PDF DOWNLOAD Bobcat X 220 Excavator Operation & Maintenance Manual (SN 508215001 & Above)

X 220 Excavator

Operation & Maintenance Manual (S/N 508215001 & Above)

6722250 (9–92) Revised (10–98)

Printed in U.S.A.

© Melroe Company 1998

OPERATOR SAFETY WARNINGS Operator must have instructions before running the machine.

Untrained operators can cause injury or death.

W–2003–1089

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

CORRECT

WRONG

CORRECT

WRONG

B–10731

MC–1862A

MC–1859A

MC–1865A

Never operate without instructions.

Read machine signs and Operation & Maintenance Manual.

Do not grasp control handles when entering canopy or cab.

Be sure controls are in neutral before starting.

Sound horn and check behind machine before starting.

Never operate without approved canopy or cab.

Never modify equipment.

Avoid steep areas or banks that could break away.

WRONG

WRONG

CORRECT

CORRECT

15° Maximum MC–1867

MC–1868

MC–1865B

15° Maximum MC–1878C

Use caution to avoid tipping–do not swing heavy load over side of track.

Operate on flat, level ground.

Keep bystanders out of maximum reach area.

Do not travel or turn with bucket extended.

Never carry riders.

Never exceed a 15° slope to the side.

Never travel up a slope that exceeds 15°.

CORRECT

CORRECT

CORRECT

SAFETY EQUIPMENT

Never use attachments not approved by Melroe Company.

1.

2.

3.

4.

5.

6.

25° Maximum MC–1878B

Never exceed 25° when going down or backing up a slope.

Seat Belt Swing Lock ROPS Canopy or Cab Machine Safety Signs Safety Tread Grab Handles

MC–1859A

To leave Excavator: • Lower Attachement • Stop Engine

Fasten seat belt securely.

Operate controls only from operator’s seat.

OSW20–1097

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540, 543 Loader Service Manual

CONTENTS FOREWORD FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

CALIFORNIA PROPOSITION 65 WARNING

SAFETY

OPERATING INSTRUCTIONS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

REFERENCE INFORMATION

PREVENTIVE MAINTENANCE

Write the correct information for YOUR Bobcat Hydraulic Excavator in the spaces below. Always use these numbers when referring to your Hydraulic Excavator.

SPECIFICATIONS

Bobcat Hydraulic Excavator Serial Number . . . . . . . . . . . . .

Engine Serial Number . . . . . . . .

NOTES:

YOUR BOBCAT EXCAVATOR DEALER: ADDRESS: PHONE: Melroe Company P.O. Box 128 Gwinner, ND 58040–0128 Melroe Europe J. Huysmanslaan 59 B–1651 LOT BELGIUM

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

Melroe Company is ISO 9001 certified ISO 9001 is a set of international standards that control the processes and procedures which we use to design, develop, manufacture, distribute, and service Melroe Company products.

British Standards Institute (BSI) is the Certified Registrar Melroe chose to assess the Company’s compliance with the ISO 9001 set of standards. The BSI registration certifies that the two Melroe manufacturing plants and the Melroe corporate offices (Gwinner, Bismarck & Fargo) in North Dakota are in compliance with ISO 9001. Only certified assessors, like BSI, can grant registrations. Since registration requires this third–party auditing, it is irrefutable evidence of conformance.

Continued certification is subject to periodic audits.

ISO 9001 means that as a company we say what we do and do what we say. In other words, we have established procedures and policies, and we provide evidence that the procedures and policies are followed.

What does ISO 9001 mean to Bobcat Customers? It means that Melroe Company produces your Bobcat loader, Excavator or Spra–Coupe, and attachments with strict attention to details, using the latest technology and proven techniques.

REGULAR MAINTENANCE ITEMS 3974113

ENGINE OIL FILTER

6667352

FUEL FILTER

897064

AIR CLEANER

6666606

RADIATOR CAP

6653336

HYDRAULIC FILTER

6669318

BATTERY

6658230

ETHELENE GLYCOL ANTI–FREEZE

6563328

BLACK GOLD Hydraulic/Hydrostatic Fluid – 5 Gallons

6657299

MOTOR OIL 15W40 CE/SG – 1 Qt.

6657300

MOTOR OIL 15W40 CE/SG – 5 Qt.

6657301

MOTOR OIL 10W30 CE/SG – 1 Qt.

6657302

MOTOR OIL 10W30 CE/SG – 5 Qt.

6657303

MOTOR OIL 30 CE/SG – 1 Qt.

6657304

MOTOR OIL 30 CE/SG – 5 Qt.

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

FOREWORD FOREWORD This manual gives the owner/operator necessary operating, preventive maintenance instruction for the Bobcat Hydraulic Excavator.

Read this manual completely and know the Bobcat Hydraulic Excavator before operating and servicing it. All references to left or right on the excavator are given in relation to the operator’s left or right hand while in the operator’s seat.

For further information, see your Bobcat Excavator dealer Parts Manuals, Service Manuals and extra Operation & Maintenance Manuals are also available.

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v BOBCAT HYDRAULIC EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . vi

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

SERIAL NUMBER LOCATIONS

A

Always use the FULL serial number (including the first four digits) when requesting service 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 different procedure in doing a specific service operation.

HYDRAULIC EXCAVATOR SERIAL NUMBER The excavator serial number is on the front of the machine frame, to the right of the boom [A].

P–00806

ENGINE SERIAL NUMBER

B

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

P–00842

DELIVERY REPORT

C

The Delivery Report items must be explained to the owner/operator by the dealer. The dealer is to fill out the form and the owner/operator signs the form to indicate his understanding [C].

v

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

BOBCAT HYDRAULIC EXCAVATOR IDENTIFICATION

CONTROL LEVERS ROPS

OPERATORS MANUAL STORAGE CONTAINER

ENGINE COVER

TRACK FRAME TRACK ARM CYLINDER

GRAB HANDLES

BOOM

OPERATOR SEAT BUCKET CYLINDER

ARM

AUXILIARY LINES BLADE CYLINDER

BUCKET LINK

BOOM CYLINDER BLADE

BUCKET

vi

P–00833 P–00798

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

SAFETY SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix, x FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi MACHINE SIGNS (DECALS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii, xiii

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SAFETY

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SAFETY INSTRUCTIONS SAFETY IS THE OPERATOR’S RESPONSIBILITY The Bobcat Hydraulic Excavator is a highly maneuverable and compact machine. In operation, it is rugged and useful under a wide variety of conditions. This presents an operator with hazards which are common for off highway, rough terrain applications but not unique for use of Bobcat Hydraulic Excavator. The excavator has an internal combustion engine with resultant heat and exhaust. All exhaust gases can kill or cause illness so the excavator must be used with adequate ventilation. The excavator must not be used in an area with explosive dusts or gases or so that the engine exhaust can contact flammable material. Some excavators maybe equipped with a spark arrestor muffler which is required for operation in certain areas.

The dealer recommends the capabilities of the excavator and attachments for each application. The dealer demonstrates the safe operation of the excavator according to the manufacturer’s instructional materials which are also available to all operators. The dealer can also identify unsafe modifications or use of unapproved attachments. The attachments and buckets are designed for rated capacity and secure fastening to the Bobcat Hydraulic Excavator. The user must check with the dealer or Melroe Company literature or load diagram to identify safe loads.

The following publications provide information on the safe use and maintenance of the excavator and attachments: • The Delivery Report is used to check whether complete instructions have been given to the new owner and that the machine is in safe operating condition.

• The Operation & Maintenance Manual delivered with the Bobcat Hydraulic Excavator gives operating information as well as routine maintenance information. It is a part of the machine and must stay with the machine when it is sold.

Replacement Operation & Maintenance Manuals can be purchased from your dealer.

• Every Bobcat Hydraulic Excavator has machine signs (or decals) which instruct on the safe care and operation. The signs and their location are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat Hydraulic Excavator dealer.

• The Bobcat Hydraulic Excavator has a plastic Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English, French, German, Dutch, Italian, Spanish, Portugese, Finnish, Danish, and Swedish editions.

• The CIMA safety manual contains information for safe operation and maintenance.

• The Service Manual and Parts Manual are optional manuals available from your Bobcat Hydraulic Excavator dealer for use by mechanics to do shop–type service and repair.

• The Bobcat Compact Excavator Operator Training Course is available through your local dealer. This course is intended to provide rules and practices of correct operation of the Hydraulic Excavator.

• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.

