Bobcat 331, 331E, 334 Compact Excavator Service Manual 6986943(12-14) – PDF DOWNLOAD

Description

Bobcat 331, 331E, 334 Compact Excavator Service Manual 6986943(12-14) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 331, 331E, 334 Compact Excavator Service Manual 6986943(12-14) – PDF DOWNLOAD

Language : English
Pages : 850
Downloadable : Yes
File Type : PDF
Size:26.9 MB

DESCRIPTION:

Bobcat 331, 331E, 334 Compact Excavator Service Manual 6986943(12-14) – PDF DOWNLOAD

FOREWORD

This manual is for the Bobcat excavator mechanic. It provides necessary servicing and adjustment procedures for the Bobcat excavator and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc

A general inspection of the following items must be made after the excavator has had service or repair:

TABLE OF CONTENTS:

Bobcat 331, 331E, 334 Compact Excavator Service Manual 6986943(12-14) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrester Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Excavator Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
EXCAVATOR IDENTIFICATION 17
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE EXCAVATOR 23
Procedure 23
UPPERSTRUCTURE SLEW LOCK 25
Operation 25
LIFTING THE EXCAVATOR 27
Procedure 27
OPERATOR CAB (ROPS / TOPS) 29
Description 29
Cab Door 30
Front Window 30
Front Wiper 32
Window Washer Reservoir 32
Right Side Windows 33
Heating, Ventilation, and Air Conditioning Duct 34
TRANSPORTING THE EXCAVATOR ON A TRAILER 35
Loading And Unloading 35
Fastening 35
TAILGATE 37
Opening And Closing 37
Adjusting The Bumper 37
Adjusting The Latch 37
RIGHT SIDE COVER 39
Opening And Closing 39
Adjusting The Latch 39
SERVICE SCHEDULE 41
Chart 41
AIR CLEANER SERVICE 43
Daily Check 43
Replacing The Filter Elements 43
ENGINE COOLING SYSTEM 45
Cleaning 45
Checking Level 45
Replacing The Coolant 46
FUEL SYSTEM 47
Fuel Specifications 47
Biodiesel Blend Fuel 47
Filling The Fuel Tank 48
Fuel Filters 49
Draining The Fuel Tank 49
Removing Air From The Fuel System 50
ENGINE LUBRICATION SYSTEM 51
Checking And Adding Engine Oil 51
Oil Chart 51
Removing And Replacing Oil And Filter 52
HYDRAULIC SYSTEM 53
Checking And Adding Hydraulic Oil 53
Hydraulic Fluid Chart 53
Removing And Replacing The Hydraulic Filter 54
Replacing The Case Drain Filter 54
Removing And Replacing The Hydraulic Fluid 55
LUBRICATION OF THE HYDRAULIC EXCAVATOR 57
Lubrication Locations 57
TRAVEL MOTOR 61
Checking And Adding Oil 61
Removing And Replacing Oil 61
SPARK ARRESTER MUFFLER 63
Cleaning Procedure 63
ENGINE ACCESSORY DRIVE BELT 65
Belt Adjustment 65
SEAT BELT 67
Inspection And Maintenance 67
PIVOT PINS 69
Inspection And Maintenance 69
EXCAVATOR STORAGE AND RETURN TO SERVICE 71
Storage 71
Return to Service 71
STOPPING THE ENGINE AND LEAVING THE EXCAVATOR 73
Procedure 73
Emergency Exits 74
REMOTE START TOOL KIT – MEL1563 75
Remote Start Tool Kit – MEL1563 75
Service Tool Harness Control – MEL1565 76
Service Tool Harness Communicator – MEL1566 77
REMOTE START TOOL (SERVICE TOOL) KIT – 7003031 79
Description 79
Remote Start Tool (Service Tool) – 7003030 80
Excavator Service Tool Harness – 6689747 81
Computer Service Tool Harness – 6689746 82
HYDRAULIC SYSTEM 83
HYDRAULIC/HYDROSTATIC SCHEMATICS 87
HYDRAULIC SYSTEM INFORMATION 89
Glossary Of Hydraulic / Hydrostatic Symbols For Excavators 89
Troubleshooting The Hydraulic Circuit 92
Troubleshooting The Cylinder Circuit 93
Troubleshooting The Swing (Upperstructure Slew) Circuit 94
Troubleshooting The Travel Circuit 95
CYLINDER (BOOM) 97
Testing 97
Removal And Installation 99
Parts Identification 102
Disassembly 103
Assembly 105
CYLINDER (ARM) 109
Testing 109
Removal And Installation 111
Parts Identification 113
