Caterpillar Cat 225 EXCAVATOR (Prefix 20S) Service Repair Manual (20S00001 and up)

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Product EXCAVATOR Model 225 EXCAVATOR
20S Configuration 225 EXCAVATOR 20S00001-UP
(MACHINE)
Disassembly and Assembly 215B 225 HYDRAULIC
PUMP AND MOTORS (PISTON TYPE) Media Number
-SENR3248-00 Publication Date -01/10/1985
Date Updated -11/10/2001
Motors (Swing And Track) SMCS - 5058-015
5058-016 Disassemble Motors (Swing And
Track) NOTE There are several sizes of the bent
axis type motors. Only one size of motor is shown
here, however, the disassembly and assembly
remains the same for all sizes. Special tools
that are needed for a particular size of motor
are identified in the tool chart by motor
type. It is necessary to see two tool charts for
a complete listing. Special tools are common for
all motors are listed in the first tool chart.
Special tools for a particular size of motor are
identified in the other tool charts by motor
type.
2

• START BY
• remove track motor
• remove swing motor
• Put plugs in the open oil passages. Clean the
  outside of the motor thoroughly.

3

1. Remove the plugs from two case drain holes (1).
   Drain any oil from the motor that remains.
2. Put tape around splined drive shaft (2) to
   prevent damage to the drive shaft or seals during
   disassembly of the motor.

4. Tap the cover with a plastic hammer to release
some of the pressure against retaining ring (3).
Use tool (A), and remove retaining ring (3).
5. Use two screw drivers, and remove front cover
(4). Remove the O-ring seal and the shims that
are behind front cover (4).
NOTE Pump drive shaft seal (5) will be destroyed
if it is removed from front cover (4). 6. Remove
lip-type seal (5) from the front cover.
4

1. Turn the motor around, and put alignment marks on
   the rear cover plate and the motor housing for
   assembly purposes.
2. Remove six bolts (6) and lockwashers that hold
   the rear cover plate to the motor housing.

1. Rotate rear cover plate (7) on the locating pin,
   and remove it from the motor housing.
2. Note the position of locating pin hole (9) on the
   control plate that the locating pin in rear cover
   plate (7) was removed from.
3. Remove O-ring seal (8) from the motor housing.

12. Remove control plate (11) from motor housing
(12). Note the condition of the bronze surface
on cylinder block (10) and the mating surface of
control plate (11).
5
NOTICE Use only a puller such as tooling (B) to
remove the rotary group. Do not use a
slidehammer type puller or damage to the motor
may result.
13. Use tooling (B), and remove the rotary group
from motor housing (12). Make sure cylinder
block (10) does not bind as it is pulled through
the motor housing.

1. Remove tooling (B) from rotating group (13).
2. Pull cylinder block (10) from the drive shaft and
   piston assembly (14).
3. Remove four Bellville washers (16) and spring
   collar (15) from the center pin bore of cylinder
   block (10).

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1. Use a section of pipe or wood blocks, and put the
   drive shaft and piston assembly in position as
   shown.
2. Position each piston (18) perpendicular to
   retaining plate (17), and remove them by pulling
   straight out. Do this for the seven pistons. The
   center pin cannot be removed at this time.

19. Check seven pistons (18) at area (X) for
scratches and pitting. Make replacements if
necessary.
Piston rings (19) may break apart during removal
from the pistons. If the rings are to be
removed, wear eye protection to prevent possible
personal injury from flying parts.
20. Use a screwdriver, and remove piston rings
(19) from the piston.

1. Remove seven screws (21) that hold retainer plate
   (17) to the drive shaft assembly. The screws
   were installed with Thread Lock so they will be
   difficult to remove. Impact the screw heads first
   to break the seal, and remove by using
   additional leverage on the screwdriver as shown.
2. Remove retainer plate (17), center pin (20) and
   the ring that holds the center pin in place.

