Bobcat A220
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Manual
S/N 519611001 & Above
S/N 519711001 & Above
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6901245 (3-06) Printed in U.S.A. © Bobcat Company 2006
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
B-10731a B-15590 B-15591
Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG
B-15592 B-15593 B-15599
Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-15600 B-15601 B-6589
B-16102 B-16102
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW08-0805
ALPHABETICAL INDEX
AIR CLEANER .................................................... 70-01 FRONT AUXILIARY HYDRAULIC COUPLER
AIR CLEANER SERVICE ....................................... 10-01 BLOCK (S/N 519611124 & Above) ........................10-01
AIR CONDITIONING SERVICE.............................. 80-01 FUEL SYSTEM........................................................10-01
AIR CONDITIONING SYSTEM FLOW ................... 80-01 FUEL TANK .............................................................50-01
ALTERNATOR ........................................................ 60-01
AUXILIARY PRESSURE RELEASE GENERAL AIR CONDITIONING
(ACCUMULATOR) (EARLY MODELS) ................. 20-01 SERVICE GUIDELINES ........................................80-01
AWS CONTROLLER .............................................. 60-01
HEATER COIL .........................................................80-01
BASIC TROUBLESHOOTING ................................ 80-01 HEATER/AC FAN ....................................................80-01
BATTERY................................................................ 60-01 HEATER VALVE ......................................................80-01
BICS™ SYSTEM .................................................... 60-01 HUB .........................................................................40-01
BOBCAT CONTROLLER ........................................ 60-01 HYDRAULIC CONNECTION SPECS ............... SPEC-01
BOBCAT 2001 CONTROLLER (EARLY MODELS) 60-01 HYDRAULIC CONTROL VALVE .............................20-01
BOB-TACH ............................................... 10-01, 50-01 HYDRAULIC FLUID RESERVOIR ..........................20-01
BRAKE .................................................................... 40-01 HYDRAULIC/HYDROSTATIC FILTER ....................20-01
BRAKE (TWO-SPEED) (EARLY MODLES) ........ 40-01 HYDRAULIC/HYDROSTATIC FLUID
BRAKE (TWO-SPEED) (LATER MODLES) ........ 40-01 SPECIFICATIONS ........................................... SPEC-01
BUCKET POSITION VALVE ................................... 20-01 HYDRAULIC/HYDROSTATIC SYSTEM..................10-01
HYDRAULIC PUMP ................................................20-01
CHAINCASE ........................................................... 40-01 HYDRAULIC PUMP (HI FLOW) ..............................20-01
CHARGE PRESSURE ............................................ 30-01 HYDRAULIC SYSTEM INFORMATION ..................20-01
COOLING FAN ....................................................... 70-01 HYDROSTATIC MOTOR ..................................... 30-01
COMPONENTS ...................................................... 80-01 HYDROSTATIC MOTOR (CARRIER) ..................30-01
COMPRESSOR ...................................................... 80-01 HYDROSTATIC MOTOR (TWO-SPEED) ............30-01
CONDENSER ......................................................... 80-01 HYDROSTATIC PUMP ........................................ 30-01
CONTROL PANEL .................................................. 50-01 HYDROSTATIC SYSTEM INFORMATION ..........30-01
CONTROL .............................................................. 50-01
CONVERSIONS ............................................ SPEC-01 INSIDE ACESS PANEL (EARLY MODLES)............50-01
CYLINDER (LIFT) ................................................... 20-01 INSIDE ACESS PANEL (LATER MODLES) ............50-01
CYLINDER (POWER BOB-TACH).......................... 20-01 INSTRUMENT PANEL.............................................60-01
CYLINDER (STEERING) ........................................ 20-01
CYLINDER (TILT) ................................................... 20-01 LIFT ARMS ..............................................................50-01
LIFT ARM BY-PASS CONTROL VALVE .............. 20-01
DIAGNOSTICS SERVICE CODES ..................... 60-01 LIFT ARM SUPPORT DEVICE ........................... 10-01
DRIVE BELT ........................................................... 30-01 LIFT AND TILT ACTUATOR CALIBRATION ...........60-01
DRIVE COMPONENTS .......................................... 40-01 LIFTING AND BLOCKING THE LOADER...............10-01
LIGHTS ................................................................60-01
ELECTRICAL/HYDRAULIC CONTROLS LOADER SPECIFICATIONS ............................. SPEC-01
REFERENCE ........................................................ 60-01 LOADER TORQUE............................................ SPEC-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01 LUBRICATING THE LOADER.................................10-01
ENGINE ................................................................. 70-01
ENGINE COMPONENTS AND TESTS ................. 70-01 MAIN RELIEF VALVE ..............................................20-01
ENGINE COOLING SYSTEM ................................. 10-01 MUFFLER................................................................70-01
ENGINE LUBRICATION SYSTEM.......................... 10-01
ENGINE SPECIFICATIONS ........................... SPEC-01 OIL COOLER (SEAL TO CONNECT) (STC)...........30-01
ENGINE SPEED CONTROL (EARLY MODELS) ... 70-01 OPERATOR CAB .........................................10-01, 50-01
ENGINE SPEED CONTROL (LATER MODELS).... 70-01 OPERATOR SEAT (STANDARD)............................50-01
EVAPORATOR........................................................ 80-01 OPERATOR SEAT (SUSPENSION)........................50-01
EVAPORATOR/HEATER UNIT ............................... 80-01
EXPANSION VALVE ............................................... 80-01 POWER BOB-TACH (OPTION) ............... 10-01, 50-01
POWER BOB-TACH BLOCK (EARLY MODLES) ...20-01
FAN GEARBOX ...................................................... 10-01 POWER BOB-TACH BLOCK (LATER MODLES)....20-01
FINAL DRIVE TRANSMISSION (CHAINCASE) ..10-01 PRESSURE RELIEF VALVE ...................................80-01
FLYWHEEL AND HOUSING ................................70-01 PRESSURE SWITCH..............................................80-01
ALPHABETICAL INDEX (CONT’D)
RADIATOR...............................................................70-01
REAR AUXILIARY DIVERTER VALVE ....................20-01
REAR DOOR ...................................................... 50-01
REAR GRILL ....................................................... 50-01
RECEIVER/DRIER ..................................................80-01
RECONDITIONING THE ENGINE ..........................70-01
REGULAR MAINTENANCE ....................................80-01
REMOTE START ................................................ 10-01
SAFETY ..................................................................80-01
SEAT BAR ...............................................................50-01
SEAT BAR SENSOR ...............................................60-01
SELECT VALVE.......................................................20-01
SERVICE SCHEDULE ............................................10-01
SERVICE PC (LAPTOP COMPUTER) ....................60-01
SPEED SENSOR ....................................................60-01
STARTER (NIPPONDENSO) ..................................60-01
STARTER (VALEO) .................................................60-01
STEERING BLOCK .................................................40-01
STEERING SOLENOID...........................................60-01
SYSTEM CHARGING AND RECLAMATION ..........80-01
SYSTEM TROUBLESHOOTING CHART ...............80-01
TEMPERATURE/PRESSURE .................................80-01
THERMOSTAT.........................................................80-01
TIRE MAINTENANCE .............................................10-01
TORQUE SPECIFICATIONS FOR BOLTS .... SPEC-01
TOWING THE LOADER ..........................................10-01
TRACTION LOCK....................................................60-01
TRANSPORTING THE BOBCAT LOADER.............10-01
TROUBLESHOOTING.............................................70-01
WHEEL POSITION SENSORS ...............................60-01
CONTENTS SAFETY &
MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC
SYSTEM
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
HYDROSTATIC
BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . XI SYSTEM
SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
DRIVE
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 SYSTEM
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01 MAIN FRAME
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
ELECTRICAL
ELECTRICAL SYSTEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . 60-01 SYSTEM &
ANALYSIS
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01 ENGINE
SERVICE
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
HVAC
HVAC
SPECIFICATIONS
SPECIFICAT
A220 Bobcat Loader
I Service Manual
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:
1. Check lift arm support device, 9. The parking brake must
replace if damaged. (Stored function correctly.
Position)
2. Check that ROPS mounting 10. Enclosure door latches must
hardware is tightened and is open and close freely.
Bobcat approved.
3. The seat belt must be 11. Bob-Tach wedges and
correctly installed, functional linkages must function
and in good condition. correctly and be in good
condition.
4. The seat bar must be 12. Safety treads must be in good
correctly adjusted, clean and condition.
lubricated.
5. Check lift arm support device; 13. Check for correct function of
replace if damaged. indicator lamps (Optional on
some models).
6. Machine signs must be 14. Check hydraulic fluid level,
legible and in the correct engine oil level and fuel
location. supply.
7. Steering levers and foot 15. Inspect for fuel, oil or
pedals must return to neutral. hydraulic fluid leaks.
8. Check for correct function of 16. Lubricate the loader.
the work lights.
A220 Bobcat Loader
II Service Manual
17. Check the condition of the 22. Operate the loader and check
battery and cables. all functions.
18. Inspect the air cleaner for 23. Check for any field
damage or leaks. Check the modification not completed.
condition of the element.
19. Check the electrical charging 24. Check for correct function of
system. the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.
20. Check tires for wear and Recommend to the owner that all
pressure. necessary corrections be made
before the machine is returned to
service.
21. Inspect for loose or broken
parts or connections.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the State of California
to cause cancer, birth defects and other
reproductive harm.
A220 Bobcat Loader
III Service Manual
A220 Bobcat Loader
IV Service Manual
SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or
service. Untrained operators and failure to follow • An Operator’s Handbook fastened to the operator
instructions can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903 operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
WARNING • The AEM Safety Manual delivered with the machine
gives general safety information.
Warnings on the machine and in the manuals are for
your safety. Failure to obey warnings can cause • The Service Manual and Parts Manual are available
injury or death. from your dealer for use by mechanics to do shop-
W-2044-1285 type service and repair work.
• The Skid-Steer Loader Operator Training Course is
available through your local dealer or at
IMPORTANT www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
of correct operation of the Skid-Steer Loader. The
This notice identifies procedures which must be
course is available in English and Spanish versions.
followed to avoid damage to the machine.
I-2019-0284
• Service Safety Training Courses are available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com. They provide information for
safe and correct service procedures.
• The Skid-Steer Loader Safety Video is available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.
SI SSL-0206 SM
A220 Bobcat Loader
V Service Manual
SAFETY INSTRUCTIONS (CONT’D)
The dealer and owner/operator review the recommended
uses of the product when delivered. If the owner/operator
will be using the machine for a different application(s) he
or she must ask the dealer for recommendations on the
new use.
Call Before You Dig
1-888-258-0808
When you call, you will be directed to a location in
your state/city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.)
SI SSL-0206 SM
A220 Bobcat Loader
VI Service Manual
SAFETY INSTRUCTIONS (CONT’D) • Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump
Fire Prevention starting.
The machine and attachments have components that are • Use the procedure in the Operation & Maintenance
at high temperature under normal operating conditions. Manual for cleaning the spark arrestor muffler (if
The primary source of high temperatures is the engine equipped).
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a source of arcs or Figure 1
sparks.
Flammable debris (leaves, straw, etc.) must be removed
regularly. If flammable debris is allowed to accumulate, it
will increase fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential hazard.
The spark arrestor muffler is designed to control the
emission of hot particles from the engine and exhaust
system, but the muffler and the exhaust gases are still
hot.
• Do not use the machine where exhaust, arcs, sparks
or hot components can contact flammable material,
explosive dust or gases.
• The operator cab, engine compartment, and engine
• Know where fire extinguishers and first aid kits are
cooling system must be inspected every day and
located and how to use them. Fire extinguishers are
cleaned if necessary to prevent fire hazard and
available from your Bobcat dealer [Figure 1].
overheating.
• Check all electrical wiring and connections for
damage. Keep the battery terminals clean and tight.
Repair or replace any damaged part.
• Check fuel and hydraulic tubes, hoses and fittings for
damage and leakage. Never use open flame or bare
skin to check for leaks. Tighten or replace any parts
that show leakage. Always clean fluid spills. Do not
use gasoline or diesel fuel for cleaning parts. Use
commercial nonflammable solvents.
• Do not use ether or starting fluids on any engine
which has glow plugs. These starting aids can cause
explosion and injure you or bystanders.
• Always clean the machine, disconnect the battery,
and disconnect the wiring from the controllers before
welding. Cover rubber hoses, battery and all other
flammable parts. Keep a fire extinguisher near the
machine when welding. Have good ventilation when
grinding or welding painted parts. Wear a dust mask
when grinding painted parts. Toxic dust or gas can be
produced.
• Stop the engine and let it cool before adding fuel. NO
SMOKING!
SI SSL-0206 SM
A220 Bobcat Loader
VII Service Manual
A220 Bobcat Loader
VIII Service Manual
SERIAL NUMBER LOCATION Engine Serial Number
Always use the serial number of the loader when Figure 3
requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Loader Serial Number
Figure 2
P-24798
Figure 4
N-19358
The loader serial number plate is located on the outside
of the loader frame [Figure 2].
Explanation of loader Serial Number:
XXXX XXXXX
P-24799
Model 1.-Model/ Engine Model 2.-Production
Combination Sequence (Series)
The engine serial number is located on the valve cover
at the right side of the engine [Figure 3]. There is also
1. The four digit Model/Engine Combination Module
an extra S/N tag attached to the engine (Item) [Figure 4]
number identifies the model number and engine
combination.
2. The five digit Production Sequence Number identifies
the order which the loader is produced.
A220 Bobcat Loader
IX Service Manual
DELIVERY REPORT
Figure 5
B-16315
The Delivery Report must be filled out by the dealer and
signed by the owner or operator when the Bobcat loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [Figure
5].
A220 Bobcat Loader
X Service Manual
BOBCAT LOADER IDENTIFICATION
FRONT LIGHTS OPERATOR SEAT
WITH SEAT BELT
GRAB HANDLES
REAR AUXILIARY
STEERING
QUICK COUPLERS
LEVER
TILT CYLINDER FRONT AUXILIARY
QUICK COUPLERS
SAFETY TREAD
† BUCKET
BUCKET STEPS
B-15987
zOPERATOR CAB
SEAT BAR (ROPS & FOPS)
REAR GRILL
LIFT ARM
SUPPORT DEVICE
TAIL LIGHT
LIFT ARM
LIFT CYLINDER
REAR
LIGHT
REAR DOOR
B-15988
* TIRES
OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)
* TIRES - The Bobcat loader is factory equipped with heavy duty flotation tires. See Specifications Section and your
Bobcat dealer for available tires.
† BUCKET - Several different buckets and other attachments are available for the Bobcat loader.
z ROPS, FOPS - Roll Over Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective Structure
per SAEJ1043 and ISO 3449, Level I. Level II is available. The Bobcat loader is base-equipped with a standard operator
cab as shown. Extra insulated cab is available as an option (Reduced noise level).
A220 Bobcat Loader
XI Service Manual
A220 Bobcat Loader
XII Service Manual
SAFETY & MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
SAFETY &
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1 MAINTENANCE
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . 10-90-1
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 10-110-1
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1 DRIVE
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2 SYSTEM
FAN GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . 10-130-1
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Replacing The Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1 ELECTRICAL
SYSTEM &
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 ANALYSIS
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 ENGINE
Removing Air From The Fuel System . . . . . . . . . . . . . . . 10-100-2 SERVICE
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . 10-120-1
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic/Hydrostatic Filter Replacement . . . . . . . . . . . . 10-120-1 SPECIFICATIONS
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Steering Filter Replacment . . . . . . . . . . . . . . . . . . . . . . . 10-120-3
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Disengaging The Lift Arm Support Device. . . . . . . . . . . . . 10-20-2
Engaging The Lift Arm Support Device . . . . . . . . . . . . . . . 10-20-1
LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Continued On Next Page
A220 Bobcat Loader
10-01 Service Manual
SAFETY & MAINTENANCE (CONT’D)
POWER BOB-TACH (OPTION) . . . . . . . . . . . . . . . . . . . . . . . .10-151-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . .10-151-1
REMOTE START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-60-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-60-4
Procedure For Loader With Attachment Control Harness . . .10-60-2
Procedure For Loader Without Attachment Control Harness 10-60-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-70-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-70-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-170-1
Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-170-1
Tire Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-170-1
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-170-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-50-1
Procedure For Non-Two-Speeds . . . . . . . . . . . . . . . . . . . . . .10-50-1
Procedure For Two-Speeds . . . . . . . . . . . . . . . . . . . . . . . . . .10-50-2
TRANSPORTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . .10-40-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-40-1
A220 Bobcat Loader
10-02 Service Manual
LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
WARNING
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Handbook and
signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs,
adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained
P-24835
operators and failure to follow instructions can
cause injury or death.
W-2003-0199
Put floor jack under the rear of the loader [Figure 10-10-
2].
Figure 10-10-1
Lift the rear of the loader and install jackstands [Figure
10-10-2].
Figure 10-10-3
B-7023A
Read the removal and installation, disassembly and
assembly, etc., completely to become familiar with the P-24836
procedure before beginning [Figure 10-10-1].
Always park the loader on a level surface. Put the floor jack under the front of the loader [Figure 10-
10-3].
Lift the front of the loader and put jackstands under the
WARNING axle tubes. [Figure 10-10-3].
NOTE: Make sure the jackstands do not touch the
Put jackstands under the front axles and rear corners
tires.
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
A220 Bobcat Loader
10-10-1 Service Manual
A220 Bobcat Loader
10-10-2 Service Manual
LIFT ARM SUPPORT DEVICE Engaging The Lift Arm Support Device
Maintenance and service work can be done with the lift Figure 10-20-1
arms lowered. If the lift arms are raised, use the following
procedures to engage and disengage an approved lift
arm support device:
1
WARNING 2
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
N-19368
Install jackstands under the rear of the loader. Disconnect
WARNING the spring from the lift arm support device retaining pin
(Item 1). Support the lift arm support device (Item 2)
[Figure 10-20-1] with your hand and remove the
Service lift arm support device if damaged or if parts
retaining pin.
are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
Figure 10-20-2
causing injury or death.
W-2271-1197
N-19369
Lower the lift arm support device on top of the lift cylinder.
Hook the free end of the spring (Item 1) [Figure 10-20-2]
to the lift arm support device so there will be no
interference with the support device engagement.
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine.
A220 Bobcat Loader
10-20-1 Service Manual
LIFT ARM SUPPORT DEVICE (CONT’D) Figure 10-20-5
Engaging The Lift Arm Support Device (Cont’d)
Figure 10-20-3
N
N-10707
N-19372
Raise the lift arms a small amount and the spring will lift
N-19370 the support device off the lift cylinder rod [Figure 10-20-
5]. Lower the lift arms. Stop the engine.
Raise the lift arms, until the lift arm support device drops Disconnect the spring from the bracket.
onto the lift cylinder rod (Inset) [Figure 10-20-3].
Raise the seat bar and move pedals until both pedals
Lower the lift arms slowly until the support device is held lock.
between the lift arm and the lift cylinder. Stop the engine.
Raise the seat bar and move pedals until both pedals Raise the support device into storage postion and insert
lock. pin through lift arm support device and bracket (Item 1)
[Figure 10-20-1 on Page 1].
Install pin (Item 1) [Figure 10-20-3] into the rear of the lift
arm support device below the cylinder rod. Connect spring to pin. [Figure 10-20-1 on Page 1].
Disengaging The Lift Arm Support Device
Figure 10-20-4
N-19371
Remove the pin from the lift arm support device.
Connect the spring (Item 1) [Figure 10-20-4] from the lift
arm support device to the bracket below the lift arms.
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine.
A220 Bobcat Loader
10-20-2 Service Manual
OPERATOR CAB Figure 10-30-1
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat. Changes to the cab
can cause loss of operator protection from rollover
and falling objects, and result in injury or death.
W-2069-1299
The Bobcat loader has an operator cab (ROPS and
FOPS) as standard equipment to protect the operator P-24836
from rollover and falling objects. Check with your dealer if
the operator cab has been damaged. The seat belt must
be worn for roll over protection. Install jackstands under the rear of the loader frame
[Figure 10-30-1].
ROPS/FOPS - Roll Over Protective Structure per SAE
J1040 and ISO 3471, and Falling Object Protective Figure 10-30-2
Structure per SAE J1043 and ISO 3449, Level I. Level II
is available.
Level I - Protection from falling bricks, small concrete
blocks, and hand tools encountered in operations such
as highway maintenance, landscaping, and other
construction site services.
Level II - Protection from falling trees, rocks; for
machines involved in site clearing, overhead demolition
or forestry.
Raising The Operator Cab
Always stop the engine before raising or lowering the N-19364 N-19365
cab.
Stop the loader on a level surface. Lower the lift arms. If Loosen the nut (both sides) at the front corner of the
the lift arms must be up while raising the operator cab, operator cab.
install the lift arm support device. (See LIFT ARM
SUPPORT DEVICE on Page 10-20-1.) Remove the nuts and plates [Figure 10-30-2] (both
sides).
A220 Bobcat Loader
10-30-1 Service Manual
OPERATOR CAB (CONT’D) Always stop the engine before raising or lowering the
cab.
RaisingThe Operator Cab (Cont’d)
NOTE: Make sure the seat bar is fully raised or
Figure 10-30-3 lowered when lowering the cab. Always use
the grab handles to lower the cab.
Pull down on the bottom of the operator cab until it stops
at the latching mechanism [Figure 10-30-4].
Release the latching mechanism (Inset) [Figure 10-30-4]
and pull the cab all the way down.
Figure 10-30-5
P-24832
Lift on the grab handle and bottom of the operator cab
slowly until the cab is all the way up and the latching
mechanism engages [Figure 10-30-3].
Lowering The Operator Cab
Figure 10-30-4
N-19364 N-19365
Install the plates and nuts [Figure 10-30-5] (both sides).
Tighten the nuts to 40-50 ft.-lbs. (54-68 Nm) torque.
N-20120
P-24831
A220 Bobcat Loader
10-30-2 Service Manual
OPERATOR CAB (CONT’D) FRONT DOOR (If Equipped)
Emergency Exit Figure 10-30-8
Figure 10-30-6
N-20171
N-19385
NOTE: When the special applications kit is installed,
the front door cannot be used for an
The front opening on the operator cab and rear window emergency exit.
provide exits.
NOTE: When the special applications kit is installed,
Rear Window (If Equipped) the front door cannot be used for an
emergency exit.
Pull on the tag on the top of the rear window to remove
the rubber cord [Figure 10-30-6]. Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [Figure 10-30-8].
Figure 10-30-7
Figure 10-30-9
X
P-24830
P-24472
Push the rear window out of the rear of the operator cab.
Push the window out with your foot [Figure 10-30-9] at
Exit through the rear of the operator cab [Figure 10-30- any corner of the window.
7].
Exit through the front door.
A220 Bobcat Loader
10-30-3 Service Manual
A220 Bobcat Loader
10-30-4 Service Manual
TRANSPORTING THE LOADER Figure 10-40-2
Procedure
WARNING
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury. N-19048A P-24778A
W-2058-0494
Figure 10-40-1
1 P-24877
N-19522
A loader with an empty bucket or no attachment must be
The rear of the trailer must be blocked or supported (Item
loaded backward onto the transport vehicle [Figure 10-
1) [Figure 10-40-1] when loading or unloading the loader
40-1].
to prevent the front end of the trailer from raising up.
Be sure the transport and towing vehicles are of
Use the following procedure to fasten the Bobcat loader
adequate size and capacity (See Capacities on Page
to the transport vehicle to prevent the loader from moving
SPEC-10-4.)
during sudden stops or when going up or down slopes
[Figure 10-40-2].
• Lower the bucket or attachment to the floor.
• Stop the engine.
• Engage the parking brake.
• Install chains at the front and rear loader tie down
positions (Inset) [Figure 10-40-2].
• Fasten each end of the chain to the transport vehicle.
A220 Bobcat Loader
10-40-1 Service Manual
A220 Bobcat Loader
10-40-2 Service Manual
TOWING THE LOADER Figure 10-50-2
Procedure For Non-Two-Speeds
IMPORTANT
Do not push or pull the machine at more than 2 MPH
(3,2 km/h) or for a distance of more than 25 feet (7,6
meters) with the towing tool in place.
I-2017-0389
1
Figure 10-50-1
N-18409
• Press the TRACTION LOCK OVERRIDE Button
(Item 1) [Figure 10-50-2].
• Tow the Bobcat at 2 MPH (3,2 km/hr) or less for not
more than 25 feet (7,6 meters).
1 If the electrical system is not functioning, contact your
Bobcat loader dealer.
P-26475
To prevent damage to the loaders hydrostatic system, the
loader must be towed only a short distance at slow
speed. (Example: Moving the loader onto a transport
vehicle).
The towing chain (or cable) must be rated at 1 & 1/2
times the weight of the loader. (See LOADER
SPECIFICATIONS on Page SPEC-10-1.)
• Turn the key switch to RUN (Item 1) [Figure 10-50-1]
(Standard Panel) OR press the RUN / ENTER Button
(Deluxe).
A220 Bobcat Loader
10-50-1 Service Manual
TOWING THE LOADER (CONT’D) Figure 10-50-4
Procedure For Two-Speeds
2
WARNING P-24847
Never work on a machine with the lift arms up unless Disengage the parking brake solenoid valve by pushing
the lift arms are secured by an approved lift arm IN on the red Traction Lock By-Pass Knob (Item 1)
support device. Failure to use an approved lift arm [Figure 10-50-4] and turning it 1/4 TURN
support device can allow the lift arms or attachment counterclockwise. The knob will come out to release
to fall and cause injury or death. the solenoid valve.
W-2059-0598
Connect a Port-a-Power to the coupler (Item 2) [Figure
Figure 10-50-3 10-50-4].
P-24846
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the protective cover (Item 1) [Figure 10-50-3]
from the parking brake solenoid.
A220 Bobcat Loader
10-50-2 Service Manual
TOWING THE LOADER (CONT’D)
Procedure For Two-Speeds (Cont’d)
Figure 10-50-5
P-24848
Operate the Port-a-Power 350-400 PSI (2413-2758 kPa)
to release the brake [Figure 10-50-5].
Lower the operator cab and tow the loader.
Before operating the loader again, disconnect the Port-a-
Power.
Engage the parking brake solenoid valve, by pushing
IN on the red Traction Lock By-Pass Knob (Item 1)
[Figure 10-50-4] and turning it 1/4 TURN clockwise.
A220 Bobcat Loader
10-50-3 Service Manual
A220 Bobcat Loader
10-50-4 Service Manual
REMOTE START Raise the operator cab (if required by the procedure).
(See Raising The Operator Cab on Page 10-30-1.)
Procedure For Loader Without Attachment Control
Harness Open the rear door of the loader.
Figure 10-60-1 Remove the cap (Item 1) [Figure 10-60-2] from the
loader harness (Item 1) [Figure 10-60-3].
Figure 10-60-3
1
P13841
2
The tool listed will be needed to do the followng
P-24838
Procedure:
MEL1563-Remote Start Tool Kit When the remote start procedure is completed, replace
the loader connector cap (Item 2) [Figure 10-60-3].
The remote start (Item 1) [Figure 10-60-1] is required
when the operator cab is in the raised position for service
and the service technician needs to turn the key switch
ON or start the engine. Example: adjusting the steering
linkage.
Figure 10-60-2
P-24837
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the lift arms (if required by the procedure) and
install an approved lift arm support device. (See
Engaging The Lift Arm Support Device on Page 10-20-1.)
A220 Bobcat Loader
10-60-1 Service Manual
REMOTE START (CONT”D) Procedure For Loader With Attachment Control
Harness
Procedure For Loader Without Attachment Control
Harness (Cont’d) Figure 10-60-5
Figure 10-60-4
P13841
P-24839
The tool listed will be needed to do the following
procedure:
Connect the remote start tool to the engine harness
connector (Item 1) [Figure 10-60-4]. MEL1563 - Remote Start Tool Kit
The extra connector on the remote start harness is not The remote start (Item 1) [Figure 10-60-5] is required
used in the remote start procedure and should remain when the operator cab is in the raised position for service
capped. and the service technician needs to turn the key switch
ON or start the engine. Example: adjusting the steering
NOTE: The key switch on the right-hand side linkage.
operator panel must be in the OFF position or
the Remote Start Kit will not operate. Lift and block the loader.(See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the lift arms (if required by the procedure) and
WARNING install an approved lift arm support device. (See
Engaging The Lift Arm Support Device on Page 10-20-1.)
AVOID INJURY OR DEATH
Raise the operator cab (See Raising The Operator Cab
With the 7-pin connector plugged into the loader and
on Page 10-30-1.)
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
Open the rear door of the loader
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
service technician will be working the engine area it
is important to remove the operator panel keys.
A220 Bobcat Loader
10-60-2 Service Manual
REMOTE START (CONT’D) Figure 10-60-8
Procedure for Loader With Attachment Control
Harness (Cont’d)
Figure 10-60-6 1
P-24842
Connect the remote start tool (Item 1) [Figure 10-60-8] to
the loader harness connector (Item 2) [Figure 10-60-7].
P-24840
The connector (Item 2) [Figure 10-60-8] on the remote
start harness is not used in the remote start procedure
Figure 10-60-7 and should remain capped.
NOTE: The key switch on the right-hand side
operator panel must be in the OFF position or
the Remote Start Kit will not operate.
WARNING
2
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
P-24841
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
Lift and block the loader.(See LIFTING AND BLOCKING service technician will be working the engine area it
THE LOADER on Page 10-10-1.) is important to remove the operator panel keys.
W-2357-0899
Raise the lift arms (if required by the procedure) and
install an approved lift arm support device. (See
Engaging The Lift Arm Support Device on Page 10-20-1.)
Raise the operator cab (if required by the procedure).
(See Raising The Operator Cab on Page 10-30-1.)
Open the rear door of the loader.
Disconnect the attachment control harness (Item 1)
[Figure 10-60-6] & [Figure 10-60-7] from the loader
harness.
A220 Bobcat Loader
10-60-3 Service Manual
REMOTE START (CONT’D) traction lock OVERRIDE, in this position the wheels are
able to turn.
Procedure
The maximum flow/variable flow switch (Item 2) [Figure
Figure 10-60-9 10-60-10] is used to activate the auxiliary hydraulics.
Pressing the switch once will activate variable flow.
Pressing the switch again will activate maximum flow.
The switch will illuminate to indicate which flow rate is
active. Pressing the switch a third time will turn the flow
OFF. The switch is used when checking pressures and
flow rate.
The auxiliary pressure release (Item 3) [Figure 10-60-10]
is used to release hydraulic pressure to the front and/or
1 rear auxiliary couplers. To release pressure; push and
hold the switch for three seconds.
NOTE: With the engine running; pushing and holding
the pressure release switch will cause the
P13841 engine to stop in three seconds. To relieve the
pressure; continue to press the switch after
the engine has stopped.
The remote start tool (Item 1) [Figure 10-60-9] has three
rocker switches.
Figure 10-60-10
2 1
3
N-19541
The traction lock switch (Item 1) [Figure 10-60-10] is
used to turn traction lock ON or OFF. Push the switch to
the override position. The switch will illuminate to indicate
A220 Bobcat Loader
10-60-4 Service Manual
SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service
schedule is a guide for correct maintenance of the Bobcat loader.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and signs
(decals) on machine. Follow warnings and instructions in the manuals when
WARNING making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0903
SERVICE SCHEDULE HOURS
ITEM SERVICE REQUIRED ■ ■ ■ ▼
8-10 50 100 250 500 1000 3000
Engine Oil Check the oil level and add as needed.
Engine Air Filter and Air System Check display panel. Service only when required. Check for leaks and damaged
components.
Engine Cooling System Clean debris from oil cooler, radiator & grill.
Lift Arms, Cyl., Bob-Tach Pivot Lubricate with multi-purpose lithium based grease.
Pins, Wedges and Steering
Cylinders
Tires Check for damaged tires and correct air pressure.
Seat Bar, Control Interlocks, Seat Check the condition of seat belt. Clean or replace seat beltretractors as needed.
Belt, Seat Belt Retractors Check the sear bar and control interlocks for correct operation. Clean dirt and
debris from moving parts.
Bobcat Interlock Control Systems Check that four (4) BICS™ indicator lights and functions are activated. (See
(BICS™)
BICS™ SYSTEM on Page 60-110-1.)
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
Operator Cab Check the fastening bolts, washers and nuts. Check the condition of the cab.
Indicators and Lights Check for correct operation of all indicators and lights.
Fuel Filter Remove the trapped water.
Heater and A/C Filters Clean or replace filters as needed during heating/cooling season.
Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and leaks. Repair or
Tubelines replace as needed.
Final Drive Trans. (Chaincase) Check oil level. Add oil as needed.
Wheel Nuts ❏Check for loose wheel nuts and tighten to 105-115 ft.-lbs. (142-156 Nm) torque
Parking Brake Check operation.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Engine/Hydro. Drive Belt *Check for wear or damage. Check idler arm stop.
Alternator Belt Check tension and adjust as needed.
Air Condition Belt Check belt for wear. Adjust or replace as needed.
Bobcat Interlock Control System Check the function of the lift arm by-pass control.
(BICS™)
Fuel Filter Replace filter element.
Steering King Pins Lubricate with multi-purpose lithium based grease.
Hydraulic Reservoir Breather Cap Replace the reservoir breather cap.
Hyd./Hydro. Filter ●Replace the filter element.
Engine Oil and Filter ^Replace oil and filter. Use CD or better grade oil and Bobcat filter. ^ ❍
Steering Filter ^Replace the filter
Final Drive Trans. (Chaincase) Replace the fluid.
Hydraulic Reservoir Replace the fluid.
Case Drain Filters Replace the filters.
Engine Valves #Adjust the engine valves.
Wheel Bearings & Outer Axle Repack the wheel bearings. Grease internal splines in hub yolk.
Splines
Engine Timing Belt ▼Replace the timing belt and belt tensioner assy.
❏ Check wheel nut torque every 8 hours for the first 24 hours.
* Inspect the new belt after first 50 hours.
● Also replace hydraulic/hydrostatic filter element at the first 50 hours and when the transmission warning light comes ON.
^ First oil and filter change must occur at 50 hours; 500 hours thereafter.
# After the first 500 hours on new engine, adjust engine valves; 1000 hours thereafter. SERVICE SCHEDULE10-70-1 for procedure.)
A220 Bobcat Loader
10-70-1 Service Manual
A220 Bobcat Loader
10-70-2 Service Manual
AIR CLEANER SERVICE OUTER FILTER
Replacing Filter Element Figure 10-80-3
Figure 10-80-1
2
1
P-24843
B-15552
B-15553
Disengage the clamps (Item 1) and remove the dust
cover (Item 2) [Figure 10-80-3].
It is important to change the air filter element only when
the Air Cleaner Icon in the right panel is ON (Item 1) Figure 10-80-4
[Figure 10-80-1] and you hear three beeps from the
alarm.
Replace the inner filter every third time the outer filter is
replaced or as indicated.
Figure 10-80-2
1
2
P-24844
1
Remove the outer filter element (Item 1) [Figure 10-80-
4].
NOTE: Make sure all sealing surfaces are free of dirt
B-15551B and debris.
Install a new outer element.
Press and hold the LIGHT Button (Item 1) [Figure 10-80-
2] for two seconds. Install the dust cover and fasten the clamps.
If the filter element needs replacement, the CODE [01- Check the air intake hose and the air cleaner housing for
17.] (Air Filter Plugged) will show in the HOURMETER / damage. Make sure all connections are tight.
CODE DISPLAY (Item 2) [Figure 10-80-2] .
A220 Bobcat Loader
10-80-1 ServiceManual
AIR CLEANER SERVICE (CONT’D) Figure 10-80-6
Replacing Filter Element (Cont'd)
Figure 10-80-5
1 P-24843
NOTE: Make sure all sealing surfaces are free of dirt
P-24845 and debris
Intall the new inner element.
INNER FILTER
Install the dust cover and fasten the clamps (Item 1)
Only replace the inner filter element under the following [Figure 10-80-6].
conditions:
• Replace the inner filter element every third time the
outer filter is replaced.
• After the outer element has been replaced, start the
engine and run at full RPM. If the HOURMETER /
CODE DISPLAY shows [01-17.] (Air Filter
Plugged), replace the inner filter element.
Remove the inner filter element (Item 1) [Figure 10-80-
5].
A220 Bobcat Loader
10-80-2 Service Manual
ENGINE COOLING SYSTEM Figure 10-90-3
Check the cooling system every day to prevent over-
heating, loss of performance or engine damage.
Cleaning The Cooling System
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
1
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running. P-24810
• Tools are being used.
W-2019-1285
Raise the oil cooler, and support it, so both sides can be
cleaned.
Figure 10-90-1
Use air pressure or water pressure to clean the top of the
engine oil cooler (Item 1) [Figure 10-90-3].
1 Figure 10-90-4
Access
Cover
P-24809
Lift the grill (Item 1) [Figure 10-90-1].
Figure 10-90-2
N-19361
NOTE: The access cover (both sides) must be in
place to ensure correct air flow through the oil
cooler which will ensure cooling for the
engine and hydraulic system [Figure 10-90-4].
P-24808
Remove the fasteners (Item 1) [Figure 10-90-2] (both
sides) and raise the A/C condenser clear of the oil cooler
(If so equipped).
Check cooling system for leaks.
A220 Bobcat Loader
10-90-1 Service Manual
A220 Bobcat Loader
10-90-2 Service Manual
FUEL SYSTEM Figure 10-100-2
Fuel Specifications WRONG
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1.
The following is one suggested blending guideline which
should prevent fuel gelling problems:
TEMP. F° (C°) NO. 2 NO.1
+15° (9° ) 100% 0%
Down to -20° (-20°) 50% 50%
Below - 20° (29°) 0% 100% B-15602
We recommend an operator contact their fuel supplier for
local recommendations. Use a clean, approved safety container to add fuel of the
correct specifications. Add fuel only in an area that has
Filling The Fuel Tank free movement of air and no open flames or sparks. NO
SMOKING! [Figure 10-100-2].
Install and tighten the fuel fill cap [Figure 10-100-1].
WARNING
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0887
Figure 10-100-1
N-19408
Remove the fuel fill cap (Item 1) [Figure 10-100-1].
A220 Bobcat Loader
10-100-1 Service Manual
FUEL SYSTEM (CONT”D) Removing Air From The Fuel System
Fuel Filter After replacing the fuel filter element or when the fuel
tank has run out of fuel, the air must be removed from the
Figure 10-100-3 fuel system prior to starting the engine.
Loosen the air vent plug (Item 2) [Figure 10-100-3] at the
top of the fuel filter.
2
Figure 10-100-4
1
N-19327 1
(See SERVICE SCHEDULE on Page 10-70-1.) for the
recommended service interval when to remove the water
from the fuel filter.
N-19325
Loosen the drain (Item 1) [Figure 10-100-3] at the
bottom of the filter element to drain any water from the Operate the hand pump (priming bulb) (Item 1) [Figure
filter. 10-100-4] until the fuel flows from the air vent plug with
no air bubbles.
(See SERVICE SCHEDULE on Page 10-70-1.) for the
recommended service interval when to replace the fuel Tighten the air vent plug.
filter.
To replace the fuel filter element, use a filter wrench to
remove the filter element (Item 3) [Figure 10-100-3].
Clean the area around the filter housing. Put oil on the
seal of the new filter element. Install the fuel filter, and
hand tighten. Remove the air from the fuel system.
A220 Bobcat Loader
10-100-2 Service Manual
ENGINE LUBRICATION SYSTEM Use a good quality motor oil that meets API Service
Classification of CD, CE or better. (See Oil Chart below.)
Checking Engine Oil
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Figure 10-110-1
N-19327
Check the engine oil level every day.
Before starting the engine for the work shift, open the
rear door. Remove the dipstick (Item 1) [Figure 10-110-
1].
Keep the oil level between the marks on the dipstick.
A220 Bobcat Loader
10-110-1 Service Manual
ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-110-3
Replacing Oil And Filter
Figure 10-110-2 1
1
N-19325
Remove the oil filter (Item 1) [Figure 10-110-3].
N-19328
Clean the filter housing surface. Put clean oil on the new
oil filter gasket. Install the filter and hand tighten only.
(See SERVICE SCHEDULE on Page 10-70-1.) for the
service interval for replacing the engine oil and filter. Install and tighten the drain plug.
Run the engine until it is at operating temperature. Stop Remove the filler cap (Item 2) [Figure 10-110-1 on Page
the engine. 1].
Open the rear door. Remove the drain plug (Item 1) Put 10 qts. (9,5 L) of oil in the engine.
[Figure 10-110-2]. Drain the oil into container.
Start the engine and let it run for several minutes. Stop
the engine. Check for leaks and check the oil level. Add
oil as needed if it is not at the top mark on the dipstick.
A220 Bobcat Loader
10-110-2 Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM Figure 10-120-3
Checking And Adding Fluid
Figure 10-120-1 1
SIGHT
GAUGE
P-4613
P-24849
NOTE: Before installing the fill cap, make sure the
N-19361 rubber gasket (Item 1) [Figure 10-120-3] is
installed on the fill cap.
Use only recommended fluid in the hydraulic system. Hydraulic/Hydrostatic Filter Replacement
(See HYDRAULIC FLUID SPECIFICATIONS on Page
SPEC-60-1.) Figure 10-120-4
To check the reservoir, use the following procedure:
Put the Bobcat loader on a level surface. Lower the lift
arms and tilt the Bob-Tach fully back. Stop the engine.
Check the fluid level at the sight gauge [Figure 10-120-
1]. The fluid level must show in the sight gauge. 1
Figure 10-120-2
P-24850
1
See SERVICE SCHEDULE on Page 10-70-1 for the
correct service interval.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Use a filter wrench to remove the filter elements (Items 1)
N-19360 [Figure 10-120-4].
Later Model Loaders have a single hydraulic/hydrostatic
If fluid is needed, remove the fill cap (Item 1) [Figure 10- filtration system.
120-2].
Clean the surface of the filter housing where the element
Add the fluid as needed to bring the level to the center of seal contacts the housing. Put clean oil on the rubber
the sight gauge. seal of the filter elements.
Install and hand tighten the filter elements.
A220 Bobcat Loader
10-120-1 Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)
Replacing Hydraulic Fluid
WARNING
Figure 10-120-5
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Figure 10-120-6
1 1
1
N-19496
See SERVICE SCHEDULE on Page 10-70-1 for the
service interval.
2
Replace the fluid if it becomes contaminated or after
major repair.
P-24814
Clean the hydrostatic motor case drain filter thoroughly
after a major repair. Disconnect the hoses from the hydrostatic motor case
drain filter (Item 1) [Figure 10-120-6].
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.) Remove the case drain filters (Item 2) [Figure 10-120-6]
and clean thoroughly with clean solvent.
Remove the left side hydrostatic motor cover.
Install the case drain filter and tighten the hoses.
Pull the reservoir drain hose (Item 1) [Figure 10-120-5]
out the motor cover hole. Remove the plug and drain the Install the plug in the reservoir drain hose and tighten.
fluid into a container. Install the motor covers. (Both sides.)
Replace the filter element. (See Hydraulic/Hydrostatic Add the correct fluid to the reservoir until the fluid level is
Filter Replacement on Page 10-120-1.) at the sight gauge. (See HYDRAULIC FLUID
SPECIFICATIONS on Page SPEC-60-1.)
Lower the operator cab. Start the engine an doperate the
WARNING loader hydraulic controls. Stop the engine. Check for
leaks. Check the fluid level in the resevoir and add as
needed.
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496
A220 Bobcat Loader
10-120-2 Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)
Steering Filter Replacment
Figure 10-120-7
P-26700
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the filter mount bracket bolt (Item 1) [Figure 10-
120-7].
Figure 10-120-8
P-26701
Disconnect the inlet hose (Item 1) [Figure 10-120-8]
from the gear pump to the filter.
Disconnect the outlet hose (Item 2) [Figure 10-120-8]
from the filter to the steering valve.
Remove the filter mount clamp (Item 3) [Figure 10-120-
8].
Discard the filter and install a new filter.
A220 Bobcat Loader
10-120-3 Service Manual
A220 Bobcat Loader
10-120-4 Service Manual
FINAL DRIVE TRANSMISSION (CHAINCASE) Replacing The Oil
Checking And Adding Oil Figure 10-130-2
Figure 10-130-1
1
1
P1616
P-24815
To drain the oil from the chaincase, remove the cover
(Item 1) [Figure 10-130-2] which is installed over the
The chaincase contains the final drive sprockets and drain plug at the rear of the chaincase.
chains and uses the same type of oil as the hydraulic/
hydrostatic system. (See HYDRAULIC FLUID Figure 10-130-3
SPECIFICATIONS on Page SPEC-60-1.)
To check the chaincase oil level, use the following
procedure:
Drive the loader on a level surface. Stop the engine.
Remove the plug (Item 1) [Figure 10-130-1] from the
front of the chaincase housing.
1
If oil can be reached with the tip of the your finger through
the hole the oil level is correct.
If the level is low, add oil through the check plug hole until
the oil flows from the hole. Install and tighten the plug. P1619
Remove the drain plug (Item 1) [Figure 10-130-3] and
drain the oil into a container.
Check the drain plug and replace if necessary.
A220 Bobcat Loader
10-130-1 Service Manual
A220 Bobcat Loader
10-130-2 Service Manual
FAN GEARBOX
Checking And Adding Oil
Figure 10-140-1
Gear Lube 1
Level
P-24851
See SERVICE SCHEDULE on Page 10-70-1 for the
correct service interval.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the plug (Item 1) [Figure 10-140-1] to check the
lubricant level.
When checking the gearbox lube level, make sure the
level does not go above the center line of the shaft in the
gearbox [Figure 10-140-1]. Use SAE 90W gear lube if
the level is low.
A220 Bobcat Loader
10-140-1 Service Manual
A220 Bobcat Loader
10-140-2 Service Manual
BOB-TACH Figure 10-150-3
Inspection And Maintenance
BOB-TACH
WEDGE
Figure 10-150-1
WEDGE MUST CONTACT
N-17047 LOWER EDGE OF HOLE
IN THE ATTACHMENT
B-15177
The spring loaded wedge (Item 1) [Figure 10-150-1]
N-17027 must contact the lower edge of the hole in the attachment
(Item 1) [Figure 10-150-2] and [Figure 10-150-3].
Move the Bob-Tach levers to engage the wedges [Figure If the wedge does not contact the lower edge of the hole
10-150-1]. The levers and wedges must move freely. [Figure 10-150-2] and [Figure 10-150-3], the
attachment will be loose and can come off the Bob-Tach.
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-150-1]. Figure 10-150-4
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Levers must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588
Figure 10-150-2
TS-1062
Inspect the mounting frame on the attachment and the
Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-150-4]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
Look for cracked welds. Contact your Bobcat dealer for
1 repair or replacement parts.
Lubricate the wedges. (See POWER BOB-TACH
(OPTION) on Page 10-151-1 and See LUBRICATING
N-17046 THE LOADER on Page 10-160-1.)
A220 Bobcat Loader
10-150-1 Service Manual
A220 Bobcat Loader
10-150-2 Service Manual
POWER BOB-TACH (OPTION) Figure 10-151-3
Inspection And Maintenance
Figure 10-151-1
Front-Center Panel
1
Wedge Must Contact
Lower Edge Of Hole
In The Attachment N-17047
If the wedge does not contact the lower edge of the hole
P-24800 P-24800 [Figure 10-151-3], the attachment will be loose and can
come off the Bob-Tach.
Push and hold the BOB-TACH "WEDGES UP" switch Figure 10-151-4
[Figure 10-151-1] until wedges are fully raised. Push and
hold the BOB-TACH "WEDGES DOWN" switch [Figure
10-151-1] until the wedges are fully down. The wedges
must move freely.
Figure 10-151-2
TS-1062
Inspect the mounting frame on the attachment and the
Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-151-4]. Replace any parts including
N-17047 decals and lever that are damaged, bent, or missing.
Keep all fasteners tight. Inspect the hoses and fittings for
leaks.
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-151-2] Look for cracked welds. Contact your Bobcat dealer for
and must contact the lower edge of the hole in the repair or replacement parts.
attachment [Figure 10-151-2] and (Item 1) [Figure 10-
151-3]. Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1 and See LUBRICATING THE LOADER on
Page 10-160-1.)
A220 Bobcat Loader
10-151-1 Service Manual
A220 Bobcat Loader
10-151-2 Service Manual
LUBRICATING THE LOADER Figure 10-160-3
Procedure
Figure 10-160-1
1
N-19358
3. Lift Arm Pivot Pin (Both Sides) [Figure 10-160-3].
B-16318
Figure 10-160-4
Lubricate the loader as specified in the SERVICE
SCHEDULE Contents Page 10-01, for the best
performance of the loader.
Record the operating hours each time you lubricate the
Bobcat loader.
4
Always use a good quality lithium based multi-purpose
grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Lubricate the following locations on the loader:
1. Rod End Lift Cylinder (Both Sides) [Figure 10-160-1] P7641
Figure 10-160-2
4. Base End Tilt Cylinder [Figure 10-160-4].
2 P-24852
2. Base End Lift Cylinder (Both Sides) [Figure 10-160-
2].
A220 Bobcat Loader
10-160-1 Service Manual
LUBRICATING THE LOADER (CONT’D) Figure 10-160-7
Procedure (Cont'd)
Figure 10-160-5 8
9
5
P-24819
8. King Pins [Figure 10-160-7] (All Wheels).
N-19501
9. Cylinder Shafts [Figure 10-160-7] (All Wheels).
5. Rod End Tilt Cylinder [Figure 10-160-5].
Figure 10-160-6
N-19500
6. Bob-Tach Pivot Pin (Both Sides [Figure 10-160-6].
7. Bob-Tach Wedge (Both Sides) [Figure 10-160-6].
A220 Bobcat Loader
10-160-2 Service Manual
TIRE MAINTENANCE Figure 10-170-2
Wheel Nuts
Figure 10-170-1
B-9976
Check the tires regularly for wear, damage, and
P-24816 pressure. (See SERVICE SCHEDULE on Page 10-70-1.)
Rear tires usually wear faster than front tires. To keep tire
See SERVICE SCHEDULE on Page 10-70-1 for the wear even, move the front tires to the rear and rear tires
service interval to check the wheel nuts [Figure 10-170- to the front [Figure 10-170-2].
1].
It is important to keep the same size tires on each side of
When installing wheel nuts, tighten to 160 ft.-lbs. (217 the loader. If different sizes are used, each tire will be
Nm) torque. turning at a different rate and cause excessive wear. The
tread bars of all the tires must face the same direction.
When checking wheel nuts, tighten to 140 ft.-lbs. (190
Nm) torque . Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
Tire Rotation capability. Check for the correct pressure before
operating the loader.
Tire Mounting
WARNING Tires are to be repaired only by an authorized person
using the proper procedures and safety equipment. Tires
Do not inflate tires above specified pressure. Failure
and rims must always be checked for correct size before
to use correct tire mounting procedure can cause an
mounting. Check rim and tire bead for damage.
explosion which can result in injury or death.
W-2078-1285
The rim flange must be cleaned and free of rust. The tire
bead and rim flange must be lubricated with a rubber
lubricant before mounting the tire, avoid excessive
pressure which can rupture the tire and cause serious
IMPORTANT injury or death. During inflation of the tire, check the tire
pressure frequently to avoid over inflation.
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
I-2057-0794
A220 Bobcat Loader
10-170-1 Service Manual
A220 Bobcat Loader
10-170-2 Service Manual
HYDRAULIC SYSTEM
AUXILIARY PRESSURE RELEASE (ACCUMULATOR) (EARLY
MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1 SAFETY &
MAINTENANCE
BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-2 HYDRAULIC
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . 20-90-1 SYSTEM
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1 DRIVE
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5 SYSTEM
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
CYLINDER (POWER BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5 ELECTRICAL
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1 SYSTEM &
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4 ANALYSIS
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-2
ENGINE
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 SERVICE
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-4 SPECIFICATIONS
Rod End Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
CYLINDER (STEERING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1
Removal (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1
Removal (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-4
FRONT AUXILARY HYDRAULIC COUPLER BLOCKFRONT AUXILIARY
HYDRAULIC COUPLER BLOCK (S/N 519611124 & ABOVE) . . 20-131-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 20-131-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-131-1
Continued On Next Page
A220 Bobcat Loader
20-01 Service Manual
HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . .20-40-1
Actuator Removal And Installation (Out Of Loader). . . . . . . . . . . . . . . .20-40-8
Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-20
Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . .20-40-19
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . .20-40-24
Auxiliary Electric Solenoid Disassembly And Assembly . . . . . . . . . . .20-40-24
BICS™ Valve Lift Arm By-Pass Orifice Removal And Installation . . . .20-40-10
BICS™ Valve Check Valve Removal And Installation . . . . . . . . . . . . . 20-40-11
BICS™ Valve Solenoid Removal And Installation . . . . . . . . . . . . . . . .20-40-13
BICS™ Valve Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-14
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-26
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-15
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-16
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-21
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-16
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-17
Port-Auxiliary Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-26
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-18
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-3
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-22
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1
Draining The Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1
Hydraulic Fluid Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
HYDRAULIC PUMP (HI FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-61-1
Checking The Output Of The High Flow Pump . . . . . . . . . . . . . . . . . . .20-61-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-61-9
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-61-8
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-61-3
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-1
Checking The Output Of The Auxiliary Pump . . . . . . . . . . . . . . . . . . . .20-60-1
Checking The Output Of The Steering Pump . . . . . . . . . . . . . . . . . . . .20-60-2
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-8
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-7
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-3
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-1
Tighten Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-5
HYDRAULIC/HYDROSTATIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-70-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-70-1
Continued On Next Page
A220 Bobcat Loader
20-02 Service Manual
HYDRAULIC SYSTEM (CONT’D)
LIFT ARM BY-PASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-2
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3
Checking The Main Relief Valve At Front Auxiliary Hydraulics . . . . . . . 20-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-2
POWER BOB-TACH BLOCK (EARLY MODELS) . . . . . . . . . . . . . . . . . . . 20-120-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-120-1
POWER BOB-TACH BLOCK (LATER MODELS) . . . . . . . . . . . . . . . . . . .20-121-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-121-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-121-1
REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2
SELECT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Checking The High Flow Pump Relief Valve . . . . . . . . . . . . . . . . . . . . 20-100-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-100-2
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-100-6
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (See TORQUE
SPECIFICATIONS FOR BOLTS on Page SPEC-40-1.) UNLESS OTHERWISE
SPECIFIED
A220 Bobcat Loader
20-03 Service Manual
A220 Bobcat Loader
20-04 Service Manual
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
S/N 519611001 - 519611123
S/N 519711001 - 519711003
(PRINTED APRIL 2004)
V-0110legend
Printable Version Click Here
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 34 LOAD SHUTTLE VALVE - BLEED OFF 53 HYDRAULIC STEERING PUMP - Gear Type
Capacity . . . . . . 18.8 Qts. (17.8 L) (SCREEN) 13.0 GPM (49,2 L/min.) at High Engine Idle
PILOT ACTIVATED DIRECTIONAL CONTROL
17 ONE WAY RESTRICTOR - BOOM DOWN 35 VALVE - FOR REAR AUXILIARY - NORMALLY 54 FILTER - STEERING (10 MICRON)
2 FILTER - CASE DRAIN (90 Micron)
CLOSED. ("P2" and "F2")
18 LOAD CHECK VALVE - LIFT AND TILT 55 SOLENOID ACTIVATED
3 FILTER - HYDRAULIC (CANISTER) 36 PILOT ACTIVATED DIRECTIONAL CONTROL PROPORTIONAL FLOW CONTROL
VALVE - FOR REAR AUXILIARY - NORMALLY
4 SPRING LOADED FILTER BY-PASS 19 RELIEF VALVE - MAIN: VALVE - STEERING
OPEN ("D1" and "P1")
VALVE: 45-55 PSI (3,1-3,8 Bar) 2950-3050 PSI (203-210 Bar) PILOT ACTIVATED DIRECTIONAL
at Front Quick Couplers 37 56 SOLENOID ACTIVATED PRESSURE
5 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - FOR REAR AUXILIARY - CONTROL VALVE
CONTROL VALVE - HYDRAULIC 20 RELIEF VALVE - PORT: NORMALLY OPEN ("D2" and "P2") 0-2000 PSI (0-138 Bar)
POWERED BOB-TACH 3500 PSI (241 Bar) FILTER - DIVERTER VALVE (SCREEN)
38 57 STEERING CYLINDER
21 ANTICAVITATION VALVE INTEGRATED IN SOLENOID
6 DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (2,5-3,0 Bar) SOLENOID ACTIVATED DIRECTIONAL 58 CHECK VALVE - 270 PSI (18,6 Bar)
22 RELIEF/ANTICAVITATION VALVE - 39 CONTROL VALVE - TO ACTIVATE REAR
FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END) AUXILIARY ("SV1") 59 PRESSURE CONTROL PILOT
7
3500 PSI (241 Bar)
40 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - 2 COILS
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE VALVE - FOR REAR AUXILIARY - NORMALLY 0 - 0.085 Ampere
VALVE CLOSED ("P1" and "F1")
24 SOLENOID ACTIVATED DIRECTIONAL 41 CHECK VALVE - BICS CONTROL VALVE 60 DISPLACEMENT CONTROL SPOOL
9 FIXED CAPACITY DISPLACEMENT
CONTROL VALVE - AUXILIARY
BIDIRECTIONAL HYDROSTATIC 42 LIFT ARM BY-PASS RESTRICTOR
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional)
3500 PSI (241 Bar) 43 CHECK VALVE - AUXILIARY
10 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH
44 PUMP SERVO
SPOOL PRESSURE: 5000 PSI (345 Bar)
11 PILOT ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH 45 VARIABLE CAPACITY DISPLACEMENT
CONTROL VALVE - UNLOADING BIDIRECTIONAL HYDROSTATIC PUMP
SPOOL 28 RELIEF VALVE - CHARGE: 46 TWO-STAGE RELIEF
120 degrees F. (53 degrees C.)Fluid 1000/2000 PSI (69/138 Bar)
12 PILOT ACTIVATED DIRECTIONAL 350 PSI (24,1 Bar) at High Engine Idle
CONTROL VALVE - TILT CONTROL 47 SOLENOID ACTIVATED DIRECTIONAL
29 CHARGE PUMP CONTROL VALVE (TWO COIL)
13 PILOT ACTIVATED DIRECTIONAL 12.0 GPM (45,4 L/min.) at High Engine Idle 48 RELIEF VALVE - 1200 PSI (82,7 Bar)
CONTROL VALVE - LIFT CONTROL
30 HYDRAULIC PUMP . . . . . . . Gear Type
14 SOLENOID ACTIVATED DIRECTIONAL 20.0 GPM (75,8 L/min.) at High Engine Idle 49 RESTRICTOR - 0.015 inch (0,381 mm)
CONTROL VALVE - BICS CONTROL
31 DRIVE MOTOR SHUTTLE VALVE 50 PRESSURE COMPENSATED FLOW
15 PULL BUTTON ACTIVATED CONTROL
DIRECTIONAL CONTROL VALVE - LIFT 32 SHUTTLE RELIEF VALVE:
ARM BY-PASS 200 PSI (13,8 Bar) 51 RELIEF VALVE - PORT:
3500 PSI (241 Bar)
33 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR NOTE: Unless otherwise specified
52 SOLENOID ACTIVATED DIRECTIONAL
AUXILIARY ("SV2") springs have NO significant
CONTROL VALVE - BUCKET POSITION
pressure value.
VALVE (ON/OFF)
Printed in U.S.A. V-0110legend (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
S/N 519611001 - 519611123
S/N 519711001 - 519711003 DIVERTER VALVE (OPTIONAL)
(PRINTED APRIL 2004)
V-0110 38
HYDROSTATIC M2 M1
PUMP
Printable Version Click Here 26 PILOT
39
26
STEERING VALVE
28 57 55 55 57
CHARGE M3
DRIVE MOTOR INLET 40 36
MALE MALE F1 D1 MALE
29
M4
45
31 M 34
32 44 CASE 58 58
5 (REAR QUICK
DRAIN COUPLERS)
33 35 37
60
F2 D2
FEMALE
Control FEMALE FEMALE
Module 58 58
9 (EDC) 55
P1 P2
59 55 57
57
56
X1 X2
P T
X2 X1
Control
Module 59
(EDC)
54
HYDROSTATIC HYDRAULIC FILTER
PUMP
3
BUCKET POSITION VALVE (OPTIONAL)
60
OIL
4 D
COOLER
8
M4
M
5 45 44
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
HYDRAULIC CONTROL VAVLE 10
28 BOB-TACH
43
CASE CYLINDER
DRAIN (OPTIONAL) 11
27
M2 M1
HYDRAULIC 24 24
25 B
POWERED
BOB-TACH A B
(OPTIONAL)
30
OUTLET AUXILIARY
SPOOL
INLET
53
OUTLET 23 TILT CYLINDER
22
INLET 48 BICS CONTROL VALVE
47
46
50
A B 12
DR TILT
51
49 CYLINDER
SPOOL
P1 P2
5 21
DRIVE MOTOR
18
PP
20 LIFT CYLINDERS
9 17
13
A B
LIFT
CYLINDER
SPOOL
31 32
18 42
19 14 WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
DRAIN CIRCUITS
2 COMPONENTS
LIFT ARM BY- PASS
VALVE
15
Printed in U.S.A.
V-0110 (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE OPTION
S/N 519611001 - 519611084
S/N 519711001 - 519711003
(PRINTED APRIL 2004) Printable Version Click Here
V-0104legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 34 LOAD SHUTTLE VALVE - BLEED OFF 53 FIXED CAPACITY DISPLACEMENT
Capacity . . . . . . . . . . 18.8 Qts. (17.8 L) (SCREEN) BIDIRECTIONAL HYDROSTATIC
35 PILOT ACTIVATED DIRECTIONAL CONTROL MOTOR
2 FILTER - CASE DRAIN (90 Micron) 17 ONE WAY RESTRICTOR - BOOM DOWN VALVE - FOR REAR AUXILIARY - NORMALLY 54 HYDRAULIC BRAKE - SPRING APPLIED -
CLOSED. ("P2" and "F2") PRESSURE TO RELEASE
3 18 LOAD CHECK VALVE - LIFT AND TILT
FILTER - HYDRAULIC (CANISTER) 36 PILOT ACTIVATED DIRECTIONAL CONTROL
VALVE - FOR REAR AUXILIARY - NORMALLY 55 PUSH BUTTON SOLENOID ACTIVATED
4 SPRING LOADED FILTER BY-PASS 19 RELIEF VALVE - MAIN: DIRECTIONAL CONTROL VALVE -
2950-3050 PSI (203-210 Bar) OPEN ("D1" and "P1")
VALVE: 45-55 PSI (3,1-3,8 Bar) BRAKE
at Front Quick Couplers 37 PILOT ACTIVATED DIRECTIONAL
5 PILOT ACTIVATED DIRECTIONAL 56 SOLENOID ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: CONTROL VALVE - FOR REAR AUXILIARY -
CONTROL VALVE - HYDRAULIC CONTROL VALVE - MAKE-UP
3500 PSI (241 Bar) NORMALLY OPEN ("D2" and "P2")
POWERED BOB-TACH
38 FILTER - DIVERTER VALVE (SCREEN) 57 SOLENOID ACTIVATED DIRECTIONAL
21 ANTICAVITATION VALVE
6 DIFFERENTIAL PRESSURE SWITCH: INTEGRATED IN SOLENOID CONTROL VALVE - TWO SPEED
36-44 PSI (2,5-3,0 Bar) 22 RELIEF/ANTICAVITATION VALVE - 39 SOLENOID ACTIVATED DIRECTIONAL 58 BRAKE DIAGNOSTIC PLUG
FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END) CONTROL VALVE - TO ACTIVATE REAR
7 59 PILOT ACTIVATED DIRECTIONAL
3500 PSI (241 Bar) AUXILIARY ("SV1")
40 PILOT ACTIVATED DIRECTIONAL CONTROL CONTROL VALVE - TWO SPEED
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE
VALVE - FOR REAR AUXILIARY - NORMALLY DRIVE MOTOR
VALVE
CLOSED ("P1" and "F1") 60 PUMP SERVO
24 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT 41 CHECK VALVE - BICS CONTROL VALVE
CONTROL VALVE - AUXILIARY 61 HYDRAULIC STEERING PUMP - Gear Type
BIDIRECTIONAL HYDROSTATIC
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 42 LIFT ARM BY-PASS RESTRICTOR 13.0 GPM (49,2 L/min.) at High Engine Idle
3500 PSI (241 Bar) 62 FILTER - STEERING (10 MICRON)
10 PILOT ACTIVATED DIRECTIONAL 43 CHECK VALVE - AUXILIARY
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH 63 SOLENOID ACTIVATED
SPOOL PRESSURE: 5000 PSI (345 Bar) 44 DISPLACEMENT CONTROL SPOOL PROPORTIONAL FLOW CONTROL
VALVE - STEERING
11 PILOT ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH 45 VARIABLE CAPACITY DISPLACEMENT 64 SOLENOID ACTIVATED PRESSURE
CONTROL VALVE - UNLOADING BIDIRECTIONAL HYDROSTATIC PUMP CONTROL VALVE
SPOOL 28 RELIEF VALVE - CHARGE: 0-2000 PSI (138 Bar)
46 TWO-STAGE RELIEF
12 PILOT ACTIVATED DIRECTIONAL 120 degrees F. (53 degrees C.)Fluid 65 STEERING CYLINDER
1000/2000 PSI (69 / 138 Bar)
CONTROL VALVE - TILT CONTROL 350 PSI (24,1 Bar) at High Engine Idle
47 66 CHECK VALVE - 270 PSI (18,6 Bar)
SOLENOID ACTIVATED DIRECTIONAL
13 PILOT ACTIVATED DIRECTIONAL 29 CHARGE PUMP CONTROL VALVE (TWO COIL) 67 PRESSURE CONTROL PILOT
CONTROL VALVE - LIFT CONTROL 12.0 GPM (45,4 L/min.) at High Engine Idle
48 RELIEF VALVE - 1200 PSI (82,7 Bar) VALVE - 2 COILS
14 SOLENOID ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . . . Gear Type 0 - 0.085 Ampere
CONTROL VALVE - BICS CONTROL 20.0 GPM (75,8 L/min.) at High Engine Idle 49 RESTRICTOR - 0.015 inch (0,381 mm)
15 PULL BUTTON ACTIVATED 31 DRIVE MOTOR SHUTTLE VALVE
DIRECTIONAL CONTROL VALVE - 50 PRESSURE COMPENSATED FLOW
LIFT ARM BY-PASS 32 SHUTTLE RELIEF VALVE: CONTROL
200 PSI (13,8 Bar) 51 RELIEF VALVE - PORT:
33 SOLENOID ACTIVATED DIRECTIONAL 3500 PSI (241 Bar)
CONTROL VALVE - BLEED OFF REAR 52 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
AUXILIARY ("SV2") CONTROL VALVE - BUCKET POSITION springs have NO significant
VALVE (ON/OFF) pressure value.
Printed in U.S.A. V-0104legend (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE OPTION
S/N 519611001 - 519611084
S/N 519711001 - 519711003 DIVERTER VALVE (OPTIONAL)
(PRINTED APRIL 2004)
V-0104 38
Printable Version Click Here HYDROSTATIC PILOT
39
M2 M1
PUMP
26 26
TWO SPEED DRIVE MOTOR
STEERING VALVE
40 36 65 65
28 63 63
CHARGE M3 MALE MALE F1 D1
31 32 INLET MALE
29
M4 34
45 (REAR QUICK (FRONT AUXILIARY
M COUPLERS) LEFT SIDE LIFT ARM
60 CASE 66 66
5
DRAIN
33 35 37
F2 D2
FEMALE
59 44 FEMALE FEMALE
54
53 Control P1 P2
Module 66 66
(EDC) 67 63
9 63
65
65
64
X1 X2
P T
X2 X1
Control
Module 67
(EDC)
62
HYDROSTATIC HYDRAULIC FILTER
PUMP
3
BUCKET POSITION VALVE (OPTIONAL)
44 OIL
4 D
COOLER
8
M4
M
5 60
45
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
HYDRAULIC CONTROL VAVLE 10
28 BOB-TACH
43
CASE CYLINDER
DRAIN (OPTIONAL) 11
M2 M1 HYDRAULIC 27
POWERED
BOB-TACH 24 24
(OPTIONAL) 25 B
A B
30
OUTLET AUXILIARY
SPOOL
58 INLET
61
OUTLET 23
TWO SPEED VALVE TILT CYLINDER
B1 22
INLET BICS CONTROL VALVE
48
47
55 46
B 50
TWO SPEED DRIVE MOTOR
A B 12
DR TILT
56 9 49 51
CYLINDER
P2 SPOOL
P1
5 21
54 53
C PP
18
P D 59 20 LIFT CYLINDERS
17
13
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
19 14 WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
T DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY- PASS
VALVE
15
Printed in U.S.A.
V-0104 (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
S/N 519611001 - 519611123
S/N 519711001 - 519711003
(PRINTED APRIL 2004)
V-0109legend Printable Version Click Here
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 34 LOAD CHECK VALVE - SELECT VALVE 53 HYDRAULIC HIGH FLOW PUMP - Gear Type
Capacity . . . . . . . . . . . 18.8 Qts. (17.8 L) (SCREEN) (HIGH FLOW) 10.0 GPM (37,9 L/min.) at High Engine Idle
2 17 ONE WAY RESTRICTOR - BOOM DOWN 35 SOLENOID ACTIVATED DIRECTIONAL 54 SELECT VALVE RESTRICTOR
FILTER - CASE DRAIN (90 Micron)
CONTROL VALVE - HIGH FLOW
3 18 LOAD CHECK VALVE - LIFT AND TILT 55 HYDRAULIC STEERING PUMP - Gear Type
FILTER - HYDRAULIC (CANISTER)
36 SOLENOID ACTIVATED DIRECTIONAL
13.0 GPM (49,2 L/min.) at High Engine Idle
4 SPRING LOADED FILTER BY-PASS 19 RELIEF VALVE - MAIN: CONTROL VALVE - DIVERTER
VALVE: 45-55 PSI (3,1-3,8 Bar) 2950-3050 PSI (203 -210 Bar) 56 FILTER - STEERING (10 MICRON)
at Front Quick Couplers 37 RELIEF VALVE - MAIN (HIGH FLOW)
5 PILOT ACTIVATED DIRECTIONAL 3000 PSI (207 Bar) 57 SOLENOID ACTIVATED
CONTROL VALVE - HYDRAULIC 20 RELIEF VALVE - PORT: PROPORTIONAL FLOW CONTROL
POWERED BOB-TACH 3500 PSI (241 Bar) 38 VALVE - STEERING
SOLENOID ACTIVATED DIRECTIONAL
21 ANTICAVITATION VALVE CONTROL VALVE (TWO COIL)
6 DIFFERENTIAL PRESSURE SWITCH: 58 SOLENOID ACTIVATED PRESSURE
36-44 PSI (2,5-3,0 Bar) CONTROL VALVE
22 RELIEF/ANTICAVITATION VALVE - 39 PILOT TO OPEN CHECK VALVE
0-2000 PSI (0-138 Bar)
FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END)
7
3500 PSI (241 Bar) 40 SOLENOID ACTIVATED DIRECTIONAL 59 STEERING CYLINDER
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE CONTROL VALVE - BLEED OFF
60 CHECK VALVE - 270 PSI (18,6 Bar)
VALVE
41 CHECK VALVE - BICS CONTROL VALVE
24 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT 61 PRESSURE CONTROL PILOT
CONTROL VALVE - AUXILIARY 42 LIFT ARM BY-PASS RESTRICTOR
BIDIRECTIONAL HYDROSTATIC VALVE - 2 COILS
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 0 - 0.085 Ampere
3500 PSI (241 Bar) 43 CHECK VALVE - AUXILIARY
10 PILOT ACTIVATED DIRECTIONAL 62 DISPLACEMENT CONTROL SPOOL
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH 44 FILTER - CASE DRAIN (Attachment)
SPOOL PRESSURE: 5000 PSI (345 Bar) 63 PUMP SERVO
45 VARIABLE CAPACITY DISPLACEMENT
11 PILOT ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH
BIDIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - UNLOADING 46
28 RELIEF VALVE - CHARGE: TWO-STAGE RELIEF
SPOOL
120 degrees F. (53 degrees C.)Fluid 1000/2000 PSI (69/138 Bar)
12 PILOT ACTIVATED DIRECTIONAL 350 PSI (24,1 Bar) at High Engine Idle 47 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL CONTROL VALVE (TWO COIL)
29 CHARGE PUMP
13 PILOT ACTIVATED DIRECTIONAL 12.0 GPM (45,4 L/min.) at High Engine Idle 48 RELIEF VALVE - 1200 PSI (82,7 Bar)
CONTROL VALVE - LIFT CONTROL
30 HYDRAULIC PUMP . . . . . . . . . . Gear Type 49 RESTRICTOR - 0.015 inch (0,381 mm)
14 SOLENOID ACTIVATED DIRECTIONAL 20.0 GPM (75,8 L/min.) at High Engine Idle
CONTROL VALVE - BICS CONTROL
31 DRIVE MOTOR SHUTTLE VALVE 50 PRESSURE COMPENSATED FLOW
15 PULL BUTTON ACTIVATED CONTROL
DIRECTIONAL CONTROL VALVE - LIFT 32 SHUTTLE RELIEF VALVE: 51 RELIEF VALVE - PORT:
ARM BY-PASS 200 PSI (13,8 Bar) 3500 PSI (241 Bar)
33 REAR AUXILIARY BLEED SHUTTLE 52 SOLENOID ACTIVATED DIRECTIONAL
VALVE CONTROL VALVE - BUCKET POSITION NOTE: Unless otherwise specified
VALVE (ON/OFF) springs have NO significant
pressure value.
Printed in U.S.A. V-0109legend (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
S/N 519611001 - 519611123
S/N 519711001 - 519711003
(PRINTED APRIL 2004)
V-0109 HYDROSTATIC M2 M1
PUMP
Printable Version Click Here 26 26
STEERING
VALVE
28 59 57 57 59
CHARGE M3
DRIVE MOTOR INLET
29
SELECT VALVE C2 C1
M4
(RIGHT SIDE LIFT ARM
45 QUICK COUPLERS)
31 M 40
32 63 CASE 60 60
5
MALE
MALE
FEMALE
FEMALE
DRAIN
33
39 39
62 (REAR QUICK COUPLERS)
Control
Module 54 61 60 60
9 (EDC) 57
57
61 38 34
59 59
58
X1 X2 FEMALE
PRESS PB
X2 X1 36 (FRONT AUXILIARY
Control LEFT SIDE LIFT ARM)
61
Module 37 35
(EDC)
MALE
T
DRAIN 56
HYDROSTATIC HYDRAULIC FILTER (MALE)
PUMP 44
3
BUCKET POSITION VALVE (OPTIONAL)
OIL
62 4 D
COOLER
8
M4
M
5 63
45
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
HYDRAULIC CONTROL VAVLE 10
28
BOB-TACH
43
CASE CYLINDER
DRAIN (OPTIONAL) 11
M2 M1 27
HYDRAULIC 24 24
25 B
POWERED
BOB-TACH A B
(OPTIONAL)
30
OUTLET AUXILIARY
SPOOL
INLET
55
OUTLET 23
TILT CYLINDER
22
INLET BICS CONTROL VALVE
48
47
OUTLET
46
53 50
A B 12
DR TILT
51
49 CYLINDER
SPOOL
P1 P2
5 21
DRIVE MOTOR
18
20 LIFT CYLINDERS
9 17
13
A B
LIFT
CYLINDER
SPOOL
31 32
18 42
19 14 WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
DRAIN CIRCUITS
2 COMPONENTS
LIFT ARM BY- PASS
VALVE
15
1
Printed in U.S.A.
V-0109 (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW AND TWO SPEED VALVE OPTION
S/N 519611001 - 519611084
S/N 519711001 - 519711003
(PRINTED APRIL 2004) Printable Version Click Here
V-0101legend
LEGEND
1 RESERVOIR: 19 RELIEF VALVE - MAIN: 37 RELIEF VALVE - MAIN (HIGH FLOW) 56 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . 18.8 Qts. (17.8 L) 2950-3050 PSI (203-210 Bar) 3000 PSI (207 Bar) CONTROL VALVE - MAKE-UP
2 FILTER - CASE DRAIN (90 Micron) at Front Quick Couplers
38 57 SOLENOID ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
3 FILTER - HYDRAULIC (CANISTER) 3500 PSI (241 Bar) CONTROL VALVE (TWO COIL)
58 BRAKE DIAGNOSTIC PLUG
SPRING LOADED FILTER BY-PASS 21 ANTICAVITATION VALVE 39 PILOT TO OPEN CHECK VALVE
4
VALVE: 45-55 PSI (3,1-3,8 Bar)
22 RELIEF/ANTICAVITATION VALVE - 59 PILOT ACTIVATED DIRECTIONAL
40 SOLENOID ACTIVATED DIRECTIONAL
5 PILOT ACTIVATED DIRECTIONAL PORT (TILT BASE END) CONTROL VALVE - TWO SPEED
CONTROL VALVE - BLEED OFF
CONTROL VALVE - HYDRAULIC 3500 PSI (241 Bar) DRIVE MOTOR
POWERED BOB-TACH 41 CHECK VALVE - BICS CONTROL VALVE
23 ONE WAY RESTRICTOR VALVE 60 HYDRAULIC HIGH FLOW PUMP - Gear Type
6 DIFFERENTIAL PRESSURE SWITCH: 10.0 GPM (37,9 L/min.) at High Engine Idle
42 LIFT ARM BY-PASS RESTRICTOR
36-44 PSI (2,5-3,0 Bar) 24 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY 61 SELECT VALVE RESTRICTOR
7 FLOW DIVIDER ADJUSTMENT VALVE 43 CHECK VALVE - AUXILIARY
25 RELIEF VALVE - PORT: . . . . . (Optional) 62 HYDRAULIC STEERING PUMP- Gear Type
8 CHECK VALVE - BUCKET POSITION 44 FILTER - CASE DRAIN (Attachment)
3500 PSI (241 Bar) 13.0 GPM (49,2 L/min.) at High Engine Idle
VALVE
26 RELIEF/REPLENISHING VALVE - HIGH 45 VARIABLE CAPACITY DISPLACEMENT 63 FILTER - STEERING (10 MICRON)
9 FIXED CAPACITY DISPLACEMENT
PRESSURE: 5000 PSI (345 Bar) BIDIRECTIONAL HYDROSTATIC PUMP
BIDIRECTIONAL HYDROSTATIC
27 CHARGE PRESSURE SWITCH 46 TWO-STAGE RELIEF 64 SOLENOID ACTIVATED
MOTOR
1000/2000 PSI (69/138 Bar) PROPORTIONAL FLOW CONTROL
10 PILOT ACTIVATED DIRECTIONAL 28 RELIEF VALVE - CHARGE: 47 VALVE - STEERING
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL 120 degrees F. (53 degrees C.)Fluid CONTROL VALVE (TWO COIL) 65 SOLENOID ACTIVATED PRESSURE
SPOOL 350 PSI (24,1 Bar) at High Engine Idle CONTROL VALVE
48 RELIEF VALVE - 1200 PSI (82,7 Bar)
11 PILOT ACTIVATED DIRECTIONAL 0-2000 PSI (138 Bar)
29 CHARGE PUMP
CONTROL VALVE - UNLOADING 49
12.0 GPM (45,4 L/min.) at High Engine Idle RESTRICTOR - 0.015 inch (0,381 mm) 66 STEERING CYLINDER
SPOOL
30 HYDRAULIC PUMP . . . . . . . . . Gear Type
12 PILOT ACTIVATED DIRECTIONAL 50 PRESSURE COMPENSATED FLOW 67 CHECK VALVE - 270 PSI (18,6 Bar)
CONTROL VALVE - TILT CONTROL 20.0 GPM (75,8 L/min.) at High Engine Idle
CONTROL
31 DRIVE MOTOR SHUTTLE VALVE 68 PRESSURE CONTROL PILOT
13 PILOT ACTIVATED DIRECTIONAL 51 RELIEF VALVE - PORT:
CONTROL VALVE - LIFT CONTROL 3500 PSI (241 Bar) VALVE - 2 COILS
32 SHUTTLE RELIEF VALVE: 0 - 0.085 Ampere
14 SOLENOID ACTIVATED DIRECTIONAL 200 PSI (13,8 Bar) 52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL CONTROL VALVE - BUCKET POSITION 69 DISPLACEMENT CONTROL SPOOL
33 REAR AUXILIARY BLEED SHUTTLE VALVE VALVE (ON/OFF)
15 PULL BUTTON ACTIVATED
53 FIXED CAPACITY DISPLACEMENT 70 PUMP SERVO
DIRECTIONAL CONTROL VALVE - LIFT 34 LOAD CHECK VALVE - SELECT VALVE
ARM BY-PASS (HIGH FLOW) BIDIRECTIONAL HYDROSTATIC
MOTOR
16 FILTER - BICS CONTROL VALVE 35 SOLENOID ACTIVATED DIRECTIONAL 54 HYDRAULIC BRAKE - SPRING APPLIED -
(SCREEN) CONTROL VALVE - HIGH FLOW PRESSURE TO RELEASE
17 ONE WAY RESTRICTOR - BOOM DOWN
36 SOLENOID ACTIVATED DIRECTIONAL 55 PUSH BUTTON SOLENOID ACTIVATED
DIRECTIONAL CONTROL VALVE - NOTE: Unless otherwise specified
CONTROL VALVE - DIVERTER
18 LOAD CHECK VALVE- LIFT AND TILT BRAKE springs have NO significant
pressure value.
Printed in U.S.A. V-0101legend (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW AND TWO SPEED VALVE OPTION
S/N 519611001 -519611084
S/N 519711001 - 519711003
(PRINTED APRIL 2004)
V-0101 HYDROSTATIC
M2 M1
PUMP
Printable Version Click Here 26 26
TWO SPEED DRIVE MOTOR
STEERING VALVE
28 66 64 64 66
CHARGE
M3
31 32 INLET
29
SELECT VALVE C1 C2
M4
45 (RIGHT SIDE LIFT ARM
CASE QUICK COUPLERS)
M
70 40 67 67
5 DRAIN
MALE
MALE
FEMALE
FEMALE
33
39 39
59 69 (REAR QUICK COUPLERS)
54
53 Control
Module 61 61 67 67
(EDC) 64
9 68 34 64
38 66 66
65
X1 X2 FEMALE
PRESS P T
(FRONT AUXILIARY
X2 X1 36 LEFT SIDE LIFT ARM)
Control
Module 68 PB MALE 63
37 35
(EDC)
T
DRAIN
HYDROSTATIC HYDRAULIC FILTER (MALE)
PUMP 44
3
BUCKET POSITION VALVE (OPTIONAL)
69 OIL
COOLER D
8
M4
M
5 70
45
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
HYDRAULIC CONTROL VAVLE 10
28 BOB-TACH
43
CYLINDER
CASE
(OPTIONAL) 11
DRAIN
M2 M1 27
HYDRAULIC 24 24
POWERED 25 B
BOB-TACH A B
(OPTIONAL)
30
OUTLET AUXILIARY
SPOOL
58 INLET
62
OUTLET 23
TWO SPEED VALVE TILT CYLINDER
B1 22
INLET BICS CONTROL VALVE
48
47
OUTLET
55 46
B 60 50
TWO SPEED DRIVE MOTOR
A B 12
DR 49 TILT
56 9 51
CYLINDER
SPOOL
P1 P2
5 21
54 53
C
18
P D 59 20 LIFT CYLINDERS
17
13
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
19 14 WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
T DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY- PASS
VALVE
15
Printed in U.S.A.
V-0101 (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE OPTION
S/N 519611085 - 519611123
S/N 5197 (None built with this S/N break)
(PRINTED APRIL 2004) Printable Version Click Here
V-0270legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 34 LOAD SHUTTLE VALVE - BLEED OFF
52 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . . . . . 18.8 Qts. (17.8 L) (SCREEN)
35 PILOT ACTIVATED DIRECTIONAL CONTROL CONTROL VALVE - BUCKET POSITION
2 FILTER - CASE DRAIN (90 Micron) 17 ONE WAY RESTRICTOR - BOOM DOWN VALVE - FOR REAR AUXILIARY - NORMALLY VALVE (ON/OFF)
CLOSED. ("P2" and "F2") 53 FIXED CAPACITY DISPLACEMENT
3 18 LOAD CHECK VALVE - LIFT AND TILT
FILTER - HYDRAULIC (CANISTER) 36 PILOT ACTIVATED DIRECTIONAL CONTROL BIDIRECTIONAL HYDROSTATIC
19 RELIEF VALVE - MAIN: VALVE - FOR REAR AUXILIARY - NORMALLY MOTOR
4 SPRING LOADED FILTER BY-PASS
2950-3050 PSI (203-210 Bar) OPEN ("D1" and "P1")
VALVE: 45-55 PSI (3,1-3,8 Bar) 54 HYDRAULIC BRAKE - SPRING APPLIED -
at Front Quick Couplers 37 PILOT ACTIVATED DIRECTIONAL PRESSURE TO RELEASE
5 PILOT ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: CONTROL VALVE - FOR REAR AUXILIARY -
CONTROL VALVE - HYDRAULIC 55 PUSH BUTTON SOLENOID ACTIVATED
3500 PSI (241 Bar) NORMALLY OPEN ("D2" and "P2")
POWERED BOB-TACH DIRECTIONAL CONTROL VALVE -
21 ANTICAVITATION VALVE 38 FILTER - DIVERTER VALVE (SCREEN)
6 DIFFERENTIAL PRESSURE SWITCH: BRAKE
INTEGRATED IN SOLENOID
36-44 PSI (2,5-3,0 Bar) 22 RELIEF/ANTICAVITATION VALVE - 39 SOLENOID ACTIVATED DIRECTIONAL 56 SOLENOID ACTIVATED DIRECTIONAL
PORT (TILT BASE END) CONTROL VALVE - TO ACTIVATE REAR CONTROL VALVE - MAKE-UP
7 FLOW DIVIDER ADJUSTMENT VALVE
3500 PSI (241 Bar) AUXILIARY ("SV1") 57 SOLENOID ACTIVATED DIRECTIONAL
8 CHECK VALVE - BUCKET POSITION 40 PILOT ACTIVATED DIRECTIONAL CONTROL CONTROL VALVE - TWO SPEED
23 ONE WAY RESTRICTOR VALVE
VALVE VALVE - FOR REAR AUXILIARY - NORMALLY
CLOSED ("P1" and "F1") 58 DISPLACEMENT CONTROL SPOOL
24 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT 41 CHECK VALVE - BICS CONTROL VALVE 59 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
BIDIRECTIONAL HYDROSTATIC
CONTROL VALVE - TWO SPEED
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 42 LIFT ARM BY-PASS RESTRICTOR
DRIVE MOTOR
3500 PSI (241 Bar)
10 PILOT ACTIVATED DIRECTIONAL 43 CHECK VALVE - AUXILIARY 60 PUMP SERVO
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH
SPOOL PRESSURE: 5000 PSI (345 Bar) 44 PRESSURE CONTROL PILOT 61 HYDRAULIC STEERING PUMP - Gear Type
VALVE - 2 COILS 13.0 GPM (49,2 L/min.) at High Engine Idle
11 PILOT ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH
0 - 0.085 Ampere 62 FILTER - STEERING (10 MICRON)
CONTROL VALVE - UNLOADING
SPOOL 28 RELIEF VALVE - CHARGE: 45 VARIABLE CAPACITY DISPLACEMENT 63 SOLENOID ACTIVATED
120 degrees F. (53 degrees C.)Fluid BIDIRECTIONAL HYDROSTATIC PUMP PROPORTIONAL FLOW CONTROL
12 PILOT ACTIVATED DIRECTIONAL VALVE - STEERING
CONTROL VALVE - TILT CONTROL 350 PSI (24,1 Bar) at High Engine Idle 46 TWO-STAGE RELIEF
1000/2000 PSI (69 / 138 Bar) 64 SOLENOID ACTIVATED PRESSURE
13 PILOT ACTIVATED DIRECTIONAL 29 CHARGE PUMP CONTROL VALVE
CONTROL VALVE - LIFT CONTROL 12.0 GPM (45,4 L/min.) at High Engine Idle 47 SOLENOID ACTIVATED DIRECTIONAL 0-2000 PSI (0-138 Bar)
CONTROL VALVE (TWO COIL) 65 STEERING CYLINDER
14 SOLENOID ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . . . Gear Type
CONTROL VALVE - BICS CONTROL 20.0 GPM (75,8 L/min.) at High Engine Idle 48 RELIEF VALVE - 1200 PSI (82,7 Bar) 66 CHECK VALVE - 270 PSI (18,6 Bar)
15 PULL BUTTON ACTIVATED 31 DRIVE MOTOR SHUTTLE VALVE 49 RESTRICTOR - 0.015 inch (0,381 mm)
DIRECTIONAL CONTROL VALVE -
LIFT ARM BY-PASS 32 SHUTTLE RELIEF VALVE:
50 PRESSURE COMPENSATED FLOW
200 PSI (13,8 Bar)
CONTROL
33 SOLENOID ACTIVATED DIRECTIONAL 51 RELIEF VALVE - PORT: NOTE: Unless otherwise specified
CONTROL VALVE - BLEED OFF REAR
3500 PSI (241 Bar) springs have NO significant
AUXILIARY ("SV2")
pressure value.
Printed in U.S.A. V-0270legend (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE OPTION
S/N 519611085 - 519611123
S/N 5197 (No machines built DIVERTER VALVE (OPTIONAL)
with S/N break) 38
(PRINTED April 2004)
V-0270 39
HYDROSTATIC M2 M1 PILOT
Printable Version Click Here PUMP
26 26
TWO SPEED DRIVE MOTOR
STEERING VALVE
40 36 65 65
28 63 63
CHARGE M3 MALE MALE F1 D1
31 32 INLET MALE
29
M4 34
45 (REAR QUICK (FRONT AUXILIARY
M COUPLERS) LEFT SIDE LIFT ARM
60 CASE 66 66
5
DRAIN
33 35 37
F2 D2
FEMALE
59 58 FEMALE FEMALE
54
53 Control P1 P2
Module 66 66
(EDC) 44 63
9 63
65
65
64
X1 X2
P T
X2 X1
Control
Module 44
(EDC)
62
HYDROSTATIC HYDRAULIC FILTER
PUMP
3
BUCKET POSITION VALVE (OPTIONAL)
58 OIL
4 D
COOLER
8
M4
M
5 60
45
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
HYDRAULIC CONTROL VAVLE 10
28 BOB-TACH
43
CASE CYLINDER
DRAIN (OPTIONAL) 11
M2 M1 HYDRAULIC 27
POWERED
BOB-TACH 24 24
(OPTIONAL) 25 B
A B
30
OUTLET AUXILIARY
SPOOL
INLET
61
OUTLET 23
TWO SPEED VALVE TILT CYLINDER
22
INLET BICS CONTROL VALVE
48
47
55
46
B
50
TWO SPEED DRIVE MOTOR
A B 12
DR TILT
56 9 49 51
CYLINDER
P2 SPOOL
P1
5 21
54 53
C PP
18
P D 59 20 LIFT CYLINDERS
17
13
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
19 14 WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
TT DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY- PASS
VALVE
15
Printed in U.S.A.
V-0270 (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW AND TWO SPEED VALVE OPTION
S/N 519611085 - 519611123
S/N 5197 (No machines built with this S/N break)
(PRINTED APRIL 2004) Printable Version Click Here
V-0267legend
LEGEND
1 RESERVOIR: 19 RELIEF VALVE - MAIN: 37 RELIEF VALVE - MAIN (HIGH FLOW) 56 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . 18.8 Qts. (17.8 L) 2950-3050 PSI (203-210 Bar) 3000 PSI (207 Bar) CONTROL VALVE - MAKE-UP
2 FILTER - CASE DRAIN (90 Micron) at Front Quick Couplers
38 57 SOLENOID ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
3 FILTER - HYDRAULIC (CANISTER) 3500 PSI (241 Bar) CONTROL VALVE (TWO COIL)
58 BRAKE DIAGNOSTIC PLUG
SPRING LOADED FILTER BY-PASS 21 ANTICAVITATION VALVE 39 PILOT TO OPEN CHECK VALVE
4
VALVE: 45-55 PSI (3,1-3,8 Bar)
22 RELIEF/ANTICAVITATION VALVE - 59 PILOT ACTIVATED DIRECTIONAL
40 SOLENOID ACTIVATED DIRECTIONAL
5 PILOT ACTIVATED DIRECTIONAL PORT (TILT BASE END) CONTROL VALVE - TWO SPEED
CONTROL VALVE - BLEED OFF
CONTROL VALVE - HYDRAULIC 3500 PSI (241 Bar) DRIVE MOTOR
POWERED BOB-TACH 41 CHECK VALVE - BICS CONTROL VALVE
23 ONE WAY RESTRICTOR VALVE 60 HYDRAULIC HIGH FLOW PUMP - Gear Type
6 DIFFERENTIAL PRESSURE SWITCH: 10.0 GPM (37,9 L/min.) at High Engine Idle
42 LIFT ARM BY-PASS RESTRICTOR
36-44 PSI (2,5-3,0 Bar) 24 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY 61 SELECT VALVE RESTRICTOR
7 FLOW DIVIDER ADJUSTMENT VALVE 43 CHECK VALVE - AUXILIARY
25 RELIEF VALVE - PORT: . . . . . (Optional) 62 HYDRAULIC STEERING PUMP- Gear Type
8 CHECK VALVE - BUCKET POSITION 44 FILTER - CASE DRAIN (Attachment)
3500 PSI (241 Bar) 13.0 GPM (49,2 L/min.) at High Engine Idle
VALVE
26 RELIEF/REPLENISHING VALVE - HIGH 45 VARIABLE CAPACITY DISPLACEMENT 63 FILTER - STEERING (10 MICRON)
9 FIXED CAPACITY DISPLACEMENT
PRESSURE: 5000 PSI (345 Bar) BIDIRECTIONAL HYDROSTATIC PUMP
BIDIRECTIONAL HYDROSTATIC
27 CHARGE PRESSURE SWITCH 46 TWO-STAGE RELIEF 64 SOLENOID ACTIVATED
MOTOR
1000/2000 PSI (69/138 Bar) PROPORTIONAL FLOW CONTROL
10 PILOT ACTIVATED DIRECTIONAL 28 RELIEF VALVE - CHARGE: 47 VALVE - STEERING
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL 120 degrees F. (53 degrees C.)Fluid CONTROL VALVE (TWO COIL) 65 SOLENOID ACTIVATED PRESSURE
SPOOL 350 PSI (24,1 Bar) at High Engine Idle CONTROL VALVE
48 RELIEF VALVE - 1200 PSI (82,7 Bar)
11 PILOT ACTIVATED DIRECTIONAL 0-2000 PSI (0-138 Bar)
29 CHARGE PUMP
CONTROL VALVE - UNLOADING 49
12.0 GPM (45,4 L/min.) at High Engine Idle RESTRICTOR - 0.015 inch (0,381 mm) 66 STEERING CYLINDER
SPOOL
30 HYDRAULIC PUMP . . . . . . . . . Gear Type
12 PILOT ACTIVATED DIRECTIONAL 50 PRESSURE COMPENSATED FLOW 67 CHECK VALVE - 270 PSI (18,6 Bar)
CONTROL VALVE - TILT CONTROL 20.0 GPM (75,8 L/min.) at High Engine Idle
CONTROL
31 DRIVE MOTOR SHUTTLE VALVE 68 PRESSURE CONTROL PILOT
13 PILOT ACTIVATED DIRECTIONAL 51 RELIEF VALVE - PORT:
CONTROL VALVE - LIFT CONTROL 3500 PSI (241 Bar) VALVE - 2 COILS
32 SHUTTLE RELIEF VALVE: 0 - 0.085 Ampere
14 SOLENOID ACTIVATED DIRECTIONAL 200 PSI (13,8 Bar) 52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL CONTROL VALVE - BUCKET POSITION 69 DISPLACEMENT CONTROL SPOOL
33 REAR AUXILIARY BLEED SHUTTLE VALVE VALVE (ON/OFF)
15 PULL BUTTON ACTIVATED
53 FIXED CAPACITY DISPLACEMENT 70 PUMP SERVO
DIRECTIONAL CONTROL VALVE - LIFT 34 LOAD CHECK VALVE - SELECT VALVE
ARM BY-PASS (HIGH FLOW) BIDIRECTIONAL HYDROSTATIC
MOTOR
16 FILTER - BICS CONTROL VALVE 35 SOLENOID ACTIVATED DIRECTIONAL 54 HYDRAULIC BRAKE - SPRING APPLIED -
(SCREEN) CONTROL VALVE - HIGH FLOW PRESSURE TO RELEASE
17 ONE WAY RESTRICTOR - BOOM DOWN
36 SOLENOID ACTIVATED DIRECTIONAL 55 PUSH BUTTON SOLENOID ACTIVATED
DIRECTIONAL CONTROL VALVE - NOTE: Unless otherwise specified
CONTROL VALVE - DIVERTER
18 LOAD CHECK VALVE- LIFT AND TILT BRAKE springs have NO significant
pressure value.
Printed in U.S.A. V-0267legend (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW AND TWO SPEED VALVE OPTION
S/N 519611085 - 519611123
S/N 5197 (No machines
built with this S/N break)
(PRINTED APRIL 2004) HYDROSTATIC
M2 M1
V-0267 PUMP
26 26
Printable Version Click Here TWO SPEED DRIVE MOTOR
STEERING VALVE
28 66 64 64 66
CHARGE
M3
31 32 INLET
29
SELECT VALVE C1 C2
M4
45 (RIGHT SIDE LIFT ARM
CASE QUICK COUPLERS)
M
71 40 67 67
5 DRAIN
MALE
MALE
FEMALE
FEMALE
33
39 39
59 69 (REAR QUICK COUPLERS)
54
53 Control
Module 61 61 67 67
(EDC) 64
9 68 34 64
38 66 66
65
X1 X2 FEMALE
PRESS P T
(FRONT AUXILIARY
X2 X1 36 LEFT SIDE LIFT ARM)
Control
Module 68 PB MALE 63
37 35
(EDC)
T
DRAIN
HYDROSTATIC HYDRAULIC FILTER (MALE)
PUMP 44
3
BUCKET POSITION VALVE (OPTIONAL)
69 OIL
COOLER D
8
M4
M
5 71
45
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
HYDRAULIC CONTROL VAVLE 10
28 BOB-TACH
43
CYLINDER
CASE
(OPTIONAL) 11
DRAIN
M2 M1 27
HYDRAULIC 24 24
POWERED 25 B
BOB-TACH A B
(OPTIONAL)
30
OUTLET AUXILIARY
SPOOL
INLET
62
OUTLET 23
TWO SPEED VALVE TILT CYLINDER
22
INLET BICS CONTROL VALVE
48
47
OUTLET
55
46
B
60 50
TWO SPEED DRIVE MOTOR
A B 12
DR 49 TILT
56 9 51
CYLINDER
SPOOL
P1 P2
5 21
54 53
C
18
P D 59 20 LIFT CYLINDERS
17
13
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
19 14 WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
T DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY- PASS
VALVE
15
Printed in U.S.A.
V-0267 (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
S/N 519611124 - 519611311
S/N 519711004 - 519711140
(PRINTED APRIL 2004)
V-0273legend
Printable Version Click Here
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 34 LOAD SHUTTLE VALVE - BLEED OFF 53 HYDRAULIC STEERING PUMP - Gear Type
Capacity . . . . . . 18.8 Qts. (17.8 L) (SCREEN) 13.0 GPM (49,2 L/min.) at High Engine Idle
PILOT ACTIVATED DIRECTIONAL CONTROL
17 ONE WAY RESTRICTOR - BOOM DOWN 35 VALVE - FOR REAR AUXILIARY - NORMALLY 54 FILTER - STEERING (10 MICRON)
2 FILTER - CASE DRAIN (90 Micron)
CLOSED. ("P2" and "F2")
18 LOAD CHECK VALVE - LIFT AND TILT 55 SOLENOID ACTIVATED
3 FILTER - HYDRAULIC (CANISTER) 36 PILOT ACTIVATED DIRECTIONAL CONTROL PROPORTIONAL FLOW CONTROL
VALVE - FOR REAR AUXILIARY - NORMALLY
4 SPRING LOADED FILTER BY-PASS 19 RELIEF VALVE - MAIN: VALVE - STEERING
OPEN ("D1" and "P1")
VALVE: 45-55 PSI (3,1-3,8 Bar) 2950-3050 PSI (203-210 Bar) PILOT ACTIVATED DIRECTIONAL
at Front Quick Couplers 37 56 SOLENOID ACTIVATED PRESSURE
5 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - FOR REAR AUXILIARY - CONTROL VALVE
CONTROL VALVE - HYDRAULIC 20 RELIEF VALVE - PORT: NORMALLY OPEN ("D2" and "P2") 0-2000 PSI (0-138 Bar)
POWERED BOB-TACH 3500 PSI (241 Bar) FILTER - DIVERTER VALVE (SCREEN)
38 57 STEERING CYLINDER
21 ANTICAVITATION VALVE INTEGRATED IN SOLENOID
6 DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (2,5-3,0 Bar) SOLENOID ACTIVATED DIRECTIONAL 58 CHECK VALVE - 270 PSI (18,6 Bar)
22 RELIEF/ANTICAVITATION VALVE - 39 CONTROL VALVE - TO ACTIVATE REAR
FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END) AUXILIARY ("SV1") 59 PRESSURE CONTROL PILOT
7
3500 PSI (241 Bar)
40 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - 2 COILS
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE VALVE - FOR REAR AUXILIARY - NORMALLY 0 - 0.085 Ampere
VALVE CLOSED ("P1" and "F1")
24 SOLENOID ACTIVATED DIRECTIONAL 41 CHECK VALVE - BICS CONTROL VALVE 60 DISPLACEMENT CONTROL SPOOL
9 FIXED CAPACITY DISPLACEMENT
CONTROL VALVE - AUXILIARY
BIDIRECTIONAL HYDROSTATIC 42 LIFT ARM BY-PASS RESTRICTOR
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 61 FRONT AUXILIARY MANUAL
3500 PSI (241 Bar) PRESSURE BLEED-OFF VALVE
43 CHECK VALVE - AUXILIARY
10 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH 62 PUMP SERVO
44 FILTER - CASE DRAIN (Attachment)
SPOOL PRESSURE: 5000 PSI (345 Bar)
11 PILOT ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH 45 VARIABLE CAPACITY DISPLACEMENT
CONTROL VALVE - UNLOADING BIDIRECTIONAL HYDROSTATIC PUMP
SPOOL 28 RELIEF VALVE - CHARGE: 46 TWO-STAGE RELIEF
120 degrees F. (53 degrees C.)Fluid 1000/2000 PSI (69/138 Bar)
12 PILOT ACTIVATED DIRECTIONAL 350 PSI (24,1 Bara) at High Engine Idle
CONTROL VALVE - TILT CONTROL 47 SOLENOID ACTIVATED DIRECTIONAL
29 CHARGE PUMP CONTROL VALVE (TWO COIL)
13 PILOT ACTIVATED DIRECTIONAL 12.0 GPM (45,4 L/min.) at High Engine Idle 48 RELIEF VALVE - 1200 PSI (82,7 Bar)
CONTROL VALVE - LIFT CONTROL
30 HYDRAULIC PUMP . . . . . . . Gear Type
14 SOLENOID ACTIVATED DIRECTIONAL 20.0 GPM (75,8 L/min.) at High Engine Idle 49 RESTRICTOR - 0.015 inch (0,381 mm)
CONTROL VALVE - BICS CONTROL
31 DRIVE MOTOR SHUTTLE VALVE 50 PRESSURE COMPENSATED FLOW
15 PULL BUTTON ACTIVATED CONTROL
DIRECTIONAL CONTROL VALVE - LIFT 32 SHUTTLE RELIEF VALVE:
ARM BY-PASS 200 PSI (13,8 Bar) 51 RELIEF VALVE - PORT:
3500 PSI (241 Bar)
33 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR NOTE: Unless otherwise specified
52 SOLENOID ACTIVATED DIRECTIONAL
AUXILIARY ("SV2") springs have NO significant
CONTROL VALVE - BUCKET POSITION
pressure value.
VALVE (ON/OFF)
Printed in U.S.A. V-0273legend (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
S/N 519611124 - 519611311
S/N 519711004 - 519711140 DIVERTER VALVE (OPTIONAL)
(PRINTED APRIL 2004)
V-0273 38
HYDROSTATIC M2 M1
Printable Version Click Here PUMP
26 PILOT
39
26
STEERING VALVE
28 INTEGRATED QUICK 57 55 55 57
CHARGE M3
DRIVE MOTOR INLET COUPLER BLOCK
40 36
MALE MALE F1 D1 61
29
MALE
M4
45
31 M 34 MALE
32 62 CASE 58 58
5 (REAR QUICK
DRAIN COUPLERS)
FEMALE
33 35 37 61
60
F2 D2
Control FEMALE FEMALE
Module 58 58
9 (EDC) 55
P1 P2
59 55 57
57
56
X1 X2
P T
X2 X1 44
Control
Module 59
(EDC)
54
HYDROSTATIC HYDRAULIC FILTER
PUMP
3
BUCKET POSITION VALVE (OPTIONAL)
60
OIL
4 D
COOLER
8
M4
M
5 45 62
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
HYDRAULIC CONTROL VAVLE 10
28 BOB-TACH
43
CASE CYLINDER
DRAIN (OPTIONAL) 11
27
M2 M1
HYDRAULIC 24 24
25 B
POWERED
BOB-TACH A B
(OPTIONAL)
30
OUTLET AUXILIARY
SPOOL
INLET
53
OUTLET 23 TILT CYLINDER
22
INLET 48 BICS CONTROL VALVE
47
46
50
A B 12
DR TILT
51
49 CYLINDER
SPOOL
P1 P2
5 21
DRIVE MOTOR
18
PP
20 LIFT CYLINDERS
9 17
13
A B
LIFT
CYLINDER
SPOOL
31 32
18 42
19 14 WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
DRAIN CIRCUITS
2 COMPONENTS
LIFT ARM BY- PASS
VALVE
15
Printed in U.S.A.
V-0273 (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE OPTION
S/N 519611124 - 519611311
S/N 519711004 - 519711140
(PRINTED APRIL 2004) Printable Version Click Here
V-0271legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 34 LOAD SHUTTLE VALVE - BLEED OFF 53 FIXED CAPACITY DISPLACEMENT
Capacity . . . . . . . . . . 18.8 Qts. (17.8 L) (SCREEN) BIDIRECTIONAL HYDROSTATIC
35 PILOT ACTIVATED DIRECTIONAL CONTROL MOTOR
2 FILTER - CASE DRAIN (90 Micron) 17 ONE WAY RESTRICTOR - BOOM DOWN VALVE - FOR REAR AUXILIARY - NORMALLY 54 HYDRAULIC BRAKE - SPRING APPLIED -
CLOSED. ("P2" and "F2") PRESSURE TO RELEASE
3 18 LOAD CHECK VALVE - LIFT AND TILT
FILTER - HYDRAULIC (CANISTER) 36 PILOT ACTIVATED DIRECTIONAL CONTROL
VALVE - FOR REAR AUXILIARY - NORMALLY 55 PUSH BUTTON SOLENOID ACTIVATED
4 SPRING LOADED FILTER BY-PASS 19 RELIEF VALVE - MAIN: DIRECTIONAL CONTROL VALVE -
2950-3050 PSI (203-210 Bar) OPEN ("D1" and "P1")
VALVE: 45-55 PSI (3,1-3,8 Bar) BRAKE
at Front Quick Couplers 37 PILOT ACTIVATED DIRECTIONAL
5 PILOT ACTIVATED DIRECTIONAL 56 SOLENOID ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: CONTROL VALVE - FOR REAR AUXILIARY -
CONTROL VALVE - HYDRAULIC CONTROL VALVE - MAKE-UP
3500 PSI (241 Bar) NORMALLY OPEN ("D2" and "P2")
POWERED BOB-TACH
38 FILTER - DIVERTER VALVE (SCREEN) 57 SOLENOID ACTIVATED DIRECTIONAL
21 ANTICAVITATION VALVE
6 DIFFERENTIAL PRESSURE SWITCH: INTEGRATED IN SOLENOID CONTROL VALVE - TWO SPEED
36-44 PSI (2,5-3,0 Bar) 22 RELIEF/ANTICAVITATION VALVE - 39 SOLENOID ACTIVATED DIRECTIONAL 58 DISPLACEMENT CONTROL SPOOL
FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END) CONTROL VALVE - TO ACTIVATE REAR
7 59 PILOT ACTIVATED DIRECTIONAL
3500 PSI (241 Bar) AUXILIARY ("SV1")
40 PILOT ACTIVATED DIRECTIONAL CONTROL CONTROL VALVE - TWO SPEED
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE
VALVE - FOR REAR AUXILIARY - NORMALLY DRIVE MOTOR
VALVE
CLOSED ("P1" and "F1") 60 PUMP SERVO
24 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT 41 CHECK VALVE - BICS CONTROL VALVE
CONTROL VALVE - AUXILIARY 61 HYDRAULIC STEERING PUMP - Gear Type
BIDIRECTIONAL HYDROSTATIC
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 42 LIFT ARM BY-PASS RESTRICTOR 13.0 GPM (49,2 L/min.) at High Engine Idle
3500 PSI (241 Bar) 62 FILTER - STEERING (10 MICRON)
10 PILOT ACTIVATED DIRECTIONAL 43 CHECK VALVE - AUXILIARY
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH 63 SOLENOID ACTIVATED
SPOOL PRESSURE: 5000 PSI (345 Bar) 44 FILTER - CASE DRAIN (Attachment) PROPORTIONAL FLOW CONTROL
VALVE - STEERING
11 PILOT ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH 45 VARIABLE CAPACITY DISPLACEMENT 64 SOLENOID ACTIVATED PRESSURE
CONTROL VALVE - UNLOADING BIDIRECTIONAL HYDROSTATIC PUMP CONTROL VALVE
SPOOL 28 RELIEF VALVE - CHARGE: 0-2000 PSI (0-138 Bar)
46 TWO-STAGE RELIEF
12 PILOT ACTIVATED DIRECTIONAL 120 degrees F. (53 degrees C.)Fluid 65 STEERING CYLINDER
1000/2000 PSI (69 / 138 Bar)
CONTROL VALVE - TILT CONTROL 350 PSI (24,1 Bar) at High Engine Idle
47 66 CHECK VALVE - 270 PSI (18,6 Bar)
SOLENOID ACTIVATED DIRECTIONAL
13 PILOT ACTIVATED DIRECTIONAL 29 CHARGE PUMP CONTROL VALVE (TWO COIL) 67 PRESSURE CONTROL PILOT
CONTROL VALVE - LIFT CONTROL 12.0 GPM (45,4 L/min.) at High Engine Idle
48 RELIEF VALVE - 1200 PSI (82,7 Bar) VALVE - 2 COILS
14 SOLENOID ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . . . Gear Type 0 - 0.085 Ampere
CONTROL VALVE - BICS CONTROL 20.0 GPM (75,8 L/min.) at High Engine Idle 49 RESTRICTOR - 0.015 inch (0,381 mm) 68 FRONT AUXILIARY MANUAL
15 PULL BUTTON ACTIVATED 31 DRIVE MOTOR SHUTTLE VALVE PRESSURE BLEED-OFF VALVE
DIRECTIONAL CONTROL VALVE - 50 PRESSURE COMPENSATED FLOW
LIFT ARM BY-PASS 32 SHUTTLE RELIEF VALVE: CONTROL
200 PSI (13,8 Bar) 51 RELIEF VALVE - PORT:
33 SOLENOID ACTIVATED DIRECTIONAL 3500 PSI (241 Bar)
CONTROL VALVE - BLEED OFF REAR 52 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
AUXILIARY ("SV2") CONTROL VALVE - BUCKET POSITION springs have NO significant
VALVE (ON/OFF) pressure value.
Printed in U.S.A. V-0271legend (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE OPTION
S/N 519611124 - 519611311
DIVERTER VALVE (OPTIONAL)
S/N 519711004 - 519711140
38
(PRINTED APRIL 2004)
V-0271 39
HYDROSTATIC M2 M1 PILOT
PUMP
Printable Version Click Here 26 26
TWO SPEED DRIVE MOTOR
STEERING VALVE
(FRONT AUXILIARY
40 36 65 65
28 LEFT SIDE LIFT ARM 63 63
CHARGE M3 MALE MALE F1 D1 INTEGRATED QUICK
31 32 INLET
68 COUPLER BLOCK
29
MALE
M4 34
45 (REAR QUICK
M COUPLERS) MALE
60 CASE 66 66
5
DRAIN
33 35 37
F2 FEMALE
D2
59 58 FEMALE FEMALE 68
54
53 Control P1 P2
Module 66 66
(EDC) 67 63
9 63
44 65
65
64
X1 X2
P T
X2 X1
Control
Module 67
(EDC)
62
HYDROSTATIC HYDRAULIC FILTER
PUMP
3
BUCKET POSITION VALVE (OPTIONAL)
58 OIL
4 D
COOLER
8
M4
M
5 60
45
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
HYDRAULIC CONTROL VAVLE 10
28 BOB-TACH
43
CASE CYLINDER
DRAIN (OPTIONAL) 11
M2 M1 HYDRAULIC 27
POWERED
BOB-TACH 24 24
(OPTIONAL) 25 B
A B
30
OUTLET AUXILIARY
SPOOL
INLET
61
OUTLET 23
TWO SPEED VALVE TILT CYLINDER
22
INLET BICS CONTROL VALVE
48
47
55
46
B
50
TWO SPEED DRIVE MOTOR
A B 12
DR TILT
56 9 49 51
CYLINDER
P2 SPOOL
P1
5 21
54 53
C PP
18
P D 59 20 LIFT CYLINDERS
17
13
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
19 14 WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
TT DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY- PASS
VALVE
15
Printed in U.S.A.
V-0271 (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
S/N 519611124 - 519611311
S/N 519711004 - 519711140
(PRINTED APRIL 2004) Printable Version Click Here
V-0275legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 34 LOAD CHECK VALVE - SELECT VALVE 53 HYDRAULIC HIGH FLOW PUMP - Gear Type
Capacity . . . . . . . . . . . 18.8 Qts. (17.8 L) (SCREEN) (HIGH FLOW) 10.0 GPM (37,9 L/min.) at High Engine Idle
2 17 ONE WAY RESTRICTOR - BOOM DOWN 35 SOLENOID ACTIVATED DIRECTIONAL 54 SELECT VALVE RESTRICTOR
FILTER - CASE DRAIN (90 Micron)
CONTROL VALVE - HIGH FLOW
3 18 LOAD CHECK VALVE - LIFT AND TILT 55 HYDRAULIC STEERING PUMP - Gear Type
FILTER - HYDRAULIC (CANISTER)
36 SOLENOID ACTIVATED DIRECTIONAL
13.0 GPM (49,2 L/min.) at High Engine Idle
4 SPRING LOADED FILTER BY-PASS 19 RELIEF VALVE - MAIN: CONTROL VALVE - DIVERTER
VALVE: 45-55 PSI (3,1-3,8 Bar) 2950-3050 PSI (203-210 Bar) 56 FILTER - STEERING (10 MICRON)
at Front Quick Couplers 37 RELIEF VALVE - MAIN (HIGH FLOW)
5 PILOT ACTIVATED DIRECTIONAL 3000 PSI (207 Bar) 57 SOLENOID ACTIVATED
CONTROL VALVE - HYDRAULIC 20 RELIEF VALVE - PORT: PROPORTIONAL FLOW CONTROL
POWERED BOB-TACH 3500 PSI (241 Bar) 38 VALVE - STEERING
SOLENOID ACTIVATED DIRECTIONAL
21 ANTICAVITATION VALVE CONTROL VALVE (TWO COIL)
6 DIFFERENTIAL PRESSURE SWITCH: 58 SOLENOID ACTIVATED PRESSURE
36-44 PSI (2,5-3,0 Bar) CONTROL VALVE
22 RELIEF/ANTICAVITATION VALVE - 39 PILOT TO OPEN CHECK VALVE
0-2000 PSI (0-138 Bar)
FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END)
7
3500 PSI (241 Bar) 40 SOLENOID ACTIVATED DIRECTIONAL 59 STEERING CYLINDER
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE CONTROL VALVE - BLEED OFF
60 CHECK VALVE - 270 PSI (18,7 Bar)
VALVE
41 CHECK VALVE - BICS CONTROL VALVE
24 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT 61 PRESSURE CONTROL PILOT
CONTROL VALVE - AUXILIARY 42 LIFT ARM BY-PASS RESTRICTOR
BIDIRECTIONAL HYDROSTATIC VALVE - 2 COILS
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 0 - 0.085 Ampere
3500 PSI (241 Bar) 43 CHECK VALVE - AUXILIARY
10 PILOT ACTIVATED DIRECTIONAL 62 DISPLACEMENT CONTROL SPOOL
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH 44 FILTER - CASE DRAIN (Attachment)
SPOOL PRESSURE: 5000 PSI (345 Bar)
45 VARIABLE CAPACITY DISPLACEMENT 63 FRONT AUXILIARY MANUAL
11 PILOT ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH PRESSURE BLEED-OFF VALVE
BIDIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - UNLOADING 46 64 PUMP SERVO
28 RELIEF VALVE - CHARGE: TWO-STAGE RELIEF
SPOOL
120 degrees F. (53 degrees C.)Fluid 1000/2000 PSI (69/138 Bar)
12 PILOT ACTIVATED DIRECTIONAL 350 PSI (24,1 Bar) at High Engine Idle 47 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL CONTROL VALVE (TWO COIL)
29 CHARGE PUMP
13 PILOT ACTIVATED DIRECTIONAL 12.0 GPM (45,4 L/min.) at High Engine Idle 48 RELIEF VALVE - 1200 PSI (82,7 Bara)
CONTROL VALVE - LIFT CONTROL
30 HYDRAULIC PUMP . . . . . . . . . . Gear Type 49 RESTRICTOR - 0.015 inch (0,381 mm)
14 SOLENOID ACTIVATED DIRECTIONAL 20.0 GPM (75,8 L/min.) at High Engine Idle
CONTROL VALVE - BICS CONTROL
31 DRIVE MOTOR SHUTTLE VALVE 50 PRESSURE COMPENSATED FLOW
15 PULL BUTTON ACTIVATED CONTROL
DIRECTIONAL CONTROL VALVE - LIFT 32 SHUTTLE RELIEF VALVE: 51 RELIEF VALVE - PORT:
ARM BY-PASS 200 PSI (13,8 Bar) 3500 PSI (241 Bar)
33 REAR AUXILIARY BLEED SHUTTLE 52 SOLENOID ACTIVATED DIRECTIONAL
VALVE CONTROL VALVE - BUCKET POSITION NOTE: Unless otherwise specified
VALVE (ON/OFF) springs have NO significant
pressure value.
Printed in U.S.A. V-0275legend (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
S/N 519611124 - 519611311
S/N 519711004- 519711140
(PRINTED APRIL 2004)
V-0275 HYDROSTATIC M2 M1
PUMP
26
Printable Version Click Here 26
STEERING
VALVE
28 59 57 57 59
CHARGE M3
DRIVE MOTOR INLET
29
SELECT VALVE C2 C1
M4
(RIGHT SIDE LIFT ARM
45 QUICK COUPLERS)
31 M 40
32 64 CASE 60 60
5
MALE
MALE
FEMALE
FEMALE
DRAIN
33
39 39
62 (REAR QUICK COUPLERS)
Control
Module 54 61 INTEGRATED QUICK
60 60
9 COUPLER BLOCK
(EDC) 57
57
61 38 34
MALE 59 59
58
X1 X2
PRESS PB 63
MALE
X2 X1 36 63
Control
61
Module 37 35 FEMALE
(EDC)
T
56
HYDROSTATIC HYDRAULIC FILTER
PUMP 44
3
BUCKET POSITION VALVE (OPTIONAL)
OIL
62 4 D
COOLER
8
M4
M
5 64
45
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
HYDRAULIC CONTROL VAVLE 10
28
BOB-TACH
43
CASE CYLINDER
DRAIN (OPTIONAL) 11
M2 M1 27
HYDRAULIC 24 24
25 B
POWERED
BOB-TACH A B
(OPTIONAL)
30
OUTLET AUXILIARY
SPOOL
INLET
55
OUTLET 23
TILT CYLINDER
22
INLET BICS CONTROL VALVE
48
47
OUTLET
46
53 50
A B 12
DR TILT
51
49 CYLINDER
SPOOL
P1 P2
5 21
DRIVE MOTOR
18
20 LIFT CYLINDERS
9 17
13
A B
LIFT
CYLINDER
SPOOL
31 32
18 42
19 14 WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
DRAIN CIRCUITS
2 COMPONENTS
LIFT ARM BY- PASS
VALVE
15
1
Printed in U.S.A.
V-0275 (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW AND TWO SPEED VALVE OPTION
S/N 519611124 - 519611311
S/N 519711004 - 519711140
(PRINTED APRIL 2004) Printable Version Click Here
V-0268legend
LEGEND
1 RESERVOIR: 19 RELIEF VALVE - MAIN: 37 RELIEF VALVE - MAIN (HIGH FLOW) 56 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . 18.8 Qts. (17.8 L) 2950-3050 PSI (203-210 Bar) 3000 PSI (207 Bar) CONTROL VALVE - MAKE-UP
2 FILTER - CASE DRAIN (90 Micron) at Front Quick Couplers
38 57 SOLENOID ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
3 FILTER - HYDRAULIC (CANISTER) 3500 PSI (241 Bar) CONTROL VALVE (TWO COIL)
58 BRAKE DIAGNOSTIC PLUG
SPRING LOADED FILTER BY-PASS 21 ANTICAVITATION VALVE 39 PILOT TO OPEN CHECK VALVE
4
VALVE: 45-55 PSI (3,1-3,8 Bar)
22 RELIEF/ANTICAVITATION VALVE - 59 PILOT ACTIVATED DIRECTIONAL
40 SOLENOID ACTIVATED DIRECTIONAL
5 PILOT ACTIVATED DIRECTIONAL PORT (TILT BASE END) CONTROL VALVE - TWO SPEED
CONTROL VALVE - BLEED OFF
CONTROL VALVE - HYDRAULIC 3500 PSI (241 Bar) DRIVE MOTOR
POWERED BOB-TACH 41 CHECK VALVE - BICS CONTROL VALVE
23 ONE WAY RESTRICTOR VALVE 60 HYDRAULIC HIGH FLOW PUMP - Gear Type
6 DIFFERENTIAL PRESSURE SWITCH: 10.0 GPM (37,9 L/min.) at High Engine Idle
42 LIFT ARM BY-PASS RESTRICTOR
36-44 PSI (2,5-3,0 Bar) 24 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY 61 SELECT VALVE RESTRICTOR
7 FLOW DIVIDER ADJUSTMENT VALVE 43 CHECK VALVE - AUXILIARY
25 RELIEF VALVE - PORT: . . . . . (Optional) 62 HYDRAULIC STEERING PUMP- Gear Type
8 CHECK VALVE - BUCKET POSITION 44 FILTER - CASE DRAIN (Attachment)
3500 PSI (241 Bar) 13.0 GPM (49,2 L/min.) at High Engine Idle
VALVE
26 RELIEF/REPLENISHING VALVE - HIGH 45 VARIABLE CAPACITY DISPLACEMENT 63 FILTER - STEERING (10 MICRON)
9 FIXED CAPACITY DISPLACEMENT
PRESSURE: 5000 PSI (345 Bar) BIDIRECTIONAL HYDROSTATIC PUMP
BIDIRECTIONAL HYDROSTATIC
27 CHARGE PRESSURE SWITCH 46 TWO-STAGE RELIEF 64 SOLENOID ACTIVATED
MOTOR
1000/2000 PSI (69/138 Bar) PROPORTIONAL FLOW CONTROL
10 PILOT ACTIVATED DIRECTIONAL 28 RELIEF VALVE - CHARGE: 47 VALVE - STEERING
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL 120 degrees F. (53 degrees C.)Fluid CONTROL VALVE (TWO COIL) 65 SOLENOID ACTIVATED PRESSURE
SPOOL 350 PSI (24,1 Bar) at High Engine Idle CONTROL VALVE
48 RELIEF VALVE - 1200 PSI (82,7 Bar)
11 PILOT ACTIVATED DIRECTIONAL 0-2000 PSI (0-138 Bar)
29 CHARGE PUMP
CONTROL VALVE - UNLOADING 49
12.0 GPM (45,4 L/min.) at High Engine Idle RESTRICTOR - 0.015 inch (0,381 mm) 66 STEERING CYLINDER
SPOOL
30 HYDRAULIC PUMP . . . . . . . . . Gear Type
12 PILOT ACTIVATED DIRECTIONAL 50 PRESSURE COMPENSATED FLOW 67 CHECK VALVE - 270 PSI (18,6 Bar)
CONTROL VALVE - TILT CONTROL 20.0 GPM (75,8 L/min.) at High Engine Idle
CONTROL
31 DRIVE MOTOR SHUTTLE VALVE 68 PRESSURE CONTROL PILOT
13 PILOT ACTIVATED DIRECTIONAL 51 RELIEF VALVE - PORT:
CONTROL VALVE - LIFT CONTROL 3500 PSI (241 Bar) VALVE - 2 COILS
32 SHUTTLE RELIEF VALVE: 0 - 0.085 Ampere
14 SOLENOID ACTIVATED DIRECTIONAL 200 PSI (13,8 Bar) 52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL CONTROL VALVE - BUCKET POSITION 69 DISPLACEMENT CONTROL SPOOL
33 REAR AUXILIARY BLEED SHUTTLE VALVE VALVE (ON/OFF)
15 PULL BUTTON ACTIVATED
53 FIXED CAPACITY DISPLACEMENT 70 PUMP SERVO
DIRECTIONAL CONTROL VALVE - LIFT 34 LOAD CHECK VALVE - SELECT VALVE
ARM BY-PASS (HIGH FLOW) BIDIRECTIONAL HYDROSTATIC
MOTOR 71 FRONT AUXILIARY MANUAL PRESSURE
16 FILTER - BICS CONTROL VALVE 35 BLEED-OFF VALVE
SOLENOID ACTIVATED DIRECTIONAL 54 HYDRAULIC BRAKE - SPRING APPLIED -
(SCREEN) CONTROL VALVE - HIGH FLOW PRESSURE TO RELEASE
17 ONE WAY RESTRICTOR - BOOM DOWN
36 SOLENOID ACTIVATED DIRECTIONAL 55 PUSH BUTTON SOLENOID ACTIVATED
DIRECTIONAL CONTROL VALVE - NOTE: Unless otherwise specified
CONTROL VALVE - DIVERTER
18 LOAD CHECK VALVE- LIFT AND TILT BRAKE springs have NO significant
pressure value.
Printed in U.S.A. V-0268legend (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW AND TWO SPEED VALVE OPTION
S/N 519611124 - 519611311
S/N 5197 11004 - 519711140
(PRINTED APRIL 2004)
V-0268 HYDROSTATIC
M2 M1
PUMP
26 26
Printable Version Click Here TWO SPEED DRIVE MOTOR
STEERING VALVE
28 66 64 64 66
CHARGE
M3
31 32 INLET
29
SELECT VALVE C1 C2
M4
45 (RIGHT SIDE LIFT ARM
CASE QUICK COUPLERS)
M
70 40 (OPTIONAL) 67 67
5 DRAIN
MALE
MALE
FEMALE
FEMALE
33
39 39
59 69 (REAR QUICK COUPLERS)
54
53 Control INTEGRATED QUICK
Module 61 61 COUPLER BLOCK 67 67
(EDC) 64
9 68 34 MALE 64
38 66 66
71 65
X1 X2 MALE
PRESS 71 P T
X2 X1 36
Control FEMALE
Module 68 PB 63
37 35
(EDC)
HYDROSTATIC HYDRAULIC FILTER
PUMP 44
3
BUCKET POSITION VALVE (OPTIONAL)
69 OIL
COOLER D
8
M4
M
5 70
45
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
HYDRAULIC CONTROL VAVLE 10
28 BOB-TACH
43
CYLINDER
CASE
(OPTIONAL) 11
DRAIN
M2 M1 27
HYDRAULIC 24 24
POWERED 25 B
BOB-TACH A B
(OPTIONAL)
30
OUTLET AUXILIARY
SPOOL
INLET
62
OUTLET 23
TWO SPEED VALVE TILT CYLINDER
22
INLET BICS CONTROL VALVE
48
47
OUTLET
55
46
B
60 50
TWO SPEED DRIVE MOTOR
A B 12
DR 49 TILT
56 9 51
CYLINDER
SPOOL
P1 P2
5 21
54 53
C
18
P D 59 20 LIFT CYLINDERS
17
13
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
19 14 WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
T DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY- PASS
VALVE
15
Printed in U.S.A.
