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Bobcat 220 Excavator Service Repair Workshop Manual – PDF Download
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Bobcat 220 Excavator Service Repair Workshop Manual
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Description
Bobcat 220 Excavator Service Repair Workshop Manual
FILE DETAILS:
Bobcat 220 Excavator Service Repair Workshop Manual
LANGUAGE:ENGLISH
PAGES:299
DOWNLOADABLE:YES
FILE TYPE:PDF
BOBCAT 220 EXCAVATOR SERVICE REPAIR WORKSHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat 220 Excavator Service Repair Workshop Manual
This manual is for the Bobcat hydraulic excavator mechanic. It provides necessary servicing and adjustment procedures for the hydraulic excavator and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the hydraulic excavator has had service or repair:
1. Check that the operator canopy is in good condition and is not modified.
2. Check that operating canopy mounting hardware is tightened and is Melroe approved.
3. The seat belt must be correctly installed, functional and in good condition.
4. Inspect for loose or broken parts or connections.
5. Machine signs must be legible and in the correct location.
6. Steering levers, control levers and foot pedal must return to neutral.
7. Inspect the air cleaner for damage or leaks. Check the condition of the element.
8. Check the electrical charging system
TABLE OF CONTENTS:
Bobcat 220 Excavator Service Repair Workshop Manual
MAINTENANCE SAFETY.......................................... 3 SERVICE MANUAL REVISION..................................... 5 220-1................................................... 5 FOREWORD.................................................... 7 CONTENTS.................................................... 9 SAFETY INSTRUCTIONS..................................... 11 SERIAL NUMBER LOCATIONS................................. 12 HYDRAULIC EXCAVATOR SERIAL NUMBER....................... 12 ENGINE SERIAL NUMBER.................................... 12 DELIVERY REPORT......................................... 12 HYDRAULIC EXCAVATOR IDENTIFICATION...................... 13 PREVENTIVE MAINTENANCE...................................... 15 SERVICE SCHEDULE........................................ 17 ENGINE COVER............................................ 18 AIR CLEANER SERVICE..................................... 18 FUEL SYSTEM............................................. 19 Fuel System Service................................. 19 Fuel Filter......................................... 20 Removing Air From The Fuel System................... 20 ENGINE LUBRICATION SYSTEM............................... 21 Engine Oil And Filter Replacement................... 21 COOLING SYSTEM.......................................... 22 Coolant Level....................................... 22 Coolant Replacement................................. 22 HYDRAULIC SYSTEM........................................ 23 Checking And Adding Fluid........................... 23 Diagnostic Couplers................................. 23 Replacement Of The Hydraulic Filter................. 24 Hydraulic Reservoir................................. 24 Replacement fo the Hydraulic Fluid.................. 24 USING A BOOSTER BATTERY (JUMP STARTING)................. 25 Procedure........................................... 25 LUBRICATION OF THE HYDRAULIC EXCAVATOR.................. 26 Procedure........................................... 26 HYDRAULIC SECTION........................................... 29 HYDRAULIC SCHEMATICS.................................... 31 HYDRAULIC SYSTEM TROUBLESHOOTING........................ 41 HYDRAULIC SERVICE INFORMATION........................... 47 Description......................................... 47 Checking the Main Relief Valves..................... 47 HYDRAULIC PUMPS......................................... 49 Removal And Installation............................ 49 HYDRAULIC PUMP ASSEMBLY................................. 50 Disassembly......................................... 51 Assembly............................................ 54 HYDRAULIC CONTROL VALVE (6-Spool)....................... 56 Removal And Installation............................ 56 6 Spool Control Valve Assembly...................... 57 Disassembly and Assembly............................ 58 Disassembly......................................... 58 Inlet Section (R.H. and L.H. Travel)................ 59 Disassembly..................................... 59 Assembly........................................ 60 Valve Sections (Boom, Bucket & Arm)................. 61 Disassembly..................................... 61 Assembly........................................ 62 Valve Sections (Auxiliary).......................... 63 Disassembly..................................... 63 Assembly........................................ 64 Port Relief Valve................................... 66 Disassembly..................................... 66 Assembly ....................................... 66 Adjustment Procedure............................ 66 Main Relief Valve................................... 68 Disassembly..................................... 68 Assembly........................................ 68 Adjustment Procedure............................ 69 HYDRAULIC CONTROL VALVE (3 Spool)....................... 71 Removal and Installation............................ 71 3 Spool Control Valve Assembly...................... 72 Disassembly......................................... 73 INLET SECTION (Housing Swing)....................... 74 Disassembly..................................... 74 Assembly........................................ 74 END COVER (Boom Swing) and VALVE SECTION (Blade).... 75 Disassembly..................................... 75 Assembly........................................ 77 Load Check Block.................................... 79 Disassembly..................................... 79 Assembly........................................ 79 Build-up Valve...................................... 81 Assembly........................................ 81 Main Relief Valve................................... 82 Disassembly..................................... 82 Assembly........................................ 82 Adjustment Procedure............................ 83 BOOM CYLINDER........................................... 85 Removal And Installation............................ 85 Boom Shield......................................... 85 Boom Cylinder....................................... 85 DIPPERARM CYLINDER...................................... 86 Removal And Installation............................ 86 BUCKET CYLINDER......................................... 87 Removal And Installation............................ 