Bobcat Excavator X220 Service Manual 6720230 - PDF DOWNLOAD

X 220 Excavator

Dealer Copy -- Not for Resale

Service Manual (S/N 508211999 & Below)

Doosan purchased Bobcat Company from Ingersoll-Rand Company in 2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging to Ingersoll-Rand Company in this manual is historical or nominative in nature, and is not meant to suggest a current affiliation between Ingersoll-Rand Company and Bobcat Company or the products of either.

6720230 (6-12) 1 of 258

Printed in U.S.A.

© Melroe Company 1989

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CONTENTS SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i. . .

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii. . .

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii. . . .

HYDRAULIC EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . iii. .

PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 ...

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 ....

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–1 ....

UPPER WORKS & SWING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–1 ..

MAIN FRAME & TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–1 ...

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ....

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–1 ....

TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–1 ....

PREVENTIVE MAINTENANCE

HYDRAULIC SYSTEM

DRIVE SYSTEM

UPPER WORKS & SWING SECTION

ELECTRICAL SYSTEM

ENGINE SERVICE

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MAIN FRAME & TRACKS

TECHNICAL DATA

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FOREWORD This manual is for the Bobcat hydraulic excavator mechanic. It provides necessary servicing an d adjustment procedures for the hydraulic excavator and its component parts and systems.Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

1. Check that the operatorcanopy is in good condition and is not modified.

9. Safety treads must be in good condition.

2. Check that the operating canopy mounting hardware is tightened and is Melroe approved.

10. Check for the correct function of the the indicator lamps.

3.

The seat belt must be correctly installed, functional and in good condition.

11. Check hydraulic fluid level, engine oil and fuel supply.

4.

Inspect for loose or broken parts or connections.

12. Inspect for fuel, oil orhydraulic leaks..

5.

Machine signs must be legible and in the correct location.

13. Lubricate excavator.

6.

Steering levers, control levers and foot pedals must return to neutral. Control lock must lock controls securely.

14. Check the condition of battery and cables.

7.

Inspect the air cleaner for damage or leaks. Check the condition of the element.

15. Check for any field modifications not completed.

Check the electrical charging system.

Recommend to the owner that all necessary corrections be made before the machine is returned to service.

8.

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A general inspection of the following items must be made after the hydraulic excavator has had servic e or repair:

the hydraulic

the

FIELD MODIFICATION

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SAFETY INSTRUCTIONS

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.

W–2003–0797

The following publications provide information on the safe use and maintenance of the excavator and attachments:

• The Delivery Report is used to assure that complete instructions have been given tothe new owner and that the machine is in safe operating condition.

• The Operation & Maintenance Manual delivered with the excavator gives operating information as well as routin

maintenance and service procedures. It is a part of the excavator and must stay with the machine when it is sold.

e

• The excavator has machine signs (decals) which instruct on the safe operation and care. The signs and their locations

are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat Excavator deale r.

• The CIMA Safety Manual delivered with the excavator gives information for safe operating and standard signals. repair work.

Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.

W–2044–1285

This notice identifies procedures which must be followed to avoid damage to the machine.

I–2019–0284

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• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and

Safety Alert Symbol: This Safety Symbol is used for important safety messages. When you see this symbol follow the safety message to avoid personal injury or death.

• Wear tight fitting clothing and any other required safety apparel when operating or servicing the excavator.

• Wear safety glasses when maintaining or servicing the excavator.

• Exhaust gases can kill, vent engine exhaust outdoors.

• Know where fire extinguishers and first aid kits are located and how to use them.

• Do not run the excavator where exhaust, arcs, sparks or hot components can contact flammable material, explosive du st or gases.

• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to chec k for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuelorf cleaning parts. Use commercial nonflammable solvents.

• Do not use ether or starting fluids on an engine that has glow plugs. These starting aids can explode and injure you.

• Clean the excavator before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fi re extinguisher near the excavator when welding.

• Have good ventilation when welding or grinding painted parts. Wear a dust mask when grinding painted parts. Toxic dust or gas can be produced.

• Stop the engine and let it cool before adding fuel. No smoking!

• Use the procedure in this manual for installing, connecting and jump starting batteries.

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SERIAL NUMBER LOCATIONS

A

Always use the serial number of the machine when requesting service information or when ordering parts.

Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a dif ferent procedure in doing a specific service operation.

HYDRAULIC EXCAVATOR SERIAL NUMBER The excavator serial number plate is on the machine frame, at the left side near the front corner [A].

N–07348

ENGINE SERIAL NUMBER

N–07349

DELIVERY REPORT

C

The Delivery Report must be filled out by the dealer and signed by the owner or operator when the excavator is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely [C].

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B

The engine serial number is located on the engine block, near the fuel injection pump [B].

HYDRAULIC EXCAVATOR IDENTIFICATION CONTROL LEVERS

OPERATOR CANOPY

ENGINE COVER

SWING LOCK UPPER WORKS

BLADE

TRACK

TRACK FRAME GRAB HANDLES DIPPERSTICK CYLINDER

OPERATOR SEAT

BUCKET CYLINDER

BUCKET LINK

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BOOM

BOOM CYLINDER CONTROL LOCK BLADE CYLINDER DIPPERSTICK

BUCKET 9 of 258

B–14810 B–14811

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PREVENTIVE MAINTENANCE Page Number

PREVENTIVE MAINTENANCE

AIR CLEANER SERVICE Replacing the Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–2 ..

COOLING SYSTEM Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 ....

Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–6 ...

ENGINE COVER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–3 ....

ENGINE LUBRICATION SYSTEM Checking the Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 ...

Engine Oil and Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 ..

FUEL SYSTEM Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–3 ...

Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–3 ...

HYDRAULIC SYSTEM Checking and Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–7 ..

Replacement of the Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 ..

Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–8 ...

LUBRICATION OF THE EXCAVATOR Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–10 ....

SERVICE SCHEDULE Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–1 ....

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FINAL DRIVE CASE Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–12 ...

Draining Final Drive Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 ...

USING A BOOSTER BATTERY (JUMP STARTING) Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–9 ....

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SERVICE SCHEDULE Maintenance work must be done at regular intervals. Failure to do so will result in excessivewear and early failures. The service schedule is a guide for correct maintenance of the Hydraulic Excavator.

Instructions are necessary before operating or servicing machine.

Read Operation & Maintenance Manuals, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death .

W–2003–1289

SERVICE REQUIRED

Engine Air Cleaner Engine Oil Engine Coolant System Indicator Lights Operator Canopy Seat Belt & Control Lock Safety Signs (Decals) & Safety Treads

Check & empty dust cup as required.

Check the oil level & add oil as needed.

Check radiator coolant level.

Check for correct operation.

Check the fastening bolts, nuts, & condition of canopy.

Check the condition, operation & that fasteners are tight.

Check for damaged signs (decals) and safety treads.

Replace any safety signs and safety treads that are damaged or worn.

Check & adjust tension.

Check fluid level.

Drain water and sediment from fuel tank.

Lubricate two grease fittings.

Lubricate one grease fitting.

Replace oil & filter element.

Tracks Hydraulic Reservoir Fuel Tank Swing Circle Swing Pinion Engine Oil & Filter All Machinery Pivot Points Alternator Belt Final Drive Case Hydraulic Filter Fuel Filter Battery Air Cleaner Cooling System Alternator & Starter Engine Valve Clearance Cooling System Hydraulic Tank Final Drive Case

8–10

Lubricate 20 grease fittings.

Check & adjust tension.

Check fluid level & add oil as needed.

Replace filter element.

Replace filter element.

Check & clean cable ends & check electrolyte level.

Replace the filter element.

Clean the radiator fins.

Check the condition.

Check & adjust valve clearance.

Drain, flush & add new coolant to the cooling system.

Change the fluid, clean fill neck strainer& suction strainer.

Change the fluid.

50

100

250

500 1000

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ITEM

After the first 250 hours of machine operation do the following procedures: • Change oil in final drive case.

• Check and adjust engine valve clearance.

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ENGINE COVER

A

Procedure

AVOID INJURY Never service or adjust the machine when the engine is running unless instructed to do so in the manual.

W–2012–0290 N–07367

Keep the engine cover closed when operating the machine.

W–2141–0189

B

Open the engine cover to service the engine. Pull on the latches and lift the engine cover until it is fully raised[A].

1 Replacing the Filter Element See the Service Schedule Page 1–1 for the service interval.

correct

Service the air cleaner as follows: 1. Remove the dust cup (Item 1) [B].

N–07368

C

2. Remove the wing nut (Item 1) [C].

1

N–07369

D

3. Remove the filter element [D].

4. Check the air cleaner housing for damage.

5. Install a new air filter element. Install and tighten the wing nut.

6. Install the dust cap so the arrow points up.

7. Check that the air cleaner hose clamps are tight.

N–07370 14 of 258

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AIR CLEANER SERVICE

FUEL SYSTEM

A

Fuel Specifications Use Number 2 diesel fuel in the engine. During very cold temperatures, Number 1 fuel can be used.

Fuel System Service

1

The fuel level in the tank is indicated by the plastic tube (Item 1) [A] on the side of the tank.

N–07371

Stop and cool the engine before adding fuel.

NO SMOKING! Failure to obey warnings can cause an explosion or fire.

B

W–2063–0887

N–07372

C

Turn the fill cap to remove it from the fuel tank [C].

NOTE: The fuel fill strainer can be removed for cleaning. Make sure it is installed before adding fuel to the tank.

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Use the key to unlock the fuel fill cap [B].

Use a clean, approved safety container to add fuel to the tank.

Add fuel only in an area that has a free movement of air and no open flames or sparks. NO SMOKING! After the tank is full, install and tighten the fuel fill cap.

N–07373

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FUEL SYSTEM (Cont’d)

A

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W–2103–1285 N–07375

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To remove the water and sediment from the fuel tank, open the drain in the bottom of the tank [A].

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ENGINE LUBRICATION SYSTEM

A

Checking the Engine Oil Check the engine oil every day.

Stop the engine. Open the engine cover.

Remove the dipstick [A].

Keep the oil level between the marks on the dipstick.

Use a good quality motor oil that meets API Service Classification of CC or CD. (See Fuel, Coolant and Lubricants Chart Page 8–9.)

N–07378

Engine Oil and Filter Replacement

B

See the SERVICE SCHEDULE Page 1–1 for the correct service interval.

Use the following procedure to change the oil and filter:

Turn the upper works so there is clearance for the engine oil drain plug. Stop the engine.

1

Remove the drain plug (Item 1) [B]. Drain the oil into a container.

N–07379

C

Remove the oil filter (Item 1) [C], using a filter wrench.

Clean the filter housing surface. Put clean oil on the filter gasket. Install the new filter and hand tighten only.

Dealer Copy -- Not for Resale

Run the engine until it is at operating temperature.

1

N–07380

D

Remove the oil fill cap[D]. Put 3.5 quarts (3,4 L) of oil into the engine. (See Fuel, Coolant and Lubricants Chart Page 8–9.)

Start the engine and let it run for several minutes. Stop the engine. Check the oil filter for leaks.

Check the oil level and add oil as needed to bring it to the top mark on the dipstick.

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COOLING SYSTEM

A

Coolant Level When the engine is cool, remove the radiator cap [A].

The coolant level must be 3/4”–1” (19–25 mm) belowthe radiator filler neck.

If the coolant level is low , add premixed coolant (50% ethylene glycol and 50% water) to the radiator.

Coolant Replacement

N–07382

B

Do not remove radiator cap when the engine is hot. You can be seriously burned.

W–2070–1285

Turn the upper works so there is access tothe engine and radiator underneath. Stop the engine.

Loosen and remove the radiator cap [A].

Open the radiator drain valve (Item 1) [B].

Drain all the coolant from the system.

N–07383

When all the coolant is removed, close the drain valve.

Premix 50% water and 50% ethylene glycol in a separate container. Fill the radiator with premixed coolant until it is full.

Run the engine at idle speed for about 5–10 minutes to remove the air from the cooling system (leave the radiator cap off during this operation).

Stop the engine. Check the coolant level and add as needed, bringing it 3/4”–1” (19–25 mm) below the filler neck. Install the radiator cap and tighten.

Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure.

• Flying debris or loose material is present.

• Engine is running.

• Tools are being used.

W–2019–1285

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1

HYDRAULIC SYSTEM

A

Checking and Adding Fluid To check and add hydraulic fluid to the reservoir, use the following procedure: Put the machine on a flat surface.

Retract the dipperstick and bucket cylinders, put the bucket on the ground, and raise the blade. Stop the engine.

1

Check the hydraulic fluid level, it must be visible and between the marks in the sight gauge (Item 1) [A].

N–09091

N–09161

C

Remove the reservoir fill cover [C].

Add the correct fluid to the reservoir until it is at the top mark in the sight gauge [A]. (See Fuel, Coolant and Lubricants Chart Page 8–9.)

Install the reservoir cover, make sure the O–ring is in the correct position.

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B

If the fluid level is low , remove the four bolts from the reservoir cover [B].

Install and tighten the bolts.

N–09162

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HYDRAULIC SYSTEM (Cont’d)

A

Replacement of the Hydraulic Filter See the Service Schedule Page 1–1 for the service interval.

correct

1

Open the engine cover. Use a filter wrench and remove the filter element (Item 1) [A].

Clean the housing where the filter gasket makes contact.

Put clean fluid on the gasket. Install the new filter element and hand tighten only.

Start the engine. Run the machine through thehydraulic functions. Stop the engine. Check the fluid level at the reservoir and add as needed. Check the filter area for leaks.

N–09163

B

Hydraulic Reservoir See the Service Schedule Page 1–1 for the service interval.

2

correct

Retract the dipperstick and bucket cylinder , lower the bucket to the ground. Stop the engine.

3

1

Remove the hydraulic filter. Remove the drain plug (Item 1) [B] from the bottom of the reservoir.

Remove the hose clamps (Item 2)[B] and disconnect the hoses. Remove the bolts (Item 3) [B] from the flange.

Turn the bolts into the threaded holes in the flange to push the mesh screen out of the reservoir.

N–09090

Clean all the parts with clean solvent and air dry them.

Replace the parts and tighten the bolts, hose clamps and drain plug.

Add approximately 7.0 gals. (26,5 L) of fluid to the reservoir. (See Fuel, Coolant and Lubricants Chart Page 8–9.)

Run the machine through the hydraulic functions. Stop the engine. Check the fluid level and add as needed.

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W–2103–1285

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Move the upper works so there is a clearance for the reservoir between the track frame.

USING A BOOSTER BATTERY (JUMP STARTING)

A

Procedure

1

If it becomes necessary to use an extra battery to start the engine, BE CAREFUL! Make sure the swing lock pin is in the engaged position.

The key switch must be in the OFF position.

2

The booster battery must be 12 volt.

Open the engine cover.

Connect the end of the first cable to the positive (+) terminal of the booster battery. Connect the other end of the same cable to the starter terminal (Item 1) [A].

N–07387

Connect the end of the second cable to the negative (–) terminal of the booster battery. Connect the other end of the same cable to the machine frame (Item 2) [A].

Start the engine. After the engine is running, remove the cable (Item 2) [A] connected to the frame first.

Disconnect cable from the starter terminal (Item 1) [A].

Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at engine frame.

Do not jump start or charge a frozen battery.

Warm battery to 60°F. (16°C.) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery.

Battery gas can explode and cause serious injury.

Damage to the alternator can occur if:

• Engine is operated with battery cables

W–2066–0490

disconnected.

• Battery cables are connected when using a fast charger or when welding on the loader (Remove both cables from the battery).

• Extra battery cables (booster cables) are connected wrong.

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NOTE: Also see Cold Starting Procedure in the Operation & Maintenance Manual.

I–2023–1285

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LUBRICATION OF THE EXCAVATOR

A

Procedure Lubricate the Hydraulic Excavator as specified in the Service Schedule Page 1–1 for the best performance of the machine.

1

2

2

Always use a good quality lithium based multi–purpose grease when lubricating the machine. Apply the lubricant until extra grease shows.

3

Ref. Description (# of Fittings) 1. Blade Cylinder Rod End (1) [A].

2. Blade Pivots (2) [A].

3. Blade Cylinder Base End (1) [A].

N–07397

B

4. Boom Cylinder Rod End (1) [B].

N–07398

C

5. Boom Pivot Pin (1) [C].

6. Boom Swing Bracket Pivot (2) [C].

7. Boom Cylinder Base End (1) [C].

5

6

6

7

N–07399

8. Boom Cylinder Rod End (1) [D].

9. Dipperstick Cylinder Base End (1) [D].

D

9

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4

LUBRICATION OF THE HYDRAULIC EXCA VATOR (Cont’d)

A 10

Procedure (Cont’d) Ref. Description (# of Fittings)

11

10. Dipperstick Cylinder Rod End (1) [A].

11. Dipperstick Pivot Pin (1) [A].

12. Bucket Cylinder Base End (1) [A].

12

N–07401

B

13. Bucket Cylinder Rod End (1) [B].

14. Bucket Link Pivots (2) [B].

15. Bucket Pivots (4) [B].

14 13

15 14 15

N–07402

16. Boom Cylinder Base End (1) [C].

C

17. Swing Circle Pinion (1) [C].

16

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15

17

N–07403

18. Swing Circle (2) [D].

D

18

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FINAL DRIVE CASE

A

220ExcavatorServiceManual(S/N508211999&Below)#6720230–PreventiveMaintenanceSection

Checking Oil Level Put the machine on a flat level surface.

1

Position the plug (Item 1) [A] parallel to the ground.

Remove one of the plugs (Item 1) [A].

Add oil through the hole if the oil level is below the hole.

(See Fuel, Coolant and Lubricant Chart Page 8–9.)

Install and tighten the plug.

Repeat the procedure for the other side.

P–05906

Draining Final Drive Case See the Service Schedule Page 1–1 for the service interval.

B

correct

Remove the bottom plug (Item 1) [B] and the top plug (Item 2) [B].

2

After the oil is removed, install and tighten the bottom plug.

1

Add .33 quarts (0,3 L) of oil to the top plug hole. Install the plug.

Use the same procedure for Checking Oil Level. Add oil as needed.

P–05907

Repeat the procedure for the other side.

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Put the machine on a flat level surface with the plugs positioned as shown in figure [A].

HYDRAULIC SYSTEM Page Number ARM CYLINDER Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–26 ...

BLADE CYLINDER Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–27 ...

HYDRAULIC SYSTEM

BOOM CYLINDER Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–25 ...

BOOM SWING CYLINDER Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–28 ...

BUCKET CYLINDER Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–27 ...

HYDRAULIC CYLINDER (Melroe Cylinders) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–31 ....

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–29 ....

HYDRAULIC PUMP Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–13 ....

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8 ....

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–7 ...

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5 ...

HYDRAULIC RESERVOIR Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22 ...

Suction Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24 ....

HYDRAULIC SERVICE INFORMATION Checking The Main Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–3 ..

Dealer Copy -- Not for Resale

HYDRAULIC CONTROL VALVE Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–19 ...

SOLENOID VALVE Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–42 ....

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–39 ....

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–38 ...

SWING CYLINDER LOCK VALVE Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–48 ....

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–47 ....

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–46 ...

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HYDRAULIC SERVICE INFORMATION

A

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

I–2003–0888

1

2

1

There are two main relief valves (Item 1) [A] and port relief valves (Item 2) [A] in the hydraulic system.

MC–01205

B

Checking The Main Relief Valves The tools listed will be needed to do the following procedure: OEM1238 OEM1239 – Hydraulic Tester 6657708 – Test Fitting 6657709 – Hose Adapter

1

Stop the engine and raise the engine cover.

Disconnect the outlet hose (Item 1 or 2) [B] from the hydraulic pump and connect that hose to the outlet of the tester.

N–07538

NOTE: Install the adapter 6657709 between outlet hose of tester and outlet hose of the pump.

Remove the outlet fitting from the pump being tested and install the test fitting 6657708.

Dealer Copy -- Not for Resale

2

Connect the inlet of the tester to the test fitting in the pump.

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HYDRAULIC SERVICE INFORMATION (Cont’d)

A

Checking the Main Relief Valves (Cont’d) NOTE: Open the flow control knob (Item 1) [A] fully to prevent pump damage.

1

NOTE: Refer to the hydraulic flow chart valve section.

Start the engine and run at low RPM. Make sure the tester is connected correctly. If no flow is indicated at the tester, the hoses are connected wrong.

Increase the engine speed to full RPM. W arm the hydraulic fluid to 140 °F (60°C) by turning the restrictor valve until the gauge reads about 1000 PSI (6895 kPa).

Do not exceed system pressure.

N–11433

Stroke a cylinder to it’s limit, in the section being tested, to open the relief valve.

The relief valve pressure should open at 2133 PSI (14707 kPa) ± 75 PSI. The flow should be 10.7 GPM (40,5 L/min.) on a new pump.

Dealer Copy -- Not for Resale

Release the pressure on the cylinder being tested.

Close the flow control knob (Item 1)[A] slowly, to 100 PSI below relief valve setting, and record the high pressure.

NOTE: The high pressure flow must be at least 80% of free flow. %=

HIGH PRESSURE FLOW (GPM) FREE FLOW (GPM)

X 100

If high pressure flow is less than 80% of free flow , remove the hydraulic pump for repair or replacement.

Repeat the testing procedure and use the samereadings as shown above.

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HYDRAULIC PUMP

A

Removal And Installation

1

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

N–07537

I–2003–0888

Disconnect the two inlet hoses (Item 1) hydraulic pump.

B

[A] from the

Drain the hydraulic fluid in a container.

N–07538

C

Loosen the pump mounting bolts [C].

Dealer Copy -- Not for Resale

Disconnect the two pressure hoses [B].

N–07539

Remove the bolts and washers from the pump flange[D].

D

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HYDRAULIC PUMP (Cont’d)

A

Removal And Installation (Cont’d) Remove the hydraulic pump from the bell housing [A].

Dealer Copy -- Not for Resale

N–07541

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HYDRAULIC PUMP Parts Identification

Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt

5

12 8

2

6

5

4

14 15 13

14

11 9 7 4

1

16

10

Dealer Copy -- Not for Resale

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

6 25

3 5

26

22 20 18

24 6 14

5

4

23 14 21 19 17

4

6

B–14926

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HYDRAULIC PUMP

A

Disassembly

1

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

P–08236

I–2003–0888

B

Use solvent to clean the outside of thehydraulic pump of oil and dirt.

Clamp the mounting flange of the pump in a vise that has padded jaws.

Mark the housing for ease of assembly.

Remove the four bolts (Item 1) [A] and washers.

Remove the cover [B].

P–08237

Remove the two back–up rings (Item 1) [C].

C 1

P–08238

Remove the two seals (Items 1 & 2) [D].

D 2

1

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NOTE: During disassembly, put all parts on clean work surface.

HYDRAULIC PUMP (Cont’d)

A

Disassembly (Cont’d) Remove the pump section body [A].

P–08240

B

1

P–08292

Remove the two seals (Items 1 & 2)[C] from the bottom of the pump section.

C

Dealer Copy -- Not for Resale

Remove the back–up rings (Item 1) [B] from the bottom of the pump section.

