220 6720503 SM 6-90 PDF

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

(S/N 508212001 & Above)
6720503(6–90)–7.5C Printed in U.S.A. © Melroe Company 1997
1 of 305
2 of 305
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING 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
instructions can cause injury or death. W-2003-0903
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
B-10731a B-14148 B-14142

Never service the Bobcat Use the correct procedure to lift Cleaning and maintenance are
Hydraulic Excavator without and support the excavator. required daily.
instructions. Always lift the blade fully before
installing jackstands.
WRONG WRONG WRONG

B-14147 B-14141 B-14145
Have good ventilation when Vent exhaust to outside when Always lower the bucket and
welding or grinding painted engine must be run for service. blade to the ground before doing
parts. Exhaust system must be tightly any maintenance.
Wear dust mask when grinding sealed. Exhaust Fumes can kill Never modify equipment or add
painted parts. Toxic dust and gas without warning. attachments not approved by
can be produced. Bobcat Company.
WRONG WRONG WRONG
B-14146 B-14143 B-6589

B-16102 B-16102
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust machine exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the excavator.
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
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ALPHABETICAL INDEX
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . 1–1 MELROE CONTROL VALVE LEVER . . . . . . . . . . . . 3–1

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 MELROE HYDRAULIC CONTROL VALVE . . . . . . . 2–1
AUXILIARY COUPLERS . . . . . . . . . . . . . . . . . . . . . . . 2–1
AUXILIARY FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

BLADE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
BLADE LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
BOOM AND DIPPERSTICK . . . . . . . . . . . . . . . . . . . . 5–1
BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 SEAT AND MOUNTING FRAME . . . . . . . . . . . . . . . . 5–1
BOOM SWING BRACKET . . . . . . . . . . . . . . . . . . . . . 5–1 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
BOOM SWING CYLINDER . . . . . . . . . . . . . . . . . . . . . 2–1 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . 7–1
BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
SWING CIRCLE GEAR . . . . . . . . . . . . . . . . . . . . . . . . 4–1
CENTER SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . 4–1 SWING CYLINDER LOCK VALVE . . . . . . . . . . . . . . . 2–1
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
CONTROL AND STEERING LEVERS . . . . . . . . . . . 3–1 TIMING GEAR, CAMSHAFT AND OIL PUMP . . . . . 7–1
CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . . 7–1 TIMING GEAR COVER . . . . . . . . . . . . . . . . . . . . . . . . 7–1
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TRACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
CYLINDER LINERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TRACK FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
TRACK IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
DIPPERARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 2–1 TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
DRIVE MOTOR (S/N 12001–12929) . . . . . . . . . . . . . 3–1
DRIVE MOTOR (S/N 12930 & Above) . . . . . . . . . . . . 3–1 UPPER WORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

DUKES HYDRAULIC CONTROL VALVE . . . . . . . . . 2–1 USING A BOOSTER BATTERY (JUMP STARTING) 1–1
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 6–1 VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
ENGINE COMPRESSION . . . . . . . . . . . . . . . . . . . . . . 7–1 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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) . . . . . . . . . . . . . . . 3–1

FINAL DRIVE (S/N 12930 & Above) . . . . . . . . . . . . . 3–1
FLOOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . 8–1
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
FUEL INJECTOR NOZZLES . . . . . . . . . . . . . . . . . . . . 7–1
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . 7–1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
HOLDING VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 2–1
HYDRAULIC EXCAVATOR SPECIFICATIONS . . . . 8–1
HYDRAULIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . 2–1
HYDRAULIC SERVICE INFORMATION . . . . . . . . . . 2–1
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
LOCKING LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

LUBRICATION OF THE EXCAVATOR . . . . . . . . . . . 1–1
5 of 305
220 (S/N 508212001 & Above) Excavator
Service Manual
6 of 305
325 (514011001 & 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 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 or hydraulic
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 Recommend to the owner that all
damage or leaks. Check the necessary corrections be made
condition of the element. before the machine is returned to
service.
8. Check the electrical charging

system.

7 of 305 –3 Service Manual

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


10 of 305 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–2003–1289
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 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. 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.
11 of 305 i Service Manual
SERIAL NUMBER LOCATIONS
Always use the serial number of the machine when
A
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

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

N–07349
DELIVERY REPORT C
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].

12 of 305 ii Service Manual
HYDRAULIC EXCAVATOR IDENTIFICATION
CONTROL LEVERS
ROPS
ENGINE
COVER
BOOM

BLADE
TRACK TRACK FRAME
GRAB
HANDLES
DIPPERSTICK CYLINDER
OPERATOR SEAT
BUCKET
CYLINDER
BOOM
BUCKET CYLINDER
LINK
SWING LOCK
DIPPERSTICK
BLADE CYLINDER
BUCKET
N–09635
B–14810
B–14811
13 of 305 iii Service Manual
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ExcavatorServiceManual(S/N508212001–508214999)#6720503–ContentsSection

14 of 305 iv Service Manual
PREVENTIVE MAINTENANCE
PREVENTIVE
Page MAINTENANCE
Number
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
Diagnostic Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8

Replacement Of The Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
LUBRICATION OF THE EXCAVATOR

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

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

15 of 305 –1––1– Service Manual

16 of 305 –1–0– 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 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 cab.
Seat Belt Check the condition & that fasteners are tight.
Safety Signs (Decals) Check for damaged signs (decals) replace as needed.
Tracks Check & adjust tension.
Hydraulic Reservoir Check fluid level.
All Machinery Pivot
Points Lubricate 20 grease fittings
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.
Alternator Belt Check & adjust tension.
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.
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
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
N–09653
4. Remove the filter element [D]. D

5. Check the air cleaner housing for damage.
6. Check the condition of the element replace if

necessary.
7. Check the seal (Item1) [D]. 1
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.
10. Check that the air cleaner hose clamps are tight. N–09654

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

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
Fuel Filter B
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
Removing Air From The Fuel System C

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

ENGINE LUBRICATION SYSTEM
Check the engine oil every day.
A
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
Engine Oil And Filter Replacement B

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.
3. Remove the drain plug (Item 1) [B]. Drain the oil into N–09661
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 D
LUBRICANTS Chart, Page 8–1).
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

COOLING SYSTEM
Coolant Level
A
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 Wear safety glasses to prevent eye injury when
coolant until it is full. any of the following conditions exist:
• When fluids are under pressure.
7. Run the engine at idle speed for about 5–10 minutes • Flying debris or loose material is present.
to remove the air from the cooling system (leave the • Engine is running.
radiator cap off during this operation).
• Tools are being used.
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.

HYDRAULIC SYSTEM
Checking And Adding Fluid
A
To check and add hydraulic fluid to the reservoir, use the 1
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
4. If the fluid level is not correct, use the key to unlock B

the reservoir cap, remove the cap [B].

N–09670
5. Remove the screen from the fill neck and replace it C

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

HYDRAULIC SYSTEM (Cont’d)
Replacement Of The Hydraulic Filter
A
1. Open the engine cover.
2. Use a filter wrench and remove the filter element 1

(Item 1) [A].
3. Clean the housing where the filter gasket makes

contact.
4. Put clean fluid on the gasket. Install the new filter N–09672
element and hand tighten only.
5. Start the engine. Run the machine through the

hydraulic functions. Stop the engine. Check the fluid
B
level at the reservoir and add as needed. Check the 1
filter area for leaks.
Hydraulic Reservoir

1. Move the upper works so there is clearance for the

reservoir at the track frame.
2. Retract the dipperstick and bucket cylinder, lower N–09673
the bucket to the ground. Stop the engine.
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
6. Install the drain plug. fuel and oil. Failure to use care around
combustibles can cause explosion or fire
7. Add approximately 7.0 gals. (26,5 L) of fluid to the which can result in injury or death.
reservoir. (See FUEL, COOLANT AND W–2103–1285
LUBRICANTS Chart Page 8–1.)
8. Run the machine through the hydraulic functions.

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

USING A BOOSTER BATTERY (JUMP STARTING)
Procedure
A 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.
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–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. Keep arcs, sparks, flames and lighted tobacco
Disconnect cable from the starter terminal (Item 1) [A]. 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
Damage to the alternator can occur if: or charging.
• Engine is operated with battery cables Battery gas can explode and cause serious
disconnected. injury.
• Battery cables are connected when using a W–2066–1296
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 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) 3
1. Blade Cylinder Rod End (1) [A].
2. Blade Pivots (2) [A].
3. Blade Cylinder Base End (1) [A]. N–09675
4. Boom Swing Cylinder Rod End (1) [B].

B 5
5. Boom Base Pivot (1) [B].
6. Boom Swing Bracket Pivot (2) [B].
7. Boom Cylinder Base End (1) [B].
6

7
N–09676
8. Boom Cylinder Rod End (1) [C].

9. Dipperstick Cylinder Base End (1) [C]. C
9
8
N–09677
10. Dipperstick Cylinder Rod End [D].

11. Dipperstick Base Pivot (1) [D]. D 10
12. Bucket Cylinder Base End (1) [D]. 11
12
N–09678

LUBRICATION OF THE HYDRAULIC EXCAVATOR
(Cont’d) A 14
Ref. Description (# of Fittings)
13
13. Bucket Cylinder Rod End (1) [A].
14. Bucket Link Pivots (2) [A].
15. Bucket Pivots (4) [A].
15
N–09679
16. Boom Swing Cylinder Base End (1) [B]. B

16
N–09680
17. Swing Circle Pinion (1) [C]. C
17
N–09681
18. Swing Circle (2) [D].

D
18
CD–09144

220
ExcavatorServiceManual(S/N508212001–508214999)#6720503–PreventiveMaintenanceSection

HYDRAULIC SECTION
Page
Number
AUXILIARY COUPLERS
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–61 HYDRAULIC
SYSTEM
AUXILIARY FITTINGS
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–61
BLADE CYLINDER
BOOM CYLINDER
BOOM SWING CYLINDER

BUCKET CYLINDER
DIPPERARM CYLINDER

DUKES HYDRAULIC CONTROL VALVE
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–16
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
Center Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–20
Main Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–21
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
Testing And Adjustment Of The Port Relief Valve . . . . . . . . . . . . . . . . . . 2–22
HOLDING VALVES
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–39
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–38
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–40
HYDRAULIC CYLINDER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–53
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–51
HYDRAULIC FILTER
HYDRAULIC PUMP
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
HYDRAULIC RESERVOIR
Revised Feb. 98 220 (S/N 508212001 & Above) Excavator

HYDRAULIC SECTION (Cont’d)
Page
Number
HYDRAULIC SERVICE INFORMATION

Checking The Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
MELROE HYDRAULIC CONTROL VALVE

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–30
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–25
Main Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–36
SWING CYLINDER LOCK VALVE

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–43
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–42
SHUTTLE VALVE
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–65
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–63

Revised Feb. 98 220 (S/N 508212001 & Above) Excavator

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54 of 305
HYDRAULIC SERVICE INFORMATION
A 1
2
When repairing hydrostatic and hydraulic

systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage 1
the system.
CONTROL
2
I–2003–0888
VALVES
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
1. Diagnostic Coupler Check 2

2. Hydraulic Tester Check
SWING
Diagnostic Coupler Check can be done by using the MOTOR
following tools:
MC–01383
MEL1355 –– Test Kit
MEL1335–3 –– 5000 PSI Gauge
MEL1335–12 –– Coupler
Connect the coupler from the tool kit to the gauge.
B
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.
Stroke a cylinder to it’s limit, in the section being tested, 2
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) N–10089
PUMP 2: 2550 PSI (17580 kPa)
The Hydraulic Tester Check can be done by using the
following tools:
C
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
N–10090
each pump.
HYDRAULIC SERVICE INFORMATION (Cont’d)
A
NOTE: Open the flow control knob (Item 1) [A] fully
to prevent pump damage.
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. Warm the 1
hydraulic fluid to 140°F (60°C) by turning the restrictor
valve until the gauge reads about 1000 PSI (6895 kPa). N–10091
Do not exceed system pressure.
Stroke a cylinder to it’s limit, in the section being tested,
to open the relief valve. B 3 2 1
The relief valve pressure should be as follows:
PUMP 1: 2550 PSI (17580 kPa) [B]
PUMP 2: 2550 PSI (17580 kPa) [B]
PUMP 3: 2550 PSI (17580 kPa) [B]
Release the pressure on the cylinder being tested.

The flow should be 4 GPM (16 L/min.) on a new pump at
2700 RPM.
Close the flow control knob (Item 1) [A] slowly, to 100 PSI
below relief valve setting, and record the free flow.
N–09674
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 same readings
as shown above.

HYDRAULIC PUMP
Removal And Installation
A

ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888 N–10092
Disconnect the inlet hoses from the hydraulic pump [A]. B
Drain the hydraulic fluid in a container.

Disconnect the pressure hoses [B].
N–10090
Remove the bolts and washers from the pump flange [C].
C
N–10093
Remove the hydraulic pump from the flywheel housing

[D]. D
N–10094

HYDRAULIC PUMP (Cont’d)
Parts Identification
1. PLATE
2. GEAR 7
3. SHAFT
4. GEAR
5. SEAL
6. PLATE
7. PLATE 6 8
8. ELBOW
9. COVER
10. BOLT
2 4
5
5
2
1

7
6 8
2
4
5
5
10
9
2
4
5
NOTE: Check the Parts Fiche for serviceable parts.

B–13263

A
Disassembly

the system. N–12657
I–2003–0888
Clean the exterior of the pump prior to disassembly. B

Mark the hydraulic pump sections for proper positioning
of section during assembly.
NOTE: Do not pry components apart. Lightly

tapping with plastic hammer on sections will
separate sections without marring the
mating surfaces.

Remove the bolts from the pump cover [A].
Remove the cover section from the pump [B].
NOTE: Bushings are not serviceable. If the bushings N–12658

need replacing, order a new cover from
Melroe parts.
C 1
Remove the first gear plate (Item 1) [C] and the two dowel
pins (Item 2) [C].
2 2
N–12659
Remove the drive gear retaining ring from the drive shaft
[D]. D
N–12660

Revised May 92
A
Disassembly (Cont’d) 2
Remove the drive gear (Item 1) [A] from the drive shaft
and remove the idler gear (Item 2) [A]. Remove the 1
woodruff key (Item 3) [B] from the driveshaft.
N–12661
Remove the retaining ring from the drive shaft [B]. B

N–12662
Remove the bushing section from the pump [C]. C

NOTE: Bushings are not serviceable. If the bushings
need replacing, order a new bushing section
from the Melroe Parts.
N–12663
Remove the second gear plate and dowel pins [D]. D
N–12664

Revised May 92
A 2
Disassembly (Cont’d)
Remove the second drive gear (Items 1) [A] and the idler 1
gear (Item 2) [A].
Remove the woodruff key (Item 3) [A].
3
N–12665
Remove the second bushing plate.

NOTE: Bushings are not serviceable. If the bushings
B
need replacing, order a new bushing section
from Melroe Parts.
Remove the third gear plate and dowel pins.
Remove the third drive gear, idler gear and the woodruff
key.

Remove the drive shaft from the pump [B].
N–12666
Remove the shaft seal from the pump mounting plate [C].
C
N–12667
Clean and inspect all parts [D].

D
Any gears that need replacing should be replaced in sets.
Inspect the bushing plates in the area that the gears

contact the bushing plate side faces for grooves or
scratches. Replace if damaged.
Inspect the gear plates in the area around the outer
diameter of the gear for grooves or pits. Replace if
damages.
N–12668

61 of 305
Revised May 92 –2–7– Service Manual
A
Inspect the oil holes in the corners of the bearing plates
[A]. Make sure that these holes are open. When
reassembling the pump, these holes must be orientated
in the same location in the pump.
Remove the elbows from the bushing plates and replace
the O–rings on the elbows.
NOTE: The pump must be disassembled in order to

remove these elbows.
N–12669
Assembly Tool
B 0.200 inch
(5 mm) Seal
Install the seal into the cover plate [B].
NOTE: Extreme care must be used when replacing

the shaft seal. It must be installed square into B–13735
the seal bore and with the metal case to the
outside of the pump. The seal must go into
the cover plate 0.200 inch (5 mm) from the

front face.
N–12670
Apply grease to the new O–rings.

Install the O–ring into the housing grooves [C].
C
N–12671
Apply grease to the seal lips and to the inner diameter of

the seal.
D
Install the drive shaft into the cover plate [D]. Slowly
rotate the drive shaft as it passes thru the seal.
NOTE: Use care when installing the drive shaft thru

the seal so that the drive shaft splines do not
cut the seal lips.
N–12666

Revised May
6292
of 305 –2–8– Service Manual
A
Assembly (Cont’d)
1
Reassemble the pump in reverse order.
Make sure that all sections are installed in the proper
order and that they are orientated correctly.
Install the cover plate (Item 1) [A] onto the pump. Install
the four mounting bolts.
Rotate the drive shaft to check for any binding of
components.
Torque all bolts evenly to avoid distorting the pump.
N–12672
Recheck by rotating shaft after torquing and check for
binding.
Tighten bolts to 190–210 inch–lbs. (21–24 Nm) torque.
(This torque is for non–lubricated (dry) threads.)
Fill hydraulic pump with clean oil and make sure that
pump has a supply of oil from the hydraulic system prior
to operating pump. The pump must not be run dry.

