Bobcat S220 Skid-Steer Loader Service Manual 6904154 (3-09) – PDF DOWNLOAD

Description

Bobcat S220 Skid-Steer Loader Service Manual 6904154 (3-09) – PDF DOWNLOAD

FILE DETAILS:

Bobcat S220 Skid-Steer Loader Service Manual 6904154 (3-09) – PDF DOWNLOAD

Language : English
Pages : 1035
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S220 Skid-Steer Loader Service Manual 6904154 (3-09) – PDF DOWNLOAD

S/N 530711001 & Above
S/N 530811001 & Above

FOREWORD:

This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

A general inspection of the following items must be made after the loader has had service or repair:

TABLE OF CONTENTS:

Bobcat S220 Skid-Steer Loader Service Manual 6904154 (3-09) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 8
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrestor Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Loader Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 15
LOADER IDENTIFICATION 16
SAFETY AND MAINTENANCE 17
LIFTING AND BLOCKING THE LOADER 21
Procedure 21
LIFT ARM SUPPORT DEVICE 23
Installing 23
Removing 24
OPERATOR CAB 25
Description 25
Raising 25
Lowering 26
Cab Door Sensor 27
TRANSPORTING LOADER ON A TRAILER 29
Loading And Unloading 29
Fastening 29
TOWING THE LOADER 31
Procedure 31
REMOTE START TOOL KIT-MEL1563 33
Remote Start Tool – MEL1563 33
Service Tool Harness Control – MEL1565 34
Service Tool Harness Communicator – MEL1566 35
Remote Start Procedure 36
REMOTE START TOOL (SERVICE TOOL) KIT – 6689779 39
Description 39
Remote Start Tool (Service Tool) – 6689778 40
Loader Service Tool Harness – 6689747 41
Computer Service Tool Harness – 6689746 42
Remote Start Procedure 43
SERVICE SCHEDULE 47
Chart 47
AIR CLEANER SERVICE 49
Replacing Filter Elements 49
ENGINE COOLING SYSTEM 51
Cleaning 51
Checking Level 52
Removing And Replacing Coolant 52
FUEL SYSTEM 53
Fuel Specifications 53
Biodiesel Blend Fuel 53
Filling The Fuel Tank 54
Fuel Filter 54
Removing Air From The Fuel System 55
ENGINE LUBRICATION SYSTEM 57
Checking And Adding Engine Oil 57
Engine Oil Chart 57
Removing And Replacing Oil And Filter 58
HYDRAULIC / HYDROSTATIC SYSTEM 59
Checking And Adding Fluid 59
Hydraulic / Hydrostatic Fluid Chart 59
Removing And Replacing Hydraulic Fluid 60
Removing And Replacing Hydraulic / Hydrostatic Filter 61
Removing And Replacing Case Drain Filters 62
Removing And Replacing Hydraulic Charge Filter 63
Breather Cap 64
FINAL DRIVE TRANSMISSION (CHAINCASE) 65
Checking And Adding Oil 65
Removing And Replacing Oil 65
BOB-TACH (HAND LEVER) 67
Inspection And Maintenance 67
BOB-TACH (POWER – OPTION) 69
Inspection And Maintenance 69
LUBRICATING THE LOADER 71
Lubrication Locations 71
TIRE MAINTENANCE 73
Wheel Nuts 73
Rotating 73
Mounting 74
SPARK ARRESTOR MUFFLER 75
Cleaning Procedure 75
PIVOT PINS 77
Inspection And Maintenance 77
LOADER STORAGE AND RETURN TO SERVICE 79
Storage 79
Return to Service 79
STOPPING THE ENGINE AND LEAVING THE LOADER 81
Procedure 81
Emergency Exit 82
HYDRAULIC SYSTEM 83
HYDRAULIC / HYDROSTATIC SCHEMATICS 89
HYDRAULIC SYSTEM INFORMATION 121
Glossary Of Hydraulic / Hydrostatic Symbols 121
Troubleshooting 125
CYLINDER (LIFT) 127
Testing 127
Removal And Installation 128
Parts Identification 130
Disassembly 131
Assembly 133
CYLINDER (TILT) 135
Testing 135
Removal And Installation 136
Base End Pivot Pin Removal And Installation 138
Parts Identification 139
Disassembly 140
Assembly 142
CYLINDER (BOB-TACH) 145
Testing 145
Removal And Installation 146
Parts Identification 147
Disassembly 148
Assembly 149
MAIN RELIEF VALVE 153
Description 153
Testing 154
Adjusting 156
Removal And Installation 157
HYDRAULIC CONTROL VALVE (STANDARD) 159