V-0268 (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
S/N 519611312 - 519611407
S/N 519711141 - 519711197
(PRINTED APRIL 2004) Printable Version Click Here
V-0274legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 34 LOAD SHUTTLE VALVE - BLEED OFF 53 HYDRAULIC STEERING PUMP - Gear Type
Capacity . . . . . . 18.8 Qts. (17.8 L) (SCREEN) 13.0 GPM (49,2 L/min.) at High Engine Idle
PILOT ACTIVATED DIRECTIONAL CONTROL
17 ONE WAY RESTRICTOR - BOOM DOWN 35 VALVE - FOR REAR AUXILIARY - NORMALLY 54 FILTER - STEERING (10 MICRON)
2 FILTER - CASE DRAIN (90 Micron)
CLOSED. ("P2" and "F2")
18 LOAD CHECK VALVE - LIFT AND TILT 55 SOLENOID ACTIVATED
3 FILTER - HYDRAULIC (CANISTER) 36 PILOT ACTIVATED DIRECTIONAL CONTROL PROPORTIONAL FLOW CONTROL
VALVE - FOR REAR AUXILIARY - NORMALLY
4 SPRING LOADED FILTER BY-PASS 19 RELIEF VALVE - MAIN: VALVE - STEERING
OPEN ("D1" and "P1")
VALVE: 45-55 PSI (3,1-3,8 Bar) 2950-3050 PSI (203-210 Bar) PILOT ACTIVATED DIRECTIONAL
at Front Quick Couplers 37 56 SOLENOID ACTIVATED PRESSURE
5 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - FOR REAR AUXILIARY - CONTROL VALVE
CONTROL VALVE - HYDRAULIC 20 RELIEF VALVE - PORT: NORMALLY OPEN ("D2" and "P2") 0-2000 PSI (0-138 Bar)
POWERED BOB-TACH 3500 PSI (241 Bar) FILTER - DIVERTER VALVE (SCREEN)
38 57 STEERING CYLINDER
21 ANTICAVITATION VALVE INTEGRATED IN SOLENOID
6 DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (2,5-3,0 Bar) SOLENOID ACTIVATED DIRECTIONAL 58 CHECK VALVE - 270 PSI (18,7 Bar)
22 RELIEF/ANTICAVITATION VALVE - 39 CONTROL VALVE - TO ACTIVATE REAR
FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END) AUXILIARY ("SV1") 59 PRESSURE CONTROL PILOT
7
3500 PSI (241 Bar)
40 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - 2 COILS
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE VALVE - FOR REAR AUXILIARY - NORMALLY 0 - 0.085 Ampere
VALVE CLOSED ("P1" and "F1")
24 SOLENOID ACTIVATED DIRECTIONAL 41 CHECK VALVE - BICS CONTROL VALVE 60 DISPLACEMENT CONTROL SPOOL
9 FIXED CAPACITY DISPLACEMENT
CONTROL VALVE - AUXILIARY
BIDIRECTIONAL HYDROSTATIC 42 LIFT ARM BY-PASS RESTRICTOR
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 61 FRONT AUXILIARY MANUAL
3500 PSI (241 Bar) PRESSURE BLEED-OFF VALVE
43 CHECK VALVE - AUXILIARY
10 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH 62 PUMP SERVO
44 FILTER - CASE DRAIN (Attachment)
SPOOL PRESSURE: 5000 PSI (345 Bar)
11 PILOT ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH 45 VARIABLE CAPACITY DISPLACEMENT
CONTROL VALVE - UNLOADING BIDIRECTIONAL HYDROSTATIC PUMP
SPOOL 28 RELIEF VALVE - CHARGE: 46 TWO-STAGE RELIEF
120 degrees F. (53 degrees C.)Fluid 1000/2000 PSI (69/138 Bar)
12 PILOT ACTIVATED DIRECTIONAL 350 PSI (24,1 Bar) at High Engine Idle
CONTROL VALVE - TILT CONTROL 47 SOLENOID ACTIVATED DIRECTIONAL
29 CHARGE PUMP CONTROL VALVE (TWO COIL)
13 PILOT ACTIVATED DIRECTIONAL 12.0 GPM (45,4 L/min.) at High Engine Idle 48 RELIEF VALVE - 1200 PSI (82,7 Bar)
CONTROL VALVE - LIFT CONTROL
30 HYDRAULIC PUMP . . . . . . . Gear Type
14 SOLENOID ACTIVATED DIRECTIONAL 20.0 GPM (75,8 L/min.) at High Engine Idle 49 RESTRICTOR - 0.015 inch (0,381 mm)
CONTROL VALVE - BICS CONTROL
31 DRIVE MOTOR SHUTTLE VALVE 50 PRESSURE COMPENSATED FLOW
15 PULL BUTTON ACTIVATED CONTROL
DIRECTIONAL CONTROL VALVE - LIFT 32 SHUTTLE RELIEF VALVE:
ARM BY-PASS 200 PSI (13,8 Bar) 51 RELIEF VALVE - PORT:
3500 PSI (241 Bar)
33 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR NOTE: Unless otherwise specified
52 SOLENOID ACTIVATED DIRECTIONAL
AUXILIARY ("SV2") springs have NO significant
CONTROL VALVE - BUCKET POSITION
pressure value.
VALVE (ON/OFF)
Printed in U.S.A. V-0274legend (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
S/N 519611312 - 519611407
S/N 519711141 - 519711197 DIVERTER VALVE (OPTIONAL)
(PRINTED APRIL 2004)
V-0274 38
HYDROSTATIC M2 M1
Printable Version Click Here PUMP
26 PILOT
39
26
STEERING VALVE
28 INTEGRATED QUICK 57 55 55 57
CHARGE M3
DRIVE MOTOR INLET COUPLER BLOCK
40 36
MALE MALE F1 D1 61
29
MALE
M4
45
31 M 34 MALE
32 62 CASE 58 58
5 (REAR QUICK
DRAIN COUPLERS)
FEMALE
33 35 37 61
60
F2 D2
Control FEMALE FEMALE
Module 58 58
9 (EDC) 55
P1 P2
59 55 57
57
56
X1 X2
P T
X2 X1 44
Control
Module 59
(EDC)
54
HYDROSTATIC HYDRAULIC FILTER
PUMP
3
BUCKET POSITION VALVE (OPTIONAL)
60
OIL
4 D
COOLER
8
M4
M
5 45 62
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
HYDRAULIC CONTROL VAVLE 10
28
43
CASE
DRAIN 27 11
M2 M1
24 24
25 B
BOB-TACH A B
CYLINDER
(OPTIONAL)
30
OUTLET AUXILIARY
HYDRAULIC SPOOL
INLET
53 POWERED
OUTLET BOB-TACH 23
(OPTIONAL) TILT CYLINDER
22
INLET BICS CONTROL VALVE
48
47 A B 12
51 TILT
46 CYLINDER
SPOOL
50
21
DRIVE MOTOR
18
DR LIFT CYLINDERS
9 20 17
49
13
P1 P2
5 A B
LIFT
PP CYLINDER
SPOOL
31 32
18 42
19 14 WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
DRAIN CIRCUITS
2 COMPONENTS
LIFT ARM BY- PASS
VALVE
15
Printed in U.S.A.
V-0274 (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE OPTION
S/N 519611312 - 519611407
S/N 519711141 - 519711197
(PRINTED APRIL 2004) Printable Version Click Here
V-0272legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 34 LOAD SHUTTLE VALVE - BLEED OFF 53 FIXED CAPACITY DISPLACEMENT
Capacity . . . . . . . . . . 18.8 Qts. (17.8 L) (SCREEN) BIDIRECTIONAL HYDROSTATIC
35 PILOT ACTIVATED DIRECTIONAL CONTROL MOTOR
2 FILTER - CASE DRAIN (90 Micron) 17 ONE WAY RESTRICTOR - BOOM DOWN VALVE - FOR REAR AUXILIARY - NORMALLY 54 HYDRAULIC BRAKE - SPRING APPLIED -
CLOSED. ("P2" and "F2") PRESSURE TO RELEASE
3 18 LOAD CHECK VALVE - LIFT AND TILT
FILTER - HYDRAULIC (CANISTER) 36 PILOT ACTIVATED DIRECTIONAL CONTROL
VALVE - FOR REAR AUXILIARY - NORMALLY 55 PUSH BUTTON SOLENOID ACTIVATED
4 SPRING LOADED FILTER BY-PASS 19 RELIEF VALVE - MAIN: DIRECTIONAL CONTROL VALVE -
2950-3050 PSI (203-210 Bar) OPEN ("D1" and "P1")
VALVE: 45-55 PSI (3,1-3,8 Bar) BRAKE
at Front Quick Couplers 37 PILOT ACTIVATED DIRECTIONAL
5 PILOT ACTIVATED DIRECTIONAL 56 SOLENOID ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: CONTROL VALVE - FOR REAR AUXILIARY -
CONTROL VALVE - HYDRAULIC CONTROL VALVE - MAKE-UP
3500 PSI (241 Bar) NORMALLY OPEN ("D2" and "P2")
POWERED BOB-TACH
38 FILTER - DIVERTER VALVE (SCREEN) 57 SOLENOID ACTIVATED DIRECTIONAL
21 ANTICAVITATION VALVE
6 DIFFERENTIAL PRESSURE SWITCH: INTEGRATED IN SOLENOID CONTROL VALVE - TWO SPEED
36-44 PSI (2,5-3,0 Bar) 22 RELIEF/ANTICAVITATION VALVE - 39 SOLENOID ACTIVATED DIRECTIONAL 58 DISPLACEMENT CONTROL SPOOL
FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END) CONTROL VALVE - TO ACTIVATE REAR
7 59 PILOT ACTIVATED DIRECTIONAL
3500 PSI (241 Bar) AUXILIARY ("SV1")
40 PILOT ACTIVATED DIRECTIONAL CONTROL CONTROL VALVE - TWO SPEED
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE
VALVE - FOR REAR AUXILIARY - NORMALLY DRIVE MOTOR
VALVE
CLOSED ("P1" and "F1") 60 PUMP SERVO
24 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT 41 CHECK VALVE - BICS CONTROL VALVE
CONTROL VALVE - AUXILIARY 61 HYDRAULIC STEERING PUMP - Gear Type
BIDIRECTIONAL HYDROSTATIC
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 42 LIFT ARM BY-PASS RESTRICTOR 13.0 GPM (49,2 L/min.) at High Engine Idle
3500 PSI (241 Bar) 62 FILTER - STEERING (10 MICRON)
10 PILOT ACTIVATED DIRECTIONAL 43 CHECK VALVE - AUXILIARY
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH 63 SOLENOID ACTIVATED
SPOOL PRESSURE: 5000 PSI (345 Bar) 44 FILTER - CASE DRAIN (Attachment) PROPORTIONAL FLOW CONTROL
VALVE - STEERING
11 PILOT ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH 45 VARIABLE CAPACITY DISPLACEMENT 64 SOLENOID ACTIVATED PRESSURE
CONTROL VALVE - UNLOADING BIDIRECTIONAL HYDROSTATIC PUMP CONTROL VALVE
SPOOL 28 RELIEF VALVE - CHARGE: 0-2000 PSI (0-138 Bar)
46 TWO-STAGE RELIEF
12 PILOT ACTIVATED DIRECTIONAL 120 degrees F. (53 degrees C.)Fluid 65 STEERING CYLINDER
1000/2000 PSI (69 / 138 Bar)
CONTROL VALVE - TILT CONTROL 350 PSI (24,1 Bara) at High Engine Idle
47 66 CHECK VALVE - 270 PSI (18,7 Bar)
SOLENOID ACTIVATED DIRECTIONAL
13 PILOT ACTIVATED DIRECTIONAL 29 CHARGE PUMP CONTROL VALVE (TWO COIL) 67 PRESSURE CONTROL PILOT
CONTROL VALVE - LIFT CONTROL 12.0 GPM (45,4 L/min.) at High Engine Idle
48 RELIEF VALVE - 1200 PSI (82,7 Bar) VALVE - 2 COILS
14 SOLENOID ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . . . Gear Type 0 - 0.085 Ampere
CONTROL VALVE - BICS CONTROL 20.0 GPM (75,8 L/min.) at High Engine Idle 49 RESTRICTOR - 0.015 inch (0,381 mm) 68 FRONT AUXILIARY MANUAL
15 PULL BUTTON ACTIVATED 31 DRIVE MOTOR SHUTTLE VALVE PRESSURE BLEED-OFF VALVE
DIRECTIONAL CONTROL VALVE - 50 PRESSURE COMPENSATED FLOW
LIFT ARM BY-PASS 32 SHUTTLE RELIEF VALVE: CONTROL
200 PSI (13,8 Bar) 51 RELIEF VALVE - PORT:
33 SOLENOID ACTIVATED DIRECTIONAL 3500 PSI (241 Bar)
CONTROL VALVE - BLEED OFF REAR 52 SOLENOID ACTIVATED DIRECTIONAL NOTE: Unless otherwise specified
AUXILIARY ("SV2") CONTROL VALVE - BUCKET POSITION springs have NO significant
VALVE (ON/OFF) pressure value.
Printed in U.S.A. V-0272legend (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE OPTION
S/N 519611312 - 519611407
S/N 519711141 - 519711197 DIVERTER VALVE (OPTIONAL)
(PRINTED APRIL 2004) 38
V-0272
39
HYDROSTATIC M2 M1 PILOT
Printable Version Click Here PUMP
26 26
TWO SPEED DRIVE MOTOR
STEERING VALVE
(FRONT AUXILIARY
40 36 65 65
28 LEFT SIDE LIFT ARM 63 63
CHARGE M3 MALE MALE F1 D1 INTEGRATED QUICK
31 32 INLET
68 COUPLER BLOCK
29
MALE
M4 34
45 (REAR QUICK
M COUPLERS) MALE
60 CASE 66 66
5
DRAIN
33 35 37
F2 FEMALE
D2
59 58 FEMALE FEMALE 68
54
53 Control P1 P2
Module 66 66
(EDC) 67 63
9 63
44 65
65
64
X1 X2
P T
X2 X1
Control
Module 67
(EDC)
62
HYDROSTATIC HYDRAULIC FILTER
PUMP
3
BUCKET POSITION VALVE (OPTIONAL)
58 OIL
4 D
COOLER
8
M4
M
5 60
45
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
HYDRAULIC CONTROL VAVLE 10
28 BOB-TACH
43
CASE CYLINDER
DRAIN (OPTIONAL) 11
M2 M1 HYDRAULIC 27
POWERED
BOB-TACH 24 24
(OPTIONAL) 25 B
A B
30
OUTLET AUXILIARY
SPOOL
INLET
61
OUTLET 23
TWO SPEED VALVE TILT CYLINDER
22
INLET BICS CONTROL VALVE
48
47
55
46
B
50
TWO SPEED DRIVE MOTOR
A B 12
DR TILT
56 9 49 51
CYLINDER
P2 SPOOL
P1
5 21
54 53
C PP
18
P D 59 20 LIFT CYLINDERS
17
13
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
19 14 WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
TT DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY- PASS
VALVE
15
Printed in U.S.A.
V-0272 (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
S/N 519611312 - 519611407
S/N 519711141 - 519711197
(PRINTED APRIL 2004) Printable Version Click Here
V-0276legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 34 LOAD CHECK VALVE - SELECT VALVE 53 HYDRAULIC HIGH FLOW PUMP - Gear Type
Capacity . . . . . . . . . . . 18.8 Qts. (17.8 L) (SCREEN) (HIGH FLOW) 10.0 GPM (37,9 L/min.) at High Engine Idle
2 17 ONE WAY RESTRICTOR - BOOM DOWN 35 SOLENOID ACTIVATED DIRECTIONAL 54 SELECT VALVE RESTRICTOR
FILTER - CASE DRAIN (90 Micron)
CONTROL VALVE - HIGH FLOW
3 18 LOAD CHECK VALVE - LIFT AND TILT 55 HYDRAULIC STEERING PUMP - Gear Type
FILTER - HYDRAULIC (CANISTER)
36 SOLENOID ACTIVATED DIRECTIONAL
13.0 GPM (49,2 L/min.) at High Engine Idle
4 SPRING LOADED FILTER BY-PASS 19 RELIEF VALVE - MAIN: CONTROL VALVE - DIVERTER
VALVE: 45-55 PSI (3,1-3,8 Bar) 2950-3050 PSI (203-210 Bar) 56 FILTER - STEERING (10 MICRON)
at Front Quick Couplers 37 RELIEF VALVE - MAIN (HIGH FLOW)
5 PILOT ACTIVATED DIRECTIONAL 3000 PSI (207 Bar) 57 SOLENOID ACTIVATED
CONTROL VALVE - HYDRAULIC 20 RELIEF VALVE - PORT: PROPORTIONAL FLOW CONTROL
POWERED BOB-TACH 3500 PSI (241 Bar) 38 VALVE - STEERING
SOLENOID ACTIVATED DIRECTIONAL
21 ANTICAVITATION VALVE CONTROL VALVE (TWO COIL)
6 DIFFERENTIAL PRESSURE SWITCH: 58 SOLENOID ACTIVATED PRESSURE
36-44 PSI (2,5-3,0 Bar) CONTROL VALVE
22 RELIEF/ANTICAVITATION VALVE - 39 PILOT TO OPEN CHECK VALVE
0-2000 PSI (0-138 Bar)
FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END)
7
3500 PSI (241 Bar) 40 SOLENOID ACTIVATED DIRECTIONAL 59 STEERING CYLINDER
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE CONTROL VALVE - BLEED OFF
60 CHECK VALVE - 270 PSI (18,7 Bar)
VALVE
41 CHECK VALVE - BICS CONTROL VALVE
24 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT 61 PRESSURE CONTROL PILOT
CONTROL VALVE - AUXILIARY 42 LIFT ARM BY-PASS RESTRICTOR
BIDIRECTIONAL HYDROSTATIC VALVE - 2 COILS
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 0 - 0.085 Ampere
3500 PSI (241 Bar) 43 CHECK VALVE - AUXILIARY
10 PILOT ACTIVATED DIRECTIONAL 62 DISPLACEMENT CONTROL SPOOL
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH 44 FILTER - CASE DRAIN (Attachment)
SPOOL PRESSURE: 5000 PSI (345 Bar)
45 VARIABLE CAPACITY DISPLACEMENT 63 FRONT AUXILIARY MANUAL
11 PILOT ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH PRESSURE BLEED-OFF VALVE
BIDIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - UNLOADING 46 64 PUMP SERVO
28 RELIEF VALVE - CHARGE: TWO-STAGE RELIEF
SPOOL
120 degrees F. (53 degrees C.)Fluid 1000/2000 PSI (69/138 Bar)
12 PILOT ACTIVATED DIRECTIONAL 350 PSI (24,1 Bar) at High Engine Idle 47 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL CONTROL VALVE (TWO COIL)
29 CHARGE PUMP
13 PILOT ACTIVATED DIRECTIONAL 12.0 GPM (45,4 L/min.) at High Engine Idle 48 RELIEF VALVE - 1200 PSI (82,7 Bar)
CONTROL VALVE - LIFT CONTROL
30 HYDRAULIC PUMP . . . . . . . . . . Gear Type 49 RESTRICTOR - 0.015 inch (0,381 mm)
14 SOLENOID ACTIVATED DIRECTIONAL 20.0 GPM (75,8 L/min.) at High Engine Idle
CONTROL VALVE - BICS CONTROL
31 DRIVE MOTOR SHUTTLE VALVE 50 PRESSURE COMPENSATED FLOW
15 PULL BUTTON ACTIVATED CONTROL
DIRECTIONAL CONTROL VALVE - LIFT 32 SHUTTLE RELIEF VALVE: 51 RELIEF VALVE - PORT:
ARM BY-PASS 200 PSI (13,8 Bar) 3500 PSI (241 Bar)
33 REAR AUXILIARY BLEED SHUTTLE 52 SOLENOID ACTIVATED DIRECTIONAL
VALVE CONTROL VALVE - BUCKET POSITION NOTE: Unless otherwise specified
VALVE (ON/OFF) springs have NO significant
pressure value.
Printed in U.S.A. V-0276legend (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
S/N 519611312 - 519611407
S/N 519711141 - 519711197
(PRINTED APRIL 2004)
V-0276 HYDROSTATIC M2 M1
PUMP
Printable Version Click Here 26 26
STEERING
VALVE
28 59 57 57 59
CHARGE M3
DRIVE MOTOR INLET
29
SELECT VALVE C2 C1
M4
(RIGHT SIDE LIFT ARM
45 QUICK COUPLERS)
31 M 40
32 64 CASE 60 60
5
MALE
MALE
FEMALE
FEMALE
DRAIN
33
39 39
62 (REAR QUICK COUPLERS)
Control
Module 54 61 INTEGRATED QUICK
60 60
9 COUPLER BLOCK
(EDC) 57
57
61 38 34
MALE 59 59
58
X1 X2
PRESS PB 63
MALE
X2 X1 36 63
Control
61
Module 37 35 FEMALE
(EDC)
T
56
HYDROSTATIC HYDRAULIC FILTER
PUMP 44
3
BUCKET POSITION VALVE (OPTIONAL)
OIL
62 4 D
COOLER
8
M4
M
5 64
45
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
HYDRAULIC CONTROL VAVLE 10
28
BOB-TACH
43
CASE CYLINDER
DRAIN (OPTIONAL) 11
M2 M1 27
HYDRAULIC 24 24
25 B
POWERED
BOB-TACH A B
(OPTIONAL)
30
OUTLET AUXILIARY
SPOOL
INLET
55
OUTLET 23
TILT CYLINDER
22
INLET BICS CONTROL VALVE
48
47
OUTLET
46
53 50
A B 12
DR TILT
51
49 CYLINDER
SPOOL
P1 P2
5 21
DRIVE MOTOR
18
20 LIFT CYLINDERS
9 17
13
A B
LIFT
CYLINDER
SPOOL
31 32
18 42
19 14 WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
DRAIN CIRCUITS
2 COMPONENTS
LIFT ARM BY- PASS
VALVE
15
1
Printed in U.S.A.
V-0276 (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW AND TWO SPEED VALVE OPTION
S/N 519611312 - 519611407
S/N 519711141 - 519711197
(PRINTED APRIL 2004) Printable Version Click Here
V-0269legend
LEGEND
1 RESERVOIR: 19 RELIEF VALVE - MAIN: 37 RELIEF VALVE - MAIN (HIGH FLOW) 56 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . 18.8 Qts. (17.8 L) 2950-3050 PSI (203-210 Bar) 3000 PSI (207 Bar) CONTROL VALVE - MAKE-UP
2 FILTER - CASE DRAIN (90 Micron) at Front Quick Couplers
38 57 SOLENOID ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
3 FILTER - HYDRAULIC (CANISTER) 3500 PSI (241 Bar) CONTROL VALVE (TWO COIL)
58 BRAKE DIAGNOSTIC PLUG
SPRING LOADED FILTER BY-PASS 21 ANTICAVITATION VALVE 39 PILOT TO OPEN CHECK VALVE
4
VALVE: 45-55 PSI (3,1-3,8 Bar)
22 RELIEF/ANTICAVITATION VALVE - 59 PILOT ACTIVATED DIRECTIONAL
40 SOLENOID ACTIVATED DIRECTIONAL
5 PILOT ACTIVATED DIRECTIONAL PORT (TILT BASE END) CONTROL VALVE - TWO SPEED
CONTROL VALVE - BLEED OFF
CONTROL VALVE - HYDRAULIC 3500 PSI (241 Bar) DRIVE MOTOR
POWERED BOB-TACH 41 CHECK VALVE - BICS CONTROL VALVE
23 ONE WAY RESTRICTOR VALVE 60 HYDRAULIC HIGH FLOW PUMP - Gear Type
6 DIFFERENTIAL PRESSURE SWITCH: 10.0 GPM (37,9 L/min.) at High Engine Idle
42 LIFT ARM BY-PASS RESTRICTOR
36-44 PSI (2,5-3,0 Bar) 24 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY 61 SELECT VALVE RESTRICTOR
7 FLOW DIVIDER ADJUSTMENT VALVE 43 CHECK VALVE - AUXILIARY
25 RELIEF VALVE - PORT: . . . . . (Optional) 62 HYDRAULIC STEERING PUMP- Gear Type
8 CHECK VALVE - BUCKET POSITION 44 FILTER - CASE DRAIN (Attachment)
3500 PSI (241 Bar) 13.0 GPM (49,2 L/min.) at High Engine Idle
VALVE
26 RELIEF/REPLENISHING VALVE - HIGH 45 VARIABLE CAPACITY DISPLACEMENT 63 FILTER - STEERING (10 MICRON)
9 FIXED CAPACITY DISPLACEMENT
PRESSURE: 5000 PSI (345 Bar) BIDIRECTIONAL HYDROSTATIC PUMP
BIDIRECTIONAL HYDROSTATIC
27 CHARGE PRESSURE SWITCH 46 TWO-STAGE RELIEF 64 SOLENOID ACTIVATED
MOTOR
1000/2000 PSI (69/138 Bar) PROPORTIONAL FLOW CONTROL
10 PILOT ACTIVATED DIRECTIONAL 28 RELIEF VALVE - CHARGE: 47 VALVE - STEERING
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL 120 degrees F. (53 degrees C.)Fluid CONTROL VALVE (TWO COIL) 65 SOLENOID ACTIVATED PRESSURE
SPOOL 350 PSI (24,1 Bar) at High Engine Idle CONTROL VALVE
48 RELIEF VALVE - 1200 PSI (82,7 Bar)
11 PILOT ACTIVATED DIRECTIONAL 0-2000 PSI (0-138 Bar)
29 CHARGE PUMP
CONTROL VALVE - UNLOADING 49
12.0 GPM (45,4 L/min.) at High Engine Idle RESTRICTOR - 0.015 inch (0,381 mm) 66 STEERING CYLINDER
SPOOL
30 HYDRAULIC PUMP . . . . . . . . . Gear Type
12 PILOT ACTIVATED DIRECTIONAL 50 PRESSURE COMPENSATED FLOW 67 CHECK VALVE - 270 PSI (18,6 Bar)
CONTROL VALVE - TILT CONTROL 20.0 GPM (75,8 L/min.) at High Engine Idle
CONTROL
31 DRIVE MOTOR SHUTTLE VALVE 68 PRESSURE CONTROL PILOT
13 PILOT ACTIVATED DIRECTIONAL 51 RELIEF VALVE - PORT:
CONTROL VALVE - LIFT CONTROL 3500 PSI (241 Bar) VALVE - 2 COILS
32 SHUTTLE RELIEF VALVE: 0 - 0.085 Ampere
14 SOLENOID ACTIVATED DIRECTIONAL 200 PSI (13,8 Bar) 52 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL CONTROL VALVE - BUCKET POSITION 69 DISPLACEMENT CONTROL SPOOL
33 REAR AUXILIARY BLEED SHUTTLE VALVE VALVE (ON/OFF)
15 PULL BUTTON ACTIVATED
53 FIXED CAPACITY DISPLACEMENT 70 PUMP SERVO
DIRECTIONAL CONTROL VALVE - LIFT 34 LOAD CHECK VALVE - SELECT VALVE
ARM BY-PASS (HIGH FLOW) BIDIRECTIONAL HYDROSTATIC
MOTOR 71 FRONT AUXILIARY MANUAL PRESSURE
16 FILTER - BICS CONTROL VALVE 35 BLEED-OFF VALVE
SOLENOID ACTIVATED DIRECTIONAL 54 HYDRAULIC BRAKE - SPRING APPLIED -
(SCREEN) CONTROL VALVE - HIGH FLOW PRESSURE TO RELEASE
17 ONE WAY RESTRICTOR - BOOM DOWN
36 SOLENOID ACTIVATED DIRECTIONAL 55 PUSH BUTTON SOLENOID ACTIVATED
DIRECTIONAL CONTROL VALVE - NOTE: Unless otherwise specified
CONTROL VALVE - DIVERTER
18 LOAD CHECK VALVE- LIFT AND TILT BRAKE springs have NO significant
pressure value.
Printed in U.S.A. V-0269legend (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW AND TWO SPEED VALVE OPTION
S/N 519611312 - 519611407
S/N 519711141 - 519711197
(PRINTED APRIL 2004)
V-0269 HYDROSTATIC
M2 M1
PUMP
26
Printable Version Click Here TWO SPEED DRIVE MOTOR
26
STEERING VALVE
28 66 64 64 66
CHARGE
M3
31 32 INLET
29
SELECT VALVE C1 C2
M4
45 (RIGHT SIDE LIFT ARM
CASE QUICK COUPLERS)
M
70 40 (OPTIONAL) 67 67
5 DRAIN
MALE
MALE
FEMALE
FEMALE
33
39 39
59 69 (REAR QUICK COUPLERS)
54
53 Control INTEGRATED QUICK
Module 61 61 COUPLER BLOCK 67 67
(EDC) 64
9 68 34 MALE 64
38 66 66
71 65
X1 X2 MALE
PRESS 71 P T
X2 X1 36
Control FEMALE
Module 68 PB 63
37 35
(EDC)
HYDROSTATIC HYDRAULIC FILTER
PUMP 44
3
BUCKET POSITION VALVE (OPTIONAL)
69 OIL
COOLER D
8
M4
M
5 70
45
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
HYDRAULIC CONTROL VAVLE 10
28 BOB-TACH
43
CYLINDER
CASE
(OPTIONAL) 11
DRAIN
M2 M1 27
HYDRAULIC 24 24
POWERED 25 B
BOB-TACH A B
(OPTIONAL)
30
OUTLET AUXILIARY
SPOOL
INLET
62
OUTLET 23
TWO SPEED VALVE TILT CYLINDER
22
INLET BICS CONTROL VALVE
48
47
OUTLET
55
46
B
60 50
TWO SPEED DRIVE MOTOR
A B 12
DR 49 TILT
56 9 51
CYLINDER
SPOOL
P1 P2
5 21
54 53
C
18
P D 59 20 LIFT CYLINDERS
17
13
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
19 14 WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
T DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY- PASS
VALVE
15
Printed in U.S.A.
V-0269 (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
S/N 519611408 AND ABOVE
S/N 519711198 AND ABOVE
(PRINTED APRIL 2004)
V-0528legend Printable Version Click Here
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 34 LOAD SHUTTLE VALVE - BLEED OFF 53 HYDRAULIC STEERING PUMP - Gear Type
Capacity . . . . . . 18.8 Qts. (17.8 L) (SCREEN) 13.0 GPM (49,2 L/min.) at High Engine Idle
PILOT ACTIVATED DIRECTIONAL CONTROL
17 ONE WAY RESTRICTOR - BOOM DOWN 35 VALVE - FOR REAR AUXILIARY - NORMALLY 54 FILTER - STEERING (10 MICRON)
2 FILTER - CASE DRAIN (90 Micron)
CLOSED. ("P2" and "F2")
18 LOAD CHECK VALVE - LIFT AND TILT 55 SOLENOID ACTIVATED
3 FILTER - HYDRAULIC (CANISTER) 36 PILOT ACTIVATED DIRECTIONAL CONTROL PROPORTIONAL FLOW CONTROL
VALVE - FOR REAR AUXILIARY - NORMALLY
4 SPRING LOADED FILTER BY-PASS 19 RELIEF VALVE - MAIN: VALVE - STEERING
OPEN ("D1" and "P1")
VALVE: 45-55 PSI (3,1-3,8 Bar) 2950-3050 PSI (203-210 Bar) PILOT ACTIVATED DIRECTIONAL
at Front Quick Couplers 37 56 SOLENOID ACTIVATED PRESSURE
5 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - FOR REAR AUXILIARY - CONTROL VALVE
CONTROL VALVE - HYDRAULIC 20 RELIEF VALVE - PORT: NORMALLY OPEN ("D2" and "P2") 0-2000 PSI (0-138 Bar)
POWERED BOB-TACH 3500 PSI (241 Bar) FILTER - DIVERTER VALVE (SCREEN)
38 57 STEERING CYLINDER
21 ANTICAVITATION VALVE INTEGRATED IN SOLENOID
6 DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (2,5-3,0 Bar) SOLENOID ACTIVATED DIRECTIONAL 58 CHECK VALVE - 270 PSI (18,7 Bar)
22 RELIEF/ANTICAVITATION VALVE - 39 CONTROL VALVE - TO ACTIVATE REAR
FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END) AUXILIARY ("SV1") 59 PRESSURE CONTROL PILOT
7
3500 PSI (241 Bar)
40 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - 2 COILS
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE VALVE - FOR REAR AUXILIARY - NORMALLY 0 - 0.085 Ampere
VALVE CLOSED ("P1" and "F1")
24 SOLENOID ACTIVATED DIRECTIONAL 41 CHECK VALVE - BICS CONTROL VALVE 60 DISPLACEMENT CONTROL SPOOL
9 FIXED CAPACITY DISPLACEMENT
CONTROL VALVE - AUXILIARY
BIDIRECTIONAL HYDROSTATIC 42 LIFT ARM BY-PASS RESTRICTOR
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 61 FRONT AUXILIARY MANUAL
3500 PSI (241 Bar) PRESSURE BLEED-OFF VALVE
43 CHECK VALVE - AUXILIARY
10 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH 62 PUMP SERVO
44 FILTER - CASE DRAIN (Attachment)
SPOOL PRESSURE: 5000 PSI (345 Bar)
11 PILOT ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH 45 VARIABLE CAPACITY DISPLACEMENT 63 ORIFICE - 0.120 inch (3,0 mm) Restriction
CONTROL VALVE - UNLOADING BIDIRECTIONAL HYDROSTATIC PUMP
SPOOL 28 RELIEF VALVE - CHARGE: 64 ORIFICE - 0.025 inch (0,63 mm) Restriction
46 RELIEF VALVE - 2000 PSI (138 Bar)
120 degrees F. (53 degrees C.)Fluid
12 PILOT ACTIVATED DIRECTIONAL 350 PSI (24,1 Bar) at High Engine Idle 65 ORIFICE - 0.030 inch (0,76 mm) Restriction
CONTROL VALVE - TILT CONTROL 47 SOLENOID ACTIVATED DIRECTIONAL
29 CHARGE PUMP CONTROL VALVE (TWO COIL)
13 PILOT ACTIVATED DIRECTIONAL 12.0 GPM (45,4 L/min.) at High Engine Idle 48 RELIEF VALVE - 1200 PSI (82,7 Bar)
CONTROL VALVE - LIFT CONTROL
30 HYDRAULIC PUMP . . . . . . . Gear Type
14 SOLENOID ACTIVATED DIRECTIONAL 20.0 GPM (75,8 L/min.) at High Engine Idle 49 CHECK VALVE - With 80 PSI (5,5 Bar)
CONTROL VALVE - BICS CONTROL Spring
31 DRIVE MOTOR SHUTTLE VALVE 50 CHECK VALVE - With 300 PSI (20,7 Bar)
15 PULL BUTTON ACTIVATED
Spring
DIRECTIONAL CONTROL VALVE - LIFT 32 SHUTTLE RELIEF VALVE:
ARM BY-PASS 200 PSI (13,8 Bar) 51 RELIEF VALVE - PORT:
3500 PSI (241 Bar)
33 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BLEED OFF REAR NOTE: Unless otherwise specified
52 SOLENOID ACTIVATED DIRECTIONAL
AUXILIARY ("SV2") springs have NO significant
CONTROL VALVE - BUCKET POSITION
pressure value.
VALVE (ON/OFF)
Printed in U.S.A. V-0528legend (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
S/N 519611408 AND ABOVE
S/N 519711198 AND ABOVE DIVERTER VALVE (OPTIONAL)
(PRINTED APRIL 2004)
V-0528 38
HYDROSTATIC M2 M1
Printable Version Click Here PUMP 39
26 26 PILOT
STEERING VALVE
28 INTEGRATED QUICK 57 55 55 57
CHARGE M3
DRIVE MOTOR INLET COUPLER BLOCK
40 36
MALE MALE F1 D1 61
29
MALE
M4
45
31 M 34 MALE
32 62 CASE 58 58
5 (REAR QUICK
DRAIN COUPLERS)
FEMALE
33 35 37 61
60
F2 D2
Control FEMALE FEMALE
Module 58 58
9 (EDC) 55
P1 P2
59 55 57
57
56
X1 X2
P T
X2 X1 44
Control
Module 59
(EDC)
54
HYDROSTATIC HYDRAULIC FILTER
PUMP
3
BUCKET POSITION VALVE (OPTIONAL)
60
OIL
4 D
COOLER
8
M4
M
5 45 62
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
HYDRAULIC CONTROL VAVLE 10
28
43
CASE
DRAIN 27 11
M2 M1
24 24
25 B
A B
30 BOB-TACH
CYLINDER AUXILIARY
OUTLET
(OPTIONAL) SPOOL
INLET
53
OUTLET HYDRAULIC
23 TILT CYLINDER
POWERED
22
INLET BOB-TACH BICS CONTROL VALVE
DR (OPTIONAL)
49
50
A B 12
48 46 TILT
51
CYLINDER
64 65
47 63 SPOOL
PP 21
DRIVE MOTOR
P2 18
P1 5
20 LIFT CYLINDERS
9 17
13
A B
LIFT
CYLINDER
SPOOL
31 32
18 42
19 14 WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
DRAIN CIRCUITS
2 COMPONENTS
LIFT ARM BY- PASS
VALVE
15
Printed in U.S.A.
V-0528 (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE OPTION
S/N 5196111408 AND ABOVE
S/N 519711198 AND ABOVE
(PRINTED APRIL 2004) Printable Version Click Here
V-0529legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 34 LOAD SHUTTLE VALVE - BLEED OFF 53 FIXED CAPACITY DISPLACEMENT
Capacity . . . . . . . . . . 18.8 Qts. (17.8 L) (SCREEN) BIDIRECTIONAL HYDROSTATIC
35 PILOT ACTIVATED DIRECTIONAL CONTROL MOTOR
2 FILTER - CASE DRAIN (90 Micron) 17 ONE WAY RESTRICTOR - BOOM DOWN VALVE - FOR REAR AUXILIARY - NORMALLY 54 HYDRAULIC BRAKE - SPRING APPLIED -
CLOSED. ("P2" and "F2") PRESSURE TO RELEASE
3 18 LOAD CHECK VALVE - LIFT AND TILT
FILTER - HYDRAULIC (CANISTER) 36 PILOT ACTIVATED DIRECTIONAL CONTROL
VALVE - FOR REAR AUXILIARY - NORMALLY 55 PUSH BUTTON SOLENOID ACTIVATED
4 SPRING LOADED FILTER BY-PASS 19 RELIEF VALVE - MAIN: DIRECTIONAL CONTROL VALVE -
2950-3050 PSI (203-210 Bar) OPEN ("D1" and "P1")
VALVE: 45-55 PSI (3,1-3,8 Bar) BRAKE
at Front Quick Couplers 37 PILOT ACTIVATED DIRECTIONAL
5 PILOT ACTIVATED DIRECTIONAL 56 SOLENOID ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: CONTROL VALVE - FOR REAR AUXILIARY -
CONTROL VALVE - HYDRAULIC CONTROL VALVE - MAKE-UP
3500 PSI (241 Bar) NORMALLY OPEN ("D2" and "P2")
POWERED BOB-TACH
38 FILTER - DIVERTER VALVE (SCREEN) 57 SOLENOID ACTIVATED DIRECTIONAL
21 ANTICAVITATION VALVE
6 DIFFERENTIAL PRESSURE SWITCH: INTEGRATED IN SOLENOID CONTROL VALVE - TWO SPEED
36-44 PSI (2,5-3,0 Bar) 22 RELIEF/ANTICAVITATION VALVE - 39 SOLENOID ACTIVATED DIRECTIONAL 58 DISPLACEMENT CONTROL SPOOL
FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END) CONTROL VALVE - TO ACTIVATE REAR
7 59 PILOT ACTIVATED DIRECTIONAL
3500 PSI (241 Bar) AUXILIARY ("SV1")
40 PILOT ACTIVATED DIRECTIONAL CONTROL CONTROL VALVE - TWO SPEED
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE
VALVE - FOR REAR AUXILIARY - NORMALLY DRIVE MOTOR
VALVE
CLOSED ("P1" and "F1") 60 PUMP SERVO
24 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT 41 CHECK VALVE - BICS CONTROL VALVE
CONTROL VALVE - AUXILIARY 61 HYDRAULIC STEERING PUMP - Gear Type
BIDIRECTIONAL HYDROSTATIC
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 42 LIFT ARM BY-PASS RESTRICTOR 13.0 GPM (49,2 L/min.) at High Engine Idle
3500 PSI (241 Bar) 62 FILTER - STEERING (10 MICRON)
10 PILOT ACTIVATED DIRECTIONAL 43 CHECK VALVE - AUXILIARY
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH 63 SOLENOID ACTIVATED
SPOOL PRESSURE: 5000 PSI (345 Bar) 44 FILTER - CASE DRAIN (Attachment) PROPORTIONAL FLOW CONTROL
VALVE - STEERING
11 PILOT ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH 45 VARIABLE CAPACITY DISPLACEMENT 64 SOLENOID ACTIVATED PRESSURE
CONTROL VALVE - UNLOADING BIDIRECTIONAL HYDROSTATIC PUMP CONTROL VALVE
SPOOL 28 RELIEF VALVE - CHARGE: 0-2000 PSI (0-138 Bar)
46 RELIEF VALVE - 2000 PSI (138 Bar)
12 PILOT ACTIVATED DIRECTIONAL 120 degrees F. (53 degrees C.)Fluid 65 STEERING CYLINDER
CONTROL VALVE - TILT CONTROL 350 PSI (24,1 Bara) at High Engine Idle
47 SOLENOID ACTIVATED DIRECTIONAL 66 CHECK VALVE - 270 PSI (18,7 Bar)
13 PILOT ACTIVATED DIRECTIONAL 29 CHARGE PUMP CONTROL VALVE (TWO COIL)
CONTROL VALVE - LIFT CONTROL 12.0 GPM (45,4 L/min.) at High Engine Idle 48 67 PRESSURE CONTROL PILOT
RELIEF VALVE - 1200 PSI (82,7 Bar)
VALVE - 2 COILS
14 SOLENOID ACTIVATED DIRECTIONAL 30 HYDRAULIC PUMP . . . . . . . . . Gear Type 49 CHECK VALVE - With 80 PSI (5,5 Bar) 0 - 0.085 Ampere
CONTROL VALVE - BICS CONTROL 20.0 GPM (75,8 L/min.) at High Engine Idle Spring 68 FRONT AUXILIARY MANUAL
15 PULL BUTTON ACTIVATED 31 DRIVE MOTOR SHUTTLE VALVE 50 CHECK VALVE - With 300 PSI (520,7 Bar) PRESSURE BLEED-OFF VALVE
DIRECTIONAL CONTROL VALVE - Spring 69 ORIFIVE - 0.120 inch (3,0 mm) Restriction
LIFT ARM BY-PASS 32 SHUTTLE RELIEF VALVE: 51 RELIEF VALVE - PORT:
200 PSI (13,8 Bar) 3500 PSI (241 Bar) 70 ORIFIVE - 0.025 inch (0,63 mm) Restriction
33 SOLENOID ACTIVATED DIRECTIONAL 52 SOLENOID ACTIVATED DIRECTIONAL 71 ORIFIVE - 0.030 inch (0,76 mm) Restriction
CONTROL VALVE - BLEED OFF REAR CONTROL VALVE - BUCKET POSITION
AUXILIARY ("SV2") VALVE (ON/OFF) NOTE: Unless otherwise specified springs
have NO significant pressure value.
Printed in U.S.A. V-0529legend (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH TWO SPEED VALVE OPTION
S/N 519611408 AND ABOVE
S/N 519711198 AND ABOVE DIVERTER VALVE (OPTIONAL)
(PRINTED APRIL 2004) 38
V-0529
39
HYDROSTATIC M2 M1 PILOT
Printable Version Click Here PUMP
26 26
TWO SPEED DRIVE MOTOR
STEERING VALVE
(FRONT AUXILIARY
40 36 65 65
28 LEFT SIDE LIFT ARM 63 63
CHARGE M3 MALE MALE F1 D1 INTEGRATED QUICK
31 32 INLET
68 COUPLER BLOCK
29
MALE
M4 34
45 (REAR QUICK
M COUPLERS) MALE
60 CASE 66 66
5
DRAIN
33 35 37
F2 FEMALE
D2
59 58 FEMALE FEMALE 68
54
53 Control P1 P2
Module 66 66
(EDC) 67 63
9 63
44 65
65
64
X1 X2
P T
X2 X1
Control
Module 67
(EDC)
62
HYDROSTATIC HYDRAULIC FILTER
PUMP
3
BUCKET POSITION VALVE (OPTIONAL)
58 OIL
4 D
COOLER
8
M4
M
5 60
45
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
HYDRAULIC CONTROL VAVLE 10
28
43
CASE
DRAIN 11
M2 M1 27
24 24
25 B
A B
30
OUTLET AUXILIARY
BOB-TACH SPOOL
INLET
61 CYLINDER
OUTLET (OPTIONAL) 23
TWO SPEED VALVE TILT CYLINDER
22
INLET BICS CONTROL VALVE
HYDRAULIC
POWERED
55 BOB-TACH
DR (OPTIONAL)
B
49
TWO SPEED DRIVE MOTOR
A B 12
50 51 TILT
56 9
CYLINDER
48 46 SPOOL
53 70 21
C 54 69 71
47
18
PP
P D 59 20 LIFT CYLINDERS
17
P1 P2 13
5
57 A B
LIFT
CYLINDER
SPOOL
A
18 42
31 32
19 14 WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
TT DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY- PASS
VALVE
15
Printed in U.S.A.
V-0529 (4-7-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
S/N 519611408 AND ABOVE
S/N 519711198 AND ABOVE
(PRINTED APRIL 2004) Printable Version Click Here
V-0530legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE 34 LOAD CHECK VALVE - SELECT VALVE 53 HYDRAULIC HIGH FLOW PUMP - Gear Type
Capacity . . . . . . . . . . . 18.8 Qts. (17.8 L) (SCREEN) (HIGH FLOW) 10.0 GPM (37,9 L/min.) at High Engine Idle
2 17 ONE WAY RESTRICTOR - BOOM DOWN 35 SOLENOID ACTIVATED DIRECTIONAL 54 SELECT VALVE RESTRICTOR
FILTER - CASE DRAIN (90 Micron)
CONTROL VALVE - HIGH FLOW
3 18 LOAD CHECK VALVE - LIFT AND TILT 55 HYDRAULIC STEERING PUMP - Gear Type
FILTER - HYDRAULIC (CANISTER)
36 SOLENOID ACTIVATED DIRECTIONAL
13.0 GPM (49,2 L/min.) at High Engine Idle
4 SPRING LOADED FILTER BY-PASS 19 RELIEF VALVE - MAIN: CONTROL VALVE - DIVERTER
VALVE: 45-55 PSI (3,1-3,8 Bar) 2950-3050 PSI (203-210 Bar) 56 FILTER - STEERING (10 MICRON)
at Front Quick Couplers 37 RELIEF VALVE - MAIN (HIGH FLOW)
5 PILOT ACTIVATED DIRECTIONAL 3000 PSI (207 Bar) 57 SOLENOID ACTIVATED
CONTROL VALVE - HYDRAULIC 20 RELIEF VALVE - PORT: PROPORTIONAL FLOW CONTROL
POWERED BOB-TACH 3500 PSI (241 Bar) 38 VALVE - STEERING
SOLENOID ACTIVATED DIRECTIONAL
21 ANTICAVITATION VALVE CONTROL VALVE (TWO COIL)
6 DIFFERENTIAL PRESSURE SWITCH: 58 SOLENOID ACTIVATED PRESSURE
36-44 PSI (2,5-3,0 Bar) CONTROL VALVE
22 RELIEF/ANTICAVITATION VALVE - 39 PILOT TO OPEN CHECK VALVE
0-2000 PSI (0-138 Bar)
FLOW DIVIDER ADJUSTMENT VALVE PORT (TILT BASE END)
7
3500 PSI (241 Bar) 40 SOLENOID ACTIVATED DIRECTIONAL 59 STEERING CYLINDER
8 CHECK VALVE - BUCKET POSITION 23 ONE WAY RESTRICTOR VALVE CONTROL VALVE - BLEED OFF
60 CHECK VALVE - 270 PSI (18,7 Bar)
VALVE
41 CHECK VALVE - BICS CONTROL VALVE
24 SOLENOID ACTIVATED DIRECTIONAL
9 FIXED CAPACITY DISPLACEMENT 61 PRESSURE CONTROL PILOT
CONTROL VALVE - AUXILIARY 42 LIFT ARM BY-PASS RESTRICTOR
BIDIRECTIONAL HYDROSTATIC VALVE - 2 COILS
MOTOR 25 RELIEF VALVE - PORT: . . . . . (Optional) 0 - 0.085 Ampere
3500 PSI (241 Bar) 43 CHECK VALVE - AUXILIARY
10 PILOT ACTIVATED DIRECTIONAL 62 DISPLACEMENT CONTROL SPOOL
CONTROL VALVE - FLOW CONTROL 26 RELIEF/REPLENISHING VALVE - HIGH 44 FILTER - CASE DRAIN (Attachment)
SPOOL PRESSURE: 5000 PSI (345 Bar)
45 VARIABLE CAPACITY DISPLACEMENT 63 FRONT AUXILIARY MANUAL
11 PILOT ACTIVATED DIRECTIONAL 27 CHARGE PRESSURE SWITCH PRESSURE BLEED-OFF VALVE
BIDIRECTIONAL HYDROSTATIC PUMP
CONTROL VALVE - UNLOADING 46 64 PUMP SERVO
SPOOL 28 RELIEF VALVE - CHARGE: RELIEF VALVE - 2000 PSI (138 Bar)
120 degrees F. (53 degrees C.)Fluid
12 PILOT ACTIVATED DIRECTIONAL 47 65 ORIFICE - 0.120 inch (3,0 mm) Restriction
350 PSI (24,1 Bar) at High Engine Idle SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TILT CONTROL CONTROL VALVE (TWO COIL)
29 CHARGE PUMP 66 ORIFICE - 0.025 inch (0,63 mm)
13 PILOT ACTIVATED DIRECTIONAL 12.0 GPM (45,4 L/min.) at High Engine Idle 48 RELIEF VALVE - 1200 PSI (82,7 Bar) Restriction
CONTROL VALVE - LIFT CONTROL
30 HYDRAULIC PUMP . . . . . . . . . . Gear Type 49 CHECK VALVE - With 80 PSI (5,5 Bar) 67 ORIFICE - 0.030 inch (0,76 mm)
14 SOLENOID ACTIVATED DIRECTIONAL 20.0 GPM (75,8 L/min.) at High Engine Idle Spring Restriction
CONTROL VALVE - BICS CONTROL
31 DRIVE MOTOR SHUTTLE VALVE 50 CHECK VALVE - With 300 PSI (20,7 Bar)
15 PULL BUTTON ACTIVATED Spring
DIRECTIONAL CONTROL VALVE - LIFT 32 SHUTTLE RELIEF VALVE: 51 RELIEF VALVE - PORT:
ARM BY-PASS 200 PSI (13,8 Bar) 3500 PSI (241 Bar)
33 REAR AUXILIARY BLEED SHUTTLE 52 SOLENOID ACTIVATED DIRECTIONAL
VALVE CONTROL VALVE - BUCKET POSITION NOTE: Unless otherwise specified
VALVE (ON/OFF) springs have NO significant
pressure value.
Printed in U.S.A. V-0530legend (4-8-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW OPTION
S/N 519611408 AND ABOVE
S/N 519711198 AND ABOVE
(PRINTED APRIL 2004)
V-0530 HYDROSTATIC M2 M1
PUMP
Printable Version Click Here 26 26
STEERING VALVE
28 59 57 57 59
CHARGE M3
DRIVE MOTOR INLET
29
SELECT VALVE C2 C1
M4
(RIGHT SIDE LIFT ARM
45 QUICK COUPLERS)
31 M 40
32 64 CASE 60 60
5
MALE
MALE
FEMALE
FEMALE
DRAIN
33
39 39
62 (REAR QUICK COUPLERS)
Control
Module 54 61 INTEGRATED QUICK
60 60
9 COUPLER BLOCK
(EDC) 57
57
61 38 34
MALE 59 59
58
X1 X2
PRESS PB 63
MALE
X2 X1 36 63
Control
61
Module 37 35 FEMALE
(EDC)
T
56
HYDROSTATIC HYDRAULIC FILTER
PUMP 44
3
BUCKET POSITION VALVE (OPTIONAL)
OIL
62 4 D
COOLER
8
M4
M
5 64
45
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
HYDRAULIC CONTROL VAVLE 10
28
43
CASE
DRAIN 11
M2 M1 27
24 24
25 B
A B
30
OUTLET AUXILIARY
SPOOL
INLET
55 BOB-TACH
OUTLET CYLINDER 23
(OPTIONAL) TILT CYLINDER
22
INLET BICS CONTROL VALVE
HYDRAULIC
OUTLET POWERED
BOB-TACH
DR (OPTIONAL)
53
49
A B 12
51 TILT
50 CYLINDER
SPOOL
48 46
21
DRIVE MOTOR
66 67 18
47 65
PP 20 LIFT CYLINDERS
9 17
P2 13
P1 5
A B
LIFT
CYLINDER
SPOOL
31 32
18 42
19 14 WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
DRAIN CIRCUITS
2 COMPONENTS
LIFT ARM BY- PASS
VALVE
15
1
Printed in U.S.A.
V-0530 (4-8-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW AND TWO SPEED VALVE OPTION
S/N 519611408 AND ABOVE
S/N 519711198 AND ABOVE
(PRINTED APRIL 2004) Printable Version Click Here
V-0531legend
LEGEND
1 RESERVOIR: 19 RELIEF VALVE - MAIN: 37 RELIEF VALVE - MAIN (HIGH FLOW) 56 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . 18.8 Qts. (17.8 L) 2950-3050 PSI (203-210 Bar) 3000 PSI (207 Bar) CONTROL VALVE - MAKE-UP
2 FILTER - CASE DRAIN (90 Micron) at Front Quick Couplers
38 57 SOLENOID ACTIVATED DIRECTIONAL
20 RELIEF VALVE - PORT: SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO SPEED
3 FILTER - HYDRAULIC (CANISTER) 3500 PSI (241 Bar) CONTROL VALVE (TWO COIL)
58 BRAKE DIAGNOSTIC PLUG
SPRING LOADED FILTER BY-PASS 21 ANTICAVITATION VALVE 39 PILOT TO OPEN CHECK VALVE
4
VALVE: 45-55 PSI (3,1-3,8 Bar) 59 PILOT ACTIVATED DIRECTIONAL
22 RELIEF/ANTICAVITATION VALVE - 40 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO SPEED
5 PILOT ACTIVATED DIRECTIONAL PORT (TILT BASE END) DRIVE MOTOR
CONTROL VALVE - BLEED OFF
CONTROL VALVE - HYDRAULIC 3500 PSI (241 Bar) 60 HYDRAULIC HIGH FLOW PUMP - Gear Type
POWERED BOB-TACH 41 CHECK VALVE - BICS CONTROL VALVE
23 ONE WAY RESTRICTOR VALVE 10.0 GPM (37,9 L/min.) at High Engine Idle
6 DIFFERENTIAL PRESSURE SWITCH: 61 SELECT VALVE RESTRICTOR
42 LIFT ARM BY-PASS RESTRICTOR
36-44 PSI (2,5-3,0 Bar) 24 SOLENOID ACTIVATED DIRECTIONAL
7 FLOW DIVIDER ADJUSTMENT VALVE CONTROL VALVE - AUXILIARY 43 CHECK VALVE - AUXILIARY 62 HYDRAULIC STEERING PUMP- Gear Type
25 RELIEF VALVE - PORT: . . . . . (Optional) 13.0 GPM (49,2 L/min.) at High Engine Idle
8 CHECK VALVE - BUCKET POSITION 44 FILTER - CASE DRAIN (Attachment)
3500 PSI (241 Bar) 63 FILTER - STEERING (10 MICRON)
VALVE
26 RELIEF/REPLENISHING VALVE - HIGH 45 VARIABLE CAPACITY DISPLACEMENT
9 FIXED CAPACITY DISPLACEMENT 64 SOLENOID ACTIVATED
PRESSURE: 5000 PSI (345 Bar) BIDIRECTIONAL HYDROSTATIC PUMP
BIDIRECTIONAL HYDROSTATIC PROPORTIONAL FLOW CONTROL
27 CHARGE PRESSURE SWITCH 46 RELIEF VALVE - 2000 PSI (138 Bar) VALVE - STEERING
MOTOR
10 PILOT ACTIVATED DIRECTIONAL 28 RELIEF VALVE - CHARGE: 47 SOLENOID ACTIVATED DIRECTIONAL 65 SOLENOID ACTIVATED PRESSURE
CONTROL VALVE - FLOW CONTROL 120 degrees F. (53 degrees C.)Fluid CONTROL VALVE (TWO COIL) CONTROL VALVE
SPOOL 350 PSI (24,1 Bar) at High Engine Idle 0-2000 PSI (0-138 Bar)
48 RELIEF VALVE - 1200 PSI (82,7 Bar)
11 PILOT ACTIVATED DIRECTIONAL 66 STEERING CYLINDER
29 CHARGE PUMP
CONTROL VALVE - UNLOADING 49 CHECK VALVE - 80 PSI (5,5 Bar) Spring
12.0 GPM (45,4 L/min.) at High Engine Idle 67 CHECK VALVE - 270 PSI (18,6 Bar)
SPOOL
30 HYDRAULIC PUMP . . . . . . . . . Gear Type
12 PILOT ACTIVATED DIRECTIONAL 50 CHECK VALVE - 300 PSI (20,7 Bar) Spring 68 PRESSURE CONTROL PILOT VALVE -
CONTROL VALVE - TILT CONTROL 20.0 GPM (75,8 L/min.) at High Engine Idle
(2 COILS) 0 - 0.085 Ampere
31 DRIVE MOTOR SHUTTLE VALVE
13 PILOT ACTIVATED DIRECTIONAL 51 RELIEF VALVE - PORT: 69 DISPLACEMENT CONTROL SPOOL
CONTROL VALVE - LIFT CONTROL 3500 PSI (241 Bar)
32 SHUTTLE RELIEF VALVE:
14 52 SOLENOID ACTIVATED DIRECTIONAL 70 PUMP SERVO
SOLENOID ACTIVATED DIRECTIONAL 200 PSI (13,8 Bar)
CONTROL VALVE - BICS CONTROL CONTROL VALVE - BUCKET POSITION
33 REAR AUXILIARY BLEED SHUTTLE VALVE 71 FRONT AUXILIARY MANUAL PRESSURE
VALVE (ON/OFF)
15 PULL BUTTON ACTIVATED BLEED-OFF VALVE
DIRECTIONAL CONTROL VALVE - LIFT 34 LOAD CHECK VALVE - SELECT VALVE 53 FIXED CAPACITY DISPLACEMENT
72 ORIFICE - 0.120 inch (3,0 mm) Restriction
ARM BY-PASS (HIGH FLOW) BIDIRECTIONAL HYDROSTATIC
MOTOR 73 ORIFICE - 0.025 inch (0,63 mm) Restriction
16 FILTER - BICS CONTROL VALVE 35 SOLENOID ACTIVATED DIRECTIONAL 54 HYDRAULIC BRAKE - SPRING APPLIED -
(SCREEN) CONTROL VALVE - HIGH FLOW PRESSURE TO RELEASE 74 ORIFICE - 0.030inch (0,76 mm) Restriction
17 ONE WAY RESTRICTOR - BOOM DOWN
36 SOLENOID ACTIVATED DIRECTIONAL 55 PUSH BUTTON SOLENOID ACTIVATED
DIRECTIONAL CONTROL VALVE - NOTE: Unless otherwise specified
CONTROL VALVE - DIVERTER
18 LOAD CHECK VALVE- LIFT AND TILT BRAKE springs have NO significant
pressure value.
Printed in U.S.A. V-0531legend (4-8-04)
A220 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH HIGH FLOW AND TWO SPEED VALVE OPTION
S/N 519611408 AND ABOVE
S/N 519711198 AND ABOVE
(PRINTED APRIL 2004)
V-0531 HYDROSTATIC
M2 M1
PUMP
Printable Version Click Here 26 26
TWO SPEED DRIVE MOTOR
STEERING VALVE
28 66 64 64 66
CHARGE
M3
31 32 INLET
29
SELECT VALVE C1 C2
M4
45 (RIGHT SIDE LIFT ARM
CASE QUICK COUPLERS)
M
70 40 (OPTIONAL) 67 67
5 DRAIN
MALE
MALE
FEMALE
FEMALE
33
39 39
59 69 (REAR QUICK COUPLERS)
54
53 Control INTEGRATED QUICK
Module 61 61 COUPLER BLOCK 67 67
(EDC) 64
9 68 34 MALE 64
38 66 66
71 65
X1 X2 MALE
PRESS 71 P T
X2 X1 36
Control FEMALE
Module 68 PB 63
37 35
(EDC)
HYDROSTATIC HYDRAULIC FILTER
PUMP 44
3
BUCKET POSITION VALVE (OPTIONAL)
69 OIL
COOLER D
8
M4
M
5 4
45 70
7
6
CHARGE
29
INLET
M3
26 A
26 M3
52 C
HYDRAULIC CONTROL VAVLE 10
28
43
CASE
DRAIN 11
M2 M1 27
24 24
25 B
A B
30
OUTLET AUXILIARY
SPOOL
INLET
62
OUTLET 23
TWO SPEED VALVE TILT CYLINDER
22
INLET BICS CONTROL VALVE
BOB-TACH
CYLINDER
OUTLET
55 (OPTIONAL)
B
HYDRAULIC
60 POWERED
BOB-TACH
TWO SPEED DRIVE MOTOR
DR (OPTIONAL) 12
A B
51 TILT
56 9
49 CYLINDER
SPOOL
53 21
C 54 50
18
P D 59 48 46 20 LIFT CYLINDERS
17
73 74 13
47 72
PP
57 A B
LIFT
P1 P2 CYLINDER
5
SPOOL
A
18 42
31 32
19 14 WORKING CIRCUITS
16 41 16 PILOT CIRCUITS
T DRAIN CIRCUITS
COMPONENTS
2 LIFT ARM BY- PASS
VALVE
15
Printed in U.S.A.
V-0531 (4-8-04)
HYDRAULIC SYSTEM INFORMATION
A220 Bobcat Loader
20-10-1 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)
A220 Bobcat Loader
20-10-2 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)
A220 Bobcat Loader
20-10-3 Service Manual
A220 Bobcat Loader
20-10-4 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)
Troubleshooting
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized bobcat service personnel adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
The hydraulic system will not operate 1,2,3,5,8
The transmission warning light comes ON when hydraulics are operating 1,3
Slow hydraulic system action 1,3,4,6,8
Hydraulic action is not smooth 1,4,5,6,7
Lift arms go up slowly at full engine RPM 1,3,4,6,7,8,9
The lift arms or Bob-Tach will move when the pedal is in neutral position 4
The lift arms come down with the pedal in the neutral position 4,9,10,11
By-pass valve stuck 12
By-pass valve stem bent or broken 13
KEY TO CORRECT THE CAUSE
1. The fluid level is not correct.
2. The pedal linkage is disconnected.
3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.
5. Relief Valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid (See HYDRAULIC FLUID SPECIFICATIONS on Page SPEC-60-1.)
8. Using the loader from more than its rated capacity.
9. Internal leak in the lift cylinder(s).
10. External leak from the lift cylinder(s).
11. Damaged lift spool.
12. Rotate shaft.
13. Replace manual spool cartridge.
A220 Bobcat Loader
20-10-5 Service Manual
HYDRAULIC SYSTEM INFORMATION (CONT’D)
Tighten Procedures
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
For Tightening Torques For Hydraulic Fittings,
Tubelines Etc., (See HYDRAULIC CONNECTION
SPECIFICATIONS on Page SPEC-50-1.)
A220 Bobcat Loader
20-10-6 Service Manual
CYLINDER (LIFT) Figure 20-20-4
Checking
1
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496 CD-15068
Figure 20-20-3 Install a plug (Item1) [Figure 20-20-4] in the hose and
tighten.
Engage the parking brake. Lower the seat bar. Start the
1 engine and push the top (toe) of the lift pedal.
If there is any leakage from the open port, remove the lift
cylinder for repair. Repeat the procedure to check the
other lift cylinder.
Removal And Installation
Figure 20-20-5
CD-15067
Lower the lift arms. Stop the engine. Raise the seat bar.
Check only one cylinder at a time. Disconnect the hose
(Item 1) [Figure 20-20-3] which goes to the base end of
the lift cylinder.
P7960
Raise the lift arms so the rod end retaining pin will clear
the loader frame for removal.
Have a second person put jackstands under the Bob-
Tach to support the lift arms. [Figure 20-20-5]. Stop the
engine.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
A220 Bobcat Loader
20-20-1 Service Manual
CYLINDER (LIFT) (CONT’D)
Removal And Installation (Cont’d)
WARNING
Figure 20-20-6
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Figure 20-20-8
1 1
CD-15069
Remove the retaining bolt and nut (Item 1) [Figure 20-
20-6] from the pivot pin on the rod end of the cylinder.
Installation: Tighten the retainer bolt and nut to 18-20 ft.-
lbs. (24-27 Nm) torque.
CD-15073
Remove the pivot pin from the rod end of the cylinder.
Mark the hoses for correct installation.
Figure 20-20-7
Disconnect the two hoses (Item 1) [Figure 20-20-8] from
the lift cylinder.
Remove the lift cylinder.
CD-15070
Remove the retaining bolt and nut (Item 1) [Figure 20-
20-7] from the pivot pin on the base end of the cylinder.
Installation: Tighten the retainer bolt and nut to 18-20 ft.-
lbs. (24-27 Nm) torque.
Remove the pivot pin from the base end of the cylinder
[Figure 20-20-7].
Slide the cylinder forward for clearance to disconnect the
hoses.
A220 Bobcat Loader
20-20-2 Service Manual
CYLINDER (LIFT) (CONT’D)
Parts Identification
1. Tube 9. O-ring
2. O-ring 10. Spacer
3. Plug 11. O-ring
4. Case 12. Washer
5. O-ring 13. Head
6. Nut 14. Seal
7. Piston 15. Seal
8. Ring 16. Rod
10
9
TS-1060a 8
16
7
3 6
2 5
15
1 14
3
2 13
4
12
11
TS-1060B
TS-1060
A220 Bobcat Loader
20-20-3 Service Manual
CYLINDER (LIFT) (CONT’D) Figure 20-20-11
Disassembly 3
Figure 20-20-9
2
1
P7430
Remove the seal (Item 1), and the O-ring (Item 2) from
P7429
P7429 the piston (Item 3) [Figure 20-20-11].
Figure 20-20-12
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook Spanner Wrench
Hold the hydraulic cylinder over a drain pan and move
the rod in and out slowly to remove the fluid from the
cylinder. 3
2
Put the base end of the cylinder in a vise. 1
Use a spanner wrench to loosen the head [Figure 20-20-
9].
Figure 20-20-10
P7422
4
3
2 Remove the thick O-ring (Item 1), and the back-up
washer (Item 2) [Figure 20-20-12] from the groove in the
1 head.
Remove the thin O-ring (Item 3) [Figure 20-20-12].
P7428
Remove the head and the rod assembly from the cylinder
[Figure 20-20-10]. Put the rod end in a vise.
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-10].
A220 Bobcat Loader
20-20-4 Service Manual
CYLINDER (LIFT) (CONT’D) Always install new O-rings and seals during assembly.
Disassembly (Cont’d) Lubricate all O-rings and seals with hydraulic oil during
installation.
Figure 20-20-13
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-20-14].
Allow the seal to stretch for 30 seconds before installing it
on the piston.
Figure 20-20-15
2
3 1 3
1
P7426
Remove the wiper seat (Item 1), and rod seal (Item 2)
[Figure 20-20-13].
Remove the O-ring (Item 3) [Figure 20-20-13] from the
rod seal.
P7430
Assembly
Standard Piston: Install the seal (Item 1) and O-ring (Item
Figure 20-20-14 2) on the piston (Item 3) [Figure 20-20-15].
P7424
Use the following tools to assemble the cylinder:
MEL1396 - Seal Installation Tool
MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other
damage. Replace any damaged parts.
A220 Bobcat Loader
20-20-5 Service Manual
CYLINDER (LIFT) (CONT’D) Figure 20-20-18
Assembly (Cont'd)
Figure 20-20-16
2
3
P7422
Install the thin O-ring (Item 1) [Figure 20-20-18].
P7427
Install the back-up washer (Item 2) and thick O-ring (Item
3) [Figure 20-20-18] into the groove on the head.
Install the rod seal on the rod seal tool [Figure 20-20-16].
Figure 20-20-19
NOTE: During installation the O-ring side of the seal
must be toward the inside of the cylinder. 1
2
Rotate the handles to collapse the rod seal [Figure 20- 3
20-16]. 4
Figure 20-20-17
P7428
NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit.
Install the head (Item 1), and spacer (Item 2) [Figure 20-
P7425 20-19].
Install the piston (Item 3), and the nut (Item 4) [Figure
Install the rod seal in the head [Figure 20-20-17]. 20-20-19].
Install the wiper seal with the wiper toward the outside of Tighten the nut (Item 4) [Figure 20-20-19] to 400 ft.-lbs.
the head. (542 Nm) torque.
A220 Bobcat Loader
20-20-6 Service Manual
CYLINDER (LIFT) (CONT’D)
Assembly (Cont'd)
Figure 20-20-20
P7429
Put the base end of the hydraulic cylinder in a vise.
Tighten the head using a spanner wrench [Figure 20-20-
20].
A220 Bobcat Loader
20-20-7 Service Manual
A220 Bobcat Loader
20-20-8 Service Manual
CYLINDER (TILT) Removal And Installation
Checking Figure 20-21-2
Figure 20-21-1
P7694
P1187
Remove the attachment. Roll the Bob-Tach fully forward
[Figure 20-21-2].
Figure 20-21-3
WARNING
1
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496
Remove the attachment. Roll the Bob-Tach fully back.
Stop the engine. Raise the seat bar.
P7693
Disconnect the hose (Item 1) [Figure 20-21-1] which
goes to the base end of the tilt cylinder.
Stop the engine. Raise the seat bar.
Put a plug in the hose and tighten.
Remove the retainer bolt and nut (Item 1) [Figure 20-21-
Install a test hose between cylinder and a drain pan. 3] from the rod end pivot pin.
Engage the parking brake. Lower the seat bar. Start the Installation: Tighten the retainer nut to 18-20 ft.-lbs. (24-
engine and push the bottom (heel) of the tilt pedal. If 27 Nm) torque.
there is leakage from the open port, remove the tilt
cylinder for repair.
A220 Bobcat Loader
20-21-1 Service Manual
CYLINDER (TILT) (CONT’D)
Removal And Installation (Cont'd)
WARNING
Figure 20-21-4
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Figure 20-21-6
P7695
Remove the rod end pivot pin (Item 1) [Figure 20-21-4].
Engage the parking brake. Lower the seat bar. Start the 1
engine and push the bottom (heel) of the tilt pedal until
rod end of cylinder is fully retracted.
P7679
Disconnect both hydraulic hoses (Items 1) [Figure 20-
21-4]. Remove the base end pivot pin (Item 1) [Figure 20-21-
6].
Plug fittings on tilt cylinder.
Remove the tilt cylinder from the loader.
Figure 20-21-5
Rod End Seal
Figure 20-21-7
P7678 1
Remove the retainer bolt and nut (Item 1) [Figure 20-21-
P-3911
5] from the base end pivot pin.
Installation: Tighten the retainer nut and bolt to 18-20 ft.- Remove the old seal (both sides) from the rod end of the
lbs. (24-27 Nm) torque. tilt cylinder.
Install the new seals (Item 1) [Figure 20-21-7] with the lip
facing out.
A220 Bobcat Loader
20-21-2 Service Manual
CYLINDER (TILT) (CONT’D)
Rod End Seal (Cont’d)
Figure 20-21-8
P-3910
Using two pieces of shim stock, install the rod end of the
tilt cylinder into the Bob-Tach [Figure 20-21-8].
Be careful not to damage the new seals during
installation.
Hold the rod end in position and remove the shim stock.
A220 Bobcat Loader
20-21-3 Service Manual
CYLINDER (TILT) (CONT’D)
Parts Identification
1. Case
2. Plug
3. O-ring
4. Tube
5. Nut
6. Clamp
7. Bolt
8. Nut
9. Piston
10. Seal 3
11. O-ring MC1688A MC-1688B
12. O-ring 2
13. Washer 1
4
14. O-ring
15. Head 6 5
16. Seal
17. Seal
18. Rod
19. Seal
20. Bushing
7
15
9
10 16
11 17
12
13 18
19 20
19
14
MC-1688C MC-1688D TS-1233B
A220 Bobcat Loader
20-21-4 Service Manual
CYLINDER (TILT) (CONT’D) Figure 20-21-11
Disassembly
3
Figure 20-21-9
2
1
P7430
Remove the seal (Item 1), and O-ring (Item 2) from the
P7435 piston (Item 3) [Figure 20-21-11].
Figure 20-21-12
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook
Spanner Wrench
Hold the hydraulic cylinder over a drain pan and move
the rod in and out slowly to remove the fluid from the 3
cylinder. 2
Put the base end of the cylinder in a vise. 1
Use a spanner wrench to loosen the head [Figure 20-21-
9].
Figure 20-21-10 P7422
Remove the thick O-ring (Item 1), and the back-up
3
2 washer (Item 2) [Figure 20-21-12] from the groove in the
1 head.
Remove the thin O-ring (Item 3) [Figure 20-21-12].
P7434
Remove the head and the rod assembly from the cylinder
[Figure 20-21-10]. Put the rod end in a vise.
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-21-10].
A220 Bobcat Loader
20-21-5 Service Manual
CYLINDER (TILT) (CONT’D) Always install new O-rings and seals during assembly.
Disassembly (Cont’d) Lubricate all O-rings and seals with hydraulic oil during
installation.
Figure 20-21-13
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-21-14].
Allow the seal to stretch for 30 seconds before installing it
on the piston.
Figure 20-21-15
3 1
1
P7426
Remove the wiper seat (Item 1), and rod seal (Item 2)
[Figure 20-21-13].
Remove the O-ring (Item 3) [Figure 20-21-13] from the
rod seal.
P7438
Assembly
Install the seal and O-ring on the piston (Item 1) [Figure
Figure 20-21-14 20-21-15].
Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for about
three minutes.
P7424
Use the following tools to assemble the cylinder:
MEL1396 - Seal Installation Tool
MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other
damage. Replace any damaged parts.
A220 Bobcat Loader
20-21-6 Service Manual
CYLINDER (TILT) (CONT’D) Figure 20-21-18
Assembly (Cont'd)
Figure 20-21-16
P7422
Install the thin O-ring (Item 1) [Figure 20-21-18].
P7427
Install the back-up washer (Item 2) and thick O-ring (Item
3) [Figure 20-21-18] into the groove on the head.
Install the rod seal on the rod seal tool [Figure 20-21-16].
Figure 20-21-19
NOTE: During installation the O-ring side of the seal
must be toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 20- 1
21-16]. 3 2
Figure 20-21-17
P7434
NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit.
Install the head (Item 1), and the piston (Item 2) [Figure
P7425 20-21-19]. The small diameter of the piston goes into the
cylinder tube first.
Install the rod seal in the head [Figure 20-21-17]. Grease the piston where the nut contacts the piston. Do
not get grease on the threads.
Install the wiper seal with the wiper toward the outside of
the head. Install the nut (Item 3) [Figure 20-21-19].
Tighten the nut to 100 ft.-lbs. (136 Nm) torque.
A220 Bobcat Loader
20-21-7 Service Manual
CYLINDER (TILT) (CONT’D)
Assembly (Cont'd)
Figure 20-21-20
P-10450 P-10456
P10450
Mark the end of the shaft and nut [Figure 20-21-20].
Tighten the nut an additional 135 degrees or 2-1/4 flats
[Figure 20-21-20].
Figure 20-21-21
P7435
Put the base end of the hydraulic cylinder in a vise.
Tighten the head using a spanner wrench [Figure 20-21-
21].
A220 Bobcat Loader
20-21-8 Service Manual
CYLINDER (POWER BOB-TACH) Figure 20-22-2
Checking
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285 1
N-23032
WARNING Disconnect the hose (Item 1) [Figure 20-22-2] from the
power Bob-Tach cylinder base end port.
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
Figure 20-22-3
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury. 1
W-2072-0496
2
Figure 20-22-1
N-23033
Install a plug in the hose (Item 1) [Figure 20-22-3] and
tighten.
Engage the parking brake. Lower the seat bar. Start the
engine.
N-23031
Push and hold the BOB-TACH "WEDGES UP" Switch
(Front Accessory Panel).
Tilt the Bob-Tach forward, so it is parallel to the floor
[Figure 20-22-1]. If there is any leakage from the base end cylinder port
(Item 2) [Figure 20-22-3], remove the lift cylinder for
repair.
A220 Bobcat Loader
20-22-1 Service Manual
CYLINDER (POWER BOB-TACH) (CONT’D)
Removal And Installation
Figure 20-22-4
1 2
N-23031
Disconnect the hoses (Items 1 & 2) [Figure 20-22-4]
from the cylinder fittings.
Install plugs and cap on fittings.
Figure 20-22-5
1
1
N-23034
Remove the bolts (Item 1) [Figure 20-22-5].
Installation: Tighten the bolts to 25-28 ft.-lbs. (34-38
Nm) torque.
Remove the washers and cylinder from the lever pivots.
A220 Bobcat Loader
20-22-2 Service Manual
CYLINDER (POWER BOB-TACH) (CONT’D)
Parts Identification
1. Cylinder 8. Ring
2. Nut 9. O-ring
3. Piston 10. Head
4. O-ring 11. Seal
5. Ring 12. Seal
6. Spacer 13. Rod
7. O-ring
2 3
4
5
6
7
8
9
10
11
12
13
B16276
A220 Bobcat Loader
20-22-3 Service Manual
CYLINDER (POWER BOB-TACH) (CONT’D) Remove the nut (Item 1) [Figure 20-22-7], piston (Item 2)
[Figure 20-22-7] and head (Item 3) [Figure 20-22-7]
Disassembly from the rod.
Figure 20-22-6 Figure 20-22-8
3
2
1
P16293 P16295
Use the following tools to disassemble the cylinder: Piston: Remove the O-ring (Item 1), and seal (Item 2)
from the piston (Item 3) [Figure 20-22-8].
MEL1074 - O-ring Seal Hook
Spanner Wrench Figure 20-22-9
Hold the hydraulic cylinder over a drain pan and move 5
the rod in and out slowly to remove the fluid from the 3
cylinder. 4
Put the base end of the cylinder in a vise.
2
Use a spanner wrench to loosen the head [Figure 20-22- 1
6].
Figure 20-22-7
2
3
1 N-20611
Remove the wiper seal (Item 1), and rod seal (Item 2),
the back up washer (Item 3) the thin O-ring (Item 4) and
the thick O-ring (Item 5) [Figure 20-22-9] from the head.
P16294
Remove the head and rod assembly from the cylinder
[Figure 20-22-7]. Put the rod end in a vise.
A220 Bobcat Loader
20-22-4 Service Manual
CYLINDER (POWER BOB-TACH) (CONT’D) Figure 20-22-11
Assembly
3 1
Figure 20-22-10 2
P16295
Piston: Install the O-ring (Item 1) and seal (Item 2) on the
P7424 piston (Item 3) [Figure 20-22-11].
NOTE: The piston center hole (Item 4) [Figure 20-22-
Use the following tools to assembly the cylinder: 11] has a bevel on one end. The bevel goes
toward the rod.
MEL1396 - Seal Installation Tool
MEL1033 - Rod Seal Installation Tool Figure 20-22-12
Piston Ring Compressor
Spanner Wrench
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other
damage. Replace any damaged parts.
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic oil during
installation.
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-22-10]. N-20612
Allow the seal to stretch for 30 seconds before installing it
on the piston. Install the rod seal on the rod seal tool [Figure 20-22-12].
NOTE: During installation the O-ring side of the seal
must be toward the inside of the cylinder.
A220 Bobcat Loader
20-22-5 Service Manual
CYLINDER (POWER BOB-TACH) (CONT’D) Figure 20-22-15
Assembly (Cont'd)
Figure 20-22-13
1
2
3
P7422
Install the thin O-ring (Item 1) [Figure 20-22-15].
N-20613
Install the back-up washer (Item 2) and thick O-ring (Item
3) [Figure 20-22-15] into the groove on the head.
Rotate the handles to collapse the rod seal [Figure 20-
22-13]. NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the seal kit.
Figure 20-22-14
Figure 20-22-16
3
1 2
4
P7425
P16294
Install the rod seal in the head [Figure 20-22-14].
Install the head (Item 1), and spacer (Item 2) [Figure 20-
Install the wiper seal with the wiper toward the outside of 22-16].
the head.
Install the piston (Item 3) [Figure 20-22-16].
Lift Cylinder: Grease the piston where the nut contacts
the piston. Do not get grease on the threads. Install the
new nut (Item 4) [[Figure 20-22-16].
Tighten the nut to 90 ft.-lbs. (122 Nm) torque.
A220 Bobcat Loader
20-22-6 Service Manual
CYLINDER (POWER BOB-TACH) (CONT’D)
Assembly (Cont'd)
Figure 20-22-17
P16293
Put the base end of the hydraulic cylinder in a vise.
Tighten the head using a spanner wrench [Figure 20-22-
17].
A220 Bobcat Loader
20-22-7 Service Manual
A220 Bobcat Loader
20-22-8 Service Manual
CYLINDER (STEERING) Figure 20-23-3
Removal (Front)
Figure 20-23-1
P-24924
Remove the two retainer bolts (Item 1) [Figure 20-23-3]
P-24816 from wheel position sensor/steering cylinder cover.
Remove the wheel position sensor/steering cylinder
Lift and block the loader. (See LIFTING AND BLOCKING cover from the loader.
THE LOADER on Page 10-10-1.)
Figure 20-23-4
Remove the tire/wheel assembly [Figure 20-23-1].
Figure 20-23-2
1
1
1
P-28215
P-26077 Remove the retainer bolt (Item 1) [Figure 20-23-4] from
the cylinder rod cover.
Remove the four bolts (Item 1) [Figure 20-23-2] from the Remove the cover from the loader.
hydrostatic motor cover.
Remove the hydrostatic motor cover.
A220 Bobcat Loader
20-23-1 Service Manual
CYLINDER (STEERING (CONT’D) Figure 20-23-7
Removal (Front) (Cont’d)
Figure 20-23-5
1
1
P-26075
Raise the operator cab. (See Raising The Operator Cab
P-28216 on Page 10-30-1.)
Remove the three mount bolts (Item 1) [Figure 20-23-7]
Remove the retainer (Item 1) [Figure 20-23-5] from the on the left foot rest.
steering cylinder pin.
Remove the foot rest from the loader.
Figure 20-23-6
Figure 20-23-8
P-28217
P-26076
Remove the steering cylinder pin (Item 1) [Figure 20-23-
6]. Remove the two mount bolts (Item 1) [Figure 20-23-8]
from the access panel.
Remove the access panel from the loader.
A220 Bobcat Loader
20-23-2 Service Manual
CYLINDER (STEERING) (CONT’D) Figure 20-23-11
Removal (Front) (Cont'd)
Figure 20-23-9
1
1
P-26080
Remove the rod end hydraulic hose (Item 1) [Figure 20-
P-26078 23-11], by going through the motor cover access hole.
Figure 20-23-12
Remove the bolt (Item 1) [Figure 20-23-9] from the base
end steering cylinder pin.
Figure 20-23-10 1
P-26081
Remove the base end cylinder pin (Item 1) [Figure 20-
P-26079 23-12].
Mark the hydraulic hoses for proper installation.
Remove the base end hydraulic hose (Item 1) [Figure
20-23-10].
A220 Bobcat Loader
20-23-3 Service Manual
CYLINDER (STEERING) (CONT’D) Figure 20-23-15
Removal (Front) (Cont'd)
Figure 20-23-13
2
P-28218
Remove the two retainer bolts (Item 1) [[Figure 20-23-
P-26082 15] from wheel position sensor/steering cylinder cover.
Remove the six mount bolts (Item 2) [Figure 20-23-15]
Remove the steering cylinder, from the loader [Figure from the loader access cover.
20-23-13].
Remove the wheel position sensor/steering cylinder
Removal (Rear) cover from the loader.
Figure 20-23-14 Figure 20-23-16
P-26083 P-26085
Lift and block the loader. (See LIFTING AND BLOCKING Disconnect the wheel position sensor wire (Item 1)
THE LOADER on Page 10-10-1.) [Figure 20-23-16].
Remove the tire/wheel assembly [Figure 20-23-14].
A220 Bobcat Loader
20-23-4 Service Manual
CYLINDER (STEERING) (CONT’D) Figure 20-23-19
Removal (Rear) (Cont'd)
Figure 20-23-17
1
P-26089
Remove the bolt (Item 1) [Figure 20-23-19] from the rod
P-26086 end cylinder pin.
Figure 20-23-20
Push the harness connector (Item 1) [Figure 20-23-17]
through the access cover.
Remove the access cover from the loader.
Figure 20-23-18
1
P-26090
Remove the rod end cylinder pin (Item 1) [Figure 20-23-
20].
P-26088
Remove the four bolts (Item 1) [Figure 20-23-18] from
the motor cover.
Remove the motor cover from the loader.
A220 Bobcat Loader
20-23-5 Service Manual
CYLINDER (STEERING) (CONT’D) Figure 20-23-23
Removal (Rear) (Cont’d)
Figure 20-23-21
P-26093
1
Remove the base end cylinder pin (Item 1) [Figure 20-
P-26091 23-23].
Figure 20-23-24
Mark the hydraulic hoses for proper installation.
Remove the base and rod cylinder hoses (Item 1)
[Figure 20-23-21].
Figure 20-23-22
1
P-26094
Remove the steering cylinder from the loader [Figure
20-23-24].
P-26092
Remove the retainer bolt (Item 1) [Figure 20-23-22] from
the base end cylinder pin.
A220 Bobcat Loader
20-23-6 Service Manual
MAIN RELIEF VALVE
Checking The Main Relief Valve At Front Auxiliary
Hydraulics
WARNING
Figure 20-30-1 Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Figure 20-30-2
1
2
P5061
The tools listed will be needed to do the following
procedure:
MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit
Turn the key switch to the OFF position, as the engine
stops running, turn the key switch all the way to the left to
release the hydraulic pressure at the front auxiliary quick
couplers.
Lift and block the loader. (See LIFTING AND BLOCKING B-15551
THE LOADER on Page 10-10-1.)
Connect the IN port of the hydraulic tester to the female Start the engine and run at low engine idle RPM. Push
quick coupler on the loader [Figure 20-30-1]. the mode switch (Item 1) (on the instrument panel) two
times to engage the front auxiliary hydraulics, the light
Connect the OUT port of the hydraulic tester to the male (Item 2) [Figure 20-30-2] will come ON.
quick coupler on the loader [Figure 20-30-1].
WARNING
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
A220 Bobcat Loader
20-30-1 Service Manual
MAIN RELIEF VALVE (CONT’D) Removal And Installation
Checking The Main Relief Valve At Front Auxiliary Figure 20-30-4
Hydraulics (Cont’d)
Figure 20-30-3
Right
Steering
1 Lever 1
Control
N-20039
P-26697 Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Push the button (Item 1) [Figure 20-30-3] for fluid flow to The main relief valve (Item 1) is located at the lower front
the quick couplers. of the control valve. The main relief valve (Item 1)
[Figure 20-30-4] is located at the lower front of the
Watch the flow meter on the hydraulic tester to make control valve.
sure the flow is correct. Increase the engine speed to full
RPM.
There should be 20.0 GPM (75,8 L/min.) free flow. Turn
the restrictor control, on the tester, until the main relief IMPORTANT
valve opens. The correct pressure for the main relief is
2950-3050 PSI (20340-21030 kPa). When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
If the relief pressure is not correct, stop the engine. parts clean. Always use caps and plugs on hoses,
Adjust or replace the main relief valve (See Checking tubelines and ports to keep dirt out. Dirt can quickly
The Main Relief Valve At Front Auxiliary Hydraulics on damage the system.
Page 20-30-1.) I-2003-0888
A220 Bobcat Loader
20-30-2 Service Manual
MAIN RELIEF VALVE (CONT’D) Adjustment
Removal And Installation (Cont’d) Figure 20-30-7
Figure 20-30-5
2 1
N-23265
N-23264
If the pressure is not correct, adjust the main relief valve.
Remove the end cap (Item 2) [Figure 20-30-5] .
Remove the right motor cover.
Turn the adjusting screw (Item 1) [Figure 20-30-7] in or
Clean the area around the control valve.
out until the pressure is correct. Turning screw in will
Loosen and remove the main relief valve (Item 1) [Figure increase pressure.
20-30-5].
NOTE: If the correct pressure can not be reached,
Installation: Tighten the main relief valve to 35-40 ft.-lbs. replace the main relief valve. Check the
(47-54 Nm) torque. pressure setting of the new relief valve.
Figure 20-30-6
CD-15092
Remove the O-rings and back-up washers from the main
relief valve [Figure 20-30-6].
Clean the main relief valve in clean solvent. Use air
pressure to dry the valve.
Install new O-rings and back-up washers. Install the main
relief valve and tighten [Figure 20-30-4]. Check the
pressure again. (See Checking The Main Relief Valve At
Front Auxiliary Hydraulics on Page 20-30-1.)
A220 Bobcat Loader
20-30-3 Service Manual
A220 Bobcat Loader
20-30-4 Service Manual
HYDRAULIC CONTROL VALVE Figure 20-40-2
Actuator Removal And Installation (In Loader)
WARNING 1
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P-26817
Figure 20-40-1
Remove the loader control panel. (See CONTROL
1 PANEL on Page 50-100-1.)
Mark the actuator wiring harness connectors for proper
installation.
Unplug the actuator connectors (Item 1) [Figure 20-40-2]
from the loader harness.
Figure 20-40-3
N-23246
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Stop the engine. Raise the seat bar.
Remove the access cover (Item 1) [Figure 20-40-1]
from the right side of the loader frame. 1
P-26818
Remove the two screws (Item 1) [Figure 20-40-3] from
the actuator retainer.
Installation: Tighten the bolts to 90-100 in.-lbs. (10,2-
11,3 Nm) torque.
A220 Bobcat Loader
20-40-1 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-6
Actual Removal And Installation (In Loader) (Cont’d)
Figure 20-40-4 1
P-26822
2
Check and replace the O-ring (Item 1) [Figure 20-40-6]
P-26819 on the spacer.
Figure 20-40-7
Pull the actuator (Item 1) [Figure 20-40-4] away from the
control valve.
Use a punch to remove the actuator pin (Item 2) [Figure
20-40-4] from the actuator and spool.
Remove the actuator from the hydraulic control valve.
NOTE: The calibration procedure must be followed
when replacing a lift or tilt actuator. (See LIFT
AND TILT ACTUATOR CALIBRATION on Page
1
60-160-1.)
Figure 20-40-5
P-26821
1
Check and replace the O-ring (Item 1) [Figure 20-40-7]
on the control valve housing.
P-26820
Remove the spacer (Item 1) [Figure 20-40-5].
A220 Bobcat Loader
20-40-2 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Disconnect the three hoses (Item 1) [Figure 20-40-8]
from the lift arm by-pass control valve.
Removal And Installation
Cap and plug the hoses and fittings.
Figure 20-40-9
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
N-23632
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death. At the right fender, remove the two mounting bolts and
W-2059-0598
nuts (Item 1) [Figure 20-40-9] from the lift arm by-pass
mount.
Figure 20-40-8
Remove the lift arm by-pass valve and mount from the
loader.
1
Figure 20-40-10
1
1
P-26823
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on P-26824
Page 10-20-1.)
Stop the engine. Raise the seat bar. Disconnect the wire harness connector (Item 1) [Figure
20-40-10] from the charge pressure sender.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Drain the hydraulic reservoir. (See Draining The Fluid
Reservoir on Page 20-80-1.)
Remove the control panel. (See CONTROL PANEL on
Page 50-100-1.)
Clean the area around the control valve.
A220 Bobcat Loader
20-40-3 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-13
Removal And Installation (Cont'd)
Figure 20-40-11
P-26826
Disconnect both harness connectors (Item 1) [Figure 20-
P-26825 40-13] from the actuators.
Figure 20-40-14
Disconnect the wire harness connector (Item 1) [Figure
20-40-11] from auxiliary valve solenoids.
Figure 20-40-12
P-26827
1 Open the rear door.
N-23635
Remove the loader alternator. (See ALTERNATOR on
Page 60-30-1.)
Disconnect the harness connector (Item 1) [Figure 20-
40-12] from the BICS valve solenoid connector. The fixed end main valve hose assembly (Item 1) [Figure
20-40-14] is connected to a fixed end fitting on the
control valve. The hose is routed to the back upright
where the hose is connected to a tee fitting that feeds the
base end of both lift cylinders. The hose can only be
removed at the back tee fitting.
Cap and plug the hose and fitting.
A220 Bobcat Loader
20-40-4 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-17
Removal And Installation (Cont'd)
2
Figure 20-40-15
1
1
P-26830
Install a chain hoist (Item 1) [Figure 20-40-17] to the
P-26828 control valve.
Disconnect the hydraulic hose (Item 2) [Figure 20-40-17]
Loosen the fixed end main valve hose assembly (Item 1) that goes from the control valve to the auxiliary gear
[Figure 20-40-15] from the control valve. pump.
The hose can be removed from the control valve by Cap the hose and plug the fitting.
rotating the hose assembly.
Figure 20-40-18
Cap the hose and plug the fitting.
Figure 20-40-16
P-26833
P-26829 Remove the right side motor cover.
Remove the right rear wheel/tire assembly from the
Remove the hydraulic hose (Item 1) [Figure 20-40-16] loader.
from the control valve to the auxiliary pressure release
accumulator. Remove the right side pump access cover.
Remove the case drain hose (Item 2) [Figure 20-40-16] At the right side motor cover access hole, remove the
from the control valve to the case drain filter. inlet tubeline fitting (Item 1) [Figure 20-40-18] from the
bottom of the control valve.
A220 Bobcat Loader
20-40-5 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-21
Removal And Installation (Cont'd)
Figure 20-40-19
1 2
3 1
P-26834
Disconnect the lift tubeline (Item 1) [Figure 20-40-21]
P-26832 from the control valve.
Cap and plug the tubeline and fitting.
At the top of the control valve, remove the tubeline clamp
mount bolt (Item 1) and remove the inlet tubeline (Item 2) Remove the control valve mount bracket from the loader.
[Figure 20-40-19] from the control valve mount plate.
Figure 20-40-22
Remove the two control valve mount plate mounting bolts
and nuts (Item 3) [Figure 20-40-19] from the loader
fender.
Figure 20-40-20
P-26835
Disconnect the hydraulic fitting (Item 1) [Figure 20-40-
22] from the charge pressure sender.
P-26831
Move the charge pressure sender and hose assembly to
the side, to allow clearance for the control valve removal.
At the right side pump access cover hole, remove the two
control valve mount bolts (Item 1) [Figure 20-40-20] from
the mounting plate.
A220 Bobcat Loader
20-40-6 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-25
Removal And Installation (Cont'd)
Figure 20-40-23
1
P-26838
Remove the lift tubeline (Item 1) [Figure 20-40-25] that
P-26836 goes from the control valve to the bucket position valve.
(If so equipped.)
Mark all tubelines for correct installation. Figure 20-40-26
Remove the two bucket position tubelines (Item 1)
[Figure 20-40-23]. (If so equipped.)
Figure 20-40-24
2
1
P-26839
1
Disconnect the auxiliary tubeline (Item 1) [Figure 20-40-
26] from the control valve.
P-26837
Cap and plug the tubeline and fitting.
Disconnect the three auxiliary tubelines that are
connected to the fitting (Item 1) [Figure 20-40-24].
Remove the fitting from the loader.
Disconnect the tilt tubeline (Item 2) [Figure 20-40-24]
from the fitting on the control valve.
A220 Bobcat Loader
20-40-7 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-29
Removal And Installation (Cont'd)
Figure 20-40-27
N-19113
Use a drift pin and hammer to remove the actuator pin
P-26840 (Item 1) [Figure 20-40-29] from the actuator and the lift
or tilt spool.
Lower the chain hoist and valve to allow clearance so the Figure 20-40-30
actuators can clear the tubelines.
Rotate the valve upward until the actuators are above the
tubelines [Figure 20-40-27].
Remove the control valve from the loader.
Actuator Removal And Installation (Out Of Loader)
4
Figure 20-40-28
2 3
1 N-19114
Remove the actuator (Item 1) [Figure 20-40-30].
Remove the O-ring (Item 2) [Figure 20-40-30].
1
2 Remove the spacer block (Item 3) [Figure 20-40-30].
1
Remove the O-ring (Item 4) [Figure 20-40-30].
N-19112
NOTE: The calibration procedure must be followed
when replacing a lift or tilt actuator. (See LIFT
Remove the two screws (Item 1) [Figure 20-40-28] on AND TILT ACTUATOR CALIBRATION on Page
the actuator retainer. 60-160-1.)
Installation: Tighten the bolt and nut to 90-100 in.-lbs.
(10,2-11,3 Nm) torque.
Pull the actuator (Item 2) [Figure 20-40-28] away from
the control valve.
A220 Bobcat Loader
20-40-8 Service Manual
HYDRAULIC CONTROL VALVE) (CONT’D) Figure 20-40-33
BICS™ Valve Removal And Installation
Figure 20-40-31
1
1
1
1 2
P-28324
Replace the four large O-rings (Item 1) and small O-ring
P-28322 (Item 2) [Figure 20-40-33] from the top of the control
valve.
Loosen the six mounting bolts (Item 1) [Figure 20-40-31]
from the BICS™ valve.
Remove the mounting bolts.
Figure 20-40-32
P-28323
Remove the BICS™ valve assembly (Item 1) [Figure 20-
40-32] from the top of the control valve.
A220 Bobcat Loader
20-40-9 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) BICS™ Valve Lift Arm By-Pass Orifice Removal And
Installation
BICS™ Valve Removal And Installation (Cont’d)
Figure 20-40-35
Figure 20-40-34
3 6 1
1 2
5
4
P-28332
P-28322
Remove the fitting (Item 1) [Figure 20-40-35] from the
Install the six mounting bolts. BICS™ valve.
The chart below lists the correct torque specifications
and tightening sequence when reinstalling the BICS™
valve assembly to the hydraulic control valve. Thoroughly
clean and dry bolts and threads in valve. Use liquid
adhesive LOCTITE #242.
Step Torque Sequence
1 110-130 in. 0 lbs.
(12,4-14,7 Nm)
2 190-210in.-lbs. 1,2,3,4,5 & 6
(21,5-23,7Nm)
3* 190-210in.-lbs.
(21,5-23,7Nm)
*Torque must be 190-210 in.-lbs. (21,5-23,7 Nm) for
every bolt or repeat step 3.
A220 Bobcat Loader
20-40-10 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) HYDRAULIC CONTROL VALVE (CONT’D)
BICS™ Valve Lift Arm By-Pass Orifice Removal And BICS™ Valve Check Valve Removal And Installation
Installation (Cont’d)
Figure 20-40-38
Figure 20-40-36
P-28334
P-28333
Remove the check valve (Item 1) [Figure 20-40-38].
Figure 20-40-37
Installation: Tighten the check valve to 20 ft.-lbs. (27
Nm) torque.
Figure 20-40-39
2
1
N-18685
Using a flat blade screw driver, remove the lift arm by-
pass orifice (Item 1) [Figure 20-40-36] & [Figure 20-40- N-18684
37].
Orifice size is 0.078 inch. Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-40-39].
Clean and inspect the orifice. Replace as needed.
Install new O-rings (Item 1) [Figure 20-40-39] and back-
Reverse the removal procedure to install the lift arm by- up ring (Item 2) [Figure 20-40-40] on the check valve.
pass orifice.
Check valve (Item 3) [Figure 20-40-39] has a rating of 5-
10 PSI.
A220 Bobcat Loader
20-40-11 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-42
BICS™ Valve Check Valve Removal And Installation
(Cont’d)
Figure 20-40-40
1 1
P-28336
Figure 20-40-43
P-8956
Clean and inspect the screen (Item 1) [Figure 20-40-40]
on the end of the valve.
Reverse the removal procedure to install the BICS™
check valve.
1
BICS™ Valve Lock Valve Removal And Installation
Figure 20-40-41
P-28337
2 Loosen and remove the lock valve(s) (Item 1) [Figure 20-
40-42] & [Figure 20-40-43] from the valve.
1
Installation: Tighten the lock valve(s) to 25 ft.-lbs. (34
Nm) torque.
P-28335
There are two lock valves on the BICS™ valve, lift lock
valve (Item 1) and tilt lock valve (Item 2) [Figure 20-40-
41].
A220 Bobcat Loader
20-40-12 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-46
BICS™ Valve Lock Valve Removal And Installation
(Cont’d)
1
Figure 20-40-44
1
1
N-18693
2
Remove the O-rings (Item 1) [Figure 20-40-46] from
2 both ends of the coil.
2 N-18690
Figure 20-40-47
Remove the O-rings (Item 1) and back-up rings (Item 2)
[Figure 20-40-44] from both the tilt and lift lock valves.
Install new O-rings (Item 1) and back-up rings (Item 2) 1
[Figure 20-40-44] on the tilt and lift lock valves.
Reverse the removal procedure to install the lock valve.
BICS™ Valve Solenoid Removal And Installation
Figure 20-40-45
P-28340
1 Remove the solenoid stem (Item 1) [Figure 20-40-47].
Installation: Tighten the stem to 20 ft.-lbs. (27 Nm)
torque.
2
P-28338
Remove the nut (Item 1) [Figure 20-40-45] from the
solenoid cartridge.
Installation: Tighten the mounting nut to 53 in.-lbs. (6
Nm) torque.
Remove the coil (Item 2) [Figure 20-40-45].
A220 Bobcat Loader
20-40-13 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) BICS™ Valve Solenoid Testing
BICS™ Valve Solenoid Removal And Installation Figure 20-40-49
(Cont’d)
Figure 20-40-48
3
2
P9175
1
N-18694 Use an Ohm meter to measure coil resistance [Figure
20-40-49]
Remove the O-rings (Item 1) and back-up rings (Item 2) Coil wires do not have polarity.
[Figure 20-40-48] from the stem.
Use only new O-rings and apply oil to all O-rings and
Clean all parts in solvent and dry with compressed air. back-up rings before installation.
Inspect all parts for wear and replace as needed. Correct resistance for the auxiliary, lift, and tilt lock coils
are 7-10 ohms
NOTE: The screen (Item 3) [Figure 20-40-48] can be
cleaned with solvent. If it is torn or worn it The other coils (BICS™, diverter, select valve) are 5-8
needs to be replaced ohms.
Use only new O-rings and apply oil to all o-rings and
back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-40-46] & [Figure
20-40-48] and new back-up rings (Item 2) [Figure 20-40-
48] on the stem.
A220 Bobcat Loader
20-40-14 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-50
Identification Chart
H1
Item A220 Loader H2
A1 Lift Cylinder Base End/Restrictor
A2 Tilt Cylinder Base End
H3
A3 Auxiliary Hydraulics C4
B1 Lift Cylinder Rod End B3 A3
G3 D3
B2 Tilt Cylinder Rod End C3
D2
B3 Auxiliary Hydraulics G2 B2 A2 E2
C1 Load Check Valve/Lift Function C2
F2 D1
B1 A1 E1
C2 Load Check Valve/Tilt Function
F1 C1
C3 Orificed Load Check Valve/Auxiliary Function MR
C4 Outlet Fluid Flow TS-2136
D1 Lift Spool Detent
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool/Centering Spring
E1 Port Relief Valve - 3500 PSI
E2 Anti-Cavitation/Port Relief Valve - 3500PSI
F1 Anti-Cavitation Valve
F2 Port Relieve Valve - 3500 PSI
G1 Lift Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H1 Auxiliary Electric Solenoid
H2 Plug/Port Relief (Optional) - 3500 PSI
H3 Auxiliary ElectricSsolenoid
MR Main Relief Valve - 3000 PSI
A220 Bobcat Loader
20-40-15 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D)
Lift Base End Restrictor
IMPORTANT
Figure 20-40-51
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
1 damage the system.
I-2003-0888
Figure 20-40-53
N-21159
1
Remove the BICS™ valve assembly from the control
valve. (See BICS™ Valve Removal And Installation on
Page 20-40- 9.)
Remove the restrictor (Item 1) [Figure 20-40-51] from
the lift section base end port.
P-28324
Load Check Valve
Mark each valve section, spool and related parts so that
Figure 20-40-52 they will be returned to their original valve section during
assembly.
Use bolts to fasten the control valve to a work bench for
easier disassembly and assembly procedures.
Loosen and remove the load check valve plugs (Item 1)
1 [Figure 20-40-53].
1
Installation: Always use new O-rings. Tighten the plugs
to 35-40 ft.-lbs. (47-54 Nm) torque.
2
P-28324
Remove the BICS™ valve assembly from the control
valve. (See BICS™ Valve Removal And Installation on
Page 20-40- 9.)
Remove the four large O-rings (Item 1) and small O-ring
(Item 2) [Figure 20-40-52]. Always replace these O-rings
before installing the BICS™ valve assembly
A220 Bobcat Loader
20-40-16 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Main Relief Valve
Load Check Valve (Cont'd) Figure 20-40-56
Figure 20-40-54
1
2 3 P-28326
P-28325
Loosen the main relief valve (Item 1) [Figure 20-40-56].
Remove the spring (Item 1) and poppet (Item 2) from, the Figure 20-40-57
load check plug (Item 3) [Figure 20-40-54].
Figure 20-40-55
P-28327
N-20078 P-28324 Remove the main relief valve (Item 1) [Figure 20-40-57].
The auxiliary section (Item 1) may have a load check with
an orifice located in the center of the poppet (Item 2)
[Figure 20-40-55].
A220 Bobcat Loader
20-40-17 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-60
Main Relief Valve
Figure 20-40-58
1
2 3 5
4
1
B-06764
B-06764
1. Relief Valve
2. O-ring
3. Sleeve
N-19034
4. O-ring
5. Glide Ring
Loosen the port relief valve (Item 1) [Figure 20-40-59] &
P-28328 [Figure 20-40-60].
Installation: Always use new O-rings and back-up
Remove the O-rings, sleeve, and glide ring from the main washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
relief valve [Figure 20-40-58].
Figure 20-40-61
Installation: Always use new O-rings, sleeve, and glide
ring. TIghten to 35-40 ft.-lbs. (47-54 Nm) torque.
Port Relief Valve
Figure 20-40-59
N-18981
Remove the port relief valve (Item 1) [Figure 20-40-61].
N-19000
A220 Bobcat Loader
20-40-18 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-64
Port Relief Valve (Cont’d)
Figure 20-40-62
4 1
2
1
1. O-ring
N-18980
2. Back-up Washer
3. O-ring
4. Relief Valve Remove the anti-cavitation/port relief valve (Item 1)
N-18844 [Figure 20-40-64] from the control valve for the tilt
section.
Remove the O-rings and back-up washer from the port Figure 20-40-65
relief valve [Figure 20-40-62].
Anti-Cavitation Valve/Port Relief Valve
Figure 20-40-63 1
N-18843
Remove the O-rings (Item 1) [Figure 20-40-65] from the
anti-cavitation/port relief valve.
N-19003
Loosen the anti-cavitation valve (Item 1) [Figure 20-40-
63].
Installation: Always use new O-rings and back-up
washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
A220 Bobcat Loader
20-40-19 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-68
Anti-Cavitation Valve 1 2
3 4
Figure 20-40-66
E-01509
1. Anti-Cavitation Valve
2. O-ring
1
3. Back-up Washer
4. O-ring
P-28331
Remove the O-rings and back-up washer from the anti-
P-28329 cavitation valve [Figure 20-40-68].
Figure 20-40-67
N-19036A
Remove the anti-cavitation valve (Item 1) [Figure 20-40-
66] & [Figure 20-40-67] from the control valve.
A220 Bobcat Loader
20-40-20 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-71
Lift Spool Removal And Installation
Figure 20-40-69
N-19003
1 Remove the screws (Item 1) [Figure 20-40-71] from the
N-19112 cap.
Figure 20-40-72
Remove the actuator (Item 1) [Figure 20-40-69] from the
control valve. (See Actuator Removal And Installation (In
Loader) on Page 20-40-1.)
Figure 20-40-70
2
N-18983
1
2
Remove the spool assembly (Item 1) [Figure 20-40-72]
and seal from the control valve.
N-19114
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
20-40-70] from the lift spool.
A220 Bobcat Loader
20-40-21 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-75
Tilt Spool Removal And Installation
Figure 20-40-73
1
1
2
1 N-19003
Remove the screws (Item 1) [Figure 20-40-75] from the
P-28320 end cap.
Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3
Remove the bolts (Item 1) to pull the actuator (Item 2) Nm) torque.
[Figure 20-40-73] from the spacer.
Figure 20-40-76
Figure 20-40-74
2
N-18985
2 1 P-28321
Remove the spool assembly (Item 1) [Figure 20-40-76]
Remove the spacer (Item 1) and O-rings (Item 2) [Figure and seal from the control valve.
20-40-74] from the tilt spool.
Assembly: Always use a new spool seal.
A220 Bobcat Loader
20-40-22 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-79
Lift And Tilt Spool Disassembly And Assembly 1
2
3
Figure 20-40-77
N-18944A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
N-18942 3), and washer (Item 4) [Figure 20-40-79].
Figure 20-40-80
Put the linkage end of the spool in the vise [Figure 20-
40-77]. 2
Install the spool tool (Item 1) [Figure 20-40-77] over the 1
centering spring.
Figure 20-40-78
1 1
N-18930 N-18943
Remove the spool seal(s) (Item 1) and the back-up
washer (Item 2) [Figure 20-40-80].
Assembly: Always use a new spool seal.
N-19014
Remove the bolt (Item 1) [Figure 20-40-78] holding the
centering spring to the spool.
Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3
Nm) torque.
Remove spring tool from the spring assembly.
A220 Bobcat Loader
20-40-23 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-83
Auxiliary Spool Removal And Installation
Figure 20-40-81
1
N-18988
Remove the spool (Item 1) [Figure 20-40-83].
N-19003
Assembly: Put grease on all the centering spring
component parts.
Remove the screws (Item 1) [Figure 20-40-81] from the
end cap (both sides). Auxiliary Electric Solenoid Disassembly And
Assembly
Installation: Tighten the screws to 90-100 in.-lbs. (10,2-
11,3 Nm) torque. Figure 20-40-84
Figure 20-40-82
1 P-28341
N-18987
Remove the nut (Item 1) [Figure 20-40-84] from both
solenoids.
Remove the end cap, O-ring, springs and washer (both
sides) [Figure 20-40-82]. Installation: Tighten the nut to 8-12 ft.-lbs. (11-16 Nm)
torque.
Assembly: Always use a new spool seal.
A220 Bobcat Loader
20-40-24 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-87
Auxiliary Electric Solenoid Disassembly And
Assembly (Cont’d)
Figure 20-40-85
2
2
1
1
P-28344
Disconnect the tubeline (Item 1) and remove the screws
(Item 2) [Figure 20-40-87] from the end cap.
P-28342
Installation: Tighten the screws to 90-100 in.-lbs. (10,2-
11,3 Nm) torque.
Remove the coil (Item 1) and the stem (Item 2) [Figure
20-40-85]. Figure 20-40-88
Installation: Tighten the stem to 20 ft.-lbs. (27 Nm)
torque.
Figure 20-40-86
P-28345
Remove the end cap and solenoid assembly (Item 1).
Remove the O-ring, springs, and washer [Figure 20-40-
N-18795 88].
Remove the O-rings (Item 1) [Figure 20-40-86] from the
stem.
A220 Bobcat Loader
20-40-25 Service Manual
HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-91
Port-Auxiliary Section Disassembly
Port Relief (Optional)
Figure 20-40-89
1 2
N-18843
1
Remove the O-rings (Item 1) [Figure 20-40-90] &
P-28343 [Figure 20-40-91] and back-up ring (Item 2) [Figure 20-
40-90] & [Figure 20-40-91] from the plug.
Remove the plug (Item 1) [Figure 20-40-89] or optional Cleaning And Inspection
port relief valve from the control valve.
Clean all components with clean solvent and dry with
NOTE: The optional port relief (Item 1) [Figure 20-40- compressed air.
89] is 3500 PSI (24129 kPa).
Check the spools for wear or scratches.
Figure 20-40-90
Check that the spools are not loose in their bore.
Plug Check that the centering springs are not broken.
Check that the load check valve seats are not worn.
2
Check the load check poppets for damage.
Check the rubber boots and retainers.
Replace the parts as needed.
1
Use new O-rings and back-up rings.
1
N-18800 Apply oil to all new O-rings and back-up rings before
installation.
A220 Bobcat Loader
20-40-26 Service Manual
LIFT ARM BY-PASS CONTROL VALVE Remove the two mounting bolts (Item 2) [Figure 20-50-
1].
Inspecting
Figure 20-50-1 Installation: Tighten the mounting bolts to (180-200 Nm)
torque.
Figure 20-50-2
1
1
1
P-26698
Raise the lift arms 6 feet (2 m) off the ground. Stop the
P-26699
engine. Turn the Lift Arm By-Pass Control Knob
clockwise 1/4 turn. Then pull up and hold the Lift Arm By-
Pass Control Knob until the lift arms slowly lower. Remove the lift arm by-pass valve.
Removal And Installation
Remove the two bolts (Item 1) [Figure 20-50-2] to
replace the by-pass valve mounting bracket if necessary.
Reverse the removal procedure to install the lift arm by-
pass valve in the loader.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the control panel. (See CONTROL PANEL on
Page 50-100-1.)
Disconnect the hydraulic hoses (Item 1) [Figure 20-50-1]
and cap and plug the lines.
A220 Bobcat Loadere
20-50-1 Service Manual
LIFT ARM BY-PASS CONTROL VALVE (CONT’D)
Disassembly And Assembly
Figure 20-50-3
2
2
P7939
Remove the by-pass valve (Item 1) [Figure 20-50-3]
from the valve block. Inspect the by-pass valve for
damage and replace if necessary.
Installation: Tighten the valve to 33-37 ft.-lbs. (45-50
Nm) torque.
Inspect the hydraulic fittings (Item 2) [Figure 20-50-3] on
the valve block for damage and replace if necessary.
A220 Bobcat Loader
20-50-2 Service Manual
HYDRAULIC PUMP Figure 20-60-2
Checking The Output Of The Auxiliary Pump
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Figure 20-60-1 P7753
Connect the INLET hose from the tester to the OUTLET
1 of the pump. Connect the OUTLET hose from the tester
to the tubeline which was disconnected from the hose
[Figure 20-60-2].
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM.
Warm the fluid to 140°F. (60°C.) by turning the restrictor
control on the tester to about 1000 PSI (6895 kPa). DO
N-19740
NOT exceed system relief pressure. Open the restrictor
control and record the free flow (GPM) at full RPM.
The tools listed will be needed to do the following
procedure: Turn the restrictor down to system operating pressure.
MEL10003 - Hydraulic Tester DO NOT EXCEED SYSTEM RELIEF PRESSURE. (3300
PSI) The highest pressure flow must be at least 80% of
MEL10006 - Hydraulic Test Kit free flow.
NOTE: Make sure all the air is removed from the HIGH PRESSURE FLOW (GPM)
%= X100
hydraulic system before beginning the test. FREE FLOW (GPM)
Air in the system can give an inaccurate test.
*Relief pressure must be per specification before A low percentage may indicate a pump problem.
the test is done.
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Connect the remote start switch. (See REMOTE START
on Page 10-60-1.)
Disconnect the OUTLET hose (Item 1) [Figure 20-60-1]
from the pump.
A220 Bobcat Loader
20-60-1 Service Manual
HYDRAULIC PUMP (CONT’D) Figure 20-60-4
Checking The Output Of The Steering Pump
1
Figure 20-60-3
1
P-26701
Disconnect the OUTLET hose from the pump (Item 1)
P-26700 [Figure 20-60-4] from the filter.
The tools listed will be needed to do the following
procedure:
MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit
NOTE: Make sure all the air is removed from the
hydraulic system before beginning the test.
Air in the system can give an inaccurate test.
*Relief pressure must be per specification
before the test is done.
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Raise the operator cab.(See Raising The Operator Cab
on Page 10-30-1.)
Connect the remote start switch. (See REMOTE START
on Page 10-60-1.)
Remove the filter mount bracket bolt (Item 1) [Figure 20-
60-3].
A220 Bobcat Loader
20-60-2 Service Manual
HYDRAULIC PUMP (CONT’D) Removal And Installation
Checking The Output Of The Steering Pump (Cont’d)
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
WARNING
Figure 20-60-5
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Figure 20-60-6
P-26702
Connect the INLET hose from the tester to the OUTLET
of the pump. Connect the OUTLET hose from the tester
to the filter which was disconnected from the hose
[Figure 20-60-5].
Start the engine and run at low idle RPM. Make sure the
P-26594
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full Raise the lift arms and install an approved lift arm support
RPM. device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Warm the fluid to 140°F. (60°C.) by turning the restrictor
control on the tester to about 1000 PSI (6895 kPa). DO Raise the operator cab. (See Raising The Operator Cab
NOT exceed system relief pressure. Open the restrictor on Page 10-30-1.)
control and record the free flow (GPM) at full RPM.
Drain the hydraulic reservoir. (See Draining The Fluid
Turn the restrictor down to system operating pressure. Reservoir on Page 20-80-1.)
DO NOT EXCEED SYSTEM RELIEF PRESSURE. (2000
PSI) The highest pressure flow must be at least 80% of Place the loader on jackstands. (See Procedure on Page
free flow. 10-10-1.)
HIGH PRESSURE FLOW (GPM)
%= X100 Remove the right rear tire assembly [Figure 20-60-6]
FREE FLOW (GPM)
A low percentage may indicate a pump problem.
A220 Bobcat Loader
20-60-3 Service Manual
HYDRAULIC PUMP (CONT’D) Figure 20-60-9
Removal And Installation (Cont’d)
Figure 20-60-7
2
2 1
P-26734
1 Mark all the hydraulic hoses for proper installation.
P-26595A
Remove the two outlet hoses (Item 1) [Figure 20-60-9]
from the gear pump.
Remove the two bolts (Item 1) [Figure 20-60-7] from the
wheel position sensor/steering cylinder cover. Figure 20-60-10
Remove the six mount bolts (Item 2) [Figure 20-60-7]
from the access panel.
Figure 20-60-8
P-26640
1
Remove the two return hoses (Item 1) [Figure 20-60-10]
from the pump.
P-26596
Remove the wheel position sensor/steering cylinder
cover from the loader.
Disconnect the wheel position sensor harness (Item 1)
[Figure 20-60-8] from the loader harness.
Push the loader harness connector through the hole in
the access panel.
Remove the access panel from the loader.
A220 Bobcat Loader
20-60-4 Service Manual
HYDRAULIC PUMP (CONT’D) Figure 20-60-13
Removal And Installation (Cont'd)
Figure 20-60-11
1 P-26644
2 Remove the lower pump mount bolt (Item 1) [Figure 20-
P-26733 60-13].
Figure 20-60-14
Remove the hydraulic hose (Item 1) [Figure 20-60-11]
from the return hose fitting, at the front side of the gear
pump.
Remove the two return hoses (Item 2) [Figure 20-60-11]
from the gear pump. 1
Figure 20-60-12
P-26646
Remove the front pump mount bolt (Item 1) [Figure 20-
60-14].
1
P-26643
Remove the pump mounting bolt (Item 1) [Figure 20-60-
12] from the engine mount casting.
Installation: Tighten the mounting bolts to 25-27 ft.-lbs.
(34-37 Nm) torque.
A220 Bobcat Loader
20-60-5 Service Manual
HYDRAULIC PUMP (CONT’D)
Removal And Installation (Cont'd)
Figure 20-60-15
P-26648
Remove the pump-tail stock support bracket (Item 1)
[Figure 20-60-15].
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Figure 20-60-16
P-26647
Remove the front pump mount bolt (Item 1) [Figure 20-
60-16].
Remove the gear pump from the loader.
A220 Bobcat Loader
20-60-6 Service Manual
HYDRAULIC PUMP (CONT’D)
Parts Identification
10
9
8 4
6 7
5
4
1 2 3
13
15
7 4
5 13
2 3 4
11
12
1. Body
2. Seal
3. Seal
4. Seal
5. Wear Plate
6. Section
7. Wear Plate
8. Pin
9. Body
10. Bolt
11. Seal
12. Cover
13. Pin
14. Section
15. Shaft
TS-1022
A220 Bobcat Loader
20-60-7 Service Manual
HYDRAULIC PUMP (CONT’D) Figure 20-60-18
Disassembly And Assembly
IMPORTANT 1
When repairing hydrostatic and hydraulic systems,
clean the work area before disasembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-43020
Figure 20-60-17
Set the pump on end, and remove the pump end section
(Item 1) [Figure 20-60-18] from the steering pump.
Figure 20-60-19
1
1
1
1
P-43019
1 2
Mark the pump sections for correct assembly [Figure 20-
60-17].
P-39139
Remove the eight pump housing bolts (Item 2) [Figure
20-60-17].
Remove the wear plate (Item 1) and the section seal
Installation: Tighten the eight bolts (Item 1) [Figure 20- (Item 2) [Figure 20-60-19].
60-17] to 45-50 ft.-lbs (60-67 Nm) torque.
A220 Bobcat Loader
20-60-8 Service Manual
HYDRAULIC PUMP (CONT’D) Figure 20-60-22
Disassembly And Assembly (Cont'd)
Figure 20-60-20
4
1
2
P-39142
1 NOTE: Inspect the steering pump center section (Item
P-39140 1) [Figure 20-60-22]. If excessive wear or
damage is visible, the pump must be
replaced.
Inspect the wear plate (Item 1) and the section seal (Item
2) [Figure 20-60-20] and replace as needed. Figure 20-60-23
NOTE: Position the wear plate (Item 1) [Figure 20-60-
20] inlets and traps as shown with the bronze
side toward the gears.
NOTE: Inspect the pump end section (Item 3) and
1
bushings (Item 4) [Figure 20-60-20]. If
excessive wear or damage is visible, the
pump must be replaced.
Figure 20-60-21
P-43022
Remove the idler gear (Item 1) [Figure 20-60-23] from
the steering pump.
P-43021
Remove the steering pump center section (Item 1)
[Figure 20-60-21] from the auxillary pump.
A220 Bobcat Loader
20-60-9 Service Manual
HYDRAULIC PUMP (CONT’D) Figure 20-60-26
Disassembly And Assembly (Cont'd)
Figure 20-60-24
P-39146
NOTE: Inspect the drive gear (Item 1) [Figure 20-60-
P-39144 26]. If excessive wear or damage is visible, the
pump must be replaced.
NOTE: Inspect the idler gear (Item 1) [Figure 20-60- Figure 20-60-27
24]. If excessive wear or damage is visible, the
pump must be replaced.
Figure 20-60-25
3
1
1
2
P-43024
Remove the wear plate (Item 1) and section seal (Item 2)
P-43023 [Figure 20-60-27] from the front section of the steering
pump.
Remove the drive gear (Item 1) [Figure 20-60-25] from Remove the locating pins (Item 3) [Figure 20-60-27]
the steering pump. from the front section of the steering pump.
A220 Bobcat Loader
20-60-10 Service Manual
HYDRAULIC PUMP (CONT’D) Figure 20-60-30
Disassembly And Assembly (Cont'd)
Figure 20-60-28
P-39149
1
NOTE: Later serial number pumps have no oil drain
P-39148 galley [Figure 20-60-30].
Figure 20-60-31
Inspect the wear plate (Item 1) and the section seal (Item
2) [Figure 20-60-28] and replace as needed.
NOTE: Position the wear plate (Item 1) [Figure 20-60-
28] inlets and traps as shown with the bronze
side toward the gears.
Figure 20-60-29
1
2
2
P-43026
1
Remove the Pre-load seal (Item 1) [Figure 20-60-31]
from the front section of the charge pump.
P-43025
Remove the load seal (Item 1) [Figure 20-60-29] from
the front section of the charge pump.
NOTE: Earlier serial number pumps have an oil drain
galley (Item 2) [Figure 20-60-29].
A220 Bobcat Loader
20-60-11 Service Manual
HYDRAULIC PUMP (CONT’D) Figure 20-60-34
Disassembly And Assembly (Cont'd)
Figure 20-60-32 1
2
1
2 P-43028
Remove the wear plate (Item 1) [Figure 20-60-34] &
P-39151 [Figure 20-60-35] and section seal (Item 2) [Figure 20-
60-34] & [Figure 20-60-35] from the pump section.
Inspect the load seal (Item 1) and the Pre-load seal (Item Figure 20-60-35
2) [Figure 20-60-32] and replace as needed.
Figure 20-60-33
3
1 1
2 P-43029
P-43027 NOTE: Position wear plate (Item 1) [Figure 20-60-35]
inlets and traps as shown with bronze side
toward gears.
Inspect the pump center section and bushings (Item 1)
[Figure 20-60-33]. If excessive wear or damage is NOTE: Inspect the pump center section (Item 3) and
visible, the pump must be replaced. bushings (Item 4) [Figure 20-60-35]. If
excessive wear or damage is visible, the
Remove the pump center section (Item 2) [Figure 20-60- pump must be replaced.
33].
A220 Bobcat Loader
20-60-12 Service Manual
HYDRAULIC PUMP (CONT’D) Figure 20-60-38
Disassembly And Assembly (Cont'd)
Figure 20-60-36 1
P-43032
Remove the idler gear (Item 1) [Figure 20-60-38] &
P-43030 [Figure 20-60-39].
Figure 20-60-39
Remove the pump section (Item 1) [Figure 20-60-36]
from the pump end section.
Figure 20-60-37
1
1
P-43033
NOTE: Inspect the idler gear (Item 1) [Figure 20-60-
P-43031 39]. If excessive wear or damage is visible, the
pump must be replaced.
NOTE: Inspect the pump section (Item 1) [Figure 20-
60-37]. If excessive wear or damage is visible,
the pump must be replaced.
A220 Bobcat Loader
20-60-13 Service Manual
HYDRAULIC PUMP (CONT’D) Figure 20-60-42
Disassembly And Assembly (Cont'd)
Figure 20-60-40
P-43036
Remove the spline shaft (Item 1) [Figure 20-60-42] from
P-43034 the end of the drive gear.
NOTE: Inspect the spline shaft (Item 1) [Figure 20-60-
Remove the drive gear (Item 1) [Figure 20-60-40] from 42]. If excessive wear or damage is visible, the
the pump end section. pump must be replaced.
Figure 20-60-41 Figure 20-60-43
1
1
P-43035 P-43037
NOTE: Inspect the drive gear (Item 1) [Figure 20-60- Remove the wear plate (Item 1) and section seal (Item 2)
41]. If excessive wear or damage is visible, the [Figure 20-60-43].
pump must be replaced.
Remove the locating pins (Item 3) [Figure 20-60-43].
A220 Bobcat Loader
20-60-14 Service Manual
HYDRAULIC PUMP (CONT’D) Figure 20-60-46
Disassembly And Assembly (Cont'd)
Figure 20-60-44
1
2
P-43040
Remove the pre-load seal (Item 1) [Figure 20-60-46].
P-43038
Figure 20-60-47
Inspect the wear plate (Item 1) and the section seal (Item 1
2) [Figure 20-60-44].
NOTE: Position wear plate (Item 1) [Figure 20-60-44]
inlets and traps as shown with bronze side 2
toward gears.
Figure 20-60-45
P-43041
1
NOTE: Inspect the pump end section (Item 1) and
bushings (Item 2) [Figure 20-60-47]. If
excessive wear or damage is visible, the
pump must be replaced.
P-43039
Remove the load seal (Item 1) [Figure 20-60-45].
A220 Bobcat Loader
20-60-15 Service Manual
A220 Bobcat Loader
20-60-16 Service Manual
HYDRAULIC PUMP (HI FLOW) Figure 20-61-2
Checking The Output Of The High Flow Pump
1
WARNING P-26595
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm Remove the two bolts (Item 1) [Figure 20-61-2] from the
support device. Failure to use an approved lift arm wheel position sensor/steering cylinder cover.
support device can allow the lift arms or attachment
to fall and cause injury or death. Remove the six mount bolts (Item 2) [Figure 20-61-2]
W-2059-0598 from the access panel.
Figure 20-61-3
Figure 20-61-1
P-26596
P-26594
Remove the wheel position sensor/steering cylinder
Raise the lift arms and install an approved lift arm support
cover from the loader.
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Disconnect the wheel position sensor harness (Item 1)
[Figure 20-61-3] from the loader harness.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Push the loader harness connector through the hole in
the access panel.
Place the loader on jackstands. (See Procedure on Page
10-10-1.)
Remove the access panel from the loader.
Remove the right rear tire assembly [Figure 20-61-1].
A220 Bobcat Loader
20-61-1 Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT’D) Push the mode switch (on the remote start switch) to
engage the front auxiliary hydraulics, the light will come
Checking The Output Of The High Flow Pump ON. Push the button (on the right steering lever) for fluid
(Cont'd) pressure to the quick coupler (fluid pressure will go over
main relief). Record the highest pressure (PSI) and flow
The tools listed will be needed to do the following (GPM). The high pressure flow must be at least 80% of
procedure: free flow.
MEL10003 - Hydraulic Tester HIGH PRESSURE FLOW (GPM)
%= X100
MEL10006 - Hydraulic Test Kit FREE FLOW (GPM)
NOTE: Make sure all the air is removed from the
hydraulic system before beginning the test.
Air in the system can give an inaccurate test.
WARNING
*Relief pressure must be per specification
before the test is done. Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Figure 20-61-4 Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
2
A low percentage may indicate a pump problem.
P-26598
Disconnect the OUTLET hose from the pump fitting
(Item1)[Figure 20-61-4]. Turn the 90° elbow fitting (Item
2) [Figure 20-61-4] toward the outside of the loader.
Connect the INLET hose from the tester to the OUTLET
fitting on the pump (Item 2) [Figure 20-61-4] Connect the
OUTLET hose from the tester to the hose (Item 1)
[Figure 20-61-4] which was disconnected from the pump
fitting.
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM.
Warm the fluid to 140°F. (60°C.) by turning the restrictor
control on the tester to about 1000 PSI (6895 kPa). DO
NOT exceed system relief pressure. Open the restrictor
control and record the free flow (GPM) at full RPM.
A220 Bobcat Loader
20-61-2 Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT’D) Figure 20-61-6
Removal And Installation
1
WARNING P-26595
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm Remove the two bolts (Item 1) [Figure 20-61-6] from the
support device. Failure to use an approved lift arm wheel position sensor/steering cylinder cover.
support device can allow the lift arms or attachment
to fall and cause injury or death. Remove the six mount bolts (Item 2) [Figure 20-61-6]
W-2059-0598 from the access panel.
Figure 20-61-7
Figure 20-61-5
P-26596
P-26594
Remove the wheel position sensor/steering cylinder
Raise the lift arms and install an approved lift arm support
cover from the loader.
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Disconnect the wheel position sensor harness (Item 1)
[Figure 20-61-7] from the loader harness.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Push the loader harness connector through the hole in
the access panel.
Drain the hydraulic reservoir. (See Draining The Fluid
Reservoir on Page 20-80-1.)
Remove the access panel from the loader.
Place the loader on jackstands. (See Procedure on Page
10-10-1.)
Remove the right rear tire assembly [Figure 20-61-5].
A220 Bobcat Loader
20-61-3 Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT’D) Figure 20-61-9
Removal And Installation (Cont'd)
Figure 20-61-8 2
1
P-26734
Disconnect the hose (Item 1) [Figure 20-61-9] from the
P-26598 steering section of the hydraulic pump.
Cap and plug the hose and fiting.
Drain the hydraulic reservoir. (See Draining The Fluid
Reservoir on Page 20-80-1.) Disconnect the hose (Item 2) [Figure 20-61-9] from the
auxiliary section of the hydraulic pump.
Remove the alternator. If Equipped with Power Bob-Tach
and A/C. (See ALTERNATOR on Page 60-30-1.) Cap and plug the hose and fiting.
Remove the A/C compressor. (If so equipped) (See Figure 20-61-10
COMPRESSOR on Page 80-110-1.)
Remove the power Bob-Tach block. (If so equipped)
(See Removal And Installation on Page 20-120-1 [early
models] or See Removal And Installation on Page 20- 1
121-1 [later models])
Mark all the hydraulic hoses for proper installation.
Disconnect the hose (Item 1) [Figure 20-61-8] from the
hi-flow section of the hydraulic pump.
Cap and plug the hose and fiting.
P-26639
At the front side of the hydraulic pump, disconnect the
hydraulic hose (Item 1) [Figure 20-61-10] that goes from
the pump to the control valve.
Cap and plug the hose and fitting.
A220 Bobcat Loader
20-61-4 Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT’D) Figure 20-61-13
Removal And Installation (Cont'd)
Figure 20-61-11
1
1
1
P-26642
Remove the inlet fitting (Item 1) [Figure 20-61-13] from
P-26640 the front of the gear pump.
Figure 20-61-14
At the front side of the gear pump, loosen the clamps
(Item 1) [Figure 20-61-11] and disconnect the two pump
inlet hoses.
