Caterpillar Cat 325C and 325C L Excavator (Prefix JLC) Service Repair Manual Instant Download

1
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 Required Tools Required Tools 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.
3

• Illustration 1 g00614029
• Note Wear sleeves are not installed at the
  factory. The wear sleeve is included with the
  replacement rear seal.
• Install Tooling (A) in the bore of the crankshaft
  rear sleeve.
• 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.
• Remove Tooling (B), Tooling (A), and the
  crankshaft wear sleeve from the end of the
  crankshaft.

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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
i01929732
Crankshaft Wear Sleeve (Rear) - Install SMCS -
1161-012-ZV Installation Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
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 Keep all parts clean from
contaminants. Contaminants may cause rapid wear
and shortened component life.
1. Ensure that the rear of the crankshaft is
thoroughly clean and dry prior to the
installation of the crankshaft rear seal.
6

• Illustration 1 g01003875
• Fasten Tooling (C) to the rear of the crankshaft
  with Tooling (D). Hand tighten Tooling (D).
• Position the crankshaft rear seal and crankshaft
  rear sleeve (1) on Tooling (C). Position Tooling
  (E) on Tooling (C).

Illustration 2 Typical example
g01003866

• 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.
• 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.
• 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.
• Remove Tooling (E), Tool (E), and Tooling (C).
• End By
• a. Install the flywheel. Refer to Disassembly and
  Assembly, "Flywheel - Install".

7
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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
i02374834
Crankshaft - Install SMCS - 1202-012 Installation
Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 8T-5096 Dial Indicator Group 1
NOTICE Keep all parts clean from
contaminants. Contaminants may cause rapid wear
and shortened component life.
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
8
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.

• Illustration 1 g01184978
• 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.
• 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.
• 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.

9

• Illustration 2 g01028042
• Install the bolts for main bearing caps (2).
  Tighten the bolts to a torque of 54 7 Nm (40
  5 lb ft).
• Turn the bolts for an additional 90 5 degrees
  (1/4 turn).
• Install connecting rod caps (3). Refer to
  Disassembly and Assembly, "Pistons and Connecting
  Rods - Install".
• 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
• Install the front housing. Refer to Disassembly
  and Assembly, "Housing (Front) - Install".
• Install the engine oil pump. Refer to Disassembly
  and Assembly, "Engine Oil Pump - Install".
• Install the flywheel housing. Refer to
  Disassembly and Assembly, "Flywheel Housing -
  Remove and Install".

Copyright 1993 - 2020 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Thu Jul 9 234258 UTC0800 2020
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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
i01984006
Crankshaft Gear - Remove and Install SMCS -
1204-010-GE Removal Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 8B-7551 Bearing Puller 1
A 8B-7549 Puller Leg 2
A 3H-0465 Push-Puller Plate 4
A 6B-6682 Full Nut 2
A 8B-7560 Step Plate 1
A 1P-0820 Hydraulic Puller 1
A 9U-6600 Hand Hydraulic Pump 1
Start By a. Remove the crankshaft. Refer to
Disassembly and Assembly, "Crankshaft -
Remove". NOTICE Keep all parts clean from
contaminants. Contaminants may cause rapid wear
and shortened component life.
11

• Illustration 1 g00988783
• Use Tooling (A) in order to remove crankshaft
  gear (3) from crankshaft (1).
• Remove woodruff key (2).

Installation Procedure NOTICE Keep all parts
clean from contaminants. Contaminants may cause
rapid wear and shortened component life.
12
Illustration 2
g00988783
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".
Copyright 1993 - 2020 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Thu Jul 9 234354 UTC0800 2020
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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
i05977048
Bearing Clearance - Check SMCS - 1203-535
1219-535 Measurement Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 198-9142 Plastic Gauge (Green) 0.025 to 0.076 mm (0.001 to 0.003 inch) 1
A 198-9143 Plastic Gauge (Red) 0.051 to 0.152 mm (0.002 to 0.006 inch) 1
A 198-9144 Plastic Gauge (Blue) 0.102 to 0.229 mm (0.004 to 0.009 inch) 1
A 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 Keep all parts
clean from contaminants. Contaminants may cause
rapid wear and shortened component life.
14
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).
• 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.
• 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.
• 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.

15
Illustration 1 Typical Example
g01152855
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.
Copyright 1993 - 2020 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Thu Jul 9 234449 UTC0800 2020
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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
i01984226
Idler Pulley - Remove and Install SMCS - 1358-010
Illustration 1
g01028295
Copyright 1993 - 2020 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Thu Jul 9 234545 UTC0800 2020
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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
i01930316
Belt Tensioner - Remove and Install SMCS -
1358-010 Removal Procedure

• Illustration 1 g01011962
• Use a breaker bar to release the tension on belt
  tensioner (1). Remove the drive belt.
• Remove bolt (2) and belt tensioner (1).

Installation Procedure
18

• Illustration 2 g01011962
• Position belt tensioner (1) on the cylinder
  block. Install bolt (2).
• Install the drive belt. Use a breaker bar to
  release tension on belt tensioner (1).

Copyright 1993 - 2020 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Thu Jul 9 234641 UTC0800 2020
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Previous Screen
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
i01379733
Electronic Control Module - Remove and
Install SMCS - 1901-010 Removal Procedure 1.
Remove the fuel lines from the fuel cooled ECM
(if equipped).
Illustration 1 Typical example
g00609591

• Loosen screw (1) until wiring harness (4) can be
  disconnected. Disconnect wiring harness
• (4) from electronic control module (2).
• Remove four bolts (3). Remove the electronic
  control module from the engine.

Installation Procedure
20
Illustration 2 Typical example
g00609591

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 Nm (53 9 lb in).
3. Reconnect the fuel lines to the fuel cooled ECM
   (if equipped).

Copyright 1993 - 2020 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
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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
i01378281
Alternator - Remove and Install SMCS -
1405-010 Removal Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 1U-7117 Breaker Bar 1
NOTICE Keep all parts clean from
contaminants. Contaminants may cause rapid wear
and shortened component life.

1. Use Tool (A) to release the tension on the belt
   tensioner.
2. Remove the drive belt from the alternator drive
   pulley.

22

• Illustration 1 g00728265
• Place an index mark on all electrical wires that
  are connected to alternator (1). Disconnect all
  electrical wires from the alternator.
• Remove two bolts (2).
• Remove alternator (1) from the mounting bracket.
• Installation Procedure
• Table 2

Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 1U-7117 Breaker Bar 1
NOTICE Keep all parts clean from
contaminants. Contaminants may cause rapid wear
and shortened component life.
23

• Illustration 2 g00728265
• Position alternator (1) on the mounting bracket.
  Install two bolts (2).
• Install the drive belt on the alternator drive
  pulley.
• Use Tool (A) on the belt tensioner in order to
  tighten the drive belt.
• Connect all electrical wires to the alternator.
  Use the index marks to correctly connect the
  wires.

Copyright 1993 - 2020 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Thu Jul 9 234832 UTC0800 2020
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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
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.
Illustration 1
g06119357
26

• Disconnect cable strap (1).
• Place an index mark on all of the harness
  assemblies. Disconnect the harness assemblies
  from electric starting motor (2).
• Fasten a suitable lifting device to electric
  starting motor (4). The weight of electric
  starting motor (4) is approximately 35 kg (77
  lb).
• Remove bolts (3).
• Remove electric starting motor (4) and the gasket
  from the flywheel housing.
• Installation Procedure
• Install electric starting motor (4) in reverse
  order of removal.

Copyright 1993 - 2020 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Thu Jul 9 234928 UTC0800 2020
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friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.ebo
oklibonline.com