Bobcat 220 Excavator Repair Service Manual - 6722345

(S/N: 15001 & Above) 
- 
This workshop repair service manual PDF download for the 220 Bobcat Mini Hydraulic Excavator has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Bobcat Excavator 220
S/N: 15001 & Above


TABLE OF CONTENTS :

SAFETY INSTRUCTIONS 
SERIAL NUMBER LOCATIONS 
DELIVERY REPORT 
HYDRAULIC EXCAVATOR IDENTIFICATION 
PREVENTIVE MAINTENANCE 
HYDRAULIC SECTION 
DRIVE SECTION 
UPPER WORKS & SWING SECTION 
MAIN FRAME & TRACKS 
ELECTRICAL SYSTEM 
ENGINE SERVICE 
TECHNICAL DATA 


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6722345 (9-92)-7.50C
Total Pages : 299


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

-

MAINTENANCE SAFETY
SERVICE MANUAL REVISION
    220-1
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
        Replacement fo the Hydraulic Fluid
    USING A BOOSTER BATTERY (JUMP STARTING)
        Procedure
    LUBRICATION OF THE HYDRAULIC EXCAVATOR
        Procedure
        
HYDRAULIC SECTION
    HYDRAULIC SCHEMATICS
    HYDRAULIC SYSTEM TROUBLESHOOTING
    HYDRAULIC SERVICE INFORMATION
        Description
        Checking the Main Relief Valves
    HYDRAULIC PUMPS
        Removal And Installation
    HYDRAULIC PUMP ASSEMBLY
        Disassembly
        Assembly
    HYDRAULIC CONTROL VALVE (6-Spool)
        Removal And Installation
        6 Spool Control Valve Assembly
        Disassembly and Assembly
        Disassembly
        Inlet Section (R.H. and L.H. Travel)
            Disassembly
            Assembly
        Valve Sections (Boom, Bucket & Arm)
            Disassembly
            Assembly
        Valve Sections (Auxiliary)
            Disassembly
            Assembly
        Port Relief Valve
            Disassembly
            Assembly 
            Adjustment Procedure
        Main Relief Valve
            Disassembly
            Assembly
            Adjustment Procedure
    HYDRAULIC CONTROL VALVE (3 Spool)
        Removal and Installation
        3 Spool Control Valve Assembly
        Disassembly
        INLET SECTION (Housing Swing)
            Disassembly
            Assembly
        END COVER (Boom Swing) and VALVE SECTION (Blade)
            Disassembly
            Assembly
        Load Check Block
            Disassembly
            Assembly
        Build-up Valve
            Assembly
        Main Relief Valve
            Disassembly
            Assembly
            Adjustment Procedure
    BOOM CYLINDER
        Removal And Installation
        Boom Shield
        Boom Cylinder
    DIPPERARM CYLINDER
        Removal And Installation
    BUCKET CYLINDER
        Removal And Installation
    BLADE CYLINDER
        Removal And Installation
    BOOM SWING CYLINDER
        Removal And Installation
    HYDRAULIC CYLINDER
        Disassembly
        Assembly
    HYDRAULIC FILTER ASSEMBLY
        Removal and Installation
    AUXILIARY COUPLERS
    JOYSTICK MANIFOLD WITH ACCUMULATOR
        Removal And Installation
        Disassembly And Assembly
    DRAIN BLOCK
        Removal And Installation
        Filter Screen
        Drain Block
    OIL COOLER
    JOYSTICK CONTROL CHANGE
    
DRIVE SECTION
    FLOORMAT AND FLOOR PANELS
        Removal And Installation
    LEFT CONTROL CONSOLE
        Microswitch Adjustment Procedure
        Lockout Microswitch Removal and Installation
        Console Cover Removal and Installation
        Joystick Removal And Installation
        Removal And Installation
        Fuel Tank Removal and Installation
        Lock Lever Removal And Installation
        Lock Lever Adjustment Procedure
        Latch Hook Removal and Installation
        Gas Spring Removal And Installation
        Upper Console Removal And Installation
    RIGHT CONTROL CONSOLE (ROPS CANOPY MODELS)
        (CAB MODELS)
        Console Cover Removal And Installation
        Joystick Removal And Installation
        Control Console Removal And Installation
        Hydraulic Tank Removal And Installation
    TRAVEL LEVERS
        Removal And Installation
    RIGHT HAND PEDAL (Boom Swing)
        Removal And Installation
    LEFT HAND PEDAL (Auxiliary)
        Removal And Installation
    ROCKERSHAFT
        Removal And Installation
    LINKAGE RODS
        Removal And Installation
    BLADE LEVER
        Removal And Installation
    FINAL DRIVE
        Removal And Installation
    DRIVE MOTOR ASSEMBLY
        Parts Identification
    DRIVE MOTOR
        Disassembly
        Assembly
        Check Oil Level
        Draining Final Drive Case
    JOYSTICK
        Parts Identification
        Disassembly And Assembly
        
UPPER WORKS AND SWING SECTION
    SWING MOTOR
        Testing The Cross Port Reliefs
        Start The Engine
        Removing The Cross Port Reliefs
        Removal And Installation
        Disassembly
        Assembly
        Motor Timing
    UPPER WORKS
        Removal And Installation
        Installation
    CENTER SWIVEL JOINT
        Removal and Installation
        Disassembly and Assembly
    SWING CIRCLE GEAR
        Removal And Installation
    ROPS CANOPY
        Removal And Installation
    CAB
        Removal And Installation
        
MAIN FRAME AND TRACKS
    ENGINE COVER
        Removal And Installation
    SEAT AND MOUTING FRAME
        Removal And Installation
    SEAT MOUNT
        Removal And Installation
    SPEED LEVER
        Removal And Installation
    SWING LOCK LEVER AND PIN
        Removal And Installation
    BUCKET
        Removal And Installation
        Installation
    ARM
        Removal And Installation
    BOOM 
        Removal And Installation
    SWING POST
        Removal And Installation
        Bushing Replacement
    TRACK
        Track Tension Adjustment
        Removal And Installation
        Damage Identification And Causes
    TRACK IDLER
        Parts Identification
        Disassembly
        Assembly
    TRACK ROLLER
        Parts Identification
        Disassembly
        Assembly
        Disassembly
        
ELECTRICAL SYSTEM
    ELECTRICAL SCHEMATICS
    6 ELECTRICAL SYSTEM
        TROUBLESHOOTING
    ELECTRICAL SYSTEM
        Description
        Fuse
        Electrical System Service
    BATTERY
        Checking The Battery
        Removal And Installation
    ALTERNATOR
        Checking The Alternator Output
        Belt Adjustment
        ELECTRICAL CONNECTION
        Removal And Installation
        Disassembly And Assembly
        Checking Rotor, Stator And Rectifier
    STARTER
        Removal And Installation
        Disassembly And Assembly
        Cleaning And Inspection
    HORN
        Removal And Installation
    FUEL LEVEL SENDOR
        Removal And Installation
        
ENGINE SERVICE
    7 ENGINE SERVICE
    TROUBLESHOOTING
    VALVE CLEARANCE
        Adjustment
    ENGINE COMPRESSION
        Checking
    FUEL FILTER
        Element
        Removing Air From The Fuel System
        Fuel Filter Assembly 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
    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 (KUPOTA)
        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
    OIL SPECIFICATIONS
    
    -