Bobcat X 225 Excavator Service Manual 6720874 (1–91) - PDF DOWNLOAD

X 225 Excavator Service Manual (S/N 508312000 & Above)

6720874 (1–91)

Printed in U.S.A.

© Melroe Company 1991

MAINTENANCE SAFETY WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow W-2003-0903 instructions can cause injury or death.

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

CORRECT

B-10731a

Never service the Hydraulic Excavator instructions.

Bobcat without

CORRECT

CORRECT

B-14148

Use the correct procedure to lift and support the excavator.

Always lift the blade fully before installing jackstands.

B-14142

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B-14147

B-14141

B-14145

Have good ventilation when welding or grinding painted parts.

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

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

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

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

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

WRONG

WRONG

WRONG

B-14146

B-14143 B-16102

B-6589 B-16102

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

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

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

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

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

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

Use eye protection approved for type of welding.

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

Lead-acid batteries produce flammable and explosive gases.

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

Batteries contain acid which burns eyes or skin on contact.

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

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

MSW20-0805

CONTENTS SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi HYDRAULIC EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . vii PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 UPPER WORKS & SWING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 MAIN FRAME & TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

PREVENTIVE MAINTENANCE

HYDRAULIC SYSTEM

DRIVE SYSTEM

UPPER WORKS & SWING SYSTEM

MAIN FRAME & TRACKS

ELECTRICAL SYSTEM

ENGINE SERVICE

SPECIFICATIONS

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225 (S/N 12000 & Above) Excavator Service Manual

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225 (S/N 12000 & 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 ROPS/FOPS (Including sidescreens) is in good condition and is not modified.

9. Safety treads must in good condition.

2. Check that ROPS mounting hardware is tightened and is Melroe approved.

10. Check for correct function of indicator lamps (Optional on some models).

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

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

4. Inspect for loose or broken parts or connections.

12. Inspect for fuel, oil or hydraulic fluid leaks.

5. Machine signs must be legible and in the correct location.

13. Lubricate the loader.

6. Steering levers, control levers and foot pedals must return to neutral. Check that foot pedals lock and control lever locks are in working condition.

14. Check the condition of the battery and cables.

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

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

8. Check the electrical charging system.

iii

225 (S/N 12000 & Above) Excavator Service Manual

iv

225 (S/N 12000 & Above) Excavator Service Manual

SAFETY INSTRUCTIONS

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

W–2003–1289

The following publications provide information on the safe use and maintenance of the loader and attachments:

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

• The Operation & Maintenance Manual delivered with the loader gives operating information as well as routine maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat Excavator dealer.

• The excavator has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat Excavator dealer.

• The CIMA Safety Manual delivered with the excavator gives information for safe operating and standard signals.

• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and repair work.

Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.

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

I–2019–0284

W–2044–1285

Safety Alert Symbol: This Safety Symbol is used for important safety messages. When you see this symbol follow the safety message to avoid personal injury or death.

v

225 (S/N 12000 & Above) Excavator Service Manual

SAFETY INSTRUCTIONS (Cont’d) • Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing the excavator. Safety glasses, hearing 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.

Call Before You Dig 1–888–258–0808 When you call, you will be directed to a location in your state/city for information about burried lines (telephone, cable TV, water, sewer, gas,etc.).

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225 (S/N 12000 & Above) Excavator Service Manual

SERIAL NUMBER LOCATIONS

A

Always use the serial number of the loader 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 is on the front of the machine frame, to the left of the boom [A].

CD–10469

ENGINE SERIAL NUMBER

B

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

CD–10408

DELIVERY REPORT

C

The Delivery Report must be filled out by the dealer and signed by the owner or operator when the Bobcat loader is delivered. The form contents must be explained to the owner. Make sure it is filled out completely [C].

vii

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC EXCAVATOR IDENTIFICATION 220ServiceManual#6720874S/N508312000&Above–ContentsSection

* ROPS/FOPS CANOPY

ARM CYLINDER

ENGINE COVER

ARM

SWING FRAME BLADE TRACK FRAME CONTROL LEVERS

TRACK BOOM

OPERATOR SEAT

BUCKET CYLINDER

BOOM CYLINDER BUCKET LINK

• BUCKET

BLADE CYLINDER

* ROPS, FOPS – Roller–Over Protective Structure, Falling Object Protective Structure, per SAE J1040 and SAE J1043. The bobcat Excavator is base–equipped with a standard canopy as shown.

• Factory option bucket viii

225 (S/N 12000 & Above) Excavator Service Manual

PREVENTIVE MAINTENANCE

PREVENTIVE MAINTENANCE Page Number AIR CLEANER SERVICE Replacing the Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 COOLING SYSTEM Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 ENGINE COVER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 ENGINE LUBRICATION SYSTEM Checking the Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 Engine Oil and Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 FUEL SYSTEM Fuel Filters (S/N 12648 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 FINAL DRIVE CASE Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 Draining Final Drive Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 HYDRAULIC SYSTEM Checking and Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 Replacement of the Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 LUBRICATION OF THE HYDRAULIC EXCAVATOR Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10 SERVICE SCHEDULE Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 USING A BOOSTER BATTERY (Jump Starting) Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9

–1––1–

225 (S/N 12000 & Above) Excavator Service Manual

–1–0–

225 (S/N 12000 & Above) Excavator Service Manual

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

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

W–2003–0797

ITEM Engine Air Cleaner

Engine Oil Engine Coolant System Indicator Lights Operator Cab Seat Belt Safety Signs (Decals) Tracks Hydraulic Reservoir All Machinery Pivot Points Fuel Tank/Fuel Filter Swing Circle Swing Pinion Alternator Belt Engine Oil & Filter Final Drive Case Hydraulic Filter Fuel Filters Battery Cooling System Alternator & Starter Engine Valve Clearance Cooling System Hydraulic Tank Final Drive Case * • • • ** • •

SERVICE REQUIRED

8–10

50

100

250

J

500 1000

Empty the dust cup. Replace the filter element only when the red ring shows in the indicator window. Check for leaks and damaged components.

Check the oil level & add oil as needed.

Check coolant level in recovery tank.

Check for correct operation.

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

Check the condition & that fasteners are tight.

Check for damaged signs (decals) replace as needed.

Check & adjust tension.

Check fluid level.

Lubricate 20 grease fittings.

Drain water and sediment from fuel tank/filter.

Lubricate two grease fittings.

Lubricate one grease fitting.

Check & adjust tension.

Replace oil & filter element.

Check fluid level & add oil as needed.

Replace filter element.

Replace filter elements.

Check & clean cable ends & check electrolyte level.

Clean the radiator fins.

Check the condition.

Check and adjust valve clearance.

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

Change the fluid, clean fill neck strainer.

Change the oil.

* * *

**

**

After the first 50 hours of machine operation do the following: Check the condition of the alternator belt Replace the hydraulic filter Replace the engine oil and filter After the first 250 hours of machine operation do the following: Change oil in final drive case Check and adjust engine valve clearance

J Or every 12 months.

Revised Mar. 98

–1–1–

225 (S/N 12000 & Above) Excavator Service Manual

ENGINE COVER

A

Procedure

AVOID INJURY Never service or adjust the machine when the engine is running unless instructed to do so in this manual.

W–2012–0290 Keep the engine cover closed when operating the machine.

W–2141–0189

N–10429

B

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

AIR CLEANER SERVICE Replacing the Filter Element See the SERVICE SCHEDULE Page 1–1 for the correct service interval.

1

Replace the filter element when the red ring shows in the window of the condition indicator.

NOTE: Push the button on the condition indicator and start the engine. If the red ring does not show, do not replace the filter element.

N–08176

C

Service the air cleaner as follows: Loosen the clamp on the dust cup.

Remove the dust cup [B].

Remove the rubber cap (Item 1) [B] to clean the dust cup.

Remove the wing nut (Item 1) [C].

1

N–08178

Remove the filter element [D].

D

Check the air cleaner housing for damage.

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

Install the dust cap so the arrow points up.

Check that all the air cleaner hose clamps are tight.

Push the button on the condition indicator so the red ring does not show.

N–08179

–1–2–

225 (S/N 12000 & Above) Excavator Service Manual

FUEL SYSTEM

A

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

1

Stop and cool the engine before adding fuel.

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

N–10415

W–2063–0887

Fuel System Service

B

The fuel level in the tank is indicated by the fuel gauge (Item 1) [A] when the engine is running.

Use the key to un–lock the fuel fill door.

Turn the fill cap to remove it [B].

N–10431

NOTE: The fuel fill strainer can be removed for cleaning [C]. Make sure it is installed before adding fuel to the tank.

C

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.

N–10432

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

W–2103–1285

–1–3–

225 (S/N 12000 & Above) Excavator Service Manual

FUEL SYSTEM (Cont’d)

A

Fuel System Service (Cont’d) To remove the water and sediment from the fuel tank, remove the drain plug (Item 1) [A] on the bottom of the tank.

1

N–10433

Fuel Filters (S/N 12648 & Above)

B

To remove the water from the fuel filter element, open the drain valve (Item 1) [B] at the bottom of the fuel filter element. When fuel, free of water emerges from the drain valve, close the drain valve.

1

CD–13228

Revised May 93

–1–4–

225 (S/N 12000 & Above) Excavator Service Manual

ENGINE LUBRICATION SYSTEM

A

Checking the Engine Oil Check the engine oil every day.

Stop the engine. Open the engine cover.

Remove the dipstick [A].

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

N–10437

B

Engine Oil and Filter Replacement See the SERVICE SCHEDULE Page 1–1 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 swing frame so the engine oil can drain between the tracks. Stop the engine.

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

1 N–10473

C

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.

1

Install and tighten the oil drain plug.

NOTE: Use only a Melroe approved oil filter. A non approved filter may not be of the quality needed to last 250 hours of engine operation, and could cause engine damage. See your Parts Manual or Microfiche for the correct part number of the oil filter.

N–10438

Remove the oil fill cap [D]. Put oil into the engine. (See FUEL, COOLANT AND LUBRICANTS Page 8–8.)

D

Start the engine and let it run for several minutes. Stop the engine. Check for leaks at the oil filter.

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

N–10439

Revised Mar. 98

–1–5–

225 (S/N 12000 & Above) Excavator Service Manual

COOLING SYSTEM

A

Coolant Level When the engine is cool, the coolant level in the recovery tank (Item 1) [A] must be half full.

1

If the coolant level is low, add pre–mixed coolant (50% water and 50% ethylene glycol) to the recovery tank.

N–10440

Coolant Replacement

B

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

W–2070–1285

Turn the upperstructure so there is access to the engine and radiator from underneath. Stop the engine.

N–10441

Loosen and remove the radiator cap [B].

C

Open the radiator drain valve (Item 1) [C] at the bottom of radiator. This will drain the entire system.

Drain all the coolant from the system.

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

Pre–mix 50% water and 50% ethylene glycol in a separate container. Fill the radiator with the pre–mixed coolant until it is full. Add coolant to the recovery tank until it is half full.

1

Run the engine at idle speed for about 5–10 minutes to remove the air from the cooling system (leave the radiator cap off during this operation).

B–13026

Stop the engine. Check the coolant level and add as needed to bring it up to the radiator the filler neck. Install the radiator cap and tighten.

–1–6–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC SYSTEM

A

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

Remove oil fill cap [A].

N–10447

B

Check the condition of the fill strainer [B].

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

N–10448

C

Check the hydraulic fluid level, it must be visible in the sight gauge (Item 1) [C] located on the side of the hydraulic reservoir.

Add the correct fluid to the reservoir until it is visible in the sight gauge. (See FUEL, COOLANT AND LUBRICANTS Page 8–8.)

1

Install the reservoir cap.

Replacement of the Hydraulic Filter

N–10449

See the SERVICE SCHEDULE Page 1–1 for the correct service interval.

D

Open the engine cover.

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

1

Clean the housing where the filter gasket makes contact.

Put clean grease 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 around the filter for leaks.

N–10450

–1–7–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC SYSTEM (Cont’d)

A

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

Turn the upperstructure so there is clearance for the reservoir at the track frame.

Retract the arm and bucket cylinders, lower the bucket to the ground. Stop the engine.

Remove the hydraulic filter. (See Page 1–7.)

Remove the drain plug from the bottom of the reservoir [A].

N–10451

Clean all the parts with clean solvent and air dry them.

Replace the filter. Install the mesh screen and tighten the bolts, hose clamp and drain plug.

Add approximately 10.5 gals. (40 L) of fluid to the reservoir. (See FUEL, COOLANT AND LUBRICANTS Page 8–8.)

Run the machine through the hydraulic functions. Check the fluid level and add as needed.

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

W–2103–1285

–1–8–

225 (S/N 12000 & Above) Excavator Service Manual

USING A BOOSTER BATTERY (Jump Starting)

A

Procedure If it is necessary to use a booster battery to start the engine, BE CAREFUL!

1

The key switch must be in the OFF position.

The booster battery must be 12 volt.

Open the engine cover [A].

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 positive (+) battery cable terminal (Item 1) [A] of the machine battery.

2 N–10446

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 frame (Item 2) [A].

NOTE: See Cold Starting Procedure in Operation & Maintenance Manual.

Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at engine frame.

Start the engine. After the engine is running, remove the cable (Item 2) [A] connected to the frame first.

Disconnect the cable from the machine battery (Item 1) [A].

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 injury.

W–2066–0490

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.

I–2023–1285

–1–9–

225 (S/N 12000 & Above) Excavator Service Manual

LUBRICATION OF THE HYDRAULIC EXCAVATOR

A

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

1 2

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

2

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–10454

B

4. Boom Swing Bracket (2) [B].

5. Boom Base Pivot (1) [B].

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

5 4 6

4 N–10455

7. Boom Swing Cylinder Rod End (1) [C].

8. Swing Circle Pinion (1) [C].

C 8

7 N–10456

9. Boom Cylinder Rod End (1) [D].

D

10. Arm Cylinder Base End (1) [D].

10

9

N–10457

–1–10–

225 (S/N 12000 & Above) Excavator Service Manual

LUBRICATION OF THE HYDRAULIC EXCAVATOR (Cont’d)

A 11

Procedure (Cont’d) Ref. Description (# of Fittings) 11. Arm Cylinder Rod End (1) [A].

12. Arm Base Pivot (1) [A].

13. Bucket Cylinder Base End (1) [A].

13 12

N–10458

B

14. Bucket Cylinder Rod End (1) [B].

15. Bucket Link Pivots (2) [B].

15

16. Bucket Pivots (4) [B].

16 14

N–10459

17. Swing Circle Ball Bearings (2) [C].

C

NOTE: Do Not overgrease the ball bearings or damage to the seals could result.

17

N–10474

18. Boom Swing Cylinder Base End (1) [D]. (Under the right side of upper frame.)

D

18

N–10475

–1–11–

225 (S/N 12000 & Above) Excavator Service Manual

FINAL DRIVE CASE

A

220ServiceManual#6720874S/N508312000&Above–PreventiveMaintenanceSection

Checking Oil Level Put machine on a flat level surface with the plugs positioned as shown in figure [A].

Remove the top plug (Item 1) [A].

Add oil through the hole if the oil level is below the hole.

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

1

2

Install and tighten the plug.

Repeat the procedure for the other side.

N–10460

Draining Final Drive Case See the SERVICE SCHEDULE Page 1–1 for the correct service interval.

Put the machine on flat level surface with the plugs positioned as shown in figure [A].

Remove the bottom plug (Item 2) [A] and top plug (Item 1) [A].

After all the oil is removed, install and tighten the bottom plug.

Add .55 quarts (0,5 L) of oil to the top plug hole. Install the plug.

Repeat the procedure for the other side.

–1–12–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC SECTION Page Number ARM CYLINDER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–43 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–48 BLADE CYLINDER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–47

HYDRAULIC SYSTEM

BOOM DROP VALVE (NORDIC–OPTION) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–43 BOOM CYLINDER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–42 BOOM SWING CYLINDER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–47 BUCKET CYLINDER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–44 HYDRAULIC CONTROL VALVE (6–Spool) Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10 HYDRAULIC CONTROL VALVE (3–Spool) Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–23 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–25 HYDRAULIC FILTER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–41 HYDRAULIC PUMP Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3 HYDRAULIC RESERVOIR Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–40 HYDRAULIC SERVICE INFORMATION Checking the Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 JOYSTICK CONTROL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–55 OIL COOLER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–39 PORT BLOCK Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–38 PRESSURE REDUCING VALVE Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–37

Revised Apr. 93

–2––1–

225 (S/N 12000 & Above) Excavator Service Manual

–2–0–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC SERVICE INFORMATION

A

1

When making repairs on 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.

2

2

2

2 1

I–2003–0284

CONTROL VALUES

Description There are three relief valves (Item 1) [A], five port relief valves (Item 2) [A], joystick relief valve (Item 3) [A] and unloading relief valve (Item 4) [A] in the hydraulic system.

3

1 4 MC–1410

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

B

1. Diagnostic Coupler Check 2. Hydraulic Tester Check Diagnostic Coupler Check can be done by using the following tools: MEL1355 – Test Kit MEL1355–3 – 5000 PSI Gauge MEL1355–12 – Coupler NOTE: The test can be done by one person in the operator’s seat if the hose from the kit is used.

N–10594

Connect the coupler from the tool kit to the gauge.

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

Start the engine and run at full RPM. Stroke a cylinder to it’s limit, in the section being tested, to open the relief valve.

Repeat the procedure for each pump.

The system relief valve for each pump has a nominal setting of 2350 PSI (16201 kPa), back pressure of approximately 200 PSI (1379 kPa) will affect the gauge reading.

–2–1–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC SERVICE INFORMATION (Cont’d)

A

The Hydraulic Tester Check can be done by using one of the following tools: OEM1238 – Hydraulic Tester (Shown) OEM1239 – Hydraulic Tester Stop the engine and raise the engine cover.

Disconnect the outlet hose from the hydraulic pump being tested and connect that hose to the outlet of the tester.

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

1 N–10595

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

B

NOTE: Open the flow control knob (Item 1) [A] fully to prevent pump damage.

NOTE: Refer to the hydraulic flow chart valve section.

3

Start the engine and run at low RPM. Make sure that the tester is connected correctly. If no flow is indicated at the tester, the hoses are connected wrong.

2

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 approximately 1000 PSI (6895 kPa). Do not exceed system pressure. Open the valve after oil is warm.

1 N–10597

Stroke a cylinder to end of stroke, in the section being tested, to check the relief valve.

The system relief valve for each pump has nominal setting of 2350 PSI (1620 kPa), back pressure of approximately 200 PSI (1379 kPa) will affect the gauge reading.

Release the pressure on the cylinder being tested.

The flow will be 7.1 GPM (27 L/min.) on a good pump at 2600 RPM. Record the free flow at high idle.

Operate a cylinder to the end of its stroke and record the reading.

NOTE: The high pressure flow must be at least 80% of free flow. %=

HIGH PRESSURE FLOW (GPM) FREE FLOW (GPM)

x 100

If the high pressure flow is less than 80% of free flow, remove the hydraulic pump for repair or replacement.

Repeat the testing procedure on the other pumps as required.

–2–2–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC PUMP

A

Disassembly & Assembly

1 When making repairs on 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.

I–2003–0284

N–10596

NOTE: Mark the hoses and tubelines for correct installation.

Disconnect the inlet hoses (Item 1) [A] from the hydraulic pump.

B

Drain the hydraulic fluid into a container.

Disconnect the pressure hoses [A].

Loosen the pump mounting bolts [B].

Remove the bolts.

Installation: Tighten the bolts to 13–14 ft.–lbs. (18–24 Nm) torque.

N–10597

Parts Identification TRIPLE GEAR PUMP 1.

2.

3.

4.

5.

6.

7.

3

Plate O–ring Gears Body Seal Gasket Washer

1

1

4

2

5

2

6 2

1 4

3

1 2

5 6

1

3

1 2

2 6 4

2 5 7 1

D–02106

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225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC PUMP (Cont’d)

A

Disassembly and Assembly (Cont’d)

When making repairs on 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.

P–01119

I–2003–0284

B

Clean the external pump surfaces. Mark the pump sections for ease of assembly [A].

Clamp the pump in a vise with protective jaws [A].

NOTE: Do Not over tighten the vise or pump distortion may occur.

Loosen the eight bolts from the front pump cover [A].

Installation: Tighten the bolts to 25–28 ft.–lbs. (34–38 Nm) torque.

Remove the pump from the vise.

P–01121

Remove the eight bolts and remove the front pump cover [B].

C

Remove the pump end cover (Item 1) [C], pump body (Item 2) [C], drive gear (Item 3) [C], idler gear (Item 4) [C], wear plate (Item 5) [C] and the dowel key (Item 6) [C].

6 3 2

1

NOTE: The dowel key (Item 6) [C] must be removed from the shaft so that the shaft can be removed from the next pump section.

5 4 P–01118

Remove the adapter plate (Item 1) [D], pump body (Item 2) [D], drive gear (Item 3) [D], idler gear (Item 4) [D], wear plate (Item 5) [D] and the dowel key (Item 6) [D].

D 6 1

3

2

5 4 Revised Apr. 93

–2–4–

P–01120

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC PUMP (Cont’d)

A

3

Disassembly and Assembly (Cont’d) Remove adapter plate (Item 1) [A], pump body (Item 2) [A], drive gear and shaft assembly (Item 3) [A], idler gear (Item 4) [A] and the wearplate (Item 5) [A].

2

1

NOTE: The drive gear can be removed from the drive shaft (Item 3) [A] but these parts are not serviceable separately and must be replaced as an assembly if damaged.

5 4 P–01122

B

Remove the O–ring from the two center adapter plates and the front cover [B].

P–01125

Remove the gasket (Item 1) [C] and the molded O–ring (Item 2) [C] from the two center adapter plates and the front cover.

C

1 2

P–01123

Remove the gasket from the two center adapter plates and the front cover [D].

D

P–01124

Revised Apr. 93

–2–5–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC PUMP (Cont’d)

A

Disassembly and Assembly (Cont’d) Remove the O–ring from the rear cover [A].

P–01128

B

Clamp the front pump cover in a vise with protective jaws and remove the shaft seal and the back–up washer [B].

Turn the front pump cover over and reclamp the cover in the vise.

Install the back–up washer into the front cover seal opening.

NOTE: The seal is not to be installed so that it is flush with the inner front cover flange. The back–up washer will have some freeplay between the front cover flange and the seal.

P–01129

Use a seal installation driver and install the front cover seal to the depth of .22–.25 inch (5,5–6,4 mm) from the front edges of the seal opening [C].

C

.22’’ .25’’

B–13815

P–01126

Measure the seal depth [D]. The seal must not be pressed completely into the housing.

D

P–01133

Revised Apr. 93

–2–6–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC PUMP (Cont’d)

A

Disassembly and Assembly (Cont’d) Inspect for wear on the gear tooth contact points on the internal diameters of the pump bodies [A].

P–01131

Inspect the side faces of the adapter plates for wear [B].

B

P–01127

Check all bushings for excessive wear [C].

C

NOTE: The bushings are not replaceable. If the bushings need replacing, order a complete adapter plate, end cover or front cover from Melroe Parts.

Install new seals (lubricated with oil) and reassemble pump in reverse order.

NOTE: When installing wear plates, the wear plates are installed so that they contact the gaskets.

The gaskets and the molded O–ring maintain a slight amount of pressure against the wear plate and the gears.

P–01130

After the pump has been reassembled and the bolts have been torqued, rotate the pump shaft. The rotating torque will be approximately 108 in–lbs. (12 Nm) and make sure that there is no binding.

Revised Apr. 93

–2–7–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6 Spool)

A

Removal and Installation

When making repairs on 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.

CD–10598

I–2003–0284

B

Remove the rear floor panel. (See Page 5–3.)

Remove the seat. (See Page 5–3.)

Remove the swing motor cover. (See Page 5–3.)

Remove the left control console. (See Page 3–2.)

Mark all the hoses for correct installation.

Disconnect the hand control lever hoses [A].

Disconnect the inlet and outlet hose from the control valve [B].

CD–10599

Disconnect the hoses from the control valve [C].

C

CD–10600

D

Remove the three mounting bolts from under the control valve [D].

CD–10601

Revised Apr. 93

–2–8–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6 Spool) (Cont’d)

A

Removal and Installation (Cont’d) Remove the control valve from the machine [A].

CD–10602

Parts Identification Control Valve Assembly (6 Spool) 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Main Relief Valve Port Relief Valve Plugs R.H. Travel Boom Bucket Auxiliary Arm L.H. Travel Orifice Plate

1 10 2 4

2 3

5

10 2

2

8 3

6 3

7

2

9

1

D–2099

Revised Apr. 93

–2–9–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6 Spool) (Cont’d)

A

Disassembly and Assembly

When making repairs on 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.

P–00287

I–2003–0284

B

Clean the control valve assembly with solvent.

Disassembly Mark the sections for ease of assembly.

Remove the nuts and washers from the three thru studs [A].

Set the valve assembly on its end and remove the inlet valve section from the valve assembly [B].

NOTE: Some versions of this valve use a .01’’ (0,25 mm) thick shim between each valve section, installed on the through studs. If shims are present during disassembly, valves must be reassembled with shims. If no shims are present, discard shims from the seal kits and reassemble without the shims.

P–00291

C

Continue to remove all the valve sections [C].

NOTE: Between sections 3 and 4 and sections 4 and 5 is a metal disc that blocks the oil flow. Make a note of these locations as these discs must be reinstalled in these locations for correct valve operation.

P–00292

Remove the four O–rings from the side face of each of the valve sections [D].

D

NOTE: If only the valve section O–rings need replacing, clean and dry the side faces of the sections and the O–ring glands.

Install new O–rings (and shims if applicable) and reassemble the valve.

See Page 2–13 for tightening torque.

P–00264

Revised Apr. 93

–2–10–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6 Spool) (Cont’d)

A

Inlet Section (R.H. and L.H. Travel) Disassembly Use a vise with protective jaws and clamp the valve section.

Remove the main relief valve from the valve section [A].

Installation: Tighten the relief valve to 35–40 ft.–lbs.

(47–54 Nm) torque.

NOTE: If the relief valve is disassembled, the relief pressure setting must be reset.

P–00689

See Page 2–16 for relief valve repair.

Remove the two bolts from the end cap and remove the end cap from the valve section [B].

B

Installation: Tighten the bolts to 5–6 ft.–lbs. (6–8 Nm) torque.

P–00691

Insert a pin into 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 [C]. Do Not use any type of tool to grip the finished surface of the spool or the spool will be damaged.

C

NOTE: The spring is under pressure, use care when removing the spring retaining bolt.

The spool and the housing are not serviceable separately.

The spool does not need to be removed from the housing except to clean oil passages if contamination is found. If the spool is removed, use care not to scratch the spool surface and Do Not intermix the spools and the housing.

P–00692

Pull the spool into the housing far enough to remove the spool O–ring from the bore in the valve section [D].

D

Use a brass tool to remove the O–ring. Do Not scratch the bore of the valve section while removing the O–ring or leakage may occur.

Check the O–ring gland for contamination and clean as necessary.

P–00275

Revised Apr. 93

–2–11–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6 Spool) (Cont’d)

A

Inlet Section (R.H. and L.H. Travel) Disassembly (Cont’d) Install a new O–ring into the bore of the valve section by pinching the O–ring and inserting it into the O–ring gland [A].

P–00277

B

Use a brass tool and position the O–ring firmly into the O–ring gland [B].

Apply oil to the O–ring.

Slowly rotate the spool and push it through the O–ring.

Then pull the spool through the valve section far enough to gain access to the spool O–ring on the opposite end of the valve. Repeat the steps for removing and installing the spool O–rings.

P–00275

C

Inlet Section (R.H. and L.H. Travel) Assembly Apply LOCTITE #242 to the threads of the spring retaining bolt.

Install the spacer, spring, spring retainer and the spring retaining bolt into the end of the spool. Insert a pin through the hole in the spool and tighten the spring retaining bolt [C].

Tighten the bolt to 2–3 ft.–lbs. (2–4 Nm) torque.

P–00271

Install the end cap over the spring and install the two (2) lock washers and bolts [D].

D

Tighten the bolts to 5–6 ft.–lbs. (6–8 Nm) torque.

P–00266

Revised Apr. 93

–2–12–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6 Spool) (Cont’d)

A

Valve Sections (Boom, Bucket & Arm) Disassembly Use a vise with protective jaws and clamp the valve section [A].

