Caterpillar cat 305.5 mini hydraulic excavator (prefix dck) service repair manual (dck00001 and up)

Service Repair Manual
Models
305.5 Mini Hydraulic Excavator

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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 -RENR9437-08 Publication Date -01/09/2018 Date Updated -17/09/2018
i02328456
Track Roller - Remove and Install
SMCS - 4180-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-9745 Air/Hydraulic Jack Gp 1
1. Release the tension on the track. Refer to Operation and Maintenance Manual, "Track
Adjustment - Adjust".
Illustration 1 g01162908
2. Raise the machine by using Tooling (A).
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3. Place suitable cribbing between the track and the roller frame. Lower the machine onto the
suitable cribbing by using Tooling (A). Remove bolts (1) and track roller (2).
Installation Procedure
Table 2
Required Tools

1. Install track roller (2) and bolts (1). Raise the machine by using Tooling (A) and remove the
suitable cribbing between the track and the roller frame. Lower the machine to the ground
by using Tooling (A).
2. Apply tension to the track. Refer to Operation and Maintenance Manual, "Track Adjustment
- Adjust".
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Thu Feb 13 15:39:19 UTC+0800 2020

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i02329739
Track - Separate
SMCS - 4170-076
Separation Procedure
Table 1
Required Tools
B 260-9412 Chain As 1
1. Release the tension on the track. Refer to Operation and Maintenance Manual, "Track

3. Rotate track assembly (1) until the master pin is on the top position. Place suitable cribbing
under track assembly (1).
4. Remove bolts (2) and track shoe (3). Remove bolts (4) and track shoe (5).
5. Attach Tooling (B) and a suitable lifting device to track assembly (1). Remove cotter pin (7)
from master pin (6). Use a suitable hammer and a suitable punch in order to remove master
pin (6).

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i02331434
Track - Connect
SMCS - 4170-077
Connection Procedure
Table 1
Required Tools
B 260-9412 Chain As 1
1. Attach Tooling (B) and a suitable lifting device to track assembly (1). Use the suitable
lifting device in order to lift track assembly (1) into position. Install master pin (6) and
install cotter pin (7).

2. Install track shoe (5) and install bolts (4). Install track shoe (3) and install bolts (2).
4. Remove the suitable cribbing from track assembly (1) and lower the machine to the ground.
5. Apply tension on the track. Refer to Operation and Maintenance Manual, "Track

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i02330446
Front Idler and Track Adjuster - Remove
SMCS - 4157-011; 4158-011; 4159-011
Removal Procedure
Start By:
a. Separate the track in the front. Refer to Disassembly and Assembly, "Track - Separate".
1. Slide track assembly (1) away from the front idler and track adjuster (2). Attach a suitable
lifting device to the front idler and track adjuster (2). The weight of front idler and track
adjuster (2) is approximately 57 kg (125 lb). Remove the front idler and track adjuster (2).
Thu Feb 13 15:42:10 UTC+0800 2020

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i02330834
Front Idler and Track Adjuster - Install
SMCS - 4157-012; 4158-012; 4159-012
Installation Procedure
1. Attach a suitable lifting device to the front idler and track adjuster (2). The weight of the
front idler and track adjuster (2) is approximately 57 kg (125 lb). Install the front idler and
track adjuster (2). Slide track assembly (1) over the front idler and track adjuster (2).
2. Connect the front of the track. Refer to Disassembly and Assembly, "Track - Connect".
Thu Feb 13 15:43:06 UTC+0800 2020

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i02328787
Recoil Spring - Remove
SMCS - 4158-011
Removal Procedure
Start By:
a. Remove the front idler and the track adjuster. Refer to Disassembly and Assembly, "Front
Idler and Track Adjuster - Remove".
1. Remove recoil spring assembly (1).
Thu Feb 13 15:44:03 UTC+0800 2020

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i04294437
Recoil Spring - Disassemble
SMCS - 4158-015
Disassembly Procedure
Table 1
Required Tools
A 4C-9540 Recoil Spring Bench 1
B
146-2457 Hydraulic Power Supply Gp 1
223-3506 Hydraulic Cylinder and Lines Gp 1
C
8F-0024 Hose Assembly 2
3B-7722 Bushing 2
1P-2376 Coupler Assembly 2
1P-2377 Plug 1
D 8S-9971 Adapter for Ram 1
E 275-5820 Spacer 1
Start By:
a. Remove the recoil spring. Refer to Disassembly and Assembly, "Recoil Spring - Remove".
Sudden release of spring force can cause injury.

