220 6720230 enUS SM

X 220
Excavator
Service
Manual
Dealer Copy -- Not for Resale

(S/N 508211999 & Below)
Doosan purchased Bobcat Company from Ingersoll-Rand Company in

2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Bobcat Company or the products of
either.
6720230 (6-12) Printed in U.S.A. © Melroe Company 1989
1 of 258
2 of 258
CONTENTS
PREVENTIVE
MAINTENANCE
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i. . .
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii. . .
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii. . . .
HYDRAULIC EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . iii. .
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 ... HYDRAULIC
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 .... SYSTEM
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–1
....
UPPER WORKS & SWING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–1 ..
MAIN FRAME & TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–1 ...
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 .... DRIVE
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–1.... SYSTEM
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–1....
UPPER WORKS
& SWING
SECTION
MAIN FRAME
& TRACKS

ELECTRICAL
SYSTEM
ENGINE
SERVICE
TECHNICAL
DATA
220 (S/N 508211999 & Below) Excavator

3 of 258 –3 Service Manual

FOREWORD
This manual is for the Bobcat hydraulic excavator mechanic. It provides necessary servicing an d
adjustment procedures for the hydraulic excavator and its component parts and systems.Refer to the
Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the hydraulic excavator has had servic
e
or repair:
1. Check that the operatorcanopy 9. Safety treads must be in good
is in good condition and is not condition.
modified.
2. Check that the operating 10. Check for the correct function
canopy mounting hardware is of the the indicator lamps.
tightened and is Melroe
approved.
3. The seat belt must be 11. Check hydraulic fluid level,

correctly installed, functional engine oil and fuel supply.
and in good condition.

4. Inspect for loose or broken 12. Inspect for fuel, oil orhydraulic
parts or connections. leaks..
5. Machine signs must be legible 13. Lubricate the hydraulic

and in the correct location. excavator.
6. Steering levers, control levers 14. Check the condition of the

and foot pedals must return to battery and cables.
neutral. Control lock must lock
controls securely.
7. Inspect the air cleaner for 15. Check for any field
damage or leaks. Check the modifications not completed.
FIELD
condition of the element. MODIFICATION
8. Check the electrical charging Recommend to the owner that all

system. necessary corrections be made
before the machine is returned to
service.


6 of 258 0 Service Manual
SAFETY INSTRUCTIONS
Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual,
Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure
to follow instructions can cause injury or death.
W–2003–0797
The following publications provide information on the safe use and maintenance of the excavator and attachments:
• The Delivery Report is used to assure that complete instructions have been given tothe new owner and that the machine
is in safe operating condition.
• The Operation & Maintenance Manual delivered with the excavator gives operating information as well as routin e
maintenance and service procedures. It is a part of the excavator and must stay with the machine when it is sold.
• The excavator has machine signs (decals) which instruct on the safe operation and care. The signs and their locations
are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat Excavator deale
r.
• The CIMA Safety Manual delivered with the excavator gives information for safe operating and standard signals.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and

repair work.
Warnings on the machine and in the This notice identifies procedures

manuals are for your safety. Failure to which must be followed to avoid
obey warnings can cause injury or damage to the machine.
death. W–2044–1285 I–2019–0284
Safety Alert Symbol: This Safety Symbol is used for important safety
messages. When you see this symbol follow
the safety message to avoid personal injury or death.
• Wear tight fitting clothing and any other required safety apparel when operating or servicing the excavator.
• Wear safety glasses when maintaining or servicing the excavator.
• Exhaust gases can kill, vent engine exhaust outdoors.
• Know where fire extinguishers and first aid kits are located and how to use them.
• Do not run the excavator where exhaust, arcs, sparks or hot components can contact flammable material, explosive du
st
or gases.
• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to chec
k
for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuelorf
cleaning parts. Use commercial nonflammable solvents.
• Do not use ether or starting fluids on an engine that has glow plugs. These starting aids can explode and injure you.
• Clean the excavator before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fi re
extinguisher near the excavator when welding.
• Have good ventilation when welding or grinding painted parts. Wear a dust mask when grinding painted parts. Toxic dust
or gas can be produced.
• Stop the engine and let it cool before adding fuel. No smoking!
• Use the procedure in this manual for installing, connecting and jump starting batteries.
7 of 258 i Service Manual
SERIAL NUMBER LOCATIONS
A
Always use the serial number of the machine when
requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a dif ferent procedure in doing a specific service
operation.
HYDRAULIC EXCAVATOR SERIAL NUMBER
The excavator serial number plate is on the machine

frame, at the left side near the front corner [A].
N–07348
ENGINE SERIAL NUMBER

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

N–07349
DELIVERY REPORT
C
The Delivery Report must be filled out by the dealer and
signed by the owner or operator when the excavator is
delivered. An explanation of the form must be given to
the
owner. Make sure it is filled out completely [C].

8 of 258 ii Service Manual
HYDRAULIC EXCAVATOR IDENTIFICATION
CONTROL LEVERS
OPERATOR
CANOPY
ENGINE COVER
BOOM
SWING LOCK

UPPER WORKS BLADE
TRACK TRACK FRAME
GRAB HANDLES
DIPPERSTICK CYLINDER
OPERATOR SEAT
BUCKET CYLINDER
BOOM
CYLINDER
BUCKET LINK
CONTROL LOCK
BLADE CYLINDER
DIPPERSTICK
BUCKET
B–14810
B–14811
9 of 258 iii Service Manual
220ExcavatorServiceManual(S/N508211999&Below)#6720230–ContentsSection

10 of 258 iv Service Manual
PREVENTIVE MAINTENANCE
PREVENTIVE
Page MAINTENANCE
Number
AIR CLEANER SERVICE

Replacing the Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–2
..
COOLING SYSTEM
Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
....
Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–6 ...
ENGINE COVER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–3
....
ENGINE LUBRICATION SYSTEM

Checking the Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
...
Engine Oil and Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 ..
FINAL DRIVE CASE
Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–12
...
Draining Final Drive Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12...
FUEL SYSTEM
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–3
...

Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–3...
HYDRAULIC SYSTEM
Checking and Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–7 ..
Replacement of the Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 ..
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–8
...
LUBRICATION OF THE EXCAVATOR

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–10
....
SERVICE SCHEDULE
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–1
....
USING A BOOSTER BATTERY (JUMP STARTING)

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–9
....

11 of 258 –1––1– Service Manual

12 of 258 –1–0– Service Manual
SERVICE SCHEDULE
Maintenance work must be done at regular intervals. Failure to do so will result in excessivewear and early failures. The
service schedule is a guide for correct maintenance of the Hydraulic Excavator.
Instructions are necessary before operating or servicing machine.

Read Operation & Maintenance Manuals, Handbook and signs
(decals) on machine. Follow warnings and instructions in the
manuals when making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service. Failure to
follow instructions can cause injury or death .
W–2003–1289
ITEM SERVICE REQUIRED 8–10 50 100 250 500 1000

Engine Air Cleaner Check & empty dust cup as required.
Engine Oil Check the oil level & add oil as needed.
Engine Coolant System Check radiator coolant level.
Indicator Lights Check for correct operation.
Operator Canopy Check the fastening bolts, nuts, & condition of canopy.

Seat Belt & Control Lock Check the condition, operation & that fasteners are tight.
Safety Signs (Decals) & Check for damaged signs (decals) and safety treads.
Safety Treads Replace any safety signs and safety treads that are
damaged or worn.
Tracks Check & adjust tension.
Hydraulic Reservoir Check fluid level.
Fuel Tank Drain water and sediment from fuel tank.
Swing Circle Lubricate two grease fittings.
Swing Pinion Lubricate one grease fitting.
Engine Oil & Filter Replace oil & filter element.
All Machinery Pivot
Points Lubricate 20 grease fittings.
Alternator Belt Check & adjust tension.
Final Drive Case Check fluid level & add oil as needed.
Hydraulic Filter Replace filter element.
Fuel Filter Replace filter element.
Battery Check & clean cable ends & check electrolyte level.
Air Cleaner Replace the filter element.
Cooling System Clean the radiator fins.
Alternator & Starter Check the condition.
Engine Valve Clearance Check & adjust valve clearance.
Cooling System Drain, flush & add new coolant to the cooling system.
Hydraulic Tank Change the fluid, clean fill neck strainer& suction strainer.
Final Drive Case Change the fluid.
After the first 250 hours of machine operation do the following procedures:
• Change oil in final drive case.
• Check and adjust engine valve clearance.

ENGINE COVER
Procedure
A
AVOID INJURY
Never service or adjust the machine when the
engine is running unless instructed to do so in
the manual.
W–2012–0290
N–07367
Keep the engine cover closed when operating
the machine.
W–2141–0189
B
Open the engine cover to service the engine. Pull on the
latches and lift the engine cover until it is fully raised[A].
1
AIR CLEANER SERVICE
Replacing the Filter Element

See the Service Schedule Page 1–1 for the correct
service interval.
Service the air cleaner as follows:
1. Remove the dust cup (Item 1) [B]. N–07368
2. Remove the wing nut (Item 1) [C]. C
N–07369
3. Remove the filter element [D]. D

4. Check the air cleaner housing for damage.
5. Install a new air filter element. Install and tighten the

wing nut.
6. Install the dust cap so the arrow points up.
7. Check that the air cleaner hose clamps are tight.
N–07370

FUEL SYSTEM
Fuel Specifications
A
Use Number 2 diesel fuel in the engine. During very cold
temperatures, Number 1 fuel can be used.
Fuel System Service
The fuel level in the tank is indicated by the plastic tube 1
(Item 1) [A] on the side of the tank.
N–07371
Stop and cool the engine before adding fuel.

NO SMOKING! Failure to obey warnings can B
cause an explosion or fire.
W–2063–0887
Use the key to unlock the fuel fill cap [B].

N–07372
Turn the fill cap to remove it from the fuel tank [C].
C
NOTE: The fuel fill strainer can be removed for
cleaning. Make sure it is installed before
adding fuel to the tank.
Use a clean, approved safety container to add fuel to the

tank.
Add fuel only in an area that has a free movement of air
and no open flames or sparks. NO SMOKING!
After the tank is full, install and tighten the fuel fill cap.
N–07373

FUEL SYSTEM (Cont’d)
A
Always clean up spilled fuel or oil. Keep heat,

flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.
W–2103–1285
To remove the water and sediment from the fuel tank, N–07375
open the drain in the bottom of the tank [A].

ENGINE LUBRICATION SYSTEM
Checking the Engine Oil
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 API Service
Classification of CC or CD. (See Fuel, Coolant and
Lubricants Chart Page 8–9.)
N–07378
Engine Oil and Filter Replacement
See the SERVICE SCHEDULE Page 1–1 for the correct
service interval.
B
Use the following procedure to change the oil and filter:
Run the engine until it is at operating temperature.
Turn the upper works 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 1
container.
N–07379
Remove the oil filter (Item 1) [C], using a filter wrench.

C
Clean the filter housing surface. Put clean oil on the filter
gasket. Install the new filter and hand tighten only.
N–07380
Remove the oil fill cap[D]. Put 3.5 quarts (3,4 L) of oil into
the engine. (See Fuel, Coolant and Lubricants Chart D
Page 8–9.)
Start the engine and let it run for several minutes. Stop the
engine. Check the oil filter for leaks.
Check the oil level and add oil as needed to bring it to the
top mark on the dipstick.
N–07381

COOLING SYSTEM
Coolant Level
A
When the engine is cool, remove the radiator cap [A].
The coolant level must be 3/4”–1” (19–25 mm) belowthe
radiator filler neck.
If the coolant level is low , add premixed coolant (50%
ethylene glycol and 50% water) to the radiator.
Coolant Replacement
N–07382
B
Do not remove radiator cap when the engine is
hot. You can be seriously burned.
W–2070–1285
Turn the upper works so there is access tothe engine and

radiator underneath. Stop the engine. 1

Loosen and remove the radiator cap [A].
Open the radiator drain valve (Item 1) [B].
Drain all the coolant from the system.
N–07383
When all the coolant is removed, close the drain valve.
Premix 50% water and 50% ethylene glycol in a separate
container. Fill the radiator with premixed coolant until it is
full.
Run the engine at idle speed for about 5–10 minutes to
remove the air from the cooling system (leave the radiator
cap off during this operation).
Stop the engine. Check the coolant level and add as
needed, bringing it 3/4”–1” (19–25 mm) below the filler
neck. Install the radiator cap and tighten.
Wear safety glasses to prevent eye injury when

any of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W–2019–1285

HYDRAULIC SYSTEM
Checking and Adding Fluid
A
To check and add hydraulic fluid to the reservoir, use the
following procedure:
Put the machine on a flat surface.
Retract the dipperstick and bucket cylinders, put the
bucket on the ground, and raise the blade. Stop the
engine. 1
Check the hydraulic fluid level, it must be visible and
between the marks in the sight gauge (Item 1) [A].
N–09091
If the fluid level is low , remove the four bolts from the
reservoir cover [B].
B

N–09161
Remove the reservoir fill cover [C].

C
Add the correct fluid to the reservoir until it is at the top
mark in the sight gauge [A]. (See Fuel, Coolant and
Lubricants Chart Page 8–9.)
Install the reservoir cover, make sure the O–ring is in the
correct position.
Install and tighten the bolts.
N–09162

HYDRAULIC SYSTEM (Cont’d)
Replacement of the Hydraulic Filter
A
service interval. 1
Open the engine cover. Use a filter wrench and remove
the filter element (Item 1) [A].
Clean the housing where the filter gasket makes contact.
Put clean fluid on the gasket. Install the new filter element
and hand tighten only.
Start the engine. Run the machine through thehydraulic
functions. Stop the engine. Check the fluid level at the N–09163
reservoir and add as needed. Check the filter area for
leaks.
Hydraulic Reservoir
B
2
service interval.
Move the upper works so there is a clearance for the
reservoir between the track frame.
Retract the dipperstick and bucket cylinder , lower the 1

bucket to the ground. Stop the engine. 3
Remove the hydraulic filter. Remove the drain plug (Item

1) [B] from the bottom of the reservoir.
Remove the hose clamps (Item 2)[B] and disconnect the N–09090
hoses. Remove the bolts (Item 3) [B] from the flange.
Turn the bolts into the threaded holes in the flange to push
the mesh screen out of the reservoir.
Clean all the parts with clean solvent and air dry them.
Replace the parts and tighten the bolts, hose clamps and
drain plug.
Add approximately 7.0 gals. (26,5 L) of fluid to the
reservoir. (See Fuel, Coolant and Lubricants Chart Page
8–9.)
Run the machine through the hydraulic functions. Stop
the engine. Check the fluid level and add as needed.
Always clean up spilled fuel or oil. Keep heat,

flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.
W–2103–1285

USING A BOOSTER BATTERY (JUMP STARTING)
Procedure
A
If it becomes necessary to use an extra battery to start the 1
engine, BE CAREFUL! Make sure the swing lock pin is in
the engaged position.
The key switch must be in the OFF position.
2
The booster battery must be 12 volt.
Open the engine cover.
Connect the end of the first cable to the positive (+)
terminal of the booster battery. Connect the other end of
the same cable to the starter terminal (Item 1) [A]. N–07387
Connect the end of the second cable to the negative (–)

terminal of the booster battery. Connect the other end of
the same cable to the machine frame (Item 2) [A].
NOTE: Also see Cold Starting Procedure in the
Operation & Maintenance Manual.
Start the engine. After the engine is running, remove the
cable (Item 2) [A] connected to the frame first.
Disconnect cable from the starter terminal (Item 1) [A]. Keep arcs, sparks, flames and lighted tobacco
away from batteries. When jumping from
booster battery make final connection

(negative) at engine frame.
Do not jump start or charge a frozen battery.
Warm battery to 60°F. (16°C.) before connecting
to a charger. Unplug charger before connecting
or disconnecting cables to battery.
Damage to the alternator can occur if: Battery gas can explode and cause serious
injury.
• Engine is operated with battery cables W–2066–0490
disconnected.
• Battery cables are connected when using a
fast charger or when welding on the loader
(Remove both cables from the battery).
• Extra battery cables (booster cables) are
connected wrong.
I–2023–1285

LUBRICATION OF THE EXCAVATOR
Procedure
A
Lubricate the Hydraulic Excavator as specified in the 1
Service Schedule Page 1–1 for the best performance of
the machine. 2 2
Always use a good quality lithium based multi–purpose

grease when lubricating the machine. Apply the lubricant
until extra grease shows.
3
Ref. Description (# of Fittings)
1. Blade Cylinder Rod End (1) [A].
2. Blade Pivots (2) [A]. N–07397
3. Blade Cylinder Base End (1) [A].
4. Boom Cylinder Rod End (1) [B]. B

N–07398
5. Boom Pivot Pin (1) [C]. C

6. Boom Swing Bracket Pivot (2) [C]. 5 6
7. Boom Cylinder Base End (1) [C].
7 6
N–07399
8. Boom Cylinder Rod End (1) [D].

9. Dipperstick Cylinder Base End (1) [D].
D
9
N–07400

LUBRICATION OF THE HYDRAULIC EXCA VATOR
(Cont’d) A
Procedure (Cont’d) 10
Ref. Description (# of Fittings)
11
10. Dipperstick Cylinder Rod End (1) [A].
11. Dipperstick Pivot Pin (1) [A]. 12
12. Bucket Cylinder Base End (1) [A].
N–07401
13. Bucket Cylinder Rod End (1) [B]. B

14. Bucket Link Pivots (2) [B].
15. Bucket Pivots (4) [B].
14
15
13

15
14
15
N–07402
16. Boom Cylinder Base End (1) [C].

17. Swing Circle Pinion (1) [C]. C
16 17
N–07403
18. Swing Circle (2) [D].

D
18
N–07404

FINAL DRIVE CASE
220ExcavatorServiceManual(S/N508211999&Below)#6720230–PreventiveMaintenanceSection
Checking Oil Level

A
Put the machine on a flat level surface.
Position the plug (Item 1) [A] parallel to the ground. 1
Remove one of the plugs (Item 1) [A].
Add oil through the hole if the oil level is below the hole.
(See Fuel, Coolant and Lubricant Chart Page 8–9.)
Install and tighten the plug.
Repeat the procedure for the other side.
P–05906
Draining Final Drive Case
See the Service Schedule Page 1–1 for the
service interval.
correct B
Put the machine on a flat level surface with the plugs
positioned as shown in figure [A].
Remove the bottom plug (Item 1) [B] and the top plug 2
(Item 2) [B].
After the oil is removed, install and tighten the bottom

plug. 1
Add .33 quarts (0,3 L) of oil to the top plug hole. Install the
plug.
Use the same procedure for Checking Oil Level. Add oil P–05907
as needed.
Repeat the procedure for the other side.

HYDRAULIC SYSTEM
Page
Number
ARM CYLINDER
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–26
... HYDRAULIC
SYSTEM
BLADE CYLINDER
...
BOOM CYLINDER
...
BOOM SWING CYLINDER
...
BUCKET CYLINDER
...
HYDRAULIC CONTROL VALVE

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

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–29
....
HYDRAULIC PUMP
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–13
....
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
....
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–7...
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5 ...
HYDRAULIC RESERVOIR
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22 ...
Suction Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24
....
HYDRAULIC SERVICE INFORMATION

Checking The Main Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–3
..
SOLENOID VALVE
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–42
....
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–39
....
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–38
...
SWING CYLINDER LOCK VALVE
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–48
....
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–47
....
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–46
...

Revised July 97
220 (S/N 508211999 & Below)

Revised July 97258
26 of –2–2– Service Manual
27 of 258
28 of 258
29 of 258
30 of 258
31 of 258
32 of 258
33 of 258
34 of 258
HYDRAULIC SERVICE INFORMATION
A 1
When repairing hydrostatic and hydraulic

systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888 1 2
MC–01205
There are two main relief valves (Item 1) [A] and port
relief valves (Item 2) [A] in the hydraulic system. B
Checking The Main Relief Valves
The tools listed will be needed to do the following
procedure: 2
OEM1238
OEM1239 – Hydraulic Tester

6657708 – Test Fitting
6657709 – Hose Adapter 1
Stop the engine and raise the engine cover.
Disconnect the outlet hose (Item 1 or 2) [B] from the
hydraulic pump and connect that hose to the outlet of the N–07538
tester.
NOTE: Install the adapter 6657709 between outlet

hose of tester and outlet hose of the pump.
Remove the outlet fitting from the pump being tested and
install the test fitting 6657708.
Connect the inlet of the tester to the test fitting in the
pump.

Revised July 97
HYDRAULIC SERVICE INFORMATION (Cont’d)
Checking the Main Relief Valves (Cont’d)
A
NOTE: Open the flow control knob (Item 1) [A] fully
to prevent pump damage.
1
NOTE: Refer to the hydraulic flow chart valve
section.
Start the engine and run at low RPM. Make sure the tester
is connected correctly. If no flow is indicated at the tester,
the hoses are connected wrong.
Increase the engine speed to full RPM. W arm the N–11433
hydraulic fluid to 140 °F (60°C) by turning the restrictor
valve until the gauge reads about 1000 PSI (6895 kPa).
Do not exceed system pressure.
Stroke a cylinder to it’s limit, in the section being tested,
to open the relief valve.
The relief valve pressure should open at 2133 PSI (14707
kPa) ± 75 PSI. The flow should be 10.7 GPM (40,5 L/min.)
on a new pump.
Release the pressure on the cylinder being tested.

