manual-systems-hydraulic-excavator-325d-caterpillar-components-operation.pdf. manual-systems-hydraulic-excavator-325d-ca
SERV7105-12 Vol. 12, No. 1 December 2005
GLOBAL SERVICE LEARNING TECHNICAL PRESENTATION
325D HYDRAULIC EXCAVATOR INTRODUCTION
New Product Introduction (NPI)
325D HYDRAULIC EXCAVATOR INTRODUCTION AUDIENCE Service personnel who understand the principles of machine systems operation, diagnostic equipment, and testing and adjusting procedures.
CONTENT This presentation provides new and different New Product Introduction (NPI) information on the 325D Hydraulic Excavator. This presentation may be used for self-paced and self-directed training. This first printing contains information on the EAME Market Gosselies produced 325D only. The 325D will be available in the NACD and APD markets early in 2006.
OBJECTIVES After learning the information in this presentation, the technician will be able to: 1. locate and identify the new major components on the 325D Hydraulic Excavator, and 2. explain the operation of the new components in the system.
REFERENCES NOTE: The references listed below are only for the EAME Market Gosselies produced 325D. Reference materials for Aurora and Akashi produced 325D machines will be released at a later date. 325D Hydraulic Excavator Specalog
HEHH3290
325D Hydraulic Excavator Specifications Manual
RENR7233
325D Hydraulic Excavator Systems Operations Manual
RENR7234
325D Hydraulic Excavator Test and Adjust Manual
RENR7235
325D Hydraulic Excavator Parts Book
SEBP4442
325D Hydraulic Excavator Tool Control Systems Operation
RENR7389
Estimated Time: 1 Hour Visuals: 37 Handouts: 4 Form: SERV7105-12 Date: Vol. 12, No. 1, 2005 © 2005 Caterpillar Inc.
SERV7105-12 Vol. 12, No. 1, 2005
-3-
NPI
TABLE OF CONTENTS INTRODUCTION ..................................................................................................................5 Similarities and Differences .............................................................................................6 MACHINE WALK-AROUND...............................................................................................7 OPERATOR'S STATION......................................................................................................13 ENGINE................................................................................................................................24 HYDRAULIC SYSTEM ......................................................................................................26 MAINTENANCE ITEMS ....................................................................................................40 TOOL CONTROL SYSTEM ...............................................................................................41 CONCLUSION.....................................................................................................................43 HYDRAULIC SCHEMATIC COLOR CODE.....................................................................44 HANDOUTS.........................................................................................................................45 POSTTEST ...........................................................................................................................46 POSTTEST ANSWER KEY ................................................................................................48
SERV7105-12 Vol. 12, No. 1, 2005
-4-
NOTES
NPI
SERV7105-12 Vol. 12, No. 1, 2005
-5-
NPI
325D HYDRAULIC EXCAVATORS INTRODUCTION
© 2005 Caterpillar Inc.
