Caterpillar Cat 305E2 Mini Hydraulic Excavator (Prefix H5M) Service Repair Manual (H5M00001 and up).pdf

Service Repair Manual
Models
305E2 Mini Hydraulic Excavator

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Product: MINI HYD EXCAVATOR
Model: 305E2 MINI HYD EXCAVATOR H5M
Configuration: 305E2 Mini Hydraulic Excavator H5M00001-UP (MACHINE) POWERED BY C2.4 Engine
Disassembly and Assembly
C2.4 Tier 4 Final Engines for Caterpillar Built Machines
Media Number -UENR7319-02 Publication Date -01/07/2018 Date Updated -01/08/2018
i06523433
Inlet Manifold - Remove and Install
SMCS - 1058-010
Removal Procedure
Start By:
a. Remove exhaust gas recirculation valve.
b. Remove fuel injection lines.
c. Remove fuel manifold (rail).
Illustration 1 g06008649
1. Remove bolt (1).
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305E2 Mini Hydraulic Excavator H5M00001-UP (MACHINE) POWERED BY C2.4 ...
2020/2/3
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2. Remove bolts (2) and inlet manifold (3).
Installation Procedure
1. Install inlet manifold (3) in the reverse order of removal.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Feb 3 23:11:27 UTC+0800 2020
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i06539555
Inlet and Exhaust Valves - Remove and Install
SMCS - 1105-010
Removal Procedure
Table 1
Required Tooling
Tool Part Number Part Description Qty
A 5S-1330 Valve Spring Compressor 1
Start By:
a. Remove cylinder head.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Clean the bottom mating surface of the cylinder head. Check the depth of the valves below
the face of the cylinder head before the valve springs are removed. Refer to Specifications,
"Cylinder Head Valves" for the correct dimensions.
2. Place a temporary identification mark on the heads of the valves to identify the correct
position.
3. Use a suitable lifting device to position the cylinder head with the valve springs upward.
The weight of the cylinder head is approximately 28 kg (61 lb).
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Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
4. Install Tooling (A) in position on the cylinder head and compress the valve spring to
remove inlet and exhaust valves (1).
NOTICE
Ensure that the valve spring is compressed squarely or damage to the
valve stem may occur.
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5. Remove valve cap (2). Apply sufficient pressure to Tooling (A) to remove valve keepers
(3).
6. Slowly release pressure on Tooling (A).
7. Place a temporary identification make on valve spring (5) to identify the correct position.
8. Remove valve spring retainer (4), valve spring (5), and valve (6).
9. Remove Tooling (A).
10. Remove valve stem seals (7) from the cylinder head.
11. Repeat Step 4 through Step 10 for the remaining valves.
1. Install valves (6) in the reverse order of removal.
2. Clean all components of the cylinder head assembly. Ensure that all posts, all coolant
passages, and all lubrication passages in the cylinder head are free from debris. Follow Step
2.a through Step 2.e to inspect components of the cylinder head assembly. Replace any
components that are worn or damaged.
a. Inspect the cylinder head for wear and for damage. Refer to System Operation,
Testing and Adjusting, "Cylinder Head Inspect" for the correct procedure.
b. Inspect the valve seats for wear and for damage. Refer to Specifications, "Cylinder
Head Valves" for further information.
c. Inspect the valve guides for wear and for damage. Refer to Specifications, "Cylinder
d. Inspect the valves (6) for wear and for damage. Refer to Specifications, "Cylinder
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e. Inspect valve springs (5) for damage and for the correct length. Refer to
Specifications, "Cylinder Head Valves" for further information.
3. Lubricate the stems of valves (6) with clean engine oil. Install valves (6) in the appropriate
positions in the cylinder head. Check the depth of the valves below the face of the cylinder
head. Refer to Specifications, "Cylinder Head Valves" for more information.
Mon Feb 3 23:12:24 UTC+0800 2020
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i06546055
Engine Oil Cooler - Remove and Install
SMCS - 1378-010
Removal Procedure
NOTICE
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
before opening any compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and mandates.
1. Drain the coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant -
Change" for the correct draining and filling procedures.
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2. Remove engine oil filter (1).
3. Remove clamp (3) and clamp (5). Disconnect hose assembly (2) and hose assembly (4).
4. Remove connector (7), engine oil cooler (6), and the collar.
1. Install engine oil cooler (6) in the reverse order of removal.
a. Tighten connector (7) to a torque of 40 N·m to 44 N·m (30 lb ft to 32 lb ft).
Mon Feb 3 23:13:21 UTC+0800 2020
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i06546117
Engine Oil Pump - Remove and Install
SMCS - 1304-010; 1315-010
Removal Procedure
Table 1
Required Tooling
A 1P-2321 Puller As. 1
Start By:
a. Remove front housing.
NOTICE
containing fluids.
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1. Remove nut (3).
2. Use Tooling (A) to remove gear (1).
3. Remove bolts (2), engine oil pump (4), and the gasket.
1. Install engine oil pump (4) in the reverse order of removal.
Mon Feb 3 23:14:17 UTC+0800 2020
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i06512587
Water Pump - Remove and Install
SMCS - 1361-011; 1361-012
Removal Procedure
NOTICE
NOTICE
containing fluids.
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2. Remove bolts (2), suction fan (1), and the fan spacer.
3. Loosen bolt (5), the bolts, and the bracket assembly (not shown). Move alternator (4) and
remove belt (6) .
4. Remove pulley (3).
5. Remove clamp (10) and hose assembly (9).
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6. Remove nut (7), bolts (8), water pump (11), and the gasket.
1. Install water pump (11) in the reverse order of removal.
Mon Feb 3 23:15:14 UTC+0800 2020
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i06515139
Water Temperature Regulator - Remove and Install
SMCS - 1355-010
Removal Procedure
Table 1
Required Tooling
A - Loctite 5009 Hi-Tack Gasket Sealant -
NOTICE
containing fluids.
Note: Coolant only needs drained to below the water temperature regulator.
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2. Remove bolts (1), cover (2), and the gasket.
3. Remove water temperature regulator (3).
1. Install water temperature regulator (3) in the reverse order of removal.
a. Apply Tooling (A) to cover (2).
Mon Feb 3 23:16:11 UTC+0800 2020
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i06577986
Water Temperature Regulator - Remove and Install
SMCS - 1355-010
Removal Procedure
NOTICE
performance of inspection, maintenance, testing, adjusting, and repair
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat®
products.
1. Drain the coolant to a level that is below the water temperature regulator. Refer to
"Operation and Maintenance Manual", Cooling System Coolant (ELC) - Change for the
correct draining procedure.
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2. Loosen clamp (1) and disconnect hose (3). Remove two bolts (4). Remove cover (2) and the
gasket.
3. Remove water temperature regulator (5).
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1. Install water temperature regulator (5) in the reverse order of removal.
Mon Feb 3 23:17:08 UTC+0800 2020
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i06546123
Flywheel - Remove and Install
SMCS - 1156-010
Removal Procedure
Table 1
Required Tooling
A 421-5660 Lifting Eye Assembly 1
B —
Guide Stud
12 mm - 1.25 - by 100 mm
2
NOTICE
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1. Insert the flywheel stopper tool.
2. Remove bolts (1).
3. Insert Tooling (B).
4. Use Tooling (A) and a suitable lifting device to remove flywheel (2). The weight of
flywheel (2) is approximately 25 kg (55 lb).
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Caterpillar Cat 305E2 Mini Hydraulic Excavator (Prefix H5M) Service Repair Manual (H5M00001 and up).pdf

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