Caterpillar cat 245 excavator (prefix 94 l) service repair manual (94l00001 00254)

Service Repair Manual
Models
245 EXCAVATOR

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Product: EXCAVATOR
Model: 245 EXCAVATOR 94L
Configuration: 245 EXCAVATOR 94L00001-00254 (MACHINE) POWERED BY 3406 ENGINE
Disassembly and Assembly
245 EXCAVATOR VEHICLE SYSTEMS
Media Number -SENR7339-02 Publication Date -01/01/1983 Date Updated -12/10/2001
Bucket And Boom Pilot Control Valve
SMCS - 5452-11; 5452-12
Remove Bucket And Boom Pilot Control Valve
1. Remove the knob from control lever (1).
2. Remove the three covers (2).
3. Remove the foot support (5).
4. Disconnect the oil lines (6) from valve.
5. Remove the three bolts (4) from valve, and the three bolts (3) from support assembly.
1/3245 EXCAVATOR 94L00001-00254 (MACHINE) POWERED BY 3406 ENGINE(H...
2019/10/9https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

6. Remove the bucket and boom pilot control valve (7).
7. Remove the two cotter pins and pins (9).
8. Remove the support assembly (8) from pilot control valve.
Install Bucket And Boom Pilot Control Valve
1. Put the support assembly (1) in position on pilot control valve. Install the two pins (2) and cotter
pins.
2. Put the bucket and boom pilot control valve (3) in position.

3. Install the three bolts (4) in support assembly and the three bolts (5) in valve.
4. Connect the oil lines (7) to valve.
5. Install foot support (6).
6. Install the three covers (8).
7. Install the knob on control lever.
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Wed Oct 9 23:40:56 UTC+0800 2019

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Product: EXCAVATOR
Stick And Swing Pilot Control Valve
SMCS - 5452-11; 5452-12
Remove Stick And Swing Pilot Control Valve
1. Remove the knob from control lever (1).
2. Remove the two covers (2).
3. Remove the foot support (3).
4. Disconnect the linkage (5) from safety lever.
5. Disconnect the oil lines (7) from valve.
6. Remove the three bolts (6) from valve, and the three bolts (4) from support assembly.

7. Remove stick and swing pilot control valve (8).
8. Remove the two cotter pins and pins (10).
9. Remove the support assembly (9) from pilot control valve.
Install Stick And Swing Pilot Control Valve
1. Put the support assembly (1) in position on pilot control valve. Install the cotter pins and pins.
2. Put the stick and swing pilot control valve (2) in position.

3. Install the three bolts (3) in support assembly and the three bolts (5) in valve.
4. Connect the oil lines (6) to valve.
5. Connect linkage (4) to safety lever.
6. Install the foot support (8).
7. Install the two covers (7).
8. Install the knob on control lever.
Wed Oct 9 23:41:52 UTC+0800 2019

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Product: EXCAVATOR
Pilot Control Valves
SMCS - 5452-15; 5452-16; 5452
Disassemble Pilot Control Valve
start by:
a) remove bucket and boom pilot control valve or stick and swing pilot control valve
1. Remove the plugs (1), shims (3), and guides (2). Put identification on the shims as to their
location in valve body.
2. Remove the two plugs and valve stems (4). Put identification on the valve stems as to their
location in valve body.
3. Remove the retainers and springs from each valve stem.
4. Remove the two lip-type seals from valve body.

Assemble Pilot Control Valves
1. Install the two seals in valve body with the lips of seals toward inside of valve body.
2. Put retainers (6) and (13) in position on valve stems, and install the two springs and retainers (2)
and (9).
NOTE: The springs (4) and (11) are the same. The longer spring (3) must be installed on the
bucket or swing valve stem (5). The spring (10), that has the greater force of compression, must be
installed on the boom or stick valve stem (12).
3. Put the two valve stems in their respective positions in valve body, and install plugs (1).
4. Install the guides (14), shims (8), and plugs (7) in their respective positions in valve body. The
shims (8) must be of correct thickness to keep stem rotation to a minimum but still have free
movement of valve stems.
end by:
a) install stick and swing pilot control valve or bucket and boom pilot control valve
Wed Oct 9 23:42:48 UTC+0800 2019

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Product: EXCAVATOR
Speed And Direction Pilot Control Valve
SMCS - 5462-11; 5462-12; 5462-15; 5462-16
Remove Speed And Direction Pilot Control Valve
1. Disconnect the seven oil lines (2) from the control valve.
2. Disconnect the two hoses (4) from the foot control for the windshield washer.
3. Remove the two supports (3).
4. Remove the bolts (5) from bracket.
5. Remove the speed and direction pilot control valve (1) and the bracket as a unit. The weight of
the unit is 70 lb. (32 kg).
Install Speed And Direction Pilot Control Valve

1. Put the bracket and speed and direction pilot control valve (1) in position. Install the bolts that
hold the bracket in place.
2. Install the two foot supports.
3. Connect the two hoses to the foot control for the windshield washer.
4. Connect the seven oil lines (2) to the speed and direction pilot control valve.
Disassemble Speed And Direction Pilot Control Valve
start by:
a) remove speed and direction pilot control valve.
1. Remove the two foot pedals (2).
2. Remove the two bolts (5) from each support.
3. Remove the two supports (4) and two stems.
4. Remove the control lever (3).
5. Remove the four bolts (9) and bracket (1).

