![Caterpillar 236 246 248 Repair Manual 4YZ 5SZ 6LZ [Skid Steer Loader]](https://youfixthis.com/wp-content/uploads/2016/07/2016-07-13_17-30-18-300x300.jpg)
![Caterpillar 329D L 329D LN Repair Manual XDB EBM [Excavators]](https://youfixthis.com/wp-content/uploads/2016/10/2016-10-21_20-50-20-300x300.jpg)
This is the full Caterpillar SIS repair set for the 301.5, 301.6 and 301.8 mini excavators (serial prefixes 3YW1-Up, BDH1-Up and BFA1-Up), built from RENR2808 Machine Systems, the RENR2803 Engine Supplement and the SENR5022/5023/5027 engine manuals for the Cat 3003, 3013, 3014 and 3024 diesels. These are mechanical machines, so everything gets diagnosed the old way: pressure gauges and a stopwatch against printed specs. The book gives you those numbers - main relief at 19100 +/- 500 kPa for boom and stick, pilot pressure at 3400 +/- 300 kPa, boom cycle times to the tenth of a second. Hydraulic schematics for all three models, plus disassembly and assembly for pumps, motors, swivel, cylinders and the complete engine.
What's Inside This Caterpillar 301.5, 301.6, 301.8 Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Schematic | 32-125 | 301.8 Hydraulic System Schematic, 301.5 and 301.6 Hydraulic System Schematic, Electrical System Schematics |
| Air Inlet and Exhaust System | 126-146 | Air Cleaner, Exhaust Manifold, Inlet Manifold, Muffler |
| Basic Engine | 147-408 | Camshaft, Crankshaft, Cylinder Block, Cylinder Head, Flywheel, Compression Test, Engine Valve Lash, Bearing Inspection |
| Cooling System | 409-459 | Fan Drive, Water Pump, Water Temperature Regulator, Radiator |
| Electrical and Starting System - Systems Operation | 460-1017 | Alternator, Battery, Charging System, Electric Starting System, Sensors and Senders |
| Electrical and Starting System - Testing and Adjusting | 1018-1166 | Charging System Test, Battery Test, Starting System Test, Sensor Test |
| Electrical and Starting System - Troubleshooting | 1167-1366 | Electrical Troubleshooting Procedures, Circuit Tests |
| Electrical and Starting System - Specifications, Disassembly and Assembly | 1367-1413 | Alternator Remove and Install, Starting Motor Remove and Install, Wiring Harness |
| Engine Arrangement | 1414-1488 | Engine Mounting and Arrangement |
| Frame and Body | 1489-1506 | Frame, Body Panels |
| Fuel System | 1507-1612 | Fuel Filter, Fuel Injection Lines, Fuel Injection Pump, Fuel Injection Nozzles |
| Hydraulic System | 1613-2029 | Gear Pumps, Pilot Hydraulic System, Main Control Valve, Bank Valve, Swing System, Swivel, Relief Valve Test and Adjust, Cylinders, Operational Checks |
| Implements | 2030-2057 | Boom, Stick, Bucket Linkage |
| Lubrication System | 2058-2090 | Engine Oil Pump, Engine Oil Relief Valve, Oil Filter |
| Operator Station | 2091-2106 | Cab, Controls, Seat |
| Power Train | 2107-2177 | Piston Motor (Swing), Gerotor Motor (Travel), Final Drive |
| Service Equipment and Supplies | 2178-2183 | Service Tooling and Supplies |
| Torque Specifications | 2184-2231 | Metric ISO Fasteners, English SAE Fasteners, Fittings, Plugs, Hose Clamps |
| Undercarriage | 2232-2290 | Undercarriage Frame, Track Roller, Front Idler, Recoil Spring |
| Work Tools | 2291-2303 | Work Tool Hydraulics and Mounting |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| at high idle, hydraulic oil 50 to 60 C | ||
| Boom cycle time | extend 3.1 +/- 0.5 s, retract 2.4 +/- 0.5 s | p. 1690 |
| Main relief valve pressure (boom, stick) | 19100 +/- 500 kPa (2770 +/- 72 psi) | p. 1712 |
| All Models | ||
| Stick cycle time | extend 4.3 +/- 0.5 s, retract 2.9 +/- 0.2 s | p. 1690 |
| Bucket cycle time | extend 2.8 +/- 0.3 s, retract 2.1 +/- 0.2 s | p. 1690 |
| Swing time | 18.4 +/- 0.8 s for 3 revolutions | p. 1690 |
| Main relief valve pressure (blade) | 17650 +/- 450 kPa (2560 +/- 65 psi) | p. 1712 |
| Line relief valve pressure (stick, boom) | 21850 +/- 250 kPa (3200 +/- 35 psi) | p. 1727 |
| Pilot system pressure | 3400 +/- 300 kPa (490 +/- 45 psi) | p. 1706 |
| High idle speed | 2535 to 2585 rpm | |
| Engines covered | Caterpillar 3003, 3013, 3014 and 3024 diesel | |
| Serial prefixes | 301.8 BFA1-Up; 301.5 and 301.6 3YW1-Up and BDH1-Up | |
| pilot accumulator | ||
| Accumulator charge pressure | 900 kPa (130 psi) at 20 C | |
Caterpillar 301.5, 301.6, 301.8 Common Problems This Manual Covers
Hard starting or no start after fuel filter or injection line work, usually from air trapped in the fuel system.
