Caterpillar 302.5 302.5C Mini Hydraulic Excavator Workshop Service Manual 4AZ GBB PDF - MCAT302.5GBB4AZ.zip

Thorough factory-level service and repair manuals, complete with electrical wiring schematics, covering the Caterpillar 302.5 MINI HYD EXCAVATOR (serial number prefix 4AZ/GBB). Inside, you'll find every piece of workshop documentation needed to service, troubleshoot, fix, and rebuild this machine.

The Caterpillar 302.5 MINI HYD EXCAVATOR workshop service manual contains:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 621 pages

File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)

Manual Type: Disassembly & Assembly, Testing & Adjusting, Specifications, Systems Operation, Electrical Schematic...

Language: English

302.5 MINI HYD EXCAVATOR 4AZ

302.5C MINI HYD EXCAVATOR GBB

RENR2843 - Disassembly and Assembly (302.5 Mini Hydraulic Excavator Engine Supplement).pdf

RENR2844 - Specifications (302.5 Mini Hydraulic Excavator Machine Systems).pdf

RENR2845 - Systems Operation (302.5 Mini Hydraulic Excavator Hydraulic System).pdf

RENR2846 - Testing and Adjusting (302.5 Mini Hydraulic Excavator).pdf

RENR2847 - Schematic (302.5 Mini Hydraulic Excavator Hydraulic System).pdf

RENR2848 - Disassembly and Assembly (302.5 Mini Hydraulic Excavator Machine Systems).pdf

RENR2849 - Schematic (302.5 Mini Hydraulic Excavator Electrical Sysem (For Serial Numbers 4AZ1-5768)).pdf

RENR8136 - Schematic (302.5 Mini Hydraulic Excavator Electrical Sysem (For Serial Numbers 4AZ5769-UP).pdf

RENR2843 - Disassembly and Assembly (302.5 Mini Hydraulic Excavator Engine Supplement)............2

Pump Mounting Housing and Flange - Remove and Install............3

Engine - Install............7

Engine - Remove............13

Hood - Remove and Install............20

Muffler - Remove and Install............22

Air Cleaner - Remove and Install............26

Hydraulic Oil Cooler - Install............29

Hydraulic Oil Cooler - Remove............33

Radiator and Fan - Install............38

Radiator and Fan - Remove............42

Water Temperature Regulator - Remove and Install............47

Water Pump - Remove and Install............51

Fuel Filter and Water Separator - Remove and Install............54

Bottom Guard - Remove and Install............58

Electric Starting Motor - Remove and Install............60

Alternator - Remove and Install............64

Hydraulic System Pressure - Release............69

RENR2844 - Specifications (302.5 Mini Hydraulic Excavator Machine Systems)............70

Cab Mounting............71

Track Carrier Roller............73

Track Roller............75

Sprocket............76

Track............77

Recoil Spring............78

Governor Control............79

Fuel Tank............81

Counterweight Mounting............82

Stick Cylinder............83

Bucket Cylinder............84

Boom Swing Cylinder............85

Boom Cylinder............86

Blade Lift Cylinder............87

Piston Motor (Travel)............88

Piston Motor (Swing)............90

Swivel............92

Swing Gear and Bearing............94

Bank Valve............96

Speed and Direction Controls............98

Joystick Control and Mounting............99

Load Control Valve (Boom)............101

Solenoid Valve (Work Tool Lowering)............102

Pilot and Travel Speed Manifold............103

Hydraulic Oil Filter............105

Piston and Gear Pump............106

Hydraulic Tank............108

RENR2845 - Systems Operation (302.5 Mini Hydraulic Excavator Hydraulic System)............109

Combined Function Hydraulic Operation............110

Swivel............112

Piston Motor (Travel)............114

Control Valve (Straight Travel)............117

Travel System............119

Piston Motor (Swing)............122

Swing System............125

Boom Lowering Control Valve............127

Stick Hydraulic System............129

Bucket Hydraulic System............131

Boom Hydraulic System............133

Return Hydraulic System............135

Pilot Valve (Joystick)............138

Pilot and Travel Speed Manifold............141

Pilot Hydraulic System............143

Relief Valve (Line)............147

Relief Valve (Main)............149

Bank Valve............151

Piston and Gear Pump............178

General Information............182

RENR2846 - Testing and Adjusting (302.5 Mini Hydraulic Excavator)............186

Worksheets - Troubleshoot............187

Load Control Valve (Boom) - Test and Adjust............193

Piston and Gear Pump - Test and Adjust............197

Piston Motor (Swing) - Test............200

Relief Valve (Line) - Test and Adjust............208

Relief Valve (Main) - Test and Adjust............217

Accumulator (Pilot) - Test and Charge............224

Pilot System Pressure - Test............229

Hydraulic Oil Contamination - Test............232

Hydraulic System Pressure - Release............234

Hydraulic System Troubleshooting............235

Operational Checks............240

Visual Inspection............246

General Information............247

RENR2847 - Schematic (302.5 Mini Hydraulic Excavator Hydraulic System)............249

