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Product:MINIHYDEXCAVATOR
Model:305.5DMINIHYDEXCAVATORFLZ
Configuration:305.5DMiniExcavatorFLZ00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual
303.5DCR,304DCR,305DCRand305.5DCRMiniHydraulicExcavators
MediaNumber-SEBU8574-03PublicationDate-01/06/2015DateUpdated-07/03/2016
Foreword
SMCS-1000;7000
LiteratureInformation
Thismanualshouldbestoredintheoperator'scompartmentintheliteratureholderorseatback literaturestoragearea.
Thismanualcontainssafetyinformation,operationinstructions,transportationinformation, lubricationinformationandmaintenanceinformation.
Somephotographsorillustrationsinthispublicationshowdetailsorattachmentsthatcanbedifferent fromyourmachine.Guardsandcoversmighthavebeenremovedforillustrativepurposes.
Continuingimprovementandadvancementofproductdesignmighthavecausedchangestoyour machinewhicharenotincludedinthispublication.Read,studyandkeepthismanualwiththe machine.
Wheneveraquestionarisesregardingyourmachine,orthispublication,pleaseconsultyourCat dealerforthelatestavailableinformation.
Safety
Thesafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifiesthetextand locationsofwarningsignsandlabelsusedonthemachine.
Readandunderstandthebasicprecautionslistedinthesafetysectionbeforeoperatingorperforming lubrication,maintenanceandrepaironthismachine.
Operation
Theoperationsectionisareferenceforthenewoperatorandarefresherfortheexperiencedoperator. Thissectionincludesadiscussionofgauges,switches,machinecontrols,attachmentcontrols, transportationandtowinginformation.
Photographsandillustrationsguidetheoperatorthroughcorrectproceduresofchecking,starting, operatingandstoppingthemachine.
Operatingtechniquesoutlinedinthispublicationarebasic.Skillandtechniquesdevelopasthe operatorgainsknowledgeofthemachineanditscapabilities.
Maintenance
Themaintenancesectionisaguidetoequipmentcare.TheMaintenanceIntervalSchedule(MIS)lists theitemstobemaintainedataspecificserviceinterval.Itemswithoutspecificintervalsarelisted underthe"WhenRequired"serviceinterval.TheMaintenanceIntervalScheduleliststhepage numberforthestep-by-stepinstructionsrequiredtoaccomplishthescheduledmaintenance.Usethe MaintenanceIntervalScheduleasanindexor"onesafesource"forallmaintenanceprocedures.
MaintenanceIntervals
Usetheservicehourmetertodetermineservicingintervals.Calendarintervalsshown(daily,weekly, monthly,etc.)canbeusedinsteadofservicehourmeterintervalsiftheyprovidemoreconvenient servicingschedulesandapproximatetheindicatedservicehourmeterreading.Recommendedservice shouldalwaysbeperformedattheintervalthatoccursfirst.
Underextremelysevere,dustyorwetoperatingconditions,morefrequentlubricationthanisspecified inthemaintenanceintervalschartmightbenecessary.
Performserviceonitemsatmultiplesoftheoriginalrequirement.Forexample,atevery500service hoursor3months,alsoservicethoseitemslistedunderevery250servicehoursormonthlyandevery 10servicehoursordaily.
CaliforniaProposition65Warning
DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCaliforniatocause cancer,birthdefects,andotherreproductiveharm.
Batteryposts,terminalsandrelatedaccessoriescontainleadandleadcompounds.Washhandsafter handling.
CertifiedEngineMaintenance
Propermaintenanceandrepairisessentialtokeeptheengineandmachinesystemsoperating correctly.Astheheavydutyoff-roaddieselengineowner,youareresponsiblefortheperformanceof therequiredmaintenancelistedintheOwnerManual,OperationandMaintenanceManual,and ServiceManual.
Itisprohibitedforanypersonengagedinthebusinessofrepairing,servicing,selling,leasing,or tradingenginesormachinestoremove,alter,orrenderinoperativeanyemissionrelateddeviceor elementofdesigninstalledonorinanengineormachinethatisincompliancewiththeregulations (40CFRPart89).Certainelementsofthemachineandenginesuchastheexhaustsystem,fuel system,electricalsystem,intakeairsystemandcoolingsystemmaybeemissionrelatedandshould notbealteredunlessapprovedbyCaterpillar.