Figure 20-61-12
1 1
1
P-26643
Loosen and remove the pump mounting bolt and nut
(Item 1) [Figure 20-61-14].
P-26641
Installation: Tighten the mounting bolt to 25-27 ft.-lbs.
(34-37 Nm) torque.
Loosen the clamps (Item 1) [Figure 20-61-12] and
disconnect the three pump inlet hoses.
A220 Bobcat Loader
20-61-5 Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT’D) Figure 20-61-17
Removal And Installation (Cont'd)
Figure 20-61-15
P-26648
Remove the pump tail-stock support bracket (Item 1)
P-26644 [Figure 20-61-17].
Figure 20-61-18
Remove the pump mounting bolt (Item 1) [Figure 20-61-
15].
Installation: Tighten the mounting bolt to 25-27 ft.-lbs.
(34-37 Nm) torque.
1
Figure 20-61-16
P-26647
Remove the rear pump mounting bolt (Item 1) [Figure
20-61-18].
Installation: Tighten the mounting bolt to 25-27 ft.-lbs.
P-26646 (34-37 Nm) torque.
Remove the front pump mounting bolt (Item 1) [Figure
20-61-16].
Installation: Tighten the mounting bolt to 25-27 ft.-lbs.
(34-37 Nm) torque.
A220 Bobcat Loader
20-61-6 Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT’D)
Removal And Installation (Cont'd)
Figure 20-61-19
P-26650
Figure 20-61-20
P-26652
NOTE: Before the gear pump can be removed from
the hydrostatic pump, the complete pump
assembly must be raised and supported, as
shown using a bolt and nut between the
hyrostatic pump and the chain case cover
(Item 1) [Figure 20-61-19]. The pump assembly
needs to be raised only enough for the gear
pump to clear the pump mount (Item 1)
[Figure 20-61-20].
Remove the gear pump from the loader.
A220 Bobcat Loader
20-61-7 Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT’D)
Parts Identification
12
11
9 4
10 2
8
5 6 7 4
3
1 2 4
15
8
19
3
16
15
4
6 7
2 4 18
1. Section
2. Wear Plate
15 17 3. Pin
7 4 4. Seal
13 6
5. Body
6. Seal
14 7. Seal
8. Pin
9. Shaft
10. Section
11. Body
12. Bolt
13. Seal
14. Cover
15. Wear Plate
16. Pin
17. Section
18. Body
19. Shaft
B-18248
A220 Bobcat Loader
20-61-8 Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT’D) Figure 20-61-22
Disassembly And Assembly
Mark the pump sections for correct assembly.
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
P-43066
I-2003-0888
Figure 20-61-21 Remove the Hi-flow pump end section (Item 1) [Figure
20-61-22] from the pump.
Figure 20-61-23
2
2
2 P-43065 1
2
Remove the four bolts (Item 1) [Figure 20-61-21]. P-43067
Installation: Tighten the assembly bolts to 45-50 ft.-lbs
(60-67 Nm) torque. Remove the wear plate (Item 1) and section seal (Item 2)
[Figure 20-61-23] from the pump end section.
Remove the four bolts (Item 2) [Figure 20-61-21].
Installation: Tighten the assembly bolts to 30 ft.-lbs (41
Nm) torque.
A220 Bobcat Loader
20-61-9 Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT’D) Figure 20-61-26
Disassembly And Assembly (Cont'd)
Figure 20-61-24
3 P-43070
1
2 NOTE: Inspect the pump center section (Item 1)
P-43068 [Figure 20-61-26]. If excessive wear or
damage is visible, the pump must be
replaced.
NOTE: Position wear plate (Item 1) inlets and traps as
shown with bronze side toward gears. Figure 20-61-27
Replace the section seal (Item 2) [Figure 20-
61-24].
NOTE: Inspect the pump end section (Item 3) and
bushings (Item 4) [Figure 20-61-24]. If
excessive wear or damage is visible, the 1
pump must be replaced.
Figure 20-61-25
P-43071
Remove the idler gear (Item 1) [Figure 20-61-27].
P-43069
Remove the pump center section (Item 1) [Figure 20-61-
25] from the pump.
A220 Bobcat Loader
20-61-10 Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT’D) Figure 20-61-30
Disassembly And Assembly (Cont'd)
Figure 20-61-28
P-43074
NOTE: Inspect the drive gear (Item 1) [Figure 20-61-
P-43072 30]. If excessive wear or damage is visible, the
pump must be replaced.
NOTE: Inspect the idler gear (Item 1) [Figure 20-61- Figure 20-61-31
28]. If excessive wear or damage is visible, the
pump must be replaced.
1
Figure 20-61-29
P-43075
Remove the wear plate (Item 1) and section seal (Item 2)
P-43073 [Figure 20-61-31] from the pump center section.
Remove the drive gear (Item 1) [Figure 20-61-29].
A220 Bobcat Loader
20-61-11 Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT’D) Figure 20-61-34
Disassembly And Assembly (Cont'd)
Figure 20-61-32
2 P-39149
NOTE: Later serial number pumps have no oil drain
P-43076 galley [Figure 20-61-34].
Figure 20-61-35
NOTE: Position wear plate (Item 1) inlets and traps as
shown with bronze side toward gears.
Replace the section seal (Item 2) [Figure 20-
61-32].
Figure 20-61-33
1 P-39180
2
Remove the pre-load seal (Item 1) [Figure 20-61-35].
P-39179
Remove the load seal (Item 1) [Figure 20-61-33].
NOTE: Earlier serial number pumps have an oil drain
galley (Item 2) [Figure 20-61-33].
A220 Bobcat Loader
20-61-12 Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT’D) Figure 20-61-38
Disassembly And Assembly (Cont'd)
Figure 20-61-36
2
P-43078
Remove the wear plate (Item 1) and section seal (Item 2)
P-39151 [Figure 20-61-38] from the pump section.
Figure 20-61-39
Inspect both seals [Figure 20-61-36].
3
Figure 20-61-37
1
4
1
2
P-43079
P-43077 NOTE: Position wear plate (Item 1) inlets and traps as
shown with bronze side toward gears.
Replace the section seal (Item 2) [Figure 20-
Remove the pump center section (Item 1) [Figure 20-61- 61-39].
37].
NOTE: Inspect the pump center section (Item 3) and
bushings (Item 4) [Figure 20-61-39]. If
excessive wear or damage is visible, the
pump must be replaced.
A220 Bobcat Loader
20-61-13 Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT’D) Figure 20-61-42
Disassembly And Assembly (Cont'd)
Figure 20-61-40
2 1
P-43081
Remove the idler gear (Item 1) [Figure 20-61-42] from
P-43080 the steering pump.
Figure 20-61-43
Remove the spline shaft (Item 1) [Figure 20-61-40].
Remove the pump center section (Item 2) [Figure 20-61-
40] from the pump.
Figure 20-61-41
P-39144
1 NOTE: Inspect the idler gear (Item 1) [Figure 20-61-
43]. If excessive wear or damage is visible, the
pump must be replaced.
P-39142
NOTE: Inspect the steering pump center section (Item
1) [Figure 20-61-41]. If excessive wear or
damage is visible, the pump must be
replaced.
A220 Bobcat Loader
20-61-14 Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT’D) Figure 20-61-46
Disassembly And Assembly (Cont'd)
Figure 20-61-44
3
1
2
P-43083
Remove the wear plate (Item 1) and section seal (Item 2)
P-43082 [Figure 20-61-46] from the front section of the steering
pump.
Remove the drive gear (Item 1) [Figure 20-61-44] from Remove the locating pins (Item 3) [Figure 20-61-46]
the steering pump. from the front section of the steering pump.
Figure 20-61-45 Figure 20-61-47
1 2
P-39146 1
P-43084
NOTE: Inspect the drive gear (Item 1) [Figure 20-61- Inspect the wear plate (Item 1) and the section seal (Item
45]. If excessive wear or damage is visible, the 2) [Figure 20-61-47] and replace as needed.
pump must be replaced.
NOTE: Position the wear plate (Item 1) [Figure 20-61-
47] inlets and traps as shown with the bronze
side toward the gears.
A220 Bobcat Loader
20-61-15 Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT’D) Figure 20-61-50
Disassembly And Assembly (Cont'd)
Figure 20-61-48
1
2
1
P-39151
Inspect the load seal (Item 1) and the pre-load seal (Item
P-43085 2) [Figure 20-61-50] and replace as needed.
Figure 20-61-51
Remove the load seal (Item 1) [Figure 20-61-48] from
the front section of the steering pump.
Figure 20-61-49
P-43087
Inspect the pump center section and bushings (Item 1)
P-43086 [Figure 20-61-51]. If excessive wear or damage is
visible, the pump must be replaced.
Remove the pre-load seal (Item 1) [Figure 20-61-49]
from the front section of the steering pump.
A220 Bobcat Loader
20-61-16 Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT’D) Figure 20-61-54
Disassembly And Assembly (Cont'd)
3
Figure 20-61-52
2 P-43090
NOTE: Position wear plate (Item 1) inlets and traps as
P-43088 shown with bronze side toward gears.
Replace the section seal (Item 2) [Figure 20-
61-54].
Remove the pump center section (Item 1) [Figure 20-61-
52] from the pump sections. NOTE: Inspect the pump center section (Item 3) and
bushings (Item 4) [Figure 20-61-54]. If
Figure 20-61-53 excessive wear or damage is visible, the
pump must be replaced.
Figure 20-61-55
1
2
P-43089
Remove the wear plate (Item 1) and section seal (Item 2)
P-39218
[Figure 20-61-53] from the pump section.
Remove the pump section (Item 1) [Figure 20-61-55]
from the pump end section.
A220 Bobcat Loader
20-61-17 Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT’D) Figure 20-61-58
Disassembly And Assembly (Cont'd)
Figure 20-61-56
P-39221
NOTE: Inspect the idler gear (Item 1) [Figure 20-61-
P-39219 58]. If excessive wear or damage is visible, the
pump must be replaced.
NOTE: Inspect the pump section (Item 1) [Figure 20- Figure 20-61-59
61-56]. If excessive wear or damage is visible,
the pump must be replaced.
Figure 20-61-57
1
1
P-39222
Remove the drive gear (Item 1) [Figure 20-61-59] from
P-39220 the pump end section.
Remove the idler gear (Item 1) [Figure 20-61-57].
A220 Bobcat Loader
20-61-18 Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT’D) Figure 20-61-62
Disassembly And Assembly (Cont'd)
Figure 20-61-60 3
2
1
3
P-39225
Remove the wear plate (Item 1) and section seal (Item 2)
P-39223 [Figure 20-61-62].
Remove the locating pins (Item 3) [Figure 20-61-62].
Remove the drive gear (Item 1) [Figure 20-61-60] from
the pump end section. Figure 20-61-63
NOTE: Inspect the drive gear (Item 1) [Figure 20-61-
60]. If excessive wear or damage is visible, the
pump must be replaced.
Figure 20-61-61
P-43091
1
Inspect the wear plate (Item 1) and the section seal (Item
2) [Figure 20-61-63].
P-39224 NOTE: Position wear plate (Item 1) [Figure 20-61-63]
inlets and traps as shown with bronze side
toward gears.
Remove the spline shaft (Item 1) [Figure 20-61-61] from
the end of the drive gear.
NOTE: Inspect the spline shaft (Item 1) [Figure 20-61-
61]. If excessive wear or damage is visible, the
pump must be replaced.
A220 Bobcat Loader
20-61-19 Service Manual
HYDRAULIC PUMP (HI FLOW) (CONT’D) Figure 20-61-66
Disassembly And Assembly (Cont'd)
1
Figure 20-61-64
P-43094
NOTE: Inspect the pump end section (Item 1) and
P-43092 bushings (Item 2) [Figure 20-61-66]. If
excessive wear or damage is visible, the
pump must be replaced.
Remove the load seal (Item 1) [Figure 20-61-64].
Figure 20-61-65
P-43093
Remove the pre-load seal (Item 1) [Figure 20-61-65].
A220 Bobcat Loader
20-61-20 Service Manual
HYDRAULIC/HYDROSTATIC FILTER Figure 20-70-2
Housing Removal And Installation
1
WARNING P-26896
Never work on a machine with the lift arms up unless Remove the four mounting bolts (Item 1) [Figure 20-70-
the lift arms are secured by an approved lift arm 2].
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Installation: Tighten the mounting bolts to 25 ft.-lbs. (34
to fall and cause injury or death. Nm) torque.
W-2059-0598
Figure 20-70-3
Figure 20-70-1
2
1
P-26897
P-26895
Install the tool 10STC (Item 1) [Figure 20-70-3] to the
Raise the lift arms and install an approved lift arm support inside of the rubber sleeve.
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.) Slide the rubber sleeve (Item 2) [Figure 20-70-3] out
toward the filter housing fitting. The connector will
Raise the operator cab. (See Raising The Operator Cab release.
on Page 10-30-1.)
NOTE: When installing the cooler hoses, the fittings
Disconnect the wire connector (Item 1) [Figure 20-70-1] should make a clicking sound when pushed
from the hydraulic filter sender and switch. together.
A220 Bobcat Loader
20-70-1 Service Manual
HYDRAULIC/HYDROSTATIC FILTER (CONT’D)
Housing Removal And Installation (Cont’d)
Figure 20-70-4
P-26898
Disconnect the hose clamp and hose (Item 1) [Figure
20-70-4] from the filter housing.
Disconnect the electrical wire (Item 2) [Figure 20-70-4]
from the back of the filter housing.
Remove the filter housing/filter assembly.
Bobcat Loader
20-70-2 Service Manual
HYDRAULIC FLUID RESERVOIR Remove the steering valve. (See on Page -1.)
Draining The Fluid Reservoir Remove bucket position valve (If so equipped).
Figure 20-80-1 Remove the select valve (If so equipped).
Remove the two bucket position valve mount plate bolts
(Item 1) [Figure 20-80-2].
Remove the mount bracket.
Remove the two fill hose clamps (Item 2) [Figure 20-80-
2].
Remove the hydraulic fill hose.
1
Figure 20-80-3
N-19496
Remove the left side access cover from the loader frame.
Pull the reservoir drain hose (Item 1) [Figure 20-80-1]
out the side of the loader frame.
1
Remove the hose end cap and drain fluid in a container
[Figure 20-80-1].
Removal And Installation
Figure 20-80-2
N-19728
2 Remove the two hydraulic hoses (Item 1) [Figure 20-80-
3] from the reservoir.
N-19727
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Drain the fluid from the reservoir [Figure 20-80-1].
Remove the control panel. (See CONTROL PANEL on
Page 50-100-1.)
Remove the Brake Two-Speed block. (If so equipped) -
((See BRAKE on Page 40-10-1.)
A220 Bobcat Loader
20-80-1 ServiceManual
HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-80-6
Removal And Installation (Cont'd)
Figure 20-80-4
1
N-19731
Remove the reservoir from loader.
N-19729
Remove the rear tank bracket (Item 1) [Figure 20-80-6]
from the loader.
Remove the two bolts (Item 1) [Figure 20-80-4].
Hydraulic Fluid Screen
Installation: Tighten the bolt to 16-20 ft.-lbs. (21-27 Nm)
torque. Figure 20-80-7
Remove the mounting strap.
Slide the reservoir forward.
2
Figure 20-80-5
1 1
N-19610
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
N-19730 Remove the two hose clamps (Item 1) and remove the
hydraulic fill hose (Item 2) [Figure 20-80-7] from the
hydraulic reservoir.
At the left motor cover hole, remove the drain hose (Item
1) [Figure 20-80-5] from the tank.
Remove the supply hose (Item 2) [Figure 20-80-5] from
the tank.
A220 Bobcat Loader
20-80-2 Service Manual
HYDRAULIC FLUID RESERVOIR (CONT’D)
Hydraulic Fluid Screen
Figure 20-80-8
N-17718A
Remove the hydraulic fluid screen (Item 1) [Figure 20-
80-8] from the reservoir.
Wash the screen in clean solvent and air dry, before
replacing.
A220 Bobcat Loader
20-80-3 ServiceManual
A220 Bobcat Loader
20-80-4 Service Manual
BUCKET POSITION VALVE Figure 20-90-3
Solenoid Removal And Installation
Figure 20-90-1
1
2
1
N-18191
Inspect the solenoid stem and replace the O-rings (Item
N-23648 1) and the back-up washer (Item 2) [Figure 20-90-3].
Solenoid Testing
Disconnect the steering levers from the pump.
Figure 20-90-4
Disconnect the wire harness connector (Item 1) [Figure
20-90-1] from the bucket position shut-off solenoid.
Remove the solenoid nut (Item 2) [Figure 20-90-1].
Installation: Tighten the solenoid nut to 60 in.-lbs. (6,78
Nm) torque.
Figure 20-90-2
P9175
Use a test meter to measure coil resistance [Figure 20-
1 90-4]. Coil wires do not have polarity. Correct resistance
for the pressure relief (small) coil is 9.8 ohms.
N-23649
Remove the solenoid stem (Item 1) [Figure 20-90-2]
from the bucket position valve.
Installation: Put oil on O-rings and back-up washers and
tighten the solenoid stem to 30-35 ft.-lbs. (40,8-47,6 Nm)
torque.
A220 Bobcat Loader
20-90-1 Service Manual
BUCKET POSITION VALVE (CONT’D) Figure 20-90-6
Removal And Installation
1
2
WARNING N-23650
Never work on a machine with the lift arms up unless Remove the solenoid nut (Item 1) [Figure 20-90-6].
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm Installation: Tighten the nut to 60 in.-lbs. (6,78 Nm)
support device can allow the lift arms or attachment torque.
to fall and cause injury or death.
W-2059-0598
Remove the solenoid (Item 2) and solenoid stem (Item 3)
[Figure 20-90-6].
Figure 20-90-5
Figure 20-90-7
1
1
1
N-23648
N-23651
Start the engine. Raise the lift arms and install an
approved lift arm support device. (See Engaging The Lift Disconnect tubelines (Item 1) [Figure 20-90-7] from the
Arm Support Device on Page 10-20-1.) A port on the BPV tee fitting.
Stop the engine.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Disconnect the electric solenoid connector (Item 1)
[Figure 20-90-5].
A220 Bobcat Loader
20-90-2 Service Manual
BUCKET POSITION VALVE (CONT’D) Figure 20-90-10
Removal And Installation (Cont'd)
Figure 20-90-8
N-23654
Remove the mounting bolts (Item 1) [Figure 20-90-10].
N-23652
Installation: Tighten the mounting bolts and nuts to 15
ft.-lbs. (20 Nm) torque.
Remove the tubeline (Item 1) [Figure 20-90-8] from the
B port to the control valve. Remove the bucket position valve from the loader.
Figure 20-90-9
N-23653
Disconnect the tubeline (Item 1) [Figure 20-90-9] from
the C port on the BPV.
C is bottom in rod end of tilt.
Disconnect the tubeline (Item 2) [Figure 20-90-9] from
the D port on the BPV.
D is top in base end of tilt.
A220 Bobcat Loader
20-90-3 Service Manual
BUCKET POSITION VALVE (CONT’D) Figure 20-90-13
Disassembly And Assembly
Figure 20-90-11
1
N-19072
Remove the flow adjustment valve and O-ring (Item 1)
N-19069 [Figure 20-90-13]
NOTE: Always install new O-rings before any parts
Remove the solenoid nut (Item 1) [Figure 20-90-11]. are installed into the valve. Check the parts
for wear or damage and replace as needed.
Installation: Tighten the nut to 60 in.-lbs. (6,78 Nm)
torque. Figure 20-90-14
Figure 20-90-12
1 1
N-19041
N-19070
Remove the plug (Item 1) [Figure 20-90-14]
Remove the solenoid (Item 1) and the solenoid stem
(Item 2) [Figure 20-90-12].
Installation: Tighen the solenoid stem to 30-35 ft.-lbs.
(40,8-47,6 Nm) torque.
A220 Bobcat Loader
20-90-4 Service Manual
BUCKET POSITION VALVE (CONT’D) Figure 20-90-17
Disassembly And Assembly (Cont’d)
Figure 20-90-15
N-19045
1
Remove the plug [Figure 20-90-17].
N-18339
Figure 20-90-18
Remove the plug (Item 1) [Figure 20-90-15]
Check the flow control spool for wear, check the o-ring on
the plug and replace as needed.
Figure 20-90-16 3
N-19046
1
2 Remove the plug (Item 1), spring (Item 2) and unloading
spool (Item 3) [Figure 20-90-18].
3 Check all parts and replace as needed. Install a new O-
N-19042 ring on the plug before installing.
Remove the tilt cylinder check valve (Item 1) spring (Item
2) and plug (Item 3) [Figure 20-90-16]. Check for wear,
check the O-ring and replace as needed
A220 Bobcat Loader
20-90-5 Service Manual
A220 Bobcat Loader
20-90-6 Service Manual
SELECT VALVE Figure 20-100-2
Checking The High Flow Pump Relief Valve
2
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
1
WARNING P-34742
Put jackstands under the front axles and rear corners If the loader is not equipped with secondary front
of the frame before running the engine for service. hydraulics.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death. Connect the IN port of the hydraulic tester to the female
W-2017-0286
quick coupler (Item 1) [Figure 20-100-2] of the rear
auxiliary on the loader.
MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit Connect the OUT port of the hydraulic tester to the male
quick coupler (Item 2) [Figure 20-100-2] of the rear
Lift and block the loader. (See LIFTING AND BLOCKING auxiliary on the loader.
THE LOADER on Page 10-10-1.)
Figure 20-100-3
Figure 20-100-1
2 2
1
B-15551
P9153
Start the engine and run at low idle RPM. Push the mode
Connect the IN port of the hydraulic tester to the female switch (Item 1) once (on the instrument panel) to engage
quick couplers (Item 1) [Figure 20-100-1] at the the front auxiliary hydraulics momentary, the light (Item 2)
secondary front hydraulics on the loader. (If so [Figure 20-100-3] will come ON.
equipped.)
Connect the OUT port of the hydraulic tester to the male
quick coupler (Item 2) [Figure 20-100-1] at the
secondary front hydraulics on the loader. (If so
equipped.)
A220 Bobcat Loader
20-100-1 Service Manual
SELECT VALVE (CONT’D) O-rings (Item 2) and back-up ring (Item 3) [Figure 20-
100-5] for damage.
Checking The High Flow Pump Relief Valve (Cont’d)
Replace the relief valve if required. This relief valve is not
Figure 20-100-4 adjustable.
Removal And Installation
1
Figure 20-100-6
P-24820
Push the rocker switch on the left joystick (Item 1)
[Figure 20-100-4] for fluid pressure to the secondary 1
P-26776
female quick coupler.
Watch the flow meter on the hydraulic tester to make Raise the operator cab. (See Raising The Operator Cab
sure the flow is correct. Increase the engine speed to full on Page 10-30-1.)
RPM.
Remove the control panel. (See CONTROL PANEL on
The free flow should be approximately 10.0 GPM (37,85 Page 50-100-1.)
L/min.). Turn the restrictor control, on the tester, until the
main relief valve opens. The correct pressure for the Mark the electrical connectors for proper installation.
main relief is approximately 3000 PSI (20685 kPa).
Disconnect the five solenoid electrical connectors (Item
Release the rocker switch (Item 1) [Figure 20-100-4] to 1) [Figure 20-100-6] from the loader harness.
disengage the flow to the secondary quick couplers.
Figure 20-100-7
Figure 20-100-5
1
3
1
1
2 P-26777
2
P-09174 P-26775
Remove the three hydraulic hoses (Item 1) [Figure 20-
If the relief pressure is not correct, stop the engine. 100-7] from the valve.
Remove and inspect the relief valve (Item 1). Inspect the
Cap and plug the hoses and fittings.
A220 Bobcat Loader
20-100-2 Service Manual
SELECT VALVE (CONT’D) Figure 20-100-10
Removal And Installation (Cont’d)
Figure 20-100-8
2
1
3
5 4
P9168
P-26778
IMPORTANT
Remove the hose clamp (Item 1) [Figure 20-100-8] and
remove the hose from the select valve. When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Cap and plug the hose and fitting. parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
Disconnect the tubeline (Item 2) [Figure 20-100-8] from damage the system.
the valve. I-2003-0888
Cap and plug the tubeline and the fitting. Clean the select valve to remove dirt before disassembly.
Figure 20-100-9 Remove the solenoid valve coils in [Figure 20-100-10].
NOTE: The controls wiring harness colors are listed
below for identification during select valve
assembly installation.
1 Second aux. male coupler (Item 1) [Figure 20-100-10]
Brown
Second aux. female coupler (Item 2) [Figure 20-100-10]
White
Second aux. pressure relief (Item 3) [Figure 20-100-10]
Green
High Flow (Item 4) [Figure 20-100-10] Blue
Second aux. diverter (Item 5) [Figure 20-100-10] Yellow
P-26779
Remove the two mount bolts (Item 1) [Figure 20-100-9].
Remove the select valve from the loader.
Disassembly And Assembly
A220 Bobcat Loader
20-100-3 Service Manual
SELECT VALVE (CONT’D) Figure 20-100-13
Removal And Installation (Cont’d)
Figure 20-100-11
1 1
2
3 P9170
2
Remove the 4-way solenoid valve (Item 1) [Figure 20-
P9177
100-13].
Remove the 2-way solenoid valve (Item 2) [Figure 20-
100-13].
Figure 20-100-12
Remove the 2-way solenoid valves (Item 3) [Figure 20-
100-13].
Inspect the solenoid valves for contamination or damage.
Wash all parts in clean solvent. Use air pressure to dry
them. Install new O-rings and back-up washers.
Assembly: Put oil on O-rings and back-up washers.
1 Install and tighten the solenoid valves (Items 1 & 3) to 25
ft.-lbs. (33,9 Nm) torque. Tighten the solenoid valve (Item
2 2) [Figure 20-100-13] to 20 ft.-lbs. (27,1 Nm) torque.
Figure 20-100-14
2
2
2
P9169
Assembly: The coils largest opening (Item 1) [Figure
20-100-11] must position on the valve shoulder (Item 2)
[Figure 20-100-11]. Install the washer (Item 1) [Figure
20-100-12] between the double coils. Install the coils and
tighten the nuts (Item 2) [Figure 20-100-12] to 5 ft.-lbs.
(6,7 Nm) torque. 1
3
2
P9171
Remove the relief valve (Item 1), check valve (Item 2)
and pilot piston (Item 3) [Figure 20-100-14] located
between the check valves (Item 2) [Figure 20-100-14]
and (Item 3) [Figure 20-100-15]
A220 Bobcat Loader
20-100-4 Service Manual
SELECT VALVE (CONT’D) Assembly: Put oil on O-rings and back-up washers and
pilot piston (Item 1) [Figure 20-100-14]. Install and
Removal And Installation (Cont’d) tighten the relief valve (Item 1) [Figure 20-100-14] to 25
ft.-lbs. (33,9 Nm) torque. Install the pilot piston (Item 3)
Figure 20-100-15 [Figure 20-100-14] in the post between the check valves
(Item 2) [Figure 20-100-14] and (Item 3) [Figure 20-100-
5 15]. Install the check valves and load shuttle (Item 1)
4
[Figure 20-100-15] and tighten to 20 ft.-lbs. (27,1 Nm)
torque. Install the fitting (Item 2) [Figure 20-100-15] and
tighten to 35 ft.-lbs. (47,4 Nm) torque.
N-00503
1 2
P9172
Remove the load shuttle (Item 1). Remove the fitting
(Item 2). Remove the check valve (Item 3) [Figure 20-
100-15].
Inspect the relief valve, check valves, piston, load shuttle
and fitting for contamination or damage. Wash all parts in
clean solvent. Use air pressure to dry them. Install new
O-rings and back-up washers.
The load shuttle (Item 1) has a ball (Item 5) that must
move free inside the shuttle, the plug (Item 4) [Figure 20-
100-15] can be removed to clean the shuttle and ball.
Figure 20-100-16
P9176
The fitting (Item 2) [Figure 20-100-15] and [Figure 20-
100-16] has a poppet valve. The poppet valve allows flow
out of the select valve only. Inspect the poppet for
smooth opening and closing.
A220 Bobcat Loader
20-100-5 Service Manual
SELECT VALVE (CONT’D)
Solenoid Testing
Figure 20-100-17
P9175
Use a test meter to measure coil resistance [Figure 20-
100-17]. Coil wires do not have polarity. Correct
resistance for the pressure relief (small) coil is 7-10 ohms
and the other coils 5-8 ohms.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
A220 Bobcat Loader
20-100-6 Service Manual
REAR AUXILIARY DIVERTER VALVE Remove the pilot check valves from block ports PC1 and
PC2 (Item 1) [Figure 20-110-2].
Disassembly
Remove the shuttle check valve from block port SH1
(Item 2) [Figure 20-110-2].
IMPORTANT Figure 20-110-3
When repairing hydrostatic and hydraulic systems, 4
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
2
tubelines and ports to keep dirt out. Dirt can quickly 3
damage the system.
I-2003-0888
5
2
Figure 20-110-1 2
3
2 1
N-0528
Remove the nuts (Item 1), seal washers (Item 2), and
solenoid valve coils (Item 3) [Figure 20-110-3].
Remove the diverter control solenoid valve (Item 4) from
port SV1. Remove the pressure relieving solenoid valve
1 (Item 5) [Figure 20-110-3] from block port SV2.
1
N-0527 Inspection
Inspect cartridges, check valves, solenoid valves and
Clean the diverter block to remove dirt before sealing washers for contamination or damage. Wash all
disassembly. Block ports are labeled for correct parts in clean solvent. Use air pressure for drying them.
assembly. Install new O-rings and back-up washers.
Remove the logic cartridge valves from block ports LC1 Inspect diverter block cavities for contamination. Wash
and LC2 (Item 1) [Figure 20-110-1]. block in clean solvent. Use air pressure to dry.
Figure 20-110-2
2
N-0529
A220 Bobcat Loader
20-110-1 Service Manual
REAR AUXILIARY DIVERTER VALVE (CONT’D)
Solenoid Testing
Figure 20-110-4
P9137
Use a test meter to measure coil resistance [Figure 20-
110-4]. Coil wires do not have polarity. Correct resistance
is 6-9 ohms.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
Assembly
Put oil on O-rings and back-up washers.
Tighten the Logic cartridge valves (Item 1) [Figure 20-
110-1] to 65 ft.-lbs. (88 Nm) torque.
Tighten the pilot check valves (Item 1), and shuttle check
valve (Item 2) [Figure 20-110-2] to 35 ft.-lbs. (47 Nm)
torque.
Tighten the solenoid valves (Items 4 & 5) to 12 ft.-lbs.
(16,3 Nm) torque. Install the sealing washers (Item 2)
and coils (Item 3). Tighten the nuts (Item 1) [Figure 20-
110-3] to 10 in.-lbs. (1,13 Nm) torque.
A220 Bobcat Loader
20-110-2 Service Manual
POWER BOB-TACH BLOCK (EARLY MODELS) Figure 20-120-2
Removal And Installation
2
2
1
WARNING P-26595
Never work on a machine with the lift arms up unless Remove the two bolts (Item 1) [Figure 20-120-2] from
the lift arms are secured by an approved lift arm the wheel position sensor/steering cylinder cover.
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Remove the six mount bolts (Item 2) [Figure 20-120-2]
to fall and cause injury or death. from the access cover.
Figure 20-120-3
Figure 20-120-1
P-26596
P-26594
Remove the wheel position sensor/steering cylinder
Raise the lift arms and install an approved lift arm support cover from the loader.
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.) Disconnect the wheel position sensor harness (Item 1)
[Figure 20-120-3] from the loader harness.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.) Push the loader harness connector through the hole in
the access cover.
Drain the hydraulic reservoir. (See Draining The Fluid
Reservoir on Page 20-80-1.) Remove the access cover from the loader.
Place the loader on jackstands. (See Procedure on Page
10-10-1.)
Remove the right rear tire assembly [Figure 20-120-1].
A220 Bobcat Loader
20-120-1 Service Manual
POWER BOB-TACH BLOCK (EARLY MODELS) Figure 20-120-6
(CONT’D)
Removal And Installation (Cont'd)
Figure 20-120-4
P-26600
1
Remove the hydraulic hose (Item 1) [Figure 20-120-6]
that goes from the gear pump to the steering block. Cap
P-26598 and plug the hose.
Figure 20-120-7
Disconnect the hydraulic hose (Item 1) [Figure 20-120-4]
that goes from the gear pump to the select valve.
Plug and cap the hose and fitting. 1
Figure 20-120-5
1
P-26601
Remove the hydraulic hose that goes from the top of the
Power Bob-Tach Block to the control valve (Item
1)[Figure 20-120-7].
P-26599
Remove the A/C compressor (If so equipped). (See
COMPRESSOR on Page 80-110-1.)
Remove the hydraulic fitting (Item 1) [Figure 20-120-5]
from the gear pump. Plug the hole. Remove the alternator. (See ALTERNATOR on Page 60-
30-1.)
A220 Bobcat Loader
20-120-2 Service Manual
POWER BOB-TACH BLOCK (EARLY MODELS) Figure 20-120-10
(CONT’D)
Removal And Installation (Cont'd)
Figure 20-120-8 1
P-26607
Remove the four Power Bob-Tach Block mount bolts
1 1 (Item 1) [Figure 20-120-10].
P-26605
Installation: Tighten the mount bolts to 25-28 ft.-lbs. (34-
38 Nm) torque.
Mark the hydraulic hoses for proper installation.
Remove the Power Bob-Tach Block from the loader.
Remove the three hydraulic hoses (Item 1) [Figure 20-
120-8] from the back of the Power Bob-Tach block.
Cap and plug the hoses and the fittings.
Figure 20-120-9
P-26606
Mark the two electrical connectors (Item 1) [Figure 20-
120-9] for proper installation.
Disconnect the two solenoid connectors, from the loader
harness.
A220 Bobcat Loader
20-120-3 Service Manual
POWER BOB-TACH BLOCK (EARLY MODELS) Figure 20-120-12
(CONT’D)
Disassembly And Assembly
Figure 20-120-11
2
1
3
P-26103
Remove the spring (Item 1) and compensator (Item 2)
[Figure 20-120-12].
P-26100
Check the O-ring (Item 3) [Figure 20-120-12] on the plug
and replace as needed.
Figure 20-120-13
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Clean the diverter block (Item 1) [Figure 20-120-11] to
remove dirt before disassembly. Block ports are labeled 1
for correct assembly.
Remove the plug (Item 2) [Figure 20-120-11]. P-26105
Installation: Tighten the plug to 46 ft.-lbs. (62,4 Nm)
torque. Remove the plug (Item 1) [Figure 20-120-13].
Installation: Tighten the plug to 120 ft.-lbs. (13,6 Nm)
torque.
A220 Bobcat Loader
20-120-4 Service Manual
POWER BOB-TACH BLOCK (EARLY MODELS) Figure 20-120-16
(CONT’D)
Disassembly And Assembly (Cont'd) 6
Figure 20-120-14
P-26208A
3
2
1
4
5 P-26112
2
1 3 Remove the pressure reducing valve plug (Item 1)
[Figure 20-120-15] &[Figure 20-120-16].
P-26107
Installation: Tighten the pressure reducing valve plug to
to 46 ft.-lbs. (62,4 Nm) torque.
Remove the spring (Item 1) and check ball (Item 2)
[Figure 20-120-14]. Remove the relief piston (Item 2), spring (Item 3), ball
seat spring guide (Item 4) [Figure 20-120-16].
Check the O-ring (Item 3) [Figure 20-120-14] on the plug
and replace as needed. Check the O-ring (Item 5) [Figure 20-120-16] on the
pressure reducing valve plug and replace as needed.
Figure 20-120-15
NOTE: The relief valve seat (Item 6) [Figure 20-120-
16] is a non-serviceable part. If seat is
damaged, order a new power Bob-Tach block
from Bobcat parts.
1
P-26109
A220 Bobcat Loader
20-120-5 Service Manual
POWER BOB-TACH BLOCK (EARLY MODELS) Figure 20-120-19
(CONT’D)
Disassembly And Assembly (Cont'd)
Figure 20-120-17
P-26116
1 Figure 20-120-20
P-26113
Figure 20-120-18
4
3
2
P-26117
3
Remove the nut (Item 1) [Figure 20-120-19] & [Figure
2 1 20-120-20].
P-26114
Installation: Tighten the nut to 5 ft.-lbs. (6,8 Nm) torque.
Remove the plug (Item 1) [Figure 20-120-17] & [Figure Remove the first solenoid coil (Item 2), spacer (Item 3)
20-120-18]. and the second solenoid coil (Item 4) [Figure 20-120-
20].
Installation: Tighten the plug to 32 in.-lbs. (3,6 Nm)
torque. NOTE: Remember the solenoid coil orientation for
ease of installation.
Check the O-ring (Item 2) [Figure 20-120-18] on the plug
and replace as needed.
Check the O-ring (Item 3) [Figure 20-120-18] and
replace as needed.
A220 Bobcat Loader
20-120-6 Service Manual
POWER BOB-TACH BLOCK (EARLY MODELS) Figure 20-120-23
(CONT’D)
Disassembly And Assembly (Cont'd)
Figure 20-120-21
1
P-26123
1
Figure 20-120-24
P-26120
Remove the solenoid valve stem (Item 1) [Figure 20-
120-21].
Installation: Tighten the solenoid valve stem to 20 ft.-lbs.
(27,1 Nm) torque.
Figure 20-120-22
2
1
1
3 P-26309
Remove the plug (Item 1) [Figure 20-120-23] & [Figure
20-120-24].
Installation: Tighten the plug to 120 in.-lbs. (13,6 Nm)
2 torque.
Remove the dowel pin shuttle (Item 2) [Figure 20-120-
24].
P-26122
Check the O-ring (Item 3) [Figure 20-120-24] and
replace as needed.
Check the O-rings and back-up washers (Item 1) [Figure
20-120-22] and replace as needed.
Installation: Put oil on O-rings and back-up washers.
Check the O-ring (Item 2) [Figure 20-120-22] and
replace as needed.
A220 Bobcat Loader
20-120-7 Service Manual
POWER BOB-TACH BLOCK (EARLY MODELS) Figure 20-120-27
(CONT’D)
Disassembly And Assembly (Cont'd)
Figure 20-120-25
P-26128
Figure 20-120-28
1
P-26125
Figure 20-120-26
2
P-26129
2
1
Remove the plug (Item 1) [Figure 20-120-27] & [Figure
20-120-28].
3 P-26127
Installation: Tighten the plug to 198 in.-lbs. (22,4 Nm)
torque.
Remove the plug (Item 1) [Figure 20-120-25] & [Figure
20-120-26]. Check the O-ring (Item 2) [Figure 20-120-28] and
replace as needed.
Installation: Tighten the plug to 198 in.-lbs. (22,4 Nm)
torque.
Remove the pilot piston (Item 2) [Figure 20-120-26].
Check the O-ring (Item 3) [Figure 20-120-26] and
replace as needed.
A220 Bobcat Loader
20-120-8 Service Manual
POWER BOB-TACH BLOCK (EARLY MODELS) Figure 20-120-31
(CONT’D)
Disassembly And Assembly (Cont'd)
Figure 20-120-29
P-26133
Make sure orifice is clean and not plugged [Figure 20-
120-31].
P-26130
Figure 20-120-30
2
1
3 P-26132
Remove the plug (Item 1) [Figure 20-120-29] & [Figure
20-120-30].
Installation: Tighten the plug to 32 in.-lbs. (3,6 Nm)
torque.
Remove the orifice (Item 2) [Figure 20-120-30] with a
5/32 inch allen wrench.
Installation: Hand tighten until snug.
A220 Bobcat Loader
20-120-9 Service Manual
POWER BOB-TACH BLOCK (EARLY MODELS) Figure 20-120-34
(CONT’D)
Disassembly And Assembly (Cont'd)
Figure 20-120-32
P-26137
Remove the plug (Item 1) [Figure 20-120-34]
1
P-26134 Installation: Tighten the plug to 120 in.-lbs. (13,6 Nm)
torque.
Figure 20-120-33 Figure 20-120-35
3
2 1
1
4 P-26136
2
P-26139
Remove the plug (Item 1) [Figure 20-120-32] & [Figure Remove the dowel pin orifice (Item 1) [Figure 20-120-
20-120-33]. 35].
Installation: Tighten the plug to 198 in.-lbs. (22,4 Nm) Check the O-ring (Item 2) [Figure 20-120-35] and
torque. replace as needed.
Remove the relief spring (Item 2) [Figure 20-120-33].
Remove the ball seat spring guide (Item 3) [Figure 20-
120-33].
Check the O-ring (Item 4) [Figure 20-120-33] and
replace as needed.
A220 Bobcat Loader
20-120-10 Service Manual
POWER BOB-TACH BLOCK (EARLY MODELS) Figure 20-120-38
(CONT’D)
Disassembly And Assembly (Cont'd)
Figure 20-120-36
P-26141
Remove the plug (Item 1) [Figure 20-120-38].
P-26140 Installation: Tighten the plug to 32 in.-lbs. (3,6 Nm)
torque.
Remove the plug (Item 1) [Figure 20-120-36] & [Figure Figure 20-120-39
20-120-37].
Installation: Tighten the plug to 32 in.-lbs. (3,6 Nm)
torque.
Figure 20-120-37
2
1
3
P-26143
2 Remove the flow control spring (Item 1) [Figure 20-120-
39].
1
P-26141 Remove the flow control (Item 2) [Figure 20-120-39].
Check the O-ring (Item 3) [Figure 20-120-39] and
Check the O-ring (Item 2) [Figure 20-120-37] and replace as needed.
replace as needed.
A220 Bobcat Loader
20-120-11 Service Manual
A220 Bobcat Loader
20-120-12 Service Manual
POWER BOB-TACH BLOCK (LATER MODELS) Figure 20-121-2
Removal And Installation
2
2
WARNING 1
P-26595
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm Remove the two bolts (Item 1) [Figure 20-121-2] from
support device. Failure to use an approved lift arm the wheel position sensor/steering cylinder cover.
support device can allow the lift arms or attachment
to fall and cause injury or death. Remove the six mount bolts (Item 2) [Figure 20-121-2]
W-20590598 from the access cover.
Figure 20-121-3
Figure 20-121-1
P-26596
P-26594
Remove the wheel position sensor/steering cylinder
Raise the lift arms and install an approved lift arm support
cover from the loader.
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Disconnect the wheel position sensor harness (Item 1)
[Figure 20-121-3] from the loader harness.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Push the loader harness connector through the hole in
the access cover.
Drain the hydraulic reservoir. (See Draining The Fluid
Reservoir on Page 20-80-1.)
Remove the access cover from the loader.
Place the loader on jackstands. (See Procedure on Page
10-10-1.)
Remove the right rear tire assembly [Figure 20-121-1].
A220 Bobcat Loader
20-121-1 Service Manual
POWER BOB-TACH BLOCK (LATER MODELS) Figure 20-121-6
(CONT’D)
Removal And Installation (Cont'd)
Figure 20-121-4
P-26600
1
Remove the hydraulic hose (Item 1) [Figure 20-121-6]
that goes from the gear pump to the steering block. Cap
P-26598 and plug the hose.
Remove the A/C compressor (If so equipped). (See
Disconnect the hydraulic hose (Item 1) [Figure 20-121-4] COMPRESSOR on Page 80-110-1.)
that goes from the gear pump to the select valve.
Remove the alternator. (See ALTERNATOR on Page 60-
Plug and cap the hose and fitting. 30-1.)
Figure 20-121-5
P-26599
Remove the hydraulic fitting (Item 1) [Figure 20-121-5]
from the gear pump. Plug the hole.
A220 Bobcat Loader
20-121-2 Service Manual
POWER BOB-TACH BLOCK (LATER MODELS) Figure 20-121-9
(CONT’D)
Removal And Installation (Cont'd) 1
1
Figure 20-121-7
P-48591
1
Remove the four mounting bolts (Item 1) [Figure 20-121-
9].
P-26606
Installation: Tighten the mounting bolts to 25-28 ft.-lbs.
(34-38 Nm) torque.
Disconnect and cap the two electrical solenoid
connectors (Item 1) [Figure 20-121-7] from the loader Remove the power Bob-Tach block.
electrical harness.
Figure 20-121-8
2
2
P-48590
Disconnect and cap the outlet hose (Item 1) [Figure 20-
121-8] from block.
Mark the hydraulic hoses for proper installation.
Disconnect and cap the hose (Item 2) [Figure 20-121-8]
from block.
A220 Bobcat Loader
20-121-3 Service Manual
POWER BOB-TACH BLOCK (LATER MODELS) Figure 20-121-11
(CONT’D)
Disassembly And Assembly
Figure 20-121-10
3
1
4
2 1
P-48120
Remove the spring guide (Item 1), spring (Item 2) and the
spool (Item 3) [Figure 20-121-11].
P-48115
Check the O-ring (Item 4) [Figure 20-121-11] on the plug
and replace as needed.
Clean the block (Item 1) [Figure 20-121-10] to remove
dirt before disassembly. Block ports are labeled for Figure 20-121-12
correct assembly.
Remove the plug (Item 2) [Figure 20-121-10].
Installation: Tighten the plug to 25-30 ft.-lbs. (34-40,6
Nm) torque.
IMPORTANT 1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
P-48116
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-121-12].
Installation: Tighten the plug to 12-14 ft.-lbs. (16,3-19
Nm) torque.
A220 Bobcat Loader
20-121-4 Service Manual
POWER BOB-TACH BLOCK (LATER MODELS) Figure 20-121-15
(CONT’D)
Disassembly And Assembly (Cont'd)
Figure 20-121-13
1
P-48122
Do not remove the plugs (Item 1) [Figure 20-121-15].
P-48382 NOTE: Do not remove plugs. If the plugs are removed
the internal pressure relieving spring setting
will be altered.
Remove the check valve (Item 1) [Figure 20-121-13].
Figure 20-121-16
Installation: Oil the check valve and O-rings and tighten
the check valve to to 20-25 ft.-lbs. (27,1-34 Nm) torque.
Figure 20-121-14
2
1
P-48384
3
Remove the plug (Item 1) [Figure 20-121-16], inspect
P-48119 the O-ring and replace as needed.
Installation: Tighten the plug (Item 1) [Figure 20-121-
Inspect the check valve (Item 1) and piston assembly 16] to 12-14 ft.-lbs. (16,3-19 Nm) torque.
(Item 2) [Figure 20-121-14].
Check the O-rings and back up washers (Item 3) [Figure
20-121-14] on the check valve and piston assembly and
replace as needed.
A220 Bobcat Loader
20-121-5 Service Manual
POWER BOB-TACH BLOCK (LATER MODELS) Figure 20-121-19
(CONT’D)
Disassembly And Assembly (Cont'd)
3
Figure 20-121-17
2
2
1
P-48106
Remove the first solenoid coil (Item 1), spacer (Item 2)
and the second solenoid coil (Item 3) [Figure 20-121-
P-48664 19].
NOTE: Remember the solenoid coil orientation for
Remove the orifice screw (Item 2) located behind the ease of installation.
plug (Item 1) [Figure 20-121-17].
Figure 20-121-20
Installation: Tighten the orifice screw (Item 2) [Figure
20-121-17] to 6-8 ft.-lbs. (8,1-10,8 Nm) torque.
Figure 20-121-18
1
1
2
P-48386
Remove the the solenoid stem (Item 1) [Figure 20-121-
P-48127 20].
Installation: Tighten the solenoid stem to to 20-25 ft.-lbs.
NOTE: This plug is a zero leak plug and should not be (27,1-34 Nm) torque.
removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-121-18].
Remove the solenoid nut (Item 2) [Figure 20-121-18].
Installation: Tighten the solenoid valve stem nut to 15-
45 in.-lbs. (1,7-5,1 Nm) torque.
A220 Bobcat Loader
20-121-6 Service Manual
POWER BOB-TACH BLOCK (LATER MODELS) Figure 20-121-23
(CONT’D)
Disassembly And Assembly (Cont'd)
Figure 20-121-21 1
P-48174
1
Remove the screened orifice plug (Item 1) [Figure 20-
121-23].
P-48175
Installation: Tighten the screened orifice plug to to 11-12
ft.-lbs. (14,9-16,3 Nm) torque.
Remove the armature rod assembly (Item 1) [Figure 20-
121-21]. Figure 20-121-24
Figure 20-121-22
2
2
1
1
P-48138
P-48173
Inspect the screened orifice plug (Item 1) [Figure 20-
121-24] for damage replace as needed. If the screened
Inspect the solenoid stem (Item 1), armature assembly orifice plug is blocked replace with a new plug.
(Item 2) and the spool (Item 3) for damage [Figure 20-
121-22]. Check the O-ring (Item 2) [Figure 20-121-24] and
replace as needed.
NOTE: If the solenoid stem is damaged (Item 1) check
the armature assembly (Item 2) for damage.
The armature assembly (Item 2) and spool
(Item 3) are non-serviceable parts. If they are
damaged, order a new power Bob-Tach block
assembly from Bobcat parts [Figure 20-121-
22].
A220 Bobcat Loader
20-121-7 Service Manual
A220 Bobcat Loader
20-121-8 Service Manual
AUXILIARY PRESSURE RELEASE (ACCUMULATOR)
(EARLY MODELS)
Removal and Installation WARNING
Figure 20-130-1 Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Figure 20-130-2
2 2
1
1
P-26773
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Stop the engine. Raise the seat bar.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Clean the area around the control valve.
Remove the right side motor cover (Item 1) , by removing
the four bolts (Item 2) [Figure 20-130-1].
P-24037
IMPORTANT Locate the accumulator (Item 1)[Figure 20-130-2]
through the right motor cover opening.
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
A220 Bobcat Loader
20-130-1 Service Manual
AUXILIARY PRESSURE RELEASE (ACCUMULATOR)
(EARLY MODELS) (CONT’D)
Removal and Installation (Cont’d)
Figure 20-130-3
P-26825
Remove the accumulator hose (Item1 ) [Figure 20-130-
3] and cap.
Figure 20-130-4
2
1
P-24060
Remove accumulator mounting nut (Item 1) [Figure 20-
130-4] , while reaching through motor cover opening and
holding the accumulator.
Remove accumulator through the motor cover opening.
A220 Bobcat Loader
20-130-2 Service Manual
FRONT AUXILARY HYDRAULIC COUPLER Disassembly And Assembly
BLOCKFRONT AUXILIARY HYDRAULIC COUPLER
BLOCK (S/N 519611124 & ABOVE) Figure 20-131-2
Removal and Installation
IMPORTANT
2
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all 4
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 3
damage the system.
I-2003-0888
P-34661
Figure 20-131-1
Figure 20-131-3
2
1 1
3 6 2
4
5 3
P-31242
P-34760
Disconnect the auxiliary hoses (Item 1) and drain hose
(Item 2) [Figure 20-131-1] from the coupler block.
Remove the male coupler (Item 1) [Figure 20-131-2] &
Remove the two mounting bolts (Item 3) [Figure 20-131- [Figure 20-131-3].
1].
Installation: Tighten the male coupler (Item 1) [Figure
20-131-2] & [Figure 20-131-3] to 59 ft.-lbs. (80 Nm)
Remove the drain coupler (Item 2) [Figure 20-131-2] &
[Figure 20-131-3].
Installation: Tighten the drain coupler (Item 2) [Figure
20-131-2] & [Figure 20-131-3] to 37 ft.-lbs. (50 Nm)
Remove the female coupler (Item 3) [Figure 20-131-2] &
[Figure 20-131-3].
Installation: Tighten the female coupler (Item 3) [Figure
20-131-2] & [Figure 20-131-3] to 59 ft.-lbs. (80 Nm)
Remove the fittings (Item 4) [Figure 20-131-2] & [Figure
20-131-3] check the O-rings (Item 5) [Figure 20-131-3]
and replace as needed.
Remove the springs (Item 6) [Figure 20-131-3].
A220 Bobcat Loader
20-131-1 Service Manual
FRONT AUXILARY HYDRAULIC COUPLER Figure 20-131-6
BLOCKFRONT AUXILIARY HYDRAULIC COUPLER
BLOCK (S/N 519611124 & ABOVE) (CONT’D)
Disassembly And Assembly (Cont’d) 1
Figure 20-131-4
1
2
P-34665
Check the O-rings (Item 1) back-up O-rings (Item 2)
[Figure 20-131-6] for damage and replace as needed.
P-34663 Figure 20-131-7
Check the O-ring (Item 1) [Figure 20-131-4] for damage
1
and replace as needed.
Figure 20-131-5
P-34664
Check the O-rings (Item 1) back-up O-rings (Item 2)
[Figure 20-131-7] for damage and replace as needed.
P-34701
Press center of male couplers down and check the O-ring
(Item 1) [Figure 20-131-5] for damage and replace as
needed.
A220 Bobcat Loader
20-131-2 Service Manual
HYDROSTATIC SYSTEM
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
SAFETY &
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1 MAINTENANCE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . 30-50-1 HYDROSTATIC
Tensioner Pulley Removal And Installation . . . . . . . . . . . . 30-50-2 SYSTEM
Tensioner Pulley Tension Spring . . . . . . . . . . . . . . . . . . . . 30-50-4
HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 DRIVE
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-7 YSTEM
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-2
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
HYDROSTATIC MOTOR (TWO-SPEED) . . . . . . . . . . . . . . . . 30-21-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-13 ELECTRICAL
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-5 SYSTEM &
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-11 ANALYSIS
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
ENGINE
HYDROSTATIC MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . 30-22-1 SERVICE
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-5
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-1 SPECIFICATIONS
Continued On Next Page
A220 Bobcat Loader
30-01 Service Manual
HYDROSTATIC SYSTEM (CONT’D)
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-37
Charge Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-24
Charge Pump Installation. . . . . . . . . . . . . . . . . . . . . . . . . 30-40-25
Charge Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-22
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-15
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-27
Hydrostatic Pump Calibration . . . . . . . . . . . . . . . . . . . . . . 30-40-4
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-33
Parts Identification (Left Half). . . . . . . . . . . . . . . . . . . . . . 30-40-12
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . 30-40-10
Pump Controller Neutral Adjustment . . . . . . . . . . . . . . . . 30-40-50
Pump Controller Removal And Installation . . . . . . . . . . . . 30-40-1
Pump Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 30-40-47
Pump Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-17
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-8
Shaft Seal And Shaft Installation . . . . . . . . . . . . . . . . . . . 30-40-20
Shaft Seal And Shaft Replacement . . . . . . . . . . . . . . . . . 30-40-18
System Check Relief Valves (High Pressure Relief, Charge Check
& By-Pass Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-14
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . 30-10-1
Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
OIL COOLER (SEAL TO CONNECT) (STC). . . . . . . . . . . . . . 30-60-1
Hydraulic Oil Cooler Removal and Installation. . . . . . . . . . 30-60-1
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (See
UNLESS
TORQUE SPECIFICATIONS FOR BOLTS on Page SPEC-40-1.)
OTHERWISE SPECIFIED
A220 Bobcat Loader
30-02 Service Manual
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
WARNING
The following trouble shooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
PROBLEM CAUSE
No drive on one side, in one direction. 1,2
No drive on one side in both direcctions. 2,3,4,5
The loader does not move in a straight line. 2,3,5,6,7
The hydraulic system is overheating. 8,9,10,11
Service3 code HP2 appears (Warning, low charge pressure) or the warning light comes ON. 8,11,12,13,14,
KEY TO CORRECT THE CAUSE
1. The hydrostatic pump replenishing valves are not seating.
2. The steering linkage needs adjustment.
3. The hydraulic pump has damage.
4. The final drive chains are broken.
5. .The hydraulic motor has damage
6. The tires do not have the correct tire pressure.
7.The tires are not the same size.
8. The hydraulic fluid is not at the correct level.
9. The oil cooler has a restriction.
10. The tempurature sending switch is not operating correctly.
11. The loader is not being operated at the correct RPM.
12.The sender is defective.
13. Pump is defective or worn hydrostatics.
14. Hydraulic filter is plugged
A220 Bobcat Loader
30-10-1 Service Manual
HYDROSTATIC SYSTEM INFORMATION (CONT’D) Figure 30-10-1
Replenishing Valve Function
The functions of the replenishing valves are: CHARGE OIL
• To give replacement fluid to the low pressure side of
the hydrostatic circuit. Replacement fluid is needed
because of normal internal leakage and the controlled
flow to the oil cooler for cooling; Function 1 [Figure
30-10-1] .
• To keep high pressure fluid out of the low pressure
side of the hydrostatic circuitry; Function 2 [Figure
30-10-1] Oil Replacment
FUNCTION 1
Valve Moves for Charge
See HYDROSTATIC MOTOR on Page 30-20-1(M46
Pump) or See HYDROSTATIC MOTOR (TWO-SPEED)
on Page 30-21-1 (M44 Pump) for valve location and
repair information.
IMPORTANT
When repairing hydrostatic and hydraulic systems, Valve Stays on Seat to
clean the work area before disassembly and keep all FUNCTION 2 Hold High Pressure for Drive
parts clean. Always use caps and plugs on hoses,
B-2804
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
A220 Bobcat Loader
30-10-2 Service Manual
HYDROSTATIC MOTOR Figure 30-20-2
Removal And Installation
1 1
1 2
1
1
1
WARNING N-17876
Never work on a machine with the lift arms up unless Remove the ten mounting bolts (Item 1) [Figure 30-20-
the lift arms are secured by an approved lift arm 2].
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment NOTE: The two bolts (Item 2) [Figure 30-20-2] mount
to fall and cause injury or death. the cam ring to the motor, and do not have to
W-2059-0598
be removed, to remove the motor from the
loader.
Figure 30-20-1
Remove the motor/cam ring section from the loader.
Removal And Installation (Cont’d)
Figure 30-20-3
N-17874
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the lift arms and install an approved lift arm support P5405
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Remove the piston/roller section (Item 1) [Figure 30-20-
Raise the operator cab. (See Raising The Operator Cab 3] from the loader, if it was not removed with the motor/
on Page 10-30-1.) cam ring.
Remove the motor cover.
To remove the motor carrier. (See HYDROSTATIC
Mark the hoses for correct installation. MOTOR CARRIER on Page 30-22-1.)
Disconnect the case drain hose (Item 1) [Figure 30-20-
1].
Disconnect the high pressure hoses (Item 2) [Figure 30-
20-1].
A220 Bobcat Loader
30-20-1 Service Manual
HYDROSTATIC MOTOR (CONT’D)
Parts Identification
3
3
1
2
5
4 6
87
4 9
10
12
11
13
26 23 14 15
27 25
28
29
30
16
22 21
24 20
19
18
17
1. Distributor 17. Plug
2. Spring 18. O-ring
3. Seal 19. Spring
4. O-ring 20. Shim
5. Plug 21. Poppet
6. O-ring 22. O-ring
7. Spring 23. Seal
8. Washer 24. O-ring
9. Spool 25. Seal
10. Spring 26. O-ring
11. Rear Housing 27. Cam
12. Plug 28. Roller
13. O-ring 29. Piston
14. O-ring 30. Block
15. Stop Pin
16. Bolt
C-3374A
A220 Bobcat Loader
30-20-2 Service Manual
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-6
Disassembly
1
Figure 30-20-4
N-17863
Remove the cam ring (Item 1) [Figure 30-20-6] from the
N-17861 motor housing.
Figure 30-20-7
Remove the piston/roller section (Item 1) [Figure 30-20-
4] from the motor.
Figure 30-20-5 1
1
N-17864
Remove the stop pin (Item 1) [Figure 30-20-7] from the
N-17860 rear motor housing.
Remove the two cam ring mounting bolts (Item 1)
[Figure 30-20-5]
A220 Bobcat Loader
30-20-3 Service Manual
HYDROSTATIC MOTOR (CONT’D) Remove the two O-rings, that are located under the
seals.
Disassembly (Cont'd)
Figure 30-20-10
Figure 30-20-8
1
1
2
1
N-17869
N-17865
Remove the nine springs (Item 1) [Figure 30-20-10] from
Use a brass drift punch, thru the stop pin hole (Item 1) to the distributor.
remove the distributor (Item 2) [Figure 30-20-8].
Figure 30-20-11
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1
Figure 30-20-9
N-17870
Remove the two seals (Item 1) [Figure 30-20-11] from
the distributor.
Remove the two O-rings, that are located under the
1
seals.
N-17866
Remove the two seals (Item 1) [Figure 30-20-9] from the
housing.
A220 Bobcat Loader
30-20-4 Service Manual
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-14
Disassembly (Cont'd)
Figure 30-20-12
2
1
P-5765
1 2 3 4
Apply low air pressure to each port in the cylinder block
N-17872 to remove the roller (Item 1) and piston/ring assembly
(Item 2) [Figure 30-20-14].
Remove the plug (Item 1) spring (Item 2) shim (Item 3) NOTE: Put all the roller/piston assembly back in their
and poppet (Item 4) [Figure 30-20-12]. original position.
Inspect all parts and replace as needed.
Figure 30-20-13
2 3 4 2 1
N-17871
Remove the plug (Item 1) springs (Item 2) spool (Item 3)
and washer (Item 4) [Figure 30-20-13].
Inspect all parts and replace as needed.
A220 Bobcat Loader
30-20-5 Service Manual
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-17
Inspection
Figure 30-20-15
P5759
Check the cylinder block surface for scratches [Figure
N-17870 30-20-17].
Check all the roller/piston assembly for scratches and
Clean all parts in clean solvent and use air pressure to wear [Figure 30-20-17].
dry them. DO NOT use cloth or paper because small
pieces of material can get into the system and cause Replace the parts as needed.
damage.
Before the motor is assembled, check the following
items:
Check the distributor surface for scratches [Figure 30-
20-15].
Figure 30-20-16
P5753
Check the cam ring inside surface for wear and scratches
[Figure 30-20-16].
A220 Bobcat Loader
30-20-6 Service Manual
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-19
Assembly
IMPORTANT 1
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888.
N-17870
NOTE: Always use new O-rings and seals when
assembling the hydrostatic motor.
Install new O-rings and seals (Item 1) [Figure 30-20-19]
Figure 30-20-18 on the distributor.
Figure 30-20-20
2
1
1
P5765
N-17869
Install the roller (Item 1) in the piston (Item 2) [Figure 30-
20-18].
Put grease on the springs (Item 1) [Figure 30-20-20] to
Dip the roller/piston assembly into oil and install into the hold them in place.
bore in the cylinder.
Install the springs into the distributor.
Repeat for each roller/piston assembly.
A220 Bobcat Loader
30-20-7 Service Manual
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-23
Assembly (Cont’d)
Figure 30-20-21
N-17866
1 2 3 1 4
Install the two seals (Item 1) [Figure 30-20-23] into the
N-17871 housing, over the top of the O-rings, with minimum
distortion.
nstall the spring (Item 1) spool (Item 2) washer (Item 3) Lightly smear grease over the seals.
[Figure 30-20-21] and spring into the rear housing.
Figure 30-20-24
Replace the O-ring (Item 4) [Figure 30-20-21] on the
plug.
Install the plug into the rear housing and tighten to 18-22 2 3
ft-lbs. (25-30 Nm) torque.
Figure 30-20-22
1 N-17868
Install the stop pin (Item 1) [Figure 30-20-24] and tighten
4 3 1 to 7-9 ft.-lbs. (10-12 Nm) torque.
2
Install the distributor (Item 2) [Figure 30-20-24] into the
N-17872 housing.
Align the distributor hole (Item 3) [Figure 30-20-24] with
Install the poppet (Item 1) the shim (Item 2) spring (Item the stop pin. When aligned correctly, the distributor can
3) [Figure 30-20-22] into the rear housing. be depressed slightly.
Replace the O-ring (Item 4) [Figure 30-20-22] on the
plug.
Install the plug into the rear housing and tighten to 9-11
ft-lbs. (12-15 Nm) torque.
Install the two O-rings into the housing.
A220 Bobcat Loader
30-20-8 Service Manual
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-27
Assembly (Cont'd)
1
Figure 30-20-25
1
1
N-17860
Install the two cam ring mounting bolts (Item 1) [Figure
N-17862 30-20-27] and tighten to 50 ft.-lbs. (67,8 Nm) torque.
Figure 30-20-28
Lightly smear grease on the O-ring.
Install the O-ring (Item 1) [Figure 30-20-25] on the rear
housing.
Figure 30-20-26
N-17861
Install the piston/roller section (Item 1) [Figure 30-20-28]
in the motor.
N-17863 Install the motor on the loader and tighten the mount
bolts to 110 ft.-lbs. (149,2 Nm) torque.
Install the cam ring (Item 1) [Figure 30-20-26] on the NOTE: Before operating the hydrostatic motor, make
rear housing and align the mounting bolt holes. sure it is full of oil. There are several methods
to fill the motor with oil; (1) with the case drain
hose disconnected, fill the motor with oil
through the case drain port; (2) with the case
drain hose disconnected, BICS™ brake
locked, engine running, stroke the steering
lever until oil comes out of the case drain port.
A220 Bobcat Loader
30-20-9 Service Manual
A220 Bobcat Loader
30-20-10 Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) Figure 30-21-2
Removal And Installation
WARNING N-22484
Never work on a machine with the lift arms up unless Mark the hoses for correct installation.
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm Disconnect the hydraulic hose (Item 1) [Figure 30-21-2]
support device can allow the lift arms or attachment that goes to the two-speed port on the two-speed/brake
to fall and cause injury or death. block.
W-2059-0598
Disconnect the hydraulic hose (Item 2) [Figure 30-21-2]
that goes to the brake port on the two-speed/brake block.
Figure 30-21-1
Disconnect the hydraulic hose (Item 3) [Figure 30-21-2]
that goes to the make-up port on the two-speed/brake
block.
Figure 30-21-3
1 1
N-22483
Lift and block the loader. (See HYDROSTATIC MOTOR
CARRIER on Page 30-22-1.)
Raise the lift arms and install an approved lift arm support N-22485
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Disconnect the hydraulic hose (Item 1) [Figure 30-21-3]
Raise the operator cab. (See Raising The Operator Cab that goes to the case drain filter.
on Page 10-30-1.)
Drain the hydraulic reservoir. (See Draining The Fluid
Reservoir on Page 20-80-1.)
Remove the motor cover mount bolts (Item 1) [Figure
30-21-1].
Remove the motor cover from the loader.
A220 Bobcat Loader
30-21-1 Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D) Figure 30-21-6
Removal And Installation (Cont'd)
Figure 30-21-4
N-22487
2
Remove the 10 (12 mm) mount bolts (Item 1) [Figure 30-
N-22486 21-6] from the motor.
NOTE: The two smaller diameter bolts (8 mm), hold
Remove the hydraulic fitting (Item 1) [Figure 30-21-4] the cam ring to the motor and do not have to
from the motor. be remove for motor removal.
Remove the eight flange bolts (Item 2) [Figure 30-21-4] Remove the motor from the loader.
from the high pressure hoses on the motor.
Figure 30-21-7
Installation: Install the lower collar to the motor and
connect the high pressure hoses behind the collar, then
install the upper collar and tighten the bolts to 25 ft.-lbs.
(34 Nm) torque.
Figure 30-21-5
1
N-22535
Installation: Replace the O-ring (Item 1) [Figure 30-21-
7] and hold it in place with a light cover of lithium base
grease. Tighten the 10 mounting bolts to 110 ft.-lbs. (149
N-22488 Nm) torque.
Remove the hydraulic fitting (Item 1) [Figure 30-21-5]
from the motor.
A220 Bobcat Loader
30-21-2 Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D)
Parts Identification
8
7
6
5
4
3
2
29
28
26 27
9 25
17
25
16 31
15
39
10 34
33
11 37 38
36
18 21 35
19 24
22
14 20
23 48
12 13 47
46 49
45
44
43
32
42
41
40
B-16657
A220 Bobcat Loader
30-21-3 Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D)
Parts Identification (Cont'd)
Ref. Description
1. Motor
2. Distributor
3. Spring
4. Seal/O-ring
5. Seal/O-ring
6. Seal/O-ring
7. Seal/O-ring
8. Seal/O-ring
9. Bushing
10. Roller
11. Piston
12. Block
13. Cam
14. Quad Ring
15. Plug
16. O-ring
17. Locating Pin
18. Housing
19. Shim
20. O-ring
21. Poppet
22. Spring
23. Plug
24. Bolt
25. Spring
26. Spool
27. Washer
28. O-ring
29. Plug
30. Housing
31. Quad Ring
32. Bushing
33. Snap Ring
34. Snap Ring
35. Spool
36. Spring
37. Washer
38. Quad Ring
39. Bolt
40. Shaft
41. Brake Disc-Outer
42. Brake Disc-Inner
43. Piston
44. O-ring
45. Washer
46. Washer
47. Gasket
48. Cover
49. Bolt
A220 Bobcat Loader
30-21-4 Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D) Figure 30-21-10
Disassembly
Figure 30-21-8
1
3
N-22491
Remove the cover plate gasket (Item 1) [[Figure 30-21-
N-22489 10].
Remove the disk spring washer (Item 2) and the disk
NOTE: Mark the motor, brake and motor carrier spring (Item 3) [Figure 30-21-10] from the brake
housings for proper alignment for ease of housing.
assembly[Figure 30-21-8].
NOTE: Mark the top side of the disk spring for proper
Drain the oil from the motor casing. installation.
Figure 30-21-9 Figure 30-21-11
1
2
N-22490 N-22493
Remove the twelve mounting bolts (Item 1) [Figure 30- Remove the piston from the brake housing [Figure 30-
21-9] from the brake cover plate. 21-11].
NOTE: Unscrew the bolts alternately, one turn at a NOTE: The use of air pressure through the brake line
time to release the preload on the end cap. connection (Item 2) [Figure 30-21-11] will aid
in piston removal.
Remove the cover plate from the brake housing.
A220 Bobcat Loader
30-21-5 Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D) Figure 30-21-14
Disassembly (Cont'd)
Figure 30-21-12
N-22496
Remove the O-ring (Item 1) [Figure 30-21-14] from the
N-22494 brake housing.
Figure 30-21-15
Remove the eight mounting bolts (Item 1) [Figure 30-21-
12] from the brake housing.
Remove the brake housing (Item 2) [Figure 30-21-12]
from the rear housing. 1
Figure 30-21-13
1
N-22497
Remove the seal (Item 1) [Figure 30-21-15] from the
brake housing.
N-22495
Remove the brake disks (Item 1) [Figure 30-21-13] from
the brake shaft.
Remove the O-ring (Item 2) [Figure 30-21-13] from the
housing.
A220 Bobcat Loader
30-21-6 Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D) Figure 30-21-18
Disassembly (Cont'd)
Figure 30-21-16
1
1
2
N-22502
Remove the plug (Item 1) [Figure 30-21-18] from the
N-22499 housing.
Installation: Tighten the plug to 18-22 ft.-lbs. (25-30 Nm)
Remove the two-speed spool spool (Item 1) [Figure 30- torque.
21-16] from the housing assembly.
Remove the plugs (Item 2) [Figure 30-21-18] from the
Figure 30-21-17 housing.
Installation: Tighten the plugs to 9-11 ft.-lbs. (12-15 Nm)
1 torque.
Figure 30-21-19
4 1
3
2
N-22501
Inspect the spool (Item 1), the spring (Item 2) washer
(Item 3) and the snap ring (Item 4) [Figure 30-21-17],
and replace as needed.
N-22503
NOTE: The spool (Item 1) [Figure 30-21-17] is marked
with either an A or B. The spool must be Remove the flushing spool assembly (Item 1) [Figure 30-
replaced with a spool with the same mark. 21-19] from the housing.
A220 Bobcat Loader
30-21-7 Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D) Figure 30-21-22
Disassembly (Cont'd)
Figure 30-21-20
4
1 1
2 3
N-22506
Remove the poppet assembly (Item 1) [Figure 30-21-22]
N-22504 from the housing.
Figure 30-21-23
Remove the spring (Item 1), washer (Item 2) , and and
rear spring (Item 3) from the spool (Item 4) [Figure 30-
21-20].
Inspect all parts and replace as needed.
Figure 30-21-21
3 2
1
N-22507
Inspect the poppet (Item 1), shim (Item 2) and spring
(Item 3) [Figure 30-21-23] for wear and replace as
needed.
N-22505
Remove the plug (Item 1) [Figure 30-21-21] from the
housing.
Installation: Tighten the plug to 9-11 ft.-lbs. (12-15 Nm)
torque.
A220 Bobcat Loader
30-21-8 Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D) Figure 30-21-26
Disassembly (Cont'd)
Figure 30-21-24
1 1
N-22511
Remove the roller/piston assembly (Item 1) [Figure 30-
N-22508 21-26] from the cylinder block.
NOTE: Put all roller/piston assembles back in the
Loosen the two (8 mm) cam ring mount bolts (Item 1) original bore.
[Figure 30-21-24].
Figure 30-21-27
Turn the housing, cam ring, and rotating group assembly
over and place on a stand.
Remove the cam ring mount bolts, and remove the cam
ring from the housing.
Figure 30-21-25 1
N-22512
2
Remove the brake shaft (Item 1) [Figure 30-21-27] from
the housing.
N-22509
Remove the cylinder block (Item 1) [Figure 30-21-25]
from the housing.
Remove the O-ring (Item 2) [Figure 30-21-25] from the
housing.
A220 Bobcat Loader
30-21-9 Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D) Figure 30-21-30
Disassembly (Cont'd)
Figure 30-21-28 1
N-22516
NOTE: The distributor removal, is best accomplished
N-22513 by lifting the housing (Item 1) 2-3 inches
above a wooden surface, and dropping the
housing [Figure 30-21-30].
NOTE: The snap ring end of the shaft (Item 1) [Figure
30-21-28] goes up toward the cam ring end of Figure 30-21-31
the motor.
Figure 30-21-29
N-22521
N-22515 Remove the locating pin (Item 1) [Figure 30-21-31] from
the distributor.
Remove the distributor (Item 1) [Figure 30-21-29] from
the housing.
A220 Bobcat Loader
30-21-10 Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D) Figure 30-21-34
Disassembly (Cont'd)
Figure 30-21-32
2 1
N-22519
Remove the six seals (Item 1), and six back-up O-rings
N-22522 (Item 2) [Figure 30-21-34] from the distributor.
Inspection
Remove the twelve springs (Item 1) [Figure 30-21-32]
from the distributor. Figure 30-21-35
Figure 30-21-33
N-22498
N-22523
Clean all parts in clean solvent and use air pressure to
dry them. Do Not use cloth or paper because small
Remove the bushing (Item 1) [Figure 30-21-33] from the pieces of material can get into the system and cause
distributor, if worn or scratched. damage.
Before the motor is assembled, check the following
items:
Check the brake piston (Item 1) and seal (Item 2)
[Figure 30-21-35] and replace as needed.
A220 Bobcat Loader
30-21-11 Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D) Figure 30-21-38
Inspection (Cont’d)
Figure 30-21-36
3
1
N-22526
Check all rollers (Item 1), pistons (Item 2) and piston
N-22520 rings (Item 3) [Figure 30-21-38] for wear and replace as
needed.
Check the surfaces of the distributor for wear and NOTE: Put all roller/piston assembly back in their
scratches [Figure 30-21-36]. original position.
Figure 30-21-37 Figure 30-21-39
N-22510 N-22514
Check the cam ring inside surface for wear and scratches Check the brake shaft (Item 1) [Figure 30-21-39] for
[Figure 30-21-37]. wear and replace as needed.
Check the brake shaft snap ring (Item 2) [Figure 30-21-
39] and replace as needed.
A220 Bobcat Loader
30-21-12 Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D) Figure 30-21-42
Assembly
Figure 30-21-40 1
N-22525
1
Install a new bushing (Item 1) [Figure 30-21-42] in the
N-22511 distributor if the old bushing was removed.
Figure 30-21-43
NOTE: Always use new O-rings and seals when
assembling the motor and brake assemblies.
Dip the roller/piston assembly (Item 1) [Figure 30-21-40]
1
in oil and replace back its original bore.
Repeat procedure for each roller/piston assembly.
Figure 30-21-41
N-22522
Install new O-rings and seals on the distributor [Figure
30-21-43]
NOTE: When installing seals, apply a light coating of
oil to the seal and the mating surfaces of the
distributor. Install the O-rings and seals, allow
N-22518 30 minutes for the seals to set on the
distributor before installing the distributor in
the housing.
Apply a small amount of grease to the locating pin (Item
1) [Figure 30-21-41] and install the locating pin in the Using a small amount of grease, install the twelve springs
housing. into the distributor valve (Item 1 ) [Figure 30-21-43] .
A220 Bobcat Loader
30-21-13 Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D) Figure 30-21-46
Assembly (Cont'd)
1
Figure 30-21-44
N-22513
Install the brake shaft (Item 1) [Figure 30-21-46] in the
N-22515 housing.
Figure 30-21-47
Install the distributor (Item 1) [Figure 30-21-44] in the
housing.
1
Figure 30-21-45
1
N-22512
Apply a light coating of grease, and install the O-ring
N-22516 (Item 1) [Figure 30-21-47] to the housing.
Align the locating pin (Item 1) [Figure 30-21-45] in the
housing with the alignment hole in the distributor, and tap
the distributor in place with a rubber mallet.
A220 Bobcat Loader
30-21-14 Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D) Figure 30-21-50
Assembly (Cont'd)
Figure 30-21-48
2
1
1
N-22499
Install a new O-ring on the housing assembly (Item 1)
N-22509 [Figure 30-21-50] and lightly smear with grease.
Install the two speed spool (Item 2)[Figure 30-21-50].
Install the cylinder block assembly (Item 1) [Figure 30-
21-48] to the brake shaft. Figure 30-21-51
Install the cam ring to the rear housing and start the
mount bolts and finger tighten.
Figure 30-21-49
1
N-22496
1 1 Install a new O-ring on the housing assembly (Item 1)
[[Figure 30-21-51] and lightly smear with grease.
N-22508
Turn the motor so that it sets on the cam ring, and
cylinder block [Figure 30-21-49].
NOTE: Be careful when turning or moving the motor
so the cylinder block stays in the motor
housing.
Tighten the two cam ring mounting bolts to 26-29 ft.-lbs.
(35-39 Nm) torque.
A220 Bobcat Loader
30-21-15 Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D) Figure 30-21-54
Assembly (Cont'd)
Figure 30-21-52
N-22530
Install the brake disc pack starting with an outer disc
N-18348 (Item 1) [Figure 30-21-54] and alternating with an inner
disc, throughout the pack.
Measure the thickness of the individual brake disc's Figure 30-21-55
[Figure 30-21-52] to determine the amount of wear on
each disc.
The normal thickness of the individual brake disc is .039
in. (1 mm). 1
If the individual disc's thickness is .037 in. (0,95 mm) or
less, replace the complete disc pack.
Figure 30-21-53
1
2 N-22532
End the disc pack with an outer disc (Item 1) [Figure 30-
21-55].
N-22529
Install the brake housing (Item 1) [Figure 30-21-53] on
the motor housing and align the marks.
Install the eight mounting bolts (Item 2) [Figure 30-21-
53] and tighten evenly to 52-57 ft.-lbs. (70-77 Nm)
torque.
A220 Bobcat Loader
30-21-16 Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D) Figure 30-21-58
Assembly (Cont'd)
Figure 30-21-56
N-22493
Install the piston (Item 1) [Figure 30-21-58] in the brake
N-22533 housing.
NOTE: If the brake pack was not replaced, the
Install the brake seal (Item 1) [Figure 30-21-56]. procedure described below for determining
brake washer thickness, need not be
Figure 30-21-57 preformed.
Install the motor assembly in a hydraulic press. Apply a
downward force of 4500 lbs. (20 Kn), on the brake piston
[Figure 30-21-58].
NOTE: The 4500 lbs. of force, is NOT the amount of
pressure required by the press. It is the
amount of downward force applied by the
1 press.
The amount of force applied to the brake piston, by the
press, is determined by the diameter of the piston on the
press cylinder and the PSI applied to the press piston.
N-22498 Determine the diameter of the piston on the press
cylinder d and use the following formula to determine the
PSI of pressure to apply to the press cylinder piston.
Lightly coat the piston with oil and install a new piston
seal (Item 1) [Figure 30-21-57]. 1432
( d=6 in.
2 ) 3(Squared) =9 1432
9
=159 PSI
Example: d= 6 in. (152 mm) piston diameter of the
press cylinder. Apply 159 PSI (1,096 kPa) pressure to
the press cylinder piston.
A220 Bobcat Loader
30-21-17 Service Manual
HYDROSTATIC MOTOR (TWO-SPEED) (CONT’D) Figure 30-21-61
Assembly (Cont'd)
Figure 30-21-59
1
1
2
N-22491
The correct washer thickness must be determined
N-22534 beforethe washer (Item 1) [Figure 30-21-61] can be
installed.
With the motor in a hydraulic press and the Use the recorded measurement obtained in [Figure 30-
predetermined amount of pressure applied on the 21-59]. Plus the thickness of the gasket (Item 2) [Figure
piston, use a straight edge, and measure the distance 30-21-60], which is .012 in. (0,3 mm). Minus the
from the top of the brake housing (Item 1) to the top of thickness of the brake plate (Item 1) [Figure 30-21-60],
the piston (Item 2) [Figure 30-21-59]. which is .281 in. (7,15 mm).
Record the measurement to three decimal places. Select a washer, or combination of washers to suit the
calculated thickness within + .006 in. (0,15 mm).
Remove the motor from the hydraulic press.
Install the proper brake washer or washers.
Figure 30-21-60
Figure 30-21-62
N-22492
N-22490
Install the brake plate (Item 1) [Figure 30-21-60].
Install the brake end cover (Item 1) [Figure 30-21-62].
Install the end plate gasket (Item 2) [Figure 30-21-60].
Install the twelve end cover mount bolts and tighten
evenly to 10-12 ft.-lbs. (14-16 Nm) torque.
A220 Bobcat Loader
30-21-18 Service Manual
HYDROSTATIC MOTOR CARRIER Figure 30-22-2
Removal And Installation
Figure 30-22-1
1
1
P5467
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the lift arm and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the fluid from the chaincase. (See CHAINCASE
P5489
on Page 40-40-1.)
Remove the front axle. (See DRIVE COMPONENTS on Slide the motor carrier toward the rear and remove the
Page 40-30-1.) rear drive chain.
If the motor carrier is removed from the right side, NOTE: For easier access for the motor carrier
remove the lift arm by-pass control valve (See LIFT ARM coming out and going into the chaincase, tie
BY-PASS CONTROL VALVE on Page 20-50-1.) and the front drive chain to the chaincase with a
remove the hydraulic control valve. (See HYDRAULIC wire [Figure 30-22-2].
CONTROL VALVE on Page 20-40-1.)
Slide the motor carrier out of the chaincase far enough to
Remove the six mounting bolts (Item 1) [Figure 30-22-1] install a chain and chain hoist to the carrier [Figure 30-
from the carrier. 22-2].
Installation: Tighten the mounting bolts to 330 ft.-lbs. NOTE: When installing the motor carrier into the
(447 Nm) torque. loader, use caution to protect the wheel speed
washer from damage.
A220 Bobcat Loader
30-22-1 Service Manual
HYDROSTATIC MOTOR CARRIER (CONT’D)
Parts Identification
1 2 3
4 6
5
4
3 7
8
1. Snap Ring
2. Spacer
3. Bearing
4. Race
5. Seal
6. Housing
7. Speed Washer
8. Shaft
PE-1395A
A220 Bobcat Loader
30-22-2 Service Manual
HYDROSTATIC MOTOR CARRIER (CONT’D) Put the motor carrier in a hydraulic press [Figure 30-22-
4].
Disassembly
Put a small amount of pressure on the shaft to release
Figure 30-22-3 the pre-load on the snap ring.
Figure 30-22-5
P5760
P-28155
Remove the large O-ring from the groove (Item 1)
[Figure 30-22-3] in the housing.
Remove the snap ring (Item 1) [Figure 30-22-5] and
Figure 30-22-4 washer from the shaft.
Figure 30-22-6
P5766
P-28154 Use a hydraulic press, remove the shaft from the housing
[Figure 30-22-6].
A220 Bobcat Loader
30-22-3 Service Manual
HYDROSTATIC MOTOR CARRIER (CONT’D) Figure 30-22-9
Disassembly (Cont’d)
Figure 30-22-7
P-28158
Use the hydraulic press to remove the bearing from the
P-28156 shaft [Figure 30-22-9].
Figure 30-22-10
NOTE: The bearing (Item 1) and the wheel speed
washer (Item 2) [Figure 30-22-7], must both be
replaced, due to damage to the wheel speed
washer from removing the bearing.
Figure 30-22-8
1
1
2
P-28162
Remove the wheel speed washer (Item 1) [Figure 30-22-
10] from the shaft.
P-28157
Install the bearing puller tool (Item 1) [Figure 30-22-8]
under the bearing flange, between the bearing and the
speed washer.
A220 Bobcat Loader
30-22-4 Service Manual
HYDROSTATIC MOTOR CARRIER (CONT’D) Figure 30-22-13
Disassembly (Cont'd)
2
Figure 30-22-11
2 1
P5762
Install the second seal (Item 1) [Figure 30-22-13] into the
P-28164 housing with the seal lip facing toward you.
Use the tool (Item 2) [Figure 30-22-13] as shown in the
Remove the two seals (Item 1) [Figure 30-22-11] from figure.
the housing.
Figure 30-22-14
Check the bearing cup (Item 2) [Figure 30-22-11] (both
sides) and replace as needed.
Assembly
Figure 30-22-12
P-28159
Check the new wheel speed washer with a straight edge,
to be sure it is square [Figure 30-22-14].
P5764 If the washer is more than .080 (2,03 mm) out of square,
it must be replaced.
The tool listed will be needed to the following procedure:
MEL1431 - Seal Driver Tool
Install the first seal (Item 1) [Figure 30-22-12] into the
housing with the seal lip facing away from you.
Use the tool (Item 2) [Figure 30-22-12] as shown in the
figure.
A220 Bobcat Loader
30-22-5 Service Manual
HYDROSTATIC MOTOR CARRIER (CONT’D) Figure 30-22-17
Assembly (Cont'd)
Figure 30-22-15
P-28162
Install the wheel speed washer on the shaft [Figure 30-
P-28162 22-17].
Figure 30-22-18
Inspect the wheel speed washer for damage to the
magnetic surface (Item 1) [Figure 30-22-15].
NOTE: Do not contact the magnetic surface of the
wheel speed washer (Item 1) [Figure 30-22-
15], with a magnet. This may cause damage to
the magnetic surface.
Figure 30-22-16
P-28161
1
Align the three pins (Item 1) [Figure 30-22-18] in the
sprocket.
P-28160
The wheel speed washer, has three alignment pins (Item
1) [Figure 30-22-16].
A220 Bobcat Loader
30-22-6 Service Manual
HYDROSTATIC MOTOR CARRIER (CONT’D) Figure 30-22-20
Assembly (Cont'd)
Figure 30-22-19
1 2
P-28163
Install the bearing on the shaft [Figure 30-22-19].
Use a pipe (Item 1) [Figure 30-22-19] with O.D. that
seats on the I.D. of the bearing.
Seat the bearing on the shaft, down against the wheel
speed washer.
P-5769
NOTE: The wheel speed washer should be tight on
the shaft.
Install the shaft/bearing assembly into the housing.
Install the bearing (Item 1) using the tool (Item 2) [Figure
30-22-20] (MEL1431).
After the bearing is seated. Install the washer and snap
ring on the shaft.
It may be necessary to use the tool to push the washer
and snap ring down into position because of the pre-load
on the bearings.
A220 Bobcat Loader
30-22-7 Service Manual
A220 Bobcat Loader
30-22-8 Service Manual
CHARGE PRESSURE Figure 30-30-3
Testing
Figure 30-30-1
1
2 4 N-19742A
1 3
Disconnect the hydraulic hose (Item 1) [Figure 30-30-3]
P-43196 from the charge pressure sender.
Figure 30-30-4
The tools needed to check charge pressure, hydraulic
hose (Item 1), T fitting (P/N 13K-5) (Item 2), Hydraulic
guage (1000 PSI) (Item 3) and adapter fitting (P/N 93F-5)
(Item 4) [Figure 30-30-1].
1
Figure 30-30-2
3 P-43198
2
Install the T fitting (P/N 13K-5) (Item 1) [Figure 30-30-4].
P-43197
Connect the guage (Item 1), to the adapter fitting (P/N
93F5) (Item 2) [Figure 30-30-2].
Connect the hydraulic hose (Item 3) [Figure 30-30-2] to
the adapter fitting. Tighten all connections.
Raise the loader lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
Place the loader on jackstands. (See Procedure on Page
10-10-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
A220 Bobcat Loader
30-30-1 Service Manual
CHARGE PRESSURE (SENDER) (CONT’D) Removal And Installation
Testing (Cont’d) Figure 30-30-6
Figure 30-30-5
2
N-19742A
1
P-43200
Disconnect the wire (Item 1) [Figure 30-30-6] from the
sender.
Install the hose (Item 1) [Figure 30-30-5], that was
disconnected from the charge pressure sender, to the T Remove the hydraulic hose (Item 2) [Figure 30-30-6]
fitting. from the charge pressure sender.
Install the hose (Item 2) [Figure 30-30-5], that is Remove the charge pressure sender from the control
attached to the pressure guage, to the T fitting. valve at the connector (Item 3) [Figure 30-30-6].
Tighten the hydraulic fittings
Start the loader and run at an idle and allow the hydraulic
fluid to warm to 140 degrees Farenheit.
The charge pressure at high idle, with the fluid
temperature of 140 degree Farenheit is 390-430 PSI with
the pump in neutral.
A220 Bobcat Loader
30-30-2 Service Manual
HYDROSTATIC PUMP Figure 30-40-3
Pump Controller Removal And Installation
Figure 30-40-1
P-26465
Remove the control spool bore plug (Item 1) [Figure 30-
P-26463 40-3] at the front side of the pump.
Figure 30-40-4
Locate the two pump controllers (Item 1) [Figure 30-40-
1] on the hydrostatic pumps.
Figure 30-40-2
1
P-26469
Do Not remove the spring (Item 1) [Figure 30-40-4],as it
P-26464 is attached to the control spool.
Disconnect the electrical connectors (Item 1) [Figure 30-
40-2] from the loader harness.
A220 Bobcat Loader
30-40-1 Service Manual
HYDROSTATIC PUMP (CONT'D) Figure 30-40-7
Pump Controller Removal And Installation (Cont'd)
Figure 30-40-5
1 1
1
P-26472
Use a small amount of grease on a new gasket and
P-26465A install the gasket on the pump controller (Item 1) [Figure
30-40-7].
Remove the seven mount bolts (Item 1) and four shorter Be sure the pump surface is clean.
(Item 2) [Figure 30-40-5] from the pump controller.
Figure 30-40-8
Remove the controller from the pump.
Remove the controller gasket from the pump.
2 1
Installation:
Figure 30-40-6
P-26473
Align the summing link pin (Item 1) on the pump with the
bore (Item 2) [Figure 30-40-8] in the pump controller
module.
P-26471
Be sure the summing link pin (Item 1) [Figure 30-40-6] is
in the center.
A220 Bobcat Loader
30-40-2 Service Manual
HYDROSTATIC PUMP (CONT'D) Figure 30-40-11
Pump Controller Removal And Installation (Cont'd)
Figure 30-40-9
1
1 1
P-26469
Be sure the spring (Item 1) [Figure 30-40-11] is properly
P-26465A attached to the control spool.
Figure 30-40-12
Install the pump controller on the hydrostatic pump.
Align the bolt holes.
Install the seven mount bolts, three longer (Item 1) and 2
four shorter (Item 2) [Figure 30-40-9].
1
Figure 30-40-10
7 4
3
1 (8)
P-26465
2
Install the control spool bore plug (Item 1) [Figure 30-40-
12] in the pump and tighten to 30-70 ft.-lbs. (41-94 Nm)
torque.
5
6 Connect the electrical connectors (Item 2) [Figure 30-40-
P-30692 12] to the loader harness.
NOTE: When a pump controller is replaced the
Tighten the controller mounting bolts to 11-13 ft.-lbs. (15- hydrostatic pumps must be calibrated. (See
17.5 Nm) torque using the tightening pattern [Figure 30- Hydrostatic Pump Calibration on Page 30-40-
40-10]. 4.)
A220 Bobcat Loader
30-40-3 Service Manual
HYDROSTATIC PUMP (CONT'D) Turn the key (Item 1) [Figure 30-40-13] to the RUN
position or press the RUN/ENTER button (Item 1)
Hydrostatic Pump Calibration [Figure 30-40-14] for power, without starting the loader.
Figure 30-40-15
WARNING
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
Figure 30-40-13
1
P-24825
Verify the parking brake (Item 1) [Figure 30-40-15] is
OFF.
Figure 30-40-16
P-26475
Figure 30-40-14
P-26478
Move the left joystick to the forward position and toward
the side screen [Figure 30-40-15] and hold in position.
1
P-26480
This procedure is for single and two-speed loaders.
Place the loader on jackstands. (See Procedure on Page
10-10-1.)
Operator must be in the seat and the seat bar down.
Verify that the wheels are straight.
A220 Bobcat Loader
30-40-4 Service Manual
HYDROSTATIC PUMP (CONT'D) Figure 30-40-19
Hydrostatic Pump Calibration (Cont'd)
Figure 30-40-17
P-26476
1
Move the left joystick to the reverse position and toward
P-26477A the operator [Figure 30-40-19] and hold in position.
Figure 30-40-20
Press the PRESS TO OPERATE LOADER Button (Item
1) [Figure 30-40-17].
Three audible beeps will sound and an error code (Item
2) (38-05 & 38-07) will be displayed if the operator
presses the PRESS FOR CODES, (LIGHTS) switch
(Item 3) [Figure 30-40-17].
Figure 30-40-18
1
1
P-26477A
Press the PRESS TO OPERATE LOADER Button (Item
1) [Figure 30-40-20].
P-26479
The warning light (Item 1) [Figure 30-40-18] on the right
console will continue to be ON.
A220 Bobcat Loader
30-40-5 Service Manual
HYDROSTATIC PUMP (CONT'D) Figure 30-40-23
Hydrostatic Pump Calibration (Cont'd)
Figure 30-40-21
2
1
3
1
P-26477 B
Press the PRESS TO OPERATE LOADER Button (Item
P-26479 1) [Figure 30-40-23].
Three audible beep will sound and the error code (Item 2)
The warning light (Item 1)[Figure 30-40-21] on the right [Figure 30-40-23] (38-98) will be displayed if the
console will continue to be ON. operator presses the PRESS FOR CODES (LIGHTS)
switch.
Figure 30-40-22
Start the engine from the RUN, RUN/ENTER position.
DO NOT TURN TO OFF POSITION. This would cancel
the calibration mode and the procedure would have to be
repeated.
Figure 30-40-24
P-26474
Allow the left joystick to go to the neutral position [Figure
30-40-22].
P-26481
Move the throttle (Item 1) [Figure 30-40-24] to high idle.
NOTE: If at any time, during calibration, the operator
needs to stop the machine, turn the key OFF,
lift the seat bar, or return the joystick to the
neutral position
The calibration procedure will stop.
To return to calibration mode the operator must
start the complete procedure from the
beginning.
A220 Bobcat Loader
30-40-6 Service Manual
HYDROSTATIC PUMP (CONT'D) Figure 30-40-26
Hydrostatic Pump Calibration (Cont'd)
Figure 30-40-25
P-26483
Move and hold the left joystick to the reverse position
P-26482 [Figure 30-40-26].
The pump controller will start increasing the electrical
Move and hold the left joystick to the forward position current to the hydrostatic pumps until it sees a pulse from
[Figure 30-40-25] until the forward calibration is the wheel speed sensors.
completed.
The loader wheels will rotate a short distance in reverse
each time it sees a pulse.
The pump controller will start increasing the electrical
current to the hydrostatic pumps until it sees a pulse from The wheels will rotate slightly in a reverse direction up to
the wheel sensors. five times, there will be an audible beep. Continue
holding the joystick forward.
The loader wheels will rotate a short distance forward
each time it sees a pulse. The four wheels will then go to Full Speed Reverse.
Continue holding the joystick in the reverse position until
the wheels stop and there is an audible beep. Reverse
The wheels will rotate slightly in a forward direction up to
calibration is complete.
five times, there will be an audible beep. Continue
holding the joystick forward. NOTE: If the wheels do not stop going in Full Speed
Reverse in 2 minutes or less, there was an
The four wheels will then go to Full Speed Forward. error in the calibration procedure. The
Continue holding the joystick in the forward position until operator must shut the loader OFF, and start
the wheels stop and there is an audible beep. Forward the calibration procedure from the beginning.
calibration is complete.
There will be an audible beep and the PRESS TO
OPERATE LOADER and TRACTION lights will go out.
NOTE: If the wheels do not stop going in Full Speed
The SEAT BAR and LIFT AND TILT lights will remain on.
Forward in 2 minutes or less, there was an The 38-98 error code will clear.
error in the calibration procedure. The
operator must shut the loader OFF, and start Allow the joystick to go to the neutral position.
the calibration procedure from the beginning.
The calibration procedure is completed.
Press the PRESS TO OPERATE LOADER button. Move
the joystick to forward position [Figure 30-40-26] and
check for normal forward wheel rotation.
Move the joystick to the reverse position [Figure 30-40-
26] and check for normal reverse wheel rotation.
Stop the engine, and remove the loader from jackstands.
Start the loader, press the PRESS TO OPERATE
LOADER button and return to normal loader operation.
A220 Bobcat Loader
30-40-7 Service Manual
HYDROSTATIC PUMP (CONT'D) Figure 30-40-29
Removal And Installation
Figure 30-40-27
P5557
1 Remove the washer and nut (Item 1) [Figure 30-40-29]
P5552 from the hydrostatic pump drive shaft.
Installation: Tighten the nut to 175-200 ft.-lbs. (237-271
Remove the hydrostatic pump/engine assembly from the Nm) torque.
loader. (See HYDROSTATIC MOTOR on Page 30-20-1.)
Figure 30-40-30
Remove the belt shield clips (Item 1) and belt shield (Item
2) [Figure 30-40-27].
Figure 30-40-28
2
1
1
3 P5657
Install the nut on the end of the pump drive shaft (without
P5554 washer).
Use a puller (Item 1) [Figure 30-40-30] to remove the
Loosen the stop mounting bolts (Item1) [Figure 30-40- pulley from the pump drive shaft.
28].
Loosen the spring tension bolt (Item 2) [Figure 30-40-
28].
Remove the drive belt (Item 3) [Figure 30-40-28].
A220 Bobcat Loader
30-40-8 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-33
Removal And Installation (Cont’d)
Figure 30-40-31
P-28073
1
Remove the mounting bolt (Item 1) [Figure 30-40-33] at
P5658 the hydraulic pump end of the pump.
Remove the hydrostatic pump from the mounting bracket
Figure 30-40-32 and drive belt housing.
P-28072
Remove the two mounting bolts (Item 1) [Figure 30-40-
31] and nuts (Item 1) [Figure 30-40-32].
Installation: Tighten the mounting bolts and nuts to 65-
70 ft.-lbs. (88-95 Nm) torque. Make sure the key (Item 2)
[Figure 30-40-31] is installed.
A220 Bobcat Loader
30-40-9 Service Manual
HYDROSTATIC PUMP (CONT’D)
Parts Identification (Right Half)
2 5 1
23
24 25
26
20 21 27
19 28 21
22 29 20
18
17 19
14 30 18 17
13 16 33
4 23 16 33
6 15 31 34
7 29 34
8 32
35 36
9
3
39
37
10
11 38
66 42 43 41 40
68 46
70 65 44 45 48
67 47 49
52
69 51
64 63 64
5
43 63 50 55
15
14 53
72 54
71 73 56
32
75 74
76 31
28
73 27
77 57
26
25 78
23 25 58
60 61 34
24
62 33
59
60
B-16054A
A220 Bobcat Loader
30-40-10 Service Manual
HYDROSTATIC PUMP (CONT’D)
Parts Identification (Right Half) (Cont'd)
Ref. Description Ref. Description
1. Pump 40. Link
2. Pump 41. Link
3. Housing 42. Link
4. O-ring 43. Pin
5. Bolt 44. Key
6. Snap Ring 45. Coupler
7. Seal 46. Snap Ring
8. O-ring 47. Geroter
9. Snap Ring 48 Bearing
10. Bearing 49. Cover
11. Shaft 50. O-ring
12. Shaft 51. O-ring
13. Bearing 52. Gasket
14. Plug 53. Cover
15. O-ring 54. Screw
16. Spring 55. O-ring
17. Valve 56. Gear Pump
18. O-ring 57. Spool
19. Washer 58. Spring
20. O-ring 59. Bracket
21. Valve 60. Screw
22. Nut 61. Screw
23. O-ring 62. Nut
24. Plug 63. Plug
25. Screw 64. Pin
26. Cover 65. Filter
27. Gasket 66. Poppet
28. Ring 67. Spring
29. O-ring 68. O-ring
30. Servo 69. Adjuster
31. Plug 70. Nut
32. O-ring 71. Rotating Piece
33. Plug 72. Valve Plate
34. O-ring 73. Bearing
35. Screw 74. Cam
36. Screw 75. Bearing
37. Control 76. Swashplate
38. Gasket 77. Gasket
39. Screw 78. Cover
A220 Bobcat Loader
30-40-11 Service Manual
HYDROSTATIC PUMP (CONT’D)
Parts Identification (Left Half)
5
2
1
23
22
25
26
23 27
19
28
18 20 21
29
22
17 19
16 18
14 30 17
13 23 33
16
4
29 34 33
6 15 31 34
7 32
8
56 35 36
9
3
39 38
10
11
38
12 66 41 40
42 43 46
68
70 44 45 48
65 47
49
67
69 51 52
63 64
64
43 63 50
55
15
14
72 53
54
71
73
75 74 32
31
76 28
73 27
57
25 26
77
78 23 25 58
60
61 34
24
62 59
33
60
B-16055A
A220 Bobcat Loader
30-40-12 Service Manual
HYDROSTATIC PUMP (CONT’D)
Parts Identification (Left Half (Cont’d)
Ref. Description Ref. Description
1. Pump 40. Link
2. Pump 41. Link
3. Housing 42. Link
4. O-ring 43. Pin
5. Bolt 44. Key
6. Snap Ring 45. Coupler
7. Seal 46. Snap Ring
8. O-ring 47. Geroter
9. Snap Ring 48 Bearing
10. Bearing 49. Cover
11. Shaft 50. O-ring
12. Shaft 51. O-ring
13. Bearing 52. Gasket
14. Plug 53. Cover
15. O-ring 54. Screw
16. Spring 55. O-ring
17. Valve 56. Key
18. O-ring 57. Spool
19. Washer 58. Spring
20. O-ring 59. Bracket
21. Valve 60. Screw
22. Nut 61. Screw
23. O-ring 62. Nut
24. Plug 63. Plug
25. Screw 64. Pin
26. Cover 65. Filter
27. Gasket 66. Poppet
28. Ring 67. Spring
29. O-ring 68. O-ring
30. Servo 69. Adjuster
31. Plug 70. Nut
32. O-ring 71. Rotating Piece
33. Plug 72. Valve Plate
34. O-ring 73. Bearing
35. Screw 74. Cam
36. Screw 75. Bearing
37. Control 76. Swashplate
38. Gasket 77. Gasket
39. Screw 78. Cover
A220 Bobcat Loader
30-40-13 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-36
System Check Relief Valves (High Pressure Relief,
Charge Check & By-Pass Valve) 3
Figure 30-40-34
2
1
1 1
1
P-28615
Check the valve seat plug O-rings (Item 1) and back-up
ring (Item 2) [Figure 30-40-36], and replace as needed.
P-28613
Check the valve seat surface (Item 3) [Figure 30-40-36]
for scratches and replace as needed.
There are four system check relief valves (Item 1)
[Figure 30-40-34] in the hydrostatic pump. Two are Figure 30-40-37
located on the back side of each pump half.
Figure 30-40-35
1 1
P-28616
P-28614 Remove relief valve assembly (Item 1) [Figure 30-40-37]
from the pump housing.
Remove the valve seat plug (Item 1) [Figure 30-40-35] Check the conical spring (Item 2) [Figure 30-40-36] to be
from the pump. sure it is retained on the relief valve. DO NOT REMOVE.
A220 Bobcat Loader
30-40-14 Service Manual
HYDROSTATIC PUMP (CONT’D) Charge Relief Valve
System Check Relief Valves (High Pressure Relief, Figure 30-40-40
Charge Check & By-Pass Valve) (Cont'd)
Figure 30-40-38
1 1
P-28613
P-28617 There are two charge pressure relief valves (Item 1)
[Figure 30-40-40].
Install relief valve into the pump housing spring first The charge pressure relief valves are located on the
[Figure 30-40-38]. bottom side of the pumps, with one valve on each pump
section [Figure 30-40-40].
Figure 30-40-39
Figure 30-40-41
P-28614
P-28625
Install the valve seat plug (Item 1) [Figure 30-40-39]
from the pump, and tighten to 30-70 ft.-lbs. (40-95 Nm) Mark plug (Item 1) lock nut (Item 2) and housing (Item 3)
torque. [Figure 30-40-41] for ease of assembly.
Loosen the lock nut.
Loosen the charge pressure plug, and remove the
complete assembly from the pump housing.
A220 Bobcat Loader
30-40-15 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-44
Charge Relief Valve (Cont'd)
Figure 30-40-42
1
2
P-28627
Install the poppet (Item 1) and spring (Item 2) [Figure 30-
P-28626 40-44] into the pump housing.
Figure 30-40-45
Check and replace the O-ring (Item 1) [Figure 30-40-42].
Figure 30-40-43
1 2
2
3
1
P-28625
P-28627 Install the plug (Item 1) and its lock nut (Item 2) [Figure
30-40-45], align the marks made during disassembly.
Tighten to 34-42 ft.-lbs. (47-57 Nm) torque.
Inspect the poppet (Item 1) [Figure 30-40-43] and the
mating seat in the pump housing for damage or foreign
material.
Inspect the spring (Item 2) and the adjustable charge
relief valve (Item 3) [Figure 30-40-43].
A220 Bobcat Loader
30-40-16 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-48
Pump Separation
1
Figure 30-40-46
1 P-28640
2
Replace the O-rings (Item 1) [Figure 30-40-48].
P-28638
Remove the two mount bolts (Item 1) [Figure 30-40-46].
(Front and Rear.)
Remove the lifting bracket (Item 2) [Figure 30-40-46]
from the pump.
Figure 30-40-47
P-28639
Separate the two hydrostatic pumps [Figure 30-40-47].
A220 Bobcat Loader
30-40-17 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-51
Shaft Seal And Shaft Replacement
1
Figure 30-40-49
P-28643
Remove the O-ring (Item 1) [Figure 30-40-51] from the
P-28641 top of the bearing.
Figure 30-40-52
Remove the snap ring (Item 1) [Figure 30-40-49].
Figure 30-40-50
1
P-28648
P-28642 Using a press, remove the old seal (Item 1) [Figure 30-
40-52] from the seal carrier.
With the pump shaft up, remove the seal carrier
assembly (Item 1) [Figure 30-40-50] using a screwdriver.
A220 Bobcat Loader
30-40-18 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-55
Shaft Seal And Shaft Replacement (Cont'd)
Figure 30-40-53
P-28646
Remove the snap ring (Item 1) [Figure 30-40-55] from
P-28644 the shaft.
Figure 30-40-56
Press a new seal into the shaft bearing side of the seal
carrier (Item 1) [Figure 30-40-53].
Figure 30-40-54
P-28753
Remove the roller bearing [Figure 30-40-56] from the
P-28645 shaft.
Inspect the bearing for wear and replace as needed.
Grip the splines or threads of the input shaft and remove
the pump shaft and roller bearing assembly (Item 1)
[Figure 30-40-54].
A220 Bobcat Loader
30-40-19 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-59
Shaft Seal And Shaft Installation
Figure 30-40-57
P-28646
Install the bearing and snap ring on the shaft [Figure 30-
P-28752 40-59].
Figure 30-40-60
Inspect the shaft [Figure 30-40-57] for wear and replace
as needed.
Figure 30-40-58
P-28645
Install the shaft and roller bearing in the pump housing
P-28754 [Figure 30-40-60].
Inspect the snap ring [Figure 30-40-58] and replace as
needed.
A220 Bobcat Loader
30-40-20 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-63
Shaft Seal And Shaft Installation (Cont'd)
Figure 30-40-61
P-28648
Lubricate the seal (Item 1) [Figure 30-40-63] with
P-28643 petroleum jelly.
Figure 30-40-64
Install the O-ring (Item 1) [Figure 30-40-61] on top of the
shaft bearing.
Figure 30-40-62 2
1
P-28641
Slide the seal carrier (Item 1) [Figure 30-40-64]
P-28647 assembly over the shaft and into the housing bore. Press
against the O-ring. Hold downward pressure against the
shaft to compress the cylinder block spring while
Wrap the spline or key way with a thin layer of plastic to pressing the seal carrier into place.
prevent damage to the seal lip during installation [Figure
30-40-62]. Install the retaining ring (Item 2) [Figure 30-40-64].
Lubricate the O-ring with petroleum jelly [Figure 30-40-
62].
A220 Bobcat Loader
30-40-21 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-67
Charge Pump Removal
Figure 30-40-65
P-28669
Remove the old charge pump cover gasket (Item 1)
P-28668 [Figure 30-40-67].
Figure 30-40-68
Position the pump so the auxiliary mounting pad is facing
up. 1
Mark pump housing for proper installation [Figure 30-40-
65].
Figure 30-40-66
1
1 P-28670
1 Remove the alignment pins (Item 1) [Figure 30-40-68].
Remove the gerotor cover (Item 2) [Figure 30-40-68].
P-28667
Remove the six auxiliary mount pad mount bolts (Item 1)
[Figure 30-40-66].
Remove the charge pump cover.
A220 Bobcat Loader
30-40-22 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-71
Charge Pump Removal (Cont'd)
Figure 30-40-69
P-28673
Remove the inner gerotor and drive coupler (Item 1)
P-28671 [Figure 30-40-71].
Figure 30-40-72
Remove the old gerotor cover O-rings (Item 1) [Figure
30-40-69].
Figure 30-40-70 1
1 P-28674
Remove the retainer ring from the drive coupler (Item 1)
P-28672 [Figure 30-40-72].
Remove the outer gerotor assembly from the pump
housing (Item 1) [Figure 30-40-70].
Remove the gerotor cover alignment pin from the
housing.
A220 Bobcat Loader
30-40-23 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-75
Charge Pump Removal (Cont'd)
2
Figure 30-40-73
1
P-28675A
1
2 Inspect the inner gerotor assembly (Item 1) [Figure 30-
P-28675 40-75] for scratches and wear, if it must be replaced,
replace both the outer and inner gerotors as a set.
Remove the inner gerotor (Item 1) and key (Item 2) Inspect the drive coupler (Item 2) [Figure 30-40-75] for
[Figure 30-40-73] from the drive couple. wear, and replace as needed.
Charge Pump Inspection Figure 30-40-76
Figure 30-40-74
1 2
P-28675B
P-28757
Inspect the gerotor drive key (Item 1) and retainer ring
(Item 2) [Figure 30-40-76], and replace as needed.
Inspect the outer gerotor assembly [Figure 30-40-74] for
scratches and wear, if it must be replaced, replace both
the outer and inner gerotors as a set.
A220 Bobcat Loader
30-40-24 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-79
Charge Pump Inspection (Cont’d)
2
Figure 30-40-77
P-28673
Be sure the pump surface (Item 1) [Figure 30-40-79] is
P-28758 clean and free of gasket material.
Install the drive coupler/inner gerotor in the pump
Inspect the inside of the gerotor cover (Item 1) [Figure housing (Item 2) [Figure 30-40-79].
30-40-77] for scratches and foreign material, replace as
needed. Figure 30-40-80
Charge Pump Installation
Figure 30-40-78
2
1
4
2
P-28672
3
1 Install the outer gerotor (Item 1) and gerotor cover
P-28675 alignment pin (Item 2) [Figure 30-40-80].
Install the key (Item 1) in the drive coupler (Item 2)
[Figure 30-40-78].
Install the inner gerotor (Item 3) and the retaining ring
(Item 4) [Figure 30-40-78] on the drive coupler.
Lubricate the gerotor assembly with clean oil.
A220 Bobcat Loader
30-40-25 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-83
Charge Pump Installation (Cont'd) 1
Figure 30-40-81
1
1
P-28670
Install the charge pump cover locating pins (Item 1)
P-28671 [Figure 30-40-83].
Figure 30-40-84
Install the new O-rings (Item 1) [Figure 30-40-81] on the
gerotor cover.
Figure 30-40-82
1
2
P-28669
Install a new charge pump cover gasket (Item 1) [Figure
P-28676 30-40-84]
.
Install the gerotor cover over the gerotor assembly (Item
1) and align the pin in the cover (Item 2) [Figure 30-40-
82].
A220 Bobcat Loader
30-40-26 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-87
Charge Pump Installation (Cont'd)
Figure 30-40-85
1
1
1 P-28678
Press down on the swashplate with the handle of a clean
P-28667 rubber mallet (Item 1) [Figure 30-40-87] and remove the
side cover.
Align the charge pump cover on the alignment pins. Figure 30-40-88
Install the six cover bolts (Item 1) [Figure 30-40-85] and
tighten to 26-32 ft.-lbs. (36-43 Nm) torque.
1
Disassembly
Figure 30-40-86
P-28679
1
Remove the gasket (Item 1) [Figure 30-40-88] from side
cover.
P-28677
Separate the two hydrostatic pumps. (See Pump
Separation on Page 30-40-17.)
Remove the charge pump. (See Charge Pump Removal
on Page 30-40-22.)
Remove the shaft and shaft seal. (See Shaft Seal And
Shaft Replacement on Page 30-40-18.)
Remove the six side cover bolts (Item 1) [Figure 30-40-
86].
A220 Bobcat Loader
30-40-27 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-91
Disassembly (Cont'd)
Figure 30-40-89
1
2 P-28683
Remove the swash plate needle bearing assembly (Item
P-28680 1) [Figure 30-40-91]. It may be necessary to rotate the
servo piston, so the bearing can be removed.
Lift the swash plate (Item 1) and remove cylinder block Figure 30-40-92
(Item 2) [Figure 30-40-89].
Figure 30-40-90
1
1
P-28684
P-28682 Remove the valve plate timing pin (Item 1) [Figure 30-
40-92].
Remove the swash plate (Item 1) [Figure 30-40-90].
A220 Bobcat Loader
30-40-28 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-95
Disassembly (Cont'd)
Figure 30-40-93
P-28687
Remove the control spool plug (Item 1) [Figure 30-40-
P-28685 95].
Figure 30-40-96
Remove the valve plate (Item 1) [Figure 30-40-93].
Figure 30-40-94
1 1
P-26469
P-28686 Do Not remove the spring (Item 1) [Figure 30-40-96], as
it is attached to the control spool.
Remove the seven mounting bolts from the electrical
displacement control (Item 1) [Figure 30-40-94].
A220 Bobcat Loader
30-40-29 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-99
Disassembly (Cont'd)
Figure 30-40-97
P-28698
Remove control spool and spring (Item 1) [Figure 30-40-
P-28688 99].
Figure 30-40-100
Move the control spool and summing link (Item 1)
[Figure 30-40-97] until the summing link disconnects
from the control spool.
Figure 30-40-98
P-28691
1
Remove the linkage pivot bolt (Item 1) [Figure 30-40-
100].
P-28689
Remove the summing link (Item 1) [Figure 30-40-98].
A220 Bobcat Loader
30-40-30 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-103
Disassembly (Cont'd)
Figure 30-40-101 1
1 2
2
1
P-28700
Remove the five servo cover mount bolts (Item 1)
P-28692 [Figure 30-40-103] from the servo cover that does NOT
have the servo piston neutral adjustment tie bolt.
Slide the control feedback link (Item 1) toward the servo Remove the cover (Item 2) [Figure 30-40-103] and
piston and disengage it from the neutral adjustment link gasket.
(Item 2) [Figure 30-40-101].
Figure 30-40-104
Remove the control feedback link.
Figure 30-40-102
1
1
P-28701
P-28694 Remove the servo piston adjustment seal nut (Item 1)
[Figure 30-40-104] and discard.
Remove the neutral adjustment link (Item 1) [Figure 30- NOTE: Once a servo adjustment seal nut has been
40-102] from the pump housing. removed, it should be discarded and replaced
with new, to insure a proper seal.
A220 Bobcat Loader
30-40-31 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-107
Disassembly (Cont'd)
1
Figure 30-40-105
1
1
P-28705
Remove the servo cover (Item 1) [Figure 30-40-107]
P-28703 from the servo piston.
Figure 30-40-108
Remove the five servo piston cover mount bolts (Item 1)
[Figure 30-40-105].
1
Figure 30-40-106
P-28706
Remove the piston seals (Item 1) [Figure 30-40-108]
P-28704 and O-rings located under the seals, from the servo
piston.
Remove the servo cover and servo piston (Item 1)
[Figure 30-40-106] from the pump.
A220 Bobcat Loader
30-40-32 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-111
Disassembly (Cont'd)
Inspection: Rotating Group
1
Figure 30-40-109 1
P-28744
1
Remove the three holddown pins (Item 1) [Figure 30-40-
111] and retainer ring.
P-28681 Inspection
Figure 30-40-112
Remove the piston assemblies and slipper retainer (Item
1) [Figure 30-40-109] from the cylinder block.
Figure 30-40-110
P-28745
Inspect the cylinder block surface, that runs against the
P-28743 valve plate (Item 1) [Figure 30-40-112] for nicks or burrs.
Remove the ball guide (Item 1) [Figure 30-40-110].
A220 Bobcat Loader
30-40-33 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-115
Inspection (Cont'd)
Figure 30-40-113
1
P-28750
Check the pump housing and housing piston bore (Item
P-28746 1) [Figure 30-40-115] for piston seal fragments,
scratches or damage.
Check the cylinder bores (Item 1) [Figure 30-40-113] for Figure 30-40-116
grooves or scratches.
Figure 30-40-114
1
2
P-28706
P-28747 Check the surface of the servo piston (Item 1) [Figure
30-40-116] for scratches or damage.
Check the piston slippers (Item 1) [Figure 30-40-114] for
any excess wear or damage.
Check the pistons (Item 2) [Figure 30-40-114] for any
discoloration, due to excessive heat.
A220 Bobcat Loader
30-40-34 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-119
Inspection (Cont'd)
Figure 30-40-117
1 1
P-28756
Check the swashplate needle bearing (Item 1) [Figure
P-28751 30-40-119] and replace as needed, as this bearing is a
serviceable part.
Check the valve plate for wear. Run a finger nail over the Figure 30-40-120
diameter of the sealing land surface (Item 1) [Figure 30-
40-117]. It should be free of deep groves.
Figure 30-40-118
P-28767
1
Check the pump housing swashplate needle bearing
P-28755 (Item 1) [Figure 30-40-120] for wear. If this bearing
needs to be changed, the complete pump housing must
be replaced, as the bearing is a non-serviceable part.
Check the swashplate surface (Item 1) [Figure 30-40-
118] for scratches or damage.
Check the swashplate bearing surface (Item 2) [Figure
30-40-118] for wear.
A220 Bobcat Loader
30-40-35 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-123
Inspection (Cont'd)
Figure 30-40-121 1
P-28690
Check the summing link (Item 1) [Figure 30-40-123] for
P-28679 wear and replace as needed.
Figure 30-40-124
Check the pump side cover swashplate needle bearing
(Item 1) [Figure 30-40-121] for wear. If this bearing
needs to be changed, the complete pump side cover
must be replaced, as the bearing is a non-serviceable
part.
1
Figure 30-40-122
P-28696
Check the linkage pivot bolt (Item 1) [Figure 30-40-124]
for wear and replace as needed.
P-28699
Check the control spool and spring (Item 1) [Figure 30-
40-122] for wear and replace as needed.
A220 Bobcat Loader
30-40-36 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-127
Inspection (Cont'd)
Figure 30-40-125
P-28697
1
Check the complete linkage assembly for wear [Figure
P-28693 30-40-127].
Assembly
Check the control feedback link (Item 1) [Figure 30-40-
125] for wear and replace as needed. Figure 30-40-128
Figure 30-40-126
P-28789
P-28695
Position the pump housing so the charge pump face is
pointing downward [Figure 30-40-128].
Check the neutral adjustment link (Item 1) [Figure 30-40-
126] for wear and replace as needed.
A220 Bobcat Loader
30-40-37 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-131
Assembly (Cont'd)
Figure 30-40-129
2
1
P-28786
Install the servo piston in the corresponding housing bore
P-28788 in the pump housing [Figure 30-40-131].
Install the non-tie bolt end of the servo piston into the
Figure 30-40-130 housing first [Figure 30-40-131].
Be sure the cavity for the servo piston/swashplate needle
bearing (Item 1) [Figure 30-40-131] faces the center of
the housing.
Figure 30-40-132
1
P-28787
Install a new O-ring (Item 1) [Figure 30-40-129] and new
piston ring (Item 2) [Figure 30-40-129] on the tie bolt end
of the servo piston (Item 1) [Figure 30-40-130].
P-28785
Lubricate the piston ring with a liberal amount of
hydraulic oil.
Push the servo piston through the housing far enough
that the other O-ring and piston seal may be installed
(Item 1) [Figure 30-40-132].
NOTE: Do not let the tie bolt end of the piston ring
pass completely through its bore. This will
cause damage to the new piston rings earlier
installed.
Install the new O-ring and piston ring.
Lubricate the piston ring with a liberal amount of
hydraulic oil.
A220 Bobcat Loader
30-40-38 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-135
Assembly (Cont'd)
1 1
Figure 30-40-133
1
1
1
1
P-28782
Install the second servo cover gasket and cover. Install
P-28784 the five mount bolts (Item 1) [Figure 30-40-135] and
tighten to 11-13 ft.-lbs. 15-17,5 Nm) torque.
Push the servo piston back through the bore so the tie Figure 30-40-136
bolt sticks back out of the housing and the piston is
almost flush with the housing [Figure 30-40-133].
1
Install a new servo cover gasket (Item 1) [Figure 30-40-
133]. 1
Figure 30-40-134
1 1
P-28701
Tighten the tie bolt end, mount bolts (Item 1) [Figure 30-
40-136] to 11-13 ft.-lbs. 15-17,5 Nm) torque.
Install a new adjustment seal nut (Item 2) [Figure 30-40-
P-28783 136] and tighten until the sealing face touches the servo
cover.
Spin the servo cover down as far as possible and slide NOTE: The pump neutral adjustment must be made
the piston back in the housing so the servo cover is to the pump after it is installed in the loader.
holding the gasket against the housing [Figure 30-40- (See Pump Neutral Adjustment on Page 30-40-
134]. 47.)
Install the five servo cover mount bolts and finger tighten.
A220 Bobcat Loader
30-40-39 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-139
Assembly (Cont'd)
Figure 30-40-137
P-28763
Install the center pin on the control feedback link (Item 1)
P-28781 into the bore in the neutral adjustment link (Item 2)
[Figure 30-40-139].
Rotate the pump housing so that the control face is
accessible [Figure 30-40-137].
Figure 30-40-138
P-28780
Install the control spool and spring (Item 1) [Figure 30-
40-38] into the pump housing.
A220 Bobcat Loader
30-40-40 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-142
Assembly (Cont'd)
Figure 30-40-140
1
2
1
3
P-28776
The neutral adjustment link (Item 1) should mate and
P-28778 engage the neutral adjustment screw (Item 2), and both
links should align with the pivot screw hole (Item 3)
[Figure 30-40-142].
Figure 30-40-141
Figure 30-40-143
1
2
P-28777
P-28775
Install the end of the feedback link containing the hole
(Item 1) [Figure 30-40-140] & [Figure 30-40-141] into Install the linkage pivot screw (Item 1) [Figure 30-40-
the servo piston slot (Item 2) [Figure 30-40-141]. 143] and tighten to 6-11 ft.-lbs. (8-15 Nm) torque.
A220 Bobcat Loader
30-40-41 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-146
Assembly (Cont'd)
Figure 30-40-144
P-28772
Shift the control spool to the center of the housing until
P-28774 the summing link pin (Item 1) [Figure 30-40-146] is
located in the center.
Install the summing link (Item 1) [Figure 30-40-144] on to Figure 30-40-147
the feedback link pin.
Figure 30-40-145
P-28771
P-28773 Install a new gasket (Item 1) [Figure 30-40-147] on the
pump housing controller face.
Move the control spool (Item 1) until the summing link
(Item 2) [Figure 30-40-145] lines up with the flat spot on
the control spool.
A220 Bobcat Loader
30-40-42 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-150
Assembly (Cont'd)
Figure 30-40-148 1
P-28687
Install the control spool bore plug (Item 1) [Figure 30-40-
P-28769 150] and tighten to 30-70 ft.-lbs (41-94 Nm) torque.
Figure 30-40-151
Install the control module on the pump housing.
NOTE: The pin on the summing link (Item 1) must
engage the bore (Item 2) [Figure 30-40-148] on
the control module for proper control
operation.
Figure 30-40-149
P-28768
1
Install the valve plate timing pin (Item 1) [Figure 30-40-
151] and allow it to stick out roughly 1/16 Inch, (1,588
mm) beyond the interface of the pump housing side
cover.
P-28770
Install the seven controller mount bolts (Item 1) [Figure
30-40-149] and tighten to 11-13 ft.-lbs. (15-17.5 Nm)
torque.
A220 Bobcat Loader
30-40-43 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-154
Assembly (Cont'd)
Figure 30-40-152
2 P-28766
Install the swashplate needle bearing (Item 1) [Figure
P-28684 30-40-154] on the swashplate, so the letters on the
bearing face the swashplate.
Install the pump valve plate (Item 1) and engage the Figure 30-40-155
valve plate timing pin (Item 2) [Figure 30-40-152].
Lubricate the top surface of the valve plate with a coating
of hydraulic fluid.
1
Figure 30-40-153
P-28765
Install the swashplate and needle bearing into the servo
piston cavity (Item 1) [Figure 30-40-155].
P-28767
Be sure the servo piston cavity (Item 1) [Figure 30-40-
153] is facing the center of the pump.
A220 Bobcat Loader
30-40-44 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-158
Assembly (Cont'd)
Figure 30-40-156
P-28743
Install the ball guide (Item 1) [Figure 30-40-158] on the
P-28748 hold down pins.
Figure 30-40-159
Lightly coat all parts with hydraulic oil, before installing
the cylinder block.
Place the retainer ring (Item 1) [Figure 30-40-156] in the
cylinder block, so that it sits approximately 1/8 inch
(3,175 mm) below the surface.
Figure 30-40-157
P-28681
1 Install the slipper retainer, containing the slippers and
pistons [Figure 30-40-159].
Apply a liberal amount of hydraulic oil to the top and
bottom of the slippers and cylinder block.
P-28749
Install the three hold down pins (Item 1) [Figure 30-40-
157], making sure they are setting squarely in the
grooves.
A220 Bobcat Loader
30-40-45 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-162
Assembly (Cont'd)
Figure 30-40-160
P-28764
Install a new gasket (Item 1) [Figure 30-40-162] on the
P-28682 side cover.
Figure 30-40-163
Figure 30-40-161
1
1
P-28779
P-28680
Press down on the swashplate, with a clean rubber
Lift the end of the swashplate (Item 1) [Figure 30-40- mallet.
160] and insert the cylinder block assembly (Item 1)
[Figure 30-40-161]. Install the side cover/swashplate bearing assembly (Item
1) [Figure 30-40-163] into the pump housing.
Visually center the cylinder block assembly over the
valve plate [Figure 30-40-161].
A220 Bobcat Loader
30-40-46 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-166
Assembly (Cont'd)
Figure 30-40-164
1
P-28791
The pump neutral adjustment sets the position of the
P-28677 servo piston and pump swashplate relative to the
controlling mechanism.
Align the holes and the gasket, and install the six Place the loader on jackstands. (See Procedure on Page
mounting bolts (Item 1) [Figure 30-40-164] and tighten to 10-10-1.)
11-13 ft.-lbs (15-17,5) Nm torque.
Raise the lift arms, and install an approved lift arm
Install the shaft assembly into the pump housing. (See support device. (See Engaging The Lift Arm Support
Shaft Seal And Shaft Installation on Page 30-40-20.) Device on Page 10-20-1.)
Install the charge pump. (See Charge Pump Removal on Raise the operator cab. (See Raising The Operator Cab
Page 30-40-22.) on Page 10-30-1.)
Pump Neutral Adjustment Connect the remote start tool. (See REMOTE START on
Page 10-60-1.)
Figure 30-40-165
Connect a hydraulic hose between port M4 (Item 1)
[Figure 30-40-165] on the back side of the hydrostatic
pump, and port M5 (Item 1) [Figure 30-40-166] on the
1 front side of the hydrostatic pump, to equalize the
pressures on both ends of the servo piston.
P-28790
A220 Bobcat Loader
30-40-47 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-169
Pump Neutral Adjustment (Cont'd)
Figure 30-40-167
P-28790
1
Loosen the pump neutral adjustment lock nut (Item 1)
P-28791 [Figure 30-40-169].
Start the loader using the remote start tool and run at an
Remove the plug (Item 1) [Figure 30-40-167] from the idle.
M1 port on the front side of the pump, and install a 500
PSI pressure gauge. Figure 30-40-170
Figure 30-40-168
P-28790A
1
P-28791
Turn the adjustment screw (Item 1) [Figure 30-40-170]
clockwise, until one of the gauges registers an increase
Remove the plug (Item 1) [Figure 30-40-168] from the in system pressure. Mark the position of the adjustment
M2 port on the front side of the pump, and install a 500 screw.
PSI pressure gauge.
A220 Bobcat Loader
30-40-48 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-173
Pump Neutral Adjustment (Cont’d)
Figure 30-40-171
P-28790A
1
While holding the adjustment screw (Item 1) in position,
P-28790A tighten the seal lock nut (Item 2) [Figure 30-40-173] to
21-37 ft.-lbs. (28-51 Nm) torque.
Turn the adjustment screw (Item 1) [Figure 30-40-171] Shut loader OFF.
counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the Remove the hydraulic hose from the M4 and M5 ports on
adjustment screw. the pump. Install the plugs and tighten.
Figure 30-40-172 Remove the pressure gauges from the M1 and M2 ports
on the pump. Install the plugs and tighten.
NOTE: This pump is equipped with an EDC
Controller. The Controller Neutral Adjustment
procedure must be performed, before running
the loader. (See Pump Controller Neutral
Adjustment on Page 30-40-50.)
P-28790A
Turn the adjustment screw (Item 1) [Figure 30-40-172]
clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
A220 Bobcat Loader
30-40-49 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-175
Pump Controller Neutral Adjustment
Figure 30-40-174
P-28790
Remove the M4 plug (Item 1) [Figure 30-40-175] and
P-26464 install a 500 PSI pressure gauge.
Figure 30-40-176
The pump controller neutral adjustment, aligns the pump
swashplate and the control spool so that a zero angle
control setting provides a zero degree swashplate
setting. This adjustment should be performed whenever
any part of the control or swashplate mechanisms are
adjusted or removed or after the pump neutral setting is
adjusted.
Place the loader on jackstands. (See Procedure on Page
10-10-1.) 1
Raise the lift arms, and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
P-28791
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the M5 plug (Item 1) [Figure 30-40-176] and
Connect the remote start tool. (See REMOTE START on install a 500 PSI pressure gauge.
