Bobcat 331 331E 334 Service Manual 6903830 (10-09) – PDF DOWNLOAD

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Bobcat 331 331E 334 Service Manual 6903830 (10-09) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 331 331E 334 Service Manual 6903830 (10-09) – PDF DOWNLOAD

Language : English
Pages : 977
Downloadable : Yes
File Type : PDF
Size:26.0 MB

DESCRIPTION:

Bobcat 331 331E 334 Service Manual 6903830 (10-09) – PDF DOWNLOAD

331 – S/N 234313000 & Above
331E – S/N 234412000 & Above
334 – S/N 234513000 & Above
(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 6903830 (10-09) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrestor 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
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE EXCAVATOR 21
Procedure 21
UPPERSTRUCTURE SLEW LOCK 23
Operation (Early Models) 23
Operation (Later Models) 23
LIFTING THE EXCAVATOR 25
Procedure 25
OPERATOR CAB (ROPS/TOPS) 27
Emergency Exit 27
Cab Door 28
Front Window 29
Right Side Windows 31
TRANSPORTING THE EXCAVATOR 33
TAILGATE 35
Opening And Closing The Tailgate 35
Adjusting The Bumper 35
Adjusting The Latch 35
RIGHT SIDE COVER 37
Opening And Closing The Right Side Cover 37
SERVICE SCHEDULE 39
Chart 39
AIR CLEANER SERVICE 41
Daily Check 41
Replacing The Filters 41
HEATER AIR FILTER (WITH CAB OPTION ONLY) 43
Removal And Installation 43
ENGINE COOLING SYSTEM 45
Replacing The Coolant 45
Checking Coolant Level 46
Cleaning The Cooling System 47
FUEL SYSTEM 49
Fuel Specifications 49
Filling The Fuel Tank 49
Removing Water From The Fuel Filter 50
Draining The Fuel Tank 50
Fuel Filter 51
Removing Air From The Fuel System 51
ENGINE LUBRICATION SYSTEM 53
Checking Engine Oil 53
Oil Chart 53
Replacing Oil And Filter 54
HYDRAULIC SYSTEM 55
Checking And Adding Hydraulic Fluid 55
Replacing The Hydraulic Fluid 56
Replacing The Hydraulic Filter 57
Replacing The Case Drain Filter 57
Diagnostic Couplers 57
LUBRICATION OF THE HYDRAULIC EXCAVATOR 59
Procedure 59
TRAVEL MOTOR 63
Checking Oil Level 63
Draining The Travel Motor 63
SPARK ARRESTOR MUFFLER 65
ENGINE ACCESSORY DRIVE BELT 67
Belt Tension 67
Belt Adjustment 67
SEAT BELT 69
Inspection And Maintenance 69
HYDRAULIC SYSTEM 71
HYDRAULIC / HYDROSTATIC SCHEMATIC 77
HYDRAULIC SYSTEM INFORMATION 81
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators 81
Troubleshooting The Hydraulic Circuit 84
Troubleshooting The Cylinder Circuit 85
Troubleshooting The Swing (Upperstructure Slew) Circuit 86
Troubleshooting The Travel Circuit 87
BOOM CYLINDER 89
Testing 89
Removal And Installation 92
Parts Identification 95
Disassembly 96
Assembly 98
ARM CYLINDER 101
Testing 101
Removal And Installation 103
Parts Identification 105
Disassembly 106
Assembly 108
BOOM SWING CYLINDER 111
Testing 111
Removal And Installation 113
Parts Identification 115
Disassembly 116
Assembly 118
BUCKET CYLINDER 121
Testing 121
Removal And Installation (Standard And Long Arm) 123
Removal And Installation (Extendible Arm) 125
Parts Identification 128
Disassembly 129
Assembly 131
BLADE CYLINDER 135
Testing 135
Removal And Installation 137
Parts Identification 138
Disassembly 139
Assembly 141
EXTENDIBLE ARM CYLINDER 145
Removal And Installation 145
Parts Identification 147
CLAMP CYLINDER 149
Testing 149
Removal And Installation 150
Parts Identification 151
Disassembly 152
Assembly 155
MAIN RELIEF VALVE 161
Testing And Adjusting The Main Relief Valve 161
PORT RELIEF VALVES 165
Testing And Adjusting Port Relief Valve Pressure 165
CROSSPORT RELIEF VALVES 167
Testing And Adjusting The Crossport Relief Valves 167
PRESSURE REDUCING VALVE 171
Testing And Adjusting The Pressure Reducing Valve 171