87 BLADE CYLINDER.......................................... 88 Removal And Installation............................ 88 BOOM SWING CYLINDER..................................... 89 Removal And Installation............................ 89 HYDRAULIC CYLINDER...................................... 91 Disassembly......................................... 91 Assembly............................................ 93 HYDRAULIC FILTER ASSEMBLY...............................100 Removal and Installation............................100 AUXILIARY COUPLERS......................................100 JOYSTICK MANIFOLD WITH ACCUMULATOR......................101 Removal And Installation............................101 Disassembly And Assembly............................103 DRAIN BLOCK.............................................104 Removal And Installation............................104 Filter Screen.......................................104 Drain Block.........................................104 OIL COOLER..............................................105 JOYSTICK CONTROL CHANGE.................................106 DRIVE SECTION...............................................107 FLOORMAT AND FLOOR PANELS...............................109 Removal And Installation............................109 LEFT CONTROL CONSOLE....................................111 Microswitch Adjustment Procedure....................111 Lockout Microswitch Removal and Installation........112 Console Cover Removal and Installation..............113 Joystick Removal And Installation...................116 Removal And Installation............................117 Fuel Tank Removal and Installation..................120 Lock Lever Removal And Installation.................122 Lock Lever Adjustment Procedure.....................123 Latch Hook Removal and Installation.................124 Gas Spring Removal And Installation.................125 Upper Console Removal And Installation..............126 RIGHT CONTROL CONSOLE (ROPS CANOPY MODELS)..............127 (CAB MODELS)........................................127 Console Cover Removal And Installation..............128 Joystick Removal And Installation...................130 Control Console Removal And Installation............131 Hydraulic Tank Removal And Installation.............135 TRAVEL LEVERS...........................................136 Removal And Installation............................136 RIGHT HAND PEDAL (Boom Swing)...........................138 Removal And Installation............................138 LEFT HAND PEDAL (Auxiliary).............................140 Removal And Installation............................140 ROCKERSHAFT.............................................142 Removal And Installation............................142 LINKAGE RODS............................................144 Removal And Installation............................144 BLADE LEVER.............................................145 Removal And Installation............................145 FINAL DRIVE.............................................148 Removal And Installation............................148 DRIVE MOTOR ASSEMBLY....................................149 Parts Identification................................149 DRIVE MOTOR.............................................150 Disassembly.........................................150 Assembly............................................160 Check Oil Level.....................................169 Draining Final Drive Case...........................169 JOYSTICK................................................170 Parts Identification................................170 Disassembly And Assembly............................171 UPPER WORKS AND SWING SECTION...............................175 SWING MOTOR.............................................177 Testing The Cross Port Reliefs......................177 Start The Engine....................................177 Removing The Cross Port Reliefs.....................177 Removal And Installation............................178 Disassembly.........................................178 Assembly............................................179 Motor Timing........................................180 UPPER WORKS.............................................181 Removal And Installation............................181 Installation........................................182 CENTER SWIVEL JOINT.....................................184 Removal and Installation............................184 Disassembly and Assembly............................184 SWING CIRCLE GEAR.......................................185 Removal And Installation............................185 ROPS CANOPY.............................................186 Removal And Installation............................186 CAB.....................................................187 Removal And Installation............................187 MAIN FRAME AND TRACKS.......................................191 ENGINE COVER............................................193 Removal And Installation............................193 SEAT AND MOUTING FRAME..................................194 Removal And Installation............................194 SEAT MOUNT..............................................195 Removal And Installation............................195 SPEED LEVER.............................................196 Removal And Installation............................196 SWING LOCK LEVER AND PIN................................196 Removal And Installation............................196 BUCKET..................................................197 Removal And Installation............................197 Installation........................................197 ARM.....................................................198 Removal And Installation............................198 BOOM ...................................................200 Removal And Installation............................200 SWING POST..............................................202 Removal And Installation............................202 Bushing Replacement.................................203 TRACK...................................................204 Track Tension Adjustment............................204 Removal And Installation............................205 Damage Identification And Causes....................205 TRACK IDLER.............................................216 Parts Identification................................216 Disassembly.........................................217 Assembly............................................219 TRACK ROLLER............................................223 Parts Identification................................223 Disassembly.........................................224 