Bobcat 331 331E 334 Service Manual 6902743 (11-09) – PDF DOWNLOAD

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Bobcat 331 331E 334 Service Manual 6902743 (11-09) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 331 331E 334 Service Manual 6902743 (11-09) – PDF DOWNLOAD

Language : English
Pages : 828
Downloadable : Yes
File Type : PDF
Size:23.8 MB

DESCRIPTION:

Bobcat 331 331E 334 Service Manual 6902743 (11-09) – PDF DOWNLOAD

331 – S/N 234311001 – 234312999
331E – S/N 234411001 – 234411999
334 – S/N 234511001 – 234512999
(G Series)

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.

SAFETY INSTRUCTIONS

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death.

The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments

TABLE OF CONTENTS:

Bobcat 331 331E 334 Service Manual 6902743 (11-09) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 9
SAFETY INSTRUCTIONS 12
FIRE PREVENTION 14
Maintenance 14
Operation 14
Electrical 14
Hydraulic System 14
Fueling 14
Starting 14
Spark Arrestor Exhaust System 14
Welding And Grinding 15
Fire Extinguishers 15
SERIAL NUMBER LOCATIONS 17
Excavator Serial Number 17
Engine Serial Number 17
DELIVERY REPORT 18
BOBCAT EXCAVATOR IDENTIFICATION 19
SAFETY AND MAINTENANCE 21
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
Emergency Exit 29
Cab Door 30
Front Window 31
Right Side Windows 33
TRANSPORTING THE EXCAVATOR 35
TAILGATE 37
Opening And Closing The Tailgate 37
Adjusting The Bumper 37
Adjusting The Latch 37
RIGHT SIDE COVER 39
Opening And Closing The Right Side Cover 39
SERVICE SCHEDULE 41
Chart 41
AIR CLEANER 43
Daily Check 43
Replacing The Filters 43
HEATER AIR FILTER (WITH CAB OPTION ONLY) 45
Removal And Installation 45
COOLING SYSTEM 47
Replacing The Coolant 47
Checking Coolant Level 48
Cleaning The Cooling System 49
FUEL SYSTEM 51
Fuel Specifications 51
Filling The Fuel Tank 51
Removing Water From The Fuel Filter 52
Draining The Fuel Tank 52
Fuel Filter 53
Removing Air From The Fuel System 53
ENGINE LUBRICATION SYSTEM 55
Checking Engine Oil 55
Oil Chart 55
Replacing Oil And Filter 56
HYDRAULIC SYSTEM 57
Checking And Adding Hydraulic Oil 57
Replacing The Hydraulic Oil 58
Replacing The Hydraulic Filter 59
Replacing The Case Drain Filter 59
Diagnostic Couplers 60
LUBRICATION OF THE HYDRAULIC EXCAVATOR 61
Procedure 61
TRAVEL MOTOR 65
Checking Oil Level 65
Draining The Travel Motor 65
SPARK ARRESTOR MUFFLER 67
ENGINE ACCESSORY DRIVE BELT 69
Belt Tension 69
Belt Adjustment 69
SEAT BELT 71
Inspection And Maintenance 71
HYDRAULIC SYSTEM 73
HYDRAULIC / HYDROSTATIC SCHEMATICS 77
HYDRAULIC SYSTEM INFORMATION 79
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators 79
Troubleshooting The Hydraulic Circuit 82
Troubleshooting The Cylinder Circuit 83
Troubleshooting The Swing (Upperstructure Slew) Circuit 84
Troubleshooting The Travel Circuit 85
BOOM CYLINDER 87
Testing 87
Removal And Installation 90
Parts Identification 93
Disassembly 94
Assembly 96
ARM CYLINDER 99
Testing 99
Removal And Installation 101
Parts Identification 103
Disassembly 104
Assembly 106
BOOM SWING CYLINDER 109
Testing 109
Removal And Installation 110
Parts Identification 112
Disassembly 113
Assembly 115
BUCKET CYLINDER 119
Testing 119
Removal And Installation (Standard And Long Arm) 121
Removal And Installation (Extendable Arm) 123
Parts Identification 126