Description 159
Removal And Installation 160
Identification Chart 164
Mount Bracket Removal And Installation 165
Lift Load Check Valve Removal And Installation 165
Load Check Valve Removal And Installation (Tilt & Auxiliary) 166
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 166
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 167
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 168
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 168
Port Relief Valve Removal And Installation 169
Plug Removal And Installation 170
Rubber Boot Removal and Installation 171
End Cap Block Removal and Installation 172
Lift Spool And Detent Removal And Installation 173
Tilt Spool Removal And Installation 183
Auxiliary Spool Removal And Installation 185
Auxiliary Solenoid Removal And Installation 187
Solenoid Removal And Installation 188
Lock Valve Removal And Installation 189
Lift Arm Bypass Orifice Removal And Installation 191
Main Relief Valve Removal And Installation 191
Check Valve Removal And Installation 192
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 193
Description 193
Removal And Installation 194
Actuator Removal And Installation (In Loader) 198
Actuator Removal And Installation (Out Of Loader) 200
Identification Chart 203
Mount Bracket Removal And Installation 204
Lift Load Check Valve Removal And Installation 204
Load Check Valve Removal And Installation (Tilt & Auxiliary) 205
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 205
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 206
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 207
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 207
Port Relief Valve Removal And Installation 208
Plug Removal And Installation 209
End Cap Block Removal And Installation 210
Lift Spool And Detent Removal And Installation 211
Tilt Spool Removal And Installation 216
Auxiliary Spool Removal And Installation 218
Auxiliary Solenoid Removal And Installation 220
Solenoid Removal And Installation 221
Lock Valve Removal And Installation 222
Lift Arm Bypass Orifice Removal And Installation 224
Main Relief Valve Removal And Installation 224
Check Valve Removal And Installation 225
LIFT ARM BYPASS CONTROL VALVE 227
Description 227
Testing 227
Removal And Installation 228
Disassembly And Assembly 229
HYDRAULIC PUMP (STANDARD) 231
Description 231
Pump Test at Quick Couplers 232
Direct Pump Test (Standard Section) 233
Direct Pump Test (Charge Section) 235
Removal And Installation 239
Hydraulic Pump Start Up 241
Parts Identification 242
Disassembly And Assembly 243
HYDRAULIC PUMP (STANDARD) (HIGH FLOW) 245
Description 245
Pump Test At Quick Couplers 246
Direct Pump Test (Standard Section) 247
Direct Pump Test (Charge Section) 249
Direct Pump Test (High Flow Section) 253
High Flow Relief Valve Adjustment 255
High Flow Relief Valve Removal And Installation 258
Solenoid Removal And Installation 259
Removal And Installation 260
Hydraulic Pump Start Up 262
Parts Identification 264
Disassembly And Assembly 265
HYDRAULIC PUMP (SJC) 267
Description 267
Pump Test At Quick Couplers 268
Direct Pump Test (Standard Section) 269
Direct Pump Test (Charge Section) 271
Removal And Installation 275
Hydraulic Pump Start Up 277
Parts Identification 278
Disassembly And Assembly 279
HYDRAULIC PUMP (SJC) (HIGH FLOW) 281
Description 281
Pump Test At Quick Couplers 282
Direct Pump Test (Standard Section) 283
Direct Pump Test (Charge Section) 285
Direct Pump Test (High Flow Section) 289
High Flow Relief Valve Adjustment 291
High Flow Relief Valve Removal And Installation 294
Solenoid Removal And Installation 295
Removal And Installation 296
Hydraulic Pump Start Up 298
