Service manual Caterpillar 308E2SR Mini Hydraulic Excavator with C3.3B Engine | JC500001-UP

Air Conditioning and Heating R134a for All Cat Machines
– General Information
– Refrigerant Orifice Tube System
– Refrigerant Compressor
– Refrigerant Compressor
– Refrigerant Compressor
– Refrigerant Condenser
– Refrigerant Condenser
– Refrigerant Receiver-Dryer
– Refrigerant Receiver-Dryer
– Refrigerant Expansion Valve
– In-line Refrigerant Dryer
– Identifying the Refrigerant
– In-line Refrigerant Dryer
– Refrigerant Orifice Tube Assembly
– Refrigerant Orifice Tube Assembly
– Evaporator Coil
– Refrigerant Accumulator
– Refrigerant Accumulator
– Refrigerant Accumulator
– Refrigerant Compressor Protection System
– Temperature Control
– Temperature Control
– Identifying the Refrigerant
– Pressure Switch (Refrigerant)
– Pressure Switch (Refrigerant)
– Cab Pressurization and Filtration System
– Cab Pressurization and Filtration System
– Cab Pressurization and Filtration System
– Condensate Drainage System
– Condensate Drainage System
– Service Intervals
– Service Intervals
– Glossary of Terms
– Identifying the Air Conditioning System
– General Troubleshooting Information
– General Troubleshooting Information
– Machine Preparation for Testing and Adjusting
– Machine Preparation for Testing and Adjusting
– Air Conditioning Performance – Test
– Refrigerant Leakage – Test
– Manifold Gauge Set (Refrigerant) – Install
– Manifold Gauge Set (Refrigerant) – Install
– Refrigerant Recovery
– Refrigerant Recovery
– Identifying the Air Conditioning System
– Refrigerant System – Flush
– Refrigerant Oil – Test
– Refrigerant Compressor – Test
– Refrigerant Compressor – Test
– Refrigerant Compressor – Test
– Refrigerant System – Evacuate
– Refrigerant System – Evacuate
– Refrigerant System – Charge
– Refrigerant System – Charge
– Manifold Gauge Set (Refrigerant) – Remove
– Identifying the Heating System
– Manifold Gauge Set (Refrigerant) – Remove
– Compressor Protection System – Test
– Compressor Protection System – Test
– Electronic Heat Control – Test
– Electronic Heat Control – Test
– Heater Performance – Test
– Heating and Air Conditioning Service Publications
– General Information
– General Information
– Machine Preparation for Disassembly and Assembly
– Refrigerant Expansion Valve System
– Air Conditioner Lines – Remove and Install
– Refrigerant Compressor – Remove and Install
– Refrigerant Accumulator – Remove and Install
– Refrigerant Expansion Valve – Remove and Install
– Refrigerant Receiver-Dryer – Remove and Install
– In-Line Refrigerant Dryer – Remove and Install
– Refrigerant Orifice Tube Assembly – Remove and Install
– Refrigerant Expansion Valve System
– Refrigerant Orifice Tube System
– General Information
Disassembly and Assembly 308ECR and 308ESR Mini Hydraulic Excavators Machine Systems
– Accumulator – Remove and Install
– Blade – Remove and Install
– Blade Cylinder – Remove and Install
– Blade Cylinder – Remove and Install
– Blower Motor (Air Conditioner, Heater) – Remove and Install
– Boom – Remove and Install – Two Piece Boom – Primary Boom
– Boom – Remove and Install – Two Piece Boom, Upper Boom
– Boom Cylinder – Remove and Install
– Boom Cylinder – Remove and Install
– Boom Cylinder – Remove and Install – Boom Offset Cylinder –
– Boom Cylinder – Remove and Install – Two Piece Boom
– Boom Cylinder – Remove and Install – Two Piece Boom –
– Bucket – Remove and Install
– Bucket Cylinder – Remove and Install
– Bucket Linkage – Remove and Install
