Caterpillar Cat 245B EXCAVATOR (Prefix 1SJ) Service Repair Manual (1SJ00001-00712)

Service Repair Manual
Model
245B EXCAVATOR
245B EXCAVATOR 1SJ00001-00712 (MACHINE) POWERED BY 3406 ENGINE(... 1/12
Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 245B EXCAVATOR 1SJ
Configuration: 245B EXCAVATOR 1SJ00001-00712 (MACHINE) POWERED BY 3406 ENGINE
Disassembly and Assembly

245B EXCAVATOR VEHICLE SYSTEMS
Media Number -SENR3898-01 Publication Date -01/05/2003 Date Updated -19/10/2004
SENR38980033
Pump Drive
SMCS - 3108-016; 3108-010; 3108-015
Remove And Install Pump Drive
Start By:
a. remove piston pump (front)
b. remove piston pump (rear)
c. remove swing pump
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1. Fasten to a hoist and remove the air cleaner and inlet tube (1) for the turbocharger as a unit.
Weight of the air cleaner and tube is 41 kg (90 lb).
2. Remove two bolts (3) that hold the bracket and manifold (2) to the pump drive housing. Move
manifold (2) aside.
3. Remove four bolts (5). Move hose support bracket (4) aside.
4. Remove four mounting bolts (6).
5. Remove the six bolts and swing down rear guard assembly (7).
6. Position tooling (A) as shown and lift the rear of the engine until there is approximately 1.6 mm
(.062 in) clearance between the pump drive and the rear engine support frame.
7. Fasten tooling (B) and a hoist to pump drive (8). Remove twelve bolts (9) holding pump drive
(8) to the flywheel housing. Remove the pump drive. Weight of the pump drive is 240 kg (530 lb).
NOTE: The following steps are for the installation of the pump drive.
8. Fasten tooling (B) and a hoist to pump drive (8). Position the pump drive on the flywheel
housing.
NOTE: Turn the engine to get the flywheel and the pump drive in alignment.
NOTICE
Make sure the pump drive ring is correctly installed on the flywheel
with the flat side to the flywheel.
9. Install twelve bolts (9).
10. Lower pump drive (8) on to the rear engine supports. Install four bolts (6) to a torque of 550 ±
56 N·m (410 ± 42 lb ft).
11. Position hose support assembly (4) and install four bolts.
12. Position manifold (2) and install two bolts (3).
13. Install the air cleaner and inlet tube (1).
14. Raise rear guard assembly (7) in position and secure with the six bolts.
15. Fill the pump drive with oil to the correct level. See the Operation And Maintenance Manual.
Start By:
a. install swing pump
b. install piston pump (rear)
c. install piston pump (front)
Disassemble Pump Drive
Start By:
a. remove pump drive
1. Remove the plug from the cover and drain the oil from the pump drive.
Typical Example
2. Remove bolt (1) and retainer and spring (2).
3. Use tooling (A) and loosen spider (3) and the flange from the splines on the input gear. Remove
spider (3) and flange from the input gear.
4. Remove rubber blocks (4) from spider (3).
5. Remove bolts (5) that hold spider (3) to flange (6). Remove spider (3) from the flange.
6. Fasten to a hoist and turn the pump drive over in the position shown.
7. Remove bolts (8) and bolt and spacer (7). Remove tube assembly (9) and the oil level gauge
assembly from the cover.
8. Remove the bolts that hold outer bearing cages (10) in position.
9. Install two 1/2" -13 NC forcing screws and tighten them evenly to loosen cages (10) from the
pump drive cover. Remove cages (10) and shims (11) from the cover. Keep the shims and cages
together for installation purposes.
10. Using tooling (B), remove the bearing cups from outer cages (10).
11. Remove O-ring seals (12) from cages (10).
12. Remove the bolts that hold cage (13) in position and install two 5/8" -11 NC forcing screws in
the cage. Tighten the forcing screws evenly to loosen cage (13) from the cover. Remove cage (13)
and shims (14) from the cover. Keep the shims and cage together for installation purposes.
13. Remove lip type seal (15) from cage (13).
14. Use tooling (C) to remove the bearing cup from cage (13).
15. Remove the O-ring seal (16) from cage (13).
16. Remove the bolts that hold cover (17) to case (18). Install two 1/2" -13 NC forged eyebolts
and fasten a hoist to the cover as shown.
17. Use two 3/8" -16 NC forcing screws to loosen cover (17) from case (18). Remove the cover
from the case. The weight of cover (17) is 50 kg (110 lb).
18. Remove gears (19) and gear (20) from the case.
19. Remove the bearing cones from each end of the gears (19) with tooling (D).
20. Use tooling (E) to remove the bearing cone from the end of gear (20) that is shown.
21. Use tooling (D) to remove the bearing cone from the opposite end of gear (20).
22. Use tooling (C) to remove the three bearing cups from case (18).
NOTE: If necessary, remove fittings (21) from case (18).
