Caterpillar Cat 225 EXCAVATOR (Prefix 51U) Service Repair Manual Instant Download (51U00001)

Service Repair Manual

Models

225 EXCAVATOR

225 EXCAVATOR 51U00001-00589 (MACHINE)(UEG0663S - 00) - Documentation

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Shutdown SIS Previous Screen Product: EXCAVATOR Model: 225 EXCAVATOR 51U Configuration: 225 EXCAVATOR 51U00001-00589 (MACHINE)

Disassembly and Assembly 225 EXCAVATOR VEHICLE SYSTEMS Media Number -SENR7907-00

Publication Date -01/02/1979

Date Updated -12/10/2001

Swing Drive SMCS - 5459-12; 5459-15; 5459-16; 5459-11

Remove Swing Drive

start by: a) release oil pressure in main system

Do not disconnect or remove any oil lines until all oil pressure in main system has been released.

1. Remove bolts (2), then remove hose clamp (3).

2. Remove bolts (1) to remove hoses (4).

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3. Disconnect hoses (5), (6) and (9) from the motor.

4. Remove bolts (8), then remove bracket (7) from the oil lines.

5. Remove bolt (10) to disconnect linkage (11) from lever (13). Remove two bolts (12) that hold the linkage and spacer to the swing drive cover.

6. Remove oil lines (14) and (15) from three stem and five stem control valves.

7. Remove four bolts (16) from each side of the swing drive.

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8. Remove three bolts from the swing drive case. Install one 1/2"-13 NC forged eyebolt in the case. Install tooling (A). Fasten a hoist and lift the swing drive until the pinion on the output shaft is above the hole in the upper frame. Remove the swing drive (17). The weight of the swing drive is 1100 lb. (495 kg).

Install Swing Drive

1. Install one 1/2"-13 NC forged eyebolt in the swing drive case. Install tooling (A). Put 2P2506 Anti-Seize Compound on the finished surfaces of the cartridge (output shaft housing). Fasten a hoist and put the swing drive (1) in position on the upper frame.

NOTE: Turn the swivel brake drum to get alignment of the pinion and swing gear.

2. Install the four bolts on each side of the swing drive. Tighten the bolts to a torque of 560 ± 60 lb.ft. (764 ± 80 N·m).

3. Remove tooling (A) and the eyebolt. Install the three bolts in the swing drive case. Tighten the bolts to a torque of 100 ± 10 lb.ft. (135 ± 14 N·m).

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225 EXCAVATOR 51U00001-00589 (MACHINE)(UEG0663S - 00) - Documentation

4. Put linkage (2) in position on the swing drive cover with spacer, clamp (4) and the two bolts that hold it.

5. Connect linkage (2) to lever (5) with the bolt (3) that holds it.

6. Connect hoses (6), (7) and (12) to the swing motor. Install three and five stem control valve lines (8) and (11) with bracket (9) and the bolts (6) that hold them.

7. Put the four hoses (14) in position on bracket, then install hose clamp (13) and bolts (15) that hold it.

8. Fill the swing motor with SAE 10W hydraulic oil.

NOTICE

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225 EXCAVATOR 51U00001-00589 (MACHINE)(UEG0663S - 00) - Documentation

Do not start the engine without the swing motor filled with oil.

Disassemble Swing Drive

start by: a) remove swing drive b) remove swing motor c) disassemble swing brake

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1. Fasten a hoist and put the swing drive in position on stand (A). The weight of the swing drive is 900 lb. (408 kg).

2. Remove the six bolts from bearing cage (1).

3. Install two 1/2"-13NC forcing screws and remove bearing cage and shims (2).

4. Install tooling (B) and remove the bearing cup. Remove O-ring seal (3) and lip-type seal from the cage.

5. Remove the bolts from the cover. Install two 1/2"-13NC forcing screws (4) and loosen cover (5) from case.

6. Install a 1/2"-13NC forged eyebolt and a 3/8"-16NC forged eyebolt in the cover. Fasten a hoist and remove cover (5). The weight of the cover is 160 lb. (73 kg). Remove the oil from the case.