Disassembly 114
Assembly 116
CYLINDER (BOOM SWING) 121
Testing 121
Removal And Installation 123
Parts Identification 125
Disassembly 126
Assembly 128
CYLINDER (BUCKET) 131
Testing 131
Removal And Installation (Standard And Long Arm) 132
Removal And Installation (Extendable Arm) 134
Parts Identification 136
Disassembly 137
Assembly 139
CYLINDER (BLADE) 143
Testing 143
Removal And Installation 145
Parts Identification 146
Disassembly 147
Assembly 149
CYLINDER (EXTENDABLE ARM) 153
Removal And Installation 153
Parts Identification 155
Disassembly 156
Assembly 158
CYLINDER (CLAMP) 161
Testing 161
Removal And Installation 162
Parts Identification 163
Disassembly 164
Assembly 167
VALVE (MAIN RELIEF) 171
Testing And Adjusting The Main Relief Valve 171
VALVES (PORT RELIEF) 175
Testing And Adjusting Port Relief Valve Pressure 175
VALVES (CROSSPORT RELIEF) 177
Testing And Adjusting The Crossport Relief Valves 177
VALVE (PRESSURE REDUCING) 181
Testing And Adjusting The Pressure Reducing Valve 181
HYDRAULIC CONTROL VALVE 183
Description 183
Removal And Installation 183
Parts Identification 189
Disassembly 190
Right Travel Valve Section Disassembly And Assembly 191
Left Travel Valve Section Disassembly And Assembly 195
Blade Valve Section Disassembly And Assembly 199
Slew Valve Section Disassembly And Assembly 208
Auxiliary Valve Section Disassembly And Assembly 212
Bucket Valve Section Disassembly And Assembly 217
Arm Valve Section Disassembly And Assembly 222
Boom Valve Section Disassembly And Assembly 226
Boom Swing Valve Section Disassembly And Assembly 231
Inlet Section Disassembly And Assembly 236
Assembly 241
HYDRAULIC PUMP 247
Description 247
Torque Adjustment 248
Testing The Piston Pump 249
Testing Auxiliary Hydraulic Flow 251
Removal And Installation 252
Coupler Removal And Installation 253
Hydraulic Pump Start Up 254
Parts Identification 255
Disassembly 256
Assembly 264
MANIFOLD ASSEMBLY / ACCUMULATOR 273
Description 273
Removal And Installation 273
Parts Identification 276
Disassembly And Assembly 277
TRAVEL MOTOR 287
Removal And Installation 287
Parts Identification 288
Disassembly 289
Assembly 298
SWIVEL JOINT 309
Description 309
Removal And Installation 309
Parts Identification 311
Disassembly 312
Assembly 313
SWING MOTOR 317
Removal And Installation 317
Parts Identification 320
Disassembly 321
Assembly 325
SWING MOTOR DRIVE CARRIER 331
Removal And Installation 331
Parts Identification 332
Disassembly 333
Assembly 335
CONTROL PATTERN SELECTOR VALVE 339
Removal And Installation 339
Parts Identification 340
Disassembly 341
Assembly 342
RIGHT CONTROL LEVER (JOYSTICK) 343
Testing 343
Handle Removal And Installation 344
Joystick Assembly Removal And Installation 348
Parts Identification 351
Disassembly 352
Assembly 356
LEFT CONTROL LEVER (JOYSTICK) 361
Testing 361
Handle Removal And Installation 362
Joystick Assembly Removal And Installation 365
Parts Identification 367
Disassembly 368
Assembly 372
HYDRAULIC FILTER MOUNT 377
Removal And Installation 377
HYDRAULIC RESERVOIR 379
Removal And Installation 379
OIL COOLER 381
Removal And Installation 381
DIRECT TO TANK VALVE 383
Removal And Installation 383
Parts Identification 384
Disassembly And Assembly 385
CASE DRAIN FILTER 387
Removal And Installation 387
BOOM SWING LOCK VALVE 389
Removal And Installation 389
Parts Identification 390
Disassembly 391
Assembly 394
TRAVEL CONTROL VALVE 399
Removal and Installation 399
Parts Identification 400
Disassembly And Assembly 401
HYDRAULIC X-CHANGE™ VALVE 405
Removal And Installation 405
Parts Identification 408
Disassembly 409
Assembly 416
SLEW LOCK VALVE 423
Description 423
Removal And Installation 423
Parts Identification 424