– Bucket Linkage – Remove and Install
– Cab – Remove and Install
– Cab – Remove and Install
– Check Valve (Cooler Bypass) – Remove and Install
– Check Valve (Slow Return) – Remove and Install
– Control – Remove and Install – Communication Radio
– Control – Remove and Install – Product Link Cellular Antenna
– Control Manifold (Pilot Oil) – Remove and Install
– Counterweight – Remove and Install
– Duo-Cone Conventional Seals – Install
– Evaporator Coil – Remove and Install
– Final Drive and Travel Motor – Assemble
– Final Drive and Travel Motor – Disassemble
– Final Drive and Travel Motor – Install
– Final Drive and Travel Motor – Remove
– Front Idler and Recoil Spring – Install
– Front Idler and Recoil Spring – Remove
– Fuel Tank – Remove and Install
– Gear Pump (Pilot) – Remove and Install
– Heater Core – Remove and Install
– Heating and Air Conditioning Unit – Remove and Install
– Hydraulic Lockout Control – Remove and Install
– Hydraulic Tank – Remove and Install
– Hydraulic Track Adjusters – Install
– Hydraulic Track Adjusters – Remove
– Main Control Valve – Assemble
– Main Control Valve – Disassemble
– Main Control Valve – Remove and Install
– Main Hydraulic Pump – Assemble
– Main Hydraulic Pump – Disassemble
– Main Hydraulic Pump – Remove and Install
– Offset Boom – Remove and Install
– Offset Boom Cylinder – Remove and Install
– Pedal Control and Mounting – Remove and Installl
– Pilot Valve (Blade) – Assemble
– Pilot Valve (Blade) – Disassemble
– Pilot Valve (Blade) – Remove and Install
– Pilot Valve (Joystick) – Assemble
– Pilot Valve (Joystick) – Disassemble
– Pilot Valve (Joystick) – Remove and Install
– Pilot Valve (Travel) – Assemble
– Pilot Valve (Travel) – Disassemble
– Pilot Valve (Travel) – Remove and Install
– Pilot Valve (Travel) – Remove and Install
– Recoil Spring – Assemble
– Recoil Spring – Disassemble
– Relief Valve (Pilot) – Remove and Install
– Relief Valve (Pilot) – Remove and Install
– Seat – Remove and Install
– Solenoid Valve (Hydraulic Lockout) – Remove and Install
– Solenoid Valve (Medium Pressure) – Remove and Install
– Solenoid Valve (Swing Boom) – Remove and Install
– Solenoid Valve (Travel Speed) – Remove and Install
– Solenoid Valve (Work Tool) – Remove and Install
– Sprocket – Remove and Install
– Stick – Remove and Install
– Stick – Remove and Install
– Stick Cylinder – Remove and Install
– Stick Cylinder – Remove and Install
– Swing Drive – Assemble
– Swing Drive – Disassemble
– Swing Drive – Remove and Install
– Swing Motor – Assemble
– Swing Motor – Disassemble
– Swing Motor – Remove and Install
– Swivel – Assemble
– Swivel – Disassemble
– Swivel – Remove and Install
– System Pressure – Release
– Track – Connect
– Track – Remove and Install
– Track – Separate
– Track Adjuster – Assemble
– Track Adjuster – Disassemble
– Track Carrier Roller – Remove and Install
– Track Roller – Remove and Install
– Undercarriage Frame – Install
– Undercarriage Frame – Remove
– Window Wiper Motor – Remove and Install
– Window Wiper Motor – Remove and Install
Disassembly and Assembly C3.3B Engines for Caterpillar Built Machines
– Alternator – Remove and Install
– Bearing Clearance – Check
– Boost Pressure Sensor – Remove and Install
– Bridge Dowels – Remove and Install
– Camshaft and Valve Lifters – Remove and Install
– Camshaft Gear – Remove and Install
– Camshaft Position Sensor – Remove and Install
– Camshaft Position Sensor Bushing – Remove and Install
– Connecting Rod Bearings – Remove and Install