1
INTRODUCTION The 325D is a new model from Caterpillar and is a direct replacement for the 325C Hydraulic Excavator. The 325D was first introduced in December 2005 to the EAME market. The 325D operating weight is approximately 29,240 Kg (64,500 lbs) for a long undercarriage machine. The 325D fits in the 25 metric ton class of excavators. The 325D is a versatile machine capable of performing a wide range of tasks by using various work tools available. The presentation discusses the component locations and systems operation of the Gosselies produced 325D Hydraulic Excavator. Basic engine and machine component locations will be discussed. The travel system and implement hydraulics will also be covered. There will be different machine arrangements available in the EAME market, including: - 325D L (325D excavator with a long, fixed standard width undercarriage) - 325D LN (325D excavator with a long, fixed narrow width undercarriage)
SERV7105-12 Vol. 12, No. 1, 2005
-6-
NPI
SIMILARITIES AND DIFFERENCES FEATURES
DIFFERENT
SIMILAR
SAME
X
Machine Appearance OperatorÕ s Station
X
Engine
X X
Implement Hydraulic System X
Monitoring System
X
Maintenance Items Tool Control Systems
X
Machine ECM
X
Travel System
X
Undercarriage
X
2
Similarities and Differences The above chart displays the similarities and differences between the 325D and the 325C. This illustration compares the basic features of the 325D to the previous 325C. The chart illustrates if the features are different, similar, or the same. New and improved features include: - Tier III ACERT engine - Cab and styling - Monitoring system
SERV7105-12 Vol. 12, No. 1, 2005
-7-
1
2
3
4
3
MACHINE WALKAROUND - Stick (1) - Boom (2) - Operator station (3) - Access door behind cab (4) - Engine access cover (5) - Access door to radiator compartment (6) - Counterweight (7)
NPI
5
6
7
SERV7105-12 Vol. 12, No. 1, 2005
-8-
NPI
5
1
2
3 6 4
4
The compartment behind the operator station includes the following components: - Machine and Tool Control ECM (1) - Air conditioning condenser and receiver (2) - Window washer reservoir (3) - Master disconnect switch and circuit breakers (4) - Dual element, radial seal air filter (5) - Batteries (6)
SERV7105-12 Vol. 12, No. 1, 2005
-9-
NPI
6
1
2 7 3 8 4 9 5
5
The radiator access compartment is located in front of the counter weight. The door is hinged on the right and has a locking latch on the left side to keep it closed. This door provides access to assist in cleaning some of the cooling system components. - Air to Air After Cooler (ATAAC) (1) - Fuel pressure sensors (2) - Hydraulic oil cooler (3) - Fuel priming pump (4) (will be changed to electric) - Fuel filter (5) - Ether start aid solenoid (6) - Engine coolant overflow bottle (7) - Fuel water separator (8) - Radiator (located behind the water separator and coolant overflow bottle) (9) - Pattern change valve (not shown) located on compartment floor.
SERV7105-12 Vol. 12, No. 1, 2005
- 10 -
1
2
NPI
3
4
5
6
This illustration shows access to the top of the machine from the right side. The engine access cover (1) allows access to the engine from the top of the machine. The machine hydraulic oil reservoir (2) is located between the pump compartment and the diesel fuel tank on the right side of the machine and is accessed from the top of the machine. The diesel fuel filler cap (3) is accessed from the top of the machine. The storage compartment (4) is located in the front of the machine. The step and hand rail (5) at the right front of the machine can be used for access to the top of the machine.
SERV7105-12 Vol. 12, No. 1, 2005
- 11 -
NPI
1 11 2 10
3
9 8
4
7 5
6
7
The illustration shows the pump compartment on the right side of the machine. The compartment is accessed from the right side of the machine when the rear access door is open. Some of the visible components are: - Quick coupler solenoid valve (1) - Engine oil S•O•S port (2) - Engine oil filter (3) - Pilot pump (4) - Medium pressure solenoids (5) - Medium pressure circuit pump (6) - Pressure taps for auxiliary tool solenoids (7) - Pilot filter (8) - Pilot system S•O•S port (9) - Pilot system pressure port (10) - Pilot system relief valve (11)
SERV7105-12 Vol. 12, No. 1, 2005
- 12 -
NPI
12
20
13 19 14 18 15 17
16
8
Additional visible components are: - Power shift solenoid and proportional reducing valve (PSPRV) (12) - Right pump horsepower adjustment (13) - Right pump swashplate maximum angle adjustment (14) - Right pump (15) - Left pump (16) - Left pump horsepower adjustment (17) - Left pump swashplate maximum angle adjustment (18) - Hydraulic system return oil filter (19) - Case drain filter (20)
SERV7105-12 Vol. 12, No. 1, 2005
- 13 -
NPI
9
OPERATOR'S STATION The 325D contains a newly designed cab and introduces a new operator's station with improved visibility and operator comfort. For operator comfort the new cab offers a fully adjustable air suspended seat with side-to-side shock absorption, which provides maximum operator comfort. The new "D" series monitor provides increased functionality for the operator. Conveniently placed switches, gauges, information display, and controls improve operator comfort, awareness, and efficiency. The fuse panel is relocated to the left side of the lunch box compartment behind the operator’s seat. A 24 volt AM FM radio is standard in the right console.