23. Fasten to a hoist and turn case (18) over. Remove lip-type seal (22) from the case.
Assemble Pump Drive
1. Thoroughly clean all parts to be used again. Make sure the old gasket material is removed from
the contact surfaces of the cover and case.
2. Using tooling (F), install the seal in the case. Make sure the lip of the seal is toward the inside
as shown. Put clean oil on the lip of the seal.
3. Fasten to a hoist and turn the case over. Install fittings (21) in the case.
4. Lower the temperature of the three bearing cups (23) and install them in the case as shown.
After the bearing cups are at ambient (atmospheric) temperature again, make sure they are tight
against the shoulder in the case assembly.
5. Heat bearing cones (24) for the three gears to a maximum temperature of 135°C (275°F). Install
the bearing cones on each side of the three gears. After the bearing cones are at ambient
(atmospheric) temperature again, make sure they are tight against the shoulders on the gears.
6. Install outer gears (19) and center gear (20) in the case.
7. Use two 1/2" -13 NC forged eyebolts to fasten a hoist to cover (17). Put 6V5765 Sealant on the
contacting surfaces of the cover and case.
8. Put cover (17) in position on the case and install the bolts that hold the unit together.
9. Use tooling (G) to install the seal in the center cage with the lip of the seal toward the inside of
the cage. Install the seal until dimension "X" is 1.5 ± 0.8 mm (.06 ± .03 in). Put clean oil on the lip
of the seal.
245B EXCAVATOR 1SJ00001-00712 (MACHINE) POWERED BY 3406 ENGIN... 10/12
10. Lower the temperature of the three bearing cups for the outer bearing cages (10) and the center
bearing cage (13). Install the bearing cups in the cages. After the bearing cups are at ambient
(atmospheric) temperature again, make sure they are tight against the shoulders in the case
assembly.
11. Install the original shims that were removed with the three cages. Install the outer cages (10)
and center cage (13) in the cover without O-ring seals. Install the bolts to hold the cages.
12. Make sure the breather (25) is installed on the cover.
13. Put oil level gauge and tube assembly (9) with the gasket in position on the cover. Install the
bolts to hold the unit in position.
14. Install tooling (H) in the spline of the input gear. Make sure the tooling is in a vertical position
and tighten nut enough to hold the tooling rigidly in place. Tool (H) is used to move the gears up
and down to check gear end clearance.
NOTICE
Do not tighten the nut too much. Damage to the spline in the gear can
be the result.
15. Install indicator group (J).
16. Push down on the handle of tooling (H) and turn the gear backward and forward 90° in each
direction approximately six times. Make a setting of the indicator group on zero.
17. Lift up on the handle of tooling (H) and turn the gear backward and forward 90° in each
direction. Look at the indicator group while tooling (H) is lifted up and check the end clearance.
Add or remove shims under cage to get a 0.20 ± 0.05 mm (.008 ± .002 in) end clearance.
18. Remove cage and install the O-ring seal on cage. Put oil on the seal. Install the bearing cage on
cover with the oil passage in the cover in alignment with the oil passage in the cage.
19. Follow the procedure in Steps 11 through 18 for the two outside cages except for:
a. Use a piece of 8S9355, XT-3 Hydraulic Hose, 38.1 mm (1.5 in) long with a 25.4 mm (1 in)
inside diameter which has been cut through one side, to adapt tool (H) to the larger splines in the
two outside gears. Put the piece of hose (13) over the lower part of tool (H).
b. The anvil of indicator (J) must be put directly on the gear hub, not on the end of tool (H), to get
the desired accuracy.
20. Put spider (3) in position on flange (6) and install bolts (5).
21. Install rubber blocks (4) on spider (3) as shown.
22. Put 5P960 Multipurpose Grease on the external splines of the input gear for flange (6).
23. Install spider (3) and flange (6) on the input gear splines.
Typical Example
24. Put 5P960 Multipurpose Grease on the face of the washer and the threads of bolt (1). Put
washer and retainer (5) in position. Install bolt (1) and tighten it to a torque of 270 ± 27 N·m (200
± 20 lb ft). Then tighten the bolt (1) 60 ± 5° more.
End By:
a. install pump drive
Copyright 1993 - 2019 Caterpillar Inc. Sat Oct 12 23:54:39 UTC+0800 2019
All Rights Reserved.
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Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 245B EXCAVATOR 1SJ
Configuration: 245B EXCAVATOR 1SJ00001-00712 (MACHINE) POWERED BY 3406 ENGINE
Disassembly and Assembly