Parts Identification 300
Disassembly And Assembly 301
HYDRAULIC/HYDROSTATIC FILTERS 303
Description 303
Housing Removal And Installation 303
Charge Filter Housing Removal And Installation 305
HYDRAULIC FLUID RESERVOIR 307
Description 307
Removal And Installation 307
Hydraulic Fluid Screen 310
OIL COOLER 311
Description 311
Removal And Installation 311
BUCKET POSITION VALVE 313
Description 313
Solenoid Removal And Installation 314
Solenoid Testing 315
Removal And Installation 315
Disassembly And Assembly 316
REAR AUXILIARY DIVERTER VALVE 319
Description 319
Solenoid Testing 319
Removal And Installation 320
Disassembly And Assembly 322
BOB-TACH (POWER) BLOCK 329
Description 329
Removal And Installation 329
Disassembly And Assembly 331
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 335
Description 335
Removal and Installation 335
Disassembly And Assembly 336
HYDROSTATIC SYSTEM 339
HYDROSTATIC SYSTEM INFORMATION 341
Troubleshooting 341
Description 342
HYDROSTATIC MOTOR 343
Description 343
Removal And Installation 344
Parts Identification 346
Disassembly And Assembly 347
HYDROSTATIC MOTOR (TWO-SPEED) 351
Description 351
Removal And Installation 352
Parts Identification 355
Disassembly 357
Assembly 363
HYDROSTATIC MOTOR CARRIER 367
Description 367
Removal and Installation 368
Parts Identification 369
Disassembly 370
Assembly 371
HYDROSTATIC MOTOR CARRIER (SJC) 373
Description 373
Removal and Installation 374
Parts Identification 375
Disassembly 376
Assembly 378
CHARGE PRESSURE 381
Description 381
Testing 382
Sender Removal And Installation 384
Adjusting 385
HYDROSTATIC PUMP 387
Description 387
Removal And Installation 388
Hydrostatic Pump Start Up 390
Replenishing / High Pressure Relief Valve Removal And Installation 391
Parts Identification (Left Half) 392
Parts Identification (Right Half) 393
Disassembly 394
Assembly 401
HYDROSTATIC PUMP (SJC) 407
Description 407
Hydraulic Controller Removal And Installation 408
Removal And Installation 410
Hydrostatic Pump Start Up 412
Parts Identification 413
High Pressure Relief And ByPass Valve 414
Charge Relief Valve 415
Disassembly And Assembly 416
Mechanical Neutral Adjustment 433
Hydraulic Controller Neutral Adjustment 436
DRIVE BELT 439
Description 439
Drive Belt Shield Removal And Installation 439
Adjusting 440
Belt Removal And Installation 440
Tensioner Pulley Removal And Installation 441
Tensioner Pulley Tension Spring Removal And Installation 443
CASE DRAIN FILTER 445
Description 445
Disassembly And Assembly 445
DRIVE SYSTEM 447
BRAKE (S/N 530714318 & BELOW AND 530811605 & BELOW) 449
Description 449
Disc Removal And Installation 450
BRAKE (S/N 530714319 & ABOVE AND 530811606 & ABOVE) 453
Description 453
Disc Removal And Installation 454
BRAKE (TWO-SPEED) 457
Description 457
Block Removal And Installation 458
Block Disassembly And Assembly 460
DRIVE COMPONENTS 465
Description 465
Axle Seal Removal And Installation 466
Axle, Sprocket And Bearings Removal And Installation 468
Chain Removal And Installation 473
Description 474
Axle Seal Removal And Installation 475
Axle, Sprocket And Bearings Removal And Installation 477
Chain Removal And Installation 482
CHAINCASE 485
Description 485
Front Cover Removal And Installation 485
Center Cover Removal And Installation 486
Rear Cover Removal And Installation 487
MAIN FRAME 489
SEAT BAR 493
Description 493
Removal And Installation 493
Disassembly And Assembly 495
Compression Spring Disassembly And Assembly 496
OPERATOR CAB 497
Gas Cylinder Removal And Installation 497
Gas Cylinder Bracket Disassembly And Assembly 499
Removal And Installation 500
OPERATOR SEAT 503
Removal And Installation 503
Seat Belt Removal And Installation 503