SERV7105-12 Vol. 12, No. 1, 2005
- 14 -
NPI
1
2
10
The hydraulic activation lever (1) has been redesigned for the 325D, however, its purpose is still the same. With the lever in the DOWN position (shown), the hydraulic activation solenoid is in the de-activated position. The ground level emergency engine shutoff switch (2) is located on the bottom of the seat mount. The shutoff switch will shut off the engine without having to climb into the cab. Once the shutoff switch is turned ON and then OFF, the key start switch must be cycled for the machine to operate again.
SERV7105-12 Vol. 12, No. 1, 2005
- 15 -
3
4
NPI
5
6
2
7
1
11
All of the operator functions are incorporated into the right side of the operator's station. They are: - Engine speed dial switch (1) - Key start switch (2) - Cigar lighter (3) - Soft switch panel (4) - Rocker switches (5) - HVAC controls (6) - Radio (7)
SERV7105-12 Vol. 12, No. 1, 2005
- 16 -
1
5
2
NPI
4
3
6
7
8
12
The soft switch panel includes switches that either turn a function on/off or allow the operator to toggle through different modes of the selected function. The soft switches provide the operator with the following functions: Two-speed travel (1) When the button is pushed the travel speed is toggled between low and auto. - The rabbit indicator indicates auto speed. - The tortoise indicator indicates low speed. Automatic Engine Speed Control (AESC) Switch (2) The AESC function automatically reduces engine speed while there is no hydraulic demand, which reduces noise and fuel consumption. - The AESC switch disables and enables the AESC function. - The first stage AESC reduces the engine speed by 100 rpm after there has been no hydraulic demand for approximately three seconds. - The second stage AESC reduces the engine rpm to approximately 1300 rpm after there has been no hydraulic demand for an additional three seconds. - The second stage AESC delay times and rpm can be changed using the monitor or Caterpillar Electronic Technician (Cat ET).
SERV7105-12 Vol. 12, No. 1, 2005
- 17 -
NPI
Travel alarm cancel (3) The travel alarm cancel switch is a momentary two-position switch. - The travel alarm sounds when travel is detected. - The travel alarm stops immediately if the travel alarm cancel switch is depressed. - The travel alarm switch is reset every time the travel pressure switch opens. Work tool switch (4) The work tool switch will display the selected work tool on the monitor display. Press the switch repeatedly to change the selected work tool. When the desired work tool is highlighted in the monitor display press the "OK" button on the monitor to select the work tool shown. Work lights (5) The work lights switch toggles between the different work light combinations. - Pattern 1 - Chassis work lights and cab work lights. - Pattern 2 - Chassis work lights, cab work lights, and boom work lights. Upper window wipers (6) The wiper switch toggles between the different modes of the wipers. - Six second delay. - Three second delay. - Continuous operation. - Off. Upper window washer (7) The windshield washer fluid switch is an ON/OFF switch. Heavy lift (8) The heavy lift mode can be selected to boost lifting capability and provide improved controlability of heavy loads. - When heavy lift is turned on, the main relief valve maximum pressure increases from 35,000 MPa (5080 psi) to 36,000 MPa (5225 psi), making it possible to operate at the high pressure. - In heavy lift mode, the maximum engine speed is limited to engine speed dial 6 (1510 ± 90 rpm). - Hydraulic horsepower maximum output is reduced to 60%.
