Caterpillar Cat M325D L MH EXCAVATOR (Prefix KAY) Service Repair Manual (KAY02000 and up).pdf

Service Repair Manual
Models
M325D L MH EXCAVATOR

Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: M325D L MH EXCAVATOR KAY
Configuration: M325D L Material Handler KAY02000-UP (MACHINE) POWERED BY C7 Engine
Disassembly and Assembly
M325D Material Handler Machine Systems
Media Number -RENR9719-02 Publication Date -01/03/2011 Date Updated -16/03/2011
i02233131
Swing Drive - Assemble
SMCS - 5459-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 2
B 5P-5197 Pliers 1
E 138-7574 Link Bracket 2
F 138-7575 Link Bracket 3
G 5P-3931 Anti-Seize Compound 1
H 1U-8846 Gasket Sealant 1
J 9S-3263 Thread Lock Compound 1
K 1P-0520 Driver Gp 1
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are
worn or damaged, use new parts for replacement.
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https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Illustration 1 g01126093
1. Use Tooling (K) to install lip seals (28) and O-ring seal (29) in bearing cage (27) .
Note: Lubricate the seals and the seal surface of the shaft with the lubricant that is being
sealed prior to installation of bearing cage (27) .
2. Install bearing cage (27) on pinion shaft (24) .
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3. Raise the temperature of bearing (30). Install bearing (30) on pinion shaft (24) .
4. Install spacer (31) .
5. Raise the temperature of bearing (32). Install bearing (32) on pinion shaft (24) .
6. Use Tooling (B ) to install retaining ring (23) on pinion shaft (24) and against bearing (32) .
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Note: Ensure that bearings (30) and (32) are aligned while pinion shaft (24) is positioned.
7. Apply Tooling (G) to the inside diameter of swing drive housing (25) .
8. Attach Tooling (F) and a suitable lifting device to pinion shaft (24) .
9. Lower the temperature of pinion shaft (24) .
10. Install pinion shaft (24) in swing drive housing (25). The weight of pinion shaft (24) is
approximately 50 kg (110 lb).
11. Remove Tooling (F) and the lifting device from pinion shaft (24). Attach Tooling (E) and a
suitable lifting device to swing drive housing (25). The combined weight of swing drive
housing (25), pinion shaft (24), and bearing cage (27) is approximately 151 kg (333 lb).
12. Lift the swing drive vertically. Use a hammer and a drift to align bearing (30) in the lower
bore of swing drive housing (25). When the bearing is properly aligned in the bore, pinion
shaft (24) will drop into the proper position within swing drive housing (25) .
13. ApplyTooling (H) on the threads of bolts (26) .
14. Install bolts (26) .
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15. Use two people or a suitable lifting device to install ring gear (22). The weight of ring gear
(22) is approximately 46 kg (102 lb).
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16. Install bearings (20) in gear (19) .
17. Position thrust washers (21) on each side of gear (19). Install gear (19) in carrier assembly
(14). Install shaft (18) in carrier assembly (14) and through gear (19). Make sure that the pin
hole in shaft (18) is aligned with the pin hole in the carrier.
18. Install pin (17) in carrier assembly (14) and into shaft (18). Install pin (17) until pin (17) is
even with the outside surface of carrier assembly (14). Orient the split in the pin
horizontally to the carrier assembly. Align the split in the pin to the left or to the right.
19. Make a stake mark on each side of the hole for pin (17). This will prevent pin (17) from
falling out of the pin hole. Each stake mark should be approximately 1.5 mm (0.06 inch)
from the outside diameter of the pin hole.
20. Repeat Steps 16 through 19 in order to install the remaining three gears (19) .
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21. Use a suitable lifting device to install carrier assembly (14) in ring gear (22). The weight of
carrier assembly (14) is approximately 39 kg (86 lb).
22. Install retaining ring (16) in carrier assembly (14) .
23. Install spacer (15) .
24. Install retaining ring (13) in gear (12) .
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25. Install gear (12). Install retaining ring (11) .