To prevent the possibility of injury, follow the procedure to relieve the
spring pressure.
1. Install Tooling (D) on Tooling (B).
(1) Adjustable support

Tooling (A)
( 2) Reaction plate
(3) Movable plate
2. Determine the position for the recoil spring assembly in Tooling (A). Locate adjustable
support (1) of Tooling (A) in this position. Level the adjustable support.
3. Measure the free length of the recoil spring assembly. Remove the cotter pin. Adjust the
space from reaction plate (2) to movable plate (3) in order to fit the measured length.
Typical Example
4. Attach a suitable lifting device to recoil spring assembly (4). The weight of recoil spring
assembly (4) is approximately 16 kg (35 lb). Position the recoil spring assembly on
adjustable support (1) in Tooling (A). Align the centerline of the recoil spring assembly
with the centerline of Tooling (A) by moving the adjustable support.

Tooling (A)
( 2) Reaction plate
(3) Movable plate
5. Use the following procedure to position the recoil spring assembly in Tooling (A).
a. Level the recoil spring assembly by repositioning the adjustable support.
b. Use Tooling (E) and position the recoil spring assembly so that nut (6) is centered in
the hole of reaction plate (2).
c. Install two pins (5) on the back side of reaction plate (2), as shown.
d. Operate Tooling (B) enough to hold the recoil spring assembly in position between
reaction plate (2) and movable plate (3).
e. Be sure that the recoil spring assembly is leveled and centered in Tooling (A).
6. Close covers (7) on Tooling (A). Operate Tooling (B) and slowly compress the recoil spring
assembly until the nut is free to move.

7. Locate nut (6) through the opening in Tooling (A). Remove nut (6) from the retaining rod.
Use Tooling (B) and slowly release the force on the recoil spring assembly.
8. Open covers (7) on Tooling (A). Attach a suitable lifting device to the disassembled recoil
spring assembly. Remove the recoil spring assembly from Tooling (A).
9. Remove washer (10), retaining rod (9), and spring (8).
Thu Feb 13 15:45:00 UTC+0800 2020

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i05813460
Recoil Spring - Assemble
SMCS - 4158-016
Assembly Procedure
Table 1
Required Tools
A 4C-9540 Recoil Spring Bench 1
B
146-2457 Hydraulic Power Supply Gp 1
223-3506 Hydraulic Cylinder and Lines Gp 1
C
8F-0024 Hose Assembly 2
3B-7722 Bushing 2
1P-2376 Coupler Assembly 2
1P-2377 Plug 1
D 8S-9971 Adapter for Ram 1
E 275-5820 Spacer 1
F - Loctite Anti-seize Compound 1
Several tons of force are required to compress the recoil spring during
assembly.

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Do not compress the spring assembly until the covers on the tooling have
been closed.
It is possible for the recoil spring to twist under load and come out of the
tooling resulting in injury or death.
Note: Check the condition of the threads on support assembly (9) and on nut (6). If the threads are
damaged, use new parts for replacement.
1. Install Tooling (D) on Tooling (B).
(1) Adjustable support

Tooling (A)
( 2) Reaction plate
(3) Movable plate
2. Determine the position for the recoil spring assembly in Tooling (A). Place adjustable
support (1) of Tooling (A) in this position. Level the adjustable support.
3. Loosely assemble the recoil spring assembly. Apply Tooling (F) to the threads of support
assembly (9). Install recoil spring (8) onto support assembly (9). Install support (10) and nut
(6). Do not tighten nut (6) at this time.

Typical Example
4. Attach a suitable lifting device to the recoil spring assembly. Position the recoil spring
assembly (4) in Tooling (A). The weight of recoil spring assembly (4) is approximately
16 kg (35 lb). Use the following procedure to properly position recoil spring assembly (4) in
Tooling (A).
a. Level the recoil spring assembly by repositioning the adjustable support (1).
b. Position the recoil spring assembly so that nut (6) and the washer can be installed
through the access hole in reaction plate (2).
c. Install two pins (5) on the back side of reaction plate (2), as shown.
d. Operate Tooling (B) enough to hold the recoil spring assembly in position between
reaction plate (2) and movable plate (3).
e. Be sure that recoil spring assembly (4) is leveled and centered in Tooling (A).
f. Remove the suitable lifting device from recoil spring assembly (4).

Caterpillar cat 305.5 mini hydraulic excavator (prefix dck) service repair manual (dck00001 and up)

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