Caterpillar Mini Hydraulic Excavator 305.5E2

Warning: Do not use a pneumatic device, serious damage will occur.

Flywheel installed in the reverse order of removal

Clean engine oil applied to the threads of bolts

Tighten bolts to a torque of 98 N·m to 108 N·m (72 lb ft to 80 lb ft)

Sign off on the flywheel installation

Start By: a. Remove front housing.

NOTICE: Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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. Dispose of all fluids according to local regulations and mandates.

Ensure that Timing Marks (X) on the idler gear and the crankshaft gear are aligned.

Ensure that Timing Marks (Y) on the idler gear and the camshaft gear are aligned.

Ensure that Timing Marks (Z) on the idler gear and the fuel injection pump gear are aligned.

Remove bolts (1), gear control collar (3), and idler gear (2).

Use Tooling (A) and a suitable press to remove idler gear bearing (4).

Note: Make a temporary mark on the cylinder block in order to show the position of the oil hole.

a. Remove valve mechanism cover.

1. Remove bolts (2) and rocker shaft assembly (1).

2. Place an identification mark on pushrods (3) to show the location. Remove pushrods (3).

Note: Identification mark will ensure that the pushrods can be installed in the original positions. Do not interchange the positions of used pushrods.

1. Install pushrods (3) and rocker shaft assembly (1) in the reverse order of removal.;

a. Remove electric starting motor.

b. Remove diesel particulate filter.

d. Remove crankshaft position sensor.

1. Remove bolts (1) and bracket assembly (2)

2. Remove bolts (3) and flywheel housing (4).

1. Install idler gear (2) in the reverse order of removal.

a. Ensure that the gears, cylinder block surface, and idler gear (2) are clean and free from wear or damage. If necessary, replace any components that are worn or damaged

b. Lubricate idler shaft (6) with clean engine oil.

c. Lubricate idler gear bearing surface (4) with clean engine oil.

d. Apply clean engine oil to bolts (5). ;