Service Manual Bobcat s220 530711001

6904154 (3-09) Printed in U.S.A. Bobcat Company 2009

Service ManualS220 Skid-Steer Loader

S/N 530711001 & AboveS/N 530811001 & Above

EQUIPPED WITHBOBCAT INTERLOCK

CONTROL SYSTEM (BICS)

MAINTENANCE SAFETY

Never service the Bobcat Skid-Steer Loader without instructions.

Have good ventilation whenwelding or grinding paintedparts.Wear dust mask when grindingpainted parts. Toxic dust and gascan be produced.Avoid exhaust fume leaks whichcan kill without warning. Exhaustsystem must be tightly sealed.

Stop, cool and clean engine offlammable materials beforechecking fluids.Never service or adjust loaderwith the engine running unlessinstructed to do so in themanual.Avoid contact with leakinghydraulic fluid or diesel fuelunder pressure. It can penetratethe skin or eyes.Never fill fuel tank with enginerunning, while smoking or whennear open flame.

Disconnecting or loosening anyhydraulic tubeline, hose, fitting,component or a part failure cancause lift arms to drop. Do not gounder lift arms when raisedunless supported by anapproved lift arm support device.Replace it if damaged.

Keep body, jewelry and clothingaway from moving parts,electrical contact, hot parts andexhaust.Wear eye protection to guardfrom battery acid, compressedsprings, fluids under pressureand flying debris when enginesare running or tools are used.Use eye protection approved fortype of welding.Keep rear door closed except forservice. Close and latch doorbefore operating the loader.

Never work on loader with liftarms up unless lift arms are heldby an approved lift arm supportdevice. Replace if damaged.Never modify equipment or addattachments not approved byBobcat Company.

Lead-acid batteries produceflammable and explosive gases.Keep arcs, sparks, flames andlighted tobacco away frombatteries.Batteries contain acid whichburns eyes or skin on contact.Wear protective clothing. If acidcontacts body, flush well withwater. For eye contact flush welland get immediate medicalattention.

Use the correct procedure to lift orlower operator cab.

Cleaning and maintenance arerequired daily.

MSW08-0805

WRONG

B-16102B-6589

B-10731a

CORRECT

B-15590

CORRECT

B-15591

CORRECT

B-15599

WRONGWRONG

B-15593

WRONG

B-15592

B-15600

WRONG WRONG

B-16102B-15601

WARNINGInstructions are necessary before operating or servicing machine. Read andunderstand the Operation & Maintenance Manual, Operators Handbook andsigns (decals) on machine. Follow warnings and instructions in the manualswhen making repairs, adjustments or servicing. Check for correct function afteradjustments, repairs or service. Untrained operators and failure to followinstructions can cause injury or death. W-2003-0903

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 & MaintenanceManual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcatreplacement parts. The Service Safety Training Course is available from your Bobcat dealer.

Safety Alert Symbol: This symbol with a warning statement, means: Warning, be alert! Your safety is involved! Carefully read the message that follows.

ALPHABETICAL INDEXS220 Service Manual

ACCESS PANEL (INSIDE) ..................................... 50-01ACCESS PANEL (INSIDE) (SJC) ........................... 50-01AIR CLEANER ........................................................ 70-01AIR CLEANER SERVICE ....................................... 10-01AIR CONDITIONING SYSTEM FLOW ................... 80-01ALTERNATOR ........................................................ 60-01

BACK UP ALARM SYSTEM ................................... 60-01BATTERY................................................................ 60-01BLOWER FAN ........................................................ 80-01BOBCAT CONTROLLER (ACS) ............................. 60-01BOBCAT CONTROLLER (MAIN)............................ 60-01BOBCAT CONTROLLER (SJC) (DRIVE) ............... 60-01BOBCAT INTERLOCK CONTROL SYSTEM (BICS) ................................................... 60-01BOB-TACH (HAND LEVER) .................... 10-01, 50-01BOB-TACH (POWER) BLOCK ............................ 20-01BOB-TACH (POWER- OPTION) ...........10-01, 50-01BRAKE.................................................................... 40-01BRAKE (TWO-SPEED)........................................... 40-01BUCKET POSITION VALVE ................................20-01

CAB DOOR............................................................. 50-01CALIBRATION ........................................................ 60-01CAMSHAFT AND TIMING GEARS......................... 70-01CASE DRAIN FILTER............................................. 30-01CHAINCASE ........................................................... 40-01CHARGE PRESSURE............................................ 30-01COMPRESSOR ...................................................... 80-01CONDENSER ......................................................... 80-01CONTROL HANDLE / LEVER ................................ 50-01CONTROL HANDLE / LEVER (ACS) .....................50-01CONTROL PANEL..................................................50-01CONTROL PANEL SETUP ..................................... 60-01CONTROL PANEL (SJC).................................... 50-01CONTROL PEDALS (ACS) .................................... 50-01CONTROL PEDALS AND LINKAGES.................... 50-01CONTROL SYSTEM (ACS).................................... 60-01CONVERSIONS ............................................SPEC-01CRANKSHAFT AND PISTONS .............................. 70-01CYLINDER HEAD................................................... 70-01CYLINDER (LIFT) ................................................... 20-01CYLINDER (BOB-TACH) ........................................ 20-01CYLINDER (TILT) ................................................ 20-01DIAGNOSTICS SERVICE CODES ..................... 60-01DRIVE BELT ........................................................... 30-01DRIVE COMPONENTS .......................................... 40-01

ELECTRICAL / HYDRAULIC CONTROLS .............60-01ELECTRICAL/HYDRAULIC CONTROLS (SJC) ..... 60-01ELECTRICAL SYSTEM INFORMATION ................ 60-01ENGINE COOLING SYSTEM...................... 10-01, 70-01ENGINE INFORMATION ........................................ 70-01ENGINE LUBRICATION SYSTEM.......................... 10-01ENGINE SPEED CONTROL .................................. 70-01ENGINE SPEED CONTROL (SJC) ........................ 70-01EVAPORATOR........................................................ 80-01EVAPORATOR / HEATER UNIT ............................. 80-01

EXPANSION VALVE................................................80-01FINAL DRIVE TRANSMISSION (CHAINCASE) . 10-01FLYWHEEL AND HOUSING ................................ 70-01FLYWHEEL RPM SENSOR ................................. 60-01FRONT AUXILIARY HYD. COUPLER BLOCK .......20-01FUEL SYSTEM.............................................10-01, 70-01FUEL TANK .............................................................50-01

HEATER COIL.........................................................80-01HEATER VALVE ......................................................80-01HYDRAULIC CONNECTION SPECS ............... SPEC-01HYDRAULIC CONTROL VALVE (ACS) OR (SJC)..20-01HYDRAULIC CONTROL VALVE (STANDARD) ......20-01HYDRAULIC FLUID RESERVOIR ..........................20-01HYDRAULIC FLUID SPECIFICATIONS............ SPEC-01HYDRAULIC / HYDROSTATIC FILTERS ................20-01HYDRAULIC / HYDROSTATIC SYSTEM................10-01HYDRAULIC PUMP (STANDARD) (HIGH FLOW)..20-01HYDRAULIC PUMP (STANDARD) .........................20-01HYDRAULIC PUMP (SJC) (HIGH FLOW)...............20-01HYDRAULIC PUMP (SJC) ......................................20-01HYDRAULIC SYSTEM INFORMATION ..................20-01HYDROSTATIC MOTOR ..................................... 30-01HYDROSTATIC MOTOR (TWO-SPEED) ................30-01HYDROSTATIC MOTOR CARRIER........................30-01HYDROSTATIC MOTOR CARRIER (SJC)..............30-01HYDROSTATIC PUMP .........................................30-01HYDROSTATIC PUMP (SJC) ............................. 30-01HYDROSTATIC SYSTEM INFORMATION ..........30-01

INSTRUMENT PANELS ..........................................60-01

JOYSTICK CONTROL ............................................50-01

LIFT ARMS..............................................................50-01LIFT ARM BYPASS CONTROL VALVE .............. 20-01LIFT ARM SUPPORT DEVICE ........................... 10-01LIFTING AND BLOCKING THE LOADER...............10-01LIGHTS ................................................................60-01(S220) LOADER SPECIFICATIONS ................. SPEC-01LOADER STORAGE AND RETURN TO SERVICE 10-01LUBRICATION SYSTEM.........................................70-01LUBRICATING THE LOADER.................................10-01

MAIN RELIEF VALVE ..............................................20-01MAINTENANCE CLOCK .........................................60-01MUFFLER................................................................70-01

OIL COOLER...........................................................20-01OPERATOR CAB .........................................10-01, 50-01OPERATOR SEAT...................................................50-01OPERATOR SEAT (SUSPENSION)........................50-01

PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START) ..................................................................60-01PIVOT PINS ............................................................10-01