OPERATOR SEAT (SUSPENSION) 505
Removal And Installation 505
Slide Rail Removal And Installation 506
Seat Belt Removal And Installation 506
Cushion Removal And Installation 507
Back Removal And Installation 508
Shock Removal And Installation 508
3-Point Seat Belt Removal And Installation 509
BOB-TACH (HAND LEVER) 511
Description 511
Removal And Installation 511
Lever And Wedge Disassembly And Assembly 514
Pivot Pin Bushing And Seal Removal And Installation 515
BOB-TACH (POWER – OPTION) 517
Description 517
Removal And Installation 517
Lever And Wedge Disassembly And Assembly 520
Pivot Pin Bushing And Seal Removal And Installation 522
LIFT ARMS 523
Removal And Installation 523
REAR GRILL 527
Removal And Installation 527
REAR DOOR 529
Removal And Installation 529
Striker Removal And Installation 530
Striker Disassembly And Assembly 530
Striker (Adjusting) 531
Latch Removal And Installation 532
FUEL TANK 533
Removal And Installation 533
Fuel Level Sender Removal And Installation 535
Fuel Fill Screen Removal And Installation 535
CONTROL PEDALS AND LINKAGES 537
Description 537
Pedal Removal And Installation 538
Linkage Removal And Installation 539
Pedal (Adjusting) 540
CONTROL PEDALS (ACS) 541
Description 541
Foot Sensor Removal And Installation 542
Foot Pedal Removal And Installation 543
Foot Pedal Linkage Disassembly And Assembly 544
CONTROL PANEL (S/N 530714202 & BELOW AND 530811539 & BELOW) 545
Description 545
Removal And Installation 546
Shock Removal And Installation 548
Shaft Removal And Installation 548
Shaft Disassembly And Assembly 549
Linkage Removal And Installation 550
Pintle Arm Disassembly and Assembly 554
Linkage Neutral (Adjusting) 555
Linkage Travel (Adjusting) 559
CONTROL PANEL (S/N 530714203 & ABOVE AND 530811540 & ABOVE) 563
Description 563
Removal And Installation 564
Shock Removal And Installation 566
Shaft Removal And Installation 567
Linkage Removal And Installation 568
Pintle Arm Disassembly and Assembly 572
Linkage Neutral (Adjusting) 573
Linkage Travel (Adjusting) 577
CONTROL PANEL (S/N 530714202 & BELOW AND 530811539 & BELOW) (SJC) 581
Description 581
Removal And Installation 582
CONTROL PANEL (S/N 530714203 & ABOVE AND 530811540 & ABOVE) (SJC) 585
Description 585
Removal And Installation 586
CONTROL HANDLE / LEVER 589
Description 589
Lever Removal And Installation 589
Boot Removal And Installation 590
CONTROL HANDLE / LEVER (ACS) 591
Description 591
Handle Sensor Removal And Installation 591
Handle Removal And Installation 594
Handle Disassembly And Assembly 595
Lever Removal And Installation 596
Boot Removal And Installation 597
JOYSTICK CONTROL 599
Description (Earlier Models And Later Models) 599
Testing (Earlier Models And Later Models) 600
Removal And Installation (Earlier Models) 601
Removal And Installation (Later Models) 602
Boot Removal And Installation (Earlier Models) 603
Joystick Mount Removal And Installation (Earlier Models) 603
Joystick Mount Removal And Installation (Earlier Models) (Cont’d) 604
Joystick Mount Removal And Installation (Later Models) 604
ACCESS PANEL (INSIDE) 605
Removal And Installation (Left) 605
Removal And Installation (Right) 605
ACCESS PANEL (INSIDE) (SJC) 607
Removal And Installation (Left) 607
Removal And Installation (Right) 608
WINDOW (REAR) 611
Removal 611
Installation 611
WINDOW (TOP) 613
Removal And Installation 613
WINDOW (SIDE) 615
Removal And Installation 615
WINDOW (FRONT DOOR) 617
Removal (Standard Window) 617
Installation (Standard Window) 618
Removal And Installation (Special Applications Window) 620
CAB DOOR 621
Description 621
Removal And Installation 621
Aligning 622
Adjusting 623
Checking Operation 623