1

2

P–08241

Remove the two bushings (Items 1 & 2) bottom of the pump section.

D

[D] from the

1

2

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HYDRAULIC PUMP (Cont’d)

A

Disassembly (Cont’d) Remove the gears (Items 1 & 2) [A].

2

1

P–08243

Remove the two bushings (Item 1)[B] from the top of the pump section.

1 P–08244

Remove the center plate from the pump section [C].

C

P–08245

Remove the drive coupler (Item 1)[D] from the drive gear.

D

1

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B

HYDRAULIC PUMP (Cont’d)

A

Disassembly (Cont’d) Remove the two back–up rings (Item 1) [A].

1

P–08247

Remove the two seals (Items 1 & 2) [B].

B

1 P–08248

Remove the pump section [C].

C

Dealer Copy -- Not for Resale

2

P–08249

Remove the two back–up rings (Item 1) bottom of the pump section.

[D] from the

D

1

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HYDRAULIC PUMP (Cont’d)

A

Disassembly (Cont’d) Remove the two seals (Items 1 & 2) [A] from the bottom of the pump section.

2

1

P–08251

Remove the two bushings (Item 1)[B] from the bottom of the pump section.

1

P–08252

Remove the two drive gears (Items 1 & 2) [C] from the bottom of the pump section.

C

2

1

P–08253

Remove the two bushings (Item 1)[D] from the top of the pump section.

D

1

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B

HYDRAULIC PUMP (Cont’d)

A

Disassembly (Cont’d) Remove the snap ring (Item 1) [A] and seal (Item 2) [A] from the flange.

2

1 P–08255

Assembly

B

Clean all parts in solvent and dry with compressed air.

Apply clean hydraulic fluid to all seals and back–up rings.

Install the new seal (Item 2)[A] and snap ring (Item 1)[A].

Install the bushings (Item 1) [B] at the same time in the pump section until they are flush with top surface.

1

2

NOTE: Install the bushings as shown towards the intake side (large port) (Item 2) [B].

P–08254

NOTE: Do not force the bushings.

C

Turn the pump section over. Do not allow the bushings to drop out of the pump section.

Install the gears (Items 1 & 2) [C].

1

Dealer Copy -- Not for Resale

Apply clean hydraulic fluid to the bushings and inside of both pump sections.

2

P–08253

Install the bushings (Item 1) [D].

D

NOTE: Install the bushings as shown towards the intake side (large port) (Item 2) [D].

1

2 P–08252

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HYDRAULIC PUMP (Cont’d)

A

Assembly (Cont’d) Apply oil and install the two new seals (Items 1 & 2) [A].

2

1

P–08251

[B] to the

B

1

P–08250

Install the bottom pump section on the flange [C].

C

NOTE: Make sure the alignment marks are incorrect alignment.

NOTE: Make sure the back–up rings and the seals stay in their correct position when installing the pump section on the flange.

P–08249

D

Apply oil and install the two new seals (Item 1 & 2) [D].

2

1 P–08248 46 of Revised July 97258

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Install the two new back–up rings (Item 1) bottom of the pump section.

HYDRAULIC PUMP (Cont’d)

A

Assembly (Cont’d) Install the two new back–up rings (Item 1) [A].

1

P–08247

Install the drive coupler [B].

P–08246

Install the center plate [C].

C

Dealer Copy -- Not for Resale

B

P–08245

D

Install the bushings (Item 1) [D] at the same time in the pump section until they are flush with the top surface.

NOTE: Do not force the bushings.

NOTE: Install the bushings as shown towards the intake side (large port) (Item 2) [D].

Turn the pump section over. Do not allow the bushings to drop out of the pump section.

1

2 P–08244

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HYDRAULIC PUMP (Cont’d)

A

Assembly (Cont’d) Install the gears (Items 1 & 2) [A].

1

2 P–08243

Install the bushings (Item 1) [B].

1

2 P–08242

Apply oil and install the two seals (Items 1 & 2) [C].

C

1

2

P–08241

D

Install the back–up rings (Item 1) [D].

1

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B

NOTE: Install the bushings as shown towards the intake side (large port) (Item 2) [B].

HYDRAULIC PUMP (Cont’d)

A

Assembly (Cont’d) Install the pump section on the center plate [A].

NOTE: Make sure the alignment marks are incorrect alignment.

NOTE: Make sure the back–up rings and the seals stay in their correct position when installing the pump section on the flange.

P–08240

Install the two seals (Items 1 & 2) [B].

B

1

P–08239

Install the back–up rings (Item 1) [C].

C 1

Dealer Copy -- Not for Resale

2

P–08238

D

Install the cover [D].

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HYDRAULIC PUMP (Cont’d)

A

Assembly (Cont’d)

1

Install the four bolts (Item 1) [A] and washers. Tighten to 34 ft.–lbs. (46 Nm) of torque in a crisscross manor.

Rotate the shaft to see if it rotates freely.

Dealer Copy -- Not for Resale

P–08236

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HYDRAULIC CONTROL VALVE

A

Removal and Installation

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

N–07542

I–2003–0888

B

Mark all the hoses and tubelines for correct installation.

Disconnect all the hoses for the boom, dipperstick and bucket cylinders [A].

N–07543

C

Remove the tubeline clamp [C].

Dealer Copy -- Not for Resale

Remove the bolts from the tubeline clamp [B].

N–07544

Disconnect the two auxiliary hoses [D].

Remove the two fittings for clearance when removing the control valve/control lever assembly.

D

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HYDRAULIC CONTROL VALVE (Cont’d)

A

Removal and Installation (Cont’d) Disconnect the hoses from the inlet section of the control valve (both sides) [A].

N–07546

N–07547

C

Disconnect the linkage from the boom swing and blade control levers [C].

N–07548

D

Remove the bolts from the boom swing and bladecontrol lever mounting bracket [D].

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Dealer Copy -- Not for Resale

B

Disconnect all the tubelines and hoses from the control valve [B].

HYDRAULIC CONTROL VALVE (Cont’d)

A

Removal and Installation (Cont’d) Remove the boom swing and blade control lever assembly [A].

N–07550

B

Remove all the bolts from the control valve/control lever mounting plate [B].

N–07551

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Lift the control valve/control lever assembly from the machine.

220 (S/N 508211999 & Below) Excavator Service Manual

HYDRAULIC RESERVOIR

A

Removal and Installation

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

N–07552

I–2003–0888

B

Remove the engine and hydraulic pump from the machine. (See Page 7–1.)

Remove the operator canopy.

Remove the fuel tank. (See Page 5–1.)

Mark all the hoses for correct installation.

Disconnect the three return hoses from the tee fittings on the hydraulic filter housing [A].

Remove the hydraulic filter element [B].

N–07553

Remove the tee fittings [C].

C

N–07554

D

Loosen the filter housing from the reservoir [D].

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Dealer Copy -- Not for Resale

Remove the seat and mounting frame. (See Page 5–1.)

HYDRAULIC RESERVOIR (Cont’d)

A

Removal and Installation (Cont’d) Remove the filter element housing [A].

Remove the instrument panel and disconnect the wire harness. (See Page 6–1.)

N–07556

N–07557

C

Remove the upper mounting bolts from the reservoir [C].

Dealer Copy -- Not for Resale

B

Remove the lower mounting bolts from the hydraulic reservoir [B].

N–07558

D

Remove the bolts from the upright frame [D].

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HYDRAULIC RESERVOIR (Cont’d)

A

Removal and Installation (Cont’d) Slide the upright frame away from the hydraulic reservoir [A].

Lift and remove the hydraulic reservoir from the machine [A].

N–07560

B

Suction Filter To remove and install the mesh screen filter from the hydraulic reservoir, use the following procedure:

N–07561

C

Turn two bolts into the threaded holes in the mounting flange to push the flange out of the reservoir [C].

N–07562

Remove the mesh screen and mounting flange assembly from the reservoir [D].

Use clean solvent to clean the suction filter pressure to dry the mesh screen.

D

. Use air

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Remove the bolts from the mounting flange [B].

BOOM CYLINDER

A

220ExcavatorServiceManual(S/N508211999&Below)#6720230–HydraulicSystemSectionPart1of2

Removal and Installation NOTE: Refer to Pages 2–29 through 2–31 for servicing the cylinder.

Put the bucket on the floor. Stop the engine.

Support the boom using a chain hoist.

Move the hydraulic controls to release the hydraulic pressure.

N–07564

B When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

Disconnect the two hoses from the boom cylinder.

Remove the retainer bolt and nut from the boom cylinder base end pin [A].

N–07565

Remove the cylinder base end pin [B].

C

Lower the base end of the boom cylinder to the floor.

1 Remove the retainer bolt (Item 1) [C] and nut from the cylinder rod end pin.

Remove the cylinder rod end pin. Remove the cylinder from the boom.

Dealer Copy -- Not for Resale

I–2003–0888

boom

N–07566

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ARM CYLINDER

A

Removal and Installation NOTE: Refer to Pages 2–29 through 2–31 for servicing the cylinder.

Put the bucket on the floor. Stop the engine.

Support the boom using a chain hoist.

Move the hydraulic controls to release the hydraulic pressure.

1 N–07567

B When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

I–2003–0888

Disconnect the two hoses from the arm cylinder [A].

Remove the retainer bolt (Item 1) [A] and nut from the cylinder base end pin.

N–07568

Remove the cylinder base end pin.

Remove the retainer bolt (Item 1) [B] and nut from the cylinder rod end pin.

Remove the cylinder rod end pin.

Remove the cylinder from the arm.

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1

BUCKET CYLINDER

A

Removal and Installation NOTE: Refer to Pages 2–17 through 2–25 for servicing the cylinder.

Put the bucket on the floor. Stop the engine.

1

Move the hydraulic controls to release the hydraulic pressure.

2

N–07568

B

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

1 Disconnect the two hoses (Item 1) [A] from the bucket cylinder.

Remove the retainer bolt (Item 2) [A] and nut from the cylinder base end pin [A].

N–07569

Remove the cylinder base end pin.

C

Remove the retainer bolt (Item 1) [B] and nut from the cylinder rod end pin.

3

Remove the cylinder rod end pin.

1

Remove the bucket cylinder.

BLADE CYLINDER

4

Removal and Installation NOTE: Refer to Pages 2–17 through 2–25 for servicing the cylinder.

Dealer Copy -- Not for Resale

I–2003–0888

2

N–07397

Put the blade on the floor . Stop the engine. Move the blade control lever to release the hydraulic pressure.

Remove the hose fitting cover (Item 1) [C].

Disconnect the two hoses (Item 2) [C].

Remove the retainer bolt (Item 3) [C], nut and base end pin from the blade cylinder.

Remove the retainer bolt (Item 4) [C] and nut from the cylinder rod end pin.

Remove the cylinder rod end pin. Remove the blade cylinder.

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BOOM SWING CYLINDER

A

Removal and Installation NOTE: Refer to Pages 2–29 through 2–31 for servicing the cylinder.

1

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

N–07570

B

I–2003–0888

Disconnect the grease tube (Item 1) [A] from the boom swing cylinder base end pin.

Disconnect the hoses (Item 1) [B] from the cylinder.

Remove the retainer bolt from the cylinder base end pin.

Remove the cylinder base end pin.

N–07573

C

Remove the retainer bolt from the cylinder rod end pin [C].

N–07571

D

Remove the cylinder rod end pin [D].

Remove the boom swing cylinder.

N–07572

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Dealer Copy -- Not for Resale

1

Remove the floor panels. (See Page 3–1).

HYDRAULIC CYLINDER (Melroe Cylinders)

A

Disassembly NOTE: The drawings may not show the cylinder exactly as it appears, but the procedure is correct for all cylinders.

Put the base end of the hydraulic cylinder in a drain pan.

Move the rod in and out to remove the fluid from the cylinder. Move the rod slowly so the fluid will go directly into the drain pan.

Put the base end of the cylinder in a vise.

Use the adjustable gland nut wrencher (MEL1075) to loosen the head [A].

B–07000

B

Remove the rod assembly from the cylinder case [B].

Remove the cylinder case from the vise.

B–07001

C

FOR CYLINDERS USING PISTON RETAINING BOLTS: Loosen the bolt from the piston end of the rod [C].

Dealer Copy -- Not for Resale

Put the rod end in the vise.

B–13745

D

FOR CYLINDERS USING PIST ON RETAINING LOCK NUT: Loosen the nut from the piston end of the rod [D].

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HYDRAULIC CYLINDER (Melroe Cylinders) (Cont’d)

A

Disassembly (Cont’d) Remove the bolt (Item 1) [A] from the rod.

2

1

3

Pull the piston off the rod (Item 2 ) [A].

Pull the head (Item 3) [A] off the rod.

CD–12677

B

Remove the O–ring (Item 1) [B] and back–up washer (Item 2) [B] from the head with seal hook (MEL1074).

Remove the O–ring (Item 3) [B] from the head.

2 3

B–13743

C

Remove the wiper seal [C].

B–07005

D

Remove the oil seal from the head [D].

B–07006

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1

HYDRAULIC CYLINDER (Melroe Cylinders) (Cont’d)

A

Disassembly (Cont’d) FOR PISTONS WITH SINGLE RING GROOVE: Cut the old teflon seal and remove the seal from the piston [A].

B–03689

B

Remove the O–ring from the piston [B].

While servicing the cylinder, do not damage the parts.

Inspect for nicks, scratches or otherwise damaged or bent parts before assembling the cylinder. Replace parts that appear damaged in any way. The cylinder may not function correctly if there is damage to any of the parts.

Destroy all the O–rings and seals and replace them with NEW O–rings and seals.

B–03703

C

Assembly Install the O–ring on the piston [C].

Dealer Copy -- Not for Resale

Wash the cylinder parts in solvent and air dry them.

B–12812

D

NOTE: Do not overstretch the seal.

Install the seal on the tool (MEL1396) and stretch it until it fits the piston [D].

Allow the O–ring to stretch for 30 seconds before removing it from the tool.

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HYDRAULIC CYLINDER (Melroe Cylinders) (Cont’d)

A

Assembly (Cont’d) Install the seal on the piston [A].

B–12813

Use a ring compressor to compress the seal to the correct size [B].

B

B–12811

C

FOR PISTONS WITH THREE RING GROOVES: Remove the two split rings (Item 1) [C] from the piston.

1

B–13736

Cut the old teflon seal and remove the seal from the piston [D].

D

B–13738

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Dealer Copy -- Not for Resale

Leave the piston in the ring compressor for 3 minutes.

HYDRAULIC CYLINDER (Melroe Cylinders) (Cont’d)

A

Assembly (Cont’d) Remove the O–ring from the piston [A].

Wash the cylinder parts in solvent and air dry them.

While servicing the cylinder do not damage the parts.

Inspect for nicks, scratches or otherwise damaged or bent parts before assembling the cylinder. Replace parts that appear damaged in any way. The cylinder may not function correctly if there is damage to any of the parts.

Destroy all the O–rings and seals and replace them with NEW O–rings and seals.

B–13737

B–13739

C

NOTE: Do not overstretch the seal.

Install the seal on the tool (MEL1396) and stretch it until it fits the piston [C].

Dealer Copy -- Not for Resale

B

Install the O–ring on the pistons center groove [B].

B–12809

Install the seal on the pistons center groove [D].

D

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HYDRAULIC CYLINDER (Melroe Cylinders) (Cont’d)

A

Assembly (Cont’d) Use a ring compressor to compress the seal to the correct size [A].

Leave the piston in the ring compressor for 3 minutes.

B–13740

B

Install the two outer split rings onto the piston [B].

B–13741

C

Install the oil seal on the rod seal tool (MEL1033) [C].

NOTE: The O–ring side of the oil seal goes toward the inside of the cylinder.

O–ring Side

B–03702

Install the oil seal in the head [D].

D

B–03671

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Dealer Copy -- Not for Resale

NOTE: Position the gaps of the piston rings so that they are at 180° from each other.

HYDRAULIC CYLINDER (Melroe Cylinders) (Cont’d)

A

Assembly (Cont’d) Install the wiper seal with the lip toward the outside of the head [A].

B–03682

1

CD–12674

C

Install the back–up washer (Item 1) [C] and O–ring (Item 2) [C] onto the head.

2

Dealer Copy -- Not for Resale

B

Install the O–ring (Item 1) [B] onto the head.

1

CD–12675

D

Apply grease to the inside of the head and to the lips of the seals.

Inspect the beveled edge of the rod for nicks or sharp edges [D]. Remove these with a file prior to installing the gland on the rod or damage to the seals may occur.

Install the head on the rod [D].

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HYDRAULIC CYLINDER (Melroe Cylinders) (Cont’d)

A

Assembly (Cont’d) FOR CYLINDERS USING PISTON RETAINING BOLTS: Install the piston on the rod with the recessed end of the piston toward the head [A].

Lubricate the retainer bolt with oil and install the retainer bolt through the piston and into the rod.

Tighten the bolt to 185–215 ft.–lbs.(250–291 Nm) torque.

CD–12677

FOR CYLINDERS USING PIST ON RETAINING LOCK NUT:

B

Install the piston on the rod with the tapered end of the piston towards the head [B].

With aluminum piston and 0.875 inch thread diameter , tighten the nut to 250 ft.–lbs. (339 Nm) torque.

With steel piston and 0.875 inch thread diameter, tighten the nut to 300 ft.–lbs. (407 Nm) torque.

With steel piston and 1.000 inch thread diameter, tighten the nut to 400 ft.–lbs. (542 Nm) torque.

B–07002

C

Inspect the inside of the cylinder case for nicks and scratches. If the cylinder case has minor scuf fing, the cylinder case can be honed [C]. Use a flexible hone and lubricate with oil during the honing process.

Thoroughly wash the inside of the cylinder case after the honing process.

N–12678

D

Put oil on the seal surface of the cylinder case [D].

B–07013

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Dealer Copy -- Not for Resale

Clean and dry the cylinder rod threads and install the new nut (supplied with seal kit) [B].

HYDRAULIC CYLINDER (Melroe Cylinders) (Cont’d)

A

Assembly (Cont’d) Put oil on the teflon seal on the piston [A].

B–13744

B–07001

C

Put oil on the seals on the head [C].

Put oil on the threads of the head.

Dealer Copy -- Not for Resale

B

Install the rod assembly in the cylinder case [B].

B–07014

Use the adjustable gland nut tighten the head [D].

D

wrench (MEL1075) to

NOTE: Gland to be tightened until it is flush withthe end of the cylinder case.

Move the rod in and out of the cylinder case and make sure that it moves freely.

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SOLENOID VALVE Parts Identification

Compensator O–ring O–ring Back–up Ring Valve Body Plug O–ring Check Valve O–ring Back–up Ring O–ring Restrictor Plate 0.130” Back–up Ring O–ring O–ring Valve Stem Coil Nut Back–up Ring O–ring O–ring Relief Valve O–ring Plug

17

18 23

16

13

14

24

22

15 19

12

20

21

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1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

6 7

5

4

2

3

4

4

3

3

4

9

1

10

11

8

B–14927

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A

SOLENOID VALVE Disassembly Clamp the valve in a vise that has padded jaws.

Remove the nut (Item 1) [A] and coil (Item 2)[A] from the valve stem.

2 1

P–08627

Remove the valve stem (Item 1) [B] from the valve body.

B

P–08628

Remove the restrictor plate (Item 1) [C] from the valve body.

C 1

Dealer Copy -- Not for Resale

1

P–08629

Remove the O–rings (Item 1) [D] and back–up ring (Item 2) [D] from the valve stem.

D 2

1

1 P–08630

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SOLENOID VALVE (Cont’d)

A

Disassembly (Cont’d) Remove the relief valve (Item 1) [A] from the valve body.

1

P–08631

Remove the plug (Item 1) [B] from the end of the relief valve.

B

P–08632

C

Remove the O–ring (Item 1)[C] from the plug (Item 2)[C].

Remove the O–ring (Item 3) [C] and back–up rings (Item 4) [C] from the relief valve.

4

2

1

3

3 P–08633

D

Remove the check valve (Item 1)[D] from the valve body.

1

P–08634

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1

SOLENOID VALVE (Cont’d)

A

Disassembly (Cont’d) Remove the O–ring (item 1) [A] and the seal (Item 2) [A] from the check valve.

1

2 P–08635

[B] from the

B

1

P–08636

C

Remove the O–rings (Item 1)[C] and back–up rings (Item 2) [C] from the compensator valve.

2

2

2

Dealer Copy -- Not for Resale

Remove the compensator valve (Item 1) valve body.

1

1

P–08637

D

Remove the plug (Item 1) [D] from the valve body.

1

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SOLENOID VALVE (Cont’d)

A

Disassembly (Cont’d)

1

Remove the O–ring (Item 1) [A] from the plug.

Assembly Clean all parts in solvent and dry with compressed air .

The valves are not serviceable. If the valves do not operate correctly after cleaning, the relief valves must be replaced. Order new valves from Melroe Parts.

P–08639

Apply oil and install a new O–ring (Item 1)[A] on the plug.

B

1

P–08638

C

Apply oil and install new O–rings (Item 1) [C] and back–up rings (Item 2) [C] on the compensator valve.

2

1

2

2

1 P–08637

D

Dip the compensator valve in clean hydraulic fluid.

Install the compensator valve (Item 1) [D] in the valve body.

1

P–08636

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Install the plug (Item 1) [B] in the valve body.

SOLENOID VALVE (Cont’d)

A

Assembly (Cont’d) Apply oil and install new O–ring (Item 1) [A] and seal (Item 2) [A] on the check valve.

1

2 P–08635

1

P–08634

C

Apply oil and install a new O–ring (Item 1)[C] on the plug (Item 2) [C].

Apply oil and install new O–rings (Item 3) [C] and back–up ring (Item 4) [C] on the relief valve.

4

2

3

1

Dealer Copy -- Not for Resale

B

Install the check valve (Item 1) [B] in the valve body.

3 P–08633

D

Install the plug (Item 1) [D] in the end of the relief valve.

1

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SOLENOID VALVE (Cont’d)

A

Assembly (Cont’d) Dip the relief valve (Item 1)[A] in clean hydraulic fluid and install in the valve body.

1

P–08631

Make sure the restrictor plate (Item 1) [B] orifice is open.

B

Install the restrictor plate (Item 1) [B] in the valve body.

P–08629

C

Apply oil and install new O–rings (Item 1) [C] and back–up ring (Item 2) [C] on the valve stem.

2

1 P–08630

D

Dip the valve stem (Item 1)[D] in clean hydraulic fluidand install in the valve body.

1

P–08628

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1

SOLENOID VALVE (Cont’d)

A

Assembly (Cont’d) Install the coil (Item 1)[A] and nut (Item 2)[A] on the valve stem.

Tighten to 4–6 ft.–lbs. (5–8 Nm) torque.

1

NOTE: If the coil is over torqued it may cause valve failure.

2

Dealer Copy -- Not for Resale

P–08627

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220 (S/N 508211999 & Below) Excavator Service Manual

SWING CYLINDER LOCK VALVE Parts Identification

1.

2.

3.

4.