63 of 305
DUKES HYDRAULIC CONTROL VALVE
A
When repairing hydrostatic and hydraulic 1

ports to keep dirt out. Dirt can quickly damage PI–10095
the system.
I–2003–0888
B
Remove the control panel shield (See Page 3–1).
The main relief valves (Item 1) [A] are located on either
end of the control valve, one on top and one on the
bottom.
Remove the cotter pins and clevis pins from the spools

[A].
Mark all the hoses and tubelines for correct installation.
Disconnect all the tubelines and hoses from the control N–10096
valve [B].
C
Remove the control valve mounting bolts [C].
N–10097
D
Remove the control valve [D].
N–10098

Revised May6492
of 305 –2–10– Service Manual
DUKES HYDRAULIC CONTROL VALVE (Cont’d)
1. PORT RELIEF VALVE

2. VALVE
3. TUBE
4. BACK–UP RING
5. O–RING
6. TUBE
7. BACK–UP RING
8. O–RING
9. PLUG
10. PLUG
11. MAIN RELIEF VALVE 1
12. PORT RELIEF VALVE
13. VALVE
2
1

5
4
3
4 5
11
5 4
8 3
7 4 5
6 13
11 7
8
10 8
7
6
7
1 9 8
12
NOTE: Check Parts Fiche for serviceable parts.

D–02043

65 of 305
A 7
The six–spool control valve is composed of three
housings, the two housings on the end contain three
spools each and one main relief valve each.
Each spool controls: [A]
1. Boom
2. Swing
3. L.H. Travel
4. R.H. Travel 7
5. Bucket
6. Arm 6
1
The main relief valves (Item 7) [A] are set at 2400 PSI and 2 3 4 5
is adjusted by an adjusting screw and jam nut. P–08684
Disassembly
Prior to disassembly:
B 1
Clean the outside of the valve.

Drain the oil.
Select a clean environment.
Handle with care.
Mark the control valve for ease of assembly [B]. Remove

the four bolts (Item 1) [B] from the assembly (two on top
and two on the bottom).
1
P–08685
Remove the main relief valves (Item 1) [C] from the valve
assembly. C
P–08686
Remove the adjusting screw (Item 1) [D] and nut

assembly (Item 2) [D] from the main relief valve and D
discard.
2
NOTE: These parts will need to be ordered from 1
Melroe Parts.
P–08687

A
Remove the O–rings (Item 1) [A] and the back–up ring 2 1
(Item 2) [A] from the main relief valve and discard.
1 2
P–08688
Remove the port relief valve (Item 1) [B] from the valve
assembly. B
NOTE: Port relief valves should be reinstalled in the
original hole.

1
P–08689
Remove the O–rings (Item 1) [C] and the back–up ring

(Item 2) [C] from the plug housing (Item 3) [C]. (See Page C
2–22 for adjustment.)
1 1
3 2
P–08690
Remove the relief plug (Item 1) [D] from the valve

assembly. D
P–08691

A
Remove the O–rings (Item 1) [A] and the back–up ring 3 1
(Item 2) [A] from the plug (Item 3) [A].
Repeat this procedure for remaining relief plugs.
1 2
P–08300
Remove the plug and O–ring (Item 1) [B].

B

P–08692
Remove the plug and O–ring (Item 1) [C].

C
1
P–08693
Remove the spring (Item 1) [D] and poppet (Item 2) [D]

from the valve. D
P–08700

A
2
NOTE: The poppet (Item 2) [A] installs in the control 1
valve port with the spring seat hole pointing
up. Repeat this procedure for the remaining
plug.
P–08694 B–14801
Remove the two bolts (Item 1) [B].

Remove the end cap (Item 2) [B] from the valve
B
assembly.
Repeat this procedure for remaining end caps.

2
P–08695
Insert a hardened pin (Item 1) [C] in the hole in the spool

to keep it from turning while loosening the bolt (Item 2)
[C].
C
1
2
P–08696
Remove the bolt (Item 1) [D], spacer (Item 2) [D], the

spring (Item 3) [D] and the washer (Item 4) [D] from the
D
valve assembly.
3 2
Repeat this procedure for remaining spring assemblies. 4 1
P–08697

A
Push the spool in the valve far enough to remove the
O–ring (Item 1) [A].
Repeat this procedure to remove the O–ring on the other
end of the spool.
Repeat this procedure to remove the O–rings on the
remaining spools.
1
NOTE: The spools are not serviceable separately,
the spools don’t need to be removed from the
valve housing, except to clean the oil
P–08698
passages if contamination is found. If the
spools are removed, use care not to scratch
the finished surface and do not intermix the
spools in the spool bore. B
Assembly
Prior to Assembly:
Clean all parts with oil and dry with compressed air.
Put grease on all O–rings.

Push the spool (Item 1) [B] in the valve far enough to
install the new O–ring. Repeat this procedure to install the 1
O–ring on the other end of the spool.
NOTE: Repeat this procedure to install the O–rings
on the remaining spools. P–08698
Install the washer (Item 1) [C] on the end of the valve

spool, then insert the spacer (Item 2) [C] in the spring C
(Item 3) [C].
Apply thread lock (LOCTITE 242) on the end of the bolt
(Item 4) [C] and install.
3
NOTE: Excessive LOCTITE could hamper proper
operation.
1 4
2
P–08699
Insert a hardened pin (Item 1) [D] in the hole in the spool

to keep it from turning while tightening the bolt (Item 2)
[D].
D
Tighten the bolt to 2–3 ft.–lbs. (2.7–4.1 Nm) of torque.
1
Repeat this procedure for the remaining spools.
P–08696

A
Assembly (Cont’d)
Install the end cap (Item 1) [A] and the two screws (Item
2) [A] on the valve assembly and tighten.
Tighten the screws to 2–3 ft.–lbs. (2.7–4.1 Nm) torque.
Repeat this procedure for the remaining end caps. 2
1
P–08695
Install the spring (Item 1) [B] and poppet (Item 2) [B] into
the valve assembly.
B
NOTE: The poppet (Item 2) [B] installs in the control
valve port with the spring seat hole pointing 3 1 2
up.
Repeat this procedure for the remaining plugs (Item 3)
[B].

P–08700
Install a new O–ring onto the plug (Item 1) [C] and install
in the valve assembly. C
Tighten the plug to 15–20 ft.–lbs. (20.3–27.1 Nm) torque. 1
Repeat this procedure for the remaining plugs.
P–08693
Install a new O–ring on the plug (Item 1) [D] and install in

the valve assembly. D
Tighten the plug to 15–20 ft.–lbs. (20.3–27.1 Nm) torque.
P–08692

A
Assembly (Cont’d)
Install new O–rings (Item 1) [A] and a back–up ring (Item 1 1
2) [A] on the relief plug (Item 3) [A].
Repeat this procedure for remaining plugs.
3 2
P–08300
Install the relief plug (Item 1) [B] in the valve housing.

Tighten the plug to 25–30 ft.–lbs. (34.0–40.7 Nm) torque.
B

P–08691
Install new O–rings (Item 1) [C] and the back–up ring

(Item 2) [C] on the port relief valve (Item 3) [C]. C
NOTE: Port relief valve should be reinstalled into the
original hole. 3 1
Repeat this procedure for remaining port relief valves.
1 2
P–08690
Install port relief valve assembly (Item 1) [D] into the valve
housing. D
Tighten the plugs to 25–30 ft.–lbs. (34.0–40.7 Nm) of
torque. (See Page 2–22 for adjustment.)
Repeat this procedure for remaining plugs.
P–08689

A
Assembly (Cont’d)
Install new O–rings (Item 1) [A] and back–up ring (Item 1 1
2) [A] to the main relief valve (Item 3) [A].
3 2
P–08688
Install the new bolt (Item 1) [B] and nut assembly (Item
2) [B] in the main relief valve (Item 3) [B]. B
3
1 2

P–08687
Install the main relief valve (Item 1) [C] in the valve

assembly. C
Tighten the main relief valves to 35–40 ft.–lbs. (47.5–54.2
Nm) torque.
Repeat this procedure for remaining relief valve.
P–08686
Align the mark from earlier and install the four bolts (Item D 1
1) [D] and tighten.
Tighten the bolts to 8–10 ft.–lbs. (11.0–13.6 Nm) torque.
1
P–08685

A
Center Housing
Disassembly and Assembly
Once the control valve assembly is separated and the
center housing is removed. 1
Remove the three tubes (Item 1) [A] from the housing on
both sides.
NOTE: The top spacer on both sides is smaller.
P–08701
Remove the O–rings (Item 1) [B] and back–up ring (Item

2) [B] from the spacer (Item 3) [B] and replace them with B
new.
1 3 1

2
P–08702
Reinstall the tube spacers (Item 1) [C] in the housing on

both sides. C 2
Remove the plug and O–ring (Item 2) [C].
Install a new O–ring on the plug.
Tighten the plug to 15–20 ft.–lbs. (20.3–27.1 Nm) torque. 1
P–08701

A 2
Main Relief Valve Adjustment 1
Install a 5000 PSI (34,475 kPa) gauge on the pump
section 2 (Item 1) [A].
NOTE: Pump section 1 is closest to the engine.
Start the engine and warm the hydraulic fluid to normal
operating temperature.
Engage the boom circuit until the boom is completely
extended. Continuing to engage the boom circuit will
cause the main relief valve to go over relief.
Record the pressure. N–09674
The correct pressure for the relief valve is 2400 PSI

(16545 kPa). B
If main relief valve adjustment is required, loosen the
locknut (Item 1) [B].
Turn the adjusting screw (Item 2) [B] clockwise to
increase pressure, counterclockwise to decrease
pressure. 1

When the correct pressure of 2400 PSI (16545 kPa) is
reached, torque the locknut against the relief valve
cartridge to 10 ft.–lbs. (13.6 Nm). 2
NOTE: The adjusting screw must be held in place P–08703

while torquing the locknut to avoid changing
the relief setting.
Remove the 5000 PSI (34,475 kPa) gauge from section

C 1
2.
Install the gauge on the pump section 1 (Item 2) [A].
Engage the bucket circuit until the bucket is completely
extended.
NOTE: Valve removed for photo clarity.

1
Continue to engage the bucket circuit until the main relief
valve goes over relief.
If adjustment of the main relief valve (Item 1) [C] is P–08684
required, loosen the locknut (Item 1) [B].
Turn the adjusting screw (Item 2) [B] clockwise to
increase pressure, counterclockwise to decrease
pressure.
When the correct pressure of 2400 PSI (16545 kPa) is
reached, torque the locknut against the relief valve
cartridge to 10 ft.–lbs. (13.6 Nm).

A
Testing And Adjustment Of The Port Relief Valve
A portable hydraulic hand pump will be used to test the
work port relief valves.
The hand pump must have clean hydraulic fluid that is
compatible with the Melroe hydraulic fluid or use
SAE–10W–30 motor oil.
Install the hand pump hose and a pressure gauge
(minimum of 5000 PSI) into the valve section work port
in which the port relief valve is located [A].
Pressurize this section with the hand pump until the port
P–08704
relief valve opens and make a note of the pressure
reading.
NOTE: The valve is removed for photo clarity. B
If the port relief pressure setting needs to be adjusted,
release the hydraulic pressure in the hand pump.
Remove the plug (Item1) [B] from the housing.

P–08705
Remove the spring (Item 1) [C], shims (Item 2) [C] and

poppet (Item 3) [C] from the housing (Item 4) [C]. C
Add or remove shims (Item 2) [C] on the poppet (Item 3) 4
[C], until proper adjustment is reached.
PORT RELIEF PRESSURES

Arm Section 3
Arm Cylinder Base End 2850 PSI (19648 kPa)
Arm Cylinder Rod End 2850 PSI (19648 kPa)
2
Boom Section
Boom Cylinder Base End 2850 PSI (19648 kPa) 1
Boom Cylinder Rod End 2850 PSI (19648 kPa)
P–08706

MELROE HYDRAULIC CONTROL VALVE
A
1
NOTE: Refer to the Component Repair Manual for
servicing the Melroe Control Valve.

systems, clean the work area before N–10099
the system.
I–2003–0888
B
Remove the floor panels. (See Page 3–1.)

The relief valve (Item1) [A] is located in the rear of the
control valve.

Mark all the hoses and tubelines for correct installation.
Remove the floor panel mounting bracket bolts [B].

N–10100
Remove the bracket.
C
Remove the cotter pins and clevis pins from the spools
[C].
N–10101
Remove the hoses and tubelines from the control valve

[D]. D
N–10102

MELROE HYDRAULIC CONTROL VALVE (Cont’d)
A
Removal And Installation (Cont’d)
Remove the mounting bolts from the control valve [A].
N–10103
B
Remove the control valve from the machine [B].

N–10104
1. BOOT
2. RETAINER
3. SPOOL 12
4. QUAD RING 7
5. O–RING 11
6. HOUSING 10
7. MAIN RELIEF VALVE 9
8. WASHER 8
9. SPRING 13
4
10. COLLAR 12
11. ADAPTOR
12. BONNET 11
13. COLLAR 6 10
4 9
8
13
4 4
3
2
13 5
3
2
13
3
1 2 4
5
13
1
1
D–02042

220ExcavatorServiceManual(S/N508212001–508214999)#6720503–HydraulicSectionPart1of3
A
The Melroe Three Spool Control Valve has one valve
housing containing three spools and one main relief 4
valve.
The spools control the boom swing (Item 1) [A], blade
(Item 2) [A], and auxiliary (Item 3) [A] functions.
The main relief valve (Item 4) [A] is set at 2400 psi (16545
kPA) and is adjusted by a set screw.
Disassembly
1 2 3 P–8296
B
When making repairs on hydrostatic and
hydraulic systems, clean the work area before
the system.
I–2003–0284

Clean the control valve with solvent.
1 1 1
Remove the three plugs (Item 1) [B] and drain the P–8297
hydraulic fluid from the control valve.
Remove the O–rings (Item 1) [C] from the three plugs.
C
P–8298
Remove the two load check plugs (Item 1) [D].
D
1
P–8299

A
Remove the O–rings (Item 1) [A] from both plugs.
P–8300
Remove the spring (Item 1) [B] and poppet (Item 2) [B]

from both load check valves. B

1 2
P–8301
Remove the main relief valve (Item 1) [C] (See page

2–36 for main relief valve adjustment). C
1
P–8302
Remove the slide ring (Item 1) [D], O–rings (Item 2 &

Item 3) [D] and backup ring (Item 4) [D] from the main
relief valve. D
2 4
1 3
CD–0011

8098
Revised Feb. of 305 –2–26– Service Manual
A
Boom Swing And Blade Sections
1
Remove the two screws (Item 1) [A] and bonnet (Item 2)
[A] from the control valve.
2
P–8303
Insert a hardened pin in the hole in the actuating end of

the spool to keep the spool from turning. B
Do not use any type of tool to grip the finished surface of
the spool or the spool will be damaged.
Loosen the spring retaining bolt from the end of the spool
[B].
NOTE: The spring is under pressure. Use care when

removing the spring retainer bolt.
P–8304
Remove the bolt (Item 1) [C], adapter (Item 2) [C], collar

(Item 3) [C], spring (Item 4) [C], washer (Item 5) [C] and C
bushing (Item 6) [C].
1 2 3 4 5 6
P–8305
Remove the two screws (Item 1) [D], retainer (Item 2) [D]

and dust boot (Item 3) [D] from the actuating end of the D 2
spool.
3
1
P–8306

81 of 305
Revised Feb. 98 –2–27– Service Manual
A
Remove the bushing (Item 1) [A].
P–8307
Push the spool in the valve housing far enough to remove

the seal (Item 1) [B]. Use a brass tool to remove the quad
ring.
B
Do not scratch the spool bore while removing the seal or
leakage may occur.

1
P–8308
Push the spool in the valve housing far enough to remove

the rear seal (Item 1) [C]. C
Repeat the above procedure for the blade spool.
P–8309
Auxiliary Section
Remove the two screws (Item 1) [D] and bonnet (Item 2) D
[D].
2
P–8310

8298
A
Insert a hardened pin in the hole in the actuating end of
the spool to retain the spool from turning.
Loosen the spring retaining bolt from the end of the spool
[A].
NOTE: The spring is under pressure. Use care when

removing the spring retaining bolt.
P–8311
Remove the bolt (Item 1) [B], adapter (Item 2) [B], collar

(Item 3) [B], spring (Item 4) [B] and washer (Item 5) [B]. B

2 1
5 4 3
P–8312
Remove the bushing (Item 1) [C] and O–ring (Item 2) [C].

