BOBCAT 220 MINI EXCAVATOR Service Repair Manual Instant Download (SN 508211999 & Below)

1
X 220
Excavator Service Manual (S/N 508211999 Below)
6720230 (589)
Printed in U.S.A.
? Melroe Company 1989
2
CONTENTS
PREVENTIVE MAINTENANCE
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . i SERIAL NUMBER LOCATIONS . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ii DELIVERY REPORT . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . ii HYDRAULIC EXCAVATOR
IDENTIFICATION . . . . . . . . . . . . . . . . .
. . . . . . . . . iii PREVENTIVE MAINTENANCE . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 11 HYDRAULIC SYSTEM . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 21 DRIVE SYSTEM . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 31
UPPER WORKS SWING SECTION . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 41 MAIN
FRAME TRACKS . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
51 ELECTRICAL SYSTEM . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 61 ENGINE SERVICE . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 71 TECHNICAL DATA . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 81
HYDRAULIC SYSTEM
DRIVE SYSTEM
UPPER WORKS SWING SECTION MAIN FRAME
TRACKS
ELECTRICAL SYSTEM
ENGINE SERVICE TECHNICAL DATA
220 (S/N 508211999 Below) Excavator Service
Manual
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3
FOREWORD This manual is for the Bobcat hydraulic
excavator mechanic. It provides necessary
servicing and adjustment procedures for the
hydraulic excavator and its component parts and
systems. Refer to the Operation Maintenance
Manual for operating instructions, starting
procedure, daily checks, etc. A general
inspection of the following items must be made
after the hydraulic excavator has had service or
repair
1. Check that the operator canopy is in good
condition and is not modified.
9. Safety treads must be in good condition.
2. Check that the operating
10. Check for the correct function of the the
indicator lamps.
canopy mounting hardware is
tightened and is Melroe approved.
3. The seat belt must be
11. Check hydraulic fluid level, engine oil and
fuel supply.
correctly installed, functional and in good
condition.
4. Inspect for loose or broken parts or
connections.
12. Inspect for fuel, oil or hydraulic leaks..
5. Machine signs must be legible and in the
correct location.
13. Lubricate the hydraulic excavator.
6. Steering levers, control levers and foot
pedals must return to neutral. Control lock must
lock controls securely.
14. Check the condition of the battery and
cables.
7. Inspect the air cleaner for damage or leaks.
Check the condition of the element.
15. Check for any field modifications not
completed.
FIELD MODIFICATION
Recommend to the owner that all necessary
corrections be made before the machine is
returned to service.
8. Check the electrical charging system.
220 (S/N 508211999 Below) Excavator Service
Manual
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SAFETY INSTRUCTIONS

• Instructions are necessary before operating or
  servicing machine. Read Operation Maintenance
  Manual, Handbook and signs (decals) on machine.
  Follow warnings and instructions in the manuals
  when making repairs, adjustments or servicing.
  Check for correct function after adjustments,
  repairs or service. Failure
• to follow instructions can cause injury or death.
• W20030797
• The following publications provide information on
  the safe use and maintenance of the excavator and
  attachments
• The Delivery Report is used to assure that
  complete instructions have been given 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.
• 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
  shoptype service and repair work.

Warnings on the machine and in the manuals are
for your safety. Failure to obey warnings can
cause injury or
This notice identifies procedures which must be
followed to avoid damage to the
machine. I20190284
death.
W20441285

• Safety Alert Symbol This Safety Symbol is used
  for important safety messages. When you see this
  symbol follow the safety message to avoid
  personal injury or death.
• Wear tight fitting clothing and any other
  required safety apparel when operating or
  servicing the excavator.
• Wear safety glasses when maintaining or servicing
  the excavator.
• Exhaust gases can kill, vent engine exhaust
  outdoors.
• Know where fire extinguishers and first aid kits
  are located and how to use them.
• Do not run the excavator where exhaust, arcs,
  sparks or hot components can contact flammable
  material, explosive dust or gases.
• 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.
• Do not use ether or starting fluids on an engine
  that has glow plugs. These starting aids can
  explode and injure you.
• Clean the excavator before doing any welding.
  Cover rubber hoses, battery and all other
  flammable parts. Keep a fire extinguisher near
  the excavator when welding.
• Have good ventilation when welding or grinding
  painted parts. Wear a dust mask when grinding
  painted parts. Toxic dust or gas can be
  produced.
• Stop the engine and let it cool before adding
  fuel. No smoking!
• Use the procedure in this manual for installing,
  connecting and jump starting batteries.
• 220 (S/N 508211999 Below) Excavator
• i Service Manual