Close the flow control knob (Item 1)[A] slowly, to 100 PSI
below relief valve setting, and record the high pressure.
NOTE: The high pressure flow must be at least 80%

of free flow.
HIGH PRESSURE FLOW (GPM)

%= X 100
FREE FLOW (GPM)
If high pressure flow is less than 80% of free flow

, remove
the hydraulic pump for repair or replacement.
Repeat the testing procedure and use the samereadings
as shown above.
220 (S/N 508211999 & Below)

Revised July 97258
HYDRAULIC PUMP
Removal And Installation
A
1

the system. N–07537
I–2003–0888
Disconnect the two inlet hoses (Item 1) [A] from the B

hydraulic pump.
Drain the hydraulic fluid in a container.
Disconnect the two pressure hoses [B].

N–07538
Loosen the pump mounting bolts [C].

C
N–07539
Remove the bolts and washers from the pump flange[D].

D
N–07540

Revised July 97
HYDRAULIC PUMP (Cont’d)
Removal And Installation (Cont’d)
A
Remove the hydraulic pump from the bell housing [A].
N–07541
220 (S/N 508211999 & Below)

Revised July 97258
HYDRAULIC PUMP
Parts Identification
1. Snap Ring
2. Seal
3. Cover
4. Backup Ring
5. Backup Ring 5
6. Seal
7. Bushing
8. Bushing
9. Gear
10. Gear 12
11. Bushing 10 16
12. Bushing
13. Drive Coupler 8
14. Seal 6
5 4
15. Housing 14
16. Center Plate
17. Bushing
18. Bushing 15
19. Gear
20. Gear 13 14
21. Bushing
22. Bushing 11

23. Housing 9
24. Cover
25. Washer
26. Bolt 7
4 6
2 25
1 3
5
26
22
20
18 24
6
14 4
5
23
14
21
19
17
6
4
B–14926

Revised July 97
HYDRAULIC PUMP
A 1
Disassembly

the system. P–08236
I–2003–0888
Use solvent to clean the outside of thehydraulic pump of B

oil and dirt.
NOTE: During disassembly, put all parts on clean

work surface.
Clamp the mounting flange of the pump in a vise that has

padded jaws.

Mark the housing for ease of assembly.
Remove the four bolts (Item 1) [A] and washers.
Remove the cover [B]. P–08237
Remove the two back–up rings (Item 1) [C].

C
1
P–08238
Remove the two seals (Items 1 & 2) [D].

D
1
2
P–08239
220 (S/N 508211999 & Below)

Revised July 97258
A
Disassembly (Cont’d)
Remove the pump section body [A].
P–08240
Remove the back–up rings (Item 1) [B] from the bottom

of the pump section. B
1

P–08292
Remove the two seals (Items 1 & 2)[C] from the bottom
of the pump section. C
1
2
P–08241
Remove the two bushings (Items 1 & 2)

bottom of the pump section.
[D] from the
D
1 2
P–08242

Revised July 97
A
Remove the gears (Items 1 & 2) [A].
1 2
P–08243
Remove the two bushings (Item 1)[B] from the top of the
pump section. B

1
P–08244
Remove the center plate from the pump section [C].

C
P–08245
Remove the drive coupler (Item 1)[D] from the drive gear.
D
P–08246
220 (S/N 508211999 & Below)

Revised July 97258
A
Remove the two back–up rings (Item 1) [A].
1
P–08247
Remove the two seals (Items 1 & 2) [B].

B
2

1
P–08248
Remove the pump section [C].

C
P–08249
Remove the two back–up rings (Item 1) [D] from the

bottom of the pump section.
D
P–08250

Revised July 97
A
Remove the two seals (Items 1 & 2) [A] from the bottom
of the pump section.
1 2
P–08251
Remove the two bushings (Item 1)[B] from the bottom of

the pump section. B

1
P–08252
Remove the two drive gears (Items 1 & 2) [C] from the
bottom of the pump section. C
1 2
P–08253
Remove the two bushings (Item 1)[D] from the top of the
pump section.
D
P–08254
220 (S/N 508211999 & Below)

Revised July 97258
A
Remove the snap ring (Item 1) [A] and seal (Item 2) [A]
from the flange.
1
P–08255
Assembly
Clean all parts in solvent and dry with compressed air.
B
Apply clean hydraulic fluid to all seals and back–up rings.
Apply clean hydraulic fluid to the bushings and inside of
both pump sections.
Install the new seal (Item 2)[A] and snap ring (Item 1)[A].

Install the bushings (Item 1) [B] at the same time in the
pump section until they are flush with top surface. 1 2
NOTE: Install the bushings as shown towards the
intake side (large port) (Item 2) [B].
P–08254
NOTE: Do not force the bushings.
Turn the pump section over. Do not allow the bushings to C

drop out of the pump section.
Install the gears (Items 1 & 2) [C].
1 2
P–08253
Install the bushings (Item 1) [D].

D
intake side (large port) (Item 2) [D].
1
2
P–08252

Revised July 97
A
Assembly (Cont’d)
Apply oil and install the two new seals (Items 1 & 2) [A].
1 2
P–08251
Install the two new back–up rings (Item 1) [B] to the

bottom of the pump section. B

1
P–08250
Install the bottom pump section on the flange [C].

C
NOTE: Make sure the alignment marks are incorrect
alignment.
NOTE: Make sure the back–up rings and the seals

stay in their correct position when installing
the pump section on the flange.
P–08249
Apply oil and install the two new seals (Item 1 & 2) [D].
D
2
P–08248
220 (S/N 508211999 & Below)

Revised July 97258
A
Assembly (Cont’d)
Install the two new back–up rings (Item 1) [A].
1
P–08247
Install the drive coupler [B].

B

P–08246
Install the center plate [C].

C
P–08245
Install the bushings (Item 1) [D] at the same time in the

pump section until they are flush with the top surface. D
NOTE: Do not force the bushings.

intake side (large port) (Item 2) [D].
Turn the pump section over. Do not allow the bushings to

drop out of the pump section.
1
2
P–08244

Revised July 97
A
Assembly (Cont’d)
Install the gears (Items 1 & 2) [A].
1 2
P–08243
Install the bushings (Item 1) [B].

B
intake side (large port) (Item 2) [B].

1
2
P–08242
Apply oil and install the two seals (Items 1 & 2) [C].
C
1
2
P–08241
Install the back–up rings (Item 1) [D]. D
P–08292
220 (S/N 508211999 & Below)

Revised July 97258
A
Assembly (Cont’d)
Install the pump section on the center plate [A].
NOTE: Make sure the alignment marks are incorrect

alignment.
NOTE: Make sure the back–up rings and the seals

stay in their correct position when installing
the pump section on the flange.
P–08240
Install the two seals (Items 1 & 2) [B].

B
2

P–08239
Install the back–up rings (Item 1) [C].

C
P–08238
Install the cover [D]. D
P–08237

Revised July 97
A 1
Assembly (Cont’d)
Install the four bolts (Item 1) [A] and washers. Tighten to
34 ft.–lbs. (46 Nm) of torque in a crisscross manor.
Rotate the shaft to see if it rotates freely.
P–08236
220 (S/N 508211999 & Below)

Revised July 97258
HYDRAULIC CONTROL VALVE
Removal and Installation
A

I–2003–0888
Mark all the hoses and tubelines for correct installation.

B
Disconnect all the hoses for the boom, dipperstick and
bucket cylinders [A].
Remove the bolts from the tubeline clamp [B].

N–07543
Remove the tubeline clamp [C].

C
N–07544
Disconnect the two auxiliary hoses [D].

D
Remove the two fittings for clearance when removing the
control valve/control lever assembly.
N–07545

Revised July 97
HYDRAULIC CONTROL VALVE (Cont’d)
Removal and Installation (Cont’d)
A
Disconnect the hoses from the inlet section of the control
valve (both sides) [A].
N–07546
Disconnect all the tubelines and hoses from the control

valve [B].
B

N–07547
Disconnect the linkage from the boom swing and blade

control levers [C]. C
N–07548
Remove the bolts from the boom swing and bladecontrol

lever mounting bracket [D]. D
N–07549
220 (S/N 508211999 & Below)

Revised July 97258
HYDRAULIC CONTROL VALVE (Cont’d)
A
Remove the boom swing and blade control lever
assembly [A].
N–07550
Remove all the bolts from the control valve/control lever

mounting plate [B].
B
Lift the control valve/control lever assembly from the
machine.

N–07551

Revised July 97
HYDRAULIC RESERVOIR
A

I–2003–0888
Remove the engine and hydraulic pump from the

B
machine. (See Page 7–1.)
Remove the operator canopy.
Remove the seat and mounting frame. (See Page 5–1.)
Remove the fuel tank. (See Page 5–1.)

Mark all the hoses for correct installation.
Disconnect the three return hoses from the tee fittings on
the hydraulic filter housing [A].
Remove the hydraulic filter element [B]. N–07553
Remove the tee fittings [C].

C
N–07554
Loosen the filter housing from the reservoir [D].

D
N–07555
220 (S/N 508211999 & Below)

Revised July 97258
HYDRAULIC RESERVOIR (Cont’d)
A
Remove the filter element housing [A].
Remove the instrument panel and disconnect the wire
harness. (See Page 6–1.)
N–07556
Remove the lower mounting bolts from the hydraulic

reservoir [B].
B

N–07557
Remove the upper mounting bolts from the reservoir [C].

C
N–07558
Remove the bolts from the upright frame [D].

D
N–07559

Revised July 97
HYDRAULIC RESERVOIR (Cont’d)
A
Slide the upright frame away from the hydraulic reservoir
[A].
Lift and remove the hydraulic reservoir from the machine
[A].
N–07560
Suction Filter B
To remove and install the mesh screen filter from the
hydraulic reservoir, use the following procedure:
Remove the bolts from the mounting flange [B].

N–07561
Turn two bolts into the threaded holes in the mounting

flange to push the flange out of the reservoir [C]. C
N–07562
Remove the mesh screen and mounting flange assembly

from the reservoir [D]. D
Use clean solvent to clean the suction filter . Use air
pressure to dry the mesh screen.
N–07563
220 (S/N 508211999 & Below)

Revised July 97258
BOOM CYLINDER
220ExcavatorServiceManual(S/N508211999&Below)#6720230–HydraulicSystemSectionPart1of2

A
NOTE: Refer to Pages 2–29 through 2–31 for
servicing the cylinder.
Put the bucket on the floor. Stop the engine.

Support the boom using a chain hoist.
Move the hydraulic controls to release the hydraulic
pressure.
N–07564
B
the system.
I–2003–0888

Disconnect the two hoses from the boom cylinder.
Remove the retainer bolt and nut from the boom cylinder
base end pin [A].
N–07565
Remove the cylinder base end pin [B].

C
Lower the base end of the boom cylinder to the floor.
1
Remove the retainer bolt (Item 1) [C] and nut from the
cylinder rod end pin.
Remove the cylinder rod end pin. Remove the boom
cylinder from the boom.
N–07566

Revised July 97
ARM CYLINDER
A

Support the boom using a chain hoist.
pressure.
1
N–07567
B
use caps and plugs on hoses, tubelines and 1
the system.
I–2003–0888

Disconnect the two hoses from the arm cylinder [A].
Remove the retainer bolt (Item 1) [A] and nut from the
cylinder base end pin.
N–07568
Remove the cylinder base end pin.
Remove the retainer bolt (Item 1) [B] and nut from the
Remove the cylinder rod end pin.
Remove the cylinder from the arm.
220 (S/N 508211999 & Below)

Added July5897of 258 –2–26– Service Manual
BUCKET CYLINDER
A


1 2
pressure.
N–07568
When repairing hydrostatic and hydraulic B

the system.
I–2003–0888
1

Disconnect the two hoses (Item 1) [A] from the bucket
cylinder.
Remove the retainer bolt (Item 2) [A] and nut from the
cylinder base end pin [A].
N–07569
Remove the cylinder base end pin.
C
Remove the retainer bolt (Item 1) [B] and nut from the 3
Remove the cylinder rod end pin. 1
Remove the bucket cylinder.
BLADE CYLINDER 2
4

servicing the cylinder. N–07397
Put the blade on the floor . Stop the engine. Move the
blade control lever to release the hydraulic pressure.
Remove the hose fitting cover (Item 1) [C].
Disconnect the two hoses (Item 2) [C].
Remove the retainer bolt (Item 3) [C], nut and base end
pin from the blade cylinder.
Remove the retainer bolt (Item 4) [C] and nut from the
Remove the cylinder rod end pin. Remove the blade
cylinder.

Added
59 ofJuly
258 97 –2–27– Service Manual
BOOM SWING CYLINDER
A
servicing the cylinder. 1

systems, clean the work area before N–07570
the system. B
I–2003–0888
Remove the floor panels. (See Page 3–1). 1
Disconnect the grease tube (Item 1) [A] from the boom

swing cylinder base end pin.

Disconnect the hoses (Item 1) [B] from the cylinder.
Remove the retainer bolt from the cylinder base end pin.
Remove the cylinder base end pin. N–07573
end pin [C].

Remove the retainer bolt from the cylinder rod C
N–07571
Remove the cylinder rod end pin [D]. D

Remove the boom swing cylinder.
N–07572
220 (S/N 508211999 & Below)

HYDRAULIC CYLINDER (Melroe Cylinders)
Disassembly
A
NOTE: The drawings may not show the cylinder
exactly as it appears, but the procedure is
correct for all cylinders.
Put the base end of the hydraulic cylinder in a drain pan.

Move the rod in and out to remove the fluid from the
cylinder. Move the rod slowly so the fluid will go directly
into the drain pan.
Put the base end of the cylinder in a vise.
Use the adjustable gland nut wrencher (MEL1075) to B–07000
loosen the head [A].
Remove the rod assembly from the cylinder case [B].
B
Remove the cylinder case from the vise.
Put the rod end in the vise.

B–07001
FOR CYLINDERS USING PISTON RETAINING BOLTS:

C
Loosen the bolt from the piston end of the rod [C].
B–13745
FOR CYLINDERS USING PIST ON RETAINING LOCK

NUT: D
Loosen the nut from the piston end of the rod [D].
B–07002

Added
61 ofJuly
HYDRAULIC CYLINDER (Melroe Cylinders) (Cont’d)
A 2
1
Remove the bolt (Item 1) [A] from the rod.

3
Pull the piston off the rod (Item 2 ) [A].
Pull the head (Item 3) [A] off the rod.
CD–12677
Remove the O–ring (Item 1) [B] and back–up washer

(Item 2) [B] from the head with seal hook (MEL1074).
B
Remove the O–ring (Item 3) [B] from the head.

3
B–13743
Remove the wiper seal [C].

C
B–07005
Remove the oil seal from the head [D].

D
B–07006
220 (S/N 508211999 & Below)

A
FOR PISTONS WITH SINGLE RING GROOVE:
Cut the old teflon seal and remove the seal from the piston
[A].
B–03689
Remove the O–ring from the piston [B]. B

Wash the cylinder parts in solvent and air dry them.
While servicing the cylinder, do not damage the parts.
Inspect for nicks, scratches or otherwise damaged or
bent parts before assembling the cylinder. Replace parts
that appear damaged in any way. The cylinder may not
function correctly if there is damage to any of the parts.

Destroy all the O–rings and seals and replace them with
NEW O–rings and seals.
B–03703
Assembly
C
Install the O–ring on the piston [C].
B–12812
NOTE: Do not overstretch the seal. D

Install the seal on the tool (MEL1396) and stretch it until
it fits the piston [D].
Allow the O–ring to stretch for 30 seconds before
removing it from the tool.
B–12809

Added
63 ofJuly
Assembly (Cont’d)
A
Install the seal on the piston [A].
B–12813
Use a ring compressor to compress the seal to the correct

size [B].
B
Leave the piston in the ring compressor for 3 minutes.

B–12811
FOR PISTONS WITH THREE RING GROOVES:

C
Remove the two split rings (Item 1) [C] from the piston.
B–13736
Cut the old teflon seal and remove the seal from the piston
[D]. D
B–13738
220 (S/N 508211999 & Below)

Assembly (Cont’d)
A
Remove the O–ring from the piston [A].
Wash the cylinder parts in solvent and air dry them.
While servicing the cylinder do not damage the parts.
Inspect for nicks, scratches or otherwise damaged or
bent parts before assembling the cylinder. Replace parts
that appear damaged in any way. The cylinder may not
function correctly if there is damage to any of the parts.
Destroy all the O–rings and seals and replace them with
NEW O–rings and seals.
B–13737
Install the O–ring on the pistons center groove [B]. B

B–13739
NOTE: Do not overstretch the seal. C

Install the seal on the tool (MEL1396) and stretch it until
it fits the piston [C].
B–12809
Install the seal on the pistons center groove [D].

D
B–13742

Added
65 ofJuly
Assembly (Cont’d)
A
Use a ring compressor to compress the seal to the correct
size [A].
Leave the piston in the ring compressor for 3 minutes.
B–13740
Install the two outer split rings onto the piston [B]. B
NOTE: Position the gaps of the piston rings so that
they are at 180° from each other.

B–13741
Install the oil seal on the rod seal tool (MEL1033) [C].
C
NOTE: The O–ring side of the oil seal goes toward
the inside of the cylinder.
O–ring Side
B–03702
Install the oil seal in the head [D].

D
B–03671
220 (S/N 508211999 & Below)

Assembly (Cont’d)
A
Install the wiper seal with the lip toward the outside of the
head [A].
B–03682
Install the O–ring (Item 1) [B] onto the head. B

CD–12674
Install the back–up washer (Item 1) [C] and O–ring (Item

2) [C] onto the head. C 2
CD–12675
Apply grease to the inside of the head and to the lips of D

the seals.
Inspect the beveled edge of the rod for nicks or sharp
edges [D]. Remove these with a file prior to installing the
gland on the rod or damage to the seals may occur.
Install the head on the rod [D].
CD–12676

Added
67 ofJuly
Assembly (Cont’d)
A
FOR CYLINDERS USING PISTON RETAINING BOLTS:
Install the piston on the rod with the recessed end of the
piston toward the head [A].
Lubricate the retainer bolt with oil and install the retainer
bolt through the piston and into the rod.
Tighten the bolt to 185–215 ft.–lbs.(250–291 Nm) torque.
CD–12677
FOR CYLINDERS USING PIST ON RETAINING LOCK

NUT: B
Install the piston on the rod with the tapered end of the
piston towards the head [B].
Clean and dry the cylinder rod threads and install the new
nut (supplied with seal kit) [B].
With aluminum piston and 0.875 inch thread diameter ,
tighten the nut to 250 ft.–lbs. (339 Nm) torque.

With steel piston and 0.875 inch thread diameter, tighten
the nut to 300 ft.–lbs. (407 Nm) torque.
With steel piston and 1.000 inch thread diameter, tighten
the nut to 400 ft.–lbs. (542 Nm) torque. B–07002
Inspect the inside of the cylinder case for nicks and

scratches. If the cylinder case has minor scuf fing, the C
cylinder case can be honed [C]. Use a flexible hone and
lubricate with oil during the honing process.
Thoroughly wash the inside of the cylinder case after the
honing process.
N–12678
Put oil on the seal surface of the cylinder case [D].

D
B–07013
220 (S/N 508211999 & Below)

Assembly (Cont’d)
A
Put oil on the teflon seal on the piston [A].
B–13744
Install the rod assembly in the cylinder case [B].

B

B–07001
Put oil on the seals on the head [C].

C
Put oil on the threads of the head.
B–07014
Use the adjustable gland nut

tighten the head [D].
wrench (MEL1075) to
D
NOTE: Gland to be tightened until it is flush withthe
end of the cylinder case.
Move the rod in and out of the cylinder case and make
sure that it moves freely.
B–07000

Added
69 ofJuly
SOLENOID VALVE
1. Compensator
2. O–ring
3. O–ring
4. Back–up Ring 18
5. Valve Body 17
6. Plug
7. O–ring 24
8. Check Valve 23
9. O–ring 16
10. Back–up Ring 22
11. O–ring
12. Restrictor Plate 0.130” 15
13. Back–up Ring 14 21
14. O–ring 13 20
15. O–ring 12 19
16. Valve Stem
17. Coil
18. Nut
19. Back–up Ring
20. O–ring
21. O–ring
22. Relief Valve

23. O–ring
24. Plug
6
7
3
4
4
3
4
4
3
2 11
10
1 9
8
B–14927
220 (S/N 508211999 & Below)

SOLENOID VALVE
A
Disassembly
Clamp the valve in a vise that has padded jaws.
Remove the nut (Item 1) [A] and coil (Item 2)[A] from the
valve stem. 2
P–08627
Remove the valve stem (Item 1) [B] from the valve body.
B
1

P–08628
Remove the restrictor plate (Item 1) [C] from the valve

body. C
P–08629
Remove the O–rings (Item 1) [D] and back–up ring (Item

2) [D] from the valve stem. D
2
1 1
P–08630

Added
71 ofJuly
SOLENOID VALVE (Cont’d)
A
Remove the relief valve (Item 1) [A] from the valve body.
P–08631
Remove the plug (Item 1) [B] from the end of the relief
valve. B
1

P–08632
Remove the O–ring (Item 1)[C] from the plug (Item 2)[C]. C
Remove the O–ring (Item 3) [C] and back–up rings (Item
4) [C] from the relief valve.
2 4
3 3
1
P–08633
Remove the check valve (Item 1)[D] from the valve body.
D
P–08634
220 (S/N 508211999 & Below)

A
Remove the O–ring (item 1) [A] and the seal (Item 2) [A]
from the check valve.
1 2
P–08635
Remove the compensator valve (Item 1) [B] from the

valve body. B

P–08636
Remove the O–rings (Item 1)[C] and back–up rings (Item

2) [C] from the compensator valve.
C
2 2 2
1 1
P–08637
Remove the plug (Item 1) [D] from the valve body. D 1
P–08638

Added
73 ofJuly
A
Remove the O–ring (Item 1) [A] from the plug. 1
Assembly
Clean all parts in solvent and dry with compressed air .
The valves are not serviceable. If the valves do not
operate correctly after cleaning, the relief valves must be
replaced. Order new valves from Melroe Parts.
Apply oil and install a new O–ring (Item 1)[A] on the plug. P–08639
Install the plug (Item 1) [B] in the valve body. B 1

P–08638
[C] and back–up

Apply oil and install new O–rings (Item 1)
rings (Item 2) [C] on the compensator valve.
C
2 2 2
1 1
P–08637
Dip the compensator valve in clean hydraulic fluid.

