Complete repair service manual with Electrical Wiring Diagrams for Bobcat 220, X220, X225, X231 Excavators, with all the workshop information to maintain, diagnose, and repair like professional mechanics.

Bobcat Excavators workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

6720124 (11-89) - 220 Excavator Operation & Maintenance Manual.pdf
6720230 (5-89) - X220 Excavator Service Manual.pdf
6720230 (6-12) - X220 Excavator Service Manual.pdf
6720347 (6-12) - X 225 Excavator Service Manual.pdf
6720347 (11-89) - X 225 Excavator Service Manual.pdf
6720379 (11-89) - 220 Excavator Operation & Maintenance Manual.pdf
6720448 (4-92) - 220 Excavator Operation & Maintenance Manual.pdf
6720496 (4-90) - X 231 Excavator Service Manual.pdf
6720496 (6-12) - X 231 Excavator Service Manual.pdf
6720503 (6-12) - X220 Excavator Service Manual.pdf
6720503 (6-90) - X220 Excavator Service Manual.pdf
6720537 (9-98) - X 225 Excavator Operation & Maintenance Manual.pdf
6720874 (1-91) - X 225 Excavator Service Manual.pdf
6720874 (6-12) - X 225 Excavator Service Manual.pdf
6722178 (3-92) - X 231 Excavator Service Manual.pdf
6722178 (6-12) - X 231 Excavator Service Manual.pdf
6722250 (10-98) - X220 Excavator Operation & Maintenance Manual.pdf
6722345 (9-92) - 220 Excavator Service Manual.pdf

Total Pages: 4,359 pages
File Format: PDF (bookmarked, Searchable, Printable, high qualit)
Language: English

TABLE OF CONTENTS

6720124 (11-89) - 220 Excavator Operation & Maintenance Manual...1
  OPERATOR SAFETY WARNINGS...2
  FOREWORD...3
  CONTENTS...3
    SAFETY INSTRUCTIONS...5
    FIRE PREVENTIONS...6
    SERIAL NUMBER LOCATIONS...7
      Hydraulic Excavator Serial Number...7
      Engine Serial Number...7
    DELIVERY REPORT...7
    HYDRAULIC EXCAVATOR IDENTIFICATION...8
    SAFETY SIGNS (DECALS)...9
  OPERATING INSTRUCTIONS...11
    GETTING ON AND OFF THE MACHINE...13
    SEAT...13
    SEAT BELT...13
    INSTRUMENT PANEL...14
    KEY SWITCH...14
    LEVER & CONTROL LOCATIONS...15
    CONTROL LEVERS...16
      Operation Of Left Control Lever (ISO)...16
      Operation Of Right Control Lever (ISO)...16
      Control Lever Lock Operation...17
    FUEL CONTROL LEVER...18
    STEERING LEVERS...18
      Forward And Reverse Travel...18
      Turning...19
      Making A Counter-Rotation Turn...19
    BOOM SWING LEVER...20
    BLADE CONTROL LEVER...20
    SWING LOCK...21
    BEFORE STARTING THE ENGINE...22
    STARTING THE ENGINE...22
      Normal Starting Procedure...22
      Cold Starting Procedure...23
    PARKING THE HYDRAULIC EXCAVATOR...23
    OPERATING PROCEDURE...24
      Breaking In A New Machine...24
      General Operation Suggestions...24
    TRANSPORTING THE HYDRAULIC EXCAVATOR...25
    BUCKET...26
      Removal ...26
      Installation...26
  PREVENTIVE MAINTENANCE...27
    MAINTENANCE SAFETY...28
    SERVICE SCHEDULE...29
    ENGINE COVER...30
    AIR CLEANER SERVICE...30
    FUEL SYSTEM...31
      Fuel System Service...31
      Fuel Filters...32
      Removing Air From The Fuel System...32
    ENGINE LUBRICATION SYSTEM...33
      Engine Oil And Filter Replacement...33
    COOLING SYSTEM...34
      Coolant Level...34
      Coolant Replacement...34
    ALTERNATOR BELT ADJUSTMENT...35
    ELECTRICAL SYSTEM...36
      Fuses...36
      Fuse Arrangement...36
      Service The Electrical System...36
      Using A Booster Battery (Jump Starting)...37
      Removal And Installation Of The Battery...38
    HYDRAULIC SYSTEM...39
      Checking And Adding Fluid (S/N 11308 & Below)...39
      Checking And Adding Fluid (S//N 11309 - 11500)...40
      Replacement Of The Hydraulic Filter...40
      Hydraulic Reservoir...41
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...42
    FINAL DRIVE CASE...44
      Checking Oil Level...44
      Draining Final Drive Case...44
    TRACK TENSION...45
      Adjustment...45
  SPECIFICATIONS...47
    HYDRAULIC EXCAVATOR SPECIFICATIONS...49
      Machine Dimensions...49
      Lifting Capacity With Blade Off Ground...50
      Performance & Operation...50
      Engine...50
      Hydraulic System...50
      Swing System...51
      Hydraulic Cylinders...51
      Drive System...51
      Brakes...51
      Undercarriage...51
      Track...51
      Capacities...51
      Digging Force...51
    FUEL, COOLANT AND LUBRICANTS...52
    OIL SPECIFICATIONS...52
  WARRANTY...55
6720230 (5-89) - X220 Excavator Service Manual...57
  CONTENTS...59
  FOREWORD...61
    SAFETY INSTRUCTIONS...63
    SERIAL NUMBER LOCATIONS...64
    HYDRAULIC EXCAVATOR SERIAL NUMBER...64
    ENGINE SERIAL NUMBER...64
    DELIVERY REPORT...64
    HYDRAULIC EXCAVATOR IDENTIFICATION...65
  PREVENTIVE MAINTENANCE...67
    SERVICE SCHEDULE...69
    ENGINE COVER...70
      Procedure...70
    AIR CLEANER SERVICE...70
      Replacing the Filter Element...70
    FUEL SYSTEM...71
      Fuel Specifications...71
      Fuel System Service...71
    ENGINE LUBRICATION SYSTEM...73
      Checking the Engine Oil...73
      Engine Oil and Filter Replacement...73
    COOLING SYSTEM...74
      Coolant Level...74
      Coolant Replacement...74
    HYDRAULIC SYSTEM...75
      Checking and Adding Fluid...75
      Replacement of the Hydraulic Filter...76
      Hydraulic Reservoir...76
    USING A BOOSTER BATTERY (JUMP STARTING)...77
      Procedure...77
    LUBRICATION OF THE EXCAVATOR...78
      Procedure...78
    FINAL DRIVE CASE...80
      Checking Oil Level...80
      Draining Final Drive Case...80
  HYDRAULIC SYSTEM...81
    HYDRAULIC SCHEMATICS...83
    HYDRAULIC SERVICE INFORMATION...91
      Checking The Main Relief Valves...91
    HYDRAULIC PUMP...93
      Removal And Installation...93
      Parts Identification...95
      Disassembly...96
      Assembly...101
    HYDRAULIC CONTROL VALVE...107
      Removal and Installation...107
    HYDRAULIC RESERVOIR...110
      Removal and Installation...110
      Suction Filter...112
    BOOM CYLINDER...113
      Removal and Installation...113
    ARM CYLINDER...114
      Removal and Installation...114
    BUCKET CYLINDER...115
      Removal and Installation...115
    BLADE CYLINDER...115
      Removal and Installation...115
    BOOM SWING CYLINDER...116
      Removal and Installation...116
    HYDRAULIC CYLINDER (Melroe Cylinders)...117
      Disassembly...117
      Assembly...119
    SOLENOID VALVE...126
      Parts Identification...126
    SOLENOID VALVE...127
      Disassembly...127
      Assembly...130
    SWING CYLINDER LOCK VALVE...134
      Parts Identification...134
    SWING CYLINDER LOCK VALVE...135
      Disassembly...135
      Assembly...136
  DRIVE SYSTEM...139
    FLOOR PANEL...141
      Removal and Installation...141
    CONTROL AND STEERING LEVERS...143
      Swing/Arm Control Lever...143
      Control Lever Lock Mechanism...144
      Boom/Bucket Control Lever...145
      Steering Levers...146
    DRIVE MOTOR...147
      Removal and Installation...147
      Disassembly...149
      Assembly...159
  UPPER WORKS AND SWING SECTION...169
    SWING MOTOR...171
      Removal and Installation...171
      Parts Identification...172
      Disassembly...173
      Assembly...174
      Motor Timing...175
      Parts Identification...176
      Disassembly...177
      Assembly...182
      Brake Valve Parts Identification...189
      Brake Valve Disassembly...190
      Control Valve Assembly...192
      Control Valve Testing...194
    UPPER WORKS...195
      Removal And Installation...195
      Swing Motor Installation...197
    CENTER SWIVEL JOINT...198
      Removal And Installation...198
      Disassembly And Assembly...198
    SWING CIRCLE GEAR...199
      Removal And Installation...199
  MAIN FRAME AND TRACKS...201
    ENGINE COVER...203
      Removal and Installation...203
    SEAT AND MOUNTING FRAME...204
      Removal and Installation...204
    FUEL TANK...205
      Removal and Installation...205
    BOOM AND DIPPERSTICK...206
      Removal and Installation...206
    BOOM SWING BRACKET...209
      Removal and Installation...209
    TRACK...210
      Track Tension Adjustment...210
      Removal and Installation...210
    TRACK FRAME...211
      Disassembly and Assembly...211
    TRACK IDLER...212
      Parts Identification...212
      Disassembly...213
      Assembly...215
    TRACK ROLLER...221
      Parts Identification...221
      Disassembly...222
      Assembly...224
  ELECTRICAL SYSTEM...229
    ELECTRICAL SCHEMATICS...231
      TROUBLESHOOTING...233
      Description...233
      Fuses...234
      Electrical System Service...234
    BATTERY...235
      Checking the Battery...235
      Removal and Installation...235
    ALTERNATOR...236
      Belt Adjustment...236
      Removal and Installation...236
    STARTER...237
      Removal and Installation...237
      Disassembly and Assembly...238
      Cleaning and Inspection...238
    INSTRUMENT PANEL...239
      Lights, Hourmeter and Ignition Switch...239
      Removal and Installation...239
  ENGINE SERVICE...241
    TROUBLESHOOTING...243
    VALVE CLEARANCE...244
      Adjustment...244
    ENGINE COMPRESSION...245
      Checking...245
    FUEL FILTER...246
      Fuel Filters...246
      Removing Air From the Fuel System...246
    FUEL INJECTION PUMP...247
      Checking the Injection Pump...247
      Removal and Installation...247
      Timing the Injection Pump...249
    FUEL INJECTOR NOZZLES...250
      Removal and Installation...250
      Checking the Injector Nozzle...251
    GLOW PLUGS...252
      Removal and Installation...252
      Checking the Glow Plug...252
    ENGINE...253
      Removal and Installation...253
    MUFFLER...257
      Removal and Installation...257
    RADIATOR...259
      Removal and Installation...259
    ENGINE FLYWHEEL...261
      Removal and Installation...261
      Flywheel Ring Gear...263
    CYLINDER HEAD...264
      Removal of the Cylinder Head...264
      Disassembly of the Cylinder Head...265
      Servicing the Cylinder Head and Valves...266
      Checking the Valve Springs...267
      Checking the Rocker Arm and Shaft...268
      Assembling the Cylinder Head...268
      Installing the Cylinder Head...268
    TIMING GEAR COVER...270
      Removal and Installation...270
    TIMING GEAR, CAMSHAFT AND OIL PUMP...272
      Removal and Installation...272
      Oil Pump Service...274
      Servicing the Camshaft...275
    CRANKSHAFT AND PISTONS...276
      Removal and Installation...276
      Crankshaft Service...279
      Servicing the Connecting Rods and Pistons...280
    CYLINDER LINERS...282
      Checking the Cylinder Liners...282
      Cylinder Liner Installation...282
    WATER PUMP...283
      Removal and Installation...283
      Disassembly and Assembly...283
  SPECIFICATIONS...285
    HYDRAULIC EXCAVATOR SPECIFICATIONS...287
      Machine Dimensions...287
      PERFORMANCE...288
      ENGINE...288
      HYDRAULIC SYSTEM...288
      SWING SYSTEM...288
      HYDRAULIC CYLINDERS...288
      DRIVE SYSTEM...289
      BRAKES...289
      UNDERCARRIAGE...289
      TRACK SHOES...289
      CAPACITIES...289
      DIGGING FORCE...289
    ENGINE SPECIFICATIONS (KUBOTA)...290
      Engine...290
      Fuel Injector Nozzles...290
      Fuel Injection Pump...290
      Cylinder Head...290
      Valves...290
      Valve Springs...290
      Rocker Arms...290
      Camshaft...291
      Cylinders...291
      Piston Rings...291
      Pistons...291
      Crankshaft...291
      Oil Pump...292
      Thermostat...292
      Engine Torque...293
      Crankshaft Re–Grind Data...294
    FUEL, COOLANT AND LUBRICANTS...295
    OIL SPECIFICATIONS...295
      Description...295
  SERVICE MANUAL REVISION...297
    220-1...297
    220-2...299
    220-3...301
    220-4...303
    220-5...305
    220-6...307
    220-7...309
    220-8...311
6720230 (6-12) - X220 Excavator Service Manual...313
  CONTENTS...315
  FOREWORD...317
    SAFETY INSTRUCTIONS...319
    SERIAL NUMBER LOCATIONS...320
    HYDRAULIC EXCAVATOR SERIAL NUMBER...320
    ENGINE SERIAL NUMBER...320
    DELIVERY REPORT...320
    HYDRAULIC EXCAVATOR IDENTIFICATION...321
  PREVENTIVE MAINTENANCE...323
    SERVICE SCHEDULE...325
    ENGINE COVER...326
      Procedure...326
    AIR CLEANER SERVICE...326
      Replacing the Filter Element...326
    FUEL SYSTEM...327
      Fuel Specifications...327
      Fuel System Service...327
    ENGINE LUBRICATION SYSTEM...329
      Checking the Engine Oil...329
      Engine Oil and Filter Replacement...329
    COOLING SYSTEM...330
      Coolant Level...330
      Coolant Replacement...330
    HYDRAULIC SYSTEM...331
      Checking and Adding Fluid...331
      Replacement of the Hydraulic Filter...332
      Hydraulic Reservoir...332
    USING A BOOSTER BATTERY (JUMP STARTING)...333
      Procedure...333
    LUBRICATION OF THE EXCAVATOR...334
      Procedure...334
    FINAL DRIVE CASE...336
      Checking Oil Level...336
      Draining Final Drive Case...336
  HYDRAULIC SYSTEM...337
    HYDRAULIC SCHEMATICS...339
    HYDRAULIC SERVICE INFORMATION...347
      Checking The Main Relief Valves...347
    HYDRAULIC PUMP...349
      Removal And Installation...349
      Parts Identification...351
      Disassembly...352
      Assembly...357
    HYDRAULIC CONTROL VALVE...363
      Removal and Installation...363
    HYDRAULIC RESERVOIR...366
      Removal and Installation...366
      Suction Filter...368
    BOOM CYLINDER...369
      Removal and Installation...369
    ARM CYLINDER...370
      Removal and Installation...370
    BUCKET CYLINDER...371
      Removal and Installation...371
    BLADE CYLINDER...371
      Removal and Installation...371
    BOOM SWING CYLINDER...372
      Removal and Installation...372
    HYDRAULIC CYLINDER (Melroe Cylinders)...373
      Disassembly...373
      Assembly...375
    SOLENOID VALVE...382
      Parts Identification...382
    SOLENOID VALVE...383
      Disassembly...383
      Assembly...386
    SWING CYLINDER LOCK VALVE...390
      Parts Identification...390
    SWING CYLINDER LOCK VALVE...391
      Disassembly...391
      Assembly...392
  DRIVE SYSTEM...395
    FLOOR PANEL...397
      Removal and Installation...397
    CONTROL AND STEERING LEVERS...399
      Swing/Arm Control Lever...399
      Control Lever Lock Mechanism...400
      Boom/Bucket Control Lever...401
      Steering Levers...402
    DRIVE MOTOR...403
      Removal and Installation...403
      Disassembly...405
      Assembly...415
  UPPER WORKS AND SWING SECTION...425
    SWING MOTOR...427
      Removal and Installation...427
      Parts Identification...428
      Disassembly...429
      Assembly...430
      Motor Timing...431
      Parts Identification...432
      Disassembly...433
      Assembly...438
      Brake Valve Parts Identification...445
      Brake Valve Disassembly...446
      Control Valve Assembly...448
      Control Valve Testing...450
    UPPER WORKS...451
      Removal And Installation...451
      Swing Motor Installation...453
    CENTER SWIVEL JOINT...454
      Removal And Installation...454
      Disassembly And Assembly...454
    SWING CIRCLE GEAR...455
      Removal And Installation...455
  MAIN FRAME AND TRACKS...457
    ENGINE COVER...459
      Removal and Installation...459
    SEAT AND MOUNTING FRAME...460
      Removal and Installation...460
    FUEL TANK...461
      Removal and Installation...461
    BOOM AND DIPPERSTICK...462
      Removal and Installation...462
    BOOM SWING BRACKET...465
      Removal and Installation...465
    TRACK...466
      Track Tension Adjustment...466
      Removal and Installation...466
    TRACK FRAME...467
      Disassembly and Assembly...467
    TRACK IDLER...468
      Parts Identification...468
      Disassembly...469
      Assembly...471
    TRACK ROLLER...477
      Parts Identification...477
      Disassembly...478
      Assembly...480
  ELECTRICAL SYSTEM...485
    ELECTRICAL SCHEMATICS...487
      TROUBLESHOOTING...489
      Description...489
      Fuses...490
      Electrical System Service...490
    BATTERY...491
      Checking the Battery...491
      Removal and Installation...491
    ALTERNATOR...492
      Belt Adjustment...492
      Removal and Installation...492
    STARTER...493
      Removal and Installation...493
      Disassembly and Assembly...494
      Cleaning and Inspection...494
    INSTRUMENT PANEL...495
      Lights, Hourmeter and Ignition Switch...495
      Removal and Installation...495
  ENGINE SERVICE...497
    TROUBLESHOOTING...499
    VALVE CLEARANCE...500
      Adjustment...500
    ENGINE COMPRESSION...501
      Checking...501
    FUEL FILTER...502
      Fuel Filters...502
      Removing Air From the Fuel System...502
    FUEL INJECTION PUMP...503
      Checking the Injection Pump...503
      Removal and Installation...503
      Timing the Injection Pump...505
    FUEL INJECTOR NOZZLES...506
      Removal and Installation...506
      Checking the Injector Nozzle...507
    GLOW PLUGS...508
      Removal and Installation...508
      Checking the Glow Plug...508
    ENGINE...509
      Removal and Installation...509
    MUFFLER...513
      Removal and Installation...513
    RADIATOR...515
      Removal and Installation...515
    ENGINE FLYWHEEL...517
      Removal and Installation...517
      Flywheel Ring Gear...519
    CYLINDER HEAD...520
      Removal of the Cylinder Head...520
      Disassembly of the Cylinder Head...521
      Servicing the Cylinder Head and Valves...522
      Checking the Valve Springs...523
      Checking the Rocker Arm and Shaft...524
      Assembling the Cylinder Head...524
      Installing the Cylinder Head...524
    TIMING GEAR COVER...526
      Removal and Installation...526
    TIMING GEAR, CAMSHAFT AND OIL PUMP...528
      Removal and Installation...528
      Oil Pump Service...530
      Servicing the Camshaft...531
    CRANKSHAFT AND PISTONS...532
      Removal and Installation...532
      Crankshaft Service...535
      Servicing the Connecting Rods and Pistons...536
    CYLINDER LINERS...538
      Checking the Cylinder Liners...538
      Cylinder Liner Installation...538
    WATER PUMP...539
      Removal and Installation...539
      Disassembly and Assembly...539
  SPECIFICATIONS...541
    HYDRAULIC EXCAVATOR SPECIFICATIONS...543
      Machine Dimensions...543
      PERFORMANCE...544
      ENGINE...544
      HYDRAULIC SYSTEM...544
      SWING SYSTEM...544
      HYDRAULIC CYLINDERS...544
      DRIVE SYSTEM...545
      BRAKES...545
      UNDERCARRIAGE...545
      TRACK SHOES...545
      CAPACITIES...545
      DIGGING FORCE...545
    ENGINE SPECIFICATIONS (KUBOTA)...546
      Engine...546
      Fuel Injector Nozzles...546
      Fuel Injection Pump...546
      Cylinder Head...546
      Valves...546
      Valve Springs...546
      Rocker Arms...546
      Camshaft...547
      Cylinders...547
      Piston Rings...547
      Pistons...547
      Crankshaft...547
      Oil Pump...548
      Thermostat...548
      Engine Torque...549
      Crankshaft Re–Grind Data...550
    FUEL, COOLANT AND LUBRICANTS...551
    OIL SPECIFICATIONS...551
      Description...551
  SERVICE MANUAL REVISION...553
    220-1...553
    220-2...555
    220-3...557
    220-4...559
