Caterpillar cat 325 excavator (prefix 2 jk) service repair manual (2jk00001 and up)

Service Repair Manual
Models
325 325L EXCAVATOR

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Product: EXCAVATOR
Model: 325 L EXCAVATOR 2JK
Configuration: 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)
Disassembly and Assembly
325, 325B and 325L Excavators
Media Number -RENR1178-03 Publication Date -01/09/2000 Date Updated -09/10/2001
i01767061
Final Drive - Disassemble
SMCS - 4050-015
Disassembly Procedure For The Final Drive On CIPI
Undercarriage Arrangements Which Are Based On 325 and
325B Track Type Excavators
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-2420 Transmission Repair Stand 1
B 138-7573 Link Bracket 2
C 1P-1860 Retaining Ring Pliers 1
D
6B-6682 Full Nut 1
1P-5546 Crossblock 1
5P-8248 Hard Washer 4
6V-3142 Plate 1
(1)
Threaded Rod 1
(2)
Spacer 4
E 138-7574 Link Bracket 2
F 8B-7561 Step Plate 1
5F-7465 Puller Gp 1
1H-3107 Push-Puller Tool Gp 1
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1H-3112 Bearing Cup Puller Gp 1
1P-5551 Adjustable Screw Assembly 1
( 1 )
The 16 NF threaded rod is 280 mm (11 inch) long × 19 mm (0.75 inch) in diameter.
( 2 )
The spacer's outer diameter is 64 mm (2.5 inch). The spacer's inner diameter is 25.4 mm (1.0 inch). The spacer's
thickness is 6.4 mm (.25 inch).
Start By:
A. Remove the final drive. Refer to Disassembly and Assembly, "Final Drive - Remove" in this
manual.
1. Thoroughly clean the outside of the final drive prior to disassembly.
2. Put an alignment mark across the sections of the final drive for assembly purposes. The
parts must be reinstalled in the part's original locations.
Illustration 1 g00511587
3. Fasten the final drive to Tool (A), as shown. The combined weight of the final drive and
final drive sprocket is approximately 361 kg (795 lb).
4. Remove 20 bolts (1) and the washers that secure the cover to the final drive.
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5. Use a soft faced hammer and break the seal between cover (2) and the ring gear. Fasten
Tool (B) and a hoist to cover (2), as shown. Remove the cover. The weight of the cover is
approximately 32 kg (70 lb).
6. Remove thrust plate (5) from the cover.
7. Remove 12 socket head bolts (3) and ring gear (4) from the cover.
8. Remove sun gear (6). Remove carrier assembly (7) by lifting the carrier assembly straight
up. The weight of the carrier assembly is approximately 14 kg (30 lb).
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Note: Two spacers (8) are used with carrier assembly (7). One of the spacers fits on the top
side of carrier assembly (7). The other spacer (8) is located in the carrier of carrier assembly
(15) .
9. Remove spacer (8) from carrier assembly (7) .
Note: Planetary gears (11) might have oil grooves "L". Note the position of the oil grooves
in relation to the carrier for assembly purposes.
10. Remove retaining ring (9) with Tool (C). Remove two thrust washers (10) and planetary
gear (11) from the carrier. Remove bearing (12) from the planetary gear.
11. Repeat Step 10 in order to remove the other two planetary gears from the carrier.
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12. Use a screwdriver, and remove retaining ring (13) from the carrier. Remove sun gear (14)
from the carrier.
13. Use two people in order to remove carrier assembly (15). Remove the carrier assembly by
pulling the carrier assembly straight up. The weight of the carrier assembly is approximately
25 kg (55 lb).
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Note: Spacer (16) may remain with carrier assembly (15), or the spacer may remain with
carrier assembly (24). Refer to Step 19.
14. Remove spacer (16) from carrier assembly (15) .
Note: If spring pin (17) is recessed below the outside surface of the carrier, measure the
depth of the spring pin and record this measurement for assembly purposes.
15. Drive spring pin (17) into planetary shaft (18) with a hammer and a punch.
Note: Planetary gears (20) might have oil grooves "M". Note the position of the oil grooves
16. Remove planetary shaft (18), two thrust washers (19) and planetary gear (20) from the
carrier. Remove bearing (21) from the planetary gear. Remove spring pin (17) from
planetary shaft (18) with a hammer and a punch.
17. Repeat Steps 15 and 16 in order to remove the other two planetary gears from the carrier.
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18. Use a screwdriver, and remove retaining ring (22). Remove sun gear (23) from the carrier.
Typical example
19. If spacer (16) was not removed in Step 14, remove the spacer from carrier assembly (24) at
this time.
20. Slide a piece of steel bar stock between the planetary gears in carrier assembly (24), as
shown. Make sure that the bar stock is centered in the carrier assembly. Fasten a lifting sling
and a hoist to the steel bar stock, as shown. Slowly lift carrier assembly (24) from the final
drive. The weight of the carrier assembly is approximately 36 kg (80 lb).
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Typical example
Note: If spring pin (25) is recessed below the outside surface of the carrier, measure the
depth of the spring pin and record this measurement for assembly purposes.
21. Drive spring pin (25) into planetary shaft (26) with a hammer and a punch.
Note: Planetary gears (28) might have oil grooves "N". Note the position of the oil grooves
22. Remove planetary shaft (26), two thrust washers (27) and planetary gear (28) from the
carrier. Remove two bearings (29) from the planetary gear. Drive spring pin (25) out of
planetary shaft (26) with a hammer and a punch.
23. Repeat Steps 21 and 22 in order to remove the other planetary gears from the carrier.
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Note: It will be necessary to pry ring gear (30) away from main housing (31) in order to
install the lifting slings.
24. Fasten lifting slings and a hoist to ring gear (30), as shown. Remove the ring gear from main
