Caterpillar cat 245 excavator (prefix 94 l) service repair manual (94l00255 and up)

Service Repair Manual
Models
245 EXCAVATOR

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Product: EXCAVATOR
Model: 245 EXCAVATOR 94L
Configuration: 245 EXCAVATOR 94L00255-UP (MACHINE) POWERED BY 3406 ENGINE
Disassembly and Assembly
Starting Motor - Delco 50-MT
Media Number -SENR3860-03 Publication Date -01/03/2007 Date Updated -06/07/2016
i02711568
Starting Motor - Assemble
SMCS - 1453-016
Assemble the Starting Motor
Note: The following procedure is only for the 24 volt starting motor.
Table 1
Tools Needed
1P-0510 Driver Gp
1P-1855 Retaining Ring Pliers
1. Lubricate the following items with SAE 20W oil: bushings, seals and oil wicks.
Illustration 1 g00705427
2. Put the field winding assembly (35) and pole shoes (34) in position in the starting motor
housing. Install the twelve screws (37) and tighten to a torque of 20.3 � 2.3 N�m
(180 � 20 lb in). Install the motor terminal (36), the washers and the nut. Tighten the nut to
a torque of 30 � 3 N�m (22 � 2.0 lb ft).
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3. Use a 1P-0510 Driver Gp to install the bushing (32) and the seal (33) into the shift lever
housing .
4. Install the seals on the shaft (31). Position the shift lever assembly (28) into the shift lever
housing. Use a 1P-1855 Retaining Ring Pliers to install the shaft (31) and the snap ring .
5. Install the O-ring seal and the gasket onto the shift lever housing. Set the shift lever housing
assembly (29) onto the starting motor housing in the correct position. Install the seven bolts
and tighten the bolts (30) to a torque of 12.2 � 2.7 N�m (108 � 24 lb in).

6. Use 5P-0960 Molybdenum Grease to lubricate the armature assembly bushing areas. Do not
grease the armature core or the commutator.
7. Put the pinion drive assembly (27) into position in the fork of the shift lever. Put the spacer
on the armature assembly (26). Install the armature assembly (26) into the starting motor
housing and the shift lever housing. Slide the armature assembly (26) into the pinion drive
assembly (27).
8. Use a 1P-0510 Driver Gp to install the bushing (25) into the pinion drive housing (23).

9. Slide the pinion drive housing assembly (23) onto the shift lever housing in the correct
position. Install the six screws (24) and tighten to a torque of 20 � 3 N�m (178 � 27 lb in).
10. Position the insulator (22), the plate (21) and the brush holders onto the brush plate
assembly. Install the screws (20) and tighten the screws .

11. Use a 1P-0510 Driver Gp in order to install the bushing (19) into the rear frame assembly
(14) .
12. Install the O-ring seal (18) onto the rear frame assembly. Position the gasket onto the brush
plate assembly (16). Put the washers and the insulator on the negative terminal.
13. Position brush plate assembly (16) onto the rear frame and install the three screws. Install
the negative terminal insulator, the washers and the nut. Tighten the nut to a torque of
30 � 3 N�m (22 � 2 lb ft).

14. Install the brushes (15) with the brush springs against the side of each brush. Tighten the
lead screw for the brushes to a torque of 2.9 � 1.0 N�m (26 � 8 lb in).
15. Put the washer onto the armature assembly. Position the rear frame assembly (14) over the
commutator. Push the brushes (15) into the holders so that the springs are on top of the
brushes.
16. Put the rear frame assembly against the starting motor housing in the correct position. Install
the six bolts and tighten the bolts to a torque of 12.2 � 2.7 N�m (108 � 24 lb in). Connect the
wire assembly to the negative terminal on the end frame assembly.
17. Connect the three field winding leads (38) to the brush plate assembly. Tighten the screws
to a torque of 2.9 � 1.0 N�m (26 � 8 lb in). Install the three gaskets and plugs on the starting
motor housing.

18. Install the washer, the retainer, the boot, the spring, the retainer and the ring onto the
plunger.
19. Position the plunger assembly (10) into the shift lever housing. Install the nut finger tight.
The plunger assembly will need to be adjusted for the correct pinion clearance after the
starting motor has been completely assembled.
20. Position the solenoid (7) over the plunger assembly. Install the bolts (9) and tighten the bolts
to a torque of 12.2 � 2.7 N�m (108 � 24 lb in). Tighten the clamp.
21. Install the contact assembly (6). Install the insulator, the lockwashers, the washers, the nuts
and the gasket onto the terminal assembly. Tighten the small nuts to a torque of
2.25 � 0.25 N�m (20 � 2.2 lb in). Tighten the larger nuts to a torque of 30 � 3 N�m
(22 � 2 lb ft).
22. Connect the leads (5) to the back of the terminal assembly (2). Install the terminal assembly,
the bolts and the nuts onto the solenoid. Tighten the nuts to a torque of 2.25 � 0.25 N�m
(20 � 2.2 lb in). Connect the negative wire assembly to the ground terminal. Tighten the nut
to a torque of 30 � 3 N�m (22 � 2 lb ft).
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Oct 10 12:45:42 UTC+0800 2019

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Product: EXCAVATOR
26SI Series Alternator
Media Number -RENR1252-01 Publication Date -01/10/1999 Date Updated -09/10/2001
i01167081
Alternator - Disassemble
SMCS - 1405-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 6V-7070 Digital Multimeter 1
B Variable Power Supply 1
Start By:
A. Remove the alternator. Refer to Disassembly and Assembly, "Alternator - Remove" for the
machine that is being serviced.
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism.
1. Remove the pulley nut, the washer, the pulley, and the fan.

