Caterpillar cat 305 d mini hydraulic excavator (prefix xer) service repair manual (xer00001 and up)

Service Repair Manual
Models
305D Mini Hydraulic Excavator

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Product: MINI HYD EXCAVATOR
Model: 305D CR MINI HYD EXCAVATOR XER
Configuration: 305D Mini Hydraulic Excavator XER00001-UP (MACHINE) POWERED BY S4Q2T Engine
Disassembly and Assembly
303.5D CR, 304D CR, 305D CR and 305.5D CR Mini Hydraulic Excavators Machine
Systems
Media Number -UENR0102-01 Publication Date -01/12/2014 Date Updated -17/12/2014
i03982575
Support (Swing Boom) - Remove
SMCS - 7051-S4
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-1862 Retaining Ring Pliers 1
B 140-7742 Sleeve 2
C
5P-4197 Spacer 1
1P-1832 Adapter 1
4C-9633 Puller Stud 1
6V-3160 Double Acting Cylinder 1
9U-6833 Nut 1
3S-6224 Electric Hydraulic Pump Gp 1
D
1P-1832 Adapter 1
9U-6833 Nut 1
Start By:
1/9305D Mini Hydraulic Excavator XER00001-UP (MACHINE) POWERED BY S4Q2T...
2020/2/6https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw...

A. Remove the boom cylinder. Refer to, "Boom Cylinder - Remove and Install".
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for
installation purposes. Plug all lines, hoses, and tubes in order to prevent fluid loss and to keep
contaminants from entering the system.
Illustration 1 g01233687
1. Disconnect hose assemblies (2) from tube assemblies (1) that are located at the rear of the
boom. All hose assemblies (2) and tube assemblies (1) should be capped and the caps
should be tight.

2. Attach Tooling (B) and a suitable lifting device to boom assembly (3). The weight of boom
assembly (3) is approximately 522 kg (1150 lb).
3. Remove bolt (5) and pin assembly (4). Remove boom assembly (3) .

4. Remove bolt (8) and pin assembly (7). Position swing boom cylinder (6) to the side.
5. Remove bolts (9) and guard (10) .
6. Install pin assembly (4) and bolt (5) that held the head end of the stick cylinder. Pin
assembly (4) is used for the removal of support (11). Attach a suitable lifting device to pin
assembly (4) and support (11). The weight of support (11) is approximately 160 kg (350 lb).

7. Remove bolts (13) and (14). Remove pins (12) and (15) .

8. Pull hose assemblies (16) and (17) out of support (11) .
9. Use Tooling (B) in order to remove retaining ring (18) that secures lower hitch pin (19) .

10. Drive upper hitch pin (20) downward onto lower hitch pin (19) that was referenced in the
previous step. Use upper hitch pin (20) in order to drive lower hitch pin (19) out of the
machine. Drive upper hitch pin (20) downward through the bore of the lower hitch pin (19).
Upper hitch pin (20) and lower hitch pin (19) should be removed from the bottom of the
machine.
Note: Note the location of each hitch pin. Upper hitch pin (20) is longer than lower hitch
pin (19) .
11. Remove support (11) from the machine. Note the location of any shims (21) that may be
present.

12. Use Tooling (C) in order to remove bearings (22) .

13. Use Tooling (D) in order to remove bearings (23) .
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Feb 6 12:22:36 UTC+0800 2020

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Systems
i06713551
Support (Swing Boom) - Install
SMCS - 7051-S4
Installation Procedure
Table 1
Required Tools
A 1P-1862 Retaining Ring Pliers 1
B 140-7742 Sleeve 2
D
1P-1832 Adapter 1
9U-6833 Nut 1
Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning
fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be
deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or
damaged, use new parts for replacement. Dirt and other contaminants can damage the precision
component. Perform assembly procedures on a clean work surface. Keep components covered and
protected always.

1. Lower the temperature of bearings (22) and (23). Use Tooling (D) to install bearings (22)
and (23).

NOTICE
Typical Example.
2. Install pin assembly (4) and bolt (5) that held the head end of the stick cylinder. Pin
assembly (4) is used for the installation of support (11). Attach a suitable lifting device to
pin assembly (4) and support (5). The weight of support (11) is approximately 160 kg
(350 lb).
Install support (11) onto the machine. Note the location of any shims (21) that may be
present.

3. Install upper hitch pin (20) from the top of the hitch. Install bolts (19).
4. Install lower hitch pin (17) from the bottom of the hitch. Install pin (18) and the bolt.

5. Pull hose assemblies (16) and (17) into support (11).
6. Remove the suitable lifting device. Remove bolt (5) and pin assembly (4) from support (11).
7. Install guard (10) and bolts (9).

8. Move swing boom cylinder (6) into position. Install pin assembly (7) and bolt (8).
9. Attach Tooling (B) and a suitable lifting device to boom assembly (3). The weight of boom
10. Install boom assembly (3). Install pin assembly (4) and bolt (5).
11. Connect hose assemblies (2) to tube assemblies (1) that are located on the rear of the boom.

End By:
a. Install the boom cylinder. Refer to , "Boom Cylinder - Remove and Install".
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Feb 6 12:23:33 UTC+0800 2020

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Systems
i04012853
Upper Frame and Undercarriage Frame - Separate
SMCS - 4150-076; 7051-076
Separate Procedure
Table 1
Required Tools
A 189-0410 Shackle As 2
B 1U-9200 Lever Puller Hoist 2
C 140-7742 Sleeve 1
D 189-0412 Shackle As 1
E 138-7574 Link Bracket 3
F 6V-6146 Load Leveling Beam 1
G 1U-9204 Lever Puller Hoist 1
Start By:
A. Remove the bucket. Refer to , "Bucket - Remove".
B. Remove the boom cylinder. Refer to , "Boom Cylinder - Remove and Install".
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers

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before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
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 work tools have been lowered to the ground, and
the 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.
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for
installation purposes. Plug all lines, hoses, and tubes in order to prevent fluid loss and to keep
contaminants from entering the system.
Note: Cleanliness is an important factor. Before you begin the removal procedure, you should
thoroughly clean the exterior of the components in order to prevent dirt from entering the internal
mechanism.

1. Attach Tooling (A) and a suitable lifting device to boom assembly (1) . The weight of boom
2. Attach Tooling (B) and Tooling (C) to boom assembly (1) and stick assembly (2) in order to
secure stick assembly (2) to boom assembly (1) .

3. Attach Tooling (D) to a suitable lifting device. Attach Tooling (B) to stick assembly (2) .
4. Remove cable straps (5) . Disconnect harness assemblies (4) from lamp assembly (3) .
5. Disconnect clamp (6) from boom assembly (1) .

6. Disconnect hose assemblies (7) .
7. Remove bolt (8) and pin (9) in order to remove boom assembly (1) .

Caterpillar cat 305 d mini hydraulic excavator (prefix xer) service repair manual (xer00001 and up)

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