SERV7105-12 Vol. 12, No. 1, 2005
- 18 -
1
2
3
NPI
4
13
The toggle and rocker switch panel contains switches that control additional functions: Quick coupler lock control (1) The quick coupler lock control switch is a spring centered toggle switch. - The top position locks the quick coupler. - The bottom position unlocks the quick coupler. Fine swing control (2) The fine swing control switch is a two-position rocker switch. - The top position activates fine swing control. Fine swing control improves the swing control during swing deceleration. - The bottom position deactivates fine swing control. Rear window washer (3) The rear window washer fluid switch is a two-position rocker switch. - The top position activates the windshield washer fluid. - The bottom position deactivates the windshield washer fluid.
SERV7105-12 Vol. 12, No. 1, 2005
- 19 -
Rear window wiper (4) The rear window wiper switch is a two-position rocker switch. - The top position activates the wiper. - The bottom position deactivates the wiper.
NPI
SERV7105-12 Vol. 12, No. 1, 2005
- 20 -
NPI
1
3
4
2
14
The back-up switches are located behind the right armrest. The right switch (1) controls the engine rpm. The left switch (2) toggles between back-up and auto. The left switch activates/deactivates the Back-up Mode. When Back-up Mode is active, a fixed power shift pressure is provided to the pumps. The fixed power shift pressure limits maximum pump output and allows the machine to continue operating in a Derate Mode. Machine productivity will be limited while the machine is in Back-up Mode. The right switch is used to control the engine speed while Back-up Mode is active. Holding the right switch in the DOWN position decreases the engine rpm. Holding the right switch in the UP position increases the engine rpm. The diagnostic connector (3) is located inside of the operator's station behind the right armrest, beside the back-up switches. The HVAC control ECM (4) is also located below the right console.
SERV7105-12 Vol. 12, No. 1, 2005
- 21 -
NPI
1
5
2
6
3
7
4
8
15
The 325D monitor has been updated. The 325D shares this new monitor with the 320D, 323D, 324D, 330D, 345C, 365C, and the 385C machines. The monitor is a full color Liquid Crystal Display (LCD) that displays the various parameters of the machine. - Alert Indicator (1) - Clock (2) - Fuel Gauge (3) - Hydraulic Oil Temperature Gauge (4) - Engine Speed Dial Indicator (5) - Engine Coolant Temperature Gauge (6) - Operating Hours (7) - Work Tool Indicator (8)
SERV7105-12 Vol. 12, No. 1, 2005
- 22 -
1
3
NPI
2
5
4
7
6
8
16
The monitor contains eight buttons that control navigation on the monitor screen. The four directional button are left (1), up (2), down (3), and right (4). The directional buttons navigate the cursor through the various screens. The four navigational buttons are home (5), menu (6), back (7), and OK (8).
SERV7105-12 Vol. 12, No. 1, 2005
- 23 -
NPI
17
The fuse panel for the 325D has been relocated to the left side of the lunch box panel behind the operator's seat.
SERV7105-12 Vol. 12, No. 1, 2005
- 24 -
NPI
6
1
5 2
4
3
18
ENGINE The 325D is equipped with a C7 ACERT Engine (1). It is rated at 140 kW (188 hp) at 1800 rpm. Also visible is the engine crankcase breather (2), engine oil dipstick (3), S•O•S coolant sampling valve (4), engine oil fill (5), and the inlet air heater (6).
SERV7105-12 Vol. 12, No. 1, 2005
- 25 -
19
The engine cooling fan on the 325D is now mechanically driven off the front of the engine.
NPI
SERV7105-12 Vol. 12, No. 1, 2005
- 26 -
NPI
MAIN HYDRAULIC SYSTEM Stick Cylinder Bucket Cylinder Swing Motor
Boom Cylinders
Travel Motors
Main Control Valve Group
Pilot Control Valves
Priority Valves
Pilot Manifold
Pilot Pump
Main Hydraulic Pumps
M
Tank
20
HYDRAULIC SYSTEM The 325D uses a negative flow type hydraulic system. The main control valve and pumps are similar to the 325C. The engine cooling fan is now driven off of the engine. The 325D continues using many of the “C “excavator features, such as automatic priorities and tool control systems.