    220-5...561
    220-6...563
    220-7...565
    220-8...567
    220-9...569
6720347 (11-89) - X 225 Excavator Service Manual...571
  MAINTENANCE SAFETY...573
  CONTENTS...575
  FOREWORD...577
    SAFETY INSTRUCTIONS...579
    SERIAL NUMBER LOCATIONS...580
    HYDRAULIC EXCAVATOR SERIAL NUMBER...580
    ENGINE SERIAL NUMBER...580
    DELIVERY REPORT...580
    HYDRAULIC EXCAVATOR IDENTIFICATION...581
  PREVENTIVE MAINTENANCE...583
    SERVICE SCHEDULE...585
    ENGINE COVER...586
      Procedure...586
    AIR CLEANER SERVICE...586
      Replacing The Filter Element...586
    FUEL SYSTEM...587
      Fuel Specifications...587
      Fuel System Service...587
    ENGINE LUBRICATION SYSTEM...589
      Checking The Engine Oil...589
      Engine Oil And Filter Replacement...589
    COOLING SYSTEM...590
      Coolant Level...590
      Coolant Replacement...590
    HYDRAULIC SYSTEM...591
      Checking And Adding Fluid...591
      Replacement Of The Hydraulic Filters...592
      Hydraulic Reservoir...592
    USING A BOOSTER BATTERY (JUMP STARTING)...593
      Procedure...593
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...594
      Procedure...594
    FINAL DRIVE CASE...596
      Checking Oil Level...596
  HYDRAULIC SECTION...597
    HYDRAULIC SCHEMATICS...599
    HYDRAULIC SERVICE INFORMATION...605
      Description...605
      Checking The Control Valve Relief Valves...605
      Checking The Locking Lever Relief Valve...607
      With Locking Lever Up (By–Passing Relief Valve)...607
      Checking The Auxiliary Relief Valve...607
    HYDRAULIC PUMP...608
      Removal And Installation...608
      Disassembly...609
      Assembly...611
    HYDRAULIC CONTROL VALVE...615
      Removal And Installation...615
    CONTROL VALVE...617
      Disassembly And Assembly...617
      Relief Valve Pressure Setting Adjustment...632
      Main Relief Valve...632
      Work Port Relief Valves...634
    HYDRAULIC RESERVOIR...635
      Removal And Installation...635
      Suction Filter...636
    BOOM CYLINDER...637
      Removal And Installation...637
    DIPPERSTICK CYLINDER...638
      Removal And Installation...638
    BUCKET CYLINDER...639
      Removal And Installation...639
    BLADE CYLINDER...640
      Removal And Installation...640
    BOOM SWING CYLINDER...641
      Removal And Installation...641
    HYDRAULIC CYLINDER...642
      Disassembly...642
      Assembly...646
    SWING CYLINDER LOCK VALVE...652
      Parts Identification...652
      Disassembly...653
      Assembly...654
    SOLENOID VALVE...656
      Parts Identification...656
      Disassembly...657
      Assembly...660
    HYDRAULIC FILTER...664
      Removal And Installation...664
      Untitled...665
  DRIVE SECTION...667
    HYDRAULIC CONTROL LEVERS...669
      Swing/Dipperstick Control Lever...669
      Boom/Bucket Control Lever...671
      Disassembly And Assembly...671
    THROTTLE LEVER...675
      Removal And Installation...675
    BLADE CONTROL LEVER...675
      Removal And Installation...675
    CONTROL LOCKING ARM...676
      Removal And Installation...676
    PANEL LIFT CYLINDER...677
      Removal And Installation...677
    LOCKING LEVER VALVE...678
      Removal And Installation...678
    LOCKING LEVER CABLE...679
      Removal And Installation...679
    CONTROL PANEL BASE...680
      Removal And Installation...680
    FOOT PEDAL AND STEERING LEVER LINKAGE...681
      Removal And Installation...681
    STEERING LEVERS...682
      Removal And Installation...682
    FINAL DRIVE...683
      Removal And Installation...683
    DRIVE MOTOR...685
      Disassembly...685
      Assembly...697
    FINAL DRIVE CASE...708
      Check Oil Level...708
      Draining Final Drive Case...708
  UPPER WORKS AND SWING SECTION...709
    SWING MOTOR...711
      Removal And Installation...711
    SWING MOTOR ASSEMBLY...712
      Brake Valve...712
        Parts Identification...712
        Disassembly...713
        Assembly...716
      Relief Valve...719
        Disassembly...719
        Assembly...720
        Adjustment for Model 225...722
      Piston Housing...723
        Parts Identification...723
        Disassembly...724
        Assembly...727
      Reduction Gear...732
        Parts Identification...732
        Disassembly...733
        Assembly...737
    UPPER WORKS...742
      Removal And Installation...742
    SWING CIRCLE GEAR...743
      Removal And Installation...743
    CENTER SWIVEL JOINT...744
      Removal And Installation...744
      Disassembly And Assembly...744
  MAIN FRAME AND TRACKS...745
    ENGINE COVER...747
      Removal And Installation...747
    FLOOR PANELS...748
      Removal And Installation...748
    SEAT AND MOUNTING FRAME...750
      Removal And Installation...750
    SWING MOTOR COVER...750
      Removal And Installation...750
    FUEL TANK...751
      Removal And Installation...751
    BUCKET...752
      Removal And Installation...752
    DIPPERSTICK...753
      Removal And Installation...753
    BOOM...753
      Removal And Installation...753
    BOOM SWING BRACKET...755
      Removal And Installation...755
    BLADE...756
      Removal And Installation...756
    TRACK...757
      Track Tension Adjustment...757
    TRACK FRAME...759
      Disassembly And Assembly...759
    TRACK IDLER...760
      Parts Identification...760
      Disassembly...761
      Assembly...763
    RUBBER TRACK IDLER...767
      Parts Identification...767
      Disassembly...768
      Assembly...770
    TOOL BOX...774
      Removal And Installation...774
    TRACK ROLLER...775
      Parts Identification...775
      Disassembly...776
      Assembly...778
    RUBBER TRACK ROLLER...782
      Parts Identification...782
      Disassembly...783
      Assembly...785
    ROPS WINDOWS...789
      Front Window Removal...789
      Side Window Removal...790
  ELECTRICAL SYSTEM...791
    ELECTRICAL SCHEMATICS...793
    TROUBLESHOOTING...794
      Chart...794
    ELECTRICAL SYSTEM...794
      Description...794
      Fuses...795
      Electrical System Service...795
    BATTERY...796
      Checking The Battery...796
      Removal And Installation...796
    ALTERNATOR...797
      Belt Adjustment...797
      Removal And Installation...797
    STARTER...798
      Removal And Installation...798
      Disassembly And Assembly...799
      Cleaning And Inspection...799
    FUEL LEVEL SENDER...800
      Removal And Installation...800
      Checking...800
    DISPLAY MODULE...801
      Removal And Installation...801
    INSTRUMENT PANEL...801
      Removal And Installation...801
      Testing And Troubleshooting...802
      Engine Temperature Circuit Test (display module installed)...804
      Testing The Display Panel...804
      Fuel Level Circuit Test (display module installed)...806
      Testing The Display Panel...806
      Fuel Level Sender...807
      Engine Oil Pressure Circuit Test (display module installed)...808
      Testing The Display Panel...808
      Battery Charge Circuit Test (display module installed)...809
      Glow Plug Circuit Test (display module installed)...810
      Engine Temperature Circuit Test (display module removed)...811
      Fuel Level Circuit Test (display module removed)...812
      Engine Oil Pressure Circuit Test (display module removed)...813
      Battery Charge Circuit Test (display module removed)...814
      Glow Plug Circuit Test (display module removed)...815
    VOLTAGE REGULATOR/GLOW PLUG TIMER...816
      Removal And Installation...816
    WIPER MOTOR AND SWITCH...817
  ENGINE SERVICE...820
    TROUBLESHOOTING...822
      Chart...822
    VALVE CLEARANCE...823
      Adjustment...823
    ENGINE COMPRESSION...824
      Checking...824
    FUEL FILTER...825
      Final Filter...825
      In–Line Filter...825
    ELECTRIC FUEL PUMP...826
      Removal And Installation...826
    FUEL INJECTION PUMP...827
      Checking The Injection Pump...827
      Removal And Installation...828
      Timing The Injection Pump...829
    FUEL INJECTOR NOZZLES...830
      Removal And Installation...830
      Checking The Injector Nozzle...831
    GLOW PLUGS...832
      Removal And Installation...832
      Checking The Glow Plug...832
    RADIATOR...833
      Removal And Installation...833
    MUFFLER...835
      Removal And Installation...835
    AIR CLEANER...836
      Removal And Installation...836
    ENGINE...837
      Removal And Installation...837
    ENGINE FLYWHEEL...838
      Removal And Installation...838
      Flywheel Ring Gear...840
    CYLINDER HEAD...841
      Removal...841
      Disassembly...842
      Servicing The Cylinder Head And Valves...843
      Checking Valve Springs...844
      Checking Rocker Arm And Shaft...845
      Assembling The Cylinder Head...845
      Installation...845
    TIMING GEAR COVER...847
      Removal And Installation...847
    TIMING GEAR, CAMSHAFT AND OIL PUMP...849
      Removal And Installation...849
      Oil Pump Service...851
      Servicing The Camshaft...852
    CRANKSHAFT AND PISTONS...853
      Removal And Installation...853
      Crankshaft Service...856
      Servicing The Connecting Rods And Pistons...857
    CYLINDER LINERS...859
      Checking The Cylinder Liners...859
      Cylinder Liner Installation...859
    WATER PUMP...860
      Removal And Installation...860
      Disassembly And Assembly...860
  TECHNICAL DATA...862
    EXCAVATOR SPECIFICATIONS...864
      Machine Dimensions...864
      Performance And Operation...865
      Engine...865
      Hydraulic System...865
      Swing System...865
      Hydraulic Cylinders...865
      Drive System...866
      Brakes...866
      Track Shoes...866
      Capacities...866
      Digging Force...866
    ENGINE SPECIFICATIONS...867
      Fuel Injection Nozzles...867
      Fuel Injection Pump...867
      Cylinder Head...867
      Valves...867
      Valve Springs...867
      Rocker Arms...867
      Camshaft...867
      Cylinder...868
      Piston Rings...868
      Pistons...868
      Crankshaft...868
      Oil Pump...868
      Engine Oil Specifications...868
      Engine Bolt Torque...869
      Re–Grinding The Crankshaft...870
    FUEL, COOLANT AND LUBRICANTS...871
      Chart...871
    OIL SPECIFICATIONS...871
      Description...871
  SERVICE MANUAL REVISION...872
    225-1...872
    225-2...874
    225-3...876
    225-4...878
    225-5...880
    225-6...882
    225-7...884
6720347 (6-12) - X 225 Excavator Service Manual...886
  MAINTENANCE SAFETY...888
  CONTENTS...890
  FOREWORD...892
    SAFETY INSTRUCTIONS...894
    SERIAL NUMBER LOCATIONS...895
    HYDRAULIC EXCAVATOR SERIAL NUMBER...895
    ENGINE SERIAL NUMBER...895
    DELIVERY REPORT...895
    HYDRAULIC EXCAVATOR IDENTIFICATION...896
  PREVENTIVE MAINTENANCE...898
    SERVICE SCHEDULE...900
    ENGINE COVER...901
      Procedure...901
    AIR CLEANER SERVICE...901
      Replacing The Filter Element...901
    FUEL SYSTEM...902
      Fuel Specifications...902
      Fuel System Service...902
    ENGINE LUBRICATION SYSTEM...904
      Checking The Engine Oil...904
      Engine Oil And Filter Replacement...904
    COOLING SYSTEM...905
      Coolant Level...905
      Coolant Replacement...905
    HYDRAULIC SYSTEM...906
      Checking And Adding Fluid...906
      Replacement Of The Hydraulic Filters...907
      Hydraulic Reservoir...907
    USING A BOOSTER BATTERY (JUMP STARTING)...908
      Procedure...908
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...909
      Procedure...909
    FINAL DRIVE CASE...911
      Checking Oil Level...911
  HYDRAULIC SECTION...912
    HYDRAULIC SCHEMATICS...914
    HYDRAULIC SERVICE INFORMATION...920
      Description...920
      Checking The Control Valve Relief Valves...920
      Checking The Locking Lever Relief Valve...922
      With Locking Lever Up (By–Passing Relief Valve)...922
      Checking The Auxiliary Relief Valve...922
    HYDRAULIC PUMP...923
      Removal And Installation...923
      Disassembly...924
      Assembly...926
    HYDRAULIC CONTROL VALVE...930
      Removal And Installation...930
    CONTROL VALVE...932
      Disassembly And Assembly...932
      Relief Valve Pressure Setting Adjustment...947
      Main Relief Valve...947
      Work Port Relief Valves...949
    HYDRAULIC RESERVOIR...950
      Removal And Installation...950
      Suction Filter...951
    BOOM CYLINDER...952
      Removal And Installation...952
    DIPPERSTICK CYLINDER...953
      Removal And Installation...953
    BUCKET CYLINDER...954
      Removal And Installation...954
    BLADE CYLINDER...955
      Removal And Installation...955
    BOOM SWING CYLINDER...956
      Removal And Installation...956
    HYDRAULIC CYLINDER...957
      Disassembly...957
      Assembly...961
    SWING CYLINDER LOCK VALVE...967
      Parts Identification...967
      Disassembly...968
      Assembly...969
    SOLENOID VALVE...971
      Parts Identification...971
      Disassembly...972
      Assembly...975
    HYDRAULIC FILTER...979
      Removal And Installation...979
      Untitled...980
  DRIVE SECTION...982
    HYDRAULIC CONTROL LEVERS...984
      Swing/Dipperstick Control Lever...984
      Boom/Bucket Control Lever...986
      Disassembly And Assembly...986
    THROTTLE LEVER...990
      Removal And Installation...990
    BLADE CONTROL LEVER...990
      Removal And Installation...990
    CONTROL LOCKING ARM...991
      Removal And Installation...991
    PANEL LIFT CYLINDER...992
      Removal And Installation...992
    LOCKING LEVER VALVE...993
      Removal And Installation...993
    LOCKING LEVER CABLE...994
      Removal And Installation...994
    CONTROL PANEL BASE...995
      Removal And Installation...995
    FOOT PEDAL AND STEERING LEVER LINKAGE...996
      Removal And Installation...996
    STEERING LEVERS...997
      Removal And Installation...997
    FINAL DRIVE...998
      Removal And Installation...998
    DRIVE MOTOR...1000
      Disassembly...1000
      Assembly...1012
    FINAL DRIVE CASE...1023
      Check Oil Level...1023
      Draining Final Drive Case...1023
  UPPER WORKS AND SWING SECTION...1024
    SWING MOTOR...1026
      Removal And Installation...1026
    SWING MOTOR ASSEMBLY...1027
      Brake Valve...1027
        Parts Identification...1027
        Disassembly...1028
        Assembly...1031
      Relief Valve...1034
        Disassembly...1034
        Assembly...1035
        Adjustment for Model 225...1037
      Piston Housing...1038
        Parts Identification...1038
        Disassembly...1039
        Assembly...1042
      Reduction Gear...1047
        Parts Identification...1047
        Disassembly...1048
        Assembly...1052
    UPPER WORKS...1057
      Removal And Installation...1057
    SWING CIRCLE GEAR...1058
      Removal And Installation...1058
    CENTER SWIVEL JOINT...1059
      Removal And Installation...1059
      Disassembly And Assembly...1059
  MAIN FRAME AND TRACKS...1060
    ENGINE COVER...1062
      Removal And Installation...1062
    FLOOR PANELS...1063
      Removal And Installation...1063
    SEAT AND MOUNTING FRAME...1065
      Removal And Installation...1065
    SWING MOTOR COVER...1065
      Removal And Installation...1065
    FUEL TANK...1066
      Removal And Installation...1066
    BUCKET...1067
      Removal And Installation...1067
    DIPPERSTICK...1068
      Removal And Installation...1068
    BOOM...1068
      Removal And Installation...1068
    BOOM SWING BRACKET...1070
      Removal And Installation...1070
    BLADE...1071
      Removal And Installation...1071
    TRACK...1072
      Track Tension Adjustment...1072
    TRACK FRAME...1074
      Disassembly And Assembly...1074
    TRACK IDLER...1075
      Parts Identification...1075
      Disassembly...1076
      Assembly...1078
    RUBBER TRACK IDLER...1082
      Parts Identification...1082
      Disassembly...1083
      Assembly...1085
    TOOL BOX...1089
      Removal And Installation...1089
    TRACK ROLLER...1090
      Parts Identification...1090
      Disassembly...1091
      Assembly...1093
    RUBBER TRACK ROLLER...1097
      Parts Identification...1097
      Disassembly...1098
      Assembly...1100
    ROPS WINDOWS...1104
      Front Window Removal...1104
      Side Window Removal...1105
  ELECTRICAL SYSTEM...1106
    ELECTRICAL SCHEMATICS...1108
    TROUBLESHOOTING...1110
      Chart...1110
    ELECTRICAL SYSTEM...1110
      Description...1110
      Fuses...1111
      Electrical System Service...1111
    BATTERY...1112
      Checking The Battery...1112
      Removal And Installation...1112
    ALTERNATOR...1113
      Belt Adjustment...1113
      Removal And Installation...1113
    STARTER...1114
      Removal And Installation...1114
      Disassembly And Assembly...1115
      Cleaning And Inspection...1115
    FUEL LEVEL SENDER...1116
      Removal And Installation...1116
      Checking...1116
    DISPLAY MODULE...1117
      Removal And Installation...1117
    INSTRUMENT PANEL...1117
      Removal And Installation...1117
      Testing And Troubleshooting...1118
      Engine Temperature Circuit Test (display module installed)...1120
      Testing The Display Panel...1120
      Fuel Level Circuit Test (display module installed)...1122
      Testing The Display Panel...1122
      Fuel Level Sender...1123
      Engine Oil Pressure Circuit Test (display module installed)...1124
      Testing The Display Panel...1124
      Battery Charge Circuit Test (display module installed)...1125
      Glow Plug Circuit Test (display module installed)...1126
      Engine Temperature Circuit Test (display module removed)...1127
      Fuel Level Circuit Test (display module removed)...1128
      Engine Oil Pressure Circuit Test (display module removed)...1129
      Battery Charge Circuit Test (display module removed)...1130
      Glow Plug Circuit Test (display module removed)...1131
    VOLTAGE REGULATOR/GLOW PLUG TIMER...1132
      Removal And Installation...1132
    WIPER MOTOR AND SWITCH...1133
  ENGINE SERVICE...1136
    TROUBLESHOOTING...1138
      Chart...1138
    VALVE CLEARANCE...1139
      Adjustment...1139
    ENGINE COMPRESSION...1140
      Checking...1140
    FUEL FILTER...1141
      Final Filter...1141
      In–Line Filter...1141
    ELECTRIC FUEL PUMP...1142
      Removal And Installation...1142
    FUEL INJECTION PUMP...1143
      Checking The Injection Pump...1143
      Removal And Installation...1144
      Timing The Injection Pump...1145
    FUEL INJECTOR NOZZLES...1146
      Removal And Installation...1146
      Checking The Injector Nozzle...1147
    GLOW PLUGS...1148
      Removal And Installation...1148
      Checking The Glow Plug...1148
    RADIATOR...1149
      Removal And Installation...1149
    MUFFLER...1151
      Removal And Installation...1151
    AIR CLEANER...1152
      Removal And Installation...1152
    ENGINE...1153
      Removal And Installation...1153
    ENGINE FLYWHEEL...1154
      Removal And Installation...1154
      Flywheel Ring Gear...1156
    CYLINDER HEAD...1157
      Removal...1157
      Disassembly...1158
      Servicing The Cylinder Head And Valves...1159
      Checking Valve Springs...1160
      Checking Rocker Arm And Shaft...1161
