BOBCAT 220 EXCAVATOR Service Repair Manual (SN 508212001 & Above)

X 220 Excavator Service Manual (S/N 508212001 & Above)

6720503(6–90)–7.5C

Printed in U.S.A.

© Melroe Company 1997

MAINTENANCE SAFETY WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s 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. Untrained operators and failure to follow W-2003-0903 instructions can cause injury or death.

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

CORRECT

B-10731a

Never service the Hydraulic Excavator instructions.

Bobcat without

CORRECT

CORRECT

B-14148

Use the correct procedure to lift and support the excavator.

Always lift the blade fully before installing jackstands.

B-14142

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B-14147

B-14141

B-14145

Have good ventilation when welding or grinding painted parts.

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

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

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

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

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

WRONG

WRONG

WRONG

B-14146

B-14143 B-16102

B-6589 B-16102

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

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

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

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

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

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

Use eye protection approved for type of welding.

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

Lead-acid batteries produce flammable and explosive gases.

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

Batteries contain acid which burns eyes or skin on contact.

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

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer.

MSW20-0805

ALPHABETICAL INDEX AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . .

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUXILIARY COUPLERS . . . . . . . . . . . . . . . . . . . . . . .

AUXILIARY FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . .

1–1 6–1 2–1 2–1

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BLADE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BLADE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BOOM AND DIPPERSTICK . . . . . . . . . . . . . . . . . . . .

BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BOOM SWING BRACKET . . . . . . . . . . . . . . . . . . . . .

BOOM SWING CYLINDER . . . . . . . . . . . . . . . . . . . . .

BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . .

6–1 2–1 3–1 5–1 2–1 5–1 2–1 2–1

CENTER SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL AND STEERING LEVERS . . . . . . . . . . .

CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . .

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER LINERS . . . . . . . . . . . . . . . . . . . . . . . . . . .

4–1 1–1 3–1 3–1 7–1 7–1 7–1

DIPPERARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . .

DRIVE MOTOR (S/N 12001–12929) . . . . . . . . . . . . .

DRIVE MOTOR (S/N 12930 & Above) . . . . . . . . . . . .

DUKES HYDRAULIC CONTROL VALVE . . . . . . . . .

2–1 3–1 3–1 2–1

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 ENGINE COMPRESSION . . . . . . . . . . . . . . . . . . . . . . 7–1 ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 5–1 ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . 1–1 ENGINE OIL SPECIFICATIONS . . . . . . . . . . . . . . . . 8–1 ENGINE SPECIFICATIONS (KUBOTA) . . . . . . . . . . 8–1 FINAL DRIVE (S/N 12001–12929) . . . . . . . . . . . . . . .

FINAL DRIVE (S/N 12930 & Above) . . . . . . . . . . . . .

FLOOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . .

FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL INJECTOR NOZZLES . . . . . . . . . . . . . . . . . . . .

FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . .

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MELROE CONTROL VALVE LEVER . . . . . . . . . . . . 3–1 MELROE HYDRAULIC CONTROL VALVE . . . . . . . 2–1 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 SEAT AND MOUNTING FRAME . . . . . . . . . . . . . . . .

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . .

SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . .

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWING CIRCLE GEAR . . . . . . . . . . . . . . . . . . . . . . . .

SWING CYLINDER LOCK VALVE . . . . . . . . . . . . . . .

SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5–1 1–1 7–1 6–1 4–1 2–1 4–1

TIMING GEAR, CAMSHAFT AND OIL PUMP . . . . .

TIMING GEAR COVER . . . . . . . . . . . . . . . . . . . . . . . .

TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRACK FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRACK IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7–1 7–1 5–1 5–1 5–1 5–1

UPPER WORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 USING A BOOSTER BATTERY (JUMP STARTING) 1–1 VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

3–1 3–1 3–1 8–1 7–1 7–1 7–1 1–1 5–1

GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 HOLDING VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC EXCAVATOR SPECIFICATIONS . . . .

HYDRAULIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC SERVICE INFORMATION . . . . . . . . . .

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .

2–1 6–1 2–1 8–1 2–1 3–1 2–1 2–1 2–1 1–1

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 LOCKING LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 LUBRICATION OF THE EXCAVATOR . . . . . . . . . . . 1–1

220 (S/N 508212001 & Above) Excavator Service Manual

FOREWORD This manual is for the Bobcat hydraulic excavator mechanic. It provides necessary servicing and 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 service or repair: 1. Check that the operator canopy is in good condition and is not modified.