For Sections With Port Relief Valves Remove the work port relief valve from the section [A].

Installation: Tighten the port relief valve to 25–30 ft.–lbs.

(34–40 Nm) torque.

NOTE: If the relief valve is disassembled, the relief pressure setting must be reset.

P–00289

See Page 2–14 for port relief valve repair.

B

For Sections With Port Relief Plugs Remove the port relief plug from the valve section [B].

Installation: Tighten the port relief plugs to 25–30 ft.–lbs.

(34–40 Nm) torque.

P–00293

Remove the O–ring (Item 1) [C], back–up ring (Item 2) [C] and the O–ring (Item 3) [C] from the relief plug (Item 4) [C].

C 4 3 2

1

P–00294

Loosen the four bolts from the spool cover [D].

D

Installation: Tighten the bolts to 5–6 ft.–lbs. (6–8 Nm) torque.

P–00300

Revised Apr. 93

–2–13–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6 Spool) (Cont’d)

A

Valve Sections (Boom, Bucket & Arm) Disassembly (Cont’d) Remove the bolts (Item 1) [A], lockwashers (Item 2) [A], spool cover (Item 3) [A], O–ring (Item 4) [A], spool stop (Item 5) [A] and the spring (Item 6) [A].

6 5

3

4

Repeat steps [D] (on previous page) and step [A] to disassemble the opposite end of the valve section.

The spool and the housing are not serviceable separately.

The spool does not need to be removed from the housing except to clean oil passages if contamination is found. If the spool is removed, use care not to scratch the spool surface and Do Not intermix the spools and the housings.

The spools must be reinstalled in the same orientation as originally installed.

2

1 P–00302

B

Turn the valve section over and remove the plug (Item 1) [B], spring (Item 2) [B] and the load check plug (Item 3) [B].

3

Remove the O–ring (Item 4) [B] from the plug (Item 1) [B].

2

Installation: Tighten the plug to 15–20 ft.–lbs. (20–27 Nm) torque.

4

1

NOTE: When installing the load check poppet, make sure that the poppet is inserted into the housing with the grooves in the poppet towards the spring and the plug.

Valve Sections (Boom, Bucket & Arm) Assembly

P–00295

Clean parts in solvent and dry.

Use new O–rings and assemble components in reverse order.

Apply oil to the O–rings and the load check poppet when assembling.

Revised Apr. 93

–2–14–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6 Spool) (Cont’d)

A

Valve Sections (Auxiliary) Disassembly

3

2

1

Use a vise with protective jaws and clamp the valve section [A].

4

Remove the port relief plugs from the valve section [A].

P–00294

Installation: Tighten the relief plug to 25–30 ft.–lbs.

(34–40 Nm) torque.

Remove the O–ring (Item 1) [A], back–up ring (Item 2) [A] and the O–ring (Item 3) [A] from the relief plug (Item 4) [A].

P–00290

B

Remove the two bolts and lockwashers and the end cap from the valve section [B].

P–00299

C

Insert a pin into the hole in the actuating end of the spool to retain the spool from turning [C].

Loosen the spring retaining bolt from the end of the spool [C]. Do Not use any type of tool to grip the finished surface of the spool or the spool will be damaged.

NOTE: The spring is under pressure, use care when removing the spring retaining bolt.

P–00301

Remove the spring retaining bolt (Item 1) [D], spring retainer (Item 2) [D], spring (Item 3) [D] and the spacer (Item 4) [D] from the end of the spool. Remove the O–ring (Item 5) [D] from the spring retaining bolt (Item 1) [D].

D 4

Installation: Apply LOCTITE #242 to the spring retaining bolt threads and tighten the bolt to 2–3 ft.–lbs. (2–4 Nm) torque.

3

5 2 1

P–00298

Revised Apr. 93

–2–15–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6 Spool) (Cont’d)

A

Valve Sections (Auxiliary) Disassembly (Cont’d) Pull the spool into the housing far enough to remove the spool O–ring from the bore in the valve section [A].

Use a brass tool to remove the O–ring. Do Not scratch the bore of the valve section while removing the O–ring or leakage may occur.

Check the O–ring gland for contamination and clean as necessary.

NOTE: The spool and the section housing are not serviceable separately. The spool does not need to be removed from the housing except to clean oil passages if contamination is found. If the spool is removed, use care not to scratch the spool surface and Do Not intermix the spools and the housings.

P–00275

B

Install a new O–ring into the bore of the valve section by pinching the O–ring and inserting it into the O–ring gland [B].

P–00277

C

Use a brass tool and position the O–ring firmly into the O–ring gland [C].

Apply oil to the O–ring.

Slowly rotate the spool and push it through the O–ring.

Then pull the spool through the valve section far enough to gain access to the spool O–ring on the opposite end of the valve section. Repeat steps [A], [B] and [C].

P–00275

Turn the valve section over and remove the plug from the bottom of the valve section [D].

D

Remove the O–ring from the plug [D].

Installation: Tighten the plug to 15–20 ft.–lbs. (20–27 Nm) torque.

Valve Sections (Auxiliary) Assembly Clean the parts in solvent and dry.

Use new O–rings and assemble parts in reverse order.

Apply oil to the O–rings during assembly.

P–00297

Revised Apr. 93

–2–16–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6 Spool) (Cont’d)

A

Valve Sections (Auxiliary) Assembly (Cont’d) Apply oil to the new section O–rings and install the O–rings onto the side face of the valve sections [A].

Install a washer and a nut onto one end of the thru studs with at least two threads extending past the nut.

P–00694

B

Install the three bolts through the inlet section and place the inlet section on a bench with the O–rings facing upwards [B].

NOTE: If the valves were originally equipped with .01’’ (0,25 mm) shims between the section, install the shims over the through bolts between each section. If no shims were originally on valves, discard the shims from the seal kits.

Check each valve section for location marks. Make sure that the valve sections are installed in the correct order.

Install the valve sections onto the thru studs. Make sure that the two metal discs are installed between sections 3 and 4 and sections 4 and 5 [B].

P–00292

Install the three washers and nuts on the thru studs, finger tighten only at this time.

C

Place the valve assembly on a flat surface with the mounting feet facing upwards. Make sure that the center sections are flush. Snug up the nuts on the thru studs.

Turn the valve assembly over and place it on the mounting feet. Be sure that the mounting feet protrude below the hex plugs on all the center sections. Finish tightening the nuts [C].

Tighten the nuts to 12–15 ft.–lbs. (16–20 Nm) torque.

P–00287

Recheck the mounting feet for level setting, and the center sections for proper clearance.

NOTE: Test the valve spool operation by stroking each exposed spool and check for smooth operation in both directions. If the valve is not properly torqued, the spools may stick or may not return to neutral. If this occurs, loosen the through bolt nuts and repeat the correct torquing procedure.

Revised Apr. 93

–2–17–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6 Spool) (Cont’d)

A

Port Relief Valve

6

Port Relief Valve Pressure Setting

8

2

Boom relief set at: (Rod End) Front . . . . . . . . . . . . . 3000 PSI (20690 kPa) (Base End) Rear . . . . . . . . . . . . 3000 PSI (20690 kPa)

3 9

Arm relief set at: (Rod End) Rear . . . . . . . . . . . . . 3000 PSI (20690 kPa) (Base End) Front . . . . . . . . . . . . 3000 PSI (20690 kPa)

1

7 5

4 P–00296

Disassembly Remove the end plug (Item 1) [A] from the housing (Item 2) [A].

Remove the spring (Item 3) [A], shims (Item 4) [A] and the poppet (Item 5) [A].

Remove the O–ring (Item 6) [A], back–up ring (Item 7) [A] and the O–ring (Item 8) [A] from the housing (Item 2) [A].

Wear safety glasses to prevent eye injury when any of the following conditions exist:

Remove the O–ring (Item 9) [A] from the end plug (Item 1) [A].

• • • •

Clean all parts in solvent and dry.

Inspect the poppet for scratches or wear at the pilot point.

If damage is found, a new port relief valve assembly will need to be ordered from Melroe parts.

When fluids are under pressure.

Flying debris or loose material is present.

Engine is running.

Tools are being used.

W–2019–1285

Assembly Apply oil to the O–rings and back–up rings and install. Be careful not to overstretch these parts during installation.

Apply oil to the poppet and install in the housing.

Install the shims onto the poppet shaft with the thickest shims next to the poppet.

Install the spring and the end plug.

Tighten the end plug to 15–20 ft.–lbs. (20–27 Nm) torque.

Install the port relief valve into the appropriate valve section.

Tighten the end plug to 25–30 ft.–lbs. (34–40 Nm) torque.

Adjustment Procedure 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 30W motor oil.

Revised Apr. 93

–2–18–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6 Spool) (Cont’d)

A

Port Relief Valve (Cont’d) 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 relief valve opens and make a note of the pressure reading.

P–00747

B

If the port relief pressure setting needs to be adjusted, release the hand pump pressure valve and then remove the port relief end plug and spring [B].

Remove shim(s) to reduce the pressure or add shim(s) to increase the pressure setting [B].

NOTE: The shims will vary in thickness (.021 or .0035) and in quantities.

Reinstall the springs and the end plug and retests and readjust the port relief valve until the correct settings are obtained.

P–00304

Revised Apr. 93

–2–19–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6 Spool) (Cont’d)

A

Main Relief Valve

2

Main relief valves set at 2350 PSI (16201 kPa).

Wear safety glasses to prevent eye injury when any of the following conditions exist:

• • • •

1 P–00267

When fluids are under pressure.

Flying debris or loose material is present.

Engine is running.

Tools are being used.

B

W–2019–1285

5

Disassembly

4

3

Remove the main relief valve (Item 1) [A] from the valve assembly (Item 2) [A]. If the valve assembly is not being disassembled, plug the main relief cavity to avoid contamination.

1

2

Remove the O–ring (Item 1) [B], back–up washer (Item 2) [B], O–ring (Item 3) [B] and back–up washer (Item 4) [B] from the housing (Item 5) [B].

Remove the adjusting bolt assembly (Item 6) [B] from the housing (Item 5) [B] and remove the sealing washer (Item 7) [B] from the adjusting bolt. The jam nut (Item 8) [B] does not need to be removed from the adjusting bolt.

7

8

6 P–00279

Assembly Apply oil to the O–rings, back–up washers and the sealing washers and install. Be careful not to overstretch these parts during installation.

Install the adjusting bolt into the relief housing. Leave the adjusting bolt loose until the adjustment procedure is performed.

Install the main relief valve into the valve housing [A].

Tighten the main relief to 35–40 ft.–lbs. (47–54 Nm) torque.

Revised Apr. 93

–2–20–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6 Spool) (Cont’d)

A

Main Relief Valve (Cont’d) Main relief valves seat at 2350 PSI (16201 kPa).

Main Relief Valve Adjustment Procedure To adjust the main relief valves, the hydraulic circuit back pressure must be known.

Install OEM–1238 or OEM–1239 hydraulic tester and hose adapter 6657709 into the pump pressure circuit that is next to the engine [A]. (Pump outlet to tester inlet/tester outlet to hose going to the valve.) Open the flow control knob (Item 1) [A] on the tester to full open.

1 N–10595

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).

Take a gauge reading of the hydraulic circuit back pressure and record this information.

Wear safety glasses to prevent eye injury when any of the following conditions exist:

Turn the excavator engine off.

• • • •

Repeat this test procedure on the center hydraulic pump circuit.

The recorded circuit back pressure will need to be added to the relief valve pressure setting that is listed above.

This will assure accurate relief valve settings;

When fluids are under pressure.

Flying debris or loose material is present.

Engine is running.

Tools are being used.

W–2019–1285

EXAMPLE: The circuit next to the engine has 150 PSI (1034 Nm) back pressure, add 150 PSI (1034 Nm) to 2350 PSI (17580 Nm) and set the relief valve to 2500 PSI (18614 Nm). The circuit in the center of the pump has 225 PSI (1551 Nm) back pressure, add 225 PSI (1551 Nm) to 2350 PSI (17580 Nm) and set that relief valve to 2575 PSI (19130 Nm).

NOTE: This is only applicable to the main relief valves. Work port relief valves are to be set per the chart on Page 2–14.

NOTE: When testing the main relief valves, the appropriate cylinder for the relief valve being tested, will have to be extended or retracted fully to activate the relief valves. Make sure that there is adequate clearance for excavator movement and that no unauthorized personnel are in the work area.

If adequate room is not available, the hydraulic work hoses can be removed from the control valve section being tested and the control valve ports plugged.

Revised Apr. 93

–2–21–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (6 Spool) (Cont’d)

A

Main Relief Valve (Cont’d) Install a pressure gauge (Item 1) [A] (minimum of 5000 PSI) into the pressure line at the inlet section of both sides of the control valve [A] or install the diagnostic coupler gauge (MEL1355–3) onto the appropriate pump section which supplies the hydraulic pressure to the valve section being tested [B].

1

P–00303

B

Run the hydraulic pump at maximum rated RPM (high idle on engine).

Stroke a spool and check the pressure gauge PSI reading.

Loosen the jam nut on the relief valve adjusting bolt [A].

Turn the bolt clockwise to increase the pressure, counterclockwise to decrease the pressure [A]. When the correct pressure setting is obtained, tighten the jam nut while holding the adjusting bolt from turning [C].

N–10594

Recheck the gauge reading after tightening the jam nut to assure that the correct setting has been maintained.

C

P–00288

Revised Apr. 93

–2–22–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3 Spool)

A

The 3 spool control valve contains two valves, a 2350 PSI Main Relief valve and a 200 PSI Pressure Build–up valve.

After engine start–up, the pressure builds in the system to charge an accumulator and at 200 PSI the Pressure Build–up valve opens and allows excess oil to return to tank.

2

The 200 PSI build–up is used for initial joystick function.

1

Removal and Installation

CD–10603

B

When making repairs on 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.

I–2003–0284

Remove the center floor panel. (See Page 5–2.)

Remove the front floor panel. (See Page 3–9.)

Mark all hoses for correct installation.

CD–10604

Remove the cotter pin (Item 1) [A] and linkage pin from the boom swing spool.

C

Remove the lock nuts (Item 2) [A] and bolt from the blade spool [A].

1

Remove the hoses from the control valve [B].

1 Remove the two hand control hoses (Item 1) [C] from the control valve.

Remove the three mounting bolts from the control valve [D].

CD–10605

Remove the control valve.

D

CD–10606

Revised Apr. 93

–2–23–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3 Spool) (Cont’d) Parts Identification CONTROL VALVE ASSEMBLY (3 Spool) (S/N 12001–12023) 1.

2.

3.

4.

5.

6.

Pressure Build–Up Valve Lock Valve Boom Swing Blade Swing Motor Main Relief Valve

2

5

4 1

6 3 D–02102

CONTROL VALVE ASSEMBLY (3 Spool) (S/N 12024 & Above) 1.

2.

3.

4.

5.

6.

2

Pressure Build–Up Valve Lock Valve Boom Swing Blade Swing Motor Main Relief Valve

2

5

4 1

6

3 D–02118

Revised Apr. 93

–2–24–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3 Spool) (Cont’d)

A

220ServiceManual#6720874S/N508312000&Above–HydraulicSystemSectionPart1of3

When making repairs on 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.

I–2003–0284 P–00262

Clean the control valve assembly with solvent.

B

Disassembly Mark the sections for ease of assembly.

Remove the nuts and washers from the three thru studs [A].

Set the valve assembly on its end and remove the valve sections from the valve assembly [B].

NOTE: Some versions of this valve use a .01’’ (0,25 mm) thick shim between each valve section, installed on the through studs. If shims are present during disassembly, valves must be reassembled with shims. If no shims are present, discard shims from the seal kits and reassemble without the shims.

P–00265

C

Remove the four O–rings from the side face of the valve section [C]. Do Not scratch the side faces of the valve sections.

NOTE: If only the valve section O–rings need replacing, clean and dry the side faces of the sections and the O–ring glands. Install new O–rings and reassemble the valve. See Page 2–28 for tightening torque.

P–00264

Revised Apr. 93

–2–25–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3 Spool) (Cont’d)

A

Inlet Section (Housing Swing) Disassembly Use a vise with protective jaws and clamp the valve section [A].

Remove the relief valve from the inlet section [A].

Installation: Tighten the relief valve to 35–40 ft.–lbs.

(47–54 Nm) torque.

See Page 2–30 for relief valve repair.

P–00267

Loosen the four bolts from the spool cover [B].

B

Remove the four bolts (Item 1) [C], lock washers (Item 2) [C], cover (Item 3) [C], O–ring (Item 4) [C], spool stop (Item 5) [C] and spring (Item 6) [C] from the end of the valve section.

P–00269

C

Installation: Tighten the bolts to 5–6 ft.–lbs. (6–8 Nm) torque.

Repeat step [C] to disassemble the opposite end of the valve section.

The spool and the housing are not serviceable separately.

The spool does not need to be removed from the housing except to clean oil passages if contamination is found. If the spool is removed, use care not to scratch the spool surface and Do Not intermix the spools and the housings.

5

6

3

Turn the valve section over and remove the plug (Item 1) [D], spring (Item 2) [D] and the lock check poppet (Item 3) [D]. Remove the O–ring (Item 4) [D] from the plug (Item 1) [D].

1

4

2

P–00270

D

Installation: Tighten the plug to 15–20 ft.–lbs. (20–27 Nm) torque.

NOTE: When installing the load check poppet, make sure that the poppet is inserted into the housing with the grooves in the poppet towards the spring and the plug.

2

Assembly

4

1

Clean all parts in solvent and dry.

Use new O–rings and reassemble the components in reverse order.

3

Apply oil to the O–rings and the load check poppet when assembling components.

Revised Apr. 93

P–00285

–2–26–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3 Spool) (Cont’d)

A

End Cover (Boom Swing) and Valve Section (Blade) Disassembly NOTE: The photos may not show the valve section exactly as it appears; but the procedure is correct for these valve sections except as noted in the steps.

Use a vise with protective jaws and clamp the valve section [A].

(For End Cover [Boom Swing] Section Only) Remove the build up valve from the end cover section [A].

P–00272

See Page 2–29 for build up valve repair.

B

Remove the four bolts holding the load check block to the top of the valve section [B].

P–00268

Lift the load check block off of the valve section [C].

C

See Page 2–27 for load check block disassembly.

P–00273

Remove the two O–rings from the top face of the valve section [D].

D

NOTE: Use care not to scratch or mar the machined surfaces of the valve section.

P–00274

Revised Apr. 93

–2–27–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3 Spool) (Cont’d)

A

End Cover (Boom Swing and Valve Section (Blade) Disassembly (Cont’d) Remove the two bolts and lock washers from the end cap and remove the end cap from the valve section [A].

P–00266

B

Insert a pin into 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 [B]. Do Not use any type of tool to grip the finished surface of the spool or the spool will be damaged.

NOTE: The spring is under pressure, use care when removing the spring retaining bolt.

P–00271

Remove the spring retaining bolt (Item 1) [C], spring retainer (Item 2) [C], spring (Item 3) [C] and spacer (Item 4) [C] from the end of the spool.

C

4

Pull the spool into the housing far enough to remove the spool O–ring from the bore in the valve section [D].

3

2

1

P–00276

D

Use a brass tool to remove the O–ring. Do Not scratch the bore of the valve section while removing the O–ring or leakage may occur.

Check the O–ring gland for contamination and clean as necessary.

NOTE: The spool and the section housing are not serviceable separately. The spool does not need to be removed from the housing except to clean oil passages if contamination is found. If the spool is removed, use care not to scratch the spool surface and Do Not intermix the spools and the housings.

Revised Apr. 93

P–00275

–2–28–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3 Spool) (Cont’d)

A

End Cover (Boom Swing) and Valve Section (Blade) Disassembly (Cont’d) Install a new O–ring into the bore of the valve section by pinching the O–ring and inserting it into the O–ring gland [A].

P–00277

B

Use a brass tool and position the O–ring firmly into the O–ring gland [B].

Apply oil to the O–ring.

Slowly rotate the spool and push it through the O–ring.

Then pull the spool through the valve section far enough to gain access to the spool O–ring on the opposite end of the valve. Repeat the steps for removing and installing the spool O–rings.

P–00275

C

End Cover (Boom Swing) and Valve Section (Blade) Assembly Apply LOCTITE #242 to the threads of the spring retaining bolt.

Install the spacer, spring, spring retainer and the spring retaining bolt into the end of the spool. Insert a pin through the hole in the spool and tighten the spring retaining bolt [C].

Tighten the bolt to 2–3 ft.–lbs. (2–4 Nm) torque.

P–00271

Install the end cap over the spring and install the two lock washers and bolts [D].

D

Tighten the bolts to 5–6 ft.–lbs. (6–8 Nm) torque.

P–00266

Revised Apr. 93

–2–29–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3 Spool) (Cont’d)

A

End Cover (Boom Swing) and Valve Section (Blade) Assembly (Cont’d) Check the top face O–ring grooves for contamination and clean as necessary [A].

Install the two new O–rings onto the top face of the valve section [A].

P–00281

B

Install the load check block onto the valve section [B].

P–00273

C

Install the four bolts through the load check valve and into the valve section [C].

Tighten the bolt to 5–6 ft.–lbs. (6–8 Nm) torque.

P–00268

(For End Cover [Boom Swing] Section Only)

D

Apply oil to the O–ring and install the build up valve into the valve section [D].

Tighten the build up valve to 20–25 ft.–lbs. (27–34 Nm) torque.

P–00267

Revised Apr. 93

–2–30–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3 Spool) (Cont’d)

A

Load Check Block Disassembly Install the load check block into a vise with protective jaws [A].

Remove the check valves from both ends of the load check block [A].

P–00278

B

Remove the two check valves (Item 1) [B] and the spool (Item 2) [B].

1 2

1

P–00280

C

Remove the O–ring (Item 1) [C], back–up washer (Item 2) [C] and the O–ring (Item 3) [C] from the check valve.

Assembly

2

Clean the check valve in solvent and dry.

Lubricate the new seals with oil and install new O–ring (Item 3) [C], back–up washer (Item 2) [C] and O–ring 9Item 1) [C] onto the check valves.

Apply oil to the O–rings and to the spool and reassemble the load check block.

3

Tighten the check valves to 15–20 ft.–lbs. (20–27 Nm) torque.

Revised Apr. 93

1

–2–31–

P–00282

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3 Spool) (Cont’d)

A

Assembly (Cont’d) Apply oil to the new section O–rings and install the O–rings onto the side face of each of the valve sections block [A].

Install a washer and a nut onto one end of the thru studs with at least two threads extending past the nut.

P–00694

B

Install the three thru bolts thru the inlet section and place the inlet section on a bench with the O–rings facing upwards [B].

NOTE: If the valves were originally equipped with .01’’ (0,25 mm) shims between the sections, install the shims over the thru bolts between each section. If no shims were originally on the valves, discard the shims from the seal kits.

Check each valve section for location marks. Make sure that the valve sections are installed in the correct order.

Install the three washers and nuts on the thru studs, finger tighten only at this time.

P–00265

C

Place the valve assembly on a flat surface with the mounting feet flat on the surface. Make sure that the mounting feet protrude below the hex plugs on the bottom of the sections. Finish tightening the nuts [C].

Tighten the nut to 12–15 ft.–lbs. (16–20 Nm) torque.

Recheck the mounting feet for level settings and the center section for proper clearance.

NOTE: Test the valve spool operation by stoking each exposed spool and check for smooth operation in both directions. If the valve is not properly torqued, the spools may stick or may not return to neutral. If this occurs, loosen the thru bolt nuts and repeat the correct tightening procedure.

Revised Apr. 93

P–00262

–2–32–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3 Spool) (Cont’d)

A

Build–Up Valve Remove the build–up valve from the valve [A].

Installation: Tighten the build–up valve to 20–25 ft.–lbs.

(27–34 Nm) torque.

NOTE: If the control valve assembly is not being disassembled, plug the build–up port to avoid contamination.

P–00272

Remove the end plug (Item 1) [B], spring (Item 2) [B], piston (Item 3) [B] and the snap ring (Item 4) [B] from the build–up housing (Item 5) [B].

B

5 1

Remove and discard the O–rings.

NOTE: The build–up piston (Item 3) [B] should not be disassembled as it is factory set and cannot be reset.

2 3

Clean all parts in solvent and dry.

4

Inspect all parts for wear or damage, if damage is found order a new build–up valve assembly from Melroe Parts.

P–0283

Assembly

C

Reassemble parts in reverse order.

Pressure Gauge

Apply oil to the new O–ring before installing.

Testing Procedure: Install a gauge (5000 PSI minimum) into the pressure circuit at the valve [C].

Start excavator and run engine at idle.

The build–up valve must develop 200 PSI (271 Nm) back pressure to charge the accumulator. The build–up valve is not field adjustable, if back pressure is wrong, order a new build–up valve from Melroe Parts.

Revised Apr. 93

B–13877

–2–33–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3 Spool) (Cont’d)

A

Main Relief Valve

2

Main relief valves set at 2350 PSI (16201 kPa)

Wear safety glasses to prevent eye injury when any of the following conditions exist:

• • • •

1 P–00267

When fluids are under pressure.

Flying debris or loose material is present.

Engine is running.

Tools are being used.

B

W–2019–1285

5

Disassembly

4

3

Remove the main relief valve (Item 1) [A] from the valve assembly (Item 2) [A]. If the valve assembly is not being disassembled, plug the main relief cavity to avoid contamination.

1

2

Remove the O–ring (Item 1) [B], back–up washer (Item 2) [B], O–ring (Item 3) [B] and back–up washer (Item 4) [B] from the housing (Item 5) [B].

Remove the adjusting bolt assembly (Item 6) [B] from the housing (Item 5) [B] and remove the sealing washer (Item 7) [B] from the adjusting bolt. The jam nut (Item 8) [B] does not need to be removed from the adjusting bolt.

7

8

6 P–00279

Assembly Apply oil to the O–rings, back–up washers and the sealing washers and install. Be careful not to overstretch these parts during installation.

Install the adjusting bolt into the relief housing. Leave the adjusting bolt loose until the adjustment procedure is performed.

Install the main relief valve into the valve housing [A].

Tighten the main relief to 35–40 ft.–lbs. (47–54 Nm) torque.

Revised Apr. 93

–2–34–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3 Spool) (Cont’d)

A

Main Relief Valve Assembly (Cont’d) Main relief valves seat at 2350 PSI (16201 kPa).

Main Relief Valve Adjustment Procedure To adjust the main relief valves, the hydraulic circuit back pressure must be known.

Install OEM–1238 or OEM–1239 hydraulic tester and hose adapter 6657709 into the pump pressure circuit that is next to the engine [A]. (Pump outlet to tester inlet/tester outlet to hose going to the valve.) Open the flow control knob (Item 1) [A] on the tester to full open.

1 N–10595

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).

Take a gauge reading of the hydraulic circuit back pressure and record this information.

Wear safety glasses to prevent eye injury when any of the following conditions exist:

Turn the excavator engine off.

• • • •

Repeat this test procedure on the center hydraulic pump circuit.

The recorded circuit back pressure will need to be added to the relief valve pressure setting that is listed above.

This will assure accurate relief valve settings;

When fluids are under pressure.

Flying debris or loose material is present.

Engine is running.

Tools are being used.

W–2019–1285

EXAMPLE: The circuit next to the engine has 150 PSI (1034 Nm) back pressure, add 150 PSI (1034 Nm) to 2350 PSI (17580 Nm) and set the relief valve to 2500 PSI (18614 Nm). The circuit in the center of the pump has 225 PSI (1551 Nm) back pressure, add 225 PSI (1551 Nm) to 2350 PSI (17580 Nm) and set that relief valve to 2575 PSI (19130 Nm).

NOTE: When testing the main relief valves, the appropriate cylinder for the relief valve being tested, will have to be extended or retracted fully to activate the relief valves. Make sure that there is adequate clearance for excavator movement and that no unauthorized personnel are in the work area.

If adequate room is not available, the hydraulic work hoses can be removed from the control valve section being tested and the control valve ports plugged.

Revised Apr. 93

–2–35–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CONTROL VALVE (3 Spool) (Cont’d)

A

Main Relief Valve Adjustment Procedure (Cont’d) Install a pressure gauge (Item 1) [A] (minimum of 5000 PSI) into the pressure line at the inlet section of both sides of the control valve [A] or install the diagnostic coupler gauge (MEL1355–3) onto the appropriate pump section which supplies the hydraulic pressure to the valve section being tested [B].