housing (31). The weight of the ring gear is approximately 48 kg (105 lb).
25. Remove O-ring seal (32) from main housing (31) .
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Typical example
26. Remove socket head bolts (33) from gear (34) .
27. Use Tooling (D) to remove gear (34) from the housing.
28. Remove shims (35) from the housing.
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29. Fasten Tool (E) and a hoist to main housing (31), as shown. Separate the main housing and
the final drive sprocket from the motor housing. The combined weight of the main housing
and final drive sprocket is approximately 82 kg (180 lb).
30. Remove Duo-Cone seal (36) from the motor housing.
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31. Remove Duo-Cone seal (37) from the main housing.
32. Use Tooling (F) to remove bearings (38) and (39) from the main housing.
33. If necessary, remove the final drive sprocket from the main housing. Refer to Disassembly
and Assembly, "Final Drive Sprocket - Remove and Install" in this manual for the procedure
to remove the final drive sprocket from the main housing.
Disassembly Procedure For The Final Drive On CIPI
Undercarriage Arrangements Which Are Based On 325C
Track Type Excavators
Table 2
Required Tools
Tool Part Number Part Description Qty
A 1P-2420 Transmission Repair Stand 1
B 138-7573 Link Bracket 2
C 1P-1863 Retaining Ring Pliers 1
D 194-3878 Spanner Socket 1
E 138-7574 Link Bracket 2
F 5F-7366 Forcing Screw 1
1P-5546 Crossblock 1
1U-9889 Crossblock 1
1P-0520 Driver Group 1
6V-7888 Puller Leg 2
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1H-3112 Puller Assembly 1
1P-5551 Adjustable Screw Assembly 1
Start By:
A. Remove the final drive. Refer to Disassembly and Assembly, "Final Drive - Remove".
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of
the component should be thoroughly cleaned. This will prevent dirt from entering the
internal mechanism.
1. Put an alignment mark across the sections of the final drive for assembly purposes. The
parts must be reinstalled in the part's original locations.
2. Fasten the final drive to Tooling (A), as shown. The combined weight of the final drive and
final drive sprocket is approximately 312 kg (688 lb).
3. Remove bolts (1) and the washers that hold the cover in position.
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4. Remove the setscrews from the cover. Fasten Tooling (B) and a hoist to cover (2), as
shown. Remove the cover. The weight of the cover is approximately 32 kg (70 lb).
5. Remove twelve bolts (3). Remove gear (5). Check plate (6). Replace plate (6) if wear is
shown. Remove plug (4) from cover (2) .
6. Remove O-ring seal (7) from plug (4) .
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7. Remove gear (8). Remove spacer (9) .
8. Remove retaining ring (10) with Tooling (C). Remove washer (11). Remove gear (12).
Remove bearing assembly (13). Remove second washer (11) .
9. Repeat Step 8 for the additional two gear assemblies.
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10. Remove retaining ring (14) .
11. Remove carrier assembly (15) .
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13. Remove retaining ring (18). Remove carrier (19) .
14. Remove carrier (19) by lifting the carrier straight up. The weight of the carrier is
approximately 14 kg (30 lb).
15. Disassemble carrier assembly (19), as follows.
a. Drive spring pin (20) into planetary shaft (21) with a hammer and a punch.
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b. Remove planetary shaft (21) with spring pin (20) from the carrier assembly.
c. Remove spring pin (20) from planetary shaft (21) with a hammer and a punch.
d. Remove two thrust washers (22) and planetary gear (24) from the carrier assembly.
e. Remove bearing (23) from planetary gear (24) .
16. Repeat Steps 15.a through 15.e in order to remove the other two planetary gears from the
carrier.
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18. Remove carrier assembly (27) .
19. Remove carrier assembly (27) by lifting the carrier straight up. The weight of the carrier
assembly is approximately 38 kg (85 lb).
Note: It will be necessary to use an appropriate lifting device or two people to remove
carrier (27) .
20. Disassemble carrier assembly (27), as follows.
a. Drive spring pin (29) into planetary shaft (28) with a hammer and a punch.
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b. Remove planetary shaft (28) with spring pin (29) from the carrier assembly.
c. Remove spring pin (29) from planetary shaft (28) with a hammer and a punch.
d. Remove two thrust washers (30) and planetary gear (32) from the carrier assembly.
e. Remove two bearings (31) from the planetary gear.
21. Repeat Steps 20.a through 20.e in order to remove the other two planetary gears from the
carrier.
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22. Remove gear (33). The weight of gear is approximately 41 kg (90 lb).
Note: Use two technicians to remove gear (33) .
23. Remove O-ring seal (34) .
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24. Remove peening operation from stopper plate assembly (35) .
Note: Removal of the peening operation will allow stopper plate assembly to move without
damage to parts.
25. Install Tooling (D). Remove stopper plate assembly (35) .
26. Install Tooling (E) to sprocket housing (36). Lift sprocket housing (36) and sprocket (37).
Remove sprocket housing (37) from housing (38). The weight of housing (36), sprocket
housing (37) and housing (38) is approximately 118 kg (260 lb).
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27. Remove Duo-Cone seal kit (39) from housing (38) .
28. Rotate sprocket housing (36) .
29. Remove Duo-Cone seal kit (39) .
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Caterpillar cat 325 excavator (prefix 2 jk) service repair manual (2jk00001 and up)

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