D
Install the compensator valve (Item 1) [D] in the valve
body.
P–08636
220 (S/N 508211999 & Below)

A
Assembly (Cont’d)
[A] and seal (Item
Apply oil and install new O–ring (Item 1)
2) [A] on the check valve.
1 2
P–08635
Install the check valve (Item 1) [B] in the valve body. B

1
P–08634
Apply oil and install a new O–ring (Item 1)[C] on the plug
(Item 2) [C].
C
[C] and back–up
ring (Item 4) [C] on the relief valve. 2 4
1 3 3
P–08633
Install the plug (Item 1) [D] in the end of the relief valve. D
1
P–08632

Added
75 ofJuly
A
Assembly (Cont’d)
Dip the relief valve (Item 1)[A] in clean hydraulic fluid and
install in the valve body.
P–08631
Make sure the restrictor plate (Item 1) [B] orifice is open.

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

P–08629
[C] and back–up

ring (Item 2) [C] on the valve stem.
C
2
P–08630
Dip the valve stem (Item 1)[D] in clean hydraulic fluidand

install in the valve body. D
1
P–08628
220 (S/N 508211999 & Below)

A
Assembly (Cont’d)
Install the coil (Item 1)[A] and nut (Item 2)[A] on the valve
stem.
Tighten to 4–6 ft.–lbs. (5–8 Nm) torque.
1
NOTE: If the coil is over torqued it may cause valve
failure. 2
P–08627

Added
77 ofJuly
1. Plug
2. O–ring
3. Spring
4. Ball
5. Check Valve Body
6. O–ring
7. Back–up Ring 1
8. Spool
9. Valve Body
2

5
C–03458
220 (S/N 508211999 & Below)

A
Disassembly 2 1
Before disassembly:
Clean the outside of the valve.
Disassemble the valve in a clean area.
Clamp the valve (Item 1)[A] in the vise, with padded jaws,
and remove the check valve (Item 2) [A] (both sides).
P–08320
Clamp the check valve (Item 1) [B] in the vise, with

padded jaws, and loosen the cap (Item 2) [B] (on both
valves).
B
2
1

P–08321
Remove the cap (Item 1) [C] the spring (Item 2) [C] and
the check ball (Item 3) [C] from the check valve (Item 4)
[C].
C
Remove the O–ring (Item 5) [C] from the cap (Item 1)[C] 4
1 2
(on both valves).
5 3
P–08322
Remove the large O–ring (Item 1) [D], the small O–ring

(Item 2) [D] and the backup ring (Item 3) [D] from the D
check valve (Item 4) [D] (on both valves).
4 3
1 2
P–08323

Added
79 ofJuly
SWING CYLINDER LOCK VALVE (Cont’d)
A 2
Remove the spool (Item 1) [A] from the valve body (Item
2) [A].
NOTE: Be careful not to scratch or damage the

spool.
1
P–08324
Assembly
B
Before assembly:
1 2
Clean all parts with solvent and dry with
compressed air.
Put oil on all O–rings.
4
[A] in the valvebody
Apply oil and install the spool (Item 1)

(Item 2) [A].
Install the large O–ring (Item 1)[B] the small O–ring (Item
2) [B] and the backup ring (Item 3)[B] on the check valve 3
(Item 4) [B].
P–08323
Install the O–ring (Item 1) [C] on the cap (Item 2) [C].

C
Install the check ball (Item 3) [C] the spring (Item 4) [C].
5
Install the cap (Item 2) [C] in the check valve (Item 5)[C] 2
and tighten by hand. 4
1 3
P–08322
Clamp the check valve (Item 1) [D] in a vise with padded

jaws, and tighten the cap (Item 2) [D]. D
2
1
P–08321
220 (S/N 508211999 & Below)

SWING CYLINDER LOCK VALVE (Cont’d)
A
Assembly (Cont’d) 2 1
Clamp the valve (Item 1) [A] in a vise with padded jaws
and tighten the check valve (Item 2) [A] (both sides).
P–08320

Added
81 ofJuly
220ExcavatorServiceManual(S/N508211999&Below)#6720230–HydraulicSystemSectionPart2of2
220 (S/N 508211999 & Below)

DRIVE SYSTEM
Page
Number
CONTROL AND STEERING LEVERS

Boom/Bucket Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–5 ..
Control Lever Lock Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–4 ..
Steering Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–6
...
Swing/Arm Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3 ...
DRIVE MOTOR DRIVE

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–19
.... SYSTEM
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9
....
FINAL DRIVE
...
FLOOR PANEL
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
...


FLOOR PANEL
A
Remove the knobs from the control levers.
Remove the rubber boots from the control levers.
Remove the three bolts from the control lever cover [A].
N–07574
Remove the cover over the top of the control levers [B]. B

N–07575
Disconnect the linkage from the auxiliary foot pedal [C].

C
CD–07576
Remove the floor panel bolts [D].

D
N–07577

FLOOR PANEL (Cont’d)
A
Remove the floor panel from the machine [A].
N–07578

CONTROL AND STEERING LEVERS
Swing/Arm Control Lever
A
Use the following procedure to remove and install the
swing/arm control lever:
NOTE: The control valve and control levers are

removed from the machine as an assembly .
(See Page 2–3 for the correct procedure.)
Remove the retainer bolt from the shaft for the bellcrank
[A].
N–07579
Disconnect the control linkage from the bellcrank [B].

B

N–07580
Remove the shaft (Item 1) [C] from the bellcranks.

C
N–07581
Remove the nut at the control lever pivot bolt. Remove

the
control lever assembly [D]. D
N–07582

CONTROL AND STEERING LEVERS (Cont’d)
Swing/Arm Control Lever (Cont’d)
A
Remove the snap ring and washers from the pivot shaft
[A].
N–07583
Remove the control lever. Inspect the parts for wear .

Check the roller bearings [B]. B
Replace the parts as needed.

N–07584
Control Lever Lock Mechanism

C
Remove the swing/arm control lever. (See Page 3–3.)
Disconnect the spring [C].
N–07585
Remove the bolts from the lock mechanism mounting

bracket [D]. D
N–07586

A
Control Lever Lock Mechanism (Cont’d)
Remove the lock lever and mounting bracket assembly
[A].
N–07587
Disconnect the linkage from the control valve spool [B]. B

N–07588
Remove the bellcrank and linkage [C]. C

Inspect the parts and replace as needed.
N–07589
Boom/Bucket Control Lever

D
Disconnect the linkage from the bellcrank [D].
N–07590

Boom/Bucket Control Lever (Cont’d)
A
Remove the snap ring and washers [A].
Remove the control lever.
N–07591
Inspect all the parts. Check the roller bearings [B]. B

Replace the parts as needed.

CD–07952
Steering Levers
C
Disconnect the linkage from the bellcranks.
Remove the two roll pins (Item 1)[C] from the pivot shaft.
Remove the shaft and remove the steering levers.
Inspect the parts and replace as needed.
1
1
N–07593

DRIVE MOTOR
A
Remove the bolts from the track frame cover [A].
Installation: Tighten the bolts to 48 ft.–lbs. (65 Nm)
torque.
N–07594
Remove the cover [B]. B

Lift and block the side of the track frame where the final
drive motor will be removed.
Release the track tension and remove the track. (See
Page 5–8.)

When repairing hydrostatic and hydraulic CD–07595
ports to keep dirt out. Dirt can quickly damage C
the system.
I–2003–0888
Mark the hoses for correct installation.

Disconnect the hoses from the drive motor [C].
N–07596
Loosen and remove the final drive mounting bolts [D].

D
Installation: Put LOCTITE on the bolts and tighten to 80
ft.–lbs. (108 Nm) torque.
N–07597

DRIVE MOTOR (Cont’d)
A
Remove the motor , sprocket and reduction gear
assembly from the track frame [A].
N–07598

A

the system.
I–2003–0888
P–00335
The following tool will need to be fabricated by a local

machine shop for reassembly purposes:
B
Floating Seal Installation Tool. (See Page 3–20.)
Disassembly
Remove the drain plugs from the end cover of the drive
motor. Drain the oil into a container [A].

Remove the two spool caps from the valve end cover[B].
P–00336
Remove the spring and washer from each end of the

housing and remove the spool [C]. C Spool
Washer
Spring
P–00337
To disassemble the spool, insert a hardened pin through

the hole in the spool gland and use a vise with protective
jaws to hold the spool [D].
D
Remove the two end plugs from the ends of the spool.
Hardened Pin
NOTE: DO NOT use any type of clamp tool on the
spool. Any marring or scratches in the spool
and the spool must be replaced.
P–00338

Added
93 ofJuly
A
Remove the spring (Item 1) [A] and the poppet (Item 2)
[A] from the ends of the spool. 1 1
Use solvent and clean all spool components.
Dry with compressed air.
2 2
P–00340
Remove the six bolts holding the valve end plate onto the
housing [B].
B

P–00341
Lift off the valve end plate and remove thetwo dowel pins
(Item 1) [C] and the O–ring (Item 2) [C]. C
3
NOTE: The dowel pin (Item 3) [C] is staked into the 1
valve plate end cover. Do not remove unless
damaged.
2 1
P–00342
Remove the bearing from the valve end plate [D].

D
Use a slide hammer bearing puller.
P–00344

A
Bronze Side
Remove the valve plate [A].
NOTE: The bronze side of the valve plate goes

towards the rotating group.
P–00343
Remove the rotating group from the motor housing [B].

B

P–00345
Disassemble the pistons (Item 1) [C], retainer plate (Item

2) [C], conical spacer (Item 3) [C], the three pins (Item 4)
[C] from the piston housing (Item 5) [C].
C 5
3
1
4
P–00348
Turn the piston housing over and remove the snap ring
from the housing [D].
D
Install a bolt and flat washer through the center of the
piston housing. The outer diameter of the washer should
be smaller than the snap ring but larger enough to make
good contact with the spring spacer top face. Install a nut
on the bolt and tighten until the spring is compressed.
Remove the snap ring and loosen the nut to remove the
spring.
NOTE: The spring inside the piston housing is

under pressure, use care when removing the
snap ring from the piston housing.
P–00350

Added
95 ofJuly
A
Remove the snap ring (Item 1) [A], collar (Item 2) [A],
spring (Item 3) [A] and the collar (Item 4) [A] from the 3
piston housing. 4
2 1
P–00354
Turn the motor over and remove the end cap retaining
plug from the side of the housing [B].
B

P–00355
Install two 3/8 PT metric bolts (or eye bolts) into the drain
plug holes. Use a bar between the bolts (or through the C
eyebolts) and turn the cover counterclockwise to remove
the cover [C].
P–00357
Remove the O–ring from the end cover [D].

D
P–00346

Added July96
92of 258 –3–12– Service Manual
A
Remove the thrust plate from the planetary assembly[A].
P–00347
Lift the planetary assembly from the motor housing [B]. B

P–00349
Remove the planetary pin by driving the spring pin into the
center of the planetary pin [C]. C
P–00353
Remove the pin (Item 1) [D], bearing (Item 2) [D], and

gear (Item 3) [D] from the planetary assembly. D
NOTE: The spring pin (Item 4) [D] that was driven
into the center of the planetary pin (Item 1) 1
[D], will now have to be driven out of the 2 3
planetary pin.
4
P–00359

Added
97 ofJuly
A
Remove the planetary thrust washer from the housing
[A].
P–00352
Remove the center driveshaft from the housing [B]. B

P–00356
Remove the gearhub from the housing [C].

C
Snap Ring
NOTE: The snap ring does not need to be removed
unless damaged.
P–00358
Remove the plug from the housing (closest to the flange)

[D]. D
NOTE: The second plug does not need to be
removed unless there is leakage or damage.
P–00362

Added July98
A
Steel Balls
Remove the 109 or 110 steel balls that are used to retain
the motor housing to the hub bearing [A] & [B].
The balls must be removed through the plug hole. Use
solvent and flush oil off of the steel balls and the mating
surfaces of the bearing and motor housing.
Use a magnet and remove the exposed steel balls from
the plug hole. Use short bursts of compressed air to force
the first few steel balls to the plug hole and remove these
with the magnet. Continue this process until no more balls
will appear at the plug hole.
P–00363
NOTE: Use care with the following process not to
allow the wire to become lodged or to break
off inside the motor. B Wire
Use a length of 16 gauge mechanics wire and bend a
tight, close loop at one end of the wire. Insert
the wire into
the plug hole and carefully feed the wire around the
diameter of the bearing and force the steel balls to the
hole. Remove the exposed balls with a magnet and Steel
continue this process until all 109 balls are removed and Balls
the end of the wire is visible through the hole. Carefully

remove the wire. DO NOT break the wire of f inside the
housing when removing the wire.
MC–01678
Use a three jaw puller and remove the motor housing[C].

C
P–00364
Drive the three spring pins into the planetary pins on the
internal planetary assembly [D].
D
P–00311

Added
99 ofJuly
A
Bend a hook onto a piece of stiff wire and use this wire to
hook the spring pin in the center of theplanetary pins and
pull the planetary pins out of the housing [A].
P–00314
Remove the thrust washers (Item 1) [B], gear (Item 2)

[B], spacer (Item 3) [B], bearing (Item 4) [B] and the pin
B
(Item 5) [B] from the housing.
With the planetary pins (Item 5) [B] removed, the spring
pins (Item 6) [B] will now have to be driven out of the
center of the planetary pins. 4
1 2

1
5
6 3
P–00317
Remove the three set screws from thehousing [C]. These

set screws retain the bearing nut from loosening from the C
housing.
P–00315
If a bearing nut tool of the correct size is available, use it

to remove the bearing nut. If a tool is not available, use a D
punch and hammer and tap the outer diameter of the
bearing nut to remove it from the motor hub [D].
P–00316

Added July100
A
Carefully remove the double race bearing from the hub
[A].
NOTE: The inner and outer races of this bearing are

not permanently retained to each other. If not
lifted off as an assembly , the races will
separate and the steel balls will come loose.
P–00313
Remove the top half of the floating seal from the hub[B]. B

P–00321
Use a screw driver and pry the lower half of the floating
seal from the hub and remove [C]. C
P–00320
Use a punch and tap the swash plate and drive shaft out D
of the center of the hub [D].
P–00322

Added July
101 of 258 92 –3–17– Service Manual
A
Remove the seal from the hub [A].
P–00318
Press the drive shaft and bearing out of the swash plate
[B].
B
NOTE: The dowel pin in the swash plate is
removable, but do not remove it unless it is
damaged.

P–00325
Press the bearing off of the drive shaft [C].

C
Inspect all parts for damage and replace parts as
necessary. Use new seal and O–rings when assembling
the drive motor.
P–00326

Added July102
Assembly
A
Press a new bearing onto the driveshaft [A].
Press only on the internal bearing race surface.
P–00328
Press the bearing and driveshaft into the swash plate[B].

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

P–00330
Install the seal into the hub [C].

C
NOTE: The lipside of the seal faces upwards as
viewed in [C].
P–00329
Align the dowel pin on the swash plate with the hole in the
hub [D]. D
NOTE: Use a plastic or wood dowel and tap the face
of the swash plate to seat the swash plate to
the hub. Dowel Pin
NOTE: DO NOT mar or scratch the face of the swash
plate or it will have to be replaced.
P–00323

Added July
Assembly (Cont’d)
A 170 mm
160 mm
Floating seal installation tool [A]. This tool can be made 6.9 142.8/143 mm
mm
by a local machine shop. 7.3 141.5/141.8 mm
7.9/8.1 mm
20.1 mm
5 mm 132/133 mm
142.8 mm
143.0 15°
R 0.3 mm
R 0.2 mm
MC–01678
Apply petroleum jelly to the O–ringof the floating seal [B]. B

Install the floating seal into the installation tool [B].
NOTE: The O–ring side of the floating seal is

upwards in the installation tool as viewed in
[B].

P–00333
Apply petroleum jelly to the floating seal surface of the

hub. C
Turn the floating seal and installation tool over and set in
place in the hub [C].
Using both hands, evenly press down on the installation
tool to insert the floating seal into the hub [C].
P–00327
Install the other half of the floating seal onto the hub [D].
Apply petroleum jelly to the O–ring of the floating seal.
D
NOTE: The O–ring of the floating seal faces

upwards.
P–00321

Added July104
Assembly (Cont’d)
A
Carefully install the double roller bearing onto the hub[A].
P–00313
Install the bearing nut onto the hub [B]. B

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

P–00319
Install the three retaining set screws [C].

C
Tighten the set screws to 22–29 ft.–lbs. (30–39 Nm)
torque.
After set screws are torqued, use a center punch and
stake the hub to the set screws.
P–00315
Apply oil to the inner planetary bearings. Install the

spacer, bearing and the thrust washers into the hub D
planetary. Insert the planetary pins and drive the spring
pin through the hub and into the planetary pin.
Use a center punch and stake the hub to the spring pin
[D].
P–00306

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

squarely onto the hub so that the planetary
gears do not shave metal off of the housing
splines. If this happens the housing and the
planetary gears will be damaged.
P–00334
Insert the 109 steel balls into the hole in the side of the hub
[B]. B
Steel Balls

P–00363
Install the plug into the hub [C]. C

Tighten the plug to 5–6 ft.–lbs. (7–9 Nm) torque.
P–00362
Install the snap ring onto the gear hub (if previously D Snap Ring
removed) and install the gear hub intothe planetary gear
assembly [D].
NOTE: The gear hub must be installed with the

narrow section of the gear upwards (when
viewed using the snap ring as the dividing
line).
P–00358

Added July106
Assembly (Cont’d)
A
Install the center driveshaft through the center of the gear
hub [A].
P–00356
Install the planetary thrust washer onto the planetary hub

[B].
B

P–00352
Assemble the planetary assembly by installing the C

bearing (Item 2) [C] into the gear (Item 3) [C].
Install the gear (Item 3)[C] into the planetary housing and
insert the planetary pin (Item 1) [C] through the gear . 1 3
Align the hole in the planetary pin and the planetary 2
housing and install the spring pin (Item 4) [C].
4
P–00359
Use a center punch and stake the planetary hub to the

spring pin [D]. This will prevent the spring pin from D
working out of the planetary hub.
P–00360

Added July
Assembly (Cont’d)
A
Install the planetary gear assembly intothe motor housing
[A].
The planetary hubs internally splined collar will face
downwards into the housing. The external surface of the
collar must fit over the previously installed thrust washer
and the splines must match up with the gear hub. Rotate
the motor housing to align the gears and the splines.
P–00349
Install the thrust plate onto the planetary gear assembly

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

P–00347
Install a new O–ring onto the end cover [C]. Apply oil to
the O–ring. C
P–00346
Install the two 3/8 PT metric bolts (or eyebolts) into the
drain plug holes in the end cover [D]. D
Install the end cover into the housing and use a bar to
tighten the end cover into the housing. T ighten the end
cover until the hole in the side face on the cover is
centered into the hole in the side of the housing.
P–00357

Added July108
220ExcavatorServiceManual(S/N508211999&Below)#6720230–DriveSystemSectionPart1of2
Assembly (Cont’d)
A
Install the dog point set screw into the side of thehousing
[A]. The point of the set screw must seat freely into the
hole in the end cover. Adjust the end cover until the hole
in the housing and the hole in the cover align properly.
Tighten the set screw to 13–18 ft.–lbs. (18–24 Nm)
torque.
P–00355
Install the collar (Item 1) [B], spring (Item 2) [B], collar

(Item 3) [B] and snap ring (Item 4) [B] into the piston
B
housing.
Install a bolt and a flat washer through the
spacers and the
spring. Insert these parts through the piston housingand 1 2
install a nut. The outer diameter of the washer should be 3 4
smaller than the inner diameter ofthe snap ring, but large
enough to make good contact with the spring spacer top
face. Tighten the nut to compress the spring and install

the snap ring. Loosen the nut and remove the bolt and
washer.
P–00354
Assemble the rotating group by applying petroleum jelly

to the three pins (Item 4) [C]. Insert the pins (Item 4) [C] C
into the notches in the splined inner diameterof the piston 5
housing (Item 5) [C]. Set the conical spacer (Item 3) [C]
over the pins (Item 4)[C] and on top of the piston housing 3
(Item 5) [C]. Insert the pistons (Item 1) [C] into the 1
retainer plate (Item 2) [C]. Apply clean hydraulic fluid to
the outer diameter of the piston (Item 1)[C] and insert the
pistons into the piston housing (Item 5) [C].
2
4
P–00348
Turn the drive motor on its side and apply oil to the face
of the swash plate. Install the rotating groupinto the drive D
motor hub and onto the piston driveshaft [D].
P–00345

Added July
Assembly (Cont’d)
A
Install a new O–ring into the groove in themotor face [A].
P–00305
Press the bearing into the valve end plate [B]. B

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

P–00332
Apply a film of petroleum jelly to the steel face of the

valve
plate. Install the valve plate (bronze side faces upwards) C
onto the valve end plate [C]. The notch in the valve plate
must align with the dowel pin in the valve end plate.
Dowel Pin
P–00309
Insert the two dowel pins into the drive motor hub and
install the valve end plate onto the drive motor [D]. D
Dowel Pin
P–00310

Added July110
Assembly (Cont’d)
A
Install the six bolts into the valve end plate [A].
Insert a pin through the holes in the hub and the housing
to keep the hub from rotating and tighten the six bolts.
Tighten the bolts to 21–26 ft.–lbs. (29–35 Nm) torque.
Remove the pin that was installed to keep the hub and
housing from rotating.
P–00341
Apply oil to the outer diameter of the poppets and install

the poppets (tapered end in first) into the spool[B]. Install
B
the spring into the cavity of the poppets. Install a new
O–ring onto the end plugs [B].

