Bobcat 220 Excavator 6722345 (9-92) (Preview)
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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