1

P–00303

B

Run the hydraulic pump at maximum rated RPM (high idle on engine).

Stroke a spool and check the pressure gauge PSI reading.

Loosen the jam nut on the relief valve adjusting bolt [A].

Turn the bolt clockwise to increase the pressure, counterclockwise to decrease the pressure [A]. When the correct pressure setting is obtained, tighten the jam nut while holding the adjusting bolt from turning [C].

N–10594

Recheck the gauge reading after tightening the jam nut to assure that the correct setting has been maintained.

C

P–00288

Revised Apr. 93

–2–36–

225 (S/N 12000 & Above) Excavator Service Manual

PRESSURE REDUCING ACCUMULATOR

VALVE

WITH

A

The Pressure Reducing valve body contains two valves, the Pressure Reducing valve (Item 1) [C] and a Safety Relief valve (Item 2) [C].

The valve body is connected to the accumulator.

The pressure reducing valve supplies 363 PSI (2500 kPa) to the joysticks to activate the control valve spools.

This accumulator provides short term reserve pressure for joystick function with engine off.

Removal and Installation CD–10607

B When making repairs on 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.

I–2003–0284

Remove the center floor panel. (See Page 5–2.)

CD–10608

Mark the hoses for correct installation.

Remove the hoses and tubelines from the reducing valve [A].

Remove the two mounting bolts from under the swing frame [B].

Parts Identification

C

1.

2.

3.

4.

5.

Accumulator Pressure Reducing Valve Valve Body Safety Valve Spool 2 1

3

4 5

Revised Apr. 93

–2–37–

225 (S/N 12000 & Above) Excavator Service Manual

ACCUMULATOR / VALVE

A

Disassembly

1

Clean the outside of the valve.

2

Disassemble the valve in a clean area.

Use a vise with protective jaws to clamp the valve body.

Remove the accumulator (Item 1) [A] and seal (Item 2) [A].

NOTE: The accumulator does not need to be discharged before removal.

P–8148

Remove the adaptor (Item 1) [B].

B 1

P–8149

Remove the O–ring (Item 1) [C] from the adapter.

C

2 P–8154

Remove the spring (Item 1) [D] and seat (Item 2) [D] from the spool.

D

NOTE: Be careful when removing the seat and spool so as not to scratch the polished surfaces.

Scratches in the polished surface will cause internal leakage.

1

2

P–8151

Revised Mar. 98

–2–38–

225 (S/N 12000 & Above) Excavator Service Manual

ACCUMULATOR / VALVE (Cont’d)

A

Disassembly (Cont’d) Using two (2) pieces of .090 inch wire with a 90° bend on the end, remove the spool by inserting the wires through the center orifice and engaging two (2) of the ports [A].

P–8152

Remove the spool by pulling straight up on the wires [B].

B

P–8153

Remove the O–ring (Item 1) [C] from the spool.

C

1 P–8166

Remove the copper seal (Item 1) [D] from the valve body.

D

1

P–8155

Revise Mar. 98

–2–39–

225 (S/N 12000 & Above) Excavator Service Manual

ACCUMULATOR / VALVE (Cont’d)

A

Disassembly (Cont’d)

2

Cut and remove the wire seal (Item 1) [A].

3

Loosen the locknut (Item 2) [A] and remove the adjusting screw (Item 3) [A].

NOTE: The safety relief valve must be reset to the correct pressure setting if it is removed from the valve body.

1 P–8156

Remove the spring (Item 1) [B] and valve (Item 2) [B].

B 1

2

P–8157

Remove the plug (Item 1) [C] and copper washer from the accumulator end of the valve body.

C

1 P–8158

Remove the spool from the valve body [D].

D

P–8159

Revised Mar. 98

–2–40–

225 (S/N 12000 & Above) Excavator Service Manual

ACCUMULATOR / VALVE (Cont’d)

A

Disassembly (Cont’d) Remove the plug (Item 1) [A] and washer (Item 2) [A] from the adjustment end of the valve body.

2 1

P–8160

Remove the shim (Item 1) [B], spring (Item 2) [B] and spring seat (Item 3) [B] from the valve body.

B 3

2 1

P–8161

Remove the plug (Item 1) [C], washer (Item 2) [C] and check ball (Item 3) [C] from one side of the valve body.

C 1

2 3

P–8162

Remove the plug (Item 1) [D] and washer from the opposite side of the valve body.

D 1

P–8150

Revised Mar. 98

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225 (S/N 12000 & Above) Excavator Service Manual

ACCUMULATOR / VALVE (Cont’d)

A

Disassembly (Cont’d)

1

Remove the plug (Item 1) [A] and washer from the bottom of the valve body.

Assembly Before assembly: Clean all parts in solvent and dry with compressed air.

Inspect all valves, seats and spools for wear.

P–8163

Install the bottom plug (Item 1) [A] and a new washer in the bottom of the valve body.

B

Install the side plug (Item 1) [B] and a new washer in the side of the valve body.

1

P–8150

Install the check ball (Item 1) [C] into the valve body.

C

Install a new washer (Item 2) [C] and plug (Item 3) [C] into the valve body.

2

3

1

P–8162

Install the spring seat (Item 1) [D] , spring (Item 2) [D], and spring shim (Item 3) [D] into the valve body.

D

2

1

3

P–8161

Revised Mar. 98

–2–42–

225 (S/N 12000 & Above) Excavator Service Manual

ACCUMULATOR / VALVE (Cont’d)

A

Assembly (Cont’d) Install the new washer (Item 1) [A] and plug (Item 2) [A] on the valve body.

1 2

P–8160

Put clean hydraulic fluid on the spool (Item 1) [B].

B

Install the spool (Item 1) [B] in the valve body.

1

P–8159

Install a new copper washer and plug (Item 1) [C] in the valve body.

C

1 P–8158

D

Put clean hydraulic fluid on the valve (Item 1) [D].

Install the valve (Item 1) [D] and spring (Item 2) [D] in the valve body.

NOTE: The safety relief valve must be reset to the correct pressure setting before the accumulator valve can be put back in service.

See page 2–37J for adjustment procedure.

2

1

P–8157

Revised Mar. 98

–2–43–

225 (S/N 12000 & Above) Excavator Service Manual

ACCUMULATOR / VALVE (Cont’d)

A

Assembly (Cont’d)

2

Install the adjustment screw (Item 1) [A], locknut (Item 2) [A], and washer (Item 3) [A] in the valve body.

3

1

P–8156

Install a new washer (Item 1) [B] in the valve body.

B

1

P–8155

Apply oil and install a new O–ring (Item 1) [C] on the spool.

C

Put clean hydraulic fluid on the spool.

Install the spool in the valve body.

1 P–8166

Apply clean hydraulic fluid on the seat.

D

Install the seat (Item 1) [D] in the spool.

Install the spring (Item 2) [D] in the seat (Item 1) [D].

2

1

P–8151

Revised Mar. 98

–2–44–

225 (S/N 12000 & Above) Excavator Service Manual

ACCUMULATOR / VALVE (Cont’d)

A

Assembly (Cont’d) Use care when installing the O–ring so the threads do not cut the O–ring.

Apply oil to the new O–ring (Item 1) [A] and install the O–ring (Item 1) [A] on the adapter.

1 P–8154

Install the adapter (Item 1) [B] in the valve body.

B 1

P–8149

Install the seal (Item 1) [C] and accumulator (Item 2) [C] on the adaptor.

C 2

NOTE: The accumulator pressure should be checked before putting the accumulator valve back in service. See page 2–47 for the procedure.

1

P–8148

Revised Mar. 98

–2–45–

225 (S/N 12000 & Above) Excavator Service Manual

ACCUMULATOR / VALVE (cont’d )

A

Setting the Safety Relief Valve

1

2 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.

CD–12314

W–2019–1285

Remove the tank return line and install a clear line leading to a drain pan in its place.

Start the excavator and run at low idle. Engage the blade lever until the blade is fully raised. Continue to engage the blade lever.

Loosen the locknut (Item 1) [A], and turn the adjustment screw (Item 2) [A] counterclockwise until hydraulic fluid starts to leak out the tank return line (clear line installed previously).

Slowly turn the adjustment screw (Item 2) [A] clockwise until the flow out the tank return line stops.

Turn the adjustment screw an additional 3/4 of a turn clockwise and tighten the locknut.

Revised Mar. 98

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225 (S/N 12000 & Above) Excavator Service Manual

ACCUMULATOR

A

Charging The hydraulic accumulator provides 200 PSI (1379 kPa) short term reserve pressure for joystick function with the engine off.

The following tool will be needed to test and service the accumulator: MEL1435 accumulator servicing and test kit.

Remove the pressure reducing valve and accumulator from the excavator.

1

Install the accumulator in a vise with protective jaws.

B–14476

Remove the protective cover (Item 1) [A] from the accumulator.

B

Install the hand wheel, bleed screw and gauge assembly (Item 1) [B] on the accumulator.

5

NOTE: Before installing the gauge assembly on the accumulator, be sure the hand wheel (Item 4) [B] is open and the bleed screw (Item 5) [B] is closed.

1 3

Connect the nitrogen bottle adapter (Item 2) [B] to the gauge assembly (Item 1) [B] with the hose (Item 3) [B].

4

Open the nitrogen bottle.

2

Slowly close the hand wheel (Item 4) [B] until 200 PSI (1379 kPa) is reached. Increase the pressure until its slightly higher than needed. Close the nitrogen bottle.

B–14477

Bleed off the excess pressure by opening and closing the bleed screw (Item 5) [B].

Recheck the pressure after allowing the accumulator to stabilize for five minutes.

Bleed off or add more nitrogen into the accumulator as needed.

NOTE: Use only nitrogen for charging the accumulator to prevent explosions and fire hazards.

Revised Mar. 98

–2–47–

225 (S/N 12000 & Above) Excavator Service Manual

PORT BLOCK

A

Removal and Installation Remove the center floor panel. (See Page 5–2.)

Mark the tubelines for the correct installation.

Remove the tubelines from the port block [A].

CD–10609

B

Remove the mounting bolts [B].

CD–10610

Remove the port block [C].

C

CD–10611

Revised Apr. 93

–2–48–

225 (S/N 12000 & Above) Excavator Service Manual

OIL COOLER

A

Removal and Installation

1 1

When making repairs on 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.

N–10612

I–2003–0284

B

Raise the engine cover.

Remove the hoses from the oil cooler [A].

Remove the nuts (Item 1) [A] from the mounting bolts.

(The oil cooler shown is for models with S/N 12001–12162 which used a two point mounted oil cooler.

For models with S/N 12163 and above, these use a four point mounted oil cooler. Remove the four bolts and washers.

Remove the oil cooler [B].

N–10613

NOTE: Do not damage the radiator fins when removing the oil cooler.

Revised Apr. 93

–2–49–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC RESERVOIR

A

220ServiceManual#6720874S/N508312000&Above–HydraulicSystemSectionPart2of3

Removal and Installation

When making repairs on 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.

N–10451

I–2003–0284

B

Remove the fuel tank. (See Page 5–5.)

Remove the drain plug from the bottom of the reservoir [A]. Drain the fluid into a container.

1

Disconnect the reservoir return line (Item 1) [B].

2 Remove the supply hose clamp (Item 2) [B] and disconnect the hose.

N–10638

Remove the bolts from the reservoir base [C].

C

Remove the reservoir.

N–10639

Revised Apr. 93

–2–50–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC FILTER ASSEMBLY

A

Removal and Installation Raise the engine cover.

Remove the inlet and outlet hoses from the filter [A].

Drain the fluid into a container.

N–10640

B

Remove the mounting bolts from the filter assembly [B].

N–10641

Revised Apr. 93

–2–51–

225 (S/N 12000 & Above) Excavator Service Manual

BOOM CYLINDER

A

Removal and Installation See Page 2–48 – 2–54 for Disassembly and Assembly procedure.

Put the bucket on the floor. Stop the engine.

When making repairs on 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.

N–10642

B

I–2003–0284

Disconnect the two hoses from the boom cylinder.

Remove the retainer bolt and nut from the boom cylinder base end pin [A].

1

Remove the cylinder base end pin.

Lower the base end of the boom cylinder to the floor.

N–08553

Remove the retainer bolt (Item 1) [B] and nut from the cylinder rod end pin.

C

Remove the cylinder rod end pin. Remove the boom cylinder from the boom.

BOOM DROP VALVE (NORDIC–OPTION) Removal and Installation These are for Excavators sold in Scandinavian countries only.

1

The boom drop valve is located on the boom cylinder and prevents the boom from dropping if a hydraulic line should rupture.

N–12541

If a line ruptures and the boom is off the ground, lower the boom as follows:

D

Stop the engine.

Remove the relief valve cap [C].

Mark the position of the relief valve (Item 1) [C].

NOTE: Turn the relief valve back in the exact number of turns after boom is lowered.

Slowly back out the relief valve until the boom is lowered to the ground [D].

N–12542

Revised Apr. 93

–2–52–

225 (S/N 12000 & Above) Excavator Service Manual

BOOM DROP VALVE (NORDIC–OPTION) (Cont’d)

A

Removal and Installation (Cont’d) Lower the boom to the ground. Stop the engine.

2

Remove the tubelines (Item 1) [A] from the drop valve.

Remove the nuts (Item 2) [A] from the u–bolt and remove the drop valve.

Installation: The arrow on the orifice fitting (Item 3) [A] should point toward base of boom cylinder.

1

3

ARM CYLINDER N–12414

Removal and Installation

B

See Page 2–48 – 2–54 for Disassembly and Assembly procedure.

Put the bucket on the floor. Stop the engine.

Move the hydraulic controls to release the hydraulic pressure.

1 When making repairs on 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.

N–08554

C

I–2003–0284

Disconnect the two hoses from the arm cylinder [B].

Remove the retainer bolt (Item 1) [B] and nut from the boom cylinder base end pin.

Remove the cylinder base end pin.

1

Remove the retainer bolt (Item 1) [C] and nut from the cylinder rod end pin.

N–10643

Remove the cylinder rod end pin..

Remove the cylinder from the arm.

Revised Apr. 93

–2–53–

225 (S/N 12000 & Above) Excavator Service Manual

BUCKET CYLINDER

A

Removal and Installation

2

See Page 2–48 – 2–54 for Disassembly and Assembly procedure.

Put the bucket on the floor. Stop the engine.

Move the hydraulic controls to release the hydraulic pressure.

1

N–10644

When making repairs on 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.

B

I–2003–0284

Disconnect the two hoses (Item 1) [A] from the bucket cylinder.

1

Remove the retainer bolt (Item 1) [B] and nut from the cylinder rod end pin.

N–08544

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 bucket cylinder.

Revised Apr. 93

–2–54–

225 (S/N 12000 & Above) Excavator Service Manual

BLADE CYLINDER

A

Removal and Installation See Page 2–48 – 2–54 for Disassembly and Assembly procedure.

Put the blade on the floor. Stop the engine. Move the blade control to release the hydraulic pressure.

Remove the four bolts from the blade cylinder guard [A].

N–10645

B

Remove the two guards [B].

N–10646

C

Disconnect the two hoses [C].

N–10695

Remove the retainer bolt (Item 1) [D], nut and base end pin from the blade cylinder.

D

1 CD–08546

Added Apr. 93

–2–55–

225 (S/N 12000 & Above) Excavator Service Manual

BLADE CYLINDER (Cont’d)

A

Removal and Installation (Cont’d)

1

Remove the cotter key (Item 1) [A] from the cylinder rod end pin.

Remove the cylinder rod end pin (Item 2) [A]. Remove the blade cylinder.

2 N–08547

Added Apr. 93

–2–56–

225 (S/N 12000 & Above) Excavator Service Manual

BOOM SWING CYLINDER

A

Removal and Installation See Page 2–48 – 2–54 for Disassembly and Assembly procedure.

1 When making repairs on 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.

N–08548

B

I–2003–0284

Disconnect the hoses (Item 1) [A] from the cylinder.

Remove the retainer bolt form the cylinder base end pin.

Remove the cylinder base end pin [B].

N–08207

Remove the retainer bolt from the cylinder rod end pin [C].

C

Remove the cylinder rod end pin.

Remove the boom swing cylinder.

N–08549

Added Apr. 93

–2–57–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CYLINDER

A

Disassembly 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 loosen the head [A].

B–07000

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

Loosen the bolt from the piston end of the rod [C].

C

B–13745

D

Remove the bolt (Item 1) [D] from the rod.

Pull the piston off the rod (Item 2) [D].

3

2

1

Pull the head (Item 3) [D] off the rod.

CD–12673

Added Apr. 93

–2–58–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CYLINDER (Cont’d)

A

Disassembly (Cont’d) Remove the O–ring (Item 1) [A] and back–up washer (Item 2) [A] from the head with seal hook (MEL1074).

1

Remove the O–ring (Item 3) [A] from the head.

2 3

B–13743

B

Remove the wiper seal [B].

B–07005

C

Remove the oil seal from the head [C].

B–07006

Cut the old teflon seal and remove the seal from the piston [D].

D

B–03689

Added Apr. 93

–2–59–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CYLINDER (Cont’d)

A

Disassembly (Cont’d) 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–03703

B

Assembly Install the O–ring on the piston [B].

B–12812

NOTE: Do not overstretch the seal.

C

Install the seal on the tool (MEL1396) and stretch it until it fits the piston [C].

Allow the O–ring to stretch for 30 seconds before removing it from the tool.

B–12809

Install the seal on the piston [D].

D

B–12813

Added Apr. 93

–2–60–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CYLINDER (Cont’d)

A

Assembly (Cont’d) Use a ring compressor to compress the seal to the correct size [A].

Leave the piston in the ring compressor for three minutes.

B–12811

B

Install the oil seal on the rod seal tool (MEL1033) [B].

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 [C].

C

B–03671

Install the wiper seal with the lip toward the outside of the head [D].

D

B–03682

Added Apr. 93

–2–61–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CYLINDER (Cont’d)

A

Assembly (Cont’d) Install the O–ring (Item 1) [A] onto the head.

1

CD–12674

B

Install the back–up washer (Item 1) [B] and O–ring (Item 2) [B] onto the head.

2

1

CD–12675

C

Apply grease to the inside of the head and to the lips of the seals.

Inspect the beveled edge of the rod for nicks or sharp edges [C]. 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 [C].

CD–12676

Install the piston on the rod with the recessed end of the piston toward the head [D].

D

Lubricate the retainer bolt with oil and install the retainer bolt through the piston and into the rod.

Tighten the bolt to the following torque: For Boom Swing cylinder; tighten the bolt to 185–215 ft.–lbs. (250–292 Nm) torque.

For Blade cylinder and Bucket cylinder; tighten the bolt to 400–425 ft.–lbs. (543–577 Nm) torque.

For Arm cylinder and Boom cylinder; tighten the bolt to 590–640 ft.–lbs. (800–868 Nm) torque.

Added Apr. 93

CD–12677

–2–62–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CYLINDER (Cont’d)

A

Assembly (Cont’d) Inspect the inside of the cylinder case for nicks and scratches. If the cylinder case has minor scuffing the cylinder case can be honed [A]. Use a flexible hone and lubricate with oil during the honing process.

Thoroughly wash the inside of the cylinder case after honing process.

The following hones can be ordered from OTC Service Tools: MEL1418 – 2’’ Diameter Hones OEM6275 – 2–3/4 – 3’’ Diameter Hone OEM6270 – 3 – 3–1/2’’ Diameter Hone OEM6271 – 3–1/2 – 4’’ Diameter Hone

CD–12678

B

Put oil on the seal surface of the cylinder case [B].

B–07013

Put oil on the Teflon seal on the piston [C].

C

B–07012

Install the rod assembly in the cylinder case [D].

D

B–07001

Added Apr. 93

–2–63–

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC CYLINDER (Cont’d)

A

Assembly (Cont’d) Put oil on the seals on the head [A].

Put oil on the threads of the head.

B–07014

B

Use the adjustable gland nut wrench (MEL1075) to tighten the head [B].

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

Added Apr. 93

–2–64–

225 (S/N 12000 & Above) Excavator Service Manual

JOYSTICK CONTROL CHANGE

A

Remove the seal. (See Page 5–1.)

Remove the center floor panel. (See Page 5–2.)

ISO PATTERN Control Valve

1

Remove the swing motor cover and rear floor panel. (See Page 5–3.)

4 R.H. Travel Boom

Remove the left control panel base (Page 3–9).

Bucket

To change I.S.O. to Standard control pattern do the following:

Auxiliary Arm

Mark the hoses that attach to the valve spool as shown [A].

L.H. Travel

3

2

Remove the boom control hose (Item 1) [A] and the arm control hose (Item 2) [A] and relocate (switch) these hoses on the control valve [B].

Remove the arm control hose (Item 3) [A] and the boom control hose (Item 4) [A] and relocate (switch) these hoses on the control valve [B].

STANDARD PATTERN

B

Control Valve

2

After the hoses have been switched, the hoses must be as shown [B].

B–13429

3 R.H. Travel

The R.H. joystick will now control the arm (Arm out and Arm in) and the bucket curl.

Boom Bucket

The L.H. joystick will now control the boom (Boom up and Boom down) and the upperstructure swing.

Auxiliary Arm

Do not exchange any of the hoses on the top of the control valve to the work cylinders. Switch only the hoses that connect the joystick to the control valve spools.

L.H. Travel

4

1

B–13429

Clean the existing decals on the control consoles with soap and water and let dry.

STANDARD PATTERN

C

Install the standard control pattern decals (P/N 6537457 for R.H. console and P/N 6537456 for the L.H. console) on top of the existing control pattern decals.

Control Valve

2

To change Standard to I.S.O. control pattern do the following:

3 R.H. Travel Boom

Mark the hoses on the end of each valve spool as shown [C].

Bucket

Through the center panel access, remove the arm control hose (Item 1) [C] and the boom control hose (Item 2) [C] and relocate these hoses on the control valve [D].

Auxiliary

Remove the boom control hose (Item 3) [C] and the arm control hose (Item 4) [C] and relocate these hoses on the control valve [D].

L.H. Travel

Arm

4

1

B–13429

After the hoses have been switched, the hoses must be as shown [D].

ISO PATTERN

D

The R.H. joystick will now control the boom (Boom up and Boom down) and the bucket curl.

Control Valve

1

The L.H. joystick will now control the arm (Arm out and Arm in) and the upperstructure swing.

4 R.H. Travel

Do not exchange any of the hoses on the top of the control valve to the work cylinders. Switch only the hoses that connect the joystick to the control valve spools.

Boom Bucket Auxiliary

Clean the existing decals on the control consoles with soap and water and let dry.

Arm L.H. Travel

Install the I.S.O. control pattern decals (P/N 6537588 for the R.H. console and P/N 6537587 for the L.H. console) on top of the existing control pattern decals.

Added Apr. 93

2

3 B–13429

–2–65–

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–2–66–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE SYSTEM Page Number CONTROL LEVERS Blade Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8 Throttle Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9 DRIVE MOTOR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–31 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–19 FINAL DRIVE Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE SYSTEM

3–15 3–16 3–19 3–31

FOOT PEDAL AND STEERING LEVERS Bushing Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–14 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13 JOYSTICK Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4 LEFT CONSOLE Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 Lockout Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 LEFT JOYSTICK Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3 RIGHT CONSOLE Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11

Revised Apr. 93

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225 (S/N 12000 & Above) Excavator Service Manual

–3–0–

225 (S/N 12000 & Above) Excavator Service Manual

LEFT CONSOLE

A

Lockout Valve Removal and Installation Raise the console.

Remove the mounting bolts [A].

Mark the hoses for correct installation.

N–10614

B

Remove the hoses from the lockout valve [B].

1

Remove the nuts (Item 1) [B] from the mounting bolts.

Remove the lockout valve.

Installation: Use mounting plate slots to adjust lockout valve plunger (Item 1) [A] to fully depressed position when console is in lowered position.

CD–10615

C

Cylinder Removal and Installation Remove the cotter pins (Item 1) [C] from the base end and rod end of the cylinder.

1

Cylinder contains high pressure gas. Do not open. Opening cylinder can release rod and cause injury or death.

W–2113–0288 CD–10616

–3–1–

225 (S/N 12000 & Above) Excavator Service Manual

LEFT CONSOLE (Cont’d)

A

Removal and Installation Lower the boom and blade to the ground Stop the engine.

Remove the swing motor cover and the rear floor panel.

(See Page 5–3.)

Remove the left console hose from the right console tee fitting [A].

CD–10617

B

Remove the left console mounting bolts [B].

CD–10618

C

Remove the right console hose (Item 1) [C] from the left console tee fitting.

1

CD–10619

Remove the hand control lever hoses from the control valve [D].

D

Remove the left console.

CD–11131

–3–2–

225 (S/N 12000 & Above) Excavator Service Manual

LEFT JOYSTICK Removal and Installation Remove the left console cover.

Mark the hoses for the correct installation.

Remove the hoses from the joystick control.

Remove the joystick mounting bolts.

Installation: Tighten the bolts to 6–7 ft.–lbs. (8–10 Nm) torque.

Parts Identification LEFT JOYSTICK 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Plug Rod Seat Spring Bellows Nut Actuator Joint Plate Bolt Handle Assembly

5

6 11 7 1

8

2 9

3 4

4

9

10 D–1973

Revised June 92

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225 (S/N 12000 & Above) Excavator Service Manual

JOYSTICK

A

Disassembly and Assembly NOTE: The following shows the procedure on the R.H. joystick. The procedure for the L.H. joystick is the same except it does not have the horn switch in the handle.

Remove the cap from the control lever [A].

CD–08508

Remove the screws from the handle [B].

B

CD–08509

C

Remove the screws from the horn wires [C].

NOTE: Mark the wires for the correct installation.

CD–11679

D

Remove the rubber boot from the control lever [D].

CD–11680

Revised June 92

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225 (S/N 12000 & Above) Excavator Service Manual

JOYSTICK (Cont’d)

A

Disassembly and Assembly (Cont’d) Remove the joystick lever and the lock nut (Item 1) [A].

1

Remove the adjustment nut (Item 2) [A] and the horn wires.

2

Remove the push rod disc (Item 3) [A].

3

Installation: Apply grease to the disc contact surface.

Tighten the disc until it touches the push rods equally then tighten the adjustment nut to 43 in.–lbs. (5 Nm) torque.

NOTE: To test the joystick for proper rod disc adjustment. Blow air at 10 PSI into the P port of the joystick and adjust the disc downward until air starts to flow out of ports 1, 2, 3 & 4.

Back off the rod disc until the air flow stops.

Tighten the adjustment nut to 43 in.–lbs. (5 Nm) torque.

CD–11681

B

Remove the joint [B].

Installation: Tighten the joint to 30 in.–lbs. (3,4 Nm) torque.

CD–11682

Remove the plate [C].

C

Installation: Align the hole in the plate with the valve body hole.

CD–11683

D

Use screwdrivers to remove the plugs [D].

CD–11684

Revised June 92

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225 (S/N 12000 & Above) Excavator Service Manual

JOYSTICK (Cont’d)

A

Disassembly and Assembly (Cont’d) Remove the push rod from the plug [A].

Check the push rod crown for wear [A].

CD–11685

B

Remove the O–ring (Item 1) [B] and seal (Item 2) [B] from the plug.

2 1

CD–11686

C

Installation: Be sure the seal lip is toward the valve body [C].

Seal Lip

O–Ring

B–13517

D

Remove the spool assembly from the valve body [D].

NOTE: Install the spool assemblies in the same location from where they are removed.

CD–11687

Revised June 92

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225 (S/N 12000 & Above) Excavator Service Manual

JOYSTICK (Cont’d)

A

1

Disassembly and Assembly (Cont’d) Push the spring seat down to remove the washers (Item 1) [A].

CD–11688

B

Remove the spring seat, spring and washers from the spool [B].

CD–11689

Remove the two bolts from the port plate [C].

C

Installation: Tighten the bolts to 26 in.–lbs. (3 Nm) torque.

CD–11690

D

Remove the port plate (Item 1) [D], and O–ring (Item 2) [D] from the valve body.

1

Use a new O–ring during assembly.

Installation: Align the dowel pin (Item 3) [D] with the dowel pin hole in the valve body.

3

2

Dowel Pin Hole

CD–11691

Revised June 92

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225 (S/N 12000 & Above) Excavator Service Manual

CONTROL LEVERS

A

Removal and Installation Loosen the two bolts to remove the arm rest [A].

