304.5 Mini Hydraulic Excavator Machine Systems Caterpillar

Removal Procedure

Start By:

1. Remove the stick. Refer to Disassembly and Assembly, "Stick - Remove and Install".
2. Remove the stick cylinder. Refer to Disassembly and Assembly, "Stick Cylinder - Remove and Install".
3. Remove the boom cylinder. Refer to Disassembly and Assembly, "Boom Cylinder - Remove and Install".

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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.

Note: Put identification marks on all lines and on all wires for installation purposes. Plug all lines. This will help to prevent fluid loss and this helps to keep contaminants from entering the system.

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Illustration 1	g00719837

1. Use Tooling (A) to support the boom.

2. Disconnect wires (1) and (2) .

3. Cut strap (3) and move the wire aside.

4. Remove bolt (4) and the washer.

5. Remove boom light (5) from the boom.

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Illustration 2	g00719939

6. Remove two bolts (6) and washers.

7. Remove cover (7) from the boom.

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Illustration 3	g00719978

8. Disconnect lines (8), (9), (10), (11), (12), and (13) .

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Illustration 4	g00719991

9. Disconnect lines (14) and (15) .

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Illustration 5	g00720007

10. Remove two nuts (16) and washers.

11. Remove two clamps (17) .

12. Remove nut (18) .

13. Remove nut (19) and hose (20) .

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Illustration 6	g00720042

14. Remove nut (21) .

15. Remove nut (22) and hose (23) .

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Illustration 7	g00720094

16. Remove two bolts (24) and washers.

17. Remove two clamps (25) .

18. Remove tube (26) .

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Illustration 8	g00720100

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Illustration 9	g00720123

19. Remove nut (27), washers, and bolt (29) .

20. Remove two clamps (28) .

21. Remove tubes (30) and (31) .

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Illustration 10	g00720285

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Illustration 11	g00720292

22. Remove nut (32), washers, and bolt (34) .

23. Remove two clamps (33) .

24. Remove tubes (35) and (36) .

25. Remove two bolts (37) and washers.

26. Remove two clamps (38) .

27. Remove tube (39) .

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Illustration 12	g00720297

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Illustration 13	g00720312

28. Use a suitable lifting device to support the boom.

29. Remove two bolts (42), washers, and plate (43) .

30. Remove pin assembly (41) from the boom.

31. Use a suitable lifting device to remove boom (40) from the upper structure. Weight of the boom is 173 kg (381 lb).

Installation Procedure

Note: Be sure that the boom pin assembly and boom pin bores are thoroughly clean prior to installation of the boom.

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Illustration 14	g00720297

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Illustration 15	g00720312

1. Apply a thin coat of 1P-0808 Multipurpose Grease on the machined diameter of the pin bore and boom pin assembly. Use a suitable lifting device to support boom (40) into position. Weight of the boom is 173 kg (381 lb).

2. Install pin assembly (41) into the boom.

3. Position plate (43) and install washers and two bolts (42) .

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Illustration 16	g00720285

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Illustration 17	g00720292

4. Position tube (39) to the boom.

5. Place two clamps (38) to the boom.

6. Install washers and two bolts (37). Tighten the bolts.

7. Position tubes (35) and (36) to the boom.

8. Place two clamps (33) to the tubes.

9. Install washers, bolt (34), and nut (32) to the tubes. Tighten the nut and the bolt.

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Illustration 18	g00720100

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Illustration 19	g00720123

10. Position tubes (30) and (31) to the boom.

11. Place two clamps (28) to the tubes.

12. Install washers, bolt (29) and nut (27) to the tubes. Tighten the nut and the bolt.

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Illustration 20	g00720094

13. Position tube (26) to the boom.

14. Place two clamps (25) to the tube.

15. Install washers and two bolts (24). Tighten the bolts.

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Illustration 21	g00720042

16. Position hose (23) and install nut (22). Tighten the nut.

17. Install nut (21). Tighten the nut.

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Illustration 22	g00720007

18. Position hose (20) and install nut (19). Tighten the nut.

19. Place two clamps (17) on the tubes.

20. Install washers and two nuts (16). Tighten the nuts.

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Illustration 23	g00719991

21. Connect lines (14) and (15) to the tubes.

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Illustration 24	g00719978

22. Connect lines (8), (9), (10), (11), (12), and (13) to the tubes.

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Illustration 25	g00719939

23. Position cover (7) to the boom.

24. Install washers and two bolts (6) .

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Illustration 26	g00719837

25. Position boom light (5) to the boom.

26. Install the washer and bolt (4) the boom light. Tighten the bolt.

27. Connect wires (1) and (2) .

28. Replace a new strap (3) .

29. Remove Tooling (A) from the boom.

End By:

1. Install the boom cylinder. Refer to Disassembly and Assembly, "Boom Cylinder - Remove and Install".
2. Install the stick cylinder. Refer to Disassembly and Assembly, "Stick Cylinder - Remove and Install".
3. Install the stick. Refer to Disassembly and Assembly, "Stick - Remove and Install".