caterpillar 305.5 mini hyd excavator DCK service manual

Get the most out of your caterpillar 305.5 mini hyd excavator with this comprehensive service manual. Effortlessly maintain your equipment and maximize its longevity with step-by-step instructions and helpful tips. Empower yourself to tackle any job with confidence - because a well-maintained excavator is a reliable one.

1. 30
5.5

MINI HYD EXCAVATOR







Printed by Heavy Equipment Manuals


Printed in U.S.A
v2.20



Heavy Equipment Manuals

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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
Media Number -KENR5078-00 Publication Date -01/11/2007 Date Updated -01/12/2014
KENR50780012
General
SMCS - 5051-012
Information Location
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
Media Number -RENR9437-07 Publication Date -01/01/2017 Date Updated -23/01/2017
i02336431
Blade - Remove and Install
SMCS - 6060-010
Removal Procedure
Table 1
Required Tools
ToolPart NumberPart DescriptionQty
A 189-0410 Shackle As 2
B 1P-0520 Driver Gp 1
1.Position the blade on the ground. Rotate the machine to the side in order to gain access to the
blade.
Illustration 1 g01166033

5. 2.Remove bolts (1) and guard (2).
Illustration 2 g01166068
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.
Illustration 3 g01166070

6. Illustration 4 g01166073
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 g01166080
5.Remove lip seals (9). Use Tooling (B) in order to remove bushing (10). Repeat for the other
side.
Installation Procedure
Table 2
Required Tools
ToolPart NumberPart DescriptionQty
A 189-0410 Shackle As 2
B 1P-0520 Driver Gp 1

7. Illustration 6 g01166080
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).
Illustration 7 g01166070
Illustration 8 g01166073

8. 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 g01166068
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 g01166033
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

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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
Media Number -RENR9437-07 Publication Date -01/01/2017 Date Updated -23/01/2017
i02393831
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

10. 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.
Illustration 1 g01166033
2.Remove bolts (1) and guard (2).
Illustration 2 g01166055
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).

11. Disassembly and Assembly
Table 1
Required Tools
ToolPart Number Part Description Qty
A
5P-4749 Bearing Puller Adapter 1
4C-9633 Puller Stud 1
9S-5565 Pin Puller Sleeve As 1
9U-6833 Nut 1
3S-6224 Electric Hydraulic Pump Gp 1
6V-3160 Double Acting Cylinder 1
B
9U-7868 Spanner Wrench 1
204-6213 Adjustable Adapter Plate 1
130-1810 Pin Group 1
C 1P-0510 Driver Gp 1
D 127-4904 Hydraulic Cylinder Repair Stand Gp 1
E 195-4609 Seal Pick 1
Illustration 3 g01195387

12. 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
Illustration 4 g01166055
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 g01166033
2.Install guard (2) and bolts (1).

13. Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Oct 12 14:50:24 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
Media Number -RENR9437-07 Publication Date -01/01/2017 Date Updated -23/01/2017
i02326982
Blower Motor (Heater) - Remove and Install
SMCS - 7304-010-BW
Removal Procedure
Start By:
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).
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15. Illustration 2 g01162401
2.Remove clip (5) and cage (6).
Installation Procedure
Illustration 3 g01162401
1.Install cage (6) and install clip (5).
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17. Illustration 4 g01162400
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".
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Oct 12 15:08:15 UTC+0530 2020
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18. Shutdown SIS
Previous Screen
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
Media Number -RENR9437-07 Publication Date -01/01/2017 Date Updated -23/01/2017
i02335614
Boom - Install
SMCS - 6501-012
Installation Procedure
Table 1
Required Tools
ToolPart NumberPart DescriptionQty
A 6V-3155 Brace 1
Illustration 1 g01165756
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).

19. Install pin assembly (13) and bolt (14). Connect hose assemblies (15). Install hose assemblies
(15) and tube assemblies (16), if necessary.
Illustration 2 g01165748
Illustration 3 g01165753
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).

20. Illustration 4 g01165744
3.Install the cable straps. Connect harness assembly (8).
Illustration 5 g01165741
4.Install panel (7) and bolts (6).
Illustration 6 g01165740
5.Connect hose assemblies (5).

21. 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 g01165729
8.Install Tooling (A).
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".
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Mon Oct 12 14:58:25 UTC+0530 2020

22. Private Network For SIS Licensees.

23. Shutdown SIS
Previous Screen
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
Media Number -RENR9437-07 Publication Date -01/01/2017 Date Updated -23/01/2017
i02335473
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

24. 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 g01165729
1.Remove Tooling (A). Position the boom on the ground.
Note: Tooling (A) was used in the removal of the stick.
Illustration 2 g01165735
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.

25. Illustration 3 g01165738
3.Disconnect hose assemblies (4).
Illustration 4 g01165740
4.Disconnect hose assemblies (5).
Illustration 5 g01165741

26. 5.Remove bolts (6) and panel (7).
Illustration 6 g01165744
6.Disconnect harness assembly (8). Cut the cable straps.
Illustration 7 g01165748
Illustration 8 g01165753

27. 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.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Oct 12 14:57:34 UTC+0530 2020

28. Shutdown SIS
Previous Screen
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
Media Number -RENR9437-07 Publication Date -01/01/2017 Date Updated -23/01/2017
i02336996
Boom Bearings and Seals - Remove and Install
SMCS - 6501-010-BD; 6501-010-SA
Removal Procedure
Table 1
Required Tools
ToolPart Number Part Description Qty
A 6V-3155 Brace 1
B 6V-3155 Brace 1
C 1U-9200 Lever Puller Hoist 1
D 189-0409 Shackle As 1
E
9S-5565 Pin Puller Sleeve As 1
4K-0684 Washer 1
6V-3160 Double Acting Cylinder 1
3S-6224 Electric Hydraulic Pump Gp 1
1P-1834 Bearing Puller Adapter 1
4C-9633 Puller Stud 1
9U-6833 Nut 1
4C-9633 Puller Stud 1

29. 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 g01166379

30. Illustration 2 g01166380
1.Install Tooling (A) to the stick cylinder. Install Tooling (B) to the bucket cylinder.
Illustration 3 g01166412
2.Remove bolt (1) and guard (2).
Illustration 4 g01166424

31. 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.
Illustration 5 g01166429
4.Disconnect hose assemblies (6).
Illustration 6 g01166431
5.Disconnect hose assemblies (7).

32. Illustration 7 g01166432
6.Remove bolts (8) and panel (9).
Illustration 8 g01166433
7.Disconnect harness assembly (10).
Illustration 9 g01166435

33. This is the sample of the sample click on
the download link for complete manual
DOWNLOAD LINK
For some reason if link demos not work
download this pdf and then click