Bobcat S220 S220 Turbo Skid-Steer Loader Workshop Repair Service Manual and Operation Maintenance PDF Download - MBOBS220.zip

A full-service repair manual featuring complete electrical wiring diagrams for the Bobcat S220 Skid-Steer Loader, packed with shop-level guidance so you can service, troubleshoot, and fix your machine just like a trained technician.

Inside the Bobcat S220 Skid-Steer Loader workshop service repair manual, you'll find:

* 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