The dealer and owner/operator review the recommended uses of the excavator and attachments when excavator is delivered. If the owner/operator will be using the excavator for a different application than was originally demonstrated by the dealer, ask the dealer for recommendations on the new use.

SI22–0398

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

BEFORE OPERATING THE BOBCAT HYDRAULIC EXCAVATOR 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.

Operator must have instructions before operating Bobcat loader or excavator and approved attachment.

Untrained operators can cause injury or death.

W–2253–0996 B–10731

The Excavator must be in good operating condition before use.

Check all of the items on the Service Schedule under the 8–10 hour column.

For your safety, warnings are on the machine and in the Operation & Maintenance manual. Failure to obey warnings can cause injury or death.

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

W–2044–1285

I–2019–0284

SAFE OPERATION NEEDS A QUALIFIED OPERATOR* A QUALIFIED OPERATOR MUST DO THE FOLLOWING:

• UNDERSTAND THE WRITTEN INSTRUCTIONS, RULES AND REGULATIONS • The written instructions from Melroe Company include the delivery report, operator handbook, Operation & Maintenance Manual, and machine signs (decals).

• Check the rules and regulations at your location.

• HAVE TRAINING WITH ACTUAL OPERATION • Operator training must consist of a demonstration and verbal instruction. This training is given by your excavator dealer before the excavator is delivered.

• The new operator should start in an area without bystanders and use all the controls until he can operate safely under all conditions of the work area.

• KNOW THE WORK CONDITIONS • For each material to be handled, the operator must know how to avoid exceeding the rated lift capacity of the excavator. For example, you should not use the excavator for lifting heavy objects.

• The operator must know any prohibited uses or work areas, for example, he needs to know about excessive slopes.

• Know the location of any underground lines. Call local utilities or ONE CALL before you dig.

• Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing excavator. Safety glasses,

hearing protection or an excavator special application kit are required for some work. See your dealer about Melroe Safety equipment.

* For an operator to be qualified, he must not use drugs or alcoholic drinks which impair his alertness or coordination while working. An operator who is taking prescription drugs must get medical advice to determine if he can safely operate a machine.

SI23–0398

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

FIRE PREVENTION The excavator has several components that are at high temperature under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks. These conditions make it important to avoid applications where explosive dust or gases can be ignited by arcs, sparks or heat.

Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it will increase the fire hazard. The excavator must be cleaned as often as necessary to avoid this accumulation. This flammable debris in the engine compartment can be a fire hazard when the machine is parked with a hot engine.

If equipped the spark arrestor muffler is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the exhaust gases are still hot. This spark arrestor muffler does not change the need to avoid use of the excavator in an atmosphere with explosive dust or gases or where the exhaust can contact flammable material.

• Do not use the Hydraulic Excavator where explosive dust or gases can be ignited by arcs, sparks, hot components or exhaust gases.

• The operator cab, engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent overheating. Remove all flammable material.

• Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any damaged part.

• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Tighten or replace any parts that show leakage. Always clean fluid spills.

• Do not use ether or starting fluids on any engine which has glow plugs. These starting aids can explode and injure bystanders.

• Always clean the excavator before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the machine when welding.

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

• Use the procedure in Operation & Maintenance Manual for connecting the battery.

• Use the procedure in the Operation & Maintenance Manual for servicing the spark arrestor muffler (if equipped) every 100 hours of operation.

• Know where fire extinguishers and first aid kits are located and how to use them. A fire extinguisher is available from your Bobcat Dealer.

SI24–0398

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

MACHINE SIGNS (DECALS) Follow the instructions on all the Machine Signs (Decals) that are on the Excavator. Replace any damaged machine signs and be sure they are in the correct location. Machine signs are available from your Bobcat Excavator dealer.

6537595

6575673

6587425 ISO 6587427 Standard 6643356

6643355

6577754 6536807

P–00833

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

MACHINE SIGNS (DECALS) (Cont’d) Follow the instructions on all the Machine Signs (Decals) that are on the Excavator. Replace any damaged machine signs and be sure they are in the correct location. Machine signs are available from your Bobcat Excavator dealer.

6587426 ISO 6587428 Standard

6587424 6587139

6577754 6587423

6534739

6587124 6586698

P–00798

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220ExcavatorOperation&MaintenanceManual#6722250S/N508215000&Above–ContentsSection

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OPERATING INSTRUCTIONS AUDIBLE ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 AUXILIARY OPERATION PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 BLADE CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 BOOM SWING PEDAL AND LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 CAB ELECTRICAL (Cab Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 CONTROL LEVER (JOYSTICK) LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CONTROL LEVERS (JOYSTICKS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Operation Of Left Control Lever (ISO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Operation Of Right Control Lever (ISO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CONTROL LEVERS (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Operation Of Left Control Lever (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . 8 Operation Of Right Control Lever (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . 8 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ENGINE STOP CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 GETTING ON AND OFF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 HEATER CONTROL (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 HORN BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 LIFTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Breaking In A New Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 General Operation Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Operating In Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 PARKING THE HYDRAULIC EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SPEED CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cold Temperature Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Normal Starting Procedure (With Engine Warm) . . . . . . . . . . . . . . . . . . . . . . 14 STEERING LEVERS/FOOT PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Forward And Reverse Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SWING LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 TRANSPORTING THE HYDRAULIC EXCAVATOR . . . . . . . . . . . . . . . . . . . . 19

–1–

OPERATING INSTRUCTIONS

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

GETTING ON AND OFF THE MACHINE

A

Use the grab handles, the tracks and the safety treads to get on and off the machine [A].

P–00846

B

Fasten the seat belt snugly. Adjust the seat belt so that the buckle is centered between your hips [B].

P–00753

C

Lower the control console(s) before Starting the Engine.

(See Page 13 [C]).

P–00809

Pull the lever (Item 1) [D] to the rear to release and raise the control console.

D

NOTE: On Excavators equipped with ROPS canopy, both the left and right control consoles can be raised for operator access. On Excavators with enclosed cab, only the left control console can be raised.

1

P–00807

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

SEAT

A

The operator seat can be adjusted as follows: Release the seat adjustment lever (Item 1) [A]. Slide the seat backward or forward for easy reach of the machine controls.

NOTE: For ease of access to the seat adjustment lever, have the left hand console in the raised position.

1

P–00751

The handle (Item 1) [B] has three adjustments for operator weight.

B 1

P–00801

C

Turn the knob (Item 1) [C] to angle the back of the seat for operator comfort.

1

P–00804

D

CONTROL LEVER (JOYSTICK) LOCK The control lock microswitch (Item 1) [D] disconnects the hydraulics from the joystick control levers when the control console(s) are in the raised position. (The joystick control levers will not operate with the console(s) raised).

NOTE: The travel levers, blade lever, boom swing pedal and the attachment operation pedal functions are NOT affected by the control lock.

1

P–00816

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

CONTROL LEVER (JOYSTICK) LOCK (Cont’d)

A

Lower the control console(s) to engage the joystick control levers [A].

P–00809

B

INSTRUMENTS

1

The right control console has the following indicator lamps [B]:

2

1. Engine Temperature Lamp – (Overheat indicator) When the engine coolant temperature exceeds the allowable temperature range, the lamp comes ON and the audible alarm sounds. STOP the engine.

3 4

2. Engine Oil Lamp – When the engine oil pressure is low, the lamp comes ON and the audible alarm sounds. STOP the engine.

3. Charging Lamp – The lamp comes ON when the alternator is NOT charging the battery.

P–00803

4. Preheat Indicator Lamp – When turning the keyswitch to the HEAT position, the lamp comes ON showing the glow plugs are heating.

C 1

The left control console has the following indicator lamp and instrument [C]:

2

1. Low Fuel Indicator Lamp – When the fuel is low, (.8 gal. [3.1 L]), the lamp comes ON. Add fuel.

2. Fuel Gauge – Shows the amount of fuel in tank.

Inside the engine compartment are the following instruments and fuses [D]:

P–00805

1. Hourmeter – Records the total operating hours. (If the ignition key is left in the run position, with the engine OFF, the hourmeter will continue to run and the audible alarm will sound).

D 3

2

1

2. Fuse – Ignition (25 Amp) – This fuse supplies the power for engine start up, gauge functions, horn, and audible alarm and control console microswitches.

3. Fuse Accessories (25 Amp) – This fuse supplies power for the cab heater (if equipped) and accessories.

P–00761

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

AUDIBLE ALARM

A

An audible alarm (Item 1) [A] located in the right hand console, will sound when these conditions exist:

1

When the key is in the ON position with the engine stopped.

When there is low engine oil pressure.

