Caterpillar Cat 245D EXCAVATOR (Prefix 7ZJ) Service Repair Manual (7ZJ00001 and up).pdf

Service Repair Manual
Model
245D EXCAVATOR

Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 245D EXCAVATOR 7ZJ
Configuration: 245D EXCAVATOR 7ZJ00001-UP (MACHINE) POWERED BY 3406 ENGINE
Disassembly and Assembly
3406C DIESEL ENGINES FOR CATERPILLAR BUILT MACHINES
Media Number -SENR6409-02 Publication Date -01/07/2006 Date Updated -19/05/2015
SENR64090006
Automatic Timing Advance
SMCS - 1272-010; 1272-015; 1272-016
Remove & Install Automatic Timing Advance
1. Remove nuts (1), cover (2), and the gasket.
2. Put No. 1 piston at the top center compression position (TC) with the following procedure:
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245D EXCAVATOR 7ZJ00001-UP (MACHINE) POWERED BY 3406 ENGINE(SE...
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a. Remove plug (3), two bolts and cover (2) from the flywheel housing.
b. Install Tool (B) in the flywheel housing. Use Tool (B) to slowly rotate the engine in the
direction of normal rotation, (counterclockwise as seen from the flywheel end of the engine), until
timing bolt (4) can be installed in the flywheel housing and into the hole in the flywheel.
c. Remove the valve cover from the valve cover base. Check to see if both rocker arms (5) for the
No. 1 cylinder can be moved backward and forward.
NOTE: The No. 1 piston is at the top center compression position (TC) when the timing bolt is
installed in the flywheel and both rocker arms for the No. 1 cylinder can be moved backward and
forward. If both rocker arms cannot be moved, the No. 1 piston is not at the top center
compression position (TC). Remove the timing bolt from the flywheel and rotate the engine in the
direction for normal rotation, (counterclockwise as seen from the flywheel end of the engine one
full turn 360 degrees, and install the timing bolt again.
3. Remove the timing bolt, and use Tool (B) to rotate the engine in the opposite direction of
normal rotation (clockwise as seen from the flywheel end of the engine) a minimum of 30
degrees.
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NOTE: The timing is correct if Tool (A) and the timing bolt can be installed at the same time. The
timing procedure in the Testing & Adjustment Manual must be done again if the timing bolt and
Tool (A) can not be installed at the same time.
4. Remove the plug from the timing pin hole in the fuel injection pump housing. Install Tool (A)
in the timing pin hole.
5. Remove eight bolts (6) and automatic timing advance (7).
6. Remove gear (9) from fuel injection pump camshaft (8).
The following steps are for the installation procedure.
7. Install gear (9) on fuel injection pump camshaft (8).
8. Install two 3/8 in 16 NC x 6 in (152.4 mm) long guide bolts (10). Space the guide bolts evenly.
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NOTICE
There is a light spring located beneath the flyweight cover (12). Hold
cover (12) while removing last nut (11). Slowly remove flyweight cover
(12) to avoid dropping the spring.
9. Remove four nuts (11) and remove flyweight cover (12).
10. Put automatic timing advance (13) in position on the fuel injection pump camshaft, and install
four bolts (14). Tighten bolts (14) just past finger tight. Remove guide bolts (15).
11. Install four nuts (16). Install Tool (C).
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12. Tighten four knurled nuts (17) finger tight.
NOTICE
Do not use any tools to tighten the knurled nuts.
13. Install all mounting bolts (14) and tighten to 55 ± 10 N·m (41 ± 7 lb ft).
14. Loosen knurled nuts (17). Remove four nuts (16) and remove Tool (C).
15. Install the spring and flyweight cover (12). Install four nuts (16). Tighten nuts (16) to a torque
of 6 ± 1 N·m (53 ± 9 lb in).
16. Install a gasket and timing advance cover (2). Tighten eight nuts (1) to a standard torque.
17. Remove timing pin (A) and replace the plug in the fuel pump housing.
18. Remove timing bolt (4) and replace the plug. Install cover (2) on the flywheel housing.
19. Check the dynamic timing curve. See Testing & Adjusting Manual SENR6471 for the proper
specifications.
Disassemble Automatic Timing Advance
Start By:
a. remove automatic timing advance
1. Remove four nuts (1) and remove retainer (2) from automatic timing advance.
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2. Remove spring (3) and race (4).