26. Install bearing (9) in gear (8) .
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27. Position thrust washers (10) on each side of gear (8). Install gear (8) and thrust washers (10)
in carrier assembly (4). Install shaft (6) in carrier assembly (4) and through gear (8). Make
sure that the pin hole in shaft (6) is aligned with the pin hole in carrier assembly (4) .
28. Install pin (7) in carrier assembly (4) and into shaft (6). Install pin (7) until pin (7) is even
with the outside surface of carrier assembly (4). Orient the split in pin (7) horizontally to
carrier assembly (4). Align the split in pin (7) to the left or to the right.
29. Make a stake mark on each side of the pin hole in carrier assembly (4). This will prevent
spring (7) from falling out of the pin hole. Each stake mark should be approximately 1.5
mm (0.06 inch) from the outside diameter of the pin hole.
30. Repeat Steps 24 through 29 in order to install the remaining three planetary gears in the
carrier assembly.
31. Install sun gear (5) in carrier assembly (4) .
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32. Use a suitable lifting device or two people to install carrier assembly (4). The weight of
carrier assembly (4) is approximately 23 kg (50 lb).
33. Apply Tooling (H) on the flange surfaces of the ring gear and cover (2) .
34. Use Tooling (A) and a suitable lifting device to position cover (2) on the swing drive.
35. Apply Tooling (J) on the thread of bolts (1). Install bolts (1). Tighten bolts (1) to a torque of
270 ± 40 N·m (200 ± 30 lb ft).
End By: Install the swing drive. Refer to Disassembly and Assembly, "Swing Drive - Install".
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Tue Nov 17 10:13:05 UTC+0800 2020
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M325D L Material Handler KAY02000-UP (MACHINE) POWERED BY C7 Engi...
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Shutdown SIS
Previous Screen
Product: EXCAVATOR
i02229749
Swing Drive - Install
SMCS - 5459-012
Installation Procedure
Table 1
Required Tools
A
132-8223 Hydraulic Pump and Motor Gp 1
1U-6221 Hydraulic Torque Wrench Gp 1
132-8143 Wrench Link 1
B 138-7573 Link Bracket 2
D 5P-3931 Anti-Seize Compound 1
E 1U-8846 Gasket Sealant 1
F 9S-3263 Thread Lock Compound 1
1. Apply Tooling (D) on the locating pin in the main frame. Also, apply Tooling (D) in the pin
bore in the main frame.
2. Apply Tooling (E) on the mating surface of the main frame and the swing drive housing.
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3. Attach Tooling (B) and a suitable lifting device to swing drive (2). The weight of swing
drive (2) is approximately 310 kg (683 lb). Use Tooling (B) and the suitable lifting device to
position swing drive (2) on the machine.
4. Apply Tooling (F) on the threads of bolts (1). Install bolts (1). Tighten bolts (1) with
Tooling (A) .
5. Fill swing drive (2) with oil. Refer to Operation and Maintenance Manual, "Swing Drive Oil
- Check".
End By: Install the swing motor. Refer to Disassembly and Assembly, "Swing Motor - Install".
Tue Nov 17 10:14:01 UTC+0800 2020
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Shutdown SIS
Previous Screen
Product: EXCAVATOR
i02291905
Upper Frame and Undercarriage Frame - Separate
SMCS - 4150-076; 7051-076
Separation Procedure
Table 1
Required Tools
A
8S-7641 Tube 2
8S-8048 Saddle 2
8S-7615 Pin 4
8S-7625 Collar 2
4C-6486 Stand 2
8S-7650 Cylinder As 2
4C-5809 Electric Hydraulic Pump Gp 1
B FT-3013 Link Assembly 1
C FT-2765 Support Beam As 1
D 8S-7641 Tube 2
8S-8048 Saddle 2
8S-7615 Pin 4
8S-7625 Collar 2
4C-6486 Stand 2
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E
132-8112 Torque Wrench Gp 1
Start By:
A. Remove the stick. Refer to Disassembly and Assembly, "Stick - Remove".
Note: Put identification marks on all hose assemblies and on all tube assemblies for installation
purposes.
1. Park the machine on level ground. Turn the upper frame to a 90 degree angle from the
undercarriage.
2. Remove the front drive shaft and the rear drive shaft. Refer to Disassembly and Assembly,
"Drive Shaft - Remove and Install".
