Bobcat X331, X331E, X334 Excavator 6903830 (10-09) (Preview)
MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
– FOREWORD
– SAFETY INSTRUCTIONS
– FIRE PREVENTION
— Maintenance
— Operation
— Electrical
— Hydraulic System
— Fueling
— Starting
— Spark Arrestor Exhaust System
— Welding And Grinding
— Fire Extinguishers
– SERIAL NUMBER LOCATIONS
— Excavator Serial Number
— Engine Serial Number
– DELIVERY REPORT
SAFETY AND MAINTENANCE
– LIFTING AND BLOCKING THE EXCAVATOR
— Procedure
– UPPERSTRUCTURE SLEW LOCK
— Operation (Early Models)
— Operation (Later Models)
– LIFTING THE EXCAVATOR
— Procedure
– OPERATOR CAB (ROPS/TOPS)
— Emergency Exit
— Cab Door
— Front Window
— Right Side Windows
– TRANSPORTING THE EXCAVATOR
– TAILGATE
— Opening And Closing The Tailgate
— Adjusting The Bumper
— Adjusting The Latch
– RIGHT SIDE COVER
— Opening And Closing The Right Side Cover
– SERVICE SCHEDULE
— Chart
– AIR CLEANER SERVICE
— Daily Check
— Replacing The Filters
– HEATER AIR FILTER (WITH CAB OPTION ONLY)
— Removal And Installation
– ENGINE COOLING SYSTEM
— Replacing The Coolant
— Checking Coolant Level
— Cleaning The Cooling System
– FUEL SYSTEM
— Fuel Specifications
— Filling The Fuel Tank
— Removing Water From The Fuel Filter
— Draining The Fuel Tank
— Fuel Filter
— Removing Air From The Fuel System
– ENGINE LUBRICATION SYSTEM
— Checking Engine Oil
— Oil Chart
— Replacing Oil And Filter
– HYDRAULIC SYSTEM
— Checking And Adding Hydraulic Fluid
— Replacing The Hydraulic Fluid
— Replacing The Hydraulic Filter
— Replacing The Case Drain Filter
— Diagnostic Couplers
– LUBRICATION OF THE HYDRAULIC EXCAVATOR
— Procedure
– TRAVEL MOTOR
— Checking Oil Level
— Draining The Travel Motor
– SPARK ARRESTOR MUFFLER
– ENGINE ACCESSORY DRIVE BELT
— Belt Tension
— Belt Adjustment
– SEAT BELT
— Inspection And Maintenance
HYDRAULIC SYSTEM
– HYDRAULIC / HYDROSTATIC SCHEMATIC
– 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
– BOOM CYLINDER
— Testing
— Removal And Installation
— Parts Identification
— Disassembly
— Assembly
– ARM CYLINDER
— Testing
— Removal And Installation
— Parts Identification
— Disassembly
— Assembly
– BOOM SWING CYLINDER
— Testing
— Removal And Installation
— Parts Identification
— Disassembly
— Assembly
– BUCKET CYLINDER
— Testing
— Removal And Installation (Standard And Long Arm)
— Removal And Installation (Extendible Arm)
— Parts Identification
— Disassembly
— Assembly
– BLADE CYLINDER
— Testing
— Removal And Installation
— Parts Identification
— Disassembly
— Assembly
– EXTENDIBLE ARM CYLINDER
— Removal And Installation
— Parts Identification
– CLAMP CYLINDER
— Testing
— Removal And Installation
— Parts Identification
— Disassembly
— Assembly
– MAIN RELIEF VALVE
— Testing And Adjusting The Main Relief Valve
– PORT RELIEF VALVES
— Testing And Adjusting Port Relief Valve Pressure
– CROSSPORT RELIEF VALVES
— Testing And Adjusting The Crossport Relief Valves
– PRESSURE REDUCING VALVE
— Testing And Adjusting The Pressure Reducing Valve
– HYDRAULIC CONTROL VALVE (S/N 234313000 – 234316876, S/N 234412000 – 234413318, S/N 234513000 – 234515532)
— Description
— Removal And Installation
— Parts Identification
– HYDRAULIC CONTROL VALVE (S/N 234316877 & ABOVE, S/N 234413319 & ABOVE, S/N 234515533 & ABOVE)
— 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
— 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
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 (Without Replaceable Shaft)
— Recoil Spring Cylinder Parts Identification (With Replaceable Shaft)
— Recoil Spring Cylinder (With Replaceable Shaft)