P–00340
Insert a hardened dowel pin through the hole in the spool

gland and use a vice with protective jaws tohold the spool
from turning. Tighten the end plugs [C]. C
Tighten the plugs to 18–21 ft.–lbs. (24–29 Nm) torque.
Hardened Pin
P–00338
Apply oil to the spool and install the spool into the valve
end plate [D].
D Spool Washer
Install the washer over the end of the spool and the
spring
[D].
Spring
P–00337

Added July
220ExcavatorServiceManual(S/N508211999&Below)#6720230–DriveSystemSectionPart2of2
Assembly (Cont’d)
A
Install a new O–ring on the end plugs. Apply oil to the
O–rings and install the plugs.
Tighten the plugs to 86–101 ft.–lbs. (117–137 Nm) torque
[A].
P–00336
NOTE: Before the drive motor can be put into

service, gear lube 90 will need to be added to
B
the drive motor. See Page 1–1 1 for oil
installation and checking procedure.
Install the three end plugs into the end cover [B].
Tighten the two outer plugs (M8) to 21–29 ft.–lbs. (29–39

Nm) torque.
P–00335

Added July112
UPPER WORKS AND SWING SECTION
Page
Number
CENTER SWIVEL JOINT

Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–30 ..
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–30
..
SWING CIRCLE GEAR

..
SWING MOTOR
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6,
. . . . 4–14
Brake Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–24 ...
Brake Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–22 ..
Brake Valve Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–21 ..
Brake Valve Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–26 ... UPPER WORKS
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–5,
. . . 4–9 &
Motor Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–7
... SWING SECTION
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4,
. . . 4–8
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–3 ..
UPPER WORKS
Alignment Pin Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–28..

Alignment Screw Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–29 ..
..
Swing Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–29
..

Revised
113 of July

Revised July
11497
of 258 –4–2– Service Manual
SWING MOTOR
A
Remove the seat and seat mounting frame. (See Page
5–1.)
When repairing hydrostatic and hydraulic N–07599

ports to keep dirt out. Dirt can quickly damage B
the system.
I–2003–0888
Mark the hoses for correct installation.

Remove the hoses.

Remove the mounting bolts [A]. On early production
machines, quantity four, on later production machines,
quantity six bolts.
Tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque.
N–07600
Remove the swing motor from the machine [B].

Revised
115 of July
SWING MOTOR
1. Bolt
2. Housing
3. Plug
4. O–ring
5. Spring
6. Pin
7. Seal
8. Plate
9. Valve
10. O–ring
11. Plate
12. Drive
13. Geroler
14. Drive 15
15. Plate 17 10 16
16. Seal
17. Snap Ring
18. Housing
19. Shaft 23
20. O–ring
21. Retainer 18
22. Seal 19
23. Bolt
20

21
22
5
6
7
9
11 5
6 2
4
10 8
3
10
14
12
13
10
B–13496

Revised July
11697
SWING MOTOR (Cont’d)
Disassembly
A 4 Quad Seal 2
Cap
Screw (8)
Clean the motor and drain the oil from the motor.
5 3
Use a soft jaw vise to hold the motor by the mounting
flange. Square Cut Seal
Seal Retainer
NOTE: Do not disassemble the geroler (Item 1) [A].
The geroler has machined close tolerances.
Damage may occur during reassembly. Race Seal Shaft
and O–ring
Mark the bearing housing by the alignment groove for
assembly. The alignment groove aligns the case drain
hole in the valve housing.
Shaft and
Disassemble the motor. Bearing Housing
NOTE: The cap screws (Item 2) [A] are held by thread Square Cut
bonding adhesive. DO NOT exceed 70 in–lbs. Seal Retaining
to remove the screws. Use a propanetorch to Ring
heat the screw heads. This will melt the
adhesive on the screws. Shift Face
Seal
Discard the screws and remove the seal retainer (Item 3)
[A]. Wear
Plate
Remove the quad seal (Item 4) [A] and the square cut Square Cut
seal (Item 5) [A] from the retainer. Seal Drive

NOTE: Check the seal retainer for cracks. Order a
new retainer from Melroe Parts, if needed. 1
Geroler
Square Cut
Seal Valve
Drive
Valve
Plate
Square Cut
Seal
Valve
Balance
Inner and Outer Ring
Face Seals
Pin and
Plug Spring
O–ring Valve
Housing
Bolt (4)
B–13496

Revised
117 of July
Assembly
A
1
4

ports to keep dirt out. Dirt can quickly damage 2 1
the system. B–13401
I–2003–0888
NOTE: Order a swing motor repair kit from Melroe

Parts.
Clean the seal surfaces on the retainer (Item 1) [A] and

install a new quad seal (Item 2) [A] and the square cut
seal (Item 3) [A] in the retainer.
Lubricate the inner edge of the quad seal and the square

cut seal with petroleum jelly.
Install the retainer on the motor using two cap screws
(Item 4) [A] 180° from one another.
Tighten the cap screws to 60 in–lbs (6,7 Nm) torque.
Screw the tap (from the kit) in and out of the six remaining
holes.
Use compressed air to blow loose particles from the
holes.
Apply clean solvent to each hole and blow them dry.
Wash the new cap screws in solvent, blow them dry and
apply two or three drops of thread adhesive (LOCTITE
#609) to the threads.
Install the new cap screws in the six holes and tighten to
60 in–lbs. (6,7 Nm) torque.
Remove the two cap screws installed earlier.
Repeat the hole cleaning procedure, apply two or three
drops of thread adhesive (LOCTITE #609) to thethreads.
Install the screws and tighten to 60 in.–lbs. (6,7 Nm)
torque.

Revised July
11897
Assembly (Cont’d)
A Wear Plate Shaft Face
Seal
Clamp the shaft and bearing housing so the output shaft

is down.
Pour a small amount of clean hydraulic fluid into the shaft
and bearing housing for start–up lubrication.
Shaft
Install the shaft face seal and wear plate as shown [A].
Install the drive, Geroler and valve drive.
Shaft and Bearing

Housing B–13495
Motor Timing
B Rotate Valve
Clockwise Until
The direction that the output shaft rotates is determined Spline Teeth
by timing. Time the motor as follows: Mesh
Valve
[B].
Locate the largest open pocket in the Geroler (Item 1)
Align One of the
Install the valve plate (Item 2)[B] and locate the open slot Valve Side
that is over the largest open Geroler pocket. Opening With the

Valve Largest Open
Align one of the side openings in the valve with the valve Geroler Pocket
plate slot that is over the largest open Geroler pocket. Plate
2
Engage the valve with the valve drive (Item 3) [B] by
rotating it clockwise until the spline teeth mesh (1/2 tooth).
3
Valve
Drive
Alignment
Geroler Groove
1
Largest Open
Pocket
B–13495
Install the inner and outer face seals on the balance ring
as shown [C].
C
Install the springs, pins and balance ring in the valve Pin Notch
housing. Hold the balance ring in place, through the Inner Face
forward port in the valve housing, while installing the valve Seal
housing over the valve. Outer Face
Seal
Install and tighten the four bolts in a crisscross pattern.
Tighten the bolts to 37 ft.–lbs. (50 Nm) torque. Tighten the
case drain plug to 50 in.–lbs. 95,5 Nm) torque.
Balance Ring
B–13495

Revised
119 of July
SWING MOTOR
1. Plug
2. O–ring
3. Ball
4. Bolt
5. Plug 32
6. O–ring
7. Housing
8. O–ring 31
9. Spring 30
10. Pin
11. Seal
12. Seal 29
13. Plate
14. Valve
15. O–ring 20 28
16. Plate
17. Drive 8
18. O–ring
19. Geroler
20. Drive 19 27
21. Plate
22. Seal
23. Snap Ring
24. Bearing

25. Housing 18
26. Bearing 26
27. Gear
28. O–ring 17
29. Retainer 8
30. Bolt
31. Seal 16 25
32. Back–up Ring
15 24
14 23
18
13
12 22
11
10 21
9
8
6
5 18
7
3
2
4
1
B–12743

Revised July
12097
SWING MOTOR
A
Disassembly
1
Drain the hydraulic fluid from the swing motor.
Clean the swing motor with cleaning fluid and dry.

systems, clean the work area before P–08210
the system.
I–2003–0888
B
Clamp the swing motor in a vise that has soft or padded

jaws.
Remove the two fittings (Item1) [A] from the connectors.
Remove the brake valve (Item 2) [A] from the swing

motor.
1
Remove the two connectors (Item 1) [B] from the swing
motor.
P–08211
Remove the plug (Item 1) [C] and O–ring.

Remove the plug (Item 2) [C].
C
P–08212
Remove the two plugs (Item 1) [D], O–rings (Item 2) [D]

and check balls (Item 3) [D] from the top of the swing
motor. D
2
1
1 3
P–08213

Revised
121 of July
A 1
Mark the motor sections for ease of assembly [A].
Remove the four bolts (Item 1) [A] from the top of the
motor. 2
Remove the valve housing (Item 2) [A] from the motor.
P–08214
Remove the balance ring (Item 1) [B], inner seal (Item 2)

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

2
4
P–08215
Remove the two alignment pins (Item 1) [C] and springs

(Item 2) [C] from the valve housing. C
2
1
1
P–08216
Remove the valve (Item 1) [D] from the motor.

D
NOTE: See page 4–19 for timing the motor when
installing the valve, valve drive and geroler.
P–08217

Revised July
12297
A
Remove the valve plate (Item 1) [A].
P–08218
Remove the two O–rings (Item 1) [B] from the bottom of

the valve plate. B
Remove the valve drive shaft (Item 2) [B] from the 1
geroler.
2

P–08219
Remove the geroler (Item 1) [C].

C
P–08220
Remove the two O–rings (Item 1) [D] from the top of the
wear plate. D
P–08221

Revised
123 of July
A 1
3
Remove the wear plate (Item 1) [A] from the bearing 2
housing.
Remove the seal (Item 2)[A] from the bottom of the wear
plate (Item 1) [A].
Remove the drive shaft (Item 3)[A] from the output shaft.
Inspect the female spline for wear or damage, in the
output gear.
4
Remove the snap ring (Item 4) [A] from the output shaft.
P–08222
Turn the bearing housing over. Heat the eight bolt heads
[B] to melt the thread lock material and remove the bolts. B
NOTE: If the bolt heads are not heated and thethread
lock material not melted the bolt heads could
twist off on removal.

P–08223
Press the output shaft out of the bearing carrier [C].

C
P–08224
Remove the O–ring (Item 1) [D] from the seal retainer.

D
Remove the seal retainer (Item 2) [D] from the output
shaft.
1
P–08225

Revised July
12497
A
Remove the seal (Item 1)[A] and backup ring (Item 2)[A] 1
from the seal retainer.
P–08226
Remove the bearing race from the output shaft [B].

B

P–08227
[C].
Tap the bearing out of the carrier using a brass punch
C
NOTE: Use only a brass or bronze punch to remove
the bearing or damage to the bearing can
result.
P–08228
Press the bottom bearing out of the bearing carrier [D].

D
P–08229

Revised
125 of July
A
Assembly
Check the wear plate, geroler , valve plate, valve, and
balance ring for wear and scratches.
If any of these parts are damaged, order new parts.
Clean the seal retainer bolt holes with a 6x1 mm tap [A].
Use compressed air to blow any loose thread lock
material out of the bolt holes.
P–08230
Press the bottom bearing in the bearing carrier [B].

B

P–08231
Press the top bearing in the bearing carrier [C].

C
P–08232
Press a new bearing race on the output shaft [D].

D
P–08233

Revised July
12697
A
Assembly (Cont’d)
Apply oil and install a new seal (Item 1) [A] and backup 1
ring (Item 2) [A] in the seal retainer.
P–08226
Install the seal retainer (Item 1) [B] on the output shaft.

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

2
P–08225
Press the output shaft in the bearing carrier [C].

C
P–08256
Install the snap ring (Item 1) [D] on the output shaft.

D
P–08257

Revised
127 of July
A
Assembly (Cont’d)
Apply thread lock (LOCTITE #262) to the eight seal 1 1
retainer bolts (Item 1) [A] and tighten to 104–130 in.–lbs.
(12–15 Nm) torque.
1 1
1 1
1
P–08223
Pour a small amount of cleanhydraulic fluid in the bearing

carrier to provide start up lubrication. B
Apply oil and install a new O–ring (Item 1) [B] on the
bearing carrier.

1
P–08258
Install a new shaft face seal in the wear plate [C].

C Wear Plate Shaft Face
Seal
Shaft
Shaft and Bearing

Housing B–13495
Install the drive shaft (Item 1) [D] in the output shaft.

Install the wear plate (Item 2) [D] on the bearing carrier. D 2
1
P–08222

Revised July
12897
A
Assembly (Cont’d)
Apply oil and install two new O–rings (Item 1 & 2) [A] on 2
the wear plate. 1
Install the geroler on the wear plate, engaging the teeth

of the output shaft drive [B]. P–08221
TIMING THE HYDRAULIC MOTOR B

The timing of the motor controls the direction of rotation
of the output shaft. The timing parts are as follows:
1.) Geroler Assembly
2.) Valve Drive
3.) Valve Plate
4.) Valve

1
Find the largest opening (Item 1) [B] in the geroler
assembly [B]. Mark the outside of the geroler at this point.
P–08220
Install the valve drive shaft (Item 1) [C].

C
1
P–08234
Apply oil and install two O–rings (Item 1) [D] on the valve
plate. D
1
P–08219

Revised
129 of July
A 1
Assembly (Cont’d)
Align the drain hole (Item 1)[A] in the valve plate with the
drain hole (Item 1) [A] in the geroler. 2
Make sure the slot opening of the valve plate (Item 2)[A]
is aligned with the largest opening of the geroler (Item 3) 1
[A].
Install the valve plate.
3
P–08235
Install the valve on the valve plate.

Align one of the side ports with the mark on the geroler
B
housing.
Turn the valve clockwise a small amount until the teeth
on
the valve drive engage [B].

P–08236
Install the two springs (Item 1) [C] and two pins (Item 2)
[C] in the valve housing.
C
1
2 2
P–08216
Install the inner (Item 1) [D] and outer (Item 2) [D] face D
seals on the balance ring (Item 3) [D] as shown.
1 2
B–13495

Revised July
13097
A 1
Assembly (Cont’d)
2
Install the balance ring (Item 1) [A] in the valve housing
and engage the alignment pins (Item 2) [A] with the slots
in the balance ring.
Apply oil and install new O–rings (Item 3 & 4) [A] on the
valve housing.
4 3
P–08215
Using a small flat blade screwdriver,go through one of the

connector ports and hold the balance ringin position [B]. B
Install the valve housing on the motor.

P–08259
Install the four bolts (Item 1) [C] on the top of the motor
assembly and tighten to 36–40 ft.–lbs. (49–54 Nm) torque
in a crisscross pattern.
C 1 1
1 1
P–08214
Apply oil and install new O–rings (Item 1) [D] on the top
plugs (Item 2) [D]. D
1
Install the check balls (Item 3) [D] and plugs (Item 2) [D] 2 3
in the valve housing.
P–08213

Revised
131 of July
A
Assembly (Cont’d)
[A] in the
Apply thread sealant and install the plug (Item 1)
side of the valve housing.
[A].
Apply oil and install a new O–ring on the plug (Item 2)
Install the plug (Item 2) [A] in the side of the valve
housing.
The timing can be checked before installation.
1. Lay motor on side. 1
2. Fill right port with oil.
3. Turn drive shaft clockwise, oil should go down in 2
port if timed correctly. P–08212
Apply oil and install new O–rings on the connectors. B

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

1
P–08211
Install the brake valve (Item 1) [C] on the connectors.

Install the two fittings (Item 2) [C].
C
2
P–08210

Revised July
13297
Brake Valve Parts Identification
1. Nut
2. Nut
3. Screw 1
4. Cartridge 2
5. O–ring 3
6. O–ring 4
7. Plug
8. Retainer
9. Spring 5
10. Valve
11. Seat 7
12. Seal 8
13. Orfice 9
14. Plug 6
15. O–ring 10
16. Spring 11
17. Ball
18. Body 13
19. Bushing
20. Connector
21. O–ring
12
21

20 14
15
5 16
17
17 19
16 18
15
14
12 13
11
10
9
8
7
5 6
2 3
C–03138

Revised
133 of July
A
Brake Valve Disassembly 1
Remove the two fittings (Item 1)[A] from the connectors.
Remove the control valve (Item 2) [A] from the swing
motor.
Clamp the control valve in a vise that has padded jaws.
P–08210
Remove the plugs (Item 1) [B] from both ends of the
valve.
B
1
1

P–08260
Remove the O–ring (Item 1)[C] from the plug (Item 2)[C].
Remove the spring (Item 3)[C] and check ball (Item4) [C]
from both ends of the valve.
C
1 4
2
3
P–08261
Remove the cross port relief valves (Item 1)[D] from both
ends of the valve body.
D
1 1
P–08293

Revised July
13497
A
Brake Valve Disassembly (Cont’d)
Remove the spring (Item 1) [A] and retainer (Item 2) [A] 4
from the cartridge. 6 2
Remove the cap (Item 3) [A], locknut (Item 4) [A], and

adjustment screw (Item 5) [A].
Remove the plug (Item 6) [A].
Remove the O–ring (Item 7)[A] from the plug (Item 6)[A]. 3 5 7 1
8
Remove the O–ring (Item 8) [A] from the cartridge.
P–08262
Remove the valve (Item 1) [B] from both ends of the

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

P–08263
Remove the valve seat (Item 1)[C] from the control valve
by using two pieces of 0.090 inch wire. C
1
P–08264
Bend the ends of the wire in a 90° and insert the wire in
the center port of the valve seat, and engage two of the D
valve seat side ports.
Pull straight up on the wires to remove thevalve seat [D].
P–08265

Revised
135 of July
A
Brake Valve Disassembly (Cont’d)
Remove the copper seal (Item 1)[A] from the valve seat.
2
Removing the orifice (Item 2) [A] from the valve seat is
only necessary if the orifice cannot be cleaned to
satisfactory results with solvent.
1
P–08266
Remove the orifice from the valve seat using a brass

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

P–08267
Control Valve Assembly

C
Press the orifice (Item 1) [C] in the valve seat.
Install a new copper seal (Item 1) [A] on the valve seat. 1
P–08268
Put clean hydraulic fluid on the valve seat.

Install the valve seat in the valve body [D].
D
P–08264

Revised July
13697
220ExcavatorServiceManual(S/N508211999&Below)#6720230–UpperWorksandSwingSectionPart1of2
A
Brake Valve Assembly (Cont’d)
Apply clean hydraulic fluid to the valve (Item 1) [A].
Install the valve in the valve seat. 1
P–08263
Apply oil and install a new O–ring (Item 1)[B] on the plug
(Item 2) [B]. B
Install the plug (Item 2) [B] in the cartridge.
Install the spring retainer (Item 3) [B] and spring (Item 4) 6 2 3
[B] in the cartridge.
Install the adjustment screw (Item 5) [B] in the cartridge.

Install the locknut (Item 6) [B] and cap (Item 7) [B] on the
adjustment screw (Item 5) [B].
7 5 1 4
Apply oil and install a new O–ring (Item 8) [B] on the 8
cartridge.
NOTE: If the cross port relief valve is disassembled, P–08262
the relief pressure will need to be reset. See
Page 4–26 for testing and adjustment
procedures.
C
Install the cross port relief valves (Item 1) [C] on both
ends of the valve body.
P–08293
Apply oil and install a new O–ring (Item 1)[D] on the plug
(Item 2) [D]. D
1 3
Install the check ball (Item 3) [D] and spring (Item 4) [D]
in the valve body.
Install the plug (Item 2) [D] in the valve body.
2
4
P–08261

Revised
137 of July
A
Brake Valve Assembly (Cont’d)
Apply oil and install four new O–rings on bothsides of the
connector ports [A].
P–08269
Install the control valve (Item 1) [B] on the swing motor.

