304 Mini Hydraulic ExcavatorEngine Supplement and Machine Systems Caterpillar

Assembly Procedure

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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Illustration 1	g00764899

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) .

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Illustration 2	g00764880

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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Illustration 3	g00764867

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).

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Illustration 4	g00764855

4. If necessary, install valve (42) . Install bearing (43) .

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Illustration 5	g00764227

5. Install bearing (41) . Install pins (40) .

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Illustration 6	g00862921

6. Use Tooling (C) in order to install Duo-Cone seal kit (39) .

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Illustration 7	g00764198

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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Illustration 8	g00764194

8. Install gear (33) , and shaft assemblies (32) .

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Illustration 9	g00764176

9. Install gear (31) .

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Illustration 10	g00764796

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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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Illustration 11	g00765016

11. Install spindle (27) into housing (28) .

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Illustration 12	g00764056

12. Install two retaining rings (26) .

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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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Illustration 13	g00763684

15. Install pivots (23) , and lip seal (24) .

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Illustration 14	g00763623

16. Install bearing (22) . Install shaft (21) .

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Illustration 15	g00763613

17. Install gears (19) . Install gear (20) .

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Illustration 16	g00763605

18. Use Tooling (A) in order to install retaining rings (18) .

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Illustration 17	g00763603

19. Install O-ring seal (17) .

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Illustration 18	g00763597

20. Install cover (16) .

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Illustration 19	g00764991

21. Install ring (14) into the groove between cover (15) and the final drive housing.

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Illustration 20	g00763560

22. Install plugs (1) .

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Illustration 21	g00763590

23. Install spring (13) , and piston (12) .

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Illustration 22	g00763585

24. Install swashplate (11) .

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Illustration 23	g00763958

25. Install pins (10) into barrel (8) . Install guide (9) .

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Illustration 24	g00763935

26. Use the identification marks on piston assemblies (6) in order to locate the pistons in the retainer plate (7) and the barrel (8) . Install piston assemblies (6) and retainer plate (7) into barrel (8) as a unit.

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Illustration 25	g00763578

27. Install barrel assembly (5) .

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Illustration 26	g00763571

28. Install port plate (4) .

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Illustration 27	g00763551

29. Install plate (3) . Install four bolts (2) . Tighten the bolts to a torque of 29.4 ± 5 N·m (22 ± 4 lb ft).

End By: Install the piston motor (travel). Refer to Disassembly and Assembly, "Piston Motor (Travel) - Install" in this manual.