Caterpillar Cat 225 EXCAVATOR (Prefix 51U) Service Repair Manual (51U00590-02033)

1
Service Repair Manual
Models 225 EXCAVATOR
2
Shutdown SIS
Previous Screen
Product EXCAVATOR Model 225 EXCAVATOR
51U Configuration 225 EXCAVATOR 51U00590-02033
(MACHINE)
Disassembly and Assembly 225 EXCAVATOR VEHICLE
SYSTEMS Media Number -SENR7907-00 Publication
Date -01/02/1979
Date Updated -12/10/2001

• Pump Drive
• SMCS - 3108-16 3108-11 3108-12 3108-15
• Remove Pump Drive
• start by
• remove muffler
• remove axial piston pump (front)
• remove axial piston pump (rear)
• 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.

1. Disconnect governor control linkage (2) from the
   governor and bracket.
2. Remove the eight nuts (1) that hold air cleaner
   to the inlet pipe. Remove air cleaner (3).

3

1. Remove bolts (7) and remove muffler bracket (5).
2. 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.
4
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
• Install two 3/8"-16 NC guide pins in the flywheel
  housing.
• 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.
5
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 Nm).
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 Nm).
8. Install shield (5) with the bolts (6) that
hold it. Tighten these bolts to a torque of 100
10 lb.ft. (135 14 Nm).
6
https//www.aservicemanualpdf.com/ My Dear
Friend! Thank you very much for visiting. Full
manual if required, please enter the following
URL into your browser. https//www.aservicemanual
pdf.com/
7
9. Install muffler bracket (7) with the bolts
that hold it. Tighten these bolts to a torque of
100 10 lb.ft. (135 14 Nm).

• 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 Nm).
• Connect governor control linkage (9) to the
  governor.
• Fill the pump drive with oil to the correct
  level.
• Fill the hydraulic tank with oil to the correct
  level. end by
• install pilot system pump
• install axial piston pump (rear)
• install axial piston pump (front)
• install muffler
• Operation location is in ENGINE DISASSEMBLY AND
  ASSEMBLY section.

Disassemble Pump Drive
8
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).

1. 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).
2. 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).
9
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
10. Remove the two lip-type seals (11) from the
case.
Assemble Pump Drive
1. 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.

1. 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.
2. Lower the temperature of the three bearing cups
   (1). Install the cups in the case.

11
4. Heat bearing cones (3) for the three gears in
oil to a maximum temperature of 275F (135C).
Install the cones on each side of the three gears.
5. Install gears (4), (5), and (6) in the case.

1. 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.
2. Install the bolts that hold the cover to the
   case. Tighten the bolts to a torque of 100 10
   lb.ft. (135 14 Nm). 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 Nm).

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.
12
9. Lower the temperature of bearing cups (8).
Install the cups in the outer bearing cages.

• 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 Nm).
• 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.

1. Install indicator group (D).
2. 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.

13

1. 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.
2. 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 Nm).
3. 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 Nm).
Follow the procedures in Steps 11 through 16 and
check the end clearance for the bearings on gear
(5).

1. 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 Nm). Follow the procedures in
   Steps 11 through 16 and check the end clearance
   for the bearings on gear (6).
2. Remove the four bolts along the top of the cover
   for the shield. end by

14
a) install pump drive
Copyright 1993 - 2021 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Fri Jan 1 103220 UTC0800 2021
15
Shutdown SIS
Previous Screen
Product EXCAVATOR Model 225 EXCAVATOR
51U Configuration 225 EXCAVATOR 51U00590-02033
(MACHINE)
Disassembly and Assembly 225 EXCAVATOR VEHICLE
SYSTEMS Media Number -SENR7907-00 Publication
Date -01/02/1979
Date Updated -12/10/2001
Stick And Swing Pilot Control Valve SMCS -
5452-11 5452-12 Remove Stick And Swing Pilot
Control Valve

1. Remove four screws (4), cover (5) and rubber
   molding (2).
2. Remove control knob (1) and rubber boot (3).

3. Disconnect service meter wires (6).
16
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).
Install Stick And Swing Pilot Control Valve
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.
17
3. Put cover in position enough to connect
service meter wires (4).
4. Install rubber boot (6) and knob (5) on
control lever. Install rubber molding (7) and
cover (8). Install cover (8) on control panel
with the four screws that hold it.
Copyright 1993 - 2021 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Fri Jan 1 103316 UTC0800 2021
18
Shutdown SIS
Previous Screen
Product EXCAVATOR Model 225 EXCAVATOR
51U Configuration 225 EXCAVATOR 51U00590-02033
(MACHINE)
Disassembly and Assembly 225 EXCAVATOR VEHICLE
SYSTEMS Media Number -SENR7907-00 Publication
Date -01/02/1979
Date Updated -12/10/2001
Bucket And Boom Pilot Control Valve SMCS -
5452-11 5452-12 Remove Bucket And Boom Pilot
Control Valve
1. Remove three bolts (1) from the seat support.
Turn seat toward track.
2. Remove knob (2) and rubber boot (3) from
control lever. Remove four screws (6) from cover
(4). Remove cover and rubber molding (5).
19

1. Disconnect wires (7) from indicator light.
2. 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.
20

1. Install cable tie (4).
2. Connect indicator light wires (3).

1. Install boot (6) and knob (5) on control lever.
2. Put cover (8) and rubber molding (7) in position
   on control panel. Install the four screws that
   hold cover to panel.

