Caterpillar cat 303 cr mini hydraulic excavator (prefix dma) service repair manual (dma00001 and up)

Service Repair Manual
Models
303 CR Mini Hydraulic
Excavator

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Product: MINI HYD EXCAVATOR
Model: 303 MINI HYD EXCAVATOR DMA
Configuration: 303 CR Mini Hydraulic Excavator DMA00001-UP (MACHINE) POWERED BY S3L2 Engine
Disassembly and Assembly
303 CR Mini Hydraulic Excavator Machine Systems
Media Number -RENR5593-01 Publication Date -01/01/2004 Date Updated -13/01/2004
i01920827
Main Control Valve - Assemble
SMCS - 5051-016
Assembly Procedure
NOTICE
Failure to properly assemble parts or failure to follow established
procedures can lead to damage of the parts and assembly.
To avoid damage to parts, always identify and mark the parts so that
they can be installed in the same location. Ensure that gear surfaces
align. Never force parts during assembly.
Spring force can cause personal injury or death.
Do not repair until you have read the Operation and Maintenance
Manual.
Note: Only a small number of components within the main control valve are serviced
components. A large number of nonserviceable items must be disassembled in order to access the
serviced components.
Note: Keep all of the internal parts of the main control valve clean and lubricated.
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1. Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help prevent dirt from entering the
internal mechanism.
Illustration 1 g00999509
(A) Bucket Block Assembly
(B) Boom II Block Assembly
(C) Boom Block Assembly
(D) Left Travel Block Assembly
(E) Straight Travel Block Assembly
(F) Right Travel Block Assembly
(G) Stick (Arm) Block Assembly
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(H) Auxililiary (PTO) Block Assembly
(I) Boom Up Block Assembly
(J) Swing Block Assembly
(K) Blade Assembly
(L) Boom Swing Block Assembly
2. The above photo displays the functional positions of the valves within the main control
valve.
Note: Place identification marks on the valves. The valves MUST be assembled in the same
configuration.
Note: The main control valve will be assembled in reverse order.
Note: Do not mix components from one valve to another valve. Valve components MUST
be returned to the original valve.
3. Assemble Block Assembly (L), as follows:
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.
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a. Install spring (176) onto valve (175). Install O-ring seal (177) onto plug (178). Install
plug (178) into spring (176). Install plug (178) and valve (175) into block assembly
(L) .
b. Install O-ring seal (174) onto cover (173) .
c. Install O-ring seal (172) onto cover (167) .
d. Install spool (171) into Block Assembly (L) .
Note: Lubricate the spool with a light coating of hydraulic oil at the time of
installation.
Note: The spool must be oriented properly.
e. Install O-ring seal (170) onto valve (169). Install valve (169) into Block Assembly
(L). Tighten valve (169) to a torque of 39 ± 5 N·m (29 ± 4 lb ft).
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f. Install cover (167) onto Block Assembly (L) .
g. Install O-ring seals (166) and (165) onto Block Assembly (L) .
h. Install Block Assembly (L) onto the threaded rods.
4. Assemble Block Assembly (K), as follows:
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plug (164) into spring (162). Install plug (164) and valve (161) into Block Assembly
(K) .
b. Install O-ring seal (160) onto valve (159). Install valve (159) into Block Assembly
(K). Tighten valve (159) to a torque of 39 ± 5 N·m (29 ± 4 lb ft).
c. Install washer (157) onto the spool.
d. Install O-ring seals (158) onto the spool.
Note: The outer O-ring seal is tapered.
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e. Install spool assembly (156) into Block Assembly (K) .
Note: Lubricate the spool with a light coating of hydraulic oil prior to assembly.
f. Install cover (155). Install allen head bolts (154) .
g. Install O-ring seals (153) onto the opposite end of the spool.
Note: The outer O-ring seal is tapered.
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h. Install cover (152). Install bolts (151) .
i. Install linkage (150). Secure linkage (150) with pin (149) and cotter pin (148) .
j. Install O-ring seals (147) and (146) onto Block Assembly (L) .
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k. Install Block Assembly (K) onto the threaded rods.
5. Assemble Block Assembly (J), as follows:
(J) .
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b. Install O-ring seal (141) onto cover (142) .
c. Install cover (142). Install allen head bolts (140) .
d. Install spool (139) .
installation.
e. Install O-ring seal (137) onto cover (138) .
f. Install cover (138) onto Block Assembly (J) .
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g. Install O-ring seals (135) and (134) onto Block Assembly (J) .
h. Install Block Assembly (J) onto the threaded rods.
6. Assemble Block Assembly (I), as follows:
(I) .
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b. Install spring (127) onto valve (126). Install O-ring seal (128) onto plug (129). Install
plug (129) into spring (127). Install plug (129) and valve (126) into block assembly
(I) .
c. Install O-ring seals (125) into block (123) .
d. Install O-ring seals (124) into block (123) .
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e. Install manifold block (123) onto Block Assembly (I). Secure manifold block (123)
with allen head bolts (122) .
f. Install O-ring seal (121) onto cover (116) .
g. Install spool (120) into Block Assembly (I) .
installation.
h. Install O-ring seal (119) onto valve (118). Install valve (118) into block assembly (I).
Tighten valve (118) to a torque of 39 ± 5 N·m (29 ± 4 lb ft).
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i. Install cover (116) onto Block Assembly (J) .
j. Secure cover (116) with bolts (117) .
k. Install O-ring seals (115) and (114) onto Block Assembly (I) .
l. Install Block Assembly (I) onto the threaded rods.
7. Assemble Block Assembly (H), as follows:
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(H) .
b. Install O-ring seal (109) onto cover (108). Install cover (108) into Block Assembly
(H) .
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c. Install O-ring seal (107) onto cover (104) .
d. Install spool (106) into Block Assembly (H) .
installation.
e. Install cover (104) onto Block Assembly (H) .
f. Secure cover (104) with bolts (105) .
g. Install O-ring seals (103) and (102) onto block assembly (H) .
h. Install Block Assembly (H) onto the threaded rods.
8. Assemble Block Assembly (G), as follows:
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(G) .
b. Install O-ring seal (97) onto cover (96). Install cover (96) onto Block Assembly (G) .
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c. Install O-ring seal (95) onto valve (94). Install valve (94) into Block Assembly (G).
d. Install O-ring seal (93) onto cover (88) .
e. Install spool (92) into Block Assembly (G) .
installation.
f. Install O-ring seal (91) onto valve (90). Install valve (90) into Block Assembly (G).
g. Install cover (88) onto Block Assembly (G) .
h. Secure cover (88) with two bolts (89) .
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i. Install spring (85) onto valve (84). Install O-ring seal (86) onto plug (87). Install plug
(101) into spring (99). Install plug (87) and valve (84) into Block Assembly (G) .
j. Install O-ring seals (83) and (82) onto Block Assembly (G) .
k. Install Block Assembly (G) onto the threaded rods.
9. Assemble Block Assembly (F), as follows:
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Caterpillar cat 303 cr mini hydraulic excavator (prefix dma) service repair manual (dma00001 and up)

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