305C CR MINI HYD EXCAVATOR

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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

i04020373

Air Inlet and Exhaust System - Inspect

SMCS - 1050-040

Measuring exhaust manifold distortion

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
Less than
Exhaust manifold distortion
0.150 mm (0.0059 inch)

Copyright 1993 - 2020 Caterpillar Inc. Fri Nov 6 12:02:06 UTC+0530 2020
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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

i04077149

Air Inlet and Exhaust System - Install

SMCS - 1050-012

Installing inlet and exhaust system

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).

Copyright 1993 - 2020 Caterpillar Inc. Fri Nov 6 12:02:20 UTC+0530 2020
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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

i04077129

Air Inlet and Exhaust System - Remove

SMCS - 1050-011

Removing inlet and exhaust system

Illustration 1 g02285674

Removing sequence

(1) Air hose

(2) Air inlet elbow

(3) Inlet manifold

(4) Exhaust manifold

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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

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 high-
temperature 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)

Copyright 1993 - 2020 Caterpillar Inc. Fri Nov 6 12:01:23 UTC+0530 2020
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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

i04023331

Cooling System - Install

SMCS - 1350-012

Installation cooling system

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Illustration 1 g02239533

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).

Copyright 1993 - 2020 Caterpillar Inc. Fri Nov 6 12:01:37 UTC+0530 2020
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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

i04037726

Cooling System - Remove

SMCS - 1350-011

Removing cooling system

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.

Copyright 1993 - 2020 Caterpillar Inc. Fri Nov 6 12:01:08 UTC+0530 2020
All Rights Reserved.
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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

i04020349

Cylinder Head and Valve Mechanism - Assemble

SMCS - 1100-016; 1102-016

Installing valve stem seal

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.

Copyright 1993 - 2020 Caterpillar Inc. Fri Nov 6 11:59:16 UTC+0530 2020
All Rights Reserved.
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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

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 g02203053

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

(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.
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.

Removing valve and valve spring

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