305C CR Caterpillar Mini Hyd Excavator Service Repair Manual by quality service repair manual

Product: MINI HYD EXCAVATOR

Model: 305C CR MINI HYD EXCAVATOR HWJ

Configuration: 305 C CR Mini Hydraulic Excavator HWJ00001-UP (MACHINE) POWERED BY S4Q2T Engine

Disassembly and Assembly

S4Q2-T Engine

Media Number -KENR6788-04

Publication Date -01/09/2013

Air Inlet and Exhaust System - Inspect

SMCS - 1050-040

Measuring exhaust manifold distortion

Date Updated -12/09/2013

i04020373

Illustration 1 g02239554

1. Check the flange for crack.

2. Check the flange surface for distortion. If the distortion exceeds the standard, retouch the surface.

Table 1 Item Standard

Exhaust manifold distortion Less than 0.150 mm (0.0059 inch)

Product: MINI HYD EXCAVATOR

Model: 305C CR MINI HYD EXCAVATOR HWJ

Configuration: 305 C CR Mini Hydraulic Excavator HWJ00001-UP (MACHINE) POWERED BY S4Q2T Engine

Disassembly and Assembly

S4Q2-T Engine

Media Number -KENR6788-04 Publication Date -01/09/2013 Date Updated -12/09/2013

Air Inlet and Exhaust System - Install

SMCS - 1050-012

Installing inlet and exhaust system

i04077149

Illustration 1 g02285694

1. Replace all the inlet and exhaust system gaskets.

2. Exhaust gasket installing at exhaust manifold side (1) .

3. Exhaust gasket installing at cylinder head side (2) .

4. Tighten the clamps (3) to 7 ± 1 N·m (62 ± 9 lb in).

5. Dimension for (A) 1.0 mm (0.04 inch).

6. Radius for (B) 5.0 mm (0.20 inch).

Product: MINI HYD EXCAVATOR

Model: 305C CR MINI HYD EXCAVATOR HWJ

Configuration: 305 C CR Mini Hydraulic Excavator HWJ00001-UP (MACHINE) POWERED BY S4Q2T Engine

Disassembly and Assembly

S4Q2-T Engine

Media Number -KENR6788-04

Publication Date -01/09/2013 Date Updated -12/09/2013

Air Inlet and Exhaust System - Remove

SMCS - 1050-011

Removing inlet and exhaust system

i04077129

This is the sample of the manual

Click on the download link for complete Manual

Illustration 1

Removing sequence

Air hose

Air inlet elbow

Inlet manifold

Exhaust manifold

g02285674

(1)

(2)

(3)

(4)

Product: MINI HYD EXCAVATOR

Model: 305C CR MINI HYD EXCAVATOR HWJ

Configuration: 305 C CR Mini Hydraulic Excavator HWJ00001-UP (MACHINE) POWERED BY S4Q2T Engine

Disassembly and Assembly

S4Q2-T Engine

Media Number -KENR6788-04 Publication Date -01/09/2013 Date Updated -12/09/2013

i04020371

Cooling System - Disassemble/Inspect/Assemble

SMCS - 1350-017; 1350-040

Disassembling, inspecting, and reassembling water pump

Illustration 1 g02239513

Disassembling sequence

(1) Water pump cover

(2) Gasket

(3) Water pump

Inspect the water pump cover (1) for crack, water leakage, and distortion. Replace both the gaskets (2) during assembly. Inspect the water pump (3) for crack, water leakage, damage, impeller, and shaft of rotation.

Inspecting water pump for smooth rotation

Illustration 2 g02239514

Check to make sure that the impeller and shaft of water pump rotate smoothly without noise and irregularities. If faulty, replace the water pump assembly.

Disassembling, inspecting, and reassembling thermostat

Illustration 3 g02239515

Disassembling sequence

(1) Thermostat cover

(2) Gasket

(3) Thermostat

(4) Thermostat case

Inspecting thermostat

Note: Be careful of burns or a fire when measuring temperature, as it involves a hightemperature and open flame.

Illustration 4 g02239516

To test the thermostat operation, immerse the thermostat in a container filled with water. Heat the water, while measuring the water temperature. Record the temperature at the conditions shown in the table below. If the temperatures are not within the standard range, replace the thermostat.

Note: Stir the water in the container with a stick to ensure uniform temperature distribution. Before installing the thermostat, be sure to check the valve opening temperature stamped on the thermostat valve side face.

