308D Caterpillar Mini Hyd Excavator Operation and Maintenance Manual by quality service repair manual

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Product:MINIHYDEXCAVATOR

Model:308DMINIHYDEXCAVATORGBT

Configuration:308DMiniHydraulicExcavatorGBT00001-UP(MACHINE)POWEREDBY4M40Engine

OperationandMaintenanceManual

308DCRMiniHydraulicExcavator

MediaNumber-SEBU8199-09PublicationDate-01/06/2015DateUpdated-18/05/2016

Foreword

SMCS-1054;108K;1261;1263;1308;5068;7342

LiteratureInformation

Thismanualshouldbestoredintheoperator'scompartmentintheliteratureholderorseatback literaturestoragearea.

Thismanualcontainssafetyinformation,operationinstructions,transportationinformation, lubricationinformationandmaintenanceinformation.

Somephotographsorillustrationsinthispublicationshowdetailsorattachmentsthatcanbedifferent fromyourmachine.Guardsandcoversmighthavebeenremovedforillustrativepurposes.

Continuingimprovementandadvancementofproductdesignmighthavecausedchangestoyour machinewhicharenotincludedinthispublication.Read,studyandkeepthismanualwiththe machine.

Wheneveraquestionarisesregardingyourmachine,orthispublication,pleaseconsultyourCat dealerforthelatestavailableinformation.

Safety

Thesafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifiesthetextand locationsofwarningsignsandlabelsusedonthemachine.

Readandunderstandthebasicprecautionslistedinthesafetysectionbeforeoperatingorperforming lubrication,maintenanceandrepaironthismachine.

Operation

s00037320

Theoperationsectionisareferenceforthenewoperatorandarefresherfortheexperiencedoperator. Thissectionincludesadiscussionofgauges,switches,machinecontrols,attachmentcontrols, transportationandtowinginformation.

Photographsandillustrationsguidetheoperatorthroughcorrectproceduresofchecking,starting, operatingandstoppingthemachine.

Operatingtechniquesoutlinedinthispublicationarebasic.Skillandtechniquesdevelopasthe operatorgainsknowledgeofthemachineanditscapabilities.

Maintenance

Themaintenancesectionisaguidetoequipmentcare.TheMaintenanceIntervalSchedule(MIS)lists theitemstobemaintainedataspecificserviceinterval.Itemswithoutspecificintervalsarelisted underthe"WhenRequired"serviceinterval.TheMaintenanceIntervalScheduleliststhepage numberforthestep-by-stepinstructionsrequiredtoaccomplishthescheduledmaintenance.Usethe MaintenanceIntervalScheduleasanindexor"onesafesource"forallmaintenanceprocedures.

MaintenanceIntervals

Usetheservicehourmetertodetermineservicingintervals.Calendarintervalsshown(daily,weekly, monthly,etc.)canbeusedinsteadofservicehourmeterintervalsiftheyprovidemoreconvenient servicingschedulesandapproximatetheindicatedservicehourmeterreading.Recommendedservice shouldalwaysbeperformedattheintervalthatoccursfirst.

Underextremelysevere,dustyorwetoperatingconditions,morefrequentlubricationthanisspecified inthemaintenanceintervalschartmightbenecessary.

Performserviceonitemsatmultiplesoftheoriginalrequirement.Forexample,atevery500service hoursor3months,alsoservicethoseitemslistedunderevery250servicehoursormonthlyandevery 10servicehoursordaily.

CaliforniaProposition65Warning

DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCaliforniatocause cancer,birthdefects,andotherreproductiveharm.

Batteryposts,terminalsandrelatedaccessoriescontainleadandleadcompounds.Washhandsafter handling.

CertifiedEngineMaintenance

Propermaintenanceandrepairisessentialtokeeptheengineandmachinesystemsoperating correctly.Astheheavydutyoff-roaddieselengineowner,youareresponsiblefortheperformanceof therequiredmaintenancelistedintheOwnerManual,OperationandMaintenanceManual,and ServiceManual.