When there is high engine coolant temperature.

KEY SWITCH The key switch has the following functions [B]: P–02343

A. Key switch is OFF. B. PREHEAT position – Hold switch in this position for a maximum of 15 seconds to activate the glow plugs for starting in cold weather conditions.

B A

C. START the engine.

B

D

D. ON (run) position – When the engine is running release the key and this position is obtained automatically.

C NOTE: Always turn key switch and all accessories to OFF position after the engine is stopped or battery will discharge. Audible alarm will sound if the key is in the ON position with the engine stopped.

P–02180

See Pages 14 and 15 for the starting procedure.

C

CAB ELECTRICAL (If equipped) The cab overhead console has the following components [C]: 1. Wiper Switch – off, low and high speed.

4

2. Light Switch – controls the front exterior lights and the fuel gauge backlight.

3

2

5

1

3. Radio – (if equipped) 4. Fuse – cab, this fuse supplies power for cab exterior lights, interior light and wiper.

P–00769

5. Interior Light – push button on the side of the light to activate.

D

HEATER CONTROL (If equipped) The rotary switch (Item 1) [B] controls the heater fan motors, off, low and high speed [D].

1

The temperature control (Item 2) [D] controls the heat range.

2

P–00768

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

CONTROL LEVERS (JOYSTICKS)

A

The work equipment is operated by using the left and right control levers (joysticks) [A] & [B].

Operation Of Left Control Lever (ISO) Arm and Swing (Decal P/N 6587426).

The left lever is used to operate the arm and to swing the upperstructure [A]: 1. Arm Out

P–00805

2. Arm Out and Bucket Dump 3. Bucket Dump 4. Arm In and Bucket Dump 5. Arm In 6. Arm In and Bucket Curl 7. Bucket Curl 8. Arm Out and Bucket Curl

Before swinging the upper works, make sure the swing lock is disengaged.

PI–08226

I–2051–0189

B

Operation Of Right Control Lever (ISO) Boom and Bucket (Decal P/N 6587425) The right lever is used to operate the boom and bucket [B]: 1. Boom Lower 2. Boom Lower and Bucket Dump 3. Bucket Dump

P–00803

4. Boom Raise and Bucket Dump 5. Boom Raise 6. Boom Raise and Bucket Curl 7. Bucket Curl 8. Boom Lower and Bucket Curl

Before leaving the machine: • Lower the attachments to the ground.

• Stop the engine & remove the key.

W–2167–0195 PI–08227

–7–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

CONTROL LEVERS (STANDARD)

A

The work equipment is operated by using the right and left control levers (joysticks) [A] & [B].

Operation Of Left Control Lever (STANDARD) Boom and Swing (Decal P/N 6587428) The left lever is used to operate the boom and swing the upperstructure [A]: 1. Boom Lower

P–00805

2. Boom Lower and Swing Right 3. Swing Right 4. Boom Raise and Swing Right 5. Boom Raise 6. Boom Raise and Swing Left 7. Swing Left 8. Boom Lower and Swing Left

Before swinging the upper works, make sure the swing lock is disengaged.

PI–02864

I–2051–0189

B

Operation Of Right Control Lever (STANDARD) Arm and Bucket (Decal P/N 6587427) The right lever is used to operate the arm and bucket [B]: 1. Arm Out 2. Arm Out and Bucket Dump 3. Bucket Dump

P–00803

4. Arm In and Bucket Dump 5. Arm In 6. Arm In and Bucket Curl 7. Bucket Curl 8. Arm Out and Bucket Curl

Before leaving the machine: • Lower the attachments to the ground.

• Stop the engine & remove the key.

W–2167–0195 PI–02863

–8–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

SWING LOCK

A

When the swing locking lever (Item 1) [A] is engaged (locked position), the upperstructure of the excavator is locked to the track frame and will not swing. The upperstructure must be parallel to the track frame to engage the swing lock.

1 P–00767

B

Lift the swing lock lever (Item 1) [B] to disengage the upperstructure from the track frame. Put the lever in the unlocked position.

1

AVOID INJURY The swing lock lever must be engaged when transporting the machine.

W–2197–0595 P–00757

C

Swing Control Lever (Joystick)

Never engage the swing control lever when the swing lock pin is engaged. Engage the swing lock pin only after the upper works is parallel with the track frame.

I–2052–0189

P–00805

HORN BUTTON

D

The horn button (Item 1) [D] is located in the right control lever (joystick) grip.

1

P–00808

–9–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

SPEED CONTROL LEVER

A

The speed control lever is used to control the engine speed [A].

2

1. LOW IDLE POSITION – Pull the lever backward (position 1) for low idle, (Approximately 1000 RPM).

1

2. HIGH IDLE POSITION – Push the lever fully forward (position 2) for full engine RPM, (Approximately 2500 RPM).

P–00813

ENGINE STOP CONTROL

B

Pull the knob up to STOP the engine [B]. (When the engine has stopped, push the stop control knob down to the operating position. This will avoid possible starter damage if engine start–up is attempted and the stop control knob has been left in the OFF position).

P–00812

–10–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

STEERING LEVERS/FOOT PEDALS

A

Forward And Reverse Travel NOTE: The following procedures describe forward, reverse, right & left as though you were seated in the operator’s seat.

1

2

FORWARD

Put the blade so that it is at the front of the machine as you sit in the operator’s seat. Slowly push both steering levers* forward for forward travel. Pull both steering levers backward for reverse travel.

NEUTRAL

*There are also foot pedals to operate the steering levers in the same manner.

REVERSE

B

Right Pivot Turn (Forward)

P–00811

C

Left Pivot Turn (Forward)

• Check the blade location before traveling.

When the blade is to the rear, operate the steering levers/foot pedals in the opposite direction to when the blade is in the front.

• Move the steering levers/foot pedals slowly. Abrupt lever motion will cause the machine to jerk.

W–2138–0189

Turning B–10979 MC–02109

Right Turn Push the left steering lever forward to turn to the right [B] while traveling in a forward direction.

D

Pull the left steering lever backward to turn to the right [D] while traveling in a reverse direction.

Right Pivot Turn (Reverse)

E

Left Pivot Turn (Reverse)

Spin–Turn Right Push the left steering lever forward and pull the right steering lever backward [F].

Left Turn Push the right steering lever forward to turn to the left [C] while traveling in a forward direction.

B–10979 MC–02109 MC–2109

Pul the right steering lever backward to turn to the left [E] while traveling in a reverse direction.

Spin–Turn Left Push the right steering lever forward and pull the left steering lever backward [G].

F

G

Counter–Rotation Turn (Right)

Counter–Rotation Turn (Left) B–10979 MC–02109

–11–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

BOOM SWING PEDAL AND LOCK

A

Raise the pedal lock/foot rest (Item 1) [A] to operate the boom swing pedal.

Push the pedal (Item 2) [A] on the right side to swing the boom to the right and push the pedal on the left side to swing the boom to the left.

B–11164

NOTE: The purpose of the boom swing pedal is to offset the boom with respect to the upperstructure for digging close to a structure.

1 2 P–02175

BLADE CONTROL LEVER

B

The lever (Item 1) [B] is used to raise and lower the blade.

A

1

Position A – Pushed Forward – Lowers the blade.

Position B – Neutral – Blade is stopped and held in position.

Position C – Pulled Backward – Raises the blade.

B C

NOTE: Keep the blade lowered when digging to help stabilize the machine.

P–02182

–12–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

AUXILIARY OPERATION PEDAL

A 1

AVOID BURNS Hydraulic fluid, tubes, fittings and quick couplers can get hot when running machine and attachments. Be careful when connecting and disconnecting quick couplers.

W–2220–0396

2 P–02175

Raise the pedal lock/foot rest (Item 1) [A] to operate the auxiliary operation pedal.

B

The pedal (Item 2) [A] controls optional equipment when mounted on the arm.

The excavator is equipped with 2–way flow auxiliary lines.

Push pedal (Item 2) [A] to activate hydraulic function.

Right side of pedal is hydraulic pressure to the female coupler and left is hydraulic pressure to the male coupler.

2

The female coupler (Item 1) [B] is pressurized, the male coupler (Item 2) [B] is returned when pedal is pushed to the right.

1

P–00814

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, 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–2144–0189

–13–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

DAILY INSPECTION Check the following items before starting each day: • Operator Canopy or Cab (ROPS) and mounting • hardware.

• Seat belt and mounting hardware.

• Damaged decals, replace as needed.

• Air cleaner and intake hoses.

• Engine coolant level and for coolant leaks.

