Bobcat Excavator 220 225 231 Series - Service and Owners Manual

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BOBCAT EXCAVATOR (220 225 231 SERIES) - SERVICE AND OWNERS MANUAL

- Service Manual And Owners Manual, to Bobcat Excavator 220 225 231 Series.


CONTENTS:

220 6720124 OM 11-89
 
- OPERATOR SAFETY WARNINGS
- FOREWORD
- CONTENTS
- SAFETY INSTRUCTIONS
- FIRE PREVENTIONS
- SERIAL NUMBER LOCATIONS
- Hydraulic Excavator Serial Number
- Engine Serial Number
- DELIVERY REPORT
- HYDRAULIC EXCAVATOR IDENTIFICATION
- SAFETY SIGNS (DECALS)
- OPERATING INSTRUCTIONS
- GETTING ON AND OFF THE MACHINE
- SEAT
- SEAT BELT
- INSTRUMENT PANEL
- KEY SWITCH
- LEVER & CONTROL LOCATIONS
- CONTROL LEVERS
- Operation Of Left Control Lever (ISO)
- Operation Of Right Control Lever (ISO)
- Control Lever Lock Operation
- FUEL CONTROL LEVER
- STEERING LEVERS
- Forward And Reverse Travel
- Turning
- Making A Counter-Rotation Turn
- BOOM SWING LEVER
- BLADE CONTROL LEVER
- SWING LOCK
- BEFORE STARTING THE ENGINE
- STARTING THE ENGINE
- Normal Starting Procedure
- Cold Starting Procedure
- PARKING THE HYDRAULIC EXCAVATOR
- OPERATING PROCEDURE
- Breaking In A New Machine
- General Operation Suggestions
- TRANSPORTING THE HYDRAULIC EXCAVATOR
- BUCKET
- Removal
- Installation
- PREVENTIVE MAINTENANCE
- MAINTENANCE SAFETY
- SERVICE SCHEDULE
- ENGINE COVER
- AIR CLEANER SERVICE
- FUEL SYSTEM
- Fuel System Service
- Fuel Filters
- Removing Air From The Fuel System
- ENGINE LUBRICATION SYSTEM
- Engine Oil And Filter Replacement
- COOLING SYSTEM
- Coolant Level
- Coolant Replacement
- ALTERNATOR BELT ADJUSTMENT
- ELECTRICAL SYSTEM
- Fuses
- Fuse Arrangement
- Service The Electrical System
- Using A Booster Battery (Jump Starting)
- Removal And Installation Of The Battery
- HYDRAULIC SYSTEM
- Checking And Adding Fluid (S/N 11308 & Below)
- Checking And Adding Fluid (S//N 11309 - 11500)
- Replacement Of The Hydraulic Filter
- Hydraulic Reservoir
- LUBRICATION OF THE HYDRAULIC EXCAVATOR
- FINAL DRIVE CASE
- Checking Oil Level
- Draining Final Drive Case
- TRACK TENSION
- Adjustment
- SPECIFICATIONS
- HYDRAULIC EXCAVATOR SPECIFICATIONS
- Machine Dimensions
- Lifting Capacity With Blade Off Ground
- Performance & Operation

- Engine
- Hydraulic System
- Swing System
- Hydraulic Cylinders
- Drive System
- Brakes
- Undercarriage
- Track
- Capacities
- Digging Force
- FUEL, COOLANT AND LUBRICANTS
- OIL SPECIFICATIONS
- WARRANTY

