Caterpillar Cat 225 EXCAVATOR (Prefix 51U) Service Repair Manual (51U02832 and up).pdf

Service Repair Manual
Models
225 EXCAVATOR

Remove Swing Drive
start by:
a) release oil pressure in main system
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225 EXCAVATOR 51U02832-UP (MACHINE) POWERED BY 3208 ENGINE(SEB...
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Do not disconnect or remove any oil lines until all oil pressure in main
system has been released.
1. Remove clamp (2).
2. Remove four oil lines (1).
3. Remove bracket (5).
4. Disconnect inlet and outlet oil lines (3) from the swing motor.
5. Disconnect case drain line (4) from the swing motor.
6. Disconnect linkage (8) from lever (9). Remove two bolts (7) that hold the linkage and spacer to
the swing drive cover.
7. Remove oil lines (6) and (10).
8. Remove clamp (14).
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9. Disconnect oil line (12) from the three stem control valve. Pull oil line away from over swing
drive.
10. Remove oil line (11).
11. Remove the four bolts (13) from each side of the swing drive.
12. Remove three bolts from the swing drive case. Install one 1/2"-13NC forged eyebolt in the
case. Install tooling (A). Fasten a hoist and lift the swing drive until the pinion on the output shaft
is above the hole in the upper frame. Remove the swing drive. The weight of the swing drive is
1100 lb. (499 kg).
Install Swing Drive
1. Install one 1/2"-13NC forged eyebolt in the swing drive case. Install tooling (A). Put 4S9416
Anti-Seize Compound on the finished surfaces of the cartridge (output shaft housing). Fasten a
hoist and put the swing drive in position on the upper frame.
NOTE: Turn the swing brake drum to get alignment of the pinion and swing gear.
2. Install the four bolts (1) on each side of the swing drive. Tighten the bolts to a torque of 560 ±
60 lb.ft. (77.5 ± 8.3 mkg).
3. Remove tooling (A) and the eyebolt. Install the three bolts in the swing drive case. Tighten the
bolts to a torque of 100 ± 10 lb.ft. (13.8 ± 1.4 mkg).
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4. Install oil line (7).
5. Pull oil line (8) into position on the three stem control valve. Install the bolts that hold the oil
line to the valve.
6. Install clamp (9).
7. Install oil lines (2) and (3).
8. Install two bolts (4) that hold the spacer and linkage to the cover. Connect linkage (5) to lever
(6).
9. Connect case drain line (11) to the swing motor.
10. Fill the swing motor with SAE 10W hydraulic oil.
NOTICE
Do not start engine without first filling the motor with oil.
11. Connect inlet and outlet oil lines (10) to the motor.
12. Install bracket (12).
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13. Install the four oil lines (13).
14. Install clamp (14).
Disassemble Swing Drive
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start by:
a) remove swing drive
b) remove swing motor
c) disassemble swing brake
1. Fasten a hoist and put the swing drive in position on stand (A). The weight of the swing drive is
900 lb. (408 kg).
2. Remove the six bolts from bearing cage (1).
3. Install two 1/2"-13NC forcing screws and remove bearing cage and shims (2).
4. Install tooling (B) and remove the bearing cup. Remove O-ring seal (3) and lip-type seal from
the cage.
5. Remove the bolts from the cover. Install two 1/2"-13NC forcing screws (4) and loosen cover (5)
from case.
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6. Install a 1/2"-13NC forged eyebolt and a 3/8"-16NC forged eyebolt in the cover. Fasten a hoist
and remove cover (5). The weight of the cover is 160 lb. (73 kg). Remove the oil from the case.
7. Install tooling (C) and remove the bearing cup from cover. Remove bearing cup (6) with a
hammer and punch.
8. Remove the eight bolts (7).
9. Fasten a hoist to gear (9). Lift the output shaft until gear (8) can be removed. Remove the gear.
Remove the output shaft from the case. The weight of the output shaft is 350 lb. (159 kg).
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10. Install tooling (D) and remove the bearing cone from gear (8).
11. Install tooling (E) and remove bearing cone (10) from the gear.
12. Remove gear (11), coupling (12) and pinion (13) from the case.
13. Install tooling (E) and remove the bearing cones for gear (11) and pinion (13).
14. Install tooling (C) and remove the bearing cup from the case.
15. Remove cages (14) and the shims from the case.
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16. Install tooling (C) and remove the bearing cups from the cages. Remove O-ring seals (15).
17. Fasten a hoist to the output shaft and put it in position on stand (F). Use chains to hold output
shaft in place.
18. Loosen the bolt in the end of the shaft.
19. Turn the output shaft 180° on stand (F). Use chains to hold the output shaft in place.
20. Loosen the bolt in the end of the shaft.
21. Fasten a hoist to the output shaft and remove it from stand (F).
22. Remove the bolt, retainer (16), and shims (17).
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225 EXCAVATOR 51U02832-UP (MACHINE) POWERED BY 3208 ENGINE(S...