9. Safety treads must be in good condition.

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

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

3.

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

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

4.

Inspect for loose or broken parts or connections.

12. Inspect for fuel, oil or hydraulic leaks.

5.

Machine signs must be legible and in the correct location.

13. Lubricate excavator.

6.

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

14. Check the condition of the battery and cables.

7.

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

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

8.

Check the electrical charging system.

–3

the

hydraulic

220 (S/N 508212001 & Above) Excavator Service Manual

CONTENTS SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii HYDRAULIC EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . iii PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 UPPER WORKS & SWING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 MAIN FRAME & TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

PREVENTIVE MAINTENANCE

HYDRAULIC SYSTEM

DRIVE SYSTEM

UPPER WORKS & SWING SECTION

MAIN FRAME & TRACKS

ELECTRICAL SYSTEM

ENGINE SERVICE

TECHNICAL DATA

–1

220 (S/N 508212001 & Above) Excavator 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–2003–1289 The following publications provide information on the safe use and maintenance of the loader and attachments:

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

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

Replacement Operation & Maintenance Manuals can be ordered from your Bobcat excavator dealer.

• 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 dealer.

• 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 manuals are for your safety. Failure to obey warnings can cause injury or death.

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

I–2019–0284

W–2044–1285

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. Always wear safety glasses when maintaining or servicing the excavator. Safety glasses, hear-

ing protection or loader special application kits are required for some work. See your dealer for Melroe Safety equipment.

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

• Do not use the Bobcat excavator where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.

• The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent a fire hazard and overheating.

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

• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check

for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.

• Follow any environmental safety regulations when disposing of used fluids such as engine oil, grease or anti–freeze.

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

• Always clean the excavator and disconnect the battery before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the excavator when welding. Have good ventilation when grinding or welding 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 the Operation & Maintenance or Service Manuals for connecting the battery. i

220 (S/N 508212001 & Above) Excavator 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 different procedure in doing a specific service operation.

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

N–09633

ENGINE SERIAL NUMBER

B

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

N–07349

C

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

ii

220 (S/N 508212001 & Above) Excavator Service Manual

HYDRAULIC EXCAVATOR IDENTIFICATION

CONTROL LEVERS ROPS

ENGINE COVER BOOM

BLADE TRACK FRAME

TRACK

GRAB HANDLES DIPPERSTICK CYLINDER

OPERATOR SEAT BUCKET CYLINDER

BUCKET LINK

BOOM CYLINDER

SWING LOCK

DIPPERSTICK

BLADE CYLINDER

BUCKET

N–09635 B–14810 B–14811

iii

220 (S/N 508212001 & Above) Excavator Service Manual

PREVENTIVE MAINTENANCE Page Number

PREVENTIVE MAINTENANCE

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 COOLING SYSTEM Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 ENGINE LUBRICATION SYSTEM Engine Oil And Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 FUEL SYSTEM Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 HYDRAULIC SYSTEM Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Replacement Of The Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–7 1–7 1–8 1–8

LUBRICATION OF THE EXCAVATOR Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10 SERVICE SCHEDULE Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 USING A BOOSTER BATTERY (JUMP STARTING) Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9

–1––1–

220 (S/N 508212001 & Above) Excavator Service Manual

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

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

W–2003–0797

ITEM Engine Air Cleaner Engine Oil Engine Coolant System Indicator Lights Operator Canopy Seat Belt Safety Signs (Decals) Tracks Hydraulic Reservoir All Machinery Pivot Points Fuel Tank Swing Circle Swing Pinion Engine Oil & Filter Alternator Belt Hydraulic Filter Fuel Filter Battery Air Cleaner Cooling System Alternator & Starter Engine Valve Clearance Cooling System Hydraulic Tank

SERVICE REQUIRED

8–10

50

100

250

500 1000

Check & empty dust cup as required.

Check the oil level & add oil as needed.

Check radiator coolant level.

Check for correct operation.

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

Check the condition & that fasteners are tight.

Check for damaged signs (decals) replace as needed.

Check & adjust tension.

Check fluid level.

Lubricate 20 grease fittings Drain water and sediment from fuel tank.

Lubricate two grease fittings.

Lubricate one grease fitting.

Replace oil & filter element.

Check & adjust tension.

Replace filter element.

Replace filter element.

Check & clean cable ends & check electrolyte level.

Replace the filter element.

Clean the radiator fins.

Check the condition.

Check & adjust valve clearance.

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

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

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

• Check and adjust engine valve clearance.