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7. Install tooling (C) and remove the bearing cup from cover. Remove bearing cup (6) with a hammer and punch.

8. Remove the eight bolts (7).

9. Fasten a hoist to gear (9). Lift the output shaft until gear (8) can be removed. Remove the gear.

Remove the output shaft from the case. The weight of the output shaft is 350 lb. (159 kg).

10. Install tooling (D) and remove the bearing cone from gear (8).

11. Install tooling (E) and remove bearing cone (10) from the gear.

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225 EXCAVATOR 51U00001-00589 (MACHINE)(UEG0663S - 00) - Documentation

12. Remove gear (11), coupling (12) and pinion (13) from the case.

13. Install tooling (E) and remove the bearing cones for gear (11) and pinion (13).

14. Install tooling (C) and remove the bearing cup from the case.

15. Remove cages (14) and the shims from the case.

16. Install tooling (C) and remove the bearing cups from the cages. Remove O-ring seals (15).

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17. Fasten a hoist to the output shaft and put it in position on stand (F). Use chains to hold output shaft in place.

18. Loosen the bolt in the end of the shaft.

19. Turn the output shaft 180° on stand (F). Use chains to hold the output shaft in place.

20. Loosen the bolt in the end of the shaft.

21. Fasten a hoist to the output shaft and remove it from stand (F).

22. Remove the bolt, retainer (16), and shims (17).

23. Remove gear (18) and spacer (19) from the shaft.

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24. Remove the bolt, retainer, and O-ring seal from end of shaft.

25. Install tooling (G) and remove the pinion.

26. Remove retainer (21). Remove the O-ring seal from the retainer.

27. Remove the Duo-Cone seal (20) with tool (H).

28. Remove retainer (23). Remove O-ring seal (22) from the retainer.

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225 EXCAVATOR 51U00001-00589 (MACHINE)(UEG0663S - 00) - Documentati...

29. Install tooling (I) and push the shaft out of the bearing cone. Remove bearing cone (24).

30. Remove shaft (26) from cartridge (25).

31. Install tooling (J) and remove the bearing cone from the shaft.

32. Remove bearing cups (27) from the cartridge.

Assemble Swing Drive

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1. Heat bearing cone (2) in oil to a maximum temperature of 275°F (135°C). Start the bearing cone on shaft (1).

NOTE: The bearing cone will be pushed into correct position when the pinion is installed.

2. Install the O-ring seal on retainer (3). Install the Duo-Cone seal in retainers (3) and (4) with tool (A).

NOTE: The rubber seals and all surfaces that make contact with the seals must be clean and dry.

After installation of the seals, put oil on the contact surfaces of the metal seals.

3. Put retainer (3) in position on the shaft.

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4. Install the O-ring seal in retainer (4). Put the retainer in position on the shaft.

5. Put 2P2506 Anti-Seize Compound on the shaft and pinion splines. Put pinion (5) in position on end of shaft. Install tooling (B) and retainer (6). Push the pinion and bearing cone into position on the shaft with a force of 30 ± 10 ton (265 ± 90 kN).

NOTE: The pinion and bearing cone are in correct position when the retainer is against the end of the shaft.

6. Lower the temperature of the two bearing cups. Install bearing cups (7) in cartridge (8). Fasten a hoist to he cartridge. Lower the cartridge into position on the shaft.

7. Heat bearing cone (9) in oil to a maximum temperature of 275°F (135°C). Put the bearing cone in position on the shaft.

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8. Install spacer (10) on the shaft.