S220 Service Manual

ALPHABETICAL INDEX (CONTD)REAR AUXILIARY DIVERTER VALVE....................20-01REAR DOOR ...................................................... 50-01REAR GRILL ....................................................... 50-01RECEIVER / DRIER ................................................80-01REGULAR MAINTENANCE ....................................80-01REMOTE START TOOL ......................................10-01REMOTE START TOOL (SERVICE TOOL) ............10-01

SEAT BAR ...............................................................50-01SEAT BAR SENSOR ...............................................60-01SERVICE PC (LAPTOP COMPUTER) ....................60-01SERVICE SCHEDULE ........................................... 10-01SPEED SENSOR (SJC) ..........................................60-01SPARK ARRESTOR MUFFLER..............................10-01STARTER ................................................................60-01STEERING DRIFT COMPENSATION.....................60-01STOPPING THE ENGINE AND LEAVING THE LOADER........................................................10-01SYSTEM CHARGING AND RECLAMATION ..........80-01

THERMOSTAT.........................................................80-01TIRE MAINTENANCE .............................................10-01TORQUE SPECIFICATIONS FOR BOLTS .... SPEC-01TOWING THE LOADER ..........................................10-01TRACTION LOCK....................................................60-01TRANSPORTING LOADER ON A TRAILER ..........10-01TROUBLESHOOTING.............................................80-01TURBOCHARGER ..................................................70-01

WINDOW (FRONT DOOR) .....................................50-01WINDOW (REAR)....................................................50-01WINDOW (SIDE) .....................................................50-01WINDOW (TOP) ......................................................50-01

CONTENTS

S

SAFETY &

SI S220 Service Manual

FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01

SPECIFICATION

HYDROSTATIC

MAIN FRAME

SYSTEM

SYSTEMDRIVE

ELECTRICAL

MAINTENANCE

SYSTEM &ANALYSIS

SERVICEENGINE

SPECIFICATION

HVAC

HYDRAULICSYSTEM

FOREWORDThis manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustmentprocedures 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:

FW SSL-1008 SM

1. Check that the ROPS/FOPS(Including side screens) is ingood condition and is notmodified.

9. The parking brake mustfunction correctly.

2. Check that ROPS mountinghardware is tightened and isBobcat approved.

10. Enclosure door latches mustopen and close freely.

3. The seat belt must becorrectly installed, functionaland in good condition.

11. Bob-Tach wedges andlinkages must functioncorrectly and be in goodcondition.

4. The seat bar must becorrectly adjusted, clean andlubricated.

12. Safety treads must be in goodcondition.

5. Check lift arm support device,replace if damaged.

13. Check for correct function ofindicator lamps.

6. Machine signs (decals) mustbe legible and in the correctlocation.

14. Check hydraulic fluid level,engine oil level and fuelsupply.

7. Steering levers, hand controlsand foot pedals must return toneutral (as applicable).

15. Inspect for fuel, oil orhydraulic fluid leaks.

8. Check for correct function ofthe work lights.

16. Lubricate the loader.II S220 Service Manual

III S220 Service Manual

FW SSL-1008 SM

17. Check the condition of thebattery and cables.

23. Operate the machine andcheck all functions.

18. Inspect the air cleaner fordamage or leaks. Check thecondition of the element.

24. Check for correct function ofthe Bobcat Interlock ControlSystem (BICS) before themachine is returned to thecustomer.

19. Check the electrical chargingsystem.

25. Check for proper function offront horn and back-up alarm(if equipped).

20. Check tires for wear andpressure. Check tracks forwear and tension. Use onlyapproved tires or tracks.

26. Check function or condition of all equipped options and accessories (examples: fire extinguisher, rotating beacon, lift kits, etc.).

21. Inspect for loose or brokenparts or connections.

27. Recommend to the ownerthat all necessary correctionsbe made before the machineis returned to service.

22. Check for any fieldmodification not completed.

CALIFORNIAPROPOSITION 65 WARNING

Diesel engine exhaust and some of itsconstituents are known to the state of California

to cause cancer, birth defects and otherreproductive harm.

IV S220 Service Manual

FW SSL-1008 SM

SAFETY INSTRUCTIONS The following publications provide information on theV S220 Service Manual

WARNINGInstructions are necessary before operating orservicing machine. Read and understand theOperation & Maintenance Manual, OperatorsHandbook and signs (decals) on machine. Followwarnings and instructions in the manuals whenmaking repairs, adjustments or servicing. Check forcorrect function after adjustments, repairs or service.Untrained operators and failure to follow instructionscan cause injury or death.

W-2003-0903

IMPORTANTThis notice identifies procedures which must befollowed to avoid damage to the machine.

I-2019-0284

DANGERThe signal word DANGER on the machine and in themanuals indicates a hazardous situation which, if notavoided, will result in death or serious injury.

D-1002-1107

WARNINGThe signal word WARNING on the machine and in themanuals indicates a potentially hazardous situationwhich, if not avoided, could result in death or seriousinjury.

W-2044-1107

safe use and maintenance of the Bobcat machine andattachments:

The Delivery Report is used to assure that completeinstructions have been given to the new owner andthat the machine is in safe operating condition.

The Operation & Maintenance Manual delivered withthe machine or attachment contains operatinginformation as well as routine maintenance andservice procedures. It is a part of the machine and canbe stored in a container provided on the machine.Replacement Operation & Maintenance Manuals canbe ordered from your Bobcat dealer.

Machine signs (decals) instruct on the safe operationand care of your Bobcat machine or attachment. Thesigns and their locations are shown in the Operation& Maintenance Manual. Replacement signs areavailable from your Bobcat dealer.

An Operators Handbook fastened to the operatorcab. Its brief instructions are convenient to theoperator. The handbook is available from your dealerin an English edition or one of many other languages.See your Bobcat dealer for more information ontranslated versions.

The AEM Safety Manual delivered with the machinegives general safety information.

The Service Manual and Parts Manual are availablefrom your dealer for use by mechanics to do shop-type service and repair work.

The Skid-Steer Loader Operator Training Course isavailable through your local dealer or atwww.training.bobcat.com or www.bobcat.com.This course is intended to provide rules and practicesof correct operation of the Skid-Steer Loader. Thecourse is available in English and Spanish versions.

Service Safety Training Courses are available fromyour Bobcat dealer or at www.training.bobcat.comor www.bobcat.com. They provide information forsafe and correct service procedures.

The Skid-Steer Loader Safety Video is available fromyour Bobcat dealer or at www.training.bobcat.comor www.bobcat.com.

SI SSL-1008 SM

This symbol with a warning statement means:Warning, be alert! Your safety is involved!Carefully read the message that follows.

Safety Alert Symbol

SAFETY INSTRUCTIONS (CONTD)VI S220 Service Manual

The dealer and owner / operator review therecommended uses of the product when delivered. If theowner / operator will be using the machine for a differentapplication(s) he or she must ask the dealer forrecommendations on the new use.

Call Before You DigDial 811 (USA Only)

1-888-258-0808 (USA & Canada)When you call, you will be directed to a location in yourstate / province, or city for information about buried lines(telephone, cable TV, water, sewer, gas, etc.).

Cutting or drilling concrete containing sand or rockcontaining quartz may result in exposure to silica dust.Do not exceed Permissible Exposure Limits (PEL) tosilica dust as determined by OSHA or other job site Rulesand Regulations. Use a respirator, water spray or othermeans to control dust. Silica dust can cause lung diseaseand is known to the state of California to cause cancer.

SI SSL-1008 SM

FIRE PREVENTION Hydraulic SystemVII S220 Service Manual

Maintenance

The machine and some attachments have componentsthat are at high temperatures under normal operatingconditions. The primary source of high temperatures isthe engine and exhaust system. The electrical system, ifdamaged or incorrectly maintained, can be a source ofarcs or sparks.

Flammable debris (leaves, straw, etc.) must be removedregularly. If flammable debris is allowed to accumulate, itcan cause a fire hazard. Clean often to avoid thisaccumulation. Flammable debris in the enginecompartment is a potential fire hazard.

The operators area, engine compartment and enginecooling system must be inspected every day and cleanedif necessary to prevent fire hazards and overheating.

All fuels, most lubricants and some coolants mixtures areflammable. Flammable fluids that are leaking or spilledonto hot surfaces or onto electrical components cancause a fire.

Operation

Do not use the machine where exhaust, arcs, sparks orhot components can contact flammable material,explosive dust or gases.

Electrical

Check all electrical wiring and connections for damage.Keep the battery terminals clean and tight. Repair orreplace any damaged part or wires that are loose orfrayed.

Battery gas can explode and cause serious injury. Usethe procedure in the Operation & Maintenance Manualfor connecting the battery and for jump starting. Do notjump start or charge a frozen or damaged battery. Keepany open flames or sparks away from batteries. Do notsmoke in battery charging area.

