Caterpillar Cat 325D L Excavator (Prefix ERK) Service Repair Manual (ERK00001 and up).pdf

Service Repair Manual
Models
325D L Excavator

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Product: EXCAVATOR
Model: 325D L EXCAVATOR ERK
Configuration: 325D L Excavator ERK00001-UP (MACHINE) POWERED BY C7 Engine
Disassembly and Assembly
C7
Engines for Caterpillar Built Machines
Media Number -RENR9218-13 Publication Date -01/06/2014 Date Updated -04/06/2014
i06555904
Unit Injector Sleeve - Remove
SMCS - 1713-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 372-7975 Injector Sleeve Tool 1
B 454-6623 Tap (6 inch) 2
C 8S-4716 Bolts (1/4 - 28) 2
D 6V-2166 Slide Hammer Puller Gp 1
Start By:
a. Remove the unit injectors.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the
correct draining procedures.
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325D L Excavator ERK00001-UP (MACHINE) POWERED BY C7 Engine(SEBP536...
2020/5/24
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Illustration 1 g03500197
2. Position Tooling (A) at the bottom of the unit injector sleeve.
3. Install Tooling (B). Use Tooling (B) to cut threads into the side of the unit injector sleeve.
Repeat for opposite side.
4. Install Tooling (C).
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5. Thread Tooling (D) into the top of Tooling (A). Use Tooling (D) to remove the unit injector
sleeve.
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All Rights Reserved.
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Sun May 24 09:10:24 UTC+0800 2020
3/3
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Product: EXCAVATOR
C7
i05528089
Unit Injector Sleeve - Install
SMCS - 1713-012
Installation Procedure
Table 1
Required Tools
A 372-7975 Injector Sleeve Tool 1
E - Loctite 620 -
F 4C-5552 Large Bore Brush 1
NOTICE
1. Thoroughly clean the unit injector sleeves and the bores for the unit injectors. Tooling (F)
may be used on the bores.
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2. Apply clean engine oil to O-ring seals (1) .
3. Apply a thin coating of Tooling (E) around the outer circumference of unit injector sleeve
(2) at Surface (Z) .
4. Use Tooling (A) and a hammer to position unit injector sleeve (2) in the cylinder head.
Note: Allow Tooling (E) to cure for two hours at 21 °C (70 °F) before filling the engine
with fuel or coolant. Longer curing time is required for lower temperatures.
5. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the
correct filling procedures.
End By: Install the unit injectors.
Sun May 24 09:11:19 UTC+0800 2020
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Product: EXCAVATOR
C7
i05683072
Unit Injector Hydraulic Pump - Remove
SMCS - 1714-011
Removal Procedure for Non-Dual Tapered Roller Bearing
HEUI Pump
Table 1
Required Tools
A 192-5092 Removal Tool 1
NOTICE
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
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Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
Non-Dual Taper Roller Bearing HEUI pump
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Dual Taper Roller Bearing HEUI pump
Note: Refer to Illustrations 1 and 2 in order to identify each unit injection hydraulic pump.
1. Disconnect hose assembly (5) and tube assembly (4) .
2. Use Tooling (A) in order to disconnect hose assembly (6) .
3. Disconnect harness assembly (3) from unit injector hydraulic pump (2) .
4. Remove bolts (1) . Remove unit injector hydraulic pump (2) .
Removal Procedure for Dual Tapered Roller Bearing HEUI
Pump
Table 2
Required Tools
A 192-5092 Removal Tool 1
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NOTICE
NOTICE
performance of inspection, maintenance, testing, adjusting, and repair
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
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1. Disconnect harness assembly (1) . Use Tooling (A) in order to disconnect hose assembly
(4) . Disconnect hose assemblies (3) and (5) and position aside. Remove tube assembly (2) .
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2. Remove adapters (6) and (7) .
3. Support unit injector hydraulic pump (8) and remove bolts (9) .
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4. Rotate unit injector hydraulic pump (9) counterclockwise as shown, then remove unit
injector hydraulic pump (9) .
5. Remove O-ring seal (10) .
Sun May 24 09:12:15 UTC+0800 2020
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Product: EXCAVATOR
C7
i05683413
Unit Injector Hydraulic Pump - Install
SMCS - 1714-012
Installation Procedure for Non-Dual Tapered Roller Bearing
HEUI Pump
NOTICE
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1. Position unit injector hydraulic pump (2) in the front housing.
2. Install bolts (1) .
3. Connect harness assembly (3) to unit injector hydraulic pump (2) .
4. Connect hose assembly (6) .
5. Connect tube assembly (4) and hose assembly (5) .
Installation Procedure for Dual Tapered Roller Bearing
HEUI Pump
Table 1
Required Tools
A 129-1967 Multipurpose Grease -
Note: If replacing a non-dual tapered roller bearing HEUI pump with a dual tapered roller bearing
HEUI pump, refer to Special Instruction, REHS8178 for rework and installation procedures.
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Note: If a dowel pin is installed in the mounting flange of the unit injector hydraulic pump
