVOIR
        Draining The Fluid Reservoir
        Removal And Installation
        Hydraulic Fluid Screen
    BUCKET POSITION VALVE
        Solenoid Removal And Installation
        Solenoid Testing
        Removal And Installation
        Disassembly And Assembly
    SELECT VALVE
        Checking The High Flow Pump Relief Valve
        Removal And Installation
        Disassembly And Assembly
        Solenoid Testing
    REAR AUXILIARY DIVERTER VALVE
        Disassembly
        Inspection
        Solenoid Testing
        Assembly
    POWER BOB-TACH BLOCK (EARLY MODELS)
        Removal And Installation
        Disassembly And Assembly
    POWER BOB-TACH BLOCK (LATER MODELS)
        Removal And Installation
        Disassembly And Assembly
    AUXILIARY PRESSURE RELEASE (ACCUMULATOR) (Early models)
        Removal and Installation
    FRONT AUXILARY HYDRAULIC COUPLER BLOCK (S/N 519611124 & Above)
        Removal and Installation
        Disassembly And Assembly
        
HYDROSTATIC SYSTEM
    HYDROSTATIC SYSTEM INFORMATION
        Troubleshooting Chart
        Replenishing Valve Function
    HYDROSTATIC MOTOR
        Removal And Installation
        Parts Identification
        Disassembly
        Inspection
        Assembly
    HYDROSTATIC MOTOR (TWO-SPEED)
        Removal And Installation
        Parts Identification
        Disassembly
        Inspection
        Assembly
    HYDROSTATIC MOTOR CARRIER
        Removal And Installation
        Parts Identification
        Assembly
    CHARGE PRESSURE
        Testing
        Removal And Installation
    HYDROSTATIC PUMP
        Pump Controller Removal And Installation
        Hydrostatic Pump Calibration
        Removal And Installation
        Parts Identification (Right Half)
        Parts Identification (Left Half)
        System Check Relief Valves (High Pressure Relief, Charge Check & Bypass Valve)
        Charge Relief Valve
        Pump Separation
        Shaft Seal And Shaft Replacement
        Shaft Seal And Shaft Installation
        Charge Pump Removal
        Charge Pump Inspection
        Charge Pump Installation
        Disassembly
        Inspection
        Assembly
        Pump Neutral Adjustment
        Pump Controller Neutral Adjustment
    DRIVE BELT
        Shield Removal And Installation
        Adjustment
        Replacement
        Tensioner Pulley Removal And Installation
        Tensioner Pulley Tension Spring
    OIL COOLER (SEAL TO CONNECT) (STC)
        Hydraulic Oil Cooler Removal and Installation
        
DRIVE SYSTEM
    BRAKE
        Disc Removal And Installation
    BRAKE (TWO-SPEED) (EARLY MODELS)
        Block Removal And Installation
        Block Disassembly And Assembly
    BRAKE (TWO SPEED) (LATER MODELS)
        Block Removal And Installation
        Block Disassembly And Assembly
        Wiring Diagram
        Removal And Installation
    DRIVE COMPONENTS
        Axle Seal Removal And Installation
        Axle, Sprocket And Bearings Removal And Installation
        Drive Chain Removal And Installation
    CHAINCASE
        Front Chaincase Cover Removal And Installation
        Rear Chaincase Cover Removal And Installation
    HUB
        Removal
        Installation
        Disassembly
        Inspection
        Assembly
        
MAINFRAME
    SEAT BAR
        Removal And Installation
        Assembling Components
        Compression Spring Disassembly And Assembly
    OPERATOR CAB
        Gas Cylinder Removal And Installation (Dual Gas Spring)
        Gas Cylinder Removal And Installation (3rd Gas Spring)
        Gas Cylinder Bracket Disassembly and Assembly
        Removal And Installation
    OPERATOR SEAT (STANDARD)
        Removal And Installation
        Seat Belt Removal And Installation
    OPERATOR SEAT (SUSPENSION)
        Removal And Installation
        Slide Rail Removal And Installation
        Cushion Removal And Installation
        Back Removal And Installation
        Shock Removal And Installation
    BOB-TACH
        Removal And Installation
        Bob-Tach Lever And Wedge
        Bob-Tach Stops
        Pivot Pin Bushing And Seal Replacement
    POWER BOB-TACH
        Inspection And Maintenance
        Power Bob-Tach Lever And Wedge
        Removal And Installation
        Pivot Pin Bushing And Seal Replacement
    LIFT ARMS
        Removal And Installation
    REAR GRILL
        Removal And Installation
    REAR DOOR
        Removal And Installation (Early Loaders)
        Adjusting The Rear Door Latch
        Striker Removal And Installation (Later Loaders)
        Adjusting The Striker (Later Loaders)
        Latch Removal And Installation (Later Loaders)
    FUEL TANK
        Removal And Installation
        Fuel Level Sender
        Fuel Pick-Up Screen/Check Valve
    CONTROL
        Joystick Testing (Right & Left)
        Joystick Removal (Right & Left)
        Joystick Boot Removal (Right & Left)
        Lever Assembly Removal (Right & Left)
    CONTROL PANEL
        Removal And Installation
    INSIDE ACCESS PANEL (EARLY MODELS)
        Panel Removal (Right)
        Panel Removal (Left)
    INSIDE ACCESS PANEL (LATER MODELS)
        Panel Removal (Right)
        