HYDRAULIC CONTROL VALVE (S/N 234313000 – 234316876, S/N 234412000 – 234413318, S/N 234513000 – 234515532) 173
Description 173
Removal And Installation 174
Parts Identification 180
HYDRAULIC CONTROL VALVE (S/N 234316877 & ABOVE, S/N 234413319 & ABOVE, S/N 234515533 & ABOVE) 247
Description 247
Removal And Installation 248
Parts Identification 254
Disassembly 255
Right Travel Valve Section Disassembly And Assembly 257
Left Travel Valve Section Disassembly And Assembly 261
Blade Valve Section Disassembly And Assembly 265
Slew Valve Section Disassembly And Assembly 274
Auxiliary Valve Section Disassembly And Assembly 279
Bucket Valve Section Disassembly And Assembly 284
Arm Valve Section Disassembly And Assembly 289
Boom Valve Section Disassembly And Assembly 294
Boom Swing Valve Section Disassembly And Assembly 299
Inlet Section Disassembly And Assembly 304
Assembly 309
HYDRAULIC PUMP 315
Description 315
Torque Adjustment 316
Testing The Piston Pump 317
Testing Auxiliary Hydraulic Flow 319
Removal And Installation 320
Coupler Removal And Installation 321
Parts Identification 322
Disassembly 323
Assembly 331
MANIFOLD ASSEMBLY/ ACCUMULATOR 339
Description 339
Removal And Installation 339
Parts Identification 342
Disassembly And Assembly 343
TRAVEL MOTOR 353
Removal And Installation 353
Parts Identification 354
Disassembly 355
Assembly 365
SWIVEL JOINT 377
Description 377
Removal And Installation 377
Parts Identification 379
Disassembly 380
Assembly 381
SWING MOTOR 385
Removal And Installation 385
Parts Identification 388
Disassembly 389
Assembly 394
SWING MOTOR DRIVE CARRIER 401
Removal And Installation 401
Parts Identification 402
Disassembly 403
Assembly 405
CONTROL PATTERN SELECTOR VALVE 409
Removal And Installation 409
Parts Identification 410
Disassembly 411
Assembly 412
RIGHT CONTROL LEVER (JOYSTICK) 413
Testing 413
Handle Removal And Installation 414
Joystick Assembly Removal And Installation 418
Parts Identification 421
Disassembly 422
Assembly 427
LEFT CONTROL LEVER (JOYSTICK) 433
Testing 433
Handle Removal And Installation 434
Joystick Assembly Removal And Installation 437
Parts Identification 439
Disassembly 440
Assembly 445
HYDRAULIC FILTER MOUNT 451
Removal And Installation 451
HYDRAULIC RESERVOIR 453
Removal And Installation 453
OIL COOLER 455
Removal And Installation 455
DIRECT TO TANK VALVE 457
Removal And Installation 457
Parts Identification 458
Disassembly And Assembly 459
CASE DRAIN FILTER 461
Removal And Installation 461
BOOM SWING LOCK VALVE 463
Removal And Installation 463
Parts Identification 464
Disassembly 465
Assembly 468
TRAVEL CONTROL VALVE 473
Removal and Installation 473
Parts Identification 474
Disassembly And Assembly 475
HYDRAULIC X-CHANGE VALVE 479
Removal And Installation 479
Parts Identification 483
Disassembly 484
Assembly 492
UNDERCARRIAGE 499
BLADE 501
Removal And Installation 501
TRACKS 503
Track Lug Height 503
Adjustment 503
Rubber Track Removal And Installation 506
Steel Track Removal And Installation 509
TRACK FRAME 513
Disassembly And Assembly 513
Recoil Spring Cylinder (Without Replaceable Shaft) 515
Recoil Spring Cylinder Parts Identification (With Replaceable Shaft) 516
Recoil Spring Cylinder (With Replaceable Shaft) 517
TRACK DAMAGE IDENTIFICATION 519
Cutting Of Steel Cords 519
Abrasion Of Embedded Metals 520
Separation Of Embedded Metals 521
Separation Of Embedded Metals Due To Corrosion 523
Cuts On The Lug Side Rubber 524
Cracks On The Lug Side Rubber Due To Fatigue 525
Lug Abrasion 526
Cracks And Cuts On The Lug Side Rubber 527
Abrasion Of The Track Roller Side 528
Cuts On The Edges Of Track Roller Side 529
TRACK IDLER 531
Parts Identification 531
Disassembly 532
Assembly 534
TRACK ROLLER 537