      Assembling The Cylinder Head...1161
      Installation...1161
    TIMING GEAR COVER...1163
      Removal And Installation...1163
    TIMING GEAR, CAMSHAFT AND OIL PUMP...1165
      Removal And Installation...1165
      Oil Pump Service...1167
      Servicing The Camshaft...1168
    CRANKSHAFT AND PISTONS...1169
      Removal And Installation...1169
      Crankshaft Service...1172
      Servicing The Connecting Rods And Pistons...1173
    CYLINDER LINERS...1175
      Checking The Cylinder Liners...1175
      Cylinder Liner Installation...1175
    WATER PUMP...1176
      Removal And Installation...1176
      Disassembly And Assembly...1176
  TECHNICAL DATA...1178
    EXCAVATOR SPECIFICATIONS...1180
      Machine Dimensions...1180
      Performance And Operation...1181
      Engine...1181
      Hydraulic System...1181
      Swing System...1181
      Hydraulic Cylinders...1181
      Drive System...1182
      Brakes...1182
      Track Shoes...1182
      Capacities...1182
      Digging Force...1182
    ENGINE SPECIFICATIONS...1183
      Fuel Injection Nozzles...1183
      Fuel Injection Pump...1183
      Cylinder Head...1183
      Valves...1183
      Valve Springs...1183
      Rocker Arms...1183
      Camshaft...1183
      Cylinder...1184
      Piston Rings...1184
      Pistons...1184
      Crankshaft...1184
      Oil Pump...1184
      Engine Oil Specifications...1184
      Engine Bolt Torque...1185
      Re–Grinding The Crankshaft...1186
    FUEL, COOLANT AND LUBRICANTS...1187
      Chart...1187
    OIL SPECIFICATIONS...1187
      Description...1187
  SERVICE MANUAL REVISION...1188
    225-1...1188
    225-2...1190
    225-3...1192
    225-4...1194
    225-5...1196
    225-6...1198
    225-7...1200
    225-8...1202
6720379 (11-89) - 220 Excavator Operation & Maintenance Manual...1204
  OPERATOR SAFETY WARNINGS...1205
  FOREWORD...1206
  CONTENTS...1206
    SAFETY INSTRUCTIONS...1208
    FIRE PREVENTION...1209
    SERIAL NUMBER LOCATIONS...1210
      Hydraulic Excavator Serial Number...1210
      Engine Serial Number...1210
    DELIVERY REPORT...1210
    HYDRAULIC EXCAVATOR IDENTIFICATION...1211
    SAFETY SIGNS (DECALS)...1212
  OPERATING INSTRUCTIONS...1214
    GETTING ON AND OFF THE MACHINE...1216
    SEAT...1216
    SEAT BELT...1216
    INSTRUMENT PANEL...1217
    KEY SWITCH...1217
    LEVER & CONTROL LOCATIONS...1217
    CONTROL LEVERS...1218
      Operation Of Left Control Lever (ISO)...1218
      Operation Of Right Control Lever (ISO)...1218
      Control Lever Lock Operation...1219
    FUEL CONTROL LEVER...1219
    ENGINE STOP CONTROL...1219
    STEERING LEVERS...1220
      Forward And Reverse Travel...1220
      Turning...1220
      Making A Counter-Rotation Turn...1220
    BOOM SWING LEVER...1221
    BLADE CONTROL LEVER...1221
    SWING LOCK...1221
    BEFORE STARTING THE ENGINE...1222
    STARTING THE ENGINE...1222
      Normal Starting Procedure...1222
      Cold Starting Procedure...1223
    PARKING THE HYDRAULIC EXCAVATOR...1223
    OPERATING PROCEDURE...1224
      Breaking In A New Machine...1224
      General Operation Suggestions...1224
    TRANSPORTING THE HYDRAULIC EXCAVATOR...1225
    BUCKET...1226
      Removal...1226
      Installation...1226
  PREVENTIVE MAINTENANCE...1228
    MAINTENANCE SAFETY...1229
    SERVICE SCHEDULE...1230
    ENGINE COVER...1231
    AIR CLEANER SERVICE...1231
    FUEL SYSTEM...1232
      Fuel System Service...1232
      Fuel Filters...1233
      Removing Air From The Fuel System...1233
    ENGINE LUBRICATION SYSTEM...1234
      Engine Oil And Filter Replacement...1234
    COOLING SYSTEM...1235
      Coolant Level...1235
      Coolant Replacement...1235
    ALTERNATOR BELT ADJUSTMENT...1236
    ELECTRICAL SYSTEM...1237
      Fuse...1237
      Service The Electrical System...1237
      Using A Booster Battery (Jump Starting)...1238
      Removal And Installation Of The Battery...1239
    HYDRAULIC SYSTEM...1240
      Checking And Adding Fluid...1240
      Replacement Of The Hydraulic Filter...1241
      Hydraulic Reservoir...1241
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...1242
    FINAL DRIVE CASE...1244
      Checking Oil Level...1244
      Draining Final Drive Case...1244
    TRACK TENSION...1245
      Adjustment...1245
  SPECIFICATIONS...1246
    HYDRAULIC EXCAVATOR SPECIFICATIONS...1248
      Machine Dimensions...1248
      Lifting Capacity With Blade Off Ground...1249
      Performance & Operation...1249
      Engine...1249
      Hydraulic System...1249
      Swing System...1250
      Hydraulic Cylinders...1250
      Drive System...1250
      Brakes...1250
      Undercarriage...1250
      Track...1250
      Capacities...1250
      Digging Force...1250
    FUEL, COOLANT AND LUBRICANTS...1251
    OIL SPECIFICATIONS...1251
  WARRANTY...1254
6720448 (4-92) - 220 Excavator Operation & Maintenance Manual...1256
  OPERATOR SAFETY WARNINGS...1257
  FOREWORD...1258
  CONTENTS...1258
  SAFETY...1260
    SAFETY INSTRUCTIONS...1262
    FIRE PREVENTION...1264
    SERIAL NUMBER LOCATIONS...1265
      Hydraulic Excavator Serial Number...1265
      Engine Serial Number...1265
    DELIVERY REPORT...1265
    HYDRAULIC EXCAVATOR IDENTIFICATION...1266
    SAFETY SIGNS (DECALS)...1267
  OPERATING INSTRUCTIONS...1270
    GETTING ON AND OFF THE MACHINE...1272
    SEAT...1272
    SEAT BELT...1272
    INSTRUMENT PANEL...1273
    KEY SWITCH...1273
    CONTROL LEVER LOCK...1273
    CONTROL LEVERS...1274
      Operation Of Left Control Lever (ISO)...1274
      Operation Of Right Control Lever (ISO)...1274
    CONTROL LEVER (Standard)...1275
      Operation Of Left Control Lever...1275
      Operation Of Right Control Lever...1275
    SWING LOCK...1276
    HORN BUTTON...1276
    FUEL CONTROL LEVER...1276
    ENGINE STOP CONTROL...1276
    STEERING LEVERS...1277
      Forward And Reverse Travel...1277
      Turning...1277
      Making A Counter-Rotation Turn...1277
    BOOM SWING PEDAL...1278
    BLADE CONTROL LEVER...1278
    AUXILIARY CONTROL PEDAL...1278
    BEFORE STARTING THE ENGINE...1279
    STARTING THE ENGINE...1279
      Normal Starting Procedure...1279
      Cold Starting Procedure...1280
    OPERATING PROCEDURE...1281
      Breaking In A New Machine...1281
      General Operation Suggestions...1281
    PARKING THE HYDRAULIC EXCAVATOR...1282
    TRANSPORTING THE HYDRAULIC EXCAVATOR...1283
    LIFTING THE EXCAVATOR...1284
    BUCKET...1285
      Removal...1285
      Installation...1285
  PREVENTIVE MAINTENANCE...1286
    MAINTENANCE SAFETY...1287
    SERVICE SCHEDULE...1288
    ENGINE COVER...1289
    AIR CLEANER SERVICE...1289
    FUEL SYSTEM...1290
      Fuel System Service...1290
      Fuel Filters...1291
      Removing Air From The Fuel System...1291
    ENGINE LUBRICATION SYSTEM...1292
      Engine Oil And Filter Replacement...1292
    COOLING SYSTEM...1293
      Coolant Level...1293
      Coolant Replacement...1293
    ALTERNATOR BELT ADJUSTMENT...1294
    ELECTRICAL SYSTEM...1295
      Fuse...1295
      Service The Electrical System...1295
      Using A Booster Battery (Jump Starting)...1296
      Removal And Installation Of The Battery...1297
    HYDRAULIC SYSTEM...1298
      Checking And Adding Fluid...1298
      Diagnostic Couplers...1298
      Replacement Of The Hydraulic Filter...1299
      Hydraulic Reservoir...1299
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...1300
    TRACK TENSION...1302
      Adjustment...1302
    FINAL DRIVE CASE...1303
      Checking Oil Level...1303
      Draining Final Drive Case...1303
  HYDRAULIC EXCAVATOR SPECIFICATIONS...1304
    Machine Dimensions...1304
    Lifting Capacity With Blade Off Ground...1305
    Performance & Operation...1305
    Engine...1305
    Hydraulic System...1305
    SPECIFICATIONS...1306
    Swing System...1308
    Hydraulic Cylinders...1308
    Drive System...1308
    Brakes...1308
    Undercarriage...1308
    Track...1308
    Capacities...1308
    Digging Force...1308
  FUEL, COOLANT AND LUBRICANTS...1309
  OIL SPECIFICATIONS...1309
  WARRANTY...1310
6720496 (4-90) - X 231 Excavator Service Manual...1312
  MAINTENANCE SAFETY...1314
  CONTENTS...1316
    FOREWORD...1318
    SAFETY INSTRUCTIONS...1320
    SERIAL NUMBER LOCATIONS...1322
    HYDRAULIC EXCAVATOR SERIAL NUMBER...1322
    ENGINE SERIAL NUMBER...1322
    DELIVERY REPORT...1322
    HYDRAULIC EXCAVATOR IDENTIFICATION...1323
  PREVENTIVE MAINTENANCE...1324
    SERVICE SCHEDULE...1326
    ENGINE COVER...1327
      Procedure...1327
    AIR CLEANER...1327
      Replacing the Filter Element...1327
    FUEL SYSTEM...1328
      Fuel Specifications...1328
      Fuel System Service...1328
    ENGINE LUBRICATION SYSTEM...1329
      Checking the Engine Oil...1329
      Engine oil and Filter Replacement...1329
    COOLING SYSTEM...1330
      Coolant Level...1330
      Coolant Replacement...1330
    HYDRAULIC SYSTEM...1331
      Checking and Adding Fluid...1331
      Replacement of the Hydraulic Filters...1331
      Hydraulic Reservoir...1332
    ELECTRICAL SYSTEM...1333
      Using A Booster Battery (Jump Starting)...1333
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...1334
    SWING MOTOR GEAR REDUCTION...1336
    FINAL DRIVE CASE...1336
      Checking Oil Level...1336
      Draining Final Drive Case...1336
  HYDRAULIC SECTION...1338
    HYDRAULIC SCHEMATICS...1340
    HYDRAULIC SERVICE INFORMATION...1345
      Description...1345
      Checking the Main Relief Valves...1345
      Checking the Locking Lever Relief Valve...1347
      With Locking Lever Down (Going Over Relief) Strokethe Bucket (Curl)...1347
      Checking the Auxiliary Relief Valve...1347
    HYDRAULIC PUMP...1348
      Removal and Installation...1348
      Disassembly...1349
      Assembly...1351
    HYDRAULIC CONTROL VALVE...1355
      Removal and Installation...1355
    CONTROL VALVE...1357
      Disassembly and Assembly...1357
      Disassembly and Assembly...1358
        Blade, Boom Swing, Bucket, L.H. Travel, Auxiliaryand House Swing Valve Sections...1358
        R.H. Travel Valve Section...1362
        Hydraulically Activated Valve Sections...1366
        Main Relief Valves...1368
        Work Port Relief Valves...1370
      Relief Valve Pressure Setting Adjustment...1372
        MAIN RELIEF VALVE...1372
        Work Port Relief Valves...1374
    SOLENOID VALVE...1375
      Removal and Installation...1375
      Parts Identification...1376
      Disassembly...1377
      Assembly...1380
    OIL COOLER...1384
      Removal and Installation...1384
    HYDRAULIC RESERVOIR...1385
      Removal and Installation...1385
    SUCTION FILTER...1386
    BOOM CYLINDER...1387
      Removal and Installation...1387
      Parts Identification...1388
    DIPPERSTICK CYLINDER...1389
      Removal and Installation...1389
      Parts Identification...1390
    BUCKET CYLINDER...1391
      Removal and Installation...1391
      Parts Identification...1392
    BLADE CYLINDER...1393
      Removal and Installation...1393
      Parts Identification...1394
    BOOM SWING CYLINDER...1395
      Removal and Installation...1395
      Parts Identification...1396
    HYDRAULIC CYLINDER...1397
      Disassembly...1397
      Assembly...1401
    SWING CYLINDER LOCK VALVE...1407
      Parts Identification...1407
      Disassembly...1408
      Assembly...1409
    HYDRAULIC FILTER...1411
      Removal and Installation...1411
    AUXILIARY ROUTING...1411
    JOYSTICK CONTROL CHANGE...1413
  DRIVE SECTION...1415
    HYDRAULIC CONTROL LEVERS...1417
      Swing/Dipperstick Control Lever...1417
    JOYSTICK...1418
      Disassembly and Assembly...1418
      Parts Identification...1422
      Boom/Bucket Control Lever...1423
    THROTTLE LEVER...1424
      Removal and Installation...1424
    BLADE CONTROL LEVER...1424
      Removal and Installation...1424
    CONTROL LOCKING ARM...1425
      Removal and Installation...1425
    GAS CYLINDER...1426
      Removal and Installation...1426
    LOCKING LEVER VALVE...1427
      Removal and Installation...1427
    LOCKING LEVER CABLE...1428
      Removal and Installation...1428
    CONTROL PANEL BASE...1429
      Removal and Installation...1429
    FOOT PEDAL AND STEERING LEVER LINKAGE...1430
      Removal and Installation...1430
    STEERING LEVERS...1431
      Removal and Installation...1431
    FINAL DRIVE...1432
      Removal and Installation...1432
    TRAVEL MOTOR...1434
      Disassembly...1434
      Assembly...1445
  UPPER WORKS AND SWING SECTION...1459
    SWING MOTOR...1461
      Removal and Installation...1461
    BRAKE VALVE...1462
      Disassembly...1462
      Assembly...1466
    SWING MOTOR...1469
      Disassembly...1469
      Assembly...1474
    REDUCTION GEAR...1479
      Disassembly...1479
      Assembly...1483
    RELIEF VALVE...1487
      Disassembly...1487
      Assembly...1489
      Adjustment...1491
    UPPER WORKS AND SWING CIRCLE GEAR...1492
      Removal and Installation...1492
      Reinstalling the Swing Bearing...1495
    CENTER SWIVEL JOINT...1498
      Removal and Installation (Through Upper Access Removal)...1498
  MAIN FRAME AND TRACKS...1501
    ENGINE COVER...1503
      Removal and Installation...1503
    ROPS...1504
      Removal and Installation...1504
      Front Window Removal & Installation...1505
      Side Window Removal & Installation...1506
    REAR FLOOR PANEL...1507
      Removal and Installation...1507
    FOOT PEDALS...1508
      Removal and Installation...1508
    SEAT AND MOUNTING FRAME...1509
      Removal and Installation...1509
    SWING MOTOR COVER...1509
      Removal and Installation...1509
    ENGINE SHROUD...1510
      Removal and Installation...1510
    FUEL TANK...1511
      Removal and Installation...1511
    BUCKET...1512
      Removal and Installation...1512
    DIPPERSTICK...1513
      Removal and Installation...1513
    BOOM...1513
      Removal and Installation...1513
    BOOM SWING BRACKET...1515
      Removal and Installation...1515
    BLADE...1516
      Removal and Installation...1516
    TRACK TENSION...1517
      Adjustment...1517
      Removal and Installation...1518
    TRACK FRAME...1519
      Disassembly and Assembly...1519
    TRACK IDLER...1520
      Parts Identification...1520
      Disassembly...1521
      Assembly...1523
    TRACK FRAME...1527
    TOOL BOX...1527
      Removal and Installation...1527
    TRACK ROLLER...1528
      Parts Identification...1528
      Disassembly...1529
      Assembly...1531
    OVERHEAD CONSOLE...1535
      Removal and Installation...1535
  ELECTRICAL SYSTEM...1537
    TROUBLESHOOTING...1539
      Chart...1539
    ELECTRICAL SYSTEM...1539
      Description...1539
      Fuses...1540
      Electrical System Service...1540
    BATTERY...1541
      Checking the Battery...1541
      Removal and Installation...1541
    ALTERNATOR...1542
      Belt Adjustment...1542
      Removal and Installation...1542
    FUEL SHUT–DOWN RELAY...1543
      Removal and Installation...1543
    STARTER...1543
      Removal and Installation...1543
      Disassembly and Assembly...1544
    FUEL LEVEL SENDER...1545
      Removal and Installation...1545
      Checking...1545
    DISPLAY MODULE...1546
      Removal and Installation...1546
    INSTRUMENT PANEL...1546
      Removal and Installation...1546
    DISPLAY MODULE...1547
      Testing and Trouble Shooting...1547
      Engine Temperature Circuit Test (with display module installed in the excavator.)...1549
      Testing the Display Panel...1549
      Fuel Level Circuit Test (with display module installed in the excavator)...1551
      Testing the Display Panel...1551
      Fuel Level Sender...1552
      Engine Oil Pressure Circuit Test (with display module installed in the excavator)...1553
      Testing the Display Module...1553
      Battery Charge Circuit Test (with display module installed in the excavator.)...1554
      Glow Plug Circuit Test (with display module installed in the excavator)...1555
      Engine Temperature Circuit Test (with display module removed from the excavator.)...1556
      Fuel Level Circuit Test (with display module removed from the excavator.)...1557
      Engine Oil Pressure Circuit Test (with display module removed from the excavator.)...1558
      Battery Charge Circuit Test (with display module removed from the excavator.)...1559
    VOLTAGE REGULATOR/GLOW PLUG TIMER...1561
      Removal and Installation...1561
    DIVERTER VALVE SWITCH...1561
      Removal and Installation...1561
    DOME LIGHT...1562
      Removal and Installation...1562
    WINDSHIELD WIPER...1563
      Removal and Installation...1563
    FRONT LIGHTS...1564
      Removal and Installation...1564
      Lamp Replacement...1564
    CONSOLE SWITCHES...1565
      Removal and Installation...1565
    WIPER MOTOR AND SWITCH...1566
  ENGINE SERVICE...1567
    TROUBLESHOOTING...1569
    VALVE CLEARANCE...1570
      Adjustment...1570
    ENGINE COMPRESSION...1571
      Checking...1571
    FUEL FILTER...1572
      Final Filter...1572
      In–Line Filter...1572
    ELECTRIC FUEL PUMP...1573
      Removal and Installation...1573
    FUEL SHUT–DOWN SOLENOID...1573
      Removal and Installation...1573
    FUEL INJECTION PUMP...1574
      Checking the Injection Pump...1574
      Removal and Installation...1575
      Timing the Injection Pump...1576
    FUEL INJECTOR NOZZLES...1577
      Removal and Installation...1577
      Checking the Injector Nozzle...1578
    GLOW PLUGS...1579
      Removal and Installation...1579
      Checking the Glow Plug...1579
    RADIATOR...1580
      Removal and Installation...1580
    AIR CLEANER...1582
      Removal an Installation...1582
    MUFFLER...1583
      Removal and Installation...1583
    HEATER...1584
      Removal and Installation...1584
    ENGINE...1585
      Removal and Installation...1585
    ENGINE FLYWHEEL...1586
      Removal and Installation...1586
      Flywheel Ring Gear...1588
    CYLINDER HEAD...1589
      Removal...1589
      Disassembly...1590
      Servicing the Cylinder Head...1590
      Assembly...1592
      Installation...1592
    ENGINE REPAIR...1593
      Removing the Timing Gear, Camshaft and Oil Pump...1596
      Removing the Pistons and Crankshaft...1597
      Servicing the Timing Gear and Camshaft...1599
      Servicing the Connecting Rods and Pistons...1600
      Servicing the Crankshaft...1602
      Servicing the Cylinder Liners...1603
      Lubrication System...1604
      Oil Pump Service...1605
      Water Pump Service...1605
    ENGINE ASSEMBLY...1607
      Installing the Crankshaft...1607
      Installing the Pistons...1607
      Installing the Camshaft and Timing Gears...1607
      Installing the Gearcase...1609
  TECHNICAL DATA...1611
    EXCAVATOR SPECIFICATIONS...1613
      Machine Dimensions...1613
      PERFORMANCE & OPERATION...1614
      Engine...1614
      Hydraulic System...1614
      Swing System...1614
      Hydraulic Cylinders...1614
      DRIVE SYSTEM...1615
      BRAKES...1615
      UNDERCARRIAGE...1615
      TRACK SHOES...1615
      CAPACITIES...1615
      MISCELLANEOUS...1615
    ENGINE SPECIFICATIONS...1616
