This service repair manual provides professional and comprehensive details to maintain and repair a Caterpillar 308D Mini Hydraulic Excavator. With easy-to-understand instructions and hundreds of detailed diagrams, this manual enables accurate diagnosis and repair. Download and keep your repair records organized and up-to-date.

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Media Number -RENR9740-00 Publication Date -01/05/2008
Product: MINI HYD EXCAVATOR
Model: 308D MINI HYD EXCAVATOR FYC
Configuration: 308D Mini Hydraulic Excavator FYC00001-UP (MACHINE) POWERED BY 4M40 Engine
Date Updated -16/05/2008
i 02947850
Disassembly and Assembly
308D CR Excavator Engine Supplement
Removal Procedure
Aftercooler - Remove and Install
SMCS - 1063-010
Start By:
A.Remove the engine hood. Refer to Disassembly and Assembly, "Hood - Remove and Install".
Illustration 1 g01461648

3. 3.Remove bolt (3) .
2.Remove panel (2) .
1.Disconnect two hoses (1) .
Illustration 2
Illustration 3
g01461867
g01461649

4. Illustration 4
Illustration 5
g01461889
g01461889
4.Remove bolts (6) and place refrigerant receiver-dryer (5) to the side. Remove bolts (8) and
bracket assembly (7). Remove the bolts from the rear of aftercooler (4). Remove aftercooler
(4) .
Installation Procedure

5. 2.
3.
Install bolt (3) .
Install panel (2) .
1.Position aftercooler (4). Install bracket assembly (7) and bolts (8). Install the bolts for the rear
of aftercooler (4). Position refrigerant receiver-dryer (5) and install bolts (6) .
Illustration 6
Illustration 7
g01461649
g01461867

6. Illustration 8 g01461648
4.Connect two hoses (1) .
End By: Install the engine hood. Refer to Disassembly and Assembly, "Hood - Remove and Install".
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Jun 17 15:07:00 UTC+0530 2022

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Media Number -RENR9740-00 Publication Date -01/05/2008
Product: MINI HYD EXCAVATOR
Model: 308D MINI HYD EXCAVATOR FYC
Configuration: 308D Mini Hydraulic Excavator FYC00001-UP (MACHINE) POWERED BY 4M40 Engine
Date Updated -16/05/2008
i 02943201
Disassembly and Assembly
308D CR Excavator Engine Supplement
Removal Procedure
Muffler - Remove and Install
SMCS - 1062-010
1.Open the engine hood.
2.Remove exhaust stack (1). Remove clamp (3) and cover (2) .
Illustration 1 g01458874

8. Illustration 2
View from the bottom rear of the muffler
Illustration 3
View from the bottom front of the muffler
g01458882
g01458885
3.Remove clamp (4) .
4.Disconnect tube assembly (5) .

9. Illustration 4
Illustration 5
g01458886
g01458886
5.Remove clamps (6) and muffler (7) .
1.Position muffler (7) and install clamps (6) .
Installation Procedure

10. Illustration 7
View from the bottom rear of the muffler
Illustration 6
View from the bottom front of the muffler
g01458885
g01458882
3. Install clamp (4) .
2.Connect tube assembly (5) .

11. Illustration 8 g01458874
4.Install cover (2) and clamp (3). Install exhaust stack (1).
5.Close the engine hood.
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
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Media Number -RENR9740-00 Publication Date -01/05/2008
Product: MINI HYD EXCAVATOR
Model: 308D MINI HYD EXCAVATOR FYC
Configuration: 308D Mini Hydraulic Excavator FYC00001-UP (MACHINE) POWERED BY 4M40 Engine
Date Updated -16/05/2008
i 02953232
Disassembly and Assembly
308D CR Excavator Engine Supplement
Installation Procedure
Turbocharger - Install
1.
SMCS - 1052-012
Install turbocharger (26). Install bolts (24) and bolts (23). Connect tube assemblies (27) and
(25).
Illustration 1 g01468709

13. Illustration 2
Illustration 3
g01468708
g01468707
2.
3.Connect hose (20) .
Install shield (22) and bolts (21) .

14. Illustration 4
Illustration 5
Illustration 6
g01468632
g01467576
g01467568
4.
5.Position panel (11) .
Install shield (18). Install bolts (19) and (17).

15. Illustration 7
Illustration 8
g01467578
g01467571
6
.
7
.
8.Close door (12) .
Install panel (13) and bolt (16) .
Install four bolts (15) in panel (13). Install bolt (14) in panel (13) .

16. Illustration 9
Illustration 10
Illustration 11
g01467575
g01467581
g01467567
9. Install six bolts (10) in panel (11) .

