Product: MINI HYD EXCAVATOR
Model: 303.5E2 CR MINI HYD EXCAVATOR BG8
Configuration: 303.5E 2CR Mini Hydraulic Excavator BG800001-UP (MACHINE) POWERED BY C1.7 Engine
Disassembly and Assembly
C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Bearing Clearance - Check
SMCS - 1203-535; 1219-535
Measurement Procedure
Table 1
Required Tools
Gauge (Green)
Plastic Gauge (Red)
to 0.152 mm (0.002 to 0.006 inch)
Plastic Gauge (Blue) 0.102 to 0.229 mm (0.004 to 0.009 inch)
Plastic Gauge (Yellow)
0.230 to 0.510 mm (0.009 to 0.020 inch)
Note: Refer to Specification UENR0995 "Engine Design" for non-specified engine Torque Values.
Note: Plastic gauge may not be necessary when the engine is in the chassis.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: Caterpillar does not recommend the checking of the actual bearing clearances particularly on small engines. The checking can result in the possibility of obtaining inaccurate information and the possibility of damaging the bearing or the journal surfaces. Each Caterpillar engine bearing is quality checked for specific wall thickness.
Note: The measurements should be within specifications and the correct bearings should be used. If the crankshaft journals and the bores for the block and the rods were measured during disassembly, no further checks are necessary. However, if the technician still wants to measure the bearing clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journalswith small diametersif clearancesare less than 0.10 mm (0.004 inch).
NOTICE
Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.
The technician must be careful to use Tooling (A) correctly. The following points must be remembered:
• Ensure that the backs of the bearings and the bores are clean and dry.
• Ensure that the bearing locking tabs are properly seated in the tab grooves.
• The crankshaft must be free of oil at the contact pointsof Tooling (A).
1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap.
Note: Do not allow Tooling (A) to extend over the edge of the bearing.
2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap isinstalled.
Note: Do not turn the crankshaft when Tooling (A) is installed.
3. Carefully remove the cap, but do not remove Tooling (A). Measure the width of Tooling (A) while Tooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration 1.
Illustration 1 g01152855
TypicalExample
4. Remove all of Tooling (A) before you install the bearing cap.
Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all parts of Tooling (A) are not the same width. Measure the major width in order to ensure that the parts are within the specification range. Refer to SpecificationsManual, "Connecting Rod Bearing Journal" and Specifications Manual, "Main Bearing Journal" for the correct clearances.
Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
Wed Aug 19 12:06:00 UTC+0530 2020
Product: MINI HYD EXCAVATOR
Model: 303.5E2 CR MINI HYD EXCAVATOR BG8
Configuration: 303.5E 2CR Mini Hydraulic Excavator BG800001-UP (MACHINE) POWERED BY C1.7 Engine
Disassembly and Assembly
C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -UENR0128-11 Publication Date -01/08/2015 Date Updated -09/06/2016
Camshaft - Remove and Install SMCS - 1210-010
Removal Procedure
1
A - Magnets 8
Start By:
a. Remove the rocker shaft and pushrods.
b. Remove the front housing.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1
1. Ensure that Timing Marks (Y) on the idler gear and the camshaft gear are aligned. Refer to illustration 1.
Illustration 2
2. Use a magnet to hold up the lifters in order to remove the camshaft.
Illustration 3
Do not damage the lobes or the bearings when the camshaft is removed or installed.
3. Remove bolts (2) and the washers.
4. Carefully remove camshaft (1) from the cylinder block.
Installation Procedure
1. Install camshaft (1) in the reverse order of removal.
a. Apply engine oil to threads and torque bolts (2) to 24 to 27 N·m (18.0 to 20.0 lb ft). Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
This is the sample of the manual
Click on the download link for complete Manual
Product: MINI HYD EXCAVATOR
Model: 303.5E2 CR MINI HYD EXCAVATOR BG8
Configuration: 303.5E 2CR Mini Hydraulic Excavator BG800001-UP (MACHINE) POWERED BY C1.7 Engine
Disassembly and Assembly
C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -UENR0128-11
Camshaft Gear - Remove and Install
SMCS - 1210-010-GE
Removal Procedure
Table 1
A 1P-0510 Driver Group 1
B 8B-7551 Puller Assembly 1
Start By:
a. Remove the camshaft.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and mandates.
Illustration 1
1. Use Tooling (A) in order to remove camshaft gear (1) from camshaft (2). Use Tooling (B) in order to install camshaft gear (1) onto camshaft (2).
Illustration 2
2. Remove plate (3) from camshaft (2).
3. If necessary, remove the key from the nose of the camshaft.
Installation Procedure
1. Install camshaft gear (1) in the reverse order of removal.
a. Ensure that the camshaft gear and the key are clean and free from wear and damage.
Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
Wed Aug 19 12:03:17 UTC+0530 2020
Product: MINI HYD EXCAVATOR
Model: 303.5E2 CR MINI HYD EXCAVATOR BG8
Configuration: 303.5E 2CR Mini Hydraulic Excavator BG800001-UP (MACHINE) POWERED BY C1.7 Engine
Disassembly and Assembly
C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -UENR0128-11
Publication Date -01/08/2015
Connecting Rod Bearings - Install
SMCS - 1219-012
Installation Procedure
Date Updated -09/06/2016 i05399036
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
Discard all used Connecting Rod fasteners.
1. Ensure that the bearing shells are clean and free from wear and damage. If necessary, replace the bearing shells.
1
2. Install upper bearing shell (6) into connecting rod (5) . Ensure that the locating tab for the upper bearing shell is correctly seated in the slot in connecting rod (5) .
Note: The ends of the upper bearing shell must be centered in the connecting rod. The ends of the upper bearing shell are to be positioned equally in relation to the mating faces of the connecting rod.
3. Lubricate upper bearing shell (6) with clean engine oil.
Illustration 2
4. Carefully pull connecting rod (5) against the crankshaft.
5. Clean connecting rod cap (4) . Install the lower bearing shell into connecting rod cap (4) . Ensure that the locating tab for the lower bearing shell is correctly seated in the slot in connecting rod cap (4) .
6. Lubricate the crankshaft and lubricate the lower bearing shell with clean engine oil.
7. Install connecting rod cap (4) to the connecting rod.
Note: Ensure that etched Number on connecting rod cap (4) matches etched Number on the connecting rod. Ensure the correct orientation of the connecting rod cap. The locating tab for the upper bearing shell and the lower bearing shell should be on the same side.
8. Install new bolts (3) to the connecting rod. Apply engine oil to the threads and tighten the bolts evenly to a torque of 41 to 46 N·m (30 to 34 lb ft).
3
9. Position engine oil screen (1) and install the O-ring seal and bolt (2) .
10. Repeat Step 2 through Step 8 for the remaining connecting rod bearings.
Note: If all connecting rod bearings require replacement, the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following pairs of cylinders. 1 with 4 and 2 with 3. Ensure that both pairs of the connecting rod bearings are installed before changing from one pair of cylinders to another pair of cylinders. Refer to Disassembly and Assembly, "Connecting Rod Bearings - Install" for the correct procedure.
End By: Install the engine oil pan.
Product: MINI HYD EXCAVATOR
Model: 303.5E2 CR MINI HYD EXCAVATOR BG8
Configuration: 303.5E 2CR Mini Hydraulic Excavator BG800001-UP (MACHINE) POWERED BY C1.7 Engine
Disassembly and Assembly
C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -UENR0128-11
Publication Date -01/08/2015
Connecting Rod Bearings - Remove
SMCS - 1219-011
Removal Procedure
Start By:
a. Remove the engine oil pan.
Date Updated -09/06/2016
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
Discard all used Connecting Rod fasteners.
Note: If all connecting rod bearings require replacement, the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following pairs of cylinders. 1 with 4 and 2 with 3Ensure that both pairs of the connecting rod bearings are installed before changing
from one pair of cylinders to another pair of cylinders. Refer to Disassembly and Assembly, "Connecting Rod Bearings - Install" for the correct procedure.
Illustration 1
g02720399
1. Remove bolt (2), the O-ring seal, and oil pump screen (1).
Illustration 2
g02720401
2. The connecting rod and the connecting rod cap should have an etched Number (X) on the side. The number on the connecting rod and the connecting rod cap must match. If necessary, make a temporary mark on the connecting rod and connecting rod cap (4) in order to identify the cylinder number.
3. Remove bolts (3). Remove connecting rod cap (4) from the connecting rod.
4. Carefully push connecting rod (5) into the cylinder bore until connecting rod (5) is clear of the crankshaft. Remove upper bearing shell (6) from connecting rod (5). Keep the bearing shells together.
5. Repeat Step 2 through Step 4 for the remaining bearing shells.
Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved.
Private Network For SIS Licensees. Wed Aug 19 12:04:41 UTC+0530 2020
Product: MINI HYD EXCAVATOR
Model: 303.5E2 CR MINI HYD EXCAVATOR BG8
Configuration: 303.5E 2CR Mini Hydraulic Excavator BG800001-UP (MACHINE) POWERED BY C1.7 Engine
Disassembly and Assembly
C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -UENR0128-11 Publication Date -01/08/2015 Date Updated -09/06/2016
Coolant Temperature Sensor - Remove and Install
SMCS - 1906-010
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
Care must be taken to ensure that fluidsare contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulationsand mandates.
i05243665
1. Drain the coolant from the cooling system to a level belowthe coolant temperature sensor. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct draining procedure.
