Caterpillar Cat 305CR Mini Hydraulic Excavator (Prefix DSA) Service Repair Manual (DSA00001 and up).pdf

Service Repair Manual
Models
305CR Mini Hydraulic Excavator

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Product: MINI HYD EXCAVATOR
Model: 305 MINI HYD EXCAVATOR DSA
Configuration: 305CR Mini Hydraulic Excavator DSA00001-UP (MACHINE) POWERED BY K4N Engine
Disassembly and Assembly
305 Mini Hydraulic Excavator Machine Systems
Media Number -RENR5546-04 Publication Date -01/08/2007 Date Updated -07/08/2007
i01671197
Travel Motor - Remove
SMCS - 4351-011
Removal Procedure
Start By:
A. Release the hydraulic system pressure. Refer to Disassembly and Assembly, "Hydraulic
System Pressure - Release".
B. Remove the track. Refer to Disassembly and Assembly, "Track - Remove and Install".
C. Remove the final drive sprocket. Refer to Disassembly and Assembly, "Final Drive
Sprocket - Remove and Install".
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.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
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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, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Note: Put identification marks on all lines and on all hoses for installation purposes. Plug all lines
and all hoses. This helps to prevent fluid loss and this helps to keep contaminants from entering
the system.
Illustration 1 g00723963
1. Remove bolts (1) and washers.
2. Remove cover (2) .
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3. Disconnect hose assemblies (3), (4), (5), and (6) from the travel motor.
4. Use a suitable lifting device to support the travel motor.
5. Remove bolts (7) and washers from the travel motor.
6. Remove travel motor (8) from the undercarriage frame with a suitable lifting device. Weight
of the travel is 60 kg (132 lb).
7. Repeat Steps 1 through 6 for the other side of the travel motor.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Feb 14 17:40:48 UTC+0800 2020
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i01669600
Travel Motor - Disassemble
SMCS - 4351-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-1862 Snap Ring Pliers 1
B 1U-7588 Pry Bar 2
Start By:
A. Remove the piston motor (travel). Refer to Disassembly and Assembly, "Piston Motor
(Travel) - Remove" in this manual.
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, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
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Note: Put identification marks on the travel motor and on all lines for installation purposes. Plug
all lines. This will help to prevent fluid loss and this helps to keep contaminants from entering the
system.
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism.
1. Put an alignment mark across the section of the travel motor and the final drive for assembly
purposes. The parts must be reinstalled in the original locations of the parts.
2. Remove plugs (1). Drain the oil.
3. Remove bolts (2). Remove plate (3) .
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4. Remove port plate (4) .
5. Remove barrel assembly (5) .
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6. Put identification marks on piston assemblies (6) in order to indicate the locations of the
pistons in the retainer plate (7) and the barrel (8). Remove piston assemblies (6) and retainer
plate (7) from barrel (8) as a unit. Separate the piston assemblies from the retainer plate.
7. Remove guide (9) and pins (10) from barrel (8) .
8. Remove swashplate (11) .
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9. Remove piston (12), and spring (13) .
10. Use a 0.25 mm (0.010 inch) feeler gauge to a 0.38 mm (0.015 inch) feeler gauge. Remove
ring (14) from the groove between cover (15) and the final drive housing.
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11. Remove cover (16) .
12. Remove O-ring seal (17) .
13. Use Tooling (A) in order to remove retaining rings (18) .
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14. Remove gears (19). Remove gear (20) .
15. Remove shaft (21). Remove bearing (22) .
16. Remove pivots (23), and lip seal (24) .
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NOTICE
The thread lock compound that is used on the reamer bolts may cause
the reamer bolts to seize during removal.
The reamer bolts should be slowly removed by hand. Do not use an
impact wrench in order to remove the reamer bolts. If the reamer bolts
will no longer turn during removal, do not force or complete the
removal. Instead, tighten the bolts, then try to loosen them again.
17. Carefully remove bolts (25). Remove retaining rings (26) .
18. Use Tooling (B) in order to separate spindle (27) from housing (28) .
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19. Remove flange (29), and bearing (30) .
20. Remove gear (31) .
21. Remove shaft assemblies (32), and gear (33) .
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22. Remove bearing cone (35), and bearing cone (38) from shaft (34). Remove bearing (36),
and bearing (37) from shaft (34) .
23. Remove Duo-Cone seal kit (39). Remove pins (40). Remove bearing (41) .
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24. If necessary, remove valve (42). Remove bearing (43) .
25. Remove plugs (44), and the O-ring seals. Remove springs (45), stoppers (46), and spool
(47) .
26. Remove plugs (48), and the O-ring seals. Remove springs (49), and stoppers (50) .
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27. If necessary, remove plugs (51). Remove plug (52), and the O-ring seal. Remove plug (53) .
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Feb 14 17:41:44 UTC+0800 2020
12/12
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i02404421
Travel Motor - Assemble
SMCS - 4351-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-1862 Snap Ring Pliers 1
B 1U-7588 Pry Bar 2
C 1U-6439 Duo-Cone Seal Installer 1
D 5P-3931 Anti-Seize Compound 1
E 9S-3263 Thread Lock Compound 1
Note: Replace all O-ring seals and gaskets. Apply a light film of"10W" oil to all components
before assembly.
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are
worn or damaged, use new parts for replacement.
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1. If necessary, install plugs (51) . Tighten the plugs to a torque of 12.3 ± 2.45 N·m (109 ± 22
lb in). Install plug (52) , and the O-ring seal. Install plug (53) .
2. Install stoppers (50) , and springs (49) . Install plugs (48) , and the O-ring seals. Tighten
plugs to a torque of 79 ± 10 N·m (58 ± 7 lb ft).
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3. Install spool (47) . Install stoppers (46) , and springs (45) . Install plugs (44) , and the O-ring
seals. Tighten the plugs to a torque of 195 ± 15 N·m (144 ± 11 lb ft).
4. If necessary, install valve (42) . Install bearing (43) .
5. Install bearing (41) . Install pins (40) .
3/12
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6. Use Tooling (C) in order to install Duo-Cone seal kit (39) .
7. Install bearing (36) , and bearing (37) on shaft (34) . Install bearing cone (35) , and bearing
cone (38) on shaft (34) .
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8. Install gear (33) , and shaft assemblies (32) .
9. Install gear (31) .
NOTICE
During installation of the flange plate, keep the flange plate level and
true. If the flange plate is not kept level and true, galling of the flange
plate will result.
10. Install bearing (30) , and flange (29) .
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11. Install spindle (27) into housing (28) .
12. Install two retaining rings (26) .
NOTICE
If bolts (25) are not tightened evenly, a small amount at a time, the
flange plate will tilt resulting in seizure of the bolts. Also, the seating
face of each bolt must be in face-to-face contact with the flange plate
after they are tightened to the specified torque value.
13. Make sure that bolts (25) are thoroughly clean and dry. Apply Tooling (D) on the shank of
each bolt. Apply Tooling (E) to the threads of each bolt.
14. Install bolts (25) . Tighten bolts (25) evenly by tightening the bolts in small increments.
Tighten bolts (25) to a final torque of 252 ± 39 N·m (186 ± 29 lb ft).
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Caterpillar Cat 305CR Mini Hydraulic Excavator (Prefix DSA) Service Repair Manual (DSA00001 and up).pdf

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