Disassembly 127
Assembly 129
BLADE CYLINDER 133
Testing 133
Removal And Installation 135
Parts Identification 136
Disassembly 137
Assembly 139
EXTENDIBLE ARM CYLINDER 143
Removal And Installation 143
Parts Identification 145
Disassembly 146
Assembly 148
CLAMP CYLINDER 151
Testing 151
Removal And Installation 152
Parts Identification 153
Disassembly 154
Assembly 157
MAIN RELIEF VALVES 163
Testing And Adjusting The Main Relief Valves 163
PORT RELIEF VALVES 167
Testing And Adjusting Port Relief Valve Pressure 167
CROSSPORT RELIEF VALVES 169
Testing And Adjusting The Crossport Relief Valves 169
PRESSURE REDUCING VALVE 173
Testing And Adjusting The Pressure Reducing Valve 173
HYDRAULIC CONTROL VALVE 175
Description 175
Removal And Installation 176
Control Valve Identification 184
Disassembly 185
Right Travel Valve Section Disassembly And Assembly 187
Boom Swing Valve Section Disassembly And Assembly 192
Boom Valve Section Disassembly And Assembly 199
Left Travel Valve Section Disassembly And Assembly 203
Arm Valve Section Disassembly And Assembly 208
Bucket Valve Section Disassembly And Assembly 212
Auxiliary Valve Section Disassembly And Assembly 216
Boost Valve Section Disassembly And Assembly 220
Blade Valve Section Disassembly And Assembly 224
Slew Valve Section Disassembly And Assembly 229
Assembly 233
HYDRAULIC PUMP 241
Description 241
Torque Adjustment 242
Testing The Piston Pump 243
Testing The Gear Pump 245
Testing Auxiliary Hydraulic Flow 247
Removal And Installation 248
Coupler Removal And Installation 249
Gear Pump Parts Identification 250
Piston Pump Parts Identification 251
Disassembly 252
Gear Pump Disassembly 253
Gear Pump Assembly 256
Piston Pump Disassembly 259
Piston Pump Assembly 267
Assembly 275
MANIFOLD ASSEMBLY/ ACCUMULATOR 277
Description 277
Removal And Installation 277
Parts Identification 281
Disassembly 282
Assembly 292
TRAVEL MOTOR 303
Removal And Installation 303
Parts Identification 304
Disassembly 305
Assembly 315
SWIVEL JOINT 327
Description 327
Removal And Installation 327
Parts Identification 329
Disassembly 330
Assembly 331
SWING MOTOR 335
Removal And Installation 335
Parts Identification 338
Disassembly 339
Assembly 344
SWING MOTOR DRIVE CARRIER 351
Removal And Installation 351
Parts Identification 352
Disassembly 353
Assembly 355
CONTROL PATTERN SELECTOR VALVE 359
Removal And Installation 359
Parts Identification 360
Disassembly 361
Assembly 362
RIGHT CONTROL LEVER (JOYSTICK) 363
Testing 363
Handle Removal And Installation 364
Joystick Assembly Removal And Installation 368
Parts Identification 371
Disassembly 372
Assembly 377
LEFT CONTROL LEVER (JOYSTICK) 383
Testing 383
Handle Removal And Installation 384
Joystick Assembly Removal And Installation 387
Parts Identification 389
Disassembly 390
Assembly 395
HYDRAULIC FILTER MOUNT 401
Removal And Installation 401
HYDRAULIC RESERVOIR 403
Removal And Installation 403
OIL COOLER 405
Removal And Installation 405
DIRECT TO TANK VALVE 407
Removal And Installation 407
Parts Identification 408
Disassembly And Assembly 409
BUILD UP VALVE 411
Description 411
Removal And Installation 411
Parts Identification 412
Disassembly And Assembly 413
CASE DRAIN FILTER 415
Removal And Installation 415
UNDERCARRIAGE 417
BLADE 419
Removal And Installation 419
TRACKS 421
Track Lug Height 421
Adjustment 421