or in the front housing at the unit injector hydraulic pump mounting location, remove the
dowel pin before installing the unit injector hydraulic pump.
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1. Install O-ring seal (10) . Apply Tooling (A) to O-ring seal (10) , the mounting flange of the
unit injector hydraulic pump, and the back of the front housing at the mounting location of
the unit injector hydraulic pump.
2. Position unit injector hydraulic pump (9) as shown, then rotate clockwise to final
installation orientation.
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3. Install bolts (8) hand-tight.
Note: Do not fully tighten bolts (8) until all of the hoses and the tubes are connected to unit
injection hydraulic pump (9) .
4. Install adapters (6) and (7) .
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5. Install tube assembly (2) hand-tight.
6. Connect hose assembly (4) . Install hose assemblies (3) and (5) hand-tight.
7. Tighten bolts (8) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
8. Tighten tube assembly (2) , hose assemblies (5) , and hose assembly (3) .
9. Install harness assembly (1) .
Sun May 24 09:13:11 UTC+0800 2020
6/6
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Product: EXCAVATOR
C7
i02300949
Turbocharger - Remove
SMCS - 1052-011
Removal Procedure
NOTICE
NOTICE
performance of inspection, maintenance, testing, adjusting and repair
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
1/2
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1. Disconnect tube assembly (3) and tube assembly (4) .
2. Remove nuts (1), turbocharger (2), and the gasket from the exhaust manifold.
Sun May 24 09:14:07 UTC+0800 2020
2/2
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Product: EXCAVATOR
C7
i04000959
Turbocharger - Install
SMCS - 1052-012
Table 1
Required Tools
A 5P-3931 Anti-Seize Compound -
NOTICE
1. Apply Tooling (A) to the threads of the mounting studs for the turbocharger.
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Note: Discard the nuts after use. Use new nuts for installation.
2. Position the gasket and turbocharger (2) on the exhaust manifold. Install nuts (1) .
3. Tighten nuts (1) to a torque of 54 ± 5 N·m (40 ± 4 lb ft).
4. Connect tube assembly (4) and tube assembly (3) .
Sun May 24 09:15:02 UTC+0800 2020
2/2
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Product: EXCAVATOR
C7
i02301075
Exhaust Manifold - Remove and Install
SMCS - 1059-010
Removal Procedure
1/4
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1. Disconnect tube assembly (3) and tube assembly (5) .
2. Attach a suitable lifting device to exhaust manifold (2) and the turbocharger. The weight of
exhaust manifold (2) and the turbocharger is approximately 40 kg (88 lb).
3. Remove bolts (1) and locks (4) .
4. Remove exhaust manifold (2), the turbocharger, and the gaskets from the cylinder head
assembly.
Table 1
Required Tools
A 2P-2333 High Temperature Sealer 1
B 5P-3931 Anti-Seize Compound 1
NOTICE
Excessive use of sealant can cause damage to components.
To avoid component damage use only the amount of sealant necessary
for the application.
2/4
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1. Apply Tooling (A) to the outside diameter of the male ends of exhaust manifold (2).
Assemble exhaust manifold (2) and remove the excess sealer from the joints.
2. Apply Tooling (B) to the threads of bolts (1). Attach a suitable lifting device to exhaust
manifold (2) and the turbocharger. The weight of exhaust manifold (2) and the turbocharger
is approximately 40 kg (88 lb). Position the gaskets, exhaust manifold (2), and the
turbocharger on the cylinder head assembly. Install locks (4) and bolts (1) .
3. Connect tube assembly (3) and tube assembly (5) .
4. Tighten Bolt (1) through Bolt (12) in a numerical sequence.
Tighten bolts to the following torque. ... 4 ± 1 N·m (35 ± 9 lb in)
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5. Tighten Bolt (1) through Bolt (12) again in a numerical sequence.
Tighten bolts to the following torque. ... 45 ± 5 N·m (33 ± 4 lb ft)
6. Bend the locking tab over the flat of each bolt head.
Note: Prior to starting or running the engine, allow the sealant in the exhaust manifold joints
to air dry for 24 hours.
Sun May 24 09:15:58 UTC+0800 2020
4/4
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Product: EXCAVATOR
C7
i02307246
Air Inlet Heater Solenoid - Remove and Install
SMCS - 1090-010-OD
Removal Procedure
Accidental engine starting can cause injury or death to personnel
working on the equipment.
To avoid accidental engine starting, disconnect the battery cable from
the negative (-) battery terminal. Completely tape all metal surfaces of
the disconnected battery cable end in order to prevent contact with
other metal surfaces which could activate the engine electrical system.
Place a Do Not Operate tag at the Start/Stop switch location to inform
personnel that the equipment is being worked on.
1. Disconnect the battery.
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2. Disconnect harness assemblies (2) and harness assemblies (3) .
3. Remove air inlet heater solenoid (1) .
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Caterpillar Cat 325D L Excavator (Prefix ERK) Service Repair Manual (ERK00001 and up).pdf

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