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Product: EXCAVATOR
Model: 225 EXCAVATOR 51U
Configuration: 225 EXCAVATOR 51U00590-02033 (MACHINE)
Disassembly and Assembly
225 EXCAVATOR VEHICLE SYSTEMS
Media Number -SENR7907-00
Pump Drive
SMCS - 3108-16; 3108-11; 3108-12; 3108-15
Remove Pump Drive
start by:
a) remove muffler *
b) remove axial piston pump (front)
c) remove axial piston pump (rear)
d) remove pilot system pump
*Operation location is in ENGINE DISASSEMBLY AND ASSEMBLY section.
NOTE: If there has been no hydraulic system failure, see subject BLOCKER PLATES on Page 8.
1. Remove oil from the hydraulic tank and pump drive housing.
2. Disconnect governor control linkage (2) from the governor and bracket.
3. Remove the eight nuts (1) that hold air cleaner to the inlet pipe. Remove air cleaner (3).
4. Remove bolts (7) and remove muffler bracket (5).
5. Remove bolts (6), then remove shield (4).
6. Remove the two bolts (8) that hold pump drive to frame.
7. Loosen the four bolts (9) that hold the front engine support to the frame.
8. Lift the pump drive and install a .50 in. (12.7 mm) steel spacer between bottom of flywheel housing and top of frame. Lower the pump drive until flywheel housing is on the spacer.
9. Remove bolts (11), then remove bracket (10) from crossover pipe.
10. Install two 5/8" - 11 NC forged eyebolts in the pump drive housing, then fasten a hoist. Remove remainder of bolts (11). Remove pump drive (12). Weight of the pump drive is 430 lb. (194 kg).
Install Pump Drive
1. Install two 3/8"-16 NC guide pins in the flywheel housing.
2. Install two 5/8"-11 NC forged eyebolts in the pump drive housing, then fasten a hoist.
3. Put pump drive (1) in position on the flywheel housing and install the bolts that hold it.
4. Install bracket (2) on crossover pipe with the bolts that hold it.
5. Lift the pump drive housing until the steel spacer between the frame and flywheel housing can be removed. Remove the spacer.
6. Install the two bolts (3) that hold pump drive to the frame. Tighten these bolts to a torque of 315 ± 50 lb.ft. (430 ± 70 N·m).
7. Install the four bolts (4) that hold engine supports to the frame. Tighten these bolts to a torque of 90 ± 15 lb.ft. (120 ± 20 N·m).
8. Install shield (5) with the bolts (6) that hold it. Tighten these bolts to a torque of 100 ± 10 lb.ft. (135 ± 14 N·m).
9. Install muffler bracket (7) with the bolts that hold it. Tighten these bolts to a torque of 100 ± 10 lb.ft. (135 ± 14 N·m).
10. Install air cleaner (10) with the eight nuts (8) that hold it to the inlet pipe. Tighten the nuts to a torque of 20 ± 5 lb.ft. (25 ± 7 N·m).
11. Connect governor control linkage (9) to the governor.
12. Fill the pump drive with oil to the correct level.
13. Fill the hydraulic tank with oil to the correct level. end by:
a) install pilot system pump
b) install axial piston pump (rear)
c) install axial piston pump (front)
d) install muffler *
*Operation location is in ENGINE DISASSEMBLY AND ASSEMBLY section.
Disassemble Pump Drive
start by:
a) remove pump drive
1. Remove the six bolts that hold bearing cage (1) to the cover. Install two 5/8"-11NC forcing screws and remove the bearing cage and shims (2).
2. Remove the six bolts that hold bearing cage (3) to the cover. Install two 5/8"-11NC forcing screws and remove the bearing cage and shims (4).
3. Remove the bearing cup from cage (3) with a hammer and punch. Remove the O-ring seal from the cage.
4. Remove the six bolts that hold bearing cage (5) to the cover. Install two 5/8"-11NC forcing screws and remove the bearing cage and shims (6).
5. Remove the lip-type seals from cages (1) and (5). Install tooling (A) and remove the bearing cups from the cages. Remove the O-ring seals from the cages.
6. Remove the bolts that hold the cover to the case. Install two 1/2"-13NC forcing screws and loosen the cover from the case. Remove the forcing screws and install two 1/2"-13NC forged eyebolts in the cover. Fasten a hoist and remove cover (7) from the case. The weight of the cover is 90 lb. (41 kg).
7. Remove gears (8), (9), and (10) from the case.
8. Install tooling (B) and remove the bearing cones from each side of the three gears.
9. Install tooling (C) and remove the three bearing cups from the case.
10. Remove the two lip-type seals (11) from the case.
Assemble Pump Drive
Install the lip-type seal with the lip of the seal toward the inside of the case with tooling (B). Put oil on the lip of the seal.
