Bobcat Excavator (220 225 231 Series) Service and Owners Manual
220 225 231 series
SERVICE AND OWNERS MANUAL
BOBCAT EXCAVATOR (220 225 231 SERIES) - SERVICE AND OWNERS MANUAL - Service Manual And Owners Manual, to Bobcat Excavator (220 225 231 Series). CONTENTS: 220 6720124 OM 11-89 - OPERATOR SAFETY WARNINGS - FOREWORD - CONTENTS - SAFETY INSTRUCTIONS - FIRE PREVENTIONS - SERIAL NUMBER LOCATIONS - Hydraulic Excavator Serial Number - Engine Serial Number - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - SAFETY SIGNS (DECALS) - OPERATING INSTRUCTIONS - GETTING ON AND OFF THE MACHINE - SEAT - SEAT BELT - INSTRUMENT PANEL - KEY SWITCH - LEVER & CONTROL LOCATIONS - CONTROL LEVERS - Operation Of Left Control Lever (ISO) - Operation Of Right Control Lever (ISO) - Control Lever Lock Operation - FUEL CONTROL LEVER - STEERING LEVERS - Forward And Reverse Travel - Turning - Making A Counter-Rotation Turn - BOOM SWING LEVER - BLADE CONTROL LEVER - SWING LOCK - BEFORE STARTING THE ENGINE - STARTING THE ENGINE - Normal Starting Procedure - Cold Starting Procedure - PARKING THE HYDRAULIC EXCAVATOR - OPERATING PROCEDURE - Breaking In A New Machine - General Operation Suggestions - TRANSPORTING THE HYDRAULIC EXCAVATOR - BUCKET - Removal - Installation - PREVENTIVE MAINTENANCE - MAINTENANCE SAFETY - SERVICE SCHEDULE - ENGINE COVER - AIR CLEANER SERVICE - FUEL SYSTEM - Fuel System Service - Fuel Filters - Removing Air From The Fuel System - ENGINE LUBRICATION SYSTEM - Engine Oil And Filter Replacement - COOLING SYSTEM - Coolant Level - Coolant Replacement - ALTERNATOR BELT ADJUSTMENT - ELECTRICAL SYSTEM - Fuses - Fuse Arrangement - Service The Electrical System - Using A Booster Battery (Jump Starting) - Removal And Installation Of The Battery - HYDRAULIC SYSTEM - Checking And Adding Fluid (S/N 11308 & Below) - Checking And Adding Fluid (S//N 11309 - 11500) - Replacement Of The Hydraulic Filter - Hydraulic Reservoir - LUBRICATION OF THE HYDRAULIC EXCAVATOR - FINAL DRIVE CASE - Checking Oil Level - Draining Final Drive Case - TRACK TENSION - Adjustment - SPECIFICATIONS - 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 - FUEL, COOLANT AND LUBRICANTS - OIL SPECIFICATIONS - WARRANTY 220 6720230 SM-5-89 - 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 SERVICE - 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 Filter - Hydraulic Reservoir - USING A BOOSTER BATTERY (JUMP STARTING) - Procedure - LUBRICATION OF THE EXCAVATOR - Procedure - FINAL DRIVE CASE - Checking Oil Level - Draining Final Drive Case - HYDRAULIC SYSTEM - HYDRAULIC SCHEMATICS - HYDRAULIC SERVICE INFORMATION - Checking The Main Relief Valves - HYDRAULIC PUMP - Removal And Installation - Parts Identification - Disassembly - Assembly - HYDRAULIC CONTROL VALVE - Removal and Installation - HYDRAULIC RESERVOIR - Removal and Installation - Suction Filter - BOOM CYLINDER - Removal and Installation - ARM CYLINDER - Removal and Installation - BUCKET CYLINDER - Removal and Installation - BLADE CYLINDER - Removal and Installation - BOOM SWING CYLINDER - Removal and Installation - HYDRAULIC CYLINDER (Melroe Cylinders) - Disassembly - Assembly - SOLENOID VALVE - Parts Identification - SOLENOID VALVE - Disassembly - Assembly - SWING CYLINDER LOCK VALVE - Parts Identification - SWING CYLINDER LOCK VALVE - Disassembly - Assembly - DRIVE SYSTEM - FLOOR PANEL - Removal and Installation - CONTROL AND STEERING LEVERS - Swing/Arm Control Lever - Control Lever Lock Mechanism - Boom/Bucket Control Lever - Steering Levers - DRIVE MOTOR - Removal and Installation - Disassembly - Assembly - UPPER WORKS AND SWING SECTION - SWING MOTOR - Removal and Installation - Parts Identification - Disassembly - Assembly - Motor Timing - Parts Identification - Disassembly - Assembly - Brake Valve Parts Identification - Brake Valve Disassembly - Control Valve Assembly - Control Valve Testing - UPPER WORKS - Removal And Installation - Swing Motor Installation - 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 - 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 SCHEMATICS - TROUBLESHOOTING - 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 - INSTRUMENT PANEL - Lights, Hourmeter and Ignition Switch - Removal and Installation - ENGINE SERVICE - TROUBLESHOOTING - VALVE CLEARANCE - Adjustment - ENGINE COMPRESSION - Checking - FUEL FILTER - Fuel Filters - Removing Air From the Fuel System - 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 - MUFFLER - Removal and Installation - RADIATOR - Removal and Installation - ENGINE FLYWHEEL - Removal and Installation - Flywheel Ring Gear - CYLINDER HEAD - Removal of the Cylinder Head - Disassembly of the Cylinder Head - Servicing the Cylinder Head and Valves - Checking the Valve Springs - Checking the 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 - SPECIFICATIONS - HYDRAULIC EXCAVATOR SPECIFICATIONS - Machine Dimensions - PERFORMANCE - ENGINE - HYDRAULIC SYSTEM - SWING SYSTEM - HYDRAULIC CYLINDERS - DRIVE SYSTEM - BRAKES - UNDERCARRIAGE - TRACK SHOES - 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 - Crankshaft Re–Grind Data - FUEL, COOLANT AND LUBRICANTS - OIL SPECIFICATIONS - Description - SERVICE MANUAL REVISION - 220-1 - 220-2 - 220-3 - 220-4 - 220-5 - 220-6 - 220-7 - 220-8 220 6720379 OM 11-89 - OPERATOR SAFETY WARNINGS - FOREWORD - CONTENTS - SAFETY INSTRUCTIONS - FIRE PREVENTION - SERIAL NUMBER LOCATIONS - Hydraulic Excavator Serial Number - Engine Serial Number - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - SAFETY SIGNS (DECALS) - OPERATING INSTRUCTIONS - GETTING ON AND OFF THE MACHINE - SEAT - SEAT BELT - INSTRUMENT PANEL - KEY SWITCH - LEVER & CONTROL LOCATIONS - CONTROL LEVERS - Operation Of Left Control Lever (ISO) - Operation Of Right Control Lever (ISO) - Control Lever Lock Operation - FUEL CONTROL LEVER - ENGINE STOP CONTROL - STEERING LEVERS - Forward And Reverse Travel - Turning - Making A Counter-Rotation Turn - BOOM SWING LEVER - BLADE CONTROL LEVER - SWING LOCK - BEFORE STARTING THE ENGINE - STARTING THE ENGINE - Normal Starting Procedure - Cold Starting Procedure - PARKING THE HYDRAULIC EXCAVATOR - OPERATING PROCEDURE - Breaking In A New Machine - General Operation Suggestions - TRANSPORTING THE HYDRAULIC EXCAVATOR - BUCKET - Removal - Installation - PREVENTIVE MAINTENANCE - MAINTENANCE SAFETY - SERVICE SCHEDULE - ENGINE COVER - AIR CLEANER SERVICE - FUEL SYSTEM - Fuel System Service - Fuel Filters - Removing Air From The Fuel System - ENGINE LUBRICATION SYSTEM - Engine Oil And Filter Replacement - COOLING SYSTEM - Coolant Level - Coolant Replacement - ALTERNATOR BELT ADJUSTMENT - ELECTRICAL SYSTEM - Fuse - Service The Electrical System - Using A Booster Battery (Jump Starting) - Removal And Installation Of The Battery - HYDRAULIC SYSTEM - Checking And Adding Fluid - Replacement Of The Hydraulic Filter - Hydraulic Reservoir - LUBRICATION OF THE HYDRAULIC EXCAVATOR - FINAL DRIVE CASE - Checking Oil Level - Draining Final Drive Case - TRACK TENSION - Adjustment - SPECIFICATIONS - 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 - FUEL, COOLANT AND LUBRICANTS - OIL SPECIFICATIONS - WARRANTY 220 6720448 OM 4-92 - OPERATOR SAFETY WARNINGS - FOREWORD - CONTENTS - SAFETY - SAFETY INSTRUCTIONS - FIRE PREVENTION - SERIAL NUMBER LOCATIONS - Hydraulic Excavator Serial Number - Engine Serial Number - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - SAFETY SIGNS (DECALS) - OPERATING INSTRUCTIONS - GETTING ON AND OFF THE MACHINE - SEAT - SEAT BELT - INSTRUMENT PANEL - KEY SWITCH - CONTROL LEVER LOCK - CONTROL LEVERS - Operation Of Left Control Lever (ISO) - Operation Of Right Control Lever (ISO) - CONTROL LEVER (Standard) - Operation Of Left Control Lever - Operation Of Right Control Lever - SWING LOCK - HORN BUTTON - FUEL CONTROL LEVER - ENGINE STOP CONTROL - STEERING LEVERS - Forward And Reverse Travel - Turning - Making A Counter-Rotation Turn - BOOM SWING PEDAL - BLADE CONTROL LEVER - AUXILIARY CONTROL PEDAL - BEFORE STARTING THE ENGINE - STARTING THE ENGINE - Normal Starting Procedure - Cold Starting Procedure - OPERATING PROCEDURE - Breaking In A New Machine - General Operation Suggestions - PARKING THE HYDRAULIC EXCAVATOR - TRANSPORTING THE HYDRAULIC EXCAVATOR - LIFTING THE