6
SERIAL NUMBER LOCATIONS Always use the serial
number of the machine when requesting service
information or when ordering parts. Early or
later models (identification made by serial
number) may use different parts, or it may be
necessary to use a different procedure in doing
a specific service operation. HYDRAULIC
EXCAVATOR SERIAL NUMBER The excavator serial
number plate is on the machine frame, at the
left side near the front corner A.
A

N07348
ENGINE SERIAL NUMBER The engine serial number is
located on the engine block, near the fuel
injection pump B.
B

N07349
DELIVERY REPORT The Delivery Report must be
filled out by the dealer and signed by the owner
or operator when the excavator is delivered. An
explanation of the form must be given to the
owner. Make sure it is filled out completely C.
C
220 (S/N 508211999 Below) Excavator Service
Manual
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7
HYDRAULIC EXCAVATOR IDENTIFICATION
CONTROL LEVERS OPERATOR CANOPY ENGINE COVER BOOM SWING LOCK UPPER WORKS BLADE TRACK TRACK FRAME GRAB HANDLES DIPPERSTICK CYLINDER OPERATOR SEAT BUCKET CYLINDER BOOM CYLINDER BUCKET LINK CONTROL LOCK BLADE CYLINDER DIPPERSTICK CONTROL LEVERS OPERATOR CANOPY ENGINE COVER BOOM SWING LOCK UPPER WORKS BLADE TRACK TRACK FRAME GRAB HANDLES DIPPERSTICK CYLINDER OPERATOR SEAT BUCKET CYLINDER BOOM CYLINDER BUCKET LINK CONTROL LOCK BLADE CYLINDER DIPPERSTICK
BUCKET B14810 B14811
220 (S/N 508211999 Below) Excavator Service
Manual
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8
PREVENTIVE MAINTENANCE
PREVENTIVE MAINTENANCE
Page Number
AIR CLEANER SERVICE Replacing the Filter Element
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 12 COOLING SYSTEM Coolant
Level . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 16 Coolant Replacement . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 16 ENGINE COVER Procedure . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
13 ENGINE LUBRICATION SYSTEM Checking the Engine
Oil . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 15 Engine Oil
and Filter Replacement . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 15 FINAL DRIVE
CASE Checking Oil Level . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 112 Draining Final Drive Case . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 112 FUEL SYSTEM Fuel
Specifications . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 13 Fuel System Service . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 13 HYDRAULIC SYSTEM Checking and
Adding Fluid . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
17 Replacement of the Hydraulic Filter . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
18 Hydraulic Reservoir . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 18 LUBRICATION OF THE
EXCAVATOR Procedure . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 110 SERVICE
SCHEDULE Chart . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 11 USING A BOOSTER
BATTERY (JUMP STARTING) Procedure . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 19
220 (S/N 508211999 Below) Excavator Service
Manual
11
9
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. Instruct
ions are necessary before operating or servicing
machine. Read Operation Maintenance Manuals,
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check
for correct function after adjustments, repairs
or service. Failure to follow instructions can
cause injury or death. W20031289