220 6720230 SM-5-89

- CONTENTS
- FOREWORD
- SAFETY INSTRUCTIONS
- SERIAL NUMBER LOCATIONS
- HYDRAULIC EXCAVATOR SERIAL NUMBER
- ENGINE SERIAL NUMBER
- DELIVERY REPORT
- HYDRAULIC EXCAVATOR IDENTIFICATION
- PREVENTIVE MAINTENANCE
- SERVICE SCHEDULE
- ENGINE COVER
- Procedure
- AIR CLEANER SERVICE
- Replacing the Filter Element
- FUEL SYSTEM
- Fuel Specifications
- Fuel System Service
- ENGINE LUBRICATION SYSTEM
- Checking the Engine Oil
- Engine Oil and Filter Replacement
- COOLING SYSTEM
- Coolant Level
- Coolant Replacement
- HYDRAULIC SYSTEM
- Checking and Adding Fluid
- Replacement of the Hydraulic Filter
- Hydraulic Reservoir
- USING A BOOSTER BATTERY (JUMP STARTING)
- Procedure
- LUBRICATION OF THE EXCAVATOR
- Procedure
- FINAL DRIVE CASE
- Checking Oil Level
- Draining Final Drive Case
- HYDRAULIC SYSTEM
- HYDRAULIC SCHEMATICS
- HYDRAULIC SERVICE INFORMATION
- Checking The Main Relief Valves
- HYDRAULIC PUMP
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- HYDRAULIC CONTROL VALVE
- Removal and Installation
- HYDRAULIC RESERVOIR
- Removal and Installation
- Suction Filter
- BOOM CYLINDER
- Removal and Installation
- ARM CYLINDER
- Removal and Installation
- BUCKET CYLINDER
- Removal and Installation
- BLADE CYLINDER
- Removal and Installation
- BOOM SWING CYLINDER
- Removal and Installation
- HYDRAULIC CYLINDER (Melroe Cylinders)
- Disassembly
- Assembly
- SOLENOID VALVE
- Parts Identification
- SOLENOID VALVE
- Disassembly
- Assembly
- SWING CYLINDER LOCK VALVE
- Parts Identification
- SWING CYLINDER LOCK VALVE
- Disassembly
- Assembly
- DRIVE SYSTEM
- FLOOR PANEL
- Removal and Installation
- CONTROL AND STEERING LEVERS
- Swing/Arm Control Lever
- Control Lever Lock Mechanism
- Boom/Bucket Control Lever
- Steering Levers
- DRIVE MOTOR
- Removal and Installation
- Disassembly
- Assembly
- UPPER WORKS AND SWING SECTION
- SWING MOTOR
- Removal and Installation
- Parts Identification
- Disassembly
- Assembly
- Motor Timing
- Parts Identification
- Disassembly
- Assembly
- Brake Valve Parts Identification
- Brake Valve Disassembly
- Control Valve Assembly
- Control Valve Testing
- UPPER WORKS
- Removal And Installation
- Swing Motor Installation
- CENTER SWIVEL JOINT
- Removal And Installation
- Disassembly And Assembly
- SWING CIRCLE GEAR
- Removal And Installation
- MAIN FRAME AND TRACKS
- ENGINE COVER
- Removal and Installation
- SEAT AND MOUNTING FRAME
- Removal and Installation
- FUEL TANK
- Removal and Installation
- BOOM AND DIPPERSTICK
- Removal and Installation
- BOOM SWING BRACKET
- Removal and Installation
- TRACK
- Track Tension Adjustment
- Removal and Installation
- TRACK FRAME
- Disassembly and Assembly
- TRACK IDLER
- Parts Identification
- Disassembly
- Assembly
- TRACK ROLLER
- Parts Identification
- Disassembly
- Assembly
- ELECTRICAL SYSTEM
- ELECTRICAL SCHEMATICS
- TROUBLESHOOTING
- Description
- Fuses
- Electrical System Service
- BATTERY
- Checking the Battery
- Removal and Installation
- ALTERNATOR
- Belt Adjustment
- Removal and Installation
- STARTER
- Removal and Installation
- Disassembly and Assembly
- Cleaning and Inspection
- INSTRUMENT PANEL
- Lights, Hourmeter and Ignition Switch
- Removal and Installation
- ENGINE SERVICE
- TROUBLESHOOTING
- VALVE CLEARANCE
- Adjustment
- ENGINE COMPRESSION
- Checking
- FUEL FILTER
- Fuel Filters
- Removing Air From the Fuel System
- FUEL INJECTION PUMP
- Checking the Injection Pump
- Removal and Installation
- Timing the Injection Pump
- FUEL INJECTOR NOZZLES
- Removal and Installation
- Checking the Injector Nozzle
- GLOW PLUGS
- Removal and Installation
- Checking the Glow Plug
- ENGINE
- Removal and Installation
- MUFFLER
- Removal and Installation
- RADIATOR
- Removal and Installation
- ENGINE FLYWHEEL
- Removal and Installation
- Flywheel Ring Gear
- CYLINDER HEAD
- Removal of the Cylinder Head
- Disassembly of the Cylinder Head
- Servicing the Cylinder Head and Valves
- Checking the Valve Springs

