305E2 CR Caterpillar Mini Hyd Excavator Operation and Maintenance Manual by quality service repair manual

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Product:MINIHYDEXCAVATOR

Model:305E2CRMINIHYDEXCAVATORBZ5

Configuration:305E2CRMiniHydraulicExcavatorBZ500001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual

303.5E2,304E2,305.5E2and305E2MiniHydraulicExcavators

MediaNumber-SEBU9410-03PublicationDate-01/09/2015DateUpdated-11/05/2016

Foreword

SMCS-1000;7000;7405

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).

WedNov2515:41:23UTC+05302020

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Product:MINIHYDEXCAVATOR

Model:305E2CRMINIHYDEXCAVATORBZ5

Configuration:305E2CRMiniHydraulicExcavatorBZ500001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual 303.5E2,304E2,305.5E2and305E2MiniHydraulicExcavators

MediaNumber-SEBU9410-03PublicationDate-01/09/2015DateUpdated-11/05/2016

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)

WedNov2514:57:47UTC+05302020

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Product:MINIHYDEXCAVATOR

Model:305E2CRMINIHYDEXCAVATORBZ5

Configuration:305E2CRMiniHydraulicExcavatorBZ500001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual

303.5E2,304E2,305.5E2and305E2MiniHydraulicExcavators

MediaNumber-SEBU9410-03PublicationDate-01/09/2015DateUpdated-11/05/2016

AirCleanerDustValve-Clean/Inspect

SMCS-1051-571-VL

1.Opentherightsideaccessdoor.

2.Theairfilterhousingislocatedontherightsideoftheenginecompartment.

3.Checkthedustvalveafterevery10servicehoursorattheendofeachday.Actuatethevalve bysqueezingthelipsofthevalveinordertoremoveanyaccumulateddebris.

4.Closetherightsideaccessdoor.

i04661209

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Product:MINIHYDEXCAVATOR

Model:305E2CRMINIHYDEXCAVATORBZ5

Configuration:305E2CRMiniHydraulicExcavatorBZ500001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual

303.5E2,304E2,305.5E2and305E2MiniHydraulicExcavators

MediaNumber-SEBU9410-03PublicationDate-01/09/2015DateUpdated-11/05/2016

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.

WedNov2515:00:21UTC+05302020

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Product:MINIHYDEXCAVATOR

Model:305E2CRMINIHYDEXCAVATORBZ5

Configuration:305E2CRMiniHydraulicExcavatorBZ500001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual

303.5E2,304E2,305.5E2and305E2MiniHydraulicExcavators

MediaNumber-SEBU9410-03PublicationDate-01/09/2015DateUpdated-11/05/2016

Battery-Clean

SMCS-1401-070

Cleanthebatterysurfacewithacleancloth.Keeptheterminalscleanandkeeptheterminalscoated withpetroleumjelly.Installthepostcoverafteryoucoattheterminalpostwithpetroleumjelly.

WedNov2515:00:34UTC+05302020

i00934864

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Product:MINIHYDEXCAVATOR

Model:305E2CRMINIHYDEXCAVATORBZ5

Configuration:305E2CRMiniHydraulicExcavatorBZ500001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual

303.5E2,304E2,305.5E2and305E2MiniHydraulicExcavators

MediaNumber-SEBU9410-03PublicationDate-01/09/2015DateUpdated-11/05/2016

Battery-Recycle

SMCS-1401-561

Alwaysrecycleabattery.Neverdiscardabattery.

Alwaysreturnusedbatteriestooneofthefollowinglocations:

•Abatterysupplier

•Anauthorizedbatterycollectionfacility

•Recyclingfacility

WedNov2515:00:49UTC+05302020

i06543763

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

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Product:MINIHYDEXCAVATOR

Model:305E2CRMINIHYDEXCAVATORBZ5

Configuration:305E2CRMiniHydraulicExcavatorBZ500001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual

303.5E2,304E2,305.5E2and305E2MiniHydraulicExcavators

MediaNumber-SEBU9410-03PublicationDate-01/09/2015DateUpdated-11/05/2016

BatteryHold-Down-Tighten

SMCS-7257

Tightenthehold-downsforthebatteryinordertopreventthebatteriesfrommovingduringmachine operation.