ITEM SERVICE REQUIRED 810 50 100 250 500 1000
Engine Air Cleaner Check empty dust cup as required.
Engine Oil Check the oil level add oil as needed.
Engine Coolant System Check radiator coolant level.
Indicator Lights Check for correct operation.
Operator Canopy Check the fastening bolts, nuts, condition of canopy.
Seat Belt Control Lock Check the condition, operation that fasteners are tight.
Safety Signs (Decals) Safety Treads Check for damaged signs (decals) and safety treads. Replace any safety signs and safety treads that are damaged or worn.
Tracks Check adjust tension.
Hydraulic Reservoir Check fluid level.
Fuel Tank Drain water and sediment from fuel tank.
Swing Circle Lubricate two grease fittings.
Swing Pinion Lubricate one grease fitting.
Engine Oil Filter Replace oil filter element.
All Machinery Pivot
Points Lubricate 20 grease fittings.
Alternator Belt Check adjust tension.
Final Drive Case Check fluid level add oil as needed.
Hydraulic Filter Replace filter element.
Fuel Filter Replace filter element.
Battery Check clean cable ends check electrolyte level.
Air Cleaner Replace the filter element.
Cooling System Clean the radiator fins.
Alternator Starter Check the condition.
Engine Valve Clearance Check adjust valve clearance.
Cooling System Drain, flush add new coolant to the cooling system.
Hydraulic Tank Change the fluid, clean fill neck strainer suction strainer.
Final Drive Case Change the fluid.

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

220 (S/N 508211999 Below) Excavator Service
Manual
11
10
ENGINE COVER Procedure
A

N07367
AVOID INJURY Never service or adjust the machine
when the engine is running unless instructed to
do so in the manual. W20120290 Keep the
engine cover closed when operating
the machine.
W21410189
B
1 1 1
N07368

• Open the engine cover to service the engine. Pull
  on the latches and lift the engine cover until
  it is fully raised A.
• AIR CLEANER SERVICE
• Replacing the Filter Element
• See the Service Schedule Page 11 for the correct
  service interval.
• Service the air cleaner as follows
• Remove the dust cup (Item 1) B.
• Remove the wing nut (Item 1) C.

C
1 1 1
N07369
D

N07370

1. Remove the filter element D.
2. Check the air cleaner housing for damage.
3. Install a new air filter element. Install and
   tighten the wing nut.
4. Install the dust cap so the arrow points up.
5. Check that the air cleaner hose clamps are tight.

220 (S/N 508211999 Below) Excavator Service
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12
11
FUEL SYSTEM Fuel Specifications Use Number 2
diesel fuel in the engine. During very cold
temperatures, Number 1 fuel can be used. Fuel
System Service The fuel level in the tank is
indicated by the plastic tube (Item 1) A on
the side of the tank.
A
1 1 1
N07371
Stop and cool the engine before adding fuel.
NO SMOKING! Failure to obey warnings can cause
an explosion or fire. W20630887
B

N07372
Use the key to unlock the fuel fill cap B.
C

N07373
Turn the fill cap to remove it from the fuel tank
C. NOTE The fuel fill strainer can be removed
for cleaning. Make sure it is installed before
adding fuel to the tank. Use a clean, approved
safety container to add fuel to the tank. Add
fuel only in an area that has a free movement of
air and no open flames or sparks. NO
SMOKING! After the tank is full, install and
tighten the fuel fill cap.
220 (S/N 508211999 Below) Excavator Service
Manual
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12
FUEL SYSTEM (Contd)
A

N07375
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. W21031285 To remove the
water and sediment from the fuel tank, open the
drain in the bottom of the tank A.
220 (S/N 508211999 Below) Excavator Service
Manual
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13
ENGINE LUBRICATION SYSTEM Checking the Engine
Oil Check the engine oil every day. Stop the
engine. Open the engine cover. Remove the
dipstick A. Keep the oil level between the
marks on the dipstick. Use a good quality motor
oil that meets API Service Classification of CC
or CD. (See Fuel, Coolant and Lubricants Chart
Page 89.) Engine Oil and Filter Replacement See
the SERVICE SCHEDULE Page 11 for the correct
service interval. Use the following procedure to
change the oil and filter Run the engine until
it is at operating temperature. Turn the upper
works so there is clearance for the engine oil
drain plug. Stop the engine. Remove the drain
plug (Item 1) B. Drain the oil into a
container.
A