Install the two fittings (Item 2) [B] on the connectors.
B
2
Control Valve Testing
The control valve used on the swing motor has two relief
valves mounted on each side of the valve body . These
valves work to dampen the swing stop, preventing
damage to the swing motor. The relief valves also prevent

the upperstructure from independent movement, or
creeping, until the swing circuit is engaged.
1
The relief valves, control valve, and swing motor are
shown removed from the excavator for photo clarity [B].
P–08210
Disconnect the outlet hose (Item 1)[C] from pump section

1. C
NOTE: Pump section 1 is the closest to the engine.
Install a tee in between the pump section 1 outlet and the

outlet hose.
Install a 5000 PSI gauge on the tee fitting. W arm the
excavator up to operating temperature.
With the swing lock engaged, actuate the swing circuit in

one direction. Record the pressure. Activate the swing 1
circuit in the opposite direction. Record the pressure.
If adjustment is needed, remove the cap (Item 1)[D] and N–07538
loosen the lock nut (Item 2) [D].
Turn the adjustment screw (Item 3) [D] until the correct
pressure is recorded on the gauge. D
NOTE: The valve is shown out of the excavator for
photo clarity.
The correct pressure for the cross port relief valves is as 2

follows: 1
S/N 11001–11500 . . . . . . . 1635 PSI (11273 KPA)

S/N 11501–11703 . . . . . . . 1500 PSI (10342 KPA)
S/N 11704–11999 . . . . . . . 1150 PSI (7929 KPA)
The front cross port relief valve controls the clockwise 3
direction of rotation while the rear relief valve controlsthe
counterclockwise direction of rotation. P–08270

Added July138
UPPER WORKS
A
Remove the operator canopy.
Remove the seat and seat mounting frame. (See Page
5–1.)
Remove the engine. (See Page 7–1.)
Remoe the hydraulic reservoir. (See Page 2–1.)
Remove the floor panel. (See Page 3–1.)
N–07601
Remove the hydraulic control valve. (See Page 2–1.)
Remove the boom/dipperstick assembly . (See Page
5–1.)
B
Remove the swing motor. (See Page 4–1.)
Loosen and remove all the bolts around the swing circle
gear [A] & [B].
Installation: Tighten the bolts to 44–47 ft.–lbs. (60–65

Nm) torque.
Connect a chain hoist to the upper works frma and lift it
off the swing circle gear.
N–07602

Added July
UPPER WORKS (Cont’d)
A Alignment pin hole
locations
When installing the frame onto the swing bearing, one of
two different procedures will need to be followed for
proper reassembly alignment. Determine which of these
procedures to use by inspecting the frame. If the frame
has three locating holes, 0.200 inch in diameter
, as shown
in [A] use the alignment pin procedure. If these holes are
not in the frame, use the alignment screw procedure.
B–13727
Alignment Pin Procedure

Connect a chain hoist to the frame and lower the frame
B
onto the swing bearing. Maintain a slight amount of frame
weight on the chain hoist. Alignment Pin Tapered Alignment
P/N 6539805 Screw P/N 6539680
Remove any paint from the three alignment pin holes in
the frame.

B–13728
Apply LOCTITE to the threads of the mounting bolts (Item

1) [C] and install the bolts thru the frame and into the
swing bearing. DO NOT tighten the bolts at this time.
C 2
1
3
NOTE: If lockwashers were used on the original
bolts (Item 1), replace the lockwashers with
hardened flat washers (P/N 27E–6), (Item 2)
[C].
[C]
Insert the three alignment pins (P/N 6539805) (Item 3)
into the alignment holes.
Reposition the frame as necessary until the alignment
pins (Item 3) [C] will slide thru the frame and into theteeth
of the swing bearing.
B–13717
With the pins installed, lower the frame onto the swing
bearing and remove the chain hoist.
Tighten the mounting bolts to 44–47 ft.–lbs. (60–65 Nm)
torque.
Remove the alignment pins (Item 3) [C] from the frame.
The swing motor can now be installed. SeeInstallation Of
Swing Motor Page 4–3.
Revised April 92 220 (S/N 508211999 & Below) Excavator

Added July140
UPPER WORKS (Cont’d)
A 2 1
Alignment Screw Procedure 3
Connect a chain hoist to the frame and lower the frame
onto the swing bearing. Maintain a slight amount of frame
weight on the chain hoist. 1
Install the three alignment screws (P/N 6539680), (Item

1) [A] thru the frame and into the swing bearing, equally
space these screws around the swing bearing.
Lower the frame onto the swing bearing while evenly
tightening the three alignment screws until they aretight.
The tapered head of the alignment screws will guide the
frame into alignment with the swing bearing.
Apply LOCTITE to the mounting bolts (Item 2) [A] and
install the bolts thru the frame and into the swingbearing.
Tighten the bolts to 44–47 ft.–lbs. (60–65 Nm) torque. B–13718
NOTE: If lock washers were used on the original

bolts (Item 2) [A], replace the lock washers B 2
1
with hardened flat washers (P/N 27E–6) (Item
3) [A].

Remove the three alignment screws (Item 1)[A] from the
frame.
Apply LOCTITE to the threads of the remainingbolts and
install them into the frame. T ighten the bolts to 44–47
ft.–lbs. (60–65 Nm) torque.
Remove the chain hoist from the frame.
Swing Motor Installation

Do the following for either the alignment pin or the
alignment bolt procedure
Install the swing motor (Item 1) [B] into the frame. B–13719
Apply LOCTITE to the threads of the bolts (Item 2) [B]

and install.
Tighten these bolts to 29–37 ft.–lbs. (40–50 Nm) torque.
Remove the caps and/or plugs from the swing motor but
do not install any hoses.
The swing motor gear to the swing bearing gear
engagement must be checked to insure that there is back
lash between the gears through 360° of frame rotation.
Check for back lash by moving the frame back and forth
at several points throughout the frames rotation. There
must be some backlash present.

Added July
CENTER SWIVEL JOINT
A
Raise the back of the machine.
Use jackstands under the machine frame.

systems, clean the work area before CD–10481
the system.
B
I–2003–0888
[A].
Remove the bolts from the plate below the swivel joint
Remove the plate.
5

Disconnect all the hoses from the swivel joint [B].

Remove the four mounting bolts (Item 1) [B].
Installation: Add LOCTITE and tighten the bolts to 1
15–18 ft.–lbs. (20–25 Nm) torque.
4
Remove the center swivel joint from the track frame.
Disassembly And Assembly

Remove the bolts (Item 2) [B].
Remove the end plate (Item 3) [B].
Remove the end plate (Item 4) [B] from the end of the 2
rotor. 3
B–12744
Remove the rotor (Item 5) [B] from the housing.
NOTE: Tap the rotor lightly with a rubber hammer if
needed for removal.
Check the condition of the O–rings and seal.

Check the rotor and housing for scratches or wear marks.
Use grease or hydraulic oil on the O–rings and seal during
assembly.
Assemble the swivel joint in reverse order.

Added July142
SWING CIRCLE GEAR
A
Remove the upper works from the swing circle gear
. (See
Page 4–27.)
There is an S (Item 1) [A] stamped on the swing gear ,
make sure this mark is located to either side of the center
line of the machine.
1
N–07606
Remove the bolts from the swing circle gear [B]. B

Installation: Add LOCTITE and tighten the bolts to
44–47 ft.–lbs. (60–65 Nm) torque.
Use a chain hoist to remove the swing circle gear.
Always replace the seal when installing the swing circle
gear.

N–07605
Position the outer ring soft zone to either side of the

center
line of the machine when installing the swing frame on the
C Outer Ring
track frame [C] & [D].
Inner Soft Zone

Ring
”S”
Tracks
MC–01415
NOTE: The soft zone can be located by the filler plug

in the outer ring [D]. D
Filler Plug
Soft Zone D–02029

Added July
220ExcavatorServiceManual(S/N508211999&Below)#6720230–UpperWorksandSwingSectionPart2of2

Added July144
MAIN FRAME AND TRACKS
Page
Number
BOOM AND DIPPERSTICK

...
BOOM SWING BRACKET
...
ENGINE COVER
...
FUEL TANK
...
IDLER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–9d
....
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9a
....
ROLLER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–14
.... MAIN FRAME
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11
.... & TRACKS

SEAT AND MOUNTING FRAME
...
TRACK
...
Track Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
...
TRACK FRAME
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–9
..

Revised Feb. 95

ENGINE COVER
A
Open the engine cover.
Remove the retainer clip from the rod end pin of the gas
cylinder [A].
N–07607
Remove the retainer clip from the baseend pin of the gas
cylinder [B].
B
Hold the engine cover and remove the gas cylinder
. Close
the engine cover.

Cylinder contains high pressure gas. Do not
open. Opening cylinder can release rod and
cause injury or death. N–07608
W–2113–0288
Remove the bolts from the hinge (both sides) [C].

C
N–07609
Remove the engine cover from the machine [D]. D
N–07610

SEAT AND MOUNTING FRAME
A
Remove the bolts from the hinge (both sides) [A].
N–07611
Remove the seat from the mounting frame [B]. B

Disconnect and remove the battery. (See Page 6–3.)

N–07612
Disconnect the throttle linkage [C].

C
N–07613
Remove the bolts from the seat mounting frame.

D
Remove the seat mounting frame [D].
N–07614

FUEL TANK
A
NOTE: On some machines, the seat and mounting
frame may have to be removed (Page 5–2) so
there is enough clearance for fuel tank
removal.
Drain the fuel from the tank into a container.

Disconnect the fuel switch wire [A].
N–07615
Remove the fuel tank mounting bolts [B] & [C].

B

N–07616
N–07617
Lift and move the fuel tank forward. Disconnect the fuel
hoses. Remove the electrical harness from the fuel tank D
[D].
Remove the fuel tank from the machine.
N–07618

BOOM AND DIPPERSTICK
A
Remove the retainer bolts (Item 1) [A] from the bucket
pins.
Remove the bucket pins and remove the bucket.
Lower the boom and dipperstick to the floor . Stop the
engine.
Move the control to release the hydraulic pressure.
N–07569
Disconnect the hoses from the tubelines [B]. B

the system.
I–2003–0888 N–07542
NOTE: It may be necessary to remove the tubeline C

clamp so there will be clearance for the
wrenches and the hoses can be
disconnected from the tubelines [C] & [D].
N–07543
N–07544

BOOM AND DIPPERSTICK (Cont’d)
A
Remove the retainer bolt and nut from the boom cylinder
base end pivot pin [A].
N–07564
Remove the boom cylinder base end pin [B]. B

Lower the boom cylinder to the floor.
Connect a chain hoist to the boom and dipperstick.

N–07565
Remove the retainer bolt and nut from the boom pivot pin
[C]. C
N–07619
Remove the boom pivot pin [D].

D
Installation: Make sure to install the washer(s) that were
removed when the boom was removed from the swing
bracket [D].
N–07620

BOOM AND DIPPERSTICK (Cont’d)
A
Lift the boom slowly and remove it from the boom swing
bracket [A].
N–07621

BOOM SWING BRACKET
A
Remove the boom and dipperstick. (See Page 5–5.)
Remove the retainer bolt from the boom swing cylinder
rod end [A].
N–07571
Remove the boom swing cylinder rod end pin [B]. B

N–07572
Remove the retainer bolt and nut from the boom swing
bracket pivot pin [C]. C
N–07622
Remove the boom swing bracket pivot pin [D].

D
Remove the boom swing bracket.
N–07623

TRACK
Track Tension Adjustment
A
NOTE: The wear of the pins and bushings on the

undercarriage vary with the work conditions
and different types of soil conditions. It is
necessary to inspect track tension to
maintain the correct tension. See Service
Schedule Page 1–1 for the correct service
interval.
Raise the machine using the boom and dipperstick as

shown in figure [A]. Stop the engine.
N–07407
B Add Grease Here
AVOID INJURY
Keep fingers and hands out of pinch points
when checking the track tension.
W–2142–0189

Measure the drop of the track at the middle of the span.
If the gap is between 0.39”–0.78” (10–20 mm), the track
tension is correct. If not, loosen one bolt and remove the
other bolt from the cover.
Add grease to the fitting until the track tension is correct B–13134
[B].
Repeat the procedure for the other side. C
Lift and block the side of the machine where the track will
be removed.
Slowly remove the valve from the recoil spring cylinder
[C].
NOTE: A chain hoist can be used to pull up on the

track so all the tension is released from the
recoil spring cylinder for easier removal of
the track. N–07624
Remove the track from the front track idler [D].

D
Remove the track from the frame and rear drive sprocket.
N–07625

TRACK FRAME
220ExcavatorServiceManual(S/N508211999&Below)#6720230–MainFrameandTracksSectionPages1–9
Disassembly and Assembly

A
Use the following procedure to remove the different parts
from the track frame:
Remove the track. (See Page 5–8.)
Slide the front track idler out of the track frame to remove
it [A]. (See Page 5–9a for disassembly and assembly
procedure.)
CD–07626
Remove the sliding plate [B]. B

CD–07627
Slide the recoil spring cylinder forward and remove it from

the track frame [C]. C
N–07628
Loosen the drive gear bolts [D].

D
Installation: Put LOCTITE on the bolts and tighten to 80
ft.–lbs. (108 Nm) torque.
N–07629

Revised
155 ofFeb.
TRACK IDLER
2
4
5
3
6
8
7

6
5
4 1
C–03127
Ref. Description Ref. Description

1. Pin 5. Snap Ring
2. Block 6. Bearing
3. Snap Ring 7. Shaft
4. Seal 8. Idler

156 of 258
Added Feb. 95 –5–9a– Service Manual
TRACK IDLER (Cont’d)
The following tools must be fabricated for this procedure:
A
Driver Tool – See [A].
Support Fixture – Tube, 3” ID x 1/4” wall x 6” long. 3.50’’
(90 mm)
2.75’’
(70 mm)
0.03’’
(0,75 m) 1.35’’
Chamfer (30 mm) Dia.
3 Places 2.40”
(60 mm) Dia. B–14204
Disassembly
Remove the roll pin and block from each end of the shaft
B
[B].

CD–00289
Remove the snap ring from each side of the idler [C].
C
CD–00288
Use a wire brush to remove any corrosion or paint from

both ends of the exposed shaft that could affect seal D
removal or damage the new seal during installation [D].
CD–00290

157 of 258
Added Feb. 95 –5–9b– Service Manual
A
Apply penetrating oil to both ends of the exposed shaft to
ease removal of the inner part of the seal.
Remove the inner part of the seal using two screwdrivers
[A].
CD–00287
Remove the outer part of the seal from the idler using two
screwdrivers [B].
B
Pour the oil out of the idler . Discard the oil in an
appropriate manner.
Turn the idler assembly over and remove the other seal.

CD–00285
Remove the snap ring from each side of the idler [C].
C
CD–00278
Using the fabricated driver tool and support fixture, press

or drive the shaft and bearing assembly out of the idler D Driver Tool
[D].
Support
Fixture
CD–00277

158 of 258
Added Feb. 95 –5–9c– Service Manual
TRACK ROLLER (Cont’d)
A
Inspect the bearings for rust or for rough spots. The
bearings must turn freely. If any damage is found, replace
the bearings. If replacement of the bearings is necessary,
use a two or three jaw puller, remove the two bearings
from the shaft [A].
CD–00273
Assembly B
Remove all paint and corrosion from the seal surface on
both sides of the idler [B].
Be sure all parts are clean before assembly.

CD–00271
Using the driver tool, install a new bearing, with the

numbered side upward, onto the shaft [C]. Press only on
C
the inner diameter of the bearing.
CD–00272
Using the driver tool, install the shaft and bearing

assembly into the idler [D]. D
CD–00274

159 of 258
Added Feb. 95 –5–9d– Service Manual
Assembly (Cont’d)
A
Install the snap ring [A].
CD–00275
Turn the idler assembly over. B

Using the driver tool, install the other bearing, with the
numbered side upward, into the idler [B].

CD–00276
Install the snap ring [C].

C
CD–00278
Using a dial indicator, check the endplay of the shaft [D].

D Install
Shims
If the endplay is greater than 0.030 inch (0,76 mm) then Between
the bearing must be shimmed. Bearings
and
Cut a shim from the necessary thickness shim stock and
install the shim between the bearing and the shoulder on Shaft
the shaft. Shoulder
B–14726
CD–00280

160 of 258
Added Feb. 95 –5–9e– Service Manual
Assembly (Cont’d)
A
Separate the inner and outer halves of the seals.
Apply grease to the grooves on the outer part of a new
seal [A].
CD–00281
Apply a small bead of high temperature silicone sealant

around the flange surface of the seal [B].
B

CD–00282
Using the driver tool, install the outer part of the new seal
into the idler [C]. C
NOTE: The inner and outer parts of the seal must be
installed separately so the air will escape
from under the seal.
CD–00284
Using the driver tool, install the inner part of the seal over
the shaft [D]. D
NOTE: The inner part of the seal must be pressed
down level with the outer part of the seal to
seal properly.
CD–00286

Added Feb. 95
161 of 258 –5–9f– Service Manual
220ExcavatorServiceManual(S/N508211999&Below)#6720230–MainFrameandTracksSectionPages9a–9g
Assembly (Cont’d)
A
Turn the idler assembly over. Using a syringe, add 35 cc
of SAE 10W–30 oil to the assembly [A].
Repeat steps A through D on Page 5–9f to install the
remaining seal.
Check for leaks.
CD–00283
Install the snap ring on each side of the idler [B]. B

CD–00288
Install the roll pin and block on each end of the shaft[C].
C
The two blocks must point the same direction.
CD–00289

162 of 258
Added Feb. 95 –5–9g– Service Manual

163 of 258
Added Feb. 95 –5–9– Service Manual
TRACK FRAME (Cont’d)
Assembly (Cont’d)
A
Remove the drive gear bolts [A].
Remove the drive gear from the drive motor and planetary
gear assembly.
NOTE: See Page 3–7 to remove and install the drive

motor and planetary gear assembly.
CD–07630
Loosen the nuts at the track roller on both sides of the

track frame [B]. B

CD–07631
Remove the track roller [C].

C
CD–07632

Added Feb. 164
TRACK ROLLER
2
1 3
4
5
6
10

8
7
6
5
4
3
1
2
C–03143
TRACK ROLLER
Ref. Description Ref. Description

1. Washer 6. Seal
2. Nut 7. Snap Ring
3. Washer 8. Bearing
4. Spacer 9. Shaft
5. Snap Ring 10. Roller

165 of 258
The following tools must be fabricated for this procedure:
A
Driver Tool – (See [A]).
Support Fixture – Tubing, 3” ID x 1/4” wall x 6” long.
B–14203
Disassembly
Remove the snap ring from each end of the shaft [B].
B

CD–00331
Use a wire brush to remove any corrosion or paint from

both ends of the exposed shaft that could affect seal
removal or damage the new seal during installation [C]. C
CD–00330
Apply penetrating oil to both ends of the exposed shaft to

ease removal of the inner part of the seal.
D
Remove the inner part of the seal using two screwdrivers
[D].
CD–00328

Added Feb. 166
A
Remove the outer part of the seal from the roller using two
screwdrivers [A].
Pour the oil out of the roller. Discard the oil in an
appropriate manner.
Turn the roller assembly over and removethe other seal.
CD–00324
Remove the snap ring from each side of the roller [B]. B

CD–00320
Using the fabricated driver tool and support fixture, press

or drive the shaft and bearing assembly out of the roller C
[C].
Driver Tool
Support Fixture
CD–00318
Inspect the bearings for rust or rough spots. Thebearings

must turn freely . If any damage is found, replace the D
bearings. If replacement of the bearings is necessary
, use
a two or three jaw puller, remove the two bearings from
the shaft [D].
CD–00312

167 of 258
Assembly
A
Remove all paint and corrosion from the seal surface on
both sides of the roller [A].
Be sure all parts are clean before assembly.
CD–00310
Using the driver tool, install a new bearing, with the

numbered side upward, onto the shaft [B]. Press only on
the inner diameter of the bearing.
B

CD–00311
Using the driver tool, install the shaft and bearing

assembly into the roller [C]. C
CD–00313
Install the snap ring [D].

D
CD–00314

Added Feb. 168
Assembly (Cont’d)
A
Turn the roller assembly over.
Using the driver tool, install the other bearing, with the
numbered side upward, into the roller [A].
CD–00316
Install the snap ring [B]. B

CD–00320
Using a dial indicator, check the endplay of the shaft [C].

C Install
Shims
If the endplay is greater than 0.030 inch (0,76 mm) then Between
the bearing must be shimmed. Bearings
and
Cut a shim from the necessary thickness shim stock and Shaft
install the shim between the bearing and the shoulder on
the shaft. Shoulder
B–14726
CD–00322
Separate the inner and outer halves of the seal.

D
Apply grease to the grooves on the outer part of a new
seal [D].
CD–00325

169 of 258
Assembly (Cont’d)
A
Apply a small bead of high temperature silicone sealant
around the flange surface of the seal [A].
CD–00326
Using the driver tool, install the outer part of the new seal
into the roller [B].
B
NOTE: The inner and outer parts of the seal must be
installed separately so the air will escape
from under the seal.

CD–00323
Using the driver tool, install the inner part ofthe new seal
over the shaft [C]. C
NOTE: The inner part of the seal must be pressed
down level with the outer part of the seal to
seal properly.
CD–00327
Turn the roller assembly over. Using s syringe, add 25 cc

of SAE 10W–30 oil to the assembly [D]. D
Repeat Page 5–15 steps D through Page 5–16 Step Cto
install the remaining seal.
Check for leaks.
CD–00321

Added Feb. 170
Assembly (Cont’d)
A
Install the spacer and the snap ring on each end of the
shaft [A].
CD–00331

171 of 258
220ExcavatorServiceManual(S/N508211999&Below)#6720230–MainFrameandTracksSectionPages10–18

Added Feb. 172
ELECTRICAL SYSTEM
Page
Number
ALTERNATOR
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–4
...
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4 ...
BATTERY
Checking the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–3
...
...
ELECTRICAL SYSTEM
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1....
Electrical System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2 ...
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–2
....
Fuse Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–2 ...
INSTRUMENT PANEL
Lights, Hourmeter and Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7 ..
...
STARTER
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–6 ..