245B EXCAVATOR VEHICLE SYSTEMS
Media Number -SENR3898-01 Publication Date -01/05/2003 Date Updated -19/10/2004
SENR38980034
Swing Motor
SMCS - 5058-010; 5058-015; 5058-016
Remove And Install Swing Motor
1. Disconnect oil lines (1), (2), and (3).
2. Install tooling (A) and a hoist to the swing motor. Remove four bolts (4) and remove the swing
motor. Weight of the swing motor is 113 kg (250 lb).
NOTE: The following steps are for the installation of the swing motor.
3. Install tooling (A) and a hoist to the swing motor. Position the swing motor on the swing brake
housing and install four bolts (4).
4. Connect case drain oil line (3).
5. Fill the swing motor with clean hydraulic oil.
NOTICE
Do not start the engine until the swing motor is filled with oil.
6. Connect oil lines (1) and (2).
Disassemble Swing Motor (Earlier)
Start By:
a. remove swing motor
1. Fasten adapter and bracket (1), part of tooling (A) to the swing motor as shown with three 3/4" -
10 NC bolts 2 1/4 inches long. Fasten a hoist and put the swing motor in position on the engine
sand of tooling (A). Weight of the swing motor is 95 kg (210 lb).
2. Loosen plugs (2) in the shuttle valve. Remove bolts (3) and shuttle valve (4) from the pump
head.
3. Remove plugs (2), O-ring seals (5), balls (6) and pin (7) from the shuttle valve. Remove O-ring
seals (8) and (9) from the shuttle valve.
4. Bend the lock back and remove bolt (10), the lock and retainer from the shaft.
5. Put identification on the pump head as to its location on the body for correct alignment at
assembly. Remove bolts (11) and pump head (12) from the body.
6. Remove O-ring seal (13) from body (14).
7. Put identification on body (14) as to its location on the lower body.
NOTICE
Do not let the pump barrel fall when body (14) is removed. Install
protective plate (B) on the pump barrel. Keep protective plate (B) on
the pump barrel at all times to prevent damage to the face of the pump
barrel.
8. Remove bolts (15) and body (14) from the lower body.
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9. Remove O-ring seal (17) from the lower body.
NOTE: It is not necessary to install the barrel over the same pistons at assembly so identification
on the barrel and pistons is not necessary.
10. Carefully remove barrel (16) from the pistons.
NOTE: It is necessary to remove tool (B) from the barrel to remove the snap ring and shaft (18).
Install tool (B) on the barrel again as soon as shaft (18) is removed.
11. Use tool (C) to remove the snap ring that holds shaft (18) in place. Remove shaft (18) from the
barrel.
12. Remove spring (20) and tube (19) from shaft (18).
The spring on shaft (18) can cause injury if all the tension in the spring
is not released before tool (D) is removed. To prevent injury be sure all
the tension in the spring is released before tool (D) is removed from the
shaft.
13. Use tool (D) and a 5/16" bolt at least 6 1/2 inches long with a nut and washers to put the spring
in compression so the snap ring can be removed from the groove in shaft (18). Use tool (E) to
remove the snap ring from the groove. Carefully loosen the bolt in tool (D) to release all the
tension in the spring. Remove tool (D) after the tension in the spring is released.
14. Remove snap ring (23), retainer (22), race (21) and bearing (26), spring (24) and race (25)
from shaft (18).
15. Use tool (F) to remove the snap ring that holds the bearing race on shaft (18).
16. Use tooling (G) as shown to remove race (27) from the end of shaft (18).
17. Use tool (H) to remove snap ring (28) from the barrel.
18. Use tooling (J) and a press to remove the bearing from the barrel (16).
NOTICE
Links (30) must be installed in the same inserts in drive plate (31) they
are removed from so put identification on links (30) as to their location
in drive plate (31). Be extra careful not to damage the highly finished
surfaces of the pistons.
19. Use tool (C) to remove snap rings (29) that hold links (30) in position on drive plate (31).
Remove the piston assemblies from the drive plate.
NOTICE
Pistons (32) must be installed on the same links they are removed from
so put identification on the pistons and links.
20. Use tool (K) to remove snap ring (34) from piston (32). Remove piston (32), retainer (33),
snap rings (34), (29) and retainer (35) from the link. Disassemble the remainder of the piston
assemblies.
21. Remove the bolts that hold retainer (36) to the body and use screwdrivers in notches (37) to
remove the retainer from the body.
22. Remove seal (38) and O-ring seal (39) from the retainer.
23. Fasten tool (L) to a work bench, over a hold that is 63.5 mm (2.50 in) in diameter.
24. Use two 3/4" -10 NC forged eyebolts and fasten a hoist to body (42). Remove the body from
the bracket of tooling (A). The weight of the body is 36 kg (80 lb).
25. Put body (42) in position on tool (L) as shown. Make sure pin (40) is engaged with the notch
(groove) on the outside diameter of drive plate (31).
26. Bend the tab of the lock from spanner nut (41).
NOTICE
When tool (M) is used to loosen the spanner nut, be sure the teeth on
the spanner socket do not engage in the teeth of the lock.
27. Use tool (M) to remove the spanner nut from the drive plate.
28. Remove shims (43) from the drive plate.
29. Put body (42) in a press with a support under the body so drive plate (31) can be pushed out
the bottom of the body. Put tool (N) on the end of drive plate (31) and push the drive plate out of
the body. Do not let the drive plate fall when it is free of the smaller bearing cone in body (42).
30. Remove the smaller bearing cone from body (42).
31. Use tooling (O) to remove the small bearing cup from body (42).
32. Use tooling (O) to remove the larger bearing cup from body (42).
33. Use a hammer and punch to push the roll pin in drive plate (31) into the joint assembly inside
the drive plate.

