Caterpillar Cat 304E Mini Hydraulic Excavator (Prefix TSR) Service Repair Manual Instant Download

1
Service Repair Manual
Models 304E Mini Hydraulic Excavator
2
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Product MINI HYD EXCAVATOR Model 304E MINI HYD
EXCAVATOR TSR Configuration 304E Mini Hydraulic
Excavator TSR00001-UP (MACHINE) Disassembly and
Assembly 303E CR, 303.5E, 304E, 305.5E and 305E
Mini Hydraulic Excavators Machine Systems Media
Number -UENR0148-04 Publication Date
-01/10/2016 Date Updated -25/10/2016
i04777975
Evaporator Coil - Remove and Install SMCS -
7343-010 Removal Procedure Start By a. Remove
the heating and air conditioning unit.
Illustration 1
g01226046
1. Remove screws (1).
3
Illustration 2 g01226042 2. Remove cab air
filter (2). Remove cap (3) and louver (4).
Illustration 3 g01226033 3. Disconnect harness
assemblies (5) and (6).
Illustration 4 g01225163 4. Remove screws (7)
and switch assembly (8).
4
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Illustration 5 g01226099 5. Disconnect relay
assemblies (11) and (12). Remove screws (9) and
cover (10).
Illustration 6 g01226109 6. Remove hose (13).
Remove screws (15) and (16). Remove cover (14).
Illustration 7
g01226380
7. Remove evaporator coil (17).
Installation Procedure
6
Illustration 8
g01226380
1. Install evaporator coil (17).
Illustration 9 g01226109 2. Install cover (14).
Install screws (15) and (16). Install hose (13).
Illustration 10 g01226099 3. Install cover (10)
and screws (9). Connect relay assemblies (11) and
(12).
7
Illustration 11 g01225163 4. Install switch
assembly (8) and screws (7).
Illustration 12
g01226033
5. Connect harness assemblies (5) and (6).
Illustration 13 g01226042 6. Install louver (4)
and cap (3). Install cab air filter (2).
8
Illustration 14
g01226046

• Install screws (1).
• End By
• a. Install the heating and air conditioning unit.

Copyright 1993 - 2020 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Tue Feb 18 232608 UTC0800 2020
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Product MINI HYD EXCAVATOR Model 304E MINI HYD
EXCAVATOR TSR Configuration 304E Mini Hydraulic
Excavator TSR00001-UP (MACHINE) Disassembly and
Assembly 303E CR, 303.5E, 304E, 305.5E and 305E
Mini Hydraulic Excavators Machine Systems Media
Number -UENR0148-04 Publication Date
-01/10/2016 Date Updated -25/10/2016
i03987031
Track Carrier Roller - Remove and Install SMCS -
4154-010 Removal Procedure
Personal injury or death can result from grease
under pressure. Grease coming out of the relief
valve under pressure can penetrate the body
causing injury or death. Do not watch the relief
valve to see if grease is escaping. Watch the
track or track adjustment cylinder to see if the
track is being loosened. Loosen the relief valve
one turn only. If track does not loosen, close
the relief valve and contact your Caterpillar
dealer.
1. Release the tension on the track. Refer to
Operation and Maintenance Manual, "Track -
Adjust".
10
Illustration 1 g01229382 2. Attach a suitable
lifting device to track (1). Raise track (1).
Remove bolt (2) and remove track carrier roller
(3).
Installation Procedure

• Illustration 2 g01229382
• Attach a suitable lifting device to track (1).
  Raise track (1). Install track carrier roller (3)
  and bolt (2).
• Apply tension on the track. Refer to Operation
  and Maintenance Manual, "Track - Adjust".

Copyright 1993 - 2020 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Tue Feb 18 232705 UTC0800 2020
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Product MINI HYD EXCAVATOR Model 304E MINI HYD
EXCAVATOR TSR Configuration 304E Mini Hydraulic
Excavator TSR00001-UP (MACHINE) Disassembly and
Assembly 303E CR, 303.5E, 304E, 305.5E and 305E
Mini Hydraulic Excavators Machine Systems Media
Number -UENR0148-04 Publication Date
-01/10/2016 Date Updated -25/10/2016
i03983332
Track Roller - Remove and Install SMCS -
4180-010 Removal Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 1U-9745 Air/Hydraulic Jack Gp 1
Personal injury or death can result from grease
under pressure. Grease coming out of the relief
valve under pressure can penetrate the body
causing injury or death. Do not watch the relief
valve to see if grease is escaping. Watch the
track or track adjustment cylinder to see if the
track is being loosened. Loosen the relief valve
one turn only. If track does not loosen, close
the relief valve and contact your Caterpillar
dealer.
1. Release the tension on the track. Refer to
Operation and Maintenance Manual, "Track -
Adjust".
12
Illustration 1 g01229409 2. Use Tooling (A) in
order to raise the side of the machine.
Illustration 2 g01229411 3. Remove bolt (1) and
remove track roller (2). Installation
Procedure Table 2
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 1U-9745 Air/Hydraulic Jack Gp 1
13
Illustration 3
g01229411
1. Install track roller (2) and bolts (1).

• Illustration 4 g01229409
• Use Tooling (A) in order to lower the side of the
  machine.
• Adjust the tension on the track. Refer to
  Operation and Maintenance Manual, "Track -
  Adjust".

