John Deere 220DW Wheeled Excavator Repair Service Manual - TM10545
Complete official Repair service manual for John Deere 220DW Wheeled Excavator, with all the workshop information to maintain, repair, and rebuild like professional mechanics.
John Deere 220DW Wheeled Excavator workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
TM10545 - John Deere 220DW Wheeled Excavator Technical Manual (Repair).pdf
TM10545 - John Deere 220DW Wheeled Excavator Technical Manual (Repair).epub
Total Pages: 1,019 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
Foreword
General Information
Safety
Torque Values
Wheels
Wheels and Fasteners
Axles, Differentials and Suspension Systems
Drive Axle Housing and Support
Differential or Bevel Drive
Axle Shaft, Bearings, And Reduction Gears
Axles, Differentials, and Suspension System Hydraulics
Transmission
Removal and Installation
Gear, Shafts, and Power Shift Clutches
Hydraulic System
Engine
Removal and Installation
Engine Auxiliary System
Cooling System
Intake System
External Fuel Supply System
Dampener Drive (Flex Coupling)
Elements
Steering System
Removal and Installation
Steering Hydraulic System
Service Brakes
Service Brake Active Elements
Service Brakes Hydraulic System
Frame or Supporting Structure
Frame Installation
Chassis Weights
Operator`s Station
Removal and Install
Operator Enclosure
Seat and Seat Belt
Heating and Air Conditioning
Excavator
Buckets
Frames
Hydraulic System
Swing or Pivoting System
Mechanical Drive Elements
Hydraulic System
Dealer Fabricated Tools
TABLE OF CONTENTS.....1
Section 00: General Information.....12
Group 0001: Safety.....12
Recognize Safety Information.....15
Follow Safety Instructions.....16
Operate Only If Qualified.....17
Wear Protective Equipment.....18
Avoid Unauthorized Machine Modifications.....19
Add Cab Guarding for Special Uses.....20
Inspect Machine.....21
Stay Clear of Moving Parts.....22
Avoid High-Pressure Fluids.....23
Avoid High-Pressure Oils.....24
Beware of Exhaust Fumes.....25
Prevent Fires.....26
Prevent Battery Explosions.....27
Handle Chemical Products Safely.....28
Dispose of Waste Properly.....29
Prepare for Emergencies.....30
Use Steps and Handholds Correctly.....31
Start Only From Operator's Seat.....32
Use and Maintain Seat Belt.....33
Prevent Unintended Machine Movement.....34
Avoid Work Site Hazards.....35
Keep Riders Off Machine.....37
Avoid Backover Accidents.....38
Avoid Machine Tip Over.....39
Use Special Care When Lifting Objects.....40
Add and Operate Attachments Safely.....41
Park and Prepare for Service Safely.....42
Service Cooling System Safely.....43
Remove Paint Before Welding or Heating.....44
Service Tires Safely.....45
Make Welding Repairs Safely.....46
Drive Metal Pins Safely.....47
Group 0003: Torque Values.....13
Metric Bolt and Cap Screw Torque Values.....50
Additional Metric Cap Screw Torque Values.....52
Unified Inch Bolt and Cap Screw Torque Values.....54
Service Recommendations for 37° Flare and 30° Cone Seat Connectors.....56
Service Recommendations for O-Ring Boss Fittings.....58
O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators.....60
Service Recommendations for Flared Connections—Straight or Tapered Threads.....63
O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations.....65
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations.....67
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations.....70
Service Recommendations for Metric Series Four Bolt Flange Fitting.....73
Service Recommendations For Inch Series Four Bolt Flange Fittings.....75
Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations.....77
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings.....79
Service Recommendations For O-Ring Boss Fittings With Shoulder.....82
Metric 24° O-Ring Seal DIN 20078 Service Recommendations.....85
Section 01: Wheels.....89
Group 0110: Wheels and Fasteners.....89
Wheel Remove and Install.....94
Tire Remove and Install.....98