      Fuel Injection Nozzles...1616
      Fuel Injection Pump...1616
      Cylinder Head...1616
      Valves...1616
      Valve Springs...1616
      Rocker Arms...1616
      Camshaft...1616
      Cylinder...1617
      Piston Rings...1617
      Pistons...1617
      Crankshaft...1617
      Oil Pump...1617
      Engine Oil Specifications...1617
      ENGINE BOLT TORQUE...1618
      Re–Grinding The Crankshaft...1619
    FUEL, COOLANT AND LUBRICANTS...1620
    OIL SPECIFICATIONS...1620
      Description...1620
  SERVICE MANUAL REVISON...1621
    231-1...1621
    231-2...1623
    231-3...1625
    231-4...1627
    231-5...1629
    231-6...1631
    231-7...1633
    231-8...1635
    231-9...1637
6720496 (6-12) - X 231 Excavator Service Manual...1639
  MAINTENANCE SAFETY...1641
  CONTENTS...1643
    FOREWORD...1645
    SAFETY INSTRUCTIONS...1647
    SERIAL NUMBER LOCATIONS...1649
    HYDRAULIC EXCAVATOR SERIAL NUMBER...1649
    ENGINE SERIAL NUMBER...1649
    DELIVERY REPORT...1649
    HYDRAULIC EXCAVATOR IDENTIFICATION...1650
  PREVENTIVE MAINTENANCE...1651
    SERVICE SCHEDULE...1653
    ENGINE COVER...1654
      Procedure...1654
    AIR CLEANER...1654
      Replacing the Filter Element...1654
    FUEL SYSTEM...1655
      Fuel Specifications...1655
      Fuel System Service...1655
    ENGINE LUBRICATION SYSTEM...1656
      Checking the Engine Oil...1656
      Engine oil and Filter Replacement...1656
    COOLING SYSTEM...1657
      Coolant Level...1657
      Coolant Replacement...1657
    HYDRAULIC SYSTEM...1658
      Checking and Adding Fluid...1658
      Replacement of the Hydraulic Filters...1658
      Hydraulic Reservoir...1659
    ELECTRICAL SYSTEM...1660
      Using A Booster Battery (Jump Starting)...1660
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...1661
    SWING MOTOR GEAR REDUCTION...1663
    FINAL DRIVE CASE...1663
      Checking Oil Level...1663
      Draining Final Drive Case...1663
  HYDRAULIC SECTION...1665
    HYDRAULIC SCHEMATICS...1667
    HYDRAULIC SERVICE INFORMATION...1677
      Description...1677
      Checking the Main Relief Valves...1677
      Checking the Locking Lever Relief Valve...1679
      With Locking Lever Down (Going Over Relief) Strokethe Bucket (Curl)...1679
      Checking the Auxiliary Relief Valve...1679
    HYDRAULIC PUMP...1680
      Removal and Installation...1680
      Disassembly...1681
      Assembly...1683
    HYDRAULIC CONTROL VALVE...1687
      Removal and Installation...1687
    CONTROL VALVE...1689
      Disassembly and Assembly...1689
      Disassembly and Assembly...1690
        Blade, Boom Swing, Bucket, L.H. Travel, Auxiliaryand House Swing Valve Sections...1690
        R.H. Travel Valve Section...1694
        Hydraulically Activated Valve Sections...1698
        Main Relief Valves...1700
        Work Port Relief Valves...1702
      Relief Valve Pressure Setting Adjustment...1704
        MAIN RELIEF VALVE...1704
        Work Port Relief Valves...1706
    SOLENOID VALVE...1707
      Removal and Installation...1707
      Parts Identification...1708
      Disassembly...1709
      Assembly...1712
    OIL COOLER...1716
      Removal and Installation...1716
    HYDRAULIC RESERVOIR...1717
      Removal and Installation...1717
    SUCTION FILTER...1718
    BOOM CYLINDER...1719
      Removal and Installation...1719
      Parts Identification...1720
    DIPPERSTICK CYLINDER...1721
      Removal and Installation...1721
      Parts Identification...1722
    BUCKET CYLINDER...1723
      Removal and Installation...1723
      Parts Identification...1724
    BLADE CYLINDER...1725
      Removal and Installation...1725
      Parts Identification...1726
    BOOM SWING CYLINDER...1727
      Removal and Installation...1727
      Parts Identification...1728
    HYDRAULIC CYLINDER...1729
      Disassembly...1729
      Assembly...1733
    SWING CYLINDER LOCK VALVE...1739
      Parts Identification...1739
      Disassembly...1740
      Assembly...1741
    HYDRAULIC FILTER...1743
      Removal and Installation...1743
    AUXILIARY ROUTING...1743
    JOYSTICK CONTROL CHANGE...1745
  DRIVE SECTION...1747
    HYDRAULIC CONTROL LEVERS...1749
      Swing/Dipperstick Control Lever...1749
    JOYSTICK...1750
      Disassembly and Assembly...1750
      Parts Identification...1754
      Boom/Bucket Control Lever...1755
    THROTTLE LEVER...1756
      Removal and Installation...1756
    BLADE CONTROL LEVER...1756
      Removal and Installation...1756
    CONTROL LOCKING ARM...1757
      Removal and Installation...1757
    GAS CYLINDER...1758
      Removal and Installation...1758
    LOCKING LEVER VALVE...1759
      Removal and Installation...1759
    LOCKING LEVER CABLE...1760
      Removal and Installation...1760
    CONTROL PANEL BASE...1761
      Removal and Installation...1761
    FOOT PEDAL AND STEERING LEVER LINKAGE...1762
      Removal and Installation...1762
    STEERING LEVERS...1763
      Removal and Installation...1763
    FINAL DRIVE...1764
      Removal and Installation...1764
    TRAVEL MOTOR...1766
      Disassembly...1766
      Assembly...1777
  UPPER WORKS AND SWING SECTION...1791
    SWING MOTOR...1793
      Removal and Installation...1793
    BRAKE VALVE...1794
      Disassembly...1794
      Assembly...1798
    SWING MOTOR...1801
      Disassembly...1801
      Assembly...1806
    REDUCTION GEAR...1811
      Disassembly...1811
      Assembly...1815
    RELIEF VALVE...1819
      Disassembly...1819
      Assembly...1821
      Adjustment...1823
    UPPER WORKS AND SWING CIRCLE GEAR...1824
      Removal and Installation...1824
      Reinstalling the Swing Bearing...1827
    CENTER SWIVEL JOINT...1830
      Removal and Installation (Through Upper Access Removal)...1830
  MAIN FRAME AND TRACKS...1833
    ENGINE COVER...1835
      Removal and Installation...1835
    ROPS...1836
      Removal and Installation...1836
      Front Window Removal & Installation...1837
      Side Window Removal & Installation...1838
    REAR FLOOR PANEL...1839
      Removal and Installation...1839
    FOOT PEDALS...1840
      Removal and Installation...1840
    SEAT AND MOUNTING FRAME...1841
      Removal and Installation...1841
    SWING MOTOR COVER...1841
      Removal and Installation...1841
    ENGINE SHROUD...1842
      Removal and Installation...1842
    FUEL TANK...1843
      Removal and Installation...1843
    BUCKET...1844
      Removal and Installation...1844
    DIPPERSTICK...1845
      Removal and Installation...1845
    BOOM...1845
      Removal and Installation...1845
    BOOM SWING BRACKET...1847
      Removal and Installation...1847
    BLADE...1848
      Removal and Installation...1848
    TRACK TENSION...1849
      Adjustment...1849
      Removal and Installation...1850
    TRACK FRAME...1851
      Disassembly and Assembly...1851
    TRACK IDLER...1852
      Parts Identification...1852
      Disassembly...1853
      Assembly...1855
    TRACK FRAME...1859
    TOOL BOX...1859
      Removal and Installation...1859
    TRACK ROLLER...1860
      Parts Identification...1860
      Disassembly...1861
      Assembly...1863
    OVERHEAD CONSOLE...1867
      Removal and Installation...1867
  ELECTRICAL SYSTEM...1869
    TROUBLESHOOTING...1871
      Chart...1871
    ELECTRICAL SYSTEM...1871
      Description...1871
      Fuses...1872
      Electrical System Service...1872
    BATTERY...1873
      Checking the Battery...1873
      Removal and Installation...1873
    ALTERNATOR...1874
      Belt Adjustment...1874
      Removal and Installation...1874
    FUEL SHUT–DOWN RELAY...1875
      Removal and Installation...1875
    STARTER...1875
      Removal and Installation...1875
      Disassembly and Assembly...1876
    FUEL LEVEL SENDER...1877
      Removal and Installation...1877
      Checking...1877
    DISPLAY MODULE...1878
      Removal and Installation...1878
    INSTRUMENT PANEL...1878
      Removal and Installation...1878
    DISPLAY MODULE...1879
      Testing and Trouble Shooting...1879
      Engine Temperature Circuit Test (with display module installed in the excavator.)...1881
      Testing the Display Panel...1881
      Fuel Level Circuit Test (with display module installed in the excavator)...1883
      Testing the Display Panel...1883
      Fuel Level Sender...1884
      Engine Oil Pressure Circuit Test (with display module installed in the excavator)...1885
      Testing the Display Module...1885
      Battery Charge Circuit Test (with display module installed in the excavator.)...1886
      Glow Plug Circuit Test (with display module installed in the excavator)...1887
      Engine Temperature Circuit Test (with display module removed from the excavator.)...1888
      Fuel Level Circuit Test (with display module removed from the excavator.)...1889
      Engine Oil Pressure Circuit Test (with display module removed from the excavator.)...1890
      Battery Charge Circuit Test (with display module removed from the excavator.)...1891
    VOLTAGE REGULATOR/GLOW PLUG TIMER...1893
      Removal and Installation...1893
    DIVERTER VALVE SWITCH...1893
      Removal and Installation...1893
    DOME LIGHT...1894
      Removal and Installation...1894
    WINDSHIELD WIPER...1895
      Removal and Installation...1895
    FRONT LIGHTS...1896
      Removal and Installation...1896
      Lamp Replacement...1896
    CONSOLE SWITCHES...1897
      Removal and Installation...1897
    WIPER MOTOR AND SWITCH...1898
  ENGINE SERVICE...1899
    TROUBLESHOOTING...1901
    VALVE CLEARANCE...1902
      Adjustment...1902
    ENGINE COMPRESSION...1903
      Checking...1903
    FUEL FILTER...1904
      Final Filter...1904
      In–Line Filter...1904
    ELECTRIC FUEL PUMP...1905
      Removal and Installation...1905
    FUEL SHUT–DOWN SOLENOID...1905
      Removal and Installation...1905
    FUEL INJECTION PUMP...1906
      Checking the Injection Pump...1906
      Removal and Installation...1907
      Timing the Injection Pump...1908
    FUEL INJECTOR NOZZLES...1909
      Removal and Installation...1909
      Checking the Injector Nozzle...1910
    GLOW PLUGS...1911
      Removal and Installation...1911
      Checking the Glow Plug...1911
    RADIATOR...1912
      Removal and Installation...1912
    AIR CLEANER...1914
      Removal an Installation...1914
    MUFFLER...1915
      Removal and Installation...1915
    HEATER...1916
      Removal and Installation...1916
    ENGINE...1917
      Removal and Installation...1917
    ENGINE FLYWHEEL...1918
      Removal and Installation...1918
      Flywheel Ring Gear...1920
    CYLINDER HEAD...1921
      Removal...1921
      Disassembly...1922
      Servicing the Cylinder Head...1922
      Assembly...1924
      Installation...1924
    ENGINE REPAIR...1925
      Removing the Timing Gear, Camshaft and Oil Pump...1928
      Removing the Pistons and Crankshaft...1929
      Servicing the Timing Gear and Camshaft...1931
      Servicing the Connecting Rods and Pistons...1932
      Servicing the Crankshaft...1934
      Servicing the Cylinder Liners...1935
      Lubrication System...1936
      Oil Pump Service...1937
      Water Pump Service...1937
    ENGINE ASSEMBLY...1939
      Installing the Crankshaft...1939
      Installing the Pistons...1939
      Installing the Camshaft and Timing Gears...1939
      Installing the Gearcase...1941
  TECHNICAL DATA...1943
    EXCAVATOR SPECIFICATIONS...1945
      Machine Dimensions...1945
      PERFORMANCE & OPERATION...1946
      Engine...1946
      Hydraulic System...1946
      Swing System...1946
      Hydraulic Cylinders...1946
      DRIVE SYSTEM...1947
      BRAKES...1947
      UNDERCARRIAGE...1947
      TRACK SHOES...1947
      CAPACITIES...1947
      MISCELLANEOUS...1947
    ENGINE SPECIFICATIONS...1948
      Fuel Injection Nozzles...1948
      Fuel Injection Pump...1948
      Cylinder Head...1948
      Valves...1948
      Valve Springs...1948
      Rocker Arms...1948
      Camshaft...1948
      Cylinder...1949
      Piston Rings...1949
      Pistons...1949
      Crankshaft...1949
      Oil Pump...1949
      Engine Oil Specifications...1949
      ENGINE BOLT TORQUE...1950
      Re–Grinding The Crankshaft...1951
    FUEL, COOLANT AND LUBRICANTS...1952
    OIL SPECIFICATIONS...1952
      Description...1952
  SERVICE MANUAL REVISON...1953
    231-1...1953
    231-2...1955
    231-3...1957
    231-4...1959
    231-5...1961
    231-6...1963
    231-7...1965
    231-8...1967
    231-9...1969
    231-10...1971
6720503 (6-12) - X220 Excavator Service Manual...1973
  MAINTENANCE SAFETY...1975
  ALPHABETICAL INDEX...1977
  FOREWORD...1979
  CONTENTS...1981
    SAFETY INSTRUCTIONS...1983
    SERIAL NUMBER LOCATIONS...1984
    HYDRAULIC EXCAVATOR SERIAL NUMBER...1984
    ENGINE SERIAL NUMBER...1984
    DELIVERY REPORT...1984
    HYDRAULIC EXCAVATOR IDENTIFICATION...1985
  PREVENTIVE MAINTENANCE...1987
    SERVICE SCHEDULE...1989
    ENGINE COVER...1990
    AIR CLEANER SERVICE...1990
    FUEL SYSTEM...1991
      Fuel System Service...1991
      Fuel Filter...1992
      Removing Air From The Fuel System...1992
    ENGINE LUBRICATION SYSTEM...1993
      Engine Oil And Filter Replacement...1993
    COOLING SYSTEM...1994
      Coolant Level...1994
      Coolant Replacement...1994
    HYDRAULIC SYSTEM...1995
      Checking And Adding Fluid...1995
      Diagnostic couplers...1995
      Replacement Of The Hydraulic Filter...1996
      Hydraulic Reservoir...1996
    USING A BOOSTER BATTERY (JUMP STARTING)...1997
      Procedure...1997
    LUBRICATION OF THE EXCAVATOR...1998
      Procedure...1998
  HYDRAULIC SECTION...2001
    HYDRAULIC SCHEMATICS...2003
    HYDRAULIC SERVICE INFORMATION...2039
      Description...2039
      Checking The Relief Valves...2039
    HYDRAULIC PUMP...2041
      Removal And Installation...2041
      Parts Identification...2042
      Disassembly...2043
      Assembly...2046
    DUKES HYDRAULIC CONTROL VALVE...2048
      Removal And Installation...2048
      Parts Identification...2049
      Disassembly...2050
      Assembly...2054
      Center Housing...2058
      Disassembly and Assembly...2058
      Main Relief Valve Adjustment...2059
      Testing And Adjustment Of The Port Relief Valve...2060
    MELROE HYDRAULIC CONTROL VALVE...2061
      Removal And Installation...2061
      Disassembly...2063
      Boom Swing And Blade Sections...2065
      Auxiliary Section...2066
      Assembly...2068
      Auxiliary...2068
      Main Relief Valve Adjustment...2074
    HOLDING VALVES...2075
      Removal And Installation...2075
      Parts Identification...2075
      Disassembly...2076
      Assembly...2077
      Testing...2078
    SWING CYLINDER LOCK VALVE...2079
      Removal And Installation...2079
      Parts Identification...2079
      Disassembly...2080
      Assembly...2081
    HYDRAULIC RESERVOIR...2083
      Removal And Installation...2083
    BOOM CYLINDER...2084
      Removal And Installation...2084
    DIPPERARM CYLINDER...2085
      Removal And Installation...2085
    BUCKET CYLINDER...2086
      Removal And Installation...2086
    BLADE CYLINDER...2087
      Removal And Installation...2087
    BOOM SWING CYLINDER...2088
      Removal And Installation...2088
    HYDRAULIC CYLINDER...2089
      Disassembly...2089
        For Piston With Single Ring Groove...2091
      Assembly...2091
        For Pistons with three Ring Grooves...2092
        For Cylinders Using Piston Retaining Bolts...2096
        For Cylinders Using Piston Retaining Lock Nuts...2096
    HYDRAULIC FILTER...2098
      Removal And Installation...2098
    AUXILIARY COUPLERS...2099
      Removal And Installation...2099
    AUXILIARY FITTINGS...2099
      Removal And Installation...2099
    SHUTTLE VALVE...2100
      Parts Identification...2100
      Disassembly...2101
      Assembly...2103
  DRIVE SECTION...2105
    FLOOR PANEL...2107
      Removal And Installation...2107
    CONTROL AND STEERING LEVERS...2109
      Adjustment...2109
      Removal And Installation...2109
      Lever Disassembly And Assembly...2112
    LOCKING LEVER...2113
      Removal And Installation...2113
    CONSOLE...2115
      Removal And Installation...2115
    PEDAL...2116
      Removal And Installation...2116
    BLADE LEVER...2117
      Linkage Removal And Installation...2117
      Lever Removal And Installation...2117
    MELROE CONTROL VALVE LEVER...2118
      Removal And Installation...2118
    FINAL DRIVE...2120
      For S/N 12001–12929 (for S/N 12930 & Above SeePage 3–39)...2120
      Removal And Installation...2120
    DRIVE MOTOR...2121
      Parts Identification...2121
      Disassembly...2122
      Assembly...2129
    HYDRAULIC MOTOR...2138
      Disassembly...2138
      Assembly...2141
    FINAL DRIVE...2145
      For S/N 12930 & Above...2145
      Removal And Installation...2145
    DRIVE MOTOR...2146
      Parts Identification...2146
      Disassembly...2147
      Assembly...2157
  UPPER WORKS AND SWING SECTION...2167
    SWING MOTOR...2169
      Removing The Cross Port Reliefs...2169
      Removal And Installation...2169
      Disassembly...2170
      Assembly...2171
      Motor Timing...2172
    UPPER WORKS...2173
      Removal And Installation...2173
      Alignment Pin Procedure...2174
      Alignment Screw Procedure...2175
      Installation Of Swing Motor...2175
    CENTER SWIVEL JOINT...2176
      Removal And Installation...2176
      Disassembly And Assembly...2176
    SWING CIRCLE GEAR...2177
      Removal And Installation...2177
  MAIN FRAME AND TRACKS...2179
    ENGINE COVER...2181
      Removal And Installation...2181
    SEAT AND MOUNTING FRAME...2182
      Removal And Installation...2182
    FUEL TANK...2183
      Removal And Installation...2183
    BOOM AND DIPPERSTICK...2184
      Removal And Installation...2184
    BOOM SWING BRACKET...2186
      Removal And Installation...2186
      Bushing Removal And Installation...2187
    TRACK...2188
      Track Tension Adjustment...2188
      Removal And Installation...2189
    TRACK FRAME...2190
      Disassembly And Assembly...2190
    TRACK IDLER...2191
      Parts Identification...2191
      Disassembly...2192
      Assembly...2194
    TRACK ROLLER...2199
      Parts Identification...2199
      Disassembly...2200
      Assembly...2202
  ELECTRICAL SYSTEM...2207
    ELECTRICAL SCHEMATIC...2209
    ELECTRICAL SYSTEM...2211
      Troubleshooting...2211
      Description...2211
      Fuses...2212
      Electrical System Service...2212
    BATTERY...2213
      Checking The Battery...2213
      Removal And Installation...2213
    ALTERNATOR...2214
      Checking The Alternator Output...2214
      Belt Adjustment...2214
      Removal And Installation...2215
      Parts Identification...2215
    STARTER...2216
      Removal And Installation...2216
      Disassembly And Assembly...2217
      Cleaning And Inspection...2217
    INSTRUMENT PANEL...2218
      Removal And Installation...2218
    HORN...2219
      Removal And Installation...2219
      Horn Switch Removal And Installation...2219
  ENGINE SERVICE...2221
    ENGINE SERVICE...2223
      Troubleshooting...2223
    VALVE CLEARANCE...2224
      Adjustment...2224