Table 1

Item Standard

Temperature at which valve starts opening 75 to 78 °C (167 to 172 °F)

Temperature at which valve lift becomes 8.0 mm (0.31 inch) or more. 90 °C (194 °F)

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Product: MINI HYD EXCAVATOR

Model: 305C CR MINI HYD EXCAVATOR HWJ

Configuration: 305 C CR Mini Hydraulic Excavator HWJ00001-UP (MACHINE) POWERED BY S4Q2T Engine

Disassembly and Assembly

S4Q2-T Engine

Media Number -KENR6788-04

Publication Date -01/09/2013 Date Updated -12/09/2013

Cooling System - Install

SMCS - 1350-012

Installation cooling system

i04023331

Illustration 1

1. Replace all the gaskets, O-rings, and rubber hoses.

2. Tighten the thermostat cover bolts (1) to 18 ± 2 N·m (159 ± 18 lb in).

3. Tighten the water pump bolts (2) to 10 ± 1 N·m (88 ± 9 lb in).

Product: MINI HYD EXCAVATOR

Model: 305C CR MINI HYD EXCAVATOR HWJ

Configuration: 305 C CR Mini Hydraulic Excavator HWJ00001-UP (MACHINE) POWERED BY S4Q2T Engine

Disassembly and Assembly

S4Q2-T Engine

Media Number -KENR6788-04

Publication Date -01/09/2013 Date Updated -12/09/2013

Cooling System - Remove

SMCS - 1350-011

Removing cooling system

i04037726

Illustration 1 g02239553

Removing sequence

(1) Water pump assembly

(2) Thermostat

Replace the gaskets (3) during installation.

Inspect the rubber hose (4) for cracked, distortion, and damage.

Inspect the thermostat (2) for crack and damage.

Inspect the water pump assembly (1) for crack, water leakage, and damage.

Product: MINI HYD EXCAVATOR

Model: 305C CR MINI HYD EXCAVATOR HWJ

Configuration: 305 C CR Mini Hydraulic Excavator HWJ00001-UP (MACHINE) POWERED BY S4Q2T Engine

Disassembly and Assembly

S4Q2-T Engine

Media Number -KENR6788-04 Publication Date -01/09/2013 Date Updated -12/09/2013

Cylinder Head and Valve Mechanism - Assemble

SMCS - 1100-016; 1102-016

Installing valve stem seal

i04020349

Note: Do not apply oil or liquid gasket to the inner side of stem seal that comes in contact with the valve guide.

Illustration 1 g02237654 (1) Stem seal installer (P/N:32C91-10400)

(2) Valve stem seal

(3) Valve guide

(4) Valve

1. Apply engine oil to the lip of new valve stem seal.

2. Push the shoulder of the valve stem seal and fit the valve stem steal into the valve guide.

3. Insert the valve stem seal into the valve guide using the valve stem seal installer.

Installing valve and valve spring

Illustration 2 g02237675

1. Install the valve spring and retainer on the valve guide. Install the valve cotter using a valve spring pusher (5) .

Illustration 3 g02237793

2. Tap the top of valve stem lightly several times with a soft hammer to make sure that the valve spring and valve cotter are properly installed and seated firmly.

Installing cylinder head gasket

Note: Do not use liquid gasket.

Illustration 4 g02237796

1. Wipe off oil, grease, and other stains from the cylinder head bottom surface and the crankcase upper surface with a shop towel.

2. Install the cylinder head gasket that has been coated with liquid gasket onto the crankcase with the dowel pin (6) and the hole in alignment.

Installing cylinder head assembly

Illustration 5 g02237813

Install the cylinder head on the crankcase by aligning the cylinder head with the dowel pins (6) .

Note: Be careful not to displace the cylinder gasket when installing.

Tightening cylinder head bolts

Illustration 6 g02237817

Tightening sequence of cylinder head bolts.

White arrow shows front of engine.

Tighten the cylinder head bolts (7) in the numerical sequence to 118 ± 5 N·m (87 ± 4 lb ft).

Reassembling rocker shaft assembly

Illustration 7 g02237873 (8) Reassembling mark

1. Apply engine oil to the rocker shaft.

2. When reassembling, install the rocker shaft assembly in the original position.

Note: If the rocker shaft assembly is not installed in the original position, the clearance becomes different. The different may result in a defect such as wear increase.