Check hydraulic tubes, hoses and fittings for damageand leakage. Never use open flame or bare skin to checkfor leaks. Hydraulic tubes and hoses must be properlyrouted and have adequate support and secure clamps.Tighten or replace any parts that show leakage.

Always clean fluid spills. Do not use gasoline or dieselfuel for cleaning parts. Use commercial nonflammablesolvents.

Fueling

Stop the engine and let it cool before adding fuel. Nosmoking! Do not refuel a machine near open flames orsparks. Fill the fuel tank outdoors.

Starting

Do not use ether or starting fluids on any engine that hasglow plugs or air intake heater. These starting aids cancause explosion and injure you or bystanders.

Use the procedure in the Operation & MaintenanceManual for connecting the battery and for jump starting.

Spark Arrestor Exhaust System

The spark arrestor exhaust system is designed to controlthe emission of hot particles from the engine and exhaustsystem, but the muffler and the exhaust gases are stillhot.

Check the spark arrestor exhaust system regularly tomake sure it is maintained and working properly. Use theprocedure in the Operation & Maintenance Manual forcleaning the spark arrestor muffler (if equipped).

SI SSL-1008 SM

FIRE PREVENTION (CONTD)VIII S220 Service Manual

Welding And Grinding

Always clean the machine and attachment, disconnectthe battery, and disconnect the wiring from the Bobcatcontrollers before welding. Cover rubber hoses, batteryand all other flammable parts. Keep a fire extinguishernear the machine when welding.

Have good ventilation when grinding or welding paintedparts. Wear dust mask when grinding painted parts.Toxic dust or gas can be produced.

Dust generated from repairing nonmetallic parts such ashoods, fenders or covers can be flammable or explosive.Repair such components in a well ventilated area awayfrom open flames or sparks.

Fire Extinguishers

Know where fire extinguishers and first aid kits arelocated and how to use them. Inspect the fireextinguisher and service the fire extinguisher regularly.Obey the recommendations on the instructions plate.

SI SSL-1008 SM

SERIAL NUMBER LOCATIONS Engine Serial NumberIX S220 Service Manual

Always use the serial number of the loader whenrequesting service information or when ordering parts.Early or later models (identification made by serialnumber) may use different parts, or it may be necessaryto use a different procedure in doing a specific serviceoperation.

Loader Serial Number

Figure 1

The loader serial number plate is located on the outsideof the loader frame [Figure 1].

Explanation of loader Serial Number:

1. The four digit Model/Engine Combination Modulenumber identifies the model number and enginecombination.

2. The five digit Production Sequence Number identifiesthe order which the loader is produced.

Figure 2

The engine serial number is located on the engine block[Figure 2].

DELIVERY REPORT

Figure 3

The Delivery Report must be filled out by the dealer andsigned by the owner or operator when the Bobcat loaderis delivered. An explanation of the form must be given tothe owner. Make sure it is filled out completely [Figure3].

P-43900

XXXX XXXXX

Model 1.-Model/ Engine Combination

Model 2.-Production Sequence (Series)

P-48339

B-16315

LOADER IDENTIFICATIONX S220 Service Manual

FRONTLIGHTS

GRABHANDLES

OPERATOR SEATwith SEAT BELT

& SEAT BAR

TILTCYLINDERS

BUCKET

REAR AUXILIARY QUICK COUPLERS

FRONT AUXILIARYQUICK COUPLERS

STEPSBUCKETSTEPS

REARGRILL LIFT

CYLINDER

LIFT ARMSUPPORT DEVICE

TAILLIGHT

REARLIGHT

TIRES

REARDOOR

LIFT ARM

Optional or Field Accessory (Not Standard Equipment) TIRES - Tires shown may not be standard. The machine is factory equipped with standard tires. Other tires are available. Bucket - Several different buckets and other attachments are available for this machine. 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.

OPERATOR CAB(ROPS / FOPS)

B-19813A

B-19816A

SAFETY AND MAINTENANCE

S10-01 S220 Service Manual

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

BOB-TACH (POWER - OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141-1Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1Checking And Adding Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1Engine Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1Removing And Replacing Oil And Filter. . . . . . . . . . . . . . . . . . . . . . 10-110-2

FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . 10-130-1Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2Fuel Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . 10-100-3

HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 10-120-1Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-6Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1Removing And Replacing Case Drain Filters. . . . . . . . . . . . . . . . . . 10-120-4Removing And Replacing Hydraulic Charge Filter. . . . . . . . . . . . . . 10-120-5Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . 10-120-2Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . 10-120-3

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1Installing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1Removing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2

LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-10-1Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

Continued On Next Page

SAFETY &

SYSTEMDRIVE

ELECTRICAL

MAINTENANCE

SYSTEM &ANALYSIS

ENGINESERVICE

SPECIFICATION

SAFETY AND MAINTENANCE (CONTD)10-02 S220 Service Manual

LOADER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . 10-190-1Return to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1Cab Door Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

REMOTE START TOOL KIT-MEL1563. . . . . . . . . . . . . . . . . . . . . . 10-60-1Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-4Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1Service Tool Harness Communicator - MEL1566 . . . . . . . . . . . 10-60-3Service Tool Harness Control - MEL1565 . . . . . . . . . . . . . . . . . 10-60-2

REMOTE START TOOL (SERVICE TOOL) KIT - 6689779 . . . . . . 10-61-1Computer Service Tool Harness - 6689746 . . . . . . . . . . . . . . . . 10-61-4Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1Loader Service Tool Harness - 6689747 . . . . . . . . . . . . . . . . . . 10-61-3Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-5Remote Start Tool (Service Tool) - 6689778 . . . . . . . . . . . . . . . 10-61-2

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

STOPPING THE ENGINE AND LEAVING THE LOADER . . . . . . 10-200-1Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-2Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-2Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Continued On Next Page

SAFETY AND MAINTENANCE (CONTD)10-03 S220 Service Manual

TRANSPORTING LOADER ON A TRAILER . . . . . . . . . . . . . . . . . 10-40-1Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARDTORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISESPECIFIED.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMSMAY VARY.

10-04 S220 Service Manual

LIFTING AND BLOCKING THE LOADER Figure 10-10-510-10-1 S220 Service Manual

Procedure

Figure 10-10-4

WARNINGAVOID INJURY OR DEATH

Instructions are necessary before operating orservicing machine. Read and understand theOperation & Maintenance Manual, OperatorsHandbook and signs (decals) on machine. Followwarnings and instructions in the manuals whenmaking repairs, adjustments or servicing. Check forcorrect function after adjustments, repairs or service.Untrained operators and failure to follow instructionscan cause injury or death.

W-2003-0807

Read the Removal & Installation, Disassembly &Assembly, etc. completely to become familiar with theprocedure before beginning [Figure 10-10-4].

Always park the loader on a level surface.

WARNINGPut jackstands under the front axles and rear cornersof the frame before running the engine for service.Failure to use jackstands can allow the machine tofall or move and cause injury or death.

W-2017-0286

Lift the rear of the loader and install jackstands [Figure10-10-5].

Figure 10-10-6

Lift the front of the loader and put jackstands under theaxle tubes [Figure 10-10-6].

NOTE: Make sure the jackstands do not touch thetires.

B-7023A

P-31290A

P-31676

10-10-2 S220 Service Manual

LIFT ARM SUPPORT DEVICE Figure 10-20-210-20-1 S220 Service Manual

Installing

WARNINGNever work on a machine with the lift arms up unlessthe lift arms are secured by an approved lift armsupport device. Failure to use an approved lift armsupport device can allow the lift arms or attachmentto fall and cause injury or death.Service lift arm support device if damaged or if partsare missing. Using a damaged lift arm support orwith missing parts can cause lift arms to dropcausing injury or death.

W-2572-0407

Remove attachment from the loader.

Figure 10-20-1

Put jackstands under the rear corners of the loader frame(Inset) [Figure 10-20-1].Disconnect the spring from the lift arm support deviceretaining pin (Item 1) [Figure 10-20-1]. Support the liftarm support device (Item 2) [Figure 10-20-1] with yourhand and remove the retaining pin (Item 3) [Figure 10-20-1].

Lower the lift arm support device to the top of the liftcylinder. Hook the free end of the spring (Item 1) [Figure10-20-2] to the lift arm support device so there will be nointerference with the support device engagement.

Sit in the operators seat, fasten the seat belt and lowerthe seat bar. Start the engine.Figure 10-20-3

Raise the lift arms until the lift arm support device dropsonto the lift cylinder rod (Item 1) [Figure 10-20-3]

Lower the lift arms slowly until the support device is heldbetween the lift arm and the lift cylinder. Stop the engine.Raise the seat bar and move both pedals until bothpedals lock.