Page 10-60-1.)
Disconnect the pump controllers (Item 1) [Figure 30-40-
174] from the loader wiring harness.
A220 Bobcat Loader
30-40-50 Service Manual
HYDROSTATIC PUMP (CONT’D) Figure 30-40-179
Pump Controller Neutral Adjustment (Cont’d)
Figure 30-40-177
1
1
P-28791B
Turn the adjustment screw (Item 1) [Figure 30-40-179]
P-28791 counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the
adjustment screw.
Loosen the control spool neutral adjustment seal lock nut
(Item 1) [Figure 30-40-177]. Figure 30-40-180
Start the loader using the remote start tool and run at an
idle.
Figure 30-40-178
P-28791B
1 Turn the adjustment screw (Item 1) [Figure 30-40-180]
clockwise, to a position halfway between the recorded
P-28791B positions. The pressure gauges should read equal
pressures.
Turn the adjustment screw (Item 1) [Figure 30-40-178]
clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.
A220 Bobcat Loader
30-40-51 Service Manual
HYDROSTATIC PUMP (CONT’D)
Pump Controller Neutral Adjustment (Cont'd)
Figure 30-40-181
1
P-28791B
While holding the adjustment screw (Item 1) in position,
tighten the seal lock nut (Item 2) [Figure 30-40-181] to
10-18 ft.-lbs. (14-24 Nm) torque.
Shut loader OFF.
Remove the pressure gauges from the M4 and M5 ports
on the pump. Install the plugs and tighten.
Connect the pump controller wire connector to the loader
wiring harness.
A220 Bobcat Loader
30-40-52 Service Manual
DRIVE BELT Adjustment
Shield Removal And Installation Figure 30-50-3
Figure 30-50-1
2
1
P-05554
P-26581
1
2
Stop the engine.
Open the rear door.
Remove the three belt shield holddown clips (Item 1)
[Figure 30-50-1].
Figure 30-50-2
P- 4681
The drive belt idler arm stop is located on the left side of
the engine below the air cleaner [Figure 30-50-3].
Loosen the two bolts (Item 1) [Figure 30-50-3] and slide
the stop against the idler arm. Tighten the bolts.
There is no adjustment for the spring, just make sure the
spring bolt (Item 2) [Figure 30-50-3] is tight.
Replacement
P-26582 Remove the belt shield. (See DRIVE BELT on Page 30-
50-1.)
Remove the belt shield from the drive belt housing
Loosen the two stop mounting bolts (Item 1) [Figure 30-
[Figure 30-50-2].
50-3].
Loosen the spring tension bolt (Item 2) [Figure 30-50-3].
Remove the fan drive belt from the tensioner pulley.
Remove the drive belt from the hydrostatic pump pulley
and flywheel pulley.
A220 Bobcat Loader
30-50-1 Service Manual
DRIVE BELT (CONT’D) Figure 30-50-6
Replacement (Cont’d)
2
Figure 30-50-4
P5554
Remove the two stop mounting bolts (Item 1) [Figure 30-
P7894 50-6].
Remove the stop.
Remove the drive belt [Figure 30-50-4].
Remove the spring tension bolt (Item 2) [Figure 30-50-
Tensioner Pulley Removal And Installation 6].
Figure 30-50-5 Figure 30-50-7
1
1
P5552 P5548
Remove the belt shield clips (Item 1) [Figure 30-50-5]. Remove the end cap (Item 1) [Figure 30-50-7] from the
tensioner pulley arm.
Remove the belt shield (Item 2) [Figure 30-50-5].
A220 Bobcat Loader
30-50-2 Service Manual
DRIVE BELT (CONT’D) Figure 30-50-10
Tensioner Pulley Removal And Installation (Cont'd)
Figure 30-50-8
P5553
Check the arm seal (Item 1) [Figure 30-50-10]. Replace
P5555 the seal as needed.
Figure 30-50-11
Remove the mounting bolt (Item 1) [Figure 30-50-8] from
the tensioner pulley arm.
Figure 30-50-9
2
P5561
Remove the pulley mounting bolt [Figure 30-50-11].
P5560
Remove the pulley/arm assembly (Item 1) [Figure 30-50-
9] from the engine housing.
Remove the arm bushing (Item 2) [Figure 30-50-9].
Check for wear and replace as needed.
A220 Bobcat Loader
30-50-3 Service Manual
DRIVE BELT (CONT’D) Figure 30-50-14
Tensioner Pulley Removal And Installation (Cont'd)
Figure 30-50-12
1
P5563
Remove the end block (Item 1) [Figure 30-50-14] (both
P5559 ends) from the spring.
Check the spring for wear and etc. Replace the spring as
Disassemble the pulley and bearing as shown in [Figure needed.
30-50-12].
Check the spring end blocks for wear and replace as
Check the parts for wear and replace as needed. needed.
Tensioner Pulley Tension Spring
Figure 30-50-13
P5551
Remove the base end bolt (Item 1) [Figure 30-50-13]
from the spring block.
Remove the tension spring from the engine housing.
A220 Bobcat Loader
30-50-4 Service Manual
OIL COOLER (SEAL TO CONNECT) (STC) Figure 30-60-3
Hydraulic Oil Cooler Removal and Installation
Figure 30-60-1
1
N-19545A
Install tool 10STC (Item 1) [Figure 30-60-2] & [Figure
P-26759 30-60-3] to the outside of the rubber sleeve.
Figure 30-60-4
Open the rear door of the loader.
Raise and remove the rear grill [Figure 30-60-1].
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-26760
Figure 30-60-2
Slide the rubber sleeve in toward the radiator. The
connector will release [Figure 30-60-4].
Repeat the procedure for the other hose and fitting on the
oil cooler.
NOTE: When installing the cooler hoses, the fittings
1 should make a clicking sound when pushed
together.
Lift up the oil cooler and remove the cooler from the
loader.
Reverse the removal procedure to install the oil cooler.
P-26761
A220 Bobcat Loader
30-60-1 Service Manual
A220 Bobcat Loader
30-60-2 Service Manual
DRIVE SYSTEM
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-10-1
SAFETY &
BRAKE (TWO-SPEED) (EARLY MODELS) . . . . . . . . . . . . . . 40-11-1 MAINTENANCE
Block Disassembly And Assembly. . . . . . . . . . . . . . . . . . . 40-11-3
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-11-1
BRAKE (TWO SPEED) (LATER MODELS) . . . . . . . . . . . . . . 40-12-1
Block Disassembly And Assembly. . . . . . . . . . . . . . . . . . . 40-12-2
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-12-1
DRIVE
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1 SYSTEM
Front Chaincase Cover Removal And Installation . . . . . . . 40-40-1
Rear Chaincase Cover Removal And Installation . . . . . . . 40-40-1
DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . 40-30-1
Axle, Sprocket And Bearings Removal And Installation. . . 40-30-2
Drive Chain Removal And Installation . . . . . . . . . . . . . . . . 40-30-7 ELECTRICAL
SYSTEM &
HUB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1 ANALYSIS
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-7
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-10 ENGINE
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-3 SERVICE
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
STEERING BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 40-20-4 SPECIFICATIONS
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-3
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
A220 Bobcart Loader
40-01-1 Service Manual
A220 Bobcat Loader
40-01-2 Service Manual
BRAKE Figure 40-10-2
Disc Removal And Installation
WARNING P-26688
Never work on a machine with the lift arms up unless Mark the four hydraulic hoses for proper installation.
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm Remove the four hydraulic hoses (Item 1) [Figure 40-10-
support device can allow the lift arms or attachment 2] from the steering valve.
to fall and cause injury or death.
W-2059-0598 Cap and plug the hoses and the fittings.
Figure 40-10-1 Figure 40-10-3
1
2
P-26687 P-26689
Raise the lift arms and install an approved lift arm support Remove the two mount bolts and nuts (Item 1) [Figure
device. (See Engaging The Lift Arm Support Device on 40-10-3] from the steering block.
Page 10-20-1.)
Move the steering block to the left side of the loader to
Raise the loader operator cab. (See OPERATOR CAB on allow clearance for the solenoid removal.
Page 10-30-1.)
At the steering block (Item 1), disconnect the brake
solenoid wiring connector (Item 2) [Figure 40-10-1].
A220 Bobcat loader
40-10-1 Service Manual
BRAKE (CONT’D) Figure 40-10-6
Disc Removal And Installation (Cont'd)
Figure 40-10-4
2
2
1
P-26692
Remove the traction lock solenoid (Item 1) and the
P-26690 spring (Item 2) [Figure 40-10-6].
Figure 40-10-7
Remove the two mount bolts (Item 1) [Figure 40-10-4]
from the steering block mount bracket.
Remove the mount bracket (Item 2) [Figure 40-10-4]
from the loader.
Figure 40-10-5 1
P-26693
1
NOTE: Mark the front side of the solenoid mount
bracket (Item 1) [Figure 40-10-7], for proper
installation.
P-26691 Remove the two mount bolts (Item 2) [Figure 40-10-7]
from the traction lock solenoid mount block.
Remove the two solenoid mount bolts (Item 1) [Figure Remove the mount block from the loader.
40-10-5].
A220 Bobcat Loader
40-10-2 Service Manual
BRAKE (CONT’D) Figure 40-10-10
Disc Removal And Installation (Cont'd)
Figure 40-10-8
1 1
P7799
Remove the two nuts (Item 1) [Figure 40-10-10] from the
P-26694 disc bolts.
Figure 40-10-11
Remove the wedge assembly (Item 1) [Figure 40-10-8]
from the brake guides.
Figure 40-10-9
1
1
1
P7801
Remove the two disc bolts (Item 1) [Figure 40-10-11]
P-26695 from the disc.
Remove the twelve transmission cover mount bolts (Item
1) [Figure 40-10-9].
Remove the transmission cover from the loader.
A220 Bobcat loader
40-10-3 Service Manual
BRAKE (CONT’D) Figure 40-10-14
Disc Removal And Installation (Cont'd)
3 3
Figure 40-10-12
1 2
P13003
Installation: Bolting the disc to the snap ring provides
P7800 proper disc alignment. Disc and shaft are shown
removed for photo clarity. The snap ring end gap (Item 1)
must be between the disc bolts (Item 2) and sprocket
A snap ring pliers with 90° tips are needed for removing teeth (Item 3) [Figure 40-10-14] after the brake disc is
the brake disc snap ring. installed on the shaft.
Pull the disc away from snap ring.
Remove the snap ring (Item 1) [Figure 40-10-12] from
the end of the carrier shaft.
Figure 40-10-13
P7865
Remove the disc (Item 1) [Figure 40-10-13] from the
shaft.
A220 Bobcat Loader
40-10-4 Service Manual
BRAKE (TWO-SPEED) (EARLY MODELS) Figure 40-11-3
Block Removal And Installation
Figure 40-11-1
P-26336
Disconnect the two hydraulic hoses (Item 1) [Figure 40-
P-26334 11-3] from the brake/two speed block.
Cap and plug the hoses and the fittings.
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.) Figure 40-11-4
Remove the control panel. (See CONTROL PANEL on
Page 50-100-1.)
Mark all hydraulic hoses for proper installation.
1
Disconnect the four hydraulic hoses (Item 1) [Figure 40-
11-1] from the brake/two speed block.
Cap and plug the hoses and the fittings.
Figure 40-11-2
1 P-26337
Disconnect the wire harness connector (Item 1) [Figure
40-11-4] from the make-up valve solenoid.
P-26335
Disconnect the two hydraulic hoses (Item 1) [Figure 40-
11-2] from the brake/two speed block.
Cap and plug the hoses and the fittings.
A220 Bobcat Loader
40-11-1 Service Manual
BRAKE (TWO-SPEED) (EARLY MODELS) (CONT’D) Figure 40-11-7
Block Removal And Installation (Cont'd)
Figure 40-11-5 2
1
1
2 P-26340
Remove the AWS block mount bolts and nuts (Item 1)
P-26338 [Figure 40-11-7] .
Remove the brake/two-speed mount plate (Item 2)
Disconnect the wire harness connector (Item 1) [Figure [Figure 40-11-7] from the AWS block.
40-11-5] from the brake solenoid.
Disconnect the wire harness connector (Item 2) [Figure
40-11-5] from the two-speed solenoid.
Figure 40-11-6
P-26339
Turn the hydraulic fitting (Item 1) [Figure 40-11-6] to
allow for clearance to remove the mounting bolt.
Remove the two mounting bolts (Item 2) [Figure 40-11-6]
from the brake/two-speed block.
Remove the brake/two-speed block from the loader.
A220 Bobcat Loader
40-11-2 Service Manual
BRAKE (TWO-SPEED) (EARLY MODELS) (CONT’D) Figure 40-11-10
Block Disassembly And Assembly
Figure 40-11-8 1
1 2
1
1
N-22580
1
Check the back-up washers (Item 1) and O-rings (Item 2)
N-22578 [Figure 40-11-10] for wear and replace as needed.
Figure 40-11-11
Mark all hydraulic hoses and fittings for proper
installation.
Remove the hydraulic fittings (Item 1) [Figure 40-11-8]
from the block.
Figure 40-11-9
1
2
N-22581
Loosen the electrical solenoid nut (Item 1) [Figure 40-11-
11] from the make-up valve solenoid.
Assembly: Tighten the nut to 60-84 in.-lbs. (6,78-9,49
N-22579 Nm) torque.
Remove the check valve (Item 1) [Figure 40-11-9] from
the two-speed valve.
Remove the check valve (Item 2) [Figure 40-11-9] from
the brake valve.
NOTE: The check valves (Items 1 & 2) [Figure 40-11-
9] are interchangable.
A220 Bobcat Loader
40-11-3 Service Manual
BRAKE (TWO-SPEED) (EARLY MODELS) (CONT’D) Figure 40-11-14
Block Disassembly And Assembly (Cont'd)
Figure 40-11-12
N-22584
Assembly: Always install new O-rings and back-up
N-22583 washers [Figure 40-11-14]. Tighten the solenoid valve to
20 ft.-lbs. (27,1 Nm) torque.
Use a test meter and test the solenoid (Item 1) [Figure Figure 40-11-15
40-11-12] for resistance.
The resistance value for the solenoid coil can be found
on the electrical schmatic. (See LOADER
SPECIFICATIONS on Page SPEC-10-1.)
Figure 40-11-13
N-22585
Remove the plug (Item 1) [Figure 40-11-15] from the
1 brake/two-speed block.
N-22582
Remove the solenoid valve (Item 1) [Figure 40-11-13]
from the block.
A220 Bobcat Loader
40-11-4 Service Manual
BRAKE (TWO-SPEED) (EARLY MODELS) (CONT’D) Figure 40-11-18
Block Disassembly And Assembly (Cont'd)
1
Figure 40-11-16
N-22610
1
Use a test meter and test the solenoid (Item 1) [Figure
N-22586 40-11-18] for resistance.
The resistance value for the solenoid coil can be found
Check the O-ring (Item 1) [Figure 40-11-16] on the plug on the electrical schmatic. (See LOADER
and replace as needed. SPECIFICATIONS on Page SPEC-10-1.)
Figure 40-11-17 Replace the O-rings (Item 2) [Figure 40-11-18].
Figure 40-11-19
1 1
N-22587
N-22588
Remove the two speed solenoid nut (Item 1) [Figure 40-
11-17].
Remove the solenoid valve (Item 1) [Figure 40-11-19]
Assembly: Tighten the nut to 60-84 in.-lbs. (6,78-9,49 from the block.
Nm) torque.
A220 Bobcat Loader
40-11-5 Service Manual
BRAKE (TWO-SPEED) (EARLY MODELS) (CONT’D) Figure 40-11-22
Block Disassembly And Assembly (Cont'd)
Figure 40-11-20
1
N-22613
Use a test meter and test the solenoid (Item 1) [Figure
N-22611 40-11-22] for resistance.
The resistance value for the solenoid coil can be found
Assembly: Always install new O-rings. Tighten the on the electrical schmatic. (See LOADER
solenoid valve to 20 ft.-lbs. (27,1 Nm) torque. SPECIFICATIONS on Page SPEC-10-1.)
Check the O-rings [Figure 40-11-20] and replace as Figure 40-11-23
needed.
Figure 40-11-21
N-22612
N-22587 Remove the solenoid valve (Item 1) [Figure 40-11-23]
from the block.
Remove the brake solenoid nut (Item 1) [Figure 40-11-
21].
Assembly: Tighten the nut to 60-84 in.-lbs. (6,78-9,49
Nm) torque.
A220 Bobcat Loader
40-11-6 Service Manual
BRAKE (TWO-SPEED) (EARLY MODELS) (CONT’D)
Block Disassembly And Assembly (Cont'd)
Figure 40-11-24
1
N-22614
Assembly: Always install new O-rings and back-up
washers. Tighten the solenoid valve to 20 ft.-lbs. (27,1
Nm) torque.
Check the O-rings and back-up washers [Figure 40-11-
24] and replace as needed.
A220 Bobcat Loader
40-11-7 Service Manual
A220 Bobcat Loader
40-11-8 Service Manual
BRAKE (TWO SPEED) (LATER MODELS) Figure 40-12-3
Block Removal And Installation
Figure 40-12-1
1
1
1
1 1
1 2
P-34382
Disconnect the wire harness connector (Item 1) [Figure
P-34378 40-12-3] from the brake solenoid.
Disconnect the wire harness connector (Item 2) [Figure
Lift and block the loader. (See LIFTING AND BLOCKING 40-12-3] from the two speed solenoid.
THE LOADER on Page 10-10-1.)
Figure 40-12-4
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Mark all hydraulic hoses for proper installation.
1
Disconnect the six hydraulic hoses (Item 1) [Figure 40-
12-1] from the brake/two speed block.
Figure 40-12-2
1 P-34383
1
Disconnect the wire harness connector (Item 1) [Figure
40-12-4] from the make-up valve solenoid.
P-34381
Disconnect the two hydraulic hoses (Item 1) [Figure 40-
12-2] from the brake/two speed block.
Cap and plug the hoses and the fittings.
A220 Bobcat Loader
40-12-1 Service Manual
BRAKE (TWO SPEED) (LATER MODELS) (CONT’D) Block Disassembly And Assembly
Block Removal And Installation (Cont'd) Figure 40-12-7
Figure 40-12-5
1
1 1
1
1
P-34097
P-34384
Mark all hydraulic hoses and fittings for proper
installation.
Remove the two mounting bolts (Item 1) [Figure 40-12-
5] from the brake/two-speed block. Remove the hydraulic fittings (Item 1) [Figure 40-12-7]
from the block.
Remove the brake/two-speed block from the loader.
Figure 40-12-8
Figure 40-12-6
1
2
2
P-34098
P-26340
Remove the check valve (Item 1) [Figure 40-12-8] from
Remove the AWS block mount bolts and nuts (Item 1) the two-speed valve.
[Figure 40-12-6] .
Remove the check valve (Item 2) [Figure 40-12-8] from
Remove the brake/two-speed mount plate (Item 2) the brake valve.
[Figure 40-12-6] from the AWS block.
NOTE: The check valves (Items 1 & 2) [Figure 40-12-
8] are interchangable.
A220 Bobcat Loader
40-12-2 Service Manual
BRAKE (TWO SPEED) (LATER MODELS) (CONT’D) Figure 40-12-11
Block Disassembly And Assembly (Cont'd)
Figure 40-12-9
1
2
P-34112
Use a test meter and test the make-up valve solenoid
N-22580 (Item 1) [Figure 40-12-11] for resistance.
The resistance value for the solenoid coil can be found
Check the back-up washers (Item 1) and O-rings (Item 2) on the electrical schematic. (See ELECTRICAL SYSTEM
[Figure 40-12-9] for wear and replace as needed. INFORMATION on Page 60-10-1.)
Figure 40-12-10 Figure 40-12-12
1 2
1
P-34099 P-34111
Remove the electrical solenoid nut (Item 1) [Figure 40- Use a test meter and test the brake solenoid (Item 1)
12-10] from the make-up valve solenoid. [Figure 40-12-12] from the block.
Remove the electrical solenoid nut (Item 2) [Figure 40- The resistance value for the solenoid coil can be found
12-10] from the brake solenoid. on the electrical schematic. (See ELECTRICAL SYSTEM
INFORMATION on Page 60-10-1.)
Assembly: Tighten the solenoid nuts to 60-84 in.-lbs.
(6,78-9,49 Nm) torque.
A220 Bobcat Loader
40-12-3 Service Manual
BRAKE (TWO SPEED) (LATER MODELS) (CONT’D) Figure 40-12-15
Block Disassembly And Assembly (Cont'd)
Figure 40-12-13
P-34105A
1
2
Check the O-rings [Figure 40-12-15] on the brake valve
P-34101 stem and replace as needed.
Tighten the solenoid valve to 20 ft.-lbs. (27,1 Nm) torque.
Remove the make-up valve solenoid stem (Item 1)
[Figure 40-12-13] from the block Figure 40-12-16
Remove the brake solenoid stem (Item 2) [Figure 40-12-
13] from the block
Figure 40-12-14
P-34102
Remove the four plugs (Item 1) [Figure 40-12-16] from
the brake/two speed block.
N-22584
Assembly: Always install new O-rings and back-up
washers [Figure 40-12-14] on the make-up valve
solenoid. Tighten the solenoid valve to 20 ft.-lbs. (27,1
Nm) torque.
A220 Bobcat Loader
40-12-4 Service Manual
BRAKE (TWO SPEED) (LATER MODELS) (CONT’D) Figure 40-12-19
Block Disassembly And Assembly (Cont'd)
1
Figure 40-12-17
N-22610
1 Use a test meter and test the solenoid (Item 1) [Figure
P-34103 40-12-19] for resistance.
The resistance value for the solenoid coil can be found
Check the O-rings (Item 1) [Figure 40-12-17] on the on the electrical schematic. (See ELECTRICAL SYSTEM
plugs and replace as needed. INFORMATION on Page 60-10-1.)
Figure 40-12-18 Replace the O-rings (Item 2) [Figure 40-12-19].
Figure 40-12-20
1
P-34104
P-34589
Remove the two speed solenoid nut (Item 1) [Figure 40-
12-18].
Remove the solenoid valve (Item 1) [Figure 40-12-20]
Assembly: Tighten the nut to 60-84 in.-lbs. (6,78-9,49 from the block.
Nm) torque.
A220 Bobcat Loader
40-12-5 Service Manual
BRAKE (TWO SPEED) (LATER MODELS) (CONT’D)
Block Disassembly And Assembly (Cont'd)
Figure 40-12-21
N-22611
Check the O-rings [Figure 40-12-21] and replace as
needed.
Assembly: Tighten the solenoid valve to 20 ft.-lbs. (27,1
Nm) torque.
A220 Bobcat Loader
40-12-6 Service Manual
STEERING BLOCK
Wiring Diagram
P-26449
2
9 1
4
8 5
P-26439
A220 Bobcat Loader
40-20-1 Service Manual
STEERING BLOCK (CONT’D)
Wiring Diagram (Cont’d)
SOLENOID NO. FUNCTION CONNECTOR COLOR TIE WIRING HARNESS NO.
1 Front Left Rod C443 Blue 4040 & 2890
2 Front Left Base C499 Red 4030 & 2940
3 Front Right Rod C461 White 4020 & 2950
4 Front Right Base C440 Purple 4010 & 2960
5 Left Rear Rod C447 Black 4170 & 2850
6 Left Rear Base C446 Pink 4160 & 2840
7 Right Rear Rod C445 Yellow 4070 & 2830
8 Right Rear Base C444 Green 4050 & 2820
9 Pressure Control Solenoid C448 Orange 4060 & 2870
A220 Bobcat Loader
40-20-2 Service Manual
STEERING BLOCK (CONT’D) Cap and plug the hydraulic hoses and fittings.
Removal And Installation Figure 40-20-3
Figure 40-20-1
1
1
1
P-26343
P-26341
Mark all wire connector for proper installation.
Raise the lift arms and install an approved lift arm support Disconnect the nine solenoid wire connectors (Item 1)
device. (See Engaging The Lift Arm Support Device on [Figure 40-20-3].
Page 10-20-1.)
Figure 40-20-4
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the brake/two speed block. (See BRAKE (TWO
1
SPEED) (LATER MODELS) on Page 40-12-1.)
Mark all hydraulic hoses for proper installation.
Disconnect the four hydraulic hoses (Item 1) [Figure 40-
20-1] from the steering block.
Cap and plug the hydraulic hoses and fittings.
Figure 40-20-2
P-26344
Mark the hydraulic hoses for proper installation.
Remove the two hydraulic hoses (Item 1) [Figure 40-20-
1 1 4] that come from the pump.
Cap and plug the hydraulic hoses and fittings.
P-26342
Disconnect the four hydraulic hoses (Item 1) [Figure 40-
20-2] from the steering block.
A220 Bobcat Loader
40-20-3 Service Manual
STEERING BLOCK (CONT’D) Disassembly And Assembly
Removal And Installation (Cont'd) Figure 40-20-7
Figure 40-20-5
1
1
P-26439
P-26345
Mark all solenoids for proper installation.
Remove the two mount bolts and nuts (Item 1) [Figure Remove the solenoid nut (Item 1) [Figure 40-20-7] .
40-20-5].
Installation: Tighten to 5 ft.-lbs. (6,8 Nm) torque.
Remove the brake/two-speed mount plate.
Figure 40-20-8
Figure 40-20-6
P-26440
P-26346
Remove the O-ring (Item 1) [Figure 40-20-8] from the
Remove the steering block (Item 1) [Figure 40-20-6] solenoid nut.
from the loader.
Check the O-ring and replace as needed.
A220 Bobcat Loader
40-20-4 Service Manual
STEERING BLOCK (CONT’D) Figure 40-20-11
Disassembly And Assembly (Cont'd)
Figure 40-20-9 2
P-26443
Remove the O-ring (Item 1) from the washer (Item 2)
P-26441 [Figure 40-20-11].
Check the O-ring and replace as needed.
Remove the rod end solenoid (Item 1) [Figure 40-20-9]
from the right front wheel solenoid stem. Figure 40-20-12
Figure 40-20-10
1
P-26444
P-26442
Remove the base end solenoid (Item 1) [Figure 40-20-
12] from the right front wheel.
Remove the washer and O-ring (Item 1) [Figure 40-20-
10] from base end solenoid.
A220 Bobcat Loader
40-20-5 Service Manual
STEERING BLOCK (CONT’D) Figure 40-20-15
Disassembly And Assembly (Cont'd)
1
Figure 40-20-13
1
P-26303
Check the five O-rings (Item 1) and six back-up washers
P-26445 (Item 2) [Figure 40-20-15] on the solenoid stem.
Replace the O-ring and back-up washers and as needed.
Remove the O-ring (Item 1) [Figure 40-20-13] from the
solenoid stem. Figure 40-20-16
Check the O-ring and replace as needed.
1
Figure 40-20-14
3
2
1
P-26439
NOTE: The disassembly and assembly of the left
P-26446 front (Item 1), left rear (Item 2) and right rear
(Item 3) [Figure 40-20-16] solenoids can be
done by following the procedure for the right
Remove the solenoid stem (Item 1) [Figure 40-20-14]. front solenoid. (See Disassembly And
Assembly on Page 40-20-4.)
Installation: Tighten the solenoid stem to 12 ft.-lbs. (16,3
Nm) torque.
A220 Bobcat Loader
40-20-6 Service Manual
STEERING BLOCK (CONT’D) Figure 40-20-19
Disassembly And Assembly (Cont'd)
1
Figure 40-20-17
P-26451
Remove the solenoid (Item 1) [Figure 40-20-19] from the
P-26439 proportional pressure control valve.
Figure 40-20-20
Remove the nut (Item 1) [Figure 40-20-17] from make-
up valve solenoid.
Installation: Tighten to 7-ft.-lbs. (9,5 Nm) torque.
Figure 40-20-18 1
P-26452
Remove the O-ring (Item 1) [Figure 40-20-20] from the
1 solenoid stem.
P-26450 Check the O-ring and replace as needed.
Remove the solenoid stem.
Remove the O-ring (Item 1) [Figure 40-20-18] from the
solenoid nut. Installation: Tighten the solenoid stem to 12 ft.-lbs. (16,3
Nm) torque.
Check the O-ring and replace as needed.
A220 Bobcat Loader
40-20-7 Service Manual
STEERING BLOCK (CONT’D) Figure 40-20-23
Disassembly And Assembly (Cont'd)
Figure 40-20-21
1
2
1
P-26455
Do Not Adjust the screw (Item 1) [Figure 40-20-23].
P-26453 (This is preset from the factory.)
Figure 40-20-24
Check the two O-rings (Item 1) and back-up ring (Item 2)
[Figure 40-20-21].
Replace the O-rings and back-up ring as needed.
Figure 40-20-22
P-26456
1
Remove the plug (Item 1) [Figure 40-20-24].
P-26454
Check the screen (Item 1) [Figure 40-20-22] at the base
of the solenoid stem, and clean as needed.
A220 Bobcat Loader
40-20-8 Service Manual
STEERING BLOCK (CONT’D) Figure 40-20-27
Disassembly And Assembly (Cont'd)
2
Figure 40-20-25
1
1 P-26458
Check the two O-rings (Item 1) and back-up ring (Item 2)
P-26457 [Figure 40-20-27].
Replace the O-rings and back-up ring as needed.
Check and replace the O-ring (Item 1) [Figure 40-20-25]
on the plug. Figure 40-20-28
Figure 40-20-26
P-26446
P-26446
Remove the upper left relief valve (Item 1) [Figure 40-20-
28].
Remove the upper right relief valve (Item 1) [Figure 40-
20-26].
A220 Bobcat Loader
40-20-9 Service Manual
STEERING BLOCK (CONT’D) Figure 40-20-31
Disassembly And Assembly (Cont'd)
Figure 40-20-29 2
P-26458
1
Check the two O-rings (Item 1) and back-up ring (Item 2)
P-26458 [Figure 40-20-31].
Replace the O-rings and back-up ring as needed.
Check the two O-rings (Item 1) and back-up ring (Item 2)
[Figure 40-20-29]. Figure 40-20-32
Replace the O-rings and back-up ring as needed.
Figure 40-20-30
P-26460
Remove the left side relief valve (Item 1) [Figure 40-20-
P-26459 32].
Remove the right side relief valve (Item 1) [Figure 40-20-
30].
A220 Bobcat Loader
40-20-10 Service Manual
STEERING BLOCK (CONT’D)
Disassembly And Assembly (Cont'd)
Figure 40-20-33
P-26458
Check the two O-rings (Item 1) and back-up ring (Item 2)
[Figure 40-20-33].
Replace the O-rings and back-up ring as needed.
A220 Bobcat Loader
40-20-11 Service Manual
A220 Bobcat Loader
40-20-12 Service Manual
DRIVE COMPONENTS Figure 40-30-3
Axle Seal Removal And Installation
Figure 40-30-1
2
1
P-24945
Before installing the axle seal, pack the seal spring
P-24946 groove (Item 1) [Figure 40-30-3] with a high quality
lithium base grease.
Lift and block the loader. (See LIFTING AND BLOCKING Also apply a light coat of grease to the seal surface (Item
THE LOADER on Page 10-10-1.) 2) [Figure 40-30-3] that contacts the hub yoke surface.
Remove the tire/wheel assembly. Figure 40-30-4
Installation: Tighten the wheel nuts to 105-115 ft.-lbs.
(142-155 Nm) torque.
Remove the hub assembly. (See HUB on Page 40-50-1.)
Remove the seal (Item 1) [Figure 40-30-1] from the
loader axle.
Figure 40-30-2
P-24947
1
Install the axle seal on the seal driver, MEL1604 [Figure
40-30-4].
P-24944
The axle seal must be installed with the metal side (Item
1) [Figure 40-30-2] facing the loader hub.
A220 Bobcat Loader
40-30-1 Service Manual
DRIVE COMPONENTS (CONT’D) NOTE: The procedure shown for removal and
installation of the axle, sprocket and bearings
Axle Seal Removal And Installation (Cont'd) is for a front axle. This procedure will be the
same for the rear axle, after removal of some
Figure 40-30-5 hydraulic components.
WARNING
P-24946
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
Install the new seal in the loader axle (Item 1) [Figure 40- support device. Failure to use an approved lift arm
30-5]. support device can allow the lift arms or attachment
to fall and cause injury or death.
Install the loader hub on the axle, being careful not to W-2059-0598
damage the axle seal.
Raise the lift arms and install an approved lift arm support
Axle, Sprocket And Bearings Removal And
device. (See Engaging The Lift Arm Support Device on
Installation
Page 10-20-1.)
Figure 40-30-6
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the loader control panel. (See CONTROL
PANEL on Page 50-100-1.)
1
Remove the wheel tire assembly (See Contents Page
10-01)
Remove the hub assembly from the loader. (See HUB on
Page 40-50-1.)
P-26425
Remove the eight bolts (Item 1) [Figure 40-30-6] from
the front transmission cover
The tools listed will be needed to do the following
procedure: Remove the front transmission cover.
MEL1420 - Bearing Driver
MEL1607 - Snap Ring Installer
A220 Bobcat Loader
40-30-2 Service Manual
DRIVE COMPONENTS (CONT’D) Figure 40-30-9
Axle, Sprocket And Bearings Removal And
Installation (Cont'd)
Figure 40-30-7
P-26426
Remove the axle bolt (Item 1) [Figure 40-30-9] and
washer.
P-26426
Figure 40-30-10
Remove the oil from the transmission (Item 1) [Figure
40-30-7].
Figure 40-30-8
P-26428
Loosen the bolt (Item 1) [Figure 40-30-11]. With a pry
1
bar move the axle and bolt toward the outside to give
P-26427 clearance for the bolt and washer to be removed.
Remove the axle seal (Item 1) [Figure 40-30-8] .
A220 Bobcat Loader
40-30-3 Service Manual
DRIVE COMPONENTS (CONT’D) Figure 40-30-13
Axle, Sprocket And Bearings Removal And
Installation (Cont'd)
1
Figure 40-30-11
P-26431
1 Remove the fiber spacer (Item 1) [Figure 40-30-13] and
replace as needed.
P-26429
Figure 40-30-14
Install the axle bolt and washer (Item 1) [Figure 40-30-
11] to the outer end of the axle, and use it to aid in pulling
the axle.
1
Figure 40-30-12
2
1
P-26432
Remove the snap ring (Item 1) [Figure 40-30-14].
P-26430
Remove the axle (Item 1) and spacer (Item 2) [Figure
40-30-12] from the axle tube.
A220 Bobcat Loader
40-30-4 Service Manual
DRIVE COMPONENTS (CONT’D) Figure 40-30-17
Axle, Sprocket And Bearings Removal And
Installation (Cont'd)
Figure 40-30-15
P-26436
Use MEL1420 Bearing Driver Tool and a threaded rod
[Figure 40-30-17].
P-26433
Figure 40-30-18
With a 3-13/16 bearing driver, come through the outer
end of the axle tube, drive the bearing out of the axle
tube [Figure 40-30-15].
Figure 40-30-16
P-26434
Install bearing driver and threaded rod in the
transmission end of the axle tube [Figure 40-30-18].
P-26433
Install the bearing in the axle. Be sure the bearing is
square in the axle tube (Item 1) [Figure 40-30-16].
A220 Bobcat Loader
40-30-5 Service Manual
DRIVE COMPONENTS (CONT’D) Figure 40-30-21
Axle, Sprocket And Bearings Removal And
Installation (Cont'd)
Figure 40-30-19
P-26437
Install axle and plastic axle bushing (Item 1) [Figure 40-
30-21] into axle tube.
P-26435
Figure 40-30-22
Install a plate (Item 1) and nut on the threaded rod at the
axle end [Figure 40-30-19].
Tighten the nuts and draw the bearing into the axle tube.
Figure 40-30-20
P-26438
Align the axle, sprocket and chain [Figure 40-30-22].
Using a pry bar hold the sprocket and chain in position.
Align the axle splines into the sprocket spline, and lightly
P-26432 drive the axle into place.
Install the snap ring (Item 1) [Figure 40-30-20].
A220 Bobcat Loader
40-30-6 Service Manual
DRIVE COMPONENTS (CONT’D) Drive Chain Removal And Installation
Axle, Sprocket And Bearings Removal And
Installation (Cont'd)
Figure 40-30-23
Figure 40-30-24
REAR CHAIN
1
P-26426
Install the axle washer and bolt [Figure 40-30-23].
FRONT CHAIN
Installation: Tighten the bolts to 475-525 ft.-lbs. (644-
710 Nm) torque.
P7866
Replace the oil in the transmission.
Install the transmission cover. Raise the loader lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Raise the loader operator cab. (See OPERATOR CAB on
Page 10-30-1.)
Drain the fluid from the chaincase. (See CHAINCASE on
Page 40-40-1.)
Remove the front (or rear) chaincase cover. (See
CHAINCASE on Page 40-40-1.)
Remove the front (or rear) axle and sprocket. (See
DRIVE COMPONENTS on Page 40-30-1.)
Remove the front (or rear) drive chain from the
chaincase.
A220 Bobcat Loader
40-30-7 Service Manual
DRIVE COMPONENTS (CONT’D) Figure 40-30-25
Axle, Sprocket And Bearings Removal And
Installation (Cont'd)
WARNING
DO NOT exceed the recommended torque of 130 ft.-
lbs. (176 Nm). The tool may fail under too much
torque. Put cloth around the tool to protect yourself
from flying debris.
W-2233-0296
B-13504
WARNING The tool listed is needed for the following procedure:
MEL1037 - Chain Link Tool
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
Installation: If a new chain is installed, a connector link
support device. Failure to use an approved lift arm
must be used to connect the chain together.
support device can allow the lift arms or attachment
to fall and cause injury or death.
Install the new chain around the carrier shaft.
W-2059-0598
Use MEL1037 Chain Link Tool and #100 chain adapter.
Secure the tool and place the connector link and chain in
the tool as shown [Figure 40-30-25].
Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-30-25]. Tighten the
threaded rod of the chain link tool to 180 ft.-lbs. (176 Nm)
torque.
Secure the tool and place the connector link and chain in
the tool as shown [Figure 40-30-25].
Turn the threaded rod of the tool and press the connector
link together on the chain . Tighten the threaeded rod of
the chain link tool to 180-ft-lbs. (176 Nm) torque.
A220 Bobcat Loader
40-30-8 Service Manual
CHAINCASE Figure 40-40-2
Front Chaincase Cover Removal And Installation
Figure 40-40-1
P-26696
1
Raise the lift arms and install an approved lift arm support
P4800 device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Remove the parking brake pedal. Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the mounting bolts from the front chaincase
cover (Item 1) [Figure 40-40-1]. Disconnect the hydrostatic hoses [Figure 40-40-2] .
Remove the cover. Remove the eight mounting bolts from the rear chaincase
cover (Item 1) [Figure 40-40-2].
Rear Chaincase Cover Removal And Installation
NOTE: The auxiliary tubeline at the rear port of
hydraulic control valve may need to be
disconnected to provide clearance for cover
front bolt removal.
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
A220 Bobcat Loader
40-40-1 Service Manual
A220 Bobcat Loader
40-40-2 Service Manual
HUB Figure 40-50-3
Removal
Figure 40-50-1
P-24931
Remove the retainer bolt (Item 1) [Figure 40-50-3] from
P-24816 the steering cylinder pin.
Figure 40-50-4
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)
Remove the tire/wheel assembly [Figure 40-50-1].
1
Figure 40-50-2
P-24932
Remove the steering cylinder pin (Item 1) [Figure 40-50-
4].
P-24930
Attach a hook and hoist to the hub (Item 1) [Figure 40-
50-2].
Support the hub for removal.
A220 Bobcat Loader
40-50-1 Service Manual
HUB (CONT’D) Figure 40-50-7
Removal (Cont'd)
1
Figure 40-50-5
P-24935
Remove the bearing seal (Item 1) [Figure 40-50-7] from
P-24933 the top and bottom king pins.
Figure 40-50-8
Remove the (4) bolts (Item 1) [Figure 40-50-5] from the
top and bottom king pins.
Remove the king pins from the hub assembly.
Figure 40-50-6 1
1
P-24936
Remove the bearing (Item 1) [Figure 40-50-8] from the
top and bottom king pins.
P-24934 Remove the wheel position sensor (Item 2) [Figure 40-
50-8]. (See WHEEL POSITION SENSORS on Page 60-
140-1.) (From the top king pin only.)
Slide the hub assembly (Item 1) [Figure 40-50-6] from
the loader axle.
A220 Bobcat Loader
40-50-2 Service Manual
HUB (CONT’D) Installation
Removal (Cont'd) Figure 40-50-11
Figure 40-50-9
P-24940
P-24939
Install the race (Item 1) [Figure 40-50-11] in the top and
bottom king pins.
Figure 40-50-10
Figure 40-50-12
P-24940
P-24941
Remove the bearing race (Item 1) [Figure 40-50-9] &
[Figure 40-50-10] from the top and bottom king pins. Using a 2-13/16'' driver, seat the race (Item 1) [Figure
40-50-12] in the top and bottom king pins.
A220 Bobcat Loader
40-50-3 Service Manual
HUB (CONT’D) Figure 40-50-15
Installation (Cont'd)
2
Figure 40-50-13
1 2
P-24968
NOTE: Before installation, pack the internal splines
P-24936 in the hub (Item 1) [Figure 40-50-15] with
grease.
Install the wheel position sensor (Item 1) [Figure 40-50- Align the yoke (Item 1) on the hub assembly with the
13]. (See WHEEL POSITION SENSORS on Page 60- loader axle (Item 2) [Figure 40-50-15].
140-1.) (In the top king pin only.)
Figure 40-50-16
Pack the bearings (Item 2) [Figure 40-50-13], and install
the bearings in the top and bottom races.
Figure 40-50-14
P-24967
Rotate the yoke (Item 1) [Figure 40-50-16] until the
P-24942 P-24935 splines on the yoke align with the splines on the loader
axle.
Install the seal (Item 1) [Figure 40-50-14] metal side Slide the hub assembly in until the king pin holes on the
towards the outside, in the top and bottom king pins. hub assembly align with the holes in the axle.
A220 Bobcat Loader
40-50-4 Service Manual
HUB (CONT’D) Figure 40-50-19
Installation (Cont'd)
Figure 40-50-17
1
P-24981B
Figure 40-50-20
P-24969
Install the lower king pin (Item 1) [Figure 40-50-17], with
the grease zerk toward the loader.
Install the four mount bolts and finger tighten. 1
Figure 40-50-18
P-24972
1
Remove the wheel position indexing pin (Item 1) [Figure
40-50-19] & [Figure 40-50-20] from the upper king pin.
Figure 40-50-21
P-24970
Remove the plug (Item 1) [Figure 40-50-18] from the top 1
king pin.
P-24974
Install the upper king pin (Item 1) [Figure 40-50-21], with
the grease zerk toward the loader.
A220 Bobcat Loader
40-50-5 Service Manual
HUB (CONT’D) Figure 40-50-24
Installation (Cont'd)
2
1
Figure 40-50-22
1
1
P-24978A
3 3
P-24976
P-24977A
Install the wheel position indexing pin (Item 1) [Figure
P-24975 40-50-23] in the upper king pin (Item 1) [Figure 40-50-
24].
Install the four mount bolts (Item 1) [Figure 40-50-22] in The fork (Item 2) [Figure 40-50-23] & [Figure 40-50-24]
the upper king pin. on the end of the indexing pin must align with the notches
(Item 3) [Figure 40-50-24] in the wheel position sensor.
Tighten the bolts to 70 ft.-lbs (95 Nm) torque. (Both upper
and lower king pin mount bolts.) Figure 40-50-25
Figure 40-50-23
1
1 1
P-24981A
P-24973
Slightly turn the indexing pin until the positioning lobes on
the pin drops into the indexing grooves (Item 1) [Figure
40-50-25] in the king pin.
A220 Bobcat Loader
40-50-6 Service Manual
HUB (CONT’D) Figure 40-50-28
Installation (Cont’d)
Figure 40-50-26
P-26040
Check the O-ring (Item 1) [Figure 40-50-28] on the back
P-24933 side of the hub retainer washer, replace as needed.
Figure 40-50-29
Install the plug (Item 1) [Figure 40-50-26] in the upper
king pin, and tighten to 20 ft.-lbs (27 Nm) torque.
Install the tire/wheel assembly. 1
Remove the loader from jackstands.
Disassembly
Figure 40-50-27
P-26032
1
Remove the hub assembly (Item 1) [Figure 40-50-29]
from the spline shaft.
P-26031
Remove the hub retainer bolt and washer (Item 1)
[Figure 40-50-27].
A220 Bobcat Loader
40-50-7 Service Manual
HUB (CONT’D) Figure 40-50-32
Disassembly (Cont'd)
Figure 40-50-30
1
P-26035
Inspect the hub for any damage, to the splines (Item 1)
P-26033 [Figure 40-50-32], or to the bearing surface.
Figure 40-50-33
Remove the spacer (Item 1) [Figure 40-50-30] from the
back side of the hub.
Figure 40-50-31
1
P-26037
Using a dead blow hammer, remove the u-joint yoke
P-26034 assembly (Item 1) [Figure 40-50-33] from the housing.
Remove the bearing (Item 1) [Figure 40-50-31] from the
hub.
A220 Bobcat Loader
40-50-8 Service Manual
HUB (CONT’D) Figure 40-50-36
Disassembly (Cont'd)
1
Figure 40-50-34
P-26045
Remove the inner seal (Item 1) [Figure 40-50-36] from
P-26038 the yoke assembly.
Figure 40-50-37
Remove the outer housing seal (Item 1) [Figure 40-50-
34].
3
Figure 40-50-35 2
1
1
1
1 1
1
P-26046
Remove the eight bolts (Item 1) and remove the male
P-26039 yoke (Item 2) and the female yoke (Item 3) [Figure 40-
50-37], from the U-joint.
Remove the bearing races (Item 1) [Figure 40-50-35]
from the housing.
A220 Bobcat Loader
40-50-9 Service Manual
HUB (CONT’D) Figure 40-50-40
Inspection
Figure 40-50-38
P-26050
Check the u-joint [Figure 40-50-40].
P-26048
Figure 40-50-41
Before the hub is assembled, check the following items:
Check the female yoke [Figure 40-50-38].
Figure 40-50-39
P-26036
Inspect the bearings for any damage [Figure 40-50-41].
If the bearings need replacement, the bearing races must
P-26049 be replaced also.
Check the male yoke [Figure 40-50-39].
A220 Bobcat Loader
40-50-10 Service Manual
HUB (CONT’D) Figure 40-50-44
Assembly
Figure 40-50-42 1
1
2
P-26039
1 3
Use MEL1605 and install new bearing races (Item 1)
P-26047 [Figure 40-50-44] in the housing.
Figure 40-50-45
Install the female yoke (Item 1) and the male yoke (Item
2) to the U-joint (Item 3) [Figure 40-50-42].
Figure 40-50-43
1 1
1
1 1
P-26051
Pack the bearing with lithium grease.
P-26046
Install the new bearing (Item 1) [Figure 40-50-45] in the
inside of the housing.
Install the eight mounting bolts (Item 1) [Figure 40-50-
43] and tighten to 90-110 ft.-lbs (122-149 Nm) torque.
A220 Bobcat Loader
40-50-11 Service Manual
HUB (CONT’D) Figure 40-50-48
Assembly (Cont'd)
Figure 40-50-46
P-26053
Install the yoke assembly (Item 1) [Figure 40-50-48] into
P-26043 the seal.
Figure 40-50-49
Figure 40-50-47
1
1
P-26037
P-26052
Use MEL1606 and install the inner seal (Item 1) [Figure
40-50-46] & [Figure 40-50-47] with the metal side of the
seal away from the bearing.
A220 Bobcat Loader
40-50-12 Service Manual
HUB (CONT’D) Figure 40-50-52
Assembly (Cont'd)
Figure 40-50-50
P-26033
Install the spacer (Item 1) [Figure 40-50-52] on the hub.
P-26041
Figure 40-50-53
Use MEL1606 and install the seal (Item 1) [Figure 40-50-
49] & [Figure 40-50-50] with the letter stamped side 1
away from the bearing.
Figure 40-50-51
1
P-26054
Install the hub assembly (Item 1) [Figure 40-50-53] on
the spline shaft in the housing.
P-26034
Pack the bearing with lithium grease.
Install the bearing (Item 1) [Figure 40-50-51] on the hub.
A220 Bobcat Loader
40-50-13 Service Manual
HUB (CONT’D) Figure 40-50-55
Assembly (Cont'd)
Figure 40-50-54
P-26031
1
Install the hub retainer bolt and washer (Item 1) [Figure
P-26040 40-50-55]. Tighten the bolt to 350 ft.-lbs. (475 Nm)
torque.
Install the O-ring (Item 1) [Figure 40-50-54] on the back
side of the hub retainer washer.
A220 Bobcat Loader
40-50-14 Service Manual
MAIN FRAME
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Bob-Tach Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-4 SAFETY &
Pivot Pin Bushing And Seal Replacement . . . . . . . . . . . . . 50-40-5 MAINTENANCE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Joystick Boot Removal (Right & Left) . . . . . . . . . . . . . . . . 50-90-3
Joystick Removal (Right & Left). . . . . . . . . . . . . . . . . . . . . 50-90-2
Joystick Testing (Right & Left) . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Lever Assembly Removal (Right & Left) . . . . . . . . . . . . . . 50-90-3 DRIVE
SYSTEM
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1 MAIN FRAME
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
Fuel Pick-Up Screen/Check Valve . . . . . . . . . . . . . . . . . . . 50-80-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1 ELECTRICAL
SYSTEM &
INSIDE ACCESS PANEL (EARLY MODELS) . . . . . . . . . . . . 50-110-1 ANALYSIS
Panel Removal (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-2
Panel Removal (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
ENGINE
INSIDE ACCESS PANEL (LATER MODELS) . . . . . . . . . . . . .50-111-1 SERVICE
Panel Removal (Right). . . . . . . . . . . . . . . . . . . . . . . . . . . .50-111-1
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1 SPECIFICATIONS
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Gas Cylinder Bracket Disassembly and Assembly . . . . . . 50-20-4
Gas Cylinder Removal And Installation (Dual Gas Spring) 50-20-1
Gas Cylinder Removal And Installation (3rd Gas Spring) . 50-20-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-4
OPERATOR SEAT (STANDARD) . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . 50-30-1
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . 50-31-1
Back Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-31-3
Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . 50-31-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-1
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . 50-31-4
Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . 50-31-2
Continued On Next Page
A220 Bobcat Loader
50-01 Service Manual
MAIN FRAME (CONT’D)
POWER BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . 50-41-1
Power Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . 50-41-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-3
Pivot Pin Bushing And Seal Replacement . . . . . . . . . . . . . 50-41-5
REAR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Adjusting The Rear Door Latch . . . . . . . . . . . . . . . . . . . . . 50-70-2
Adjusting The Striker (Later Loaders) . . . . . . . . . . . . . . . . 50-70-3
Latch Removal And Installation (Later Loaders) . . . . . . . . 50-70-4
Removal And Installation (Early Loaders) . . . . . . . . . . . . . 50-70-1
Striker Removal And Installation (Later Loaders) . . . . . . . 50-70-3
REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Removal And Installation (Early Loaders) . . . . . . . . . . . . . 50-60-1
SEAT BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Assembling Components . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
Compression Spring Disassembly And Assembly . . . . . . . 50-10-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
A220 Bobcat Loader
50-02 Service Manual
SEAT BAR Figure 50-10-3
Removal And Installation
Figure 50-10-1
1 N-18572
Raise the loader operator cab. (See OPERATOR CAB on
P-24263 Page 10-30-1.)
Remove the seat bar mounting nuts (Item 1) [Figure 50-
Raise the seat bar (Item 1) [Figure 50-10-1]. 10-3] (both sides).
Figure 50-10-2 Installation: Tighten the nuts to 28ft.-lbs (38 Nm)
torque.
Lower the operator cab. (See Lowering The Operator
Cab on Page 10-30-2.)
Figure 50-10-4
N-18463
Disconnect the seat bar sensor (Item 1) [Figure 50-10-2]
from the cab harness.
Lower the seat bar.
N-19224
Remove the seat bar (Item 1) [Figure 50-10-4] from the
operator cab.
Reverse the above procedure to install the seat bar into
the operator cab.
A220 Bobcat Loader
50-10-1 Service Manual
SEAT BAR (CONT’D) Seat Bar Mount (Item 1)
Mounting Bolt (Item 2)
Assembling Components Keyed Plastic Bushing (Item 3)
Seat Bar (Item 4)
Figure 50-10-5 Magnetic Bushing Assembly (Item 5)
Pivot Bushing (Item 6)
4 Sensor Bracket (Item 7)
5 6
Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9)
7 Mounting Nut (Item 10)
3
Installation: Tighten the mounting bolt (Item 2) [Figure
50-10-5] & [Figure 50-10-6] to 50-70 in.-lbs. (5,6-7,9
2 8 Nm) torque.
9
10
1
N-19383
Figure 50-10-6
4 9
5 8
3 6
2 10
N-19219
Assemble the parts as shown for the left side of the seat
bar pivot assembly [Figure 50-10-5] & [Figure 50-10-6].
A220 Bobcat Loader
50-10-2 Service Manual
SEATBAR (CONT’D) Seat Bar Mount (Item 1)
Mounting Nut (Item 2)
Assembling Components (Cont'd) Pivot Bushing (Item 3)
Spacer Bushing (Item 4)
Figure 50-10-7 Seat Bar (Item 5)
Keyed Plastic Bushing (Item 6)
5 Mounting Bolt (Item 7)
6
4
Installation: Tighten the mounting bolt (Item 7) [Figure
3 50-10-7] & [Figure 50-10-8] to 50-70 in.-lbs. (5,6-7,9 Nm)
torque.
2 7
N-19340
Figure 50-10-8
4
2 3 5
6
N-19220
Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-7] & [Figure 50-10-8].
A220 Bobcat Loader
50-10-3 Service Manual
SEATBAR (CONT’D) Assembly: Apply LOCTITE #518 adhesive to the bolt
threads. Adjust the compression spring by turning the
Compression Spring Disassembly And Assembly bolt in past the end of the clevis three turns.
Figure 50-10-9 NOTE: For procedures requiring the use of LOCTITE
#518 adhesive, thoroughly clean and dry
affected parts before the application of
1
LOCTITE #518
N-19222
Figure 50-10-10
6 7
5
4 6
2
1
N-19384
Turn the bolt (Item 1) [Figure 50-10-9] & [Figure 50-10-
10] out of the clevis.
A220 Bobcat Loader
50-10-4 Service Manual
OPERATOR CAB Figure 50-20-2
Gas Cylinder Removal And Installation (Dual Gas
Spring)
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death.
W-2113-0288
1
Figure 50-20-1 N-19621
Raise the operator cab stop. (See Raising The Operator
Cab on Page 10-30-1.)
2
Remove the bolts (Item 1) [Figure 50-20-2] from the gas
cylinder mounting brackets,
N-19619
Remove the operator cab stop (Item 1) [Figure 50-20-1]
(both sides).
Note: If the operator cab is equipped with a rear
window, the rear grill and rear grill mounts
(Item 2) [Figure 50-20-1] must be removed to
prevent window damage
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the bolts (Item 1) [Figure 50-20-2] from the gas
cylinder mounting bracket.
A220 Bobcat Loader
50-20-1 Service Manual
OPERATOR CAB (CONT’D) Gas Cylinder Removal And Installation (3rd Gas
Spring)
Gas Cylinder Removal And Installation (Dual Gas
Spring) (Cont’d)
Figure 50-20-3
WARNING
Cylinder contains high pressure gas. Do not open.
1
Opening cylinder can release rod and cause injury or
death.
W-2113-0288
Figure 50-20-5
N-19651
Figure 50-20-4
P-31545
1
Remove the operator cab stop (Item 1) (Item 1) [Figure
50-20-5]. (Both sides.)
NOTE: Be careful not to break the rear window (if so
equipped) when the cab is raised after the cab
stops are removed.
N-19652 Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Use a pliers to unlock cotter pin (Item 1) [Figure 50-20-3]
& [Figure 50-20-4].
NOTE: Cotter pin (Item 1) [Figure 50-20-4] is shown in
locked position.
Remove the cotter pin.
Remove the gas cylinder.
Installation: Twist the ends of cotter pin to re-lock it.
A220 Bobcat Loader
50-20-2 Service Manuel
OPERATOR CAB (CONT’D) Figure 50-20-8
Gas Cylinder Removal And Installation (3rd Gas
Spring) (Cont'd)
Figure 50-20-6
2
1
P-43354
1
Remove the retaining pins (Item 1) [Figure 50-20-8] from
the lower pivot pins.
P-43839
Remove the gas cylinders (Item 2) [Figure 50-20-8] from
the operator cab.
Install a chain (Item 1) [Figure 50-20-6] from the
operator cab to the loader main frame to prevent the cab
from tipping forward when the gas cylinder(s) are
removed.
Figure 50-20-7
P-39601
Remove the retaining pins (Item 1) [Figure 50-20-7] from
the cab pivot pins.
A220 Bobcat Loader
50-20-3 Service Manual
OPERATOR CAB (CONT’D) Removal And Installation
Gas Cylinder Bracket Disassembly and Assembly Figure 50-20-11
Figure 50-20-9
2
1
1
1
N-19365
P1008
Remove the cab nut and holddown plate (Item 1) [Figure
50-20-11] (both sides).
Remove the clevis (Item 1)and washer (Item 2) [Figure
50-20-9] from the end of the gas cylinder. Installation: Tighten the nut to 40-50 ft.-lbs. (54-68Nm)
Remove the gas cylinder from the outer housing. Figure 50-20-12
Assembly: Install a replacement cylinder inside the
cylinder housing.
Figure 50-20-10 2
P1006
Apply a small amount of LOCTITE on the threads of the
cylinder rod [Figure 50-20-10].
N-19623
Reinstall the washer and clevis on the cylinder rod.
Disconnect the wiring harness connectors (Item 1)
[Figure 50-20-12].
Disconnect the operator cab ground wire (Item 2) [Figure
50-20-2]
A220 Bobcat Loader
50-20-4 Service Manuel
OPERATOR CAB (CONT’D) Figure 50-20-15
Removal And Installation (Cont’d)
Figure 50-20-13
1
P7713
Move the operator cab forward a small amount for
P-26612 clearance at the pivot mounting brackets [Figure 50-20-
15].
Install a sling (Item 1) [Figure 50-20-13] on the grab Install the pivot bolt, washer (one on each side) and nut
handles of the operator cab. Connect a chain hoist to the (Item 1) [Figure 50-20-15] (both sides).
sling.
Install the sling under the pivot bolt and pivot of the
Remove both gas cylinders. (See Gas Cylinder Removal operator cab [Figure 50-20-15].
And Installation (Dual Gas Spring) on Page 50-20-1.)
After the gas cylinders are removed, lower the operator
cab using the chain hoist.
Figure 50-20-14
N-19620
Remove the nut (Item 1) [Figure 50-20-14] from the pivot
bolt (both sides).
Installation: Tighten the pivot bolt and nut to 25-35 ft.-
lbs. (34-47 Nm) torque.
Remove the pivot bolt (both sides).
A220 Bobcat Loader
50-20-5 Service Manual
OPERATOR CAB (CONT’D)
Removal And Installation (Cont’d)
Figure 50-20-16
P-26614
Connect the slings to a chain hoist and remove the
operator cab from the loader [Figure 50-20-16].
A220 Bobcat Loader
50-20-6 Service Manuel
OPERATOR SEAT (STANDARD) Seat Belt Removal And Installation
Removal And Installation Figure 50-30-3
Figure 50-30-1
1
1
2
1
N-20729A
N-20729
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.) Locate the seat belt bolts under seat pan insulation
(Items 1 & 2) [Figure 50-30-3] and peel back or cut
Remove the four seat mounting nuts (Item 1) [Figure 50- insulation to gain access to the head.
30-1] and washers from the operator seat mounting
studs. Figure 50-30-4
Installation: Tighten the mounting nuts to 20 ft.-lbs. (27
Nm) torque.
NOTE: Ensure the washers are installed.
Figure 50-30-2
N-20655
Remove the two nuts (Items 1 & 2) [Figure 50-30-4].
Installation: Tighten nut (Item 1) to 54 ft.-lbs. (73 Nm)
torque. Tighten nut (Item 2) [Figure 50-30-4] to 34 ft.-lbs.
P10564 P10563 (46 Nm) torque.
Repeat for other half of seat belt and guide
Lower the cab and install one of the mounting washer
and nut [Figure 50-30-2].
NOTE: With the seat removed the cab will raise.
Reverse the removal procedure to install the operator
seat.
A220 Bobcat Loader
50-30-1 Service Manual
A220 Bobcat Loader
50-30-2 Service Manual
OPERATOR SEAT (SUSPENSION) Figure 50-31-3
Removal And Installation
Figure 50-31-1
1
1
1
2
N-20974
NOTE: Assure seat tethers are securely fastened to
N-20647 seatbelt studs (Item 1) and seat rail studs
(Item 2) [Figure 50-31-3].
Raise the operator cab. (See Raising The Operator Cab Figure 50-31-4
on Page 10-30-1.)
Remove the four seat mounting nuts (Item 1) [Figure 50-
31-1] and washers from the operator seat mounting
studs.
Installation: Tighten the mounting nuts to 20 ft.-lbs. (27
Nm) torque.
Figure 50-31-2
N-20973
NOTE: Verify the front two seat rail studs have
washers attached (Item 1) [Figure 50-31-4].
P10564 P10563
Lower the cab and install one of the mounting washer
and nut [Figure 50-31-2].
NOTE: With the seat removed the cab will raise.
Reverse the removal procedure to install the operator
seat.
A220 Bobcat Loader
50-31-1 Service Manual
OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-31-7
Slide Rail Removal And Installation
2
Figure 50-31-5 1 1
1
1
2
2
1
1
N-18582
Figure 50-31-8
N-18587
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.) 1
Remove the operator seat. (See OPERATOR SEAT
(STANDARD) on Page 50-30-1.)
Remove the two slide rail mounting bolts (Item 1) [Figure
50-31-5].
Remove the slide rail (Item 2) [Figure 50-31-5] from the
bottom of the seat frame.
N-18581
Reverse the removal procedure to install the operator
seat back side rail.
Remove the cushion (Item 2) [Figure 50-31-7] from the
Cushion Removal And Installation seat frame (Item 1) [Figure 50-31-8].
Figure 50-31-6
N-18579
Press the two buttons (Item 1)[Figure 50-31-6] & [Figure
50-31-7] and lift the seat cushion.
A220 Bobcat Loader
50-31-2 ServiceManual
OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-31-11
Cushion Removal And Installation (Cont’d)
Figure 50-31-9
1 1
N-18578
Remove the two mounting screws (Item 1) [Figure 50-
N-18580 31-11] from the seat back and remove the back.
Reverse the removal procedure to install the operator
Inspect the seat ride adjustment [Figure 50-31-9]. seat back.
Reverse the removal procedure to install the operator
seat back.
Back Removal And Installation
Figure 50-31-10
N-18583
Pull the seat back adjustment lever (Item 1) [Figure 50-
31-10] and tilt the seat back all the way forward.
A220 Bobcat Loader
50-31-3 Service Manual
OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-31-14
Shock Removal And Installation
Figure 50-31-12 1
1
1
1 2 N-18586
NOTE: The seat shock mounting studs (Item 1)
N-18584 [Figure 50-31-14] are replaceable.
Reverse the removal procedure to install the operator
Figure 50-31-13 seat shock.
N-18585
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the operator seat. (See OPERATOR SEAT
(SUSPENSION) on Page 50-31-1.)
Remove the seat shock retaining pin (Item 1) [Figure 50-
31-12] & [Figure 50-31-13] (Both ends.)
Remove the seat shock (Item 2) [Figure 50-31-12] &
[Figure 50-31-13].
A220 Bobcat Loader
50-31-4 ServiceManual
BOB-TACH Figure 50-40-3
Removal And Installation
Figure 50-40-1
P7695
Remove the rod end pivot pin (Item 1) [Figure 50-40-3].
P7694
Figure 50-40-4
With the lift arms all the way down, tilt the Bob-Tach
forward so it is parallel to the floor [Figure 50-40-1].
Figure 50-40-2
P-3911
Remove the tilt cylinder rod end.
P7693 Remove the seals (Item 1) [Figure 50-40-4].
Remove the retainer bolt (Item 1) [Figure 50-40-2] from
the pivot pin.
Installation: Tighten the retainer bolt to 18-20 ft.-lbs. (24-
27 Nm) torque.
A220 Bobcat Loader
50-40-1 Service Manual
BOB-TACH (CONT’D) Figure 50-40-7
Removal And Installation (Cont’d)
Figure 50-40-5
P7696
Install an adapter (Item 1) [Figure 50-40-7] into the Bob-
P-3910 Tach pivot pin.
Install the slide hammer into the adapter and pull the
Installation: Use two pieces of shim stock (light pivot pin from the lift arms/Bob-Tach.
cardboard), install the rod end of the tilt cylinder into the
Bob-Tach [Figure 50-40-5]. NOTE: Always inspect Bob-Tach pivot pin bushings
and seals in lift arm for wear or damage.
Be careful not to damage the seals during installation. Replace as needed.
NOTE: Removal procedure is shown for the right
side. Left side procedure is the same.
Figure 50-40-6
P7697
Remove the retainer bolt and nut (Item 1) [Figure 50-40-
6] from the Bob-Tach pivot pin.
Installation: Tighten the bolt and retainer nut to 25 ft.-
lbs. (34 Nm) torque.
A200 Bobcat Loader
50-40-2 Service Manual
BOB-TACH (CONT’D) Figure 50-40-10
Bob-Tach Lever And Wedge
Figure 50-40-8
P7681
Remove the Bob-Tach lever (Item 1) [Figure 50-40-10].
P7694
Figure 50-40-11
Use the following procedure to remove and install the
Bob-Tach lever, spring, and wedge.
With the lift arms fully down, tilt the Bob-Tach forward so
it is parallel with the floor [Figure 50-40-8].
1
Figure 50-40-9
P7682
Remove the roll pin (Item 1) [Figure 50-40-11] from the
Bob-Tach wedge assembly.
3
1
2
P7680
Remove the lever mounting nut (Item 1), washer (Item 2)
and spring (Item 3) [Figure 50-40-9].
Installation: Tighten the nut to 25-28 ft.-lbs. (34-38 Nm)
torque.
A220 Bobcat Loader
50-40-3 Service Manual
BOB-TACH (CONT’D) Reverse the removal procedure to install the Bob-Tach
lever and wedge assembly.
Bob-Tach Lever And Wedge (Cont’d)
Bob-Tach Stops
Figure 50-40-12
Figure 50-40-14
P7683
P7952
Remove the spring, bolt and clevis assembly (Item 1)
[Figure 50-40-12]. Remove and replace the Bob-Tach stop (Item 1) [Figure
50-40-14] (both sides) if worn or damaged.
Remove the wedge from the Bob-Tach frame.
NOTE: The Bob-Tach stop (Item 1) [Figure 50-40-14]
Always replace bent or broken wedges. must contact the lift arm at the same time the
tilt cylinder reaches full extension. Use
Figure 50-40-13 available shims to adjust the Bob-Tach stop
and tilt cylinder sequence as closely as
possible.
5
4
3
P7684
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3)
or clevis (Item 4) are damaged, put the assembly in the
vise for disassembly. Loosen and remove the bolt (Item
1) [Figure 50-40-13] with a 5/16 inch allen wrench.
Replace the worn or damaged parts as needed.
Before installation of the parts, put grease on the handle
pivot (Item 2), Bob-Tach handle pivot (Item 5), and bolt
(Item 1) [Figure 50-40-13].
A200 Bobcat Loader
50-40-4 Service Manual
BOB-TACH (CONT’D) Figure 50-40-17
Pivot Pin Bushing And Seal Replacement
Figure 50-40-15
P7950
Use a driver to install new seals. The pivot pin can be
P7948 used to locate seal [Figure 50-40-17].
Use a seal pick to remove seals (Item 1) [Figure 50-40-
15] on both sides of pivot bushing.
Figure 50-40-16
P7949
Remove and replace bushing with a driver tool and
hammer [Figure 50-40-16].
A220 Bobcat Loader
50-40-5 Service Manual
A200 Bobcat Loader
50-40-6 Service Manual
POWER BOB-TACH Figure 50-41-3
Inspection And Maintenance
Bob-Tach
Wedge
Figure 50-41-1
Front Accessory Panel
Wedge Must Contact
Lower Edge Of Hole
In The Attachment B-15177
The wedges must extend through the holes in the
B-15891 attachment mounting frame (Item 1) [Figure 50-41-2].
B-15891
The spring loaded wedge must contact the lower edge of
Move the Power Bob-Tach switch [Figure 50-41-1] to the hole in the attachment (Item 1) [Figure 50-41-2] and
engage the wedges. The levers and wedges must move [Figure 50-41-3].
freely.
If the wedge does not contact the lower edge of the hole
[Figure 50-41-2] and [Figure 50-41-3], the attachment
will be loose and can come off the Bob-Tach.
WARNING Figure 50-41-4
Bob-Tach wedges must extend through the holes in
attachment. Levers must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588
Figure 50-41-2
TS-1062
Inspect the mounting frame on the attachment and the
1 Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 50-41-4]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
N-17991 Look for cracked welds. Contact your Bobcat dealer for
repair or replacement parts.
Lubricate the wedges (See LUBRICATING THE
LOADER on Page 10-160-1.)
A220 Bobcat Loader
50-41-1 Service Manual
POWER BOB-TACH (CONT’D) Figure 50-41-7
Power Bob-Tach Lever And Wedge
Figure 50-41-5
1
2
P7681
2
Remove the Bob-Tach lever (Item 1) [Figure 50-41-7].
N-21417
Figure 50-41-8
Use the following procedure to remove and install the
Bob-Tach lever, spring, and wedge.
With the lift arms fully down, tilt the Bob-Tach forward so
it is parallel with the floor.
1
Remove the cylinder hoses (Item 1) [Figure 50-41-5].
Remove the cylinder mounting bolts and washers (Item
2) [Figure 50-41-5].
Figure 50-41-6
P7682
Remove the roll pin (Item 1) [Figure 50-41-8] from the
Bob-Tach wedge assembly.
1
2
3
N-21416
Remove the lever mounting nut (Item 1), washer (Item 2)
and spring (Item 3) [Figure 50-41-6].
Installation: Tighten the nut to 25-28 ft.-lbs. (34-38 Nm)
torque.
A220 Bobcat Loader
50-41-2 Service Manual
POWER BOB-TACH (CONT’D) Reverse the removal procedure to install the Bob-Tach
lever and wedge assembly.
Power Bob-Tach Lever And Wedge (Cont’d)
Removal And Installation
Figure 50-41-9
Figure 50-41-11
P7683
N-21417
Remove the spring, bolt and clevis assembly (Item 1)
[Figure 50-41-9]. With the lift arms all the way down, tilt the Bob-Tach
forward so it is parallel to the floor [Figure 50-41-11]
Remove the wedge from the Bob-Tach frame.
Figure 50-41-12
Always replace bent or broken wedges.
Figure 50-41-10
5 1
P7693
4 3
P7684 Remove the retainer bolt (Item 1) [Figure 50-41-12] from
the pivot pin.
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3) Installation: Tighten the retainer bolt to 18-20 ft.-lbs. (24-
or clevis (Item 4) are damaged, put the assembly in the 27 Nm) torque.
vise for disassembly. Loosen and remove the bolt (Item
1) [Figure 50-41-10] with a 5/16 inch allen wrench.
Replace the worn or damaged parts as needed.
Before installation of the parts, put grease on the handle
pivot (Item 2), Bob-Tach handle pivot (Item 5), and bolt
(Item 1) [Figure 50-41-10].
A220 Bobcat Loader
50-41-3 Service Manual
POWER BOB-TACH (CONT’D) Figure 50-41-15
Removal And Installation(Cont’d)
Figure 50-41-13
P-3910
1
Installation: Use two pieces of shim stock (light
P7695 cardboard), install the rod end of the tilt cylinder into the
Bob-Tach [Figure 50-41-15].
Remove the rod end pivot pin (Item 1) [Figure 50-41-13]. Be careful not to damage the seals during installation.
Figure 50-41-14 NOTE: Removal procedure is shown for the right
side. Left side procedure is the same.
Figure 50-41-16
P-3911
Remove the tilt cylinder rod end.
P7697
Remove the seals (Item 1) [Figure 50-41-14].
Remove the retainer bolt an nut (Item 1) [Figure 50-41-
16] from the Bob-Tach pivot pin.
Installation: Tighten the bolt and retainer nut to 25 ft.-
lbs. (34 Nm) torque.
A220 Bobcat Loader
50-41-4 Service Manual
POWER BOB-TACH (CONT’D) Pivot Pin Bushing And Seal Replacement
Removal And Installation (Cont’d) Figure 50-41-19
Figure 50-41-17
1
P7948
P7696
Use a seal pick to remove seals (Item 1) [Figure 50-41-
19] on both sides of pivot bushing.
Install an adapter (Item 1) [Figure 50-41-17] into the
Bob-Tach pivot pin. Figure 50-41-20
Install the slide hammer into the adapter and pull the
pivot pin from the lift arms/Bob-Tach.
NOTE: Always inspect Bob-Tach pivot pin bushings
and seals in lift arm for wear or damage.
Replace as needed.
Figure 50-41-18
1
P7949
Remove and replace bushing with a driver tool and
hammer [Figure 50-41-20].
P7952
Remove and replace the Bob-Tach stop (Item 1) [Figure
50-41-18] (both sides) if worn or damaged.
NOTE: The Bob-Tach stop (Item 1) [Figure 50-41-18]
must contact the lift arm at the same time the
tilt cylinder reaches full extension. Use
available shims to adjust the Bob-Tach stop
and tilt cylinder sequence as closely as
possible.
A220 Bobcat Loader
50-41-5 Service Manual
POWER BOB-TACH (CONT’D)
Pivot Pin Bushing And Seal Replacement (Cont’d)
Figure 50-41-21
P7950
Use a driver to install new seals. The pivot pin can be
used to locate seal [Figure 50-41-21].
A220 Bobcat Loader
50-41-6 Service Manual
LIFT ARMS Figure 50-50-3
Removal And Installation
Figure 50-50-1
1
1
P-26619
1
Remove the tilt tubeline mounting clamp (Item 1) [Figure
P7729 50-50-3] from the back of the lift arm crossmember.
In the operator cab, turn the ignition key to the ON
The items listed are necessary for the following position.
procedure:
Press the PRESS TO OPERATE button.
Three Lifting Straps - 7 ft. in length (with looped ends)
Chain Hoist Place the seat bar in the down position.
Install jackstands under the rear corners of the loader. Place the loader lift pedal (Handle, with AHC) in the float
position.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the two auxiliary tubeline clamps (Item 1)
[Figure 50-50-1] from the left lift arm (if so equipped).
Figure 50-50-2
N-19654
Remove the two mounting bolts (Item 1) [Figure 50-50-
2] from the front auxiliary quick coupler mounting bracket
(if so equipped).
A220 Bobcat Loader
50-50-1 Service Manual
LIFT ARMS (CONT’D) Remove the tilt tubelines from the lift arms and put the tilt
cylinder on the floor.
Removal And Installation (Cont'd)
Figure 50-50-6
Figure 50-50-4
1
2
2
3
1
P7728
P7726
Remove the lift arm support device mounting bolt and nut
Figure 50-50-5 (Item 1) [Figure 50-50-6].
Installation: Tighten the mounting bolt and nut to 15-17
ft.-lbs. (20-23 Nm) torque.
Remove the nut and retainer bolt (Item 2) [Figure 50-50-
6] from the pivot pin for the lift cylinder rod end (both
sides).
Installation: Tighten the retainer bolt and nut to 15-17 ft.-
lbs. (20-23 Nm) torque.
Remove the pivot pin for the lift cylinder (both sides).
1
NOTE: Drive out all pivot pins from the opposite side
P7730 that the retainer bolt was removed from.
Remove the lift arm support device (Item 3) [Figure 50-
Wrap the lifting strap around the lift arm crossmember as 50-6].
shown in Figure [Figure 50-50-4]. Connect both loops of
the lifting strap to a chain hoist. Lower the lift arms with the chain hoist.
Raise the lift arms enough to remove the auxiliary
tubelines (if so equipped) from the lift arms [Figure 50-
50-5].
Remove the Bob-Tach from the lift arms. (See POWER
BOB-TACH on Page 50-41-1.)
Remove the nut and retainer bolt (Item 1) [Figure 50-50-
4] from the pivot pin for the base of the tilt cylinder.
Remove the pivot pin from the base end of the tilt cylinder
(Item 2) [Figure 50-50-4].
Remove the tilt cylinder (Item 1) [Figure 50-50-5] from
the lift arms.
A220 Bobcat Loader
50-50-2 Service Manual
LIFT ARMS (CONT’D) Figure 50-50-9
Removal And Installation (Cont'd)
Figure 50-50-7
P-26618
Raise the lift arms with the chain hoist so the lift arms are
P-26621 free from the loader.
Pull the lift arms away from the loader [Figure 50-50-9].
Install the lift strap on the lift arm as shown in [Figure 50-
50-7] (both sides). Lower the lift arms slowly and put them on the floor.
Install the pivot pin (Item 1) [Figure 50-50-7] retainer bolt
and nut (both sides).
Connect the loops of the lifting straps to the chain hoist
(both lift straps).
Figure 50-50-8
P-26620
Remove the nut and retainer bolt (Item 1) [Figure 50-50-
8] from the lift arm pivot pin (both sides).
Installation: Tighten the retainer bolt and nut to 15-17 ft.-
lbs. (20-23 Nm) torque.
Remove the pivot pin (Item 2) [Figure 50-50-8] from the
lift arms (both sides).
A220 Bobcat Loader
50-50-3 Service Manual
A220 Bobcat Loader
50-50-4 Service Manual
REAR GRILL Figure 50-60-3
Removal And Installation
Figure 50-60-1 1
P7946
Lower the rear grill.
N-19411
Remove the cotter pin and the pivot pin (Item 1) [Figure
50-60-3] (both sides).
Raise the rear grill [Figure 50-60-1].
Figure 50-60-4
Support the rear grill.
Figure 50-60-2
P7947
N-19412 Remove the rear grill from the loader [Figure 50-60-4].
Remove the nut (Item 1) [Figure 50-60-2] to disconnect
the gas cylinder from the rear grill.
A220 Bobcat Loader
50-60-1 Service Manual
A220 Bobcat Loader
50-60-2 Service Manual
REAR DOOR Figure 50-70-2
Removal And Installation (Early Loaders)
2
Figure 50-70-1
P10889
1
Open the rear door.
Disconnect the light harness connector (Item 1) [Figure
50-70-1] from the engine harness.
Remove the light bulbs from the light housing and
P-26617
remove the light housing (Item 2) [Figure 50-70-1] from
the rear door (both sides).
Install a nylon sling (Item 1) [Figure 50-70-2] through the
holes for the light housings.
Connect a chain hoist (Item 2) [Figure 50-70-2] to the
nylon sling.
A220 Bobcat Loader
50-70-1 Service Manual
REAR DOOR (CONT’D) Adjusting The Rear Door Latch
Removal And Installation (Early Loaders) (Cont’d) Figure 50-70-4
Figure 50-70-3
2
1
N-19320
The door catch (Item 1) [Figure 50-70-4] can be adjusted
side to side for alignment with the door latch.
Figure 50-70-5
1
N-19658
1
Remove the nuts from the top and bottom hinge bolts
(Item 1) [Figure 50-70-3] and remove the hinge bolts.
N-19321
Installation:Tigthen the mounting bolts and nuts to 25-28
ft.-lbs. (34-38 Nm) torque. The door stop (Item 2) [Figure
50-70-3] is installed in the top hinge bolt. The door latch (Item 1) [Figure 50-70-5] can be adjusted
forward or backward for alignment with the door catch.
Remove the rear door from the loader frame and lay it flat
on the floor.
A220 Bobcat Loader
50-70-2 Service Manual
REAR DOOR (CONT’D) Adjusting The Striker (Later Loaders)
Striker Removal And Installation (Later Loaders) Figure 50-70-7
Figure 50-70-6
1
1
P-31126
1
P-31126
Loosen the two striker assembly mount bolts (Item 1)
[Figure 50-70-7].
Remove the two striker mount bolts (Item 1) [Figure 50-
70-6]. Align the striker assembly in the center of the mounting
holes.
Remove the striker assembly from the loader.
Tighten the striker assembly, top mount bolt only, until it
will hold the striker assembly in the enter of the mounting
slots.
Shut the rear door. (This will align the striker assembly to
the correct position.)
Open the rear door.
Tighten both striker mount bolts (Item 1) [Figure 50-70-
7].
Close the rear door.
A220 Bobcat Loader
50-70-3 Service Manual
REAR DOOR (CONT’D) Figure 50-70-10
Latch Removal And Installation (Later Loaders)
Figure 50-70-8
P-31128
Remove the lever (Item 1) [Figure 50-70-10] from the
1 rear door.
P-31125
Disconnect the spring (Item 1) [Figure 50-70-8] from the
tailgate.
Remove the bolt and nut (Item 2) [Figure 50-70-8] from
the door latch.
Figure 50-70-9
P-31127
Remove the spring (Item 1) [Figure 50-70-9] from the
door handle.
Remove the spring (Item 2) [Figure 50-70-9] from the
door latch.
Remove the door latch (Item 3) [Figure 50-70-9] from the
lever.
A220 Bobcat Loader
50-70-4 Service Manual
FUEL TANK Figure 50-80-3
Removal And Installation
Figure 50-80-1 2
1
P4855
Disconnect the fuel fill hose (Item 1) [Figure 50-80-3].
P1616
Disconnect the tank vent hose (Item 2) [Figure 50-80-3].
Remove the cover (Item 1) [Figure 50-80-1] which is Figure 50-80-4
installed over the drain plug.
Figure 50-80-2
P7918
P1619 Remove the bolts (Item 1) [Figure 50-80-4] from the
battery holddown plate.
Remove the drain plug (Item 1) [Figure 50-80-2]. Remove the battery holddown plate from the loader.
Drain the fuel into a container.
Check the drain plug and replace if necessary.
Remove the engine/hydrostatic pump assembly from the
loader. (See ENGINE on Page 70-80-1.)
A220 Bobcat Loader
50-80-1 Service Manual
FUEL TANK (CONT’D) Figure 50-80-7
Removal And Installation (Cont'd)
Figure 50-80-5
P7922
Check the fuel level sender with an ohmmeter as follows
P7923 [Figure 50-80-7]
Fuel Level - 30 Seconds Delay
Remove the mounting plate (Item 1) [Figure 50-80-5] for Full - 30 ohms
the battery holdown plate. Empty - 270 ohms
Short - 0 ohms
Lift the fuel tank and remove it from the loader frame. Open - 300+ ohms
Fuel Level Sender Fuel float and magnet must slide freely on the shaft
[Figure 50-80-7].
Figure 50-80-6
Fuel Pick-Up Screen/Check Valve
2 Figure 50-80-8
3 2
3
1
1
P7921
Remove the fuel level sender (Item 1) [Figure 50-80-6].
P7919
The fuel pick-up screen/check valve (Item 1) [Figure 50-
80-8] is located in the fuel tank, connected to the fitting
(Item 2) [Figure 50-80-6].
Inspect the screen/check valve, hose and grommets.
Inspect the clamp (Item 3) [Figure 50-80-6] and (Item 2)
[Figure 50-80-8]. Replace the parts as needed.
A220 Bobcat Loader
50-80-2 Service Manual
CONTROL Figure 50-90-3
Joystick Testing (Right & Left)
1
Figure 50-90-1
1 2
P-28312
Disconnect the joystick harness connector (Item 1)
P-28301 [Figure 50-90-3] from the loader wiring harness (Item 2)
[Figure 50-90-3].
The tools listed will be needed to do the following Install the test harness (Item 3) [Figure 50-90-3]
procedure: between the two connectors.
MEL1608-Joystick Test Harness [Figure 50-90-1] Turn the remote start key to ON position without starting
MEL1563-Remote Start Tool Multimeter the loader.
Check the voltage between pin 3 and pin 5 on the joystick
Figure 50-90-2 test harness (Item 3) [Figure 50-90-3].
The voltage should be between 2.45 and 2.55 volts.
Figure 50-90-4
P-28311
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
P-28310
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab Repeat the procedure at the right joystick wiring harness
on Page 10-30-1.) connector (Item 1) [Figure 50-90-4]. (If needed.)
Connect the remote start tool to the loader. (See
REMOTE START on Page 10-60-1.)
At the back side of the control panel, locate the left
joystick wire connector (Item 1) [Figure 50-90-2].
A220 Bobcat Loader
50-90-1 Service Manual
CONTROL (CONT’D) Figure 50-90-7
Joystick Removal (Right & Left)
Figure 50-90-5
1
P-26222
Remove the two outside joystick mount bolts (Item 1)
P-26220 [Figure 50-90-7].
Figure 50-90-8
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Roll the joystick rubber boot (Item 1) [Figure 50-90-5]
down from the joystick handle.
Figure 50-90-6
1
P-26223
Remove the joystick from the rubber boot [Figure 50-90-
8].
P-26221
Remove the two inside joystick mount bolts (Item 1)
[Figure 50-90-6].
A220 Bobcat Loader
50-90-2 Service Manual
CONTROL (CONT’D) Lever Assembly Removal (Right & Left)
Joystick Boot Removal (Right & Left) Figure 50-90-11
Figure 50-90-9
1
1
P-26226
P-26224
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Disconnect the electrical harness (Item 1) [Figure 50-90- Page 10-20-1.)
9] from the joystick.
Raise the operator cab. (See Raising The Operator Cab
Remove the joystick from the loader. on Page 10-30-1.)
Figure 50-90-10 Remove the joystick. (See Joystick Removal (Right &
Left) on Page 50-90-2.)
Remove the joystick wiring grommet (Item 1) [Figure 50-
90-11]
Figure 50-90-12
P-26225 1
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
P-26227
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Disconnect the joystick wiring harness connector (Item 1)
Remove the joystick. ( See Joystick Testing (Right & Left) [Figure 50-90-12].
on Page 50-90-1.)
Remove the joystick boot from the control lever assembly
[Figure 50-90-10].
A220 Bobcat Loader
50-90-3 Service Manual
CONTROL (CONT’D) Figure 50-90-15
Lever Assembly Removal (Right & Left) (Cont'd)
Figure 50-90-13
P-26230
Remove the two control lever mounting bolts (Item 1)
P-26228 [Figure 50-90-15].
Figure 50-90-16
Remove the wiring harness grommet (Item 1) [Figure
50-90-13] from the lower steering lever assembly.
Figure 50-90-14
P-26231
Remove the control lever from the loader [Figure 50-90-
P-26229 16].
Remove the wiring harness (Item 1) [Figure 50-90-14]
from the control lever assembly.
A220 Bobcat Loader
50-90-4 Service Manual
CONTROL PANEL Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Removal And Installation
Remove the lift arm by-pass control knob and washer
(Item 1) [Figure 50-100-1].
WARNING Figure 50-100-2
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
1
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm P-26233
support device can allow the lift arms or attachment
to fall and cause injury or death.
Remove the control panel mount bolt (Item 1) [Figure 50-
W-2059-0598
100-2].
Figure 50-100-3
Figure 50-100-1
P-26234
Remove the two control panel mount bolts (Item 1)
[Figure 50-100-3].
Installation: Tighten the control panel mounting bolts to
25-28 ft.-lbs. (34-38 Nm) torque.
P-26232
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
A220 Bobcat Loader
50-100-1 Service Manual
CONTROL PANEL (CONT’D) Figure 50-100-6
Removal And Installation (Cont’d)
Figure 50-100-4
1
1
P-26237
Remove the two side panel mount bolts (Item 1) [Figure
P-26235 50-100-6], to allow clearance for the removal of the
control panel.
Remove the fuse cover mount bolts (Item 1) [Figure 50- Installation: Tighten the control panel mounting bolts to
100-4]. 25-28 ft.-lbs. (34-38 Nm) torque.
Remove the fuse cover. Figure 50-100-7
Figure 50-100-5
1
2
P-26227
P-26236
Disconnect the right joystick wire harness connector
(Item 1) [Figure 50-100-7].
Remove the control panel mount bolt (Item1) [Figure 50-
100-5] from the left side of the control panel.
Remove the two side panel mount bolts (Item 2) [Figure
50-100-5], to allow clearance for the removal of the
control panel.
Installation: Tighten the control panel mounting bolts to
25-28 ft.-lbs. (34-38 Nm) torque.
A220 Bobcat Loader
50-100-2 Service Manual
CONTROL PANEL (CONT’D) Figure 50-100-10
Removal And Installation (Cont'd)
Figure 50-100-8
1 1
P-26240
Remove the two mount bolts (Item 1) [Figure 50-100-10]
P-26238 from the foot rests.
Figure 50-100-11
Disconnect the left joystick wire harness connector (Item
1) [Figure 50-100-8]. 1 1
Figure 50-100-9
1 1
P-26241
Remove the front four mount bolts (Item 1) [Figure 50-
P-26239 100-11] from the foot rests.
Remove the foot rests from the loader.
Remove the two control panel mount bolts (Item 1)
[Figure 50-100-9].
Remove the control panel from the loader.
A220 Bobcat Loader
50-100-3 Service Manual
CONTROL PANEL (CONT’D)
Removal And Installation (Cont'd)
Figure 50-100-12
1
1
P-26242
Remove the two mount bolts (Item 1) [Figure 50-100-12]
from the lower fill panel.
Remove the panel from the loader.
A220 Bobcat Loader
50-100-4 Service Manual
INSIDE ACCESS PANEL (EARLY MODELS) Figure 50-110-3
Panel Removal (Right)
Figure 50-110-1
1
1
P-28505
Remove the top access panel mount bolt (Item 1)
P-26144 [Figure 50-110-3]
Figure 50-110-4
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the three mounting bolts (Item 1) [Figure 50-
110-1], from the right side foot rest.
Remove the foot rest, from the loader.
Figure 50-110-2
P-28506
Remove the inside access panel/engine speed control
assembly from loader [Figure 50-110-4].
1
P-28504
Loosen the two lower access panel mount bolt (Item 1)
[Figure 50-110-2].
A220 Bobcat Loader
50-110-1 Service Manual
INSIDE ACCESS PANEL (EARLY MODELS) (CONT’D) Figure 50-110-7
Panel Removal (Left)
Figure 50-110-5
P-26163
Remove the inside access panel (left side) from loader
P-26075 [Figure 50-110-7].
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the three mounting bolts (Item 1) [Figure 50-
110-5], from the left foot rest.
Remove the foot rest from the loader.
Figure 50-110-6
P-26162
Remove the top mounting bolt (Item 1) [Figure 50-110-
6].
Loosen the two lower mounting bolts (Item 2) [Figure 50-
110-6].
A220 Bobcat Loader
50-110-2 Service Manual
INSIDE ACCESS PANEL (LATER MODELS) Figure 50-111-3
Panel Removal (Right)
Figure 50-111-1
1 1
P-34546
Disconnect the foot operated speed control linkage (Item
P-34544 1) [Figure 50-111-3] from the hand operated speed
control lever arm.
Raise the lift arms and install an approved lift arm support Remove the foot operated speed control assembly from
device. (See Engaging The Lift Arm Support Device on the loader.
Page 10-20-1.)
Figure 50-111-4
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the three mounting bolts (Item 1) [Figure 50-
111-1], from the right side foot rest. 2
Remove the foot rest, from the loader.
1
Figure 50-111-2
1
P-34547
2
Loosen the two mount bolts (Item 1) [Figure 50-111-4]
from the front inside access panel.
Remove the mount bolt (Item 2) [Figure 50-111-4] from
the front inside access panel.
P-34545 Remove the inside access panael from the loader.
Remove the mount bolt (Item 1) [Figure 50-111-2] from
the foot operated speed control assembly.
Loosen the two mount bolts (Item 2) [Figure 50-111-2]
from the foot operated speed control assembly.
A220 Bobcat Loader
50-111-1 Service Manual
INSIDE ACCESS PANEL (LATER MODELS) (CONT’D) Figure 50-111-7
Panel Removal (Right) (Cont’d)
Figure 50-111-5
1
1
1 2
P-34553
Lift the speed control pin (Item 1) from the notch (Item 2)
P-34548 [Figure 50-111-7] in throttle cable.
Figure 50-111-8
Remove the two mount bolts (Item 1) [Figure 50-111-5]
from the hand operated speed control lever.
Figure 50-111-6
P-34549
At the bottom right side of the control panel, remove the
P-34551 keeper and pin (Item 1) [Figure 50-111-8] that connects
the speed control linkage arm to the speed control cable.
Lift slightly on the speed control handle and move it
toward the front of the loader [Figure 50-111-6].
A220 Bobcat Loader
50-111-2 Service Manual
INSIDE ACCESS PANEL (LATER MODELS) (CONT’D) Figure 50-111-11
Panel Removal (Right) (Cont’d)
Figure 50-111-9
1
1
1
2
P-34554
Remove the five mount bolts (Item 1) [Figure 50-111-11]
P-34550 from the access panel.
Remove the mount bolt (Item 2) [Figure 50-111-11] from
Remove the mount bolt and nut (Item 1) [Figure 50-111- the lever assembly. Move the lever assembly a slight
9] from the speed control linkage arm. amount toward the center of the loader, to allow
clearance for the panel to be removed.
Remove the speed control linkage arm (Item 1) [Figure
50-111-9] from the access panel. Remove the panel from the loader.
Figure 50-111-10
P-34555
At the bottom right side of the control panel, behind the
lift arm by-pass valve, remove the two bolts and nuts
(Item 1) [Figure 50-111-10] that mount the engine speed
cable to the access panel.
A220 Bobcat Loader
50-111-3 Service Manual
A220 Bobcat Loader
50-111-4 Service Manual
ELECTRICAL SYSTEM ANALYSIS
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Alternator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1 SAFETY &
Charging System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2 MAINTENANCE
Alternator Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Low Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
High Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-5
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-7 DRIVE
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-7 SYSTEM
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-7
Rotor Continuity Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-8
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-8
AWS CONTROLLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-4 ELECTRICAL
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1 SYSTEM &
ANALYSIS
BOBCAT CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-2
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-2
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-4 ENGINE
SERVICE
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing The Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . 60-20-3 SPECIFICATIONS
BICS™ SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Inspecting The BICS™ Controller (Engine STOPPED - Key ON) . . 60-110-1
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine
STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Inspecting The LIft Arm By-Pass Control . . . . . . . . . . . . . . . . . . . . . 60-110-1
Inspecting The Seat Bar Sensor (Engine RUNNING). . . . . . . . . . . . 60-110-1
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . 60-110-1
Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-3
BOBCAT 2001 CONTROLLER (EARLY MODELS) . . . . . . . . . . . . . . . 60-70-1
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
DIAGNOSTICS SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Number Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-3
Continued On Next Page
A220 Bobcat Loader
60-01-1 Service Manual
ELECTRICAL SYSTEM ANALYSIS (CONT’D)
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE . . . . . . . . . . . . . . 60-170-2
Controls Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-2
ELECTRICAL SYSTEM INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Relay Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-3
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Deluxe Panel Removal And Installation (Right Side) . . . . . . . . . . . . . . . 60-50-11
Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Option and Field Accessory Panels (If Equipped) . . . . . . . . . . . . . . . . . . 60-50-8
Right Panel - (Deluxe) (With Keyless Start) . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Right Panel Set Up Display Options (Deluxe) . . . . . . . . . . . . . . . . . . . . . 60-50-4
Right Panel - (Standard) (With Key Switch) . . . . . . . . . . . . . . . . . . . . . . . 60-50-2
Standard & Deluxe Panel Removal And Installation (Left Side). . . . . . . 60-50-12
Standard Panel Removal And Installation (Right Side) . . . . . . . . . . . . . 60-50-10
LIFT AND TILT ACTUATOR CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
SEAT BAR SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
BICS™ Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Connecting The Service PC To Remote Start Tool . . . . . . . . . . . . . . . . 60-150-1
SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
STEERING SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Continued On Next Page
A220 Bobcat Loader
60-01-2 Service Manual
ELECTRICAL SYSTEM ANALYSIS (CONT’D)
STARTER (NIPPONDENSO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-12
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-9
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-12
STARTER (VALEO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-1
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-4
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-7
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-10
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-1
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Description Of The Control System . . . . . . . . . . . . . . . . . . . . . 60-130-5
Inspecting The Control System . . . . . . . . . . . . . . . . . . . . . . . . 60-130-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
WHEEL POSITION SENSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
Sensor Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . 60-140-4
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-3
Wheel Alignment (Calibration) . . . . . . . . . . . . . . . . . . . . . . . . 60-140-10
Wheel Alignment (Failed Sensor) . . . . . . . . . . . . . . . . . . . . . . 60-140-2
Wheel Alignment (Field Adjustment) . . . . . . . . . . . . . . . . . . . . 60-140-6
A220 Bobcat Loader
60-01-3 Service Manual
A220 Bobcat Loader
60-01-4 Service Manual
LEFT RIGHT LEFT PANEL REAR ROD
C413
FRONT
WORKLIGHTS
4430 A A 7.5 ohm
2910 G GROUND
12V
BROWN TIE STRAP 2430 B B
9340 D HEADLIGHTS
B A A B 1210 E PROTECTED POWER
A220 WIRING SCHEMATIC C434 C435 1910 F COMPUTER POWER
REAR BASE
C414
B A A B 4440 A A 7.5 ohm
9110 H SYSTEM Tx
12V
WHITE TIE STRAP 2440 B B
2750
6110
6120
2760
WIRES CONNECT BY 9210 K SYSTEM Rx
S/N 519611001 - 519611299 LETTER ACROSS SEE FUSE/RELAY
H H
9300 A CLOCK/LATCH
C421
C407
CONNECTORS CENTER J J A 4370 DIVERTER
9310 B DATA NOT
S/N 519711001 - 519711124
C416
A B (EUROPEAN A 6100 A A 6100 USED B 2370 4450 A A 7.5 ohm
B A LIGHTING) 9330 J START
12V
THIS PAGE M M 2900 YELLOW TIE STRAP 2450 B B
9320 C BUZZER
(PRINTED APRIL 2004) SOME CONNECTOR C C 9340
C422
BODIES NOT SHOWN D D 9200 A 4380
V-0086 FOR DRAWING CLARITY E E 9100
9320 + BUZZER
NOT
USED B 2380
SEE ACS -
C408
SEE CONTROL 2930
CONNECTOR E MODULE J4
B 4500 F F 4500 1930 RIGHT PANEL
Printable Version Click Here RED = RED
RNG = ORANGE
BLK = BLACK
THIS PAGE THIS PAGE 2740 S
P
S
P
2740
1900
2770
BRAKE
SWITCH 9330 J START
HYD. LOCK VALVE REAR AUX RELIEF
LBL = LIGHT BLUE BATTERY FEED 1000-1999 RED, RED/WHT, RNG 9310 B DATA
C417
C420
DBL = DARK BLUE GROUND 2000-2999 BLK R R 1200 9.8 ohm A A 4410 4480 A A 9.8 ohm
9300 A CLOCK/LATCH GREEN TIE STRAP
12V
LGN = LIGHT GREEN MONITORING 3000-3999 LBL B B 9350 12V B B 2410 2480 B B
DGN = DARK GREEN HYDRAULIC 4000-4999 LGN
C
9220 K SYSTEM Rx
YEL = YELLOW ATTACHMENT CONTROLS 5000-5999 YEL SEE ACS L L 3900
LIGHTS 6000-6999 PNK B SEAT BAR 9120 H SYSTEM Tx
2530 GROUNDS
PNK = PINK
ACCESSORIES 7000-7999 WHT CONNECTOR D G G 3920
SENSOR
FRONT ROD HIGH FLOW / 900 LOAD SENSE
WHT = WHITE 1920 F COMPUTER POWER
C418
C415
ENGINE 8000-8999 TAN THIS PAGE K K A A A 4330 4460 A A
2480 BRN = BROWN 3910 3.3 ohm 7.5 ohm
COMMUNICATION 9000-9999 PUR 1220 E PROTECTED POWER
PWM 12V
2460 TAN = TAN N N B B 2330 BLUE TIE STRAP 2460 B B
2910 9350 D RUN/ENTER SWITCH
PUR = PURPLE
9110
9210
2900
9340
9200
9100
1900
1200
9350
3900
3920
3910
2900 2920
2450 GRY = GRAY 2930
MAIN 2920 G GROUND
2440 2400 2770 CAB 2000 FRONT BASE
FRAME C OPEN
FUEL SENDER 2750 2740
C419
2430 2760 3.3 ohm A A 4340
HARNESS - 6719422
2340 CAB HARNESS - 6727178 PWM
B B 2340
B3
B2
C3
B1
D2
D1
D3
A1
A2
A3
C2
C1
E3
E1
E2
F3
F2
F1
2330 TWO SPEED
C441
C406
2520 C C 4350 A A
J2 WHITE 5.5 ohm
C442
FUEL SENDER 3100 A A 3100 3100 B1 F1 4340 2350 B 12V
2100 A A PROTECTED
POWER
COMPUTER
POWER
SYSTEM Tx OPEN OPEN
SEATBAR SENSOR
SUPPLY
B
30-270 ohm
2490 B B 3110 B B 3110 F1 F1 E1
D C
B1 A1 F2 4330
1 1
CONTROL
900 FLOW
F3 1200 1900 9100 3900 H1 4410 BUCKET POSITION
K3
K2
K1
2420 OPEN
KEY/ENTER
SYSTEM Rx OPEN OPEN
SEATBAR
C423
SWITCH SENSOR SIGNAL
2410 D J2 C K3 4420 A A 6.7 ohm
F2 E2 B2 A2
900 LOAD SENSE
12V
C405
WHITE
2 2
HIGH FLOW /
A 3700 E2
REAR AUX
A 3700 K2
DIVERTER
2420 B B
RELIEF
4460
2380 2390 AIR FILTER
4470
9350 9200 3920
4450
J3
J2
J1
HEADLIGHT SEATBAR SENSOR
GROUND OPEN OPEN OPEN
SWITCH B B 3710 3010 F2 SWITCH GROUND
F3 4360
2370 D C
F3 E3 B3 A3
D3 3 3 G2 4430
TWO SPEED
SOLENOID
HYD LOCK
POSITION
2200
BUCKET
2900 9340 3910
4350
4420
4410
H3
H2
H1
2000
G1 4440
t J2 4450
TRACTION HOLD
2240
REAR BASE
REAR ROD
HYD TEMP SENDER
C
4200
4430
4440
3300 C 3300 B3 J3
G3
G2
G1
RESERVED
4480
GROUNDS
DIGITAL 2
SENSOR
3010
SPARE
500-3000 ohm
(hall)
F3
F2
F1
D
2800 +A
3310 D 3310
CONTROL MODULE J1 4460
C102
SPOOL LOCK
FRONT BASE
FRONT ROD
3400 A A 3400 C1 H3
FILTER SIGNAL
HYD CHARGE PRESS 4350
HYD CHARGE
J4 WHITE
4360
ENG SPEED
4330
4340
AIR FILTER
F3
F2
F1
3610
3700
SIGNAL
3600
SIGNAL
C
3430
E3
E2
E1
2300 SENDER 0.5-7.5 V 3420 E E 3420 C2 H2 4420
3510
- B 3410 F F 3410 D2 4840
PRESS SIGNAL
PRESSURE +
2600
WHITE
HYD OIL FILTER
ENG OIL
B
ENG OIL
3430
3520
J4
B 3430 E3
3500
OPEN
C2 4830
D3
D2
D1
J1 BLACK
PRESSURE SWITCH
2110 SEE LEFT B2 4820
PWM SIGNAL
HYDRAULIC FILTER HARNESS - 6717247 HANDLE
PWM +
4300
PWM -
C A3
4320
4310
4640 A2 4810
E3
E2
E1
BLACK
CONNECTOR
J1
2740
THIS PAGE B3 1400
2730 SEE CAB CONNECTOR
EHC OUTPUT
PRESS SIGNAL
RH SKI UP
HYD CHARGE ENG COOLANT
HYD CHARGE
PRESSURE +
LH SKI UP
2120 A3 4500 B
RESERVED
(AC INPUT)
9410
4840
4940
3420
3400
D3
D2
D1
2720 THIS PAGE
C3
C2
C1
+ SEE
A D1 4940
2710 ENGINE OIL A A 3500 3500 D1
C107
CONTROL
PRESSURE C C1
RH SKI DOWN
4930
LH SKI DOWN
FUEL SENDER
EHC INPUT
3520 3520 D2
HYDRAULIC
2350 C C SPARE ACCESSORY UNSWITCHED
MODULE
9400
3300
3100
SIGNAL
4830
4930
3200
-
C3
C2
C1
CAN HIGH OPEN OPEN STARTER FEEDBACK
STARTER RELAY FUEL HOLD
SENDER
TEMP
TEMP
B3
B2
B1
OUTPUT 2 RELAY OUTPUT OPEN BATTERY IN (1)
0.5-7.5 V
B 3510
B1 4920
J1 THIS
B B K1 J1 H1 G1 F1 E1 D1 C1 B1 A1
8800 1110
A1 4910 PAGE
LH AUX LEFT
9500 8000 8250 8210
BRAKE SW
RH FRONT
ANALOG 2
ANALOG 1
DETENT
HANDLE
4640
ATTACHMENT BRAKE PULL
SPARE
SPARE
REAR WKLT BRAKE PULL UNSWITCHED
FLOAT
4820
4920
C106
1400
OUT
E2
B3
B2
B1
CAN LOW OPEN FUEL PULL RELAY GROUND
4310
A3
A2
A1
KEY INPUT RELAY FEEDBACK RELAY BATTERY IN (2)
SPEED A A 3600 3600 E1 J3
C
SENSOR
K2 J2 H2 G2 F2 BLACK E2 D2 C2 B2 A2 E3 4320
B B 3610
RH TWO SPEED
LH AUX RIGHT
9600 9800 6210 4150 4110 8110 2110 1120
BRAKE SW
E1 4300
4500
4810
4910
TWO SPEED TRAVEL MARKER LT GLOW PLUG GLOW PLUG FUEL PULL UNSWITCHED
A3
A2
A1
C3
IN
CAN SELECT OPEN GROUND
MAKE-UP CONTROL RELAY FEEDBACK RELAY FEEDBACK BATTERY IN (3)
K3 J3 H3 G3 F3 E3 D3 C3 B3 A3
K1
ENGINE t 9700 4730 6320 8550 8510 8150 2100 1130 C3 9400
J3
C104
4220
COOLANT A A 3200 3200 B2 D3 9410
SENDER
BLAC
2520
4240
4810
4820
4830
4840
4640
1480
4940
4300
4320
4310
4230
4910
4920
2530
1490
4930
500-3000 ohm B B 3210 G3 4200
ALTERNATOR SUPPLY K
H3
G1
G3
G2
H1
D3
D1
C1
C3
C2
B2
B3
D2
A3
A2
A1
H2
K1
K2
K3
B1
E3
E1
E2
F3
F2
F1
J1
J2
J3
1020
B D C G F E K J H A E H J A F G B C K D
C110
B B
A A 1800
C409 C410
B NOT USED ON NOT USED ON
4730
4110
8000
6320
6210
8550
8510
8250
8210
8150
8110
2110
2100
4150
1130
1120
1110
9800
9500
9600
9700
6510
6410
7200
4390
2360
MODEL A220 MODEL A220
2015
4 4
C101
3 3 A B
1015 1 1 2800
STARTER 3.2 ohm
12V 2 2 8100
C458
M R
8250
FUEL SHUTOFF A B TWO-SPEED
MAKE-UP
B
S 5 ohm
8200
12V
GLOW PLUGS
TAILGATE / WORKLIGHTS 6716419 1.0 ohms Each
F F
2600 B B 2600 HR HR HR HR
RIGHT
2620 6200 6200 H H 6200
WORKLIGHT
C103
6210 6310 A A 6310
8590
8580
8570
8560
9410
9400
LEFT
2630 6210 E E 6400
WORKLIGHT SEE CAB
D D 6500 CONNECTOR
RIGHT (EUROPEAN
2610 6320 G G 6600
TAILLIGHT LIGHTING) B A
C404
BACKUP 7100 C C 7100 A TO OPTIONS THIS PAGE
LEFT
2640 6330 ALARM B (BACKUP C473
TAILLIGHT
2650 ALARM SWITCH) C407 B A
A
J 2730 ACS
9420
2650
9420
P 6600 JUMPER
2640
6000
2630 2600 M 6500
2620 L 6400
2610 F 4730
D 4235
R
C488
C 4275 TRACTION LOCK
E 4550
TWO SPEED BRAKE
N 6300 WHT TO BLK =
C425
C425
4200 A A HOLD
0.26 ohm
A
S 1700
2200 C C RED TO BLK= B 9.8 ohm
A 1140 10.9 ohm
4100 B B PULL C
H 1150
B
G
K (ALTERNATOR
1800 & KITS)
TO OPTIONS
(ACCESSORY CONNECTOR) FUSE 11
25A
J
8000
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1700 1055
P
C489
B 2720 MARKER REAR GLOW N
SWITCHED FUEL TRACTION
LIGHT LIGHT PLUG STARTER PULL 4220 M
(COMPUTER)
A 1720 1720 POWER LOCK
FUSE 4
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A 4275 L
25A
TO OPTIONS (ATTACHMENT)
FUSE 10 4550 K
(ACCESSORY 30 85 30 85 30 85 30 85 30 85 30 85 85 30
CONNECTOR) 25A 9720 E
1710
1050
2000
2010
1330
2020
2030
1320
2010
2020
1060
2030
2040
2060
1350
2040
2050
2050
2060
1360
1030
9620 D
C492
(HEATER SEE CONTROL R
) 1 FUSE 2 120 MODULE J2 TO ALL WHEEL
FUSE FUSE 3 FUSE 6 FUSE 5 E 9210 G STEER CONTROLLER
15A 30A 30A OHM
25A 15A THIS PAGE
RESISTOR S
MAINFRAME HARNESS 6730297 1140
9520 C
1150 1160
SEE CONTROL 2240 H
MODULE J2 9110 F
1070 D
RELAY GROUNDS 2000-2060 THIS PAGE
FUSE 9 FUSE 12 1740 B
ARE CONNECTED IN SERIES 25A 25A
FUSE / RELAY CENTER (UNSWITCHED
POWER) (ACS)
1170 A
FUSE 5 FUSE 1 FUSE 9
TRACTION HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER
FUSE 6 FUSE 2 LIGHT POWER FUSE 10
LIGHT
FUEL PULL FR & MK LT ATTCHMNT
1040
1080
30A 15A 25A
FUSE 7 FUSE 3 FUSE 11
REAR LT ALT & KITS
1160
1730
9800
9510
9610
9710
2710
15A GLOW FUEL TRACTION 25A
STARTER
FUSE 8 FUSE 4 PLUG PULL PULL FUSE 12
COMPUTER ACS 1050
25A 25A - + 1300
1060
F E D A B C G
TO OPTIONS
100A
1010 1030
C426 (ATTACHMENT
ACD & REMOTE CONTROL)
1310 START CONNECTOR
Printed in U.S.A.
1040 V-0086 (4-8-04)
BATTERY 1080
PROTECTED POWER E
PROTECTED POWER E
RUN/ENTER SWITCH D
COMPUTER POWER F
COMPUTER POWER F
RIGHT PANEL
CLOCK/LATCH
HEADLIGHTS
LEFT PANEL
REAR ROD
CLOCK/LATCH
OPEN
C413
GROUND
SYSTEM Tx
DATA
START
BUZZER
START
DATA
SYSTEM Rx
SYSTEM Tx
GROUND
C421
A A 4430 4370 1
SYSTEM Rx
7.5 ohm NOT USED ON
12V 2
B B 2430 BROWN TIE STRAP 2370 MODEL A220
BUZZER
C422
4380 1
NOT USED ON
A220 WIRING SCHEMATIC 6733137 REAR BASE 2380 2 MODEL A220
C414
HIGH FLOW A A 4440 BICS HYDRAULIC LOCK
G
C
D
K
A
B
B
A
K
J
J
7.5 ohm
C420
C415
A A A A 4460 12V 4410 A A
7.5 ohm B B 2440 WHITE TIE STRAP
9.8 ohm
S/N 519611300 & ABOVE 12V B B B B 2460 BLUE TIE STRAP 2410 B B 12V
2920
9350
1220
1920
9120
9220
9300
9310
9330
2930
9320
9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
BUCKET POSITIONING FRONT ROD
C423
C418
S/N 519711125 & ABOVE A A
C441
TWO SPEED 7.5 ohm 4350 9.8 ohm A A 4420 4330 1 1 3.3 ohm
SOLENOID 12V 12V
B B 2350 B B 2420 2330 2 2 PWM FRONT BASE
(PRINTED APRIL 2004)
C419 C106
4340 1 1 3.3 ohm
CAB 6727178
C437
A A 4390 2340 2 2 PWM
V-0266 TWO SPEED
MAKE-UP
5 ohm
12V B B 2360
DIVERTER
3600 A A
FRAME
Printable Version Click Here
C416
SPEED
MAIN
4450 A A 7.5 ohm SENSOR
3610 B B
WORKLIGHTS
12V
YELLOW TIE STRAP 2450 B B
FRONT
2530 GROUNDS
2480
SWITCH
BRAKE
WIRES CONNECT BY FRONT AUX RELIEF
1930
2460
2000
LETTER ACROSS
C424
4490 A A 11 ohm SEE J1
C104 C405
2450 CONNECTORS
7 GREEN TIE 12V THIS PAGE ENGINE
C435
2490 B B 3210 B B
RIGHT
2440 2400 A B STRAP
COOLANT
2760 B B
t
B A C 3200 A A SENDER
2430 6120 A A
REAR AUX RELIEF 500-3000 ohm
2340
SEAT
BAR
RED = RED SOME CONNECTOR
CAB
C417
A A 3700 A A
C434
4480 AIR FILTER 6110 A A
LEFT
2330 RNG = ORANGE BODIES NOT SHOWN 9.8 ohm
3300
4330
4360
4340
2110
3700
4410
3200
SWITCH
4440
4430
4420
12V B B
2770
2520 BLK = BLACK FOR DRAWING CLARITY 2480 B B SEE J1 B 3710 B
B
3600
2750
4350
4470
4460
4450
4390
THIS PAGE
C476
LBL = LIGHT BLUE FUEL
2100 3110 B B 3110 B B
DBL = DARK BLUE SENDER
LGN = LIGHT GREEN 3100 A A 3100 A A - +8
2360 30-270 ohm 2910
BATTERY FEED 1000-1999 RED, RED/WHT, RNG
DGN = DARK GREEN
GROUND 2000-2999 BLK
J1 J2 C C
2920 2900
C
2930
A
2420 YEL = YELLOW 31 J1 J2
MONITORING 3000-3999 LBL 6 18 29 26 32 12 22 1 41 3 21 10 38 48 8 18 2770
PNK = PINK 2750
2410 HYDRAULIC 4000-4999 LGN 2740
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
11 WHT = WHITE ATTACHMENT CONTROLS 5000-5999 YEL FUEL SENDER HARNESS 2760
COOLANT 28 3100
2380 2390 BRN = BROWN LIGHTS 6000-6999 PNK
SPOOL SPARE FRONT COMPUTER SYSTEM LH AUX L HAND
TEMP SIGNAL
PWM +8V ENG SPEED
SIGNAL
TAN = TAN ACCESSORIES 7000-7999 WHT
LOCK ANALOG 1 ROD GROUND Tx RIGHT SERIAL IN SUPPLY
6719422
2370 PUR = PURPLE 1 2 3 4 5 6 7 8 9 10
ENGINE 8000-8999 TAN
11 9110 D
M
G
N
D
C
H
2900 4810
P
S
A
GRY = GRAY 4360 9100 3200
J
2200 COMMUNICATION 9000-9999 PUR 4330 9210 4300 3600
7 9210 E
2000
R HAND
SERIAL IN
REAR
BASE
SPARE
ANALOG 2
PROTECTED
POWER
SYSTEM
Rx
LH AUX
LEFT
SPARE
DIGITAL 1
AIR FILTER
SIGNAL
PWM -
RH FRONT
DETENT
23 9400 F
SEE
CONNECTOR
C408
M
R
D
C
H
K
P
S
A
N
L
14 15 16 18 19
F
11 13 17 20
J
2240 12 C492
1200 9200 3700 4920 42 9410 G
9110 4440 4820 4310
2350
A A BOBCAT CONTROLLER FRONT REAR STATUS COMPUTER SEAT BAR LH SKI FUEL PWM RH SKI
3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
HYDRAULIC CHARGE BASE ROD IN DOWN
OPEN
SENDER SIGNAL DOWN
PRESSURE SENDER C C
POWER +8v
J2
2800 21 22 23 24 25 26 27 28 29 30
0.5 - 7.5 V 3400 A A 3400 3400 15 9400 1900 3900
P05 4830 3100 4320 4930
3610 B B 4340 4430
2300 3420 E E 3420 3420 47 BUCKET 35 3910
3510 OPEN POSITION OPEN
KEY/ENTER SEATBAR
GROUND
LH SKI
UP OPEN GROUND OPEN
RH SKI
UP
A
SWITCH
C102
HYDRAULIC 3410 F F 3410 3010 23 45 3920
31 32 33 34 35 36 37 38 39 40
C477
2600 TEMPERATURE
SENDER
B B 3310 D D 3310
4420 9350 3910 4840 2110 4940 25 3900 C407
A B SEE FUSE/RELAY
2110 500-3000 ohm A 3300 C C 3300 C HYD LOCK STATUS 34 9350
SEE J2 SEE J2 SOLENOID OUT FLOAT HEADLIGHT SEATBAR BRAKE SW
OPEN
HYDRAULIC
TEMP OPEN CENTER THIS PAGE
SWITCH SIGNAL IN OPEN
THIS PAGE THIS PAGE 14 1200
2740 HYDRAULIC OIL 41 42 43 44 45 46 47 48 49 50
3430 B B 3430 3 4410 9410 9340 3300 24 1900
FILTER SWITCH 4640 3920 4500
2730
2120 RESERVED HYD FILTER TWO SPEED RESERVED TWO SPEED SPARE LEFT GLOW PLUG TRACTION LOCK 46 4500
RELAY
2720 OPEN PULL / 963
HYDRAULIC FILTER 6717247
(AC INPUT) SIGNAL SWITCH (BOOTSTRAP) MAKE-UP BLINKER
23 OUTPUT 1
5 9100
2710 1 2 3 4 5 6 7 8 9 10
3430 4910 4390 6410 8510 4110
15 9200
RESERVED STARTER UNSWITCHED CAN HYD CHARGE RIGHT TRACTION HIGH FLOW / REAR WKLT
44 9340
(hall) FEEDBACK BATTERY (1) HIGH PRESS +8V BLINKER LOCK HOLD 900 LOAD RELAY OPEN
A A 3500 3500 37 4 2900
C107
11 12 13 14 15 16 17 18 19 20
C C 3520 3520 49 40 4940
8250 1110 9500 3400 6510 4200 4460 6210
0.5-7.5 V B 3510 30 4930
B TRACTION LOCK SENSOR TRAVEL F&R AUX RESERVED UNSWITCHED
ENGINE OIL
SPARE
DIGITAL 2 PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 RELIEF (SENSOR GRND) BATTERY (2)
DIVERTER STARTER
RELAY
20 4920
PRESSURE 21 22 23 24 25 26 27 28 29 30
SENDER 4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
TWO SPEED FUEL PULL UNSWITCHED 29 4320
CAN GLOW PLUG ENG OIL MARKER LT FUEL PULL
SOLENOID FEEDBACK BATTERY (3) OPEN GROUND
SELECT FEEDBACK PRESS +8v RELAY RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
6320
43 4640
4350 8150 1130 9700 8550 3500 2100 8110
HANDLE SWITCH PWR / RESERVED ATTACHMENT +5V HYD CHARGE ENG OIL RESERVED
36 4840
SPARE
POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY PRESS SIGNAL HORN PRESS SIGNAL (FAN OUTPUT)
OUTPUT 2
26 4830
41 42 43 44 45 46 47 48 49 50
16 4820
1400 8000 9800 3420 7200 3520
J1 6 4810
J2
C101
25 42 39 19 36 9 12 30 32 40 38 10 22 33 28 13 44 14 24 34 16 8 48 17 41 4
1 1 2800 16
3.2 ohm 12V
2 2 8100 J1 29
FUEL SHUT OFF
4910
4730
4110
7200
6510
6410
4200
1400
8000
6320
6210
8550
8510
8250
8210
8150
8110
2100
4150
1130
1120
1110
9800
9500
9600
9700
STARTER
1480
4810
4820
4830
4840
4640
4300
4320
4310
4910
4920
4930
4940
4230
2530
1490
2520
4240
M R
C109
1015 B B 8250
S
G
H
C
D
E
G
F
B
D
C
H
A
K
F
J
J
A A 8200
C410 C409
TRACTION LOCK
C110
1020 B B 1020 TWO SPEED BRAKE
NOT USED ON NOT USED ON
C425
1015 A A 1800 4200 A A
A HOLD
C425
BAT MODEL A200 MODEL A200
2200 C C B 9.8 ohm
ALTERNATOR
2015 GLOW PLUGS 4100 B B C
PULL
TAILGATE / WORKLIGHTS 6716419 1.0 ohm each
WHT TO BLK =
F F 0.26 ohm
RIGHT RED TO BLK=
WORKLIGHT
2620 6200 2600 B B 2600 HR HR HR HR
10.9 ohm
6210 6200 H H 6200
8590
8570
8560
8580
C103
LEFT
WORKLIGHT
2630 6210 6310 A A 6310
E E 6400
RIGHT
2610 6320 D D 6500
TAILLIGHT
G G 6600 SEE CAB
8500
C404
LEFT TO CONNECTOR
TAILLIGHT
2640 6330 BACKUP 7100 C C 7100 A OPTIONS THIS PAGE
ALARM 2650
B (BACKUP
ALARM SWITCH) C407
2650 A
J 2730
2640
P 6600
2630 2600
6000
M 6500
2620
L 6400
2610
F 4730
D 4235
TO N 6300
C488
OPTIONS
(ACCESSORY C 4275
CONNECTOR) E 4550
S 1700
A 1140 1740
H 1150
R
B
G
TRACTION
K (ALTERNATOR LOCK
1800 & KITS)
FUSE 11
25A
8010
6300
6000
6320
6200
6210
8500
8550
8510
8200
8210
8100
8150
8110
4110
4150
4100
1130
1120
1110
6310
1700 1055 4220 M
TO
C489
OPTIONS GLOW 7200 J
B 2720 SWITCHED MARKER REAR FUEL
COMPUTER
(ACCESSORY LIGHT LIGHT PLUG STARTER TRACTION 4275 L
POWER PULL
A 1720 1720
FUSE 4
CONNECTOR) 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK
25A
6410 P
(ATTACHMENT) 6510 N
FUSE 10 30 85 30 85 30 85 30 85 30 85 30 85 85 30
25A 4550 K
1730
1050
2010
2000
1330
2030
2020
1320
2020
2010
1060
2040
2030
1030
2060
1350
2050
2040
2060
2050
1360
9720 E
C492
TO ALL WHEEL
(HEATER 9620 D STEER CONTROLLER
) 1
FUSE FUSE 2 FUSE 3 FUSE 6 FUSE 5
15A
G 9410 S
25A 15A 30A 30A
120
1140 SEE J2 F 9400 R
CONNECTOR
MAINFRAME HARNESS 6732061 E 9210 G
1150 1160 9520 C
1070 2240 H
FUSE 9 FUSE 12 1740 B
25A 25A
FUSE / RELAY CENTER (UNSWITCHED
POWER) (ACS)
D 9110
1170 A
F
1080
1040
FUSE 5 FUSE 1 FUSE 9
TRACTION HEATER
FRONT &
REAR SWITCH
UNSWITCHED
V-0266 (4-8-04)
30A 25A 25A
MARKER 1160
1730
9800
9510
9610
9710
2710
FUSE 6 FUSE 2 LIGHT POWER FUSE 10
LIGHT
FUEL PULL FR & MK LT ATTCHMNT
30A 15A 25A 1050
FUSE 7 FUSE 3 FUSE 11
G
-
D
C
E
A
B
1300
F
REAR LT ALT & KITS
+ TO OPTIONS
1060
FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT CONTROL)
26
COMPUTER ACS
ACD & REMOTE START
1310 CONNECTOR LOCATED
25A 25A
1040 ABOVE BATTERY
1080
BATTERY
A220 WIRING SCHEMATIC WIRES CONNECT BY
RED = RED
RNG = ORANGE
BLK = BLACK
BATTERY FEED 1000-1999 RED, RED/WHT, RNG
GROUND 2000-2999 BLK
S/N 519611001 AND ABOVE LETTER ACROSS
CONNECTORS
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
MONITORING 3000-3999 LBL
HYDRAULIC 4000-4999 LGN
ATTACHMENT CONTROLS 5000-5999 YEL
A B LIGHTS 6000-6999 PNK
S/N 519711001 AND ABOVE B A
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
ACCESSORIES 7000-7999 WHT
ENGINE 8000-8999 TAN
COMMUNICATION 9000-9999 PUR
(PRINTED APRIL 2004) SOME CONNECTOR WHT = WHITE
BRN = BROWN
BODIES NOT SHOWN TAN = TAN
V-0113 FOR DRAWING CLARITY PUR = PURPLE
GRY = GRAY
Printable Version Click Here
ALL WHEEL STEER CONTROL HARNESS - 6726663 & 6733293
TO ALL WHEEL TO ALL WHEEL TO ALL WHEEL
J3
TO ALL WHEEL
STEER CONTROLLER J2 STEER CONTROLLER J1 STEER CONTROLLER J4 STEER CONTROLLER
K G P E R F N M D L C B J A H S SH GA B D C P F E R N M L K J A B K J G F C D E H
D E F R C B J H S A K L M N P G
3130
4250
2690
2680
4260
4270
2670
2660
4280
9520
9620
1180
1190
2250
2500
2980
2880
2970
2810
2870
1500
1740
2260
1590
1555
2650
1 2 3 A B C D A B C D
C456 C451 C452
A B C D A B C D
1 2 3
RED
DGN
BLK
RIGHT RIGHT LEFT LEFT
1 2 3 DRIVE DRIVE DRIVE DRIVE
REVERSE FORWAR REVERSE FORWARD
D ohm
20 ohm 16 20 ohm 16 ohm
DRIVE COILS
Right Rear
Wheel
Position
C497
TO C B A
1520
4530
9010
4540
2080
4520
1510
4510
9000
2070
OPTIONS
ORANGE TIE STRAP
YELLOW TIE STRAP
401TIE STRAP
405TIE STRAP
123 4 56 1 23 4 5 6
BLACK TIE STRAP
WHITE TIE STRAP
BLACK TIE STRAP
WHITE TIE STRAP
BLUE TIE STRAP
PINK TIE STRAP
403STRAP
9420 *
C449 C450
9000
4950
7200
6410
9620
9010
1170
6510
9520
1740
2240
1580
2630
2180
1240
3060
2620
1570
1230
2170
3050
4070
4060
402
404
4170
416
123 4 56 123 4 56
2640
1565
3140
2560
1560
PURPLE
3040
2550
1550
3030
RED TIE
0
0
2960
2950
2940
2890
2830
0
2840
2850
2820
GREEN
1530
3020
2570
1540
2580
3000
3070
3080
J P N B C D E A H K F G R L M S 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 JOYSTICK JOYSTICK
710
0
C492 LIFT ACTUATOR 3 2 1 3 2 1 3 2 1 HARNESS - HARNESS -
WHT
WHT
RED
BRN
RED
BRN
LGN
LGN
TO MAINFRAME
BLK
BLK
TILT ACTUATOR
HARNESS 6729397 6729397
TO MAINFRAME A B A B B A A B B A A B B A A B B A A B C429 C428
HARNESS
1 2 3 4 1 2 3 4 C457 C498 C455
C404 C440 C461 C499 C443 C444 C445 C446 C447 C448 LIFT ACTUATOR TILT ACTUATOR 3 4 5 6 27 1 3 4 5 6 27 1
A B B A A B B A A B B A A B B A A B 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
C454 C453 3 2 1 3 2 1 3 2 1
* NOTE: On connector C492, wire C459 C460
1 2 3 4 1 2 3 4
DGN
RED
9420 is on harness 6733293 only. BLK 3 4 5 6 27 1 3 4 5 6 27 1
RED
RED
RED
DGN
DGN
DGN
RED
DGN
RED
BLK
BLK
BLK
BLK
BLK
RED
BLK
Front Front Front Front Right Right Left Left Pressure
Right Right Left Left Rear Rear Rear Rear Control 3 2 1 3 2 1 3 2 1
Base Rod Base Rod Base Rod Base Rod
7 ohms
10 ohms 10 ohms 10 ohms 10 ohms 10 ohms 10 ohms 10 ohms 10 ohms LEFT HANDLE RIGHT HANDLE
HALL HALL
M M EFFECT
STEERING SOLENOIDS SENSOR
EFFECT
SENSOR
Left Front Left Rear Right
2070
Wheel Wheel Front
2080 Left Side Right Position Position Steering
SENSOR GROUND (5V)
Wheel Side Sensor
2570
Speed Wheel
2580 2500 Speed
2550 SENSOR POWER (5V)
1510 SENSOR POWER (5V) 1550 SUPPLY #2
2560 SUPPLY #1
1520 1555 1590
2620 1500
1530 1560
2630
1540 1565
2650
1570
2640
1580
Printed in U.S.A. V-0113 (4-8-04)
A220 WIRING SCHEMATIC POWER BOB-TACH
OPTIONS Printable Version Click Here STROBE OR
TO OPTIONS
(POWER BOB-TACH) TO OPTIONS
SOLENOID
C606
S/N 519611001 AND ABOVE
S/N 519711001 AND BEACON
POWER BOB-TACH
SWITCH
2770 E A 7000 A A
FLASHER
2760 D D 2760 B B DOME LIGHT
C601
C601
TO OPTIONS
ABOVE
(PRINTED APRIL 2004)
1
7000 A C
SWITCH
C608
BEACON SWITCH 2 A RED
C607
V-0114 2 1 C B 7010 B B POWER BOB-TACH
6 SOLENOID B BLK
5 HAZARD SWITCH 7010 B E 2770 A A
LEFT RIGHT C609 3
4
WIRES CONNECT BY
LETTER ACROSS
FLASHER
LIGHT
FLASHER
LIGHT 2 1 TO 1130
L
6010
2 1
6430 5
4 DOME LIGHT
STROBE/BEACON 3 X 3
CONNECTORS 1180
1 2
A B TO OPTIONS TO OPTIONS
(EXTERIOR CAB)
5
4
6530
6 POWER BOB-TACH HARNESS -
B A 6700 E 6 2750
E 6700 TO MAINFRAME
6730770
2775
TO OPTIONS 2755 AWS SWITCH
TO OPTIONS A D 2780
SOME CONNECTOR
2790
2795
(EXTERIOR CAB) 1
C670
4550 E
C670
BODIES NOT SHOWN (4 WAY FLASHER) C
B 6540 2 3
FOR DRAWING CLARITY 6440 1 2 2785 2780 D 2745 R
C669
F
C669
6440 4
2785 2 1 6440 F 2755 4235 D
A 5 4275 C FRONT WIPER
6540 3 3 6540 B 6 FRONT WIPER
C K M BOTTLE AND TANK
M BOTTLE AND TANK
C488
BATTERY FEED 1000-1999 RED, RED/WHT, RNG
GROUND 2000-2999 BLK
4 WAY FLASHER EXTERIOR CAB HARNESS - G FRONT WIPER FRONT WIPER
B MOTOR
MONITORING 3000-3999 LBL
HYDRAULIC 4000-4999 LGN HARNESS - 6718873 6718872 2730 J
V
MOTOR
ATTACHMENT CONTROLS 5000-5999 YEL V
LIGHTS 6000-6999 PNK
1700 S M M
ACCESSORIES 7000-7999 WHT 6400 L
ENGINE 8000-8999 TAN
6500 M C622
7200 or YEL
7150 or DGN
COMMUNICATION 9000-9999 PUR C622
7200 or YEL
2765 or BRN
7150 or DGN
2765 or BRN
1150 H L X L X
N
P
RED = RED
F TO OPTIONS
RNG = ORANGE
2745
TO OPTIONS
2745
BLK = BLACK A (DELUXE ACCESSORY) (DELUXE ACCESSORY)
LBL = LIGHT BLUE
DBL = DARK BLUE STANDARD ACCESSORY HARNESS - 6727468 C 7310
C 7310
LGN = LIGHT GREEN B 2735 2755 B B B 2735 2755 B B
C610
C667
C610
C667
DGN = DARK GREEN E 7160 C C
YEL = YELLOW E 7150 7160 C C DOOR SENSOR
TO OPTIONS
A 7210 A A
C617 OR C642
PNK = PINK (HVAC OR HVAC/ACCESSORY) A 7210 A A
WHT = WHITE D
BRN = BROWN 1140 B F 7190 2 7180 2
2 2
TAN = TAN F
PUR = PURPLE
1740
2740
A
C
WIPER HARNESS - 6729739 D 4710 1 1 4720 1 1
GRY = GRAY
FLASHER TO OPTIONS
(POWER BOB-TACH)
REAR WIPER WIPER HARNESS - 6730885
MOTOR
LIGHT SWITCH POWER BOB-TACH 2770 E
BEACON SWITCH
SWITCH
V
1 2760 D M
2745 6420 TO HORN
C601
6 5 2 1 REAR WIPER 1710 CONNECTOR
4 7000 A SWITCH
2
C412
1130 6010 HAZARD SWITCH C TRAVEL CONTROL
2750 B
L 6520
3 X 1 3 1720
1180 6430 7010 B 2 1 FRONT WIPER
LOCKOUT SWITCH HORN RELAY 1730 A
1 2 2 3
3 4 7220 SWITCH
5
4 1 85 86
4 5 2 2770 7200
6530 3
TO OPTIONS 5 6 1730 87
6 2750 2 1 2750 30
(EXTERIOR CAB) 6 4 1750 TO OPTIONS 87A 2760 ADDITIONAL POWER
5 4730 LEFT BLINKER RELAY
E 6700 2725 3 2715 (DELUXE ACCESSORY) CONNECTOR
3 4
C490
D 2780 6 5 E 85 86 2740 B
4 2780 6415
C670
7310 87
B 6540 5 D 6410 6410 30 1740 A
C411
TO OPTIONS 6 87A 6020
F 6440 (DOME LIGHT) 6 C
A B
C608
2710 B 6000
TO AWS TO MAINFRAME
C 6300 1110 A A 6510 CONTROLS B C A
TO OPTIONS (AWS HORN/ RIGHT BLINKER
C489
2 1190
2720 B
BLINKER HARNESS) RELAY C497
1 2700
1720 A
6410 D 85 86
TO OPTIONS 2790 6515
6510 A POWER 2790 87
C411
(FRONT WIPER) 6510 30
PLUG 6010
6000 B C 87A
C F
E AWS HORN/BLINKER HARNESS - 6726662
C667
7210 A
AWS SWITCH TO MAINFRAME 4710 D
1
1770 4550 E 1760 E
2
3 R 2735 B
4
2755 4235 D
5 4275
6 C
K
G AIR CONDITIONER SWITCH
B THERMOSTAT
3100 A A
C488
2730
C630
J
C612
OFF A 7010 B B
6400 L
6500 LOW B 2310 2205 C C
M 2100
1150 MEDIUM TO OPTIONS (AC)
H
6300 HIGH
N
6600 P
HERE OR TO OPTIONS
TO EUR0. LIGHTS 4730 F (HVAC JUMPER) HEATER VALVE
CONNECTOR 1140 A
DBL A A 3200 1300 A A RED 10
C613
1700 S
WHT B B 7200 D D WHT 8 M
C614
7000
C BLK C C 2110 2130 C C BLK 7
1110
POTENTIOMETER B B
DELUXE ACCESSORY HARNESS - 6727190 1000 B E
F
E
F
L BLOWER MOTOR
5000 3 3 YEL
M
1200 2 2 RED
C611
H 1010 1 1 RNG M
2200 4 4 BLK
BLOWER SWITCH POWER RELAY TO OPTIONS
5 5
(HVAC or DELUXE ACCESSORY)
6 6 85 86
1740 2210
C617 or
87 A
C636
30
87A 1190 B
HVAC HARNESS - 6725933 2740 C
TO OPTIONS (HVAC)
TO OPTIONS (HVAC) HEATER VALVE
C631
C612
B B 2310 2300 B
A 1300 A A RED 10
C633
A A 7030 A
D 7200 B B WHT 8 M
C614
C 2130 C C BLK 7
AIR CONDITIONER DIODE
B
CLUTCH SOLENOID
C426 To Mainframe SSL 7-PIN
E
SSL 7-PIN
CAN CONNECTOR D F C E A B G
Harness CAN CONNECTOR F HVAC JUMPER HARNESS -
KEY "RUN" D YEL D 6725934 OR 6725936
7020
7010
UNSW POWER 2 RED F
9800
1160
9700
1710
9500
9600
2710
CAN SHIELD C DGN C
SW POWER 1 RNG E To Mainframe
TO OPTIONS TO OPTIONS
KEY "RUN" D 9800 PUR C705 J1 - 8-PIN CAN LOW B LBL A
Harness
(HVAC) (DELUXE ACCESSORY)
B A
UNSW POWER 2 1160 RED/WHT 2720 H GROUND CAN HIGH A WHT B C 2740 C
C636
C642
CAN SHIELD C 9710 PUR 9710 F CAN SHIELD GROUND 3 BLK G C632
B 1140 B
7-PIN B A
SW POWER 1 1730 RNG 1720 B SW POWER A 1740 A
CAN LOW B 9620 PUR 9610 E CAN LOW C666 C426 ATTACHMENT
CONNECTOR
AIR CONDITIONER
CAN HIGH A 9520 PUR 9510 D CAN HIGH HVAC/ACCESSORY
GROUND 3 2730 BLK C OPEN CONTROL HARNESS - 6718426 HARNESS -
7-PIN A OPEN
HARNESS -
C666 ATTACHMENT
CONNECTOR G OPEN 6725390 6719630 EVAPORATOR (AC)
PRESSURE SWITCH
J
BOOM-MOUNTED
N ACD CONNECTORS
SW POWER K 1740
GROUND B 2740 C703 J2 - 10-PIN BLACK
E OUTPUT E 5100 5100 C E OUTPUT
TO ENGINE OR MAINFRAME
F OUTPUT F 5350 5350 H F OUTPUT
TO MAINFRAME
G OUTPUT G 5400 5400 J G OUTPUT 7100 C
2650 F RNG C
H OUTPUT H 5050 5050 B H OUTPUT BACK-UP
C103
C OUTPUT C 5300 5300 G C OUTPUT 6600 G ALARM RNG/DGN F
C103
D OUTPUT D 5150 5150 D D OUTPUT BACK-UP
6400 E G
A OUTPUT A 5250 5250 F A OUTPUT ALARM 6310 A E
M OUTPUT M 5200 5200 E B OUTPUT 6500 D PNK A
ID (K TO L) L 5910 5000 A J OUTPUT 6200 H D
ID (K TO P) P 5510 5450 K K OUTPUT 2600 B DBL/WHT H
BLK B
C506 14-PIN
C704
6340
ATTACHMENT J3 - 10-PIN GRAY
2620
2610
6610
6320
6620
6330
2640
CONNECTOR
5900 J ID #1
DBL/WHT
5500 A ID #2
BLK
BLK
PNK
PNK
BLK
BLK
B ID #3
F E D C B A 2630 6210
E F C A B D
C ID #4
C604 C605 REGISTRATION LEFT WORK RIGHT WORK
D ID #0
E F C A B D F E D C B A LAMP
E OPEN
F OPEN LEFT RIGHT
LEFT RIGHT
WORK WORK
G OPEN TAILLIGHT TAILLIGHT
LIGHT LIGHT
H OPEN DELUXE EUROPEAN
DELUXE ATTACHMENT CONTROL HARNESS - 6729380 & 6732730 K REAR LIGHT HARNESS - 6714350
OPEN
LEFT TAILLIGHT RIGHT TAILLIGHT
TAILLIGHT HARNESS - 6718198
V-0114 (4-8-04)
Printed in U.S.A.