    ENGINE COMPRESSION...2225
      Checking...2225
    FUEL FILTER...2226
      Removing Air From The Fuel System...2226
      Fuel Filter Removal And Installation...2226
    FUEL INJECTION PUMP...2227
      Checking The Injection Pump...2227
      Removal And Installation...2227
      Timing The Injection Pump...2229
    FUEL INJECTOR NOZZLES...2230
      Removal And Installation...2230
      Checking The Injector Nozzle...2231
    GLOW PLUGS...2232
      Removal And Installation...2232
      Checking The Glow Plug...2232
    ENGINE...2233
      Removal And Installation...2233
    SPARK ARRESTOR MUFFLER...2238
      Removal And Installation...2238
    RADIATOR...2239
      Checking The Radiator And Radiator Cap...2239
      Removal And Installation...2239
    OIL COOLER...2241
      Removal And Installation...2241
    ENGINE FLYWHEEL...2242
      Removal And Installation...2242
      Hydraulic Pump Coupler...2242
      Flywheel Ring Gear...2242
    CYLINDER HEAD...2243
      Removal Of The Cylinder Head...2243
      Disassembly Of The Cylinder Head...2244
      Servicing The Cylinder Head And Valves...2245
      Checking Valve Springs...2246
      Checking Rocker Arm And Shaft...2247
      Assembling The Cylinder Head...2247
      Installing The Cylinder Head...2247
    TIMING GEAR COVER...2249
      Removal And Installation...2249
    TIMING GEAR, CAMSHAFT AND OIL PUMP...2251
      Removal And Installation...2251
      Oil Pump Service...2253
      Servicing The Camshaft...2254
    CRANKSHAFT AND PISTONS...2256
      Removal And Installation...2256
      Crankshaft Service...2258
      Servicing The Connecting Rods And Pistons...2259
    CYLINDER LINERS...2261
      Checking The Cylinder Liners...2261
      Cylinder Liner Installation...2261
    WATER PUMP...2262
      Removal And Installation...2262
      Disassembly And Assembly...2262
  TECHNICAL DATA...2263
    HYDRAULIC EXCAVATOR SPECIFICATIONS...2265
      Machine Dimensions...2265
      Lifting Capacity With Blade Off Ground...2266
      PERFORMANCE & OPERATION...2267
      ENGINE...2267
      HYDRAULIC SYSTEM...2267
      SWING SYSTEM...2267
      HYDRAULIC CYLINDERS...2267
      DRIVE SYSTEM...2267
      BRAKES...2268
      UNDERCARRIAGE...2268
      TRACK...2268
      CAPACITIES...2268
      DIGGING FORCE...2268
    ENGINE SPECIFICATIONS (KUBOTA)...2269
      Engine...2269
      Fuel Injector Nozzles...2269
      Fuel Injection Pump...2269
      Cylinder Head...2269
      Valves...2269
      Valve Springs...2269
      Rocker Arms...2269
      Camshaft...2270
      Cylinders...2270
      Piston Rings...2270
      Pistons...2270
      Crankshaft...2270
      Oil Pump...2271
      Thermostat...2271
      Engine Torque...2272
      Re–Grinding The Crankshaft...2273
    FUEL, COOLANT AND LUBRICANTS...2274
      Chart...2274
    ENGINE OIL SPECIFICATIONS...2274
      Description...2274
      Propylene Glycol (Factory Installed)...2274
  SERVICE MANUAL REVISION...2275
    220-1...2275
    220-2...2277
    220-3...2279
    220-4...2281
    220-5...2283
    220-6...2285
    220-7...2287
    220-8...2289
    220-9...2292
6720503 (6-90) - X220 Excavator Service Manual...2293
  MAINTENANCE SAFETY...2295
  ALPHABETICAL INDEX...2297
  FOREWORD...2299
  CONTENTS...2301
    SAFETY INSTRUCTIONS...2303
    SERIAL NUMBER LOCATIONS...2304
    HYDRAULIC EXCAVATOR SERIAL NUMBER...2304
    ENGINE SERIAL NUMBER...2304
    DELIVERY REPORT...2304
    HYDRAULIC EXCAVATOR IDENTIFICATION...2305
  PREVENTIVE MAINTENANCE...2307
    SERVICE SCHEDULE...2309
    ENGINE COVER...2310
    AIR CLEANER SERVICE...2310
    FUEL SYSTEM...2311
      Fuel System Service...2311
      Fuel Filter...2312
      Removing Air From The Fuel System...2312
    ENGINE LUBRICATION SYSTEM...2313
      Engine Oil And Filter Replacement...2313
    COOLING SYSTEM...2314
      Coolant Level...2314
      Coolant Replacement...2314
    HYDRAULIC SYSTEM...2315
      Checking And Adding Fluid...2315
      Diagnostic couplers...2315
      Replacement Of The Hydraulic Filter...2316
      Hydraulic Reservoir...2316
    USING A BOOSTER BATTERY (JUMP STARTING)...2317
      Procedure...2317
    LUBRICATION OF THE EXCAVATOR...2318
      Procedure...2318
  HYDRAULIC SECTION...2321
    HYDRAULIC SCHEMATICS...2323
    HYDRAULIC SERVICE INFORMATION...2347
      Description...2347
      Checking The Relief Valves...2347
    HYDRAULIC PUMP...2349
      Removal And Installation...2349
      Parts Identification...2350
      Disassembly...2351
      Assembly...2354
    DUKES HYDRAULIC CONTROL VALVE...2356
      Removal And Installation...2356
      Parts Identification...2357
      Disassembly...2358
      Assembly...2362
      Center Housing...2366
      Disassembly and Assembly...2366
      Main Relief Valve Adjustment...2367
      Testing And Adjustment Of The Port Relief Valve...2368
    MELROE HYDRAULIC CONTROL VALVE...2369
      Removal And Installation...2369
      Disassembly...2371
      Boom Swing And Blade Sections...2373
      Auxiliary Section...2374
      Assembly...2376
      Auxiliary...2376
      Main Relief Valve Adjustment...2382
    HOLDING VALVES...2383
      Removal And Installation...2383
      Parts Identification...2383
      Disassembly...2384
      Assembly...2385
      Testing...2386
    SWING CYLINDER LOCK VALVE...2387
      Removal And Installation...2387
      Parts Identification...2387
      Disassembly...2388
      Assembly...2389
    HYDRAULIC RESERVOIR...2391
      Removal And Installation...2391
    BOOM CYLINDER...2392
      Removal And Installation...2392
    DIPPERARM CYLINDER...2393
      Removal And Installation...2393
    BUCKET CYLINDER...2394
      Removal And Installation...2394
    BLADE CYLINDER...2395
      Removal And Installation...2395
    BOOM SWING CYLINDER...2396
      Removal And Installation...2396
    HYDRAULIC CYLINDER...2397
      Disassembly...2397
        For Piston With Single Ring Groove...2399
      Assembly...2399
        For Pistons with three Ring Grooves...2400
        For Cylinders Using Piston Retaining Bolts...2404
        For Cylinders Using Piston Retaining Lock Nuts...2404
    HYDRAULIC FILTER...2406
      Removal And Installation...2406
    AUXILIARY COUPLERS...2407
      Removal And Installation...2407
    AUXILIARY FITTINGS...2407
      Removal And Installation...2407
    SHUTTLE VALVE...2408
      Parts Identification...2408
      Disassembly...2409
      Assembly...2411
  DRIVE SECTION...2413
    FLOOR PANEL...2415
      Removal And Installation...2415
    CONTROL AND STEERING LEVERS...2417
      Adjustment...2417
      Removal And Installation...2417
      Lever Disassembly And Assembly...2420
    LOCKING LEVER...2421
      Removal And Installation...2421
    CONSOLE...2423
      Removal And Installation...2423
    PEDAL...2424
      Removal And Installation...2424
    BLADE LEVER...2425
      Linkage Removal And Installation...2425
      Lever Removal And Installation...2425
    MELROE CONTROL VALVE LEVER...2426
      Removal And Installation...2426
    FINAL DRIVE...2428
      For S/N 12001–12929 (for S/N 12930 & Above SeePage 3–39)...2428
      Removal And Installation...2428
    DRIVE MOTOR...2429
      Parts Identification...2429
      Disassembly...2430
      Assembly...2437
    HYDRAULIC MOTOR...2446
      Disassembly...2446
      Assembly...2449
    FINAL DRIVE...2453
      For S/N 12930 & Above...2453
      Removal And Installation...2453
    DRIVE MOTOR...2454
      Parts Identification...2454
      Disassembly...2455
      Assembly...2465
  UPPER WORKS AND SWING SECTION...2475
    SWING MOTOR...2477
      Removing The Cross Port Reliefs...2477
      Removal And Installation...2477
      Disassembly...2478
      Assembly...2479
      Motor Timing...2480
    UPPER WORKS...2481
      Removal And Installation...2481
      Alignment Pin Procedure...2482
      Alignment Screw Procedure...2483
      Installation Of Swing Motor...2483
    CENTER SWIVEL JOINT...2484
      Removal And Installation...2484
      Disassembly And Assembly...2484
    SWING CIRCLE GEAR...2485
      Removal And Installation...2485
  MAIN FRAME AND TRACKS...2487
    ENGINE COVER...2489
      Removal And Installation...2489
    SEAT AND MOUNTING FRAME...2490
      Removal And Installation...2490
    FUEL TANK...2491
      Removal And Installation...2491
    BOOM AND DIPPERSTICK...2492
      Removal And Installation...2492
    BOOM SWING BRACKET...2494
      Removal And Installation...2494
      Bushing Removal And Installation...2495
    TRACK...2496
      Track Tension Adjustment...2496
      Removal And Installation...2497
    TRACK FRAME...2498
      Disassembly And Assembly...2498
    TRACK IDLER...2499
      Parts Identification...2499
      Disassembly...2500
      Assembly...2502
    TRACK ROLLER...2507
      Parts Identification...2507
      Disassembly...2508
      Assembly...2510
  ELECTRICAL SYSTEM...2515
    ELECTRICAL SCHEMATIC...2517
    ELECTRICAL SYSTEM...2518
      Troubleshooting...2518
      Description...2518
      Fuses...2519
      Electrical System Service...2519
    BATTERY...2520
      Checking The Battery...2520
      Removal And Installation...2520
    ALTERNATOR...2521
      Checking The Alternator Output...2521
      Belt Adjustment...2521
      Removal And Installation...2522
      Parts Identification...2522
    STARTER...2523
      Removal And Installation...2523
      Disassembly And Assembly...2524
      Cleaning And Inspection...2524
    INSTRUMENT PANEL...2525
      Removal And Installation...2525
    HORN...2526
      Removal And Installation...2526
      Horn Switch Removal And Installation...2526
  ENGINE SERVICE...2528
    ENGINE SERVICE...2530
      Troubleshooting...2530
    VALVE CLEARANCE...2531
      Adjustment...2531
    ENGINE COMPRESSION...2532
      Checking...2532
    FUEL FILTER...2533
      Removing Air From The Fuel System...2533
      Fuel Filter Removal And Installation...2533
    FUEL INJECTION PUMP...2534
      Checking The Injection Pump...2534
      Removal And Installation...2534
      Timing The Injection Pump...2536
    FUEL INJECTOR NOZZLES...2537
      Removal And Installation...2537
      Checking The Injector Nozzle...2538
    GLOW PLUGS...2539
      Removal And Installation...2539
      Checking The Glow Plug...2539
    ENGINE...2540
      Removal And Installation...2540
    SPARK ARRESTOR MUFFLER...2545
      Removal And Installation...2545
    RADIATOR...2546
      Checking The Radiator And Radiator Cap...2546
      Removal And Installation...2546
    OIL COOLER...2548
      Removal And Installation...2548
    ENGINE FLYWHEEL...2549
      Removal And Installation...2549
      Hydraulic Pump Coupler...2549
      Flywheel Ring Gear...2549
    CYLINDER HEAD...2550
      Removal Of The Cylinder Head...2550
      Disassembly Of The Cylinder Head...2551
      Servicing The Cylinder Head And Valves...2552
      Checking Valve Springs...2553
      Checking Rocker Arm And Shaft...2554
      Assembling The Cylinder Head...2554
      Installing The Cylinder Head...2554
    TIMING GEAR COVER...2556
      Removal And Installation...2556
    TIMING GEAR, CAMSHAFT AND OIL PUMP...2558
      Removal And Installation...2558
      Oil Pump Service...2560
      Servicing The Camshaft...2561
    CRANKSHAFT AND PISTONS...2563
      Removal And Installation...2563
      Crankshaft Service...2565
      Servicing The Connecting Rods And Pistons...2566
    CYLINDER LINERS...2568
      Checking The Cylinder Liners...2568
      Cylinder Liner Installation...2568
    WATER PUMP...2569
      Removal And Installation...2569
      Disassembly And Assembly...2569
  TECHNICAL DATA...2570
    HYDRAULIC EXCAVATOR SPECIFICATIONS...2572
      Machine Dimensions...2572
      Lifting Capacity With Blade Off Ground...2573
      PERFORMANCE & OPERATION...2574
      ENGINE...2574
      HYDRAULIC SYSTEM...2574
      SWING SYSTEM...2574
      HYDRAULIC CYLINDERS...2574
      DRIVE SYSTEM...2574
      BRAKES...2575
      UNDERCARRIAGE...2575
      TRACK...2575
      CAPACITIES...2575
      DIGGING FORCE...2575
    ENGINE SPECIFICATIONS (KUBOTA)...2576
      Engine...2576
      Fuel Injector Nozzles...2576
      Fuel Injection Pump...2576
      Cylinder Head...2576
      Valves...2576
      Valve Springs...2576
      Rocker Arms...2576
      Camshaft...2577
      Cylinders...2577
      Piston Rings...2577
      Pistons...2577
      Crankshaft...2577
      Oil Pump...2578
      Thermostat...2578
      Engine Torque...2579
      Re–Grinding The Crankshaft...2580
    FUEL, COOLANT AND LUBRICANTS...2581
      Chart...2581
    ENGINE OIL SPECIFICATIONS...2581
      Description...2581
      Propylene Glycol (Factory Installed)...2581
  SERVICE MANUAL REVISION...2582
    220-1...2582
    220-2...2584
    220-3...2586
    220-4...2588
    220-5...2590
    220-6...2592
    220-7...2594
    220-8...2596
6720537 (9-98) - X 225 Excavator Operation & Maintenance Manual...2598
  OPERATOR SAFETY WARNINGS...2599
  CONTENTS...2600
    REGULAR MAINTENANCE ITEMS...2601
    FOREWORD...2602
    SERIAL NUMBER LOCATIONS...2604
    HYDRAULIC EXCAVATOR SERIAL NUMBER...2604
    ENGINE SERIAL NUMBER...2604
    DELIVERY REPORT...2604
    HYDRAULIC EXCAVATOR IDENTIFICATION...2605
  SAFETY...2606
    SAFETY INSTRUCTIONS...2608
    FIRE PREVENTION...2610
    MACHINE SIGNS (DECALS)...2611
  OPERATING INSTRUCTIONS...2614
    GETTING ON AND OFF THE MACHINE...2616
    SEAT...2617
    CONTROL CONSOLE LEVER LOCK...2617
    INSTRUMENT PANEL...2618
    LIGHT SWITCH...2618
    CONTROL LEVERS...2619
      Operation Of Left Control Lever (ISO)...2619
      Operation Of Right Control Lever (ISO)...2619
      Operation Of Left Control Lever (STANDARD)...2620
      Operation Of Right Control Lever (STANDARD)...2620
    SPEED CONTROL LEVER...2621
    HORN BUTTON...2621
    SWING LOCKING LEVER...2621
    STEERING LEVERS/FOOT PEDALS...2622
      Forward And Reverse Travel...2622
      Turning...2622
      Making A Counter–Rotation Turn...2622
    BOOM SWING PEDAL...2623
    AUXILIARY OPERATION PEDAL LOCK/FOOTREST...2623
    BLADE CONTROL LEVER...2623
    DAILY INSPECTION...2624
    STARTING/STOPPING THE ENGINE...2624
      Normal Starting Procedure (With Engine Warm)...2624
      Cold Temperature Starting Condition...2625
    OPERATING PROCEDURE...2626
      Breaking In A New Machine...2626
      General Operation Suggestions...2626
      Operating On Slopes...2627
      Operating In Water...2628
    PARKING THE HYDRAULIC EXCAVATOR...2628
    TRANSPORTING THE HYDRAULIC EXCAVATOR...2629
    LIFTING THE EXCAVATOR...2630
    BUCKET...2631
      Removal...2631
      Installation...2631
  PREVENTIVE MAINTENANCE...2632
    MAINTENANCE SAFETY...2633
    SERVICE SCHEDULE...2634
    ENGINE COVER...2635
    AIR CLEANER SERVICE...2635
    FUEL SYSTEM...2637
      Fuel Specifications...2637
      Fuel System Service...2637
      Fuel Filters (S/N 12001–12647)...2638
      Removing Air From The Fuel System (S/N 12001–12647)...2638
      Fuel Filters (S/N 12548 & Above)...2639
      In–line Fuel Filter (If equipped)...2639
      Removing Air From The Fuel System (S/N 12538 & Above)...2639
    ENGINE LUBRICATION SYSTEM...2640
      Engine Oil And Filter Replacement...2640
    COOLING SYSTEM...2641
      Coolant Level...2641
      Coolant Replacement...2641
    ALTERNATOR/FAN BELT ADJUSTMENT...2642
    ELECTRICAL SYSTEM...2643
      Fuses...2643
      Service The Electrical System...2643
      Using A Booster Battery (Jump Starting)...2644
      Removal And Installation Of The Battery...2645
    HYDRAULIC SYSTEM...2646
      Checking And Adding Fluid...2646
      Replacement Of The Hydraulic Filter...2646
      Hydraulic Reservoir...2647
      Diagnostic Couplers...2647
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...2648
    SWING MOTOR GEAR REDUCTION...2650
    FINAL DRIVE CASE...2650
      Checking Oil Level...2650
      Draining Final Drive Case...2650
    TRACK TENSION...2651
      Adjustment...2651
      Rubber Tracks...2651
      Steel Tracks...2652
  SPECIFICATIONS...2654
    HYDRAULIC EXCAVATOR SPECIFICATIONS...2656
      OPERATIONS & PERFORMANCE...2658
      ENGINE...2658
      HYDRAULIC SYSTEM...2658
      SWING SYSTEM...2658
      HYDRAULIC CYLINDERS...2659
      DRIVE SYSTEM...2659
      BRAKES...2659
      UNDERCARRIAGE...2659
      TRACK...2659
      CAPACITIES...2659
      MISCELLANEOUS...2659
      Machine Dimensions...2656
      Lifting Capacity With Blade Off Ground (Model 225 with Canopy)...2657
      Lifting Capacity With Blade Off Ground (Model 225 with Cab)...2657
    FUEL, COOLANT AND LUBRICANTS...2660
    ENGINE OIL SPECIFICATIONS...2660
      Description...2660
    BUCKET SPECIFICATIONS...2661
    ADDITIONAL PUBLICATIONS...2662
  WARRANTY...2663
6720874 (1-91) - X 225 Excavator Service Manual...2664
  MAINTENANCE SAFETY...2666
  CONTENTS...2668
    FOREWORD...2670
    SAFETY INSTRUCTIONS...2672
    SERIAL NUMBER LOCATIONS...2674
    HYDRAULIC EXCAVATOR SERIAL NUMBER...2674
    ENGINE SERIAL NUMBER...2674
    DELIVERY REPORT...2674
    HYDRAULIC EXCAVATOR IDENTIFICATION...2675
  PREVENTIVE MAINTENANCE...2676
    SERVICE SCHEDULE...2678
    ENGINE COVER...2679
      Procedure...2679
    AIR CLEANER SERVICE...2679
      Replacing the Filter Element...2679
    FUEL SYSTEM...2680
      Fuel Specifications...2680
      Fuel System Service...2680
      Fuel Filters (S/N 12648 & Above)...2681
    ENGINE LUBRICATION SYSTEM...2682
      Checking the Engine Oil...2682
      Engine Oil and Filter Replacement...2682
    COOLING SYSTEM...2683
      Coolant Level...2683
      Coolant Replacement...2683
    HYDRAULIC SYSTEM...2684
      Checking and Adding Fluid...2684
      Replacement of the Hydraulic Filter...2684
      Hydraulic Reservoir...2685
    USING A BOOSTER BATTERY (Jump Starting)...2686
      Procedure...2686
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...2687
      Procedure...2687
    FINAL DRIVE CASE...2689
      Checking Oil Level...2689
      Draining Final Drive Case...2689
      Untitled...2690
  HYDRAULIC SECTION...2690
    HYDRAULIC SCHEMATICS...2692
    HYDRAULIC SERVICE INFORMATION...2703
      Description...2703
      Checking the Relief Valves...2703
    HYDRAULIC PUMP...2705
      Disassembly & Assembly...2705
      Parts Identification...2705
    HYDRAULIC CONTROL VALVE (6 Spool)...2710
      Removal and Installation...2710
      Parts Identification...2711
      Disassembly and Assembly...2712
        Disassembly...2712
        Inlet Section (R.H. and L.H. Travel) Disassembly...2713
        Inlet Section (R.H. and L.H. Travel) Assembly...2714
        Valve Sections (Boom, Bucket & Arm) Disassembly...2715
        Valve Sections (Boom, Bucket & Arm) Assembly...2716
        Valve Sections (Auxiliary) Disassembly...2717
        Valve Sections (Auxiliary) Assembly...2718
      Port Relief Valve...2720
        Disassembly...2720
        Assembly...2720
        Adjustment Procedure...2720
      Main Relief Valve...2722
        Disassembly...2722
