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

1
Service Repair Manual
Models 225 EXCAVATOR
2
Remove Swing Drive
start by a) release oil pressure in main system
3
Do not disconnect or remove any oil lines until
all oil pressure in main system has been
released.

1. Remove clamp (2).
2. Remove four oil lines (1).

1. Remove bracket (5).
2. Disconnect inlet and outlet oil lines (3) from
   the swing motor.
3. Disconnect case drain line (4) from the swing
   motor.

1. Disconnect linkage (8) from lever (9). Remove two
   bolts (7) that hold the linkage and spacer to
   the swing drive cover.
2. Remove oil lines (6) and (10).
3. Remove clamp (14).

4

1. Disconnect oil line (12) from the three stem
   control valve. Pull oil line away from over swing
   drive.
2. Remove oil line (11).
3. Remove the four bolts (13) from each side of the
   swing drive.

12. Remove three bolts from the swing drive case.
Install one 1/2"-13NC forged eyebolt in the
case. Install tooling (A). Fasten a hoist and
lift the swing drive until the pinion on the
output shaft is above the hole in the upper
frame. Remove the swing drive. The weight of the
swing drive is 1100 lb. (499 kg).
Install Swing Drive
1. Install one 1/2"-13NC forged eyebolt in the
swing drive case. Install tooling (A). Put 4S9416
Anti-Seize Compound on the finished surfaces of
the cartridge (output shaft housing). Fasten a
hoist and put the swing drive in position on the
upper frame. NOTE Turn the swing brake drum to
get alignment of the pinion and swing gear.

1. Install the four bolts (1) on each side of the
   swing drive. Tighten the bolts to a torque of 560
   60 lb.ft. (77.5 8.3 mkg).
2. Remove tooling (A) and the eyebolt. Install the
   three bolts in the swing drive case. Tighten the
   bolts to a torque of 100 10 lb.ft. (13.8 1.4
   mkg).

5

1. Install oil line (7).
2. Pull oil line (8) into position on the three stem
   control valve. Install the bolts that hold the
   oil line to the valve.
3. Install clamp (9).
4. Install oil lines (2) and (3).
5. Install two bolts (4) that hold the spacer and
   linkage to the cover. Connect linkage (5) to
   lever (6).

• Connect case drain line (11) to the swing motor.
• Fill the swing motor with SAE 10W hydraulic oil.
• NOTICE
• Do not start engine without first filling the
  motor with oil.

1. Connect inlet and outlet oil lines (10) to the
   motor.
2. Install bracket (12).

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1. Install the four oil lines (13).
2. Install clamp (14).

Disassemble Swing Drive
8

• start by
• remove swing drive
• remove swing motor
• disassemble swing brake
• 1. Fasten a hoist and put the swing drive in
  position on stand (A). The weight of the swing
  drive is 900 lb. (408 kg).

1. Remove the six bolts from bearing cage (1).
2. 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.
9
6. Install a 1/2"-13NC forged eyebolt and a
3/8"-16NC forged eyebolt in the cover. Fasten a
hoist and remove cover (5). The weight of the
cover is 160 lb. (73 kg). Remove the oil from the
case.
7. Install tooling (C) and remove the bearing cup
from cover. Remove bearing cup (6) with a hammer
and punch.
8. Remove the eight bolts (7).
9. Fasten a hoist to gear (9). Lift the output
shaft until gear (8) can be removed. Remove the
gear. Remove the output shaft from the case. The
weight of the output shaft is 350 lb. (159 kg).
10

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

12. Remove gear (11), coupling (12) and pinion
(13) from the case.
13. Install tooling (E) and remove the bearing
cones for gear (11) and pinion (13).

1. Install tooling (C) and remove the bearing cup
   from the case.
2. Remove cages (14) and the shims from the case.

11
16. Install tooling (C) and remove the bearing
cups from the cages. Remove O-ring seals (15).
17. Fasten a hoist to the output shaft and put it
in position on stand (F). Use chains to hold
output shaft in place.

1. Loosen the bolt in the end of the shaft.
2. Turn the output shaft 180 on stand (F). Use
   chains to hold the output shaft in place.
3. Loosen the bolt in the end of the shaft.
4. Fasten a hoist to the output shaft and remove it
   from stand (F).

