Bobcat X231 Excavator Repair Service Manual – 6720496

(S/N: 508911999 & Below)
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This workshop repair service manual PDF download for the X-231 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 231
S/N: 508911999 & Below

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 : 6720496 (4–90)
Total Pages : 327

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
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
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 Filters
Hydraulic Reservoir
ELECTRICAL SYSTEM
Using A Booster Battery (Jump Starting)
LUBRICATION OF THE HYDRAULIC EXCAVATOR
SWING MOTOR GEAR REDUCTION
FINAL DRIVE CASE
Checking Oil Level
Draining Final Drive Case

HYDRAULIC SECTION
HYDRAULIC SCHEMATICS
HYDRAULIC SERVICE INFORMATION
Description
Checking the Main Relief Valves
Checking the Locking Lever Relief Valve
With Locking Lever Down (Going Over Relief) Strokethe Bucket (Curl)
Checking the Auxiliary Relief Valve
HYDRAULIC PUMP
Removal and Installation
Disassembly
Assembly
HYDRAULIC CONTROL VALVE
Removal and Installation
CONTROL VALVE
Disassembly and Assembly
Disassembly and Assembly
Blade, Boom Swing, Bucket, L.H. Travel, Auxiliaryand House Swing Valve Sections
R.H. Travel Valve Section
Hydraulically Activated Valve Sections
Main Relief Valves
Work Port Relief Valves
Relief Valve Pressure Setting Adjustment
MAIN RELIEF VALVE
Work Port Relief Valves
SOLENOID VALVE
Removal and Installation
Parts Identification
Disassembly
Assembly
OIL COOLER
Removal and Installation
HYDRAULIC RESERVOIR
Removal and Installation
SUCTION FILTER
BOOM CYLINDER
Removal and Installation
Parts Identification
DIPPERSTICK CYLINDER
Removal and Installation
Parts Identification
BUCKET CYLINDER
Removal and Installation
Parts Identification
BLADE CYLINDER
Removal and Installation
Parts Identification
BOOM SWING CYLINDER
Removal and Installation
Parts Identification
HYDRAULIC CYLINDER
Disassembly
Assembly
SWING CYLINDER LOCK VALVE
Parts Identification
Disassembly
Assembly
HYDRAULIC FILTER
Removal and Installation
AUXILIARY ROUTING
JOYSTICK CONTROL CHANGE

DRIVE SECTION
HYDRAULIC CONTROL LEVERS
Swing/Dipperstick Control Lever
JOYSTICK
Disassembly and Assembly
Parts Identification
Boom/Bucket Control Lever
THROTTLE LEVER
Removal and Installation
BLADE CONTROL LEVER
Removal and Installation
CONTROL LOCKING ARM
Removal and Installation
GAS CYLINDER
Removal and Installation
LOCKING LEVER VALVE
Removal and Installation
LOCKING LEVER CABLE
Removal and Installation
CONTROL PANEL BASE
Removal and Installation
FOOT PEDAL AND STEERING LEVER LINKAGE
Removal and Installation
STEERING LEVERS
Removal and Installation
FINAL DRIVE
Removal and Installation
TRAVEL MOTOR
Disassembly
Assembly

UPPER WORKS AND SWING SECTION
SWING MOTOR
Removal and Installation
BRAKE VALVE
Disassembly
Assembly
SWING MOTOR
Disassembly
Assembly
REDUCTION GEAR
Disassembly
Assembly
RELIEF VALVE
Disassembly
Assembly
Adjustment
UPPER WORKS AND SWING CIRCLE GEAR
Removal and Installation
Reinstalling the Swing Bearing
CENTER SWIVEL JOINT
Removal and Installation (Through Upper Access Removal)

MAIN FRAME AND TRACKS
ENGINE COVER
Removal and Installation
ROPS
Removal and Installation
Front Window Removal & Installation
Side Window Removal & Installation
REAR FLOOR PANEL
Removal and Installation
FOOT PEDALS
Removal and Installation
SEAT AND MOUNTING FRAME
Removal and Installation
SWING MOTOR COVER
Removal and Installation
ENGINE SHROUD
Removal and Installation
FUEL TANK
Removal and Installation
BUCKET
Removal and Installation
DIPPERSTICK
Removal and Installation
BOOM
Removal and Installation
BOOM SWING BRACKET
Removal and Installation
BLADE
Removal and Installation
TRACK TENSION
Adjustment
Removal and Installation
TRACK FRAME
Disassembly and Assembly
TRACK IDLER
Parts Identification
Disassembly
Assembly
TRACK FRAME
TOOL BOX
Removal and Installation
TRACK ROLLER
Parts Identification
Disassembly
Assembly
OVERHEAD CONSOLE
Removal and Installation