7. Put seat into its correct position and install
the three bolts that hold seat support to the
floor.
Copyright 1993 - 2021 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Fri Jan 1 103412 UTC0800 2021
21
Shutdown SIS
Previous Screen
Product EXCAVATOR Model 225 EXCAVATOR
51U Configuration 225 EXCAVATOR 51U00590-02033
(MACHINE)
Disassembly and Assembly 225 EXCAVATOR VEHICLE
SYSTEMS Media Number -SENR7907-00 Publication
Date -01/02/1979
Date Updated -12/10/2001
Pilot Control Valves SMCS - 5452-16
5452-15 Disassemble Pilot Control Valves start
by a) remove bucket and boom pilot control valve
or stick and swing pilot control valve

1. Remove three bolts (1) and remove control lever.
2. Loosen nuts (6) and remove ball and socket joints
   (5) from valve spools.
3. Remove large bolt (2) and block (3) from valve
   body. Remove rubber pads (4).

1. Remove two bolts and manifold (7) from valve
   body. Remove two O-ring seals from manifold (7).
2. Remove two valve spools (8) from the valve body.

22
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.
Assemble Pilot Control Valves
1. Install spring retainers (5), shims (7),
retainer (4), springs (6), retainer (3), shims
(1) and spring retainers (2).
23
2. Install the two lip type seals in the valve
body with tool group (A). Install seals with the
lip toward inside of valve body.
3. Install valve spools (9) in the valve body.
Install new O-ring seals on manifold (8). Install
manifold on valve body with the two bolts that
hold it.
4. Put rubber pads (12) over valve spools.
Install block (13) and bolt (11) on valve body.
Install ball and socket joints (14) on valve
spool. Put control lever in position over ball
and socket joints, then install bolts (10). end
by a) install stick and swing pilot control
valve or bucket and boom pilot control valve
Copyright 1993 - 2021 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Fri Jan 1 103508 UTC0800 2021
24
Shutdown SIS
Previous Screen
Product EXCAVATOR Model 225 EXCAVATOR
51U Configuration 225 EXCAVATOR 51U00590-02033
(MACHINE)
Disassembly and Assembly 225 EXCAVATOR VEHICLE
SYSTEMS Media Number -SENR7907-00 Publication
Date -01/02/1979
Date Updated -12/10/2001
Speed And Direction Pilot Control Valve SMCS -
5462-12 5462-15 5462-16 5462-11 Remove Speed
And Direction Pilot Control Valve

1. Remove back cotter pin and pin (2) and spacer
   from each pedal. Remove pedals (1).
2. Remove two bolts (3) from each pedal support.
   Remove pedal stems.
3. Slide boot (4) up on control lever.

4. Remove two clamps (5) from the lines.
25
5. Disconnect wire (7). Disconnect seven oil
lines (6) from the control valve. Remove two
bolts (8) from each side of the valve. Lower the
valve.
6. Remove bolt (9) that holds directional lever
(10) to valve. Remove control valve (11).
Install Speed And Direction Pilot Control Valve
1. Put control valve (2) in position on tracks.
Connect directional lever (1) to the valve with
the bolt that holds it.
2. Push control valve up into position and
install the four bolts (4) that hold it. Connect
wire (5). Connect the seven oil lines (3) to the
control valve.
26
Thank you very much for your reading. Please
Click Here. Then Get COMPLETE MANUAL. NO WAITING
GET MORE OTHER MANUALS
https//www.aservicemanualpdf.com/
NOTE If there is no response to click on the
link above, please download the PDF document
first and then click on it.
GET MORE OTHER MANUALS
https//www.aservicemanualpdf.com/
27
3. Install two clamps (6) on the oil lines.

• Push rubber boot (9) down on control lever.
  Install pedal supports with the two bolts (8)
  that hold it.
• Install two pedals (7) with the pins (10) and
  cotter pins that hold them.
• Disassemble Speed And Direction Pilot Control
  Valve
• start by
• a) remove speed and direction pilot control valve

1. Remove the two foot pedals (2).
2. Remove the two bolts (5) from each support.
3. Remove the two supports (4) and two stems.
4. Remove the control lever (3).
5. Remove the four bolts (9) and bracket (1).
6. Remove the forward valve group (6) and reverse
   valve group (8) from steering valve group (7).

28
7. Remove the covers from valve groups (6) and
(8).

1. Remove slug (13), spring (16), and valve stem
   (12) from valve bodies.
2. Remove bolt (10), retainer (14), shims (11), and
   spring (15) from valve stem. Keep shims for use
   during assembly of valve group. Remove the seal
   from valve bodies.

1. Remove cover (26) from body. Remove key (23) and
   washer (22) from shaft (18).
2. Loosen bolt (25), and remove bearing (19), shaft
   (18), lever (21), and washer (24).
3. Remove the seal (20) and bearing (17).

13. Remove the cover (32), springs (31) and (30),
retainers (29) and (28), and valve stems (27).
Put location marks on valve stems as to their
location in valve body.
Assemble Speed And Direction Pilot Control Valve
29

1. Put valve stems (15) and (16) in their respective
   positions in valve body with grooves (slots) (1)
   in stems toward the openings for the oil lines in
   valve body (29).
2. Install retainers (30) and (32), springs (34) and
   (31), and cover (33).

• Install bearings (3) and (5). Install seal (2) in
  valve body with lip of the seal toward bearing
  (3).
• Install shaft (4), lever (9), washer (11), and
  key (7). Put lever in position on shaft and
  tighten bolt (12). Install cover (10).
• NOTE The grooves (slots) (1) in valve stems (15)
  and (16) must be visible (can be seen) through
  the openings for the oil lines in valve body (29)
  after installation of lever (9).
• Install washer (6) and key (8) on the shaft.

30
https//www.aservicemanualpdf.com/ My Dear
Friend! Thank you very much for visiting. Full
manual if required, please enter the following
URL into your browser. https//www.aservicemanual
pdf.com/