EXCAVATOR - BUCKET - Removal - Installation - PREVENTIVE MAINTENANCE - MAINTENANCE SAFETY - SERVICE SCHEDULE - ENGINE COVER - AIR CLEANER SERVICE - FUEL SYSTEM - Fuel System Service - Fuel Filters - Removing Air From The Fuel System - ENGINE LUBRICATION SYSTEM - Engine Oil And Filter Replacement - COOLING SYSTEM - Coolant Level - Coolant Replacement - ALTERNATOR BELT ADJUSTMENT - ELECTRICAL SYSTEM - Fuse - Service The Electrical System - Using A Booster Battery (Jump Starting) - Removal And Installation Of The Battery - HYDRAULIC SYSTEM - Checking And Adding Fluid - Diagnostic Couplers - Replacement Of The Hydraulic Filter - Hydraulic Reservoir - LUBRICATION OF THE HYDRAULIC EXCAVATOR - TRACK TENSION - Adjustment - FINAL DRIVE CASE - Checking Oil Level - Draining Final Drive Case - HYDRAULIC EXCAVATOR SPECIFICATIONS - Machine Dimensions - Lifting Capacity With Blade Off Ground - Performance & Operation - Engine - Hydraulic System - SPECIFICATIONS - Swing System - Hydraulic Cylinders - Drive System - Brakes - Undercarriage - Track - Capacities - Digging Force - FUEL, COOLANT AND LUBRICANTS - OIL SPECIFICATIONS - WARRANTY 220 6720503 SM 6-90 - 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 - 220-8 220 6722250 OM 10-98 - OPERATOR SAFETY WARNINGS - CONTENTS - REGULAR MAINTENANCE ITEMS - FOREWORD - SERIAL NUMBER LOCATIONS - HYDRAULIC EXCAVATOR SERIAL NUMBER - ENGINE SERIAL NUMBER - DELIVERY REPORT - BOBCAT HYDRAULIC EXCAVATOR IDENTIFICATION - SAFETY - SAFETY INSTRUCTIONS - FIRE PREVENTION - MACHINE SIGNS (DECALS) - OPERATING INSTRUCTIONS - GETTING ON AND OFF THE MACHINE - SEAT - CONTROL LEVER (JOYSTICK) LOCK - INSTRUMENTS - AUDIBLE ALARM - KEY SWITCH - CAB ELECTRICAL (If Equipped) - HEATER CONTROL (If Equipped) - CONTROL LEVER (JOYSTICKS) - Operation Of Left Control Lever (ISO) - Operation Of Right Control Lever (ISO) - CONTROL LEVERS (STANDARD) - Operation Of Left Control Lever (STANDARD) - Operation Of Right Control Lever (STANDARD) - SWING LOCK - HORN BUTTON - SPEED CONTROL LEVER - ENGINE STOP CONTROL - STEERING LEVERS/FOOT PEDALS - Forward And Reverse Travel - Turning - Right Turn - Left Turn - BOOM SWING PEDAL AND LOCK - BLADE CONTROL LEVER - AUXILIARY OPERATION PEDAL - DAILY INSPECTION - STARTING THE ENGINE - Normal Starting Procedure (With Engine Warm) - Cold Temperature Starting Procedure - OPERATING PROCEDURE - Breaking In A New Machine - Operating In Water - PARKING THE HYDRAULIC EXCAVATOR - TRANSPORTING THE HYDRAULIC EXCAVATOR - LIFTING THE EXCAVATOR - BUCKET - Removal - Installation - PREVENTIVE MAINTENANCE - MAINTENANCE SAFETY - SERVICE SCHEDULE - ENGINE COVER - AIR CLEANER SERVICE - Filter Replacement - FUEL SYSTEM - Fuel Specification - Filling The Fuel Tank - Fuel Filters - Removing Air From The Fuel System - ENGINE LUBRICATION SYSTEM - Engine Oil And Filter Replacement - COOLING SYSTEM - Coolant Level - Coolant Replacement - Propylene Glycol - ALTERNATOR BELT ADJUSTMENT - ELECTRICAL SYSTEM - Fuses - Service The Electrical System - Using A Booster Battery (Jump Starting) - Removal And Installation Of The Battery - HYDRAULIC SYSTEM - Checking And Adding Fluid - Diagnostic Couplers - Replacement of the Hydraulic Filter - Hydraulic Reservoir - Replacement Of The Hydraulic Fluid - LUBRICATION OF THE HYDRAULIC EXCAVATOR - FINAL DRIVE CASE - Checking Oil Level - TRACK TENSION - Adjustment - JOYSTICK CONTROL CHANGE - ISO To Standard Control Pattern - Standard To ISO Control Pattern - SPECIFICATIONS - HYDRAULIC EXCAVATOR SPECIFICATIONS - Machine Dimensions - Lifting Capacity - FUEL, COOLANT AND LUBRICANTS - ENGINE OIL SPECIFICATIONS - Description - WARRANTY 220 6722345 SM 9-92 - 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 225 6720281 OM 12-90 - OPERATOR SAFETY WARNINGS - FOREWORD - CONTENTS - SAFETY INSTRUCTIONS - FIRE PREVENTION - SERIAL NUMBER LOCATIONS - Hydraulic Excavator Serial Number - Engine Serial Number - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - SAFETY SIGNS (DECALS) - OPERATING INSTRUCTIONS - GETTING ON AND OFF THE MACHINE - SEAT - INSTRUMENT PANEL - KEY SWITCH - CONTROL LEVER LOCK - CONTROL LEVERS - Operation