ELECTRICAL SYSTEM INFORMATION
WIRING SCHEMATIC
A220 (S/N 519611001 AND ABOVE)
(S/N 519711001 AND ABOVE)
(PRINTED SEPTEMBER 2001)
V-0086
WIRING SCHEMATIC
A220 (S/N 519611001 AND ABOVE)
(S/N 519711001 AND ABOVE)
(PRINTED SEPTEMBER 2001)
V-0113
OPTIONS
WIRING SCHEMATIC
OPTIONS
A220 (S/N 519611001 AND ABOVE)
(S/N 519711001 AND ABOVE)
(PRINTED SEPTEMBER 2001)
V-0114
A220 Bobcat Loader
60-10-1 Service Manual
A220 Bobcat Loader
60-10-2 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Instructions are necessary before operating or
most common. Many of the recommended procedures servicing machine. Read and understand the
must be done by authorized Bobcat Service Personnel Operation & Maintenance Manual, Handbook and
only. signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs,
adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained
operators and failure to follow instructions can
cause injury or death.
W-2003-0199
PROBLEM CAUSE
Battery will not take a charge. 1,2,3,4,5
Alternator will not charge. 1,2,5
Starter will not turn the engine. 2,3,4,6,7,8,9
KEY TO CORRECT THE CAUSE
1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.
A220 Bobcat Loader
60-10-3 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT'D) Figure 60-10-3
Description
Figure 60-10-1
P-26235
1
The electrical system is also protected by fuses and
P13849 relays under the fuse panel cover (Item 1) [Figure 60-10-
3] located in the cab on the steering control panel.
The loader has a 12 volt, negative ground alternator
charging system. The electrical system is protected by a
100 amp master fuse (Item 1) [Figure 60-10-1] to protect
against serious system overloads that could lead to IMPORTANT
burned up harness or loader damage.
Do Not use silicone base sprays and/or sealants on
harness connectors or components.
I-2123-0397
IMPORTANT Figure 60-10-4
Do Not use silicone base sprays and/or sealants on
harness connectors or components.
I-2123-0397
Figure 60-10-2
1
1
P-26235
The fuse panel cover (Item 1) [Figure 60-10-4] & [Figure
60-10-6] has a decal inside to show the location and amp
ratings.
P-24811
The fuse holder is located in the engine compartment
(Item 1) [Figure 60-10-2].
A220 Bobcat Loader
60-10-4 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT'D) Relay Switch Location
Fuse Location Figure 60-10-6
Figure 60-10-5 1
N-19661
P-26239
Remove the cover to check or replace the fuses.
The location and sizes are shown in [Figure 60-10-5] &
F9
[Figure 60-10-6].
F5 F1 E D C B
Ref Description Ref Description
B Switch Power F Glow Plugs
F6 F2 F10 C Rear Lights G Fuel Shutoff
D Front & Marker Lights H Traction
E Not Used J Starter
F7 F3 F G H J F11
F8 F4 F12
FUSES RELAYS FUSES
N-18465A
Remove the cover to check or replace the fuses.
The location and sizes are shown in [Figure 60-10-5] &
[Figure 60-10-6].
Ref Description Amp. Ref Description Amp.
F1 Heater 25 F9 Unswitched Attch. 25
F2 Front & Marker Lights 15 F10 Switched Attach. 25
F3 Rear Lights 15 F11 Alternator & Kits 25
F4 Bobcat Controller 25 F12 AHC Power 25
F5 Traction 30
F6 Fuel Shutoff 30
F7 Not Used --
F8 Not Used --
A220 Bobcat Loader
60-10-5 Service Manual
ELECTRICAL SYSTEM INFORMATION (CONT’D)
Solenoid Test
Figure 60-10-7
P9175
Use a test meter to measure coil resistance [Figure 60-
10-7]. Coil wires do not have polarity. Correct resistance
for the pressure relief (small) coil is 7-10 ohm and the
other coils 5-8 ohms.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
A220 Bobcat Loader
60-10-6 Service Manual
BATTERY Figure 60-20-2
Removal And Installation
2
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body. 1
In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
P-24813
minutes.
If electrolyte is taken internally drink large quantities Remove the battery hold down clamp (Item 1) [Figure
of water or milk! DO NOT induce vomiting. Get 60-20-2].
prompt medical attention.
W-2065-1296
Disconnect the positive (+) cable (Item 2) [Figure 60-20-
2] from the battery.
Figure 60-20-1
Remove the battery from the loader.
P-24812
Open the rear door.
Disconnect the negative (-) cable (Item 1) [Figure 60-20-
1] from the battery.
Remove the bolt from the cable clamp (Item 2) [Figure
60-20-1] and loader frame.
A220 Bobcat Loader
60-20-1 Service Manual
BATTERY (CONT’D) Figure 60-20-5
Removal And Installation (Cont'd)
Figure 60-20-3
P-24812
Installation: The short negative cable must be
P9589 connected at the cable clamp and ground bolt (Item 1)
[Figure 60-20-5] to insure proper system ground and
cable routing.
Figure 60-20-4
Connect and tighten the battery cables. Connect the
negative (-) cable last to prevent sparks.
P9590
Installation: Always clean the terminals and cable ends
when installing a new battery as shown in [Figure 60-20-
3] and [Figure 60-20-4].
When installing the battery in the loader, do not touch any
metal parts with the battery terminal posts.
A220 Bobcat Loader
60-20-2 Service Manual
BATTERY (CONT’D) Using A Booster Battery (Jump Starting)
Servicing The Electrical System
WARNING
WARNING Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
Batteries contain acid which burns eyes and skin on rubber gloves to keep acid off body.
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body. In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention
In case of acid contact, wash immediately with water. and wash eye with clean, cool water for at least 15
In case of eye contact get prompt medical attention minutes.
and wash eye with clean, cool water for at least 15
minutes. If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get
If electrolyte is taken internally drink large quantities prompt medical attention.
of water or milk! DO NOT induce vomiting. Get W-2065-1296
prompt medical attention.
W-2065-1296
Figure 60-20-6
WARNING
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at engine frame.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F (16°C) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury.
W-2066-1296
P9588
The battery cables must be clean and the connections
tight. Remove acid or corrosion from the battery and IMPORTANT
cables with a sodium bicarbonate (baking soda) and
water solution as shown in [Figure 60-20-6]. Damage to the alternator can occur if:
• Engine is operated with battery cables
Clean the terminals and cable ends as shown in figure disconnected.
[Figure 60-20-3] and [Figure 60-20-4]. • Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
Check the electrolyte level in the battery. Add distilled both cables from the battery.)
water as needed. • Extra battery cables (booster cables) are
connected wrong.
Put Battery Saver P/N 6664458 or grease on the battery I-2023-1285
terminals and cable ends to prevent corrosion.
A220 Bobcat Loader
60-20-3 Service Manual
BATTERY (CONT’D) If it is necessary to use a booster battery to start the
engine, BE CAREFUL! There must be one person in the
Using A Booster Battery (Jump Starting) (Cont’d) operator's seat and one person to connect and
disconnect the battery cables.
Figure 60-20-7
The key switch must be in the OFF position. The booster
battery to be used must be 12 volt.
Connect the end of the first cable (Item 1) [Figure 60-20-
7] to the positive (+) terminal of the booster battery.
Connect the other end of the same cable (Item 2) [Figure
2 60-20-7] to the positive terminal on the starter.
4
Connect the end of the second cable (Item 3) [Figure 60-
20-7] to the negative (-) terminal of the booster battery.
1
P-10813
Connect the other end of the same cable (Item 4) [Figure
60-20-7] to the engine.
Keep cables away from moving parts. Start the engine.
After the engine has started, remove the ground (-) cable
(Item 4) [Figure 60-20-7] first.
Remove the cable from the starter.
P-7661A
A220 Bobcat Loader
60-20-4 Service Manual
ALTERNATOR The black cover has been removed to show alternator
rectifier/regulator assembly. The alternator contains field
Adjusting The Alternator Belt coil diodes (low current) (Item 1) [Figure 60-30-2],
grounded heat sink (Item 2) [Figure 60-30-2] & [Figure
Figure 60-30-1 60-30-3], B+ power heat sink (Item 3) [Figure 60-30-2] &
2 [Figure 60-30-3], regulator (Item 4) [Figure 60-30-2] &
[Figure 60-30-3], and four pair of large power diodes
(Item 1) [Figure 60-30-3] on the underside of the rectifier.
Figure 60-30-3
4
1 1
3
P-26602
Stop the engine.
1 1
Raise the operator cab. (See Raising The Operator Cab 1
on Page 10-30-1.) 2 P-24542
Loosen the alternator adjustment bolts (Item 1) [Figure
60-30-1]. NOTE: The rectifier/regulator assembly has been
removed from the alternator and flipped over
At the front side of the altenator, loosen the alternator
for component identification [Figure 60-30-3].
mounting bolt (Item 2) [Figure 60-30-1].
Move the alternator until the belt has 5/16 inch (8,0 mm)
movement at the middle of the belt span with 15 lbs. (66
N) of force.
Tighten the adjustment bolts and mounting bolt.
Lower the operator cab. (See Lowering The Operator
Cab on Page 10-30-2.)
Alternator Identification
Figure 60-30-2
2
1
P-24416
4
1
3
P-24417
A220 Bobcat Loader
60-30-1 Service Manual
ALTERNATOR (CONT’D) Figure 60-30-4
Charging System Check
1
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
2
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
P-34325
minutes.
If electrolyte is taken internally drink large quantities If the charging system malfunctions check the following:
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. Check the condition and tension of the alternator belt.
W-2065-1296 (See Adjusting The Alternator Belt on Page 60-30-1.) If
belt is worn or deteriorated replace.
Inspect the alternator wiring harness and connectors at
WARNING alternator. Harness and connectors must be clean and
tight.
Check the fuse for the alternator in the fuse panel. If fuse
Keep arcs, sparks flames and lighted tobacco away
is burned, find the cause and repair/replace. If fuse is in
from batteries. When jumping from booster battery
doubt, remove it and check for continuity.
make final connection (negative) at engine frame.
Check the electrolyte level in the battery. Add distilled
Do not jump start or charge a frozen or damaged water as needed. (Does not apply to maintenance free
battery. Warm battery to 60°F (16°C) before batteries.)
connecting to a charger. Unplug charger before
Verify the charge of the battery. Make sure battery is fully
connecting or disconnecting cables to battery. Never
charged.
lean over battery while boosting, testing or charging.
Disconnect the battery cables (negative first, then
Battery gas can explode and cause serious injury. positive). Inspect the cable clamps and battery posts for
W-2066-1296 corrosion. Remove acid or corrosion from the battery
and cables with a sodium bicarbonate and water
solution. Put grease on the cable ends and battery
terminals to prevent corrosion. Reconnect the cable to
the positive terminal.
IMPORTANT With the key off, connect a test light between the
negative battery post and the disconnected negative
Damage to the alternator can occur if: cable clamp.
• Engine is operated with battery cables
disconnected. 1. If the test light does not light up, reattach the clamp
• Battery cables are connected when using a fast and proceed to alternator voltage test. (See Below.)
charger or when welding on the loader. (Remove 2. If the test light lights up, there is a short (drain) in the
both cables from the battery.) electrical system of the loader. The short must be
• Extra battery cables (booster cables) are repaired before the charging system can be checked.
connected wrong.
I-2023-1285 3. Disconnect the alternator B+ terminal (Item 1) [Figure
60-30-4] and L & S terminal connector (Item 2)
[Figure 60-30-4] and if the test light goes out, the
alternator is faulty. If the test light stays on, find the
short in the system and repair it.
A220 Bobcat Loader
60-30-2 Service Manual
ALTERNATOR (CONT’D) Low Voltage Test
Alternator Voltage Test Figure 60-30-6
Figure 60-30-5
P-34325
P-24560
Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 60-30-6] off the alternator.
Open rear door. (See REAR DOOR on Page 50-70-1.)
Turn the remote start tool key to the ON position.
Connect the remote start tool to the loader. (See
REMOTE START on Page 10-60-1.) Figure 60-30-7
Turn the engine on with the remote start tool and run at
idle. With a voltmeter, check the voltage between the B+
terminal and ground at the starter [Figure 60-30-5].
The voltage must be higher than 13.5 volts but lower than
14.7 volts at 70° F (Alternator Temperature). 1 P-24566
If the voltage is higher that 14.7 volts, proceed to the
following high voltage test.
If the voltage is lower than 13.5 volts, run the engine at 2
high idle and recheck voltage. If voltage is still below 13.5
volts, proceed with the following low voltage test.
P-34325
Check the voltage across the "L" terminal (Item 1) and
ground (Item 2) [Figure 60-30-7]. The voltage should be
what the battery voltage is. If not, check wire harness,
relay and fuses. If the wire harness, relay and fuses are
OK then remove alternator for replacement or repair.
A220 Bobcat Loader
60-30-3 Service Manual
ALTERNATOR (CONT’D)
High Voltage Test
IMPORTANT
Figure 60-30-8
Damage to the alternator can occur if:
1 • Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
P-24568
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
Figure 60-30-9
2
N-19699
1
Turn engine OFF and remove the L & S Terminal
connector (Item 1) [Figure 60-30-6] off the alternator.
2
Check the continuity between the "S" terminal (Item 1)
and the positive (+) terminal on the battery or starter
terminal (Item 2) [Figure 60-30-8]. There should be
continuity. If no continuity, replace wire harness.
If voltage is still above 14.7 volts at 70° F (Alternator
P-34325
Temperature), then remove alternator for replacement or
repair.
Place jackstands under the rear corners of the loader.
Removal And Installation
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Disconnect the negative (-) cable from the battery.
Disconnect the red wire (Item 1) [Figure 60-30-9] from
the alternator which comes from the battery.
WARNING Disconnect the wiring harness connector (Item 2) [Figure
60-30-9] from the alternator.
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
A220 Bobcat Loader
60-30-4 Service Manual
ALTERNATOR (CONT’D) NOTE: In the diode tests there should be continuity
in one direction only. Meter readings should
Removal And Installation (Cont’d) be different when probes are reversed. If the
diode being tested shows no continuity or
Figure 60-30-10 continuity in both directions, replace the
rectifier assembly.
2
Figure 60-30-12
1 1
P-26602
Remove the adjustment bolts (Item 1) [Figure 60-30-10]
P-24532
from the mounting bracket.
Remove the alternator belt (Item 2) [Figure 60-30-10] NOTE: Use the diode function (Item 1) [Figure 60-30-
from the alternator pulley. 12] on the multimeter.
At the front of the alternator, remove the mounting bolt Figure 60-30-13
(Item 3) [Figure 60-30-10].
Remove the alternator from the loader.
1
Rectifier Continuity (Diode) Test
Figure 60-30-11
1
2
3
1
P-24527
1
Touch the probes to the terminals (Item 1) [Figure 60-30-
13] of each diode and read the meter.
1
Reverse the probes to check the diode in the other
P-24416 direction.
Meter readings should be different when probes are
Remove the two screws (Item 1), nut/washer (Item 2) and reversed.
the plastic cover (Item 3) [Figure 60-30-11] from the
alternator.
A220 Bobcat Loader
60-30-5 Service Manual
ALTERNATOR (CONT’D) Figure 60-30-16
Rectifier Continuity (Diode) Test (Cont’d)
Figure 60-30-14
1
P-24535
Reverse the probes to check in the other direction
P-24558 [Figure 60-30-15].
There should be continuity in one direction only. Meter
Touch one probe to the diode (Item 1) [Figure 60-30-14] readings should be different when probes are reversed. If
and the other probe to each heat sink and read the meter. there is no continuity or continuity in both directions,
replace regulator.
Reverse the probes to check the diode in the other
direction.
Meter readings should be different when probes are
reversed.
Alternator Regulator Test
Figure 60-30-15
P-24533
Touch one probe to the "L" terminal (Item 1) and the other
probe to the ground (Item 2) [Figure 60-30-15].
A220 Bobcat Loader
60-30-6 Service Manual
ALTERNATOR (CONT’D) Stator Continuity Test
Disassembly Figure 60-30-18
Figure 60-30-17
1. Alternator 11. Bearing
2. Nut 12. Stator
3. Pulley 13. Bracket
4. Spacer 14. Sleeve
5. Bolt 15. Regulator
6. Bracket 16. Rectifier
7. Bolt 17. Cover
8. Bearing 18. Spacer
9. Retainer 19. Nut
10. Rotor
7
1 6
P-24537
4 7 13 14
3
2 12 5 Use an ohmmeter to test the stator.
11 Touch the probes to two of the bare stator wires [Figure
10 60-30-18].
9
8 Move one of the probes to the third wire.
The readings should be the same.
19
18 If there is no continuity, replace the stator.
17 Stator Ground Test
16 Figure 60-30-19
15
C-3529B
Disassemble the alternator [Figure 60-30-17].
Remove the regulator cover.
Remove the four bolts holding halves together.
Pry the halves apart (use a press if needed).
Use a soft jaw vise to hold rotor while removing pulley
nut.
Remove front case half from the rotor using a plastic P-24538
hammer or press.
Unsolder the stator leads from the rectifier. Remove the Touch one probe to a bare stator lead and the other
stator. probe to the bare metal surface of the stator [Figure 60-
30-19].
Unsolder the two leads between the rectifier and
regulator. Remove the regulator from rectifier. There should be no continuity.
Replace the stator if there is continuity.
A220 Bobcat Loader
60-30-7 Service Manual
ALTERNATOR (CONT’D) Assembly
Rotor Continuity Test Figure 60-30-22
Figure 60-30-20
P-24557
P-24524
Reverse the order of disassembly.
Touch the probes to the slip rings [Figure 60-30-20]. Do not assemble the rear case half.
The ohmmeter should read between 3.0-4.0 ohms. Place the rotor in soft jaws when tightening the shaft nut
(Item 1) [Figure 60-30-22]. Tighten to 72 ± 14.5 ft.-lbs.
If there is no continuity replace the rotor. (98 ± 20 Nm) torque.
Rotor Ground Test Install the rear case half and the remaining parts.
Figure 60-30-21
P-24525
Touch one probe to one of the slip rings and the other
probe to the rotor shaft [Figure 60-30-21].
There should be no continuity.
Replace the rotor if there is continuity.
A220 Bobcat Loader
60-30-8 Service Manual
STARTER (NIPPONDENSO) Removal And Installation
Checking Figure 60-40-3
Figure 60-40-1
Bat
S
M
Cranking
Motor 1
N-19699
A-1992
Open the rear door.
The key switch must be in the OFF position. Disconnect the negative (-) cable from the battery.
The battery must be at full charge. Disconnect the positive (+) cable (Item 1) [Figure 60-40-
3] at the starter.
The cable connections on the battery must be clean and
tight. Figure 60-40-4
Connect a jumper wire between S terminal and BAT
terminal [Figure 60-40-3].
If the starter turns but does not turn the engine, the
starter drive has a defect.
Figure 60-40-2
Bat
S
1
M
1
N-19700
Cranking Disconnect the two wires (Item 1) [Figure 60-40-4] from
Motor the starter solenoid.
A-1991
Connect a jumper wire between the M terminal and the
BAT terminal [Figure 60-40-2].
If the starter turns, the defect is in the solenoid.
If the starter does not turn, the starter is defective.
A220 Bobcat Loader
60-40-1 Service Manual
STARTER (NIPPONDENSO)
Removal And Installation (Cont’d)
Figure 60-40-5
N-19701
Remove the two starter mounting bolts (Item 1) [Figure
60-40-5].
Disconnect the ground wires.
Figure 60-40-6
N-19702
Remove the two starter mounting bolts (Item 1) [Figure
60-40-6]
Remove the starter.
A220 Bobcat Loader
60-40-2 Service Manual
STARTER (NIPPONDENSO) (CONT’D)
Parts Identification
1. Felt Washer
2. Bearing
3. Armature 8
4. Bearing
5. Field Windings 10
6 7 9
Housing Assy.
6. Cover 11. Brushes
7. Brush Holder 5 12. Cover
8. Cover 13. Gasket
9. Bolt 14. Screw
10. Bolt 4 15. PInion Shaft
16. Nut
3
17. Washer
18. Nut
19. Washer
1 20. Roller
17 11 13
12
16
18 14
20 19
21 15
22 11
25 18
16
24
17
23
35
21. Retainer
34 22. Pinion
33 23. Ball
24. Spring
25. Housing
31
26. Screw
28 27. Washer
27 30 32 28. O-ring
26 29. Housing
30. Gear
31. Spring
32. O-ring
33. Drive
34. Spring
29 35. Shaft
D-2297
A220 Bobcat Loader
60-40-3 Service Manual
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-9
Disassembly
Figure 60-40-7
1 N-15160
Remove the frame (Item 1) [Figure 60-40-9] from the
N-15158 magnetic switch.
Figure 60-40-10
Remove the cable (Item 1) [Figure 60-40-7] from the
magnetic switch.
Figure 60-40-8
1
1 1
N-15161
1
Remove the bolts (Item 1) from the brush cover (Item 2)
N-15159 [Figure 60-40-10].
Remove the cover (Item 2) [Figure 60-40-10].
Remove the bolts (Item 1) [Figure 60-40-8].
A220 Bobcat Loader
60-40-4 Service Manual
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-13
Disassembly (Cont'd)
1
Figure 60-40-11
1
1
N-15162
Remove the bolts (Item 1) [Figure 60-40-13] from the
3 N-00980 starter housing.
Figure 60-40-14
Using a needle nose pliers, pull the brush springs (Item
1) back and remove the brushes (Item 2) [Figure 60-40-
11]. 1
NOTE: The brushes are non-replaceable. If the
brushes are worn order a new brush holder
(for the negative brushes) and yoke (for the
positive brushes).
Remove the brush holder (Item 3) [Figure 60-40-11]
from the end of the armature.
Figure 60-40-12
N-15163
Remove the starter housing (Item 1) [Figure 60-40-14]
1 from the magnetic switch.
2
2
N-00981
Remove the armature (Item 1) [Figure 60-40-12] from
the frame.
Remove the bearings (Item 2) [Figure 60-40-12] from
both ends of the armature.
A220 Bobcat Loader
60-40-5 Service Manual
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-17
Disassembly (Cont'd)
Figure 60-40-15
1
N-15166
1
Remove the O-ring (Item 1) [Figure 60-40-17].
N-15164
Figure 60-40-18
Remove the ball (Item 1) [Figure 60-40-15] from the
pinion shaft.
2
Figure 60-40-16
N-00987
Press down on the pinion (Item 1) and retainer (Item 2)
1 [Figure 60-40-18].
N-15165
Tap the starter pinion/clutch assembly (Item 1) [Figure
60-40-16] out of the starter housing.
A220 Bobcat Loader
60-40-6 Service Manual
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-21
Disassembly (Cont'd)
Figure 60-40-19
3
1 2
N-00989
Remove the pinion shaft (Item 1) and spring (Item 2) from
N-15011 the over running clutch (Item 3) [Figure 60-40-21].
Figure 60-40-22
Remove the snap ring (Item 1) [Figure 60-40-19].
Figure 60-40-20
1
3
1 N-15167
4 2
N-00988 Remove the spring (Item 1) [Figure 60-40-22] from the
magnetic switch housing.
Remove the retainer (Item 1) and pinion (Item 2) [Figure
60-40-20].
Remove the spring seat (Item 3) and spring (Item 4)
[Figure 60-40-20].
A220 Bobcat Loader
60-40-7 Service Manual
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-25
Disassembly (Cont'd)
Figure 60-40-23
1
2
1
1 1 N-15150
3
Remove the bolts (Item 1) [Figure 60-40-25] from the
N-15168 magnetic switch.
Figure 60-40-26
Remove the idler gear (Item 1), retainer (Item 2) and
rollers (Item 3) [Figure 60-40-23] from the magnetic
switch housing.
Figure 60-40-24
1
3 2
N-15151
Remove the cover (Item 1), gasket (Item 2) and switch
1 (Item 3) [Figure 60-40-26].
N-15169
Remove the washer (Item 1) [Figure 60-40-24] from the
idler gear shaft.
A220 Bobcat Loader
60-40-8 Service Manual
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-29
Inspection And Repair
Figure 60-40-27
N-00997
Armature Winding Continuity Test: Use a circuit tester,
B-14455 touch the probes to two commutator segments [Figure
60-40-29]. There should be continuity at any point. If
there is no continuity, the winding is open-circuited,
Inspect the brush cover for discoloration, indication the replace the armature.
starter has been overheated.
Figure 60-40-30
Inspect the pinion teeth for wear and damage.
Armature Short-Circuit Test: Use a growler tester, put the
armature on the growler and hold a hack saw blade
against the armature core while slowly rotating the
armature [Figure 60-40-27]. A short circuited armature
causes the blade to vibrate and be attracted to the core.
An armature which is short-circuited must be replaced.
Figure 60-40-28
B-14458
Commutator Run-Out Test: check the commutator run-
out as shown in [Figure 60-40-30].
Service Limit - 0.020 inch (0,4 mm)
If the commutator exceeds the service limit, repair as
needed.
N-00996
Armature Winding Ground Test: Use a circuit tester,
touch one probe to a commutator segment and the other
probe to the armature core [Figure 60-40-28]. There
should be no continuity. If there is continuity, the
armature is grounded and must be replaced.
A220 Bobcat Loader
60-40-9 Service Manual
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-32
Inspection And Repair (Cont'd)
Figure 60-40-31
N-00999
Check the field windings for wear and damage.
B-14460
Check all the connections for clean and tight solder
joints.
Measure the segment mica depth (Item 1) [Figure 60-40-
31]. Field Winding Ground Test: Use a circuit tester, touch
one probe to the field winding end of the brush and the
Service Limit - 0.008 inch (0,2 mm) other probe to the surface of the frame [Figure 60-40-
32]. There should be no continuity. If there is continuity,
If it is worn, replace the armature. the field windings are grounded.
Check the commutator surface for burned spots which Replace the frame.
usually indicates an open-circuit, and correct it using
#400 sand paper. Figure 60-40-33
N-15005
Field Windings Continuity Test: Use a circuit tester, touch
one probe to the wire and the other probe to the brush
[Figure 60-40-33]. There should be continuity. If there is
no continuity, the field windings are open-circuited.
Replace the frame.
A220 Bobcat Loader
60-40-10 Service Manual
STARTER (NIPPONDENSO) (CONT’D) Pull the pinion out (to the engaged position) [Figure 60-
40-35] and allow it to snap back to the retracted position.
Inspection And Repair (Cont'd) The pinion must fully return to the retracted position.
Figure 60-40-34 The following tests should be done without the armature
assembly. Install the magnetic switch in the switch
housing.
NOTE: Each test should be performed a short time (3
to 5 seconds) to prevent the magnetic switch
winding from burning. Each test should be
performed with 12 volts.
Figure 60-40-36
C
50
N-15006
Inspect the brushes for wear and damage.
Replace the brush holder and yoke if the brushes need
replacement.
M.T.
Check brush spring, for damage or rust. Replace as
needed.
B-14471
Brush Holder Insulation Test: Use a circuit tester, touch
one probe to the positive brush holder plate and the other Pull-In Test: Connect the wires as shown in [Figure 60-
probe to the holder plate [Figure 60-40-34]. There 40-36]. When connecting Terminal C and M.T. are
should be no continuity. If there is continuity, replace or closed, the pinion should engage.
repair.
Figure 60-40-37
Figure 60-40-35
C 50
M.T.
B-14470
N-15012
Hold-In Test: With the same conditions as in the pull-in
NOTE: Assemble the over running clutch, pinion test, open the connecting Terminal C [Figure 60-40-37].
shaft, springs, and pinion for this test. The pinion should remain in the engaged position.
Inspect the pinion, it must rotate freely in the direction of
the starter rotation and lock in the opposite rotation.
A220 Bobcat Loader
60-40-11 Service Manual
STARTER (NIPPONDENSO) (CONT’D) Clamp the starter in a vise. Using a 12 volt battery and
ammeter, connect the positive wire of the battery, and the
Inspection And Repair (Cont'd) ammeter to the terminal [Figure 60-40-39]. Connect the
negative wire to the starter body. Using a jumper wire,
Figure 60-40-38 connect the 50 terminal to the main terminal.
The starter should show smooth and steady rotation
immediately after the pinion is engaged, it should draw
C 50 less than the specified current.
Service Limit - 220 Amp. Maximum Draw
Assembly
Figure 60-40-40
M.T.
B-14469
Return Test: With the same conditions as in the hold-in
test, open the connecting Terminal 50 [Figure 60-40-38].
The pinion should return immediately.
M.T. Main Terminal to which the main cable
from the battery is connected.
C C - Terminal to which the wire from the 1 3
field windings is connected. 2 N-15151
50 50 - Terminal to which the wire from the
starting switch or stator relay is
connected. Clean all parts and apply high temperature grease to the
armature bearing, return spring, steel ball, over running
No Load Test clutch, and idler gear rollers.
Figure 60-40-39 Install the switch plunger (Item 1), gasket (Item 2) and
cover (Item 3) [Figure 60-40-40] on the switch housing.
Ammeter
Figure 60-40-41
50
M.T.
1
Starter B-14440
The following test should be done after reassembling the 1 N-15150
starter:
Install the bolts (Item 1) [Figure 60-40-41].
A220 Bobcat Loader
60-40-12 Service Manual
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-44
Assembly (Cont'd)
Figure 60-40-42
N-15152
1
Install the roller/retainer assembly (Item 1) [Figure 60-
N-15169 40-44] on the idler gear shaft.
Figure 60-40-45
Install the washer (Item 1) [Figure 60-40-42] on the idler
gear shaft.
Figure 60-40-43
1
2
N-15153
Install the idler gear (Item 1) [Figure 60-40-45] over the
N-15007 retainer.
Install the rollers (Item 1) in the retainer (Item 2) [Figure
60-40-43].
A220 Bobcat Loader
60-40-13 Service Manual
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-48
Assembly (Cont'd)
Figure 60-40-46
2
N-15010
1 Install the spring (Item 1) and spring seat (Item 2)
N-15167 [Figure 60-40-48] on the pinion shaft.
Figure 60-40-49
Install the spring (Item 1) [Figure 60-40-46] in the
magnetic switch housing.
3
Figure 60-40-47
3 1
2 1
N-15011
Install the pinion (Item 1) and retainer (Item 2) [Figure
N-00989 60-40-49] on the pinion shaft.
Press down on the pinion (Item 1) and install the snap
Install the spring (Item 1) over the pinion shaft (Item 2). ring (Item 3) [Figure 60-40-49] on the pinion shaft.
Install the pinion shaft (Item 2) in the over running clutch
(Item 3) [Figure 60-40-47]. Pull the retainer (Item 2) over the snap ring (Item 3)
[Figure 60-40-49].
Stand the clutch assembly on end.
A220 Bobcat Loader
60-40-14 Service Manual
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-52
Assembly (Cont'd)
Figure 60-40-50
N-15164
Install the ball (Item 1) [Figure 60-40-52] in the end of
1
N-15166 the pinion shaft.
Figure 60-40-53
Install the O-ring (Item 1) [Figure 60-40-50] in the starter
housing.
Figure 60-40-51
1 N-15163
1 Install the starter housing (Item 1) [Figure 60-40-53] on
N-15165 the magnetic switch housing.
Install the pinion shaft/over running clutch assembly
(Item 1) [Figure 60-40-51] in the starter housing.
A220 Bobcat Loader
60-40-15 Service Manual
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-56
Assembly (Cont'd)
Figure 60-40-54
1
1
N-15014
1 Install the bearings (Item 1) [Figure 60-40-55] & [Figure
N-15162 60-40-56] on both ends of the armature.
Figure 60-40-57
Install the bolts (Item 1) [Figure 60-40-54] in the starter
housing. Tighten the bolts to 60-104 in.-lbs. (6,7-11,8
Nm) torque.
Figure 60-40-55
1
N-00981
1
Install the armature (Item 1) [Figure 60-40-57] in the
frame.
N-15013
A220 Bobcat Loader
60-40-16 Service Manual
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-60
Assembly (Cont'd)
Figure 60-40-58
1
N-15156
1
Install the brush holder (Item 1) [Figure 60-40-60] on the
N-15154 end of the armature.
Figure 60-40-61
Install the frame/armature assembly (Item 1) [Figure 60-
40-58] on the housing.
Figure 60-40-59 2
1
1
N-15157
Using the needle nose pliers, pull the brush springs (Item
N-15155 1) back and install the brushes (Item 2) [Figure 60-40-
61].
NOTE: Make sure the notch (Item 1) in the frame
matches up with the notch (Item 2) [Figure 60-
40-59] in the housing.
A220 Bobcat Loader
60-40-17 Service Manual
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-63
Assembly (Cont'd) 1
Figure 60-40-62
3
1
N-15158
2
2 Install the cable (Item 1) [Figure 60-40-63] on the
3 N-15159 magnetic switch. Tighten the nut to 18-26 ft.-lbs. (24-35
Nm) torque.
Install the brush cover (Item 1) and bolts (Item 2) [Figure
60-40-62]. Tighten the bolts to 23-40 in.-lbs. (3,0-5,0 Nm)
torque.
Install the thru bolts (Item 3) [Figure 60-40-62]. Tighten
the bolts to 60-104 in.-lbs. (7-12 Nm) torque.
A220 Bobcat Loader
60-40-18 Service Manual
STARTER (VALEO) Removal And Installation
Checking Figure 60-41-3
Figure 60-41-1
Bat
S
M
1
Cranking
Motor
P-34326
A-1992
Open the rear door.
The key switch must be in the OFF position. Disconnect the negative(-) cable from the battery.
The battery must be at full charge. Disconnect the wires and positive (+) cable (Item 1)
[Figure 60-41-3] from the starter solenoid.
The cable connections on the battery must be clean and
tight. Figure 60-41-4
Connect a jumper wire between S terminal and BAT
terminal [Figure 60-41-1].
If the starter turns but does not turn the engine, the
starter drive has a defect. 1
Figure 60-41-2
Bat 1
S
M
P-34328
Cranking Disconnect the wires (Item 1) [Figure 60-41-4] from the
Motor starter solenoid.
A-1991
Connect a jumper wire between the M terminal and the
BAT terminal [Figure 60-41-2].
If the starter turns, the defect is in the solenoid.
If the starter does not turn, the starter is defective.
A220 Bobcat Loader
60-41-1 Service Manual
STARTER (VALEO)
Removal And Installation (Cont’d)
Figure 60-41-5
P-34327
Remove the three mounting bolts (Item 1) [Figure 60-41-
5].
Remove the starter from the engine.
A220 Bobcat Loader
60-41-2 Service Manual
STARTER (VALEO) (CONT’D)
Parts Identification
1. Starter 30
2. Shaft 13. Lever
3. Gear 14. Gear
4. Washer 15. Bracket
5. Shaft 16. Spring
6. Stop Ring 34 17. Gear
33
7. Lever 18. Stop
8. Holder 19. Stop Ring
13
9. Spring 20. Ball
10. Spring 21. Armature
36 22. Washer
11. Plate
11 23. Seal
12. Seal 9
10 24. Yoke
31
32 7
21
15
14 19
16 20
17
19 18
5 8
14
6
29
1 4
3
28
2
27
35
25. Holder
26. Bracket
26 27. Ring
22
28. Bolt
29. Bolt
23 25 30. Switch
31. Seal
23 32. Bolt
33. Washer
34. Nut
24 35. Boot
36. Bracket
B-16488
A220 Bobcat Loader
60-41-3 Service Manual
STARTER (VALEO) (CONT’D) Figure 60-41-8
Disassembly And Assembly
Figure 60-41-6
1
1
1
2
P-34596
Remove the bolts (Item 1) from the brush cover (Item 2)
P-34594 [Figure 60-41-8].
Remove the cover (Item 2) [Figure 60-41-8].
Remove the cable (Item 1) [Figure 60-41-6] from the
magnetic switch. Figure 60-41-9
Remove the bolts (Item 2) [Figure 60-41-6].
Installation: Tighten the bolts to 63-129 ft.lbs. (7,1-14,6 2
Nm) torque.
Figure 60-41-7
1
1 2
4
3
3
N-00980
Using a needle nose pliers, pull the brush springs (Item
1) back and remove the brushes (Item 2) [Figure 60-41-
9].
P-34595 NOTE: The brushes are non-replaceable. If the
brushes are worn order a new brush holder
(for the negative brushes) and yolk (for the
Remove the armature, yoke, brush holder and rear positive brushes).
bracket assemblies (Item 1) from the front assembly
(Item 2) [Figure 60-41-7]. Remove the brush holder (Item 3) [Figure 60-41-9] from
the end of the armature.
NOTE: When separating the parts there will be a steel
ball (Item 3)located at the end of the armature
shaft (Item 4) [Figure 60-41-7].
Installation: Apply grease to the steel ball (Item 3)and
install into the end of the armature shaft (Item 4) [Figure
60-41-7] .
A220 Bobcat Loader
60-41-4 Service Manual
STARTER (VALEO) (CONT’D) Figure 60-41-12
Disassembly And Assembly (Cont'd)
1
Figure 60-41-10
2
3
2 P-34600
Inspect the magnetic switch (Item 1), the spring (Item
P-34598 2),and the plunger (Item 3) [Figure 60-41-12] for wear
and replace as needed.
Remove the armature (Item 1) [Figure 60-41-10] from Figure 60-41-13
the frame.
Remove the bearing (Item 2) [Figure 60-41-10] from the
end of the armature.
Figure 60-41-11
3 2
1
P-34601
Remove the center bracket (Item 1) [Figure 60-41-13]
P-34599
Remove the bolts (Item 1) [Figure 60-41-11] from the
magnetic switch.
Installation: Tighten bolts to 34-69 ft.-lbs. ( 3,8-7,8 Nm)
torque.
Remove the front assembly (Item 2) from the magnetic
switch (Item 3) [Figure 60-41-11].
A220 Bobcat Loader
60-41-5 Service Manual
STARTER (VALEO) (CONT’D) Figure 60-41-16
Disassembly And Assembly (Cont'd)
Figure 60-41-14
1
3
2
2 2 4
P-34604
1 Remove the snap ring (Item 3) [Figure 60-41-15] &
P-34602 [Figure 60-41-16]
Remove the retainer (Item 2) [Figure 60-41-15] &
Remove the rubber retainer (Item 1) [Figure 60-41-14]. [Figure 60-41-16] and pinion (Item 1) [Figure 60-41-15]
& [Figure 60-41-16].
Remove the planetary gears (Item 2) [Figure 60-41-14]
and inspect for damage. Remove the spring (Item 4) [Figure 60-41-16].
Figure 60-41-15 Installation: Inspect all parts for wear and replace as
needed.
3 2
P-34603
Press down on the pinion (Item 1) [Figure 60-41-15] &
[Figure 60-41-16] and retainer (Item 2) [Figure 60-41-
15] & [Figure 60-41-16].
A220 Bobcat Loader
60-41-6 Service Manual
STARTER (VALEO) (CONT’D) Figure 60-41-19
Inspection And Repair
Figure 60-41-17
N-00997
Armature Winding Continuity Test: Use a circuit tester,
B-14455 touch the probes to two commutator segments [Figure
60-41-19]. There should be continuity at any point. If
there is no continuity, the winding is open-circuited,
Inspect the brush cover for discoloration, indication the replace the armature.
starter has been overheated.
Figure 60-41-20
Inspect the pinion teeth for wear and damage.
Armature Short-Circuit Test: Use a growler tester, put the
armature on the growler and hold a hack saw blade
against the armature core while slowly rotating the
armature [Figure 60-41-17]. A short circuited armature
causes the blade to vibrate and be attracted to the core.
An armature which is short-circuited must be replaced.
Figure 60-41-18
B-14458
Commutator Run-Out Test: check the commutator run-
out as shown in [Figure 60-41-20].
Service Limit - 0.002 inch (0,7 mm)
If the commutator exceeds the service limit, repair as
needed.
N-00996
Armature Winding Ground Test: Use a circuit tester,
touch one probe to a commutator segment and the other
probe to the armature core [Figure 60-41-18]. There
should be no continuity. If there is continuity, the
armature is grounded and must be replaced.
A220 Bobcat Loader
60-41-7 Service Manual
STARTER (VALEO) (CONT’D)
Inspection And Repair (Cont'd) Figure 60-41-22
Figure 60-41-21
N-00999
B-14460
Check the field windings for wear and damage.
Measure the segment mica depth (Item 1) [Figure 60-41- Check all the connections for clean and tight solder
21]. joints.
Service Limit - 0.012 inch (0,3 mm) Field Winding Ground Test: Use a circuit tester, touch
one probe to the field winding end of the brush and the
If it is worn, replace the armature. other probe to the surface of the frame [Figure 60-41-
22]. There should be no continuity. If there is continuity,
Check the commutator surface for burned spots which the field windings are grounded.
usually indicates an open-circuit, and correct it using
#400 sand paper. Replace the frame.
Figure 60-41-23
N-15005
Field Windings Continuity Test: Use a circuit tester, touch
one probe to the wire and the other probe to the brush
[Figure 60-41-23]. There should be continuity. If there is
no continuity, the field windings are open-circuited.
Replace the frame.
A220 Bobcat Loader
60-41-8 Service Manual
STARTER (VALEO) (CONT’D) Figure 60-41-26
Inspection And Repair (Cont'd)
1
Figure 60-41-24
2
P-34675
P-34674
Pull-In Test: Use circuit tester, touch one probe to the
N-15006 starter motor terminal (Item 1) and one probe to the S
terminal (Item 2) [Figure 60-41-26].
Inspect the brushes for wear and damage.
Replace the brush holder and yoke if the brushes need
replacement.
Check brush spring, for damage or rust. Replace as
needed.
Brush Holder Insulation Test: Use a circuit tester, touch
one probe to the positive brush holder plate and the other
probe to the holder plate [Figure 60-41-24]. There
should be no continuity. If there is continuity, replace or
repair.
Figure 60-41-25
1
2
P-34673
Hold-In Test: Use circuit tester, touch one probe to the
mounting bolt (Item 1) and one probe to the S terminal
(Item 2) [Figure 60-41-25] on the magnetic switch.
A220 Bobcat Loader
60-41-9 Service Manual
STARTER (VALEO) (CONT’D)
No Load Test
Figure 60-41-27
Ammeter
50
M.T.
Starter B-14440
The following test should be done after reassembling the
starter:
Clamp the starter in a vise. Using a 12 volt battery and
ammeter, connect the positive wire of the battery, and the
ammeter to the terminal [Figure 60-41-27]. Connect the
negative wire to the starter body. Using a jumper wire,
connect the 50 terminal to the main terminal.
The starter should show smooth and steady rotation
immediately after the pinion is engaged, it should draw
less than the specified current.
Service Limit - 1470 Amp. at Stall Condition
Clean all parts and apply high temperature grease to the
armature bearing, return spring, steel ball, over running
clutch, and idler gear rollers.
A220 Bobcat Loader
60-41-10 Service Manual
INSTRUMENT PANEL ◆ SHUTDOWN feature only in Deluxe Right Panel or
Factory Option with Standard Panel.
Left Panel
Figure 60-50-1
The left instrument panel is the same for both Standard and the
Deluxe Instrument Panels[Figure 60-50-1]. 2
The table below shows the DESCRIPTION and FUNCTION / 1
3
OPERATION for each of the components of the left panel.
4 5 6 7 8
Press and hold LIGHTS Button (Item 4) [Figure 60-50-1]
for two seconds to view SERVICE CODES in the
HOURMETER/CODE DISPLAY (Item 2) [Figure 60-50-
1]. If more than one SERVICE CODE is present, the
codes will scroll on the HOURMETER/CODE DISPLAY.
* See ELECTRICAL SYSTEM Service Manual for further
13 10 11 12
description of 9
14
B-15551
Ref. NO Description Function / Operation
1 TEMPERATURE GAUGE Shows the engine coolant temperature.
2 HOURMETER / CODE DISPLAY /GLOW PLUG HOURMETER- Records operating hours of loader. CODE DISPLAY- Displays numeric
COUNTDOWN SERVICE CODES* relating to the loader monitoring system. COUNTDOWN- Glow Plug time
remaining.
3 FUEL GAUGE Shows the amount of fuel in the tank.
4 LIGHTS / HOLD FOR CODES LIGHTS- Press once for FRONT LIGHTS. Press a second time for FRONT AND REAR lights.
Press a third time to turn all lights off. HOLD FOR CODES- Press and hold two seconds for
display of SERVICE CODES* [Figure 60-50-1]. (CODES* show only when there is an error
found by loader monitoring system).
5 BUCKET POSITIONING (Option) Press to engage the BUCKET POSITIONING function. Press again to disengage. Press and
hold 2 seconds to view BASE or SHTDN (◆ SHUTDOWN) feature in HOURMETER/CODE
DISPLAY.
ATTACHMENT AUXILIARY HYDRAULICS
6 HIGH FLOW (Option) Press to engage the HIGH FLOW auxiliary hydraulics.Press again to disengage.
7 MAXIMUM FLOW / VARIABLE FLOW Press once to engage the VARIABLE FLOW auxiliary hydraulics. Press a second time to
engage MAXIMUM FLOW. Press a third time to disengage all auxiliary hydraulics.[VARIABLE
FLOW allows for slow-to-fast movement of auxiliary functions (The farther you move the switch,
the faster the movement of the auxiliary functions.) MAXIMUM FLOW allows for only fast
movement.
8 AUXILIARY PRESSURE RELEASE Press and hold for two seconds.The engine will stop. Hydraulic pressure will be released in the
auxiliary circuit.
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
See BICS™ SYSTEM on Page 60-110-1
9 PRESS TO OPERATE LOADER Press to activate BICS™ System when the Seat Bar is down and operator is seated in the
operating position.
10 SEAT BAR The light comes ON when the seat bar is down.
11 LIFT & TILT VALVE The light comes ON when the seat bar is down and the PRESS TO OPERATE Button is
pressed. The lift and tilt functions can be operated when the light is ON.
12 TRACTION The light comes ON when the seat bar is down, engine is running, and parking brake is
released. The loader can be moved forward or backward when the light is ON.
13 TRACTION LOCK OVERRIDE (Functions Only When Seat Bar Is Raised And The Engine Is Running) Press to unlock the
brakes. Allows you to use the control levers to move the loader forward or backward when using
the backhoe attachment or for the loader service. (See TRACTION LOCK on
Page 60-130-1.). Press a second time to lock the brakes.
14 ALARM The ALARM beeps when there is an Error, WARNING or ◆SHUTDOWN condition.
A220 Bobcat Loader
60-50-1 Service Manual
INSTRUMENT PANEL (CONT’D) The right instrument panel shown [Figure 60-50-2] is the
Standard Panel.
Right Panel - (Standard) (With Key Switch)
The table below shows the Icons and other components
of the Right Standard Panel.
Figure 60-50-2
The right instrument panel shown [Figure 60-50-2] is the
15 17 19 21 23 25 27 Standard Panel.
The table below shows the Icons and other components of the
Right Standard Panel
16 18 20 22 24 26 28
● ACD Icon will also be ON when the 7 pin/14 pin Connector
Harness (Opt./Acc.) is installed and the selector switch is in the
14 pin position.
◆ SHUTDOWN feature only in Deluxe Right Panel or Factory
Option with Standard Panel. (Engine can be restarted to move
or relocate loader.)
29
* These functions are monitored and have SERVICE CODES
associated with them. (See DIAGNOSTICS SERVICE
B-15552
CODES on Page 60-90-1.)
OPT. OR ICON/
REF. FUNCTION ALARM CODE CONDITION DESCRIPTION
STD. LIGHT
Advanced Hand Opt. ON 3 Beeps * Error Error with Advanced Hand Controls (AHC)
15 Controls (AHC)
Attachment Std. ON --- - --- Electrical controlled attachment is present.●
16 Control Std. FLASHING 3 Beeps * Error Error with Attachment Control Device (ACD)
Device (ACD)
General Std. ON 3 Beeps * Error Error with one or more engine or hydraulic functions.
17 Warning Std.^Opt. ON 3 Beeps * WARNING Engine speed high or in shutdown.
FLASHING Continuous * SHUTDOWN Engine speed very high. Engine will stop in 10 seconds.
18 NOT USED
Fuel Std. ON 3 Beeps * Error Fuel level sender system fault.
19 Level Std. ON 3 Beeps * WARNING Fuel level low.
Glow Std. ON --- - --- Glow plugs are energized.
20 Plugs Std. FLASHING 3 Beeps * Error Error with glow plugs
System Voltage Std. ON 3 Beeps * WARNING Voltage low, high or very high.
21
Seat Belt Std. ON --- - --- Light stays on for 45 seconds to remind operator to fasten seat belt.
22
Engine Std. ON 3 Beeps * Error Engine Oil Pressure sender out of range.
23 Oil Pressure Std. ON 3 Beeps * WARNING Engine oil level low.
◆Opt. FLASHING Continuous * SHUTDOWN Engine oil pressure very low. Engine will shutdown in 10 seconds.
Hydrostatic Std. ON 3 Beeps * Error Hydraulic oil pressure sender out of range.
24 Charge Std. ON 3 Beeps * WARNING Hydraulic oil pressure low.
Pressure ◆Opt. FLASHING Continuous * SHUTDOWN Hydraulic charge pressure very low. Engine will stop in 10 seconds.
Engine Std. ON 3 Beeps * Error Engine coolant sender out of range.
25 Coolant Std. ON 3 Beeps * WARNING Engine coolant temperature high.
Temperature ◆Opt. FLASHING Continuous * SHUTDOWN Engine coolant temperature very high. Engine will stop in 10 seconds.
Hydraulic Std. ON 3 Beeps * Error Hydraulic oil temperature out of range.
26 Oil Std. ON 3 Beeps * WARNING Hydraulic oil temperature high.
Temperature ◆Opt. FLASHING Continuous * SHUTDOWN Hydraulic oil temperature very high. Engine will stop in 10 seconds.
Engine Std. ON 3 Beeps * Error Air filter with high restriction.
27 Air Filter Std. FLASHING 3 Beeps * WARNING Air filter switch not connected.
Hydraulic Std. ON 3 Beeps * Error Hydraulic filter with high restriction.
Filter Std. FLASHING 3 Beeps * WARNING Hydraulic filter switch not connected.
28
29 Key Switch - - - - - Used to start and stop the engine.
A220 Bobcat Loader
60-50-2 Service Manual
INSTRUMENT PANEL (CONT’D) Figure 60-50-3
Right Panel - (Deluxe) (With Keyless Start)
1. Display Panel: The Display Panel is where all system 1
setup, monitoring, troubleshooting, and error 3
conditionsare displayed.
2
2. Function Icons: The lower left area of the Deluxe Panel
has the same Icons as the Standard Panel See Right
Panel - (Standard) (With Key Switch) on Page 60-50-
2. These Icons are only visible when the
4
monitoring system has detected an error.
3. Selection Buttons: The four Selection Buttons allow
you to select items from the Display Panel and scroll 6 5 B-15553
throughscreens.
4. Keypad: The numeric keypad (Item 4) [Figure 60- Figure 60-50-4
50-3] has two functions:
(a)To enter a number code (password) to allow
starting the engine (Keyless Start).
(b)To enter a number as directed for further use of the
Display Panel.
The first screen you will see on your new loader will be as
shown in [Figure 60-50-4].
When this screen is on the display you can enter the
password and start the engine or change the Display
Panel setup features.
B-16656
NOTE: Your new loader (with Deluxe Instrument
Panel) will have a Owner Password. Your
dealer will provide you with this password. Figure 60-50-5
Change the password to one that you will
easily remember to prevent unauthorized use
of your loader. (See ELECTRICAL SYSTEM
SERVICE MANUAL.) Keep your password in a
safe place for future needs.
Start Engine: Use the Keypad to enter the numbers
(letters) of your password and press the RUN / ENTER
key (Item 5) [Figure 60-50-3].
Press and hold the START Button (Item 6) [Figure 60-
50-3] until the engine starts.
Change Language: Press the Selection Button at the end
of the arrow [Figure 60-50-4] to go to the next screen. B-16655
Use the Keypad to select the number of the language
[Figure 60-50-5].
Press EXIT. The screen will return to [Figure 60-50-4].
You can then enter the password and start the engine.
A220 Bobcat Loader
60-50-3 Service Manual
INSTRUMENT PANEL (CONT’D)
Right Panel Set Up Display Options (Deluxe)
Icon Identification
Icon Description
Make selection by pressing SELECTION BUTTON LOCK / UNLOCK: Allows machine to be
opposite the Icon. locked. You must lock machine to activate
security system.
When system is unlocked, the user can
press RUN / ENTER then press START
to begin operation.
A valid password will need to be entered
at startup to run a locked machine.
TOOL / SETUP: Access system options.
Use to set clock, check system warnings,
select language, set passwords, etc.
HELP: Access help on current menu
? item.
EXIT EXIT returns you to previous level menu.
11:23 CLOCK / JOB CLOCK: Press to clear or
0.0 lock job clock; TOOL /SETUP to set time.
UP ARROW: Goes backward one
screen. DOWN ARROW: Goes forward
one screen.
OUTLINE ARROWS: No screen avail-
able (backward / forward).
SELECTION ARROW: USE TO
SELECT MENU ITEM.
Goes to the NEXT screen series.
NEXT EXAMPLE: The next Active Warning
screen.
INFO Goes to more information about an
attachment.
YES/NO Answer yes/no to current setup question.
CLEAR Removes previously installed password.
SET Set accepts current installed password.
A220 Bobcat Loader
60-50-4 Service Manual
INSTRUMENT PANEL IDENTIFICATION (CONT’D)
Right Panel Setup Display Options (Deluxe) (Cont’d)
Deluxe Panel Setup
Press
TOOL/SETUP
Press
LOADER
FEATURES
Press
DISPAY
OPTIONS
Press
ADJUST
CONTRAST
Press
UP or Down
Arrow to
Change
Contrast
Press EXIT to
return to
previous level
menu .
A220 Bobcat Loader
60-50-5 Service Manual
INSTRUMENT PANEL IDENTIFICATION (CONT’D)
Right Panel Setup Display Options (Deluxe) (Cont’d)
All new machines with Deluxe Instruments arrive at
Bobcat Dealerships with the panel in locked mode. This
means that a password must be used to start the engine.
Passwords
For security purposes, your dealer may change the
password and set it in the locked mode. Your dealer
will provide you with the password.
Enter Password on
Keypad
Owner Password: Allows for the full use of the loader
and to setup the Deluxe Panel. Owner can select a
password to allow starting & operating the loader and Press Enter to
modify the setup if the Deluxe Panel. Owner should Continue
change the password as soon as possible for security
of the loader.
Re-enter new
User Password: Allows starting and operating the password. Press
loader; cannot change password or any of the other Enter to Continue
setup features. (See left)
Changing the Password Right Instrument Panel
Display Screen
Press Enter to
Press
Continue
TOOL / SETUP
(See left)
Press More EXAMPLES:
PASSWORD Clocks
UTILITIES TOOL / SETUP
LOADER FEATURES
DISPLAY OPTIONS
CLOCKS
SET CLOCK
Use the keypad to set time.
Press RUN / ENTER to set clock.
Press EXIT to return to previous level menu.
Press RESET JOB CLOCK (Password required).
MODIFY OWNER Press CLEAR to reset job clock to zero.
or Press LOCK / UNLOCK to unlock.
MODIFY USER Enter Password and Press Run/Enter.
Languages
TOOL / SETUP
LOADER FEATURES
DISPLAY OPTIONS
LANGUAGES
Select the language, press RUN / ENTER
Press EXIT to return to previous level menu.
A220 Bobcat Loader
60-50-6 Service Manual
INSTRUMENT PANEL IDENTIFICATION (CONT’D)
Right Panel Setup Display Options (Deluxe) (Cont’d)
Vitals (Monitor engine, hydraulic / hydrostatic,
electrical functions when engine is running.)
TOOL / SETUP
LOADER FEATURES
VITALS
Press SELECTION ARROW to select METRIC
or ENGLISH (M/E) readouts
You can monitor real-time readouts of:
Engine Oil Pressure
Engine Coolant Temperature
Hydraulic Charge Pressure
Hydraulic Oil Temperature
System Voltage
Engine Speed
The Display Panel is easy to use. Continue to set
your own preferences for running / monitoring your
Bobcat Loader.
A220 Bobcat Loader
60-50-7 Service Manual
INSTRUMENT PANEL IDENTIFICATION (CONT’D)
Option and Field Accessory Panels (If Equipped) Figure 60-50-7
Figure 60-50-6 SIDE ACCESSORY PANEL
SIDE ACCESSORY PANEL
7 8 9
N-22284B
1 2 3 4 5 6
N-22284A
Side Accessory Panel [Figure 60-50-6] and [Figure 60-50-7]
Ref. No. Description Function / Operation
1. POWER PLUG Provides a 12V receptacle for accessories.
2. NOT USED ---
3. FRONT WIPER Press the top of the switch to start the front wiper (press and hold for
wiper fluid). Press the bottom of the switch to stop the wiper.
4. REAR WIPER Press the bottom of the switch to start the rear wiper. Press the top of
the switch to provide washer fluid to clean the rear window.
5. NOT USED ---
6. NOT USED ---
7. FAN MOTOR Turn clockwise To increase fan speed; counterclockwise to decrease.
There are four positions: OFF -1 -2 -3.
8. AIR CONDITIONING Press the top of the switch to start; press the bottom to stop. (Fan
switch must be on for A/C to operate.)
9. TEMPERATURE CONTROL Turn clockwise to increase the temperature’ counterclockwise to
decrease.
A220 Bobcat Loader
60-50-8 Service Manual
INSTRUMENT PANEL IDENTIFICATION (CONT’D)
Option and Field Accessory Panels (If Equipped)
(Cont’d)
Figure 60-50-8
FRONT ACCESSORY PANEL
10 11 12 13 14 15 16 17
B-15891
Front Accessory Panel [Figure 60-50-8]
Ref. No. Description Function / Operation
10. ALL WHEEL STEER/SKID- Press top of switch to select ALL WHEEL STEER; bottom for
STEER SELECTOR SKID-STEER
11. NOT USED ---
12. POWER BOB-TACH Press and hold the left side to disengage the Bob-Tach wedges.
Press and hold the right side to engage the wedges into the mounting
frame holes.
13. PARKING BRAKE Press the top to engage the PARKING BRAKE; bottom to disengage.
14. TURN SIGNAL INDICATORS Indicates left or right TURN SINGALS are ON.
15. HAZARD LIGHTS Press the left side to turn the HAZARD LIGHTS ON; right side to turn
OFF.
16. ROTATING BEACON Press the left side to turn the ROTATING BEACON ON; right side to
turn OFF.
17. NOT USED ---
A220 Bobcat Loader
60-50-9 Service Manual
INSTRUMENT PANEL (CONT’D) Figure 60-50-11
Standard Panel Removal And Installation (Right Side)
Figure 60-50-9
1
1
N-20140
Ignition Switch Removal and Installation (Standard
N-18410 Panel)
Disconnect the key switch wiring harness (Item 1)
Remove the three mounting bolts (Item 1) [Figure 60-50- [Figure 60-50-11] from the back of the control panel.
9].
Figure 60-50-12
Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
holes in the panels.
Figure 60-50-10
1
1
N-18410
Remove the ignition key (Item 1) from the switch.
Remove the ignition switch retaining nut (Item 2) [Figure
N-20158 60-50-12] from the switch.
Pull the right instrument panel down and disconnect the
wire harness connector (Item 1) [Figure 60-50-10] from
the panel.
Remove the panel from the loader cab.
A220 Bobcat Loader
60-50-10 Service Manual
INSTRUMENT PANEL (CONT’D) Figure 60-50-15
Standard Panel Removal And Installation (Right Side)
(Cont’d)
Figure 60-50-13
N-20163
Pull the right instrument panel down and disconnect the
wire harness connector (Item 1) [Figure 60-50-15] from
N-20141 the panel.
Remove the panel from the loader cab.
Ignition Switch Removal And Installation Standard Panel
(Cont'd) Figure 60-50-16
Remove the ignition switch (Item 1) [Figure 60-50-13]
from the control panel.
Deluxe Panel Removal And Installation (Right Side)
Figure 60-50-14
1
N-20142
1
NOTE: The instrument panel (Item 1) [Figure 60-50-
16] must be replaced as a complete unit.
N-20103
Remove the three mounting bolts (Item 1) [Figure 60-50-
14].
Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
holes in the panels.
A220 Bobcat Loader
60-50-11 Service Manual
INSTRUMENT PANEL (CONT’D) Figure 60-50-19
Standard & Deluxe Panel Removal And Installation
(Left Side)
Figure 60-50-17
1
1
1
N-20144
Alarm Removal and Installation
N-18409 Remove the left side instrument panel.
Remove the retaining nut (Item 1) [Figure 60-50-19]
Remove the three mounting bolts (Item 1) [Figure 60-50- from the loader alarm.
17].
Remove the alarm from the loader instrument panel.
Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded Bulb Removal And Installation
holes in the panels.
Figure 60-50-20
Figure 60-50-18
3
2
1
2
1
N-20145
N-20165
Remove the left side instrument panel. (See Standard &
Pull the left instrument panel down and disconnect the Deluxe Panel Removal And Installation (Left Side) on
wire harness connector (Item 1) [Figure 60-50-18] from Page 60-50-12.)
the loader alarm.
Remove the two light bulb covers (Item 1) [Figure 60-50-
Disconnect the wire harness connector (Item 2) [Figure 20] from the back of the instrument panel.
60-50-18] from the loader instrument panel.
NOTE: The wiring harness (Item 3) [Figure 60-50-18]
is an optional accessory harness.
Remove the instrument panel from the loader.
A220 Bobcat Loader
60-50-12 Service Manual
INSTRUMENT PANEL (CONT’D) Figure 60-50-22
Standard & Deluxe Panel Removal And Installation
(Left Side) (Cont’d)
Figure 60-50-21
N-20147
To install the bulbs, place them in the sockets and turn
clockwise [Figure 60-50-22].
N-20146
With a flat blade screw driver, turn the light bulb
counterclockwise [Figure 60-50-21] and remove from
the panel.
A220 Bobcat Loader
60-50-13 Service Manual
A220 Bobcat Loader
60-50-14 Service Manual
LIGHTS Figure 60-60-3
Front Removal And Installation
Figure 60-60-1
1
1
N-19351
Remove the bulb (Item 1) [Figure 60-60-3] from the
N-19348 socket.
Reverse the above procedure to install the bulb.
Open the rear door.
Disconnect the negative (-) cable from the battery. (See
BATTERY on Page 60-20-1.)
Remove the light housing (Item 1) [Figure 60-60-1] from
the operator cab.
Figure 60-60-2
N-19349
Remove the bulb assembly (Item 1) [Figure 60-60-2]
from the light housing by turning bulb assembly a 1/4
turn.
A220 Bobcat Loader
60-60-1 Service Manual
LIGHTS (CONT’D) Figure 60-60-5
Rear Removal And Installation
Figure 60-60-4
1
2
N-19339
Using care press the rear light and housing from the door
N-19655 [Figure 60-60-5].
Reverse this procedure for installation.
Remove the bulb assembly (Items 1 & 2) from the light
housing (Item 3) [Figure 60-60-4] by turning bulb
assembly a 1/4 turn.
A220 Bobcat Loader
60-60-2 Service Manual
BOBCAT 2001 CONTROLLER (EARLY MODELS) Figure 60-70-2
Removal And Installation
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
P-26165
Figure 60-70-1
Unplug the individual harness connectors from the
1 controller [Figure 60-70-2].
1
NOTE: The connectors are keyed and will only plug
in one way.
Figure 60-70-3
P-26164
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.) P-26166
Remove the inside access panel (left side). (See INSIDE
ACCESS PANEL (EARLY MODELS) on Page 50-110-1.) Loosen the three controller mount bolts (Item 1) [Figure
60-70-3].
Remove the four connector mount bolts (Item 1) [Figure
60-70-1] from the harness connectors. Installation: Tighten the mounting bolts to 12-14 ft.-lbs
(16-19 Nm) torque.
Installation: Tighten the connector bolts to 30-35 in.-lbs.
(3,39-3,96 Nm) torque.
A220 Bobcat Loader
60-70-1 Service Manual
BOBCAT 2001 CONTROLLER (EARLY MODELS)
(CONT’D)
Identification Chart
TS-1941
A220 Bobcat Loader
60-70-2 Service Manual
BOBCAT 2001 CONTROLLER (EARLY MODELS)
(CONT’D)
Identification Chart (Cont'd)
J1 J2
BLACK 18 PIN CONNECTOR WHITE 18 PIN CONNECTOR
(ALL BLUE WIRES) (MOSTLY BLUE AND PURPLE WIRES)
3520
3500 OPEN
3400 9200
3600 9100 9210
3100
1900
OPEN 3900
O PEN
F E D C B A F E D C B A
1200
1 OPEN 1 3920
3010 2 OPEN 2
3 3
4640
OPEN
3300 2900 3910
3700
3430
OPEN
J1 3200
OPEN
9350 J2 9110
OPEN
9340 OPEN
3420 OPEN
OPEN
VIEWED FROM MATING END
X = NO CONNECTION VIEWED FROM MATING END
X = NO CONNECTION
J3 J4
BLACK 30 PIN CONNECTOR WHITE 30 PIN CONNECTOR
(MULTI COLOR WIRES) (MOSTLY GREEN WIRES)
6210 8250 4330 4300
OPEN 4340
OPEN 8210 4440 4940
8000 OPEN 4410 4930
7200 4920
OPEN 4460
2110 4820
K J H G F E D C B A 1110
K J H GF E D C B A 4910
9500 OPEN
1 1120 1 4810
9600 2 1130 OPEN 2 4500
3 3
9700 OPEN
2100 1400
OPEN 4450
4390
9800
J3 8150
8110 4800
4420
J4 9400
4830
8510 9410
4730 4110 4350 4840
6410 8550 4430 4320
6510 4150 4200 4310
6320 4360
VIEWED FROM MATING END VIEWED FROM MATING END
X = NO CONNECTION X = NO CONNECTION
V-0097
A220 Bobcat Loader
60-70-3 Service Manual
A220 Bobcat Loader
60-70-4 Service Manual
A220 Bobcat Loader
60-71-1 Service Manual
BOBCAT CONTROLLER
Identification Chart
41 50 41
50
40 31 40 31
30 21 30 21
20 11 20 11
10 1 10 1
9 8 7 6 5 4 3 2 9 8 7 6 5 4 3 2
J1 J2
Controller
Harness Connector View Harness Connector View
41 50 41 50
31
J1 40 31 J2 40
21 30 21 30
11 20 11 20
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
V-171/V-172
A220 Bobcat Loader
60-71-2 Service Manual
BOBCAT CONTROLLER (CONT’D)
Identification Chart (Cont’d)
Harness Connector View
41 50
J1
1400 8000 X 9800 X X 3420 7200 3520 X
31 X 8150 1130 9700 X 8550 3500 2100 6320 8110
40
21 X 4150 3010 9600 4730 4470 X 1120 4450 8210
30
11 X 8250 1110 9500 3400 6510 4200 4460 6210 8800
20
X X 3430 4910 X X X 6410 8510 4110
1 2 3 4 5 6 7 8 9 10
Harness Connector View
41 4410 9410 4640 9340 3920 4500 X 3300 X X
50
31 X 4420 X 9350 3910 J2 4840 X 2110 X 4940
40
21 4340 4430 9400 1900 3900 4830 X 3100 4320 4930
30
11 9110 4440 X 1200 9200 4820 X 3700 4310 4920
20
4360 X 4330 2900 9100 4810 9210 3200 4300 3600
1 2 3 4 5 6 7 8 9 10
V-172
A220 Bobcat Loader
60-71-3 Service Manual
BOBCAT CONTROLLER (CONT’D) Figure 60-71-3
Removal And Installation
Figure 60-71-1
1 1
1
1
1
P-43812
Remove the six panel mount bolts (Item 1) [Figure 60-
P-43810 71-3] and remove the rear panel.
Figure 60-71-4
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Stop the engine. Raise the seat bar.
Lift and block the rear of the loader. (See LIFT AND TILT
ACTUATOR CALIBRATION on Page 60-160-1.) 1
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the three foot rest mount bolts (Item 1) [Figure
60-71-1] from the left side foot rest.
P-43813
Remove the foot rest from the loader.
Figure 60-71-2 Remove the two harness connector bolts (Item 1)
[Figure 60-71-4].
Installation: Tighten the connector mounting bolts to 30-
35 in.-lbs. (3,39-3,96 Nm) torque.
1
Unplug the two harness connectors from the controller.
1 NOTE: The connectors are keyed and will only plug
in one way.
1
P-43811
Remove the three panel mount bolts (Item 1) [Figure 60-
71-3] and remove the front panel.
A220 Bobcat Loader
60-71-4 Service Manual
BOBCAT CONTROLLER (CONT’D)
Removal And Installation (Cont’d)
Figure 60-71-5
P-37105
Remove the top controller mount bolt (Item 1) [Figure
60-71-5].
Loosen the two controller mounting bolts (Item 2) [Figure
60-71-5].
Installation: Tighten the controller mounting bolts to 12-
14 ft.-lbs. (16-19 Nm) torque.
Remove the system controller from the loader.
A220 Bobcat Loader
60-71-5 Service Manual
A220 Bobcat Loader
60-71-6 Service Manual
AWS CONTROLLER Figure 60-72-2
Removal
Figure 60-72-1
1
P-26160
Press in on the connector release, (toward the connector
P-26158 [Figure 60-72-2] to release the connector.
Figure 60-72-3
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
1
to fall and cause injury or death.
W-2059-0598
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.) P-26159
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.) Loosen the three control mounting bolts (Item 1) [Figure
60-72-3] on the right side fender.
Remove the engine speed control. (See ENGINE SPEED
CONTROL (EARLY MODELS) on Page 70-20-1.) Installation: Tighten the mounting bolts to 12-14 ft.-lbs
(16-19 Nm) torque.
Remove the inside access panel (right side). (See
INSIDE ACCESS PANEL (EARLY MODELS) on Page Lift and remove the controller from the fender.
50-110-1.)
Disconnect the four electrical connectors (Item 1) [Figure
60-72-1].
A220 Bobcat Loader
60-72-1 Service Manual
AWS CONTROLLER (CONT’D) The wire location (Item 1) [Figure 60-72-5] & [Figure
60-72-6], are printed on the individual wire connectors, in
Removal (Cont’d) the locations shown.
Figure 60-72-4 NOTE: The wire location letters (A,H,J,&S) have been
made larger to show there location on the
wiring connector. The actual letters on the
connectors are smaller.
J2
J3
J4
J1
P-26161
Remove the AWS controller [Figure 60-72-4].
Figure 60-72-5
A H
P-26886
Figure 60-72-6
J S
P-26885A
A220 Bobcat Loader
60-72-2 Service Manual
A220 Bobcat Loader
60-72-3 Service Manual
AWS CONTROLLER (CONT'D)
Identification Chart
J1 J2
J4 J3
V-0103
A220 Bobcat Loader
60-72-4 Service Manual
AWS CONTROLLER (CONT'D)
Identification Chart (Cont'd)
LEFT W HEEL LEFT W HEEL RIGHT WHEEL RIGHT W HEEL BUCKET BUCKET TILT LIFT
SPEED (1ST DIRECTION DIRECTION SPEED (1ST LEVEL LEVEL POSITION POSITION
INPUT) (2ND INPUT) (2ND INPUT) INPUT) ANALOG 1 ANALOG 2 FEEDBACK FEEDBACK
A B C D E F G H
3020 3080 3070 3000 OPEN OPEN 3050 3060
J1 RIGHT
JOYSTICK
RIGHT
JOYSTICK
LEFT
JOYSTICK Y
LEFT
JOYSTICK X
FRONT RIGHT FRONT LEFT REAR LEFT
W HEEL WHEEL W HEEL STEERING
Y AXIS X AXIS AXIS AXIS POSITION POSITION POSITION MODE SELECT
J K L M N P R S
4520 4510 4540 4530 3140 3040 3030 4950
FRONT
REAR LEFT FRONT LEFT BACKUP
LIFT SPOOL SENSOR STEERING RIGHT TILT SPOOL
SOL. SOL. ALARM
FORW ARD SUPPLY PRESS. CNTRL SOL. REVERSE
EXTEND RETRACT
RETRACT
A B C D E F G H
1240 1590 4060 4160 4020 4040 7100 2170
LIFT SPOOL
REAR LEFT
SOL.
REAR RIGHT
SOL.
REAR
RIGHT
SOL.
FRONT RIGHT
SOL. EXTEND
FRONT LEFT
SOL.
TILT SPOOL
FORW ARD
J2
REVERSE GROUND RETRACT EXTEND EXTEND
RETRACT
J K L M N P R S
2180 2260 4170 4070 4050 4010 4030 1230
RIGHT FWD RIGHT FORWARD BUCKET
RIGHT REV LOW LOW LEFT FWD HIGH HIGH SIDE LEVEL DIGITAL
SIDE OUTPUT SIDE OUTPUT SIDE OUTPUT OUTPUT 2
K J H G F
2690 2680 4110 4090 OPEN
J4 LEFT FWD LOW LEFT REV LOW LEFT REV HIGH RIGHT REV HIGH
REAR RIGHT
WHEEL POSITION
SIDE OUTPUT SIDE OUTPUT SIDE OUTPUT
SIDE OUTPUT
A
E D C B
3130
2660 2670 4270 4250
REAR LEFT REAR RIGHT UNSW ITCHED
SW ITCHED PRESSURE SOL. SOL. FRONT LEFT FRONT RIGHT
GROUND BATTERY IN (2)
BATTERY IN CNTRL RTRN RETURN RETURN SOL. RETURN
SOL. RETURN
S R P N M L K J
2250 1740 2870 2810 2970 2880 2980 1180
J3
BUCKET UNSWITCHED
SENSOR HIGH FLOW
HIGH FLOW LEVEL SENSOR BATTERY IN (1)
GROUND CAN LOW CAN HIGH
OUTPUT OUTPUT DIGITAL 1 SUPPLY
A B C D E F G H
2500 9620 9520 OPEN OPEN 3145 1500 1190
Connectors are Viewed From the Wire Side.
V-0111 (6-14-01)
V-0111
A220 Bobcat Loader
60-72-5 Service Manual
A220 Bobcat Loader
60-72-6 Service Manual
SPEED SENSOR Figure 60-80-3
Testing
Figure 60-80-1 2
1
3
P-28307
Locate the speed sensor (Item 1) [Figure 60-80-3] on the
P-28302 left side hydrostatic motor carrier.
Disconnect the speed sensor wire connector (Item 2)
The tools listed will be needed to do the following from the loader harness wire connector (Item 3) [Figure
procedure: 60-80-3].
MEL1609-Wheel Speed Sensor Test Harness [Figure
Figure 60-80-4
60-80-1]
MEL1563-Remote Start Tool
Multimeter 1
Figure 60-80-2
P-28309
1 Connect the speed sensor test harness (Item 1) [Figure
60-80-4] in line, between the loader wiring harness and
the speed sensor harness.
P-28306
Turn the remote start key to ON position without starting
the loader.
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on Take a voltage reading, with the multimeter, at the speed
Page 10-20-1.) sensor test harness, between pin 1 and pin 3 (Item 1)
[Figure 60-80-4].
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.) The voltage should be between 5 volts.
Connect the remote start tool to the loader. (See Repeat the procedure for the opposite side speed
REMOTE START on Page 10-60-1.) sensor. (If needed.)
Locate the speed sensor (Item 1) [Figure 60-80-2] on the
right side hydrostatic motor carrier.
A220 Bobcat Loader
60-80-1 Service Manual
SPEED SENSOR (CONT'D) Figure 60-80-7
Removal
Figure 60-80-5 1
P-26290
2 Lift the speed sensor (Item 1) [Figure 60-80-7] out from
P-26288 the motor carrier.
Figure 60-80-8
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the two, speed sensor mount bolts (Item 1)
[Figure 60-80-5] from the top of the hydrostatic motor
carrier.
Remove the mount plate (Item 2) [Figure 60-80-5].
Figure 60-80-6
P-26291
1
Remove the speed sensor [Figure 60-80-8].
P-26289
Disconnect the speed sensor electrical harness
connector (Item 1) [Figure 60-80-6].
A220 Bobcat Loader
60-80-2 Service Manual
SPEED SENSOR (CONT'D) Figure 60-80-11
Removal (Cont'd)
Figure 60-80-9
1
1
P-26292
Installation: Be sure to install the speed sensor (Item 1)
P-26293 [Figure 60-80-11] pointing toward the transmission case.
Figure 60-80-12
The electrical connector can be replaced.
Remove the connector wedge (Item 1) [Figure 60-80-9].
Figure 60-80-10
1
2
P-26295
Installation: The alignment pin (Item 1) at the bottom of
the speed sensor must be installed in the hole (Item 2)
P-26294 [Figure 60-80-12] in the motor carrier.
With a thin screwdriver lift the tabs and remove the wires
from the connector [Figure 60-80-10].
Wire Code
1 Red
2 White
3 Black
4 Blue
A220 Bobcat Loader
60-80-3 Service Manual
A220 Bobcat Loader
60-80-4 Service Manual
DIAGNOSTICS SERVICE CODES
Display
Figure 60-90-1
B-15551
Press and hold the LIGHTS Button (Item 1) [Figure 60-
90-1] for two seconds to view SERVICE CODES in the
HOURMETER/CODE DISPLAY (Item 2) [Figure 60-90-
1]. If more than one SERVICE CODE is present, the
codes will scroll on the HOURMETER/CODE DISPLAY.
NOTE: Corroded or loose grounds can cause
multiple service codes and/or abnormal
symptoms. All dash lights flashing, buzzer
going off, headlights and taillights flashing,
could indicate a bad ground. The same
symptoms could apply if the voltage is low,
such as loose or corroded battery cables. If
you observe these symptoms, check grounds
and positive leads first.
A220 Bobcat Loader
60-90-1 Service Manual
DIAGNOSTICS SERVICE CODES (CONT’D) The following word errors may be displayed.
Display (Cont’d) REPLY One or both instrument panel(s) not
communicating with the controller.
Figure 60-90-2
INPUT The controller not communicating with the left
1 instrument panel.
CODE The controller is asking for a password.
(Deluxe instrument panel only.)
ERROR The wrong password was entered. (Deluxe
instrument panel only.)
NOTE: The following troubleshooting procedures are
intended for active codes only - those
displayed on the hourmeter.
If a code is active (displayed) and the operator
keys OFF, then back ON and the code does
not reappear - ‘NONE’ displayed, we no longer
have an active code. This is referred to as an
intermittent fault.
In this situation the following troubleshooting
B-15551A procedures may be inaccurate.
The troubleshooting procedures can be
Figure 60-90-3 followed on intermittent codes, but the
harness and connectors should be inspected
1 carefully and moved back and forth during
voltage and continuity tests. It is not
recommended to replace the controller if the
code is not active (intermittent) and no other
causes for the error code are found.
Replacing the controller for active and
intermittent codes is a last effort in the
troubleshooting procedures only, when no
1
other problem can be found.
B-15551B
Service Codes may be either a word (Item 1) [Figure 60-
90-2] or a number (Item 1) [Figure 60-90-3]. (See the
following pages for the number codes and trouble
shooting trees.)
A220 Bobcat Loader
60-90-2 Service Manual
DIAGNOSTICS SERVICE CODE (CONT’D)
NOTE: For Service Codes See DIAGNOSTICS SERVICE CODES on Page 60-90-1. See Troubleshooting Chart on
Page 60-10-3 for Troubleshooting Trees.
Number Codes List
CODE CODE
01-16 Air filter not connected 09-09 Fuel level low
01-17 Air filter plugged 09-21 Fuel level out of range high
09-22 Fuel level out of range low
02-16 Hydraulic charge filter not connected
02-17 Hydraulic charge filter plugged 11-05 Seat bar sensor short to battery
11-06 Seat bar sensor short to ground
03-09 Battery voltage low
03-10 Battery voltage high 12-21 Front auxiliary PWM switch out of range high
03-11 Battery voltage extremely high 12-22 Front auxiliary PWM switch out of range low
03-14 Battery voltage extremely low 12-23 Front auxiliary PWM switch not calibrated
03-22 Battery voltage out of range low
13-05 Fuel shut-off solenoid secondary short to battery
04-09 Engine oil pressure low 13-06 Fuel shot-off solenoid secondary short to ground
04-14 Engine oil pressure extremely low 13-07 Fuel shut-off solenoid secondary open circuit
04-15 Engine oil pressure shutdown level
04-21 Engine oil pressure out of range high 14-02 Fuel shut-off solenoid primary error ON
04-22 Engine oil pressure out of range low 14-03 Fuel shut-off solenoid primary error OFF
05-09 Hydraulic charge pressure low 15-02 Traction lock solenoid primary error ON
05-14 Hydraulic charge pressure extremely low 15-03 Traction lock solenoid primary error OFF
05-15 Hydraulic charge pressure shutdown level
05-21 Hydraulic charge pressure out of range high 16-05 Traction lock solenoid secondary short to battery
05-22 Hydraulic charge pressure of range low 16-06 Traction lock solenoid secondary short to ground
16-07 Traction lock solenoid secondary open circuit
06-10 Engine speed high
06-11 Engine speed extremely high 17-05 Hydraulic lock valve solenoid short to battery
06-13 Engine speed no signal 17-06 Hydraulic lock valve solenoid short to ground
06-15 Engine speed shutdown level 17-07 Hydraulic lock valve solenoid open circuit
06-18 Engine speed out of range
18-05 Spool lock solenoid short to battery
07-10 Hydraulic oil temperature high 18-06 Spool lock solenoid short to ground
07-11 Hydraulic oil temperature extremely high 18-07 Spool lock solenoid open circuit
07-15 Hydraulic oil temperature shut level
07-21 Hydraulic oil temperature out of range high 19-02 Bucket position solenoid error ON
07-22 Hydraulic oil temperature out of range low 19-03 Bucket position solenoid error OFF
08-10 Engine coolant temperature high 20-02 Two-speed solenoid error ON
08-11 Engine coolant temperature extremely high 20-03 Two-speed solenoid error OFF
08-15 Engine coolant temperature shutdown level
08-21 Engine coolant temperature out of range high 21-02 Glow plug error ON
08-22 Engine coolant temperature out of range low 21-03 Glow plugs error OFF
A220 Bobcat Loader
60-90-3 Service Manual
DIAGNOSTICS SERVICE CODE (CONT’D)
NOTE: For Service Codes See DIAGNOSTICS SERVICE CODES on Page 60-90-1. See Troubleshooting Chart on
Page 60-10-3 for Troubleshooting Trees.
Number Codes List (Cont’d)
CODE CODE
22-02 Starter output error ON 33-23 Constant data not calibrated
22-03 Starer output error OFF
34-04 Deluxe not downgraded in error
23-02 Rear base solenoid error ON
23-03 Rear base solenoid error OFF 36-48 ACD multiple controllers present
24-02 Rear rod solenoid error ON 37-02 Two-speed secondary error ON
24-03 Rear rod solenoid error OFF 37-03 Two-speed secondary error OFF
25-02 Rear auxiliary relief solenoid error ON 80-02 ACD output ‘A’ error ON
25-03 Rear auxiliary relief solenoid error Off 80-03 ACD output ‘A’ error Off
26-02 Front base solenoid error ON 81-02 ACD output ‘B’ error ON
26-03 Front base solenoid error OFF 81-03 ACD output’ B’ error OFF
27-02 Front rod solenoid error ON 82-02 ACD output ‘C’ error ON
27-03 Front rod solenoid error OFF 82-03 ACD output ‘C’ error OFF
28-02 Diverter solenoid error ON 83-02 ACD output ‘D’ error ON
28-03 Diverter solenoid error OFF 83-03 ACD output ‘D’ error OFF
29-02 High flow solenoid error ON 84-02 ACD output ‘E’ error ON
29-03 High flow solenoid error OFF 84-03 ACD output ‘E’ error OFF
30-28 Watchdog failure (internal)
31-28 Recovery mode failure (internal)
A220 Bobcat Loader
60-90-4 Service Manual
DIAGNOSTICS SERVICE CODE (CONT’D)
NOTE: For Service Codes See DIAGNOSTICS SERVICE CODES on Page 60-90-1. See Troubleshooting Chart on
Page 60-10-3 for Troubleshooting Trees.
Number Codes List (Cont’d)
CODE CODE
38-04 AWS controller in error 38-49 AWS rear right steering solenoid error ON
38-05 AWS left joystick X axis not calibrated 38-50 AWS rear left steering solenoid error OFF
38-06 AWS right joystick X axis not calibrated 38-51 AWS steering pressure solenoid error ON
38-07 AWS left joystick Y axis not calibrated 38-52 AWS back-up alarm error ON
38-08 AWS right joystick Y axis not calibrated 38-53 AWS left forward drive solenoid error OFF
38-09 Not Used 38-54 AWS left reverse drive solenoid error OFF
38-10 Not Used 38-55 AWS right forward drive solenoid error OFF
38-11 AWS lift actuator not calibrated 38-56 AWS right reverse drive solenoid error OFF
38-12 AWS tilt actuator not calibrated 38-57 AWS front right extend steering solenoid error OFF
38-13 AWS lift actuator wiring fault 38-58 AWS front right retract steering solenoid error OFF
38-14 AWS tilt actuator wiring fault 38-59 AWS front left extend steering solenoid error OFF
38-15 AWS right wheel speed wiring fault 38-60 AWS front left retract steering solenoid error OFF
38-16 AWS left wheel speed wiring fault 38-61 AWS rear right extend steering solenoid error OFF
38-17 AWS tilt actuator reduced performance 38-62 AWS rear right retract steering solenoid error OFF
38-18 AWS lift actuator reduced performance 38-63 AWS rear left extend steering solenoid error OFF
38-19 AWS left joystick X axis out of range high 38-64 AWS rear left retract steering solenoid error OFF
38-20 AWS right joystick X axis out of range high 38-65 AWS steering pressure solenoid error OFF
38-21 AWS left joystick Y axis out of range high 38-66 AWS back-up alarm error OFF
38-22 AWS right joystick Y axis out of range high 38-67 AWS CAN communication time out
38-23 AWS front right steering sensor out of range high 38-68 AWS wheel angles (alignment) not calibrated
38-24 AWS front left steering sensor out of range high 38-69 AWS lift & tilt actuators calibration fault
38-25 AWS rear right steering sensor out of range high 38-70 AWS recovery mode failure
38-26 AWS rear left steering sensor out of range high 38-71 AWS battery out of range
38-27 AWS lift actuator short to battery 38-72 AWS drive pump not calibrated
38-28 AWS tilt actuator short to battery 38-73 AWS steering mode switch flipped while operating
38-29 AWS left joystick X axis out of range low 38-74 AWS uncommanded right wheel speed error ON
38-30 AWS right joystick X axis out of range low 38-75 AWS uncommanded left wheel speed error ON
38-31 AWS left joystick Y axis out of range low 38-76 AWS undercurrent-steer pressure solenoid
38-32 AWS left joystick Y axis out of range low 38-77 AWS undercurrent-front right extend steer solenoid
38-33 AWS front right steering sensor out of range low 38-78 AWS undercurrent-front right retract steer solenoid
38-34 AWS front left steering sensor out of range low 38-79 AWS undercurrent-front left extend steer solenoid
38-35 AWS rear right steering sensor out of range low 38-80 AWS undercurrent-front left retract steer solenoid
38-36 AWS rear left steering sensor out of range low 38-81 AWS undercurrent-rear right extend steer solenoid
38-37 AWS 5 volt sensor supply 1 out of range low 38-82 AWS undercurrent-rear right retract steer solenoid
38-38 AWS 5 Volt sensor supply 2 out of range low 38-83 AWS undercurrent-rear left extend steer solenoid
38-39 AWS lift actuator short to ground 38-84 AWS undercurrent-rear left retract steer solenoid
38-40 AWS tilt actuator short to ground 38-85 AWS 5 Volt sensor supply 1 out of range high
38-41 AWS tilt actuator wrong direction 38-86 AWS 5 Volt sensor supply 2 out of range high
38-42 AWS lift actuator wrong direction 38-87 AWS front right steering error
38-43 AWS left forward drive solenoid error ON 38-88 AWS front left steering error
38-44 AWS left reverse drive solenoid error ON 38-89 AWS rear right steering error
38-45 AWS right forward drive solenoid error ON 38-90 AWS rear left steering error
38-46 AWS right reverse drive solenoid error ON 38-91 AWS right speed sensor missing pulses
38-47 AWS front right steering solenoid error ON 38-92 AWS left speed sensor missing pulses
38-48 AWS front left steering solenoid error ON 38-98 AWS controller in drive calibration mode
38-99 AWS controller in wheel position calibration mode
A220 Bobcat Loader
60-90-5 Service Manual
DIAGNOSTICS SERVICE CODE (CONT’D)
NOTE: For Service Codes See DIAGNOSTICS SERVICE CODES on Page 60-90-1. See Troubleshooting Chart on
Page 60-10-3 for Troubleshooting Trees.
Number Codes List (Cont'd)
CODE CODE
39-04 Left smart grip in error 85-02 ACD output ‘F’ ON
85-03 ACD output ‘F’ OFF
40-04 Right smart grip in error
86-02 ACD output ‘G’ ON
44-02 Horn error ON 86-03 ACD output ‘G’ OFF
44-03 Horn error OFF
87-02 ACD output ‘H’ ON
45-02 Right blinker error ON 87-03 ACD output ‘H’ OFF
45-03 Right blinker error OFF
90-02 Service tool output ‘C’ error ON
46-02 Left blinker error ON 90-03 Service tool output ‘C’ error OFF
46-03 Left blinker error OFF
91-02 Service tool output ‘D’ error ON
47-21 8 volt reference out of range high 91-03 Service tool output ‘D’ error OFF
47-22 8 volt reference out of range low
92-02 Service tool output ‘E’ error ON
48-05 Front light output short to battery 92-03 Service tool output ‘E; error OFF
48-06 Front light output short to ground
93-02 Service tool output ‘F’ error ON
49-05 Rear light output short to battery 93-03 Service tool output ‘F’ error OFF
49-06 Rear light output short to ground
80-02 ACD output ‘A’ error ON
80-03 ACD output ‘A’ error OFF
81-02 ACD output ‘B’ error ON
81-03 ACD output ‘B’ error OFF
82-02 ACD output ‘C’ error ON
82-03 ACD output ‘C’ error OFF
83-02 ACD output ‘D’ error On
83-03 ACD output ‘D’ error OFF
84-02 ACD output ‘E’ error ON
84-03 ACD output ‘E’ error OFF
A220 Bobcat Loader
60-90-6 Service Manual
4 CONNECTOR CONTROLLER
Code 38-04:
AWS CONTROLLER IN ERROR
Refer to appropriate Electrical Schematic for circuit description. BOBCAT
CONTROLLER
K J H G F E D C B A
1
J4
Check fuse F10. Check fuse F12. 2
3
J2
Fuse bad. Install MEL-1608 test harness into J3
Replace fuse. handle connector C449. With key switch HARNESS SIDE
"ON", check for 5.0 volts between pin 1 J3
J1
and pin 5 of test harness.
5.0 Volts.
0 Volts.
Unplug J3 connector on Bobcat controller, unplug
Remove AWS connector J3. Do a voltage
C492 connector. If ACD or Remote Start Tool is
check between J3, pin H and ground, and
connected, unplug devices at C426 connector Check
J3, pin J and ground. With key switch "ON",
resistance on J3, pin K1, wire 9500 and K2, wire
check between J3, pin R and ground.
9600. Resistance should be approximately 120
ohms.
12.0 Volts. 0 Volts.
Power to AWS is Troubleshoot 12.0 Resistance measures 120 ohms.
Resistance is
OK. Replace AWS Volts back to F10 or Measure C492, pin C, wire 9520 to
incorrect. Repair or
controller. F12 fuse. Repair or pin D, wire 9620, mainframe
replace mainframe
replace harness. harness side. Resistance should be
harness.
AWS CONTROLLER 120 ohms.
J2 J3
Resistance is Resistance measures 120 ohms.
S R P N M L K J
incorrect. Repair or Check continuity C492, pin D, wire
A B C D E F G H replace mainframe 9620, AWS harness side to AWS,
J4 harness. J3, pin B, wire 9620. Check
J1 J3 continuity C492, pin C, wire 9520 to
HARNESS SIDE AWS, J3, pin C, wire 9520.
No continuity, Continuity.
J K L M N P R S S R P N M L K J open. Repair or Wiring appears
A B C D E F G H H G F E D C B A
replace AWS OK. Replace AWS
harness. controller.
C492 C492
MAINFRAME AWS
HARNESS SIDE HARNESS SIDE
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be found at
this time. Probable causes may include: loose connections, corrosion, pushed back pins, the controller,
the wiring harness or a combination of these problems.
NOTE: Also, if this code is active, before attempting the AWS troubleshooting diagnostics, a quick check would
be to unplug the ACD controller (if equipped) from the loader, key on/off sequence and see if code clears. If the
code clears, the problem is in the ACD circuit and not the AWS circuit. To trouble shoot the ACD circuit: If an
attachment is hooked up to the loader, unhook the attachment electrical harness. If the code clears, check the
attachment electrical harness. If the code remains, unplug the boom harness from the ACD controller and check
for code 38-04. If the code clears, check the boom harness. If the code remains, replace the ACD controller.
A220 Bobcat Loader
60-90-7 Service Manual
Code 38-05:
AWS LEFT JOYSTICK X AXIS NOT CALIBRATED
Refer to appropriate electrical schematics for circuit description.
Power up system.
With left joystick in neutral position,
push the "Press To Operate" button.
Code clears. Code remains.
Non-electrical issue. Unplug left joystick connector
Handle was being held C449. Install MEL-1608 test
out of neutral. harness in-line.
With handle in neutral, measure
voltage between pin 2 and pin 5
of test harness. Voltage should
be 2.45 - 2.55 Volts.
Voltage is OK. The
Voltage is low. system appears OK.
Replace left joystick. Replace AWS
controller *.
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-8 Service Manual
Code 38-06:
AWS RIGHT JOYSTICK X AXIS NOT CALIBRATED
Refer to appropriate electrical schematics for circuit description.
Power up system.
With right joystick in neutral position,
push the "Press To Operate" button.
Code clears. Code remains.
Non-electrical issue. Unplug right joystick connector
Handle was being held C450. Install MEL-1608 test
out of neutral. harness in-line.
With handle in neutral, measure
voltage between pin 2 and pin 5
of test harness. Voltage should
be 2.45 - 2.5 Volts.
Voltage is low. Voltage is OK. The
Replace right system appears OK.
joystick. Replace AWS
controller *.
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
this time. Probable causes may include: loose connections, corrosion, pushed back pins, the c
the wiring harness or a combination of these problems.
NOTE
If the loader is generating 38-06 or 38-08 or both during operation, check for a defective cab do
associated wiring from the cab back to the Bobcat Controller. If the loader does not have a cab
wire 4730 back at the Bobcat Controller for voltage. There should be 0 Volts on this wire. If 12
present, there is a problem with the wiring harness. Refer to the correct wiring schematic in the
service manual.
A220 Bobcat Loader
60-90-9 Service Manual
Code 38-07:
AWS LEFT JOYSTICK Y AXIS NOT CALIBRATED
Refer to appropriate electrical schematics for circuit description.
Power up system.
With left joystick in neutral position,
push the "Press To Operate" button.
Code clears. Code remains.
Non-electrical issue. Unplug left joystick connector
Handle was being held C449. Install MEL-1608 test
out of neutral. harness in-line.
With handle in neutral, measure
voltage between pin 3 and pin 5
of test harness. Voltage should
be 2.45 - 2.55 Volts.
Voltage is OK. The
Voltage is low. system appears OK.
Replace left joystick. Replace AWS
controller *.
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-10 Service Manual
Code 38-08:
AWS RIGHT JOYSTICK Y AXIS NOT CALIBRATED
Refer to appropriate electrical schematics for circuit description.
Power up system.
With right joystick in neutral position,
push the "Press To Operate" button.
Code clears. Code remains.
Non-electrical issue. Unplug right joystick connector
Handle was being held C450. Install MEL-1608 test
out of neutral. harness in-line.
With handle in neutral, measure
voltage between pin 3 and pin 5
of test harness. Voltage should
be 2.45 - 2.55 Volts.
Voltage is OK. The
Voltage is low.
system appears OK.
Replace right
Replace AWS
joystick.
controller *.
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
this time. Probable causes may include: loose connections, corrosion, pushed back pins, the c
the wiring harness or a combination of these problems.
NOTE:
If code 38-08 or 38-06 is displayed during operation, check for a defective cab door switch or as
wiring from the cab back to the Bobcat Controller. If the loader does not have a cab door, check
back at the Bobcat Controller for voltage. There should be 0 volts on this wire. If 12 volts is pre
a problem with the wiring harness. Refer to the correct schematic in the Loader Service Manua
A220 Bobcat Loader
60-90-11 Service Manual
Code 38-11:
AWS LIFT ACTUATOR NOT CALIBRATED
Refer to appropriate Electrical
Schematic for circuit description.
Swap the Lift Actuator connector C429
with the Tilt Actuator connector C428.
Code changes to Code remains. Swap C428 and
38-12 "Tilt Actuator Not C429 connectors back to there
Calibrated". Actuator is original locations.
bad or mechanical or
valve spool bind.
Does lift actuator "Kick" at power up.
Actuator "Kicks". Inspect valve No "Kick". Unplug C429 actuator
and/or mounting for signs of connector. Check resistance,
binding or misalignment. actuator side, C429, pin 5, to pin 8.
(Red and Black wires.)
Binding or Less than 10 ohms. Unplug AWS
Looks OK. Greater than 10 connector J2, check continuity, J2,
misalignment.
Replace actuator. ohms. Actuator is pin J, wire 2180, to connector C429,
Mechanical issue.
bad. Replace. pin 8, wire 2180, AWS harness side.
Check continuity, J2, pin A, wire
AWS CONTROLLER 1240, to connector C429, pin 5, wire
A B C D E F G H
1240, AWS harness side.
J3
J2
J K L M N P R S
Continuity.
Open.
J2 The circuit appears
Repair or replace
HARNESS SIDE OK. Replace AWS
J4 AWS harness.
J1 controller *.
8 7 6 5 5 6 7 8
1 2 3 4 4 3 2 1
C429 C429
HARNESS SIDE ACTUATOR SIDE
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-12 Service Manual
Code 38-12:
AWS TILT ACTUATOR NOT CALIBRATED
Refer to appropriate Electrical
Schematic for circuit description.
Swap the Tilt Actuator connector C428
with the Lift Actuator connector C429.
Code changes to Code remains. Swap C428 and
38-11 "Lift Actuator Not C429 connectors back to there
Calibrated". Actuator is original locations.
bad or mechanical or
valve spool bind.
Does tilt actuator "Kick" at power up.
Actuator "Kicks". Inspect valve No "Kick". Unplug C428 actuator
and/or mounting for signs of c on nec t or . Che c k r e si s ta nc e,
binding or misalignment. actuator side, C428, pin 5, to pin 8.
(Red and Black wires.)
Less than 10 ohms. Unplug AW S
Binding or Greater than 10 connector J2, check continuity, J2,
Looks OK.
misalignment. ohms. Actuator is pin S, wire 1230, to connector C428,
Replace actuator.
Mechanical issue. bad. Replace. pin 5, wire 1230, AWS harness side.
Check continuity, J2, pin H, wire
2170, to connector C428, pin 8, wire
AWS CONTROLLER
2170, AWS harness side.
A B C D E F G H
J3
J2
J K L M N P R S
J2 Continuity.
J4 Open.
HARNESS SIDE The circuit appears
J1 Repair or replace
OK. Replace AWS
AWS harness.
controller *.
8 7 6 5 5 6 7 8
1 2 3 4 4 3 2 1
C429 C429
HARNESS SIDE ACTUATOR SIDE
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-13 Service Manual
Code 38-13:
AWS LIFT ACTUATOR FAULT
Refer to appropriate Electrical
Schematic for circuit description.
Swap lift actuator connector C429 with
tilt actuator connector C428.
Code remains 38-13. Swap
Code changes to 38-14.
C428 and C429 ac tuator
Actuator is bad. Replace.
connectors back.
Unplug AWS connector J2,
check resistance, harness
side, J2, pin J, wire 2180, to
J2, pin A, wire 1240.
Resistance is less than 10
Resistance is greater than
ohms. Wiring and actuator
10 ohms. Repair or replace
appear OK. Replace AWS
AWS harness.
controller *.
AWS CONTROLLER
A B C D E F G H J2 J3
J K L M N P R S
J2 J4
HARNESS SIDE J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-14 Service Manual
Code 38-14:
AWS TILT ACTUATOR FAULT
Refer to appropriate Electrical
Schematic for circuit description.
Swap tilt actuator connector C428 with
lift actuator connector C429.
Code remains 38-14. Swap
Code changes to 38-13.
C428 and C429 ac tuator
Actuator is bad. Replace.
connectors back.
Unplug AWS connector J2,
check resistance, harness
side, J2, pin S, wire 1230, to
J2, pin H, wire 2170.
Resistance is less than 10
Resistance is greater than
ohms. Wiring and actuator
10 ohms. Repair or replace
appear OK. Replace AWS
AWS harness.
controller *.
AWS CONTROLLER
A B C D E F G H J2 J3
J K L M N P R S
J2 J4
HARNESS SIDE J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-15 Service Manual
Code 38-15:
AWS RIGHT WHEEL SPEED WIRING FAULT
Refer to appropriate electrical schematics for circuit description.
Are codes 38-13, 38-14
and 38-16 also displayed.
Yes. No.
Remove J3 connector on AWS controller. Unplug right wheel speed connector
Check continuity, pin G, wire1500 to C453. Plug in MEL-1609 test harness
connector C453, pin 1, wire 1530. to the AWS harness side of C453.
Unplug left wheel speed connector
C454. Plug in the other side of MEL-
No continuity. Continuity. 1609 test harness into the left wheel
Repair or replace C h e c k c o n t i n u i t y AW S speed sensor.
AWS harness. connector J3, pin A, wire
2500 to connector C453,
pin 3, wire 2620. Power up the system.
Check codes. 38-16 should be displayed
"AWS Left Wheel Speed Wiring Fault".
No continuity. Remove J1 connector from AWS
Repair or replace controller. Check continuity from
AWS harness. J1, pin C, wire 3070 to connector Only code 38-16 is
C453, pin 4, wire 3070. Check displayed. Replace right
continuity from J1, pin D, wire 3000 wheel speed sensor.
to C453, pin 2, wire 3000.
3 2
4 1
One or both show Continuity on both.
open. Repair or replace Replace AWS
AWS harness. controller *. C453
HARNESS SIDE
AWS CONTROLLER
S K
J2 J3 R P N M L J
A B C D E F G H
J4 J3
A B C D E F G H J1 HARNESS SIDE
J K L M N P R S
J1
HARNESS SIDE
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-16 Service Manual
Code 38-16:
AWS LEFT WHEEL SPEED WIRING FAULT
Refer to appropriate electrical schematics for circuit description.
Are codes 38-13, 38-14
and 38-15 also displayed.
Yes. No.
Remove J3 connector on AWS controller. Unplug left wheel speed connector
Check continuity, pin G, wire1500 to C454. Plug in MEL-1609 test harness
connector C454, pin 1, wire 1540. to the AWS harness side of C454.
Unplug right wheel speed connector
C453. Plug in the other side of MEL-
No continuity. Continuity. 1609 test harness into the right wheel
Repair or replace Check continuity AW S speed sensor.
AWS harness. connector J3, pin A, wire
2500 to connector C454,
pin 3, wire 2630. Power up the system.
Check codes. 38-15 should be displayed
"AWS Right Wheel Speed Wiring Fault".
No continuity. Remove J1 connector from AWS
Repair or replace controller. Check continuity from
AWS harness. J1, pin B, wire 3080 to connector Only code 38-15 is
C454, pin 4, wire 3080. Check displayed. Replace left
continuity from J1, pin A, wire 3020 wheel speed sensor.
to C454, pin 2, wire 3020.
3 2
4 1
One or both show Continuity on both.
open. Repair or replace Replace AWS C453
AWS harness. controller *. HARNESS SIDE
AWS CONTROLLER
S K
J2 J3 R P N M L J
A B C D E F G H
J4 J3
A B C D E F G H J1 HARNESS SIDE
J K L M N P R S
J1
HARNESS SIDE
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-17 Service Manual
Code 38-17:
AW S TILT ACTUATOR REDUCED PERFORM ANCE
T h is e rro r c o d e w ill n o t b e d is p la y to th e o p e ra to r. It w ill b e lo g g e d to th e B o b c a t C o n tro lle r a n d
displayed on th e diag nostic screen on th e service prog ram on the lap top compute r. If th e op erator
complains of sluggish operation, check to see if this alarm is being logged by checking the codes on the
diagnostic screen. This code determines that the actuator is not getting to its command position within a
spe cifie d time p eriod. C he ck for binding prob le ms, sticking valve spoo l, o r the p ossib ility th at the
actuator is going bad. Remove the actuator, inspect components for rubbing. Check operation of the
spool, if everything looks OK, install new actuator using the correct torquing instructions.
A220 Bobcat Loader
60-90-18 Service Manual
Code 38-18:
AW S LIFT ACTUATO R REDUCED PERFO RM ANCE
T h is e rro r c o d e w ill n o t b e d is p la y to th e o p e ra to r. It w ill b e lo g g e d to th e B o b c a t C o n tro lle r a n d
displayed o n the d ia gno stic scree n on the se rvice p rogra m on th e lapto p comp uter. If the ope rator
complains of sluggish operation, check to see if this alarm is being logged by checking the codes on the
diagn ostic scree n. Th is co de d etermin es th at the actu ator is no t getting to its command ed p osition
within a specified time period. Check for binding problems, sticking valve spool, or the possibility that
the actuator is going bad. Remove the actuator, inspect components for rubbing. Check operation of the
spool, if everything looks OK, install new actuator using the correct torquing instructions.
A220 Bobcat Loader
60-90-19 Service Manual
Code 38-19:
AWS LEFT JOYSTICK X AXIS OUT OF RANGE HIGH
Refer to appropriate electrical schematics for circuit description.
Is code 38-85 "5.0 Volt Sensor Supply
1 Out Of Range High" also displayed.
Yes. Unplug left joystick connector C449.
Troubleshoot 38-85 Is code 38-29 "Left Joystick X Axis
code. Out Of Range Low" now displayed?
Yes. No.
Reconnect C449 connector. Code 38-19 is still displayed. Install
Disconnect C459 connector located MEL-1608 test harness in-line on
within the joystick. Is code 38-29 "Left connector C449.
Joystick X Axis Out Of Range Low"
now displayed?
Measure voltage between pin 2 and
pin 5 of the test harness. Voltage
should be approximately 2.5 Volts.
No.
Yes.
Repair or replace joystick
Replace joystick.
harness 6729397.
Voltage is high. Reads 2.5 Volts. The
Repair or replace system appears OK.
AWS harness. Replace AWS controller *.
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be found at
this time. Probable causes may include: loose connections, corrosion, pushed back pins, the controller,
the wiring harness or a combination of these problems.
NOTE: Check before joystick replacement:
Locate the joystick harness wires where they exit the joystick, behind the steering lever panels of the loader. This
harness plugs into the mainframe harness via a gray 6 pin connector. Slightly tug on each of the five joystick
harness wires, where they enter the connector, to check for broken wires. If a broken wire is found repair or
replace the joystick harness.
A220 Bobcat Loader
60-90-20 Service Manual
Code 38-20:
AWS RIGHT JOYSTICK X AXIS OUT OF RANGE HIGH
Refer to appropriate electrical schematics for circuit description.
Is code 38-85 "5.0 Volt Sensor Supply
1 Out Of Range High" also displayed.
Yes. Unplug right joystick connector C450.
Troubleshoot 38-85 Is code 38-30 "Right Joystick X Axis
code. Out Of Range Low" now displayed?
Yes. No.
Reconnect C450 connector. Code 38-20 is still displayed. Install
Disconnect C460 connector located MEL-1608 test harness in-line on
within the joystick. Is code 38-30 connector C450.
"Right Joystick X Axis Out Of Range
Low" now displayed?
Measure voltage between pin 2 and
pin 5 of the test harness. Voltage
should be approximately 2.5 Volts.
No.
Yes.
Repair or replace joystick
Replace joystick.
harness 6729397.
Voltage is high. Reads 2.5 Volts. The
Repair or replace system appears OK.
AWS harness. Replace AWS controller *.
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be found at
this time. Probable causes may include: loose connections, corrosion, pushed back pins, the controller,
the wiring harness or a combination of these problems.
NOTE: Check before joystick replacement:
Locate the joystick harness wires where they exit the joystick, behind the steering lever panels of the loader. This
harness plugs into the mainframe harness via a gray 6 pin connector. Slightly tug on each of the five joystick harness
wires, where they enter the connector, to check for broken wires. If a broken wire is found repair or replace the
joystick harness.
A220 Bobcat Loader
60-90-21 Service Manual
Code 38-21:
AWS LEFT JOYSTICK Y AXIS OUT OF RANGE HIGH
Refer to appropriate electrical schematics for circuit description.
Is code 38-85 "5.0 Volt Sensor Supply
1 Out Of Range High" also displayed.
Yes. Unplug left joystick connector C449.
Troubleshoot 38-85 Is code 38-31 "Left Joystick Y Axis
code. Out Of Range Low" now displayed?
Yes. No.
Reconnect C449 connector. Code 38-21 is still displayed. Install
Disconnect C459 connector located MEL-1608 test harness in-line on
within the joystick. Is code 38-31 "Left connector C449.
Joystick Y Axis Out Of Range Low"
now displayed?
Measure voltage between pin 3 and
pin 5 of the test harness. Voltage
should be approximately 2.5 Volts.
No.
Yes.
Repair or replace joystick
Replace joystick.
harness 6729397.
Voltage is high. Reads 2.5 Volts. The
Repair or replace system appears OK.
AWS harness. Replace AWS controller *.
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be found at
this time. Probable causes may include: loose connections, corrosion, pushed back pins, the controller,
the wiring harness or a combination of these problems.
NOTE: Check before joystick replacement:
Locate the joystick harness wires where they exit the joystick, behind the steering lever panels of the loader. This
harness plugs into the mainframe harness via a gray 6 pin connector. Slightly tug on each of the five joystick harness
A220 Bobcat Loader
60-90-22 Service Manual
Code 38-22:
AWSRIGHTJOYSTICKYAXISOUT OFRANGEHIGH
Refer to appropriate electrical schematics for circuit description.
Is code 38-85 "5.0 Volt Sensor Supply
1 Out Of Range High" also displayed.
Yes. Unplug right joystick connector C450.
Troubleshoot 38-85 Is code 38-32 "Right Joystick YAxis
code. Out Of Range Low" nowdisplayed?
Yes. No.
Reconnect C450 connector. Code 38-22 is still displayed. Install
Disconnect C460 connector located MEL-1608 test harness in-line on
within the joystick. Is code 38-32 connector C450.
"Right Joystick Y Axis Out Of Range
Low" nowdisplayed?
Measure voltage between pin 3 and
pin 5 of the test harness. Voltage
should be approximately 2.5 Volts.
No.
Yes.
Repair or replace joystick
Replace joystick.
harness 6729397.
Voltage is high. Reads 2.5 Volts. The
Repair or replace systemappears OK.
AWSharness. Replace AWScontroller *.
* If the alarmis intermittent and not on at the time of testing, the cause of the alarmmay not be found at
this time. Probable causes may include: loose connections, corrosion, pushed back pins, the controller,
the wiring harness or a combination of these problems.
NOTE: Check before joystick replacement:
Locate the joystick harness wires where they exit the joystick, behind the steering lever panels of the loader. This
harness plugs into the mainframe harness via a gray 6 pin connector. Slightly tug on each of the five joystick harness
A220 Bobcat Loader
60-90-23 Service Manual
Code 38-23:
AWS FRONT RIGHT STEERING SENSOR OUT OF RANGE HIGH
Check codes to see if 38-86 "AWS 5 VOLT SUPPLY 2
OUT OF RANGE HIGH" is also displayed.
Yes. No.
Troubleshoot Was wheel assembly
38-86 Code disassembled?
No. Yes.
Disconnect sensor connector C455. Is tire angle excessive.
Check for bent or pushed back pins.
No. Yes.
Is wiring on connector correct. Steering cylinder is
Refer to Electrical Schematic. disconnected.
Connect cylinder
Yes.
No.
Disconnect sensor
Correct signal and
connector C455. Check for
power wires.
bent or pushed back pins.
Code 38-23 is still active.
Code changes to 38-33 "AWS
Install MEL-1603 test harness on
Front Right Steering Sensor
C455 connector. Do a voltage check
Out Of Range Low".
between pins 2 & 3 of test harness.
Disassemble sensor.
Correct voltage is 0.25 - 4.62 Volts.
Is sensor drive pin missing?
Voltage is higher
Voltage is correct.
than 4.62 Volts.
The system appears
Repair or replace
OK. Replace AWS
AWS harness
controller *.
Yes. No.
Replace pin. Repair or replace
sensor.
If you need to finish a job or need to “limp home” use the following procedure:
1. Seat bar down, depress the ‘PTO’ and ‘Traction Lock Override’ buttons at the same time.
2. One or more codes will be displayed in the hour meter display: Fl, Fr, rL, rr.
3. Move the joystick to the disabled wheel. When the wheel is aligned, depress ‘PTO’ the display will now show:
Fl-A, Fr-A, rL-A, rr-A, (aligned)
4. When all 4 BIC’s lights are lit, the wheels are aligned, the loader will operate in Skid Steer Mode only. If loader is
shut down you must repeate alignment procedure again.
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be found at
this time. Probable causes may include: loose connections, corrosion, pushed back pins, the controller,
the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-24 Service Manual
Code 38-24:
AWS FRONT LEFT STEERING SENSOR OUT OF RANGE HIGH
Check codes to see if 38-86 "AWS 5 VOLT SUPPLY 2
OUT OF RANGE HIGH" is also displayed.
Yes. No.
Troubleshoot Was wheel assembly
38-86 Code disassembled?
No.
Disconnect sensor connector C457. Yes.
Check for bent or pushed back pins. Is tire angle excessive.
No. Yes.
Is wiring on connector correct. Refer to Steering cylinder is disconnected.
Electrical Schematic. Connect cylinder
Yes.
No.
Disconnect sensor
Correct signal and power
connector C457. Check for
wires.
bent or pushed back pins.
Code changes to 38-34 "AWS
Front Left Steering Sensor Out Code 38-24 is still active.
Of Range Low". Disassemble Install MEL-1603 test harness on
sensor. C457 connector. Do a voltage check
between pins 2 & 3 of test harness.
Correct voltage is 0.25 - 4.62 Volts.
Is sensor drive pin missing? Voltage is correct. Voltage is higher
The system appears than 4.62 Volts.
OK. Replace AWS Repair or replace
controller *. AWS harness.
No.
Yes.
Repair or replace
Replace pin.
sensor.
If you need to finish a job or need to “limp home” use the following procedure:
1. Seat bar down, depress the ‘PTO’ and ‘Traction Lock Override’ buttons at the same time.
2. One or more codes will be displayed in the hour meter display: Fl, Fr, rL, rr.
3. Move the joystick to the disabled wheel. When the wheel is aligned, depress ‘PTO’ the display will now show:
Fl-A, Fr-A, rL-A, rr-A, (aligned)
4. When all 4 BIC’s lights are lit, the wheels are aligned, the loader will operate in Skid Steer Mode only. If loader is
shut down you must repeate alignment procedure again.
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be found at
this time. Probable causes may include: loose connections, corrosion, pushed back pins, the controller,
the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-25 Service Manual
Code 38-25:
AWS REAR RIGHT STEERING SENSOR OUT OF RANGE HIGH
Check codes to see if 38-86 "AWS 5 VOLT SUPPLY 2 OUT OF RANGE HIGH" is also displayed.
Yes. No.
Troubleshoot Was wheel assembly
38-86 Code disassembled?
No. Yes.
Disconnect sensor connector Is tire angle
C456. Check for bent or pushed excessive.
back pins.
No. Yes.
Is wiring on connector correct. Steering cylinder is disconnected.
Refer to Electrical Schematic. Connect cylinder
Yes.
No.
Disconnect sensor connector
Correct signal and
C456. Check for bent or pushed
power wires.
back pins.
Code 38-25 is still active.
Code changes to 38-35 "AWS Rear
Install MEL-1603 test harness on C456 connector. Do a
Right Steering Sensor Out Of
voltage check between pins 2 & 3 of test harness. Correct
Range Low". Disassemble sensor.
voltage is 0.25 - 4.62 Volts.
Is sensor drive pin missing?
Voltage is correct. The Voltage is higher than
system appears OK. 4.62 Volts. Repair or
Replace AWS controller *. replace AWS harness.
No.
Yes.
Repair or replace
Replace pin.
sensor.
If you need to finish a job or need to “limp home” use the following procedure:
1. Seat bar down, depress the ‘PTO’ and ‘Traction Lock Override’ buttons at the same time.
2. One or more codes will be displayed in the hour meter display: Fl, Fr, rL, rr.
3. Move the joystick to the disabled wheel. When the wheel is aligned, depress ‘PTO’ the display will now show:
Fl-A, Fr-A, rL-A, rr-A, (aligned)
4. When all 4 BIC’s lights are lit, the wheels are aligned, the loader will operate in Skid Steer Mode only. If loader is
shut down you must repeate alignment procedure again.
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be found at
this time. Probable causes may include: loose connections, corrosion, pushed back pins, the controller,
the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-26 Service Manual
Code 38-26:
AWS REAR LEFT STEERING SENSOR OUT OF RANGE HIGH
Check codes to see if 38-86 "AWS 5 VOLT SUPPLY 2
OUT OF RANGE HIGH" is also displayed.
Yes. No.
Troubleshoot Was wheel assembly
38-86 Code disassembled?
No.
Yes.
Disconnect sensor
Is tire angle
connector C498. Check for
excessive.
bent or pushed back pins.
Yes.
No.
Steering cylinder is
Is wiring on connector correct.
disconnected. Connect
Refer to Electrical Schematic.
cylinder
Yes. No.
Disconnect sensor Correct signal and
connector C498. Check for power wires.
bent or pushed back pins.
Code changes to 38-36 "AWS Code 38-26 is still active.
Rear Left Steering Sensor Out Install MEL-1603 test harness on
Of Range Low". Disassemble C498 connector. Do a voltage check
sensor. between pins 2 & 3 of test harness.
Correct voltage is 0.25 - 4.62 Volts.
Is sensor drive pin missing?
Voltage is correct. The Voltage is higher than
system appears OK. Replace 4.62 Volts. Repair or
AWS controller *. replace AWS harness.
Yes. No.
Replace pin. Repair or replace sensor.
If you need to finish a job or need to “limp home” use the following procedure:
1. Seat bar down, depress the ‘PTO’ and ‘Traction Lock Override’ buttons at the same time.
2. One or more codes will be displayed in the hour meter display: Fl, Fr, rL, rr.
3. Move the joystick to the disabled wheel. When the wheel is aligned, depress ‘PTO’ the display will now show:
Fl-A, Fr-A, rL-A, rr-A, (aligned)
4. When all 4 BIC’s lights are lit, the wheels are aligned, the loader will operate in Skid Steer Mode only. If loader is
shut down you must repeate alignment procedure again.
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be found at
this time. Probable causes may include: loose connections, corrosion, pushed back pins, the controller,
the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-27 Service Manual
Code 38-27:
AWS LIFT ACTUATOR SHORT TO BATTERY
Refer to appropriate Electrical Schematic for circuit description.
Does code occur when
engaging float operation?
No.
Yes. Check codes to see if 38-85
Perform handle calibration. "AWS 5 Volt Sensor Supply 1
Refer to 38-06 service code. Out Of Range High" is also
displayed.
Yes. No.
Troubleshoot Swap actuator
38-85 Code. connectors C428
and C429.
Code rem ains 38-27. Swap
Code changes to 38-28. harness connectors back. Install
Actuator is bad. Replace. MEL-1554 test harness on C429
connector.
Do a 5.0 Volt check between
pins 1 and 3 of test harness.
0 Volts. 5.0 Volts OK. Check voltage 5.0 Volts High.
Ground wire is open. b e t we e n p i n s 1 a n d 2 o f t e s t Should display Code 38-85.
Repair or replace AWS har nes s. V olt ag e sh oul d r ea d
harness. approximately 2.0 Volts.
Troubleshoot
2.0 Volts OK. The 2.0 Volts High. Remove actuator connector 38-85 Code.
system appears OK. C429, remove AWS connector J1. Remove
Replace AWS controller *. positive battery cable. Do a continuity
check, connector C429, pin 2, wire 3060, to
positive battery cable. C429
HARNESS SIDE
5 6 7 8
Continuity. No continuity, open.
4 3 2 1
Repair or replace The system appears OK.
harness. Replace AWS controller *.
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-28 Service Manual
Code 38-28:
AWS TILT ACTUATOR SHORT TO BATTERY
Refer to appropriate Electrical Schematic for circuit description.
Check codes to see if 38-85
"AW S 5 Volt Sensor Supply 1
O ut O f R ange H igh" is also
displayed.
Yes. No.
Troubleshoot Swap actuator
38-85 Code. c onne cto rs C 4 28
and C429.
Code remains 38-28. Swap
Code changes to 38-27. harness connectors back. Install
Actuator is bad. Replace. MEL-1554 test harness on C428
connector.
Do a 5.0 Volt check between
pins 1 and 3 of test harness.
0 Volts. 5.0 Volts OK. Check voltage
Ground wire is open. between pins 1 and 2 of test 5.0 Volts High.
Repair or replace AW S harne ss. Voltage s hould read Should display Code 38-85.
harness. approximately 2.0 Volts.
Troubleshoot
38-85 Code.
2.0 Volts OK. The 2.0 Volts High. Remove actuator connector
system appears OK. C428, remove AWS connector J1. Remove
Replace AWS controller *. po sitive b attery c able. D o a c ontinuity
check, connector C428, pin 2, wire 3050, to
positive battery cable.
C428
HARNESS SIDE
5 6 7 8
Continuity. No continuity, open.
Repair or replace The system appears OK. 4 3 2 1
harness. Replace AW S controller *.