ELECTRICAL SYSTEM & ANALYSIS 625
ELECTRICAL SCHEMATICS 629
ELECTRICAL SYSTEM INFORMATION 642
Glossary Of Electrical Symbols 642
Cab Harness Connectors 645
Mainframe Harness Connectors 646
Description 648
Troubleshooting 650
Fuse And Relay Location / Identification 651
Solenoid Testing 652
BATTERY 654
Removal And Installation 654
Servicing 655
Using A Booster Battery (Jump Starting) 655
ALTERNATOR 658
Belt Adjustment 658
Charging System Inspection 659
Alternator Voltage Testing 660
Low Voltage Testing 660
High Voltage Testing 661
Removal And Installation 662
Parts Identification 663
STARTER 664
Testing 664
Removal And Installation 665
Parts Identification 666
INSTRUMENT PANELS 668
Left Panel 668
Right Panel (Key Switch) 669
Right Panel (Keyless) 670
Side And Front Panels 672
Removal And Installation (Left And Right) 673
Bulb Removal And Installation (Left Only) 676
Key Switch Removal And Installation 677
Alarm Removal And Installation 678
Front Panel Removal And Installation 678
LIGHTS 680
Front Removal And Installation 680
Rear Removal And Installation 681
Cab Light Removal And Installation 681
BOBCAT CONTROLLER (MAIN) 682
Description 682
Connector Identification 683
Removal And Installation 685
BOBCAT CONTROLLER (ACS) 686
Description 686
Connector And Wire Identification 687
Removal And Installation 688
BOBCAT CONTROLLER (SJC) (DRIVE) 690
Description 690
Connector Identification 691
Removal And Installation 693
SPEED SENSOR (SJC) 694
Description 694
Testing 695
Removal And Installation 696
DIAGNOSTIC SERVICE CODES 698
Description 698
Service Codes List 699
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) 706
Description 706
Inspecting The BICS Controller (Engine STOPPED – Key ON) 707
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 707
Inspecting The Seat Bar Sensor (Engine RUNNING) 707
Inspecting The Traction Lock (Engine RUNNING) 707
Inspecting The Lift Arm Bypass Control 707
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) 707
Troubleshooting 708
Troubleshooting Chart 709
SEAT BAR SENSOR 710
Description 710
Troubleshooting 711
Testing 712
Removal And Installation 713
Bobcat Interlock Control System (BICS) Circuit Test 714
TRACTION LOCK 716
Description 716
Troubleshooting 717
Removal And Installation (Single Speed) 718
Inspecting (Single And Two Speed) 722
CONTROL SYSTEM (ACS) 724
Description 724
Troubleshooting Chart 725
Handle Sensor Connector Disassembly And Assembly 726
Switch Handle Removal 727
Switch Handle Installation 729
Actuator Connector Disassembly And Assembly 732
Handle Lock Solenoid Removal And Installation 733
Handle Lock Solenoid Disassembly And Assembly 734
Foot Sensor Disassembly And Assembly 734
Foot Lock Solenoid Removal And Installation 735
ELECTRICAL / HYDRAULIC CONTROLS 736
Identification Chart 736
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 738
Identification Chart 738
SERVICE PC (LAPTOP COMPUTER) 742
Connecting Remote Start Tool 742
Connecting Remote Start Tool (Service Tool) 742
CALIBRATION 744
Description 744
Actuator Testing 744
Lift And Tilt Calibration (ACS) 746
Lift And Tilt Calibration (SJC) 748
Hydrostatic Pump Calibration (SJC) 750
STEERING DRIFT COMPENSATION 756
Description 756
Selecting And Adjusting 756
Exiting And Saving 757
FLYWHEEL RPM SENSOR 758
Description 758
Adjustment 759
CONTROL PANEL SETUP 760
Right Panel Setup (Keyless) 760
Attachment Control Information (Keyless) 761
PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START) 762
Password Description 762
Changing The Owner And User Passwords 763
Password Lockout Feature 764
MAINTENANCE CLOCK 766
Description 766
Setup 767
Reset 771
BACK-UP ALARM SYSTEM 772
Description 772