5.

6.

7.

8.

9.

Plug O–ring Spring Ball Check Valve Body O–ring Back–up Ring Spool Valve Body

1

2

3

Dealer Copy -- Not for Resale

4

5

6 7

8

9

C–03458

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SWING CYLINDER LOCK VALVE

A

Disassembly

2

1

Before disassembly: Clean the outside of the valve.

Disassemble the valve in a clean area.

Clamp the valve (Item 1)[A] in the vise, with padded jaws, and remove the check valve (Item 2) [A] (both sides).

P–08320

Clamp the check valve (Item 1) [B] in the vise, with padded jaws, and loosen the cap (Item 2) [B] (on both valves).

B 2

P–08321

Remove the cap (Item 1) [C] the spring (Item 2) [C] and the check ball (Item 3) [C] from the check valve (Item 4) [C].

C

Remove the O–ring (Item 5) [C] from the cap (Item 1)[C] (on both valves).

4

1

2

Dealer Copy -- Not for Resale

1

3

5

P–08322

D

Remove the large O–ring (Item 1) [D], the small O–ring (Item 2) [D] and the backup ring (Item 3) [D] from the check valve (Item 4) [D] (on both valves).

4

3

1

2 P–08323

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SWING CYLINDER LOCK VALVE (Cont’d)

A

Disassembly (Cont’d)

2

Remove the spool (Item 1) [A] from the valve body (Item 2) [A].

NOTE: Be careful not to scratch or damage the spool.

1

P–08324

Assembly

B

Before assembly:

1

Clean all parts with solvent and dry with compressed air.

Put oil on all O–rings.

2

Install the large O–ring (Item 1)[B] the small O–ring (Item 2) [B] and the backup ring (Item 3)[B] on the check valve (Item 4) [B].

3 P–08323

Install the O–ring (Item 1) [C] on the cap (Item 2) [C].

C

Install the check ball (Item 3) [C] the spring (Item 4) [C].

Install the cap (Item 2) [C] in the check valve (Item 5)[C] and tighten by hand.

5

2

4

1

3 P–08322

Clamp the check valve (Item 1) [D] in a vise with padded jaws, and tighten the cap (Item 2) [D].

D 2

1

P–08321

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Dealer Copy -- Not for Resale

4

Apply oil and install the spool (Item 1) [A] in the valvebody (Item 2) [A].

SWING CYLINDER LOCK VALVE (Cont’d)

A

Assembly (Cont’d) Clamp the valve (Item 1) [A] in a vise with padded jaws and tighten the check valve (Item 2) [A] (both sides).

2

1

Dealer Copy -- Not for Resale

P–08320

81 ofJuly 258 97 Added

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Dealer Copy -- Not for Resale

220ExcavatorServiceManual(S/N508211999&Below)#6720230–HydraulicSystemSectionPart2of2

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DRIVE SYSTEM Page Number CONTROL AND STEERING LEVERS Boom/Bucket Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–5 ..

Control Lever Lock Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–4 ..

Steering Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–6 ...

Swing/Arm Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3 ...

DRIVE MOTOR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–19 ....

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9 ....

DRIVE SYSTEM

FINAL DRIVE Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7 ...

Dealer Copy -- Not for Resale

FLOOR PANEL Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 ...

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FLOOR PANEL

A

Removal and Installation Remove the knobs from the control levers.

Remove the rubber boots from the control levers.

Remove the three bolts from the control lever cover [A].

N–07574

N–07575

C

Disconnect the linkage from the auxiliary foot pedal [C].

Dealer Copy -- Not for Resale

B

Remove the cover over the top of the control levers [B].

CD–07576

D

Remove the floor panel bolts [D].

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FLOOR PANEL (Cont’d)

A

Removal and Installation (Cont’d) Remove the floor panel from the machine [A].

Dealer Copy -- Not for Resale

N–07578

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CONTROL AND STEERING LEVERS

A

Swing/Arm Control Lever Use the following procedure to remove and install the swing/arm control lever: NOTE: The control valve and control levers are removed from the machine as an assembly .

(See Page 2–3 for the correct procedure.)

Remove the retainer bolt from the shaft for the bellcrank [A].

N–07579

Disconnect the control linkage from the bellcrank [B].

N–07580

Remove the shaft (Item 1) [C] from the bellcranks.

C

Dealer Copy -- Not for Resale

B

1

N–07581

Remove the nut at the control lever pivot bolt. Remove the control lever assembly [D].

D

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CONTROL AND STEERING LEVERS (Cont’d)

A

Swing/Arm Control Lever (Cont’d) Remove the snap ring and washers from the pivot shaft [A].

N–07583

Remove the control lever. Inspect the parts for wear .

Check the roller bearings [B].

B

N–07584

C

Control Lever Lock Mechanism Remove the swing/arm control lever. (See Page 3–3.)

Disconnect the spring [C].

N–07585

D

Remove the bolts from the lock mechanism mounting bracket [D].

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Dealer Copy -- Not for Resale

Replace the parts as needed.

CONTROL AND STEERING LEVERS (Cont’d)

A

Control Lever Lock Mechanism (Cont’d) Remove the lock lever and mounting bracket assembly [A].

N–07587

N–07588

C

Remove the bellcrank and linkage [C].

Inspect the parts and replace as needed.

Dealer Copy -- Not for Resale

B

Disconnect the linkage from the control valve spool [B].

N–07589

D

Boom/Bucket Control Lever Disconnect the linkage from the bellcrank [D].

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CONTROL AND STEERING LEVERS (Cont’d)

A

Boom/Bucket Control Lever (Cont’d) Remove the snap ring and washers [A].

Remove the control lever.

N–07591

B

Inspect all the parts. Check the roller bearings [B].

CD–07952

C

Steering Levers Disconnect the linkage from the bellcranks.

Remove the two roll pins (Item 1)[C] from the pivot shaft.

Remove the shaft and remove the steering levers.

Inspect the parts and replace as needed.

1

1

N–07593

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Dealer Copy -- Not for Resale

Replace the parts as needed.

DRIVE MOTOR

A

Removal and Installation Remove the bolts from the track frame cover [A].

Installation: Tighten the bolts to 48 ft.–lbs. (65 Nm) torque.

N–07594

B

Remove the cover [B].

Lift and block the side of the track frame where the final drive motor will be removed.

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

CD–07595

C

I–2003–0888

Mark the hoses for correct installation.

Dealer Copy -- Not for Resale

Release the track tension and remove the track. (See Page 5–8.)

Disconnect the hoses from the drive motor [C].

N–07596

D

Loosen and remove the final drive mounting bolts [D].

Installation: Put LOCTITE on the bolts and tighten to 80 ft.–lbs. (108 Nm) torque.

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DRIVE MOTOR (Cont’d)

A

Removal and Installation (Cont’d) Remove the motor , sprocket and reduction gear assembly from the track frame [A].

Dealer Copy -- Not for Resale

N–07598

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DRIVE MOTOR (Cont’d)

A

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

I–2003–0888

P–00335

The following tool will need to be fabricated by a local machine shop for reassembly purposes:

B

Floating Seal Installation Tool. (See Page 3–20.)

Disassembly

Remove the two spool caps from the valve end cover[B].

P–00336

Remove the spring and washer from each end of the housing and remove the spool [C].

C

Spool

Washer

Dealer Copy -- Not for Resale

Remove the drain plugs from the end cover of the drive motor. Drain the oil into a container [A].

Spring

P–00337

To disassemble the spool, insert a hardened pin through the hole in the spool gland and use a vise with protective jaws to hold the spool [D].

D

Remove the two end plugs from the ends of the spool.

Hardened Pin

NOTE: DO NOT use any type of clamp tool on the spool. Any marring or scratches in the spool and the spool must be replaced.

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DRIVE MOTOR (Cont’d)

A

Disassembly (Cont’d) Remove the spring (Item 1) [A] and the poppet (Item 2) [A] from the ends of the spool.

1

1

Use solvent and clean all spool components.

Dry with compressed air.

2

2

P–00340

B

P–00341

C

Lift off the valve end plate and remove thetwo dowel pins (Item 1) [C] and the O–ring (Item 2) [C].

3

NOTE: The dowel pin (Item 3) [C] is staked into the valve plate end cover. Do not remove unless damaged.

1

2

1

P–00342

Remove the bearing from the valve end plate [D].

D

Use a slide hammer bearing puller.

P–00344

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Dealer Copy -- Not for Resale

Remove the six bolts holding the valve end plate onto the housing [B].

DRIVE MOTOR (Cont’d)

A

Disassembly (Cont’d)

Bronze Side

Remove the valve plate [A].

NOTE: The bronze side of the valve plate goes towards the rotating group.

P–00343

Remove the rotating group from the motor housing [B].

P–00345

Disassemble the pistons (Item 1) [C], retainer plate (Item 2) [C], conical spacer (Item 3) [C], the three pins (Item 4) [C] from the piston housing (Item 5) [C].

C

5 3

1

Dealer Copy -- Not for Resale

B

2 4 P–00348

D

Turn the piston housing over and remove the snap ring from the housing [D].

Install a bolt and flat washer through the center of the piston housing. The outer diameter of the washer should be smaller than the snap ring but larger enough to make good contact with the spring spacer top face. Install a nut on the bolt and tighten until the spring is compressed.

Remove the snap ring and loosen the nut to remove the spring.

NOTE: The spring inside the piston housing is under pressure, use care when removing the snap ring from the piston housing.

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DRIVE MOTOR (Cont’d)

A

Disassembly (Cont’d) Remove the snap ring (Item 1) [A], collar (Item 2) [A], spring (Item 3) [A] and the collar (Item 4) [A] from the piston housing.

4

3 2

1

P–00354

P–00355

Install two 3/8 PT metric bolts (or eye bolts) into the drain plug holes. Use a bar between the bolts (or through the eyebolts) and turn the cover counterclockwise to remove the cover [C].

C

P–00357

D

Remove the O–ring from the end cover [D].

P–00346

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Dealer Copy -- Not for Resale

B

Turn the motor over and remove the end cap retaining plug from the side of the housing [B].

DRIVE MOTOR (Cont’d)

A

Disassembly (Cont’d) Remove the thrust plate from the planetary assembly[A].

P–00347

P–00349

Remove the planetary pin by driving the spring pin into the center of the planetary pin [C].

C

Dealer Copy -- Not for Resale

B

Lift the planetary assembly from the motor housing [B].

P–00353

D

Remove the pin (Item 1) [D], bearing (Item 2) [D], and gear (Item 3) [D] from the planetary assembly.

NOTE: The spring pin (Item 4) [D] that was driven into the center of the planetary pin (Item 1) [D], will now have to be driven out of the planetary pin.

1

2

3

4 P–00359 97 ofJuly 258 92 Added

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DRIVE MOTOR (Cont’d)

A

Disassembly (Cont’d) Remove the planetary thrust washer from the [A].

housing

P–00352

P–00356

C

Remove the gearhub from the housing [C].

NOTE: The snap ring does not need to be removed unless damaged.

Snap Ring

P–00358

Remove the plug from the housing (closest to the flange) [D].

D

NOTE: The second plug does not need to be removed unless there is leakage or damage.

P–00362

Added July98 92of 258

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220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

B

Remove the center driveshaft from the housing [B].

DRIVE MOTOR (Cont’d)

A

Disassembly (Cont’d)

Steel Balls

Remove the 109 or 110 steel balls that are used to retain the motor housing to the hub bearing [A] & [B].

The balls must be removed through the plug hole. Use solvent and flush oil off of the steel balls and the mating surfaces of the bearing and motor housing.

Use a magnet and remove the exposed steel balls from the plug hole. Use short bursts of compressed air to force the first few steel balls to the plug hole and remove these with the magnet. Continue this process until no more balls will appear at the plug hole.

NOTE: Use care with the following process not to allow the wire to become lodged or to break off inside the motor.

P–00363

B

Use a length of 16 gauge mechanics wire and bend a tight, close loop at one end of the wire. Insert the wire into the plug hole and carefully feed the wire around the diameter of the bearing and force the steel balls to the hole. Remove the exposed balls with a magnet and continue this process until all 109 balls are removed and the end of the wire is visible through the hole. Carefully remove the wire. DO NOT break the wire of f inside the housing when removing the wire.

Wire

MC–01678

Use a three jaw puller and remove the motor housing[C].

C

Dealer Copy -- Not for Resale

Steel Balls

P–00364

Drive the three spring pins into the planetary pins on the internal planetary assembly [D].

D

P–00311 99 ofJuly 258 92 Added

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220 (S/N 508211999 & Below) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Disassembly (Cont’d) Bend a hook onto a piece of stiff wire and use this wire to hook the spring pin in the center of theplanetary pins and pull the planetary pins out of the housing [A].

P–00314

B

Remove the thrust washers (Item 1) [B], gear (Item 2) [B], spacer (Item 3) [B], bearing (Item 4) [B] and the pin (Item 5) [B] from the housing.

With the planetary pins (Item 5) [B] removed, the spring pins (Item 6) [B] will now have to be driven out of the center of the planetary pins.

1

2

6 Remove the three set screws from thehousing [C]. These set screws retain the bearing nut from loosening from the housing.

1

5

3

P–00317

C

P–00315

If a bearing nut tool of the correct size is available, use it to remove the bearing nut. If a tool is not available, use a punch and hammer and tap the outer diameter of the bearing nut to remove it from the motor hub [D].

D

P–00316

Added July100 92of 258

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220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

4

DRIVE MOTOR (Cont’d)

A

Disassembly (Cont’d) Carefully remove the double race bearing from the hub [A].

NOTE: The inner and outer races of this bearing are not permanently retained to each other. If not lifted off as an assembly , the races will separate and the steel balls will come loose.

P–00313

P–00321

C

Use a screw driver and pry the lower half of the floating seal from the hub and remove [C].

Dealer Copy -- Not for Resale

B

Remove the top half of the floating seal from the hub[B].

P–00320

D

Use a punch and tap the swash plate and drive shaft out of the center of the hub [D].

P–00322 101 of 258 92 Added July

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220 (S/N 508211999 & Below) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Disassembly (Cont’d) Remove the seal from the hub [A].

P–00318

B

Press the drive shaft and bearing out of the swash plate [B].

P–00325

C

Press the bearing off of the drive shaft [C].

Inspect all parts for damage and replace parts as necessary. Use new seal and O–rings when assembling the drive motor.

Clean all parts in solvent and dry with compressed air.

P–00326

Added July102 92 of 258

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220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

NOTE: The dowel pin in the swash plate is removable, but do not remove it unless it is damaged.

DRIVE MOTOR (Cont’d)

A

Assembly Press a new bearing onto the driveshaft [A].

Press only on the internal bearing race surface.

P–00328

Use a press tube that only contacts the outer bearing race and use a tapered fixture to hold the swash plate square to the press.

B

P–00330

C

Install the seal into the hub [C].

NOTE: The lipside of the seal faces upwards as viewed in [C].

Dealer Copy -- Not for Resale

Press the bearing and driveshaft into the swash plate[B].

P–00329

Align the dowel pin on the swash plate with the hole in the hub [D].

NOTE: Use a plastic or wood dowel and tap the face of the swash plate to seat the swash plate to the hub.

D Dowel Pin

NOTE: DO NOT mar or scratch the face of the swash plate or it will have to be replaced.

P–00323 103 of 258 92 Added July

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220 (S/N 508211999 & Below) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Assembly (Cont’d) Floating seal installation tool [A]. This tool can be made by a local machine shop.

170 mm 160 mm

6.9 mm 7.3

5 mm

142.8/143 mm 141.5/141.8 mm 7.9/8.1 mm 20.1 mm

132/133 mm 142.8 mm 143.0 15°

R 0.3 mm R 0.2 mm MC–01678

B

Apply petroleum jelly to the O–ringof the floating seal [B].

Install the floating seal into the installation tool [B].

P–00333

Apply petroleum jelly to the floating seal surface of the hub.

C

Turn the floating seal and installation tool over and set in place in the hub [C].

Using both hands, evenly press down on the installation tool to insert the floating seal into the hub [C].

P–00327

D

Install the other half of the floating seal onto the hub [D].

Apply petroleum jelly to the O–ring of the floating seal.

NOTE: The O–ring of the floating seal faces upwards.

P–00321

Added July104 92 of 258

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220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

NOTE: The O–ring side of the floating seal is upwards in the installation tool as viewed in [B].

DRIVE MOTOR (Cont’d)

A

Assembly (Cont’d) Carefully install the double roller bearing onto the hub[A].

P–00313

B

Install the bearing nut onto the hub [B].

P–00319

C

Install the three retaining set screws [C].

Tighten the set screws to 22–29 ft.–lbs. (30–39 Nm) torque.

After set screws are torqued, use a center punch stake the hub to the set screws.

and

Dealer Copy -- Not for Resale

Tighten the bearing nut to 45–48 ft.–lbs. (61–65 Nm) torque.

P–00315

D

Apply oil to the inner planetary bearings. Install the spacer, bearing and the thrust washers into the hub planetary. Insert the planetary pins and drive the spring pin through the hub and into the planetary pin.

Use a center punch and stake the hub to the spring pin [D].

P–00306 105 of 258 92 Added July

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220 (S/N 508211999 & Below) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Assembly (Cont’d) Install the housing onto the hub and press into position [A]. The housing must be pressed onto the hub until the groove in the bearing is centered in the hub plug hole.

NOTE: Make sure that the housing is pressed squarely onto the hub so that the planetary gears do not shave metal off of the housing splines. If this happens the housing and the planetary gears will be damaged.

P–00334

Insert the 109 steel balls into the hole in the side of the hub [B].

B

P–00363

C

Install the plug into the hub [C].

Tighten the plug to 5–6 ft.–lbs. (7–9 Nm) torque.

P–00362

D

Install the snap ring onto the gear hub (if previously removed) and install the gear hub intothe planetary gear assembly [D].

Snap Ring

NOTE: The gear hub must be installed with the narrow section of the gear upwards (when viewed using the snap ring as the dividing line).

P–00358

Added July106 92 of 258

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220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

Steel Balls

DRIVE MOTOR (Cont’d)

A

Assembly (Cont’d) Install the center driveshaft through the center of the gear hub [A].

P–00356

B

P–00352

C

Assemble the planetary assembly by installing the bearing (Item 2) [C] into the gear (Item 3) [C].

Install the gear (Item 3)[C] into the planetary housing and insert the planetary pin (Item 1) [C] through the gear .

Align the hole in the planetary pin and the planetary housing and install the spring pin (Item 4) [C].

1

4

2

3

Dealer Copy -- Not for Resale

Install the planetary thrust washer onto the planetary hub [B].

P–00359

D

Use a center punch and stake the planetary hub to the spring pin [D]. This will prevent the spring pin from working out of the planetary hub.

P–00360 107 of 258 92 Added July

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220 (S/N 508211999 & Below) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Assembly (Cont’d) Install the planetary gear assembly intothe motor housing [A].

The planetary hubs internally splined collar will face downwards into the housing. The external surface of the collar must fit over the previously installed thrust washer and the splines must match up with the gear hub. Rotate the motor housing to align the gears and the splines.

P–00349

P–00347

C

Install a new O–ring onto the end cover [C]. Apply oil to the O–ring.

P–00346

D

Install the two 3/8 PT metric bolts (or eyebolts) into the drain plug holes in the end cover [D].

Install the end cover into the housing and use a bar to tighten the end cover into the housing. T ighten the end cover until the hole in the side face on the cover is centered into the hole in the side of the housing.

P–00357

Added July108 92 of 258

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220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

B

Install the thrust plate onto the planetary gear assembly [B]. The cogs of the thrust plate must align with the notches in the planetary hub.

DRIVE MOTOR (Cont’d)

A

220ExcavatorServiceManual(S/N508211999&Below)#6720230–DriveSystemSectionPart1of2

Assembly (Cont’d) Install the dog point set screw into the side of thehousing [A]. The point of the set screw must seat freely into the hole in the end cover. Adjust the end cover until the hole in the housing and the hole in the cover align properly.

Tighten the set screw to 13–18 ft.–lbs. (18–24 Nm) torque.

P–00355

B

Install a bolt and a flat washer through the spacers and the spring. Insert these parts through the piston housingand install a nut. The outer diameter of the washer should be smaller than the inner diameter ofthe snap ring, but large enough to make good contact with the spring spacer top face. Tighten the nut to compress the spring and install the snap ring. Loosen the nut and remove the bolt and washer.

1

2 3

4

P–00354

Assemble the rotating group by applying petroleum jelly to the three pins (Item 4) [C]. Insert the pins (Item 4) [C] into the notches in the splined inner diameterof the piston housing (Item 5) [C]. Set the conical spacer (Item 3) [C] over the pins (Item 4)[C] and on top of the piston housing (Item 5) [C]. Insert the pistons (Item 1) [C] into the retainer plate (Item 2) [C]. Apply clean hydraulic fluid to the outer diameter of the piston (Item 1)[C] and insert the pistons into the piston housing (Item 5) [C].

C

5 3

1

Dealer Copy -- Not for Resale

Install the collar (Item 1) [B], spring (Item 2) [B], collar (Item 3) [B] and snap ring (Item 4) [B] into the piston housing.

2 4

P–00348

D

Turn the drive motor on its side and apply oil to the face of the swash plate. Install the rotating groupinto the drive motor hub and onto the piston driveshaft [D].

P–00345 109 of 258 92 Added July

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220 (S/N 508211999 & Below) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Assembly (Cont’d) Install a new O–ring into the groove in themotor face [A].

P–00305

B

Press the bearing into the valve end plate [B].

If a new valve end plate is being used, or if the locating dowel pin was removed from the valve end plate, press the dowel pin into the valve end plate [B].

P–00332

C

Apply a film of petroleum jelly to the steel face of the valve plate. Install the valve plate (bronze side faces upwards) onto the valve end plate [C]. The notch in the valve plate must align with the dowel pin in the valve end plate.

Dowel Pin

P–00309

D

Insert the two dowel pins into the drive motor hub and install the valve end plate onto the drive motor [D].

Dowel Pin

P–00310

Added July110 92 of 258

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220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

Dowel Pin

DRIVE MOTOR (Cont’d)

A

Assembly (Cont’d) Install the six bolts into the valve end plate [A].

Insert a pin through the holes in the hub and the housing to keep the hub from rotating and tighten the six bolts.

Tighten the bolts to 21–26 ft.–lbs. (29–35 Nm) torque.

Remove the pin that was installed to keep the hub and housing from rotating.

P–00341

P–00340

Insert a hardened dowel pin through the hole in the spool gland and use a vice with protective jaws tohold the spool from turning. Tighten the end plugs [C].

C

Tighten the plugs to 18–21 ft.–lbs. (24–29 Nm) torque.

Hardened Pin

Dealer Copy -- Not for Resale

B

Apply oil to the outer diameter of the poppets and install the poppets (tapered end in first) into the spool[B]. Install the spring into the cavity of the poppets. Install a new O–ring onto the end plugs [B].

P–00338

Apply oil to the spool and install the spool into the valve end plate [D].

D

Install the washer over the end of the spool and the spring [D].