N07378
B
1 1 1
N07379
C
1 1 1
N07380
Remove the oil filter (Item 1) C, using a
filter wrench. Clean the filter housing surface.
Put clean oil on the filter gasket. Install the
new filter and hand tighten only.
D

N07381
Remove the oil fill cap D. Put 3.5 quarts (3,4
L) of oil into the engine. (See Fuel, Coolant
and Lubricants Chart Page 89.) Start the
engine and let it run for several minutes. Stop
the engine. Check the oil filter for
leaks. Check the oil level and add oil as needed
to bring it to the top mark on the dipstick.
220 (S/N 508211999 Below) Excavator Service
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15
14
COOLING SYSTEM Coolant Level When the engine is
cool, remove the radiator cap A. The coolant
level must be 3/41 (1925 mm) below the
radiator filler neck. If the coolant level is
low, add premixed coolant (50 ethylene glycol
and 50 water) to the radiator. Coolant
Replacement
A

N07382
Do not remove radiator cap when the engine
is hot. You can be seriously burned. W20701285
B
1 1 1
N07383
Turn the upper works so there is access to the
engine and radiator underneath. Stop the
engine. Loosen and remove the radiator cap A.
Open the radiator drain valve (Item 1) B.
Drain all the coolant from the system. When all
the coolant is removed, close the drain
valve. Premix 50 water and 50 ethylene glycol
in a separate container. Fill the radiator with
premixed coolant until it is full. Run the
engine at idle speed for about 510 minutes to
remove the air from the cooling system (leave the
radiator cap off during this operation). Stop
the engine. Check the coolant level and add as
needed, bringing it 3/41 (1925 mm) below the
filler neck. Install the radiator cap and
tighten.

• Wear safety glasses to prevent eye injury when
  any of the following conditions exist
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
• W20191285

220 (S/N 508211999 Below) Excavator Service
Manual
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15
HYDRAULIC SYSTEM Checking and Adding Fluid To
check and add hydraulic fluid to the reservoir,
use the following procedure Put the machine on
a flat surface. Retract the dipperstick and
bucket cylinders, put the bucket on the ground,
and raise the blade. Stop the engine. Check the
hydraulic fluid level, it must be visible and
between the marks in the sight gauge (Item 1) A.
A
1 1 1
N09091
B

N09161
If the fluid level is low, remove the four bolts
from the reservoir cover B.
C

N09162
Remove the reservoir fill cover C. Add the
correct fluid to the reservoir until it is at the
top mark in the sight gauge A. (See Fuel,
Coolant and Lubricants Chart Page 89.) Install
the reservoir cover, make sure the Oring is in
the correct position. Install and tighten the
bolts.
220 (S/N 508211999 Below) Excavator Service
Manual
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16
HYDRAULIC SYSTEM (Contd) Replacement of the
Hydraulic Filter See the Service Schedule Page
11 for the correct service interval. Open the
engine cover. Use a filter wrench and remove the
filter element (Item 1) A. Clean the housing
where the filter gasket makes contact. Put clean
fluid on the gasket. Install the new filter
element and hand tighten only. Start the
engine. Run the machine through the hydraulic
functions. Stop the engine. Check the fluid level
at the reservoir and add as needed. Check the
filter area for leaks. Hydraulic Reservoir See
the Service Schedule Page 11 for the correct
service interval. Move the upper works so there
is a clearance for the reservoir between the
track frame. Retract the dipperstick and bucket
cylinder, lower the bucket to the ground. Stop
the engine. Remove the hydraulic filter. Remove
the drain plug (Item 1) B from the bottom of
the reservoir. Remove the hose clamps (Item 2)
B and disconnect the hoses. Remove the bolts
(Item 3) B from the flange. Turn the bolts
into the threaded holes in the flange to push
the mesh screen out of the reservoir. Clean all
the parts with clean solvent and air dry them.
Replace the parts and tighten the bolts, hose
clamps and drain plug. Add approximately 7.0
gals. (26,5 L) of fluid to the reservoir. (See
Fuel, Coolant and Lubricants Chart Page
89.) Run the machine through the hydraulic
functions. Stop the engine. Check the fluid
level and add as needed.
A
1 1 1
N09163
B
2
1
3
N09090
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. W21031285
220 (S/N 508211999 Below) Excavator Service
Manual
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17
USING A BOOSTER BATTERY (JUMP STARTING) Procedure
If it becomes necessary to use an extra battery
to start the engine, BE CAREFUL! Make sure the
swing lock pin is in the engaged position. The
key switch must be in the OFF position. 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. Connect the end
of the second cable to the negative () terminal
of the booster battery. Connect the other end of
the same cable to the machine frame (Item 2)
A. NOTE Also see Cold Starting Procedure in
the Operation Maintenance Manual. Start the
engine. After the engine is running, remove the
cable (Item 2) A connected to the frame first.
Disconnect cable from the starter terminal (Item
1) A.
A
1 2 1 2 1 2
N07387
Keep arcs, sparks, flames and lighted tobacco
away from batteries. When jumping from booster
battery make final connection (negative) at
engine frame. Do not jump start or charge a
frozen battery. Warm battery to 60?F. (16?C.)
before connecting to a charger. Unplug charger
before connecting or disconnecting cables to
battery. Battery gas can explode and cause serious

