Caterpillar Cat E450 EXCAVATOR (Prefix 3HG) Service Repair Manual (3HG00001 and up).pdf

Service Repair Manual
Models
E450 EXCAVATOR

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Product: EXCAVATOR
Model: E450 EXCAVATOR 3HG
Configuration: E450 TRACK-TYPE EXCAVATOR 3HG00001-UP (MACHINE) POWERED BY 6D22-TC ENGINE
General Service Information
E450 EXCAVATOR TRAVEL MOTOR
Media Number -SENR4471-00 Publication Date -01/04/1988 Date Updated -11/10/2001
4. Disassembly
4-1 Preparation
Make the following preparations prior to disassembly:
(1) Workbench with vise
The workbench must have enough space to palce and hold parts during work. Soft jaws are needed
for the vise.
(2) Tools and supplies
Prepare the tools and supplies shown in 3-2.
4-2 General Precautions
(1) Use care in handling precision made parts during work to avoid damage caused by striking
other parts or by being dropped.
(2) Never strike or prize parts forcibly when they are held fast, so as to prevent damage, burring,
oil leakage or lowered performance. Use care and patience.
(3) Protect parts from corrosion and dust when disassembly is interrupted for some time. Parts rust
easily due to moisture or dust when left disassembled.
4-3 Disassembly Procedure
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(1) Disassembly of travel motor
1. Remove the VP plug from the casing with a socket and a torque wrench to discharge the
residual oil from the casing and the cylinder.
Use an oil container with 2l (0.5 gal) or more capacity to catch the oil.
2. Remove the O-ring from the VP plug.
3. Remove two hexagon bolts positioned symmetrically with a socket and a torque wrench.
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4. Run the eyebolts (M12) into the bolt holes from which the two bolts were removed in above
step and hoist the motor using a wire rope and a crane.
5. Clean the outer circumference of the travel motor with kerosene, then dry by compressed air.
Cover all ports with shipping plugs and tapes.
6. Lower the travel motor to a workbench with the output shaft coming on bottom. Then remove
the eyebolts.
7. Remove the selector valve assembly from the motor by removing the hexagon socket bolts with
a hexagon wrench.
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8. Remove the brake cover by removing the eight bolts with a socket wrench.
* Since the brake cover will be pushed up by the brake spring force when the bolts are removed,
use care and loosen evenly.* First loosen 4 bolts shown with shadow, then loosen the remaining 4
little by little.
9. Remove the O-ring from the brake cover.
* Do not reuse the O-ring removed.
10. Pull out the brake springs from the brake piston.
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11. Remove the brake piston from the valve cover.
Take out the brake piston straight to ease its removal.
12. Remove the piston rings from the brake piston.
Removal of the piston rings is not necessary if no damage or scratch is found on their
circumferences.
13. Remove the retaining ring from the shaft using a snapring pliers.
14. Remove the spline coupling from the shaft.
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15. Remove the friction plates and the separator plates from the valve cover.
16. Remove the brake shim from the valve cover.
17. Remove the remaining retaining ring from the shaft using a snapring pliers.
Check the brake spacer for any abnormality. Unless abnormality is found on the brake spacer, its
removal is not necessary.
18. Remove the orifice from the valve cover using a hexagon wrench.
Removal of the orifice is not necessary unless any abnormality is found in function of negative
brake.
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19. Screw a bolt (M6) into the seal bushing then take it out from the valve cover.
Removal of the seal bushing is not necessary unless any abnormality is found in the function of
the pressure release valve.
20. Remove the O-ring from the seal bushing.
Do not reuse the O-ring removed.
21. Remove the spool and the spring from the valve cover using a tweezers.
Removal of the spool and the spring is not necessary unless any abnormality is found in function
of the pressure release valve.
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22. Photo at the left shows press fitting of pressure relief valve parts using a hand hammer and
steel angle.
Since the spring guide is press-fitted in bushing, which is further pressed into the valve cover,
disassembly is not possible.
23. Remove the plug from the valve cover using a hexagon wrench.
Removal of the plug is not necessary unless any abnormality is found in the function of the high
pressure selector valve.
24. Remove the O-ring from the plug
1) Since the stopper, ball and seat for the high pressure selector valve are press-fitted in the valve
cover, removal of these parts is not possible.
2) See REASSEMBLY PROCEDURE for construction of high pressure selector valve.
3) Obviously, this step is not necessary if step (23) is not done.
25. Remove the hexagon socket bolts from the valve cover using a hexagon wrench.
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26. Run the eyebolts (M12) into the bolt holes in the valve cover.