2021/1/2

23. Remove gear (18) and spacer (19) from the shaft.
24. Remove the bolt, retainer, and O-ring seal from end of shaft.
25. Install tooling (G) and remove the pinion.
26. Remove retainer (21). Remove the O-ring seal from the retainer.
27. Remove the Duo-Cone seal (20) with tool (H).
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28. Remove retainer (23). Remove O-ring seal (22) from the retainer.
29. Install tooling (I) and push the shaft out of the bearing cone. Remove bearing cone (24).
30. Remove shaft (26) from cartridge (25).
31. Install tooling (J) and remove the bearing cone from the shaft.
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32. Remove bearing cups (27) from the cartridge.
Assemble Swing Drive
1. Heat bearing cone (2) in oil to a maximum temperature of 275°F (135°C). Start the bearing
cone on shaft (1).
NOTE: The bearing cone will be pushed into correct position when the pinion is installed.
13/21
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2. Install the O-ring seal on retainer (3). Install the Duo-Cone seal in retainers (3) and (4) with tool
(A).
NOTE: The rubber seals and all surfaces that make contact with the seals must be clean and dry.
After installation of the seals, put oil on the contact surfaces of the metal seals.
3. Put retainer (3) in position on the shaft.
4. Install the O-ring seal in retainer (4). Put the retainer in position on the shaft.
5. Put 4S9416 Anti-Seize Coumpound on the shaft and pinion splines. Put pinion (5) in position
on end of shaft. Install tooling (B) and retainer (6). Push the pinion and bearing cone into position
on the shaft with a force of 30 ± 10 tons (27 ± 9 M.tons).
NOTE: The pinion and bearing cone are in correct position when the retainer is against the end of
the shaft.
14/21
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6. Lower the temperature of the two bearing cups. Install bearing cups (7) in cartridge (8). Fasten a
hoist to the cartridge. Lower the cartridge into position on the shaft.
7. Heat bearing cone (9) in oil to a maximum temperature of 275°F (135°C). Put the bearing cone
in position on the shaft.
8. Install spacer (10) on the shaft.
9. Put the gear in position on the shaft. Put two lengths of solder (11) having a diameter of .059 in.
(1.50 mm) on the end of the shaft. Install the bolt and retainer. Tighten the bolt to a torque of 100
lb.ft. (13.8 mkg). Remove the bolt and retainer. Measure the thickness of the solder. Install shims
that are the same thickness as the average thickness of the solder minus .004 to .007 in. (0.1 to
0.18 mm). Install the bolt and retainer.
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10. Fasten a hoist to the output shaft. Put the shaft in position on stand (C). Use chains to hold
shaft in place.
11. Install the O-ring seal, retainer, and bolt in end of shaft for the pinion. Tighten the bolt to a
torque of 1200 ± 120 lb.ft. (165.9 ± 16.6 mkg).
12. Turn the shaft 180° on the stand. Tighten the bolt in the end of the shaft to a torque of 1200 ±
120 lb.ft. (165.9 ± 16.6 mkg).
13. Fasten a hoist to the swing drive case. Put case in position on stand (D). The weight of the case
is 160 lb. (73 kg).
14. Fasten a hoist to the output shaft and remove it from stand (C). Put the shaft in position in the
case. Install two bolts. Make five revolutions of the shaft. Check the torque needed to keep the
shaft turning freely. The torque must be 13 ± 3 lb.ft. (1.8 ± 0.4 mkg). Make an adjustment to the
thickness of the shims if the torque is not correct. Remove shaft from case.
15. Lower the temperature of the bearing cups for cages (12). Install the cups in the cages.
16. Install the cages without shims and O-ring seals in the case. Install two bolts in each cage.
NOTE: Do not tighten the bolts. The cages are installed at this time to keep the pinion and gear in
position.
17. Lower the temperature of the bearing cup (13). Install the cup in the case.
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18. Heat bearing cones (14) in oil to a maximum temperature of 275°F (135°C). Install the cones
on pinion (15).
19. Put pinion (15) in position in the bearing cage. Put coupling (16) in position on the pinion.
20. Heat bearing cones (17) and (19) in oil to a maximum temperature of 275°F (135°C). Install
the cones on gear (18).
21. Put gear (18) into position in the bearing cage.
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22. Heat bearing cones (20) and (22) in oil to a maximum temperature of 275°F (135°C). Install
cones on gear (21).
23. Clean the old gasket material from the contact surfaces of the cartridge and case. Put 7M7260
Liquid Gasket on the surfaces.
