Caterpillar Cat 308E2CR Mini Hydraulic Excavator (Prefix MC5) Service Repair Manual (MC500001 and up).pdf

Service Repair Manual
Models
308E2CR Mini Hydraulic Excavator

Shutdown SIS
Previous Screen
Product: MINI HYD EXCAVATOR
Model: 308E2CR MINI HYD EXCAVATOR MC5
Configuration: 308E2CR Mini Hydraulic Excavator MC500001-UP (MACHINE) POWERED BY C3.3B Engine
Disassembly and Assembly
308ECR and 308ESR Mini Hydraulic Excavators Machine Systems
Media Number -UENR3284-03 Publication Date -01/12/2017 Date Updated -05/12/2017
i07114054
Stick - Remove and Install
SMCS - 6502-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 283-1495 Stand Assembly 1
B 1U-9200 Lever Puller Hoist 1
C
123-3804 Bearing Puller Adapter 1
9S-5565 Pin Puller Sleeve As 1
4C-9634 Puller Stud 1
6V-3160 Double Acting Cylinder 1
4K-0684 Hard Washer 1
9U-6832 Nut 1
350-7768 Electric Hydraulic Pump Gp (115V)
1
Start By:
a. Remove the bucket.
1/8
308E2CR Mini Hydraulic Excavator MC500001-UP (MACHINE) POWERED BY C3...
2020/1/4
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw...

At operating temperature, the hydraulic oil is hot and under pressure.
Hot oils can cause burns.
To prevent possible personal injury, release the pressure in the work
tool hydraulic circuit (boom, stick, bucket, and swing), travel circuits,
and the hydraulic oil tank at the filler cap before any hydraulic lines or
components are disconnected or removed.
Remove the filler cap only when the engine is stopped and the filler cap
is cool enough to touch.
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.
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: Put identification marks on all hoses. Plug all hose assemblies. This action helps to prevent
fluid loss, and this action helps to keep contaminants from entering the system.
Illustration 1 g01518715
1. Lower the boom onto Tooling (A). Lower stick (1) to the ground, as shown.
2. Release the hydraulic system pressure. Refer to Disassembly and Assembly, "System
Pressure - Release".
2/8
2020/1/4

3. Disconnect hose assemblies (2) and (3) from both side of stick (1).
4. Attach a suitable lifting device to the rod end of stick cylinder (4).
5. Remove retaining bolt (8), nuts (6), and pin (7). Remove shims (5).
6. Secure the cylinder rod, as shown. Lower stick cylinder (4) onto the boom with suitable
cribbing.
7. Install pin (7) and secure pin (7) by installing retaining bolt (8) and hand tightening nuts (6).
Install a suitable sling and a suitable lifting device around pin (7) for removal purposes.
3/8
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8. Attach Tooling (B) and a suitable lifting device to stick (1).
9. Remove bolts (9) and remove washer (10). Remove pin (11) and the shims.
10. Remove stick (1). Use Tooling (B) and a suitable lifting device to lower stick (1) onto
suitable blocking. The weight of stick (1) is approximately 345 kg (760 lb).
11. Remove seals (12) and (14). Use Tooling (C) to remove bearings (13). Remove bearings
(15).
Installation Procedure
Table 2
Required Tools
4/8
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B 1U-9200 Lever Puller Hoist 1
D 5P-0960 Grease Cartridge 1
E 1P-0510 Driver Gp 1
Note: Make sure that the stick pin bore, the bucket pin bores, the bucket pins, the flange, and the
O-ring seals are thoroughly clean prior to installation of the bucket.
Note: Check the condition of the seals and the bearings. If the seals or bearings are worn or
damaged, use new parts for replacement.
1. Lower the temperature of bearings (13) and (15). Prior to installing bearings (13) and (15),
check that the bore is free of paint and grease.
2. Use Tooling (E) to install bearings (13) and (15). Use Tooling (E) to install seals (12) and
(14). Install bearings (13) and (15) with bearing identification outward.
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3. Position stick (1). Use Tooling (B) and a suitable lifting device to position stick (1) onto the
boom. The weight of stick (1) is approximately 345 kg (760 lb).
4. Apply Tooling (D) to pin (11). Position the shims and install pin (11). Adjust lateral
clearance of the shims to a maximum distance of 0.80 mm (0.03 inch).
5. Install washer (10) and bolt (9). Remove Tooling (B) and all suitable lifting devices.
6/8
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6. Remove pin (7), bolt (8), and nuts (6).
7. Attach a suitable lifting device around stick cylinder (4).
8. Raise stick cylinder (4). Apply Tooling (D) to pin (7). Position shims (5) and install pin (7).
Adjust lateral clearance of shims (5) to a maximum distance of 1.00 mm (0.040 inch).
9. Install bolt (8) and install nuts (6). Remove any suitable lifting devices.
10. Use the following procedure to tighten all the nuts:
a. Position the outside nut even with the end of the retaining bolt or 0.5mm (0.02 inch)
beyond the end of the retaining bolt.
b. Tighten the inside nut against the outside nut to a torque of 70 ± 15 N·m
(50 ± 10 lb ft).
7/8
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11. Connect hose assemblies (2) and (3) on both side of stick (1).
12. Raise and lower stick (1) and the boom. Remove Tooling (A).
End By:
a. Install the bucket.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Jan 4 22:24:51 UTC+0800 2020
8/8
2020/1/4