Install pin (Item 2) [Figure 10-20-3] into the rear of the liftarm support device below the cylinder rod.

P-43743P-43747

1

32

P-43744

1

N-20524BP-54470A

1 2

LIFT ARM SUPPORT DEVICE (CONTD) Figure 10-20-510-20-2 S220 Service Manual

Removing

Remove the pin from the lift arm support device.

Figure 10-20-4

Connect the spring (Item 1) [Figure 10-20-4] from the liftarm support device to the bracket below the lift arms.

Sit in the operators seat fasten the seat belt and lowerthe seat bar. Start the engine.

Raise the lift arms a small amount. The spring will lift thesupport device off the lift cylinder rod [Figure 10-20-5].Lower the lift arms. Stop the engine.

Raise the seat bar, disconnect the seat belt, move pedalsuntil both pedals lock and exit the cab.

Disconnect the spring from the bracket.

Raise the support device into storage position and insertpin through lift arm support device and bracket. (SeeLIFT ARM SUPPORT DEVICE on Page PM-1) Hook thespring to the lift arm support device retaining pin.

Remove the jackstands.

P-43745

1 P-43746

OPERATOR CAB Figure 10-30-110-30-1 S220 Service Manual

Description

The Bobcat Loader has an operator cab (ROPS andFOPS) as standard equipment to protect the operatorfrom rollover and falling objects. Check with your dealer ifthe operator cab has been damaged. The seat belt mustbe worn for rollover protection.

ROPS / FOPS - Roll Over protective Structure per ISO3471, and Falling Object Protective Structure per SAEJ1043 and ISO 3449, Level I. Level II is available.

Level IProtection from falling bricks, small concrete blocks,and hand tools encountered in operations such ashighway maintenance, landscaping, and otherconstruction sites.

Level IIProtection from falling trees, rocks: for machinesinvolved in site clearing, overhead demolition orforestry.

WARNINGNever modify operator cab by welding, grinding,drilling holes or adding attachments unlessinstructed to do so by Bobcat Company. Changes tothe cab can cause loss of operator protection fromrollover and falling objects, and result in injury ordeath.

W-2069-0200

Raising

Always stop the engine before raising or lowering thecab.

Stop the loader on a level surface. Lower the lift arms. Ifthe lift arms must be up while raising the operator cab,install the lift arm support device. (See LIFT ARMSUPPORT DEVICE on Page 10-20-1.)

Install jackstands under the rear of the loader frame[Figure 10-30-1].

Figure 10-30-2

Remove the nuts and plates [Figure 10-30-2] (bothsides) at the front corners of the cab.

NOTE: On Advanced Control System (ACS) equippedmachines, the steering levers could contactthe cab frame while raising or lowering theoperator cab. The engine MUST be stoppedbefore raising or lowering the cab.

P-43747

P-31289P-31288

OPERATOR CAB (CONTD)10-30-2 S220 Service Manual

Raising (Contd)

Figure 10-30-3

Lift on the grab handles and bottom of the operator cab[Figure 10-30-3] slowly until the cab is all the way up andthe latching mechanism engages.

Lowering

Always stop the engine before raising or lowering thecab.

NOTE: Always use the grab handles to lower the cab.

Figure 10-30-4

Pull down on the bottom of the operator cab until it stopsat the latching mechanism [Figure 10-30-4].

NOTE: The weight of the cab increases whenequipped with options and accessories suchas cab door, heater, air conditioning, etc. Inthese cases, the cab may need to be raisedslightly from the latch to be able to release thelatch.

NOTE: On Advanced Control System (ACS) equippedmachines, the steering levers could contactthe cab frame while raising or lowering theoperator cab. The engine MUST be stoppedbefore raising or lowering the cab.

Support the cab and release the latching mechanism(Inset) [Figure 10-30-4]. Remove your hand from thelatch mechanism when the cab is past the latch stop. Useboth hands to lower the cab all the way down.

WARNINGPINCH POINT CAN CAUSE INJURY

Remove your hand from the latching mechanismwhen the cab is past the latch stop.

W-2469-0803

Figure 10-30-5

[Figure 10-30-5] Install the plates and nuts (both sides).

Tighten the nuts to 40-45 ft.-lb. (54-61 Nm) torque.

P-31267

P-31268AN-20120

P-31289P-31288

OPERATOR CAB (CONTD)10-30-3 S220 Service Manual

Cab Door Sensor

This machine may be equipped with a Cab Door Sensor.

Figure 10-30-6

The cab door (option) has a sensor (Item 1) [Figure 10-30-6] installed which deactivates the lift and tilt valveswhen the door is open.

CLOSE DOOR TO OPERATE lift and tilt valves.

The LIFT & TILT VALVE light (Item 2) [Figure 10-30-6]will be ON when the door is closed and the PRESS TOOPERATE LOADER Button is pressed.

P-68116

1

2

P-68115

B-15551J

TRANSPORTING LOADER ON A TRAILER Fastening10-40-1 S220 Service Manual

Loading And Unloading

WARNINGAVOID SERIOUS INJURY OR DEATH

Adequately designed ramps of sufficient strength areneeded to support the weight of the machine whenloading onto a transport vehicle. Wood ramps canbreak and cause personal injury.

W-2058-0807

Be sure the transport and towing vehicles are ofadequate size and capacity. (See Capacities on PageSPEC-10-4.)

Figure 10-40-1

A loader with an empty bucket or no attachment must beloaded backward onto the transport vehicle [Figure 10-40-1].

The rear of the trailer must be blocked or supported (Item1) [Figure 10-40-1] when loading or unloading the loaderto prevent the front end of the trailer from raising up.

Figure 10-40-2

Use the following procedure to fasten the Bobcat loaderto the transport vehicle to prevent the loader from movingduring 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.

Fasten each end of the chain to the transport vehicle.

Install chains at the front and rear loader tie downpositions (Inset) [Figure 10-40-2].

P-43631A

1

P-43632A

P-31230A

6595014

P-31228A

TOWING THE LOADER10-50-1 S220 Service Manual

Procedure

Because of the design of the loader, there is not arecommended towing procedure.

The loader can be lifted onto a transport vehicle.

The loader can be skidded a short distance to movefor service (EXAMPLE: Move onto a transportvehicle.) without damage to the hydrostatic system.(The tires/tracks will not turn.) There might be slightwear to the tires/tracks when the loader is skidded.

The towing chain (or cable) must be rated at 1 & 1/2times the weight of the loader (See Performance onPage SPEC-10-2.)

REMOTE START TOOL KIT-MEL1563 Figure 10-60-210-60-1 S220 Service Manual

Remote Start Tool - MEL1563

Tools that will be needed to complete the following stepsare:

MEL1563 - Remote Start ToolMEL1565 - Service Tool Harness ControlMEL1566 - Service Tool Harness Communicator(Computer Interface)

Figure 10-60-1

The remote start tool (Item 1) [Figure 10-60-1] isrequired when the service technician is checking thehydraulic/hydrostatic system or adjusting the steeringlinkage.

The traction lock switch (Item 1) [Figure 10-60-2] is usedto turn traction lock ON or OFF. Push the switch to theoverride position. The switch will illuminate to indicatetraction lock OVERRIDE, in this position the wheels areable to turn.

The maximum flow/variable flow switch (Item 2) [Figure10-60-2] is used to activate the auxiliary hydraulics.Pressing the switch once will activate maximum flow.Pressing the switch again will activate variable flow. Theswitch 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 flowrate.

The auxiliary pressure release (Item 3) [Figure 10-60-2]is used to release hydraulic pressure to the front and/orrear auxiliary couplers. To release pressure; push andhold the switch for a few seconds.

NOTE: With the engine running; pushing and holdingthe pressure release switch will cause theengine to stop. To relieve the pressure; pressthe switch until the engine stops.

P16114

1 P16117

1

23

REMOTE START TOOL-MEL1563 (CONT'D) Service Tool Harness Control - MEL156510-60-2 S220 Service Manual

Remote Start Tool - MEL1563 (Contd)

Figure 10-60-3

Figure 10-60-4

The 10-pin rectangular connector (Item 1) [Figure 10-60-3] is used to update software in the DeluxeInstrumentation Panel (Item 1) [Figure 10-60-4].

NOTE: The Service PC must be connected to theremote start tool to update the deluxe panelsoftware.

The panel must be removed from inside the operator caband plugged into this connector [Figure 10-60-3].

Figure 10-60-5

The service tool harness control (Item 1) [Figure 10-60-5] is used to connect the remote start tool (Item 2)[Figure 10-60-5] to the electrical system on the loader.

Figure 10-60-6

Remove the plug (Item 1) [Figure 10-60-6] from theloader harness connector.

Connect the service tool harness control to the loaderharness connector.