Itisprohibitedforanypersonengagedinthebusinessofrepairing,servicing,selling,leasing,or tradingenginesormachinestoremove,alter,orrenderinoperativeanyemissionrelateddeviceor elementofdesigninstalledonorinanengineormachinethatisincompliancewiththeregulations (40CFRPart89).Certainelementsofthemachineandenginesuchastheexhaustsystem,fuel system,electricalsystem,intakeairsystemandcoolingsystemmaybeemissionrelatedandshould notbealteredunlessapprovedbyCaterpillar.

MachineCapacity

Additionalattachmentsormodificationsmayexceedmachinedesigncapacitywhichcanadversely affectperformancecharacteristics.Includedwouldbestabilityandsystemcertificationssuchas brakes,steering,androlloverprotectivestructures(ROPS).ContactyourCatdealerforfurther information.

CatProductIdentificationNumber

EffectiveFirstQuarter2001theCatProductIdentificationNumber(PIN)haschangedfrom8to17 characters.Inanefforttoprovideuniformequipmentidentification,Caterpillarandotherconstruction equipmentmanufacturersaremovingtocomplywiththelatestversionoftheproductidentification numberingstandard.Non-roadmachinePINsaredefinedbyISO10261.ThenewPINformatwill applytoallCatmachinesandgeneratorsets.ThePINplatesandframemarkingwilldisplaythe17 characterPIN.Thenewformatwilllooklikethefollowing:

2.MachineDescriptor(characters4-8)

3.CheckCharacter(character9)

4.MachineIndicatorSection(MIS)orProductSequenceNumber(characters10-17).Thesewere previouslyreferredtoastheSerialNumber.

MachinesandgeneratorsetsproducedbeforeFirstQuarter2001willmaintaintheir8characterPIN format.

Componentssuchasengines,transmissions,axles,etc.andworktoolswillcontinuetousean8 characterSerialNumber(S/N).

SatJan213:32:37UTC+05302021

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Product:MINIHYDEXCAVATOR

Model:308DMINIHYDEXCAVATORGBT

Configuration:308DMiniHydraulicExcavatorGBT00001-UP(MACHINE)POWEREDBY4M40Engine

OperationandMaintenanceManual 308DCRMiniHydraulicExcavator

MediaNumber-SEBU8199-09PublicationDate-01/06/2015DateUpdated-18/05/2016

AccessDoorandCoverLocations

i03775920

SatJan209:24:25UTC+05302021

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Product:MINIHYDEXCAVATOR

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Configuration:308DMiniHydraulicExcavatorGBT00001-UP(MACHINE)POWEREDBY4M40Engine

OperationandMaintenanceManual 308DCRMiniHydraulicExcavator

MediaNumber-SEBU8199-09PublicationDate-01/06/2015DateUpdated-18/05/2016

i01644425

AirConditioner/CabHeaterFilter(Recirculation)Inspect/Replace

SMCS-1054-510-A/C;1054-040-A/C

NOTICE

Anairrecirculationfilterelementpluggedwithdustwillresultin decreasedperformanceandservicelifetotheairconditionerorcab heater.

Topreventdecreasedperformance,cleanthefilterelement,as required.

Illustration1g00849969

Therecirculationfilterisontheleftsideoftheoperatorseat.

Illustration2g00849975

1.Toremovethefilterelement,removethecoverbolts.

2.Toremovethefilter,pullthefilterawayfromtheoperatorseat.

3.RefertoOperationandMaintenanceManual,"GeneralHazardInformation"beforeusing pressureairtocleantheairfilterelement.

4.Cleanthefilterelementwithamaximumof200kPa(30psi)pressureair.

5.Afteryoucleanthefilterelement,inspectthefilterelement.Ifthefilterelementisdamagedor badlycontaminated,useanewfilterelement.Makesurethatthefilterelementisdry.

SatJan209:26:33UTC+05302021

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Product:MINIHYDEXCAVATOR

Model:308DMINIHYDEXCAVATORGBT

Configuration:308DMiniHydraulicExcavatorGBT00001-UP(MACHINE)POWEREDBY4M40Engine

OperationandMaintenanceManual

MediaNumber-SEBU8199-09PublicationDate-01/06/2015DateUpdated-18/05/2016

Battery-Clean

SMCS-1401-070

Cleanthebatterysurfacewithacleancloth.Keeptheterminalscleanandkeeptheterminalscoated withpetroleumjelly.Installthepostcoverafteryoucoattheterminalpostwithpetroleumjelly.