C
Remove the seal (Item 3) [C] from the inside of the
bushing (Item 1) [C].
3
P–8313
Remove the two bolts (Item 1) [D], retainer (Item 2) [D]

and dust boot (Item 3) [D] from the actuating end of the
spool.
D
1
2
1
3
P–8314

83 of 305
A
Remove the bushing (Item 1) [A] and O–ring (Item 2) [A].
Remove the seal (Item 3) [A] from the inside of the
bushing (Item 1) [A].
The spools are not serviceable separately. 2
The spools do not need to be removed from the valve 1
housing except to clean the oil passages if contamination
is found.
If the spools are removed, use care not to scratch the 3
finished surface. P–8313
Always install the spools in the bores they were removed

from. B
Assembly
1
Auxiliary
Clean all parts in solvent and dry with compressed air. If
the spools were removed apply clean hydraulic oil to the 2

spools and install the spools in their original bores.
Apply oil and install a new seal (Item 1) [B] in the bushing
(Item 2) [B]. Do this for both the front and rear bushings.
NOTE: Install the seal with the open side towards the
valve body. P–8315
Apply oil and install a new O–ring (Item 1) [C].

C
Install the bushing (Item 2) [C] on the actuating end of the
valve housing.
P–8316
Install the boot (Item 1) [D] and retainer (Item 2) [D].

Slide the boot (Item 1) [D] toward the valve housing to
D
seat the boot in the spool groove. 3
2
Install the two bolts (Item 3) [D] and tighten to 90–100
in.–lbs. (10,0–11,5 Nm) torque.
3
1
P–8314

8498
A
Assembly (Cont’d)
Apply oil and install a new O–ring (Item 1) [A].
Install the bushing (Item 2) [A] on the end of the valve
housing.
1
2
P–8313
Install the washer (Item 1) [B], spring (Item 2) [B], collar

(Item 3) [B], adapter (Item 4) [B] and bolt (Item 5) [B]. B

4 5
1 2 3
P–8312
Insert a hardened pin in the hole of the actuating end of

the spool to keep the spool from turning. C
Tighten the bolt on the end of the spool [C].
Tighten the bolt (Item 5) [C] to 90–100 in.–lbs. (10,0–11,5
Nm) torque.
P–8311
Install the bonnet (Item 1) [D] with the two bolts (Item 2)
[D].
D
Tighten the bolts (Item 2) [D] to 90–100 in.–lbs.
(10,0–11,5 Nm) torque.
NOTE: After installing the bonnet (Item 1) [D] check 2

that the spool will return to the neutral
position freely when it is pulled out or
pushed in.
1
P–8310

85 of 305
A
Assembly (Cont’d)
Boom Swing and Blade Section
Apply oil and install a new front seal (Item 1) [A].
Use a brass tool to seat the seal in the bore.
valve body.
1
P–8308
Push the spool in the housing far enough to install the new
rear seal (Item 1) [B]. B
Use a brass tool to seat the seal in the bore.
valve body.

1
P–8309
Install the bushing (Item 1) [C] on the actuating end of the

spool. C
P–8307
Install the boot (Item 1) [D] and retainer (Item 2) [D].

Slide the boot toward the valve housing to seat the boot
D
3 2
(Item 1) [D] in the spool groove.
Install the two screws (Item 3) [D] and tighten to 90–100
in.–lbs. (10,0–11,5 Nm) torque.
1
3
P–8306

8698
A
Assembly (Cont’d)
Install the bushing (Item 1) [A], washer (Item 2) [A],
spring (Item 3) [A], collar (Item 4) [A], adapter (Item 5) [A]
and bolt (Item 6) [A].
6 5 4 3 2 1
P–8305
Insert a hardened pin in the hole at the actuating end of

the spool to keep the spool from turning. B
Tighten the bolt on the end of the spool [B].
Tighten the bolt (Item 1) [B] to 90–100in.–lbs. (10.0–11.5
Nm) torque.

P–8304
Install the bonnet (Item 1) [C] with the two bolts (Item 2)
[C]. C
Tighten the bolts (Item 2) [C] to 90–100 in.–lbs.
(10.0–11.5 Nm) torque.
NOTE: After installing the bonnet (Item 1) [C] check

that the spool will return to the neutral 2
position freely when it is pulled out or
pushed in.
Repeat the above procedure for the blade spool.
1
P–8303
Apply oil and install new O–rings (Item 1) [D] on the three
load check plugs. D
P–8317

87 of 305
A
Assembly (Cont’d)
Apply oil and install the poppet (Item 1) [A] and spring
(Item 2) [A] in both load check valve ports.
2
1
P–8301
Install the load check valve plug (Item 1) [B] on both load
check valve ports. B
1

P–8299
Apply oil to and install new O–rings (Item 1) [C] on the

three plugs. C
P–8298
Install the three plugs (Item 1) [D] in the valve housing.

D
1 1 1
P–8297

8898
A
Assembly (Cont’d)
Apply oil and install new O–rings (Item 1 & Item 3) [A],
backup ring (Item 2) [A] and glide ring (Item 4) [A] on the
main relief valve. 2 4
1 3
CD–0011
Apply oil to the main relief valve. Install the main relief
valve (Item 1) [B] in the valve housing. B
Tighten the main relief valve to 35–40 ft.–lbs. (47–54 Nm)
of torque.

1
P–8302

89 of 305
A
Main Relief Valve Adjustment
Install a 5000 psi (34,475 kPA) gauge on pump section 3
[A].
NOTE: Pump section 3 is the farthest away from the

engine.
Start the engine and warm the hydraulic fluid to operating
temperature. Increase engine speed to full RPM.
Engage the auxiliary circuit, using the auxiliary hydraulic
control pedal.
N–10089
This will cause the main relief valve on the three spool
control valve to open to warm the engine oil.
Record the pressure reading. B
Reduce engine RPM and stop engine.
The relief pressure at the pump should be 2400 psi
(16545 kPA).
If relief valve adjustment is required, remove the cap 3
(Item 1) [B] and loosen the locknut (Item 2) [B] on the

main relief valve (Item 3) [B].
2
NOTE: The control valve is shown out of the
excavator for clarity.
1
P–8318
Turn the adjustment screw (Item 1) [C] clockwise to

increase the pressure or counterclockwise to reduce the C
pressure.
Tighten the locknut (Item 2) [C] and retest.
When the correct pressure reading is obtained, install the
cap (Item 1) [B] on the main relief valve (Item 3) [B].
1
P–8319

9098
HOLDING VALVES
A

disassembly and keep all parts clean. Always N–10105
the system.
I–2003–0888 B
Mark the hoses and tubelines for the correct installation.

Remove the tubelines from the front of the holding valves
[A].

Remove the hoses from the rear of the holding valves [B].
N–10106
Remove the two mounting bolts [C].

C
Installation: Tighten the bolts to 65–70 ft.–lbs. (88–95
Nm) Torque.
Remove the holding valve.
Parts Identification N–10107
1. Plug
2. O–ring 10
3. Spring
4. Washer
5. Plug 5
6. O–ring 6
7
7. Spring 8
8. Ball 9
9. Spool
10. Valve Body 8
67
5 4
3
2
1
C–03193

91 of 305
HOLDING VALVES (Cont’d)
A
Disassembly
Clamp the valve in a vise that has padded jaws.
Remove the plug (Item 1) [A], spring (Item 2) [A] and
washer (Item 3) [A] from both ends of the valve. 3
2
1
P–08325
Remove the O–rings (Item 1) [B] from both plugs.

B
1

P–08326
Remove the spool from the valve body [C].

NOTE: Use care not to scratch or damage the spool.
C
Scratches in the spool can cause internal
leakage.
P–08327
Insert a hardened pin through a hole in the spool to keep

it from turning in the vise. D
Clamp the spool in a vise that has padded jaws and 1
remove the spool plug (Item 1) [D], from both ends of the
spool.
P–08328

9298
A
Remove the spring (Item 1) [A] and check ball (Item 2) [A]
from both ends of the spool. 2
1
P–08329
Remove the O–rings (Item 1) [B] from both spool plugs

(Item 2) [B]. B
Assembly
2 1
Clean all parts in solvent and dry with compressed air.
Apply oil and install new O–rings (Item 1) [B] on both
spool plugs (Item 2) [B].

P–08330
Install the check balls (Item 1) [C], springs (Item 2) [C]

and spool plugs (Item 3) [C] in the spool. C
1 1 3
3
2 2
P–08331
Apply clean hydraulic fluid to the spool and install the

spool in the valve body [D]. D
P–08327

93 of 305
A
Assembly (Cont’d)
Apply oil and install new O–rings (Item 1) [A] on the plugs.
1
P–08326
Install the washer (Item 1) [B], spring (Item 2) [B] and

plug (Item 3) [B] on both ends of the valve. B
1
3 2

P–08325
Testing
Install a portable hydraulic hand pump on one of the ports
C
marked V (Item 1) [C].
NOTE: The hand pump must have clean hydraulic 1

fluid that is compatible with Melroe hydraulic
fluid, or use SAE 10–30 motor oil.
Install a plug on the corresponding port marked M (Item

1) [D].
Pressurize the valve. The spool must shift at 100 PSI (690 2
kPa) maximum.
Remove the hand pump and plug.
P–08907
Install the hand pump on the second port marked V (Item
2) [C].
Install the plug on the corresponding port marked M (Item
D
2) [D].
Repeat the test procedure.
P–08908

9498
SWING CYLINDER LOCK VALVE
A
1
1
ports to keep dirt out. Dirt can quickly damage N–09925
the system.
I–2003–0888
B
Remove the two right floor panels. (See Page 3–1.)
Mark the hoses for correct installation.
Remove the hoses (Item 1) [A] from the lock valve.

Remove the mounting bolt [B].
N–09923
1. PLUG
2. O–RING 1
3. SPRING
4. BALL 2
5. CHECK VALVE BODY
6. O–RING
7. BACK–UP RING 3
8. SPOOL 4
9. VALVE BODY
6
7
NOTE: Check Parts Fiche for serviceable parts. C–03193

95 of 305
SWING CYLINDER LOCK VALVE (Cont’d)
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

9698
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
Apply oil and install the spool (Item 1) [A] in the valve body

(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

97 of 305
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

9898
HYDRAULIC RESERVOIR
A
Lower the blade and boom to the ground.
Raise the engine cover.
Remove the return hose from the inside hydraulic pump
[A].
Drain the fluid from the reservoir.
N–10092
Remove the return hose from the hydraulic filter outlet

[B]. B

N–10108
Remove the mounting bolts from the reservoir [C].

C
N–10109
Remove the hydraulic reservoir [D].

D
N–10110

99 of 305
BOOM CYLINDER
A
NOTE: Refer to the pages 2–51 – 2–59 for servicing
the Cylinder.
Lower the bucket to the floor. Stop the engine.

Support the boom using a chain hoist.
Move the hydraulic controls to release the hydraulic
pressure.
N–10111
B
1
the system.

I–2003–0888
Disconnect the two hoses from the boom cylinder.

Remove the retainer bolt and nut from the boom cylinder N–10112
base end pin.
Remove the cylinder base end pin [A].
Lower the base end of the cylinder to the floor.
Remove the retainer bolt and nut from the cylinder rod
end pin [B].
Remove the cylinder rod end pin. Remove the boom
cylinder from the boom.
Installation: Tighten the nut to allow NO endplay of the
bolt (Item 1) [B].

100
Revised Feb. 98of 305 –2–46– Service Manual
DIPPERARM CYLINDER
A
NOTE: Refer to the Pages 2–51 – 2–59 for servicing
the Cylinder.

Support the boom using a chain hoist. 1

pressure.
N–10113
B
the system.
I–2003–0888
1

Disconnect the two hoses from the dipperarm cylinder.
Remove the retainer bolt (Item 1) [A] and nut from the
cylinder base end pin. N–10114
Remove the cylinder base end pin.
Remove the retainer bolt (Item 1) [B] and nut from the
cylinder rod end pin.
Remove the cylinder rod end pin.
Remove the cylinder from the dipperarm.
Installation: Tighten the bolt to allow NO endplay of the
bolt (Item 1) [A] &[B].

101 of Feb.
Revised 305 98 –2–47– Service Manual
BUCKET CYLINDER
A
2
NOTE: Refer to the Pages 2–51 – 2–59 servicing the
Cylinder.

pressure.
1
PI–10115
When repairing hydrostatic and hydraulic B

the system. 1
I–2003–0888

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. N–09679
Remove the cylinder base end pin.

C
Remove the retainer bolt (Item 1) [B] and nut from the
cylinder rod end pin. 1
Remove the cylinder rod end pin.
Installation: Tighten the bolt to allow NO endplay of the
bolt (Item 2) [A].
Remove the bucket cylinder and shims (Item 1) [C].
N–10116

102
BLADE CYLINDER
A
NOTE: Refer to the Pages 2–51 – 2–59 for servicing
the Cylinder.
Lower the blade to the floor. Stop the engine.

Move the blade control to release the hydraulic pressure.
Remove the four nuts from the blade cylinder shield [A].
PI–10117
Remove the blade cylinder shields [B]. B

the system. PI–10118
I–2003–0888
Remove the blade cylinder hoses (Item 1) [C].

C 2
Remove the rod end bolt (Item 2) [C] and pin.

Remove the base end bolt (Item 3) [C] and pin.
Installation: Tighten the nut to allow no endplay of the
bolt (Items 2 & 3) [C].
Remove the blade cylinder. 1
3
PI–10119

103 of Feb.
Revised 305 98 –2–49– Service Manual
BOOM SWING CYLINDER

A
NOTE: Refer to the pages 2–51 – 2–59 for servicing
the Cylinder.

systems, clean the work area before N–10120
the system. B
I–2003–0888
Lower the bucket and blade to the floor. Stop the engine.

Disconnect the hoses (Item 1) [A] from the cylinder.
Remove the retainer bolt from the cylinder base end pin.
N–10121
Remove the cylinder base end pin [B].
C
Remove the retainer bolt from the cylinder rod end pin [C].
N–10122
Remove the cylinder rod end pin [D]. D

Remove the boom swing cylinder.
N–10123

104
HYDRAULIC CYLINDER
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 wrench (MEL1075) to B–07000
loosen the head [A].
B
Remove the rod assembly from the cylinder case [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 Piston Retaining Lock Nut D

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

105 Feb.
Added of 305 98 –2–51– Service Manual
HYDRAULIC CYLINDER (Cont’d)
A 3 2 1
Remove the bolt or the lock nut (Item 1) [A] from the rod.
Pull the piston off the rod (Item 2) [A].
Pull the head (Item 3) [A] off the rod.
CD–12673
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

Added Feb.106
98of 305 –2–52– Service Manual
A
For Piston 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

107 Feb.
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 three minutes.

B–12811
For Pistons with three Ring Grooves

Remove the two split rings (Item 1) [C] from the piston. C
B–13736
Cut the old teflon seal and remove the seal from the piston
[D].
D
B–13738

Added Feb.108
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

109 Feb.
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 three 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

Added Feb.110
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

the seals. D
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

111 Feb.
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 thru the piston and into the rod.
Tighten the bolt to 185–215 ft.–lbs. (250–291 Nm) torque.
PI–12677
For Cylinders Using Piston Retaining Lock Nuts B

Install the piston on the rod with the tapered end of the
piston towards the head [B].
Lubricate the threads and install the nut [B].
Tighten the nut to 315–385 ft.–lbs. (427–522 Nm) torque.

B–07002
Inspect the inside of the cylinder case for nicks and

scratches. If the cylinder case has minor scuffing 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
honing process.
CD–12678
Put oil on the seal surface of the cylinder case [D].

D
B–07013

Added Feb.112
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 wrench (MEL1075) to

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

113 Feb.
HYDRAULIC FILTER
A
Raise the engine cover.
Drain the hydraulic reservoir. (See Page 1–1.)
Remove the hoses from the filter [A].
N–10124
Remove the mounting bolts from the filter [B]. B

Remove the hydraulic filter.

N–10125

Added Feb.114
AUXILIARY COUPLERS
A
Remove the bolt from the quick coupler cover [A].
Remove the cover.
N–10126
Mark the hoses for correct installation. B

Remove the hoses from the quick coupler fittings [B].

N–10127
AUXILIARY FITTINGS C
Remove the auxiliary hoses from the auxiliary fittings.
Remove the tubelines from the auxiliary fittings [C].
N–10128
Remove the lock nut from the auxiliary fittings [D].