– Coolant Temperature Sensor – Remove and Install
– Crankshaft and Main Bearings – Install
– Crankshaft and Main Bearings – Remove
– Crankshaft Front Seal – Remove and Install
– Crankshaft Position Sensor – Remove and Install
– Crankshaft Pulley – Remove and Install
– Crankshaft Rear Seal and Wear Sleeve – Install – Includes
– Crankshaft Rear Seal and Wear Sleeve – Remove – Includes
– Cylinder Head – Remove and Install
– Diesel Particulate Filter – Assemble
– Diesel Particulate Filter – Disassemble
– Diesel Particulate Filter – Remove and Install
– Electric Starting Motor – Remove and Install
– Electronic Unit Injector – Remove and Install
– Engine Oil Cooler – Remove and Install
– Engine Oil Pan – Remove and Install
– Engine Oil Pressure Sensor – Remove and Install
– Engine Oil Pump – Remove and Install
– Engine Oil Relief Valve – Remove and Install
– Exhaust Gas Recirculation Valve – Remove and Install
– Exhaust Manifold – Remove and Install
– Flywheel – Remove and Install
– Flywheel Housing – Remove and Install
– Fuel Injection Lines – Remove and Install
– Fuel Injection Pump – Remove and Install
– Fuel Manifold (Rail) – Remove and Install
– Fuel Manifold (Rail) – Remove and Install
– Fumes Disposal Filter – Remove and Install
– Glow Plugs – Remove and Install
– Housing (Front) – Remove and Install
– Idler Gear – Remove and Install
– Inlet Air Temperature Sensor – Remove and Install
– Inlet and Exhaust Valve Guides – Remove and Install
– Inlet and Exhaust Valve Springs – Remove and Install
– Inlet and Exhaust Valves – Remove and Install
– Inlet Manifold – Remove and Install
– Pistons and Connecting Rods – Assemble
– Pistons and Connecting Rods – Disassemble
– Pistons and Connecting Rods – Remove and Install
– Pressure Sensor (Mass Air Flow) – Remove and Install
– Rocker Shaft – Assemble
– Rocker Shaft – Disassemble
– Rocker Shaft and Push Rod – Remove and Install
– Turbocharger – Remove and Install
– V-Belts – Remove and Install
– Valve Mechanism Cover – Remove and Install
– Water Pump – Remove and Install
– Water Temperature Regulator – Remove and Install
Schematic Caterpillar 308E2 CR and 308E2 SR Excavator Electrical System
– Features
– Cover Page
– Information
– Component Location
– Vol 1 – Machine (SR – Standard and Crane)
– Vol 2 – Machine (CR – Crane)
– Vol 3 – Machine (CR – Standard)
– Connector Location
– Vol 1 – Machine (SR – Standard and Crane)
– Vol 2 – Machine (CR – Crane)
– Vol 3 – Machine (CR – Standard)
– Schematics
– Function Isolation Tools
– Grids On/Off
– All Circuits Off
– All Circuits On
– Vol 1 – Machine (SR – Standard and Crane)
– Unspecified Circuit
– 032 (Red) (Battery Power)
– Black (Ground)
– 640 (Blue) (Key Power)
– 021 (Orange) (Starting)
– 190 (Dk Pink) (Start Aid)
– 258 (Dk Purple) (Machine Control Circuit)
– 346 (Med Green) (Monitor Circuit)
– 430 (Dk Gray) (Machine Security)
– 509 (Lt Pink) (Engine Master)
– 613 (Dk Yellow) (Heat/AC)
– 4665 (Tan) (Turn/Wiper/Washer)
– CON 346 (CAT Data Link)
– CON 509 (CAN Data Link)
– CON 032 (RS232/485 Data Link)
– CON 190 (CAN Data Link A)
– SUB 651 (Blue Gray) (Ethernet)
– Vol 2 – Machine (CR – Crane)
– Unspecified Circuit
– Black (Ground)
– 032 (Red) (Battery Power)
– 640 (Blue) (Key Power)
– 021 (Orange) (Starting)
– 190 (Dk Pink) (Start Aid)
– 258 (Dk Purple) (Machine Control Circuit)
– 346 (Med Green) (Monitor Circuit)
– 430 (Dk Gray) (Machine Security)
– 509 (Lt Pink) (Engine Master)
– 613 (Dk Yellow) (Heat/AC)
– 4665 (Tan) (Turn/Wiper/Washer)