SatJan209:26:48UTC+05302021

i00934864

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Product:MINIHYDEXCAVATOR

Model:308DMINIHYDEXCAVATORGBT

Configuration:308DMiniHydraulicExcavatorGBT00001-UP(MACHINE)POWEREDBY4M40Engine

OperationandMaintenanceManual

308DCRMiniHydraulicExcavator

MediaNumber-SEBU8199-09PublicationDate-01/06/2015DateUpdated-18/05/2016

Battery-Recycle

SMCS-1401-561

Alwaysrecycleabattery.Neverdiscardabattery.

Alwaysreturnusedbatteriestooneofthefollowinglocations:

•Abatterysupplier

•Anauthorizedbatterycollectionfacility

•Recyclingfacility

i06543763

SatJan209:27:02UTC+05302021

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Product:MINIHYDEXCAVATOR

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Configuration:308DMiniHydraulicExcavatorGBT00001-UP(MACHINE)POWEREDBY4M40Engine

OperationandMaintenanceManual 308DCRMiniHydraulicExcavator

MediaNumber-SEBU8199-09PublicationDate-01/06/2015DateUpdated-18/05/2016

BatteryHold-Down-Tighten

SMCS-7257

Tightenthehold-downsforthebatteryinordertopreventthebatteriesfrommovingduringmachine operation.

PrivateNetworkForSISLicensees.

SatJan209:27:16UTC+05302021

i00934872

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Product:MINIHYDEXCAVATOR

Model:308DMINIHYDEXCAVATORGBT

Configuration:308DMiniHydraulicExcavatorGBT00001-UP(MACHINE)POWEREDBY4M40Engine

OperationandMaintenanceManual

308DCRMiniHydraulicExcavator

MediaNumber-SEBU8199-09PublicationDate-01/06/2015DateUpdated-18/05/2016

BatteryorBatteryCable-Inspect/Replace

SMCS-1401-510;1401-561;1401-040;1402-040;1402-510

Personalinjurycanresultfrombatteryfumesorexplosion. Batteriesgiveoffflammablefumesthatcanexplode.Electrolyteisan acidandcancausepersonalinjuryifitcontactstheskinoreyes.

Preventsparksnearthebatteries.Sparkscouldcausevaporstoexplode. Donotallowjumpercableendstocontacteachotherortheengine. Improperjumpercableconnectionscancauseanexplosion.

Alwayswearprotectiveglasseswhenworkingwithbatteries.

1.TurnalloftheswitchestotheOFFposition.TurntheenginestartswitchkeytotheOFF position.

2.TurnthebatterydisconnectswitchtotheOFFposition.Removethekey.

3.Disconnectthenegativebatterycableatthebattery.

4.Disconnectthepositivebatterycableatthebattery.

5.Disconnectthebatterycablesatthebatterydisconnectswitch.Thebatterydisconnectswitchis connectedtothemachineframe.

6.Makenecessaryrepairsorreplacethebattery.

i04064489

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7.Connectthebatterycableatthebatterydisconnectswitch.

8.Connectthepositivebatterycableofthebattery.

9.Connectthenegativebatterycableofthebattery.

10.InstallthekeyandturnthebatterydisconnectswitchtotheONposition.

SatJan209:27:30UTC+05302021

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Product:MINIHYDEXCAVATOR

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Configuration:308DMiniHydraulicExcavatorGBT00001-UP(MACHINE)POWEREDBY4M40Engine

OperationandMaintenanceManual 308DCRMiniHydraulicExcavator

MediaNumber-SEBU8199-09PublicationDate-01/06/2015DateUpdated-18/05/2016

Belts-Inspect/Adjust/Replace

i01914481

SMCS-1357-040;1357-510;1357-025;1358-025;1358-510;1359-025;1359-040-BE;1359-040; 1359-510-BE;1359-510;1359-025-BE;1361-510;1361-025-BE;1361-025;1361-040-BE;1361040;1361-510-BE;1397-025;1397-040;1397-510;1405-036;1405-040-BE;1405-040;1405-510BE;1405-025-BE;1405-510;1405-025;1802-025;1802-510

NOTICE

TheV-beltmustbetensionedcorrectly.Failuretotensionthebelt properlycouldcausedamagetothebeltand/ortotheairconditioner compressor.