Spool

Washer

Spring

P–00337 111 of 258 92 Added July

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220 (S/N 508211999 & Below) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

220ExcavatorServiceManual(S/N508211999&Below)#6720230–DriveSystemSectionPart2of2

Assembly (Cont’d) Install a new O–ring on the end plugs. Apply oil to the O–rings and install the plugs.

Tighten the plugs to 86–101 ft.–lbs. (117–137 Nm) torque [A].

P–00336

B

NOTE: Before the drive motor can be put into service, gear lube 90 will need to be added to the drive motor. See Page 1–1 1 for oil installation and checking procedure.

Tighten the two outer plugs (M8) to 21–29 ft.–lbs. (29–39 Nm) torque.

P–00335

Added July112 92 of 258

–3–28–

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

Install the three end plugs into the end cover [B].

UPPER WORKS AND SWING SECTION Page Number CENTER SWIVEL JOINT Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–30 ..

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–30 ..

SWING CIRCLE GEAR Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–31 ..

UPPER WORKS Alignment Pin Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–28 ..

Alignment Screw Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–29 ..

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–27 ..

Swing Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–29 ..

113 of July 258 97 Revised

–4–1–

UPPER WORKS & SWING SECTION

Dealer Copy -- Not for Resale

SWING MOTOR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6, . . . . 4–14 Brake Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–24 ...

Brake Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–22 ..

Brake Valve Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–21 ..

Brake Valve Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–26 ...

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–5, . . . 4–9 Motor Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–7 ...

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4, . . . 4–8 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–3 ..

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale 11497 of 258 Revised July

–4–2–

220 (S/N 508211999 & Below) Excavator Service Manual

SWING MOTOR

A

Removal and Installation Remove the seat and seat mounting frame. (See Page 5–1.)

Remove the fuel tank. (See Page 5–1.)

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

N–07599

B

I–2003–0888

Mark the hoses for correct installation.

Remove the mounting bolts [A]. On early production machines, quantity four, on later production machines, quantity six bolts.

Tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque.

N–07600

Remove the swing motor from the machine [B].

115 of July 258 97 Revised

–4–3–

Dealer Copy -- Not for Resale

Remove the hoses.

220 (S/N 508211999 & Below) Excavator Service Manual

SWING MOTOR Parts Identification Bolt Housing Plug O–ring Spring Pin Seal Plate Valve O–ring Plate Drive Geroler Drive Plate Seal Snap Ring Housing Shaft O–ring Retainer Seal Bolt

17

10

16

15

23 18

19 20 21 22

1

7

6

5

9 11

6

10

8

5

2

4 3

10 14 12 13 10

B–13496

11697 of 258 Revised July

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220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

A

Disassembly

2

4 Quad Seal

Cap Screw (8)

Clean the motor and drain the oil from the motor.

Use a soft jaw vise to hold the motor by the mounting flange.

NOTE: Do not disassemble the geroler (Item 1) [A].

The geroler has machined close tolerances.

Damage may occur during reassembly.

Mark the bearing housing by the alignment groove for assembly. The alignment groove aligns the case drain hole in the valve housing.

5

3

Square Cut Seal

Seal Retainer

Race Seal and O–ring

Shaft

Shaft and Bearing Housing

Disassemble the motor.

NOTE: The cap screws (Item 2) [A] are held by thread bonding adhesive. DO NOT exceed 70 in–lbs. to remove the screws. Use a propanetorch to heat the screw heads. This will melt the adhesive on the screws.

Discard the screws and remove the seal retainer (Item 3) [A].

Square Cut Seal

Retaining Ring

Shift Face Seal

Wear Plate

Square Cut Seal

Remove the quad seal (Item 4) [A] and the square cut seal (Item 5) [A] from the retainer.

NOTE: Check the seal retainer for cracks. Order a new retainer from Melroe Parts, if needed.

Drive

Dealer Copy -- Not for Resale

SWING MOTOR (Cont’d)

1 Geroler Square Cut Seal

Valve Drive Valve Plate

Square Cut Seal

Valve Balance Ring

Inner and Outer Face Seals Plug

Pin and Spring

O–ring

Valve Housing Bolt (4)

117 of July 258 97 Revised

–4–5–

B–13496

220 (S/N 508211999 & Below) Excavator Service Manual

SWING MOTOR (Cont’d)

A

Assembly

1 4

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

2

I–2003–0888

1

B–13401

NOTE: Order a swing motor repair kit from Melroe Parts.

Clean the seal surfaces on the retainer (Item 1) [A] and install a new quad seal (Item 2) [A] and the square cut seal (Item 3) [A] in the retainer.

Dealer Copy -- Not for Resale

Lubricate the inner edge of the quad seal and the square cut seal with petroleum jelly.

Install the retainer on the motor using two cap screws (Item 4) [A] 180° from one another.

Tighten the cap screws to 60 in–lbs (6,7 Nm) torque.

Screw the tap (from the kit) in and out of the six remaining holes.

Use compressed air to blow loose particles from the holes.

Apply clean solvent to each hole and blow them dry.

Wash the new cap screws in solvent, blow them dry and apply two or three drops of thread adhesive (LOCTITE #609) to the threads.

Install the new cap screws in the six holes and tighten to 60 in–lbs. (6,7 Nm) torque.

Remove the two cap screws installed earlier.

Repeat the hole cleaning procedure, apply two or three drops of thread adhesive (LOCTITE #609) to thethreads.

Install the screws and tighten to 60 in.–lbs. (6,7 Nm) torque.

11897 of 258 Revised July

–4–6–

220 (S/N 508211999 & Below) Excavator Service Manual

SWING MOTOR (Cont’d)

A

Assembly (Cont’d)

Shaft Face Seal

Wear Plate

Clamp the shaft and bearing housing so the output shaft is down.

Pour a small amount of clean hydraulic fluid into the shaft and bearing housing for start–up lubrication.

Shaft

Install the shaft face seal and wear plate as shown [A].

Install the drive, Geroler and valve drive.

Shaft and Bearing Housing

B

The direction that the output shaft rotates is determined by timing. Time the motor as follows:

Rotate Valve Clockwise Until Spline Teeth Mesh

Valve

Locate the largest open pocket in the Geroler (Item 1) [B].

Align One of the Valve Side Opening With the Largest Open Geroler Pocket

Install the valve plate (Item 2)[B] and locate the open slot that is over the largest open Geroler pocket.

Valve Plate

Align one of the side openings in the valve with the valve plate slot that is over the largest open Geroler pocket.

Engage the valve with the valve drive (Item 3) [B] by rotating it clockwise until the spline teeth mesh (1/2 tooth).

Dealer Copy -- Not for Resale

Motor Timing

B–13495

2 3 Valve Drive Alignment Groove

Geroler

1 Largest Open Pocket B–13495

Install the inner and outer face seals on the balance ring as shown [C].

Install the springs, pins and balance ring in the valve housing. Hold the balance ring in place, through the forward port in the valve housing, while installing the valve housing over the valve.

C Inner Face Seal

Pin Notch Outer Face Seal

Install and tighten the four bolts in a crisscross pattern.

Tighten the bolts to 37 ft.–lbs. (50 Nm) torque. Tighten the case drain plug to 50 in.–lbs. 95,5 Nm) torque.

Balance Ring

B–13495 119 of July 258 97 Revised

–4–7–

220 (S/N 508211999 & Below) Excavator Service Manual

SWING MOTOR Parts Identification Plug O–ring Ball Bolt Plug O–ring Housing O–ring Spring Pin Seal Seal Plate Valve O–ring Plate Drive O–ring Geroler Drive Plate Seal Snap Ring Bearing Housing Bearing Gear O–ring Retainer Bolt Seal Back–up Ring

32 30

31 29

20

28

8 19

27

18

Dealer Copy -- Not for Resale

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

26 17

8 25

16

15

24

14

23 18

13

22

12 11

5

6

21

10 9

8

7

3 1

2

18

4

B–12743 12097 of 258 Revised July

–4–8–

220 (S/N 508211999 & Below) Excavator Service Manual

SWING MOTOR

A

Disassembly

1

Drain the hydraulic fluid from the swing motor.

Clean the swing motor with cleaning fluid and dry.

2 When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

P–08210

B

I–2003–0888

Remove the two fittings (Item1) [A] from the connectors.

Remove the brake valve (Item 2) [A] from the swing motor.

1

Remove the two connectors (Item 1) [B] from the swing motor.

P–08211

Remove the plug (Item 1) [C] and O–ring.

C

Remove the plug (Item 2) [C].

Dealer Copy -- Not for Resale

Clamp the swing motor in a vise that has soft or padded jaws.

2 1 P–08212

Remove the two plugs (Item 1) [D], O–rings (Item 2) [D] and check balls (Item 3) [D] from the top of the swing motor.

D

2 1

1

3

P–08213 121 of July 258 97 Revised

–4–9–

220 (S/N 508211999 & Below) Excavator Service Manual

SWING MOTOR (Cont’d)

A

Disassembly (Cont’d)

1

Mark the motor sections for ease of assembly [A].

Remove the four bolts (Item 1) [A] from the top of the motor.

2

Remove the valve housing (Item 2) [A] from the motor.

P–08214

Remove the balance ring (Item 1) [B], inner seal (Item 2) [B], outer seal (Item 3) [B], and O–rings (Item 4)[B] from the valve housing.

B

3

2 4

Remove the two alignment pins (Item 1) [C] and springs (Item 2) [C] from the valve housing.

P–08215

C 2

1

1

P–08216

D

Remove the valve (Item 1) [D] from the motor.

NOTE: See page 4–19 for timing the motor when installing the valve, valve drive and geroler.

1

P–08217 12297 of 258 Revised July

–4–10–

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

1

SWING MOTOR (Cont’d)

A

Disassembly (Cont’d) Remove the valve plate (Item 1) [A].

1

P–08218

Remove the two O–rings (Item 1) [B] from the bottom of the valve plate.

1

(Item 2) [B] from the

2

P–08219

Remove the geroler (Item 1) [C].

C

Dealer Copy -- Not for Resale

Remove the valve drive shaft geroler.

B

1

P–08220

D

Remove the two O–rings (Item 1) [D] from the top of the wear plate.

1

P–08221 123 of July 258 97 Revised

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220 (S/N 508211999 & Below) Excavator Service Manual

SWING MOTOR (Cont’d)

A

Disassembly (Cont’d) Remove the wear plate (Item 1) housing.

1 3

2

[A] from the bearing

Remove the seal (Item 2)[A] from the bottom of the wear plate (Item 1) [A].

Remove the drive shaft (Item 3)[A] from the output shaft.

Inspect the female spline for wear or damage, in the output gear.

4

Remove the snap ring (Item 4) [A] from the output shaft.

P–08222

Turn the bearing housing over. Heat the eight bolt heads [B] to melt the thread lock material and remove the bolts.

B

P–08223

Press the output shaft out of the bearing carrier [C].

C

P–08224

Remove the O–ring (Item 1) [D] from the seal retainer.

D

Remove the seal retainer (Item 2) [D] from the output shaft.

2

1 12497 of 258 Revised July

–4–12–

P–08225

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

NOTE: If the bolt heads are not heated and thethread lock material not melted the bolt heads could twist off on removal.

SWING MOTOR (Cont’d)

A

Disassembly (Cont’d) Remove the seal (Item 1)[A] and backup ring (Item 2)[A] from the seal retainer.

1

2

P–08226

Remove the bearing race from the output shaft [B].

P–08227

Tap the bearing out of the carrier using a brass punch [C].

C

NOTE: Use only a brass or bronze punch to remove the bearing or damage to the bearing can result.

Dealer Copy -- Not for Resale

B

P–08228

Press the bottom bearing out of the bearing carrier [D].

D

P–08229 125 of July 258 97 Revised

–4–13–

220 (S/N 508211999 & Below) Excavator Service Manual

SWING MOTOR (Cont’d)

A

Assembly Clean all parts in solvent and dry with compressed air.

Check the wear plate, geroler , valve plate, valve, and balance ring for wear and scratches.

If any of these parts are damaged, order new parts.

Clean the seal retainer bolt holes with a 6x1 mm tap [A].

Use compressed air to blow any loose thread lock material out of the bolt holes.

P–08230

Press the bottom bearing in the bearing carrier [B].

P–08231

Press the top bearing in the bearing carrier [C].

C

P–08232

D

Press a new bearing race on the output shaft [D].

P–08233 12697 of 258 Revised July

–4–14–

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

B

SWING MOTOR (Cont’d)

A

Assembly (Cont’d) Apply oil and install a new seal (Item 1) [A] and backup ring (Item 2) [A] in the seal retainer.

1

2

P–08226

Install the seal retainer (Item 1) [B] on the output shaft.

1

2 Press the output shaft in the bearing carrier [C].

P–08225

C

Dealer Copy -- Not for Resale

B

Apply oil and install a new O–ring (Item 2)[B] on the seal retainer.

P–08256

D

Install the snap ring (Item 1) [D] on the output shaft.

1

P–08257 127 of July 258 97 Revised

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220 (S/N 508211999 & Below) Excavator Service Manual

SWING MOTOR (Cont’d)

A

Assembly (Cont’d)

1

Apply thread lock (LOCTITE #262) to the eight seal retainer bolts (Item 1) [A] and tighten to 104–130 in.–lbs.

(12–15 Nm) torque.

1

1

1 1

1 1 P–08223

Pour a small amount of cleanhydraulic fluid in the bearing carrier to provide start up lubrication.

[B] on the

1 P–08258

Install a new shaft face seal in the wear plate [C].

C Wear Plate

Shaft Face Seal

Shaft

Shaft and Bearing Housing Install the drive shaft (Item 1) [D] in the output shaft.

D

Install the wear plate (Item 2) [D] on the bearing carrier.

B–13495

2 1

P–08222 12897 of 258 Revised July

–4–16–

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

Apply oil and install a new O–ring (Item 1) bearing carrier.

B

SWING MOTOR (Cont’d)

A

Assembly (Cont’d) Apply oil and install two new O–rings (Item 1 & 2) [A] on the wear plate.

2

1

Install the geroler on the wear plate, engaging the teeth of the output shaft drive [B].

P–08221

B

TIMING THE HYDRAULIC MOTOR

1.) Geroler Assembly 2.) Valve Drive 3.) Valve Plate 4.) Valve

1

Find the largest opening (Item 1) [B] in the geroler assembly [B]. Mark the outside of the geroler at this point.

P–08220

Install the valve drive shaft (Item 1) [C].

C

1

Dealer Copy -- Not for Resale

The timing of the motor controls the direction of rotation of the output shaft. The timing parts are as follows:

P–08234

D

Apply oil and install two O–rings (Item 1) [D] on the valve plate.

1

P–08219 129 of July 258 97 Revised

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220 (S/N 508211999 & Below) Excavator Service Manual

SWING MOTOR (Cont’d)

A

Assembly (Cont’d)

1

Align the drain hole (Item 1)[A] in the valve plate with the drain hole (Item 1) [A] in the geroler.

2

Make sure the slot opening of the valve plate (Item 2)[A] is aligned with the largest opening of the geroler (Item 3) [A].

1

Install the valve plate.

3 P–08235

Install the valve on the valve plate.

B

Align one of the side ports with the mark on the geroler housing.

P–08236

C

Install the two springs (Item 1) [C] and two pins (Item 2) [C] in the valve housing.

1

2

2

P–08216

D

Install the inner (Item 1) [D] and outer (Item 2) [D] face seals on the balance ring (Item 3) [D] as shown.

1

2

3 B–13495 13097 of 258 Revised July

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220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

Turn the valve clockwise a small amount until the teeth on the valve drive engage [B].

SWING MOTOR (Cont’d)

A

Assembly (Cont’d)

1

2

Install the balance ring (Item 1) [A] in the valve housing and engage the alignment pins (Item 2) [A] with the slots in the balance ring.

Apply oil and install new O–rings (Item 3 & 4) [A] on the valve housing.

3

4 Using a small flat blade screwdriver,go through one of the connector ports and hold the balance ringin position [B].

P–08215

B

P–08259

Install the four bolts (Item 1) [C] on the top of the motor assembly and tighten to 36–40 ft.–lbs. (49–54 Nm) torque in a crisscross pattern.

C

1

1

1

1

Dealer Copy -- Not for Resale

Install the valve housing on the motor.

P–08214

D

Apply oil and install new O–rings (Item 1) [D] on the top plugs (Item 2) [D].

2

Install the check balls (Item 3) [D] and plugs (Item 2) [D] in the valve housing.

1

3

1

P–08213 131 of July 258 97 Revised

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220 (S/N 508211999 & Below) Excavator Service Manual

SWING MOTOR (Cont’d)

A

Assembly (Cont’d) Apply thread sealant and install the plug (Item 1) [A] in the side of the valve housing.

Apply oil and install a new O–ring on the plug (Item 2) [A].

Install the plug (Item 2) housing.

[A] in the side of the valve

The timing can be checked before installation.

1. Lay motor on side.

2. Fill right port with oil.

3. Turn drive shaft clockwise, oil should go down in port if timed correctly.

1 2

P–08212

B

Apply oil and install new O–rings on the connectors.

1

P–08211

Install the brake valve (Item 1) [C] on the connectors.

C

Install the two fittings (Item 2) [C].

2

1

P–08210

13297 of 258 Revised July

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220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

Install the connectors (Item 1) [B] in the valve housing.

SWING MOTOR (Cont’d) Brake Valve Parts Identification Nut Nut Screw Cartridge O–ring O–ring Plug Retainer Spring Valve Seat Seal Orfice Plug O–ring Spring Ball Body Bushing Connector O–ring

3

4

2

1

5

9

8

7 6

10 11 13

12

21 20

Dealer Copy -- Not for Resale

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

14 15 5 17

16

5

14

15

16

19

17 18

12 13 11 9 5 6

7

10

8

4 2 3

1 C–03138

133 of July 258 97 Revised

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220 (S/N 508211999 & Below) Excavator Service Manual

SWING MOTOR (Cont’d)

A

Brake Valve Disassembly

1

Remove the two fittings (Item 1)[A] from the connectors.

Remove the control valve (Item 2) [A] from the swing motor.

Clamp the control valve in a vise that has padded jaws.

2

P–08210

Remove the plugs (Item 1) [B] from both ends of the valve.

B

P–08260

Remove the O–ring (Item 1)[C] from the plug (Item 2)[C].

C

Remove the spring (Item 3)[C] and check ball (Item4) [C] from both ends of the valve.

4

1

2

3

P–08261

Remove the cross port relief valves (Item 1)[D] from both ends of the valve body.

D 1

1

P–08293 13497 of 258 Revised July

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220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

1

1

SWING MOTOR (Cont’d)

A

Brake Valve Disassembly (Cont’d) Remove the spring (Item 1) [A] and retainer (Item 2) [A] from the cartridge.

4

2

6

Remove the cap (Item 3) [A], locknut (Item 4) [A], and adjustment screw (Item 5) [A].

Remove the plug (Item 6) [A].

Remove the O–ring (Item 7)[A] from the plug (Item 6)[A].

3

5

7

Remove the O–ring (Item 8) [A] from the cartridge.

8

1 P–08262

Remove the valve (Item 1) [B] from both ends of the control valve.

B

NOTE: Be careful not to scratch the valve or valve seat.

P–08263

Remove the valve seat (Item 1)[C] from the control valve by using two pieces of 0.090 inch wire.

C 1

Dealer Copy -- Not for Resale

1

P–08264

Bend the ends of the wire in a 90° and insert the wire in the center port of the valve seat, and engage two of the valve seat side ports.

D

Pull straight up on the wires to remove thevalve seat [D].

P–08265 135 of July 258 97 Revised

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220 (S/N 508211999 & Below) Excavator Service Manual

SWING MOTOR (Cont’d)

A

Brake Valve Disassembly (Cont’d) Remove the copper seal (Item 1)[A] from the valve seat.

2

Removing the orifice (Item 2) [A] from the valve seat is only necessary if the orifice cannot be cleaned to satisfactory results with solvent.

1 P–08266

Remove the orifice from the valve seat using a brass punch [B].

B

P–08267

Control Valve Assembly

C

Clean all parts in solvent and dry with compressed air.

Press the orifice (Item 1) [C] in the valve seat.

1

Install a new copper seal (Item 1) [A] on the valve seat.

P–08268

Put clean hydraulic fluid on the valve seat.

D

Install the valve seat in the valve body [D].

P–08264 13697 of 258 Revised July

–4–24–

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

NOTE: Use only a brass or bronze punch to remove the orifice or damage to the orifice canresult.

SWING MOTOR (Cont’d)

A

220ExcavatorServiceManual(S/N508211999&Below)#6720230–UpperWorksandSwingSectionPart1of2

Brake Valve Assembly (Cont’d) Apply clean hydraulic fluid to the valve (Item 1) [A].

1

Install the valve in the valve seat.

P–08263

Apply oil and install a new O–ring (Item 1)[B] on the plug (Item 2) [B].

B

Install the plug (Item 2) [B] in the cartridge.

6

Install the spring retainer (Item 3) [B] and spring (Item 4) [B] in the cartridge.

3

2

Install the locknut (Item 6) [B] and cap (Item 7) [B] on the adjustment screw (Item 5) [B].

NOTE: If the cross port relief valve is disassembled, the relief pressure will need to be reset. See Page 4–26 for testing and adjustment procedures.

Install the cross port relief valves (Item 1) ends of the valve body.

5

7

[B] on the

Apply oil and install a new O–ring (Item 8) cartridge.

1

8

4 P–08262

C

[C] on both

Dealer Copy -- Not for Resale

Install the adjustment screw (Item 5) [B] in the cartridge.

P–08293

D

Apply oil and install a new O–ring (Item 1)[D] on the plug (Item 2) [D].

3

1

Install the check ball (Item 3) [D] and spring (Item 4) [D] in the valve body.

Install the plug (Item 2) [D] in the valve body.

2

4

P–08261 137 of July 258 97 Revised

–4–25–

220 (S/N 508211999 & Below) Excavator Service Manual

SWING MOTOR (Cont’d)

A

Brake Valve Assembly (Cont’d) Apply oil and install four new O–rings on bothsides of the connector ports [A].

P–08269

Install the control valve (Item 1) [B] on the swing motor.

B

Install the two fittings (Item 2) [B] on the connectors.

The control valve used on the swing motor has two relief valves mounted on each side of the valve body . These valves work to dampen the swing stop, preventing damage to the swing motor. The relief valves also prevent the upperstructure from independent movement, or creeping, until the swing circuit is engaged.

1

The relief valves, control valve, and swing motor are shown removed from the excavator for photo clarity [B].

P–08210

Disconnect the outlet hose (Item 1)[C] from pump section 1.

NOTE: Pump section 1 is the closest to the engine.

C

Install a tee in between the pump section 1 outlet and the outlet hose.

Install a 5000 PSI gauge on the tee fitting. W excavator up to operating temperature.

arm the

With the swing lock engaged, actuate the swing circuit in one direction. Record the pressure. Activate the swing circuit in the opposite direction. Record the pressure.

1

If adjustment is needed, remove the cap (Item 1)[D] and loosen the lock nut (Item 2) [D].