– CON 346 (CAT Data Link)
– CON 509 (CAN Data Link)
– CON 032 (RS232/485 Data Link)
– SUB 651 (Blue Gray) (Ethernet)
– Vol 3 – Machine (CR – Standard)
– Unspecified Circuit
– Black (Ground)
– 032 (Red) (Battery Power)
– 640 (Blue) (Key Power)
– 021 (Orange) (Starting)
– 190 (Dk Pink) (Start Aid)
– 258 (Dk Purple) (Machine Control Circuit)
– 346 (Med Green) (Monitor Circuit)
– 430 (Dk Gray) (Machine Security)
– 509 (Lt Pink) (Engine Master)
– 613 (Dk Yellow) (Heat/AC)
– 4665 (Tan) (Turn/Wiper/Washer)
– CON 346 (CAT Data Link)
– CON 509 (CAN Data Link)
– CON 032 (RS232/485 Data Link)
– SUB 651 (Blue Gray) (Ethernet)
– Machine Views
– Vol 1 – Machine (SR – Standard and Crane)
– Below Cab Platform
– Cab Behind seat
– Cab Below Seat
– Cab Left Side
– Cab Right Side
– Cab Roof
– Engine Front
– Engine Rear
– Machine Below Boom Support
– Machine Boom
– Machine Left Rear
– Machine Left Side View
– Machine Main Valve
– Machine Right Rear
– Machine Right Side
– Vol 2 – Machine (CR – Crane)
– Below Cab Platform
– Cab Behind Seat
– Cab Below Seat
– Cab Left Side
– Cab Right Side
– Cab Roof
– Machine Below Boom Support
– Machine Boom
– Machine Left Rear
– Machine Left Side View
– Machine Main Valve
– Machine Right Rear
– Machine Right Side
– Vol 3 – Machine (CR – Standard)
– Below Cab Platform
– Cab Behind Seat
– Cab Below Seat
– Cab Front View
– Cab Left Side
– Cab Right Side
– Cab Roof
– Machine Below Boom Support
– Machine Boom
– Machine Left Rear
– Machine Main Valve
– Machine Right Rear
– Machine Right Side
Schematic Caterpillar 308E2 SR Excavator Hydraulic System
– Features
– Cover Page
– Information
– Component Location
– Tap Location
– Schematic
– Machine Views
– Machine – Front View
– Machine – Left Side View
– Machine – Right Side View
Specifications 308E2 Mini Hydraulic Excavator Machine System
– Air Cleaner
– Air Conditioner Lines
– Auxiliary Hydraulic Lines
– Auxiliary Hydraulic Lines
– Auxiliary Hydraulic Lines
– Blade Mounting
– Boom – 3.7 m (12.14 ft)
– Boom – 3.7 m (12.14 ft)
– Boom – Offset
– Boom Cylinder
– Boom Cylinder
– Boom Cylinder
– Boom Cylinder
– Boom Cylinder Lines
– Boom Cylinder Lines
– Boom Lines
– Boom Lines
– Bucket
– Bucket Adjuster
– Bucket Cylinder
– Bucket Cylinder
– Bucket Linkage
– Bucket Linkage
– Cab
– Cab Air Duct
– Counterweight
– Cutting Edge
– Cylinder Guard
– Front Idler
– Front Lines
– Fuel Lines
– Fuel Tank and Mounting
– Grease Lines
– Handle Control (Travel)
– Hydraulic Tank and Filter
– Hydraulic Tank Mounting
– Joystick Control
– Limit Switch (Hydraulic Lockout)
– Main Control Valve
– Main Control Valve
– Main Hydraulic Pump
– Main Hydraulic Pump Mounting
– Manifold and Reducing Valve (Pilot Oil)
– Operator Console
– Pilot Lines
– Pilot Lines
– Pilot Valve (Joystick)
– Pilot Valve (Travel)
– Pilot Valve – Boom
– Radiator and Hydraulic Oil Cooler
– Radio (AM/FM)
– Rear View Mirror
– Recoil Spring
– Refrigerant Compressor Mounting
– Refrigerant Condenser and Mounting
– Return Lines
– Rollover Protective Structure (ROPS) Mounting
– Seat Belt
– Sprocket
– Stick Cylinder
– Stick Lines
– Stick Lines – Long
– Stick Lines – Medium
– Swing Gear and Bearing
– Track
– Track Adjuster
– Track Carrier Roller
– Track Roller
– Track Roller (Single Flange)
– Track Roller Mounting
– Travel Motor and Mounting
– Travel Motor Guard
– Upper Frame
– Upper Frame
– Wiring (Console)
Specifications C3.3B Engines for Caterpillar Built Machines
– Alternator and Regulator
– Boost Pressure Sensor
– Camshaft
– Connecting Rod