• Damage to the alternator can occur if
• Engine is operated with battery cables
  disconnected.
• Battery cables are connected when using a fast
  charger or when welding on the loader (Remove
  both cables from the battery).
• Extra battery cables (booster cables) are
  connected wrong.
• I20231285

injury.
W20660490
220 (S/N 508211999 Below) Excavator Service
Manual
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18
LUBRICATION OF THE EXCAVATOR Procedure Lubricate
the Hydraulic Excavator as specified in the
Service Schedule Page 11 for the best
performance of the machine. Always use a good
quality lithium based multipurpose grease when
lubricating the machine. Apply the lubricant
until extra grease shows.
A
1
2
2
3

• Ref. Description ( of Fittings)
• Blade Cylinder Rod End (1) A.
• Blade Pivots (2) A.
• Blade Cylinder Base End (1) A.

N07397
B
4. Boom Cylinder Rod End (1) B.
4
N07398
C

1. Boom Pivot Pin (1) C.
2. Boom Swing Bracket Pivot (2) C.
3. Boom Cylinder Base End (1) C.

5
6
6
7
N07399

1. Boom Cylinder Rod End (1) D.
2. Dipperstick Cylinder Base End (1) D.

D
9
8
N07400
220 (S/N 508211999 Below) Excavator Service
Manual
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19
LUBRICATION OF THE HYDRAULIC EXCAVATOR (Contd) Pr
ocedure (Contd) Ref. Description ( of
Fittings)
A
10
11