9. Put the gear in position on the shaft. Put two lengths of solder (11) having a diameter of .059 in.

(1.50 mm) on the end of the shaft. Install the bolt and retainer. Tighten the bolt to a torque of 100 lb.ft. (135 N·m). Remove the bolt and retainer. Measure the thickness of the solder. Install shims that are the same thickness as the average thickness of the solder minus .004 to .007 in. (0.10 to 0.18 mm). Install the bolt and retainer.

10. Fasten a hoist to the output shaft. Put the shaft in position on tool (C). Use chains to hold shaft in place.

11. Install the O-ring seal, retainer and bolt in end of shaft for the pinion. Tighten the bolt to a torque of 1200 ± 120 lb.ft. (1620 ± 160 N·m).

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12. Turn the shaft 180° on the stand. Tighten the bolt in the end of the shaft to a torque of 1200 ± 120 lb.ft. (1620 ± 160 N·m).

13. Fasten a hoist to the swing drive case. Put case in position on tool (D). The weight of the case is 160 lb. (73 kg).

14. Fasten a hoist to the output shaft and remove it from tool (C). Put the shaft in position in the case. Install two bolts. Make five revolutions of the shaft. The shaft must turn freely at a torque of 13 ± 3 lb.ft. (18 ± 4 N·m). Make an adjustment to the thickness of the shims if the torque is not correct. Remove shaft from case.

15. Lower the temperature of the bearing cups for cages (12). Install the cups in the cages.

16. Install the cages without shims and O-ring seals in the case. Install two bolts in each cage.

NOTE: Do not tighten the bolts. The cages are installed at this time to keep the pinion and gear in position.

17. Lower the temperature of the bearing cup (13). Install the cup in the case.

18. Heat bearing cones (14) in oil to a maximum temperature of 275°F (135°C). Install the cones on pinion (15).

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19. Put pinion (15) in position in the bearing cage. Put coupling (16) in position on the pinion.

20. Heat bearing cones (17) and (19) in oil to a maximum temperature of 275°F (135°C). Install the cones on gear (18).

21. Put gear (18) into position in the bearing cage.

22. Heat bearing cones (20) and (22) in oil to a maximum temperature of 275°F (135°C). Install cones on gear (21).

23. Clean the old gasket material from the contact surfaces of the cartridge and case. Put 7M7260 Liquid Gasket on the surfaces.

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24. Install two 5/8" 11 NC guide pins (24) in the cartridge. Fasten a hoist to output shaft (23).

25. Lower the output shaft into the case until gear (21) can be installed. Install the gear. Lower the output shaft into position on the case.

26. Remove the two guide pins from the cartridge. Install the bolts that hold the cartridge in place.

Tighten the bolts to a torque of 200 ± 20 lb.ft. (270 ± 25 N·m).

27. Lower the temperature of bearing cups (25). Install the cups in the cover.

28. Clean the old gasket material from the contact surfaces of the cover and case. Put 7M7260 Liquid Gasket Material on the surfaces.

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29. Install a 1/2"-13 NC forged eyebolt and a 3/8"-16 NC forged eyebolt in the cover. Fasten a hoist and put cover (26) in position on the case. Install the bolts that hold the cover to the case.

Tighten the bolts to a torque of 100 ± 10 lb.ft. (135 ± 14 N·m).

30. Lower the temperature of bearing cup (27). Install the cup in the bearing cage. Install the lip type seal with the lip of the seal toward the top of the cage with tooling (E). Put oil on the lip of the seal.

31. Put the cage in position on the cover without shims and O-ring seal. Install two bolts 180° apart. Turn the gear (21) while the bolts are tightened evenly to a torque of 10 lb.in. (1.1 N·m).

Measure the gap between the cage and cover at the two bolt locations with feeler gauge (28).

32. Install shims that are the same thickness as the average gap measured plus .000 to .003 in. (0.0 to 0.08 mm). Install the O-ring seal on the cage. Put the cage in position on the cover. Install bolts (29) and tighten them to a torque of 100 ± 10 lb.ft. (135 ± 14 N·m).