2. Remove 4 screws (1). Remove plate (2) .
3. Remove 7 screws (3). Remove cover (4) .
4. Remove gasket (5) .

5. Remove 2 insulated screws (6). Remove the 3 leads.
Note: The regulator and the mounting plate are coated with dielectric grease. If the grease is
removed, reapply the grease.
6. Remove nut (7) .
7. Remove grounded mounting screw (8) .
8. Remove regulator (9) .

9. Remove mounting plate (10). The mounting plate may be stuck to the regulator.
Note: The 3 output diodes (11) are located in heat sink (12). These diodes are identical in
polarity. Diode (11) has red insulation on the wire. The 3 ground diodes (13) are located in
housing (14). These diodes are identical in polarity. Diode (13) has black insulation on the
wire.
10. Remove 3 nuts (15). Disconnect 3 stator phase leads. Disconnect 3 phase leads. Disconnect
6 diode leads.
Table 2
Alternator
Ground
Current Flow of the Output
Diodes
Current Flow of the Ground
Diodes
Negative
Lead to the Heat Sink Housing to the Lead
Red Wire Black Wire

11. Remove the screw and insulator (16). Disconnect capacitor lead (17) .
12. Remove the 3 screws and insulators (18). Disconnect wire (19) .
13. If the "R" terminal is used, remove the following components: nut (20), lead (21), the
washer and terminal (21) .

14. Remove screw (23) and remove diode trio (24) .
15. Remove the nut and washer (25). Remove insulator (26). Remove alternator output terminal
(27) .
16. Remove separator (28) .
Note: Many of the alternator's internal components are covered with dielectric grease. If the
grease is removed, reapply the grease.
17. Remove the heat sink and diode assembly (12) from housing (14). Insulator (29) may be
stuck to heat sink (12) .

Note: Do not damage exposed stator windings or field windings. Bumping the windings or
scraping the windings may break the insulation. Broken insulation may create a short circuit
or a ground.
18. Remove 4 bolts (30). Carefully separate housing (31) from housing (14) .
19. Pull apart stator (32) and housing (14). Guide the stator leads and the grommet through the
hole as the stator is removed from housing (14) .

20. Remove 3 screws (33). Remove the coil and support (34) from housing (14). Guide the field
leads and the grommet through the hole as the coil is removed from housing (14) .
21. Position a small screwdriver in slot (35). Pry cap (36) from housing (14) .

Note: Do not strike the bearing. Shocks from striking the housing can cause damage.
22. Wipe the excess grease from the bearing well. Press bearing (37) into the housing. Remove
the inner race.
23. Remove 4 screws (38) from housing (31) .
24. Lift rotor (39) and bearing (40) from housing (31) .
25. Pull bearing (40) from rotor (39) .
26. Pull retainer (41) from rotor (39) .
27. Pull collar (42) from rotor (39) .

Note: Do not strike the bushing. Shocks from striking the housing can cause damage.
28. Press bushing (43) from housing (14) .
Note: Do not strike the diodes. The shock of such an impact can damage the diodes. Use
proper tools in order to press or pull the diodes from the mountings. As much as 890 N (200
lb) of force may be needed to remove a diode.
29. Remove 3 diodes (13) from housing (14) .
30. Remove diode (11) from heat sink (12) .
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Oct 10 12:47:04 UTC+0800 2019
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Product: EXCAVATOR
26SI Series Alternator
Media Number -RENR1252-01 Publication Date -01/10/1999 Date Updated -09/10/2001
i01167078
Alternator - Assemble
SMCS - 1405-016
Assembly Procedure
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are
worn or damaged, use new parts for replacement.
Note: Do not strike the diodes. The shock of such an impact can damage the diodes. Use
proper tools in order to press the diodes in the mountings.
1. Install 3 diodes (11) in heat sink (12) .

Note: Do not strike the bushing. Shocks from striking the housing can cause damage.
2. Press bushing (43) in housing (14) .
3. Install 3 diodes (13) in housing (14) .
4. Press collar (42) on rotor (39) .
5. Slide retainer (41) on rotor (39) .
6. Press bearing (40) on rotor (39) .

7. Press housing (31) on rotor (39) and bearing (40) .
8. Install 4 screws (38) in housing (31) .
Note: Do not strike the bearing. Shocks from striking the housing can cause damage.
9. Install the inner race. Press bearing (37) into the housing.

10. Press cap (36) in housing (14) .
11. Install the coil and support (34) in housing (14). Guide the field leads and the grommet
through the hole as the coil is installed in housing (14). Install 3 screws (33) .
12. Press the stator (32) and housing (14) together. Guide the stator leads and the grommet
through the hole as the stator is installed in housing (14) .

Caterpillar cat 245 excavator (prefix 94 l) service repair manual (94l00255 and up)

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Caterpillar cat 245 excavator (prefix 94 l) service repair manual (94l00255 and up)