SERV7105-12 Vol. 12, No. 1, 2005
- 27 -
NPI
1 2
21
The pilot pump (1) is driven off the right hydraulic pump. The pilot pump draws oil from the main pump suction line. The oil is sent to the pilot filter and then to the pilot system. The medium pressure pump (2), when installed, is driven off the left hydraulic pump. The medium pressure pump also draws oil from the main pump suction line.
SERV7105-12 Vol. 12, No. 1, 2005
- 28 -
NPI
1
2
3
4
22
The 325D pilot manifold is the same as the "C" pilot manifold. The pilot manifold is accessible by removing the cover plate under the machine, behind the swing bearing. The manifold is located directly below the main control valve. Pilot manifold components visible are: - Two-speed travel solenoid (1) - Swing brake solenoid (2) - Hydraulic activation valve (3) - Hydraulic activation solenoid (4)
SERV7105-12 Vol. 12, No. 1, 2005
- 29 -
NPI
Travel Motor Left
High Pressure Line
Travel Motor Right
Swing Motor
Single
Single
Double
Double
325D HYDRAULIC SCHEMATIC NEUTRAL
P
aR2
BL2
BL1
Travel Right
BR1
AL1
aL2 BL3 bL1
aR1
Boom Cylinder
Bucket Cylinder
AR3
PU2
PL2
AL2
Travel Left
aL1
aR1
AR4
BR3
BL1
AL3
AL1
AL1
aL1
AR1
AR1
BR1
BR3
BL1 aR1
aR2
AR3
AR4
aR4
BR4
aR3
bR1
Boom Cylinder
BR4
PU2
Stick Cylinder AL3
BL3
Stick 1 OUT
Boom 2 PL2
bL4
bL3
Swing R bL2
bL1
Bucket OPEN
Travel R Atch FWD
Trv L FWD
bR1
bR2
bR3
Boom 1 UP
bR4
Stick 2 OUT
P
Swing
Stick
Boom
Bucket
No.1 Travel
No.2 Swing No.3 Lock
OUT
IN
RIGHT
LEFT
OPEN CLOSE
DOWN
UP
M
Out
bR4
aR3
aR4
bR3
bL3
bL2
bL4
In
aL2 P
23 The main hydraulic system is a negative flow controlled system. The main hydraulic system supplies hydraulic power at high pressures and high flow rates to perform work. Two main hydraulic pumps supply oil to the main control valve group. The individual hydraulic circuits are controlled by valves in the the main control valve group. The main hydraulic system supplies the following circuits: - Swing - Stick - Travel - Boom - Bucket - Tool control
SERV7105-12 Vol. 12, No. 1, 2005
- 30 -
3
2
1
NPI
8
7 4
5 9
6
24
The 325D uses a Caterpillar designed main hydraulic pump group (1) rated at 2 x 235 L/Min (2 x 65 gpm). The pump group is similar to the pump group used on the 325C. The right pump (6) is driven by the engine via a flexible coupling. The left pump (9) is driven directly off the right pump. Each pump rotating group has its own regulator. The regulators are used to adjust the output flow of the pumps. Each pump rotating group also has its own pressure tap and pressure sensor. A power shift PRV (2) is mounted on the top, rear of the right regulator case. The power shift PRV uses pilot system oil and sends it to the main hydraulic pumps as a control signal pressure. The power shift pressure is measured at pressure tap (3). Additional pump and components shown in this photo are: - Right pump regulator horsepower adjustment (4) - Right pump regulator swashplate maximum angle adjustment (5) - Left pump regulator horsepower adjustment (7) - Left pump regulator swashplate maximum angle adjustment (8)
SERV7105-12 Vol. 12, No. 1, 2005
- 31 -
NPI
7 1
6
2
3
4
5
25
The 325D contains one case drain filter (1) for the pump case drain and the swing and travel system case drains. The case drain filter is located in the main pump compartment. The pilot oil filter (4) is also located in the main pump compartment. The pilot oil filter base contains the pilot system relief valve (2), the hydraulic system S•O•S test port (3), and the pilot oil pressure test port (5). The hydraulic oil level sight gauge (6) is located on the rear of the hydraulic tank and is visible in the pump compartment. The return hydraulic system oil filter (7) is also located in the pump compartment.