Yourenginecanbeequippedwithawaterpump,withafandrive,andwithanalternator.Yourengine canalsobeequippedwithaccessorydrivebelts.Formaximumengineperformanceandmaximum utilizationofyourengine,inspectthebeltsforwearandforcracking.Checkthebelttension.Adjust thebelttensioninordertominimizebeltslippage.Beltslippagewilldecreasethebeltlife.Belt slippagewillalsocausepoorperformanceofthealternatorandofanydrivenequipment.

Ifnewbeltsareinstalled,recheckthebeltadjustmentafter30minutesofoperation.Iftwobeltsor morearerequiredforanapplication,replacethebeltsinbeltsets.Ifonlyonebeltofapairisreplaced, thenewbeltwillcarrymoreload.Thisisduetothefactthattheolderbeltsarestretched.The additionalloadonthenewbeltcouldcausethenewbelttobreak.

WaterPumpBelt,FanDriveBelt,andAlternatorBelt

Illustration2g00418343 (1)Alternatormountingbolt (2)Nut (3)Adjustingbolt

1.Opentheenginehood.

2.Applyapproximately98N(22lb)offorcemidwaybetweenthepulleys.

3.Measurethedeflectionofthebelt.Thebeltshoulddeflect8to11mm(5/16to7/16inch).

4.Ifthedeflectionisnotcorrect,loosenalternatormountingbolt(1)andnut(2).Turnadjusting bolt(3)inordertoadjustthebelttension.

5.Whentheadjustmentiscorrect,tightenbolt(1)toatorqueof21±4N·m(15±3lbft).Tighten nut(2)toatorqueof41±8N·m(30±6lbft).

6.Checkthedeflectionofthebeltagain.

Note:Ifanewbeltisinstalled,checkthebeltadjustmentagainafter30minutesofengine operationattheratedenginespeed.

AirConditionerBelt

(4)Collar (5)Adjustingbolt

1.Applyapproximately98N(22lb)offorcemidwaybetweenthepulleys.

2.Measurethedeflectionofthebelt.Thebeltshoulddeflect7to10mm(1/4to3/8inch).

3.Ifthedeflectionisnotcorrect,loosencollar(4).Turnadjustingbolt(5)inordertoadjustthe belttension.

4.Whentheadjustmentiscorrect,tightencollar(4)toatorqueof100±20N·m(75±15lbft).

5.Checkthedeflectionagain.

Note:Ifanewbeltisinstalled,recheckthebeltadjustmentagainafter30minutesofoperation.

6.Closetheenginehood.

SatJan209:27:45UTC+05302021

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Configuration:308DMiniHydraulicExcavatorGBT00001-UP(MACHINE)POWEREDBY4M40Engine

OperationandMaintenanceManual

308DCRMiniHydraulicExcavator

MediaNumber-SEBU8199-09PublicationDate-01/06/2015DateUpdated-18/05/2016 i01914958

BladeCuttingEdges-Inspect/Replace

SMCS-

Personalinjuryordeathcanresultfromafallingblade. Blockthebladebeforechangingthecuttingedgesandtheendbits.

Checkthecuttingedgeofthebladeandtheendbitsofthebladeforwear.Ifanyofthepartshave signsofunusualwearordamage,replacethepart.

1.Raisethebladeandplaceblockingunderneaththeblade.

2.Lowerthebladeontotheblocking.

3.Removebolts(1),washers(4)andnuts(5).

4.Removecuttingedge(2)andendbits(3).

5.Cleanthesurfacebetweenthecuttingedgeandtheendbits.

6.Turnthecuttingedgeand/ortheendbitsupside-downifthoseedgesarenotworn.

7.Ifbothsidesofthecuttingedgeandtheendbitsareworn,replacethepartswithnewparts.

8.Installthenewpartsortherotatedpartswithbolts(1).Tightentheboltstoatorqueof 270±40N·m(200±30lbft).

9.Raisethebladeandremovetheblocking.

10.Lowerthebladetotheground.

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OperationandMaintenanceManual 308DCRMiniHydraulicExcavator

MediaNumber-SEBU8199-09PublicationDate-01/06/2015DateUpdated-18/05/2016

BladeLinkage-Lubricate

SMCS-6060-086

Note:Caterpillarrecommendstheuseof5%molybdenumgreaseforlubricatingthebladelinkage. RefertoSpecialPublication,SEBU6250,"CaterpillarMachineFluidsRecommendations"formore informationonmolybdenumgrease.