- Checking the Rocker Arm and Shaft
- Assembling the Cylinder Head
- Installing the Cylinder Head
- TIMING GEAR COVER
- Removal and Installation
- TIMING GEAR, CAMSHAFT AND OIL PUMP
- Removal and Installation
- Oil Pump Service
- Servicing the Camshaft
- CRANKSHAFT AND PISTONS
- Removal and Installation
- Crankshaft Service
- Servicing the Connecting Rods and Pistons
- CYLINDER LINERS
- Checking the Cylinder Liners
- Cylinder Liner Installation
- WATER PUMP
- Removal and Installation
- Disassembly and Assembly
- SPECIFICATIONS
- HYDRAULIC EXCAVATOR SPECIFICATIONS
- Machine Dimensions
- PERFORMANCE
- ENGINE
- HYDRAULIC SYSTEM
- SWING SYSTEM
- HYDRAULIC CYLINDERS
- DRIVE SYSTEM
- BRAKES
- UNDERCARRIAGE
- TRACK SHOES
- CAPACITIES
- DIGGING FORCE
- ENGINE SPECIFICATIONS (KUBOTA)
- Engine
- Fuel Injector Nozzles
- Fuel Injection Pump
- Cylinder Head
- Valves
- Valve Springs
- Rocker Arms
- Camshaft
- Cylinders
- Piston Rings
- Pistons
- Crankshaft
- Oil Pump
- Thermostat
- Engine Torque
- Crankshaft Re–Grind Data
- FUEL, COOLANT AND LUBRICANTS
- OIL SPECIFICATIONS
- Description
- SERVICE MANUAL REVISION
- 220-1
- 220-2
- 220-3
- 220-4
- 220-5
- 220-6
- 220-7
- 220-8

220 6720379 OM 11-89

- OPERATOR SAFETY WARNINGS
- FOREWORD
- CONTENTS
- SAFETY INSTRUCTIONS
- FIRE PREVENTION
- SERIAL NUMBER LOCATIONS
- Hydraulic Excavator Serial Number
- Engine Serial Number
- DELIVERY REPORT
- HYDRAULIC EXCAVATOR IDENTIFICATION
- SAFETY SIGNS (DECALS)
- OPERATING INSTRUCTIONS
- GETTING ON AND OFF THE MACHINE
- SEAT
- SEAT BELT
- INSTRUMENT PANEL
- KEY SWITCH
- LEVER & CONTROL LOCATIONS
- CONTROL LEVERS
- Operation Of Left Control Lever (ISO)
- Operation Of Right Control Lever (ISO)
- Control Lever Lock Operation
- FUEL CONTROL LEVER
- ENGINE STOP CONTROL
- STEERING LEVERS
- Forward And Reverse Travel
- Turning
- Making A Counter-Rotation Turn
- BOOM SWING LEVER
- BLADE CONTROL LEVER
- SWING LOCK
- BEFORE STARTING THE ENGINE
- STARTING THE ENGINE
- Normal Starting Procedure
- Cold Starting Procedure
- PARKING THE HYDRAULIC EXCAVATOR
- OPERATING PROCEDURE
- Breaking In A New Machine
- General Operation Suggestions
- TRANSPORTING THE HYDRAULIC EXCAVATOR
- BUCKET
- Removal
- Installation
- PREVENTIVE MAINTENANCE
- MAINTENANCE SAFETY
- SERVICE SCHEDULE
- ENGINE COVER
- AIR CLEANER SERVICE
- FUEL SYSTEM
- Fuel System Service
- Fuel Filters
- Removing Air From The Fuel System
- ENGINE LUBRICATION SYSTEM
- Engine Oil And Filter Replacement
- COOLING SYSTEM
- Coolant Level
- Coolant Replacement
- ALTERNATOR BELT ADJUSTMENT
- ELECTRICAL SYSTEM
- Fuse
- Service The Electrical System
- Using A Booster Battery (Jump Starting)
- Removal And Installation Of The Battery
- HYDRAULIC SYSTEM
- Checking And Adding Fluid
- Replacement Of The Hydraulic Filter
- Hydraulic Reservoir
- LUBRICATION OF THE HYDRAULIC EXCAVATOR
- FINAL DRIVE CASE
- Checking Oil Level
- Draining Final Drive Case
- TRACK TENSION
- Adjustment
- SPECIFICATIONS
- HYDRAULIC EXCAVATOR SPECIFICATIONS
- Machine Dimensions
- Lifting Capacity With Blade Off Ground
- Performance & Operation
- Engine
- Hydraulic System
- Swing System
- Hydraulic Cylinders
- Drive System
- Brakes
- Undercarriage
- Track
- Capacities
- Digging Force
- FUEL, COOLANT AND LUBRICANTS
- OIL SPECIFICATIONS
- WARRANTY