WedNov2515:01:02UTC+05302020

i01586700

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Product:MINIHYDEXCAVATOR

Model:305E2CRMINIHYDEXCAVATORBZ5

Configuration:305E2CRMiniHydraulicExcavatorBZ500001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual

303.5E2,304E2,305.5E2and305E2MiniHydraulicExcavators

MediaNumber-SEBU9410-03PublicationDate-01/09/2015DateUpdated-11/05/2016

BatteryorBatteryCable-Inspect/Replace

SMCS-1401-561;1401-040;1401-510;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.

i01999587

7.Connectthepositivebatterycableofthebattery.

8.Connectthenegativebatterycableofthebattery.

9.Installthekeyintotheenginestartswitch.

WedNov2515:01:17UTC+05302020

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Product:MINIHYDEXCAVATOR

Model:305E2CRMINIHYDEXCAVATORBZ5

Configuration:305E2CRMiniHydraulicExcavatorBZ500001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual

303.5E2,304E2,305.5E2and305E2MiniHydraulicExcavators

MediaNumber-SEBU9410-03PublicationDate-01/09/2015DateUpdated-11/05/2016

Belt-Inspect/Adjust/Replace

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

i04658409

Illustration1g02791557 (1)Adjustingbolt (2)Adjustingbracket (3)Alternatormountingbolt (4)Alternatormountingbolt (5)Belt (6)Bolt (A)Alternatorpulley (B)Crankshaftpulley (C)Waterpumppulley

1.Opentheengineaccessdoor.

2.Removethefanguard.

3.Applyapproximately98N(22lb)offorcemidwaybetweenthepulleys.

4.Measurethedeflectionofthebelt.Thebeltshoulddeflect7to9mm(9/32to11/32inch).

5.Ifthedeflectionisnotcorrect,loosenbolt(6),andalternatormountingbolts(3)and(4).Turn adjustingbolt(1)counterclockwiseinordertomovethealternatorforwardtoadjustbelt(5)to thespecifiedtension.

6.Whentheadjustmentiscorrect,tightenbolt(6),andalternatormountingbolts(3)and(4) securely.

7.Checkthedeflectionofthebeltagain.

8.Closetheengineaccessdoor.

Note:Ifanewbeltisinstalled,checkthebeltadjustmentagainafter30minutesofengineoperation attheratedenginespeed.

AirConditionerBelt(IfEquipped)

NOTICE

TheV-beltmustbetensionedcorrectly.Failuretotensionthebelt properlycouldcausedamagetothebeltand/ortotheairconditioner compressor.

1.Opentheengineaccessdoor.

2.Removethebottomaccessguard.

3.Removethefanguard.

Illustration2g01190210 (7)Nut (8)Adjustmentbolt

4.Checkthebelttension.

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

5.Ifthedeflectionisnotcorrect,loosennut(7).Turnadjustingbolt(8)inordertoadjustthebelt tension.

6.Adjustthebelttension.

7.Whentheadjustmentiscorrect,tightenbolt(7)toatorqueof28±7N·m(21±5lbft)and tightenbolts(8)toatorqueof28±7N·m(21±5lbft).

8.Checkthedeflectionagain.

9.Closetheengineaccessdoor.

Note:Ifanewbeltisinstalled,checkthebeltadjustmentagainafter30minutesofengineoperation attheratedspeed.

WedNov2515:01:35UTC+05302020

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Product:MINIHYDEXCAVATOR

Model:305E2CRMINIHYDEXCAVATORBZ5

Configuration:305E2CRMiniHydraulicExcavatorBZ500001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual

303.5E2,304E2,305.5E2and305E2MiniHydraulicExcavators

MediaNumber-SEBU9410-03PublicationDate-01/09/2015DateUpdated-11/05/2016 i02304927

BladeLinkage-Lubricate

SMCS-6060-086

S/N-AC51-UP

S/N-BZ51-UP

S/N-CR91-UP

S/N-DF51-UP

S/N-FR51-UP

S/N-GC51-UP

S/N-NC51-UP

Loweralltheworktoolsandthebladetotheground.