Wipeallfittingsbeforeyouapplylubricant.

1.Applylubricantthroughfitting(1).Thisfittingislocatedontheheadendofthebladecylinder.

i02055581

2.Applylubricantthroughfitting(2).Thisfittingislocatedontherodendofthebladecylinder.

Illustration2g00413982

3.Applylubricantthroughfitting(3)andthroughfitting(4).Thesefittingsarelocatedonthebar thatsupportstheblade.

SatJan209:28:19UTC+05302021

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OperationandMaintenanceManual

308DCRMiniHydraulicExcavator

MediaNumber-SEBU8199-09PublicationDate-01/06/2015DateUpdated-18/05/2016

BoomandStickLinkage-Lubricate

SMCS-6501-086;6502-086

Note:Caterpillarrecommendstheuseof5P-0960MolybdenumGreaseforlubricatingtheboom, stickandbucketcontrollinkage.RefertoSpecialPublication,SEBU6250,"CaterpillarMachine FluidsRecommendations"formoreinformationonmolybdenumgrease.

Applylubricantthroughallfittingsafteroperationunderwater.

Wipeallfittingsbeforeyouapplylubricant.

i01664167

1.Applylubricantthroughthefittingatthebaseoftheboom.

Illustration2g00411721

2.Applylubricantthroughthefittingsatthebaseoftheboomcylinder.

Illustration3g00746217

3.Applylubricantthroughfitting(1).Thisfittingislocatedontherodendoftheboomcylinder.

4.Applylubricantthroughfitting(2).Thisfittingislocatedontheheadendofthestickcylinder.

5.Applylubricantthroughfitting(3).Thisfittingislocatedatthejunctionoftheboomandthe stick.

Illustration4g00746218

Illustration5g00746219

6.Applylubricantthroughfitting(4).Thisfittingislocatedontherodendofthestickcylinder.

7.Applylubricantthroughfitting(5).Thisfittingislocatedatthejunctionoftheboomandthe stick.

8.Applylubricantthroughfitting(6).Thisfittingislocatedontheheadendofthebucket cylinder.

SatJan209:28:35UTC+05302021

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OperationandMaintenanceManual

308DCRMiniHydraulicExcavator

MediaNumber-SEBU8199-09PublicationDate-01/06/2015DateUpdated-18/05/2016

Boom,Stick,andFrame-Inspect

SMCS-6501;6502;6506

i04518297

Allearthmovingequipmentispronetoahighdegreeofwear.Regularinspectionsforstructural damagearenecessary.

Theintervalbetweentheseinspectionsdependsonthefactorsthatfollow.

•Theageofthemachine

•Theseverityoftheapplication

•Theloadsthathavebeencarriedonthemachine

•Theamountofroutineservicingthathasbeencarriedout

Ifthemachinehasbeeninvolvedinanykindofaccident,themachinemustbeinspectedthoroughly. Inspectthemachineregardlessofthedateofthelastinspection.

Themachinemustbecleanbeforethemachineisinspected.

Properrepairofframesandstructuresrequiresspecificknowledgeofthefollowingsubjects.

•Materialsthathavebeenusedtomanufacturetheframemembers

•Framememberconstruction

•Repairtechniquesthatarerecommendedbythemanufacturer.

ConsultyourCaterpillardealerifrepairsarenecessary.YourCaterpillardealerisqualifiedtocarry outrepairsonyourbehalf.

AllrepairsshouldbecarriedoutbyaCaterpillardealer.Ifyoucarryoutyourownrepairs,contact yourCaterpillardealerforadviceaboutproperrepairtechniques.

Particularattentionshouldbegiventoallweldedstructures.Thefollowingitemsshouldbe thoroughlyinspectedforcracksandfordefects:

•Boom

•Stick

•Blade(ifequipped)

•Liftingpoints

•Upperframe

•Lowerframe

Theareashighlightedareofparticularimportancebutotherareas mustnotbeneglected.Theentirestructuremustbecarefully examined. Boom

Illustration1g01425291

Typicalexample

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