–1–1–

220 (S/N 508212001 & Above) Excavator Service Manual

ENGINE COVER

A

Never service or adjust the machine when the engine is running unless instructed to do so in this manual W–2012–1285 Keep the engine cover closed when operating the machine.

W–2141–0189

N–09651

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

B

AIR CLEANER SERVICE See the SERVICE SCHEDULE (See Page 1–1) for the correct service interval.

Service the air cleaner as follows: 1. Loosen the clamp on the air cleaner [B].

N–09652

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

C

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

3

2 1

N–09653

D

4. Remove the filter element [D].

5. Check the air cleaner housing for damage.

6. Check the condition of the element replace if necessary.

1

7. Check the seal (Item1) [D].

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

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

N–09654

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

–1–2–

220 (S/N 508212001 & Above) Excavator Service Manual

FUEL SYSTEM

A

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

1

Stop and cool the engine before adding fuel.

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

W–2063–0887 N–09655

Fuel System Service

B

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

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

Turn the fill cap to remove [B].

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

Add fuel only in an area that has a free movement of air and no open flames or sparks. NO SMOKING!

N–09118

After the tank is full, install and tighten the fuel fill cap.

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

W–2103–1285

–1–3–

220 (S/N 508212001 & Above) Excavator Service Manual

FUEL SYSTEM (Cont’d)

A

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

N–09657

B

Fuel Filter See the SERVICE SCHEDULE (See Page 1–1) for the correct service interval.

To remove water from filter open drain valve (Item 1) [B].

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

Replace the element and hand tighten only.

1

N–09658

C

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

Open the vent valve on the injection pump.

Squeeze the primer bulb to fill the filter [C].

Leave the vent open slightly.

Start the engine. When the engine runs smoothly, close the vent valve.

N–09659

–1–4–

220 (S/N 508212001 & Above) Excavator Service Manual

ENGINE LUBRICATION SYSTEM

A

Check the engine oil every day.

Stop the engine. Open the engine cover.

Remove the dipstick [A].

Keep the oil level between the marks on the dipstick.

Use a good quality motor oil that meets API Service Classification of CC–CE or CD. (See FUEL, COOLANT AND LUBRICANTS Chart, Page 8–1.)

N–09660

B

Engine Oil And Filter Replacement See the SERVICE SCHEDULE (See Page 1–1) for the correct service interval.

Use the following procedure to change the oil and filter:

1

1. Run the engine until it is at operating temperature.

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

N–09661

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

C 4. Remove the oil filter (Item 1) [C], using a filter wrench.

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

6. Install and tighten the oil drain plug.

1

N–09662

7. Remove the oil fill cap [D]. Put 4.5 quarts (4,3 L) of oil into the engine. (See FUEL, COOLANT AND LUBRICANTS Chart, Page 8–1).

D

8. Start the engine and let it run for several minutes.

Stop the engine. Check for leaks at the oil filter.

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

N–09663

–1–5–

220 (S/N 508212001 & Above) Excavator Service Manual

COOLING SYSTEM

A

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

The coolant level must be 0.750–1.0 inches (19–25 mm) below the filler neck at the radiator.

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

Coolant Replacement

N–09126

B

1

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

W–2070–1285

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

2. Loosen and remove the radiator cap [A].

N–09145

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

4. Drain all the coolant from the system.

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

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

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.

7. 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).

W–2019–1285

8. Stop the engine. Check the coolant level and add as needed, bringing it 0.750–1.0 inches (19–25 mm) below the filler neck. Install the radiator cap and tighten.

–1–6–

220 (S/N 508212001 & Above) Excavator Service Manual

HYDRAULIC SYSTEM

A

Checking And Adding Fluid

1

To check and add hydraulic fluid to the reservoir, use the following procedure: 1. Put the machine on a flat level surface.

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

2

3. The hydraulic fluid level must be visible in the top sight gauge (Item 1) [A] and no lower than the bottom sight gauge (Item 2) [A].

N–09669

B

4. If the fluid level is not correct, use the key to unlock the reservoir cap, remove the cap [B].

N–09670

C

5. Remove the screen from the fill neck and replace it if damaged [C].

6. 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 8–1.)

7. Install and lock the reservoir cap.

N–09671

Diagnostic couplers

D

1

Diagnostic couplers are located at each hydraulic pump (Item 1) [D].

The couplers can be used to check circuit pressures.

Refer to Page 2–1 for test procedure and tools needed for testing.

