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

Service Repair Manual

Models

308E2CR Mini Hydraulic Excavator

308E 2CR Mini Hydraulic Excavator EC200001-UP (MACHINE) POWERED BY C3...

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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

A

278-4138

(1)

Part Description Fuel System Protection Gp

Qty (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...

Illustration 1

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2. Mark the alignment of the pump gear and the idler gear for installation purposes.

Illustration 2

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Illustration 3

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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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308E 2CR Mini Hydraulic Excavator EC200001-UP (MACHINE) POWERED BY C3...

Illustration 4

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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)

Illustration 5

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5. Remove the two bolts (not shown) to separate gear (10) from gear (8) .

Installation Procedure

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Illustration 6

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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).

Illustration 7

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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).

Illustration 8

g03337770

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Illustration 9

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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.

Fri Jan 10 23:17:38 UTC+0800 2020

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308E 2CR Mini Hydraulic Excavator EC200001-UP (MACHINE) POWERED BY C3...

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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

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 CatÂŽ 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.

Illustration 1

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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).

Illustration 2

g02891136

4. Remove seal (5) from electronic unit injector (4).

5. Repeat Steps 2 through 3 for the remaining electronic unit injectors.

Installation Procedure

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Illustration 3

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Illustration 4

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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.

Copyright 1993 - 2020 Caterpillar Inc.

Fri Jan 10 23:18:35 UTC+0800 2020

All Rights Reserved.

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308E 2CR Mini Hydraulic Excavator EC200001-UP (MACHINE) POWERED BY C3...

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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

i05305909

Turbocharger - Remove and Install SMCS - 1052-010

Removal Procedure

Illustration 1

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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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308E 2CR Mini Hydraulic Excavator EC200001-UP (MACHINE) POWERED BY C3...

Illustration 2

g02782214

4. Remove bolts (7) and housing (8) and the gasket.

5. Remove four nuts (6) and turbocharger (1) and the gasket.

Installation Procedure Note: Refer to Specifications, "Engine Design" for non-specified engine torque values.

Illustration 3

g02782214

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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308E 2CR Mini Hydraulic Excavator EC200001-UP (MACHINE) POWERED BY C3...

Illustration 4

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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).

Copyright 1993 - 2020 Caterpillar Inc.

Fri Jan 10 23:19:32 UTC+0800 2020

All Rights Reserved.

Private Network For SIS Licensees.

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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

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".

Illustration 1

g03098499

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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308E 2CR Mini Hydraulic Excavator EC200001-UP (MACHINE) POWERED BY C3...

Illustration 2

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3. Disconnect hose (4). Remove mass air flow sensor assembly (5).

Illustration 3

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4. Remove screws (6). Remove mass airflow pressure sensor (7).

Installation Procedure

Illustration 4

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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).

Illustration 5

g03098529

Illustration 6

g03070082

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).

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308E 2CR Mini Hydraulic Excavator EC200001-UP (MACHINE) POWERED BY C3...

Illustration 7

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g03098499

3. Tighten clamps (3). Install clip (2). Connect harness assembly (1).

4. Refer to Operation and Maintenance Manual, "Radiator Tilting".

Copyright 1993 - 2020 Caterpillar Inc.

Fri Jan 10 23:20:28 UTC+0800 2020

All Rights Reserved.

Private Network For SIS Licensees.

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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

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.

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308E 2CR Mini Hydraulic Excavator EC200001-UP (MACHINE) POWERED BY C3...

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.

Illustration 1

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1. Drain coolant below exhaust gas recirculation valve level. Remove heat shield (1).

Illustration 2

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2. Disconnect hoses (2) and (3). Remove bolts (4).

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308E 2CR Mini Hydraulic Excavator EC200001-UP (MACHINE) POWERED BY C3...

Illustration 3

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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).

Illustration 4

g03366813

4. Remove screws (13) and reed valve (12) from exhaust gas recirculation valve (5).

Installation Procedure 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).

Copyright 1993 - 2020 Caterpillar Inc.

Fri Jan 10 23:21:25 UTC+0800 2020

All Rights Reserved.

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