ELECTRICAL SYSTEM ANALYSIS
    ELECTRICAL SCHEMATICS
    ELECTRICAL SYSTEM INFORMATION
        Troubleshooting Chart
        Description
        Fuse Location
        Relay Switch Location
        Solenoid Test
    BATTERY
        Removal And Installation
        Servicing The Electrical System
        Using A Booster Battery (Jump Starting)
    ALTERNATOR
        Adjusting The Alternator Belt
        Alternator Identification
        Charging System Check
        Alternator Voltage Test
        Low Voltage Test
        High Voltage Test
        Removal And Installation
        Rectifier Continuity (Diode) Test
        Alternator Regulator Test
        Disassembly
        Stator Continuity Test
        Stator Ground Test
        Rotor Continuity Test
        Rotor Ground Test
        Assembly
    STARTER (NIPPONDENSO)
        Checking
        Removal And Installation
        Removal And Installation (Cont’d)
        Parts Identification
        Disassembly
        Inspection And Repair
        No Load Test
        Assembly
    STARTER (VALEO)
        Checking
        Removal And Installation
        Removal And Installation (Cont’d)
        Parts Identification
        Disassembly And Assembly
        Inspection And Repair
        No Load Test
    INSTRUMENT PANEL
        Left Panel
        Right Panel - (Standard) (With Key Switch)
        Right Panel - (Deluxe) (With Keyless Start)
        Right Panel Set Up Display Options (Deluxe)
        Option and Field Accessory Panels (If Equipped)
        Standard Panel Removal And Installation (Right Side)
        Deluxe Panel Removal And Installation (Right Side)
        Standard & Deluxe Panel Removal And Installation (Left Side)
    LIGHTS
        Front Removal And Installation
        Rear Removal And Installation
    BOBCAT 2001 CONTROLLER (EARLY MODELS)
        Removal And Installation
        Identification Chart
    BOBCAT CONTROLLER
        Identification Chart
        Removal And Installation
    AWS CONTROLLER
        Removal
        Identification Chart
    SPEED SENSOR
        Testing
        Removal
    DIAGNOSTICS SERVICE CODES
        Display
        Number Codes List
    STEERING SOLENOID
        Removal
    BICS™ SYSTEM
        Inspecting The BICS™ Controller (Engine STOPPED - Key ON)
        Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)
        Inspecting The Seat Bar Sensor (Engine RUNNING)
        Inspecting The Traction Lock (Engine RUNNING)
        Inspecting The LIft Arm Bypass Control
        Troubleshooting Chart
        Troubleshooting Guide
    SEAT BAR SENSOR
        Troubleshooting Chart
        Test
        Removal And Installation
        BICS™ Circuit Test
    TRACTION LOCK
        Troubleshooting Chart
        Removal And Installation
        Description Of The Control System
        Inspecting The Control System
    WHEEL POSITION SENSORS
        Operation
        Wheel Alignment (Failed Sensor)
        Testing
        Sensor Removal And Installation
        Wheel Alignment (Field Adjustment)
        Wheel Alignment (Calibration)
    SERVICE PC (LAPTOP COMPUTER)
        Connecting The Service PC To Remote Start Tool
    LIFT AND TILT ACTUATOR CALIBRATION
        Procedure
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
        Controls Identification Chart
        
