Caterpillar cat 325 c excavator (prefix bkh) service repair manual (bkh00001 and up)

Service Repair Manual
Models
325C EXCAVATOR

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Product: EXCAVATOR
Model: 325C EXCAVATOR BKH
Configuration: ISJ HEX COMMONALITY CHART BKH00001-UP (MACHINE)
Disassembly and Assembly
3126B Engines for Caterpillar Built Machines
Media Number -SENR9581-06 Publication Date -01/08/2018 Date Updated -17/08/2018
i02372770
Pistons and Connecting Rods - Install
SMCS - 1225-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 173-5529 Piston Ring Compressor 1
B 4C-5593 Anti-Seize Compound 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
The joint between the connecting rod and the connecting rod cap is
produced by fracturing. The connecting rod assembly must be handled
with care in order to avoid damage to the mating surfaces. The
connecting rod assembly must be replaced if any damage occurs to the
mating surfaces. New connecting rod assemblies come with the
connecting rod caps bolted on the connecting rod.
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Use only a soft jawed vise to hold the connecting rod assembly when
removing the connecting rod cap bolts. Use only a soft faced hammer
to tap the connecting rod cap when separating the connecting rod cap
from the connecting rod.
Failure to use a soft jawed vise and a soft faced hammer may result in
damage to the connecting rod assembly.
NOTICE
Always use new connecting rod bolts during the installation of
connecting rod assemblies that have fractured joints. Never reuse
connecting rod bolts during the reassembly of fractured joint
connecting rods.
Reusing connecting rods bolts during reassembly of fractured joint
connecting rods may result in engine damage.
1. Ensure that the fractured joints of the connecting rod are clean prior to installation. Use
compressed air or a wire brush to clean the joints.
2. Apply clean engine oil to the pistons, the piston rings, and the cylinder bore.
Illustration 1 g00634923
3. Position the piston rings so that the end gaps are located 120 degrees from each other.
Install Tooling (A) in order to compress the piston rings.
4. With the number one crankshaft throw at the bottom center, install the piston and
connecting rod in the engine. Ensure that the proper piston and connecting rod are in the
corresponding cylinder with the bearing retainer notch toward the right side of the engine.
The etched number on the connecting rod must be positioned on the right side of the engine.
5. Line up the piston and the connecting rod with the crankshaft. Use a soft faced hammer and
tap the piston into the cylinder bore until Tooling (A) comes off of the piston.

6. Before connecting rod (1) comes in contact with the crankshaft, install the upper half of
connecting rod bearing (4). Ensure that the bearing tab engages with the slot in connecting
rod (1).
7. Apply clean engine oil to the surface of the upper half of connecting rod bearing (4). Use a
soft faced hammer in order to tap the piston into the cylinder bore while you guide
connecting rod (1) onto the crankshaft.
8. Place the lower half of connecting rod bearing (5) in corresponding connecting rod cap (3).
Ensure that the bearing tab engages with the groove in connecting rod cap (3).
9. Apply clean engine oil to the surface of the lower half of connecting rod bearing (5). Install
connecting rod cap (3) on connecting rod (1). Ensure that the number on connecting rod cap
(3) matches the number on connecting rod (1). Ensure that the numbers are on the same
side.
10. Apply Tooling (B) to the new connecting rod bolts.
11. Install new connecting rod bolts (2). Tighten connecting rod bolts (2) to a torque of
70 ± 5 N·m (52 ± 4 lb ft).
12. Place an index mark on each connecting rod bolt. Tighten each connecting rod bolt (2) for
an additional 120 ± 5 degrees (1/3 turn).
End By:
a. Install the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets -
Remove and Install".
b. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Install".
c. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".

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Product: EXCAVATOR
i01983695
Crankshaft Main Bearings - Remove
SMCS - 1203-011
Removal Procedure
Table 1
Required Tools
A 2P-5518 Main Bearing Tool 1
Start By:
a. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Remove".
NOTICE

1. Remove bolts (1). Remove crankshaft main bearing cap (2).
2. Remove the lower half of the crankshaft main bearing from crankshaft main bearing cap (2).

NOTICE
If the crankshaft is turned in the wrong direction, the tab of the
crankshaft main bearing will be pushed between the crankshaft and
the cylinder block. this can cause damage to either or both the
crankshaft and the cylinder block.
3. Install Tooling (A).
4. Turn the crankshaft in order to remove the upper half of the crankshaft main bearing.
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All Rights Reserved.
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Sat May 16 00:32:07 UTC+0800 2020

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Product: EXCAVATOR
i01518323
Crankshaft Main Bearings - Install
SMCS - 1203-012
Table 1
Required Tools
A 2P-5518 Main Bearing Tool 1
B 8T-5096 Dial Indicator Group 1
NOTICE
Note: Place clean engine oil on the crankshaft main bearings prior to assembly. Ensure that the
tabs on the back side of the crankshaft main bearings fit in the grooves of the crankshaft main
bearing caps and the cylinder block.

1. Use Tool (A) and install the upper halves of the crankshaft main bearings in the cylinder
block. Do not put oil on the back of the crankshaft main bearing.
2. Install the lower halves of the crankshaft main bearings in crankshaft main bearing caps (2).
Do not put oil on the back of the crankshaft main bearing.
NOTICE
Crankshaft main bearing caps should be installed with the part
number toward the right side of the engine. Crankshaft main bearing
caps are to be identified by stamped numbers 1 through 7 located on
the bottom surface. The thrust plate is used on the number 6
crankshaft main bearing only.
3. Place crankshaft main bearing caps (2) in position on the cylinder block. Place clean engine
oil or Molylube on the bolt threads and on the washer face. Install bolts (1).
4. Tighten bolts (1) to a torque of 54 ± 7 N·m (40 ± 5 lb ft). Tighten each bolt (1) for an
additional 90 ± 5 degrees (1/4 turn).

5. Check the end play of the crankshaft with Tool (B). The end play must be 0.07 mm
(0.003 inch) to 0.32 mm (0.013 inch).
End By:
a. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Install".
Sat May 16 00:33:03 UTC+0800 2020

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Product: EXCAVATOR
i02374826
Crankshaft - Remove
SMCS - 1202-011
Removal Procedure
Start By:
a. Remove the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing -
b. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Remove".
c. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) -
Remove".
NOTICE

1. Remove main bearing caps (2).
2. Remove connecting rod caps (3).

3. Put identification marks on the gear train for installation purposes. Attach a suitable lifting
device to each end of crankshaft (1). Carefully remove crankshaft (1) from the cylinder
block. The weight of crankshaft (1) is approximately 60 kg (132 lb).
Sat May 16 00:33:59 UTC+0800 2020

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Product: EXCAVATOR
i01931442
Crankshaft Wear Sleeve (Rear) - Remove - If Equipped
SMCS - 1161-011-ZV
Removal Procedure
Table 1
Required Tools
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

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.
Sat May 16 00:34:55 UTC+0800 2020

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Product: EXCAVATOR
i01929732
Crankshaft Wear Sleeve (Rear) - Install
SMCS - 1161-012-ZV
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.

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

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.

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 -
Sat May 16 00:36:46 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

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

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".
Sat May 16 00:37:42 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.

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.
Sat May 16 00:38:38 UTC+0800 2020

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Product: EXCAVATOR
i01984226
Idler Pulley - Remove and Install
SMCS - 1358-010
Sat May 16 00:39:34 UTC+0800 2020

Caterpillar cat 325 c excavator (prefix bkh) service repair manual (bkh00001 and up)

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