Of Left Control Lever (ISO) - Operation Of Right Control Lever (ISO) - Operation Of Left Control Lever - Operation Of Right Control Lever - FUEL CONTROL LEVER - HORN BUTTON - SWING LOCK - STEERING LEVERS - Forward And Reverse Travel - Turning - Making A Counter-Rotation Turn - BLADE CONTROL LEVER - BOOM SWING PEDAL - ATTACHMENT OPERATION PEDAL - DAILY INSPECTION - STARTING THE ENGINE - Normal Starting Condition - Cold Temperature Starting Condition - PARKING THE HYDRAULIC EXCAVATOR - OPERATING PROCEDURE - Breaking In A New Machine - General Operation Suggestions - Operating In Water - Lifting The Excavator - TRANSPORTING THE HYDRAULIC EXCAVATOR - BUCKET - Removal - Installation - PREVENTIVE MAINTENANCE - MAINTENANCE SAFETY - SERVICE SCHEDULE - ENGINE COVER - AIR CLEANER SERVICE - FUEL SYSTEM - Fuel System Service - Fuel Filters - Removing Air From The Fuel System - ENGINE LUBRICATION SYSTEM - Engine Oil And Filter Replacement - COOLING SYSTEM - Coolant Level - Coolant Replacement - ALTERNATOR BELT ADJUSTMENT - ELECTRICAL SYSTEM - Fuses - Fuse Arrangement - Service The Electrical System - Using A Booster Battery (Jump Starting) - Removal And Installation Of The Battery - HYDRAULIC SYSTEM - Checking And Adding Fluid - Replacement Of The Hydraulic Filters - Hydraulic Reservoir - LUBRICATION OF THE HYDRAULIC EXCAVATOR - SWING MOTOR GEAR REDUCTION - FINAL DRIVE CASE - Checking Oil Level - Draining Final Drive Case - TRACK TENSION - Adjustment - SPECIFICATIONS - 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 - FUEL, COOLANT AND LUBRICANTS - OIL SPECIFICATIONS - WARRANTY 225 6720347 SM-11-89 - 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 SERVICE - 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 - USING A BOOSTER BATTERY (JUMP STARTING) - Procedure - LUBRICATION OF THE HYDRAULIC EXCAVATOR - Procedure - FINAL DRIVE CASE - Checking Oil Level - HYDRAULIC SECTION - HYDRAULIC SCHEMATICS - HYDRAULIC SERVICE INFORMATION - Description - Checking The Control Valve Relief Valves - Checking The Locking Lever Relief Valve - With Locking Lever Up (By–Passing Relief Valve) - Checking The Auxiliary Relief Valve - HYDRAULIC PUMP - Removal And Installation - Disassembly - Assembly - HYDRAULIC CONTROL VALVE - Removal And Installation - CONTROL VALVE - Disassembly And Assembly - Relief Valve Pressure Setting Adjustment - Main Relief Valve - Work Port Relief Valves - HYDRAULIC RESERVOIR - Removal And Installation - Suction Filter - BOOM CYLINDER - Removal And Installation - DIPPERSTICK CYLINDER - Removal And Installation - BUCKET CYLINDER - Removal And Installation - BLADE CYLINDER - Removal And Installation - BOOM SWING CYLINDER - Removal And Installation - HYDRAULIC CYLINDER - Disassembly - Assembly - SWING CYLINDER LOCK VALVE - Parts Identification - Disassembly - Assembly - SOLENOID VALVE - Parts Identification - Disassembly - Assembly - HYDRAULIC FILTER - Removal And Installation - Untitled - DRIVE SECTION - HYDRAULIC CONTROL LEVERS - Swing/Dipperstick Control Lever - Boom/Bucket Control Lever - Disassembly And Assembly - THROTTLE LEVER - Removal And Installation - BLADE CONTROL LEVER - Removal And Installation - CONTROL LOCKING ARM - Removal And Installation - PANEL LIFT 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 - DRIVE MOTOR - Disassembly - Assembly - FINAL DRIVE CASE - Check Oil Level - Draining Final Drive Case - UPPER WORKS AND SWING SECTION - SWING MOTOR - Removal And Installation - SWING MOTOR ASSEMBLY - Brake Valve - Parts Identification - Disassembly - Assembly - Relief Valve - Disassembly - Assembly - Adjustment for Model 225 - Piston Housing - Parts Identification - Disassembly - Assembly - Reduction Gear - Parts Identification - Disassembly - Assembly - UPPER WORKS - Removal And Installation - SWING CIRCLE GEAR - Removal And Installation - CENTER SWIVEL JOINT - Removal And Installation - Disassembly And Assembly - MAIN FRAME AND TRACKS - ENGINE COVER - Removal And Installation - FLOOR PANELS - Removal And Installation - SEAT AND MOUNTING FRAME - Removal And Installation - SWING MOTOR COVER - 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 - Track Tension Adjustment - TRACK FRAME - Disassembly And Assembly - TRACK IDLER - Parts Identification - Disassembly - Assembly - RUBBER TRACK IDLER - Parts Identification - Disassembly - Assembly - TOOL BOX - Removal And Installation - TRACK ROLLER - Parts Identification - Disassembly - Assembly - RUBBER TRACK ROLLER - Parts Identification - Disassembly - Assembly - ROPS WINDOWS - Front Window Removal - Side Window Removal - ELECTRICAL SYSTEM - ELECTRICAL SCHEMATICS - TROUBLESHOOTING - Chart - 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 - DISPLAY MODULE - Removal And Installation - INSTRUMENT PANEL - Removal And Installation - Testing And Troubleshooting - Engine Temperature Circuit Test (display module installed) - Testing The Display Panel - Fuel Level Circuit Test (display module installed) - Testing The Display Panel - Fuel Level Sender - Engine Oil Pressure Circuit Test (display module installed) - Testing The Display Panel - Battery Charge Circuit Test (display module installed) - Glow Plug Circuit Test (display module installed) - Engine Temperature Circuit Test (display module removed) - Fuel Level Circuit Test (display module removed) - Engine Oil Pressure Circuit Test (display module removed) - Battery Charge Circuit Test (display module removed) - Glow Plug Circuit Test (display module removed) - VOLTAGE REGULATOR/GLOW PLUG TIMER - Removal And Installation - WIPER MOTOR AND SWITCH - ENGINE SERVICE - TROUBLESHOOTING - Chart - VALVE CLEARANCE - Adjustment - ENGINE COMPRESSION - Checking - FUEL FILTER - Final Filter - In–Line Filter - ELECTRIC FUEL PUMP - 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 - MUFFLER - Removal And Installation - AIR CLEANER - Removal And Installation - ENGINE - Removal And Installation - ENGINE FLYWHEEL - Removal And Installation - Flywheel Ring Gear - CYLINDER HEAD - Removal - Disassembly - Servicing The Cylinder Head And Valves - Checking Valve Springs - Checking Rocker Arm And Shaft - Assembling The Cylinder Head - Installation - 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 - EXCAVATOR SPECIFICATIONS - Machine Dimensions - Performance And Operation - Engine - Hydraulic System - Swing System - Hydraulic Cylinders - Drive System - Brakes - Track Shoes - Capacities - Digging Force - 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 - Chart - OIL SPECIFICATIONS - Description - SERVICE MANUAL REVISION - 225-1 - 225-2 - 225-3 - 225-4 - 225-5 - 225-6 - 225-7 225 6720537 OM 9-98 - OPERATOR SAFETY WARNINGS - CONTENTS - REGULAR MAINTENANCE ITEMS - FOREWORD - SERIAL NUMBER LOCATIONS - HYDRAULIC EXCAVATOR SERIAL NUMBER - ENGINE SERIAL NUMBER - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - SAFETY - SAFETY INSTRUCTIONS - FIRE PREVENTION - MACHINE SIGNS (DECALS) - OPERATING INSTRUCTIONS - GETTING ON AND OFF THE MACHINE - SEAT - CONTROL CONSOLE LEVER LOCK - INSTRUMENT PANEL - LIGHT SWITCH - CONTROL LEVERS - Operation Of Left Control Lever (ISO) - Operation Of Right Control Lever (ISO) - Operation Of Left Control Lever (STANDARD) - Operation Of Right Control Lever (STANDARD) - SPEED CONTROL LEVER - HORN BUTTON - SWING LOCKING LEVER - STEERING LEVERS/FOOT PEDALS - Forward And Reverse Travel - Turning - Making A Counter–Rotation Turn - BOOM SWING PEDAL - AUXILIARY OPERATION PEDAL LOCK/FOOTREST - BLADE CONTROL LEVER - DAILY INSPECTION - STARTING/STOPPING THE ENGINE - Normal Starting Procedure (With Engine Warm) - Cold Temperature Starting Condition - OPERATING PROCEDURE - Breaking In A New Machine - General Operation Suggestions - Operating On Slopes - Operating In Water - PARKING THE HYDRAULIC EXCAVATOR - TRANSPORTING THE HYDRAULIC EXCAVATOR - LIFTING THE EXCAVATOR - BUCKET - Removal - Installation - PREVENTIVE MAINTENANCE - MAINTENANCE SAFETY - SERVICE SCHEDULE - ENGINE COVER - AIR CLEANER SERVICE - FUEL SYSTEM - Fuel Specifications - Fuel System Service - Fuel Filters (S/N 12001–12647) - Removing Air From The Fuel System (S/N 12001–12647) - Fuel Filters (S/N 12548 & Above) - In–line Fuel Filter (If equipped) - Removing Air From The Fuel System (S/N 12538 & Above) - ENGINE