Caterpillar cat 302.2 d mini hydraulic excavator (prefix ljg) service repair manual (ljg00001 and up)

Service Repair Manual
Models
302.2D Mini Hydraulic Excavator

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Product: MINI HYD EXCAVATOR
Model: 302.2D MINI HYD EXCAVATOR LJG
Configuration: 302.2D Mini Hydraulic Excavator LJG00001-UP (MACHINE)
Disassembly and Assembly
301.7D, 302.2D and 302.4D Mini Hydraulic Excavators
Media Number -UENR3253-01 Publication Date -01/05/2015 Date Updated -12/05/2015
i05212950
Flywheel - Remove and Install
SMCS - 1156-010
Removal Procedure
Start By:
A. Remove the pump drive coupling.
Illustration 1 g03335836
1. Remove bolts (1). Remove flywheel (2).
Installation Procedure
1. Install flywheel (2) in the reverse order of removal.
2. Tighten bolts (1) to a torque of 84 N·m (62 lb ft)
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301.7D, 302.2D and 302.4D Mini Hydraulic Excavators Machine Systems
i05228978
System Pressure - Release
SMCS - 4350-553-PX; 5050-553-PX; 6700-553-PX
Release Procedure (Hydraulic System Pressure)
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the attachments have been lowered, oil is cool before
removing any components or lines. Remove the oil filler cap only when
the engine is stopped, and the filler cap is cool enough to touch with
your bare hand.
1. Lower the work tools to the ground.
2. Turn the engine start switch to the OFF position.
3. Turn the key to the ON position without starting the machine.
4. Move the joysticks through the full range of travel, releasing any pressure that may be
present in the hydraulic system.
5. Push the auxiliary circuit control in both directions, releasing any pressure that may be
present in the auxiliary system.
6. Turn the key to the OFF position.
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7. The pressure in the hydraulic system has now been released. Hydraulic lines and
components can now be removed.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Mar 7 21:11:43 UTC+0800 2020
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2020/3/7