– Coolant Temperature Sensor
– Crankcase Breather
– Crankshaft
– Cylinder Block
– Cylinder Head
– Cylinder Head Valves
– Diesel Particulate Filter
– Electric Starting Motor
– Engine Design
– Engine Design
– Engine Oil Cooler
– Engine Oil Pan
– Engine Oil Pump
– Exhaust Manifold
– Flywheel
– Flywheel Housing
– Fuel Injection Lines
– Fuel Injector
– Gear Group (Front)
– Piston and Rings
– Speed/Timing Sensor
– Valve Mechanism
– Valve Mechanism Cover
– Water Temperature Regulator
Systems Operation & Testing and Adjusting 308E2 Mini Hydraulic Excavator Machine System
– Accumulator (Pilot)
– Accumulator (Pilot) – Test and Charge
– Blade Hydraulic System
– Boom Hydraulic System
– Boom Hydraulic System
– Bucket Hydraulic System
– Bypass Valve (Return) – Bypass Check Valve
– Check Valve (Load)
– Check Valve (Return Makeup) – Slow Return Check Valve
– Control Valve (Boom Lowering)
– Control Valve (Stick Lowering)
– Cutoff Pressure (Main Pump) – Test and Adjust
– Cylinder Drift – Check
– Cylinder Speed – Check
– Cylinder Speed – Check
– Cylinders (Boom, Stick and Bucket)
– Displacement Change Valve
– E-Fence – Set – Calibration
– Engine Performance – Test – Engine Speed
– Final Drive
– General Information
– General Testing and Adjusting Information
– Hydraulic Oil Cooler
– Hydraulic System Air – Purge
– Hydraulic Tank and Filter
– Machine Drift on a Slope – Check
– Main Control Valve
– Main Control Valve
– Main Hydraulic Pump
– Main Hydraulic System
– Main Hydraulic System
– Main Pump (Flow) – Test
– Offset Boom Hydraulic System
– Offset Boom Hydraulic System – E-Fence Hydraulic System
– Oil Makeup (Swing System)
– Oil Makeup (Travel System)
– One-Way Flow Hydraulic System
– Operational Checks
– Pilot Hydraulic System
– Pilot Hydraulic System
– Pilot Valve (Joystick)
– Pilot Valve (Swing Parking Brake)
– Pilot Valve (Travel)
– Position Sensor – Calibrate – Front Linkage
– Pump Control (Main Hydraulic)
– Pump Control (Output Flow) – Adjust
– Relief Valve (Line)
– Relief Valve (Swing)
– Relief Valve (Swing) – Test
– Return Hydraulic System
– Shovel Crane
– Shovel Crane
– Solenoid Valve (Hydraulic Lockout)
– Specifications
– Stick Hydraulic System
– Stick Hydraulic System
– Swing Drive
– Swing Hydraulic System
– Swing Motor
– Swing Motor – Test – Measurement of Case Drain Oil
– Swing Speed and Overswing on Level Ground – Check
– Swing Speed and Swing Drift on a Slope – Check
– Swivel
– Travel Counterbalance Valve
– Travel Hydraulic System
– Travel Motor
– Travel Motor – Test – Measurement of Case Drain Oil
– Travel on Level Ground – Test
– Travel on Level Ground – Test – Optional Test
– Travel Parking Brake
– Two-Way Flow Hydraulic System
– Visual Inspection
Systems Operation E2-Series Mini Hydraulic Excavators MiniHex Monitor
– Control Mode Menu
– Diagnostic Info
– Display Module
– General Information
– Main Menu
– Maintenance Information Menu
– Performance Information Menu
– Prestart Monitoring Function
– Security System Menu
– Security System Password Entry
– Service Menu
– Settings Menu
– System Schematic
– Warning Operation
– Warning Operation
– Work Tool Menu
Systems Operation, Testing and Adjusting C3.3B Engines for Caterpillar Built Machines
– Air in Fuel – Test
– Air Inlet and Exhaust System
– Air Inlet and Exhaust System – Inspect
– Alternator – Test
– Basic Engine
– Battery – Test
– Compression – Test
– Connecting Rod Bearings – Inspect
– Cooling System
– Cooling System – Check – Overheating
– Cooling System – Inspect
– Cooling System – Test