22. Remove the bolt, retainer (16), and shims
(17).
12

1. Remove gear (18) and spacer (19) from the shaft.
2. 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).
13
28. Remove retainer (23). Remove O-ring seal (22)
from the retainer.
29. Install tooling (I) and push the shaft out of
the bearing cone. Remove bearing cone (24).
30. Remove shaft (26) from cartridge (25).
31. Install tooling (J) and remove the bearing
cone from the shaft.
14
32. Remove bearing cups (27) from the cartridge.
Assemble Swing Drive
1. Heat bearing cone (2) in oil to a maximum
temperature of 275F (135C). Start the bearing
cone on shaft (1). NOTE The bearing cone will be
pushed into correct position when the pinion is
installed.
15

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

4. Install the O-ring seal in retainer (4). Put
the retainer in position on the shaft.
5. Put 4S9416 Anti-Seize Coumpound on the shaft
and pinion splines. Put pinion (5) in position
on end of shaft. Install tooling (B) and retainer
(6). Push the pinion and bearing cone into
position on the shaft with a force of 30 10
tons (27 9 M.tons). NOTE The pinion and
bearing cone are in correct position when the
retainer is against the end of the shaft.
16
6. Lower the temperature of the two bearing cups.
Install bearing cups (7) in cartridge (8). Fasten
a hoist to the cartridge. Lower the cartridge
into position on the shaft.
7. Heat bearing cone (9) in oil to a maximum
temperature of 275F (135C). Put the bearing
cone in position on the shaft.
8. Install spacer (10) on the shaft.
9. Put the gear in position on the shaft. Put two
lengths of solder (11) having a diameter of .059
in. (1.50 mm) on the end of the shaft. Install
the bolt and retainer. Tighten the bolt to a
torque of 100 lb.ft. (13.8 mkg). Remove the bolt
and retainer. Measure the thickness of the
solder. Install shims that are the same
thickness as the average thickness of the solder
minus .004 to .007 in. (0.1 to 0.18 mm). Install
the bolt and retainer.
17
10. Fasten a hoist to the output shaft. Put the
shaft in position on stand (C). Use chains to
hold shaft in place.

1. Install the O-ring seal, retainer, and bolt in
   end of shaft for the pinion. Tighten the bolt to
   a torque of 1200 120 lb.ft. (165.9 16.6
   mkg).
2. Turn the shaft 180 on the stand. Tighten the
   bolt in the end of the shaft to a torque of 1200
   120 lb.ft. (165.9 16.6 mkg).
3. Fasten a hoist to the swing drive case. Put case
   in position on stand (D). The weight of the case
   is 160 lb. (73 kg).
4. Fasten a hoist to the output shaft and remove it
   from stand (C). Put the shaft in position in the
   case. Install two bolts. Make five revolutions of
   the shaft. Check the torque needed to keep the
   shaft turning freely. The torque must be 13 3
   lb.ft. (1.8 0.4 mkg). Make an adjustment to the
   thickness of the shims if the torque is not
   correct. Remove shaft from case.

• Lower the temperature of the bearing cups for
  cages (12). Install the cups in the cages.
• 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
18. Heat bearing cones (14) in oil to a maximum
temperature of 275F (135C). Install the cones
on pinion (15).
19. Put pinion (15) in position in the bearing
cage. Put coupling (16) in position on the pinion.
20. Heat bearing cones (17) and (19) in oil to a
maximum temperature of 275F (135C). Install
the cones on gear (18).
21. Put gear (18) into position in the bearing
cage.
19

1. Heat bearing cones (20) and (22) in oil to a
   maximum temperature of 275F (135C). Install
   cones on gear (21).
2. Clean the old gasket material from the contact
   surfaces of the cartridge and case. Put 7M7260
   Liquid Gasket on the surfaces.

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

1. 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.
2. Remove the two guide pins from the cartridge.
   Install the bolts that hold the cartridge in
   place. Tighten the bolts to a torque of 200 20
   lb.ft. (27.7 2.8 mkg).