N–07538

Turn the adjustment screw (Item 3) [D] until the correct pressure is recorded on the gauge.

D

NOTE: The valve is shown out of the excavator for photo clarity.

The correct pressure for the cross port relief valves is as follows:

1

2

S/N 11001–11500 . . . . . . . 1635 PSI (11273 KPA) S/N 11501–11703 . . . . . . . 1500 PSI (10342 KPA) S/N 11704–11999 . . . . . . . 1150 PSI (7929 KPA) The front cross port relief valve controls the clockwise direction of rotation while the rear relief valve controlsthe counterclockwise direction of rotation.

Added July138 97 of 258

3 P–08270

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220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

2

Control Valve Testing

UPPER WORKS

A

Removal And Installation Remove the operator canopy.

Remove the fuel tank. (See Page 5–1.)

Remove the seat and seat mounting frame. (See Page 5–1.)

Remove the engine. (See Page 7–1.)

Remoe the hydraulic reservoir. (See Page 2–1.)

Remove the floor panel. (See Page 3–1.)

N–07601

Remove the hydraulic control valve. (See Page 2–1.)

B

Remove the boom/dipperstick assembly . (See Page 5–1.)

Remove the swing motor. (See Page 4–1.)

Installation: Tighten the bolts to 44–47 ft.–lbs. (60–65 Nm) torque.

Connect a chain hoist to the upper works frma and lift it off the swing circle gear.

N–07602

139 of 258 97 Added July

–4–27–

Dealer Copy -- Not for Resale

Loosen and remove all the bolts around the swing circle gear [A] & [B].

220 (S/N 508211999 & Below) Excavator Service Manual

UPPER WORKS (Cont’d)

A

When installing the frame onto the swing bearing, one of two different procedures will need to be followed for proper reassembly alignment. Determine which of these procedures to use by inspecting the frame. If the frame has three locating holes, 0.200 inch in diameter , as shown in [A] use the alignment pin procedure. If these holes are not in the frame, use the alignment screw procedure.

Alignment pin hole locations

B–13727

Connect a chain hoist to the frame and lower the frame onto the swing bearing. Maintain a slight amount of frame weight on the chain hoist.

B Alignment Pin P/N 6539805

Remove any paint from the three alignment pin holes in the frame.

Tapered Alignment Screw P/N 6539680

B–13728

Apply LOCTITE to the threads of the mounting bolts (Item 1) [C] and install the bolts thru the frame and into the swing bearing. DO NOT tighten the bolts at this time.

C 3

2

1

NOTE: If lockwashers were used on the original bolts (Item 1), replace the lockwashers with hardened flat washers (P/N 27E–6), (Item 2) [C].

Insert the three alignment pins (P/N 6539805) (Item 3) [C] into the alignment holes.

Reposition the frame as necessary until the alignment pins (Item 3) [C] will slide thru the frame and into theteeth of the swing bearing.

B–13717

With the pins installed, lower the frame onto the swing bearing and remove the chain hoist.

Tighten the mounting bolts to 44–47 ft.–lbs. (60–65 Nm) torque.

Remove the alignment pins (Item 3) [C] from the frame.

The swing motor can now be installed. SeeInstallation Of Swing Motor Page 4–3.

Revised April 92 Added July140 97 of 258

–4–28–

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

Alignment Pin Procedure

UPPER WORKS (Cont’d)

A

Alignment Screw Procedure Connect a chain hoist to the frame and lower the frame onto the swing bearing. Maintain a slight amount of frame weight on the chain hoist.

2 3

1

1

Install the three alignment screws (P/N 6539680), (Item 1) [A] thru the frame and into the swing bearing, equally space these screws around the swing bearing.

Lower the frame onto the swing bearing while evenly tightening the three alignment screws until they aretight.

The tapered head of the alignment screws will guide the frame into alignment with the swing bearing.

Apply LOCTITE to the mounting bolts (Item 2) [A] and install the bolts thru the frame and into the swingbearing.

Tighten the bolts to 44–47 ft.–lbs. (60–65 Nm) torque.

B–13718

NOTE: If lock washers were used on the original bolts (Item 2) [A], replace the lock washers with hardened flat washers (P/N 27E–6) (Item 3) [A].

2

1

Dealer Copy -- Not for Resale

B

Remove the three alignment screws (Item 1)[A] from the frame.

Apply LOCTITE to the threads of the remainingbolts and install them into the frame. T ighten the bolts to 44–47 ft.–lbs. (60–65 Nm) torque.

Remove the chain hoist from the frame.

Swing Motor Installation Do the following for either the alignment pin or alignment bolt procedure

the

Install the swing motor (Item 1) [B] into the frame.

B–13719

Apply LOCTITE to the threads of the bolts (Item 2) [B] and install.

Tighten these bolts to 29–37 ft.–lbs. (40–50 Nm) torque.

Remove the caps and/or plugs from the swing motor but do not install any hoses.

The swing motor gear to the swing bearing gear engagement must be checked to insure that there is back lash between the gears through 360° of frame rotation.

Check for back lash by moving the frame back and forth at several points throughout the frames rotation. There must be some backlash present.

141 of 258 97 Added July

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220 (S/N 508211999 & Below) Excavator Service Manual

CENTER SWIVEL JOINT

A

Removal And Installation Raise the back of the machine.

Use jackstands under the machine frame.

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

CD–10481

B

I–2003–0888

Remove the bolts from the plate below the swivel joint [A].

5

Mark all the hoses for correct installation.

Disconnect all the hoses from the swivel joint [B].

Remove the four mounting bolts (Item 1) [B].

1

Installation: Add LOCTITE and tighten the bolts to 15–18 ft.–lbs. (20–25 Nm) torque.

4

Remove the center swivel joint from the track frame.

Disassembly And Assembly Remove the bolts (Item 2) [B].

Remove the end plate (Item 3) [B].

Remove the end plate (Item 4) [B] from the end of the rotor.

3

2 B–12744

Remove the rotor (Item 5) [B] from the housing.

NOTE: Tap the rotor lightly with a rubber hammer if needed for removal.

Check the condition of the O–rings and seal.

Check the rotor and housing for scratches or wear marks.

Use grease or hydraulic oil on the O–rings and seal during assembly.

Assemble the swivel joint in reverse order.

Added July142 97 of 258

–4–30–

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

Remove the plate.

SWING CIRCLE GEAR

A

Removal And Installation Remove the upper works from the swing circle gear . (See Page 4–27.)

There is an S (Item 1) [A] stamped on the swing gear , make sure this mark is located to either side of the center line of the machine.

1

N–07606

B

Remove the bolts from the swing circle gear [B].

Installation: Add LOCTITE and tighten the bolts to 44–47 ft.–lbs. (60–65 Nm) torque.

Always replace the seal when installing the swing circle gear.

N–07605

C

Position the outer ring soft zone to either side of the center line of the machine when installing the swing frame on the track frame [C] & [D].

Outer Ring

Inner Ring ”S”

Tracks NOTE: The soft zone can be located by the filler plug in the outer ring [D].

Dealer Copy -- Not for Resale

Use a chain hoist to remove the swing circle gear.

Soft Zone

MC–01415

D

Filler Plug Soft Zone 143 of 258 97 Added July

–4–31–

D–02029

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

220ExcavatorServiceManual(S/N508211999&Below)#6720230–UpperWorksandSwingSectionPart2of2

Added July144 97 of 258

–4–32–

220 (S/N 508211999 & Below) Excavator Service Manual

MAIN FRAME AND TRACKS Page Number BOOM AND DIPPERSTICK Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 ...

BOOM SWING BRACKET Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7 ...

ENGINE COVER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 ...

FUEL TANK Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 ...

IDLER Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–9d ....

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9a ....

SEAT AND MOUNTING FRAME Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 ...

TRACK Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8 ...

Track Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8 ...

TRACK FRAME Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–9 ..

145 of 258 Revised Feb. 95

–5––1–

MAIN FRAME & TRACKS Dealer Copy -- Not for Resale

ROLLER Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–14 ....

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11 ....

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale 146 of 258

–5–0–

220 (S/N 508211999 & Below) Excavator Service Manual

ENGINE COVER

A

Removal and Installation Open the engine cover.

Remove the retainer clip from the rod end pin of the gas cylinder [A].

N–07607

B

Remove the retainer clip from the baseend pin of the gas cylinder [B].

Cylinder contains high pressure gas. Do not open. Opening cylinder can release rod and cause injury or death.

N–07608

W–2113–0288

C

Remove the bolts from the hinge (both sides) [C].

Dealer Copy -- Not for Resale

Hold the engine cover and remove the gas cylinder . Close the engine cover.

N–07609

D

Remove the engine cover from the machine [D].

N–07610 147 of 258

–5–1–

220 (S/N 508211999 & Below) Excavator Service Manual

SEAT AND MOUNTING FRAME

A

Removal and Installation Remove the bolts from the hinge (both sides) [A].

N–07611

B

Remove the seat from the mounting frame [B].

N–07612

C

Disconnect the throttle linkage [C].

N–07613

D

Remove the bolts from the seat mounting frame.

Remove the seat mounting frame [D].

N–07614 148 of 258

–5–2–

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

Disconnect and remove the battery. (See Page 6–3.)

FUEL TANK

A

Removal and Installation NOTE: On some machines, the seat and mounting frame may have to be removed (Page 5–2) so there is enough clearance for fuel tank removal.

Drain the fuel from the tank into a container.

Disconnect the fuel switch wire [A].

N–07615

N–07616

C

Dealer Copy -- Not for Resale

B

Remove the fuel tank mounting bolts [B] & [C].

N–07617

Lift and move the fuel tank forward. Disconnect the fuel hoses. Remove the electrical harness from the fuel tank [D].

D

Remove the fuel tank from the machine.

N–07618 149 of 258

–5–3–

220 (S/N 508211999 & Below) Excavator Service Manual

BOOM AND DIPPERSTICK

A

Removal and Installation Remove the retainer bolts (Item 1) [A] from the bucket pins.

Remove the bucket pins and remove the bucket.

Lower the boom and dipperstick to the floor . Stop the engine.

Move the control to release the hydraulic pressure.

Mark all the hoses for correct installation.

N–07569

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

I–2003–0888

N–07542

C

NOTE: It may be necessary to remove the tubeline clamp so there will be clearance for the wrenches and the hoses can be disconnected from the tubelines [C] & [D].

N–07543

D

N–07544 150 of 258

–5–4–

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

B

Disconnect the hoses from the tubelines [B].

BOOM AND DIPPERSTICK (Cont’d)

A

Removal and Installation (Cont’d) Remove the retainer bolt and nut from the boom cylinder base end pivot pin [A].

N–07564

B

Remove the boom cylinder base end pin [B].

Lower the boom cylinder to the floor.

N–07565

C

Remove the retainer bolt and nut from the boom pivot pin [C].

Dealer Copy -- Not for Resale

Connect a chain hoist to the boom and dipperstick.

N–07619

D

Remove the boom pivot pin [D].

Installation: Make sure to install the washer(s) that were removed when the boom was removed from the swing bracket [D].

N–07620 151 of 258

–5–5–

220 (S/N 508211999 & Below) Excavator Service Manual

BOOM AND DIPPERSTICK (Cont’d)

A

Removal and Installation (Cont’d) Lift the boom slowly and remove it from the boom swing bracket [A].

Dealer Copy -- Not for Resale

N–07621

152 of 258

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220 (S/N 508211999 & Below) Excavator Service Manual

BOOM SWING BRACKET

A

Removal and Installation Remove the boom and dipperstick. (See Page 5–5.)

Remove the retainer bolt from the boom swing cylinder rod end [A].

N–07571

N–07572

C

Remove the retainer bolt and nut from the boom swing bracket pivot pin [C].

Dealer Copy -- Not for Resale

B

Remove the boom swing cylinder rod end pin [B].

N–07622

D

Remove the boom swing bracket pivot pin [D].

Remove the boom swing bracket.

N–07623 153 of 258

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220 (S/N 508211999 & Below) Excavator Service Manual

TRACK

A

Track Tension Adjustment NOTE: The wear of the pins and bushings on the undercarriage vary with the work conditions and different types of soil conditions. It is necessary to inspect track tension to maintain the correct tension. See Service Schedule Page 1–1 for the correct service interval.

Raise the machine using the boom and dipperstick as shown in figure [A]. Stop the engine.

N–07407

B

Add Grease Here

AVOID INJURY

Keep fingers and hands out of pinch points when checking the track tension.

Measure the drop of the track at the middle of the span.

If the gap is between 0.39”–0.78” (10–20 mm), the track tension is correct. If not, loosen one bolt and remove the other bolt from the cover.

B–13134

Add grease to the fitting until the track tension is correct [B].

C

Repeat the procedure for the other side.

Removal and Installation Lift and block the side of the machine where the track will be removed.

Slowly remove the valve from the recoil spring cylinder [C].

NOTE: A chain hoist can be used to pull up on the track so all the tension is released from the recoil spring cylinder for easier removal of the track.

N–07624

Remove the track from the front track idler [D].

Remove the track from the frame and rear drive sprocket.

D

N–07625 154 of 258

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220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

W–2142–0189

TRACK FRAME

A

220ExcavatorServiceManual(S/N508211999&Below)#6720230–MainFrameandTracksSectionPages1–9

Disassembly and Assembly Use the following procedure to remove the different parts from the track frame: Remove the track. (See Page 5–8.)

Slide the front track idler out of the track frame to remove it [A]. (See Page 5–9a for disassembly and assembly procedure.)

CD–07626

CD–07627

Slide the recoil spring cylinder forward and remove it from the track frame [C].

C

Dealer Copy -- Not for Resale

B

Remove the sliding plate [B].

N–07628

D

Loosen the drive gear bolts [D].

Installation: Put LOCTITE on the bolts and tighten to 80 ft.–lbs. (108 Nm) torque.

N–07629 155 ofFeb. 258 95 Revised

–5–9–

220 (S/N 508211999 & Below) Excavator Service Manual

TRACK IDLER Parts Identification

1

2 4 5

3

6 8

6 5 4

1

2 3 C–03127

156 of 258 Added Feb. 95

Ref.

Description

Ref.

Description

1.

2.

3.

4.

Pin Block Snap Ring Seal

5.

6.

7.

8.

Snap Ring Bearing Shaft Idler

–5–9a–

Dealer Copy -- Not for Resale

7

220 (S/N 508211999 & Below) Excavator Service Manual

TRACK IDLER (Cont’d) The following tools must be fabricated for this procedure:

A

Driver Tool – See [A].

Support Fixture – Tube, 3” ID x 1/4” wall x 6” long.

3.50’’ (90 mm) 2.75’’ (70 mm)

0.03’’ (0,75 m) Chamfer 3 Places

Remove the roll pin and block from each end of the shaft [B].

B–14204

B

CD–00289

C

Remove the snap ring from each side of the idler [C].

CD–00288

Use a wire brush to remove any corrosion or paint from both ends of the exposed shaft that could affect seal removal or damage the new seal during installation [D].

D

CD–00290 157 of 258

Added Feb. 95

–5–9b–

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

Disassembly

2.40” (60 mm) Dia.

1.35’’ (30 mm) Dia.

TRACK IDLER (Cont’d)

A

Disassembly (Cont’d) Apply penetrating oil to both ends of the exposed shaft to ease removal of the inner part of the seal.

Remove the inner part of the seal using two screwdrivers [A].

CD–00287

Remove the outer part of the seal from the idler using two screwdrivers [B].

Pour the oil out of the idler appropriate manner.

B

. Discard the oil in an

CD–00285

C

Remove the snap ring from each side of the idler [C].

Dealer Copy -- Not for Resale

Turn the idler assembly over and remove the other seal.

CD–00278

Using the fabricated driver tool and support fixture, press or drive the shaft and bearing assembly out of the idler [D].

D

Driver Tool

Support Fixture CD–00277 158 of 258 Added Feb. 95

–5–9c–

220 (S/N 508211999 & Below) Excavator Service Manual

TRACK ROLLER (Cont’d)

A

Disassembly (Cont’d) Inspect the bearings for rust or for rough spots. The bearings must turn freely. If any damage is found, replace the bearings. If replacement of the bearings is necessary , use a two or three jaw puller, remove the two bearings from the shaft [A].

CD–00273

B

Assembly Remove all paint and corrosion from the seal surface on both sides of the idler [B].

CD–00271

Using the driver tool, install a new bearing, with the numbered side upward, onto the shaft [C]. Press only on the inner diameter of the bearing.

C

CD–00272

D

Using the driver tool, install the shaft and bearing assembly into the idler [D].

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Added Feb. 95

–5–9d–

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

Be sure all parts are clean before assembly.

TRACK IDLER (Cont’d)

A

Assembly (Cont’d) Install the snap ring [A].

CD–00275

B

Turn the idler assembly over.

CD–00276

C

Install the snap ring [C].

Dealer Copy -- Not for Resale

Using the driver tool, install the other bearing, with the numbered side upward, into the idler [B].

CD–00278

D

Using a dial indicator, check the endplay of the shaft [D].

If the endplay is greater than 0.030 inch (0,76 mm) then the bearing must be shimmed.

Cut a shim from the necessary thickness shim stock and install the shim between the bearing and the shoulder on the shaft.

Install Shims Between Bearings and Shaft Shoulder B–14726

CD–00280 160 of 258 Added Feb. 95

–5–9e–

220 (S/N 508211999 & Below) Excavator Service Manual

TRACK IDLER (Cont’d)

A

Assembly (Cont’d) Separate the inner and outer halves of the seals.

Apply grease to the grooves on the outer part of a new seal [A].

CD–00281

CD–00282

Using the driver tool, install the outer part of the new seal into the idler [C].

C

NOTE: The inner and outer parts of the seal must be installed separately so the air will escape from under the seal.

CD–00284

Using the driver tool, install the inner part of the seal over the shaft [D].

D

NOTE: The inner part of the seal must be pressed down level with the outer part of the seal to seal properly.

CD–00286 161 of 258

Added Feb. 95

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220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

B

Apply a small bead of high temperature silicone sealant around the flange surface of the seal [B].

TRACK IDLER (Cont’d)

A

220ExcavatorServiceManual(S/N508211999&Below)#6720230–MainFrameandTracksSectionPages9a–9g

Assembly (Cont’d) Turn the idler assembly over. Using a syringe, add 35 cc of SAE 10W–30 oil to the assembly [A].

Repeat steps A through D on Page 5–9f to install the remaining seal.

Check for leaks.

CD–00283

CD–00288

C

Install the roll pin and block on each end of the shaft[C].

The two blocks must point the same direction.

Dealer Copy -- Not for Resale

B

Install the snap ring on each side of the idler [B].

CD–00289

162 of 258 Added Feb. 95

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220 (S/N 508211999 & Below) Excavator Service Manual

TRACK FRAME (Cont’d)

A

Assembly (Cont’d) Remove the drive gear bolts [A].

Remove the drive gear from the drive motor and planetary gear assembly.

NOTE: See Page 3–7 to remove and install the drive motor and planetary gear assembly.

CD–07630

Loosen the nuts at the track roller on both sides of the track frame [B].

CD–07631

Remove the track roller [C].

C

CD–07632

Added Feb. 164 95 of 258

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220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

B

TRACK ROLLER Parts Identification 2 1

3 4

5

6 7 8

9

Dealer Copy -- Not for Resale

10 8 7 6 5 4 3 1

2

C–03143

TRACK ROLLER

165 of 258

Added Feb. 95

Ref.

Description

Ref.

Description

1.

2.

3.

4.

5.

Washer Nut Washer Spacer Snap Ring

6.

7.

8.

9.

10.

Seal Snap Ring Bearing Shaft Roller

–5–11–

220 (S/N 508211999 & Below) Excavator Service Manual

TRACK ROLLER (Cont’d) The following tools must be fabricated for this procedure:

A

Driver Tool – (See [A]).

Support Fixture – Tubing, 3” ID x 1/4” wall x 6” long.

B–14203

Disassembly

CD–00331

Use a wire brush to remove any corrosion or paint from both ends of the exposed shaft that could affect seal removal or damage the new seal during installation [C].

C

CD–00330

Apply penetrating oil to both ends of the exposed shaft to ease removal of the inner part of the seal.

Remove the inner part of the seal using two screwdrivers [D].

D

CD–00328

Added Feb. 166 95 of 258

–5–12–

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

B

Remove the snap ring from each end of the shaft [B].

TRACK ROLLER (Cont’d)

A

Disassembly (Cont’d) Remove the outer part of the seal from the roller using two screwdrivers [A].

Pour the oil out of the roller. Discard the oil in an appropriate manner.

Turn the roller assembly over and removethe other seal.

CD–00324

CD–00320

Using the fabricated driver tool and support fixture, press or drive the shaft and bearing assembly out of the roller [C].

C Driver Tool

Dealer Copy -- Not for Resale

B

Remove the snap ring from each side of the roller [B].

Support Fixture

CD–00318

D

Inspect the bearings for rust or rough spots. Thebearings must turn freely . If any damage is found, replace the bearings. If replacement of the bearings is necessary , use a two or three jaw puller, remove the two bearings from the shaft [D].

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Added Feb. 95

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220 (S/N 508211999 & Below) Excavator Service Manual

TRACK ROLLER (Cont’d)

A

Assembly Remove all paint and corrosion from the seal surface on both sides of the roller [A].

Be sure all parts are clean before assembly.

CD–00310

Using the driver tool, install a new bearing, with the numbered side upward, onto the shaft [B]. Press only on the inner diameter of the bearing.

CD–00311

C

Using the driver tool, install the shaft and bearing assembly into the roller [C].

CD–00313

D

Install the snap ring [D].

CD–00314

Added Feb. 168 95 of 258

–5–14–

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

B

TRACK ROLLER (Cont’d)

A

Assembly (Cont’d) Turn the roller assembly over.

Using the driver tool, install the other bearing, with the numbered side upward, into the roller [A].

CD–00316

CD–00320

C

Using a dial indicator, check the endplay of the shaft [C].

If the endplay is greater than 0.030 inch (0,76 mm) then the bearing must be shimmed.

Cut a shim from the necessary thickness shim stock and install the shim between the bearing and the shoulder on the shaft.

Dealer Copy -- Not for Resale

B

Install the snap ring [B].

Install Shims Between Bearings and Shaft Shoulder

B–14726

CD–00322

D

Separate the inner and outer halves of the seal.

Apply grease to the grooves on the outer part of a new seal [D].

CD–00325 169 of 258

Added Feb. 95

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220 (S/N 508211999 & Below) Excavator Service Manual

TRACK ROLLER (Cont’d)

A

Assembly (Cont’d) Apply a small bead of high temperature silicone sealant around the flange surface of the seal [A].

CD–00326

Using the driver tool, install the outer part of the new seal into the roller [B].

B

CD–00323

Using the driver tool, install the inner part ofthe new seal over the shaft [C].

C

NOTE: The inner part of the seal must be pressed down level with the outer part of the seal to seal properly.

CD–00327

Turn the roller assembly over. Using s syringe, add 25 cc of SAE 10W–30 oil to the assembly [D].