P16116

1

P16120

1

P16114

2

1

N-19561

1

REMOTE START TOOL-MEL1563 (CONT'D) Service Tool Harness Communicator - MEL156610-60-3 S220 Service Manual

Service Tool Harness Control - MEL1565 (Contd)

Figure 10-60-7

Loaders equipped with an attachment harness (Item 1)[Figure 10-60-7] must disconnect the attachmentharness from the loader harness (Item 2) [Figure 10-60-7].

Connect the service tool harness to the ACD connectorand the loader harness connector.

NOTE: To monitor, diagnose or load new softwarethe Service PC must be connected to theRemote Start Tool Switch.

Figure 10-60-8

The service tool harness communicator (Item 1) [Figure10-60-8] is required to connect remote start tool to theService PC (Item 2) [Figure 10-60-8].

N-19631

1

2

P16119

1

2

REMOTE START TOOL KIT-MEL1563 (CONTD) Figure 10-60-1110-60-4 S220 Service Manual

Remote Start Procedure

The tool listed will be needed to do the followingprocedure:

MEL1563: Remote Start Tool Kit

Figure 10-60-9

The remote start tool (Item 1) [Figure 10-60-9] isrequired when the operator cab is in the raised positionfor service and the service technician needs to turn thekey switch on or start the engine. Example: adjusting thesteering linkage.

Lift and block the loader.

Raise the lift arms (if required by the procedure) andinstall an approved lift arm support device.

Raise the operator cab (if required by the procedure).Open the rear door of the loader.

Figure 10-60-10

Remove the plug (Item 1) [Figure 10-60-10] ordisconnect the attachment control harness (Item 1)[Figure 10-60-11] if connected.Figure 10-60-12

Connect the remote start tool to the engine harnessconnector [Figure 10-60-12].NOTE: The key switch on the right-hand side

operator panel must be in the off position orthe Remote Start Kit will not operate.


With the 7-pin connector plugged into the loader andRemote Start Key Switch in the OFF position, theloader can still be started from the operator panelinside the cab. Placing the key switch of the remotestart tool in the run position disconnects theoperator panel key switch from the start circuit. If theservice technician will be working the engine area itis important to remove the operator panel keys.

W-2357-0899

P16115

1

N-19151

1

N-19150

1

P13861

REMOTE START TOOL KIT-MEL1563 (CONT'D) Figure 10-60-1410-60-5 S220 Service Manual

Remote Start Procedure (Cont'd)

Figure 10-60-13

The remote start tool (Item 1) [Figure 10-60-13] hasthree rocker switches.

The traction lock switch (Item 1) [Figure 10-60-14] isused to turn traction lock on or off. Push the switch to theoverride position. The switch will illuminate to indicatetraction lock OVERRIDE, in this position the wheels areable to turn.

The maximum flow/variable flow switch (Item 2) [Figure10-60-14] 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 isactive. Pressing the switch a third time will turn the flowOFF. The switch is used when checking pressures andflow rate.

The auxiliary pressure release (Item 3) [Figure 10-60-14]is used to release hydraulic pressure to the front and/orrear auxiliary couplers. To release pressure; push andhold the switch for three seconds.

NOTE: With the engine running; pushing and holdingthe pressure release switch will cause theengine to stop in three seconds. To relieve thepressure; continue to press the switch afterthe engine has stopped.

P16116

1

P16118

32 1

REMOTE START TOOL KIT-MEL1563 (CONT'D)10-60-6 S220 Service Manual

Remote Start Procedure (Cont'd)

NOTE: With the engine running; pushing and holdingthe pressure release switch will cause theengine to stop in three seconds. To relieve thepressure at the rear or right hand auxiliary, (Ifso equipped.) continue to hold the switch forthree seconds after the engine has stopped.

Figure 10-60-15

Push the couplers on the front auxiliary block toward theblock and hold for five seconds to release the frontauxiliary pressure [Figure 10-60-15].

P-34661

REMOTE START TOOL (SERVICE TOOL) KIT - 10-61-1 S220 Service Manual

6689779

Description

The Remote Start Tool (Service Tool) Kit is a replacementtool for MEL 1563 Remote Start Tool and MEL 1400B -BOSS Diagnostic Tool.

The Remote Start Tool (Service Tool) Kit, P/N 6689779,can be used to service older loaders with the BOSSsystem using the supplied BOSS Service Tool HarnessP/N 6689745.

The Remote Start Tool (Service Tool) Kit, P/N 6689779,can be used to service newer loaders using the suppliedharness P/N 6689747.

A computer can be connected to the Remote Start Tool(Service Tool) for diagnostics and software updates usingthe computer harness P/N 6689746 in conjunction withthe loader harness.

REMOTE START TOOL (SERVICE TOOL) KIT - The Remote Start Tool (Service Tool) (Item 1) [Figure 10-10-61-2 S220 Service Manual

6689779 (CONT'D)Remote Start Tool (Service Tool) - 6689778

Tools that will be needed to complete the following stepsare:

Order from Bobcat Parts P/N: 6689779 - Remote StartTool (Service Tool) KitKit Includes:6689778 - Remote Start Tool (Service Tool)6689747 - Loader Service Tool Harness 6689746 - Computer Service Tool Harness6689745 - BOSS Service Tool Harness

Figure 10-61-16

The remote start tool (Item 1) [Figure 10-61-16] isrequired when the service technician is checking thehydraulic / hydrostatic system or adjusting the steeringlinkage.

Figure 10-61-17

61-17] has five buttons.

The STOP button (Item 2) [Figure 10-61-17] is used tostop the Remote Start Tool (Service Tool) fromcommunicating and stop the loader engine.

The RUN button (Item 3) [Figure 10-61-17] is used toturn the Remote Start Tool (Service Tool) on andactivates the loader ignition power. The button willilluminate to indicate the service tool is active.

The START button (Item 4) [Figure 10-61-17] is used tostart the loader engine.

The traction lock button (Item 5) [Figure 10-61-17] isused to turn traction lock ON or OFF. Push the button andthe button will illuminate indicating the traction lock isdisabled in which the wheels or tracks are able to turn.

Loader S/N: xxxx60000 & Below

The auxiliary button (Item 6) [Figure 10-61-17] is used toactivate the auxiliary hydraulics. The button will illuminateto indicate the auxiliary hydraulics are active. Pressingthe button once will activate maximum flow. Pressing thebutton again will activate variable flow. Pressing thebutton a third time will turn the flow OFF. The button isused when checking pressures and flow rate.

Loader S/N: xxxx60001 & Above

The auxiliary button (Item 6) [Figure 10-61-17] is used toactivate the auxiliary hydraulics. The button will illuminateto indicate the auxiliary hydraulics are active. Pressingthe button a second time will turn the flow OFF. Thebutton is used when checking pressures and flow rate.

P-76678

1

P-76439

2

5

6 4

3

1

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-2010-61-3 S220 Service Manual

6689779 (CONT'D)Loader Service Tool Harness - 6689747

Figure 10-61-18

The loader service tool harness (Item 1) [Figure 10-61-18] is used to connect the remote start tool (service tool)(Item 2) [Figure 10-61-18] to the electrical system on theloader.

Figure 10-61-19

Loaders without an attachment control harness, removethe loader harness cap (Item 1) [Figure 10-61-19] andconnect the Loader Service Tool Harness from theRemote Start Tool (Service Tool).

Loaders with an attachment control harness (7 pin or 14pin), the attachment harness (Item 1) must bedisconnected from the loader harness (Item 2) [Figure10-61-20].

When the remote start procedure is completed, replacethe loader connector cap (Item 1) [Figure 10-61-19] orreconnect the attachment control harness to the loaderharness [Figure 10-61-20].

P-76678

2

1

P-76451

1

P-76452

1

2

REMOTE START TOOL (SERVICE TOOL) KIT - Computer Service Tool Harness - 668974610-61-4 S220 Service Manual

6689779 (CONT'D)Loader Service Tool Harness - 6689747 (Contd)

Figure 10-61-21

NOTE: The Remote Start Tool (Service Tool)connection harness has two connectors (Item1) and (Item 3). The main connector (Item 1)[Figure 10-61-21] is always used forconnection to the loader harness.

The second connector (Item 3) [Figure 10-61-21] is used for attachment ACD upgrades orattachment operational diagnostics only. Thisconnector has a cap attached to it to preventdamage or corrosion when not in use.

Connect the Remote Start Tool (Service Tool) connector(Item 1) to the loader harness connector (Item 2) and theother Remote Start Tool (Service Tool) connector to theACD harness connector (Item 3) [Figure 10-61-21].

NOTE: The right instrument panel (Key Switch orKeyless) must be in the off position or theRemote Start Tool (Service Tool) will notoperate.

Figure 10-61-22

The computer service tool harness (Item 1) [Figure 10-61-22] is required to connect remote start tool (servicetool) to the Service PC (Item 2) [Figure 10-61-22].