33. Fasten a hoist and turn the swing drive over on tool (D).

34. Remove one of the bearing cages.

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35. Turn the output shaft while the bolts in cage (30) are tightened evenly to a torque of 10 lb.in.

(1.1 N·m). Measure the gap between the cage and case at the two bolt locations with feeler gauge.

36. Install shims (31) that are the same thickness as the average gap measured plus .000 to .003 in.

(0.00 to 0.08 mm). Install the O-ring seal on the cage. Put the cage in position on the case. Install the bolts and tighten them to a torque of 100 ± 10 lb.ft. (135 ± 14 N·m).

37. Install cage (32) without shims and O-ring seal. Install two bolts 180° apart. Turn the output shaft while the bolts are tightened evenly to a torque of 10 lb.in. (1.1 N·m). Measure the gap between the cage and case at the two bolt locations with a feeler gauge.

38. Install shims (33) that are the same thickness as the average gap measured plus .000 to .003 in.

(0.00 to 0.008 mm). Install the O-ring seal on the cage. Put the cage in position on the case. Install the bolts and tighten to a torque of 100 ± 10 lb.ft. (135 ± 14 N·m).

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39. Make five revolutions of the output shaft. The shaft must turn freely at a torque of 20 ± 4 lb.ft.

(25 ± 5 N·m). Make an adjustment to the thickness of shims at the pinion or gears if the torque is not correct.

40. Fasten a hoist and remove the swing drive from tool (D). After the swing drive has been installed, fill the swing drive with oil to the correct level. end by: a) assemble swing brake b) install swing motor c) install swing drive Copyright 1993 - 2020 Caterpillar Inc.

Thu Dec 31 22:43:49 UTC+0800 2020

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Shutdown SIS Previous Screen Product: EXCAVATOR Model: 225 EXCAVATOR 51U Configuration: 225 EXCAVATOR 51U00001-00589 (MACHINE)

Disassembly and Assembly 225 EXCAVATOR VEHICLE SYSTEMS Media Number -SENR7907-00

Publication Date -01/02/1979

Date Updated -12/10/2001

Swing Brake SMCS - 5460-15; 5460-16

Disassemble Swing Brake

1. Remove the bolt and retainer that hold the brake drum to the brake shaft. Remove brake drum (1).

2. Disconnect the brake linkage.

3. Remove the four bolts that hold plate (4) to the bearing cage. Remove the plate and brake linings (2). Remove lever (3).

4. Remove the three springs that hold the brake linings to the plate. Remove the brake linings.

Assemble Swing Brake

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1. Put the brake linings in position on the plate. Install the three springs that hold the brake linings to the plate.

2. Install lever (3). Put plate (4) and brake linings (1) in position on the bearing cage. Install four bolts (2) that hold the plate to the bearing cage.

3. Connect brake linkage (7).

4. Install brake drum (8) on the brake shaft.

NOTE: The spline on the brake shaft and brake drum must be clean and dry at assembly.

5. Install retainer (6) and bolt (5). Tighten the bolt to a torque of 200 ± 20 lb.ft. (270 ± 25 N·m).

Copyright 1993 - 2020 Caterpillar Inc.

Thu Dec 31 22:44:44 UTC+0800 2020

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225 EXCAVATOR 51U00001-00589 (MACHINE)(UEG0663S - 00) - Documentation

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Shutdown SIS Previous Screen Product: EXCAVATOR Model: 225 EXCAVATOR 51U Configuration: 225 EXCAVATOR 51U00001-00589 (MACHINE)

Disassembly and Assembly 225 EXCAVATOR VEHICLE SYSTEMS Media Number -SENR7907-00

Publication Date -01/02/1979

Date Updated -12/10/2001

Swing Motor SMCS - 5058-11; 5058-12

Remove Swing Motor

1. Disconnect oil lines (1), (2) and (3) from the swing motor.

2. Remove one bolt from each side of the swing motor.

3. Install two 1/2"-13 NC forged eyebolts in the swing motor and fasten a hoist. Remove swing motor (4). Weight of the swing motor is 140 lb. (63 kg).

