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Bobcat 220 Excavator Service Manual (SN 508211001-508211999)

Format: PDF (Printable Document)

File Language: English

File Pages: 258

File Size: 10.34 MB (Speed Download Link)

Brand: Bobcat

Model: 220 Excavator

Book No: 6720230

Serial No: SN 508211001-508211999

Type of Document: Service Manual

Categories: ,

$ 45

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Bobcat 220 Excavator Service Manual (SN 508211001-508211999)

On a real job, the Bobcat 220 compact excavator is a trenching and utility machine for plumbers, fence guys, small site prep, and farm work. The service manual is what I keep on the bench when a 220 comes in with weak hydraulics, swing issues, or electrical gremlins. People grab this when they need actual repair steps, not just how to run the joysticks. If you're trying to keep an older 220 earning money instead of sitting dead in the yard, this is the book you want.

What this manual helps you do

  • Diagnose hydraulic problems on the 220, trace hoses and valves, and follow test procedures with a gauge set
  • Check and adjust engine-related items on the small diesel, including fuel, cooling, and basic governor/linkage work
  • Follow teardown and reassembly steps for major components like cylinders, drive motors, and swing system parts
  • Troubleshoot electrical faults using wiring diagrams, connector callouts, and step-by-step checks with a meter
  • Verify adjustments after repairs so the machine digs, swings, and tracks the way the factory intended

Who this is for

This is for anyone working on a Bobcat 220 excavator in the serial range 508211001 to 508211999: small contractors, owner-operators, rental fleets, and shop or field techs. If you just need operating tips or safety info, you want the operator's handbook, not this service manual.

FAQ

Q: Is this a searchable PDF, and can I read the wiring diagrams on a laptop?

A: These manuals are normally supplied as searchable PDFs, and the wiring diagrams are clear enough to zoom in on connector and wire labels.

Q: How do I know it fits my machine?

A: Check your serial plate. If your 220 excavator serial number falls between 508211001 and 508211999, this is the correct manual.

Q: Is this the right document if I'm planning a rebuild?

A: Yes. This is the workshop service manual, meant for real repairs and diagnostics, not basic operation or just parts lookup.

Bottom line: If you own or service a Bobcat 220 excavator in that serial range and you're doing your own repairs, this is the right manual. If your serial doesn't match, skip it.

📘 Show Index

Table of Contents:

  • 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
    • 220-9

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