P-76453

1

1

2

3

P-76454

P-76450

1

2


6689779 (CONT'D)Remote Start Procedure


With the 7-pin connector plugged into the loader andRemote Start Tool RUN button is not illuminated, theloader can still be started from the operator panelinside the cab.

Pressing the RUN button on the Remote Start Tooldisconnects the operator panel from the start circuit.If the service technician will be working in the enginearea it is important to remove the operator panel keyor lock the keypad with a unique password.

W-2647-0707

The tool listed will be needed to do the followingprocedure:

6689779: Remote Start Tool (Service Tool) Kit

Figure 10-61-23

The Remote Start Tool (Service Tool) (Item 1) [Figure 10-61-23] is required when the operator cab is in the raisedposition for service and the service technician needs toturn on the loader or start the engine. Example: adjustingthe steering linkage.

Lift and block the loader.

Raise the lift arms (if required by the procedure) andinstall an approved lift arm support device.

Raise the operator cab (if required by the procedure).Open the rear door of the loader.

Loaders without an attachment control harness, removethe loader harness cap (Item 1) [Figure 10-61-24] andconnect the Loader Service Tool Harness from theRemote Start Tool (Service Tool).

Figure 10-61-25

Loaders with an attachment control harness (7 pin or 14pin), the attachment harness (Item 1) must bedisconnected from the loader harness (Item 2) [Figure10-61-25].

When the remote start procedure is completed, replacethe loader connector cap (Item 1) [Figure 10-61-25] orreconnect the attachment control harness to the loaderharness [Figure 10-61-25].

P-76450

1

P-76451

1

P-76452

1

2


6689779 (CONT'D)Remote Start Procedure (Cont'd)

Figure 10-61-26

NOTE: The Remote Start Tool (Service Tool)connection harness has two connectors (Item1) and (Item 3). The main connector (Item 1)[Figure 10-61-26] is always used forconnection to the loader harness.

The second connector (Item 3) [Figure 10-61-26] is used for attachment ACD upgrades orattachment operational diagnostics only. Thisconnector has a cap attached to it to preventdamage or corrosion when not in use.

Connect the Remote Start Tool (Service Tool) connector(Item 1) to the loader harness connector (Item 2) and theother Remote Start Tool (Service Tool) connector to theACD harness connector (Item 3) [Figure 10-61-26].NOTE: The right instrument panel (Key Switch or

Keyless) must be in the off position or theRemote Start Tool (Service Tool) will notoperate.

The Remote Start Tool (Service Tool) (Item 1) [Figure 10-61-27] has five buttons.

The STOP button (Item 2) [Figure 10-61-27] is used tostop the Remote Start Tool (Service Tool) fromcommunicating and stop the loader engine.

The RUN button (Item 3) [Figure 10-61-27] is used toturn the Remote Start Tool (Service Tool) on andactivates the loader ignition power. The button willilluminate to indicate the service tool is active.

The START button (Item 4) [Figure 10-61-27] is used tostart the loader engine.

The traction lock button (Item 5) [Figure 10-61-27] isused to turn traction lock ON or OFF. Push the button andthe button will illuminate indicating the traction lock isdisabled in which the wheels or tracks are able to turn.


The auxiliary button (Item 6) [Figure 10-61-27] is used toactivate the auxiliary hydraulics. The button will illuminateto indicate the auxiliary hydraulics are active. Pressingthe button once will activate maximum flow. Pressing thebutton again will activate variable flow. Pressing thebutton a third time will turn the flow OFF. The button isused when checking pressures and flow rate.


The auxiliary button (Item 6) [Figure 10-61-27] is used toactivate the auxiliary hydraulics. The button will illuminateto indicate the auxiliary hydraulics are active. Pressingthe button a second time will turn the flow OFF. Thebutton is used when checking pressures and flow rate.

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6689779 (CONT'D)Remote Start Procedure (Cont'd)

Figure 10-61-28

The gear icon with the left facing arrows (Item 1) [Figure10-61-28] will illuminate and blink when the RUN key ispressed and the loader is communicating with the servicetool.

The computer icon with the right facing arrows (Item 2)[Figure 10-61-28] will illuminate and blink when theRemote Start Tool (Service Tool) is transmitting data toand from the computer.


NOTE: To relieve the pressure at the rear orsecondary front auxiliary, (if equipped) pressand hold the AUXILIARY PRESSURERELEASE button on the left instrument panelfor three seconds after the engine hasstopped.


NOTE: To relieve the pressure at the rear orsecondary front auxiliary, (if equipped) pressthe RUN button on the remote start tool. Thenpress the auxiliary (AUX) hydraulics button onthe remote start tool and move the AUXILIARYHydraulic Switch on the to the right and leftseveral times.

Push the couplers on the front auxiliary block toward theblock and hold for five seconds to release the frontauxiliary pressure [Figure 10-61-29].P-76441

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P-34661

SERVICE SCHEDULE10-70-1 S220 Service Manual

ChartMaintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. Theservice schedule is a guide for correct maintenance of the Bobcat Loader.

Or every 12 months. Perform at first 50 hours, then as scheduled. Check every 8 - 10 hours for the first 24 hours, then at 50 hour intervals. Replace the hydraulic / hydrostatic filter element after the first 50 hours, then when the transmission warning light

comes ON while operating or as scheduled. Change oil and filter every 250 hours when operating under severe conditions. Perform at first 500 hours, then as scheduled.

SERVICE SCHEDULE HOURSITEM SERVICE REQUIRED 8-10 50 100 250

500

1000

Engine Oil Check the oil level and add as needed. Do not overfill.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 and grill. Check coolant level COLD and

add premixed coolant as needed.Fuel Filter Remove the trapped water.Lift Arms, Cylinders, Bob-Tach Pivot Pins and Wedges

Lubricate with multi-purpose lithium based grease.

Tires Check for damaged tires and correct air pressure. Inflate to MAXIMUM pressure shown on the sidewall of the tire.

Seat Bar, Control Interlocks, Seat Belt, Seat Belt Retractors

Check the condition of seat belt. Clean or replace seat belt retractors as needed. Check the seat bar and control interlocks for correct operation. Clean dirt and debris from moving parts.

Bobcat Interlock Control Systems (BICS)

Check for correct function. Lift and Tilt functions MUST NOT operate with seat bar raised. See details in this Manual.

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.Heater and A/C Filters (If Equipped)

Clean or replace filters as needed.

Hydraulic Fluid, Hoses and Tubelines

Check fluid level and add as needed. Check for damage and leaks. Repair or replace as needed.

Final Drive Trans. (Chaincase), Check fluid level and add as needed.Parking Brake, Foot Pedals, Hand Controls and Steering Levers or Joysticks

Check for correct operation. Repair or adjust as needed.

Wheel Nuts Check for loose wheel nuts and tighten to correct torque. (See TIRE MAINTENANCE in this manual.)

Spark Arrestor Muffler Clean the spark chamber.Battery Check cables, connections and electrolyte level. Add distilled water as needed.Steering Lever Pivots Grease fittings.Fuel Filter Replace filter element.Engine / Hydro. Drive Belt Check for wear or damage. Check idler arm stop. Drive Belts (Alternator, air conditioner, water pump)

Check condition and tension. Adjust or replace as needed.Bobcat Interlock Control System (BICS)

Check the function of the lift arm bypass control.

Hydraulic / Hydrostatic Filter, Charge Filter, Reservoir Breather

Replace the hydraulic / hydrostatic filter, charge filter, and the reservoir breather.

Engine Oil and Filter Replace oil and 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.

Coolant Replace the coolant Every 2 years

WARNINGInstructions are necessary before operating or servicing machine. Read andunderstand the Operation & Maintenance Manual, Operators Handbook andsigns (decals) on machine. Follow warnings and instructions in the manualswhen making repairs, adjustments or servicing. Check for correct functionafter adjustments, repairs or service. Untrained operators and failure to followinstructions can cause injury or death. W-2003-0903

AIR CLEANER SERVICE Outer Filter10-80-1 S220 Service Manual

Replacing Filter Elements

Figure 10-80-1

It is important to change the air filter element only whenthe Air Cleaner Icon in the right panel is ON (Item 1)[Figure 10-80-1] and you hear three beeps from thealarm.

Replace the inner filter every third time the outer filter isreplaced or as indicated.

Figure 10-80-2

Press and hold the LIGHT Button (Item 1) [Figure 10-80-2] for two seconds.

If the filter element needs replacement, the CODE [01-17] (Air Filter Plugged) will show in the HOURMETER /CODE DISPLAY (Item 2) [Figure 10-80-2].

Figure 10-80-3

Remove the wing nut and remove the dust cover (Item 1)[Figure 10-80-3].