D

Repeat Page 5–15 steps D through Page 5–16 Step Cto install the remaining seal.

Check for leaks.

CD–00321

Added Feb. 170 95 of 258

–5–16–

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

NOTE: The inner and outer parts of the seal must be installed separately so the air will escape from under the seal.

TRACK ROLLER (Cont’d)

A

Assembly (Cont’d) Install the spacer and the snap ring on each end of the shaft [A].

Dealer Copy -- Not for Resale

CD–00331

171 of 258

Added Feb. 95

–5–17–

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

220ExcavatorServiceManual(S/N508211999&Below)#6720230–MainFrameandTracksSectionPages10–18

Added Feb. 172 95 of 258

–5–18–

220 (S/N 508211999 & Below) Excavator Service Manual

ELECTRICAL SYSTEM Page Number ALTERNATOR Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–4 ...

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4 ...

BATTERY Checking the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–3 ...

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3 ...

ELECTRICAL SYSTEM Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ....

Electrical System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2 ...

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–2 ....

Fuse Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–2 ...

STARTER Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–6 ..

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6 ...

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5 ...

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ...

173 of 258

–6––1–

ELECTRICAL SYSTEM

Dealer Copy -- Not for Resale

INSTRUMENT PANEL Lights, Hourmeter and Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7 ..

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7 ...

220 (S/N 508211999 & Below) Excavator Service Manual

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–6–0–

220 (S/N 508211999 & Below) Excavator Service Manual

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TROUBLESHOOTING The following troubleshooting chart is provided as an assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service personnel only.

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.

W–2003–0797

CAUSE

Battery will not take a charge.

1, 2, 3, 4, 5

Alternator will not charge.

1, 2, 5

Starter will not turn the engine.

2, 3, 4, 6, 7, 8, 9

KEY TO CORRECT THE CAUSE 1.

2.

3.

4.

5.

6.

7.

8.

9.

Alternator belt is loose or damaged.

Battery connections are dirty or loose.

Battery is damaged.

The ground connection is not making a good contact.

The alternator is damaged.

The engine is locked.

The starter is damaged.

The wiring or the solenoid is damaged.

Check the fuses.

Dealer Copy -- Not for Resale

PROBLEM

Description The excavator has a 12 volt, negative ground electrical system. There are two main circuits.

The charging circuit has an alternator, regulator and a battery.

The starting circuit has a starter motor , solenoid and ignition switch for starting the engine.

The electrical system is protected by fuses, installed in the instrument panel. Fuses protect the electrical system from an overload. The reason for the overload must be determined before starting the engine.

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–6–1–

220 (S/N 508211999 & Below) Excavator Service Manual

ELECTRICAL SYSTEM (Cont’d)

A

Fuses The fuses protect the electrical system from damage. To replace the fuse(s), loosen the screw and remove the cover [A].

Replace the fuse(s) with the same type and capacity.

NOTE: Before replacing any fuse(s), make sure the key switch is in the OFF position.

N–09091

Fuse Arrangement [B].

Fuse Capacity

Circuit

1.

2.

3.

4.

10 Amp. 10 Amp. 10 Amp. 10 Amp.

Not Used

B

4

2 1

3 N–07385

Electrical System Service Use the following procedure to system:

C

service the electrical

Check that the battery cable ends are clean and tight.

Remove any acid or corrosion from the battery cable ends with a baking soda and water solution [C]. Cover the battery terminals with grease to prevent corrosion.

Water and Baking Soda Solution

Check the electrolyte level in the battery . Add distilled water as needed.

Check the alternator belt for wear and correct tension.

Check that all wire connections are secure.

178 of 258

A–02741

–6–2–

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

Ref.

BATTERY

A

Checking the Battery The tool listed will be needed to do the procedure:

following

MEL10004A – Battery Tester To make a safe and complete check of the battery , see the Melroe Battery Manual (P/N 6566047). The battery manual has all the information needed for checking and servicing the battery.

Removal and Installation Raise the operator seat [A].

N–07410

Batteries contain acid which burns eyes and skin on contact. W ear goggles, protective clothing and rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes.

1 N–07633

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

C

W–2065–1296

Disconnect the negative (–) cable first [B].

Disconnect the positive (+) cable.

Dealer Copy -- Not for Resale

B

Remove the battery holddown clamp (Item 1) [B].

Remove the battery from the machine.

Always clean the terminals and battery ends, even when installing a new battery.

Reverse the procedure for battery installation.

179 of 258

B–03707

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220 (S/N 508211999 & Below) Excavator Service Manual

ALTERNATOR

A

Belt Adjustment Stop the engine. Open the engine cover.

The belt should deflect about 1/2” (13 mm) when pressed between the alternator pulley and crankshaft pulley with approximately 13 lbs. (58 N) force [A].

N–07394

N–07395

C

Loosen the adjustment bolt [C].

Move the alternator until the belt tension is correct.

Tighten the adjustment bolt and mounting bolt.

Replace the belt if it has stretched or there are cracks in the belt. Check the pulley grooves, make sure the belt is not in contact with the bottom of the grooves in the pulleys.

N–07396

D

Removal and Installation Disconnect the negative (–) cable from the battery.

Disconnect the alternator wires [D].

Remove the adjustment bolt [C].

Remove the alternator belt.

Remove the mounting bolt [B].

Remove the alternator from the bracket.

N–07652 180 of 258

–6–4–

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

B

If the tension is not correct, loosen the alternator mounting bolt [B].

STARTER

A

Removal and Installation Raise the operator seat. Disconnect the negative cable from the battery.

(–)

Disconnect the wires from the starter [A].

N–07634

B

Remove the mounting bolts from the starter [B].

N–07635

181 of 258

–6–5–

Dealer Copy -- Not for Resale

Remove the starter from the bell housing.

220 (S/N 508211999 & Below) Excavator Service Manual

STARTER (Cont’d)

A

Disassembly and Assembly Disassemble the starter as shown in figure [A].

Cleaning and Inspection

Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure.

• Flying debris or loose material is present.

• Engine is running.

• Tools are being used.

W–2019–1285

NOTE: Do not use solvent to clean the drive assembly. The solvent will remove the lubricant and the drive will slip.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

Check the following items: Armature Broken or burned insulation.

Loose connections at commutator.

Open or grounded circuits.

Worn shaft or bearings.

Rough commutator.

Field Coils Broken or burned insulation.

Electrical continuity.

Brush connections.

Drive Gear Worn teeth.

Tooth engagement (drive gear must engage ring gear by 1/2 the depth of the ring gear tooth).

Brush Holders Broken springs.

Broken insulation.

Spring tension.

182 of 258

–6–6–

Starter Yoke Assy.

Armature Bearing Bearing Nut Retainer Pinion Shaft Snap Ring Spring Spring Clutch Roller Pinion Housing Frame Holder Assy.

Spring Solenoid Gasket Bushing Bushing Bushing Bushing

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

Cover Plate Plate Plunger Bolt Washer Washer Bolt Bolt Nut Nut O–ring O–ring Nut Washer Screw Screw Washer Bolt Nut Ball Spring Retainer Bolt Clutch Assy.

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

Use a brush and air pressure toclean the drive, field coils, armature and starter housing.

INSTRUMENT PANEL

A

Lights, Hourmeter and Ignition Switch Use the following procedure to remove or install any light, etc. from the instrument panel: Lift the operator seat. Disconnect the negative (–) cable from the battery.

Remove the screws from the cover panel [A].

on the instrument

N–07636

Lift the cover [B].

N–07637

C

Removal and Installation Lift the operator seat. Disconnect the negative (–) cable from the battery.

Remove the bolts on both sides of the instrument panel housing [C] & [D].

Dealer Copy -- Not for Resale

B

Remove the defective part and install the new part.

N–07638

D

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220 (S/N 508211999 & Below) Excavator Service Manual

INSTRUMENT PANEL (Cont’d)

A

220ExcavatorServiceManual(S/N508211999&Below)#6720230–ElectricalSystemSection

Removal and Installation (Cont’d) Pull the instrument panel away from the hydraulic reservoir [A].

N–07640

B

Disconnect the wiring harness connectors [B].

N–07641

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–6–8–

220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

Remove the instrument panel assembly from the machine.

ENGINE SERVICE Page Number CRANKSHAFT AND PISTONS Crankshaft Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–37 ...

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–34 ...

Servicing the Connecting Rods and Pistons . . . . . . . . . . . . . . . . . . . . . 7–38 .

CYLINDER HEAD Assembling the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–26 ..

Checking the Rocker Arm and Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–26 ..

Checking the Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–25 ..

Disassembly of the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–23 ..

Installing the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–26 ..

Removal of the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–22 ..

Servicing the Cylinder Head and Valves . . . . . . . . . . . . . . . . . . . . . . . . .7–24 .

CYLINDER LINERS Checking the Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–40 ..

Cylinder Liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–40 ...

ENGINE COMPRESSION Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–3 ....

ENGINE FLYWHEEL Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–21 ...

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–19 ...

FUEL FILTER Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4 ....

Removing Air From the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4 ..

FUEL INJECTION PUMP Checking the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–5 ..

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5 ...

Timing the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7 ...

ENGINE SERVICE

Dealer Copy -- Not for Resale

ENGINE Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11 ...

FUEL INJECTOR NOZZLES Checking the Injector Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–9 ..

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 ...

Timing the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7 ...

GLOW PLUGS Checking the Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10 ...

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10 ...

MUFFLER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–15 ...

RADIATOR Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–17 ...

185 of 258 Revised July 91

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220 (S/N 508211999 & Below) Excavator Service Manual

ENGINE SERVICE Page Number TIMING GEAR, CAMSHAFT AND OIL PUMP Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–32 ...

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–30 ...

Servicing the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–33 ...

TIMING GEAR COVER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–28 ...

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 ...

VALVE CLEARANCE Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2 ....

Dealer Copy -- Not for Resale

WATER PUMP Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–41 ..

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41 ...

186 of 258 Revised July 91

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TROUBLESHOOTING The following troubleshooting chart is provided as an assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service personnel only.

Slow cranking speed.

Engine will not start.

Difficult to start.

No power from engine.

Engine is mis–firing.

Too much fuel consumption.

Black exhaust.

Blue/white exhaust.

Low oil pressure.

Engine knocking.

Engine running rough.

Vibration.

High oil pressure.

Overheating.

Too much crankcase pressure.

Poor compression.

Start and stop.

CAUSE 1, 2, 3, 4 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28 10,12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50 4, 31, 32, 33, 34, 35, 37, 39, 52 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43 4, 33, 36 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 51 22, 27, 29, 30, 40, 49 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53 9, 10, 11

KEY TO CORRECT THE CAUSE 1. Battery capacity low.

2. Bad electrical connections.

3. Faulty starter motor.

4. Incorrect grade of oil.

5. Low cranking speed.

6. Fuel tank empty.

7. Faulty stop control operation.

8. Plugged fuel line.

9. Plugged fuel filter.

10. Restriction in the air cleaner.

11. Air in the fuel system.

12. Faulty fuel injection pump.

13. Faulty fuel injectors.

14. Broken injection pump drive.

15. Incorrect injection pump timing.

16. Incorrect valve timing.

17. Poor compression.

18. Plugged fuel tank vent.

19. Incorrect grade of fuel.

20. Exhaust pipe restriction.

21. Cylinder head gasket leaking.

22. Overheating.

23. Cold running.

24. Incorrect tappet adjustment.

25. Sticking valves.

26. Incorrect high pressure fuel lines.

27. Worn cylinder bores.

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28. Worn valves and seats.

29. Broken or worn piston rings.

30. Worn valve stems or guides.

31. Worn or damaged bearings.

32. Not enough oil in the oil pan.

33. Switch is defective.

34. Oil pump worn.

35. Relief valve is stuck open.

36. Relief valve is stuck closed.

37. Broken relief valve spring.

38. Faulty suction pipe.

39. Plugged oil filter.

40. Piston seizure.

41. Incorrect piston height.

42. Faulty engine mounting.

43. Incorrect alignment of flywheel.

44. Faulty thermostat.

45. Restriction in water jacket.

46. Loose alternator belt.

47. Plugged radiator.

48. Faulty water pump.

49. Plugged breather pipe.

50. Damaged valve stem oil deflectors.

51. Coolant level too low.

52. Plugged oil pump pipe strainer.

53. Broken valve spring.

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PROBLEM

220 (S/N 508211999 & Below) Excavator Service Manual

VALVE CLEARANCE

A

Adjustment

0.006”– 0.007” (0,15–0,18 mm)

Adjust the valve clearance with the engine stopped and cold.

The correct valve clearance is 0.006”–0.007” (0,15–0,18 mm) [A].

Make sure the piston is at T .D.C. when making the adjustment for the valves of the particular cylinder.

A–02730

B–05893

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B

Put the correct size feeler gauge between the rocker arm and valve stem. Turn the adjustment bolt until the clearance is correct [B].

ENGINE COMPRESSION

A

Checking The tool listed will be needed to do the procedure:

following

OEM1074 – Engine Compression Kit The engine must be at operating temperature.

Remove the fuel injector nozzles from the engine. (See Page 7–8.)

Install the compression adapter into thecylinder head [A].

B–12827

Connect the compression gauge [B].

The compression must be at least 75% of 337–448 PSI (2324–3089 kPa) with no more than 50 PSI (345 kPa) difference between the cylinders.

B–12828

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B

Turn the engine with the starter (must turn at least 175 RPM). Run the test for each cylinder two times for 5–10 seconds.

220 (S/N 508211999 & Below) Excavator Service Manual

FUEL FILTER

A

Fuel Filters See the Service Schedule Page 1–1 for the service interval to service the fuel filters.

correct

Use a filter wrench to remove the final fuel filter (Item 1) [A].

Put some oil on the new filter gasket. Install the new filter element and hand tighten only.

2

1

N–07376

B

Remove the in–line fuel filter (Item 1) [B] and replace it with a new filter element.

1

Removing Air From the Fuel System

Open the vent plug (Item 2)[A] on the top of the final fuel filter housing.

Turn the key switch to the ON position. The fuel system has an electric fuel pump and when the fuel flows through the vent plug with no air bubbles, close the vent plug.

Turn the key switch to the OFF position.

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N–07377

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220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

After replacing the fuel filters or after running out of fuel, air must be removed from the fuel system.

FUEL INJECTION PUMP

A

Checking the Injection Pump The injection pump contains parts which have a very close tolerance and its operation has a directeffect on the performance of the engine.

Do not attempt to maintain or adjust unless you are trained and have the correct equipment.

B–05959

I–2028–0289

B The tools listed will be needed to do the following procedure: MEL1237 – Adapter Fuel Line MEL1173–1 – Pressure Gauge

2

Disconnect the high pressure fuel line at the pump [A].

Loosen the other end of the same high pressure line so it can be turned away from the fitting.

Connect the adapter fuel line (Item 1) [B] to the fitting.

B–08235

Connect the pressure gauge (Item 2) [B].

C

Crank the engine, with the starter , to increase the pressure to 2133 PSI (14707 kPa). Align the plunger at T.D.C. The pressure should hold at 2133 PSI (14707 kPa), at least 5 seconds. If not, repair or replace the injection pump.

Dealer Copy -- Not for Resale

1

To check the discharge pressure at the fuel injection pump, use the following procedure:

Removal and Installation NOTE: To remove the fuel injection pump, either remove the engine from the machine (See Page 7–11) or remove the seat, seat mounting frame and fuel tank. (See Page 5–3.) Remove the access panel from the machine frame.

B–05960

Clean the area around the fuel injection pump. Remove the high pressure fuel lines.

Disconnect the glow plug wires [C].

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FUEL INJECTION PUMP (Cont’d)

A

Removal and Installation (Cont’d) Disconnect the throttle linkage cable from the injection pump.

Remove the bolts from the intake manifold. Remove the intake manifold [A].

B–06567

B

Disconnect the fuel inlet hose (Item 1)[B] and return hose (Item 2) [B].

1

B–06964

C

Remove the engine lift hook (Item 1) [C].

Remove the four nuts from the injection pump [C].

1

Installation: Tighten the nuts to 17–20 ft.–lbs. (23–27 Nm) torque.

B–05965

D

Align the pin (Item 1) [D] in the control rack with the slot in the engine block.

Remove the injection pump.

Installation: When the injection pump is installed, make sure the pin (Item 1) [D] on the control rack is correctly installed on the fork lever . If the slot is not installed correctly, the engine will run over maximum speed and serious damage can result.

NOTE: Make sure the same number shims are installed under the injection pump. The shims are used for engine timing.

1 B–05966

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2

FUEL INJECTION PUMP (Cont’d)

A

Timing the Injection Pump NOTE: The engine timing marks are located on the engine flywheel. Remove the hydraulic pumps and mounting brackets.

Timing the fuel injection pump is done by changing the number of shims (Item 1) [A] between the injection pump and engine block.

1

Each shim will change the timing 1.5 degrees. Thetiming of the pump will be later when a shim is added, and earlier when a shim is removed.

B–10007

B

Use the following procedure to time the injection pump: 1. Remove the number 1 cylinder high pressure line from the injection pump.

3. With fuel supply to the injection pump, rotate the engine counterclockwise (viewed from the flywheel end of the engine). Fuel must flow from the pipe as the mark on the flywheel and the dot (punch mark) are in alignment [B].

4. The correct timing for the engine is 23–25 degrees B.T.D.C. Add or subtract shim(s) as needed to adjust the delivery time of the fuel injection pump.

N–07642

5. Repeat Step 3 several times forcorrect timing mark alignment before adding or removing shim(s).

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2. Install a short pipe in the number 1 outlet of the pump. Point the pipe up (vertical).

220 (S/N 508211999 & Below) Excavator Service Manual

FUEL INJECTOR NOZZLES

A

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes causing serious injury. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. W ear safety goggles. If fluid enters skin or eyes, get immediate medical attention.

W–2074–1285

B–05958

Some problems caused by faulty injector nozzles:

B

The engine is hard to start or will not start.

Rough engine operation at idle.

The engine will not have full power.

The engine exhaust smoke is black, white or blue.

Removal and Installation

B–05969

C

Do not bend the high pressure fuel injection tubes when removing or installing them.

I–2029–0289

The tool listed will be needed to do the procedure:

following

MEL1181 – Nozzle Socket Disconnect the high pressure fuel lines from the fuel injectors [A].

Disconnect the other end of the fuel lines from the injection pump. Remove the high pressure fuel lines.

B–05970

D

Disconnect the return fuel hoses (Item 1) [B].

Remove the banjo fitting from the fuel injector [B].

Use the special socket and loosen the injector nozzle[C].

Installation: Tighten the injector nozzle to 29–36 ft.–lbs.

(39–49 Nm) torque.

Remove the injector nozzle from the cylinder head [D].

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1

FUEL INJECTOR NOZZLES (Cont’d)

A

Checking the Injector Nozzle

3

2

Do not disassemble or test the fuel injector nozzles unless you have the correct service and testing tools.

1

I–2027–0284

B–04103

The tool listed will be needed to do the procedure:

following

B

MEL10018 – Injector Nozzle Tester

Each spacer is 0.004” (0,10 mm) thick and will change the release pressure by about 142 PSI (980 kPa). The release pressure should be 1920–2133 PSI (13238–14707 kPa).

Connect the injector nozzle to the tester with the nozzle down [B].

Operate the hand lever slowly and note the opening pressure. If the pressure is not correct, disassemble the injector nozzle and add or remove spacer(s) (Item 1) [A] as needed.

A–02513

C

Assemble the nozzle and check the pressure again.

Tighten the nozzle body (Item 3) [A] to 43–58 ft.–lbs.

(59–79 Nm) torque.

Spring

CORRECT

NOTE: Do not over tighten, or slow action of the valve will occur.

WRONG

Dealer Copy -- Not for Resale

You can adjust the release pressure of the injector nozzle by adding or removing spacer(s) (Item 1)[A] from the top of the nozzle spring (Item 2) [A].

Pressure Pin Holder

Nozzle Body

Check for internal leakage. Operate the hand lever until the pressure is almost enough to open the injectorvalve.

Needle Valve

Record the pressure. Release the hand lever. Check the pressure drop for 10 seconds. If the pressure drop more is than 740 PSI (5102 kPa), the nozzle is damaged.

A–02621

Check that the spray pattern is correct [C]: Fuel does not come out the side of the nozzle.

Drops of fuel are not present at the nozzle.

The nozzle has an even flow coming from the nozzle.

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes causing serious injury. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. W ear safety goggles. If fluid enters skin or eyes, get immediate medical attention.

W–2074–1285

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220 (S/N 508211999 & Below) Excavator Service Manual

GLOW PLUGS

A

Removal and Installation Remove the high pressure fuel lines from the injector nozzles and injection pump.

Do not bend the high pressure fuel injection tubes when removing or installing them.

I–2029–0289

B–05960

Disconnect the glow plug wires [A].

B–06567

Remove the glow plugs from the cylinder head [C].

C

B–05972

D

Checking the Glow Plug Connect a voltmeter to the terminal end of the glow plug, touch the other lead from the voltmeter to the heating end of the glow plug [D].

The reading must be approximately 1.5 OHMS. If the resistance is zero OHMS, the glow plug has a short circuit. If the resistance is infinite, the coil ofthe glow plug is broken.

B–11571 196 of 258

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220 (S/N 508211999 & Below) Excavator Service Manual

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B

Remove the intake manifold [B].

ENGINE

A

Removal and Installation Remove the engine cover. (See Page 5–1.)

Drain the cooling system.

Remove the muffler. (See Page 7–15.)

Disconnect the top radiator hose [A].

Disconnect the lower radiator hose and engine block drain hose.

N–07643

Loosen the air cleaner hose clamp [B].

N–07644

Loosen the air cleaner hose clamps at the intake manifold and air cleaner [C].

C

Remove the hose.

Dealer Copy -- Not for Resale

B

Remove the air cleaner intake hose.

N–07645

D

Remove the nut from the throttle linkage cable end [D].

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220 (S/N 508211999 & Below) Excavator Service Manual

ENGINE (Cont’d)

A

Removal and Installation (Cont’d) Loosen the large nut on the throttle linkage cable [A].

Disconnect the throttle linkage from the fuel injection pump and mounting bracket.

N–07647

N–07648

C

Disconnect the two inlet hoses from the hydraulic pump [C].

Drain the hydraulic fluid into a container.

N–07537

D

Disconnect the two high pressure hoses from the hydraulic pump [D].

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B

Disconnect the fuel hose and fuel return hose from the fuel injection pump [B].

ENGINE (Cont’d)

A

Removal and Installation (Cont’d) Remove the nuts from the four engine mounting brackets [A].

N–07649

N–07650

C

Disconnect the wire from the oil pressure switch [C].

Dealer Copy -- Not for Resale

B

Disconnect the wire from the temperature switch [B].

N–07651

D

Disconnect the two alternator wires [D].

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220 (S/N 508211999 & Below) Excavator Service Manual

ENGINE (Cont’d)

A

Removal and Installation (Cont’d) Disconnect the wires from the starter [A].

N–07634

B

Connect a chain hoist to the engine lift hooks [B].