3. Remove four cap screws (5), two retainer plates (6) and remove carrier group (7) from
automatic timing advance.
4. Remove snap ring (8), tapered race (9), spool (10) and weights (11) from carrier (7).
5. Remove race (12) from carrier (7).
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6. Remove four bolts (13).
7. Remove plate (14), ring (16) and ring (17) from carrier assembly (15). Remove seals (19) and
(20) from carrier assembly (15). Remove seal (18) from plate (14).
Assemble Automatic Timing Advance
1. Install new seals (18), (19) and (20).
2. Lubricate seal (18), (19) and (20) with engine oil then carefully install carrier assembly (15)
into ring (17). Install ring (16) and plate (14).
3. Align proper bolt holes and install four bolts (13).
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4. Position race (12) into carrier (7).
5. Position weights (11), spool (10), tapered race (9) and snap ring (8) into carrier (7).
6. Lubricate spool (10) and lower it into position in the automatic timing advance. Position
retainer plates (6) and install four cap screws (5). Tighten cap screws (5) to a torque of 3.4 ± 0.4
N·m (30 ± 4 lb in).
7. Position race (4) and spring (3).
NOTE: When installing retainer (2), be sure spring (3) properly engages retainer adjustment
screw.
8. Position retainer (2) and install four nuts (1).
End By:
a. install automatic timing advance
8/9
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Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Sep 9 12:36:47 UTC+0800 2019
9/9
2019/9/9

Shutdown SIS
Previous Screen
Product: EXCAVATOR
SENR64090007
Fuel Injection Pump Housing & Governor
SMCS - 1286-010
Remove & Install Pump Housing & Governor
Start By:
a. Remove the Automatic Timing Advance.
1. Remove tube assembly (1). Check the gasket at the cylinder block for damage and replace with
a new part if necessary.
2. Remove dipstick assembly (2).
3. Remove six fuel injection lines (3). Cap or plug immediately. See topic, "Remove & Install Fuel
Injection Lines" in this module for more information.
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4. Disconnect hose assembly (4). Cap and plug all openings immediately.
5. Remove bracket (5).
6. Disconnect hose assemblies (6) and (7). Cap or plug all openings immediately.
7. Attach a strap and a lifting device to fuel injection pump housing and governor (9).
8. Remove the nuts and bolts (8) that hold the unit to the timing gear housing.
9. Remove the fuel injection pump housing and governor (9). The weight of the fuel injection
pump housing and governor is 59.5 kg (132 lb).
NOTE: For installation of the fuel injection pump and housing, reverse the removal steps.
NOTE: Refer to Testing & Adjusting Manual SENR6471 for adjustments.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Sep 9 12:37:35 UTC+0800 2019
2/2
2019/9/9

Shutdown SIS
Previous Screen
Product: EXCAVATOR
SENR64090008
Governor
SMCS - 1264-015; 1264-016
Disassemble Governor
*Part of 6V4095 Pump and Governor Reconditioning Tool Group.
IN
Start By:
a. remove fuel injection pump housing and governor
b. remove fuel transfer pump
NOTE: If it is desired to only remove the governor so the fuel injection pump housing can be
disassembled, do only steps 1, 2, 3, 16, 22, 25, 26, 27, 28, 32, 34 and 37.
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1. Put the fuel injection pump housing and governor in position on Tool (A).
2. Remove the bolts, fuel ratio control (1) and shutoff solenoid (2) from rear governor housing (3).
3. Remove the bolts, rear governor housing (3) and the gasket from the front governor housing.
4. Remove governor spring (4), the two wave washers, one flat washer and the seat from the guide
in the rear governor housing.
5. Remove bolt (5) that holds lever assembly (6) to the shaft assembly.
NOTE: There is a key in the slot groove of the shaft assembly that must be removed before the
shaft assembly is removed from the rear governor housing.
6. Remove shaft assembly (7), lever (6) and lever (8) from the rear governor housing.
NOTE: Put an alignment mark on lever (9) for correct assembly purposes.
7. Remove bolt (10), lever assembly (9) and spring (11) from shaft assembly (7).
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8. Remove plug (12) and lip-type seal (13) from the housing.
NOTE: Spacers (14) and (16) are different sizes. Make sure they are assembled in the correct
position.