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i05221871
Blade Cylinder - Remove and Install - Long
SMCS - 7562-010-BG
Specifications
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Table 1
Specification for 395-1281 Hydraulic Cylinder Gp
Item Qty
Part Specification Description
1 1 -
Before assembly, lubricated the threads with clean oil.
Tighten the head to 300 to 350 N·m (221 to 258 lb ft).
2 1 -
Before assembly, apply Locktite 638 to the outer surface of
the bearing.
3 1
395-1286 Piston
Rod
Diameter is
35 mm (1.4 inch).
4 2
395-1218 Bushing Bore after assembly is
32 mm (1.3 inch).
5 1
395-1256 Cylinder
As
Bore is
60 mm (2.4 inch).
6 1 -
Left Hand Thread
Tighten the nut to
10 to 20 N·m (89 to 177 lb in).
Bend the collar of the piston at two places on the flat sides
of the nut.
7 1 -
Tighten the piston to
25 to 35 N·m (221 to 310 lb in).
- - -
Stroke length is
140.0 ± 1.5 mm (5.51 ± 0.06 inch).
Specifications
2/4
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Table 2
Specification for 395-1267 Blade Cylinder Gp
Item Qty
Part Specification Description
1 1 -
Before assembly, apply Locktite 638 to the outer surface of
the bearing.
2 1 -
Tighten the head to
300 to 350 N·m (221 to 258 lb ft).
3 1 -
25 to 35 N·m (221 to 310 lb in).
4 1 -
Left-hand thread
Tighten the nut to
10 to 20 N·m (89 to 177 lb in).
Bend the collar of the piston at two places on the flat sides
of the nut.
A 1
395-1255 Cylinder
As
Bore is
70 mm (2.6 inch).
B 1
395-1287 Piston
Rod
Diameter is
40 mm (1.6 inch).
C 2
395-1218 Bushing Bore after assembly is
32 mm (1.3 inch).
- - -
Stroke length is
140.0 ± 1.5 mm (5.51 ± 0.06 inch).
Removal Procedure
Start By:
A. Release the hydraulic system pressure.
Cylinders equipped with lock valves can remain pressurized for very
long periods of time, even with the hoses removed.
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Failure to relieve pressure before removing a lock valve or
disassembling a cylinder can result in personal injury or death.
Ensure all pressure is relieved before removing a lock valve or
disassembling a cylinder.
1. Remove cover (1).
2. Disconnect hose assemblies (2). Remove pins (3). Remove blade cylinder (4) .
1. Install blade cylinder (4) in the reverse order of removal.
Sat Mar 7 21:12:40 UTC+0800 2020
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i05181955
Blade - Remove and Install
SMCS - 6060-010
Removal Procedure
1. Remove pin (1) .
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2. Install suitable cribbing under blade arm (2) .
3. Remove pins (3) from blade arm (2) .
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4. Attach a suitable lifting device to blade (4). The weight of blade (4) is approximately 77 kg
(170 lb). Remove blade (4) .
1. Install blade (4) in the reverse order of removal.
Sat Mar 7 21:13:36 UTC+0800 2020
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i05172079
Bucket - Remove and Install
SMCS - 6001-010; 6101-010
Removal Procedure
1. Make sure that the bucket is setting flat with the stick in a vertical position.
2. Remove pins (1) and Lift stick (2) in order to remove bucket (3) .
1. Install bucket (3) in the reverse order of the removal.
Sat Mar 7 21:14:33 UTC+0800 2020
1/1
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i05226011
Bucket Linkage - Remove and Install
SMCS - 6513-010
Specifications
Table 1
Specification for 417-7566 Bucket Linkage Gp
Item Qty Part Specification Description
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1 1 229-9247 Pin As Diameter is
29.945 to 29.960 mm (1.1789 to 1.1795 inch).
2 1 Bushing
Bore after assembly is
30 mm (1.2 inch).
3 1 Bushing
Bore after assembly is
32 mm (1.3 inch).
Removal Procedure
Start By:
A. Remove the bucket.
1. Position the stick in a level position on suitable blocking and retract the bucket cylinder.
2. Release the hydraulic system pressure. Refer to Disassembly and Assembly, "Hydraulic
System Pressure - Release".
3. Remove fasteners (1) and the pins. Remove bucket linkage (2)
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4. Remove bearings (3).
5. Remove bearings (4).
Table 2
Required Tools
Tool Part Number Part Description Qty
A
FT-3038 Puller Adapter 1
FT-3039 Receiving Sleeve 1
6V-3160 Single Acting Cylinder 1
1U-7519 Electric Hydraulic Pump 1
4C-9633 Puller Stud 1
9U-6833 Nut 1
126-8928 Hard Washer
When you are using hydraulic cylinders and puller studs, always ensure
that the rated capacity of the puller stud meets or exceeds the rated
capacity of the hydraulic cylinder. If the puller stud does not meet or
exceed the rated capacity of the hydraulic cylinder, a sudden failure of
the puller stud could occur. The sudden failure of the puller stud could
result in personal injury or death.
3/5
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1. Lower the temperature of bearings (4). Use Tooling (A) to install bearings (4) into bucket
linkage (2). Lower temperature of bearings (3) and using Tooling (A) install bearings (3) into
the stick assembly.
2. Position bucket linkage (2). Install the pins and fasteners (1).
4/5
2020/3/7

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i05233336
Bucket Cylinder - Remove and Install
SMCS - 5457-010
S/N - LJ51-UP
S/N - LJ61-UP
S/N - LJG1-UP
S/N - LJN1-UP
Specifications
1/3
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Table 1
Specification for 419-9101 Hydraulic Cylinder Gp
Item Qty Part Specification Description
1 2 379-2769 Bushing
Bore before assembly is
32 mm (1.3 inch).
2 1 395-1285 Piston Rod
Diameter is
35 mm (1.4 inch).
3 1 -
350 to 400 N·m (258 to 295 lb ft).
- - -
Stroke length is
445.0 ± 0.7 mm (17.52 ± 0.03 inch).
Removal Procedure
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1. Position bucket flat on the ground.
2. Release the hydraulic system pressure. Refer to Disassembly and Assembly, "Hydraulic system
Pressure - Release".
Note: Cleanliness is an important factor. Thoroughly clean the exterior of the components before you
begin the removal procedure. Cleaning will help to prevent dirt from entering the internal mechanism.
1. Attach a suitable lifting device to bucket cylinder (1). The bucket cylinder (1) is approximately
21kg (45 lb).
2. Disconnect hose assemblies (4). Remove pins (2) and (3) .
1. Install boom cylinder (1) in the reverse order of removal.
Sat Mar 7 21:16:27 UTC+0800 2020
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Caterpillar cat 302.2 d mini hydraulic excavator (prefix ljg) service repair manual (ljg00001 and up)

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