CD–10620

Remove the blade knob and throttle knob [B].

B

Remove the mounting screws from the console cover.

N–10621

Remove the instrument panel mounting screws [C].

C

Remove the instrument panel.

N–10622

D

Remove the wire harness from the instrument panel socket [D].

N–10623

Revised June 92

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225 (S/N 12000 & Above) Excavator Service Manual

CONTROL LEVERS (Cont’d)

A

Removal and Installation (Cont’d) Remove the nut from the ignition switch [A].

Push the ignition switch into the console cover.

Remove the console cover.

N–10624

B

Throttle Lever Remove the nut from the throttle linkage [B].

CD–10625

Remove the nut from the throttle lever pivot [C].

C

Installation: Tighten the nut to allow throttle movement with 15 lbs. pressure.

N–10626

D

Remove the flat washer (Item 1) [D], the wave washer (Item 2) [D] and the lever (Item 3) [D].

3

2 1 N–10627

Revised June 92

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225 (S/N 12000 & Above) Excavator Service Manual

CONTROL LEVERS (Cont’d)

A

Removal and Installation (Cont’d) Remove the friction washer [A].

NOTE: The spring (Item 1) [A] returns the throttle lever from the stop position to the idle position.

1

N–10628

B

Loosen the lock nut (Item 1) [B] to remove the throttle cable form the right console.

N–10629

C

Blade Lever Hold the lock nut and turn the bolt form the blade lever [C].

N–10630

Remove the blade cable from the lever [D].

D

Remove the lever mounting bolt (Item 1) [D] to remove the blade lever.

1

N–10631

Revised June 92

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225 (S/N 12000 & Above) Excavator Service Manual

RIGHT CONSOLE

A

Removal and Installation Remove the console cover. (See Page 3–8.)

Remove the swing motor cover. (See Page 5–3.)

Remove the fuse panel mounting bolts [A].

CD–10632

Remove the ground wire [B].

B

CD–10633

Disconnect the horn wire [C].

C

CD–10634

D

Remove the right hand control drain hose (Item 1) [D] from the tee below the console.

1

CD–10635

Revised June 92

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225 (S/N 12000 & Above) Excavator Service Manual

RIGHT CONSOLE (Cont’d)

A

Removal and Installation (Cont’d) Remove the hand control hoses from the control valve [A].

CD–10636

Remove the mounting bolts form the right console [B].

B

Remove the right console.

See Page 3–4 for Disassembly and Assembly procedure of joystick.

CD–10637

Parts Identification RIGHT JOYSTICK 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Plug Rod Seat Spring Bellows Nut Actuator Joint Plate Bolt Handle Assembly

5 6

11

7 1

8

2 9

3 4

4

9 10 Revised June 92

–3–12–

D–01972

225 (S/N 12000 & Above) Excavator Service Manual

FOOT PEDAL AND STEERING LEVERS

A

Removal and Installation Remove the center floor panel. (See Page 5–2.)

Disconnect the linkage rods from the control valve spools [A].

Remove the mounting bolts [A].

CD–10647

Remove the mounting bolts from the front floor panel [B].

B

Remove the boom swing linkage from the right foot pedal.

CD–10648

Lift the steering levers and floor panel from the machine [C].

C

CD–10649

Remove the nuts (Item 1) [D] from the linkage bolts.

D

Remove the linkage bolts from the bracket.

1

1

CD–10650

Revised June 92

–3–13–

225 (S/N 12000 & Above) Excavator Service Manual

FOOT PEDAL AND STEERING LEVERS (Cont’d)

A

Bushing Removal and Installation Remove the nut from the pivot bolt [A].

CD–10651

Remove the pivot bolt and washers from the pedal bushing [B].

B

NOTE: Install the washers in the same location during assembly of all pivot bushings.

CD–10652

C

Remove the pivot bushing [C].

NOTE: Put oil on the O–rings during assembly.

Remove the bolt (Item 1) [C] from the top side of the floor plate.

1

CD–10653

Added June 92

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225 (S/N 12000 & Above) Excavator Service Manual

FINAL DRIVE

A

Removal and Installation Remove the bolts from the track frame cover [A].

Installation: Tighten the bolts to 15–18 ft.–lbs. (20–15 Nm) torque.

CD–08564

Remove the cover.

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 5–11.)

When making repairs on 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.

N–08566

C

I–2003–0284

Mark the hoses for correct installation.

Disconnect the hoses from the drive motor [B].

Loosen and remove the final drive mounting bolts [C].

Installation: Put LOCTITE #242 on the bolts and tighten to 48–55 ft.–lbs. (65–75 Nm) torque.

CD–08567

D

Remove the motor, sprocket and reduction gear assembly from the track frame [D].

CD–08568

Added June 92

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225 (S/N 12000 & Above) Excavator Service Manual

FINAL DRIVE (Cont’d) Parts Identification 1

TRAVEL MOTOR (With Brake) (NORDIC) 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

2 3

Upper Plate Spring Cylinder Block Piston Disc Retainer Shaft Bearing Seal Nut Gear Cover Floating Seal

4 5 6 1

13

7 8

8 10

6

7

1 11 11

1 8 11

8 12

D–02104

1

TRAVEL MOTOR (Without Brake) 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

2

Plate Spring Cylinder Block Retainer Shaft Bearing Seal Nut Gear Cover Floating Seal

3 4 1 5

11

6

7

6 8

4

6

9

1 9

9 1

6 10

D–01974

Added June 92

–3–16–

225 (S/N 12000 & Above) Excavator Service Manual

FINAL DRIVE (Cont’d) Parts Identification (Cont’d) TRAVEL MOTOR (With Brakes) 1.

2.

3.

4.

5.

6.

7.

8.

9.

Cap O–ring Spring Seat Plug Poppet Check Valve Body Pin

1 2 3 4 5 2 3 6

7

6 3 2 5 5 8

9 5 2

2

4 3 3

2 1

B–13372

Added June 92

–3–17–

225 (S/N 12000 & Above) Excavator Service Manual

FINAL DRIVE (Cont’d) Parts Identification (Cont’d) TRAVEL MOTOR (With Brakes) 1.

2.

3.

4.

5.

6.

7.

8.

9.

Cap O–ring Spring Seat Plug Poppet Check Valve Body Pin

1 2 3 4 5 2 3 6

7

6 3 2 5 5 8

4

9

3 2 1 B–12777

Added June 92

–3–18–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR

A

When making repairs on 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.

I–2003–0284 P–01759

The following tools will be needed for disassembly and/or reassembly purposes:

B

Floating Seal installation tool (MEL1412, available from OTC Service Tools) (See Page 3–31) and bearing nut tool. (See Page 3–28) (make locally.)

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 through 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.

NOTE: DO NOT use any type of clamp tool on the spool. The spool must be replaced if it has scratches or any other damage to the machined surfaces.

Hardened Pin

P–00338

Added Apr. 93

–3–19–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Disassembly (Cont’d)

2

Remove the spring (Item 1) [A] and the poppet (Item 2) [A] from the ends of the spool.

2

1

1

Use solvent and clean and dry all spool components.

P–00340

B

Remove the six bolts holding the valve end plate onto the housing [B].

P–00341

C

Lift off the valve end plate and remove the two dowel pins (Item 1) [C] and the O–ring (Item 2) [C].

3

NOTE: The dowel pin (Item 3) [C] is staked into the valve plate end cover, do not remove unless damaged.

1

2

1 P–00342

Remove the bearing from the valve end plate [D].

D

Use a slide hammer bearing puller.

P–00344

Added Apr. 93

–3–20–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Disassembly (Cont’d)

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] and the three pins (Item 4) [C] from the piston housing (Item 5) [C]

C 5 3

1

1 1 P–00348

D

NOTE: The spring inside the piston housing is under pressure, use care when removing the snap ring from the piston housing.

Install a bolt and flat washer through 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 [D].

P–00350

Added Apr. 93

–3–21–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Disassembly (Cont’d) Disassemble the snap ring (Item 1) [A], collar (Item 2) [A], spring (Item 3) [A] and the collar (Item 4) [A] from the piston housing.

3 1

4

The following 4 steps (Page 3–22 [B] through Page 3–23 [A]) are for drive motors with brakes; for drive motors without brakes, skip to step [B] on Page 3–23.

2

P–00354

B

Remove the eight springs from the brake piston [B].

B–13850

C

Remove the brake piston from the drive motor hub by blowing compressed air into the park brake release port [C].

Park Brake Release Port

Remove the two O–rings (Items 1 & 2) [D] from the brake piston.

B–13851

D

2

1 B–13852

Added Apr. 93

–3–22–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Disassembly (Cont’d) Remove the brake disc from the drive motor hub [A].

B–13853

B

Clamp the housing flange into a vise and remove the plug from the side of the housing [B].

P–00464

C

If the drive motor lube oil has not already been drained, do so now.

Remove the two plugs from the cover of the drive motor housing [C]. Drain the fluid into a container. Dispose of this fluid properly.

P–00433

Install two bolts (PT 3/8 mm threads) into the plug holes in the cover [D]. Install a flat blade screw driver tip into the hole in the side of the housing and use a bar to turn the end cover [D]. Turn the end cover until the lock wire starts to come out of the housing hole [D].

D

P–00466

Added Apr. 93

–3–23–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Disassembly (Cont’d) Pull the lock wire out while turning the end cover until the wire is completely removed from the housing [A].

P–00468

Remove the drive motor from the vise and set on a flat surface.

B

Remove the end cover from the drive motor housing [B].

P–00461

Remove the O–ring from the edge of the cover [C].

C

P–00472

D

Remove the thrust plate from the planetary assembly [D].

P–00473

Added Apr. 93

–3–24–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

220ServiceManual#6720874S/N508312000&Above–DriveSystemSectionPart1of2

Disassembly (Cont’d) Remove the three planetary gears from the planetary holder [A].

P–00475

Remove the drive gear shaft from the housing [B].

B

P–00474

Remove the planetary holder from the housing [C].

C

P–00477

D

Remove the three needle bearings and bearing races from the holder [D].

Spring Pins

NOTE: The spring pins do not need to be removed or replaced unless damaged.

P–00479

Added Apr. 93

–3–25–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Disassembly (Cont’d) Remove the drive gear from the center of the planetary gears [A].

NOTE: The snap ring does not need to be removed from the gear unless it is damaged.

Snap Ring

P–00470

B

Remove the four screws holding the retaining ring to the inner planetary [B].

NOTE: These screws have thread lock applied and are difficult to remove. Apply heat to the heads of the screws to soften the adhesive.

P–00478

Remove the retaining ring [C].

C

P–00481

Remove the four gears, needle bearings, bearing races and the thrust washers [D].

D

P–00480

Added Apr. 93

–3–26–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Disassembly (Cont’d) Remove the plug from the notched area in the travel motor flange [A].

P–00485

B

Remove the 131 or 132 steel balls that retain the drive motor housing to the drive motor hub [B] & [C].

The balls must be removed through the plug hole. Use solvent to flush oil off of the steel balls and the mating surfaces of the bearing and housing.

Use a magnet to remove the exposed steel balls from the plug hole. Use short bursts 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.

NOTE: Use care with the following process not to allow the wire to become lodged or to break off inside the motor.

P–00487

Use a length of 16 gauge mechanics wire and bend a tight, closed loop at one end of the wire. Insert the wire into the plug hole and carefully push the wire around the diameter of the bearing to force the steel balls to the hole.

C

Wire Steel Balls

Remove the exposed balls with a magnet and continue this process until all 132 balls are removed and the end of the wire is visible through the hole. Carefully remove the wire, DO NOT break the wire off inside the housing when removing the wire [C].

NOTE: If balls seem to be lodged in the housing, it may be necessary to use a press or a three jaw puller to center the ball bearing groove into the center of the plug hole.

MC–01678

Use a three jaw puller to remove the travel motor housing [D].

D

P–00488

Added Apr. 93

–3–27–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Disassembly (Cont’d) Remove the three set screws that retain the bearing nut from turning [A].

P–00486

Use the bearing nut socket [C], to remove the bearing nut from the drive motor hub [B].

B Bearing Nut Socket Bearing Nut

B–13762

C

Bearing nut socket dimensions [C].

12.8 13 mm

This tool can be made at a local machine shop.

16 mm 4 Places

Weld

152 mm 146 mm

90 mm 10 mm

9 mm 100 mm MC–01696

Carefully remove the double race bearing from the hub [D].

D

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–00483

Added Apr. 93

–3–28–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Disassembly (Cont’d) Remove the top half of the floating seal from the hub [A].

P–00490

Pry the lower half of the floating seal from the hub [B].

B

P–00492

Use a punch to tap the rotating group drive shaft and bearing out of the hub [C].

C

P–00491

D

Remove the drive shaft and bearing from the hub [D].

P–00493

Added Apr. 93

–3–29–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Disassembly (Cont’d) Remove the seal from the hub [A].

P–00496

Use a press to press the drive shaft out of the bearing [B].

B

P–00487

Added Apr. 93

–3–30–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Assembly Install a new bearing onto the rotating group drive shaft [A].

NOTE: Use a press tube that contacts the inner bearing race.

P–00494

Floating seal installation tool [B].

B

This tool (MEL1412) is available through OTC Service Tools.

7.87’’ (200 mm) 7.13’’ (181 mm)

0.27’’ (6,8 mm)

0.20’’ (5 mm) 0.67’’ (17 mm)

6.73/6.74’’ (171,0/171,2 mm) 6.64/6.65’’ (168,7/168,9 mm)

0.34’’ (8,6 mm) 6.73/6.74’’ (171,0/171,2 mm)

6.22/6.23’’ (157,9/158,1 mm)

15°

RO 0.12’’ (,3 mm) RO 0.08’’ (,2 mm) MC–01678

Put grease on the floating seal O–ring and on the floating seal surface of the drive motor hub.

C

Install the floating seal into the installation tool [C].

P–00333

Turn the seal and installation tool over and set it in place in the hub [D].

D

Using both hands, evenly press down on the installation tool to insert the floating seal into the hub [D].

The tool presses against the O–ring and the floating seal housing and guides it into the hub.

P–00498

Added Apr. 93

–3–31–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Assembly (Cont’d) Apply grease to the O–ring of the other half of the floating seal.

Install the top half of the floating seal onto the previously installed floating seal half [A].

NOTE: The O–ring of this half of the floating seal faces upwards.

P–00490

Carefully install a new double roller bearing onto the hub [B].

B

Install the bearing nut onto the bearing, tighten the nut so that the bearing is seated against the hub but not tight.

The bearing nut will be tightened more in a later step.

P–00483

Press the drive motor housing onto the hub [C].

C

NOTE: Make sure that the housing is positioned over the bearing and the top half floating seal.

P–00499

Added Apr. 93

–3–32–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Assembly (Cont’d) Use a spring scale to check the housing start up load [A].

Use the bearing nut socket to tighten the bearing nut until there is 10–15 ft.–lbs. (1.5–2.0 kgf) force need for housing start up load.

P–00504

After the correct start up load has been set, install the three set screws to retain the bearing nut [B].

B

Tighten the set screws to 21–29 ft–lbs. (29–39 Nm) torque.

P–00502

Use a center punch to stake the hub to the set screw so that the set screws will not come loose [C].

C

P–00503

Turn the motor on its side and install the 132 steel balls into the housing hole [D].

D

NOTE: If the steel balls will not easily flow into the bearing groove, it may be necessary to use a press or a three jaw puller to center the ball bearing groove into the center of the plug hole.

P–00363

Added Apr. 93

–3–33–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Assembly (Cont’d) Install the plug into the housing [A].

Tighten the plug to 5–6 ft.–lbs. (6–8 Nm) torque.

P–00485

B

Apply a light coating of petroleum jelly to the needle bearing and install the bearings into the gears [B].

Install the bearing race into the needle bearings [B].

P–00482

C

Apply a small amount of petroleum jelly on the thrust washer. Install the thrust washer into the notched groove in the side of the gear and the beveled edge of the thrust washer will face up as viewed in [C].

Turn the gear assemblies over and install them onto the pinion stub shafts on the hub. The beveled edge of the thrust washer must match up to the beveled edge of the stub shaft at the hub face and the thrust washers must remain seated in the notched groove of the gear.

Beveled Edge

Notched Groove

If installed correctly, the top face of the gear will be slightly lower than the top face of the stub shaft.

P–00484

Install retaining ring on the top of the stub shafts [D].

D

P–00481

Added Apr. 93

–3–34–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Assembly (Cont’d) Clean the screw threads of any dried on thread locking compound and inspect the screws. Replace screws if any damage is found.

Put LOCTITE #262 on the threads of the screws. Install the four screws through the retainer ring [A].

Tighten the screws to 36–72 ft.–lbs. (4,1–8,1 Nm) torque.

P–00476

Install the snap ring onto the drive gear (if previously removed) and install the drive gear into the center of the planetary gears [B].

B

NOTE: The gear must be installed with the narrow section of the gear upwards (when viewed using the snap ring as the dividing line).

Snap Ring

P–00470

Install new spring pins into the stub shafts (if the spring pins were removed) and install the planetary holder onto the drive gear [C].

C

P–00477

Install the bearing race onto the stub shafts. Put a small mount of petroleum jelly on the needle bearings and install over the bearing races. Install the planetary gears over needle bearings [D].

D

P–00475

Added Apr. 93

–3–35–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Assembly (Cont’d) Install the drive shaft into the planetary gears [A].

P–00474

Put the four holes in the thrust plate over the spring pins in the stub shafts [B].

B

P–00473

C

Put petroleum jelly and install a new O–ring onto the end cover [C].

P–00471

Install the end cover onto the housing [D].

D

P–00467

Added Apr. 93

–3–36–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Assembly (Cont’d) Clamp the drive motor in a vise and install two bolts (3/8 PT thread) into the end cover [A].

Bend a 1/4 inch hook in the end of the lock wire. Insert the hook end of the lock wire into the hole in the side of the motor and into the slot on the edge of the end cover.

Turn the end cover with a bar and insert the lock wire into the hole as it moves around the end cover [A].

P–00469

B

Install the plug into the lock wire hole [B].

Tighten the plug to 72–96 in.–lbs. (8,1–10,8 Nm) torque.

P–00464

C

Remove the drive motor from the vise.

Set the motor on the end cover on a flat surface.

Put a small amount of petroleum jelly on the outer diameter of the seal and install the seal into the drive motor [C].

NOTE: The lip side of the seal faces up as viewed in [C].

Put a small amount of petroleum jelly on the seal lips.

P–00501

Put a small amount of petroleum jelly on the end of the rotating group drive shaft and press the shaft and bearing into the hub [D].

D

NOTE: Make sure that the end of the shaft is aligned through the center of the seal prior to pressing the shaft in place.

P–00495

Added Apr. 93

–3–37–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Assembly (Cont’d) The following 4 steps are for drive motors with brakes (Page 3–38 [A] thru 3–38 [D]); for drive motors without brakes, skip to step [A] on Page 3–39.

Install the brake disc plate into the drive motor hub [A].

B–13853

Install new O–rings (Items 1 & 2) [B] onto the brake piston.

B

2

1 B–13852

C

Apply oil to the inner and outer diameter of the brake piston and to the O–rings.

Install the brake piston into the drive motor hub [C].

B–13851

Install the eight springs into the brake piston [D].

D

The following steps apply to travel motors with or without brakes.

B–13850

Added Apr. 93

–3–38–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Assembly (Cont’d) Install the collar (Item 1) [A], spring (Item 2) [A], collar (Item 3) [A] and snap ring (Item 4) [A] into the piston housing.

3 1

Install a bolt and flat washer through the spacers and the spring. Insert these parts through 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 contract with the spring and install the snap ring. Loosen the nut and remove the bolt and washer.

4

2

P–00354

B

Assemble the rotating group by applying petroleum jelly to the three pins (Item 4) [B]. Insert the pins (Item 4) [B] into the notches in the splined inner diameter of the piston housing (Item 5) [B]. Set the conical spacer (Item 3) [B] over the pins (Item 4) [B] and on top of the piston housing (Item 5) [B]. Insert the pistons (Item 2) [B] into the retainer plate (Item 2) [B]. Apply clean hydraulic fluid to the outer diameter of the piston (Item 1) [B] and insert the pistons into the piston housing (Item 5) [B].

5 3

1

2 4 P–00348

C

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 [C].

On drive motors with brakes: Make sure that the splined diameter of the piston housing meshes with the splined inner diameter of the brake disc.

P–00345

Added Apr. 93

–3–39–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

Assembly (Cont’d) Install a new O–ring into the groove in the motor [A].

P–00305

B

Press the bearing into the valve end plate [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

C

Apply a film of petroleum jelly to the steel face of the valve plate. Install the valve plate (bronze side faces upwards) onto valve end plate [C]. The notch in the valve plate must align with the dowel pin in the valve end plate.

On drive motors with brakes: Install the small O–ring onto the brake actuating port gland.

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

On drive motors with brakes: Make sure that the eight brake piston springs are inserted into the holes int he valve end plate and the brake piston.

Dowel Pin

P–00310

Added Apr. 93

–3–40–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

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

B

Apply oil to the outer diameter of the poppets and install the poppets (tapered end in first) into the spool [B]. Insert the spring into the cavity of the poppets. Install a new O–ring onto the end plugs and install the plug [B].

P–00340

C

Insert a hardened dowel pin through the hole in the spool 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.

NOTE: DO NOT use any type of clamp tool on the spool. The spool must be replaced if it has scratches on any other damage to the machined surface.

P–00338

Apply oil to the spool and install the spool into the valve end plate [D].

D

Spool Washer

Install the washer over the end of the spool and the spring [D].

Spring

P–00337

Added Apr. 93

–3–41–

225 (S/N 12000 & Above) Excavator Service Manual

DRIVE MOTOR (Cont’d)

A

220ServiceManual#6720874S/N508312000&Above–DriveSystemSectionPart2of2

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 the drive motor. See information below for oil installation and checking procedure.

B

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.

FINAL DRIVE CASE Check Oil Level

P–00335

Put the machine on a flat level surface with the plugs position as shown in figure [C].

C

Remove the plug (Item 1) [C].

Add oil through the hole if the oil level is below the hole.

(See FUEL, COOLANT AND LUBRICANT Page 8–8.)

Install and tighten the plug.

1

Repeat the procedure for the other side.

2

Draining Final Drive Case See the SERVICE SCHEDULE Page 1–1 for correct service interval.

N–10460

Put machine on a flat level surface with the plugs position as shown in figure [C].

Remove the bottom plug (Item 2) [C] and the top plug (Item 1) [C].

After all the gear lube is removed, install and tighten the bottom plug.

Add .55 quarts (0,5 L) of oil to the top plug hole. Install the plug.

Repeat the procedure for the other side.

Added Apr. 93

–3–42–

225 (S/N 12000 & Above) Excavator Service Manual

UPPER WORKS AND SWING SYSTEM Page Number CENTER SWIVEL JOINT Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–35 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–33 SWING MOTOR Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4–2 4–1 4–3 4–12

SWING GEAR BRAKE (NORDIC OPTION) Solenoid Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–26 UPPER WORKS AND SWING CIRCLE GEAR Alignment Pins (Not Threaded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alignment Pins (Threaded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Revised Jan. 94

–4––1–

4–32 4–31 4–27 4–30 4–28

UPPER WORKS & SWING SYSTEM

225 (S/N 12000 & Above) Excavator Service Manual

–4–0–

225 (S/N 12000 & Above) Excavator Service Manual

SWING MOTOR

A

Removal and Installation

1

Remove the seat and swing motor cover. (See Page 5–1.)

When making repairs on 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.

CD–10700

B

I–2003–0284

Mark the hoses for correct installation.

1

NOTE: Use caps and plugs on all hydraulic hoses and fittings.

2

Remove the pressure hoses (Item 1) [A] from the swing motor.

Remove the center swivel joint drain hose (Item 1) [B] and swing motor drain hose (Item 2) [B].

CD–10654

Remove the mounting bolts from the swing motor [C].

C

CD–10655

Remove the swing motor.

D

CD–10656

–4–1–

225 (S/N 12000 & Above) Excavator Service Manual

SWING MOTOR (Cont’d) Parts Identification SWING MOTOR (Without Brakes) 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Snap Bearing Coupler O–ring Flange Spacer Nut Housing Seal Cover Shaft

1 2

3 1

7 2

4 5

8

4

9

6

4 2

4

10 11 D–02105

SWING MOTOR (With Brakes) 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Snap Bearing Coupler O–ring Flange Spacer Nut Housing Seal Cover Shaft

1 2

3 1

4

4

4 1 5 6

11

2

7 12

7 4

5 2

8 9 10

5

5 1

13

14

D–02108

–4–2–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (WITH OR WITHOUT BRAKES)

A

Disassembly The following procedure contains information for the repair of the gear box with or without brakes. The photos used may appear different than the unit you are repairing, but the procedure is the same. Some steps will be marked as for units with brakes only or without brakes only so follow the steps closely.

CD–13073

When making repairs on 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.

B

I–2003–0284

Drain the lubrication oil from the gear box case by removing one of the side plugs. Turn the case on its side and drain the oil out of the drain hole.

Make an alignment mark down the side of the gear box for correct assembly.

1

Remove the eight bolts from the top housing flange [A].

CD–13074

Remove top housing flange assembly [B].

C

Remove the O–ring (Item 1) [B] from the mating housing face.

For With Brakes Only Remove the eight bolts from the center housing flange [C].

N–13075

For With Brakes Only

D

Remove the center housing flange assembly [B].

CD–13076

Revised Jan. 94

–4–3–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Disassembly (Cont’d) For With Brakes Only Remove the brake coupling shaft from the top of the lower housing [A].

N–13077

B

For Without Brakes Only Remove the center spacer ring from the top of the lower housing [B].

CD–13060

C

Remove the sun gear from the lower housing [C].

CD–13067

Remove the ring gear spacer from the top of the lower housing [D].

D

CD–13068

Revised Jan. 94

–4–4–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Disassembly (Cont’d) Remove the planetary gear assembly from the lower housing [A].

NOTE: The planetary gear assembly components are not serviceable separately. If any of these parts are damaged, a complete planetary gear assembly must be ordered from Melroe Parts Operation.

CD–13080

The bearing retainer nut is staked to the output shaft. To allow for easier removal of the nut, use a wedge shaped chisel inserted into the groove in the output shaft. Drive the chisel into the shaft groove to displace the metal from the factory stake in the bearing retainer nut [B].

B

CD–13061

Use bearing nut removal tool (MEL1417) and remove the bearing nut from the output shaft [C].

C

Use shaft retainer tool (MEL1419) to hold the gear end of the shaft from rotating while removing the bearing nut.

Fasten the housing to the shaft retaining tool and fasten the shaft retaining tool to a stationary bench.

P–01918

D

Press the output shaft from the lower housing [D].

CD–13082

Revised Jan. 94

–4–5–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Disassembly (Cont’d) Use a two jaw puller and remove the dust cap, dust cup and the tapered bearing cone from the output shaft [A].

CD–13083

B

Remove the tapered bearing cone from the lower housing [B].

CD–13084

Remove the bearing spacer from the lower housing [C].

C

CD–13085

Remove the two O–rings from the internal diameter of the bearing spacer [D].

D

CD–13062

Revised Jan. 94

–4–6–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Disassembly (Cont’d) Use an internal puller and remove the lower bearing cup from the lower housing [A].

CD–13063

Use a press and remove the opposite side tapered bearing cup and the seal retainer [B].

B

CD–13064

Remove the O–ring from the outer diameter of the seal retainer and remove the seal from the inner diameter of the seal retainer [C].

C

CD–13065

The following eight steps; Page 4–5 [D] through Page 4–11 [C] are for disassembly of gear boxes equipped with brakes. For gear boxes without brakes, go to Page 4–11 [D].

D

Use a press and compress the spring retainer ring.

Remove the snap ring from the center housing [D].

Release the pressure on the press.

N–13086

Revised Jan. 94

–4–7–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Disassembly (Cont’d) Remove the spring retainer ring [A].

N–13087

B

Remove the six springs from the brake piston [B].

N–13088

Turn the center housing over and remove the snap ring [C].

C

N–13089

Remove the brake disc retaining ring from the center housing [D].

D

N–13090

Revised Jan. 94

–4–8–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Disassembly (Cont’d) Remove the brake discs from the center housing (six external tooth and five internal tooth discs) [A].

N–13091

B

Use a press and remove the brake piston from the center housing [B].

