Bobcat 331, 331E, 334 Compact Excavator 6986943 (12-14) (Preview)
MAINTENANCE SAFETY
CONTENTS
FOREWORD
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrester Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATIONS
Excavator Serial Number
Engine Serial Number
DELIVERY REPORT
EXCAVATOR IDENTIFICATION
SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE EXCAVATOR
Procedure
UPPERSTRUCTURE SLEW LOCK
Operation
LIFTING THE EXCAVATOR
Procedure
OPERATOR CAB (ROPS / TOPS)
Description
Cab Door
Front Window
Front Wiper
Window Washer Reservoir
Right Side Windows
Heating, Ventilation, and Air Conditioning Duct
TRANSPORTING THE EXCAVATOR ON A TRAILER
Loading And Unloading
Fastening
TAILGATE
Opening And Closing
Adjusting The Bumper
Adjusting The Latch
RIGHT SIDE COVER
Opening And Closing
Adjusting The Latch
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Daily Check
Replacing The Filter Elements
ENGINE COOLING SYSTEM
Cleaning
Checking Level
Replacing The Coolant
FUEL SYSTEM
Fuel Specifications
Biodiesel Blend Fuel
Filling The Fuel Tank
Fuel Filters
Draining The Fuel Tank
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Oil Chart
Removing And Replacing Oil And Filter
HYDRAULIC SYSTEM
Checking And Adding Hydraulic Oil
Hydraulic Fluid Chart
Removing And Replacing The Hydraulic Filter
Replacing The Case Drain Filter
Removing And Replacing The Hydraulic Fluid
LUBRICATION OF THE HYDRAULIC EXCAVATOR
Lubrication Locations
TRAVEL MOTOR
Checking And Adding Oil
Removing And Replacing Oil
SPARK ARRESTER MUFFLER
Cleaning Procedure
ENGINE ACCESSORY DRIVE BELT
Belt Adjustment
SEAT BELT
Inspection And Maintenance
PIVOT PINS
Inspection And Maintenance
EXCAVATOR STORAGE AND RETURN TO SERVICE
Storage
Return to Service
STOPPING THE ENGINE AND LEAVING THE EXCAVATOR
Procedure
Emergency Exits
REMOTE START TOOL KIT – MEL1563
Remote Start Tool Kit – MEL1563
Service Tool Harness Control – MEL1565
Service Tool Harness Communicator – MEL1566
REMOTE START TOOL (SERVICE TOOL) KIT – 7003031
Description
Remote Start Tool (Service Tool) – 7003030
Excavator Service Tool Harness – 6689747
Computer Service Tool Harness – 6689746
HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols For Excavators
Troubleshooting The Hydraulic Circuit
Troubleshooting The Cylinder Circuit
Troubleshooting The Swing (Upperstructure Slew) Circuit
Troubleshooting The Travel Circuit
CYLINDER (BOOM)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (ARM)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (BOOM SWING)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (BUCKET)
Testing
Removal And Installation (Standard And Long Arm)
Removal And Installation (Extendable Arm)
Parts Identification
Disassembly
Assembly
CYLINDER (BLADE)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (EXTENDABLE ARM)
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (CLAMP)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
VALVE (MAIN RELIEF)
Testing And Adjusting The Main Relief Valve
VALVES (PORT RELIEF)
Testing And Adjusting Port Relief Valve Pressure
VALVES (CROSSPORT RELIEF)
Testing And Adjusting The Crossport Relief Valves
VALVE (PRESSURE REDUCING)
Testing And Adjusting The Pressure Reducing Valve
HYDRAULIC CONTROL VALVE
Description
Removal And Installation
Parts Identification
Disassembly
Right Travel Valve Section Disassembly And Assembly
Left Travel Valve Section Disassembly And Assembly
Blade Valve Section Disassembly And Assembly
Slew Valve Section Disassembly And Assembly
Auxiliary Valve Section Disassembly And Assembly
Bucket Valve Section Disassembly And Assembly
Arm Valve Section Disassembly And Assembly
Boom Valve Section Disassembly And Assembly