– Cylinder Block – Inspect
– Electric Starting System – Test
– Electrical System
– Engine Crankcase Pressure (Blowby) – Test
– Engine Oil Pressure – Test
– Engine Oil Pump – Inspect
– Engine Speed – Check
– Engine Valve Lash – Inspect/Adjust – C3.3B Engines
– Excessive Bearing Wear – Inspect
– Excessive Engine Oil Consumption – Inspect
– Exhaust Temperature – Test
– Finding Top Center Position for No. 4 Piston
– Fuel Injector – Test
– Fuel Quality – Test
– Fuel System
– Fuel System – Inspect
– Fuel System – Inspect
– General Information
– General Information
– Lubrication System
– Main Bearings – Inspect
– Piston Ring Groove – Inspect
– Turbocharger – Inspect
– Water Temperature Regulator – Test
Troubleshooting C3.3B and C3.8 Engines for Caterpillar Built Machines
– Acceleration Is Poor or Throttle Response Is Poor
– Alternator Problem – Charging Problem and/or Noisy
– Battery Problem
– Cat ET Service Features – DEF Dosing System Test
– Component Location
– Coolant Contains Oil
– Coolant Level Is Low
– Coolant Temperature Is High
– Cooling Fan Is Always ON
– Cylinder Is Noisy
– Data Link – Test
– DEF Concentration Is Incorrect
– DEF Injector Trim File – Install – Injector Trim Code – Install
– DEF Line Heater – Test
– DEF Module Does Not Respond
– DEF Pressure Is High
– DEF Pressure Is Low
– DEF Pump – Test
– DEF Tank Level Is Low
– DEF Tank Temperature Is High
– DEF Tank Temperature Is Low
– Diagnostic Capabilities
– Diagnostic Trouble Codes
– Diesel Particulate Filter Active Regeneration Occurrence Is
– Diesel Particulate Filter Error
– Diesel Particulate Filter Regeneration Does Not Occur
– ECM – Replace
– ECM Memory – Test
– ECM Software – Install
– Electrical Connectors
– Electrical Connectors – Inspect
– Electrical Power Supply – Test
– Electronic Service Tool Does Not Communicate
– Electronic Service Tools
– Engine Cranks but Does Not Start
– Engine Does Not Crank
– Engine Has Early Wear
– Engine Has Mechanical Noise (Knock)
– Engine Injector Trim File – Install
– Engine Misfires, Runs Rough or Is Unstable
– Engine Misfires, Runs Rough or Is Unstable
– Engine Monitoring System
– Engine Overspeeds
– Engine Shutdown Occurs Intermittently
– Engine Stalls at Low RPM
– Engine Top Speed Is Not Obtained
– Engine Vibration Is Excessive
– Exhaust Has Excessive White Smoke
– Exhaust System Contains Oil
– Exhaust Temperature Is High
– Fuel Consumption Is Excessive
– Fuel Rail Pressure Is High
– Fuel Rail Pressure Is Low
– Fuel Rail Temperature Is High
– General Information
– Injector Data Incorrect – Test
– Injector Data Incorrect – Test
– Injector Solenoid – Test
– Injector Solenoid – Test – Fuel Injector
– Injector Trim File – Install
– Intake Manifold Air Temperature Is High
– Motorized Valve – Test
– NOx Conversion Is Low
– NOx Reduction System (NRS) – Test
– NOx Sensor – Test
– Oil Consumption Is Excessive
– Oil Contains Coolant
– Oil Contains Fuel
– Oil Pressure Is Low
– Relay – Test – ECM Main Relay
– SCR Catalyst Has Incorrect Inlet Temperature
– Sensor Signal (Analog, Active) – Test
– Sensor Signal (Analog, Passive) – Test
– Sensor Supply – Test
– Service Information Report
– Solenoid Valve – Test – Pressure Relief Valve
– Solenoid Valve – Test – Solenoid Valves that Connect to the
– Solenoid Valve – Test – Solenoid Valves that Connect to the
– Solenoid Valve – Test – Suction Control Valve
– Speed/Timing – Test
– Starting Aid – Test
– Test ECM Mode
– Turbocharger Failure
– Valve Lash Is Excessive
– Welding Precaution