Caterpillar Cat 245 EXCAVATOR (Prefix 95V) Service Repair Manual (95V00001-00470).pdf

Service Repair Manual
Models
245 EXCAVATOR

Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 245 EXCAVATOR 95V
Configuration: 245 EXCAVATOR 95V00001-00470 (MACHINE)
Disassembly and Assembly
3406 VEHICULAR ENGINE FOR 245 EXCAVATORS
Media Number -SENR7338-01 Publication Date -01/06/1979 Date Updated -12/10/2001
Fuel Injection Pump Housing
SMCS - 1253-15; 1253-16
Disassemble Fuel Injection Pump Housing
start by:
a) separation of governor from fuel injection pump housing
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245 EXCAVATOR 95V00001-00470 (MACHINE)(UEG0866S - 00) - Documentation
2019/10/11
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1. Remove protection caps and felt washers (1) from pumps.
2. Use wrench (A) to remove the bushings (2) that hold fuel injection pumps into housing.
Remove the seals (3).
3. Use extractor (B) to remove pumps from the pump housing.
NOTE: Fuel injection pumps for direct injection and precombustion chamber engines are similar.
See Illustration A96047X1 on Page 38.
4. Remove the bonnet (4), ring (5), spring (6), and check valve (7) from barrel (8).
5. Remove the plunger assembly (11), washer (10), and spring (9) from barrel.
NOTICE
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Be careful not to cause damage to plunger assemblies. Keep same
cylinder pump and plunger together, the plunger from one pump
cannot be installed in another pump.
6. Remove the rack (12) from the housing.
7. Remove the spacers (13) and the lifters (14) from the housing.
NOTE: Keep the spacers and lifters together with identification as to their location in the pump
housing.
8. Remove two bolts (16), lock, and two sleeves from the gear assembly.
9. Remove the gear assembly (15) from camshaft.
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10. Remove two bolts, plate (17), and spacer that hold camshaft in position in pump housing.
11. Remove the camshaft from the pump housing.
12. Use tool group (C) to remove the camshaft bearings from the pump housing.
13. Remove the bearings for fuel rack from the pump housing.
Assemble Fuel Injection Pump Housing
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1. Use tool group (C) to install the camshaft bearings in fuel injection pump housing. Install
bearing in governor end of housing so oil hole in bearing is in alignment with oil hole in housing.
2. Use tooling (F) to install bearing with a groove for the rack.
3. Use tooling (E) to install the other bearing for the rack.
4. Put clean engine oil on the camshaft. Install the camshaft in the pump housing.
5. Install the spacer, plate (1), and two bolts that hold camshaft in place in pump housing.
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6. Put the gear assembly (2) in position on end of camshaft. Be sure the rod (3) is in the groove of
camshaft.
7. Install the sleeves (4), lock, and two bolts on the gear assembly.
8. Install the spacers (5) with their respective lifters (6) in pump housing. If new lifters and/or
pumps are to be installed, make adjustment of fuel pump timing dimension. See SETTING THE
INJECTION PUMP TIMING DIMENSION: OFF ENGINE in 3406 VEHICLE ENGINE,
TESTING AND ADJUSTING.
9. Install the rack (7) in the pump housing.
10. Assemble the fuel injection pumps as follows:
a) Put clean fuel on all parts.
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b) Install spring, washers, and plunger in the barrel.
c) Install the spring, check valve, bonnet, and ring on the barrel.
NOTICE
The plunger from one pump can not be installed in another pump. Do
not install the pumps until rack (7) is in center position (centered).
11. Use pointer group (D) to put rack (7) in center position. Push the rack into pointer (D) to get
the center position.
NOTE: The rack will be extended .156 in. (3.963 mm) from the end of pump housing (opposite
the governor) when rack is in center position.
12. Install fuel injection pumps with extractor (B). Turn the camshaft until lobe of camshaft is
down on pump to be installed. Look down the pump and make grooves in bonnet and barrel in
alignment with groove (slot) in the pump gear. The groove (slot) of gear must be in line with
center of these grooves. Put the pump so grooves are in alignment with guide pins in housing
bores. Install the pump in its respective bore in housing.
13. Install seal (8) and bushing (9). Put pressure by hand to extractor (B). Tighten bushing by hand
(finger tight only) until bushing is even with top of housing. If bushing can not be installed by
hand, remove bushing and pump. Make grooves in alignment and install again.
NOTICE
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Do not put force on bushings by installation with a wrench to make it
even with pump housing. Pump is not installed correctly if force has to
be used to install bushing.
14. Check the rack movement (travel) after each pump is installed. Total rack movement (travel)
must be .800 in. (20.32 mm). See INSTALLATION OF INJECTION PUMPS in 3406 VEHICLE
ENGINE, TESTING AND ADJUSTING.
15. Tighten the bushing with wrench (A) to a torque of 150 ± 10 lb.ft. (205 ± 14 N·m). Remove
wrench (A) and install felt seals and protection caps.
end by:
a) connection of governor to fuel injection pump housing.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Oct 11 23:51:04 UTC+0800 2019
8/8
2019/10/11