D
Remove the auxiliary fittings.
N–10129

115 Feb.
SHUTTLE VALVE
1. Plug
2. O–ring
3. Relief Valve
4. Back–up Ring
5. Adapter
6. Ball
7. Housing

3
2
3
5 3
3
2 2
5 3
2 6
1
4
2
4 7 2
2
4
2
5
B–14925

Added Feb.116
SHUTTLE VALVE (Cont’d)
A
Disassembly
Clamp the shuttle valve in a vise that has padded jaws. 1
Remove the relief valve (Item 1) [A] from the end of the
valve housing.
P–8619
Remove the plug (Item 1) [B] from the end of the relief
valve. B
1

P–8620
Remove the O–rings (Item 1) [C] from the relief valve and
plug. C
Remove the back–up rings (Item 2) [C] from the relief
valve. 2
1
1 1
P–8621
Remove the relief valve (Item 1) [D] from the top of the
valve housing. D 1
P–8622

117 Feb.
A
Remove the O–rings (Item 1) [A] and back–up rings (Item 2
2) [A] from the relief valve.
1 1
P–8623
Remove the fittings (Item 1) [B] and check balls (Item 2)

[B] from one side of the housing. B
2 1

1
P–8624
Remove the fittings (Item 1) [C] from the opposite side of

the housing. C
P–8625
Remove the O–rings (Item 1) [D] from the four (4) fittings. D
P–8626

Added Feb.118
A
Assembly
Clean all parts in solvent and dry with compressed air.
The relief valves cannot be disassembled. If the relief
valves do not operate correctly after cleaning, the relief
valves must be replaced. Order new relief valves from
Melroe Parts.
Apply oil and install new O–rings (Item 1) [A] on the four
(4) fittings.
1
P–8626
Install the two (2) fittings (Item 1) [B] on the one side of
the housing. B

P–8625
Install the check balls (Item 1) [C] and fittings (Item 2) [C]
on the opposite side of the housing. C
1 2
2
P–8624
Apply oil and install new O–rings (Item 1) [D] and back–up
rings (Item 2) [D] on the relief valve. D
2
1 1
P–8623

119 Feb.
A 1
Assembly (Cont’d)
Dip the relief valve (Item 1) [A] in clean hydraulic fluid and
install in the top of the housing.
P–8622
Apply oil and install new O–rings (Item 1) [B] and back–up
rings (Item 2) [B]. B
2

1 1 1
P–8621
Install the plug (Item 1) [C] on the end of the relief valve.
C
1
P–8620
Dip the relief valve (Item 1) [D] in clean hydraulic fluid and
install in the end of the valve housing. D
1
P–8619

Added Feb.120
DRIVE SECTION
Page
Number
BLADE LEVER
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11
CONSOLE
CONTROL AND STEERING LEVERS DRIVE

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3 SECTION
Lever Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
DRIVE MOTOR (S/N 12001–12929)

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16
DRIVE MOTOR (S/N 12930 & Above)
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–51
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–41

FINAL DRIVE (S/N 12001–12929)

FINAL DRIVE (S/N 12930 & Above)
FLOOR PANEL
HYDRAULIC MOTOR
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–35
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–32
LOCKING LEVER
MELROE CONTROL VALVE LEVER

PEDAL
Revised July 92 220 (S/N 508212001 & Above) Excavator


FLOOR PANEL
A
Remove the two bolts in each floor mat retaining plate.
Remove the plate and spacers (Item 1) [A] from the floor
plate (each side).
N–10130
Remove the floor mat [B]. B

N–10131
Remove the swing lock pin [C].

C
N–10132
Remove the right floor panel to work on the boom swing

cylinder or horn. D
1
Remove the three bolts (Item 1) [D] to remove the right
floor panel.
N–10133

FLOOR PANEL (Cont’d)
A
The center floor panel and right floor panel can be
removed together.
Remove the two bolts (Item 1) [A] to remove the center 1
and right floor panels.
N–10134
B
Remove the left floor panel bolts [B].

N–10135
C
Remove the floor panel [C].
N–10136

CONTROL AND STEERING LEVERS
Adjustment
A
The locking lever (Item 1) [A] when lowered, engages the
control levers.
1
If the control levers do not center the control valve spools
when in the locked position, adjustment must be made as
follows:
Remove the control panel bolts.
N–10137
Remove the control panel shield [B]. B

N–10138
Loosen the lock nut on the linkage [C].

C
Remove the cotter pin (Item 1) [C] and the clevis pin (Item
2) [C].
Remove the clevis from the spool and turn the clevis as
needed.
Connect the linkage and recheck the locking lever.
1 2
N–10139

D
Remove the bolts from the top cover [D].
Remove the top cover.
N–10140

CONTROL AND STEERING LEVERS (Cont’d)
A
Remove the knobs and handles from the control levers
[A].
N–10141
Remove the bolts from the control lever plate [B]. B

Remove the screws (Item 1) [B] from the rubber boots.

1
N–10142
Remove the control lever plate [C].

C
N–10143
Disconnect the linkage rods from the control valve spools.

(See Page 2–1.) D
NOTE: For lever removal purposes the center spool
linkage (Item 1) [D] must be removed from
both outside levers.
Remove the lever linkage.
N–10144

A
Remove the snap ring [A].
N–10145
Remove the flat washer [B]. B

N–10146
Remove the lever and linkage [C]. C
N–10147
Remove the two wave washers [D].

D
N–10148

Lever Disassembly And Assembly
A
Remove the bolt from the travel lever [A].
NOTE: Put a mark on the lever and pivot so after 1
assembly the lock pin (Item 2) [A] aligns with
the lock lever bar.
Remove the nut (Item 1) [A] to remove the linkage.
N–10149
Remove the nut (Item 1) [B], flat washer (Item 2) [B] and
wave washer (Item 3) [B] to remove the pivot assembly B 6
(Item 4) [B].
Check the condition of the O–rings (Item 5) [B] on the
bushing.
Remove the nut (Item 6) [B] to remove the linkage.

5 4 3 2 1
N–10150
Check the condition of the O–rings (Item 1) [C] on the

control lever pivot bushings. C
N–10151

LOCKING LEVER
A
Remove the control panel shield. (See Page 3–3.)
Remove the bolts (two each end) from the locking lever
bar [A].
N–10152
Remove the spring from the locking lever bar and the
locking lever pivot [B].
B

N–10153
Remove the mounting bolt from the locking lever pivot

arm [C]. C
N–10154
Remove the pivot arm [D].

D
N–10155

LOCKING LEVER (Cont’d)
A
Remove the nut and mounting bolt from the locking lever
arm [A].
Installation: Tighten the nut to 25–28 ft.–lbs (35–38 Nm)
torque.
N–10156
Remove the locking lever arm [B]. B

N–10157

CONSOLE
A
Remove the Dukes control valve. (See Page 2–1.)
Remove the left floor panel. (See Page 3–2.)
Remove the Melroe control valve linkage from the
console base (both sides) [A].
N–10158
Remove the four mounting bolts from the base of the

console [B].
B

N–10159
Remove the console [C]. C
N–10160

PEDAL
A
Remove the nut from the pedal pivot [A].
N–10161
Remove the pedal, the bolt, the washers (Item 1) [B] and
bushing (Item 2) [B] from the console base.
B
Check the condition of the O–rings (Item 3) [B] on the
bushing. 3
1

2
N–10162

BLADE LEVER
A
Linkage Removal And Installation
Remove the floor panel. (See Page 3–1.)
Remove the nut from the lever end of the linkage [A].
N–10163
Remove the nut from the front end of the linkage [B]. B

N–10164
Lever Removal And Installation C

Loosen the nut on the lever pivot bolt [C].
N–10165
Remove the nut, flat washer and wave washers from the
blade lever pivot bushing [D].
D
N–10166

BLADE LEVER (Cont’d)
Lever Removal And Installation (Cont’d)
A
Remove the bushing from the blade lever pivot mount [A].
Check the condition of the O–rings on the bushing.
N–10167
MELROE CONTROL VALVE LEVER B

Remove the linkage from the Melroe control valve and the
blade lever.

Remove the two nuts and bolts from each end bearing
[B].
NOTE: Mark the linkage locations for correct

installation.
N–10168
Remove the nuts from the linkage bolts [C]. C
N–10169
Remove the bearing from the control lever shaft [D].

D
Remove the roll pin (Item 1) [D] and the lever (Item 2) [D]
from the shaft. 2
NOTE: Mark the lever location for correct
installation.
N–10170

MELROE CONTROL VALVE LEVER (Cont’d)
A
Remove the lever from the shaft [A].
N–10171
Put the lever in a vise and use a puller to replace worn

bushings [B].
B

N–10172

FINAL DRIVE
For S/N 12001–12929 (for S/N 12930 & Above See
A
Page 3–39)

CD–10173
the system.
I–2003–0888
B
Remove the bolts from the track frame cover [A].

Nm) torque.

Remove the cover [B].
N–10174

C
Disconnect the pressure hoses from the drive motor [C].
N–10175
Remove the case drain hose from the drive motor [D].
D
N–10176
Revised July 92of 305 220 (S/N 508212001 & Above) Excavator
136 –3–14– Service Manual
FINAL DRIVE (Cont’d)
A
Loosen and remove the drive motor mounting bolts [A].
Nm) torque.
Remove the drive motor.
N–10177
Put the drive motor in a vise to remove the drive sprocket

[B].
B
Installation: Tighten the cap screws to 48–55 ft.–lbs.
(65–75 Nm) torque.

DRIVE MOTOR
CD–10178
WITHOUT BRAKES WITH BRAKES

1. MOTOR 1. MOTOR
2. O–RING 2. O–RING 2
8
3. GEAR 3. GEAR
4. HUB 4. HUB 2
5. SEAL 5. SEAL 7
6. SNAP RING 3 6. SNAP RING
7. BEARING 3 7. BEARING 6
9
8. HOUSING 8. HOUSING
9. COVER 4 9. COVER
3 10. BACKUP 5
WASHERS 6
2 3
1 11. BRAKE
DISCS 6 4
12. BELLEVILLE
6 WASHERS
9 13. BRAKE
PISTON 3
2 14. BRAKE
8 BUSHING 10
15. RING 3
2 10
7 6 13 11
15
6 1 2
5
14
2
12
B–13253 C–03242
Revised April 92 220 (S/N 508212001 & Above) Excavator

DRIVE MOTOR (Cont’d)
A

the system.
I–2003–0888
N–12482
The following tools will need to be fabricated by a local

machine shop for reassembly purposes: B
Bearing Disassembly Tool (See Page 3–22).
Floating Seal Installation Tool (See Page 3–25).
Disassembly
Remove the snap ring by inserting a screwdriver blade

behind the snap ring. Work the screwdriver blade around
the motor housing until the snap ring is loose [A].
Remove the cover from the drive motor hub [B].

N–12483
Remove the O–ring from the groove in the hub [C]. C
N–12484
Remove the three snap rings from the planet gear pins
[D].
D
N–12485
Added April138
92 of 305 220 (S/N 508212001 & Above) Excavator
–3–16– Service Manual
A
Remove the top thrust washer from the planet gears. Lift
the gear and needle bearings out as an assembly by using
the thrust washer that is under the gear as the lift point
[A]. Use care to prevent the needle bearings from falling
out of the center of the planet gears.
N–12486
Remove the drive gear and the coupling [B]. B

N–12487
Remove the eight bolts holding the drive motor assembly

to the gear box housing [C]. C
Make a note of the T and X marks that are stamped on the
drive motor and the gear box housing. These will be used
for alignment at assembly.
xx
N–12488
Remove the drive motor assembly [D]. D
N–12489
Added April 92 220 (S/N 508212001 & Above) Excavator

A
Remove the spacer ring [A].
NOTE: The following two pages include information

on drive motors with brakes. If drive motor
does not have brakes, go to Page 3–20.
N–10504
Remove the two belville washers [B]. B

Wear safety glasses to prevent eye injury when
any of the following conditions exist:
• Flying debris or loose material is present.
• Engine is running. N–10503
W–2019–1285
C
Remove the brake piston [C].
Compressed air can be blown into the X hole to force the
piston out of the housing.
N–10502
Remove the piston bushing [D]. D

Remove the three O–rings and back–up rings from the
piston bushing and the housing grooves.
N–10501

A
Remove the brake hub from the inside of the brake discs
[A].
N–10500
Remove the snap ring from the inside of the gear [B]. B

N–10499
Remove the eleven internal and external tooth brake

discs [C].
C
N–10498
Remove the spacer [D]. D
N–10497

A
Remove the larger O–ring from the housing groove [A].
N–12490
Remove the two small O–rings from the housing [B]. B

N–12491
Turn the gearbox over.

C
Remove the snap ring [C].
N–12492
Clamp the gearbox into a vise or other suitable retaining

device [D]. D
Insert two or three bolts into the hubs threaded holes.
Evenly tighten the bolts to separate hub from the gear box
housing [D].
NOTE: Use a M10 bolt with a minimum of 80 mm

(3.250 inches) of threads.
N–12493

A
Remove the O–ring from the hub groove [A].
N–12494
Remove the snap ring [B]. B

N–12495
Remove the spacer ring [C].

C
N–12496
Remove the bearing from the hub using a press [D]. Use
a press tube that contacts only the external bearing race. D
N–12497

A
Remove the bearing from the gear box housing [A]. Use
a bearing puller and the bearing tool (Shown in insert [B])
to pull the bearing off of the gear box housing.
NOTE: If this bearing is to be reused, extreme care

must be used to not scratch the bottom
bearing face because this is a finished
surface that is used as the mating surface
with the floating seal.
N–12498
7 mm Dia.
Bearing disassembly tool [B]. B 6 mm R.
This tool can be made at a local machine shop.
18.5 mm
9 mm
7 mm 7 mm
13 mm

18.5 mm
70 mm R. 13 mm
73 mm R.
88 mm R.
M6x1
2 mm B–13725
Loosen the floating seals steel race by prying out with a

screwdriver blade [C]. C
N–12499
Remove the floating seal (steel race and O–ring) from the
gear box flange [D]. D
N–12500
Added April144
92of 305 220 (S/N 508212001 & Above) Excavator
A
The three planet gear shafts that are in the gear box
housing are not replaceable [A]. These shafts have
LOCTITE applied and are pressed into the housing. If any
of the three shafts are damaged, a new housing will be
needed along with three new sets of gear assemblies
(which include the new shafts).
Inspect all components for damage. If any of the gears in

the gearbox assembly are damaged, all the gear
components should be replaced. Replace all seals and/or
O–rings.
N–12501
Assembly B
Install the bearing into the hub with press [B]. Use a press
tube that contacts only the external bearing race [B].

N–12502
Install the spacer into the hub [C]. C
N–12496
Install the snap ring into the hub [D]. D
N–12495

Assembly (Cont’d)
A
Apply a film of grease to the O–ring.
Install the O–ring into the hub groove [A].
N–12494
Install the second bearing into the hub [B]. B

NOTE: Make sure that the finished surface of this
bearing is facing outwards and that this
surface has no scratches. Any imperfections
in the finished surface can damage the
floating seal. Use a plastic spacer ring to
protect the bearing surface while pressing.
Also make sure that the O–ring [A] is in its

groove as the bearing will be pressed over
the O–ring
N–12503
If new planetary gear shafts are needed, do the following

two steps, [C] and [D]. If the planet gear shafts do not
C
need replacing, go to step [A] on next page.
Apply LOCTITE 601 to the smaller diameter end of the
shafts. Press the three shafts into the housing [C].
N–12504
Apply LOCTITE to the threads of the bolts. Install the

three bolts into the shafts [D]. D
Tighten the bolts to 8 ft.–lbs. (10.5 Nm) torque.
N–12505

220ExcavatorServiceManual(S/N508212001–508214999)#6720503–DriveSectionPart1of3
A
Assembly (Cont’d)
Apply a film of grease to the floating seal O–ring and to
the seal groove in the housing. Position the seal onto the
housing [A].
N–12558
Position the seal installation tool over the seal so that the
metal seal ring fits up into the installation tool flange [B]. B

N–12557
Press down evenly on the installation tool to insert the

floating seal into the housing flange [C].
C
See inset [D] for the dimensions needed for installation
tool fabrication.
This tool can be made at a local machine shop.
N–12559
Floating seal installation tool dimensions [D]. D

24 mm
11 mm
127 mm
3 mm
142,0–141,9 mm
143,0–142,9 mm
155 mm
B–13724

Assembly (Cont’d)
A
Install the hub onto the gear box housing [A]. Use a press
tube that contacts only the external race of the top
bearing.
N–12506
Install the snap ring [B]. B

N–12492
With a thrust washer underneath the gears and needle

bearings, install the pinion gear assemblies onto the C
shafts [C].
N–12486
Install the top thrust washers over the gears and install
the snap rings [D]. D
N–12485
Added April148
Assembly (Cont’d)
A
On the inside face of the gear box cover is a bronze wear
plug. This wear plug will need to be replaced if the
assembled parts will not meet the dimension shown [A].
Lay a straight edge across the motor mounting surface
[A]. Measure the distance from the top edge of the gear
hubs snap ring to the bottom edge of the straight edge.
Dimension must be as shown [A].
C–03307
Remove the bronze plug (if necessary) and press in the

new bronze plug into the cover [B].
B

N–12507
Install the O–ring into the hub groove [C].

C
N–12484
Install the cover into the hub [D].

D
N–12483

A
Assembly (Cont’d)
Install the snap ring [A].
N–12482
Turn the gear box over and install the sun gear [B]. B
NOTE: The following three pages are for drive
motors with brakes. If drive motor does not
have brakes go to Page 3–30 [D].