Inspecting 772
Adjusting Switch Position 773
Troubleshooting (Standard And ACS) 774
Troubleshooting (Joystick) 775
Alarm Removal And Installation 776
Switch Removal And Installation 776
ENGINE SERVICE 778
ENGINE INFORMATION 782
Description 782
Specifications 783
Torque Values 787
Troubleshooting 788
Engine Removal And Installation 790
Engine Mount Replacement 799
Compression -Checking 800
ENGINE SPEED CONTROL 802
Removal And Installation 802
Cable Removal And Installation 803
ENGINE SPEED CONTROL (SJC) 804
Removal And Installation 804
Disassembly And Assembly 807
Speed Control Cable Removal And Installation 809
MUFFLER 810
Removal And Installation 810
AIR CLEANER 812
Housing Removal And Installation 812
ENGINE COOLING SYSTEM 814
Radiator Removal And Installation (S/N 530713065 & Below, 530811453 & Below) 814
Radiator Removal And Installation (S/N 530713066 & Above, 530811454 & Above) 816
Radiator Mount Removal And Installation 818
Hydraulic Fan Motor Description (S/N 530713065 & Below, 530811453 & Below) 819
Blower Housing Removal And Installation (S/N 530713065 & Below, 530811453 & Below) 819
Fan Removal And Installation (S/N 530713065 & Below, 530811453 & Below) 821
Hydraulic Fan Motor Removal And Installation (S/N 530713065 & Below, 530811453 & Below) 822
Hydraulic Fan Motor Disassembly And Assembly (S/ N 530713065 & Below, 530811453 & Below) 822
Hydraulic Fan Motor Description (S/N 530713066 – 530740000, 530811454 – 530840000) 823
Axial Fan Housing Removal And Installation (S/N 530713066 – 530740000, 530811454 – 530840000) 823
Axial Fan Removal And Installation (S/N 530713066 – 530740000, 530811454 – 530840000) 825
Hydraulic Fan Motor Removal And Installation (S/N 530713066 – 530740000, 530811454 – 530840000) 827
Hydraulic Fan Motor Disassembly And Assembly (S/ N 530713066 – 530740000, 530811454 – 530840000) 827
Hydraulic Fan Motor Description (S/N 530740001 & Above, 530840001 & Above) 828
Axial Fan Housing Removal And Installation (S/N 530740001 & Above, 530840001 & Above) 828
Axial Fan Removal And Installation (S/N 530740001 & Above, 530840001 & Above) 831
Hydraulic Fan Motor Removal And Installation (S/N 530740001 & Above, 530840001 & Above) 832
Hydraulic Fan Motor Disassembly And Assembly (S/ N 530740001 & Above, 530840001 & Above) 833
Water Pump Removal And Installation 834
Water Pump Disassembly And Assembly 835
Thermostat Housing Removal And Installation 835
LUBRICATION SYSTEM 838
Oil Pan Removal And Installation 838
Oil Pump Removal And Installation 839
Oil Pump Inspection 840
Oil Filter Cooler Removal And Installation 843
Engine Oil Pressure – Testing 844
FUEL SYSTEM 846
Fuel Camshaft Removal And Installation 846
Injection Pump Governor Housing Removal And Installation 848
Injection Pump Governor Housing Disassembly And Assembly 850
Fuel ShutOff Solenoid – Checking 852
Fuel ShutOff Solenoid – Removal And Installation 852
Fuel Injection Pump Removal And Installation 853
Fuel Injection Pump Housing Removal 861
Fuel Injection Pump Housing Installation 865
Injection Pump Timing 868
Fuel Injector Removal and Installation 871
Fuel Injector Nozzle Pressure – Checking 872
Nozzle Spraying Condition 873
Valve Seat Tightness 873
CYLINDER HEAD 874
Intake Air Heater – Testing 874
Intake Air Heater Removal And Installation 874
Valve Clearance Adjustment 875
Valve Timing – Checking 876
Cylinder Head Removal And Installation 877
Cylinder Head Disassembly And Assembly 880
Cylinder Head – Servicing 880
Cylinder Head Top Clearance 881
Valve Guide – Checking 882
Reconditioning The Valve And Valve Seat 884
Valve Spring 886
Valve Tappets 887
Rocker Arm And Shaft – Checking 888
CRANKSHAFT AND PISTONS 890