Illustration 1
g02798196
2. Disconnect harnessassembly (2) from coolant temperature sensor (1).
3. Use a deep socket in order to remove coolant temperature sensor (1) from water temperature regulator (3).
Installation Procedure
1. Install coolant temperature sensor (1) in the reverse order of removal.
a. Use caution when tighten down harnessassembly (2).
Product: MINI HYD EXCAVATOR
Model: 303.5E2 CR MINI HYD EXCAVATOR BG8
Configuration: 303.5E 2CR Mini Hydraulic Excavator BG800001-UP (MACHINE) POWERED BY C1.7 Engine
Disassembly and Assembly
C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -UENR0128-11
Publication Date -01/08/2015
Crankshaft Front Seal - Install
SMCS - 1160-012
Installation Procedure
Date Updated -09/06/2016
i05243515
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: The crankshaft front seal should be installed dry. Lubricate the inner rubber portion of the crankshaft front seal.
1. Inspect the nose of the crankshaft for damage. Ensure that the crankshaft is clean and dry.
Illustration 1
2. Position a new crankshaft front seal (3). Install crankshaft front seal (3).
Illustration 2
3. Lubricate the inner rubber portion of the crankshaft front seal. Position sleeve (2) on the crankshaft and install key (1).
End By:
a. Install the crankshaft pulley. Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Wed Aug 19 12:00:10 UTC+0530 2020
Product: MINI HYD EXCAVATOR
Model: 303.5E2 CR MINI HYD EXCAVATOR BG8
Configuration: 303.5E 2CR Mini Hydraulic Excavator BG800001-UP (MACHINE) POWERED BY C1.7 Engine
Disassembly and Assembly
C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -UENR0128-11
Publication Date -01/08/2015 Date Updated -09/06/2016
Crankshaft Front Seal - Remove
SMCS - 1160-011
Removal Procedure
Start By:
a. Remove the crankshaft pulley.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and mandates.
i05243500
1
1. Remove key (1) and sleeve (2) from the crankshaft.
Illustration 2
2. Remove crankshaft front seal (3).
Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
Wed Aug 19 11:59:57 UTC+0530 2020
Product: MINI HYD EXCAVATOR
Model: 303.5E2 CR MINI HYD EXCAVATOR BG8
Configuration: 303.5E 2CR Mini Hydraulic Excavator BG800001-UP (MACHINE) POWERED BY C1.7 Engine
Disassembly and Assembly
C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -UENR0128-11
Publication Date -01/08/2015
Crankshaft Gear - Remove and Install
SMCS - 1204-010-GE
Removal Procedure
Table 1
Required Tools
Tool Part Number
Part Description Qty
A 1P-2321 Puller Assembly 1
Start By:
a. Remove the idler gear.
Date Updated -09/06/2016
i05243662
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1
1. Remove o-ring (1) and collar (2).
Illustration 2
Illustration 3
2. Use Tooling (A) in order to remove crankshaft gear (3) from crankshaft (4).
3. If necessary, remove key (5) from crankshaft (4).
Note: Do not remove the key from the crankshaft unless the key is damaged.
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
2. Install crankshaft gear (2) in the reverse order of the removal.
Note: The crankshaft gear (2) taper needs to face toward the cylinder block when installed.
1993 - 2020 Caterpillar Inc.
Product: MINI HYD EXCAVATOR
Model: 303.5E2 CR MINI HYD EXCAVATOR BG8
Configuration: 303.5E 2CR Mini Hydraulic Excavator BG800001-UP (MACHINE) POWERED BY C1.7 Engine
Disassembly and Assembly
C1.7, C1.8 and C2.4 Tier 4 Interim and EU Stage 3A Engines for Caterpillar Built Machines
Media Number -UENR0128-11 Publication Date -01/08/2015 Date Updated -09/06/2016
Crankshaft Main Bearings - Install
SMCS - 1203-012
Installation Procedure
Table 1
Required Tools
Tool
B 387-1351
C 129-1967
i05243660
Crankshaft Bearing Driver -
Multipurpose White Grease 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: Install the main bearings dry when the clearance checks are made.
Note: Install the crankshaft main bearings upper and lower halves, with the bearing tabs fitting into the notch of the crankshaft main bearing cases.
This is the sample of the manual
Click on the download link for complete Manual
1
2
1. Use Tooling (B) and install crankshaft main bearing (12) into the front of the cylinder block. Install crankshaft main bearing (12) with the seam on the right or left side of the cylinder block.
Note: When the bearing clearance is checked, and the engine is in an upright position, or on the side. The crankshaft must be supported against the upper halves of the main bearings. Procedure is done in order to get a correct measurement with Tooling (B). If the crankshaft is not supported, the weight of the crankshaft will cause an incorrect reading. If the engine is not in an upright position or on the side, is not necessary to support the crankshaft.
Note: Refer to Guideline For Reusable Parts, SEBV0544, "Engine Bearings and Crankshafts" for complete details concerning the measurement of bearing clearances.