Bobcat X231 Excavator Service Manual – 6722178 (3–92)

(S/N: 508912001 & Above)
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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: 508912001 & Above

TABLE OF CONTENTS :

SAFETY
PREVENTIVE MAINTENANCE
HYDRAULIC SECTION
DRIVE SECTION
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
Product Code : 6722178 (3–92)
Total Pages : 337

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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CONTENTS
FOREWORD
SAFETY
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
HYDRAULIC EXCAVATOR SERIAL NUMBER
ENGINE SERIAL NUMBER
DELIVERY REPORT
HYDRAULIC EXCAVATOR IDENTIFICATION
MACHINE SIGNS TRANSLATIONS (DECALS)

PREVENTIVE MAINTENANCE
SERVICE SCHEDULE
ENGINE COVER
Procedure
AIR CLEANER SERVICE
Replacing the Filter Element
FUEL SYSTEM
Fuel Specifications
Fuel System Service
Fuel Filters
In–line Fuel Filter (If Equipped)
Removing Air From The Fuel System
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
Diagnostic Couplers
USING A BOOSTER BATTERY (JUMP STARTING)
Procedure
LUBRICATION OF THE HYDRAULIC EXCAVATOR
Procedure
FINAL DRIVE CASE
Checking Oil Level
Draining Final Drive Case
HYDRAULIC SECTION

HYDRAULIC SECTION
HYDRAULIC SCHEMATICS
HYDRAULIC SERVICE INFORMATION
Description
MAIN RELIEF VALVES
Checking the Relief Valve Pressure Settings
Adjustment Procedure
(With Dual Pressure Relief Valves) (S/N 508912381 & Above)
HYDRAULIC PUMP FLOW TEST
HYDRAULIC PUMP
Removal And Installation
HYDRAULIC PUMP
Disassembly And Assembly
HYDRAULIC CONTROL VALVE (Six Spool)
Removal And Installation
Parts Identification
Disassembly And Assembly
HYDRAULIC CONTROL VALVE (Three Spool)
Removal And Installation
Parts Identification
Disassembly And Assembly
Pressure Build–up Valve Adjustment Procedure
PRESSURE REDUCING VALVE WITH ACCUMULATOR
Removal And Installation
Parts Identification
ACCUMULATOR/VALVE
Disassembly
Assembly
Setting The Safety Relief Valve
ACCUMULATOR
Charging
AUXILIARY SELECTOR VALVE
Removal And Installation
Disassembly And Assembly
TWO SPEED VALVE
Removal And Installation
Parts Identification
PORT BLOCK
Removal And Installation
OIL COOLER
Removal And Installation
HYDRAULIC RESERVOIR AND FUEL RESERVOIR
Removal And Installation
HYDRAULIC FILTER ASSEMBLY
Removal And Installation
BOOM CYLINDER
Removal And Installation
Parts Identification
ARM 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
JOYSTICK CONTROL CHANGE

DRIVE SECTION
LEFT CONSOLE
Lockout Valve Removal and Installation
Cylinder Removal and Installation
Removal and Installation
LEFT JOYSTICK
Removal and Installation
Disassembly and Assembly
Parts Identification
RIGHT CONSOLE
Removal and Installation
RIGHT CONSOLE COVER
Removal and Installation
THROTTLE LEVER
Low Idle Adjustment
High Idle Adjustment
Removal and Installation
CONTROL CABLES
Throttle Cable
Blade Cable and Lever
FOOT PEDAL AND STEERING LEVERS
Removal and Installation
Bushing Removal and Installation
FINAL DRIVE
Removal and Installation
Parts Identification
TRAVEL MOTOR
Disassembly
Assembly

UPPER WORKS AND SWING SECTION
SWING MOTOR
Removal and Installation
Disassembly
Assembly
CROSS–OVER RELIEF VALVE
Disassembly
Assembly
SWING MOTOR
Parts Identification
SWING GEAR BOX ASSEMBLY (WITH OR WITHOUT BRAKES)
Disassembly
Assembly
UPPER WORKS AND SWING CIRCLE GEAR
Removal and Installation
Swing Bearing Removal
Swing Bearing Installation
CENTER SWIVEL JOINT
Removal And Installation (through upper access removal)
Removal And Installation (through bottom access cover)
Parts Identification

MAIN FRAME AND TRACKS
ENGINE COVER
Removal and Installation
SEAT AND MOUNTING FRAME
Removal and Installation
CENTER FLOOR PANEL
Removal and Installation
SWING MOTOR COVER
Removal and Installation
REAR FLOOR PANEL
Removal and Installation
INSPECTION COVER
Removal and Installation
TOOL BOX
Removal and Installation
BUCKET
Removal and Installation
ARM
Removal and Installation
BOOM
Removal and Installation
BOOM SWING BRACKET
Removal and Installation
WORK GROUP HOSE INSTALLATION
Hose Mounting and Dimensions
BLADE
Removal and Installation
TRACK
Track Tension Adjustment
Rubber Tracks
Steel Tracks
Removal and Installation (Rubber Track)
Removal and Installation (Steel Track)
TRACK FRAME
Disassembly and Assembly
TRACK IDLER
Parts Identification
Disassembly
Assembly
Disassembly and Assembly
TRACK ROLLER
Parts Identification
Disassembly
Assembly
ROPS
Removal and Installation
Front Window Removal
Side Window Removal

ELECTRICAL SYSTEM
ELECTRICAL CHARTS
TROUBLESHOOTING
ELECTRICAL SYSTEM
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
FUEL LEVEL SENDER
Removal and Installation
Checking
INSTRUMENT PANEL
Removal And Installation
HOURMETER
Removal And Installation
WIPER MOTOR AND SWITCH

ENGINE SYSTEM
TROUBLESHOOTING
VALVE CLEARANCE
Adjustment
ENGINE COMPRESSION
Checking
FUEL SYSTEM
Fuel Filters
Fuel Filter Assembly
In–Line Fuel Filter (if equipped)
Removing Air From the Fuel System
FUEL SHUT–OFF SOLENOID
Adjustment
Removal and Installation
FUEL INJECTION PUMP
Checking the Injection Pump
Removal and Installation
Timing the Injection Pump
FUEL INJECTOR NOZZLES
Checking the Injector Nozzle
GLOW PLUGS
Removal and Installation
Checking the Glow Plug
RADIATOR
Removal and Installation
AIR CLEANER
Removal and 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 Gearcase
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 Gearcase

TECHNICAL DATA
HYDRAULIC EXCAVATOR SPECIFICATIONS
Machine Dimensions
Lifting Capacity With Blade Off Ground (Model 231 with Canopy)
Lifting Capacity With Blade Off Ground (Model 231 with Cab)
Engine
Hydraulic System
Swing System
Hydraulic Cylinders
Drive System
Brakes
Undercarriage
Track
Capacities
Miscellaneous
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

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