– 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 CIRCLE GEAR
— Swing Bearing Installation
UPPERSTRUCTURE & 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 PLATE
— Removal And Installation (Canopy Equipped Excavators)
— Removal And Installation (Cab Equipped Excavators)
– FUEL TANK
— Removal And Installation
– HORN
— Removal And Installation (Early Models)
— Removal And Installation (Later Models)
– 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 (Early Models)
— Arm To Bucket And Bucket Link Bushing Removal And Installation (Later Models)
– EXTENDIBLE 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 (Early Models)
— Removal And Installation (Later Models)
— Disassembly And Assembly (Later Models)
– RIGHT SIDE COVER
— Removal And Installation
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 (Early Models)
— Boom Light Disassembly And Assembly (Early Models)
— Boom Light Removal And Installation (Later Models)
— Boom Light Bulb Replacement (Later Models)
– 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 ARRESTOR 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 (EARLY MODELS)
— Flywheel Removal And Installation
— Hydraulic Pump Coupler
— Flywheel Ring Gear
– ENGINE FLYWHEEL (LATER MODELS)
— Flywheel Removal And Installation
— Hydraulic Pump Coupler
— 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, AIR CONDITIONING
– HEATER COIL (EARLY MODELS)
— Removal And Installation With A/C
— Removal And Installation Without A/C
– HEATER COIL (LATER MODELS)
— Removal And Installation With A/C
— Removal And Installation Without A/C
– BLOWER FAN (EARLY MODELS)
— Removal And Installation
— Disassembly And Assembly
– BLOWER FAN (LATER MODELS)
— Removal And Installation
— Disassembly And Assembly
— Resistor Removal And Installation
– HEATER VALVE (EARLY MODELS)
— Removal And Installation
– HEATER VALVE (LATER MODELS)
— 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 (EARLY MODELS)
— Poor A/C Performance
— Cleaning The A/C Evaporator Coil & Heater Coil
— Engine Accessory Drive Belt Inspection
— Checking The Electrical System
— Engine Coolant By-Passing The Heater Valve
– BASIC TROUBLESHOOTING (LATER MODELS)
— Poor A/C Performance
— Cleaning The A/C Evaporator Coil & 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 (EARLY MODELS)
— Removal And Installation
— Disassembly And Assembly
– EVAPORATOR/HEATER UNIT (LATER MODELS)
— Removal And Installation
— Disassembly And Assembly
– THERMOSTAT (EARLY MODELS)
— Removal And Installation
– THERMOSTAT (LATER MODELS)
— Removal And Installation
– EXPANSION VALVE (EARLY MODELS)
— Removal And Installation
– EVAPORATOR VALVE (LATER MODELS)
— Removal And Installation
– EVAPORATOR (EARLY MODELS)
— Removal And Installation
– EVAPORATOR (LATER MODELS)
— Removal And Installation
SPECIFICATIONS
– SPECIFICATIONS
— 331 & 334 Excavator Machine Dimensions
— 331E Excavator Machine Dimensions
— Performance
— Controls
— Engine
— Hydraulic System
— Hydraulic Cylinders
— Hydraulic Cycle Times
— Drive System
— Undercarriage
— Track
— 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
– FUEL, COOLANT AND LUBRICANTS
— Chart
– CONVERSIONS
— Decimal And Millimeter Equivalents
— U.S. To Metric Conversion
SERVICE MANUAL REVISION
– Revision No: 331 / 331E / 334 – 1
– Revision No: 331 / 331E / 334 – 2
– Revision No: 331 / 331E / 334 – 3
– Revision No: 331 / 331E / 334 – 4
– Revision No: 331 / 331E / 334 – 5
– Revision No: 331 / 331E / 334 – 6
– Revision No: 331 / 331E / 334 – 7
– Revision No: 331 / 331E / 334 – 8
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