24. Install two 5/8"11 NC guide pins (24) in the cartridge. Fasten a hoist to output shaft (23).
25. Lower the output shaft into the case until gear (21) can be installed. Install the gear. Lower the
output shaft into position on the case.
26. Remove the two guide pins from the cartridge. Install the bolts that hold the cartridge in place.
Tighten the bolts to a torque of 200 ± 20 lb.ft. (27.7 ± 2.8 mkg).
27. Lower the temperature of bearing cups (25). Install the cups in the cover.
18/21
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28. Clean the old gasket material from the contact surfaces of the cover and case. Put 7M7260
Liquid Gasket on the surfaces.
29. Install a 1/2"-13NC forged eyebolt and a 3/8"-16NC forged eyebolt in the cover. Fasten a hoist
and put cover (26) in position on the case. Install the bolts that hold the cover to the case. Tighten
the bolts to a torque of 100 ± 10 lb.ft. (13.8 ± 1.4 mkg).
30. Lower the temperature of bearing cup (27). Install the cup in the bearing cage. Install the lip-
type seal with the lip of the seal toward the top of the cage with tool (E). Put oil on the lip of the
seal.
31. Put the cage in position on the cover without shims and O-ring seal. Install two bolts 180°
apart. Tighten the bolts evenly to a torque of 10 lb.in. (11.5 cm.kg) while turning gear (21).
Measure the gap between the cage and cover at the two bolt locations with feeler gauge (28).
19/21
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32. Install shims that are the same thickness as the average gap measured plus .000 to .003 in. (0.0
to 0.08 mm). Install the O-ring seal on the cage. Put the cage in position on the cover. Install bolts
(29) and tighten to a torque of 100 ± 10 lb.ft. (13.8 ± 1.4 mkg).
33. Fasten a hoist and turn the swing drive over on stand (D).
34. Remove one of the bearing cages.
35. Tighten the bolts in cage (30) evenly to a torque of 10 lb.in. (11.5 cm.kg) while turning the
output shaft. Measure the gap between the cage and case at the two bolt locations with feeler
gauge.
36. Install shims (31) that are the same thickness as the average gap measured plus .000 to .003 in.
(0.00 to 0.08 mm). Install the O-ring seal on the cage. Put the cage in position on the case. Install
the bolts and tighten to a torque of 100 ± 10 lb.ft. (13.8 ± 1.4 mkg).
37. Install cage (32) without shims and O-ring seal. Install two bolts 180° apart. Tighten the bolts
evenly to a torque of 10 lb.in. (11.5 cm.kg) while turning the output shaft. Measure the gap
between the cage and case at the two bolt locations with a feeler gauge.
20/21
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38. Install shims (33) that are the same thickness as the average gap measured plus .000 to .003 in.
(0.00 to 0.08 mm). Install the O-ring seal on the cage. Put the cage in position on the case. Install
the bolts and tighten to a torque of 100 ± 10 lb.ft. (13.8 ± 1.4 mkg).
39. Make five revolutions of the output shaft. Check the torque needed to keep the shaft turning
freely. The torque must be 20 ± 4 lb.ft. (2.8 ± 0.6 mkg). Make an adjustment to the thickness of
shims at the pinion or gears if the torque is not correct.
40. Fasten a hoist and remove the swing drive from stand (D). After the swing drive has been
installed, fill the swing drive with oil to the correct level.
end by:
a) assemble swing brake
b) install swing motor
c) install swing drive
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Jan 2 23:54:43 UTC+0800 2021
21/21
2021/1/2

Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 225 EXCAVATOR 51U
Configuration: 225 EXCAVATOR 51U02832-UP (MACHINE) POWERED BY 3208 ENGINE
Disassembly and Assembly
225 EXCAVATOR VEHICLE SYSTEMS
Media Number -REG01510-01 Publication Date -01/03/1977 Date Updated -10/10/2001
Swivel Group
SMCS - 5060-15; 5060-16; 5060-11; 5060-12
Remove Swivel Group
1. Remove two bolts (2) and bar (3).
2. Remove six bolts (1) from manifold.
3. Disconnect the four oil lines (4) from side of swivel housing.
4. Disconnect drain line (5).
1/6
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5. Disconnect the pilot oil line for the parking brakes from swivel housing.
6. Put a floor jack in position under swivel group.
7. Remove the eight bolts that hold swivel group to the frame.
8. Lower the swivel group (6) and remove it from under machine. Weight of swivel group is 300
lb. (136 kg).
9. Remove the Duo-Cone seal (7) from the manifold and swivel group with tool (A).
Install Swivel Group
1. Turn the rotor (1) in swivel housing so the dowel (2) is in position shown.
2. Check to see that all O-ring seals (3) are in position.
3. Install the Duo-Cone seal in the swivel group and manifold with tool (A).
2/6
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NOTE: The rubber seals and all surfaces that make contact with the seals must be clean and dry.
