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Bobcat 220 Excavator Service Manual (SN 508212001-508214999)

Format: PDF (Printable Document)

File Language: English

File Pages: 320

File Size: 18.22 MB (Speed Download Link)

Brand: Bobcat

Model: 220 Excavator

Book No: 6720503

Serial No: SN 508212001-508214999

Type of Document: Service Manual

Categories: ,

$ 45

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Bobcat 220 Excavator Service Manual (SN 508212001-508214999)

A Bobcat 220 is a small excavator that spends its days trenching, cleaning ditches, loading manure, and doing tight-space digging where a big hoe won't fit. The service manual is what you grab when a boom cylinder starts leaking, the swing motor gets weak, or the wiring gremlins show up and you've only got a weekend to sort it out. It's written for people who actually turn wrenches and need to know what comes apart first and what to check before buying parts.

What this manual helps you do

  • Diagnose weak digging, slow functions, or odd noises by tracing the hydraulic and hydrostatic systems step by step
  • Check and set pressures on the main and pilot circuits so the machine actually pulls and swings like it should
  • Follow teardown and reassembly procedures for things like cylinders, pumps, motors, and final drives
  • Troubleshoot electrical issues using wiring diagrams so you can chase dead circuits, bad switches, and sensor faults
  • Replace and adjust linkages, swing and travel components, and other wear parts without guessing on order or setup

Who this is for

This manual is for anyone running or fixing a Bobcat 220 excavator in the serial range 508212001 to 508214999: small contractors, farm owners, shop mechanics, or rental fleets. If you only want basic controls, safety, and daily checks, you want the operator's handbook instead, not this service manual.

FAQ

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

A: Yes, it's typically a searchable PDF and the wiring diagrams are clear enough to zoom in on and read on-screen.

Q: How do I know if it fits my exact 220?

A: If your serial number falls between 508212001 and 508214999, this is the right service manual for your machine.

Q: Is this the right thing if I'm planning a major repair or rebuild?

A: Yes, this is the workshop-level manual you want for real repairs, not just basic operation or parts lookup.

Bottom line, if your 220's serial number is in that range and you're planning to do your own repairs, this is the manual you need. If you just want to learn how to run the machine, skip it.

📘 Show Index

Table of Contents:

  • 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
    • 220-9

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