• Engine oil level and for engine leaks.

• Clean engine area of any flammable material.

• Hydraulic fluid level and system for leaks.

• Grease all pivot points.

• Cylinder and attachment pivot points.

• Track Tension.

• Repair broken and loose parts.

Fluids such as engine oil, hydraulic fluid, coolants, etc. must be disposed of in an environmentally safe manner.

Some regulations require that certain spills and leaks on the ground must be cleaned in a specific manner. See local, state and federal regulations for correct disposal.

AVOID INJURY OR DEATH When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside. Exhaust fumes contain odorless, invisible gases which can kill without warning.

W–2050–1285

• Engines can have hot parts and hot exhaust gas. Keep flammable material away.

• Do not use machines in atmosphere containing explosive gas.

W–2051–1086

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, 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.

A

W–2144–0189

STARTING THE ENGINE Normal Starting Procedure (With Engine Warm) Fasten the seat belt.

Lower the control console(s) to the locked position.

Put all control levers in the neutral position [A].

Make sure the engine stop control knob is down [B].

Turn the key to the START position (Inset) [B].

P–0811

When the engine is started, release the key and it will return to the run (ON) position.

B

Stop the engine if the warning lights and audible alarm do not go OFF. Check for the trouble before starting the engine again.

Do not engage the starter for longer than 15 seconds at a time. Longer use can damage the starter by overheating. Cool the starter for one minute between uses.

I–2034–0284

PI–02824

–14–

P–00812

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

Cold Temperature Starting Procedure Use the following procedure to make starting easier:

2

1

Replace the engine oil with the correct type and viscosity for the anticipated starting temperature. (See OIL SPECIFICATIONS Page 48.)

Make sure the battery is fully charged.

Install an engine heater.

P–00813

B

Do not use ether with glow plugs (preheat) systems. Explosion can result which can cause injury or death.

W–2071–1285

Follow the steps under Normal Starting Procedure and repeat the steps below until engine starts: Push the speed control lever fully forward (Position 2) [A].

Turn the key to HEAT position. The light will come on [B].

Preheat the engine for approximately 15 seconds.

Turn the key to START position and start the engine [B].

PI–02824

Release the key, and it will return to the run (ON) position.

When the engine speed increases, move the speed control lever immediately to the idling position (1) [A].

Do not engage the starter for longer than 15 seconds at a time. Longer use can damage the starter by over heating. Cool the starter for one minute between uses.

I–2034–0284

–15–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

OPERATING PROCEDURE

When operating in water or crossing streams, first check the soil conditions, depth and flow of water. Never operate in water higher than the bottom of the swing circle.

Breaking In A New Machine When operating on a public road or highway, always follow local regulations. For example: Slow Moving Vehicle Sign or Directional Signals may be required.

NOTE: Be careful when removing the machine from water. The engine may become filled with water and damage could result.

A new machine requires careful operation during the first 100 hours to break in various parts.

Do not operate the machine when visibility is poor (fog, mist or smoke).

If a machine is subjected to hard use during the initial operation, the performance and service life will be reduced.

If it is necessary to operate the control levers when moving the machine near a cliff, road shoulders, or sloping ground, stop the machine travel before operating any work equipment levers.

Do the following when operating a new machine: • After starting, let the engine idle for 5 minutes so the engine and components can warm up.

Do not dig under the machine.

Check with utility companies, for underground electrical, water, gas lines, etc. Work slowly in areas of underground utilities.

• Avoid operation with heavy loads or at high speeds.

• Avoid sudden starting or stopping or abrupt motions.

Do not allow the bucket teeth to contact the ground when swinging the upperstructure.

General Operation Suggestions

Do not move the machine with the bucket in the ground or trench.

Know where the first aid kit and fire extinguisher are and know how to use them. Know how to contact emergency assistance.

Do not use the bucket as a breaker or pile driver. It is better to excavate hard or rocky ground after breaking it with other equipment. This will reduce damage to the machine.

When operating on uneven ground or in places where there are obstacles, do the following: • Operate as slow as possible and avoid sudden changes in direction.

To brake the machine when going down a slope, put the steering levers in NEUTRAL position. This will engage the hydrostatic braking.

• Avoid traveling over objects (such as rocks, trees, stumps, etc.).

When the engine stops on a slope, move the steering levers to the neutral position. Lower the boom/bucket.

When working in wet or soft ground, put planking on the ground to prevent the machine from getting stuck. If the machine is stuck in soft soil, use the following procedure to move the machine to firm ground:

NOTE: The ignition switch must be in the ON position with the engine stopped to activate the accumulator pressure to lower the boom/bucket to the ground.

• If one track or both tracks are stuck in soft soil, push the bucket down against the ground to raise the track (or tracks, one side at a time) off the ground.

Start the engine and resume the operation.

• Place timber (planks) under the track(s) and drive the machine to firm ground.

• It may help to put the bucket into the ground in front and move the arm as if you were digging to help move the machine.

–16–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

OPERATING PROCEDURES (Cont’d)

A

TRAVELING DOWN OR BACKING UP SLOPES

AVOID INJURY OR DEATH • Do not travel across or up slopes which are

over 15 degrees to the side, or to the back of machine or 25 degrees to the front. Keep boom centered while traveling.

• Keep attachments as low as possible when traveling on slopes or in rough conditions.

MC–1878B

W–2198–0595

B

When going down a slope, control the speed with the steering levers and the speed control lever.

TRAVELING ON SIDE SLOPES

TRAVELING UP SLOPES

15 °Maximum

15° Maximum

When going down grades that exceed 15 degrees, put the machine in the position shown, and run the engine slowly.

Operate as slow as possible and avoid sudden changes in lever direction.

Avoid traveling over objects (such as rocks, trees, stumps, etc.).

MC–1878C

C

Keep attachments as low as possible when traveling on slopes or on rough conditions.

RECOMMENDED POSITION FOR WORKING ON A SLOPE

W–2199–0595

Stop the machine travel before moving the upper equipment controls. Never allow the blade to strike a solid object. Damage to the blade or hydraulic cylinder can result.

It is recommended to level the work area [C].

If this is not possible, the following procedures should be used: MC–1865C

Do not work on slopes which are over 15 degrees.

Slow down the work cycle. Avoid working with the tracks across the slope as this reduces stability and increases the tendency for the machine to slide. Position the excavator with the blade down hill and lowered.

Avoid swinging or extending the bucket farther than necessary in a down hill direction. When you must swing the bucket down hill, keep the dipper arm low and skid the bucket downhill.

When working with the bucket on the uphill side, keep the bucket as close to the ground as possible. Dump the spoil far enough away from the trench or hole to prevent the possibility of a cave in.

–17–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

OPERATING PROCEDURES (Cont’d)

A

Operating In Water Mud and water should be removed from the machine before parking. If possible, park the machine on boards or concrete to prevent the track or undercarriage from freezing to the ground and preventing machine movement.

Water Level

Do not operate or immerse the Excavator in water higher than the bottom of the swing circle [A].

Properly grease the Excavator when it has been operated or immersed in water for a period of time.

MC–01722

Water must be removed from the cylinder rods. If water freezes to the cylinder rod, the cylinder seals can be damaged when the rod is retracted.

B

PARKING THE HYDRAULIC EXCAVATOR Stop the machine on level ground. Lower the attachments to the ground.

1

Run the engine at idle speed for about 5 minutes to allow it to cool.

Pull the engine stop control (Item 1) [B] to stop the engine.

NOTE: After the engine has stopped, push the stop control knob down to operating position.

This will avoid possible starter damage if engine start–up is attempted with stop control in the OFF position.

PI–02824

P–00812

Turn the key switch to the OFF position (Inset) [B].

Disconnect the seat belt. Remove the key from the switch to prevent operation of machine by unauthorized personnel.

–18–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

TRANSPORTING THE HYDRAULIC EXCAVATOR

A

Make sure the parking brakes on the transport vehicle are engaged and wheels are blocked.

Align the ramps with the center of the transport vehicle.

Secure the ramps to the truck bed and be sure ramp angle does not exceed 15 degrees.

Use metal loading ramps and slip resistant surface.

Make sure the ramps are the correct length and width, and can support the weight of the machine.

Determine the direction of the track movement before moving the machine (blade forward). Engage the swing lock pin to lock the upperstructure.

P–02279

Move the machine forward onto the transport vehicle [A].

B

Do not change direction of the machine while it is on the ramps.

After loading the machine, position the arm and bucket as shown [B].

Put blocks under the front and rear of the track shoes.