9. Use needle nose pliers, and remove the shaft. Remove spacer (14), lever (15) and spacer (16)
from the governor housing.
10. Remove two setscrews and locknuts (17) if necessary.
11. Release spring (18) from the notch in the housing. Remove snap ring (19), and remove shaft
(20) from the housing. Remove lever (21) and spring (18).
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12. Remove liptype seal (22) from the housing.
13. If necessary, remove the screws, cover (23) and the gasket from the governor housing.
14. Remove high idle cover (24) and three O-ring seals (25).
15. Remove liptype seal (26), dashpot valve (27), fitting (25), insulator and high idle adjustment
(28) from the rear housing.
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16. Remove two bolts (29), housing (30) and the gasket from the fuel pump housing.
17. Remove bolts (31), and remove torque control group (32) from the block.
NOTICE
Depending on the different engine applications, torque control groups
will vary. Inspect all parts for wear and damage, and make a note of
the correct sequence of the parts for assembly purposes.
NOTE: For additional information, see Specifications Manual SENR6470.
18. Remove the bolts and block (33) for the full load stop from the housing.
19. Remove the bolt that holds collar (35) to bolt (36).
20. Remove collar (35) and spring (34) from bolt (36). Remove bolt (36) from the block.
21. If necessary, remove the stop screw and the power setting screw from collar (35).
5/18
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NOTE: It may be necessary to turn the piston to remove the servo from the rack.
22. Remove the three bolts and governor servo (37) from the fuel injection pump housing.
23. Remove lockring (43), seat (42), spring (41) and sleeve (40) from valve (39). Remove lockring
(38) from the groove in the center of valve (39).
24. Remove sleeve (44), valve (45) and piston (46) from the governor servo. Remove O-ring seal
(50) from sleeve (44). Do not remove pin (47). If pin (47) and lever (48) or cylinder (49) are worn
or damaged replace the assembly.
25. Use Tool (C) to hold spring (51) under compression so the ring on the governor shaft can be
removed.
26. Remove the ring, and carefully remove Tool (C).
27. Remove bearing (52), the sleeve and spring (51) from the governor shaft.
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28. Remove ring (53) and dashpot assembly (54) from the governor shaft.
29. Use Tool (B), and remove ring (60) from seat (57).
30. Remove ring (59) and spool (58) from seat (57).
31. Remove seat (57), and spring (56) from shield (55).
32. Remove spring (62), if equipped, and riser (61) from the governor shaft.
33. Remove ring (63), races (64) and bearing (65) from the riser.
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34. Remove the bolts and carrier assembly (66) from the fuel injection pump housing.
35. Remove dowels (68) and flyweights (69) from the carrier assembly.
36. Remove dowel (67) from the governor shaft, and remove the governor shaft from the carrier
assembly.
37. Remove races (70) and (72) and bearing (71) from the camshaft in the fuel injection pump
housing.
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Assemble Governor
*Pump and Governor Reconditioning Tool Group
9/18
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1. Put the fuel injection pump housing in position on Tool (A). Install race (3), bearing (2) and
race (1) on the end of the camshaft in the fuel injection pump housing.
2. Put flyweights (5) in position on carrier assembly (4), and install dowels (6) to hold the
flyweights in place. The flyweights must move freely on the dowels and have 0.010 to 0.230 mm
(.0004 to .0090 in) end play.
3. Install governor shaft (7) on carrier assembly (4).
4. Install dowel (8) in governor shaft (7), and slide carrier assembly (4) down on the governor
shaft until dowel (8) fits into the slot in the carrier assembly.
5. Install carrier assembly (4) on the end of the camshaft.
6. Install race (12), bearing (11), race (10) and ring (9) on riser (13).
10/18
245D EXCAVATOR 7ZJ00001-UP (MACHINE) POWERED BY 3406 ENGINE(S...
2019/9/9

7. Install riser (13) and spring (14), if equipped, on the governor shaft.
8. Install spool (18) and ring (19) on seat (17), and use Tool (B) to install ring (20) to hold them in
position.
9. Install seat (17) on spring (16) and spring (16) on shield (15).
10. Install dashpot assembly (21) on the governor shaft.
11. Install ring (22) in the groove on the governor shaft. Install sleeve (23), spring (25), the sleeve
and bearing (24) on the governor shaft.