Parts Identification 537
Disassembly 538
Assembly 540
SWING CIRCLE GEAR 543
Swing Bearing Removal 543
SWING CIRCLE GEAR 544
Swing Bearing Installation 544
UPPERSTRUCTURE & SWING SECTION 545
UPPERSTRUCTURE 549
Removal 549
Installation 552
ROPS CANOPY 555
Removal And Installation 555
CAB 559
Removal And Installation 559
Door Removal And Installation 564
Front Window Removal And Installation 565
Right Side Rear Sliding Window Removal And Installation 568
Right Side Front Sliding Window Removal And Installation 568
Right Side Front And Rear Sliding Window Weather Strip Removal And Installation 569
Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation 569
Glass Removal 570
Glass Installation 571
SEAT AND SEAT MOUNT 577
Removal And Installation 577
RIGHT CONSOLE 579
Console Cover Removal And Installation 579
Console Base Removal And Installation 580
LEFT CONSOLE 583
Lower Console Cover Removal And Installation 583
Upper Console Cover Removal And Installation 585
Compression Spring Removal And Installation 586
Compression Spring Disassembly And Assembly 587
Lock Lever Removal And Installation 589
Console Removal And Installation 591
Disassembly And Assembly 595
Console Base Removal And Installation 598
ENGINE SPEED CONTROL 599
Removal And Installation 599
Adjustment (Later Models) 600
BLADE CONTROL 601
Lever Removal And Installation 601
Linkage Removal And Installation 602
Linkage Bar Removal And Installation 604
Lower Linkage Removal And Installation 606
RIGHT PEDAL AND LINKAGE 609
Pedal Removal And Installation 609
Pedal Disassembly And Assembly 610
Linkage Removal And Installation 612
TRAVEL CONTROLS 613
Removal And Installation 613
Disassembly And Assembly 614
Adjustment 616
Control Linkage Removal And Installation 618
FLOOR MAT AND FLOOR PLATE 619
Removal And Installation (Canopy Equipped Excavators) 619
Removal And Installation (Cab Equipped Excavators) 620
FUEL TANK 621
Removal And Installation 621
HORN 625
Removal And Installation (Early Models) 625
Removal And Installation (Later Models) 626
SWING FRAME 627
Removal And Installation 627
Boom Swing Frame Hose Routing 631
Bushing Removal 632
Bushing Installation 633
BOOM 635
Removal And Installation 635
STANDARD AND LONG ARM 637
Removal And Installation 637
Arm To Boom Bushing Removal And Installation 638
Arm To Bucket And Bucket Link Bushing Removal And Installation (Early Models) 639
Arm To Bucket And Bucket Link Bushing Removal And Installation (Later Models) 640
EXTENDIBLE ARM 643
Removal And Installation 643
Disassembly And Assembly 647
BUCKET 649
Bucket Teeth Removal And Installation 649
Bucket Side Cutting Edge Removal And Installation 650
CLAMP 651
Removal And Installation 651
TAILGATE 653
Removal And Installation 653
Latch Removal And Installation 654
X-CHANGE™ 655
Removal And Installation 655
Disassembly 657
Assembly 661
Check Proper Latch Engagement 667
X-CHANGE (HYDRAULIC) 671
Removal And Installation 671
Parts Identification 674
Disassembly 675
Assembly 680
UPPERSTRUCTURE SLEW LOCK 689
Removal And Installation (Early Models) 689
Removal And Installation (Later Models) 690
Disassembly And Assembly (Later Models) 690
RIGHT SIDE COVER 693
Removal And Installation 693
ELECTRICAL SYSTEM AND ANALYSIS 695
ELECTRICAL SCHEMATICS 697
ELECTRICAL SYSTEM INFORMATION 700
Troubleshooting Chart 700
Description 701
Fuse And Relay Location 701
BATTERY 702
Servicing 702
Removal And Installation 703
Using A Booster Battery (Jump Starting) 704
ALTERNATOR 706
Engine Accessory Drive Belt 706
Removal And Installation 707
Alternator Identification 709
Charging System Check 710
Alternator Voltage Test 712
Low Voltage Test 712
High Voltage Test 713