Shutdown SIS
Previous Screen
Product: EXCAVATOR
Inlet Manifold (Precombustion Chamber)
SMCS - 1058-11; 1058-12
Remove Inlet Manifold (Precombustion Chamber)
1. Disconnect the air line from the precleaner to the muffler.
2. Loosen clamp (1). Move the precleaner up and clear of the elbow (4).
3. Remove bolts (2). Loosen clamp (3). Remove elbow (4).
4. Remove bolts (6) that hold the elbow to the inlet manifold.
5. Disconnect line (8) for the fuel ratio control.
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6. Remove bolts (7) that hold the inlet manifold to the cylinder head.
7. Remove inlet manifold (5) and the gaskets.
Install Inlet Manifold (Precombustion Chamber)
1. Put the gaskets and inlet manifold (1) in position on the cylinder head. Install the bolts that hold
it.
2. Install the bolts that hold elbow (2) to the inlet manifold.
3. Connect line (3) for the fuel ratio control to the inlet manifold.
4. Put the elbow for the air cleaner inlet in position on the inlet manifold and air cleaner housing.
Install the bolts that hold the elbow to the inlet manifold. Tighten the clamp that holds it to the air
cleaner housing.
5. Put the precleaner in position on the elbow. Tighten the clamp that holds it.
6. Connect the air line from the precleaner to the muffler.
Fri Oct 11 23:52:00 UTC+0800 2019
2/2
2019/10/11

Shutdown SIS
Previous Screen
Product: EXCAVATOR
Aftercooler (Direct Injection)
SMCS - 1063-11; 1063-12
Remove Aftercooler (Direct Injection)
NOTE: Engine is removed from the machine for photo purposes only.
1. Remove the hood section over the aftercooler.
2. Drain the coolant to a level below the aftercooler.
3. Loosen clamp (1). Disconnect the hose from the precleaner.
4. Remove bolts (2) and spacers that hold the elbow to the aftercooler housing.
5. Loosen clamp (3). Remove elbow (4) and precleaner from the engine as a unit.
6. Remove bolts (5). Pull fuel filter base (6) and filter (7) clear of the aftercooler housing.
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7. Remove bolt (9) and washer that hold the pipe in the turbocharger.
8. Remove bolts (12), nuts and washer. Remove cover (10) and tube from the aftercooler cover.
9. Remove pipe (11) and adapter (8) from the engine as a unit.
10. Remove bolts (13). Remove elbow (14) from the end of the aftercooler housing and the elbow.
11. Remove adapters (15) and (16) from the aftercooler core.
12. Remove bolts (17). Remove elbow (18) from the opposite end of the aftercooler housing.
13. Remove adapters (19) and (20) from the aftercooler core.
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14. Remove bolts (22) that hold the cover to the housing. Remove cover (21).
15. Remove aftercooler core (23) from the housing.
16. Remove bolts (25) that hold the aftercooler housing to the cylinder head. Remove aftercooler
housing (24).
Install Aftercooler (Direct Injection)
1. Check all O-ring seals for wear or damage. If necessary, make a replacement. Put a small
amount of clean SAE 30 oil on the O-ring seals before assembly.
2. Install aftercooler housing (1) on the cylinder head.
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3. Install gasket (3) on the housing. Install aftercooler core (2) in the housing.
4. Install gasket (5) on the aftercooler core. Install cover (4) on the housing.
5. Install adapters (6) and (7) in the aftercooler core.
6. Install elbow (8) on the housing and elbow.
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7. Install adapters (9) and (10) on the other end of the aftercooler core.
8. Install elbow (11) on the housing and elbow.
9. Check O-ring seals (14) for wear or damage. If necessary, make a replacement. Put clean SAE
30 oil on the O-ring seals.
10. Put pipe (12) and adapter (13) in position on the turbocharger and aftercooler housing. Install
the bolt and washer in the turbocharger.
11. Put the cover and tube in position on the housing. Install the bolts, nuts and washer that hold
the adapter and cover to the aftercooler housing.
12. Put fuel filter base (15) and fuel filter (16) in position on the aftercooler cover. Install the bolts
and spacers that hold it.
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13. Put elbow (19) and precleaner in position on the cover and hose (18). Install the bolts and
spacers that hold the elbow to the aftercooler cover. Tighten the clamp on hose (18).
14. Connect hose (17) to the precleaner. Tighten the clamp that holds it.
15. Install the hood section over the aftercooler.
16. Fill the cooling system with coolant to the correct level. See LUBRICATION AND
MAINTENANCE GUIDE.
Fri Oct 11 23:52:56 UTC+0800 2019
6/6
2019/10/11