Rubber Track Removal And Installation 424
Steel Track Removal And Installation 427
TRACK FRAME 431
Disassembly And Assembly 431
Recoil Spring Cylinder Disassembly And Assembly (Without Replaceable Shaft) 433
Recoil Spring Cylinder Parts Identification (With Replaceable Shaft) 434
Recoil Spring Assembly And Cylinder Disassembly And Assembly (With Replaceable Shaft) 435
TRACK DAMAGE IDENTIFICATION 437
Cutting Of Steel Cords 437
Abrasion Of Embedded Metals 438
Separation Of Embedded Metals 439
Separation Of Embedded Metals Due To Corrosion 440
Cuts On The Lug Side Rubber 441
Cracks On The Lug Side Rubber Due To Fatigue 442
Lug Abrasion 443
Cracks And Cuts On The Lug Side Rubber 444
Abrasion Of The Track Roller Side 445
Cuts On The Edges Of Track Roller Side 446
TRACK IDLER 449
Parts Identification 449
Disassembly 450
Assembly 452
TRACK ROLLER 455
Parts Identification 455
Disassembly 456
Assembly 458
SWING CIRCLE GEAR 461
Swing Bearing Removal 461
Swing Bearing Installation 462
UPPERSTRUCTURE & SWING SECTION 463
UPPERSTRUCTURE 467
Removal 467
Installation 470
ROPS CANOPY 473
Removal And Installation 473
CAB 477
Removal And Installation 477
Door Removal And Installation 482
Front Window Removal And Installation 483
Right Side Rear Sliding Window Removal And Installation 486
Right Side Front Sliding Window Removal And Installation 486
Right Side Front And Rear Sliding Window Weather Strip Removal And Installation 487
Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation 487
Glass Removal 488
Glass Installation 489
SEAT AND SEAT MOUNT 495
Removal And Installation 495
RIGHT CONSOLE 497
Console Cover Removal And Installation 497
Console Base Removal And Installation 498
LEFT CONSOLE 501
Lower Console Cover Removal And Installation 501
Upper Console Cover Removal And Installation 502
Compression Spring Removal And Installation 503
Compression Spring Disassembly And Assembly 504
Lock Lever Removal And Installation 506
Console Removal And Installation 508
Disassembly And Assembly 512
Console Base Removal And Installation 515
ENGINE SPEED CONTROL 517
Removal And Installation 517
BLADE CONTROL 519
Lever Removal And Installation 519
Linkage Removal And Installation 520
Linkage Bar Removal And Installation 522
Lower Linkage Removal And Installation 523
RIGHT PEDAL AND LINKAGE 525
Pedal Removal And Installation 525
Pedal Disassembly And Assembly 526
Linkage Removal And Installation 528
TRAVEL CONTROLS 529
Removal And Installation 529
Disassembly And Assembly 530
Adjustment 533
FLOOR MAT AND FLOOR PLATE 537
Removal And Installation (Canopy Equipped Excavators) 537
Removal And Installation (Cab Equipped Excavators) 538
FUEL TANK 539
Removal And Installation 539
HORN 545
Removal And Installation (Earlier Models) 545
Removal And Installation (Later Models) 546
SWING FRAME 547
Boom Swing Bracket Removal And Installation 547
Boom Swing Bracket Hose Installation 551
Bushing Removal 552
Bushing Installation 553
BOOM 555
Removal And Installation 555
STANDARD AND LONG ARM 557
Removal And Installation 557
Arm To Boom Bushing Removal And Installation 558
Arm To Bucket And Bucket Link Bushing Removal And Installation 559
EXTENDIBLE ARM 561
Removal And Installation 561
Disassembly And Assembly 564
BUCKET 565
Bucket Teeth Removal And Installation 565
Bucket Side Cutting Edge Removal And Installation 566
CLAMP 567
