Caterpillar Cat 325C Excavator (Prefix JLC) Service Repair Manual (JLC00001 and up).pdf

Service Repair Manual
Models
325C and 325C L Excavator

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Product: EXCAVATOR
Model: 325C EXCAVATOR JLC
Configuration: 325C & 325C L Excavators JLC00001-UP (MACHINE) POWERED BY 3126 Engine
Disassembly and Assembly
3126B Engines for Caterpillar Built Machines
Media Number -SENR9581-06 Publication Date -01/08/2018 Date Updated -17/08/2018
i01931442
Crankshaft Wear Sleeve (Rear) - Remove - If Equipped
SMCS - 1161-011-ZV
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 4C-4869 Distorter Ring 1
B 5P-7312 Seal Distorter 1
Start By:
a. Remove the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear
Seal - Remove".
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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325C & 325C L Excavators JLC00001-UP (MACHINE) POWERED BY 3126 Engine...
2020/7/9
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Illustration 1 g00614029
Note: Wear sleeves are not installed at the factory. The wear sleeve is included with the
replacement rear seal.
1. Install Tooling (A) in the bore of the crankshaft rear sleeve.
2. Install Tooling (B) between Tooling (A) and the crankshaft wear sleeve. Turn Tooling (B)
until the edge of Tooling (B) makes a crease in the crankshaft wear sleeve. Make a crease in
the crankshaft wear sleeve at two other locations around the crankshaft wear sleeve until the
crankshaft wear sleeve is loose.
3. Remove Tooling (B), Tooling (A), and the crankshaft wear sleeve from the end of the
crankshaft.
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Thu Jul 9 23:41:06 UTC+0800 2020
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Product: EXCAVATOR
i01929732
Crankshaft Wear Sleeve (Rear) - Install
SMCS - 1161-012-ZV
Installation Procedure
Table 1
Required Tools
C(1)
132-8772 Seal Locator 1
D(1)
1U-7596 Bolt 2
E(1)
1U-7597 Sleeve Ring 1
F(1)
1U-7594 Seal Installer 1
G(1)
9S-8858 Nut 1
(1)
Part of the 1U-7598 Seal Installer
NOTICE
1. Ensure that the rear of the crankshaft is thoroughly clean and dry prior to the installation of
the crankshaft rear seal.
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2. Fasten Tooling (C) to the rear of the crankshaft with Tooling (D). Hand tighten Tooling (D).
3. Position the crankshaft rear seal and crankshaft rear sleeve (1) on Tooling (C). Position
Tooling (E) on Tooling (C).
Typical example
4. Position Tooling (F) over Tooling (C) and Tooling (E). Install Tooling (G). Tighten Tooling
(G) in order to install the crankshaft rear seal and the crankshaft wear sleeve.
5. Remove Tooling (G), Tooling (F), and Tooling (E). Turn over Tooling (E). Install Tooling
(E), Tooling (F), and Tooling (G). Tighten Tooling (G) in order to complete the installation
of the crankshaft rear seal and the crankshaft wear sleeve.
6. Remove Tooling (G) and Tooling (F). Check Tooling (E) and Tooling (C). The faces of
Tooling (E) and Tooling (C) will be flush if the crankshaft rear seal and the crankshaft wear
sleeve are properly installed. Refer to the Specifications module for more information.
7. Remove Tooling (E), Tool (E), and Tooling (C).
End By:
a. Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".
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Product: EXCAVATOR
i02374834
Crankshaft - Install
SMCS - 1202-012
Table 1
Required Tools
A 8T-5096 Dial Indicator Group 1
NOTICE
NOTICE
Ensure that the crankshaft main bearing tabs engage with the grooves
in the block and the crankshaft main bearing cap.
Note: The number six main bearing is the thrust bearing.
1. Clean the bearing surfaces in the cylinder block for the main bearings. Apply clean engine
oil on the upper main bearing. Do not put engine oil on the back side of the bearing
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surfaces. Install the upper main bearing in the cylinder block. Ensure that the tab on the
back side of the bearing engages with the groove in the cylinder block.