Figure 10-80-4

Remove the wing nut and pull the outer filter element(Item 1) [Figure 10-80-4] out and discard.

NOTE: Make sure all sealing surfaces are free of dirtand debris.

Install new filter. Push all the way in until it contacts thebase of the housing. Install wing nut.

Install the dust cover and the wing nut [Figure 10-80-3].

Check the air intake hose and the air cleaner housing fordamage. Make sure all connections are tight.

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AIR CLEANER SERVICE (CONTD) Figure 10-80-610-80-2 S220 Service Manual

Replacing Filter Elements (Contd)

Inner Filter

Only replace the inner filter element under the followingconditions:

Replace the inner filter element every third time theouter filter is replaced.

After the outer element has been replaced, start theengine and run at full RPM. If the HOURMETER /CODE DISPLAY shows [01-17] (Air Filter Plugged),replace the inner filter element.

Figure 10-80-5

Remove the inner filter element (Item 1) [Figure 10-80-5].

NOTE: Make sure all sealing surfaces are free of dirtand debris.

Install the new inner element [Figure 10-80-5].

Install the outer element.

Install the dust cover and the wing nut [Figure 10-80-6](Be sure the evacuator is down).

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ENGINE COOLING SYSTEM Figure 10-90-210-90-1 S220 Service Manual

Check the cooling system every day to prevent over-heating, loss of performance or engine damage.


Wear safety glasses to prevent eye injury when anyof the following conditions exist: When fluids are under pressure. Flying debris or loose material is present. Engine is running. Tools are being used.

W-2019-0907

Cleaning

Open the rear door.

Remove the rear grill.

Figure 10-90-1

Use low air pressure or water pressure to clean the top ofthe air conditioning condenser (Item 1) [Figure 10-90-1],if equipped.

Raise the overflow tank (Item 2) slightly and remove thetwo fasteners (Inset) [Figure 10-90-1].

NOTE: Be careful when raising and lowering the airconditioning condenser so that the airconditioning condenser does not fall on theoil cooler and damage the fins.

Raise the air conditioning condenser (Item 1) and uselow air pressure or water pressure to clean the top of theoil cooler (Item 2) [Figure 10-90-2].Figure 10-90-3

NOTE: Be careful when raising and lowering the oilcooler so that the oil cooler does not fall onthe radiator and damage the fins.

Raise the oil cooler (Item 1) and use low air pressure orwater pressure to clean the top of the radiator (Item 2)[Figure 10-90-3].Lower the oil cooler.

Lower the air conditioning condenser, if equipped.

Install the fasteners and lower the overflow tank. Checkthe cooling system for leaks.

Install the rear grill and close the rear door.

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ENGINE COOLING SYSTEM (CONTD) Removing And Replacing Coolant10-90-2 S220 Service Manual

Checking Level


Remove the coolant fill cap (Item 1) [Figure 10-90-5].Check coolant level. The level markers are on the tank.Coolant must be at the bottom marker when the engine iscold; top marker when hot.


IMPORTANTAVOID ENGINE DAMAGE

Always use the correct ratio of water to antifreeze.

Too much antifreeze reduces cooling systemefficiency and may cause serious premature enginedamage.

Too little antifreeze reduces the additives whichprotect the internal engine components; reduces theboiling point and freeze protection of the system.

Always add a premixed solution. Adding full strengthconcentrated coolant can cause serious prematureengine damage.

I-2124-0497

Figure 10-90-4

NOTE: All access covers (Item 1) [Figure 10-90-4](both sides) must be in place to ensurecorrect air flow through the oil cooler whichwill ensure proper cooling for the engine andhydraulic systems.


Figure 10-90-5

Remove the coolant fill cap (Item 1) [Figure 10-90-5].

Disconnect the hose from the engine block to the oil filtercooler (Item 2) [Figure 10-90-5]. Drain the coolant into acontainer. Recycle or dispose of coolant in anenvironmentally safe manner.

Mix new coolant in a separate container. (See Capacitieson Page SPEC-10-4.)NOTE: The loader is factory filled with propylene

glycol coolant (purple color). DO NOT mixpropylene glycol with ethylene glycol.

Add premixed coolant, 47% water and 53% propyleneglycol to the recovery tank. (See Checking Level on PagePM-2.)One gallon and one pint (4,3 L) of propylene glycol mixedwith one gallon (3,8 L) of water is the correct mixture ofcoolant to provide a -34F (-37C) freeze protection.Fill the tank until it is at the lower marker on the tank.

Use a refractometer to check the condition of propyleneglycol in your cooling system and replace the coolant fillcap.

NOTE: When installing the coolant fill cap, the capmust be tightened until it clicks.

Run the engine until it is at operating temperature. Stopthe engine. Check the coolant level when cool. Addcoolant as needed.


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FUEL SYSTEM as cleaning the fuel system and replacing fuel filters10-100-1 S220 Service Manual

Fuel Specifications

Use only clean, high quality diesel fuel, Grade No. 2 orGrade No. 1.

The following is one suggested blending guideline whichshould prevent fuel gelling during cold temperatures:

The following fuels may be used in this machine:

Low Sulfur (500 ppm sulfur) Diesel Fuel.

Ultra Low Sulfur (15 ppm sulfur) Diesel Fuel.

Biodiesel Blend Fuel - Must contain no more than fivepercent biodiesel mixed with low sulfur or ultra lowsulfur petroleum based diesel. This is commonlymarketed as B5 blended diesel fuel. B5 blendeddiesel fuel must meet ASTM D975 (US Standard) orEN590 (EU Standard) specifications.


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 causeexplosion or fire.

W-2103-0508

Biodiesel Blend Fuel

Biodiesel blend fuel has unique qualities that should beconsidered before using in this machine:

Cold weather conditions can lead to plugged fuelsystem components and hard starting.

Biodiesel blend fuel is an excellent medium formicrobial growth and contamination which can causecorrosion and plugging of fuel system components.

Use of biodiesel blend fuel may result in prematurefailure of fuel system components, such as pluggedfuel filters and deteriorated fuel lines.

Shorter maintenance intervals may be required, such

and fuel lines.

Using biodiesel blended fuels containing more thanfive percent biodiesel can affect engine life and causedeterioration of hoses, tubelines, injectors, injectorpump and seals.

Apply the following guidelines if biodiesel blend fuel isused:

Ensure the fuel tank is as full as possible at all timesto prevent moisture from collecting in the fuel tank.

Ensure that the fuel tank cap is securely tightened.

Biodiesel blend fuel can damage painted surfaces,remove all spilled fuel from painted surfacesimmediately.

Drain all water from the fuel filter daily beforeoperating the machine.

Do not exceed engine oil change interval. Extendedoil change intervals can cause engine damage.

Before vehicle storage; drain the fuel tank, refill with100% petroleum diesel fuel, add fuel stabilizer andrun the engine for at least 30 minutes.

NOTE: Biodiesel blend fuel does not have long termstability and should not be stored for morethan three months.

TEMPERATURE F (C) NO. 2 NO. 1+15 (9) 100% 0%

Down to -20 (-29) 50% 50%Below -20 (-29) 0% 100%

FUEL SYSTEM (CONTD) Fuel Filter10-100-2 S220 Service Manual

Filling The Fuel Tank


Stop and cool the engine before adding fuel. NOSMOKING! Failure to obey warnings can cause anexplosion or fire.

W-2063-0807

Figure 10-100-1

Remove the fill cap (Item 1) [Figure 10-100-1].Figure 10-100-2

Use a clean, approved safety container to add fuel of thecorrect specification. Add fuel only in an area that hasfree movement of air and no open flames or sparks NOSMOKING [Figure 10-100-2].Install and tighten the fuel cap (Item 1) [Figure 10-100-1].

For the service interval for removing water from, orreplacing the fuel filter (See SERVICE SCHEDULE onPage 10-70-1.)

Figure 10-100-3

Loosen the drain (Item 1) [Figure 10-100-3] at thebottom of the filter element to remove water from thefilter.

Remove the filter element (Item 2) [Figure 10-100-3].

Clean the area around the filter housing. Put clean oil onthe seal of the new filter element. Install the fuel filter, andhand tighten.

Remove air from the fuel system. (See Removing AirFrom The Fuel System on Page 10-100-3.)



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FUEL SYSTEM (CONTD)10-100-3 S220 Service Manual

Removing Air From The Fuel System

After replacing the filter element or when the fuel tankhas run out of fuel, the air must be removed from the fuelsystem before starting the engine.


Diesel fuel or hydraulic fluid under pressure canpenetrate skin or eyes, causing serious injury ordeath. Fluid leaks under pressure may not be visible.Use a piece of cardboard or wood to find leaks. Donot use your bare hand. Wear safety goggles. If fluidenters skin or eyes, get immediate medical attentionfrom a physician familiar with this injury.