N–07653

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220 (S/N 508211999 & Below) Excavator Service Manual

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Slowly lift the engine and remove it from the excavator [B].

MUFFLER

A

Removal and Installation Loosen the exhaust pipe clamp [A].

N–07654

N–07655

C

Remove the exhaust pipe [C].

Dealer Copy -- Not for Resale

B

Remove the two bolts from the exhaust pipe mounting bracket [B].

N–07656

Remove the two bolts and nuts from the exhaust manifold [D].

D

N–07657 201 of 258

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220 (S/N 508211999 & Below) Excavator Service Manual

MUFFLER (Cont’d)

A

Removal and Installation (Cont’d) Remove the nuts from the two muffler holddown clamps [A].

N–07658

N–07659

C

Remove the holddown clamps [C].

N–07660

D

Remove the muffler [D].

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B

Remove the bolts from the two muffler holddown clamps [B].

RADIATOR

A

Removal and Installation Drain the cooling system.

Disconnect the top radiator hose [A].

Disconnect the lower radiator hose and engine block drain hose.

N–07643

B

NOTE: Figure [B] is shown for photo clarity .

N–07662

C

Remove the nut and washer from the radiator mounting bracket [C].

Dealer Copy -- Not for Resale

Remove the two mounting bolts from the radiator mounting bracket on the side of the radiator, toward the frame [B].

N–07663

D

Remove the bolts from the mounting bracket [D].

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RADIATOR (Cont’d)

A

Removal and Installation (Cont’d) Remove the radiator mounting bracket [A].

N–07665

NOTE: Figure [B] is shown for clarity.

B

1 1

N–07666

C

Lift the radiator from the machine [C].

N–07667

Remove the lower mounting brackets. Remove the bolts and remove the radiator shroud [D].

D

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Remove the four bolts (Item 1)[B] which fasten the lower radiator mounting brackets to the frame.

ENGINE FLYWHEEL

A

Removal and Installation NOTE: The flywheel can be removed with the engine installed in the machine. The following photos show the engine removed from the machine for photo clarity.

If the engine is not removed; disconnect the two inlet hoses from the hydraulic pump [A].

Drain the hydraulic fluid into a container.

N–07537

B

If the engine is not removed, disconnect the two high pressure hoses from the hydraulic pump [B].

N–07538

C

Remove the two mounting bolts from the hydraulicpump [C].

Dealer Copy -- Not for Resale

Remove the muffler from the engine. (See Page 7–15.)

N–07669

D

Remove the hydraulic pump from the flywheel bell housing [D].

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220 (S/N 508211999 & Below) Excavator Service Manual

ENGINE FLYWHEEL (Cont’d)

A

Removal and Installation (Cont’d) Remove the two bottom bolts from the muf fler bracket [A].

N–07671

N–07672

C

Remove the muffler bracket and the two spacers [C].

N–07673

D

Remove all the bolts from the flywheel bell housing [D].

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220 (S/N 508211999 & Below) Excavator Service Manual

Dealer Copy -- Not for Resale

B

Remove the two top bolts from the muffler bracket [B].

ENGINE FLYWHEEL (Cont’d)

A

Removal and Installation (Cont’d) Remove the bell housing assembly [A].

N–07675

Remove the hydraulic pump coupler [C].

Remove the bolts from the flywheel [D].

Installation: Tighten the bolts 40–43 ft.–lbs. (54–59 Nm) torque.

Remove the flywheel.

N–07677

C

Flywheel Ring Gear

Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure.

• Flying debris or loose material is present.

• Engine is running.

• Tools are being used.

Dealer Copy -- Not for Resale

B

Remove the bolts from the hydraulic pump coupler [B].

N–07678

D

W–2019–1285

The ring gear on the flywheel is an interface fit. Heat the ring gear enough to expand it and hit it evenly with a hammer to remove it.

Clean the outer surface of the flywheel to give a smooth fit.

Clean the new ring gear and heat it to a temperature of 450°–500° (232°–260° C).

Fit the ring gear over the flywheel. Make sure the gear is seated correctly.

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N–07679

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220 (S/N 508211999 & Below) Excavator Service Manual

CYLINDER HEAD

A

Removal of the Cylinder Head Drain the cooling system.

Remove the nuts from the valve cover.

Remove the valve cover and gasket [A].

B–05094

B

Disconnect and remove high pressure fuel lines [B].

B–05882

Remove the nuts from the rocker arm supports. Remove the rocker arm assembly [C].

C

Remove the push rods [D].

D

Mark the push rods so they will be returned to their original position.

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Remove the fuel injector nozzles. (See Page 7–10.)

CYLINDER HEAD (Cont’d)

A

Removal of the Cylinder Head (Cont’d) Remove the cylinder head from the engine block [A].

B–05101

B

Remove the head gasket and O–ring from the engine block [B].

B–05886

C

Disassembly of the Cylinder Head The tool listed will be needed to do the procedure:

following

MEL10121 – Valve Tool Use a valve spring compression tool to remove the valves [C].

Dealer Copy -- Not for Resale

NOTE: Some engines may use a shim and some do not. If a shim is present it must be used during reassembly. The shim (if used) must be installed between the cylinder head and gasket.

B–05889

Remove the valve cap (Item 1) [D] and valve spring collet (Item 2) [D].

D

Remove the valve spring retainer (Item 3) [D] and spring (Item 4) [D].

5

2

6

1

4

Remove the seal (Item 5) [D] and the valve (Item 6) [D].

Seal

Valve

Spring

Collets

Cap

3 Retainer B–04122

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CYLINDER HEAD (Cont’d)

A

Removal of the Cylinder Head (Cont’d) Remove the thermostat housing and thermostat [A].

B–03643

B

Servicing the Cylinder Head and Valves

1

Clean the surface of the cylinder head.

Put a straight edge (Item 1) [B] on the cylinder head.

Put a feller gauge (Item 2) [B] between the straight edge and the surface of the cylinder head.

The maximum distortion of the head surface + 0.002” (+ 0, 051 mm) in 4” (102 mm) of the length of the cylinder head surface.

2 A–02735

If the measurement is more than the specifications, the cylinder head must be replaced.

C

Clean the valve seat and combustion chamber. Measure the width of the valve seat [C].

B–03632

D

The correct width of the seat is 0.083” (2,1 mm). The correct angle of the valve and seat is 45° [D].

A

C

Valve Contacting Width

B Grind the valve seats as follows: Use a 45° cutter to grind the surface of the valve seat.

Use a 15° cutter to grind the top surface of the valve seat.

Use a 65° or 70° cutter to grind the bottom surface of the valve seat to finish the valve seat to a 0.083” (2,1 mm) width.

Grind the valve surface to 45°.

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Corrected Surface of Valve Seat Uncorrected Surface of Valve Seat A–45° Cutter B–45° Cutter C–65° or 70° Cutter A–02729 220 (S/N 508211999 & Below) Excavator Service Manual

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NOTE: Do not put the straight edge across the combustion chambers.

CYLINDER HEAD (Cont’d)

A

220ExcavatorServiceManual(S/N508211999&Below)#6720230–EngineServiecSectionPart1of2

Servicing the Cylinder Head and Valves (Cont’d) Install the valve in the seat and check the depth [A].

The specifications for the depth of the valve is 0.043”–0.051” (1,09–1,30 mm).

If the measurement is more than specifications, add the correct thickness of washer under the valve spring to keep the correct spring tension.

B–03634

B

Clean the valve guide. Install the valve in the cylinder head. Install a dial indicator [B].

Replace the valve guide and valves as needed. Make sure to ream the inside diameter of the new guide to the correct dimension of 0.276”–0.277” (7,01–7,04 mm)

B–03698

C

Checking the Valve Springs Measure the valve spring. The length of the spring must be 1.382”–1.402” (35,1–35,6 mm). Check the valve spring with a square to make sure it is straight [C].

Dealer Copy -- Not for Resale

Measure the clearance of the valve guide and the valve.

The measurement must be 0.0014”–0.0026” (0,04–0,07 mm).

B–03680

Put the valve spring in a tester [D].

Push down on the spring 1.22” (31 mm), the compression load must be 16.5 lbs. (7,5 kg).

Replace the valve spring if it does specifications.

D

not meet these

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CYLINDER HEAD (Cont’d)

A

Checking the Rocker Arm and Shaft Measure the inside diameter of the rocker arm bushing and the shaft diameter [A].

The inside diameter of the rocker 0.433”–0.435” (11,0–11,05 mm).

arm bushing is

The shaft diameter is 0.432”–0.433” (10,97–11,0 mm).

If the measurements are not within specification,replace the parts.

Assembling the Cylinder Head

B–03697

Install the valves. Put oil on the valve seal and install the seal on the valve stem.

B

Install the valve spring and retainer . Install the spring collet and valve cap.

Installing the Cylinder Head Install the O–ring in the cylinder block [B].

B–05890

C

Install the new head gasket [C].

Install the shim (if present during disassembly). The shim goes between the cylinder head and gasket.

NOTE: Use the same shim again or replace it with a shim of the same thickness.

B–05886

Install the cylinder head. Put oil on the cylinder head bolts.

Tighten the bolts and nuts to 29–33 ft.–lbs. (40–45 Nm) torque. Use the tighten sequence as shown in figure[D].

D

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Install the thermostat. Install the thermostat housing and a new gasket.

CYLINDER HEAD (Cont’d)

A

Installing the Cylinder Head (Cont’d) Lower the piston to be measured for the clearance. Put a piece of solder in the injector port [A]. Make sure the solder does not touch the valve.

Turn the engine crankshaft (manually) until the piston goes over T.D.C. Remove the solder and measure it. The thickness must be 0.024”–0.031” (0,6–0,8 mm). If the measurement is not within this specification, remove the cylinder head.

Install the correct shim between the cylinder head and gasket.

B–04068

Install the cylinder head. Tighten the bolts and nuts to 29–33 ft.–lbs. (40–45 Nm) torque. Use the tightening sequence on Page 7–26, figure [D].

B

B–05881

C

Install the rocker arms [C].

Install the injector nozzles. (See Page 7–10.)

Install the high pressure fuel lines.

Adjust the valve clearance. (See Page 7–2.)

Dealer Copy -- Not for Resale

Install the push rods [B].

D

Install the valve cover with a new gasket [D].

Connect the radiator hose. Add coolant to the cooling system.

NOTE: Make sure to tighten the cylinder head bolts and nuts to the correct torque after the engine has been operated for 30 minutes.

Readjust the valve clearance.

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TIMING GEAR COVER

A

Removal and Installation NOTE: It may be easier to remove and install the timing gear cover with the engine removed from the machine.

Remove the fuel injection pump. (See Page 7–5.)

Remove the side plate from the governor housing.

Disconnect the governor spring from the governor fork [A].

B–03676

Remove the plate for the speed control and governor spring [B].

B–03647

Remove the start spring from the gear case [C].

C

B–03678

Straighten the washer on the crankshaft pulley. Remove the nut and washer.

Installation: Tighten the nut to 101–1 (137–157 Nm) torque.

D

16 ft.–lbs.

Use a puller and remove the pulley [D].

Remove the crankshaft key.

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B

TIMING GEAR COVER (Cont’d)

A

Removal and Installation (Cont’d) Remove the bolts from the gearcase.

Installation: Tighten the bolts to 13–15 ft.–lbs. (18–21 Nm) torque.

Remove the gear case and O–rings [A].

B–05895

Installation: Install new crankshaft seal. Install the three O–rings. Put non–drying adhesive on the edge of the gearcase cover [B].

B

Oil Seal B–03617

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O–rings

220 Excavator (S/N 11999 & Below) Service Manual

TIMING GEAR, CAMSHAFT AND OIL PUMP

A

Removal and Installation Remove the cylinder head. (See Page 7–22.)

3 2

1

Remove the tappets.

Remove the timing gearcase cover. (See Page 7–28.)

Remove the crankshaft collar (Item 1) [A], O–ring (Item 2) [A] and oil slinger (Item 3) [A].

B–03637

B–05918

Remove the idler gear (Item 1) [C].

C

Remove the idler gear collar (Item 2) [C] from the shaft.

1

B–03699

Align the holes in the camshaft gear with the stop plate bolts.

D

Remove the bolts from the camshaft stop plate [D].

Installation: Tighten the bolts to 14–15 ft.–lbs. (18–21 Nm) torque.

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B

Remove the snap ring and washer from the idler gear [B].

TIMING GEAR, CAMSHAFT AND OIL PUMP (Cont’d)

A

Removal and Installation (Cont’d) Remove the camshaft [A].

B–03655

B

Remove the two bolts that hold the fork lever on the fuel camshaft.

Installation: Tighten the fork lever bolts to 60–72 in.–lbs.(6,8–8,1 Nm) torque.

B–05919

C

Remove the stop (Item 1) [C] for the fuel camshaft.

Remove the fuel camshaft [C].

Dealer Copy -- Not for Resale

Remove the fork lever [B].

B–05922

D

Installation: Make sure the timing marks on the gears are aligned when installing the gears [D].

Gear backlash is 0.0017”–0.0045” (0,043–0,114 mm).

The limit permitted is 0.0079” (0,2 mm).

Injection Pump Gear

Crankshaft Gear

Idler Gear

Camshaft Gear B–05927 217 of 258

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TIMING GEAR, CAMSHAFT AND OIL PUMP (Cont’d)

A

Removal and Installation (Cont’d) Remove the crankshaft gear with a puller [A].

Remove the crankshaft key.

B–03686

B

Oil Pump Service Straighten the washer on the gear of the oil pump.

Remove the bolt from the oil pump gear.

Remove the oil pump gear [B].

B–05923

C

Remove the oil pump bolts and oil pump [C].

Installation: Tighten the oil pump bolts to 60–72 in.–lbs.

(6,8–8,1 Nm) torque.

B–05925

D

Check the clearance between the inner and outer rotor [D].

The clearance for the inner rotor is 0.004”–0.006” (0,10–0,15 mm). The wear limit is 0.008” (0,20 mm).

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Installation: Tighten the bolt to 60–72 in.–lbs. (6,8–8,1 Nm) torque.

TIMING GEAR, CAMSHAFT AND OIL PUMP (Cont’d)

A

Oil Pump Service (Cont’d) Check the clearance between the outer rotor and the body of the oil pump [A].

The clearance for the outer rotor is 0.004”–0.008” (0,10–0,20) mm).

At rated engine speed, the normal oil pressure is 28–64 PSI (193–441 kPa). It must not be lower than 28 PSI (196 kPa).

A–02732

B

Servicing the Camshaft Measure the camshaft bearing in the engine block [B].

B–03620

C

Measure the camshaft journal [C].

The specification is 1.296”–1.297” (32,91–32,94 mm). If the measurements are not within limits, replace the parts as needed.

Dealer Copy -- Not for Resale

The specification is 1.299”–1.300” (32,99–33,02 mm).

The wear limit is 0.002”–0.0036” (0,051–0,091 mm).

A–02761

D

Put the camshaft in V–blocks. Install a dial indicator on the journals [D].

Turn the camshaft slowly. The wear limit is 0.002” (0,05 mm).

If the camshaft measurements are not within the specifications, replace the part as needed.

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TIMING GEAR, CAMSHAFT AND OIL PUMP (Cont’d)

A

Servicing the Camshaft (Cont’d) Measure the highest point on each camshaft lobe [A].

The specification is 1.058” (26,87 mm).

The wear limit is 1.056” (26,82 mm).

B–05001

B

Installation: After the crankshaft is installed, check the clearance for the camshaft gear . Mount a dial indicator [B].

B–03672

C

CRANKSHAFT AND PISTONS Removal and Installation The tools listed will be needed to do the following procedure: MEL1063 – Ring Compressor MEL1064 – Piston Ring Expander Remove the cylinder head. (See Page 7–22.)

Remove the gear case cover. (See Page 7–28.)

Remove the timing gears. (See Page 7–30.)

B–05924

Remove the flywheel.

Remove the oil pan [C].

22091 of 258 Revised July

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Hold one gear while turning the other gear . The specification is 0.0017”–0.0045” (0,043–0,114 mm). The wear limit is 0.0079” (0,2 mm).

CRANKSHAFT AND PISTONS (Cont’d)

A

Removal and Installation (Cont’d) Remove the oil pump tube and screen damage the O–ring on the tube.

[A]. Do not

Straighten the washer on the connecting rod Remove the connecting rod nuts and bolts.

bolts.

B–05920

B Remove the cap and bearing from the connecting rod[B].

Installation: Put oil on the bolts and tighten to 26–30 ft. lbs. (35–41 Nm) torque.

A–02731

C

Installation: Tighten the rod cap bolts to torque as follows [C]: Machine Bolt (13 mm size head) . . . . . . 27–31 ft.–lbs.

(36–42 Nm) Forged Bolt (12 mm size head) . . . . . . . . 33–36 ft.–lbs.

(45–49 Nm)

OLD

13 mm

Tightening Torque 27–31 ft.–lbs. (36–42 Nm)

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NOTE: Make sure the marks on the connecting rod and bearing cap are in alignment when installing the bearing cap [B].

NEW 12 mm (Cold Forged Flange Bolt)

Tightening Torque 33–36 ft.–lbs. (36–42 Nm) B–13445

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CRANKSHAFT AND PISTONS (Cont’d)

A

Removal and Installation (Cont’d) Straighten the washer on the bolts that hold the main bearings in position. Remove the main bearing bolts from the engine block [A].

Installation: Tighten the bolts to 40–50 ft.–lbs. (64–68 Nm) torque.

B–03644

Straighten the washer on the bolts that hold the rear cover in position. Remove the bolts.

B

Install two bolts in the rear cover and pull the cover out [B].

B–03648

C

Installation: Check the crankshaft end play with a dial indicator [C]. The normal end play is 0.006”–0.012” (0,15–0,30 mm). Replace the thrust bearing if the end play exceeds 0.020” (0,5 mm).

B–10072

D

Remove the crankshaft from the rear of the engine block [D].

NOTE: Do not damage the crankshaft when removing it from the engine block.

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Installation: Install a new seal in the rear cover. Tighten the bolts to 22–25 ft.–lbs.(29–34 Nm) torque.

CRANKSHAFT AND PISTONS (Cont’d)

A

Crankshaft Service Straighten the washers on the main bearing bolts.

Remove the bolts from the bearing cap halves [A].

Remove the halves of the main bearings.

NOTE: When installing the bearing cap halves, make sure to position the markings on the bearing caps toward the flywheel. Thrust washers must be installed with oil grooves facing outward.

Installation: Tighten the bolts to 15–17 ft.–lbs. (20–24 Nm) torque.

B–04092

B

NOTE: Be sure the plugs that come with a new crankshaft are installed in the crankshaft or engine damage will occur.

A–02763

Check the inside diameter of the crankshaft bearing in the engine block [C].

C

The specification is 1.732”–1.734” (43,99–44,04 mm).

The wear limit is 0.008” (0,20 mm).

Dealer Copy -- Not for Resale

Put the crankshaft on V–blocks. Put a dial indicator on the center journal [B]. Turn the crankshaft slowly . The specification is 0.008” (0,02 mm). The wear limit is 0.003” (0,08 mm).

B–03631

Check the outside diameter of the #1 crankshaft journal [D]. The specification is 1.730”–1.7303” (43,94–43,95 mm). The wear limit is 0.008” (0,20 mm).

D

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CRANKSHAFT AND PISTONS (Cont’d)

A

Servicing the Connecting Rods and Pistons Remove the piston rings (Item 1)[A] and piston pin (Item 2) [A].

2

1

B–03621

B

Alignment Marks B–03614

C

Put the piston ring on the bottom of the cylinder bore[C].

Check the clearance of the ring gap. The specifications are: Top and 2nd Ring . . . 0.010”–0.0158” (0,25–0,40 mm) Oil Ring . . . . . . . . . . . . 0.008”–0.0158” (0,20–0,40 mm) Wear Limit . . . . . . . . . . . . . . . . . . . . . . .0.05” .

(1,27 mm)

B–03622

D

Measure the piston pin hole [D].

The specifications are 0.787”–0.788” (19,98–20,02 mm).

The wear limit is 0.789” (20,04 mm).

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Installation: Position the top ring so the gap is not lined up with the piston pin. Position the other rings so there is a gap every 90 ° [B]. Use a ring compressor to install the pistons in the engine block with the marks away from the camshaft.

CRANKSHAFT AND PISTONS (Cont’d)

A

Servicing the Connecting Rods and Pistons (Cont’d) Measure the piston pin (Item 1) [A] and the connecting rod bushing (Item 2) [A].

The specifications are 0.788”–0.789” (20,03–20,04 mm).

Clearance between piston pin and bushing is 0.0006”–0.0015” (0,015–0,04 mm). The wear limit is 0.006” (0,15 mm).

2 1 B–03633

B

Install the connecting rod on the tool for checking connecting rod alignment [B].

NOTE: Be sure the bushing diameter of the connecting rod is within specifications.

B–04067

C

Check the connecting rod bearings [C].

The specifications are 1.457”–1.459” (37,00–37,06 mm).

The wear limit is 0.008” (0,20 mm).

Dealer Copy -- Not for Resale

Check the clearance in the piston pin area. The specification is 0.0008” (0,020 mm). The wear limit is 0.002” (0,05 mm).

A–02727

D

Check the connecting rod journals [D].

The specifications are 1.455”–1.456” (36,96–36,98 mm).

The wear limit is 0.008” (0,20 mm).

A

If the connecting rod journals arenot within specifications, grind the journals as follows [D]: B

Crankshaft corner radius must be 0.138”R + 0.008” (3,5 mmR+ 0,20 mm).

The oil hole must be chamfered to 0.039”–0.059”R (0,99–1,5 mmR).

A

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220 Excavator (S/N 11999 & Below) Service Manual

CYLINDER LINERS

A

Checking the Cylinder Liners The tools listed will be needed to do the following procedure: MEL1060 – Ridge Reamer MEL1180 – Dry Line Puller Check the inside diameter of the cylinder liner [A].

B–10073

To find the maximum wear, check the inside diameter in three different locations [B].

B

The specifications are 2.677”–2.678” (67,99–68,02).The wear limit is + 0.006” (+0,15 mm). cylinder

than to

NOTE: Make sure you use the correct oversize pistons and rings.

If the cylinder liner is not within the specifications, replace the cylinder liner. These are dry cylinder liners.

A–02717

Cylinder Liner Installation Clean and rub oil on the bores of theengine block. Clean and put oil on the outside of the cylinder liners. Install the cylinder liners into the engine block with the chamfered end down.

The top of the liner must be even with the top of the engine block machined surface.

After installation, bore and/or hone the cylinder liner to 2.677”–2.678” (67,99–68,02 mm).

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When the cylinder liner has more wear specifications, bore and hone the 2.697”–2.698” (68,5–68,53 mm).

WATER PUMP

A

Removal and Installation Drain the cooling system.

Remove the radiator. (See Page 7–17).

Remove the alternator belt.

Remove the fan.

Remove the water pump bolts.

Remove the water pump [A].

B–05926

Installation: Always use a new gasket when installing the water pump.

