305.5 Caterpillar Mini Hyd Excavator Service Repair Manual

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Product: MINI HYD EXCAVATOR

Model: 305.5 MINI HYD EXCAVATOR DCK

Configuration: 305.5 Mini Hydraulic Excavator DCK00001-UP (MACHINE) POWERED BY 4M40 Engine

Disassembly and Assembly 4M40 DIESEL ENGINE SHOP MANUAL

Shutdown SIS

Media Number -KENR5078-00 Publication Date -01/11/2007 Date Updated -01/12/2014

General

SMCS - 5051-012

Information Location

KENR50780012

This shop manual is published for the information and guidance of personnel responsible for maintenance of Mitsubishi 4M40 series diesel engine, and includes procedures for adjustment and maintenance services. We earnestly look forward to seeing that this manual is made full use of in order to perform correct services with no wastage.

Disassembly and Assembly information is located under General Service Information.

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Mon Oct 12 15:49:18 UTC+0530 2020

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Product: MINI HYD EXCAVATOR

Model: 305.5 MINI HYD EXCAVATOR DCK

Configuration: 305.5 Mini Hydraulic Excavator DCK00001-UP (MACHINE) POWERED BY 4M40 Engine

Disassembly and Assembly

305.5 and 306 Mini Hydraulic Excavators Machine Systems

i02336431

Blade - Remove and Install

SMCS - 6060-010

Removal Procedure Table 1

1. Position the blade on the ground. Rotate the machine to the side in order to gain access to the blade.

2. Remove bolts (1) and guard (2).

2

3. Attach a suitable lifting device to blade cylinder (3). The weight of blade cylinder (3) is approximately 36 kg (80 lb). Remove bolt (5) and pin assembly (4). Lower the rod end of blade cylinder (3) to the ground.

3

Illustration 4

4. Install pin assembly (4) and install bolt (5) that was removed in the previous step. Attach Tooling (A) and a suitable lifting device to blade (6). The weight of blade (6) is approximately 227 kg (500 lb).

Remove bolt (7) and pin assembly (8). Repeat for the other side. Remove blade (6).

Illustration 5

5. Remove lip seals (9). Use Tooling (B) in order to remove bushing (10). Repeat for the other side.

Installation Procedure

1. Lower the temperature of bushing (10). Use Tooling (B) in order to install bushing (10) to a depth of 5.00 mm (0.1969 inch). Repeat for the other side. Use Tooling (B) in order to install lip seals (9).

2. Attach Tooling (A) and a suitable lifting device to blade (6). The weight of blade (6) is approximately 227 kg (500 lb).

Install blade (6). Install pin assembly (8) and bolt (7).

Illustration 9

3. Attach a suitable lifting device to the rod end of blade cylinder (3). The weight of blade cylinder (3) is approximately 36 kg (80 lb). Raise the rod end of blade cylinder (3) into position and install pin assembly (4) and bolt (5).

Illustration 10

4. Install guard (2) and bolts (1).

Copyright 1993 - 2020 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Mon Oct 12 14:50:38 UTC+0530 2020

This is the sample of the manual

Click on the download link for complete Manual

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Product: MINI HYD EXCAVATOR

Model: 305.5 MINI HYD EXCAVATOR DCK

Configuration: 305.5 Mini Hydraulic Excavator DCK00001-UP (MACHINE) POWERED BY 4M40 Engine

Disassembly and Assembly

305.5 and 306 Mini Hydraulic Excavators Machine Systems

Blade Cylinder - Remove and Install

SMCS - 7562-010-BG

Removal Procedure

Start By:

a. Release the hydraulic system pressure. Refer to Disassembly and Assembly, "Hydraulic Sytem Pressure - Release".

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.

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.

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.

1. Position the blade on the ground. Rotate the machine to the side in order to gain access to the blade cylinder.

1

2. Remove bolts (1) and guard (2).

2

3. Attach a suitable lifting device to blade cylinder (3). The weight of blade cylinder (3) is approximately 68 kg (150 lb). Disconnect hose assemblies (5). Remove pin assemblies (4) and (6). Remove blade cylinder (3).

Disassembly and Assembly

Note: Tooling (A) is used for the removal and the installation of bearings (4) and (5). Tooling (B) is used for the removal and the installation of cylinder head (1).

(3) Torque for locknut ... 2210 N·m (1630 lb ft)

(2) Lubricate the sealing lip slightly with the lubricant that is being sealed.

(1) Torque for head ... 834 N·m (615 lb ft)

Installation Procedure

4

1. Attach a suitable lifting device to blade cylinder (3). The weight of blade cylinder (3) is approximately 68 kg (150 lb). Install blade cylinder (3). Install pin assemblies (4) and (6). Connect hose assemblies (5).

Illustration 5

2. Install guard (2) and bolts (1).

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Product: MINI HYD EXCAVATOR

Model: 305.5 MINI HYD EXCAVATOR DCK

Configuration: 305.5 Mini Hydraulic Excavator DCK00001-UP (MACHINE) POWERED BY 4M40 Engine

Disassembly and Assembly

305.5 and 306 Mini Hydraulic Excavators Machine Systems

Blower Motor (Heater) - Remove and Install

SMCS - 7304-010-BW

Removal Procedure

Start By:

Shutdown SIS

a. Remove the cab heater. Refer to Disassembly and Assembly, "Cab Heater - Remove".