LUBRICATION SYSTEM - Engine Oil And Filter Replacement - COOLING SYSTEM - Coolant Level - Coolant Replacement - ALTERNATOR/FAN BELT ADJUSTMENT - ELECTRICAL SYSTEM - Fuses - Service The Electrical System - Using A Booster Battery (Jump Starting) - Removal And Installation Of The Battery - HYDRAULIC SYSTEM - Checking And Adding Fluid - Replacement Of The Hydraulic Filter - Hydraulic Reservoir - Diagnostic Couplers - LUBRICATION OF THE HYDRAULIC EXCAVATOR - SWING MOTOR GEAR REDUCTION - FINAL DRIVE CASE - Checking Oil Level - Draining Final Drive Case - TRACK TENSION - Adjustment - Rubber Tracks - Steel Tracks - SPECIFICATIONS - HYDRAULIC EXCAVATOR SPECIFICATIONS - OPERATIONS & PERFORMANCE - ENGINE - HYDRAULIC SYSTEM - SWING SYSTEM - HYDRAULIC CYLINDERS - DRIVE SYSTEM - BRAKES - UNDERCARRIAGE - TRACK - CAPACITIES - MISCELLANEOUS - Machine Dimensions - Lifting Capacity With Blade Off Ground (Model 225 with Canopy) - Lifting Capacity With Blade Off Ground (Model 225 with Cab) - FUEL, COOLANT AND LUBRICANTS - ENGINE OIL SPECIFICATIONS - Description - BUCKET SPECIFICATIONS - ADDITIONAL PUBLICATIONS - WARRANTY 225 6720874 SM 1-91 - 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 SERVICE - Replacing the Filter Element - FUEL SYSTEM - Fuel Specifications - Fuel System Service - Fuel Filters (S/N 12648 & Above) - 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 - USING A BOOSTER BATTERY (Jump Starting) - Procedure - LUBRICATION OF THE HYDRAULIC EXCAVATOR - Procedure - FINAL DRIVE CASE - Checking Oil Level - Draining Final Drive Case - Untitled - HYDRAULIC SECTION - HYDRAULIC SCHEMATICS - HYDRAULIC SERVICE INFORMATION - Description - Checking the Relief Valves - HYDRAULIC PUMP - Disassembly & Assembly - Parts Identification - HYDRAULIC CONTROL VALVE (6 Spool) - Removal and Installation - Parts Identification - Disassembly and Assembly - Disassembly - Inlet Section (R.H. and L.H. Travel) Disassembly - Inlet Section (R.H. and L.H. Travel) Assembly - Valve Sections (Boom, Bucket & Arm) Disassembly - Valve Sections (Boom, Bucket & Arm) Assembly - Valve Sections (Auxiliary) Disassembly - Valve Sections (Auxiliary) Assembly - Port Relief Valve - Disassembly - Assembly - Adjustment Procedure - Main Relief Valve - Disassembly - Assembly - Adjustment Procedure - HYDRAULIC CONTROL VALVE (3 Spool) - Removal and Installation - Parts Identification - Disassembly - Inlet Section (Housing Swing) - Disassembly - Assembly - End Cover (Boom Swing) and Valve Section (Blade) Disassembly - End Cover (Boom Swing) and Valve Section (Blade) Assembly - Load Check Block - Disassembly - Assembly - Build–Up Valve - Assembly - Main Relief Valve - Disassembly - Assembly - Main Relief Valve Adjustment Procedure - PRESSURE REDUCING VALVE WITHACCUMULATOR - Removal and Installation - Parts Identification - ACCUMULATOR / VALVE - Disassembly - Assembly - Setting the Safety Relief Valve - ACCUMULATOR - Charging - PORT BLOCK - Removal and Installation - OIL COOLER - Removal and Installation - HYDRAULIC RESERVOIR - Removal and Installation - HYDRAULIC FILTER ASSEMBLY - Removal and Installation - BOOM CYLINDER - Removal and Installation - BOOM DROP VALVE (NORDIC–OPTION) - Removal and Installation - ARM CYLINDER - Removal and Installation - BUCKET CYLINDER - Removal and Installation - BLADE CYLINDER - Removal and Installation - BOOM SWING CYLINDER - Removal and Installation - HYDRAULIC CYLINDER - Disassembly - Assembly - JOYSTICK CONTROL CHANGE - DRIVE SYSTEM - LEFT CONSOLE - Lockout Valve Removal and Installation - Cylinder Removal and Installation - Removal and Installation - LEFT JOYSTICK - Removal and Installation - Parts Identification - JOYSTICK - Disassembly and Assembly - CONTROL LEVERS - Removal and Installation - Throttle Lever - Blade Lever - RIGHT CONSOLE - Removal and Installation - Parts Identification - FOOT PEDAL AND STEERING LEVERS - Removal and Installation - Bushing Removal and Installation - FINAL DRIVE - Removal and Installation - Parts Identification - DRIVE MOTOR - Disassembly - Assembly - FINAL DRIVE CASE - Check Oil Level - Draining Final Drive Case - UPPER WORKS AND