Caterpillar Cat 308E2CR Mini Hydraulic Excavator (Prefix EC2) Service Repair Manual (EC200001 and up).pdf

Service Repair Manual
Models
308E2CR Mini Hydraulic Excavator

Shutdown SIS
Previous Screen
Product: MINI HYD EXCAVATOR
Model: 308E2 CR MINI HYD EXCAVATOR EC2
Configuration: 308E 2CR Mini Hydraulic Excavator EC200001-UP (MACHINE) POWERED BY C3.3B Engine
Disassembly and Assembly
C3.3B Tier 4 Final and EU Stage 3B Engines for Caterpillar Built Machines
Media Number -UENR3278-07 Publication Date -01/09/2014 Date Updated -11/07/2016
i06020083
Fuel Injection Pump - Remove and Install
SMCS - 1251-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 278-4138 Fuel System Protection Gp (1)
1
( 1 )
This tool can only be used one time.
Do not open the high pressure fuel system without allowing the fuel
system to purge. After the engine has shut down, allow the fuel system
to purge for ten minutes. This operating fuel system contains high
pressure. Exposure to high pressure fuel can result in personal injury.
Note: Use Caterpillar Electronic Technician (ET) to verify that the fuel system pressure is at zero
before opening the fuel system.
Note: Use Tooling (A) after any fuel line has been disconnected.
1. Ensure that number four piston is at the top center position on the compression stroke. Refer
to Systems Operation, Testing and Adjusting, "Finding Top Center Position for No. 4
Piston".
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308E 2CR Mini Hydraulic Excavator EC200001-UP (MACHINE) POWERED BY C3...
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Illustration 1 g03337739
2. Mark the alignment of the pump gear and the idler gear for installation purposes.
3. Remove tube assembly (1) . Remove banjo bolt (2) to disconnect hose assembly (4) .
Disconnect hose assembly (3) and harness assemblies (5) . Remove nuts (6) to remove fuel
injection pump (7) .
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4. Remove gear mounting nut. Remove gear (8) with a suitable gear puller (9) . Remove gear
(8) from fuel injection pump (7)
5. Remove the two bolts (not shown) to separate gear (10) from gear (8) .
Installation Procedure
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1. Align gear (10) to gear (8) with pin (11) and the two bolts (not shown). Tighten the two
bolts (not shown) to a torque of 10 to 11 N·m (89 to 97 lb in).
2. Install gear (8) and nut (11) on fuel injection pump (7) . Tighten nut (11) to a torque of 63.5
± 4.5 N·m (47 ± 3 lb ft).
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3. Install fuel injection pump (7) and nuts (6) . Connect harness assemblies (5) and hose
assembly (3) . Install banjo bolt (2) to connect hose assembly (4) . Install tube assembly (1) .
Tighten nuts (6) to a torque of 25.5 ± 1.5 N·m (226 ± 13 lb in). Tighten banjo bolt (2) to a
torque of 10 ± 2 N·m (89 ± 18 lb in). Tighten tube assembly (1) to a torque of 35 ± 5 N·m
(26 ± 3 lb ft).
4. If a new supply pump is installed, then a fuel pump calibration is required. Use Caterpillar
Electronic Technician (ET) version 2013A or newer version to perform the fuel pump
calibration.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Jan 10 23:17:38 UTC+0800 2020
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Shutdown SIS
Previous Screen
i07542694
Electronic Unit Injector - Remove and Install
SMCS - 1290-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 5F-4764 Pry Bar 1
B 278-4138 Fuel System Protection Gp(1)
1
(1)
This tool can only be used one time.
Start By:
a. Remove the valve mechanism cover.
Do not open the high pressure fuel system without allowing the fuel
system to purge. After the engine has shut down, allow the fuel system to
purge for ten minutes. This operating fuel system contains high
pressure. Exposure to high pressure fuel can result in personal injury.
Note: Use Cat®
Electronic Technician (CatET) Service Tool to verify that the fuel system pressure
is at zero before opening the fuel system.
Note: Use Tooling (B) after any fuel line has been disconnected.
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Note: Place an identification mark on electronic unit injectors (4) for installation purposes. Each
electronic unit injector (4) must be reinstalled in the original location in the cylinder head.
1. Remove tube assembly (1) and discard the gaskets (not shown) from electronic unit injector
(4).
2. Remove nut (2) to remove injector clamp (3).
3. Use Tooling (A) to remove electronic unit injector (4).
4. Remove seal (5) from electronic unit injector (4).
5. Repeat Steps 2 through 3 for the remaining electronic unit injectors.
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Note: If new electronic unit injectors (4) are installed, the QR codes on top of the injector
must be documented in the engine ECM using Cat®
Electronic Technician (CatET) Service
Tool. Caterpillar recommends documenting the new injector codes on-line. Go to SISWeb
and select "View More"under "Additional Service Information". Select the "C3.3B and C3.8
Downloads" link. The new injector trim codes can be entered through the "C3.3B and C3.8
ECU Trim Data Registration". For more information refer to Troubleshooting , "Injector
Trim File- Install - Injector Trim Code- Install".