Section 02: Axles, Differentials and Suspension Systems.....101
Group 0201: Drive Axle Housing and Support.....101
Front Axle Remove and Install.....107
Front Axle Disassemble and Assemble.....112
Front Axle Adjustment.....128
Rear Axle Remove and Install.....129
Rear Axle Disassemble and Assemble.....135
Group 0210: Differential or Bevel Drive.....101
Differential Disassemble and Assemble.....153
Check Gear Tooth Contact Pattern.....159
Group 0250: Axle Shaft, Bearings, And Reduction Gears.....101
Front Axle Planetary Drive Remove and Install.....172
Front Axle Planetary Drive Disassemble and Assemble.....181
Rear Axle Planetary Drive Remove and Install.....189
Rear Axle Planetary Drive Disassemble and Assemble.....194
Group 0260: Axles, Differentials, and Suspension System Hydraulics.....101
Axle Lock Cylinder Remove and Install.....956
Axle Lock Cylinder Disassemble and Assemble.....959
Axle Lock Cylinder Check Valve Remove and Install.....961
Axle Lock Cylinder Check Valve Disassemble and Assemble.....963
Section 03: Transmission.....208
Group 0300: Removal and Installation.....208
Drive Shaft Remove and Install.....212
Transmission Remove and Install.....215
Group 0350: Gear, Shafts, and Power Shift Clutches.....208
Drive Shaft Disassemble and Assemble.....221
Transmission Disassemble.....225
Transmission Assemble.....247
Group 0360: Hydraulic System.....208
Travel Motor Remove and Install.....297
Travel Motor Start-Up Procedure.....301
Travel Motor Counterbalance Valve Remove and Install.....303
Travel Motor Counterbalance Valve Disassemble and Assemble.....305
Travel Pilot Valve Remove and Install.....312
Travel Pilot Valve Disassemble and Assemble.....313
Transmission Control Valve Remove and Install.....867
Travel Shockless Valve Remove and Install.....316
Travel Shockless Valve Disassemble and Assemble.....318
Transmission Shift Interlock Remove and Install.....320
Transmission Shift Interlock Disassemble and Assemble.....322
Section 04: Engine.....334
Group 0400: Removal and Installation.....334
Engine Remove and Install.....347
Turbocharger Remove and Install.....358
Turbocharger Inspection.....360
Exhaust Manifold Remove and Install.....361
Valve Cover Remove and Install.....363
Lower Valve Cover Remove and Install.....365
Rocker Arm Shaft Assembly Remove and Install.....366
Rocker Arm Shaft Assembly Disassemble and Assemble.....368
Rocker Arm Shaft Assembly Inspection.....370
Intake Manifold Remove and Install.....373
Reed Valve Remove and Install.....375
Coolant Pump Remove and Install.....377
Coolant Pump Inspection.....379
Cylinder Head Remove and Install.....380
Cylinder Head Disassemble and Assemble.....387
Cylinder Head Inspection.....399
Front Cover Remove and Install.....404
Cylinder Block Disassemble and Assemble.....411
Cylinder Block Inspection.....417
Camshaft Remove and Install.....421
Camshaft Disassemble and Assemble.....424
Camshaft Inspection.....426
Flywheel Remove and Install.....429
Flywheel Disassemble and Assemble.....433
Flywheel Housing Remove and Install.....435
Timing Gear Train Remove and Install.....440
Engine Oil Pan Remove and Install.....447
Crankshaft Remove and Install.....450
Crankshaft Disassemble and Assemble.....457
Crankshaft Inspection.....460
Piston and Connecting Rod Remove and Install.....465
Piston and Connecting Rod Disassemble and Assemble.....468
Piston and Connecting Rod Inspection.....471
Engine Oil Pump Remove and Install.....478
Engine Oil Pump Disassemble and Assemble.....482
Engine Oil Pump Inspection.....484
Engine Oil Cooler Remove and Install.....487
Engine Oil Cooler Disassemble and Assemble.....491
Thermostat Housing Remove and Install.....492
Thermostat Remove and Install.....494
Thermostat Inspection.....497
Exhaust Gas Recirculation (EGR) Cooler Remove and Install.....499
High Pressure Fuel Pump Remove and Install.....501
High Pressure Fuel Pump Disassemble and Assemble.....507