MachineCapacity
Additionalattachmentsormodificationsmayexceedmachinedesigncapacitywhichcanadversely affectperformancecharacteristics.Includedwouldbestabilityandsystemcertificationssuchas brakes,steering,androlloverprotectivestructures(ROPS).ContactyourCatdealerforfurther information.
CatProductIdentificationNumber
EffectiveFirstQuarter2001theCatProductIdentificationNumber(PIN)haschangedfrom8to17 characters.Inanefforttoprovideuniformequipmentidentification,Caterpillarandotherconstruction equipmentmanufacturersaremovingtocomplywiththelatestversionoftheproductidentification numberingstandard.Non-roadmachinePINsaredefinedbyISO10261.ThenewPINformatwill applytoallCatmachinesandgeneratorsets.ThePINplatesandframemarkingwilldisplaythe17 characterPIN.Thenewformatwilllooklikethefollowing:
2.MachineDescriptor(characters4-8)
3.CheckCharacter(character9)
4.MachineIndicatorSection(MIS)orProductSequenceNumber(characters10-17).Thesewere previouslyreferredtoastheSerialNumber.
MachinesandgeneratorsetsproducedbeforeFirstQuarter2001willmaintaintheir8characterPIN format.
Componentssuchasengines,transmissions,axles,etc.andworktoolswillcontinuetousean8 characterSerialNumber(S/N).
Copyright1993-2020CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
MonOct1913:17:19UTC+05302020
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Product:MINIHYDEXCAVATOR
Model:305.5DMINIHYDEXCAVATORFLZ
Configuration:305.5DMiniExcavatorFLZ00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual 303.5DCR,304DCR,305DCRand305.5DCRMiniHydraulicExcavators
MediaNumber-SEBU8574-03PublicationDate-01/06/2015DateUpdated-07/03/2016
Illustration2g01191685
Illustration3g03306679
1.Unlatchtherightaccessdoorandfullyopen.
Note:Whenopeningright-handaccessdoormakesuregasspring(1)locksintoplace.
OperationofthePushButtonReleasefortheAccessDoor
Whenclosingtheaccessdoor,onlyoperatethepush-buttonreleaseby hand.
Failuretoremovehandsfromthepush-buttonreleasebeforeclosingthe accessdoorcouldresultinpersonalinjury.
Besuretoremovehandsfromthepush-buttonreleasebeforecompletely closingtheaccessdoor.
2.Inordertoclosetheright-handaccessdoor,presspush-buttonrelease(2)inordertounlockthe gasspring.
3.Releasethepushbuttonandslowlyclosetheright-handaccessdoor.
AccessCover(Battery)
Copyright1993-2020CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
MonOct1911:46:32UTC+05302020
PreviousScreen
Product:MINIHYDEXCAVATOR
Model:305.5DMINIHYDEXCAVATORFLZ
Configuration:305.5DMiniExcavatorFLZ00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual
303.5DCR,304DCR,305DCRand305.5DCRMiniHydraulicExcavators
MediaNumber-SEBU8574-03PublicationDate-01/06/2015DateUpdated-07/03/2016 i02788833
AirConditioner/CabHeaterFilter(Recirculation)Inspect/Replace
SMCS-1054-040-A/C;1054-510-A/C
NOTICE
Anairrecirculationfilterelementpluggedwithdustwillresultin decreasedperformanceandservicelifetotheairconditionerorcab heater.
Topreventdecreasedperformance,cleanthefilterelement,as required.
Thefilterelementislocatedonthelowerrightsideofthecab.
1.Inordertoremovethefilterelement,slidethefilterelementoutward.
2.Inspectthefilterelement.Ifthefilterelementisdirty,cleanthefilterelementwithamild solutionofsoapandwarmwater.
Note:Donotuseorganicsolventsinordertocleanthefilterelement.
3.Thefilterelementmayalsobecleanedwithamaximumof200kPa(30psi)pressureair.
Note:RefertoOperationandMaintenanceManual,"GeneralHazardInformation"beforeusing pressureairtocleanthefilterelement.
4.Afteryoucleanthefilterelement,inspectthefilterelement.Ifthefilterelementisdamagedor badlycontaminated,useanewfilterelement.