Disassembly And Assembly 425
UNDERCARRIAGE 429
BLADE 431
Removal And Installation 431
TRACKS 433
Track Lug Height 433
Adjustment 433
Rubber Track Removal And Installation 436
Steel Track Removal And Installation 439
TRACK FRAME 443
Disassembly And Assembly 443
Recoil Spring Cylinder (S/N AACS11750 & Below, A9K511103 & Below, A9K711102 & Below And A9K911051 & Below) 445
Recoil Spring Cylinder Parts Identification (With Replaceable Shaft) (S/N AACS11751 & Above, A9K511104 & Above, A9K711103 & Above And A9K91102 & Above) 446
Recoil Spring Cylinder (With Replaceable Shaft) (S/N AACS11751 & Above, A9K511104 & Above, A9K711103 & Above And A9K911052 & Above) 447
TRACK DAMAGE IDENTIFICATION 449
Cutting Of Steel Cords 449
Abrasion Of Embedded Metals 450
Separation Of Embedded Metals 451
Separation Of Embedded Metals Due To Corrosion 452
Cuts On The Lug Side Rubber 453
Cracks On The Lug Side Rubber Due To Fatigue 454
Lug Abrasion 455
Cracks And Cuts On The Lug Side Rubber 456
Abrasion Of The Track Roller Side 457
Cuts On The Edges Of Track Roller Side 458
TRACK IDLER 461
Parts Identification 461
Disassembly 462
Assembly 464
TRACK ROLLER 467
Parts Identification 467
Disassembly 468
Assembly 469
SWING CIRCLE GEAR 471
Swing Bearing Removal 471
Swing Bearing Installation 472
UPPERSTRUCTURE AND SWING SECTION 473
UPPERSTRUCTURE 477
Removal 477
Installation 480
ROPS CANOPY 483
Removal And Installation 483
CAB 485
Removal And Installation 485
Door Removal And Installation 489
Front Window Removal And Installation 490
Right Side Rear Sliding Window Removal And Installation 493
Right Side Front Sliding Window Removal And Installation 493
Right Side Front And Rear Sliding Window Weather Strip Removal And Installation 494
Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation 494
Glass Removal 494
Glass Installation 495
SEAT AND SEAT MOUNT 501
Removal And Installation 501
RIGHT CONSOLE 503
Console Cover Removal And Installation 503
Console Base Removal And Installation 504
LEFT CONSOLE 507
Lower Console Cover Removal And Installation 507
Upper Console Cover Removal And Installation 508
Compression Spring Removal And Installation 509
Compression Spring Disassembly And Assembly 510
Lock Lever Removal And Installation 511
Console Removal And Installation 512
Disassembly And Assembly 516
Console Base Removal And Installation 519
ENGINE SPEED CONTROL 521
Removal And Installation 521
Adjustment (Later Models) 522
BLADE CONTROL 523
Lever Removal And Installation 523
Linkage Removal And Installation 524
Linkage Bar Removal And Installation 525
Lower Linkage Removal And Installation 527
RIGHT PEDAL AND LINKAGE 529
Pedal Removal And Installation 529
Pedal Disassembly And Assembly 530
Linkage Removal And Installation 532
TRAVEL CONTROLS 533
Removal And Installation 533
Disassembly And Assembly 534
Adjustment 535
Control Linkage Removal And Installation 537
FLOOR MAT AND FLOOR PANEL 539
Removal And Installation (Canopy Equipped Excavators) 539
Removal And Installation (Cab Equipped Excavators) 540
FUEL TANK 541
Removal And Installation 541
HORN 545
Removal And Installation 545
SWING FRAME 547
Removal And Installation 547
Boom Swing Frame Hose Routing 550
Bushing Removal 551
Bushing Installation 552
BOOM 553
Removal And Installation 553
STANDARD AND LONG ARM 555
Removal And Installation 555
Arm To Boom Bushing Removal And Installation 556
Arm To Bucket And Bucket Link Bushing Removal And Installation 557
Arm To Bucket And Bucket Link Bushing Removal And Installation (Cont’d) 558
EXTENDABLE ARM 559
Removal And Installation 559
Disassembly And Assembly 562
BUCKET 563
Bucket Teeth Removal And Installation 563
Bucket Side Cutting Edge Removal And Installation 564