17. 12. Install cover (5) and bolts (6) .
10.Position refrigerant condenser (4), as shown.
11.Install cover (8). Install bolts (9) and (7) .
13.Position refrigerant condenser (4), as shown.
14.Install bolts (3) .
Illustration 12
Illustration 13
g01467570
g01467569

18. Illustration 14 g01467573
15.Install panel (2) and bolts (1) .
16.Turn the battery disconnect switch to the ON position.
End By: Install the engine hood. Refer to Disassembly and Assembly, "Hood - Remove and Install".
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Jun 17 15:07:38 UTC+0530 2022

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Media Number -RENR9740-00 Publication Date -01/05/2008
Product: MINI HYD EXCAVATOR
Model: 308D MINI HYD EXCAVATOR FYC
Configuration: 308D Mini Hydraulic Excavator FYC00001-UP (MACHINE) POWERED BY 4M40 Engine
Date Updated -16/05/2008
i 02952502
Disassembly and Assembly
308D CR Excavator Engine Supplement
Removal Procedure
Turbocharger - Remove
SMCS - 1052-011
1.Remove bolts (1) and panel (2) .
Start By:
A.Remove the engine hood. Refer to Disassembly and Assembly, "Hood - Remove and Install".
Illustration 1 g01463947

20. Illustration 2
Illustration 3
g01463967
g01464187
2.Remove bolts (3). Position refrigerant condenser (4), as shown.

21. Illustration 4
Illustration 5
g01466067
g01466128
3.Remove bolts (6) and cover (5) .

22. Illustration 6
Illustration 7
g01466208
g01466227
5.Remove six bolts (10) from panel (11) .
4.Remove bolts (7) and (9). Remove cover (8) .

23. Illustration 8
Illustration 9
Illustration 10 g01466852
g01466229
g01466247
6.Open door (12) .
7.Remove bolt (14) from panel (13). Remove four bolts (15) from panel (13) .
8.Remove bolt (16) and panel (13) .

24. Illustration 11
Illustration 12
g01467027
g01467067
10.Remove panel (11) .
9.Place refrigerant condenser (4) aside, as shown.

25. Illustration 13
Illustration 14
Illustration 15
g01468632
g01468707
g01468708
12.Disconnect hose (20) .
13.Remove bolts (21) and shield (22) .
11.Remove bolts (17) and (19). Remove shield (18) .

26. Illustration 16 g01468709
14.Disconnect tube assemblies (25) and (27). Remove bolts (23) and bolts (24). Remove
turbocharger (26) .
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Jun 17 15:07:27 UTC+0530 2022

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Media Number -RENR9740-00 Publication Date -01/05/2008
Product: MINI HYD EXCAVATOR
Model: 308D MINI HYD EXCAVATOR FYC
Configuration: 308D Mini Hydraulic Excavator FYC00001-UP (MACHINE) POWERED BY 4M40 Engine
Date Updated -16/05/2008
i 02948234
Disassembly and Assembly
308D CR Excavator Engine Supplement
Removal Procedure
Refrigerant Compressor - Remove and Install
SMCS - 1802-010; 7320-010
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.
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.
Start By:
A.Remove the counterweight. Refer to Disassembly and Assembly, "Counterweight - Remove
and Install".
NOTICE

28. Personal injury can result from contact with refrigerant.
Contact with refrigerant can cause frost bite. Keep face and hands away
to help prevent injury.
Protective goggles must always be worn when refrigerant lines are
opened, even if the gauges indicate the system is empty of refrigerant.
Always use precaution when a fitting is removed. Slowly loosen the
fitting. If the system is still under pressure, release it slowly in a well
ventilated area.
Personal injury or death can result from inhaling refrigerant through a
lit cigarette.
Inhaling air conditioner refrigerant gas through a lit cigarette or other
smoking method or inhaling fumes released from a flame contacting air
conditioner refrigerant gas, can cause bodily harm or death.
Do not smoke when servicing air conditioners or wherever refrigerant
gas may be present.
Use a certified recovery and recycling cart to properly remove the
refrigerant from the air conditioning system.
2.Remove belt (4) for the compressor. Refer to Operation and Maintenance Manual, "Belts -
Inspect/Adjust/Replace".
1.Recover the air conditioner refrigerant from the air conditioner system. Refer to Service
Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the
procedure. Refer to Special Instruction, NENG2500, "Air Conditioning Tools" for the tools.
Illustration 1 g01462050

29. 3.Remove clips (1). Disconnect harness assembly (2). Disconnect hose assemblies (3) .
4.Remove bolts (6) and refrigerant compressor (5) .
1.Position refrigerant compressor (5) and install bolts (6) .
2.Connect hose assemblies (3). Connect harness assembly (2). Install clips (1) .
3.Install belt (4) for the compressor. Refer to Operation and Maintenance Manual, "Belts -
Inspect/Adjust/Replace".
4.Charge the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and
Heating Systems with R-134a Refrigerant" for the procedure. Refer to Special Publication,
NENG2500, "Air Conditioning Tools" for the tools.
End By: Install the counterweight. Refer to Disassembly and Assembly, "Counterweight - Remove
and Install".
Installation Procedure
Illustration 2 g01462050
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Jun 17 15:08:17 UTC+0530 2022

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Media Number -KENR6163-01 Publication Date -01/10/2010
Product: MINI HYD EXCAVATOR
Model: 308D MINI HYD EXCAVATOR FYC
Configuration: 308D Mini Hydraulic Excavator FYC00001-UP (MACHINE) POWERED BY 4M40 Engine
Date Updated -20/10/2010
i 02942168
Specifications
308D Excavator Machine System Specifications
Engine Mounting
SMCS - 1152
S/N - -
(1) Install the four brackets so that the surface which comes in contact with the rubber mount becomes
horizontal.
Illustration 1 g01458302

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