6. Remove the forward valve group (6) and reverse valve group (8) from steering valve group (7).
7. Remove the covers from valve groups (6) and (8).
8. Remove slug (13), spring (16), and valve stem (12) from valve bodies.
9. Remove bolt (10), retainer (14), shims (11), and spring (15) from valve stem. Keep shims for
use during assembly of valve group. Remove the seal from valve bodies.
10. Remove cover (26) from body. Remove key (23) and washer (22) from shaft (18).
11. Loosen bolt (25), and remove bearing (19), shaft (18), lever (21), and washer (24).
12. Remove the seal (20) and bearing (17).
13. Remove the cover (32), springs (31) and (30), retainers (29) and (28), and valve stems (27).
Put location marks on valve stems as to their location in valve body.
Assemble Speed And Direction Pilot Control Valve

1. Put valve stems (15) and (16) in their respective positions in valve body with grooves (slots) (1)
in stems toward the openings for the oil lines in valve body (29).
2. Install retainers (30) and (32), springs (34) and (31), and cover (33).
3. Install bearings (3) and (5). Install seal (2) in valve body with lip of the seal toward bearing (3).
4. Install shaft (4), lever (9), washer (11), and key (7). Put lever in position on shaft and tighten
bolt (12). Install cover (10).
NOTE: The grooves (slots) (1) in valve stems (15) and (16) must be visible (can be seen) through
the openings for the oil lines in valve body (29) after installation of lever (9).
5. Install washer (6) and key (8) on the shaft.

6. Install seals (13) with the lips of the seals toward the inside of the valve bodies.
7. Install springs (22), shims (21), retainers (20), and bolts (14) on stems (23) and (24).
8. Install valve stems (23) and (24), springs (26), and slugs (25) in valve bodies (18) and (19).
Install covers (27) and (28).
9. Put valve bodies (18) and (19) in position on valve body (29), and install the bolts. Make sure O
-ring seals are in place in valve bodies.
10. Install bracket (35) on control valve.
11. Install control lever (37).
12. Install stems (17), supports (38), and bolts.
13. Install the two foot pedals (36).
end by:
a) install speed and direction pilot control valve

b) check adjustment of valve (See TESTING THE CONTROL VALVES FOR SPEED AND
DIRECTION in TESTING AND ADJUSTING)
Wed Oct 9 23:43:43 UTC+0800 2019

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Product: EXCAVATOR
Line Relief Valves
SMCS - 5117-11; 5117-12
Remove Line Relief Valves
Do not remove any of the line relief valves until all oil pressure in main
system has been released.
1. Remove plug (1), spring (2) and valve (3).
2. Remove the cartridge (8). Put identification marks on valve (3) and cartridge (8) as to their
location in control valve.

3. Remove seat (4), valve (5), spring (6) and shims (7) from valve (3). Put identification on shims
for use during installation of valve.
NOTE: There are six line relief valves in each control valve.
Install Line Relief Valves
1. Install the O-ring seals on cartridge (8), plug (1) and seat (3).
2. Install the original thickness of shims (5), spring (4), valve (6) and seat (3) in valve (7).
3. Install cartridge (8) in its respective location in the control valve.
4. Install valve (7) in its respective location in the control valve.
5. Install spring (2) and plug (1).
6. Check the adjustment of line relief valve. See CHECKING AND ADJUSTMENT OF LINE
RELIEF in TESTING AND ADJUSTING.
Wed Oct 9 23:44:39 UTC+0800 2019

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Product: EXCAVATOR
Load Check Valves
SMCS - 5117-11; 5117-12
Remove Load Check Valve
Do not remove any of the load check valves until all oil pressure in main
NOTE: There are three load check valves in the three stem control valves and five load check
valves in the five stem control valves.
1. Remove plug (1), spring and valve from the control valve.
Install Load Check Valves

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1. Install load check valve (3), spring (2) and plug (1) in control valve.
2. Start engine and run all cylinders through full strokes.
3. Stop engine and check oil level in hydraulic tank. Fill tank as necessary.
Wed Oct 9 23:45:35 UTC+0800 2019

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Product: EXCAVATOR
Make-Up Valves
SMCS - 5117-12; 5117-11
Remove Make-Up Valve
Do not remove any of the makeup valves until until all oil pressure in
main system has been released.
1. Remove plug (1), spring and valve from the control valve.
Install Make-Up Valves
1. Install the make-up valve (3), spring (2) and plug (1) in the control valve.

2. Start the engine and run all cylinders through full strokes.
3. Stop engine and check oil level in hydraulic tank. Fill tank as needed.
LOAD CHECK VALVES
MAKE-UP VALVES

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Product: EXCAVATOR
Three Stem Control Valve
SMCS - 5451-12; 5451-15; 5451-16; 5451-11
Remove Three Stem Control Valve
Do not disconnect or remove any oil lines until all oil pressure in main
1. Disconnect oil lines (1) and (2) from the control valve.
2. Disconnect the six oil lines (3) from the control valve.
3. Disconnect oil line (5) and remove oil line (4) to the boom vent valve.
4. Remove the bolts that hold block (7) to the control valve.
5. Disconnect the six pilot oil lines (6) from the control valve. Put plugs in all the lines and
openings in the control valve.

Caterpillar cat 245 excavator (prefix 94 l) service repair manual (94l00001 00254)

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