2. Put clean engine oil on the journals of the crankshaft bearing. Attach a suitable lifting
device to crankshaft (1). The weight of crankshaft (1) is approximately 60 kg (132 lb).
Carefully install the crankshaft in the cylinder block.
3. Clean the bearing surface of the main bearing caps. Install the lower main bearing in the
crankshaft main bearing caps. Ensure that the tab on the back side of the bearing engages
with the groove in the main bearing cap. Apply clean engine oil on the lower main bearing.
Do not put engine oil on the back side of the bearing surfaces.
4. Install crankshaft main bearing caps with the part numbers toward the right hand side of the
cylinder block. The numbers should start at the front of the engine. Place clean engine oil or
Molylube on the bolt threads and the washers.
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5. Install the bolts for main bearing caps (2). Tighten the bolts to a torque of 54 ± 7 N·m
(40 ± 5 lb ft).
6. Turn the bolts for an additional 90 ± 5 degrees (1/4 turn).
7. Install connecting rod caps (3). Refer to Disassembly and Assembly, "Pistons and
Connecting Rods - Install".
8. Check the end play of crankshaft (1) with Tooling (A). The end play must be
0.07 to 0.32 mm (0.003 to 0.013 inch).
End By:
a. Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install".
b. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Install".
c. Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing -
Remove and Install".
Thu Jul 9 23:42:58 UTC+0800 2020
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Product: EXCAVATOR
i01984006
Crankshaft Gear - Remove and Install
SMCS - 1204-010-GE
Removal Procedure
Table 1
Required Tools
A
8B-7551 Bearing Puller 1
8B-7549 Puller Leg 2
3H-0465 Push-Puller Plate 4
6B-6682 Full Nut 2
8B-7560 Step Plate 1
1P-0820 Hydraulic Puller 1
9U-6600 Hand Hydraulic Pump 1
Start By:
a. Remove the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Remove".
NOTICE
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1. Use Tooling (A) in order to remove crankshaft gear (3) from crankshaft (1).
2. Remove woodruff key (2).
NOTICE
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1. Position woodruff key (2) in crankshaft (1).
Hot oil and hot components can cause personal injury. Do not allow hot
oil or hot components to contact the skin.
2. Raise the temperature of crankshaft gear (3). Install crankshaft gear (3) on crankshaft (1).
End By:
a. Install the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Install".
Thu Jul 9 23:43:54 UTC+0800 2020
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Product: EXCAVATOR
i05977048
Bearing Clearance - Check
SMCS - 1203-535; 1219-535
Measurement Procedure
Table 1
Required Tools
A
198-9142
Plastic Gauge (Green)
0.025 to 0.076 mm
(0.001 to 0.003 inch)
1
198-9143
Plastic Gauge (Red)
0.051 to 0.152 mm
(0.002 to 0.006 inch)
1
198-9144
Plastic Gauge (Blue)
0.102 to 0.229 mm
(0.004 to 0.009 inch)
1
198-9145
Plastic Gauge (Yellow)
0.230 to 0.510 mm
(0.009 to 0.020 inch)
1
Note: Plastic gauge may not be necessary when the engine is in the chassis.
NOTICE
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Note: Cat does not recommend the checking of the actual bearing clearances particularly on small
engines. This is because of the possibility of obtaining inaccurate results and the possibility of
damaging the bearing or the journal surfaces. Each Cat engine bearing is quality checked for
specific wall thickness.
Note: The measurements should be within specifications and the correct bearings should be used.
If the crankshaft journals and the bores for the block and the rods were measured during
disassembly, no further checks are necessary. However, if the technician still wants to measure the
bearing clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals
with small diameters if clearances are less than 0.10 mm (0.004 inch).
NOTICE
Lead wire, shim stock or a dial bore gauge can damage the bearing
surfaces.
The technician must be very careful to use Tooling (A) correctly. The following points must be
remembered:
• Ensure that the backs of the bearings and the bores are clean and dry.
• Ensure that the bearing locking tabs are properly seated in the tab grooves.
• The crankshaft must be free of oil at the contact points of Tooling (A).