The Fuel System section covers the fuel filter, injection lines, injection pump and nozzles, including the correct sequence for bleeding air out and checking pump and nozzle condition, so you stop cranking a starter flat and fix the actual air leak or timing problem.
Manual Section: Fuel System p. 1507Boom, stick or bucket moves slow, stalls under load, or one circuit is weak while the others feel fine.
Use the Hydraulic System operational checks: time each cycle against the printed specs, then test main relief (19100 +/- 500 kPa for boom and stick) and line reliefs. The section separates a tired gear pump from a misadjusted or leaking relief valve before you buy parts.
Manual Section: Hydraulic System - Relief Valve Test and Adjust, Operational Checks p. 1687Controls feel lazy, sticky or unresponsive even though main pressures test fine, pointing at the pilot circuit.
The Pilot Hydraulic System coverage gives the 3400 +/- 300 kPa pilot pressure spec, the accumulator charge check (900 kPa at 20 C) and the test points, so you can confirm whether contamination or a weak pilot supply is starving the control valve spools.
Manual Section: Hydraulic System - Pilot Hydraulic System p. 1704Machine overheats or runs hot on long dig cycles, often blamed on the thermostat when the real cause is elsewhere.
The Cooling System section covers the water pump, water temperature regulator, fan drive and radiator with removal, inspection and installation procedures, so you can test the regulator and check the pump instead of throwing parts at a plugged radiator core.
Manual Section: Cooling System p. 409Frequently Asked Questions
My boom feels weak and slow. How do I know if the machine is actually worn out?
This is exactly what the book is for. Warm the oil to 50 to 60 C, run high idle (2535 to 2585 rpm) and time the cycles: boom should extend in 3.1 +/- 0.5 seconds and retract in 2.4 +/- 0.5. Stick extends in 4.3 +/- 0.5, bucket in 2.8 +/- 0.3. Three swing revolutions should take 18.4 +/- 0.8 seconds. If you are outside those windows, the Testing and Adjusting section walks you to a pressure test to split pump wear from relief valve trouble. p. 1690
What should the main relief pressure be, and can I adjust it myself?
Main relief for boom and stick is 19100 +/- 500 kPa (2770 +/- 72 psi) at high idle with oil at 50 to 60 C; the blade circuit relief is 17650 +/- 450 kPa (2560 +/- 65 psi), and the stick and boom line reliefs sit higher at 21850 +/- 250 kPa (3200 +/- 35 psi). The manual shows where to tee in the gauge and the adjust procedure for each valve. Pilot system pressure should read 3400 +/- 300 kPa (490 +/- 45 psi) - low pilot pressure gives you lazy, notchy controls even when the main pump is healthy. p. 1712
Which engine is in my machine, and does this cover the engine too?
These machines used the Caterpillar 3003, 3013, 3014 and 3024 diesels, all mechanically injected - no ECM, no fault codes, nothing to plug a scan tool into. The set bundles the actual Cat engine manuals (SENR5022, SENR5023, SENR5027) plus the RENR2803 Engine Supplement, so you get compression testing, valve lash, injection pump and nozzle service, crank and cam specs, the whole engine.
Does it cover my serial number?
It covers the 301.8 from serial prefix BFA1-Up, and the 301.5 and 301.6 from prefixes 3YW1-Up and BDH1-Up. The prefix is the first three or four characters of the serial number on the machine's data plate. If your plate starts with one of those, this is your book.
Are the hydraulic and electrical schematics included?
Yes. There is a dedicated Schematic section with the 301.8 hydraulic system schematic, a combined hydraulic schematic covering the 301.5 and the 301.6, and the electrical system schematics. On a machine this age, half the electrical work is chasing corroded grounds and tired connectors, and a wiring schematic beats guessing every time.
Reviews
There are no reviews yet.