N–12508
Install the spacer ring into the gear box housing [C]. C
N–10497
Install a sintered external tooth disc, next install an

internal tooth steel disc [D]. Alternate the order of these D
discs until there are six sintered and five steel discs
installed.
N–10498

Assembly (Cont’d)
A
Install the snap ring into the brake gear hub [A].
N–10499
Align the teeth of the steel discs and install the brake gear
hub into the brake discs [B].
B

N–10500
Install the O–rings and backup washers into the housing

[C]. C Ring
Install the O–ring and backup washer into the piston Belville
Washers O–ring
bushing [C].
NOTE: Make sure the O–rings and backup washers Brake

are in the position shown and that the backup Piston
Back–up
washers do not get twisted during the piston Washer
bushing installation [C]. Discs
Spacer
Piston
Bushing
MC–01413
Install the piston bushing into the housing [D].

D
NOTE: Be sure that the O–ring is facing outwards
when the bushing is installed [C].
N–10501

Assembly (Cont’d)
A
Install the piston into the housing [A].
NOTE: Be sure that the O–rings do not get twisted in

the housing while the piston is installed.
N–10502
Install the belleville washers into the housing [B]. The

washers must be installed so that the external surface of B
the washers touch.

N–10503
Install the spacer rings [C].

C
N–10504
Install the two smaller O–rings into the housing [D].

D
N–12491
Added April152
A
Assembly (Cont’d)
Install the O–ring into the housing [A].
N–12490
Install the hydraulic motor assembly onto the gear box

housing [B].
B
Align the T and X on motor and the housing.

N–12489
Install the eight bolts [C]. C

Tighten to 180–200 in.–lbs. (21–23 Nm) torque.
x x
N–12488

HYDRAULIC MOTOR
A

the system.
I–2003–0888
PI–12509
Disassembly
B
Mount the motor into a vise with protective jaws or other
suitable retaining device [A].
Mark the edge of the motor for ease of component
alignment during assembly.
Remove the eight bolts [A].

Remove the end cover [B].
Remove the O–ring [C]. PI–12510
Remove the valve plate [D]. PI–12511
PI–12512
Added April154
HYDRAULIC MOTOR (Cont’d)
A
Remove the input shaft [A].
PI–12513
Remove the snap ring from the input shaft [B]. B

PI–12514
Remove the seven inside rotor rollers [C]. C
PI–12515
Remove the inside rotor plate [D].

D
PI–12516

A
Remove the outer rotor plate [A].
PI–12517
Remove the outer eight rotor rollers [B]. B

PI–12518
Remove the two poppet balls [C]. C
PI–12519
Remove the center housing [D].

D
PI–12520
Added April156
A
Remove the O–ring [A].
PI–12521
Press out the input shaft bushing from the mounting

flange [B].
B

PI–12522
Assembly C

• Flying debris or loose material is present. 0,5 mm
• Engine is running. 0,7 mm
• Tools are being used. B–13726
W–2019–1285
D
Press the new bushing into the mounting flange [B]. The
gap in the bushing can be in any position in the flange.
Press the bushing into the flange to the dimensions
shown [C].
Use compressed air and remove any shavings created
when pressing in the bushing.
Install the O–ring into the mounting flange [D].
PI–12523

A
Assembly (Cont’d)
Install the inner rotor [A].
The beveled edge on the center splines must be face
down.
PI–12524
Install the snap ring onto the input shaft [B]. B

PI–12514
Insert the input shaft into the rotor and thru the mounting
flange [C].
C
PI–12525
Install the seven rotor rollers [D].

D
PI–12526

A
Assembly (Cont’d)
Install the outer rotor [A].
PI–12527
Install the center housing and insert the eight rotor rollers
[B].
B
Make sure that the poppet ball valve seats are facing
upwards on the center housing.

PI–12528
Install the valve plate [C]. C

The beveled edge of the valve plate splines must face
downwards.
NOTE: The control windows of the valve plate must

not be obscured by the inner rollers. If
necessary, rotate the valve plate one spline
further.
PI–12529
Install the poppet balls into the valve seats of the valve
plate [D]. D
PI–12560

A
Assembly (Cont’d)
Install the O–ring into the end cover [A].
PI–12511
Install the end cover onto the input shaft [B]. B

PI–12530
Install the eight bolts [C]. C

Initial torque: Tighten the bolts to 13 ft.–lbs. (10 Nm)
torque.
The motor shaft must be rotated during final torque
process, tighten the bolts to 47 ft.–lbs. (35 Nm) torque.
This motor does not use a shaft seal, a certain amount of
oil seepage at the shaft end is permissible.
PI–12531

FINAL DRIVE
A
For S/N 12930 & Above
Remove the bolts from the track frame cover [A].
Nm) torque.
N–07594
Remove the cover [B]. B

Lift and block the side of the track frame where the final
drive will be removed.
Release the track tension and remove the track. (See
Page 5–1.)

When repairing hydrostatic and hydraulic CD–07595
C
the system.
I–2003–0888

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
48–55 ft.–lbs. (65–75 Nm) torque.
N–07597
Revised July 92 220 (S/N 508212001 & Above) Excavator

FINAL DRIVE (Cont’d)
A
Remove the motor, sprocket and reduction gear
assembly from the track frame [A].
DRIVE MOTOR
N–07598
1. Valve Plate 1. Housing 7. Piston

2. Spring 2. Hub 8. Cover
3. O–ring 6 3. Seal 9. Plate
4. Poppet 4. Bearing 10. O–ring
5. Spool 5. Nut 11. Holder
6. Plug 6. Gear
2

10
4
6
3
2 11
4
7
4
6
5 3
4 2 3
2
3 6 5
6 1 4
6 6
4
9
3
1 10
6
8
2
6
B–12777 D–01922
Added July162
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 3–52.)
Disassembly
Remove the drain plugs from the end cover of the drive
motor [A]. Drain the oil into a container.

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 thru 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 July 92 220 (S/N 508212001 & Above) Excavator

A
2 2
Remove the spring (Item 1) [A] and the poppet (Item 2)
[A] from the ends of the spool. 1 1
Use solvent and clean and dry all spool components.
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 the two dowel pins
(Item 1) [C] and the O–ring (Item 2) [C].
C
3
NOTE: The dowel pin (Item 3) is staked into the valve 1
plate end cover, do not remove unless
damaged.
1
2
P–00342
Remove the bearing from the valve end plate [D].

D
Use a slide hammer bearing puller.
P–00344

A
Remove the valve plate [A]. Bronze
Side
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 C
4) [C] from the piston housing (Item 5) [C]. 5 2
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 thru the center of the piston
housing. The outer diameter of the washer should be
smaller than the snap ring but large 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

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 thru the
C
eyebolts) and turn the cover counterclockwise and
remove the cover [C].
P–00357
Remove the O–ring from the end cover [D].

D
P–00346

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)
[D], will now have to be driven out of the 1 3
planetary pin. 2
4
P–00359

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

NOTE: The snap ring does not need to be removed Snap Ring
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 July168
A
Disassembly (Cont’d) Steel Balls
Remove the 109 or 110 steel balls that are used to retain
the motor housing to the hub bearing [A] & [B].
The balls must be removed thru 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 burst 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
Wire
off inside the motor. B
Use a length of 16 gauge mechanics wire and bend a Steel Balls
tight, close loop at one end of the wire. Insert the wire into
the plug hole and carefully feed the wire around the
diameter of the bearing and force the steel balls to the
hole. Remove the exposed balls with a magnet and
continue this process until all 109 balls are removed and
the end of the wire is visible thru the hole. Carefully

remove the wire, DO NOT break the wire off inside the
housing when removing the wire.
MC–01678A
Use the 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

A
Bend a hook onto a piece of stiff wire and use this wire to
hook the spring pin in the center of the planetary 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
B
planetary pin (Item 5) [B] from the housing.
With the planetary pins (Item 5) [B] removed, the spring
pins (Item 6) [B] will now have to be driven out of the
center of the planetary pins.
2 4

1 1
5 3
6 P–00317
Remove the three set screws from the housing [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 June 92 220 (S/N 508212001 & Above) Excavator

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

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 July 172

A
Assembly
Press 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]. B
Use a press tube that only contracts the outer bearing
race 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

A 170 mm
Assembly (Cont’d)
160 mm
Floating seal installation tool [A]. This tool can be made 142.8/143 mm
by a local machine shop. 6.9 mm 141.5/141.8 mm
7.3 7.9 8.1 mm
20.1 mm
5 mm 132/133 mm
15°
R 0.3
142.8mm mm R 0.2 mm
143.0
MC–O1678
Apply petroleum jelly to the O–ring of 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 July 174

A
Assembly (Cont’d)
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 thru the hub and into the planetary pin.
Use a center punch and stake the hub to the spring pin
[D].
P–00306

A
Assembly (Cont’d)
Install the housing onto the hub and press into position
[A]. The housing must be pressed onto the hub until the
groove in the bearing is centered in the hub plug hole.
NOTE: Make sure that the housing is pressed
squarely onto the hub so that the planetary
gears do not shave metal off of the housing
splines. If this happens the housing and the
planetary gears will be damaged.
P–00334
Insert the 109 steel balls into the hole in the side of the hub
[B]. B
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
removed) and install the gear hub into the planetary gear D Snap Ring
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 June 92 220 (S/N 508212001 & Above) Excavator

A
Assembly (Cont’d)
Install the center driveshaft thru 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

bearing (Item 2) [C] into the gear (Item 3) [C].
C
Install the gear (Item 3) [C] into the planetary housing and 1 3
insert the planetary pin (Item 1) [C] thru the gear. Align the 2
hole in the planetary pin and the planetary 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 92
A
Assembly (Cont’d)
Install the planetary gear assembly into the 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. Tighten 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

A
Assembly (Cont’d)
Install the dog point set screw into the side of the housing
[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 flat washer thru the spacers and the 2
spring. 1
3 4
Insert these parts thru the piston housing and install a nut.

The outer diameter of the washer should be smaller than
the inner diameter of the snap ring but large enough to
make good contact with the spring spacer top surface.
Tighten the nut to compress the spring and install the
snap ring.
P–00354
Loosen the nut and remove the bolt and washer.
C
Assemble the rotating group by applying petroleum jelly 5 2
to the three pins (Item 4) [C].
Insert the pins (Item 4) [C] into the notches in the splined 3
1
inner diameter of the piston housing (Item 5) [C].
Set the conical spacer (Item 3) [C] over the pins (Item 4)
[C] and on top of the piston housing (Item 5) [C].
Insert the pistons (Item 1) [C] into the retainer plate (Item
2) [C].
Apply clean hydraulic fluid to the outer diameter of the
piston (Item 1) [C] and insert the pistons into the piston 4
P–00348
housing (Item 5) [C].
D
Turn the drive motor on its side and apply oil to the face
of the swash plate.
Install the rotating group into the drive motor hub and onto
the piston driveshaft [D].
P–00345

A
Assembly (Cont’d)
Install a new O–ring into the groove in the motor 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 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 Pins
P–00310

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

B
the poppets (tapered end in first) into the spool [B]. Insert 1 1
the spring into the cavity of the poppets. Install a new
O–ring onto the end plugs and install the plugs [B]. 2 2

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

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

A
Assembly (Cont’d)
Install a new O–ring onto 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 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

UPPER WORKS AND SWING SECTION
Page
Number
CENTER SWIVEL JOINT

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
SWING CIRCLE GEAR

SWING MOTOR
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Motor Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
Removing The Cross Port Reliefs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 UPPER WORKS
& SWING
UPPER WORKS SECTION


SWING MOTOR
Removing The Cross Port Reliefs
A
Remove the battery and seat. (See Page 5–1.)
Loosen the two cross port reliefs (Item 1) [A].
PI–10179
Remove the relief valves (Item 1) [B]. B

1
PI–10180

C
Remove the pressure tubelines and drain tubelines [C].
PI–10181
Remove the mounting bolts from the swing motor [D].

D
Nm) torque.
PI–10182
Revised June 91 220 (S/N 508212001 & Above) Excavator

SWING MOTOR (Cont’d)
Remove the swing motor [A].
A
Disassembly
Clear the motor and drain the oil from the motor.
Use a soft jaw vise to hold the motor by the mounting
flange.
NOTE: Do not disassemble the geroler (Item 1) [B].
The geroler has machined close tolerances.
Damage may occur during reassembly.
Mark the bearing housing by the alignment groove for
assembly. The alignment groove aligns the case drain
hole in the valve housing.
PI–10183
Disassemble the motor.
NOTE: The cap screws (Item 2) [B] are held by thread
bonding adhesive. DO NOT exceed 70
in.–lbs. to remove screws. Use a propane
torch to heat the screw heads. This will melt
the adhesive on the screws.
Discard the screws and remove the seal retainer (Item 3)
[B].
Remove the quad seal (Item 4) [B] and the square cut

seat (Item 5) [B] from the retainer.
NOTE: Check the seal retainer for cracks. Order a
new retainer from Melroe Parts, if needed.
B
Valve
Housing
Bolt
Pin and (4)
Spring
Balance
Valve Ring
Valve Plate Valve
1 Drive O–ring
Geroler
Plug
Wear Drive Inner and Outer
Shaft and Bearing Plate Face Seals
Housing Square Cut
Retaining Seal
Ring
Square Cut
3 Seal
2 Shaft Square Cut
Seal Retainer Seal
Cap
Screw Square Face
(8) Square Cut Seal
Seal
Race Seal
and O–ring
Square Cut
Quad Seal Seal
4 5
B–13496

SWING MOTOR (Cont’d)
Assembly
A
1
4

ports to keep dirt out. Dirt can quickly damage 2 3
the system. B–13401
I–2003–0888
NOTE: Order a swing motor repair kit from Chicago

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 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 LOCTITE 609 to the threads.
Install the screws and tighten to 60 in.–lbs. (6,7 Nm)
torque.
Revised 220 (S/N 508212001 & Above) Excavator

187 of June
305 91
SWING MOTOR (Cont’d) Wear Plate Shaft Face
Assembly (Cont’d)
A 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
Locate the largest open pocket in the Geroler (Item 1) [B].
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 450 in.–lbs. (50 Nm) torque. Tighten
the case drain plug to 50 in.–lbs. (5,5 Nm) torque.
Balance Ring
B–13495

UPPER WORKS
A
Remove the ROPS.
Remove the fuel tank. (See Page 5–1.)
Remove the seat. (See Page 5–1.)
Remove the hydraulic reservoir. (See Page 2–1.)
Remove the floor panels. (See page 3–1.)
Remove the engine. (See Page 7–1.)
Remove the boom assembly. (See Page 5–1.) PI–10184
Remove the swing motor. (See Page 4–1.)

Remove the Melroe control valve. (See Page 2–1.)
B
Remove the bolts from the Melroe control valve mounting
plate [A].
Nm) torque.

Remove the plate [B].
PI–10185
Loosen and remove all the bolts around the swing circle
gear [C].
C
Connect a chain hoist to the frame of the upper works and
lift it off the swing circle gear.
PI–10186

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].
Insert the three alignment pins (P/N 6539805) (Item 3) [C]

into the alignment holes.
Reposition the frame as necessary until the alignment
pins (Item 3) [C] will slide thru the frame and into the teeth
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. See Installation Of
Swing Motor Page 4–7.

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 are tight.
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 swing bearing.
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 5
4
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 remaining bolts and
install them into the frame.
Tighten the bolts to 44–47 ft.–lbs. (60–65 Nm) torque.
Remove the chain hoist from the frame.
Installation Of Swing Motor

Do the following for either the alignment pin or the
alignment bolt procedure
B–13719
Install the swing motor (Item 4) [B] into the frame.
Apply LOCTITE to the threads of the bolts (Item 5) [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.

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 1
I–2003–0888
Remove the bolts from the plate below the swivel joint [A].
Remove the plate.

Mark all the hoses for correct installation.
Disconnect all the hoses from the swivel joint [B].