Removal And Installation 567
TAILGATE 569
Removal And Installation 569
Latch Removal And Installation 570
X-CHANGE™ 571
Removal And Installation 571
Disassembly 573
Assembly 577
Check Proper Latch Engagement 583
RIGHT SIDE COVER 587
Removal And Installation 587
ELECTRICAL SYSTEM AND ANALYSIS 589
ELECTRICAL SCHEMATICS 591
ELECTRICAL SYSTEM INFORMATION 593
Troubleshooting Chart 593
Description 594
Fuse And Relay Location 594
BATTERY 595
Servicing 595
Removal And Installation 596
Using A Booster Battery (Jump Starting) 598
ALTERNATOR 599
Engine Accessory Drive Belt 599
Removal And Installation 600
Alternator Identification 602
Charging System Check 603
Alternator Voltage Test 605
Low Voltage Test 606
High Voltage Test 607
Rectifier Continuity (Diode) Test 608
Alternator Regulator Test 609
Parts Identification 610
Disassembly 611
Stator Continuity Test 612
Stator Ground Test 612
Rotor Continuity Test 613
Rotor Ground Test 613
Assembly 614
STARTER 615
Removal And Installation 615
Parts Identification 616
Disassembly 617
Inspection And Repair 623
Assembly 626
LIGHTS 631
Removal And Installation 631
Disassembly And Assembly 632
TWO SPEED SWITCH 633
Removal And Installation 633
FUEL LEVEL SENDER 635
Removal And Installation 635
Testing 636
DIAGNOSTICS SERVICE CODE 637
Number Codes List 637
DELUXE INSTRUMENT PANEL SETUP 639
Passwords 639
Password Entry (For Starting and Operating the Machine) 639
Changing The Owner or Operator Password 639
Password Lockout Feature 640
Job Clock 640
RPM 640
ENGINE SERVICE 641
TROUBLESHOOTING 643
Chart 643
SPARK ARRESTOR MUFFLER 645
Removal And Installation 645
AIR CLEANER 647
Removal And Installation 647
RADIATOR 649
Removal And Installation 649
ENGINE COMPONENTS AND TESTING 651
Engine Compression Checking 651
Glow Plugs Removal And Installation 652
Checking The Glow Plug 653
Fuel Shut-off Solenoid Removal And Installation 654
Fuel Injection Pump Check 655
Fuel Injection Pump Removal And Installation 656
Fuel Injection Pump Timing 659
Fuel Injector Nozzles Removal And Installation 661
Fuel Injector Nozzle Check 663
Valve Clearance Adjustment 664
ENGINE 665
Removal And Installation 665
ENGINE FLYWHEEL (EARLY MODELS) 671
Flywheel Removal And Installation 671
Hydraulic Pump Coupler 673
Flywheel Ring Gear 673
ENGINE FLYWHEEL (LATER MODELS) 675
Flywheel Removal And Installation 675
Hydraulic Pump Coupler 678
Flywheel Ring Gear 678
RECONDITIONING THE ENGINE 679
Cylinder Head Removal And Installation 679
Cylinder Head Disassembly And Assembly 682
Cylinder Head Servicing 683
Cylinder Head Top Clearance 683
Valve Guide Checking 684
Reconditioning The Valve And Valve Seat 686
Valve Spring 687
Rocker Arm And Shaft Checking 688
Timing Gearcase Cover Removal And Installation 688
Idler Gear And Camshaft Removal And Installation 691
Camshaft Servicing 693
Idler Gear And Shaft Servicing 694
Timing Gears Checking Backlash 695
Fuel Camshaft Removal And Installation 695
Fuel Camshaft Governor 696
Crankshaft Gear Removal And Installation 696
Oil Pump Removal And Installation 697
Oil Pump Service 697
Checking Engine Oil Pressure 698
Valve Tappets 699
Piston And Connecting Rod Removal And Installation 699
Piston And Connecting Rod Servicing 701
Connecting Rod Alignment 703
Crankshaft And Bearings Removal And Installation 704
Crankshaft And Bearings Servicing 706
Cylinder Bore Checking 709