1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap.
Note: Do not allow Tooling (A) to extend over the edge of the bearing.
2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an
impact wrench. Be careful not to dislodge the bearing when the cap is installed.
Note: Do not turn the crankshaft when Tooling (A) is installed.
3. Carefully remove the cap, but do not remove Tooling (A). Measure the width of Tooling
(A) while Tooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration
1.
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Typical Example
4. Remove all of Tooling (A) before you install the bearing cap.
Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all
parts of Tooling (A) are not the same width. Measure the major width in order to ensure that
the parts are within the specification range. Refer to Specifications Manual, "Connecting
Rod Bearing Journal" and Specifications Manual, "Main Bearing Journal" for the correct
clearances.
Thu Jul 9 23:44:49 UTC+0800 2020
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Product: EXCAVATOR
i01984226
Idler Pulley - Remove and Install
SMCS - 1358-010
Thu Jul 9 23:45:45 UTC+0800 2020
1/1
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Product: EXCAVATOR
i01930316
Belt Tensioner - Remove and Install
SMCS - 1358-010
Removal Procedure
1. Use a breaker bar to release the tension on belt tensioner (1). Remove the drive belt.
2. Remove bolt (2) and belt tensioner (1).
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1. Position belt tensioner (1) on the cylinder block. Install bolt (2).
2. Install the drive belt. Use a breaker bar to release tension on belt tensioner (1).
Thu Jul 9 23:46:41 UTC+0800 2020
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i01379733
Electronic Control Module - Remove and Install
SMCS - 1901-010
Removal Procedure
1. Remove the fuel lines from the fuel cooled ECM (if equipped).
Typical example
2. Loosen screw (1) until wiring harness (4) can be disconnected. Disconnect wiring harness
(4) from electronic control module (2).
3. Remove four bolts (3). Remove the electronic control module from the engine.
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Typical example
1. Position electronic control module (2) on the engine and install four bolts (3).
2. Connect wiring harness (4) to electronic control module (2). Tighten screw (1) to a torque of
6 ± 1 N·m (53 ± 9 lb in).
3. Reconnect the fuel lines to the fuel cooled ECM (if equipped).
Thu Jul 9 23:47:37 UTC+0800 2020
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Product: EXCAVATOR
i01378281
Alternator - Remove and Install
SMCS - 1405-010
Removal Procedure
Table 1
Required Tools
A 1U-7117 Breaker Bar 1
NOTICE
1. Use Tool (A) to release the tension on the belt tensioner.
2. Remove the drive belt from the alternator drive pulley.
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3. Place an index mark on all electrical wires that are connected to alternator (1). Disconnect
all electrical wires from the alternator.
4. Remove two bolts (2).
5. Remove alternator (1) from the mounting bracket.
Table 2
Required Tools
A 1U-7117 Breaker Bar 1
NOTICE
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1. Position alternator (1) on the mounting bracket. Install two bolts (2).
2. Install the drive belt on the alternator drive pulley.
3. Use Tool (A) on the belt tensioner in order to tighten the drive belt.
4. Connect all electrical wires to the alternator. Use the index marks to correctly connect the
wires.
Thu Jul 9 23:48:32 UTC+0800 2020
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Product: EXCAVATOR
i06798491
Electric Starting Motor - Remove and Install
SMCS - 1453-010
Removal Procedure
Personal injury can result from failure to disconnect the battery.
First, disconnect the negative battery cable. Then, disconnect the
positive battery cable.
A positive power lead can cause sparks if the battery is not
disconnected. Sparks can possibly result in battery explosion or fire.
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1. Disconnect cable strap (1).
2. Place an index mark on all of the harness assemblies. Disconnect the harness assemblies
from electric starting motor (2).
3. Fasten a suitable lifting device to electric starting motor (4). The weight of electric starting
motor (4) is approximately 35 kg (77 lb).
4. Remove bolts (3).
5. Remove electric starting motor (4) and the gasket from the flywheel housing.
1. Install electric starting motor (4) in reverse order of removal.
Thu Jul 9 23:49:28 UTC+0800 2020
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