Bobcat 220 Excavator Service Manual – 6722345 (9-92)

(S/N: 15001 & Above)
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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 !!!!

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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

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