220 6720448 OM 4-92

- OPERATOR SAFETY WARNINGS
- FOREWORD
- CONTENTS
- SAFETY
- SAFETY INSTRUCTIONS
- FIRE PREVENTION
- SERIAL NUMBER LOCATIONS
- Hydraulic Excavator Serial Number
- Engine Serial Number
- DELIVERY REPORT
- HYDRAULIC EXCAVATOR IDENTIFICATION
- SAFETY SIGNS (DECALS)
- OPERATING INSTRUCTIONS
- GETTING ON AND OFF THE MACHINE
- SEAT
- SEAT BELT
- INSTRUMENT PANEL
- KEY SWITCH
- CONTROL LEVER LOCK
- CONTROL LEVERS
- Operation Of Left Control Lever (ISO)
- Operation Of Right Control Lever (ISO)
- CONTROL LEVER (Standard)
- Operation Of Left Control Lever
- Operation Of Right Control Lever
- SWING LOCK
- HORN BUTTON
- FUEL CONTROL LEVER
- ENGINE STOP CONTROL
- STEERING LEVERS
- Forward And Reverse Travel
- Turning
- Making A Counter-Rotation Turn
- BOOM SWING PEDAL
- BLADE CONTROL LEVER
- AUXILIARY CONTROL PEDAL
- BEFORE STARTING THE ENGINE
- STARTING THE ENGINE
- Normal Starting Procedure
- Cold Starting Procedure
- OPERATING PROCEDURE
- Breaking In A New Machine
- General Operation Suggestions
- PARKING THE HYDRAULIC EXCAVATOR
- TRANSPORTING THE HYDRAULIC EXCAVATOR
- LIFTING THE EXCAVATOR
- BUCKET
- Removal
- Installation
- PREVENTIVE MAINTENANCE
- MAINTENANCE SAFETY
- SERVICE SCHEDULE
- ENGINE COVER
- AIR CLEANER SERVICE
- FUEL SYSTEM
- Fuel System Service
- Fuel Filters
- Removing Air From The Fuel System
- ENGINE LUBRICATION SYSTEM
- Engine Oil And Filter Replacement
- COOLING SYSTEM
- Coolant Level
- Coolant Replacement
- ALTERNATOR BELT ADJUSTMENT
- ELECTRICAL SYSTEM
- Fuse
- Service The Electrical System
- Using A Booster Battery (Jump Starting)
- Removal And Installation Of The Battery
- HYDRAULIC SYSTEM
- Checking And Adding Fluid
- Diagnostic Couplers
- Replacement Of The Hydraulic Filter
- Hydraulic Reservoir
- LUBRICATION OF THE HYDRAULIC EXCAVATOR
- TRACK TENSION
- Adjustment
- FINAL DRIVE CASE
- Checking Oil Level
- Draining Final Drive Case
- HYDRAULIC EXCAVATOR SPECIFICATIONS
- Machine Dimensions
- Lifting Capacity With Blade Off Ground
- Performance & Operation
- Engine
- Hydraulic System
- SPECIFICATIONS
- Swing System
- Hydraulic Cylinders
- Drive System
- Brakes
- Undercarriage
- Track
- Capacities
- Digging Force
- FUEL, COOLANT AND LUBRICANTS
- OIL SPECIFICATIONS
- WARRANTY