8
23. Check center pin (20) for scratches or
pitting at areas (Y). Replace the center pin if
necessary. Assemble Motors (Swing And
Track) NOTE There are several sizes of the bent
axis type motors. Only one size of motor is shown
here, however, the disassembly and assembly
remains the same for all sizes. It is necessary
to see two tool charts for a complete listing.
Special tools for a particular size of motor are
identified in the first four tool charts by motor
type. Special tools that are common for all
motors are listed in the last tool chart.
9
(No Transcript)
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1. Measure the drive shaft and bearing assembly to
   determine the thickness of the shim that will be
   used under the shaft seal cover. Refer to the
   Testing And Adjusting Manual for the proper
   measuring procedure. The Testing And Adjusting
   Manual Form Nos. are SENR3109 for the 215B and
   SENR3110 for the 225 Excavator.
2. Measure the center pin, spring collar, cylinder
   block, and control plate to determine the proper
   size spring collar that should be used for
   assembly. Refer to the Testing And Adjusting
   Manual for the proper measuring procedure. The
   Testing And Adjusting Manual Form Nos. are
   SENR3109 for the 215B and SENR3110 for the 225
   Excavator.

3. Put drive shaft and bearing assembly (4) in
position on a section of pipe or wood blocks. Put
center pin (2), retainer washer (3), and
retainer plate (1) in position on drive shaft and
bearing assembly (4).
4. Put 6V1541 Quick Cure Primer on seven screws
(5), and let it dry. Put 9S3263 Thread Lock on
the seven screws, and install them loosely to
hold retainer plate (1) to the drive shaft and
bearing assembly. Put three pistons (6) in
position to align retainer plate (1). Tighten
seven screws (5) to a torque of 6 Nm (53
lb.in.) for the Type AA2F 63 Motor. Tighten seven
screws (5) to a torque of
11
10 Nm (89 lb.in.) for the Type AA2F 80, AA2F
107, and AA2F 131 Motor. Remove three pistons
(6) from the assembly.
NOTICE All piston rings must be installed with
the marks toward the flat end of the piston or
the motor will not operate.

1. The piston rings are spherical and must be
   installed with marks (7) toward the flat end of
   piston (6). Use tooling (A), and install upper
   piston ring (8).
2. Use tooling (A), and install the lower piston
   ring with marks (7) toward the flat end of piston
   (6). Repeat Steps 5 and 6 for all seven pistons.
3. Rotate the piston rings so the end gaps of the
   upper and lower piston rings are 180 apart.

8. The spring collar that was selected in Step 2
should be used at this time. Put spring collar
(10) and four Bellville washers (11) into the
center pin bore of cylinder block (9).
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9. Put SAE 10W oil on seven pistons (12) and in
the piston bores in the cylinder block. Install
seven pistons (12) into the cylinder block as
shown.

1. Put SAE 10W oil on the center pin and in the
   center pin bore of the cylinder block. Lay the
   drive shaft and bearing assembly with the drive
   shaft horizontal. Lay the cylinder block with the
   pistons horizontal. Make sure the Bellville
   washers stay in the proper position when the
   cylinder block is put in the horizontal
   position.
2. Align center pin (13) with its bore in the
   cylinder block and assemble the unit.

12. Hold cylinder block assembly (14) and drive
shaft assembly (15) together, and put them in the
vertical position. Support them on a section of
pipe or with wood blocks. Push each piston into a
drive shaft socket through the retainer plate.
An audible click is made when each piston is
seated properly. NOTICE When all seven
pistons are seated properly in the retainer plate
sockets, the cylinder block will easily angle to
one side. Do not force the cylinder block to
angle or damage to the pistons may result.
13
13. Angle cylinder block (14) to one side.
14. Put the entire rotating group in a vise.
Allow clearance between drive shaft bearing (16)
and the top of the vise for the motor housing
when it is installed over the rotating group.
NOTICE Do not force the motor housing onto the
rotating group or damage to the motor may
result. The assembly should be done in one
smooth, easy movement. If the housing does not
fit over the rotating group easily, the problem
should be found and corrected before continuing
assembly.
15. Heat motor housing (17) evenly to a
temperature of 80C (176F). Put the motor
housing in position over the rotating group.
Move motor housing (17) down over the rotating
group, and tilt it to clear the rotating group
as it is assembled. Continue until the rotating
group bottoms out in the motor housing. A small
amount of tapping on the outside of the motor
housing may be needed, but do not force the
assembly together. Allow the motor housing to
cool before continuing assembly.
NOTE If the drive shaft is grooved at the seal
contact area, shim material up to 1.0 mm (.040
in.) maximum thickness may be used between
lip-type seal (18) and cover (19).
14
16. Use tooling (B), and install lip-type seal
(18) into cover (19).
17. The proper thickness of shim (20) was
determined in Step 1. Install shim (20). Use
5P960 Multipurpose Grease on O-ring seal (21),
and put in position on the shim.