SWING SYSTEM - SWING MOTOR - Removal and Installation - Parts Identification - SWING GEAR BOX ASSEMBLY(WITH OR WITHOUT BRAKES) - Disassembly - Assembly - SWING GEAR BRAKE (NORDIC OPTION) - Solenoid Removal and Installation - UPPER WORKS AND SWING CIRCLE GEAR - Removal and Installation - Swing Bearing Removal - Swing Bearing Installation - Alignment Pins (Not Threaded) - CENTER SWIVEL JOINT - Removal and Installation (through upper access removal) - Parts Identification - MAIN FRAME AND TRACKS - ENGINE COVER - Removal and Installation - SEAT AND MOUNTING FRAME - Removal and Installation - NORDIC SEAT AND MOUNTING FRAME (OPTIONAL) - 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 - FUEL TANK - Removal and Installation - BUCKET - Removal and Installation - ARM - Removal and Installation - BOOM - Removal and Installation - BOOM SWING BRACKET - Removal and Installation - BLADE - Removal and Installation - TRACK - Track Tension Adjustment - Removal and Installation - TRACK FRAME - Disassembly and Assembly - TRACK IDLER - Parts Identification - Disassembly - Assembly - TRACK IDLER - Parts Identification - Disassembly - Assembly - TRACK ROLLER - Parts Identification - Disassembly - Assembly - Parts Identification - Disassembly - Assembly - ROPS - Removal and Installation - NORDIC CAB (OPTIONAL) - Removal and Installation - ROPS WINDOW - Front Window Removal - Side Window Removal - Installation - ELECTRICAL SYSTEM - ELECTRICAL SCHEMATICS - 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 - DOME LIGHT - Removal and Installation - CAB CONTROL PANEL - Removal and Installation - FRONT LIGHTS - Removal and Installation - Lamp Replacement - CONSOLE SWITCHES - Removal and Installation - WINDSHIELD WIPER - Removal and Installation - WINDSHIELD WASHER (NORDIC OPTION) - Removal and Installation - Hose Removal - ENGINE COVER LIGHT (NORDIC OPTION) - Removal and Installation - ENGINE SERVICE - TROUBLESHOOTING - VALVE CLEARANCE - Adjustment - ENGINE COMPRESSION - Checking - ELECTRIC FUEL PUMP - Removal and Installation - In–Line Filter (Used on Early Model Excavators Only) - FUEL FILTER - Final Filter (S/N 12001–12647) - Fuel Filter (S/N 12648 & Above) (With Water Drain Valve) - FUEL INJECTION PUMP - Checking the Injection Pump - Removal and Installation - Timing the Injection Pump - FUEL INJECTION NOZZLES - Removal and Installation - GLOW PLUGS - Removal and Installation - Checking the Glow Plug - RADIATOR - Removal and Installation - FAN SHIELD (NORDIC OPTION) - Removal and Installation - MUFFLER - Removal and Installation - AIR CLEANER - Removal and Installation - ENGINE - Removal and Installation - ENGINE FLYWHEEL - Removal and Installation - Flywheel Ring Gear - CYLINDER HEAD - Removing 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 - SPECIFICATIONS - HYDRAULIC EXCAVATOR SPECIFICATIONS - Machine Dimensions - Lifting Capacity With Blade Off Ground - OPERATION & PERFORMANCE - ENGINE - HYDRAULIC SYSTEM - SWING SYSTEM - HYDRAULIC CYLINDERS - DRIVE SYSTEM - UNDERCARRIAGE - TRACK - CAPACITIES - DIGGING FORCE - ENGINE SPECIFICATIONS - Fuel Injection Nozzles - Fuel Injection Pump - Cylinder Head - Valves - Valve Springs - Rocker Arms - Camshaft - Cylinders - Piston Rings - Pistons - Crankshaft - Oil Pump - Engine Oil - Specifications - ENGINE TORQUE - Re–Grinding The Crankshaft - FUEL, COOLANT AND LUBRICANTS - OIL SPECIFICATIONS - Description - SERVICE MANUAL REVISION - 225-1 - 225-2 - 225-3 - 225-4 - 225-5 - 225-6 - 225-7 - 225-8 - 225-9 - 225-10 231 6720421 OM 4-92 - FOREWORD - CONTENTS - SAFETY - SAFETY INSTRUCTIONS - FIRE PREVENTION - SERIAL NUMBER LOCATIONS - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - SAFETY SIGNS (DECALS) - OPERATING INSTRUCTIONS - GETTING ON AND OFF THE MACHINE - SEAT - INSTRUMENT PANEL - KEY SWITCH - CONTROL LEVER LOCK - CONTROL LEVERS - Operation Of Left Control Lever (ISO) - Operation Of Right Control Lever (ISO) - Operation Of Left Control Lever - Operation Of Right Control Lever - FUEL CONTROL LEVER - HORN BUTTON - SWING LOCK - STEERING LEVERS - Forward And Reverse Travel - Turning - Making A Counter-Rotation Turn - BLADE