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Service Repair Manual

Disassembly and Assembly

Remove And Install Pump Drive

a. remove piston pump (front)

b. remove piston pump (rear)

c. remove swing pump

4. Remove four mounting bolts (6).

9. Install twelve bolts (9).

12. Position manifold (2) and install two bolts (3).

13. Install the air cleaner and inlet tube (1).

a. install swing pump

b. install piston pump (rear)

c. install piston pump (front)

Disassemble Pump Drive

a. remove pump drive

2. Remove bolt (1) and retainer and spring (2).

4. Remove rubber blocks (4) from spider (3).

11. Remove O-ring seals (12) from cages (10).

13. Remove lip type seal (15) from cage (13).

15. Remove the O-ring seal (16) from cage (13).

NOTE: If necessary, remove fittings (21) from case (18).

Assemble Pump Drive

12. Make sure the breather (25) is installed on the cover.

15. Install indicator group (J).

21. Install rubber blocks (4) on spider (3) as shown.

a. install pump drive

Disassembly and Assembly

Remove And Install Swing Motor

1. Disconnect oil lines (1), (2), and (3).

4. Connect case drain oil line (3).

5. Fill the swing motor with clean hydraulic oil.

6. Connect oil lines (1) and (2).

Disassemble Swing Motor (Earlier)

a. remove swing motor

6. Remove O-ring seal (13) from body (14).

7. Put identification on body (14) as to its location on the lower body.

9. Remove O-ring seal (17) from the lower body.

10. Carefully remove barrel (16) from the pistons.

28. Remove shims (43) from the drive plate.

30. Remove the smaller bearing cone from body (42).

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