Remove the four mounting bolts (Item 1) [B]. PI–10482
Installation: Add LOCTITE and tighten the bolts to

15–18 ft.–lbs. (20–25 Nm) torque. C
Remove the center swivel joint from the track frame.
Disassembly And Assembly

Remove the bolts (Item 1) [C]. 4
Remove the end plate (Item 2) [C].
Remove the end plate (Item 3) [C] from the end of the
rotor.
Remove the rotor (Item 4) [C] from the housing.
NOTE: Tap the rotor lightly with a rubber hammer if
needed for removal.
3
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.
1
2
B–12744

SWING CIRCLE GEAR
A
Remove the upper works from the swing circle gear. (See
Page 4–5.)
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].
NOTE: The soft zone can be located by the filler plug

in the outer ring [D].
Inner Soft Zone
Ring
”S”
Tracks
MC–01415
Soft Zone D–02029

220ExcavatorServiceManual(S/N508212001–508214999)#6720503–UpperWorksandSwingSection

MAIN FRAME AND TRACKS
Page
Number
BOOM AND DIPPERSTICK

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
BOOM SWING BRACKET
Bushing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7
ENGINE COVER
FUEL TANK
SEAT AND MOUNTING FRAME
TRACK
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9 MAIN FRAME
Track Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8 & TRACKS

TRACK FRAME
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10
TRACK IDLER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10d
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10b
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10a
TRACK ROLLER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11
Revised February 95 220 (S/N 508212001 & Above) Excavator


ENGINE COVER
A
Open the engine cover.
Remove the retainer clip and washer from the rod end pin
of the gas cylinder [A].
Remove the retainer clip from the base end pin of the gas
cylinder.
Hold the engine cover and remove the gas cylinder. Close
the engine cover.
PI–10187
B
Cylinder contains high pressure gas. Do not
open. Opening cylinder can release rod and
cause injury or death.
W–2113–0288

Remove the bolts from the hinge (both sides) [B].
PI–10188
Remove the engine cover from the machine [C]. C
PI–10189

SEAT AND MOUNTING FRAME
A
Disconnect the throttle cable (Item 1) [A].
PI–10190
Remove the shut–down cable [B]. B

Disconnect and remove the battery. (See Page 6–1.)

PI–10191
Remove the bolts from the seat mounting frame [C].

C
PI–10192
Remove the seat mounting frame [D].

D
PI–10193

FUEL TANK
A
Remove the plug to drain the fuel from the tank into a
container [A].
N–09657
Remove the fuel tank mounting bolts [B]. B

PI–10194
Disconnect the fuel return line [C].

C
PI–10195
Lift and move the fuel tank forward. Disconnect the fuel
supply hose [D]. D
Disconnect the electrical harness (Item 1) [D].
Remove the fuel tank from the machine.
PI–10196

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 1
engine.
Move the control to release the hydraulic pressure.
Mark all the hoses for correct installation.
PI–10197
Disconnect the hoses from the tubelines [B]. B

the system.
I–2003–0888 PI–10198
NOTE: I.S.O. and U.S. control patterns require C

different locations of the boom and
dipperstick restrictors. Mark the location of
the restrictors for correct installation [C] &
[D].
PI–10199
PI–10200

BOOM AND DIPPERSTICK (Cont’d)
A
Remove the auxiliary hoses [A].
PI–10201
Remove the bolt from the tubeline clamp [B]. B

PI–10202
Remove the boom cylinder. (See Page 2–1.)

C
Remove the boom swing cylinder. (See Page 2–1.)
Remove the retainer bolt and nut from the boom pivot pin
[C].
PI–10203
Remove the boom pivot pin and washer(s) [D].

D
Installation: Make sure to install the washer(s) that were
removed when the boom was removed from the swing
bracket [D].
PI–10204

BOOM SWING BRACKET
A
Remove the boom and dipperstick. (See Page 5–4.)
Remove the retainer bolt from the boom swing cylinder
rod end [A].
N–10122
Remove the boom swing cylinder rod end pin [B]. B

N–10123
Remove the retainer bolt and nut from the boom swing
bracket pivot pin [C]. C
PI–10205
Remove the boom swing bracket pivot pin [D].

D
Remove the boom swing bracket.
PI–10206

BOOM SWING BRACKET (Cont’d)
A
Bushing Removal And Installation
Use a puller to remove the upper bushing [A].
PI–10207
Install a bushing driver to remove the lower bushing [B]. B

Install the replacement bushings flush with the top and
bottom of the frame bracket.

PI–10208

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 [A]. Stop the engine.
PI–09682
AVOID INJURY
Keep fingers and hands out of pinch points
when checking the track tension.
W–2142–0189

Measure the track sag between the frame and the top of
the track. If the gap is between 2.250 inches–2.500
inches (57–63 mm), the track tension is correct [B].
If not, loosen one bolt and remove the other bolt from the PI–09154
cover.
Bleed Add Grease
C Here Here
Add grease to the fitting (Item 1) [C] until the track tension
is correct.
Repeat the procedure for the other side.
If the track tension is still loose after adjusting to the above
mentioned limit, it indicates the track is worn. See your 1
dealer for repairs.
B–13134
AVOID INJURY
Do not loosen the grease fitting more than one
complete rotation. Also, be careful not to
loosen any part other than the grease fitting. If
the grease fitting or any part is loosened too
much, it can fly off under high pressure. If the
grease does not ooze smoothly, try moving the
machine back and forth for a short distance.
W–2143–0189

TRACK (Cont’d)
A
Lift and block the side of the machine where the track will
be removed.
Slowly loosen the bleed fitting to remove track tension.
Slowly remove the valve from the recoil spring cylinder
[A].
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 [B].
Remove the track from the frame and rear drive sprocket. B

CD–07625

TRACK FRAME
220ExcavatorServiceManual(S/N508212001–508214999)#6720503–MainFrameandTracksSectionPages1–10

A
Use the following procedure to remove the different parts
from the track frame:
Remove the track. (See Page 5–9.)
Slide the front track idler out of the track frame to remove
it [A]. (See Page 5–10a 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 and remove the drive gear bolts [D].

D
Installation: Put LOCTITE on the bolts and tighten to 80
ft.–lbs. (108 Nm) torque.
CD–10178
Revised February 95 220 (S/N 508212001 & Above) Excavator

TRACK IDLER
2
3
4
5
6
1 7

6
5 2
3
4
D–01960
TRACK IDLER
Ref. Description Ref. Description
1. Shaft 5. Snap Ring
2. Pin 6. Bearing
3. Block 7. Idler
4. Seal
Added Feb. 95 220 (S/N 508212001 & Above) Excavator

207 of 305 –5–10a– Service Manual
TRACK IDLER (Cont’d)
The following tools must be fabricated for this procedure:
A
1. Driver Tool – See [A].
3.500”
(90 mm)
2. Support Fixture – Tube, 3.0 inches ID x 0.250 inches
wall x 6.0 inches long. 2.750”
(70 mm)
0.050”
(0,75 m) 1.350”
Chamfer (35 mm) Dia.
3 Places 2.400”
(60 mm) Dia. B–14204
Disassembly
B
Remove the roll pin and block from each end of the shaft
[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

208 of 305 –5–10b– 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

209 of 305 –5–10c– Service Manual
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

210 of 305 –5–10d– 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]. Install
D 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

211 of 305 –5–10e– 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 new 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

212 of 305 –5–10f– Service Manual
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 5–10f 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

213 of 305 –5–10g– Service Manual
220ExcavatorServiceManual(S/N508212001–508214999)#6720503–MainFrameandTracksSectionPages10a–10h

214 of 305 –5–10h– Service Manual
TRACK FRAME (Cont’d)
A
Loosen the nuts at the track roller on both sides of the
track frame [A].
PI–07631
Remove the track roller [B]. B

TRACK ROLLER
PI–07632
2
1
3
4
5
6
10 7
8
8 9
7
1. Washer 6
2. Nut
3. Washer 5
4. Spacer 4
5. Snap Ring
6. Seal 3
7. Snap Ring 1
8. Bearing 2
9. Shaft
10. Roller
C–03143

TRACK ROLLER (Cont’d)
The following tools must be fabricated for this procedure:
A
1. Driver Tool – See [A].
2. Support Fixture – Tubing, 3.0 inches ID x 0.250 3.500”
inches wall x 6.0 inches long. (90 mm)
2.250”
(60 mm)
0.050”
(0,75 mm) 1.350”
Chamfer (35 mm) Dia.
3 places 2.0”
(50 mm) Dia. B–14203
Disassembly B
Remove the snap ring from each end of the shaft [B].

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

both ends of the exposed shaft that could affect seal C
removal or damage the new seal during installation [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

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 remove the 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. The bearings

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

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

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
Install
Using a dial indicator, check the endplay of the shaft [C].
C 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–14276
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

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 of the 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 a syringe, add 25 cc

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

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

220ExcavatorServiceManual(S/N508212001–508214999)#6720503–MainFrameandTracksSectionPages11–18

ELECTRICAL SYSTEM
Page
Number
ALTERNATOR
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
Checking The Alternator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
BATTERY
Checking The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
ELECTRICAL SYSTEM
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
Electrical System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
HORN
Horn Switch, Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9

INSTRUMENT PANEL
STARTER ELECTRICAL
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7 SYSTEM


225 of 305
ELECTRICAL SYSTEM
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 Instructions are necessary before operating or
only. 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
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.
1. The charging circuit has an alternator, regulator and
a battery.
2. 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 fuse protects the electrical system from damage. To
replace the fuse turn the button and remove the fuse [A].
Replace the fuse with the same type and capacity.
NOTE: Before replacing any fuse, make sure the key

switch is in the OFF position.
PI–09664
Electrical System Service

B
Use the following procedure to service the electrical
system:
1. Check that the battery cable ends are clean and

tight. Remove any acid or corrosion from the battery
cable ends with a baking soda and water solution
[B]. Cover the battery terminals with grease to

prevent corrosion.
2. Check the electrolyte level in the battery. Add

distilled water as needed.
3. Check the alternator belt for wear and correct

tension. A–02741
4. Check that all wire connections are secure.

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]. PI–09666
Batteries contain acid which burns eyes and

skin on contact. Wear goggles, protective
clothing and rubber gloves to keep acid off

body.
In case of acid contact, wash immediately with
water. In case of eye contact get prompt medical
attention and wash eye with clean, cool water
for at least 15 minutes.
PI–10209
If electrolyte is taken internally drink large
quantities of water or milk! DO NOT induce
vomiting. Get prompt medical attention.
W–2065–1296
C
Remove the battery clamp [B].
Disconnect the negative (–) cable first [C].

Disconnect the positive (+) cable.
PI–10210
Remove the battery from the machine [D].

D
Always clean the terminals and cable ends, even when
installing a new battery.
Reverse the procedure for battery installation.
PI–10211

ALTERNATOR
Checking The Alternator Output
A
Use OEM1428 MULTIMETER to check the alternator
output.
Start the engine.
Set the multimeter to DC Volts and check the output as
follows:
Touch one probe to the battery lead on the alternator and
other probe to the body of the alternator [A].
The output reading should be 14.2 volts.
PI–10212
Belt Adjustment B
Stop the engine. Open the engine cover.
The belt should deflect about 0.500 inch (13 mm) when
pressed between the alternator pulley and crankshaft
pulley with approximately 13 lbs. (58 N) force [B].

PI–09127
If the tension is not correct, loosen the alternator

mounting bolt and 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 pulley.
PI–09128

ALTERNATOR (Cont’d)
A
Disconnect the negative (–) cable from the battery.
Disconnect the alternator wires (Item 1) [A].
1
PI–10213
Remove the adjustment bolt [B]. B

Remove the alternator belt.
Remove the mounting bolt.
Remove the alternator from the bracket.

Parts Identification PI–09128
1. PULLEY
2. SPACER
3. FAN
4. HOUSING
5. BEARING
6. ROTOR 4
3 7
7. STATOR 1 6
8. DIODE 2 2
9. REGULATOR
10. BRUSH ASSEMBLY
11. COVER
5
8 8
10
4 11
C–02999

STARTER
A
Raise the operator seat. Disconnect the negative (–)
cable from the battery.
Disconnect the wires from the starter [A].
PI–10214
Remove the mounting bolts from the starter [B]. B

Remove the starter from the bell housing.

PI–10215

STARTER (Cont’d)
A
Disassemble the starter as shown in figure [A].
Cleaning And Inspection
5
1
6
3
8 2
4 7
• When fluids are under pressure. 9
• Flying debris or loose material is present. 10
• Engine is running.
W–2019–1285
1. FRAME 11
2. WASHER
Use a brush and air pressure to clean the drive, field coils, 3. BRUSH
armature and starter housing. 4. HOLDER
5. SOLENOID

NOTE: Do not use solvent to clean the drive 6. LEVER
assembly. The solvent will remove the 7. FIELDS
lubricant and the drive will slip. 8. ARMATURE
9. DRIVE
Check the following items: 10. HOUSING
11. BUSHING
Armature B–01192
Broken or burned insulation.
Loose connections at commutator.
Open or grounded circuits.
Worn shaft or bearings.
Rough commutator.
Field Coils
Broken or burned insulation.
Electrical continuity.
Brush connections.
Drive Gear
Worn teeth.
Tooth engagement (drive gear must engage ring gear
by 1/2 the depth of the ring gear tooth).
Brush Holders
Broken springs.
Broken insulation.
Spring tension.

INSTRUMENT PANEL
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 bolts from the cover on the instrument panel
[A].
PI–10216
Lift the cover [B]. B

PI–10217
Mark the wires and refer to the electrical chart for the
correct installation. C
Remove the wires from the ignition switch [C].
PI–10218
Remove the nut from the ignition switch [D].

D
Remove the ignition switch.
PI–10219

INSTRUMENT PANEL (Cont’d)
A
Mark the wires for correct installation:
Remove the wires from the indicator lamp [A].
PI–10220
B
Remove the instrument panel mounting bolts [B].
Remove the instrument panel assembly from the
machine.

PI–10221
C 1
HORN
Remove the right floor panel. (See Page 3–1.)
Remove the wire from the horn [C].
Remove the horn mounting bolt (Item 1) [C].
PI–10222
D
Horn Switch Removal And Installation
Remove the floor panel. (See Page 3–1.)
1
Remove the rubber boot (Item 1) [D].
Remove the mounting nut (Item 2) [D]. 2
Remove the two wires (Item 3) [D] from the switch.
3
PI–10223

220
ExcavatorServiceManual(S/N508212001–508214999)#6720503–ElectricalSystemSection

ENGINE SERVICE
Page
Number
CRANKSHAFT AND PISTONS
Crankshaft Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–36
Servicing The Connecting Rods And Pistons . . . . . . . . . . . . . . . . . . . . . . 7–37
CYLINDER HEAD
Assembling The Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–25
Checking Rocker Arm And Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–25
Checking Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–24
Disassembly Of The Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–22
Installing The Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–25
Removal Of The Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–21
Servicing The Cylinder Head And Valves . . . . . . . . . . . . . . . . . . . . . . . . . 7–23
CYLINDER LINERS
Checking The Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39
Cylinder Liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39
ENGINE

ENGINE COMPRESSION
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
ENGINE FLYWHEEL
Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–20
Hydraulic Pump Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–20
ENGINE SERVICE ENGINE
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 SERVICE
FUEL FILTER
Fuel Filters Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
Removing Air From the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
FUEL INJECTOR NOZZLES
Checking The Injector Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9
FUEL INJECTION PUMP
Checking The Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
Timing The Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7
GLOW PLUGS
Checking The Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10
OIL COOLER
RADIATOR
Checking The Radiator And Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–17

ENGINE SERVICE (Cont’d)
Page
Number
SPARK ARRESTOR MUFFLER

TIMING GEAR, CAMSHAFT AND OIL PUMP
Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–31
Servicing The Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–32
TIMING GEAR COVER
VALVE CLEARANCE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
WATER PUMP
220 Hydraulic Excavator

ENGINE SERVICE
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, 19, 20, 25, 27, 28, 29
No power from engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 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, 18, 19, 22, 24, 25, 27, 29, 31, 40, 41
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40
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, 18, 21, 24, 25, 27, 28, 29, 30, 41
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. Broken valve spring. 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.
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 inch
(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 the cylinder head [A].
B–12827
Connect the compression gauge [B]. B

Turn the engine with the starter (must turn at least 175
RPM). Run the test for each cylinder two times for 5–10
seconds.
The compression must be at least 337 PSI (2324 kPa)

with no more than 50 PSI (345 kPa) difference between

the cylinders.
B–12828

FUEL FILTER
A
correct service interval for the fuel filters.
Use a filter wrench to remove the fuel filter [A].
Put some oil on the new filter gasket. Install the new filter
element and hand tighten only.
To remove water from the filter open the drain valve (Item
1) [A].
1
N–09658
Removing Air From The Fuel System B

After replacing the fuel filters or after running out of fuel,
air must be removed from the fuel system.
Open the vent valve on the injection pump.
Squeeze the priming bulb to fill the filter with fuel [B].

Leave the vent open slightly.
Start the engine. When the engine runs smoothly, close
the vent valve.
N–09659
Fuel Filter Removal And Installation

Remove the fuel lines from the filter head [C]. C
PI–10224
D
Remove the bolts from the filter head [D].
Nm) torque.
PI–10225

FUEL INJECTION PUMP
Checking The Injection Pump
A
The injection pump contains parts which have a very
close tolerance and its operation has a direct effect 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
The tools listed will be needed to do the following
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.
B–08235
Connect the adapter fuel line (Item 1) [B] to the fitting.

Connect the pressure gauge (Item 2) [B]. C
Crank the engine, with the starter, to increase the
pressure to 2133 PSI (14707 kPa). Align the plunger at
T.D.C.
The pressure should hold at 2133 PSI (14707 kPa), at
least five seconds. If not, repair or replace the injection
pump.