1. Put tool (C) over the drive shaft. Put SAE 10W
   oil on the lip-type seal, and instal cover (19).
   It may be necessary to lightly tap the cover
   into the motor housing.
2. Use tool (D), and install retaining ring (22).
3. Install tooling (E), and pull the rotating group
   up against retaining ring (22). This puts the
   rotating group in exactly the correct location
   within the housing. Remove tooling (E).

1. Put 5P960 Multipurpose Grease on O-ring seal
   (23), and install it onto the motor housing.
2. Put SAE 10W oil on the bronze surface of control
   plate (24), and install it into the motor
   housing.

15

• Align locating pin (25) on rear cover (26) with
  the single pin hole in control plate (24). Put
  rear cover (26) in position on the motor housing.
• Align the alignment marks that were put on the
  rear cover and the motor housing.
• Install six bolts and lockwashers (27), and,
  tighten to a torque of 49 Nm (36 lb.ft.) for the
  Type AA2F 63 motor. Tighten bolts (27) to a
  torque of 86 Nm (64 lb.ft.) for the Type AA2F
  80, AA2F 107 and AA2F 131 motors.
• NOTICE
• The motor must be filled with oil before
  installation or damage to the motor may result.

• 26. Put plugs in all openings except for one of
  (two) case drain holes (28) in the motor housing.
  Put the motor in the position it will be mounted
  in when it is installed on the vehicle. Use the
  highest case drain hole, and fill the motor with
  SAE 10W oil. Install a plug in the case drain
  hole.
• END BY
• install track motor
• install swing motor

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Licensees.
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Product EXCAVATOR Model 225 EXCAVATOR
20S Configuration 225 EXCAVATOR 20S00001-UP
(MACHINE) Disassembly and Assembly SUPPLEMENT
FOR HYDRAULIC SYSTEM FOR MACHINES EQUIPPED WITH
4 Media Number -SENR3051-01 Publication Date
-01/08/1984 Date Updated -11/10/2001
Pilot Valve SMCS - 5452-15 5452-16 Disassemble
Pilot Valve
1. Put a mark (1) on the body and base.
2. Remove hex-head bolt (2) from body.
3. Carefully pull base (3) away from body (4).
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NOTE Seals on the valves may make it hard to
pull base off.
4. Remove four outer springs (5).
5. Remove actuator plate (6) and swivel.
6. Remove retainer (7) and plunger (8). NOTE
There are four retainers and plungers. They pull
out very easy. The plunger for No. 2 valve is
different than the rest. Mark it to be sure it is
installed correctly during assembly.
7. Remove plunger (8) from retainer (7).
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• 8. Remove valve stem (9) from body.
• NOTE All four stems are the same. However, mark
  each one carefully with the number of the bore
  shown on the bottom of base (3).
• Assemble Pilot Valve
• Assemble the valve in reverse order of
  disassembly.
• Put valve stems back in correct bores.
• Be sure the correct plunger is installed in valve
  No. 2. The cavity in plunger for valve No. 2 is
  deeper than the other valves.
• Do not tighten the swivel too much. A small
  amount of clearance between the actuator plate
  (6) and the plungers (8) is needed.
• Actuate each valve with the actuator plate. If
  all valves operate freely, valve is ready to be
  installed in the machine.