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
...
...
ELECTRICAL
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
... SYSTEM


175 of 258
176 of 258
TROUBLESHOOTING
The following troubleshooting chart is provided as an
assistance in locating and correcting problems which are
most common. Many of the recommended procedures
must be done by authorized Bobcat Service personnel
only.
Instructions are necessary before operating or
servicing machine. Read Operation &
Maintenance Manual, Handbook and signs
(decals) on machine. Follow warnings and
instructions in the manuals when making
repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Failure to follow instructions can
cause injury or death.
W–2003–0797
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5

Alternator will not charge. 1, 2, 5

Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9
KEY TO CORRECT THE CAUSE
1. Alternator belt is loose or damaged.

2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.
Description
The excavator has a 12 volt, negative ground electrical
system. There are two main circuits.
The charging circuit has an alternator, regulator and a
battery.
The starting circuit has a starter motor , solenoid and
ignition switch for starting the engine.
The electrical system is protected by fuses, installed in
the instrument panel. Fuses protect the electrical system
from an overload. The reason for the overload must be
determined before starting the engine.

ELECTRICAL SYSTEM (Cont’d)
Fuses
A
The fuses protect the electrical system from damage. To
replace the fuse(s), loosen the screw and remove the
cover [A].
Replace the fuse(s) with the same type and capacity.
NOTE: Before replacing any fuse(s), make sure the

key switch is in the OFF position.
N–09091
Fuse Arrangement [B].

B
Ref. Fuse Capacity Circuit
1. 10 Amp. Not Used
2. 10 Amp.
3. 10 Amp.
4. 10 Amp.

2 4
1 3
N–07385
Electrical System Service

C
Use the following procedure to service the electrical
system:
Check that the battery cable ends are clean and tight. Water and
Remove any acid or corrosion from the battery cable ends Baking Soda
with a baking soda and water solution [C]. Cover the Solution
battery terminals with grease to prevent corrosion.
Check the electrolyte level in the battery . Add distilled
water as needed.
Check the alternator belt for wear and correct tension.
Check that all wire connections are secure.
A–02741

BATTERY
Checking the Battery
A
The tool listed will be needed to do the following
procedure:
MEL10004A – Battery Tester
To make a safe and complete check of the battery
, see the
Melroe Battery Manual (P/N 6566047). The battery
manual has all the information needed for checking and
servicing the battery.
Raise the operator seat [A]. N–07410
Batteries contain acid which burns eyes and

skin on contact. W ear goggles, protective
clothing and rubber gloves to keep acid off
body.

In case of acid contact, wash immediately with
water. In case of eye contact get prompt medical 1
attention and wash eye with clean, cool water
for at least 15 minutes.
N–07633
If electrolyte is taken internally drink large
quantities of water or milk! DO NOT induce
vomiting. Get prompt medical attention.
W–2065–1296 C
Disconnect the negative (–) cable first [B].
Disconnect the positive (+) cable.
Remove the battery holddown clamp (Item 1) [B].
Remove the battery from the machine.
Always clean the terminals and battery ends, even when
installing a new battery.
Reverse the procedure for battery installation. B–03707

ALTERNATOR
Belt Adjustment
A
Stop the engine. Open the engine cover.
The belt should deflect about 1/2” (13 mm) when pressed
between the alternator pulley and crankshaft pulley with
approximately 13 lbs. (58 N) force [A].
N–07394
If the tension is not correct, loosen the alternator

mounting bolt [B].
B

N–07395
Loosen the adjustment bolt [C].

C
Move the alternator until the belt tension is correct.
Tighten the adjustment bolt and mounting bolt.
Replace the belt if it has stretched or there are cracks in
the belt. Check the pulley grooves, make sure the belt is
not in contact with the bottom of the grooves in the
pulleys.
N–07396

D
Disconnect the negative (–) cable from the battery.
Disconnect the alternator wires [D].
Remove the adjustment bolt [C].
Remove the alternator belt.
Remove the mounting bolt [B].
Remove the alternator from the bracket.
N–07652

STARTER
A
Raise the operator seat. Disconnect the negative (–)
cable from the battery.
Disconnect the wires from the starter [A].
N–07634
Remove the mounting bolts from the starter [B]. B

Remove the starter from the bell housing.

N–07635

STARTER (Cont’d)
A
Disassemble the starter as shown in figure [A].
Cleaning and Inspection

• When fluids are under pressure.
• Tools are being used.
W–2019–1285
Use a brush and air pressure toclean the drive, field coils,
armature and starter housing.

NOTE: Do not use solvent to clean the drive
assembly. The solvent will remove the
lubricant and the drive will slip.
1. Starter 26. Cover
2. Yoke Assy. 27. Plate
3. Armature 28. Plate
Check the following items: 4. Bearing 29. Plunger
5. Bearing 30. Bolt
Armature 6. Nut 31. Washer
Broken or burned insulation. 7. Retainer 32. Washer
Loose connections at commutator. 8. Pinion 33. Bolt
Open or grounded circuits. 9. Shaft 34. Bolt
Worn shaft or bearings. 10. Snap Ring 35. Nut
Rough commutator. 11. Spring 36. Nut
12. Spring 37. O–ring
13. Clutch 38. O–ring
Field Coils 14. Roller 39. Nut
Broken or burned insulation. 15. Pinion 40. Washer
Electrical continuity. 16. Housing 41. Screw
Brush connections. 17. Frame 42. Screw
18. Holder Assy. 43. Washer
Drive Gear 19. Spring 44. Bolt
Worn teeth. 20. Solenoid 45. Nut
Tooth engagement (drive gear must engage ring gear 21. Gasket 46. Ball
22. Bushing 47. Spring
by 1/2 the depth of the ring gear tooth). 23. Bushing 48. Retainer
24. Bushing 49. Bolt
Brush Holders 25. Bushing 50. Clutch Assy.
Broken springs.
Broken insulation.
Spring tension.

INSTRUMENT PANEL
Lights, Hourmeter and Ignition Switch
A
Use the following procedure to remove or install any light,
etc. from the instrument panel:
Lift the operator seat. Disconnect the negative (–) cable
from the battery.
Remove the screws from the cover on the instrument
panel [A].
N–07636
Lift the cover [B].

Remove the defective part and install the new part.
B

N–07637

C
Lift the operator seat. Disconnect the negative (–) cable
from the battery.
Remove the bolts on both sides of the instrument panel
housing [C] & [D].
N–07638
N–07639

INSTRUMENT PANEL (Cont’d)
220ExcavatorServiceManual(S/N508211999&Below)#6720230–ElectricalSystemSection

A
Pull the instrument panel away from the hydraulic
reservoir [A].
N–07640
Disconnect the wiring harness connectors [B]. B

Remove the instrument panel assembly from the
machine.

N–07641

ENGINE SERVICE
Page
Number
CRANKSHAFT AND PISTONS
Crankshaft Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–37
...
...
Servicing the Connecting Rods and Pistons . . . . . . . . . . . . . . . . . . . . . 7–38 .
CYLINDER HEAD
Assembling the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–26 ..
Checking the Rocker Arm and Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–26 ..
Checking the Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–25
..
Disassembly of the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–23 ..
Installing the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–26
..
Removal of the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–22 ..
Servicing the Cylinder Head and Valves . . . . . . . . . . . . . . . . . . . . . . . . .7–24 .
CYLINDER LINERS
Checking the Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–40 ..
Cylinder Liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–40
...
ENGINE
...

ENGINE COMPRESSION
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–3
....
ENGINE FLYWHEEL
Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–21
...
...
FUEL FILTER
Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
.... ENGINE
Removing Air From the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4 .. SERVICE
FUEL INJECTION PUMP

Checking the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–5 ..
...
Timing the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7
...
FUEL INJECTOR NOZZLES

Checking the Injector Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–9 ..
...
Timing the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7
...
GLOW PLUGS
Checking the Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10
...
...
MUFFLER
...
RADIATOR
...

Revised July 91
185 of 258 Continued On Next–7––1–
Page Service Manual
ENGINE SERVICE
Page
Number
TIMING GEAR, CAMSHAFT AND OIL PUMP

Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–32
...
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–30 ...
Servicing the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–33 ...
TIMING GEAR COVER

...
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
...
VALVE CLEARANCE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
....
WATER PUMP
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–41 ..
...

Revised July 91
TROUBLESHOOTING
The following troubleshooting chart is provided as an assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start. 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29
Difficult to start. 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
No power from engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is mis–firing. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10,12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue/white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 39, 52
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration. 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure. 4, 33, 36

Overheating. 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 51
Too much crankcase pressure. 22, 27, 29, 30, 40, 49
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop. 9, 10, 11
KEY TO CORRECT THE CAUSE
1. Battery capacity low. 28. Worn valves and seats.

2. Bad electrical connections. 29. Broken or worn piston rings.
3. Faulty starter motor. 30. Worn valve stems or guides.
4. Incorrect grade of oil. 31. Worn or damaged bearings.
5. Low cranking speed. 32. Not enough oil in the oil pan.
6. Fuel tank empty. 33. Switch is defective.
7. Faulty stop control operation. 34. Oil pump worn.
8. Plugged fuel line. 35. Relief valve is stuck open.
9. Plugged fuel filter. 36. Relief valve is stuck closed.
10. Restriction in the air cleaner. 37. Broken relief valve spring.
11. Air in the fuel system. 38. Faulty suction pipe.
12. Faulty fuel injection pump. 39. Plugged oil filter.
13. Faulty fuel injectors. 40. Piston seizure.
14. Broken injection pump drive. 41. Incorrect piston height.
15. Incorrect injection pump timing. 42. Faulty engine mounting.
16. Incorrect valve timing. 43. Incorrect alignment of flywheel.
17. Poor compression. 44. Faulty thermostat.
18. Plugged fuel tank vent. 45. Restriction in water jacket.
19. Incorrect grade of fuel. 46. Loose alternator belt.
20. Exhaust pipe restriction. 47. Plugged radiator.
21. Cylinder head gasket leaking. 48. Faulty water pump.
22. Overheating. 49. Plugged breather pipe.
23. Cold running. 50. Damaged valve stem oil deflectors.
24. Incorrect tappet adjustment. 51. Coolant level too low.
25. Sticking valves. 52. Plugged oil pump pipe strainer.
26. Incorrect high pressure fuel lines. 53. Broken valve spring.
27. Worn cylinder bores.

VALVE CLEARANCE
Adjustment
A 0.006”– 0.007”
(0,15–0,18 mm)
Adjust the valve clearance with the engine stopped and
cold.
The correct valve clearance is 0.006”–0.007” (0,15–0,18
mm) [A].
Make sure the piston is at T .D.C. when making the
adjustment for the valves of the particular cylinder.
A–02730
Put the correct size feeler gauge between the rocker arm
and valve stem. Turn the adjustment bolt until the
B
clearance is correct [B].

B–05893

ENGINE COMPRESSION
Checking
A
procedure:
OEM1074 – Engine Compression Kit
The engine must be at operating temperature.
Remove the fuel injector nozzles from the engine. (See
Page 7–8.)
Install the compression adapter into thecylinder head [A].
B–12827
Connect the compression gauge [B].

Turn the engine with the starter (must turn at least 175
B
RPM). Run the test for each cylinder two times for 5–10
seconds.
The compression must be at least 75% of 337–448 PSI

(2324–3089 kPa) with no more than 50 PSI (345 kPa)
difference between the cylinders.

B–12828

FUEL FILTER
Fuel Filters
A
service interval to service the fuel filters.
Use a filter wrench to remove the final fuel filter (Item 1)
[A].
Put some oil on the new filter gasket. Install the new filter
element and hand tighten only. 2
1
N–07376
Remove the in–line fuel filter (Item 1) [B] and replace it

with a new filter element.
B
1
Removing Air From the Fuel System
After replacing the fuel filters or after running out of fuel,
air must be removed from the fuel system.
Open the vent plug (Item 2)[A] on the top of the final fuel
filter housing.

Turn the key switch to the ON position. The fuel system
has an electric fuel pump and when the fuel flows through
the vent plug with no air bubbles, close the vent plug.
Turn the key switch to the OFF position. N–07377

FUEL INJECTION PUMP
Checking the Injection Pump
A
The injection pump contains parts which have a very
close tolerance and its operation has a directeffect on the
performance of the engine.
Do not attempt to maintain or adjust unless

you are trained and have the correct B–05959
equipment.
I–2028–0289
B
procedure:
MEL1237 – Adapter Fuel Line
MEL1173–1 – Pressure Gauge
To check the discharge pressure at the fuel injection 1
pump, use the following procedure:

2
Disconnect the high pressure fuel line at the pump [A].
Loosen the other end of the same high pressure line so
it can be turned away from the fitting.
Connect the adapter fuel line (Item 1) [B] to the fitting. B–08235
Connect the pressure gauge (Item 2) [B].

Crank the engine, with the starter , to increase the C
pressure to 2133 PSI (14707 kPa). Align the plunger at
T.D.C.
The pressure should hold at 2133 PSI (14707 kPa), at
least 5 seconds. If not, repair or replace the injection
pump.
NOTE: To remove the fuel injection pump, either
remove the engine from the machine (See
Page 7–11) or remove the seat, seat mounting
frame and fuel tank. (See Page 5–3.) Remove
the access panel from the machine frame. B–05960
Clean the area around the fuel injection pump. Remove

the high pressure fuel lines.
Disconnect the glow plug wires [C].

FUEL INJECTION PUMP (Cont’d)
A
Disconnect the throttle linkage cable from the injection
pump.
Remove the bolts from the intake manifold. Remove the
intake manifold [A].
B–06567
Disconnect the fuel inlet hose (Item 1)[B] and return hose
(Item 2) [B].
B
1
2

B–06964
Remove the engine lift hook (Item 1) [C].

C
Remove the four nuts from the injection pump [C].
1
Installation: Tighten the nuts to 17–20 ft.–lbs. (23–27
Nm) torque.
B–05965
Align the pin (Item 1) [D] in the control rack with the slot
in the engine block. D
Remove the injection pump.
Installation: When the injection pump is installed, make
sure the pin (Item 1) [D] on the control rack is correctly
installed on the fork lever . If the slot is not installed
correctly, the engine will run over maximum speed and
serious damage can result.
NOTE: Make sure the same number shims are
installed under the injection pump. The 1
shims are used for engine timing.
B–05966

FUEL INJECTION PUMP (Cont’d)
Timing the Injection Pump
A
NOTE: The engine timing marks are located on the

engine flywheel. Remove the hydraulic
pumps and mounting brackets.
Timing the fuel injection pump is done by changing the

number of shims (Item 1) [A] between the injection pump
and engine block.
Each shim will change the timing 1.5 degrees. Thetiming 1
of the pump will be later when a shim is added, and earlier B–10007
when a shim is removed.
Use the following procedure to time the injection pump:
B
1. Remove the number 1 cylinder high pressure line
from the injection pump.
2. Install a short pipe in the number 1 outlet of the

pump. Point the pipe up (vertical).

3. With fuel supply to the injection pump, rotate the
engine counterclockwise (viewed from the flywheel
end of the engine). Fuel must flow from the pipe as
the mark on the flywheel and the dot (punch mark)
are in alignment [B].
4. The correct timing for the engine is 23–25 degrees N–07642

B.T.D.C. Add or subtract shim(s) as needed to
adjust the delivery time of the fuel injection pump.
5. Repeat Step 3 several times forcorrect timing mark

alignment before adding or removing shim(s).

FUEL INJECTOR NOZZLES
A
Diesel fuel or hydraulic fluid under pressure

can penetrate skin or eyes causing serious
injury. Fluid leaks under pressure may not be
visible. Use a piece of cardboard or wood to
find leaks. Do not use your bare hand. W ear
safety goggles. If fluid enters skin or eyes, get
immediate medical attention.
W–2074–1285
B–05958
Some problems caused by faulty injector nozzles:

B
The engine is hard to start or will not start.
Rough engine operation at idle.
The engine will not have full power.
The engine exhaust smoke is black, white or blue. 1

B–05969
Do not bend the high pressure fuel injection C

tubes when removing or installing them.
I–2029–0289

procedure:
MEL1181 – Nozzle Socket
Disconnect the high pressure fuel lines from the fuel
injectors [A].
Disconnect the other end of the fuel lines from the
injection pump. Remove the high pressure fuel lines.
B–05970
Disconnect the return fuel hoses (Item 1) [B]. D

Remove the banjo fitting from the fuel injector [B].
Use the special socket and loosen the injector nozzle[C].
Installation: Tighten the injector nozzle to 29–36 ft.–lbs.
Remove the injector nozzle from the cylinder head [D].
B–05971

FUEL INJECTOR NOZZLES (Cont’d)
Checking the Injector Nozzle
A 3
Do not disassemble or test the fuel injector 2

nozzles unless you have the correct service
and testing tools. 1
I–2027–0284
B–04103
procedure:
MEL10018 – Injector Nozzle Tester
B
You can adjust the release pressure of the injector nozzle
by adding or removing spacer(s) (Item 1)[A] from the top
of the nozzle spring (Item 2) [A].
Each spacer is 0.004” (0,10 mm) thick and will change the
release pressure by about 142 PSI (980 kPa). The
release pressure should be 1920–2133 PSI

(13238–14707 kPa).
Connect the injector nozzle to the tester with the nozzle
down [B].
Operate the hand lever slowly and note the opening A–02513
pressure. If the pressure is not correct, disassemble the
injector nozzle and add or remove spacer(s) (Item 1) [A]
as needed.
C Spring
Assemble the nozzle and check the pressure again.
Tighten the nozzle body (Item 3) [A] to 43–58 ft.–lbs. CORRECT WRONG Pressure
(59–79 Nm) torque. Pin Holder
NOTE: Do not over tighten, or slow action of the

valve will occur.
Nozzle Body
Check for internal leakage. Operate the hand lever until
the pressure is almost enough to open the injectorvalve.
Record the pressure. Release the hand lever. Check the Needle Valve
pressure drop for 10 seconds. If the pressure drop more
is
than 740 PSI (5102 kPa), the nozzle is damaged. A–02621
Check that the spray pattern is correct [C]:

Fuel does not come out the side of the nozzle.
Drops of fuel are not present at the nozzle.
The nozzle has an even flow coming from the nozzle.
Diesel fuel or hydraulic fluid under pressure
can penetrate skin or eyes causing serious
injury. Fluid leaks under pressure may not be
visible. Use a piece of cardboard or wood to
find leaks. Do not use your bare hand. W ear
safety goggles. If fluid enters skin or eyes, get
immediate medical attention.
W–2074–1285

GLOW PLUGS
A
Remove the high pressure fuel lines from the injector
nozzles and injection pump.
Do not bend the high pressure fuel injection

tubes when removing or installing them.
I–2029–0289
B–05960
Disconnect the glow plug wires [A].

B
Remove the intake manifold [B].

B–06567
Remove the glow plugs from the cylinder head [C].

C
B–05972
Checking the Glow Plug D

Connect a voltmeter to the terminal end of the glow plug,
touch the other lead from the voltmeter to the heating end
of the glow plug [D].
The reading must be approximately 1.5 OHMS. If the
resistance is zero OHMS, the glow plug has a short
circuit. If the resistance is infinite, the coil ofthe glow plug
is broken.
B–11571

ENGINE
A
Remove the engine cover. (See Page 5–1.)
Drain the cooling system.
Remove the muffler. (See Page 7–15.)
Disconnect the top radiator hose [A].
Disconnect the lower radiator hose and engine block
drain hose.
N–07643
Loosen the air cleaner hose clamp [B].

Remove the air cleaner intake hose.
B

N–07644
Loosen the air cleaner hose clamps at the intake manifold

and air cleaner [C]. C
Remove the hose.
N–07645
Remove the nut from the throttle linkage cable end [D].
D
N–07646

ENGINE (Cont’d)
A
Loosen the large nut on the throttle linkage cable [A].
Disconnect the throttle linkage from the fuel injection
pump and mounting bracket.
N–07647
Disconnect the fuel hose and fuel return hose from the
fuel injection pump [B].
B

N–07648
Disconnect the two inlet hoses from the hydraulic pump

[C]. C
Drain the hydraulic fluid into a container.
N–07537
Disconnect the two high pressure hoses from the

hydraulic pump [D]. D
N–07538

ENGINE (Cont’d)
A
Remove the nuts from the four engine mounting brackets
[A].
N–07649
Disconnect the wire from the temperature switch [B]. B

N–07650
Disconnect the wire from the oil pressure switch [C].

C
N–07651
Disconnect the two alternator wires [D]. D
N–07652

ENGINE (Cont’d)
A
Disconnect the wires from the starter [A].
N–07634
Connect a chain hoist to the engine lift hooks [B]. B

Slowly lift the engine and remove it from the excavator
[B].

N–07653

MUFFLER
A
Loosen the exhaust pipe clamp [A].
N–07654
Remove the two bolts from the exhaust pipe mounting

bracket [B].
B

N–07655
Remove the exhaust pipe [C].

C
N–07656
Remove the two bolts and nuts from the exhaust manifold D
[D].
N–07657

MUFFLER (Cont’d)
A
Remove the nuts from the two muffler holddown clamps
[A].
N–07658
Remove the bolts from the two muffler holddown clamps

B
[B].

N–07659
Remove the holddown clamps [C]. C
N–07660
Remove the muffler [D]. D
N–07661

RADIATOR
A
Disconnect the top radiator hose [A].
Disconnect the lower radiator hose and engine block
drain hose.
N–07643
NOTE: Figure [B] is shown for photo clarity . B

Remove the two mounting bolts from the radiator
mounting bracket on the side of the radiator, toward the
frame [B].