Boom Swing Valve Section Disassembly And Assembly
Inlet Section Disassembly And Assembly
Assembly
HYDRAULIC PUMP
Description
Torque Adjustment
Testing The Piston Pump
Testing Auxiliary Hydraulic Flow
Removal And Installation
Coupler Removal And Installation
Hydraulic Pump Start Up
Parts Identification
Disassembly
Assembly
MANIFOLD ASSEMBLY / ACCUMULATOR
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
TRAVEL MOTOR
Removal And Installation
Parts Identification
Disassembly
Assembly
SWIVEL JOINT
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
SWING MOTOR
Removal And Installation
Parts Identification
Disassembly
Assembly
SWING MOTOR DRIVE CARRIER
Removal And Installation
Parts Identification
Disassembly
Assembly
CONTROL PATTERN SELECTOR VALVE
Removal And Installation
Parts Identification
Disassembly
Assembly
RIGHT CONTROL LEVER (JOYSTICK)
Testing
Handle Removal And Installation
Joystick Assembly Removal And Installation
Parts Identification
Disassembly
Assembly
LEFT CONTROL LEVER (JOYSTICK)
Testing
Handle Removal And Installation
Joystick Assembly Removal And Installation
Parts Identification
Disassembly
Assembly
HYDRAULIC FILTER MOUNT
Removal And Installation
HYDRAULIC RESERVOIR
Removal And Installation
OIL COOLER
Removal And Installation
DIRECT TO TANK VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
CASE DRAIN FILTER
Removal And Installation
BOOM SWING LOCK VALVE
Removal And Installation
Parts Identification
Disassembly
Assembly
TRAVEL CONTROL VALVE
Removal and Installation
Parts Identification
Disassembly And Assembly
HYDRAULIC X-CHANGE™ VALVE
Removal And Installation
Parts Identification
Disassembly
Assembly
SLEW LOCK VALVE
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
UNDERCARRIAGE
BLADE
Removal And Installation
TRACKS
Track Lug Height
Adjustment
Rubber Track Removal And Installation
Steel Track Removal And Installation
TRACK FRAME
Disassembly And Assembly
Recoil Spring Cylinder (S/N AACS11750 & Below, A9K511103 & Below, A9K711102 & Below And A9K911051 & Below)
Recoil Spring Cylinder Parts Identification (With Replaceable Shaft) (S/N AACS11751 & Above, A9K511104 & Above, A9K711103 & Above And A9K91102 & Above)
Recoil Spring Cylinder (With Replaceable Shaft) (S/N AACS11751 & Above, A9K511104 & Above, A9K711103 & Above And A9K911052 & Above)
TRACK DAMAGE IDENTIFICATION
Cutting Of Steel Cords
Abrasion Of Embedded Metals
Separation Of Embedded Metals
Separation Of Embedded Metals Due To Corrosion
Cuts On The Lug Side Rubber
Cracks On The Lug Side Rubber Due To Fatigue
Lug Abrasion
Cracks And Cuts On The Lug Side Rubber
Abrasion Of The Track Roller Side
Cuts On The Edges Of Track Roller Side
TRACK IDLER
Parts Identification
Disassembly
Assembly
TRACK ROLLER
Parts Identification
Disassembly
Assembly
SWING CIRCLE GEAR
Swing Bearing Removal
Swing Bearing Installation
UPPERSTRUCTURE AND SWING SECTION
UPPERSTRUCTURE
Removal
Installation
ROPS CANOPY
Removal And Installation
CAB
Removal And Installation
Door Removal And Installation
Front Window Removal And Installation
Right Side Rear Sliding Window Removal And Installation
Right Side Front Sliding Window Removal And Installation
Right Side Front And Rear Sliding Window Weather Strip Removal And Installation
Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation
Glass Removal
Glass Installation
SEAT AND SEAT MOUNT
Removal And Installation
RIGHT CONSOLE
Console Cover Removal And Installation
Console Base Removal And Installation
LEFT CONSOLE
Lower Console Cover Removal And Installation
Upper Console Cover Removal And Installation
Compression Spring Removal And Installation
Compression Spring Disassembly And Assembly
Lock Lever Removal And Installation
Console Removal And Installation