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Product EXCAVATOR Model 225 EXCAVATOR
20S Configuration 225 EXCAVATOR 20S00001-UP
(MACHINE)
Disassembly and Assembly 225-235-245 EXCAVATORS
OPERATOR'S STATION Media Number
-SENR7714-00 Publication Date -01/08/1977
Date Updated -12/10/2001
Door Glass SMCS - 7310-11 7310-12 Remove Door
Glass
NOTE Sliding glass assemblies (groups) are
removed and installed with the same procedure.
If it is necessary to remove damaged glass, use
thick gloves to prevent injury.
1. Put tool (A) in between the two lips of seal
(1) as shown. Move tool (A) along the seal to
pull the locking lip out away from the cab. Move
the tool completely around the circumference of
the glass.
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2. With locking lip out, remove the glass (2)
from the opening. Remove seal (1) from the edge
of the window opening.
Install Door Glass
TYPICAL EXAMPLE
NOTICE Handle glass carefully.
1. Start along the side of the window panel
opening to install seal (3). Install edge (4) of
seal over panel (5) with the locking lip toward
the outside of the cab. NOTE When the glass is
installed, edge (2) must be over glass (1) as
shown.
21

• TYPICAL EXAMPLE
• Install the seal around the circumference of the
  window opening. Cut the seal to extend past the
  starting point by .125 in. (3.18 mm) per foot of
  window opening circumference. Push the ends of
  the seal together and push them over the body
  panel to make a tight, smooth joint.
• Put the lower corner of the glass in the channel
  of the seal as far as possible. Do not use too
  much force.
• Move in both directions from the starting point,
  lift the glass channel lip and the glass will
  slip into place.

5. Put a solution of soap and water on the
locking lip of the seal.

1. Install the curved end of tool (A) or (7) between
   locking lip (6) and its groove (8) at any point
   away from the seal joint.
2. Move the tool along groove (8) as shown.

22
8. Move tool (A) completely around the
circumference of the seal, the rubber lip will
lock into position around the circumference of
the glass.
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Product EXCAVATOR Model 225 EXCAVATOR
20S Configuration 225 EXCAVATOR 20S00001-UP
(MACHINE)
Disassembly and Assembly 225-235-245 EXCAVATORS
OPERATOR'S STATION Media Number
-SENR7714-00 Publication Date -01/08/1977
Date Updated -12/10/2001
Cab Door SMCS - 7308-11 7308-12 Remove Cab
Door start by a) remove door glass
1. Open the cab door (1) and fasten a hoist to
it. Remove the door hinge bolts, then remove the
cab door. Weight of the door is 115 lb. (52 kg).
Install Cab Door
1. Fasten a hoist to the cab door and put it in
position on the cab.
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2. Install the door hinge bolts (1). end by a)
install door glass
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Product EXCAVATOR Model 225 EXCAVATOR
20S Configuration 225 EXCAVATOR 20S00001-UP
(MACHINE)
Disassembly and Assembly 225-235-245 EXCAVATORS
OPERATOR'S STATION Media Number
-SENR7714-00 Publication Date -01/08/1977
Date Updated -12/10/2001
Front Window SMCS - 7310-11 7310-12 7310-15
7310-16 Remove Front Window
1. Slide lower glass (1) up and fasten into
position.
2. Release window latches (2) and let window hang
free.
3. Remove window hinge bolts (3).
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4. Remove front window (4).
Install Front Window
1. Put front window (1) in position.
2. Install window hinge bolts (2), but do not
tighten.
3. Push front window into place and then fasten
the two latches (3). Make any adjustments if
necessary, then tighten the hinge
bolts. Disassemble Front Window start by
27
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a) remove front window
1. Remove the sliding glass (1) from the window.
Remove the two window locks (2).
2. Remove two screws (3) on each side of frame
and remove lower section (4) of frame.
3. Remove glass (5) from the window frame.
Assemble Front Window
1. Slide the glass (1) into the window frame.
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2. Install lower frame (3) and the two screws (2)
that hold it.
3. Install two window locks (5) on sliding glass
(4). Install the sliding glass (4) into the
window frame. end by a) install front window
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Product EXCAVATOR Model 225 EXCAVATOR
20S Configuration 225 EXCAVATOR 20S00001-UP
(MACHINE)
Disassembly and Assembly 225-235-245 EXCAVATORS
OPERATOR'S STATION Media Number
-SENR7714-00 Publication Date -01/08/1977
Date Updated -12/10/2001
Rear Window SMCS - 7310-15 7310-16 7310-11
7310-12 Remove Rear Window
If it is necessary to remove damaged glass, use
thick gloves to prevent injury.
1. Put tool (A) in between the two lips of seal
(1) as shown. Move tool (A) along the seal to
pull the locking lip out away from the cab. Move
the tool completely around the circumference of
the glass.
32
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