5.Makesurethatthefilterelementisdry.Installthefilterelementintothefilterhousing.Make surethatthefilterelementisseatedinthebottomofthefilterhousingbeforethesystemis operated.
Copyright1993-2020CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
MonOct1911:48:31UTC+05302020
PreviousScreen
Product:MINIHYDEXCAVATOR
Model:305.5DMINIHYDEXCAVATORFLZ
Configuration:305.5DMiniExcavatorFLZ00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual
303.5DCR,304DCR,305DCRand305.5DCRMiniHydraulicExcavators
MediaNumber-SEBU8574-03PublicationDate-01/06/2015DateUpdated-07/03/2016
Battery-Clean
SMCS-1401-070
Cleanthebatterysurfacewithacleancloth.Keeptheterminalscleanandkeeptheterminalscoated withpetroleumjelly.Installthepostcoverafteryoucoattheterminalpostwithpetroleumjelly.
Copyright1993-2020CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
MonOct1911:48:45UTC+05302020
PreviousScreen
Product:MINIHYDEXCAVATOR
Model:305.5DMINIHYDEXCAVATORFLZ
Configuration:305.5DMiniExcavatorFLZ00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual
303.5DCR,304DCR,305DCRand305.5DCRMiniHydraulicExcavators
MediaNumber-SEBU8574-03PublicationDate-01/06/2015DateUpdated-07/03/2016
Battery-Recycle
SMCS-1401-561
Alwaysrecycleabattery.Neverdiscardabattery.
Alwaysreturnusedbatteriestooneofthefollowinglocations:
•Abatterysupplier
•Anauthorizedbatterycollectionfacility
•Recyclingfacility
Copyright1993-2020CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
i06543763
MonOct1911:49:01UTC+05302020
PreviousScreen
Product:MINIHYDEXCAVATOR
Model:305.5DMINIHYDEXCAVATORFLZ
Configuration:305.5DMiniExcavatorFLZ00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual
303.5DCR,304DCR,305DCRand305.5DCRMiniHydraulicExcavators
MediaNumber-SEBU8574-03PublicationDate-01/06/2015DateUpdated-07/03/2016 i01586700
BatteryHold-Down-Tighten
SMCS-7257
Tightenthehold-downsforthebatteryinordertopreventthebatteriesfrommovingduringmachine operation.
Copyright1993-2020CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
MonOct1911:49:14UTC+05302020
PreviousScreen
Product:MINIHYDEXCAVATOR
Model:305.5DMINIHYDEXCAVATORFLZ
Configuration:305.5DMiniExcavatorFLZ00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual
303.5DCR,304DCR,305DCRand305.5DCRMiniHydraulicExcavators
MediaNumber-SEBU8574-03PublicationDate-01/06/2015DateUpdated-07/03/2016
BatteryorBatteryCable-Inspect/Replace
SMCS-1401-040;1401-510;1401-561;1402-040;1402-510
Personalinjurycanresultfrombatteryfumesorexplosion. Batteriesgiveoffflammablefumesthatcanexplode.Electrolyteisan acidandcancausepersonalinjuryifitcontactstheskinoreyes.
Preventsparksnearthebatteries.Sparkscouldcausevaporstoexplode. Donotallowjumpercableendstocontacteachotherortheengine. Improperjumpercableconnectionscancauseanexplosion.
Alwayswearprotectiveglasseswhenworkingwithbatteries.
1.TurntheenginestartswitchkeytotheOFFposition.TurnalloftheswitchestotheOFF position.Removethekey.
2.Disconnectthenegativebatterycableatthebattery.
3.Disconnectthepositivebatterycableatthebattery.
4.Disconnectthebatterycablesfromthemachineifnewcablesareneeded.
5.Makenecessaryrepairsorreplacethebattery.
6.Connectthebatterycablestothemachineifthebatterycableswereremoved.
This is the sample of the manual Click on the download link for complete Manual
7.Connectthepositivebatterycableofthebattery.
8.Connectthenegativebatterycableofthebattery.
9.Installthekeyintotheenginestartswitch.