Water Pump Removal And Installation 710
Water Pump Disassembly And Assembly 710
Fan Removal And Installation 711
HEATING, VENTILATION, AIR CONDITIONING 713
HEATER COIL 715
Removal And Installation With A/C 715
Removal And Installation Without A/C 715
HEATER/AC FAN 717
Removal And Installation 717
Disassembly And Assembly 718
HEATER VALVE 721
Removal And Installation 721
AIR CONDITIONING SYSTEM FLOW 724
Principals 724
Chart 725
COMPONENTS 727
Identification 727
SAFETY 731
Safety Equipment 731
REGULAR MAINTENANCE 733
Heater Air Filter 733
Engine Accessory Drive Belt Inspection 733
Cleaning The Condenser 734
BASIC TROUBLESHOOTING 735
Poor A/C Performance 735
Cleaning The A/C Evaporator Coil & Heater Coil 736
Engine Accessory Drive Belt Inspection 737
Checking The Electrical System 738
Engine Coolant By-Passing The Heater Valve 749
GENERAL AIR CONDITIONING SERVICE GUIDELINES 751
Compressor Oil 751
Compressor Oil Check 752
Component Replacement And Refrigeration Leaks 754
SYSTEM TROUBLESHOOTING CHART 755
Blower Motor Does Not Operate 755
Blower Motor Operates Normally, But Air Flow Is Insufficient 755
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 755
The Compressor Does Not Operate At All, Or Operates Improperly 755
Gauge Pressure Related Troubleshooting 756
TEMPERATURE/PRESSURE 757
Chart 757
AIR CONDITIONING SERVICE 759
Chart 759
SYSTEM CHARGING AND RECLAMATION 761
Reclamation Procedure 761
Charging Procedure With A Manifold Gauge Set 764
COMPRESSOR 767
Removal And Installation 767
Compressor Clutch Disassembly And Assembly 769
CONDENSER 773
Removal And Installation 773
RECEIVER/DRIER 775
Removal And Installation 775
PRESSURE RELIEF VALVE 777
Removal And Installation 777
PRESSURE SWITCH 779
Removal And Installation 779
EVAPORATOR/HEATER UNIT 781
Removal And Installation 781
Disassembly And Assembly 782
THERMOSTAT 783
Removal And Installation 783
EXPANSION VALVE 785
Removal And Installation 785
EVAPORATOR 787
Removal And Installation 787
SPECIFICATIONS 789
SPECIFICATIONS 791
331 & 334 Excavator Machine Dimensions 791
331E Excavator Machine Dimensions 793
Performance 795
Controls 795
Engine 796
Hydraulic Cycle Times 796
Hydraulic Cylinders 797
Hydraulic System 797
Drive System 797
Undercarriage 798
Track 798
Electrical 798
ENGINE SPECIFICATIONS 799
Fuel Injection Nozzles 799
Fuel Injection Pump 799
Cylinder Head 799
Valves 799
Valve Springs 800
Valve Timing 800
Rocker Arms 800
Camshaft 800
Tappet 800
Cylinders 801
Piston Rings 801
Pistons 801
Connecting Rods 801
Oil Pump 801
Crankshaft 802
Timing Gear 803
Thermostat 803
Engine Bolt Torque 803
Crankshaft Re-Grind Data 804
TORQUE SPECIFICATIONS 805
Torque For General SAE Bolts 805
Torque For General Metric Bolts 805
HYDRAULIC CONNECTION SPECIFICATIONS 807
O-Ring Face Seal Connection 807
Straight Thread O-Ring Fitting 807
Tubelines And Hoses 808
Flare Fitting 808
O-Ring Flare Fitting 809
Port Seal Fitting 811
HYDRAULIC FLUID SPECIFICATIONS 813
Specifications 813
FUEL, COOLANT AND LUBRICANTS 815
Chart 815
CONVERSIONS 817
Decimal And Millimeter Equivalents 817
U S To Metric Conversion 818
SERVICE MANUAL REVISIONS 819
Revision No: 331/331E/334-1 819
Revision No: 331/331E/334-2 821
Revision No: 331/331E/334-3 823
Revision No: 331/331E/334-4 825
Revision No: 331 / 331E / 334 – 5 827

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.M