N–09674

–1–7–

220 (S/N 508212001 & Above) Excavator Service Manual

HYDRAULIC SYSTEM (Cont’d)

A

Replacement Of The Hydraulic Filter See the SERVICE SCHEDULE (See Page 1–1) for the correct service interval.

1. Open the engine cover.

1

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

3. Clean the housing where the filter gasket makes contact.

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

N–09672

B

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

1

Hydraulic Reservoir See the SERVICE SCHEDULE (See Page 1–1) for the correct service interval.

1. Move the upper works so there is clearance for the reservoir at the track frame.

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

N–09673

3. Remove the hydraulic filter.

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

5. Drain the fluid into a container.

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.

6. Install the drain plug.

7. Add approximately 7.0 gals. (26,5 L) of fluid to the reservoir.

(See FUEL, COOLANT AND LUBRICANTS Chart Page 8–1.)

W–2103–1285

8. Run the machine through the hydraulic functions.

Stop the engine. Check the fluid level and add as needed.

–1–8–

220 (S/N 508212001 & Above) Excavator Service Manual

USING A BOOSTER BATTERY (JUMP STARTING)

A

Procedure

1

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

2

The key switch must be in the OFF position.

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–09668

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

Never lean over battery while boosting, testing or charging.

Damage to the alternator can occur if:

• Engine is operated with battery cables • •

Battery gas can explode and cause serious injury.

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.

W–2066–1296

I–2023–1285

–1–9–

220 (S/N 508212001 & Above) Excavator Service Manual

LUBRICATION OF THE EXCAVATOR

A

Procedure

2

Lubricate the Hydraulic Excavator as specified in the SERVICE SCHEDULE (See Page 1–1) for the best performance of the machine.

1

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

Ref.

Description (# of Fittings)

1.

2.

3.

Blade Cylinder Rod End (1) [A].

Blade Pivots (2) [A].

Blade Cylinder Base End (1) [A].

4.

5.

6.

7.

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

Boom Base Pivot (1) [B].

Boom Swing Bracket Pivot (2) [B].

Boom Cylinder Base End (1) [B].

3 N–09675

B

5

6

7 4 N–09676

8.

9.

Boom Cylinder Rod End (1) [C].

Dipperstick Cylinder Base End (1) [C].

C 9 8

N–09677

10.

11.

12.

Dipperstick Cylinder Rod End [D].

Dipperstick Base Pivot (1) [D].

Bucket Cylinder Base End (1) [D].

D

10 11

12

N–09678

–1–10–

220 (S/N 508212001 & Above) Excavator Service Manual

LUBRICATION OF THE HYDRAULIC EXCAVATOR (Cont’d) Ref.

Description (# of Fittings)

13.

14.

15.

Bucket Cylinder Rod End (1) [A].

Bucket Link Pivots (2) [A].

Bucket Pivots (4) [A].

A

14

13

15 N–09679

16.

B

Boom Swing Cylinder Base End (1) [B].

16

N–09680

17.

C

Swing Circle Pinion (1) [C].

17

N–09681

18.

D

Swing Circle (2) [D].

18

CD–09144

–1–11–

220 (S/N 508212001 & Above) Excavator Service Manual

HYDRAULIC SERVICE INFORMATION

A

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

1

2

1

2

CONTROL VALVES

I–2003–0888

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

Checking The Relief Valves The following are two methods of checking the relief valves: 1.

Diagnostic Coupler Check

2.

Hydraulic Tester Check

1 2 SWING MOTOR

Diagnostic Coupler Check can be done by using the following tools:

MC–01383

MEL1355 –– Test Kit MEL1335–3 –– 5000 PSI Gauge MEL1335–12 –– Coupler

B

Connect the coupler from the tool kit to the gauge.

Stop the engine and connect the gauge to the diagnostic coupler on the pump being tested [B].

3

Start the engine and run at full RPM.

2

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

1

The system relief valve for each pump should read as follows [B].

PUMP 1: 2550 PSI (17580 kPa) PUMP 2: 2550 PSI (17580 kPa) PUMP 2: 2550 PSI (17580 kPa)

N–10089

C

The Hydraulic Tester Check can be done by using the following tools: OEM1238 –– Hydraulic Tester OEM1239 –– Hydraulic Tester

1

Stop the engine and raise the engine cover.

Disconnect the outlet hose from the hydraulic pump (Item 1) [C] being tested and connect that hose to the outlet of the tester.

Connect the inlet hose of the tester to the pump outlet fitting.

NOTE: The tester connections will be the same for each pump.

N–10090

–2–1–

220 (S/N 508212001 & Above) Excavator Service Manual

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