305 Caterpillar Mini Hyd Excavator Operation and Maintenance Manual by quality service repair manual

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Product:MINIHYDEXCAVATOR

Model:305MINIHYDEXCAVATORDGT

Configuration:305CRMiniHydraulicExcavatorDGT00001-UP(MACHINE)POWEREDBYK4NEngine

OperationandMaintenanceManual

305CRMiniHydraulicExcavator

MediaNumber-SEBU7428-11PublicationDate-01/08/2007DateUpdated-13/08/2007

Foreword

SMCS-7606

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

s00037320

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).

FriOct909:36:39UTC+05302020

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Product:MINIHYDEXCAVATOR

Model:305MINIHYDEXCAVATORDGT

Configuration:305CRMiniHydraulicExcavatorDGT00001-UP(MACHINE)POWEREDBYK4NEngine

OperationandMaintenanceManual

305CRMiniHydraulicExcavator

MediaNumber-SEBU7428-11PublicationDate-01/08/2007DateUpdated-13/08/2007

AccessDoorandCoverLocations

i01805832

AllRightsReserved.

PrivateNetworkForSISLicensees.

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Product:MINIHYDEXCAVATOR

Model:305MINIHYDEXCAVATORDGT

Configuration:305CRMiniHydraulicExcavatorDGT00001-UP(MACHINE)POWEREDBYK4NEngine

OperationandMaintenanceManual

305CRMiniHydraulicExcavator

MediaNumber-SEBU7428-11PublicationDate-01/08/2007DateUpdated-13/08/2007

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.

FriOct910:14:47UTC+05302020

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Product:MINIHYDEXCAVATOR

Model:305MINIHYDEXCAVATORDGT

Configuration:305CRMiniHydraulicExcavatorDGT00001-UP(MACHINE)POWEREDBYK4NEngine

OperationandMaintenanceManual

MediaNumber-SEBU7428-11PublicationDate-01/08/2007DateUpdated-13/08/2007

Battery-Clean

SMCS-1401-070

i01586674

Cleanthebatterysurfacewithacleancloth.Keeptheterminalscleanandkeeptheterminalscoated withpetroleumjelly.Installthepostcoverafteryoucoattheterminalpostwithpetroleumjelly.

FriOct910:15:04UTC+05302020

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Product:MINIHYDEXCAVATOR

Model:305MINIHYDEXCAVATORDGT

Configuration:305CRMiniHydraulicExcavatorDGT00001-UP(MACHINE)POWEREDBYK4NEngine

OperationandMaintenanceManual

305CRMiniHydraulicExcavator

MediaNumber-SEBU7428-11PublicationDate-01/08/2007DateUpdated-13/08/2007

Battery-Recycle

SMCS-1401-561

Alwaysrecycleabattery.Neverdiscardabattery.

Alwaysreturnusedbatteriestooneofthefollowinglocations:

•Abatterysupplier

•Anauthorizedbatterycollectionfacility

•Recyclingfacility

i06543763

FriOct910:15:18UTC+05302020

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Product:MINIHYDEXCAVATOR

Model:305MINIHYDEXCAVATORDGT

Configuration:305CRMiniHydraulicExcavatorDGT00001-UP(MACHINE)POWEREDBYK4NEngine

OperationandMaintenanceManual

305CRMiniHydraulicExcavator

MediaNumber-SEBU7428-11PublicationDate-01/08/2007DateUpdated-13/08/2007

BatteryHold-Down-Tighten

SMCS-7257

i01586700

Tightenthehold-downsforthebatteryinordertopreventthebatteriesfrommovingduringmachine operation.

FriOct910:15:37UTC+05302020

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Product:MINIHYDEXCAVATOR

Model:305MINIHYDEXCAVATORDGT

Configuration:305CRMiniHydraulicExcavatorDGT00001-UP(MACHINE)POWEREDBYK4NEngine

OperationandMaintenanceManual

305CRMiniHydraulicExcavator

MediaNumber-SEBU7428-11PublicationDate-01/08/2007DateUpdated-13/08/2007

BatteryorBatteryCable-Inspect/Replace

SMCS-1401-040;1401-510;1401-561;1401;1402-510;1402-040

Personalinjurycanresultfrombatteryfumesorexplosion.

Batteriesgiveoffflammablefumesthatcanexplode.Electrolyteisan acidandcancausepersonalinjuryifitcontactstheskinoreyes.

Preventsparksnearthebatteries.Sparkscouldcausevaporstoexplode. Donotallowjumpercableendstocontacteachotherortheengine. Improperjumpercableconnectionscancauseanexplosion.

Alwayswearprotectiveglasseswhenworkingwithbatteries.

1.TurntheenginestartswitchkeytotheOFFposition.TurnalloftheswitchestotheOFF position.Removethekey.

2.Disconnectthenegativebatterycableatthebattery.

3.Disconnectthepositivebatterycableatthebattery.

4.Disconnectthebatterycablesfromthemachineifnewcablesareneeded.

5.Makenecessaryrepairsorreplacethebattery.

