Caterpillar Cat 302.2D Mini Hydraulic Excavator (Prefix LJG) Service Repair Manual (LJG00001 and Up)

Service Repair Manual
Models
302.2D Mini Hydraulic Excavator

302.2D Mini Hydraulic Excavator LJG00001-UP (MACHINE)(SEBP6414 - 17) - Doc... 1/2
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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.
7. The pressure in the hydraulic system has now been released. Hydraulic lines and
components can now be removed.
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i05221871
Blade Cylinder - Remove and Install - Long

SMCS - 7562-010-BG
Specifications
Table 1
Specification for 395-1281 Hydraulic Cylinder Gp
Item Qty
Part Specification Description
Before assembly, lubricated the threads with clean oil.

1 1 -
Tighten the head to 300 to 350 N·m (221 to 258 lb ft).
Before assembly, apply Locktite 638 to the outer surface of
2 1 -
the bearing.
395-1286 Piston Diameter is
3 1
Rod 35 mm (1.4 inch).
395-1218 Bushing Bore after assembly is

4 2
32 mm (1.3 inch).
395-1256 Cylinder Bore is
5 1
As 60 mm (2.4 inch).
Left Hand Thread
6 1 - 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
Table 2
Specification for 395-1267 Blade Cylinder Gp
Item Qty
Part Specification Description
Before assembly, apply Locktite 638 to the outer surface of

1 1 -
the bearing.

2 1 - Tighten the head to
300 to 350 N·m (221 to 258 lb ft).
3 1 - Tighten the piston to
25 to 35 N·m (221 to 310 lb in).
Left-hand thread
4 1 - 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.
395-1255 Cylinder Bore is
A 1
As 70 mm (2.6 inch).
395-1287 Piston Diameter is
B 1
Rod 40 mm (1.6 inch).
395-1218 Bushing Bore after assembly is

C 2
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.
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.
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i05181955
Blade - Remove and Install

SMCS - 6060-010
Removal Procedure
1. Remove pin (1) .
2. Install suitable cribbing under blade arm (2) .
3. Remove pins (3) from blade arm (2) .
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.
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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.
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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
1 1 229-9247 Pin As Diameter is

29.945 to 29.960 mm (1.1789 to 1.1795 inch).
Bore after assembly is

2 1 Bushing
30 mm (1.2 inch).
Bore after assembly is
3 1 Bushing
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)
4. Remove bearings (3).
5. Remove bearings (4).
Table 2
Required Tools
Tool Part Number Part Description Qty
FT-3038 Puller Adapter 1
FT-3039 Receiving Sleeve 1
6V-3160 Single Acting Cylinder 1
A
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.
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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).
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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
Table 1
Specification for 419-9101 Hydraulic Cylinder Gp
Item Qty Part Specification Description

Bore before assembly is
1 2 379-2769 Bushing
32 mm (1.3 inch).
Diameter is
2 1 395-1285 Piston Rod
35 mm (1.4 inch).
Tighten the piston to

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
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.

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Service Repair Manual

302.2D Mini Hydraulic Excavator

Product: MINI HYD EXCAVATOR

Disassembly and Assembly

Flywheel - Remove and Install

A. Remove the pump drive coupling.

1. Remove bolts (1). Remove flywheel (2).

2. Tighten bolts (1) to a torque of 84 N·m (62 lb ft)

Product: MINI HYD EXCAVATOR

Disassembly and Assembly

System Pressure - Release

Release Procedure (Hydraulic System Pressure)

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.

6. Turn the key to the OFF position.

Product: MINI HYD EXCAVATOR

Disassembly and Assembly

Blade Cylinder - Remove and Install - Long

Before assembly, lubricated the threads with clean oil.

395-1218 Bushing Bore after assembly is

Before assembly, lubricated the threads with clean oil.

6 1 - Tighten the nut to

Before assembly, apply Locktite 638 to the outer surface of

Before assembly, lubricated the threads with clean oil.

4 1 - Tighten the nut to

395-1218 Bushing Bore after assembly is

A. Release the hydraulic system pressure.

Failure to relieve pressure before removing a lock valve or

Ensure all pressure is relieved before removing a lock valve or

1. Remove cover (1).

Product: MINI HYD EXCAVATOR

Disassembly and Assembly

Blade - Remove and Install

1. Remove pin (1) .

2. Install suitable cribbing under blade arm (2) .

3. Remove pins (3) from blade arm (2) .

Product: MINI HYD EXCAVATOR

Disassembly and Assembly

Bucket - Remove and Install

Product: MINI HYD EXCAVATOR

Disassembly and Assembly

Bucket Linkage - Remove and Install

1 1 229-9247 Pin As Diameter is

Bore after assembly is

A. Remove the bucket.

4. Remove bearings (3).

5. Remove bearings (4).

126-8928 Hard Washer

Product: MINI HYD EXCAVATOR

Disassembly and Assembly

Bucket Cylinder - Remove and Install

Item Qty Part Specification Description

Tighten the piston to

1. Position bucket flat on the ground.

2. Disconnect hose assemblies (4). Remove pins (2) and (3) .

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