Caterpillar cat 303.5 mini hydraulic excavator (prefix dch) service repair manual (dch00001 and up)

Service Repair Manual
Models
303.5 Mini Hydraulic Excavator

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Product: MINI HYD EXCAVATOR
Model: 303.5 MINI HYD EXCAVATOR DCH
Configuration: 303.5 Mini Hydraulic Excavator DCH00001-UP (MACHINE) POWERED BY 3013 Engine
Disassembly and Assembly
303.5 Mini Hydraulic Excavator Machine Systems
Media Number -RENR3538-02 Publication Date -01/05/2007 Date Updated -15/05/2007
i02763565
Piston Motor (Travel) - Disassemble
SMCS - 4351-015; 5058-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
(A) 1U-7600 Slide Hammer 1
(B) 205-0633 Spanner Wrench 1
(C) 9S-9152 Bearing Puller 1
(D) 1P-0510 Driver Group 1
(E) 1P-1862 Snap Ring Pliers 1
(F) 5B-0841 Bolt 1
(G) 6B-6683 Nut 2
Start By:
A. Remove the travel motor. Refer to Disassembly and Assembly, "Travel Motor - Remove" in
this manual.
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
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before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service
Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Note: Put identification marks on the travel motor and on all lines for installation purposes. Plug
all lines. This will help to prevent fluid loss and this helps to keep contaminants from entering the
system.
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism.
1. Put an alignment mark across the section of the travel motor for assembly purposes. The
parts must be reinstalled in the original locations of the parts.
Illustration 1 g00774455
2. Remove plug (2) , plug (3) , plug (4) , and the O-ring seals.

3. Install Tooling (F) and (G) at opening (2a) . Use opening (3A) in order to remove wire (5) .
4. Install Tooling (F) and Tooling (G) .

5. Remove wire (5) . through opening (3a) . Pull wire (5) and turn cover (1) in order to remove
the wire from the motor assembly.
6. Use Tooling (A) in order to remove cover (1) .
7. Remove O-ring seal (6) .

8. Remove plate (7) .
9. Remove gear (8) .
10. Remove three gears (9) .

11. Remove three bearings (10) .
12. Remove carrier (11) .

13. Remove three bearing races (12) .
14. Remove sun gear (13) . Remove four screws (14) .
15. Remove ring (15) .

16. Remove four gears (16) .
17. Remove four bearings (17) .
18. Remove four bearing races (18) . Remove four washers (19) .

19. Remove two plugs (20) .
20. Use Tooling (B) in order to remove hidden ring nut (21) .

21. Remove ring nut (21) .
22. Remove four socket head screws (22) . Remove valve assembly (23) .
23. Remove two plugs (24) , and the O-ring seals.
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24. Remove two plugs (25) , and the O-ring seals. Remove spool (26) .
25. Remove four small O-ring seals (27) . Remove two large O-ring seals (28) .
26. Remove plug (29) , and the O-ring seal. Remove spring (30) .

27. Remove plug (31) , and the O-ring seal. Remove spool (32) .
28. Remove two plugs (33) , and the O-ring seals. Remove two springs (34) , two washers (35) ,
and spool (36) .

29. Remove two plugs (37) and the O-ring seals.
Remove two springs (38) and two pistons (39) .
30. Remove six socket head bolts (40) . Remove cover (41) .
31. Remove port plate (42) .

32. Remove bearing (43) , and two O-ring seals (44) .
Note: Turn the housing on one side in order to remove the barrel assembly as a unit.
33. Remove cylinder barrel assembly (45) .

34. Remove swashplate (46) .
Note: Mark the location of the pistons in the barrel for assembly purposes.
35. Remove pistons (47) , and retainer plate (48) as a unit from barrel (45) . Remove pistons
(47) from retainer plate (48) .
36. Remove collar (49) . Remove three pins (50) .

37. Remove two balls (51) .
38. Remove two pistons (52) , and two springs (53) .
39. Remove shaft assembly (54) .

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40. Remove lip seal (55) .
41. Use a suitable press and Tooling (C) in order to remove bearing (56) from shaft (57) .

42. Remove housing (58) from housing (59) .
43. Remove duo-cone seal kit (60) .

Note: When the plug is removed (131) steel balls will fall from the housing. Place a
receptacle under the housing in order to catch the steel balls.
44. Remove plug (61) . Remove steel balls (62) from the housing.
45. Use Tooling (D) in order to remove bearing assembly (63) .
46. Remove duo-cone seal kit (64) .

Caterpillar cat 303.5 mini hydraulic excavator (prefix dch) service repair manual (dch00001 and up)

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