6.Connectthebatterycablestothemachineifthebatterycableswereremoved.

i01999587

This is the sample of the manual Click on the download link for complete Manual

7.Connectthepositivebatterycableofthebattery.

8.Connectthenegativebatterycableofthebattery.

9.Installthekeyintotheenginestartswitch.

FriOct910:15:50UTC+05302020

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Product:MINIHYDEXCAVATOR

Model:305MINIHYDEXCAVATORDGT

Configuration:305CRMiniHydraulicExcavatorDGT00001-UP(MACHINE)POWEREDBYK4NEngine

OperationandMaintenanceManual

305CRMiniHydraulicExcavator

MediaNumber-SEBU7428-11PublicationDate-01/08/2007DateUpdated-13/08/2007

Belt-Inspect/Adjust/Replace

SMCS-1357-025;1357-040;1357-510;1397-510;1397-025;1397-040

NOTICE

TheV-beltmustbetensionedcorrectly.Failuretotensionthebelt properlycouldcausedamagetothebeltand/ortotheairconditioner compressor.

i02000593

Yourenginecanbeequippedwithawaterpump,withafandrive,andwithanalternator.Yourengine canalsobeequippedwithaccessorydrivebelts.Formaximumengineperformanceandmaximum utilizationofyourengine,inspectthebeltsforwearandforcracking.Checkthebelttension.Adjust thebelttensioninordertominimizebeltslippage.Beltslippagewilldecreasethebeltlife.Belt slippagewillalsocausepoorperformanceofthealternatorandofanydrivenequipment.

Ifnewbeltsareinstalled,recheckthebeltadjustmentafter30minutesofoperation.Iftwobeltsor morearerequiredforanapplication,replacethebeltsinbeltsets.Ifonlyonebeltofapairisreplaced, thenewbeltwillcarrymoreload.Thisisduetothefactthattheolderbeltsarestretched.The additionalloadonthenewbeltcouldcausethenewbelttobreak.

WaterPumpBelt,FanDriveBelt,andAlternatorBelt

Illustration1g00823546

(1)Adjustingbolt (2)Waterpumppulley

(3)Alternatorpulley

(4)Alternatormountingbolt (5)Belt

(6)Crankshaftpulley

1.Opentheenginehood.

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.

Note:Ifanewbeltisinstalled,checkthebeltadjustmentagainafter30minutesofengine operationattheratedenginespeed.

AirConditionerBelt(IfEquipped)

TheV-beltmustbetensionedcorrectly.Failuretotensionthebelt properlycouldcausedamagetothebeltand/ortotheairconditioner compressor.

(7)Adjustmentbolt (8)Bolt

1.Checkthebelttension.

Note:Tocheckthebelttension,apply98N(22lb)offorcemidwaybetweenthepulleys. Correctlyadjustedbeltswilldeflect8to11mm(5/16to7/16inch).

2.Ifthedeflectionisnotcorrect,loosenadjustmentbolt(7)andbolts(8).

3.Adjustthebelttension.

4.Whentheadjustmentiscorrect,tightenbolt(7)toatorqueof28±7N·m(20.7±5.2lbft)and tightenbolts(8)toatorqueof28±7N·m(20.7±5.2lbft).

5.Checkthedeflectionagain.

Note:Ifanewbeltisinstalled,checkthebeltadjustmentagainafter30minutesofengine operationattheratedspeed.

FriOct910:16:05UTC+05302020

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Product:MINIHYDEXCAVATOR

Model:305MINIHYDEXCAVATORDGT

Configuration:305CRMiniHydraulicExcavatorDGT00001-UP(MACHINE)POWEREDBYK4NEngine

OperationandMaintenanceManual

305CRMiniHydraulicExcavator

MediaNumber-SEBU7428-11PublicationDate-01/08/2007DateUpdated-13/08/2007

BladeLinkage-Lubricate

SMCS-6060-086-KL

Loweralltheworktoolsandthebladetotheground. Wipeallgreasefittingsbeforelubricating.

Illustration1g00823677

i02304927

1.Applylubricanttogreasefitting(2)attheheadendofthebladecylinder.Applylubricantto greasefitting(1)attherodendofthebladecylinder.

2.Applylubricanttogreasefittings(3)and(4)forthebladelinkage.

AngleBlade(IfEquipped)

Illustration2g01154347

1.Applylubricanttogreasefitting(2)attheheadendofthebladecylinder.Applylubricantto greasefitting(1)attherodendofthebladecylinder.

2.Applylubricanttogreasefittings(3)and(4)forthebladelinkage.Applylubricanttogrease fittings(5)forthecenterpinoftheangleblade.

3.Applylubricanttogreasefitting(6)attheheadendofthecylinderoftheangleblade.Apply lubricanttogreasefitting(7)attherodendofthecylinderoftheangleblade.

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Product:MINIHYDEXCAVATOR

Model:305MINIHYDEXCAVATORDGT

Configuration:305CRMiniHydraulicExcavatorDGT00001-UP(MACHINE)POWEREDBYK4NEngine

OperationandMaintenanceManual

305CRMiniHydraulicExcavator

MediaNumber-SEBU7428-11PublicationDate-01/08/2007DateUpdated-13/08/2007

BoomandStickLinkage-Lubricate

SMCS-6501-086;6502-086

Note:Caterpillarrecommendstheuseof5P-0960MolybdenumGreaseforlubricatingtheboom, stickandbucketcontrollinkage.RefertoSpecialPublication,SEBU6250,"CaterpillarMachine FluidsRecommendations"formoreinformationonmolybdenumgrease.