ELECTRICAL SYSTEM
TROUBLESHOOTING
Chart
ELECTRICAL SYSTEM
Description
Fuses
Electrical System Service
BATTERY
Checking the Battery
Removal and Installation
ALTERNATOR
Belt Adjustment
Removal and Installation
FUEL SHUT–DOWN RELAY
Removal and Installation
STARTER
Removal and Installation
Disassembly and Assembly
FUEL LEVEL SENDER
Removal and Installation
Checking
DISPLAY MODULE
Removal and Installation
INSTRUMENT PANEL
Removal and Installation
DISPLAY MODULE
Testing and Trouble Shooting
Engine Temperature Circuit Test (with display module installed in the excavator.)
Testing the Display Panel
Fuel Level Circuit Test (with display module installed in the excavator)
Testing the Display Panel
Fuel Level Sender
Engine Oil Pressure Circuit Test (with display module installed in the excavator)
Testing the Display Module
Battery Charge Circuit Test (with display module installed in the excavator.)
Glow Plug Circuit Test (with display module installed in the excavator)
Engine Temperature Circuit Test (with display module removed from the excavator.)
Fuel Level Circuit Test (with display module removed from the excavator.)
Engine Oil Pressure Circuit Test (with display module removed from the excavator.)
Battery Charge Circuit Test (with display module removed from the excavator.)
VOLTAGE REGULATOR/GLOW PLUG TIMER
Removal and Installation
DIVERTER VALVE SWITCH
Removal and Installation
DOME LIGHT
Removal and Installation
WINDSHIELD WIPER
Removal and Installation
FRONT LIGHTS
Removal and Installation
Lamp Replacement
CONSOLE SWITCHES
Removal and Installation
WIPER MOTOR AND SWITCH

ENGINE SERVICE
TROUBLESHOOTING
VALVE CLEARANCE
Adjustment
ENGINE COMPRESSION
Checking
FUEL FILTER
Final Filter
In–Line Filter
ELECTRIC FUEL PUMP
Removal and Installation
FUEL SHUT–DOWN SOLENOID
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
RADIATOR
Removal and Installation
AIR CLEANER
Removal an Installation
MUFFLER
Removal and Installation
HEATER
Removal and Installation
ENGINE
Removal and Installation
ENGINE FLYWHEEL
Removal and Installation
Flywheel Ring Gear
CYLINDER HEAD
Removal
Disassembly
Servicing the Cylinder Head
Assembly
Installation
ENGINE REPAIR
Removing the Timing Gear, Camshaft and Oil Pump
Removing the Pistons and Crankshaft
Servicing the Timing Gear and Camshaft
Servicing the Connecting Rods and Pistons
Servicing the Crankshaft
Servicing the Cylinder Liners
Lubrication System
Oil Pump Service
Water Pump Service
ENGINE ASSEMBLY
Installing the Crankshaft
Installing the Pistons
Installing the Camshaft and Timing Gears
Installing the Gearcase

TECHNICAL DATA
EXCAVATOR SPECIFICATIONS
Machine Dimensions
PERFORMANCE & OPERATION
Engine
Hydraulic System
Swing System
Hydraulic Cylinders
DRIVE SYSTEM
BRAKES
UNDERCARRIAGE
TRACK SHOES
CAPACITIES
MISCELLANEOUS
ENGINE SPECIFICATIONS
Fuel Injection Nozzles
Fuel Injection Pump
Cylinder Head
Valves
Valve Springs
Rocker Arms
Camshaft
Cylinder
Piston Rings
Pistons
Crankshaft
Oil Pump
Engine Oil Specifications
ENGINE BOLT TORQUE
Re–Grinding The Crankshaft
FUEL, COOLANT AND LUBRICANTS
OIL SPECIFICATIONS
Description

SERVICE MANUAL REVISION
231-1
231-2
231-3
231-4
231-5
231-6
231-7
231-8
231-9

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