Disassembly And Assembly
Console Base Removal And Installation
ENGINE SPEED CONTROL
Removal And Installation
Adjustment (Later Models)
BLADE CONTROL
Lever Removal And Installation
Linkage Removal And Installation
Linkage Bar Removal And Installation
Lower Linkage Removal And Installation
RIGHT PEDAL AND LINKAGE
Pedal Removal And Installation
Pedal Disassembly And Assembly
Linkage Removal And Installation
TRAVEL CONTROLS
Removal And Installation
Disassembly And Assembly
Adjustment
Control Linkage Removal And Installation
FLOOR MAT AND FLOOR PANEL
Removal And Installation (Canopy Equipped Excavators)
Removal And Installation (Cab Equipped Excavators)
FUEL TANK
Removal And Installation
HORN
Removal And Installation
SWING FRAME
Removal And Installation
Boom Swing Frame Hose Routing
Bushing Removal
Bushing Installation
BOOM
Removal And Installation
STANDARD AND LONG ARM
Removal And Installation
Arm To Boom Bushing Removal And Installation
Arm To Bucket And Bucket Link Bushing Removal And Installation
Arm To Bucket And Bucket Link Bushing Removal And Installation (Cont’d)
EXTENDABLE ARM
Removal And Installation
Disassembly And Assembly
BUCKET
Bucket Teeth Removal And Installation
Bucket Side Cutting Edge Removal And Installation
CLAMP
Removal And Installation
TAILGATE
Removal And Installation
Latch Removal And Installation
X-CHANGE™
Removal And Installation
Disassembly
Assembly
Check Proper Latch Engagement
X-CHANGE™ (HYDRAULIC)
Removal And Installation
Parts Identification
Disassembly
Assembly
UPPERSTRUCTURE SLEW LOCK
Removal And Installation
Disassembly And Assembly
RIGHT SIDE COVER
Removal And Installation
QUICK COUPLER (KLAC™ SYSTEM)
Troubleshooting
Daily Inspection
Removal And Installation
Parts Identification
Disassembly
Assembly
QUICK COUPLER (LEHNHOFF® SYSTEM)
Troubleshooting
Daily Inspection
Removal (MS03 And MS08)
Installation (MS03 And MS08)
Parts Identification (MS03)
Disassembly And Assembly (MS03)
Parts Identification (MS08)
Disassembly (MS08)
Assembly (MS08)
ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
Description
Fuse And Relay Location
BATTERY
Servicing
Removal And Installation
Using A Booster Battery (Jump Starting)
ALTERNATOR
Engine Accessory Drive Belt
Removal And Installation
Alternator Identification
Charging System Check
Alternator Voltage Test
Low Voltage Test
High Voltage Test
Rectifier Continuity (Diode) Test
Alternator Regulator Test
Parts Identification
Disassembly
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Assembly
STARTER
Removal And Installation
Parts Identification
Disassembly
Inspection And Repair
Assembly
LIGHTS
Removal And Installation
Boom Light Removal And Installation
Boom Light Bulb Replacement
MAGNETIC LOCKOUT SENSOR
Removal And Installation
TWO SPEED SWITCH
Removal And Installation
FUEL LEVEL SENDER
Removal And Installation
Testing
DIAGNOSTICS SERVICE CODE
Number Codes List
DELUXE INSTRUMENT PANEL SETUP
Passwords
Password Entry (For Starting and Operating the Machine)
Changing The Owner Or Operator Password
Password Lockout Feature
Job Clock
RPM
ENGINE SERVICE
TROUBLESHOOTING
Chart
SPARK ARRESTER MUFFLER
Removal And Installation
AIR CLEANER
Removal And Installation
RADIATOR
Removal And Installation
ENGINE COMPONENTS AND TESTING
Engine Compression Checking
Glow Plugs Removal And Installation
Checking The Glow Plug
Fuel Shut-off Solenoid Removal And Installation
Fuel Injection Pump Check
Fuel Injection Pump Removal And Installation
Fuel Injection Pump Timing
Fuel Injector Nozzles Removal And Installation
Fuel Injector Nozzle Check
Valve Clearance Adjustment
ENGINE
Removal And Installation
ENGINE FLYWHEEL
Hydraulic Pump Coupler Removal And Installation