Copyright1993-2020CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
MonOct1911:49:28UTC+05302020
PreviousScreen
Product:MINIHYDEXCAVATOR
Model:305.5DMINIHYDEXCAVATORFLZ
Configuration:305.5DMiniExcavatorFLZ00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual
303.5DCR,304DCR,305DCRand305.5DCRMiniHydraulicExcavators
MediaNumber-SEBU8574-03PublicationDate-01/06/2015DateUpdated-07/03/2016
Belt-Inspect/Adjust/Replace
SMCS-1357-025;1357-040;1357-510;1397-025;1397-040;1397-510
NOTICE
TheV-beltmustbetensionedcorrectly.Failuretotensionthebelt properlycouldcausedamagetothebeltand/ortotheairconditioner compressor.
Formaximumengineperformanceandmaximumutilizationofyourengine,inspectthebeltsforwear andforcracking.Checkthebelttension.Adjustthebelttensioninordertominimizebeltslippage. Beltslippagewilldecreasethebeltlife.Beltslippagewillalsocausepoorperformanceofthe alternatorandofanydrivenequipment.
Ifnewbeltsareinstalled,recheckthebeltadjustmentafter30minutesofoperation.Iftwobeltsor morearerequiredforanapplication,replacethebeltsinbeltsets.Ifonlyonebeltofapairisreplaced, thenewbeltwillcarrymoreload.Thisisduetothefactthattheolderbeltsarestretched.The additionalloadonthenewbeltcouldcausethenewbelttobreak.
WaterPumpBelt,FanDriveBelt,andAlternatorBelt
(1)Adjustingbolt (2)Waterpumppulley (3)Alternatorpulley (4)Alternatormountingbolt (5)Belt (6)Crankshaftpulley
1.Opentheengineaccessdoor.
2.Applyapproximately98N(22lb)offorcemidwaybetweenthepulleys.
3.Measurethedeflectionofthebelt.Thebeltshoulddeflect8to11mm(5/16to7/16inch).
4.Ifthedeflectionisnotcorrect,loosenalternatormountingbolt(4)andadjustingbolt(1).Move thealternatorforwardandbackwardinordertoadjustbelt(5)tothespecifiedtension.
5.Whentheadjustmentiscorrect,tightenadjustingbolt(1)andmountingbolt(4)securely.
6.Checkthedeflectionofthebeltagain.
7.Closetheengineaccessdoor.
Note:Ifanewbeltisinstalled,checkthebeltadjustmentagainafter30minutesofengineoperation attheratedenginespeed.
AirConditionerBelt(IfEquipped)
TheV-beltmustbetensionedcorrectly.Failuretotensionthebelt properlycouldcausedamagetothebeltand/ortotheairconditioner compressor.
1.Opentheengineaccessdoor.
Illustration2g01190210 (7)Nut (8)Adjustmentbolt
2.Checkthebelttension.
Note:Tocheckthebelttension,apply98N(22lb)offorcemidwaybetweenthepulleys. Correctlyadjustedbeltswilldeflect8to11mm(5/16to7/16inch).
3.Ifthedeflectionisnotcorrect,loosennut(7).Turnadjustingbolt(8)inordertoadjustthebelt tension.
4.Adjustthebelttension.
5.Whentheadjustmentiscorrect,tightenbolt(7)toatorqueof28±7N·m(21±5lbft)and tightenbolts(8)toatorqueof28±7N·m(21±5lbft).
6.Checkthedeflectionagain.
7.Closetheengineaccessdoor.
Note:Ifanewbeltisinstalled,checkthebeltadjustmentagainafter30minutesofengineoperation attheratedspeed.
MonOct1911:49:42UTC+05302020
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Product:MINIHYDEXCAVATOR
Model:305.5DMINIHYDEXCAVATORFLZ
Configuration:305.5DMiniExcavatorFLZ00001-UP(MACHINE)POWEREDBYS4Q2TEngine
OperationandMaintenanceManual
303.5DCR,304DCR,305DCRand305.5DCRMiniHydraulicExcavators
MediaNumber-SEBU8574-03PublicationDate-01/06/2015DateUpdated-07/03/2016 i02304927
BladeLinkage-Lubricate
SMCS-6060-086
Loweralltheworktoolsandthebladetotheground. Wipeallgreasefittingsbeforelubricating.
Illustration1g00823677
1.Applylubricanttogreasefitting(2)attheheadendofthebladecylinder.Applylubricantto greasefitting(1)attherodendofthebladecylinder.
2.Applylubricanttogreasefittings(3)and(4)forthebladelinkage.