NOTE: To remove the fuel injection pump, either B–05960
remove the engine from the machine (See
Page 7–11) or remove the seat, seat mounting
frame and fuel tank. (See Page 5–1.) Remove
the access panel from the machine frame.
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–05964
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

front pulley of the engine.
1
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. The timing
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 one cylinder high pressure line
from the injection pump.
2. Install a short pipe in the number one outlet of the

pump. Point the pipe up (vertical).
3. With fuel supply to the injection pump, rotate the

engine in a clockwise direction (viewed from the
water pump end of the engine). Fuel must flow from
the pipe as the mark F–1 on the crankshaft pulley
and the pointer are in alignment [B].
4. The correct timing for the engine is 23–25 degrees

CD–10226
B.T.D.C. Add or subtract shim(s) as needed to
adjust the delivery time of the fuel injection pump.
5. Repeat Step three several times for correct 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 or death. Fluid leaks under pressure may
not be visible. Use a piece of cardboard or wood
to find leaks. Do not use your bare hand. Wear
safety goggles. If fluid enters skin or eyes, get
immediate medical attention from a physician
familiar with this injury. B–05958
W–2072–0496
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.
1
* The engine exhaust smoke is black, white or blue.

B–05969
C
Do not bend the high pressure fuel injection
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 B–05970
injection pump. Remove the high pressure fuel lines.
D
Disconnect the return fuel hoses (Item 1) [B].
Remove the banjo fitting from the fuel injector [B].
Use the special socket and loosen the injector nozzle [C].
Installation: Tighten the injector nozzle to 22–36 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 inch (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].
A–02513
Operate the hand lever slowly and note the opening
pressure. If the pressure is not correct, disassemble the
injector nozzle and add or remove spacer(s) (Item 1) [A]
as needed. C Spring
Assemble the nozzle and check the pressure again. CORRECT WRONG Pressure
Tighten the nozzle body (Item 3) [A] to 43–58 ft.–lbs. 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 injector valve.
Needle Valve
Record the pressure. Release the hand lever. Check the
pressure drop for 10 seconds. If the pressure drop is more A–02621
than 740 PSI (5102 kPa), the nozzle is damaged.
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.
Diesel fuel or hydraulic fluid under pressure
* The nozzle has an even flow coming from the nozzle. can penetrate skin or eyes, causing serious
injury or death. Fluid leaks under pressure may
not be visible. Use a piece of cardboard or wood
to find leaks. Do not use your bare hand. Wear
safety goggles. If fluid enters skin or eyes, get
immediate medical attention from a physician
familiar with this injury.
W–2072–0496

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 of the 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 7–16.)
Disconnect the top radiator hose [A].
Disconnect the lower radiator hose.
PI–10227
Loosen the air cleaner hose clamps from the intake

manifold and air cleaner [B].
B
Remove the hose.
NOTE: Plug the intake manifold hose after hose

removal.

PI–10228
Loosen the clamp from the air cleaner inlet hose [C]. C
PI–10232
Remove the air cleaner mounting bolts [D].

D
Remove the air cleaner.
PI–10233

ENGINE (Cont’d)
A
Remove the nut from the throttle linkage cable end [A].
N–07646
Loosen the large nut on the throttle linkage cable [B]. B

Disconnect the throttle linkage from the fuel injection
pump and mounting bracket.
Pull the shut–down cable through the engine front cover
and into the engine compartment.

N–07647
Disconnect the fuel hose and fuel return hose from the
fuel injection pump [C]. C
N–07648
Disconnect the inlet hoses from the hydraulic pumps [D].

D
Drain the hydraulic fluid into a container.
N–10092

ENGINE (Cont’d)
A
Disconnect the high pressure hoses from the hydraulic
pump [A].
N–10090
Remove the nuts from the four engine mounts [B]. B

PI–10234
Remove the bolts from the engine cover latch bracket

[C]. C
Remove the latch bracket.
PI–10235
Disconnect the wire from the glow plug [D]. D
PI–10236

ENGINE (Cont’d)
A
Disconnect the wire from the temperature switch [A].
PI–10237
Disconnect the wire from the oil pressure switch [B]. B

PI–10238
Disconnect the wires from the alternator [C]. C
PI–10213
Disconnect the wires from the starter [D].

D
PI–10214

ENGINE (Cont’d)
A
Remove the ground cable from the frame [A].
PI–10239
Connect a chain hoist to the engine lifting hooks [B]. B

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

PI–10240

SPARK ARRESTOR MUFFLER
A
Stop engine and allow the muffler to cool

before cleaning the spark chamber. Wear safety
goggles. Failure to obey can cause serious
injury.
W–2011–1285
Remove the clean out plug on the bottom of the muffler PI–10229
[A].
Start the engine and run for about 10 seconds to clean out
the muffler. B
Stop the engine and install the plug.

Remove the two bolts from the muffler mounting bracket

[B].
PI–10230
Remove the muffler [C].

C
NOTE: Plug the exhaust hole after muffler removal.
PI–10231

RADIATOR
Checking The Radiator And Radiator Cap
A
NOTE: Allow the engine to cool before removing the
radiator cap.
Remove the radiator cap and install it on the tester.

Increase the pressure to 7 PSI (3.18 kg). The pressure
should not drop more than 4.3 PSI (1.95 kg) in 10
seconds.
Replace the radiator cap if pressure does not hold.
CD–10241
Install the tester on the radiator as shown [B].

B
Increase the pressure to 7 PSI (3.18 kg) and check for
leaks.

PI–10242

C
Drain the coolant.
Remove the upper radiator hose [C].
PI–10227
Remove the bolts from the fan shield [D].

D
PI–10243

RADIATOR (Cont’d)
A
Remove the bolts from the top support bracket [A].
Remove the bolt from the top rubber mount (Item 1) [A]. 1
PI–10244
Remove the two bolts from the lower radiator mounts [B]. B

PI–10245
Remove the bolts from the radiator side support bracket

[C]. C
Remove the bracket.
PI–10246
Remove the radiator [D].

D
PI–10247

RADIATOR (Cont’d)
A
Remove the fan shield [A].
PI–10248
B
OIL COOLER
Removal And Installation 1
1
Loosen the radiator mounting bolts to remove the oil
cooler. (See Page 7–17.)

The radiator does not need to be removed to remove the
oil cooler.
Remove the bolts (Item 1) [B] from the cooler brackets.
PI–10249
C
Raise the cooler and remove the cooler hoses [C].
PI–10250

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.
Remove the hydraulic pumps. (See Page 2–1.)
Remove the flywheel housing bolts [A].
Installation: Tighten the bolts to 125–140 ft.–lbs.
Remove the flywheel housing.
CD–10251
NOTE: Check that the alignment dowels are
installed for assembly.
Remove the bolts from the hydraulic pump coupler [B]. B
Installation: Tighten the bolts to 125–140 ft.–lbs.
Remove the hydraulic pump coupler.
Hydraulic Pump Coupler
Put the pump coupler in a vise and remove the coupler

bolts [C].
Installation: Tighten the bolts to 125–140 ft.–lbs
NOTE: The coupler splined bushing must extend
from the coupler away from the flywheel as CD–10252
shown [C].
Remove the bolts from the flywheel [D].
C
Nm) torque.
Remove the flywheel.
Flywheel Ring Gear

any of the following conditions exist: CD–10253

• Flying debris or loose material is present. D
• Engine is running.
W–2019–1285
The ring gear on the flywheel is an interference fit. Heat

the ring gear enough to expand it and hit it with a hammer,
evenly to remove it.
Clean the outer surface of the flywheel to give smooth fit.
Clean the new ring gear and heat it to a temperature of
450–500° F (232–260°C).
Fit the ring gear over the flywheel. Make sure the gear is
seated correctly. CD–10254

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

Remove the fuel injector nozzles. (See Page 7–8.)

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

the rocker arm assembly [C].
C
B–05093
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)
A
Removal Of The Cylinder Head (Cont’d)
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
Remove the valve spring retainer (Item 3) [D] and spring 6
(Item 4) [D].
Remove the seal (Item 5) [D] and the valve (Item 6) [D]. 4
Seal
Collets Cap
3
Valve
Spring
Retainer B–04122

A
Disassembly Of The Cylinder Head (Cont’d)
Remove the thermostat housing and thermostat [A].
B–03643
Servicing The Cylinder Head And Valves B

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

combustion chambers.

Put a feeler gauge (Item 2) [B] between the straight edge
and the surface of the cylinder head.
2
The maximum distortion of the head surface ± 0.002 inch
(± 0,051 mm) in 4.0 inches (102 mm) of the length of the
cylinder head surface.
A–02735
If the measurement is more than the specifications, the
cylinder head must be replaced.
C
Clean the valve seat and combustion chamber. Measure
the width of the valve seat [C].
B–03632
The correct width of the seat is 0.083 inch (2,1 mm). The
correct angle of the valve and seat is 45 degrees [D].
D Valve Contacting
Width
C
A
Grind the valve seats as follows:
B
1. Use a 45 degree cutter to grind the surface of the
valve seat.
2. Use a 15 degree cutter to grind the top surface of the
valve seat. Corrected Surface
Uncorrected Surface
of Valve Seat of Valve Seat
3. Use a 65 or 70 degree cutter to grind the bottom
surface of the valve seat to finish the valve seat to
a 0.083 inch (2,1 mm) width. A–45 °Cutter
B–15 °Cutter
4. Grind the valve surface to 45 degrees. C–65 °or 70 °Cutter A–02729

A
Servicing The Cylinder Head And Valves (Cont’d)
Install the valve in the seat and check the depth [A].
The specifications for the depth of the valves is
0.043–0.051 inches (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 inches
(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 inches (7,01–7,04
mm).
B–03698
Checking Valve Springs C

Measure the valve spring. The length of the spring must
be 1.382–1.402 inches (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 inches (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

220ExcavatorServiceManual(S/N508212001–508214999)#6720503–EngineServiceSectionPart1of2
A
Checking Rocker Arm And Shaft
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 inches (11,0–11,05 mm).
The shaft diameter is 0.432–0.433 inches (10,97–11,0
mm).
If the measurements are not within specification, replace
the parts.
Assembling The Cylinder Head B–03697
Install the valves. Put oil on the valve seal and install the
seal on the valve stem. B
Install the valve spring and retainer. Install the spring
collet and valve cap.
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 shim over 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

A
Installing The Cylinder Head (Cont’d)
Lower the piston to be measure 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 inches (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. (Page 7–8.)
Install the high pressure fuel lines.
Adjust the valve clearance. (Page 7–2.)
B–05093
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 B

spring [B].

B–03647
Remove the start spring from the gear case [C]. C
B–03678
Straighten the washer on the crankshaft pulley. Remove

the nut and washer.
D
Installation: Tighten the nut to 101–116 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
Removal And Installation 2
1
Remove the cylinder head. (See Page 7–21.)
Remove the tappets.
Remove the timing gearcase cover. (See Page 7–27.)
Remove the crankshaft collar (Item 1) [A], O–ring (Item
2) [A] and oil slinger (Item 3) [A].
B–03637
Remove the snap ring and washer from the idler gear [B]. B

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

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

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

are aligned when installing the gears [D]. D
Camshaft
Gear backlash is 0.0017–0.0045 inches (0,043–0,114 Gear
mm). The limit permitted is 0.0079 inches (0,2 mm).
Injection Idler
Pump Gear
Gear
Crankshaft
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 inches
(0,10–0,15 mm). The wear limit is 0.008 inches
(0,20mm).
B–03616

A
Oil Pump Service (Cont’d)
Check the clearance between the outer rotor and the
body of the oil pump [A].
The clearance for the outer rotor is 0.004–0.008 inches
(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 inches (32,99–33,02
mm). The wear limit is 0.002–0.0036 inches
(0,051–0,091 mm).

B–03620
Measure the camshaft journal [C]. C

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 inches
(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 inches (26,87 mm).
The wear limit is 1.056 inches (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 inches (0,043–0,114 mm).
The wear limit is 0.0079 inches (0,2 mm).

B–03672

CRANKSHAFT AND PISTONS
A
procedure:
MEL1063 – Ring Compressor
MEL1064 – Piston Ring Expander
Remove the cylinder head. (See Page 7–21.)
Remove the gear case cover. (See Page 7–27.)
Remove the timing gears. (See Page 7–29.)
Remove the flywheel. B–05924
Remove the oil pan [A].

B
Remove the oil pump tube and screen [B]. 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
Remove the cap and bearing from the connecting rod [C]. C
NOTE: Make sure the marks on the connecting rod
and bearing cap are in aligned when
installing the bearing cap [C].
Installation: Put oil on the bolts and tighten to 26–30

ft.–lbs. (35–41 Nm) torque.
A–02731
B–03688
Remove the piston and connecting rod assembly from the

engine block [D].
D
NOTE: Make sure the pistons are marked so they will
be returned to the same cylinder bore.
B–03625

CRANKSHAFT AND PISTONS (Cont’d)
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 inches
C
(0,15–0,30 mm). Replace the thrust bearing if the end
play exceeds 0.020 inches (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

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

sure to position the markings on the bearing
caps toward the flywheel. Thrust washers
must be installed with oil grooves facing
outward.
Nm) torque. B–04092
NOTE: Be sure the plugs that come with a new

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

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

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

engine block [C].
mm). The wear limit is 0.008 inches (0,20 mm).
B–03631
Check the outside diameter of the number one crankshaft D

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

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

up with the the piston pin. Position the other rings so there
B
is a gap every 90 degrees [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 & 2nd Ring 0.010–0.0158 inches (0,25–0,40 mm)
Oil Ring . . . . . . . 0.008–0.0158 inches (0,20–0,40 mm)
Wear Limit . . . . . . . . . . . . . . . . . . . . . 0.05 inch (1,27 mm)
B–03622
Measure the piston pin hole [D].

D
The specifications are 0.787–0788 inches (19,98–20,02
mm). The wear limit is 0.789 inch (20,04 mm).
A–02733

A
Servicing The Connecting Rods And Pistons
(Cont’d)
Measure the piston pin (Item 1) [A] and the connecting
rod bushing (Item 2) [A].
The specifications are 0.788–0.789 inches (20,03–20,04
mm).
2
Clearance between piston pin and bushing is
0.0006–0.0015 inch (0,015–0,04 mm). The wear limit is
0.006 inch (0,15 mm).
1
NOTE: Replacement bushing specifications are B–03633
0.0006–0.0026 inches (0,015–0,066 mm).
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 inch (0,020 mm). The wear limit is
0.002 inch (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
mm). The wear limit is 0.008 inch (0,20mm).
120
A–02727
Check the connecting rod journals [D].

D 1
mm). The wear limit is 0.008 inch (0,20 mm).
If the connecting rod journals are not within specifications, 2
grind the journals as follows [D]:
1. Crankshaft corner radius must be 0.138 inch R ±

0.008 inch (3,5 mmR ± 0,20 mm).
2. The oil hole must be chamfered to 0.039–0.059
inches R (0,99–1,5 mmR).
1
A–02716

CYLINDER LINERS
A
Checking The Cylinder Liners
procedure:
MEL1060 – Ridge Reamer
MEL1180 – Dry Liner 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
mm). The wear limit is +0.006 inch (+0,15 mm).
When the cylinder liner has more wear than
specifications, bore and hone the cylinder to 2.697–2.698
inches (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 the engine 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 inches (67,99–68,02 mm).