CLAMP 565
Removal And Installation 565
TAILGATE 567
Removal And Installation 567
Latch Removal And Installation 568
X-CHANGE™ 569
Removal And Installation 569
Disassembly 571
Assembly 575
Check Proper Latch Engagement 580
X-CHANGE™ (HYDRAULIC) 583
Removal And Installation 583
Parts Identification 585
Disassembly 586
Assembly 591
UPPERSTRUCTURE SLEW LOCK 599
Removal And Installation 599
Disassembly And Assembly 599
RIGHT SIDE COVER 601
Removal And Installation 601
QUICK COUPLER (KLAC™ SYSTEM) 603
Troubleshooting 603
Daily Inspection 603
Removal And Installation 604
Parts Identification 606
Disassembly 607
Assembly 609
QUICK COUPLER (LEHNHOFF® SYSTEM) 611
Troubleshooting 611
Daily Inspection 611
Removal (MS03 And MS08) 612
Installation (MS03 And MS08) 613
Parts Identification (MS03) 614
Disassembly And Assembly (MS03) 615
Parts Identification (MS08) 616
Disassembly (MS08) 617
Assembly (MS08) 620
ELECTRICAL SYSTEM AND ANALYSIS 625
ELECTRICAL SCHEMATICS 627
ELECTRICAL SYSTEM INFORMATION 629
Troubleshooting Chart 629
Description 630
Fuse And Relay Location 630
BATTERY 631
Servicing 631
Removal And Installation 632
Using A Booster Battery (Jump Starting) 633
ALTERNATOR 635
Engine Accessory Drive Belt 635
Removal And Installation 636
Alternator Identification 638
Charging System Check 639
Alternator Voltage Test 640
Low Voltage Test 640
High Voltage Test 641
Rectifier Continuity (Diode) Test 642
Alternator Regulator Test 643
Parts Identification 644
Disassembly 645
Stator Continuity Test 645
Stator Ground Test 645
Rotor Continuity Test 645
Rotor Ground Test 646
Assembly 646
STARTER 647
Removal And Installation 647
Parts Identification 648
Disassembly 649
Inspection And Repair 655
Assembly 658
LIGHTS 663
Removal And Installation 663
Boom Light Removal And Installation 664
Boom Light Bulb Replacement 664
MAGNETIC LOCKOUT SENSOR 665
Removal And Installation 665
TWO SPEED SWITCH 667
Removal And Installation 667
FUEL LEVEL SENDER 669
Removal And Installation 669
Testing 670
DIAGNOSTICS SERVICE CODE 671
Number Codes List 671
DELUXE INSTRUMENT PANEL SETUP 673
Passwords 673
Password Entry (For Starting and Operating the Machine) 673
Changing The Owner Or Operator Password 673
Password Lockout Feature 674
Job Clock 674
RPM 674
ENGINE SERVICE 675
TROUBLESHOOTING 677
Chart 677
SPARK ARRESTER MUFFLER 679
Removal And Installation 679
AIR CLEANER 681
Removal And Installation 681
RADIATOR 683
Removal And Installation 683
ENGINE COMPONENTS AND TESTING 685
Engine Compression Checking 685
Glow Plugs Removal And Installation 686
Checking The Glow Plug 686
Fuel Shut-off Solenoid Removal And Installation 687
Fuel Injection Pump Check 688
Fuel Injection Pump Removal And Installation 689
Fuel Injection Pump Timing 691
Fuel Injector Nozzles Removal And Installation 693
Fuel Injector Nozzle Check 695
Valve Clearance Adjustment 696
ENGINE 697
Removal And Installation 697
ENGINE FLYWHEEL 703
Hydraulic Pump Coupler Removal And Installation 703
Flywheel Removal And Installation 705
Flywheel Ring Gear 705
RECONDITIONING THE ENGINE 707
Cylinder Head Removal And Installation 707
Cylinder Head Disassembly And Assembly 710
Cylinder Head Servicing 711
Cylinder Head Top Clearance 711
Valve Guide Checking 712
Reconditioning The Valve And Valve Seat 714
Valve Spring 715
Rocker Arm And Shaft Checking 716
Timing Gearcase Cover Removal And Installation 716
Idler Gear And Camshaft Removal And Installation 719
Camshaft Servicing 720
Idler Gear And Shaft Servicing 721
Timing Gears Checking Backlash 722
Fuel Camshaft Removal And Installation 722
Fuel Camshaft Governor 723
Crankshaft Gear Removal And Installation 723
Oil Pump Removal And Installation 724