Lower the boom.

Stop the engine and remove the key. Use the following procedure to fasten the Excavator to the transport vehicle:

P–02277

Fasten holddown chains to the front corners of the blade and to the tie down loop at the rear of the track frame to prevent it from moving when going up or down slopes, or during sudden stops [C] & [D].

C

Use chain binders to tighten the chains and then safety tie the chain binder levers to prevent loosening.

When transporting the machine, observe the rules, motor vehicle laws and vehicle limit ordinances. Use a transport and towing vehicle of adequate length and capacity.

P–02278

D

Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury.

W–2058–0494

P–02275

–19–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

LIFTING THE EXCAVATOR

A

Fully extend the cylinders of the bucket, arm & boom.

Put the work equipment control levers in neutral and engage the swing locking lever.

1

AVOID INJURY OR DEATH

P–03752

• Use a lifting fixture with sufficient capacity for the weight of the excavator plus any added attachments.

• Maintain center of gravity and balance when lifting.

• Do not swing boom or upperstructure.

Engage the swing locking lever.

• Never lift with operator on machine.

3

W–2202–0595

Install a bolt (Item 1) [A] through the lift plate holes and fasten with a nut.

Connect the lifting chain hook to the bolt [A].

Connect the lifting chain hooks to the left and right side of the rear frame (Item 2) [A].

Install a spreader bar (Item 3) [A] above the canopy to prevent the lifting fixture from hitting the ROPS and the rear engine cover.

MC–1857A

2

2 P–03751

–20–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

BUCKET

A

Removal

2 1

AVOID INJURY OR DEATH Stop the machine on a firm flat surface. When removing or installing attachments (such as a bucket), always have a second person in the operator’s seat, give clear signals and work carefully.

P–02221

W–2140–0189

Select a flat level surface. Put the bucket on the ground.

Remove the fasteners from the pivot pins (Items 1 & 2) [A].

Remove the pivot pins and keep them clean. Do not damage the dust seals in the arm and the link.

Installation Install the arm into the bucket and align the hole [A].

Install the pivot pin (Item 2) [A].

Attach the link to the other hole and install the pivot pin (Item 1) [A].

Install the fasteners. Add grease to the pivot pins before operation.

Never use attachments or buckets which are not approved by Melroe Company. Buckets and attachments for safe loads of specified densities are approved for each model.

Unapproved attachments can cause injury or death.

W–2052–1285

–21–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

220ExcavatorOperation&MaintenanceManual#6722250S/N508215000&Above–OperatingInstructionsSection

–22–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

PREVENTIVE MAINTENANCE AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ALTERNATOR BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Removal And Installation Of The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Service The Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

PREVENTIVE MAINTENANCE

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Engine Oil And Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 FINAL DRIVE CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Replacing Final Drive Case Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Diagnostic Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Replacement Of The Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Replacement Of The Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 JOYSTICK CONTROL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 ISO To Standard Control Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Standard To ISO Control Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 LUBRICATION OF THE HYDRAULIC EXCAVATOR . . . . . . . . . . . . . . . . . . . 37 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

–23–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

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

CORRECT

CORRECT

CORRECT

B–10731

B–14148

B–14142

Bobcat without

Use the correct procedure to lift and support the excavator.

Always lift the blade fully before installing jackstands.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

Never service the Hydraulic Excavator instructions.

B–14147

B–14141

B–14145

Have good ventilation when welding or grinding painted parts.

Wear dust mask when grinding painted parts. Toxic dust and gas can be produced.

Vent exhaust to outside when engine must be run for service.

Exhaust system must be tightly sealed. Exhaust fumes can kill without warning.

Always lower the bucket and blade to the ground before doing any maintenance.

Never modify equipment or add attachments not approved by Melroe Company.

WRONG

WRONG

WRONG

B–14146

B–14143

B–6589

Stop, cool and clean engine of flammable materials before checking fluid.

Never service or adjust machine with the engine running unless instructed to do so in the manual.

Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes.

Never fill fuel tank with engine running, while smoking or when near open flame.

Keep body, jewelry and clothing away from moving parts, electrical contacts, hot parts and exhaust.

Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding.

Keep rear door closed except for service. Close and latch door before operating the excavator.

Lead–acid batteries produce flammable and explosive gases.

Keep arcs, sparks, flames and lighted tobacco away from batteries.

Batteries contain acid which burns eyes or skin on contact.

Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts.

–24–

MSW20–1297

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

SERVICE SCHEDULE Maintenance work must be done at regular intervals.

Failure to do so will result in excessive wear 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 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

SERVICE SCHEDULE ITEM Engine Air Cleaner Engine Oil Engine Coolant System Indicator Lights Operator Canopy Seat Belt Safety Signs (Decals) Tracks Hydraulic Reservoir All Machinery Pivot Pins Fuel Tank/Fuel Filter Swing Circle Swing Pinion Engine Oil & Filter Alternator Belt Hydraulic Filter Fuel Filters Battery Air Cleaner Cooling System Alternator & Starter Engine Valve Clearance Cooling System Hydraulic Tank Case Drain Return Screen Final Drive Case

HOURS

SERVICE REQUIRED

8–10

Check & empty dust cap as required.

Check the engine oil and add as needed.

Check radiator coolant level.

Check for correct operation.

Check the fastening bolts, nuts & condition of cab.

Check the condition & that fasteners are tight.

Check for damaged signs (decals); replace as needed.

Check & adjust tension.

Check fluid level.

Lubricate 22 grease fittings.

Drain water and sediment from fuel tank/filter.

Lubricate 2 grease fittings.

Lubricate one grease fitting.

Replace oil & filter element.

Check & adjust tension.

Replace filter element.

Replace filter elements.

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 and change the fill neck strainer.

Clean the screen with solvent (if equipped).

Change the gear lube.

50

100

250

500 1000

*

*

After the first 250 hours of machine operation do the following: * Change the oil in the final drive case. * Check and adjust engine valve clearance.

–25–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

ENGINE COVER

A

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

W–2012–1285

Keep the engine cover closed when operating the machine.

W–2141–0189

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

P–00737

B

AIR CLEANER SERVICE See the SERVICE SCHEDULE Page 25 for the correct service interval.

Service the air cleaner as follows: Daily Check Loosen the clamp on the air cleaner [B].

P–00710

Remove the cover (Item 1) [C] and the dust cup (Item 2) [C].

C

Empty dust cup. Visually inspect the filter element. Do not remove element unless plugged and replacement is necessary.

3

Filter Replacement

2

Remove the wing nut (Item 3) [C].

1

P–00824

Remove the filter element [D].

Check the air cleaner housing for damage.

D

Wipe the canister and the seal surface clean with a clean cloth. Do Not use compressed air.

Check the seal (Item 1) [D] for damage. Do not use an air filter element with a damaged seal.

1

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

Install the dust cup and cover so the arrow points up.

Check that all the air cleaner hose clamps are tight.

P–00714

–26–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

FUEL SYSTEM

A

Fuel Specification

2

Use only clean, high quality diesel fuel, Grade No. 2 or Grade No. 1.

The following is suggested blending guideline which should prevent fuel gelling problems.

Temp. F° (C°)

No. 2

1

No.1

+15o(9o)

100% 0% 50% 50% Down to –20o (–29o) Below –20o (29o) 0% 100% For local recommendations, the operator can contact his fuel supplier.

P–00805

B Stop and cool the engine before adding fuel.

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

W–2063–0887

Filling The Fuel Tank The fuel level in the tank is indicated by the fuel gauge (Item 1) [A] when the ignition key is in the ON position.

NOTE: When the fuel level reaches the 1/8 fuel setting, the low fuel light (Item 2) [A] will come ON to alert the operator of this condition.

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

P–00810

Turn the fill cap to remove it.

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.

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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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

FUEL SYSTEM (Cont’d) See the SERVICE SCHEDULE Page 25 for the correct service interval.

A

To remove the water and sediment from the fuel tank, remove the fuel hose at the fuel filter inlet elbow [A]. Insert the end of the fuel hose into an approved container and drain.

1

NOTE: If fuel will not drain, squeeze the primer bulb to start the fuel to flow.

P–00823

Fuel Filters See the SERVICE SCHEDULE Page 25 for the correct service interval.

B

To remove water from filter, open the drain valve (Item 1) [B] at the bottom of the fuel filter.

Use a filter wrench to remove the final fuel filter [B].

Replace the element and hand tighten only.

1

Removing Air From The Fuel System After replacing the fuel filter or after running out of fuel, air must be removed from the fuel system before starting the engine.