Copyright 1993 - 2020 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Tue Feb 18 232802 UTC0800 2020
14
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Product MINI HYD EXCAVATOR Model 304E MINI HYD
EXCAVATOR TSR Configuration 304E Mini Hydraulic
Excavator TSR00001-UP (MACHINE) Disassembly and
Assembly 303E CR, 303.5E, 304E, 305.5E and 305E
Mini Hydraulic Excavators Machine Systems Media
Number -UENR0148-04 Publication Date
-01/10/2016 Date Updated -25/10/2016
i03983333
Track - Remove and Install SMCS -
4170-010 Removal Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 1U-9745 Air/Hydraulic Jack Gp 4
Personal injury or death can result from grease
under pressure. Grease coming out of the relief
valve under pressure can penetrate the body
causing injury or death. Do not watch the relief
valve to see if grease is escaping. Watch the
track or track adjustment cylinder to see if the
track is being loosened. Loosen the relief valve
one turn only. If track does not loosen, close
the relief valve and contact your Caterpillar
dealer.
1. Release the tension on the track. Refer to
Operation and Maintenance Manual, "Track -
Adjust".
15
Illustration 1 g01229409 2. Use Tooling (A) in
order to raise the side of the machine.
Illustration 2 g01229427 3. Use a suitable
lifting device and a suitable pry bar in order to
remove track (1). The weight of track (1) is
approximately 250 kg (550 lb). Installation
Procedure Table 2
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 1U-9745 Air/Hydraulic Jack Gp 4
16
Illustration 3 g01242884 1. Use a suitable
lifting device and a suitable pry bar in order to
install track (1). Suitable cribbing may be
placed under track (1) in order to aid in the
installation of track (1). The weight of track
(1) is approximately 250 kg (550 lb).

• Illustration 4 g01229409
• Use Tooling (A) in order to lower the side of the
  machine.
• Apply tension on the track. Refer to Operation
  and Maintenance Manual, "Track - Adjust".

Copyright 1993 - 2020 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Tue Feb 18 232859 UTC0800 2020
17
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Product MINI HYD EXCAVATOR Model 304E MINI HYD
EXCAVATOR TSR Configuration 304E Mini Hydraulic
Excavator TSR00001-UP (MACHINE) Disassembly and
Assembly 303E CR, 303.5E, 304E, 305.5E and 305E
Mini Hydraulic Excavators Machine Systems Media
Number -UENR0148-04 Publication Date
-01/10/2016 Date Updated -25/10/2016
i04777978
Front Idler, Recoil Spring and Hydraulic Track
Adjuster - Remove SMCS - 4157-011 4158-011
4159-011 Removal Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 140-7742 Sleeve 1
Start By a. Remove the track.
Illustration 1
g01229442
18
1. Attach Tooling (A) and a suitable lifting
device to the front idler, the recoil spring, and
hydraulic track adjuster (1). The weight of
front idler, recoil spring, and hydraulic track
adjuster (1) is approximately 80 kg (175 lb).
Remove the front idler, the recoil spring, and
hydraulic track adjuster (1).
Copyright 1993 - 2020 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Tue Feb 18 232955 UTC0800 2020
19
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Previous Screen
Product MINI HYD EXCAVATOR Model 304E MINI HYD
EXCAVATOR TSR Configuration 304E Mini Hydraulic
Excavator TSR00001-UP (MACHINE) Disassembly and
Assembly 303E CR, 303.5E, 304E, 305.5E and 305E
Mini Hydraulic Excavators Machine Systems Media
Number -UENR0148-04 Publication Date
-01/10/2016 Date Updated -25/10/2016
i06748710
Recoil Spring - Remove and Install SMCS -
4158-010 Removal Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 1P-0775 Seal Guide 1
A 1P-0510 Driver Gp 1
Start By a. Remove the front idler, recoil
spring, and hydraulic track adjuster.
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Illustration 1
g02817498
Illustration 2 g02817536 1. Remove hydraulic
track adjuster (1). Remove the front idler (2).
Remove cotter pin (3).
21
Illustration 3
g01181601
Illustration 4 View from bottom
g01181718
Personal injury can result from being struck by
parts propelled by a released spring force. Make
sure to wear all necessary protective
equipment. Follow the recommended procedure and
use all recommended tooling to release the
spring force.

• Position cylinder assembly (1) into a suitable
  press. Compress recoil spring (4) with Tooling
• and a suitable press. Remove nut (5) and slowly
  release the spring tension. Remove support (6)
  and recoil spring (4).
• Installation Procedure
• Table 2

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Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 1P-0775 Seal Guide 1
A 1P-0510 Driver Gp 1
Illustration 5
g01181601
Illustration 6 View from bottom
g01181718
23
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Illustration 7
g01181825
Personal injury can result from being struck by
parts propelled by a released spring force. Make
sure to wear all necessary protective
equipment. Follow the recommended procedure and
use all recommended tooling to release the
spring force.
1. Position cylinder assembly (1) and support (6)
into a suitable press. Compress recoil spring (4)
with Tooling (A) and the suitable press. Compress
recoil spring (4) so that dimension (X) is
approximately 251 1.5 mm (10 0.060 inch).
Install nut (5) and slowly release the spring
tension.
Illustration 8
g02817536
25
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the link into your browser. The full manual is
available for immediate download. https//www.eb
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