SERV7105-12 Vol. 12, No. 1, 2005
- 32 -
NPI
2 1
26
The engine oil filter (1) is remotely mounted in the pump compartment for easy serviceability. The engine oil filter base contains the engine oil S•O•S port (2).
SERV7105-12 Vol. 12, No. 1, 2005
- 33 -
1
2
3
4
5
NPI
6
7
8
9
27
The main control valve group is located in the center of the upper structure of the machine. The main control valve group receives pilot oil signals from the operator controls in the cab. Each pilot signal then causes the appropriate control valve to shift in the correct direction. When a control valve shifts, oil flows from the main hydraulic pumps to the appropriate hydraulic cylinder or hydraulic motor to perform work. The 325D main control valve is similar to the 325C valve. The valves are: - Stick 2 (1) - Boom Rod End Relief Valve (2) - Boom 1 (3) - Bucket (4) - Attachment (5) - Right Travel (6) - Straight Travel Valve (7) - Main Relief Valve (8) - Right Side NFC Relief Valve (9)
SERV7105-12 Vol. 12, No. 1, 2005
- 34 -
10
12
11
NPI
13
14
15
28
Additional valves in the main control valve are: - Left Travel (10) - Swing (11) - Stick 1 (12) - Boom 2 (13) - Auxiliary Valve for Tool Control (14) - Left Side NFC Signal Line (15)
SERV7105-12 Vol. 12, No. 1, 2005
- 35 -
NPI
1
29
Two travel pressure switches (not shown) and the swing/implement pressure switch (1), are located under the cab. The pressure switches are activated by pilot oil. The switches close at 490 ± 49 kPa (71 ± 7 psi) and open at 290 ± 0 kPa (42 ± 0 psi). The pressure switches are inputs to the Machine and Tool Control ECM. The Machine and Tool Control ECM uses these inputs to tell when a hydraulic function has been activated and will turn the Automatic Engine Speed Control (AESC)/one touch low idle back to the current speed dial setting. When only the swing/implement pressure switch is activated, the Machine and Tool Control ECM will release the swing brake. When all three pressure switches are activated, the Machine and Tool Control ECM will energize the straight travel solenoid.
SERV7105-12 Vol. 12, No. 1, 2005
- 36 -
NPI
30
The 325D has a pilot operated, two stage main relief valve. The relief valve settings are 35000 ± 490 kPa (5080 ± 71 psi) for implement/travel and 36000 ± 490 kPa (5225 ± 71 psi) for heavy lift mode. The high pressure setting for heavy lift must be correctly adjusted before adjustments can be made for implement/travel settings. Refer to the Testing and Adjusting manual RENR7235 for the proper procedure on setting the main relief valve.
SERV7104-04 03/05
- 37 -
NPI
1
2
3
31 The 325D is available with the heavy lift option. Heavy lift provides a means to have increased hydraulic pressure available to help complete the task. Heavy lift is activated by pressing the heavy lift switch (1) on the soft switch panel in the operators station. The heavy lift switch is an input to the Machine and Tool Control ECM. The Machine and Tool Control ECM limits engine speed to speed dial 6 and activates the heavy lift solenoid (2), which directs pilot oil to the main relief valve (3). At the same time the Machine and Tool Control ECM increases the power shift pressure to decrease the pump output flow. Decreasing the pump output flow provides increased controlability and hydraulic smoothness during a heavy lift operation. Heavy lift mode limits the pumps to a maximum of approximately 60% of the normal hydraulic horsepower. Heavy Lift Specs: - Engine rpm for Heavy Lift is the engine speed dial 6 setting. - Hydraulic horse power is limited to 60% of full power during Heavy Lift. - Main relief maximum pressure during Heavy Lift is 36000 kPa ± 490 kPa (5225 ± 71 psi).