1. Install a new seal (5) onto electronic unit injector (4). Install electronic unit injector (4).
2. Install injector clamp (3). Install nut (2). Tighten nut (2) to a torque of 25.5 ± 1.5 N·m
(226 ± 13 lb in).
3. Install overflow pipe (1) with new gaskets (not shown). Tighten overflow pipe (1) to a
torque of 10.5 ± 0.5 N·m (93 ± 4 lb in).
End By:
a. Install the valve mechanism cover.
Fri Jan 10 23:18:35 UTC+0800 2020
3/3
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Shutdown SIS
Previous Screen
i05305909
Turbocharger - Remove and Install
SMCS - 1052-010
Removal Procedure
1. Disconnect hose assembly (2) from turbocharger (1).
2. Remove tube assembly (3) from turbocharger (1).
3. Remove bolts (4). Remove two tube assemblies (5) and the gasket and the O-ring seal.
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4. Remove bolts (7) and housing (8) and the gasket.
5. Remove four nuts (6) and turbocharger (1) and the gasket.
Note: Refer to Specifications, "Engine Design" for non-specified engine torque values.
1. Install new gaskets.
2. Position the gasket and install turbocharger (1) on the exhaust manifold.
3. Position the gasket and housing (8) on the turbocharger (1) and install bolts (7) to
turbocharger (1).
4. Install nuts (6) on turbocharger (1). Tighten nuts (6).
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5. Position two tube assemblies (5). Install bolt (4) with the gasket and the O-ring seal.
6. Position tube assembly (3) on turbocharger (1) and install the clamps.
7. Connect hose assembly (2) on turbocharger (1).
Fri Jan 10 23:19:32 UTC+0800 2020
3/3
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Shutdown SIS
Previous Screen
i07176313
Pressure Sensor (Mass Air Flow) - Remove and Install
SMCS - 1058; 1408; 1439-010; 1923-010; 7400
Removal Procedure
1. Refer to Operation and Maintenance Manual, "Radiator Tilting".
NOTICE
The orientation of the mass air flow sensor is critical to engine
performance. A failure to orientate the mass airflow sensor correctly
could result in fault codes and not meeting emission regulations.
2. Mark the position of the mass air flow pressure sensor assembly for installation purposes.
Disconnect harness assembly (1). Remove clip (2). Loosen clamps (3).
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3. Disconnect hose (4). Remove mass air flow sensor assembly (5).
4. Remove screws (6). Remove mass airflow pressure sensor (7).
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1. Install mass airflow pressure sensor (7). Install screws (6). Tighten screws (6) to a torque of
1.47 ± 0.03 N·m (13.0 ± 0.27 lb in).
NOTICE
The orientation of the mass air flow sensor is critical to engine
performance. A failure to orientate the mass airflow sensor correctly
could result in fault codes and will not meet emission regulations.
2. Install mass air flow sensor assembly (5). Ensure that mass air flow sensor assembly (5) is
orientated 50° from the top of hose (4). Connect hose (4).
3/4
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3. Tighten clamps (3). Install clip (2). Connect harness assembly (1).
4. Refer to Operation and Maintenance Manual, "Radiator Tilting".
Fri Jan 10 23:20:28 UTC+0800 2020
4/4
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Shutdown SIS
Previous Screen
i05305930
Exhaust Gas Recirculation Valve - Remove and Install
SMCS - 108N-010
Removal Procedure
Personal injury can result from hot coolant, steam and alkali.
At operating temperature, engine coolant is hot and under pressure. The
radiator and all lines to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to relieve pressure only
when engine is stopped and cooling system pressure cap is cool enough
to touch with your bare hand.
Do not attempt to tighten hose connections when the coolant is hot, the
hose can come off causing burns.
Cooling System Coolant Additive contains alkali. Avoid contact with
skin and eyes.
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
before opening any compartment or disassembling any component
containing fluids.
1/3
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Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
Note: Refer to Specifications, "Engine Design" for non-specified engine torque values.
1. Drain coolant below exhaust gas recirculation valve level. Remove heat shield (1).
2. Disconnect hoses (2) and (3). Remove bolts (4).
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3. Disconnect harness assembly (9), hose (6) and (10). Remove bolts (11) and bolts (7).
Remove exhaust gas recirculation valve (5) and cooler assembly (8).
4. Remove screws (13) and reed valve (12) from exhaust gas recirculation valve (5).
1. Install exhaust gas recirculation valve (5) in the reverse order of removal.
a. Tighten bolts (4) and (11) to a torque of 24 to 27 N·m (212 to 239 lb in).
b. Tighten screws (13) to a torque of 10 to 11 N·m (89 to 97 lb in).
Fri Jan 10 23:21:25 UTC+0800 2020
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Caterpillar Cat 308E2CR Mini Hydraulic Excavator (Prefix EC2) Service Repair Manual (EC200001 and up).pdf

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Caterpillar Cat 308E2CR Mini Hydraulic Excavator (Prefix EC2) Service Repair Manual (EC200001 and up).pdf