N–07662
Remove the nut and washer from the radiator mounting

bracket [C].
C
N–07663
Remove the bolts from the mounting bracket [D]. D
N–07664

RADIATOR (Cont’d)
A
Remove the radiator mounting bracket [A].
N–07665
NOTE: Figure [B] is shown for clarity.

B
Remove the four bolts (Item 1)[B] which fasten the lower
radiator mounting brackets to the frame.

1
N–07666
Lift the radiator from the machine [C].

C
N–07667
Remove the lower mounting brackets. Remove the bolts

and remove the radiator shroud [D]. D
N–07668

ENGINE FLYWHEEL
A
NOTE: The flywheel can be removed with the engine

installed in the machine. The following
photos show the engine removed from the
machine for photo clarity.
If the engine is not removed; disconnect the two inlet

hoses from the hydraulic pump [A].
Drain the hydraulic fluid into a container.
N–07537
If the engine is not removed, disconnect the two high

pressure hoses from the hydraulic pump [B].
B
Remove the muffler from the engine. (See Page 7–15.)

N–07538
Remove the two mounting bolts from the hydraulicpump

[C]. C
N–07669
Remove the hydraulic pump from the flywheel bell D

housing [D].
N–07670

ENGINE FLYWHEEL (Cont’d)
A
Remove the two bottom bolts from the muf fler bracket
[A].
N–07671
Remove the two top bolts from the muffler bracket [B]. B

N–07672
Remove the muffler bracket and the two spacers [C].

C
N–07673
Remove all the bolts from the flywheel bell housing [D].
D
N–07674

ENGINE FLYWHEEL (Cont’d)
A
Remove the bell housing assembly [A].
N–07675
Remove the bolts from the hydraulic pump coupler [B]. B

Remove the hydraulic pump coupler [C].
Remove the bolts from the flywheel [D].
N–07677
Installation: Tighten the bolts 40–43 ft.–lbs. (54–59 Nm)
torque.
Remove the flywheel. C
Flywheel Ring Gear

• When fluids are under pressure. N–07678
• Tools are being used. D
W–2019–1285
The ring gear on the flywheel is an interface fit. Heat the

ring gear enough to expand it and hit it evenly with a
hammer to remove it.
Clean the outer surface of the flywheel to give a smooth
fit.
Clean the new ring gear and heat it to a temperature of
450°–500° (232°–260° C).
Fit the ring gear over the flywheel. Make sure the gear is
seated correctly. N–07679

CYLINDER HEAD
Removal of the Cylinder Head
A
Remove the nuts from the valve cover.
Remove the valve cover and gasket [A].
B–05094
Disconnect and remove high pressure fuel lines [B]. B

Remove the fuel injector nozzles. (See Page 7–10.)

B–05882
Remove the nuts from the rocker arm supports. Remove

the rocker arm assembly [C]. C
Remove the push rods [D].

D
Mark the push rods so they will be returned to their
original
position.
B–05881

CYLINDER HEAD (Cont’d)
Removal of the Cylinder Head (Cont’d)
A
Remove the cylinder head from the engine block [A].
B–05101
Remove the head gasket and O–ring from the engine

block [B].
B
NOTE: Some engines may use a shim and some do
not. If a shim is present it must be used
during reassembly. The shim (if used) must
be installed between the cylinder head and
gasket.

B–05886
Disassembly of the Cylinder Head

C
procedure:
MEL10121 – Valve Tool
Use a valve spring compression tool to remove the valves
[C].
B–05889
Remove the valve cap (Item 1) [D] and valve spring collet
(Item 2) [D]. D 5
2 1
6
Remove the valve spring retainer (Item 3) [D] and spring
(Item 4) [D]. 4
Remove the seal (Item 5) [D] and the valve (Item 6) [D]. Seal
Collets Cap
Valve 3
Spring
Retainer
B–04122

Removal of the Cylinder Head (Cont’d)
A
Remove the thermostat housing and thermostat [A].
B–03643
Servicing the Cylinder Head and Valves B 1

Clean the surface of the cylinder head.
Put a straight edge (Item 1) [B] on the cylinder head.
NOTE: Do not put the straight edge across the

combustion chambers.

Put a feller gauge (Item 2) [B] between the straight edge
and the surface of the cylinder head.
The maximum distortion of the head surface + 0.002” (+
0, 051 mm) in 4” (102 mm) of the length of the cylinder 2
head surface.
A–02735
If the measurement is more than the specifications, the
cylinder head must be replaced.
Clean the valve seat and combustion chamber. Measure
C
the width of the valve seat [C].
B–03632
The correct width of the seat is 0.083” (2,1 mm). The

correct angle of the valve and seat is 45° [D].
D A C
Valve Contacting
Width
B
Grind the valve seats as follows:
Use a 45° cutter to grind the surface of the valve seat.
Use a 15° cutter to grind the top surface of the valve seat. Corrected Surface
Use a 65° or 70° cutter to grind the bottom surface of the Uncorrected Surface of Valve Seat
valve seat to finish the valve seat to a 0.083” (2,1 mm) of Valve Seat
width. A–45° Cutter
Grind the valve surface to 45°. B–45° Cutter
C–65° or 70° Cutter A–02729

220ExcavatorServiceManual(S/N508211999&Below)#6720230–EngineServiecSectionPart1of2
Servicing the Cylinder Head and Valves (Cont’d)

A
Install the valve in the seat and check the depth [A].
The specifications for the depth of the valve is
0.043”–0.051” (1,09–1,30 mm).
If the measurement is more than specifications, add the
correct thickness of washer under the valve spring to
keep the correct spring tension.
B–03634
Clean the valve guide. Install the valve in the cylinder

head. Install a dial indicator [B].
B
Measure the clearance of the valve guide and the valve.
The measurement must be 0.0014”–0.0026” (0,04–0,07
mm).
Replace the valve guide and valves as needed. Make
sure to ream the inside diameter of the new guide to the
correct dimension of 0.276”–0.277” (7,01–7,04 mm)

B–03698
Checking the Valve Springs

C
Measure the valve spring. The length of the spring must
be 1.382”–1.402” (35,1–35,6 mm). Check the valve
spring with a square to make sure it is straight [C].
B–03680
Put the valve spring in a tester [D].

D
Push down on the spring 1.22” (31 mm), the compression
load must be 16.5 lbs. (7,5 kg).
Replace the valve spring if it does not meet these
specifications.
A–02759

Checking the Rocker Arm and Shaft
A
Measure the inside diameter of the rocker arm bushing
and the shaft diameter [A].
The inside diameter of the rocker arm bushing is
0.433”–0.435” (11,0–11,05 mm).
The shaft diameter is 0.432”–0.433” (10,97–11,0 mm).
If the measurements are not within specification,replace
the parts.
Assembling the Cylinder Head
B–03697
Install the valves. Put oil on the valve seal and install the
seal on the valve stem.
Install the valve spring and retainer . Install the spring
B
collet and valve cap.
Install the thermostat. Install the thermostat housing and
a new gasket.
Installing the Cylinder Head

Install the O–ring in the cylinder block [B].
B–05890
Install the new head gasket [C].

C
Install the shim (if present during disassembly). The shim
goes between the cylinder head and gasket.
NOTE: Use the same shim again or replace it with a

shim of the same thickness.
B–05886
Install the cylinder head. Put oil on the cylinder head bolts.
D
Tighten the bolts and nuts to 29–33 ft.–lbs. (40–45 Nm)
torque. Use the tighten sequence as shown in figure[D].
A–02773
220 Excavator (S/N 11999 & Below)

Installing the Cylinder Head (Cont’d)
A
Lower the piston to be measured for the clearance. Put
a piece of solder in the injector port [A]. Make sure the
solder does not touch the valve.
Turn the engine crankshaft (manually) until the piston
goes over T.D.C.
Remove the solder and measure it. The thickness must
be 0.024”–0.031” (0,6–0,8 mm). If the measurement is
not within this specification, remove the cylinder head.
Install the correct shim between the cylinder head and
gasket.
B–04068
Install the cylinder head. Tighten the bolts and nuts to
29–33 ft.–lbs. (40–45 Nm) torque. Use the tightening
sequence on Page 7–26, figure [D]. B
Install the push rods [B].

B–05881
Install the rocker arms [C].

C
Install the injector nozzles. (See Page 7–10.)
Install the high pressure fuel lines.
Adjust the valve clearance. (See Page 7–2.)
Install the valve cover with a new gasket [D].

D
Connect the radiator hose. Add coolant to the cooling
system.
NOTE: Make sure to tighten the cylinder head bolts

and nuts to the correct torque after the
engine has been operated for 30 minutes.
Readjust the valve clearance.
B–05094

TIMING GEAR COVER
A
NOTE: It may be easier to remove and install the

timing gear cover with the engine removed
from the machine.
Remove the fuel injection pump. (See Page 7–5.)

Remove the side plate from the governor housing.
Disconnect the governor spring from the governor fork
[A].
B–03676
Remove the plate for the speed control and governor

spring [B]. B

B–03647
Remove the start spring from the gear case [C].

C
B–03678
Straighten the washer on the crankshaft pulley. Remove

the nut and washer. D
Installation: Tighten the nut to 101–1 16 ft.–lbs.
Use a puller and remove the pulley [D].
Remove the crankshaft key.
B–05896

TIMING GEAR COVER (Cont’d)
A
Remove the bolts from the gearcase.
Nm) torque.
Remove the gear case and O–rings [A].
B–05895
Installation: Install new crankshaft seal. Install the three

O–rings. Put non–drying adhesive on the edge of the
B
gearcase cover [B].
O–rings

Oil Seal
B–03617

TIMING GEAR, CAMSHAFT AND OIL PUMP
A
3
Remove the cylinder head. (See Page 7–22.)
2 1
Remove the tappets.
Remove the timing gearcase cover. (See Page 7–28.)
Remove the crankshaft collar (Item 1) [A], O–ring (Item
2) [A] and oil slinger (Item 3) [A].
B–03637
[B].
Remove the snap ring and washer from the idler gear B

B–05918
Remove the idler gear (Item 1) [C].

Remove the idler gear collar (Item 2) [C] from the shaft. C
1
B–03699
Align the holes in the camshaft gear with the stop plate
bolts.
D
Remove the bolts from the camshaft stop plate [D].
Nm) torque.
B–05930

TIMING GEAR, CAMSHAFT AND OIL PUMP (Cont’d)
A
Remove the camshaft [A].
B–03655
Remove the two bolts that hold the fork lever on the fuel
camshaft.
B
Installation: Tighten the fork lever bolts to 60–72
in.–lbs.(6,8–8,1 Nm) torque.
Remove the fork lever [B].

B–05919
Remove the stop (Item 1) [C] for the fuel camshaft.

C
Remove the fuel camshaft [C].
B–05922
Installation: Make sure the timing marks on the gears

are aligned when installing the gears [D]. D Crankshaft
Gear
Gear backlash is 0.0017”–0.0045” (0,043–0,114 mm).
The limit permitted is 0.0079” (0,2 mm). Injection
Pump
Gear
Idler
Gear
Camshaft
Gear
B–05927

A
Remove the crankshaft gear with a puller [A].
Remove the crankshaft key.
B–03686
Oil Pump Service B

Straighten the washer on the gear of the oil pump.
Remove the bolt from the oil pump gear.
Installation: Tighten the bolt to 60–72 in.–lbs. (6,8–8,1
Nm) torque.
Remove the oil pump gear [B].

B–05923
Remove the oil pump bolts and oil pump [C].

C
Installation: Tighten the oil pump bolts to 60–72 in.–lbs.
(6,8–8,1 Nm) torque.
B–05925
Check the clearance between the inner and outer rotor

[D]. D
The clearance for the inner rotor is 0.004”–0.006”
(0,10–0,15 mm). The wear limit is 0.008” (0,20 mm).
B–03616

Oil Pump Service (Cont’d)
A
Check the clearance between the outer rotor and the
body of the oil pump [A].
The clearance for the outer rotor is 0.004”–0.008”
(0,10–0,20) mm).
At rated engine speed, the normal oil pressure is 28–64
PSI (193–441 kPa). It must not be lower than 28 PSI (196
kPa).
A–02732
Servicing the Camshaft B

Measure the camshaft bearing in the engine block [B].
The specification is 1.299”–1.300” (32,99–33,02 mm).
The wear limit is 0.002”–0.0036” (0,051–0,091 mm).

B–03620
Measure the camshaft journal [C].

C
The specification is 1.296”–1.297” (32,91–32,94 mm). If
the measurements are not within limits, replace the parts
as needed.
A–02761
Put the camshaft in V–blocks. Install a dial indicator on

the journals [D]. D
Turn the camshaft slowly. The wear limit is 0.002” (0,05
mm).
If the camshaft measurements are not within the
specifications, replace the part as needed.
A–02760

A
Servicing the Camshaft (Cont’d)
Measure the highest point on each camshaft lobe [A].
The specification is 1.058” (26,87 mm).
The wear limit is 1.056” (26,82 mm).
B–05001
Installation: After the crankshaft is installed, check the

clearance for the camshaft gear . Mount a dial indicator
B
[B].
Hold one gear while turning the other gear . The
specification is 0.0017”–0.0045” (0,043–0,114 mm). The
wear limit is 0.0079” (0,2 mm).

B–03672
CRANKSHAFT AND PISTONS C

procedure:
MEL1063 – Ring Compressor
MEL1064 – Piston Ring Expander
Remove the cylinder head. (See Page 7–22.)
Remove the gear case cover. (See Page 7–28.)
Remove the timing gears. (See Page 7–30.)
B–05924
Remove the flywheel.
Remove the oil pan [C].

Revised July
22091
CRANKSHAFT AND PISTONS (Cont’d)
A
Remove the oil pump tube and screen [A]. Do not
damage the O–ring on the tube.
Straighten the washer on the connecting rod bolts.
Remove the connecting rod nuts and bolts.
B–05920
B
Remove the cap and bearing from the connecting rod[B].
NOTE: Make sure the marks on the connecting rod
and bearing cap are in alignment when
installing the bearing cap [B].

Installation: Put oil on the bolts and tighten to 26–30 ft.
lbs. (35–41 Nm) torque.
A–02731
Installation: Tighten the rod cap bolts to torque as

follows [C]:
C
Machine Bolt (13 mm size head) . . . . . . 27–31 ft.–lbs. OLD 13 Tightening Torque
(36–42 Nm) mm 27–31 ft.–lbs. (36–42 Nm)
Forged Bolt (12 mm size head) . . . . . . . . 33–36 ft.–lbs.
(45–49 Nm)
NEW
12
mm
Tightening Torque
(Cold Forged Flange Bolt)
33–36 ft.–lbs. (36–42 Nm)
B–13445

Revised
221 of July
A
Straighten the washer on the bolts that hold the main
bearings in position. Remove the main bearing bolts from
the engine block [A].
Nm) torque.
B–03644
Straighten the washer on the bolts that hold the rear cover
in position. Remove the bolts.
B
Install two bolts in the rear cover and pull the cover out
[B].
Installation: Install a new seal in the rear cover. Tighten
the bolts to 22–25 ft.–lbs.(29–34 Nm) torque.

B–03648
Installation: Check the crankshaft end play with a dial

indicator [C]. The normal end play is 0.006”–0.012” C
(0,15–0,30 mm). Replace the thrust bearing if the end
play exceeds 0.020” (0,5 mm).
B–10072
Remove the crankshaft from the rear of the engine block

[D]. D
NOTE: Do not damage the crankshaft when
removing it from the engine block.
B–04126

Crankshaft Service
A
Straighten the washers on the main bearing bolts.
Remove the bolts from the bearing cap halves [A].
Remove the halves of the main bearings.
NOTE: When installing the bearing cap halves, make

sure to position the markings on the bearing
caps toward the flywheel. Thrust washers
must be installed with oil grooves facing
outward.
Installation: Tighten the bolts to 15–17 ft.–lbs. (20–24 B–04092
Nm) torque.
NOTE: Be sure the plugs that come with a new

crankshaft are installed in the crankshaft or B
engine damage will occur.
Put the crankshaft on V–blocks. Put a dial indicator on the

center journal [B]. Turn the crankshaft slowly . The
specification is 0.008” (0,02 mm). The wear limit is 0.003”
(0,08 mm).

A–02763
Check the inside diameter of the crankshaft bearing in the

engine block [C]. C
The specification is 1.732”–1.734” (43,99–44,04 mm).
B–03631
Check the outside diameter of the #1 crankshaft journal

[D]. The specification is 1.730”–1.7303” (43,94–43,95 D
mm). The wear limit is 0.008” (0,20 mm).
B–03618

Servicing the Connecting Rods and Pistons
A
Remove the piston rings (Item 1)[A] and piston pin (Item
2) [A].
2
1
B–03621
Installation: Position the top ring so the gap is not lined

up with the piston pin. Position the other rings so there is
B
a gap every 90 ° [B]. Use a ring compressor to install the
pistons in the engine block with the marks away from the
camshaft.

Alignment Marks
B–03614
Put the piston ring on the bottom of the cylinder bore[C].

Check the clearance of the ring gap. The specifications C
are:
Top and 2nd Ring . . . 0.010”–0.0158” (0,25–0,40 mm)
Oil Ring . . . . . . . . . . . . 0.008”–0.0158” (0,20–0,40 mm)
Wear Limit . . . . . . . . . . . . . . . . . . . . . . .0.05”
. (1,27 mm)
B–03622
Measure the piston pin hole [D].

D
The specifications are 0.787”–0.788” (19,98–20,02 mm).
A–02733

Servicing the Connecting Rods and Pistons (Cont’d)
A
Measure the piston pin (Item 1) [A] and the connecting
rod bushing (Item 2) [A].
Clearance between piston pin and bushing is
0.0006”–0.0015” (0,015–0,04 mm). The wear limit is
0.006” (0,15 mm). 2
1
B–03633
Install the connecting rod on the tool for checking

connecting rod alignment [B].
B
Check the clearance in the piston pin area. The
specification is 0.0008” (0,020 mm). The wear limit is
0.002” (0,05 mm).
NOTE: Be sure the bushing diameter of the

connecting rod is within specifications.

B–04067
Check the connecting rod bearings [C].

C
A–02727
Check the connecting rod journals [D].

D A
If the connecting rod journals arenot within specifications,
grind the journals as follows [D]:
Crankshaft corner radius must be 0.138”R + 0.008” (3,5 B
mmR+ 0,20 mm).
The oil hole must be chamfered to 0.039”–0.059”R
(0,99–1,5 mmR).
A
A–02716

CYLINDER LINERS
Checking the Cylinder Liners
A
procedure:
MEL1060 – Ridge Reamer
MEL1180 – Dry Line Puller
Check the inside diameter of the cylinder liner [A].
B–10073
To find the maximum wear, check the inside diameter in

three different locations [B]. B
The specifications are 2.677”–2.678” (67,99–68,02).The
wear limit is + 0.006” (+0,15 mm).
When the cylinder liner has more wear than
specifications, bore and hone the cylinder to
2.697”–2.698” (68,5–68,53 mm).

NOTE: Make sure you use the correct oversize
pistons and rings.
If the cylinder liner is not within the specifications, replace

the cylinder liner. These are dry cylinder liners. A–02717
Cylinder Liner Installation

Clean and rub oil on the bores of theengine block. Clean
and put oil on the outside of the cylinder liners. Install the
cylinder liners into the engine block with the chamfered
end down.
The top of the liner must be even with the top of the engine
block machined surface.
After installation, bore and/or hone the cylinder liner to
2.677”–2.678” (67,99–68,02 mm).

WATER PUMP
A
Remove the radiator. (See Page 7–17).
Remove the alternator belt.
Remove the fan.
Remove the water pump bolts.
Remove the water pump [A].
Installation: Always use a new gasket when installing B–05926
the water pump.

B
Put the water pump in a vise.
Remove the pulley.
2
Drive the shaft out of the impeller side of the water pump
[B].

Remove the seal. 4
Install a new seal when assembling the water pump. 3 1
B–05929

220ExcavatorServiceManual(S/N508211999&Below)#6720230–EngineServiecSectionPart2of2

SPECIFICATIONS
Page
Number
ENGINE SPECIFICATIONS (KUBOTA)

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–5 ....
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5....
Crankshaft Re–Grind Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–8 ..
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–5
....
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 ....
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–4
....
Engine Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–7 ....
Fuel Injector Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–4 ...
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–4 ...
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–6....
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–5
....
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5....
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 ....
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6....
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–4
....
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 ....
FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9
..

HYDRAULIC EXCAVATOR SPECIFICATIONS
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–3
....
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–3
....
Digging Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 ....
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 ....
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–2
....
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–2 ...
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–2 ...
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–1 ...
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2 ....
Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2 ....
Track Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 ....
Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 ....
OIL SPECIFICATIONS SPECIFICATIONS

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9
....