ENGINE SERVICE
    TROUBLESHOOTING
        Chart
    ENGINE SPEED CONTROL (EARLY MODELS)
        Removal
        Speed Control Stop
        Speed Control Cable
    ENGINE SPEED CONTROL (LATER MODELS)
        Removal
        Disassembly
        Speed Control Cable
    MUFFLER
        Removal And Installation
    AIR CLEANER
        Housing Removal And Installation
    RADIATOR
        Removal And Installation
    COOLING FAN
        Drive Tension Pulley Removal And Installation
        Gearbox/Blower Housing Removal And Installation
        Blower Removal And Installation
        Gearbox Parts Identification
        Gearbox Disassembly
        Gearbox Assembly
        Gearbox, Checking Backlash
    ENGINE COMPONENTS AND TESTS
        Engine Compression, Checking
        Glow Plug, Checking
        Fuel Shut-Off Solenoid Checking
        Fuel Shut-Off Solenoid Removal And Installation
        Fuel Injection Pump Removal
        Fuel Injection Pump Timing
        Fuel Injection Pump Installation
        Fuel Injector Removal And Installation
        Fuel Injector, Checking
        Fuel Injector Disassembly
        Fuel Injector Assembly
        Timing Belt Inspection
        Timing Belt Removal
        Timing Belt Installation
        Timing Belt, Replacement In The Loader
        Valve Clearance Adjustment
        Valve Timing, Checking
        Thermostat, Oil Pressure Control Valves & Heater Connections
    ENGINE
        Removal And Installation
        Mount Replacement
    FLYWHEEL AND HOUSING
        Flywheel Removal And Installation
        Ring Gear Removal And Installation
        Flywheel Housing Removal And Installation
    RECONDITIONING THE ENGINE
        Deutz Engine Tools Identification Chart
        Disassembly
        Assembly
        Cylinder, Checking
        Camshaft Bearing, Checking
        Camshaft Bearing, Removal And Installation
        Control Rod Guide Bushing Removal
        Control Rod Guide Bushing Installation
        Rear Cover Seal Removal And Installation
        Crankshaft, Checking
        Connecting Rod, Checking
        Piston, Checking
        Piston Pin, Checking
        Piston Rings Installation
        Piston Installation On The Connecting Rod
        Cylinder Head Disassembly
        Valves, Checking
        Valve Seats, Checking
        Valve Spring, Checking
        Cylinder Head Assembly
        Rocker Arm And Bracket, Checking
        Front Cover Disassembly
        Front Cover Assembly
        Turbo Charger Removal and Installation
        Crankshaft Gear Mounting Bolt Torque Procedure
        Governor Buffer Spring Adjustment
        
HEATING, VENTILATION, AIR CONDITIONING
    AIR CONDITIONING SYSTEM FLOW
        Principals
        Chart
    COMPONENTS
        Identification
    SAFETY
        Safety Equipment
    REGULAR MAINTENANCE
        Filter Elements Removal And Installation
        Compressor Drive Belt Inspection
        Cleaning The Condenser
    BASIC TROUBLESHOOTING
        Poor A/C Performance
        Cleaning The A/C Evaporator Coil & Heater Coil
        Receiver/Drier Sight Glass Inspection
        Compressor Drive Belt Inspection
        Checking The Electrical System
        Engine Coolant Bypassing The Heater Valve
        Heater Valve Not Opening Or Closing
    GENERAL AIR CONDITIONING SERVICE GUIDELINES
        Compressor Oil
        Compressor Oil Check
        Component Replacement And Refrigeration Leaks
    SYSTEM TROUBLESHOOTING CHART
        Gauge Pressure Related Troubleshooting
        Troubleshooting Tree
    TEMPERATURE/PRESSURE
        Chart
    AIR CONDITIONING SERVICE
        Chart
    SYSTEM CHARGING AND RECLAMATION
        Reclamation Procedure
        Charging Procedure With A Manifold Gauge Set
        Charging Procedure
    COMPRESSOR
        Removal And Installation
        Compressor Clutch Disassembly
    CONDENSER
        Removal And Installation
    RECEIVER/DRIER
        Removal And Installation
    PRESSURE RELIEF VALVE
        Removal and Installation
    PRESSURE SWITCH
        Removal And Installation
    EVAPORATOR/HEATER UNIT
        Removal And Installation
        Disassembly And Assembly
    THERMOSTAT
        Removal And Installation
    EXPANSION VALVE
        Removal And Installation
    EVAPORATOR
        Removal And Installation
    HEATER COIL
        Removal And Installation With A/C
        Removal And Installation Without A/C
    HEATER/AC FAN
        Removal And Installation
        Disassembly And Assembly
        Wire Connector Removal And Installation
    HEATER VALVE
        Removal And Installation
        Disassembly And Assembly
        
SPECIFICATIONS
    LOADER SPECIFICATIONS
        Machine Dimensions
        Performance
        Controls
        Engine
        Hydraulic System
        Electrical
        Drive System
        Capacities
        Tires
    ENGINE SPECIFICATIONS
        General
        Fuel System
        Valves, Valve Guide And Seat Insert
        Piston And Rings
        Connecting Rod
        Cylinder Head And Block
        Crankshaft And Main Bearings
        Camshaft And Bearings
        Oil Pump
    LOADER TORQUE
        Specifications
    TORQUE SPECIFICATIONS FOR BOLTS
        Torque For General SAE Bolts
        Torque For General Metric Bolts
    HYDRAULIC CONNECTION SPECIFICATIONS
        O-ring Face Seal Connection
        Straight Thread O-ring Fitting
        Tubelines And Hoses
        Flare Fitting
        O-ring Flare Fitting
        Port Seal Fitting
    HYDRAULIC FLUID SPECIFICATIONS
        Specifications
    CONVERSIONS
        Decimal And Millimeter Equivalents
        U.S. To Metric Conversion
        
SERVICE MANUAL REVISION
    A220-1
    A220-2
    A220-3
    A220-4
    
    -