Shutdown SIS
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i07115276
Boom Cylinder - Remove and Install
SMCS - 5456-010
Removal Procedure
Table 1
Required Tools
Cylinders equipped with lock valves can remain pressurized for very
long periods of time, even with the hoses removed.
Failure to relieve pressure before removing a lock valve or
disassembling a cylinder can result in personal injury or death.
1/8
2020/1/4

Ensure all pressure is relieved before removing a lock valve or
disassembling a cylinder.
NOTICE
containing fluids.
Cat®
products.
NOTICE
containing fluids.
Cat®
products.
Note: Put identification marks on all hoses. Plug all hose assemblies to help prevent fluid loss, and to keep
contaminants from entering the system.
2/8
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1. Attach a suitable lifting device to boom cylinder (4). The weight of boom cylinder (4) is
approximately 116 kg (255 lb).
Note: Note the position of the shims for installation purposes.
2. Remove retaining bolt (1) and nuts (2). Remove pin (3) and the shims.
3. Lower boom cylinder (4) onto Tooling (A) so that boom cylinder (4) is in a horizontal position.
Retract the cylinder rod for boom cylinder (4).
4. Remove hose assemblies (5).
5. Remove bolt (7), pin assembly (6), and the shims.
6. Remove boom cylinder (4).
3/8
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7. Remove clamps (9). Remove support assembly (10). Remove tube assemblies (11).
Disassembly and Assembly Procedure
Table 2
Required Tools
B 152-4252 Hydraulic Cylinder Repair Stand Gp 1
C 7M-7456 Bearing Mount Compound 1
D 1P-0808 Multipurpose Grease 1
E 195-4609 Seal Pick 1
F
1
1P-1834 Bearing Puller Adapter 1
9U-6832 Nut 1
G 350-7768 Electric Hydraulic Pump Gp (115V)
1
1P-1833 Bearing Puller Adapter 1
4/8
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9U-6832 Nut 1
(1) Use Tooling (F) to remove and install the bearing.
(2) Torque for the nut ... 3600 ± 180 N·m (2655 ± 133 lb ft)
(3) Apply Tooling (D) to all seals prior to assembly.
(4) Lubricate sealing lips with a thin covering of the lubricant that is being sealed.
(5) Apply Tooling (C) to the seal groove prior to assembling the wiper seal.
(6) Use Tooling (G) to remove and install the bearing.
Installation Procedure
Table 3
Required Tools
B 5P-0960 Grease Cartridge 1
Note: Check O-ring seals for wear or for damage. Replace the components, if necessary.
1. Make sure that the pin bores in the boom and in the boom cylinder are clean and free of dirt prior to
installation of the boom cylinder.
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2. Install tube assemblies (11).
3. Install support assembly (10). Tighten the bolts to a torque of 39 ± 8 N·m (29 ± 6 lb ft).
4. Install clamps (9). Tighten the bolts to a torque of 50 ± 10 N·m (37 ± 7 lb ft).
5. Apply Tooling (B) to the bore for pin assembly (6).
6/8
2020/1/4

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6. Use a suitable lifting device to position boom cylinder (4) onto Tooling (A) and on the machine, as
shown. Install the shims and pin (6). Adjust the shims to achieve a maximum clearance of 1.0 mm
(0.04 inch). Install bolt (7).
7. Connect hose assemblies (5).
8. Use the suitable lifting device to raise boom cylinder (4) and extend the rod to position the cylinder
onto the boom.
9. Apply Tooling (B) to the bore for pin (3). Install pin (3) and the shims. Install retaining bolt (1) and
nuts (2).
10. Use the following procedure to tighten all the nuts:
a. Position the outside nut even with the end of the retaining bolt or 0.5 mm (0.02 inch) beyond
the end of the retaining bolt.
b. Tighten the inside nut against the outside nut to a torque of 70 ± 15 N·m (50 ± 10 lb ft).
11. Remove all suitable lifting devices.
Sat Jan 4 22:25:48 UTC+0800 2020
7/8
2020/1/4

Shutdown SIS
Previous Screen
i07119239
Boom Cylinder - Remove and Install
SMCS - 5456-010
S/N - CE81-UP
S/N - HAM1-UP
S/N - HEL1-UP
S/N - JC51-UP
S/N - KC51-UP
S/N - MC51-UP
S/N - PC81-UP
Removal Procedure
Table 1
Required Tools
1/9
2020/1/4

Cylinders equipped with lock valves can remain pressurized for very
long periods of time, even with the hoses removed.
Failure to relieve pressure before removing a lock valve or
disassembling a cylinder can result in personal injury or death.
Ensure all pressure is relieved before removing a lock valve or
disassembling a cylinder.
NOTICE
containing fluids.
Cat®
products.
NOTICE
containing fluids.
Cat®
products.
2/9
2020/1/4

1. Attach a suitable lifting device to boom cylinder (4). The weight of boom cylinder (4) is
approximately 116 kg (255 lb).
Note: Note the position of the shims for installation purposes.
2. Remove retaining bolt (1) and nuts (2). Remove pin (3) and the shims.
3. Lower boom cylinder (4) onto Tooling (A) so that boom cylinder (4) is in a horizontal position.
Retract the cylinder rod for boom cylinder (4).
3/9
2020/1/4

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Caterpillar Cat 308E2CR Mini Hydraulic Excavator (Prefix MC5) Service Repair Manual (MC500001 and up).pdf