Open the vent screw (Item 1) [C] on the injection pump.

P–00840

C

Open the bleed screw on the top of the fuel filter housing (Item 1) [A].

1

Squeeze the primer bulb (Item 1) [D] to fill the filter.

P–00727

When fuel, free of air bubbles, comes from the filter housing, close the bleed screw.

Leave the vent on the injection pump slightly open.

D

Start the engine. When the engine runs smoothly, close the vent screw on the injection pump.

NOTE: If engine fails to start after above procedure is performed, it will be necessary to bleed the injector lines, do the following: – Loosen the three (3) injector line lock nuts, one turn.

– While cranking engine, as fuel emerges from injector lines, slowly tighten the injector line lock nuts.

1 –28–

P–00826

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

ENGINE LUBRICATION SYSTEM

A

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 the correct API Service Classification of CD or better. (See FUEL, COOLANT AND LUBRICATION Chart Page 48.)

P–00825

Engine Oil And Filter Replacement See the SERVICE SCHEDULE Page 25 for the correct service interval.

B

Use the following procedure to change the oil and filter:

1

Run the engine until it is at operating temperature.

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

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

P–00837

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.

Install and tighten the oil drain plug.

Clean the area around the dipstick and remove the dipstick [A].

1 P–00731

Remove the dipstick tube cap [D]. Use a funnel and put 4.5 quarts (4,3 L) of oil into the engine. (See FUEL, COOLANT AND LUBRICATION Chart Page 48).

D

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

Check the oil level and add oil as needed if it is not at the top mark on the dipstick.

P–00831

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

COOLING SYSTEM

A

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

The coolant level must be 3/4–1 inch (19–25 mm) below the filler neck at the radiator.

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

Coolant Replacement

P–00838

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

W–2070–1285

1

Turn the upperstructure so there is access to the engine and radiator from between the tracks. Stop the engine.

When the engine is cool, loosen and remove the radiator cap [A].

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

P–00835

Drain all the coolant into a container.

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

Propylene Glycol Pre–mix 50% water and 50% ethylene glycol in a separate container. Fill the radiator with the pre–mixed 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 to bring it 3/4–1 inch (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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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

ALTERNATOR BELT ADJUSTMENT

A

To adjust the belt tension, use the following procedure: Stop the engine. Open the engine cover.

The belt should deflect about 5/8 inch (16 mm) when pressed between the water pump pulley and crankshaft pulley with approximately 22 lbs. (10 kg) pressure [A].

P–00829

If the tension is not correct, loosen the alternator mounting bolt.

B

Loosen the adjustment bolt [B].

Move the alternator until the belt tension is correct.

Tighten the adjustment bolt and alternator 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 groove in the pulleys.

P–00828

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

ELECTRICAL SYSTEM The excavator has a 12 volt, negative ground charging system.

A 2

1

Fuses The following fuses protect these circuits from overload: 1. 25 amp: This fuse protects the engine starting circuit, gauge functions, horn, audible alarm and control console microswitches.

2. 25 amp: This fuse protects the cab heater (if equipped) and the accessories.

Replace all fuses with the same type and capacity.

NOTE: Before replacing any fuse, find and fix the problem that caused the circuit overload.

Make sure the key switch is in the OFF position before replacing the fuse.

P–00834

B

Service The Electrical System Slide the seat forward.

Remove the pins from the seat plate [B].

Raise the operator cab [C].

The battery cables must be clean and tight [D]. Remove any acid or corrosion from the battery and cables using a sodium bicarbonate and water solution. Cover the battery terminals and cable ends with battery saver grease.

P–00848

C

Check for broken or loose connections.

With factory equipped battery, no maintenance is needed as this is a maintenance free battery.

If the machine has had a Melroe parts replacement battery installed, check the electrolyte level in the battery.

If it is lower than 1/2 inch (13 mm) above the plates, add distilled water only.

P–00850

Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

D

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.

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

W–2065–1296

P–00852

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

Using A Booster Battery (Jump Starting) If it is necessary to use a booster battery to start the engine, BE CAREFUL! Make sure the swing lock is in the engaged position.

The key switch must be in the OFF position.

The booster battery must be 12 volt.

Open the engine cover [A].

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 positive (+) battery cable terminal (Item 1) [B] & [C].

P–00737

B

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 frame (Item 2) [B] & [C].

NOTE: See Cold Temperature Starting Procedure, Page 15.

2

1

Start the engine. After the engine is running, remove the negative (–) cable (Item 2) [B] connected to the frame first. Disconnect the cable from the starter terminal (Item 1) [B] & [C].

P–00836

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

Never lean over battery while boosting, testing or charging.

Battery gas can explode and cause serious injury.

W–2066–1296

Damage to the alternator can occur if:

• Engine is operated with battery cables

When jump starting from a second machine:

• Battery cables are connected when using a

If ‘‘jump starting’’ the excavator from a battery installed in a second machine, make sure that the second machine is NOT running while using the glow plugs. High voltage spikes from a running machine can burn out the glow plugs.

disconnected.

fast charger or when welding on the loader (Remove both cables from the battery).

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

I–2060–0195

I–2023–1285

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d) Removal And Installation Of The Battery

A

Move the operator seat to the full forward locked position.

Remove the two retaining pins from the seat plate [A].

P–00848

Tilt the operator seat forward [B].

B

Disconnect the negative (–) cable (Item 1) [C] first.

Disconnect the positive (+) cable (Item 2) [C].

Remove the two bolts (item 3) [C] and remove the holddown clamp (Item 4) [C].

P–00850

Remove the battery from the compartment [D].

Always clean the terminal and the cable ends, even when installing a new battery.

C 1

Install the battery. Install the holddown clamp and the two bolts.

3

NOTE: Do not touch any metal to the battery terminals.

(–)

Connect the battery cables. Connect the negative (–) cable (Item 1) [C] last to prevent sparks at the terminal.

(+)

2

4 P–00853

Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

D

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.

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

W–2065–1296 P–00849

–34–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

HYDRAULIC SYSTEM

A

Checking And Adding Fluid

Prior to checking the hydraulic fluid level, retract the arm and bucket cylinder, put the bucket on the ground and raise the blade.

1

I–2076–0795

P–00843

Put the machine on a level surface.

B

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

The hydraulic fluid level must be visible in the center of the sight gauge (Item 1) [A].

If the fluid level is not correct, remove the reservoir cap [B].

P–00847

C

Check the condition of the fill strainer [C]. The strainer must be installed in the fill neck when adding oil.

Add the correct fluid to the reservoir until it is in the center of the sight gauge [A]. (See Fuel, Coolant and Lubricants Chart, Page 48.)

Install the reservoir cap.

P–00844

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

HYDRAULIC SYSTEM (Cont’d)

A

Diagnostic Couplers Diagnostic couplers are located at each section of the hydraulic pump (Item 1) [A].

The couplers can be used to check circuit pressures.

(Refer to the Service Manual.)

1 Prior to checking the hydraulic fluid level, retract the arm and bucket cylinder, put the bucket on the ground and raise the blade.

I–2076–0795

P–00832

B

Replacement of the Hydraulic Filter See the SERVICE SCHEDULE Page 25 for the correct service interval.

1

Open the engine cover.

Remove the filter element (Item 1) [B].

Clean the housing where the filter gasket makes contact.

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

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

P–00830

C

Hydraulic Reservoir Replacement Of The Hydraulic Fluid

1

See the SERVICE SCHEDULE Page 25 for the correct service interval.

Move the upperstructure so there is clearance for the reservoir drain between the tracks.

Retract the arm and bucket cylinders, lower the bucket to the ground. Stop the engine.

P–00859

Remove the hydraulic filter element [B].

Remove the drain plug (Item 1) [C] from the bottom of the reservoir.

Drain the fluid into a container.

Install the drain plug.

Install the filter. (See information above.)

Add the correct fluid to the reservoir until it is visible in the sight gauge (approximately 3.75 gals. [14,2 L.] to fill only the reservoir). (See Fuel, Coolant and Lubricants Chart Page 48.)

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

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

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

LUBRICATION OF THE HYDRAULIC EXCAVATOR

A

Lubricate the Hydraulic Excavator as specified in the SERVICE SCHEDULE Page 25 for the best performance of the machine.

1

Record the operating hours each time you lubricate the Hydraulic Excavator.

2

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

Ref. 1.

2.

3.

Description (# of Fittings)

3

Blade Cylinder Rod End, every 8–10 hours (1) [A].

Blade Pivots, every 8–10 hours (2) [A].

