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Caterpillar Cat 325 EXCAVATOR (Prefix 2JK) Service Repair Manual (2JK00001 and up)

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Caterpillar Cat 325 EXCAVATOR (Prefix 2JK) Service Repair Manual (2JK00001 and up)

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  1. Service Repair Manual Models 325325L EXCAVATOR

  2. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documentat... 1/24 Shutdown SIS Previous Screen 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 6B-6682 Full Nut 1 1P-5546 Crossblock 1 5P-8248 Hard Washer 4 D 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 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  3. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documentat... 2/24 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  4. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documentat... 3/24 Illustration 2 g00511600 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). Illustration 3 g00511631 6. Remove thrust plate (5) from the cover. 7. Remove 12 socket head bolts (3) and ring gear (4) from the cover. Illustration 4 g00511636 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  5. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documentat... 4/24 Illustration 5 g00511640 Illustration 6 g00572334 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  6. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documentat... 5/24 Illustration 7 g00511653 12. Use a screwdriver, and remove retaining ring (13) from the carrier. Remove sun gear (14) from the carrier. Illustration 8 g00511661 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  7. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documentat... 6/24 Illustration 9 g00511682 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) . Illustration 10 g00511735 Illustration 11 g00572352 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 in relation to the carrier for assembly purposes. 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  8. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documentat... 7/24 Illustration 12 g00511788 18. Use a screwdriver, and remove retaining ring (22). Remove sun gear (23) from the carrier. Illustration 13 g00511795 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  9. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documentat... 8/24 Illustration 14 g00511799 Typical example Illustration 15 g00572382 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 in relation to the carrier for assembly purposes. 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  10. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documentat... 9/24 Illustration 16 g00511809 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). Illustration 17 g00511825 25. Remove O-ring seal (32) from main housing (31) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  11. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documen... 10/24 Illustration 18 g00511857 Typical example Illustration 19 g00511869 26. Remove socket head bolts (33) from gear (34) . 27. Use Tooling (D) to remove gear (34) from the housing. Illustration 20 g00511872 28. Remove shims (35) from the housing. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  12. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documen... 11/24 Illustration 21 g00511882 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). Illustration 22 g00511906 30. Remove Duo-Cone seal (36) from the motor housing. Illustration 23 g00511934 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  13. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documen... 12/24 Illustration 24 g00511939 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 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  14. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documen... 13/24 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. Illustration 25 g00708089 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. Illustration 26 g00708090 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  15. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documen... 14/24 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). Illustration 27 g00879362 5. Remove twelve bolts (3). Remove gear (5). Check plate (6). Replace plate (6) if wear is shown. Remove plug (4) from cover (2) . Illustration 28 g00879365 6. Remove O-ring seal (7) from plug (4) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  16. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documen... 15/24 Illustration 29 g00780428 7. Remove gear (8). Remove spacer (9) . Illustration 30 g00780432 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  17. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documen... 16/24 Illustration 31 g00781401 10. Remove retaining ring (14) . Illustration 32 g00781407 11. Remove carrier assembly (15) . Illustration 33 g00781412 12. Remove gear (16). Remove spacer (17) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  18. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documen... 17/24 Illustration 34 g00781466 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). Illustration 35 g00879368 15. Disassemble carrier assembly (19), as follows. a. Drive spring pin (20) into planetary shaft (21) with a hammer and a punch. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  19. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documen... 18/24 Illustration 36 g00781476 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. Illustration 37 g00781516 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. Illustration 38 g00781529 17. Remove gear (25). Remove spacer (26) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  20. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documen... 19/24 Illustration 39 g00781559 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. Illustration 40 g00781719 a. Drive spring pin (29) into planetary shaft (28) with a hammer and a punch. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  21. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documen... 20/24 Illustration 41 g00781601 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. Illustration 42 g00781607 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. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

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  23. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documen... 21/24 Illustration 43 g00781730 22. Remove gear (33). The weight of gear is approximately 41 kg (90 lb). Note: Use two technicians to remove gear (33) . Illustration 44 g00781807 23. Remove O-ring seal (34) . Illustration 45 g00781815 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  24. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documen... 22/24 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. Illustration 46 g00781830 25. Install Tooling (D). Remove stopper plate assembly (35) . Illustration 47 g00879371 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). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

  25. 325, 325L EXCAVATOR 2JK00001-UP (MACHINE)(SEBP2008 - 03) - Documen... 23/24 Illustration 48 g00781858 27. Remove Duo-Cone seal kit (39) from housing (38) . 28. Rotate sprocket housing (36) . Illustration 49 g00781895 29. Remove Duo-Cone seal kit (39) . Illustration 50 g00781907 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis... 2020/7/29

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