Assembly............................................226 Disassembly.........................................217 ELECTRICAL SYSTEM...........................................231 ELECTRICAL SCHEMATICS...................................233 6 ELECTRICAL SYSTEM.....................................234 TROUBLESHOOTING.....................................234 ELECTRICAL SYSTEM.......................................234 Description.........................................234 Fuse................................................235 Electrical System Service...........................235 BATTERY.................................................236 Checking The Battery................................236 Removal And Installation............................236 ALTERNATOR..............................................238 Checking The Alternator Output......................238 Belt Adjustment.....................................238 ELECTRICAL CONNECTION...............................238 Removal And Installation............................239 Disassembly And Assembly............................240 Checking Rotor, Stator And Rectifier................240 STARTER.................................................243 Removal And Installation............................243 Disassembly And Assembly............................244 Cleaning And Inspection.............................244 HORN....................................................245 Removal And Installation............................245 FUEL LEVEL SENDOR.......................................245 Removal And Installation............................245 ENGINE SERVICE..............................................246 7 ENGINE SERVICE........................................248 TROUBLESHOOTING.........................................248 VALVE CLEARANCE.........................................249 Adjustment..........................................249 ENGINE COMPRESSION......................................250 Checking............................................250 FUEL FILTER.............................................251 Element.............................................251 Removing Air From The Fuel System...................251 Fuel Filter Assembly Removal And Installation.......251 FUEL INJECTION PUMP.....................................252 Checking The Injection Pump.........................252 Removal And Installation............................252 Timing The Injection Pump...........................254 FUEL INJECTOR NOZZLES...................................255 Removal And Installation............................255 Checking The Injector Nozzle........................256 GLOW PLUGS..............................................257 Removal And Installation............................257 Checking The Glow Plug..............................257 ENGINE..................................................258 Removal And Installation............................258 SPARK ARRESTOR MUFFLER..................................263 Removal And Installation............................263 RADIATOR................................................264 Checking The Radiator And Radiator Cap..............264 Removal And Installation............................264 ENGINE FLYWHEEL.........................................267 Removal And Installation............................267 Hydraulic Pump Coupler..............................267 Flywheel Ring Gear..................................267 CYLINDER HEAD...........................................268 Removal Of The Cylinder Head........................268 Disassembly Of The Cylinder Head....................269 Servicing The Cylinder Head And Valves..............270 Checking Valve Springs..............................271 Checking Rocker Arm And Shaft.......................272 Assembling The Cylinder Head........................272 Installing The Cylinder Head........................272 TIMING GEAR COVER.......................................274 Removal And Installation............................274 TIMING GEAR, CAMSHAFT AND OIL PUMP......................276 Removal And Installation............................276 Oil Pump Service....................................278 Servicing The Camshaft..............................279 CRANKSHAFT AND PISTONS..................................281 Removal And Installation............................281 Crankshaft Service..................................283 Servicing The Connecting Rods And Pistons...........284 CYLINDER LINERS.........................................286 Checking The Cylinder Liners........................286 Cylinder Liner Installation.........................286 WATER PUMP..............................................287 Removal And Installation............................287 Disassembly And Assembly............................287 TECHNICAL DATA..............................................288 HYDRAULIC EXCAVATOR SPECIFICATIONS......................290 Machine Dimensions..................................290 Lifting Capacity With Blade Off Ground..............291 PERFORMANCE & OPERATION.............................292 ENGINE..............................................292 HYDRAULIC SYSTEM....................................292 SWING SYSTEM........................................292 HYDRAULIC CYLINDERS.................................292 DRIVE SYSTEM........................................292 BRAKES..............................................293 UNDERCARRIAGE.......................................293 TRACK...............................................293 CAPACITIES..........................................293 DIGGING FORCE.......................................293 ENGINE SPECIFICATIONS (KUPOTA)..........................294 Engine..............................................294 Fuel Injector Nozzles...............................294 Fuel Injection Pump.................................294 Cylinder Head.......................................294 Valves..............................................294 Valve Springs.......................................294 Rocker Arms.........................................294 Camshaft............................................295 Cylinders...........................................295 Piston Rings........................................295 Pistons.............................................295 Crankshaft..........................................295 Oil Pump............................................296 Thermostat..........................................296 ENGINE TORQUE.......................................297 Re-Grinding The Crankshaft..........................298 FUEL, COOLANT AND LUBRICANTS............................299 OIL SPECIFICATIONS......................................299
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