W-2072-0807

Figure 10-100-4

Open the vent (Item 1) [Figure 10-100-4] on the fuel filterhousing.

Squeeze the hand pump (priming bulb) (Item 2) [Figure10-100-4] until fuel flows from the vent with no airbubbles.

Close the vent (Item 1) [Figure 10-100-4].

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ENGINE LUBRICATION SYSTEM Engine Oil Chart10-110-1 S220 Service Manual

Checking And Adding Engine Oil

Check the engine oil level every day before starting theengine for the work shift.

Figure 10-110-1

Park the machine on level ground. Open the rear doorand remove the dipstick (Item 1) [Figure 10-110-1].

Keep the oil level between the marks on the dipstick. Donot overfill.

Use good quality motor oil that meets API ServiceClassification of CD or better (See Oil Chart, above).

Install the dipstick and close the rear door.P-48345

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ENGINE LUBRICATION SYSTEM (CONTD)10-110-2 S220 Service Manual

Removing And Replacing Oil And Filter

For the service interval for replacing the engine oil andfilter. (See SERVICE SCHEDULE on Page 10-70-1.)

Run the engine until it is at operating temperature. Stopthe engine.

Open the rear door and remove the drain hose from itsstorage position (Item 4) [Figure 10-110-1].

Figure 10-110-2

Remove the drain plug (Item 1) [Figure 10-110-2] anddrain the oil into a container and recycle or dispose ofused oil in an environmentally safe manner.

Remove the oil filter (Item 2) [Figure 10-110-1] and cleanthe filter housing surface.

Put oil on the new filter gasket, install the filter and handtighten.

Install and tighten the drain plug.

Remove the fill cap (Item 3) [Figure 10-110-1].

Put oil in the engine. (See Capacities on Page SPEC-10-4), for the correct quantity. Do not overfill.

Start the engine and let it run for several minutes. Stopthe engine and check for leaks at the filter.

Remove the dipstick (Item 1) [Figure 10-110-1] andcheck the oil level.

Add oil as needed if it is not at the top mark on thedipstick.

Install the dipstick and close the rear door.



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HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart10-120-1 S220 Service Manual

Checking And Adding Fluid

Use only recommended fluid in the hydraulic system.(See Specifications on Page SPEC-40-1.) and [Figure10-120-3].Put the loader on a level surface, lower the lift arms andtilt the Bob-Tach fully back.

Stop the engine.

Figure 10-120-1

Check the fluid level in the sight gauge (Item 1) [Figure 10-120-1].Figure 10-120-2

Remove the fill cap (Item 1) [Figure 10-120-2].Add fluid as needed to bring the level to the center of thesight gauge.

NOTE: Before installing the fill cap, make sure the rubbergasket is installed on fill cap (Inset) [Figure 10-120-2].

Install the fill cap [Figure 10-120-2].

Figure 10-120-3

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HYDRAULIC / HYDROSTATIC SYSTEM (CONTD) Figure 10-120-610-120-2 S220 Service Manual

Removing And Replacing Hydraulic Fluid

See your SERVICE SCHEDULE for the correct serviceinterval. (See SERVICE SCHEDULE on Page 10-70-1.)Replace the fluid if it becomes contaminated or aftermajor repair.Always replace the hydraulic / hydrostatic filter, the casedrain filters and the hydraulic charge filter whenever thehydraulic fluid is replaced. (See Removing AndReplacing Hydraulic / Hydrostatic Filter on Page 10-120-3.)Remove the fill cap and raise the operator cab. (SeeRaising on Page 10-30-1.)Figure 10-120-4

Remove the two hose clamps and remove the hose (Item1) [Figure 10-120-4].Figure 10-120-5

Remove and clean the hydraulic fill screen (Item 1)[Figure 10-120-5]. Use low air pressure to dry thescreen.

Install screen, hose and hose clamps.

Remove the hydrostatic motor cover (Item 1) [Figure 10-120-6]. (Left Side)

Figure 10-120-7

Pull the reservoir drain hose out the left motor cover hole.Remove the plug (Item 1) [Figure 10-120-7] and drainthe fluid into a container.

Recycle or dispose of used fluid in an environmentallysafe manner.

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HYDRAULIC / HYDROSTATIC SYSTEM (CONTD) Removing And Replacing Hydraulic / Hydrostatic 10-120-3 S220 Service Manual

Removing And Replacing Hydraulic Fluid (Contd)



W-2103-0508

Install the plug in the reservoir drain hose and tighten.Install the motor cover.

Lower the operator cab. (See Lowering on Page 10-30-2.)

Add the correct fluid to the reservoir until the fluid level isat the center of the sight gauge. (See Checking AndAdding Fluid on Page 10-120-1.)

Filter

See your SERVICE SCHEDULE for the correct serviceinterval. (See SERVICE SCHEDULE on Page 10-70-1.)

Raise the operator cab. (See Raising on Page 10-30-1.)

Figure 10-120-8

Remove the filter (Item 1) [Figure 10-120-8].

Clean the surface of the filter housing where the filterseal contacts the housing.

Put clean oil on the seal of the new filter element. Installand hand tighten the filter element.



W-2103-0508


Start the engine and operate the loader hydrauliccontrols.

Stop the engine and check for leaks at the filter.

Check the fluid level in the reservoir and add as needed.(See Checking And Adding Fluid on Page 10-120-1.)

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Removing And Replacing Case Drain Filters

See your SERVICE SCHEDULE for the correct serviceinterval. (See SERVICE SCHEDULE on Page 10-70-1.)

Raise the operator cab. (See Raising on Page 10-30-1.)

Figure 10-120-9

Disconnect the hoses and fittings from the hydrostaticmotor case drain filter (Item 1) [Figure 10-120-9].Remove the mounting clamp and discard the filter.

Install fittings on new filter, install new filter, install themounting clamp, connect and tighten the hoses.

Remove the left lower side cover (Item 1) [Figure 10-120-10].

Disconnect the hoses and fittings from the attachmentcase drain filter (Item 2) [Figure 10-120-10]. Removeand discard the filter.

Install fittings on new filter, install new filter, connect andtighten the hoses and install the left lower side cover.



W-2103-0508


Start the engine and operate the loader hydrauliccontrols.

Stop the engine and check for leaks at the filters.


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Removing And Replacing Hydraulic Charge Filter

The hydraulic charge filter is located under the cab. Forthe correct service interval (See SERVICE SCHEDULEon Page 10-70-1.)Raise the cab. (See Raising on Page 10-30-1.)Earlier Models

Figure 10-120-11

Remove the filter (Item 1) [Figure 10-120-11].Clean the surface of the filter housing where the filterseal contacts the housing.

Put clean oil on the seal of the new filter. Install and handtighten the new filter.Later Models

Figure 10-120-12

Place a suitable container below the filter housing andremove the filter housing (Item 1) [Figure 10-120-12].Recycle or dispose of used fluid in an environmentallysafe manner.

Remove and discard the filter element (Item 1) [Figure10-120-13].Clean the surface of the filter housing and the filter basewhere they contact the filter element seal.

Put clean oil on the seal of the new filter element. Installthe element on the filter base. Install and tighten the filterhousing to 35-40 ft.-lb. (47-54 Nm) torque.All Models



W-2103-0508



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Lower the cab. (See Lowering on Page 10-30-2.)Start the engine and operate the loader hydrauliccontrols.Stop the engine and check for leaks at the filter.


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HYDRAULIC / HYDROSTATIC SYSTEM (CONTD)10-120-6 S220 Service Manual

Breather Cap

See the SERVICE SCHEDULE for the correctreplacement interval. (See SERVICE SCHEDULE onPage 10-70-1.)Figure 10-120-14

Remove the breather cap (Item 1) [Figure 10-120-14]and discard.

Install new breather cap.



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FINAL DRIVE TRANSMISSION (CHAINCASE) Removing And Replacing Oil10-130-1 S220 Service Manual

Checking And Adding Oil

The chaincase contains the final drive sprockets andchains and uses the same type of oil as the hydraulic/hydrostatic system. (See Hydraulic System on PageSPEC-10-3.)

Stop the loader on a level surface.

Stop the engine.

Figure 10-130-1

Remove the drain plug (Item 1) [Figure 10-130-1] fromthe front of the chaincase housing.

If oil can be reached with the tip of your finger through thehole, the oil level is correct.

If the level is low, add oil through the check plug hole untilthe oil flows from the hole.

Install and tighten the plug.

Remove the check plug (Item 1) [Figure 10-130-1] fromthe front of the chaincase housing.

Figure 10-130-2

Use a pump to suction the oil from the chaincase [Figure10-130-2]Recycle or dispose of the used oil in an environmentallysafe manner.

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Documents

Service Manual Bobcat s220 530711001