Rectifier Continuity (Diode) Test 714
Alternator Regulator Test 715
Parts Identification 716
Disassembly 717
Stator Continuity Test 717
Stator Ground Test 718
Rotor Continuity Test 718
Rotor Ground Test 719
Assembly 719
STARTER 722
Removal And Installation 722
Parts Identification 723
Disassembly 724
Inspection And Repair 730
Assembly 733
LIGHTS 738
Removal And Installation 738
Boom Light Removal And Installation (Early Models) 739
Boom Light Disassembly And Assembly (Early Models) 739
Boom Light Removal And Installation (Later Models) 740
Boom Light Bulb Replacement (Later Models) 740
MAGNETIC LOCKOUT SENSOR 742
Removal And Installation 742
TWO SPEED SWITCH 744
Removal And Installation 744
FUEL LEVEL SENDER 746
Removal And Installation 746
Testing 747
DIAGNOSTICS SERVICE CODE 748
Number Codes List 748
DELUXE INSTRUMENT PANEL SETUP 750
Passwords 750
Password Entry (For Starting and Operating the Machine) 750
Changing The Owner Or Operator Password 750
Password Lockout Feature 751
Job Clock 751
RPM 751
ENGINE SERVICE 752
TROUBLESHOOTING 754
Chart 754
SPARK ARRESTOR MUFFLER 756
Removal And Installation 756
AIR CLEANER 758
Removal And Installation 758
RADIATOR 760
Removal And Installation 760
ENGINE COMPONENTS AND TESTING 762
Engine Compression Checking 762
Glow Plugs Removal And Installation 763
Checking The Glow Plug 764
Fuel Shut-off Solenoid Removal And Installation 765
Fuel Injection Pump Check 766
Fuel Injection Pump Removal And Installation 767
Fuel Injection Pump Timing 770
Fuel Injector Nozzles Removal And Installation 772
Fuel Injector Nozzle Check 774
Valve Clearance Adjustment 775
ENGINE 776
Removal And Installation 776
ENGINE FLYWHEEL (EARLY MODELS) 782
Flywheel Removal And Installation 782
Hydraulic Pump Coupler 784
Flywheel Ring Gear 784
ENGINE FLYWHEEL (LATER MODELS) 786
Flywheel Removal And Installation 786
Hydraulic Pump Coupler 788
Flywheel Ring Gear 788
RECONDITIONING THE ENGINE 790
Cylinder Head Removal And Installation 790
Cylinder Head Disassembly And Assembly 793
Cylinder Head Servicing 794
Cylinder Head Top Clearance 794
Valve Guide Checking 795
Reconditioning The Valve And Valve Seat 797
Valve Spring 798
Rocker Arm And Shaft Checking 799
Timing Gearcase Cover Removal And Installation 799
Idler Gear And Camshaft Removal And Installation 802
Camshaft Servicing 803
Idler Gear And Shaft Servicing 804
Timing Gears Checking Backlash 805
Fuel Camshaft Removal And Installation 805
Fuel Camshaft Governor 806
Crankshaft Gear Removal And Installation 806
Oil Pump Removal And Installation 807
Oil Pump Service 807
Checking Engine Oil Pressure 808
Valve Tappets 809
Piston And Connecting Rod Removal And Installation 809
Piston And Connecting Rod Servicing 811
Connecting Rod Alignment 813
Crankshaft And Bearings Removal And Installation 814
Crankshaft And Bearings Servicing 816
Cylinder Bore Checking 820
Water Pump Removal And Installation 820
Water Pump Disassembly And Assembly 821
Fan Removal And Installation 822
HEATING, VENTILATION, AIR CONDITIONING 824
HEATER COIL (EARLY MODELS) 828
Removal And Installation With A/C 828
Removal And Installation Without A/C 828
HEATER COIL (LATER MODELS) 830
Removal And Installation With A/C 830
Removal And Installation Without A/C 830
BLOWER FAN (EARLY MODELS) 832
Removal And Installation 832
Disassembly And Assembly 833
BLOWER FAN (LATER MODELS) 836
Removal And Installation 836
Disassembly And Assembly 837
Resistor Removal And Installation 838
HEATER VALVE (EARLY MODELS) 840
Removal And Installation 840
HEATER VALVE (LATER MODELS) 842
Removal And Installation 842
AIR CONDITIONING SYSTEM FLOW 845
Principals 845
Chart 846
COMPONENTS 848
Identification 848
SAFETY 852
Safety Equipment 852