N–13092

Remove the two O–rings and the two back–up rings from the internal diameter of the center housing [C].

C

N–13093

Remove the snap ring from the top housing flange [D].

D

CD–13094

Revised Jan. 94

–4–9–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Disassembly (Cont’d) Use a press and remove the input shaft and bearings from the top housing flange [A].

CD–13095

Remove the seal from the top housing flange [B].

B

CD–13096

Use a two or three jaw bearing puller and remove the two bearings from the input shaft [C].

C

CD–13097

Remove the snap ring from the internal diameter of the input shaft [D].

D

CD–13098

Revised Jan. 94

–4–10–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Disassembly (Cont’d) Remove the plug from the input shaft [A].

CD–13099

B

Remove the O–ring from the internal diameter of the input shaft [B].

CD–13100

Revised Jan. 94

–4–11–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Assembly Install the seal into the output spacer ring [A].

CD–13101

Put petroleum jelly on the O–ring and install the O–ring onto the outer diameter of the output spacer ring [B].

B

CD–13102

C

Put the output spacer ring assembly into the lower housing [C]. Push the spacer ring in until it is flush with the internal shoulder of the housing.

NOTE: The seal side of the spacer ring assembly contacts the internal shoulder of the housing.

CD–13103

Install the outer bearing cup into the lower housing [D].

D

CD–13104

Revised Jan. 94

–4–12–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Assembly (Cont’d) Press the outer bearing cup into the lower housing until it is flush with the spacer ring [A]

CD–13105

Turn the lower housing over and install the inner bearing cup into the lower housing [B]

B

CD–13106

Press the inner bearing cup into the lower housing until it is flush with the flange [C].

C

CD–13107

Put the outer bearing cone on a support tube that contacts only the inner bearing race [D].

D

CD–13108

Revised Jan. 94

–4–13–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX (Cont’d)

A

Assembly (Cont’d) Put the lower housing on the bearing [A].

CD–13109

Do not install the O–rings into the bearing spacer at this time. They will be installed later.

B

Install the bearing spacer into the lower housing [B].

NOTE: The O–ring end of the bearing spacer will face up.

CD–13110

Install the inner bearing cone into the top of the lower housing [C].

C

CD–13111

Added Jan. 94

–4–14–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Assembly (Cont’d) Press down on the top bearing cone using 1100 lbs. (500 Kg) of pressure [A].

Manually rotate the lower housing to determine the smoothness and rotational resistance of the lower housing.

CD–13112

B

If the rotation of the lower housing is difficult, install 0.039’’ (0,1 mm) shim(s) (Melroe P/N 13EM–4561) between the bearing spacer ring and the bearing cone [B].

If the lower housing rotates too easily, remove the bearing spacer ring and lap the end of the spacer ring until rotational resistance is adequate [B].

CD–13113

C

Install the spacer on the output shaft [C].

CD–13114

D

Install the outer dust cap on the output shaft [D].

CD–13115

Added Jan. 94

–4–15–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Assembly (Cont’d) Install the inner dust cup on the output shaft [A].

CD–13116

B

Fill the inner dust cup with a quality bearing grease [B].

CD–13117

C

Pack the bearing cone with a quality bearing grease and install the outer bearing cone on the output shaft [C].

CD–13118

Install the bearing spacer (and any bearing shims, if needed) on the output shaft [D].

D

The O–ring end of the spacer ring faces up.

CD–13119

Added Jan. 94

–4–16–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Assembly (Cont’d) Put petroleum jelly on the two O–rings. Carefully install the two O–rings over the threaded shaft and down to the bearing spacer.

Use a tool with a curved smooth end to push the O–rings into the bearing spacer [A].

CD–13066

Put a quality bearing grease on the two bearing cups.

Install the lower housing on the output shaft [B].

B

CD–13120

Pack the bearing cone with a quality grease and install the inner bearing cone on the output shaft and down on the bearing cup [C].

C

CD–13121

D

Install the bearing nut on the output shaft [D].

Use bearing nut tool (MEL1417) and tighten the bearing nut to 325–400 ft.–lbs. (450–550 Nm) torque.

Use the shaft retainer tool (MEL1419) to hold the gear end of the shaft from rotating while installing the bearing nut.

Fasten the housing to the shaft retainer tool and fasten the shaft retainer tool to a stationary bench.

P–1918

Added Jan. 94

–4–17–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Assembly (Cont’d) Use a center punch and stake the bearing nut to the output shaft to prevent the nut from loosening [A].

CD–13123

The following 12 steps, Page 4–18 [B] through Page 4–21 [B] is for the assembly of gear boxes with brakes.

For gear boxes without brakes, go to Page 4–21 [C].

B

Apply petroleum jelly to the O–rings and back–up rings and install the two O–rings and the two back–up rings into the center (brake) housing [B].

NOTE: The back–up rings are to the outer edges and the O–rings to the inner edges of the O–ring grooves.

N–13124

C

Apply petroleum jelly to the outer diameter of the brake piston. Install the brake piston into the center housing [C].

N–13125

Use a press and push the brake piston in until it contacts the inner housing flange [D].

D

CD–13126

Added Jan. 94

–4–18–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Assembly (Cont’d) Install the six springs into the brake piston holes [A].

N–13127

The springs should be installed into the brake piston as shown [B].

B Springs

Springs

MC–01761

C

Install the spring retainer into the housing [C].

N–13128

Use a press and compress the spring retainer and springs downward so the snap ring can be installed into the center housing [D].

D

N–13129

Added Jan. 94

–4–19–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Assembly (Cont’d) Rotate the mounting tabs of the snap rings so that they are positioned in the housing drain port openings, as shown [A].

N–13130

B

Use a portable hand pump using SAE 30 W motor oil and apply 735 PSI (50 bar) pressure to activate the brake piston and compress the brake springs [B].

This will allow easier assembly of the additional brake components.

N–13131

C

Install the brake coupling shaft into the brake housing [C].

N–13132

Install an external tooth bronze brake disc into the housing first, then install an internal tooth steel disc into the housing and over the brake coupling shaft [D].

D

Alternate the brake discs until six external tooth and five internal tooth discs are installed.

N–13133

Added Jan. 94

–4–20–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Assembly (Cont’d) Install the spacer ring into the brake housing [A].

N–13134

B

Install the snap ring into the brake housing [B].

Release the pressure from the portable hand pump and allow the brake piston to pressurize the brake discs.

N–13135

C

Apply petroleum jelly to the O–ring and install the O–ring into the input shaft [C].

CD–13136

Install the plug into the internal diameter of the input shaft [D].

D

CD–13137

Added Jan. 94

–4–21–

225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Assembly (Cont’d) Install the snap ring into the input shaft [A].

CD–13138

Press the input shaft into the new bearing [B].

B

CD–13139

Turn the input shaft over and press the input shaft into the second new bearing [C].

C

CD–13140

Apply petroleum jelly to the internal and external surfaces of the new seal and install the seal into the top housing flange [D].

D

CD–13141

Added Jan. 94

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225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Assembly (Cont’d) Press the input shaft assembly into the top housing flange [A].

CD–13142

Install the snap ring into the top housing flange to retain the input shaft [B].

B

CD–13143

C

Apply petroleum jelly to the O–ring and install the O–ring into the lower housing [C].

CD–13144

Install the planetary gear assembly into the lower housing [D].

D

CD–13145

Added Jan. 94

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225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

Assembly (Cont’d) Install the ring gear spacer to the top of the housing and onto the planetary gears [A].

CD–13146

Install the sun gear into the planetary gears [B].

B

CD–13147

C

For With Brakes Only Install the brake coupling onto the sun gear [C].

N–13148

For With Brakes Only

D

Apply petroleum jelly to the O–ring and install the O–ring into the center (brake) housing [D].

N–13149

Added Jan. 94

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225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BOX ASSEMBLY (Cont’d)

A

220Service Manual #6720874 S/N 508312000 & Above – Upper Works And Swing System Section Part 1 of 2

Assembly (Cont’d) For With Brakes Only Install the center (brake) housing onto the lower housing [A].

Install the eight bolts into the center housing and tighten the bolts to 29–37 ft.–lbs. (40–50 Nm) torque.

N–13150

B

For Without Brakes Only

O–ring

Apply petroleum jelly to the O–rings and install the O–ring into the center spacer.

Install the center spacer onto the lower housing and align the bolt holes [B].

CD–13060

Apply petroleum jelly to the O–ring and install the O–ring into the center (brake) housing or to the center spacer ring.

C

Install the top housing onto the gear box [C].

O–ring CD–13151

Install the eight bolts into the top housing [D]. Tighten the bolts to 27–37 ft.–lbs. (40–50 Nm) torque.

D

CD–13152

Added Jan. 94

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225 (S/N 12000 & Above) Excavator Service Manual

SWING GEAR BRAKE (NORDIC OPTION)

A

The swing motor brake is solenoid operated and is controlled by a push–pull knob (Item 1) [A] located on the top rear surface of the right control console.

Push knob down (normal position) to engage the brake.

1

Pull the knob up to disengage the brake.

N–12413

Solenoid Removal and Installation

B

Lower the boom to the ground.

Stop the engine.

Remove the center floor panel. (See Page 5–2.)

Remove the swing motor cover. (See Page 5–3.)

Disconnect the wire harness from the solenoid [B].

N–12539

C

Remove the solenoid (Item 1) [C] from the solenoid block (Item 2) [C].

2 1

NOTE: Replace the O–rings on the solenoid during installation.

N–12540

Added Jan. 94

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225 (S/N 12000 & Above) Excavator Service Manual

UPPER WORKS AND SWING CIRCLE GEAR

A

This section involves the removal and installation of the complete upperstructure from the track frame.

Removal and Installation Connect a lifting sling to the excavator at the rear of the swing frame and to the lift hook holes in the boom [A].

The boom must be in full raised position and centered to the front of the excavator [B].

N–12217

NOTE: The dimensions shown are approximate only, adjust the lift sling until the excavator is evenly supported.

B

30’’ (762 mm)

42’’ (1067)

108’’ (3103 mm)

AVOID INJURY OR DEATH • Use a lifting fixture with sufficient capacity for the weight of the excavator plus any added attachments.

• Maintain center of gravity and balance when lifting.

• Do not swing boom or upperstructure.

Engage the swing locking lever.

• Never lift with operator on machine.

31.25’’ (794 mm) MC–01561

C

W–2202–0595

Mark the upperstructure to the swing bearing and to the track frame for assembly [C].

N–12218

Partially disassemble the upperstructure from the swing bearing by removing all but four bolts which are spaced at 90 degrees from each other [D]. The upperstructure must be rotated to gain access to the bolts for removal.

Start the engine and run it at idle. Remove a bolt from the swing bearing, then move out of the way of upperstructure and slowly rotate the excavator until access to the next bolt is available. Remove this bolt and continue the above procedure.

D

NOTE: For disassembly safety a minimum of four evenly spaced bolts must remain installed, to be removed later.

Remove the floor mat and floor plate. (See Page 5–2.)

Added Jan. 94

N–12219

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225 (S/N 12000 & Above) Excavator Service Manual

UPPER WORKS AND SWING CIRCLE GEAR (Cont’d)

A

Removal and Installation (Cont’d) Remove the swivel joint retainer bolt and nut [A].

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

CD–13274

B

I–2003–0888

Mark the eight hoses and fittings on the top portion of the swivel for correct installation [B] Remove the hoses from the swivel joint.

Apply a light amount of lifting pressure to the upperstructure with the lift sling. Remove the four remaining bolts holding the upperstructure to the swing bearing.

N–13276

Lift the upperstructure off of the swing bearing. Position the upperstructure onto suitable supporting stands or blocks [C].

C

N–12222

Added Jan. 94

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225 (S/N 12000 & Above) Excavator Service Manual

UPPER WORKS AND SWING CIRCLE GEAR (Cont’d)

A

Swing Bearing Removal Install a c–clamp or other suitable retainer to prevent the swing bearing from turning while being removed [A].

CD–12224

B

Remove the 24 bolts and nuts that hold the swing bearing to the track frame [B].

CD–12225

Mark the top surface of the swing bearing for ease of reassembly. Remove the swing bearing from the track frame [C].

C

CD–12226

Remove the grease cover from the track frame. Clean and inspect the grease cover for damage [D]. Replace if necessary.

D

CD–12227

Added Jan. 94

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225 (S/N 12000 & Above) Excavator Service Manual

UPPER WORKS AND SWING CIRCLE GEAR (Cont’d)

A

Swing Bearing Installation If reusing the existing swing bearing, use top side and edge aligning marks to correctly position swing bearing.

If a new swing bearing is being installed, locate soft zone area [A].

FRONT OF MACHINE

INNER RACE Soft zone is identified by a letter ‘‘S’’ stamped on ring

Install the swing bearing so that the soft zone is positioned to either the L.H. or R.H. side of the excavator.

NOTE: DO NOT locate the soft zone to the front or rear of excavator.

OUTER RACE Soft zone is at the Ball Bearing filler plug

PI–13677

Install the 24 bolts and lock nuts [B].

B

Tighten the locknuts to 90 ft.–lbs. (120 Nm) torque.

CD–12228

Run a tap (12 mm) into the tapped holes in the upperstructure to remove any dried LOCTITE or burrs [C].

C

CD–12229

Grease the swing bearing gear with lubricate grease or equivalent [D].

D

CD–12231

Added Jan. 94

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225 (S/N 12000 & Above) Excavator Service Manual

UPPER WORKS AND SWING CIRCLE GEAR (Cont’d)

A

Swing Bearing Installation (Cont’d) Make three alignment pins by using M12 x 110 mm (P/N 7GM–12110) long bolts. Cut the head off of these bolts at 3.50 in. (90 mm) and then taper this end of the bolts [A].

3.50 in. (90 mm) Install these three pins into the upperstructure at approximately 120° apart [A]. These will act as alignment pins while lowering the house frame onto the swing bearing.

B–13678

B

Install the upperstructure onto the swing bearing using the alignment marks and the alignment pins [B].

Make sure the swing motor gear teeth mesh with the swing bearing teeth and that the swivel joint is centered into the upperstructure access hole.

B–13693

Install the three tapered head alignment bolts (P/N 6535902) through the swing bearing and into the upperstructure [C]. These bolts should be spaced at approximately 120°. This procedure will properly align the upperstructure for correct sing motor gear to the swing bearing ring gear clearance.

C

Tighten these three tapered bolts to 60 ft.–lbs. (81 Nm) torque.

Remove the three, 3.50 inch (90 mm) alignment pins from the upperstructure.

These headless pins can be removed from the bottom.

Install the swivel joint retainer bolt and jam nut. Tighten the jam nut to 75 ft.–lbs. (100 Nm) torque.

N–13278

Install the hoses and fittings that were removed earlier.

Start the engine and run at idle to rotate the upperstructure to gain access to the swing bearing bolt holes.

Apply LOCTITE #242 to the threads of the bolts. Install the bolts into all holes (except the three with the alignment bolts installed). Tighten these bolts to 80 ft.–lbs. (108 Nm) torque.

Remove the three alignment bolts (P/N 6535902). Install the three remaining bolts. Tighten these bolts to 80 ft.–lbs.

(108 Nm) torque.

Install the floor plate and floor mat.

Check the hydraulic fluid level and add as necessary.

Added Jan. 94

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225 (S/N 12000 & Above) Excavator Service Manual

UPPER WORKS AND SWING CIRCLE GEAR (Cont’d)

A

Alignment Pins (Not Threaded)

Alignment Pin Holes

If upper works is being replaced, use the special alignment pins in the holes provided on the following machines [A].

S/N 12001–12059 – DOES NOT have alignment pin holes.

S/N 12060 & Above – HAS alignment pin holes.

NOTE: Be sure to mark all hose locations when replacing the upper works. Refer to the correct section of this Service Manual during assembly of upper works.

MC–01646

Remove any paint from the three alignment pin holes.

Use a chain hoist to lower the upper works on the swing bearing.

Install the three alignment pins in the three holes provided.

Apply LOCTITE #242 to the threads of all the bolts.

If bolts were originally equipped with lock washers, discard the lock washers and replace with hardened washers (P/N 27E–7).

Rotate the upper works to install and tighten the bolts to 80 ft.–lbs. (108 Nm) torque.

Added Jan. 94

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225 (S/N 12000 & Above) Excavator Service Manual

CENTER SWIVEL JOINT

A

Removal and Installation (through upper access removal) Remove the upper works from the swing gear and track frame. (See Page 4–3.)

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.

1

N–13279

B 1

I–2003–0888

Mark all the hoses for correct installation.

Disconnect the hoses from the swivel joint [A].

Remove the bolts from the plate (Item 1) [A] below the center swivel joint.

2

Installation: Tighten the bolts to 48–55 ft.–lbs. (65–75 Nm) torque. Use LOCTITE #242 on the bolt threads.

1

Remove the center swivel joint from the track frame.

C–03299

Removal and Installation (through bottom access cover) Lower blade and boom to the ground.

Stop Engine.

Put jackstands under the blade and front and rear corners of the under carriage before working under the machine. Failure to block up the machine may allow it to move or fall and result in injury or death.

W–2218–1195

Remove 2 and loosen 2 bolts (Item 1) [B] from the access cover (Item 2) [B] and remove the access plate (Item 2) [B] from the bottom of the under carriage. The plate mounting holes are slotted so that the plate can be slid out.

Installation: Tighten the bolts to 30–37 ft.–lbs. (40–50 Nm) torque.

Added Jan. 94

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225 (S/N 12000 & Above) Excavator Service Manual

CENTER SWIVEL JOINT (Cont’d)

A

Removal and Installation (through bottom access cover) (Cont’d)

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.

C–03300

I–2003–0888

B Mark or tag the hoses and fittings for correct installation [A].

Remove the bottom eight hoses from the swivel joint [A].

Remove the six side elbows from the side of the swivel joint.

NOTE: Mark fitting alignment angle for ease of installation.

Remove the floor mat and floor panels. (Refer to Page 5–2 for the correct procedure.)

Remove the top seven hoses from the swivel joint from the top side [B].

CD–12248

C

Remove the four bolts (Item 1) [C] holding the swivel joint to the track frame.

Installation: Tighten the bolts to 48–55 ft.–lbs. (65–75 Nm) torque. Use LOCTITE #242 on the bolt threads.

Rotate the swivel joint 90 degrees [C]. Lower the swivel joint out of the bottom of under carriage.

Inspect the fitting O–rings for damage and replace as necessary.

1 C–03301

Added Jan. 94

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225 (S/N 12000 & Above) Excavator Service Manual

CENTER SWIVEL JOINT (Cont’d) Parts Identification

3 SWIVEL JOINT 1.

2.

3.

4.

5.

6.

7.

8.

9.

1

Bolt Rotor Plug O–Rings Seal Body Cap Cover Washer

2 6 4

9 4 4 7 9 1

5

8

1 9 1

Added Jan. 94

–4–35–

C–03160

225 (S/N 12000 & Above) Excavator Service Manual

220Service Manual #6720874 S/N 508312000 & Above – Upper Works And Swing System Section Part 2 of 2

–4–36–

225 (S/N 12000 & Above) Excavator Service Manual

MAIN FRAME AND TRACKS Page Number ARM Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9 BLADE Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12 BOOM Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9 BOOM SWING BRACKET Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11 BUCKET Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8 CENTER FLOOR PANEL Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 ENGINE COVER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 FUEL TANK Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7 INSPECTION COVER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6

MAIN FRAME & TRACKS

NORDIC CAB (OPTIONAL) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–45 NORDIC SEAT AND MOUNTING FRAME (OPTIONAL) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 REAR FLOOR PANEL Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5 ROPS Front Window Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–45 Side Window Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–47 ROPS WINDOW Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–46 SEAT AND MOUNTING FRAME Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 SWING MOTOR COVER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5 TOOL BOX Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6 TRACK Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14 Track Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13 TRACK FRAME Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–15 TRACK IDLER Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–20, 5–27 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–18, 5–25 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–17, 5–24 TRACK ROLLER Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–34, 5–41 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–32, 5–39 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–31, 5–38

Revised Mar. 98

–5–1–

225 (S/N 12000 & Above) Excavator Service Manual

–5–2–

225 (S/N 12000 & Above) Excavator Service Manual

ENGINE COVER

A

Removal and Installation Open the engine cover.

Remove the retainer clip from the rod end pin of the gas cylinder [A].

N–10657

Remove the retainer clip from the base end pin of the gas cylinder.

B

Hold the engine cover and remove the gas cylinder. Close the engine cover.

Cylinder contains high pressure gas. Do not open. Opening cylinder can release rod and cause injury or death.

W–2113–0288

N–10658

C

Remove the bolts from hinge [B].

Remove the engine cover from the machine.

SEAT AND MOUNTING FRAME Removal and Installation Remove the four mounting bolts [C].

N–10659

Remove the seat and mount [D].

D

N–10660

Revised Mar. 98

–5–3–

225 (S/N 12000 & Above) Excavator Service Manual

NORDIC SEAT AND MOUNTING FRAME (OPTIONAL)

A

Removal and Installation Remove the four mounting bolts (Item 1) [A] from the side brackets.

Remove the four bolts (Item 2) [A] from the seat mounting bracket.

2

1 2 N–12359

Remove the seat and mount [B].

B

N–12360

C

CENTER FLOOR PANEL Removal and Installation Remove the bolts from the floor mat guard [C].

1 Remove the metal edge from the floor mat [D].

N–10661

D

N–10662

Revised Mar. 98

–5–4–

225 (S/N 12000 & Above) Excavator Service Manual

CENTER FLOOR PANEL (Cont’d)

A

Removal and Installation (Cont’d) Remove the bolts from the center floor panel [A].

N–10663

Remove the floor panel [B].

B

N–10664

SWING MOTOR COVER

C

Removal and Installation Remove the bolts from the swing motor cover [C].

Remove the swing motor.

CD–10665

REAR FLOOR PANEL

D

Removal and Installation Remove the bolts from the rear floor panel [D].

Remove the rear floor panel.

CD–10666

Revised Mar. 98

–5–5–

225 (S/N 12000 & Above) Excavator Service Manual

INSPECTION COVER

A

Removal and Installation Remove the seat and mounting frame. (See Page 5–1.)

Remove the mounting bolts [A].

Remove the inspection cover.

CD–10667

B

TOOL BOX Removal and Installation Raise the engine cover.

Remove the bolts from the tool box [B].

CD–10668

Remove the tool box [C].

C

N–10669

Revised Mar. 98

–5–6–

225 (S/N 12000 & Above) Excavator Service Manual

FUEL TANK

A

Removal and Installation

2

Drain the fuel from the tank into a container.

Disconnect the fuel switch wire (Item 1) [A], the ground wire (Item 2) [A] and the low level sensor (Item 3) [A].

1 3 N–10670

Remove the fuel tank mounting bolts [B] & [C].

B

N–10671

C

N–10672

Lift and move the fuel tank forward. Disconnect the fuel hoses [D].

D

Remove the fuel tank from the machine.

N–10673

Revised Mar. 98

–5–7–

225 (S/N 12000 & Above) Excavator Service Manual

BUCKET

A

Removal and Installation Remove the retainer clips from the bucket pins [A].

N–08597

Remove the bucket pins [B].

B

CD–08598

C

Remove the nuts and bolts from the bucket teeth [C].

N–08599

Remove the bucket teeth [D].

D

N–08600

Revised Mar. 98

–5–8–

225 (S/N 12000 & Above) Excavator Service Manual

ARM

A

Removal and Installation Support the arm with a chain hoist.

Disconnect the bucket cylinder hoses. (See Page 2–15.)

Remove the rod end of the arm cylinder from the arm.

(See Page 2–14.)

Remove the bolt from the arm pivot pin [A].

N–08601

Remove the arm pivot pin [B].

B

N–08602

Remove the auxiliary hoses from the arm [C].

C

N–08680

BOOM

D

Removal and Installation Support the boom with a chain hoist.

Remove the auxiliary hoses from the boom [D].

1

Lower hose (Item 1) [D] connects to the outside auxiliary fitting.

N–08603

Revised Mar. 98

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225 (S/N 12000 & Above) Excavator Service Manual

BOOM (Cont’d)

A

Removal and Installation (Cont’d) Remove all the cylinder hoses from the tubelines on the boom [A].

Remove the boom cylinder base end from the boom swing bracket. (See Page 2–13.)

N–10674

Remove the bolt from the boom pivot pin [B].

B

N–10675

C

Remove the boom pivot pin [C].

N–08606

Remove the boom [D].

D

N–08607

Revised Mar. 98

–5–10–

225 (S/N 12000 & Above) Excavator Service Manual

BOOM SWING BRACKET

A

Removal and Installation Remove the boom and arm. (See Page 5–7.)

Remove the boom swing cylinder rod end pin. (See Page 2–18.)

Remove the hose retaining bracket [A].

Pull the hoses out of the boom swing bracket.

N–10676

Remove the retainer bolt and nut from the boom swing bracket pivot pin [B].

B

N–08609

C

Remove the boom swing bracket pivot pin [C].

Remove the boom swing bracket.

N–08610

Revised Mar. 98

–5–11–

225 (S/N 12000 & Above) Excavator Service Manual

BLADE

A

Removal and Installation Lower the blade to the ground.

Remove the blade cylinder hoses. (See Page 2–17.)

Remove the cylinder. (See Page 2–17.)

Remove the cotter pins from the blade arm pivot pins (both sides) [A].

CD–08611

B

Remove the blade arm pivot pins [B].

CD–08612

Revised Mar. 98

–5–12–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK

A

Track Tension Adjustment 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 arm [A].

N–10461

Raise the blade and install jackstands under the blade and swing frame [B].

B

Stop the engine.

AVOID INJURY Keep fingers and hands out of pinch points when checking the track tension.

W–2142–0189

N–10677

C

Measure the track sag at the center of the track, between the lower edge of the track frame and the top surface of the track [C] & [D].

Rubber Track . . . . . . . . . . . . . . 2.25’’–2.75’’ (57–69 mm) Steel Track . . . . . . . . . . . . . 4.25’’–4.75’’ (108–120 mm)

Rubber Track

2.25’’–2.75’’ (57–59 mm)

Center of Track CD–13226

D

Steel Track

4.25–4.75 inch (108–120 mm)

Center of Track CD–13227

Revised Mar. 98

–5–13–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK (Cont’d)

A

Track Tension Adjustment (Cont’d) Add grease to the fitting (Item 1) [A] until the track tension is correct.

1

N–10425

B

If tension is to tight, loosen the bleed fitting (Item 1) [B] until the track tension is correct.

2

NOTE: Do not loosen the grease fitting (Item 2) [B].

Repeat the procedure for the other side.

1

N–10472

Removal and Installation

C

Lift and block the side of the machine where the track will be removed [C].

Loosen the bleed fitting (Item 1) [B] and allow the grease to bleed out of the recoil spring cylinder.

NOTE: Do not loosen the grease fitting (Item 2) [B].

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–10677

Remove the track from the front track idler [D].

D

Remove the track from the frame and rear drive sprocket.

N–10678

Revised Mar. 98

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225 (S/N 12000 & Above) Excavator Service Manual

TRACK FRAME

A

Disassembly and Assembly Use the following procedure to remove the different parts from the track frame: Remove the track. (See Page 5–14.)

Slide the front track idler out of the track frame to remove it [A].

See Page 5–16 or 5–24 for Disassembly and Assembly procedure.

N–10679

Remove the sliding plate [B].

B

N–10680

C

Slide the recoil spring cylinder forward and remove it from the track frame [C].

N–10681

Remove the drive gear bolts [D].

D

Installation: Put LOCTITE on the bolts and tighten to 80 ft.–lbs. (108 Nm) torque.

Remove the drive gear from the drive motor and planetary gear assembly.

CD–08617

Revised Mar. 98

–5–15–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK FRAME (Cont’d)

A

Disassembly and Assembly (Cont’d) Remove the guide block bolts [A].

CD–08618

B Loosen the nuts at the track roller on both sides of the track frame [B].

CD–08619

C Remove the track roller [C].

See Page 5–31 or 5–38 for Disassembly or Assembly procedure.

CD–08620

Revised Mar. 98

–5–16–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK IDLER Parts Identification NOTE: For use on all steel tracks and on interchangeable rubber track (6663906). (See BTI E–030 for detailed information.) See Page 5–24 for track idler used with rubber tracks (6662301 & 6663953).

3 2

4 5 6 1

7

6

3

5 4

2

D–01960

TRACK IDLER Ref. 1.

2.

3.

4.