Blade Cylinder Base End, every 8–10 hours (1) [A].

P–00860

B 4.

5.

6.

7.

6

Boom Swing Cylinder Rod End, every 8–10 hours (1) [B].

Boom Cylinder Base End, every 8–10 hours (1) [B].

Boom Base Pivot, every 8–10 hours (1) [B].

Swing Circle Pinion, every 50 hours (1) [B]. Install 4 pumps of grease from a grease gun into the grease fitting. Rotate the upperstructure 180o and install 4 more pumps of grease into the grease fitting.

7

5 4 P–00806

C 8.

9.

Boom Swing Bracket Pivot, every 8–10 hours (2) [C].

Frame Swing Bracket Pivot, every 8–10 hours (1) [C].

8

9

P–00863

D 10.

11.

12.

13.

14.

12 11

Boom Cylinder Rod End, every 8–10 hours (1) [D].

Arm Cylinder Base End, every 8–10 hours (1) [D].

Arm Cylinder Rod End, every 8–10 hours (1) [D].

Arm Base Pivot, every 8–10 hours (1) [D].

Bucket Cylinder Base End, every 8–10 hours (1) [D].

13

14

10 P–00862

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

LUBRICATION OF THE HYDRAULIC EXCAVATOR (Cont’d)

A

Ref. 15.

16

16.

17.

Description (# of Fittings) Bucket Cylinder Rod End, every 8–10 hours (1) [A].

Bucket Link Pivots, every 8–10 hours (2) [A].

Bucket Pivots, every 8–10 hours (3) [A].

17 15

P–00815

18.

Boom Swing Cylinder Base End, every 8–10 hours (1) [B].

B

18

NOTE: Access to the grease fitting is from under the upperstructure, right side.

P–00864

19.

Swing Circle Ball Bearing, every 50 hours (2) [C].

C

NOTE: Do not over grease the swing circle or damage to the seal could result. Install 4 to 5 pumps of grease from a grease gun into each of the 2 grease fittings. Rotate the upperstructure 90o and install 4 to 5 pumps of grease into each of the 2 grease fittings.

19

P–00865

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

FINAL DRIVE CASE

A

Checking Oil Level Put the machine on a level surface.

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

1

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

1

Add gear lube through the hole if the gear lube level is below the hole. (See Fuel, Coolant and Lubricant Chart, Page 48.)

Install and tighten the plug.

P–05906

Repeat the procedure for the other side.

Replacing Final Drive Case Oil

B

See the SERVICE SCHEDULE Page 25 for correct service interval.

2

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

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

1

After all the gear lube is removed, install and tighten the bottom plug.

Add .3 quarts (0,3 L) of gear lube to the top plug hole.

Install the plug.

P–05907

Move the excavator until the plugs are positioned parallel to the ground [A].

Use the same procedure as for Checking Oil Level, (See information above) add additional oil as needed.

Repeat the procedure for the other side.

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

TRACK TENSION NOTE: The wear of the parts on the undercarriage vary with the working conditions and the different types of soil conditions. It is necessary to inspect track tension to maintain the correct tension. (See SERVICE SCHEDULE Page 25 for the correct service interval.)

A

Adjustment Raise one side of the machine (approximately 4 inches) using the boom and arm as shown in [A].

Raise the blade fully and install jackstands under the blade and the track frame. Operate the boom until all machine weight is on the jackstands.

P–00858

B

Stop the engine.

2.25 – 2.50’’ (57 – 63 mm)

AVOID INJURY Keep fingers and hands out of pinch points when checking the track tension.

W–2142–0189

Center Of Track Measure the distance between the frame and the top of the track. If the distance is between 2.25–2.50 inch (57–63 mm), the track tension is correct [B].

If not, loosen one bolt and remove the other bolt from the cover [C].

P–00854

C

Add grease to the fitting (Item 1) [D] until the track tension is correct.

Cover

If track tension is too tight, decrease the track tension pressure by loosening the bleed screw (Item 2) [D] (maximum of 1 turn) and allow grease to flow out of the bleed screw. When the tension is correct, tighten the bleed screw.

Repeat the procedure for the other side.

If the track tension is still loose after adjusting to the above mentioned limit, it indicates the track is worn. See your dealer for repairs.

P–00845

D

AVOID INJURY

Bleed Here

2

Do not loosen the grease fitting more than one complete rotation. Also, be careful not to loosen any part other than the grease fitting. If the grease fitting or any part is loosened too much, it can fly off under high pressure. If the grease does not ooze smoothly, try moving the machine back and forth for a short distance.

W–2143–0189

Add Grease Here

1

B–13134

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

JOYSTICK CONTROL CHANGE

A

ISO To Standard Control Pattern To change from ISO to STANDARD joystick controls, do the following procedure:

3

1 2

4

Open the tool box door.

Remove the hose cover plate.

Remove the bottom plate from the tool box.

Mark and remove hoses (Items 1, 2, 3 & 4) [A] from the bulkhead elbows.

P–02348

B

Install the hoses onto the new locations as shown (Items 1, 2, 3 & 4) [B].

Install new decals (P/N 6587427) onto the right hand console and (P/N 6587428) onto the left hand console.

4

2 1

3

After exchange of the hoses, the right joystick will now control arm (raise and lower) and the bucket (curl). The left joystick will control the boom (raise and lower) and the upperstructure (swing).

See Service Manual for additional information.

P–02348

C

Standard To ISO Control Pattern To change from STANDARD to ISO joystick controls, do the following procedure:

1

3 4

2

Open the tool box door.

Remove the hose cover plate.

Remove the bottom plate from the tool box.

Mark and remove hoses (Items 1, 2, 3 & 4) [C] from the bulkhead elbows.

P–02348

Install the hoses onto the new locations as shown (Items 1, 2, 3 & 4) [D].

D

Install new decals (P/N 6587425) onto the right hand console and (P/N 6587426) onto the left hand console.

2 1

4 3

After exchange of the hoses, the right joystick will now control boom (raise and lower) and the bucket (curl). The left joystick will control the arm (raise and lower) and the upperstructure (swing).

See Service Manual for additional information.

P–02348

–41–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

220ExcavatorOperation&MaintenanceManual#6722250S/N508215000&Above–PreventiveMaintenanceSection

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

SPECIFICATIONS ENGINE OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 FUEL, COOLANT AND LUBRICANT CHART . . . . . . . . . . . . . . . . . . . . . . . . . 48 HYDRAULIC EXCAVATOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 45 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Digging Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Lifting Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Std. Track Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 SPECIFICATIONS

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

HYDRAULIC EXCAVATOR

S All dimensions are shown in inches. Respective metric dimensions are given in

SPECIFICATIONS

S Where applicable, specification conform to SAE or ISO standards and are subject to

millimeters enclosed by parentheses.

change without notice.

Machine Dimensions A – 102.7 (2609) B – 38.62 (981) C – 86.8 (3205) D – 28.75 (730) E – 9.84 (250) F – 102.7 (2609) G – 10.4 (264) H – 43.8 (1112) I – 58.3 (1480) J – 35.7 (907)

K – 17.15 (435) L – 45.8 (1164) M – 1.02 (26) N – 20.10 (511) O – 23.62 (600)

O

N

MC–1720

C

L K H

G E MC–1718

J

F

I

D A

B

MC–1717

C D A B C D

G

E

H

F

E F G H

J A B

M

I

K

J MC–1719

–45–

K

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 Max. digging depth blade down

With 40.2 (1023) Dipperarm 79.87 (2029) 47.43 (1205) 147.8 (3754) 144 (3657) 129.5 (3288) 90.2 (2291.4) 63 (1601) 100.1 (2542.6) 73.1 (186) 4.9 (124) 83.7 (2125)

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

HYDRAULIC EXCAVATOR SPECIFICATIONS Lifting Capacity

SPECIFICATIONS WEIGHTS Operating Weight (Includes 20” Bucket) Travel Speed . . . . . . . . . . . . . . . . . . . . . .

CONTROLS Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Excavator . . . . . . . . . . . . . . . . . . . . . . . . .

220 ROPS Canopy – 3250 Lbs. (1474 kg) 1.1 MPH (1,74 km/hr.)

Two Hand or Foot Levers Two pilot–operated joysticks control boom, bucket, arm and cab swing.

Right foot pedal controls boom swing. Left foot pedal controls auxiliary hydraulics. The blade is controlled by a separate lever.

ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horsepower . . . . . . . . . . . . . . . . . . . . . . .

Maximum Governed RPM (Full Load) (No Load) . .

Low Idle Speed . . . . . . . . . . . . . . . . . . . .