High Pressure Fuel Rail Remove and Install.....509
Fuel Injection Nozzle Remove and Install.....511
Starter Remove and Install.....513
Alternator Remove and Install.....515
Section 05: Engine Auxiliary System.....517
Group 0510: Cooling System.....517
Radiator Remove and Install.....521
Hydraulic Oil Cooler Remove and Install.....524
Intercooler Remove and Install.....527
Fuel Cooler Remove and Install.....530
Fan, Fan Guard, and Fan Shroud Remove and Install.....531
Coolant Recovery Tank Remove and Install.....534
Group 0520: Intake System.....517
Air Cleaner Remove and Install.....537
Group 0560: External Fuel Supply System.....517
Fuel Tank Remove and Install.....544
Primary Fuel Filter (Water Separator) Remove and Install.....549
Final Fuel Filter Remove and Install.....550
Section 07: Dampener Drive (Flex Coupling).....551
Group 0752: Elements.....551
Damper Drive (Flex Coupling) Remove and Install.....554
Section 09: Steering System.....556
Group 0900: Removal and Installation.....556
Steering Wheel Remove and Install.....559
Steering Column Remove and Install.....561
Steering Valve Remove and Install.....566
Group 0960: Steering Hydraulic System.....556
Steering Cylinder Disassemble and Assemble.....583
Section 10: Service Brakes.....594
Group 1011: Service Brake Active Elements.....594
Front Axle Brake Disassemble and Assemble.....611
Rear Axle Brake Disassemble and Assemble.....627
Group 1060: Service Brakes Hydraulic System.....594
Brake Valve Remove and Install.....646
Brake Valve Disassemble and Assemble.....650
Brake Accumulator Remove and Install.....654
Brake Accumulator Charge Valve Remove and Install.....658
Brake Accumulator Charge Valve Disassemble and Assemble.....662
Section 17: Frame or Supporting Structure.....665
Group 1740: Frame Installation.....665
Welding On Machine.....667
Welding Repair of Major Structure.....668
Group 1749: Chassis Weights.....665
Counterweight Remove and Install.....675
Section 18: Operator's Station.....680
Group 1800: Removal and Install.....680
Cab Remove and Install.....687
Group 1810: Operator Enclosure.....680
Sliding Windows Remove and Install.....695
Windowpanes Remove and Install.....697
Windowpanes Dimensions.....698
Group 1821: Seat and Seat Belt.....680
Seat Remove and Install.....704
Seat Belt Remove and Install.....706
Mechanical Suspension Seat Disassemble and Assemble.....708
Air Suspension Seat Disassemble and Assemble—If Equipped.....710
Left and Right Console Covers Remove and Install.....712
Group 1830: Heating and Air Conditioning.....680
Refrigerant Cautions and Proper Handling.....719
Flush and Purge Air Conditioner System.....720
R134a Refrigerant Oil Information.....724
R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure.....726
Recover R134a Refrigerant.....728
Evacuate R134a System.....729
Charge R134a System.....731
Compressor Remove and Install.....732
Condenser Remove and Install.....734
Heater and Air Conditioner Remove and Install.....736
Receiver-Dryer Remove and Install.....744
Section 33: Excavator.....746
Group 3302: Buckets.....746
Bucket Remove and Install.....751
Bucket Pin-Up Data.....753
Group 3340: Frames.....746
Bucket Links Remove and Install.....757
Arm Remove and Install.....759
Monoblock Boom Remove and Install.....767
Two Piece Boom Upper Section Remove and Install.....773
Two Piece Boom Lower Section Remove and Install.....778
Inspect Pins, Bushings and Bosses—Front Attachment.....781
Bushings and Seal Remove and Install.....784
Outrigger Remove and Install.....786
Blade Assembly Remove and Install.....788
Blade Disassemble and Assemble.....791
Group 3360: Hydraulic System.....746
Apply Vacuum to Hydraulic Oil Tank.....796
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy.....798
Pump 1 and 2 Remove and Install.....800
Pump 1 and 2 Disassemble and Assemble.....804
Pump 1 and 2 Inspection.....816
Pump 1 and 2 Start-Up Procedure.....821
Pump 1 and 2 Regulator Remove and Install.....823