After installation of the seals, put oil on the contact surfaces of the metal seals.
4. Put the swivel group on a floor jack. Lift the swivel group into position with dowel (2) in swivel
group in alignment with dowel hole in manifold.
5. Install the bolts (4).
6. Connect the pilot oil line for parking brake.
7. Connect the oil drain line.
8. Connect the four oil lines from the track motors to the swivel group.
9. Install six bolts (5) in manifold.
10. Install bar (7) and two bolts (6) that hold bar to manifold.
11. Put a feeler gauge between bolt (9) and the frame. Make an adjustment to nut (8) and bolt (9)
on each side of the swivel group to get a total clearance of .06 in. (1.5 mm) between bolt (9) and
the frame.
Disassemble Swivel Group
3/6
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start by:
a) remove swivel group
1. Remove bolts (1) and manifold (2).
2. Remove the O-ring seal from manifold.
3. Remove washer (3).
4. Install tooling (A), and remove rotor (4).
4/6
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5. Remove the eight inner seals (5) and eight outer seals from housing.
Assemble Swivel Group
1. Install the eight outer seals and eight inner seals (1) in swivel housing.
2. Put oil on inner seals (1) and on rotor (2).
3. Install two 3/8"-16NC forged eyebolts in rotor (2). Fasten a hoist and put rotor in position in
swivel housing (3).
5/6
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4. Install tooling (A) and push the rotor into position.
5. Install washer (6). Put O-ring seal (5) in manifold (4), and install manifold on housing.
6. Install the twelve bolts that hold the manifold to the housing.
end by:
a) install swivel group
Sat Jan 2 23:55:39 UTC+0800 2021
6/6
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Shutdown SIS
Previous Screen
Product: EXCAVATOR
Track Motors
SMCS - 5058-11; 5058-12
Remove Track Motors
1. Remove the cover from over the track motors. The weight of the cover is 75 lb. (34 kg).
2. Put a floor jack in position under guard (1). Remove the bolts that hold the guard in place.
Lower the guard to the ground. The weight of the guard is 435 lb. (197 kg).
3. Disconnect inlet and outlet oil lines (3). Disconnect drain line (2) from the track motor. Put
plugs in the oil lines to prevent loss of hydraulic oil.
4. Fasten a hoist to the track motor. Remove two bolts (4) that hold the motor to the parking brake
housing. Remove the track motor. The weight of the track motor is 140 lb. (64 kg).
Install Track Motors
1. Check to see that the O-ring seal is in position on the track motor.
1/2
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2. Fasten a hoist to track motor (1). Put the motor in position on the parking brake housing. Install
the two bolts that hold the motor in place.
3. Remove the plugs from the inlet and outlet oil lines. Connect the oil lines to the track motor.
4. Remove elbow (2) from the motor. Fill the motor with SAE 10W hydraulic oil.
NOTICE
Do not start engine without first filling the motor with oil.
5. Install the elbow in the motor. Remove the plug from the drain line. Connect the drain line to
the motor.
6. Put a floor jack in position under the guard. Lift the guard into position. Install the bolts that
hold the guard in place.
7. Install cover (3) over the track motors.
Sat Jan 2 23:56:35 UTC+0800 2021
2/2
2021/1/2

Shutdown SIS
Previous Screen
Product: EXCAVATOR
Parking Brakes
SMCS - 4353-12; 4353-15; 4353-16; 4353-11
Remove Parking Brakes
Make sure machine is on level ground before removing the parking
brakes.
start by:
a) remove track motors
1. Disnonnect oil line (2). Put a plug in the oil line to prevent loss of hydraulic oil.
1/6
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2. Fasten a hoist to the parking brake housing. Remove six bolts (1). Remove parking brake (4).
The weight of the parking brake is 110 lb. (50 kg).
3. Remove adapter (3).
Install Parking Brakes
1. Check to see that the snap ring is in position on the inside of adapter (1). Install the adapter.
2. Inspect the O-ring seal on the front of the parking brake. Install a new seal if needed.
NOTE: If discs and plates have been removed, put clean final drive oil on both sides of discs and
plates.
3. Fasten a hoist to the parking brake housing. Put parking brake (4) in position on the final drive
case. Install six bolts (2).
NOTE: Tighten the six bolts evenly to compress the springs inside the parking brake.
4. Remove the plug from the oil line. Connect the line to the parking brake.
5. After the track motor has been installed, remove valve (3). Add one quart of clean final drive
oil. Install the valve.
end by:
a) install track motors
Disassemble Parking Brakes
2/6
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Caterpillar Cat 225 EXCAVATOR (Prefix 51U) Service Repair Manual (51U02832 and up).pdf

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Caterpillar Cat 225 EXCAVATOR (Prefix 51U) Service Repair Manual (51U02832 and up).pdf