27. Fasten a wire rope to the eyebolts and lift the valve cover off the casing using a crane.
If the valve plate comes out integral with the valve cover due to tight-fit to the valve cover, use
care not to drop the valve plate when operating the crane. Also, slowly lower the valve cover to a
workbench not to scratch the sliding surface of the valve plate.
28. Lower the valve cover to a workbench with its front side coming on top.
29. Remove the O-ring from the valve cover.
Do not reuse the O-ring removed.
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30. Remove the O-rings from the casing.
31. Remove the valve plate from the cylinder.
1) To ease removal, insert the tip of a screwdriver into the clearance between the valve plate and
the cylinder then lightly prize it for separating.
2) When prizing with a screwdriver, use care not to scratch the sliding surfaces.
32. Reposition the remaining whole work horizontally.
Use the eyebolts run into the holes in the casing when repositioning.
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33. Remove the cylinder straight complete with the piston and shoe assemblies, the set plate and
the retainer from the shaft.
Use care not to damage the piston assemblies, set plate and retainer.
34. Remove the set plate and piston and shoe assemblies from the cylinder.
35. Remove the piston and shoe assemblies from the set plate.
36. Remove the retainer from the cylinder.
37. Remove the disc springs and spring shim from the retainer.
If no defect is noticed, reinstall the disc springs and the shim in the retainer.
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38. Reposition the remaining whole work with the front casing side coming on top.
Remove the hexagon socket bolts with a hexagon wrench.
39. Remove the front cover by running two hexagon socket bolts into the tapped holes for removal
in the front casing.
Be sure to evenly tighten the two bolts. Failure to do so could incline the front cover, resulting in
difficulty in its removal.
40. Remove the O-ring from the front cover.
41. Place a circular plate on the oil seal then remove the oil seal from the front cover using a press.
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1) A circular plate may be hit with a hammer if a press is not available.
2) Do not reuse the oil seal removed.
42. Remove the shaft from the casing, keeping it true.
Lightly tap the end surface of the shaft from the opposite side with a plastic-faced hammer for
removing the shaft.
43. Reposition the casing with the rear side coming on top.
Use the eyebolts when repositioning.
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44. Remove the plug from the casing using a hexagon wrench.
45. Remove the O-ring from the plug.
46. Remove the stopper from the casing.
For removing the stopper, put both hands in the casing, catch the inclined area of the stopper, raise
a bit then take it out straight from the casing.
47. Remove the swash plate from the casing.
1) When removing, keep the swash plate in an oblique position.
2) Use care not to scratch the inner surface of the casing.
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48. Remove the conrod L, tilting piston and spring from the front casing.
49. Remove the conrod S, tilting piston and spring from the front casing.
50. Turn the casing upside down with the front side coming on top.
51. Remove the hexagon socket bolts using a hexagon wrench.
52. Remove the front casing from the casing.
If the front casing can not be removed easily, lightly tap the periphery of the front casing with a
plastic-faced hammer.
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53. Remove the O-ring from the front casing.
54. Remove the O-rings from the casing.
(2) Disassembly of bearing
Check the bearings for abnormality before disassembly. Unless any abnormality is noticed,
disassembly is not necessary.
Check points;
* Inner races and rollers of needle bearings for flaking or surface roughness.* Abnormal noise
when rotating the outer race of ball bearing or flaking on ball surfaces.
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1. Remove the retaining ring from the shaft with a snapring pliers.
2. Since the ball bearing and needle bearings are shrink-fitted on the shaft and a bearing puller
cannot be installed, removal of these bearings is not possible. If defective, replace as a
combination with the shaft.
3. When a bearing must be removed from the shaft, using a grinder, make a slit in the inner race of
the bearing so that catches of a bearing puller are installed.
4. Remove the outer race of the needle bearing from the front casing using a hand hammer and a
steel angle.
5. Remove the locking ring from the valve cover using a snapring pliers.
1) Removal of the remaining needle bearing is not necessary unless any defect is noticed.
2) The oil seal must be removed before removing the locking ring from the valve cover.
6. If defective, remove the needle bearing from the valve cover using an oil seal installer, steel
angle and hand hammer.
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Caterpillar Cat E450 EXCAVATOR (Prefix 3HG) Service Repair Manual (3HG00001 and up).pdf

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