Caterpillar cat el240 hydraulic excavator (prefix 1 fg) service repair manual (1fg00001 and up)

Service Repair Manual
Models
E240, EL240 HYDRAULIC
EXCAVATOR

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Product: EXCAVATOR
Model: E240 EXCAVATOR 1FG
Configuration: E240, EL240 HYDRAULIC EXCAVATORS 1FG00001-UP (MACHINE) POWERED BY 3304 ENGINE
General Service Information
E180, EL180, E240, EL240, E240B & EL240B EXCAVATORS IDLER WH
Media Number -SENR4825-00 Publication Date -01/09/1989 Date Updated -11/10/2001
Disassembly
Preparation
Make the following preparations prior to disassembly:
1. Workbench
The workbench must have enough space to place and hold parts during work. Soft jaws are needed
for the vise.
2. Tools and supplies
Prepare the tools and supplies shown in SERVICING.
General Precautions
1. Use care in handling precision-made parts during work to avoid damage caused by striking
other parts or from being dropped.
2. Never strike or prize parts forcibly even if 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.
Disassembly Procedures
1/4E240, EL240 HYDRAULIC EXCAVATORS 1FG00001-UP (MACHINE) POWERE...
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1. Clean idler wheel with steam cleaner.
2. Remove tapered plug (1) from bearing (3) with a ratchet handle and hexagon socket.
3. Drain engine oil from the idler wheel.
4. Remove spring pin (2) from bearing (3) with a press and a pushing rod and discard it.
NOTE: Do not reuse spring pin (2).
5. Remove bearing (3) from shaft (8).
6. Fasten a hoist to bearing (3), and remove bearing (3) complete with shaft (8) from wheel (6).
7. Remove spring pin (2) from bearing (3) with a pushing rod and a press and discard it.

8. Remove shaft (8) from bearing (3).
9. Remove O-ring (7) from shaft (8).
10. Remove floating seal (4) from wheel (6) with a spatula.
NOTE: Do not reuse floating seal (4).
11. Remove floating seal (4) from bearing (3) with a spatula.
NOTE: Do no reuse floating seal (4).
12. Remove bushing (5) from wheel (6).

NOTE: Do not reuse bushing (5). Remove bushing (5) only when badly damaged or deformed.
Cleaning, Washing
1. Wash parts in a washing sink containing kerosene.
NOTE: Soak parts in the kerosene for some time and then wash them clean. Soaking will loosen
deposits of greasy matter and dirt.
Rinsing
1. Rinse the washed parts in the rinsing sink filled with clean kerosene by gently shaking each part
in the kerosene.
2. Wipe each rinsed part with clean lint-free cloths to remove dripping kerosene.
NOTE: Direct compressed air into the oil fill port of the wheel and thoroughly dry them in a clean
place. After drying, put a small amount of engine oil on each part.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Nov 20 23:58:31 UTC+0800 2019

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Product: EXCAVATOR
Maintenance Standards

1. Idler wheel dimensions
2. Repair by build-up welding
Preheating: 150 to 250°C (302 to 482°F)
Electrodes: HF-450 or HF-500
Weld in flat position, without tilting the electrode more than 45° from the vertical.

For welding, use a symmetrical sequence build-up method. After depositing weave beads and
building up the weld metal to the desired thickness, weld along the edges.
NOTICE
Do not cool build-up welding with water quickly.
NOTE: Dry welding rod thoroughly. (Use care for humidity.)
Wed Nov 20 23:59:27 UTC+0800 2019