2. Turn the case over and install the lip-type seal (2) with the lip of the seal toward the outside of the case with tooling (B). Put oil on the lip of the seal.
3. Lower the temperature of the three bearing cups (1). Install the cups in the case.
1.
4. Heat bearing cones (3) for the three gears in oil to a maximum temperature of 275°F (135°C). Install the cones on each side of the three gears.
5. Install gears (4), (5), and (6) in the case.
6. Install two 1/2"-13NC forged eyebolts in the cover. Fasten a hoist. Clean the old gasket material from the contact surfaces of the cover and case. Put 7M7260 Liquid Gasket on the surfaces. Put cover (7) in position on the case.
7. Install the bolts that hold the cover to the case. Tighten the bolts to a torque of 100 ± 10 lb.ft. (135 ± 14 N·m). Install four of the bolts in every other hole that hold the shield in place along the top of the cover. Tighten the bolts to a torque of 100 ± 10 lb.ft. (135 ± 14 N·m).
8. Install the lip-type seals in the outer bearing cages with the lip of the seals toward the inside of the cages with tooling (C). Put oil on the lip of the seals.
9. Lower the temperature of bearing cups (8). Install the cups in the outer bearing cages.
10. Install a new package of shims on the cover for bearing cage (10). Install the cage without the O-ring seal. Install the bolts that hold the cage in place. Tighten the bolts to a torque of 42 ± 5 lb.ft. (58 ± 7 N·m).
11. Install tooling (A) in the splines of the gear. Hold the handle of tooling (A). Make sure the tooling is in vertical position and tighten nut (9) enough to hold the tooling rigidly in place.
NOTICE
Do not tighten the nut too much. Damage to the splines in the gear can be the result.
12. Install indicator group (D).
13. Push down on the handle of tooling (A) and rotate the gear backward and forward 90° in each direction approximately six times. Set the indicator group on zero.
14. Lift up on the handle of tooling (A) and turn the gear backward and forward 90° in each direction approximately six times. Look at the indicator group and lift up on tooling (A) and check the end clearance. Remove indicator group (D), tooling (A) and bearing cage (10). Remove enough shims from the shim package to give .008 ± .002 in. (.020 ± 0.05 mm) end clearance.
15. Install the O-ring seal on the cage. Put oil on the seal. Install the bearing cage on the cover. Install the bolts in the cage. Tighten the bolts to a torque of 42 ± 5 lb.ft. (58 ± 7 N·m).
16. Follow the procedures in Steps 11 through 14 and check the end clearance again. The end clearance must be .008 ± .002 in. (.020 ± 0.05 mm).
17. Lower the temperature of the bearing cup for cage (11). Install the cup in the cage. Install a new package of shims for cage (11) on the cover. Install the bearing cage without the cover. Install the bearing cage without the O-ring seal. Install the bolts in the cage. Tighten the bolts to a torque of 42 ± 5 lb.ft. (58 ± 7 N·m). Follow the procedures in Steps 11 through 16 and check the end clearance for the bearings on gear (5).
18. Install a new package of shims on the cover for bearing cage (12). Install the bearing cage without the O-ring seal. Install the bolts in the cage. Tighten the bolts to a torque of 42 ± 5 lb.ft. (58 ± 7 N·m). Follow the procedures in Steps 11 through 16 and check the end clearance for the bearings on gear (6).
19. Remove the four bolts along the top of the cover for the shield. end by:
4. Remove two cable ties (7), then disconnect seven oil lines (8) from the control valve.
5. Remove three bolts (9). Remove control valve (10).
1. Put control valve (1) in position on the control panel with the three bolts that hold it.
2. Connect the seven oil lines (3) to the control valve. Install the two cable ties (2) that hold wiring harness to the lines.
3. Put cover in position enough to connect service meter wires
4. Remove cable tie (8).
5. Disconnect eight oil lines (9) from the control valve.
6. Remove the three bolts (10) that hold control valve to control panel. Remove control valve (11).
Install Bucket And Boom Pilot Control Valve
1. Put the control valve (1) in position on the control panel with the three bolts that hold it.
2. Connect eight oil lines (2) to the control valve.
6. Remove two lip type seals (9) from the valve body.
7. Remove retainers (10), shims (12), retainer (11), spring (15), retainer (13), shims (16) and retainers (14) from valve spool.
1. Install spring retainers (5), shims (7), retainer (4), springs (6), retainer (3), shims (1) and spring retainers (2).
3. Install two clamps (6) on the oil lines.
4. Push rubber boot (9) down on control lever. Install pedal supports with the two bolts (8) that hold it.