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12. Use Tool (C) to hold spring (25) under compression, and install the ring in the groove on the
governor shaft.
13. Install O-ring seal (26) on sleeve (27). Install piston (29) and sleeve (27) in the governor servo
as shown.
14. Install valve (28) in the governor servo as shown.
15. Install lockring (33) in the groove near the center of valve (28). Put sleeve (34), spring broken
link spring (35) and seat (36) in position on valve (28), and install lockring (37) to hold them in
place.
16. Put governor servo (30) in position on the fuel injection pump housing with piston (29)
engaged over the rack. Make sure the lever is engaged in the slot groove of riser (13).
12/18
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17. If dowel (43) was removed, install it in block (44) 31 ± 0.5 mm (1.22 ± .02 in) above the
outside surface of the block.
18. Install bolt (45) in block (44) and spring (38) on bolt (45).
19. Install stop screw (40) and the locknut on collar (42). Install power setting screw (41) and the
locknut on the collar.
20. Install collar (42) on bolt (45). Make an alignment of the hole in the collar with the notch in
bolt (45), and install bolt (39).
21. If the dowels that align block (44) with the front governor housing were removed, install them
4.0 ± 0.5 mm (.16 ± .02 in) above the outside surface of the front governor housing.
22. Put block (44) in position on the front governor housing with the holes in the block in
alignment with dowels in the front governor housing.
23. Install dowels (46) in the front governor housing 6.0 ± 0.5 mm (.24 ± .02 in) above the outside
surface of the front governor housing.
24. Assemble torque spring group (47) in the correct sequence, and install it on the block.
13/18
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To avoid possible personal injury and damage to the engine when front
governor housing (48) is installed on the fuel injection pump housing,
make sure the flange on bolt (45) is behind the shield of the dashpot. If
the flange on the bolt is installed on the wrong side of the shield, the
riser in the governor will be held in the maximum fuel delivery position.
25. Install the gasket and front governor housing (48) on the fuel injection pump housing. Make
sure the flange on bolt (45) is behind the shield of dashpot (21).
26. Check the seal on dashpot valve (51) for damage or wear, and make a replacement if
necessary.
27. Install dashpot valve (51), insulator (49), fitting (50) high idle screw (52) and the locknut in
rear governor housing (53). Tighten insulator (49) to a torque of 4.5 ± 0.5 N·m (40 ± 4.4 lb in).
28. Use Tool (D), and install seal (54) with the lip of the seal down as shown. Put clean engine oil
on the lip of the seal. Install high idle screw cover (55) and O-ring seal (56).
14/18
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29. Install the liptype seals in housing (53) with Tool (D) as shown.
30. Install the gasket and cover (57) in the governor housing.
31. Put clip (60) in position on shaft (61), and install shaft (61) into the housing through spring
(59) and lever (58). Put the key in the lever in alignment with the keyway in the shaft.
32. Install clip (62) on the shaft, and install screw (63) and the locknut on the lever. Put the end of
the spring in position in the notch in the housing as shown.
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33. Install screws (64) and locknuts (65) on lever assembly (66). Tighten locknuts (65) to a torque
of 1.70 ± 0.25 N·m (15 ± 3 lb in).
34. Install shaft (68) in the housing. Install long spacer (67), lever assembly (66) and the short
spacer on shaft (68).
35. Check the condition of the O-ring seal on the plug. Lubricate the O-ring seal with clean engine
oil, and install the plug to hold shaft (68) in position.
36. Install lever assembly (72) on shaft assembly (73). Be sure the alignment marks on the
components are in alignment with each other.
37. Install shaft assembly (73) into the housing. Put washer (71) and lever (74) in position on the
shaft assembly. Put key (70) in the key slot on shaft assembly (73), and install lever (69) over the
key on the shaft assembly. Align the bolt hole in lever (69) with groove (75) in the shaft assembly,
and install the bolt.
38. Install seat (76), wave washer (78), washer (79), wave washer (80) and spring (81) on guide
(77).
To avoid possible personal injury and damage to the engine when rear
governor housing (53) in installed on the fuel injection pump housing,
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Caterpillar Cat 245D EXCAVATOR (Prefix 7ZJ) Service Repair Manual (7ZJ00001 and up).pdf

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