WATER PUMP
220ExcavatorServiceManual(S/N508212001–508214999)#6720503–EngineServiceSectionPart2of2
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.
Drive the shaft out of the impeller side of the water pump

[B]. (4) (2)
Remove the seal. (3) (1)
Install a new seal when assembling the water pump.
B–05929

TECHNICAL DATA
Page
Number
ENGINE SPECIFICATIONS (KUBOTA)
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Engine Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8
Fuel Injector Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–7
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6
Re–Grinding The Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–7
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
FUEL, COOLANT AND LUBRICANTS
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–10

HYDRAULIC EXCAVATOR SPECIFICATIONS
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
Digging Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Lifting Capacity With The Blade Off Ground . . . . . . . . . . . . . . . . . . . . . . . 8–2
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
Performance And Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 TECHNICAL
DATA
ENGINE OIL SPECIFICATIONS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–10


HYDRAULIC EXCAVATOR SPECIFICATIONS
Machine Dimensions
All dimensions are shown in inches. Respective metric dimensions are given
in millimeters enclosed by parentheses.
Where applicable, specifications

conform to SAE standards.
Specifications are subject to change
without notice.
144.0” (3653 mm)
103.0” (2613 mm)
85.0”
(2166 mm)
16.400”

(417 mm)
45.0”
(1146 mm)
9.800” 44.100”
(250 mm) 10.300” (1120 mm)
(262 mm) 0.710”
28.700” 36.0” (18 mm)
(730 mm) (914 mm)
38.600” 58.70”
(980 mm) (1490 mm)
17.600”
(447 mm)
23.600”
(600 mm)
MC–01350
MC–01349

HYDRAULIC EXCAVATOR SPECIFICATIONS (Cont’d) With 40.2 (1023)
Dipperstick
Machine Dimensions (Cont’d) A Max. digging depth 80.2 (2041.4)
B Max. vertical wall depth 48 (1201.3)
All dimensions are shown in inches. Respective metric
dimensions are given in millimeters enclosed by C Max. digging reach 147.3 (3747.4)
parentheses. D Max. digging reach at ground level 143.6 (3655.2)
E Max. digging height 122.4 (3114.4)
Where applicable, specifications conform to SAE standards. F Max. dumping height 84.4 (2148.6)
Specifications are subject to change without notice. G Min. swing radius
C
(when using boom swing) 52.6 (1337.5)
D
H Max. height of Min. swing radius 95.1 (2420)
G I Max. lift above ground (blade) 6.6 (167.4)
J Max. drop below ground blade 5.6 (141.9)
K Max. digging depth blade down 86.6 (2205)
E H
F
I
B J
A K

MC–01343
Lifting Capacity With Blade Off Ground
Chart dimensions are shown in millimeters. Inch

dimensions are shown in parentheses.
MC–01342
Lift Point
Height (r) Lift Radius – mm (in.) (r) Lift Radius – mm (in.) (r) Lift Radius – mm (in.)
mm Rated Lift Capacity Over End Rated Lift Capacity Over End Rated Lift Capacity Over Side
h
(in) Blade Down – kg (lb.) Blade Up – kg (lb.) Blade Up – kg (lb.)
1500 2000 2500 Max. 1500 2000 2500 Max. 1000 1500 2000 2500 Max.
(59.1) (78.7) (98.4) (59.1) (78.7) (98.4) (39.4) (59.1) (78.7) (98.4)
2000 166 166 113
(78.7) (365)* (365)* (248)*
1500 178 178 178 178 178 102
(59.1) (392)* (392)* (392)* (392)* (392)* (225)
1000 297 225 190 297 225 190 334 218 147 92
(39.4) (653)* (496)* (418)* (653)* (496)* (418)* (735) (480) (323) (203)
500 625 376 285 202 625 376 232 164 307 204 143 92
(19.7) (1375)* (827)* (626)* (444)* (1375)* (827)* (510) (360) (675) (450) (315) (203)
Ground 751 435 306 218 511 324 239 170 392 273 188 140 94
(1653)* (957)* (674)* (479)* (1125) (713) (525) (375) (863) (600) (413) (308) (206)
–500 613 376 277 237 524 336 222 188 443 256 188 145 102
(–19.7) (1349)* (827)* (609)* (522)* (1153)* (740)* (488) (413) (975) (563) (413) (319) (225)
–775 593 376 257 218 443 298 257 218 443 239 170 145 102
(–30.5) (1305)* (827)* (566)* (479)* (975) (656) (566)* (479)* (975) (525) (375) (319) (263)

HYDRAULIC EXCAVATOR SPECIFICATIONS (Cont’d)
PERFORMANCE & OPERATION
Operating Weight W/ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3090 lbs. (1405kg)
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 MPH (1,73 km/hr.)
Controls:
Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two Hand Levers
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two joystick levers control boom, bucket, dipperstick and swing.
Hand lever controls blade. Foot control for boom swing.
Foot control for auxiliary hydraulics.
ENGINE
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kubota
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–750 BW–CLARK–2
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
Low Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 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, 37 Amp.
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt, 425 Cold Crank Amps.
HYDRAULIC SYSTEM
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Triple Section Gear Pumps
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 x 4.00 GPM (15,1 L/min.) = Auxiliary Flow 8 GPM (30,28 L/min.)
System Relief Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2400 PSI (16545 kPa)
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–Spool (Aux. Blade & Boom), 6–Spool
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orbit Motor
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orbit Motor
SWING SYSTEM
Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orbit Motor with a Pinion
Swing Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Row Shear Type Ball Bearings W/Internal
Gears Built into Swing Circle
Swing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.02 RPM @ 2500 RPM
Boom Swing (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 degrees
(Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 degrees
HYDRAULIC CYLINDERS
Bore Dia. Rod Dia. Stroke
Boom . . . . . . . . . . . . . . . . . . . . . . . . 2.38 (60) 1.38 (35) 12.8 (325)
Dipperstick . . . . . . . . . . . . . . . . . . . 2.38 (60) 1.38 (35) 17.32 (440)
Bucket . . . . . . . . . . . . . . . . . . . . . . . 2.38 (60) 1.38 (35) 15.16 (385)
Boom Swing . . . . . . . . . . . . . . . . . . 2.38 (60) 1.38 (35) 13.62 (246)
Blade . . . . . . . . . . . . . . . . . . . . . . . . 2.38 (60) 1.38 (35) 2.75 (70)
DRIVE SYSTEM
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Each Track is Independently Driven by an Orbit Motor.
Type of Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power is Transferred Through a Planetary Gear Reduction
Maximum Drawbar Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2560 lbs. (1161 kg)
Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 degrees

HYDRAULIC EXCAVATOR SPECIFICATIONS (Cont’d)
220
BRAKES
Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Lock On Motor Circuit
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Motor & Hold Pin Lock
UNDERCARRIAGE
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crawler–Tractor Design Undercarriage. Sealed Track With
Reinforced Box–Section Adjusters With Shock Absorbing Recoil System.
TRACK
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 Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 Gals. (25 L)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 Qts. (5,7 L)
Engine Oil & Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 Qts. (4,3 L)
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Gals. (26,5 L)

DIGGING FORCE
Dipperstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1613 lbs. (733 kg)
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3127 lbs. (1420 kg) @ 2400 PSI

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 (13719–14705 kPa)

Fuel Tightness Nozzle Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1848 PSI (12740 kPa) Dry Nozzle
Fuel Injection Pump
Fuel Tightness of Plunger . . . . . . . . . . . . . . . . 8 Seconds: Initial Pressure Drop From 1237–1031 PSI (8529–7109 kPa)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sec. or Less
Fuel Tightness of Delivery Valve . . . . . . . . . . . . . 10 Seconds: Initial Pressure Drop From 1422–71 PSI (9805–490 kPa)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sec. or Less
Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23–25 degrees B.T.D.C.
Cylinder Head
Cylinder Distortion Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05) in 3.900 (100) of the length of the cylinder head

Thickness of Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0413–0.0453 inch (1,05–1,15 mm)
Thickness of Gasket Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2)
Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020–0.030 (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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035–0.043 (0,9–1,1)
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.220 (31)
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0017–0.0045 (0,042–0,115)
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.0059 (+0,015)
Piston Rings
Ring Gap (Top & 2nd Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010–0.016 (0,25–0,41)

Ring Gap, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0078–0.0158 (0,20–0,40)

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.787–0.788 (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 (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0006–0.0015 (0,015–0,04)
(Service Replacement Parts) . . . . . . . . . . . . . . . . 0.0006–0.0026 (0,015–0,066)
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008 (0,02)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002(0,05)
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 (43,984–44,04)
Clearance between Crankshaft Journals & Bearing No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0013–0.0042 (0,03–0,106)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2)
Clearance between Crankshaft Journals & Bearing No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0013–0.0036 (0,034–0,092)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0079 (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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–36 29–49
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 SPECIAL BOLT SPECIAL 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)

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parenthesis.
Re–Grinding The Crankshaft
If the standard size bearing cannot be used due to excessive wear of the crankpin and crankshaft journals, use undersize
or oversize bearings.
D
3 C
2
A B

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

0.008 in. 15261–2391–1 Crankshaft 1.7218–1.7224 in. 020US
A (0,2 mm) U/S Bearing #1 (43,733–43,750 mm)
(0,4 mm) U/S Bearing #1 (43,534–43,550 mm)
B (0,2 mm) U/S Bearing #2 (43,734–43,749 mm)
(0,4 mm) U/S Bearing #2 (43,534–43,550 mm)
0.008 in. 15531–297–1 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 0.04–0.06 in. (1–1,5 mm) chamfer. Use an oil stone to
3 chamfer the oil hole.

FUEL, COOLANT AND LUBRICANTS
220
ExcavatorServiceManual(S/N508212001–508214999)#6720503–TechnicalDataSection
Chart
Use this chart for correct selection of Fuel, Coolant and Lubricants.
RECOMMENDED SAE VISCOSITY NUMBER CAPACITY

(LUBRICATION OILS FOR ENGINE CRANKCASE)
RESERVOIR KIND OF FLUID C°–34 –29 –23 –18 –13 –7 –1 +4 +10 +15 +21 +27 +32 +38 +43 +49 +54 +60
Refill
Engine oil pan Use SAE SAE 40 or 20W–50
4.5 qts.
Viscosity (4,3 L)
Number as SAE 10W–30
Listed With API
Classification SAE 15W–40
CD or Better
SAE 5W–30
SAE 30W
SAE 20W–20
SAE 10W
F°–30 –20 –10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120 +130 +140
TEMPERATURE RANGE ANTICIPATED BEFORE

NEXT OIL CHANGE

Fuel Tank Diesel Fuel No. 1 6.60 gal.
50/50 (25 L)
No. 2
Cooling System Coolant 3.0qts.

Mixture** (2,85 L)
Hydraulic Tank Bobcat Fluid
6563328* 7.0 Gals.
(26,5 L)
* If Bobcat fluid (P/N 6563328) is not available, use Engine Oil SAE 10W–30/10W–40, Class SE, or better.
ENGINE OIL SPECIFICATIONS ** COOLANT MIXTURE

Description Propylene Glycol (Factory Installed)
When fuel sulphur content is less than 0.5% change the Add premixed coolant; 47% water and 53% propylene
engine oil and filter as shown in the SERVICE SCHEDULE glycol to the recovery tank if the coolant level is low.
(See Page 1–1.)
One gallon and one pint of propylene glycol mixed with one
Change engine oil and filter according to the following gallon of water is the correct mixture of coolant to provide
chart if fuel sulphur content is above 0.5%. a –34°F (–37°C) freeze protection.
Fuel Sulphur Change Interval Of Use a refractometer to check the condition of propylene
Content Engine & Oil Filter glycol in your cooling system.
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 SAE 10W engine oil.
Use API Classification CD or CE engine oil, if API
Classification CC is used, reduce the engine oil change
interval to half the hours.

220–1
® Revision Number
13 November 1990
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT EXCAVATOR
SERVICE MANAGER X
Model 220 (S/N 508212001 & Above) SALES MANAGER
Manual No. 6720503 (6–90)
NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.
The following is a revision to the 220 Excavator Service Manual P/N 6720503 (6–90).
Take out the following pages and put in the revised pages shown below:

TAKE OUT PUT IN
Hydraulic Flow Chart #6720536 & Chart Legend Hydraulic Flow Chart #6720536 & Chart Legend
(Printed June 1990) (Printed November 1990)
Hydraulic Flow Chart #6720535 & Chart Legend Hydraulic Flow Chart #6720535 & Chart Legend
(Printed June 1990) (Printed November 1990)
Hydraulic Schematic (I.S.O.) #6720655
& Chart Legend
Hydraulic Schematic (STANDARD) #6720654
& Chart Legend
4–3, 4–4 4–3 (Revised Nov. 90), 4–4
4–5 4–5 (Revised Nov. 90)
290 of 305
291 of 305
220–2
® Revision Number
27 June 1991
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER X
Manual No. 6720503 (6–90)
The following pages are a revision to the 220 Excavator Service Manual P/N 6720503 (6–90).

TAKE OUT PUT IN
220 Excavator I.S.O Hydraulic Schematic
W/Brake (S/N 12286 & Above)
Section 4 Content Page Section 4 Content Page (Revised June 91)
4–1, 4–2 4–1 (Revised June 91), 4–2 (Revised June 91)
4–3, 4–4 4–3 (Revised June 91), 4–4 (Revised June 91)
4–5 4–5 (Revised June 91)
4–6 (Added June 91)
4–7 (Added June 91)
292 of 305
293 of 305
220–3
® Revision Number
14 April 1992
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER X
Manual No. 6720503 (6–90)

TAKE OUT PUT IN
Section 3 Content Page Section 3 Content Page (Revised Apr. 92)
3–15 3–15 (Revised Apr. 92)
3–16 Thru 3–37 (Added Apr. 92)
Section 4 Content Page (Revised June 91) Section 4 Content Page (Revised Apr. 92)
4–5 (Revised June 91), 4–6 (Added June 91) 4–5 (Revised Apr. 92), 4–6 (Revised Apr. 92)
4–7 (Added June 91) 4–7 (Revised Apr. 92), 4–8 (Revised Apr. 92)
4–9 (Added Apr. 92)
7–3, 7–4 7–3 (Revised Apr. 92), 7–4
294 of 305
295 of 305
220–4
® Revision Number
5 May 1992
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER X
Manual No. 6720503 (6–90)

TAKE OUT PUT IN
Section 2 Content Page Section 2 Content Page (Revised May 92)
2–5 thru 2–18 2–5 (Revised May 92) thru 2–18 (Revised May 92)
2–19 (Added May 92) thru 2–32 (Added May 92)
296 of 305
297 of 305
220–5
® Revision Number
12 June 1992
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER X
Manual No. 6720503 (6–90)

TAKE OUT PUT IN
HYDRAULIC FLOW CHART #6720535 HYDRAULIC SYSTEM OPERATION CHART #6720535
& Chart Legend (Printed November 1990) & Chart Legend (Printed June 1992)
HYDRAULIC SCHEMATIC (U.S.) (MC–1386) HYDRAULIC SYSTEM OPERATION CHART #6722104
& Chart Legend (Printed June 1992)
HYDRAULIC SCHEMATIC (I.S.O.) (MC–1384)
HYDRAULIC SYSTEM OPERATION CHART #6722103
HYDRAULIC SCHEMATIC (I.S.O.) (MC–1447) & Chart Legend (Printed June 1992)
298 of 305
299 of 305
220–6
® Revision Number
29 July 1992
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER X
Manual No. 6720503 (6–90)

TAKE OUT PUT IN
Secrion 3 Contents Page (Revised Apr. 92) Section 3 Contents Page (Revised July 92)
3–13, 3–14 3–13, 3–14 (Revised July 92)
3–39 3–39 (Revised July 92), 3–40 (Added July 92)
3–41 thru 3–60 (Added July 92)
300 of 305
301 of 305
220–7
® Revision Number
23 February 1995
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER X
Manual No. 6720503 (6–90)
Take out the pages shown and put in the revised pages as follows:

TAKE OUT PUT IN
Secrion 5 – Contents Page Section 5 – Contents Page (Revised Feb. 95)
5–9, 5–10 5–10 thru 5–10f (Added Feb. 95)
5–11 5–11 thru 5–17 (Added Feb. 95)
302 of 305
303 of 305
220–8
® Revision Number
February 9, 1998
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER X
Manual No. 6720503 (6–90)
Put in the added pages as follows:

TAKE OUT PUT IN
Section 2 Section 2
Do Not remove the Hydraulic Flow Charts in Section 2
304 of 305
305 of 305

220 6720503 SM 6-90 PDF

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Dealer Copy -- Not for Resale

6720503(6–90)–7.5C Printed in U.S.A. © Melroe Company 1997

CORRECT CORRECT CORRECT

B-10731a B-14148 B-14142

Dealer Copy -- Not for Resale

B-14146 B-14143 B-6589

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . 1–1 MELROE CONTROL VALVE LEVER . . . . . . . . . . . . 3–1

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

Dealer Copy -- Not for Resale

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 6–1 VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

FINAL DRIVE (S/N 12001–12929) . . . . . . . . . . . . . . . 3–1

GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

HOLDING VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

LOCKING LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1

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

220 (S/N 508212001 & Above) Excavator

220 (S/N 508212001 & Above) Excavator

Dealer Copy -- Not for Resale

220 (S/N 508212001 & Above) Excavator

220 (S/N 508212001 & Above) Excavator

Dealer Copy -- Not for Resale

ENGINE SERIAL NUMBER

Dealer Copy -- Not for Resale

220 (S/N 508212001 & Above) Excavator

Dealer Copy -- Not for Resale

TRACK TRACK FRAME

Dealer Copy -- Not for Resale

220 (S/N 508212001 & Above) Excavator

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Dealer Copy -- Not for Resale

LUBRICATION OF THE EXCAVATOR

USING A BOOSTER BATTERY (JUMP STARTING)

220 (S/N 508212001 & Above) Excavator

220 (S/N 508212001 & Above) Excavator

ITEM SERVICE REQUIRED 8–10 50 100 250 500 1000

Dealer Copy -- Not for Resale

220 (S/N 508212001 & Above) Excavator

Never service or adjust the machine when the

Keep the engine cover closed when operating

Open the engine cover to service the engine. Pull on the

AIR CLEANER SERVICE

Dealer Copy -- Not for Resale

1. Loosen the clamp on the air cleaner [B].

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

4. Remove the filter element [D]. D

6. Check the condition of the element replace if

7. Check the seal (Item1) [D]. 1

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

220 (S/N 508212001 & Above) Excavator

Stop and cool the engine before adding fuel.

Fuel System Service

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

Dealer Copy -- Not for Resale

Always clean up spilled fuel or oil. Keep heat,

220 (S/N 508212001 & Above) Excavator

Dealer Copy -- Not for Resale