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Product: EXCAVATOR
Reassembly
Reassembly, as a rule, is made in reverse of disassembly.
Preparation
Prepare a workbench, tools and supplies in the same way as for servicing and disassembly.
General Precautions
1. Pay the same attention to the general disassembly precautions.
2. Check prior to reassembly to ensure that all parts are free from metal particles or forein matter,
and that parts are free from burs or scratches. Remove any burs or scratches with an oil stone.
3. As a rule, renew O-rings.
4. Use care when fitting O-rings to prevent damage. (Apply a small amount of grease to make
them smooth.)
Reassembly Procedures
1. Install bushing (5) into wheel (6) with a tool (sleeve I) and a press.
NOTE: Before installation, put a small amount of grease on outside surface of bushing (5) to ease
its installation. During installation, keep the vertical center lines through bushing (5) and wheel (6)
in alignment, and gradually and evenly push bushing (5) in not to damage bushing (5) and/or

wheel (6). Do not press bushing in all the way in one step but stop once when it goes in about 3 to
4 mm (0.118 to 0.157 in.), then realign the cores.
2. Put a small amount of engine oil on O-rings of floating seal (4).
NOTE: Use care and do not apply excessive oil which may by mistaken as oil leakage.
3. Clean bearing (3) housing with cleaning solvent.
4. Install floating seal (4) in bearing (3) with seal installer.
NOTE: After installation, check to be sure that floating seal (4) snugly seats in bearing (3).
5. Put a small amount of engine oil on O-rings (7), and install O-rings (7) on shaft (8).
6. Install shaft (8) into bearing (3).
NOTE: During installation, keep the vertical center lines through shaft (8) and bearing (3) not to
damage O-rings (7).

7. After making sure that spring pin (2) holes of bearing (3) and shaft (8) are in alignment, drive
spring pin (2) in with a hammer and pushing rod until its foremost end goes in the pin hole of shaft
(8) just a little.
NOTE: Be sure the slit of spring pin (2) is toward outside and aligned with the horizontal center
line through the wheel, as shown below.
8. Press fit spring pin (2) into bearing (3) and shaft (8) using a press.
9. Remove grease from floating seal (4) sliding surfaces with solvent.
10. Wipe floating seal (4) sliding surfaces with waste cloth.
11. Apply a coat of engine oil to floating seal (4) sliding surface.
NOTE: Do not apply engine oil excessively which may be mistaken as oil leakage.
12. Install shaft (8) into wheel (6).

13. Clean wheel (6) housing with cleaning solvent.
14. Put a small amount of engine oil on floating seal (4), and put floating seal (4) in position in
wheel (6).
NOTE: After installation, check to be sure that floating seal (4) snugly seats in wheel (6).
15. Then push floating seal (4) into wheel (6) with a seal installer.
NOTE: After installation, check to be sure that floating seal (4) snugly seats in wheel (6).
16. Install bearing (3) on shaft (8).
NOTE: During installation, keep the vertical center lines through bearing (3) and shaft (8) in
alignment not to damage O-ring (7).
To install, push bearing (3) while rocking it right and left just a little.

17. Push bearing (3) against wheel (6) with a press until spring pin holes of bearing (3) and shaft
(8) are in alignment. Drive spring pin (2) into the pin holes with a hammer and pushing rod until
its foremost end goes in the pin hole of shaft (8) just a little.
Air tightness check
18. Wind seal tape around tapered plug (1), then install tapered plug (1) in bearing (3) by
tightening with ratchet handle and hexagon socket.
19. Connect air compressor to bearing (3) oil filling port using a press.
20. Apply pressurized air and ensure that no air leaks from inside of idler wheel.

NOTE: Add pressure of 2.5 to 2.7 kgf/cm2
(35.6 to 38.4 psi) to the inside of the idler wheel
through the filler port and close the valve. After at least 30 seconds, check to be sure that the
pressure reading on the gauge has not decreased.
If decreased, it's an indication of an occurrence of abnormality. In this case, after making sure that
the air compressor is correctly installed, disassemble again and have necessary repairs made.
21. Remove tapered plug (1) from bearing (3) using ratchet handle and hexagon socket.
22. Press fit spring pin (2) into bearing (3) and shaft (8) using a press.
23. Attach plug to bearing (3) oil filling port with a spanner, then connect flexible hose of oil filler
to plug.
24. Fill idler wheel with engine oil using oil filler.
NOTE: Refill capacity;