Illustration 1 g01162400

1. Remove bolts (3) and bracket (4). Remove bolts (1) and blower motor (2).

i02326982

Illustration 2

2. Remove clip (5) and cage (6).

Installation Procedure

g01162401

Illustration 3

1. Install cage (6) and install clip (5).

g01162401

Illustration 4

2. Install blower motor (2) and install bolts (1). Install bracket (4) and install bolts (3).

End By:

a. Install the cab heater. Refer to Disassembly and Assembly, "Cab Heater - Install".

Mon Oct 12 15:08:15 UTC+0530 2020

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Product: MINI HYD EXCAVATOR

Model: 305.5 MINI HYD EXCAVATOR DCK

Configuration: 305.5 Mini Hydraulic Excavator DCK00001-UP (MACHINE) POWERED BY 4M40 Engine

Disassembly and Assembly

305.5 and 306 Mini Hydraulic Excavators Machine Systems

Shutdown SIS

Boom - Install

SMCS - 6501-012

Installation Procedure Table 1

Illustration 1

1. Attach a suitable lifting device to stick cylinder (12). The weight of stick cylinder (12) is approximately 68 kg (150 lb). Install stick cylinder (12).

Install pin assembly (13) and bolt (14). Connect hose assemblies (15). Install hose assemblies (15) and tube assemblies (16), if necessary.

2

3

2. Attach a suitable lifting device to boom (9). The weight of boom (9) is approximately 363 kg (800 lb). Install boom (9). Install pin assembly (10) and bolt (11).

Illustration 4

3. Install the cable straps. Connect harness assembly (8).

Illustration 5

4. Install panel (7) and bolts (6).

Illustration 6

5. Connect hose assemblies (5).

Illustration 7 g01165738

6. Connect hose assemblies (4).

Illustration 8

g01165735

7. Attach a suitable lifting device to boom cylinder (3). The weight of boom cylinder (3) is approximately 36 kg (80 lb). Raise boom cylinder (3) into position. Install pin assembly (2) and install bolt (1) .

Illustration 9

8. Install Tooling (A).

g01165729

Note: Tooling (A) will be used for the installation of the stick.

End By:

a. Install the stick. Refer to Disassembly and Assembly, "Stick - Install".

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Product: MINI HYD EXCAVATOR

Model: 305.5 MINI HYD EXCAVATOR DCK

Configuration: 305.5 Mini Hydraulic Excavator DCK00001-UP (MACHINE) POWERED BY 4M40 Engine

Disassembly and Assembly

305.5 and 306 Mini Hydraulic Excavators Machine Systems

Boom - Remove

SMCS - 6501-011

Removal Procedure

Start By:

a. Remove the stick. Refer to Disassembly and Assembly, "Stick - Remove".

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.

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.

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.

Illustration 1

1. Remove Tooling (A). Position the boom on the ground.

Note: Tooling (A) was used in the removal of the stick.

2

2. Attach a suitable lifting device to boom cylinder (3). The weight of boom cylinder (3) is approximately 36 kg (80 lb). Remove bolt (1) and pin assembly (2). Lower boom cylinder (3) to the ground.

3

Illustration 4

Illustration 5

5. Remove bolts (6) and panel (7).

6

6. Disconnect harness assembly (8). Cut the cable straps.

7

Illustration 8

7. Attach a suitable lifting device to boom (9). The weight of boom (9) is approximately 363 kg (800 lb). Remove bolt (11) and pin assembly (10). Remove boom (9).

Illustration 9 g01165756

8. Attach a suitable lifting device to stick cylinder (12). The weight of stick cylinder (12) is approximately 68 kg (150 lb).

If necessary, remove hose assemblies (15) and tube assemblies (16). Disconnect hose assemblies (15). Remove bolt (14) and pin assembly (13). Remove stick cylinder (12). If necessary, remove hose assemblies (15) and tube assemblies (16). Copyright 1993 - 2020 Caterpillar Inc.

Rights Reserved.

Network For SIS Licensees. Mon Oct 12 14:57:34 UTC+0530 2020

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Product: MINI HYD EXCAVATOR

Model: 305.5 MINI HYD EXCAVATOR DCK

Configuration: 305.5 Mini Hydraulic Excavator DCK00001-UP (MACHINE) POWERED BY 4M40 Engine

Disassembly and Assembly

305.5 and 306 Mini Hydraulic Excavators Machine Systems

Boom Bearings and Seals - Remove and Install

SMCS - 6501-010-BD; 6501-010-SA

Removal Procedure

Table 1

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.

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.

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.

Illustration 1

2

1. Install Tooling (A) to the stick cylinder. Install Tooling (B) to the bucket cylinder.

Illustration 3

2. Remove bolt (1) and guard (2).

g01166412

Illustration 4

g01166424

3. Attach a suitable lifting device to boom cylinder (5). The weight of boom cylinder (5) is approximately 36 kg (80 lb). Remove bolt (3) and pin assembly (4). Lower boom cylinder (5) to the ground.

5

4. Disconnect hose assemblies (6).

Illustration 6

5. Disconnect hose assemblies (7).

This is the sample of the manual

Click on the download link for complete Manual

Illustration 7

6. Remove bolts (8) and panel (9).

Illustration 8

7. Disconnect harness assembly (10).

g01166433

Illustration 9

g01166435