27. Lower the temperature of bearing cups (25).
Install the cups in the cover.
20
28. Clean the old gasket material from the
contact surfaces of the cover and case. Put
7M7260 Liquid Gasket on the surfaces.
29. Install a 1/2"-13NC forged eyebolt and a
3/8"-16NC forged eyebolt in the cover. Fasten a
hoist and put cover (26) in position on the
case. Install the bolts that hold the cover to
the case. Tighten the bolts to a torque of 100
10 lb.ft. (13.8 1.4 mkg).
30. Lower the temperature of bearing cup (27).
Install the cup in the bearing cage. Install the
lip- type seal with the lip of the seal toward
the top of the cage with tool (E). Put oil on the
lip of the seal.
31. Put the cage in position on the cover without
shims and O-ring seal. Install two bolts 180
apart. Tighten the bolts evenly to a torque of 10
lb.in. (11.5 cm.kg) while turning gear (21).
Measure the gap between the cage and cover at the
two bolt locations with feeler gauge (28).
21

• 32. Install shims that are the same thickness as
  the average gap measured plus .000 to .003 in.
  (0.0 to 0.08 mm). Install the O-ring seal on the
  cage. Put the cage in position on the cover.
  Install bolts
• (29) and tighten to a torque of 100 10 lb.ft.
  (13.8 1.4 mkg).
• Fasten a hoist and turn the swing drive over on
  stand (D).
• Remove one of the bearing cages.

35. Tighten the bolts in cage (30) evenly to a
torque of 10 lb.in. (11.5 cm.kg) while turning
the output shaft. Measure the gap between the
cage and case at the two bolt locations with
feeler gauge.
36. Install shims (31) that are the same
thickness as the average gap measured plus .000
to .003 in. (0.00 to 0.08 mm). Install the
O-ring seal on the cage. Put the cage in position
on the case. Install the bolts and tighten to a
torque of 100 10 lb.ft. (13.8 1.4 mkg).
37. Install cage (32) without shims and O-ring
seal. Install two bolts 180 apart. Tighten the
bolts evenly to a torque of 10 lb.in. (11.5
cm.kg) while turning the output shaft. Measure
the gap between the cage and case at the two
bolt locations with a feeler gauge.
22

• Install shims (33) that are the same thickness as
  the average gap measured plus .000 to .003 in.
  (0.00 to 0.08 mm). Install the O-ring seal on the
  cage. Put the cage in position on the case.
  Install the bolts and tighten to a torque of 100
  10 lb.ft. (13.8 1.4 mkg).
• Make five revolutions of the output shaft. Check
  the torque needed to keep the shaft turning
  freely. The torque must be 20 4 lb.ft. (2.8
  0.6 mkg). Make an adjustment to the thickness of
  shims at the pinion or gears if the torque is not
  correct.
• Fasten a hoist and remove the swing drive from
  stand (D). After the swing drive has been
  installed, fill the swing drive with oil to the
  correct level.
• end by
• assemble swing brake
• install swing motor
• install swing drive

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Product EXCAVATOR Model 225 EXCAVATOR
51U Configuration 225 EXCAVATOR 51U02832-UP
(MACHINE) POWERED BY 3208 ENGINE
Disassembly and Assembly 225 EXCAVATOR VEHICLE
SYSTEMS Media Number -REG01510-01 Publication
Date -01/03/1977
Date Updated -10/10/2001
Swivel Group SMCS - 5060-15 5060-16 5060-11
5060-12 Remove Swivel Group

1. Remove two bolts (2) and bar (3).
2. Remove six bolts (1) from manifold.

1. Disconnect the four oil lines (4) from side of
   swivel housing.
2. Disconnect drain line (5).

24

1. Disconnect the pilot oil line for the parking
   brakes from swivel housing.
2. Put a floor jack in position under swivel group.
3. Remove the eight bolts that hold swivel group to
   the frame.

8. Lower the swivel group (6) and remove it from
under machine. Weight of swivel group is 300 lb.
(136 kg).
9. Remove the Duo-Cone seal (7) from the manifold
and swivel group with tool (A).
Install Swivel Group

1. Turn the rotor (1) in swivel housing so the dowel
   (2) is in position shown.
2. Check to see that all O-ring seals (3) are in
   position.
3. Install the Duo-Cone seal in the swivel group and
   manifold with tool (A).

25
NOTE The rubber seals and all surfaces that make
contact with the seals must be clean and dry.
After installation of the seals, put oil on the
contact surfaces of the metal seals. 4. Put the
swivel group on a floor jack. Lift the swivel
group into position with dowel (2) in swivel
group in alignment with dowel hole in manifold.

1. Install the bolts (4).
2. Connect the pilot oil line for parking brake.
3. Connect the oil drain line.
4. Connect the four oil lines from the track motors
   to the swivel group.