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-29 Service Manual
Code 38-29:
AWS LEFT JOYSTICK X AXIS OUT OF RANGE LOW
Refer to appropriate electrical schematics for circuit description.
Is code 38-37 "5.0 Volt Supply 1 Out
Of Range Low" also displayed?
No.
Yes. Verify that handle connectors C449
Troubleshoot 38-37 code. and C459 are plugged in.
AWS CONTROLLER Unplug connectors C449 and C450.
J3 Install MEL-1608 test harness in-line
J1 J2
from connector C449 mainframe
HARNESS SIDE harness side to connector C450 right
A B C D E F G H
J4 joystick side.
J K L M N P R S
J1
Power up system. Codes will be displayed.
Is code 38-29 still displayed?
No. Yes.
Remove left joystick connector Connect test harness MEL-1608
C459 located with-in joystick. in-line on connector C449. Check
for 5.0 Volts between pin 1 and
Check continuity, C459 harness pin 5 of the test harness.
side, from pin 2 (ground) to all
other pins of harness 6729397.
5.0 Volts OK.
5.0 Volts low. Check signal voltage
Repair or replace between pin 2 and pin 5 of
No continuity - open.
AWS harness. the test harness. Should read
Continuity. With connectors C449 and
Repair or replace C459 disconnected, do a 2.45 - 2.55 Volts.
harness 6729397. continuity check on harness
6729397 - end to end. Check Lower than 2.45 Volts.
C449, pin 2 to C459, pin 4. Unplug J1 connector on Reads 2.45 - 2.55 Volts.
Check C449, pin 1 to C459, AWS controller. Check Check continuity, connector
pin 3. Check C449, pin 5 to continuity between pin 2, C449, pin 2, wire 4530 to
C459, pin 2. wire 4530 and pin 5, wire AWS controller J1, pin M,
2080 (ground) of C449 wire 4530.
connector (AWS harness
Harness checks OK. No continuity on one or side).
Replace joystick more checks. Repair or
assembly. replace harness 6729397. No continuity - Continuity.
open. Repair The system appears
4 3 3 4
or replace OK. Replace AWS
AWS harness. controller *.
5 2 2 5
6 1 1 6
Continuity. No continuity .
Repair or replace Replace both joystick 1 2 3 4 5 6 7
C449 C449 AWS harness. assemblies.
AWS C459
JOYSTICK
HARNESS SIDE HARNESS SIDE
HARNESS SIDE
NOTE: AWS/SJC: If tree above does not locate fault check the following: Locate the joystick harness wires where
they exit the joystick. This harness plugs into the mainframe harness via gray 6 pin connector. Slightly tug on
each of the 5 joystick harness wires, where they feed into the connector, check for broken wires. If a broken
wire(s) is found, repair or replace the harness.
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be found at
this time. Probable causes may include: loose connections, corrosion, pushed back pins, the controller,
the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-30 Service Manual
Code 38-30:
AWS RIGHT JOYSTICK X AXIS OUT OF RANGE LOW
Refer to appropriate electrical schematics for circuit description.
Is code 38-37 "5.0 Volt Supply 1 Out Of
Range Low" also displayed?
No.
Yes. Verify that handle connectors C450
Troubleshoot 38-37 and C460 are plugged in.
code.
AWS CONTROLLER
Unplug connectors C449 and C450. Install
J2 J3 MEL-1608 test harness in-line from connector
J1 C450 mainframe harness side to connector
HARNESS SIDE C449 left joystick side.
A B C D E F G H
J4
J1 Power up system. Codes will be displayed.
J K L M N P R S
Is code 38-30 still displayed?
No.
Remove right joystick connector Yes.
C460 located with-in joystick. Connect test harness MEL-1608 in-line on connector
C450. Check for 5.0 Volts between pin 1 and pin 5 of the
Check continuity, harness side from pin 2 test harness.
(ground) to all other pins of harness 6729397.
5.0 Volts OK.
5.0 Volts low. Check signal voltage
No continuity - open. Repair or replace between pin 2 and pin 5 of
Continuity. With connectors C450 and C460 AWS harness. the test harness. Should read
Repair or replace disconnected, do a continuity check 2.45 - 2.5 Volts.
harness 6729397. on harness 6729397 - end to end.
Check C450, pin 2 to C460, pin 4.
Check C450, pin 1 to C460, pin 3.
Lower than 2.45 Volts.
Check C450, pin 5 to C460, pin 2. Reads 2.45 - 2.55 Volts.
Unplug J1 connector on AWS
Check continuity,
controller. Check continuity
connector C450, pin 2, wire
between pin 2, wire 4510 and pin
4510 to AWS controller J1,
5, wire 2070 (ground) of C450
pin K, wire 4510.
connector (AWS harness side).
Harness checks No continuity on one or
OK. Replace joystick more checks. Repair or
assembly. replace harness 6729397. No continuity - Continuity.
open. Repair or The circuit appears
4 3 3 4 replace AWS OK. Replace AWS
5 2 2 5 harness. controller *.
6 1 1 6
Continuity. No continuity . 1 2 3 4 5 6 7
C450 Repair or replace Replace both joystick
C450
AWS JOYSTICK AWS harness. assemblies. C460
HARNESS SIDE HARNESS SIDE HARNESS SIDE
NOTE: AWS/SJC: If tree above does not locate fault check the following: Locate the joystick harness wires where
they exit the joystick. This harness plugs into the mainframe harness via gray 6 pin connector. Slightly tug on
each of the 5 joystick harness wires, where they feed into the connector, check for broken wires. If a broken
wire(s) is found, repair or replace the harness.
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be found at
this time. Probable causes may include: loose connections, corrosion, pushed back pins, the controller,
the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-31 Service Manual
Code 38-31:
AWS LEFT JOYSTICK Y AXIS OUT OF RANGE LOW
Refer to appropriate electrical schematics for circuit description.
Is code 38-37 "5.0 Volt Supply 1 Out Of
Range Low" also displayed?
Yes. No.
Troubleshoot 38-37 Verify that handle connectors C449
code. and C459 are plugged in.
AWS CONTROLLER
Unplug connectors C449 and C450. Install MEL-1608
J2 J3
J1 test harness in-line from connector C449 mainframe
HARNESS SIDE harness side to connector C450 right joystick side.
A B C D E F G H
J4
J1 Power up system. Codes will be displayed.
K
J L M N P R S
Is code 38-31 still displayed?
No. Yes.
Remove left joystick connector C459 located with-in joystick. Connect test harness MEL-1608 in-
line on connector C449. Check for
5.0 Volts between pin 1 and pin 5
Check continuity, harness side of the test harness.
from pin 2 (ground) to all other
pins of harness 6729397.
5.0 Volts OK.
5.0 Volts low. Check signal voltage
No continuity - open.
Repair or replace between pin 3 and pin 5 of
Continuity. With connectors C449 and
AWS harness. the test harness. Should
Repair or replace C459 disconnected, do a
harness 6729397. continuity check on read 2.45 - 2.55 Volts.
harness 6729397 - end to
end. Check C449, pin 3 to
C459, pin 5. Check C449, Lower than 2.45 Volts. Reads 2.45 - 2.55 Volts.
pin 1 to C459, pin 3. Check Unplug J1 connector on Check continuity,
C449, pin 5 to C459, pin 2. AWS controller. Check connector C449, pin 3, wire
continuity between pin 3, 4540 to AWS controller J1,
wire 4540 and pin 5, wire pin L, wire 4540.
2080 (ground) of C449
Harness checks No continuity on one or connector (AWS harness
OK. Replace joystick more checks. Repair or side).
assembly. replace harness 6729397. No continuity - Continuity. The
open. Repair or circuit appears OK.
replace AWS Replace AWS
4 3 3 4 harness. controller *.
5 2 2 5
Continuity. No continuity .
1 1 6
6
Repair or replace Replace both joystick 1 2 4 5 6 7
3
C449 AWS harness. assemblies.
C449
AWS C459
JOYSTICK
HARNESS SIDE HARNESS SIDE
HARNESS SIDE
NOTE: AWS/SJC: If tree above does not locate fault check the following: Locate the joystick harness wires where
they exit the joystick. This harness plugs into the mainframe harness via gray 6 pin connector. Slightly tug on
each of the 5 joystick harness wires, where they feed into the connector, check for broken wires. If a broken
wire(s) is found, repair or replace the harness.
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be found at
this time. Probable causes may include: loose connections, corrosion, pushed back pins, the controller,
the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-32 Service Manual
Code 38-32:
AWS RIGHT JOYSTICK Y AXIS OUT OF RANGE LOW
Refer to appropriate electrical schematics for circuit description.
Is code 38-37 "5.0 Volt Supply 1 Out Of
Range Low" also displayed?
Yes. No.
Troubleshoot 38-37 Verify that handle connectors C450
code. and C460 are plugged in.
AWS CONTROLLER
Unplug connectors C449 and C450.
Install MEL-1608 test harness in-line
J2 J3 from connector C450 mainframe
J1
HARNESS SIDE harness side to connector C449 right
joystick side.
A B C D E F G H
J4
J K L M N P R S
J1 Power up system. Codes will be displayed.
Is code 38-32 still displayed?
Yes.
No. Connect test harness MEL-1608 in-
Remove right joystick connector C460 located with-in joystick. line on connector C450. Check for
5.0 Volts between pin 1 and pin 5
of the test harness.
Check continuity, harness side from pin 2
(ground) to all other pins of harness 6729397.
5.0 Volts OK.
5.0 Volts low.
Check signal voltage
No continuity - open. Repair or replace
between pin 3 and pin 5 of
Continuity. With connectors C450 and AWS harness.
the test harness. Should
Repair or replace C460 disconnected, do a read 2.45 - 2.55 Volts.
harness 6729397. continuity check on
harness 6729397 - end to
end. Check C450, pin 3 to Lower than 2.45 Volts.
C460, pin 5. Check C450, Unplug J1 connector on Reads 2.45 - 2.55 Volts.
pin 1 to C460, pin 3. Check AWS controller. Check Check continuity,
C450, pin 5 to C460, pin 2. continuity between pin 3, connector C450, pin 3, wire
wire 4520 and pin 5, wire 4520 to AWS controller J1,
2070 (ground) of C450 pin J, wire 4520.
connector (AWS harness
side).
Harness checks OK. No continuity on one or
Replace joystick more checks. Repair or No continuity - open.
assembly. replace harness 6729397. Continuity. The circuit
Repair or replace AWS
appears OK.
harness.
4 3 3 4
Replace AWS controller *.
5 2 2 5 Continuity. No continuity .
6 1 1 6
Repair or replace Replace both 1 2 3 4 5 6 7
AWS harness. joystick assemblies.
C450 C450 C460
AWS JOYSTICK HARNESS SIDE
HARNESS SIDE HARNESS SIDE
NOTE: AWS/SJC: If tree above does not locate fault check the following: Locate the joystick harness wires where
they exit the joystick. This harness plugs into the mainframe harness via gray 6 pin connector. Slightly tug on
each of the 5 joystick harness wires, where they feed into the connector, check for broken wires. If a broken
wire(s) is found, repair or replace the harness.
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be found at
this time. Probable causes may include: loose connections, corrosion, pushed back pins, the controller,
the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-33 Service Manual
Code 38-33:
AWS FRONT RIGHT STEERING SENSOR OUT OF RANGE LOW Sheet 1 0f 2
Check codes to see if 38-38 "AWS 5 VOLT SUPPLY 2 OUT OF
RANGE LOW" is also displayed.
Yes. No.
Troubleshoot W as wheel assembly
38-38 Code disassembled?
Yes.
No. Is tire angle
Disconnect sensor excessive.
connector C455. Check for
bent or pushed back pins.
Yes.
No.
Steering cylinder is
Is wiring on connector correct.
disconnected.
Refer to Electrical Schematic.
Connect cylinder
Yes.
No.
Disconnect sensor connector
Correct signal and
C455. Check for bent or
ground wires.
pushed back pins.
If another sensor is available,
replace sensor. Check to see if
38-38 code is active.
Yes.
No. Install MEL-1603 test harness on
Sensor was bad. C455 connector. Do a voltage check
between pins 1 & 2 of test harness.
0 Volts 5.0 Volts
Repair or replace Check voltage between pins 2 & 3 of test harness
AWS harness. for a voltage between 0.25 and 4.62 Volts.
Continued on next page.
A220 Bobcat Loader
60-90-34 Service Manual
Code 38-33:
Sheet 2 0f 2
AWS FRONT RIGHT STEERING SENSOR OUT OF RANGE LOW
Continued from previous page.
Voltage is below 0.25 Volts. Voltage is between 0.25 - 4.62 Volts.
Disconnect C455 connector, also disconnect Remove J1 connector on AWS
AWS connector J1. Check continuity from J1, controller. Check continuity from J1, pin
pin N, wire 3140, to a valid ground. N, wire 3140, to pin 3 of test harness.
Open, no
Continuity. Continuity. Electrical
No continuity. continuity. Repair
Repair or replace circuit appears OK.
Disassemble wheel sensor. or replace AWS
AWS harness. Replace AWS controller *.
harness.
Is sensor drive pin missing or
broken.
Yes. No.
Repair or replace Repair or replace
pin. sensor.
AWS CONTROLLER
J1 J2 J3
HARNESS SIDE
A B C D E F G H
J4
J K L M N P R S
J1
If you need to finish a job or need to “limp home” use the following procedure:
1. Seat bar down, depress the ‘PTO’ and ‘Traction Lock Override’ buttons at the same time.
2. One or more codes will be displayed in the hour meter display: Fl, Fr, rL, rr.
3. Move the joystick to the disabled wheel. When the wheel is aligned, depress ‘PTO’ the display will now show:
Fl-A, Fr-A, rL-A, rr-A, (aligned)
4. When all 4 BIC’s lights are lit, the wheels are aligned, the loader will operate in Skid Steer Mode only. If loader is
shut down you must repeate alignment procedure again.
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be found at
this time. Probable causes may include: loose connections, corrosion, pushed back pins, the controller,
the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-35 Service Manual
Code 38-34:
AWS FRONT LEFT STEERING SENSOR OUT OF RANGE LOW Sheet 1 0f 2
Check codes to see if 38-38 "AWS 5 VOLT SUPPLY 2 OUT OF
RANGE LOW" is also displayed.
Yes. No.
Troubleshoot W as wheel assembly
38-38 Code disassembled?
Yes.
No. Is tire angle
Disconnect sensor excessive.
connector C457. Check for
bent or pushed back pins.
Yes.
No.
Steering cylinder is
Is wiring on connector correct.
disconnected.
Refer to Electrical Schematic.
Connect cylinder
Yes. No.
Disconnect sensor Correct signal and
connector C457. Check for ground wires.
bent or pushed back pins.
If another sensor is available,
replace sensor. Check to see if
38-38 code is active.
Yes.
No. Install MEL-1603 test harness on C457
Sensor was bad.
connector. Do a voltage check between
pins 1 & 2 of test harness.
0 Volts
5.0 Volts
Repair or replace
Check voltage between pins 2 & 3 of test harness
AWS harness.
for a voltage between 0.25 and 4.62 Volts.
Continued on next page.
A220 Bobcat Loader
60-90-36 Service Manual
C ode 38-34:
S hee t 2 0 f 2
A W S FR O N T LE FT S T E E R IN G S E N S O R O U T O F R A N G E LO W
C ontinued from previous page .
V oltag e is below 0.2 5 V olts. V oltag e is betw ee n 0 .25 - 4.62 V olts.
D isconnect C 45 7 connector, also d isconnect R em ove J1 conne ctor on AW S
A W S connector J1. C heck continuity from J1 , co ntroller. C heck continuity fro m J1, pin
p in P , w ire 3040, to a valid ground . P , w ire 3040, to pin 3 of test harness.
O pen , no
C ontin uity. C on tinuity. E lectrical
N o co ntinuity. con tinuity. R epair
R epair o r replace circuit appe ars O K .
D isassem ble w hee l se nsor. or replace A W S
A W S h arness. R eplace A W S controller *.
h arness.
Is senso r drive pin m issin g or
broken .
Y es. N o.
R ep air or replace R e pair or rep lace
p in. senso r.
A W S C O N TR O LLE R
J1 J2 J3
H A R N E S S S ID E
A B C D E F G H
J4
J K L M N P R S
J1
If you ne ed to finish a job or nee d to “lim p h om e” use the follo w ing p ro cedu re :
1. S eat bar dow n , depress th e ‘P TO ’ an d ‘Traction L ock O verride’ buttons at th e sam e tim e .
2. O ne or m ore codes w ill be displayed in the hour m eter display : Fl, Fr, rL, rr.
3. M ove the joystick to the disabled w heel. W he n the w heel is aligne d, depre ss ‘P TO ’ the d isplay w ill n ow sh ow :
Fl-A , Fr-A , rL-A , rr-A , (aligned)
4. W hen all 4 B IC ’s lights are lit, the w heels are a lign ed , th e load er w ill opera te in S kid S tee r M ode o nly. If loade r is
shut dow n you m ust repeate alig nm ent proced ure again .
* If th e ala rm is interm itte nt and not on at the tim e of testing , the cause of the a larm m ay not b e foun d at
th is tim e. P robab le ca uses m ay include: loose conne ction s, co rro sion , push ed back pins, the contro ller,
th e w irin g harne ss o r a com bina tion o f these problem s .
A220 Bobcat Loader
60-90-37 Service Manual
Code 38-35:
AWS REAR RIGHT STEERING SENSOR OUT OF RANGE LOW Sheet 1 0f 2
Check codes to see if 38-38 "AWS 5 VOLT SUPPLY 2 OUT
OF RANGE LOW" is also displayed.
Yes. No.
Troubleshoot W as wheel assembly
38-38 Code disassembled?
No. Yes.
Disconnect sensor Is tire angle
connector C456. Check for excessive.
bent or pushed back pins.
Yes.
No.
Steering cylinder is
Is wiring on connector correct.
disconnected.
Refer to Electrical Schematic.
Connect cylinder
Yes. No.
Disconnect sensor Correct signal and
connector C456. Check for ground wires.
bent or pushed back pins.
If another sensor is available,
replace sensor. Check to see if
38-38 code is active.
Yes.
No.
Install MEL-1603 test harness on C456
Sensor was bad.
connector. Do a voltage check between
pins 1 & 2 of test harness.
0 Volts
5.0 Volts
Repair or replace
Check voltage between pins 2 & 3 of test harness
AWS harness.
for a voltage between 0.25 and 4.62 Volts.
Continued on next page.
A220 Bobcat Loader
60-90-38 Service Manual
Code 38-35
AWSREARRIGHTSTEERINGSENSOROUTOF
RANGELOW
Continuedfromprevious
page
Voltageis below0.25volts. Voltageis in between .25 –4.62Volts.
Disconnect C456 connector, also Remove J4connector on AWS
disconnect AWSconnector J4. Checkl controller. Check continuity fromJ4
continuity fromJ4pin A, wire3130 , to pinA, wire3130, topin3of test
a valid ground harness
Nocontinuity.
Continuity. Repair or Continuity. Electrical circuit
Disassemblewheel Open, nocontinuity.
replaceharness appears OK. ReplaceAWS
sensor Repair or replaceharness.
Controller
Is sensor drivepin missingor broken?
Yes. No.
Repair or Replace Repair or replace
pin. sensor
A220 Bobcat Loader
60-90-39 Service Manual
Code 38-36:
AWS REAR LEFT STEERING SENSOR OUT OF RANGE LOW Sheet 1 0f 2
Check codes to see if 38-38 "AWS 5 VOLT SUPPLY 2 OUT
OF RANGE LOW" is also displayed.
Yes. No.
Troubleshoot Was wheel assembly
38-38 Code disassembled?
No. Yes.
Disconnect sensor Is tire angle
connector C498. Check for excessive.
bent or pushed back pins.
Yes.
No.
Steering cylinder is
Is wiring on connector correct.
disconnected.
Refer to Electrical Schematic.
Connect cylinder
Yes. No.
Disconnect sensor Correct signal and
connector C498. Check for ground wires.
bent or pushed back pins.
If another sensor is available,
replace sensor. Check to see if
38-38 code is active.
Yes.
No.
Install MEL-1603 test harness on C498
Sensor was bad. connector. Do a voltage check between
pins 1 & 2 of test harness.
0 Volts
5.0 Volts
Repair or replace
Check voltage between pins 2 & 3 of test harness
AWS harness.
for a voltage between 0.25 and 4.62 Volts.
Continued on next page.
A220 Bobcat Loader
60-90-40 Service Manual
C ode 38-36:
S heet 2 0f 2
A W S R E A R LE FT S TE E R IN G S E N S O R O U T O F R AN G E LO W
C ontinued from previous page .
V oltage is below 0.25 V olts. V o ltage is betw een 0 .25 - 4.62 V olts.
D isconnect C 498 connector, also disconnect R em ove J1 connector on AW S
A W S connector J1. C heck continuity from J1, controller. C heck continu ity from J1, pin
pin R , w ire 3030 , to a valid gro und. R , w ire 3030 , to pin 3 of test harness.
O p en, no
C ontinuity. C ontinuity. E lectrical
N o continuity. continuity. R epair
R epair or replace circu it appears O K .
D isassem ble w heel sensor. or replace A W S
A W S harness. R eplace A W S controller *.
harness.
Is sensor drive pin m issing or
broken .
Y es. N o.
R epair or replace R epair or replace
pin. sensor.
A W S C O NTR O L LE R
J2 J3
J1
H A R N E S S S ID E
A B C D F G H
J4
E
J1
J K L M N P R S
If you need to finish a job or need to “lim p hom e ” use the follow ing procedure :
1. S eat bar dow n , depre ss the ‘P TO ’ and ‘Traction Lock O verride’ buttons at the sam e tim e .
2. O ne or m ore codes w ill be displayed in the hour m eter display: Fl, Fr, rL , rr.
3. M ove the joystick to the disabled w heel. W hen the w heel is aligned , depress ‘P TO ’ the display w ill now show :
Fl-A , Fr-A , rL-A , rr-A , (aligned)
4. W hen all 4 B IC ’s lights are lit, the w heels are aligned , the loader w ill o perate in S kid S teer M o de only. If lo ader is
shut dow n you m ust repeate alignm ent procedure again .
* If the alarm is interm ittent and not on at the tim e of testing, th e cause o f the alarm m ay not be found at
this tim e. P robable causes m ay include: loo se connections, corrosion, pushed back pins, the controller,
the w iring harness or a com bination of these problem s.
A220 Bobcat Loader
60-90-41 Service Manual
Code 38-37:
AWS 5.0 VOLT SUPPLY 1 OUT OF RANGE LOW
Refer to appropriate electrical schematics for circuit description.
Install MEL-1608 joystick test harness
into the left joystick connector C449 or
the right joystick connector C450.
Check for 5.0 Volts between pin 1 and
pin 5 of the test harness.
5.0 Volts. 5.0 Volts low.
System appears OK. Unplug one sensor at a time (left
Replace AWS joystick, right joystick, lift actuator, tilt
controller *. actuator, left wheel speed sensor,
right wheel speed sensor), while
measuring the voltage.
Low voltage.
5.0 Volts.
Unplug AWS connector J3. Check
Replace bad sensor.
continuity on J3, pin G, wire 1500 to a
valid ground.
Continuity. High resistance,
Repair or replace possibly open? The circuit
AWS harness. appears OK. Replace AWS
controller *.
AWS CONTROLLER
J2 J3 S R P N M L K J
A B C D E F G H
J4 J3
J1 HARNESS SIDE
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-42 Service Manual
Code 38-38:
AWS 5.0 VOLT SUPPLY 2 OUT OF RANGE LOW
Refer to appropriate electrical schematics for circuit description.
Install MEL-1608 wheel position
sensor test harness into any of the 4
wheel position sensor connectors.
Check for 5.0 Volts between pin 1 and
pin 2 of the test harness.
5.0 Volts. 5.0 Volts low.
System appears OK. Unplug each wheel sensor, one
Replace AWS sensor at a time (left front, left rear,
controller *. right front and right rear), while
measuring the voltage.
Low voltage.
5.0 Volts.
Unplug AWS connector J2. Check
Replace bad sensor.
continuity on J2, pin B, wire 1590 to a
valid ground.
Continuity. High resistance,
Repair or replace possibly open? The system
AWS harness. appears OK. Replace AWS
controller *.
AWS CONTROLLER
A B C D E F G H
J2 J3
J K L M N P R S
J2
HARNESS SIDE J4
J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-43 Service Manual
Code 38-39:
AWS LIFT ACTUATOR SHORT TO GROUND Sheet 1 of 2
Refer to appropriate Electrical Schematic for circuit description.
Check codes to see if 38-37 "AWS 5 VOLT SUPPLY 1 OUT
OF RANGE LOW" is also displayed.
Yes. No.
Troubleshoot Do es c od e o c c ur a t
38-37 Code start-up of system?
No.
Yes.
Does actuator drive one
Swap actuator connectors,
direction OK, but faults in
C428 and C429.
opposite direction.
Code changes to Code remains 38-39.
Yes. No. 38-40. Actuator Swap harness
Replace AWS Remove actuator connector is bad. Replace. connectors back.
controller *. C429. Remove AW S Install MEL 1554 test
connector J2. Check harness on C429
c on ti nu it y on c on ne c to r connector.
C429, pin 8, wire 2180, to
ground. Check continuity on
connector C429, pin 5, wire
Do a 5.0 Volt check
1240, to ground.
between pins 1 and 3 of
test harness.
Short to ground. Open. The circuit
Repair or replace appears OK. Continued On Next Page
harness. Replace AWS
controller *.
C429 AWS CONTROLLER
AWS
HARNESS SIDE A B C D E F G H
J2 J3
5 6 7 8
J K L M N P R S
4 3 2 1 J2
HARNESS SIDE J4
J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-44 Service Manual
Code 38-39:
AWS LIFT ACTUATOR SHORT TO GROUND Sheet 2 of 2
Refer to appropriate Electrical Schematic for circuit description.
Continued From Previous Page
5.0 Volts 5.0 Volts OK. Check
If less than 0.1 Volt is seen.
Low. Should
Remove actuator connector C429. voltage between pins 1
display 38-37
Remove AWS connector J3. Check and 2 of test harness.
code. Vol tag e s ho ul d re ad
continuity on C429, pin 3, wire
1580, to AW S, J 3, pin G , wire approximately 2.0 Volts.
1500. Check continuity on C429,
pin 1, wire 2630, to a valid ground. Troubleshoot
38-37 Code.
Open. Continuity. The
Repair or replace circuit appears OK.
harness. Replace AWS
controller *.
2.0 Volts OK. Remove
2.0 Volts LOW. Remove actuator connector
actuator connector C429. C429. Rem ove AW S
Remove AWS connector connector J1. Check
J1. Check continuity on continuity on C429, pin
C429, pin 2, wire 3060, 2, wire 3060, to J1, pin
to a valid ground. H, wire 3060.
Open. Continuity. The
Shorted. No continuity. The circuit appears OK.
Repair or replace
Repair or replace circuit appears OK. Replace AWS
C429 harness.
harness. Replace AWS controller *.
AWS controller *.
HARNESS SIDE
5 6 7 8
AWS CONTROLLER
4 3 2 1
J2 J3 S R P N M L K J
J1 A C D H
B E F G
HARNESS SIDE
J3
A B C D E F G H J4 HARNESS SIDE
J1
J K L M N P R S
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-45 Service Manual
Code 38-40:
AWS TILT ACTUATOR SHORT TO GROUND Sheet 1 of 2
Refer to appropriate Electrical Schematic for circuit description.
Check codes to see if 38-37 "AWS 5 VOLT SUPPLY 1 OUT
OF RANGE LOW" is also displayed.
Yes No
Troubleshoot Does c ode occ ur at
38-37 Code start-up of system?
No
Yes
Does actuator drive one
Swap actuator connectors,
direction OK, but faults in
C428 and C429.
opposite direction.
Yes Code remains 38-40.
No Code changes to
Replace AWS Swap harness
Remove actuator 38-39. Actuator is
controller *. connectors back.
connector C428. Remove bad. Replace.
AWS connector J2. Check Install MEL 1554 test
continuity on connector harness on C428
C428, pin 8, wire 2170, to connector.
ground. Check continuity
on connector C428, pin 5,
wire 1230, to ground.
Do a 5.0 Volt check between
pins 1 and 3 of test harness.
Short to ground. Open. The Continued On Next Page
Repair or replace circuit appears OK.
harness. Replace AWS
controller *.
C428 AWS CONTROLLER
AWS
HARNESS SIDE A B C D E F G H
J2 J3
5 6 7 8
J K L M N P R S
4 3 2 1 J2
HARNESS SIDE
J4
J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-46 Service Manual
Code 38-40:
AWS TILT ACTUATOR SHORT TO GROUND Sheet 2 of 2
Refer to appropriate Electrical Schematic for circuit description.
Continued From Previous Page
5.0 Volts OK. Check
If less than 0.1 Volt is seen. 5.0 Volts Low. Should voltage between pins 1
Remove actuator connector display 38-37 code. and 2 of test har nes s .
C428. Remove AWS connector
Voltage should read
J3. Check continuity on C428,
approximately 2.0 Volts.
pin 3, wire 1570, to AWS, J3,
pin G, wire 1500. Check Troubleshoot
continuity on C428, pin 1, wire 38-37 Code.
2620, to a valid ground.
Open. Continuity. The 2.0 Volts LOW. Remove 2.0 Volts OK. Remove
Repair or replace circuit appears OK. actuator connector C428. actuator connector
harness. Replace AWS Remove AWS connector C428. Rem ove AW S
controller *. J1. Check continuity on connector J1. Check
C428, pin 2, wire 3050, to continuity on C428, pin
a valid ground. 2, wire 3050, to J1, pin
G, wire 3050.
Shorted. No continuity. Open. Continuity.
Repair or replace The circuit appears Repair or replace The circuit appears
harness. OK. Replace AWS harness. OK. Replace AWS
C428 controller *. controller *.
AWS
HARNESS SIDE
5 6 7 8
4 3 2 1
AWS CONTROLLER
J2 J3 S R P N M L K J
J1 A C D H
B E F G
HARNESS SIDE
J3
A B C D E F G H J4 HARNESS SIDE
J1
J K L M N P R S
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-47 Service Manual
Code 38-41:
AW S TILT ACTUATOR W RONG DIRECTION
Refer to appropriate Electrical Schematic for circuit description.
S w a p a c tu a to r c o n n e c to rs C 4 2 8 a n d
C429, command actuator movement.
Code 38-42 is now Code 38-41 is still
displayed. Actuator is bad. displayed. Bad harness,
Replace. repair or replace.
A220 Bobcat Loader
60-90-48 Service Manual
Code 38-42:
AW S LIFT ACTUATOR W RONG DIRECTION
Refer to appropriate Electrical Schematic for circuit description.
S w a p a c tu a to r c o n n e c to rs C 4 2 8 a n d
C429, command actuator movement.
Code 38-41 is now Code 38-42 is still
displayed. Actuator is bad. displayed. Bad harness,
Replace. repair or replace.
A220 Bobcat Loader
60-90-49 Service Manual
Code 38-43:
AWS LEFT FORWARD DRIVE SOLENOID ERROR ON
Refer to appropriate electrical schematics for circuit description.
Support loader on jackstands. Disconnect
C452 connector. Install MEL-1611 test
harness in line on C452 connector. Power
up the system.
Check voltage between pin C
and pin D of the test harness
Voltage reads 0 Volts.
Move joystick forward. Voltage should Voltage reads 0.23
read 0.23 - 1.36 Volts. Release Volts or higher.
joystick, make sure voltage returns to
0 Volts. Repeat process a few times.
Returns to 0 Volts. Voltage reads 0.23
System appears OK. Volts or higher.
Possible AWS controller
problem *.
Power system down. Check
continuity on C452 connector,
pin B to pin C, drive coil side.
No continuity, open.
Continuity.
Unplug AWS controller, J4 connector. Check
Repair or replace pump
continuity on C452 connector, pin B, wire 2670
controller containing drive
to pin C, wire 2660, AWS harness side.
coils, located on the pump.
No continuity, open. Continuity.
Reconnect J4 connector. Power system Repair or replace D C B A A B C D
up. Check voltage on C452 connector, AWS harness.
pin D, wire 4280 to ground, check
voltage, pin C, wire 2660 to ground. C452 C452
AWS DRIVE
HARNESS SIDE COIL SIDE
AWS CONTROLLER
Voltage reads 0.23 0 Volts. The
Volts. Repair or replace system appears OK. J3 J4
J2
AWS harness. Replace AWS AWS
controller *. HARNESS SIDE
K J H G F
J4
J1 E D C B A
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be found at
this time. Probable causes may include: loose connections, corrosion, pushed back pins, the controller,
the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-50 Service Manual
Code 38-45:
AWS RIGHT FORWARD DRIVE SOLENOID ERROR ON
Refer to appropriate electrical schematics for circuit description.
Support loader on jackstands. Disconnect C451
connector. Install MEL-1611 test harness in line on
C451 connector. Power up the system.
Check voltage between pin C
and pin D of the test harness
Voltage reads 0 Volts.
Move joystick forward. Voltage should Voltage reads 0.23
read 0.23 - 1.36 Volts. Release Volts or higher.
joystick, make sure voltage returns to
0 Volts. Repeat process a few times.
Returns to 0 Volts. Voltage reads 0.23
System appears OK. Volts or higher.
Possible AWS controller
problem *.
Power system down. Check
continuity on C451 connector,
pin B to pin C, drive coil side.
No continuity, open.
Continuity.
Unplug AWS controller, J4 connector. Check
Repair or replace pump
continuity on C451 connector, pin B, wire 2690
controller containing drive
to pin C, wire 2680, AWS harness side.
coils, located on the pump.
No continuity, open. Continuity.
Reconnect J4 connector. Power system Repair or replace D C B A A B C D
up. Check voltage on C451 connector, AWS harness.
pin D, wire 4260 to ground, check
voltage, pin C, wire 2680 to ground. C451 C451
AWS DRIVE
HARNESS SIDE COIL SIDE
AWS CONTROLLER
Voltage reads 0.23 0 Volts. The
Volts. Repair or replace circuit appears OK. J3 J4
J2
AWS harness. Replace AWS AWS
controller *. HARNESS SIDE
K J H G F
J4
J1 E D C B A
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be found at
this time. Probable causes may include: loose connections, corrosion, pushed back pins, the controller,
the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-51 Service Manual
Code 38-46:
AWS RIGHT REVERSE DRIVE SOLENOID ERROR ON
Refer to appropriate electrical schematics for circuit description.
Support loader on jackstands. Disconnect C451
connector. Install MEL-1611 test harness in line on
C451 connector. Power up the system.
Check voltage between pin A
and pin B of the test harness
Voltage reads 0 Volts.
Move joystick in reverse direction. Voltage Voltage reads 0.30
should read 0.30 - 1.70 Volts. Release Volts or higher.
joystick, make sure voltage returns to 0
Volts. Repeat process a few times.
Returns to 0 Volts. Voltage reads 0.30
System appears OK. Volts or higher.
Possible AWS controller
problem *.
Power system down. Check
continuity on C451 connector,
pin B to pin C, drive coil side.
No continuity, open.
Continuity.
Unplug AWS controller, J4 connector. Check
Repair or replace pump
continuity on C451 connector, pin B, wire 2690
controller containing drive
to pin C, wire 2680, AWS harness side.
coils, located on the pump.
No continuity, open. Continuity.
Reconnect J4 connector. Power system Repair or replace D C B A A B C D
up. Check voltage on C451 connector, AWS harness.
pin A, wire 4250 to ground, check
voltage, pin B, wire 2690 to ground. C452 C452
AWS DRIVE
HARNESS SIDE COIL SIDE
AWS CONTROLLER
Voltage reads 0.30 0 Volts. The
Volts. Repair or replace circuit appears OK. J3 J4
Replace AWS J2
AWS harness. AWS
controller *. HARNESS SIDE
K J H G F
J4
J1 E D C B A
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-52 Service Manual
Code 38-47:
AW S FRONT RIGHT STEERING SOLENOID ERROR ON
Refer to appropriate Electrical Schem atic for circuit description.
Unplug AW S harness connectors C440
and C461. Turn key switch to run.
C ode rem ains 38-47. P ossible C od e 3 8 -4 7 c le a rs . P o w er o ff.
harness wires shorted to Connect one solenoid coil at a tim e.
power. C heck voltage pin B to Pow er up. N ote which connection
ground on C440 or C461. generates the 38-47 code.
P o w e r o f f . R e c o n n e c t s o le n o id
connectors, unplug the J2
conne ctor on the A W S con troller.
Below 5.6 Volts. Circuit 5.6 Volts and above. Power up.
appears OK. Replace AW S Harness is shorted to power.
controller *. Repair or replace harness.
Code 38-47 clears. The Code rem ains 38-47.
system appears OK. Repair connector wires that
Replace AW S controller *. generated the 38-47 code
in previous step or replace
the AW S harness.
AW S CONTROLLER
A B A B
A B C D E F G H
J2 J3
C440 C461 J K L M N P R S
AW S AW S
J2
HARNESS SIDE HARNESS SIDE
AW S
HARNESS SIDE J4
J1
* If the alarm is interm ittent and not on at the tim e of testing, the cause of the alarm m ay not be
fo u nd at this tim e. Prob ab le cau ses m ay in clu de: lo ose co nn ectio n s, co rro sio n, p u sh ed back
pins, the controller, the w iring harness or a combination of these problem s.
A220 Bobcat Loader
60-90-53 Service Manual
C o de 38-48:
AW S FR O N T L E FT S T E E R IN G S O L E N O ID E R R O R O N
R efer to appropriate E lectrical S chem atic for circuit description.
U nplug A W S harness connectors C 443
and C 499. T urn key switch to run.
C o d e re m a in s 3 8 -4 8 . P o s s ib le C o d e 3 8 -4 8 c le a rs . P o w e r o ff.
h a rn e s s w ire s s h orte d to C onnect one solenoid coil at a tim e.
p o w e r. C h e c k v o lta g e p in B to P o w e r u p . N o te w h ic h c o n n e c tio n
ground on C 443 or C 499. generates the 38-48 code.
P o w e r o f f . R e c o n n e c t s o le n o id
connectors, unplug the J2
c o n n e c to r o n th e A W S c o n tr o lle r .
B elow 5.6 V olts. 5.6 V olts and above. P ower up.
C ircuit appears O K . H arness is shorted to power.
R eplace A W S controller *. R epair or replace harness.
C ode 38-47 clears. T he C ode rem ains 38-48.
system appears O K . R epair connector w ires that
R eplace A W S controller *. generated the 38-48 code
in previous step or replace
the A W S harness.
AW S C O N T R O LLE R
A B A B
A B C D E F G H
J2 J3
C 443 C 499 J K L M N P R S
AW S AW S
J2
H AR N E S S S ID E H AR N E S S S ID E
AW S
H AR N E S S S ID E J4
J1
* If th e alarm is in te rm itte n t a n d n o t o n a t th e tim e o f tes tin g , th e c au se o f th e alarm m a y n o t b e
fo u n d a t th is tim e . P ro b a b le c a u s e s m a y in c lu d e : lo o s e c o n n e c tio n s , c o rro s io n , p u s h e d b a c k
p ins, the controller, the w iring harness o r a co m b inatio n o f these problem s.
A220 Bobcat Loader
60-90-54 Service Manual
Code 38-49:
AW S REAR RIGHT STEERING SOLENOID ERROR ON
Refer to appropriate Electrical Schem atic for circuit description.
Unplug AW S harness connectors C444
and C445. Turn key switch to run.
C ode rem ains 38-49. P ossible C od e 3 8 -4 9 c le a rs . P o w er o ff.
harness wires shorted to Connect one solenoid coil at a tim e.
power. C heck voltage pin B to Pow er up. N ote which connection
ground on C444 or C445. generates the 38-49 code.
P o w e r o f f . R e c o n n e c t s o le n o id
connectors, unplug the J2
conne ctor on the A W S con troller.
Below 5.6 Volts. Circuit 5.6 Volts and above. Power up.
appears OK. Replace Harness is shorted to power.
AW S controller *. Repair or replace harness.
Code 38-49 clears. The Code rem ains 38-49.
system appears OK. Repair connector wires that
Replace AW S controller *. generated the 38-49 code
in previous step or replace
the AW S harness.
AWS CONTROLLER
A B A B
A B C D E F G H
J2 J3
C444 C445 J K L M N P R S
AW S AWS
J2
HARNESS SIDE HARNESS SIDE
AW S
HARNESS SIDE J4
J1
* If the alarm is interm ittent and not on at the tim e of testing, the cause of the alarm m ay not be
found at this tim e. Probable causes m ay include: loose connections, corrosion, pushed back
pins, the controller, the w iring harness or a combination of these problem s.
A220 Bobcat Loader
60-90-55 Service Manual
C ode 38-50:
AW S R E AR LE FT S TE E R IN G S O LE N O ID E R R O R O N
R efer to appropriate Electrical S chem atic for circuit description.
U nplug AW S harness connectors C 446
and C 447. T urn key sw itch to run.
C o d e re m a in s 3 8 -5 0 . P o s s ib le C o d e 3 8 -5 0 c le a r s . P o w e r o ff.
harness w ire s shorte d to C onnect one solenoid coil at a tim e.
p o w e r. C h e c k v o lta g e p in B to P o w e r u p . N o te w h ic h c o n n e c tio n
ground on C 446 or C 447. generates the 38-50 code.
P o w e r o f f. R e c o n n e c t s o le n o id
connectors, unplug the J2
c o n n e c to r o n th e A W S c o n tro lle r .
Below 5.6 Volts. 5.6 Volts and above. P ow er up.
C ircuit appears O K . H arness is shorted to power.
R eplace AW S controller *. R epair or replace harness.
C ode 38-50 clears. T he C ode rem ains 38-50.
system appears O K. R epair connector wires that
R eplace AW S controller *. generated the 38-50 code
in previous step or replace
the A W S harness.
AW S C O N T R O LL ER
A B A B
A B C D E F G H
J2 J3
C 446 C 447 J K L M N P R S
AW S AW S
J2
H AR N E S S S ID E H AR N E S S S ID E
AW S
H AR N E SS SID E J4
J1
* If th e ala rm is in te rm itten t an d n o t o n a t th e tim e o f te stin g , th e c au se o f th e alarm m ay n o t b e
fo u n d a t th is tim e . P ro b a b le c a u s e s m a y in c lu d e : lo o s e c o n n e c tio n s , c o rro s io n , p u s h e d b a c k
pins, th e controller, th e w irin g harn ess o r a co m bin ation of these p ro blem s.
A220 Bobcat Loader
60-90-56 Service Manual
C o d e 3 8 -5 1 :
AW S S TE E R IN G P R E S S U R E S O LE N O ID E R R O R O N
R e fe r to ap p ro pria te E le ctrica l S ch em a tic fo r circuit d escrip tio n.
U n p lu g A W S h a r n e s s c o n n e c t o r
C 44 8 . T u rn k ey sw itch to run .
C o d e re m a in s 3 8 -5 1 . P o s s ib le C o d e 3 8 -5 1 cle a rs. P o w e r o ff.
h a r n e s s w ir e s s h o rte d to R e c o n n e c t s o le n o id c o n n e c to r
p o w e r. C h e c k v o lta g e p in B to C 4 4 8 , u n p lu g th e J 2 c o n n e c to r o n
g ro u nd o n C 4 4 8. th e A W S con tro ller. P o w e r u p.
B e lo w 5 .6 V o lts. 5.6 V o lts a n d ab o ve . C o d e 3 8-5 1 cle ars.
C ircuit ap p e ars O K . H a rn ess is sh orted C o d e re m ain s 3 8 -51 .
T he s yste m a p pe a rs
R ep lace A W S to p o w er. R ep a ir o r R e p air o r re p la ce
O K . R e pla ce A W S
co n tro lle r *. rep la ce ha rn e ss. th e A W S h arn e ss.
co n tro ller *.
AW S C O N T R O L L E R
A B
A B C D E F G H
J2 J3
C 44 8 J K L M N P R S
AW S
J2
H AR N E S S S ID E
AW S
H AR N E S S S ID E J4
J1
* If th e a la rm is in te rm itte n t a n d n o t o n a t th e tim e o f te s tin g , th e c a u s e o f th e a la rm m a y n o t b e
fo u n d a t th is tim e . P ro b a b le c a u s e s m a y in c lu d e : lo o s e c o n n e c tio n s , c o rro s io n , p u s h e d b a c k
p in s, th e co n tro lle r, th e w irin g h a rn es s o r a c o m b in a tio n o f th e s e p ro b le m s.
A220 Bobcat Loader
60-90-57 Service Manual
Code 38-52:
AWS BACK-UP ALARM ERROR ON
Back-up Alarm Signal is on when it should be off.
Troubleshoot a possible short to power
on wire 7100: Unplug C404 connector.
Service code Code remains.
clears. Bad AWS
Reconnect C404
harness, C404 to
connector. Remove
back-up alarm.
AWS connector J2.
Repair or replace.
Service code
Code remains.
clears. Bad AWS
Possibly a bad AWS
harness. Repair or
controller *.
replace.
AWS CONTROLLER
A B
A B C D E F G H
J2 J3
C404 J K L M N P R S
AWS
J2
HARNESS SIDE
AWS
HARNESS SIDE J4
J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-58 Service Manual
Code 38-53:
AWS LEFT FORWARD DRIVE SOLENOID ERROR OFF
Refer to appropriate electrical schematics for circuit description.
Remove J4 connector from AW S
controller. Check resistance from J4, pin
H, wire 4280 to J4, pin E, wire 2640.
Should read approximately 16 ohms.
Approximately 16 ohms. Open.
Check continuity from J4, pin Unplug C452 c onnec tor. Chec k
H, wire 4280 to loader ground. resistance across pin C and pin D,
drive coil side. Should read
approximately 16 ohms.
Continuity. Open. The
Repair or replace circuit appears OK. Open.
AWS harness. Replace AWS Approximately 16 Repair or replace
controller *. ohms. Repair or pump controller
replace AWS harness. containing drive coils,
AWS CONTROLLER located on pump.
C452
J2 J3 DRIVE
J4
COIL SIDE
AWS
HARNESS SIDE A B C D
J4 K J H G F
J1 A
E D C B
PUMP CONTROLLER
DRIVE COIL LOCATION
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-59 Service Manual
Code 38-54:
AWS LEFT REVERSE DRIVE SOLENOID ERROR OFF
Refer to appropriate electrical schematics for circuit description.
Re m o v e J 4 c o n n e c t o r f r o m AW S
controller. Check resistance from J4, pin
C, wire 4270 to J4, pin D, wire 2670.
Should read approximately 20 ohms.
Approximately 20 ohms. Open.
Check continuity from J4, pin Unplug C452 connector. Check
C, wire 4270 to loader ground. resistance across pin A and pin B,
drive coil side. Should read
approximately 20 ohms.
Continuity. Open. The
Repair or replace circuit appears OK. Open.
AWS harness. Replace AWS Approximately 20 Repair or replace
controller *. ohms. Repair or pump controller
replace AWS harness. containing drive coils,
located on pump.
AWS CONTROLLER
C452
J2 J3 J4 DRIVE
AWS COIL SIDE
HARNESS SIDE A B C D
J4 K J H G F
J1 A
E D C B
PUMP CONTROLLER
DRIVE COIL LOCATION
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-60 Service Manual
Code 38-55:
AWS RIGHT FORWARD DRIVE SOLENOID ERROR OFF
Refer to appropriate electrical schematics for circuit description.
Remove J4 connector f rom AW S
controller. Check resistance from J4, pin
G, wire 4260 to J4, pin J, wire 2680.
Should read approximately 16 ohms.
Approximately 16 ohms. Open.
Check continuity from J4, pin Unplug C451 c onnec t or. Check
G, wire 4260 to loader ground. resistance across pin C and pin D,
drive coil side. Should read
approximately 16 ohms.
Continuity. Open. The
Repair or replace circuit appears OK. Open.
AWS harness. Replace AWS Approximately 16 Repair or replace
controller *. ohms. Repair or pump controller
replace AWS harness. containing drive coils,
AWS CONTROLLER located on pump.
J2 J3 J4
C451
AWS
DRIVE
HARNESS SIDE
COIL SIDE
J4 K J H G F
A B C D
J1 A
E D C B
PUMP CONTROLLER
DRIVE COIL LOCATION
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-61 Service Manual
Code 38-56:
AWS RIGHT REVERSE DRIVE SOLENOID ERROR OFF
Refer to appropriate electrical schematics for circuit description.
Remove J4 connector from AW S
controller. Check resistance from J4, pin
B, wire 4250 to J4, pin K, wire 2690.
Should read approximately 20 ohms.
Approximately 20 ohms. Open.
Check continuity from J4, pin Unplug C451 connector. Check
B, wire 4250 to loader ground. resistance across pin A and pin B,
drive coil side. Should read
approximately 20 ohms.
Continuity. Open. The
Repair or replace circuit appears OK. Open.
AWS harness. Replace AWS Approximately 20 Repair or replace
controller *. ohms. Repair or pump controller
replace AWS harness. containing drive coils,
located on pump.
AWS CONTROLLER
J2 J3 J4
C451
AWS
DRIVE
HARNESS SIDE
COIL SIDE
J4 K J H G F
A B C D
J1 A
E D C B
PUMP CONTROLLER
DRIVE COIL LOCATION
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-62 Service Manual
Code 38-57:
AWS FRONT RIGHT EXTEND STEERING SOLENOID ERROR OFF
Refer to appropriate Electrical Schematic for circuit description.
Unplug AWS harness connector C440.
Measure resistance of solenoid coil.
Open or no Resistance is within
resistance. specification. Approximately
Replace coil. 9.79 Ohms.
Remove AWS connector J2. Check
continuity J2, pin P, wire 4010 to
C440, pin A, harness side.
Continuity. Open.
Check continuity from J2, pin No continuity. Repair
P, wire 4010 to ground. or replace harness.
Open. Continuity.
Remove AW S connector J3. Check Repair or replace
continuity from J3, pin K, wire 2980 to harness.
C440, pin B, wire 2960, harness side.
Continuity. Open.
Check continuity from J3, pin No continuity. Repair
K, wire 2980 to a valid ground. or replace harness.
C440
SOLENOID C440
Open. Continuity. HARNESS SIDE
COIL SIDE
No continuity. The Repair or replace
circuit appears OK. harness. A B B A
Replace AWS
controller *.
J2
AWS AWS CONTROLLER
HARNESS SIDE J3
AWS
J2 J3 HARNESS SIDE
A B C D E F G H
S R P N M L K J
J K L M N P R S
A B C D E F G H
J4
J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-63 Service Manual
Code 38-58:
AWS FRONT RIGHT RETRACT STEERING SOLENOID ERROR OFF
Refer to appropriate Electrical Schematic for circuit description.
Unplug AWS harness connector C461.
Measure resistance of solenoid coil.
Open or no Resistance is within
resistance. specification. Approximately
Replace coil. 9.79 Ohms.
Remove AWS connector J2. Check
continuity J2, pin E, wire 4020 to
C461, pin A, harness side.
Continuity. Open.
Check continuity from J2, pin No continuity. Repair
E, wire 4020 to ground. or replace harness.
Open. Continuity.
Remove AWS connector J3. Check Repair or replace
continuity from J3, pin K, wire 2980 to harness.
C461, pin B, wire 2950, harness side.
Continuity. Open.
Check continuity from J3, pin No continuity. Repair
K, wire 2980 to a valid ground. or replace harness.
C461
SOLENOID C461
Open. Continuity. COIL SIDE HARNESS SIDE
No continuity. The Repair or replace
circuit appears OK. harness. A B B A
Replace AWS
controller *.
J2
AWS AWS CONTROLLER
HARNESS SIDE J3
AWS
J2 J3 HARNESS SIDE
A B C D E F G H
S R P N M L K J
J K L M N P R S
A B C D E F G H
J4
J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-64 Service Manual
Code 38-59:
AWS FRONT LEFT EXTEND STEERING SOLENOID ERROR OFF
Refer to appropriate Electrical Schematic for circuit description.
Unplug AWS harness connector C499.
Measure resistance of solenoid coil.
Open or no Res i s t anc e i s wi t hi n
resistance. specification. Approximately
Replace coil. 9.79 Ohms.
Remove AWS connector J2. Check
continuity J2, pin R, wire 4030 to
C499, pin A, harness side.
Continuity. Open.
Check continuity from J2, pin No continuity. Repair
R, wire 4030 to ground. or replace harness.
Open. Continuity.
Remove AWS connector J3. Check Repair or replace
continuity from J3, pin L, wire 2880 to harness.
C499, pin B, wire 2940, harness side.
Continuity. Open.
Check continuity from J3, pin L, No continuity. Repair
wire 2880 to a valid ground. or replace harness.
C499
SOLENOID C499
Open. COIL SIDE HARNESS SIDE
No continuity. The Continuity.
circuit appears OK. Repair or replace A B B A
Replace AWS harness.
controller *.
J2
AWS AWS CONTROLLER
HARNESS SIDE J3
AWS
J2 J3 HARNESS SIDE
A B C D E F G H
S R P N M L K J
J K L M N P R S
A B C D E F G H
J4
J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-65 Service Manual
Code 38-60:
AWS FRONT LEFT RETRACT STEERING SOLENOID ERROR OFF
Refer to appropriate Electrical Schematic for circuit description.
Unplug AWS harness connector C443.
Measure resistance of solenoid coil.
Open or no Re s i s t a n c e i s wi t h i n
resistance. specification. Approximately
Replace coil. 9.79 Ohms.
Remove AWS connector J2. Check
continuity J2, pin F, wire 4040 to
C443, pin A, harness side.
Continuity. Open.
Check continuity from J2, pin No continuity. Repair
F, wire 4040 to ground. or replace harness.
Open. Continuity.
Remove AWS connector J3. Check Repair or replace
continuity from J3, pin L, wire 2880 to harness.
C443, pin B, wire 2890, harness side.
Continuity. Open.
Check continuity from J3, pin L, No continuity. Repair
wire 2880 to a valid ground. or replace harness.
C443
SOLENOID C443
Open. Continuity. COIL SIDE HARNESS SIDE
No continuity. The Repair or replace
circuit appears OK. harness. A B B A
Replace AWS
controller *. J2
AWS AWS CONTROLLER
HARNESS SIDE J3
AWS
J2 J3 HARNESS SIDE
A B C D E F G H
S R P N M L K J
J K L M N P R S
A B C D E F G H
J4
J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-66 Service Manual
Code 38-61:
AWS REAR RIGHT EXTEND STEERING SOLENOID ERROR OFF
Refer to appropriate Electrical Schematic for circuit description.
Unplug AWS harness connector C444.
Measure resistance of solenoid coil.
Open or no R e s i s t a n c e i s wi t h i n
resistance. specification. Approximately
Replace coil. 9.79 Ohms.
Remove AWS connector J2. Check
continuity J2, pin N, wire 4050 to
C444, pin A, harness side.
Continuity. Open.
Check continuity from J2, pin No continuity. Repair
N, wire 4050 to ground. or replace harness.
Open. Continuity.
Remove AWS connector J3. Check Repair or replace
continuity from J3, pin M, wire 2970 to harness.
C444, pin B, wire 2820, harness side.
Continuity. Open.
Check continuity from J3, pin No continuity. Repair
M, wire 2970 to a valid ground. or replace harness.
C444
SOLENOID C444
Open. COIL SIDE HARNESS SIDE
No continuity. The Continuity.
circuit appears OK. Repair or replace A B B A
Replace AWS harness.
controller *.
J2
AWS AWS CONTROLLER
HARNESS SIDE J3
AWS
J2 J3 HARNESS SIDE
A B C D E F G H
S R P N M L K J
J K L M N P R S
A B C D E F G H
J4
J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-67 Service Manual
Code 38-62:
AWS REAR RIGHT RETRACT STEERING SOLENOID ERROR OFF
Refer to appropriate Electrical Schematic for circuit description.
Unplug AWS harness connector C445.
Measure resistance of solenoid coil.
Open or no Res i s t ance i s wi t hi n
resistance. specification. Approximately
9.79 Ohms.
Replace coil.
Remove AWS connector J2. Check
continuity J2, pin M, wire 4070 to
C445, pin A, harness side.
Continuity. Open.
Check continuity from J2, pin No continuity. Repair
M, wire 4070 to ground. or replace harness.
Open. Continuity.
Remove AWS connector J3. Check Repair or replace
continuity from J3, pin M, wire 2970 to harness.
C445, pin B, wire 2830, harness side.
Continuity. Open.
Check continuity from J3, pin No continuity. Repair
M, wire 2970 to a valid ground. or replace harness.
C445
Open. SOLENOID C445
No continuity. The Continuity. COIL SIDE HARNESS SIDE
circuit appears OK. Repair or replace
Replace AWS harness. A B B A
controller *.
J2
AWS AWS CONTROLLER
HARNESS SIDE J3
AWS
J2 J3 HARNESS SIDE
A B C D E F G H
S R P N M L K J
J K L M N P R S
A B C D E F G H
J4
J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-68 Service Manual
Code 38-63:
AWS REAR LEFT EXTEND STEERING SOLENOID ERROR OFF
Refer to appropriate Electrical Schematic for circuit description.
Unplug AWS harness connector C446.
Measure resistance of solenoid coil.
Open or no Resistance is within
resistance. specification. Approximately
Replace coil. 9.79 Ohms.
Remove AWS connector J2. Check
continuity J2, pin D, wire 4160 to
C446, pin A, harness side.
Continuity. Open.
Check continuity from J2, pin No continuity. Repair
D, wire 4160 to ground. or replace harness.
Open. Continuity.
Remove AWS connector J3. Check Repair or replace
continuity from J3, pin N, wire 2810 to harness.
C446, pin B, wire 2840, harness side.
Continuity. Open.
Check continuity from J3, pin No continuity. Repair
N, wire 2810 to a valid ground. or replace harness.
C446
SOLENOID C446
Open.
Continuity. COIL SIDE HARNESS SIDE
No continuity. The
circuit appears OK. Repair or replace
harness. A B B A
Replace AWS
controller *.
J2
AWS AWS CONTROLLER
HARNESS SIDE J3
AWS
J2 J3 HARNESS SIDE
A B C D E F G H
S R P N M L K J
J K L M N P R S
A B C D E F G H
J4
J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-69 Service Manual
Code 38-64:
AWS REAR LEFT RETRACT STEERING SOLENOID ERROR OFF
Refer to appropriate Electrical Schematic for circuit description.
Unplug AWS harness connector C447.
Measure resistance of solenoid coil.
Open or no Re s i s t a n c e i s wi t h i n
resistance. specification. Approximately
Replace coil. 9.79 Ohms.
Remove AWS connector J2. Check
continuity J2, pin L, wire 4170 to
C447, pin A, harness side.
Continuity. Open.
Check continuity from J2, pin No continuity. Repair
L, wire 4170 to ground. or replace harness.
Open. Continuity.
Remove AWS connector J3. Check Repair or replace
continuity from J3, pin N, wire 2810 to harness.
C447, pin B, wire 2850, harness side.
Continuity. Open.
Check continuity from J3, pin No continuity. Repair
N, wire 2810 to a valid ground. or replace harness.
C447 C447
SOLENOID HARNESS SIDE
Open. Continuity.
COIL SIDE
No continuity. The Repair or replace
circuit appears OK. harness. B A
A B
Replace AWS
controller *. J2
AWS AWS CONTROLLER
HARNESS SIDE J3
AWS
J2 J3 HARNESS SIDE
A B C D E F G H
S R P N M L K J
J K L M N P R S
A B C D E F G H
J4
J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-70 Service Manual
Code 38-65:
AWS STEERING PRESSURE SOLENOID ERROR OFF
Refer to appropriate Electrical Schematic for circuit description.
Unplug AWS harness connector C448.
Measure resistance of solenoid coil.
Open or no Resi stance i s wi t hi n
resistance. specification. Approximately
Replace coil. 9.79 Ohms.
Remove AWS connector J2. Check
continuity J2, pin C, wire 4060 to
C448, pin A, harness side.
Continuity. Open.
Check continuity from J2, pin No continuity. Repair
C, wire 4060 to ground. or replace harness.
Open. Continuity.
Remove AWS connector J3. Check Repair or replace
continuity from J3, pin P, wire 2870 to harness.
C448, pin B, wire 2870, harness side.
Continuity. Open.
Check continuity from J3, pin No continuity. Repair
P, wire 2870 to a valid ground. or replace harness.
C448
SOLENOID C448
Open. COIL SIDE HARNESS SIDE
Continuity.
No continuity. The
Repair or replace
circuit appears OK. A B B A
harness.
Replace AWS
controller *.
J2
AWS AWS CONTROLLER
HARNESS SIDE J3
AWS
J2 J3 HARNESS SIDE
A B C D E F G H
S R P N M L K J
J K L M N P R S
A B C D E F G H
J4
J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-71 Service Manual
Code 38-66:
AWS BACKUP ALARM ERROR OFF
Backup Alarm Signal Is Off When It Should Be ON.
Disconnect Backup Alarm at alarm terminals.
Check continuity across backup alarm.
Continuity.
Open. Remove AWS controller J2 connector.
No continuity. Replace With back-up alarm still disconnected,
backup alarm. check continuity, J2, pin G, wire 7100 to
back-up alarm terminal, wire 7100.
Open. Continuity.
No continuity. Repair or With connectors still
replace wiring harness. disconnected at alarm. Check
cont inuit y, back - up alar m
terminal, wire 7100 to ground.
Continuity. No Continuity.
repair or replace Check back-up alarm
wiring harness. terminal, wire 2650 (ground)
to loader ground.
Open. Continuity.
No continuity. Repair or Wiring appears OK.
replace wiring harness. Possibly a bad AWS
Controller *.
J2
AWS AWS CONTROLLER C404
HARNESS SIDE ALARM SIDE C404
HARNESS SIDE
J2 J3
A B C D E F G H
A B
B A
J K L M N P R S
J4
J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-72 Service Manual
Code 38-67:
AWS CAN COMMUNICATIONS TIME OUT
This error code occurs when there is a loss of communications
between the AWS controller and the Bobcat controller.
Check Bobcat controller J3 connector, C492 connector
and AWS controller J3 connector. Check for moisture,
corrosion, pushed back or spread open pins.
Connector Connector appears OK. Check continuity, Bobcat
problems. controller J3 connector, pin K1, wire 9500 to AWS
Repair or replace controller J3 connector, pin C, wire 9520. Check
harness. continuity Bobcat controller J3 connector, pin K2, wire
9600 to AWS controller J3 connector, pin B, wire 9620.
No continuity, open.
Continuity checks OK. Disconnect C492 connector. Check C492, pin C, wire
The circuit appears OK. 9520 (AWS harness side) to AWS J3 connector, pin
Swap out AWS controller C, wire 9520. Check C492, pin D, wire 9620 (AWS
and Bobcat controller, harness side) to AWS J3, pin G, wire 9620.
one at a time to determine
defective controller *.
C492 Continuity.
Open.
AWS Check C492, pin C, wire 9520 (mainframe
Repair or replace
HARNESS SIDE harness side) to Bobcat controller J3, pin K1,
AWS harness.
S R P N M L K J wire 9500. Check C492, pin D, wire 9620
H G F D D C B A
( m a i n f r a m e h a r n e s s s i d e ) t o Bo b c a t
E
controller J3, pin K2, wire 9600.
J K L M N P R S
A B C D E F G H
Open. Continuity.
Repair or replace Intermittent harness
C492
mainframe harness. problem, recheck all
MAINFRAME
harness connectors
HARNESS SIDE
and wires.
BOBCAT
AWS CONTROLLER
CONTROLLER
J3
AWS J4
K J H GF E D C B A
J2 J3 HARNESS SIDE J4 1
2
S R P N M L K J J2 3
A B C D E F G H
J2
J4 J3
J1 J3 MAINFRAME
J1 J3 HARNESS SIDE
J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-73 Service Manual
Code 38-69:
AWS LIFT AND TILT NOT CALIBRATED
See your loader Service Manual, Contents Page 60-01for the correct procedure for "Lift And Tilt Calibration.
A220 Bobcat Loader
60-90-74 Service Manual
Code 38-70:
RECOVERY MODE FAILURE
Multiple (Recovery Mode) failures.
If diagnostic tool has not been connected. If diagnostic service tool is connected
Chec k batter y c ables , 100 Am p f us e for up-grade or recalibration.
connections, fuse 12 connections and C492
connector pins.
Ignore code.
This is normal when
up-grading or
recalibration.
Any moisture, corrosion, Connections appear OK.
loose or damaged Rem ove J3 connector from
connections or pins. Repair AW S controller. Disconnect
or replace harness or positive (+) cable from battery.
components
Check continuity between J3, pin H,
wire 1190 and the positive (+) battery
cable and J3, pin J, wire 1180 and the
positive (+) battery cable.
Continuity. No continuity.
Possible AWS Repair or replace
controller problems. harness.
Replace controller *.
AWS
CONTROLLER
J3
AWS
J2 J3 HARNESS SIDE
S R P N M L K J
A B C D E F G H
J4
J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-75 Service Manual
Code 38-71:
AWS BATTERY OUT OF RANGE
Refer to appropriate electrical schematic for circuit description.
Are any battery codes displayed?
Codes 03-09 thru 03-22.
Yes. No.
Refer to battery Remove AWS connector J3. Check
error codes. J3, pin J, wire 1180 and J3, pin H,
wire 1190 for 12.0 Volts.
12 Volts high. 12 Volts low.
Refer to battery Disconnect positive battery cable.
error codes. Check continuity between AW S
connector J3, pin J , wire 1180 to
positive (+) battery cable and J3, pin H,
wire 1190 to positive (+) battery cable.
Continuity. H i g h r e s i s t a n c e , o p e n ?
Check continuity J3, pin J, wire Unplug C492. Check continuity, mainframe
1180 to ground and J3, pin H, harness side, pin A, wire 1170 to
wire 1190 to ground. disconnected positive (+) battery cable.
High resistance, Continuity. Open. Repair or Continuity.
open? The circuit Unplug C492. Recheck replace mainframe Check continuity C492, pin A,
appears OK. continuity J3, pin J, wire harness. wire 1170, AWS harness side
Replace AWS 1180 to ground and J3, pin to AWS connector J3, pin J,
controller *. H, wire 1190 to ground. wire 1180 and C492, pin A,
wire 1170 to AWS connector
J3, pin H, wire 1190.
Continuity. High resistance, open?
Repair or replace Repair or replace
AWS harness. Continuity. Open.
mainframe harness. Intermittent problem. Repair or replace
AWS CONTROLLER Repeat test procedure. AWS harness.
J2 J3
J K L M N P R S S R P N M L K J
S R P N M L K J A B C D E F G H H G F D D C B A
E
A B C D E F G H
J4 C492 C492
J1 MAINFRAME AWS
J3
HARNESS SIDE HARNESS SIDE
HARNESS SIDE
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-76 Service Manual
Code 38-72:
DRIVE PUMP NOT CALIBRATED
See Service Manual, Page 30-01 for Pump Calibration procedure.
A220 Bobcat Loader
60-90-77 Service Manual
A220 Bobcat Loader
60-90-78 Service Manual
Code 38-73:
AWS STEERING MODE SWITCH FLIPPED WHILE OPERATING Sheet 1 0f 2
or (STUCK IN AWS OR SKID MODE)
Refer to appropriate electrical schematic for circuit description.
Most likely the operator flipped the switch while operating the loader. Recover by pressing the "Press To
Operate" button. However, if the code remains and the operator did not flip the switch, check the following:
AW S stuck in AW S or SKID mode.
Stuck in Skid m ode, switch is in AW S
m ode. Unplug C488 ac cessory plug Continued on next page.
and power up system.
S w itc h e s to A W S m o d e . R e m a in s in S K I D m o d e .
Plug C488 back in. Unplug U n plu g C 4 9 2 c o n ne c to r.
AW S/SKID switch. C heck C492 m ainfram e
harness side for 12.0 Volts
on pin K, wire 4500.
Switches to Remains in
SKID mode. AW S mode.
Repair or replace Replace AW S/
12.0 Volts. 0 Volts.
cab harness. SKID switch. Plug C492 back in.
Repair or replace
mainframe harness. Unplug AW S connector
J1. Check for 12.0 Volts
AWS/SKID on J1, pin 5, wire 4950.
SWITCH LOCATION
12.0 Volts. 0 Volts.
Repair or replace Turn power off. Check
AW S harness. continuity on AW S connector
J3, pin G, wire 1500 to J1, pin
5, wire 1950.
P-24472
AWS CONTROLLER Continuity. High resistance,
Repair or replace open? The circuit
AW S harness. appears OK. Replace
J2 J3 AW S controller *.
J1
AWS J3 C492
HARNESS SIDE AWS HARNESS MAINFRAME
SIDE HARNESS SIDE
J4
A B C D E F G H J1 S R P N M L K J J K L M N P R S
A B C D E F G H A H
B C D E F G
J K L M N P R S
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-79 Service Manual
Code 38-73:
AWS STEERING MODE SWITCH FLIPPED WHILE OPERATING Sheet 2 0f 2
or (STUCK IN AWS OR SKID MODE)
Refer to appropriate electrical schematic for circuit description.
Most likely the operator flipped the switch while operating the loader. Recover by pressing the "Press To
Operate" button. However, if the code remains and the operator did not flip the switch, check the following:
AW S stuck in AW S or SKID mode.
Continued from previous page.
Stuc k in AW S m ode, AWS CONTROLLER
See previous page. switch is in SKID
mode. Check fuse F11.
J2 J3
J1
AWS
HARNESS SIDE
Fuse blown. Fuse OK. J4
Replace fuse. Check for 12.0 Volts A B C D E F G H
J1
at fuse F11. J K L M N P R S
0 Volts. 12.0 Volts.
Trace circuit back thru switched Unplug C492 connector. Check continuity,
C492
power relay, back to battery C492 m ainfram e harness side, pin K, wire
MAINFRAME
power to determine cause. 4550 to fuse F11 with switch in SKID mode.
HARNESS SIDE
J K L M N P R S
A B C D E F G H
Continuity. Open.
Unplug AW S c onnector J1. U nplug ac cessory connector C488.
Check continuity C492, pin K, Check continuity, C488, cab harness
wire 4950, AW S harness side side, pin S, wire 1700 to pin E, wire
to AW S connector J1, pin S, 4550 with switch in SKID mode.
wire 4950.
Open. Continuity.
Open. Continuity. The Remove switch. Check C heck continuity, C488,
Repair or replace circuit appears OK. continuity, pin 1 to pin 2 mainframe harness side, pin S,
AW S harness. Replace AW S of switch when in SKID wire 1700 to fuse F11.
controller *. mode.
Open. Continuity.
Repair or replace Check continuity, C488, pin
mainframe E, wire 4550, m ainf ram e
Open. Continuity.
harness. harness side to C492, pin
Switch is bad. Repair or replace
K, w ir e 45 5 0 m ain f ra m e
Replace. cab harness.
harness side.
C488 C488
MAINFRAME CAB
HARNESS SIDE HARNESS SIDE Open. Continuity.
S R P N M L K J J K L M N P R S
Repair or replace Intermittent
F
mainframe problem. Repeat
H G E D C B A A B C D E F G H
harness. test procedure.
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-80 Service Manual
Code 38-74:
AWS UNCOMMANDED RIGHT WHEEL SPEED ERROR ON
Refer to appropriate electrical schematics for circuit description.
Mechanical Failure.
Restart loader. Does it lug down
or turn over too slow to start.
Yes.
No.
Possible contamination
Place loader on jackstands
(material) in valve.
and start. Release brake.
Repair or replace drive
Do wheels rotate?
pump.
No.
Yes. Possible intermittent
Possible failure of drive mechanical or electrical
pump controller. Repair fault. Drive loader, if fault
or replace. reoccurs, repeat above
procedure.
SJC LOADERS
Description of problem: Moving in the reverse direction, the operator will get a 38-95 or
right speed sensor reverse direction) code. When the operator goes in the forward dire
74 or 38-75 ( left or right uncommanded wheel speed.
Solution/Information: Carefully check the wire routing of the speed sensor harness to m
wires are not stressed or rubbing through in the area of the harness clamp. If the wiring
the wheel speed sensor on the side the code is indicating.
A220 Bobcat Loader
60-90-81 Service Manual
Code 38-75:
AWS UNCOMMANDED LEFT WHEEL SPEED ERROR ON
Refer to appropriate electrical schematics for circuit description.
Mechanical Failure.
Restart loader. Does it lug down
or turn over too slow to start.
Yes.
No.
Possible contamination
Place loader on jackstands
(material) in valve.
and start. Release brake.
Repair or replace drive
Do wheels rotate?
pump.
No.
Yes. Possible intermittent
Possible failure of drive mechanical or electrical
pump controller. Repair fault. Drive loader, if fault
or replace. reoccurs, repeat above
procedure.
SJC LOADERS
Description of problem: Moving in the reverse direction, the operator will get a 38-95 or 38-96 (left or right speed sensor reverse
direction) code. When the operator goes in the forward direction, code 38-74 or 38-75 ( left or right uncommanded wheel speed.
Solution/Information: Carefully check the wire routing of the speed sensor harness to make sure the wires are not stressed or
rubbing through in the area of the harness clamp. If the wiring is OK, replace the wheel speed sensor on the side the code is
indicating.
A220 Bobcat Loader
60-90-82 Service Manual
Code 38-76:
AWS UNDER CURRENT STEERING PRESSURE SOLENOID
Refer to appropriate Electrical Schematic for circuit description.
Do a battery voltage check
across battery terminals.
12.0 volts or higher. Under 12.0 Volts.
Disconnect C448 connector. Load check battery.
Measure resistance of coil.
Battery appears Battery defective.
OK. Recharge.
Coil resistance Replace battery.
Res i st ance i s wi t hi n
is low. Repair speci f i cat i on.
or replace coil. Approximately 7.2 ohms.
38-76 code clears.
Disconnect AWS connector J2. Battery was low.
Disconnect C448 connector. 38-76 code clears but
Check continuity from C448, reoccurs after use. Charging
pin A to pin B, AWS harness system is defective. Refer to
side. the loader service manual
electrical section to
troubleshoot charging
system.
Continuity. No continuity.
Repair or replace Check continuity from
harness. C448, pin A, wire 4060 to
machine ground.
Continuity. No continuity.
Repair or replace Electrical circuit appears
harness. OK. Replace AWS
controller *.
AWS CONTROLLER
A B C D E F G H
J2 J3
A B B A
J K L M N P R S
C448 C448 J2
COIL SIDE HARNESS SIDE AWS J4
HARNESS SIDE J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-83 Service Manual
Code 38-77:
AWS UNDER CURRENT FRONT RIGHT EXTEND STEER SOLENOID
Refer to appropriate Electrical Schematic for circuit description.
Do a battery voltage check
across battery terminals.
12.0 volts or higher. Under 12.0 Volts.
Disconnect C440 connector. Load check battery.
Measure resistance of coil.
Battery appears
Battery defective.
OK. Recharge.
Coil resistance Resistance is within Replace battery.
is low. Replace s p e c i f i c a t i o n .
coil. Approximately 9.79 ohms.
38-77 code clears. 38-77 code clears but reoccurs
Battery was low. after use. Charging system is
defective. Refer to the loader
Disconnect AW S connector J2. service manual electrical
Disconnect C440 connector. Check section to troubleshoot
continuity from C440, pin A to pin charging system.
B, AWS harness side.
Continuity. No continuity.
Repair or replace Check continuity from
harness. C440, pin A, wire 4010 to
machine ground.
Continuity. No continuity.
Repair or replace Electrical circuit appears
harness. OK. Replace AWS
controller.
AWS CONTROLLER
A B C D E F G H
J2 J3
A B B A
J K L M N P R S
C440 C440 J2
COIL SIDE HARNESS SIDE AWS J4
HARNESS SIDE J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-84 Service Manual
Code 38-78:
AWS UNDER CURRENT FRONT RIGHT RETRACT STEER SOLENOID
Refer to appropriate Electrical Schematic for circuit description.
Do a battery voltage c heck
across battery terminals.
Under 12.0 Volts.
Load check battery.
12.0 volts or higher.
Disconnect C461 connector.
Measure resistance of coil.
Battery appears Battery defective.
OK. Recharge. Replace battery.
Coil resistance Resistance is within
is low. Replace s p e c i f i c a t i o n .
coil. Approximately 9.79 ohms. 38-78 code clears. 38-78 code clears but reoccurs
Battery was low. after use. Charging system is
defective. Refer to the loader
Disconnect AW S connector J2. service manual electrical
Disconnect C461 connector. Check section to troubleshoot
continuity from C461, pin A to pin charging system.
B, AWS harness side.
Continuity. No continuity.
Repair or replace Check continuity from
harness. C461, pin A, wire 4020 to
machine ground.
Continuity. No continuity.
Repair or replace Electrical circuit appears
harness. OK. Replace AWS
controller *.
AWS CONTROLLER
A B C D E F G H
J2 J3
A B B A
J K L M N P R S
C461 C461 J2
COIL SIDE HARNESS SIDE AWS J4
HARNESS SIDE J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-85 Service Manual
Code 38-79:
AWS UNDER CURRENT FRONT LEFT EXTEND STEER SOLENOID
Refer to appropriate Electrical Schematic for circuit description.
Do a battery voltage check
across battery terminals.
12.0 volts or higher. Under 12.0 Volts.
Disconnect C499 connector. Load check battery.
Measure resistance of coil.
Coil resistance Resistance is within Battery appears Battery defective.
is low. Replace OK. Recharge.
s p e c i f i c a t i o n . Replace battery.
coil. Approximately 9.79 ohms.
Disconnect AW S connector J2. 38-79 code clears but reoccurs
Disconnect C499 connector. Check 38-79 code clears.
Battery was low. after use. Charging system is
continuity from C499, pin A to pin defective. Refer to the loader
B, AWS harness side. service manual electrical
section to troubleshoot
charging system.
Continuity. No continuity.
Repair or replace Check continuity from
harness. C499, pin A, wire 4030 to
machine ground.
Continuity. No continuity.
Repair or replace Electrical circuit appears
harness. OK. Replace AWS
controller *.
AWS CONTROLLER
A B C D E F G H
J2 J3
A B B A
J K L M N P R S
C499 C499 J2
COIL SIDE HARNESS SIDE AWS J4
HARNESS SIDE J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-86 Service Manual
Code 38-80:
AWS UNDER CURRENT FRONT LEFT RETRACT STEER SOLENOID
Refer to appropriate Electrical Schematic for circuit description.
Do a battery voltage check
across battery terminals.
12.0 volts or higher. Under 12.0 Volts.
Disconnect C443 connector. Load check battery.
Measure resistance of coil.
Battery appears
Battery defective.
Coil resistance Resistance is within OK. Recharge.
Replace battery.
is low. Replace s p e c i f i c a t i o n .
coil. Approximately 9.79 ohms.
Disconnect AW S connector J2. 38-80 code clears but reoccurs
Disconnect C443 connector. Check 38-80 code clears.
Battery was low. after use. Charging system is
continuity from C443, pin A to pin defective. Refer to the loader
B, AWS harness side. service manual electrical
section to troubleshoot
charging system.
Continuity. No continuity.
Repair or replace Check continuity from
harness. C443, pin A, wire 4040 to
machine ground.
Continuity. No continuity.
Repair or replace Electrical circuit appears
harness. OK. Replace AWS
controller *.
AWS CONTROLLER
A B C D E F G H
J2 J3
A B B A
J K L M N P R S
C443 C443 J2
COIL SIDE HARNESS SIDE AWS J4
HARNESS SIDE J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-87 Service Manual
Code 38-81:
AWS UNDER CURRENT REAR RIGHT EXTEND STEER SOLENOID
Refer to appropriate Electrical Schematic for circuit description.
Do a battery voltage check
across battery terminals.
12.0 volts or higher. Under 12.0 Volts.
Disconnect C444 connector. Load check battery.
Measure resistance of coil.
Battery appears
Battery defective.
Coil resistance OK. Recharge. Replace battery.
Resistance is within
is low. Replace s p e c i f i c a t i o n .
coil. Approximately 9.79 ohms.
Disconnect AW S connector J2. 38-81 code clears. 38-81 code clears but reoccurs
Disconnect C444 connector. Check Battery was low. after use. Charging system is
continuity from C444, pin A to pin defective. Refer to the loader
B, AWS harness side. service manual electrical
section to troubleshoot
charging system.
Continuity. No continuity.
Repair or replace Check continuity from
harness. C444, pin A, wire 4050 to
machine ground.
Continuity. No continuity.
Repair or replace Electrical circuit appears
harness. OK. Replace AWS
controller *. AWS CONTROLLER
A B C D E F G H
J2 J3
A B B A
J K L M N P R S
C444 C444 J2
COIL SIDE HARNESS SIDE AWS J4
HARNESS SIDE J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-88 Service Manual
Code 38-82:
AWS UNDER CURRENT REAR RIGHT RETRACT STEER SOLENOID
Refer to appropriate Electrical Schematic for circuit description.
Do a battery voltage check
across battery terminals.
12.0 volts or higher. Under 12.0 Volts.
Disconnect C445 connector. Load check battery.
Measure resistance of coil.
Battery appears Battery defective.
Coil resistance Resi stance i s wi thi n OK. Recharge.
is low. Replace Replace battery.
specification.
coil. Approximately 9.79 ohms.
Disconnect AWS connector J2.
Disconnect C445 connector. Check 38-82 code clears. 38-82 code clears but reoccurs
continuity from C445, pin A to pin Battery was low. after use. Charging system is
B, AWS harness side. defective. Refer to the loader
service manual electrical
section to troubleshoot
charging system.
Continuity. No continuity.
Repair or replace Check continuity from
harness. C445, pin A, wire 4070 to
machine ground.
Continuity. No continuity.
Repair or replace Electrical circuit appears
harness. OK. Replace AWS
controller *.
AWS CONTROLLER
A B C D E F G H
J2 J3
A B B A
J K L M N P R S
C445 C445 J2
COIL SIDE HARNESS SIDE AWS J4
HARNESS SIDE J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-89 Service Manual
Code 38-83:
AWS UNDER CURRENT REAR LEFT EXTEND STEER SOLENOID
Refer to appropriate Electrical Schematic for circuit description.
Do a battery voltage check
across battery terminals.
12.0 volts or higher. Under 12.0 Volts.
Disconnect C446 connector. Load check battery.
Measure resistance of coil.
Coil resistance Battery appears
Resistance is within Battery defective.
is low. Replace OK. Recharge.
s p e c i f i c a t i o n . Replace battery.
coil. Approximately 9.79 ohms.
Disconnect AW S connector J2. 38-83 code clears but reoccurs
Disconnect C446 connector. Check 38-83 code clears.
Battery was low. after use. Charging system is
continuity from C446, pin A to pin defective. Refer to the loader
B, AWS harness side. service manual electrical
section to troubleshoot
charging system.
Continuity. No continuity.
Repair or replace Check continuity from
harness. C446, pin A, wire 4160 to
machine ground.
Continuity. No continuity.
Repair or replace Electrical circuit appears
harness. OK. Replace AWS
controller *.
AWS CONTROLLER
A B C D E F G H
J2 J3
A B B A
J K L M N P R S
C446 C446 J2
COIL SIDE HARNESS SIDE AWS J4
HARNESS SIDE J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-90 Service Manual
Code 38-84:
AWS UNDER CURRENT REAR LEFT RETRACT STEER SOLENOID
Refer to appropriate Electrical Schematic for circuit description.
D o a b a tt e r y v o l ta g e c h e c k
across battery terminals.
Under 12.0 Volts.
12.0 volts or higher.
Load check battery.
Disconnect C447 connector.
Measure resistance of coil.
Battery appears
Battery defective.
OK. Recharge.
Coil resistance Resistance is within Replace battery.
is low. Replace s p e c i f i c a t i o n .
coil. Approximately 9.79 ohms.
D is c o n n e c t A W S c o n n e c to r J 2 . 38-84 code clears. 38-84 code clears but reoccurs
Disconnect C447 connector. Check Battery was low. after use. Charging system is
continuity from C447, pin A to pin defective. Refer to the loader
B, AW S harness side. service manual electrical
section to troubleshoot
charging system.
Continuity. No continuity.
Repair or replace C h e c k c o n ti n u i ty f r o m
harness. C447, pin A, wire 4170 to
machine ground.
Continuity. No continuity.
Repair or replace Electrical circuit appears
harness. OK. Replace AW S
controller *.
AWS CONTROLLER
A B B A A B C D E F G H
J2 J3
C447 C447 J K L M N P R S
COIL SIDE HARNESS SIDE
J2
AWS J4
HARNESS SIDE J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-91 Service Manual
Code 38-85:
AWS 5.0 VOLT SENSOR SUPPLY 1 OUT OF RANGE HIGH
Refer to appropriate electrical schematics for circuit description.
Install MEL-1608 joystick test harness into
left joystick connector C449 or right joystick
c onnec tor C450. Chec k for 5.0 Volts
between pin 1 and pin 5 of test harness.
5.0 Volts. 5.0 volts high.
The system appears Unplug AW S connector J3.
OK. Replace AWS Recheck 5.0 Volts at connector
controller *. C449 or C450, between pin 1 and
pin 5 of test harness.
0 Volts. The
system appears OK. 5.0 Volts or
Replace AWS higher. Repair or
controller *. replace AWS
harness.
AWS CONTROLLER
S R P N M L K J
J2 J3 A B C D E F G H
3 4 3 4
J3
2 5 2 5 AWS
J4 HARNESS SIDE
1 6 1 6
J1
C449 C450
AWS AWS
HARNESS SIDE HARNESS SIDE
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-92 Service Manual
Code 38-86:
AWS 5.0 VOLT SENSOR SUPPLY 2 OUT OF RANGE HIGH
Refer to appropriate electrical schematics for circuit description.
Install MEL-1603 wheel position sensor test harness
into any of the 4 wheel position sensor connectors
(C455, C456, C457 or C498). Check for 5.0 Volts
between pin 1 and pin 2 of test harness.
5.0 Volts. 5.0 volts high.
The system appears Unplug AW S connector J2.
OK. Replace AWS Recheck 5.0 Volts at any of the 4
controller *. wheel position sensor connectors
between pin 1 and pin 2 of the test
harness.
0 Volts. The
system appears OK. 5.0 Volts or
Replace AWS higher. Repair or
controller *. replace AWS
harness.
AWS CONTROLLER
A B C D E F G H
J2 J3
1 2 3 1 2 3
J K L M N P R S
C455 C456
J2
AWS AWS J4
AWS J1
HARNESS SIDE HARNESS SIDE
HARNESS SIDE
1 2 3 1 2 3
C457 C498
AWS AWS
HARNESS SIDE HARNESS SIDE
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-93 Service Manual
Code 38-87:
AWS FRONT RIGHT (Steering Mechanical Failure) WHEEL BLOCKED
Refer to appropriate Electrical Schematic for circuit description.
Check front right steering
cylinder to see if it is bent.
Bent cylinder. Repair Cylinder appears OK.
or replace cylinder. Did error occur after
loader was repaired.
Yes. No.
Are steering coils hooked up to Check front right steering coils to
proper electrical connectors? Are see if retaining nuts are tight. Refer
coils orientated on stem correctly? to steering block diagram.
Are coil retaining nuts tight? Refer
to AW S electrical schematic or
steering block diagram.
Yes.
No.
Are there any hydraulic
Tighten nuts.
leaks.
Yes. No.
Verify that hose connections Correct wiring or coil
are correct at steering block orientation.
and cylinders. Refer to loader No.
service manual for diagrams. Disassemble front right king pin Yes.
assembly to check if drive pin Repair leaks.
on wheel position sensor is
broke. Refer to loader service
manual.
Yes.
No.
Are there any hydraulic
Correct hose
leaks.
connections
No. Yes.
Repair or replace solenoid Repair or replace
valve cartridge. Cartridge is drive pin.
If king pin assembly was bent or plugged with
worked on, did the drive pin Yes. contaminants.
get assembled in the Repair leaks.
housing?
No. Yes.
Assemble pin Repair or replace solenoid
in housing. valve cartridge. Cartridge is
bent or plugged with
contaminants.
A220 Bobcat Loader
60-90-94 Service Manual
Code 38-88:
AWS FRONT LEFT (Steering Mechanical Failure) WHEEL BLOCKED
Refer to appropriate Electrical Schematic for circuit description.
Check front left steering
cylinder to see if it is bent.
Bent cylinder. Repair Cylinder appears OK.
or replace cylinder. Did error occur after
loader was repaired.
Yes. No.
Are steering coils hooked up to Check front left steering coils to
proper electrical connectors? Are see if retaining nuts are tight. Refer
coils orientated on stem correctly? to steering block diagram.
Are coil retaining nuts tight? Refer
to AW S electrical schematic or
steering block diagram.
Yes.
No.
Are there any hydraulic
Tighten nuts.
leaks.
Yes. No.
Verify that hose connections Correct wiring or coil
are correct at steering block orientation.
and cylinders. Refer to loader No.
service manual for diagrams. Disassemble front left Yes.
king pin assembly to Repair leaks.
check if drive pin on
wheel position sensor is
broke. Refer to loader
Yes. service manual.
No.
Are there any hydraulic
Correct hose
leaks.
connections
No. Yes.
Repair or replace solenoid Repair or replace
If king pin assembly was valve cartridge. Cartridge is drive pin.
worked on, did the drive Yes. bent or plugged with
pin get assembled in the Repair leaks. contaminants.
housing?
No. Yes.
Assemble pin Repair or replace solenoid
in housing. valve cartridge. Cartridge is
bent or plugged with
contaminants.
A220 Bobcat Loader
60-90-95 Service Manual
Code 38-89:
AWS REAR RIGHT (Steering Mechanical Failure) WHEEL BLOCKED
Refer to appropriate Electrical Schematic for circuit description.
Check rear right steering
cylinder to see if it is bent.
Bent cylinder. Repair Cylinder appears OK.
or replace cylinder. Did error occur after
loader was repaired.
Yes. No.
Are steering coils hooked up to Check rear right steering coils to
proper electrical connectors? Are see if retaining nuts are tight. Refer
coils orientated on stem correctly? to steering block diagram.
Are coil retaining nuts tight? Refer
to AW S electrical schematic or
steering block diagram.
Yes.
No.
Are there any hydraulic
Tighten nuts.
leaks.
Yes. No.
Verify that hose connections Correct wiring or coil
are correct at steering block orientation.
and cylinders. Refer to loader No.
service manual for diagrams. Disassemble rear right Yes.
king pin assembly to Repair leaks.
check if drive pin on
wheel position sensor is
broke. Refer to loader
Yes. service manual.
No.
Are there any hydraulic
Correct hose
leaks.
connections
No. Yes.
Repair or replace solenoid Repair or replace
If king pin assembly was valve cartridge. Cartridge is drive pin.
worked on, did the drive Yes. bent or plugged with
pin get assembled in the Repair leaks. contaminants.
housing?
No. Yes.
Assemble pin Repair or replace solenoid
in housing. valve cartridge. Cartridge is
bent or plugged with
contaminants.
A220 Bobcat Loader
60-90-96 Service Manual
Code 38-90:
AWS REAR LEFT (Steering Mechanical Failure) WHEEL BLOCKED
Refer to appropriate Electrical Schematic for circuit description.
Check rear left steering
cylinder to see if it is bent.
Bent cylinder. Repair Cylinder appears OK.
or replace cylinder. Did error occur after
loader was repaired.
No.
Yes. Check rear left steering coils to see
Are steering coils hooked up to if retaining nuts are tight. Refer to
proper electrical connectors? Are steering block diagram.
coils orientated on stem correctly?
Are coil retaining nuts tight? Refer
to AW S electrical schematic or
steering block diagram.
Yes.
No.
Are there any hydraulic
Tighten nuts.
leaks.
Yes. No.
Verify that hose connections Correct wiring or coil
are correct at steering block orientation. No.
and cylinders. Refer to loader Disassem ble rear left Yes.
service manual for diagrams. king pin assembly to Repair leaks.
check if drive pin on
wheel position sensor is
broke. Refer to loader
service manual.
Yes.
No.
Are there any hydraulic
Correct hose
leaks.
connections
No. Yes.
Repair or replace solenoid Repair or replace
valve cartridge. Cartridge is drive pin.
If king pin assembly was bent or plugged with
worked on, did the drive Yes. contaminants.
pin get assembled in the Repair leaks.
housing?
No. Yes.
Assemble pin Repair or replace solenoid
in housing. valve cartridge. Cartridge is
bent or plugged with
contaminants.
A220 Bobcat Loader
60-90-97 Service Manual
C o d e 3 8 -9 1 :
R IG H T S P E E D S E N S O R M IS S IN G P U L S E S
S w a p o u t rig h t s p e e d s e n s o r.
C o d e re m a in s .
C o d e c le a rs .
R e m o v e A W S c o n tro lle r, J 1 c o n n e c to r.
S peed sensor
L o o k fo r c o rro s io n o n p in s .
w as bad.
P in s c o rro d e d . P in s O K .
R e p a ir o r re p la c e D is c o n n e c t c o n n e c to r C 4 5 3
h a rn e s s . L o o k fo r c o rro s io n o n p in s .
P in s O K .
P in s c o rro d e d . C heck AW S h a rn e s s fo r
R e p a ir o r re p la c e p o s s ib le b re a k o r d a m a g e .
h a rn e s s . C heck fo r in te rm itte n t
c o n n e c tio n s o n c o n n e c to rs .
H a rn e s s E v e ry th in g
d a m a g e d . R e p a ir a p p e a rs O K .
o r re p la c e R e p la c e A W S
h a rn e s s . c o n tro lle r *.
C453 AW S C O N TRO LLER
C453 W HEEL SPEED
J1
H A R N E S S S ID E S E N S O R S ID E
H A R N E S S S ID E J2 J3
3 2 2 3
A B C D E F G H
4 1 1 3
J K L M N P R S J4
J1
A D D IT IO N A L IN F O R M A T IO N :
U s e th e D ia g n o s e / C a lib ra te s c re e n in th e S e rv ic e A n a ly z e r p ro g ra m to m o n ito r th e w h e e l s p e e d rp m . If o n e
s id e is d is p la y in g 0 rp m , w e d e fin ite ly h a v e a s p e e d s e n s o r p ro b le m . R e m o v e th e s e n s o r a n d c h e c k fo b u ild -
u p o f a g ra y p a s te lik e s u b s ta n c e , c le a n if n e c e s s a ry , a n d re in s ta ll th e s e n s o r. If th e d is p la y s till s h o w s 0 rp m ,
re p la c e th e s e n s o r.
If o n e s id e is s lo w e r/fa s te r th a n th e o th e r, m a rk th e w h e e l o n e a c h s id e o f th e lo a d e r a n d p h y s ic a lly c o u n t
w h e e l rp m . C o m p a re th is v a lu e to th e s p e e d s e n s o r to d e te rm in e w h ic h w h e e l s e n s o r is m is s in g p u ls e s .
C le a n th e s e n s o r a n d re te s t. If p ro b le m c o n tin u e s re p la c e th e s e n s o r.
* If th e a la rm is in te rm itte n t a n d n o t o n a t th e tim e o f te s tin g , th e c a u s e o f th e a la rm m a y n o t b e fo u n d a t
th is tim e . P ro b a b le c a u s e s m a y in c lu d e : lo o s e c o n n e c tio n s , c o rro s io n , p u s h e d b a c k p in s , th e c o n tro lle r,
th e w irin g h a rn e s s o r a c o m b in a tio n o f th e s e p ro b le m s .
A220 Bobcat Loader
60-90-98 Service Manual
C o d e 3 8 -9 2 :
L E F T S P E E D S E N S O R M IS S IN G P U L S E S
S w a p o u t le ft s p e e d s e n s o r.
C o d e re m a in s .
C o d e c le a rs .
R e m o v e A W S c o n tro lle r, J 1 c o n n e c to r.
Speed sensor
L o o k fo r c o rro s io n o n p in s .
was bad.
P in s c o rro d e d . P in s O K .
R e p a ir o r re p la c e D is c o n n e c t c o n n e c to r C 4 5 4
h a rn e s s . L o o k fo r c o rro s io n o n p in s .
P in s O K .
P in s c o rro d e d . C heck AW S h a rn e s s fo r
R e p a ir o r re p la c e p o s s ib le b re a k o r d a m a g e .
h a rn e s s . C heck fo r in te rm itte n t
c o n n e c tio n s o n c o n n e c to rs .
H a rn e s s E v e ry th in g
d a m a g e d . R e p a ir a p p e a rs O K .
o r re p la c e R e p la c e A W S
h a rn e s s . c o n tro lle r *.
A W S CO NTR O LLER
J1 C454
H A R N E S S S ID E W HEEL SPEED C454
J2 J3
S E N S O R S ID E H A R N E S S S ID E
B C D F G H 2
A E
2 3 3
J K L M N P R S
1 3 4 1 J4
J1
A D D IT IO N A L IN F O R M A T IO N :
U s e th e D ia g n o s e / C a lib ra te s c re e n in th e S e rv ic e A n a ly z e r p ro g ra m to m o n ito r th e w h e e l s p e e d rp m . If o n e
s id e is d is p la y in g 0 rp m , w e d e fin ite ly h a v e a s p e e d s e n s o r p ro b le m . R e m o v e th e s e n s o r a n d c h e c k fo b u ild -
u p o f a g ra y p a s te lik e s u b s ta n c e , c le a n if n e c e s s a ry , a n d re in s ta ll th e s e n s o r. If th e d is p la y s till s h o w s 0 rp m ,
re p la c e th e s e n s o r.
If o n e s id e is s lo w e r/fa s te r th a n th e o th e r, m a rk th e w h e e l o n e a c h s id e o f th e lo a d e r a n d p h y s ic a lly c o u n t
w h e e l rp m . C o m p a re th is v a lu e to th e s p e e d s e n s o r to d e te rm in e w h ic h w h e e l s e n s o r is m is s in g p u ls e s .
C le a n th e s e n s o r a n d re te s t. If p ro b le m c o n tin u e s re p la c e th e s e n s o r.
* If th e a la rm is in te rm itte n t a n d n o t o n a t th e tim e o f te s tin g , th e c a u s e o f th e a la rm m a y n o t b e fo u n d a t
th is tim e. P ro b a b le c a u s e s m a y in c lu d e : lo o s e c o n n e c tio n s, c o rro s io n , p u s h e d b a c k p in s, th e c o n tro lle r,
th e w irin g h a rn e s s o r a c o m b in a tio n o f th e s e p ro b le m s .
A220 Bobcat Loader
60-90-99 Service Manual
Code 38-93:
UNRESPONSIVE RIGHT SPEED SENSOR
Remove the right speed sensor. Check
for metal filings on the magnetic disc.
Filings on disc. Disc is clean.
Clean disc. Reinstall the Reinstall the sensor as close to the
sensor as close to the disc as possible without contact.
disc as possible without
contact.
Code clears. Code 38-93 remains.
Sensor was out of Disconnect C453 connector. Check continuity of
position. C453, AWS harness side, pin 2, wire 3000 to J1,
pin D of AWS controller. Check continuity of C453,
pin 4, wire 3070 to J1, pin C of AWS controller.
Check continuity C453, pin 3, wire 2570 to chassis
ground. All checks should show continuity.
AWS CONTROLLER Continuity.
No continuity. Enable AWS system. Check for
Repair or replace 5.0 Volts on C453 connector,
J2 J3 AWS harness. pin 1, wire 1530.
J4
J1 5.0 Volts. No 5.0 Volts.
Wiring appears OK. Use wiring schematic
Replace wheel speed to trace wiring back to
J1
C453 sensor. determine cause of no
HARNESS SIDE
HARNESS SIDE 5.0 Volts.
A B C D E F G H
3 2
J K L M N P R S
4 1
ADDITIONAL INFORMATION:
Use the Diagnose/ Calibrate screen in the Service Analyzer program to monitor the wheel speed rpm. If one
side is displaying 0 rpm, we definitely have a speed sensor problem. Remove the sensor and check fo build-
up of a gray paste like substance, clean if necessary, and reinstall the sensor. If the display still shows 0 rpm,
replace the sensor.
If one side is slower/faster than the other, mark the wheel on each side of the loader and physically count
wheel rpm. Compare this value to the speed sensor to determine which wheel sensor is missing pulses.
Clean the sensor and retest. If problem continues replace the sensor.
A220 Bobcat Loader
60-90-100 Service Manual
Code 38-94:
UNRESPONSIVE LEFT SPEED SENSOR
Remove the left speed sensor. Check
for metal filings on the magnetic disc.
Filings on disc. Disc is clean.
Clean disc. Reinstall the Reinstall the sensor as close to the
sensor as close to the disc as possible without contact.
disc as possible with-out
contact.
Code clears. Code 38-94 remains.
Sensor was out of Disconnect C454 connector. Check continuity of
position. C454, AWS harness side, pin 2, wire 3020 to J1,
pin A of AWS controller. Check continuity of C454,
pin 4, wire 3080 to J1, pin B of AWS controller.
AWS CONTROLLER Check continuity C454, pin 3, wire 2580 to chassis
ground. All checks should show continuity.
J2 J3
Continuity.
J4 No continuity. Enable AWS system. Check for
J1 Repair or replace 5.0 Volts on C454 connector,
AWS harness. pin 1, wire 1540.
J1
HARNESS SIDE
A B C D E F G H
5.0 Volts. No 5.0 Volts.
Wiring appears OK. Use wiring schematic
J K L M N P R S Replace wheel speed to trace wiring back to
sensor. determine cause of no
C454 5.0 Volts.
HARNESS SIDE
3 2
4 1
ADDITIONAL INFORMATION:
Use the Diagnose/ Calibrate screen in the Service Analyzer program to monitor the wheel speed rpm. If one
side is displaying 0 rpm, we definitely have a speed sensor problem. Remove the sensor and check fo build-
up of a gray paste like substance, clean if necessary, and reinstall the sensor. If the display still shows 0 rpm,
replace the sensor.
If one side is slower/faster than the other, mark the wheel on each side of the loader and physically count
wheel rpm. Compare this value to the speed sensor to determine which wheel sensor is missing pulses.
Clean the sensor and retest. If problem continues replace the sensor.
A220 Bobcat Loader
60-90-101 Service Manual
Code 38-98:
AW S CO NTRO LLER IN DRIVE CALIBRATION M ODE
This code is displayed when performing the Drive Pump Calibration. If this code is displayed and the
pump was not being calibrated, it is likely the operator did a keystroke sequence to initiate calibration.
Follow th e D rive Pump C alibration procedu re o utline d u nde r se rvice code 38 -72 "D rive Pu mp N ot
Calibrated" to complete the calibration and clear the code.
A220 Bobcat Loader
60-90-102 Service Manual
Code 38-99:
AW S CONTRO LLER IN W HEEL PO SITION CALIBRATION M ODE
This code is displayed when performing the W heel Position Calibration. If this code is displayed and the
whee l po sitio n was no t be in g calib rated , it is likely the o pera tor did a keystroke se que nce to initiate
calibration. Follow the W heel Position Calibration procedure outlined under service code 38-68 "W heel
Angles (Alignment) Not Calibrated" to complete the calibration and clear the code.
A220 Bobcat Loader
60-90-103 Service Manual
4 CONNECTOR BOBCAT CONTROLLER
Code 39-04:
LEFT SMART GRIP IN ERROR
Are codes 38-04 "AWS In Error" and 40-04
"Right Smart Grip In Error" also displayed?
Yes. No.
Troubleshoot Are codes 38-29 "AWS Left Joystick X
38-04 code. Axis Out Of Range Low" and 38-31
"AW S Lef t Joystick Y Axis O ut O f
3 4
Range Low" also displayed?
2 5
1 6
Yes. No. C459
C449 Troubleshoot 38-29 Has the Bobcat controller or JOYSTICK
and 38-31 codes. AW S controller been HARNESS SIDE
AWS
replaced or reprogrammed?
HARNESS SIDE 1 2 3 4 5 6 7
4 3
Yes. No.
5 2
Reprogram Bobcat/ C he c k c o nt in ui t y, c o nn ec t o r
6 1
AWS controller. C449, pin 4, wire 9010, AW S
harness side to Bobcat controller
C449 connector J2, pin B1, wire 9210.
JOYSTICK
HARNESS SIDE
No continuity. Continuity.
Check continuity, Bobcat controller Disconnect connector C459 in joystick base.
connector J2, pin B1, wire 9210 to Check continuity, C459, pin 6 to connector
connector C492, pin G, wire 9210, C449, pin 4, joystick harness side..
mainframe harness side.
Continuity. No continuity,
Continuity. Replace joystick open. Repair or
No continuity.
Check connector C492, pin G, assembly. replace joystick
Repair or replace
wire 9010, AWS harness side to harness 6729397.
mainframe harness.
connector C449, pin 4, wire 9010.
BOBCAT
CONTROLLER
J4
No continuity, open. Continuity. J2
Repair or replace Recheck C492 connector. HARNESS SIDE
F E D C B A
AWS harness. Recheck continuity, connector
C449, pin 4, wire 9010, AW S 1 J2
2
harness side to Bobcat controller 3
connector J2, pin B1, wire 9210. J3
C492 C492 J1
AWS MAINFRAME
HARNESS SIDE HARNESS SIDE
Continuity, intermittent
S R P N M L K J
connection - grease connections J K L M N P R S
H G F D D C B A using dielectric grease. A B C D E F G H
E
A220 Bobcat Loader
60-90-104 Service Manual
4 CONNECTOR BOBCAT CONTROLLER
Code 40-04:
RIGHT SMART GRIP IN ERROR
Are codes 38-04 "AWS In Error" and 39-04
"Left Smart Grip In Error" also displayed?
Yes. No.
Troubleshoot Are codes 38-30 "AWS Right Joystick
38-04 code. X Axis Out Of Range Low" and 38-32
"AW S Right Joystick Y Axis Out Of
Range Low" also displayed?
3 4
2 5 C460
1 6
JOYSTICK
Yes. No. HARNESS SIDE
Troubleshoot 38-30 Has the Bobcat controller or
C450 and 38-32 codes. AW S controller been 1 2 3 4 5 6 7
AWS replaced or reprogrammed?
HARNESS SIDE
4 3
Yes. No.
5 2
Reprogram Bobcat/ C h ec k c on t inu it y, c on ne c t or
6 1 AWS controller. C450, pin 4, wire 9000, AW S
harness side to Bobcat controller
C450 connector J2, pin B2, wire 9110.
JOYSTICK
HARNESS SIDE
No continuity. Continuity.
Check continuity, Bobcat controller Disconnect connector C460 in joystick base.
connector J2, pin B2, wire 9110 to Check continuity, C460, pin 6 to connector
connector C492, pin F, wire 9110, C450, pin 4, joystick harness side.
mainframe harness side.
Continuity. No continuity,
No continuity. Continuity. Replace joystick open. Repair or
Repair or replace Check connector C492, pin F, assembly. replace joystick
mainframe harness. wire 9000, AW S harness side to harness 6729397.
connector C450, pin 4, wire 9000.
BOBCAT
CONTROLLER
J2
No continuity, open. Continuity. J4
HARNESS SIDE
Repair or replace Recheck C492 connector. F E D C B A
AWS harness. Recheck continuity, connector 2
3
C450, pin 4, wire 9000, AW S J2
harness side to Bobcat controller
connector J2, pin B2, wire 9110.
J3
C492 C492 J1
AWS MAINFRAME
HARNESS SIDE HARNESS SIDE
Continuity, intermittent
S R P N M L K J
connection - grease connections J K L M N P R S
H G F D D C B A using dielectric grease. A B C D E F G H
E
A220 Bobcat Loader
60-90-105 Service Manual
4 CONNECTOR BOBCAT CONTROLLER
Code 44-02:
HORN ERROR ON
Horn signal is on when it should be off.
Troubleshoot a possible short
to power on wire 7200.
Remove C497 connector.
Service code clears. Bad Code remains.
harness C497 to horn relay, Reconnect C497.
wire 7200. Repair or replace. Remove C492.
Service code clears. Bad Code remains. Remove Bobcat
AWS harness C492 to controller J3 connector. Check for
C497. Repair or replace. power on C492, pin J, wire 7200, main
frame harness side.
C492
MAINFRAME 12 volts.
HARNESS SIDE No voltage.
Mainframe harness has a
Wire appears OK. Possible
J K L M N P R S short to power. Repair or
bad Bobcat controller *.
A B C D E F G H
replace harness.
C492
AWS
HARNESS SIDE BOBCAT
CONTROLLER
S R P N M L K J
H F E A
G D C B
J4
J3
HARNESS SIDE
J2 K J H GF E D C B A
C497 1
AWS 2
3
HARNESS SIDE J3
J1
A B C
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-106 Service Manual
4 CONNECTOR BOBCAT CONTROLLER
Code 44-03:
HORN ERROR OFF
Horn signal is off when it should be on.
Swap out horn relay.
Error code 44-03 remains.
Error code
Troubleshoot a possible short to
clears. Relay
ground or open on wire 7200.
was bad.
Remove Bobcat controller J1
connector. Remove C497 connector.
Check continuity J1, pin 48, wire 7200
to C497, pin C, wire 7200.
No continuity. Continuity.
R em ove C 492 con nect or . C hec k Check C497, pin C, wire 7200 front
continuity C492 AWS harness side, pin horn harness side to horn relay
J, wire 7200 to C497, pin C, wire 7200. socket, terminal 86, wire 7200.
Continuity.
Continuity. No continuity. No continuity. Reconnect all connectors
Repair or replace Repair or replace Repair or replace except J1. Remove horn relay.
mainframe harness. mainframe harness. horn harness. Check continuity J1, pin 48,
wire 7200 to ground.
Open. Continuity.
No continuity. Check continuity, Remove C497 connector,
horn relay socket, terminal 85, repeat previous continuity
wire 2770 to ground. check.
Continuity. No continuity. Continuity.
No continuity.
Wiring appears OK. Repair wire 2770 or Remove C492 connector,
Repair or replace
Possible bad replace horn/blinker repeat previous continuity
horn harness.
Bobcat controller *. harness. check.
C492
BOBCAT
AWS
CONTROLLER
HARNESS SIDE
No continuity. Continuity.
S M K
Repair or replace
R P N L J
J4 Repair or replace
H G F E D C B A
AWS harness. mainframe harness.
J1
J2 C497 C497
HARNESS SIDE
AWS HORN
F E D C B A
HARNESS SIDE HARNESS SIDE
1
2
J3 A B C C B A
3 J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-107 Service Manual
4 CONNECTOR BOBCAT CONTROLLER
Code 45-02:
RIGHT BLINKER ERROR ON
Right blinker signal is on when it should be off.
Troubleshoot a possible short to
power on wire 6515. Remove C497
connector.
Alarm clears. Alarm remains.
Bad harness C497 to right Reconnect C497. Remove
blinker relay, wire 6515. C492 connector.
Repair or replace.
Alarm clears. Alarm remains.
Bad AWS harness Remove Bobcat controller J1
C492 to C497. Repair connector. Check for power on
or replace. C492, pin N, wire 6510,
mainframe harness side.
12 Volts. No voltage.
Mainframe harness has a Wire appears OK.
short to power. Repair or Possible bad Bobcat
replace harness. controller *.
C492 BOBCAT
MAINFRAME CONTROLLER
HARNESS SIDE
J K L M N P R S J4
A B C D E F G H
J1
C497 HARNESS SIDE J2
F E D C B A
AWS
1
HARNESS SIDE 2 J3
A B C 3 J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-108 Service Manual
4 CONNECTOR BOBCAT CONTROLLER
Code 45-03:
RIGHT BLINKER ERROR OFF
Right blinker signal is off when it should be on.
Swap out right blinker relay.
Error code 45-03 remains.
Error code clears. Troubleshoot a possible short to
Relay was bad. ground or open on wire 6515.
Remove Bobcat controller J3
connector. Remove C497 connector.
Check continuity J3, pin G3, wire 6515
to C497, pin A, wire 6515.
No continuity. Continuity.
Remove C492 connector. Check Check C497, pin A, wire 6515 blinker
continuity, AWS harness side, C492, pin harness side to right blinker relay
N, wire 6515 to C497, pin A, wire 6515. socket, terminal 86, wire 6515.
Continuity.
Continuity. No continuity. No continuity.
Reconnect all connectors
Repair or replace Repair or replace Repair or replace
except J3. Remove right blinker
mainframe harness. AWS harness. blinker harness.
relay. Check continuity J3, pin
G3, wire 6515 to ground.
Open. Continuity.
No continuity. Check continuity, Remove C497 connector,
blinker relay socket, terminal repeat previous continuity
85, wire 2790 to ground. check.
Continuity. No continuity. No continuity. Continuity.
Wiring appears OK. Repair wire 2790 or Repair or replace Remove C492 connector,
Possible bad replace horn/blinker blinker harness. repeat previous continuity
Bobcat controller *. harness. check.
BOBCAT C492
CONTROLLER AWS
HARNESS SIDE No continuity. Continuity.
Repair or replace Repair or replace
J4 S R P N M L K J
AWS harness.
H F A
mainframe harness.
G E D C B
J2 J3
HARNESS SIDE C497 C497
K J H G F E D C B A AWS BLINKER
J3 1 HARNESS SIDE HARNESS SIDE
J1 2
3 A B C C B A
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-109 Service Manual
4 CONNECTOR BOBCAT CONTROLLER
Code 46-02:
LEFT BLINKER ERROR ON
Left blinker signal is on when it should be off.
Troubleshoot a possible short to
power on wire 6415. Remove C497
connector.
Alarm clears. Alarm remains.
Bad harness C497 to left Reconnect C497. Remove
blinker relay, wire 6415. C492 connector.
Repair or replace.
Alarm clears. Alarm remains.
Bad AWS harness Remove Bobcat controller J1
C492 to C497. Repair connector. Check for power on
or replace. C492, pin P, wire 6410,
mainframe harness side.
12 Volts. No voltage.
Mainframe harness has a Wire appears OK.
short to power. Repair or Possible bad Bobcat
replace harness. controller *.
C497 C497
BOBCAT AWS BLINKER
CONTROLLER HARNESS SIDE HARNESS SIDE
A B C C B A
J4
J1
HARNESS SIDE C492
MAINFRAME
F E D C B A J2 HARNESS SIDE
1
2 J K L M N P R S
3
J3 A B C D E F G H
J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-110 Service Manual
4 CONNECTOR BOBCAT CONTROLLER
Code 46-03:
LEFT BLINKER ERROR OFF
Left blinker signal is off when it should be on.
Swap out left blinker relay.
Error code 46-03 remains.
Error code clears. Troubleshoot a possible short to
Relay was bad. ground or open on wire 6415.
Remove Bobcat controller J3
connector. Remove C497 connector.
Check continuity J3, pin G2, wire 6415
to C497, pin B, wire 6415.
No continuity. Continuity.
Remove C492 connector. Check Check C497, pin B, wire 6415 blinker
continuity, AWS harness side, C492, pin harness side to left blinker relay
P, wire 6415 to C497, pin B, wire 6415. socket, terminal 86, wire 6415.
Continuity.
Continuity. No continuity. No continuity.
Reconnect all connectors
Repair or replace Repair or replace Repair or replace
except J3. Remove left blinker
mainframe harness. AWS harness. blinker harness.
relay. Check continuity J3, pin
G2, wire 6415 to ground.
Open. Continuity.
No continuity. Check continuity, Remove C497 connector,
blinker relay socket, terminal r e p e a t p r e v i o u s c o n t i n u it y
85, wire 2780 to ground. check.
Continuity. No continuity.
No continuity. Continuity.
Wiring appears OK. Repair wire 2780 or
Repair or replace Remove C492 connector,
Possible bad replace horn/blinker
blinker harness. repeat previous continuity
Bobcat controller *. harness.
check.
BOBCAT C492
CONTROLLER AWS
HARNESS SIDE No continuity. Continuity.
J4 S R P N M L K J
Repair or replace Repair or replace
H
AWS harness. mainframe harness.
G F E D C B A
J2 J3
HARNESS SIDE C497 C497
K J H G F E D C B A AWS BLINKER
J3 1 HARNESS SIDE HARNESS SIDE
J1 2
3 A B C C B A
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-111 Service Manual
4 CONNECTOR BOBCAT CONTROLLER
Code 47-21:
8 VOLT REFERENCE OUT OF RANGE HIGH
Unplug the engine temperature sender, engine oil pressure sender,
hydraulic temperature sender, hydraulic temperature sender,
hydraulic charge pressure sender, right hand front auxiliary PWM
switch and the seat bar sensor, one at a time.
Code clears. Code remains.
Replace defective Unplug J1 connector from
sender/sensor. Bobcat controller. A number of
codes will be displayed. Check
to see if code 47-21 clears.
Code clears. 8.0 Volt Code remains.
signal wire shorted to Wi t h seat bar s ensor
12.0 Volts. Repair or disconnected, unplug J2
replace mainframe connect or f r om Bobcat
harness. controller. Check continuity of
pins, A1, A2 and A3 to all other
pins of J2 connector.
Continuity. No continuity.
Repair or replace Disconnect right handle connector C409.
cab harness. Disconnect J4 connector from from the Bobcat
controller. Check continuity of pins E1, E2 and
E3 to all other pins of the J4 connector.
Continuity. No continuity.
Repair or replace Remove positive battery cable.
mainframe harness. Check continuity pins A1, A2 and
A3 to positive battery cable.
J2
HARNESS SIDE BOBCAT
CONTROLLER
FED CBA Continuity. No continuity.
1 Repair or replace The circuit appears
2
shorted harness. OK. Replace Bobcat
3 J4
controller *.
J1
HARNESS SIDE J2
FED CBA
1 J3
2
3 J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-112 Service Manual
4 CONNECTOR BOBCAT CONTROLLER
Code 47-22:
8 VOLT REFERENCE OUT OF RANGE LOW
Unplug the engine temperature sender, engine oil pressure
sender, hydraulic temperature sender, hydraulic temperature
sender, hydraulic charge pressure sender, right handle front
auxiliary PWM switch and the seat bar sensor, one at a time.
Code clears. Code remains.
Replace defective Unplug J1 connector from
sender/sensor. Bobcat controller. A number of
codes will be displayed. Check
to see if code 47-22 clears.
Code remains.
Code clears. 8.0 Volt With seat bar sensor
signal wire shorted to disconnected, unplug J2
ground. Repair or replace connector from Bobcat
mainframe harness. controller. Check continuity of
pins, A1, A2 and A3 to all other
pins of J2 connector.
No continuity.
Continuity.
Disconnect right handle connector
Repair or replace
C409. Disconnect J4 connector
cab harness.
from Bobcat controller. Check
continuity of pins E1, E2 and E3 to
all other pins of J4 connector.
Continuity. No continuity.
Repair or replace Check continuity, pins A1,
mainframe harness. A2 and A3 to ground.
J2
HARNESS SIDE
BOBCAT
F E D C B A
CONTROLLER Continuity. No continuity.
1
2 Repair or replace The circuit appears
3
shorted harness. OK. Replace Bobcat
J4 controller *.
J1
HARNESS SIDE J2
F E D C B A
1
2 J3
3
J1
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-113 Service Manual
Code 48-05:
FRONT LIGHT OUTPUT SHORT TO BATTERY
Remove front and
marker light relay.
48-05 code remains.
48-05 code clears. Rem ove J3 connector from
Replace relay. B obc at con troller. Ch eck fo r
voltage between front light relay
socket, terminal 2 and ground.
0 Volts.
12.0 Volts. Repair or Check continuity between J3
replace mainframe connector, pin F3, wire 6320
harness. and all other pins of J3
connector.
Continuity. No continuity.
Repair or replace The circuit appears
shorted harness. OK. Repair Bobcat
controller.
D 1
5 2
3
BOBCAT FRONT & MARKER
4 LIGHT RELAY
CONTROLLER
J4
J3
J2 HARNESS SIDE
K J H G F E D C B A
1
J3 2
3
J1
P-26239
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-114 Service Manual
Code 48-06:
FRONT LIGHT OUTPUT SHORT TO GROUND
Remove front and
marker light relay.
48-06 code remains.
48-06 code clears. Remove J3 connector from Bobcat
Replace relay. c ontr oller. C heck f or c ont inu it y
between front light relay sock et,
terminal 2 and ground.
No continuity.
Continuity. Check continuity between J3
Repair or replace connector, pin F3, wire 6320
mainframe harness. and all of the other pins of J3
connector.
Continuity. No continuity.
Repair or replace The circuit appears
mainframe harness. OK. Repair Bobcat
controller *.
D 1
5 2
3
BOBCAT FRONT & MARKER
4 LIGHT RELAY
CONTROLLER
J4
J3
J2 HARNESS SIDE
K J H G F E D C B A
1
J3 2
3
J1
P-26239
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-115 Service Manual
Code 49-05:
REAR LIGHT OUTPUT SHORT TO BATTERY
Remove rear light relay.
49-05 code remains.
49-05 code clears. Remove J3 connector from Bobcat
Replace relay. controller. Check for voltage between
rear light relay socket, terminal 2 and
ground.
0 Volts.
12.0 Volts. Check continuity between J3
Repair or replace connector, pin F2, wire 6210
mainframe harness. and all of the other pins of J3
connector.
Continuity. No continuity.
Repair or replace The circuit appears
mainframe harness. OK. Repair Bobcat
controller *.
C 1
5 2
3
BOBCAT REAR
4 LIGHT RELAY
CONTROLLER
J4
J3
J2 HARNESS SIDE
K J H G F E D C B A
1
J3 2
3
J1
P-26239
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-116 Service Manual
Code 49-06:
REAR LIGHT OUTPUT SHORT TO GROUND
Remove rear light relay.
49-06 code remains.
49-06 code clears. Remove J3 connector from Bobcat
Replace relay. co ntro ller. Ch eck f o r co ntinuity
between rear light relay sock et,
terminal 2 and ground.
No continuity.
Continuity. Check continuity between J3
Repair or replace connector, pin F2, wire 6210
mainframe harness. and all of the other pins of J3
connector.
Continuity. No continuity.
Repair or replace The circuit appears
mainframe harness. OK. Repair Bobcat
controller *.
C 1
5 2
3
BOBCAT REAR
4 LIGHT RELAY
CONTROLLER
J4
J3
J2 HARNESS SIDE
K J H GF E D C B A
1
J3 2
3
J1
P-26239
* If the alarm is intermittent and not on at the time of testing, the cause of the alarm may not be
found at this time. Probable causes may include: loose connections, corrosion, pushed back
pins, the controller, the wiring harness or a combination of these problems.
A220 Bobcat Loader
60-90-117 Service Manual
A220 Bobcat Loader
60-90-118 Service Manual
STEERING SOLENOID Figure 60-100-3
Removal
Figure 60-100-1
1
1
3
4 2
P-26299
Remove the nut from the solenoid stem (Item 1) [Figure
P-26297 60-100-3].
Installation: Tighten to 60-84 in.-lbs. (6,8-9,5 Nm)
Remove the control panel. (See CONTROL PANEL on torque.
Page 50-100-1.)
Figure 60-100-4
List of steering block and solenoid location [Figure 60-
100-1]:
1 Left Front Wheel
2 Left Rear Wheel
3 Right Front Wheel
4 Right Rear Wheel
Figure 60-100-2
P-26300
1
Mark the solenoids for proper installation [Figure 60-100-
4].
Remove the solenoids from the stem.
P-26298
Remove the two wiring connectors (Item 1) [Figure 60-
100-2] from the solenoids.
NOTE: The wiring harness have color sta-straps for
proper installation. If sta-straps are missing
mark the connectors for proper installation.
A220 Bobcat Loader
60-100-1 Service Manual
STEERING SOLENOID (CONT'D) Figure 60-100-7
Removal (Cont'd) 1
Figure 60-100-5
1
2
P-26303
Check and replace the five O-rings (Item 1) and six back-
P-26301 up washers (Item 2) [Figure 60-100-7] on the solenoid
stem.
Check the solenoid O-rings (Item 1) [Figure 60-100-5].
Figure 60-100-6
P-26302
Remove the solenoid stem (Item 1) [Figure 60-100-6].
A220 Bobcat Loader
60-100-2 Service Manual
BICS™ SYSTEM 2. Raise the Seat Bar fully. All four BICS™ lights (Items
1, 2, 3, & 4) [Figure 60-110-1] [PRESS TO
Inspecting The BICS™ Controller (Engine STOPPED - OPERATE LOADER, SEAT BAR, LIFT & TILT
Key ON) VALVE and TRACTION*] on left instrument panel
should be OFF [Figure 60-110-1].
NOTE: Record what lights are blinking (if any) and
WARNING number of light flashes.
TROUBLESHOOTING on Page 70-10-1.)
(See
AVOID INJURY OR DEATH
Inspecting Deactivation Of The Auxiliary Hydraulics
The Bobcat Interlock Control System (BICS™) must
System (Engine STOPPED - Key ON)
deactivate the lift, tilt and traction drive functions. If it
does not, contact your dealer for service. DO NOT
3. Sit in the operator's seat, lower the Seat Bar, and
modify the system.
W-2151-0394
press the PRESS TO OPERATE LOADER Button.
Press the auxiliary hydraulics FLOW Button. The
auxiliary FLOW Button light will come ON. Raise the
Figure 60-110-1 Seat Bar. The light should be OFF.
Inspecting The Seat Bar Sensor (Engine RUNNING)
4. Sit in the operator's seat, lower the seat bar, engage
the parking brake pedal and fasten the seat belt.
5. Start the engine and operate at low idle. Press the
PRESS TO OPERATE LOADER Button. While
raising the lift arms, raise the Seat Bar fully. The lift
arms should stop. Repeat using the tilt function.
Inspecting The Traction Lock (Engine RUNNING)
6. Fasten the seat belt, disengage the parking brake
pedal, press the PRESS TO OPERATE LOADER
Button and raise the Seat Bar fully. Move the steering
levers slowly forward and backward. The TRACTION
lock should be engaged. Lower the Seat Bar. Press
the PRESS TO OPERATE LOADER Button.
7. Engage the parking brake pedal and move the control
levers slowly forward and backward. The TRACTION
lock should be engaged.
NOTE: *The TRACTION light on the left instrument
panel will remain OFF until the engine is
started, the PRESS TO OPERATE LOADER
1 2 3 4 Button is pressed and the parking brake is
disengaged.
Inspecting The LIft Arm By-Pass Control
B-15551
8. Raise the lift arms 6 feet (2 meters) off the ground.
1. Sit in the operator's seat. Turn key ON (Standard Stop the engine.
Panel), press RUN / ENTER Button (Deluxe Panel),
lower the Seat Bar and disengage the parking brake Turn the lift arm by-pass control knob clockwise 1/4
pedal. Press the PRESS TO OPERATE LOADER turn. Pull up and hold the lift arm by-pass control knob
Button. Three BICS™ lights (Items 1, 2, & 3) [Figure until the lift arms slowly lower.
60-110-1] [PRESS TO OPERATE LOADER, SEAT
BAR, and LIFT & TILT VALVE] on left instrument
panel should be ON [Figure 60-110-1].
A220 Bobcat Loader
60-110-1 Service Manual
BICS™ SYSTEM (CONT’D)
Troubleshooting Chart
WARNING
The following troubleshooting guide is provided for
assistance in locating and correcting BICS™ system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION#
All indicator lights flashing 5
One of the indicator lights flashing 1
Intermittent indicator lights 2, 3, 4
SOLUTION SUGGESTIONS
1. Refer to BICS™ troubleshooting guide. (See TROUBLESHOOTING on Page 70-10-1.)
2. Check wire connections on Bobcat controller to make sure connectors are locked into place.
3. Check pins in connectors for pins pushed back or bent.
4. Use seatbar sensor tester MEL1428 to isolate problem between sensor and controller and wiring.
5. Possible low or high voltage.
A220 Bobcat Loader
60-110-2 Service Manual
BICS™ SYSTEM (CONT’D) The following chart shows the effects which can happen
to the loader, and the probable causes when the BICS™
Troubleshooting Guide System lights are off or flashing and associated service
codes. (See DIAGNOSTICS SERVICE CODES on Page
60-90-1.)
NOTES:
Multiple SERVICE CODES and/or Abnormal Symptoms
Effect on can be caused by corroded or loose ground. Check
Operation grounds and both battery connections.
of Loader
Indicator When Light ERROR OFF = shorted to ground or bad fuse, faulty wir-
Light Light ON Light Off is OFF ing,
faulty open relay, no voltage from relay to controller.
1 ERROR ON = shorted to battery voltage, faulty wiring,
PRESS TO PRESS TO faulty closed relay.
Lift, tilt, and
OPERATE OPERATE
traction func-
LOADER LOADER *Normal BiCS™ operating voltage is less that the electri-
tions will not
Button is Button is not cal system voltage.
operate.
pressed. pressed. SERVICE CODE Means System Error
2 (See Your Bobcat Dealer for Service
No. of Service
Flashes Code Causes
Lift and tilt
Seat Bar is Seat Bar is Seat Bar sensor circuit shorted
functions will
down. up. 2 11-05 to battery voltage*.
not operate.
Seat Bar sensor circuit shorted
3 11-06 to ground.
3
Valve output circuit is open.
1 17-07
Lift, tilt and Valve output circuit shorted to
Control Control valve
traction func- 2 17-05 battery voltage*.
valve can cannot be
tions will not Valve output circuit shorted to
be used. used.
operate. 3 17-06 ground.
Controller not grounded or inter-
4 3 17-06 mittent ground.
Traction lock hold solenoid cir-
1 16-07 cuit is open.
Traction lock hold solenoid cir-
Loader can- 2 16-05 cuit shorted to battery voltage*.
Loader can Loader can-
not be Traction lock hold solenoid cir-
be moved not be moved
moved for- 3 16-06 cuit shorted to ground.
forward & forward and
ward and traction lock pull solenoid circuit
backward backward
backward. is shorted to battery voltage* -
5 15-02 ERROR ON (Should be OFF).
Traction low pull solenoid circuit
6 15-03 ERROR OFF (Should be ON).
2 3 4
Continuous 03-09 System voltage low.
SEAT BAR LIFT & TILT VALVE TRACTION
Flashing 03-10 System voltage high.
A220 Bobcat Loader
60-110-3 Service Manual
A220 Bobcat Loader
60-110-4 Service Manual
SEAT BAR SENSOR
Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting BICS™ system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION#
Indicator light does not come ON when seat bar is lowered. 1,2,3,4,5
SOLUTION SUGGESTIONS
1. Check sensor wire connection.
2. Use the BICS™ sensor tester MEL 1428 with seat bar adapter MEL 1567 to check sensor
controller.
3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.
5. Check magnet collar magnets for contamination such as metal particles.
A220 Bobcat Loader
60-120-1 Service Manual
SEAT BAR SEBSOR (CONT’D) Figure 60-120-3
Test
Figure 60-120-1
1
P-4698
The toggle switch (Item 2) [Figure 60-120-3] can be in
N-18463 either the Absent or Present position.
If there is no power light (Item 1) [[Figure 60-120-3] on
Use Sensor Tester (MEL1428) and seat bar sensor tester the sensor tester, check the tester or wiring harness.
adapter (MEL1567) for the following procedure:
Figure 60-120-4
Connect the seat bar adapter sensor leads (MEL1567) to
the sensor tester.
Disconnect the seat bar sensor connector (Item 1)
[Figure 60-120-1].
1
Figure 60-120-2
1
P-4699
N-19557 Lower the seat bar. The Sensor Test light (Item 1)
[Figure 60-120-4] should illuminate.