CONTROL LEVER - BOOM SWING PEDAL - OPTIONAL EQUIPMENT PEDAL - DAILY INSPECTION - STARTING THE ENGINE - Normal Starting Procedure - Cold Starting Procedure - PARKING THE HYDRAULIC EXCAVATOR - OPERATING PROCEDURES - Breaking In A New Machine - General Operation Suggestions - Operating In Water - TRANSPORTING THE HYDRAULIC EXCAVATOR - PREVENTIVE MAINTENANCE - MAINTENANCE SAFETY - BUCKET - Removal - Installation - SERVICE SCHEDULE - ENGINE COVER - AIR CLEANER SERVICE - FUEL SYSTEM - Fuel System Service - Fuel Filters - Removing Air From The Fuel System - ENGINE LUBRICATION SYSTEM - Engine Oil And Filter Replacement - COOLING SYSTEM - Coolant Level - Coolant Replacement - ALTERNATOR BELT ADJUSTMENT - ELECTRICAL SYSTEM - Fuses - Fuse Arrangement - Service The Electrical System - Using A Booster Battery (Jump Starting) - Removal And Installation Of The Battery - HYDRAULIC SYSTEM - Checking And Adding Fluid - Replacement Of The Hydraulic Filters - Hydraulic Reservoir - LUBRICATION OF THE HYDRAULIC EXCAVATOR - SWING MOTOR GEAR REDUCTION - FINAL DRIVE CASE - Checking Oil Level - Draining Final Drive Case - TRACK TENSION - Adjustment - SPECIFICATIONS - 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 - Miscellaneous - FUEL, COOLANT AND LUBRICANTS - OIL SPECIFICATIONS - WARRANTY 231 6720496 SM 4-90 - 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 REVISON - 231-1 - 231-2 - 231-3 - 231-4 - 231-5 - 231-6 - 231-7 - 231-8 - 231-9 231 6720943 OM 9-98 - OPERATOR SAFETY WARNINGS - CONTENTS - FOREWORD - SERIAL NUMBER LOCATIONS - HYDRAULIC EXCAVATOR SERIAL NUMBER - ENGINE SERIAL NUMBER - DELIVERY REPORT - HYDRAULIC EXCAVATOR IDENTIFICATION - SAFETY - SAFETY INSTRUCTIONS - FIRE PREVENTION - MACHINE SIGNS TRANSLATIONS (DECALS) - OPERATING INSTRUCTIONS - GETTING ON AND OFF THE MACHINE - SEAT - CONTROL LEVER (JOYSTICK) LOCK - INSTRUMENT PANEL - FUSES - KEY SWITCH - CONTROL LEVERS - Operation Of Left Control Lever (ISO) - Operation Of Right Control Lever (ISO) - Operation Of Left Control Lever (Standard) - Operation Of Right Control Lever (Standard) - SWING LOCKING LEVER - HORN BUTTON - SPEED CONTROL LEVER - STEERING LEVERS/FOOT PEDALS - Forward And Reverse Travel - Turning - Making A Counter–Rotation Turn - BOOM SWING PEDAL - AUXILIARY OPERATION PEDAL AND LOCK/FOOTREST - BLADE CONTROL LEVER - TWO–SPEED FOOT PEDAL - DAILY INSPECTION - STARTING THE ENGINE - Normal Starting Procedure (W/Engine Warm) - Cold Temperature Starting Condition - OPERATING PROCEDURE - Breaking In A New Machine - Operating In Water - PARKING THE HYDRAULIC EXCAVATOR - TRANSPORTING THE HYDRAULIC EXCAVATOR - LIFTING THE HYDRAULIC EXCAVATOR - BUCKET - Removal - Installation - PREVENTIVE MAINTENANCE - MAINTENANCE SAFETY - SERVICE SCHEDULE - ENGINE COVER - AIR CLEANER SERVICE - FUEL SYSTEM - Fuel System Service - Fuel Filters - In–Line Fuel Filter (If Equipped) - Removing Air From The Fuel System - ENGINE LUBRICATION SYSTEM - Engine Oil And Filter Replacement - COOLING SYSTEM - Coolant Level - Coolant Replacement - ALTERNATOR BELT ADJUSTMENT - ELECTRICAL SYSTEM - Fuses - Service The Electrical System - Using A Booster Battery (Jump Starting) - Removal And Installation Of The Battery - Electric Solenoid (Engine Stop) - ROPS Electrical - Heater Control - HYDRAULIC SYSTEM - Check And Adding Fluid - Replacement Of The Hydraulic Filter - Hydraulic Reservoir - LUBRICATION OF THE HYDRAULIC EXCAVATOR - Checking Oil Level - TRACK TENSION - Adjustment - Rubber Tracks - SPECIFICATIONS - 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) - OPERATIONS & PERFORMANCE - ENGINE - HYDRAULIC SYSTEM - SWING SYSTEM - HYDRAULIC CYLINDERS - DRIVE SYSTEM - BRAKES - UNDERCARRIAGE - TRACK - CAPACITIES - MISCELLANEOUS - FUEL, COOLANT AND LUBRICANTS - OIL SPECIFICATIONS - Description - BUCKET SPECIFICATIONS - WARRANTY 231 6722178 SM 3-92 - 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 REVISON - 231-1 - 231-2 - 231-3 - 231-4 - 231-5 - 231-6 - 231-7
Bobcat Excavator (220 225 231 Series) Service and Owners Manual
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
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