REGULAR MAINTENANCE 854
Heater Air Filter 854
Engine Accessory Drive Belt Inspection 854
Cleaning The Condenser 855
BASIC TROUBLESHOOTING (EARLY MODELS) 856
Poor A/C Performance 856
Cleaning The A/C Evaporator Coil & Heater Coil 857
Engine Accessory Drive Belt Inspection 858
Checking The Electrical System 859
Engine Coolant By-Passing The Heater Valve 868
BASIC TROUBLESHOOTING (LATER MODELS) 870
Poor A/C Performance 870
Cleaning The A/C Evaporator Coil & Heater Coil 871
Engine Accessory Drive Belt Inspection 872
Checking The Electrical System 873
Engine Coolant By-Passing The Heater Valve 883
GENERAL AIR CONDITIONING SERVICE GUIDELINES 884
Compressor Oil 884
Compressor Oil Check 885
Component Replacement And Refrigeration Leaks 887
SYSTEM TROUBLESHOOTING CHART 888
Blower Motor Does Not Operate 888
Blower Motor Operates Normally, But Air Flow Is Insufficient 888
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 888
The Compressor Operates Improperly Or Not At All 888
Gauge Pressure Related Troubleshooting 889
TEMPERATURE/PRESSURE 890
Chart 890
AIR CONDITIONING SERVICE 892
Chart 892
SYSTEM CHARGING AND RECLAMATION 894
Reclamation Procedure 894
Charging Procedure With A Manifold Gauge Set 897
COMPRESSOR 902
Removal And Installation 902
Compressor Clutch Disassembly And Assembly 904
CONDENSER 908
Removal And Installation 908
RECEIVER/DRIER 910
Removal And Installation 910
PRESSURE RELIEF VALVE 912
Removal And Installation 912
PRESSURE SWITCH 914
Removal And Installation 914
EVAPORATOR/HEATER UNIT (EARLY MODELS) 916
Removal And Installation 916
Disassembly And Assembly 917
EVAPORATOR/HEATER UNIT (LATER MODELS) 918
Removal And Installation 918
Disassembly And Assembly 919
THERMOSTAT (EARLY MODELS) 920
Removal And Installation 920
THERMOSTAT (LATER MODELS) 922
Removal And Installation 922
EXPANSION VALVE (EARLY MODELS) 924
Removal And Installation 924
EVAPORATOR VALVE (LATER MODELS) 926
Removal And Installation 926
EVAPORATOR (EARLY MODELS) 928
Removal And Installation 928
EVAPORATOR (LATER MODELS) 930
Removal And Installation 930
SPECIFICATIONS 932
SPECIFICATIONS 934
331 & 334 Excavator Machine Dimensions 934
331E Excavator Machine Dimensions 936
Performance 938
Controls 938
Engine 939
Hydraulic System 939
Hydraulic Cylinders 940
Hydraulic Cycle Times 940
Drive System 940
Undercarriage 940
Track 941
Electrical 941
ENGINE SPECIFICATIONS 942
Fuel Injection Nozzles 942
Fuel Injection Pump 942
Cylinder Head 942
Valves 942
Valve Springs 943
Valve Timing 943
Rocker Arms 943
Camshaft 943
Tappet 943
Cylinders 944
Piston Rings 944
Pistons 944
Connecting Rods 944
Oil Pump 944
Crankshaft 945
Timing Gear 945
Thermostat 945
Engine Bolt Torque 946
Crankshaft Re-Grind Data 947
TORQUE SPECIFICATIONS 948
Torque For General SAE Bolts 948
Torque For General Metric Bolts 948
HYDRAULIC CONNECTION SPECIFICATIONS 950
O-Ring Face Seal Connection 950
Straight Thread O-Ring Fitting 950
Tubelines And Hoses 951
Flare Fitting 951
O-Ring Flare Fitting 952
Port Seal Fitting 954
HYDRAULIC FLUID SPECIFICATIONS 956
Specifications 956
FUEL, COOLANT AND LUBRICANTS 958
Chart 958
CONVERSIONS 960
Decimal And Millimeter Equivalents 960
U S To Metric Conversion 961
SERVICE MANUAL REVISION 962
Revision No: 331 / 331E / 334 – 1 962
Revision No: 331 / 331E / 334 – 2 964
Revision No: 331 / 331E / 334 – 3 966
Revision No: 331 / 331E / 334 – 4 968
Revision No: 331 / 331E / 334 – 5 970
Revision No: 331 / 331E / 334 – 6 972
Revision No: 331 / 331E / 334 – 7 974
Revision No: 331 / 331E / 334 – 8 976

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• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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