Revised Mar. 98

Description

Ref.

Idler Block Pin Seal

5.

6.

7.

–5–17–

Description Snap Ring Bearing Shaft

225 (S/N 12000 & Above) Excavator Service Manual

TRACK IDLER (Cont’d)

A

The following tools must be fabricated for this procedure: 1. Driver Tool – See [A].

2. Support Fixture – Tube, 3’’ ID x 1/4’’ wall x 6 inches long.

4.50’’ (115 mm) 3.50’’ (90 mm)

0.03’’ (0,75 mm) Chamfer 3 places 2.70’’ (70 mm) Dia. Disassembly

1.60’’ (40 mm) Dia.

B–14205

B

Remove the roll pin and block from each end of the shaft [B].

CD–00230

Use a wire brush to remove any corrosion or paint from both ends of the exposed shaft that could affect seal removal or damage the new seal during installation [C].

C

CD–00231

Apply penetrating oil to both ends of the exposed shaft to ease removal of the inner part of the seal.

D

Remove the inner parts of the seal using two screwdrivers [D].

CD–00232

Revised Mar. 98

–5–18–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK IDLER (Cont’d)

A

Disassembly (Cont’d) Remove the outer part of the seal from the idler using two screwdrivers [A].

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–00234

B

Remove the snap ring from each side of the idler [B].

CD–00239

C

Using the fabricated driver tool and support fixture, press or drive the shaft and bearing assembly out of the idler [C].

Driver Tool

Support Fixture CD–00240

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 [D].

D

CD–00244

Revised Mar. 98

–5–19–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK IDLER (Cont’d)

A

Assembly Remove all paint and corrosion from the seal surface on both sides of the idler [A].

Be sure all parts are clean before assembly.

CD–00245

B

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.

CD–00246

C

Using the driver tool, install the shaft and bearing assembly into the idler [C].

CD–00247

Install the snap ring [D].

D

CD–00248

Added Mar. 98

–5–20–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK IDLER (Cont’d)

A

Assembly (Cont’d) Turn the idler assembly over.

Using the driver tool, install the other bearing, with the numbered side upward, into the idler [A].

CD–00249

Install the snap ring [B].

B

CD–00250

C

Using a dial indicator, check the endplay of the shaft [C] If the endplay is greater than 0.030 inch (0,76 mm) then the bearing must be shimmed.

Cut a shim from the necessary thickness shim stock and install the shim between the bearing and the shoulder on the shaft.

Install Shims Between Bearings and Shaft Shoulder B–14276

CD–00242

Separate the inner and outer halves of the seals.

D

Apply grease to the grooves on the outer part of a new seal [D]

CD–00238

Added Mar. 98

–5–21–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK IDLER (Cont’d)

A

Assembly (Cont’d) Apply a mall bead of high temperature silicone sealant around the flange surface of the seal [A].

CD–00237

B

Using the driver tool, install the outer part of the new seal into the idler [B].

NOTE: The inner and outer parts of the seal must be installed separately so the air will escape from under the seal.

CD–00235

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–00233

D

Turn the idler assembly over. Using a syringe add 80 cc of SAE 10W/30 oil to the assembly [D].

Repeat Page 5–21 Step [D] thru Page 5–22 Step [C] install the remaining seal.

Check for leaks.

CD–00236

Added Mar. 98

–5–22–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK IDLER (Cont’d)

A

Assembly (Cont’d) Install the roll pin and block on each end of the shaft [A].

The two blocks must point the same direction.

CD–00230

Added Mar. 98

–5–23–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK IDLER Parts Identification NOTE: For use on all rubber tracks (6662301 and 6663953) only. (See BTI E–030 for detailed information.) See Page 5–16 for track idler used with steel tracks and interchangeable rubber track (6663906).

3

2 5 4 5 6

1

7

6 5 3

4

2

5

C–03127

TRACK IDLER Ref. 1.

2.

3.

4.

Added Mar. 98

Description

Ref.

Idler Block Pin Seal

5.

6.

7.

–5–24–

Description Snap Ring Bearing Shaft

225 (S/N 12000 & Above) Excavator Service Manual

TRACK IDLER (Cont’d)

A

220Service Manual #6720874 S/N 508312000 & Above – Main Frame And Tracks Section Part 1 of 2

The following tools must be fabricated for this procedure: 1. Driver Tool – See [A].

2. Support Fixture – Tubing, 3’’ ID x 1/4’’ x 6 inches long.

4.50’’ (115 mm) 3.50’’ (90 mm)

0.03’’ (0,75 mm) Chamfer 3 places 2.70’’ (70 mm) Dia.

1.60’’ (40 mm) Dia.

B–14205

B

Disassembly Remove the roll pin and block from each end of the shaft [B].

CD–00270

C

Use a wire brush to remove any corrosion or paint from both ends of the exposed shaft that could affect seal removal or damage the new seal during installation [C].

CD–00269

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].

t Added Mar. 98

–5–25–

CD–00268

225 (S/N 12000 & Above) Excavator Service Manual

TRACK IDLER (Cont’d)

A

Disassembly (Cont’d) Remove the outer part of the seal from the idler using two screwdrivers [A].

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–00266

Remove the snap ring from each side of the idler [B].

B

CD–00257

Using the fabricated driver tool and support fixture, press or drive the shaft and bearing assembly out of the idler [C].

C Driver Tool

Support Fixture 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 bearing is necessary, use a two or three jaw puller, remove the two bearings from the shaft [D].

CD–00258

D

CD–00252

Added Mar. 98

–5–26–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK IDLER (Cont’d)

A

Assembly Remove all paint and corrosion from the seal surface on both sides of the idler [A].

Be sure all parts are clean before assembly.

CD–00251

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–00253

C

Using the driver tool, install the shaft and bearing assembly into the idler [C].

CD–00254

Install the snap ring [D].

D

CD–00255

Added Mar. 98

–5–27–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK IDLER (Cont’d)

A

Assembly (Cont’d) Turn the idler assembly over.

Using the driver tool, install the other bearing, with the numbered side upward, into the idler [A].

CD–00256

B

Install the snap ring [B].

CD–00257

C

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

If the endplay is greater than 0.030 inch (0,76 mm) then the bearing must be shimmed.

Cut a shim from the necessary thickness shim stock and install the shim between the bearing and the shoulder on the shaft.

Install Shims Between Bearings and Shaft Shoulder B–14276

CD–00260

Separate the inner and outer halves of the seals.

D

Apply grease to the grooves on the outer part of a new seal [D].

CD–00262

Added Mar. 98

–5–28–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK IDLER (Cont’d)

A

Assembly (Cont’d) Apply a small bead of high temperature silicone sealant around the flange surface of the seal [A].

CD–00263

B

Using the driver tool, install the outer part of the new seal into the idler [B].

NOTE: The inner and outer parts of the seal must be installed separately so the air will escape from under the seal.

CD–00264

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–00267

Turn the roller assembly over. Using a syringe add 50 cc of SAE 10W/30 oil to the assembly [D].

D

Repeat Page 5–28 Step [D] thru Page 5–29 Step [C] to install the remaining seal.

Check for leaks.

CD–00259

Added Mar. 98

–5–29–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK IDLER (Cont’d)

A

Assembly (Cont’d) Install the roll pin and block on each end of the shaft [A].

CD–00270

Added Mar. 98

–5–30–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK ROLLER Parts Identification NOTE: For use on all steel tracks and on interchangeable rubber track (6663906). (See BTI E–030 for detailed information.) See Page 5–38 for track idler used with rubber tracks (6662301 & 6663953).

2 3 4

1

5 7 6 8 9 10

8 6 7 5 1 4

3 2

D–01958

TRACK ROLLER Ref. 1.

2.

3.

4.

5.

Added Mar. 98

Description

Ref.

Description

Spacer Nut Washer Washer Snap Ring

6.

7.

8.

9.

10.

Snap Ring Seal Bearing Shaft Roller

–5–31–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK ROLLER (Cont’d)

A

The following tools must be fabricated for this procedure: 1. Driver Tool – See [A].

2. Support Fixture – Tube, 3’’ ID x 1/4’’ wall x 6 inches long.

4.50’’ (115 mm) 3.50’’ (90 mm)

0.03’’ (0,75 mm) Chamfer 3 places 2.70’’ (70 mm) Dia. Disassembly

1.60’’ (40 mm) Dia.

B–14205

B

Remove the snap ring and spacer from each end of the shaft [B].

CD–00309

C

Use a wire brush to remove any corrosion or paint from both ends of the exposed shaft that could affect seal removal or damage the new seal during installation [C].

CD–00306

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–00305

Added Mar. 98

–5–32–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK ROLLER (Cont’d)

A

Disassembly (Cont’d) 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–00303

Remove the snap ring from each side of the roller [B].

B

CD–00299

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 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 [D].

CD–00298

D

CD–00292

Added Mar. 98

–5–33–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK ROLLER (Cont’d)

A

Assembly 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–00293

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–00291

C

Using the driver tool, install the shaft and bearing assembly into the roller [C].

CD–00294

Install the snap ring [D].

D

CD–00295

Added Mar. 98

–5–34–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK ROLLER (Cont’d)

A

Assembly (Cont’d) Turn the roller assembly over.

Using the driver tool, install the other bearing, with the numbered side upward, into the roller [A].

CD–00296

Install the snap ring [B].

B

CD–00199

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

C

If the endplay is greater than 0.030 inch (0,76 mm) then the bearing must be shimmed.

Cut a shim from the necessary thickness shim stock and install the shim between the bearing and the shoulder on the shaft.

Install Shims Between Bearings and Shaft Shoulder B–14276

CD–00301

Separate the inner and outer halves of the seals.

D

Apply grease to the grooves on the outer part of a new seal [D].

CD–00238

Added Mar. 98

–5–35–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK ROLLER (Cont’d)

A

Assembly (Cont’d) Apply a small bead of high temperature silicone sealant around the flange surface of the seal [A].

CD–00237

B

Using the driver tool, install the outer part of the new seal into the roller [B].

NOTE: The inner and outer parts of the seal must be installed separately so the air will escape from under the seal.

CD–00302

C

Using the driver tool, install the inner part of the new seal over the shaft [C].

NOTE: The inner part of the seal must be pressed down level with the outer part of the seal to seal properly.

CD–00304

D

Turn the roller assembly over. Using a syringe add 100 cc of SAE 10W/30 oil to the assembly [D].

Repeat Page 5–35 Step [D] thru Page 5–36 Step [C] to install the remaining seal.

Check for leaks.

CD–00300

Added Mar. 98

–5–36–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK ROLLER (Cont’d)

A

Assembly Install the spacer and snap ring on each end of the shaft [A].

CD–00309

Added Mar. 98

–5–37–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK ROLLER Parts Identification NOTE: For use on all rubber tracks (6662301 and 6663953) only. (See BTI E–030 for detailed information.) See Page 5–31 for track idler used with steel tracks and interchangeable rubber track (6663906).

2 3

4

5

7 6 8 9 1

8 6 7 5 4 3 2

D–01960

TRACK ROLLER Ref. 1.

2.

3.

4.

5.

Added Mar. 98

Description

Ref.

Roller Nut Washer Washer Snap Ring

6.

7.

8.

9.

–5–38–

Description Snap Ring Seal Bearing Shaft

225 (S/N 12000 & Above) Excavator Service Manual

TRACK ROLLER (Cont’d)

A

The following tools must be fabricated for this procedure: 1. Driver Tool – See [A].

2. Support Fixture – Tubing, 3’’ ID x 1/4’’ wall x 6 inches long.

4.50’’ (115 mm) 3.50’’ (90 mm)

0.03’’ (0,75 mm) Chamfer 3 places 2.70’’ (70 mm) Dia.

1.60’’ (40 mm) Dia.

B–14205

B

Disassembly Remove the snap ring from each end of the shaft [B].

CD–00350

Use a wire brush to remove any corrosion or paint from both ends of the exposed shaft that could affect seal removal or damage the new seal during installation [C].

C

CD–00349

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–00347

Added Mar. 98

–5–39–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK ROLLER (Cont’d)

A

Disassembly (Cont’d) 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–00344

B

Remove the snap ring from each side of the roller [B].

CD–00341

C

Put the support fixture below the roller.

Using the fabricated driver tool and support fixture, with the solid end facing the shaft, push the shaft and the lower bearing out of the roller [C].

Use Driver Tool Against The End Of The Shaft Not Against The Bearing.

The upper bearing will stay in the housing.

Support Fixture Using a two or three jaw puller, remove the bearing from the shaft [D].

CD–00338

D

Remove the bearing from the roller [D].

Inspect the bearings for rust or for rough spots. The bearings must turn freely. If any damage is found, replace the bearings.

CD–00335

Added Mar. 98

–5–40–

CD–00334

225 (S/N 12000 & Above) Excavator Service Manual

TRACK ROLLER (Cont’d)

A

Assembly 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–00333

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–00336

C

Using the driver tool, install the shaft and bearing assembly into the roller [C].

CD–00337

Install the snap ring [D].

D

CD–00339

Added Mar. 98

–5–41–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK ROLLER (Cont’d)

A

Assembly (Cont’d) Turn the roller assembly over.

Using the driver tool, install the other bearing, with the numbered side upward, into the roller [A].

CD–00340

B

Install the snap ring [B].

CD–00341

C

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

If the endplay is greater than 0.030 inch (0,76 mm) then the bearing must be shimmed.

Cut a shim from the necessary thickness shim stock and install the shim between the bearing and the shoulder on the shaft.

Install Shims Between Bearings and Shaft Shoulder B–14276

CD–00343

Separate the inner and outer halves of the seals.

D

Apply grease to the grooves on the outer part of a new seal [D].

CD–00238

Added Mar. 98

–5–42–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK ROLLER (Cont’d)

A

Assembly (Cont’d) Apply a small bead of high temperature silicone sealant around the flange surface of the seal [A].

CD–00237

B

Using the driver tool, install the outer part of the new seal into the roller [B].

NOTE: The inner and outer parts of the seal must be installed separately so the air will escape from under the seal.

CD–00345

Using the driver tool, install the outer part of the new seal into the roller [B].

C

NOTE: The inner part of the seal must be pressed down level with the outer part of the seal to seal properly.

CD–00346

Turn the roller assembly over. Using a syringe add 70 cc of SAE 10W/30 oil to the assembly [D].

D

Repeat Page 5–42 Step [D] thru Page 5–43 Step [C] to install the remain seal.

Check for leaks.

CD–00342

Added Mar. 98

–5–43–

225 (S/N 12000 & Above) Excavator Service Manual

TRACK ROLLER (Cont’d)

A

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

CD–00350

Added Mar. 98

–5–44–

225 (S/N 12000 & Above) Excavator Service Manual

ROPS

A

Removal and Installation Remove the bolts from the front and rear supports [A].

Installation: Tighten the rear support bolts to 29–37 ft.–lbs. (40–50 Nm) torque. Tighten the front support bolts to 48–55 ft.–lbs. (65–75 Nm) torque.

N–10682

Use a chain hoist to remove the ROPS [B].

B

N–10683

C

NORDIC CAB (OPTIONAL) Removal and Installation Remove the front lights and install lifting eyes through the light holes.

Connect chains to the lift eyes and to the slots inside the cab behind the operator’s seat.

Remove the bolts from the plate behind the operator’s seat [C].

N–09492

Remove the bolts from inside the frame behind the operator’s seat [D].

D

Installation: Tighten the bolts to 40–45 ft.–lbs. (54–61 Nm) torque.

N–09493

Added Mar. 98

–5–45–

225 (S/N 12000 & Above) Excavator Service Manual

NORDIC CAB (OPTIONAL) (Cont’d)

A

Removal and Installation (Cont’d) Remove the bolts from the front corners of the cab (2 each side) [A].

Installation: Tighten the bolts to 40–45 ft.–lbs. (54–61 Nm) torque.

N–12381

Use a chain hoist to remove the cab [B]

B

N–12382

C

ROPS WINDOW

1

Front Window Removal Remove the screws (Item 1) [C] from the window frame.

NOTE: Cabs with S/N M8960B–1 & Above use a single bead of urethane around the window perimeter only.

2

NOTE: Cabs with S/N M8960A–50 & Below only, use an extra bead of urethane under the window flange.

D–02094

All Cabs: Use a utility knife to cut the urethane from the window perimeter [D].

D

Remove the window from the ROPS frame.

Cab S/N M8960A–50 & Above Only: From the inside of the cab, force a corner of the window out slightly, use wedges to hold window in position.

Cut the urethane bead from the window flange until the window is free from the ROPS frame.

Remove the two screws (Item 2) [C] that hold the center post in the window frame. Remove the center post.

Spread the frame and remove the glass or clean the channel of all broken glass particles, if necessary.

Added Mar. 98

N–11660

–5–46–

225 (S/N 12000 & Above) Excavator Service Manual

ROPS WINDOW (Cont’d)

A

Front Window Removal (Cont’d) Installation: Install the glazing vinyl on 3 sides of the stationary glass. Hold the vinyl in place with tape during installation.

Apply water diluted liquid soap on channels during window installation.

Install the glass in one side of the channel, spread the frame and use a putty knife to control glazing vinyl while guiding window into position Push glass into bottom position.

N–11661

Install the glazing vinyl and center post on top of stationary window.

Install the screws in the center post to hold frame. DO NOT TIGHTEN. Install the sliding glass in one side of the frame, spread the frame and use a putty knife to control glazing vinyl and guide the window in position.

Tighten the screws into the center post.

Use a utility knife to cut the tape from the window.

Install the window in the opening, install the (4) screws and apply a bead of urethane on the perimeter of the window [A].

Side Window Removal NOTE: The removal procedure for the side window is the same as the front window. (See Page 5–30.)

Installation Remove the glass or clean the channel of all broken glass particles, if necessary.

Install the locks on glass.

Install the sliding glass in one side of the frame, spread the frame and use a putty knife to control glazing vinyl and guide the window in position.

Install the window in the opening, install the four screws and apply a bead of urethane on the perimeter of the window [A].

Added Mar. 98

–5–47–

225 (S/N 12000 & Above) Excavator Service Manual

220Service Manual #6720874 S/N 508312000 & Above – Main Frame And Tracks Section Part 2 of 2

Added Mar. 98

–5–48–

225 (S/N 12000 & Above) Excavator Service Manual

ELECTRICAL SYSTEM Page Number ALTERNATOR Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4 BATTERY Check the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3 CAB CONTROL PANEL Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9 CONSOLE SWITCHES Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11 DOME LIGHT Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9 ELECTRICAL SYSTEM Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuse Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6–1 6–2 6–2 6–2

ENGINE COVER LIGHT (NORDIC OPTION) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14

ELECTRICAL SYSTEM

FRONT LIGHTS Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10 FUEL LEVEL SENDER Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7 INSTRUMENT PANEL Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8 STARTER Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5 TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 WINDSHIELD WIPER (NORDIC OPTION) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12 WINDSHIELD WASHER Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13

Revised Apr. 92

–6––1–

225 (S/N 12000 & Above) Excavator Service Manual

–6–0–

225 (S/N 12000 & Above) Excavator Service Manual

TROUBLESHOOTING The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service personnel only.

Instructions 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.

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 ELECTRICAL SYSTEM Description The excavator has a 12 volt, negative ground electrical system. There are two main circuits.

1. The charging circuit has an alternator (with integral regulator) and a battery.

2. The starting circuit has a starter motor, solenoid and starter switch for starting the engine.

Fuses protect the electrical system from an overload.

The reason for the overload must be found before starting the engine.

–6–1–

225 (S/N 12000 & Above) Excavator Service Manual

ELECTRICAL SYSTEM (Cont’d)

A

Fuses The fuses protect the electrical system from damage. To replace the fuse(s), loosen the screw and rotate the cover down.

NOTE: Before replacing any fuse(s), make sure the key switch is in the OFF position.

N–10444

Fuse Arrangement [B] Ref.

B

Fuse Capacity

1.

15 Amp.

2.

20 Amp.

3.

10 Amp.

4.

10 Amp.

1 2

3 4

N–10445

Electrical System Service

C

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

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

Check the electrolyte level in the battery. Add distilled water as needed.

Check the alternator belt for wear and correct tension.

Check that all wire connections are tight.

N–10446

–6–2–

225 (S/N 12000 & Above) Excavator Service Manual

BATTERY

A

Checking the Battery 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.

Removal and Installation

N–08173

Open the engine cover [A].

B 1

Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

3 2

In case of acid contact, wash immediately with water for several minutes and get medical attention in case of eye contact.

W–2065–1286 N–10446

Disconnect the negative (–) cable (Item 1) first [B].

Disconnect the positive (+) cable (Item 2) [B].

Remove the wing nut and the battery holddown clamp (Item 3) [B].

Remove the battery from the machine.

Always clean the terminals and cable ends, even when installing a new battery.

Reverse the procedure for battery installation.

–6–3–

225 (S/N 12000 & Above) Excavator Service Manual

ALTERNATOR

A

Belt Adjustment Stop the engine. Open the engine cover.

The belt should deflect about 1/2’’ (13 mm) when pressed between the water pump pulley and crankshaft pulley with approximately 13 lbs. (58 N) force [A].

If the tension is not correct, loosen the alternator mounting bolt.

N–10442

B

Loosen the adjustment bolt (Item 1) [B].

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 pulleys.

1

CD–10443

C

Removal and Installation Disconnect the negative (–) cable from the battery.

Disconnect the alternator wires [C].

Remove the adjustment bolt [B].

Remove the alternator belt.

Remove the mounting bolt.

Remove the alternator from the bracket.

N–08624

–6–4–

225 (S/N 12000 & Above) Excavator Service Manual

STARTER

A

Removal and Installation Remove the operator seat and seat mount to gain access to the starter.

Disconnect the negative (–) cable from the battery.

Disconnect the wires from the starter [A].

N–08625

Remove the mounting bolts from the starter [B].

B

Remove the starter from the bell housing.

N–08626

–6–5–

225 (S/N 12000 & Above) Excavator Service Manual

STARTER (Cont’d)

4

A

Disassembly and Assembly

3

Disassemble the starter as shown in figure [A].

Cleaning and Inspection 1

2

Wear safety glasses to prevent eye injury when any of the following conditions exist:

• • • •

8 10

When fluids are under pressure.

Flying debris or loose material is present.

Engine is running.

Tools are being used.

11

9

W–2019–1285

7

Use a brush and air pressure to clean the drive, field coils, armature and starter housing.

NOTE: Do not use solvent to clean the drive assembly. The solvent will remove the lubricant and the drive will slip.

1.

2.

3.

4.

5.

6.

Check the following items: Armature Broken or burned insulation.

Loose connections at commutator.

Open or grounded circuits.

Worn shaft or bearings.

Rough commutator.

Armature Bearing Yoke Frame Bolt Frame

7. Clutch 8. Gear 9. Switch Assy.

10. Plunger 11. Cover

6 5 B–13014

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.

–6–6–

225 (S/N 12000 & Above) Excavator Service Manual

FUEL LEVEL SENDER

A

Removal and Installation Drain the fuel from the reservoir.

1

Remove the wire from the fuel switch screw (Item 1) [A], and the ground wire screw (Item 2) [A].

Remove the sender mounting bolts.

Remove the sender.

1

Checking N–10670

Use an ohmmeter to check the resistance of the fuel sender.

–6–7–

225 (S/N 12000 & Above) Excavator Service Manual

INSTRUMENT PANEL

A

Removal and Installation Remove the mounting screws from the instrument panel [A].

Lift the instrument panel.

N–10622

B

Unplug the wire harness form the instrument panel socket [B].

Refer the Operation & Maintenance Manual for the Instrument Panel Operation.

N–10623

–6–8–

225 (S/N 12000 & Above) Excavator Service Manual

DOME LIGHT

A

Removal and Installation Remove the screws from the light cover [A].

Remove the cover.

N–09499

Remove the switch nut from the cover [B].

B

N–09500

C

Remove the dome light [C].

N–09501

CAB CONTROL PANEL

D

Removal and Installation Remove the mounting screws from the control panel.

Disconnect the wire harness and remove the control panel [D].

N–12543

–6–9–

225 (S/N 12000 & Above) Excavator Service Manual

FRONT LIGHTS

A

Removal and Installation Remove the harness wires from the lights [A].

N–09505

B

Remove the nut from the light mounting stud (Item 1) [B].

Remove the light [B].

1

N–09506

Lamp Replacement

C

Remove the screws from the back of the light housing [C].

N–09507

Remove the wire connector from the light [D].

D

N–09508

–6–10–

225 (S/N 12000 & Above) Excavator Service Manual

CONSOLE SWITCHES

A

Removal and Installation NOTE: Remove the wires from the switches and fuse. Mark the wires for correct installation.

Remove the knob from the wiper washer switch [A].

N–09509

Remove the nut from the wiper/washer switch [B].

B

N–09510

Use a small screwdriver to loosen the screw from the light knob [C].

C

Remove the light switch knob.

N–09511

D

Remove the nut from the light switch [D].

N–09512

–6–11–

225 (S/N 12000 & Above) Excavator Service Manual

WINDSHIELD WIPER

A

Removal and Installation Remove the wires from the wiper motor [A].

Mark the wires for installation.

N–09502

B

Remove the nuts from the wiper arms [B].

N–09503

C

Remove the nuts and bolts from the wiper mount [C].

N–09504

–6–12–

225 (S/N 12000 & Above) Excavator Service Manual

WINDSHIELD WASHER (NORDIC OPTION)

A

The windshield washer pump is located in the water bottle (Item 1) [A] which is mounted in the engine area.

6

Removal and Installation Raise the engine cover.

Remove the hose (Item 2) [A] from the water bottle.

5

Drain fluid into a container.

Disconnect the wire (Item 4) [A] from the pump.

Remove the mounting screw (Item 3) [A].

A

Remove the washer bottle and pump assembly.

Hose Removal Remove the cab control panel.

3

Remove the hose (Item 6) [A] from the fitting by the wiper motor.

1

Remove the hose from the water bottle fitting [A].

Drain the fluid into a container [A].

Disconnect washer hose (Item 5) [A] from the wiper and cab fitting.

A

NOTE: Use windshield washer fluid in water bottle.

4

2

D–02134

–6–13–

225 (S/N 12000 & Above) Excavator Service Manual

ENGINE COVER LIGHT (NORDIC OPTION)

A

220ServiceManual#6720874S/N508312000&Above–ElectricalSystemSection

The engine cover light is mounted on the center hinge of the engine cover and use a standard 1141 bulb [A].

The wire harness is routed through the rear wall of the cab and is connected to an open terminal on the fuse panel.

Removal and Installation Raise the engine cover.

Remove the light cover (Item 1) [A] and remove the bulb (Item 2) [A].

Disconnect the harness end (Item 3) [A] from the light terminal and the fuse terminal to remove the harness.

3 B

1

2

3

D–02134

–6–14–

225 (S/N 12000 & Above) Excavator Service Manual

ENGINE SERVICE Page Number AIR CLEANER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–15 CRANKSHAFT AND PISTONS Crankshaft Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–35 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–33 Servicing the Connecting Rods and Pistons . . . . . . . . . . . . . . . . . . . . . . 7–36 CYLINDER HEAD Assembly the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Rocker Arm and Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly of the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal of the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing the Cylinder Head and Valves . . . . . . . . . . . . . . . . . . . . . . . . . .

7–24 7–24 7–23 7–21 7–24 7–20 7–22

CYLINDER LINERS Checking the Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–38 Cylinder Liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–38 ELECTRIC FUEL PUMP Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4 ENGINE Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–16 ENGINE COMPRESSION Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3 ENGINE FLYWHEEL Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–19 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–17

ENGINE SERVICE

FAN SHIELD (NORDIC OPTION) Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13 FUEL FILTER Final Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5 In–Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5 FUEL INJECTOR NOZZLES Checking the Injector Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9 FUEL INJECTION PUMP Checking the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7 Timing the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–18 GLOW PLUGS Checking the Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11

Revised Apr. 92

–7––1–

225 (S/N 12000 & Above) Excavator Service Manual

ENGINE SERVICE (Cont’d) Page Number MUFFLER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–14 RADIATOR Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–12 TIMING GEAR, CAMSHAFT AND OIL PUMP Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–30 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–28 Servicing the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–31 TIMING GEAR COVER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–26 TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 VALVE CLEARANCE Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2 WATER PUMP Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39

–7–0–

225 (S/N 12000 & Above) Excavator Service Manual

TROUBLESHOOTING The following troubleshooting chart is provided for 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.

Engine will not start.

Difficult to start.