220 6720503 SM 6-90

- MAINTENANCE SAFETY
- ALPHABETICAL INDEX
- FOREWORD
- CONTENTS
- SAFETY INSTRUCTIONS
- SERIAL NUMBER LOCATIONS
- HYDRAULIC EXCAVATOR SERIAL NUMBER
- ENGINE SERIAL NUMBER
- DELIVERY REPORT
- HYDRAULIC EXCAVATOR IDENTIFICATION
- PREVENTIVE MAINTENANCE
- SERVICE SCHEDULE
- ENGINE COVER
- AIR CLEANER SERVICE
- FUEL SYSTEM
- Fuel System Service
- Fuel Filter
- Removing Air From The Fuel System
- ENGINE LUBRICATION SYSTEM
- Engine Oil And Filter Replacement
- COOLING SYSTEM
- Coolant Level
- Coolant Replacement
- HYDRAULIC SYSTEM
- Checking And Adding Fluid
- Diagnostic couplers
- Replacement Of The Hydraulic Filter
- Hydraulic Reservoir
- USING A BOOSTER BATTERY (JUMP STARTING)
- Procedure
- LUBRICATION OF THE EXCAVATOR
- Procedure
- HYDRAULIC SECTION
- HYDRAULIC SCHEMATICS
- HYDRAULIC SERVICE INFORMATION
- Description
- Checking The Relief Valves
- HYDRAULIC PUMP
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- DUKES HYDRAULIC CONTROL VALVE
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- Center Housing
- Disassembly and Assembly
- Main Relief Valve Adjustment
- Testing And Adjustment Of The Port Relief Valve
- MELROE HYDRAULIC CONTROL VALVE
- Removal And Installation
- Disassembly
- Boom Swing And Blade Sections
- Auxiliary Section
- Assembly
- Auxiliary
- Main Relief Valve Adjustment
- HOLDING VALVES
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- Testing
- SWING CYLINDER LOCK VALVE
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- HYDRAULIC RESERVOIR
- Removal And Installation
- BOOM CYLINDER
- Removal And Installation
- DIPPERARM CYLINDER
- Removal And Installation
- BUCKET CYLINDER
- Removal And Installation
- BLADE CYLINDER
- Removal And Installation
- BOOM SWING CYLINDER
- Removal And Installation
- HYDRAULIC CYLINDER
- Disassembly
- For Piston With Single Ring Groove
- Assembly
- For Pistons with three Ring Grooves
- For Cylinders Using Piston Retaining Bolts
- For Cylinders Using Piston Retaining Lock Nuts
- HYDRAULIC FILTER
- Removal And Installation
- AUXILIARY COUPLERS
- Removal And Installation
- AUXILIARY FITTINGS
- Removal And Installation
- SHUTTLE VALVE
- Parts Identification
- Disassembly
- Assembly
- DRIVE SECTION
- FLOOR PANEL
- Removal And Installation
- CONTROL AND STEERING LEVERS
- Adjustment
- Removal And Installation
- Lever Disassembly And Assembly
- LOCKING LEVER
- Removal And Installation
- CONSOLE
- Removal And Installation
- PEDAL
- Removal And Installation
- BLADE LEVER
- Linkage Removal And Installation
- Lever Removal And Installation
- MELROE CONTROL VALVE LEVER
- Removal And Installation
- FINAL DRIVE
- For S/N 12001–12929 (for S/N 12930 & Above SeePage 3–39)
- Removal And Installation
- DRIVE MOTOR
- Parts Identification
- Disassembly
- Assembly
- HYDRAULIC MOTOR
- Disassembly
- Assembly
- FINAL DRIVE
- For S/N 12930 & Above
- Removal And Installation
- DRIVE MOTOR
- Parts Identification
- Disassembly
- Assembly
- UPPER WORKS AND SWING SECTION
- SWING MOTOR
- Removing The Cross Port Reliefs
- Removal And Installation
- Disassembly
- Assembly
- Motor Timing
- UPPER WORKS
- Removal And Installation
- Alignment Pin Procedure
- Alignment Screw Procedure
- Installation Of Swing Motor
- CENTER SWIVEL JOINT
- Removal And Installation
- Disassembly And Assembly
- SWING CIRCLE GEAR
- Removal And Installation
- MAIN FRAME AND TRACKS
- ENGINE COVER
- Removal And Installation
- SEAT AND MOUNTING FRAME
- Removal And Installation
- FUEL TANK
- Removal And Installation
- BOOM AND DIPPERSTICK
- Removal And Installation
- BOOM SWING BRACKET
- Removal And Installation
- Bushing Removal And Installation
- TRACK
- Track Tension Adjustment
- Removal And Installation
- TRACK FRAME
- Disassembly And Assembly
- TRACK IDLER
- Parts Identification
- Disassembly
- Assembly
- TRACK ROLLER
- Parts Identification
- Disassembly
- Assembly
- ELECTRICAL SYSTEM
- ELECTRICAL SCHEMATIC
- ELECTRICAL SYSTEM
- Troubleshooting
- Description
- Fuses
- Electrical System Service
- BATTERY
- Checking The Battery
- Removal And Installation
- ALTERNATOR
- Checking The Alternator Output
- Belt Adjustment
- Removal And Installation
- Parts Identification
- STARTER
- Removal And Installation
- Disassembly And Assembly
- Cleaning And Inspection
- INSTRUMENT PANEL
- Removal And Installation
- HORN
- Removal And Installation
- Horn Switch Removal And Installation
- ENGINE SERVICE
- ENGINE SERVICE
- Troubleshooting
- VALVE CLEARANCE
- Adjustment
- ENGINE COMPRESSION
- Checking
- FUEL FILTER
- Removing Air From The Fuel System
- Fuel Filter Removal And Installation
- FUEL INJECTION PUMP
- Checking The Injection Pump