3. After reassembling, make sure the rocker arm and oil pipe move freely.

Inserting push rod

1. Insert each push rod into hole in the cylinder head.

2. Make sure that the ball end of each push rod is placed correctly on the tappet cup.

Installing rocker shaft assembly

Illustration 8 g02237874

1. Install the valve caps to the valve heads.

2. Tighten the long bolts (9) of the rocker bracket to 15 ± 2 N·m (133 ± 18 lb in).

3. Tighten the short bolts (10) of the rocker bracket to 11.3 ± 1.5 N·m (100.0 ± 13.0 lb in)

Adjusting valve clearance

Illustration 9 g02237883

(A) valve clearance 0.250 mm (0.0098 inch)

(11) Adjustment screw

(12) Lock nut

Adjust the valve clearance.

For adjusting procedures, refer to Adjustment and Operation.

Product: MINI HYD EXCAVATOR

Model: 305C CR MINI HYD EXCAVATOR HWJ

Configuration: 305 C CR Mini Hydraulic Excavator HWJ00001-UP (MACHINE) POWERED BY S4Q2T Engine

Disassembly and Assembly

S4Q2-T Engine

Media Number -KENR6788-04 Publication Date -01/09/2013 Date Updated -12/09/2013

i04013730

Cylinder Head and Valve Mechanism - Disassemble and Inspect

SMCS - 1100-015; 1100-040; 1102-015; 1102-040

Disassembling and inspecting cylinder head and valve mechanism

Illustration 1

Disassembling sequence

(1) Rocker cover

(2) Adjusting screw

(3) Bolt (short)

(4) Bolt (long)

(5) Valve cap

(6) Snap ring

(7) Rocker arm

(8) Rocket shaft bracket

(9) Rocket shaft spring

g02203053

(10) Rocket shaft

(11) Push rod

(12) Cylinder head bolt

(13) Cylinder head

(14) Valve cotter

(15) Valve retainer

(16) Valve spring

(17) Inlet valve

(18) Exhaust valve

(19) Valve stem seal

(20) Cylinder head gasket

Removing rocker shaft assembly

Note: Always loosen shorter bolts first. Failing to do so may damage the rocker shaft bracket.

Illustration 2 g02203033

1. Loosen the rocker arm adjusting screws by rotating about one turn.

2. Loosen the shorter rocker bracket bolts first.

3. Then, loosen the longer rocker bracket bolts.

4. Remove the rocker bracket bolts, and remove the rocker shaft assembly from the cylinder head.

5. Remove push rods.

Disassembling rocker shaft assembly

Illustration 3 g02203034

1. Be sure to arrange the parts in order during disassembly. Keep the original combination of rocker arm and shaft assembly, and when reassembling. Make sure to install the rocker arm and shaft assembly in the original positions to restore the same clearance between the rocker shaft and rocker arm.

2. Do not remove the rocker bushing unless rocker bushing is defective or its inside diameter exceeds the limit.

Removing cylinder head assembly

Note: When removing the cylinder head gasket, be careful not to damage the cylinder head or crankcase surface by tools such as a screwdriver.

This is the sample of the manual

Click on the download link for complete Manual

Illustration 4 g02203035

1. Remove the cylinder head bolt.

2. Remove the cylinder head assembly by lifting cylinder head assembly up.

Note: If the cylinder head assembly cannot be removed due to crimping of the cylinder head gasket. Tap the thick area on the side of the cylinder head using a plastic hammer to give a shock.

3. Remove the gasket from the cylinder head.

Note: If there is a cylinder head problem, check the bolts for tightness with a torque wrench before removing the cylinder head bolts.

305C CR Caterpillar Mini Hyd Excavator Service Repair Manual

Air Inlet and Exhaust System - Inspect

Measuring exhaust manifold distortion

Air Inlet and Exhaust System - Install

Installing inlet and exhaust system

Air Inlet and Exhaust System - Remove

Removing inlet and exhaust system

Inspecting water pump for smooth rotation

Cooling System - Install

Installation cooling system

Cooling System - Remove

Removing cooling system

Cylinder Head and Valve Mechanism - Assemble

Installing valve stem seal

Installing valve and valve spring

Installing cylinder head gasket

Installing cylinder head assembly

Tightening cylinder head bolts

Reassembling rocker shaft assembly

Inserting push rod

Installing rocker shaft assembly

Adjusting valve clearance

Removing rocker shaft assembly

Disassembling rocker shaft assembly

Removing cylinder head assembly

Removing valve and valve spring