No power from engine.

1, 2, 3, 4 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29 8, 9, 10, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28, 29

Engine is mis–firing.

Too much fuel consumption.

Black exhaust.

Blue/white exhaust.

8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28 10, 12, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29 10, 12, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50

Low oil pressure.

Engine knocking.

Engine running rough.

4, 31, 32, 33, 34, 35, 37, 38, 39, 52 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53

Vibration.

High oil pressure.

Overheating.

Too much crankcase pressure.

12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43 4, 33, 36 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51 22, 27, 29, 30, 40, 49

Poor compression.

Start and stop

10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53 9, 10, 11

KEY TO CORRECT THE CAUSE 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

Battery capacity low.

Bad electrical connections.

Faulty starter motor.

Incorrect grade of oil.

Low cranking speed.

Fuel tank empty.

Faulty stop control operation.

Plugged fuel line.

Plugged fuel filter.

Restriction in the air cleaner.

Air in the fuel system.

Faulty fuel injection pump.

Faulty fuel injectors.

Broken injection pump drive.

Incorrect injection pump timing.

Incorrect valve timing.

Poor compression.

Plugged fuel tank vent.

Incorrect grade of fuel.

Exhaust pipe restriction.

Cylinder head gasket leaking.

Overheating.

Cold running.

Incorrect tappet adjustment.

Sticking valves.

Incorrect high pressure fuel lines.

Worn cylinder bores.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

53.

–7–1–

Worn valves and seat.

Broken or worn piston rings.

Worn valve stems or guides.

Worn or damaged bearings.

Not enough oil in the oil pan.

Switch is defective.

Oil pump worn.

Relief valve is stuck open.

Relief valve is stuck closed.

Broken relief valve spring.

Faulty suction pipe.

Plugged oil filter.

Piston seizure.

Incorrect piston height.

Faulty engine mounting.

Incorrect alignment of flywheel.

Faulty thermostat.

Restriction in water jacket.

Loose alternator belt.

Plugged radiator.

Plugged breather pipe.

Plugged breather pipe.

Damaged valve stem oil deflectors.

Coolant level too low.

Plugged oil pump pipe strainer.

Broken valve spring.

225 (S/N 12000 & Above) Excavator Service Manual

VALVE CLEARANCE

A

Adjustment

0.006’’–0.007’’ (0,15–0,18 mm)

Adjust the valve clearance with the engine stopped and cold.

The correct valve clearance (Intake & Exhaust) is 0.006’’–0.007’’ (0,15–0,18 mm) [A].

Make sure the piston is at T.D.C. when making the adjustment of the valves for the particular cylinder.

A–02730

B

Put the correct size feeler gauge between the rocker arm and valve stem. Turn the adjustment bolt until the clearance is correct [B].

B–05893

–7–2–

225 (S/N 12000 & Above) Excavator Service Manual

ENGINE COMPRESSION

A

Checking Use MEL1063 – Engine Compression Kit to do the following procedure.

The engine must be at operating temperature.

The compression must be at least 75% of 337–448 PSI (2324–3089 kPa) with no more than 50 PSI (345 kPa) difference between the cylinders.

Remove the nut and the glow plug wire [A].

CD–08635

Remove the glow plug [B].

B

CD–08636

Install the compression tester in the glow plug hole [C].

C

CD–08637

Connect the compression gauge to the tester [D].

Turn the engine with the starter and check the gauge pressure.

D

CD–08638

–7–3–

225 (S/N 12000 & Above) Excavator Service Manual

ELECTRIC FUEL PUMP

A

No air removal from the fuel system is necessary when filters are changed or if the machine runs out of fuel.

2

The electric fuel pump will self bleed the system by turning the ignition key to the ON position.

1

Removal and Installation Remove the hose clamps (Items 1 & 2) [A] from the fuel pump.

N–10684

B

Disconnect the electric fuel pump wire from the harness [B].

N–10685

C

Remove the mounting bolts from the fuel pump bracket [C].

Remove the electric fuel pump.

N–10686

In–Line Filter (Used on Early Model Excavators Only)

D

1

Remove the hose clamp (Item 1) [D] from the in–line filter.

Remove the fuel hose.

Remove the bolt (Item 2) [D] from the filter clamp and remove the filter.

2

N–10689

Revised May 93

–7–4–

225 (S/N 12000 & Above) Excavator Service Manual

FUEL FILTER

A

Final Filter (S/N 12001–12647)

1

See the SERVICE SCHEDULE Page 1–1 for the correct service interval to service the fuel filters.

Close the valve (Item 1) [A] when removing the fuel lines from the filter.

N–10687

B

Remove the mounting bolts from the filter [B].

N–10688

C

Fuel Filter (S/N 12648 & Above) (With Water Drain Valve) See the SERVICE SCHEDULE Page 1–1 for the correct service interval to service the fuel filters.

1

To remove water from the filter, open the drain valve (Item 1) [C]. When fuel, free of water emerges from the drain valve, close the drain valve.

CD–13228

Remove the fuel lines from the filter (Item 1) [D].

D

1

Plug the fuel lines.

Remove the mounting bolts (Item 2) [D] from the filter housing.

2

1 CD–13229

Revised May 93

–7–5–

225 (S/N 12000 & Above) Excavator Service Manual

FUEL INJECTION PUMP

A

Checking the Injection Pump 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 equipment.

N–08645

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 pump, use the following procedure: Disconnect the high pressure fuel line at the pump [A].

Disconnect the other end of the same high pressure line [B].

N–08646

Disconnect the clamp from the fuel line [C].

C

N–08647

Connect the adapter fuel line (Item 1) [D] to the fitting.

D

Connect the pressure gauge (Item 2) [D].

Crank the engine, with the starter, to increase the pressure to 2133 PSI (14707 kPa). Align the plunger at TDC. The pressure should hold at 2133 PSI (14707 kPa), at least 5 seconds. If not, repair or replace the injection pump.

1 2 B–08235

–7–6–

225 (S/N 12000 & Above) Excavator Service Manual

FUEL INJECTION PUMP (Cont’d)

A

Removal and Installation

1

Clean the area around the fuel injection pump. Remove the high pressure fuel lines.

Disconnect the throttle linkage cable from the injection pump [A].

Loosen the jam nuts (Item 1) [A] from the bracket to remove the throttle cable.

N–08648

Disconnect the fuel inlet hose (Item 1) [B] and return hose (Item 2) [B].

B

1

2

N–08649

C

Remove the four nuts from the injection pump [C].

Installation: Tighten the nuts to 17–20 ft.–lbs. (23–27 Nm) torque.

B–13065

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 shims are used for engine timing.

1

B–13063

–7–7–

225 (S/N 12000 & Above) Excavator Service Manual

FUEL INJECTION PUMP (Cont’d)

A

Timing the Injection Pump NOTE: The engine timing marks are located on the engine flywheel. Remove the left rear motor mount [A].

N–08650

Timing the fuel injection pump is done by changing the number of shims (Item 1) [B] between the injection pump and engine block.

B

Each shim will change the timing 1.5 degrees. The timing of the pump will be later when a shim is added, and earlier when a shim is removed.

Use the following procedure to time the injection pump:

1

1. Remove the number 1 cylinder high pressure line from the injection pump.

2. Install a short pipe in the number 1 outlet of the pump. Point the pipe up (vertical).

B–10007

3. With fuel supply to the injection pump, rotate the engine counterclockwise direction (viewed from the flywheel end of the engine). Fuel must flow from the pipe as the mark on the flywheel and the pointer are in alignment [C].

C

4. The correct timing for the engine is 23–25 degrees BTDC. Add or subtract shim(s) as needed to adjust the delivery time of the fuel injection pump.

5. Repeat Step 3 several times for correct timing mark alignment before adding or removing shim(s).

N–08651

–7–8–

225 (S/N 12000 & Above) Excavator Service Manual

FUEL INJECTION NOZZLES

A

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes causing serious injury. 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.

W–2074–1285 N–08645

Some problems caused by faulty injector nozzles:

B

* The engine is hard to start or will not start. * Rough engine operating at idle. * The engine will not have full power.

1

* The engine exhaust smoke is black, whiter or blue.

Removal and Installation

B–13060

Do not bend the high pressure fuel injection tubes when removing or installing them.

C

I–2029–0289

The tool listed will be needed to do the following 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 injection pump. Remove the high pressure fuel lines.

B–13062

Disconnect the return fuel hoses (Item 1) [B].

Remove the banjo fitting from the fuel injector [B].

D

Use the special socket and loosen the injector nozzle [C].

Installation: Tighten the injector nozzle to 29–36 ft.–lbs.

(39–49 Nm) torque.

Remove the injector nozzle from the cylinder head [D].

B–13061

–7–9–

225 (S/N 12000 & Above) Excavator Service Manual

FUEL INJECTOR NOZZLES (Cont’d)

A

Checking the Injector Nozzle

3

Do not disassemble or test the fuel injector nozzles unless you have the correct service and testing tools.

2

I–2027–0284

1 B–04103

The tool listed will be needed to do the following procedure:

B

MEL1008 – Injector Nozzle Tester 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’’ (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

Assemble the nozzle and check the pressure again.

Tighten the nozzle body (Item 3) [A] to 43–58 ft.–lbs.

(59–79 Nm) torque.

Spring CORRECT

WRONG

Pressure Pin Holder Nozzle Body

NOTE: Do not over–tighten, or slow action of the valve will occur.

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 than 740 PSI (5102 kPa), the nozzle is damaged.

A–02621

Check that the spray patter is correct [C]: * Fuel does not come out the side of the nozzle. * Drops of fuel are not present at the nozzle. * The nozzle has an even flow coming from the nozzle.

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes causing serious injury. 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.

W–2074–1285

–7–10–

225 (S/N 12000 & Above) Excavator Service Manual

GLOW PLUGS

A

Removal and Installation 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

CD–08635

Disconnect the glow plug wires [A].

B

Remove the glow plugs from the cylinder head [B].

CD–08636

Checking the Glow Plug 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 [C].

C

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

–7–11–

225 (S/N 12000 & Above) Excavator Service Manual

RADIATOR

A

Removal and Installation Drain the cooling system.

Disconnect the top radiator hose [A].

Disconnect the lower radiator hose and engine block drain hose.

N–08655

B

Remove the bolts from the fan shroud [B].

Move the shroud toward the engine for clearance when removing the radiator.

N–10690

C

Remove the radiator mounting bolts [C].

N–10691

Remove the radiator drain valve [D].

D

N–08661

Revised Apr. 92

–7–12–

225 (S/N 12000 & Above) Excavator Service Manual

RADIATOR (Cont’d)

A

Removal and Installation (Cont’d) Remove the radiator [A].

CD–10692

B

Remove the radiator rubber mounts and washers [B].

N–10693

C

FAN SHIELD (NORDIC OPTION) Removal and Installation Remove the three mounting bolts from the fan shield [C].

Remove the fan shield.

N–12416

Revised Apr. 92

–7–13–

225 (S/N 12000 & Above) Excavator Service Manual

MUFFLER

A

Removal and Installation Remove the bolt from the exhaust pipe clamp [A].

N–08663

B

Remove the bolt from the muffler clamp [B].

N–08664

C

Remove the muffler clamp [C].

N–08665

Remove the muffler [D].

D

N–08666

–7–14–

225 (S/N 12000 & Above) Excavator Service Manual

AIR CLEANER

A

Removal and Installation Raise the engine cover.

Loosen the hose clamps on the air intake hose [A].

Remove the hose.

N–08667

B

Remove the bolt from the air cleaner clamp [B].

Remove the air cleaner.

N–08668

–7–15–

225 (S/N 12000 & Above) Excavator Service Manual

ENGINE

A

Removal and Installation Remove the engine cover. (See Page 5–1.)

Remove the radiator. (See Page 7–12.)

Remove the seat and swing motor cover. (See Page 5–3.)

Disconnect the battery cables from the battery.

Disconnect the engine harness [A].

N–08669

B

Remove the motor mount bolts [B].

N–10694

C

Disconnect the electric fuel pump wire [C].

Remove the fuel hose from the injection pump.

Remove the hydraulic pump mounting bolts. (See Page 2–3.)

N–10685

Connect a chain to the lift eyes on the engine and remove the engine using a chain hoist [D].

D

N–08672

–7–16–

225 (S/N 12000 & Above) Excavator Service Manual

ENGINE FLYWHEEL

A

Removal and Installation NOTE: The flywheel can be removed with the engine installed in the machine. The following photo’s show the engine removed from the machine for photo clarity.

If the engine is not removed; disconnect the two inlet hoses from the hydraulic pump [A].

Drain the hydraulic fluid into a container.

If the engine is not removed, disconnect the three high pressure hoses (Item 1) [A] from the hydraulic pump.

Remove the two mounting bolts from the hydraulic pump [B].

1

N–10596

B

Remove the hydraulic pump from the flywheel bell housing.

N–10597

–7–17–

225 (S/N 12000 & Above) Excavator Service Manual

ENGINE FLYWHEEL (Cont’d)

A

Removal and Installation (Cont’d) Remove the bolts from the flywheel housing [A].

N–08673

B

Remove the two top bolts from the muffler bracket [B].

N–08674

C

Remove the muffler bracket [C].

N–08675

Remove the cover from the flywheel housing [D].

D

N–08676

–7–18–

225 (S/N 12000 & Above) Excavator Service Manual

ENGINE FLYWHEEL (Cont’d)

A

Removal and Installation (Cont’d) Remove the bolts from the hydraulic pump coupler [A].

N–08677

Remove the hydraulic pump coupler [B].

B

Remove the bolts from the flywheel [C].

N–08678

Installation: Tighten the bolts to 40–43 ft.–lbs. (54–59 Nm) torque.

C

Remove the flywheel Flywheel Ring Gear

Wear safety glasses to prevent eye injury when any of the following conditions exist:

• • • •

N–08679

When fluids are under pressure.

Flying debris or loose material is present.

Engine is running.

Tools are being used.

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 a 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.

–7–19–

225 (S/N 12000 & Above) Excavator Service Manual

CYLINDER HEAD

A

Removing the Cylinder Head Drain the cooling system.

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 7–9.)

B–05882

Remove the nuts from the rocket 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.

Remove the cylinder head bolts.

B–05881

–7–20–

225 (S/N 12000 & Above) Excavator Service Manual

CYLINDER HEAD (Cont’d)

A

Removal 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–05866

C

Disassembly of the Cylinder Head The tool listed will be needed to do the following 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].

Remove the valve spring retainer (Item 3) [D] and spring (Item 4) [D].

D

5 2

1

6 Seal

Remove the seal (Item 5) [D] and the valve (Item 6) [D].

4

Collets Cap

3

Valve Spring

–7–21–

Retainer

B–04122

225 (S/N 12000 & Above) Excavator Service Manual

CYLINDER HEAD (Cont’d)

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].

NOTE: Do not put the straight edge across the combustion chambers.

Put a feller 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’’ (± 0,051 mm).

If the measurement is more than the specifications, the cylinder head must be planed.

A–02735

C

NOTE: Place a soft brass rod through the injector hole and tap the combustion chamber out before planing the head. Plane the same amount from the bottom side of the combustion chamber before installing it back in the head.

Clean the valve surface.

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’’ (2,1 mm). The correct angle of the valve and seat is 45 degrees [D].

D

A

C

Valve Contacting Width

B

Grind the valve seats as follows: 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 of Valve Seat

Uncorrected Surface of Valve Seat

3. Use a 65 or 70 degree cutter to grind the bottom surface of the valve seat to a 0.083’’ (2,1 mm) width.

A – 45° cutter B – 15° cutter C – 65° or 70° cutter

4. Grind the valve surface to 45 degrees.

–7–22–

A–02729

225 (S/N 12000 & Above) Excavator Service Manual

CYLINDER HEAD (Cont’d)

A

Disassembly of the Cylinder Head (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’’ (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’’ (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 .3156’’–.3161’’ (8,01–89,03 mm).

B–03698

Checking Valve Springs Measure the valve spring. The free length of the spring must be 1.6417’’–1.6614’’ (41,7–42,3 mm). Check the valve spring with a square to make sure it is straight [C].

C Free Length

B–03680

Put the valve spring in a tester [D].

D

Push down on the spring 1.38’’ (35 mm), the compression loader must be 22.5 lbs. (571,5 kg) max.

Replace the valve spring if it does not meet these specifications.

A–02759

–7–23–

225 (S/N 12000 & Above) Excavator Service Manual

CYLINDER HEAD (Cont’d)

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 0.5513’’–0.5529’’ (14,0–14,04 mm).

The shaft diameter is 0.5501’’–0.5506’’ (13,9–13,98 mm).

If the measurements are not within specification, replace the parts.

B–03697

Assembling the Cylinder Head 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

C

Install the new head gasket [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 65–68 ft.–lbs. (88–92 Nm) torque. Use the tighten sequence as shown in figure [D].

A–02773

–7–24–

225 (S/N 12000 & Above) Excavator Service Manual

CYLINDER HEAD (Cont’d)

A

220ServiceManual#6720874S/N508312000&Above–EngineServiceSectionPart1of2

Installing the Cylinder Head (Cont’d) Lower the piston to be measured 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 0.0276’’–0.0354’’ (0,70–0,89 mm). If the measurement is not within this specification, remove the cylinder head. Install the correct shim between the cylinder head and gasket.

Install the cylinder head. Tighten the bolts and nuts to 65–68 ft.–lbs. (88–92 Nm) torque. Use the tightening sequence on Page 7–24, figure [D].

B–04068

B

Install the push rods [B].

B–05881

Install the rocker arms [C].

C

Install the injector nozzles. (See Page 7–9.)

Install the high pressure fuel lines.

Adjust the valve clearance. (See 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 adjusts to the correct torque after the engine has been operated for 30 minutes.

Readjust the valve clearance.

B–05094

–7–25–

225 (S/N 12000 & Above) Excavator Service Manual

TIMING GEAR COVER

A

Removal and Installation 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 7–7.)

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 spring [B].

B

B–03647

Remove the start spring from the gearcase [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.

(137–157 Nm) torque.

Use a puller and remove the pulley [D].

Remove the crankshaft key.

B–05896

–7–26–

225 (S/N 12000 & Above) Excavator Service Manual

TIMING GEAR COVER (Cont’d)

A

Removal and Installation (Cont’d) Remove the bolts from the gearcase.

Installation: Tighten the bolts to 13–15 ft.–lbs. (18–21 Nm) torque.

Remove the gearcase 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 gearcase cover [B].

B

O–rings

Oil Seal B–03617

–7–27–

225 (S/N 12000 & Above) Excavator Service Manual

TIMING GEAR, CAMSHAFT AND OIL PUMP

A

Removal and Installation Remove the cylinder head. (See Page 7–20.)

Remove the tappets.

Remove the timing gearcase cover. (See Page 7–26.)

Remove the crankshaft collar (Item 1) [A], O–ring (Item 2) [A] and oil slinger (Item 3) [A].

2 3

1 B–03637

B

Remove the snap ring on the idler gear [B].

B–05918

C

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

Remove the idler gear collar from the shaft [C].

1

B–03699

Align the hole in the camshaft gear with the stop plate bolts.

D

Remove the bolts from the camshaft stop plate [D].

Installation: Tighten the bolts to 14–15 ft.–lbs. (18–21 Nm) torque.

B–05930

–7–28–

225 (S/N 12000 & Above) Excavator Service Manual

TIMING GEAR, CAMSHAFT AND OIL PUMP (Cont’d) Removal and Installation (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

C

Remove the stop (Item 1) [C] from the fuel camshaft.

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

Gear backlash is 0.0017’’–0.0045’’ (0,043–0,114 mm).

The limit permitted is 0.0079’’ (0,2 mm).

B–05927

–7–29–

225 (S/N 12000 & Above) Excavator Service Manual

TIMING GEAR, CAMSHAFT AND OIL PUMP (Cont’d)

A

Removal and Installation (Cont’d) 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

C

Remove the oil pump bolts and oil pump [C].

Installation: Tighten the oil pump bolts 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’’ (0,10–0,15 mm). The wear limit is 0.008’’ (0,20 mm).

B–03616

–7–30–

225 (S/N 12000 & Above) Excavator Service Manual

TIMING GEAR, CAMSHAFT AND OIL PUMP (Cont’d)

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’’ (0,10–0,20 mm).

At rated engine speed, the normal oil pressure is 43–64 PSI (196–441 kPa) it must not be lower than 36 PSI (248 kPa).

A–02732

Servicing the Camshaft

B

Measure the camshaft bearing in the engine block [B].

The specification is 1.5748’’–1.5758’’ (39–40 mm). The wear limit is 0.002’’–0.0036’’ (0,051–0,091 mm).

B–03620

Measure the camshaft journal [C].

The specification is 1.5722’’–1.5728’’ (39,93–39,94 mm).

If the measurements are not within limits, replace the parts as needed.

C

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’’ (0,05 mm).

If the camshaft measurements are not within the specifications, replace the part as needed.

A–02760

–7–31–

225 (S/N 12000 & Above) Excavator Service Manual

TIMING GEAR, CAMSHAFT AND OIL PUMP (Cont’d)

A

Servicing the Camshaft (Cont’d) Measure the highest point on each camshaft lobe [A].

The specification is 1.3134’’ (33,36 mm).

The wear limit is 1.3114’’ (33,3 mm).

B–05001

Installation: After the camshaft 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’’ (0,043–0,114 mm). The wear is 0.0059’’ (0,15 mm).

B–03672

–7–32–

225 (S/N 12000 & Above) Excavator Service Manual

CRANKSHAFT AND PISTONS

A

Removal and Installation The tools listed will be needed to do the following procedure: MEL1063 – Ring Compressor MEL1064 – Piston Ring Expander Remove the cylinder head. (See Page 7–20.)

Remove the gearcase cover. (See Page 7–26.)

Remove the timing gears. (See Page 7–28.)

B–05924

Remove the flywheel.

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].

NOTE: Make sure the marks on the connecting rod and bearing cap are in aligned when installing the bearing cap [C].

C

A–02731

Remove the piston and connecting rod assembly from the engine block [D].

NOTE: Make sure the pistons are marked so they will be returned to the same cylinder bore.

D OLD

13 mm

Installation: Tighten the rod cap bolts to torque as follows: Machine Bolt (13 mm Size Head) 27–31 ft.–lbs. (36–42 Nm).

Forged Bolt (12 mm Size Head) 33–36 ft.–lbs. (45–49 Nm).

B–03688

Tightening Torque 27–31 ft.–lbs. (36–42 Nm)

Tightening Torque 33–36 ft.–lbs. (45–49 Nm)

NEW 12 mm

(Cold Forged Flange Bolt) B–13445

–7–33–

225 (S/N 12000 & Above) Excavator Service Manual

CRANKSHAFT AND PISTONS (Cont’d)

A

Removal and Installation (Cont’d) Straighten the washer on the bolts that hold the main bearings in position. Remove the main bearing bolts from the engine block [A].

Installation: Tighten the bolts to 40–50 ft.–lbs. (64–48 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’’ (0,15–0,30 mm). Replace the thrust bearing if the end play exceeds 0.020’’ (0,5 mm).

C

B–10072

D

Remove the crankshaft from the rear of the engine block [D].

NOTE: Do not damage the crankshaft removing it from the engine block.

when

B–04126

–7–34–

225 (S/N 12000 & Above) Excavator Service Manual

CRANKSHAFT AND PISTONS (Cont’d)

A

Crankshaft Service Straighten the washers on the main bearing bolts.

Remove the bolts from the bearing cap halves [A].

Remove the halves on 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.

Installation: Tighten the bolts to 22–25 ft.–lbs.

(29,8–33,9 Nm) torque.

NOTE: Be sure the plugs that come with a new crankshaft are installed in the crankshaft, or engine damage will occur.

B–04092

B

Put the crankshaft on V–blocks. Put a dial indicator on the center journal [B]. Turn the crankshaft slowly. The specifications is 0.0008’’ (0,02 mm). The wear limit is 0.003’’ (0,08 mm).

A–02763

Check the inside diameter of the crankshaft bearing in the engine block.

C

The specification is 2.0465’’–2.0488’’ (51,9–52,03 mm).

The wear limit is 0.008’’ (0,20 mm).

B–03631

Check the outside diameter of the #1 crankshaft journal [D]. The specification is 2.0441’’–2.0449’’ (51,92–51,94 mm). The wear limit is 0.008’’ (0,20 mm).

D

B–03618

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225 (S/N 12000 & Above) Excavator Service Manual

CRANKSHAFT AND PISTONS (Cont’d)

A

Servicing the Connecting Rods and Pistons Remove the piston rings (Item 1) [A] and the piston pin (Item 2) [A].

1

1

B–03621

Installation: Position the top ring so the gap is not lined up with the piston pin. Position the other rings so there 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.

B

Alignment Marks B–03614

C

Put the piston ring on the bottom of the cylinder bore [C].

Check the clearance of the ring gap. The specifications are: Top & 2nd Ring . . 0.0118’’–0.0177’’ (0,299–0,449 mm) Oil Ring . . . . . . . . . . . 0.009’’00.0177’’ (0,22–0,449 mm) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . 0.05’’ (1,27 mm)

B–03622

Measure the piston pin hole [D].

D

The specifications are 0.787’’–0.788’’ (19,98–20,02 mm).

The wear limit is 0.789’’ (20,04 mm).

B–02733

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225 (S/N 12000 & Above) Excavator Service Manual

CRANKSHAFT AND PISTONS (Cont’d) Servicing the Connecting Rods and Pistons (Cont’d)

A

Measure the piston pin (Item 1) [A] and the connecting rod bushing (Item 2) [A].

The specifications are 0.9065’’–0.9071’’ (23,02–23,04 mm).

Clearance between piston pin and bushing on a new engine is 0.0006’’–0.0015’’ (0,015–0,04 mm). Service replacement part clearance is .0006–.0026 (0,015–0,066 mm). The wear limit is 0.006’’ (0,15 mm).

2

1

Using connecting rod hole as a guide, drill a hole through the replacement bushing and deburr the hole.

Install the connecting rod on the tool for checking connecting rod alignment [B].

B–03633

B

The specification is 0.0008’’ (0,020 mm). The wear limit is 0.002’’ (0,05 mm).

B–04067

Check the connecting rod bearings [C].

The specifications are 1.7327’’–1.7343’’ (44,01–44,05 mm). The wear limit is 0.008’’ (0,20 mm).

C

120°

A–02727

Check the O.D. of the connecting rod journals [D].

The specifications are 1.7307’’–1.7313’’ (49,95–43,97 mm). The wear limit is 0.008’’ (0,20 mm).

D

A B

If the connecting rod journals are not within specifications, grind the journals as follows [D]: 1. Crankshaft corner radius must be 0.138’’R±0.008’’ (3,5 mmR±0,20 mm).

2. The oil hole must be chamfered to 0.039’’–0.059’’R (0,99–1,5 mmR).

A A–02716

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225 (S/N 12000 & Above) Excavator Service Manual

CYLINDER LINERS

A

Checking the Cylinder Liners The tools listed will be needed to do the following 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

The specifications are 3.3465’’–3.3473’’ (85,00–85,02 mm). The wear limit is +0.006’’ (+0,15 mm).

When the cylinder liner has more wear than specifications, bore and hone the cylinder to .020 oversize. (See Parts Fiche.)

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 3.3465’’–3.3473’’ (85,00–85,02 mm).

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225 (S/N 12000 & Above) Excavator Service Manual

WATER PUMP

A

Removal and Installation Drain the cooling system.

Remove the radiator. (See Page 7–12.)

Remove the alternator belt.

Remove the fan.

Remove the water pump bolts.

Remove the water pump [A].

B–05926

Installation: Always use a new gasket when installing the water pump.

B

Disassembly and Assembly Put the water pump in a vise.

Remove the pulley.

Drive the shaft out of the impeller side of the water pump [B].

(4)

Remove the seal.

(2) (3)

Install a new seal when assembling the water pump.

(1)

B–05929

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225 (S/N 12000 & Above) Excavator Service Manual

220ServiceManual#6720874S/N508312000&Above–EngineServiceSectionPart2of2

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225 (S/N 12000 & Above) Excavator Service Manual

SPECIFICATIONS Page Number ENGINE SPECIFICATIONS Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5 Engine Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6 Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5 Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5 Re–Grinding the Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–7 Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 FUEL, COOLANT AND LUBRICANTS Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8 HYDRAULIC EXCAVATOR SPECIFICATIONS Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 Digging Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2 Lifting Capacity With Blade Off Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2 Operation Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 OIL SPECIFICATIONS Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8

–8––1–

SPECIFICATIONS

225 (S/N 12000 & Above) Excavator Service Manual

–8–0–

225 (S/N 12000 & Above) Excavator Service Manual

S

HYDRAULIC EXCAVATOR SPECIFICATIONS

S

Machine Dimensions

All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.