3. Use the hydraulics of the machine to retract cylinders (1). Use a suitable lifting device to
reposition stick cylinder pin (4) in boom (2). The weight of stick cylinder pin (4) is
approximately 54 kg (120 lb). Install plates (3) .
4. Remove the swivel. Refer to Disassembly and Assembly, "Swivel - Remove".
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5. Position Tooling (A) below stick cylinder pin (4) .
6. Remove the left side boom cylinder. Refer to Disassembly and Assembly, "Boom Cylinder -
Remove and Install".
7. Use a suitable lifting device to position Tooling (B). The weight of Tooling (B) is
approximately 227 kg (500 lb). Install pin (5). Reposition pin (7) and install plate (6) .
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8. Use a suitable lifting device to position Tooling (C) onto Tooling (D). The weight of
Tooling (C) is approximately 227 kg (500 lb).
9. Position Tooling (C) and Tooling (D) beneath counterweight (8) in order to support
counterweight (8) during the separation procedure.
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10. Disconnect tube assembly (9) .
Note: Note the orientation of bolts (10) for installation purposes.
11. Use Tooling (E) to remove bolts (10) .
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12. Use Tooling (C) and Tooling (D) to raise upper frame (11) in 6.4 mm (0.25 inch)
increments. Raise upper frame (11) enough for pinion gear (12) to clear swing bearing (13) .
13. Use a properly rated machine to pull undercarriage frame (14) from underneath upper frame
(11) .
Tue Nov 17 10:14:56 UTC+0800 2020
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Shutdown SIS
Previous Screen
Product: EXCAVATOR
i02292929
Upper Frame and Undercarriage Frame - Connect
SMCS - 4150-077; 7051-077
Connection Procedure
Table 1
Required Tools
A
8S-7641 Tube 2
8S-8048 Saddle 2
8S-7615 Pin 4
8S-7625 Collar 2
4C-6486 Stand 2
B FT-3013 Link Assembly 1
C FT-2765 Support Beam As 1
D 8S-7641 Tube 2
8S-8048 Saddle 2
8S-7615 Pin 4
8S-7625 Collar 2
4C-6486 Stand 2
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E
132-8112 Torque Wrench Gp 1
F 1U-8846 Gasket Sealant 3
G 5P-3931 Anti-Seize Compound 1
1. Apply Tooling (F) to gear and bearing (16). Apply Tooling (G) to dowel hole (15) .
Note: A locating dowel is used to align the upper frame with the undercarriage frame. Make
sure that the dowel is in position in the undercarriage frame prior to installation. Make sure
that pinion gear (12) is properly aligned with swing bearing (13) prior to installation.
2. Use a properly rated machine to pull undercarriage frame (14) under upper frame (11).
3. Use Tooling (C) and Tooling (D) to lower upper frame (11) onto undercarriage frame (14).
Lower upper frame (11) in 6.4 mm (0.25 inch) increments.
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4. Use Tooling (E) to install bolts (10). Tighten bolts (10) to a torque of 900 ± 100 N·m (664 ±
74 lb ft).
5. Connect tube assembly (9) .
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6. Attach a suitable lifting device to Tooling (C). The weight of Tooling (C) is approximately
227 kg (500 lb).
7. Remove pin (5). Remove plate (6). Reposition pin (7). Remove Tooling (B) .
8. Install the right side boom cylinder. Refer to Disassembly and Assembly, "Boom Cylinder -
Remove and Install".
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9. Remove Tooling (A) from stick cylinder pin (4) .
Note: Cylinders (1) were retracted during the separation procedure.
10. Attach a suitable lifting device to stick cylinder pin (4). The weight of stick cylinder pin (4)
is approximately 54 kg (120 lb). Remove stick cylinder pin (4) from boom (2) .
11. Install the swivel. Refer to Disassembly and Assembly, "Swivel - Install".
End By:
a. Install the front drive shaft and the rear drive shaft. Refer to Disassembly and Assembly,
"Drive Shaft - Remove and Install".
b. Install the stick. Refer to Disassembly and Assembly, "Stick - Install".
Tue Nov 17 10:15:52 UTC+0800 2020
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