        Assembly...2722
        Adjustment Procedure...2723
    HYDRAULIC CONTROL VALVE (3 Spool)...2725
      Removal and Installation...2725
      Parts Identification...2726
      Disassembly...2727
      Inlet Section (Housing Swing)...2728
        Disassembly...2728
        Assembly...2728
      End Cover (Boom Swing) and Valve Section (Blade) Disassembly...2729
      End Cover (Boom Swing) and Valve Section (Blade) Assembly...2731
      Load Check Block...2733
        Disassembly...2733
        Assembly...2733
      Build–Up Valve...2735
        Assembly...2735
      Main Relief Valve...2736
        Disassembly...2736
        Assembly...2736
      Main Relief Valve Adjustment Procedure...2737
    PRESSURE REDUCING VALVE WITHACCUMULATOR...2739
      Removal and Installation...2739
      Parts Identification...2739
    ACCUMULATOR / VALVE...2740
      Disassembly...2740
      Assembly...2744
      Setting the Safety Relief Valve...2748
    ACCUMULATOR...2749
      Charging...2749
    PORT BLOCK...2750
      Removal and Installation...2750
    OIL COOLER...2751
      Removal and Installation...2751
    HYDRAULIC RESERVOIR...2752
      Removal and Installation...2752
    HYDRAULIC FILTER ASSEMBLY...2753
      Removal and Installation...2753
    BOOM CYLINDER...2754
      Removal and Installation...2754
    BOOM DROP VALVE (NORDIC–OPTION)...2754
      Removal and Installation...2754
    ARM CYLINDER...2755
      Removal and Installation...2755
    BUCKET CYLINDER...2756
      Removal and Installation...2756
    BLADE CYLINDER...2757
      Removal and Installation...2757
    BOOM SWING CYLINDER...2759
      Removal and Installation...2759
    HYDRAULIC CYLINDER...2760
      Disassembly...2760
      Assembly...2762
    JOYSTICK CONTROL CHANGE...2767
  DRIVE SYSTEM...2769
    LEFT CONSOLE...2771
      Lockout Valve Removal and Installation...2771
      Cylinder Removal and Installation...2771
      Removal and Installation...2772
    LEFT JOYSTICK...2773
      Removal and Installation...2773
      Parts Identification...2773
    JOYSTICK...2774
      Disassembly and Assembly...2774
    CONTROL LEVERS...2778
      Removal and Installation...2778
      Throttle Lever...2779
      Blade Lever...2780
    RIGHT CONSOLE...2781
      Removal and Installation...2781
      Parts Identification...2782
    FOOT PEDAL AND STEERING LEVERS...2783
      Removal and Installation...2783
      Bushing Removal and Installation...2784
    FINAL DRIVE...2785
      Removal and Installation...2785
      Parts Identification...2786
    DRIVE MOTOR...2789
      Disassembly...2789
      Assembly...2801
    FINAL DRIVE CASE...2812
      Check Oil Level...2812
      Draining Final Drive Case...2812
  UPPER WORKS AND SWING SYSTEM...2813
    SWING MOTOR...2815
      Removal and Installation...2815
      Parts Identification...2816
    SWING GEAR BOX ASSEMBLY(WITH OR WITHOUT BRAKES)...2817
      Disassembly...2817
      Assembly...2826
    SWING GEAR BRAKE (NORDIC OPTION)...2840
      Solenoid Removal and Installation...2840
    UPPER WORKS AND SWING CIRCLE GEAR...2841
      Removal and Installation...2841
      Swing Bearing Removal...2843
      Swing Bearing Installation...2844
      Alignment Pins (Not Threaded)...2846
    CENTER SWIVEL JOINT...2847
      Removal and Installation (through upper access removal)...2847
      Parts Identification...2849
  MAIN FRAME AND TRACKS...2851
    ENGINE COVER...2853
      Removal and Installation...2853
    SEAT AND MOUNTING FRAME...2853
      Removal and Installation...2853
    NORDIC SEAT AND MOUNTING FRAME (OPTIONAL)...2854
      Removal and Installation...2854
    CENTER FLOOR PANEL...2854
      Removal and Installation...2854
    SWING MOTOR COVER...2855
      Removal and Installation...2855
    REAR FLOOR PANEL...2855
      Removal and Installation...2855
    INSPECTION COVER...2856
      Removal and Installation...2856
    TOOL BOX...2856
      Removal and Installation...2856
    FUEL TANK...2857
      Removal and Installation...2857
    BUCKET...2858
      Removal and Installation...2858
    ARM...2859
      Removal and Installation...2859
    BOOM...2859
      Removal and Installation...2859
    BOOM SWING BRACKET...2861
      Removal and Installation...2861
    BLADE...2862
      Removal and Installation...2862
    TRACK...2863
      Track Tension Adjustment...2863
      Removal and Installation...2864
    TRACK FRAME...2865
      Disassembly and Assembly...2865
    TRACK IDLER...2867
      Parts Identification...2867
      Disassembly...2868
      Assembly...2870
    TRACK IDLER...2874
      Parts Identification...2874
      Disassembly...2875
      Assembly...2877
    TRACK ROLLER...2881
      Parts Identification...2881
      Disassembly...2882
      Assembly...2884
      Parts Identification...2888
      Disassembly...2889
      Assembly...2891
      ROPS...2895
      Removal and Installation...2895
    NORDIC CAB (OPTIONAL)...2895
      Removal and Installation...2895
    ROPS WINDOW...2896
      Front Window Removal...2896
      Side Window Removal...2897
      Installation...2897
    ELECTRICAL SYSTEM...2899
    ELECTRICAL SCHEMATICS...2901
    TROUBLESHOOTING...2903
    ELECTRICAL SYSTEM...2903
      Description...2903
      Fuses...2904
      Electrical System Service...2904
    BATTERY...2905
      Checking the Battery...2905
      Removal and Installation...2905
    ALTERNATOR...2906
      Belt Adjustment...2906
      Removal and Installation...2906
    STARTER...2907
      Removal and Installation...2907
      Disassembly and Assembly...2908
      Cleaning and Inspection...2908
    FUEL LEVEL SENDER...2909
      Removal and Installation...2909
      Checking...2909
    INSTRUMENT PANEL...2910
      Removal and Installation...2910
    DOME LIGHT...2911
      Removal and Installation...2911
    CAB CONTROL PANEL...2911
      Removal and Installation...2911
    FRONT LIGHTS...2912
      Removal and Installation...2912
      Lamp Replacement...2912
    CONSOLE SWITCHES...2913
      Removal and Installation...2913
    WINDSHIELD WIPER...2914
      Removal and Installation...2914
    WINDSHIELD WASHER (NORDIC OPTION)...2915
      Removal and Installation...2915
      Hose Removal...2915
    ENGINE COVER LIGHT (NORDIC OPTION)...2916
      Removal and Installation...2916
  ENGINE SERVICE...2917
    TROUBLESHOOTING...2919
    VALVE CLEARANCE...2920
      Adjustment...2920
    ENGINE COMPRESSION...2921
      Checking...2921
    ELECTRIC FUEL PUMP...2922
      Removal and Installation...2922
      In–Line Filter (Used on Early Model Excavators Only)...2922
    FUEL FILTER...2923
      Final Filter (S/N 12001–12647)...2923
      Fuel Filter (S/N 12648 & Above) (With Water Drain Valve)...2923
    FUEL INJECTION PUMP...2924
      Checking the Injection Pump...2924
      Removal and Installation...2925
      Timing the Injection Pump...2926
    FUEL INJECTION NOZZLES...2927
      Removal and Installation...2927
    GLOW PLUGS...2929
      Removal and Installation...2929
      Checking the Glow Plug...2929
    RADIATOR...2930
      Removal and Installation...2930
    FAN SHIELD (NORDIC OPTION)...2931
      Removal and Installation...2931
    MUFFLER...2932
      Removal and Installation...2932
    AIR CLEANER...2933
      Removal and Installation...2933
    ENGINE...2934
      Removal and Installation...2934
    ENGINE FLYWHEEL...2935
      Removal and Installation...2935
      Flywheel Ring Gear...2937
    CYLINDER HEAD...2938
      Removing the Cylinder Head...2938
      Disassembly of the Cylinder Head...2939
      Servicing the Cylinder Head and Valves...2940
      Checking Valve Springs...2941
      Checking Rocker Arm and Shaft...2942
      Assembling the Cylinder Head...2942
      Installing the Cylinder Head...2942
    TIMING GEAR COVER...2944
      Removal and Installation...2944
    TIMING GEAR, CAMSHAFT AND OIL PUMP...2946
      Removal and Installation...2946
      Oil Pump Service...2948
      Servicing the Camshaft...2949
    CRANKSHAFT AND PISTONS...2951
      Removal and Installation...2951
      Crankshaft Service...2953
      Servicing the Connecting Rods and Pistons...2954
    CYLINDER LINERS...2956
      Checking the Cylinder Liners...2956
      Cylinder Liner Installation...2956
    WATER PUMP...2957
      Removal and Installation...2957
      Disassembly and Assembly...2957
  SPECIFICATIONS...2959
    HYDRAULIC EXCAVATOR SPECIFICATIONS...2961
      Machine Dimensions...2961
      Lifting Capacity With Blade Off Ground...2962
      OPERATION & PERFORMANCE...2962
      ENGINE...2962
      HYDRAULIC SYSTEM...2963
      SWING SYSTEM...2963
      HYDRAULIC CYLINDERS...2963
      DRIVE SYSTEM...2963
      UNDERCARRIAGE...2963
      TRACK...2963
      CAPACITIES...2963
      DIGGING FORCE...2963
    ENGINE SPECIFICATIONS...2964
      Fuel Injection Nozzles...2964
      Fuel Injection Pump...2964
      Cylinder Head...2964
      Valves...2964
      Valve Springs...2964
      Rocker Arms...2964
      Camshaft...2964
      Cylinders...2965
      Piston Rings...2965
      Pistons...2965
      Crankshaft...2965
      Oil Pump...2965
      Engine Oil...2965
      Specifications...2965
      ENGINE TORQUE...2966
      Re–Grinding The Crankshaft...2967
    FUEL, COOLANT AND LUBRICANTS...2968
    OIL SPECIFICATIONS...2968
      Description...2968
  SERVICE MANUAL REVISION...2969
    225-1...2969
    225-2...2971
    225-3...2973
    225-4...2975
    225-5...2977
    225-6...2979
    225-7...2981
    225-8...2983
    225-9...2985
    225-10...2987
6720874 (6-12) - X 225 Excavator Service Manual...2989
  MAINTENANCE SAFETY...2991
  CONTENTS...2993
    FOREWORD...2995
    SAFETY INSTRUCTIONS...2997
    SERIAL NUMBER LOCATIONS...2999
    HYDRAULIC EXCAVATOR SERIAL NUMBER...2999
    ENGINE SERIAL NUMBER...2999
    DELIVERY REPORT...2999
    HYDRAULIC EXCAVATOR IDENTIFICATION...3000
  PREVENTIVE MAINTENANCE...3001
    SERVICE SCHEDULE...3003
    ENGINE COVER...3004
      Procedure...3004
    AIR CLEANER SERVICE...3004
      Replacing the Filter Element...3004
    FUEL SYSTEM...3005
      Fuel Specifications...3005
      Fuel System Service...3005
      Fuel Filters (S/N 12648 & Above)...3006
    ENGINE LUBRICATION SYSTEM...3007
      Checking the Engine Oil...3007
      Engine Oil and Filter Replacement...3007
    COOLING SYSTEM...3008
      Coolant Level...3008
      Coolant Replacement...3008
    HYDRAULIC SYSTEM...3009
      Checking and Adding Fluid...3009
      Replacement of the Hydraulic Filter...3009
      Hydraulic Reservoir...3010
    USING A BOOSTER BATTERY (Jump Starting)...3011
      Procedure...3011
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...3012
      Procedure...3012
    FINAL DRIVE CASE...3014
      Checking Oil Level...3014
      Draining Final Drive Case...3014
      Untitled...3015
  HYDRAULIC SECTION...3015
    HYDRAULIC SCHEMATICS...3017
    HYDRAULIC SERVICE INFORMATION...3029
      Description...3029
      Checking the Relief Valves...3029
    HYDRAULIC PUMP...3031
      Disassembly & Assembly...3031
      Parts Identification...3031
    HYDRAULIC CONTROL VALVE (6 Spool)...3036
      Removal and Installation...3036
      Parts Identification...3037
      Disassembly and Assembly...3038
        Disassembly...3038
        Inlet Section (R.H. and L.H. Travel) Disassembly...3039
        Inlet Section (R.H. and L.H. Travel) Assembly...3040
        Valve Sections (Boom, Bucket & Arm) Disassembly...3041
        Valve Sections (Boom, Bucket & Arm) Assembly...3042
        Valve Sections (Auxiliary) Disassembly...3043
        Valve Sections (Auxiliary) Assembly...3044
      Port Relief Valve...3046
        Disassembly...3046
        Assembly...3046
        Adjustment Procedure...3046
      Main Relief Valve...3048
        Disassembly...3048
        Assembly...3048
        Adjustment Procedure...3049
    HYDRAULIC CONTROL VALVE (3 Spool)...3051
      Removal and Installation...3051
      Parts Identification...3052
      Disassembly...3053
      Inlet Section (Housing Swing)...3054
        Disassembly...3054
        Assembly...3054
      End Cover (Boom Swing) and Valve Section (Blade) Disassembly...3055
      End Cover (Boom Swing) and Valve Section (Blade) Assembly...3057
      Load Check Block...3059
        Disassembly...3059
        Assembly...3059
      Build–Up Valve...3061
        Assembly...3061
      Main Relief Valve...3062
        Disassembly...3062
        Assembly...3062
      Main Relief Valve Adjustment Procedure...3063
    PRESSURE REDUCING VALVE WITHACCUMULATOR...3065
      Removal and Installation...3065
      Parts Identification...3065
    ACCUMULATOR / VALVE...3066
      Disassembly...3066
      Assembly...3070
      Setting the Safety Relief Valve...3074
    ACCUMULATOR...3075
      Charging...3075
    PORT BLOCK...3076
      Removal and Installation...3076
    OIL COOLER...3077
      Removal and Installation...3077
    HYDRAULIC RESERVOIR...3078
      Removal and Installation...3078
    HYDRAULIC FILTER ASSEMBLY...3079
      Removal and Installation...3079
    BOOM CYLINDER...3080
      Removal and Installation...3080
    BOOM DROP VALVE (NORDIC–OPTION)...3080
      Removal and Installation...3080
    ARM CYLINDER...3081
      Removal and Installation...3081
    BUCKET CYLINDER...3082
      Removal and Installation...3082
    BLADE CYLINDER...3083
      Removal and Installation...3083
    BOOM SWING CYLINDER...3085
      Removal and Installation...3085
    HYDRAULIC CYLINDER...3086
      Disassembly...3086
      Assembly...3088
    JOYSTICK CONTROL CHANGE...3093
  DRIVE SYSTEM...3095
    LEFT CONSOLE...3097
      Lockout Valve Removal and Installation...3097
      Cylinder Removal and Installation...3097
      Removal and Installation...3098
    LEFT JOYSTICK...3099
      Removal and Installation...3099
      Parts Identification...3099
    JOYSTICK...3100
      Disassembly and Assembly...3100
    CONTROL LEVERS...3104
      Removal and Installation...3104
      Throttle Lever...3105
      Blade Lever...3106
    RIGHT CONSOLE...3107
      Removal and Installation...3107
      Parts Identification...3108
    FOOT PEDAL AND STEERING LEVERS...3109
      Removal and Installation...3109
      Bushing Removal and Installation...3110
    FINAL DRIVE...3111
      Removal and Installation...3111
      Parts Identification...3112
    DRIVE MOTOR...3115
      Disassembly...3115
      Assembly...3127
    FINAL DRIVE CASE...3138
      Check Oil Level...3138
      Draining Final Drive Case...3138
  UPPER WORKS AND SWING SYSTEM...3139
    SWING MOTOR...3141
      Removal and Installation...3141
      Parts Identification...3142
    SWING GEAR BOX ASSEMBLY(WITH OR WITHOUT BRAKES)...3143
      Disassembly...3143
      Assembly...3152
    SWING GEAR BRAKE (NORDIC OPTION)...3166
      Solenoid Removal and Installation...3166
    UPPER WORKS AND SWING CIRCLE GEAR...3167
      Removal and Installation...3167
      Swing Bearing Removal...3169
      Swing Bearing Installation...3170
      Alignment Pins (Not Threaded)...3172
    CENTER SWIVEL JOINT...3173
      Removal and Installation (through upper access removal)...3173
      Parts Identification...3175
  MAIN FRAME AND TRACKS...3177
    ENGINE COVER...3179
      Removal and Installation...3179
    SEAT AND MOUNTING FRAME...3179
      Removal and Installation...3179
    NORDIC SEAT AND MOUNTING FRAME (OPTIONAL)...3180
      Removal and Installation...3180
    CENTER FLOOR PANEL...3180
      Removal and Installation...3180
    SWING MOTOR COVER...3181
      Removal and Installation...3181
    REAR FLOOR PANEL...3181
      Removal and Installation...3181
    INSPECTION COVER...3182
      Removal and Installation...3182
    TOOL BOX...3182
      Removal and Installation...3182
    FUEL TANK...3183
      Removal and Installation...3183
    BUCKET...3184
      Removal and Installation...3184
    ARM...3185
      Removal and Installation...3185
    BOOM...3185
      Removal and Installation...3185
    BOOM SWING BRACKET...3187
      Removal and Installation...3187
    BLADE...3188
      Removal and Installation...3188
    TRACK...3189
      Track Tension Adjustment...3189
      Removal and Installation...3190
    TRACK FRAME...3191
      Disassembly and Assembly...3191
    TRACK IDLER...3193
      Parts Identification...3193
      Disassembly...3194
      Assembly...3196
    TRACK IDLER...3200
      Parts Identification...3200
      Disassembly...3201
      Assembly...3203
    TRACK ROLLER...3207
      Parts Identification...3207
      Disassembly...3208
      Assembly...3210
      Parts Identification...3214
      Disassembly...3215
      Assembly...3217
      ROPS...3221
      Removal and Installation...3221
    NORDIC CAB (OPTIONAL)...3221
      Removal and Installation...3221
    ROPS WINDOW...3222
      Front Window Removal...3222
      Side Window Removal...3223
      Installation...3223
    ELECTRICAL SYSTEM...3225
    ELECTRICAL SCHEMATICS...3227
    TROUBLESHOOTING...3229
    ELECTRICAL SYSTEM...3229
      Description...3229
      Fuses...3230
      Electrical System Service...3230
    BATTERY...3231
      Checking the Battery...3231
      Removal and Installation...3231
    ALTERNATOR...3232
      Belt Adjustment...3232
      Removal and Installation...3232
    STARTER...3233
      Removal and Installation...3233
      Disassembly and Assembly...3234
      Cleaning and Inspection...3234
    FUEL LEVEL SENDER...3235
      Removal and Installation...3235
      Checking...3235
    INSTRUMENT PANEL...3236
      Removal and Installation...3236
    DOME LIGHT...3237
      Removal and Installation...3237
    CAB CONTROL PANEL...3237
      Removal and Installation...3237
    FRONT LIGHTS...3238
      Removal and Installation...3238
      Lamp Replacement...3238
    CONSOLE SWITCHES...3239
      Removal and Installation...3239
    WINDSHIELD WIPER...3240
      Removal and Installation...3240
    WINDSHIELD WASHER (NORDIC OPTION)...3241
      Removal and Installation...3241
      Hose Removal...3241
    ENGINE COVER LIGHT (NORDIC OPTION)...3242
      Removal and Installation...3242
  ENGINE SERVICE...3243
    TROUBLESHOOTING...3245
    VALVE CLEARANCE...3246
      Adjustment...3246
    ENGINE COMPRESSION...3247
      Checking...3247
    ELECTRIC FUEL PUMP...3248
      Removal and Installation...3248
      In–Line Filter (Used on Early Model Excavators Only)...3248
    FUEL FILTER...3249
      Final Filter (S/N 12001–12647)...3249
      Fuel Filter (S/N 12648 & Above) (With Water Drain Valve)...3249
    FUEL INJECTION PUMP...3250
      Checking the Injection Pump...3250
      Removal and Installation...3251
      Timing the Injection Pump...3252
    FUEL INJECTION NOZZLES...3253
      Removal and Installation...3253
    GLOW PLUGS...3255
      Removal and Installation...3255
      Checking the Glow Plug...3255
    RADIATOR...3256
      Removal and Installation...3256
    FAN SHIELD (NORDIC OPTION)...3257
      Removal and Installation...3257
    MUFFLER...3258
      Removal and Installation...3258