B

Disassembly and Assembly Put the water pump in a vise.

Remove the pulley.

4

Remove the seal.

3

Install a new seal when assembling the water pump.

1 B–05929

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2

Drive the shaft out of the impeller side of the water pump [B].

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SPECIFICATIONS Page Number ENGINE SPECIFICATIONS (KUBOTA) Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–5 ....

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5 ....

Crankshaft Re–Grind Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–8 ..

Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–5 ....

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 ....

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–4 ....

Engine Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–7 ....

Fuel Injector Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–4 ...

Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–4 ...

Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–6 ....

Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–5 ....

Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5 ....

Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 ....

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6 ....

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–4 ....

Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 ....

HYDRAULIC EXCAVATOR SPECIFICATIONS Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–3 ....

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–3 ....

Digging Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 ....

Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 ....

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–2 ....

Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–2 ...

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–2 ...

Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–1 ...

Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2 ....

Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2 ....

Track Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 ....

Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 ....

OIL SPECIFICATIONS Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9 ....

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FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9 ..

SPECIFICATIONS

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HYDRAULIC EXCAVATOR SPECIFICATIONS

• All dimensions are shown in inches. Respective metric dimensions are given in

millimeters enclosed by parentheses.

• Where applicable, specifications conform to SAE standards. Specifications are subject to change without notice.

Machine Dimensions A – 138.8 (3526) B – 38.6 (980) C – 85.0 (2159) D – 28.7 (730) E – 9.8 (250) F – 95.3 (2420) G – 10.2 (260) H – 44.1 (1120) I – 58.7 (1490) J – 36.0 (915) K – 17.7 (450) L – 46.5 (1180) M – 0.71 (18) N – 18.1 (460) O – 23.6 (600)

N

O

MC–1208

A

C L K

G H

E J

D

D

M I

B

A

With 32.3 (820) 71.3 (1811)

I

F

B

MC–1209

C G

E

Dealer Copy -- Not for Resale

F

H

A B C D E F G H I J

J

Max. digging depth Max.vertical wall depth Max. digging reach Max. digging reach at ground level Max. digging height Max. dumping height Min. swing radius (when using boom swing) Max. height of Min. swing radius Max. lift above ground (blade) Max. drop below ground blade

71.3 (1811) 47.2 (1200) 138.0 (3505) 130.7(3320) 115.6 (2936) 77.6 (1971) 52.8 (1341) 95.7 (2431) 6.3 (160) 5.5 (140)

MC–1207

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HYDRAULIC EXCAVATOR SPECIFICATIONS (Cont’d) 220 2863 lbs. (1300 kg) 1.52 MPH (2,45 km/hr) Two Hand Levers Two joystick levers control boom, bucket, dipperstick and swing Two separate levers control boom swing and blade

ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horsepower . . . . . . . . . . . . . . . . . . . . . . . . .

Displacement . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Torque . . . . . . . . . . . . . . . . . . . . .

Maximum Governed RPM – Full Load . . .

No Load . .

Number of Cylinders . . . . . . . . . . . . . . . . . .

Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System . . . . . . . . . . . . . . . . . . . . . .

Lubrication System . . . . . . . . . . . . . . . . . . .

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Kubota D750–B–MC–1 Diesel 13.5 HP (10,1 kw) @ 2500 RPM 46.5 cu.–in. (762 cu. cm) 31 ft.–lbs. (42 Nm) @ 1800 RPM 2500 RPM 2700 RPM Three 2.68/2.76 (68/70) Liquid Forced Full Flow 12 Volt, Reduction Drive 12 Volt, 15 Amp. 12 Volt, 425 Cold Crank Amps.

HYDRAULIC SYSTEM Pump Numbers . . . . . . . . . . . . . . . . . . . . . .

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Relief Setting . . . . . . . . . . . . . . . . .

Control Valve . . . . . . . . . . . . . . . . . . . . . . . .

Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . .

Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two Double Section Gear Pumps 2 x 5.35 GPM (20,3 L/min.) = 10.7 GPM (40,5 L/min) 2133 PSI (14707 kPa) 10 Spool Two Axial Piston Orbit Motor See Page 8–9

SWING SYSTEM Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Circle . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Speed . . . . . . . . . . . . . . . . . . . . . . . .

Boom Swing (Left) . . . . . . . . . . . . . . . . . . . .

Boom Swing (Right) . . . . . . . . . . . . . . . . . .

Gear Motor Connect to a Pinion Single Row Shear Type Ball Bearings with Internal Gears Built Into Swing Circle 15.8 RPM 46.4 degrees 87.3 degrees

HYDRAULIC CYLINDERS Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dipperstick . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Swing . . . . . . . . . . . . . . . . . . . . . . . . .

Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Bore Dia. 2.36 (60) 2.36 (60) 2.36 (60) 2.36 (60) 2.36 (60)

Rod Dia. 1.38 (35) 1.38 (35) 1.38 (35) 1.38 (35) 1.38 (35)

Stroke 21.65 (550) 17.32 (440) 15.16 (385) 13.62 (346) 2.75 (70)

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PERFORMANCE Operating Weight . . . . . . . . . . . . . . . . . . . . .

Travel Speed . . . . . . . . . . . . . . . . . . . . . . . .

Controls: Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . .

Functions . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC EXCAVATOR SPECIFICATIONS (Cont’d) 220 DRIVE SYSTEM Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type of Reduction . . . . . . . . . . . . . . . . . . . .

Maximum Drawbar Pull . . . . . . . . . . . . . . .

Gradeability . . . . . . . . . . . . . . . . . . . . . . . . .

Each track is independently driven by a hydrostatic axial motor Power is transferred through a planetary gear reduction 1982 lbs. (900 kg) 30 degrees

BRAKES Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic lock on motor Hydraulic lock on motor & hold pin lock

Crawler–Tractor design undercarriage. Sealed track with reinforced box–section adjusters with shock absorbing recoil system.

TRACK SHOES Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number of Shoes . . . . . . . . . . . . . . . . . . . . .

Number of Track Rollers . . . . . . . . . . . . . . .

Ground Pressure . . . . . . . . . . . . . . . . . . . . .

Rubber 9.84 (250) Single assembly Three each side 3.43 PSI (23,7 kPa)

CAPACITIES Fuel Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System . . . . . . . . . . . . . . . . . . . . . .

Engine Oil & Filter . . . . . . . . . . . . . . . . . . . .

Hydraulic Reservoir . . . . . . . . . . . . . . . . . . .

Final Drive Case (Each) . . . . . . . . . . . . . . .

6.6 gals. (25 L) 3.0 qts. (2,85 L) 4.5 qts. (4,3 L) 7.0 gals. (26,5 L) 0.3 qts. (0,3 L)

DIGGING FORCE Dipperstick . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1784 lbs. (810 kg) 2775 lbs. (1260 kg)

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UNDERCARRIAGE Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

220 (S/N 508211999 & Below) Excavator Service Manual

ENGINE SPECIFICATIONS (KUBOTA) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Engine Compression (Operating Temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .450 . . PSI (3103 kPa) @ 200–300 RPM Fuel Injector Nozzles Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1990–2133 ....

PSI (13721–14707 kPa) Fuel Tightness Nozzle Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dry . . .Nozzle at 1848 PSI (12742 kPa) Fuel Injection Pump Fuel Tightness Plunger . . . . . . . . . . . . . . . . . . . .8 Seconds: Initial pressure drop from 1237–1031 PSI (8529–7109 kPa) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 seconds or less Fuel Tightness of Delivery Valve . . . . . . . . . . . . . . 10 . Seconds: Initial pressure drop from 1422–71 PSI (9805–490 kPa) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Seconds or Less Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23–25 . degrees B.T.D.C.

Cylinder Distortion Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 ..

(0,05) in 3.9 (100) of the length of the cylinder head Thickness of Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.04–0.05 ...

(1,02–1,3) Thickness of Gasket Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2) Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.02–0.03 (0,51–0,8) Valves Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 degrees Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.08 (2,1) O.D. of Valve Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.274–0.275 .....

(6,96–6,99) I.D. of Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.276–0.277 .....

(7,01–7,04) Clearance Between Valve Stem & Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0014–0.0026 ...

(0,035–0,065) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.004 (0,1) Depth of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.04–0.043 (1,0–1,1) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.05 (1,3) Valve Clearance (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.006–0.007 ....

(0,15–0,18) Valve Springs Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.382–1.402 (35,1–35,6) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.37 (34,8) Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.185 (30,1) Load to Compress to Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.5 . . . .lbs. (7,5 kg) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 lbs. (6,4 kg) Limit Permitted for Spring being Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.05 . . . .(1,3) Rocker Arms O.D. of Rocker Arm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.432–0.4324 ....

(10,97–10,98) I.D. of Rocker Arm Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.433–0.4346 ....

(11,0–11,04) Clearance Between Rocker Arm Shaft & Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0005–0.0026 ..

(0,013–0,07) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.005 (0,13)

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Cylinder Head

ENGINE SPECIFICATIONS (KUBOTA) (Cont’d) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Camshaft O.D. of Camshaft Bearing Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2966–1.2972 ...

(32,93–32,95) I.D. of Camshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2992–1.3002 ....

(32,99–33,025) Clearance between Camshaft Bearing & Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.002–0.0036 ..

(0,051–0,091) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.006 (0,15) Alignment of the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05) Cam Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0583 (26,88) Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.002–0.003 .

(0,051–0,08) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.008 .

(0,2) Cylinders I.D. of Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.677–2.678 ....

(67,99–68,02) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.0006 (+0,015) Piston Rings

Dealer Copy -- Not for Resale

Ring Gap (Top & 2nd Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010–0.016 ....

(0,25–0,41) Ring Gap, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.009–0.016 (0,23–0,41) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.049 (1,24) Side Clearance of Ring Groove: Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.00 . (0,0) Second Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003–0.004 (0,08–0,10) Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008–0.002 (0,02–0,051) Oversize of Piston & Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,51) Pistons

I.D. of Piston Bosses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.787–0.788 ....

(19,98–20,02) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.789 (20,04) O.D. of Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.787–0.789 .....

(19,98–20,04) I.D. of Connecting Rod Bushing (Small End, Fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.788–0.790 ..

(20,02–20,07) Clearance between Piston Pin & Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0006–0.0015 ...

(0,015–0,04) Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0008 .

(0,02) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.006 (0,15) Crankshaft

Crankshaft Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008 (0,02) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.003 (0,08) O.D. of Crankshaft Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7297–1.7303 ....

(43,93–43,95) I.D. of Crankshaft Bearing No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7317–1.7339 ....

(43,99–44,04) Clearance between Crankshaft Journals & Bearing No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0013–0.0036 .

(0,03–0,09) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.008 .

(0,2) O.D. of Connecting Rod Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4551–1.4557 ...

(36,96–36,98) I.D. of Connecting Rod Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4568–1.4587 ...

(37,003–37,051) Clearance between Connecting Rod Journal & Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0011–0.0036 ..

(0,028–0,091) Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006–0.012 .....

(0,15–0,30) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.020 .

(0,5)

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ENGINE SPECIFICATIONS (KUBOTA) (Cont’d) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Oil Pump Oil Pressure @ Rated RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28–64 . . . . PSI (193–441 kPa) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 PSI (193 kPa) Oil Pressure @ Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 . . PSI .

(69 kPa) Rotor Lobe Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.004–0.006 ....

(0,010–0,15) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.008 .

(0,2) Clearance Between Outer Rotor & Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.003–0.006 ..

(0,08–0,15) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.010 (0,25) End Clearance between Rotor & Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.003–0.005(0,08–0,13) ...

Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.008 .

(0,2) Thermostat

Dealer Copy -- Not for Resale

Opening Temperature Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177–182°F (81–84°C) Full Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203°F (95°C) Distance of Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.315 .

(8)

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220 (S/N 508211999 & Below) Excavator Service Manual

ENGINE SPECIFICATIONS (KUBOTA) (Cont’d) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Engine Torque Ft.–Lbs.

Nm

*Cylinder Head Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29–33 *Main Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15–17 *Main Bearing Case Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–25 *Flywheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–43 . *Connecting Rod Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20–22 *Rocker Arm Bracket Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15 *Idler Gear Shaft Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15–18 .

Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30–36 .

Nozzle Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30–36 .

Oil Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11–15 .

Fuel Injection Tubeline Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 11–19 Crankshaft Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101–116 ..

Injection Pump Vent Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–13

39–44 20–24 29–34 54–59 27–30 17–21 9–11 20–25 39–49 39–49 15–20 13–26 137–157 14–18

PUNCHED NUMBER

BOLT MATERIAL GRADE

None

Standard Bolts

SS41, S20C

7

Special Bolts

S43C, 248C (Refined)

9

Special Bolts

SCM3, SCR3 (Refined)

BOLT TORQUES MATERIAL GRADE

STANDARD BOLT

STANDARD BOLT

STANDARD BOLT

NOMINAL DIAMETER

SS42, S20C

S43C, S48C (Refined)

SCR3, SCM3 (Refined)

M6

6–7 ft.–lbs.

(8–9 Nm)

7–8 ft.–lbs.

(9–11 Nm)

9–11 ft.–lbs.

(12–15 Nm)

M8

13–15 ft.–lbs.

(18–20 Nm)

17–20 ft.–lbs.

(23–27 Nm)

22–25 ft.–lbs.

(30–34 Nm)

M10

29–33 ft.–lbs.

(39–45 Nm)

35–41 ft.–lbs.

(47–56 Nm)

45–52 ft.–lbs.

(61–71 Nm)

M12

46–54 ft.–lbs.

(62–73 Nm)

57–67 ft.–lbs.

(77–91 Nm)

76–87 ft.–lbs.

(103–118 Nm)

M14

80–93 ft.–lbs.

(108–126 Nm)

91–109 ft.–lbs.

(123–148 Nm)

123–145 ft.–lbs.

(167–197 Nm)

M16

123–141 ft.–lbs.

(167–191 Nm)

145–166 ft.–lbs.

(197–225 Nm)

192–224 ft.–lbs.

(260–304 Nm)

M18

181–210 ft.–lbs.

(245–285 ft.–lbs.

203–235 ft.–lbs.

(275–319 Nm)

253–297 ft.–lbs.

(343–403 Nm)

M20

246–289 ft.–lbs.

(334–392 Nm)

271–318 ft.–lbs.

(367–431 Nm)

362–420 ft.–lbs.

(491–578 Nm)

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*Lightly Oil Threads

220 (S/N 508211999 & Below) Excavator Service Manual

ENGINE SPECIFICATIONS (KUBOTA) (Cont’d) Crankshaft Re–Grind Data If the standard size bearing cannot be used due to excessive wear ofthe crankpin and crankshaft journals, use undersize or oversize bearings.

D 3

C 1 2

B

1

2

Dealer Copy -- Not for Resale

A

B–05928

REF.

SIZE

CODE NUMBER

DESCRIPTION

DIMENSION

MARK

A

0.008 in.

(0,2 mm) U/S

15261–2391–1

Crankshaft Bearing #1

1.7218–17224 in.

(43,743–43,750 mm)

020US

0.016 in.

(0,4 mm) U/S

15261–2392–1

Crankshaft Bearing #1

1.7139–1.7146 in.

(43,534–43,550 mm)

040US

0.008 in.

(0,2 mm) U/S

15261–2393–1

Crankshaft Bearing #2

1.7218–1.7224 in.

(43,734–43,750 mm)

020US

0.016 in.

(0,4 mm) U/S

15261–2394–1

Crankshaft Bearing #2

1.7139–1.7146 in.

(43,534–43,550 mm)

040US

0.008 in.

(0,2 mm) U/S

15531–2297–1

Crankpin Bearing

1.4472–1.4478 in.

(36,759–36,775 mm)

020US

0.016 in.

(0,4 mm) U/S

15531–2298–1

Crankpin Bearing

1.4393–1.4400 in.

(36,559–36,575 mm)

040US

0.008 in.

(0,2 mm) O/S

15261–2397–1 15261–2395–1

Crankshaft Thrust Bearing

0.9528–0.9547 in.

(24,20–24,25 mm)

0.20 OS

0.016 in.

(0,4 mm) O/S

15261–2398–1 15261–2396–1

Crankshaft Thrust Bearing

0.9606–0.9626 in.

(24,40–24,45 mm)

0.40 OS

B

C

D

1

Radius – 0.13–0.146 in (3,3–3,7 mm)

0.130–0.146 in.

(3,3–3,7 mm)

2

Radius – 0.11–0.126 in. (2,8–3,2 mm)

0.11–0.126 in.

(2,8–3,2 mm)

3

IMPORTANT: Oil hoses must have a 0.0394–0.0591 in. (1–1,5 mm) chamfer. Use an oil stone to chamfer the oil hole.

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FUEL, COOLANT AND LUBRICANTS Use the following chart for correct selection of Fuel, Coolant and Lubricants.

AMBIENT TEMPERATURE RESERVOIR

KIND OF FLUID

Engine Oil Pan

Engine oil

F° –30 –20 –10 0 +10 +20+30 +40 +50 +60 +70 +80 +90 +100 C° –34 –29 –23 –18–13 –7 –1 +4 +10 +15 +21 +27 +32 +38

CAPACITY Refill 4.5 qts.

(4,3 L)

SAE 30 SAE 10W

Final Drive Case (each)

Engine oil

Hydraulic Tank*

SAE 30

0.33 qts.

(0,3 L)

SAE 10W

7.0 gals (26,5 L)

SAE 10W–30 SAE 15W–40

Diesel Fuel

No. 1 No. 2

Cooling System

**See Below

Add anti–freeze

6.6 gals (25 L)

3.0 qts.

(2,85 L)

* Use Bobcat fluid (P/N 6563328) in Hydraulic System.

OIL SPECIFICATIONS Description When fuel sulphur content is less than 0.5% change the engine oil and filter as shown in the Service Schedule Page 1–1.

Dealer Copy -- Not for Resale

Fuel Tank

Change engine oil and filter according to the following chart if fuel sulphur content is above 0.5%.

Fuel Sulphur Content 0.5 to 1.0% Above 1.0%

Change Interval Of Engine & Oil Filter 1/2 of Regular Interval 1/4 of Regular Interval

When starting the engine in a temperature of lower than 32°F (0°C) use SSAE 10W engine oil.

Use API Classification CD engine oil, if API Classification CC is used, reduce the engine change interval to half the hours.

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220 (S/N 508211999 & Below) Excavator Service Manual

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220ExcavatorServiceManual(S/N508211999&Below)#6720230–SpecificationsSection

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220 (S/N 508211999 & Below) Excavator Service Manual

220–1 ®

3 July 1991

SERVICE MANUAL REVISION

Date

ROUTE TO ATTENTION

AFFECTING: Product BOBCAT EXCAVATOR

PARTS MANAGER SERVICE MANAGER SALES MANAGER

220 (S/N 508211999 & Below)

Model

Revision Number

X

Manual No. 6720230 (5–89)

NOTICE

Insert This Sheet With The Appropriate Manual For Future Reference.

Put in the added page as follows: TAKE OUT

PUT IN

HYDRAULIC FLOW CHART #6720139 (Printed May 1989)

HYDRAULIC FLOW CHART #6720139 (Printed July 1991)

CHART LEGEND #6720139 (Printed May 1989)

CHART LEGEND #6720139 (Printed July 1991)

Contents Page 2–1 thru 2–12

Contents Page (Revised July 91) 2–1 thru 2–12 (Revised July 91) 2–13, 2–14 (Added July 91)

Contents Page 4–1, 4–2 4–3, 4–4

Contents Page (Revised July 91) 4–1, 4–2 (Revised July 91) 4–3 (Revised July 91), 4–4 (Revised July 91)

SECTION 2

SECTION 4

SECTION 6 ELECTRICAL WIRING DIAGRAM #6720138 (Printed May 1989)

ELECTRICAL WIRING DIAGRAM #6720138 (Printed July 1991) ELECTRICAL WIRING DIAGRAM #6720534 (Added July 1991)

SECTION 7

241 of 258

Contents Page 7–33, 7034 7–35, 7–36

Contents Page (Revised July 91) 7–33, 7–34 (Revised July 91) 7–35 (Revised July 91), 7–36

Printed in U.S.A.

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220–2 ®

6 April 1992

SERVICE MANUAL REVISION

Date

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AFFECTING: Product BOBCAT EXCAVATOR Model

Revision Number

PARTS MANAGER SERVICE MANAGER SALES MANAGER

220 (S/N 508211999 & Below)

X

Manual No. 6720230 (5–89)

NOTICE

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SECTION 4

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Contents Page

Contents Page (Revised April 1992)

4–1 thru 4–4

4–1 thru 4–4 (Revised April 1992) 4–5 (Added April 1992) 4–6 (Added April 1992)

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SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

Revision Number

6 May 1992 Date

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220 (S/N 508211999 & Below)

X

Manual No. 6720230 (5–89)

NOTICE

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2–11 (Revised July 91) thru 2–14 (Revised July 91)

2–11 (Revised May 92) thru 2–14 (Revised May 92) 2–15 (Added May 92) thru 2–33 (Added May 92)

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220–4 Revision Number

®

30 June 1992

SERVICE MANUAL REVISION

Date

ROUTE TO ATTENTION

AFFECTING: Product BOBCAT EXCAVATOR

PARTS MANAGER SERVICE MANAGER SALES MANAGER

220 (S/N 508211999 & Below)

Model

X

Manual No. 6720230 (5–89)

NOTICE

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HYDRAULIC SECTION

HYDRAULIC SECTION

HYDRAULIC FLOW CHART #6720139 (Printed July 1991)

HYDRAULIC FLOW CHART #6720139 (Without Hi–Flow) (Printed June 1992)

HYDRAULIC SYSTEM OPERATION (Printed May 1989)

HYDRAULIC SYSTEM OPERATION (Without Hi–Flow) (Printed June 1992) HYDRAULIC FLOW CHART #6722100 (With Hi–Flow) (Printed June 1992) HYDRAULIC SYSTEM OPERATION (With Hi–Flow) (Printed June 1992)

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220–5 ®

28 July 1992

SERVICE MANUAL REVISION

Date

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AFFECTING: Product BOBCAT EXCAVATOR Model

Revision Number

PARTS MANAGER SERVICE MANAGER SALES MANAGER

220 (S/N 508211999 & Below)

X

Manual No. 6720230 (5–89)

NOTICE

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Section 3, Content Page

Section 3, Content Page (Revised July 92) 3–9 thru 3–28 (Added July 92)

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®

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

220 (S/N 508211999 & Below)

9 February 1995 Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6720230 (5–89)

NOTICE

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Section 5, Content Page 5–9

Section 5, Content Page (Revised Feb. 95) 5–9 thru 5–9g (Added Feb. 95) 5–11 thru 5–17 (Added Feb. 95)

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220–7 Revision Number

®

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

220 (S/N 508211999 & Below)

6 March 1995 Date

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X

Manual No. 6720230 (5–89)

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SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

220 (S/N 508211999 & Below)

Revision Number

8 July 1997 Date

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X

Manual No. 6720230 (5–89)

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Section 2

Section 2

Section 4

Section 4

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SERVICE MANUAL REVISION

NOTICE

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220-9 15 June 2012 Bobcat Excavator 220 6720230 (5-89)

The following Sections are a revision to the above Service Manual.

COVER

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SMR-1

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