SERV7105-12 Vol. 12, No. 1, 2005
- 38 -
1
NPI
2
32
The 325D uses automatic priorities for certain functions based on the position of the joysticks. The boom priority (1) and the swing priority (2) pressure reducing valves are located behind the swing bearing on the left side of the machine. The boom priority PRV provides boom up priority over the stick in function. The swingpriority PRV provides swing priority over the stick in or stick out function.
SERV7105-12 Vol. 12, No. 1, 2005
- 39 -
NPI
1
2
33
The 325D has one swing motor (1) that receives oil from the swing control valve. The swing control valve receives pump oil from the left pump. The swing drive oil level can be checked with dipstick (2).
SERV7105-12 Vol. 12, No. 1, 2005
- 40 -
NPI
34
MAINTENANCE ITEMS Caterpillar Electronic Technician (Cat ET) or the monitoring system can be used for testing and calibrating the machine. Extended fluid change intervals are available with the proper S•O•S procedures.
SERV7105-12 Vol. 12, No. 1, 2005
- 41 -
NPI
35
TOOL CONTROL SYSTEM The tool control system for the 325D is similar in function to the tool control systems for the 320C - 330C medium excavators, although the medium pressure circuit is now a stand-alone function. The optional tool control system maximizes work tool productivity by configuring hydraulic flow, pressure, and operator controls to match a specific work tool. System versatility enables a wide range of tools to be used. The 325D is available in the EAME market with the following factory installed Tool Control systems: - System 16 - provides two pump flow in a single direction, has a direct return system to the hydraulic tank, and includes a mechanical line relief valve (LRV) for lower psi tools (single action). - System 17 (Multifunction) - provides one or two pump flow in one or two directions (single action or double action) and has a direct return system to the hydraulic tank. System 17 has full electronic controls and features an independent medium pressure circuit used for such applications as a rotating shear or ditch cleaning bucket.
SERV7105-12 Vol. 12, No. 1, 2005
- 42 -
NPI
The 325D will be available in the NACD and APD markets early in 2006. The 325D's produced in Akashi and Aurora can be equipped with the following factory installed Tool Control systems: - System 3 (Hammer) - provides two pump flow in a single direction only. This system also includes a mechanical LRV for lower psi tools (single action). - System 5/15 (Thumb) - provides one pump flow in both directions (extend/retract double action) and can be controlled with a foot pedal (system 5) or with joystick buttons (system 15). - System 14 (Multifunction) - provides one or two pump flow in one or two directions (single action or double action). System 14 has full electronic controls and features an independent medium pressure circuit used for such applications as a rotating shear or ditch cleaning bucket.
SERV7105-12 Vol. 12, No. 1, 2005
- 43 -
NPI
36
CONCLUSION This presentation has provided New Product Introduction (NPI) information for the Caterpillar 325D Hydraulic Excavator. The new components and their locations were identified and discussed. The information in this NPI document pertains to the 325D Hydraulic Excavators that will first be produced in Gosselies for the EAME market. This document will be updated as the Akashi and Aurora produced machines near their first ship dates. Refer to the latest service literature for more information and specifications.