1. Dipperstick Cylinder Rod End (1) A.
2. Dipperstick Pivot Pin (1) A.
3. Bucket Cylinder Base End (1) A.

12
N07401
B

1. Bucket Cylinder Rod End (1) B.
2. Bucket Link Pivots (2) B.
3. Bucket Pivots (4) B.

14
15
13
15 14
15
N07402

1. Boom Cylinder Base End (1) C.
2. Swing Circle Pinion (1) C.

C
16
17
N07403
18. Swing Circle (2) D.
D
18
N07404
220 (S/N 508211999 Below) Excavator Service
Manual
111
20
FINAL DRIVE CASE Checking Oil Level Put the
machine on a flat level surface. Position the
plug (Item 1) A parallel to the ground. Remove
one of the plugs (Item 1) A. Add oil through
the hole if the oil level is below the hole.
(See Fuel, Coolant and Lubricant Chart Page
89.) Install and tighten the plug. Repeat the
procedure for the other side. Draining Final
Drive Case See the Service Schedule Page 11 for
the correct service interval. Put the machine
on a flat level surface with the plugs
positioned as shown in figure A. Remove the
bottom plug (Item 1) B and the top plug (Item
2) B. After the oil is removed, install and
tighten the bottom plug. Add .33 quarts (0,3 L)
of oil to the top plug hole. Install the
plug. Use the same procedure for Checking Oil
Level. Add oil as needed. Repeat the procedure
for the other side.
A
1 1 1
P05906
B
2 1 2 1 2 1
P05907
220 (S/N 508211999 Below) Excavator Service
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21
HYDRAULIC SERVICE INFORMATION
A
1
When repairing hydrostatic and hydraulic
systems, clean the work area before disassembly
and keep all parts clean. Always use caps and
plugs on hoses, tubelines and ports to keep dirt
out. Dirt can quickly damage the
system. I20030888
2
1
MC01205
There are two main relief valves (Item 1) A and
port relief valves (Item 2) A in the hydraulic
system. Checking The Main Relief Valves The tools
listed will be needed to do the following
procedure OEM1238 OEM1239 Hydraulic Tester
6657708 Test Fitting 6657709 Hose
Adapter Stop the engine and raise the engine
cover. Disconnect the outlet hose (Item 1 or 2)
B from the hydraulic pump and connect that
hose to the outlet of the tester. NOTE Install
the adapter 6657709 between outlet hose of
tester and outlet hose of the pump. Remove the
outlet fitting from the pump being tested and
install the test fitting 6657708. Connect the
inlet of the tester to the test fitting in the
pump.
B
2 1 2 1 2 1
N07538
220 (S/N 508211999 Below) Excavator Service
Manual
Revised July 97
23
22
HYDRAULIC SERVICE INFORMATION (Contd) Checking
the Main Relief Valves (Contd) 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 hydraulic
fluid to 140?F (60?C) by turning the restrictor
valve until the gauge reads about 1000 PSI (6895
kPa). Do not exceed system pressure. Stroke a
cylinder to its limit, in the section being
tested, to open the relief valve. The relief
valve pressure should open at 2133 PSI (14707
kPa) ? 75 PSI. The flow should be 10.7 GPM (40,5
L/min.) on a new pump. Release the pressure on
the cylinder being tested. Close the flow
control knob (Item 1) A slowly, to 100 PSI
below relief valve setting, and record the high
pressure. NOTE The high pressure flow must be
at least 80 of free flow. HIGH PRESSURE FLOW
(GPM)
A
1 1 1
N11433

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.
220 (S/N 508211999 Below) Service Manual
Revised July 97
24
23
HYDRAULIC PUMP Removal And Installation
A
1
When repairing hydrostatic and hydraulic
systems, clean the work area before disassembly
and keep all parts clean. Always use caps and
plugs on hoses, tubelines and ports to keep dirt
out. Dirt can quickly damage the
system. I20030888
N07537
B

N07538
Disconnect the two inlet hoses (Item 1) A from
the hydraulic pump. Drain the hydraulic fluid in
a container. Disconnect the two pressure hoses
B.
C

N07539
Loosen the pump mounting bolts C.
D

N07540
Remove the bolts and washers from the pump flange
D.
220 (S/N 508211999 Below) Excavator Service
Manual
Revised July 97
25
24
HYDRAULIC PUMP (Contd) Removal And Installation
(Contd) Remove the hydraulic pump from the bell
housing A.
A

N07541
220 (S/N 508211999 Below) Service Manual
Revised July 97
26
25
HYDRAULIC PUMP Parts Identification
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 5
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 12
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 10 16 16
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 5 8 14 6 4
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 15
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 13 14
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 11
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 9
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 7
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 4 6
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 3 25
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 5 26 26
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 22
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 20
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 18 24
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 6
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 14 4
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 5 23
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 14
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 21
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 19
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 17
Snap Ring Seal Cover Backup Ring Backup Ring Seal Bushing Bushing Gear Gear Bushing Bushing Drive Coupler Seal Housing Center Plate Bushing Bushing Gear Gear Bushing Bushing Housing Cover Washer Bolt 2 1 4 6
B14926
220 (S/N 508211999 Below) Excavator Service
Manual
Revised July 97
27
26
HYDRAULIC PUMP Disassembly
A
1
When repairing hydrostatic and hydraulic
systems, clean the work area before disassembly
and keep all parts clean. Always use caps and
plugs on hoses, tubelines and ports to keep dirt
out. Dirt can quickly damage the
system. I20030888
P08236
B