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25. Apply Locktite #572 to tapered plug (1), then tighten tapered plug (1) to bearing (3) with a
ratchet handle and a hexagon socket.
Thu Nov 21 00:00:22 UTC+0800 2019

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Product: EXCAVATOR
Storage Standards
Storage Of Items
1. Long-term storage of items is limited to 12 months. As a rule, items stored in excess of this
must be overhauled. All seals must be replaced and all parts must be checked for rust or other
defects.
2. Store items in conditions that prevent damage to mating surfaces.
3. Put items into service only after checking for oil leakage from seals and other likely trouble
during operation if storage has been for a period of 6 to 12 months.
4. Rust-preventive treatment must be given to all items before storing.
5. Select an appropriate place to store items, such as a dry, clean place that is not exposed to the
weather or direct sunlight. Note that items will require overhauling much earlier if stored in
unsatisfactory circumstances.
Cleaning
1. Remove dust, dirt and moisture with a clean cloth. Take necessary steps to remove rust if items
gather rust.
2. Use cleaning agent (petroleum solvent) to completely remove grease.
3. Use methyl alcohol or fingerprint remover (NP-0, JIS Z1804 or equivalent) to remove finger
marks and make surface completely clean.
4. Clean by brushing or wiping with a cloth.
5. Do not attempt to clean coated parts, parts using rubber or other materials or parts affectred by
solvents.
Internal rust prevention
Fill the internal section with volatile rust preventive agent (NP-20-1 Z1806 class 1 or equivalent)
and close with polyethylene plugs to prevent rust due to sweating.

External rust prevention
Protect noncoated parts from rust as follows:
1. Apply a coat of rust preventive grease (NP-19, JIS Z1801 class 4 or equivalent) by brushing on
mating surfaces. Give an even coat of rust-preventive oil [MIL-L-644 (P-9) or equivalent] to other
parts.
2. Cover finished items with vinyl sheet or VPI paper after coating with rust preventive
compound. Store items in a well-ventilated place. Tape up covers if necessary.
3. Remove the cover and wipe off rust preventive grease with a cloth. Use a cleaning agent
unlikely to affect rubber or similar materials for removal if necessary.
Storage Of Parts
Storage of metal parts
1. Rust prevention method
Clean parts as shown in above and apply a coat of rust-preventive grease (NP-19, JIS Z1801 class
4 or equivalent) by brushing. Cover the finished parts with vinyl sheet or VPI paper after they are
coated with rust preventive compound. Tape up covers if necessary.
2. Storage method
Place antirust treated parts on shelves individually for storage. Never place parts on top of each
other for storage.
Storage of rubber parts
1. Storage method
Store O-rings and other rubber parts in a place free from exposure to direct sunlight or high
temperature [40°C (104°F) or more] to prevent deterioration.
2. Storage period
The storage period is limited to a maximum of 12 months. Do not use parts stored in excess of 12
months.
Thu Nov 21 00:01:18 UTC+0800 2019

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Product: EXCAVATOR
E180, EL180, E240, EL240, E240B, EL240B, E300 & EL300 EXCAVA
General Notes
* This machine has been designed conforming to JIS (Japanese Industrial Standard) requirements in
which all measurements are based on the metric system. And this manual, wherever practical, these
measurements are shown to the nearest fraction in feet, pound, etc., but whenever in doubt, the
metric value shown should be used.
* Numbers indicated in ( ) in this manual are the part numbers given in structural and exploded
diagrams.
* Specifications are subject to change with or without notice owing to improvements, that may be
introduced after publication of this manual.
Conversion table for metric system indications into Foot-pound units (U.S.A.)
Thu Nov 21 00:02:40 UTC+0800 2019

Caterpillar cat el240 hydraulic excavator (prefix 1 fg) service repair manual (1fg00001 and up)

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