Pump 1 and 2 Regulator Disassemble and Assemble.....825
Pilot Pump and Steering Pump Remove and Install.....828
Pilot Pump and Steering Pump Disassemble and Assemble.....830
Pilot Pump Drive Shaft Remove and Install.....832
Pilot Pressure Regulating Valve and Filter Remove and Install.....834
Pilot Pressure Regulating Valve and Filter Disassemble and Assemble.....836
Pilot Control Shut-Off Valve Remove and Install.....837
Pilot Control Shut-Off Valve Disassemble and Assemble.....839
Solenoid Valve Manifold Remove and Install.....841
Solenoid Valve Manifold Disassemble and Assemble.....843
Torque Control and Pump Flow Rate Limit Solenoid Valve Remove and Install.....845
Swing Park Brake, Assist, Auxiliary, Positioning, and Blade/Outrigger Solenoid Valves Remove and Install.....847
Swing Park Brake, Assist, Auxiliary, Positioning, and Blade/Outrigger Solenoid Valves Disassemble and Assemble.....849
Pilot Control Valve (Left and Right) Remove and Install.....852
Pilot Control Valve (Left and Right) Disassemble and Assemble.....854
Travel Pilot Control Valve Remove and Install.....867
Travel Pilot Control Valve Disassemble and Assemble.....859
Pilot Signal Manifold Remove and Install.....861
Pilot Signal Manifold Disassemble and Assemble.....863
Control Valve Remove and Install.....867
Control Valve Separation.....870
Control Valve (5-Spool) Disassemble and Assemble.....871
Control Valve (4-Spool) Disassemble and Assemble.....882
Hydraulic Oil Tank Remove and Install.....895
Hydraulic Oil Tank Disassemble and Assemble.....900
Restriction Valve Remove and Install.....903
Hydraulic Oil Cooler Bypass Valve Remove and Install.....905
Boom Cylinder Remove and Install.....908
Boom Cylinder Disassemble and Assemble.....912
Positioning Cylinder Remove and Install—If Equipped.....915
Positioning Cylinder Disassemble and Assemble—If Equipped.....919
Arm Cylinder Remove and Install.....924
Arm Cylinder Disassemble and Assemble.....928
Bucket Cylinder Remove and Install.....932
Bucket Cylinder Disassemble and Assemble.....936
Outrigger Cylinder Remove and Install.....939
Outrigger Cylinder Disassemble and Assemble.....943
Blade Cylinder Remove and Install.....948
Blade Cylinder Disassemble and Assemble.....951
Axle Lock Cylinder Remove and Install.....956
Axle Lock Cylinder Disassemble and Assemble.....959
Axle Lock Cylinder Check Valve Remove and Install.....961
Axle Lock Cylinder Check Valve Disassemble and Assemble.....963
Hydraulic Cylinder Bleed Procedure.....965
Section 43: Swing or Pivoting System.....966
Group 4350: Mechanical Drive Elements.....966
Swing Gearbox Remove and Install.....970
Swing Gearbox Disassemble and Assemble.....973
Swing Gearbox Start-Up Procedure.....982
Upperstructure Remove and Install.....983
Swing Bearing Remove and Install.....987
Swing Bearing Disassemble and Assemble.....991
Swing Bearing Upper Seal Install.....997
Swing Bearing Lower Seal Install.....998
Group 4360: Hydraulic System.....966
Center Joint Remove and Install.....1006
Center Joint Disassemble and Assemble.....1013
Center Joint Air Test.....1016
Swing Motor and Park Brake Remove and Install.....1017
Swing Motor and Park Brake Disassemble and Assemble.....1020
Swing Motor and Park Brake Inspection.....1027
Swing Motor and Park Brake Start-Up Procedure.....1031
Crossover Relief Valve and Make-Up Check Valve Remove and Install.....1032
Make-Up Check Valve Disassemble and Assemble.....1035
Swing Dampener Valve Remove and Install.....1037
Swing Dampener Valve Disassemble and Assemble.....1039
Swing Park Brake Release Valve Remove and Install.....1041
Section 99: Dealer Fabricated Tools.....1042
Group 9900: Dealer Fabricated Tools.....1042
DFT1144 Guide Pin.....1044
DFT1119 Pump Support.....1045
DFT1220 Swing Gearbox Nut Spanner Wrench.....1046
DFT1266 Transmission Adapter.....1047
DFT1298 Axle Support.....1048
John Deere 220DW Wheeled Excavator Repair Service Manual - TM10545