1. Install six bolts (5) in manifold.
2. Install bar (7) and two bolts (6) that hold bar
   to manifold.

11. Put a feeler gauge between bolt (9) and the
frame. Make an adjustment to nut (8) and bolt (9)
on each side of the swivel group to get a total
clearance of .06 in. (1.5 mm) between bolt (9)
and the frame.
Disassemble Swivel Group
26
start by a) remove swivel group

1. Remove bolts (1) and manifold (2).
2. Remove the O-ring seal from manifold.

3. Remove washer (3).
4. Install tooling (A), and remove rotor (4).
27
5. Remove the eight inner seals (5) and eight
outer seals from housing.
Assemble Swivel Group
1. Install the eight outer seals and eight inner
seals (1) in swivel housing.

1. Put oil on inner seals (1) and on rotor (2).
2. Install two 3/8"-16NC forged eyebolts in rotor
   (2). Fasten a hoist and put rotor in position in
   swivel housing (3).

28
4. Install tooling (A) and push the rotor into
position.

• Install washer (6). Put O-ring seal (5) in
  manifold (4), and install manifold on housing.
• Install the twelve bolts that hold the manifold
  to the housing. end by
• a) install swivel group

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Product EXCAVATOR Model 225 EXCAVATOR
51U Configuration 225 EXCAVATOR 51U02832-UP
(MACHINE) POWERED BY 3208 ENGINE
Disassembly and Assembly 225 EXCAVATOR VEHICLE
SYSTEMS Media Number -REG01510-01 Publication
Date -01/03/1977
Date Updated -10/10/2001
Track Motors SMCS - 5058-11 5058-12 Remove
Track Motors 1. Remove the cover from over the
track motors. The weight of the cover is 75 lb.
(34 kg).
2. Put a floor jack in position under guard (1).
Remove the bolts that hold the guard in place.
Lower the guard to the ground. The weight of the
guard is 435 lb. (197 kg).

• Disconnect inlet and outlet oil lines (3).
  Disconnect drain line (2) from the track motor.
  Put plugs in the oil lines to prevent loss of
  hydraulic oil.
• Fasten a hoist to the track motor. Remove two
  bolts (4) that hold the motor to the parking
  brake housing. Remove the track motor. The
  weight of the track motor is 140 lb. (64 kg).
• Install Track Motors
• 1. Check to see that the O-ring seal is in
  position on the track motor.

30
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31

• Fasten a hoist to track motor (1). Put the motor
  in position on the parking brake housing. Install
  the two bolts that hold the motor in place.
• Remove the plugs from the inlet and outlet oil
  lines. Connect the oil lines to the track motor.
• Remove elbow (2) from the motor. Fill the motor
  with SAE 10W hydraulic oil.
• NOTICE
• Do not start engine without first filling the
  motor with oil.

1. Install the elbow in the motor. Remove the plug
   from the drain line. Connect the drain line to
   the motor.
2. Put a floor jack in position under the guard.
   Lift the guard into position. Install the bolts
   that hold the guard in place.

7. Install cover (3) over the track motors.
Copyright 1993 - 2021 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
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Previous Screen
Product EXCAVATOR Model 225 EXCAVATOR
51U Configuration 225 EXCAVATOR 51U02832-UP
(MACHINE) POWERED BY 3208 ENGINE
Disassembly and Assembly 225 EXCAVATOR VEHICLE
SYSTEMS Media Number -REG01510-01 Publication
Date -01/03/1977
Date Updated -10/10/2001
Parking Brakes SMCS - 4353-12 4353-15 4353-16
4353-11 Remove Parking Brakes
Make sure machine is on level ground before
removing the parking brakes.
start by a) remove track motors
1. Disnonnect oil line (2). Put a plug in the oil
line to prevent loss of hydraulic oil.
33

1. Fasten a hoist to the parking brake housing.
   Remove six bolts (1). Remove parking brake (4).
   The weight of the parking brake is 110 lb. (50
   kg).
2. Remove adapter (3).

Install Parking Brakes

• Check to see that the snap ring is in position on
  the inside of adapter (1). Install the adapter.
• Inspect the O-ring seal on the front of the
  parking brake. Install a new seal if needed.
• NOTE If discs and plates have been removed, put
  clean final drive oil on both sides of discs and
  plates.

• Fasten a hoist to the parking brake housing. Put
  parking brake (4) in position on the final drive
  case. Install six bolts (2).
• NOTE Tighten the six bolts evenly to compress
  the springs inside the parking brake.
• Remove the plug from the oil line. Connect the
  line to the parking brake.
• After the track motor has been installed, remove
  valve (3). Add one quart of clean final drive
  oil. Install the valve.
• end by
• a) install track motors

Disassemble Parking Brakes
34
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