    AIR CLEANER...3259
      Removal and Installation...3259
    ENGINE...3260
      Removal and Installation...3260
    ENGINE FLYWHEEL...3261
      Removal and Installation...3261
      Flywheel Ring Gear...3263
    CYLINDER HEAD...3264
      Removing the Cylinder Head...3264
      Disassembly of the Cylinder Head...3265
      Servicing the Cylinder Head and Valves...3266
      Checking Valve Springs...3267
      Checking Rocker Arm and Shaft...3268
      Assembling the Cylinder Head...3268
      Installing the Cylinder Head...3268
    TIMING GEAR COVER...3270
      Removal and Installation...3270
    TIMING GEAR, CAMSHAFT AND OIL PUMP...3272
      Removal and Installation...3272
      Oil Pump Service...3274
      Servicing the Camshaft...3275
    CRANKSHAFT AND PISTONS...3277
      Removal and Installation...3277
      Crankshaft Service...3279
      Servicing the Connecting Rods and Pistons...3280
    CYLINDER LINERS...3282
      Checking the Cylinder Liners...3282
      Cylinder Liner Installation...3282
    WATER PUMP...3283
      Removal and Installation...3283
      Disassembly and Assembly...3283
  SPECIFICATIONS...3285
    HYDRAULIC EXCAVATOR SPECIFICATIONS...3287
      Machine Dimensions...3287
      Lifting Capacity With Blade Off Ground...3288
      OPERATION & PERFORMANCE...3288
      ENGINE...3288
      HYDRAULIC SYSTEM...3289
      SWING SYSTEM...3289
      HYDRAULIC CYLINDERS...3289
      DRIVE SYSTEM...3289
      UNDERCARRIAGE...3289
      TRACK...3289
      CAPACITIES...3289
      DIGGING FORCE...3289
    ENGINE SPECIFICATIONS...3290
      Fuel Injection Nozzles...3290
      Fuel Injection Pump...3290
      Cylinder Head...3290
      Valves...3290
      Valve Springs...3290
      Rocker Arms...3290
      Camshaft...3290
      Cylinders...3291
      Piston Rings...3291
      Pistons...3291
      Crankshaft...3291
      Oil Pump...3291
      Engine Oil...3291
      Specifications...3291
      ENGINE TORQUE...3292
      Re–Grinding The Crankshaft...3293
    FUEL, COOLANT AND LUBRICANTS...3294
    OIL SPECIFICATIONS...3294
      Description...3294
  SERVICE MANUAL REVISION...3295
    225-1...3295
    225-2...3297
    225-3...3299
    225-4...3301
    225-5...3303
    225-6...3305
    225-7...3307
    225-8...3309
    225-9...3311
    225-10...3313
    225-11...3315
6722178 (3-92) - X 231 Excavator Service Manual...3317
  CONTENTS...3319
    FOREWORD...3321
    SAFETY...3323
    SAFETY INSTRUCTIONS...3325
    SERIAL NUMBER LOCATIONS...3327
    HYDRAULIC EXCAVATOR SERIAL NUMBER...3327
    ENGINE SERIAL NUMBER...3327
    DELIVERY REPORT...3327
    HYDRAULIC EXCAVATOR IDENTIFICATION...3328
    MACHINE SIGNS TRANSLATIONS (DECALS)...3329
  PREVENTIVE MAINTENANCE...3331
    SERVICE SCHEDULE...3333
    ENGINE COVER...3334
      Procedure...3334
    AIR CLEANER SERVICE...3334
      Replacing the Filter Element...3334
    FUEL SYSTEM...3336
      Fuel Specifications...3336
      Fuel System Service...3336
      Fuel Filters...3337
      In–line Fuel Filter (If Equipped)...3337
      Removing Air From The Fuel System...3337
    ENGINE LUBRICATION SYSTEM...3338
      Checking The Engine Oil...3338
      Engine Oil and Filter Replacement...3338
    COOLING SYSTEM...3340
      Coolant Level...3340
      Coolant Replacement...3340
    HYDRAULIC SYSTEM...3341
      Checking and Adding Fluid...3341
      Replacement of the Hydraulic Filter...3341
      Hydraulic Reservoir...3342
      Diagnostic Couplers...3342
    USING A BOOSTER BATTERY (JUMP STARTING)...3343
      Procedure...3343
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...3344
      Procedure...3344
    FINAL DRIVE CASE...3346
      Checking Oil Level...3346
      Draining Final Drive Case...3346
    HYDRAULIC SECTION...3347
  HYDRAULIC SECTION...3347
    HYDRAULIC SCHEMATICS...3349
    HYDRAULIC SERVICE INFORMATION...3360
      Description...3360
    MAIN RELIEF VALVES...3360
      Checking the Relief Valve Pressure Settings...3360
      Adjustment Procedure...3361
      (With Dual Pressure Relief Valves) (S/N 508912381 & Above)...3362
    HYDRAULIC PUMP FLOW TEST...3368
    HYDRAULIC PUMP...3369
      Removal And Installation...3369
    HYDRAULIC PUMP...3370
      Disassembly And Assembly...3370
    HYDRAULIC CONTROL VALVE (Six Spool)...3374
      Removal And Installation...3374
      Parts Identification...3375
      Disassembly And Assembly...3376
    HYDRAULIC CONTROL VALVE (Three Spool)...3391
      Removal And Installation...3391
      Parts Identification...3392
      Disassembly And Assembly...3393
      Pressure Build–up Valve Adjustment Procedure...3401
    PRESSURE REDUCING VALVE WITH ACCUMULATOR...3402
      Removal And Installation...3402
      Parts Identification...3402
    ACCUMULATOR/VALVE...3403
      Disassembly...3403
      Assembly...3407
      Setting The Safety Relief Valve...3411
    ACCUMULATOR...3412
      Charging...3412
    AUXILIARY SELECTOR VALVE...3413
      Removal And Installation...3413
      Disassembly And Assembly...3413
    TWO SPEED VALVE...3414
      Removal And Installation...3414
      Parts Identification...3415
    PORT BLOCK...3416
      Removal And Installation...3416
    OIL COOLER...3417
      Removal And Installation...3417
    HYDRAULIC RESERVOIR AND FUEL RESERVOIR...3418
      Removal And Installation...3418
    HYDRAULIC FILTER ASSEMBLY...3420
      Removal And Installation...3420
    BOOM CYLINDER...3421
      Removal And Installation...3421
      Parts Identification...3422
    ARM CYLINDER...3423
      Removal And Installation...3423
      Parts Identification...3424
    BUCKET CYLINDER...3425
      Removal And Installation...3425
      Parts Identification...3426
    BLADE CYLINDER...3427
      Removal And Installation...3427
      Parts Identification...3428
    BOOM SWING CYLINDER...3429
      Removal And Installation...3429
      Parts Identification...3430
    HYDRAULIC CYLINDER...3431
      Disassembly...3431
      Assembly...3433
    JOYSTICK CONTROL CHANGE...3438
  DRIVE SECTION...3440
    LEFT CONSOLE...3442
      Lockout Valve Removal and Installation...3442
      Cylinder Removal and Installation...3442
      Removal and Installation...3443
    LEFT JOYSTICK...3444
      Removal and Installation...3444
      Disassembly and Assembly...3445
      Parts Identification...3449
    RIGHT CONSOLE...3450
      Removal and Installation...3450
    RIGHT CONSOLE COVER...3452
      Removal and Installation...3452
    THROTTLE LEVER...3453
      Low Idle Adjustment...3453
      High Idle Adjustment...3454
      Removal and Installation...3454
    CONTROL CABLES...3455
      Throttle Cable...3455
      Blade Cable and Lever...3455
    FOOT PEDAL AND STEERING LEVERS...3456
      Removal and Installation...3456
      Bushing Removal and Installation...3457
    FINAL DRIVE...3458
      Removal and Installation...3458
      Parts Identification...3459
    TRAVEL MOTOR...3460
      Disassembly...3460
      Assembly...3476
  UPPER WORKS AND SWING SECTION...3492
    SWING MOTOR...3494
      Removal and Installation...3494
      Disassembly...3495
      Assembly...3498
    CROSS–OVER RELIEF VALVE...3502
      Disassembly...3502
      Assembly...3504
    SWING MOTOR...3506
      Parts Identification...3506
    SWING GEAR BOX ASSEMBLY (WITH OR WITHOUT BRAKES)...3507
      Disassembly...3507
      Assembly...3516
    UPPER WORKS AND SWING CIRCLE GEAR...3530
      Removal and Installation...3530
      Swing Bearing Removal...3532
      Swing Bearing Installation...3533
    CENTER SWIVEL JOINT...3535
      Removal And Installation (through upper access removal)...3535
      Removal And Installation (through bottom access cover)...3535
      Parts Identification...3537
  MAIN FRAME AND TRACKS...3538
    ENGINE COVER...3540
      Removal and Installation...3540
    SEAT AND MOUNTING FRAME...3540
      Removal and Installation...3540
    CENTER FLOOR PANEL...3541
      Removal and Installation...3541
    SWING MOTOR COVER...3542
      Removal and Installation...3542
    REAR FLOOR PANEL...3542
      Removal and Installation...3542
    INSPECTION COVER...3543
      Removal and Installation...3543
    TOOL BOX...3543
      Removal and Installation...3543
    BUCKET...3544
      Removal and Installation...3544
    ARM...3545
      Removal and Installation...3545
    BOOM...3546
      Removal and Installation...3546
    BOOM SWING BRACKET...3547
      Removal and Installation...3547
    WORK GROUP HOSE INSTALLATION...3547
      Hose Mounting and Dimensions...3547
    BLADE...3548
      Removal and Installation...3548
    TRACK...3549
      Track Tension Adjustment...3549
      Rubber Tracks...3549
      Steel Tracks...3550
      Removal and Installation (Rubber Track)...3551
      Removal and Installation (Steel Track)...3551
    TRACK FRAME...3552
      Disassembly and Assembly...3552
    TRACK IDLER...3554
      Parts Identification...3554
      Disassembly...3555
      Assembly...3557
      Disassembly and Assembly...3561
    TRACK ROLLER...3562
      Parts Identification...3562
      Disassembly...3563
      Assembly...3565
    ROPS...3570
      Removal and Installation...3570
      Front Window Removal...3570
      Side Window Removal...3571
  ELECTRICAL SYSTEM...3572
    ELECTRICAL CHARTS...3574
    TROUBLESHOOTING...3576
    ELECTRICAL SYSTEM...3576
      Description...3576
      Fuses...3577
      Electrical System Service...3577
    BATTERY...3578
      Checking the Battery...3578
      Removal and Installation...3578
    ALTERNATOR...3579
      Belt Adjustment...3579
      Removal And Installation...3579
    STARTER...3580
      Removal and Installation...3580
      Disassembly and Assembly...3581
      Cleaning and Inspection...3581
    FUEL LEVEL SENDER...3582
      Removal and Installation...3582
      Checking...3582
    INSTRUMENT PANEL...3583
      Removal And Installation...3583
    HOURMETER...3583
      Removal And Installation...3583
    WIPER MOTOR AND SWITCH...3584
  ENGINE SYSTEM...3586
    TROUBLESHOOTING...3588
    VALVE CLEARANCE...3589
      Adjustment...3589
    ENGINE COMPRESSION...3590
      Checking...3590
    FUEL SYSTEM...3591
      Fuel Filters...3591
      Fuel Filter Assembly...3591
      In–Line Fuel Filter (if equipped)...3591
      Removing Air From the Fuel System...3591
    FUEL SHUT–OFF SOLENOID...3592
      Adjustment...3592
      Removal and Installation...3592
    FUEL INJECTION PUMP...3593
      Checking the Injection Pump...3593
      Removal and Installation...3594
      Timing the Injection Pump...3595
    FUEL INJECTOR NOZZLES...3596
      Checking the Injector Nozzle...3597
    GLOW PLUGS...3598
      Removal and Installation...3598
      Checking the Glow Plug...3598
    RADIATOR...3599
      Removal and Installation...3599
    AIR CLEANER...3602
      Removal and Installation...3602
    MUFFLER...3603
      Removal and Installation...3603
    HEATER...3604
      Removal and Installation...3604
    ENGINE...3605
      Removal and Installation...3605
    ENGINE FLYWHEEL...3606
      Removal and Installation...3606
      Flywheel Ring Gear...3607
    CYLINDER HEAD...3608
      Removal...3608
      Disassembly...3609
      Servicing the Cylinder Head...3609
      Assembly...3611
      Installation...3611
    ENGINE REPAIR...3612
      Removing the Gearcase...3612
      Removing the Timing Gear, Camshaft and Oil Pump...3615
      Removing the Pistons and Crankshaft...3616
      Servicing the Timing Gear and Camshaft...3618
      Servicing the Connecting Rods and Pistons...3619
      Servicing the Crankshaft...3621
      Servicing the Cylinder Liners...3622
      Lubrication System...3623
      Oil Pump Service...3624
      Water Pump Service...3624
    ENGINE ASSEMBLY...3626
      Installing the Crankshaft...3626
      Installing the Pistons...3626
      Installing the Gearcase...3628
  TECHNICAL DATA...3630
    HYDRAULIC EXCAVATOR SPECIFICATIONS...3632
      Machine Dimensions...3632
      Lifting Capacity With Blade Off Ground (Model 231 with Canopy)...3633
      Lifting Capacity With Blade Off Ground (Model 231 with Cab)...3633
      Engine...3634
      Hydraulic System...3634
      Swing System...3634
      Hydraulic Cylinders...3634
      Drive System...3634
      Brakes...3634
      Undercarriage...3634
      Track...3634
      Capacities...3635
      Miscellaneous...3635
      Fuel Injection Nozzles...3635
      Fuel Injection Pump...3635
      Cylinder Head...3635
      Valves...3635
      Valve Springs...3635
      Rocker Arms...3635
      Camshaft...3635
      Cylinder...3636
      Piston Rings...3636
      Pistons...3636
      Crankshaft...3636
      Oil Pump...3636
      Engine Oil Specifications...3636
    ENGINE BOLT TORQUE...3637
      Re–Grinding The Crankshaft...3638
    FUEL, COOLANT AND LUBRICANTS...3639
    OIL SPECIFICATIONS...3639
      Description...3639
  SERVICE MANUAL REVISON...3640
    231-1...3640
    231-2...3642
    231-3...3644
    231-4...3646
    231-5...3648
    231-6...3650
    231-7...3652
6722178 (6-12) - X 231 Excavator Service Manual...3654
  CONTENTS...3656
    FOREWORD...3658
    SAFETY...3660
    SAFETY INSTRUCTIONS...3662
    SERIAL NUMBER LOCATIONS...3664
    HYDRAULIC EXCAVATOR SERIAL NUMBER...3664
    ENGINE SERIAL NUMBER...3664
    DELIVERY REPORT...3664
    HYDRAULIC EXCAVATOR IDENTIFICATION...3665
    MACHINE SIGNS TRANSLATIONS (DECALS)...3666
  PREVENTIVE MAINTENANCE...3668
    SERVICE SCHEDULE...3670
    ENGINE COVER...3671
      Procedure...3671
    AIR CLEANER SERVICE...3671
      Replacing the Filter Element...3671
    FUEL SYSTEM...3673
      Fuel Specifications...3673
      Fuel System Service...3673
      Fuel Filters...3674
      In–line Fuel Filter (If Equipped)...3674
      Removing Air From The Fuel System...3674
    ENGINE LUBRICATION SYSTEM...3675
      Checking The Engine Oil...3675
      Engine Oil and Filter Replacement...3675
    COOLING SYSTEM...3677
      Coolant Level...3677
      Coolant Replacement...3677
    HYDRAULIC SYSTEM...3678
      Checking and Adding Fluid...3678
      Replacement of the Hydraulic Filter...3678
      Hydraulic Reservoir...3679
      Diagnostic Couplers...3679
    USING A BOOSTER BATTERY (JUMP STARTING)...3680
      Procedure...3680
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...3681
      Procedure...3681
    FINAL DRIVE CASE...3683
      Checking Oil Level...3683
      Draining Final Drive Case...3683
    HYDRAULIC SECTION...3684
  HYDRAULIC SECTION...3684
    HYDRAULIC SCHEMATICS...3686
    HYDRAULIC SERVICE INFORMATION...3698
      Description...3698
    MAIN RELIEF VALVES...3698
      Checking the Relief Valve Pressure Settings...3698
      Adjustment Procedure...3699
      (With Dual Pressure Relief Valves) (S/N 508912381 & Above)...3700
    HYDRAULIC PUMP FLOW TEST...3706
    HYDRAULIC PUMP...3707
      Removal And Installation...3707
    HYDRAULIC PUMP...3708
      Disassembly And Assembly...3708
    HYDRAULIC CONTROL VALVE (Six Spool)...3712
      Removal And Installation...3712
      Parts Identification...3713
      Disassembly And Assembly...3714
    HYDRAULIC CONTROL VALVE (Three Spool)...3729
      Removal And Installation...3729
      Parts Identification...3730
      Disassembly And Assembly...3731
      Pressure Build–up Valve Adjustment Procedure...3739
    PRESSURE REDUCING VALVE WITH ACCUMULATOR...3740
      Removal And Installation...3740
      Parts Identification...3740
    ACCUMULATOR/VALVE...3741
      Disassembly...3741
      Assembly...3745
      Setting The Safety Relief Valve...3749
    ACCUMULATOR...3750
      Charging...3750
    AUXILIARY SELECTOR VALVE...3751
      Removal And Installation...3751
      Disassembly And Assembly...3751
    TWO SPEED VALVE...3752
      Removal And Installation...3752
      Parts Identification...3753
    PORT BLOCK...3754
      Removal And Installation...3754
    OIL COOLER...3755
      Removal And Installation...3755
    HYDRAULIC RESERVOIR AND FUEL RESERVOIR...3756
      Removal And Installation...3756
    HYDRAULIC FILTER ASSEMBLY...3758
      Removal And Installation...3758
    BOOM CYLINDER...3759
      Removal And Installation...3759
      Parts Identification...3760
    ARM CYLINDER...3761
      Removal And Installation...3761
      Parts Identification...3762
    BUCKET CYLINDER...3763
      Removal And Installation...3763
      Parts Identification...3764
    BLADE CYLINDER...3765
      Removal And Installation...3765
      Parts Identification...3766
    BOOM SWING CYLINDER...3767
      Removal And Installation...3767
      Parts Identification...3768
    HYDRAULIC CYLINDER...3769
      Disassembly...3769
      Assembly...3771
    JOYSTICK CONTROL CHANGE...3776
  DRIVE SECTION...3778
    LEFT CONSOLE...3780
      Lockout Valve Removal and Installation...3780
      Cylinder Removal and Installation...3780
      Removal and Installation...3781
    LEFT JOYSTICK...3782
      Removal and Installation...3782
      Disassembly and Assembly...3783
      Parts Identification...3787
    RIGHT CONSOLE...3788
      Removal and Installation...3788
    RIGHT CONSOLE COVER...3790
      Removal and Installation...3790
    THROTTLE LEVER...3791
      Low Idle Adjustment...3791
      High Idle Adjustment...3792
      Removal and Installation...3792
    CONTROL CABLES...3793
      Throttle Cable...3793
      Blade Cable and Lever...3793
    FOOT PEDAL AND STEERING LEVERS...3794
      Removal and Installation...3794
      Bushing Removal and Installation...3795
    FINAL DRIVE...3796
      Removal and Installation...3796
      Parts Identification...3797
    TRAVEL MOTOR...3798
      Disassembly...3798
      Assembly...3814
  UPPER WORKS AND SWING SECTION...3830
    SWING MOTOR...3832
      Removal and Installation...3832
      Disassembly...3833
      Assembly...3836
    CROSS–OVER RELIEF VALVE...3840
      Disassembly...3840
      Assembly...3842
    SWING MOTOR...3844
      Parts Identification...3844
    SWING GEAR BOX ASSEMBLY (WITH OR WITHOUT BRAKES)...3845
      Disassembly...3845
      Assembly...3854
    UPPER WORKS AND SWING CIRCLE GEAR...3868
      Removal and Installation...3868
      Swing Bearing Removal...3870
      Swing Bearing Installation...3871
    CENTER SWIVEL JOINT...3873
      Removal And Installation (through upper access removal)...3873
      Removal And Installation (through bottom access cover)...3873
      Parts Identification...3875
  MAIN FRAME AND TRACKS...3876
    ENGINE COVER...3878
      Removal and Installation...3878
    SEAT AND MOUNTING FRAME...3878
      Removal and Installation...3878
    CENTER FLOOR PANEL...3879
      Removal and Installation...3879
    SWING MOTOR COVER...3880
      Removal and Installation...3880
    REAR FLOOR PANEL...3880
      Removal and Installation...3880
    INSPECTION COVER...3881
      Removal and Installation...3881
    TOOL BOX...3881
      Removal and Installation...3881
    BUCKET...3882
      Removal and Installation...3882
    ARM...3883
      Removal and Installation...3883
    BOOM...3884
      Removal and Installation...3884