SERV7105-12 Vol. 12, No. 1, 2005
- 44 -
NPI
HYDRAULIC SCHEMATIC COLOR CODE Black - Mechanical Connection. Seal
Red - High Pressure Oil
Dark Gray - Cutaway Section
Red / White Stripes - 1st Pressure Reduction
Light Gray - Surface Color
Red Crosshatch - 2nd Reduction in Pressure
White - Atmosphere or Air (No Pressure)
Pink - 3rd Reduction in Pressure
Purple - Pneumatic Pressure
Red / Pink Stripes - Secondary Source Oil Pressure
Yellow - Moving or Activated Components
Orange - Pilot, Charge or Torque Converter Oil
Cat Yellow - (Restricted Usage) Identification of Components within a Moving Group
Orange / White Stripes - Reduced Pilot, Charge, or TC Oil Pressure
Brown - Lubricating Oil
Orange / Crosshatch - 2nd Reduction in Pilot, Charge, or TC Oil Pressure
Green - Tank, Sump, o r Return Oil
Blue - Trapped Oil
Green / White Stripes Scavenge / Suction Oil or Hydraulic Void
37
HYDRAULIC SCHEMATIC COLOR CODES The colors on the hydraulic schematics and cross-sectional views shown throughout this presentation denote specific meanings. This illustration identifies the meaning of each color.
Blue - Trapped Oil
Green - Tank, Sump, o r Return Oil
- 45 -
Green / White Stripes Scavenge / Suction Oil or Hydraulic Void
Orange / Crosshatch - 2nd Reduction in Pilot, Charge, or TC Oil Pressure
Orange / White Stripes - Reduced Pilot, Charge, or TC Oil Pressure
Cat Yellow - (Restricted Usage) Identification of Components within a Moving Group
Brown - Lubricating Oil
Orange - Pilot, Charge or Torque Converter Oil
Red / Pink Stripes - Secondary Source Oil Pressure
Pink - 3rd Reduction in Pressure
Yellow - Moving or Activated Components
Purple - Pneumatic Pressure
White - Atmosphere or Air (No Pressure)
Red Crosshatch - 2nd Reduction in Pressure
Red / White Stripes - 1st Pressure Reduction
Dark Gray - Cutaway Section
Light Gray - Surface Color
Red - High Pressure Oil
Black - Mechanical Connection. Seal
HYDRAULIC SCHEMATIC COLOR CODE
SERV7105-12 Vol. 12, No. 1, 2005 NPI Handout No. 1
SERV7105-12 Vol. 12, No. 1, 2005
- 46 -
NPI Handout No. 2
Posttest Directions: Circle the correct letter indicating the best answer for each question. 1. Which of the following features on the 325D is the same as it was on the 325C? A. B. C. D.
Engine Operator's station Undercarriage Monitoring system
2. What will cause the monitoring system master condition lamp to blink ON and OFF? A. B. C. D.
High hydraulic oil temperature Low engine oil pressure High coolant temperature Low hydraulic system oil level
3. Which Tool Control system is not available on the Gosselies produced 325D? A. B. C. D.
Medium pressure circuit System 15 System 16 System 17
4. The service tool diagnostic connector is relocated on the 325D to the: A. B. C. D.
radiator compartment air cleaner/battery compartment in the cab behind the operator's seat in the cab in the right console
5. What information is shown in the lower display window on the monitor? A. B. C. D.
Tool control currently selected Engine rpm Service meter hours Hydraulic oil pressure
6. Which component is no longer located in the radiator compartment? A. B. C. D.
Hydraulic oil cooler Machine and Tool Control ECM Fuel filter Fuel pressure sensors
SERV7105-12 Vol. 12, No. 1, 2005
- 47 -
NPI Handout No. 3
Posttest (continued) 7. Which function is not prioritized by the priority pressure reducing valves? A. B. C. D.
Boom up Stick in Boom down Stick out
8. The boom and swing priority pressure reducing valves are located: A. B. C. D.
Beneath the operator platform below the seat Behind the swing bearing on the right side Behind the swing bearing on the left side Beneath the operator platform below the foot pedals
9. The Auxiliary valve for the Tool Control is located on the left end of the main control valve. A. True B. False 10. The main implement pumps on the 325D are rated at: A. B. C. D.
2 X 230 L/min 2 X 235 L/min 2 X 240 L/min 2 X 245 L/min
SERV7105-12 Vol. 12, No. 1, 2005
Posttest Answer Key 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
C D B D A B C C A B
- 48 -
NPI Handout No. 4