Shutdown SIS
Previous Screen
Product: EXCAVATOR
Air Cleaner Housing
SMCS - 1051-11; 1051-12
Remove Air Cleaner Housing
1. Loosen the clamps (4). Slide the hose off of the air cleaner housing.
2. Loosen the two rods (1) and remove the cup. Remove the primary element (3).
3. Remove the nuts (5) and the two bolts. Remove the air cleaner housing (2) and the gasket.
Install Air Cleaner Housing
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1. Put the gasket and air cleaner housing (1) in position on the pipe. Install the nuts and two bolts
that hold the housing.
2. Install the primary element in the housing. Put the cup in position on the housing. Tighten two
rods (2) that hold it.
3. Slide the hose (3) into position on the air cleaner housing. Tighten the clamps that hold it.
Fri Oct 11 23:53:51 UTC+0800 2019
2/2
2019/10/11

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Shutdown SIS
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Product: EXCAVATOR
Water Temperature Regulator
SMCS - 1355-11; 1355-12
Remove Water Temperature Regulator
1. Drain the coolant from the cooling system to a level below the water temperature regulator.
2. Loosen the clamps that hold hose (1) to the housing for the water temperature regulator. Slide
the hose away from the housing.
3. Remove bolts (2) that hold elbow (3) to the housing for the water temperature regulator. Turn
elbow (3) away from the housing.
4. Remove bolts (4) that hold the housing for the water temperature regulator to the head.
5. Remove housing (5). Remove water temperature regulator (6). Remove the gasket from the
housing.
6. Remove the seal from the housing.
1/2
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Install Water Temperature Regulator
1. Install the seal in the water temperature regulator housing with tooling (A). Install the seal with
the lip away from the regulator.
2. Put clean engine oil on the lip of the seal. Install a new gasket on the housing.
3. Install the water temperature regulator in the housing.
4. Install water temperature regulator housing (2) on the cylinder head. Install the bolts that hold
it.
5. Turn the elbow into position on the housing. Install the bolts that hold it to the housing.
6. Install the hose (1) on the housing and tighten the clamps that hold it.
7. Fill the cooling system to the correct level.
Fri Oct 11 23:54:47 UTC+0800 2019
2/2
2019/10/11

Shutdown SIS
Previous Screen
Product: EXCAVATOR
Water Pump
SMCS - 1306-11; 1361-15; 1361-16; 1361-12
Remove Water Pump
start by:
a) remove engine oil cooler
1. Remove the clamps that hold breather tube (1) to the valve cover and the cylinder block.
Remove breather tube (1).
2. Remove the bolts that hold elbow (2) to the water temperature regulator housing. Remove
elbow (2).
3. Disconnect heater hose (4) from the water pump.
4. Loosen the clamps that hold hose (5) to the water pump. Slide hose (5) away from the pump.
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5. See the illustration for the correct location of the bolts that hold the water pump to the timing
gear plate. The bolts that have identification (X) only must be removed to remove the water pump.
6. Remove water pump (3). Remove the gasket from the timing gear plate.
Install Water Pump
1. Put the water pump (1) and a new gasket in position on the timing gear plate. Install the bolts
(4) that hold it in position.
2. Put clean SAE 30 oil on the O-ring seals on elbow (2). Put elbow (2) in position on the water
pump. Install the bolts that hold it to the water temperature regulator housing.
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3. Connect heater hose (5) to water pump.
4. Slide hose (6) into position on the water pump. Tighten the clamps that hold it.
5. Put breather tube (3) in position. Install the clamps that hold the breather tube to the valve cover
and cylinder block.
end by:
a) install engine oil cooler
Disassemble Water Pump
start by:
a) remove water pump
1. Remove bolts (1). Remove cover (2) from the water pump.
2. Remove O-ring seal (3) from the adapter.
3. Remove adapter (4) from the housing. Remove the O-ring seal from the outside diameter of the
adapter.
4. Remove bolt and retainer that hold the impeller on the shaft.
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2019/10/11

Caterpillar Cat 245 EXCAVATOR (Prefix 95V) Service Repair Manual (95V00001-00470).pdf

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