P08237
Use solvent to clean the outside of the hydraulic
pump of oil and dirt. NOTE During disassembly,
put all parts on clean work surface. Clamp the
mounting flange of the pump in a vise that has
padded jaws. Mark the housing for ease of
assembly. Remove the four bolts (Item 1) A and
washers. Remove the cover B. Remove the two
backup rings (Item 1) C.
C
1 1 1
P08238
Remove the two seals (Items 1 2) D.
D
1
2
P08239
220 (S/N 508211999 Below) Service Manual
Revised July 97
28
27
HYDRAULIC PUMP (Contd) Disassembly
(Contd) Remove the pump section body A.
A

P08240
Remove the backup rings (Item 1) B from the
bottom of the pump section.
B
1
P08292
Remove the two seals (Items 1 2) C from the
bottom of the pump section.
C
1 2 1 2 1 2
P08241
D
Remove the two bushings (Items 1 2) D from
the bottom of the pump section.
1
2
P08242
220 (S/N 508211999 Below) Excavator Service
Manual
Revised July 97
29
28
HYDRAULIC PUMP (Contd) Disassembly
(Contd) Remove the gears (Items 1 2) A.
A
1 2 1 2 1 2
P08243
Remove the two bushings (Item 1) B from the top
of the pump section.
B
1 1 1
P08244
Remove the center plate from the pump section C.
C

P08245
Remove the drive coupler (Item 1) D from the
drive gear.
D
1 1 1
P08246
220 (S/N 508211999 Below) Service Manual
Revised July 97
210
29
HYDRAULIC PUMP (Contd) Disassembly
(Contd) Remove the two backup rings (Item 1)
A.
A
1 1 1
P08247
Remove the two seals (Items 1 2) B.
B
2 1 2 1 2 1
P08248
Remove the pump section C.
C

P08249
Remove the two backup rings (Item 1) D from
the bottom of the pump section.
D
1 1 1
P08250
220 (S/N 508211999 Below) Excavator Service
Manual
Revised July 97
211
30
HYDRAULIC PUMP (Contd) Disassembly
(Contd) Remove the two seals (Items 1 2) A
from the bottom of the pump section.
A
1 2 1 2 1 2
P08251
Remove the two bushings (Item 1) B from the
bottom of the pump section.
B
1 1 1
P08252
Remove the two drive gears (Items 1 2) C from
the bottom of the pump section.
C
1 2 1 2 1 2
P08253
Remove the two bushings (Item 1) D from the top
of the pump section.
D
1 1 1
P08254
220 (S/N 508211999 Below) Service Manual
Revised July 97
212
31
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32
HYDRAULIC PUMP (Contd) Disassembly
(Contd) Remove the snap ring (Item 1) A and
seal (Item 2) A from the flange.
A
2 1 2 1 2 1
P08255
Assembly Clean all parts in solvent and dry with
compressed air. Apply clean hydraulic fluid to
all seals and backup rings. Apply clean
hydraulic fluid to the bushings and inside of
both pump sections. Install the new seal (Item 2)
A and snap ring (Item 1) A. Install the
bushings (Item 1) B at the same time in the
pump section until they are flush with top
surface. NOTE Install the bushings as shown
towards the intake side (large port) (Item 2)
B. NOTE Do not force the bushings. Turn the
pump section over. Do not allow the bushings to
drop out of the pump section. Install the gears
(Items 1 2) C.
B
1 2 1 2 1 2
P08254
C
1 2 1 2 1 2
P08253
Install the bushings (Item 1) D. NOTE Install
the bushings as shown towards the intake side
(large port) (Item 2) D.
D
1 2 1 2 1 2
P08252
220 (S/N 508211999 Below) Excavator Service
Manual
Revised July 97
213
33
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