Raise the seat bar. The Sensor Test light (Item 1) [Figure
N-19558 60-120-4] should go off.
If the above test fails, there is a problem with the seat bar
Connect the Sensor Tester (Item 1) [Figure 60-120-2] sensor.
online, to the seat bar sensor connectors. See inset
[Figure 60-120-2]. Disconnect the Sensor Tester.
Turn the key to the ON position. DO NOT START THE Replace the Seat Bar Sensor. (See SEAT BAR SENSOR
ENGINE. on Page 60-120-1.)
If the above test passes, run the seat bar sensor BICS™
circuit test. (See SEAT BAR SENSOR on Page 60-120-
1.)
A220 Bobcat Loader
60-120-2 Service Manual
SEAT BAR SENSOR (CONT’D) Figure 60-120-7
Removal And Installation
2
Figure 60-120-5 1
3
N-19383
P-26615
IMPORTANT
Remove the seat bar (Item 1) [Figure 60-120-5] from the
loader. (See SEAT BAR on Page 50-10-1.) Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
Figure 60-120-6 I-2088-1095
Remove the keyed plastic bushing (Item 1) [Figure 60-
120-7], magnetic bushing assembly (Item 2) [Figure 60-
120-7] and sensor bracket (Item 3) [Figure 60-120-7].
3 Installation: Be sure the tabs on the pivot bushing are
positioned in the slotted hole (Item 1) [Figure 60-120-7]
of the seat bar
1
Inspect all parts for damage and wear and replace if
necessary.
Reverse the removal procedure to install the seat bar
sensor.
2
N-19219
Remove the mounting bolt (Item 1) [Figure 60-120-6]
from the seat bar mount (Item 2) [Figure 60-120-6].
Installation: Tighten the mounting bolt to 50-70 in.-lbs.
(5,6-7,9 Nm) torque.
Remove the sensor mounting bolt (Item 3) [Figure 60-
120-6] and nut.
A220 Bobcat Loader
60-120-3 Service Manual
SEAT BAR SENSOR (CONT’D) When the power light is illuminated, move the toggle
switch (Item 2) [Figure 60-120-9] on the sensor tester to
BICS™ Circuit Test the Present position.
Figure 60-120-8 NOTE: The sensor test light (Item 3) [Figure 60-120-9]
is only activated by the seat bar. It will be off
with the seat bar up or on with the seat bar
down.
Figure 60-120-10
N-18463
1
Use Sensor Testers (MEL1428) and seat bar sensor
tester adapter (MEL1567) for the following procedure:
N-18409
Connect the seat bar sensor tester adapter MEL1567 to
the sensor tester.
The BICS™ seat bar indicator light (Item 1) [Figure 60-
Disconnect the seat bar sensor connector (Item 1) 120-10] should illuminate.
[Figure 60-120-8].
Figure 60-120-11
Figure 60-120-9
1
2
P-4699
P-4703
Move the toggle switch (Item 1) [Figure 60-120-11] on
Connect Sensor Tester (Item 1) [Figure 60-120-9] online the sensor tester to the Absent position.
to the seat bar sensor connectors.
The Seat Bar light (Item 1) [Figure 60-120-10] should go
Turn the key to the ON position. DO NOT START THE off.
ENGINE.
If the above test fails, there is a problem with the Bobcat
If there is no power light on the sensor tester, check the controller or the wiring harness.
tester or wiring harness.
A220 Bobcat Loader
60-120-4 Service Manual
TRACTION LOCK
Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting BICS™ system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION #
Traction lock stays engaged. 1,2,3,4,5,6,7
Intermittent activation of traction lock. 8,9,10
SOLUTION SUGGESTIONS
1. Make sure brake pedal is not engaged.
2. Maneuver loader to allow brake discs to move and remove pressure on the brake wedge so it can retract.
3. If all lights indicate the brake should be released, but it doesn’t check the brake 25 amp. fuse.
4. When checking fuse, also check other fuses. Check the fuse block for correct orientation and location
of fuse. (See ELECTRICAL SYSTEM INFORMATION on Page 60-10-1.)
5. To test the solenoid, the pull coil should be.4 to .5 ohms and the hold coil 10.5 to 11.0 ohms.
6. Check brake solenoid and cover mounting hardware for the correct torque.
7. Remove brake cover and check wedges for binding in the wedge guides.
8. Check wire connections for loose connector body.
9. Check for loose or bent pins in connectors.
10. Check for loose spade connectors in fuse holder.
A220 Bobcat Loader
60-130-1 Service Manual
TRACTION LOCK (CONT’D) Figure 60-130-2
Removal And Installation
WARNING P-26688
Never work on a machine with the lift arms up unless Mark the four hydraulic hoses for proper installation.
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm Remove the four hydraulic hoses (Item 1) [Figure 60-
support device can allow the lift arms or attachment 130-2] from the steering valve.
to fall and cause injury or death.
W-2059-0598 Cap and plug the hoses and the fittings.
Figure 60-130-1 Figure 60-130-3
2 1
P-26687 P-26689
Raise the lift arms and install an approved lift arm support Remove the two mount bolts and nuts (Item 1) [Figure
device. (See Engaging The Lift Arm Support Device on 60-130-3] from the steering block.
Page 10-20-1.)
Move the steering block to the left side of the loader to
Raise the loader operator cab. (See OPERATOR CAB on allow clearance for the solenoid removal.
Page 10-30-1.)
At the steering block (Item 1) [Figure 60-130-1],
disconnect the brake solenoid wiring connector (Item 2)
[Figure 60-130-1].
A220 Bobcat Loader
60-130-2 Service Manual
TRACTION LOCK (CONT’D) Figure 60-130-6
Removal And Installation (Cont'd)
Figure 60-130-4
2
2
1
P-26692
Remove the traction lock solenoid (Item 1) and the spring
P-26690 (Item 2) [Figure 60-130-6].
Figure 60-130-7
Remove the two mount bolts (Item 1) [Figure 60-130-4]
from the steering block mount bracket.
Remove the mount bracket (Item 2) [Figure 60-130-4]
from the loader.
1
Figure 60-130-5
P-26693A
1
NOTE: Mark the front side of the solenoid mount
bracket (Item 1) [Figure 60-130-7], for proper
installation.
P-26691 Remove the two mount bolts (Item 2) [Figure 60-130-7]
from the traction lock solenoid mount block.
Remove the two solenoid mount bolts (Item 1) [Figure Installation: Tighten the mounting bolts to 25-28 ft.-lbs.
60-130-5]. (34-38 Nm) torque.
Remove the mount block from the loader.
A220 Bobcat Loader
60-130-3 Service Manual
TRACTION LOCK (CONT’D) Figure 60-130-10
Removal And Installation (Cont'd)
4
Figure 60-130-8
3
2
1
1
N-20211
P-26694
IMPORTANT
Remove the wedge assembly (Item 1) [Figure 60-130-8]
from the brake guides. Failure to use LOCTITE may allow the traction lock
assembly to loosen up which can cause damage to
Figure 60-130-9 the traction lock system.
I-2090-1095
Remove the shaft mounting bolt (Item 1), spring (Item 2)
1 and washer (Item 3) from the assembly shaft (Item 4.
Remove the wedge (Item 5) [Figure 60-130-10] and
inspect all parts for damage or wear. Replace if
3
necessary.
Installation: Thoroughly clean and dry the shaft
2 mounting bolt (Item 1), the shaft (Item 4) and wedge
(Item 5) [Figure 60-130-10]. Use LOCTITE 242 when
assembling these parts to the traction lock assembly.
N-20148A
Remove and inspect the collar (Item 1) snap ring (Item 2)
[Figure 60-130-9] for wear or damage. Replace if
necessary.
Installation: Install the snap ring (Item 2) on the traction
lock shaft (Item 3). Install the collar (Item 1) [Figure 60-
130-9].
A220 Bobcat Loader
60-130-4 Service Manual
TRACTION LOCK (CONT’D) The Traction Lock Control System will lock the traction
drive system when the engine stops. The Traction Lock
Description Of The Control System Control System is incorporated into the BICS™ System.
Figure 60-130-11 Inspecting The Control System
Fasten the seat belt, disengage the parking brake pedal,
press the PRESS TO OPERATE LOADER Button and
raise the Seat Bar fully. Move the steering levers slowly
forward and backward. The TRACTION lock should be
engaged. Lower the Seat Bar. Press the PRESS TO
OPERATE LOADER Button.
Engage the parking brake pedal and move the steering
levers slowly forward and backward. The TRACTION
lock should be engaged.
NOTE: * The TRACTION light on the left instrument
panel [Figure 60-130-11] will remain OFF until
the engine is started, the PRESS TO
OPERATE LOADER Button is pressed and the
parking brake is disengaged.
Check the wire connections at the engine speed sensor
(Item 1) [Figure 60-130-12].
NOTE: When the Traction Lock Override Button is
activated, the Traction Lock Override Control
System will NOT engage the Traction Lock if
the engine stops.
1 2 3 4
B-15551
Figure 60-130-12
P9440
A220 Bobcat Loader
60-130-5 Service Manual
A220 Bobcat Loader
60-130-6 Service Manual
WHEEL POSITION SENSORS Figure 60-140-3
Operation
Figure 60-140-1 1
3
2
P-24825
B-15552
1
Figure 60-140-4
P-24924
Remove the two mount bolts (Item 1) [Figure 60-140-1]
and remove the wheel position sensor/steering cylinder
cover from the loader.
Figure 60-140-2 3
1 2
COVER REMOVED
B-15551M
B-15551N
1 The Icon light in the right instrument panel (Item 1)
[Figure 60-140-3] will be ON, an alarm (Item 1) [Figure
60-140-4] will sound with three (3) beeps, and an
ERROR CODE will appear in the hourmeter display (Item
2) [Figure 60-140-4] (left instrument panel).
P-24925
NOTE: All Wheel Steer light (Item 3) [Figure 60-140-3]
will be ON, but the loader will ONLY OPERATE
There is a sensor on each wheel, located inside each IN SKID STEER MODE until the sensor
axle tube (Item 1) [Figure 60-140-2], to monitor wheel problem is corrected.
position. The sensors are associated with the selected
steering mode (Skid Steer, All Wheel Steer). If there is an Stop the engine and restart. Select Skid Steer Mode
electrical interruption to the wheel position sensor(s) or (Item 2) [Figure 60-140-3]. Press the PRESS TO
other system problem, the affected wheel(s) will stay in OPERATE button (Item 3) [Figure 60-140-4]. Move the
the same position it was in when the problem occurred. left joystick to the left or right and all wheels except the
one(s) affected will align straight ahead and you can
NOTE: If the wheels are in a turned position when the operate in Skid Steer Mode for a 30-second period to
problem occurs, all wheels will STOP. move the loader to a service area. Repeat, if necessary,
to operate for another 30-second period.
Perform the Wheel Alignment procedure, See “Wheel
Alignment (Field Adjustment)” on page 60-140- 6. before
operating the loader again.
A220 Bobcat Loader
60-140-1 Service Manual
WHEEL POSITION SENSORS (CONT’D) been aligned and you can now operate the loader in
Skid Steer Mode only.
Wheel Alignment (Failed Sensor)
• If the four BICS™ lights are NOT ON, then there will
Figure 60-140-5 be another alarm sound and an Alignment Code in the
hourmeter display. Continue aligning the wheels until
all four wheels are corrected.
You can continue to use the loader in Skid Steer Mode
only, but each time the engine is stopped, the wheels
may need to be aligned again to resume operation. See
your Bobcat dealer to get the sensor corrected as soon
as possible. Do not continue to repeat the alignment
1 procedure and operate with an ERROR CODE.
3
2
B-15551N
Wheel alignment is necessary to allow the machine to be
operated in skid Steer Mode only to load onto a transport
vehicle for service or to finish the work shift.
Aligning the wheels:
• Sit in the operator's seat with the seat bar down. Start
the engine and press the PRESS TO OPERATE
LOADER and TRACTION LOCK OVERRIDE buttons
(Items 1 & 2) [Figure 60-140-5] at the same time.
You will hear the alarm sound once and one or more of
the following Alignment Codes will appear in the
hourmeter display (Item 3) [Figure 60-140-5]. Use the
code to locate the wheel that is out of alignment.
Alignment Codes:
FL (Front Left Wheel)
FR (Front Right Wheel)
rL (Rear Left Wheel)
rr (Rear Right Wheel)
• When the Alignment Code appears, move the left
joystick to the left or right to align the disabled wheel.
• When the wheel is aligned straight ahead, press the
PRESS TO OPERATE LOADER button (Item 1) [A].
The hourmeter display (Item 3) [Figure 60-140-5] will
now show the corresponding Alignment Code with the
letter "A" behind it: FL-A, Fr-A, rL-A, rr-A
This indicates that the wheel has now been manually
"Aligned".
• If the four BICS™ lights are ON, the wheels have
A220 Bobcat Loader
60-140-2 Service Manual
WHEEL POSITION SENSORS (CONT'D) Figure 60-140-8
Testing
Figure 60-140-6
P-24925
Disconnect the wheel position sensor wire connector
P-28303 (Item 1) [Figure 60-140-8] from the loader harness.
The tools listed will be needed to do the following Figure 60-140-9
procedure:
MEL1603-Wheel Angle Sensor Test Harness [Figure 60-
140-6]
MEL1563-Remote Start Tool 2
Multimeter 1
Figure 60-140-7
P-28304
Connect one end of the test harness to the loader
harness (Item 1) [Figure 60-140-9].
Connect the other end of the test harness to the wheel
1
position sensor wiring harness (Item 2) [Figure 60-140-
9].
P-24924
Turn the remote start key to ON position without starting
Raise the lift arms and install an approved lift arm support the loader.
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Connect the Remote Start Tool to the loader. (See
REMOTE START on Page 10-60-1.)
Remove the two mount bolts (Item 1) [Figure 60-140-7]
and remove the wheel position sensor/steering cylinder
cover from the loader.
A220 Bobcat Loader
60-140-3 Service Manual
WHEEL POSITION SENSORS (CONT'D) Figure 60-140-12
Testing (Cont'd)
Figure 60-140-10
P-28238
Disconnect the wheel sensor wire connector (Item 1)
P-28305 [Figure 60-140-12] from the loader wiring harness.
Figure 60-140-13
With a multimeter,) do a voltage check on pins 2 (Item 1)
and 3 (Item 2) [Figure 60-140-10] of the test harness.
The voltage should be 5 volts.
1
See DIAGNOSTICS SERVICE CODES on Page 60-90-1
for the diagnostics codes that apply to the four wheel
position sensors.
Sensor Removal And Installation
Figure 60-140-11
P-24926
With a needle nose plier, remove the wedge (Item 1)
1 [Figure 60-140-13] from the wheel sensor wire
connector.
P-28239
Remove the loader hub. (See HUB on Page 40-50-1.)
Remove the two mount bolts (Item 1) [Figure 60-140-11]
and remove the wheel position sensor/steering cylinder
cover form the loader.
A220 Bobcat Loader
60-140-4 Service Manual
WHEEL POSITION SENSORS (CONT’D) Figure 60-140-16
Sensor Removal And Installation (Cont'd)
Figure 60-140-14
P-24938
Remove the two mounting bolts (Item 1) [Figure 60-140-
P-24927 16] from the wheel sensor.
Installation: Tighten mounting bolts to 25-30 in.-lbs.
With a pointed screw driver lightly press in on the tabs (2,85-3,39 Nm) torque.
and remove the individual wires from the connector
[Figure 60-140-14]. Figure 60-140-17
Installation:
NUMBER ON WIRE COLOR 1
CONNECTOR
1 Red
2 Black
3 Blue
Figure 60-140-15
P-24929
Lift the wheel sensor up and lightly pull on the sensor
while pushing the wires (Item 1) [Figure 60-140-17] thru
1 the face of the casting.
Remove the wheel position sensor from the loader.
P-24928
Remove the wire retainer (Item 1) [Figure 60-140-15]
from the wires.
A220 Bobcat Loader
60-140-5 Service Manual
WHEEL POSITION SENSORS (CONT’D) Figure 60-140-19
Wheel Alignment (Field Adjustment)
Figure 60-140-18
P-28612
Press the Diagnose/Calibrate button (Item 1) [Figure 60-
P-28612 140-19].
Figure 60-140-20
The tools listed will be needed to do the following
procedure:
MEL1563 - Remote Start Tool
MEL1565 - Service Tool Harness Control
MEL1566 - Service Tool Harness Communicator
(Computer Interface with latest software)
Straight Edge 6 ft. long
NOTE: This procedure must be performed with two
people.
Connect the Remote Start Tool to the loader. (See
REMOTE START on Page 10-60-1.)
P-28608
Connect the Service PC to the Remote Start Tool. (See
SERVICE PC (LAPTOP COMPUTER) on Page 60-150-
1.) The Diagnostics Screen [Figure 60-140-20] will be
displayed.
Enter the Bobcat Service Analyzer screen [Figure 60-
140-18].
A220 Bobcat Loader
60-140-6 Service Manual
WHEEL POSITION SENSORS (CONT’D) Figure 60-140-23
Wheel Alignment (Field Adjustment) (Cont’d)
Figure 60-140-21
1
P-24825
The AWS switch and the position of the left joystick
P-28608 determine the side of the loader and the wheel that is
to be aligned.
With one person in the operator cab, the second person With the AWS switch (Item 1) [Figure 60-140-23] in the
start the loader, using the Remote Start Tool. AWS Mode, the left front and rear wheels can be aligned.
NOTE: If at any time during the procedure, the power Figure 60-140-24
to the loader is turned OFF before the wheels
are aligned, the complete procedure must be
repeated to insure correct alignment of the
wheels.
Click the Enter Align Mode button (Item 1) [Figure 60-
140-21] on the Service Analyzer Screen.
Figure 60-140-22
P-26474
Move the left joystick [Figure 60-140-24] forward and
backward to align the left rear wheel.
P-28609
The bottom of the Service Analyzer Screen (Item 1)
[Figure 60-140-22] will display AWS Controller Ready
For Programing.
A220 Bobcat Loader
60-140-7 Service Manual
WHEEL POSITION SENSORS (CONT'D) Figure 60-140-27
Wheel Alignment (Field Adjustment) (Cont'd)
Figure 60-140-25
P-26474
Move the left joystick [Figure 60-140-27] forward and
P-26474 backward to align the right rear wheel.
Figure 60-140-28
Move the left joystick [Figure 60-140-25] from side to
side to align the left front wheel.
Figure 60-140-26
1 P-26474
Move the left joystick [Figure 60-140-28] from side to
P-24825 side to align the right front wheel.
Press the AWS switch (Item 1) [Figure 60-140-26] into
the Skid Mode, the right front and rear wheels can be
aligned.
A220 Bobcat Loader
60-140-8 Service Manual
WHEEL POSITION SENSORS (CONT'D) Figure 60-140-30
Wheel Alignment (Field Adjustment) (Cont'd)
Figure 60-140-29
P-28586
Place a straight edge along both tires as shown in
P-28584 [Figure 60-140-30].
Use the left joystick to move the position of the wheel
Place a straight edge along both tires as shown in (front or rear) until aligned.
[Figure 60-140-29].
NOTE: Allow the joystick to go to neutral before
Use the AWS switch to select the left or right side. pushing the Set Alignment button.
Use the left joystick to move the position of the wheel Figure 60-140-31
(front or rear) to be aligned.
Move the position of the tires.
Alternate between the front and the rear tires, on the
same side, until they are aligned with the straight edge
[Figure 60-140-29].
If one or both wheels need to be aligned on the opposite
side, move the AWS switch.
P-28610
Have the person with the Service Analyzer (Lap Top
Computer) click the Set Alignment button (Item 1)
[Figure 60-140-31] on the Service Analyzer Screen.
NOTE: When the Set Alignment button is pushed, all
four wheel positions are recorded at the same
time. All four wheels must be checked to be
straight before the Set Alignment button is
pushed to ensure proper alignment.
A220 Bobcat Loader
60-140-9 Service Manual
WHEEL POSITION SENSORS (CONT'D) The tools listed will be needed to do the following
procedure:
Wheel Alignment (Field Adjustment) (Cont'd)
MEL1563 - Remote Start Tool
Figure 60-140-32 MEL1565 - Service Tool Harness Control
MEL1566 - Service Tool Harness Communicator
(Computer Interface with latest software)
Straight Edge 6ft. Long
Place the loader on jackstands. (See Procedure on Page
10-10-1.)
Remove the four wheel/tire assemblies from the loader.
(See Contents Page 10-01.)
Remove the four steering cylinder pins at the hub. (See
1 HUB on Page 40-50-1.)
Connect the Remote Start Tool to the loader. (See
P-28611 REMOTE START on Page 10-60-1.)
Connect the Service PC to the Remote Start Tool. (See
The Screen will display Wheel Alignment Successful SERVICE PC (LAPTOP COMPUTER) on Page 60-150-
(Item 1) [Figure 60-140-32]. 1.)
The procedure is completed for both sides of the loader. Turn the Remote Start Tool key to the ON position without
starting the loader.
Shut loader off.
NOTE: If at any time during the procedure, the power
Remove the Service Analyzer and Remote Start Tool. to the loader is turned OFF before the wheels
are aligned, the complete procedure must be
Wheel Alignment (Calibration) repeated to insure correct alignment of the
wheels.
Figure 60-140-33
Enter the Bobcat Service Analyzer screen [Figure 60-
140-33] on the Service PC.
Figure 60-140-34
P-28612
NOTE: A calibration procedure must be followed
when replacing a wheel position sensor, or
P-28612
AWS controller. Failure to calibrate after
component replacement may result in poor
performance. Press the Diagnose/Calibrate button (Item 1) [Figure 60-
140-34].
A220 Bobcat Loader
60-140-10 Service Manual
WHEEL POSITION SENSORS (CONT'D) Figure 60-140-37
Wheel Alignment (Calibration) (Cont'd)
Figure 60-140-35
P-28609
The bottom of the Service Analyzer Screen (Item 1)
P-28608 [Figure 60-140-37] will display AWS Controller Ready
For Programing.
The Diagnostics Screen [Figure 60-140-35] will be Figure 60-140-38
displayed.
Figure 60-140-36
P-28588
P-28608 NOTE: When the Set Alignment button is pushed, all
four wheel positions are recorded at the same
time. All four wheels must be checked to be
Click the Enter Align Mode button (Item 1) [Figure 60- straight before the Set Alignment button is
140-36] on the Service Analyzer Screen. pushed to assure proper alignment.
Place a straight edge along both hubs as shown in
[Figure 60-140-38].
Use the straight edge as a reference to ensure that the
two wheel hubs are "In Line" with each other.
NOTE: The straight edge must contact the whole
surface of each hub.
A220 Bobcat Loader
60-140-11 Service Manual
WHEEL POSITION SENSORS (CONT'D) Figure 60-140-41
Wheel Alignment (Calibration) (Cont'd)
Figure 60-140-39
P-28611
The Screen will display Wheel Alignment Successful
P-28589 [Figure 60-140-41].
The procedure is competed.
Move to the other side of the loader and place a straight
edge along both hubs, and place them in alignment Install the steering cylinder pins in the hubs of the loader.
[Figure 60-140-39].
NOTE: When the steering cylinder pins are
Figure 60-140-40 reinstalled in the hub, the wheels may be out
of alignment. This will be corrected as soon
as the loader is started, the Press To Operate
button is pushed, and the Left Joystick is
moved.
P-28610
Click the Set Alignment button (Item 1) [Figure 60-140-
40] on the Service Analyzer Screen.
A220 Bobcat Loader
60-140-12 Service Manual
WHEEL POSITION SENSORS (CONT'D)
Wheel Alignment (Calibration) (Cont'd)
Figure 60-140-42
P-26477
Remove the Service Analyzer and Remote Start Tool.
With an operator in the cab, seat bar down, start the
loader and press the Press To Operate button (Item 1)
[Figure 60-140-42].
Move the left joystick and the four wheels will move into
alignment.
Shut loader off.
Remove the loader from jackstands.
A220 Bobcat Loader
60-140-13 Service Manual
A220 Bobcat Loader
60-140-14 Service Manual
SERVICE PC (LAPTOP COMPUTER)
Connecting The Service PC To Remote Start Tool
Figure 60-150-1
1 2
P16119
Tools that will be needed to complete the following steps
are:
MEL1563 - Remote Start Tool
MEL1565 - Service Tool Harness Control
MEL1566 -Service Tool Harness Communicator
(Computer Interface)
NOTE: Make all connections with the key in the OFF
position.
The Service PC (Item 1) with the remote start tool (Item
2) [Figure 60-150-1]. When connected to the loader, the
Service PC is used to monitor, conduct diagnostic and
load software.
Connect the Service Tool Harness Communicator
(MEL1566) (Item 3) [Figure 60-150-1] to the designated
serial port on the Service PC.
NOTE: The recommended serial cable length should
not exceed 15 feet. A serial cable longer than
15 feet will create a degraded signal causing
communication errors.
Connect the other end to the connector on the remote
start tool.
Connect the remote start tool to the loader. (See
REMOTE START on Page 10-60-1.)
A220 Bobcat Loader
60-150-1 Service Manual
A220 Bobcat Loader
60-150-2 Service Manual
LIFT AND TILT ACTUATOR CALIBRATION Figure 60-160-2
Procedure
Figure 60-160-1
P-26475
Figure 60-160-3
P-28063
NOTE: This calibration procedure must be followed
when replacing the lift or tilt actuator or AWS
controller. Failure to calibrate after
component replacement may result in poor
performance or reduced life of actuator(s).
With an operator in the seat and the seat bar down.
Move the right joystick to the full forward position and 1
toward the side screen [Figure 60-160-1] and hold in
position.
P-26480
Turn the key (Item 1) [Figure 60-160-2] to the RUN
position or press the RUN/ENTER button (Item 1)
[Figure 60-160-3] for power, without starting the loader.
A220 Bobcat Loader
60-160-1 Service Manual
LIFT AND TILT ACTUATOR CALIBRATION (CONT’D)
Procedure (Cont’d)
Figure 60-160-4
1
P-26477A
At the left panel, press the PRESS TO OPERATE Button
(Item 1) [Figure 60-160-4].
Release the joystick.
An audible beep will sound and an error code (Item 2)
[Figure 60-160-4] (38-06 & 38-08) will be displayed if the
operator presses the PRESS FOR CODES, (LIGHTS)
switch.
The AWS controller will cycle the actuators.
The calibration is complete.
A220 Bobcat Loader
60-160-2 Service Manual
A220 Bobcat Loader
60-170-1 Service Manual
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
Controls Identification Chart
RIGHT HAND
1. Front Aux.
2. Front Aux.
3. Auxiliary Detent
8. (Right Ski (Up)
9. Right Ski (Down)
17 18 10. Right Blink
11. Left Blinker
2 1 16. Float (Yellow in Color)
17. Future Function
8 18. Future Function
10
11 3
9
16
P-24802
P-28316
LEFT HAND
4. Rear Aux. (Side Shift)
5. Rear Aux. (Side Shift)
6. Left Ski (Up)
7. Left Ski (Down)
12. Two-Speed (High)
13. Two-Speed (Low)
14. Horn
19 20 15. Inching Control (Grey in Color)
1 5 19. Future Function
20. Future Function
12
13 7
14
15
P-24820
P-28317
A220 Bobcat Loader
60-170-2 Service Manual
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
(CONT’D)
Controls Identification Chart (Cont’d)
xxxxxxxx Attachment
xSwitch Solenoid Number Attachment Harness Harness
Number Activated Terminal Activated Connector
RH HFH Fourteen Pin
Connector Viewed
1 1 1 1, 8 from front
2 2 2 2 (pin side of
connector)
*3 1 1 1, 8 of loader.
4 2 2, 3 6, 7 D
5 1 1, 3 5, 7 C
6 1 1, 3 5, 7 E
7 1 1, 3 5, 7 F
8 1 1, 3 5, 7 G
9 1 1, 3 5, 7 H
10,11,12, - -- --
13,14,15,
16,17,18
NOTE: All diagnostics must be done at the fourteen pin connector (Item 1).
If the ACD light flashes, check for diagnostic service codes. See the Electrical System Service Manual for
the proper procedure.
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
* Terminal K is activated with Key switch ON.
* If harness terminals K & L are jumped together, M is activated in addition to pins for switches 4-9.
* If harness terminals K & P are jumped together, the pin A only will be activated with switches 4&5.
A220 Bobcat Loader
60-170-3 Service Manual
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
(CONT’D)
Controls Identification Chart (Cont’d)
Figure 1
SOLENOID Hydraulic Coupler Wiring
NUMBER Number
1 Front Female (Rod) 4330
2 Front Male (Base) 4340
1 4 A
2 2 3 (TOP) Diverter 4450
3 2 Bleed - Rear 4480
0 4 (BOTTOM)
Male & Female
5 Rear Female (Rod) 4430
6 Rear Male (Base) 4440
7 (BOTTOM) Diverter 4450
9 8 8 (MIDDLE) High Flow 4460
Bleed - Rear 4480
9 (TOP)
Male & Female
A
1 7
2 2
6 2
5 0
H
MC-2314A
Note: Pushing the Hydraulic Pressure release button ON activates solenoids number 1, 4 and 9. The high flow
button on the left side instrument panel must be pushed ON to activate solenoid number 8.
A220 Bobcat Loader
60-170-4 Service Manual
ENGINE SERVICE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
SAFETY &
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1 MAINTENANCE
Blower Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-60-5
Drive Tension Pulley Removal And Installation . . . . . . . . . . . . . 70-60-1
Gearbox Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-12
Gearbox/Blower Housing Removal And Installation . . . . . . . . . 70-60-2
Gearbox, Checking Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-17
Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-7
Gearbox Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-6 DRIVE
SYSTEM
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-9
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
ENGINE COMPONENTS AND TESTS. . . . . . . . . . . . . . . . . . . . . . 70-70-1
Engine Compression, Checking. . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Injector Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-13 ELECTRICAL
Fuel Injector, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-11 SYSTEM &
Fuel Injector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-11 ANALYSIS
Fuel Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-8
Fuel Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-5
Fuel Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-7 ENGINE
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . 70-70-10 SERVICE
Fuel Shut-Off Solenoid Checking. . . . . . . . . . . . . . . . . . . . . . . . 70-70-4
Fuel Shut-Off Solenoid Removal And Installation . . . . . . . . . . . 70-70-5
Glow Plug, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-3
Thermostat, Oil Pressure Control Valves & Heater Connections70-70-29 SPECIFICATIONS
Timing Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-15
Timing Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-17
Timing Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-16
Timing Belt, Replacement In The Loader . . . . . . . . . . . . . . . . 70-70-21
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-26
Valve Timing, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-27
ENGINE SPEED CONTROL (EARLY MODELS) . . . . . . . . . . . . . . 70-20-1
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1
Speed Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-4
Speed Control Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-4
ENGINE SPEED CONTROL (LATER MODELS) . . . . . . . . . . . . . . 70-21-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-3
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-1
Speed Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-4
Continued on Next Page
A220 Bobcat Loader
70-01 Service Manual
ENGINE SERVICE (CONT’D)
FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Flywheel Housing Removal And Installation . . . . . . . . . . . 70-90-2
Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . 70-90-1
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . 70-90-1
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
RECONDITIONING THE ENGINE . . . . . . . . . . . . . . . . . . . . 70-100-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-6
Camshaft Bearing, Checking . . . . . . . . . . . . . . . . . . . . . 70-100-22
Camshaft Bearing, Removal And Installation. . . . . . . . . 70-100-23
Connecting Rod, Checking . . . . . . . . . . . . . . . . . . . . . . 70-100-33
Control Rod Guide Bushing Installation . . . . . . . . . . . . . 70-100-26
Control Rod Guide Bushing Removal . . . . . . . . . . . . . . 70-100-24
Crankshaft, Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-31
Crankshaft Gear Mounting Bolt Torque Procedure . . . . 70-100-61
Cylinder, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-22
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . 70-100-42
Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . 70-100-40
Deutz Engine Tools Identification Chart . . . . . . . . . . . . . . 70-100-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-2
Front Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-49
Front Cover Disassembly. . . . . . . . . . . . . . . . . . . . . . . . 70-100-44
Governor Buffer Spring Adjustment . . . . . . . . . . . . . . . . 70-100-62
Piston, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-35
Piston Installation On The Connecting Rod . . . . . . . . . . 70-100-38
Piston Pin, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-36
Piston Rings Installation. . . . . . . . . . . . . . . . . . . . . . . . . 70-100-37
Rear Cover Seal Removal And Installation . . . . . . . . . . 70-100-30
Rocker Arm And Bracket, Checking . . . . . . . . . . . . . . . 70-100-43
Turbo Charger Removal and Installation . . . . . . . . . . . . 70-100-59
Valves, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-40
Valve Seats, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-41
Valve Spring, Checking . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-42
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
A220 Bobcat Loader
70-02 Service Manual
TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common.
Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start. 2, 5, 3, 7, 8, 9, 11, 12,13, 14, 15, 16, 17, 19, 27, 28, 29
Difficult to start. 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25 ,27, 28, 29
No power to engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29,
Engine is mis-firing. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29,
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue/white exhaust. 4, 10, 15, 16, 17, 21, 23 ,27, 29, 30, 47, 46
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 39, 48
Engine knocking. 13, 15, 16, 19 ,22, 24, 25, 27, 29, 31, 40, 41, 49
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 49
Vibration. 2, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure warning. 4, 33, 36
Overheating. 10, 12, 13, 15, 16, 20, 21, 32, 40, 44, 47
Too much crankcase pressure. 22, 27, 29, 46
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 49
Start and stop. 9, 10, 11
A220 Bobcat Loader
70-10-1 Service Manual
TROUBLESHOOTING (CONT’D)
Chart (Cont’d)
KEY TO CORRECT THE CAUSE
1. Battery capacity low. 26. Incorrect high pressure fuel pipes.
2. Bad electrical connection. 27. Worn cylinder bores.
3. Faulty starter motor. 28. Worn valve and seats.
4. Incorrect grade of oil. 29. Broken, worn, or sticking piston rings.
5. Low cranking oil. 30. Worn valve stems or guides.
6. Fuel tank empty. 31. Worn or damaged bearings.
7. Faulty stop control operation. 32. Not enough oil in the oil pan.
8. Plugged fuel line. 33. Switch/sensor in defective.
9. Plugged fuel filter. 34. Oil pump worn.
10. Restriction in air cleaner. 35. Pressure relief valve is stcking open.
11. Air in the fuel system. 36. Pressure relief valve is sticking closed.
12. Faulty fuel injection pump. 37. Broken relief valve spring.
13. Faulty fuel injectors. 38. Faulty suction pipe.
14. Broken injection pump drive. 39. Plugged oil filter.
15. Incorrect injection pump timing. 40. Piston seizure.
16. Incorrect valve timing. 41. Incorrect piston height.
17. Poor compression. 42. Faulty engine mounting.
18. Plugged fuel tank vent. 43. Incorrect alignment of flywheel.
19. Incorrect grade of fuel. 44. Faulty thermostat.
20. Exhaust pipe restriction. 45. Plugged oil cooler.
21. Cylinder head gasket leaking. 46. Plugged PCV System.
22. Overheating. 47. Damaged valve stem oil deflectors.
23. Cold running. 48. Plugged oil pump pipe strainer.
24. Incorrect tappet adjustment. 49. Broken valve spring.
25. Sticking valves.
A220 Bobcat Loader
70-10-2 Service Manual
ENGINE SPEED CONTROL (EARLY MODELS) Figure 70-20-3
Removal
Figure 70-20-1
1 1
P-28505
Remove the top access panel mount bolt (Item 1)
P-26144 [Figure 70-20-3].
Figure 70-20-4
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the three mounting bolts (Item 1) [Figure 70-20-
1], from the right side foot rest.
Remove the foot rest, from the loader.
Figure 70-20-2
P-28506
Remove the inside access panel/engine speed control
1 assembly from loader [Figure 70-20-4].
2
P-28504
Loosen the two lower access panel mount bolt (Item 1)
[Figure 70-20-2]
Remove the cotter pin (Item 2) [Figure 70-20-2]
A220 Bobcat Loader
70-20-1 Service Manual
ENGINE SPEED CONTROL (EARLY MODELS) Figure 70-20-7
(CONT’D)
Removal (Cont'd) 1
Figure 70-20-5
P-28509
1
Remove the foot throttle lever (Item 1) [Figure 70-20-7].
P-28507 Figure 70-20-8
Remove the throttle spring (Item 1) [Figure 70-20-5].
1
Figure 70-20-6
P-28510
1
Remove the bushing (Item 1) [Figure 70-20-8]
P-28508 Figure 70-20-9
At the back side of the engine speed control, hold the nut
and remove the throttle lever bolt and washer (Item 1)
[Figure 70-20-6].
P-28511
Remove the curved washer (Item 1) [Figure 70-20-9].
A220 Bobcat Loader
70-20-2 Service Manual
ENGINE SPEED CONTROL (EARLY MODELS) Figure 70-20-12
(CONT’D)
Removal (Cont'd)
Figure 70-20-10
1
1
P-28514
Remove the curved washer (Item 1) [Figure 70-20-12]
from the bushing.
P-28512
Installation: The curve washer (Item 1) [Figure 70-20-
12] must be installed on the bushing, curve up toward the
Installation: The curve washer (Item 1) [Figure 70-20- hand throttle lever.
10] must be installed on the spacer, curve out toward the
hand throttle lever. Figure 70-20-13
Figure 70-20-11
1 1
P-28515
P-28513
Remove the bushing (Item 1) [Figure 70-20-13].
Remove the hand throttle lever (Item 1) [Figure 70-20-
11].
A220 Bobcat Loader
70-20-3 Service Manual
ENGINE SPEED CONTROL (EARLY MODELS) Remove the speed control lever assembly. (See
(CONT’D) Removal on Page 70-20-1 [early models] or See
Removal on Page 70-20-1 [later models])
Speed Control Stop
Remove the two mounting bolts (Item 1) [Figure 70-20-
NOTE: Mark location of the speed control stop, for 15] from the speed control cable mount bracket.
proper installation.
Figure 70-20-16
Figure 70-20-14
2
1
P-26152
P-28516
Remove the two nuts (Item 1) [Figure 70-20-16] from the
Remove the two mount bolts (Item 1) [Figure 70-20-14] speed control cable clamp.
from the speed control stop.
Remove the clamp and the mount plate from the cable.
Remove the speed control stop [Figure 70-20-14].
Figure 70-20-17
Speed Control Cable
Figure 70-20-15
P-26154
P-26151 Open the tailgate.
Remove the speed control cable linkage bolt (Item 1)
Raise the lift arm and install an approved lift arm support [Figure 70-20-17].
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
A220 Bobcat Loader
70-20-4 Service Manual
ENGINE SPEED CONTROL (EARLY MODELS)
(CONT’D)
Speed Control Cable (Cont’d)
Figure 70-20-18
P-26153
Remove the two nuts (Item 1) [Figure 70-20-18] from the
speed control cable U-bolt.
Remove the U-bolt from the mount plate and the cable.
Remove the speed control cable from the loader [Figure
70-20-15].
NOTE: Remove all sta-straps and note proper cable
routing for proper installation. Install all sta-
straps on the new speed control cable to
prevent interference with moving parts.
A220 Bobcat Loader
70-20-5 Service Manual
A220 Bobcat Loader
70-20-6 Service Manual
ENGINE SPEED CONTROL (LATER MODELS) Figure 70-21-3
Removal
Figure 70-21-1
1 1
P-34546
Disconnect the foot speed control linkage (Item 1)
P-34544 [Figure 70-21-3] from the hand control pivot arm.
Remove the foot speed control assembly from the loader.
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on Figure 70-21-4
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the three mounting bolts (Item 1) [Figure 70-21-
1], from the right side foot rest.
Remove the foot rest, from the loader. 1
Figure 70-21-2
2 P-34550
Remove the bolt and nut (Item 1) [Figure 70-21-4] from
the hand speed control pivot arm.
1
P-34545
Loosen the two lower access panel mount bolts (Item 1)
[Figure 70-21-2]
Remove the upper mount bolt (Item 2) [Figure 70-21-2]
A220 Bobcat Loader
70-21-1 Service Manual
ENGINE SPEED CONTROL (LATER MODELS) Figure 70-21-7
(CONT’D)
Removal (Cont'd)
Figure 70-21-5 1
1
1
P-34548
Remove the two bolts (Item 1) [Figure 70-21-7] from the
hand speed control lever assembly.
P-34549
Figure 70-21-8
Remove the keeper and pin (Item 1) [Figure 70-21-5]
that attaches the pivot arm to the speed control cable.
1
Remove the speed control pivot arm from the loader.
Figure 70-21-6
2 4 4
6
P-34551
At the bottom side of the control panel, move the speed
control linkage toward the rear of the loader.
3 5 3
Slide the hand speed control lever (Item 1) [Figure 70-
P-34654 21-8] forward and lift, and disconnect the assembly from
the speed control cable.
The parts that go into the pivot arm (Item 1) are the bolt
(Item 2), washers (Items 3), fiber washers (Items 4),
spacer (Item 5) and nut (Item 6) [Figure 70-21-6].
A220 Bobcat Loader
70-21-2 Service Manual
ENGINE SPEED CONTROL (LATER MODELS) Figure 70-21-11
(CONT’D)
Removal (Cont'd)
Figure 70-21-9
1
1
P-34656
2
Remove the bushing/nut (Item 1) [Figure 70-21-11] from
the pedal lever.
P-34553
Figure 70-21-12
Installation: When installing the hand speed control to
the speed control cable, be sure the speed control lever
(Item 1) fits in the notch (Item 2) [Figure 70-21-9] of the
speed control cable clevis.
Disassembly 2
Figure 70-21-10 3
1
1
P-34657
Remove the fiber washer (Item 1) [Figure 70-21-12] from
the bushing/nut.
Remove the foot pedal lever (Item 2) and linkage rod
(Item 3) [Figure 70-21-12].
P-34655
Remove the spring (Item 1) [Figure 70-21-10] from the
foot speed control assembly.
A220 Bobcat Loader
70-21-3 Service Manual
ENGINE SPEED CONTROL (LATER MODELS) Speed Control Cable
(CONT’D)
Figure 70-21-15
Disassembly
Figure 70-21-13
1
1
P-34555
P-34658 Raise the lift arm and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Remove the fiber washer (Item 1) and washer (Item 2)
[Figure 70-21-13] from the pivot bolt. Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 70-21-14
Remove the speed control lever assembly. (See
Removal on Page 70-20-1 [early models] or See
Removal on Page 70-20-1 [later models])
1
At the lower right side of the control panel, remove the
two mounting bolts (Item 1) [Figure 70-21-15] from the
speed control cable mount bracket.
Figure 70-21-16
P-34659
Remove the pivot bolt (Item 1) [Figure 70-21-14] from
the speed control.
P-26154
At the right side of the engine compartment remove the
nut (Item 1) [Figure 70-21-16] from the speed control
cable.
A220 Bobcat Loader
70-21-4 Service Manual
ENGINE SPEED CONTROL (LATER MODELS)
(CONT’D)
Speed Control Cable (Cont’d)
Figure 70-21-17
P-26153
Remove the two nuts (Item 1) [Figure 70-21-17] from the
speed control cable U-bolt.
Remove the U-bolt from the mount plate and the cable.
Remove the speed control cable from the loader.
NOTE: Remove all sta-straps and note proper cable
routing for proper installation. Install all sta-
straps on the new speed control cable to
prevent interference with moving parts.
A220 Bobcat Loader
70-21-5 Service Manual
A220 Bobcat Loader
70-21-6 Service Manual
MUFFLER Figure 70-30-3
Removal And Installation
Figure 70-30-1
P7899
1
Remove the two bolts and nuts (Item 1) [Figure 70-30-3]
P7898 from the muffler mounting bracket.
Remove the muffler.
Open the rear door.
Raise the rear grill.
Remove the four bolts and nuts (Item 1) [Figure 70-30-1]
from the engine muffler mounting bracket.
Remove the bracket.
Figure 70-30-2
P7900
Remove the three bolts and nuts (Item 1) [Figure 70-30-
2] from the muffler exhaust flange.
A220 Bobcat Loader
70-30-1 Service Manual
A220 Bobcat Loader
70-30-2 Service Manual
AIR CLEANER Figure 70-40-3
Housing Removal And Installation
Figure 70-40-1
1
P-26593
Disconnect the sensor wiring harness connector (Item 1)
2 [Figure 70-40-3] from the air cleaner.
N-19671
Remove the air cleaner housing from the loader.
Loosen the hose clamp (Item 1) [Figure 70-40-1] and
disconnect the inlet hose from the air cleaner.
Loosen the hose clamp (Item 2) [Figure 70-40-1] and
disconnect the hose from the air cleaner to the turbo
charger.
Figure 70-40-2
N-19672
Remove the two mounting bolts (Item 1) [Figure 70-40-
2].
A220 Bobcat Loader
70-40-1 Service Manual
A220 Bobcat Loader
70-40-2 Service Manual
RADIATOR Figure 70-50-3
Removal And Installation
Figure 70-50-1
1 1
P7906
1 1
2 2
Lift the oil cooler from the loader frame [Figure 70-50-3].
P7904
Figure 70-50-4
Raise the rear grill.
Remove the hydraulic oil cooler. (See OIL COOLER
(SEAL TO CONNECT) (STC) on Page 30-60-1.) 1
Remove the four mounting bolts (Item 1) [Figure 70-50-
1] from the oil cooler. 1
Disconnect the tubelines (Item 2) [Figure 70-50-1] from
the bulkhead fittings.
Figure 70-50-2
P7909
Before installing the oil cooler, check the seals (Item 1)
1 [Figure 70-50-4] at both sides of the oil cooler mounting
1
frame. Replace the seals as needed.
2 2
P7907
Loosen the tubeline fittings (Item 1) and raise the
tubelines (Item 2) [Figure 70-50-2] (both sides) as
shown and tighten the fittings so they can be used as
handles when removing or installing the oil cooler.
A220 Bobcat Loader
70-50-1 Service Manual
A220 Bobcat Loader
70-50-2 Service Manual
COOLING FAN Figure 70-60-3
Drive Tension Pulley Removal And Installation
Figure 70-60-1
P5551
Remove the bolt (Item 1) [Figure 70-60-3] & [Figure 70-
P5550 60-4].
Figure 70-60-4
Remove the fan drive belt (Item 1) [Figure 70-60-1].
Remove the idler pulley bolt (Item 2) [Figure 70-60-1].
3
Figure 70-60-2
1 3
2
4
1
N-303A
Remove the thrust washer (Item 2) [Figure 70-60-4], O-
rings (Item 3) [Figure 70-60-4] and spring (Item 4)
P4956 [Figure 70-60-4].
Check all parts for damage or wear and replace them as
Remove the spacers, bolt and washers from the arm needed.
[Figure 70-60-2].
NOTE: When making any repairs, replace the bronze
Installation: Put a small amount of grease around the bushing (Item 5) [Figure 70-60-4] with a new
outside edge on the grease rings (Item 1) [Figure 70-60- style nylon bushing. Clean all parts and
2] between ring and bearing. assemble dry. Do not lubricate. (See Parts
Mircofiche for correct part numbers.)
A220 Bobcat Loader
70-60-1 Service Manual
COOLING FAN (CONT’D) Figure 70-60-6
Gearbox/Blower Housing Removal And Installation
2
Figure 70-60-5
P7966
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
1
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the mounting bolts (Item 1) [Figure 70-60-5]
from the gas cylinder mounting bracket. (See
OPERATOR CAB on Page 10-30-1.)
Installation: Tighten the mounting bolts to 80-90 in.-lbs.
(9-10 Nm) torque. N-19623
Remove the hydraulic fluid reservoir. (See HYDRAULIC
FLUID RESERVOIR on Page 20-80-1.) Disconnect the wiring harness connectors (Item 1)
[Figure 70-60-6].
Remove the harness clamp (Item 2) [Figure 70-60-6].
Move the electrical harness down for clearance at the
blower housing.
A220 Bobcat Loader
70-60-2 Service Manual
COOLING FAN (CONT’D) Figure 70-60-9
Gearbox/Blower Housing Removal And Installation
(Cont'd) 1
Figure 70-60-7
Oil Level
1 P7936
Remove the sealant from the blower housing and loader
frame (Item 1) [Figure 70-60-9].
N-19736
Remove fuel fill hose (Item 2) [Figure 70-60-9] and the
fuel vent hose.
Remove the belt shield (Item 1) [Figure 70-60-7] from
the fan drive. Figure 70-60-10
Disconnect the breather hose (Item 2) [Figure 70-60-7]
from the fan drive housing.
Installation: When checking the fan gearbox oil level,
make sure the level does not go above the top of the
shaft in the gearbox [Figure 70-60-7]. Use 90W gear
lube oil if the level is low.
Figure 70-60-8
1
P7775
Remove the four mounting bolts (Item 1) [Figure 70-60-
10] and spacer tubes (two outside housing and two
inside housing).
1
NOTE: Remove the two rear mounting bolts first.
Installation: Use sealant on each end of the inside
P7774 spacer tubes to prevent the tubes from falling out of the
housing during installation. Tighten the mounting bolts to
25-28 ft.-lbs. (34-38 Nm) torque.
Remove the fan drive belt (Item 1) [Figure 70-60-8].
A220 Bobcat Loader
70-60-3 Service Manual
COOLING FAN (CONT’D) Figure 70-60-12
Gearbox/Blower Housing Removal And Installation
(Cont'd)
Figure 70-60-11
P7776
The blower housing must be moved away from the loader
frame if the side grills need to be replaced [Figure 70-60-
P7773 12].
To replace the side grill, remove the four mounting
Slide the blower housing forward and remove the fan/fan screws (Item 1) [Figure 70-60-12] from the blower
gearbox assembly. Remove the blower housing [Figure housing.
70-60-11].
Install the new grill and replace the screws.
Installation: Use R.T.V. sealant to re-seal the blower
housing to the loader frame (Item 1) [Figure 70-60-9].
See Gearbox/Blower Housing Removal And Installation
on Page 70-60- 2.
A220 Bobcat Loader
70-60-4 Service Manual
COOLING FAN (CONT’D) Figure 70-60-15
Blower Removal And Installation
Figure 70-60-13
CD-9953
Remove the fan from the tapered shaft [Figure 70-60-
CD-9952 15].
Figure 70-60-16
Remove the lock nut and spacer [Figure 70-60-13].
Installation: Tighten the nut to 45-55 ft.-lbs. (61-75 Nm)
torque.
1
Figure 70-60-14
2 1
CD-9954
To remove the blower housing mounting plate, remove
1
the six bolts (Item 1) [Figure 70-60-16].
P3006
Use the following procedure to remove the fan from the
shaft:
Install the nut (Item 1) [Figure 70-60-14] on the tapered
shaft to protect the shaft and threads.
Install the puller on the fan as shown [Figure 70-60-14].
As the center bolt (Item 2) [Figure 70-60-14] is tightened,
periodically strike the bolt head to loosen the fan from the
shaft.
A220 Bobcat Loader
70-60-5 Service Manual
COOLING FAN (CONT’D)
Gearbox Parts Identification
* Individual Parts not available
1
18
6
1
2 3
4 4
7
5
22
4
12 9
13
14
10
11
*16
20 15 21
1. Seal 17
2. Snap Ring (Small) 12
3. Shims (1.0 inch O.D.)
4. Bearing
5. Shaft (Long)
6. Shims (2.0 inch O.D.) 3
7. Long Key
8. Shaft (Short)
9. Short Key 4
10. Long Housing
11. Nut
13
12. Gear
13. Washer
14. Screw
15. Square Shim 14
*16. Short Housing
17. Bolt
18. Snap Ring (Large) 18
19. Cap
20. Long Housing Assy.
21. Short Housing Assy.
22. Fill Plug 19 TS-1002
A220 Bobcat Loader
70-60-6 Service Manual
COOLING FAN (CONT’D) Figure 70-60-18
Gearbox Disassembly
Figure 70-60-17
Part Number
Tag
2
P2983
3
Remove the four mounting bolts and the part number tag
P-37891 [Figure 70-60-18].
NOTE: When repairing the gearbox order the
following as needed:
WARNING
1. Complete Assembly
2. Long Housing Assembly AVOID INJURY OR DEATH
3. Long Housing Wear safety goggles to prevent eye injury when
4. Short Housing Assembly (See Note Below) drilling or grinding.
5. Internal Parts W-2108-1186
NOTE: The short housing is only available as an Figure 70-60-19
assembly. See the parts identification Page
70-60-7 for reference. (Order parts from
Melroe Parts Sales.)
NOTE: Be sure to count the number and thickness of
shims during disassembly. Install the shims
in the original location during assembly.
Remove the fan and blower housing mounting plate.
(See Gearbox/Blower Housing Removal And Installation
on Page 70-60- 2.)
Long Housing
Loosen the set screws (Item 1) and remove the pulley P2999
(Item 2) [Figure 70-60-17].
Remove the long key (Item 3) [Figure 70-60-17]. Remove the oil from the gearbox.
Drill an 1/8 inch (13 mm) hole in the seal. Use a slide
hammer tool to remove the seal [Figure 70-60-19].
A220 Bobcat Loader
70-60-7 Service Manual
COOLING FAN (CONT’D) Figure 70-60-22
Gearbox Disassembly (Cont'd)
Figure 70-60-20
P2966
Remove the screw and washer from the shaft [Figure
P2964 70-60-22].
Figure 70-60-23
Remove the small snap ring [Figure 70-60-20].
Figure 70-60-21
P3004
P2963 Support the lower flange and press the shaft from the
bearing [Figure 70-60-23].
Remove the small shims [Figure 70-60-21]. NOTE: The gear and the other bearing (pulley end)
will be removed with the shaft.
A220 Bobcat Loader
70-60-8 Service Manual
COOLING FAN (CONT’D) Figure 70-60-26
Gearbox Disassembly (Cont'd)
Figure 70-60-24
P2996
Drill an 1/8 inch (3 mm) hole in the seal. Use a slide
P3298 hammer tool to remove the seal [Figure 70-60-26].
Figure 70-60-27
Support the bearing and press the shaft from the bearing
[Figure 70-60-24].
Short Housing
WARNING
AVOID INJURY OR DEATH
Wear safety goggles to prevent eye injury when
drilling or grinding.
W-2108-1186
P2970
Figure 70-60-25
Remove the large snap ring from the flange end of the
housing [Figure 70-60-27].
P2997
Remove the end cap [Figure 70-60-25].
Use care not to damage the housing.
A220 Bobcat Loader
70-60-9 Service Manual
COOLING FAN (CONT’D) Figure 70-60-30
Gearbox Disassembly (Cont'd)
Figure 70-60-28
P2973
Remove the snap ring from the cap end of the housing
P2969 [Figure 70-60-30].
Figure 70-60-31
Remove the large shims from the housing [Figure 70-60-
28].
NOTE: Use the same size and thickness of shims
during assembly.
Figure 70-60-29
P2998
1 Press the shaft from the housing [Figure 70-60-31].
NOTE: Both bearings may come out of the housing
with the shaft. If one bearing remains in the
P2978 housing, use a non metal object to tap the
bearing from the housing.
Remove the screw and washer (Item 1) [Figure 70-60-
29] from the shaft.
A220 Bobcat Loader
70-60-10 Service Manual
COOLING FAN (CONT’D) Figure 70-60-34
Gearbox Disassembly (Cont'd)
Figure 70-60-32
P2972
Remove the key (Item 1) [Figure 70-60-34] from the
P3088 shaft.
Press the bearing from the tapered end of the shaft
[Figure 70-60-32].
Figure 70-60-33
P3001
Press the bearing, shims and gear from the shaft [Figure
70-60-33].
A220 Bobcat Loader
70-60-11 Service Manual
COOLING FAN (CONT’D) Figure 70-60-36
Gearbox Assembly
Figure 70-60-35
P2960
Install the long housing on the shaft [Figure 70-60-36].
P2961
Be sure the bearing is seated in the bore at the lower end
of the housing.
NOTE: See Note Page 70-60-7 when ordering parts
for the Fan Gearbox. Always replace seals Figure 70-60-37
during assembly. Replace the parts in the
gearbox as needed.
NOTE: Do not install the seals and cap in the housing
until after the backlash has been checked.
NOTE: Use care when pressing the bearings into the
aluminum housing. The housing can be
damaged if too much pressure is used.
NOTE: For procedures requiring the use of #242
LOCTITE adhesive, thoroughly clean and dry
affected parts before the application of #242
LOCTITE.
P2962
Long Housing
Press a bearing on the short keyed end of the long shaft Install a bearing on the long keyed end of the shaft
[Figure 70-60-35]. [Figure 70-60-37].
Support the lower bearing and press the other bearing in
the housing until the bearings seat in the housing [Figure
70-60-37].
A220 Bobcat Loader
70-60-12 Service Manual
COOLING FAN (CONT’D) Figure 70-60-40
Gearbox Assembly (Cont'd)
Figure 70-60-38
P2965
Install the gear key in the flange end of the shaft [Figure
P2963 70-60-40].
Figure 70-60-41
Install on the bearing, the same number and size shims
that were removed during disassembly [Figure 70-60-
38].
Figure 70-60-39
P2967
Align the key and gear. While supporting the bearing on
the other end, press the gear on the shaft until it seats
P2964 against the bearing [Figure 70-60-41].
Install the small snap ring in the groove above the shims
[Figure 70-60-39].
A220 Bobcat Loader
70-60-13 Service Manual
COOLING FAN (CONT’D) Figure 70-60-44
Gearbox Assembly (Cont'd)
Figure 70-60-42
P2969
Install the large shims on the bearing (flanged end)
P2966 [Figure 70-60-44].
Figure 70-60-45
Install the washer [Figure 70-60-42].
Put liquid adhesive (LOCTITE #242) on the screw
threads. Install and tighten the screw [Figure 70-60-42].
Short Housing
Figure 70-60-43
P2970
Install the large snap ring in the groove above the shims
[Figure 70-60-45].
P2968
Install a bearing in the flanged end of the housing
[Figure 70-60-43].
A220 Bobcat Loader
70-60-14 Service Manual
COOLING FAN (CONT’D) Figure 70-60-48
Gearbox Assembly (Cont'd)
Figure 70-60-46
P2976
1
Install the shaft in the housing, tapered end in the bearing
P2971 at the round flange end of the housing [Figure 70-60-48].
Figure 70-60-49
Install the short key (Item 1) [Figure 70-60-46].
Align and press the gear on the shaft (teeth toward the
tapered end of the shaft).
Figure 70-60-47
P2977
Install on the shaft, the same number and size shims that
were removed during disassembly [Figure 70-60-49].
P2975
After the gear is seated, drive the key down inside the
gear key way [Figure 70-60-47].
NOTE: This will prevent damage to the shims when
the bearing is installed later.
A220 Bobcat Loader
70-60-15 Service Manual
COOLING FAN (CONT’D) Figure 70-60-52
Gearbox Assembly (Cont'd)
Figure 70-60-50
P2978
Install the washer (Item 1) on the shaft. Put liquid
P2974 adhesive (LOCTITE #242) on the screw threads and
install the screw [Figure 70-60-52].
Install a bearing on the gear end of the shaft [Figure 70-
60-50].
Figure 70-60-51
P2973
Install the snap ring in the groove above the bearing
[Figure 70-60-51].
A220 Bobcat Loader
70-60-16 Service Manual
COOLING FAN (CONT’D) Figure 70-60-54
Gearbox, Checking Backlash
NOTE: For procedures requiring the use of #242
LOCTITE adhesive, thoroughly clean and dry
affected parts before the application of #242
LOCTITE.
Figure 70-60-53
P2981
Install the same size and number of square shims (if
present during disassembly) between the two housings
[Figure 70-60-54].
Set the long housing on the short housing with a small
amount of liquid adhesive (LOCTITE #242) between the
P2987 mounting surfaces.
NOTE: If square shims are used, put a small amount
The backlash tolerance between the gears should be of the liquid adhesive on both sides of all
0.005-0.008 inch (0,127-0,203 mm). shims.
To check the gear backlash use the following procedure: Figure 70-60-55
Put the short housing in a vise, square flange facing up
as shown [Figure 70-60-53].
Part Number
Tag
P2983
Install the four mounting bolts through the flange holes
[Figure 70-60-55].
Install the part number tag [Figure 70-60-55].
Install and tighten the nut to 25-28 ft.-lbs. (34-38 Nm)
torque.
A220 Bobcat Loader
70-60-17 Service Manual
COOLING FAN (CONT’D) Figure 70-60-58
Gearbox, Checking Backlash (Cont'd)
Figure 70-60-56
1.000”
(25,4 mm)
P-37893
1 Using a magnetic based dial indicator mounted on a
P-37894 bench vise, touch the dial stem on the bolt (Item 1)
[Figure 70-60-58].
Install the long key (Item 1) and the pulley (Item 2) Hold the locking pliers against the long housing and
[Figure 70-60-56]. rotate the pulley back and forth to read the dial gauge
[Figure 70-60-58].
Install a bolt in the set screw hole to maintain a 1.000
inch (25,4 mm) distance from the shaft center to the bolt If the backlash is GREATER than 0.008 inch (0,203 mm),
head (to be used with a dial indicator) [Figure 70-60-56]. do the following:
Figure 70-60-57 1. Remove a square shim(s) (if present) between the
two housings.
2. Remove a large shim(s) from the tapered end of the
short shaft and add a small shim(s) of the same
thickness between the bearing and the gear on the
screw end of the shaft.
If the backlash is LESS than 0.005 inch (0,127 mm) do
the following:
1. Add a square shim(s) between the two housings.
1
2. Remove a small shim(s) between the bearing and the
gear on the screw end of the short shaft and add a
P-37892 large shim(s) of the same thickness between the snap
ring and the bearing on the tapered end of the shaft.
Put the fan nut (Item 1) [Figure 70-60-57] on the shaft
and tighten snugly.
Install a locking pliers on the fan nut and support the
handle against the long housing [Figure 70-60-57].
A220 Bobcat Loader
70-60-18 Service Manual
COOLING FAN (CONT’D) Figure 70-60-60
Gearbox, Checking Backlash (Cont'd) LONG HOUSING
Figure 70-60-59
P2985
Figure 70-60-61
P3089
SHORT HOUSING
When the backlash is correct, install the seals, cap and
gear oil as follows:
Remove the bolts from the flanges and separate the two
housings.
Put liquid adhesive (LOCTITE #242) on the outside
diameter of the seal(s) [Figure 70-60-59].
P2986
Install the seal(s) flush with the housing surface [Figure
70-60-60] & [Figure 70-60-61].
Clean any oil from the flange surface.
Install the long housing on the short housing flange.
Install the four bolts and part number tag.
Install and tighten the nuts to 25-28 ft.-lbs. (34-38 Nm)
torque.
A220 Bobcat Loader
70-60-19 Service Manual
A220 Bobcat Loader
70-60-20 Service Manual
ENGINE COMPONENTS AND TESTS Figure 70-70-2
Engine Compression, Checking
Figure 70-70-1
2
N-19021
1
Remove the high pressure fuel line (Item 1) [Figure 70-
N-19024 70-2] from the fuel pump and the fuel injector.
Installation: Tighten the fuel line nuts to 10-12 ft.-lbs.
The tools listed will be needed to do the following (13,5-16,5 Nm) torque.
procedure:
Disconnect the glow plug harness (Item 2) [Figure 70-
MEL10630 - Engine Compression Tester 70-2] from the glow plug.
MEL1489 - Compression Test Adapter Remove the glow plug from the cylinder head.
Warm the engine. Installation: Tighten the glow plugs to 15-18 ft.-lbs. (20-
24 Nm) torque.
Clean the area around the fuel injection pump, injectors
and glow plugs.
Remove the electrical connection (Item 1) [Figure 70-70-
1] from the fuel shut off solenoid.
A220 Bobcat Loader
70-70-1 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-5
Engine Compression, Checking (Cont'd)
Figure 70-70-3
N-19023
Connect the compression gauge to the adapter [Figure
N-19012 70-70-5].
Turn the engine with the starter at 200 to 300 RPM. Run
Figure 70-70-4 the test for each cylinder two times at 5 to 10 seconds
each time and take the average reading.
The correct compression to the engine is 363-435 PSI
(2503-3000 kPa) with no more than 10% difference
1 between the cylinders.
N-19022
Install the compression adapter tool (Item 1) [Figure 70-
70-3] & [Figure 70-70-4] into the glow plug hole and
tighten to 15-18 ft.-lbs. (20-24 Nm) torque.
A220 Bobcat Loader
70-70-2 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-7
Glow Plug, Checking
Figure 70-70-6
P9452
Use a test meter to measure the resistance of each glow
P9451 plug.
Connect the test meter lead to the terminal of the glow
Loaders use four glow plugs, one for each cylinder. The plug as shown in figure [Figure 70-70-7].
glow plugs are located on the rear side of engine in the
cylinder head as shown in figure [Figure 70-70-6]. Touch the other lead from the test meter to the base of
the glow plug as shown in figure [Figure 70-70-7].
Unplug the wire from the glow plug (Item 1) [Figure 70-
70-6]. The reading must be approximately 0.2 ohms.
If the resistance is zero ohms the glow plug has a short
circuit and must be replaced.
If the resistance is infinite, the coil of the glow plug is
broken and the glow plug must be replaced.
A220 Bobcat Loader
70-70-3 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-9
Fuel Shut-Off Solenoid Checking
Figure 70-70-8
N-19025
1
Figure 70-70-10
N-19024
1
Remove the screw (Item 1) [Figure 70-70-8] from the
electrical connection on the fuel shut off solenoid.
Disconnect the electrical connector from the solenoid.
N-19026
Use a test meter to measure the resistance of the fuel
shut-off solenoid.
Connect the test meter leads to the terminals (Item 1)
[Figure 70-70-9] & [Figure 70-70-10].
The reading must be approximately 02.8 ohms.
If the resistance is zero ohms the solenoid has a short
circuit.
If the resistance is infinite, the coil in the solenoid is
broken.
Replace the solenoid if needed. (See Fuel Shut-Off
Solenoid Removal And Installation on Page 70-70-5.)
A220 Bobcat Loader
70-70-4 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Fuel Injection Pump Removal
Fuel Shut-Off Solenoid Removal And Installation
Figure 70-70-11
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
1 Figure 70-70-13
3 3
N-19027
2 2
Remove the two mounting bolts (Item 1) [Figure 70-70- 1
11].
Installation:Tighten the mounting bolts to 10-12 ft.-lbs.
(13,5-16,3 Nm) torque.
P5282
Remove the fuel shut-off solenoid from the engine.
The injection pump(s) contain parts which have a very
Figure 70-70-12 close tolerance and its operation has a direct effect on
the performance of the engine.
Remove the fuel tubeline (Item 1) to the fuel injection
1 pumps (Item 2) [Figure 70-70-13].
Disconnect the respective high pressure fuel line (Item 3)
[Figure 70-70-13] from the injection pump to be removed
and fuel injector.
N-19028
Check the solenoid spring (Item 1) and linkage (Item 2)
[Figure 70-70-12]. Replace the solenoid as needed.
NOTE: When installing the fuel shut-off solenoid in
the engine the linkage (Item 2) [Figure 70-70-
12] must engage the fuel control rack.
A220 Bobcat Loader
70-70-5 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-16
Fuel Injection Pump Removal (Cont’d)
2 1
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
Figure 70-70-14
P5283
Remove the fuel injection pump (Item 1) [Figure 70-70-
16].
Remove the shim (Item 2) [Figure 70-70-16].
NOTE: The shim(s) are used to time the injection
1 pump, keep the same thickness for each
injection pump.
Figure 70-70-17
P5280
Use a flare nut wrench (Item 1) [Figure 70-70-14] to
loosen the high pressure fuel line nut.
Figure 70-70-15
P5279
1 Use a magnet to remove the injection pump tappet
[Figure 70-70-17].
Inspect the tappet for wear or damage, replace as
P5281 needed.
Remove the two mounting nuts (Item 1) [Figure 70-70-
15] from the injection pump.
A220 Bobcat Loader
70-70-6 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-20
Fuel Injection Pump Removal (Cont'd)
Figure 70-70-18 Tappet
MC-2175
Measure the distance between the engine block surface
P5278 (without shim) and surface of the tappet [Figure 70-70-
20].
Install the tappet into its respective bore [Figure 70-70- Installation dimension of the injection pump is 2.32 inch
18]. (59 mm).
Fuel Injection Pump Timing EXAMPLE:
Figure 70-70-19 Specifications:
Installation Depth......................... 2.32 inch (59 mm)
Measured Depth a .................2.25 inch (57,55 mm)
Difference................................0.070 inch (1.78 mm)
1
Determine the number of shim(s) needed to get the
correct installation height.
Install the appropriate number of shim(s) on the engine
block surface.
P5284
The fuel injection pump does not need to be timed if the
tappet, shim(s) and the camshaft are not changed.
Install a depth micrometer (Item 1) [Figure 70-70-19].
A220 Bobcat Loader
70-70-7 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-23
Fuel Injection Pump Installation
2
Figure 70-70-21 1
P5288
Use the centering pin (Item 1) to remove the press-in
P5287 plug (Item 2) [Figure 70-70-23] from the injection pump.
(See RECONDITIONING THE ENGINE on Page 70-100-
1.)
Remove the plug from the engine block. Install control
rack locating pin (Item 1) [Figure 70-70-21]. (See Figure 70-70-24
RECONDITIONING THE ENGINE on Page 70-100-1.)
Figure 70-70-22
2 1
3
P5289
P5286 Install the centering pin (Item 1) into the injection pump
and into the control lever (Item 2). Align the marks (Item
3) [Figure 70-70-24] on the pump body and the control
Move the control rack until the slot (Item 1) [Figure 70- lever. Make sure the control lever is in the center
70-22] is in the center of the injection pump bore. position.
Tighten the locating pin (Item 2) [Figure 70-70-22].
A220 Bobcat Loader
70-70-8 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-27
Fuel Injection Pump Installation (Cont'd)
Figure 70-70-25
P5280
2
1 Install the high pressure fuel line.
P5294
Tighten the fuel line nut to 10-12 ft.-lbs. (13,5-16,5 Nm)
torque [Figure 70-70-27].
Install the injection pump into the engine block. Make
sure the control lever goes into the slot on the fuel control Figure 70-70-28
rack.
Install the two nuts (Item 1) [Figure 70-70-25].
Figure 70-70-26
P5285
2
Install new washers (Item 1) [Figure 70-70-28] on the
1 fuel line fastening bolt.
P5291
Install the fuel line on the injection pumps and tighten to
20-23 ft.-lbs. (27-31 Nm) torque.
Tighten the mounting nuts to 15 ft.-lbs. (21 Nm) torque
[Figure 70-70-26].
Remove the fuel control rack locating pin (Item 1) [Figure
70-70-26] and install the plug.
Remove the centering pin (Item 2) and install the press-in
plug (Item 2) [Figure 70-70-25].
A220 Bobcat Loader
70-70-9 Service Manual
ENGINE COMPONENTS AND TESTS Figure 70-70-30
Fuel Injector Removal And Installation
Figure 70-70-29
1
P5293
Remove the high pressure fuel line.
P5280
Installation: Tighten the fuel line nut to 10-12 ft.-lbs.
(13,5-16,5 Nm) torque.
Disconnect the respective high pressure fuel line from
fuel injector to be removed and fuel injection pump. Remove the bolt (Item 1) [Figure 70-70-30] and
holddown clamp from the fuel injector.
Use a flare nut wrench (Item 1) [Figure 70-70-29] to
loosen the high pressure fuel line nut. Installation: Tighten the bolt to 15.5 ft.-lbs. (21 Nm)
torque.
Figure 70-70-31
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
P5290
Remove the fuel injector (Item 1) and washer (Item 2)
[Figure 70-70-31] from the cylinder head.
A220 Bobcat Loader
70-70-10 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Fuel Injector Disassembly
Fuel Injector, Checking Figure 70-70-33
IMPORTANT
Do not disassemble or test the fuel injector nozzles
unless you have the correct service and testing
tools.
WARNING MC-2177
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or Check nozzles spray pattern [Figure 70-70-33]:
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do The spray pattern must be uniform from all four holes of
not use your bare hand. Wear safety goggles. If fluid the nozzle.
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury. The nozzles are dirty or defective:
W-2072-0496
• If the spray pattern is not uniform.
Figure 70-70-32 • If fuel drips from the end of the nozzle.
• If the spray is a solid stream instead of a mist.
Figure 70-70-34
B-8971
The tools listed will be needed to do the following
procedure: CD-15332
OEM1064 - Injection Nozzle Test
OEM1065 - Accessory Set Remove the nozzle cap nut [Figure 70-70-34].
Connect the nozzle to the test pump, in a down position
[Figure 70-70-32].
Operate the test pump until the nozzle valve opens:
Injection Pressure: . . . . . . . . . . . . . . . 3045 PSI. (210 bar)
A220 Bobcat Loader
70-70-11 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-36
Fuel Injector Disassembly (Cont’d)
Figure 70-70-35
1
2
3
5 4
6
CD-15334
The nozzle needle and body [Figure 70-70-36] are
CD-15333 lapped together and can not be exchanged with other
nozzle parts.
Disassembly the parts as shown in [Figure 70-70-35]. DO NOT touch the nozzle needle with your fingers.
1. Nozzle Cap Nut When the nozzle body is held in the upright position, the
2. Injector Nozzle needle should by its own weight slide slowly and
3. Adapter smoothly on its seat [Figure 70-70-36].
4. Thrust Pin
5. Spring NOTE: If the nozzle needle does not slide smoothly,
6. Shim(s) wash the injector nozzle parts again in clean
diesel fuel. Blow dry with compressed air. Re-
Wash all the parts in clean diesel fuel and blow dry using do the procedure again. Replace the injectors
compressed air. as needed. Wash all new injectors in clean
diesel fuel before installation.
Figure 70-70-37
CD-15335
Check the seat surface of the adapter for wear. Make
sure the centering pins are in place [Figure 70-70-37].
A220 Bobcat Loader
70-70-12 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-40
Fuel Injector Assembly
Figure 70-70-38
CD-15338
Install the thrust pin with the centering collar facing
CD-15336 toward the compression spring [Figure 70-70-40].
Figure 70-70-41
Install the shim(s) [Figure 70-70-38].
The injector opening pressure is adjusted by selecting
the correct amount of shim(s). A thicker shim will
increase the opening pressure at the injector nozzle.
Figure 70-70-39
CD-15339
Install the adapter with the centering pins toward the
thrust pin [Figure 70-70-41].
CD-15337
Install the compression spring [Figure 70-70-39].
A220 Bobcat Loader
70-70-13 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-44
Fuel Injector Assembly (Cont'd)
Figure 70-70-42
CD-15342
Tighten the cap nut to 35 ft.-lbs. (47 Nm) torque [Figure
CD-15340 70-70-44].
Check the injector nozzle on the nozzle tester before
Install the injector nozzle, make sure the center bore fits installation. (See Fuel Injector, Checking on Page 70-70-
over the centering pins of the adapter [Figure 70-70-42]. 11.)
NOTE: Be careful that the nozzle needle does not fall
out of the nozzle body.
Figure 70-70-43
CD-15340
Install the nozzle cap nut [Figure 70-70-43].
A220 Bobcat Loader
70-70-14 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-46
Timing Belt Inspection
Figure 70-70-45
P-5292A
P5298
3 Check the timing belt, sprockets and tensioner for wear,
P-5292 cracks or damage [Figure 70-70-46].
Check the timing belt in detail for the following conditions,
NOTE: The timing belt is maintenance free. Timing replace as needed.
belts that are in operation do not need to be
re-tensioned. The timing belt, belt tensioner 1. Oil deposits
and mount bolt must be replaced every 3000 2. Hardened back rubber surfaces
operating hours or every 5 years. A repair kit 3. Cracked
is available. 4. Badly worn teeth
5. Missing tooth
NOTE: If the timing belt has to be removed before 200 6. Side of belt badly worn
hours of engine operation, the timing belt can 7. Side of belt cracked
be re-used and re-tensioned according to the
procedure listed.
To do the following procedure you need the following tool:
MEL1552 - Torx Bit
Remove the bolts (Item 1) [Figure 70-70-45] from the
timing belt inspection cover.
Remove the torx bolt (Item 2) [Figure 70-70-45].
Remove the cover (Item 3) [Figure 70-70-45].
A220 Bobcat Loader
70-70-15 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-48
Timing Belt Removal
Remove the bolts (Item 1) [Figure 70-70-45] from the
timing belt inspection cover.
Remove the torx bolt (Item 2) [Figure 70-70-45].
Remove the cover (Item 3) [Figure 70-70-45].
Figure 70-70-47
3
1
P5299
4
Loosen the belt tensioner mounting bolt (Item 1) [Figure
70-70-48].
1
Loosen the belt tensioner.
1 Remove the timing belt.
2
P5295
Remove the bolts (Item 1) from the v-belt pulley (Item 2)
[Figure 70-70-47].
Remove the V-belt pulley.
Remove the bolts (Item 3) [Figure 70-70-47] from the
timing belt cover.
Remove the cover (Item 4) [Figure 70-70-47].
A220 Bobcat Loader
70-70-16 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-51
Timing Belt Installation
Figure 70-70-49
2
1
P9577 P-9578
The crankshaft plug is located at the front of the engine
P9575 block (Item 1) [Figure 70-70-51] on the exhaust manifold
side.
NOTE: Remove the fuel injectors from the cylinder Remove the plug.
head. (See Fuel Injector Removal And
Installation on Page 70-70-10.) This will let the Figure 70-70-52
crankshaft turn easier for timing belt
installation.
The camshaft plug is located at the rear of the engine 1
block (Item 1) [Figure 70-70-49] on the fuel injection
pump side. (See RECONDITIONING THE ENGINE on
Page 70-100-1.) 2
Remove the plug.
Rotate the camshaft until the notch in the camshaft can
be seen through the plug hole.
Figure 70-70-50
B-14401
Rotate the crankshaft until the flat spot on the crankshaft
throw (Item 1) [Figure 70-70-52] can be seen through
the plug hole. Turn the crankshaft back a small amount.
Install the timing tool (Item 2) [Figure 70-70-51] &
1
[Figure 70-70-52] and tighten.
Rotate the crankshaft until it hits the timing tool and
stops.
P9573
Install the timing tool (Item 1) [Figure 70-70-50] and
tighten.
A220 Bobcat Loader
70-70-17 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-55
Timing Belt Installation (Cont'd)
Figure 70-70-53
P5632
Using the dimension, align the timing belt to make sure it
P5301 is at an equal distance from the front cover [Figure 70-
70-55].
Loosen the nut at the camshaft gear [Figure 70-70-53]. Figure 70-70-56
(See RECONDITIONING THE ENGINE on Page 70-100-
1.)
Install the new timing belt.
Figure 70-70-54
N-18863
Install the belt tension tool (Item 1) [Figure 70-70-56].
(See RECONDITIONING THE ENGINE on Page 70-100-
1
1.)
P5630
Turn the idler tensioner pulley in counterclockwise
direction to obtain a scale reading of 3.0-3.5. Tighten the
Measure the distance from the edge of the belt to the idler tensioner pulley nut (Item 2) [Figure 70-70-54] to 33
front cover surface [Figure 70-70-54]. ft.-lbs. (45 Nm) torque.
A220 Bobcat Loader
70-70-18 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-59
Timing Belt Installation (Cont'd)
Figure 70-70-57
1
N-18864
Mark the crankshaft pulley (Item 1) [Figure 70-70-59].
N-18867
Make four complete crankshaft revolutions in a clockwise
direction of engine rotation. Bring the mark on the
Remove the belt tension tool. crankshaft pulley back to the same position.
Initially tighten camshaft bolt to 22 ft.-lbs. (30 Nm) Figure 70-70-60
[Figure 70-70-57].
Figure 70-70-58
N-18852
N-18866 Install the belt tension tool (Item 1) [Figure 70-70-60].
NOTE: The belt tension tool may touch the governor
With a torque degree wheel (Item 1) [Figure 70-70-58] linkage cover (Item 2) [Figure 70-70-60], but
tighten the camshaft bolt an additional 210°. will not effect the belt tightening procedure.
Remove the camshaft and crankshaft locating pins. ((See
ENGINE COMPONENTS AND TESTS on Page 70-70-
1.)
A220 Bobcat Loader
70-70-19 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-63
Timing Belt Installation (Cont'd)
Figure 70-70-61 1
P5295
NOTE: (See Valve Timing, Checking on Page 70-70-
N-18853 27.) before installing the timing belt cover.
Install the belt cover (Item 1) [Figure 70-70-63] and
Check the position of the belt tension tool (Item 1) tighten the bolts.
[Figure 70-70-61] on the belt.
Install the v-belt pulley (Item 2) [Figure 70-70-63] and
Figure 70-70-62 tighten the bolts to 30-36 ft.-lbs. (41-49 Nm) torque.
Figure 70-70-64
N-18865
1
P5292
Measure the belt tension [Figure 70-70-62], the reading
should be 6.5-9.5.
Install the timing belt inspection cover (Item 1) [Figure
NOTE: If the specified scale reading is not obtained, 70-70-64] and tighten the bolts.
repeat the installation procedure starting with
Figure [Figure 70-70-61]; (See Timing Belt
Installation on Page 70-70-17.)
Remove the belt tension tool.
A220 Bobcat Loader
70-70-20 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Remove the bolts (Item 2) [Figure 70-70-65] holding the
belt shield. Move the shield away from the work area.
Timing Belt, Replacement In The Loader
Figure 70-70-66
Figure 70-70-65
2
2
1 P9563
Loosen the alternator adjustment bolt (Item 1) [Figure
70-70-66] and remove the alternator belt.
Remove the crankshaft pulley bolts (Item 2) [Figure 70-
70-66]. Remove the pulley.
2 Figure 70-70-67
P9566
Use the following procedure to replace the timing belt,
tensioner and tensioner bolt. If the belt is broken,
additional procedures are required and noted.
2
• For Broken Belt Replacement Only 1
• Remove the engine muffler. (See MUFFLER on Page
70-30-1.) P9564
• Remove the valve cover. Remove and inspect the
rocker arms/brackets and push rods. (See Rocker Remove the throttle linkage bolts (Item 1) [Figure 70-70-
Arm And Bracket, Checking on Page 70-100-43.) 67]. Lower the throttle linkage.
NOTE: The rear door is removed for photo clarity Remove the four belt cover bolts (Item 2) [Figure 70-70-
only. 67]. Remove the front and rear belt covers.
Disconnect the negative (-) battery cable.
Loosen the screw and unplug the fuel solenoid connector
(Item 1) [Figure 70-70-65].
NOTE: Do not lose the rubber seal gasket on the
solenoid connector.
A220 Bobcat Loader
70-70-21 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-70
Timing Belt, Replacement In The Loader (Cont'd)
Figure 70-70-68
P9570
Rotate the crankshaft in correct rotation as shown in
P9575 figure [Figure 70-70-70] until the notch in the camshaft
can be seen through the access hole.
Remove the camshaft access plug (Item 1) [Figure 70- NOTE: The crankshaft must be turned in correct
70-68]. rotation. Turn clockwise as viewed from the
timing belt end of engine as shown.
Figure 70-70-69
Figure 70-70-71
1
1
P9577
P9573
Remove the crankshaft access plug (Item 1) [Figure 70-
70-69]. Install the camshaft timing tool (Item 1) [Figure 70-70-71]
and tighten. See Deutz Engine Tools Identification Chart
NOTE: The plug is located on the front of crankcase, on Page 70-100-1for correct tool.
below the turbocharger and just above the
right side front engine mount.
A220 Bobcat Loader
70-70-22 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-73
Timing Belt, Replacement In The Loader (Cont'd)
Figure 70-70-72
P9578
• Install the crankshaft timing tool (Item 1) [Figure 70-
P9605
70-73] and tighten. See Deutz Engine Tools
Identification Chart on Page 70-100-1for the correct
tool.
• For Broken Belt Replacement Only
• Rotate crankshaft against timing tool.
• Remove the number four cylinder fuel injector. (See
Fuel Injector Removal And Installation on Page 70- Install the crankshaft timing tool (Item 1) [Figure 70-70-
70-10.) 73] and Tighten. See Deutz Engine Tools Identification
Chart on Page 70-100-1 for the correct tool.
• Rotate the crankshaft and use a wire (Item 1) [Figure
Figure 70-70-74
70-70-72] in the fuel injector hole to indicate piston is
moving upward, to top dead center (T.D.C.).
NOTE: The crankshaft must be turned in correct
rotation. Turn clockwise as viewed from the
timing belt end of engine.
P9565
Remove the tensioner bolt (Item 1) [Figure 70-70-74]
and the tensioner. Remove the timing belt.
NOTE: The timing belt, belt tensioner and mount bolt
must be replaced as a set. A repair kit is
available.
Install the new timing belt, belt tensioner and mount bolt.
Do not tighten the mount bolt.
NOTE: Align the timing belt on gears to obtain equal
distance between the belt and front cover to
insure belt runs straight on gears.
A220 Bobcat Loader
70-70-23 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-77
Timing Belt, Replacement In The Loader (Cont'd)
Figure 70-70-75
P9579
Use a hex wrench to turn the idler tension pulley in
P9571 counterclockwise direction as shown in figure [Figure 70-
70-77]. Obtain a scale reading of 3.0-3.5. Tighten the
idler tension pulley mount bolt to 33 ft.-lbs. (45 Nm)
Install the camshaft gear tool (Item 1) [Figure 70-70-75]. torque.
See Deutz Engine Tools Identification Chart on Page 70-
100-1 for the correct tool. Figure 70-70-78
Loosen the camshaft gear [Figure 70-70-75].
Figure 70-70-76
P-9569
Remove the belt tension tool, hex wrench and torque
P-9576A P-9574 wrench.
Install the camshaft gear tool.
Install the belt tension tool as shown in [Figure 70-70-
76]. See Deutz Engine Tools Identification Chart on Page Tighten camshaft bolt to 22 ft.-lbs. (30 Nm) torque as
70-100-1 for correct tool. shown in figure [Figure 70-70-78]. Mark the camshaft
bolt and tighten an additional 210°.
A220 Bobcat Loader
70-70-24 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) • For Broken Belt Replacement Only
Timing Belt, Replacement In The Loader (Cont'd) • Install the push rods and rocker arms/brackets.
Replace all damaged parts. (See RECONDITIONING
Figure 70-70-79 THE ENGINE on Page 70-100-1.)
• Set the valve clearance. (See RECONDITIONING
THE ENGINE on Page 70-100-1.)
• Install the valve cover and gasket. Tighten the bolts to
75 in.-lbs. (8,5 Nm) torque.
1
Install the crankshaft and camshaft access plugs.
Install the belt covers and four mounting bolts.
Install the throttle linkage and bolts.
Install the crankshaft pulley and bolts. Tighten the bolts to
P9565A 30-36 ft.-lbs. (41-49 Nm) torque.
Install the alternator belt. Adjust the belt tension.
Remove the camshaft and crankshaft timing tools (Item
1) [Figure 70-70-79] & [Figure 70-70-81]; Page 70-70- Install the belt shield and bolts.
22).
Plug in the fuel solenoid connector and tighten the screw.
Mark the crankshaft pulley hub (Item 1) [Figure 70-70-
79]. Reconnect the negative (-) battery cable.
Figure 70-70-80
P9570
Make four complete crankshaft revolutions in the
direction of engine rotation. Bring the mark on the
crankshaft pulley back to the same position as before
[Figure 70-70-80].
Install the belt tension tool. Check the belt tension
reading. It should be 6.5-9.5.
NOTE: If the specified scale reading is not obtained,
repeat the procedure.
Remove the belt tension tool.
A220 Bobcat Loader
70-70-25 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-83
Valve Clearance Adjustment
Figure 70-70-81
P5633
Loosen the locknut and turn the set screw until the
P5297 clearance is correct.
Intake - 0.012 inch (0,3 mm)
Make the valve clearance adjustment with engine Exhaust - 0.020 inch (0,5 mm)
stopped and cold.
Tighten the locknut to 13-16 ft.-lbs. (18-22 Nm) torque.
Remove the valve cover (Item 1) [Figure 70-70-81].
When installing the valve cover bolts, tighten them to 75
in.-lbs. (8,5 Nm) torque.
Figure 70-70-82
CRANKSHAFT POSITION CRANKSHAFT POSITION
ONE TWO
Turn crankshaft Turn crankshaft further by
until valves one complete revolution
of cylinder No. 1 Overlap (360)°
DO NOT ADJUST ADJUST
MC-2174
Use the following sequence as shown in figure [Figure
70-70-82] to set the valve clearance.
Turn the crankshaft until the valves of cylinder No. 1
over-lap [Figure 70-70-82].
Turn the crankshaft by one complete revolution (360°)
and set the other valves.
A220 Bobcat Loader
70-70-26 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-86
Valve Timing, Checking
Figure 70-70-84
P9563
At the crankshaft pulley bolt, install a torque wrench and
P9575 turn the engine in the direction of rotation to 30 ft.-lbs. (40
Nm) torque [Figure 70-70-86].
Remove the camshaft access plug (Item 1) [Figure 70- Remove the torque wrench, DO NOT change the
70-84]. crankshaft position.
Figure 70-70-85
P9573
Rotate the crankshaft/camshaft until the notch in the
camshaft can be seen through the plug hole.
Install the timing tool (Item 1) [Figure 70-70-85].
A220 Bobcat Loader
70-70-27 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D)
Valve Timing, Checking, (Cont’d)
Figure 70-70-87
2
1
P-9577A P-9578A
Remove the crankshaft access plug (Item 1) [Figure 70-
70-87].
NOTE: The access plug is located on the front of the
crankcase, below the turbocharger and just
above the right side front engine mount.
Turn the crankshaft timing tool (Item 2) [Figure 70-70-87]
into the crankcase until it makes slight contact with the
crankshaft.
Mark the position of the timing tool.
The valve timing is correct if the timing tool can be turned
into the crankcase another 3/4 to 2-1/4 turns until it stops.
If the timing tool can not be turned into the crankcase the
required turns, the camshaft (valve timing) setting will
have to be redone.
A220 Bobcat Loader
70-70-28 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Remove the plug (Item 1) [Figure 70-70-88] and remove
the thermostat and spring assembly (Item 1) [Figure 70-
Thermostat, Oil Pressure Control Valves & Heater 70-89] from the engine block. (See Thermostat, Oil
Connections Pressure Control Valves & Heater Connections on Page
70-70-29.) for detail parts.
Figure 70-70-88
Installation: Install the plug and tighten to 82 ft.-lbs. (111
Nm) torque.
Remove the plug and O-ring (Item 2) [Figure 70-70-88]
and remove the spring and oil pressure control valve
(Item 2) [Figure 70-70-89] from the engine block. See
Thermostat, Oil Pressure Control Valves & Heater
1 Connections on Page 70-70-29.
Installation: Install the plug and tighten to 82 ft.-lbs. (111
Nm) torque.
Remove the adapter fitting (Item 3) [Figure 70-70-88]
plug and O-ring (Item 3) [Figure 70-70-89]. (See
Thermostat, Oil Pressure Control Valves & Heater
2 Connections on Page 70-70-29.) for detail parts.
Installation: Install the fitting and/or plug and tighten to
82 ft.-lbs. (111 Nm) torque.
Remove the plug and O-ring (Item 4) [Figure 70-70-88]
and remove the spring and oil pressure control valve
4
3 (Item 4) [Figure 70-70-89] from the engine block. (See
Thermostat, Oil Pressure Control Valves & Heater
Connections on Page 70-70-29.), for detail parts.)
5 Installation: Install the plug and tighten to 82 ft.-lbs. (111
Nm) torque.
P-18909A Remove the adapter fitting (Item 5) [Figure 70-70-88]
plug and O-ring (Item 5) [Figure 70-70-89].
Figure 70-70-89 Remove the valve and spring (Item 6) [Figure 70-70-89]
from the engine block. (See Thermostat, Oil Pressure
Control Valves & Heater Connections on Page 70-70-
1 29.), for detail parts.)
Installation: Install the fitting and/or plug and tighten to
2
82 ft.-lbs. (111 Nm) torque.
NOTE: Be sure the valve and spring (Item 6) [Figure
70-70-89] is installed as shown in Fig. [Figure
3 70-70-89].
6
5 B-14310
A220 Bobcat Loader
70-70-29 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Installation: (See Thermostat, Oil Pressure Control
Valves & Heater Connections on Page 70-70-29.)
Thermostat, Oil Pressure Control Valves & Heater [Figure 70-70-89] for location on the engine block.)
Connections (Cont'd)
Figure 70-70-92
Figure 70-70-90
2 1
1
N-18870
N-18868
NOTE: The adapter fitting (Item 1) [Figure 70-70-92] is
Remove the thermostat spring (Item 1) from the removed when a cab heater is installed on the
thermostat (Item 2) [Figure 70-70-90], inspect all parts loader. The port it comes from on the engine
and replace as needed. block is the oil out let port to the heater.
Installation: (See Thermostat, Oil Pressure Control Installation: (See Thermostat, Oil Pressure Control
Valves & Heater Connections on Page 70-70-29.) Valves & Heater Connections on Page 70-70-29.)
[Figure 70-70-89] for location on the engine block. [Figure 70-70-89] for location on the engine block.)
Figure 70-70-91
3
1
2
N-18869
Remove the spring (Item 1) from the oil pressure control
valve (Item 2). Replace the O-ring (Item 3) [Figure 70-
70-91].
The spring is marked with a yellow mark, for proper
installation. If the yellow mark is missing, the spring coil
diameter is .047 inch (1,2 mm).
A220 Bobcat Loader
70-70-30 Service Manual
ENGINE COMPONENTS AND TESTS (CONT’D) Figure 70-70-94
Thermostat, Oil Pressure Control Valves & Heater
Connections (Cont'd)
2
Figure 70-70-93
1
1
2
1
N-18872
Remove the spring (Item 1) from the valve (Item 2)
[Figure 70-70-94].
N-18871
The spring is marked with a blue mark, for proper
installation. If the blue mark is missing, the spring coil
Replace the O-ring (Item 1). Remove the spring (Item 2) diameter is .039 inch (1,0 mm).
from the oil pressure control valve (Item 3) [Figure 70-
70-93]. Installation: (See Thermostat, Oil Pressure Control
Valves & Heater Connections on Page 70-70-29.)
The spring is marked with a red mark, for proper [Figure 70-70-89] for location on the engine block.)
installation. If the red mark is missing, the spring coil
diameter is .055 inch (1,4 mm).
Installation: (See Thermostat, Oil Pressure Control
Valves & Heater Connections on Page 70-70-29.)
[Figure 70-70-89] for location on the engine block.)
A220 Bobcat Loader
70-70-31 Service Manual
A220 Bobcat Loader
70-70-32 Service Manual
ENGINE Figure 70-80-2
Removal And Installation
Figure 70-80-1
1 2 P-26464
Drain the fluid from the hydraulic reservoir. (See Draining
P-26597 The Fluid Reservoir on Page 20-80-1.)
Disconnect the two hydrostatic pump controllers (Item 1)
NOTE: The engine and hydrostatic pumps will be [Figure 70-80-2] from the loader wiring harness.
removed as an assembly.
Figure 70-80-3
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.) 2
Place the rear of the loader on jack stands. (See 1
Procedure on Page 10-10-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the rear tires. (Both Sides.)
Remove the six access cover mount bolts (Item 1)
[Figure 70-80-1]. Remove the access cover (Item 2)
[Figure 70-80-1]. (Both Sides.) P-26700
Disconnect the hydraulic hose (Item 1) [Figure 70-80-3]
from the hydraulics pump to the control valve.
Disconnect the hydraulic hose (Item 2) [Figure 70-80-3],
at the steering filter, that comes from the hydraulic pump
to the steering valve.
Cap and plug the hoses and fittings.
A220 Bobcat Loader
70-80-1 Service Manual
ENGINE (CONT’D) Figure 70-80-6
Removal And Installation (Cont'd)
1
Figure 70-80-4
2
1
P-26733
At the front side of the gear pump, disconnect the return
P-26734 hose from the steering valve (Item 1) [Figure 70-80-6].
Cap and plug the hose and the fitting.
Disconnect the hydraulic hose (Item 1) [Figure 70-80-4]
from the hydraulics Hi-flow pump. (If so equipped.) Remove the two hose clamps (Item 2) [Figure 70-80-6]
from the return hoses, and remove the hoses from the
Remove the power Bob-tach block from the back side of pump fitting.
the gear pump. (See Removal And Installation on Page
20-120-1 [early models] or See Removal And Installation Figure 70-80-7
on Page 20-121-1 [later models])
Figure 70-80-5
P-26824
1
P-26640 Disconnect the charge pressure hose (Item 1) [Figure
70-80-7] from the charge pressure sendor.
Remove the lower hose clamp (Item 1) [Figure 70-80-5]
and remove the hydraulic hose from the fitting on the
front side of the gear pump.
A220 Bobcat Loader
70-80-2 Service Manual
ENGINE (CONT’D) Figure 70-80-9
Removal And Installation (Cont'd)
Figure 70-80-8
1
2
1 P-28121
At the left side access cover, remove the fan drive belt
P-28120 (Item 1) [Figure 70-80-9] from the flywheel pulley.
Figure 70-80-10
Mark the hydraulic hoses for the correct installation.
Remove the hose (Item 1) [Figure 70-80-8] that goes to
the case drain filter.
Remove the four high pressure hoses (Item 1) [Figure
70-80-8] from the hydrostatic pump.
1
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
P-28122
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Remove the engine mount bolt (Item 1) [Figure 70-80-
I-2003-0888 10] at the left front engine mount.
Installation: Tighten the mounting bolt to 61-69 ft.-lbs.
(83-94 Nm) torque.
A220 Bobcat Loader
70-80-3 Service Manual
ENGINE (CONT’D) Disconnect the wire harness clamp (Item 3) [Figure 70-
80-12].
Removal And Installation (Cont'd)
Figure 70-80-13
Figure 70-80-11
P-28125
P-28123
Disconnect the engine temperature wires (Item 1)
Remove the engine mount bolt (Item 1) [Figure 70-80-
[Figure 70-80-13].
11] at the right front engine mount.
Installation: Tighten the mounting bolt to 61-69 ft.-lbs. Disconnect the engine oil pressure wire (Item 2) [Figure
(83-94 Nm) torque. 70-80-13].
Figure 70-80-12
3 1
2
P-28124
At the engine compartment, remove the battery. (See
Removal And Installation on Page 60-20-1.)
Remove the alternator. (See Removal And Installation on
Page 60-30-4.)
Remove the engine air cleaner. (See Housing Removal
And Installation on Page 70-40-1.)
Disconnect the engine electrical harness (Item 1) [Figure
70-80-12] from the tailgate harness.
Disconnect the fuel shut-off solenoid (Item 2) [Figure 70-
80-12].
A220 Bobcat Loader
70-80-4 Service Manual
ENGINE (CONT’D) Figure 70-80-16
Removal And Installation (Cont'd)
2
Figure 70-80-14
2 1
P-28128
1
Remove the wiring harness mounting clamp bolt (Item 1)
P-28126 [Figure 70-80-16].
Remove the mount bolt (Item 2) [Figure 70-80-16] from
Disconnect the wiring harness connector from the starter the fuel filter mount, and remove the wiring harness
(Item 1) [Figure 70-80-14]. mount clamp.
Disconnect the wiring harness connector (Item 2) [Figure
70-80-14] from the engine speed sensor.
Disconnect and plug the fuel line (Item 3) [Figure 70-80-
14].
Figure 70-80-15
P-28127
Disconnect the positive wires (Item 1) [Figure 70-80-15]
from the starter.
Disconnect the negative wires (Item 2) [Figure 70-80-15]
from the ground.
A220 Bobcat Loader
70-80-5 Service Manual
ENGINE (CONT’D) Figure 70-80-19
Removal And Installation (Cont'd)
1
Figure 70-80-17 1
2
2
1
P-28131
At the right side of the engine, remove the two throttle
P-28129 bracket mount nuts (Item 1) [Figure 70-80-19].
Disconnect the throttle linkage connector (Item 2)
Disconnect the four glow plug wire connectors (Item 1) [Figure 70-80-19].
[Figure 70-80-17].
Figure 70-80-20
Remove the wiring harness clamp mount bolt (Item 2)
[Figure 70-80-17].
Remove the loader wiring harness from the engine, and
move it to the left side of the loader to allow clearance for
the engine removal.
Figure 70-80-18
1
P-28132
1
Disconnect and cap the engine oil to cooler hoses (Item
1) [Figure 70-80-20].
P-28130
Disconnect the cab heater hoses (Item 1) [Figure 70-80-
18]. (If so equipped.)
A220 Bobcat Loader
70-80-6 Service Manual
ENGINE (CONT’D) Figure 70-80-23
Removal And Installation (Cont'd)
Figure 70-80-21
1
N-19990
Remove the right rear engine mounting bolt (Item 1)
P-28134 [Figure 70-80-23] and nut.
Installation: Tighten the bolt and nut to 61-69 ft.-lbs. (83-
Disconnect the fuel return hose (Item 1) [Figure 70-80- 94 Nm) torque.
21].
Figure 70-80-24
Cap and plug the lines.
Figure 70-80-22 1
2 2
P7917
1
P-28133 Use the dimensions from [Figure 70-80-25] (See
Removal And Installation on Page 70-80-1.) to make the
engine removal and installation brackets.
Remove the left rear engine mounting bolt (Item 1)
[Figure 70-80-22] and nut. Install the lift bracket (Item 1) [Figure 70-80-24] on the
engine.
Installation: Tighten the bolt and nut to 61-69 ft.-lbs. (83-
94 Nm) torque. Tighten the bolts (Item 2) [Figure 70-80-24] until the lift
bracket is held firmly against the valve cover.
NOTE: Bolts required are two 12x80 mm x 1.75
thread.
A220 Bobcat Loader
70-80-7 Service Manual
ENGINE (CONT’D)
Removal And Installation (Cont’d)
Figure 70-80-25
13.0
(330)
2.5
(64)
1-1/2” I.S. Dia.
2-1/2” O.S. Dia.
2.5 (64)
4.0
(102) 1-1/2” Square Tubing 1/4” (4)
2.0
(51) Thick Gusset
1.0 (25) 16.0
0.5 1.0 (25)
(406)
(12,7)
0.375
0.3125 Dia. (2) (9,5)
Use Two 3/8” x 1-1/4” Bolts
for Drilled and Tapped Holes
4.0
(102)
4.25
(108) 2.0 (51)
9.0
0.5 0.6875 (229)
(12,7) (17,5) 45°
1.0
(25)
1.75
(44,5)
1.375
(35,0) 0.66 (16,8)
4.5
(114)
8,525
(218)
1.125 1.125
(28,6) 1.75 (28,6)
(44,5)
(2) 2 x 2 x 1/4 0.775
Gusset (19,7)
3/8 Dia. Hole (4)
17.750 9/16 Gusset
Dia. Hole (2)
2-1/2 x 2-1/2 x 22
1/4” Thick
MC-1799B
A220 Bobcat Loader
70-80-8 Service Manual
ENGINE (CONT’D) Mount Replacement
Removal And Installation (Cont'd) Figure 70-80-27
Figure 70-80-26 2
1
3
1
4
7 MC-1771
Use the following procedure to install new engine
mounts:
Remove the existing mount from the engine. Refer to
engine removal and installation for engine mount
locations.
Replace all four engine mounts (two front and two rear).
Use the parts shown to install the new engine mounts
[Figure 70-80-27].
Item 1 - Square Nut - Used on left side engine mounts
P7915
Item 2 - Hex Nut - Used on right side engine mounts
Connect a chain hoist to the ring (Item 1) [Figure 70-80- Item 3 - Mount Washer
26] on the lift bracket.
Item 4 - Engine Mount
Remove the engine/hydrostatic pump assembly from the
loader [Figure 70-80-26]. Item 5 - Tube Spacer
Item 6 - Snubbing Washer
Item 7 - Mounting Bolt
A220 Bobcat Loader
70-80-9 Service Manual
ENGINE (CONT’D)
Mount Replacement (Cont’d)
Figure 70-80-28
HEAVY DUTY
ENGINE
MOUNT
Washer Engine
Mounting
Bracket
Loader
Frame Engine
Mount
Snubbing Spacer
Washer
TS-1520
Install the new engine mount as shown in the cut away
side view [Figure 70-80-28].
Tighten the mounting bolts to 61-69 ft.-lbs. (83-94 Nm)
torque.
A220 Bobcat Loader
70-80-10 Service Manual
FLYWHEEL AND HOUSING Ring Gear Removal And Installation
Flywheel Removal And Installation Figure 70-90-2
Figure 70-90-1
P5564
P5558
Remove the flywheel from the engine crankshaft [Figure
70-90-2].
Remove the drive belt. (See Replacement on Page 30-
50-1.) NOTE: The lead chamfer on ring gear tooth must face
the starter.
Remove the bolts (Item 1) [Figure 70-90-1] from the
flywheel. The ring gear (Item 1) [Figure 70-90-2] on the flywheel is
an interference fit. Heat the ring gear enough to expand it
Installation: Tighten the flywheel bolts as follows: and hit it with a hammer to remove it evenly.
Inital Torque . . . . . . . . . . . . . . . . . . . 22 ft.-lbs. (30 Nm)
Clean the outer surface of the flywheel to give it a smooth
1st Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
fit.
2nd Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Clean the new ring gear and heat it to a maximum
temperature of 428°F (220°C).
Fit the ring gear over the flywheel. Make sure the gear is
on the seat correctly.
A220 Bobcat Loader
70-90-1 Service Manual
FLYWHEEL AND HOUSING (CONT’D)
Flywheel Housing Removal And Installation
Figure 70-90-3
1
1
P5562
Remove the drive belt. (See Replacement on Page 30-
50-1.)
Remove the hydrostatic pump. (See Removal And
Installation on Page 30-40-8.)
Remove the belt tension pulley assembly. (See Tensioner
Pulley Removal And Installation on Page 30-50-2.)
Remove the starter. (See Removal And Installation on
Page 60-40-1 [NIPPONDENSO] or See Removal And
Installation on Page 60-41-1 [VALEO])
Remove the flywheel housing mounting bolts (Item 1)
[Figure 70-90-3].
Remove the flywheel housing from the engine.
A220 Bobcat Loader
70-90-2 Service Manual
RECONDITIONING THE ENGINE
Deutz Engine Tools Identification Chart
B-16718
A220 Bobcat Loader
70-100-1 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-2
Disassembly
Figure 70-100-1
CD-15481
Remove the rocker arms and brackets [Figure 70-100-
CD-15486 2].
Figure 70-100-3
Remove the starter. (See Removal And Installation on
Page 60-40-1 [NIPPONDENSO] or See Removal And
Installation on Page 60-41-1 [VALEO])
Remove the alternator. (See Removal And Installation on
Page 60-30-4.)
Drain the oil from the engine oil pan.
Remove the turbocharger. (See Turbo Charger Removal
and Installation on Page 70-100-59.)
Remove the exhaust manifold.
Remove the intake manifold. CD-15480
Remove the fuel injection pumps. (See Fuel Injection
Pump Removal on Page 70-70-5.) Remove the push rods [Figure 70-100-3].
Remove the fuel injectors. (See Fuel Injector
Disassembly on Page 70-70-11.)
Remove the oil filter.
Remove the fuel filter & fuel lift pump [Figure 70-100-1].
Remove the valve cover.
A220 Bobcat Loader
70-100-2 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-6
Disassembly (Cont'd)
Figure 70-100-4
P5292
Remove the belt pulley (Item 1) [Figure 70-100-6].
CD-15513
Remove the front cover and timing belt. (See Front Cover
Assembly on Page 70-100-49.)
Remove the cylinder head bolts [Figure 70-100-4].
Remove the crankshaft gear.
Remove the cylinder head.
Figure 70-100-7
Figure 70-100-5
CD-15471
CD-15515
Remove the oil pump [Figure 70-100-7].
Remove the oil pressure control valve [Figure 70-100-5].
Remove the oil pump relief valve (Item 1) [Figure 70-
Remove the plugs or fittings from the engine block. 100-7].
A220 Bobcat Loader
70-100-3 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-10
Disassembly (Cont'd)
Figure 70-100-8
CD-15520
Remove the connecting rod bolts [Figure 70-100-10].
CD-15518
Remove all the piston/connecting rod assembly from the
engine block.
Remove the oil pan [Figure 70-100-8].
To check the piston/connecting rod assembly. (See
Figure 70-100-9 Piston Installation On The Connecting Rod on Page 70-
100-38.)
Figure 70-100-11
CD-15519
Remove the oil suction pipe [Figure 70-100-9].
CD-15521
Remove the front cover [Figure 70-100-11].
To disassemble and assemble the front cover. (See Front
Cover Disassembly on Page 70-100-44.)
Remove the flywheel. (See Flywheel Removal And
Installation on Page 70-90-1.)
A220 Bobcat Loader
70-100-4 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-14
Disassembly (Cont'd)
Figure 70-100-12
CD-15541
Remove the camshaft [Figure 70-100-14].
CD-15524
Figure 70-100-15
Remove the rear cover [Figure 70-100-12].
To install a new rear seal and inspect the cover. (See
Rear Cover Seal Removal And Installation on Page 70-
100-30.)
Figure 70-100-13
CD-15526
Mark the location of each main bearing cap so it will be
1
returned to original position.
Remove the main bearing caps bolts [Figure 70-100-15].
CD-15525 Remove the main bearing caps.
Remove the crankshaft.
Install the timing tool (Item 1) [Figure 70-100-13] for the
camshaft. To check the crankshaft specifications. (See Crankshaft,
Checking on Page 70-100-31.)
Remove the thrust washer from the camshaft [Figure 70-
100-13]. Remove the upper half of the main bearings.
Remove the timing tool.
A220 Bobcat Loader
70-100-5 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-18
Disassembly (Cont'd)
Figure 70-100-16
CD-15531
Install the oil pressure control valve and compression
CD-15527 spring [Figure 70-100-18].
Install the plug.
Remove the tappets from the engine block [Figure 70-
100-16]. Figure 70-100-19
Assembly
Figure 70-100-17
CD-15532
Install new seals on the fittings and/or plugs.
CD-15528
Install all the fittings and/or plugs and tighten to 82 ft.-lbs.
(111 Nm) torque [Figure 70-100-19].
Install the thermostat and compression spring [Figure
70-100-17].
Install the plug and tighten to 82 ft.-lbs. (111 Nm) torque.
A220 Bobcat Loader
70-100-6 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-22
Assembly (Cont'd)
Figure 70-100-20
CD-15539
Install a new seal on the plug and install in the block.
CD-15537 Tighten the plug to 21 ft.-lbs. (28 Nm) torque [Figure 70-
100-22].
Install the plug and tighten to 37 ft.-lbs. (50 Nm) torque Figure 70-100-23
[Figure 70-100-20].
Figure 70-100-21
CD-15540
CD-15538 Install the tappets [Figure 70-100-23].
Install the oil pressure switch and tighten to 115 in.-lbs.
(13 Nm) torque [Figure 70-100-21].
A220 Bobcat Loader
70-100-7 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-26
Assembly (Cont'd)
Figure 70-100-24
CD-15542
Install the thrust washer with the lubricating groove
CD-15435 toward the crankcase [Figure 70-100-26].
Figure 70-100-27
Before installing the new piston cooling oil nozzle, check
that the bores in the block are clean and free of oil. Press
in the piston cooling nozzle as far as it will go [Figure 70-
100-24].
Figure 70-100-25
CD-15543
Install the camshaft timing tool (Item 1) [Figure 70-100-
27].
CD-15541 Tighten the camshaft thrust washer bolt to 15 ft.-lbs. (21
Nm) torque [Figure 70-100-27].
Install the camshaft [Figure 70-100-25]. Remove the timing tool.
A220 Bobcat Loader
70-100-8 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-30
Assembly (Cont'd)
Figure 70-100-28
CD-15546
Install the thrust bearings halves on the main bearing cap
CD-15544 [Figure 70-100-30].
Measure the width of the thrust washers/main bearing
Install the upper main bearing halves [Figure 70-100- cap [Figure 70-100-30].
28].
Figure 70-100-29
CD-15545
Install the other main bearing half into the main bearing
caps [Figure 70-100-29].
A220 Bobcat Loader
70-100-9 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-32
Assembly (Cont'd)
Figure 70-100-31
CD-15549
Install the main bearing locating sleeves [Figure 70-100-
CD-15548 32].
Figure 70-100-33
Measure the bearing journal width at the crankshaft
(inset) [Figure 70-100-31].
Specifications:
Journal Width Std.. . . . . . . . . . . . . . . 1.378-1.379 inch.
(35,0-35,04 mm)
Limit for O/S . . . . . . . . . . . . . . . 1.395 inch. (35,44 mm)
Determine the end play for the crankshaft [Figure 70-
100-31].
Specifications:
Std. End Play. . . . . . . . . . . . . . . . . . . 0.004-0.010 inch.
(0,1-0,273 mm) CD-15550
Wear Limit . . . . . . . . . . . . . . . . . . 0.016 inch. (0,4 mm)
Install the crankshaft into the engine block [Figure 70-
100-33].
Use new thrust washer as needed to get the correct end
play.
A220 Bobcat Loader
70-100-10 Service Manual
RECONDITIONING THE ENGINE (CONTD) Figure 70-100-36
Assembly (Cont'd)
Figure 70-100-34
CD-15553
Install the main bearing caps/main bearing assembly
CD-15551 [Figure 70-100-36].
Make sure they are returned to their original location.
Lubricate the thrust washer with grease and install them
on the main bearing cap [Figure 70-100-34]. Figure 70-100-37
Figure 70-100-35
CD-15554
CD-15552
Tighten the main bearing cup bolts as follows [Figure 70-
100-37]:
Install the main bearing/thrust washer assembly [Figure
70-100-35]. Initial Torque . . . . . . . . . . . . . . . . . . . .37 ft.-lbs. (50 Nm)
1st Step Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
NOTE: The main bearing cap No. 1, at the flywheel 2nd Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
end, the chamfer must be towards the
flywheel end.
A220 Bobcat Loader
70-100-11 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-40
Assembly (Cont'd)
Figure 70-100-38
CD-15557
Measure the distance between the top edge of the crank
CD-15555 pin (TDC) and cylinder head sealing surface at every
cylinder [Figure 70-100-40].
Put sealing compound on the rear cover [Figure 70-100- Figure 70-100-41
38].
Figure 70-100-39
A B C
CD-15558
CD-15556 Compare actual dimension with the dimension listed
[Figure 70-100-41]:
Install the rear cover complete with a new rear seal Specifications:
[Figure 70-100-39]. Piston Class A. . . . . . . . . . . . . . . . . . .7.732-7.736 inch.
(196,39-196,49 mm)
NOTE: Make sure the rear cover oil pan surface
aligns with the engine block surface.
NOTE: If the crankshaft is undersize, 0.005 inch
Tighten the bolts to 15 ft.-lbs. (21 Nm) torque [Figure 70- (0.125 mm) must be added to the dimension
100-39]. listed.
A220 Bobcat Loader
70-100-12 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-44
Assembly (Cont'd)
Figure 70-100-42
CD-15561
Install a piston ring compressor on the piston rings.
CD-15559
Install the piston/connecting rod assembly into the engine
block [Figure 70-100-44].
Install the connecting rod bearing halves into the
connecting rod [Figure 70-100-42]. NOTE: The flywheel symbol on the piston must be
toward the flywheel.
Figure 70-100-43
Figure 70-100-45
CD-15560
CD-15562
Before installing piston/connecting rod assembly, make
sure the piston ring gaps are staggered as shown, in Install the connecting rod cap on the connecting rod,
[Figure 70-100-43]. make sure the numbers are aligned [Figure 70-100-45].
A220 Bobcat Loader
70-100-13 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-48
Assembly (Cont'd)
Figure 70-100-46
CD-15565
Put sealing compound on the front cover sealing surface
CD-15563 [Figure 70-100-48].
NOTE: Make sure the camshaft/centrifugal governor
Tighten the connecting rod bolts as follows [Figure 70- connecting is clean and free of oil.
100-46]:
Initial Torque . . . . . . . . . . . . . . . . . . . .22 ft.-lbs. (30 Nm) Figure 70-100-49
1st Step Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
2nd Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
Figure 70-100-47
CD-15566
Install the front cover with the new shaft seals on the
engine block [Figure 70-100-49].
CD-15564 NOTE: Make sure the oil pan sealing surface on the
front cover aligns with the sealing surface on
the block [Figure 70-100-49].
Check that the connecting rods can be easily moved
back and forth on the crank pin [Figure 70-100-47].
A220 Bobcat Loader
70-100-14 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-52
Assembly (Cont'd)
Figure 70-100-50
CD-15468
Install the camshaft gear [Figure 70-100-52].
CD-15567
Make sure all mating surfaces are clean and free of oil.
Tighten the front cover bolts to 15 ft.-lbs. (21 Nm) torque Install the camshaft bolt [Figure 70-100-52].
[Figure 70-100-50].
Figure 70-100-53
Figure 70-100-51
CD-15469
CD-15568
Tighten the camshaft bolt finger tight only [Figure 70-
Install the crankshaft gear on the crankshaft [Figure 70- 100-53]. Camshaft gear must still turn freely.
100-51]. Make sure the mating surfaces are clean and
free of oil.
Install the bolt and tighten to 243-295 ft.-lbs. (330-400
Nm) torque.
A220 Bobcat Loader
70-100-15 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-56
Assembly (Cont'd)
Figure 70-100-54
CD-15472
Tighten the oil pump bolts to 16 ft.-lbs. (22 Nm) torque
CD-15470 [Figure 70-100-56].
Install the engine timing belt. (See Timing Belt Installation
Install a new gasket on the oil pump [Figure 70-100-54]. on Page 70-70-17.)
Figure 70-100-55 Figure 70-100-57
CD-15471 CD-15473
Install the oil pump on the engine block [Figure 70-100- Put spacers on sealing surface of the engine block and
55]. set dial indicator gauge to 0 [Figure 70-100-57]. (See
Deutz Engine Tools Identification Chart on Page 70-100-
1.)
A220 Bobcat Loader
70-100-16 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-60
Assembly (Cont'd)
Figure 70-100-58
CD-15475
Compare the measurements with the specifications to
CD-15474 determine the correct cylinder head gasket [Figure 70-
100-60].
Position the dial gauge on the piston [Figure 70-100-58]. Piston Projection Marking of Cylinder
Head Gasket
Figure 70-100-59 0.023-0.027 inch. (0,59-0,69 mm) . . . . . . . . . . .1 Notch
0.027-0.030 inch. (0,69-0,76 mm). . . . . . . . . 2 Notches
0.030-0.033 inch. (0,76-0,83 mm) . . . . . . . .. . 3 Notches
1
Figure 70-100-61
B-14695
Measure at the gauge points (Item 1) [Figure 70-100-
59].
To determine maximum piston projection measure all the CD-15476
pistons.
Make sure the dowel pins are installed in the engine
block [Figure 70-100-61].
A220 Bobcat Loader
70-100-17 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-64
Assembly (Cont'd) 8 6 4 5 9
Figure 70-100-62 10 3 1 2 7
CD-15479
Tighten the cylinder head bolts to the correct torque in
CD-15477 the correct sequence [Figure 70-100-64].
Initial Torque . . . . . . . . . . . . . . . . . . . .22 ft.-lbs. (80 Nm)
Install the cylinder head gasket [Figure 70-100-62]. 1st Stage Torque. . . . . . . . . . . . . . . . 59 ft.-lbs. (80 Nm)
Gasket is marked TOP. 2nd Stage Torque . . . . . . . . . . . . . 118 ft.-lbs. (160 Nm)
3rd Stage Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90°
Make sure the sealing surfaces of the cylinder head
gasket is free of oil.
Figure 70-100-65
Install the cylinder head.
Figure 70-100-63
CD-15480
CD-15478 Install the push rods [Figure 70-100-65].
Measure the cylinder head bolts.
Std. Length . . . . . . . . 5.90 ± 0.03 inch. (150 ± 0,8 mm)
Put a light coat of oil on the head bolts [Figure 70-100-
63].
Install the head bolts.
A220 Bobcat Loader
70-100-18 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-68
Assembly (Cont'd)
Figure 70-100-66
CD-15483
Install the valve cover gasket [Figure 70-100-68]. Install
CD-15481 the valve cover. Tighten the bolts to 75 in.-lbs. (8,5 Nm)
torque.
Install the rocker arms/bracket assembly [Figure 70-100- Install new intake manifold gasket.
66].
Install the intake manifold and tighten the bolts to 15 ft.-
Figure 70-100-67 lbs. (20 Nm) torque.
Install new exhaust manifold gaskets.
Install the exhaust manifold and tighten the bolts to 30 ft.-
lbs. (40 Nm) torque.
Figure 70-100-69
CD-15482
Tighten the rocker arm bracket bolts to 15 ft.-lbs. (21 Nm)
torque [Figure 70-100-67].
Set the valve clearance. (See Valve Seats, Checking on
Page 70-100-41.)
CD-15484
Install a new seal on the fuel lift pump [Figure 70-100-
69].
A220 Bobcat Loader
70-100-19 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-72
Assembly (Cont'd)
Figure 70-100-70
CD-15487
Tighten the lift pump bolts to 15 ft.-lbs. (21 Nm) torque
CD-15485 [Figure 70-100-72].
Install a new oil filter.
Turn the camshaft so the fuel lift pump lobe is at B.D.C.
(bottom dead center) [Figure 70-100-70]. Install the fuel injectors. (See Fuel Injector Assembly on
Page 70-70-13.)
Figure 70-100-71
Install the fuel injector pumps. (See Fuel Injection Pump
Installation on Page 70-70-8.)
Figure 70-100-73
CD-15486
Install the fuel lift pump [Figure 70-100-71].
CD-15488
Put sealing compound on the sealing surface of the oil
suction pipe [Figure 70-100-73].
A220 Bobcat Loader
70-100-20 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-76
Assembly (Cont'd)
Figure 70-100-74
B-14696
Initially install the corner bolts first and tighten to 5 in.-lbs.
CD-15489 (0,5 Nm) torque.
Install the oil pan bolts and tighten to 15 ft.-lbs. (21 Nm)
Install the oil suction pipe and tighten the bolts to 16 ft.- torque as shown in the Figure [Figure 70-100-76].
lbs. (22 Nm) torque [Figure 70-100-74].
Install the oil pan plug and tighten to 40 ft.-lbs. (55 Nm)
Figure 70-100-75 torque.
Install the flywheel. (See Flywheel Removal And
Installation on Page 70-90-1.)
Install the turbocharger. (See Turbo Charger Removal
and Installation on Page 70-100-59.)
Install the starter. (See Removal And Installation on Page
60-40-1 [NIPPONDENSO] or See Removal And
Installation on Page 60-41-1 [VALEO])
Install the alternator. (See Removal And Installation on
Page 60-30-4.)
CD-15490
Put sealing compound on the sealing surface of the oil
pan [Figure 70-100-75].
Install the oil pan
A220 Bobcat Loader
70-100-21 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-79
Cylinder, Checking
Figure 70-100-77 b 1
2
a 1 2
B-14697
Check the cylinders with engine block longitudinal (a)
CD-15319 and transverse (b) axis and in three planes [Figure 70-
100-79].
Clean the engine block and inspect for damage. Specifications:
Install the main bearing caps [Figure 70-100-77]. Cylinder Bore . . . . . . . . . . . . . . . . . .3.58 + 0.0008 inch.
(91 + 0,02 mm)
Tighten the main bearing cap bolts as follows: Wear Limit . . . . . . . . . . . . . . . . . . . 3.59 inch. (91,1 mm)
Initial Torque . . . . . . . . . . . . . . . . . . . .37 ft.-lbs. (50 Nm)
1st Stage Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
Camshaft Bearing, Checking
2nd Stage Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Figure 70-100-80
Figure 70-100-78
b
a
1 2
B-14698
Check the camshaft bearing bushings at points (1) and
CD-15421 (2) in the planes of (a) and (b) [Figure 70-100-80].
Using a dial indicator gauge check the cylinders [Figure
70-100-78].
A220 Bobcat Loader
70-100-22 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-83
Camshaft Bearing, Checking (Cont’d)
0.098±0.012 inch
0.019±0.012 inch
4.681±0.012inch
(228.1±0,3 mm)
(117.1±0,3 mm)
(118.9± 0,3mm)
4.61±0.012 inch
8.98±0.012 inch
Figure 70-100-81
(0.5±0,3 mm)
(25±0,3mm)
0
0
A B
B-14699
Use the dimensions in figure [Figure 70-100-83] to install
CD-15350 the camshaft bushings.
Figure 70-100-84
Check the camshaft bushings using a gauge [Figure 70-
100-81].
Inner Diameter . . . . . . . . . . . . . . . . . . 2.126 + 0.002 inch.
(54 + 0,054 mm)
Wear Limit . . . . . . . . . . . . . . . . . 2.129 inch. (54,08 mm)
Camshaft Bearing, Removal And Installation
Figure 70-100-82
CD-15383
When installing the new camshaft bushings make sure
the oil lube hole aligns with the oil hole in the engine
block [Figure 70-100-84].
CD-15361
Remove all the camshaft bearing bushings using a
camshaft bushing removal tool as needed [Figure 70-
100-82].
A220 Bobcat Loader
70-100-23 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-87
Camshaft Bearing Removal And Installation (Cont'd)
Figure 70-100-85
CD-15411
Remove the control rod and spring [Figure 70-100-87].
CD-15404
Figure 70-100-88
Install the new camshaft bushings using a camshaft
bushing installation tool [Figure 70-100-85].
Control Rod Guide Bushing Removal
Figure 70-100-86
CD-15412
Remove the cover [Figure 70-100-88].
CD-15409
Remove the parallel pin [Figure 70-100-86].
A220 Bobcat Loader
70-100-24 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-91
Control Rod Guide Bushing Removal (Cont'd)
Figure 70-100-89
CD-15415
Install the spacer tool in position. Pull the pipe from the
CD-15413 lower press fit [Figure 70-100-91].
NOTE: Do Not pull pipe completely out.
Drill a 7/32 inch (5,5 mm) hole on one side of the pipe
[Figure 70-100-89]. Remove the spacer tool.
NOTE: Carefully clean the engine block after drilling. Figure 70-100-92
Figure 70-100-90
CD-15416
CD-15414
Press pin in until it does not project beyond the pipe
[Figure 70-100-92]. Pull the pipe out completely.
Install the puller into the bore until the pin engages
[Figure 70-100-90].
A220 Bobcat Loader
70-100-25 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-95
Control Rod Guide Bushing Removal (Cont'd)
Figure 70-100-93
CD-15419
Install the guide on the arbor assembly with the chamfer
CD-15417 pointing toward the crankcase [Figure 70-100-95].
Figure 70-100-96
Using the tool, drive the guide bushing out [Figure 70-
100-93].
Control Rod Guide Bushing Installation
Figure 70-100-94
CD-15420
Fasten the arbor assembly and bushing on the engine
block [Figure 70-100-96].
CD-15418
Install the new bushing into the center of the arbor
assembly [Figure 70-100-94].
A220 Bobcat Loader
70-100-26 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-99
Control Rod Guide Bushing Installation (Cont'd)
Figure 70-100-97
CD-15424
Remove the guide bushing at the flywheel end of the
CD-15422 engine block [Figure 70-100-99].
Figure 70-100-100
Drive the bushing into the engine block as far as it will go
[Figure 70-100-97].
Figure 70-100-98
CD-15425
Assemble the arbor without the spacer [Figure 70-100-
CD-15423 100].
Remove the arbor assembly [Figure 70-100-98].
A220 Bobcat Loader
70-100-27 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-103
Control Rod Guide Bushing Installation (Cont'd)
Figure 70-100-101
CD-15428
Drive in the guide bushing as far as it will go, at the
CD-15426 flywheel end [Figure 70-100-103].
Figure 70-100-104
Install the guide bushing on the arbor assembly with the
chamfer pointing toward the crankcase [Figure 70-100-
101].
Figure 70-100-102
CD-15429
Remove the arbor assembly [Figure 70-100-104].
CD-15427
Fasten the arbor assembly and guide bushing to the
engine block [Figure 70-100-102].
A220 Bobcat Loader
70-100-28 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-107
Control Rod Guide Bushing Installation (Cont'd)
Figure 70-100-105
CD-15432
Install the new cover flush with the engine block [Figure
CD-15430 70-100-107].
Figure 70-100-108
Install the new pipe in the block as far as it will go with the
arbor assembly [Figure 70-100-105].
Figure 70-100-106
CD-15433
Install the control rod with starter spring into the guide
CD-15431 bushings [Figure 70-100-108].
Put sealing compound on the new cover [Figure 70-100-
106].
A220 Bobcat Loader
70-100-29 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-111
Control Rod Guide Bushing Installation (Cont'd)
Figure 70-100-109
CD-15439
Clean the seal seating surface [Figure 70-100-111].
CD-15434 Inspect the cover for damage, replace as needed.
Figure 70-100-112
Compress the starter spring. Install the parallel pin into
the recess for the control rod travel limitation [Figure 70-
100-109].
0.803±0.008 inch
(20.4±0,2 mm)
Check to make sure it is flush with the surface.
Rear Cover Seal Removal And Installation
Figure 70-100-110
B-14700
When installing the new shaft seal, use the dimension
shown in Figure [Figure 70-100-112].
CD-15438
Remove the rear cover shaft seal [Figure 70-100-110].
A220 Bobcat Loader
70-100-30 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Crankshaft, Checking
Rear Cover Seal Removal And Installation (Cont'd) Figure 70-100-114
Figure 70-100-113
CD-15443
CD-15441
Put the crankshaft on v-blocks.
Use the seal driver tool and install to the correct depth Check the main bearing journals:
[Figure 70-100-113]. (See Deutz Engine Tools
Identification Chart on Page 70-100-1.) Specifications:
Journal Diameter 2.7538 - 2.7546 inch.
(69,97 - 69,99 mm)
Each Undersize 0.010 inch. (0,25 mm)
Undersize Limit 2.7348 - 2.7356 inch.
(69.48 - 69,50 mm)
Check the thrust bearing width [Figure 70-100-114].
Specifications:
Journal Width . . . . . . . . . . . . . . . . 1.378 + 0.0016 inch.
(35 + 0,04 mm)
Wear Limit . . . . . . . . . . . . . . . . . . . 3.59 inch. (91,1 mm)
Journal Width
Each Oversize . . . . . . . . . . . . . .1.395 inch. (35,44 mm)
A220 Bobcat Loader
70-100-31 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-117
Crankshaft, Checking (Cont’d)
Figure 70-100-115
CD-15446
Check the surface of the crankshaft seal area [Figure
CD-15444 70-100-117].
Recondition the crankshaft as needed.
Check the connecting rod journals [Figure 70-100-115].
Specifications:
Pin Diameter . . . . . . . . . . . . . . . . . 2.1588 - 2.1596 inch.)
(54,97 - 54,99 mm)
Undersize Limit . . . . . . . . . . . . . . 2.1448 - 2.1456 inch.)
(54,47 - 54,49 mm)
Wear Limit . . . . . . . . . . . . . . . . . . 0.0004 inch. (0,1 mm)
Figure 70-100-116
CD-15445
Use a dial indicator and check crankshaft for out of
roundness [Figure 70-100-116].