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number of Cylinders . . . . . . . . . . . . . . .

Displacement . . . . . . . . . . . . . . . . . . . . . .

Bore x Stroke . . . . . . . . . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . .

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . .

Kubota D–750 BW–Clark2 Diesel 13.5 HP (10,1 Kw) @ 2500 RPM 2500 RPM 2700 RPM 1000 RPM 31 ft.–lbs. (42 Nm) @ 1800 RPM Three 46.5 cu.–in. (762 cu. cm.)

2.68/2.76’’ (68mm x 70mm) Forced Cartridge Type – Full Flow Dry replaceable paper cartridge

ELECTRICAL Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 Volt, Reduction Drive 12 Volt, 50 Amps.

12 Volt, 425 Cold Crank Amps

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

SPECIFICATIONS (Cont’d)

220

HYDRAULIC SYSTEM

Number of Pumps . . . . . . . . . . . . . . . . . .

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Capacity . . . . . . . . . . . . . . . . . . . . . . . . . .

System Relief Setting . . . . . . . . . . . . . .

Swing Circuits . . . . . . . . . . . . . . . . . . . . .

Auxiliary Flow . . . . . . . . . . . . . . . . . . . . . .

Control Valve . . . . . . . . . . . . . . . . . . . . . .

Three Triple Section Gear Pump 3 x 4 GPM (15,1 L/min.)

2450 PSI (16897 kPa) 1275 PSI (8793 kPa) 8.0 GPM (30 L/min.)

3–Spool, parallel Type, Open center (Blade, Swing & Boom Swing); 6–Spool, Parallel Type, Open Center (R.H. Travel, Boom, Arm, Bucket & Blade, L.H. Travel) Drive Motors Two Axial Piston Motors Swing Motor . . . . . . . . . . . . . . . . . . . . . . .

Orbit Motor Joystick Cointrol Setting . . . . . . . . . . . .

363 PSI (2500 kPa) Port Releif (Arm) Base . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3000 PSI (20690 kPa) Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3000 PSI (20690 kPa) Port Releif (Boom) Base . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3000 PSI (20690 kPa) Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3000 PSI (20690 kPa) Port Releif (Bucket) Base . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NONE Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3000 PSI (20690 kPa)

SWING SYSTEM Swing Drive . . . . . . . . . . . . . . . . . . . . . . .

Swing Circle . . . . . . . . . . . . . . . . . . . . . . .

Swing Motor . . . . . . . . . . . . . . . . . . . . . . .

Boom Swing (Left) . . . . . . . . . . . . . . . . . .

(Right) . . . . . . . . . . . . . . . . . .

HYDRAULIC CYLINDERS Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dipperstick . . . . . . . . . . . . . . . . . . . . . . . .

Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Swing . . . . . . . . . . . . . . . . . . . . . . .

Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE SYSTEM Final Drive . . . . . . . . . . . . . . . . . . . . . . . . .

Reduction . . . . . . . . . . . . . . . . . . . . . . . . .

Max Drawbar Pull . . . . . . . . . . . . . . . . . .

Gradability Traveling Down or Backing Up Slopes . . . . . . . . . . . . . . .

Traveling on Side Slopes . . . . . . . . . . . . . . . . . . . . . . . . . .

Traveling Up Slopes Forward . . . . . . . . . . . . . . . . . . . . . . . . .

Orbit Motor with a Pinion Single Row Shear Type Ball Bearings with an Internal Gear Built into Swing Circle 9.00 RPM @2500 RPM 50 degrees 90 degrees Bore Dia. in. (mm) 2.38 (60) 2.38 (60) 2.25 (57) 2.38 (60) 2.38 (60)

Stroke in. (mm) 13.14 (334) 17.32 (440) 15.16 (385) 13.62 (246) 2.76 (70)

Each Track is Independently Driven by an Axial Piston MotorType of Two Stage Planetary Gear Reduction 36.8:1 3514 (1594 kg) 25_ 15_ 15_

BRAKES Travel Service . . . . . . . . . . . . . . . . . . . . . . . . .

Parking . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Service . . . . . . . . . . . . . . . . . . . . . . . . .

Holding . . . . . . . . . . . . . . . . . . . . . . . . .

UNDERCARRIAGE Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rod Dia. in. (mm) 1.38 (35) 1.38 (35) 1.38 (35) 1.38 (35) 1.38 (35)

Hydraulic Lock on Motor Hydraulic Lock on Motor Hydraulic Lock on Motor Pin Lock Crawler–Tractor Design Undercarriage. Sealed Track Rollers with Reinforced Box–Section Track Roller Frame. Grease Type Track Adjusters with Shock Absorbing Recoil Springs.

STD TRACK SHOES Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

No. of Shoes . . . . . . . . . . . . . . . . . . . . . . .

No of Track Rollers . . . . . . . . . . . . . . . . .

Ground Pressure . . . . . . . . . . . . . . . . . . .

Rubber 9.84” (250 mm) Single Assembly Three Each Side 3.38 PSI (23,3 kPa)

CAPACITIES Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil & Filter . . . . . . . . . . . . . . . . . .

Hydraulic Reservoir . . . . . . . . . . . . . . . .

Hydraulic System Capacity . . . . . . . . .

6.5 gal. (24.6 L) 1.5 gal. (5,7 L) 4.5 qts. (4,3 L) 3.75 gal. (14,2 L) 7.25 gal. (27,4 L)

DIGGING FORCE Dipperstick . . . . . . . . . . . . . . . . . . . . . . . .

Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1892 lbs. (858 kg) 3272 lbs (1434 kg) @ 2400 PSI –47–

220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

FUEL, COOLANT AND LUBRICANTS 220ExcavatorOperation&MaintenanceManual#6722250S/N508215000&Above–SpecificationsSection

Use this chart for correct selection of Fuel, Coolant and Lubricants.

AMBIENT TEMPERATURE RESERVOIR

KIND OF FLUID

Engine oil pan

Use SAE Viscosity Number as Listed With API Classification CD or Better

CAPACITY

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

Refill 4.5 qts.

(4,3 L)

SAE 10W–30 SAE 15W–40 SAE 5W–30 SAE 30 SAE 20W/20 SAE 10W

Fuel Tank

Diesel Fuel

6.5 gals (24,6 L)

No. 1 No. 2

Cooling System

Coolane Mixture

Hydraulic Tank

Bobcat Fluid 6563328*

Tank Cap. 3.75 gals (14,2 L) System Cap. 7.25 gals.

(27,4 L)

Final Drive Case (each)

90W Gear

0.3 qts.

(0,3 L)

50/50 Water & Anti–Freeze

.

6.0 qts.

(5,7 L)

* If Bobcat fluid (P/N 6563328) is not available, use Engine Oil SAE 10W–30/10W–40, Class SE, or better.

ENGINE 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 25.

Change engine oil and filter according to the following chart if fuel sulphur content is above 0.5%.

Fuel Sulphur Content

Change Interval Of Engine & Oil Filter

0.5 to 1.0% Above 1.0%

1/2 of Regular Interval 1/4 of Regular Interval

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220 (S/N 508215001 & Above) Excavator Operation & Maintenance Manual

WARRANTY EXCAVATOR The Melroe Company warrants to its authorized dealer and authorized excavator dealers of Melroe Equipment, Ltd., who in turn, warrants to the original buyer (owner) that each Bobcat Excavator will be free from proven defects in material and workmanship for 12 months after delivery to the owner.

During the warranty period, the authorized selling Melroe Excavator dealer shall repair or replace, at his option, without charge for parts and labor, any part of the Melroe Excavator product which fails because of defects in material and workmanship. The owner shall provide the authorized excavator dealer with prompt written notice of the defect and allow reasonable time for replacement or repair.

Melroe may, at its option, request failed parts to be returned to the factory. Travel time of mechanics and transportation of the Melroe product to the authorized excavator dealer for warranty work are the responsibility of the owner.

Warranty does not cover replacement of scheduled service items such as oil, filters, turn–up parts, and other high–wear items. The warranty does not cover damages resulting from abuse, accidents, alterations, air flow obstructions, or failure to maintain or use the Melroe attachment according to the instructions applicable to it.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES (EXCEPT THOSE OF TITLE), EXPRESSED OR IMPLIED, AND THERE ARE NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL THE AUTHORIZED SELLING DEALER OR MELROE BE LIABLE FOR DOWNTIME EXPENSES, LOSS OF MACHINE USE OTHER INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES.

6570375 (1–87) Revised (3–96)

Printed in U.S.A.