Oil Pump Service 724
Checking Engine Oil Pressure 725
Valve Tappets 726
Piston And Connecting Rod Removal And Installation 726
Piston And Connecting Rod Servicing 728
Connecting Rod Alignment 730
Crankshaft And Bearings Removal And Installation 731
Crankshaft And Bearings Servicing 733
Cylinder Bore Checking 736
Water Pump Removal And Installation 737
Water Pump Disassembly And Assembly 737
Fan Removal And Installation 738
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 741
HEATER COIL 743
Removal And Installation With A/C 743
Removal And Installation Without A/C 743
BLOWER FAN 745
Removal And Installation 745
Disassembly And Assembly 746
Resistor Removal And Installation 747
HEATER VALVE 749
Removal And Installation 749
AIR CONDITIONING SYSTEM FLOW 751
Principals 751
Chart 752
COMPONENTS 753
Identification 753
SAFETY 757
Safety Equipment 757
REGULAR MAINTENANCE 759
Heater Air Filter 759
Engine Accessory Drive Belt Inspection 759
Cleaning The Condenser 760
BASIC TROUBLESHOOTING 761
Poor A/C Performance 761
Cleaning The A/C Evaporator Coil And Heater Coil 762
Engine Accessory Drive Belt Inspection 763
Checking The Electrical System 763
Engine Coolant By-Passing The Heater Valve 773
GENERAL AIR CONDITIONING SERVICE GUIDELINES 775
Compressor Oil 775
Compressor Oil Check 776
Component Replacement And Refrigeration Leaks 777
SYSTEM TROUBLESHOOTING CHART 779
Blower Motor Does Not Operate 779
Blower Motor Operates Normally, But Air Flow Is Insufficient 779
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 779
The Compressor Operates Improperly Or Not At All 779
Gauge Pressure Related Troubleshooting 780
TEMPERATURE / PRESSURE 781
Chart 781
AIR CONDITIONING SERVICE 783
Chart 783
SYSTEM CHARGING AND RECLAMATION 785
Reclamation Procedure 785
Charging Procedure With A Manifold Gauge Set 787
COMPRESSOR 791
Removal And Installation 791
Compressor Clutch Disassembly And Assembly 793
CONDENSER 797
Removal And Installation 797
RECEIVER / DRIER 799
Removal And Installation 799
PRESSURE RELIEF VALVE 801
Removal And Installation 801
PRESSURE SWITCH 803
Removal And Installation 803
EVAPORATOR / HEATER UNIT 805
Removal And Installation 805
Disassembly And Assembly 806
THERMOSTAT 807
Removal And Installation 807
EXPANSION VALVE 809
Removal And Installation 809
EVAPORATOR 811
Removal And Installation 811
SPECIFICATIONS 813
SPECIFICATIONS 815
331, 331E With Long Arm Option And 334 Excavator Machine Dimensions 815
331 With Extendable Arm Option And 331E Excavator Machine Dimensions 817
Performance 819
Controls 819
Engine 819
Hydraulic System 820
Hydraulic Cylinders 820
Hydraulic Cycle Times 821
Drive System 821
Undercarriage 821
Track 822
Ground Pressure 822
Electrical 822
ENGINE SPECIFICATIONS 823
Fuel Injection Nozzles 823
Fuel Injection Pump 823
Cylinder Head 823
Valves 823
Valve Springs 824
Valve Timing 824
Rocker Arms 824
Camshaft 824
Tappet 824
Cylinders 825
Piston Rings 825
Pistons 825
Connecting Rods 825
Oil Pump 825
Crankshaft 826
Timing Gear 827
Thermostat 827
Engine Bolt Torque 828
Crankshaft Re-Grind Data 829
TORQUE SPECIFICATIONS 831
Torque For General SAE Bolts 831
Torque For General Metric Bolts 831
HYDRAULIC CONNECTION SPECIFICATIONS 833
O-Ring Face Seal Connection 833
Straight Thread O-Ring Fitting 833
Tubelines And Hoses 834
Flare Fitting 834
O-Ring Flare Fitting 835
Port Seal Fitting 837
HYDRAULIC FLUID SPECIFICATIONS 839
Specifications 839
SERVICE TOOLS REQUIRED 841
Remote Start Tools 841
Hydraulic Tools 842
Engine Tools 844
HVAC Tools 846
CONVERSIONS 847
Decimal And Millimeter Equivalents 847
U S To Metric Conversion 848
ALPHABETICAL INDEX 849

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