- Removal And Installation
- Timing The Injection Pump
- FUEL INJECTOR NOZZLES
- Removal And Installation
- Checking The Injector Nozzle
- GLOW PLUGS
- Removal And Installation
- Checking The Glow Plug
- ENGINE
- Removal And Installation
- SPARK ARRESTOR MUFFLER
- Removal And Installation
- RADIATOR
- Checking The Radiator And Radiator Cap
- Removal And Installation
- OIL COOLER
- Removal And Installation
- ENGINE FLYWHEEL
- Removal And Installation
- Hydraulic Pump Coupler
- Flywheel Ring Gear
- CYLINDER HEAD
- Removal Of The Cylinder Head
- Disassembly Of The Cylinder Head
- Servicing The Cylinder Head And Valves
- Checking Valve Springs
- Checking Rocker Arm And Shaft
- Assembling The Cylinder Head
- Installing The Cylinder Head
- TIMING GEAR COVER
- Removal And Installation
- TIMING GEAR, CAMSHAFT AND OIL PUMP
- Removal And Installation
- Oil Pump Service
- Servicing The Camshaft
- CRANKSHAFT AND PISTONS
- Removal And Installation
- Crankshaft Service
- Servicing The Connecting Rods And Pistons
- CYLINDER LINERS
- Checking The Cylinder Liners
- Cylinder Liner Installation
- WATER PUMP
- Removal And Installation
- Disassembly And Assembly
- TECHNICAL DATA

- HYDRAULIC EXCAVATOR SPECIFICATIONS
- Machine Dimensions
- Lifting Capacity With Blade Off Ground
- PERFORMANCE & OPERATION
- ENGINE
- HYDRAULIC SYSTEM
- SWING SYSTEM
- HYDRAULIC CYLINDERS
- DRIVE SYSTEM
- BRAKES
- UNDERCARRIAGE
- TRACK
- CAPACITIES
- DIGGING FORCE
- ENGINE SPECIFICATIONS (KUBOTA)
- Engine
- Fuel Injector Nozzles
- Fuel Injection Pump
- Cylinder Head
- Valves
- Valve Springs
- Rocker Arms
- Camshaft
- Cylinders
- Piston Rings
- Pistons
- Crankshaft
- Oil Pump
- Thermostat
- Engine Torque
- Re–Grinding The Crankshaft
- FUEL, COOLANT AND LUBRICANTS
- Chart
- ENGINE OIL SPECIFICATIONS
- Description
- Propylene Glycol (Factory Installed)
- SERVICE MANUAL REVISION

AND MORE....