Install Swing Motor

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1. Install two 1/2"-13 NC forged eyebolts in the motor. Fasten a hoist and put the motor (1) in position on the swing drive cover.

2. Install two bolts that hold the swing motor. Tighten the bolts to a torque of 200 ± 20 lb.ft. (270 ± 25 N·m).

3. Connect oil lines (2), (3) and (4) to the swing motor.

4. Fill the motor with SAE 10W hydraulic oil.

NOTICE Do not start the engine with the motor not filled with oil.

Copyright 1993 - 2020 Caterpillar Inc.

Thu Dec 31 22:45:40 UTC+0800 2020

All Rights Reserved.

Private Network For SIS Licensees.

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Shutdown SIS Previous Screen Product: EXCAVATOR Model: 225 EXCAVATOR 51U Configuration: 225 EXCAVATOR 51U00001-00589 (MACHINE)

Disassembly and Assembly 225 EXCAVATOR VEHICLE SYSTEMS Media Number -SENR7907-00

Publication Date -01/02/1979

Date Updated -12/10/2001

Motors SMCS - 5058-15; 5058-16

Disassemble Motors

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225 EXCAVATOR 51U00001-00589 (MACHINE)(UEG0663S - 00) - Documentation

start by: a) remove track motors b) remove swing motor 1. Thoroughly clean the outside of the motor.

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2. Fasten a hoist to the motor. Put the motor in position on tool (A).

3. Remove the twelve bolts that hold head (1) to body (2). Remove the head.

NOTICE Be extra careful not to cause damage to the highly finished surfaces on the port plate and barrel face.

4. Remove port plate (3) from the head.

5. Install tooling (B) and remove the bearing cup from the head.

6. Make sure the plastic protective plate from tooling (C) is put in position against the barrel face.

Install tooling (C). Keep the shaft from turning with three 3/16 in (4.8 mm) diameter pins and a 1 11/16 in. (42.9 mm) socket. Remove the bearing cone from the shaft.

NOTE: Earlier motors are equipped with an anti-tip bearing. The anti-tip bearing is not needed for the motor to operate correctly. Remove the spacer, bolts, bearing, shims, and ring from the motor during disassembly of the motor. Do not install the parts at assembly of the motor.

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7. Install tooling (D) with two 7/16"-14NC forcing screws, nuts, and washers. Make sure the wood blocks make contact with the barrel face. Tighten the nuts evenly to release the pressure against and spiral snap ring (4). Remove the spiral snap ring.

Do not remove the second snap ring. The snap ring holds a large spring in the center of the barrel which is under compression. Sudden release of the spring can cause personal injury or motor damage.

8. Loosen nuts (5) evenly and remove tooling (D).

9. Remove the two screws that hold the cam in position from the rear of the motor. Install guide rods (F).

10. Put block (E) in position behind the motor. Make sure the motor shaft is in the hole in block (E). Tilt the motor and put it in a vertical position on the block.

11. Remove the body. Remove the two guide rods from cam (6).

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Suggest: If the above button click is invalid.

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12. Install tooling (G) and remove the bearing cup from the body. Remove the snap ring and liptype seal from the body.

13. Remove shaft (7) from the cam and barrel.

14. Install tooling (H) and remove the bearing cone from the shaft.

15. Put identification on each piston (8). Put a mark on barrel (9) respective to each piston location for use during assembly of pistons and barrel. Remove the cam and pistons from the barrel.

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16. Remove the eight bolts and locks that hold the retainer and shims to the cam. Remove retainer (10) and shims (11).

NOTICE Be extra careful not to cause damage to the highly finished surfaces of the pistons.

17. Remove retraction plate (12) and the pistons from the cam.

18. Remove cam wear plate (13) from the cam.

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