HYDRAULIC EXCAVATOR • All dimensions are shown in inches. Respective metric dimensions are given in
millimeters enclosed by parentheses.
SPECIFICATIONS • Where applicable, specifications conform to SAE standards. Specifications are subject
to change without notice.
Machine Dimensions
A – 138.8 (3526)
B – 38.6 (980)
C – 85.0 (2159)
D – 28.7 (730)
E – 9.8 (250)
F – 95.3 (2420) N
G – 10.2 (260)
H – 44.1 (1120)
I – 58.7 (1490)
J – 36.0 (915)
K – 17.7 (450) O
L – 46.5 (1180)
M – 0.71 (18)
N – 18.1 (460)
O – 23.6 (600)
MC–1208
A
F

C
K
G
E H
D J M
MC–1209
B I
C
D With 32.3 (820)
G 71.3 (1811)
A Max. digging depth 71.3 (1811)

B Max.vertical wall depth 47.2 (1200)
C Max. digging reach 138.0 (3505)
E H D Max. digging reach at ground level 130.7(3320)
F I E Max. digging height 115.6 (2936)
F Max. dumping height 77.6 (1971)
G Min. swing radius
(when using boom swing) 52.8 (1341)
H Max. height of Min. swing radius 95.7 (2431)
B
A J I Max. lift above ground (blade) 6.3 (160)
J Max. drop below ground blade 5.5 (140)
MC–1207

HYDRAULIC EXCAVATOR SPECIFICATIONS (Cont’d)
220
PERFORMANCE
Operating Weight . . . . . . . . . . . . . . . . . . . . . 2863 lbs. (1300 kg)
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . 1.52 MPH (2,45 km/hr)
Controls:
Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . Two Hand Levers
Functions . . . . . . . . . . . . . . . . . . . . . . . . Two joystick levers control boom, bucket, dipperstick and swing
Two separate levers control boom swing and blade
ENGINE
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kubota
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D750–B–MC–1
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 HP (10,1 kw) @ 2500 RPM
Displacement . . . . . . . . . . . . . . . . . . . . . . . . 46.5 cu.–in. (762 cu. cm)
Maximum Torque . . . . . . . . . . . . . . . . . . . . . 31 ft.–lbs. (42 Nm) @ 1800 RPM
Maximum Governed RPM – Full Load . . . 2500 RPM
No Load . . 2700 RPM
Number of Cylinders . . . . . . . . . . . . . . . . . . Three
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . . 2.68/2.76 (68/70)
Cooling System . . . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication System . . . . . . . . . . . . . . . . . . . Forced
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Flow
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt, Reduction Drive

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt, 15 Amp.
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt, 425 Cold Crank Amps.
HYDRAULIC SYSTEM
Pump Numbers . . . . . . . . . . . . . . . . . . . . . . Two
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double Section Gear Pumps
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 x 5.35 GPM (20,3 L/min.) = 10.7 GPM (40,5 L/min)
System Relief Setting . . . . . . . . . . . . . . . . . 2133 PSI (14707 kPa)
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . 10 Spool
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . Two Axial Piston
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . Orbit Motor
Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . . See Page 8–9
SWING SYSTEM
Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . Gear Motor Connect to a Pinion
Swing Circle . . . . . . . . . . . . . . . . . . . . . . . . . Single Row Shear Type Ball Bearings with Internal Gears Built Into Swing Circle
Swing Speed . . . . . . . . . . . . . . . . . . . . . . . . 15.8 RPM
Boom Swing (Left) . . . . . . . . . . . . . . . . . . . . 46.4 degrees
Boom Swing (Right) . . . . . . . . . . . . . . . . . . 87.3 degrees
HYDRAULIC CYLINDERS
Bore Dia. Rod Dia. Stroke
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 (60) 1.38 (35) 21.65 (550)
Dipperstick . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 (60) 1.38 (35) 17.32 (440)
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 (60) 1.38 (35) 15.16 (385)
Boom Swing . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 (60) 1.38 (35) 13.62 (346)
Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 (60) 1.38 (35) 2.75 (70)

HYDRAULIC EXCAVATOR SPECIFICATIONS (Cont’d)
220
DRIVE SYSTEM
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . Each track is independently driven by a hydrostatic axial motor
Type of Reduction . . . . . . . . . . . . . . . . . . . . Power is transferred through a planetary gear reduction
Maximum Drawbar Pull . . . . . . . . . . . . . . . 1982 lbs. (900 kg)
Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . 30 degrees
BRAKES
Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic lock on motor
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic lock on motor & hold pin lock
UNDERCARRIAGE
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crawler–Tractor design undercarriage. Sealed track with
reinforced box–section adjusters with shock absorbing recoil system.
TRACK SHOES
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rubber
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.84 (250)
Number of Shoes . . . . . . . . . . . . . . . . . . . . . Single assembly
Number of Track Rollers . . . . . . . . . . . . . . . Three each side
Ground Pressure . . . . . . . . . . . . . . . . . . . . . 3.43 PSI (23,7 kPa)

CAPACITIES
Fuel Tan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 gals. (25 L)
Cooling System . . . . . . . . . . . . . . . . . . . . . . 3.0 qts. (2,85 L)
Engine Oil & Filter . . . . . . . . . . . . . . . . . . . . 4.5 qts. (4,3 L)
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . 7.0 gals. (26,5 L)
Final Drive Case (Each) . . . . . . . . . . . . . . . 0.3 qts. (0,3 L)
DIGGING FORCE
Dipperstick . . . . . . . . . . . . . . . . . . . . . . . . . . 1784 lbs. (810 kg)
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2775 lbs. (1260 kg)

ENGINE SPECIFICATIONS (KUBOTA)
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Engine
Compression (Operating Temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .450

. . PSI (3103 kPa) @ 200–300 RPM
Fuel Injector Nozzles
Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1990–2133

.... PSI (13721–14707 kPa)
Fuel Tightness Nozzle Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dry . . .Nozzle at 1848 PSI (12742 kPa)
Fuel Injection Pump
Fuel Tightness Plunger . . . . . . . . . . . . . . . . . . . .8 Seconds: Initial pressure drop from 1237–1031 PSI (8529–7109 kPa)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 seconds or less
Fuel Tightness of Delivery Valve . . . . . . . . . . . . . . 10 . Seconds: Initial pressure drop from 1422–71 PSI (9805–490 kPa)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Seconds or Less
Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23–25
. degrees B.T.D.C.
Cylinder Head
Cylinder Distortion Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002

.. (0,05) in 3.9 (100) of the length of the cylinder head

Thickness of Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.04–0.05
... (1,02–1,3)
Thickness of Gasket Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2)
Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.02–0.03 (0,51–0,8)
Valves
Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 degrees

Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.08 (2,1)
O.D. of Valve Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.274–0.275
..... (6,96–6,99)
I.D. of Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.276–0.277
..... (7,01–7,04)
Clearance Between Valve Stem & Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0014–0.0026 ... (0,035–0,065)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.004 (0,1)
Depth of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.04–0.043 (1,0–1,1)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.05 (1,3)
Valve Clearance (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.006–0.007
.... (0,15–0,18)
Valve Springs
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.382–1.402 (35,1–35,6)

Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.37 (34,8)
Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.185 (30,1)
Load to Compress to Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16.5 . . . .lbs. (7,5 kg)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 lbs. (6,4 kg)
Limit Permitted for Spring being Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.05 . . . .(1,3)
Rocker Arms
O.D. of Rocker Arm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.432–0.4324

.... (10,97–10,98)
I.D. of Rocker Arm Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.433–0.4346
.... (11,0–11,04)
Clearance Between Rocker Arm Shaft & Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0005–0.0026 .. (0,013–0,07)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.005 (0,13)

ENGINE SPECIFICATIONS (KUBOTA) (Cont’d)
Camshaft
O.D. of Camshaft Bearing Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2966–1.2972 ... (32,93–32,95)

I.D. of Camshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2992–1.3002
.... (32,99–33,025)
Clearance between Camshaft Bearing & Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.002–0.0036 .. (0,051–0,091)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.006 (0,15)
Alignment of the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05)
Cam Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0583 (26,88)
Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.002–0.003
. (0,051–0,08)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.008
. (0,2)
Cylinders
I.D. of Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.677–2.678

.... (67,99–68,02)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.0006 (+0,015)
Piston Rings
Ring Gap (Top & 2nd Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010–0.016.... (0,25–0,41)

Ring Gap, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.009–0.016 (0,23–0,41)

Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.049 (1,24)
Side Clearance of Ring Groove:
Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.00
. (0,0)
Second Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003–0.004 (0,08–0,10)
Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008–0.002 (0,02–0,051)
Oversize of Piston & Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,51)
Pistons
I.D. of Piston Bosses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.787–0.788

.... (19,98–20,02)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.789 (20,04)
O.D. of Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.787–0.789
..... (19,98–20,04)
I.D. of Connecting Rod Bushing (Small End, Fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.788–0.790 .. (20,02–20,07)
Clearance between Piston Pin & Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0006–0.0015 ... (0,015–0,04)
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0008 . (0,02)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.006 (0,15)
Crankshaft
Crankshaft Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008 (0,02)

Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.003 (0,08)
O.D. of Crankshaft Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7297–1.7303
.... (43,93–43,95)
I.D. of Crankshaft Bearing No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7317–1.7339
.... (43,99–44,04)
Clearance between Crankshaft Journals & Bearing No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0013–0.0036 . (0,03–0,09)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.008
. (0,2)
O.D. of Connecting Rod Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4551–1.4557 ... (36,96–36,98)
I.D. of Connecting Rod Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4568–1.4587 ... (37,003–37,051)
Clearance between Connecting Rod Journal & Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0011–0.0036 .. (0,028–0,091)
Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006–0.012
..... (0,15–0,30)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.020
. (0,5)

Oil Pump
Oil Pressure @ Rated RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28–64 . . . . PSI (193–441 kPa)

Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 PSI (193 kPa)
Oil Pressure @ Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 . . PSI
. (69 kPa)
Rotor Lobe Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.004–0.006
.... (0,010–0,15)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.008
. (0,2)
Clearance Between Outer Rotor & Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.003–0.006 .. (0,08–0,15)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.010 (0,25)
End Clearance between Rotor & Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.003–0.005(0,08–0,13)
...
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.008
. (0,2)
Thermostat
Opening Temperature
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177–182°F (81–84°C)
Full Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203°F (95°C)
Distance of Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.315
. (8)

Engine Torque
Ft.–Lbs. Nm
*Cylinder Head Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29–33 39–44

*Main Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15–17 20–24
*Main Bearing Case Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–25 29–34
*Flywheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–43
. 54–59
*Connecting Rod Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20–22 27–30
*Rocker Arm Bracket Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15 17–21
*Idler Gear Shaft Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 9–11
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15–18
. 20–25
Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30–36
. 39–49
Nozzle Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30–36
. 39–49
Oil Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11–15
. 15–20
Fuel Injection Tubeline Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 11–19 13–26
Crankshaft Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101–116
.. 137–157
Injection Pump Vent Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–13 14–18
*Lightly Oil Threads

PUNCHED NUMBER BOLT MATERIAL GRADE
None Standard Bolts SS41, S20C
7 Special Bolts S43C, 248C (Refined)
9 Special Bolts SCM3, SCR3 (Refined)
BOLT TORQUES
MATERIAL GRADE STANDARD BOLT STANDARD BOLT STANDARD BOLT
NOMINAL DIAMETER SS42, S20C S43C, S48C (Refined) SCR3, SCM3 (Refined)
M6 6–7 ft.–lbs. 7–8 ft.–lbs. 9–11 ft.–lbs.
(8–9 Nm) (9–11 Nm) (12–15 Nm)
(18–20 Nm) (23–27 Nm) (30–34 Nm)
(39–45 Nm) (47–56 Nm) (61–71 Nm)
(62–73 Nm) (77–91 Nm) (103–118 Nm)
(108–126 Nm) (123–148 Nm) (167–197 Nm)
(167–191 Nm) (197–225 Nm) (260–304 Nm)
(245–285 ft.–lbs. (275–319 Nm) (343–403 Nm)
(334–392 Nm) (367–431 Nm) (491–578 Nm)

Crankshaft Re–Grind Data
If the standard size bearing cannot be used due to excessive wear ofthe crankpin and crankshaft journals, use undersize
or oversize bearings.
D
3 C
1
A B

1 2
B–05928
REF. SIZE CODE NUMBER DESCRIPTION DIMENSION MARK

0.008 in. 15261–2391–1 Crankshaft 1.7218–17224 in. 020US
A (0,2 mm) U/S Bearing #1 (43,743–43,750 mm)
0.016 in. 15261–2392–1 Crankshaft 1.7139–1.7146 in. 040US
(0,4 mm) U/S Bearing #1 (43,534–43,550 mm)
B (0,2 mm) U/S Bearing #2 (43,734–43,750 mm)
(0,4 mm) U/S Bearing #2 (43,534–43,550 mm)
0.008 in. 15531–2297–1 Crankpin 1.4472–1.4478 in. 020US
C (0,2 mm) U/S Bearing (36,759–36,775 mm)
0.016 in. 15531–2298–1 Crankpin 1.4393–1.4400 in. 040US
(0,4 mm) U/S Bearing (36,559–36,575 mm)
0.008 in. 15261–2397–1 Crankshaft 0.9528–0.9547 in. 0.20 OS
D (0,2 mm) O/S 15261–2395–1 Thrust Bearing (24,20–24,25 mm)
0.016 in. 15261–2398–1 Crankshaft 0.9606–0.9626 in. 0.40 OS
(0,4 mm) O/S 15261–2396–1 Thrust Bearing (24,40–24,45 mm)
0.130–0.146 in.
1 Radius – 0.13–0.146 in (3,3–3,7 mm) (3,3–3,7 mm)
0.11–0.126 in.
2 Radius – 0.11–0.126 in. (2,8–3,2 mm) (2,8–3,2 mm)
IMPORTANT: Oil hoses must have a 0.0394–0.0591 in. (1–1,5 mm) chamfer. Use an oil stone to
3 chamfer the oil hole.

FUEL, COOLANT AND LUBRICANTS
Use the following chart for correct selection of Fuel, Coolant and Lubricants.
AMBIENT TEMPERATURE CAPACITY

F° –30 –20 –10 0 +10 +20+30 +40 +50 +60 +70 +80 +90 +100
RESERVOIR KIND OF FLUID C° –34 –29 –23 –18–13 –7 –1 +4 +10 +15 +21 +27 +32 +38 Refill
Engine Oil Pan Engine oil SAE 30 4.5 qts.
(4,3 L)
SAE 10W
Final Drive Case Engine oil 0.33 qts.

(each) SAE 30 (0,3 L)
Hydraulic Tank* SAE 10W 7.0 gals

(26,5 L)
SAE 10W–30
SAE 15W–40
Fuel Tank Diesel Fuel No. 1 6.6 gals

(25 L)
No. 2

Cooling System **See Below Add anti–freeze 3.0 qts.
(2,85 L)
* Use Bobcat fluid (P/N 6563328) in Hydraulic System.

OIL SPECIFICATIONS
Description
When fuel sulphur content is less than 0.5% change the
engine oil and filter as shown in the Service Schedule
Page 1–1.
Change engine oil and filter according to the following
chart if fuel sulphur content is above 0.5%.
Fuel Sulphur Change Interval Of
Content Engine & Oil Filter
0.5 to 1.0% 1/2 of Regular Interval
Above 1.0% 1/4 of Regular Interval
When starting the engine in a temperature of lower than
32°F (0°C) use SSAE 10W engine oil.
Use API Classification CD engine oil, if API Classification
CC is used, reduce the engine change interval to half the
hours.

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

220–1
® Revision Number
3 July 1991
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT EXCAVATOR
SERVICE MANAGER X
Model 220 (S/N 508211999 & Below) SALES MANAGER
Manual No. 6720230 (5–89)
NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.
The following page is a revision to the 220 Excavator Service Manual P/N 6720230.
Put in the added page as follows:

TAKE OUT PUT IN
HYDRAULIC FLOW CHART #6720139 HYDRAULIC FLOW CHART #6720139
(Printed May 1989) (Printed July 1991)
CHART LEGEND #6720139 CHART LEGEND #6720139
SECTION 2
Contents Page Contents Page (Revised July 91)
2–1 thru 2–12 2–1 thru 2–12 (Revised July 91)
2–13, 2–14 (Added July 91)
SECTION 4
4–1, 4–2 4–1, 4–2 (Revised July 91)
4–3, 4–4 4–3 (Revised July 91), 4–4 (Revised July 91)
SECTION 6
ELECTRICAL WIRING DIAGRAM #6720138 ELECTRICAL WIRING DIAGRAM #6720138
ELECTRICAL WIRING DIAGRAM #6720534
(Added July 1991)
SECTION 7
7–33, 7034 7–33, 7–34 (Revised July 91)
7–35, 7–36 7–35 (Revised July 91), 7–36
241 of 258 Printed in U.S.A.

242 of 258
220–2
® Revision Number
6 April 1992
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER X
Manual No. 6720230 (5–89)

TAKE OUT PUT IN
SECTION 4
Contents Page Contents Page (Revised April 1992)
4–1 thru 4–4 4–1 thru 4–4 (Revised April 1992)
4–5 (Added April 1992)
4–6 (Added April 1992)
243 of 258
244 of 258
220–3
® Revision Number
6 May 1992
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER X
Manual No. 6720230 (5–89)

TAKE OUT PUT IN
2–11 (Revised July 91) thru 2–14 (Revised July 91) 2–11 (Revised May 92) thru 2–14 (Revised May 92)
2–15 (Added May 92) thru 2–33 (Added May 92)
245 of 258
246 of 258
220–4
® Revision Number
30 June 1992
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER X
Manual No. 6720230 (5–89)

TAKE OUT PUT IN
HYDRAULIC SECTION HYDRAULIC SECTION
HYDRAULIC FLOW CHART #6720139 HYDRAULIC FLOW CHART #6720139 (Without Hi–Flow)
(Printed July 1991) (Printed June 1992)
HYDRAULIC SYSTEM OPERATION HYDRAULIC SYSTEM OPERATION (Without Hi–Flow)
(Printed May 1989) (Printed June 1992)
HYDRAULIC FLOW CHART #6722100 (With Hi–Flow)
(Printed June 1992)
HYDRAULIC SYSTEM OPERATION (With Hi–Flow)
(Printed June 1992)
247 of 258
248 of 258
220–5
® Revision Number
28 July 1992
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER X
Manual No. 6720230 (5–89)

TAKE OUT PUT IN
Section 3, Content Page Section 3, Content Page (Revised July 92)
3–9 thru 3–28 (Added July 92)
249 of 258
250 of 258
220–6
® Revision Number
9 February 1995
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER X
Manual No. 6720230 (5–89)
The following page is a revision to the 220 Excavator Service Manual P/N 6720230 (5–89).

TAKE OUT PUT IN
Section 5, Content Page Section 5, Content Page (Revised Feb. 95)
5–9 5–9 thru 5–9g (Added Feb. 95)
5–11 thru 5–17 (Added Feb. 95)
251 of 258
252 of 258
220–7
® Revision Number
6 March 1995
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER X
Manual No. 6720230 (5–89)
The following page is a revision to the 220 Excavator Service Manual P/N 6720230 (5–89).

TAKE OUT PUT IN
5–10
253 of 258
254 of 258
220–8
® Revision Number
8 July 1997
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER X
Manual No. 6720230 (5–89)
The following page is a revision to the 220 Excavator Service Manual P/N 6720230 (5–89) Revised (7–96).

TAKE OUT PUT IN
Section 2 Section 2
Section 4 Section 4
255 of 258
256 of 258
ROUTE TO
ATTENTION
SERVICE MANUAL PARTS MANAGER
SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: 220-9

Date: 15 June 2012
Product: Bobcat Excavator
Model: 220
Manual No: 6720230 (5-89)

The following Sections are a revision to the above Service Manual.
COVER
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X 220

Dealer Copy -- Not for Resale

Doosan purchased Bobcat Company from Ingersoll-Rand Company in

6720230 (6-12) Printed in U.S.A. © Melroe Company 1989

Dealer Copy -- Not for Resale

220 (S/N 508211999 & Below) Excavator

220 (S/N 508211999 & Below) Excavator

3. The seat belt must be 11. Check hydraulic fluid level,

Dealer Copy -- Not for Resale

5. Machine signs must be legible 13. Lubricate the hydraulic

6. Steering levers, control levers 14. Check the condition of the

8. Check the electrical charging Recommend to the owner that all

220 (S/N 508211999 & Below) Excavator

220 (S/N 508211999 & Below) Excavator

Dealer Copy -- Not for Resale

Warnings on the machine and in the This notice identifies procedures

HYDRAULIC EXCAVATOR SERIAL NUMBER

The excavator serial number plate is on the machine

ENGINE SERIAL NUMBER

Dealer Copy -- Not for Resale

220 (S/N 508211999 & Below) Excavator

Dealer Copy -- Not for Resale

Dealer Copy -- Not for Resale

220 (S/N 508211999 & Below) Excavator

AIR CLEANER SERVICE

ENGINE LUBRICATION SYSTEM

Dealer Copy -- Not for Resale

LUBRICATION OF THE EXCAVATOR

USING A BOOSTER BATTERY (JUMP STARTING)

220 (S/N 508211999 & Below) Excavator

220 (S/N 508211999 & Below) Excavator

Instructions are necessary before operating or servicing machine.

ITEM SERVICE REQUIRED 8–10 50 100 250 500 1000

Dealer Copy -- Not for Resale

220 (S/N 508211999 & Below) Excavator

Dealer Copy -- Not for Resale

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

3. Remove the filter element [D]. D

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

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

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

220 (S/N 508211999 & Below) Excavator

Stop and cool the engine before adding fuel.

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

Dealer Copy -- Not for Resale

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

220 (S/N 508211999 & Below) Excavator

Always clean up spilled fuel or oil. Keep heat,

Dealer Copy -- Not for Resale

220 (S/N 508211999 & Below) Excavator

Dealer Copy -- Not for Resale

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

220 (S/N 508211999 & Below) Excavator

Turn the upper works so there is access tothe engine and

Dealer Copy -- Not for Resale

Wear safety glasses to prevent eye injury when

220 (S/N 508211999 & Below) Excavator

Dealer Copy -- Not for Resale

Remove the reservoir fill cover [C].