Bobcat X220 Excavator Repair Service Manual – 6720503

(S/N: 508212001 & Above)
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This workshop repair service manual PDF download for the X-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 X 220
S/N: 508212001 & Above

TABLE OF CONTENTS :

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

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6720503 (6–90)–7.5C
Total Pages : 305

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
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
220-1
220-2
220-3
220-4
220-5
220-6
220-7
220-8