Applylubricantthroughallfittingsafteroperationunderwater.

Wipeallfittingsbeforeyouapplylubricant.

i01587195

1.Applylubricantthroughthefittingsattheswingpost.

Illustration2g00823727

2.Applylubricantthroughthefittingatthebaseoftheboom.

Illustration3g00823729

3.Applylubricantthroughthefittingattheboomcylinderheadend.

Illustration4g00823733

4.Applylubricantthroughthefittingattherodendoftheboomcylinder.

Illustration5g00823737

5.Applylubricantthroughthefittingatthestickcylinderhead.

6.Applylubricantthroughthefollowingfittings:

(1)Thefittingthatislocatedbetweentheboomandthestick.

(2)Thefittingthatislocatedatthestickcylinderrodend.

(3)Thefittingthatislocatedatthebucketcylinderheadend.

7.Applylubricantthroughthefollowingfittings:

(4)Thefittingthatislocatedattheswingcylinderheadend.

(5)Thefittingthatislocatedattheswingcylinderrodend.

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Model:305MINIHYDEXCAVATORDGT

Configuration:305CRMiniHydraulicExcavatorDGT00001-UP(MACHINE)POWEREDBYK4NEngine

OperationandMaintenanceManual

305CRMiniHydraulicExcavator

MediaNumber-SEBU7428-11PublicationDate-01/08/2007DateUpdated-13/08/2007

BucketLinkage-Inspect/Adjust

SMCS-6513-025;6513-040

Unexpectedmachinemovementcancauseinjuryordeath.

Toavoidpossiblemachinemovement,movethehydrauliclockout controltothelockedpositionandattachaSpecialInstruction, SEHS7332,"DoNotOperate"orsimilarwarningtagtothehydraulic lockoutcontrol.

i01995001

NOTICE

Improperlyadjustedbucketclearancecouldcausegallingonthe contactsurfacesofthebucketandstick,resultinginexcessivenoise and/ordamagedO-ringseals.

(1)Nogap (2)Stickboss (3)Bucketclearance (4)Shims (5)Pin (6)Plate (7)Bolts (8)Washers (9)Location (10)Flange (11)Bucketboss

Theclearanceofthebucketlinkageonthismachinecanbeadjustedbyshimming.Ifthegapbetween thebucketandthestickbecomesexcessive,adjustbucketclearance(3)to0.5to1mm (.02to.04inch).

Twoshimsofdifferentthicknessareusedatlocation(9).Thethicknessesoftheshimsare0.5mm (0.02inch)and1.0mm(0.04inch).

Areaforlinkageadjustment

1.Positionthemachineonalevelsurfaceandlowerthebuckettotheground.

2.Slowlyoperatetheswingcontrolleveruntilstickboss(2)andbucketboss(11)areinfullface contactatnogap(1).Thiswillhelptodeterminethetotalclearanceoftheconnectionpointof thestickandthebucket.

3.MovethehydrauliclockoutcontroltotheLOCKEDposition.Stoptheengine.

4.Measurebucketclearance(3),whichistheexistingtotalclearance.

5.Determinethenumberofshimsthatneedtoberemovedfromshims(4)byusingthefollowing calculation:

Subtract0.5mm(0.02inch)or1.0mm(0.04inch)frombucketclearance(3).

6.Removetheappropriatenumberofshimsatlocation(9)inordertomeettheabovethickness. Makesurethatyouuseaminimumofthree0.5mm(.02inch)shims.Toremovetheshims, removebolts(7),washers(8),andplate(6).

7.Afterthecorrectnumberofshimshavebeenremovedandpin(5)isalignedwiththepinhole, installplate(6),washers(8),andbolts(7).Tightenbolts(7)toatorqueof100±20N·m (70±15lbft).

8.Afterinstallation,makesurethatbucketclearance(3)isstillcorrect.

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Product:MINIHYDEXCAVATOR

Model:305MINIHYDEXCAVATORDGT

Configuration:305CRMiniHydraulicExcavatorDGT00001-UP(MACHINE)POWEREDBYK4NEngine

OperationandMaintenanceManual

305CRMiniHydraulicExcavator

MediaNumber-SEBU7428-11PublicationDate-01/08/2007DateUpdated-13/08/2007

BucketLinkage-Lubricate

SMCS-6513-086

i02299428

Note:Caterpillarrecommendstheuseof5%MolybdenumGreaseforlubricatingtheboomandstick linkage.RefertoSpecialPublication,SEBU6250,"CaterpillarMachineFluidsRecommendations"for moreinformationonmolybdenumgrease.

Applylubricantthroughallfittingsafteroperationunderwater.

Wipeallfittingsbeforeyouapplylubricant.

This is the sample of the manual Click on the download link for complete Manual