15.4 (381) 80.4 (2042)

23.45 (595)

MC–01404

163.8 (4160) 118.7 (3021)

93.5 (2377) 53.43 (1357) 22.74 (577)

14.6 (370.9) 12.60 (320)

53.1 (1350)

43.3 (1100) 55.9 (1420)

54.3 (1372) 70.89 (1800)

MC–01402

C D G

Inches (mm)

E

H F

B

I

A B C D E F G

J

H I J

A

MC–01403

–8–1–

Max. digging depth Max.vertical wall depth Max. digging reach Max. digging reach at ground level Max. digging height Max. dumping height Max. work equipment radius W/boom at max. height & arm retracted Max. height of Min. swing radius Max. lift above ground (blade) Max. drop below ground blade

97.31(2471.6) 62.74(1593.5) 1710 (4344.2) 165.8(4213.7) 148 (3761) 101.27 (2577.2) 80.8 (2054.5) 126.4 (3211.6)) 13.6 (345.9) 9.5 (241)

225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC EXCAVATOR SPECIFICATIONS (Cont’d) Lifting Capacity With Blade Off Ground

225

OPERATION & PERFORMANCE Weights Operating Weight (W/Canopy & Rubber Track) . . . . . . . . .

(W/Cab & Rubber Track) . . . . . . . . . . . .

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tracks: Steel . . . . . . . . . . . . . . . . . . . . . . .

Rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...................................

Travel Speed . . . . . . . . . . . . . . . . . . . . . . .

Controls Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Function . . . . . . . . . . . . . . . . . . . . . . . . . . .

5898 lbs. (2677 kg) 5684 lbs. (2580 kg) 458 lbs. (208 kg) 127 lbs. (58 kg) 636 lbs. (288 kg) 490 lbs. (222 kg) 127 lbs. (58 kg) 1.35 lbs. (2,2 km/hr.)

Two Hand Levers Two joystick levers control boom, bucket, arm and swing. Left foot pedal controls auxiliary hydraulics. Right foot pedal controls boom swing.

Speparate hand lever control blade.

ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horsepower . . . . . . . . . . . . . . . . . . . . . . . .

Displacement . . . . . . . . . . . . . . . . . . . . . . .

Maximum Torque . . . . . . . . . . . . . . . . . . . .

Maximum Governed RPM – Full Load . .

No Load . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Idle Speed . . . . . . . . . . . . . . . . . . . . .

Number of Cylinders . . . . . . . . . . . . . . . . .

Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System . . . . . . . . . . . . . . . . . . . . .

Lubrication System . . . . . . . . . . . . . . . . . .

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Revised Mar. 98

Kobota D–1402–B Diesel 23.1 HP (17 kW) @ 2500 RPM 85.1 cu. in. (1395 cu. cm.)

62.9 ft.–lbs. (85 Nm) @ 1800 RPM 2500 RPM 2600 RPM 1000 RPM Three 3.25/3.23 (85/82) Liquid Pressure Cartridge Type – Full Flow 12 Volt, 1.4 Kw Reduction Drive 12 Volt, 50 Amp. 12 Volt, 400 Cold Crank Amps. at 0°F (–18°C) 75 min. reserve capacity at 25 Amps.

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225 (S/N 12000 & Above) Excavator Service Manual

HYDRAULIC EXCAVATOR SPECIFICATIONS (Cont’d) HYDRAULIC SYSTEM

225

Pump Numbers . . . . . . . . . . . . . . . . . . . . .

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Relief Setting . . . . . . . . . . . . . . . .

Control Valves . . . . . . . . . . . . . . . . . . . . . .

Three Triple Section Gear Pumps 3 x 7.14 gal./min. (27.03 L/min.)

2350 PSI (16201 kPa) 6 Spool, Parallel Type, Open Center 3 Spool, Parallel Type, Open Center Two/Axial Piston 1.05 cu. in./rev. (17.2 cc. rev.)

Orbit Motor 4.9 cu. in/rev. (80.6 cc. rev.)

1650 Psi (11375 kPa) 363 PSI (2500 kPa) 200 PSI (1379 kPa)

Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Motor . . . . . . . . . . . . . . . . . . . . . . . .

Swing Relief Setting . . . . . . . . . . . . . . . . .

Joystick Control Setting . . . . . . . . . . . . . .

Pressure Build–Up Valve . . . . . . . . . . . . .

Port Relief (Arm) Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Port Relief (Boom) Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket Relief . . . . . . . . . . . . . . . . . . . . . . .

2950 PSI (20345 kPa) 2950 PSI (20345 kPa) 2950 PSI (20345 kPa) 3400 PSI (23448 kPa) 3400 PSI (23448 kPa)

SWING SYSTEM Swing Drive . . . . . . . . . . . . . . . . . . . . . . . .

Swing Circle . . . . . . . . . . . . . . . . . . . . . . . .

Swing Speed . . . . . . . . . . . . . . . . . . . . . . .

Boom Swing (Left) . . . . . . . . . . . . . . . . . .

(Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axial Piston Motor to a 4.26:1 Planetary Drive Single Row Shear Type Ball Bearings W/Internal Gears Built Into Swing Circle 9.5 RPM 38.78 degrees 77.5 degrees

HYDRAULIC CYLINDERS Boom (Cushion–Boom Up) . . . . . . . . . . .

Arm (Cushion–Arm Retract) . . . . . . . . . .

Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Swing (Cushion Left & Right) . . . .

Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bore

Rod

Stroke

2.75 (70) 2.75 (70) 2.75 (70) 2.36 (60) 2.75 (70)

1.50 (40) 1.50 (40) 1.50 (40) 1.38 (35) 1.50 (40)

21.6 (590) 19.7 (500) 15.7 (400) 15.7 (400) 4.92 (125)

DRIVE SYSTEM Final Drive . . . . . . . . . . . . . . . . . . . . . . . . .

Type of Reduction . . . . . . . . . . . . . . . . . . .

Maximum Drawbar Pull . . . . . . . . . . . . . .

Gradeability . . . . . . . . . . . . . . . . . . . . . . . .

Each Track is Independently Driven by a Hydrostatic Axial Piston Motor 53:1 Two Stage Planetary 2500 lbs. (1134 kg) 30 degrees

UNDERCARRIAGE Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crawler–Tractor Design Undercarriage. Sealed Track Roller W/Reinforced Box–Section. Grease Type Track Adjusters W/ Shock Absorbing Recoil System

TRACK Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number of Shoes . . . . . . . . . . . . . . . . . . .

Number of Track Rollers . . . . . . . . . . . . .

Ground Pressure . . . . . . . . . . . . . . . . . . . .

Steel (Optional) 11.8 (300) 37 3 4 PSI (0,28 kPa)

Rubber (Standard) 12.6 (320) Single Assembly 3 4.16 PSI (0,29 kPa)

CAPACITIES Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System . . . . . . . . . . . . . . . . . . . . .

Engine Oil & Filter . . . . . . . . . . . . . . . . . . .

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

Final Drive Case (Each) . . . . . . . . . . . . . .

9 Gals (34 L) 6.3 Qts. (6,0 L) 6.3 Qts. (6,0) 10.5 Gals. (40 L) 0.55 Qts. (0,5 L)

DIGGING FORCE Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2683 lbs. (1218 kg) 3863 lbs. (1753 kg)

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225 (S/N 12000 & Above) Excavator Service Manual

ENGINE SPECIFICATIONS All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Fuel Injection Nozzles Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1990–2133 PSI (1372,1–1468,63 kPa) Fuel Tightness Nozzle Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry Nozzle at 1848–1990 PSI (12741,9–1372,1 kPa) Fuel Injection Pump Fuel Tightness of Plunger . . . . . . . . . . . . . . . . . . . . . 8 sec: initial pressure from 8532–7110 PSI (58828,1–49023,4 kPa) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 seconds or less Fuel Tighteness of Delivery Valve . . . . . . . . . . . . . . 10 Seconds: Initital Pressure from 1422–71 PSI (9804,7–489,5 kPa) Limited Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Seconds or Less Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23–25 degrees before TDC Cylinder Head Cylinder Head Surface Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0020 in. (0,05 mm) Thickness of Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0512–0.0630 in. (1,300–1,600 mm) Thickness of Gasket Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0079 in. (0,20 mm) Top Clearance (Piston to Head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0276–.0354 in. (0,7–9,5 mm) Head Bolt Torque (Flanged Bolt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65–68 ft.–lbs. (88–92 Nm) (Bolt & Washer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58–62 ft.–lbs. (79–83 Nm) Maximum Milling Allowed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .004 in. (0,1 mm) Valves Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0827 in. (2,1 mm) Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees O.D. of Valve Stems (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3134–.3140 in. (7,960–7,975 mm) I.D. of Valve Guides (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3156–.3161 in. (8,015–9,030 mm) Clearance Between Valve Stem & Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0016–.0028 in. (0,04–0,07 mm) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0039 in. (0,1 mm) Depth of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0433–.0512 in. (1,1–1,3 mm) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0630 in. (1,6 mm) Valve Clearance (Old) (Intake & Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071–.0087 in. (0,18–0,22 mm) Valve Springs Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6417–1.6614 in. (41,7–42,2 mm) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6220 in. (41,2 mm) Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3839 in. (35,15 mm) Load to Compress to Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.5 lbs. (12,03 kg) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 lbs. (10.22 kg) Rocker Arms O.D. of Rocker Arm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5501–0.5506 (13,973–13,984 mm) I.D. of Rocker Arm Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5512–0.5529(14,002–14,043 mm) Clearance Between Rocker Arm & Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0004–.0028 in. (0,01–0,07 mm) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059 in. (0,15 mm) Camshaft O.D. of Camshaft Bearing Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5722–1.528 in. (39,934–39,950 mm) I.D. of Camshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5748–1.5758 in. (40–40,025 mm) Clearance between Camshaft Bearing & Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .002–.0036 in. (0,50–0,091 mm) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059 (0,15 mm) Alignment of the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008 in. (0,02 mm) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 in. (0,05 mm) Cam Lobe Height (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3134 in. (33,36 mm) Gear Clearance (Backlash) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0016–.0045 in. (0,0415–0,1154 mm) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0118 in. (0,3 mm)

Revised Mar. 98

–8–4–

225 (S/N 12000 & Above) Excavator Service Manual

ENGINE SPECIFICATIONS (Cont’d) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Cylinders I.D. of Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.365–3.3473 in. (85–85,022 mm) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.0059 in. (+0,0150 mm) Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.366–3.3670 in. (85,5–85,5522 mm) Piston Rings Ring Gap (Top & 2nd Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0118–.0177 in. (0,30–0,45 mm) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0492 in. (1,25 mm) Ring Gap (Oil Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0098–0.0177 (0,25–0,45 mm) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0492 in. (1,25 mm) Side Clearance of Ring Groove: Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 Clearance Second Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0037–0.004 7 in.(0,093–0,120 mm) Oil RIng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008–0.0020 in.(0,020–0,052 mm) Pistons O.D. of Piston (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.342 (84,88 mm) O.D. of Piston (Oversize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.362 (85,39 mm) I.D. of Piston Bosses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9055–.9060 in. (23–23,013 mm) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9076 in. (23,053 mm) O.D. of Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9056–.9059 in. (23,002–23,011 mm) I.D. of Connecting Rod Bushing (Small End, Fitted) . . . . . . . . . . . . . . . . . . . . . . . . . .9065–.9071 in. (23,025–23,030 mm) Clearance between Piston Pin & Bushing (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0006–0.0015 in. (0,015–0,038 mm) (Service Replacement Parts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006–.0026 in. (0,015–0,07 mm) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059 in. (0,15 mm) Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008 in. (0,02 mm) Limited Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 in. (0,05 mm) Crankshaft I.D. of Crankshaft Main Bearing (No. 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0465–2.0488 in. (51,98–52,039 mm) I.D. of Crankshaft Main Beairng (No. 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0465–2.0482 in. (51,98–52,025 mm) Clearance Between Crankshaft Journal & Bearing (No. 1) . . . . . . . . . . . . . . . . . . . . . . . . .0016–.0046 in. (0,04–0,118 mm) Clearance Between Crankshaft Journal & Bearing (No. 2) . . . . . . . . . . . . . . . . . . . . . . . 0.0016–.0041 in. (0,04–0,104 mm) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0079 in. (0,2 mm) O.D. of Connecting Rod Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7307–1.7313 in. (43,959–43,975 mm) I.D. of Connecting Rod Beairngs (Std.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7327–1.7343 in. (44,010–44,052 mm) I.D. of Connecting Rod (Undersizes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7228–1.7234 (43,759–43,775 mm) 1.7149–1.7156 (43,559–43,575 mm) Clearance Between Connecting Rod Journal & Bearing . . . . . . . . . . . . . . . . . . . . . . . . . .0014–.0037 in. (0,035–0,393 mm) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0079 in. (0,2 mm) End Play of Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059–.0122 in. (0,15–0,21 mm) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197 in. (0,50 mm) Oil Pump Oil Pressure @ rated RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–64 PSI (294–441 kPa) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 PSI (248,2 kPa) Rotor Lobe Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0039–.0063 in. (0,10–0,16 mm) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0079 in. (0,20 mm) Clearance Between Outer Rotor and Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0043–.0075 in. (0,11–0,19 mm) Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0098 in. (0,25 mm) Engine Oil Specifications Check oil level every 8 hours of operation. (Check oil ever 4 hours on new engine during the first 50 hours of operation.)

Oil level must be between the add and full marks on the dipstick. Use a good quality detergent motor oil that meets the correct API service classification. (See Chart on Page 8–8.)

Use oil of the correct SAE viscosity for expected termperature conditions.

Revised Mar. 98

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225 (S/N 12000 & Above) Excavator Service Manual

ENGINE SPECIFICATIONS (Cont’d) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

ENGINE TORQUE Ft.–Lbs. *Cylinder Head Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65–68 *Main Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47–50 *Main Bearing Case Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22–25 *Flywheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40–43 *Connecting Rod Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27–31 *Rocker Arm Bracket Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12–15 *Idler Gear Shaft Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7–8 Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15–18 Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30–36 Nozzle Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22–36 Oil Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11–15 Fuel Injection Tubeline Fittings . . . . . . . . . . . . . . . . . . . . . . . . . .

11–19 Crankshaft Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101–116 Injection Pump Vent Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10–13

Nm 88–92 63–68 29–34 54–59 36–42 17–21 9–11 20–25 39–49 39–49 15–20 13–26 137–157 14–18

*Lightly Oil Threads

PUNCHED NUMBER None

BOLT MATERIAL GRADE Standard Bolts

SS41, S20C

7

Special Bolts

S43C, 248C (Refined)

9

Special Bolts

SCM3, SCR3 (Refinded)

BOLT TORQUES MATERIAL GRADE

STANDARD BOLT

STANDARD BOLT

STANDARD BOLT

NOMINAL DIAMETER

SS42, S20C

S43C,S–48C (Refined)

SCR3, SCM3 (Refined)

M6

6–7 ft.–lbs.

(8–9 Nm)

7–8 ft.–lbs.

(9–11 Nm)

9–11 ft.–lbs.

(12–15 Nm)

M8

13–15 ft.–lbs.

(18–20 Nm)

17–20 ft.–lbs.

(23–27 Nm)

22–25 ft.–lbs.

(30–34 Nm)

M10

29–33 ft.–lbs.

(39–45 Nm)

35–41 ft.–lbs.

(47–56 Nm)

45–52 ft.–lbs.

(61–71 Nm)

M12

46–54 ft.–lbs.

(62–73 Nm)

57–67 ft.–lbs.

(77–91 Nm)

76–87 ft.–lbs.

(103–118 Nm)

M14

80–93 ft.–lbs.

(108–126 Nm)

91–109 ft.–lbs.

(123–148 Nm)

123–145 ft.–lbs.

(167–197 Nm)

M16

123–141 ft.–lbs.

(167–191 Nm)

145–166 ft.–lbs.

(197–225 Nm)

192–224 ft.–lbs.

(260–304 Nm)

M18

181–210 ft.–lbs.

(245–285 ft.–lbs.

203–235 ft.–lbs.

(275–319 Nm)

253–297 ft.–lbs.

(343–403 Nm)

M20

246–189 ft.–lbs.

(334–392 Nm)

271–318 ft.–lbs.

(367–431 Nm)

362–420 ft.–lbs.

(491–578 Nm)

–8–6–

225 (S/N 12000 & Above) Excavator Service Manual

ENGINE SPECIFICATIONS (Cont’d) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Re–Grinding The Crankshaft If the standard size bearing cannot be used due to excessive wear of the crankpin and crank journals, use undersize or oversize bearings.

D 3

C 1 2

B

A

1

2 B–05928

REF.

SIZE

CODE NUMBER

DESCRIPTION

DIMENSION

MARK

0.008 in.

(0,2 mm) U/S

15221–2391–1

Crankshaft Bearing #1

2.0363–2.0370 in.

(51,721–51,740 mm)

020US

A

0.016 in.

(0,4 mm) U/S

15221–2392–1

Crankshaft Bearing #1

2.0284–2.091 in.

(51,7–521–51,540 mm)

040US

0.008 in (0,2 mm) U/S

15221–2393–1

Crankshaft Bearing #2

2.0363–2.0370 in.

(51,721–51,740 mm)

020US

0.016 in.

(0,4 mm) U/S

15221–2394–1

Crankshaft Bearing #2

2.0284–2.0291 in.

(51,521–51,540 mm)

040US

0.008 in.

(0,2 mm) U/S

15471–2297–1

Crankpin Bearing

1.7228–1.7234in.

43,759–43,775 mm)

020US

0.016 in.

(0,4 mm) U/S

15471–2298–1

Crankpin Bearing

1.7149–1.7156 in.

(43,559–43,575 mm)

040US

0,008 in.

(0,2 mm) O/S

15221–2397–1 15221–2395–1

Crankshaft Thrust Bearing

0.0315–0.0335 in.

(26,20–26,25 mm)

0.20 OS

0.016 in.

(0,4 mm) O/S

15221–2398–1 15221–2396–1

Crankshaft Thrust Bearing

1.0394–1.0413 in.

(26,40–26,45 mm)

0.40 OS

B

C

D

1

Radius – 0.0079–0.1181 in (0,2–3,0 mm)

2

Radius – 0.0076–0.1378 in. (0,2–3,5 mm)

3

IMPORTANT: Oil hoses must have a 0.0394–0.0591 in. (1–1,5 mm) chamfer.

Use on oil stone to chamfer the oil hole.

–8–7–

225 (S/N 12000 & Above) Excavator Service Manual

FUEL, COOLANT AND LUBRICANTS 220ServiceManual#6720874S/N508312000&Above–SpecificationsSection

Use the following chart for correct selection of Fuel, Coolant and Lubricants.

AMBIENT TEMPERATURE RESERVOIR

KIND OF FLUID

Engine oil pan

Use SAE Viscosity Number as Listed With API Classification CC, CD or CE

CAPACITY

F° –30 –20 –10 0 +10 +20+30 +40 +50 +60 +70 +80 +90 +100 C° –34 –29 –23 –18–13 –7 –1 +4 +10 +15 +21 +27 +32 +38

Refill 6.34qts.

(6,0 L)

SAE 10W–30 SAE 15W–40 SAE 5W–30 SAE 30 SAE 20W/20 SAE 10W

Fuel Tank

Diesel Fuel

9 gals (34 L)

No. 1 No. 2

Cooling System

50/50 Water & Anti–Freeze

Hydraulic Tank

Bobcat Fluid 6563328*

Tank Cap. 10.5 gals (40 L) System Capacity gals. ( L)

90W Gear

0.5 qts.

(0,5 L)

Final Drive Case (each)

50/50 Water & Anti–Freeze

6.34 qts.

(6,0 L)

*If Bobcat fluid (P/N 6563328 is not available use Engine Oil SAE 10W–30.

OIL SPECIFICATIONS Description When fuel sulphur content is less than 0.5% change the engine oil and filter as shown in the Service Schedule Page 1–3.

Change engine oil and filter according to the following chart if fuel sulphur content is above 0.5%.

Fuel Sulphur Change Interval Of Content Engine & Oil Filter 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 CE engine oil.

Revised Mar. 98

–8–8–

225 (S/N 12000 & Above) Excavator Service Manual

225–1 ®

Revision Number

29 April 1992

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

225 (S/N 12001 & Above)

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6720874 (1–91)

NOTICE

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Section 2 – Content Page

Section 2 – Content Page (Revised Apr. 92)

225 EXCAVATOR HYD. SCHEMATIC (NORDIC) (S/N 12000 & Above)

225 EXCAVATOR HYD. SCHEMATIC (NORDIC) P/N 6722177 (Added April 1992) HYDRAULIC SYSTEM OPERATION Chart Legend P/N 6722177 (Added April 1992)

2–13, 2–14

2–13 (Revised Apr. 92), 2–14 (Revised Apr. 92)

Section 4 – Content Page 4–3, 4–4 4–5

Section 4 – Content Page (Revised Apr. 92) 4–3 (Revised Apr. 92), 4–4 (Revised Apr. 92) 4–5 (Revised Apr. 92), 4–6 (Added Apr. 92) 4–7 (Added Apr. 92), 4–8 (Added Apr. 92) 4–9 (Added Apr. 92), 4–10 (Added Apr. 92) 4–11 (Added Apr. 92), 4–12 (Added Apr. 92) 4–13 (Added Apr. 92)

Section 5 – Content Page 5–1, 5–2 5–3, 5–4 5–13, 5–14

Section 5 – Content Page (Revised Apr. 92) , 5–1, 5–2 (Revised Apr. 92) 5–3 (Revised Apr. 92), 5–4 5–13, 5–14 (Revised Apr. 92) 5–15 (Added Apr. 92)

Section 6 – Content Page

Section 6 – Content Page (Revised Apr. 92)

WIRING DIAGRAM (P/N 6720677)

WIRING DIAGRAM #6722143 (STANDARD) WIRING DIAGRAM #6722176 (NORDIC OPTION) 6–9 (Added Apr. 92), 6–10 (Added Apr. 92) 6–11 (Added Apr. 92), 6–12 (Added Apr. 92) 6–13 (Added Apr. 92), 6–14 (Added Apr. 92)

Section 7 – Content Page 7–11, 7–12 7–13, 7–14

Section 7 – Content Page 7–11, 7–12 (Revised Apr. 92) 7–13 (Revised Apr. 92), 7–14

Printed in U.S.A.

225–2 ®

Revision Number

15 June 1992

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

225 (S/N 12001 & Above)

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6720874 (1–91)

NOTICE

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Section 3 – Content Page 3–3 Thru 3–12

Section 3 – Content Page (Revised June 92) 3–3 Thru 3–12 (Revised June 92) 3–13 Thru 3–18 (Added June 92)

Section 5 – Content Page 5–13 Thru 5–15 (Added Mar. 92) 4–5

Section 5 – Content Page (Revised June 92) 5–13, 5–14 (Revised June 92) 5–15 (Revised June 92), 5–16 (Revised June 92)

225–3 ®

Revision Number

12 August 1992

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

225 (S/N 12001 & Above)

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6720874 (1–91)

NOTICE

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Section 2 – Content Page 2–1 Thru 2–19

Section 2 – Content Page (Revised Aug. 92) 2–1 Thru 2–5 (Revised Aug. 92) 2–6 Thru 2–19 (Revised Aug. 92) 2–20 Thru 2–44 (Added Aug. 92)

225–4 ®

Revision Number

17 March 1993

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

225 (S/N 12001 & Above)

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6720874 (1–91)

NOTICE

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The attached pages are a revision to the 225 (12000) Service Manual (P/N 6720874).

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225 EXCAVATOR HYD. SCHEMATIC (STANDARD) (S/N 12000 & Above) (MC–1442)

225 EXCAVATOR HYD. SCHEMATIC (STANDARD) (S/N 12001 – 12162) (TS–1137)

225 EXCAVATOR HYD. SCHEMATIC (ISO) (S/N 12000 & Above) (MC–1443)

225 EXCAVATOR HYD. SCHEMATIC (ISO) (S/N 12001 – 12162) (TS–1136)

225 EXCAVATOR HYD. FLOW CHART (STANDARD) (S/N 12001 – 12162) #6720675 (Printed Jan. 1991) (Sheet 1 of 2)

225 EXCAVATOR HYD. FLOW CHART (STANDARD) (S/N 12001 – 12162) #6720675 (Sheet 1 of 2 & 2 of 2)

225 EXCAVATOR HYD. SYSTEM OPERATION (STANDARD) 225 EXCAVATOR HYD. SCHEMATIC (STANDARD) (S/N 12000 & Above) #6720675 (Printed Jan. 1991) (S/N 12163 & Above) (TS–1135) (Sheet 2 of 2) 225 EXCAVATOR HYD. SCHEMATIC (ISO) (S/N 12163 & Above) (TS–1134) 225 EXCAVATOR HYD. FLOW CHART (ISO) (S/N 12000 & Above) #6720676 (Printed Jan. 1991) (Sheet 1 of 2) 225 EXCAVATOR HYD. SYSTEM OPERATION (ISO) (S/N 12000 & Above) #6720676 (Printed Jan. 1991) (Sheet 2 of 2)

225 EXCAVATOR HYD. FLOW CHART (ISO & STANDARD) (S/N 12163 & Above) #6722590 (Sheet 1 of 2 & 2 of 2)

225–5 ®

Revision Number

28 April 1993

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

225 (S/N 12001 & Above)

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6720874 (1–91)

NOTICE

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The attached pages are a revision to the 225 (12000) Service Manual (P/N 6720874).

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Section 2 – Content Page 2–4 Thru 2–44

Section 2 – Content Page (Revised Apr. 93) 2–4 Thru 2–44 (Revised Apr. 93) 2–45 Thru 2–55 (Added Apr. 93)

Section 3 – Content Page (Revised June 92)

Section 3 – Content Page (Revised Apr. 93) 3–19 Thru 3–42 (Added Apr. 93)

225–6 ®

Revision Number

27 May 1993

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

225 (S/N 12001 & Above)

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6720874 (1–91)

NOTICE

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SECTION 1

1–1 Thru 1–4

1–1 Thru 1–4 (Revised May 93)

SECTION 5

5–11 Thru 5–16

5–11 Thru 5–16 (Revised May 93)

SECTION 7

7–3 Thru 7–6

7–3 Thru 7–6 (Revised May 93)

SECTION 8

8–1, 8–2

8–1, 8–2 (Revised May 93)

225–7 ®

Revision Number

10 January 1994

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

225 (S/N 12001 & Above)

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6720874 (1–91)

NOTICE

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The attached pages are a revision to the 225 (12000) Service Manual (P/N 6720874).

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Section 4 – Content Page 4–3 Thru 4–13

Section 4 – Content Page (Revised Jan. 94) 4–3 Thru 4–13 (Revised Jan. 94) 4–14 Thru 4–35 (Added Jan. 94)

225–8 ®

Revision Number

8 February 1995

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

225 (S/N 12001 & Above)

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6720874 (1–91)

NOTICE

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The attached pages are a revision to the 225 (12000) Service Manual (P/N 6720874).

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Section 5 – Content Page 5–13 5–14

Section 5 – Content Page (Revised Feb. 95) 5–13 Thru 5–13m (Added Feb. 95) 5–14 Thru 5–14n (Added Feb. 95)

225–9 ®

Revision Number

13 February 1998

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

225 (S/N 12001 & Above)

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6720874 (1–91)

NOTICE

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1–1, 1–2 1–5, 1–6

1–1 (Revised Feb. 98), 1–2 1–5 (Revised Feb. 98), 1–6

225–10 ®

Revision Number

2 March 1998

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT EXCAVATOR Model

225 (S/N 12001 & Above)

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6720874 (1–91)

NOTICE

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Cover (1–91)

Cover (1–91)

Cartoon

Cartoon

Foreword, Contents (i Thru iii)

Contents (i Thru viii) (Revised Mar. 98)

1–1, 1–2 1–5, 1–6

1–1 (Revised Mar. 98), 1–2 1–5 (Revised Mar. 98), 1–6

2–37 Thru 2–55

2–37 Thru 2–66 (Revised Mar. 98)

Section 5

Section 5 (Revised Mar. 98)