Flywheel Removal And Installation
Flywheel Ring Gear
RECONDITIONING THE ENGINE
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head Servicing
Cylinder Head Top Clearance
Valve Guide Checking
Reconditioning The Valve And Valve Seat
Valve Spring
Rocker Arm And Shaft Checking
Timing Gearcase Cover Removal And Installation
Idler Gear And Camshaft Removal And Installation
Camshaft Servicing
Idler Gear And Shaft Servicing
Timing Gears Checking Backlash
Fuel Camshaft Removal And Installation
Fuel Camshaft Governor
Crankshaft Gear Removal And Installation
Oil Pump Removal And Installation
Oil Pump Service
Checking Engine Oil Pressure
Valve Tappets
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod Servicing
Connecting Rod Alignment
Crankshaft And Bearings Removal And Installation
Crankshaft And Bearings Servicing
Cylinder Bore Checking
Water Pump Removal And Installation
Water Pump Disassembly And Assembly
Fan Removal And Installation
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
HEATER COIL
Removal And Installation With A/C
Removal And Installation Without A/C
BLOWER FAN
Removal And Installation
Disassembly And Assembly
Resistor Removal And Installation
HEATER VALVE
Removal And Installation
AIR CONDITIONING SYSTEM FLOW
Principals
Chart
COMPONENTS
Identification
SAFETY
Safety Equipment
REGULAR MAINTENANCE
Heater Air Filter
Engine Accessory Drive Belt Inspection
Cleaning The Condenser
BASIC TROUBLESHOOTING
Poor A/C Performance
Cleaning The A/C Evaporator Coil And Heater Coil
Engine Accessory Drive Belt Inspection
Checking The Electrical System
Engine Coolant By-Passing The Heater Valve
GENERAL AIR CONDITIONING SERVICE GUIDELINES
Compressor Oil
Compressor Oil Check
Component Replacement And Refrigeration Leaks
SYSTEM TROUBLESHOOTING CHART
Blower Motor Does Not Operate
Blower Motor Operates Normally, But Air Flow Is Insufficient
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
The Compressor Operates Improperly Or Not At All
Gauge Pressure Related Troubleshooting
TEMPERATURE / PRESSURE
Chart
AIR CONDITIONING SERVICE
Chart
SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
Charging Procedure With A Manifold Gauge Set
COMPRESSOR
Removal And Installation
Compressor Clutch Disassembly And Assembly
CONDENSER
Removal And Installation
RECEIVER / DRIER
Removal And Installation
PRESSURE RELIEF VALVE
Removal And Installation
PRESSURE SWITCH
Removal And Installation
EVAPORATOR / HEATER UNIT
Removal And Installation
Disassembly And Assembly
THERMOSTAT
Removal And Installation
EXPANSION VALVE
Removal And Installation
EVAPORATOR
Removal And Installation
SPECIFICATIONS
SPECIFICATIONS
331, 331E With Long Arm Option And 334 Excavator Machine Dimensions
331 With Extendable Arm Option And 331E Excavator Machine Dimensions
Performance
Controls
Engine
Hydraulic System
Hydraulic Cylinders
Hydraulic Cycle Times
Drive System
Undercarriage
Track
Ground Pressure
Electrical
ENGINE SPECIFICATIONS
Fuel Injection Nozzles
Fuel Injection Pump
Cylinder Head
Valves
Valve Springs
Valve Timing
Rocker Arms
Camshaft
Tappet
Cylinders
Piston Rings
Pistons
Connecting Rods
Oil Pump
Crankshaft
Timing Gear
Thermostat
Engine Bolt Torque
Crankshaft Re-Grind Data
TORQUE SPECIFICATIONS
Torque For General SAE Bolts
Torque For General Metric Bolts
HYDRAULIC CONNECTION SPECIFICATIONS
O-Ring Face Seal Connection
Straight Thread O-Ring Fitting
Tubelines And Hoses
Flare Fitting
O-Ring Flare Fitting
Port Seal Fitting
HYDRAULIC FLUID SPECIFICATIONS
Specifications
SERVICE TOOLS REQUIRED
Remote Start Tools
Hydraulic Tools
Engine Tools
HVAC Tools
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion
ALPHABETICAL INDEX
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