    BOOM SWING BRACKET...3885
      Removal and Installation...3885
    WORK GROUP HOSE INSTALLATION...3885
      Hose Mounting and Dimensions...3885
    BLADE...3886
      Removal and Installation...3886
    TRACK...3887
      Track Tension Adjustment...3887
      Rubber Tracks...3887
      Steel Tracks...3888
      Removal and Installation (Rubber Track)...3889
      Removal and Installation (Steel Track)...3889
    TRACK FRAME...3890
      Disassembly and Assembly...3890
    TRACK IDLER...3892
      Parts Identification...3892
      Disassembly...3893
      Assembly...3895
      Disassembly and Assembly...3899
    TRACK ROLLER...3900
      Parts Identification...3900
      Disassembly...3901
      Assembly...3903
    ROPS...3908
      Removal and Installation...3908
      Front Window Removal...3908
      Side Window Removal...3909
  ELECTRICAL SYSTEM...3910
    ELECTRICAL CHARTS...3912
    TROUBLESHOOTING...3914
    ELECTRICAL SYSTEM...3914
      Description...3914
      Fuses...3915
      Electrical System Service...3915
    BATTERY...3916
      Checking the Battery...3916
      Removal and Installation...3916
    ALTERNATOR...3917
      Belt Adjustment...3917
      Removal And Installation...3917
    STARTER...3918
      Removal and Installation...3918
      Disassembly and Assembly...3919
      Cleaning and Inspection...3919
    FUEL LEVEL SENDER...3920
      Removal and Installation...3920
      Checking...3920
    INSTRUMENT PANEL...3921
      Removal And Installation...3921
    HOURMETER...3921
      Removal And Installation...3921
    WIPER MOTOR AND SWITCH...3922
  ENGINE SYSTEM...3924
    TROUBLESHOOTING...3926
    VALVE CLEARANCE...3927
      Adjustment...3927
    ENGINE COMPRESSION...3928
      Checking...3928
    FUEL SYSTEM...3929
      Fuel Filters...3929
      Fuel Filter Assembly...3929
      In–Line Fuel Filter (if equipped)...3929
      Removing Air From the Fuel System...3929
    FUEL SHUT–OFF SOLENOID...3930
      Adjustment...3930
      Removal and Installation...3930
    FUEL INJECTION PUMP...3931
      Checking the Injection Pump...3931
      Removal and Installation...3932
      Timing the Injection Pump...3933
    FUEL INJECTOR NOZZLES...3934
      Checking the Injector Nozzle...3935
    GLOW PLUGS...3936
      Removal and Installation...3936
      Checking the Glow Plug...3936
    RADIATOR...3937
      Removal and Installation...3937
    AIR CLEANER...3940
      Removal and Installation...3940
    MUFFLER...3941
      Removal and Installation...3941
    HEATER...3942
      Removal and Installation...3942
    ENGINE...3943
      Removal and Installation...3943
    ENGINE FLYWHEEL...3944
      Removal and Installation...3944
      Flywheel Ring Gear...3945
    CYLINDER HEAD...3946
      Removal...3946
      Disassembly...3947
      Servicing the Cylinder Head...3947
      Assembly...3949
      Installation...3949
    ENGINE REPAIR...3950
      Removing the Gearcase...3950
      Removing the Timing Gear, Camshaft and Oil Pump...3953
      Removing the Pistons and Crankshaft...3954
      Servicing the Timing Gear and Camshaft...3956
      Servicing the Connecting Rods and Pistons...3957
      Servicing the Crankshaft...3959
      Servicing the Cylinder Liners...3960
      Lubrication System...3961
      Oil Pump Service...3962
      Water Pump Service...3962
    ENGINE ASSEMBLY...3964
      Installing the Crankshaft...3964
      Installing the Pistons...3964
      Installing the Gearcase...3966
  TECHNICAL DATA...3968
    HYDRAULIC EXCAVATOR SPECIFICATIONS...3970
      Machine Dimensions...3970
      Lifting Capacity With Blade Off Ground (Model 231 with Canopy)...3971
      Lifting Capacity With Blade Off Ground (Model 231 with Cab)...3971
      Engine...3972
      Hydraulic System...3972
      Swing System...3972
      Hydraulic Cylinders...3972
      Drive System...3972
      Brakes...3972
      Undercarriage...3972
      Track...3972
      Capacities...3973
      Miscellaneous...3973
      Fuel Injection Nozzles...3973
      Fuel Injection Pump...3973
      Cylinder Head...3973
      Valves...3973
      Valve Springs...3973
      Rocker Arms...3973
      Camshaft...3973
      Cylinder...3974
      Piston Rings...3974
      Pistons...3974
      Crankshaft...3974
      Oil Pump...3974
      Engine Oil Specifications...3974
    ENGINE BOLT TORQUE...3975
      Re–Grinding The Crankshaft...3976
    FUEL, COOLANT AND LUBRICANTS...3977
    OIL SPECIFICATIONS...3977
      Description...3977
  SERVICE MANUAL REVISON...3978
    231-1...3978
    231-2...3980
    231-3...3982
    231-4...3984
    231-5...3986
    231-6...3988
    231-7...3990
    231-8...3992
6722250 (10-98) - X220 Excavator Operation & Maintenance Manual...3994
  OPERATOR SAFETY WARNINGS...3995
  CONTENTS...3997
  REGULAR MAINTENANCE ITEMS...3998
  FOREWORD...3999
    SERIAL NUMBER LOCATIONS...4001
    HYDRAULIC EXCAVATOR SERIAL NUMBER...4001
    ENGINE SERIAL NUMBER...4001
    DELIVERY REPORT...4001
    BOBCAT HYDRAULIC EXCAVATOR IDENTIFICATION...4002
  SAFETY...4003
    SAFETY INSTRUCTIONS...4005
    FIRE PREVENTION...4007
    MACHINE SIGNS (DECALS)...4008
  OPERATING INSTRUCTIONS...4011
    GETTING ON AND OFF THE MACHINE...4013
    SEAT...4014
    CONTROL LEVER (JOYSTICK) LOCK...4014
    INSTRUMENTS...4015
    AUDIBLE ALARM...4016
    KEY SWITCH...4016
    CAB ELECTRICAL (If Equipped)...4016
    HEATER CONTROL (If Equipped)...4016
    CONTROL LEVER (JOYSTICKS)...4017
      Operation Of Left Control Lever (ISO)...4017
      Operation Of Right Control Lever (ISO)...4017
    CONTROL LEVERS (STANDARD)...4018
      Operation Of Left Control Lever (STANDARD)...4018
      Operation Of Right Control Lever (STANDARD)...4018
    SWING LOCK...4019
    HORN BUTTON...4019
    SPEED CONTROL LEVER...4020
    ENGINE STOP CONTROL...4020
    STEERING LEVERS/FOOT PEDALS...4021
      Forward And Reverse Travel...4021
      Turning...4021
      Right Turn...4021
      Left Turn...4021
    BOOM SWING PEDAL AND LOCK...4022
    BLADE CONTROL LEVER...4022
    AUXILIARY OPERATION PEDAL...4023
    DAILY INSPECTION...4024
    STARTING THE ENGINE...4024
      Normal Starting Procedure (With Engine Warm)...4024
      Cold Temperature Starting Procedure...4025
    OPERATING PROCEDURE...4026
      Breaking In A New Machine...4026
      Operating In Water...4028
    PARKING THE HYDRAULIC EXCAVATOR...4028
    TRANSPORTING THE HYDRAULIC EXCAVATOR...4029
    LIFTING THE EXCAVATOR...4030
    BUCKET...4031
      Removal...4031
      Installation...4031
  PREVENTIVE MAINTENANCE...4033
    MAINTENANCE SAFETY...4034
    SERVICE SCHEDULE...4035
    ENGINE COVER...4036
    AIR CLEANER SERVICE...4036
      Filter Replacement...4036
    FUEL SYSTEM...4037
      Fuel Specification...4037
      Filling The Fuel Tank...4037
      Fuel Filters...4038
      Removing Air From The Fuel System...4038
    ENGINE LUBRICATION SYSTEM...4039
      Engine Oil And Filter Replacement...4039
    COOLING SYSTEM...4040
      Coolant Level...4040
      Coolant Replacement...4040
      Propylene Glycol...4040
    ALTERNATOR BELT ADJUSTMENT...4041
    ELECTRICAL SYSTEM...4042
      Fuses...4042
      Service The Electrical System...4042
      Using A Booster Battery (Jump Starting)...4043
      Removal And Installation Of The Battery...4044
    HYDRAULIC SYSTEM...4045
      Checking And Adding Fluid...4045
      Diagnostic Couplers...4046
      Replacement of the Hydraulic Filter...4046
      Hydraulic Reservoir...4046
      Replacement Of The Hydraulic Fluid...4046
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...4047
    FINAL DRIVE CASE...4049
      Checking Oil Level...4049
    TRACK TENSION...4050
      Adjustment...4050
    JOYSTICK CONTROL CHANGE...4051
      ISO To Standard Control Pattern...4051
      Standard To ISO Control Pattern...4051
  SPECIFICATIONS...4053
    HYDRAULIC EXCAVATOR SPECIFICATIONS...4055
      Machine Dimensions...4055
      Lifting Capacity...4056
    FUEL, COOLANT AND LUBRICANTS...4058
    ENGINE OIL SPECIFICATIONS...4058
      Description...4058
  WARRANTY...4059
6722345 (9-92) - 220 Excavator Service Manual...4060
  MAINTENANCE SAFETY...4062
  SERVICE MANUAL REVISION...4064
    220-1...4064
  FOREWORD...4066
  CONTENTS...4068
    SAFETY INSTRUCTIONS...4070
    SERIAL NUMBER LOCATIONS...4071
    HYDRAULIC EXCAVATOR SERIAL NUMBER...4071
    ENGINE SERIAL NUMBER...4071
    DELIVERY REPORT...4071
    HYDRAULIC EXCAVATOR IDENTIFICATION...4072
  PREVENTIVE MAINTENANCE...4074
    SERVICE SCHEDULE...4076
    ENGINE COVER...4077
    AIR CLEANER SERVICE...4077
    FUEL SYSTEM...4078
      Fuel System Service...4078
      Fuel Filter...4079
      Removing Air From The Fuel System...4079
    ENGINE LUBRICATION SYSTEM...4080
      Engine Oil And Filter Replacement...4080
    COOLING SYSTEM...4081
      Coolant Level...4081
      Coolant Replacement...4081
    HYDRAULIC SYSTEM...4082
      Checking And Adding Fluid...4082
      Diagnostic Couplers...4082
      Replacement Of The Hydraulic Filter...4083
      Hydraulic Reservoir...4083
      Replacement fo the Hydraulic Fluid...4083
    USING A BOOSTER BATTERY (JUMP STARTING)...4084
      Procedure...4084
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...4085
      Procedure...4085
  HYDRAULIC SECTION...4088
    HYDRAULIC SCHEMATICS...4090
    HYDRAULIC SYSTEM TROUBLESHOOTING...4100
    HYDRAULIC SERVICE INFORMATION...4106
      Description...4106
      Checking the Main Relief Valves...4106
    HYDRAULIC PUMPS...4108
      Removal And Installation...4108
    HYDRAULIC PUMP ASSEMBLY...4109
      Disassembly...4110
      Assembly...4113
    HYDRAULIC CONTROL VALVE (6-Spool)...4115
      Removal And Installation...4115
      6 Spool Control Valve Assembly...4116
      Disassembly and Assembly...4117
      Disassembly...4117
      Inlet Section (R.H. and L.H. Travel)...4118
        Disassembly...4118
        Assembly...4119
      Valve Sections (Boom, Bucket & Arm)...4120
        Disassembly...4120
        Assembly...4121
      Valve Sections (Auxiliary)...4122
        Disassembly...4122
        Assembly...4123
      Port Relief Valve...4125
        Disassembly...4125
        Assembly ...4125
        Adjustment Procedure...4125
      Main Relief Valve...4127
        Disassembly...4127
        Assembly...4127
        Adjustment Procedure...4128
    HYDRAULIC CONTROL VALVE (3 Spool)...4130
      Removal and Installation...4130
      3 Spool Control Valve Assembly...4131
      Disassembly...4132
      INLET SECTION (Housing Swing)...4133
        Disassembly...4133
        Assembly...4133
      END COVER (Boom Swing) and VALVE SECTION (Blade)...4134
        Disassembly...4134
        Assembly...4136
      Load Check Block...4138
        Disassembly...4138
        Assembly...4138
      Build-up Valve...4140
        Assembly...4140
      Main Relief Valve...4141
        Disassembly...4141
        Assembly...4141
        Adjustment Procedure...4142
    BOOM CYLINDER...4144
      Removal And Installation...4144
      Boom Shield...4144
      Boom Cylinder...4144
    DIPPERARM CYLINDER...4145
      Removal And Installation...4145
    BUCKET CYLINDER...4146
      Removal And Installation...4146
    BLADE CYLINDER...4147
      Removal And Installation...4147
    BOOM SWING CYLINDER...4148
      Removal And Installation...4148
    HYDRAULIC CYLINDER...4150
      Disassembly...4150
      Assembly...4152
    HYDRAULIC FILTER ASSEMBLY...4159
      Removal and Installation...4159
    AUXILIARY COUPLERS...4159
    JOYSTICK MANIFOLD WITH ACCUMULATOR...4160
      Removal And Installation...4160
      Disassembly And Assembly...4162
    DRAIN BLOCK...4163
      Removal And Installation...4163
      Filter Screen...4163
      Drain Block...4163
    OIL COOLER...4164
    JOYSTICK CONTROL CHANGE...4165
  DRIVE SECTION...4166
    FLOORMAT AND FLOOR PANELS...4168
      Removal And Installation...4168
    LEFT CONTROL CONSOLE...4170
      Microswitch Adjustment Procedure...4170
      Lockout Microswitch Removal and Installation...4171
      Console Cover Removal and Installation...4172
      Joystick Removal And Installation...4175
      Removal And Installation...4176
      Fuel Tank Removal and Installation...4179
      Lock Lever Removal And Installation...4181
      Lock Lever Adjustment Procedure...4182
      Latch Hook Removal and Installation...4183
      Gas Spring Removal And Installation...4184
      Upper Console Removal And Installation...4185
    RIGHT CONTROL CONSOLE (ROPS CANOPY MODELS)...4186
      (CAB MODELS)...4186
      Console Cover Removal And Installation...4187
      Joystick Removal And Installation...4189
      Control Console Removal And Installation...4190
      Hydraulic Tank Removal And Installation...4194
    TRAVEL LEVERS...4195
      Removal And Installation...4195
    RIGHT HAND PEDAL (Boom Swing)...4197
      Removal And Installation...4197
    LEFT HAND PEDAL (Auxiliary)...4199
      Removal And Installation...4199
    ROCKERSHAFT...4201
      Removal And Installation...4201
    LINKAGE RODS...4203
      Removal And Installation...4203
    BLADE LEVER...4204
      Removal And Installation...4204
    FINAL DRIVE...4207
      Removal And Installation...4207
    DRIVE MOTOR ASSEMBLY...4208
      Parts Identification...4208
    DRIVE MOTOR...4209
      Disassembly...4209
      Assembly...4219
      Check Oil Level...4228
      Draining Final Drive Case...4228
    JOYSTICK...4229
      Parts Identification...4229
      Disassembly And Assembly...4230
  UPPER WORKS AND SWING SECTION...4234
    SWING MOTOR...4236
      Testing The Cross Port Reliefs...4236
      Start The Engine...4236
      Removing The Cross Port Reliefs...4236
      Removal And Installation...4237
      Disassembly...4237
      Assembly...4238
      Motor Timing...4239
    UPPER WORKS...4240
      Removal And Installation...4240
      Installation...4241
    CENTER SWIVEL JOINT...4243
      Removal and Installation...4243
      Disassembly and Assembly...4243
    SWING CIRCLE GEAR...4244
      Removal And Installation...4244
    ROPS CANOPY...4245
      Removal And Installation...4245
    CAB...4246
      Removal And Installation...4246
  MAIN FRAME AND TRACKS...4250
    ENGINE COVER...4252
      Removal And Installation...4252
    SEAT AND MOUTING FRAME...4253
      Removal And Installation...4253
    SEAT MOUNT...4254
      Removal And Installation...4254
    SPEED LEVER...4255
      Removal And Installation...4255
    SWING LOCK LEVER AND PIN...4255
      Removal And Installation...4255
    BUCKET...4256
      Removal And Installation...4256
      Installation...4256
    ARM...4257
      Removal And Installation...4257
    BOOM ...4259
      Removal And Installation...4259
    SWING POST...4261
      Removal And Installation...4261
      Bushing Replacement...4262
    TRACK...4263
      Track Tension Adjustment...4263
      Removal And Installation...4264
      Damage Identification And Causes...4264
    TRACK IDLER...4275
      Parts Identification...4275
      Disassembly...4276
      Assembly...4278
    TRACK ROLLER...4282
      Parts Identification...4282
      Disassembly...4283
      Assembly...4285
      Disassembly...4276
  ELECTRICAL SYSTEM...4290
    ELECTRICAL SCHEMATICS...4292
    6 ELECTRICAL SYSTEM...4293
      TROUBLESHOOTING...4293
    ELECTRICAL SYSTEM...4293
      Description...4293
      Fuse...4294
      Electrical System Service...4294
    BATTERY...4295
      Checking The Battery...4295
      Removal And Installation...4295
    ALTERNATOR...4297
      Checking The Alternator Output...4297
      Belt Adjustment...4297
      ELECTRICAL CONNECTION...4297
      Removal And Installation...4298
      Disassembly And Assembly...4299
      Checking Rotor, Stator And Rectifier...4299
    STARTER...4302
      Removal And Installation...4302
      Disassembly And Assembly...4303
      Cleaning And Inspection...4303
    HORN...4304
      Removal And Installation...4304
    FUEL LEVEL SENDOR...4304
      Removal And Installation...4304
  ENGINE SERVICE...4305
    7 ENGINE SERVICE...4307
    TROUBLESHOOTING...4307
    VALVE CLEARANCE...4308
      Adjustment...4308
    ENGINE COMPRESSION...4309
      Checking...4309
    FUEL FILTER...4310
      Element...4310
      Removing Air From The Fuel System...4310
      Fuel Filter Assembly Removal And Installation...4310
    FUEL INJECTION PUMP...4311
      Checking The Injection Pump...4311
      Removal And Installation...4311
      Timing The Injection Pump...4313
    FUEL INJECTOR NOZZLES...4314
      Removal And Installation...4314
      Checking The Injector Nozzle...4315
    GLOW PLUGS...4316
      Removal And Installation...4316
      Checking The Glow Plug...4316
    ENGINE...4317
      Removal And Installation...4317
    SPARK ARRESTOR MUFFLER...4322
      Removal And Installation...4322
    RADIATOR...4323
      Checking The Radiator And Radiator Cap...4323
      Removal And Installation...4323
    ENGINE FLYWHEEL...4326
      Removal And Installation...4326
      Hydraulic Pump Coupler...4326
      Flywheel Ring Gear...4326
    CYLINDER HEAD...4327
      Removal Of The Cylinder Head...4327
      Disassembly Of The Cylinder Head...4328
      Servicing The Cylinder Head And Valves...4329
      Checking Valve Springs...4330
      Checking Rocker Arm And Shaft...4331
      Assembling The Cylinder Head...4331
      Installing The Cylinder Head...4331
    TIMING GEAR COVER...4333
      Removal And Installation...4333
    TIMING GEAR, CAMSHAFT AND OIL PUMP...4335
      Removal And Installation...4335
      Oil Pump Service...4337
      Servicing The Camshaft...4338
    CRANKSHAFT AND PISTONS...4340
      Removal And Installation...4340
      Crankshaft Service...4342
      Servicing The Connecting Rods And Pistons...4343
    CYLINDER LINERS...4345
      Checking The Cylinder Liners...4345
      Cylinder Liner Installation...4345
    WATER PUMP...4346
      Removal And Installation...4346
      Disassembly And Assembly...4346
  TECHNICAL DATA...4347
    HYDRAULIC EXCAVATOR SPECIFICATIONS...4349
      Machine Dimensions...4349
      Lifting Capacity With Blade Off Ground...4350
      PERFORMANCE & OPERATION...4351
      ENGINE...4351
      HYDRAULIC SYSTEM...4351
      SWING SYSTEM...4351
      HYDRAULIC CYLINDERS...4351
      DRIVE SYSTEM...4351
      BRAKES...4352
      UNDERCARRIAGE...4352
      TRACK...4352
      CAPACITIES...4352
      DIGGING FORCE...4352
    ENGINE SPECIFICATIONS (KUPOTA)...4353
      Engine...4353
      Fuel Injector Nozzles...4353
      Fuel Injection Pump...4353
      Cylinder Head...4353
      Valves...4353
      Valve Springs...4353
      Rocker Arms...4353
      Camshaft...4354
      Cylinders...4354
      Piston Rings...4354
      Pistons...4354
      Crankshaft...4354
      Oil Pump...4355
      Thermostat...4355
      ENGINE TORQUE...4356
      Re-Grinding The Crankshaft...4357
    FUEL, COOLANT AND LUBRICANTS...4358
    OIL SPECIFICATIONS...4358

Bobcat Excavators 220, X220, X225, X231 Workshop Repair Service Manuals