Specifications:
Out of Roundness Max. . . . . . . . 0.002 inch. (0,05 mm)
A220 Bobcat Loader
70-100-32 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-120
Connecting Rod, Checking
Figure 70-100-118
b
a
1 2
CD-15448
Replace small end bushing as needed [Figure 70-100-
B-14701 120].
Bore for Small End Bushing . . . . .1..299 + 0.0008 inch.
When checking the connecting rod large and small end, (33 + 0,02 mm)
measure at the points (1) and (2) and in planes (a) and O.D. of Small End Bushing . . . . . .1..3017 - 1.303 inch.
(b) [Figure 70-100-118]. (33,07 - 33,11 mm)
Figure 70-100-119
Figure 70-100-121
CD-15447
CD-15449
Check the small end bushing [Figure 70-100-119].
Press in the small end bushing, make sure the lubrication
Specifications: holes are in alignment [Figure 70-100-121].
I.D. of Small End Bushing . . . . . . . 1.181 inch. (30 mm)
Wear Limit Bushing Clearance . . 0.003 inch. (0,08 mm)
A220 Bobcat Loader
70-100-33 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-124
Connecting Rod, Checking (Cont'd)
Figure 70-100-122
CD-15452
Tighten the connecting rod cap nuts as follows [Figure
CD-15450 70-100-124].
Initial Torque . . . . . . . . . . . . . . . . . . . .22 ft.-lbs. (30 Nm)
After pressing in the small end bushing, bore the bushing 1st Step Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
to the following dimensions [Figure 70-100-122]. 2nd Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
Specifications:
I.D. of Small End Bushing . . . . . . . 1.181 inch. (30 mm)
Figure 70-100-123
2908 2908
CD-15451
Install the correct cap on the correct rod [Figure 70-100-
123].
A220 Bobcat Loader
70-100-34 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Piston, Checking
Connecting Rod, Checking (Cont'd) Figure 70-100-126
Figure 70-100-125
B-8194
CD-15454
Remove the piston rings from the piston [Figure 70-100-
126].
Measure the big end bore [Figure 70-100-125]. If the
measurement is the same as the specific valve, the Remove the piston from the connecting rod.
necessary preload on the bearing halves will be
obtained. (See Connecting Rod, Checking on Page 70-100-33.) to
check connecting rod specifications.
Specifications:
Big End I.D. . . . . . . . . . . . . . . . . . . . . 2.303 + 0.0008 inch Figure 70-100-127
(58,5 + 0,02 mm)
Remove connecting rod cap. Install new bearing halves.
Tighten the connecting rod cap nuts and tighten as listed
above.
Measure the bearing halves:
Big End Bearing I.D. . . . . . . . . . . . 2.1655 - 2.167 inch.
(55,004 - 55,04 mm)
Each Undersize . . . . . . . . . . . . . 0.010 inch. (0,25 mm)
Limit For Undersize . . . . . . . . . . . . . 2.148-2.1472 inch.
(54,504 - 54,54 mm)
Radial Clearance B-8231
Wear Limit . . . . . . . . . . . . . . . . . 0.005 inch. (0,12 mm)
Check the connecting rod, without bearing halves, on a Clean and inspect piston and piston ring grooves [Figure
connecting rod tester. 70-100-127].
Specifications:
Parrallel Check-Tolerance . . . . . . 0.004 inch. (0,10 mm)
Over a Distance of . . . . . . . . . . . . . 3.94 inch. (100 mm)
Squareness Check-Tolerance . . 0.002 inch. (0,05 mm)
A220 Bobcat Loader
70-100-35 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-129
Piston Pin, Checking
Figure 70-100-128
B-8228
Using new rings, measure the ring grooves using a feeler
B-8229 gauge [Figure 70-100-129].
Specifications:
Measure the ring gap with a feeler gauge in the cylinder
[Figure 70-100-128]. Wear Limit
1st Ring . . . . . . . . . . . . . . . . . . . . 0.008 inch. (0,2 mm)
Specifications: 2nd Ring . . . . . . . . . . . . . . . . . . . . 0.006 inch. (0,16 mm)
Wear Limit 3rd Ring . . . . . . . . . . . . . . . . . . . . . 0.005 inch. (0,12 mm)
1st Ring Gap . . . . . . . . 0.012-0.020 inch. (0,3-0,5 mm)
Figure 70-100-130
2nd Ring Gap . . . . . . . . 0.031-0.039 inch. (0,8-1,0 mm)
3rd Ring Gap . . . . . . 0.018-0.028 inch. (0,45-0,7 mm)
B-8230
Check piston pin for wear [Figure 70-100-130].
Specifications:
Pin Pin O.D. . . . . .1.118-0.0002 inch. (30,0-0,005 mm)
A220 Bobcat Loader
70-100-36 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-133
Piston Rings Installation
Figure 70-100-131 1
3
TS-1928A
lst Ring - Is a double tapered ring, (Item 1) [Figure 70-
B-8194 100-132] & [Figure 70-100-133]. It is installed on the
piston with the mark TOP facing the combustion
chamber.
When installing the piston rings position them as listed
below [Figure 70-100-131]. 2nd Ring - Is a rectangular ring, (Item 2) [Figure 70-100-
132] on earlier model loaders, or an inside tapered ring
Figure 70-100-132 (Item 2) [Figure 70-100-133] which is installed on the
piston with the mark TOP facing the combustion chamber
[Figure 70-100-133], on later model loaders.
3rd Ring - Is a bevelled edge slotted oil control ring (Item
1 3) [Figure 70-100-132] & [Figure 70-100-133].
2 The gap of each ring must be offset by 180° to the other
ring.
NOTE: Check the piston rings that are installed on
your loaders engine before ordering new ring
sets from Bobcat Parts, to insure proper fit.
3
TS-1927
A220 Bobcat Loader
70-100-37 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-136
Piston Installation On The Connecting Rod
Figure 70-100-134
CD-15458
Install the piston on the connecting rod [Figure 70-100-
CD-15456 136].
Install the snap ring into the piston [Figure 70-100-134].
Figure 70-100-135
CD-15457
NOTE: The snap ring gap must be towards the piston
crown (Item 1) [Figure 70-100-135].
A220 Bobcat Loader
70-100-38 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-139
Piston Installation On The Connecting Rod (Cont'd)
1
Figure 70-100-137
3
P13908
The flywheel symbol (Item 1) [Figure 70-100-137] &
N-19068 [Figure 70-100-139] on the piston must point toward the
flywheel (Item 3) [Figure 70-100-139], when properly
installed on the connecting rod.
Figure 70-100-138
The numbers on the connecting rod and cap (Item 1)
[Figure 70-100-138] & (Item 2) [Figure 70-100-139]
point toward the camshaft side of the engine when being
install in the engine block.
Figure 70-100-140
2908 2908
CD-15451
CD-15459
Install the other side snap ring [Figure 70-100-140].
A220 Bobcat Loader
70-100-39 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Valves, Checking
Cylinder Head Disassembly Figure 70-100-142
Figure 70-100-141
B-8205
CD-15461
Measure the valve stem clearance [Figure 70-100-142].
NOTE: Do not grind the cylinder head surface, if its Specifications:
damaged, replace the cylinder head.
Wear Limit
Using a valve spring tool, remove the spring locks, valve Intake Valve . . . . . . . . . . . . . . . . 0.005 inch. (0,12 mm)
spring cap, valve spring and valve [Figure 70-100-141]. Exhaust Valve . . . . . . . . . . . . . . . . 0.006 inch. (0,15 mm)
(See Deutz Engine Tools Identification Chart on Page 70-
100-1.) Figure 70-100-143
Repeat the procedure for all the valves.
Remove the valve seals.
Clean the cylinder head and inspect for damage.
B-8204
Measure the valve stem diameter [Figure 70-100-143].
Std. Intake Valve . . . . . . . . . . . . . . . 0.314-0.0006 inch.
(7,98-0,015 mm)
Std. Exhaust Valve . . . . . . . . . . . . . . . 0.313-0.0006 inch.
(7,96-0,015 mm)
A220 Bobcat Loader
70-100-40 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-145
Valves, Checking (Cont’d)
Figure 70-100-144
Angle
CD-15463
Diameter Thickness
Measure the valve seat width [Figure 70-100-145].
B-8202
Specifications:
Width (Intake) . . . . 0.062 ± 0.016 inch. (1,58 ± 0,4 mm)
Measure the valve rim thickness [Figure 70-100-144].
(Exhaust) . . . . . . 0.067 ± 0.016 inch. (1,7 ± 0,4 mm)
Specifications:
Valve Seats, Checking
Intake Valve . . . . . . . . . . . . . . . . . 0.055 inch. (1,4 mm)
Exhaust Valve . . . . . . . . . . . . . . . . . . 0.05 inch. (1,2 mm) Figure 70-100-146
Measure the valve head diameter [Figure 70-100-144].
Specifications (BF4M1011):
Intake Valve . . . . . .1.579 ± 0.004 inch (40,1 ± 0,1 mm)
Exhaust Valve . . .1.374 ± 0.004 inch. (34,9 ± 0,01 mm)
Specifications (BF4M1011F):
Intake Valve . . . . . .1.594 ± 0.004 inch (40,5 ± 0,1 mm)
Exhaust Valve . . .1.374 ± 0.004 inch. (34,9 ± 0,01 mm)
Valve seat angle [Figure 70-100-144].
Specifications: CD-15464
Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30°
Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Measure the valve clearance between the valve head
and cylinder head sealing surface [Figure 70-100-146].
Valve penetration into cylinder head:
Specifications:
Wear Limit . . . . 0.0512 ± 0.0051 inch. (1,3 ± 0,13 mm)
A220 Bobcat Loader
70-100-41 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-149
Valve Spring, Checking
Figure 70-100-147
Inclination
Free Length
CD-15323
Square Install the valve seal on the protective sleeve and push
B-8208 the seal down [Figure 70-100-149].
Remove the protective sleeve.
Measure valve spring free length [Figure 70-100-147]
Figure 70-100-150
Specifications:
Valve Spring Diameter . . . . . . . . 0.132 inch. (3,35 mm)
Free Length . . . . . . . . . . . . . . . . . 1.74 inch. (44,3 mm)
Valve Spring Diameter . . . . . . . . 0.134 inch. (3,40 mm)
Free Length . . . . . . . . . . . . . . . . . 1.547 inch. (39,3 mm)
Inclination . . . . . . . . . . . . . . . . . . . . 0.126 inch. (3,2 mm)
Cylinder Head Assembly
Figure 70-100-148
CD-15324
Use the tool and press the valve stem as far as it will go
[Figure 70-100-150]. (See Deutz Engine Tools
Identification Chart on Page 70-100-1.)
CD-15322
Install the valve into the cylinder head [Figure 70-100-
148].
Install the protective sleeve or masking tape on the valve
stem grooves [Figure 70-100-148].
A220 Bobcat Loader
70-100-42 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Rocker Arm And Bracket, Checking
Cylinder Head Assembly (Cont'd) Figure 70-100-153
Figure 70-100-151
CD-15327
CD-15325
Disassemble the rocker arms from the bracket [Figure
70-100-153].
Install the valve spring and cap [Figure 70-100-151].
Figure 70-100-154
Figure 70-100-152
CD-15328
CD-15461
Check for wear at the following locations and replace as
Use the valve spring tool, install the valve spring tool needed [Figure 70-100-154]:
[Figure 70-100-152].
Journals
Repeat the above procedure to install all the valves. Adjusting Bolt
Rocker Arm Contact Face
Bore
A220 Bobcat Loader
70-100-43 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Front Cover Disassembly
Rocker Arm And Bracket, Checking (Cont’d) NOTE: Dynamometer testing is recommended if the
governor assembly is re-built.
Figure 70-100-155
Figure 70-100-157
CD-15330
CD-15343
Check the oil passages that they are open and clean
[Figure 70-100-155]. Remove the engine shut-down solenoid [Figure 70-100-
157].
Figure 70-100-156
Figure 70-100-158
CD-15331
CD-15344
Install the rocker arms on the bracket.
Disconnect the governor spring [Figure 70-100-158].
Install the snap ring [Figure 70-100-156].
A220 Bobcat Loader
70-100-44 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-161
Front Cover Disassembly (Cont’d)
Figure 70-100-159
1
CD-15347
Remove the centrifugal governor [Figure 70-100-161].
CD-15345
Figure 70-100-162
Mark the governor lever shaft (Item 1) [Figure 70-100-
159] for proper installation.
Remove the governor lever shaft.
Figure 70-100-160
CD-15348
Remove the camshaft seal [Figure 70-100-162].
Figure 70-100-163
CD-15346
Remove the shims below the governor lever shaft
[Figure 70-100-160].
CD-15349
Remove the crankshaft seal [Figure 70-100-163].
A220 Bobcat Loader
70-100-45 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-166
Front Cover Disassembly (Cont’d)
Figure 70-100-164
CD-15353
Remove the shut-down lever with spacer bushings
CD-15351 [Figure 70-100-166].
Figure 70-100-167
Disconnect the spring [Figure 70-100-164].
Figure 70-100-165
CD-15354
CD-15352 Remove the shaft, spacer bushing and spring [Figure
70-100-167].
Remove the dowel pin [Figure 70-100-165].
A220 Bobcat Loader
70-100-46 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-170
Front Cover Disassembly (Cont'd)
Figure 70-100-168
CD-15357
Remove the dowel pin [Figure 70-100-170].
CD-15355
Figure 70-100-171
Remove the O-ring [Figure 70-100-168].
Figure 70-100-169
CD-15358
Remove the pin from the lever [Figure 70-100-171].
CD-15356
Do not damage the cover sealing surface.
Remove the cover [Figure 70-100-169].
A220 Bobcat Loader
70-100-47 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-174
Front Cover Disassembly (Cont'd)
Figure 70-100-172
CD-15373
Before removing the torque control assembly, measure
CD-15359 the height from the cover [Figure 70-100-174] and make
a record of this for assembly.
Remove the speed control lever and spacer bushing Figure 70-100-175
[Figure 70-100-172].
Figure 70-100-173
CD-15363
CD-15360 Remove the nut and clamp [Figure 70-100-175].
Remove the torque control assembly.
Remove the O-ring [Figure 70-100-173].
A220 Bobcat Loader
70-100-48 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Front Cover Assembly
Front Cover Disassembly (Cont'd) Figure 70-100-177
Figure 70-100-176
CD-15365
CD-15364
Inspect the front cover for damage [Figure 70-100-177].
Remove the breather vent [Figure 70-100-176]. Replace the front cover as needed.
NOTE: On later model Deutz engines the breather is Figure 70-100-178
located in the valve cover. The breather vent
shown in photo [Figure 70-100-176] is used in
both engines.
B-14703
Inspect the individual parts of the torque control
assembly [Figure 70-100-178].
Replace the parts as needed.
A220 Bobcat Loader
70-100-49 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-181
Front Cover Assembly (Cont'd)
Figure 70-100-179
2
1 3
6
CD-15373
1-1.5 Turns
5 4
Install the torque control assembly to the dimensions
B-14704 taken (See Front Cover Disassembly on Page 70-100-
44.) [Figure 70-100-181] or use the procedure below:
If the torque control was disassembled, do the following Figure 70-100-182
procedure to assemble:
Turn (Item 1) as far as it will go into (Item 2) [Figure 70-
100-179], then unscrew (Item 1) 1to 1.5 turns.
Tighten the lock nut (Item 3) [Figure 70-100-179] to 12
ft.-lbs. (16 Nm) torque.
Turn (Item 4) [Figure 70-100-179] as far as it will go into
(Item 5) [Figure 70-100-179]. Turn back one full turn.
Tighten the lock nut (Item 6) [Figure 70-100-179] to 53
in.-lbs. (6 Nm) torque.
Figure 70-100-180 CD-15374
Measure the thread reach [Figure 70-100-182].
Specifications:
Thread Reach . . . . . . . . . . . . . . . . . . . 0.252 ± 0.019 inch.
(6,4 ± 0,5 mm)
NOTE: Dynamometer testing may be necessary
depending on engine performance.
Install the clamp and nut [Figure 70-100-182].
CD-15371
Install the torque control into the front cover [Figure 70-
100-180].
A220 Bobcat Loader
70-100-50 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-185
Front Cover Assembly (Cont'd)
Figure 70-100-183
CD-15377
Do Not put oil on the crankshaft seal.
CD-15375
Press the crankshaft seal into the front cover [Figure 70-
100-185].
Tighten the clamp nut to 88 in.-lbs. (10 Nm) torque
[Figure 70-100-183]. Figure 70-100-186
Figure 70-100-184 0.236± 0.039 inch
(6 ± 1mm)
B-14705
CD-15376
Adjust the distance of the shut-down stop screw to 0.236
± 0.039 inch (6 ± 1 mm) [Figure 70-100-186].
Put a light coat of oil on the camshaft seal.
Tighten the lock nut to 40 in.-lbs. (4,5 Nm) torque.
Press the camshaft seal into the front cover [Figure 70-
100-184]. (See Deutz Engine Tools Identification Chart
on Page 70-100-1.)
A220 Bobcat Loader
70-100-51 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-189
Front Cover Assembly (Cont'd)
Figure 70-100-187
0.79±0.039 inch
(20±1 mm)
B-14707
Install the shut down shaft [Figure 70-100-189].
-
B-14706
Figure 70-100-190
Adjust the minimum speed screw to 0.79 + 0.039 inch (20
± 1,0 mm) [Figure 70-100-187].
Tighten the lock nut to 40 in.-lbs. (4.5 Nm) torque.
Figure 70-100-188
CD-15382
Put grease on the O-ring and install on the shaft [Figure
70-100-190].
CD-15380
Install the spacer bushing and spring on the shut down
shaft [Figure 70-100-188].
A220 Bobcat Loader
70-100-52 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-193
Front Cover Assembly (Cont'd)
Figure 70-100-191
CD-15386
Put grease on the O-ring and install in the front cover
CD-15384 [Figure 70-100-193].
Figure 70-100-194
Install the spacer bushing [Figure 70-100-191].
Figure 70-100-192
CD-15387
CD-15385 Install the spacer bushing on the speed control lever
[Figure 70-100-194].
Install the shut down lever and dowel pin [Figure 70-100- Install the speed control lever into the front cover [Figure
192]. 70-100-194].
A220 Bobcat Loader
70-100-53 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-197
Front Cover Assembly (Cont'd)
Figure 70-100-195
CD-15390
Drive the pin into the lever [Figure 70-100-197].
B-14708
The groove in the speed control shaft must be in line with
the dowel pin bore.
When installing the speed control lever, make sure it is
installed in the correct direction [Figure 70-100-195]. Figure 70-100-198
Figure 70-100-196
CD-15391
CD-15389
Inspect the centrifugal governor for wear [Figure 70-100-
198]. Replace as needed.
Install the dowel pin into the speed control lever [Figure
70-100-196].
A220 Bobcat Loader
70-100-54 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-201
Front Cover Assembly (Cont'd)
Figure 70-100-199
CD-15394
Install centrifugal governor assembly into the front cover
CD-15392 [Figure 70-100-201].
Be careful not to damage the shaft seal.
Inspect the governor plate for wear [Figure 70-100-199].
Figure 70-100-202
Replace as needed.
Figure 70-100-200
CD-15395
CD-15393 Inspect roller lever, shaft and idling lever wear [Figure
70-100-202].
Assemble the governor plate with the centrifugal Replace the parts as needed.
governor [Figure 70-100-200].
A220 Bobcat Loader
70-100-55 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-205
Front Cover Assembly (Cont'd)
Figure 70-100-203
1
CD-15398
Measure the ball bearing (Item 1) [Figure 70-100-205],
CD-15396 by lightly pressing the roller lever.
Set the dial gauge to zero.
Install shims of at least 0.011 inch (0,3 mm) thickness at
points (Items 1 & 2) [Figure 70-100-203]. Figure 70-100-206
Figure 70-100-204
CD-15399
CD-15397
Place dial indicator on ball bearing (Item 1) [Figure 70-
100-206].
Install the governor lever shaft without the idling lever
[Figure 70-100-204]. Tighten the bolts to 81 in.-lbs. (9,2 Make record of the two readings.
Nm) torque.
The required tolerance is 0.0019 inch (0,05 mm).
NOTE: The longer space (Item 1) [Figure 70-100-204]
on the governor lever shaft goes toward the It is possible to install extra shims at (Items 1 & 2)
cover when being installed. [Figure 70-100-203] to get the required measurement.
A220 Bobcat Loader
70-100-56 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-209
Front Cover Assembly (Cont'd)
Figure 70-100-207
CD-15402
Connect the governor spring [Figure 70-100-209].
CD-15400
Figure 70-100-210
Assemble the roller lever with the idling lever and shaft
[Figure 70-100-207].
Figure 70-100-208
N-18859
CD-15403
Install the cover with new gasket. Tighten the bolts to 40
in-lbs. (4,5 Nm) torque [Figure 70-100-210].
CD-15401
Install the complete governor lever shaft assembly into
the front cover.
Tighten the bolts to 81 in.-lbs. (9,2 Nm) torque [Figure
70-100-208].
NOTE: The longer space (Item 1) [Figure 70-100-208]
on the governor lever shaft goes down toward
the cover when installed.
A220 Bobcat Loader
70-100-57 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-213
Front Cover Assembly (Cont'd)
Figure 70-100-211
CD-15407
Install new O-ring on the breather vent [Figure 70-100-
CD-15405 213].
Figure 70-100-214
Install a greased O-ring on the shut down solenoid
[Figure 70-100-211].
Figure 70-100-212
CD-15408
Install the breather vent into the front cover. Tighten the
CD-15406 bolts to 75 in.-lbs. (8,5 Nm) torque [Figure 70-100-214].
Install the shut down solenoid into the front cover [Figure
70-100-212].
Tighten the bolts to 79 in.-lbs. (9 Nm) torque.
A220 Bobcat Loader
70-100-58 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-216
Turbo Charger Removal and Installation
Figure 70-100-215
1
3
4
1
P7779
Disconnect the air cleaner hose (Item 1) [Figure 70-100-
P7780 216], inspect the air intake system.
Remove the oil tubeline (Item 2) [Figure 70-100-216]
Remove the exhaust pipe (Item 1) [Figure 70-100-215]. and clean the inside of the line with solvent or air, to
remove contaminated oil.
A220 Bobcat Loader
70-100-59 Service Manual
RECONDITIONING THE ENGINE (CONT’D) NOTE: In the event of severe engine oil
contamination, drain and flush the engine oil
Turbo Charger Removal and Installation (Cont’d) cooler, cab heater and plumbing.
Figure 70-100-217 Drain the engine oil from the crankcase and replace the
engine oil and filter. (See Replacing Oil And Filter on
Page 10-110-2.)
Start the engine and run at idle until oil pressure is
assured.
Work the unit until operating temperature of engine is
1
maintained for approximately 15 minutes.
Idle and cool the down engine approximately 3 to 4
minutes, and stop the engine.
Drain the engine oil from the crankcase again, replace
the engine oil and filter. (See Replacing Oil And Filter on
Page 10-110-2.)
Re-start engine, check for leaks and performance.
P7343
Remove the oil tubeline (Item 1) [Figure 70-100-217],
clean the inside of the line with solvent or air to remove
contaminated oil.
Remove the exhaust manifold nuts (Item 3) [Figure 70-
100-216].
Installation: Tighten the nuts to 22 ft.-lbs. (30 Nm)
torque.
Remove the hose clamps (Item 4) [Figure 70-100-216].
Remove the turbocharger from the intake manifold hose.
Install the replacement turbo.
A220 Bobcat Loader
70-100-60 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-220
Crankshaft Gear Mounting Bolt Torque Procedure
Figure 70-100-218
P13135
Mark the crankshaft gear mounting bolt (Item 1) [Figure
P5292 70-100-220].
Figure 70-100-221
The tool listed will be needed to do the following
procedure:
MEL1522 Torque Multiplier Support Device
MEL1526 Torque Multiplier 1
If the v-belt pulley is installed, remove the four bolts and
remove the pulley (Item 1) [Figure 70-100-218].
Figure 70-100-219
1
P13136
NOTE: If the torque multiplier tool (Item 1) [Figure 70-
100-221] has a degree wheel, the crankshaft
bolt does not have to be marked.
2
Install the torque multiplier tool (Item 1) [Figure 70-100-
221], with the socket, into the tool.
P13135A
Install the tool (Item 1) [Figure 70-100-219] on the
crankshaft hub using the v-belt pulley bolts.
Install the crankshaft gear mounting bolt (Item 2) [Figure
70-100-219] and tighten to 95 ft.-lbs. (130 Nm) torque.
A220 Bobcat Loader
70-100-61 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Governor Buffer Spring Adjustment
Crankshaft Gear Mounting Bolt Torque Procedure Start the loader and operate until the loader engine is at
(Cont’d) operating temperature.
Figure 70-100-222
WARNING
Engine/heat exchanger & muffler can be hot.
W-2437-0902
Figure 70-100-224
P13137
1
Figure 70-100-223 1
2
P-39119
1
Remove the two mount bolts (Item 1) [Figure 70-100-
224] from the lower timing cover.
Use MEL 1552, torx bit, to remove the torx head bolt from
the timing cover (Item 2) [Figure 70-100-224].
Remove the lower timing belt cover from the engine.
P13135
Tighten the gear bolt 210° (+ or - 10°) [Figure 70-100-
222] & [Figure 70-100-223].
A220 Bobcat Loader
70-100-62 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-227
Governor Buffer Spring Adjustment (Cont’d)
Figure 70-100-225
1
P-39122
Remove the nut (Item 1) [Figure 70-100-227] from the
P-39120 adjustment screw assembly.
Figure 70-100-228
Remove the locking compound (Item 1) [Figure 70-100-
225] from the adjustment screw.
Figure 70-100-226
3
2 1
P-39123
1
Remove the locking plate (Item 1) and spring (Item 2)
P-39121 from the adjustment screw (Item 3) [Figure 70-100-228].
Loosen the nut (Item 1) [Figure 70-100-226] on the
adjustment screw.
With a screw driver, remove the adjustment screw
assembly (Item 2) [Figure 70-100-226] from the front
cover of the engine.
A220 Bobcat Loader
70-100-63 Service Manual
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-231
Governor Buffer Spring Adjustment (Cont’d)
Figure 70-100-229
3
2
1
1
P-39121
Install the spring assembly (Item 1) in the front cover of
P-39124 the engine. Turn the adjustment screw (Item 3) in until
the O-ring on the adjustment screw contacts the front
cover, preventing oil leakage. Adjust the lock nut (Item 2)
Remove the O-ring (Item 1) [Figure 70-100-229] on the [Figure 70-100-231] until it contacts the locking plate.
adjustment screw.
Figure 70-100-232
Figure 70-100-230
1
1
P-39133
P-39122
Start the engine and adjust the low idle adjustment screw
Assemble the governor spring assembly (Item 1) [Figure (Item 1) [Figure 70-100-232] to 30 RPM below
70-100-230]. recommended engine RPM.
A220 Bobcat Loader
70-100-64 Service Manual
RECONDITIONING THE ENGINE (CONT’D)
Governor Buffer Spring Adjustment (Cont’d)
Figure 70-100-233
P-39121
At the governor buffer spring adjustment screw, hold the
lock nut (Item 1) from turning and turn the slotted screw
(Item 2) [Figure 70-100-233] clockwise until the engine
RPM is increased 30 RPM to the normal engine low idle
speed.
Stop the engine.
Secure the adjustment by holding the adjustment screw
(Item 2) and tighten the locking nut (Item 1) [Figure 70-
100-233] against the lock plate.
Start the engine and recheck the engine idle.
Stop the engine.
Install the timing belt cover.
A220 Bobcat Loader
70-100-65 Service Manual
A220 Bobcat Loader
70-100-66 Service Manual
HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SERVICE . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
SAFETY &
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . 80-10-2 MAINTENANCE
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3
Principals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Checking The Electrical System . . . . . . . . . . . . . . . . . . . . 80-50-6
Cleaning The A/C Evaporator Coil & Heater Coil . . . . . . . 80-50-2
Compressor Drive Belt Inspection . . . . . . . . . . . . . . . . . . . 80-50-5 DRIVE
Engine Coolant By-Passing The Heater Valve . . . . . . . . 80-50-13 SYSTEM
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . 80-50-14
Poor A/C Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Receiver/Drier Sight Glass Inspection . . . . . . . . . . . . . . . . 80-50-4
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
ELECTRICAL
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1 SYSTEM &
Compressor Clutch Disassembly. . . . . . . . . . . . . . . . . . . 80-110-2 ANALYSIS
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1 ENGINE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1 SERVICE
EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-190-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-190-1
HVAC
EVAPORATOR/HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . 80-160-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 80-160-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-160-1
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-180-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-180-1
GENERAL AIR CONDITIONING SERVICE GUIDELINES . . . 80-60-1
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
Compressor Oil Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-2
Component Replacement And Refrigeration Leaks. . . . . . 80-60-3
HEATER COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-200-1
Removal And Installation With A/C . . . . . . . . . . . . . . . . . 80-200-1
Removal And Installation Without A/C . . . . . . . . . . . . . . . 80-200-2
Continued on Next Page
A220 Bobcat Loader
80-01-1 Service Manual
HEATING, VENTILATION, AIR CONDITIONING (CONT’D)
HEATER/AC FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-210-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 80-210-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-210-1
Wire Connector Removal And Installation . . . . . . . . . . . . 80-210-4
HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-220-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 80-220-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-220-1
PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1
PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1
RECEIVER/DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
Cleaning The Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-3
Compressor Drive Belt Inspection . . . . . . . . . . . . . . . . . . . 80-40-2
Filter Elements Removal And Installation . . . . . . . . . . . . . 80-40-1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . 80-100-1
Charging Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-5
Charging Procedure With A Manifold Gauge Set . . . . . . 80-100-3
Reclamation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1
SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . 80-70-1
Gauge Pressure Related Troubleshooting. . . . . . . . . . . . . 80-70-2
Troubleshooting Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-4
TEMPERATURE/PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1
A220 Bobcat Loader
80-01-2 Service Manual
A220 Bobcat Loader
80-10-1 Service Manual
AIR CONDITIONING SYSTEM FLOW
Principals
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) See Chart on Page 80-10-3. takes in heated, low pressure refrigerant gas through the suction
valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge
valve (high pressure side) on the condenser (Item 2) See Chart on Page 80-10-3.
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver/drier (Item 3) See Chart on Page 80-10-3. where impurities such as
moisture and dirt are filtered out. The receiver/drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) See Chart on Page 80-10-3.
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) See Chart on Page 80-10-3. As the
refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-
pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the evaporator fan
(Item 6) See Chart on Page 80-10-3. Since the refrigerant is colder than the air, it absorbs the heat from the air and
produces cooled air, which is pushed into the cab by the fan. The moisture in the air condenses on the evaporator coil and
drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.
A220 Bobcat Loader
80-10-2 Service Manual
AIR CONDITIONING SYSTEM FLOW (CONT’D)
Chart
Thermostat
Cold Air
Evaporator
5
Evaporator
4
Expansion Valve
Blower
6
1 Compressor
2 Condenser
Pressure
Switch
Sight
Glass
Fan
Desiccant
3 Receiver Drier
Status Of R134a_______________________________________________
High Pressure Gas Low Pressure Liquid
High Pressure Liquid Low Pressure Gas
B-16691
A220 Bobcat Loader
80-10-3 Service Manual
A220 Bobcat Loader
80-10-4 Service Manual
COMPONENTS Figure 80-20-3
Identification
2
Figure 80-20-1
N-22134
Receiver/Drier: The receiver/drier (Item 1) [Figure 80-20-
P-26890 3] is the unit that receives the liquid refrigerant from the
condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
Compressor: The compressor (Item 1) [Figure 80-20-1] extra liquid refrigerant until it is needed by the evaporator.
is the pump that circulates the refrigerant throughout the
system. It raises the pressure of the refrigerant for heat Figure 80-20-4
transfer through the condenser and evaporator.
NOTE: The A/C system (Compressor) is
recommended to be turned on for at least 5
minutes weekly throughout the year to
lubricate the internal components.
1
Figure 80-20-2
1
N-22206
Pressure Relief Valve: The pressure relief valve (Item 2)
[Figure 80-20-3] is located on the receiver drier
assembly. This small brass valve (Item 1) [Figure 80-20-
4] is a safety feature that is designed to open and release
the A/C charge if the pressure reaches 535 PSI.
N-22266
Condenser: The condenser (Item 1) [Figure 80-20-2] is
the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.
A220 Bobcat Loader
80-20-1 Service Manual
COMPONENTS (CONT’D) Figure 80-20-7
Identification (Cont'd)
Figure 80-20-5
3
1
2 1
N-22087
Evaporator Coil: The evaporator coil (Item 1) [Figure 80-
N-22121 20-7] cools and dehumidifies the air before it enters the
cab.
Heater/Evaporator Unit: The heater/evaporator unit (Item Thermostat: The thermostat (Item 2) [Figure 80-20-7]
1) [Figure 80-20-5] is located behind the loader cab. The controls the temperature of the evaporator coil.
unit delivers the cold air for the A/C and warm air for heat
into the cab. The unit contains the blower, heat & A/C Heater Coil: The heater coil (Item 3) [Figure 80-20-7]
coils, thermostat and expansion valve. supplies the warm air into the cab by passing air through
the coil.
Figure 80-20-6
Figure 80-20-8
N-22150
N-22100
Expansion Valve: The expansion valve (Item 1) [Figure
80-20-6] controls the amount of refrigerant entering the Heater/Evaporator Blower: The blower (Item 1) [Figure
evaporator coil. 80-20-8] is used to push air through the heater and
evaporator coils and into the cab.
A220 Bobcat Loader
80-20-2 Service Manual
COMPONENTS (CONT’D) Figure 80-20-10
Identification (Cont'd)
Figure 80-20-9
1 1
4
N-22149
2
3
Heater Valve: The heater (Item 1) [Figure 80-20-10] is
N-22261 used to control the amount of engine coolant that flows to
the heater coil.
Control Panel: The panel (Item 1) [Figure 80-20-9] has Figure 80-20-11
three separate components.
Fan Switch: This is a four position rotary switch (Item 2)
[Figure 80-20-9]. When the fan switch is in the off 1
position the A/C will not engage, but the heat valve will
operate, as it is controlled by the ignition power.
A/C Switch: The rocker switch (Item 3) [Figure 80-20-9]
will be illuminated when the A/C is engaged.
Potentiometer: The potentiometer (Item 4) [Figure 80-
20-9] controls the Heat Valve from fully Off to fully On.
This can be used in conjunction with the A/C for defrost
of the windows and temperature control.
N-22134
Pressure Switch: The pressure switch (Item 1) [Figure
80-20-11] will disengage the compressor clutch at high
pressure readings over 384 PSI (2647 kPa) on the high
side, or if it senses very low pressure of 28 PSI (193 kPa)
or less on the high side, which indicates loss of
refrigerant.
A220 Bobcat Loader
80-20-3 Service Manual
A220 Bobcat Loader
80-20-4 Service Manual
SAFETY Figure 80-30-2
Safety Equipment
Figure 80-30-1
P16399
R-134a inside a canister or in an A/C system is a liquid
P16398 under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO 21.6 F DEGREES
“INSTANTLY”. If it spills on your skin or in your eyes you
In servicing A/C and heater systems you will be exposed should flood the area with cool water and SEEK
to high pressures, temperatures and several chemical MEDICAL ATTENTION FAST! It is a good idea to wear
hazards. Moving belts and pulleys are normal shop gloves [Figure 80-30-2] to prevent frost bite if you should
hazards get refrigerant on your hands
In addition to exercising caution in your work, DO WEAR
SAFETY GLASSES OR A FACE SHIELD [Figure 80-
30-1] when you are using R-134a or a leak detector,
adjusting service valves or the manifold gage set
connectors. Safety glasses or a transparent face shield
are practical safety items and one or the other is
absolutely required.
A220 Bobcat Loader
80-30-1 Service Manual
A220 Bobcat Loader
80-30-2 Service Manual
REGULAR MAINTENANCE Figure 80-40-3
Filter Elements Removal And Installation
Figure 80-40-1
P-28820
1
Remove the filter (Item 1) [Figure 80-40-3] from the
P-28818 cover.
The fresh air filter must be cleaned sometimes as often
Remove the two mount bolts (Item 1) [Figure 80-40-1] as twice a day, depending on the operating environment.
from the fresh air filter cover at the rear of the loader cab. The filter can be cleaned by removing and shaking it. A
small amount of air pressure can be used to clean the
Figure 80-40-2 filter. However the fresh air filter should be changed at
least 2-4 times per year in normal conditions. In
extremely dusty conditions the fresh air filter may need to
be changed weekly
1
Figure 80-40-4
2
P-28819
1
Remove the filter cover and filter (Item 1) [Figure 80-40-
2] from the loader.
P-28821P-
28821
Remove the two retaining knobs (Item 1) [Figure 80-40-
4] from the recirculating air filter cover, at the back of the
cab.
Remove the retaining cover (Item 2) [Figure 80-40-4]
from the loader cab.
A220 Bobcat Loader
80-40-1 Service Manual
REGULAR MAINTENANCE (CONT’D) Compressor Drive Belt Inspection
Filter Elements Removal And Installation (Cont'd) Figure 80-40-7
Figure 80-40-5
N-23037
P-28822
It is good rule to regularly inspect (weekly) the
compressor drive belt for tension and wear.
Remove the recirculating air filter (Item 1) [Figure 80-40-
5] from the rear of the cab. Open the rear door.
Figure 80-40-6 Check the tension on the compressor belt (Item 1)
[Figure 80-40-7].
N-22274
The recirculating air filter [Figure 80-40-6] is made of
open cell foam and should be cleaned with water. A mild
detergent may also be used. It does not require cleaning
as frequently as the fresh air intake filter.
A220 Bobcat Loader
80-40-2 Service Manual
REGULAR MAINTENANCE (CONT’D) Figure 80-40-10
Cleaning The Condenser
1
Figure 80-40-8
N-23036
2
Rotate the condenser (Item 1) [Figure 80-40-10] up
N-22976 against the right side lift arm.
Slide the hydraulic cooler (Item 2) [Figure 80-40-10]
Open the rear door. toward the rear of the loader.
Raise the rear grill on the loader. Figure 80-40-11
Check the condenser (Item 1) [Figure 80-40-8] for mud
or dirt.
Remove the two retainer clips (Item 2) [Figure 80-40-8] 1
Figure 80-40-9
N-22272
1 With water, or air, the radiator (Item 1) the oil cooler (Item
2) and the condenser (Item 3) [Figure 80-40-11]. can be
cleaned.
N-23035
Lift the condenser, and slide it toward the rear of the
loader until the mounting tabs (Item 1) [Figure 80-40-9]
clear the frame of the loader.
A220 Bobcat Loader
80-40-3 Service Manual
A220 Bobcat Loader
80-40-4 Service Manual
BASIC TROUBLESHOOTING Check the belt tension on the A/C compressor. (See
Compressor Drive Belt Inspection on Page 80-50-5.)
Poor A/C Performance
Check the A/C condenser for dirt or mud and clean if
Figure 80-50-1 necessary. (See Cleaning The Condenser on Page 80-
40-3.)
Check the A/C evaporator coil for dirt or mud and clean if
necessary. (See Cleaning The A/C Evaporator Coil &
Heater Coil on Page 80-50-2.)
Inspect the sight glass located on the receiver/drier for air
bubbles. (See Receiver/Drier Sight Glass Inspection on
Page 80-50-4.)
1
Check the engine coolant to see if it is bypassing the
heater valve. (See Cleaning The A/C Evaporator Coil &
Heater Coil on Page 80-50-2.)
N-22273
Figure 80-50-2
N-22411
Start the loader, lock the park brake, and engage the A/C
system with the blower fan on High. Run the loader at full
throttle for approximately 15 minutes, with the loader cab
door closed.
Check the temperature at the louvers (Item 1) [Figure
80-50-1] with a thermometer [Figure 80-50-2].
The louver temperature should be between 36-53°F.
(2,2-11,6°C) depending on the amount of humidity in the
air.
If louver temperature is too high. (See SYSTEM
TROUBLESHOOTING CHART on Page 80-70-1.)
Check the heater/AC fan for proper operation, or noise,
and replace if necessary.
A220 Bobcat Loader
80-50-1 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 80-50-5
Cleaning The A/C Evaporator Coil & Heater Coil
Figure 80-50-3
1 1
N-22129
Disconnect the blower fan wiring connector (Item 1)
N-22122 [Figure 80-50-5] from the loader wiring harness.
Figure 80-50-6
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
At the rear of the cab, disconnect the thermostat wiring
connector (Item 1) [Figure 80-50-3]. 1
Figure 80-50-4
2 N-22119
Remove the two mounting nuts (Item 1) [Figure 80-50-
6].
N-22130
Remove the mount bolt (Item 1) [Figure 80-50-4] from
the left side cab access cover.
Remove the access cover (Item 2) [Figure 80-50-4] from
the loader.
A220 Bobcat Loader
80-50-2 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 80-50-9
Cleaning The A/C Evaporator Coil & Heater Coil
(Cont'd)
Figure 80-50-7
1 1
N-22124
Remove the two mount bolts (Item 1) [Figure 80-50-9]
from the Evaporator/Heater Unit rear cover.
N-22120
Figure 80-50-10
Remove the two mounting nuts (Item 1) [Figure 80-50-
7].
Figure 80-50-8
1
2
N-22125
1
Remove the three mount bolts (Item 1) and the one
center mount bolt (Item 2) [Figure 80-50-10] from the
N-22123 Evaporator/Heater Unit rear cover.
Remove the rear cover from the unit.
Remove the Evaporator/Heater Unit from the rear of the
cab and place it on the fenders of the loader supported
by 2X4's [Figure 80-50-8].
Remove the two mount bolts (Item 1) [Figure 80-50-8]
from the Evaporator/Heater Unit rear cover.
A220 Bobcat Loader
80-50-3 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 80-50-13
Cleaning The A/C Evaporator Coil & Heater Coil
(Cont'd)
Figure 80-50-11
2
1
1
2
N-23039
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
N-22127 Page 10-20-1.)
Push the A/C switch to the ON position. Turn the fan
With air or water clean the heater coil (Item 1) [Figure switch to the High Speed position, with the loader ignition
80-50-11] and evaporator coil (Item 2) [Figure 80-50-11]. switch OFF.
Receiver/Drier Sight Glass Inspection Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Figure 80-50-12
Connect the remote start tool to the loader. (See
1 REMOTE START on Page 10-60-1.)
Remove the mount bolt (Item 1) [Figure 80-50-13] from
the right side cab access cover.
Remove the access cover (Item 2) [Figure 80-50-13]
from the loader.
Figure 80-50-14
N-22134
1
Inspect the sight glass (Item 1) [Figure 80-50-12],
located on the receiver/drier, weekly or if the A/C system
does not perform properly.
N-22249
Remove the protective tape (Item 1) [Figure 80-50-14]
from the sight glass.
A220 Bobcat Loader
80-50-4 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Compressor Drive Belt Inspection
Receiver/Drier Sight Glass Inspection (Cont’d) Figure 80-50-16
Figure 80-50-15
1
1
N-23037
N-22250
It is good rule to regularly inspect (weekly) the
compressor drive belt for tension and wear.
Using the remote start tool, start the loader and run at
high idle. Open the rear door.
Watch the sight glass (Item 1) [Figure 80-50-15] for Check the tension on the compressor belt (Item 1)
passing bubbles. [Figure 80-50-16].
Bubbles indicate that the system is low on refrigerant and The belt tension should be set by measuring the belt
is due for recharging. (See SYSTEM CHARGING AND deflection, which should be 0.16 in. (4mm) with a
RECLAMATION on Page 80-100-1.) deflection load of 3.5-4 lbs (1,6-1,8 kg) force.
A220 Bobcat Loader
80-50-5 Service Manual
BASIC TROUBLESHOOTING (CONT’D) NOTE: The decal inside the fuse cover, refers to the
fuse as HEATER. This fuse controls the power
Checking The Electrical System for both the Heater and the A/C systems.
Figure 80-50-17 Figure 80-50-19
2
1
1
N-22284 P-26891
Check to see if the compressor clutch is engaging. Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
With an operator in the loader seat and the cab door Page 10-20-1.)
open, turn the loader key switch to RUN (Standard Panel)
OR press the RUN/ENTER Button (Deluxe Panel), Raise the operator cab. (See Raising The Operator Cab
without starting the loader. on Page 10-30-1.)
Push the A/C switch (Item 1) to the ON position. Turn the Disconnect the loader harness (Item 1) [Figure 80-50-
blower fan switch (Item 2) [Figure 80-50-17] to the first 19] from the compressor clutch wire.
ON position.
Figure 80-50-20
The compressor clutch should make a click sound, which
indicates the clutch is engaging.
Figure 80-50-18
1
1
2 P-26892
With a multimeter, check the resistance to the
N-22287 compressor clutch at harness connector (Item 1) [Figure
80-50-20].
If the compressor clutch does not engage, check the If there is no resistance value, replace the compressor
loader fuse (Item 1) [Figure 80-50-18] located on the clutch. (See Compressor Clutch Disassembly on Page
control panel in the loader cab. 80-110-2.)
Replace the fuse if burned out.
A220 Bobcat Loader
80-50-6 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 80-50-23
Checking The Electrical System (Cont'd)
Figure 80-50-21
P-26894
1
Using a multimeter check the loader wiring harness (Item
P-26892 1) [Figure 80-50-23] for voltage.
The voltage should be around 12 volts.
With a multimeter, check the voltage to the compressor
clutch at the loader harness (Item 1) [Figure 80-50-21]. If there is no voltage at the wiring harness, check the
harness for broken wires.
The voltage reading should be around 12 volts.
Figure 80-50-24
If there is no power at the clutch, check the wiring
harness for broken wires.
If there is power at the clutch, reconnect the wiring
harness to the compressor clutch.
1
Figure 80-50-22
P-26894
1
If there is voltage at the harness, check the resistance at
the pressure switch (Item 1)[Figure 80-50-24].
If there is no resistance value, check for low refrigerant
P-26893 level. (See SYSTEM CHARGING AND RECLAMATION
on Page 80-100-1.)
Disconnect the loader harness (Item 1) from the pressure If a resistance value is seen, the pressure switch is good.
switch (Item 2) [Figure 80-50-22].
Reconnect the loader harness to the pressure switch.
A220 Bobcat Loader
80-50-7 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 80-50-27
Checking The Electrical System (Cont'd)
Figure 80-50-25
1 1
N-22259
If there is voltage at the wiring harness, check the
N-22258 thermostat (Item 1) [Figure 80-50-27] for resistance.
The resistance value of the thermostat should be 10
Disconnect the thermostat wiring connector (Item1) Ohms at 68°F (20°C).
[Figure 80-50-25] from the loader wiring harness.
If there is no resistance value, replace the thermostat.
Figure 80-50-26 (See Removal And Installation on Page 80-170-1.)
If there is a resistance value, check the blower fan.
Figure 80-50-28
N-22259
1
Check the loader harness (Item 1) [Figure 80-50-26] for
voltage. The voltage should be 12 volts.
N-22130
If there is no voltage at the wiring harness, check the
harness for broken wires. Remove the mount bolt (Item 1) [Figure 80-50-28] from
the left side cab access cover.
Remove the access cover (Item 2) [Figure 80-50-28]
from the loader.
A220 Bobcat Loader
80-50-8 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 80-50-31
Checking The Electrical System (Cont'd)
Figure 80-50-29
1
1
N-22260
If there is voltage at the wiring harness, check the
N-22129 resistance to the blower fan at the blower fan wiring
connector (Item 1) [Figure 80-50-31].
Disconnect the blower fan wiring connector (Item 1) If there is no resistance value replace the heater/AC fan.
[Figure 80-50-29] from the loader wiring harness. (See Removal And Installation on Page 80-210-1.)
Figure 80-50-30 If there is a resistance value check the climate controls at
the control panel inside the loader cab.
Figure 80-50-32
N-22260
1
Check the loader harness (Item 1) [Figure 80-50-30] for
N-22261
voltage. The voltage should be 12 volts.
If there is no voltage at the wiring harness, check the Remove the three mount bolts (Item 1) [Figure 80-50-32]
harness for broken wires. from the cab control panel.
A220 Bobcat Loader
80-50-9 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 80-50-35
Checking The Electrical System (Cont'd)
H
Figure 80-50-33 C
B
M
N-22288
If there is voltage at the wiring harness, check the blower
N-22262 switch [Figure 80-50-35] for resistance.
With the switch in the OFF position, there should be zero
Remove the control panel and wiring harness from the resistance between all terminals.
cab [Figure 80-50-33].
With the switch in the 1 position, there should be
Figure 80-50-34 resistance between C terminal and the B terminal. And
also between the C terminal and the L terminal frame
[Figure 80-50-35].
With the switch in the 2 position, there should be
resistance between C terminal and the B terminal. And
also between the C terminal and the M terminal frame
1 [Figure 80-50-35].
With the switch in the 3 position, there should be
resistance between C terminal and the B terminal. And
also between the C terminal and the H terminal frame
[Figure 80-50-35].
If any of the above resistance tests fail, replace the
N-22265 blower switch.
If the above resistance tests are good, check the A/C
Disconnect the loader wiring harness (Item 1) [Figure switch.
80-50-34] from the blower switch.
Check the loader harness for voltage. The voltage should
be 12 volts.
If there is no voltage at the wiring harness, check the
harness for broken wires.
A220 Bobcat Loader
80-50-10 Service Manual
BASIC TROUBLESHOOTING (CONT’D) If no resistance value is found, replace the A/C switch.
Checking The Electrical System (Cont'd) If a resistance value is found, check the potentiometer.
Figure 80-50-36 Figure 80-50-38
N-22264 N-22262
At the loader cab, disconnect the loader harness (Item 1) The potentiometer will effect the A/C system and also
[Figure 80-50-36] from the A/C switch. effect the operation of the heater.
Check the harness for voltage. The voltage should be 12 If heater valve does not open, or close, or the A/C does
volts. not work, check the potentiometer.
If there is no voltage at the wiring harness, check the At the loader cab, disconnect the loader harness (Item 1)
harness for broken wires. [Figure 80-50-38] from the potentiometer.
Figure 80-50-37 Figure 80-50-39
1
2
1
N-22289 N-22263
If there is voltage at the wiring harness, check the A/C Check the loader harness (Item 1) [Figure 80-50-39] for
switch [Figure 80-50-37] for resistance. voltage. The voltage should be 12 volts.
With the switch in the OFF position there should be no If there is no voltage at the wiring harness, check the
resistance between any of the three terminals on the A/C harness for broken wires.
switch.
With the switch in the ON position there should be
resistance between terminal (Item 1) and terminal (Item
2) [Figure 80-50-37].
A220 Bobcat Loader
80-50-11 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 80-50-42
Checking The Electrical System (Cont'd)
Figure 80-50-40
C
A 1
N-22175
B To check the resistance of the white wire, turn the
N-22290 potentiometer control (Item 1) to the full A/C position
[Figure 80-50-42].
If there is voltage at the wiring harness, check the Figure 80-50-43
potentiometer [Figure 80-50-40] for resistance.
The resistance should be 10 K Ohm's between wire pin A
and wire pin C frame [Figure 80-50-40].
If no resistance is found replace the potentiometer.
Figure 80-50-41
A C
B N-22290
The resistance between the wire terminal A and wire
terminal B frame [Figure 80-50-43] should be around 49
1
K Ohm's.
Check the resistance between the wire terminal C and
N-22201 wire terminal B frame [Figure 80-50-43] should be
around 39 K Ohm's.
The white wire B, (Item 1) [Figure 80-50-41], on the
potentiometer, is a resister wire.
A220 Bobcat Loader
80-50-12 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Engine Coolant By-Passing The Heater Valve
Checking The Electrical System (Cont'd) Figure 80-50-46
Figure 80-50-44
3
2 1
1
N-22284
N-22175
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
To check the resistance of the white wire, turn the Page 10-20-1.)
potentiometer control (Item 1) [Figure 80-50-44] to the
full Heater position. Push the A/C switch (Item 1) to the OFF position. Turn
the fan switch (Item 2) to the High Speed position. Turn
Figure 80-50-45 the temperature control (Item 3) [Figure 80-50-46] to the
High A/C position, with the loader ignition switch OFF.
Figure 80-50-47
A C
N-22290
B
Check the resistance between the wire terminal A and N-22131
wire terminal B frame [Figure 80-50-45] should be
around 39 K Ohm's.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Check the resistance between the wire terminal C and
wire terminal B frame [Figure 80-50-45] should be Connect the remote start tool to the loader. (See
around 49 K Ohm's. REMOTE START on Page 10-60-1.)
If the resistance is not found replace the potentiometer. Start the loader and run at high idle, for ten minutes.
Check the heater hose (Item 1) [Figure 80-50-47] for
temperature.
If the hose is hot, the heater valve is leaking by, and
needs to be replace.
A220 Bobcat Loader
80-50-13 Service Manual
BASIC TROUBLESHOOTING (CONT’D) Figure 80-50-49
Heater Valve Not Opening Or Closing
Figure 80-50-48 1
3
2 N-22131
1
Raise the operator cab. (See Raising The Operator Cab
N-22284 on Page 10-30-1.)
Connect the remote start tool to the loader. (See
Raise the lift arms and install an approved lift arm support REMOTE START on Page 10-60-1.)
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.) Place the remote start tool on the left fender of the loader,
so the heater valve can be clearly seen. Watch the valve
Push the A/C switch (Item 1) to the OFF position. Turn shaft (Item 1) [Figure 80-50-49], as the key of the remote
the fan switch (Item 2) to position 1. Turn the temperature start is turned to the ON position without starting the
control (Item 3) [Figure 80-50-48] to the High A/C loader. The heater valve should rotate. Place a mark on
position, with the loader ignition switch OFF. the loader shaft.
Turn the remote start key to the OFF position and remove
the remote start tool from fender.
Lower operator cab.
Turn the temperature control (Item 3) [Figure 80-50-48]
to the High Heater position, with the loader ignition switch
OFF.
Raise the operator cab.
Place the remote start tool on the left fender of the loader,
so the heater valve can be clearly seen. Watch the valve
shaft (Item 1) [Figure 80-50-49], as the key of the remote
start is turned to the ON position without starting the
loader. The heater valve should rotate.
If it does not rotate, check the potentiometer for proper
function. (See Checking The Electrical System on Page
80-50-6.)
Replace the heater valve. (See Removal And Installation
on Page 80-220-1.)
A220 Bobcat Loader
80-50-14 Service Manual
GENERAL AIR CONDITIONING SERVICE
GUIDELINES
Compressor Oil
Figure 80-60-1
N-22243
The compressor (Item 1) [Figure 80-60-1] is factory filled
with 150-170 cc's of PAG oil (Poly Alkelene Glycol).
Unlike engine oil, it is not necessary to frequently check
or change the compressor oil.
It is necessary to check, replenish or replace the
compressor oil in the following cases:
1. When ever the evaporator, condenser or receiver-
drier is replaced.
2. Whenever the refrigerant has leaked from the system.
3. Whenever the refrigerant is suddenly released from
the cooling cycle.
4. Whenever any oil-related problems occur in the
cooling cycle.
When one of the components (the evaporator, condenser
or receiver-drier) is replaced, one ounce of oil should be
added for each component replaced.
If the A/C compressor is changed, no oil should be added
to the system, because the compressor comes factory
filled with oil.
NOTE: Only PAG oil should be used, and never mix
R-12 and R-134a Oils.
A220 Bobcat Loader
80-60-1 Service Manual
GENERAL AIR CONDITIONING SERVICE Open the cab door and windows.
GUIDELINES (CONT'D)
Run the blower at maximum speed.
Compressor Oil Check
Run the compressor for at least 20 minutes at 800-1200
Figure 80-60-2 RPM.
Remove the compressor from the loader. (See Removal
And Installation on Page 80-110-1.)
Remove the oil drain plug (Item 1) [Figure 80-60-2] and
drain the oil through the connectors and the oil drain hole
[Figure 80-60-3].
Installation: Tighten the oil drain plug to 9.4-10.8 ft.-lbs.
1
(13-15 Nm) torque.
Figure 80-60-4
N-22245
Figure 80-60-3
1
N-22246
NOTE: After draining the oil through the drain hole
and the connectors, extract the remaining oil
through the discharge-side connector by
P-16534A rotating the drive pulley (Item 1) [Figure 80-60-
4] several times by hand.
The compressor oil should be checked as follows when
oil is being added to an in service loader.
There is a close affinity between oil and refrigerant.
During normal operation, part of the oil circulates with the
refrigerant in the system. Therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run in advance to
insure return of oil to the compressor.
If the amount of refrigerant in the system has decreased,
charge the system. (See SYSTEM CHARGING AND
RECLAMATION on Page 80-100-1.)
A220 Bobcat Loader
80-60-2 Service Manual
GENERAL AIR CONDITIONING SERVICE Component Replacement And Refrigeration Leaks
GUIDELINES (CONT'D)
Figure 80-60-6
Compressor Oil Check (Cont'd)
Figure 80-60-5
1
1
P-24229
N-22245 Whenever the A/C system is opened to the atmosphere
or there has been a leak in the system, the receiver/drier
(Item 1) [Figure 80-60-6] must be changed.
Measure the drained oil in a measuring cylinder.
Never leave hose fittings, compressor fittings or
Check the oil for contamination, dirt, metal shavings, or components uncapped while working on the A/C system.
varnish color, discard the oil if contaminated.
NOTE: If metal shavings are found in the compressor
oil, replace the complete compressor
assembly.
Add new compressor oil through the suction side
connector (Item 1) [Figure 80-60-5].
Installation: Add 150 -170 cc's of PAG oil.
NOTE: The suction port on the compressor is marked
with an S and is the larger port on the
compressor.
A220 Bobcat Loader
80-60-3 Service Manual
A220 Bobcat Loader
80-60-4 Service Manual
SYSTEM TROUBLESHOOTING CHART
Blower motor does not operate
Possible Cause Inspection Solution
1. Blown fuse. Inspect the fuse/wiring. Replace fuse/repair wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or connector.
connection.
3. Fan motor malfunction. Check the lead wires form the motor with a circuit Replace Motor.
tester.
4. Resistor malfunction. Check resistor using a circuit tester. Replace Resistor.
5. Fan motor switch Check power into and out of the fan switch. Replace Fan Switch.
malfunction.
Blower motor operates normally, but air flow is insufficient
Possible Cause Inspection Solution
1. Evaporator inlet obstruction. Check evaporator for plugging. Remove obstruction and clean
evaporator fins with air or
water.
2. Air leak. Check to make sure air hoses are properly hooked Repair of adjust.
to Louvers, and air ducts.
3. Defective thermo. switch Check thermostat using a circuit tester. Replace thermostat.
(frozen evaporator).
4. Plugged cab filters Check cab filter condition. Clean or replace filters.
Insufficient cooling although air flow and compressor operation are normal
Possible Cause Inspection Solution
1. System low on refrigerant. The high side pressure will be low and bubbles Repair any leaks and recharge
may be present in sight glass on receive drier. the refrigerant to the correct
level.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
The compressor does not operate at all, or operates improperly
Possible Cause Inspection Solution
1. Loose drive belt. The belt is vibrating or oscillating. Adjust tension.
2. Internal compressor The compressor is locked up and the belt slips. Replace compressor.
malfunction.
Magnetic clutch related
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic clutch.
5. Oil on the clutch surface. Clutch slips. Replace or clean the clutch
surface.
6. Open oil. Clutch does not engage and there is no reading Replace clutch.
when a circuit tester is connected between the coil
and terminals.
7. Broken wiring or poor Clutch will not engage. Inspect the ground and Repair.
ground. connections.
8. Wiring harness Test the conductance of the pressure switch, Check operation.
components. thermostat, Relay, etc.
A220 Bobcat Loader
80-70-1 Service Manual
SYSTEM TROUBLESHOOTING CHART (CONT'D)
Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86-96 degrees F
(30-38 degrees C) and compressor speed of approximately 2000 RPM are:
High pressure side pressure: 210-265 PSI
Low pressure side pressure: 15-33 PSI
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure.
Possible Cause Inspection Solution
Low pressure side The low pressure side pressure normally becomes too
Too high. high when the high pressure side pressure is too high. As
this is explained below, the following inspection is only
used when the low pressure side is too high.
1. Expansion valve Frost is present on the suction hose. Replace expansion valve.
opens too far.
2. Dective compressor. The high and low pressure side gauge pressures Replace compressor.
equalize when the magnetic clutch is engaged.
Low pressure side
Too low.
1. Low refrigerant The high side pressure will be low and bubbles may be Repair any leaks and recharge
charge. present in sight glass on receive drier. the refrigerant to the correct
level.
2. Clogged or closed The expansion valve’s inlet side is frosted. Moisture or Clean or replace the expansion
expansion valve. other Contaminants can be the cause. Valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion Negative low pressure reading may be shown.
valve.
4. Thermostat The evaportator is frozen. Adjust themostat’s
malfunction. temperature setting or probe
placement or replace
thermostat.
5. Restriction in Excessive frost on reciever drier. Replace reciever drier.
reciever drier.
High pressure side
Too high.
1. Poor condenser Dirty or clogged condenser fins. Condenser fans not Clean fins, and/or repair the
performance. Operating. fan.
2. Excessive The high pressure side pressure will be high. Use refrigerant recovery
refrigerant. equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
3. Excessive oil charge. The high pressure side will be high. Evacuate system. Remove oil
from condenser and
compressor. Measure oil from
compressor and add correct oil
charge back into compressor.
Flush system with nitrogen.
Replace drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
Refrigerant.
5. Restriction in drier, High pressure side will be high, and low pressure side Evacuate and flush system
condenser or high will be low. replacing defective parts.
pressure line.
A220 Bobcat Loader
80-70-2 Service Manual
SYSTEM TROUBLESHOOTING CHART (CONT'D)
Gauge Pressure Related Troubleshooting (Cont'd)
Possible Cause Inspection Solution
High pressure side Too
low.
1. Low refirgerant charge. The high side pressure will be low and bubbles may be Repair any leaks and
present in sight glass on receive drier. recharge the refrigerant to
the correct level.
System pressures Equal
1. Clutch not operating. See magnetic clutch related topics above.
2. Compressor not Equal high and low pressures. Replace compressor.
pumping.
A220 Bobcat Loader
80-70-3 Service Manual
SYSTEM TROUBLESHOOTING CHART (CONT'D)
Troubleshooting Tree
B-21491
A220 Bobcat Loader
80-70-4 Service Manual
SYSTEM TROUBLESHOOTING CHART (CONT'D)
Troubleshooting Tree (Cont’d)
B-21491A
A220 Bobcat Loader
80-70-5 Service Manual
SYSTEM TROUBLESHOOTING CHART (CONT'D)
Troubleshooting Tree (Cont’d)
B-21492
A220 Bobcat Loader
80-70-6 Service Manual
SYSTEM TROUBLESHOOTING CHART (CONT'D)
Troubleshooting Tree (Cont’d)
B-21493
A220 Bobcat Loader
80-70-7 Service Manual
A220 Bobcat Loader
80-70-8 Service Manual
TEMPERATURE/PRESSURE
Chart
NORMAL EVAPORATOR RANGE NORMAL CONDENSER RANGE
TEMP F. PSIG TEMP F. PSIG
16 15.69 93 110.20
18 17.04 94 112.10
20 18.43 95 114.10
22 19.87 100 124.30
24 21.35 102 128.50
26 22.88 104 132.90
28 24.47 106 137.30
30 26.10 108 141.90
32 27.79 110 146.50
34 29.52 112 151.30
36 31.32 114 156.10
38 33.17 116 161.10
40 35.07 118 166.10
42 37.03 120 171.30
44 39.05 122 176.60
45 40.09 124 182.00
50 45.48 126 187.50
55 51.27 128 193.10
60 57.47 130 198.90
65 64.10 135 213.70
70 71.19 140 229.40
75 78.75 145 245.80
80 86.80 150 263.00
85 95.40 155 281.10
90 104.40 160 300.10
91 106.30 165 320.10
92 108.20 170 340.80
Evaporator
Pressures represent gas temperatures inside the coil. not the coil surface. For an estimate of the temperature of the air
coming off the coil add 8-10 degrees F. to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 40 degrees F. to the ambient temperature
to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient
temperature.
Example: Ambient Temperature=90 degrees F.
90 degrees F.
+40 degrees F.
130 degrees F. condenser temperature=200 psig
Conditions and pressures will vary from system to system.
A220 Bobcat Loader
80-80-1 Service Manual
A220 Bobcat Loader
80-80-2 Service Manual
AIR CONDITIONING SERVICE
Chart
Service Company/Phone Number:
Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature At Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
Explain Services Required:
Post Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:
A220 Bobcat Loader
80-90-1 Service Manual
A220 Bobcat Loader
80-90-2 Service Manual
SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
WARNING
Figure 80-100-1
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
1 eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
NOTE: This test is run with the loader engine OFF,
and the A/C switch in the OFF position.
Figure 80-100-3
N-23024
NOTE: Before reclaiming a refrigeration system, it is
recommended to identify the type of
refrigerant that is in the A/C system and if it is
pure enough to use. The tool MEL1592,
Refrigerant Identifier (Item 1) [Figure 80-100-1]
will determine, the kind of refrigerant and any
possible harmful or dangerous substances
that may be present in the system. Thus
N-23026
preventing mixing of dangerous material with
your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems Connect the Refrigerant Identifier to the low pressure
that are reclaimed and charged from your hose [Figure 80-100-3].
MEL1581 Recovery/Recycling/Recharging
Machine. Connect the Refrigerant Identifier to its power source.
Figure 80-100-2 Follow the steps displayed on the refrigerant identifier
screen.
Allow two minutes for the refrigerant identifier to display
the type of refrigerant and air content. An alarm will
1
sound if potentially flammable hydrocarbons are present
and will also indicate on the visual display.
Disconnect the refrigerant identifier from the loader A/C.
If the refrigerant is dangerous or flammable, it must be
evacuated from the A/C system into a separate container
and properly and safely disposed of.
If R134a is found, evacuate the system.
N-22293
Remove the protective cap (Item 1) [Figure 80-100-2]
from the low pressure hose.
A220 Bobcat Loader
80-100-1 Service Manual
SYSTEM CHARGING AND RECLAMATION (CONT’D) Figure 80-100-5
Reclamation Procedure (Cont'd)
2
1
WARNING
HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
if it contacts the eyes and may cause serious
frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
N-22380
• NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air.
Any servicing work that involves release or addition Connect the reclaimer to the loader A/C charge ports.
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment, Connect the Red hose (Item 1) [Figure 80-100-5] to the
knowledge, and experience to service refrigeration high pressure port and open the valve.
equipment.
W-2373-0500
Connect the Blue hose (Item 2) [Figure 80-100-5] to the
low pressure port and open the valve.
NOTE: Only A/C trained technicians should perform
the reclaiming and recharging procedure. Figure 80-100-6
Figure 80-100-4
N-22292
N-22291
Turn the reclaimer unit [Figure 80-100-6] to the ON
position and follow the on screen instructions.
Use an approved recovery/charging unit [Figure 80-100-
4] to evacuate the system.
A220 Bobcat Loader
80-100-2 Service Manual
SYSTEM CHARGING AND RECLAMATION (CONT’D) Charging Procedure With A Manifold Gauge Set
Reclamation Procedure (Cont'd)
Figure 80-100-7
WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
Figure 80-100-8
N-22381
NOTE: The reclaimer unit, has a complete step by
step set of instructions [Figure 80-100-7] to
follow for reclimation and recharging of the A/
C system. A trained technician should follow
these instructions as they may very slightly
1
depending on the model and brand of
reclaimer used.
N-22382
Raise the loader lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Check to see that the hand valves (Item 1) [Figure 80-
100-8] are closed on the manifold gauge set.
If there is any refrigerant in the A/C system, it must be
recovered by an approved A/C reclamation procedure.
(See Reclamation Procedure on Page 80-100-1.)
A220 Bobcat Loader
80-100-3 Service Manual
SYSTEM CHARGING AND RECLAMATION (CONT’D) Figure 80-100-11
Charging Procedure With A Manifold Gauge Set
(Cont’d)
Figure 80-100-9
N-23043
2 Start the vacuum pump and open Iso-valve (Item 1)
1
[Figure 80-100-11] on the vacuum pump.
N-22382
Run the vacuum pump for at least 5-10 minutes to insure
that a vacuum has been pulled on the system.
Connect the gauges to the loader A/C charge ports.
Close the Iso-valve (Item 1) [Figure 80-100-11] (which
Connect the Red hose (Item 1) [Figure 80-100-9] to the isolates the vacuum pump from the A/C system) and turn
high pressure port and open the valve. OFF the vacuum pump.
Connect the Blue hose (Item 2) [Figure 80-100-9] to the
low pressure port and open the valve.
Figure 80-100-10
P-26942
Connect the Yellow hose (Item 1) [Figure 80-100-10] to
the vacuum pump.
A220 Bobcat Loader
80-100-4 Service Manual
SYSTEM CHARGING AND RECLAMATION (CONT’D) Figure 80-100-13
Charging Procedure
Figure 80-100-12
1 1
N-22385
A thermistor vacuum gauge (Item 1) [Figure 80-100-13]
N-22382 may be necessary to use to determine the critical
vacuum level during evacuation. It is a solid state
instrument that constantly monitors and visually indicates
Note vacuum pressure indicated on the low pressure the vacuum level.
(Blue) gauge (Item 1) [Figure 80-100-12]. Let stand for
5-10 min. and recheck the pressure for changes. The thermistor vacuum gauge is used with the vacuum
pump [Figure 80-100-13].
If the pressure drops, this may be an indication of a leak
in the A/C system. Start the vacuum pump and open Iso-valve on the
vacuum pump.
Determine the problem with the A/C system and repair it.
Be sure that both hand valves, and both charge port
valves are open.
Run the vacuum pump for at least 45 minutes to insure
that all the moisture is boiled out of the system.
Stop the vacuum pump and close the Iso-valve on the
vacuum pump.
Close both hand valves on the manifold gauge set and
remove the yellow hose from the vacuum pump that goes
to the manifold gauge set.
Remove the vacuum pump and thermister vacuum
gauge.
A220 Bobcat Loader
80-100-5 Service Manual
SYSTEM CHARGING AND RECLAMATION (CONT’D) Figure 80-100-16
Charging Procedure (Cont'd)
Figure 80-100-14
1 2 1
N-22284
2
Connect the remote start tool to the loader. (See
P-26943 REMOTE START on Page 10-60-1.)
Press the A/C (Item 1) [Figure 80-100-16] switch to ON
Place a refrigerant container with R134a (Item 1) on a position.
charging scale (Item 2) [Figure 80-100-14] and zero out
the scale. Turn fan switch (Item 2) [Figure 80-100-16] to HIGH
position.
Connect the yellow hose (Item 3) [Figure 80-100-14]
from the manifold gauge set to the valve on the Raise the operator cab. (See Raising The Operator Cab
refrigerant tank. on Page 10-30-1.)
Figure 80-100-15 Start loader engine, with the remote start switch, and run
at medium speed.
Watch the scale and run system until the predetermined
2 amount of refrigerant is added to the A/C system.
The A/C system holds 2.00 lbs. (0,91 kg) of
refrigerant.
Turn OFF the valve on the refrigerant container, and
hand valves on the manifold gauge set.
1 Turn OFF the engine, and remove the A/C charging
equipment from the loader.
N-23044 Lower the operator cab. (See Lowering The Operator
Cab on Page 10-30-2.)
Open the valve on the refrigerant container (Item 1) and
open the low pressure hand valve (Blue) (Item 2) [Figure
80-100-15] on the manifold gauge set. Allow the vacuum
to pull in the refrigerant until the pressure stabilizes.
A220 Bobcat Loader
80-100-6 Service Manual
COMPRESSOR Figure 80-110-2
Removal And Installation
Figure 80-110-1
2
1
N-22377
Remove the compressor mount bolt (Item 1) [Figure 80-
N-22379A 110-2].
Remove the compressor from the loader.
WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
Raise the loader lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Evacuate the A/C system. (See SYSTEM CHARGING
AND RECLAMATION on Page 80-100-1.)
Remove the compressor adjustment bolt (Item 1) [Figure
80-110-1].
Installation: Tighten the compressor adjustment bolt to
34 ft.-lbs. (46 Nm) torque.
Remove the compressor belt.
Mark the compressor hoses for proper installation.
Remove the compressor hoses (Item 2) [Figure 80-110-
1] from the compressor.
Installation: Tighten the compressor hoses to 22 ft.-lbs.
(29,8 Nm) torque.
Cap and plug the compressor hoses and the fittings with
with the proper A/C caps and plugs.
A220 Bobcat Loader
80-110-1 Service Manual
COMPRESSOR (CONT’D) Figure 80-110-5
Compressor Clutch Disassembly
Figure 80-110-3
1.32”
1.32”
1.32”
2
1 1
N-22275
The armature plate puller, (Item 1) can be constructed by
N-22244 drilling three 10 mm holes in a flat circular plate, located
1.32 inches apart [Figure 80-110-5].
Remove the center armature bolt (Item 1) [Figure 80- Attach the puller to the armature plate using three 8 mm
110-3]. bolts (Item 2) [Figure 80-110-5].
Installation: Tighten the armature bolt to 8-10 ft.-lbs. Figure 80-110-6
(12-14 Nm) torque.
Figure 80-110-4
N-22278
N-22277 Turn the bolts into the three 8 mm holes (Item 2) [Figure
80-110-4] on the armature plate as shown in [Figure 80-
110-6].
To remove the armature plate (Item 1) [Figure 80-110-4]
from the clutch face, you must make an armature plate
puller.
A220 Bobcat Loader
80-110-2 Service Manual
COMPRESSOR (CONT’D) Figure 80-110-8
Compressor Clutch Disassembly (Cont'd)
Figure 80-110-7
N-22280
1
Remove the shims (Item 1) [Figure 80-110-8] from either
N-22279 the armature shaft or armature plate.
Installation: Insure that the clutch has the correct
Attach a slide hammer puller (Item 1) [Figure 80-110-7] clearance by adding the shims (Item 1) [Figure 80-110-
to the armature puller disk. 8].
Remove the armature plate from the compressor clutch. The specified clearance for the clutch is 0.01-0.02 in.
(0.3-0.6 mm). Adjusting shims are available in the
following thicknesses:
0.0039 in. (0.1mm)
0.0118 in. (0.3 mm)
0.0197 in. (0.5mm)
Figure 80-110-9
N-22283
Remove the snap ring (Item 1) [Figure 80-110-9] from
the pulley assembly.
A220 Bobcat Loader
80-110-3 Service Manual
COMPRESSOR (CONT’D) Figure 80-110-12
Compressor Clutch Disassembly (Cont'd)
Figure 80-110-10
N-22371
The pulley assembly and bearing [Figure 80-110-12]
N-22369 must be replace as a complete unit.
Figure 80-110-13
Install the pulley puller tool MEL1595 on the compressor
pulley [Figure 80-110-10].
Figure 80-110-11
N-22373
Slide the wire grommet (Item 1) [Figure 80-110-13] from
N-22370 the wire holder.
Remove the pulley from the compressor [Figure 80-110-
11].
A220 Bobcat Loader
80-110-4 Service Manual
COMPRESSOR (CONT’D) Figure 80-110-16
Compressor Clutch Disassembly (Cont'd)
Figure 80-110-14
N-22375
The compressor [Figure 80-110-16] must be replaced as
N-22374 a complete unit.
Remove the coil lead wire (Item 1) [Figure 80-110-14]
from the wire holder on the compressor.
Figure 80-110-15
N-22372
Remove the three coil mount bolts (Item 1) [Figure 80-
110-15] from the compressor.
Installation: Tighten the mount bolts to 2.9-4.3 ft.-lbs. (4-
6 Nm) torque.
Remove the coil from the compressor.
A220 Bobcat Loader
80-110-5 Service Manual
A220 Bobcat Loader
80-110-6 Service Manual
CONDENSER Figure 80-120-2
Removal And Installation
Figure 80-120-1
N-22977
1
Mark the two A/C hoses (Item 1) [Figure 80-120-2] for
N-22976 proper installation.
Disconnect the two hoses from the condenser.
Remove the refrigerant from the A/C system. (See
SYSTEM CHARGING AND RECLAMATION on Page 80- Cap and plug the hoses and the condenser fittings with
100-1.) the proper A/C caps and plugs.
Open the rear door of the loader. Figure 80-120-3
Open the rear grill on the loader.
Remove the two retaining clips (Item 1) [Figure 80-120-
1] from the condenser mount bracket.
WARNING
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500 N-22978
Lift the rear of the condenser, and pull toward the rear of
the loader [Figure 80-120-3].
Remove the condenser from the loader.
A220 Bobcat Loader
80-120-1 Service Manual
CONDENSER (CONT’D)
Removal And Installation (Cont’d)
Figure 80-120-4
N-22977A
Installation: When installing the condenser, be sure the
condenser tabs (Item 1) [Figure 80-120-4] are positioned
in the slots in the loader frame.
A220 Bobcat Loader
80-120-2 Service Manual
RECEIVER/DRIER
Removal And Installation
WARNING
Figure 80-130-1
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
1
Note the flow direction on the drier (Item 1) [Figure 80-
130-2] for proper installation.
Remove the two A/C hoses (Item 2) [Figure 80-130-2]
from the receiver/drier.
Cap and plug the hoses and the receiver/drier fittings
with the proper A/C caps and plugs.
N-22134
Loosen the hose clamps (Item 3) [Figure 80-130-2] that
holds the receiver/drier to the mount.
Raise the loader lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support Remove the receiver/drier from the loader.
Device on Page 10-20-1.)
NOTE: When replacing a receiver/drier in an A/C
Raise the operator cab. (See Raising The Operator Cab system 1 fl. oz. (30 cc) of PAG oil must be
on Page 10-30-1.) added to the system when recharging.
Remove the refrigerant from the A/C system. (See Figure 80-130-3
SYSTEM CHARGING AND RECLAMATION on Page 80-
100-1.)
Mark the A/C hoses (Item 1) [Figure 80-130-1] for proper
installation.
1
Both fittings on the drier are the same size, so the hoses
can be hooked up incorrectly.
Figure 80-130-2
2 1
N-22135
Remove the two mount bolts (Item 1) [Figure 80-130-3]
from the receiver/drier mount bracket.
3
Remove the bracket from the top of the hydraulic filter
bracket.
N-22134
A220 Bobcat Loader
80-130-1 Service Manual
A220 Bobcat Loader
80-130-2 Service Manual
PRESSURE RELIEF VALVE
Removal and Installation
Figure 80-140-1
N-22205
The pressure relief valve (Item 1) [Figure 80-140-1] is
located on the drier assembly.
Figure 80-140-2
N-22206
The pressure relief valve [Figure 80-140-2] is designed
to open and release the A/C charge if the pressure
reaches 535 PSI (3689 kPa).
This will cause the A/C system to shut down, saving the
compressor.
The Pressure Relief Valve is a secondary protection
device in the A./C system, with the Pressure Switch
shutting down the system at 384 PSI (2648 kPa).
NOTE: If a Pressure Relief Valve is found open, check
the A/C system for problems. Replace the
complete receiver/drier unit.
A220 Bobcat Loader
80-140-1 Service Manual
A220 Bobcat Loader
80-140-2 Service Manual
PRESSURE SWITCH
Removal And Installation
WARNING
Figure 80-150-1
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
Remove the pressure switch (Item 1) [Figure 80-150-2]
from the A/C high pressure hose.
1
Remove the pressure switch from the loader.
Shreader Valve Removal And Installation
Figure 80-150-3
N-22256
Raise the loader lift arms and install an approved lift arm
support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
1
Disconnect the loader wire harness (Item 1) [Figure 80-
150-1] from the pressure switch wire harness.
Figure 80-150-2
N-22166
The shreader valve (Item 1) [Figure 80-150-3] is located
in the A/C high pressure hose and is located under the
pressure switch.
Raise the loader lift arms and install an approved lift arm
1 support device. (See Engaging The Lift Arm Support
Device on Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
N-22134 Remove the refrigerant from the A/C system. (See
SYSTEM CHARGING AND RECLAMATION on Page 80-
100-1.)
NOTE: The pressure switch can be change without
evacuating the A/C system. Remove the pressure switch.
With a tire valve core removal tool, remove the valve core
from the hose.
Replace with a new core.
A220 Bobcat Loader
80-150-1 Service Manual
A220 Bobcat Loader
80-150-2 Service Manual
EVAPORATOR/HEATER UNIT Figure 80-160-3
Removal And Installation
Figure 80-160-1
1
1
N-22129
Disconnect the blower fan wiring connector (Item 1)
N-22122 [Figure 80-160-3] from the loader wiring harness.
Figure 80-160-4
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Evacuate the A/C system. (See SYSTEM CHARGING
AND RECLAMATION on Page 80-100-1.)
1
At the rear of the cab, disconnect the thermostat wiring
connector (Item 1) [Figure 80-160-1].
Figure 80-160-2
N-22119
Remove the two mounting nuts (Item 1) [Figure 80-160-
2 4].
N-22130
Remove the mount bolt (Item 1) [Figure 80-160-2] from
the left side cab access cover.
Remove the access cover (Item 2) [Figure 80-160-2]
from the loader.
A220 Bobcat Loader
80-160-1 Service Manual
EVAPORATOR/HEATER UNIT (CONT’D) Figure 80-160-6
Removal And Installation (Cont'd)
Figure 80-160-5
N-22126
N-22120
WARNING
Remove the two mounting nuts (Item 1) [Figure 80-160-
5]. In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
Remove the Evaporator/Heater Unit from the rear of the
cab and place it on the fenders of the loader supported
by 2X4's [Figure 80-160-6].
Remove the two A/C hoses (Item 1) [Figure 80-160-6]
from the expansion valve.
Installation: Tighten the A/C hoses to 22 ft.-lbs. (29,8
Nm) torque.
Cap and plug the hoses and the expansion valve fittings
with the proper A/C caps and plugs.
A220 Bobcat Loader
80-160-2 Service Manual
EVAPORATOR/HEATER UNIT (CONT’D) Disassembly And Assembly
Removal And Installation (Cont'd) Figure 80-160-8
Figure 80-160-7
1
1
1
N-22065
N-22128
Remove the eight mount bolts (Item 1) [Figure 80-160-8]
from the Evaporator/Heater Unit rear cover.
Remove the heater hoses (Item 1) [Figure 80-160-7]
from the heater coil. Remove the rear cover from the unit.
Installation: Tighten the heater hoses to 22 ft.-lbs. (29,8
Nm) torque.
Remove the evaporator/heater unit from the loader
A220 Bobcat Loader
80-160-3 Service Manual
A220 Bobcat Loader
80-160-4 Service Manual
THERMOSTAT Figure 80-170-3
Removal And Installation
Figure 80-170- 1
1
N-22072
Remove the thermostat from the unit [Figure 80-170-3].
N-22069
Figure 80-170-4
NOTE: The thermostat can be changed without A
evacuating the A/C system, or removing the
evaporator/heater unit from the loader. B
Remove the rear cover from the evaporator/heater unit.
(See Disassembly And Assembly on Page 80-160-3.) C
Remove the two thermostat mount bolts (Item 1) [Figure
80-170- 1], and remove the wiring harness and grommet
from the evaporator/heater housing. 1
Figure 80-170-2
N-22072A
The wire connector (Item 1) [Figure 80-170-4] can be
change. The wiring position and color in the connector is:
A Blue
1 B White
C Black
N-22071
Remove the thermostat probe (Item 1) [Figure 80-170-2]
from the A/C evaporator coil.
A220 Bobcat Loader
80-170-1 service Manual
A220 Bobcat Loader
80-170-2 Service Manual
EXPANSION VALVE Figure 80-180-2
Removal And Installation
NOTE: The expansion valve can be changed without
removing the evaporator/heater unit from the
loader.
Figure 80-180-1
1
1 N-22073A
Remove the two evaporator fittings (Item 1) [Figure 80-
180-2] from the expansion valve.
Installation: Tighten the two evaporator fittings to 22 ft.-
lbs. (29,8 Nm) torque.
N-22150
Remove the two mount bolts (Item 2) [Figure 80-180-2].
Remove the expansion valve from the loader.
WARNING Figure 80-180-3
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500 1
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
N-22074A
Evacuate the A/C system. (See SYSTEM CHARGING
AND RECLAMATION on Page 80-100-1.)
Cap and plug the evaporator tubelines (Item 1) [Figure
Remove the two A/C hoses (Item 1) [Figure 80-180-1] 80-180-3] and the expansion valve fittings with the
from the expansion valve. proper A/C caps and plugs.
Installation: Tighten the two A/C hose fittings to 22 ft.-
lbs. (29,8 Nm) torque.
Cap and plug the hoses and the expansion valve fittings
with the proper A/C caps and plugs.
A220 Bobcat Loader
80-180-1 Service Manual
EXPANSION VALVE (CONT’D)
Removal And Installation (Cont'd)
Figure 80-180-4
N-22074A
Remove the two mount bolts (Item 1) [Figure 80-180-4]
from the expansion valve mount.
Remove the expansion valve mount from the unit.
Figure 80-180-5
N-22085
The expansion valve [Figure 80-180-5] is replaced as a
complete unit.
A220 Bobcat Loader
80-180-2 Service Manual
EVAPORATOR Figure 80-190-3
Removal And Installation
Figure 80-190-1
N-22075
Remove the two mount bolts (Item 1) from the mount
1 plate (Item 2) [Figure 80-190-3].
N-22073
Remove the mount plate from the unit.
Raise the lift arms and install an approved lift arm support
device.(See Engaging The Lift Arm Support Device on Figure 80-190-4
Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Evacuate the A/C system. (See SYSTEM CHARGING
AND RECLAMATION on Page 80-100-1.)
Remove the evaporator/heater unit from the back of the
cab. (See Removal And Installation on Page 80-160-1.)
Remove the expansion valve (Item 1) [Figure 80-190-1]
from the unit. (See Removal And Installation on Page 80- 1
180-1.)
N-22076
Figure 80-190-2
Remove the two retaining clips (Item 1) [Figure 80-190-
4] that connect the evaporator coil, to the heater coil.
Remove the evaporator coil from the unit.
N-22074
Remove the expansion valve mount bracket (Item 1)
[Figure 80-190-2] from the unit.
A220 Bobcat Loader
80-190-1 Service Manual
EVAPORATOR (CONT’D)
Removal And Installation (Cont'd)
Figure 80-190-5
N-22078
Inspect the evaporator coil [Figure 80-190-5] for leaks,
and replace as needed.
Clean with low water or air pressure.
A220 Bobcat Loader
80-190-2 Service Manual
HEATER COIL Figure 80-200-2
Removal And Installation With A/C
1
Figure 80-200-1
1
1
N-22086
Remove the rear cover from the evaporator/heater unit.
N-22128 (See Disassembly And Assembly on Page 80-160-3.)
Remove the two mount bolts (Item 1) [Figure 80-200-2]
Raise the lift arms and install an approved lift arm support from the heater coil at the expansion valve end of the
device. (See Engaging The Lift Arm Support Device on unit.
Page 10-20-1.)
Figure 80-200-3
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the evaporator/heater unit from the back of the
cab. (See Removal And Installation on Page 80-160-1.)
Mark the heater hoses (Item 1) [Figure 80-200-1] for
proper installation.
Remove the two heater hoses from the heater coil.
Cap the hoses and the heater coil with hydraulic caps 1
and plugs to prevent oil loss from the system.
Installation: Tighten the two heater hose fittings to 22 ft.- N-22087
lbs. (29,8 Nm) torque.
Remove the two retaining clips (Item 1) [Figure 80-200-
3] that connect the evaporator coil, to the heater coil.
A220 Bobcat Loader
80-200-1 Service Manual
HEATER COIL (CONT’D) Removal And Installation Without A/C
Removal And Installation With A/C (Cont'd) Figure 80-200-6
Figure 80-200-4
1
1 1
N-22128
N-22089
Raise the lift arms and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Remove the three mount bolts (Item 1) [Figure 80-200-4] Page 10-20-1.)
and remove the mount plate from the end of the unit.
Raise the operator cab. (See Raising The Operator Cab
Remove the two mount bolts (Item 2) [Figure 80-200-4] on Page 10-30-1.)
that support the heater coil tubelines to the unit.
Remove the heater unit from the back of the cab. (See
Remove the heater coil from the unit. Removal And Installation on Page 80-160-1.)
Figure 80-200-5 Mark the heater hoses (Item 1) [Figure 80-200-6] for
proper installation.
Remove the two heater hoses from the heater coil.
Cap the hoses and the heater coil with hydraulic caps
and plugs to prevent oil loss from the system.
Installation: Tighten the two heater hose fittings to 22 ft.-
lbs. (29,8 Nm) torque.
N-22090
The heater coil [Figure 80-200-5] can be cleaned with
low air or water pressure.
If the heater coil needs replacement it must be replaced
as complete unit.
A220 Bobcat Loader
80-200-2 Service Manual
HEATER COIL (CONT’D)
Removal and Installation Without A/C (Cont’d)
Figure 80-200-7
1 1
N-22093
Remove the rear cover from the evaporator/heater unit.
(See Disassembly And Assembly on Page 80-160-3.)
Remove the three mount bolts (Item 1) [Figure 80-200-7]
and remove the mount plate from the end of the unit.
Remove the two mount bolts (Item 2) [Figure 80-200-7]
that support the heater coil tubelines to the unit.
Figure 80-200-8
N-22094
Remove the two mount bolts (Item 1) [Figure 80-200-8]
from the heater coil.
Remove the heater coil from the unit.
A220 Bobcat Loader
80-200-3 Service Manual
A220 Bobcat Loader
80-200-4 Service Manual
HEATER/AC FAN Figure 80-210-2
Removal And Installation
Figure 80-210-1
1
N-22097
NOTE: On some early evaporator/heater units the
N-22096 metal was not cut out, so the blower wiring
harness (Item 1) [Figure 80-210-2] could be
removed without removing the wiring
Raise the lift arms and install an approved lift arm support connector.
device. (See Engaging The Lift Arm Support Device on
Page 10-20-1.) Figure 80-210-3
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Remove the evaporator/heater unit from the back of the 1
cab. (See Removal And Installation on Page 80-160-1.)
NOTE: The heater/AC fan assembly can be removed
from the evaporator/heater unit without
disconnecting the heater or A/C plumbing.
The unit is removed here for photo clarity.
Remove the seal (Item 1) [Figure 80-210-1] from the
side of the evaporator/heater unit.
N-22098
If the metal is not cut out on the housing, mark the area
(Item 1) [Figure 80-210-3] and remove it with a metal
shears.
A220 Bobcat Loader
80-210-1 Service Manual
HEATER/AC FAN (CONT’D) Disassembly And Assembly
Removal And Installation (Cont'd) Figure 80-210-6
Figure 80-210-4
2
1
1 1
2 N-22102
N-22099
Remove the eight mount bolts (Item 1) [Figure 80-210-6]
from the blower wheel cover.
Remove the blower fan wiring harness and grommet
(Item 1) [Figure 80-210-4] from the unit Remove the blower wheel cover from the fan housings.
Figure 80-210-5 Remove the four mount bolts (Item 2) [Figure 80-210-6]
from the fan motor mount.
1
Remove the fan motor mount.
Remove the fan motor assembly from the housing.
Figure 80-210-7
N-22100
Remove the three mount bolts (Item 1) [Figure 80-210-5]
from the blower fan housing. 1 2
Remove the blower fan housing from the evaporator/
heater unit.
N-22107
Check the blower housing (Item 1) and fan motor mount
(Item 2) [Figure 80-210-7] for wear and replace as
needed.
A220 Bobcat Loader
80-210-2 Service Manual
HEATER/AC FAN (CONT’D) Figure 80-210-10
Disassembly And Assembly (Cont'd)
Figure 80-210-8
N-22110
2 Figure 80-210-11
N-22108
Remove the outside rings (Item 1) and fan wheel covers
(Item 2) [Figure 80-210-8] from the fan motor and blower
wheels.
Figure 80-210-9
N-22112
Remove the outside blower wheel clamp (Item 1) [Figure
80-210-10] & [Figure 80-210-11] from the blower wheel.
N-22109
Inspect the end rings and fan wheel covers for wear and
replace as needed [Figure 80-210-9].
A220 Bobcat Loader
80-210-3 Service Manual
HEATER/AC FAN (CONT’D) Wire Connector Removal And Installation
Disassembly And Assembly (Cont'd) Figure 80-210-14
Figure 80-210-12
N-22103
N-22111
Figure 80-210-15
Remove the inside blower wheel clamp (Item 1) [Figure
80-210-12] from the blower wheel.
Figure 80-210-13
1
1
2
N-22104
Remove the plastic wedge (Item 1) [Figure 80-210-14] &
[Figure 80-210-15] from the center of the blower fan
N-22116 motor wiring connector.
Remove the blower wheel (Item 1) and inside ring (Item
2) [Figure 80-210-13] from the blower fan motor shaft.
Repeat the procedure for the other blower wheel.
A220 Bobcat Loader
80-210-4 Service Manual
HEATER/AC FAN (CONT’D) Figure 80-210-17
Wire Connector Removal And Installation (Cont'd)
Figure 80-210-16
1 N-22106
The wiring code for the blower fan connector [Figure 80-
N-22105 210-17] is:
With a pointed screw driver lightly press in on the tabs Number on Connector Wire Color
(Item 1) [Figure 80-210-16] and remove the individual 1 Orange
wires from the connector.
2 Red
3 Yellow
4 Black
5 Open
6 Open
A220 Bobcat Loader
80-210-5 Service Manual
A220 Bobcat Loader
80-210-6 Service Manual
HEATER VALVE Figure 80-220-3
Removal And Installation
Figure 80-220-1
N-22133
Figure 80-220-4
N-22131
Remove the mount bolt (Item 1) [Figure 80-220-1] from
the electrical relay mount.
1
Move the electrical relay to the side for clearance.
Figure 80-220-2
1
N-22139
NOTE: Early model loaders were equipped with a
heater valve that had a wiring harness, and
connector (Item 1) [Figure 80-220-3]. Later
model loaders are equipped with heater
2 valves that allowed the loader wiring harness
(Item 1) [Figure 80-220-4] to be connected
N-22132 directly to the rear of the valve.
Remove the two mount bolts (Item 1) [Figure 80-220-3]
Remove the two hydraulic hoses (Item 1) [Figure 80- from the heater valve mount bracket.
220-2] from the heater valve.
Remove the heater valve and mount bracket from the
Cap the hoses and the heater valve with hydraulic caps loader.
and plugs to prevent oil loss from the system.
Disconnect the loader wiring harness (Item 2) [Figure
80-220-2] from the heater valve.
A220 Bobcat Loader
80-220-1 Service Manual
HEATER VALVE (CONT’D) Figure 80-220-7
Disassembly And Assembly
Figure 80-220-5
1
1
N-22157
Remove the three mounting bolts (Item 1) [Figure 80-
N-22155 220-7] from the heater valve mount plate.
Figure 80-220-8
Remove the three mount bolts (Item 1) [Figure 80-220-5]
from the heater valve actuator.
Figure 80-220-6
2 1
N-22158
Remove the mount plate (Item 1) [Figure 80-220-8] from
N-22156 the heater valve bracket.
Remove the actuator (Item 1) and the three mounting
spacers (Item 2) [Figure 80-220-6] from the heater valve
mount plate.
A220 Bobcat Loader
80-220-2 Service Manual
HEATER VALVE (CONT’D)
Disassembly And Assembly (Cont'd)
Figure 80-220-9
N-22159
Remove the two mounting bolts (Item 1) [Figure 80-220-
9] from the heater valve.
Figure 80-220-10
N-22160
Remove the heater valve mount bracket (Item 1) [Figure
80-220-10] from the heater valve.
Replace the parts as needed.
A220 Bobcat Loader
80-220-3 Service Manual
A220 Bobcat Loader
80-220-4 Service Manual
SPECIFICATIONS
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-70-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . SPEC-70-1
SAFETY &
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 MAINTENANCE
Camshaft And Bearings . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Crankshaft And Main Bearings . . . . . . . . . . . . . . . . . . SPEC-20-3
Cylinder Head And Block . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3 DRIVE
Piston And Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2 SYSTEM
Valves, Valve Guide And Seat Insert . . . . . . . . . . . . . . SPEC-20-1
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . SPEC-50-1
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-2
O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . . SPEC-50-1
O-ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-3
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-5 ELECTRICAL
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . SPEC-50-2 SYSTEM &
Tubelines And Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-2 ANALYSIS
HYDRAULIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . SPEC-60-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1 ENGINE
SERVICE
LOADER SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4 SPECIFICATIONS
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
LOADER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . SPEC-40-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . SPEC-40-2
Torque For General SAE Bolts. . . . . . . . . . . . . . . . . . . SPEC-40-1
A220 Bobcat Loader
SPEC-01 Service Manual
A220 Bobcat Loader
SPEC-02 Service Manual
LOADER SPECIFICATIONS
Machine Dimensions
• Dimensions are given for loader equipped with standard tires and dirt bucket and may vary with other bucket types.
All dimensions are shown in inches. Respective metric dimensions are given in millimeters inclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
83.7
(2166)
“C”
93°
156.2
45° (3968)
21.3
(540) 121.0
(3073)
82.3 91.5
(2090) (2324)
29°
25°
43.7
8.5 (1110)
(216) 106.9 9.5
(2715) (240)
135.4
(3439)
B-16830
“B” B-16831
“C”
“A” 12.61.5 Tires - 74.2 (1825mm)
33-15.5 x 15 Tires - 79.3 (2014mm)
“B” 12-16.5 Tires - 62.2 (1580mm)
33-15.5 x 15 TiresS - 64.2 (16.31mm)
8.00-16 Solid tires-66.81 (1697)
“C” 74” BUCKET WIDTH - 74.0 (1880mm)
66” BUCKET - 68.0 (1727mm)
B-16832
Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the
loader parts.
A220 Bobcat Loader
SPEC 10-01 Service Manual
LOADER SPECIFICATIONS (CONT’D)
Performance
Rated Operating Capacity (SAE) 2000 lbs. (998 kg)
Tipping Load (SAE Rating) 4400 lbs. (1996 kg)
Operating Weight 7745 lbs. (3520 kg)
SAE Breakout Force-Lift 4000 lbf. (17793 N)
-Tilt 4150 lbf. (18460 N)
Axle Torque 6100 lbf. (27134 N)
Travel Speed - Inching 0.3.1 MPH (4,5 km/hr)
Low Range 0-6.2 MPH (9,9 km/hr)
High Range 0-12.4 MPH (19,9 km/hr)
Controls
Vehicle Steering (AWS) Direction is controlled with left hand joystick lever (LH).
Speed is controlled by joystick and hand/foot throttles.
Pattern is a “C” type.
Vehicle Steering (SSL) Direction is controlled with left joystick lever (LH).
Speed is controlled by joystick and hand/foot throttles.
Pattern is an “S” type.
Loader Hydraulics - Lift and Tilt Controlled by right hand joystick
Front Auxiliary Controlled by electrical switch on RH steering lever.
Rear Auxiliary (Option) Controlled by electrical switch on LH steering lever.
Auxiliary Pressure Release Push button on LH panel.
Engine Key-type starter switch and shutdown
Engine Speed Control Hand lever and foot pedal throttle: Key-type starter switch and shutdown.
Starting Aid Glow Plugs - automatically activated by Standard or Deluxe Instrument Panel
Service Brake Two independent hydrostatic systems controlled by LH joystick lever
Secondary Brake One of the hydrostatic transmissions
Parking Brake (Std.) Mechanical Disc, finger-operated rocker switch on center control panel
(Two-Speed Option) Spring applied, pressure release multi disk brake
Engine
Make/Model Deutz/BF4M1011F Turbo-Charged
Fuel/Cooling Diesel/Oil
Horsepower (SAE J1349 Net) 73.0 HP (54 kW)
Maximum Governed RPM 2350 RPM
Torque @ 1800 RPM (SAE Net) 176 ft.-lbs. (239 Nm)
Number of Cylinders Four
Displacement 178 cu. in. (2,92 L)
Bore/Stroke 3.59/4.41 (91/112)
Lubrication Gear Pump Pressure System with Filter
Crankcase Ventilation Closed Breathing
Air Cleaner Dry replaceable paper cartridge with safety element
Ignition Diesel-Compression
Low Idle 1125-1175 RPM
High Idle 2550-2625 RPM
A220 Bobcat Loader
SPEC 10-02 Service Manual
LOADER SPECIFICATIONS (CONT’D)
Hydraulic System
Pump Type Engine driven, Gear type
Pump Capacity @ 2615 Engine RPM 20.0 GPM (75,7 L/min.)
(Std.)
(High Flow Option) 30.0 GPM (113,5 L/min.)
System Relief at Quick Couplers 3000 PSI (206 Bar)
Filters (Charge & Implement) Full flow replaceable, 3-micron synthetic media element
Hydraulic Cylinders Doubleacting; tilt cylinders have cushioning feature on dump and rollback
Bore Diameter: Lift Cylinder (2) 2.50 (63,5)
Tilt Cylinder (1) 3.50 (88,9)
Steering Cylinder (4) 2.00 (50,8)
Rod Diameter: Lift Cylinder (2) 1.75 (44,5)
Tilt Cylinder (1) 1.63 (41,4)
Steering Cylinder (4) 1.00 (25,4)
Stroke: Lift Cylinder (2) 32.48 (825,0)
Tilt Cylinder (1) 18.17 (461,5)
Steering Cylinder (4) 4.86 (123,4)
Control Valve 3-Spool, open center type with float detent on lift and electrically controlled
auxiliary spool
Fluid Lines SAE Standard tubelines, hoses and fittings
Fluid Type Premium Grade, Antiwear Multiviscosity ISO VG46. Petroleum Based Bobcat
Fluid (P/N 6563328) If fluid is not available, use 10W-30/10W-40 Class SE
motor oil for temperatures above 0°F (-18°C)
Hydraulic Function Time:
Wheel Cycle Time (Left/Right Turn) 1.4 Seconds
Raise Lift Arms 4.1 Seconds
Lower Lift Arms 3.9 Seconds
Bucket Dump 2.0 Seconds
Bucket Rollback 2.6 Seconds
Electrical
Alternator Belt driven; 90 amps, open
Battery 12 volt; 1000 cold cranking amps @ 0°F (-18°C); 180 minute reserve capacity
Starter 12 volt; gear type; 3.62 HP (2,7 kW)
Instrumentation Gauges: Hourmeter, Fuel, Engine Coolant Temperature.
Warning lights: Fuel Level, Glow Plugs, System Voltage, Seat Belt, Engine
Coolant Temperature, Engine Oil Pressure, Hydrostatic Charge Pressure,
Hydraulic Oil Temperature, Engine Air Filter & Hydraulic Filter.
Indicators: All Wheel Steer or Skid Steer Mode Attachment Control Device,
BICS Functions, Engine/Hydraulic Systems, Shutdown Function
& Two-Speed High Range.
Optional Deluxe Instrumentation:
*Same gauges and warning lights as standard instrumentation.
*Additional bar-type gauges for: Engine Oil Pressure, System Voltage,
Hydrostatic Charge Pressure and Hydraulic Oil Temperature.
*Additional Features Incl.: Keyless Start, Clock, Job Clock, Help Screens,
Diagnostic Capability, Automatic Shutdown Function.
A220 Bobcat Loader
SPEC 10-03 Service Manual
LOADER SPECIFICATIONS (CONT’D)
Drive System
Main Drive Hydrostatic 4-wheel drive
Transmission Infinitely variable tandem hydrostatic piston pumps, driving two fully reversing
hydrostatic motors
Final Drive #100 HSOC endless roller chain and sprockets in sealed chaincase with oil
lubrication
Engine to Wheel Reduction 39:1
Axle Size 2.76 (70,1)
Wheel Bolts (8) 9/16’”
Capacities
Fuel 21 gals. (79,5 L)
Engine Cooling Oil W/Filter 16 qts. (15,1L)
Hydraulic/Hydrostatic Reservoir 4.7 gals. (17,8 L)
Hydraulic/Hydrostatic System 10.7 gals. (40,5 L)
Chaincase Reservoir 11 gals. (41,6 L)
Engine Lubricating Oil 10 qts. (9,4 L)
Tires
Standard 12-16.5, 10 Ply Rating
Flotation 31-15.5 x 15,8 Ply Rating
Recommended Pressure Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT
mix brands of tires used on the same loader.
A220 Bobcat Loader
SPEC 10-04 Service Manual
ENGINE SPECIFICATIONS
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
General
Displacement 177.7 cu. in. (2912 cu.cm.)
Bore 3.58 (91)
Stoke 4.41(112)
Crankshaft Rotation (Facing Flywheel) Counterclockwise
Ignition 4 Stroke Diesel - Compression
Combustion System Direct Injection
Compression Ratio 17-1
Compression 320-392-PSI (2206-2703 kPa) (22-27 bar)
Firing Order 1-3-4-2
Fuel System
Fuel Injection Pump Pressure (Five Revolutions) Min. 4350 PSI (29993 kPa) (300bar)
Injection Pump Testing Tightness 2175 PSI-145 PSI permissible drop/min. (14997 kPa-
1000kPa) (150 bar-10 bar)
Injection Nozzle Opening Pressure 3625 PSI + 116 (24994 kPa + 800 kPa) (250 bar + 8 bar)
Valves, Valve Guide And Seat Insert
Valve Clearance (Intake) Oil; Temp. Below 176°F 0.012 (0,3)
(80°C)
Valve Clearance (Exhaust) Oil Temp. Below 0.020 (0,5)
176°F (80°C)
Valve Guide I.D. 0.315 ± 0.0010 (8,0 ± 0,025)
Valve Seat Insert O.D. (Intake) 1.680 ± 0.0002 (42,67 ± 0,005)
Valve Seat Insert O.D. (Exhaust) 1.460 ± 0.0002 (37,075 ± 0,006)
Valve Seat Insert Bore (Intake) 1.677 ± 0.0001 (42,6 ± 0,03)
Valve Seat Insert Bore (Exhaust) 1.457 ± 0.001 (370 ± 0,03)
Valve Stem Diameter (Intake) 0.314 - 0.0006 (7,98 - 0,015)
Valve Stem Diameter (Exhaust) 0.313 - 0.0006 (7,96 - 0,015)
Valve Stem Clearance (Intake) 0.0008 - 0.0023 (0,02 - 0,06)
Wear Limit 0.005 (0,12)
Valve Stem Clearance (Exhaust) 0.0016 - 0.003 (0,04 - 0,08)
Wear Limit 0.006 (0,15)
Valve Head O.D. (Intake) 1.594 ± 0.004 (40,5 ± 0,1)
Valve Head O.D. (Exhaust) 1.374 ± 0.004 (34,9 ± 0,1)
Valve Seat Width (Intake) 0.062 ± 0.016 1,58 ± 0,4)
(Exhaust) 0.067 ± 0.016 (1,7 ± 0,4)
Seat Angle (Intake) 30°
(Exhaust) 45°
Marg Thickness (Intake) N/A
Wear Limit 0.0551 (1,4)
Marg Thickness (Exhaust) N/A
Wear Limit 0.047 (1,2)
Valve Recess 0.0512 ± 0.0051 (1,3 ± 0,13)
Wear Limit 0.0512 (1,3)
Valve Spring Free Length 0.132 (3,25) diameter 1.531 (38,9)
0.134 (3,40) diameter. 1.547 (39,3)
Valve Spring Inclination 0.126 (3,2)
A220 Bobcat Loader
SPEC-20-1 Service Manual
ENGINE SPECIFICATIONS (CONT’D)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Piston And Rings
Piston Diameter 3.578 (90,9)
I.D. for Piston Pin 1.0236 + 0.0004 - 0.0016 (26,0 + 0,01- 0,04)
Piston Pin Diameter 1.118 - 0.0002 (30,0 - 0,005)
Piston Ring Groove - 1st 0.0787 + 0.004 (2,0 + 0,10 - 0,08)
2nd 0.0787 + 0.004- 0.003 (2,0 + 0,10 - 0,08)
3rd 0.118 + 0.002-0.0008 (3,0 + 0,04 - 0,02)
Piston Ring Clearance - 1st 0.004 - 0.005 (0,09 - 0,12)
Wear Limit 0.0078 (0,2)
- 2nd 0.003 - 0.004 (0,07 - 0,10)
Wear Limit 0.006 (0,16)
- 3rd 0.015 - 0.003 (0,04 - 0,07)
Wear Limit 0.005 (0,12)
Piston Ring Gap -1st 0.0118 - .019 (0,3 - 0,5)
- 2nd 0.0315 - 0.039 (0,8 - 1,0)
- 3rd 0.018 - 0.028 (0,45 - 0,7)
Wear Limit - 1st 0.0315 - (0,8)
- 2nd 0.071 (1,8)
- 3rd 0.035 (0,9)
Bore for Piston Pin Bushing N/A
Piston Pin Bushing O. D. N/A
Piston Pin Bushing I. D. (pressed in) N/A
Piston Pin Clearance 0.0009 - 0.0016 (0,025 - 0,04)
Wear Limit 0.0031 (0,08)
Connecting Rod
Small End Bushing I.D. (pressed in) 1.181 + 0.0014 + 0.00010 (30,0 + 0,35 + 0,025)
Wear Limit 0.003 (0,08)
Bore for Small End Bushing 1.299 + 0.0008 (33,0 + 0,02)
O.D. for Small End Bushing 1.299 + 0.0043 -+ 0.0028 (33,0 + 0,11 -+ 0.07)
Parallel Check Permissible 0.0039 over a distance of 3.937 (0,10 over
100,0)
Alignment 0.002 (0,05)
Connecting Rod Width 1.063 - 0.0023 (27,0 - 0,06)
Connecting Rod End Play 0.0078 - 0.022 (0,2 - 0,56)
Wear Limit 0.0315 (0,8)
Center Distance From Small to Large Bore 6.811 ± 0.0012 (173,0 ± 0,03)
Bore for Large End Bearing 2.303 + 0.0008 (58,5, + 0,02)
Large End Bearing Shells I.D. 2.166 - 2.167 (55,004 - 55,04)
Limit for Undersize 2.146 - 2.147 (54,5 04 - 54,54)
Large End Bearing Radial Clearance 0.0009 - 0.003 (0,024 - 0,78)
Wear Limit 0.005 (0,12 mm)
Large End Bearing Width 1.008 - 0.012 (25,6 - 0,3)
A220 Bobcat Loader
SPEC-20-2 Service Manual
ENGINE SPECIFICATIONS (CONT’D)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Cylinder Head And Block
Cylinder Head Studs - Length 5.906 ± 0.031 (150,0 ± 0,8)
Cylinder Bore 3.583 + 0.0008 (91,0 + 0,02)
Wear Limit 3.587 (91,1)
Crankshaft And Main Bearings
Crankshaft Pin Width 1.220 (31,0)
Crankshaft Pin Diameter 2.165 - 0.004 - 0.0012 (55,0 - 0,01 - 0,03)
Oval Wear Limit 0.0004 (0,01)
Crankshaft Journal Width 1.378 + 0,0016 (35,0 + 0,04)
Oval Wear Limit 0.0003 (0,008)
Crankshaft Journal Diameter 2.756 - 0.0004 - 0.0012 (70,0 - 0,01 - 0,03)
Oval Wear Limit 0.0003 (0,008)
Eccentricity Max Permitted 0.002 (0,05)
Thrust Bearing Journal Width 1.378 + 0.002 (35,0 + 0,04)
Main Bearing Shell I.D. 2.757 - 2.758 (70,02 - 70,055)
Radial Clearance 0.0011 - 0.0033 (0,03 - 0,084)
Wear Limit 0.0047 (0,12)
Bearing Bore in Crankcase 2.953 + 0.0007 (75,0 + 0,019)
Thrust Bearing Stop Rings O.D. 1.374 - 0.005 (34,9 - 0,133)
Oversize 0.0157 (0,4)
Limit for Oversize 1.406 - 0.0052 (35,7 - 0,133)
Crankshaft End Play 0.0039 - 0.0106 (0,1 - 0,27)
Wear Limit 0.016 (0,4)
Camshaft And Bearings
Camshaft End Play 0.0118 - 0.0236 (0,3 - 0,6)
Wear Limit 0.0315 (0,8)
Camshaft Bearing I.D. 2.126 + 0.0021 (54,0 + 0,054)
Wear Limit 2.129 (54,08)
Radical Clearance 0.0019 - 0.0048 (0,05 - 0,124)
Cam Lift (Intake) 0.260 (6,6)
Cam Lift Exhaust 0.268 (6,8)
Oil Pump
Oil Pump Pressure Setting 101.5 PSI (700 kPa) (7bar)
Min. Eng. Oil Pressure, Oil Temp. 230°F (110°C) at :
900 RPM 20.3 PSI (140 kPa) (1.4 bar)
1800 RPM 31.9 PSI (220 kPa) (2.2 bar)
2800 RPM 43.5 PSI (300 kPa) (3.0 bar)
Thermostat Rating 203° F (95 °C)
A220 Bobcat Loader
SPEC-20-3 Service Manual
A220 Bobcat Loader
SPEC-20-4 Service Manual
LOADER TORQUE
Specifications
ITEM Ft.-Lbs. Nm
Air Intake Manifold Bolts (M8 Torx) 15 20
Adapter Housing Bolts (M12) 21-24 28-33
Camshaft Bolts (M14 x 1,5 x 110) 22 30
Plus 210 degrees
Camshaft Thrust Washer Bolt (M8) 15 20
Connecting Rod Cap Nuts 22 30
Plus 60 degrees, 60 degrees = 120 degrees
Crankcase Screw Plugs (M18) 37 50
(M24) 82 111
(M30) 12-15 16-20
Crankshaft Gear Mount Bolt 243-295 330-400
Cylinder Head Bolts - Step 1 22 30
Step 2 59 80
Step 3 118 160
Plus 90 degrees
Exhaust Manifold Bolts (M10) 30 40
Exhaust Turbocharger Nuts (M8) 22 30
Flywheel Bolts 22 30
Plus 60 degrees, 30 degrees = 90 degrees
Front Cover Bolts 15 20
Front Mount Foot Bolts (M14 x 55) 38 52
Fuel Lift Pump Bolts (M8 Torx) 15 20
Glow Plug 15-18 20-24
Injector Cap Nut 35 47
Injector Pump Mounting Nuts 15 21
Main Bearing Bolts 37 50
Plus 60 degrees, 45 degrees = 105 degrees
Oil Pan Bolts (M8) 15 20
Oil Pan Drain Plug 40 54
Oil Pump Bolts (M8 Torx) 16 22
Oil Pressure Control Valve Screw Plug 82 111
Oil Return Line Cap Nut 13-14 18-19
Oil Suction Pipe 16 22
Oil Temperature Switch 21 28
Rocker Arm Bracket Bolts (M8 Torx) 15 20
Rear Cover Bolts 15 20
Rear Mounting Foot Bolts (M12) 23 31
Starter Carrier Bolts (M12) 15-18 20-24
Starter Fastening Bolts 25-28 34-38
Thermostat Housing Screw Plug (M38) 82 111
Timing Belt Tensioner Pulley Nut 33 45
V-Belt Pulley Bolts (M10) 30-36 41-49
A220 Bobcat Loader
SPEC-30-1 Service Manual
LOADER TORQUE (CONT’D)
Specifications (Cont’d)
ITEM Ft.-Lbs. Nm
Air Intake 3-Hole Flange Bolts (M8 Torx) 54-65 6,1-7,3
Breather Vent Bolts 75 8,5
Crankcase Screw Plugs (M20) 85-104 9,6-11,7
(M10) 28-36 3,1-4,0
(M6) 13-16 1,4-1,8
(M16) 62-78 7,0-8,8
Cylinder Head Cover 75 8,5
Fuel Filter Bracket Bolt (M8) 54 6,1
Full Load Stop Screw Nut 40 4,5
Governor Lever Shaft Bolts 81 9,2
Injector Fastening Bolt (M8 Torx) 49-59 5,5-6,6
Injector Line 36-45 4,1-5,1
Minimum Speed Screw 40 4,5
Oil Filter Bracket Bolts (M6) 24-30 2,7-3,4
Oil Intake Housing Bolts (M8 Torx) 54-65 6,1-7,3
Oil Pressure Switch 115 13
Piston Cooling Oil Nozzles 11 1,2
Rocker Arm Set Screw Nut 49-59 5,5-6,6
Shut Down Stop Screw 40 4,5
Shut Down Solenoid Bolts 79 9
Thermostat Housing Bolts (M6 Torx) 20-24 2,2-2,7
Thermostat Housing Bolts (M8 Torx) 24-32 2,7-3,6
Turbocharger Backing Plate Screws 88 10
Turbocharger Compressor Housing Bolts 62 7
Turbocharger Compressor Wheel Nut 44 5
Valve Plunger Housing Bolts (M8 Torx) 24-32 2,7-3,6
A220 Bobcat Loader
SPEC-30-2 Service Manual
LOADER TORQUE (CONT’D)
Specifications (Cont’d)
ITEM Ft.-Lbs. Nm
Air Cleaner Mounting Bolts 25-28 34-38
Alternator Pulley Nut 50 68
Axle Hub Mounting Bolt 350 475
Axle Sprocket Bolt 475-525 645-710
BICS™ Control Valve Mounting Bolts 15-16 20-22
Bob-Tach Lever Pivot Bolt 25-28 34-38
Control Valve Mounting Bolts & Nuts 15-16 20-22
Engine Mounting Bolts 65-70 88-95
Exhaust Pipe to Exhaust Manifold 20-35 27-47
Filter Housing Mounting Bolts 25 34
Front Panel Bolts 16-20 22-27
Hydraulic Pump Bolts 45-50 61-68
Hydraulic Pump Mounting Bolts 25-27 34-37
Hydraulic Reservoir Strap Bolts 16-20 22-27
Hydrostatic Motor Mounting Bolts 210-230 285-310
Hydrostatic Pump Mounting Bolts 65-70 88-95
Hydrostatic Pump Pulley Bolt 175-200 237-271
Lift Arm By-Pass Control Valve Mounting Bolts 15-16 20-22
Main Frame to Chancase Bolts 300-330 410-450
Main Relief Valve 35-40 47-54
Motor Carrier Bolts 220-245 300-330
Operator Cab Fastening Nuts 40-50 54-68
Operator Cab Pivot Bolts & Nuts 25-35 34-47
Pivot Pins Lock Bolt & Nut 18-20 24-27
Seat Belt Fastening Bolts 40-45 54-61
Seat Mounting Bolts 9-11 12,2-15
Seat Bar Pivot Bolts 25-28 34-38
Wheel Nuts 105-115 142-156
A220 Bobcat Loader
SPEC-30-3 Service Manual
A220 Bobcat Loader
SPEC-30-4 Service Manual
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Melroe that have zinc phosphate coating are specified by the letter H following the part number.
THREAD
SAE GRADE 5 SAE GRADE 8
SIZE
INCH. .250 80-90 110-120
LBS. (9,0-10,2) (12,4-13,6)
(Nm) .3125 180-200 215-240
(20,3-22,6) (24,2-27-1)
FOOT .375 25-28 35-40
LBS. (34-38) (47-54)
(Nm) .4375 40-45 60-65
(54-61) (81-88)
.500 65-70 90-100
(88-95) (122-136)
.5625 90-100 125-140
(122-136) (170-190)
.625 125-140 175-190
(170-190) (240-260)
.750 220-245 300-330
(300-330) (410-450)
.875 330-360 475-525
(450-490) (645-710)
1.000 475-525 725-800
(645-710) (985-1085)
1.125 650-720 1050-1175
(880-975) (1425-1600)
1.250 900-1000 1475-1625
(1200-1360) (2000-2200)
1.375 1200-1350 2000-2200
(1630-1830) (2720-2980)
1.500 1500-1650 2600-2850
(2040-2240) (3530-3870)
1.625 2000-2800 3450-3800
(2720-2980) (4680-5150)
1.750 2500-2750 4300-4800
(3390-3730) (5830-6500)
1.875 3150-3500 5500-6100
(4270-4750) (7450-8300)
2.000 3800-4200 6500-7200
(5150-5700) (8800-9800)
A220 Bobcat Loader
SPEC-40-1 Service Manual
TORQUE SPECIFICATIONS FOR BOLTS (CONT’D)
Torque For General Metric Bolts
THREAD SIZE MATERIAL
(DIA. X PITCH) HEAD MARK 4 HEAD MARK 7 HEAD MARK 10
M 5 x 0.8 3-4 ft.-lbs.
(4-5 Nm)
M 6 x 1.0 6-7 ft.-lbs. 6-9 ft.-lbs.
(8-9 Nm) (8-12 Nm)
M 8 x 1.25 6-9 ft.-lbs. 11-16 ft.-lbs. 18-25 ft.-lbs.
(8-12 Nm) (15-22 Nm) (24-34 Nm)
M 10 x 1.25 13-18 ft.-lbs. 22-30 ft.-lbs. 36-50 ft.-lbs.
(18-24 Nm) (30-41 Nm) (49-68 Nm)
M 12 x 1.25 22-30 ft.-lbs. 40-54 ft.-lbs. 69-87 ft.-lbs.
(30-41 Nm) (54-73 Nm) (94-118 Nm)
M 14 x 1.25 36-50 ft.-lbs. 58-80 ft.-lbs. 116-137 ft.-lbs.
(49-68 Nm) (79-108 Nm) (157-186 Nm)
A220 Bobcat Loader
SPEC-40-2 Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-50-2
O-ring Face Seal Connection O-ring Face Seal Tightening Torque
x x *
Tubeline x TORQUE
Outside x Ft.-lbs.
IMPORTANT Diameter
1/4”
Thread Size
9/16” - 18
(Nm)
13 (18)
When repairing hydrostatic and hydraulic systems, 3/8” 11/16” - 16 22 (30)
clean the work area before disassembly and keep all 1/2” 13/16” - 16 40 (54)
parts clean. Always use caps and plugs on hoses,
5/8” 1” - 14 60 (81)
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. 3/4” 1-3/16” - 12 84 (114)
I-2003-0888 7/8” 1-3/16” - 12 98 (133)
1” 1-7/16” - 12 118 (160)
Figure SPEC-50-1
1-1/4” 1-11/16” - 12 154 (209)
1-1/2” 2” - 12 163 (221)
B-7575
When the fitting is tightened, you can feel when the fitting
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-50-1].
A220 Bobcat Loader
SPEC-50-1 Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS Flare Fitting
(CONT’D)
Figure SPEC-50-4
Straight Thread O-ring Fitting
Figure SPEC-50-3
Nut Nut
Washer
Washer 2
O-ring
O-ring
TS-1619
A-1852 Use the following procedure to tighten the flare fitting:
Tighten the nut until it makes contact with the seat. Make
Lubricate the O-ring before installing the fitting. Loosen a mark across the flats of both the male and female parts
the jam nut and install the fitting. Tighten the jam nut until of the connection (Item 1) [Figure SPEC-50-4]
the washer is tight against the surface [Figure SPEC-50-
3]. Use the chart [Figure SPEC-50-5 on Page 3] to find the
correct tightness needed (Item 2) [Figure SPEC-50-4]. If
Tubelines And Hoses the fitting leaks after tightening, disconnect it and inspect
the seat area for damage.
Replace any tubelines that are bent or flattened. They will
restrict flow, which will slow hydraulic action and cause
heat.
Replace hoses which show signs of wear, damage or
weather cracked rubber.
Always use two wrenches when loosening and tightening
hose or tubeline fittings.
A220 Bobcat Loader
SPEC-50-2 Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-50-7
(CONT’D)
Hex Flat Tightening Method
Flare Fitting (Cont’d)
Figure SPEC-50-5
1
Flare Fitting Tightening Torque
Tubeline x TORQUE
Outside x Ft.-lbs.
Diameter Thread Size (Nm)
1/4” 7/16” - 20 13 (18)
2
5/16” 1/2” - 20 17 (23)
3/8” 9/16” - 18 22 (30)
1/2” 3/4” - 16 40 (54)
TS-1619
5/8” 7/8” - 14 60 (81)
3/4” 1-1/16” - 12 84 (114)
Tighten the nut until it contacts with the seat. Make a
7/8” 1-3/16” - 12 98 (133) mark across the flats of both the male and female parts of
1” 1-5/16” - 12 118 (160) the connection (Item 1) [Figure SPEC-50-7].
1-1/4” 1-5/8” - 12 154 (209)
Use the chart [Figure SPEC-50-8 on Page 4] to find the
1-1/2” 1-7/8” - 12 163 (221) correct tightness needed (Item 2) [Figure SPEC-50-7]. If
2” 2-1/2” - 12 252 (342) the fitting leaks after tightening, disconnect it and inspect
the seat area for damage.
O-ring Flare Fitting
Figure SPEC-50-6
Primary O-ring Flare
Seal
Secondary
Seal
P13009
The flare is the primary seal, the O-ring is the secondary
seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-50-6].
If necessary, the O-ring-flare fitting can be used without
an O-ring.
Use the following procedure to tighten the O-ring flare
fitting.
A220 Bobcat Loader
SPEC-50-3 Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-50-9
(CONT’D)
O-ring Flare Fitting (Cont’d)
Copper Bonnet Orifice
Figure SPEC-50-8
O-ring Flare Fitting Tightening Torque
x x *
Tubeline x TORQUE
Outside x Ft.-lbs.
1
Diameter Thread Size (Nm)
1/4” 7/1” - 20 13 (18)
5/16” 1/2” - 20 17 (23)
3/8” 9/16” - 18 22 (30) P13572
1/2” 3/4” - 16 40 (54)
5/8” 7/8” - 14 60 (81) NOTE: O-ring flare fittings are not recommended in
all applications. Use the standard flare fittings
3/4” 1-1/16” - 12 84 (114)
in these applications.
7/8” 1-3/16 - 12 98 (133)
1” 1-5/16” - 12 118 (160) Do not use a O-ring flare fitting when a copper bonnet
orifice is used. When tightened the connection at the
1-1/4” 1-5/8” - 12 154 (209)
bonnet may distort the flare face and prevent it from
1-1/2” 1-7/8” - 12 163 (221) sealing.
2” 2-1/2” - 12 252 (342)
Use a standard flare fitting (Item 1) [Figure SPEC-50-9]
* If a torque wrench is used to tighten a new fitting to a as shown.
used hose/tubeline.
When a O-ring flare fitting is used as a straight thread
* If a toque wrench is used to tighten a used fittng to a port adapter the O-ring flare face is not used to seal. The
new hose/tubeline. O-ring may come off the fitting and enter the system.
* If a torque wrench is used to tighten a new fitting to a Figure SPEC-50-10
new hose/tubeline.
** If using the hex flat tightening method to tighten a new
fitting to a new hose/tubeline.
2
** If using the hex flate tighening method to tighten a
new fitting to a used hose/tubeline.
*** If using the hex flat tightening method to tighten a
used fitting to a new hose/tubeline.
1
P13573
NOTE: Always remove the O-ring (Item 1) [Figure
SPEC-50-10] from the flare face as shown.
An O-ring (Item 2) [Figure SPEC-50-10] is added to the
flat boss of the fitting to seal the connection in this
application.
A220 Bobcat Loader
SPEC-50-4 Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS Port seal and nut, washer and O-ring (O-ring Boss)
(CONT'D) fittings use the same tightening torque valve chart.
Port Seal Fitting If a torque wrench cannot be used, use the following
method.
Figure SPEC-50-11
Tighten the nut until it just makes metal to metal contact,
you can feel the resistance.
Tighten the nut with a wrench no more than one hex flat
maximum.
Do not over tighten the port seal fitting.
Nut Seals NOTE: If a torque wrench cannot be used, use the
To Fitting hex flat tightening method as an approximate
guideline.
Nut Seals NOTE: Port seal fittings are not recommended in all
To Port applications. Use O-ring boss fittings in these
applications.
Secondary O-ring Seal P-13008
The nut is the primary seal, the O-ring is the secondary
seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-50-11].
The hex portion of the nut does not contact the surface of
the component when the nut is tight.
Figure SPEC-50-12
Port Seal and O-ring Boss
Tightening Torque
x TORQUE
x Ft.-lbs.
Thread Size (Nm)
7/16” - 20 13 18)
9/16” - 18 22 (30)
3/4” -1 6 40 (54)
7/8” - 14 60 (81)
1-1/16” - 12 84 (114)
1-3/16” - 12 98 (133)
1-5/16” - 12 118 (160)
1-7/16” - 12 154 (209)
1-5/8” - 12 163 (221)
Use the following procedure to tighten the port seal
fitting:
A220 Bobcat Loader
SPEC-50-5 Service Manual
A220 Bobcat Loader
SPEC-50-6 Service Manual
HYDRAULIC FLUID SPECIFICATIONS When temperatures below zero degree F (-18°C) are
common, the loader must be kept in a warm building.
Specifications Extra warm-up time must be used each time the loader is
started during cold temperature conditions. Cold fluid will
Use Bobcat hydraulic transmission fluid (P/N 6563328). If not flow easily and it makes action on the hydraulic
this fluid is not available, use 10W-30 or 10W-40 SAE function slower. Loss of fluid flow to the hydrostatic
Motor Oil (5W-30 for 0°F [-18°C] and Below). transmission pump (indicated by TRANS light ON) can
cause transmission damage in less than 60 seconds.
DO NOT use automatic transmission fluids in the loader
or permanent damage to the transmission will result.
WARNING
WARNING During cold weather (32°F [0°C] and below), do not
operate machine until the engine has run for at least
Diesel fuel or hydraulic fluid under pressure can five minutes at less than half throttle. This warm-up
penetrate skin or eyes, causing serious injury or period is necessary for foot pedal operation and safe
death. Fluid leaks under pressure may not be visible. stopping. Do not operate controls during warm-up
Use a piece of cardboard or wood to find leaks. Do period.
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention When temperatures are below -20°F (-30°C), the
from a physician familiar with this injury. hydrostatic oil must be heated or kept warm. The
W-2072-0496 hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above 0°F (-18°C) if possible.
W-2027-1285
A220 Bobcat Loader
SPEC-60-1 Service Manual
A220 Bobcat Loader
SPEC-60-2 Service Manual
CONVERSIONS
Decimal And Millimeter Equivalents
A220 Bobcat Loader
SPEC-70-1 Service Manual
A220 Bobcat Loader
SPEC-70-2 Service Manual
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: A220-1
Date: 7 November, 2001
Product: Bobcat Loader
Model: A220
Manual No: 6901245 (9-01)
The following pages are a revision to the above Service Manual.
Take out existing pages and put in the new pages as listed below:
TAKE OUT PUT IN REVISION DECRIPTION
30-40-1 thru 30-40-6 30-40-1 thru 30-40-6 Text and photo revised
60-90-77 thru 60-90-78 60-90-77 thru 60-90-78 Text revised
Printed in U.S.A.
2
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: A220-2
Date: 3 May 2004
Product: Bobcat Loader
Model: A220
Manual No: 6901245 (5-04)
Please discard your old A220 Service Manual (P/N 6901245) Dated 9-01 and replace it with the
revised A220 Service Manual (P/N 6901245) Dated 5-04.
This Service Manual has added updates.
Printed in U.S.A.
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: A220-3
Date: 29 March 2006
Product: Bobcat Loader
Model: A220
Manual No: 6901245 (5-04)
A220 Service Manual (P/N 6901245) Dated (3-06) contains updated service information which
replaces the previous A220 Service Manual (P/N 6901245) Dated (5-04).
Printed in U.S.A.
2
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