Collage............250

Main............258

RENR2848 - Disassembly and Assembly (302.5 Mini Hydraulic Excavator Machine Systems)............259

Bank Valve - Install............262

Bank Valve - Assemble............268

Bank Valve - Disassemble............280

Bank Valve - Remove............292

Pilot Valve (Joystick) - Install............299

Pilot Valve (Joystick) - Assemble............303

Pilot Valve (Joystick) - Disassemble............305

Pilot Valve (Joystick) - Remove............307

Piston Pump - Install............311

Piston Pump - Assemble............313

Piston Pump - Disassemble............320

Piston Pump - Remove............327

Gear Pump - Install............330

Gear Pump - Remove............333

Piston and Gear Pump - Install............337

Piston and Gear Pump - Remove............341

Pilot and Travel Speed Manifold - Remove and Install............346

Boom Lowering Control Valve - Remove and Install............353

Accumulator (Hydraulic Pilot) - Remove and Install............359

Hydraulic Tank - Remove and Install............361

Swing Gear and Bearing - Remove and Install............370

Undercarriage Frame - Remove and Install............374

Piston Motor (Swing) - Install............386

Piston Motor (Swing) - Assemble............393

Piston Motor (Swing) - Disassemble............398

Piston Motor (Swing) - Remove............403

Swivel - Install............411

Swivel - Assemble............415

Swivel - Disassemble............417

Swivel - Remove............419

Piston Motor (Travel) - Install............424

Piston Motor (Travel) - Assemble............427

Piston Motor (Travel) - Disassemble............444

Piston Motor (Travel) - Remove............462

Final Drive Sprocket - Remove and Install............465

Recoil Spring - Install............468

Recoil Spring - Assemble............470

Recoil Spring - Disassemble............472

Recoil Spring - Remove............474

Front Idler and Track Adjuster - Install............476

Track Adjuster - Assemble............478

Track Adjuster - Disassemble............480

Front Idler - Assemble............482

Front Idler - Disassemble............484

Front Idler and Track Adjuster - Remove............486

Track Carrier Roller - Remove and Install............488

Track Roller - Remove and Install............493

Track - Remove and Install............498

Cab - Remove and Install............503

Cab Heater - Remove and Install............508

Seat - Remove and Install............511

Fuel Tank - Install............513

Fuel Tank - Remove............517

Counterweight - Remove and Install............522

Boom Swing Cylinder - Remove and Install............529

Boom - Remove and Install............535

Boom Cylinder - Remove and Install............542

Stick - Remove and Install............549

Stick Cylinder - Remove and Install............556

Bucket Cylinder - Remove and Install............562

Bucket Linkage - Remove and Install............566

Bucket - Remove and Install............570

Blade - Remove and Install............574

Blade Cylinder - Remove and Install............578

Hydraulic System Pressure - Release............583

Duo-Cone Conventional Seals - Install............584

RENR2849 - Schematic (302.5 Mini Hydraulic Excavator Electrical Sysem (For Serial Numbers 4AZ1-5768))............591

Collage............592

Main............600

Features............600

Cover Page............601

Information............0

Component Location............602

Connector Location............603

Specification and Related Manuals............604

Wire Description............605

Standard Electrical............606

Schematic............607

Machine View............0

Machine Harness Connector and Component Locations............608

RENR8136 - Schematic (302.5 Mini Hydraulic Excavator Electrical Sysem (For Serial Numbers 4AZ5769-UP)............609

Collage............610

Main............618

Features............618

Cover page............619

Information............0

Component Location............620

Connector Location............621

Related Manual............622

Standard Electrical............623

Schematic............624

Machine View............0

Machine Harness and Component Locations............625

Caterpillar 302.5 MINI HYD EXCAVATOR Repair Service Manuals