Piston And Connecting Rod Removal And Installation 890
Piston And Connecting Rod – Servicing 892
Cylinder Bore Checking 897
Connecting Rod Alignment 898
Crankshaft Gear Removal And Installation 898
Crankshaft And Bearings Removal and Installation 899
Crankshaft And Bearings – Servicing 903
CAMSHAFT AND TIMING GEArS 910
Timing Gearcase Cover Removal And Installation 910
Timing Gears Backlash – Checking 911
Camshaft – Servicing 912
Idle Gear And Shaft Removal And Installation 914
Idler Gear And Shaft – Servicing 915
TURBOCHARGER 918
Description 918
Testing 918
Removal And Installation 919
FLYWHEEL AND HOUSING 920
Flywheel Removal And Installation 920
Ring Gear Removal And Installation 920
Housing Removal And Installation 921
HEATING, VENTILATION, AIR CONDITIONING 922
AIR CONDITIONING SYSTEM FLOW 925
Description 925
Chart 926
Components 927
Safety Equipment 930
REGULAR MAINTENANCE 932
Filter Elements Removal And Installation 932
Compressor Drive Belt Inspection 933
Condenser 934
Air Conditioning Service Chart 935
A/C Evaporator Coil & Heater Coil 936
TROUBLESHOOTING 938
Blower Motor Does Not Operate 938
Blower Motor Operates Normally, But Air Flow Is Insufficient 938
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 938
The Compressor Does Not Operate At All, Or Operates Improperly 938
Gauge Pressure Related Troubleshooting 939
Troubleshooting Tree 941
Temperature / Pressure Chart 945
Poor A/C Performance 947
HVAC Repair And Leaks 948
Electrical System 949
Engine Coolant Bypassing The Heater Valve 956
Heater Valve Not Opening Or Closing 957
SYSTEM CHARGING AND RECLAMATION 958
Refrigerant Identification 958
Reclamation And Charging With Recovery / Charging Unit 959
Charging With A Manifold Gauge Set 961
COMPRESSOR 964
Belt Adjustment 964
Removal And Installation 964
Oil 965
Oil Check 966
Clutch Disassembly And Assembly 967
CONDENSER 972
Removal And Installation 972
RECEIVER / DRIER 974
Receiver / Drier Removal And Installation 974
Pressure Relief Valve Removal And Installation 975
Pressure Switch Removal And Installation 975
Schraeder Valve Removal And Installation 976
EVAPORATOR / HEATER UNIT 978
Removal And Installation 978
THERMOSTAT 980
Removal And Installation 980
EXPANSION VALVE 982
Removal And Installation 982
EVAPORATOR 984
Removal And Installation 984
HEATER COIL 986
Removal And Installation With A/C 986
Removal And Installation Without A/C 988
BLOWER FAN 990
Removal And Installation 990
Disassembly And Assembly 991
Connector Identification 993
HEATER VALVE 994
Removal and Installation 994
Disassembly And Assembly 995
SPECIFICATIONS 996
(S220) LOADER SPECIFICATIONS 998
Dimensions 998
Performance 999
Controls 999
Engine 999
Hydraulic System 1000
Electrical 1000
Drive System 1001
Capacities 1001
Tires 1001
TORQUE SPECIFICATIONS FOR BOLTS 1002
Torque For General SAE Bolts 1002
Torque For General Metric Bolts 1003
HYDRAULIC CONNECTION SPECIFICATIONS 1004
O-ring Face Seal Connection 1004
Straight Thread O-ring Fitting 1005
Tubelines And Hoses 1005
Flare Fitting 1006
Port Seal Fitting 1007
HYDRAULIC FLUID SPECIFICATIONS 1008
Specifications 1008
CONVERSIONS 1010
Decimal And Millimeter Equivalents 1010
U S To Metric Conversion Chart 1010
SERVICE MANUAL REVISION 1012
Revision No: S220 – 1 1012
Revision No: S220 – 2 1014
Revision No: S220 – 3 1016
Revision No: S220 – 4 1018
Revision No: S220 – 5 1020
Revision No: S220 – 6 1022
Revision No: S220 – 7 1024
Revision No: S220 – 8 1026
Revision No: S220 – 9 1028
Revision No: S220 – 10 1030
Revision No: S220 – 11 1032
Revision No: S220 – 12 1034

IMAGES PREVIEW OF THE MANUAL:

Questions? Email us: [email protected]

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.V