Wipeallgreasefittingsbeforelubricating.

Illustration1g00823677

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.

WedNov2515:01:49UTC+05302020

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Product:MINIHYDEXCAVATOR

Model:305E2CRMINIHYDEXCAVATORBZ5

Configuration:305E2CRMiniHydraulicExcavatorBZ500001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual

303.5E2,304E2,305.5E2and305E2MiniHydraulicExcavators

MediaNumber-SEBU9410-03PublicationDate-01/09/2015DateUpdated-11/05/2016

BoomandStickLinkage-Lubricate

SMCS-6501-086;6502-086

Note:Caterpillarrecommendstheuseof5%molybdenumgreaseforlubricatingtheboomandstick linkage.RefertoSpecialPublication,SEBU6250,"CaterpillarMachineFluidsRecommendations"for moreinformationongrease.

Positionthemachineintotheserviceposition.

Wipeallfittingsbeforeyouapplylubricant.

i02386747

WedNov2515:02:04UTC+05302020

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Product:MINIHYDEXCAVATOR

Model:305E2CRMINIHYDEXCAVATORBZ5

Configuration:305E2CRMiniHydraulicExcavatorBZ500001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual

303.5E2,304E2,305.5E2and305E2MiniHydraulicExcavators

MediaNumber-SEBU9410-03PublicationDate-01/09/2015DateUpdated-11/05/2016

BoomSwingCylinderPins-Lubricate

SMCS-5105-086

1.Lowerallworktoolstotheground.

2.Wipeallgreasefittingsbeforeyoulubricatethegreasefittings.

3.Applylubricanttothegreasefittingfortherodendoftheboomswingcylinder.

i04658370

4.Applylubricanttothegreasefittingfortheheadendoftheboomswingcylinder.

WedNov2515:02:35UTC+05302020

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Product:MINIHYDEXCAVATOR

Model:305E2CRMINIHYDEXCAVATORBZ5

Configuration:305E2CRMiniHydraulicExcavatorBZ500001-UP(MACHINE)POWEREDBYC2.4Engine

OperationandMaintenanceManual

303.5E2,304E2,305.5E2and305E2MiniHydraulicExcavators

MediaNumber-SEBU9410-03PublicationDate-01/09/2015DateUpdated-11/05/2016

Boom,Stick,andFrame-Inspect

SMCS-6501;6502;6506

Allearthmovingequipmentispronetoahighdegreeofwear.Regularinspectionsforstructural damagearenecessary.

Theintervalbetweentheseinspectionsdependsonthefactorsthatfollow.

•Theageofthemachine

•Theseverityoftheapplication

•Theloadsthathavebeencarriedonthemachine

•Theamountofroutineservicingthathasbeencarriedout

Ifthemachinehasbeeninvolvedinanykindofaccident,themachinemustbeinspectedthoroughly. Inspectthemachineregardlessofthedateofthelastinspection.

Themachinemustbecleanbeforethemachineisinspected.

Properrepairofframesandstructuresrequiresspecificknowledgeofthefollowingsubjects.

•Materialsthathavebeenusedtomanufacturetheframemembers

•Framememberconstruction

•Repairtechniquesthatarerecommendedbythemanufacturer.

ConsultyourCaterpillardealerifrepairsarenecessary.YourCaterpillardealerisqualifiedtocarry outrepairsonyourbehalf.

AllrepairsshouldbecarriedoutbyaCaterpillardealer.Ifyoucarryoutyourownrepairs,contact yourCaterpillardealerforadviceaboutproperrepairtechniques.

i02860835

Particularattentionshouldbegiventoallweldedstructures.Thefollowingitemsshouldbe thoroughlyinspectedforcracksandfordefects:

•Boom

•Stick

•Blade

•Liftingpoints

•Upperframe

•Lowerframe NOTICE

Theareashighlightedareofparticularimportancebutotherareas mustnotbeneglected.Theentirestructuremustbecarefully examined.

Boom

Illustration1g01425291

Checkallweldedjointsandcheckthemountingpointsforthecylinder.

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